Technical Specification Pawai Irrigation Project

ECHNICAL SPECIFICATION PAWAI IRRIGATION PROJECT
GOVERNMENT OF MADHYA PRADESH
WATER RESOURCES DEPARTMENT

(M.P.)
PAWAI irrigation project
VOLUME III
TECHNICAL SPECIFICATION
(ENVELOPE - C)
Standard Bidding Document for Turnkey Contracts
Execution of PAWAI Irrigation Project complete including construction of earth dam,

Non Over Flow and Central Spillway, energy dissipation arrangement, training wall supply
and erection of radial and stop log gate with all hoisting arrangements with hoist and trunion
bridge, Gantry Crane, fish ladder, D/S bridge and any other miscellaneous component
required including survey, investigation, planning, designing and approval / clearance from
competent authority.
land Acquisition cases and forest land if any for Dam/ Submergence, including its
maintenance upto completion of project,
Supply, erection and shifting of LT/HT line upto dam site colony, top of dam, gallery etc.
wherever required, construction of tar road from Karanjiya to Dam Site, colony and top of
dam.
Testing of all civil / electric / mechanical works as per specification, IS Codes, C.W.C. guide
lines, technical circulars and as per direction of Engineer in charge for completion of
project on Turnkey basis, preparation of documents for establishing water users association
for about 12550 Hact. of command area including operation and maintenance of whole
system and rectification if any for three year after completion of whole project.
CHIEF ENGINEER
DHASAN KEN BESIN SAGAR

M.P.
GOVERNMENT OF MADHYA PRADESH
WATER RESOURCES DEPARTMENT

(M.P.)
TENDER DOCUMENT
TURNKEY TENDER
Execution of PAWAI Irrigation Project complete including construction of earth dam, Non
Over Flow and Central Spillway, energy dissipation arrangement, training wall supply and
erection of radial and stop log gate with all hoisting arrangements with hoist and trunion
bridge, Gantry Crane, fish ladder, D/S bridge and any other miscellaneous component
required including survey, investigation, planning, designing and approval / clearance from
competent authority.
land Acquisition cases and forest land if any for Dam/ Submergence, including its
maintenance upto completion of project,
Supply, erection and shifting of LT/HT line upto dam site colony, top of dam, gallery etc.
wherever required, construction of tar road from Karanjiya to Dam Site, colony and top of
dam.
Testing of all civil / electric / mechanical works as per specification, IS Codes, C.W.C. guide
lines, technical circulars and as per direction of Engineer in charge for completion of
project on Turnkey basis, preparation of documents for establishing water users association
for about 12550 Hact. of command area including operation and maintenance of whole
system and rectification if any for three year after completion of whole project.
TENDER DOCUMENT CONTAINS FOLLOWING VOLUMES

1. Prequalification Document : Volume I
2. Tender document for Turnkey contract : Volume II
3. Technical Specifications : Volume III
4. Drawings and Design Parameters : Volume IV
5. Quality Control Manual : Volume V
1.1.1.1.1.1INDEX
Description Page No.

SECTION 1 : GENERAL 1 to 1
SECTION 2 : PREPARATORY WORK 2 to 46
SECTION 3 : LAND ACQUISITION 47
1.1.1.1.1.1INDEX
Description Page No.

SECTION 4 : EXCAVATION & EARTHWORK AND SPECIAL
48-123
ITEM OF EARTH DAM & CANAL
SECTION 5 : CONCRETE WORKS 124-203
SECTION 6 : LINING OF CANALS 204-268
SECTION 7: GATES 269-380
SECTION 8 : STONE MASONARY 381-402
SECTION 9 : STEEL AND IRON WORKS 403-459
SECTION 10 : ROAD WORK 460-496
SECTION 11 : DRILLING & GROUTING 497-576
VOLUME - III
SECTION I
GENERAL
THE SPECIFICATIONS CONTAINED UNDER DIFFERENT SECTIONS IN THIS

DOCUMENT ARE FOR GENERAL GUIDANCE. IN CASE OF DISAGREEMENT
BETWEEN THE SPECIFICATION OF THE DEPARTMENT AND STANDARD
PRACTICES BEING FOLLOWED AND/OR SPECIFICATIONS NOT PROVIDED
SPECIFICALLY, THEN RELEVANT SPECIFICATION UNDER INDIAN
STANDARDS / IRC PUBLICATIONS SHALL PREVAIL.
VOLUME III
SECTION - 2
PREPARATORY WORK
INDEX
TENDER DOCUMENT 49
TURNKEY TENDER 49
2SURVEY 58
2. GEOTECHNICAL INVESTIGATION 62
3. SUPPLEMENTARY CONDITIONS 65
4FINAL REPORT 68
APPENDIX I 69
TOPOGRAPHICAL SURVEYS, EXTENT, SCALES, CONTOUR INTERVAL,
ETC. 69
APPENDIX II 71
LOCATION AND DEPTH OF EXPLORATORY HOLES / DRIFTS / PITS ETC.
71
APPENDIX II (A) 73
LOG OF TEST PIT BORROW AND FOUNDATION INVESTIGATIONS 73
APPENDIX II(B) 74
DAILY DRILL REPORT 74
APPENDIX III 76
INVESTIGATIONS FOR ESTABLISHING SUITABILITY OF
CONSTRUCTION MATERIALS 76
APPENDIX IV 77
1 GENERAL 162
2. STANDARDS 162
3. SCOPE: 163
4. PLANNING: 163
5. SETTING OUT WORK 163
6 CLEARING, GRUBBING AND PREPARATION OF WORKS AREA: 164
7. STRIPPING, BENCHING AND FURROWING AND PLOUGHING 164
8. BENCHING UNDER EMBANKMENT 165
9. EXCAVATION OF CUTOFF OR PUDDLE TRENCH UNDER DAM
EMBANKMENT 165
10RECORDING OF CROSS SECTIONS. 167
11 CLASSIFICATIONS OF EXCAVATED MATERIAL 168
12 AUTHORITY FOR CLASSIFICATION 169
13 EXCAVATION 169
14 SLIDES/SLIPS: 170
15 OVER EXCAVATION: 170
16DEWATERING 171
17DISPOSAL OF EXCAVATED MATERIAL: 171
18EXCAVATION FOR APPEARENT WORKS: 172
19 CLASSIFICATION OF EXCAVATION: 173
20 CONSTRUCTION OPERATIONS: 173
21 PUBLIC SAFETY: 174
22 DAM EMBANKMENT CONSTRUCTION 174
23GENERAL REQUIREMENTS 178
24MATERIAL 178
25 PREPARATION OF GROUND SURFACE FOR EMBANKMENT: 179
26 COMPACTION & WATERING: 180
27 MOISTURE CONTROL: 185
28 SPECIAL PRECAUTIONS: 186
29DOWEL BANKS: 186
30WEATHER CONDITIONS: 186
31DRESSING SLOPES 186
32SETTLEMENT ALLOWANCE 187
33TOE DRAINS : 187
34SURFACE DRAINS: 187
35SIDE DRAINS: 188
36ROAD SURFACES AND PARAPETS 188
37PROTECTION: 188
38ROADS AND RAMPS: 188
39 (A) RIP-RAP ON THE UPSTREAM SLOPE OF EMBANKMENT 188
HAND PLACED RIP-RAP 188
39DRY STONE PITCHING : 190
40DRY PICKED UP BOULDER PITCHING 191
41DRY QUARRIED BOULDERS PITCHING 191
42ROCK TOE 192
43 BORROW AREAS 195
44 PREPARATION OF BORROW AREAS 195
45STRIPPING OF BORROW AREAS 195
46 BORROW PITS 196
47 BORROW AREA WATERING 196
48DRILLING AND BLASTING 196
49 USE OF EXPLOSIVES 197
50DISPOSAL OF DETERIORATED EXPLOSIVES 198
51PREPARATION OF PRIMERS 198
52CHARGING OF HOLES 198
53BLASTING 198
54ELECTRICAL FIRING 199
55PRECAUTIONS AFTER BLASTING 199
56 BEFORE COMPACTION 200
57 DURING COMPACTION 201
58 AFTER COMPACTION 201
59 FREQUENCY OF TESTING 201
60 RECORD AND REPORTS 202
61 FIELD TEST DATA 202
62 TURFING 203
1 GENERAL 139
2. STANDARDS 139
3. SCOPE: 140
4. PLANNING: 140
EMBANKMENT 142
66 EXCAVATION 146
69DEWATERING 148
77MATERIAL 155
82DOWEL BANKS: 163
86TOE DRAINS : 164
88SIDE DRAINS: 165
90PROTECTION: 165
95ROCK TOE 169
96 BORROW AREAS 172
99 BORROW PITS 173
106BLASTING 175
115 TURFING 180
1 GENERAL 163
1 TYPES OF GATES 163
2COMPONENTS & MATERIAL SPECIFICATIONS FOR DIFFERENT
GATES 163
3DESIGN CRITERIA 164
4 TYPICAL INSTALLATION OF VARIOUS TYPES OF GATES. 164
5SCOPE 165
6GENERAL SPECIFICATIONS FOR WORKMANSHIP, WELDING /
RIVETING, FINISHING AND PAINTING OF STEEL STRUCTURES
(GATES) 165
8FIXED WHEEL AND SLIDE GATES MANUFACTURES. 169
9SHOP ASSEMBLY & TESTING FOR GATES AND EMBEDDED PARTS 171
10 PAINTING 172
11 FIXED WHEEL AND SLIDE GATES ROPE DRUM HOIST 172
12FIXED WHEEL AND SLIDE GATE ERECTION 175
13INSPECTION OF BLOCK OUTS 175
14INSPECTION OF EMBEDDED PARTS 175
15INSPECTION OF THE GATE AT SITE OF ERECTION 176
16 FIXED WHEEL AND SLIDE GATES INSPECTION OF COMPLETE GATE
INSTALLATION 177
17 FIXED WHEEL AND SLIDE GATES TESTING 178
18SINGLE FACED SLUICE GATES (200 TO 1200 MM SIZE). 230
1. REFERENCES : 303
2. TERMINOLOGY 305
3. REINFORCEMENT : 307
4STRUCTURAL STEEL & IRON WORK 314
5 SPECIFICATION OF PRESTRESSED STEEL 333
ALL MATERIALS SHALL CONFORM TO SECTION 5 EXCEPT STEEL FOR
PRESTRESSING.THE PRESTRESSING STEEL SHALL CONFORM TO
EITHER OF THE FOLLOWING:PLAIN HARD DRAWN STEEL WIRE
CONFORMING TO IS: 1785 (PART I) AND IS: 1785 (PART II).COLD DRAWN
INDENTED WIRE CONFORMING TO IS: 6003HIGH TENSILE STEEL BAR
CONFORMING TO IS: 2090UNCOATED STRESS RELIEVED STRANDS
CONFORMING TO IS: 6006. 333
4 ANCHORAGES 334
5. TESTING OF PRESTRESSING STEEL AND ANCHORAGES 334
1 INTRODUCTION 256
2MATERIALS AND SOURCE: 256
3CONSTRUCTION TECHNIQUES: 256
4MACHINERY AND TOOLS: 256
5EMBANKMENT AND SUBGRADE 257
6EMBANKMENT WITH CONVENTIONAL EARTH: 257
7SUBGRADE WITH NATURAL EARTH 258
8SURFACE DRAINS 258
9SUB BASE (GRANULAR) 259
10BASE COURSE (GRANULAR) 260
11 SHOULDER 263
12 BITUMINOUS CONSTRUCTIONS 264
13 INTRODUCTION 274
14PRE-REQUISITE 274
15 SPECIFICATIONS AND CODES OF PRACTICE 275
16EARTH WORK AND GRANULAR LAYER 275
17BITUMINOUS COURSES 277
Sub-Section - 2: Preparatory Work
The contractor will be required to carry out the necessary surveys, investigations, and
preparation of land acquisition cases, to plan and layout the work on ground. The Contractor
shall be responsible for design of entire Dam and its components base on the survey and
investigation carried out
2Survey
The Engineer-in-Charge will make available to the Contractor datum points installed as
shown on the Drawings and/or by Site visit. The Contractor shall perform all necessary
surveys for Command Area, fixing alignment, for layout of structures, and preparation of cut
off statement.
2.1The Contractor shall check all datum points furnished by the Engineer-in-
Charge and submit the results to the Engineer-in-Charge. If there is any
discrepancy, the Engineer-in-Charge will make the necessary
corrections. From the datum points, the Contractor shall furnish and
place all additional stakes, templates and benchmarks necessary for
making and maintaining points, lines and elevations for layout of the
Works. All datum points shall be preserved by the Contractor, unless
approval is given to relocate them. Should any of the datum points need
to be relocated, such work shall be done by the Contractor, in
accordance with the instruction of the Engineer-in-Charge.
2.2The Engineers Representative reserves the right to check all survey work
at any time. The Engineers representative may also require correction
of inadequate surveys inaccuracies in layout of the Works or in
completion of field data by the Contractor.
2.3All field notes, computations and other records taken by the Contractor for
the purposes of surveys shall be submitted to the Engineers
Representative. All data shall be in a form suitable to allow checking.
2.4Survey Instruments and Personnel
Instruments, tools, equipment and materials for surveys shall be furnished by the
Contractor. Instruments shall be accurate, shall be subject to rigid inspection and any
defective instrument shall be promptly replaced repaired or adjusted. The following
instruments can be used for the survey works.
2.4.1Total Station Instrument
It is an instrument for precise measurement. The total station ranges with direct reflex
measurement for every day Survey Work. Total stations deliver huge versatility in a
compact and high performance package for data capture and field computations. The
total Stations provide an exceptional solution to a wide range of measurement
applications within a small, water resistant and rugged yet lightweight instrument
body capable of operating for many hours on a small internal battery.
The Direct Reflex capability of the total station makes easy to locates boundaries and
corners without gaining land access. Overhead cables, tunnels, bridges, quarry faces,
building and elevations can all be measured quickly and easily.
2.4.2Theodolite
It is an instrument for precise measurement of horizontal and vertical angles. These

are mainly of two types optional and vernier theodolites. An optical theodolite is
easy in manipulation, much lighter in weight and giving greater accuracy as compared
to any other type. The venier thedolite is not so precise as the optical one, but is still
largely used due to lower cost and simplicity of design. The optical theodolite of
specification conforming to IS:2976 1964 and the venier thedolite conforming to
specification of IS: 2988 1965 shall be used.
2.4.3Leveling Instrument
For first / second order leveling operations, primary / secondary levels or leveling
instructions are respectively used. The primary levels and secondary levels
conforming to specifications of IS: 9613 1980 and IS: 4590 1980 respectively
shall be used. Primary level is a high precision level used for height measurements for
topographical maps; engineering works such as tunneling, installation of heavy
machinery, hydroelectric project etc. height determination for geophysical purposes;
quantity reductions and to record changes of height. Secondary level is a medium
accuracy level used for second order leveling operations. These operations are under
taken for height determination for topographical works, installation of machinery,
construction of roads, railways, building works etc.
2.4.4Leveling Staff
These conforming to specifications of IS: 1779-1961 shall be used.
2.4.5Prismatic Compass
Prismatic compass, liquid and non liquid type conforming to specifications of IS:
1955-1961 and IS: 1957-1961 respectively shall be used.
2.4.6Metric Surveying Chains
These shall conform to specifications of IS: 1492-1970
2.4.7Ranging Rods
These conforming to specifications of IS: 2288-1963 shall be used.
2.4.8Vertical Staff Gauges

For the measurement of the water level on streams, different types of gauges,
recording and non recording are used. The vertical staff gauge is the type most used
because of its simplicity in installation and reading and because no mechanical device
is involved in its simple design. The requirements of specifications of IS: 4080-1967
shall be followed for the vertical staff gauges.
2.4.9Surveying chain pins (arrows), powrahs, Pick axes, Axes and Hammer:
Surveying chain pins conforming to specifications of IS: 1842-1961 and powrahs

conforming to specifications of IS: 1959-1983 shall be used. Pickaxes and beaters
used shall conform to specifications of IS: 273-1983. Ordinary hammer and axe shall
be used.
2.4.10Auger
Augers are of two types Hand augers and Spiral augers. These conforming to
IS:9110-1979 and IS: 10442-1983 shall be used for hand and spiral augers
respectively.
2.4.11Centre line stone
Chisel dressed cut stone of size 150mm x 150mm x 600mm shall be used in case, cut
stone is not available, these stones may be made of R.C.C. of size 100mm x 100mm x
450mm with nominal reinforcement.
2.4.12M.S. Plate with Anchor Bolts for permanent B.M.
M.S. Plate of size 120mm x 120mm x 6mm and anchor bolts of 10 mm dia and 300
mm length shall be used. These are to be used for standard bench marks of type
design given at Plate 2-P/1.
2.4.13Ordinary Bench Mark of Stone or R.C.C.
The ordinary bench mark shall be as per type design given at plate 2-P/2.
2.4.14Other Materials like pegs, paints etc.
Pegs may be made out of any ordinary jungle wood available near the site of work.
The size of pegs normally may be 150mm long, 500-600 sq. mm cross sectional area
at the top with lower 50mm long portion duly tapered to a point duly painted as per
specification.
2.5Accuracy
The accuracy of the survey work shall be within the following tolerances
triangulation:
- Allowable error of closure traversing: 10 seconds
- allowable error of closure 1/3000
- allowable error of distance leveling: 1/5000
- allowable error for each 1 km measured forward and backward 10mm
- allowable error of closure 10s05mm
where is the total distance of leveling expressed in km
2.6Reconnaissance and Study of Maps
2.6.1Before starting the reconnaissance it is necessary to thoroughly understand the

need, extent and limitations of the project. And before field reconnaissance is started, all
available data and maps detailed below shall be thoroughly studied to avoid waste and
repetition of effort.
i. Previous history of the area,

ii. Projects considered, investigated or constructed in the area,
iii. Topographical maps published by Survey of India,
Forest maps, maps from G.S.I. and Maps and data from Meteorological
department
2.7Guidelines for Survey investigation of Dam System
2.7.1The minimum surveys and investigations necessary for the purpose are as below:
i. Topographical surveys including preparation of survey plans to cater to the

requirements of Appendix
ii. Geological and Foundation Investigations C.W.C. guidelines for foundation
investigation of major projects are appended at appendix-
iii. Pre-irrigation soil survey and drainage soil survey.
iv. Construction Material investigations Guide lines for investigations for suitability of
construction materials are appended at Appendix .
v. Construction planning.
vi. Other miscellaneous investigation for acquisition of land under submergence,
rehabilitation measure if any,
2.8For chain and compass survey, generally no jungle clearance is required to

be done. However when the alignments are passing through jungle
other than the reserved forest, and its clearance is considered necessary
by the Engineer-in-Charge, then ordinary, medium and thick jungle
clearance depending upon the type of jungle involved can be carried out
with prior sanction/permission from the competent authority. But such
jungle clearance in widths not exceeding 1.5 m for alignment and one
metre for cross sections can only be done after obtaining prior specific
sanction of the competent authority, which shall include the type of
jungle clearance to be done in different lengths and widths as
considered necessary. When it is necessary to survey through a reserve
forest, prior sanction from the competent authority shall be required to
be taken as per the Forest Conservation Act 1980.
2.9Length of Survey
Length of the survey shall be measured along the lines on which particular type of
survey is done. For chain and compass survey it would be the length along which
chaining and compassing is to be done. For leveling, it would be the total length of the
lines along which levels are to be taken.
2.10Chaining of Final Alignment
It shall be done with due precision after setting of curves.
2.11Marking on village maps
The surveyed alignments and cross sections shall be marked on the concerned
village/Forest maps. In case of Catchment area and submergence survey, Survey Party
for Double Leveling The survey party for double leveling should invariably be headed
by the Sub-divisional Officer concerned or an officer not below the rank of an
Assistant Engineer.
2.12The general instructions for carrying out systematic leveling work and
making entries in the field/level book as appended at Appendix VII shall be
followed.
2.13DAG BAILING IN ALL TYPES OF SOIL
Dag bailing shall only be done in all types of soil which can either yield to the
ordinary application of pick and shovel, or to spade, rake or other digging implement,
and or can be removed by this ordinary application after loosening with pick axe. This
work shall normally be done for the final alignments approved by the competent
authority. The work in single spade stroke (minimum 75 mm deep) shall be carried
out for all medium and minor irrigation canal works; whereas the work in double
spade V shaped stroke (100 mm deep) shall be carried out for all major irrigation
projects and all dam alignments.
2. GEOTECHNICAL INVESTIGATION
The contractor will have to carry out detailed subsurface Geo Technical
Investigation by taking boreholes at every 500 m spacing along the
alignment of the canal. The holes will be drilled below one meter the
bed level of the canal. The contractor will lavel in position of structure
or 1.2 m below the foundation level. The contractor will submit detailed
engineering Geo Technical and rock mechanics analysis report
based on bore hole data and shall prepare Geo Technical L-Section
along the canal alignment that will decide lining of the canal system.
The contractor will then prepare detailed design and submit for
approval of the Engineer before commencement of actual work of
construction.
2.1 Exploration by Pits/Trenches/Drifts/Adits and Shafts
Open test pits, trenches, drifts and shafts are features accessible for visual
examination in sub surface exploration and exploration and afford the most complete
information on the ground penetrated. Location of pits, trenches, drifts and shafts
shall preferably be decided in consultation with an engineering geologist; invariably
to be followed for the medium and major irrigation projects.
2. Exploration by Test Pits
1. Pits are dug manually but mechanical equipment may also be used for
the purpose upto shallow depths. N dry ground, pits are economical in
comparison to bore holes upto a depth of about 5 m depending upon
the location. As the depth increases, the cost of excavating a it
increases very rapidly and it is seldom that unsupported pits are dug to
a depth exceeding 6 m except in the case of hard soils. The top of a pit
shall be kept large enough so that the dimension of the pit at the
bottom may be at least 1.2 m x 1.2 m which are sufficient to provide
necessary working space. Additional space for sheeting and timber
supports, hoisting arrangements and ladder, etc. shall be provided. A
recommended proforma for the recording of information obtained from
trial pits is given in Appendix II (A).
2. For deep pits in soil, the walls shall be supported by timber. Typical
sheeting and bracing to be adopted in such cases in shown in Plate 2-
P/3. Instead of sheeting and bracing, cribbing with 75x150 mm timber
may be used and the arrangement is shown in plate 2 P/4. In loose
materials, it is advisable to keep the space between the pit walls and
the cribbing at a minimum and also to pack the space with hay or wood
shavings, and to keep the bottom of cribbing close to the bottom of the
pit. The material from such pits is removed by buckets operated from a
hoist or windlass which should be equipped with a ratchet devise for
safety. During excavation, the bottom of the pit should be kept fairly
level and of full selection so that each lift may represent the
corresponding portion of the deposit in quality and quantity. The
excavated material should be placed round the pits as stock piles,
separated when significantly different materials are encountered, and
marked stackes should be driven into the stockpiles to indicate the
depth from which the materials were excavated in order to facilitate
logging and sampling later on. The excavated material should be
placed round the pits in the manner it is received from the excavation,
preferably in a clockwise direction. The deposits of excavated material
from the pit at every change in strata should be dumped separately in
the manner described above. Samples from these deposits should be
taken as soon as material comes out of the pit and the natural water
content of the excavated material determined.
3. Test pits left open for inspection shall be provided with covers or
barricades for safety. Pits and trenches shall be suitably fences.
Trenches and pits should be filled back properly when exploration and
physical inspections are completed and the relevant records have been
obtained.
4. When water is encountered in a pit, a suitable dewatering system may
be required for further progress. Where suction pumps are used it is
desirable that the suction hose be 10 mm larger in diameter than the
discharge opening of the pump and the suction head not more than 4.5
m. This required resetting the pump in the pit (on a frame attached to
the cribbing) at intervals of about 3.5 m. When an internal combustion
engine is used in the pet. It would be necessary to lead the exhaust
gases well away from the pit.
5. Undisturbed samples may be obtained from open pits from each
stratum if the nature of the deposit permits. For this purpose a pillar of
suitable dimensions, say, 40x40 cm should be left undisturbed at the
centre of the pit to collect undisturbed samples of required size from
each layer showing a change of for mation. If the thickness of each
layer exceeds 2 m, a second sample may be taken. These undisturbed
samples will be useful for the determination of several characteristics
of the in situ materials. Special care shall be taken to preserve the
natural moisture content of the samples.
3. Hand Auger Borings

1. Augur boring is the most common, economical and rapid
method for relatively shallow exploration of fine-grained
materials above the water table. Hand augers become
awkward and cumbersome beyond a depth of
approximately 6 m. If the work is done carefully, the layers
of different soils may be accurately located, identified and
suitable distributed samples obtained.
2. In making auger borings it is often necessary to add water to
soften a hard, dry, clayey soil so that the auger will penetrate the
soil. Also, if dry sands or silts are encountered the addition of
water will make the soil slightly cohesive and easier to pick up by
the auger. Cohesive soils can be augered successfully below the
ground water table. However, if clean non cohesive silts of
sands are encountered below the water table, they are very
difficult to extract from the hole and such material will cave unless
the hole is cased.
4. Rotary Drilling
Rotary Drilling shall be carried out with or without coring. For rotary drilling with
coring, double core barrels giving core diameters of at least 52 mm shall be used. The
radial deviation of boreholes shall not exceed 5% of the borehole depth.
1. Wherever necessary, and as approved by Engineer-in-Charge drill
holes shall be provided with casings through overburden and in rock of
poor quality. The length through overburden may be drilled without
coring. Filling of part of the hole with grout and subsequent re-drilling
shall be carried out as necessary in zones of poor rock quality.
2. In specific case, as approved by Engineer-in-Charge drill holes shall
remain open. In those cases the upper end of the hole and the part of
the hole extending through the overburden shall be provided with a
pipe closed by a cap.
3. During drilling with coring the rotation speed, feeding pressure and
amount of flushing water shall be adopted to the rock properties, so as
to obtain cores of the best possible quality.
4. Cores shall be placed in core boxes of wood or metal. The depth of
each run shall be noted in the box and core losses marked by pieces of
wood of corresponding length. The core boxes shall be transported to
and kept in a core store.
5. The water levels in the drill holes shall be measured when first
encountered and at the beginning and end of each shift. An electrical
device, including spares, shall always be available for this purpose.
6. Records of core drillings shall be submitted on daily basis within 24
hours and shall comprise.
7. Core recovery per run, as well as all core losses, Rock Quality
Designation and fracture spacing.
- Depth of each run
- Water level in the drill hole when encountered at the beginning and end of the shift.
- Length of casing, lengths grouted and re-drilled.
The form of the record shall be as agreed with the employers
3. supplementary conditions
3.1 The Contractor, shall assume full responsibility of Engineering adequacy,
coordination and timely completion of investigation, designs, drawings
and detailed estimates including all other activities with their own
modern equipment, man power and other services required connected
to the work.
3.2 The Contractor shall be fully responsible for designing and estimating of
all the connected and component works of the project. The
responsibility of the Contractor shall be,
1. To study in detail all the Engineering and design features.

2. to prepare technical specifications which are necessary for
execution of works.
3. The Contractor shall be responsible for furnishing the most
technically suitable and economical proposals. The Contract
price quoted shall include the cost of investigation, alternative
investigation, site surveys, designs, alternative designs,
estimates etc., to arrive at most economically and technically
sound and suitable proposals. No separate payment shall be
made for study of alternatives.
4. The designs and specifications are to be drafted by the
Contractor.
5. Cost of estimate.
The Contractor shall submit a complete cost estimate adopting prevailing market rates
and with current rates of prevalent U.S.R For adopting the market rates, the
quotations from the reputed firms are to be obtained and enclosed for the
items not covered by the U.S.R.
6. Preparation of all designs, drawings, estimates, command area
registers and land acquisition schedules as may be required for
complete and correct execution of all works which are included
in the scope of the work for the block, and should conform to
I.S.I specifications. All the above plans and documents shall be
supplied in 5 copies to the Executive Engineer incharge of the
work for onward submission to the competent authority i.e.,
Chief Engineer, Dhasan Ken Besin Sagar, Superintending
Enigneer, Water Resources Circle Chhatarpur (M.P.) for
approval. It is obligatory for the Contractor to make any
modifications or alternations for designs & drawings as
required by the Department and also in the proposals without
any extra payment.
7. The department shall not provide the village maps/and other
particulars to Contractor. The Contractor shall have to procure
the connected village maps and revenue records from Officers
of Revenue Department i.e. Patwari, Inspector, and Niab
Tehsildar etc. and settlement department of the restrictive area
at their own cost village Patwari. Necessary authorization letter
recommending for the issue of the above maps will be issued
by the Engineer-in-Charge.
8. Investigation of PAWAI Irrigation Project dam land &
properties survey of F.R.L. & properties survey upto M.W.L.
conducting site survey for, preparation of estimates of Dam and
its Components.
1.0 Block command Plans with 1.00M interval contours as applicable to the block.
Block command Plans are to be prepared by conducting the following items of
work.
1.1 Reconnaissance survey of PAWAI irrigation Project with the command area F.R.L.
& M.W.L. etc. verifying the village plans and topo-sheets.
1.2 By fixing the base lines and boundary lines of the area with total station and GPS
Software.
1.3 Conducting block levelling by taking levels at 100m intervals and duly taking the
net levels at closer intervals viz., 30m, 15m, 5m etc., wherever the sudden
changes of the ground occur such as nalla, rivers, mounds, ponds, dips etc., to
obtain the clear and defined configuration of the same.
1.4 Plotting C.S net levels or block levels on the concerned village plans of 1:4000
Scale, and drawing the contours at 1.00M intervals and marking the block
command plans in serial numbers as per G.S.I topo sheets pattern.
3. Detailed Survey:
Detailed survey shall be conducted for fixing the alignment of Main Dam / Subsidiary
Dam and its all components as follows:
1. Chaining
2. Taking L.S levels at 5m intervals and Cross sections shall be taken @
3m intervals along the Dam alignment and C.S. levels on the C.S at
3M intervals to a width of 90m or more on either side of the alignment
for main Dam and its components depending upon the actual
requirement.
3. Fixing of Centre Line stones of size 750mm x 150mm x 150 mm as per
the drawing enclosed at every 15m intervals along the alignment and at
every tangent points of the curve and @ I.P points etc. The Centre Line
Stones, I.P. Stones and stones at tangent points should be painted with
different colours for each, for clear identification fixing of F.R.L. stone
and MWL at every 150 m interval with different colours.
4. Painting of the stones with good quality of paint approved by the
Engineer-in-Charge.
5. Preparation of Hydraulic Particulars may be taken up only after
approval of alignment by competent authority i.e., Chief Engineer,
Dhasan Ken Besin Sagar (M.P.).
4. Drilling of Bore-Holes/ Trail pits for Dam and its Components:
1. Boreholes shall be drilled at every interval along the centerline of
the Dam and its Components for excavations.
2. Classifying the soils and noting the classification of soils in T.P /
Bore Hole Register
3. Bore holes shall also be drilled 10m beyond the maximum scour
level, or up to hard strata which ever is less for all the dam
components and core-samples of distrurbed and un-disturbed soils
are to be tested in the laboratory, to find out the bearing capacity
of soils; and the samples are to be preserved for verification by the
Engineer-in-Charge. Minimum 3 Numbers of bores one at center
of crossing, the other two on u/s and D/s of crossing are to be
drilled for each structure. Extra Bores are to be drilled wherever
necessary, depending upon the magnitude of the structure Log
book of the bores drilled shall be maintained at site, during
progress of drilling, besides preserving the core samples in wooden
core boxes at site.
5. Preparation of Estimates:
1. Earth Work Excavation:
1. The estimate of PAWAI Irrigation Project Project including earthen dam, composite
dam (central spillway) non overflow portion, radial gate, instrumentation, lighting of
gallery and top of dam, 33 KV station, dewatering pump in gallery with river
diversion work and all other connecting work.
2. The estimates for excavation and formation of PAWAI Irrigation Project Dam are to
be prepared based on the approved Hydraulic particulars and based on classification
of soils as per bore hole/ Trail pits data.
3. Cross sectional area of Dam and its components are to be worked out as per cross
sections plotted at 5m intervals.
4. Quantities of different soils may be worked out separately based on the areas
computed by preparing earth work area statements.
5. Necessary leads and lifts are to be calculated for different types of soils.
6. Rate analysis may be worked out as per current U.S.R 2009.
7. Abstract estimate may be prepared for the earth work estimates.
8. Report accompanying the estimate as per investigation standards covering all the
necessary points shall be prepared, and all salient features shall be thoroughly
discussed in the report.
3. Final Report
4.1Final report is to be prepared for each village separately covering the
following points.
4.2 F.R.L. survey with land acquisition case of land and properties.
4.3 M.W.L. survey with land acquisition case of properties.
4.4 Maintenance and operation manual with all relevent record and drawing
including as per direction of engineer-in-charge. ,
4.5 CHECKING OF SURVEY WORK:
4.5.1 The checking of field survey work, Longitudinal Section of canals and F.C and
establishment of Bench Marks to an extent of about 25% of the total work will
be carried out concurrently or separately by the department during progress of
survey. Necessary equipment and labour for carrying out such checking by the
Department shall be provided by the contractor / Tenderer.
APPENDIX I
TOPOGRAPHICAL SURVEYS, EXTENT, SCALES, CONTOUR INTERVAL, ETC.
S.No. Description Area to be Scale Contour Remark

covered/Extent Interval
of surveys
(1) (2) (3) (4) (5) (6) (7)
1. River surveys (i) L-Section 1 :10,000 1:100 - Leveling at 50m or
less interval along
(a) Major Upstream-L- the fair weather deep
project Section upto channel. Following
MWL + 5m or items shall be
to a point upto indicated on the L-
which the back Section:
water effect is
likely to extend (i) Date of survey of
from the axis of the particular
the structure, reach and water
whichever is level on that day.
less in case of
any head works (ii) Deep pool and
situated rapids, rock out
upstream crops etc.
within MWL +
5m or far these (iii) Max. Historical /
points affected observed HFL
by back water,
L-Section to be
taken upto head
works.
Downstream - 1:10,000 1:100 - - do -
10 km. from the
axis of
structure or
upto nearest
head work
whichever is
less
(ii) Cross 1:2500 1:100 - Leveling at the 50m
section : or less interval.
Following items
Upstream -X- shall be shown on
section @200m the cross-section
interval upto
MWL + 5m or i. Date of
1km. on either survey and
side of the firm water level
of surveys
(1) (2) (3) (4) (5) (6) (7)
bank whichever on the day.
is less and for a ii. Maximum
distance of water level.
2Km. from the
axis of the iii. Maxi
structure and historical /
thereafter at 1 observed
Km. interval HFL
corresponding
to the length of iv. Rapids and
the L-section. rock out
crops etc.
2. Reservoir Contour plan 1:2500 - 1 to 2 or 3m Contour interval for
covering on stone less then 10 to
(a) Major area upto an horizontal - 1 m,
Project elevation of slope 10 to 30, 2m,
MWL + 5m and slope more than
30 - 3m.
3. Dam and Grid plan with 1:2500 - 1 or 2 or 3m Contour intervals as
Dyke : contours of the per i`tem 3(a) above
site covering block leveling to be
(a) Major the area upto on 10m grid basis.
project 250m upstream
and 500m m
downstream of
the axis
extending upto
an elevationof
MWL + 5m or
more depending
upon the site
conditions (tail
channel) are
shall be
adequately
covered).
4. Soil Plan of area 1:10000 - 10m or less This may be carried
Conservation subject to or 1: out for major and
Survey erosion, slides 50000 medium projects
and slips. depending upon the
location of the area.
5. Geological Reservoir and Same as recommended under -
Maps river valley each item above or otherwise as
structure (dams, stated in the Geological report.
Barrage,
of surveys
(1) (2) (3) (4) (5) (6) (7)
Tunnel, Power
House
Penstocks,
Water
Conductor
System and
important
structures on
Canal.
6. Foundation Plan : 1:2500 - As specified Showing location of
Investigation above for the structures, bore
Maps Major 1:2500 corresponding holes, trial pits, drifts
Medium, 1:1000 structure. and points where in-
situ tests were
Minor conducted etc.
Cross Section : 1:2500 1:100 - Showing logs of bore
holes, trial pits, drifts
Major 1:2500 1:100 etc. and other feature
Medium 1:1000 1:100 of the foundation.
Minor
7. Borrow area Plan : 1:2500 - 0.5 or 1m Showing location of
and Quarries different materials of
Major construction pit/ drill
holes.
Sections : 1:2500 1:100 - Showing profile
along the grid lines
Major upto the depth
explored.
8. Soil Surveys Plan : 1:10,000
or
Major 1:15,000
APPENDIX II
Structure Minimum pattern of drilling

Spacing of Drill Holes/Pits/Drifts Depth of Drill Holes/Pits/Drifts
(1) (2) (3)
(a) Earth & Drill holes along the axis 150 m or Depth equal to half the height of the
rock fill dam less apart, with intermediate pits to
embankment at the elevation of the
delineate weak and vulnerable hole or five meter in the fresh rock
strata with a minimum number of (proved by the geo-physical or any
three to five holes in the gorge other suitable method) whichever is
portion and additional to on each less. About two holes to be extended
abutment parallel to the flow deep (equal to the maximum height
Drifts on each abutment at about 60 of the embankment in the absence of
m elevation interval with a rock at higher elevation) in the gorge
minimum of one abutment. portion and one each in abutments.
Drifts to be extended 5 m in
geologically sound strata for keying
the embankment in the absence of
rock.
(b) Masonary Drill holes along the axis at 100 m 110 m in fresh rock (proved by geo-
& concrete interval or less apart to delineate physical or any other suitable
dam / structure weak and vulnerable strata with a method) About two holes to be
minimum number of 3 to 5 holes in extended deep (equal to the
the gorge portion and additional maximum height of the embankment
two on each abutment parallel to in the absence of rock at higher
the flow. elevation) in the gorge and one each
Drifts on each abutment at about abutments.
60m elevation interval with a 10m in fresh rock (proved by
minimum of one each abutment. geophysical or any other suitable
method).
Note:
1. A minimum pattern of drilling holes and excavation of pits and drifts

has been above. Addition holes shall be drilled and pits/drifts
excavated in consultation with the Geologist/Research laboratory to
bring out clearly the foundation and abutment characteristics especially
the weak zones requiring special treatment.
2. Disturbed and/or undisturbed soil samples, foundation of rock samples, etc shall be
collected and tested at an interval of 1.5 m depth or change of strata for
laboratory tests. In situ permeability tests shall be carried out in the selected drill
holes in the different strata at different elevations. Other in-situ tests shear tests
etc shall be carried out in the holes or other suitable locations depending up on
the nature of the strata and design requirements.
3. The bearing capacity test and in-situ testing of the foundation rock shall be carried
out for item (f) to (g) at average foundation level.
4. The plans and cross section shall be prepared on the scale as indicated in Appendix
I
5. the Logs of the holes/pits/drifts shall be prepared as per Appendix II(A) to II(B)
enclosed.
APPENDIX II (A)
LOG OF TEST PIT BORROW AND FOUNDATION
INVESTIGATIONS
Feature Project . Test pit No. ..
Area designation . Co-ordinates . Ground Elevation .. Depth to ground water level ..
Method of excavation Approximate dimensions of hole Dates of excavation Hole
logged by.
Classific Dept Size Classifica Volum Weigh Percent Weigh Percent Weigh Percent Locati
ation h and tion and e of t of 0 age by t of 75 age by t of age by on of
Symbol (M) type Descripti Hole to volume to volume Plus volume in situ
Letter of on of Sampl 75mm of 0 to 125m of 75 to 125m of plus tests
Graphics Samp Material ed (M) Materi 125mm m 125mm m 125mm
le (give al in material Materi material Materi material
Taken Geologic Sampl al in . al in
al and in e sampl sampl
place e e
descriptio (K.G.)
n for
Foundatio
n
Investigat
ion)
Remarks
Record after water has reached its natural level.

This may be done as given in IS: 1498-1970 Classification and identification of soil for
general Engineering purposes (First revision)
(Weight of rock sampled X 100)/(Bulk specified gravity of rock) x (volume of hole sampled).
Record water test and density test data, if applicable, and also bulk specific gravity stating
how obtained (measured or estimated) under remarks.
APPENDIX II(B)
DAILY DRILL REPORT
Project Location Feature
Drill No. and type Pump No.
Collar elevation : Capacity and pressure used :
Ground elevation: Hole No. :
Date : Co-ordinates:
Shift: From . H to . H: Bearing of hole:
Depth of Water level Angle with vertical:
Depth drilled during the shift:
From to ..
At start of shift :
At end of shift :
Run Length Type Colour Type Water Core recovery Rate of Remark
Drilled and of of Loss penetration s
mm size Return soil/ with mat/min
of water Rock Depth
hole
From To Length Percentage Sl.
No. of
M M Cores
1 2 3 4 5 6 7 8 9 10 11 12
Supplies Casing Lowered Bits Used

Petrol Diesel Motor Misc. Size From To Type and From To Old or new
Oil Depth depth Size Depth depth with number
Drill Foreman/Supervisor Operator

Officer-in-Charge Drill Observer
DRILL OBSERVERS REMARKS
(1) Water loss during drilling may either be recorded as :
i. Complete when no water is coming out : partial : or nil water loss : or
ii. In percentage of return water (100 percent loss when no water is coming back and no
water loss (0 percent) when all the drilling water is coming back).
2. Penetration speed to special zones (soft or broken zones) and other details of
drilling like heavy vibration recorded during drilling.
3. Reasons for heavy core loss as integrated with speed of drilling;
4. Any special conditions not recorded for examere depth at which blasting was
done while driving casing, depth at which note was ground antesian water
conditions (if any observed) during drilling.
5. If water flows are encountered at the collar of the drill, then the pressure head
and discharge at the collar should be recorded. On completion of the hole, the
pressure decline over a period of time should also be recorded.
APPENDIX III
INVESTIGATIONS FOR ESTABLISHING
SUITABILITY OF CONSTRUCTION MATERIALS
1. EARTH FOR DAM
Following investigations shall be carried out :
i. The plans and sections of the borrow area shall be made on a scale of 1:2500 with
contour interval of 0.5m, showing the location and logs of test pits, bore holes spaced
about 150m apart and demarcating different types of soil. The lead for different types
of soil from the site of work for different borrow areas shall also be indicated. The
borrow areas shall be located as near the dam site as possible but not less than five
times the head of water (H) away from the toe or heel of the dam for major dams and
not less than 10 H away from the toe or heel of the dam for medium and minor dams.
ii. Soil samples shall be tested for mechanical analysis, atterberg limits, Proctor
compaction, permeability, triaxial shear tests with pore pressure measurements under
O.M.C. and saturation conditions, and suitability tests in soils with high soluble
content.
iii. The sand and gravel to be used for filters shall be tested as for concrete aggregate.
iv. Units of earthwork sampling for suitability shall be taken as per the following table :
S.No. Particulars Major Project
1. Profile E/W Quantity Above 1400 thousand cubic metre
2. Borrow are E/W quantity Above 2100 thousand cubic metre
3. Units fo profile E/W sampling 20 thousand cubic metre
4. Units of borrow area quantity 30 thousand cubic metre
5. Sampling Number of samples Minimum 100 and maximum 200
samples.
APPENDIX IV
INVESTIGATIONS FOR ESTABLISING SUITABILITY OF
CONSTRUCTION MATERIALS
1. Concrete Structures
Following investigations shall be carried out

i. Geological and related characterization of aggregates including type of
deposits, classification and characteristics of rocks, chemical suitability of
aggregates and strength tests.
ii. Investigations for the availability of natural artificial pozzolana with their
characteristics
iii. The construction material shall be tested for petrographic analysis of sand and
rock samples, grading and physical tests of sand and rock samples to assess
their suitability, presence of reactive aggregates in the area, pozzolana
materials and strength of permeability test
2. Earthwork/Embankment
Following investigation shall be carried out

i. The plans and sections of the barrow area shall be made on scale of
1:2500 with contour interval of 0.5 m showing the location and logs of
test pits, bore holes spaced about 150 m apart and demarcating
different types of soil. The lead for different types of soils from the site
of work for the different borrow areas shall also be indicated. The
borrow areas shall be located as near the embankment as possible but
not less than five times the head of water (H) away from the toe of
major embankment and ten times the head of water (H) for medium
and low size of embankment.
ii. Soil samples shall be tested for mechanical analysis, Atterberg limits,
Procter compaction, permeability, triaxial shear tests with pore
pressures measurements under OMC and saturation conditions, and
suitability tests in soils with high soluble contents.
iii. The sand and gravel to be used for filters shall be tested as for concrete
aggregates.
iv. Units of earthwork sampling for suitability shall be taken as per the
following tables
S. Particulars Minor Project Medium Projects Major projects
No.
1. Profile E/W Quantity 140 thousand 140 thousand
Above 1400
cubic meter cubic meterthousand cubic
meter
2. Borrow area E/W Quantity 210 thousand 210 to 2100 Above 2100
cubic meter thousand cubic thousand cubic
meter meter
3. Units of profile E/W 5.5 thousand 14 thousand cubic 20 thousand
sampling cubic meter meter cubic meter
4. Units of borrow area 8.5 thousand 21 thousand cubic 30 thousand
quantity cubic meter meter cubic meter
5. Sampling Number of Minimum 10 Minimum 25 Minimum 100
samples samples samples and maximum
samples
APPENDIX -
LOCATION AND NUMBER OF M.M.
Standard / Permanent Ordinary or temporary

S.No. Particulars B.M. B.M.
Location & No. Location & No.
(1) Major Dam One on either bank i. Dam alignment excluding
along the alignment river portion @10 chains
&
located D/S at a distance
Medium Dam of five times the height of
the dam away from the
C/L of the dam.
ii. One on waste weir at a
distance of 2 chains from
the mid point of the C/L
of the alignment.
iii. Spill channel & approach
channel alignment one @
every 10 chains.
(2) Minor Dam One on one bank - Same as for Sl. No. 1 above -
VOLUME III
SECTION - 3
LAND ACQUISITION
THE LAND ACQUISITION CASES ARE TO BE PREPARED AND SUBMITTED IN
THE FORMATS PRESCRIBED BY THE AUTHORITY COMPETENT TO PASS THE
AWARDS. RULES AND REGULATIONS IN RESPECT OF LAND ACQUISITION AS
ENFORCED TIME TO TIME ARE TO BE STRICTLY FOLLOWED.
VOLUME III
SECTION - 4
EXCAVATION
CONTENTS
GOVERNMENT OF MADHYA PRADESH 48

TENDER DOCUMENT 49
TURNKEY TENDER 49
50
SECTION 7: GATES 51
Volume - III 52
Section I 52
GENERAL 52
SPECIFICALLY, THEN RELEVANT SPECIFICATION UNDER INDIAN STANDARDS /
IRC PUBLICATIONS SHALL PREVAIL. 52
Volume III 53
Section - 2 53
Preparatory Work 53
INDEX 53
2 Survey 58
2.1 THE CONTRACTOR SHALL CHECK ALL DATUM POINTS
FURNISHED BY THE ENGINEER-IN-CHARGE AND SUBMIT THE
RESULTS TO THE ENGINEER-IN-CHARGE. IF THERE IS ANY
DISCREPANCY, THE ENGINEER-IN-CHARGE WILL MAKE THE
NECESSARY CORRECTIONS. FROM THE DATUM POINTS, THE
CONTRACTOR SHALL FURNISH AND PLACE ALL ADDITIONAL
STAKES, TEMPLATES AND BENCHMARKS NECESSARY FOR MAKING
AND MAINTAINING POINTS, LINES AND ELEVATIONS FOR LAYOUT OF
THE WORKS. ALL DATUM POINTS SHALL BE PRESERVED BY THE
CONTRACTOR, UNLESS APPROVAL IS GIVEN TO RELOCATE THEM.
SHOULD ANY OF THE DATUM POINTS NEED TO BE RELOCATED, SUCH
WORK SHALL BE DONE BY THE CONTRACTOR, IN ACCORDANCE
WITH THE INSTRUCTION OF THE ENGINEER-IN-CHARGE. 58
2.2 THE ENGINEERS REPRESENTATIVE RESERVES THE RIGHT TO
CHECK ALL SURVEY WORK AT ANY TIME. THE ENGINEERS
REPRESENTATIVE MAY ALSO REQUIRE CORRECTION OF
INADEQUATE SURVEYS INACCURACIES IN LAYOUT OF THE WORKS
OR IN COMPLETION OF FIELD DATA BY THE CONTRACTOR. 58
2.3 ALL FIELD NOTES, COMPUTATIONS AND OTHER RECORDS TAKEN
BY THE CONTRACTOR FOR THE PURPOSES OF SURVEYS SHALL BE
SUBMITTED TO THE ENGINEERS REPRESENTATIVE. ALL DATA
SHALL BE IN A FORM SUITABLE TO ALLOW CHECKING. 58
2.4 SURVEY INSTRUMENTS AND PERSONNEL 58
2.5 ACCURACY 60
2.6 RECONNAISSANCE AND STUDY OF MAPS 60
FOREST MAPS, MAPS FROM G.S.I. AND MAPS AND DATA FROM
METEOROLOGICAL DEPARTMENT 60
2.7 GUIDELINES FOR SURVEY INVESTIGATION OF DAM SYSTEM 61
2.8 FOR CHAIN AND COMPASS SURVEY, GENERALLY NO JUNGLE
CLEARANCE IS REQUIRED TO BE DONE. HOWEVER WHEN THE
ALIGNMENTS ARE PASSING THROUGH JUNGLE OTHER THAN THE
RESERVED FOREST, AND ITS CLEARANCE IS CONSIDERED
NECESSARY BY THE ENGINEER-IN-CHARGE, THEN ORDINARY,
MEDIUM AND THICK JUNGLE CLEARANCE DEPENDING UPON THE
TYPE OF JUNGLE INVOLVED CAN BE CARRIED OUT WITH PRIOR
SANCTION/PERMISSION FROM THE COMPETENT AUTHORITY. BUT
SUCH JUNGLE CLEARANCE IN WIDTHS NOT EXCEEDING 1.5 M FOR
ALIGNMENT AND ONE METRE FOR CROSS SECTIONS CAN ONLY BE
DONE AFTER OBTAINING PRIOR SPECIFIC SANCTION OF THE
COMPETENT AUTHORITY, WHICH SHALL INCLUDE THE TYPE OF
JUNGLE CLEARANCE TO BE DONE IN DIFFERENT LENGTHS AND
WIDTHS AS CONSIDERED NECESSARY. WHEN IT IS NECESSARY TO
SURVEY THROUGH A RESERVE FOREST, PRIOR SANCTION FROM THE
COMPETENT AUTHORITY SHALL BE REQUIRED TO BE TAKEN AS PER
THE FOREST CONSERVATION ACT 1980. 61
2.9 LENGTH OF SURVEY 61
2.10 CHAINING OF FINAL ALIGNMENT 61
2.11 MARKING ON VILLAGE MAPS 61
2.12 THE GENERAL INSTRUCTIONS FOR CARRYING OUT SYSTEMATIC
LEVELING WORK AND MAKING ENTRIES IN THE FIELD/LEVEL BOOK
AS APPENDED AT APPENDIX VII SHALL BE FOLLOWED. 61
2.13 DAG BAILING IN ALL TYPES OF SOIL 61
THE CONTRACTOR WILL HAVE TO CARRY OUT DETAILED
SUBSURFACE GEO TECHNICAL INVESTIGATION BY TAKING
BOREHOLES AT EVERY 500 M SPACING ALONG THE ALIGNMENT OF
THE CANAL. THE HOLES WILL BE DRILLED BELOW ONE METER THE
BED LEVEL OF THE CANAL. THE CONTRACTOR WILL LAVEL IN
POSITION OF STRUCTURE OR 1.2 M BELOW THE FOUNDATION LEVEL.
THE CONTRACTOR WILL SUBMIT DETAILED ENGINEERING GEO
TECHNICAL AND ROCK MECHANICS ANALYSIS REPORT BASED ON
BORE HOLE DATA AND SHALL PREPARE GEO TECHNICAL L-SECTION
ALONG THE CANAL ALIGNMENT THAT WILL DECIDE LINING OF THE
CANAL SYSTEM. THE CONTRACTOR WILL THEN PREPARE DETAILED
DESIGN AND SUBMIT FOR APPROVAL OF THE ENGINEER BEFORE
COMMENCEMENT OF ACTUAL WORK OF CONSTRUCTION. 62
2.1 EXPLORATION BY PITS/TRENCHES/DRIFTS/ADITS AND SHAFTS 62
2.3 HAND AUGER BORINGS 63
2.3.1 AUGUR BORING IS THE MOST COMMON, ECONOMICAL AND
RAPID METHOD FOR RELATIVELY SHALLOW EXPLORATION OF FINE-
GRAINED MATERIALS ABOVE THE WATER TABLE. HAND AUGERS
BECOME AWKWARD AND CUMBERSOME BEYOND A DEPTH OF
APPROXIMATELY 6 M. IF THE WORK IS DONE CAREFULLY, THE
LAYERS OF DIFFERENT SOILS MAY BE ACCURATELY LOCATED,
IDENTIFIED AND SUITABLE DISTRIBUTED SAMPLES OBTAINED. 64
3. supplementary conditions 65
3.1 THE CONTRACTOR, SHALL ASSUME FULL RESPONSIBILITY OF
ENGINEERING ADEQUACY, COORDINATION AND TIMELY
COMPLETION OF INVESTIGATION, DESIGNS, DRAWINGS AND
DETAILED ESTIMATES INCLUDING ALL OTHER ACTIVITIES WITH
THEIR OWN MODERN EQUIPMENT, MAN POWER AND OTHER
SERVICES REQUIRED CONNECTED TO THE WORK. 65
3.2 THE CONTRACTOR SHALL BE FULLY RESPONSIBLE FOR
DESIGNING AND ESTIMATING OF ALL THE CONNECTED AND
COMPONENT WORKS OF THE PROJECT. THE RESPONSIBILITY OF
THE CONTRACTOR SHALL BE, 65
3.3. DETAILED SURVEY: 66
3.5 PREPARATION OF ESTIMATES: 67
4 Final Report 68
4.1FINAL REPORT IS TO BE PREPARED FOR EACH VILLAGE
SEPARATELY COVERING THE FOLLOWING POINTS. 68
4.4 MAINTENANCE AND OPERATION MANUAL WITH ALL RELEVENT
RECORD AND DRAWING INCLUDING AS PER DIRECTION OF
ENGINEER-IN-CHARGE. , 68
4.5 CHECKING OF SURVEY WORK: 68
APPENDIX I 69
TOPOGRAPHICAL SURVEYS, EXTENT, SCALES, CONTOUR INTERVAL, ETC. 69
APPENDIX II 71
LOCATION AND DEPTH OF EXPLORATORY HOLES / DRIFTS / PITS ETC. 71
NOTE: 71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
INVESTIGATIONS FOR ESTABLISHING SUITABILITY OF CONSTRUCTION
MATERIALS 76
APPENDIX IV 77
1. CONCRETE STRUCTURES 77
2. EARTHWORK/EMBANKMENT 77
Volume III 81
Section - 3 81
Land Acquisition 81
THE LAND ACQUISITION CASES ARE TO BE PREPARED AND SUBMITTED IN THE
FORMATS PRESCRIBED BY THE AUTHORITY COMPETENT TO PASS THE
ENFORCED TIME TO TIME ARE TO BE STRICTLY FOLLOWED. 81
Volume III 82
Section - 4 82
Excavation 82
contents 82
162
Section - 4: Excavation 162
(Excavation for Dam & its comonents) 162
1 General 162
1.1 THE WORK TO BE DONE UNDER THESE SPECIFICATIONS SHALL
CONSIST OF FURNISHING ALL TOOLS, CONSTRUCTIONAL PLANT,
LABOUR, MATERIALS AND OTHER THINGS REQUIRED FOR
EXCAVATION IN ALL STRATAS. CONVEYANCE AND DISPOSAL OF THE
EXCAVATED MATERIALS, INCLUDING ALL LEADS AND LIFTS,
TEMPORARY WORK FOR PERFORMANCE OF ALL THE OPERATIONS
CONNECTED WITH THE WORK EMBRACED UNDER THE CONTRACT
SO AS TO SECURE SATISFACTORY QUALITY OF WORK. 162
1.2 CONSTRUCTION AND MAINTENANCE OF DIVERSIONS IN CASE
DIVERSION OF EXISTING COMMUNICATION LINES, CHANNELS,
NALLA OR DRAINS WHERE THEY WERE DISTURBED DUE TO
EXCAVATION OF DAM & ITS COMPONENTS. 162
2. Standards 162
3. Scope: 163
4. Planning: 163
4.1 PRIOR TO THE COMMENCEMENT OF WORK, ALL RELEVANT DATA
SHALL BE COLLECTED BY THE CONTRACTOR AND DRAWINGS
PREPARED BY HIM SHOWING THE LOCATION OF THE EXCAVATION,
SPOILS, DEPOSITION AND FILLING. ON THESE DRAWINGS, FULL
CUTTING REACHES, PARTIAL CUTTING AND PARTIAL EMBANKMENT
REACHES AND FULL EMBANKMENT REACHES SHOULD BE
DISTINCTLY INDICATED. THE QUANTITY OF MATERIAL TO BE
PLACED IN FILL SHALL BE NOTED CLEARLY IN THESE REACHES.
WHERE THE MATERIAL TO BE EXCAVATED. CONSISTS OF DIFFERENT
TYPES AND IF THE VARIOUS TYPES HAVE TO BE USED SEPARATELY IN
THE FILL OR DUMPED TO SPOIL BANK, THE QUANTITIES OF EACH
CLASS OF MATERIAL IN EACH AREA SHOULD BE SHOWN ON
DRAWINGS. 163
4.2 THE CONTRACTOR SHALL PRESENT HIS PLANNING OF THE WORK
ALONG WITH REQUIRED DETAILS TO THE EXECUTIVE ENGINEER AT
LEAST 15 DAYS BEFORE STARTING THE WORK. 163
5. Setting out Work 163
5.1 BENCH MARKS: BEFORE STARTING ANY WORK, A PERMANENT
BENCH MARK, REFERENCE LINE AND CHECK PROFILES AT
CONVENIENT POSITIONS APPROVED BY THE ENGINEER-IN-CHARGE
SHALL BE ERECTED. THE BENCH MARKS SHALL BE AS PER TYPE
DESIGN 6 AND 8 OF DEPARTMENT. THE WORKS B.M. WITH R.L.
SHALL BE CONSPICUOUSLY CARVED AND PAINTED ON THE BENCH
MARK. THE REFERENCE LINE SHALL COMPRISE OF A BASE LINE
PROPERLY DAG BELLED ON THE GROUND WITH NUMBER OF
MASONRY PILLAR. THE CHECK PROFILES SHALL BE OF SUCH
MATERIALS AND SHALL BE LOCATED AT SUCH PLACES AS TO
ENSURE EXECUTION OF ALL SLOPES, STEPS AND EXCAVATION TO
THE PROFILE OR PROFILES INDICATED IN THE APPROVED
DRAWINGS OR AS DIRECTED BY THE ENGINEER-IN-CHARGE. 163
5.2 THE SUB-DIVISIONAL OFFICER ON BEHALF OF THE ENGINEER-IN-
CHARGE SHALL HIMSELF LAYOUT ALL IMPORTANT LEVELS, ALL
CONTROL POINTS WITH RESPECT TO THIS BENCH MARK AND
REFERENCE LINE AND CORRELATE ALL LEVELS AND LOCATIONS
WITH THIS BENCH MARK AND THE REFERENCE LINE. IMPORTANT
LEVELS SHALL BE CHECKED BY THE EXECUTIVE ENGINEER. ALL
ASSISTANCE SHALL BE GIVEN FOR THE SAME BY THE AGENCY
EXECUTING THE WORK. 164
IN THE CASE OF SPREAD OUT WORKS, SEVERAL BENCH MARKS,
REFERENCE LINES AND CHECK PROFILES MAY BE NECESSARY AND
SHALL BE CONSTRUCTED AS DIRECTED BY THE ENGINEER-IN-
CHARGE. 164
5.3 EXCEPT THE MATHEMATICAL AND SURVEYING INSTRUMENT
WHICH SHALL BE PROVIDED BY THE DEPARTMENT, ALL MATERIALS
AND LABOUR FOR SETTING OUT WORKS INCLUDING
CONSTRUCTION OF BENCH MARKS, REFERENCE LINES, CHECK
PROFILES AND SURVEY REQUIRED FOR SETTING OUT WORKS AS
MAY BE REQUIRED AT THE VARIOUS STAGES OF THE CONSTRUCTION
WORKS, SHALL BE SUPPLIED OR MADE BY THE AGENCY EXECUTING
THE WORK. 164
6 ClearinG, GRUBBING AND PREPARATION OF WORKS AREA: 164
(I) ALL EXCAVATION AREAS AND DAM EMBANKMENT ARE
INCLUDING A 6 M WIDE STRIP MEASURED BEYOND AND
CONTIGUOUS TO THE LIMIT LINE OF THE AREA AS SHOWN ON THE
DRAWING SHALL BE CLEARED AND ANY ROOTS ETC. COMPLETELY
REMOVED AS SPECIFIED. ALL TREES, DOWN TIMBERS, FENCING
BUSH, RUBBISH, OTHER OBJECTIONABLE MATERIALS AND
VEGETATION SHALL BE CLEARED. ALL STUMPS AND ROOTS SHALL
BE EXCAVATED AND REMOVED. ALL ROOTS OVER 50 MM IN
DIAMETER SHALL BE REMOVED TO A DEPTH OF 90 CM BELOW THE
ORIGINAL GROUND SURFACE OR AS DIRECTED BY THE ENGINEER-
IN-CHARGE. MATERIALS THUS REMOVED WILL BE BURNT OR
COMPLETELY REMOVED FROM THE SITE. ALL FELLED TIMBER AND
FUEL SHALL BE PROPERLY STACKED AND HANDED OVER TO THE
DEPARTMENT, WHEN ASKED FOR BY THE ENGINEER-IN-CHARGE.
PILING FOR BURNING SHALL BE DONE IN SUCH A MANNER AND IN
SUCH LOCATION AS TO CAUSE THE LEAST FIRE RISK. ALL BURNING
SHALL BE THOROUGH SO THAT THE MATERIALS ARE REDUCED TO
ASHES. SPECIAL PRECAUTIONS SHALL BE TAKEN TO PREVENT FIRE
FROM SPREADING TO THE AREAS BEYOND LIMITS OF THE AREAS
SPECIFIED AND SUITABLE EQUIPMENT AND SUPPLIES FOR
PREVENTING AND SUPPRESSING FIRE SHALL BE AVAILABLE AT ALL
TIME. 164
8.1 THE ENTIRE AREA OF EMBANKMENT INCLUDING A 3 M WIDE
STRIP BEYOND AND CONTIGUOUS WITH THE AREA OF EMBANKMENT
PROPER AS SHOWN IN THE DRAWING SHALL BE STRIPPED OR
BENCHED TO A SUFFICIENT DEPTH AS DIRECTED TO REMOVED ALL
UNSUITABLE MATERIALS. THE UNSUITABLE MATERIAL TO BE
REMOVED SHALL INCLUDE LOOSE ROCK, VEGETATION, TOP SOIL,
SOD, ORGANIC SILT, SWAMP MATERIAL AND RUBBISH AND ANY
OTHER OBJECTIONABLE MATERIALS BELOW THE GROUND
SURFACE. 165
8.2 AT LOCATIONS WHERE A RIVER OR STREAM CROSSES THE
EMBANKMENT SITE, LOOSE SAND AND GRAVEL AND LOOSE
BOULDERS SHALL ALSO BE REMOVED AS DIRECTED. 165
8.3 BENCHED MATERIALS SHALL BE DISPOSED OFF IN A MANNER AS
MAY BE DIRECTED BY THE ENGINEER-IN-CHARGE AND IN SUCH A
WAY AS NOT TO DETRACT FROM THE FINISHED APPEARANCE OF
THE PROJECT. 165
9. EXCAVATION OF CUTOFF OR PUDDLE TRENCH UNDER DAM EMBANKMENT
165
9.1 PROCEDURE FOR EXCAVATION: 165
9.2 A CUT OFF TRENCH OR PUDDLE TRENCH AS SHOWN IN THE
DRAWINGS SHALL BE EXCAVATED IN THE FOUNDATION OF THE DAM
AT THE LOCATION INDICATED. THIS TRENCH SHALL EXCAVATED TO
A DEPTH OF 0.6 M TO 1.2 M INTO ROCK (DEPENDING UPON THE
PERMEABILITY OF THE ROCK) OR INTO OTHER IMPERVIOUS
STRATUM AS MAY BE APPROVED BY THE ENGINEER-IN-CHARGE.
ACCURATE TRIMMING OF THE SLOPES OF THE EXCAVATION WILL
NOT BE REQUIRED BUT THE CUTTING IN GENERAL SHALL FOLLOW
LINES AS SPECIFIED IN DRAWINGS. THE AREA TO BE EXCAVATED
SHALL BE UNWATERED. THE WATER LEVEL SHALL BE MAINTAINED
BELOW THE LEVEL OF EXCAVATION IN THE AREA AND NONE OF THE
EXCAVATION SHALL BE PERFORMED IN STANDING WATER. 165
9.3 UTILISATION OF EXCAVATED MATERIALS: 165
9.4 TRENCH EXCAVATION SHALL PREFERABLY BE STARTED AFTER
THE WHOLE BASE OF THE DAM OR ATLEAST THE SUBSTANTIAL PART
OF ITS IS CLEARED, GRUBBED, BENCHED OR STRIPPED AS REQUIRED
BY SPECIFICATIONS SO THAT SUITABLE MATERIAL OUT OF TRENCH
EXCAVATION CAN BE DIRECTLY UTILIZED FOR FORMING THE BANK,
TO MAXIMUM POSSIBLE EXTENT. 165
9.5 BLASTING OF ROCK: 165
9.6 NO BLASTING OF ROCK WOULD BE PERMITTED FOR THE
EXCAVATION IN HARD ROCK, WHEN THE EXCAVATION REACHES
WITHIN ABOUT 60 CM OF FINAL LEVELS, IF THE OPINION OF THE
ENGINEER-IN-CHARGE SUCH BLASTING WILL SHATTER AND
DISTURB THE ROCK BELOW FOUNDATION. HE MAY ALSO PUT
SIMILAR RESTRICTIONS IN CASES WHERE DAMAGE IS
APPREHENDED TO WORKS IN NEIGHBORING AREA EXISTING OR
UNDER CONSTRUCTION. IN SUCH CASES ROCK EXCAVATION SHALL
BE COMPLETED BY CHISELING AND WEDGING ETC. 165
9.7 MATERIAL RECEIVED FROM CUT OFF TRENCH OR PUDDLE
TRENCH: 165
9.8 THE MATERIALS, EXCAVATED FROM THE TRENCH SHALL, IF
SUITABLE, BE USED IN THE EMBANKMENT EITHER IMMEDIATELY OR
AFTER STOCK PILING AS CONVENIENT AND DIRECTED BY THE
ENGINEER-IN-CHARGE. THE SUITABILITY OR OTHERWISE OF THE
MATERIAL AND ZONE OF THE EMBANKMENT IN WHICH IT IS TO BE
PLACED WILL BE SPECIFIED BY THE ENGINEER-IN-CHARGE ON THE
BASIS OF LABORATORY TESTS. 165
9.9 MATERIAL EXCAVATED FROM THE TRENCH SHALL NOT BE
PLACED IN THE EMBANKMENT TILL FOUNDATION FOR THE
EMBANKMENT HAS BEEN CLEARED, STRIPPED AND PREPARED AS
SPECIFIED AND ADEQUATE ARRANGEMENTS MADE FOR WATERING
AND ROLLING THE LAYERS OF EARTH FILL IN THE EMBANKMENT.
166
9.10 MATERIALS EXCAVATED FROM THE TRENCH SHALL BE
SUBJECTED TO THE SAME DEGREE OF EMBANKMENT CONTROL AS
MATERIALS OBTAINED FROM BORROW PITS. 166
9.11 THE MATERIAL EXCAVATED FROM THE TRENCH WHICH ARE
NOT SUITABLE FOR USE IN THE EMBANKMENT SHALL BE DISPOSED
OFF IN A MANNER AS MAY BE DIRECTED BY THE ENGINEER-IN-
CHARGE AND IN SUCH A WAY AS NOT TO DETRACT FROM THE
FINISHED APPEARANCE OF THE PROJECT. 166
9.12 CUT OFF TRENCH FILLING: 166
9.13 CUTOFF TRENCH SHALL BE BACK FILLED WITH IMPERVIOUS
MATERIAL OF THE SAME SPECIFICATION AND IN THE SAME MANNER
AS FOR THE IMPERVIOUS HEARTING ZONE OF THE EMBANKMENT
OF THE DAM IN ACCORDANCE WITH SPECIFICATIONS UNDER PARA
4.9. BUT BEFORE BACK FILLING IS STARTED FOUNDATION
GROUTING IN ACCORDANCE WITH SPECIFICATIONS OF CHAPTER 22
MAY BE COMPLETED, WHERE REQUIRED, UNLESS THE ENGINEER-IN-
CHARGE DIRECTS OTHERWISE. 166
9.14 PUDDLE FILLING: 166
9.15 PUDDLE: 166
9.16 THE PUDDLE SHALL CONSIST OF GOOD RETENTIVE CLAY OF
BEST QUALITY FREE FROM ORGANIC OR OTHER FOREIGN
MATERIAL. IT SHOULD BE CLEAN AND TOUGH AND SHOULD BE
AVAILABLE NEAR THE SITE AS FAR AS POSSIBLE. THE MOST
SUITABLE CLAY IS OF THE DESCRIPTION USED FOR TILE MAKING.
SOFT SLUDGY, PEATY, SANDY, SALT OR PUFFY CLAY SHOULD BE
REJECTED. 166
9.17 THE CLAY IS TO BE WORKED OUT INTO PUDDLE BEFORE USE BY
TURNING IT OVER AND OVER AGAIN WITH PORES, WATERING AND
TREADING WITH MENS FEET INTO ONE PLASTIC HOMOGENEOUS
MASS OF THE TOUGHEST CONSISTENCY UNTIL IT GETS PLASTICITY.
166
9.18 LAYING OF PUDDLE: 166
9.19 THE PUDDLE SHALL THEN BE MADE INTO BALLS AND THROWN
INTO THE TRENCH OR IN ANY OTHER POSITION REQUIRED. NO
MORE THAN 15 CM IN THICKNESS OF PUDDLE SHALL BE DEPOSITED
IN THE PLACE AT ONE TIME AND IT MUST AT ONCE BE THOROUGHLY
KNEADED BY MENS FEET AND INCORPORATED WITH MASS BELOW
IT SO THAT THE WHOLE WILL BE UNIFORM AND NOT IN LAYERS. 166
9.20 THE TOP OF PUDDLE SHALL BE KEPT AS LEVEL AND UNIFORM AS
POSSIBLE AND SHALL ON NO ACCOUNT BE ALLOWED TO DRY. IF THE
SURFACE CRACKS AT ANY TIME IT SHALL BE DUG UP AND PUDDLE
REMADE. 166
9.21 VERTICAL JOINTS ACROSS THE PUDDLE WALL AND STEPS TO ITS
SIDE SHALL BE AVOIDED. ALL JOINTS SHALL BE MADE BY LONG
INCLINED FACES OVER LAPPING EACH OTHER. 166
9.22 THE WHOLE WIDTH OF PUDDLE TRENCH EXCAVATED SHALL BE
FILLED WITH PUDDLE ONLY SO THAT THE PUDDLE GETS
THOROUGHLY INTO THE INTERSTICES OF TRENCH WALLS. THE
JOINT NEAR THE WALL SHALL BE THOROUGHLY KNEADED WITH
MENS HELS. 166
9.23 ON HOLIDAYS AND OTHER DAYS, WHEN WORKS ARE STOPPED,
LABOUR SHOULD BE SPECIALLY EMPLOYED TO KEEP THE SURFACE
OF PUDDLE WET BY SPRINKLING OF WATER. 167
9.24 THE PUDDLE FILLING SHALL NOT BE DONE IN STANDING WATER.
WATER LEVEL IN TRENCH SHALL BE KEPT BELOW THE WORKING
LEVEL BY MEANS OF PUMPS, IF REQUIRED. 167
9.25 AS THE SURFACE OF THE PUDDLE LAYER DRIES UP, IT SHOULD
BE THOROUGHLY CONSOLIDATED WITH RAMMERS. BEFORE A NEW
LAYER OF PUDDLE IS LAID THE SURFACE OF THE PREVIOUS LAYER,
IF NOT NEWLY MADE, SHOULD BE LIGHTLY SPRINKLED WITH
WATER BY MEANS OF WATERING POTS AND KNEADED. 167
9.26 WHEN PUDDLE IS FINISHED, IT SHOULD BE IMMEDIATELY
COVERED UP IN THE WORK OR WHEN THIS IS NOT POSSIBLE, IT
SHOULD BE LIGHTLY SPRINKLED WITH WATER BY MEANS OF
WATERING POTS AND KNEADED. 167
9.27 THE SURFACE SOIL IF NOT CONFIRMING TO APPROVED
HEARTING SOIL, IS TO BE REMOVED ON BOTH SIDES OF THE PUDDLE
TRENCH FOR A BREADTH EQUAL TO THAT OF THE TOP OF THE
TRENCH, AND FOR 0.60 M DEEP, AND CONSOLIDATED IN THE SAME
WAY. 167
9.28 THIS FILLING IS TO BE CARRIED UP WITH THE PUDDLE WALL TO
A HEIGHT OF 0.6 M ABOVE GROUND LEVEL AND JOINED WITH THE
HEARTING. 167
10 RECORDING OF CROSS SECTIONS. 167
10.1 IMMEDIATELY PRIOR TO THE BEGINNING OF THE WORK, CROSS-
SECTIONS OF THE EXISTING GROUND LEVEL AT SUITABLE
INTERVALS, NORMAL TO THE AXIS OF DAM, AND OTHER CHANNELS,
SLUICE, WASTE-WEIR OR OTHER MASONRY STRUCTURES, ETC.
SHALL BE TAKEN OVER THE BASE AND SEATING OF THE CHANNELS
OR OTHER STRUCTURES, ETC. FOR SUFFICIENT DISTANCE OUTSIDE
THE LIMITS. LEVELS ON THESE CROSS-SECTIONS SHALL BE TAKEN
AT SUITABLE INTERVAL NOT EXCEEDING 5 M OR AS DIRECTED BY
THE ENGINEER-IN-CHARGE. 167
10.2 THESE CROSS-SECTIONS SHALL BE TAKEN AND PLOTTED IN INK
ON GRAPH MEASUREMENT BOOK BY THE CONSTRUCTION AGENCY
AND CHECKED BY CONSULTANT AGENCY DEPARTMENTAL OFFICER
INCHARGE OF WORK SHALL CHECK THERE LEVEL AS REQUIRED
THESE CROSS-SECTIONS SHALL FORM THE BASIS OF ALL FUTURE
MEASUREMENTS. 167
10.3 AFTER CLEARING THE AREA REQUIRED FOR DAM EXCAVATION
AND CONSTRUCTION OF EMBANKMENTS, CROSS SECTIONS SHALL
BE TAKEN AT EVERY 15M INTERVAL OR CLOSER, DEPENDING ON THE
NATURE OF GROUND, NORMAL TO AXIS OF DAM UPTO SUFFICIENT
DISTANCE OUTSIDE THE LIMITS OF THE WORK. LEVELS ON CROSS
SECTIONS SHALL BE AT 5M. INTERVALS OR CLOSER INTERVALS AS
DIRECTED BY THE ENGINEER -IN-CHARGE AND ENTERED IN LEVEL
FIELD BOOKS AND CROSS SECTIONS WILL BE PLOTTED IN GRAPH
M.B. THE CONTRACTOR SHALL WRITE A CERTIFICATE. ACCEPTED
THE MEASUREMENTS RECORDED ON PAGES FROM
________________TO ______________ AND SIGN AT THE END OF LEVELS
IN THE GRAPH M.B. IN TOKEN OF ACCEPTANCE. 167
10.4 AFTER BENCHING AND PRIOR TO COMMENCEMENT OF
EXCAVATION CROSS SECTIONAL LEVELS OF STRIPPED SURFACE
SHALL BE TAKEN AT THE SAME LOCATIONS AT INTERVALS AS
SPECIFIED IN PARA (A) ABOVE AND CERTIFIED AS MENTIONED
SHALL BE RECORDED BY THE CONTRACTOR. 167
10.5 AT THE EARLIEST, CROSS SECTIONAL PROFILES SHALL BE
PREPARED BY THE CONTRACTOR DULY PLOTTING THE PRE-LEVELS
AND THE CONTRACTORS SIGNATURE SHALL BE OBTAINED ON
THESE CROSS-SECTION SHEETS PLOTTED IN GRAPH M.B. THE CROSS
SECTIONS CALLED INITIAL CROSS SECTION TAKEN AFTER STRIPING
SHALL FORM THE BASIS OF ALL FUTURE MEASUREMENTS. THESE
INITIAL CROSS SECTIONS DULY SIGNED BY THE CONTRACTOR AND
ENGINEER-IN-CHARGE SHALL BE PRESERVED. ALL LINEAR
DIMENSIONS SHALL BE MEASURED IN METERS TO THE NEAREST 0.01
METER, VOLUMES WORKED OUT IN CUBIC METERS CORRECTED TO
0.01 CUBIC METER. HOWEVER, IN CASE OF ROCK EXCAVATION
OCCURRING IN BED OR SIDES, THE ACTUAL QUANTITY OF ROCK
SHALL BE ARRIVED BY TAKING BLOCK LEVELS AT 2.5M. INTERVALS
ALL ALONG THE ENTIRE AREA OF BED AND SIDES. 167
11.1 ALL MATERIALS INVOLVED IN EXCAVATION SHALL BE
CLASSIFIED INTO THE FOLLOWING GROUPS. 168
12 Authority for Classification 169
13 EXCAVATION 169
14.1 IF SLIDES OCCUR IN CUTTING DURING THE PROCESS OF
EXCAVATION THEY SHALL BE REMOVED BY THE CONTRACTOR AT
HIS COST AS DIRECTED BY THE ENGINEER -IN-CHARGE. 170
14.2 IF FINISHED SLOPE SLIDE INTO THE CANAL SUBSEQUENTLY
SUCH SLIPS IN ROCK SHALL BE REMOVED. 170
15.1 IN SOILS ANY EXCESS DEPTH BELOW THE SPECIFIED LEVELS
AND ANY EXCESS EXCAVATION IN SLOPES AND WIDTHS SHALL BE
MADE GOOD AT THE COST OF THE CONTRACTOR WITH SUITABLE
SOILS OF SIMILAR CHARACTERISTICS AND COMPACTED TO A
DENSITY NOT LESS THAN 95% OF PROCTORS DENSITY. 170
15.2 IN THE CANAL SECTION WHERE EXPANSIVE TYPE OF SOIL SUCH
AS C.H. TYPE OF SOIL IS ENCOUNTERED AND OVER WHICH CEMENT
CONCRETE LINING DIRECTLY BE LAID, THE CANAL PRISM SHALL BE
OVER EXCAVATED TO THE EXTENTS AS DIRECTED BY THE
ENGINEER-IN-CHARGE AND SUCH OVER EXCAVATED SECTION
SHALL BE FILLED WITH SUITABLE COHESIVE NON-SWELLING (CNS)
TYPE SOIL AND SHALL BE PLACED IN UNIFORM HORIZONTAL
LAYERS AND COMPACTED AS DIRECTED BY THE ENGINEER-IN-
CHARGE. THE OVER EXCAVATION MADE IN SUCH STRATA FILLING
BY SUITABLE SOIL LOCATING AND COMPACTING OF SUCH SOIL WILL
NOT BE PAID SEPARATELY. 170
16 DEWATERING 171
16.1 IF WATER IS MET IN THE EXCAVATION DUE TO SUB-SOIL GROUND
WATER, SPRINGS, SEEPAGE, RAIN OR OTHER CAUSES, IT SHALL BE
REMOVED BY SUITABLE DIVERSION, PUMPING OR BAILING OUT AND
THE SUB-SOIL WATER TABLE SHALL BE KEPT BELOW THE
EXCAVATION SO THAT THE EXCAVATION KEPT DRY WHENEVER SO
REQUIRED AS DIRECTED BY THE ENGINEER-IN-CHARGE CARE
SHALL BE TAKEN TO DISCHARGE THE DRAINED WATER AS NOT TO
CAUSE DAMAGE TO THE WORKS, CROPS OR ANY OTHER PROPERTY.
IN CASE OF LINED CANALS, THE SUBSOIL WATER SHALL NOT BE
ALLOWED TO ACCUMULATE IN THE BOTTOM OF THE CANAL. THE
BED/SIDES SHALL BE MOISTURE TO RECEIVE LINING AS DIRECTED
BY THE ENGINEER-IN-CHARGE. NO SEPARATE PAYMENT WILL BE
MADE FOR DEWATERING. 171
16.2 WHERE WATER IS MET WITH IN EXCAVATION DUE TO STREAM
FLOW, SEEPAGE, RAIN OR OTHER REASONS, THE CONTRACTOR
SHALL TAKE ADEQUATE MEASURES SUCH AS BAILING, PUMPING,
CONSTRUCTION OF DIVERSION CHANNELS, DRAINAGE CHANNELS,
BUNDS, COFFERDAMS AND OTHER NECESSARY WORKS KEEP THE
FOUNDATION TRENCHES DRY WHEN SO REQUIRED AND TO PROTECT
THE GREEN CONCRETE/ MASONRY AGAINST DAMAGE BY EROSION
OR SUDDEN RISING OF WATER LEVEL. THE METHODS TO BE
ADOPTED IN THIS REGARD AND OTHER DETAILS THERE OF SHALL
BE LEFT TO THE CHOICE OF THE CONTRACTOR BUT SUBJECT TO
APPROVAL OF THE ENGINEER-IN-CHARGE. 171
16.3 APPROVAL OF THE ENGINEER-IN-CHARGE SHALL HOWEVER
SHALL NOT RELIEVE THE CONTRACTOR OF THE RESPONSIBILITY
FOR THE ADEQUACY OF DEWATERING AND PROTECTION
ARRANGEMENTS AND FOR THE QUALITY AND SAFETY OF THE
WORKS. 171
16.4 THE CONTRACTOR SHALL TAKE ALL PRECAUTIONS IN
DIVERTING THE CHANNELS AND DISCHARGING THE DRAINED
WATER AS NOT TO CAUSE DAMAGE TO THE WORKS, CROPS OR ANY
OTHER PROPERTY. 171
16.5 PUMPING FROM THE INTERIOR OF A FOUNDATION SHALL BE
DONE IN SUCH A MANNER AS TO PRECLUDE THE POSSIBILITY OF
THE MOVEMENT OF WATER THROUGH ANY FRESH CONCRETE. NO.
PUMPING SHALL BE PERMITTED DURING THE PLACING OF
CONCRETE OR FOR ANY PERIOD OF ATLEAST 24 HOURS
THEREAFTER, UNLESS IT IS DONE FROM A SUITABLE SUMP
SEPARATED FROM THE CONCRETE WORKS BY WATER TIGHT WALL
OR OTHER SIMILAR MEANS. 171
17 DISPOSAL OF EXCAVATED MATERIAL: 171
18 EXCAVATION FOR Appearent works: 172
18.1 DESCRIPTION OF WORK: 172
CLASSIFIED IN ACCORDANCE WITH CLAUSE NO.11 173
20.1 PREPARATION OF FOUNDATION: 173
20.2 THE CONTRACTOR SHALL PREPARE FIRM FOUNDATION FOR
THE STRUCTURE AS SHOWN IN THE DRAWINGS. THE BOTTOM AND
SIDE SLOPES OF FOUNDATION UPON OR AGAINST WHICH THE
STRUCTURE IS TO BE PLACED SHALL BE FINISHED TO THE
PRESCRIBED LEVELS AND DIMENSIONS SHOWN ON PLANS. 173
20.3 THE BOTTOM OF THE FOUNDATION SHALL BE LEVELED BOTH
LONGITUDINALLY AND TRANSVERSELY OR STEPPED AS DIRECTED
BY ENGINEER-IN-CHARGE. BEFORE FOUNDATION CONCRETE IS
LAID, THE SURFACE SHALL BE SLIGHTLY WATERED AND RAMMED.
IN THE EVENT OF EXCAVATION HAVING BEEN MADE DEEPER THAN
THAT SHOWN ON THE DRAWINGS THE EXTRA DEPTH SHALL BE
MADE UP WITH CONCRETE OR MASONRY OF THE FOUNDATION
GRADE AT THE COST OF THE CONTRACTOR AS DIRECTED BY THE
ENGINEER-IN-CHARGE. ORDINARILY EARTH FILLING SHALL NOT BE
USED FOR THE PURPOSE TO BRING THE FOUNDATION LEVEL. IF
HARD STRATA IS NOT MET AT FOUNDATION LEVEL SHOWN IN THE
DRAWINGS EXTRA DEPTH AS DIRECTED BY ENGINEER-IN-CHARGE
SHALL BE EXCAVATED TO REMOVE UNSUITABLE MATERIAL. THE
EXTRA EXCAVATION OR EXTRA DEPTH MADE UP WITH MASONRY OR
CONCRETE WILL NOT BE PAID. 174
20.4 WHEN ROCK OR OTHER HARD STRATA IS ENCOUNTERED, IT
SHALL BE FREE FROM ALL SOFT AND LOOSE MATERIAL, CLEANED
AND CUT TO A FIRM SURFACE EITHER LEVEL, STEPPED, OR
SERRATED/NOTCHED, AS DIRECTED BY THE ENGINEER-IN-CHARGE.
ALL SEAMS SHALL BE CLEANED OUT AND FILLED WITH CEMENT
MORTAR OR GROUT TO THE SATISFACTION OF THE ENGINEER-IN-
CHARGE. 174
20.5 IF IT IS CONSIDERED NECESSARY BY THE ENGINEER-IN-CHARGE,
TO CONSOLIDATE THE FOUNDATION STRATA BY GROUTING CEMENT
SLURRY, THE DRILLING AND GROUTING OR ANY OTHER
FOUNDATION TREATMENT AS DIRECTED BY THE ENGINEER-IN-
CHARGE SHALL BE DONE BY THE CONTRACTOR 174
21.1 NEAREST, TOWNS, VILLAGES AND ALL REQUIRED PLACES,
TRENCHES AND FOUNDATION PITS SHALL BE SECURELY FENCED,
PROVIDED WITH PROPER CAUTION SIGNS AND MARKED WITH RED
LIGHTS AT NIGHT TO AVOID ACCIDENTS. THE CONTRACTOR SHALL
TAKE ADEQUATE PROTECTIVE MEASURES TO SEE THAT THE
EXCAVATION OPERATIONS DO NOT EFFECT OR DAMAGE ADJOINING
STRUCTURES OR PROPERTY. 174
22.1 SCOPE: 174
23 General Requirements 178
23.1 THE CROSS SECTIONS FOR EMBANKMENT ARE TO BE DESIGNED
TO SUIT THE CHARACTERISTICS OF THE BEST QUALITY SOILS
AVAILABLE IN THE VICINITY OF THE PROPOSED WORK. IF THE
CONTRACTOR PROPOSES TO USE ANY OTHER TYPE OF SOILS THAN
THOSE MENTIONED IN THE DESIGN TO SAVE THE LEAD AND
THEREBY THE COST, THE CONTRACTOR HAS TO FORM THE
EMBANKMENT TO THE REVISED PROFILES WORKED OUT BY THE
COMPETENT AUTHORITY. THE EXTRA QUANTITY INVOLVED WILL
NOT BE MEASURED AND PAID. THE THEORETICAL QUANTITY
REQUIRED BASED ON THE ORIGINAL CROSS-SECTIONS WILL ONLY
BE MEASURED AND PAID. BUT THE CONTRACTOR HAS TO FORM THE
BUND TO THE REVISED CROSS SECTION DESIGNED WITH THE
CHARACTERISTICS OF THE PROPOSED SOILS. THE DESIGNS GIVEN
BY THE ESTIMATE SANCTIONING AUTHORITY ARE FINAL. 178
23.2 EMBANKMENT SHALL BE BUILT TO THE HEIGHT, TOP WIDTH
AND SIDE SLOPES AS SHOWN ON THE DRAWINGS. ALL THE EDGES OF
THE EMBANKMENT SHALL BE NEATLY ALIGNED SYMMETRICAL TO
THE CENTRAL LINE. THEY SHALL BE ABSOLUTELY STRAIGHT IN ALL
REACHES EXCEPT AT BENDS. AT BENDS THEY SHALL BE SMOOTHLY
CURVED. 178
23.3 THE TOP OF EACH EMBANKMENT SHALL BE LEVELED AND
FINISHED SO AS TO BE SUITABLE FOR ROAD WAY AND GIVEN A
CROSS SLOPE TO DRAIN AWAY RAIN WATER. THE BANK CARRYING
ROAD SHALL BE GIVEN A SUITABLE CROSS SLOPE. 178
24 Material 178
24.1 THE SUITABILITY OF FOUNDATION OF PLACING EMBANKMENT
MATERIALS THEREON AND ALL MATERIALS PROPOSED FOR USE IN
CONSTRUCTION OF EMBANKMENT SHALL BE DETERMINED BY THE
CONTRACTOR WELL IN ADVANCE ON THE BASIS OF LABORATORY
TEST RESULTS. CHEMICAL AND PHYSICAL TESTS OF THE MATERIAL
PROPOSED FOR CONSTRUCTION OF EMBANKMENT SHALL BE
CARRIED OUT TO ENSURE THAT THE SOIL DOES NOT CONTAIN
SOLUBLE LIME CONTENT, SOLUBLE LIME SALT CONTENT OR
COHESION LESS FINES, IN QUANTITIES HARMFUL TO THE
EMBANKMENTS. 178
24.2 MATERIAL FOR CONSTRUCTION OF EMBANKMENT SHOULD BE
FREE FROM THE ORGANIC MATERIAL. UNLESS OTHERWISE
DIRECTED BY THE SUPERINTENDING ENGINEER/ EXECUTIVE
ENGINEER ALL MATERIALS SHALL BE DEPOSITED IN
EMBANKMENTS SO THAT COBBLES, GRAVEL AND BOULDERS ARE
WELL DISTRIBUTED THROUGH OTHER MATERIAL AND NOT NESTED
IN ANY PORTION WITHIN OR UNDER ARE EMBANKMENT AS PER
CLAUSE 6.4 OF I.S. 4701-1982. 179
24.3 SUITABLE EXCAVATED MATERIAL AVAILABLE FROM THE CUT
OFF TRENCHES, CANAL CUTTING, EXTRA CUTTING FOR SEATING TO
LINING, FOUNDATION EXCAVATION FOR STRUCTURES, APPROACH
AND TAIL CHANNELS FOR STRUCTURES, NALLA DIVERSIONS,
REMOVAL OF RAMPS ETC, SHALL BE USED FOR CONSTRUCTION OF
ADJACENT EMBANKMENTS. 179
24.4 AFTER COMPLETING THE CONSTRUCTION OF EMBANKMENTS
WITH THE MATERIALS AS INDICATED IN 37.3 ABOVE, MATERIAL
REQUIRED FOR THE CONSTRUCTION OF BALANCE EMBANKMENT
SHALL BE OBTAINED FROM THE BORROW AREAS. 179
24.5 THE SOILS AND MORUM EXCAVATED AND USEFUL FOR
CONSTRUCTION OF THE EMBANKMENT SHALL BE CLASSIFIED BY
THE ENGINEER-IN-CHARGE AS IMPERVIOUS AND SEMI-PERVIOUS
BASED ON LABORATORY TEST RESULTS. THEY SHALL BE UTILIZED
ON THE EMBANKMENT WORK. 179
25 Preparation of ground surface for embankment: 179
25.1 CLEARING SITE : CLAUSE 6 SHALL APPLY. 179
25.2 STRIPPING : CLAUSE 7 SHALL APPLY. 179
25.3 ALL PORTIONS OF EXCAVATION MADE FOR TEST PITS OR OTHER
SUBSURFACE INVESTIGATIONS, ALL HOLES, HOLLOWS AND ALL
OTHER EXISTING CAVITIES FOUND WITHIN THE AREA TO BE
COVERED AND TO THE EXTENT BELOW THE ESTABLISHED LINES OF
EXCAVATION FOR EMBANKMENT SEAT SHALL BE FILLED IN EARTH
OF THE CORRESPONDING ZONE OF THE EMBANKMENT AND
SUITABLY COMPACTED. THE PITS OF SURFACE BOULDERS SHALL BE
FILLED WITH SUITABLE MATERIAL AND COMPACTED AT NO EXTRA
COST. 179
25.4 POOLS OF WATER SHALL NOT BE PERMITTED IN THE
FOUNDATION FOR EMBANKMENT AND SUCH WATER SHALL BE
DRAINED AND CLEARED PRIOR TO PLACING THE FIRST LAYER OF
EMBANKMENT MATERIALS. 179
25.5 ON SLOPING GROUND OR IN CASE OF EXISTING BANKS, WHERE
EMBANKMENT PORTIONS ARE TO BE MODIFIED, BENCHING OF
SLOPES SHALL BE DONE WITH A LITTLE SLOPE TOWARDS THE
INSIDE OF BEACHING SO AS TO GIVE A GOOD GRIP TO THE
EMBANKMENT SOIL WITH THE SUB-GRADE. UNLESS OTHERWISE
SPECIFIED THE BENCHES SHALL BE 0.3.X.0.6.M. ON THE FRONT AND
REAR SLOPE OF THE EMBANKMENT. BEFORE BENCHING, THE BANK
SLOPES SHALL BE CLEARED OF ALL ROOTS AND VEGETABLES
MATTER AS PER SPECIFICATION 2.0. NO SEPARATE PAYMENT WILL
BE MADE FOR EITHER BENCHING OR REFILLING. THE RATE QUOTED
FOR RAISING EMBANKMENT IS INCLUSIVE OF ABOVE OPERATIONS.
THE BANK SECTION SHALL BE BROUGHT TO DESIGN STANDARDS BY
FILLING THE SCOURS WITH SUITABLE MATERIAL AND COMPACTING
TO 98% PROCTOR DENSITY BY SUITABLE MEASURE OF
COMPACTION. 179
25.6 SOIL FOUNDATION: 179
25.7 THE GROUND SURFACE UNDER EMBANKMENT AND AREA OF BED
FILLING WHEREVER NECESSARY ( EXCEPT ROCK SURFACES ) SHALL
BE LOOSENED OR SCARIFIED MAKING OPEN FURROWS BY MEANS
OF A PLOUGH, OR RIPPER OR ANY OTHER METHODS TO A DEPTH OF
NOT LESS THAN 200 MM. DEEP BELOW THE STRIPPED SURFACE AT
INTERVALS OF NOT MORE THAN 1M. TO THE SATISFACTION OF THE
ENGINEER-IN-CHARGE. ROOTS OR OTHER DEBRIS TURNED UP
DURING SCARIFYING, SHALL BE REMOVED FROM THE ENTIRE
FOUNDATION AREA FOR THE FILL. THE AREAS UNDER THE
EMBANKMENTS SHALL BE PREVENT BY SPRINKLER BEFORE THE
CONSTRUCTION OF EMBANKMENT BEGINS. THE MOISTURE
CONTENT SHALL BE OPTIMUM. 180
25.8 ROCK FOUNDATION: 180
26 Compaction & WATERING: 180
26.1 COMPACTION EQUIPMENTS : WHILE THE SPECIFICATION
BELOW PROVIDE THAT EQUIPMENT OF A PARTICULAR TYPE & SIZE
IS TO BE FURNISHED AND USED, IT IS CONTENDED THAT THE
IMPROVED COMPACTION EQUIPMENT AS MAY BE MOST SUITED TO
THE PREVAILING SITE CONDITIONS AND THE PROGRAMME OF
CONSTRUCTION SHALL BE USED. THE BROAD DETAILS OF THE
EQUIPMENTS ARE GIVEN BELOW:- 180
26.2 TAMPING ROLLER/VIBRATORY COMPACTORS SHALL BE USED
FOR COMPACTING THE EARTH FILL. THE SHEEP FOOT ROLLERS
SHALL MEET THE FOLLOWING REQUIREMENTS:- 180
(I) ROLLER DRUMS :- EACH DRUM OF A ROLLER SHALL HAVE AN
OUTSIDE DIAMETER OF NOT LESS THAN 150 CM AND SHALL BE NOT
LESS THAN 120 CM NOT MORE THAN 180 CM IN LENGTH. THE SPACE
BETWEEN TWO ADJACENT DRUMS, WHEN ON A LEVEL SURFACE
SHALL NOT BE LESS THAN 30 CM NOR MORE THAN 38 CM. EACH
DRUM SHALL BE FREE TO PIVOT ABOUT AN AXIS PARALLEL TO THE
DIRECTION OF TRAVEL. EACH DRUM SHALL BE EQUIPPED WITH A
SUITABLE PRESSURE RELIEF VALVE TO PREVENT EXCESSIVE
PRESSURES FROM DEVELOPING IN THE INTERIOR OF THE ROLLER
DRUM. 180
(II) TAMPING FEET :- AT LEAST ONE TAMPING FOOT SHALL BE
PROVIDED FOR EACH 645 SQ. CM OF DRUM SURFACE. THE SPACE
MEASURED ON THE SURFACE OF THE DRUM BETWEEN THE
CENTRES OF TWO ADJACENT TAMPING FEET SHALL NOT BE LESS
THAN 230 MM. THE CROSS SECTIONAL AREA OF EACH TAMPING
FOOT SHALL BE NOT MORE THAN 65 SQ. CM AT A PLANE NORMAL TO
THE AXIS OF THE SHANK 150 MM FROM THE DRUM SURFACE AND
SHALL BE MAINTAINED AT NOT LESS THAN 45 SQ. CM NOR MORE
THAN 65 SQ. CM AT A PLANE NORMAL TO THE AXIS OF THE SHANK
200 MM FROM THE DRUM SURFACE. 180
(III) ROLLER WEIGHT :- THE WEIGHT OF THE ROLLER WHEN FULLY
LOADED SHALL NOT BE LESS THAN 7091 KG AND THE GROUND
PRESSURE WHEN FULLY LOADED SHALL NOT BE LESS THAN 40
KG/CM 2 REQUIRED TO OBTAIN THE DESIRED COMPACTION.
TRACTOR USED FOR PULLING ROLLERS SHALL BE OF 50 H.P. TO 65
H.P. POWER TO PULL THE ROLLERS SATISFACTORILY AT A SPEED OF
4 KMS/PER HOUR WHEN THE DRUMS ARE FULLY LOADED WITH WET
SAND BALLAST. DURING OPERATION OF ROLLING, THE SPACES
BETWEEN THE TAMPING FOOT SHALL BE KEPT CLEAR OF
MATERIALS STICKING TO THE DRUM WHICH COULD IMPAIR THE
EFFECTIVENESS OF THE TAMPING ROLLERS. 180
26.3 ROLLING :- 181
26.4 TAMPING :- ROLLERS WILL NOT BE PERMITTED TO OPERATE
WITHIN 1.00 METRE OF CONCRETE AND MASONRY STRUCTURES. IN
LOCATION WHERE COMPACTION OF THE EARTH FILL MATERIAL BY
MEANS OF ROLLER IS IMPRACTICABLE OR UNDESIRABLE, THE
EARTH FILL SHALL BE SPECIALLY COMPACTED AS SPECIFIED
HEREIN AT THE FOLLOWING LOCATIONS:- 181
EARTH FILL SHALL BE SPREAD IN LAYERS OF NOT MORE THAN 10
CM IN THICKNESS WHEN LOOSE AND SHALL BE MOISTENED TO
HAVE THE REQUIRED MOISTURE CONTENT AS SPECIFIED. WHEN
EACH LAYER OF MATERIAL HAS BEEN CONDITIONED TO HAVE THE
REQUIRED MOISTURE CONTENT, IT SHALL BE COMPACTED TO THE
SPECIFIED DENSITY BY SPECIAL ROLLERS, MECHANICAL TAMPERS
OR BY OTHER APPROVED METHODS; AND ALL EQUIPMENT AND
METHODS USED SHALL BE SUBJECT TO APPROVAL BASED ON
EVIDENCE OF ACTUAL PERFORMANCE AND FIELD COMPACTION
TESTS. THE MOISTURE CONTROL AND COMPACTION SHALL BE
EQUIVALENT TO THAT OBTAINED IN THE EARTH FILL ACTUALLY
PLACED IN THE DAM EMBANKMENT IN ACCORDANCE WITH THE
SPECIFICATIONS.. 181
26.5 COHESIVE MATERIALS: 181
26.6 COHESIONLESS MATERIALS: 182
26.7 EMBANKMENT WITHOUT CONTROLLED COMPACTION 183
26.8 EMBANKMENTS WITH CONTROLLED COMPACTION 183
26.9 HOMOGENOUS SECTION: 185
26.10 ZONAL EMBANKMENTS: 185
27 Moisture CONTROL: 185
THE WATER CONTENT OF THE EARTHFILL MATERIAL PRIOR TO AND
DURING COMPACTION SHALL BE DISTRIBUTED UNIFORMLY
THROUGHOUT EACH LAYER OF MATERIALS BETWEEN 2 TO + 1 OF
THE OPTIMUM MOISTURE CONTENT FOR CASING MATERIAL AND
BETWEEN 0 TO + 2 FOR HEARTING MATERIAL. MOISTURE
DETERMINATION OF SOILS AS WELL AS NEEDLE MOISTURE
DETERMINATION OF SOIL SHALL BE CARRIED OUT AS PER IS : 2720
(PT. II) 1973, SEC 1 AND DESIGNATION E22 OF USBR / EARTH MANUAL
1968 RESPECTIVELY. 185
28 Special Precautions: 186
28.1 DURING THE ACTUAL CONSTRUCTION OF ANY EARTH WORK,
MAXIMUM USE SHOULD BE MADE OF CONSTRUCTION PLANT AND
ROUTING OF THE PLANT SHOULD BE CAREFULLY CONTROLLED TO
OBTAIN UNIFORM COMPACTION OVER AS WIDE AN AREAS AS
POSSIBLE. CARE SHOULD ALSO BE TAKEN DURING THE
COMPACTION OPERATION TO SHAPE THE SURFACE OF THE WORKS
TO FACILITATE THE SHEDDING AND TO MINIMIZE THE ABSORPTION
OF RAIN WATER, PARTICULAR ATTENTION BEING GIVEN TO THE
PREVENTION OF PENDING OF WATER. THE CONTRACTOR SHALL DO
THIS AT THE END OF EACH DAYS WORK. 186
28.2 THE EARTH MOVING MACHINERY SHALL NOT BE ALLOWED TO
PASS OVER A COMPACTED PORTION OF THE EMBANKMENT BEYOND
CERTAIN LIMITS BY VARYING THE HAULING ROUTES AND RAMPS,
THUS ENSUING THAT OVER COMPACTION DOES NOT TAKE PLACE IN
ANY PARTICULAR REACH. 186
28.3 DURING THE CONSTRUCTION, A SMALL TRANSVERSE SLOPE
FROM CENTRE TOWARDS THE EDGES SHALL BE GIVEN AND
FURTHER IN THE REACH WHEN BANK IS BEING RAISED, THE WORKS
SHALL BE TACKLED IN CONTINUOUS HORIZONTAL LAYERS TO
AVOID POOLS OF WATER AND CONCENTRATION OF ALLOW OF
WATER DURING RAINS, WHICH WILL CAUSE DAMAGES, SCOURS AND
RAIN GULLIES. 186
28.4 SPECIAL PRECAUTIONS SHALL ALSO BE TAKEN WHILE ROLLING
THE SPREAD SOIL NEAR STRUCTURES, CONDUIT, SLUICE BARRELS,
FILTERS, ROCK TOES AT THE JUNCTIONS OF BANK CONNECTIONS
WITH THE STRUCTURES, USING HAND OR POWER TAMPERS. IT IS
ESSENTIAL THAT THE COMPACTION OF FILLING SHOULD BE
CARRIED OUT IN SUCH A MANNER AS TO AVOID AN UNBALANCED
THRUST ON WALLS ETC., WHICH MIGHT DISPLACE OR DAMAGE IT.
THE EQUIPMENT SHALL BE PROVIDED WITH SUITABLY SHAPED
HEADS TO OBTAIN THE REQUIRED DENSITY. 186
29 DOWEL BANKS: 186
29.1 DOWEL BANKS SHALL BE CONSTRUCTED TO THE DIMENSIONS,
GRADES, SLOPES AS SHOWN ON THE DRAWINGS. 186
30 Weather Conditions: 186
30.1 THE EMBANKMENT MATERIAL SHALL BE PLACED ONLY WHEN
THE WEATHER CONDITIONS ARE SATISFACTORY TO PERMIT
ACCURATE CONTROL OF THE MOISTURE CONTENT IN THE
EMBANKMENT MATERIALS. DURING THAT PART OF THE
CONSTRUCTION PERIOD WHEN THE TOP SURFACE OF THE
EMBANKMENT MAY BE SUBJECT TO RAINFALL CAUSING CESSATION
OF WORK, IT SHALL BE GRADED AND ROLLED WITH A SMOOTH
WHEELED ROLLERS TO FACILITATE RUNOFF. PRIOR TO RESUMING
WORK, THE TOP SURFACE SHOULD BE SLIGHTLY SCARIFIED AND
MOISTENED OR ALLOWED TO DRY AS NECESSARY AND APPROVED
BY THE ENGINEER-IN-CHARGE. IF THE CESSATION DUE TO ANY
REASON, IS FOR A CONSIDERABLE PERIOD, TOP LAYER SHALL BE
STRIPPED TO THE REQUIRED DEPTH AS MAY BE DIRECTED BY THE
ENGINEER-IN-CHARGE SO AS TO REMOVE ANY VEGETABLE
GROWTH, LOOSE SILT OR SAND WASHINGS OR OTHER
OBJECTIONABLE MATTER. 186
30.2 THE CONTRACTOR SHALL PROVIDE SUITABLE PROTECTION
WORKS PROTECT THE SLOPE FROM EROSION DUE TO RAIN WATER.
NO PAYMENT WHATSOEVER SHALL BE MADE FOR PROVIDING SUCH
PROTECTION WORK AND RECTIFYING ANY MONSOON DAMAGES. 186
31 Dressing Slopes 186
THE OUTSIDE SLOPES OF THE EMBANKMENT SHALL BE NEATLY
DRESSED TO LINES AND GRADES AS PLACEMENT OF FILL PROGRESS.
186
ALL HUMPS AND HOLLOWS VARYING MORE THAN 15 CM FROM THE
NEAT LINES OF THE EMBANKMENT SHALL BE REGARDED.
MATERIAL USED TO FILL DEPRESSION SHALL BE THOROUGHLY
COMPACTED AND BONDED TO THE ORIGINAL SURFACE. SLOPES
SHALL BE MAINTAINED UNTIL FINAL COMPLETION AND
ACCEPTANCE. ANY MATERIAL THAT IS LOST BY RAINS,
WEATHERING OR OTHER CAUSE SHALL BE REPLACED AT HIS COST
OF AGENCY EXECUTING THE WORK. 187
32 Settlement Allowance 187
32.1 IN THE EARTH FILL EMBANKMENT WATERED, ROLLED AND
COMPACTED AT OPTIMUM MOISTURE CONTENT AND AT DRY
DENSITY EXPRESSED AS PERCENTAGE OF PROCTORS MAXIMUM
DRY DENSITY AS GIVEN IN APPENDIX-I, SETTLEMENT ALLOWANCE
OF 1% AND 2% OF THE DESIGNED HEIGHT FOR UN-YIELDING (ROCK)
AND COMPRESSIBLE (SOIL) FOUNDATIONS RESPECTIVELY SHALL BE
PROVIDED. THE BASE WIDTH OF THE DAM WILL NOT BE INCREASED
TO MAINTAIN THE DESIGN SLOPES INDICATED IN THE DRAWINGS
FOR THE ADDITIONAL HEIGHT AS SETTLEMENT ALLOWANCE, BUT
THE FOLLOWING PROCEDURE WILL BE ADOPTED. 187
32.2 SETTLEMENT ALLOWANCE WILL BE CALCULATED AT VARIOUS
LEVELS, WHERE THE SLOPE IS TO BE CHANGED AND ELEVATIONS
INCLUDING SETTLEMENT ALLOWANCE WILL BE DERIVED. THE
EMBANKMENT WIDTH AT THE DESIGNED LEVELS REMAINING SAME.
THE EDGES OF EMBANKMENT AT THE INCREASED ELEVATION
(INCLUDING SETTLEMENT), WHEN JOINED WITH THE POINT WHERE
THE SLOPE HAS CHANGED EARLIER BELOW SHALL GIVE THE SLOPE
TO BE ADOPTED FOR CONSTRUCTION. 187
32.3 IF THE EMBANKMENT IS RAISED IN MORE THAN ONE SEASON,
PROVISION FOR SETTLEMENT SHALL BE MADE IN THE LAST
SEASONS CONSTRUCTION BY SLIGHT STEEPENING OF SLOPES NEAR
THE TOP. 187
33 Toe Drains : 187
33.1 PITCHED TOE DRAINS WITH FILTER WILL BE PROVIDED
THROUGHOUT THE LENGTH OF THE DAM AT THE DOWNSTREAM
TOE OF EARTH DAM AS INDICATED IN THE DRAWINGS AND AS PER
THE DETAILS SHOWN THEREIN. THE LAYER OF HORIZONTAL FILTER
UNDER THE CASING PORTION OF DAM SHALL BE EXTENDED IN THE
TOE DRAINS TO SPECIFIED THICKNESS. THE FILTER SHALL BE
WATERED AND TAMPED WITH HAND TAMPERS. 187
33.2 THE USEFUL EXCAVATED MATERIAL OUT OF THE TOE DRAIN
SHALL BE SUITABLY UTILISED ON THE DAM AS DIRECTED BY THE
ENGINEER-IN-CHARGE. 187
34 SURFACE DRAINS: 187
34.1 THIS WORK SHALL CONSIST OF CONSTRUCTING SURFACE
DRAINS, SCHEDULE OF WORK SHALL BE SO ARRANGED THAT THE
DRAINS ARE COMPLETED IN PROPER SEQUENCE WITH CANAL
EXCAVATION WORKS AS NECESSARY SUBSEQUENTLY OR NO
DAMAGE IS CAUSED TO THESE WORKS DUE TO LACK OF DRAINAGE.
187
34.2 SURFACE DRAINS SHALL BE EXCAVATED TO THE SPECIFIED
LINES, GRADES, LEVELS AND DIMENSIONS. THE EXCAVATED SOILS
SHALL BE REMOVED FROM THE AREA ADJOINING THE DRAINS. AND
IS FOUND SUITABLE UTILIZED IN EMBANKMENT CONSTRUCTION.
ALL UNSUITABLE SOILS SHALL BE DISPOSED OFF AS DIRECTED. 187
34.3 THE EXCAVATED BED AND SIDES OF DRAINS SHALL BE DRESSED
TO BRING THESE IN CLOSE CONFORMITY WITH THE SPECIFIED
DIMENSIONS, LEVELS AND SLOPES. 187
34.4 ALL WORKS ON DRAIN CONSTRUCTIONS SHALL BE PLANNED
AND EXECUTED IN PROPER SEQUENCE WITH OTHER WORKS AS
APPROVED BY EXECUTIVE ENGINEER WITH VIEW TO ENSURE
ADEQUATE DRAINAGE FOR THE AREA. 188
35 Side drains: 188
35.1 THE LOCATION, GRADES AND SECTIONS OF THE DRAINS SHALL
BE AS SHOWN ON THE DRAWINGS AND OR AS DIRECTED.
MEASUREMENT OF EXCAVATION FOR THE ABOVE DRAINS WILL BE
MADE TO THE LINES SHOWN ON THE DRAWINGS OR AS DIRECTED.
188
36 ROAD SURFACES AND PARAPETS 188
36.1 ROAD SHALL BE CONSTRUCTED AT THE TOP OF THE
EMBANKMENT AND AT OTHER LOCATIONS AS INDICATED IN THE
DRAWING. THE ROADWAY SHALL BE AS INDICATED IN DRAWING.
THE CONSTRUCTION SHALL BE AS SPECIFIED FOR THE HIGHWAY BY
I.R.C. OR AS DIRECTED BY THE ENGINEER-IN-CHARGE. 188
36.2 THE PARAPETS SHALL ALSO BE CONSTRUCTED AFTER
ALLOWING SUFFICIENT TIME FOR THE EMBANKMENT TO UNDERGO
THE USUAL POST CONSTRUCTION SETTLEMENT IN ORDER TO AVOID
CRACKING OF THE WALLS DUE TO DIFFERENTIAL SETTLEMENT. 188
37 PROTECTION: 188
37.1 THE CONTRACTOR SHALL TAKE ALL PRECAUTIONS NECESSARY
FOR THE PROTECTION OF THE WORK BY DIVERSION OF STREAM
LOCAL SURFACE DRAINAGE, RAIN WATER ETC. IF THESE ARE
LIKELY, TO DAMAGE THE WORK. ANY DAMAGE TO EARTH WORK
DUE TO ANY REASON WHAT SO EVER SHALL BE MADE GOOD BY THE
CONTRACTOR AT HIS COST TILL THE WORK IS CERTIFIED AS
COMPLETED AND TAKEOVER BY THE SUPERINTENDING
ENGINEER/ENGINEER-IN-CHARGE. 188
38 ROADS AND RAMPS: 188
38.1 THE CONTRACTOR SHALL CONSTRUCT, OPERATION, AND
MAINTENANCE ROADS AND EARTH RAMPS ADJACENT TO THE
CANAL AND STRUCTURES AT HIS OWN EXPANSES. SUITABLE
MATERIALS FROM EXCAVATION OR BORROW AREAS SHALL BE
PLACED AS EMBANKMENT FOR THE ROADS AND RAMPS. THE WIDTH
OF THE ROAD SHALL BE NOT LESS THAN 4.25M. 188
39 (a) rip-rap on the upstream slope of embankment 188
Hand Placed Rip-Rap 188
39 Dry Stone Pitching : 190
39.1 THE DEPTH OF STONES SHALL BE ABOUT EQUAL TO THE
SPECIFIED THICKNESS OF PITCHING AND SHALL GENERALLY BE
NOT LESS THAN 0.014 CUM OR 0.021 CUM AS SPECIFIED IN THE
APPROPRIATE ITEM OF USR OR OTHER SIZE AS ORDERED BY THE
ENGINEER-IN-CHARGE HAVING REGARD TO THE NATURE OF STONES
BEING QUARRIED. THE SMALL SIZE STONES/SPALLS REQUIRED FOR
PITCHING AND WEDGING SHALL BE BROUGHT TO THE SITE ONLY TO
THE REQUIRED EXTENT AND THEY SHALL NOT TO BE USED IN TWO
OR MORE THICKNESS AS A SUBSTITUTE FOR THE STONES OF FULL
THICKNESS. A LARGE AMOUNT OF THE STONES FOR PITCHING
SHALL BE OBTAINED FROM THE REQUIRED EXCAVATION FOR
OTHER PARTS OF THE WORK. ADDITIONAL ROCK AS REQUIRED
SHALL BE OBTAINED FROM ROCK QUARRIES. 190
39.2 PLACING 190
39.3 TOLERANCE : THE TOLERANCE ON THE NOMINAL THICKNESS
OF RIP-RAP ENFORCED ON THE PERFORMED PROFILE SHALL BE 10
(TEN) PERCENT. 191
40 Dry Picked up boulder pitching 191
40.1 THE BOULDERS USED IN THIS TYPE OF PITCHING SHALL
CONSISTS OF THE ROLLED ROCK MASSES DIRECTLY PICKED UP IN
THEIR NATURAL FORM FROM THE RIVER OR THE NALLA BEDS. THE
BOULDERS SHALL BE HARD, DENSE AND RESISTANT TO ABRASION.
THE SIZE OF THE BOULDERS IN AT LEAST ONE DIRECTION SHOULD
NOT NORMALLY BE LESS THAN 22 CM. ALSO THE LEAST DIMENSION
OF SUCH BOULDERS IN ANY DIRECTION SHOULD NOT BE LESS THAN
10 CM. THE SMALLER SIZE BOULDERS/GRAVELS REQUIRED FOR
PACKING AND WEDGING SHALL BE BROUGHT TO THE SITE ONLY TO
THE REQUIRED EXTENT AND SHALL NOT BE USED IN TWO OR MORE
LAYERS AS A SUBSTITUTE FOR THE BOULDERS OF FULL THICKNESS.
191
40.2 PLACING : 191
41 Dry Quarried Boulders Pitching 191
41.1 THE SPECIFICATION AS IN CLAUSE 39 SHALL BE FOLLOWED
EXCEPT THAT THE BOULDERS OF REQUIRED SIZE SHALL BE
OBTAINED BY BREAKING BIG SIZE BOULDERS. 191
APPROPRIATE ITEM OF USR OR OTHER SIZES AS ORDERED BY THE
BEING QUARRIED. THE SMALL SIZE STONES/ SPALLS REQUIRED FOR
41.3 PLACING : BACKING OF FILTER AND/OR SPALLS WHERE
SPECIFIED ON DRAWING SHALL BE PLACED ONLY AFTER THE
UNDERLYING SLOPE SHALL BE TRIMMED NEATLY TO THE SLOPES
AND GRADES ESTABLISHED ON THE DRAWINGS. THE LOWEST
COURSE OF PITCHING SHALL BE STARTED FROM THE TOE WALL OR
THE LINE OF PINHEADERS AT THE TOE OF THE SLOPE AS MAY BE
SPECIFIED ON THE DRAWING AND THE PITCHING LAID COURSE BY
COURSE UP THE SLOPE. 192
42 ROCK TOE 192
42.1 THE ROCK FILL SHALL CONSIST OF FREE DRAINING MIXTURE
OF ROCK FRAGMENTS OF SIZES FROM 75MM TO 250MM. A LARGE
AMOUNT OF MATERIAL MAY BE OBTAINED FROM REQUIRED
EXCAVATION FOR OTHER PARTS OF THE WORK. ADDITIONAL, AS
REQUIRED SHALL BE OBTAINED FROM ROCK QUARRIES. 192
42.2 SUCCESSIVE LOADS OF MATERIAL SHALL BE DUMPED AS TO
SECURE THE BEST PRACTICABLE DISTRIBUTION OF MATERIALS.
THE LARGE ROCK FRAGMENTS SHALL BE PLACED ON THE OUTER
SLOPES AND THE SMALLER FRAGMENT SHALL BE PLACED TOWARDS
THE EARTH FILL SIDE. IN GENERAL, THE DOWNSTREAM TOE SHALL
BE PLACED IN THE MANNER TO BE APPROVED BY THE ENGINEER-IN-
CHARGE. 192
42.3 THE ROCK FILL SHALL BE PLACED IN HORIZONTAL LAYERS NOT
EXCEEDING 90 CM IN THICKNESS. THE COMPLETED FILL SHALL BE
STABLE AND NO LARGE UNFILLED SPACES SHALL BE PRESENT IN
THE FILL. 192
42.4 LARGE VOIDS, SHALL NOT BE ALLOWED ON THE DOWNSTREAM
FACE OF THE ROCK TOE, SO AS TO PREVENT CHOKING BY THE
SPILLING OF EARTH, RAIN CUTS, ETC. DURING AND AFTER
CONSTRUCTION. SUCH VOIDS SHALL BE PROPERLY PACKED WITH
STONE CHIPS OF SUITABLE SIZES. THE SURFACE OF THE ROCK TOE
SHALL BE KEPT CLEAR OF ALL EARTH AND DEBRIS SO AS NOT TO
CHOKE ITS FULL DRAINAGE CAPACITY. 192
42.5 THE FILTER LAYERS TO BE PROVIDED BEHIND AND BELOW THE
ROCK TOE SHALL SATISFY THE REQUIREMENTS OF AS BELOW 192
42.6 BASE FILTER BLANKETS: 192
43 BORROW AREAS 195
43.1 ALL MATERIALS REQUIRED FOR THE CONSTRUCTION OF
IMPERVIOUS, SEMI PERVIOUS OR PERVIOUS ZONES OF
EMBANKMENT, WHICH ARE NOT AVAILABLE FROM EXCAVATION AND
SURPLUS MATERIAL FROM OTHER REACHES SHALL BE OBTAINED
FROM DESIGNATED BORROW AREAS AS SHOWN IN DRAWINGS OR AS
DESIGNATED BY THE FIELD LABORATORY. 195
THE LIMITS OF EACH BORROW AREAS TO BE USED IN THE VARIOUS
ZONES OF EMBANKMENT SHALL BE FLAGGED IN THE FIELD AND
MATERIAL FROM EACH BORROW AREA SHALL BE PLACED ONLY IN
THE ZONES FOR WHICH IT HAS BEEN SPECIFIED. 195
THE DEPTH OF CUT IN ALL BORROW AREAS WILL BE DESIGNATED
BY THE EXECUTIVE ENGINEER AND THE CUTS SHALL BE MADE TO
SUCH DESIGNATED DEPTHS ONLY. SHALLOW CUTS WILL BE
PERMITTED IN THE BORROW AREA, IF UNSTRATIFIED MATERIAL
WITH UNIFORM MOISTURE CONTENTS ARE ENCOUNTERED. EACH
DESIGNATED BORROW AREA SHALL BE FULLY EXPLOITED BEFORE
SWITCHING OVER TO THE NEXT DESIGNATED BORROW PITS.
HAPHAZARD EXPLOITATION OF BORROW AREA SHALL NOT BE
PERMITTED. THE TYPE OF EQUIPMENT USED AND THE OPERATIONS
IN THE EXCAVATION OF MATERIALS IN BORROW AREAS SHALL BE
SUCH AS WILL PRODUCE THE REQUIRED UNIFORMITY OF MIXTURE
OF MATERIALS FOR THE EMBANKMENT. 195
BORROW PITS SHALL NOT BE OPENED WITHIN A DISTANCE OF TEN
TIMES THE HEIGHT OF THE EMBANKMENT FROM THE TOES (ON
EITHER SIDE). BORROW PITS SHALL BE OPERATED SO AS NOT TO
IMPAIR THE USEFULNESS OR MAR THE APPEARANCE OF ANY PART
OF THE WORK OR ANY OTHER PROPERTY. THE SURFACE OF WASTED
MATERIALS SHALL BE LEFT IN A REASONABLE SMOOTH AND EVEN
CONDITION. 195
44 Preparation of Borrow Areas 195
44.1 ALL AREAS REQUIRED FOR BORROWING EARTH FOR
EMBANKMENT SHALL BE CLEARED OFF ALL TREES AND STUMPS,
ROOTS, BUSHES RUBBISH AND OTHER OBJECTIONABLE MATERIAL.
PARTICULAR CARE SHALL BE TAKEN TO EXCLUDE ALL ORGANIC
MATTER FROM THE MATERIAL TO BE PLACED IN THE DAM
EMBANKMENT. ALL CLEARED ORGANIC MATERIALS SHALL BE
COMPLETELY BURNT TO ASHES OR DISPOSED OFF AS DIRECTED.
THE CLEARED AREAS SHALL BE MAINTAINED FREE OF VEGETABLE
GROWTH DURING THE PROGRESS OF THE WORK. 195
45 Stripping of Borrow Areas 195
45.1 BORROW AREA SHALL BE STRIPPED OF TOPSOIL, SOD AND ANY
OTHER MATTER WHICH IS UNSUITABLE FOR THE PURPOSE FOR
WHICH THE BORROW AREA IS TO BE EXCAVATED. STRIPPING
OPERATIONS SHALL BE LIMITED ONLY TO DESIGNATED BORROW
AREAS. MATERIALS FROM STRIPPING SHALL BE DISPOSED OFF IN
EXHAUSTED BORROW AREAS OR IN THE APPROVED ADJACENT
AREAS, AS DIRECTED. 195
46 BORROW PITS 196
46.1 THE BORROW PITS SHALL NOT NORMALLY BE MORE THAN 25M
IN LENGTH, AND 10M IN WIDTH AND 11/2 M. DEPTH. A CLEAR SPACING
OF ONE METER BETWEEN EACH PIT SHALL BE LEFT OUT. 196
46.2 THE DEPTH OF THE PITS SHALL BE SO REGULATED THAT THEIR
BOTTOM DOES NOT CUT THE HYDRAULIC GRADIENT LINE HAVING A
SLOPE 4:1 FROM THE TOP EDGE OF THE EMBANKMENT. 196
46.3 IN NO CASE THE PITS SHALL BE LOCATED WITHIN 10H FROM
THE TOE OF THE EMBANKMENT. 196
46.4 IF THE CONTRACTOR EXCAVATED THE PITS NEAR TO THE TOE
AGAINST TO THE ABOVE CLAUSES AND THE SAME IS OBSERVED AT
ANY TIME DURING OR AFTER THE EXECUTION OF WORK, THE
CONTRACTOR HAS TO FILL THE SAME PITS WITH THE SOILS
SUITABLE FOR HEARTING ZONE OF EMBANKMENT AND COMPACT
TO 98% PROCTORS DENSITY AT THE COST OF CONTRACTOR. 196
47 Borrow Area Watering 196
47.1 BORROW AREA WATERING IF NEEDED BASED ON LABORATORY
TESTS WILL BE DONE BY THE CONTRACTOR AS DECIDED BY THE
THE PLACEMENT MOISTURE CONTENT FOR PROPER COMPACTION
OF EARTHWORK SHOULD BE AS NEAR AS PRACTICABLE TO
OPTIMUM MOISTURE CONTENT AS DECIDED BY LABORATORY
TESTS. HOWEVER, DEPENDING UPON THE SITE CONDITION, THE
NATURE OF THE EARTH OF THE BORROW AREA, THE SEASON OF THE
YEAR, THE MOISTURE CONTENT OF THE EARTH OF BORROW AREA
WILL VARY OVER A WIDE RANGE. THUS IT WOULD BE NECESSARY TO
ADD WATER TO BRING THE MOISTURE CONTENT OF BORROW AREA
EARTH TO AS NEAR OMC AS PRACTICABLE. IN IRRIGATION
PROJECTS, WATERING IN BORROW AREA MAY BE DONE WHERE
WATERING AT THE PLACE OF FILL DOES NOT YIELD REQUIRED
RESULTS. WHEREVER PRACTICABLE AND SPECIALLY DURING DRY
MONTHS PERIODICAL WATERING OF THE BORROW AREA BY
TANKERS AND MOBILE UNITS MAY BE DONE TO THE EXTENT
POSSIBLE AS DECIDED BY ENGINEER-IN-CHARGE. 196
48 DRILLING AND BLASTING 196
48.1 BLASTING WHERE REQUIRED WILL BE PERMITTED ONLY WHEN
PROPER PRECAUTIONS HAVE BEEN TAKEN FOR THE PROTECTION
OF PERSONS AND PROPERTY IN ACCORDANCE WITH I.S. 4081-
1967(INDIAN STANDARD SPECIFICATION FOR SAFETY CODE FOR
BLASTING AND RELATED DRILLING OPERATIONS). WHILE
CARRYING OUT EXCAVATIONS, ADEQUATE PRECAUTIONS IN
ACCORDANCE WITH I.S. 3764-1966(INDIAN STANDARD
SPECIFICATIONS FOR SAFETY CODE FOR EXCAVATION WORK)
SHALL BE TAKEN. 196
48.2 EXPLOSIVE SUCH AS GELATIN, DETONATORS AND FUSE COILS
ETC., REQUIRED FOR THE ROCK BLASTING ARE TO BE PROCURED
BY THE CONTRACTOR AT HIS COST. IT SHALL BE RESPONSIBILITY OF
THE CONTRACTOR TO STORE THE EXPLOSIVES PURCHASED BY HIM
IN ACCORDANCE WITH THE RULES OF THE EXPLOSIVES ACT AND
OTHER RULES FRAMED BY GOVERNMENT OF INDIA. 196
48.3 CONTRACTOR SHALL ALSO FURNISH THE FOLLOWING
DETAILS:- 196
48.4 THE CONTRACTOR SHALL ACQUAINT HIMSELF WITH ALL THE
APPLICABLE LAWS AND REGULATIONS CONCERNING STORING,
HANDLING AND THE USE OF EXPLOSIVES. ALL SUCH LAWS,
REGULATIONS AND RULES, AS PREVALENT FROM TIME TO TIME
SHALL BE BINDING UPON THE CONTRACTOR. 197
48.5 THE PROVISIONS DETAILED IN THE SPECIFICATIONS ARE
SUPPLEMENTARY TO THE ABOVE LAWS; RULES AND REGULATIONS
ARE ALSO APPLICABLE. FURTHER, THE ENGINEER MAY ISSUE
MODIFICATIONS, ALTERATIONS AND NEW INSTRUCTIONS FROM
TIME TO TIME. THE CONTRACTOR SHALL COMPLY WITH THE SAME
WITHOUT THESE BEING MADE A CAUSE OF ANY CLAIMS. 197
48.6 LIST I.S CODES APPLICABLE IS FURNISHED BELOW. 197
48.7 EXCAVATION BY BLASTING WILL BE PERMITTED ONLY UNDER
THE PERSONAL SUPERVISION OF COMPETENT AND LICENSED
PERSONS AND TRAINED WORKMEN EMPLOYED. BY THE
CONTRACTOR AT HIS COST. ALL SUPERVISORS AND WORKMEN
INCHARGE OF, HANDLING, STORAGE AND BLASTING WORK SHALL
BE ADEQUATELY INSURED BY THE CONTRACTOR. 197
48.8 THE PERSON INCHARGE OF THE EXPLOSIVE MAGAZINE SHALL
BE VERY RELIABLE AND SHALL BE APPROVED BY THE ENGINEER. 197
48.9 THE CONTRACTOR SHALL MAKE SURE THAT HIS SUPERVISOR
WORKMEN ARE FULLY CONVERSANT WITH ALL THE RULES TO BE
OBSERVED IN STORING, HANDLING AND USE OF THE EXPLOSIVES. IT
SHALL BE ASSURED THAT THE SUPERVISOR INCHARGE, IS
THOROUGHLY ACQUAINTED WITH ALL THE DETAILS OF HANDLING
AND THE BLASTING OPERATIONS. 197
49.1 FOR THE TRANSPORT OF THE EXPLOSIVES AND DETONATORS
BETWEEN THE STORE AND THE SITE, CLOSED AND STRONG
CONTAINER MADE OF SOFT MATERIALS SUCH AS TIMBER, ZINC,
COPPER, LEATHER SHALL BE USED. 197
49.2 EXPLOSIVES AND DETONATORS SHALL BE CARRIED IN
SEPARATE BOXES. FOR THE CONVEYANCE OF PRIMER, SPECIAL
CONTAINER SHALL BE USED. 197
49.3 THE BOXES AND CONTAINERS USED, SHALL BE KEPT CLOSED.
EXPLOSIVES SHALL BE STORED AND USED CHRONOLOGICALLY,
EARLIER RECEIVED SHALL BE USED FIRST . A MAKE UP HOUSE
SHALL BE PROVIDED AT EACH WORKING PLACE IN WHICH
CARTRIDGES WILL BE MADE UP BY COMPETENT AND LICENSED MEN
AS REQUIRED FOR THE WORK. THE MAKE UP HOUSE SHALL BE
SEPARATED FROM OTHER BUILDINGS. ONLY ELECTRIC STORAGE
BATTERY LAMPS SHALL BE USED IN THIS HOUSE. 197
49.4 NO SMOKING SHALL BE ALLOWED IN THE MAKE UP HOUSE OR
GENERALLY WHILE DEALING WITH EXPLOSIVES. 198
50 DISPOSAL OF DETERIORATED EXPLOSIVES 198
50.1 ALL DETERIORATED EXPLOSIVES SHALL BE DISPOSED OF IN
APPROVED MANNER THE QUALITY OF THE DETERIORATED
EXPLOSIVES TO BE DISPOSED OF SHALL BE INTIMATED TO THE
ENGINEER PRIOR TO ITS DISPOSAL. 198
51 PREPARATION OF PRIMERS 198
51.1 THE PRIMERS SHALL NOT BE PREPARED NEAR OPEN FLAMES OR
FIRE. THE WORK OF PREPARATION OF PRIMERS SHALL ALWAYS BE
ENTRUSTED TO THE SAME PERSONAL. PRIMERS SHALL BE USED AS
EARLY AS POSSIBLE AFTER THEY ARE READY. 198
52 CHARGING OF HOLES 198
52.1 THE WORK OF CHARGING OF HOLES SHALL NOT COMMENCE
BEFORE ALL THE DRILLING WORK AT THE SITE IS COMPLETED AND
THE CONTRACTORS SUPERVISOR SHALL SATISFY HIMSELF TO THAT
EFFECT BY ACTUAL INSPECTION. WHILE CHARGING, OPEN LAMPS
SHALL BE KEPT AWAY. FOR CHARGING WITH POWERED
EXPLOSIVES, A NAKED FLAME SHALL NOT BE ALLOWED. ONLY
WOODEN TAMPING ROADS, WITHOUT ANY KIND OF METAL ON THE
ROD SHALL BE ALLOWED TO BE USED. THE TAMPING ROADS SHALL
HAVE CYLINDRICAL ENDS. BORE HOLE MUST BE OF SUCH SIZE THAT
THE CARTRIDGES CAN EASILY PASS DOWN THEM, THEY SHALL NOT
HOWEVER BE TOO BIG. 198
52.2 ONLY ONE CARTRIDGE SHALL BE INSERTED AT A TIME AND
GENTLY PRESSED INTO THE HOLE WITH THE TAMPING RODS. THE
SAND, CLAY OR OTHER TAMPING MATERIALS USED FOR FILLING
THE HOLES COMPLETELY SHALL NOT BE TAMPED TOO HARD. 198
53 BLASTING 198
53.1 BLASTING SHALL BE CARRIED DURING THE FIXED HOURS OF
THE DAY WHICH SHALL HAVE THE APPROVAL OF THE ENGINEER.
THE HOURS ONCE FIXED SHALL NOT BE ALTERED WITHOUT PRIOR
WRITTEN APPROVAL OF THE ENGINEER-IN-CHARGE. 198
53.2 THE SITE OF BLASTING OPERATIONS SHALL BE PROMINENTLY
DEMARCATED BY RED DANGER FLAGS. THE ORDER TO FIRE SHALL
BE GIVEN ONLY BY THE CONTRACTORS SUPERVISOR INCHARGE OF
THE WORK AND THIS ORDER SHALL BE GIVEN ONLY AFTER GIVING
THE WARNING SIGNAL THREE TIMES, SO AS TO ENABLE ALL THE
LABOUR, WATCHMEN ETC., TO REACH SAFE SHELTERS. 198
53.3 A WHISTLE/BIGGLE WITH DISTINCTIVE NOTE SHALL BE USED TO
GIVE THE WARNING SIGNALS. THE BIGGLE SHALL NOT BE USED FOR
ANY OTHER PURPOSES. ALL THE LABOUR SHALL BE MADE
ACQUAINTED WITH THE SOUND OF THE BIGGLE AND SHALL BE
STRICTLY WARNED TO LEAVE THEIR WORK IMMEDIATELY AT THE
FIRST WARNING SIGNAL AND TO MOVE FOR SAFE SHELTERS. THEY
ARE NOT TO LEAVE THE SHELTERS UNTIL ALL CLEAR SIGNAL HAS
BEEN GIVEN. 198
53.4 ALL THE ROADS AND FOOTPATHS LEADING TO THE BLASTING
AREAS SHALL BE WATCHED. 198
53.5 IN SPECIAL CASES, SUITABLE EXTRA PRECAUTIONS SHALL BE
TAKEN. THE ENGINEER-IN-CHARGE MAY HOWEVER PERMIT
BLASTING FOR UNDER GROUND EXCAVATION, WITHOUT
RESTRICTION OF FIXED TIME, PROVIDED THAT HE IS SATISFIED
THAT PROPER PRECAUTIONS ARE TAKEN TO GIVE SUFFICIENT
WARNING TO ALL CONCERNED AND THAT THE WORK OF OTHER
AGENCIES ON THE SITE IS NOT HAMPERED. FOR LIGHTNING THE
FUSE, A LAMP WITH A STRONG FLAME SUCH AS A CARBIDE LAMP
SHALL BE USED. 198
53.6 THE CONTRACTORS SUPERVISOR SHALL WATCH THE REQUIRED
TIME FOR THE FIRING OF THE FUSES AND SHALL SEE THAT ALL THE
WORKMEN ARE UNDER SAFE SHELTERS IN GOOD TIME. 199
54 ELECTRICAL FIRING 199
54.1 ONLY THE CONTRACTORS SUPERVISOR INCHARGE SHALL
POSSES KEY OF THE EXPLODER AND SHORT FIRING ACCESSORIES
AND HE SHALL KEEP IT ALWAYS WITH HIMSELF. SPECIAL
APPARATUS SHALL BE USED AS A SOURCE OF CURRENT FOR THE
BLASTING OPERATIONS; POWER LINES SHALL NOT BE TAPPED FOR
THE PURPOSE. 199
54.2 THE DETONATORS SHALL BE CHECKED BEFORE USE. FOR BLAST
IN SERIES, ONLY DETONATORS OF THE SAME MANUFACTURE AND OF
THE SAME GROUP OF ELECTRICAL RESISTANCE SHALL BE USED.
SUCH OF THE ELECTRICAL LINES AS COULD CONSTITUTE DANGER
FOR WORK OF CHARGING SHALL BE REMOVED FROM THE SITE. THE
FIRING CABLES SHALL HAVE A PROPER, INSULATING COVER SO AS
TO AVOID SHORT CIRCUITING DUE TO CONTACT WITH WATER,
METALLIC PARTS OF ROCK ETC., 199
54.3 THE FIRING CABLES SHALL BE CONNECTED TO SOURCE OF
CURRENT ONLY WHEN NOBODY IS IN THE AREA OF BLASTING.
BEFORE FIRING, THE CIRCUIT SHALL BE CHECKED BY A SUITABLE
APPARATUS. AFTER FIRING WITH OR WITHOUT AN ACTUAL BLAST,
THE CONTACT BETWEEN THE FIRING CABLE AND THE SOURCE OF
CURRENT SHALL BE CUT OFF BEFORE ANY ONE IS ALLOWED TO
LEAVE THE SHELTERS. DURING STORM RAIN THE BLASTING
OPERATION SHALL BE SUSPENDED. 199
55 PRECAUTIONS AFTER BLASTING 199
55.1 AFTER THE BLAST, THE CONTRACTORS SUPERVISOR MUST
CAREFULLY INSPECT THE WORK AND SATISFY HIMSELF THAT ALL
THE CHARGES HAVE EXPLODED. AFTER THE BLAST HAS TAKEN
PLACE IN THE UNDERGROUND WORKS, WORKMEN SHALL NOT BE
ALLOWED TO GO TO THE PLACE TILL THE TOXIC GASES ARE
EVACUATED FROM THE PLACE. 199
55.2 MISFIRES:- IF IT IS SUSPECTED THAT PART OF THE BLAST HAS
FAILED TO FIRE OR IS DELAYED SUFFICIENT TIME SHALL BE
ALLOWED TO ELAPSE BEFORE ENTERING THE DANGER ZONE.
WHEN FUSE AND BLASTING CAPS ARE USED, A SAFE TIME SHOULD
BE ALLOWED AND THEN THE CONTRACTORS SUPERVISOR ALONG
SHALL LEAVE THE SHELTER TO SEE MISFIRE. 199
55.3 NONE OF THE DRILLERS ARE TO WORK NEAR THIS HOLE UNTIL
ONE OF THE TWO FOLLOWING OPERATIONS HAVE BEEN CARRIED
OUT BY THE SUPERVISOR. 199
55.4 BEFORE LEAVING HIS WORK, THE CONTRACTORS SUPERVISOR
SHOULD INFORM THE SUPERVISOR OF THE RELIEVING SHIFT OF
ANY CASE OF MISFIRES AND SHOULD POINTOUT THE POSITION
WITH RED CROSS DENOTING THE SAME, ALSO STATING WHAT
ACTION IF ANY, HE HAS TAKEN IN THE MATTER. A REGISTER OF
MISFIRES AND THEIR LOCATION AND HOW THEY WERE DEALT WITH
SHALL BE MAINTAINED BY THE CONTRACTOR. 199
55.5 THE CONTRACTORS SUPERVISOR SHOULD ALSO AT ONCE
REPORT AT THE CONTRACTORS OFFICE ALL CASES OF MISFIRES,
THE CAUSE OF THE SAME AND STEPS WERE TAKEN IN CONNECTION
THERE WITH. 200
55.6 THE NAMES OF THE DAY AND NIGHT SHIFT SUPERVISORS OF THE
CONTRACTOR MUST BE NOTED DAILY IN THE CONTRACTORS
OFFICE. IF MISFIRE HAS BEEN FOUND TO BE DUE TO A DEFECTIVE
DETONATOR, OR DYNAMITE, THE WHOLE QUANTITY OF BOX FROM
WHICH THE DEFECTIVE ARTICLES WAS TAKEN MUST BE RETURNED
TO THE CONTRACTORS OFFICE FOR INSPECTION, AND SHALL BE
DISPOSED OF. 200
55.7 DRILLING IN THE HOLES NOT COMPLETELY EXPLODED BY
BLASTING SHALL NOT BE PERMITTED. 200
55.8 THE CONTRACTOR SHOULD PRODUCE THE FIRERS LICENSE
AND FURNISH THE PARTICULARS IN THE FOLLOWING STATEMENT.
200
55.9 BLASTING OPERATION, WHEN CONSIDERED NECESSARY SHALL
BE RESORTED TO ONLY WITH THE WRITTEN PERMISSION OF THE
ENGINEER-IN-CHARGE. PRIOR INSPECTION SHALL BE CARRIED OUT
FOR THE SAFETY OF THE PUBLIC PROPERTY. BLASTING
OPERATIONS IN THE PROXIMITY OF OVER-HEAD POWER LINES,
COMMUNICATION LINES, UTILITY LINES OR OTHER STRUCTURES
SHALL NOT BE CARRIED OUT UNTIL THE OPERATOR OR THE OWNER
OR BOTH OF SUCH LINES HAVE BEEN NOTIFIED AND
PRECAUTIONARY MEASURES DEEMED NECESSARY HAVE BEEN
TAKEN. 200
56 Before Compaction 200
56.1 MATERIALS DELIVERED TO THE FILL SHALL BE VISUALLY
EXAMINED AND THEIR PROPERTIES ESTIMATED BY WAY OF
INSPECTION. THESE CHECKS SHALL INCLUDE: 200
57 During Compaction 201
58 After Compaction 201
59 Frequency of Testing 201
59.1 THE FREQUENCIES FOR VARIOUS TESTS FOR EARTHWORK
SHALL BE IN ACCORDANCE WITH APPENDIX 6.02 OF THE M.P.W.D.
MANUAL 1983, VOL. II, PART II. 201
59.2 SPECIAL ATTENTION SHALL BE GIVEN TO THE FOLLOWING
LOCATIONS WHERE INSUFFICIENT COMPACTION IS LIKELY TO
OCCUR:- 201
60 Record and Reports 202
61 Field Test Data 202
61.1 RECORDS OF FIELD TEST DATA RESULTS SHOULD BE PRESENTED
IN THE FORM OF STATISTICAL ANALYSIS SHEETS AND SUMMARY
SHEETS IN ORDER TO PROVIDE CONTROL REQUIRED FOR
ENFORCEMENT OF STATISTICAL REQUIREMENTS OF THE
SPECIFICATIONS. 202
61.2 THE TEST DATA SUMMARY SHEETS AND INSPECTION REPORTS
BE USED TO FORM THE BASIS OF CONSTRUCTION CONTROL REPORT,
WHICH SHOULD BE ISSUED FROM THE SITE AT FORTNIGHTLY
INTERVALS DURING CONSTRUCTION SEASON. THE REPORT WOULD
CONTAIN NARRATIVE ACCOUNTS OF THE PROGRESS AND PROBLEMS
OF FILL CONSTRUCTION, STATISTICAL ANALYSIS OF TEST DATA AND
PHOTOGRAPHS OF THE FILL OPERATIONS. 202
62 Turfing 203
4.18 Transverse Contraction Joint In Dam/Barrage : 204
4.18.1 General Vertical transverse contraction joints shall be provided in the masonry
and/or concrete of the dam/barrage for convenience in construction and to provide for
contraction of masonry/concrete. The location and details of these joints shall be as shown on
the drawings. The joint shall extend through the full cross section of the dam profile and shall
be started from the foundation. The contraction joint in the concrete portion shall be smooth,
as obtained with plane surfaces of form work. In the case of masonry, the edge of the block at
the joint shall be built with selected stones and the surface plastered with cement mortar
appropriate to the zone. The finish of end block of each contraction joint shall be such that an
average thickness of 40mm plaster gives smooth plumb surface. 204
The joint shall be sealed at the upstream face by installing water stops as described in para
4.18.2 204
4.18.2 Waterstops Across Transverse Contraction Joint : 204
4.18.2.1 Materials : 204
(A) Metal Waterstop The waterstop shall be made out of 1.5mm thick strips of copper or
stainless steel as specified on the drawing conforming to IS:1972-1977 and IS:6911-1972
respectively. 204
Subject to the provisions on the drawing, the water stop shall have either of the two shapes
viz, Z and M shapes shown in Fig.A of PLATE : 1/CH-4.* 204
(B) Rubber / PVC Waterstop The rubber water stop shall be fabricated from natural rubber
and shall meet the test requirement given in relevant parts of IS:3660. 204
The PVC Waterstop shall be fabricated from a plastic compound, the basic resin of which
shall be poly vinyl chloride and shall meet the test requirements given in relevant parts of
IS:8543. The rubber/PVC Waterstop shall meet the requairements given in Table 2. 204
Table-2 : Performance Requirements of Rubber/PVC Waterstops 204
S. No. 204
Characteristics 204
Unit 204
Value 204
i. 204
Tensil Strength 204
N/mm 204
11.6 min 204
ii. 204
Ultimate Elongation 204
% 204
300 min 204
iii. 204
Tear Resistance 204
N/mm 204
4.9 min 204
iv. 204
Stiffness in Flexure 204
N/mm 204
2.46 min 204
v. 204
Accelarated Extraction 204
(a) 204
Tensil Strength 204
N/mm 204
10.5 min 204
(b) 204
% 204
250 min 204
vi. 204
Effect of Alkali (7 Days) 204
(a) 205
Weight Increase 205
% 205
0.25 max. 205
(b) 205
Weight Decrease 205
% 205
0.10 max. 205
(c) 205
Hardness Change 205
Point 205
5 205
vii. 205
Effect of Alkali (28 days) 205
(a) 205
Weight Increase 205
% 205
0.40 max. 205
(b) 205
Weight Decrease 205
% 205
0.30 max. 205
(c) 205
Dimension Change 205
% 205
1 205
*For figure See Specifications Published by Engineer-in-charge 205
Unless specified otherwise the shape and dimensions of Rubber/PVC shall be as given in
Fig.B of PLATE : 1/CH-4* 205
(c) Asphalt Waterstop Recommended specifications of asphalt are given below- 205
(a) Density 1015 - 1065 Kg/m 205
(b) Penetration at 25C 200 300 205
(c) Softening point (Ring and ball test) 80-90C 205
(d) Brittleness test on 22mm specification at 205
5C energy absorbed 0.97 Kg/m 205
The location, shape and dimensions of asphalt waterstop shall be as given in Fig.C of
PLATE : 1/CH-4* 205
4.18.2.2 Installation of Waterstops : 205
4.18.2.2.1 The joints shall be sealed at the upstream face by installing one line of metal
waterstop and one line of Rubber/PVC waterstop separated with one line of Asphalt water
seal in between, as per general arrangement shown in Fig.C of PLATE : 1/CH-4*. In addition
one line of Rubber/PVC waterstop across the joint around galleries/adits shall be provided as
shown in Fig.A of PLATE : 2/CH-4*. 205
4.18.2.2.2 The metal waterstop shall be erected in place with the help of anchor rods. 205
4.18.2.2.3 In the case of masonry dams, the surface adjacent to the blocks-outs (shown by
dotted lines in Fig.C of PLATE : 1/CH-4)* shall be irregular and the joints in the masonry
shall be raked out when mortar is green, with some stones protruding beyond the dotted lines
regularly in both directions. No such block out shall be provided in concrete dams where
concreting on either side of the water seal is done along with the concreting of the rest of
concreting block. 205
4.18.2.2.4 An asphalt waterstop, where specified shall be constructed by forming a well of
square opening with 125mm side across the contraction joints. In this asphalt well, two 12mm
dia steam heating pipes (standard black welded steel) for requalifying asphalt shall be
installed. These pipes will be rigidly clamped in place and will be provided with threads and
caps. The asphalt shall be poured in lifts corresponding to the concrete lift. The stream shall
be passed through steam heating pipes after seal is completed upto top. It shall then be
capped as in the drawing (Fig.B of PLATE : 2/CH-4 and Fig. of PLATE : 3/CH-4)* 205
4.18.2.2.5 25mm dia dowel bars 1500mm long (500mm in concrete and 1000mm in masonry)
at the rate of 500mm centre to centre in both directions shall be provided at the concrete
masonry interface of the block-out in case of masonry dam to prevent shrinkage cracks at the
interface. 205
4.18.2.2.6 Adequate provision shall be made to support and project the waterstops in position
during the progress of work and adequate care taken while removing forms so that the bond
between the seal and masonry or concrete is not broken. To provide good mechanical bond
10mm dia M.S. bars of 500mm length shall be brazed at one end to the sealing strip at 1m
vertical interval. The other end of this bar shall be hooked and tied around 20mm dia bars
embedded vertically in the block-out concrete. 206
4.18.2.2.7 The block-out shall be concreted in lifts not more than 1.5m. Minimum grade of
concrete used in block out shall be M-20. The block out of one block shall be concreted first
and the joint face given a coat of coal tar black paint conforming to IS:290-1961 and then
only the block-out of the second block shall be concreted so as to have a clear contraction
joint. 206
4.18.2.2.8 The concrete surrounding the water stops shall closely follow the masonry in the
block and at no time shall the top of concrete be lower than the general elevation of the
masonry in the lower of the two adjacent blocks by more than 1.5m. 206
4.18.2.2.9 Unless otherwise shown on the drawings, the details of waterstop arrangement (at
contraction joint between two monoliths of a dam) near the top of a non-overflow section
shall be as shown in Fig.B of PLATE : 2/CH-4* and that near the creast of an overflow
section as shown in Fig. of PLATE : 3/CH-1* and near the bottom of the dam in Fig. of
PLATE : 4/CH-4*. 206
4.18.2.2.10 If not shown otherwise on the drawings, Rubber/PVC Waterstops shall be
provided around galleries/adits at the contraction joint between two monoliths of a dam as
4.18.2.3 Jointing : 206
4.18.2.3.1 Rubber/PVC Waterstops shall be jointed in straight reaches only. The waterstops
shall be jointed carefully by heat sealing. 206
4.18.2.3.2 Jointing in Copper/Stainless Water Seals shall be by careful brazing/welding
respectively so as to form a continuous water tight diaphragm. 206
4.19 DIAPHRAGM WALL : 206
4.19.1 Materials : 206
4.19.1.1 Cement : The cement shall be ordinary Portland cement conforming to IS:269-1989
and blast furnace slag cement conforming to IS:455-1976 or pozzolana cement conforming to
IS:1489-1976. Other specifications for storage, testing etc. shall be as described under
relevant paras of Chapter 7 & 16. 206
4.19.1.2 Aggregate All the aggregate (coarse and fine) shall conform to the specification
laid down under relevant paras of Chapter 7 & 16. Unless specified otherwise well graded
coarse aggregate of 20mm size shall be used in reinforced cement concrete diaphragm wall.
For plain concrete, plastic concrete or grout cut wall (Sand, Bitumen, Cement mix) a smaller
size of aggregate may be used. 206
4.19.1.3 Water Clean water free from deleterious impurities as per specification laid down
under relevant paras of Chapter 7 & 16 shall be used in concrete mixing. Water used for
bentonite slurry shall be free from salinity and other deleterious impurities. 206
4.19.1.4 Admixtures If required, chemical admixtures in concrete shall be used as specified
in IS:456-1978. 206
4.19.1.5 Reinforcement Mild steel and high tensile steel bars and hard drawn steel
conforming to IS:432 (Pt-I)-1982. Cold twisted worked bars conforming to IS:1786-1985 and
hard drawn steel wire and fabric conforming to IS:1566-1982 shall be used and structural
steel sections conforming to IS:226-1975 shall be used. 206
4.19.1.6 Concrete Concrete shall conform to detailed specifications laid down under
relevant paras of Chapter 7 &16 and para 4.19.7.3 of this chapter. 207
4.19.1.7 Bentonite Sodium based bentonite shall be used in preparing bentonite slurry. The
concentration of bentonite slurry used shall conform to requirements discussed under para
4.19.3 for sodium and chemically contaminated ground water condition. The slurry may be
suitably processed with chemicals. 207
4.19.1.8 Grouts - In case of grout walls, the cement, clay and chemical grouts used shall be
designed and tested according to requirement of the structure. 207
4.19.1.9 Retarding Agents Retarding agents and expansive additives may be added in the
cement clay grout if required. 207
4.19.2 Equipment and Accessories - 207
4.19.2.1. Trenching Equipment Depending upon the type of soil encountered at the site and
the depth, length and thickness of diaphragm wall to be constructed, suitable trenching
equipment shall be choosen. The general trenching equipment shall include rotary boring
rigs, percussion boring rigs, trenching bucket type shovels, mechanical grabs hydraulic grabs
with Kelly bars, grabs controlled by suspended wire ropes of a crane winch, direct mud
circulation boring rigs, reverse circulation rigs and submersible motor drills for trenching
equipments. For gravelly soils, boulder deposits specially designed chiseling equipments
shall be considered. When required methods using combination of above processes may be
choosen. 207
4.19.2.2 Bentonite Slurry, Preparation and Testing Equipments Tanks of suitable sizes and
slurry pumps of suitable capacity should be used for storage, mixing and circulation of
bentonite slurry at site. A separate water pump may be used for water supply to slurry tank.
Equipment for sampling the slurry from deep trenches and testing its concentration, viscosity.
PH value and hardness of ground water in which the bentonite slurry and concrete are
prepared, should also be used. The testing of slurry after contamination with soil or cement
indicate the need of disposal or reuse as the case may be. Vibrating screens hydrocylones and
centrifuges for cleaning the bentonite slurry for reuse may be employed. 207
4.19.2.3 Concreting Equipment concrete mixers, tremie pipes of suitable length and size
and concrete pouring devices (manual or mechanical) shall be used according to the need of
the work. The lifting arrangement for tremie pipes shall be capable of doing the work with
desired speed. 207
4.19.2.4 Lifting Devices Cranes of suitable capacity and boom length should be used in the
case of precast wall panels for lowering them in the trenches. The same may be used for
stacking the panels at site during casting the panels in the casting shed. The reinforcement
cages of large depths and lengths of wall panels may be lifted by crane, derrick or any other
suitable auxillary rig. If the loads of the panel and reinforcement cage are small, this work
may also be done by which and pulley arrangement provided on the diaphragm walling rig.
Cranes or rigs with winches of adequate capacity may be used for operating the trenching
grabs as necessary. 207
4.19.2.5 General Guide Lines Choice of rotary, percussion, grabbing equipment and
equipment for direct or reverse circulation etc. shall be made to suit the soil conditions.
Vibrations and noise produced during construction should not have any damaging effect on
the people and existing structures. Consideration shall be given in selection of equipment
when they are required to work on a site with restricted space or head room. 207
4.19.3 Specification of Bentonite Slurry - 207
4.19.3.1 Bentonite powder used for preparation of slurry will be tested for its liquid limit and
the liquid limit shall not be less than 300 percent. This is normally prepared using 7% to 16%
by weight of bentonite powder in water. 208
4.19.3.2 Following tests are normally carried out on freshly prepared bentonite slurry to be
used in diaphragm walling. 208
Type of Test 208
Method of Test 208
Permissible Value at 20C 208
Density 208
Mud balance or hydrometer 208
1.04 to 1.10 g/ml 208
PH Value 208
PH indicator paper strips 208
9.5 to 12 208
Viscosity 208
Marsh cone method 208
30 to 90 seconds 208
10-minute gel strength 208
Shearometer or vane shear apparatus 208
1.4 to 10 N/m, 208
(14 to 100 dya/cm) 208
4.19.3.3 The relationship between concentration C of bentonite slurry expressed as
percentage by mass and the density Ys is given below. 208
Ys = 1.0 + 0.006 C 208
Note The above relation is valid for Indian bentonites and represents an average sample.
There may be some variations of bentonites. Laboratory calibration may be prepared for the
bentonite sample actually used. 208
4.19.3.4 Tests to determine density, viscosity, shear strength and PH value shall be carried out
until a consistant working pattern is established, taking into account the mixing process,
blending of freshly mixed bentonite slurry with previously used bentonite slurry. 208
4.19.3.5 When results show consistant behaviour, the test for shear strength and PH value
may be discontinued and only tests required to determine density and viscosity need be
carried out. 208
4.19.3.6 The frequency of testing shall be on panel basis where bentonite slurry becomes
heavily contaminated with fine sand during its first use, and may be on a daily basis where
contamination may be slight. In cases where a mechanical process is employed to remove
contaminating solids from the slurry, the frequency of slurry testing shall depend on
equipment employed. 208
4.19.3.7 Prior to placing of concrete in any panel a bentonite slurry sample shall be taken
(that is, about 0.2m from the trench bottom) and the same shall be tested for density. The
sampling shall be done carefully by an appropriate method. The density thus determined shall
not be greater than 1.25 g/ml to ensure satisfactory placing of concrete. If the slurry is found
to have higher density, the same shall be thinned by feeding in fresh bentonite slurry till the
required density is achieved. 208
4.19.3.8 Suitable slurry pumps, submersible pumps or air lift shall be used in replacing the
contaminated slurry at the bottom of trench by fresh bentonite slurry. 208
4.19.4 Bentonite Slurry and Additives : 208
4.19.4.1 Sodium based bentonite powder shall be mixed thoroughly with potable water to
form a fully dispersed lump-free homogeneous slurry. Suitable slurry taken shall be used for
this operation. The use of a slurry pump with special nozzle (Fig.A of PLATE : 5/CH-4)* is
suggested for preparing bentonite slurry. Use of paddle stirrer or other mechanical devices
such as colloidal grout mixer (Fig.3 of PLATE : 5/CH-4 may also be made for proper mixing
of slurry. The temperature of water used and of the slurry used shall not be less than 5C. 208
For proper stabilisation of the trench walls by bentonite slurry, it is essential to allow
adequate geletion period for bentonite slurry. For this purpose the slurry should not be used
for a period of minimum 12 hours after it is mixed thoroughly. 208
4.19.4.2 Where saline or chemically contaminated ground water is present, special additives
listed below may be used to render bentonite slurry fit for use. These additives are used in
very small amount of 0.1 to 0.5 percent by mass of the slurry. 209
(i) Ferrochrome lignossulphonate in combination with soda ash or bichromate of soda may be
used for effective bentonite hydration if hardness of water exceeds 200 PP. 209
(ii) Sodium carboxymethyl cellulose (S.C.M.C.) is yet another additive some times used. It
protects slurry against effects of electrolytes, accelerates filter cake formation and reduces
fluid loss by increasing the viscosity of slurry. 209
(iii) Cement contamination may be counteracted by phosphates. The calcium gets removed
and clay solids dispersed. Phosphates decrease PH value there by lowering viscosity and
yield value of slurry. 209
(i) Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase viscosity
and reduce filter loss. 209
(ii) To remove fine silty solids and clay solids from the slurry flocoulants may be used. Vinyl
acetate maleic anhydride co-polymer or polyacrylamides may be used. Gaur gum can
flocculate clays, carbonates etc. 209
(iii) Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
protective colloid against the effect of electrolytes. 209
(iv) Stability of slurry filled trenches should be worked out as per procedure described under
Appendix-II. 209
4.19.5 Guide Wall/Pre-Trench : 209
4.19.5.1 RCC guide wall/pre-trench shall be constructed prior to main slurry trenching
operation. 209
4.19.5.2 Guide walls shall be 100 to 250mm thick, 1 to 2 metre deep and made of lightly
reinforced concrete (not inferior than M 10) and shall represent the reference lines. In soft
ground or fill, guide walls may be taken deeper. When ground water is close to the surface,
guide walls higher than the surface level shall be constructed to maintain slurry head. The top
of pre-trench level will be minimum 1.5m above the high water table. 209
4.19.5.3 The clearance between finished diaphragm wall and guide wall shall be 50mm
minimum for straight panels. The clearance shall be suitably increased when the panels are
curved. The finished faces of the guide walls towards the trench shall be vertical. Guide walls
after construction shall be suitably propped where necessary to maintain specified tolerance.
Mesh or cage reinforcement shall be used in guide walls. 209
4.19.5.3.1 For heavy machinery, guide walls shall be constructed with suitable ground slab
(on both sides of the wall). 209
4.19.5.4 Guide walls get support from adjoining panels and therefore, their construction shall
be done continuously. 209
4.19.5.5 The trench shall be kept filled with bentonite slurry before the commencement of
boring/grabbing operation for any diaphragm panel. The level of bentonite slurry in the
trench shall be minimum 1.0m above the ground water table. When the boring operation is in
progress, the level of bentonite slurry will be maintained by addition of bentonite slurry. 209
4.19.6 Methods of Construction : 210
4.19.6.1 General Cast-in-situ structural R.C.C. diaphragm wall shall be constructed by
resorting to either successive panel method or alternate panel method. In successive panel
method, primary panels shall be cast first, leaving suitable gaps in between. Secondary panel
shall then be cast, resulting in a continuous diaphragm wall. The panel lengths very
depending on the soil strata and depth of trenching and surcharging, however lengths of 1.5m
to 6m are usually adopted. 210
4.19.6.2 Successive Panels Method In this method a panel shall be cast in continuation of
previously completed panel. Use of form tubes is generally a joint between primary panels
and secondary panels. However, with longer width of diaphragm wall and greater depth of
diaphragm wall it may not be possible to provide form tube due to handling, lowering and
extraction difficulties. In such a case, special tools such as semi-circular chisels are used to
effect a joint between primary and secondary panel and in this case form tubes are eliminated.
Form tubes of 1m dia and 30m length have been used successfully (Fig. of PLATE : 6/CH-
4)*. 210
4.19.6.3 Alternate Panel Method : 210
4.19.6.3.1 In this method primary panels shall be cast first leaving suitable gaps in between.
Secondary panels shall then be cast in these gaps (Fig. of PLATE : 7/CH-4)*. Two stop end
tubes are used at the ends of primary panels to support concrete and form suitable joints with
a secondary panels. 210
4.19.6.3.2 The excavated length of secondary panels may be smaller than that of primary
panels. 210
4.19.6.3.3. The shape of the secondary panel end should be such as to form a good joint with
primary panels. 210
4.19.6.3.4 Other construction techniques are same for successive and alternate panel method,
which are described below. 210
4.19.7 Stages of Construction : 210
4.19.7.1 Excavation of Trench (boring Operation) : 210
4.19.7.1.1 General Excavation of each trench panel (Fig. of PLATE : 6/CH-4)* shall be
done with the help of suitable machinery. The trench panel shall be kept filled with bentonite
slurry of suitable consistency and viscosity during the excavation period. Before
commencement of boring length of the panels will be properly demarcated on the pre-trench
wall. Panel boring can be done either by direct circulation or reverse circulation method
described below. 210
4.19.7.1.2. Direct Circulation Method : 210
(i) This method is used with rotary or percussion type rigs where drilling fluid (bentonite
slurry) is pumped through the drilled rods. It can be used for successive panel or alternate
panel construction. The stages of construction are shown in Fig of PLATE : 8/CH-4 Simple
trenching rigs for excavation may be used. 210
(ii) The trench panel may be excavated in the ground by making over lapping bore holes with
bentonite slurry jet in combination with percussion and to and from rotary motion of jetting
pipe having a suitable cutter at the tip. 210
(iii) A special semi-circular cutter shall be used for providing appropriate shale at each panel
end to form a suitable joint. 211
(iv) The operation of filling bentonite slurry in the trench shall be as described under para
4.19.5.5 and lowering of reinforcement shall be done as described under para 4.19.7.2 211
(v) For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used. 211
(vi) This method is suitable for shallow depths and bringing up lighter cuttings. 211
4.19.7.1.3 reverse Circulation Method - 211
(i) The reverse circulation method with in percussion shall be used to make trench panel in
the ground as shown in Fig.A of PLATE : 9/CH-4*. Forward and backward movement of the
rig from one end of the panel to the other and shall increase the depth of panel in zigzag
manner. 211
(ii) High capacity pumps shall be used to suck the loosened soil in this slurry filled trench.
Separators or sedimentation tanks shall be used to retain the soil cuttings, and to pass the
slurry for circulation and reuse. 211
(iii) This method is suitable for greater depths and to bring up heavier cuttings. 211
4.19.7.1.4. Other Requirements during boring operation : 211
(i) Solids in the settling tank shall be removed and kept along side. When the grabs or Kelly
method is used for boring bored muck from the grab will be left along side. 211
(ii) For overcoming any underground obstruction or boring through all types of rocks such as
soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use of chisel grab
will be made in case of grab type equipment. In case of reverse circulation equipment the
cutting tool itself will execute chiseling operation in above mentioned strata. 211
(iii) The width of cutting tool will be more or less as that of the disphragm wall. The trench
shall be finished upto founding level in the final stage of preparation by using a cutting tool
having a width of not less than 600mm before commencing placement of concrete. 211
(iv) Boring shall be continued in the manners described above upto foundation level. Depth
of the trench will be determined by taking sounding. Diaphragrm wall shall penetrate about
0.6 metre into sound rock which shall be ensured by careful soundings taken and certified by
engineer-in-charge. If there is difference of more than one metre or more in the rock level at
two ends of the panel, suitable stepping as decided by Engineer-in-Charge shall be provided.
211
(v) Before removing the equipment, the bottom of the trench will be cleaned by reverse
circulation equipment. 212
(vi) Form tubes will be lowered at each end of primary panels in case of construction by
alternate panel method and reinforcement cage shall then be lowered in the trench panel and
suitably supported. 212
4.19.7.2 Reinforcement : 212
4.19.7.2.1 Method of Preparation Method of preparation of reinforcement cage is as under :
212
(i) Reinforcement in each panel should form a cage and the vertical ends of the cage should
match with the type of joints of the panel. For ease of handling and good workmanship the
cage should be made rigid. Clear distance between reinforcement bars should not be less than
100mm for easy flow of concrete. 212
(ii) The length of the cage will be governed mostly by the depth of panel and the length of
rods available. The cage shall however be built up preferably in two fabricated matching
pieces but in no case in more than three pieces. Each subsequent reinforcement cage after the
first cage shall be securely fastened and tack welded to the lower cage before the assembly is
lowered to the trench. The steel reinforcement cages shall be clearly marked to indicate its
correct orientation for proper insertion into the trench. 212
(iii) The gap in the main bars should not be staggered more than 50 cms to avoid difficulties
in handling the cage and dropping the cage. 212
(iv) Suitable gape in the reinforcement cage will be provided for accommodating the tremie
required during concreting operation. 212
(v) The reinforcement cage will be suitably strengthened at regulat intervals and generally the
bars will be tack welded. 212
(vi) In case the reinforcement cage is heavy, angle iron frames may be utilized. 212
(vii) The concrete cover for reinforcement shall be maintained by the use of spacers. Circular
roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix shall be provided at
suitable intervals preferably one block per square metre on both sides of the cage and suitably
staggered. The diameter of spacer block will depend upon clear cover required for the
reinforcement. 212
Boxes or inserts for formation of recesses or for ground anchors shall be lowered along with
the cage to correct position and levels. Circular cover blocks are considered essential to the
reinforcement so that they will roll along the trench without damage and maintain adequate
cover. 213
(viii) The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
diameter and number should be adequate to withstand the weight of the cage. 213
(ix) The reinforcement cage should be kept hanging over pre-trench to provide a minimum
cover of 10mm at the bottom of trench and it shall be maintained in position during the
concreting of each panel. 213
(x) Rock grout pipes shall be fixed with suitable spacer bars at specified intervals. 213
4.19.7.2.2 Joining and Splicing : Joints and splices in reinforcement shall be provided at
positions shown on the approved drawing. This shall be done as per detailed specification laid
down under para 13.3.5 of Chapter 13 specifications for Steel and Iron Work. The joints
between main reinforcement bars, the links and other steel sections shall be properly welded
with respect to design considerations and handling requirements. Welding shall be done
according to relevant Indian Standard while using mild steel bars in concrete construction.
213
4.19.7.2.3 Reinforcement for Walls other than Structural Member In case the diaphragm
wall has not been designed as a structural member nominal reinforcement as per IS:456-1978
shall be provided. 213
The usual provision is 16mm dia to 20mm dia bars at 300mm to 325mm centre to centre in
both directions with a cover of 75 to 100mm at faces and at end of elements. 213
4.19.7.3 Concreting : 213
4.19.7.3.1 Concrete for the RCC diaphragm wall shall be posed of cement, sand, coarse
aggregate, water and any other admixture as decided mixed and brought to the consistency.
Random samples from fresh concrete shall be taken as specified in IS:1199-1959 and cubes
shall be made, cured and tested as described in IS:510-1959. If required the mix should be
modified to achieve the desired strength, workability, density and impermeability with
maximum permissible economy. Concrete will be designated M-20 which means that 28 days
cube strength will be 20 N/mm or 200 Kg/cm2. The water cement ratio for concrete shall be
governed by the requirement of strength, durability and workability but it shall not be greater
than 0.6. 213
The concrete shall be of uniform consistency and quality throughout any pour and for similar
parts of the same structure. However consistency and composition shall be such that the
concrete can be worked out in all corners and angles of the forms (for cap work) and that
concrete surrounds completely the reinforcement and embedded metal without causing
segregation of the ingredients. 213
4.19.7.3.2 The control of concrete is based among other factors on maintaining a fairly
uniform slump at the point of placement and holding the water cement ratio as closely as
practicable to 0.6. 214
4.19.7.3.3 The slump should be measured in accordance with the method prescribed in
IS:1199-1959. The slump of concrete should be 150mm to 200mm for ensuring easy flow
through, for tremic pipe used in concreting. 214
4.19.7.3.4 The concrete mix shall be suitably designed for the required slump and ten percent
extra cement added for under water work for laying concrete by other than tremie. 214
4.19.7.3.5 Concrete Classifications : 214
4.19.7.3.6 Concrete classification is related to the specified 28 days compressive cube
strengths and shall conform with the requirements setout in table below. 214
S. No. 214
Location 214
Classification 214
Slump 214
1 214
Concrete in RCC Diaphragm Walls 214
M-20 214
150 to 200mm 214
2 214
Concrete in RCC Capping 214
M-20 214
50 to 75mm 214
Exact mix design however, shall be determined by laboratory tests. 214
4.19.7.3.7 A minimum of 3 tests specimens shall be made for each 120 cum of each class of
concrete. There shall be atleast 3 test specimens for one day of concreting even if only a few
cubic metres of the particular concrete is manufactured in a day. Additional tests shall be
carried out as and when directed. 214
214
4.19.7.3.8 The tests shall satisfy the criteria as prescribed under para 7.2 of Chapter 7 & 16.
214
4.19.7.3.9 Concrete materials production of aggregate, batching, mixing, transporting and
preparation for placing of concrete shall be done in accordance with the relevant paras of
Chapter 7 & 16. 214
4.19.7.3.10 Placing and Compacting for Diaphragm Wall : 214
(i) The concreting shall be done by tremie pipes and the tremie diameter will be minimum
200mm. It is preferable to use threaded tremie pipes in suitable lengths. The tremie pipes
shall be clean and water tight. Depending upon the length of panels one or more tremie pipes
should be used. The elliptical or oblong tremie pipe shall be used for concrete having
aggregate of 20mm and smaller. This shall be used for walls of 20 to 30cm thickness. For
walls of greater thickness a circular tremie pipe may be used. 214
(ii) Prior to placing concrete in any panel it should be ensured that heavily contaminated
bentonite slurry has not accumulated in the bottom of trench which can impair free flow of
concrete. The contaminated bentonite slurry shall be identified by taking a sample of the
slurry from near the bottom of the trench and carry out a density test on this using a mud
balance. Density as measured shall not be greater than 1.25 gm/ml. Before pouring the
concrete through tremie pipes, the bottom of the concreting funnel should be closed through a
steel plate. The tremie should extend to the bottom of trench excavation prior to the
commencement of concrete pouring and care shall be taken to ensure that bentonite slurry
which may have entered the tremie is expelled from the tube during the initial charging
process. After funnel is filled with concrete, the plate is removed and concrete is discharged.
Thereafter concreting is done in a continuous manner upto required level. Care should be
taken during placing to avoid contamination of the concrete where two or more pipes are
used in the same panel. Simultaneously, care should be taken to ensure that the concrete level
at each pipe is maintained. 214
4.19.7.3.11 For Cap Work : 215
(i) Before placing cap concrete extra concrete already placed ruing concreting of the
diaphragm walls above designed cut off level shall be removed by chiseling manually or by
pneumatic tools. In case concrete below the designed cut off level is found to be inferior or
contaminated not conforming to specifications, the same should also be removed until
concrete of prescribed specifications is met with. Minimum 15 cms (6 inches) should
preferably be removed. The chipping shall be done in such a manner as not to loosen, crack
or shatter any part of the work beyond the approved levels at or below the cut off level. The
surface shall be cleaned thoroughly of all loose fragments, dirt, laitaree and any other
objectionable materials and shall be sound and hard in such conditions as to ensure good
bond between the old and new concrete. 215
(ii) After the surface has been cleaned and dampened as specified, surface construction joints
shall be covered wherever practicable with a layer of mortar approximately 15mm to 20m
thick. The mortar shall have the same proportions of water air entraining agent, cement and
fine aggregate as the concrete mixture to be placed upon it. The water cement ratio of the
mortar in place shall not exceed that of the concrete placed upon it and the consistency of the
mortar shall be suitable for being spread uniformly and worked, thoroughly into the
irregularities of the surface. Concrete shall be placed immediately upon the fresh mortar. 215
4.19.7.3.12 As far as it is practicable, concrete shall be placed directly in its final position and
shall not be caused to flow in a manner to permit or cause segregation. Methods and
equipment employed in placing concrete in forms shall be such as will not result in clusters or
groups of coarse aggregate being separated from the concrete mass. 216
Concrete shall be compacted to the maximum density in such manner that it is free from
pockets of coarse aggregate and is in intimate contact with surfaces of forms and embedded
materials Unless otherwise permitted all concrete shall be compacted by mechanical vibrator.
216
Compaction of concrete shall, wherever practicable be carried out by the use of adequate
immersion type vibrators to be operated at speeds of at least 6,000 revolutions per minute
when immersed in the concrete. Vibrators having vibrating head less than 100mm in diameter
shall be operated at speed of atleast 7,000 revolutions per minute in the concrete. Normally
form work shall be designed to provide for the insertion and operation of mechanical
vibrators in the placed concrete. Form vibrators shall be used wherever internal vibration is
not possible or would be inadequate. 216
During placing and until curing is completed, the concrete shall be protected against the
harmful effects of exposure to sunlight, wind and rain, as directed. 216
A tension zone, close to the wall capping is created because of rigid wall, hence 1.5m thick
clay cover over the top of concrete diaphragm wall should be provided and compacted at
OMC, to act as a plastic cap to account for any deformation without under going any
cracking. 216
4.19.8 Types of Joints : 216
Joints between the successive panels may be achieved in any of the different ways shown in
Fig.6 of PLATE:9/CH-4*. In case of alternate panel method two stop end tubes are used at
the ends of the primary panels to form suitable joints with secondary panels. 216
4.19.9 Wall of Precast RCC Panels : 216
The trench panels shall be made in the ground using normal machines or grabs. The trench
shall be kept filled up with self setting bentonite slurry. Specially designed precast RCC
panels with provision for suitable joints shall be lowered in the trench with help of crane. The
panels shall be supported in the trench by using special supports. 216
Inside face of panels before lowering them into the trench shall be treated with specified
compound. 216
The self setting bentonite slurry shall be slow setting and should develop adequate strength
and impermeability. 216
The precast panels used in the process shall provide an aesthetically pleasing surface of wall
on excavation of soil. The quality of concrete in PRECAST RCC panels should be better than
that achieved by tremie concrete method. 216
4.19.10 Grout Cut-off Walls : 216
4.19.10.1 Where Structural strength is not required the self setting, bentonite slurry may be
used to provide an impermeable cut-off wall. 216
4.19.10.2 When so specified suitably designed clay concrete or sand bentonite cement mix
may be used for diaphragm walls which are primarily meant as impermeable cut-offs. 216
4.19.11 Tolerances : 216
4.19.11.1 Guide Walls The finished faces of the guide walls towards the trench shall be
vertical, there shall be no ridges or abrupt changes on the face of the guide wall . Variation
from a straight line or a specified profile shall not exceed 25mm in 3m. 217
4.19.11.2 Diaphragm Wall : 217
4.19.11.2.1 Verticality The face of the wall and ends of the panel to be exposed shall be
vertical within a tolerance of 1:80. 217
4.19.11.2.2 The effective trimmed final wall levels shall normally be taken as 250m m below
the top of guide wall when concrete is cast to the top of the trench. If water table is high and
if required cut off is low and water table is also at depth, small concreting can be stopped at
lower level. For trimmed final wall levels below this level the vertical tolerance in profile of
concrete cast shall be between 150-500mm above the specified wall levels. 217
4.19.11.2.3 Where recesses are formed in walls, these shall be positioned within a vertical
and horizontal tolerance of 150mm. 217
4.19.11.2.4 In positioning of reinforcement, longitudinal tolerance of cage head at top of the
guide wall measured along the trench shall be 75mm and vertical tolerance at cage head in
relation to top of guide wall shall be 50mm. 217
4.19.12 Rock Grouting under the Diaphragm - 217
4.19.12.1 Specification for this work shall be as per Chapter 22. 217
4.19.12.1.1 50 to 75 diameter pipes shall be embedded in the diaphragm wall at specified
intervals. These pipes will be welded to the diaphragm wall reinforcement before it is
lowered into position. This is done to avoid drilling through diaphragm wall concrete and
reinforcement. 217
4.19.12.1.2 After the panel is completed drilling in rock will be done with pneumatic
equipment. 217
4.19.12.1.3 After drilling for a depth of 2 metres in rock, the hole will be washed with water
and water tested to find the water loss in Lugeon value. Normally the pressure is increased
in steps of 1 Kg/m to the maximum grout pressure allowed for the particular position. While
decreasing the pressure 2 to 3 readings will also be taken. This procedure will help to observe
the flow in the particular rock media (laminar or turbulent). 217
4.19.12.1.4 Generally the packer assembly with opening at the bottom and normally fitted
with 2 numbers of cup type leather washers, will be lowered to the desired depth in the hole
and water will be pumped at the required pressure. The duration of the test at any particular
packer position at a particular pressure will be about 5 minutes. After noticing the flow in the
media, the test at the particular packer position will be considered as completed. 217
A graph will be drawn showing the absorption of water in litres/minute on abscissa and
pressure on the ordinate scale. The Lugeon value is calculated by finding the absorption at
10kg/cm either by interpolation or extrapolation, per metre of the strata being tested for
permeability. 217
4.19.12.1.5 In case of fine fissures neat cement grout will be used for rock grouting. However
if the fissures are bigger having a high lugeon value a stable grout consisting of cement
bentonite and sodium silicate will be used. Bentonite in the mix will increase the injectability
of cement in the rock fissures. Whereas sodium silicate will decrease its setting time and will
avoid long travel of grout. This type of stable grout will be used only if it is found that
consumption of neat cement grout is quite heavy and refusal pressures are not obtained even
after continuous grouting for a long time. The type of mix will be decided only after
conducting some trial tests at the site. 217
The pressure which will be generally allowed for grouting will be as follows : 218
1 PSI for every foot of rock above the packer. 218
75 PSI for every foot of overburden above rock. 218
The grouting in rock will be done in suitable descending stages as directed by Engineer-in-
charge. Criteria for the curtain grouting shall be as stated in para 3.6 and 3.6.1 of IS:6066-
1971. Grouting of Rock Foundation in River Valley Projects. 218
4.19.12.2 Grouting under the Diaphragm wall joints by Tube-A Manchette Method 218
4.19.12.2.1 In order to prevent any leakage of water from the joints between the 2 panels of
the diaphragm wall the area near the diaphragm wall joints will be grouted. 218
4.19.12.2.2 Boring in over-burden will be done by rotary cum percussion drilling equipment
using the mud circulation process. 218
4.19.12.2.3 A manchette pipe will be lowered in the boreholes, this tube (A manchette pipe)
consists of 1-1/2 M.S. Pipe having openings at equal intervals (4 Nos. radial perforations
every 33 cms) covered by rubber sleeve which acts as a one way valve. 218
4.19.12.2.4 The space between the bore hole sides and the Tube-A Manchette will be filled
with plastic sheath grout, which after setting will seal the tube. A manchette with the grout
end will prevent upward leakage. The grout will consist of bentonite, cement and water and is
so designed that it is neither too hard not too soft. The strength of the sheath grout after
setting will be such that it will be punctured when the grouting starts but it will not be soft
enough to allow upward leakage along the tube A Manchette pipe. 218
4.19.12.2.5 Generally a coarse grout of cement, bentonite mix will be grouted through the
Manchette pipes in the first stages. Chemicals such as sodium silicate and monosodium
phosphate may have to be used along with bentonite in the second stage. The first stage will
be grouted at least to a pressure of 4 to 5 kg/cm, whereas higher pressures can be allowed in
the second stage grouting. 218
4.19.12.2.6 All necessary steps should be taken to ensure that the panel joints are grouted to
required efficiency as may be prescribed by the Engineer-in-charge and also to the extent that
grouting of sand between the two walls is not necessary. 218
4.19.13 Permeability test for Concrete of the Diaphragm Wall : 218
4.19.13.1 In order to observe the permeability of the concrete in the diaphragm 50 to 75mm
diameter pipes will be provided at different levels in the diaphragm wall before concreting of
the panel. 218
4.19.13.1.1 Drilling with appropriate size as may be decided by the Engineer-in-charge will
be done through these pipes for a depth of 3cm to 60cms below the bottom of the pipe. 218
4.19.13.1.2 The test will be conducted by using le Frances point permeability falling head
method. The pressure corresponding to differential hydrostatic head when the work is
completed can be applied while carrying out this test by using compressed air. 219
4.19.13.1.3 The computed permeability of the diaphragm concrete shall not be greater than 30
cm per year at pressure equivalent to a hydrostatic head of 40 metres. 219
4.19.14 Inspection of Works : 219
4.19.14.1 Test well (inspection chambers) preferably of 3m width x 2.5m depth shall be
constructed at suitable intervals as approved by the Engineer-in-charge to control
workmanship, quality and tolerance of the diaphragm wall. Adequate safety precautions shall
be taken in construction and operation of these walls. 219
4.19.15 Testing Efficiency of Diaphragm Wall : 219
4.19.15.1 Efficiency of the diaphragm wall shall be tested by observing leakage through the
diaphragm wall. V notches or other measuring devices shall be installed on the down stream
wall and seepage measured all round the year. 219
APPENDIX - I 220
CRITERA FOR CONTROL OF COMPACTED DAM EMBANKMENT 220
Type of Material 220
Percentage of No.+4 fraction by dry weight of total material 220
percentages based on minus nO.4 fraction 220
50 Feet or Less in Height 220
Greater than 50 Feet Height 220
Minimum Acceptable Density 220
Desirable Average Density 220
Moisture Limits W0-Wf 220
Moisture Limits Wo-Wf 220
1 220
2 220
3 220
4 220
5 220
6 220
7 220
8 220
Cohesive 220
0-25 220
D=95 220
D=98 220
-2 to +2 220
D=98 220
D=100 220
2 to 0 220
Soil 220
26-50 220
D=92.5 220
D=95 220
D=95 220
D=98 220
(Note 2) 220
Controlled by the Proctor Test 220
More than 50 220
(Note-1) 220
D=90 220
D=93 220
D=93 220
D=95 220
Cohesion 220
Less soils 220
Fine sands with 220
0-25 220
Dd=75 220
Dd=90 220
Soils should be very wet 220
Dd=75 220
D=90 220
Controlled by the relative density test 220
Medium sands with 220
0-25 220
Dd=70 220
Dd=85 220
Dd=70 220
D=85 220
Coarse sands with 220
0-100 gravels 220
Dd=65 220
Dd=80 220
Dd=65 220
D=80 220
Wo-Wt 220
Is the difference between optimum water content and fill water content in percent of dry
weight of soil. 220
D. 220
Is fill dry density divided by Proctor maximum dry density in per cent. 220
Dd 220
Is relative density 220
NOTES : 220
1. Cohesive soils containing more than 50 percent gravel sizes should be tested for
permeability of the total material if used as a water barrier. 220
2. For high earth dams special instructions on placement moisture limits will ordinarily be
prepared. 220
Appendix II 48
(Para 4.19 A (VI) 48
STABILITY OF SLURRY FILLED TRENCHES 48
The bentonite slurry filled in the trench imparts stability by mainly applying hydrostatic
pressure on the wall, against the impermeable thin film formed along the wall. Secondly the
slurry filled in the trench provides passive resistance against failure of the trench, and thirdly,
the shearing resistance of the slurry saturated zone and the plastering effects of the filter cake
formed also contribute towards trench stability. The hydrostatic pressure along represents 65
to 80 percent of the total stabilizing forces. If the density of slurry used is such that it can
provide a factor of safety of one due to hydrostatic pressure, then the factor of safety of the
actual trench shall be between 1.25 to 1.50. Therefore taking only hydrostatic pressure and
considering F=1, the density of slurry may be calculated as indicated by the following
formula. This formula should be used as a guide only. 48
Where 48
H = depth of the trench 48
Cu = undrained shear strength of clayey soil 48
Y = natural density of saturated soil 48
Ys = density of the slurry needed for the trench, and 48
Nc = bearing capacity factor which varies from 4 at the ground surface to 8 for deeper depths,
depending upon D/B and L/B ratio of the trench. This factor accounts for arching action in
horizontal as well as vertical directions See Figures below : 48
48
49
49
For sandy 49
Where 49
49
Ka = 49
Y = effective unit weight of the sandy soil 49
= submerged unit weight 49
= saturated weight weight of water 49
= Y sat Yw 49
The value of A depends upon ratio of the trench (see Fig. above). 49
As a general rule, level of bentonite slurry in the trench shall be minimum 1.5m higher than
the water level. 49
Volume III 59
Section - 4 59
Excavation 59
contents 59
139
1 General 139
2. Standards 139
3. Scope: 140
4. Planning: 140
DRAWINGS. 140
CHARGE. 141
THE WORK. 141
TIME. 141
SURFACE. 142
THE PROJECT. 142
142
TRENCH: 142
143
62.15 PUDDLE: 143
REJECTED. 143
143
62.20 THE TOP OF PUDDLE SHALL BE KEPT AS LEVEL AND UNIFORM
AS POSSIBLE AND SHALL ON NO ACCOUNT BE ALLOWED TO DRY. IF
THE SURFACE CRACKS AT ANY TIME IT SHALL BE DUG UP AND
PUDDLE REMADE. 143
62.21 VERTICAL JOINTS ACROSS THE PUDDLE WALL AND STEPS TO
ITS SIDE SHALL BE AVOIDED. ALL JOINTS SHALL BE MADE BY LONG
MENS HELS. 143
62.24 THE PUDDLE FILLING SHALL NOT BE DONE IN STANDING
WATER. WATER LEVEL IN TRENCH SHALL BE KEPT BELOW THE
WORKING LEVEL BY MEANS OF PUMPS, IF REQUIRED. 144
WAY. 144
62.28 THIS FILLING IS TO BE CARRIED UP WITH THE PUDDLE WALL
TO A HEIGHT OF 0.6 M ABOVE GROUND LEVEL AND JOINED WITH
THE HEARTING. 144
MEASUREMENTS. 144
66 EXCAVATION 146
69 DEWATERING 148
WORKS. 148
OTHER PROPERTY. 148
CHARGE. 151
75.1 SCOPE: 151
CURVED. 155
77 Material 155
EMBANKMENTS. 155
CLAUSE 6.4 OF I.S. 4701-1982. 156
COST. 156
COMPACTION. 156
DRUM. 157
(VI) ROLLER WEIGHT :- THE WEIGHT OF THE ROLLER WHEN FULLY
79.3 ROLLING :- 158
RAIN GULLIES. 163
82 DOWEL BANKS: 163
163
THE TOP. 164
86 Toe Drains : 164
164
88 Side drains: 165
165
90 PROTECTION: 165
92.2 PLACING 167
(TEN) PERCENT. 168
168
93.2 PLACING : 168
95 ROCK TOE 169
CHARGE. 169
THE FILL. 169
96 BORROW AREAS 172
CONDITION. 172
99 BORROW PITS 173
SHALL BE TAKEN. 173
DETAILS:- 173
104.1 THE PRIMERS SHALL NOT BE PREPARED NEAR OPEN FLAMES
OR FIRE. THE WORK OF PREPARATION OF PRIMERS SHALL ALWAYS
BE ENTRUSTED TO THE SAME PERSONAL. PRIMERS SHALL BE USED
AS EARLY AS POSSIBLE AFTER THEY ARE READY. 175
106 BLASTING 175
106.3 A WHISTLE/BIGGLE WITH DISTINCTIVE NOTE SHALL BE USED
TO GIVE THE WARNING SIGNALS. THE BIGGLE SHALL NOT BE USED
FOR ANY OTHER PURPOSES. ALL THE LABOUR SHALL BE MADE
BEEN GIVEN. 175
SHALL BE USED. 175
106.6 THE CONTRACTORS SUPERVISOR SHALL WATCH THE
REQUIRED TIME FOR THE FIRING OF THE FUSES AND SHALL SEE
THAT ALL THE WORKMEN ARE UNDER SAFE SHELTERS IN GOOD
TIME. 176
THE PURPOSE. 176
107.2 THE DETONATORS SHALL BE CHECKED BEFORE USE. FOR
BLAST IN SERIES, ONLY DETONATORS OF THE SAME MANUFACTURE
AND OF THE SAME GROUP OF ELECTRICAL RESISTANCE SHALL BE
USED. SUCH OF THE ELECTRICAL LINES AS COULD CONSTITUTE
DANGER FOR WORK OF CHARGING SHALL BE REMOVED FROM THE
SITE. THE FIRING CABLES SHALL HAVE A PROPER, INSULATING
COVER SO AS TO AVOID SHORT CIRCUITING DUE TO CONTACT WITH
WATER, METALLIC PARTS OF ROCK ETC., 176
THERE WITH. 177
108.6 THE NAMES OF THE DAY AND NIGHT SHIFT SUPERVISORS OF
THE CONTRACTOR MUST BE NOTED DAILY IN THE CONTRACTORS
DISPOSED OF. 177
177
TAKEN. 177
OCCUR:- 178
114.1 RECORDS OF FIELD TEST DATA RESULTS SHOULD BE
PRESENTED IN THE FORM OF STATISTICAL ANALYSIS SHEETS AND
SUMMARY SHEETS IN ORDER TO PROVIDE CONTROL REQUIRED FOR
SPECIFICATIONS. 179
115 Turfing 180
4.18.2 181
4.18.2.1 Materials : 181
respectively. 181
S. No. 181
Characteristics 181
Unit 181
Value 181
i. 181
Tensil Strength 181
N/mm 181
11.6 min 181
ii. 181
% 181
300 min 181
iii. 181
Tear Resistance 181
N/mm 181
4.9 min 181
iv. 181
N/mm 181
2.46 min 181
v. 181
(a) 181
Tensil Strength 181
N/mm 181
10.5 min 181
(b) 181
% 181
250 min 181
vi. 181
(a) 182
Weight Increase 182
% 182
0.25 max. 182
(b) 182
Weight Decrease 182
% 182
0.10 max. 182
(c) 182
Hardness Change 182
Point 182
5 182
vii. 182
(a) 182
Weight Increase 182
% 182
0.40 max. 182
(b) 182
Weight Decrease 182
% 182
0.30 max. 182
(c) 182
% 182
1 182
(a) Density 1015 - 1065 Kg/m 182
PLATE : 1/CH-4* 182
interface. 182
joint. 183
PLATE : 4/CH-4*. 183
4.18.2.4 Jointing : 183
in IS:456-1978. 183
choosen. 184
desired speed. 184
Type of Test 185
Method of Test 185
Density 185
1.04 to 1.10 g/ml 185
PH Value 185
9.5 to 12 185
Viscosity 185
1.4 to 10 N/m, 185
(14 to 100 dya/cm) 185
Ys = 1.0 + 0.006 C 185
carried out. 185
(v) Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase viscosity
(vi) To remove fine silty solids and clay solids from the slurry flocoulants may be used. Vinyl
(vii) Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
(viii) Stability of slurry filled trenches should be worked out as per procedure described under
Appendix-II. 186
operation. 186
4)*. 187
panels. 187
primary panels. 187
(vii) This method is used with rotary or percussion type rigs where drilling fluid (bentonite
(viii) The trench panel may be excavated in the ground by making over lapping bore holes
with bentonite slurry jet in combination with percussion and to and from rotary motion of
jetting pipe having a suitable cutter at the tip. 187
(ix) A special semi-circular cutter shall be used for providing appropriate shale at each panel
(x) The operation of filling bentonite slurry in the trench shall be as described under para
(xi) For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used. 188
(xii) This method is suitable for shallow depths and bringing up lighter cuttings. 188
(iv) The reverse circulation method with in percussion shall be used to make trench panel in
manner. 188
(v) High capacity pumps shall be used to suck the loosened soil in this slurry filled trench.
(vi) This method is suitable for greater depths and to bring up heavier cuttings. 188
(vii) Solids in the settling tank shall be removed and kept along side. When the grabs or Kelly
(viii) For overcoming any underground obstruction or boring through all types of rocks such
as soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use of chisel grab
(ix) The width of cutting tool will be more or less as that of the disphragm wall. The trench
(x) Boring shall be continued in the manners described above upto foundation level. Depth of
the trench will be determined by taking sounding. Diaphragrm wall shall penetrate about 0.6
metre into sound rock which shall be ensured by careful soundings taken and certified by
188
(xi) Before removing the equipment, the bottom of the trench will be cleaned by reverse
(xii) Form tubes will be lowered at each end of primary panels in case of construction by
189
(xi) Reinforcement in each panel should form a cage and the vertical ends of the cage should
(xii) The length of the cage will be governed mostly by the depth of panel and the length of
(xiii) The gap in the main bars should not be staggered more than 50 cms to avoid difficulties
(xiv) Suitable gape in the reinforcement cage will be provided for accommodating the tremie
(xv) The reinforcement cage will be suitably strengthened at regulat intervals and generally
the bars will be tack welded. 189
(xvi) In case the reinforcement cage is heavy, angle iron frames may be utilized. 189
(xvii) The concrete cover for reinforcement shall be maintained by the use of spacers.
Circular roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix shall be
provided at suitable intervals preferably one block per square metre on both sides of the cage
and suitably staggered. The diameter of spacer block will depend upon clear cover required
for the reinforcement. 189
cover. 190
(xviii) The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
(xix) The reinforcement cage should be kept hanging over pre-trench to provide a minimum
(xx) Rock grout pipes shall be fixed with suitable spacer bars at specified intervals. 190
190
than 0.6. 190
S. No. 191
Location 191
Classification 191
Slump 191
1 191
M-20 191
150 to 200mm 191
2 191
M-20 191
50 to 75mm 191
191
191
Chapter 7 & 16. 191
(iii) The concreting shall be done by tremie pipes and the tremie diameter will be minimum
(iv) Prior to placing concrete in any panel it should be ensured that heavily contaminated
4.19.7.3.12 For Cap Work : 192
(iii) Before placing cap concrete extra concrete already placed ruing concreting of the
(iv) After the surface has been cleaned and dampened as specified, surface construction joints
193
cracking. 193
compound. 193
reinforcement. 194
equipment. 194
permeability. 194
the panel. 195
APPENDIX - I 197
1 197
2 197
3 197
4 197
5 197
6 197
7 197
8 197
Cohesive 197
0-25 197
D=95 197
D=98 197
-2 to +2 197
D=98 197
D=100 197
2 to 0 197
Soil 197
26-50 197
D=92.5 197
D=95 197
D=95 197
D=98 197
(Note 2) 197
More than 50 197
(Note-1) 197
D=90 197
D=93 197
D=93 197
D=95 197
Cohesion 197
Less soils 197
Fine sands with 197
0-25 197
Dd=75 197
Dd=90 197
Dd=75 197
D=90 197
0-25 197
Dd=70 197
Dd=85 197
Dd=70 197
D=85 197
0-100 gravels 197
Dd=65 197
Dd=80 197
Dd=65 197
D=80 197
Wo-Wt 197
weight of soil. 197
D. 197
Dd 197
NOTES : 197
prepared. 197
Appendix II 147
(Para 4.19 A (VI) 147
Where 147
147
148
148
For sandy 148
Where 148
148
Ka = 148
= Y sat Yw 148
the water level. 148
Volume III 158
Section - 6 158
Gates 158
INDEX 158
Section - 7 : Gates 163
1 General 163
1 types of Gates 163
2.1 UNDER ALL WATER HEAD CONDITIONS, DIFFERENT TYPES OF
GATES UNDER USE IN RIVER VALLEY PROJECTS SHALL BE OF
FOLLOWING TYPES : 163
2.2 VERTICAL LIFT GATES 163
2.3 RADIAL GATES OR TAINTER GATES 163
2 Components & Material Specifications for different gates 163
3 Design Criteria 164
4 Typical installation of various types of gates. 164
5 SCOPE 165
6 General specifications for workmanship, welding / riveting, finishing and painting

5 SCOPE 165
6 General specifications for workmanship, welding / riveting, finishing and painting of steel
structures (Gates) 165
7.1 STRAIGHTENING 165
7.2 CUTTING 165
7.3 HOLING 166
7.4 RIVETING 166
7.5 BOLTING 167
7.6 WELDING 167
7.7 CASTING AND FORGINGS 168
7.8 TOLERANCES 168
7.8.1 FITS AND TOLERANCES OF VARIOUS COMPONENTS AND PARTS
SHALL BE ACCOUNTING TO THE BEST SHOP PRACTICE KEEPING IN
VIEW THE FUNCTIONAL REQUIREMENT OF THE PARTS.
TOLERANCES AND ALLOWANCES OF THE MATCHING PARTS DURING
MANUFACTURING AND ERECTION HAVE BEEN RECOMMENDED IN
RELEVANT PARAS AND ALSO AT APPENDIX D AND E. 168
7.9 PAINTING 168
7.10 SURFACE PREPARATION 169
7.11 SPRAYING 169
8 Fixed Wheel and Slide gates Manufactures. 169
8.1 MATERIALS 169
8.2 WELDING 170
8.3 MANUFACTURING TOLERANCES 170
9 Shop Assembly & testing for Gates and Embedded Parts 171
9.1 THE MANUFACTURING TOLERANCE SHALL INCLUDE SURFACE
FINISH TOLERANCE (WHEN SPECIFIED) AS SPECIFIED UNDER IS: 696-
1960. 171
9.2 SHOP ASSEMBLY OF EMBEDDED PARTS SHALL NECESSARILY BE
DONE FOR HIGH HEAD GATES. FOR MEDIUM AND LOW HEAD GATES,
IT SHALL BE DONE, IF REQUIRED. 171
9.3 GATE SHALL BE ASSEMBLED COMPLETE WITH SEALS, WHEELS
AND GUIDES EITHER IN HORIZONTAL OR VERTICAL POSITION FOR
PROPER ALIGNMENT AND INSPECTION. 171
9.4 SIDE GUIDE BLOCKS AND ROLLERS MAY BE SHIMMED, IF
NECESSARY, TO MAINTAIN REQUIRED TOLERANCE. 171
9.5 VARIATION IN THE DISTANCE BETWEEN AXES OF EACH PAN OF
SEAL SEATS, WHEEL TRACKS OR SIDE GUIDE TRACKS FOR ANY GATE
SHALL NOT EXCEED 1.5 MM. 171
9.6 EMBEDDED PARTS SHALL BE SO ASSEMBLED THAT THE
DEVIATION OF THEIR AXES FROM THE RESPECTIVE ALIGNMENT
9.7 ALL THE WHEEL OF THE GATE SHALL ROTATED SEVERAL TIMES
TO ENSURE FREE MOVEMENT. 172
9.8 THE MARKETING AND MATCH MARKING SHALL BE MADE
BEFORE ACTUAL DISPATCH OF THE COMPONENTS. 172
10 Painting 172
11 Fixed Wheel and Slide Gates Rope Drum Hoist 172
11.1 MATERIAL 172
11.1.1. ALL MATERIALS AND COMPONENTS USED IN THE
MANUFACTURE OR ASSEMBLY OF THE HOIST SHALL CONFORM TO
THE LATEST INDIAN STANDARDS. THE DUTY OF THE HOIST SHALL BE
SPECIFIED BY THE PURCHASER. THE PURCHASER HAS TO SPECIFY
THE QUALITY AND STANDARD OF SUCH MATERIAL AND
COMPONENTS. 172
11.1.2. ALL MATERIALS USED SHALL BE OF TESTED QUALITY.
ORIGINAL MANUFACTURES TEST CERTIFICATES FOR BOUGHT OUT
ITEMS LIKE THE CASTINGS, FORGINGS, WORM REDUCERS, WIRE
ROPES, MOTOR AND BRAKES ETC. SHALL BE FURNISHED BY THE
MANUFACTURER OF THE HOIST ON DEMAND. 172
11.1.3. ALL CASTING AND FORGINGS USED SHALL CONFORM TO
RELEVANT INDIAN STANDARDS, ANY REPAIR TO CASTINGS, IF
NECESSARY, SHALL BE CARRIED OUT IN ACCORDANCE WITH THE
RELEVANT INDIAN STANDARDS. FORGINGS SHALL FREE FROM ANY
DEFECT, TOOL MARK AND SHALL HAVE SMOOTH SURFACES.
FORGINGS SHALL BE HEAT TREATED WHERE DEEMED NECESSARY.
172
11.2 HOIST UNIT OF GATES AND CHECKING. 172
11.3 DRIVE UNIT GEAR BOX 173
11.4 HOIST MOTOR 173
11.5 BRAKE 173
IT SHALL BE OF APPROVED MANUFACTURE CAPACITY. IT SHALL BE
CHECKED FOR ALIGNMENT AND TIGHTNESS. BRAKE LINERS SHALL
BE OF APPROVED MANUFACTURE AND SHALL CONFORM TO THE
APPROVED SPECIFICATIONS. 173
11.6 BASE FRAME 173
11.7 HOIST DRUM 173
11.8 REDUCTION UNIT GEAR BOX 173
11.9 LINE SHAFT 173
11.10 LIMIT SWITCH 174
11.11 DIAL INDICATORS 174
11.12 HOIST ROPE 174
11.13 ROPE FIXTURES 174
11.14 ARRANGEMENT FOR MANUAL OPERATION 174
11.15 CONTROL PANEL 174
11.16 LUBRICATION OF GEARS AND BEARINGS 174
11.17 INSPECTION OF HOIST ASSEMBLY AND CHECKS 174
12 fixed wheel and slide gate erection 175
12.1 GENERAL INSPECTION : IT SHALL BE ASCERTAINED THAT THE
GATE PARTS RECEIVED AT THE SITE OF ERECTION HAVE BEEN
MANUFACTURED/FABRICATED ACCORDING TO THE DRAWINGS AND
HAVE NECESSARY MARKINGS OF SHOP INSPECTION. IT SHALL BE
ENSURED THAT ALL EXPOSED SURFACES OF EMBEDDED PARTS ARE
PROTECTED BY PAINTING, GREASING ETC. THE SURFACES OF
EMBEDDED PARTS IN CONTACT WITH CONCRETE SHALL BE FREE
FROM GREASES, PAINT ETC. FOR BETTER BONDING WITH
CONCRETE. A COATING OF CEMENT WASH/CEMENT LATEX MAY BE
GIVEN, IF NECESSARY. 175
12.2 DIMENSIONAL DIFFERENCES, IF ANY, SHALL BE ACCOUNTED
FOR BEFORE ERECTION AND THE DRAWINGS CORRECTED
ACCORDINGLY FOR ERECTION. CRITICAL DIMENSIONS SHALL BE
WORKED OUT FROM THE DRAWINGS. 175
12.3 THE REFERENCE LINES, CENTER LINE OF OPENINGS AND
LEVELS RELATIONS TO THE COMPLETED CIVIL STRUCTURE SHALL
BE ESTABLISHED ON SITE SO AS TO FACILITATE ERECTION AT
PROPER LOCATIONS. 175
12.4 IT SHALL BE ENSURED THAT THE VARIOUS COMPONENTS OF
THE HOISTING ARRANGEMENT SUCH AS MOTORS, REDUCTION GEAR
ASSEMBLY, SWITCHES, WIRE ROPES AND SHAFTING ARE PROVIDED
ACCORDING TO THE SPECIFICATIONS. 175
13 Inspection of block outs 175
13.1 CONCRETING BEHIND THE GATE GROOVE MAY BE DONE IN ONE
OR TWO STAGES. IF DONE IN TWO STAGES, IT SHALL BE ENSURED
THAT CORRECT BLOCK OUTS ARE KEPT FOR ACCOMMODATING THE
GATE PARTS AS MANUFACTURED ACCORDING TO THE
SPECIFICATIONS/DRAWINGS. IT IS ALSO TO BE ENSURED THAT THE
REQUIRED DOWEL BARS HAVING ADEQUATE LENGTHS ARE LEFT
OUT IN THE BLOCK OUTS. THE ENTIRE BLOCK-OUT IS ROUGHENED
TO ENSURE PROPER AND NECESSARY BONDAGE TO THE SECOND
STAGE CONCRETING. 175
14 Inspection of embedded parts 175
14.1 IT SHALL BE ENSURED THAT THE SILL BEAM IS CORRECTLY
POSITIONED BOTH IN LEVEL AND LOCATION. ALL THE NUTS AND
BOLTS OF ANCHORAGES OF SILL BEAM SHALL BE TIGHTENED SO AS
TO PREVENT DISLOCATION DURING AND AFTER CONCRETING. 175
14.2 THE EMBEDDED PARTS THAT IS TRACK PLATES, GUIDES, SEAL
SEATS, GATE GROOVE LINING ETC. SHALL BE CHECKED WHEN ALL
PARTS ARE IN FINAL POSITION AT LEAST UPTO DOUBLE THE GATE
HEIGHT, IN ONE OPERATION. THE CHECK SHALL BE CARRIED OUT
BOTH IN LOCATION AND LEVELS, WITH RESPECT TO SILL BEAM
ALREADY ESTABLISHED IN THE POSITION. EACH PART SHALL BE
CHECKED FIRST INDIVIDUALLY AND THEREAFTER RELATIVELY
WITH THE OTHER PARTS. IT SHALL BE ENSURED THAT THE
MANUFACTURING TOLERANCES, AS SPECIFIED ARE CONSIDERED
WHILE CREATING THESE PARTS AND EVEN AFTER ACCOUNTING
THESE TOLERANCES, THE ERECTION WORK IS CARRIED OUT
ACCORDING TO THE PROVISIONS IN DESIGN AND DRAWINGS. 175
14.3 THE TRACK PLATES AND SEAL SEATS SHALL BE ABSOLUTELY IN
TRUE ALIGNMENT. THE ALIGNMENT SHALL BE CHECKED BY MEANS
OF PLUMP BOB AND FEELER GAUGE OR MICROMETER, PREFERABLY
AT EACH 300 MM INTERVALS FROM BOTTOM TO TOP SIDE OF THE
GATE OPENING. ALTERNATIVELY, DIAGONAL CHECKING OR ANY
OTHER SATISFACTORY METHOD MAY BE ADOPTED FOR CHECKING
THE ALIGNMENTS. (THIS CHECK REQUIRES SPECIAL ATTENTION).
175
14.4 AFTER HAVING CHECKED THE TRACK PLATES AND SEAL SEATS
ON BOTH SIDES, IT SHALL BE ENSURED THAT THEY ARE IN THEIR
RESPECTIVE PLANES. IT SHALL ALSO BE CHECKED THAT TOP SEAL
SEAT, WHEREVER PROVIDED, SHALL ALSO BE IN THE REQUIRED
PLANE. (THIS CHECK REQUIRES SPECIAL ATTENTION). 176
14.5 GUIDE AND COUNTER GUIDES, IF PROVIDED, SHALL BE
CHECKED FOR TRUE LOCATION AND ALIGNMENTS. 176
14.6 GROOVE LINERS AND CORNER PROTECTION ANGLES, WHEN
PROVIDED, SHALL BE CHECKED FOR TRUE LOCATION AND
ALIGNMENT. 176
14.7 FOLLOWING CRITICAL DIMENSIONS SHALL BE CHECKED AT
INTERVALS OF 300 MM FROM BOTTOM TO DOUBLE THE GATE
HEIGHT. (SEE FIG. A & B). 176
14.8 ECCENTRICITY OR SOME SUCH ARRANGEMENT, IF PROVIDED TO
A GATE FOR ITS FINE ADJUSTMENT IN THE GROOVE, SHALL NOT BE
ACCOUNTED FOR WHILE ERECTING EMBEDDED PARTS. 176
14.9 ANCHORAGES SHALL BE FASTENED OR WELDED RIGIDLY, AFTER
FINAL ADJUSTMENT OF EMBEDDED PARTS SO AS TO PREVENT
DISLOCATION OF PARTS WHILE POURING SECOND STAGE
CONCRETE. 176
14.10 THE GATE GROOVE CONCRETING SHALL BE DONE ONLY AFTER
SATISFYING FOR ALL THESE DETAILS AND KEEPING PROPER
RECORDS THEREOF. RECHECKING OF EMBEDDED PARTS SHALL BE
DONE AFTER CONCRETING 176
15 Inspection of the gate at site of erection 176
15.1 THE GATE WHICH IS RECEIVED AT SITE DULY INSPECTED IN
WORKSHOP SHALL BE RE-INSPECTED AT SITE BEFORE LOWERING
INTO THE GATE GROOVE. OVERALL DIMENSIONS SHALL BE
CHECKED TO ENSURE THAT THE GATE FITS CORRECTLY IN THE
GATE GROOVE. IT SHALL ALSO BE ENSURED, BEFORE LOWERING,
THAT THE GATE HAS BEEN PAINTED ACCORDING TO
SPECIFICATIONS. 176
15.2 FOLLOWING CRITICAL DIMENSIONS SHALL BE CHECKED AT AN
INTERVAL OF 300 MM, WHEREVER APPLICABLE. 176
15.3 THE SEALS & SEAL BASES SHALL BE CHECKED TO ENSURE THAT
THEY ARE COPLANAR. ALL THE WHEELS SHALL BE ADJUSTED TO
ENSURE THAT WHEEL TREADS ARE IN THEIR PROPER ALIGNMENT.
THE WHEEL PINS SHALL BE LOCKED AFTER MAKING THE
ADJUSTMENT. 177
15.4 THE SEAL BOLTS SHALL BE TIGHTENED ADEQUATELY AND
UNIFORMLY. 177
15.5 THE GATE WHEELS SHALL BE CHECKED FOR FREE ROTATION
TO ENSURE THAT THEY ARE NOT JAMMED DURING
TRANSPORT/HANDLING. TO CHECK EFFECTIVENESS OF THE SEAL,
ACTUAL SEAL INTERFERENCE SHALL BE COMPARED WITH THAT
PROVIDED IN DESIGN, BECAUSE ON THIS ASPECT WILL DEPEND TO A
GREAT EXTENT THE EFFICIENCY OF SEALING ARRANGEMENT AND
EASY OPERATION OF GATE. 177
15.6 IN CASE OF COUNTER WEIGHTED GATE OR GATES WITH
BALLAST, IT SHALL BE ENSURED THAT CORRECT WEIGHT IS ADDED.
177
INSTALLATION 177
16.1 IT SHALL BE ENSURED THAT THE INSTALLATION OF VARIOUS
PARTS OF THE HOISTING ARRANGEMENTS HAVE BEEN DONE TO
SPECIFIED LOCATION AND ALIGNMENT PARTICULARLY IN RESPECT
OF CORRECT POSITIONING AND ATTACHMENT OF ROPE / STEM OF
THE GATE AS WELL AS HOIST. 177
16.2 THERE ARE SEVERAL TYPE OF HOISTING ARRANGEMENT AND
THE FOLLOWING CONSIDERATIONS SHALL BE LOOKED INTO AT THE
TIME OF ERECTION AND SUBSEQUENT INSPECTION. 177
16.3 IT SHALL BE ENSURED THAT THE GATE GROOVE, SILL AND THE
EMBEDDED PARTS ARE THOROUGHLY CLEANED AND NO FOREIGN
MATERIAL IS PRESENT IN THE GROOVE. BEFORE LOWERING THE
GATE IT SHALL BE PERFECTLY ENSURED THAT THE GATE GROOVE
IS FREE FROM ANY OBSTRUCTION. 178
16.4 THE HOIST PROVIDED FOR THE OPERATION OF THE GATE SHALL
FIRST BE ALLOWED TO RUN UNDER NO LOAD (WITHOUT
CONNECTION TO GATE) TO ENSURE ITS SATISFACTORY WORKING
AND THAT THERE IS NO UNDUE TEMPERATURE RISE DUE TO
FRICTION IN THE ROTATING / MOVING COMPONENTS. 178
17.1 THE GATE SHALL BE TESTED FIRST IN THE DRY CONDITION
WITH THE HOIST DULY CONNECTED TO THE GATES. THE GATE
SHALL BE MOVED UP, AND DOWN IN THE GROOVE TO ENSURE ITS
SMOOTH WORKING AND THAT THERE IS NO OBSTRUCTION AND NO
UNDUE EFFORT REQUIRED FOR ITS OPERATION. IN CASE THE GATE
IS NOT GOING DOWN OF ITS OWN WEIGHT OR FOUND TIGHT IN
SOME POSITION,, REASONS SHALL BE INVESTIGATED AND
REMEDIED INSTEAD OF FORCING THE GATE DOWN. WHILE TESTING
THE GATE IN DRY CONDITION THE RUBBER SEALS SHOULD BE KEPT
WET BY WATER JETTING OR OTHER SUITABLE METHODS TO AVOID
DAMAGE AND TO WEAR TO THE SEALS. 178
17.2 THE TESTING OF THE GATE SEALS IN DRY CONDITIONS SHALL
BE DONE BY VIEWING THE CONTACT SURFACE AGAINST A TIGHT
SOURCE. IT SHALL BE ENSURED THAT THE TOP SEAL RIDES
SMOOTHLY OVER THE TOP SEAL SEAT AT THE TIME OF ITS
APPROACH TO THE LATTER. 178
17.3 IN CASE OF RUBBER SEALS, WATER SHOULD BE POURED OVER
THE SEALS SO THAT THERE SHALL NOT BE DRY FRICTION OF THE
SEALS. IN CASE OF METAL CONTACT OIL OR GREASE IS TO BE USED.
NO GREASE OR LUBRICATION TO BE USED FOR RUBBER SEALS. 178
17.4 THERE SHALL BE NO NOISE OF FRICTION, ANY OTHER NOISE, NO
SIGNS OF EXCESSIVE FRICTION, NO JERKY PERFORMANCES, NO DUG
IN ANY POSITION, NO DANGLING OF THE GATE, NO TWIST IN THE
RUBBER SEALS, TOP SEAL DOES NOT LEAVE ITS PLANE AND THE
RUBBER SEALS ARE NOT OVERPRESSED. 178
17.5 THE GATE, AFTER LOWERING, IS TO BE KEPT RESTING ON THE
SILL BEAM, I.E. IN CLOSE POSITION. THE LEAKAGE TEST MAY BE
TAKEN IN THIS POSITION BY USING SUITABLE PUMP WITH
NECESSARY ARRANGEMENT OF JETTING WATER AT 1.5 TIMES THE
DESIGNED PRESSURE ON SEALING POSITIONS FROM BOTTOM TO
TOP. PARTICULARLY ALL CORNER JOINTS AND OTHER JOINTS, IF
ANY ARE TO BE TESTED TO ENSURE PERFECT WORKING OF THE
GATE. 178
17.6 THE GATE SHALL BE FULLY OPENED OR CLOSED TO ENSURE
FULL OPENING AND SATISFACTORY CLOSING. THE TIME NEEDED
FOR 300 MM OPENING OR CLOSING OF THE GATE IS TO BE
RECORDED FOR CALIBRATION PURPOSES AT THE TIME OF ACTUAL
OPERATION. 178
17.7 IN ROPE DRUM HOISTS, IT IS TO BE TESTED THAT THE GATE IS
GOING DOWN OF ITS OWN WEIGHT, OR WITH BALLAST PROVIDED,
AND NO ADDITIONAL FORCE IS NEEDED. THE GATE IS ALSO GOING
DOWN OR COMING UP VERTICALLY AND THERE IS NO UNEVEN PULL
TO THE GATE. ALSO WINDING OF ROPE OVER THE DRUMS IS
UNIFORM AND IS ACCORDING TO THE DESIGN PROVISIONS. 178
17.8 THE TESTS AS PROVIDED FROM 16.1 TO 16.4 SHALL ALSO BE
PERFORMED AGAINST WATER LOAD WHEN CONDITIONS PERMIT. 178
17.9 THE TORQUE REQUIRED FOR MOVEMENT OF THE GATE ON
LOAD SHALL BE MEASURED AND CHECKED AGAINST DESIGNED
VALUE. 179
17.10 UNDER THE DESIGNED WATER HEAD CONDITIONS THE
LEAKAGE THROUGH THE GATE SHOULD NOT EXCEED 15
LITRES/MINUTE/METER LENGTH OF THE SEAL. 179
17.11 WHEN THE GATE IS OPERATED UNDER WATER LOAD, IT IS TO
BE ENSURED THAT THERE IS NO VIBRATION TO THE GATE, HOIST OR
CIVIL STRUCTURES AT VARIOUS GATE OPENINGS. 179
17.12 BY PASS ARRANGEMENT MADE FOR WATER AND AIR VENT,
WHEN PROVIDED SHALL BE CHECKED FOR PROPER WORKING OF
THE SYSTEM. 179
Volume - iii 180
SECTION 7 HYDRO-MECHANICAL EQUIPMENT. 180
INDEX 180
Article No. Description of Article 180
2.14 TONNE T 181
2.15 2.2.1 SPILLWAY 184
2.16 THE GANTRY WILL BE PROVIDED WITH AN ANCILLARY JIB
HOIST WITH A SUITABLE GRAPPLING DEVICE AND HOIST TO
FACILITATE REMOVAL OF LOGS AND HEAVY DEBRIS FROM
RESERVOIR. EXTENSION OF TRACK SHALL BE SUITABLE TO HANDLE
THE UNITS FROM STORAGE BAY ALSO. THE POWER SUPPLY TO
CRANE SHALL BE SUITABLY PLANNED FROM CENTRAL LOCATION OF
ITS TRAVEL AND A SUITABLE TRENCH ALONG THE RAILS SHALL BE
PROVIDED FOR CABLE MOVEMENT. THE BIDDER MAY SUGGEST ANY
OTHER SUITABLE ARRANGEMENT FOR POWER SUPPLY TO THE
TRAVELING GANTRY. 187
17.15 GENERAL INSPECTION 224
17.16 INSPECTION OF PIER ANCHORAGE 225
17.17 INSPECTION OF SILL BEAM 227
17.18 INSPECTION OF WALL PLATES (SIDE SEAL SEATS) 228
17.19 INSPECTION OF GATES 228
17.20 TESTING 229
17.20.1 THE GATE SHALL BE TESTED IN A DRY CONDITION WITH
HOIST DULY CONNECTED FOR ITS SMOOTH WORKING. THE GATE
SHALL BE FULLY CLOSED OR FULLY OPENED AND IT SHALL BE
ENSURED THAT THERE IS NO OBSTRUCTION AND NO UNDUE EFFORT
REQUIRED FOR ITS OPERATION. IF THE GATE IS NOT GOING DOWN
OF ITS OWN WEIGHT OR FOUND TIGHT IN SOME POSITION, REASONS
SHALL BE INVESTIGATED AND REMEDIED INSTEAD OF FORCING THE
GATE DOWN. WHILE TESTING THE GATE IN DRY CONDITION, THE
RUBBER SEALS SHOULD BE KEPT WET BY WATER JETTING OR
SUITABLE METHODS TO AVOID DAMAGE TO THE SEALS. 229
17.20.2 THE TESTING OF GATE SEALS SHALL BE CHECKED IN THE
SAME MANNER AS EXPLAINED IN CASE OF FIXED WHEEL OR SLIDE
GATES. 230
17.20.3 UNDER THE DESIGNED WATER HEAD CONDITIONS, THE
LEAKAGE THROUGH THE GATE SHALL NOT EXCEED 15
LITRES/MINUTE/METRE LENGTH OF THE SEAL. 230
17.20.4 THE GATE IS TO BE KEPT ON THE SILL BEAM, THAT IS IN
CLOSED POSITION. THE LEAKAGE TEST, (IF PROVIDED IN THE
TERMS OF EXECUTION OF WORK), CAN BE DONE IN THE POSITION
BY USING SUITABLE PUMP WITH NECESSARY ARRANGEMENTS OF
JETTING WATER AT 1.5 TIMES, THE DESIGNED PRESSURE, ON
SEALING POSITIONS FROM BOTTOM TO TOP. ALL JOINTS, IF ANY,
SHALL BE TESTED TO ENSURE PERFECT WORKING OF THE GATE. 230
17.20.5 THE ARRANGEMENT PROVIDED FOR PREVENTING THE
TRAVEL OF THE GATE OR HOIST BEYOND THE DESIGNED LIMIT ARE
TESTED AND CHECKED FOR PROPER WORKING. THE TIME
REQUIRED FOR 300 MM OPENING OR CLOSING OF THE GATE SHALL
BE RECORDED FOR CALIBRATION PURPOSES. 230
17.20.6 THE FULL LOAD CURRENT REQUIRED FOR THE MOVEMENT
OF THE GATE ON LOAD SHALL BE MEASURED AND CHECKED
AGAINST THE DESIGNED VALUE. 230
18 Single faced sluice gates (200 to 1200 mm size). 230
18.1 GENERAL 230
18.2 CLASSIFICATION 231
18.3 MATERIALS 231
18.4 MANUFACTURE & WORKMANSHIP 231
18.5 DOOR 232
18.6 FACE (DOOR) AND SEAT (FRAME) RINGS 232
18.7 GUIDES 233
18.8 SPINDLES 233
18.9 OPERATING MECHANISM 233
Volume III 298
Section - 9 298
Steel and iron work 298
INDEX 298
1. REFERENCES : 303
2. TERMINOLOGY 305
3.1 GENERAL : THIS WORK SHALL CONSIST OF FURNISHING AND
PLACING STEEL REINFORCEMENT OF THE SHAPE AND DIMENSIONS
INDICATED IN THE DRAWINGS AND AS SPECIFIED IN THESE
SPECIFICATIONS. 307
3.1.1 ALL STEEL USED FOR REINFORCEMENT SHALL BE CLEAN, FREE
FROM OIL, GREESE, PAINTS, DUST, MORTAR, SCALES, KINKS, RUST
OR ANY ROLLING DEFECTS OR BENDS OTHER THAN THOSE
REQUIRED AS PER DRAWINGS OR AS DIRECTED BY THE ENGINEER-
IN-CHARGE. 307
3.2 QUALITY OF REINFORCEMENT : 307
3.2.1 THE STEEL REINFORCEMENT SHALL BE, ANY OF THE
FOLLOWING, AS MAY BE SPECIFIED FOR THE JOB IN QUESTION. 307
3.3 STACKING AND STORAGE : STEEL REINFORCEMENT SHALL BE
STORED IN SUCH A WAY AS TO PREVENT DISTORTION,
DETERIORATION AND CORROSION. REINFORCING BARS SHALL NOT
BE LEFT IN DIRECT CONTACT WITH THE GROUND BUT THEY SHALL
BE STACKED ON TOP OF AN ARRANGEMENT OF TIMBER SLEEPERS
OR THE LIKE SUITABLE RACKS SHALL ALSO BE USED FOR STACKING
REINFORCEMENT IN TIERS. BARS OF DIFFERENT CLASSIFICATIONS,
SIZES AND LENGTHS SHALL BE STORES SEPARATELY TO FACILITATE
ISSUES IN SUCH SIZES AND LENGTHS AS TO MINIMIZE WASTAGE IN
CUTTING FROM STANDARD LENGTHS. 308
3.4 CUTTING AND BENDING : 308
3.4.1 BARS BENT DURING TRANSPORT OR HANDLING SHALL BE
STRAIGHTENED BEFORE BEING USED ON WORK; THEY SHALL NOT
BE HEATED TO FACILITATE BENDING. 308
3.4.2 REINFORCEMENT BARS SHALL BE OF THE SIZE PRESCRIBED
AND SHALL BE ACCURATELY CUT TO LENGTH AND BENT TO SHAPE
AND FIXED IN POSITION AS SHOWN ON THE DRAWINGS OR AS
DIRECTED BY THE ENGINEER-IN-CHARGE AND SHALL CONFORM TO
IS: 2502-1963 AS REVISED FORM TIME TO TIME. THE TOLERANCE FOR
BENDING AND CUTTING SHALL BE AS GIVEN IN TABLE 1. 308
3.6 BINDING AND PLACING : 311
3.7 SUBSTITUTION : 313
3.8 BUNDLING OF BARS : 313
3.8.1 THE BUNDLES OF BARS MAY BE PROVIDED IN THE ORIGINAL
DESIGN/DRAWING OR MAY BE NECESSITATED AS REQUIREMENT OF
SUBSTITUTION. THE BARS SHALL BE BUNDLED IN SHAPES OF
TRIANGULAR, SQUARE OR L-SHAPED TO ACT AS ONE UNIT OF
REINFORCEMENT. THE BAR DIAMETERS IN A BUNDLE SHALL BE
LIMITED TO TWO NEAREST SIZES. BUNDLED BARS SHALL BE TIED
TOGETHER TO ENSURE THE BARS REMAINING TOGETHER. BARS
LARGER THAN 36MM DIA SHALL NOT BE BUNDLED EXCEPT IN
COLUMNS. 313
3.8.2 CURTAILMENT : BARS IN A BUNDLE SHALL TERMINATE AT
DIFFERENT POINTS SPACED APART BY NOT LESS THAN 40 TIMES THE
BAR DIAMETER EXCEPT FOR BUNDLES STOPPING AT A SUPPORT. 313
4 STRUCTURAL STEEL & IRON WORK 314
4. MATERIALS 314
4.2 STEEL WORK IN SINGLE SECTION FIXED INDEPENDENTLY / WITH
CONNECTING PLATE 315
4.3 STEEL WORK IN BUILT UP SECTIONS (RIVETTED AND BOLTED) :
316
THE STEEL WORK IN BUILT UP SECTIONS (RIVETTED AND BOLTED),
SUCH AS IN TRUSSES, FRAMED WORK ETC. SHALL BE COVERED BY
THE PROVISIONS IN THESE PARAS. 316
All materials shall conform to section 5 except steel for prestressing.The prestressing steel
shall conform to either of the following:Plain hard drawn steel wire conforming to IS: 1785
(Part I) and IS: 1785 (Part II).Cold drawn indented wire conforming to IS: 6003High tensile
steel bar conforming to IS: 2090Uncoated stress relieved strands conforming to IS: 6006. 333
4 Anchorages 334
9. CUTTING 335
16. POST-TENSIONING 337
20. TENSIONING PROCEDURE 339
Volume III 251
Section - 10 251
Road Works 251
INDEX 251
Section - 10 : Road Work 256
1 Introduction 256
1.1 THE PERFORMANCE OF ROADS IS DIRECTLY LINKED WITH
QUALITY OF CONSTRUCTION. ROAD CONSTRUCTION TECHNIQUES
HAVE BEEN UPGRADED RECENTLY AND USE OF NEW AND
ALTERNATE MATERIALS HAVE BEEN ADVOCATED FOR ALL TYPE OF
ROADS. IT IS LOGICAL TO SEE THAT THE PURPOSE OF ROAD
CONSTRUCTION IS TO PROVIDE A FIRM, DURABLE AND EVEN
SURFACE OF THE PAVEMENT, WHICH COULD STAND THE STRESS
IMPARTED DUE TO TRAFFIC AND CLIMATIC CONDITIONS. THE ROAD
CONSTRUCTION ACTIVITY STARTS FOR EARTHWORK FOR
EMBANKMENT AND COMPLETES WITH HIGH QUALITY SURFACE
FINISH WITH BITUMINOUS OR CONCRETE CONSTRUCTION. EACH
COMPONENT OF THE ROAD HAS APPROPRIATE CONSTRUCTION
REQUIREMENTS AND SPECIFICATION TO BE FOLLOWED. THIS
CHAPTER DEALS WITH DETAILS OF CONSTRUCTION TECHNIQUES
AND SPECIFICATIONS FOR VARIOUS PAVEMENT COURSE INVOLVING
USE OF TRADITIONAL AS WELL AS ALTERNATE AND LOCALLY
AVAILABLE MATERIALS FOR ALL-WEATHER ROADS. 256
2 Materials and source: 256
2.1 THE QUALITY OF MATERIALS, LEAD TO THE BORROW AREAS AND
CLIMATIC CONDITIONS ARE KEY FACTORS FOR COST EFFECTIVE
CONSTRUCTION. 256
3 Construction Techniques: 256
3.1 CONVENTIONAL CONSTRUCTION METHODS ARE TYPICALLY
LABOUR BASED AND MOST OF THE CONSTRUCTION OPERATIONS
ARE DONE MANUALLY. IN CASE OF MECHANIZED METHOD OF
CONSTRUCTION, MOST OF THE OPERATIONS ARE DONE WITH
MACHINES LIKE GRADER, BULLDOZER, AND PAVER, ETC.
VIBRATORY ROLLER MAY ALSO BE USED FOR COMPACTION. THE
SELECTION OF CONSTRUCTION METHODOLOGY WILL BE BASED ON
VARIOUS CONSIDERATIONS. NO DOUBT, A MODERN MECHANIZED
METHOD WILL LEAD TO LARGER AND FASTER OUTPUT AND WILL
ALSO HELP IN MAINTAINING THE BETTER QUALITY OF
CONSTRUCTION. 256
3.2 THE CONSTRUCTION OF ROADS IN SOME AREAS REQUIRES
EXTENSIVE BLASTING AND THE ROADS HAVE TO BE CARVED
THROUGH VERY STEEP AND VERTICAL ROCK FACES. THUS
EXCLUSIVE DEPENDENCE ON MANUAL LABOUR FOR WORK IN HILLY
AREAS HAS ASSOCIATED SAFETY HAZARDS. 256
4 Machinery and tools: 256
4.1 IN INDIA, ROAD CONSTRUCTION ACTIVITIES ARE ACCOMPLISHED
IN VARIOUS STAGES. THE TOOLS, APPLIANCES AND EQUIPMENT
REQUIRED FOR DIFFERENT CONSTRUCTION ACTIVITIES MAY ALSO
BE CLASSIFIED AS MANUAL AND MECHANISED METHOD. MOST OF
THE TOOLS AND APPLIANCES USED BY MANUAL LABOUR FOR
VARIOUS PHASES OF CONSTRUCTION ARE CONVENTIONAL TOOLS
AND APPLIANCES COMMON TO ALL THE ACTIVITIES AND PHASES OF
CONSTRUCTION. SPECIAL TOOLS, APPLIANCES AND EQUIPMENT ARE
ALSO USED FOR SPECIAL CONSTRUCTION ACTIVITIES LIKE
BITUMINOUS WORK AND CONSTRUCTION OF CONCRETE ROAD, ETC.
SOME MACHINES/EQUIPMENTS, LIKE, DOZERS, COMPRESSORS,
CRUSHERS, LOADER AND LOAD CARRIERS ARE ALSO COMMON TO
MOST OF THE CONSTRUCTION ACTIVITIES WHERE MECHANISED
METHODS ARE ADOPTED. THE LIST OF TOOLS APPLIANCES AND
EQUIPMENT REQUIRED FOR SEMI MECHANIZED METHOD IS GIVEN
IN APPENDIX I. ON MAJOR PROJECTS, THE WORK OF BULKY AND
REPETITIVE NATURE CAN BE DONE MORE ECONOMICALLY AND
EFFICIENTLY BY WELL-DESIGNED MACHINES. PRACTICALLY EVERY
OPERATION IN CONSTRUCTION OF ROADS CAN BE PERFORMED BY
DIFFERENT TYPES OF EQUIPMENT, BUT UNDER AND GIVEN SET OF
CONDITIONS ONLY A PARTICULAR TYPE OF MACHINE WOULD BE
MOST EFFECTIVE. THUS SELECTION OF MACHINE FOR ANY
PARTICULAR PHASE OF CONSTRUCTION REQUIRES DETAILED
STUDY ABOUT BRAND, MODEL AND SPECIFICATION OF THE VARIOUS
EQUIPMENT AVAILABLE AND THEIR SUITABILITY FOR PARTICULAR
PHASE OF CONSTRUCTION. IRC PUBLICATION MOST HANDBOOK ON
ROAD CONSTRUCTION MACHINERY, MAY BE REFERRED FOR
FURTHER DETAILS. THE SURFACE EVENNESS AND COMPACTION ARE
GENERALLY CHECKED WITH CAMBER BOARD/TEMPLATE,
STRAIGHT EDGE, DEPTH GAUGE AND DENSITY MEASURING KIT.
RECENTLY UNEVENNESS INDICATOR AND NUCLEAR DENSITY
METERS HAVE ALSO BEEN INTRODUCED FOR EXERCISING QUALITY
CONTROL IS GIVEN IN APPENDIX - II. 256
5 Embankment and Subgrade 257
5.1 CONSTRUCTION OF EMBANKMENT AND PREPARATION OF
SUBGRADE ARE PART OF EARTHWORK. THE MAIN ACTIVITIES
ASSOCIATED WITH CONSTRUCTION ARE, SOIL SURVEY AND
IDENTIFICATION OF BORROW AREAS, CONSTRUCTION OF
EMBANKMENT AND SUBGRADE. THE DETAILS ARE DISCUSSED IN
THE FOLLOWING PARAGRAPHS. 257
6 Embankment with conventional earth: 257
6.1 THE HEIGHT OF ROAD EMBANKMENT DEPENDS ON THE HIGHEST
FLOOD LEVEL (HFL) IN AREA GENERALLY 0.6 TO 1.0 M HEIGHT
ABOVE HFL IS TO BE ENSURED. THE EMBANKMENT MAY BE
CONSTRUCTED BY ROLLING IN RELATIVELY THIN LAYERS. EACH
LAYER SHOULD BE COMPACTED BY SUITABLE ROLLER TO A
DESIRED DENSITY BEFORE THE NEXT LAYER IS PLACED.
COMPACTION SHOULD BE CARRIED OUT AT OPTIMUM MOISTURE
CONTENT SO AS TO TAKE ADVANTAGE OF MAXIMUM DRY DENSITY
USING A SPECIFIED COMPACTING EFFORT AND EQUIPMENT. THE
THICKNESS OF EACH COMPACTED LAYER MAY VARY BETWEEN 150
TO 300 MM DEPENDING UPON VARIOUS FACTORS SUCH AS SOIL TYPE,
COMPACTION EQUIPMENT AND SPECIFICATIONS. USING ORDINARY
8-10 TONNE ROLLERS, COMPACTED THICKNESS SHALL NOT EXCEED
150 MM IRC:36, IRC:56, IRC:75 MAY BE REFERRED FOR
CONSTRUCTION OF EMBANKMENTS. 257
6.2 FOR IDENTIFICATION OF SUITABLE BORROW AREA, SAMPLES
MAY BE COLLECTED AT DIFFERENT DEPTHS FROM THE TEST PITS
DUG OPEN IN BORROW AREAS FROM WHERE THE EMBANKMENT
MATERIAL IS TO BE OBTAINED. THE SOIL FOR PROCESSING SHOULD
BE BROUGHT TO PROPER MOISTURE CONTENT, SO THAT THE
NEEDED DEGREE OF COMPACTION CAN BE IMPARTED WITH LEAST
EFFORT. NEEDED AMOUNT OF WATER SHOULD BE QUITE
UNIFORMLY DISPERSED IN THE ENTIRE SOIL MASS. DEPENDING
UPON THE WEATHER CONDITIONS AND TIME GAP BETWEEN
SPRINKLING OF WATER AND COMMENCEMENT OF ROLLING, AN
ALLOWANCE OF 3 TO 4 PER CENT FOR EVAPORATION SHOULD BE
MADE IN THE QUANTITY OF WATER TO BE ADDED DURING SUMMER
WHEN TEMPERATURE IS GREATER THAN 350C, IN WINTER THIS
ALLOWANCE MAY BE REDUCED TO 1 TO 2 PER CENT. FOR
EARTHWORK CONSTRUCTION, THE LOOSE THICKNESS OF THE SOIL
LAYER SHOULD NOT NORMALLY EXCEED 200 MM WHEN ORDINARY
8-10 TONNE ROLLERS ARE USED. 257
6.3 WHEN THE EARTHWORK HAS REACHED A STAGE WHERE THE
GENERAL FORM OF THE FINAL SHAPE OF THE EMBANKMENT HAS
BEEN OBTAINED, THE SPREADING OF EARTH SHOULD BE DONE IN
STRAIGHT REACHES TO A CROWNED SHAPE, AND TO
APPROPRIATELY BANKED PROFILE IF THE REACH IS ON A CURVE.
THE MOISTURE CONTENT IN THE LAID SOIL SHOULD BE THE
OPTIMUM MOISTURE CONTENT SUBJECTED TO THE PERMITTED
TOLERANCE. HIGHLY EXPANSIVE SOILS SUCH AS BLACK COTTON
SOIL SHOULD BE COMPACTED AT THE SPECIFIED MOISTURE
CONTENT, WHICH IS USUALLY ON THE WET SIDE OF THE OPTIMUM
MOISTURE CONTENT. THE TOLERANCE LIMITS OF VARIATION FROM
THE SPECIFIED MOISTURE CONTENT OMC ARE NORMALLY + 1 PER
CENT TO 2 PER CENT FOR SANDY/SILTY SOILS AND OPTIMUM
MOISTURE CONTENT (OMC) TO +2 PER CENT FOR CLAYEY/BLACK
COTTON SOILS. EARTH TO BE USED SHOULD BE GOOD SOIL, FREE
FROM SLUMPS, ROOTS AND LEAVES OF TREES, PLANTS AND
RUBBISH. THE CLODS SHOULD BE BROKEN TO LESS THAN 75 MM
SIZE. THE EQUIPMENT FOR COMPACTION OF EARTHWORK SHOULD
BE AN 8-10 TONNE SMOOTH WHEELED POWER ROLLER. HOWEVER,
IF SUCH A POWER ROLLER IS NOT AVAILABLE, THE USE OF LIGHTER
ROLLERS OF 6 TO 8 TONNE WEIGHT MAY BE PERMITTED. IN SUCH
CASES, THE THICKNESS OF LOOSE SOIL LAYER SHOULD BE
SUITABLY REDUCED AND THE NUMBER OF PASSES NEEDS TO BE
INCREASED TO ACHIEVE THE DESIRED DENSITY. 257
6.4 DENSITIES TO BE AIMED AT THE COMPACTION PROCESS SHALL
BE CHOSEN WITH DUE REGARD TO FACTORS SUCH AS SOIL TYPE,
HEIGHT OF EMBANKMENT, DRAINAGE CONDITIONS, POSITION OF
INDIVIDUAL LAYERS AND TYPE OF AVAILABLE COMPACTION
MACHINERY. EACH COMPACTED LAYER SHALL BE TESTED IN THE
FIELD FOR DENSITY AND COMPACTED FULLY BEFORE THE
OPERATIONS FOR THE NEXT LAYER COMMENCE. THE MINIMUM
FIELD DENSITY IN CASE OF THE EMBANKMENT SHALL NOT BE LESS
THAN 97 PER CENT STANDARD PROCTOR COMPACTION (IS:2720
(PART 7) 1980). THE OVERALL PROFILE SHOULD BE IMPROVED WITH
EACH SUCCESSIVE LAYER SO THAT THE SUBGRADE LEVEL IS
APPROACHED. THE PROFILE OF THE FORMATION IS AS PER LINES
AND GRADES. 258
7 Subgrade with natural earth 258
7.1 THE PREPARATION OF SUBGRADE INCLUDES ALL OPERATIONS
BEFORE THE PAVEMENT STRUCTURE COULD BE LAID OVER IT AND
COMPACTED. THUS THE PREPARATION OF SUBGRADE WOULD
INCLUDE SITE CLEARANCE (IF THE FORMATION ALREADY EXISTS),
GRADING (EMBANKMENT OR CUT SECTION) AND COMPACTION TO
DESIRED DENSITY AT OPTIMUM MOISTURE. THE SUBGRADE MAY BE
SITUATED ON EMBANKMENT OR EXCAVATION OR AT THE EXISTING
CANAL BANK. IN ALL THE CASES, SITE SHOULD BE CLEARED OFF
AND THE TOP SOIL CONSISTING OF GRASS, ROOTS, RUBBISH AND
OTHER ORGANIC MATTER ARE TO BE REMOVED. THE GRADING
OPERATION IS STARTED THEREAFTER SO AS TO BRING THE
VERTICAL PROFILE OF THE SUBGRADE TO DESIGNED GRADE AND
CAMBER. BULLDOZERS, TIPPERS AND BLADE GRADERS ARE USEFUL
EQUIPMENT TO SPEED UP THIS WORK. HIGHLY CLAYEY AND BLACK
COTTON SOIL SHALL NOT BE USED DIRECTLY AS A SUBGRADE
MATERIAL. IN SUCH CASE A CAPPING LAYER OF 100 MM THICKNESS
SHALL BE PROVIDED WITH MATERIAL OF CBR HIGHER THAN 10 PER
CENT OR GEO-TEXTILE SHALL BE USED AS A FILTER MATERIAL, IF
FOUND ECONOMICAL. IN CASE THE REACH IS IN CUTTING AND IN-
SITU SOIL IS TO BE USED FOR SUBGRADE, THE METHOD CONSISTS IN
LOOSENING OF THE SOIL TO APPROPRIATE DEPTH TO COMPACT TO
A THICKNESS OF 300 MM BRINGING THE MOISTURE TO REQUIRED
LEVEL AND COMPACTING IT WITH A SUITABLE ROLLER TO 100 PER
CENT STANDARD PROCTOR COMPACTION DENSITY. THE
COMPACTION PROCESS SHOULD COMMENCE AT THE EDGES AND
PROGRESS TOWARDS THE CENTRE EXCEPT AT SUPER-ELEVATED
PORTIONS WHERE IT SHALL COMMENCE FROM LOWER EDGES AND
PROGRESS TOWARDS HIGHER EDGE. WHEN THE REACH IS IN
FILLINGS, IT IS NECESSARY TO ENSURE THAT AT LEAST THE TOP 300
MM OF THE EMBANKMENT CONSTITUTING THE SUBGRADE OF THE
PAVEMENT SHOULD BE COMPACTED TO 100 PER CENT OF STANDARD
PROCTOR COMPACTION DENSITY IN AT LEAST TWO LAYERS AT
OPTIMUM MOISTURE CONTENT. THE SUBGRADE SHOULD BE
FINISHED TO THE DESIRED PROFILES; A CAMBER BOARD SHOULD BE
USED TO CHECK THE CROSS SLOPE. 258
8 Surface drains 258
8.1 THE FAST DISPOSAL OF RUNOFF ON THE ROAD SURFACE IS
ACHIEVED BY SURFACE DRAINAGE. SURFACE DRAINS SHALL BE
EXCAVATED TO THE SPECIFIED LINES, GRADES, LEVELS AND
DIMENSIONS BASED ON THE TYPE OF THE DRAIN. THE EXCAVATED
MATERIAL SHALL BE REMOVED FROM THE AREA ADJOINING THE
DRAINS AND IF FOUND SUITABLE, UTILISED IN EMBANKMENTS OR
SUBGRADE CONSTRUCTION. ALL UNSUITABLE MATERIALS SHALL BE
DISPOSED OF AS DIRTECTED. THE EXCAVATED BED AND SIDES OF
THE DRAINS SHALL BE DRESSED TO BRING THIS IN CLOSE
CONFORMITY WITH THE SPECIFIED DIMENSIONS, LEVELS AND
SLOPES. 258
9 Sub Base (Granular) 259
9.1 SUB-BASE IS AN INTERMEDIATE LAYER BETWEEN SUBGRADE
BASE COURSE. THE FUNCTION OF THIS LAYER IS AS A DRAINAGE
LAYER FOR THE PAVEMENT TO AVOID EXCESSIVE WETTING AND
WEAKENING OF SUBGRADE. VARIOUS MATERIALS AND TECHNIQUES
ARE USED FOR CONSTRUCTION OF SUB BASE COURSE. VARIOUS
TYPE OF CONSTRUCTION FOR SUB-BASE, WHICH ARE APPROPRIATE
FOR RURAL ROAD, ARE DETAILED HERE. 259
9.2 GRANULAR SUB-BASE (GSB): 259
9.3 COARSE SAND SUB-BASE 260
10 Base Course (Granular) 260
10.1 THE FOLLOWING SPECIFICATIONS ARE RECOMMENDED FOR
CONSTRUCTION OF GRANULAR BASE COURSE 260
10.2 WATER BOUND MACADAM (WBM) 260
10.3 CRUSHER RUN MACADAM (CRM) : THE WORK SHALL CONSIST OF
FURNISHING, PLACING AND COMPACTING CRUSHED STONE
AGGREGATE SUB-GRADE AND BASE COURSES CONSTRUCTED IN
ACCORDANCE WITH THE REQUIREMENTS SET FORTH IN THIS
SPECIFICATION AND IN CONFORMITY WITH THE LINES, GRADES,
THICKNESSES AND CROSS SECTIONS SHOWN ON THE PLAN OR AS
DIRECTED BY THE ENGINEER-IN-CHARGE. THE GRADING SHALL
CONFORM TO THE GRADING AND QUALITY REQUIREMENTS SHOWN
IN TABLE BELOW. 263
11 Shoulder 263
11.1 SHOULDER GIVES ADEQUATE SIDE SUPPORT TO THE PAVEMENT
AND ALSO DRAINS OFF SURFACE WATER FROM THE CARRIAGEWAY
TO THE ROAD SIDE DRAIN. 263
11.2 CONSTRUCTION OF SHOULDERS: THE CONSTRUCTION SHALL BE
DONE IN LAYERS EACH MATCHING THE THICKNESS OF ADJOINING
LAYER. ONLY AFTER A LAYER OF WBM, SHOULDER SHALL BE LAID
AND COMPACTED. NEXT CORRESPONDING LAYERS IN PAVEMENT
SHALL BE TAKEN UP AFTER THE COMPLETION OF FIRST LAYER OF
WBM AND SHOULDER. THIS PROCEDURE SHALL BE FOLLOWED UPTO
THE SURFACE COURSE. IN THE CASE OF BITUMINOUS COURSES,
WORK ON SHOULDER SHALL START ONLY AFTER THE PAVEMENT
COURSE HAS BEEN LAID AND COMPACTED. THE COMPACTION
REQUIREMENT OF EARTHEN SHOULDER SHALL BE 100 PERCENT OF
STANDARD PROCTOR COMPACTION DENSITY AS PER IS:2720 (PART 7)
1980. 263
DURING ALL STAGES OF SHOULDER CONSTRUCTION, THE REQUIRED
CROSS FALL SHALL BE MAINTAINED TO DRAIN OFF SURFACE WATER.
REGARDLESS OF THE METHOD OF LAYING ALL SHOULDER
CONSTRUCTION MATERIAL SHALL BE PLACED ON THE SHOULDER.
ANY SPILLED MATERIAL DRAGGED ON TO THE PAVEMENT SURFACE
SHALL BE IMMEDIATELY REMOVED WITHOUT DAMAGE TO THE
PAVEMENT. 264
12 Bituminous Constructions 264
12.1 RURAL ROADS ARE EXPECTED TO HAVE VERY LOW TRAFFIC,
AND THEREFORE, ANY ALL WEATHER SURFACING WILL PROVIDE
THE NEEDED CONNECTIVITY. BUT, WHERE THERE IS REASONABLE
VOLUME OF MOTORIZED TRAFFIC, THIN BITUMINOUS SURFACING
WILL BE DESIRABLE. THIS SECTION DEALS WITH CONSTRUCTION OF
ALL DIFFERENT BITUMINOUS CONSTRUCTION REQUIRED FOR
FLEXIBLE PAVEMENT. THE BASIC OBJECTIVE OF PROVIDING THIN
BITUMINOUS SURFACING ON RURAL ROADS IS TO SEAL GRANULAR
SURFACE COST EFFECTIVELY AND TO REDUCE MAINTENANCE
EFFORTS. 264
12.2 PRIME COAT ON GRANULAR SURFACES: PRIME COAT IS A SPRAY
APPLICATION OF LOW VISCOSITY LIQUID BITUMINOUS MATERIAL
ON TOP OF THE TOP MOST GRANULAR LAYER OF THE BASE COURSE.
PRIME COAT PERFORMS FOLLOWING IMPORTANT FUNCTIONS. 264
12.3 TACK COAT APPLICATION: TACK COAT IS A VERY LIGHT
APPLICATION OF LIQUID BITUMINOUS MATERIAL ON A BITUMINOUS
LAYER WHEN A NEW LAYER IS TO BE LAID OVER IT. IT IS USED TO
CREATE A BOND BETWEEN A NEW BITUMINOUS LAYER TO BE
PLACED ON THE EXISTING BITUMINOUS OR A PRIMED GRANULAR
LAYER. THE FOLLOWING TYPES OF LIQUID BITUMINOUS
MATERIALS CAN BE USED FOR TACK COAT APPLICATIONS: 265
13 Introduction 274
13.1 QUALITY SHOULD CONFORM TO THE CUSTOMER NEED OR
USERS REQUIREMENT IN ALL ACTIVITIES AND PROJECTS.
HOWEVER, QUALITY IS CONSIDERED AS CONFORMANCE TO
SPECIFICATIONS PARTICULARLY IN CONSTRUCTION SECTOR. THE
QUALITY CONTROL IS AN ESSENTIAL REQUIREMENT FOR ALL
WEATHER RURAL ROAD CONSTRUCTION BY ADOPTING
IRC/MORT&H SPECIFICATIONS AND CONSTRUCTION METHODS FOR
CREATING DURABLE AND LONGER LASTING ASSETS FOR RURAL
INDIA. THE OVERALL QUALITY CONTROL OF RURAL ROAD WORKS
MUST COVER CONTROLLING OF QUALITY OF MATERIALS AND THE
WORK AT SITE WITH THE HELP OF OBJECTIVE TESTS PERFORMED
AT A REASONABLE, PRE-DETERMINED FREQUENCY WITH
AFFECTING PROGRESS OR WORKS. IT IS ALWAYS TESTS PERFORMED
AT A REASONABLE, PRE-DETERMINED FREQUENCY WITHOUT
AFFECTING PROGRESS OF WORKS. IT IS ALWAYS ADVANTAGEOUS TO
HAVE SEPARATE QUALITY CONTROL UNIT, INDEPENDENT OF
CONSTRUCTION STAFF TO CONTROL AND MONITOR THE WORK. THE
GUIDELINES IN THIS REGARD ARE CONTAINED IN IRC:SP:11,
HANDBOOK OF QUALITY CONTROL FOR CONSTRUCTION OF ROADS
AND RUNWAYS, CLAUSE 900 SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS OF MORT&H SPECIFICATIONS AND IRC:SP:57,
GUIDELINES FOR QUALITY SYSTEMS FOR ROAD CONSTRUCTION.
274
14 Pre-Requisite 274
15 Specifications and Codes of Practice 275
15.1 THE SPECIFICATIONS AND CODES OF PRACTICE LAID DOWN BY
INDIAN ROADS CONGRESS, MINISTRY OF ROAD TRANSPORT AND
HIGHWAYS, AND BUREAU OF INDIAN STANDARDS ARE REQUIRED TO
BE FOLLOWED IN CONSTRUCTION OF ROADS. 275
16 Earth Work and Granular Layer 275
16.1 THE MATERIALS SUPPLIED AND THE WORKS CARRIED OUT BY
THE CONTRACTOR SHALL CONFORM TO THE SPECIFICATIONS
PRESCRIBED. FOR ENSURING THE REQUISITE QUALITY OF
CONSTRUCTION, THE MATERIALS AND WORKS SHALL BE
SUBJECTED TO QUALITY CONTROL TESTS, AS DESCRIBED
HEREINAFTER. THE TESTING FREQUENCIES INDICATED ARE THE
DESIRABLE MINIMUM AND THE ENGINEER-IN-CHARGE SHALL
RECOMMEND FOR ADDITIONAL TESTS WHENEVER FELT NECESSARY,
TO ENSURE COMPLIANCE WITH THE APPROPRIATE SPECIFICATIONS.
SOME OF THE IMPORTANT TEST ON SOIL, AGGREGATE AND
BITUMINOUS MATERIALS ARE DESCRIBED IN APPENDICES-III, IV AND
V RESPECTIVELY. FOR DETAILS, RELEVANT CODE OF PRACTICE MAY
BE REFERRED AS PER LIST GIVEN AT APPENDIX I. 275
17 Bituminous courses 277
17.1 BITUMINOUS MATERIALS CAN BE USED FOR CONSTRUCTION OF
PRIME COAT, TACK COAT MODIFIED PENETRATION MACADAM,
BITUMINOUS MACADAM, OPEN GRADED PREMIX CARPET WITH
SEAL COAT, AND CLOSELY GRADED PREMIX CARPET (MIX SEAL
SURFACING, ETC.). THE MODIFIED PENETRATION MACADAM AND
BITUMINOUS MACADAM SHALL BE USED ONLY AT SPECIAL
LOCATIONS WHERE TRAFFIC IS HEAVY AND REQUIREMENT OF
STRENGTHENING BY BITUMINOUS COURSE IS ESSENTIAL. 277
2.17 22.2 TERMINOLOGY 295
296
22.2.9 Double packer method method in which two packers are used in the drill hole. in this
case the test section is between the two packers (see fig 1b) 296
22.2.10 Split spacing grouting method- A sequence of drilling and grouting holes in which
widely spaced holes are drilled and grouted initially and the spacing is subdivided by
intermediate holes . The initial set of holes are called primary holes and intermediate holes
are termed secondary etc. according to the sequence of subdivision. 296
22.2.11 Slush grouting- Application of cement slurry to surface rock as a means of filling
cracks and surface irregularities or open joints to prevent leakage and slacking. 296
22.4.11. Core box arranging and indexing of cores : 310
24.4.11.1 General : At the site of drilling, the cores, immediately on their withdrawal from the
core barrel shall be placed in core tray and then transferred to core boxes specially made for
this purpose. 310
and the mechanical arrangement for applying pressure on the bit. The drilling outfit, however,
is generally less sophisticated than a conventional direct rotary rig. The chilled steel shots
(calyxite) are fed through the water line. During drilling the calyxite is ground by the shot bit.
Pressure is applied on the bit in addition to the weight of the drill pipe assembly. Water is
used as a drill field to lubricant the drill and remove loose debris. As the drilling proceeds,
cylindrical rollers are cut through and collected in the core barrel which is removed at
frequent intervals. The operation is not continuous and hence it is time consuming. 314
314
22.5.3 For arranging and indexing of cores and storage of core boxes, specifications under
para 22.4.11 shall be applicable. 314
22.6 Percussion Drilling : 314
This admits for flow reversal. When systamatic washing and jetting is carried out to remove
all soft material in seams it is generally not necessary to use a primary and secondary system
of holes. 321
321
22.7.5.3.2 when it is desirable to test the efficacy of consolidation grouting by comparing the
gorut absorption in primary and secondary holes a rectanglur or square pattern (see fig. 4) of
holes would be preferred. this is generally the case when the joints are irregular and relativly
free from in filling or it is not necessary to remove the material filling the joints. 321
22.7.5.4 Numbering of Great Holes : 321
22.7.5.4.1 Each hole would be assigned a number which would be used for all furture
referferences. Number would include details viz. block mumbe, stage, serial serial number of
the 321
335
337
346
349
3.6 Water should then be pumped into the section under pressure. Each pressure should be
maintained until the readings of water intake at intervals of 5 min show a nearly constant
reading of water-in-take for one particular pressure at the collar. The constant rate of water
intake should be noted. It is recommended that the tests be commenced with a low pressure at
the collar id increased limited to the availability of suitable rock cover to prevent uplift or to a
maximum equivalent to H + X (where H is the hydraulic bead to which the strata would be
subjected due to contemplated structure and X is the loss due to friction) is achieved.
Frictional loss may be determined by means of charts given in fig. 8A, SB and SC and. added
to the test pressure. In order to. avoid upheaval of the rock foundation test pressures are
generally limited to the following:- 350
352
5.1 The coefficient of permeability should be computed using the formulae given in fig.9.
The coefficient Cu and Cs in these formulae may be taken from the graphs given in Fig. 10
and fig. 11. For water percolation tests conducted above the water table, the position of the
base of Zone I should be found from the curve given in Fig.12. The - friction loss of head (L)
should be calculated or obtained from Fig.8A, 8B or 8C. This head should be deducted from
the combined head due to gravity and that due to applied pressure. Numerical examples
illustrating the use of the formulae are given in para 5,2, 354
355
Limitations Q / A < 0.10 S > 10 in method II : Thickness of each packer should be 10. 355
A = length of test section, in m. 355
a = surface area of test section, in m2 (in method 1, a is area of wall plus area of bottom) 355
Cu = conductivity coefficient unsaturated bed (see fig. 10) 355
Cs = conductivity coefficient saturated bed (see fig. 11) 355
D = distance from ground surface to bottom of hole, in m. 355
H = effective head = H2 + H3 L, in m 355
H2 = in test above water table, distance between swivel and bottom of hole in m. in test
below water table, distance between swivel and water table, in m. 355
H3 = applied pressure at collar, in m of water. 355
K = coefficient of permeability in m/s under unit gradient (multiply by 100 to get the value in
cm/s) 355
L = head loss in pipe due to friction in m of water (for quantities less than 18 1/min in 32 mm
pipe, it may be ignored. 355
Q = Steady flow into well in 3/s. 356
r = radius of test hole, in m. 356
S = Thickness of saturated material, in m. 356
Tu = U D + H 356
U = thickness of unsaturated material, in m. 356
H 356
X = percent of unsaturated stratum Tu x 100 (see fig. 12) 356
Fig. 9 Formulat for Calculation of Coefficient or Permeability 356
356
5.2 Calucation of permeability coefficient using pressure percolation test in bedrock 356
Zone 1 : 356
U = 23 m D = 7.6 m A = 3 m 356
r = 0.15 m H2 = 10 m H3 = 1.75 kg/cm2 356
= 17.5 m 356
Q = 0.0013 m3/S 356
L using 32 mm pipe at 0.0013 m3/s 356
= 23 cm loss per 3.05 m section 356
Distance from swivel to bottom of pipe 6.7 m 356
6.7 x 0.23 356
Head Loss = 3.05 = 0.514 m 357
H = (10+17.5-0.51) m = 26.99 m, Say 27 m 357
Tu = U D + H = 23-7.6 + 27 m = 42.4 m 357
H 27 x 100 357
x = Tu x 100 = 42.4 = 63.6 percent 357
358
364
1.4.1 Limiting values of pressure for each zone may be established initially on the basis of the
categorization of rock as suggested in Fig. 13. Pressure limits based on Fig. 13 should be
taken as initial values to be confirmed by trial and observation. 364
The choice of pressures may also be established by examining water test data. The method of
interpretation of water test data is described as suggested in Fig. 14 and para 1.4.1.1. These
interpretations may be generalized to establish relationship between hydraulic fracturing
pressure and overburden depth for various strata encountered. The pressure limit may be set
at 2/3rd the hydraulic fracturing pressure established by analysis of water test data. The water
test thus constitutes a basis of verification or rock categorization as per Fig. 13. 364
1.4.1.1 Interpretation of water test : 364
(A) The results of water percolation test should be interpreted on the basis of following
principles : 364
When the rate of flow for a given length of test section varies proportionate to pressure, this
is categorized as a condition of laminar flow. In a cyclic test, the flow will increase and
decrease in direct proportion of the pressure and lugeon values remain constant all over the
cyclic test. 364
Sometimes the resistance to flow increase disproportionately to the increase in pressure and
therefore the rise of flow rates is not commensurate with the increase in pressure. This may
be attributed to development of turbulent flow regime and is indicated by lugeon values
decreasing with increase of pressure. 365
367
SECTION - 4: EXCAVATION
(EXCAVATION FOR DAM & ITS COMONENTS)
1 General
1.1 The work to be done under these specifications shall consist of furnishing
all tools, constructional plant, labour, materials and other things
required for excavation in all stratas. Conveyance and disposal of the
excavated materials, including all leads and lifts, temporary work for
performance of all the operations connected with the work embraced
under the contract so as to secure satisfactory quality of work.
1.2 Construction and maintenance of diversions in case diversion of existing

communication lines, channels, nalla or drains where they were
disturbed due to excavation of Dam & its components.
2. Standards
The following listing includes the Bureau of Indian Standards applicable for the Excavation
work
1. IS: 4701-1982 Code of practice for Earth work on canal.
2. IS:7293-1974 Safety code for working with construction
machinery
3. IS:3764-1966 Safety code for excavation work
4. IS:1498-1970 Classification and identification of soils for
general Engineering purposes
5. IS: 2720(Part.2)- Method of test for soils part-2, Determination
1973
Of water. content.
6. IS 2720 (Part.7)- Method of test for soils Determination of water content dry
1980 density
Relation using light compaction.
7. IS : 2720 (Part. Method of test for soils. Determination of Dry
28)-1974
Density of soils in place by sand replacement method
8. IS: 2720 Method of test for soils (part. 29). Determination of dry density of
(Part.29)-1976 soils in
place by core cutter method
9. IS :1888-1982 Method of load test on soils
10. IS:2131-1981 Methods of standard penetration test for soils.
11. IS: 4332-1967 Methods of test for stabilized soils methods of sampling and
(part.1) preparation of stabilized soils for testing
12. IS: 2720-1983 Method of test for soils-Grain size Analysis
(Part.4)
13. IS: 2720-1985 Method of test for soils for. Determination of liquid a plastic
(part.5) limits.
14. IS: 2720-1971 Determination of dry Density moisture content-relation by
(Part.9) constant weight of soils method.
15. IS: 2720-1991 Determination of unconfined compressive Strength
(Part.10)
16. IS: 2720-1986 Method of test for soils. (Part.13) direct shear test.
(part.13)
17. IS:2720-1986 Method of test for soils: (Part.15) Determination of consolidation
(part.15) properties.
18. IS2720-1983 Method of test for soils for. Determination of Density Index,
(part.14) (relative density) of cohesion less soils.
19. IS:2720-1987 Method of test for soils Laboratory determination of C.B.R
(part.16)
20. IS:2720-1964 Method of test for soils. Determination of field moisture
(part.18) equivalent
21. IS: 2720-1977 Method of test for soils.
(part. 40) Determination of free swell index of soils.
22. IS:2720-1977 Method of test for soils. Determination of swelling pressure of
(part.41) soils
23. IS: 8237-1985 Code of practice for protection of slopes for reservoir
embankment
3. Scope:
Excavation of Dam/channel/approach channel/drain/cut off trench/key trench /toe wall/toe
drain/foundations for structures/Cut off wall/chute drains etc., in all soils/disintegrated
rock/Shale/H.R. in both wet and dry conditions and disposal of soil not useful for
construction, on spoil bank and stacking of useful stone, disposal of not useful stone,
conveyance of excavated spoil/soils including swell, conveyance of excavated rock including
voids, with all leads, lifts and delifts and formation of spoil bank/stock piles, including
dewatering, diversion of streams, formation and removal of ramps, diversion roads/approach
roads, shoring/strutting. etc., as directed by the Engineer-in-charge to complete the finished
item of work.
4. Planning:
1. Prior to the commencement of work, all relevant data shall be
collected by the contractor and drawings prepared by him
showing the location of the excavation, spoils, deposition and
filling. On these drawings, full cutting reaches, partial cutting and
partial embankment reaches and full embankment reaches
should be distinctly indicated. The quantity of material to be
placed in fill shall be noted clearly in these reaches. Where the
material to be excavated. consists of different types and if the
various types have to be used separately in the fill or dumped to
spoil bank, the quantities of each class of material in each area
should be shown on drawings.
2. The contractor shall present his planning of the work along with
required details to the Executive Engineer at least 15 days before
starting the work.
5. Setting out Work

1. Bench Marks: Before starting any work, a permanent bench
mark, reference line and check profiles at convenient positions
approved by the Engineer-in-Charge shall be erected. The bench
marks shall be as per type design 6 and 8 of Department. The
works B.M. with R.L. shall be conspicuously carved and
painted on the bench mark. The reference line shall comprise of a
base line properly dag belled on the ground with number of
masonry pillar. The check profiles shall be of such materials and
shall be located at such places as to ensure execution of all slopes,
steps and excavation to the profile or profiles indicated in the
approved drawings or as directed by the Engineer-in-Charge.
2. The Sub-Divisional Officer on behalf of the Engineer-in-Charge
shall himself layout all important levels, all control points with
respect to this bench mark and reference line and correlate all
levels and locations with this bench mark and the reference line.
Important levels shall be checked by the Executive Engineer. All
assistance shall be given for the same by the agency executing the
work.
In the case of spread out works, several bench marks, reference lines and
check profiles may be necessary and shall be constructed as directed by
the Engineer-in-Charge.
5.3 Except the mathematical and surveying instrument which shall be

provided by the department, all materials and labour for setting out
works including construction of bench marks, reference lines, check
profiles and survey required for setting out works as may be required at
the various stages of the construction works, shall be supplied or made
by the agency executing the work.
6 ClearinG, GRUBBING AND PREPARATION OF

WORKS AREA:
(i) All excavation areas and dam embankment are including a 6 m wide
strip measured beyond and contiguous to the limit line of the area as
shown on the drawing shall be cleared and any roots etc. completely
removed as specified. All trees, down timbers, fencing bush, rubbish,
other objectionable materials and vegetation shall be cleared. All
stumps and roots shall be excavated and removed. All roots over 50
mm in diameter shall be removed to a depth of 90 cm below the
original ground surface or as directed by the Engineer-in-Charge.
Materials thus removed will be burnt or completely removed from the
site. All felled timber and fuel shall be properly stacked and handed
over to the department, when asked for by the Engineer-in-Charge.
Piling for burning shall be done in such a manner and in such location
as to cause the least fire risk. All burning shall be thorough so that the
materials are reduced to ashes. Special precautions shall be taken to
prevent fire from spreading to the areas beyond limits of the areas
specified and suitable equipment and supplies for preventing and
suppressing fire shall be available at all time.
(ii) No trees shall be cut from outside of areas designated unless instructed in writing by
the Engineer-in-Charge and all trees designated outside of the areas actually
occupied by the works shall be protected carefully from the damage.
7. STRIPPING, BENCHING AND FURROWING AND

PLOUGHING
1. Benching: Benching should be provided only where the work is to
done on highly undulating stiff ground, steeply sloping ground or on
existing canal embankments. Benching shall consist of excavation of
triangular trenches with a slope of 1 in 12 with average depth of
cutting as 15 cms longitudinally below the embankment seat or in the
form of steps with height of steps not more than 30 cms. The slope of
trenches shall be towards the centre from the outer toes of the
embankment.
7.1.2 Disposal of Materials : In all the items of benching / stripping and preparation of base
on rocky strata, described in para 7.1.1, above, the material from excavation, shall be
deposited in specified areas in a manner as may be directed by the Engineer-in-Charge
and in such a way as not to detract from the finished appearance of the work.
2. All the stripped material shall be deposited beyond the catch drain at the rear
toe of embankment.
8. BENCHING UNDER EMBANKMENT

1. The entire area of embankment including a 3 m wide strip
beyond and contiguous with the area of embankment proper as
shown in the drawing shall be stripped or benched to a sufficient
depth as directed to removed all unsuitable materials. The
unsuitable material to be removed shall include loose rock,
vegetation, top soil, sod, organic silt, swamp material and rubbish
and any other objectionable materials below the ground surface.
2. At locations where a river or stream crosses the embankment site,
loose sand and gravel and loose boulders shall also be removed as
directed.
3. Benched materials shall be disposed off in a manner as may be
directed by the Engineer-in-Charge and in such a way as not to
detract from the finished appearance of the project.
9. EXCAVATION OF CUTOFF OR PUDDLE TRENCH

UNDER DAM EMBANKMENT
1. Procedure for excavation:
2. A cut off trench or puddle trench as shown in the drawings shall
be excavated in the foundation of the dam at the location
indicated. This trench shall excavated to a depth of 0.6 m to 1.2 m
into rock (depending upon the permeability of the rock) or into
other impervious stratum as may be approved by the Engineer-
in-Charge. Accurate trimming of the slopes of the excavation will
not be required but the cutting in general shall follow lines as
specified in drawings. The area to be excavated shall be
unwatered. The water level shall be maintained below the level of
excavation in the area and none of the excavation shall be
performed in standing water.
3. Utilisation of Excavated Materials:
4. Trench excavation shall preferably be started after the whole base
of the dam or atleast the substantial part of its is cleared,
grubbed, benched or stripped as required by specifications so
that suitable material out of trench excavation can be directly
utilized for forming the bank, to maximum possible extent.
5. Blasting of Rock:
6. No blasting of rock would be permitted for the excavation in hard
rock, when the excavation reaches within about 60 cm of final
levels, if the opinion of the Engineer-in-Charge such blasting will
shatter and disturb the rock below foundation. He may also put
similar restrictions in cases where damage is apprehended to
works in neighboring area existing or under construction. In such
cases rock excavation shall be completed by chiseling and
wedging etc.
7. Material Received from Cut off Trench or Puddle Trench:
8. The materials, excavated from the trench shall, if suitable, be
used in the embankment either immediately or after stock piling
as convenient and directed by the Engineer-in-Charge. The
suitability or otherwise of the material and zone of the
embankment in which it is to be placed will be specified by the
Engineer-in-Charge on the basis of laboratory tests.
9. Material excavated from the trench shall not be placed in the
embankment till foundation for the embankment has been
cleared, stripped and prepared as specified and adequate
arrangements made for watering and rolling the layers of earth
fill in the embankment.
10.Materials excavated from the trench shall be subjected to the
same degree of embankment control as materials obtained from
borrow pits.
11. The material excavated from the trench which are not suitable for
use in the embankment shall be disposed off in a manner as may
be directed by the Engineer-in-Charge and in such a way as not
to detract from the finished appearance of the project.
12.Cut off Trench Filling:
13.Cutoff trench shall be back filled with impervious material of the
same specification and in the same manner as for the impervious
hearting zone of the embankment of the dam in accordance with
specifications under para 4.9. But before back filling is started
foundation grouting in accordance with specifications of chapter
22 may be completed, where required, unless the Engineer-in-
Charge directs otherwise.
14.Puddle Filling:
15.Puddle:
16.The puddle shall consist of good retentive clay of best quality free
from organic or other foreign material. It should be clean and
tough and should be available near the site as far as possible. The
most suitable clay is of the description used for tile making. Soft
sludgy, peaty, sandy, salt or puffy clay should be rejected.
17.The clay is to be worked out into puddle before use by turning it
over and over again with pores, watering and treading with mens
feet into one plastic homogeneous mass of the toughest
consistency until it gets plasticity.
18.Laying of Puddle:
19.The puddle shall then be made into balls and thrown into the
trench or in any other position required. No more than 15 cm in
thickness of puddle shall be deposited in the place at one time and
it must at once be thoroughly kneaded by mens feet and
incorporated with mass below it so that the whole will be uniform
and not in layers.
20.The top of puddle shall be kept as level and uniform as possible
and shall on no account be allowed to dry. If the surface cracks at
any time it shall be dug up and puddle remade.
21.Vertical joints across the puddle wall and steps to its side shall be
avoided. All joints shall be made by long inclined faces over
lapping each other.
22.The whole width of puddle trench excavated shall be filled with
puddle only so that the puddle gets thoroughly into the interstices
of trench walls. The joint near the wall shall be thoroughly
kneaded with mens hels.
23.On holidays and other days, when works are stopped, labour
should be specially employed to keep the surface of puddle wet by
sprinkling of water.
24.The puddle filling shall not be done in standing water. Water level
in trench shall be kept below the working level by means of
pumps, if required.
25.As the surface of the puddle layer dries up, it should be
thoroughly consolidated with rammers. Before a new layer of
puddle is laid the surface of the previous layer, if not newly made,
should be lightly sprinkled with water by means of watering pots
and kneaded.
26.When puddle is finished, it should be immediately covered up in
the work or when this is not possible, it should be lightly
sprinkled with water by means of watering pots and kneaded.
27.The surface soil if not confirming to approved hearting soil, is to
be removed on both sides of the puddle trench for a breadth equal
to that of the top of the trench, and for 0.60 m deep, and
consolidated in the same way.
28.This filling is to be carried up with the puddle wall to a height of
0.6 m above ground level and joined with the hearting.
10. RECORDING OF CROSS SECTIONS.

1. Immediately prior to the beginning of the work, cross-sections of
the existing ground level at suitable intervals, normal to the axis
of Dam, and other channels, sluice, waste-weir or other masonry
structures, etc. shall be taken over the base and seating of the
Channels or other structures, etc. for sufficient distance outside
the limits. Levels on these cross-sections shall be taken at suitable
interval not exceeding 5 m or as directed by the Engineer-in-
Charge.
2. These cross-sections shall be taken and plotted in ink on graph
Measurement Book by the construction agency and checked by
consultant agency Departmental Officer Incharge of work shall
check there level as required these cross-sections shall form the
basis of all future measurements.
3. After clearing the area required for Dam excavation and
construction of embankments, cross sections shall be taken at
every 15M interval or closer, depending on the nature of ground,
normal to axis of Dam upto sufficient distance outside the limits
of the work. Levels on cross sections shall be at 5M. Intervals or
closer intervals as directed by the Engineer -in-charge and
entered in level field books and cross sections will be plotted in
graph M.B. The contractor shall write a certificate. Accepted the
measurements recorded on pages from ________________to
______________ and sign at the end of levels in the graph M.B. in
token of acceptance.
4. After Benching and prior to commencement of excavation cross
sectional levels of stripped surface shall be taken at the same
locations at intervals as specified in para (a) above and certified
as mentioned shall be recorded by the contractor.
5. At the earliest, cross sectional profiles shall be prepared by the
contractor duly plotting the pre-levels and the contractors
signature shall be obtained on these cross-section sheets plotted in
graph M.B. The cross sections called initial cross section taken
after striping shall form the basis of all future measurements.
These initial cross sections duly signed by the contractor and
Engineer-in-Charge shall be preserved. All linear dimensions
shall be measured in meters to the nearest 0.01 meter, volumes
worked out in cubic meters corrected to 0.01 cubic meter.
However, in case of rock excavation occurring in bed or sides, the
actual quantity of rock shall be arrived by taking block levels at
2.5M. Intervals all along the entire area of bed and sides.
11. CLASSIFICATIONS OF EXCAVATED

MATERIAL
1. All materials involved in excavation shall be classified into the
following groups.
Soft or Ordinary Soil

Generally any soil which yields to the ordinary application of pick and shovel or to spade,
rake or other digging implement, such as vegetable or organic soil, turf, gravel, sand, silt,
loam, clay peat, etc.
Hard Soil
Includes all materials which can be removed with shovel or spade after lossening with pick
axe such as clay soil mixed with lime kankar, black cotton soil for earthen bund, soft
moorum, etc.
Hard Moorum and Moorum Mixed with Boulders
Generally any material which requires the close application of picks, jumpers or scarifiers to
loosen such as hard and compact moorum and soft shale. Moorum or soil mixed with small
boulders not exceeding 25% in quantity and each less than 0.014 cum (300 mm dia) but more
than 0.004 cum in size.
Note: Boulder is rock fragment usually rounded by weathering, disintegration or exfoliation
or abrasion by water or ice, found lying loose on the surface or embedded in river bed, soil
talus, slope wash and terrace material of dissimilar origin.
Disintegrated Rock
Includes such strata which requires the close application of crow bars, picks, grafting tools,
scarifiers in suitable combination for its excavation such as soft laterite, soft conglomerate,
hard shale, soft copra, hard and compact moorum mixed with small boulders exceeding 25%
in quantity but each not exceeding 0.014 cubic metre in size.
Soft Rock
Soft Rock comprises of the following:-
i. Boulders (not greater than 0.5 cum in volume), hard laterite, hard copra and hard
conglomerate or other rock which may be quarried or split with crowbars, with casual
blasting, if required, for loosening of strata.
ii. Any rock which in dry state may be hard, requiring blasting, but when wet becomes
soft and manageable by means other than blasting.
Hard Rock (Requiring blasting)
Any rock or boulder (More than 0.5 cum in volume) which requires the use of mechanical
plant or blasting for excavation or splitting.
Hard Rock (blasting prohibited)
Hard rock requiring blasting as described as above but where blasting is prohibited for any
reason and excavation has to be carried out by chiseling, wedging or any other agreed
method.
9. Authority for Classification

The classification shall be decided by the Engineer-in-Charge and his decision shall be final.
9. EXCAVATION
1. Where sub soil water is expected the excavation shall be started preferably from the
nearest valley.
2. The contractor shall commence excavation immediately after the surface area of
ground is prepared.
3. The Government reserves the right, during the progress of work to vary the slope of
excavation or the slope of embankment and the dimensions depended thereon.
4. Suitable arrangements for drainage shall be provided to take surface water clear of
excavation during the progress of work. Sump pits if found necessary shall be
excavated at suitable places and the water thus collected shall be bailed out or let into
a near by valley at his cost. When cutting on cross sloping ground, the contractor shall
cut a catch water drain on the higher side to prevent water from flowing down the
cutting slope. No separate payment shall be made for this work unless otherwise
specified.
5. No distinction shall be made as to whether the material being excavated is wet or dry
or in water.
6. All washable materials and any soil, which generally becomes unstable on saturation
such as organic soil, loose soils and expansive soils, shall be removed as directed by
the Engineer-in-charge.
7. All Suitable excavated material within economic lead shall be used for construction of
embankments.
8. Stones of more than 75 mm. in size and indurate materials shall be removed from
material to be used for compacted embankments.
9. In soils the contractor shall not excavate out side the slopes or below the established
grades or loosen any material outside the limits of excavation. Any excess depth
excavated below the specified levels shall be made good at the cost of the contractor
to standards as prescribed by the Engineer-in-charge.
10. The method of drilling and blasting to be resorted to the excavation in rock shall be in
accordance with specification Drilling and Blasting and got approved by the
Engineer-in-Charge.
11. Above the lining, in case of lined canals and above the proposed water level in case of
unlined canals, the rock may be allowed to stand at its safe angle and no finishing is
required other than removal of rock masses which are loose and are liable to fall.
12. Except in areas of rock, all areas to be excavated shall be pre-wetted so that at the
time of excavation moisture content will be at about optimum. However, in case of
the spoils to be deposited on spoil banks such pre-wetting need not be done.
13. During rock excavation, the contractor will not be allowed to dispose of the rubble
Surplus usable rubble shall be allowed to be used in construction of rock-toe, masonry
works and for crushing to use as metal in concrete works etc., crushed sand cost
subject to approval of the Engineer-in-Charge. The Contractor may use the excavated
useful soils, stone, and other construction material free of cost for construction
purpose on this project only and the rates quoted shall include such utilization.
14. The re-gradation for tail channel and approach channel for structures and diversion of
drains or nalla shall conform to the lines, dimensions, grades, side slopes, and levels
and shown on drawings or as directed by the Engineer-in-charge.
15. Where suitable materials in excess of that required to construct adjacent embankments
or in deficit sections by conveyance or back filling of structures or to construct O&M.
Road, Ramps and Bridge approach embankments as determined by the Engineer-in-
charge in one continuous operation, then such material shall be stock piled at places
designated by the Engineer-in-Charge for later use.
16. All gangways, roads and stopping shall be such that they fall within the cross sections
so that the final dressing of slope will consist of digging and no rolling will be
required.
17. During rock excavations, over-hangs or unsafe slopes shall not be permitted.
18. Unless otherwise specified, over excavation in rocks/soils shall not be permitted.
19. Blasting in a manner as to produce over -breakage which in the opinion of Executive
Engineer is excessive shall not be permitted. Special care shall be taken to prevent
over breakages or loosening of material on bottom and side slopes against which
lining is to be placed.
20. Final cutting for 300 mm. in rock shall be carried out by controlled blasting or
trimming or by chiseling wedging, barring with the help of pneumatic paving breakers
and no extra payment will be made.
21. In the case of Fissured rock and hard rock pre-measurements shall be taken. The
contractor shall before commencing the excavation in rock etc., expose the surface.
The pre-measurements shall be taken by taking levels at 2.5M. Intervals both ways
which forms the basis for payment of excavation for rocks. Where the rock is
intermingled with ordinary soils contained pre-measurements of soils shall be taken
and measurement of soils shall be obtained after deducting from the contained
measurements, the quantity of the boulders etc. which will have to be disposed as per
direction of Engineer-in-Charge.
22. In the case of boulders they should be marked by tar-pre measurements recorded.
After removal and disposal as directed by the Executive Engineer or his subordinates
23. In case of reservoir/tank works, the useful materials excavated in the cut of trenches
key trenches approach channels from the sluices, over burden removal on the U/S and
D/S sides of surplus weir, and foundations, excavation for sluices and surplus weir,
excavated shall be used for construction purposes. Any material unsuitable for
construction purposes shall be disposed of as directed by the Engineer-in-charge.
9. SLIDES/SLIPS:
1. If slides occur in cutting during the process of excavation they
shall be removed by the contractor at his cost as directed by the
Engineer -in-charge.
2. If finished slope slide into the canal subsequently such slips in
rock shall be removed.
10. OVER EXCAVATION:

1. In soils any excess depth below the specified levels and any excess
excavation in slopes and widths shall be made good at the cost of
the contractor with suitable soils of similar characteristics and
compacted to a density not less than 95% of proctors density.
2. In the canal section where expansive type of soil such as C.H. type
of soil is encountered and over which cement concrete lining
directly be laid, the canal prism shall be over excavated to the
extents as directed by the Engineer-in-charge and such over
excavated section shall be filled with suitable cohesive non-
swelling (CNS) type soil and shall be placed in uniform horizontal
layers and compacted as directed by the Engineer-in-charge. The
over excavation made in such strata filling by suitable soil
locating and compacting of such soil will not be paid separately.
11. DEWATERING
1. If water is met in the excavation due to sub-soil ground water,
springs, seepage, rain or other causes, it shall be removed by
suitable diversion, pumping or bailing out and the sub-soil water
table shall be kept below the excavation so that the excavation
kept dry whenever so required as directed by the Engineer-in-
charge care shall be taken to discharge the drained water as not
to cause damage to the works, crops or any other property. In
case of lined canals, the subsoil water shall not be allowed to
accumulate in the bottom of the canal. The bed/sides shall be
moisture to receive lining as directed by the Engineer-in-charge.
No separate payment will be made for dewatering.
2. Where water is met with in excavation due to stream flow,
seepage, rain or other reasons, the contractor shall take adequate
measures such as bailing, pumping, construction of diversion
channels, drainage channels, bunds, cofferdams and other
necessary works keep the foundation trenches dry when so
required and to protect the green concrete/ masonry against
damage by erosion or sudden rising of water level. The methods
to be adopted in this regard and other details there of shall be left
to the choice of the contractor but subject to approval of the
Engineer-in-charge.
3. Approval of the Engineer-in-charge shall however shall not
relieve the contractor of the responsibility for the adequacy of
dewatering and protection arrangements and for the quality and
safety of the works.
4. The Contractor shall take all precautions in diverting the
channels and discharging the drained water as not to cause
damage to the works, crops or any other property.
5. Pumping from the interior of a foundation shall be done in such a
manner as to preclude the possibility of the movement of water
through any fresh concrete. No. Pumping shall be permitted
during the placing of concrete or for any period of atleast 24
hours thereafter, unless it is done from a suitable sump separated
from the concrete works by water tight wall or other similar
means.
12. DISPOSAL OF EXCAVATED MATERIAL:

1. No rehandling of excavated material due to injudicious selection of place for
dumping will be paid for.
2. Material removed in excavation including stripped top soil and expansive soils
not required for embankments, bank fill or other required earth work shall be
deposited in waste banks on right of way owned by or controlled by the
department as directed by the Engineer-in-Charge. A gap of 3 M wide shall be
left in spoil banks at 150 m intervals or as directed by Engineer-in-Charge for
disposal of drainage in accordance with clause 8.20 of IS : 4701-1982.
3. Minimum gap of 1 meter or m the depth of excavation as per drawing
(whichever is more) from the edge of the excavation at G.L. in cutting reaches
and 1 m gap from the outer toe of the embankment to the inner toe of the spoil
bank or a greater distance as prescribed by the Engineer-in-Charge shall be
maintained.
4. Where the canal is aligned on sloping ground, excavated material not required
for construction of adjacent embankments at any other place, shall be
deposited on the lower side. Where canal is on level or nearly level ground,
the material from excavation shall be deposited on embankments on both sides
of the canals.
5. In case of deep cutting the spoil shall be so disposed off as not to result in
unsightly heaps as shall be leveled and properly dressed. The top of both the
finished banks shall slope away from the inner edge with a suitable gradient.
6. If there is excess of useful material from the excavation than needed for
construction embankments of canal/reservoir/tank, it shall be used to
strengthen the embankment on either side of the canal/reservoir/tank,
deposited in low areas uphill of the canal to eliminate trap drainage, or it
should be deposited in stock piles as directed by the Engineer-in-Charge. The
disposal of excavated material shall be in accordance with clauses 8.1 of IS
4701-1982.
7. The useful rock obtained from the cutting shall not be mixed with other soils
and shall be closely stacked to the gauge separately beyond spoil bank and all
other stone not useful for construction purpose shall be deposited on the slopes
of the canal spoil bank, if the rock and soil are mixed up while depositing at
the spoil banks, suitable deduction from the agreement rate as decided by the
Engineer-in-Charge will made which is binding on the contractor.
8. Except as specially provided in these specifications for payment for conveying
or placing of individual items of excavated materials.
9. The contractor has no claim over any of the materials got out of excavation of
the canal cutting and foundation excavation.
10. The responsibility for arranging the land required for disposal of excavated
material rest with contractor, if the contractor desires the material at near by
places other than the places shown by the Engineer-in-charge, to reduce the
lead and there by the cost of conveyance.
9. EXCAVATION FOR Appearent works:

1. Description of work:
a) Excavation and depositing the soil on spoil bank or at any place specified by the
Engineer-in-charge with all leads lifts for structures shall consist of the removal of
material for the construction of foundations for the structures like Bridges, U.Ts.
Aqueducts, super-passages, retaining walls, canal side walls, in lets, out lets, head walls,
cutoff walls, pipe under-tunnels, cross regulators, off-take sluices and other similar
structures, in accordance with the requirements of these specifications and the lines
elevations and dimensions shown on the drawings or as indicated by the Engineer-in-
charge.
b) The work shall include providing all the materials, tools and plants and labour required for
presplitting and utilising controlled blasting technique over and above the normal
blasting technique in hard rock and quartzite excavation, construction of the necessary
coffer dams and cribs and their subsequent removal and necessary sheeting, shorting,
strutting, benching, draining and pumping the foundations, trimming bottom of
excavations, all leads and all lifts of excavated material back filling with selected
approved material and clearing up the site and the disposal of all surplus materials, spoil
and the stone not useful for construction purpose shall be deposited beyond the profile
of the structure, canal, stream etc., leaving a minimum gap of 5 meters. and in
accordance with clause 8.1of IS 4701-1982 or at greater distance as directed by the
Engineer-in-charge. The useful stone stacking and soils required for back filling shall be
placed at the contractors convenience without forgoing the working space. No
rehandling of materials will be paid and at the same time recovery will be made if the
obstructions are not removed after completion of the work from the final bill at the rate
calculated by the Engineer-in-charge to do the same work with other agency. In so far as
practicable, the material removed in excavation for structures shall be used for back
filling and embankments.
9. CLASSIFICATION OF EXCAVATION:
1. All materials involved in excavation shall be classified in
accordance with Clause no.11
10. CONSTRUCTION OPERATIONS:

(a) Setting-out
After the site has been cleared to the limits of excavation the work shall be set out true
to lines, curves, and slopes as shown on plans.
ii) Excavation:
(a) Excavation shall be taken to the width of the lowest step of the footing and
the sides shall be left to plumb where the nature of soil allows it.
Where the nature of soil or the depth of the trench does not permit
vertical sides, the contractor at his own expense shall put up necessary
shoring, strutting and planking or cut slopes to a safer angle or both
with due regard to the safety of personnel and works and to the
satisfaction of the Engineer-in-charge.
(b) The depth to which the excavation is to be carried out shall be as shown on
the drawings, unless the type of material encountered is such as to
require changes in which case the depth shall be as ordered by the
Engineer-in-charge and will be paid for.
(c) Excavation in rock shall be carried out by crow bars, pickaxes, chisels of
pneumatic drills etc. unless permitted by Engineer-in-charge blasting
shall not be resorted to.
(d) Where blasting is to be resorted to the same shall be carried out to the
requirements of specification 3.3and all precautions there in observed.
(e) No distinction shall be made as to whether the material being excavated is
dry or moist or in water.
The method of drilling and blasting to be adopted for hard rock including F&F rock
excavation shall be approved by the Engineer-in-charge. Blasting in a manner as to
produce over breakage which in the opinion of Engineer-in-charge is excessive shall
not be done. In order to minimise over breakage and loosening of material at the
finished surface on bottom and side slopes over which foundation concrete is to be
laid, final cutting for the last 300mm. in hard rock shall be carried out by controlled
blasting or chiseling or trimming with the help of pneumatic paying breakers. If
excavation is required to be done within 30m. From the existing structures the same
should be carried out by chiseling without resorting to blasting for which no extra
rate is payable.
1. PREPARATION OF FOUNDATION:
2. The contractor shall prepare firm foundation for the structure as
shown in the drawings. The bottom and side slopes of foundation
upon or against which the structure is to be placed shall be
finished to the prescribed levels and dimensions shown on plans.
3. The bottom of the foundation shall be leveled both longitudinally
and transversely or stepped as directed by Engineer-in-charge.
Before foundation concrete is laid, the surface shall be slightly
watered and rammed. In the event of excavation having been
made deeper than that shown on the drawings the extra depth
shall be made up with concrete or masonry of the foundation
grade at the cost of the contractor as directed by the Engineer-in-
charge. Ordinarily earth filling shall not be used for the purpose
to bring the foundation level. If hard strata is not met at
foundation level shown in the drawings extra depth as directed by
Engineer-in-charge shall be excavated to remove unsuitable
material. The extra excavation or extra depth made up with
masonry or concrete will not be paid.
4. When rock or other hard strata is encountered, it shall be free
from all soft and loose material, cleaned and cut to a firm surface
either level, stepped, or serrated/notched, as directed by the
Engineer-in-charge. All seams shall be cleaned out and filled with
cement mortar or grout to the satisfaction of the Engineer-in-
charge.
5. If it is considered necessary by the Engineer-in-charge, to
consolidate the foundation strata by grouting cement slurry, the
drilling and grouting or any other foundation treatment as
directed by the Engineer-in-charge shall be done by the
contractor
10. PUBLIC SAFETY:

1. Nearest, towns, villages and all required places, trenches and
foundation pits shall be securely fenced, provided with proper
caution signs and marked with red lights at night to avoid
accidents. The contractor shall take adequate protective measures
to see that the excavation operations do not effect or damage
adjoining structures or property.
11. DAM EMBANKMENT CONSTRUCTION

1. SCOPE:
Certain instruments for measuring the performance of the dam during construction and
afterwards are proposed to be installed by the department at locations as specified in
the drawing or as decided by the Engineer-in-Charge. Necessary facilities for the
installation and observation of these instruments shall be extended by the agency
executing the work. For installation and observation of instruments and for necessary
soil tests near the installed instruments, necessary time shall be allowed within
placement schedule.
The embankment shall be constructed (exclusive of pitching and backing of chips or filter
below pitching) generally to the lines and grades shown on the drawings, but
increased by such heights and widths determined as necessary to allow for settlement
or shrinkage as specified in para 4.9.9. Also in order that proper compaction can be
done upto the edges of the designed section duly increased for settlement and
shrinkage as stipulated above, section will be further widened by 45 cm. Subsequently
after compaction it will be dressed by trimming the slopes to proper section so that the
surface on the slopes is also as firm and compact as the top of embankment. The earth
thus trimmed could however, be used in the embankment fill. Any material that is lost
by rains, weathering or other cause shall be replaced.
The dam embankment is divided into zones within which fill materials having different
characteristic, are to be placed Placement of till within these zones as shown in the
drawings shall be performed in an orderly sequence and in efficient and workman like
manner, so as to produce within each zone, fills having such qualities of density,
strength and permeability as will ensure the highest practicable degree of stability and
performance of the whole dam embankment.
No bushes, roots, sods, or other perishable or unsuitable materials shall be placed in the
embankment. The suitability of each part of the foundation for placing embankment
materials thereon and of all materials for use in embankment construction will be
determined by the field laboratory.
The difference in elevations between core and shell zones of the dam embankment at any
cross-section above the embankment foundation shall not exceed 0.6 m unless
specifically authorised by the Engineer-in-Charge. The embankment for each zone
shall be maintained in continuous and approximately horizontal layers in the reaches
programmed for construction in that season. Where, however, due to some constraints
the dam has to be constructed in discontinuous portions or reaches, the slopes of the
bonding surface parallel to dam axis between the previously completed portions of the
dam embankment and the materials to be placed in each zone shell not be steeper than
3 to 1 in core, and 2 and 1/2 to I in other zones.
22.2 Preparation of Foundation
Foundation preparation shall be done subsequent to stripping and excavation, if any. All
portions of excavation made for test pits or other sub-surface investigations and all
other existing cavities found within the area to be covered by earthfill or of core and
shell zones, which extend below the established lines of excavation for embankment
foundation, shall be filled with earth fill of the corresponding zone of the
embankments. All test pits within a distance of 10 times the dam embankment from
the upstream toe shall be filled by impervious material. No material shall be placed in
any section of the earthfill portion of the dam embankment until the foundation for
that section is suitably prepared and has been approved by the Engineer- in-Charge.
The surface of each portion of the foundation immediately prior to receiving any material for
the earth fill shall be moist and sufficiently cleaned to obtain a suitable bond with the
embankment.
Pools of standing water will not be permitted in the foundation of the embankment and shall
be drained out prior to placing the first layer of the embankment.
(a) Rock Foundation - The treatment of the rock surface under the dam shall be so done as
to ensure a tight bond between the impervious core and foundation, for which the
following procedure shall be followed:-
(1) Before the grout curtain is installed, the area of the rock surface which is to be in
contact with the impervious core of the dam shall be exposed with rough
excavation. Hard rock projections and over-hangs shall be removed. If blasting
is to be resorted to, care shall be taken to avoid objectionable shocks to
foundation rocks and abutments. As far as possible, the whole contact area of
foundation rock and abutments after rough excavation shall be exposed at one
time to enable examination of rock surface characteristics and planning the
method of treatment. Curtain grouting where required shall be carried out in
accordance with provision under relevant para of specification, of chapter 22
"Drilling and Grouting".
(2) Cleaning and Shovelling. - After the grouting operations are over, the rock
surface shall be thoroughly cleaned. Pockets of sand and gravel and other soils
shall be removed by hand shovelling and soft erodible seams and localised
decomposition cleared out as deep as possible. Loose rock shall be removed
by wedging and hand packing. Layers of grout spilled from grouting operation
shall be chipped out and removed. Finally, the hand cleaned surface shall be
thoroughly washed with powerful water jets to remove the fines which would
have worked into the seams of the rock and obtain a clean surface.
Compressed air jets shall be used as a final step in the clean up operation.
(3) Sealing cracks. -Deep pot holes or pockets shall be filled with hand compacted
soil or concrete. If the rock surface in the bottom and sides of pot holes is
cracked, the crack should be sealed with cement grout. If the rock surface
contains too many closely spaced pot holes, the entire rock surface shall be
covered with concrete. A clay paste may be used in the smaller cracks. All the
cracks and joints and shear seams or other incompetent materials that are
exposed in the cut off trench shall be scooped out to the greatest depth
practicable (not less than twice their width at the surface)with the aid of
trowels, bars and cleaned with air water jets and then filled with slush grout.
Slush grout shall consist of cement and sand thoroughly mixed in a proportion
1 part of cement to 2 parts of sand by volume with sufficient water to produce
a highly plastic and buttery mix.
Foundation rock which is fairly impervious but has a very rugged surface shall be
treated by laying core material at a moisture content slightly above the
optimum in thin layers and compacted with mechanical equipment/small
tampers to ensure that all irregular depressions in the rock surface have been
filled with soil to create an effective/complete bond.
The moisture content and layer thickness shall be specified by the field laboratory.
Any open crack in the rock surface shall be specified by the field laboratory.
Any open crack in the rock surface shall be sealed with cement grout by
appropriate means. Fault zones or larger cracks shall be dug out to a depth as
determined by the Executive Engineer and backfilled with concrete.
(b) Soil Foundation- Soil foundations shall be scarified and loosened by means of a
plough, ripper or other methods to a depth of about 15 cms to 20 cms to the
satisfaction of the Executive Engineer. Roots or other debris turned up during
scarifying shall be removed from the entire foundation area for the fill It shall
then be moistened to slightly above the optimum moisture and compacted by
required number of passes of the compaction equipment to the same
percentage of compaction as the core. The purpose of higher than optimum-
moisture is to ensure forcing of the soil into any unseen soft zones just below
the surface. The first few lifts of fill for the embankment shall be carefully
placed, for the surface will still be rather irregular. If possible, heavy rubber
tyred rollers should be used for compaction because they will follow the
irregular surface and not bridge over small low areas as other types of rolling
equipment will do. Layers 10 cms to 15 cms thick with moisture content 1 to 2
per cent above optimum moisture content must be used to ensure uniform
compaction and a satisfactory intimate bond between the foundation soil and
the fill materials especially under the central core. The layers shall be
composed of the most impervious materials, under the central core zone.
(c) Sand Foundation - The foundation sand shall be tested for its natural relative
density. In reaches where the relative density is less than 70% the foundation
sand shall be dnsified by any of the approved methods to obtain a minimum
relative density of 7058. Until the foundation has been tested and the relative
density found to exceed 70$, earth fill shalll not be allowed to be placed. This
is necessary to minimise the effects of any structural re-adjustments in a loose
foundation.
22.3 Earth Fill Materials
The materials for the respective zones of embankment shall be obtained from borrow areas
designated by the field laboratory, which also will specify the depth of cut in the
borrow areas required for obtaining the desired gradation in the materials. In general,
all material from a particular borrow area shall be a mixture of materials obtained for
the full depth of cut. Where in a borrow area the sub-stratum occurs in well defined
layers differing considerably in mechanical analysis, so that mixture is not suitable for
any particular zone, the materials shall be excavated layer wise by scrappers or other
suitable means and the materials placed, in the zone for which it satisfies the
requirements. Where it is not practicable to obtain a mixture of materials, the finest
and most clayey material shall be placed in the cut-off trench and the central upstream
portion of the embankment. The intermediate material shall be placed between the
centre and the slopes of embankment and the coarsest material shall be placed near
the outer slopes of the embankment. No material containing a high percentage of
plastic clay shall be used in the embankment without being mixed with coarser
material.
Chemical and physical tests of soils in embankment shall be carried out to ensure that the soil
does not contain (a) soluble lime contents (b) soluble salt contents or cohesionless
fines, in quantities harmful to the embankments.
22.4 Placing Earthfill
The distribution and gradation of the materials throughout the earthfill shall be as shown on
the drawings or as directed. The fills shall be free from lenses, pockets, streaks or
layers of materials differing substantially in texture or gradation from the surrounding
materials. The combined excavation and placing operations shall be such that the
materials when compacted in the earthfill will be blended sufficiently to produce the
best practicable degree of compaction and stability. Successive loads of materials
shall be dumped on the earthfill so as to produce the best practicable distribution of
the material. The various zones shall be clearly delineated on the embankment and the
materials from the borrow areas placed accordingly.
The clay blanket shall be laid in a manner similar to clay core and compacted to same degree
of compaction at optimum moisture content.
Particular care shall be taken to ensure that materials are not so placed as will be conducive to
the formation of intermittent relatively impervious blankets in the shell zones, which
will interfere with the satisfactory drainage.
No stone, cobbles or rock fragments having maximum dimensions of more than 10 cms shall
be placed in the-earth fill (casing only). Such stones and cobbles shall be removed
either at the borrow pit or after being transported to the embankment but before the
materials in the earthfill are rolled and compacted. Such stone and cobbles shall be
used in the rip-rap or rock toe of the dam embankment, If suitable or wasted as
directed. The materials shall be placed in the earthfill in continuous horizontal layers
not more than 15 cm in thickness after being rolled as herein specified Higher
thickness of layers may also be permitted, if suitable compaction units such as
vibratory compactors are used to give required density under optimum moisture
content, but in no case the compacted thickness of the layer shall exceed 25 cm. The
extent of layers shall be determined in the field by test section. During construction, a
small transverse slope from centre towards edges should be given to avoid pools of
water forming due to rains. If in the opinion of the Executive Engineer the surface of
prepared foundation or the rolled surface of any layer of earthfill is too dry or smooth
to bond properly with the layer of materials to be placed thereon, it shall be moistened
or worked with harrow, scarifier or other suitable equipment, in an approved manner
to a sufficient depth to provide a satisfactory bonding surface before the next
succeeding layer of earthfill material is placed. If the rolled surface of any earthfill is
found to be too wet for proper compaction of the layer of earthfill material to be
placed thereon, it shall be raked up and allowed to dry, or be worked with harrow,
scarifier or any other suitable equipment to reduce the moisture content to the
required amount, and then it shall be compacted before the next succeeding layer of
earthfill material is placedJhe concrete or masonry surfaces against which earthwork
is to be placed shall be cleared and moistened prior to placing of the earthfill. Clay
leaping of plastic consistency be adopted to ensure proper bond between the earthfill
and the concrete/masonry. The foundation adjacent to the concrete structures shall be
thoroughly cleared of loose materials and moistened. In placing the earthfill on rock
foundation, the foundation shall first be prepared as detailed earlier. Care shall be
taken in placing the first layer of the fill that no damage is caused by the hauling
machinery which will get concealed by the spread layer of the fill. The soil for the
first layer shall be at a moisture content sufficient to enable satisfactory bonding of
the fill with the rock surface.
In case the whole length of embankment is not constructed simultaneously and only a portion
of embankment is constructed during one season the following procedure shall be
adopted.
The incomplete ends of embankment shall be placed at a slope not steeper than 4:1 to permit
satisfactory bonding with the portion of the embankment which is constructed later.
Old surface should be stripped or benched in accordance with the direction of the
Engineer- in-Charge.
9. General Requirements
1. The Cross sections for embankment are to be designed to suit the
characteristics of the best quality soils available in the vicinity of
the proposed work. If the contractor proposes to use any other
type of soils than those mentioned in the design to save the lead
and thereby the cost, the contractor has to form the embankment
to the revised profiles worked out by the competent authority.
The extra quantity involved will not be measured and paid. The
theoretical quantity required based on the original cross-sections
will only be measured and paid. But the Contractor has to form
the bund to the revised cross section designed with the
characteristics of the proposed soils. The designs given by the
estimate sanctioning authority are final.
2. Embankment shall be built to the height, top width and side
slopes as shown on the drawings. All the edges of the
embankment shall be neatly aligned symmetrical to the central
line. They shall be absolutely straight in all reaches except at
bends. At bends they shall be smoothly curved.
3. The top of each embankment shall be leveled and finished so as to
be suitable for road way and given a cross slope to drain away
rain water. The bank carrying road shall be given a suitable cross
slope.
10. Material
1. The suitability of foundation of placing embankment materials
thereon and all materials proposed for use in construction of
embankment shall be determined by the Contractor well in
advance on the basis of Laboratory Test results. Chemical and
Physical tests of the material proposed for construction of
embankment shall be carried out to ensure that the soil does not
contain soluble lime content, soluble lime salt content or cohesion
less fines, in quantities harmful to the embankments.
2. Material for construction of embankment should be free from the
organic material. Unless otherwise directed by the
Superintending Engineer/ Executive Engineer all materials shall
be deposited in embankments so that cobbles, gravel and
boulders are well distributed through other material and not
nested in any portion within or under are embankment as per
clause 6.4 of I.S. 4701-1982.
3. Suitable excavated material available from the cut off trenches,
canal cutting, extra cutting for seating to lining, foundation
excavation for structures, approach and tail channels for
structures, nalla diversions, removal of ramps etc, shall be used
for construction of adjacent embankments.
4. After completing the construction of embankments with the
materials as indicated in 37.3 above, material required for the
construction of balance embankment shall be obtained from the
borrow areas.
5. The soils and morum excavated and useful for construction of the
embankment shall be classified by the Engineer-in-Charge as
impervious and Semi-Pervious based on Laboratory Test results.
They shall be utilized on the embankment work.
11. Preparation of ground surface for embankment:

1. Clearing site : Clause 6 shall apply.
2. Stripping : Clause 7 shall apply.
3. All portions of excavation made for test pits or other subsurface
investigations, all holes, hollows and all other existing cavities
found within the area to be covered and to the extent below the
established lines of excavation for embankment seat shall be filled
in earth of the corresponding zone of the embankment and
suitably compacted. The pits of surface boulders shall be filled
with suitable material and compacted at no extra cost.
4. Pools of water shall not be permitted in the foundation for
embankment and such water shall be drained and cleared prior
to placing the first layer of embankment materials.
5. On sloping ground or in case of existing banks, where
embankment portions are to be modified, benching of slopes shall
be done with a little slope towards the inside of beaching so as to
give a good grip to the embankment soil with the sub-grade.
Unless otherwise specified the benches shall be 0.3.X.0.6.m. on the
front and rear slope of the embankment. Before benching, the
bank slopes shall be cleared of all roots and vegetables matter as
per specification 2.0. No separate payment will be made for either
benching or refilling. The rate quoted for raising embankment is
inclusive of above operations. The bank section shall be brought
to design standards by filling the scours with suitable material
and compacting to 98% proctor density by suitable measure of
compaction.
6. Soil foundation:
7. The ground surface under embankment and area of bed filling
wherever necessary ( except rock surfaces ) shall be loosened or
scarified making open furrows by means of a plough, or ripper or
any other methods to a depth of not less than 200 mm. deep below
the stripped surface at intervals of not more than 1m. to the
satisfaction of the Engineer-in-charge. Roots or other debris
turned up during scarifying, shall be removed from the entire
foundation area for the fill. The areas under the embankments
shall be prevent by sprinkler before the construction of
embankment begins. The moisture content shall be optimum.
8. Rock foundation:
The treatment of the rock surface under the embankment shall be done so as to ensure tight
bond between embankment and the foundation. This shall be done by the following
procedure.
i) The area of the rock surface which is to be in contact with the embankment shall be fully
exposed by removing all the loose and disintegrated rock having the surface of
rock rugged. Hard rock projects and overhangs shall be removed. If blasting is
to be resorted to, care shall be taken to avoid objectionable shocks to
foundation rock. As far as possible the whole contact area shall be exposed at
one time to enable examination of rock surface characteristics and planning
the method of treatment.
ii) Exposed rock shall be benched.
9. Compaction & WATERING:

1. Compaction Equipments : While the specification below provide
that equipment of a particular type & size is to be furnished and
used, it is contended that the improved compaction equipment as
may be most suited to the prevailing site conditions and the
programme of construction shall be used. The broad details of the
equipments are given below:-
2. Tamping roller/vibratory compactors shall be used for
compacting the earth fill. The sheep foot rollers shall meet the
following requirements:-
(i)Roller Drums :- Each drum of a roller shall have an outside diameter of not
less than 150 cm and shall be not less than 120 cm not more than
180 cm in length. The space between two adjacent drums, when
on a level surface shall not be less than 30 cm nor more than 38
cm. Each drum shall be free to pivot about an axis parallel to the
direction of travel. Each drum shall be equipped with a suitable
pressure relief valve to prevent excessive pressures from
developing in the interior of the roller drum.
(ii) Tamping Feet :- At least one tamping foot shall be provided for each 645
sq. cm of drum surface. The space measured on the surface of the
drum between the centres of two adjacent tamping feet shall not
be less than 230 mm. The cross sectional area of each tamping
foot shall be not more than 65 sq. cm at a plane normal to the axis
of the shank 150 mm from the drum surface and shall be
maintained at not less than 45 sq. cm nor more than 65 sq. cm at
a plane normal to the axis of the shank 200 mm from the drum
surface.
iii. Roller Weight :- The weight of the roller when fully loaded shall not be
less than 7091 Kg and the ground pressure when fully loaded shall not
be less than 40 Kg/cm 2 required to obtain the desired compaction.
Tractor used for pulling rollers shall be of 50 H.P. to 65 H.P. power to
pull the rollers satisfactorily at a speed of 4 Kms/per hour when the
drums are fully loaded with wet sand ballast. During operation of
rolling, the spaces between the tamping foot shall be kept clear of
materials sticking to the drum which could impair the effectiveness of
the tamping rollers.
3. Rolling :-
i. When each layer of material has been conditioned so as to have the proper
moisture content uniformly distributed through the material, it shall be
compacted by passing the tamping roller. The exact number of passes shall be
designated by the field laboratory after necessary test. The layers shall be
compacted in strips over lapping to less than 0.6 m. The rollers or loaded
vehicle shall travel in a direction parallel to the axis of the dam. Turns shall be
made carefully to ensure uniform compaction. Rollers shall always be pulled.
ii. If the foundation surface is too irregular to allow the use of large roller directly
against any structure or rock out corp, the roller shall be used to compact the
soil as close to the structure or rock out-crop as possible and the portion of the
embankment directly against the rock or the structure shall be compacted with
pneumatic hand tempers in thin layers. Sheep foot roller shall not be employed
for compaction till the thickness of the layers compacted by other mean is
greater by 30 cm than the depth of the foot of the roller drum.
4. Tamping :- Rollers will not be permitted to operate within 1.00
metre of concrete and masonry structures. In location where
compaction of the earth fill material by means of roller is
impracticable or undesirable, the earth fill shall be specially
compacted as specified herein at the following locations:-
1. Portions of the earth fill in dam embankment adjacent to masonry structures
and embankment foundations designated on the drawing as specially
compacted earth fill.
2. Earth fill in dam embankment adjacent to steep abutment and location of
instruments.
3. Earth fill at locations specially designated.
Earth fill shall be spread in layers of not more than 10 cm in thickness

when loose and shall be moistened to have the required moisture
content as specified. When each layer of material has been conditioned
to have the required moisture content, it shall be compacted to the
specified density by special rollers, mechanical tampers or by other
approved methods; and all equipment and methods used shall be
subject to approval based on evidence of actual performance and field
compaction tests. The moisture control and compaction shall be
equivalent to that obtained in the earth fill actually placed in the dam
embankment in accordance with the specifications..
5. Cohesive Materials:
a) When each layer of material has been prepared so as to have the proper moisture content
uniformly distributed throughout the material, it shall be compacted by
passing the roller. The layer shall be compacted in strips over lapping not less
than 0.30 Meter. Rolling shall commence at edges and progress towards center
longitudinally. The roller shall travel in a direction parallel to the axis of the
bank. Turns shall be made carefully to ensure uniform compaction. Density
tests shall be made after rolling and dry density attained shall be not less than
98% of the maximum dry density (standard proctor) as obtained in the
laboratory for the type of material used. The density achieved shall not
normally be less than the designed density. The dry density of soil in field
shall be determined in accordance with I.S. 2720 (Part-XXVII)-1974 or I.S.
2720(Part. XXIX)-1975.
b) Standard proctor density test shall be carried out at regular intervals to account for
variations in the borrow area materials as well as that in situ excavated
material. Not less than three tests shall be carried out to indicate variations in
the standard proctor density attained in laboratory.
c) Engineer-might review the design if necessary on examination of density test results and
the contractor shall have no claim arising out of such a review and consequent
change, If any, in the design.
d) i) In case embankment covers the barrels of cross drainage or any other structures, first
45cm. of the embankment shall not be compacted with roller but it
shall be compacted with pneumatic/hand tampers in thin layers. The
compaction above this layer of total 45cm shall be done by using
suitable light rollers to avoid damage to the structure, by adjusting the
thickness of layers until sufficient height is achieved to permit
compaction by heavy rollers. Density test shall be conducted form time
to time on site to as certain whether the compaction is attained as
specified above.
ii) Separate tests shall be conducted for each zone of the embankment for every 1500 cubic
meters of compacted earth work, at least one field density test shall be
taken in each layer. Minimum two density tests shall be taken in each
layer per day irrespective of the quantity of earth work specified above.
In case the test shows that the specified densities are not attained,
suitable measure shall be taken by the contractor either by moisture
correction or by entire removal and relaying of layer or by additional
rolling so as to obtain the specified density which shall be checked
again by taking fresh tests at the same locations. Necessary unskilled
labour required for carrying out such density tests shall be provided by
the contractor.
e) Compaction shall be achieved by the use of smooth rollers pneumatic type rollers, sheep
foot rollers, mechanical compactors like vibratory rollers, vibrating plates,
programmers, power rammers, slope compacting equipment, pneumatic
tamping equipment and such other equipment as shall be specified by the
Engineer based on type of material and actual field tests.
f) The dimensions and weight of the rollers should be such as to exert a ground pressure of
not less than 12 kg/cm2 of tamping when it is empty and 25kgs/. Cm2 When
ballasted. The number of passes required for each layer to obtain the specified
density shall be determined by actual field tests.
1. Cohesionless Materials:
1. Where compaction of cohesionless free-draining material such as sand and gravel is

required, the materials shall be deposited in horizontal layers and compacted to the
relative density specified. The excavating and placing operations shall be such that the
material, when compacted, shall be blended sufficiently to secure the highest
practicable degree of compaction and stability. Water shall be added to the materials,
if required to obtain the specified density depending on the method of compaction
being used.
2. As per clause 6.6.2.1 of I.S. 4701-1982, the thickness of embankment layer shall not
exceed 25cm. (Loose) before compaction and it should be spread over the full width
of embankment and compaction shall be done by rollers or tampers to obtain specified
density. The thickness of the horizontal layers after compaction shall not be more than
10cm.. If compaction is performed by tampers, not more than 15cm. if by 8 to 10
tonnes rollers and not more than 30cm.. If compaction is performed by vibratory or
pneumatic rollers or similar equipment. The relative density of the compacted
materials shall not be less than 70 percent as determined by laboratory tests as per I.S
2720 Part -XIV. if compaction is performed by internal vibrators, the thickness of
layers shall not be more than the penetrating depth of the vibrator.
7. Embankment without controlled compaction

1. No materials shall be placed in any section of the earth fill portion
of the embankment until the embankment seat for that section has
been approved by Executive Engineer.
2. The excavating and hauling equipments shall travel over the
embankment to evenly distribute the material and compacting
effort over the whole surface.
8. Embankments with controlled compaction

1. Bushes, roots, sods or other perishable or unsuitable material shall
not be placed in the embankment.
2. Unless otherwise specified, embankment materials shall be spread
in successive horizontal layers generally not exceeding 25cm, in
thickness (loose layer) in the zones where these are required to be
laid, extending to the full width of the embankment including
slopes at the level of the particular layer. Each layer shall be
commenced from the edge farthest from excavation. In no case
shall embankments be widened by material dumped from the top.
Top of each layer shall be kept slightly depressed in the centre.
3. Extra width of 600 mm. in thickness as measured perpendicular to
the slope shall be provided on either side so that when compacted,
lines of the finished embankment slopes shall have not less than
specified density. Later the extra width shall be neatly trimmed
and the trimmed material shall be permitted or re-use in
embankment at higher elevations. No payment shall be made for
providing removal of the extra section. Removal of extra section in
the embankment shall be deemed to have been included in the item
of compaction.
4. Thickness of layers shall be adjusted with particular type of
compactors used to give the required density by carrying out trial
compaction and requisite tests and required number of passes
should also be determined as directed by the Engineer.
5. No fresh layer shall be laid until the previous layer is properly
watered and compacted as per requirement. The work of
spreading and compaction shall be so adjusted as not to interfere
with each other and in such a way that neither of the operations is
held up because of non-completion of the rolling and watering. The
surface of the banking shall at all times of construction be
maintained true to required cross section. If the surface of any
compacted layer of earth fill is too dry or too smooth it shall be
moistened and scarified to provide a satisfactory bonding surface
before the succeeding layer is placed. All the rollers used on any
one layer of fill shall be of the same type and same weight.
6. The contractor shall ensure that only approved soils are used for
construction of embankment.
7. For proper bond of the embankment done in the previous season
with the new embankment, the work shall be carried out as
detailed below.
i) In case of the old bank to extended horizontally. It shall be cut to a slope not
steeper than 1 in 4 and the surface so prepared shall be scarified and made
loose at least for a depth of 15cm. Necessary watering shall be done and the
earth surface shall be thus prepared to receive the new embankments. The
soils shall be laid in layers and compacted to the required degree of
compaction to have a proper bond with the old one.
ii) If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, watering and placing of the new earth layer as specified above.
iii) The surface which are damaged due to rain shall be made good by filling with
proper soil duly compacted by tampers. A cross slope away from the centre of
canal of about 1in 80 shall be maintained throughout the rainy season to
ensure. proper drainage in the event of occasional rainfall. No extra or
separate payment shall be made for these items of work.
1. Settlement allowance:
i. The canal embankments shall be constructed to a higher elevation than that shown on
drawings at the rate of 2.5cm. per every one meter height of bank if power driven
equipment is used and 25cm/lmt height if other than power driven equipment is used
for compaction towards Shrinkage /Settlement.
ii. No extra or separate payment shall be made for this work as this shall be deemed to
have been included in the respective item of construction and consolidation of
embankment.
iii. Care shall be exercised that all large clods are broken and no clod bigger than say
8cm. rock, are buried in the banks.
9. Homogenous Section:
The homogeneous section for canal embankments shall be provided as specified in the
drawings. The available coarser and more pervious materials shall be placed nearby outer
slopes in order to have increasing permeability from inner to outer side. The compaction shall
be carried out as per clause 6.6.2 of I.S. 4701-1982.
10.Zonal Embankments:
In Zonal sections the selected and approved soils shall be spread to the required widths of
respective zones. All the zones shall be tackled simultaneously and the difference in level
between zone to zone shall not be more than 150mm.
9. Moisture CONTROL:
The water content of the earthfill material prior to and during compaction
shall be distributed uniformly throughout each layer of materials between
2 to + 1 of the optimum moisture content for casing material and between
0 to + 2 for hearting material. Moisture determination of soils as well as
needle moisture determination of soil shall be carried out as per IS : 2720
(Pt. II) 1973, sec 1 and designation E22 of USBR / Earth Manual 1968
respectively.
Laboratory investigations may impose some restrictions on the lower limits of the practicable
moisture contents on the basis of studies on consolidation characteristics of soils in
embankment. Hereinafter the term range of optimum practicable moisture content shall
refer to the value as described above. As far as practicable, the material shall be placed
at proper moisture content. If additional moisture is required, it shall be added by
sprinkling water before rolling of a layer. If the moisture is greater than required, the
material shall be spread and allowed to dry before starting rolling. Moisture control
shall be strictly adhered to. The moisture content shall be relatively uniform throughout
the layer of material. If necessary, ploughing, disking, harrowing or blending with other
materials may have to be resorted to, to obtain uniform moisture distribution. If the
moisture content is more or less than the range of optimum practicable moisture
content, or if it is not uniformly distributed throughout the layer, rolling and adding of
further layer shall be stopped. Further work shall be started again only when the above
conditions are satisfied.
The Moisture content of the earthfill placed against any rock outcrop or any structure shall be
slightly above the optimum, to allow it to be compacted into all irregularities of the rock
and this shall be determined by the field tests.
9. Special Precautions:
1. During the actual construction of any earth work, maximum use
should be made of construction plant and routing of the plant
should be carefully controlled to obtain uniform compaction over
as wide an areas as possible. Care should also be taken during the
compaction operation to shape the surface of the works to
facilitate the shedding and to minimize the absorption of rain
water, particular attention being given to the prevention of
pending of water. The contractor shall do this at the end of each
days work.
2. The earth moving machinery shall not be allowed to pass over a
compacted portion of the embankment beyond certain limits by
varying the hauling routes and ramps, thus ensuing that over
compaction does not take place in any particular reach.
3. During the Construction, a small transverse slope from centre
towards the edges shall be given and further in the reach when
bank is being raised, the works shall be tackled in continuous
horizontal layers to avoid pools of water and concentration of
allow of water during rains, which will cause damages, scours and
rain gullies.
4. Special precautions shall also be taken while rolling the spread
soil near structures, conduit, sluice barrels, filters, rock toes at the
junctions of bank connections with the structures, using hand or
power tampers. It is essential that the compaction of filling should
be carried out in such a manner as to avoid an unbalanced thrust
on walls etc., which might displace or damage it. The equipment
shall be provided with suitably shaped heads to obtain the
required density.
10. DOWEL BANKS:

1. Dowel Banks shall be constructed to the dimensions, grades,
slopes as shown on the drawings.
11. Weather Conditions:

1. The embankment material shall be placed only when the weather
conditions are satisfactory to permit accurate control of the
moisture content in the embankment materials. During that part
of the construction period when the top surface of the
embankment may be subject to rainfall causing cessation of
work, it shall be graded and rolled with a smooth wheeled rollers
to facilitate runoff. Prior to resuming work, the top surface
should be slightly scarified and moistened or allowed to dry as
necessary and approved by the Engineer-in-Charge. If the
cessation due to any reason, is for a considerable period, top layer
shall be stripped to the required depth as may be directed by the
Engineer-in-Charge so as to remove any vegetable growth, loose
silt or sand washings or other objectionable matter.
2. The Contractor shall provide suitable protection works protect
the slope from erosion due to rain water. No payment whatsoever
shall be made for providing such protection work and rectifying
any monsoon damages.
12. Dressing Slopes

The outside slopes of the embankment shall be neatly dressed to lines and
grades as placement of fill progress.
All humps and hollows varying more than 15 cm from the neat lines of the
embankment shall be regarded. Material used to fill depression shall be
thoroughly compacted and bonded to the original surface. Slopes shall
be maintained until final completion and acceptance. Any material that
is lost by rains, weathering or other cause shall be replaced at his cost of
agency executing the work.
9. Settlement Allowance
1. In the earth fill embankment watered, rolled and compacted at
optimum moisture content and at dry density expressed as
percentage of proctors maximum dry density as given in
Appendix-I, settlement allowance of 1% and 2% of the designed
height for un-yielding (rock) and compressible (soil) foundations
respectively shall be provided. The base width of the dam will not
be increased to maintain the design slopes indicated in the
drawings for the additional height as settlement allowance, but
the following procedure will be adopted.
2. Settlement allowance will be calculated at various levels, where
the slope is to be changed and elevations including settlement
allowance will be derived. The embankment width at the designed
levels remaining same. The edges of embankment at the increased
elevation (including settlement), when joined with the point
where the slope has changed earlier below shall give the slope to
be adopted for construction.
3. If the embankment is raised in more than one season, provision
for settlement shall be made in the last seasons construction by
slight steepening of slopes near the top.
10. Toe Drains :

1. Pitched toe drains with filter will be provided throughout the
length of the dam at the downstream toe of earth dam as
indicated in the drawings and as per the details shown therein.
The layer of horizontal filter under the casing portion of dam
shall be extended in the toe drains to specified thickness. The
filter shall be watered and tamped with hand tampers.
2. The useful excavated material out of the toe drain shall be
suitably utilised on the dam as directed by the Engineer-in-
Charge.
11. SURFACE DRAINS:

1. This work shall consist of constructing surface drains, Schedule
of work shall be so arranged that the drains are completed in
proper sequence with canal excavation works as necessary
subsequently or no damage is caused to these works due to lack of
drainage.
2. Surface drains shall be excavated to the specified lines, grades,
levels and dimensions. The excavated soils shall be removed from
the area adjoining the drains. and is found suitable utilized in
embankment construction. All unsuitable soils shall be disposed
off as directed.
3. The excavated bed and sides of drains shall be dressed to bring
these in close conformity with the specified dimensions, levels and
slopes.
4. All works on drain constructions shall be planned and executed
in proper sequence with other works as approved by Executive
Engineer with view to ensure adequate drainage for the area.
12. Side drains:

1. The location, grades and sections of the drains shall be as shown
on the drawings and or as directed. Measurement of excavation
for the above drains will be made to the lines shown on the
drawings or as directed.
13. ROAD SURFACES AND PARAPETS

1. Road shall be constructed at the top of the embankment and at
other locations as indicated in the drawing. The roadway shall be
as indicated in drawing. The construction shall be as specified for
the highway by I.R.C. or as directed by the Engineer-in-Charge.
2. The parapets shall also be constructed after allowing sufficient
time for the embankment to undergo the usual post construction
settlement in order to avoid cracking of the walls due to
differential settlement.
14. PROTECTION:
1. The contractor shall take all precautions necessary for the
protection of the work by diversion of stream local surface
drainage, rain water etc. if these are likely, to damage the work.
Any damage to earth work due to any reason what so ever shall
be made good by the contractor at his cost till the work is
certified as completed and takeover by the Superintending
Engineer/Engineer-in-Charge.
15. ROADS AND RAMPS:

1. The contractor shall construct, operation, and maintenance roads
and earth ramps adjacent to the canal and structures at his own
expanses. Suitable materials from excavation or borrow areas
shall be placed as embankment for the roads and ramps. The
width of the road shall be not less than 4.25M.
39 (a) rip-rap on the upstream slope of embankment

Hand Placed Rip-Rap
i. Rip-rap shall be hand placed on the upstream slope of the dam embankment over
backing of specified filter layers. The thickness of rip-rap layer shall be as indicated in
the drawings.
ii. Stone for rip-rap shall be hard and durable and shall not crumble on long exposure to
water, frost and air.
iii. Procedure for Placing Rip-Rap .- The hand placed riprap shall consist of one man
stones laid on edge. Starting at the bottom of the slope the stones shall be laid
compactly with staggered joints and so matched and inter-locked that they shall be
keyed together with a minimum of joint space. Rock fragments and spell shall be
driven into interstices to wedge the rip-rap in place. The wedging shall be done with
the largest chip practicable, each chip being well driven home with a hammer so that
no chip can be removed by hand. Very irregular projections shall be knocked off so
that the rip-rap presents a reasonably uniform surface free of loose stones.
iv. Hand placed riprap should preferably be laid in one course such that the layer
thickness is same as the stone size. However, at least 80 percent of the area of riprap
should have stones weighing more than 45kg. Such stone should be spread uniformly
in the area. Where such stones are not sufficient to cover the entire thickness of riprap,
the same may be laid in two layers.
If two layers of stones are used, header stones extending throughboth layers and
spaced at about 1.5 m, shall be used. Also, of the two layers, the top layer shall be of
large stones. The size of the smallest side of the heater stone shall not be less than 150
mm and its length shall be equal to the thickness of the riprap plus 150 mm so that the
header stone would project above the general top surface of the riprap by about 150
mm. Such a projection will break the wave force and would also facilitate easy
identification of the header stones. If header stones of full length are not available
from the quarry, concrete blocks of necessary size, length and shape may be
manufactured for the purpose.
In case of stone of requisite size are not available and smaller stones/ boulder locally
available are required to be used, the riprap should be laid in panels furmaed by
constructing profile walls. A portion of the area between the panels may be grouted by
pouring fluid cement mortar worked into the riprap. Hand placed riprap may be laid
flat or laid with projections (Needles).
v. The riprap shall be placed along with the fill so that a minimum of breakdown will
occur during placing and spreading.
2. Dumped Rip- Rap
i. The minimum thickness of dumped rock riprap and average rock size shall be shown in Table
1. The thickness of riprap shall in no case be less than 450 mm.
TABLE 1: MINIMUM THICKNESS OF DUMPED RIP-RAP
Maximum wave height Minimum average rock size Minimum riprap Thickness
(D50)
(m) (mm)
(mm)
0 to 1.5 300 600
1.5 to 3.0 400 750
Above 3.0 700 1000
ii. The most important criteria in Table 1 is the minimum average rock size (D50)of
riprap. For example, for waves of 2 m in height, the riprap should be composed of
rocks, half of which by weight are equal to or larger than more or less
equidimentiaonal rock with average diameter of 400 mm. The rock used for riprap
shallbe well graded from a maximum size roughly equal to 1.5 times the average size
to 50mm.
iii. Procedure for placing rip-rap. - Dumped riprap shall consist of boulders or blasted
rock fragments. It shall be dumped in place mechanically on a property graded filter
layer. The full thickness of dumped riprap shall be dumped in one layer. It shalll either
be dumped over the upstream face from the embankment. Level as the embankment is
being raised up or after the embankment had been completed. When placed during the
construction, the riprap layer should be kept a few metres lower than the construction
surface when placed after the embankment is completed, the rock should be taken to
the crest of the dam in trucks and than lowered down the slope by suitable mechanical
device. The rock shall not be allowed to drop down the slope in a chute or be pushed
down the slope., since these operations result in excessive segregation. After dumping
the rock should be worked manually with bars or other equipment to achieve a well
packed and tidy surface.
3. Graded Filter Underneath Rip-Rap
i. Graded filter shall consist of at least two layers of filter material (coarse and fine), the
thickness of each layer 'shall be as specified in the drawing.
ii. The graded filter shall consist of sand and crushed stone as shown in the drawing.
Sand used shall be clean, sound and durable and shall be free from silt, roots, brush
wood and other impurities. Sand used shall be of size passing 4.75 mm screen.
Crushed stone used for filter shall consist of rock, fragments reasonably graded upto 1
5 cm in maximum dimension.
iii. Gradation requirement for the coarse filter material with respect to riprap material
should conform to the criteria that D85 size of the coarse filter material shall not be
less than 1/10 of D15 size of the riprap material. The gradation requirements for the
fine filter with respect to embankment material should conform to the criteria that D15
size of the fine filter material shall not exceed 5 times the D85 size of the retained
embankment material. The two layers of filter shall also satisfy these criteria with
respect to each other. Where the embankment material satisfy this criteria with respect
to coarse filter, fine filter could be omitted.
iv. Before placing of filter material, the embankment shall be trimmed neatly to the slope
and grades as indicated on the drawing. The filter-material shall be placed in layers of
uniform thickness and care shall be taken to avoid segregation of coarse & fine
material in each layer, formation of pockets and mixing of material of one layer with
material of another layer of earthfill.
4. Tolerance. -
The tolerance on the nominal thickness of rip-rap enforced on the performed profile shall be
10 percent.
9. Dry Stone Pitching :

1. The depth of stones shall be about equal to the specified thickness
of pitching and shall generally be not less than 0.014 cum or 0.021
cum as specified in the appropriate item of USR or other size as
ordered by the Engineer-in-Charge having regard to the nature of
stones being quarried. The small size stones/spalls required for
pitching and wedging shall be brought to the site only to the
required extent and they shall not to be used in two or more
thickness as a substitute for the stones of full thickness. A large
amount of the stones for pitching shall be obtained from the
required excavation for other parts of the work. Additional rock
as required shall be obtained from rock quarries.
2. Placing
Backing of filter and/or spalls where specified on drawing shall be placed only after the
underlying slope shall be trimmed neatly to the slopes and grades established on the
drawings. The lowest course of pitching shall be started from the toe wall or the line of pin
headers at the toe of the slope as may be specified on the drawing and the pitching laid course
by course up the slope.
Projecting corners shall be knocked off with the hammer so as to make a rough joint at the
base. The stones shall be laid on end with broadest base down and length normal to the slope
and carefully bonded in all directions and firmly bonded on the backing of filters where
provided. The stones shall be packed with hammer of mallet closed against each other, their
general line being approximately perpendicular to the slope of the underlying surface.
After the stones have been fixed as above, the interstices shall be filled with well fitting chips
driven home.
The general face slope of the pitching when completed shall be as specified in the drawing
subject to the tolerance as given in para 39.3 below. The final surface of the pitching shall be
clear off all refuge.
1. Tolerance : The tolerance on the nominal thickness of rip-rap

enforced on the performed profile shall be 10 (Ten) percent.
10. Dry Picked up boulder pitching
1. The boulders used in this type of pitching shall consists of the
rolled rock masses directly picked up in their natural form from
the river or the nalla beds. The boulders shall be hard, dense and
resistant to abrasion. The size of the boulders in at least one
direction should not normally be less than 22 cm. Also the least
dimension of such boulders in any direction should not be less
than 10 cm. The smaller size boulders/gravels required for
packing and wedging shall be brought to the site only to the
required extent and shall not be used in two or more layers as a
substitute for the boulders of full thickness.
2. Placing :
Over the backing of filter as may be specified in the drawing, the boulders shall be placed
such that the direction in which the size of boulder is around 22 cm is placed normal
to the surface of under layer. Also the boulders shall be laid with broadest base down
and carefully bonded in all directions.
After the boulders have been fixed as above, the interstices shall be filled with well fitting
smaller size boulders / gravel driven home.
The general face sloe of the pitching when completed shall be as specified in the drawing
subject to the tolerance as given in para 39.3. The final surface of the pitching shall be
clean off all refuge.
9. Dry Quarried Boulders Pitching

1. The specification as in Clause 39 shall be followed except that the
boulders of required size shall be obtained by breaking big size
boulders.
cum as specified in the appropriate item of USR or other sizes as
stones being quarried. The small size stones/ spalls required for
3. Placing : Backing of filter and/or spalls where specified on
drawing shall be placed only after the underlying slope shall be
trimmed neatly to the slopes and grades established on the
drawings. The lowest course of pitching shall be started from the
toe wall or the line of pinheaders at the toe of the slope as may be
specified on the drawing and the pitching laid course by course
up the slope.
1. Projecting corners shall be knocked off with the hammer so as to
make as rough joint at the base. The stones shall be laid on end
with broadest base down and length normal to the slope and
carefully bonded in all directions and firmly bonded in all
directions and firmly bonded on the backing of filters where
provided. The stones shall be packed with hammer of mallet closed
against each other their general line being approximately
perpendicular to the slope of the underlying surface.
2. After the stone have been fixed as above, the interstices shall be
filled with well fitting chips driven home.
3. The general face slope of the pitching when completed shall be as
specified in the drawing subject to the tolerance as given in para
39.3. The final surface of the pitching shall be clean off all refuge.
10. ROCK TOE

1. The rock fill shall consist of free draining mixture of rock
fragments of sizes from 75mm to 250mm. A large amount of
material may be obtained from required excavation for other
parts of the work. Additional, as required shall be obtained from
rock quarries.
2. Successive loads of material shall be dumped as to secure the best
practicable distribution of materials. The large rock fragments
shall be placed on the outer slopes and the smaller fragment shall
be placed towards the earth fill side. In general, the downstream
toe shall be placed in the manner to be approved by the Engineer-
in-Charge.
3. The rock fill shall be placed in horizontal layers not exceeding 90
cm in thickness. The completed fill shall be stable and no large
unfilled spaces shall be present in the fill.
4. Large voids, shall not be allowed on the downstream face of the
rock toe, so as to prevent choking by the spilling of earth, rain
cuts, etc. during and after construction. Such voids shall be
properly packed with stone chips of suitable sizes. The surface of
the rock toe shall be kept clear of all earth and debris so as not to
choke its full drainage capacity.
5. The filter layers to be provided behind and below the rock toe
shall satisfy the requirements of as below
6. BASE FILTER BLANKETS:
1. As and where indicated in the approved drawings, filter blanket should be laid
on the base, under the down stream portion of the canal embankment. The
number of layers in the filter blankets and the thickness of each layer shall be
as specified in the drawings. Sand shall be placed and compacted to an
average relative density of 85% with a minimum relative density of 70%. The
filter shall be placed and tamped in to place in such a manner that mixing of
filter with foundation or backfill materials will not occur. The filter materials
should satisfy the following criteria.
1. The filter material shall consist of clean, sound and well graded
aggregate. The material shall be free from debris, wood, vegetable
matter, decomposed rock and other deleterious matter. The
gradation of each filter layer shall meet the following requirements
with respect to the material to be protected and also with respect to
the adjacent filter layers.
i) D. 15 of Filter material > 4 < 20
D. 15 base material
Provided the filter does not content more than 5% of material finer
than 0.07 mm (No. 200 Sieve).
ii) D. 15 of Filter material < 5
D. 85 base Material
iii) D. 50 of Filter material < 25
D. 50 base material
iv) Coefficient of Curvature CC = (D.30)2 >/<3
D.10 x D. 60
V) Co-efficient of Uniformity : Cu = D.60 > 6 for SW
D.10
and Cu = D.60 > 4 for GW
D.10
Where
SW: Sand well Graded and
GW. Aggregate well graded.

2. The base filter materials should be well graded so as to satisfy the above
mentioned criteria. The grain size curve of the filter shall be roughly parallel
to that of base materials. In the above D-15 is the size at which 15% of total
soil particles are smaller. The percentage being by weight as determined by
mechanical analysis. The D-85 size is that at which 85% of the total soil
particles are smaller. It shall be laid in single layer or in layers as per the
drawing. If more than 1 filter layer is required the same criteria shall be allow.
The final filter is considered as the base material for selection of the gradation
of the coarse filter especially in the fine range. Filter materials should not
contain more than 5% of fines i.e. materials finer than 0.075 mm. (passing
through sieve No- 2000 I.S. sieve 75 micron) and fines should be cohesion
less to ensure that filter does not sustain a crack. The filter should not have
particles larger than 75mm. so as to minimise the segregation.
3. D. 15 is the size at which 15% of the total soil particles are smaller, the
percentage being by weight, is being propped, to be determined by mechanical
analysis. D.85 size is that at which 85% of the total soil particles are smaller.
As more than one filter layer is required, similar criteria is followed in each
case, viz., the finer filter is considered as base materials for the selection of the
gradation at the coarser filter.
4. The requirement for grading of the filter shall be established by the tests
conducted in the filed laboratory on the basis of mechanical analysis of
adjacent materials, Mechanical analysis shall be performed of all samples,
which have been compacted by the methods equivalent to compaction by
roller, so that the individual particles are broken to their field condition in the
embankment.
5. The filter materials shall be compacted to an average relative density of 85%
with minimum relative density of 70% as determined by the standard U.S
Bureau of Reclamation (Relative density test for cohesionless free draining
soils)
Dd = emax e
e - max -e min.
Where e = In place void ratio
e max = void ratio in loosened state
e min = void ratio in most compacted state, and
void ratio = Volume of Voids
Volume of solids
The relative density may also be computed using the maximum and min.
density as follows.
Dd = Yd max (Yd-Y min)/Yd (Yd max-Yd. min)
Where Yd Max = Maximum dry density of soil as obtained by the laboratory
procedure
Yd min = Minimum dry density dry density of soil as obtained by
the laboratory procedure.
Yd = The dry density at which the soil is to be placed or the in place dry
density.
The thickness of each filter layer shall be less than 150mm.
42.7 Seepage Drains
The seepage drains shall be excavated to the size and bed grad as shown in the drawings so as
to allow for easy flow of seepage from the hearing toe to the open drains. These shall be
refilled with layers of sand, gravel or broken metal and boulders as shown in the drawings. In
this case greatest care will have to be taken to see that filter media do not get mixed up.
42.8 Chimney Filter
Vertical inclined filter of the dimension specified in drawings shall be constructed on the
downstream face of impervious core. The thickness of chimney filter shall be as shown in the
drawings. Materials used shall be clean, sound and durable and shall be free from silt, roots,
bush and other impurities. Filter materials shall be laid in 30 cm layers and shall be
thoroughly wetted and compacted by pneumatic tyred rollers or other approved equipment.
Materials for filter shall be compacted to obtain a minimum relative density of 70%. The
filter shall satisfy the filter criteria as given in para 42.6.1 for filter blankets.
9. BORROW AREAS
1. All materials required for the construction of impervious, semi
pervious or pervious zones of embankment, which are not
available from excavation and surplus material from other
reaches shall be obtained from designated borrow areas as shown
in drawings or as designated by the field laboratory.
The limits of each borrow areas to be used in the various zones of

embankment shall be flagged in the field and material from each
borrow area shall be placed only in the zones for which it has been
specified.
The depth of cut in all borrow areas will be designated by the Executive
Engineer and the cuts shall be made to such designated depths only.
Shallow cuts will be permitted in the borrow area, if unstratified
material with uniform moisture contents are encountered. Each
designated borrow area shall be fully exploited before switching over to
the next designated borrow pits. Haphazard exploitation of borrow area
shall not be permitted. The type of equipment used and the operations
in the excavation of materials in borrow areas shall be such as will
produce the required uniformity of mixture of materials for the
embankment.
Borrow pits shall not be opened within a distance of ten times the height of the
embankment from the toes (on either side). Borrow pits shall be
operated so as not to impair the usefulness or mar the appearance of
any part of the work or any other property. The surface of wasted
materials shall be left in a reasonable smooth and even condition.
9. Preparation of Borrow Areas

1. All areas required for borrowing earth for embankment shall be
cleared off all trees and stumps, roots, bushes rubbish and other
objectionable material. Particular care shall be taken to exclude
all organic matter from the material to be placed in the dam
embankment. All cleared organic materials shall be completely
burnt to ashes or disposed off as directed. The cleared areas shall
be maintained free of vegetable growth during the progress of the
work.
10. Stripping of Borrow Areas

1. Borrow area shall be stripped of topsoil, sod and any other matter
which is unsuitable for the purpose for which the borrow area is
to be excavated. Stripping operations shall be limited only to
designated borrow areas. Materials from stripping shall be
disposed off in exhausted borrow areas or in the approved
adjacent areas, as directed.
11. BORROW PITS

1. The borrow pits shall not normally be more than 25M in length,
and 10M in width and 11/2 M. depth. A clear spacing of one meter
between each pit shall be left out.
2. The depth of the pits shall be so regulated that their bottom does
not cut the hydraulic gradient line having a slope 4:1 from the top
edge of the embankment.
3. In no case the pits shall be located within 10H from the toe of the
embankment.
4. If the contractor excavated the pits near to the toe against to the
above clauses and the same is observed at any time during or
after the execution of work, the contractor has to fill the same pits
with the soils suitable for hearting zone of embankment and
compact to 98% proctors density at the cost of contractor.
12. Borrow Area Watering

1. Borrow area watering if needed based on laboratory tests will be
done by the contractor as decided by the Engineer-in-Charge.
The placement moisture content for proper compaction of earthwork should

be as near as practicable to optimum moisture content as decided by
laboratory tests. However, depending upon the site condition, the nature
of the earth of the borrow area, the season of the year, the moisture
content of the earth of borrow area will vary over a wide range. Thus it
would be necessary to add water to bring the moisture content of
borrow area earth to as near OMC as practicable. In irrigation
projects, watering in borrow area may be done where watering at the
place of fill does not yield required results. Wherever practicable and
specially during dry months periodical watering of the borrow area by
tankers and mobile units may be done to the extent possible as decided
by Engineer-in-Charge.
9. DRILLING AND BLASTING

1. Blasting where required will be permitted only when proper
precautions have been taken for the protection of persons and
property in accordance with I.S. 4081-1967(Indian Standard
Specification for safety code for blasting and related drilling
operations). While carrying out excavations, adequate
precautions in accordance with I.S. 3764-1966(Indian Standard
Specifications for safety code for excavation work) shall be taken.
2. Explosive such as gelatin, detonators and fuse coils etc., required
for the rock blasting are to be procured by the Contractor at his
cost. It shall be responsibility of the Contractor to store the
explosives purchased by him in accordance with the rules of the
explosives act and other rules framed by Government of India.
3. Contractor shall also furnish the following details:-
Capacity License No. and date Validity period

4. The contractor shall acquaint himself with all the applicable laws
and regulations concerning storing, handling and the use of
explosives. All such laws, regulations and rules, as prevalent from
time to time shall be binding upon the contractor.
5. The provisions detailed in the Specifications are supplementary to
the above laws; rules and regulations are also applicable. Further,
the Engineer may issue modifications, alterations and new
instructions from time to time. The contractor shall comply with
the same without these being made a cause of any claims.
6. List I.S Codes applicable is furnished below.
01 IS. 4081-1986 Safety Code blasting and related drilling operations.

02 IS. 4668-1985 Ammonium nitrate for explosives.
03 IS. 6609-19 (part 1 to5) Method test for commercial blasting explosives and
accessories.
04 IS. 7632-1975 Detonators.
05 IS. 5454-1986 Portable pneumatic Drilling machine.
06 IS. 3764-1966 Safety code for explosives work.
In addition to the above I.S codes, the specifications of A.P.S.S. and manual for
Quality control and inspection shall also be complied with.
1. Excavation by blasting will be permitted only under the personal
supervision of competent and licensed persons and trained
workmen employed. by the contractor at his cost. All supervisors
and workmen incharge of, handling, storage and blasting work
shall be adequately insured by the Contractor.
2. The person incharge of the explosive magazine shall be very
reliable and shall be approved by the Engineer.
3. The contractor shall make sure that his supervisor workmen are
fully conversant with all the rules to be observed in storing,
handling and use of the explosives. It shall be assured that the
Supervisor incharge, is thoroughly acquainted with all the details
of handling and the blasting operations.
10. USE OF EXPLOSIVES

1. For the transport of the explosives and detonators between the
store and the site, closed and strong container made of soft
materials such as timber, zinc, copper, leather shall be used.
2. Explosives and detonators shall be carried in separate boxes. For
the conveyance of primer, special container shall be used.
3. The boxes and containers used, shall be kept closed. Explosives
shall be stored and used chronologically, earlier received shall be
used first . A make up house shall be provided at each working
place in which cartridges will be made up by competent and
licensed men as required for the work. The make up house shall
be separated from other buildings. Only electric storage battery
lamps shall be used in this house.
4. No smoking shall be allowed in the make up house or generally
while dealing with explosives.
11. DISPOSAL OF DETERIORATED

EXPLOSIVES
1. All deteriorated explosives shall be disposed of in approved
manner the quality of the deteriorated explosives to be disposed
of shall be intimated to the Engineer prior to its disposal.
12. PREPARATION OF PRIMERS

1. The primers shall not be prepared near open flames or fire. The
work of preparation of primers shall always be entrusted to the
same personal. Primers shall be used as early as possible after
they are ready.
13. CHARGING OF HOLES

1. The work of charging of holes shall not commence before all the
drilling work at the site is completed and the Contractors
supervisor shall satisfy himself to that effect by actual inspection.
While charging, open lamps shall be kept away. For charging
with powered explosives, a naked flame shall not be allowed. Only
wooden tamping roads, without any kind of metal on the rod shall
be allowed to be used. The tamping roads shall have cylindrical
ends. Bore hole must be of such size that the cartridges can easily
pass down them, they shall not however be too big.
2. Only one cartridge shall be inserted at a time and gently pressed
into the hole with the tamping rods. The sand, clay or other
tamping materials used for filling the holes completely shall not
be tamped too hard.
14. BLASTING
1. Blasting shall be carried during the fixed hours of the day which
shall have the approval of the Engineer. The hours once fixed
shall not be altered without prior written approval of the
Engineer-in-charge.
2. The site of blasting operations shall be prominently demarcated
by red danger flags. The order to fire shall be given only by the
contractors supervisor incharge of the work and this order shall
be given only after giving the warning signal three times, so as to
enable all the labour, watchmen etc., to reach safe shelters.
3. A whistle/biggle with distinctive note shall be used to give the
warning signals. The biggle shall not be used for any other
purposes. All the labour shall be made acquainted with the sound
of the biggle and shall be strictly warned to leave their work
immediately at the first warning signal and to move for safe
shelters. They are not to leave the shelters until all clear signal
has been given.
4. All the roads and footpaths leading to the blasting areas shall be
watched.
5. In special cases, suitable extra precautions shall be taken. The
engineer-in-charge may however permit blasting for under
ground excavation, without restriction of fixed time, provided
that he is satisfied that proper precautions are taken to give
sufficient warning to all concerned and that the work of other
agencies on the site is not hampered. For lightning the fuse, a
lamp with a strong flame such as a carbide lamp shall be used.
6. The contractors supervisor shall watch the required time for the
firing of the fuses and shall see that all the workmen are under
safe shelters in good time.
15. ELECTRICAL FIRING

1. Only the Contractors supervisor incharge shall posses key of the
exploder and short firing accessories and he shall keep it always
with himself. Special apparatus shall be used as a source of
current for the blasting operations; power lines shall not be
tapped for the purpose.
2. The detonators shall be checked before use. For blast in Series,
only detonators of the same manufacture and of the same group
of electrical resistance shall be used. Such of the electrical lines as
could constitute danger for work of charging shall be removed
from the site. The firing cables shall have a proper, insulating
cover so as to avoid short circuiting due to contact with water,
metallic parts of rock etc.,
3. The firing cables shall be connected to source of current only
when nobody is in the area of blasting. Before firing, the circuit
shall be checked by a suitable apparatus. After firing with or
without an actual blast, the contact between the firing cable and
the source of current shall be cut off before any one is allowed to
leave the shelters. During storm rain the blasting operation shall
be suspended.
16. PRECAUTIONS AFTER BLASTING

1. After the blast, the Contractors supervisor must carefully inspect
the work and satisfy himself that all the charges have exploded.
After the blast has taken place in the underground works,
workmen shall not be allowed to go to the place till the toxic gases
are evacuated from the place.
2. MISFIRES:- If it is suspected that part of the blast has failed to
fire or is delayed sufficient time shall be allowed to elapse before
entering the danger zone. When fuse and blasting caps are used, a
safe time should be allowed and then the Contractors supervisor
along shall leave the shelter to see misfire.
3. None of the drillers are to work near this hole until one of the two
following operations have been carried out by the Supervisor.
Either (i) the supervisor should very carefully (when the tamping is of damp clay)extract the
tamping with a wooden scraper or jet of water or compressed air (using pipe of soft
materials) and withdraw the fuse with the primer and detonator attached after which a
fresh primer and detonator with fuse should be placed in this hole and fired out or (ii)
the hole may be cleared of 300mm, of caping and the direction and then be
ascertained by placing a stick in the hole. Another hole may be drilled at least 225mm
away, and parallel to it. This hole should then be charged and fired. The balance of the
cartridge and detonators found in the muck shall be removed.
4. Before leaving his work, the contractors supervisor should

inform the supervisor of the relieving shift of any case of misfires
and should pointout the position with red cross denoting the
same, also stating what action if any, he has taken in the matter. A
register of misfires and their location and how they were dealt
with shall be maintained by the contractor.
5. The contractors supervisor should also at once report at the
contractors office all cases of misfires, the cause of the same and
steps were taken in connection there with.
6. The names of the day and night shift supervisors of the
contractor must be noted daily in the contractors office. If
misfire has been found to be due to a defective detonator, or
dynamite, the whole quantity of box from which the defective
articles was taken must be returned to the contractors office for
inspection, and shall be disposed of.
7. Drilling in the holes not completely exploded by blasting shall not
be permitted.
8. The contractor should produce the firers license and furnish the particulars in the
following statement.
Sl. Name No. of firers Validity

license & date period
No.
9. Blasting operation, when considered necessary shall be resorted

to only with the written permission of the Engineer-in-charge.
Prior inspection shall be carried out for the safety of the public
property. Blasting operations in the proximity of over-head power
lines, communication lines, utility lines or other structures shall
not be carried out until the operator or the owner or both of such
lines have been notified and precautionary measures deemed
necessary have been taken.
9. Before Compaction
1. Materials delivered to the fill shall be visually examined and their
properties estimated by way of inspection. These checks shall
include:
(a) Borrow Areas

i. Excavation of borrow areas shall be limited in extent and depth as indicated on
plans.
ii. Estimation of moisture content of materials by visual examination and feel.
iii. Samples shall be taken for laboratory analysis in case the soil is of different
characteristics.
These inspection checks shall be supplemented by sampling the materials at
prescribed minimum intervals and by testing the samples in the laboratory for
gradation and moisture content.
(b) Embankment
i. Water content tests shall be carried out in the laboratory while placing the fill
materials.
ii. Moisture content shall be controlled by adding water or aerating the soil
according to laboratory test.
iii. It shall be ensured that the methods of dumping, spreading and moisture
conditions are such that which results in reducing segregation and/or variation
of moisture content to a minimum.
9. During Compaction
It is intended that the checks on operations during compaction shall verify :-
i. That the layer thickness of the materials is as specified.
ii. That the fill is compacted by the specified number of passes of the specified
machinery.
iii. That no excessive rutting, weaving or a scaling of the fill occurs during compaction.
9. After Compaction
The condition of the fill after compaction shall be observed and recorded particularly
with respect of rutting or weaving. However, the properties of materials after
compaction shall be determined primarily by field density tests. Dry density attained
shall satisfy the compaction standards as per appendix I.
9. Frequency of Testing
1. The frequencies for various tests for earthwork shall be in
accordance with Appendix 6.02 of the M.P.W.D. manual 1983,
Vol. II, Part II.
2. Special attention shall be given to the following locations where
insufficient compaction is likely to occur:-
i. The junction between areas of mechanical tamping and rolled embankment
along abutments or cut off walls.
ii. Areas where rollers turn during rolling operations.
iii. Areas where too thick a layer is being compacted.
iv. Areas where improper water content exists in a material.
v. Areas where less than specified number of roller passes were made.
vi. Areas where dirt-clogged rollers are being used to compact the materials.
vii. Areas where oversized rock which has been over looked is contained in the
fill.
viii. Areas where materials have been placed when they contained minor amounts
of frost, or at nearly freezing temperatures.
ix. Areas that were compacted by rollers that have possibly lost part of their
ballast.
x. Areas containing materials differing substantially from the average.
9. Record and Reports

Record of borrow area materials and embankment placing operations be maintained in
order to have a continuous check on the suitability and availability of fill materials
and quality of the fill. Thus, it will be possible to have complete description of
materials in any portion of the embankments. The records shall be maintained in the
form specified in Appendix II.
9. Field Test Data

1. Records of field test data results should be presented in the form
of statistical analysis sheets and summary sheets in order to
provide control required for enforcement of statistical
requirements of the specifications.
2. The test data summary sheets and inspection reports be used to
form the basis of construction control report, which should be
issued from the site at fortnightly intervals during construction
season. The report would contain narrative accounts of the
progress and problems of fill construction, statistical analysis of
test data and photographs of the fill operations.
9. EMBANKMENT TEST SECTION :
Placing of compaction methods specified will, have to be verified by test embankment
section to be built prior to starting of fill operations or at an early stage of dam
construction. The initial stage of dam construction itself could be made to serve the
purpose of test embankments. The sections referred herein shall be used to establish :-
1. Layer thickness of fill materials.
2. Optimum practicable moisture content.
3. Number of passes of sheep foot roller, or weight of vibratory roller vis-
-vis number of passes for effective compaction.
When an appreciable change in material occurs, additional test sections shall be made
during construction. The procedure for construction of test embankment sections is as
follows :
i. Select a location on the embankment where uninterrupted placing operations
are being performed. This area 15 m by 30 m should be carefully worked and
referenced so that its limits will be easily recognized. In order to expedite the
determination of moisture content to be used, more than one test section may
be established on the embankment at the same time.
ii. During construction of the test section which will most probably continue for
several shifts, a complete record of the procedure should be kept. This record
should include the number of layers placed, the spread thickness of each layer,
the moisture content, at which the materials were rolled, the designation (No.
1, No. 2, etc.) of the rollers used, the condition of the rollers (clean or dirty),
the action of the materials being rolled (such as wavy under the rollers, the
amount of penetration of the roller teeth after different number of roller trips
etc.) and the borrow pit location from which the materials came.
iii. Check the rollers to make certain that they meet all the requirements of the
specifications.
iv. Determine the required spread thickness of layer that will compact to the
specified thickness after rolling specified number of times and maintain this
thickness as long as number of roller passes is kept the same.
v. Using the available data from borrow pit investigations of the materials to be
used in the test section, the optimum moisture content as determined by
laboratory tests will be known and 3 percent less than this moisture content
should be used in the first 3 or 4 layers rolled.
vi. After 3 or 4 layers have been placed at 3 percent less than the laboratory
optimum moisture content, field density test should be made throughout the
section. These tests should be made for at least each 93 sqm of test section
area, and should be distributed over the area that they will detect the effects of
different compaction conditions encountered during construction. For
example, if the section is located near an abutment, certain parts of the area
will receive more compaction from track travel than others; hence some tests
should be made in the portion compacted only by the rollers and so reported.
vii. The next step is to compact another 3 or 4 layers at the moisture content
slightly higher (1 percent or 2 percent) than the moisture content previously
used, maintaining the same rolled thickness of layer and number of roller
passes as in above. Field density tests are again made over the test section.
viii. If the resulting field dry densities (of material passing the No. 4 sieve) from
(vii) above shown an increase with increase of moisture, again by another 1
percent or 2 percent, repeat the test. If an increase in moisture results in a
decrease in field density, then place the next layers slightly dry of the original
moisture content used and repeat the test. This procedure is nothing more than
developing on the embankment a moisture density relation or compaction
curve for a certain roller, thickness of layer, and a given number of roller trips.
If special studies during investigation have indicated that the material being
tested should be placed within certain moisture limits, or if the moisture limits
to be used have been specified, the procedure outlined above should include
tests at these moisture contents or at moisture contents both greater and
smaller than the specified.
ix. The roller compaction curve is now compared with the standard laboratory
compaction curve. If the field density of materials passing the No. 4 sieve
(from the roller curve) is greater than the standard compaction density at the
specified moisture content, the test section should be continued decreasing the
number of roller trips while maintaining the specific desirable moisture
content until the most economical compactive effort is determined. When the
roller trips are decreased, the required spread thickness of layer that will
compact to the specified thickness of compacted material should be reckoned.
x. All works connected with the embankment test section will be done
departmentally and shall be allowed without hindrance.
9. Turfing
After the slope has been dressed to line, it shall be slightly roughened to bond and hold a
surface dressing consisting of a 150mm layer of good soil. The layer shall then be raked and
lightly rolled with hand roller or hand tamped as directed by the Engineer-in-Charge. The
entire slope surface shall then be covered with a layer of turf sod. The sod shall include a mat
of roots and earth atleast 50mm thick. Sod containing an excessive amount of obnoxious
growth shall be excluded. Sods shall be carefully handled in transportation and transplanting
so that a minimum amount of obnoxious growth shall be excluded. Sods shall be carefully
handled in transportation and transplanting so that a minimum amount of earth will be lost
from the root mass. The strips of blocks of sod shall be laid on the slope in c\lose contact and
then tamped firmly in place so as to fill and close the joints between the blocks. The interval
of time between cutting and laying shall be kept to a practicable minimum and sod shall not
be permitted to dry out. Immediately after placing, the sodded slope shall be thoroughly
wetted and kept moist for 10 days. The sodded slope shall be periodically moistened, if
necessary, for a sufficient period to reestablish the plant growth. Humus sod shall be
transplanted only during an approved season. Alternatively the down stream slopes shall be
topped with a 150 mm layer of good top soil and seeded with approved grass seed as directed.
4.18 Transverse Contraction Joint In Dam/Barrage :
average thickness of 40mm plaster gives smooth plumb surface.
4.18.2
4.18.2 Waterstops Across Transverse Contraction Joint :
4.18.2.1 Materials :
respectively.
viz, Z and M shapes shown in Fig.A of PLATE : 1/CH-4.*
and shall meet the test requirement given in relevant parts of IS:3660.
IS:8543. The rubber/PVC Waterstop shall meet the requairements given in Table 2.
Table-2 : Performance Requirements of Rubber/PVC Waterstops
S. Characteristics Unit Value
No.
i. Tensil Strength N/mm 11.6 min
ii. Ultimate Elongation % 300 min
iii. Tear Resistance N/mm 4.9 min
iv. Stiffness in Flexure N/mm 2.46 min
v. Accelarated Extraction
(a) Tensil Strength N/mm 10.5 min
(b) Ultimate Elongation % 250 min
vi. Effect of Alkali (7 Days)
(a) Weight Increase % 0.25 max.
(b) Weight Decrease % 0.10 max.
(c) Hardness Change Point 5
vii. Effect of Alkali (28 days)
(c) Dimension Change % 1
*For figure See Specifications Published by Engineer-in-charge
Fig.B of PLATE : 1/CH-4*
(c) Asphalt Waterstop Recommended specifications of asphalt are given below-
(a) Density 1015 - 1065 Kg/m
(b) Penetration at 25C 200 300
(c) Softening point (Ring and ball test) 80-90C
(d) Brittleness test on 22mm specification at
5C energy absorbed 0.97 Kg/m

PLATE : 1/CH-4*
4.18.2.2 Installation of Waterstops :

shown in Fig.A of PLATE : 2/CH-4*.
4.18.2.2.2 The metal waterstop shall be erected in place with the help of anchor rods.
concreting block.
capped as in the drawing (Fig.B of PLATE : 2/CH-4 and Fig. of PLATE : 3/CH-4)*
interface.
embedded vertically in the block-out concrete.
joint.
masonry in the lower of the two adjacent blocks by more than 1.5m.
PLATE : 4/CH-4*.
3. Jointing :
shall be jointed carefully by heat sealing.
respectively so as to form a continuous water tight diaphragm.
4.19 DIAPHRAGM WALL :
1. Materials :
relevant paras of Chapter 7 & 16.
size of aggregate may be used.
bentonite slurry shall be free from salinity and other deleterious impurities.
in IS:456-1978.
steel sections conforming to IS:226-1975 shall be used.
relevant paras of Chapter 7 &16 and para 4.19.7.3 of this chapter.
suitably processed with chemicals.
designed and tested according to requirement of the structure.
cement clay grout if required.
4.19.2 Equipment and Accessories -
choosen.
centrifuges for cleaning the bentonite slurry for reuse may be employed.
desired speed.
grabs as necessary.
when they are required to work on a site with restricted space or head room.
4.19.3 Specification of Bentonite Slurry -
by weight of bentonite powder in water.
used in diaphragm walling.
Type of Test Method of Test Permissible Value at 20C
Density Mud balance or hydrometer 1.04 to 1.10 g/ml
PH Value PH indicator paper strips 9.5 to 12
Viscosity Marsh cone method 30 to 90 seconds
10-minute gel Shearometer or vane shear apparatus 1.4 to 10 N/m,
strength
(14 to 100 dya/cm)
percentage by mass and the density Ys is given below.
Ys = 1.0 + 0.006 C
There may be some variations of bentonites. Laboratory calibration may be
prepared for the bentonite sample actually used.
blending of freshly mixed bentonite slurry with previously used bentonite slurry.
carried out.
equipment employed.
required density is achieved.
contaminated slurry at the bottom of trench by fresh bentonite slurry.
4.19.4 Bentonite Slurry and Additives :
of slurry. The temperature of water used and of the slurry used shall not be less than 5C.
for a period of minimum 12 hours after it is mixed thoroughly.
very small amount of 0.1 to 0.5 percent by mass of the slurry.
(i) Ferrochrome lignossulphonate in combination with soda ash or bichromate of
soda may be used for effective bentonite hydration if hardness of water
exceeds 200 PP.
(ii) Sodium carboxymethyl cellulose (S.C.M.C.) is yet another additive some times
used. It protects slurry against effects of electrolytes, accelerates filter cake
formation and reduces fluid loss by increasing the viscosity of slurry.
(iii) Cement contamination may be counteracted by phosphates. The calcium gets
removed and clay solids dispersed. Phosphates decrease PH value there by
lowering viscosity and yield value of slurry.
i. Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase

viscosity and reduce filter loss.
ii. To remove fine silty solids and clay solids from the slurry flocoulants may be used.
Vinyl acetate maleic anhydride co-polymer or polyacrylamides may be used. Gaur
gum can flocculate clays, carbonates etc.
iii. Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
protective colloid against the effect of electrolytes.
iv. Stability of slurry filled trenches should be worked out as per procedure described
under Appendix-II.
5. Guide Wall/Pre-Trench :
operation.
of pre-trench level will be minimum 1.5m above the high water table.
Mesh or cage reinforcement shall be used in guide walls.
(on both sides of the wall).
be done continuously.
progress, the level of bentonite slurry will be maintained by addition of bentonite slurry.
4.19.6 Methods of Construction :
to 6m are usually adopted.
4)*.
4.19.6.3 Alternate Panel Method :
a secondary panels.
panels.
primary panels.
which are described below.
4.19.7 Stages of Construction :
4.19.7.1 Excavation of Trench (boring Operation) :
described below.
4.19.7.1.2. Direct Circulation Method :
i. This method is used with rotary or percussion type rigs where drilling fluid (bentonite
slurry) is pumped through the drilled rods. It can be used for successive panel or
alternate panel construction. The stages of construction are shown in Fig of PLATE :
8/CH-4 Simple trenching rigs for excavation may be used.
ii. The trench panel may be excavated in the ground by making over lapping bore holes
with bentonite slurry jet in combination with percussion and to and from rotary
motion of jetting pipe having a suitable cutter at the tip.
iii. A special semi-circular cutter shall be used for providing appropriate shale at each
panel end to form a suitable joint.
iv. The operation of filling bentonite slurry in the trench shall be as described under para
4.19.5.5 and lowering of reinforcement shall be done as described under para 4.19.7.2
v. For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used.
vi. This method is suitable for shallow depths and bringing up lighter cuttings.
4.19.7.1.3 reverse Circulation Method -
i. The reverse circulation method with in percussion shall be used to make trench panel
in the ground as shown in Fig.A of PLATE : 9/CH-4*. Forward and backward
movement of the rig from one end of the panel to the other and shall increase the
depth of panel in zigzag manner.
ii. High capacity pumps shall be used to suck the loosened soil in this slurry filled
trench. Separators or sedimentation tanks shall be used to retain the soil cuttings, and
to pass the slurry for circulation and reuse.
iii. This method is suitable for greater depths and to bring up heavier cuttings.
4. Other Requirements during boring operation :
i. Solids in the settling tank shall be removed and kept along side. When the grabs or
Kelly method is used for boring bored muck from the grab will be left along side.
ii. For overcoming any underground obstruction or boring through all types of rocks
such as soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use
of chisel grab will be made in case of grab type equipment. In case of reverse
circulation equipment the cutting tool itself will execute chiseling operation in above
mentioned strata.
iii. The width of cutting tool will be more or less as that of the disphragm wall. The
trench shall be finished upto founding level in the final stage of preparation by using a
cutting tool having a width of not less than 600mm before commencing placement of
concrete.
iv. Boring shall be continued in the manners described above upto foundation level.
Depth of the trench will be determined by taking sounding. Diaphragrm wall shall
penetrate about 0.6 metre into sound rock which shall be ensured by careful soundings
taken and certified by engineer-in-charge. If there is difference of more than one
metre or more in the rock level at two ends of the panel, suitable stepping as decided
by Engineer-in-Charge shall be provided.
v. Before removing the equipment, the bottom of the trench will be cleaned by reverse
circulation equipment.
vi. Form tubes will be lowered at each end of primary panels in case of construction by
alternate panel method and reinforcement cage shall then be lowered in the trench
panel and suitably supported.
2. Reinforcement :
i. Reinforcement in each panel should form a cage and the vertical ends of the cage
should match with the type of joints of the panel. For ease of handling and good
workmanship the cage should be made rigid. Clear distance between reinforcement
bars should not be less than 100mm for easy flow of concrete.
ii. The length of the cage will be governed mostly by the depth of panel and the length of
rods available. The cage shall however be built up preferably in two fabricated
matching pieces but in no case in more than three pieces. Each subsequent
reinforcement cage after the first cage shall be securely fastened and tack welded to
the lower cage before the assembly is lowered to the trench. The steel reinforcement
cages shall be clearly marked to indicate its correct orientation for proper insertion
into the trench.
iii. The gap in the main bars should not be staggered more than 50 cms to avoid
difficulties in handling the cage and dropping the cage.
iv. Suitable gape in the reinforcement cage will be provided for accommodating the
tremie required during concreting operation.
v. The reinforcement cage will be suitably strengthened at regulat intervals and
generally the bars will be tack welded.
vi. In case the reinforcement cage is heavy, angle iron frames may be utilized.
vii. The concrete cover for reinforcement shall be maintained by the use of spacers.
Circular roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix
shall be provided at suitable intervals preferably one block per square metre on both
sides of the cage and suitably staggered. The diameter of spacer block will depend
upon clear cover required for the reinforcement.
Boxes or inserts for formation of recesses or for ground anchors shall be
lowered along with the cage to correct position and levels. Circular cover
blocks are considered essential to the reinforcement so that they will roll
along the trench without damage and maintain adequate cover.
viii. The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
diameter and number should be adequate to withstand the weight of the cage.
ix. The reinforcement cage should be kept hanging over pre-trench to provide a minimum
cover of 10mm at the bottom of trench and it shall be maintained in position during
the concreting of each panel.
x. Rock grout pipes shall be fixed with suitable spacer bars at specified intervals.
shall be provided.
both directions with a cover of 75 to 100mm at faces and at end of elements.
4.19.7.3 Concreting :
than 0.6.
segregation of the ingredients.
practicable to 0.6.
through, for tremic pipe used in concreting.
extra cement added for under water work for laying concrete by other than tremie.
4.19.7.3.5 Concrete Classifications :
strengths and shall conform with the requirements setout in table below.
S. Location Classification Slump
No.
1 Concrete in RCC Diaphragm Walls M-20 150 to 200mm
2 Concrete in RCC Capping M-20 50 to 75mm
Exact mix design however, shall be determined by laboratory tests.
carried out as and when directed.
Chapter 7 & 16.
4.19.7.3.10 Placing and Compacting for Diaphragm Wall :
i. The concreting shall be done by tremie pipes and the tremie diameter will be
minimum 200mm. It is preferable to use threaded tremie pipes in suitable lengths. The
tremie pipes shall be clean and water tight. Depending upon the length of panels one
or more tremie pipes should be used. The elliptical or oblong tremie pipe shall be used
for concrete having aggregate of 20mm and smaller. This shall be used for walls of 20
to 30cm thickness. For walls of greater thickness a circular tremie pipe may be used.
ii. Prior to placing concrete in any panel it should be ensured that heavily contaminated
bentonite slurry has not accumulated in the bottom of trench which can impair free
flow of concrete. The contaminated bentonite slurry shall be identified by taking a
sample of the slurry from near the bottom of the trench and carry out a density test on
this using a mud balance. Density as measured shall not be greater than 1.25 gm/ml.
Before pouring the concrete through tremie pipes, the bottom of the concreting funnel
should be closed through a steel plate. The tremie should extend to the bottom of
trench excavation prior to the commencement of concrete pouring and care shall be
taken to ensure that bentonite slurry which may have entered the tremie is expelled
from the tube during the initial charging process. After funnel is filled with concrete,
the plate is removed and concrete is discharged. Thereafter concreting is done in a
continuous manner upto required level. Care should be taken during placing to avoid
contamination of the concrete where two or more pipes are used in the same panel.
Simultaneously, care should be taken to ensure that the concrete level at each pipe is
maintained.
11. For Cap Work :
i. Before placing cap concrete extra concrete already placed ruing concreting of the
diaphragm walls above designed cut off level shall be removed by chiseling manually
or by pneumatic tools. In case concrete below the designed cut off level is found to be
inferior or contaminated not conforming to specifications, the same should also be
removed until concrete of prescribed specifications is met with. Minimum 15 cms (6
inches) should preferably be removed. The chipping shall be done in such a manner as
not to loosen, crack or shatter any part of the work beyond the approved levels at or
below the cut off level. The surface shall be cleaned thoroughly of all loose
fragments, dirt, laitaree and any other objectionable materials and shall be sound and
hard in such conditions as to ensure good bond between the old and new concrete.
ii. After the surface has been cleaned and dampened as specified, surface construction
joints shall be covered wherever practicable with a layer of mortar approximately
15mm to 20m thick. The mortar shall have the same proportions of water air
entraining agent, cement and fine aggregate as the concrete mixture to be placed upon
it. The water cement ratio of the mortar in place shall not exceed that of the concrete
placed upon it and the consistency of the mortar shall be suitable for being spread
uniformly and worked, thoroughly into the irregularities of the surface. Concrete shall
be placed immediately upon the fresh mortar.
groups of coarse aggregate being separated from the concrete mass.
not possible or would be inadequate.
harmful effects of exposure to sunlight, wind and rain, as directed.
cracking.
4.19.8 Types of Joints :
the ends of the primary panels to form suitable joints with secondary panels.
4.19.9 Wall of Precast RCC Panels :
panels shall be supported in the trench by using special supports.
compound.
and impermeability.
that achieved by tremie concrete method.
4.19.10 Grout Cut-off Walls :
used to provide an impermeable cut-off wall.
may be used for diaphragm walls which are primarily meant as impermeable cut-offs.
4.19.11 Tolerances :
from a straight line or a specified profile shall not exceed 25mm in 3m.
2. Diaphragm Wall :
vertical within a tolerance of 1:80.
concrete cast shall be between 150-500mm above the specified wall levels.
and horizontal tolerance of 150mm.

relation to top of guide wall shall be 50mm.
4.19.12 Rock Grouting under the Diaphragm -
4.19.12.1 Specification for this work shall be as per Chapter 22.

reinforcement.
equipment.
the flow in the particular rock media (laminar or turbulent).
media, the test at the particular packer position will be considered as completed.
permeability.
conducting some trial tests at the site.
The pressure which will be generally allowed for grouting will be as follows :
1 PSI for every foot of rock above the packer.
75 PSI for every foot of overburden above rock.
1971. Grouting of Rock Foundation in River Valley Projects.
4.19.12.2 Grouting under the Diaphragm wall joints by Tube-A Manchette Method
the diaphragm wall the area near the diaphragm wall joints will be grouted.
using the mud circulation process.
every 33 cms) covered by rubber sleeve which acts as a one way valve.
enough to allow upward leakage along the tube A Manchette pipe.
the second stage grouting.
grouting of sand between the two walls is not necessary.
4.19.13 Permeability test for Concrete of the Diaphragm Wall :
the panel.
be done through these pipes for a depth of 3cm to 60cms below the bottom of the pipe.
completed can be applied while carrying out this test by using compressed air.
cm per year at pressure equivalent to a hydrostatic head of 40 metres.
4.19.14 Inspection of Works :
be taken in construction and operation of these walls.
4.19.15 Testing Efficiency of Diaphragm Wall :
wall and seepage measured all round the year.
APPENDIX - I
CRITERA FOR CONTROL OF COMPACTED DAM EMBANKMENT
Type of Percentage percentages based on minus nO.4 fraction

Material of No.+4 50 Feet or Less in Height Greater than 50 Feet Height
fraction by Minimum Desirable Moisture Minimum Desirable Moisture
dry weight Acceptabl Average Limits Acceptable Average Limits
of total e Density Density W0-Wf Density Density Wo-Wf
material
1 2 3 4 5 6 7 8
Cohesive 0-25 D=95 D=98 -2 to +2 D=98 D=100 2 to 0
Soil 26-50 D=92.5 D=95 D=95 D=98 (Note 2)
Controlled by More than D=90 D=93 D=93 D=95
the Proctor Test 50
(Note-1)
Cohesion Fine sands Dd=75 Dd=90 Soils Dd=75 D=90 Soils
with should be should
Less soils very wet be very
0-25 wet
Controlled by Medium Dd=70 Dd=85 Dd=70 D=85
the relative sands with
density test
0-25
Coarse Dd=65 Dd=80 Dd=65 D=80
sands with
0-100
gravels
Wo- Is the difference between optimum water content and fill water content in
Wt percent of dry weight of soil.
D Is fill dry density divided by Proctor maximum dry density in per cent.
.
Dd Is relative density
NOTES :
permeability of the total material if used as a water barrier.
prepared.
Appendix II
(Para 4.19 A (VI)

STABILITY OF SLURRY FILLED TRENCHES
The bentonite slurry filled in the trench imparts stability by mainly

applying hydrostatic pressure on the wall, against the impermeable thin
film formed along the wall. Secondly the slurry filled in the trench provides passive
resistance against failure of the trench, and thirdly, the shearing resistance of the slurry
saturated zone and the plastering effects of the filter cake formed also contribute towards
trench stability. The hydrostatic pressure along represents 65 to 80 percent of the total
stabilizing forces. If the density of slurry used is such that it can provide a factor of safety of
one due to hydrostatic pressure, then the factor of safety of the actual trench shall be between
1.25 to 1.50. Therefore taking only hydrostatic pressure and considering F=1, the density of
slurry may be calculated as indicated by the following formula. This formula should be used
as a guide only.
Where
H = depth of the trench
Cu = undrained shear strength of clayey soil
Y = natural density of saturated soil
Ys = density of the slurry needed for the trench, and
horizontal as well as vertical directions See Figures below :
For sandy
Where
KA =
Y = effective unit weight of the sandy soil
= submerged unit weight
= saturated weight weight of water
= Y sat Yw
THE VALUE OF A DEPENDS UPON RATIO OF THE TRENCH (SEE FIG. ABOVE).
the water level.
VOLUME III
SECTION - 4
EXCAVATION
CONTENTS

TENDER DOCUMENT 49
TURNKEY TENDER 49
50
SECTION 7: GATES 51
Volume - III 52
Section I 52
GENERAL 52
Volume III 53
Section - 2 53
Preparatory Work 53
INDEX 53
2 Survey 58
2.5 ACCURACY 60
4 Final Report 68
APPENDIX I 69
APPENDIX II 71
NOTE: 71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
MATERIALS 76
APPENDIX IV 77
1. CONCRETE STRUCTURES 77
2. EARTHWORK/EMBANKMENT 77
Volume III 81
Section - 3 81
Land Acquisition 81
THE LAND ACQUISITION CASES ARE TO BE PREPARED AND SUBMITTED IN THE
FORMATS PRESCRIBED BY THE AUTHORITY COMPETENT TO PASS THE
ENFORCED TIME TO TIME ARE TO BE STRICTLY FOLLOWED. 81
Volume III 82
Section - 4 82
Excavation 82
contents 82
162
1 General 162
2. Standards 162
3. Scope: 163
4. Planning: 163
DRAWINGS. 163
CHARGE. 164
THE WORK. 164
TIME. 164
SURFACE. 165
THE PROJECT. 165
165
TRENCH: 165
166
9.15 PUDDLE: 166
REJECTED. 166
166
9.20 THE TOP OF PUDDLE SHALL BE KEPT AS LEVEL AND UNIFORM AS
POSSIBLE AND SHALL ON NO ACCOUNT BE ALLOWED TO DRY. IF THE
SURFACE CRACKS AT ANY TIME IT SHALL BE DUG UP AND PUDDLE
REMADE. 166
9.21 VERTICAL JOINTS ACROSS THE PUDDLE WALL AND STEPS TO ITS
SIDE SHALL BE AVOIDED. ALL JOINTS SHALL BE MADE BY LONG
MENS HELS. 166
9.24 THE PUDDLE FILLING SHALL NOT BE DONE IN STANDING WATER.
WATER LEVEL IN TRENCH SHALL BE KEPT BELOW THE WORKING
LEVEL BY MEANS OF PUMPS, IF REQUIRED. 167
WAY. 167
9.28 THIS FILLING IS TO BE CARRIED UP WITH THE PUDDLE WALL TO
A HEIGHT OF 0.6 M ABOVE GROUND LEVEL AND JOINED WITH THE
HEARTING. 167
MEASUREMENTS. 167
13 EXCAVATION 169
16 DEWATERING 171
WORKS. 171
OTHER PROPERTY. 171
CHARGE. 174
22.1 SCOPE: 174
CURVED. 178
24 Material 178
EMBANKMENTS. 178
CLAUSE 6.4 OF I.S. 4701-1982. 179
COST. 179
COMPACTION. 179
DRUM. 180
(III) ROLLER WEIGHT :- THE WEIGHT OF THE ROLLER WHEN FULLY
26.3 ROLLING :- 181
RAIN GULLIES. 186
29 DOWEL BANKS: 186
186
THE TOP. 187
33 Toe Drains : 187
187
35 Side drains: 188
188
37 PROTECTION: 188
39.2 PLACING 190
(TEN) PERCENT. 191
191
40.2 PLACING : 191
42 ROCK TOE 192
CHARGE. 192
THE FILL. 192
43 BORROW AREAS 195
CONDITION. 195
46 BORROW PITS 196
SHALL BE TAKEN. 196
DETAILS:- 196
51.1 THE PRIMERS SHALL NOT BE PREPARED NEAR OPEN FLAMES OR
FIRE. THE WORK OF PREPARATION OF PRIMERS SHALL ALWAYS BE
ENTRUSTED TO THE SAME PERSONAL. PRIMERS SHALL BE USED AS
EARLY AS POSSIBLE AFTER THEY ARE READY. 198
53 BLASTING 198
53.3 A WHISTLE/BIGGLE WITH DISTINCTIVE NOTE SHALL BE USED TO
GIVE THE WARNING SIGNALS. THE BIGGLE SHALL NOT BE USED FOR
ANY OTHER PURPOSES. ALL THE LABOUR SHALL BE MADE
BEEN GIVEN. 198
SHALL BE USED. 198
53.6 THE CONTRACTORS SUPERVISOR SHALL WATCH THE REQUIRED
TIME FOR THE FIRING OF THE FUSES AND SHALL SEE THAT ALL THE
WORKMEN ARE UNDER SAFE SHELTERS IN GOOD TIME. 199
THE PURPOSE. 199
54.2 THE DETONATORS SHALL BE CHECKED BEFORE USE. FOR BLAST
IN SERIES, ONLY DETONATORS OF THE SAME MANUFACTURE AND OF
THE SAME GROUP OF ELECTRICAL RESISTANCE SHALL BE USED.
SUCH OF THE ELECTRICAL LINES AS COULD CONSTITUTE DANGER
FOR WORK OF CHARGING SHALL BE REMOVED FROM THE SITE. THE
FIRING CABLES SHALL HAVE A PROPER, INSULATING COVER SO AS
TO AVOID SHORT CIRCUITING DUE TO CONTACT WITH WATER,
METALLIC PARTS OF ROCK ETC., 199
THERE WITH. 200
55.6 THE NAMES OF THE DAY AND NIGHT SHIFT SUPERVISORS OF THE
CONTRACTOR MUST BE NOTED DAILY IN THE CONTRACTORS
DISPOSED OF. 200
200
TAKEN. 200
OCCUR:- 201
61.1 RECORDS OF FIELD TEST DATA RESULTS SHOULD BE PRESENTED
IN THE FORM OF STATISTICAL ANALYSIS SHEETS AND SUMMARY
SHEETS IN ORDER TO PROVIDE CONTROL REQUIRED FOR
SPECIFICATIONS. 202
62 Turfing 203
4.18.2 204
4.18.2.1 Materials : 204
respectively. 204
S. No. 204
Characteristics 204
Unit 204
Value 204
i. 204
Tensil Strength 204
N/mm 204
11.6 min 204
ii. 204
% 204
300 min 204
iii. 204
Tear Resistance 204
N/mm 204
4.9 min 204
iv. 204
N/mm 204
2.46 min 204
v. 204
(a) 204
Tensil Strength 204
N/mm 204
10.5 min 204
(b) 204
% 204
250 min 204
vi. 204
(a) 205
Weight Increase 205
% 205
0.25 max. 205
(b) 205
Weight Decrease 205
% 205
0.10 max. 205
(c) 205
Hardness Change 205
Point 205
5 205
vii. 205
(a) 205
Weight Increase 205
% 205
0.40 max. 205
(b) 205
Weight Decrease 205
% 205
0.30 max. 205
(c) 205
% 205
1 205
(a) Density 1015 - 1065 Kg/m 205
PLATE : 1/CH-4* 205
interface. 205
joint. 206
PLATE : 4/CH-4*. 206
4.18.2.3 Jointing : 206
in IS:456-1978. 206
choosen. 207
desired speed. 207
Type of Test 208
Method of Test 208
Density 208
1.04 to 1.10 g/ml 208
PH Value 208
9.5 to 12 208
Viscosity 208
1.4 to 10 N/m, 208
(14 to 100 dya/cm) 208
Ys = 1.0 + 0.006 C 208
carried out. 208
(i) Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase viscosity
(ii) To remove fine silty solids and clay solids from the slurry flocoulants may be used. Vinyl
(iii) Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
(iv) Stability of slurry filled trenches should be worked out as per procedure described under
Appendix-II. 209
operation. 209
4)*. 210
panels. 210
primary panels. 210
(i) This method is used with rotary or percussion type rigs where drilling fluid (bentonite
(ii) The trench panel may be excavated in the ground by making over lapping bore holes with
bentonite slurry jet in combination with percussion and to and from rotary motion of jetting
pipe having a suitable cutter at the tip. 210
(iii) A special semi-circular cutter shall be used for providing appropriate shale at each panel
(iv) The operation of filling bentonite slurry in the trench shall be as described under para
(v) For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used. 211
(vi) This method is suitable for shallow depths and bringing up lighter cuttings. 211
(i) The reverse circulation method with in percussion shall be used to make trench panel in
manner. 211
(ii) High capacity pumps shall be used to suck the loosened soil in this slurry filled trench.
(iii) This method is suitable for greater depths and to bring up heavier cuttings. 211
(i) Solids in the settling tank shall be removed and kept along side. When the grabs or Kelly
(ii) For overcoming any underground obstruction or boring through all types of rocks such as
soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use of chisel grab
(iii) The width of cutting tool will be more or less as that of the disphragm wall. The trench
(iv) Boring shall be continued in the manners described above upto foundation level. Depth
of the trench will be determined by taking sounding. Diaphragrm wall shall penetrate about
0.6 metre into sound rock which shall be ensured by careful soundings taken and certified by
211
(v) Before removing the equipment, the bottom of the trench will be cleaned by reverse
(vi) Form tubes will be lowered at each end of primary panels in case of construction by
212
(i) Reinforcement in each panel should form a cage and the vertical ends of the cage should
(ii) The length of the cage will be governed mostly by the depth of panel and the length of
(iii) The gap in the main bars should not be staggered more than 50 cms to avoid difficulties
(iv) Suitable gape in the reinforcement cage will be provided for accommodating the tremie
(v) The reinforcement cage will be suitably strengthened at regulat intervals and generally the
bars will be tack welded. 212
(vi) In case the reinforcement cage is heavy, angle iron frames may be utilized. 212
(vii) The concrete cover for reinforcement shall be maintained by the use of spacers. Circular
roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix shall be provided at
suitable intervals preferably one block per square metre on both sides of the cage and suitably
staggered. The diameter of spacer block will depend upon clear cover required for the
reinforcement. 212
cover. 213
(viii) The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
(ix) The reinforcement cage should be kept hanging over pre-trench to provide a minimum
(x) Rock grout pipes shall be fixed with suitable spacer bars at specified intervals. 213
213
than 0.6. 213
S. No. 214
Location 214
Classification 214
Slump 214
1 214
M-20 214
150 to 200mm 214
2 214
M-20 214
50 to 75mm 214
214
214
Chapter 7 & 16. 214
(i) The concreting shall be done by tremie pipes and the tremie diameter will be minimum
(ii) Prior to placing concrete in any panel it should be ensured that heavily contaminated
4.19.7.3.11 For Cap Work : 215
(i) Before placing cap concrete extra concrete already placed ruing concreting of the
(ii) After the surface has been cleaned and dampened as specified, surface construction joints
216
cracking. 216
compound. 216
reinforcement. 217
equipment. 217
permeability. 217
the panel. 218
APPENDIX - I 220
1 220
2 220
3 220
4 220
5 220
6 220
7 220
8 220
Cohesive 220
0-25 220
D=95 220
D=98 220
-2 to +2 220
D=98 220
D=100 220
2 to 0 220
Soil 220
26-50 220
D=92.5 220
D=95 220
D=95 220
D=98 220
(Note 2) 220
More than 50 220
(Note-1) 220
D=90 220
D=93 220
D=93 220
D=95 220
Cohesion 220
Less soils 220
Fine sands with 220
0-25 220
Dd=75 220
Dd=90 220
Dd=75 220
D=90 220
0-25 220
Dd=70 220
Dd=85 220
Dd=70 220
D=85 220
0-100 gravels 220
Dd=65 220
Dd=80 220
Dd=65 220
D=80 220
Wo-Wt 220
weight of soil. 220
D. 220
Dd 220
NOTES : 220
prepared. 220
Appendix II 48
(Para 4.19 A (VI) 48
Where 48
48
49
49
For sandy 49
Where 49
49
Ka = 49
= Y sat Yw 49
the water level. 49
Volume III 59
Section - 4 59
Excavation 59
contents 59
139
1 General 139
2. Standards 139
3. Scope: 140
4. Planning: 140
DRAWINGS. 140
CHARGE. 141
THE WORK. 141
TIME. 141
SURFACE. 142
THE PROJECT. 142
142
TRENCH: 142
143
62.15 PUDDLE: 143
REJECTED. 143
143
62.20 THE TOP OF PUDDLE SHALL BE KEPT AS LEVEL AND UNIFORM
AS POSSIBLE AND SHALL ON NO ACCOUNT BE ALLOWED TO DRY. IF
THE SURFACE CRACKS AT ANY TIME IT SHALL BE DUG UP AND
PUDDLE REMADE. 143
62.21 VERTICAL JOINTS ACROSS THE PUDDLE WALL AND STEPS TO
ITS SIDE SHALL BE AVOIDED. ALL JOINTS SHALL BE MADE BY LONG
MENS HELS. 143
62.24 THE PUDDLE FILLING SHALL NOT BE DONE IN STANDING
WATER. WATER LEVEL IN TRENCH SHALL BE KEPT BELOW THE
WORKING LEVEL BY MEANS OF PUMPS, IF REQUIRED. 144
WAY. 144
62.28 THIS FILLING IS TO BE CARRIED UP WITH THE PUDDLE WALL
TO A HEIGHT OF 0.6 M ABOVE GROUND LEVEL AND JOINED WITH
THE HEARTING. 144
MEASUREMENTS. 144
66 EXCAVATION 146
69 DEWATERING 148
WORKS. 148
OTHER PROPERTY. 148
CHARGE. 151
75.1 SCOPE: 151
CURVED. 155
77 Material 155
EMBANKMENTS. 155
CLAUSE 6.4 OF I.S. 4701-1982. 156
COST. 156
COMPACTION. 156
DRUM. 157
(VI) ROLLER WEIGHT :- THE WEIGHT OF THE ROLLER WHEN FULLY
79.3 ROLLING :- 158
RAIN GULLIES. 163
82 DOWEL BANKS: 163
163
THE TOP. 164
86 Toe Drains : 164
164
88 Side drains: 165
165
90 PROTECTION: 165
92.2 PLACING 167
(TEN) PERCENT. 168
168
93.2 PLACING : 168
95 ROCK TOE 169
CHARGE. 169
THE FILL. 169
96 BORROW AREAS 172
CONDITION. 172
99 BORROW PITS 173
SHALL BE TAKEN. 173
DETAILS:- 173
104.1 THE PRIMERS SHALL NOT BE PREPARED NEAR OPEN FLAMES
OR FIRE. THE WORK OF PREPARATION OF PRIMERS SHALL ALWAYS
BE ENTRUSTED TO THE SAME PERSONAL. PRIMERS SHALL BE USED
AS EARLY AS POSSIBLE AFTER THEY ARE READY. 175
106 BLASTING 175
106.3 A WHISTLE/BIGGLE WITH DISTINCTIVE NOTE SHALL BE USED
TO GIVE THE WARNING SIGNALS. THE BIGGLE SHALL NOT BE USED
FOR ANY OTHER PURPOSES. ALL THE LABOUR SHALL BE MADE
BEEN GIVEN. 175
SHALL BE USED. 175
106.6 THE CONTRACTORS SUPERVISOR SHALL WATCH THE
REQUIRED TIME FOR THE FIRING OF THE FUSES AND SHALL SEE
THAT ALL THE WORKMEN ARE UNDER SAFE SHELTERS IN GOOD
TIME. 176
THE PURPOSE. 176
107.2 THE DETONATORS SHALL BE CHECKED BEFORE USE. FOR
BLAST IN SERIES, ONLY DETONATORS OF THE SAME MANUFACTURE
AND OF THE SAME GROUP OF ELECTRICAL RESISTANCE SHALL BE
USED. SUCH OF THE ELECTRICAL LINES AS COULD CONSTITUTE
DANGER FOR WORK OF CHARGING SHALL BE REMOVED FROM THE
SITE. THE FIRING CABLES SHALL HAVE A PROPER, INSULATING
COVER SO AS TO AVOID SHORT CIRCUITING DUE TO CONTACT WITH
WATER, METALLIC PARTS OF ROCK ETC., 176
THERE WITH. 177
108.6 THE NAMES OF THE DAY AND NIGHT SHIFT SUPERVISORS OF
THE CONTRACTOR MUST BE NOTED DAILY IN THE CONTRACTORS
DISPOSED OF. 177
177
TAKEN. 177
OCCUR:- 178
114.1 RECORDS OF FIELD TEST DATA RESULTS SHOULD BE
PRESENTED IN THE FORM OF STATISTICAL ANALYSIS SHEETS AND
SUMMARY SHEETS IN ORDER TO PROVIDE CONTROL REQUIRED FOR
SPECIFICATIONS. 179
115 Turfing 180
4.18.2 181
4.18.2.1 Materials : 181
respectively. 181
S. No. 181
Characteristics 181
Unit 181
Value 181
i. 181
Tensil Strength 181
N/mm 181
11.6 min 181
ii. 181
% 181
300 min 181
iii. 181
Tear Resistance 181
N/mm 181
4.9 min 181
iv. 181
N/mm 181
2.46 min 181
v. 181
(a) 181
Tensil Strength 181
N/mm 181
10.5 min 181
(b) 181
% 181
250 min 181
vi. 181
(a) 182
Weight Increase 182
% 182
0.25 max. 182
(b) 182
Weight Decrease 182
% 182
0.10 max. 182
(c) 182
Hardness Change 182
Point 182
5 182
vii. 182
(a) 182
Weight Increase 182
% 182
0.40 max. 182
(b) 182
Weight Decrease 182
% 182
0.30 max. 182
(c) 182
% 182
1 182
(a) Density 1015 - 1065 Kg/m 182
PLATE : 1/CH-4* 182
interface. 182
joint. 183
PLATE : 4/CH-4*. 183
4.18.2.4 Jointing : 183
in IS:456-1978. 183
choosen. 184
desired speed. 184
Type of Test 185
Method of Test 185
Density 185
1.04 to 1.10 g/ml 185
PH Value 185
9.5 to 12 185
Viscosity 185
1.4 to 10 N/m, 185
(14 to 100 dya/cm) 185
Ys = 1.0 + 0.006 C 185
carried out. 185
(v) Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase viscosity
(vi) To remove fine silty solids and clay solids from the slurry flocoulants may be used. Vinyl
(vii) Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
(viii) Stability of slurry filled trenches should be worked out as per procedure described under
Appendix-II. 186
operation. 186
4)*. 187
panels. 187
primary panels. 187
(vii) This method is used with rotary or percussion type rigs where drilling fluid (bentonite
(viii) The trench panel may be excavated in the ground by making over lapping bore holes
with bentonite slurry jet in combination with percussion and to and from rotary motion of
jetting pipe having a suitable cutter at the tip. 187
(ix) A special semi-circular cutter shall be used for providing appropriate shale at each panel
(x) The operation of filling bentonite slurry in the trench shall be as described under para
(xi) For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used. 188
(xii) This method is suitable for shallow depths and bringing up lighter cuttings. 188
(iv) The reverse circulation method with in percussion shall be used to make trench panel in
manner. 188
(v) High capacity pumps shall be used to suck the loosened soil in this slurry filled trench.
(vi) This method is suitable for greater depths and to bring up heavier cuttings. 188
(vii) Solids in the settling tank shall be removed and kept along side. When the grabs or Kelly
(viii) For overcoming any underground obstruction or boring through all types of rocks such
as soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use of chisel grab
(ix) The width of cutting tool will be more or less as that of the disphragm wall. The trench
(x) Boring shall be continued in the manners described above upto foundation level. Depth of
the trench will be determined by taking sounding. Diaphragrm wall shall penetrate about 0.6
metre into sound rock which shall be ensured by careful soundings taken and certified by
188
(xi) Before removing the equipment, the bottom of the trench will be cleaned by reverse
(xii) Form tubes will be lowered at each end of primary panels in case of construction by
189
(xi) Reinforcement in each panel should form a cage and the vertical ends of the cage should
(xii) The length of the cage will be governed mostly by the depth of panel and the length of
(xiii) The gap in the main bars should not be staggered more than 50 cms to avoid difficulties
(xiv) Suitable gape in the reinforcement cage will be provided for accommodating the tremie
(xv) The reinforcement cage will be suitably strengthened at regulat intervals and generally
the bars will be tack welded. 189
(xvi) In case the reinforcement cage is heavy, angle iron frames may be utilized. 189
(xvii) The concrete cover for reinforcement shall be maintained by the use of spacers.
Circular roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix shall be
provided at suitable intervals preferably one block per square metre on both sides of the cage
and suitably staggered. The diameter of spacer block will depend upon clear cover required
for the reinforcement. 189
cover. 190
(xviii) The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
(xix) The reinforcement cage should be kept hanging over pre-trench to provide a minimum
(xx) Rock grout pipes shall be fixed with suitable spacer bars at specified intervals. 190
190
than 0.6. 190
S. No. 191
Location 191
Classification 191
Slump 191
1 191
M-20 191
150 to 200mm 191
2 191
M-20 191
50 to 75mm 191
191
191
Chapter 7 & 16. 191
(iii) The concreting shall be done by tremie pipes and the tremie diameter will be minimum
(iv) Prior to placing concrete in any panel it should be ensured that heavily contaminated
4.19.7.3.12 For Cap Work : 192
(iii) Before placing cap concrete extra concrete already placed ruing concreting of the
(iv) After the surface has been cleaned and dampened as specified, surface construction joints
193
cracking. 193
compound. 193
reinforcement. 194
equipment. 194
permeability. 194
the panel. 195
APPENDIX - I 197
1 197
2 197
3 197
4 197
5 197
6 197
7 197
8 197
Cohesive 197
0-25 197
D=95 197
D=98 197
-2 to +2 197
D=98 197
D=100 197
2 to 0 197
Soil 197
26-50 197
D=92.5 197
D=95 197
D=95 197
D=98 197
(Note 2) 197
More than 50 197
(Note-1) 197
D=90 197
D=93 197
D=93 197
D=95 197
Cohesion 197
Less soils 197
Fine sands with 197
0-25 197
Dd=75 197
Dd=90 197
Dd=75 197
D=90 197
0-25 197
Dd=70 197
Dd=85 197
Dd=70 197
D=85 197
0-100 gravels 197
Dd=65 197
Dd=80 197
Dd=65 197
D=80 197
Wo-Wt 197
weight of soil. 197
D. 197
Dd 197
NOTES : 197
prepared. 197
Appendix II 147
(Para 4.19 A (VI) 147
Where 147
147
148
148
For sandy 148
Where 148
148
Ka = 148
= Y sat Yw 148
the water level. 148
Volume III 158
Section - 6 158
Gates 158
INDEX 158
Section - 7 : Gates 163
1 General 163
1 types of Gates 163
5 SCOPE 165
6 General specifications for workmanship, welding / riveting, finishing and painting of steel
structures (Gates) 165
7.1 STRAIGHTENING 165
7.2 CUTTING 165
7.3 HOLING 166
7.4 RIVETING 166
7.5 BOLTING 167
7.6 WELDING 167
7.7 CASTING AND FORGINGS 168
7.8 TOLERANCES 168
7.8.1 FITS AND TOLERANCES OF VARIOUS COMPONENTS AND PARTS
SHALL BE ACCOUNTING TO THE BEST SHOP PRACTICE KEEPING IN
VIEW THE FUNCTIONAL REQUIREMENT OF THE PARTS.
TOLERANCES AND ALLOWANCES OF THE MATCHING PARTS DURING
MANUFACTURING AND ERECTION HAVE BEEN RECOMMENDED IN
RELEVANT PARAS AND ALSO AT APPENDIX D AND E. 168
7.9 PAINTING 168
7.10 SURFACE PREPARATION 169
7.11 SPRAYING 169
8 Fixed Wheel and Slide gates Manufactures. 169
8.1 MATERIALS 169
8.2 WELDING 170
8.3 MANUFACTURING TOLERANCES 170
9 Shop Assembly & testing for Gates and Embedded Parts 171
9.1 THE MANUFACTURING TOLERANCE SHALL INCLUDE SURFACE
FINISH TOLERANCE (WHEN SPECIFIED) AS SPECIFIED UNDER IS: 696-
1960. 171
9.2 SHOP ASSEMBLY OF EMBEDDED PARTS SHALL NECESSARILY BE
DONE FOR HIGH HEAD GATES. FOR MEDIUM AND LOW HEAD GATES,
IT SHALL BE DONE, IF REQUIRED. 171
9.3 GATE SHALL BE ASSEMBLED COMPLETE WITH SEALS, WHEELS
AND GUIDES EITHER IN HORIZONTAL OR VERTICAL POSITION FOR
PROPER ALIGNMENT AND INSPECTION. 171
9.4 SIDE GUIDE BLOCKS AND ROLLERS MAY BE SHIMMED, IF
NECESSARY, TO MAINTAIN REQUIRED TOLERANCE. 171
9.5 VARIATION IN THE DISTANCE BETWEEN AXES OF EACH PAN OF
SEAL SEATS, WHEEL TRACKS OR SIDE GUIDE TRACKS FOR ANY GATE
9.6 EMBEDDED PARTS SHALL BE SO ASSEMBLED THAT THE
DEVIATION OF THEIR AXES FROM THE RESPECTIVE ALIGNMENT
9.7 ALL THE WHEEL OF THE GATE SHALL ROTATED SEVERAL TIMES
TO ENSURE FREE MOVEMENT. 172
9.8 THE MARKETING AND MATCH MARKING SHALL BE MADE
BEFORE ACTUAL DISPATCH OF THE COMPONENTS. 172
10 Painting 172
11 Fixed Wheel and Slide Gates Rope Drum Hoist 172
11.1 MATERIAL 172
11.1.1. ALL MATERIALS AND COMPONENTS USED IN THE
MANUFACTURE OR ASSEMBLY OF THE HOIST SHALL CONFORM TO
THE LATEST INDIAN STANDARDS. THE DUTY OF THE HOIST SHALL BE
SPECIFIED BY THE PURCHASER. THE PURCHASER HAS TO SPECIFY
THE QUALITY AND STANDARD OF SUCH MATERIAL AND
COMPONENTS. 172
11.1.2. ALL MATERIALS USED SHALL BE OF TESTED QUALITY.
ORIGINAL MANUFACTURES TEST CERTIFICATES FOR BOUGHT OUT
ITEMS LIKE THE CASTINGS, FORGINGS, WORM REDUCERS, WIRE
ROPES, MOTOR AND BRAKES ETC. SHALL BE FURNISHED BY THE
MANUFACTURER OF THE HOIST ON DEMAND. 172
11.1.3. ALL CASTING AND FORGINGS USED SHALL CONFORM TO
RELEVANT INDIAN STANDARDS, ANY REPAIR TO CASTINGS, IF
NECESSARY, SHALL BE CARRIED OUT IN ACCORDANCE WITH THE
RELEVANT INDIAN STANDARDS. FORGINGS SHALL FREE FROM ANY
DEFECT, TOOL MARK AND SHALL HAVE SMOOTH SURFACES.
FORGINGS SHALL BE HEAT TREATED WHERE DEEMED NECESSARY.
172
11.2 HOIST UNIT OF GATES AND CHECKING. 172
11.3 DRIVE UNIT GEAR BOX 173
11.4 HOIST MOTOR 173
11.5 BRAKE 173
IT SHALL BE OF APPROVED MANUFACTURE CAPACITY. IT SHALL BE
CHECKED FOR ALIGNMENT AND TIGHTNESS. BRAKE LINERS SHALL
BE OF APPROVED MANUFACTURE AND SHALL CONFORM TO THE
APPROVED SPECIFICATIONS. 173
11.6 BASE FRAME 173
11.7 HOIST DRUM 173
11.8 REDUCTION UNIT GEAR BOX 173
11.9 LINE SHAFT 173
11.10 LIMIT SWITCH 174
11.11 DIAL INDICATORS 174
11.12 HOIST ROPE 174
11.13 ROPE FIXTURES 174
11.14 ARRANGEMENT FOR MANUAL OPERATION 174
11.15 CONTROL PANEL 174
12 fixed wheel and slide gate erection 175
12.1 GENERAL INSPECTION : IT SHALL BE ASCERTAINED THAT THE
GATE PARTS RECEIVED AT THE SITE OF ERECTION HAVE BEEN
MANUFACTURED/FABRICATED ACCORDING TO THE DRAWINGS AND
HAVE NECESSARY MARKINGS OF SHOP INSPECTION. IT SHALL BE
ENSURED THAT ALL EXPOSED SURFACES OF EMBEDDED PARTS ARE
PROTECTED BY PAINTING, GREASING ETC. THE SURFACES OF
EMBEDDED PARTS IN CONTACT WITH CONCRETE SHALL BE FREE
FROM GREASES, PAINT ETC. FOR BETTER BONDING WITH
CONCRETE. A COATING OF CEMENT WASH/CEMENT LATEX MAY BE
GIVEN, IF NECESSARY. 175
12.2 DIMENSIONAL DIFFERENCES, IF ANY, SHALL BE ACCOUNTED
FOR BEFORE ERECTION AND THE DRAWINGS CORRECTED
ACCORDINGLY FOR ERECTION. CRITICAL DIMENSIONS SHALL BE
WORKED OUT FROM THE DRAWINGS. 175
12.3 THE REFERENCE LINES, CENTER LINE OF OPENINGS AND
LEVELS RELATIONS TO THE COMPLETED CIVIL STRUCTURE SHALL
BE ESTABLISHED ON SITE SO AS TO FACILITATE ERECTION AT
PROPER LOCATIONS. 175
12.4 IT SHALL BE ENSURED THAT THE VARIOUS COMPONENTS OF
THE HOISTING ARRANGEMENT SUCH AS MOTORS, REDUCTION GEAR
ASSEMBLY, SWITCHES, WIRE ROPES AND SHAFTING ARE PROVIDED
ACCORDING TO THE SPECIFICATIONS. 175
13 Inspection of block outs 175
13.1 CONCRETING BEHIND THE GATE GROOVE MAY BE DONE IN ONE
OR TWO STAGES. IF DONE IN TWO STAGES, IT SHALL BE ENSURED
THAT CORRECT BLOCK OUTS ARE KEPT FOR ACCOMMODATING THE
GATE PARTS AS MANUFACTURED ACCORDING TO THE
SPECIFICATIONS/DRAWINGS. IT IS ALSO TO BE ENSURED THAT THE
REQUIRED DOWEL BARS HAVING ADEQUATE LENGTHS ARE LEFT
OUT IN THE BLOCK OUTS. THE ENTIRE BLOCK-OUT IS ROUGHENED
TO ENSURE PROPER AND NECESSARY BONDAGE TO THE SECOND
STAGE CONCRETING. 175
14 Inspection of embedded parts 175
14.1 IT SHALL BE ENSURED THAT THE SILL BEAM IS CORRECTLY
POSITIONED BOTH IN LEVEL AND LOCATION. ALL THE NUTS AND
BOLTS OF ANCHORAGES OF SILL BEAM SHALL BE TIGHTENED SO AS
TO PREVENT DISLOCATION DURING AND AFTER CONCRETING. 175
14.2 THE EMBEDDED PARTS THAT IS TRACK PLATES, GUIDES, SEAL
SEATS, GATE GROOVE LINING ETC. SHALL BE CHECKED WHEN ALL
PARTS ARE IN FINAL POSITION AT LEAST UPTO DOUBLE THE GATE
HEIGHT, IN ONE OPERATION. THE CHECK SHALL BE CARRIED OUT
BOTH IN LOCATION AND LEVELS, WITH RESPECT TO SILL BEAM
ALREADY ESTABLISHED IN THE POSITION. EACH PART SHALL BE
CHECKED FIRST INDIVIDUALLY AND THEREAFTER RELATIVELY
WITH THE OTHER PARTS. IT SHALL BE ENSURED THAT THE
MANUFACTURING TOLERANCES, AS SPECIFIED ARE CONSIDERED
WHILE CREATING THESE PARTS AND EVEN AFTER ACCOUNTING
THESE TOLERANCES, THE ERECTION WORK IS CARRIED OUT
ACCORDING TO THE PROVISIONS IN DESIGN AND DRAWINGS. 175
14.3 THE TRACK PLATES AND SEAL SEATS SHALL BE ABSOLUTELY IN
TRUE ALIGNMENT. THE ALIGNMENT SHALL BE CHECKED BY MEANS
OF PLUMP BOB AND FEELER GAUGE OR MICROMETER, PREFERABLY
AT EACH 300 MM INTERVALS FROM BOTTOM TO TOP SIDE OF THE
GATE OPENING. ALTERNATIVELY, DIAGONAL CHECKING OR ANY
OTHER SATISFACTORY METHOD MAY BE ADOPTED FOR CHECKING
THE ALIGNMENTS. (THIS CHECK REQUIRES SPECIAL ATTENTION).
175
14.4 AFTER HAVING CHECKED THE TRACK PLATES AND SEAL SEATS
ON BOTH SIDES, IT SHALL BE ENSURED THAT THEY ARE IN THEIR
RESPECTIVE PLANES. IT SHALL ALSO BE CHECKED THAT TOP SEAL
SEAT, WHEREVER PROVIDED, SHALL ALSO BE IN THE REQUIRED
PLANE. (THIS CHECK REQUIRES SPECIAL ATTENTION). 176
14.5 GUIDE AND COUNTER GUIDES, IF PROVIDED, SHALL BE
CHECKED FOR TRUE LOCATION AND ALIGNMENTS. 176
14.6 GROOVE LINERS AND CORNER PROTECTION ANGLES, WHEN
PROVIDED, SHALL BE CHECKED FOR TRUE LOCATION AND
ALIGNMENT. 176
14.7 FOLLOWING CRITICAL DIMENSIONS SHALL BE CHECKED AT
INTERVALS OF 300 MM FROM BOTTOM TO DOUBLE THE GATE
HEIGHT. (SEE FIG. A & B). 176
14.8 ECCENTRICITY OR SOME SUCH ARRANGEMENT, IF PROVIDED TO
A GATE FOR ITS FINE ADJUSTMENT IN THE GROOVE, SHALL NOT BE
ACCOUNTED FOR WHILE ERECTING EMBEDDED PARTS. 176
14.9 ANCHORAGES SHALL BE FASTENED OR WELDED RIGIDLY, AFTER
FINAL ADJUSTMENT OF EMBEDDED PARTS SO AS TO PREVENT
DISLOCATION OF PARTS WHILE POURING SECOND STAGE
CONCRETE. 176
14.10 THE GATE GROOVE CONCRETING SHALL BE DONE ONLY AFTER
SATISFYING FOR ALL THESE DETAILS AND KEEPING PROPER
RECORDS THEREOF. RECHECKING OF EMBEDDED PARTS SHALL BE
DONE AFTER CONCRETING 176
15 Inspection of the gate at site of erection 176
15.1 THE GATE WHICH IS RECEIVED AT SITE DULY INSPECTED IN
WORKSHOP SHALL BE RE-INSPECTED AT SITE BEFORE LOWERING
INTO THE GATE GROOVE. OVERALL DIMENSIONS SHALL BE
CHECKED TO ENSURE THAT THE GATE FITS CORRECTLY IN THE
GATE GROOVE. IT SHALL ALSO BE ENSURED, BEFORE LOWERING,
THAT THE GATE HAS BEEN PAINTED ACCORDING TO
SPECIFICATIONS. 176
15.2 FOLLOWING CRITICAL DIMENSIONS SHALL BE CHECKED AT AN
INTERVAL OF 300 MM, WHEREVER APPLICABLE. 176
15.3 THE SEALS & SEAL BASES SHALL BE CHECKED TO ENSURE THAT
THEY ARE COPLANAR. ALL THE WHEELS SHALL BE ADJUSTED TO
ENSURE THAT WHEEL TREADS ARE IN THEIR PROPER ALIGNMENT.
THE WHEEL PINS SHALL BE LOCKED AFTER MAKING THE
ADJUSTMENT. 177
15.4 THE SEAL BOLTS SHALL BE TIGHTENED ADEQUATELY AND
UNIFORMLY. 177
15.5 THE GATE WHEELS SHALL BE CHECKED FOR FREE ROTATION
TO ENSURE THAT THEY ARE NOT JAMMED DURING
TRANSPORT/HANDLING. TO CHECK EFFECTIVENESS OF THE SEAL,
ACTUAL SEAL INTERFERENCE SHALL BE COMPARED WITH THAT
PROVIDED IN DESIGN, BECAUSE ON THIS ASPECT WILL DEPEND TO A
GREAT EXTENT THE EFFICIENCY OF SEALING ARRANGEMENT AND
EASY OPERATION OF GATE. 177
15.6 IN CASE OF COUNTER WEIGHTED GATE OR GATES WITH
BALLAST, IT SHALL BE ENSURED THAT CORRECT WEIGHT IS ADDED.
177
INSTALLATION 177

INSTALLATION 177
16.3 IT SHALL BE ENSURED THAT THE GATE GROOVE, SILL AND THE
EMBEDDED PARTS ARE THOROUGHLY CLEANED AND NO FOREIGN
MATERIAL IS PRESENT IN THE GROOVE. BEFORE LOWERING THE
GATE IT SHALL BE PERFECTLY ENSURED THAT THE GATE GROOVE
IS FREE FROM ANY OBSTRUCTION. 178
16.4 THE HOIST PROVIDED FOR THE OPERATION OF THE GATE SHALL
FIRST BE ALLOWED TO RUN UNDER NO LOAD (WITHOUT
CONNECTION TO GATE) TO ENSURE ITS SATISFACTORY WORKING
AND THAT THERE IS NO UNDUE TEMPERATURE RISE DUE TO
FRICTION IN THE ROTATING / MOVING COMPONENTS. 178
17.1 THE GATE SHALL BE TESTED FIRST IN THE DRY CONDITION
WITH THE HOIST DULY CONNECTED TO THE GATES. THE GATE
SHALL BE MOVED UP, AND DOWN IN THE GROOVE TO ENSURE ITS
SMOOTH WORKING AND THAT THERE IS NO OBSTRUCTION AND NO
UNDUE EFFORT REQUIRED FOR ITS OPERATION. IN CASE THE GATE
IS NOT GOING DOWN OF ITS OWN WEIGHT OR FOUND TIGHT IN
SOME POSITION,, REASONS SHALL BE INVESTIGATED AND
REMEDIED INSTEAD OF FORCING THE GATE DOWN. WHILE TESTING
THE GATE IN DRY CONDITION THE RUBBER SEALS SHOULD BE KEPT
WET BY WATER JETTING OR OTHER SUITABLE METHODS TO AVOID
DAMAGE AND TO WEAR TO THE SEALS. 178
17.2 THE TESTING OF THE GATE SEALS IN DRY CONDITIONS SHALL
BE DONE BY VIEWING THE CONTACT SURFACE AGAINST A TIGHT
SOURCE. IT SHALL BE ENSURED THAT THE TOP SEAL RIDES
SMOOTHLY OVER THE TOP SEAL SEAT AT THE TIME OF ITS
APPROACH TO THE LATTER. 178
17.3 IN CASE OF RUBBER SEALS, WATER SHOULD BE POURED OVER
THE SEALS SO THAT THERE SHALL NOT BE DRY FRICTION OF THE
SEALS. IN CASE OF METAL CONTACT OIL OR GREASE IS TO BE USED.
NO GREASE OR LUBRICATION TO BE USED FOR RUBBER SEALS. 178
17.4 THERE SHALL BE NO NOISE OF FRICTION, ANY OTHER NOISE, NO
SIGNS OF EXCESSIVE FRICTION, NO JERKY PERFORMANCES, NO DUG
IN ANY POSITION, NO DANGLING OF THE GATE, NO TWIST IN THE
RUBBER SEALS, TOP SEAL DOES NOT LEAVE ITS PLANE AND THE
RUBBER SEALS ARE NOT OVERPRESSED. 178
17.5 THE GATE, AFTER LOWERING, IS TO BE KEPT RESTING ON THE
SILL BEAM, I.E. IN CLOSE POSITION. THE LEAKAGE TEST MAY BE
TAKEN IN THIS POSITION BY USING SUITABLE PUMP WITH
NECESSARY ARRANGEMENT OF JETTING WATER AT 1.5 TIMES THE
DESIGNED PRESSURE ON SEALING POSITIONS FROM BOTTOM TO
TOP. PARTICULARLY ALL CORNER JOINTS AND OTHER JOINTS, IF
ANY ARE TO BE TESTED TO ENSURE PERFECT WORKING OF THE
GATE. 178
17.6 THE GATE SHALL BE FULLY OPENED OR CLOSED TO ENSURE
FULL OPENING AND SATISFACTORY CLOSING. THE TIME NEEDED
FOR 300 MM OPENING OR CLOSING OF THE GATE IS TO BE
RECORDED FOR CALIBRATION PURPOSES AT THE TIME OF ACTUAL
OPERATION. 178
17.7 IN ROPE DRUM HOISTS, IT IS TO BE TESTED THAT THE GATE IS
GOING DOWN OF ITS OWN WEIGHT, OR WITH BALLAST PROVIDED,
AND NO ADDITIONAL FORCE IS NEEDED. THE GATE IS ALSO GOING
DOWN OR COMING UP VERTICALLY AND THERE IS NO UNEVEN PULL
TO THE GATE. ALSO WINDING OF ROPE OVER THE DRUMS IS
UNIFORM AND IS ACCORDING TO THE DESIGN PROVISIONS. 178
17.8 THE TESTS AS PROVIDED FROM 16.1 TO 16.4 SHALL ALSO BE
PERFORMED AGAINST WATER LOAD WHEN CONDITIONS PERMIT. 178
17.9 THE TORQUE REQUIRED FOR MOVEMENT OF THE GATE ON
LOAD SHALL BE MEASURED AND CHECKED AGAINST DESIGNED
VALUE. 179
17.10 UNDER THE DESIGNED WATER HEAD CONDITIONS THE
LEAKAGE THROUGH THE GATE SHOULD NOT EXCEED 15
LITRES/MINUTE/METER LENGTH OF THE SEAL. 179
17.11 WHEN THE GATE IS OPERATED UNDER WATER LOAD, IT IS TO
BE ENSURED THAT THERE IS NO VIBRATION TO THE GATE, HOIST OR
CIVIL STRUCTURES AT VARIOUS GATE OPENINGS. 179
17.12 BY PASS ARRANGEMENT MADE FOR WATER AND AIR VENT,
WHEN PROVIDED SHALL BE CHECKED FOR PROPER WORKING OF
THE SYSTEM. 179
Volume - iii 180
SECTION 7 HYDRO-MECHANICAL EQUIPMENT. 180
INDEX 180
Article No. Description of Article 180
2.14 TONNE T 181
2.15 2.2.1 SPILLWAY 184
2.16 THE GANTRY WILL BE PROVIDED WITH AN ANCILLARY JIB
HOIST WITH A SUITABLE GRAPPLING DEVICE AND HOIST TO
FACILITATE REMOVAL OF LOGS AND HEAVY DEBRIS FROM
RESERVOIR. EXTENSION OF TRACK SHALL BE SUITABLE TO HANDLE
THE UNITS FROM STORAGE BAY ALSO. THE POWER SUPPLY TO
CRANE SHALL BE SUITABLY PLANNED FROM CENTRAL LOCATION OF
ITS TRAVEL AND A SUITABLE TRENCH ALONG THE RAILS SHALL BE
PROVIDED FOR CABLE MOVEMENT. THE BIDDER MAY SUGGEST ANY
OTHER SUITABLE ARRANGEMENT FOR POWER SUPPLY TO THE
TRAVELING GANTRY. 187
17.15 GENERAL INSPECTION 224
17.16 INSPECTION OF PIER ANCHORAGE 225
17.17 INSPECTION OF SILL BEAM 227
17.18 INSPECTION OF WALL PLATES (SIDE SEAL SEATS) 228
17.19 INSPECTION OF GATES 228
17.20 TESTING 229
17.20.1 THE GATE SHALL BE TESTED IN A DRY CONDITION WITH
HOIST DULY CONNECTED FOR ITS SMOOTH WORKING. THE GATE
SHALL BE FULLY CLOSED OR FULLY OPENED AND IT SHALL BE
ENSURED THAT THERE IS NO OBSTRUCTION AND NO UNDUE EFFORT
REQUIRED FOR ITS OPERATION. IF THE GATE IS NOT GOING DOWN
OF ITS OWN WEIGHT OR FOUND TIGHT IN SOME POSITION, REASONS
SHALL BE INVESTIGATED AND REMEDIED INSTEAD OF FORCING THE
GATE DOWN. WHILE TESTING THE GATE IN DRY CONDITION, THE
RUBBER SEALS SHOULD BE KEPT WET BY WATER JETTING OR
SUITABLE METHODS TO AVOID DAMAGE TO THE SEALS. 229
17.20.2 THE TESTING OF GATE SEALS SHALL BE CHECKED IN THE
SAME MANNER AS EXPLAINED IN CASE OF FIXED WHEEL OR SLIDE
GATES. 230
17.20.3 UNDER THE DESIGNED WATER HEAD CONDITIONS, THE
LEAKAGE THROUGH THE GATE SHALL NOT EXCEED 15
LITRES/MINUTE/METRE LENGTH OF THE SEAL. 230
17.20.4 THE GATE IS TO BE KEPT ON THE SILL BEAM, THAT IS IN
CLOSED POSITION. THE LEAKAGE TEST, (IF PROVIDED IN THE
TERMS OF EXECUTION OF WORK), CAN BE DONE IN THE POSITION
BY USING SUITABLE PUMP WITH NECESSARY ARRANGEMENTS OF
JETTING WATER AT 1.5 TIMES, THE DESIGNED PRESSURE, ON
SEALING POSITIONS FROM BOTTOM TO TOP. ALL JOINTS, IF ANY,
SHALL BE TESTED TO ENSURE PERFECT WORKING OF THE GATE. 230
17.20.5 THE ARRANGEMENT PROVIDED FOR PREVENTING THE
TRAVEL OF THE GATE OR HOIST BEYOND THE DESIGNED LIMIT ARE
TESTED AND CHECKED FOR PROPER WORKING. THE TIME
REQUIRED FOR 300 MM OPENING OR CLOSING OF THE GATE SHALL
BE RECORDED FOR CALIBRATION PURPOSES. 230
17.20.6 THE FULL LOAD CURRENT REQUIRED FOR THE MOVEMENT
OF THE GATE ON LOAD SHALL BE MEASURED AND CHECKED
AGAINST THE DESIGNED VALUE. 230
18 Single faced sluice gates (200 to 1200 mm size). 230
18.1 GENERAL 230
18.2 CLASSIFICATION 231
18.3 MATERIALS 231
18.4 MANUFACTURE & WORKMANSHIP 231
18.5 DOOR 232
18.6 FACE (DOOR) AND SEAT (FRAME) RINGS 232
18.7 GUIDES 233
18.8 SPINDLES 233
18.9 OPERATING MECHANISM 233
Volume III 298
Section - 9 298
Steel and iron work 298
INDEX 298
1. REFERENCES : 303
2. TERMINOLOGY 305
3.1 GENERAL : THIS WORK SHALL CONSIST OF FURNISHING AND
PLACING STEEL REINFORCEMENT OF THE SHAPE AND DIMENSIONS
INDICATED IN THE DRAWINGS AND AS SPECIFIED IN THESE
SPECIFICATIONS. 307
3.1.1 ALL STEEL USED FOR REINFORCEMENT SHALL BE CLEAN, FREE
FROM OIL, GREESE, PAINTS, DUST, MORTAR, SCALES, KINKS, RUST
OR ANY ROLLING DEFECTS OR BENDS OTHER THAN THOSE
REQUIRED AS PER DRAWINGS OR AS DIRECTED BY THE ENGINEER-
IN-CHARGE. 307
3.2 QUALITY OF REINFORCEMENT : 307
3.2.1 THE STEEL REINFORCEMENT SHALL BE, ANY OF THE
FOLLOWING, AS MAY BE SPECIFIED FOR THE JOB IN QUESTION. 307
3.3 STACKING AND STORAGE : STEEL REINFORCEMENT SHALL BE
STORED IN SUCH A WAY AS TO PREVENT DISTORTION,
DETERIORATION AND CORROSION. REINFORCING BARS SHALL NOT
BE LEFT IN DIRECT CONTACT WITH THE GROUND BUT THEY SHALL
BE STACKED ON TOP OF AN ARRANGEMENT OF TIMBER SLEEPERS
OR THE LIKE SUITABLE RACKS SHALL ALSO BE USED FOR STACKING
REINFORCEMENT IN TIERS. BARS OF DIFFERENT CLASSIFICATIONS,
SIZES AND LENGTHS SHALL BE STORES SEPARATELY TO FACILITATE
ISSUES IN SUCH SIZES AND LENGTHS AS TO MINIMIZE WASTAGE IN
CUTTING FROM STANDARD LENGTHS. 308
3.4 CUTTING AND BENDING : 308
3.4.1 BARS BENT DURING TRANSPORT OR HANDLING SHALL BE
STRAIGHTENED BEFORE BEING USED ON WORK; THEY SHALL NOT
BE HEATED TO FACILITATE BENDING. 308
3.4.2 REINFORCEMENT BARS SHALL BE OF THE SIZE PRESCRIBED
AND SHALL BE ACCURATELY CUT TO LENGTH AND BENT TO SHAPE
AND FIXED IN POSITION AS SHOWN ON THE DRAWINGS OR AS
DIRECTED BY THE ENGINEER-IN-CHARGE AND SHALL CONFORM TO
IS: 2502-1963 AS REVISED FORM TIME TO TIME. THE TOLERANCE FOR
BENDING AND CUTTING SHALL BE AS GIVEN IN TABLE 1. 308
3.6 BINDING AND PLACING : 311
3.7 SUBSTITUTION : 313
3.8 BUNDLING OF BARS : 313
3.8.1 THE BUNDLES OF BARS MAY BE PROVIDED IN THE ORIGINAL
DESIGN/DRAWING OR MAY BE NECESSITATED AS REQUIREMENT OF
SUBSTITUTION. THE BARS SHALL BE BUNDLED IN SHAPES OF
TRIANGULAR, SQUARE OR L-SHAPED TO ACT AS ONE UNIT OF
REINFORCEMENT. THE BAR DIAMETERS IN A BUNDLE SHALL BE
LIMITED TO TWO NEAREST SIZES. BUNDLED BARS SHALL BE TIED
TOGETHER TO ENSURE THE BARS REMAINING TOGETHER. BARS
LARGER THAN 36MM DIA SHALL NOT BE BUNDLED EXCEPT IN
COLUMNS. 313
3.8.2 CURTAILMENT : BARS IN A BUNDLE SHALL TERMINATE AT
DIFFERENT POINTS SPACED APART BY NOT LESS THAN 40 TIMES THE
BAR DIAMETER EXCEPT FOR BUNDLES STOPPING AT A SUPPORT. 313
4 STRUCTURAL STEEL & IRON WORK 314
4. MATERIALS 314
4.2 STEEL WORK IN SINGLE SECTION FIXED INDEPENDENTLY / WITH
CONNECTING PLATE 315
4.3 STEEL WORK IN BUILT UP SECTIONS (RIVETTED AND BOLTED) :
316
THE STEEL WORK IN BUILT UP SECTIONS (RIVETTED AND BOLTED),
SUCH AS IN TRUSSES, FRAMED WORK ETC. SHALL BE COVERED BY
THE PROVISIONS IN THESE PARAS. 316
All materials shall conform to section 5 except steel for prestressing.The prestressing steel
shall conform to either of the following:Plain hard drawn steel wire conforming to IS: 1785
(Part I) and IS: 1785 (Part II).Cold drawn indented wire conforming to IS: 6003High tensile
steel bar conforming to IS: 2090Uncoated stress relieved strands conforming to IS: 6006. 333
4 Anchorages 334
9. CUTTING 335
16. POST-TENSIONING 337
20. TENSIONING PROCEDURE 339
Volume III 251
Section - 10 251
Road Works 251
INDEX 251
Section - 10 : Road Work 256
1 Introduction 256
1.1 THE PERFORMANCE OF ROADS IS DIRECTLY LINKED WITH
QUALITY OF CONSTRUCTION. ROAD CONSTRUCTION TECHNIQUES
HAVE BEEN UPGRADED RECENTLY AND USE OF NEW AND
ALTERNATE MATERIALS HAVE BEEN ADVOCATED FOR ALL TYPE OF
ROADS. IT IS LOGICAL TO SEE THAT THE PURPOSE OF ROAD
CONSTRUCTION IS TO PROVIDE A FIRM, DURABLE AND EVEN
SURFACE OF THE PAVEMENT, WHICH COULD STAND THE STRESS
IMPARTED DUE TO TRAFFIC AND CLIMATIC CONDITIONS. THE ROAD
CONSTRUCTION ACTIVITY STARTS FOR EARTHWORK FOR
EMBANKMENT AND COMPLETES WITH HIGH QUALITY SURFACE
FINISH WITH BITUMINOUS OR CONCRETE CONSTRUCTION. EACH
COMPONENT OF THE ROAD HAS APPROPRIATE CONSTRUCTION
REQUIREMENTS AND SPECIFICATION TO BE FOLLOWED. THIS
CHAPTER DEALS WITH DETAILS OF CONSTRUCTION TECHNIQUES
AND SPECIFICATIONS FOR VARIOUS PAVEMENT COURSE INVOLVING
USE OF TRADITIONAL AS WELL AS ALTERNATE AND LOCALLY
AVAILABLE MATERIALS FOR ALL-WEATHER ROADS. 256
2 Materials and source: 256
2.1 THE QUALITY OF MATERIALS, LEAD TO THE BORROW AREAS AND
CLIMATIC CONDITIONS ARE KEY FACTORS FOR COST EFFECTIVE
CONSTRUCTION. 256
3 Construction Techniques: 256
3.1 CONVENTIONAL CONSTRUCTION METHODS ARE TYPICALLY
LABOUR BASED AND MOST OF THE CONSTRUCTION OPERATIONS
ARE DONE MANUALLY. IN CASE OF MECHANIZED METHOD OF
CONSTRUCTION, MOST OF THE OPERATIONS ARE DONE WITH
MACHINES LIKE GRADER, BULLDOZER, AND PAVER, ETC.
VIBRATORY ROLLER MAY ALSO BE USED FOR COMPACTION. THE
SELECTION OF CONSTRUCTION METHODOLOGY WILL BE BASED ON
VARIOUS CONSIDERATIONS. NO DOUBT, A MODERN MECHANIZED
METHOD WILL LEAD TO LARGER AND FASTER OUTPUT AND WILL
ALSO HELP IN MAINTAINING THE BETTER QUALITY OF
CONSTRUCTION. 256
3.2 THE CONSTRUCTION OF ROADS IN SOME AREAS REQUIRES
EXTENSIVE BLASTING AND THE ROADS HAVE TO BE CARVED
THROUGH VERY STEEP AND VERTICAL ROCK FACES. THUS
EXCLUSIVE DEPENDENCE ON MANUAL LABOUR FOR WORK IN HILLY
AREAS HAS ASSOCIATED SAFETY HAZARDS. 256
4 Machinery and tools: 256
4.1 IN INDIA, ROAD CONSTRUCTION ACTIVITIES ARE ACCOMPLISHED
IN VARIOUS STAGES. THE TOOLS, APPLIANCES AND EQUIPMENT
REQUIRED FOR DIFFERENT CONSTRUCTION ACTIVITIES MAY ALSO
BE CLASSIFIED AS MANUAL AND MECHANISED METHOD. MOST OF
THE TOOLS AND APPLIANCES USED BY MANUAL LABOUR FOR
VARIOUS PHASES OF CONSTRUCTION ARE CONVENTIONAL TOOLS
AND APPLIANCES COMMON TO ALL THE ACTIVITIES AND PHASES OF
CONSTRUCTION. SPECIAL TOOLS, APPLIANCES AND EQUIPMENT ARE
ALSO USED FOR SPECIAL CONSTRUCTION ACTIVITIES LIKE
BITUMINOUS WORK AND CONSTRUCTION OF CONCRETE ROAD, ETC.
SOME MACHINES/EQUIPMENTS, LIKE, DOZERS, COMPRESSORS,
CRUSHERS, LOADER AND LOAD CARRIERS ARE ALSO COMMON TO
MOST OF THE CONSTRUCTION ACTIVITIES WHERE MECHANISED
METHODS ARE ADOPTED. THE LIST OF TOOLS APPLIANCES AND
EQUIPMENT REQUIRED FOR SEMI MECHANIZED METHOD IS GIVEN
IN APPENDIX I. ON MAJOR PROJECTS, THE WORK OF BULKY AND
REPETITIVE NATURE CAN BE DONE MORE ECONOMICALLY AND
EFFICIENTLY BY WELL-DESIGNED MACHINES. PRACTICALLY EVERY
OPERATION IN CONSTRUCTION OF ROADS CAN BE PERFORMED BY
DIFFERENT TYPES OF EQUIPMENT, BUT UNDER AND GIVEN SET OF
CONDITIONS ONLY A PARTICULAR TYPE OF MACHINE WOULD BE
MOST EFFECTIVE. THUS SELECTION OF MACHINE FOR ANY
PARTICULAR PHASE OF CONSTRUCTION REQUIRES DETAILED
STUDY ABOUT BRAND, MODEL AND SPECIFICATION OF THE VARIOUS
EQUIPMENT AVAILABLE AND THEIR SUITABILITY FOR PARTICULAR
PHASE OF CONSTRUCTION. IRC PUBLICATION MOST HANDBOOK ON
ROAD CONSTRUCTION MACHINERY, MAY BE REFERRED FOR
FURTHER DETAILS. THE SURFACE EVENNESS AND COMPACTION ARE
GENERALLY CHECKED WITH CAMBER BOARD/TEMPLATE,
STRAIGHT EDGE, DEPTH GAUGE AND DENSITY MEASURING KIT.
RECENTLY UNEVENNESS INDICATOR AND NUCLEAR DENSITY
METERS HAVE ALSO BEEN INTRODUCED FOR EXERCISING QUALITY
CONTROL IS GIVEN IN APPENDIX - II. 256
5 Embankment and Subgrade 257
5.1 CONSTRUCTION OF EMBANKMENT AND PREPARATION OF
SUBGRADE ARE PART OF EARTHWORK. THE MAIN ACTIVITIES
ASSOCIATED WITH CONSTRUCTION ARE, SOIL SURVEY AND
IDENTIFICATION OF BORROW AREAS, CONSTRUCTION OF
EMBANKMENT AND SUBGRADE. THE DETAILS ARE DISCUSSED IN
THE FOLLOWING PARAGRAPHS. 257
6 Embankment with conventional earth: 257
6.1 THE HEIGHT OF ROAD EMBANKMENT DEPENDS ON THE HIGHEST
FLOOD LEVEL (HFL) IN AREA GENERALLY 0.6 TO 1.0 M HEIGHT
ABOVE HFL IS TO BE ENSURED. THE EMBANKMENT MAY BE
CONSTRUCTED BY ROLLING IN RELATIVELY THIN LAYERS. EACH
LAYER SHOULD BE COMPACTED BY SUITABLE ROLLER TO A
DESIRED DENSITY BEFORE THE NEXT LAYER IS PLACED.
COMPACTION SHOULD BE CARRIED OUT AT OPTIMUM MOISTURE
CONTENT SO AS TO TAKE ADVANTAGE OF MAXIMUM DRY DENSITY
USING A SPECIFIED COMPACTING EFFORT AND EQUIPMENT. THE
THICKNESS OF EACH COMPACTED LAYER MAY VARY BETWEEN 150
TO 300 MM DEPENDING UPON VARIOUS FACTORS SUCH AS SOIL TYPE,
COMPACTION EQUIPMENT AND SPECIFICATIONS. USING ORDINARY
8-10 TONNE ROLLERS, COMPACTED THICKNESS SHALL NOT EXCEED
150 MM IRC:36, IRC:56, IRC:75 MAY BE REFERRED FOR
CONSTRUCTION OF EMBANKMENTS. 257
6.2 FOR IDENTIFICATION OF SUITABLE BORROW AREA, SAMPLES
MAY BE COLLECTED AT DIFFERENT DEPTHS FROM THE TEST PITS
DUG OPEN IN BORROW AREAS FROM WHERE THE EMBANKMENT
MATERIAL IS TO BE OBTAINED. THE SOIL FOR PROCESSING SHOULD
BE BROUGHT TO PROPER MOISTURE CONTENT, SO THAT THE
NEEDED DEGREE OF COMPACTION CAN BE IMPARTED WITH LEAST
EFFORT. NEEDED AMOUNT OF WATER SHOULD BE QUITE
UNIFORMLY DISPERSED IN THE ENTIRE SOIL MASS. DEPENDING
UPON THE WEATHER CONDITIONS AND TIME GAP BETWEEN
SPRINKLING OF WATER AND COMMENCEMENT OF ROLLING, AN
ALLOWANCE OF 3 TO 4 PER CENT FOR EVAPORATION SHOULD BE
MADE IN THE QUANTITY OF WATER TO BE ADDED DURING SUMMER
WHEN TEMPERATURE IS GREATER THAN 350C, IN WINTER THIS
ALLOWANCE MAY BE REDUCED TO 1 TO 2 PER CENT. FOR
EARTHWORK CONSTRUCTION, THE LOOSE THICKNESS OF THE SOIL
LAYER SHOULD NOT NORMALLY EXCEED 200 MM WHEN ORDINARY
8-10 TONNE ROLLERS ARE USED. 257
6.3 WHEN THE EARTHWORK HAS REACHED A STAGE WHERE THE
GENERAL FORM OF THE FINAL SHAPE OF THE EMBANKMENT HAS
BEEN OBTAINED, THE SPREADING OF EARTH SHOULD BE DONE IN
STRAIGHT REACHES TO A CROWNED SHAPE, AND TO
APPROPRIATELY BANKED PROFILE IF THE REACH IS ON A CURVE.
THE MOISTURE CONTENT IN THE LAID SOIL SHOULD BE THE
OPTIMUM MOISTURE CONTENT SUBJECTED TO THE PERMITTED
TOLERANCE. HIGHLY EXPANSIVE SOILS SUCH AS BLACK COTTON
SOIL SHOULD BE COMPACTED AT THE SPECIFIED MOISTURE
CONTENT, WHICH IS USUALLY ON THE WET SIDE OF THE OPTIMUM
MOISTURE CONTENT. THE TOLERANCE LIMITS OF VARIATION FROM
THE SPECIFIED MOISTURE CONTENT OMC ARE NORMALLY + 1 PER
CENT TO 2 PER CENT FOR SANDY/SILTY SOILS AND OPTIMUM
MOISTURE CONTENT (OMC) TO +2 PER CENT FOR CLAYEY/BLACK
COTTON SOILS. EARTH TO BE USED SHOULD BE GOOD SOIL, FREE
FROM SLUMPS, ROOTS AND LEAVES OF TREES, PLANTS AND
RUBBISH. THE CLODS SHOULD BE BROKEN TO LESS THAN 75 MM
SIZE. THE EQUIPMENT FOR COMPACTION OF EARTHWORK SHOULD
BE AN 8-10 TONNE SMOOTH WHEELED POWER ROLLER. HOWEVER,
IF SUCH A POWER ROLLER IS NOT AVAILABLE, THE USE OF LIGHTER
ROLLERS OF 6 TO 8 TONNE WEIGHT MAY BE PERMITTED. IN SUCH
CASES, THE THICKNESS OF LOOSE SOIL LAYER SHOULD BE
SUITABLY REDUCED AND THE NUMBER OF PASSES NEEDS TO BE
INCREASED TO ACHIEVE THE DESIRED DENSITY. 257
6.4 DENSITIES TO BE AIMED AT THE COMPACTION PROCESS SHALL
BE CHOSEN WITH DUE REGARD TO FACTORS SUCH AS SOIL TYPE,
HEIGHT OF EMBANKMENT, DRAINAGE CONDITIONS, POSITION OF
INDIVIDUAL LAYERS AND TYPE OF AVAILABLE COMPACTION
MACHINERY. EACH COMPACTED LAYER SHALL BE TESTED IN THE
FIELD FOR DENSITY AND COMPACTED FULLY BEFORE THE
OPERATIONS FOR THE NEXT LAYER COMMENCE. THE MINIMUM
FIELD DENSITY IN CASE OF THE EMBANKMENT SHALL NOT BE LESS
THAN 97 PER CENT STANDARD PROCTOR COMPACTION (IS:2720
(PART 7) 1980). THE OVERALL PROFILE SHOULD BE IMPROVED WITH
EACH SUCCESSIVE LAYER SO THAT THE SUBGRADE LEVEL IS
APPROACHED. THE PROFILE OF THE FORMATION IS AS PER LINES
AND GRADES. 258
7 Subgrade with natural earth 258
7.1 THE PREPARATION OF SUBGRADE INCLUDES ALL OPERATIONS
BEFORE THE PAVEMENT STRUCTURE COULD BE LAID OVER IT AND
COMPACTED. THUS THE PREPARATION OF SUBGRADE WOULD
INCLUDE SITE CLEARANCE (IF THE FORMATION ALREADY EXISTS),
GRADING (EMBANKMENT OR CUT SECTION) AND COMPACTION TO
DESIRED DENSITY AT OPTIMUM MOISTURE. THE SUBGRADE MAY BE
SITUATED ON EMBANKMENT OR EXCAVATION OR AT THE EXISTING
CANAL BANK. IN ALL THE CASES, SITE SHOULD BE CLEARED OFF
AND THE TOP SOIL CONSISTING OF GRASS, ROOTS, RUBBISH AND
OTHER ORGANIC MATTER ARE TO BE REMOVED. THE GRADING
OPERATION IS STARTED THEREAFTER SO AS TO BRING THE
VERTICAL PROFILE OF THE SUBGRADE TO DESIGNED GRADE AND
CAMBER. BULLDOZERS, TIPPERS AND BLADE GRADERS ARE USEFUL
EQUIPMENT TO SPEED UP THIS WORK. HIGHLY CLAYEY AND BLACK
COTTON SOIL SHALL NOT BE USED DIRECTLY AS A SUBGRADE
MATERIAL. IN SUCH CASE A CAPPING LAYER OF 100 MM THICKNESS
SHALL BE PROVIDED WITH MATERIAL OF CBR HIGHER THAN 10 PER
CENT OR GEO-TEXTILE SHALL BE USED AS A FILTER MATERIAL, IF
FOUND ECONOMICAL. IN CASE THE REACH IS IN CUTTING AND IN-
SITU SOIL IS TO BE USED FOR SUBGRADE, THE METHOD CONSISTS IN
LOOSENING OF THE SOIL TO APPROPRIATE DEPTH TO COMPACT TO
A THICKNESS OF 300 MM BRINGING THE MOISTURE TO REQUIRED
LEVEL AND COMPACTING IT WITH A SUITABLE ROLLER TO 100 PER
CENT STANDARD PROCTOR COMPACTION DENSITY. THE
COMPACTION PROCESS SHOULD COMMENCE AT THE EDGES AND
PROGRESS TOWARDS THE CENTRE EXCEPT AT SUPER-ELEVATED
PORTIONS WHERE IT SHALL COMMENCE FROM LOWER EDGES AND
PROGRESS TOWARDS HIGHER EDGE. WHEN THE REACH IS IN
FILLINGS, IT IS NECESSARY TO ENSURE THAT AT LEAST THE TOP 300
MM OF THE EMBANKMENT CONSTITUTING THE SUBGRADE OF THE
PAVEMENT SHOULD BE COMPACTED TO 100 PER CENT OF STANDARD
PROCTOR COMPACTION DENSITY IN AT LEAST TWO LAYERS AT
OPTIMUM MOISTURE CONTENT. THE SUBGRADE SHOULD BE
FINISHED TO THE DESIRED PROFILES; A CAMBER BOARD SHOULD BE
USED TO CHECK THE CROSS SLOPE. 258
8 Surface drains 258
8.1 THE FAST DISPOSAL OF RUNOFF ON THE ROAD SURFACE IS
ACHIEVED BY SURFACE DRAINAGE. SURFACE DRAINS SHALL BE
EXCAVATED TO THE SPECIFIED LINES, GRADES, LEVELS AND
DIMENSIONS BASED ON THE TYPE OF THE DRAIN. THE EXCAVATED
MATERIAL SHALL BE REMOVED FROM THE AREA ADJOINING THE
DRAINS AND IF FOUND SUITABLE, UTILISED IN EMBANKMENTS OR
SUBGRADE CONSTRUCTION. ALL UNSUITABLE MATERIALS SHALL BE
DISPOSED OF AS DIRTECTED. THE EXCAVATED BED AND SIDES OF
THE DRAINS SHALL BE DRESSED TO BRING THIS IN CLOSE
CONFORMITY WITH THE SPECIFIED DIMENSIONS, LEVELS AND
SLOPES. 258
9 Sub Base (Granular) 259
9.1 SUB-BASE IS AN INTERMEDIATE LAYER BETWEEN SUBGRADE
BASE COURSE. THE FUNCTION OF THIS LAYER IS AS A DRAINAGE
LAYER FOR THE PAVEMENT TO AVOID EXCESSIVE WETTING AND
WEAKENING OF SUBGRADE. VARIOUS MATERIALS AND TECHNIQUES
ARE USED FOR CONSTRUCTION OF SUB BASE COURSE. VARIOUS
TYPE OF CONSTRUCTION FOR SUB-BASE, WHICH ARE APPROPRIATE
FOR RURAL ROAD, ARE DETAILED HERE. 259
9.2 GRANULAR SUB-BASE (GSB): 259
9.3 COARSE SAND SUB-BASE 260
10 Base Course (Granular) 260
10.1 THE FOLLOWING SPECIFICATIONS ARE RECOMMENDED FOR
CONSTRUCTION OF GRANULAR BASE COURSE 260
10.2 WATER BOUND MACADAM (WBM) 260
10.3 CRUSHER RUN MACADAM (CRM) : THE WORK SHALL CONSIST OF
FURNISHING, PLACING AND COMPACTING CRUSHED STONE
AGGREGATE SUB-GRADE AND BASE COURSES CONSTRUCTED IN
ACCORDANCE WITH THE REQUIREMENTS SET FORTH IN THIS
SPECIFICATION AND IN CONFORMITY WITH THE LINES, GRADES,
THICKNESSES AND CROSS SECTIONS SHOWN ON THE PLAN OR AS
DIRECTED BY THE ENGINEER-IN-CHARGE. THE GRADING SHALL
CONFORM TO THE GRADING AND QUALITY REQUIREMENTS SHOWN
IN TABLE BELOW. 263
11 Shoulder 263
11.1 SHOULDER GIVES ADEQUATE SIDE SUPPORT TO THE PAVEMENT
AND ALSO DRAINS OFF SURFACE WATER FROM THE CARRIAGEWAY
TO THE ROAD SIDE DRAIN. 263
11.2 CONSTRUCTION OF SHOULDERS: THE CONSTRUCTION SHALL BE
DONE IN LAYERS EACH MATCHING THE THICKNESS OF ADJOINING
LAYER. ONLY AFTER A LAYER OF WBM, SHOULDER SHALL BE LAID
AND COMPACTED. NEXT CORRESPONDING LAYERS IN PAVEMENT
SHALL BE TAKEN UP AFTER THE COMPLETION OF FIRST LAYER OF
WBM AND SHOULDER. THIS PROCEDURE SHALL BE FOLLOWED UPTO
THE SURFACE COURSE. IN THE CASE OF BITUMINOUS COURSES,
WORK ON SHOULDER SHALL START ONLY AFTER THE PAVEMENT
COURSE HAS BEEN LAID AND COMPACTED. THE COMPACTION
REQUIREMENT OF EARTHEN SHOULDER SHALL BE 100 PERCENT OF
STANDARD PROCTOR COMPACTION DENSITY AS PER IS:2720 (PART 7)
1980. 263
DURING ALL STAGES OF SHOULDER CONSTRUCTION, THE REQUIRED
CROSS FALL SHALL BE MAINTAINED TO DRAIN OFF SURFACE WATER.
REGARDLESS OF THE METHOD OF LAYING ALL SHOULDER
CONSTRUCTION MATERIAL SHALL BE PLACED ON THE SHOULDER.
ANY SPILLED MATERIAL DRAGGED ON TO THE PAVEMENT SURFACE
SHALL BE IMMEDIATELY REMOVED WITHOUT DAMAGE TO THE
PAVEMENT. 264
12 Bituminous Constructions 264
12.1 RURAL ROADS ARE EXPECTED TO HAVE VERY LOW TRAFFIC,
AND THEREFORE, ANY ALL WEATHER SURFACING WILL PROVIDE
THE NEEDED CONNECTIVITY. BUT, WHERE THERE IS REASONABLE
VOLUME OF MOTORIZED TRAFFIC, THIN BITUMINOUS SURFACING
WILL BE DESIRABLE. THIS SECTION DEALS WITH CONSTRUCTION OF
ALL DIFFERENT BITUMINOUS CONSTRUCTION REQUIRED FOR
FLEXIBLE PAVEMENT. THE BASIC OBJECTIVE OF PROVIDING THIN
BITUMINOUS SURFACING ON RURAL ROADS IS TO SEAL GRANULAR
SURFACE COST EFFECTIVELY AND TO REDUCE MAINTENANCE
EFFORTS. 264
12.2 PRIME COAT ON GRANULAR SURFACES: PRIME COAT IS A SPRAY
APPLICATION OF LOW VISCOSITY LIQUID BITUMINOUS MATERIAL
ON TOP OF THE TOP MOST GRANULAR LAYER OF THE BASE COURSE.
PRIME COAT PERFORMS FOLLOWING IMPORTANT FUNCTIONS. 264
12.3 TACK COAT APPLICATION: TACK COAT IS A VERY LIGHT
APPLICATION OF LIQUID BITUMINOUS MATERIAL ON A BITUMINOUS
LAYER WHEN A NEW LAYER IS TO BE LAID OVER IT. IT IS USED TO
CREATE A BOND BETWEEN A NEW BITUMINOUS LAYER TO BE
PLACED ON THE EXISTING BITUMINOUS OR A PRIMED GRANULAR
LAYER. THE FOLLOWING TYPES OF LIQUID BITUMINOUS
MATERIALS CAN BE USED FOR TACK COAT APPLICATIONS: 265
13 Introduction 274
13.1 QUALITY SHOULD CONFORM TO THE CUSTOMER NEED OR
USERS REQUIREMENT IN ALL ACTIVITIES AND PROJECTS.
HOWEVER, QUALITY IS CONSIDERED AS CONFORMANCE TO
SPECIFICATIONS PARTICULARLY IN CONSTRUCTION SECTOR. THE
QUALITY CONTROL IS AN ESSENTIAL REQUIREMENT FOR ALL
WEATHER RURAL ROAD CONSTRUCTION BY ADOPTING
IRC/MORT&H SPECIFICATIONS AND CONSTRUCTION METHODS FOR
CREATING DURABLE AND LONGER LASTING ASSETS FOR RURAL
INDIA. THE OVERALL QUALITY CONTROL OF RURAL ROAD WORKS
MUST COVER CONTROLLING OF QUALITY OF MATERIALS AND THE
WORK AT SITE WITH THE HELP OF OBJECTIVE TESTS PERFORMED
AT A REASONABLE, PRE-DETERMINED FREQUENCY WITH
AFFECTING PROGRESS OR WORKS. IT IS ALWAYS TESTS PERFORMED
AT A REASONABLE, PRE-DETERMINED FREQUENCY WITHOUT
AFFECTING PROGRESS OF WORKS. IT IS ALWAYS ADVANTAGEOUS TO
HAVE SEPARATE QUALITY CONTROL UNIT, INDEPENDENT OF
CONSTRUCTION STAFF TO CONTROL AND MONITOR THE WORK. THE
GUIDELINES IN THIS REGARD ARE CONTAINED IN IRC:SP:11,
HANDBOOK OF QUALITY CONTROL FOR CONSTRUCTION OF ROADS
AND RUNWAYS, CLAUSE 900 SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS OF MORT&H SPECIFICATIONS AND IRC:SP:57,
GUIDELINES FOR QUALITY SYSTEMS FOR ROAD CONSTRUCTION.
274
14 Pre-Requisite 274
15 Specifications and Codes of Practice 275
15.1 THE SPECIFICATIONS AND CODES OF PRACTICE LAID DOWN BY
INDIAN ROADS CONGRESS, MINISTRY OF ROAD TRANSPORT AND
HIGHWAYS, AND BUREAU OF INDIAN STANDARDS ARE REQUIRED TO
BE FOLLOWED IN CONSTRUCTION OF ROADS. 275
16 Earth Work and Granular Layer 275
16.1 THE MATERIALS SUPPLIED AND THE WORKS CARRIED OUT BY
THE CONTRACTOR SHALL CONFORM TO THE SPECIFICATIONS
PRESCRIBED. FOR ENSURING THE REQUISITE QUALITY OF
CONSTRUCTION, THE MATERIALS AND WORKS SHALL BE
SUBJECTED TO QUALITY CONTROL TESTS, AS DESCRIBED
HEREINAFTER. THE TESTING FREQUENCIES INDICATED ARE THE
DESIRABLE MINIMUM AND THE ENGINEER-IN-CHARGE SHALL
RECOMMEND FOR ADDITIONAL TESTS WHENEVER FELT NECESSARY,
TO ENSURE COMPLIANCE WITH THE APPROPRIATE SPECIFICATIONS.
SOME OF THE IMPORTANT TEST ON SOIL, AGGREGATE AND
BITUMINOUS MATERIALS ARE DESCRIBED IN APPENDICES-III, IV AND
V RESPECTIVELY. FOR DETAILS, RELEVANT CODE OF PRACTICE MAY
BE REFERRED AS PER LIST GIVEN AT APPENDIX I. 275
17 Bituminous courses 277
17.1 BITUMINOUS MATERIALS CAN BE USED FOR CONSTRUCTION OF
PRIME COAT, TACK COAT MODIFIED PENETRATION MACADAM,
BITUMINOUS MACADAM, OPEN GRADED PREMIX CARPET WITH
SEAL COAT, AND CLOSELY GRADED PREMIX CARPET (MIX SEAL
SURFACING, ETC.). THE MODIFIED PENETRATION MACADAM AND
BITUMINOUS MACADAM SHALL BE USED ONLY AT SPECIAL
LOCATIONS WHERE TRAFFIC IS HEAVY AND REQUIREMENT OF
STRENGTHENING BY BITUMINOUS COURSE IS ESSENTIAL. 277
2.17 22.2 TERMINOLOGY 295
296
22.2.9 Double packer method method in which two packers are used in the drill hole. in this
case the test section is between the two packers (see fig 1b) 296
22.2.10 Split spacing grouting method- A sequence of drilling and grouting holes in which
widely spaced holes are drilled and grouted initially and the spacing is subdivided by
intermediate holes . The initial set of holes are called primary holes and intermediate holes
are termed secondary etc. according to the sequence of subdivision. 296
22.2.11 Slush grouting- Application of cement slurry to surface rock as a means of filling
cracks and surface irregularities or open joints to prevent leakage and slacking. 296
22.4.11. Core box arranging and indexing of cores : 310
24.4.11.1 General : At the site of drilling, the cores, immediately on their withdrawal from the
core barrel shall be placed in core tray and then transferred to core boxes specially made for
this purpose. 310
and the mechanical arrangement for applying pressure on the bit. The drilling outfit, however,
is generally less sophisticated than a conventional direct rotary rig. The chilled steel shots
(calyxite) are fed through the water line. During drilling the calyxite is ground by the shot bit.
Pressure is applied on the bit in addition to the weight of the drill pipe assembly. Water is
used as a drill field to lubricant the drill and remove loose debris. As the drilling proceeds,
cylindrical rollers are cut through and collected in the core barrel which is removed at
frequent intervals. The operation is not continuous and hence it is time consuming. 314
314
22.5.3 For arranging and indexing of cores and storage of core boxes, specifications under
para 22.4.11 shall be applicable. 314
22.6 Percussion Drilling : 314
This admits for flow reversal. When systamatic washing and jetting is carried out to remove
all soft material in seams it is generally not necessary to use a primary and secondary system
of holes. 321
321
22.7.5.3.2 when it is desirable to test the efficacy of consolidation grouting by comparing the
gorut absorption in primary and secondary holes a rectanglur or square pattern (see fig. 4) of
holes would be preferred. this is generally the case when the joints are irregular and relativly
free from in filling or it is not necessary to remove the material filling the joints. 321
22.7.5.4 Numbering of Great Holes : 321
22.7.5.4.1 Each hole would be assigned a number which would be used for all furture
referferences. Number would include details viz. block mumbe, stage, serial serial number of
the 321
335
337
346
349
generally limited to the following:- 350
352
5.1 The coefficient of permeability should be computed using the formulae given in fig.9.
The coefficient Cu and Cs in these formulae may be taken from the graphs given in Fig. 10
and fig. 11. For water percolation tests conducted above the water table, the position of the
base of Zone I should be found from the curve given in Fig.12. The - friction loss of head (L)
should be calculated or obtained from Fig.8A, 8B or 8C. This head should be deducted from
the combined head due to gravity and that due to applied pressure. Numerical examples
illustrating the use of the formulae are given in para 5,2, 354
355
Limitations Q / A < 0.10 S > 10 in method II : Thickness of each packer should be 10. 355
A = length of test section, in m. 355
a = surface area of test section, in m2 (in method 1, a is area of wall plus area of bottom) 355
Cu = conductivity coefficient unsaturated bed (see fig. 10) 355
Cs = conductivity coefficient saturated bed (see fig. 11) 355
D = distance from ground surface to bottom of hole, in m. 355
H = effective head = H2 + H3 L, in m 355
below water table, distance between swivel and water table, in m. 355
H3 = applied pressure at collar, in m of water. 355
cm/s) 355
pipe, it may be ignored. 355
Q = Steady flow into well in 3/s. 356
r = radius of test hole, in m. 356
S = Thickness of saturated material, in m. 356
Tu = U D + H 356
U = thickness of unsaturated material, in m. 356
H 356
X = percent of unsaturated stratum Tu x 100 (see fig. 12) 356
Fig. 9 Formulat for Calculation of Coefficient or Permeability 356
356
5.2 Calucation of permeability coefficient using pressure percolation test in bedrock 356
Zone 1 : 356
U = 23 m D = 7.6 m A = 3 m 356
r = 0.15 m H2 = 10 m H3 = 1.75 kg/cm2 356
= 17.5 m 356
Q = 0.0013 m3/S 356
L using 32 mm pipe at 0.0013 m3/s 356
= 23 cm loss per 3.05 m section 356
Distance from swivel to bottom of pipe 6.7 m 356
6.7 x 0.23 356
Head Loss = 3.05 = 0.514 m 357
H = (10+17.5-0.51) m = 26.99 m, Say 27 m 357
Tu = U D + H = 23-7.6 + 27 m = 42.4 m 357
H 27 x 100 357
x = Tu x 100 = 42.4 = 63.6 percent 357
358
364
taken as initial values to be confirmed by trial and observation. 364
test thus constitutes a basis of verification or rock categorization as per Fig. 13. 364
1.4.1.1 Interpretation of water test : 364
principles : 364
cyclic test. 364
Sometimes the resistance to flow increase disproportionately to the increase in pressure and
therefore the rise of flow rates is not commensurate with the increase in pressure. This may
be attributed to development of turbulent flow regime and is indicated by lugeon values
decreasing with increase of pressure. 365
367
SECTION - 4: EXCAVATION
(EXCAVATION FOR DAM & ITS COMONENTS)
1 General
1.1 The work to be done under these specifications shall consist of furnishing
all tools, constructional plant, labour, materials and other things
required for excavation in all stratas. Conveyance and disposal of the
excavated materials, including all leads and lifts, temporary work for
performance of all the operations connected with the work embraced
under the contract so as to secure satisfactory quality of work.
1.2 Construction and maintenance of diversions in case diversion of existing

communication lines, channels, nalla or drains where they were
disturbed due to excavation of Dam & its components.
2. Standards
The following listing includes the Bureau of Indian Standards applicable for the Excavation
work
24. IS: 4701-1982 Code of practice for Earth work on canal.
25. IS:7293-1974 Safety code for working with construction
machinery
26. IS:3764-1966 Safety code for excavation work
27. IS:1498-1970 Classification and identification of soils for
general Engineering purposes
28. IS: 2720(Part.2)- Method of test for soils part-2, Determination
1973
Of water. content.
29. IS 2720 (Part.7)- Method of test for soils Determination of water content dry
1980 density
Relation using light compaction.
30. IS : 2720 (Part. Method of test for soils. Determination of Dry
28)-1974
Density of soils in place by sand replacement method
31. IS: 2720 Method of test for soils (part. 29). Determination of dry density of
(Part.29)-1976 soils in
place by core cutter method
32. IS :1888-1982 Method of load test on soils
33. IS:2131-1981 Methods of standard penetration test for soils.
34. IS: 4332-1967 Methods of test for stabilized soils methods of sampling and
(part.1) preparation of stabilized soils for testing
35. IS: 2720-1983 Method of test for soils-Grain size Analysis
(Part.4)
36. IS: 2720-1985 Method of test for soils for. Determination of liquid a plastic
(part.5) limits.
37. IS: 2720-1971 Determination of dry Density moisture content-relation by
(Part.9) constant weight of soils method.
38. IS: 2720-1991 Determination of unconfined compressive Strength
(Part.10)
39. IS: 2720-1986 Method of test for soils. (Part.13) direct shear test.
(part.13)
40. IS:2720-1986 Method of test for soils: (Part.15) Determination of consolidation
(part.15) properties.
41. IS2720-1983 Method of test for soils for. Determination of Density Index,
(part.14) (relative density) of cohesion less soils.
42. IS:2720-1987 Method of test for soils Laboratory determination of C.B.R
(part.16)
43. IS:2720-1964 Method of test for soils. Determination of field moisture
(part.18) equivalent
44. IS: 2720-1977 Method of test for soils.
(part. 40) Determination of free swell index of soils.
45. IS:2720-1977 Method of test for soils. Determination of swelling pressure of
(part.41) soils
46. IS: 8237-1985 Code of practice for protection of slopes for reservoir
embankment
3. Scope:
Excavation of Dam/channel/approach channel/drain/cut off trench/key trench /toe wall/toe
drain/foundations for structures/Cut off wall/chute drains etc., in all soils/disintegrated
rock/Shale/H.R. in both wet and dry conditions and disposal of soil not useful for
construction, on spoil bank and stacking of useful stone, disposal of not useful stone,
conveyance of excavated spoil/soils including swell, conveyance of excavated rock including
voids, with all leads, lifts and delifts and formation of spoil bank/stock piles, including
dewatering, diversion of streams, formation and removal of ramps, diversion roads/approach
roads, shoring/strutting. etc., as directed by the Engineer-in-charge to complete the finished
item of work.
4. Planning:
3. Prior to the commencement of work, all relevant data shall be
collected by the contractor and drawings prepared by him
showing the location of the excavation, spoils, deposition and
filling. On these drawings, full cutting reaches, partial cutting and
partial embankment reaches and full embankment reaches
should be distinctly indicated. The quantity of material to be
placed in fill shall be noted clearly in these reaches. Where the
material to be excavated. consists of different types and if the
various types have to be used separately in the fill or dumped to
spoil bank, the quantities of each class of material in each area
should be shown on drawings.
4. The contractor shall present his planning of the work along with
required details to the Executive Engineer at least 15 days before
starting the work.
5. Setting out Work

3. Bench Marks: Before starting any work, a permanent bench
mark, reference line and check profiles at convenient positions
approved by the Engineer-in-Charge shall be erected. The bench
marks shall be as per type design 6 and 8 of Department. The
works B.M. with R.L. shall be conspicuously carved and
painted on the bench mark. The reference line shall comprise of a
base line properly dag belled on the ground with number of
masonry pillar. The check profiles shall be of such materials and
shall be located at such places as to ensure execution of all slopes,
steps and excavation to the profile or profiles indicated in the
approved drawings or as directed by the Engineer-in-Charge.
4. The Sub-Divisional Officer on behalf of the Engineer-in-Charge
shall himself layout all important levels, all control points with
respect to this bench mark and reference line and correlate all
levels and locations with this bench mark and the reference line.
Important levels shall be checked by the Executive Engineer. All
assistance shall be given for the same by the agency executing the
work.
In the case of spread out works, several bench marks, reference lines and
check profiles may be necessary and shall be constructed as directed by
the Engineer-in-Charge.
5.3 Except the mathematical and surveying instrument which shall be

provided by the department, all materials and labour for setting out
works including construction of bench marks, reference lines, check
profiles and survey required for setting out works as may be required at
the various stages of the construction works, shall be supplied or made
by the agency executing the work.
6 ClearinG, GRUBBING AND PREPARATION OF

WORKS AREA:
(i) All excavation areas and dam embankment are including a 6 m wide
strip measured beyond and contiguous to the limit line of the area as
shown on the drawing shall be cleared and any roots etc. completely
removed as specified. All trees, down timbers, fencing bush, rubbish,
other objectionable materials and vegetation shall be cleared. All
stumps and roots shall be excavated and removed. All roots over 50
mm in diameter shall be removed to a depth of 90 cm below the
original ground surface or as directed by the Engineer-in-Charge.
Materials thus removed will be burnt or completely removed from the
site. All felled timber and fuel shall be properly stacked and handed
over to the department, when asked for by the Engineer-in-Charge.
Piling for burning shall be done in such a manner and in such location
as to cause the least fire risk. All burning shall be thorough so that the
materials are reduced to ashes. Special precautions shall be taken to
prevent fire from spreading to the areas beyond limits of the areas
specified and suitable equipment and supplies for preventing and
suppressing fire shall be available at all time.
(ii) No trees shall be cut from outside of areas designated unless instructed in writing by
the Engineer-in-Charge and all trees designated outside of the areas actually
occupied by the works shall be protected carefully from the damage.
7. STRIPPING, BENCHING AND FURROWING AND

PLOUGHING
2. Benching: Benching should be provided only where the work is to
done on highly undulating stiff ground, steeply sloping ground or on
existing canal embankments. Benching shall consist of excavation of
triangular trenches with a slope of 1 in 12 with average depth of
cutting as 15 cms longitudinally below the embankment seat or in the
form of steps with height of steps not more than 30 cms. The slope of
trenches shall be towards the centre from the outer toes of the
embankment.
7.1.2 Disposal of Materials : In all the items of benching / stripping and preparation of base
on rocky strata, described in para 7.1.1, above, the material from excavation, shall be
deposited in specified areas in a manner as may be directed by the Engineer-in-Charge
and in such a way as not to detract from the finished appearance of the work.
3. All the stripped material shall be deposited beyond the catch drain at the rear
toe of embankment.
8. BENCHING UNDER EMBANKMENT

4. The entire area of embankment including a 3 m wide strip
beyond and contiguous with the area of embankment proper as
shown in the drawing shall be stripped or benched to a sufficient
depth as directed to removed all unsuitable materials. The
unsuitable material to be removed shall include loose rock,
vegetation, top soil, sod, organic silt, swamp material and rubbish
and any other objectionable materials below the ground surface.
5. At locations where a river or stream crosses the embankment site,
loose sand and gravel and loose boulders shall also be removed as
directed.
6. Benched materials shall be disposed off in a manner as may be
directed by the Engineer-in-Charge and in such a way as not to
detract from the finished appearance of the project.
9. EXCAVATION OF CUTOFF OR PUDDLE TRENCH

UNDER DAM EMBANKMENT
1. Procedure for excavation:
2. A cut off trench or puddle trench as shown in the drawings shall
be excavated in the foundation of the dam at the location
indicated. This trench shall excavated to a depth of 0.6 m to 1.2 m
into rock (depending upon the permeability of the rock) or into
other impervious stratum as may be approved by the Engineer-
in-Charge. Accurate trimming of the slopes of the excavation will
not be required but the cutting in general shall follow lines as
specified in drawings. The area to be excavated shall be
unwatered. The water level shall be maintained below the level of
excavation in the area and none of the excavation shall be
performed in standing water.
3. Utilisation of Excavated Materials:
4. Trench excavation shall preferably be started after the whole base
of the dam or atleast the substantial part of its is cleared,
grubbed, benched or stripped as required by specifications so
that suitable material out of trench excavation can be directly
utilized for forming the bank, to maximum possible extent.
5. Blasting of Rock:
6. No blasting of rock would be permitted for the excavation in hard
rock, when the excavation reaches within about 60 cm of final
levels, if the opinion of the Engineer-in-Charge such blasting will
shatter and disturb the rock below foundation. He may also put
similar restrictions in cases where damage is apprehended to
works in neighboring area existing or under construction. In such
cases rock excavation shall be completed by chiseling and
wedging etc.
7. Material Received from Cut off Trench or Puddle Trench:
8. The materials, excavated from the trench shall, if suitable, be
used in the embankment either immediately or after stock piling
as convenient and directed by the Engineer-in-Charge. The
suitability or otherwise of the material and zone of the
embankment in which it is to be placed will be specified by the
Engineer-in-Charge on the basis of laboratory tests.
9. Material excavated from the trench shall not be placed in the
embankment till foundation for the embankment has been
cleared, stripped and prepared as specified and adequate
arrangements made for watering and rolling the layers of earth
fill in the embankment.
10.Materials excavated from the trench shall be subjected to the
same degree of embankment control as materials obtained from
borrow pits.
11. The material excavated from the trench which are not suitable for
use in the embankment shall be disposed off in a manner as may
be directed by the Engineer-in-Charge and in such a way as not
to detract from the finished appearance of the project.
12.Cut off Trench Filling:
13.Cutoff trench shall be back filled with impervious material of the
same specification and in the same manner as for the impervious
hearting zone of the embankment of the dam in accordance with
specifications under para 4.9. But before back filling is started
foundation grouting in accordance with specifications of chapter
22 may be completed, where required, unless the Engineer-in-
Charge directs otherwise.
14.Puddle Filling:
15.Puddle:
16.The puddle shall consist of good retentive clay of best quality free
from organic or other foreign material. It should be clean and
tough and should be available near the site as far as possible. The
most suitable clay is of the description used for tile making. Soft
sludgy, peaty, sandy, salt or puffy clay should be rejected.
17.The clay is to be worked out into puddle before use by turning it
over and over again with pores, watering and treading with mens
feet into one plastic homogeneous mass of the toughest
consistency until it gets plasticity.
18.Laying of Puddle:
19.The puddle shall then be made into balls and thrown into the
trench or in any other position required. No more than 15 cm in
thickness of puddle shall be deposited in the place at one time and
it must at once be thoroughly kneaded by mens feet and
incorporated with mass below it so that the whole will be uniform
and not in layers.
20.The top of puddle shall be kept as level and uniform as possible
and shall on no account be allowed to dry. If the surface cracks at
any time it shall be dug up and puddle remade.
21.Vertical joints across the puddle wall and steps to its side shall be
avoided. All joints shall be made by long inclined faces over
lapping each other.
22.The whole width of puddle trench excavated shall be filled with
puddle only so that the puddle gets thoroughly into the interstices
of trench walls. The joint near the wall shall be thoroughly
kneaded with mens hels.
23.On holidays and other days, when works are stopped, labour
should be specially employed to keep the surface of puddle wet by
sprinkling of water.
24.The puddle filling shall not be done in standing water. Water level
in trench shall be kept below the working level by means of
pumps, if required.
25.As the surface of the puddle layer dries up, it should be
thoroughly consolidated with rammers. Before a new layer of
puddle is laid the surface of the previous layer, if not newly made,
should be lightly sprinkled with water by means of watering pots
and kneaded.
26.When puddle is finished, it should be immediately covered up in
the work or when this is not possible, it should be lightly
sprinkled with water by means of watering pots and kneaded.
27.The surface soil if not confirming to approved hearting soil, is to
be removed on both sides of the puddle trench for a breadth equal
to that of the top of the trench, and for 0.60 m deep, and
consolidated in the same way.
28.This filling is to be carried up with the puddle wall to a height of
0.6 m above ground level and joined with the hearting.
10. RECORDING OF CROSS SECTIONS.

1. Immediately prior to the beginning of the work, cross-sections of
the existing ground level at suitable intervals, normal to the axis
of Dam, and other channels, sluice, waste-weir or other masonry
structures, etc. shall be taken over the base and seating of the
Channels or other structures, etc. for sufficient distance outside
the limits. Levels on these cross-sections shall be taken at suitable
interval not exceeding 5 m or as directed by the Engineer-in-
Charge.
2. These cross-sections shall be taken and plotted in ink on graph
Measurement Book by the construction agency and checked by
consultant agency Departmental Officer Incharge of work shall
check there level as required these cross-sections shall form the
basis of all future measurements.
3. After clearing the area required for Dam excavation and
construction of embankments, cross sections shall be taken at
every 15M interval or closer, depending on the nature of ground,
normal to axis of Dam upto sufficient distance outside the limits
of the work. Levels on cross sections shall be at 5M. Intervals or
closer intervals as directed by the Engineer -in-charge and
entered in level field books and cross sections will be plotted in
graph M.B. The contractor shall write a certificate. Accepted the
measurements recorded on pages from ________________to
______________ and sign at the end of levels in the graph M.B. in
token of acceptance.
4. After Benching and prior to commencement of excavation cross
sectional levels of stripped surface shall be taken at the same
locations at intervals as specified in para (a) above and certified
as mentioned shall be recorded by the contractor.
5. At the earliest, cross sectional profiles shall be prepared by the
contractor duly plotting the pre-levels and the contractors
signature shall be obtained on these cross-section sheets plotted in
graph M.B. The cross sections called initial cross section taken
after striping shall form the basis of all future measurements.
These initial cross sections duly signed by the contractor and
Engineer-in-Charge shall be preserved. All linear dimensions
shall be measured in meters to the nearest 0.01 meter, volumes
worked out in cubic meters corrected to 0.01 cubic meter.
However, in case of rock excavation occurring in bed or sides, the
actual quantity of rock shall be arrived by taking block levels at
2.5M. Intervals all along the entire area of bed and sides.
11. CLASSIFICATIONS OF EXCAVATED

MATERIAL
1. All materials involved in excavation shall be classified into the
following groups.
Soft or Ordinary Soil

Generally any soil which yields to the ordinary application of pick and shovel or to spade,
rake or other digging implement, such as vegetable or organic soil, turf, gravel, sand, silt,
loam, clay peat, etc.
Hard Soil
Includes all materials which can be removed with shovel or spade after lossening with pick
axe such as clay soil mixed with lime kankar, black cotton soil for earthen bund, soft
moorum, etc.
Hard Moorum and Moorum Mixed with Boulders
Generally any material which requires the close application of picks, jumpers or scarifiers to
loosen such as hard and compact moorum and soft shale. Moorum or soil mixed with small
boulders not exceeding 25% in quantity and each less than 0.014 cum (300 mm dia) but more
than 0.004 cum in size.
Note: Boulder is rock fragment usually rounded by weathering, disintegration or exfoliation
or abrasion by water or ice, found lying loose on the surface or embedded in river bed, soil
talus, slope wash and terrace material of dissimilar origin.
Disintegrated Rock
Includes such strata which requires the close application of crow bars, picks, grafting tools,
scarifiers in suitable combination for its excavation such as soft laterite, soft conglomerate,
hard shale, soft copra, hard and compact moorum mixed with small boulders exceeding 25%
in quantity but each not exceeding 0.014 cubic metre in size.
Soft Rock
Soft Rock comprises of the following:-
iv. Boulders (not greater than 0.5 cum in volume), hard laterite, hard copra and hard
conglomerate or other rock which may be quarried or split with crowbars, with casual
blasting, if required, for loosening of strata.
v. Any rock which in dry state may be hard, requiring blasting, but when wet becomes
soft and manageable by means other than blasting.
Hard Rock (Requiring blasting)
Any rock or boulder (More than 0.5 cum in volume) which requires the use of mechanical
plant or blasting for excavation or splitting.
Hard Rock (blasting prohibited)
Hard rock requiring blasting as described as above but where blasting is prohibited for any
reason and excavation has to be carried out by chiseling, wedging or any other agreed
method.
9. Authority for Classification

The classification shall be decided by the Engineer-in-Charge and his decision shall be final.
9. EXCAVATION
24. Where sub soil water is expected the excavation shall be started preferably from the
nearest valley.
25. The contractor shall commence excavation immediately after the surface area of
ground is prepared.
26. The Government reserves the right, during the progress of work to vary the slope of
excavation or the slope of embankment and the dimensions depended thereon.
27. Suitable arrangements for drainage shall be provided to take surface water clear of
excavation during the progress of work. Sump pits if found necessary shall be
excavated at suitable places and the water thus collected shall be bailed out or let into
a near by valley at his cost. When cutting on cross sloping ground, the contractor shall
cut a catch water drain on the higher side to prevent water from flowing down the
cutting slope. No separate payment shall be made for this work unless otherwise
specified.
28. No distinction shall be made as to whether the material being excavated is wet or dry
or in water.
29. All washable materials and any soil, which generally becomes unstable on saturation
such as organic soil, loose soils and expansive soils, shall be removed as directed by
the Engineer-in-charge.
30. All Suitable excavated material within economic lead shall be used for construction of
embankments.
31. Stones of more than 75 mm. in size and indurate materials shall be removed from
material to be used for compacted embankments.
32. In soils the contractor shall not excavate out side the slopes or below the established
grades or loosen any material outside the limits of excavation. Any excess depth
excavated below the specified levels shall be made good at the cost of the contractor
to standards as prescribed by the Engineer-in-charge.
33. The method of drilling and blasting to be resorted to the excavation in rock shall be in
accordance with specification Drilling and Blasting and got approved by the
Engineer-in-Charge.
34. Above the lining, in case of lined canals and above the proposed water level in case of
unlined canals, the rock may be allowed to stand at its safe angle and no finishing is
required other than removal of rock masses which are loose and are liable to fall.
35. Except in areas of rock, all areas to be excavated shall be pre-wetted so that at the
time of excavation moisture content will be at about optimum. However, in case of
the spoils to be deposited on spoil banks such pre-wetting need not be done.
36. During rock excavation, the contractor will not be allowed to dispose of the rubble
Surplus usable rubble shall be allowed to be used in construction of rock-toe, masonry
works and for crushing to use as metal in concrete works etc., crushed sand cost
subject to approval of the Engineer-in-Charge. The Contractor may use the excavated
useful soils, stone, and other construction material free of cost for construction
purpose on this project only and the rates quoted shall include such utilization.
37. The re-gradation for tail channel and approach channel for structures and diversion of
drains or nalla shall conform to the lines, dimensions, grades, side slopes, and levels
and shown on drawings or as directed by the Engineer-in-charge.
38. Where suitable materials in excess of that required to construct adjacent embankments
or in deficit sections by conveyance or back filling of structures or to construct O&M.
Road, Ramps and Bridge approach embankments as determined by the Engineer-in-
charge in one continuous operation, then such material shall be stock piled at places
designated by the Engineer-in-Charge for later use.
39. All gangways, roads and stopping shall be such that they fall within the cross sections
so that the final dressing of slope will consist of digging and no rolling will be
required.
40. During rock excavations, over-hangs or unsafe slopes shall not be permitted.
41. Unless otherwise specified, over excavation in rocks/soils shall not be permitted.
42. Blasting in a manner as to produce over -breakage which in the opinion of Executive
Engineer is excessive shall not be permitted. Special care shall be taken to prevent
over breakages or loosening of material on bottom and side slopes against which
lining is to be placed.
43. Final cutting for 300 mm. in rock shall be carried out by controlled blasting or
trimming or by chiseling wedging, barring with the help of pneumatic paving breakers
and no extra payment will be made.
44. In the case of Fissured rock and hard rock pre-measurements shall be taken. The
contractor shall before commencing the excavation in rock etc., expose the surface.
The pre-measurements shall be taken by taking levels at 2.5M. Intervals both ways
which forms the basis for payment of excavation for rocks. Where the rock is
intermingled with ordinary soils contained pre-measurements of soils shall be taken
and measurement of soils shall be obtained after deducting from the contained
measurements, the quantity of the boulders etc. which will have to be disposed as per
direction of Engineer-in-Charge.
45. In the case of boulders they should be marked by tar-pre measurements recorded.
After removal and disposal as directed by the Executive Engineer or his subordinates
46. In case of reservoir/tank works, the useful materials excavated in the cut of trenches
key trenches approach channels from the sluices, over burden removal on the U/S and
D/S sides of surplus weir, and foundations, excavation for sluices and surplus weir,
excavated shall be used for construction purposes. Any material unsuitable for
construction purposes shall be disposed of as directed by the Engineer-in-charge.
9. SLIDES/SLIPS:
1. If slides occur in cutting during the process of excavation they
shall be removed by the contractor at his cost as directed by the
Engineer -in-charge.
2. If finished slope slide into the canal subsequently such slips in
rock shall be removed.
10. OVER EXCAVATION:

1. In soils any excess depth below the specified levels and any excess
excavation in slopes and widths shall be made good at the cost of
the contractor with suitable soils of similar characteristics and
compacted to a density not less than 95% of proctors density.
2. In the canal section where expansive type of soil such as C.H. type
of soil is encountered and over which cement concrete lining
directly be laid, the canal prism shall be over excavated to the
extents as directed by the Engineer-in-charge and such over
excavated section shall be filled with suitable cohesive non-
swelling (CNS) type soil and shall be placed in uniform horizontal
layers and compacted as directed by the Engineer-in-charge. The
over excavation made in such strata filling by suitable soil
locating and compacting of such soil will not be paid separately.
11. DEWATERING
1. If water is met in the excavation due to sub-soil ground water,
springs, seepage, rain or other causes, it shall be removed by
suitable diversion, pumping or bailing out and the sub-soil water
table shall be kept below the excavation so that the excavation
kept dry whenever so required as directed by the Engineer-in-
charge care shall be taken to discharge the drained water as not
to cause damage to the works, crops or any other property. In
case of lined canals, the subsoil water shall not be allowed to
accumulate in the bottom of the canal. The bed/sides shall be
moisture to receive lining as directed by the Engineer-in-charge.
No separate payment will be made for dewatering.
2. Where water is met with in excavation due to stream flow,
seepage, rain or other reasons, the contractor shall take adequate
measures such as bailing, pumping, construction of diversion
channels, drainage channels, bunds, cofferdams and other
necessary works keep the foundation trenches dry when so
required and to protect the green concrete/ masonry against
damage by erosion or sudden rising of water level. The methods
to be adopted in this regard and other details there of shall be left
to the choice of the contractor but subject to approval of the
Engineer-in-charge.
3. Approval of the Engineer-in-charge shall however shall not
relieve the contractor of the responsibility for the adequacy of
dewatering and protection arrangements and for the quality and
safety of the works.
4. The Contractor shall take all precautions in diverting the
channels and discharging the drained water as not to cause
damage to the works, crops or any other property.
5. Pumping from the interior of a foundation shall be done in such a
manner as to preclude the possibility of the movement of water
through any fresh concrete. No. Pumping shall be permitted
during the placing of concrete or for any period of atleast 24
hours thereafter, unless it is done from a suitable sump separated
from the concrete works by water tight wall or other similar
means.
12. DISPOSAL OF EXCAVATED MATERIAL:

1. No rehandling of excavated material due to injudicious selection of place for
dumping will be paid for.
2. Material removed in excavation including stripped top soil and expansive soils
not required for embankments, bank fill or other required earth work shall be
deposited in waste banks on right of way owned by or controlled by the
department as directed by the Engineer-in-Charge. A gap of 3 M wide shall be
left in spoil banks at 150 m intervals or as directed by Engineer-in-Charge for
disposal of drainage in accordance with clause 8.20 of IS : 4701-1982.
3. Minimum gap of 1 meter or m the depth of excavation as per drawing
(whichever is more) from the edge of the excavation at G.L. in cutting reaches
and 1 m gap from the outer toe of the embankment to the inner toe of the spoil
bank or a greater distance as prescribed by the Engineer-in-Charge shall be
maintained.
4. Where the canal is aligned on sloping ground, excavated material not required
for construction of adjacent embankments at any other place, shall be
deposited on the lower side. Where canal is on level or nearly level ground,
the material from excavation shall be deposited on embankments on both sides
of the canals.
5. In case of deep cutting the spoil shall be so disposed off as not to result in
unsightly heaps as shall be leveled and properly dressed. The top of both the
finished banks shall slope away from the inner edge with a suitable gradient.
6. If there is excess of useful material from the excavation than needed for
construction embankments of canal/reservoir/tank, it shall be used to
strengthen the embankment on either side of the canal/reservoir/tank,
deposited in low areas uphill of the canal to eliminate trap drainage, or it
should be deposited in stock piles as directed by the Engineer-in-Charge. The
disposal of excavated material shall be in accordance with clauses 8.1 of IS
4701-1982.
7. The useful rock obtained from the cutting shall not be mixed with other soils
and shall be closely stacked to the gauge separately beyond spoil bank and all
other stone not useful for construction purpose shall be deposited on the slopes
of the canal spoil bank, if the rock and soil are mixed up while depositing at
the spoil banks, suitable deduction from the agreement rate as decided by the
Engineer-in-Charge will made which is binding on the contractor.
8. Except as specially provided in these specifications for payment for conveying
or placing of individual items of excavated materials.
9. The contractor has no claim over any of the materials got out of excavation of
the canal cutting and foundation excavation.
10. The responsibility for arranging the land required for disposal of excavated
material rest with contractor, if the contractor desires the material at near by
places other than the places shown by the Engineer-in-charge, to reduce the
lead and there by the cost of conveyance.
9. EXCAVATION FOR Appearent works:

1. Description of work:
a) Excavation and depositing the soil on spoil bank or at any place specified by the
Engineer-in-charge with all leads lifts for structures shall consist of the removal of
material for the construction of foundations for the structures like Bridges, U.Ts.
Aqueducts, super-passages, retaining walls, canal side walls, in lets, out lets, head walls,
cutoff walls, pipe under-tunnels, cross regulators, off-take sluices and other similar
structures, in accordance with the requirements of these specifications and the lines
elevations and dimensions shown on the drawings or as indicated by the Engineer-in-
charge.
b) The work shall include providing all the materials, tools and plants and labour required for
presplitting and utilising controlled blasting technique over and above the normal
blasting technique in hard rock and quartzite excavation, construction of the necessary
coffer dams and cribs and their subsequent removal and necessary sheeting, shorting,
strutting, benching, draining and pumping the foundations, trimming bottom of
excavations, all leads and all lifts of excavated material back filling with selected
approved material and clearing up the site and the disposal of all surplus materials, spoil
and the stone not useful for construction purpose shall be deposited beyond the profile
of the structure, canal, stream etc., leaving a minimum gap of 5 meters. and in
accordance with clause 8.1of IS 4701-1982 or at greater distance as directed by the
Engineer-in-charge. The useful stone stacking and soils required for back filling shall be
placed at the contractors convenience without forgoing the working space. No
rehandling of materials will be paid and at the same time recovery will be made if the
obstructions are not removed after completion of the work from the final bill at the rate
calculated by the Engineer-in-charge to do the same work with other agency. In so far as
practicable, the material removed in excavation for structures shall be used for back
filling and embankments.
9. CLASSIFICATION OF EXCAVATION:
1. All materials involved in excavation shall be classified in
accordance with Clause no.11
10. CONSTRUCTION OPERATIONS:

(a) Setting-out
After the site has been cleared to the limits of excavation the work shall be set out true
to lines, curves, and slopes as shown on plans.
ii) Excavation:
(a) Excavation shall be taken to the width of the lowest step of the footing and
the sides shall be left to plumb where the nature of soil allows it.
Where the nature of soil or the depth of the trench does not permit
vertical sides, the contractor at his own expense shall put up necessary
shoring, strutting and planking or cut slopes to a safer angle or both
with due regard to the safety of personnel and works and to the
satisfaction of the Engineer-in-charge.
(b) The depth to which the excavation is to be carried out shall be as shown on
the drawings, unless the type of material encountered is such as to
require changes in which case the depth shall be as ordered by the
Engineer-in-charge and will be paid for.
(c) Excavation in rock shall be carried out by crow bars, pickaxes, chisels of
pneumatic drills etc. unless permitted by Engineer-in-charge blasting
shall not be resorted to.
(d) Where blasting is to be resorted to the same shall be carried out to the
requirements of specification 3.3and all precautions there in observed.
(e) No distinction shall be made as to whether the material being excavated is
dry or moist or in water.
The method of drilling and blasting to be adopted for hard rock including F&F rock
excavation shall be approved by the Engineer-in-charge. Blasting in a manner as to
produce over breakage which in the opinion of Engineer-in-charge is excessive shall
not be done. In order to minimise over breakage and loosening of material at the
finished surface on bottom and side slopes over which foundation concrete is to be
laid, final cutting for the last 300mm. in hard rock shall be carried out by controlled
blasting or chiseling or trimming with the help of pneumatic paying breakers. If
excavation is required to be done within 30m. From the existing structures the same
should be carried out by chiseling without resorting to blasting for which no extra
rate is payable.
1. PREPARATION OF FOUNDATION:
2. The contractor shall prepare firm foundation for the structure as
shown in the drawings. The bottom and side slopes of foundation
upon or against which the structure is to be placed shall be
finished to the prescribed levels and dimensions shown on plans.
3. The bottom of the foundation shall be leveled both longitudinally
and transversely or stepped as directed by Engineer-in-charge.
Before foundation concrete is laid, the surface shall be slightly
watered and rammed. In the event of excavation having been
made deeper than that shown on the drawings the extra depth
shall be made up with concrete or masonry of the foundation
grade at the cost of the contractor as directed by the Engineer-in-
charge. Ordinarily earth filling shall not be used for the purpose
to bring the foundation level. If hard strata is not met at
foundation level shown in the drawings extra depth as directed by
Engineer-in-charge shall be excavated to remove unsuitable
material. The extra excavation or extra depth made up with
masonry or concrete will not be paid.
4. When rock or other hard strata is encountered, it shall be free
from all soft and loose material, cleaned and cut to a firm surface
either level, stepped, or serrated/notched, as directed by the
Engineer-in-charge. All seams shall be cleaned out and filled with
cement mortar or grout to the satisfaction of the Engineer-in-
charge.
5. If it is considered necessary by the Engineer-in-charge, to
consolidate the foundation strata by grouting cement slurry, the
drilling and grouting or any other foundation treatment as
directed by the Engineer-in-charge shall be done by the
contractor
10. PUBLIC SAFETY:
1. Nearest, towns, villages and all required places, trenches and
foundation pits shall be securely fenced, provided with proper
caution signs and marked with red lights at night to avoid
accidents. The contractor shall take adequate protective measures
to see that the excavation operations do not effect or damage
adjoining structures or property.
11. DAM EMBANKMENT CONSTRUCTION

1. SCOPE:
Certain instruments for measuring the performance of the dam during construction and
afterwards are proposed to be installed by the department at locations as specified in
the drawing or as decided by the Engineer-in-Charge. Necessary facilities for the
installation and observation of these instruments shall be extended by the agency
executing the work. For installation and observation of instruments and for necessary
soil tests near the installed instruments, necessary time shall be allowed within
placement schedule.
The embankment shall be constructed (exclusive of pitching and backing of chips or filter
below pitching) generally to the lines and grades shown on the drawings, but
increased by such heights and widths determined as necessary to allow for settlement
or shrinkage as specified in para 4.9.9. Also in order that proper compaction can be
done upto the edges of the designed section duly increased for settlement and
shrinkage as stipulated above, section will be further widened by 45 cm. Subsequently
after compaction it will be dressed by trimming the slopes to proper section so that the
surface on the slopes is also as firm and compact as the top of embankment. The earth
thus trimmed could however, be used in the embankment fill. Any material that is lost
by rains, weathering or other cause shall be replaced.
The dam embankment is divided into zones within which fill materials having different
characteristic, are to be placed Placement of till within these zones as shown in the
drawings shall be performed in an orderly sequence and in efficient and workman like
manner, so as to produce within each zone, fills having such qualities of density,
strength and permeability as will ensure the highest practicable degree of stability and
performance of the whole dam embankment.
No bushes, roots, sods, or other perishable or unsuitable materials shall be placed in the
embankment. The suitability of each part of the foundation for placing embankment
materials thereon and of all materials for use in embankment construction will be
determined by the field laboratory.
The difference in elevations between core and shell zones of the dam embankment at any
cross-section above the embankment foundation shall not exceed 0.6 m unless
specifically authorised by the Engineer-in-Charge. The embankment for each zone
shall be maintained in continuous and approximately horizontal layers in the reaches
programmed for construction in that season. Where, however, due to some constraints
the dam has to be constructed in discontinuous portions or reaches, the slopes of the
bonding surface parallel to dam axis between the previously completed portions of the
dam embankment and the materials to be placed in each zone shell not be steeper than
3 to 1 in core, and 2 and 1/2 to I in other zones.
22.2 Preparation of Foundation
Foundation preparation shall be done subsequent to stripping and excavation, if any. All
portions of excavation made for test pits or other sub-surface investigations and all
other existing cavities found within the area to be covered by earthfill or of core and
shell zones, which extend below the established lines of excavation for embankment
foundation, shall be filled with earth fill of the corresponding zone of the
embankments. All test pits within a distance of 10 times the dam embankment from
the upstream toe shall be filled by impervious material. No material shall be placed in
any section of the earthfill portion of the dam embankment until the foundation for
that section is suitably prepared and has been approved by the Engineer- in-Charge.
The surface of each portion of the foundation immediately prior to receiving any material for
the earth fill shall be moist and sufficiently cleaned to obtain a suitable bond with the
embankment.
Pools of standing water will not be permitted in the foundation of the embankment and shall
be drained out prior to placing the first layer of the embankment.
(a) Rock Foundation - The treatment of the rock surface under the dam shall be so done as
to ensure a tight bond between the impervious core and foundation, for which the
following procedure shall be followed:-
(1) Before the grout curtain is installed, the area of the rock surface which is to be in
contact with the impervious core of the dam shall be exposed with rough
excavation. Hard rock projections and over-hangs shall be removed. If blasting
is to be resorted to, care shall be taken to avoid objectionable shocks to
foundation rocks and abutments. As far as possible, the whole contact area of
foundation rock and abutments after rough excavation shall be exposed at one
time to enable examination of rock surface characteristics and planning the
method of treatment. Curtain grouting where required shall be carried out in
accordance with provision under relevant para of specification, of chapter 22
"Drilling and Grouting".
(2) Cleaning and Shovelling. - After the grouting operations are over, the rock
surface shall be thoroughly cleaned. Pockets of sand and gravel and other soils
shall be removed by hand shovelling and soft erodible seams and localised
decomposition cleared out as deep as possible. Loose rock shall be removed
by wedging and hand packing. Layers of grout spilled from grouting operation
shall be chipped out and removed. Finally, the hand cleaned surface shall be
thoroughly washed with powerful water jets to remove the fines which would
have worked into the seams of the rock and obtain a clean surface.
Compressed air jets shall be used as a final step in the clean up operation.
(3) Sealing cracks. -Deep pot holes or pockets shall be filled with hand compacted
soil or concrete. If the rock surface in the bottom and sides of pot holes is
cracked, the crack should be sealed with cement grout. If the rock surface
contains too many closely spaced pot holes, the entire rock surface shall be
covered with concrete. A clay paste may be used in the smaller cracks. All the
cracks and joints and shear seams or other incompetent materials that are
exposed in the cut off trench shall be scooped out to the greatest depth
practicable (not less than twice their width at the surface)with the aid of
trowels, bars and cleaned with air water jets and then filled with slush grout.
Slush grout shall consist of cement and sand thoroughly mixed in a proportion
1 part of cement to 2 parts of sand by volume with sufficient water to produce
a highly plastic and buttery mix.
Foundation rock which is fairly impervious but has a very rugged surface shall be
treated by laying core material at a moisture content slightly above the
optimum in thin layers and compacted with mechanical equipment/small
tampers to ensure that all irregular depressions in the rock surface have been
filled with soil to create an effective/complete bond.
The moisture content and layer thickness shall be specified by the field laboratory.
Any open crack in the rock surface shall be specified by the field laboratory.
Any open crack in the rock surface shall be sealed with cement grout by
appropriate means. Fault zones or larger cracks shall be dug out to a depth as
determined by the Executive Engineer and backfilled with concrete.
(b) Soil Foundation- Soil foundations shall be scarified and loosened by means of a
plough, ripper or other methods to a depth of about 15 cms to 20 cms to the
satisfaction of the Executive Engineer. Roots or other debris turned up during
scarifying shall be removed from the entire foundation area for the fill It shall
then be moistened to slightly above the optimum moisture and compacted by
required number of passes of the compaction equipment to the same
percentage of compaction as the core. The purpose of higher than optimum-
moisture is to ensure forcing of the soil into any unseen soft zones just below
the surface. The first few lifts of fill for the embankment shall be carefully
placed, for the surface will still be rather irregular. If possible, heavy rubber
tyred rollers should be used for compaction because they will follow the
irregular surface and not bridge over small low areas as other types of rolling
equipment will do. Layers 10 cms to 15 cms thick with moisture content 1 to 2
per cent above optimum moisture content must be used to ensure uniform
compaction and a satisfactory intimate bond between the foundation soil and
the fill materials especially under the central core. The layers shall be
composed of the most impervious materials, under the central core zone.
(c) Sand Foundation - The foundation sand shall be tested for its natural relative
density. In reaches where the relative density is less than 70% the foundation
sand shall be dnsified by any of the approved methods to obtain a minimum
relative density of 7058. Until the foundation has been tested and the relative
density found to exceed 70$, earth fill shalll not be allowed to be placed. This
is necessary to minimise the effects of any structural re-adjustments in a loose
foundation.
22.3 Earth Fill Materials
The materials for the respective zones of embankment shall be obtained from borrow areas
designated by the field laboratory, which also will specify the depth of cut in the
borrow areas required for obtaining the desired gradation in the materials. In general,
all material from a particular borrow area shall be a mixture of materials obtained for
the full depth of cut. Where in a borrow area the sub-stratum occurs in well defined
layers differing considerably in mechanical analysis, so that mixture is not suitable for
any particular zone, the materials shall be excavated layer wise by scrappers or other
suitable means and the materials placed, in the zone for which it satisfies the
requirements. Where it is not practicable to obtain a mixture of materials, the finest
and most clayey material shall be placed in the cut-off trench and the central upstream
portion of the embankment. The intermediate material shall be placed between the
centre and the slopes of embankment and the coarsest material shall be placed near
the outer slopes of the embankment. No material containing a high percentage of
plastic clay shall be used in the embankment without being mixed with coarser
material.
Chemical and physical tests of soils in embankment shall be carried out to ensure that the soil
does not contain (a) soluble lime contents (b) soluble salt contents or cohesionless
fines, in quantities harmful to the embankments.
22.4 Placing Earthfill
The distribution and gradation of the materials throughout the earthfill shall be as shown on
the drawings or as directed. The fills shall be free from lenses, pockets, streaks or
layers of materials differing substantially in texture or gradation from the surrounding
materials. The combined excavation and placing operations shall be such that the
materials when compacted in the earthfill will be blended sufficiently to produce the
best practicable degree of compaction and stability. Successive loads of materials
shall be dumped on the earthfill so as to produce the best practicable distribution of
the material. The various zones shall be clearly delineated on the embankment and the
materials from the borrow areas placed accordingly.
The clay blanket shall be laid in a manner similar to clay core and compacted to same degree
of compaction at optimum moisture content.
Particular care shall be taken to ensure that materials are not so placed as will be conducive to
the formation of intermittent relatively impervious blankets in the shell zones, which
will interfere with the satisfactory drainage.
No stone, cobbles or rock fragments having maximum dimensions of more than 10 cms shall
be placed in the-earth fill (casing only). Such stones and cobbles shall be removed
either at the borrow pit or after being transported to the embankment but before the
materials in the earthfill are rolled and compacted. Such stone and cobbles shall be
used in the rip-rap or rock toe of the dam embankment, If suitable or wasted as
directed. The materials shall be placed in the earthfill in continuous horizontal layers
not more than 15 cm in thickness after being rolled as herein specified Higher
thickness of layers may also be permitted, if suitable compaction units such as
vibratory compactors are used to give required density under optimum moisture
content, but in no case the compacted thickness of the layer shall exceed 25 cm. The
extent of layers shall be determined in the field by test section. During construction, a
small transverse slope from centre towards edges should be given to avoid pools of
water forming due to rains. If in the opinion of the Executive Engineer the surface of
prepared foundation or the rolled surface of any layer of earthfill is too dry or smooth
to bond properly with the layer of materials to be placed thereon, it shall be moistened
or worked with harrow, scarifier or other suitable equipment, in an approved manner
to a sufficient depth to provide a satisfactory bonding surface before the next
succeeding layer of earthfill material is placed. If the rolled surface of any earthfill is
found to be too wet for proper compaction of the layer of earthfill material to be
placed thereon, it shall be raked up and allowed to dry, or be worked with harrow,
scarifier or any other suitable equipment to reduce the moisture content to the
required amount, and then it shall be compacted before the next succeeding layer of
earthfill material is placedJhe concrete or masonry surfaces against which earthwork
is to be placed shall be cleared and moistened prior to placing of the earthfill. Clay
leaping of plastic consistency be adopted to ensure proper bond between the earthfill
and the concrete/masonry. The foundation adjacent to the concrete structures shall be
thoroughly cleared of loose materials and moistened. In placing the earthfill on rock
foundation, the foundation shall first be prepared as detailed earlier. Care shall be
taken in placing the first layer of the fill that no damage is caused by the hauling
machinery which will get concealed by the spread layer of the fill. The soil for the
first layer shall be at a moisture content sufficient to enable satisfactory bonding of
the fill with the rock surface.
In case the whole length of embankment is not constructed simultaneously and only a portion
of embankment is constructed during one season the following procedure shall be
adopted.
The incomplete ends of embankment shall be placed at a slope not steeper than 4:1 to permit
satisfactory bonding with the portion of the embankment which is constructed later.
Old surface should be stripped or benched in accordance with the direction of the
Engineer- in-Charge.
9. General Requirements
1. The Cross sections for embankment are to be designed to suit the
characteristics of the best quality soils available in the vicinity of
the proposed work. If the contractor proposes to use any other
type of soils than those mentioned in the design to save the lead
and thereby the cost, the contractor has to form the embankment
to the revised profiles worked out by the competent authority.
The extra quantity involved will not be measured and paid. The
theoretical quantity required based on the original cross-sections
will only be measured and paid. But the Contractor has to form
the bund to the revised cross section designed with the
characteristics of the proposed soils. The designs given by the
estimate sanctioning authority are final.
2. Embankment shall be built to the height, top width and side
slopes as shown on the drawings. All the edges of the
embankment shall be neatly aligned symmetrical to the central
line. They shall be absolutely straight in all reaches except at
bends. At bends they shall be smoothly curved.
3. The top of each embankment shall be leveled and finished so as to
be suitable for road way and given a cross slope to drain away
rain water. The bank carrying road shall be given a suitable cross
slope.
1. Material
1. The suitability of foundation of placing embankment materials
thereon and all materials proposed for use in construction of
embankment shall be determined by the Contractor well in
advance on the basis of Laboratory Test results. Chemical and
Physical tests of the material proposed for construction of
embankment shall be carried out to ensure that the soil does not
contain soluble lime content, soluble lime salt content or cohesion
less fines, in quantities harmful to the embankments.
2. Material for construction of embankment should be free from the
organic material. Unless otherwise directed by the
Superintending Engineer/ Executive Engineer all materials shall
be deposited in embankments so that cobbles, gravel and
boulders are well distributed through other material and not
nested in any portion within or under are embankment as per
clause 6.4 of I.S. 4701-1982.
3. Suitable excavated material available from the cut off trenches,
canal cutting, extra cutting for seating to lining, foundation
excavation for structures, approach and tail channels for
structures, nalla diversions, removal of ramps etc, shall be used
for construction of adjacent embankments.
4. After completing the construction of embankments with the
materials as indicated in 37.3 above, material required for the
construction of balance embankment shall be obtained from the
borrow areas.
5. The soils and morum excavated and useful for construction of the
embankment shall be classified by the Engineer-in-Charge as
impervious and Semi-Pervious based on Laboratory Test results.
They shall be utilized on the embankment work.
2. Preparation of ground surface for embankment:

6. Clearing site : Clause 6 shall apply.
7. Stripping : Clause 7 shall apply.
8. All portions of excavation made for test pits or other subsurface
investigations, all holes, hollows and all other existing cavities
found within the area to be covered and to the extent below the
established lines of excavation for embankment seat shall be filled
in earth of the corresponding zone of the embankment and
suitably compacted. The pits of surface boulders shall be filled
with suitable material and compacted at no extra cost.
9. Pools of water shall not be permitted in the foundation for
embankment and such water shall be drained and cleared prior
to placing the first layer of embankment materials.
10.On sloping ground or in case of existing banks, where
embankment portions are to be modified, benching of slopes shall
be done with a little slope towards the inside of beaching so as to
give a good grip to the embankment soil with the sub-grade.
Unless otherwise specified the benches shall be 0.3.X.0.6.m. on the
front and rear slope of the embankment. Before benching, the
bank slopes shall be cleared of all roots and vegetables matter as
per specification 2.0. No separate payment will be made for either
benching or refilling. The rate quoted for raising embankment is
inclusive of above operations. The bank section shall be brought
to design standards by filling the scours with suitable material
and compacting to 98% proctor density by suitable measure of
compaction.
11. Soil foundation:
12.The ground surface under embankment and area of bed filling
wherever necessary ( except rock surfaces ) shall be loosened or
scarified making open furrows by means of a plough, or ripper or
any other methods to a depth of not less than 200 mm. deep below
the stripped surface at intervals of not more than 1m. to the
satisfaction of the Engineer-in-charge. Roots or other debris
turned up during scarifying, shall be removed from the entire
foundation area for the fill. The areas under the embankments
shall be prevent by sprinkler before the construction of
embankment begins. The moisture content shall be optimum.
13.Rock foundation:
The treatment of the rock surface under the embankment shall be done so as to ensure tight
bond between embankment and the foundation. This shall be done by the following
procedure.
i) The area of the rock surface which is to be in contact with the embankment shall be fully
exposed by removing all the loose and disintegrated rock having the surface of
rock rugged. Hard rock projects and overhangs shall be removed. If blasting is
to be resorted to, care shall be taken to avoid objectionable shocks to
foundation rock. As far as possible the whole contact area shall be exposed at
one time to enable examination of rock surface characteristics and planning
the method of treatment.
ii) Exposed rock shall be benched.
9. Compaction & WATERING:

1. Compaction Equipments : While the specification below provide
that equipment of a particular type & size is to be furnished and
used, it is contended that the improved compaction equipment as
may be most suited to the prevailing site conditions and the
programme of construction shall be used. The broad details of the
equipments are given below:-
2. Tamping roller/vibratory compactors shall be used for
compacting the earth fill. The sheep foot rollers shall meet the
following requirements:-
(i)Roller Drums :- Each drum of a roller shall have an outside diameter of not
less than 150 cm and shall be not less than 120 cm not more than
180 cm in length. The space between two adjacent drums, when
on a level surface shall not be less than 30 cm nor more than 38
cm. Each drum shall be free to pivot about an axis parallel to the
direction of travel. Each drum shall be equipped with a suitable
pressure relief valve to prevent excessive pressures from
developing in the interior of the roller drum.
(ii) Tamping Feet :- At least one tamping foot shall be provided for each 645
sq. cm of drum surface. The space measured on the surface of the
drum between the centres of two adjacent tamping feet shall not
be less than 230 mm. The cross sectional area of each tamping
foot shall be not more than 65 sq. cm at a plane normal to the axis
of the shank 150 mm from the drum surface and shall be
maintained at not less than 45 sq. cm nor more than 65 sq. cm at
a plane normal to the axis of the shank 200 mm from the drum
surface.
vi. Roller Weight :- The weight of the roller when fully loaded shall not be
less than 7091 Kg and the ground pressure when fully loaded shall not
be less than 40 Kg/cm 2 required to obtain the desired compaction.
Tractor used for pulling rollers shall be of 50 H.P. to 65 H.P. power to
pull the rollers satisfactorily at a speed of 4 Kms/per hour when the
drums are fully loaded with wet sand ballast. During operation of
rolling, the spaces between the tamping foot shall be kept clear of
materials sticking to the drum which could impair the effectiveness of
the tamping rollers.
3. Rolling :-
i. When each layer of material has been conditioned so as to have the proper
moisture content uniformly distributed through the material, it shall be
compacted by passing the tamping roller. The exact number of passes shall be
designated by the field laboratory after necessary test. The layers shall be
compacted in strips over lapping to less than 0.6 m. The rollers or loaded
vehicle shall travel in a direction parallel to the axis of the dam. Turns shall be
made carefully to ensure uniform compaction. Rollers shall always be pulled.
ii. If the foundation surface is too irregular to allow the use of large roller directly
against any structure or rock out corp, the roller shall be used to compact the
soil as close to the structure or rock out-crop as possible and the portion of the
embankment directly against the rock or the structure shall be compacted with
pneumatic hand tempers in thin layers. Sheep foot roller shall not be employed
for compaction till the thickness of the layers compacted by other mean is
greater by 30 cm than the depth of the foot of the roller drum.
4. Tamping :- Rollers will not be permitted to operate within 1.00
metre of concrete and masonry structures. In location where
compaction of the earth fill material by means of roller is
impracticable or undesirable, the earth fill shall be specially
compacted as specified herein at the following locations:-
4. Portions of the earth fill in dam embankment adjacent to masonry structures
and embankment foundations designated on the drawing as specially
compacted earth fill.
5. Earth fill in dam embankment adjacent to steep abutment and location of
instruments.
6. Earth fill at locations specially designated.
Earth fill shall be spread in layers of not more than 10 cm in thickness

when loose and shall be moistened to have the required moisture
content as specified. When each layer of material has been conditioned
to have the required moisture content, it shall be compacted to the
specified density by special rollers, mechanical tampers or by other
approved methods; and all equipment and methods used shall be
subject to approval based on evidence of actual performance and field
compaction tests. The moisture control and compaction shall be
equivalent to that obtained in the earth fill actually placed in the dam
embankment in accordance with the specifications..
5. Cohesive Materials:
a) When each layer of material has been prepared so as to have the proper moisture content
uniformly distributed throughout the material, it shall be compacted by
passing the roller. The layer shall be compacted in strips over lapping not less
than 0.30 Meter. Rolling shall commence at edges and progress towards center
longitudinally. The roller shall travel in a direction parallel to the axis of the
bank. Turns shall be made carefully to ensure uniform compaction. Density
tests shall be made after rolling and dry density attained shall be not less than
98% of the maximum dry density (standard proctor) as obtained in the
laboratory for the type of material used. The density achieved shall not
normally be less than the designed density. The dry density of soil in field
shall be determined in accordance with I.S. 2720 (Part-XXVII)-1974 or I.S.
2720(Part. XXIX)-1975.
b) Standard proctor density test shall be carried out at regular intervals to account for
variations in the borrow area materials as well as that in situ excavated
material. Not less than three tests shall be carried out to indicate variations in
the standard proctor density attained in laboratory.
c) Engineer-might review the design if necessary on examination of density test results and
the contractor shall have no claim arising out of such a review and consequent
change, If any, in the design.
d) i) In case embankment covers the barrels of cross drainage or any other structures, first
45cm. of the embankment shall not be compacted with roller but it
shall be compacted with pneumatic/hand tampers in thin layers. The
compaction above this layer of total 45cm shall be done by using
suitable light rollers to avoid damage to the structure, by adjusting the
thickness of layers until sufficient height is achieved to permit
compaction by heavy rollers. Density test shall be conducted form time
to time on site to as certain whether the compaction is attained as
specified above.
ii) Separate tests shall be conducted for each zone of the embankment for every 1500 cubic
meters of compacted earth work, at least one field density test shall be
taken in each layer. Minimum two density tests shall be taken in each
layer per day irrespective of the quantity of earth work specified above.
In case the test shows that the specified densities are not attained,
suitable measure shall be taken by the contractor either by moisture
correction or by entire removal and relaying of layer or by additional
rolling so as to obtain the specified density which shall be checked
again by taking fresh tests at the same locations. Necessary unskilled
labour required for carrying out such density tests shall be provided by
the contractor.
e) Compaction shall be achieved by the use of smooth rollers pneumatic type rollers, sheep
foot rollers, mechanical compactors like vibratory rollers, vibrating plates,
programmers, power rammers, slope compacting equipment, pneumatic
tamping equipment and such other equipment as shall be specified by the
Engineer based on type of material and actual field tests.
f) The dimensions and weight of the rollers should be such as to exert a ground pressure of
not less than 12 kg/cm2 of tamping when it is empty and 25kgs/. Cm2 When
ballasted. The number of passes required for each layer to obtain the specified
density shall be determined by actual field tests.
1. Cohesionless Materials:
3. Where compaction of cohesionless free-draining material such as sand and gravel is

required, the materials shall be deposited in horizontal layers and compacted to the
relative density specified. The excavating and placing operations shall be such that the
material, when compacted, shall be blended sufficiently to secure the highest
practicable degree of compaction and stability. Water shall be added to the materials,
if required to obtain the specified density depending on the method of compaction
being used.
4. As per clause 6.6.2.1 of I.S. 4701-1982, the thickness of embankment layer shall not
exceed 25cm. (Loose) before compaction and it should be spread over the full width
of embankment and compaction shall be done by rollers or tampers to obtain specified
density. The thickness of the horizontal layers after compaction shall not be more than
10cm.. If compaction is performed by tampers, not more than 15cm. if by 8 to 10
tonnes rollers and not more than 30cm.. If compaction is performed by vibratory or
pneumatic rollers or similar equipment. The relative density of the compacted
materials shall not be less than 70 percent as determined by laboratory tests as per I.S
2720 Part -XIV. if compaction is performed by internal vibrators, the thickness of
layers shall not be more than the penetrating depth of the vibrator.
7. Embankment without controlled compaction

1. No materials shall be placed in any section of the earth fill portion
of the embankment until the embankment seat for that section has
been approved by Executive Engineer.
2. The excavating and hauling equipments shall travel over the
embankment to evenly distribute the material and compacting
effort over the whole surface.
8. Embankments with controlled compaction

1. Bushes, roots, sods or other perishable or unsuitable material shall
not be placed in the embankment.
2. Unless otherwise specified, embankment materials shall be spread
in successive horizontal layers generally not exceeding 25cm, in
thickness (loose layer) in the zones where these are required to be
laid, extending to the full width of the embankment including
slopes at the level of the particular layer. Each layer shall be
commenced from the edge farthest from excavation. In no case
shall embankments be widened by material dumped from the top.
Top of each layer shall be kept slightly depressed in the centre.
3. Extra width of 600 mm. in thickness as measured perpendicular to
the slope shall be provided on either side so that when compacted,
lines of the finished embankment slopes shall have not less than
specified density. Later the extra width shall be neatly trimmed
and the trimmed material shall be permitted or re-use in
embankment at higher elevations. No payment shall be made for
providing removal of the extra section. Removal of extra section in
the embankment shall be deemed to have been included in the item
of compaction.
4. Thickness of layers shall be adjusted with particular type of
compactors used to give the required density by carrying out trial
compaction and requisite tests and required number of passes
should also be determined as directed by the Engineer.
5. No fresh layer shall be laid until the previous layer is properly
watered and compacted as per requirement. The work of
spreading and compaction shall be so adjusted as not to interfere
with each other and in such a way that neither of the operations is
held up because of non-completion of the rolling and watering. The
surface of the banking shall at all times of construction be
maintained true to required cross section. If the surface of any
compacted layer of earth fill is too dry or too smooth it shall be
moistened and scarified to provide a satisfactory bonding surface
before the succeeding layer is placed. All the rollers used on any
one layer of fill shall be of the same type and same weight.
6. The contractor shall ensure that only approved soils are used for
construction of embankment.
7. For proper bond of the embankment done in the previous season
with the new embankment, the work shall be carried out as
detailed below.
i) In case of the old bank to extended horizontally. It shall be cut to a slope not
steeper than 1 in 4 and the surface so prepared shall be scarified and made
loose at least for a depth of 15cm. Necessary watering shall be done and the
earth surface shall be thus prepared to receive the new embankments. The
soils shall be laid in layers and compacted to the required degree of
compaction to have a proper bond with the old one.
ii) If the old bank is to be raised vertically, vegetation shall be cleared followed by
scarifying, watering and placing of the new earth layer as specified above.
iii) The surface which are damaged due to rain shall be made good by filling with
proper soil duly compacted by tampers. A cross slope away from the centre of
canal of about 1in 80 shall be maintained throughout the rainy season to
ensure. proper drainage in the event of occasional rainfall. No extra or
separate payment shall be made for these items of work.
1. Settlement allowance:
iv. The canal embankments shall be constructed to a higher elevation than that shown on
drawings at the rate of 2.5cm. per every one meter height of bank if power driven
equipment is used and 25cm/lmt height if other than power driven equipment is used
for compaction towards Shrinkage /Settlement.
v. No extra or separate payment shall be made for this work as this shall be deemed to
have been included in the respective item of construction and consolidation of
embankment.
vi. Care shall be exercised that all large clods are broken and no clod bigger than say
8cm. rock, are buried in the banks.
9. Homogenous Section:
The homogeneous section for canal embankments shall be provided as specified in the
drawings. The available coarser and more pervious materials shall be placed nearby outer
slopes in order to have increasing permeability from inner to outer side. The compaction shall
be carried out as per clause 6.6.2 of I.S. 4701-1982.
10.Zonal Embankments:
In Zonal sections the selected and approved soils shall be spread to the required widths of
respective zones. All the zones shall be tackled simultaneously and the difference in level
between zone to zone shall not be more than 150mm.
9. Moisture CONTROL:
The water content of the earthfill material prior to and during compaction
shall be distributed uniformly throughout each layer of materials between
2 to + 1 of the optimum moisture content for casing material and between
0 to + 2 for hearting material. Moisture determination of soils as well as
needle moisture determination of soil shall be carried out as per IS : 2720
(Pt. II) 1973, sec 1 and designation E22 of USBR / Earth Manual 1968
respectively.
Laboratory investigations may impose some restrictions on the lower limits of the practicable
moisture contents on the basis of studies on consolidation characteristics of soils in
embankment. Hereinafter the term range of optimum practicable moisture content shall
refer to the value as described above. As far as practicable, the material shall be placed
at proper moisture content. If additional moisture is required, it shall be added by
sprinkling water before rolling of a layer. If the moisture is greater than required, the
material shall be spread and allowed to dry before starting rolling. Moisture control
shall be strictly adhered to. The moisture content shall be relatively uniform throughout
the layer of material. If necessary, ploughing, disking, harrowing or blending with other
materials may have to be resorted to, to obtain uniform moisture distribution. If the
moisture content is more or less than the range of optimum practicable moisture
content, or if it is not uniformly distributed throughout the layer, rolling and adding of
further layer shall be stopped. Further work shall be started again only when the above
conditions are satisfied.
The Moisture content of the earthfill placed against any rock outcrop or any structure shall be
slightly above the optimum, to allow it to be compacted into all irregularities of the rock
and this shall be determined by the field tests.
9. Special Precautions:
1. During the actual construction of any earth work, maximum use
should be made of construction plant and routing of the plant
should be carefully controlled to obtain uniform compaction over
as wide an areas as possible. Care should also be taken during the
compaction operation to shape the surface of the works to
facilitate the shedding and to minimize the absorption of rain
water, particular attention being given to the prevention of
pending of water. The contractor shall do this at the end of each
days work.
2. The earth moving machinery shall not be allowed to pass over a
compacted portion of the embankment beyond certain limits by
varying the hauling routes and ramps, thus ensuing that over
compaction does not take place in any particular reach.
3. During the Construction, a small transverse slope from centre
towards the edges shall be given and further in the reach when
bank is being raised, the works shall be tackled in continuous
horizontal layers to avoid pools of water and concentration of
allow of water during rains, which will cause damages, scours and
rain gullies.
4. Special precautions shall also be taken while rolling the spread
soil near structures, conduit, sluice barrels, filters, rock toes at the
junctions of bank connections with the structures, using hand or
power tampers. It is essential that the compaction of filling should
be carried out in such a manner as to avoid an unbalanced thrust
on walls etc., which might displace or damage it. The equipment
shall be provided with suitably shaped heads to obtain the
required density.
10. DOWEL BANKS:

1. Dowel Banks shall be constructed to the dimensions, grades,
slopes as shown on the drawings.
11. Weather Conditions:

1. The embankment material shall be placed only when the weather
conditions are satisfactory to permit accurate control of the
moisture content in the embankment materials. During that part
of the construction period when the top surface of the
embankment may be subject to rainfall causing cessation of
work, it shall be graded and rolled with a smooth wheeled rollers
to facilitate runoff. Prior to resuming work, the top surface
should be slightly scarified and moistened or allowed to dry as
necessary and approved by the Engineer-in-Charge. If the
cessation due to any reason, is for a considerable period, top layer
shall be stripped to the required depth as may be directed by the
Engineer-in-Charge so as to remove any vegetable growth, loose
silt or sand washings or other objectionable matter.
2. The Contractor shall provide suitable protection works protect
the slope from erosion due to rain water. No payment whatsoever
shall be made for providing such protection work and rectifying
any monsoon damages.
12. Dressing Slopes

The outside slopes of the embankment shall be neatly dressed to lines and
grades as placement of fill progress.
All humps and hollows varying more than 15 cm from the neat lines of the
embankment shall be regarded. Material used to fill depression shall be
thoroughly compacted and bonded to the original surface. Slopes shall
be maintained until final completion and acceptance. Any material that
is lost by rains, weathering or other cause shall be replaced at his cost of
agency executing the work.
9. Settlement Allowance
1. In the earth fill embankment watered, rolled and compacted at
optimum moisture content and at dry density expressed as
percentage of proctors maximum dry density as given in
Appendix-I, settlement allowance of 1% and 2% of the designed
height for un-yielding (rock) and compressible (soil) foundations
respectively shall be provided. The base width of the dam will not
be increased to maintain the design slopes indicated in the
drawings for the additional height as settlement allowance, but
the following procedure will be adopted.
2. Settlement allowance will be calculated at various levels, where
the slope is to be changed and elevations including settlement
allowance will be derived. The embankment width at the designed
levels remaining same. The edges of embankment at the increased
elevation (including settlement), when joined with the point
where the slope has changed earlier below shall give the slope to
be adopted for construction.
3. If the embankment is raised in more than one season, provision
for settlement shall be made in the last seasons construction by
slight steepening of slopes near the top.
10. Toe Drains :

1. Pitched toe drains with filter will be provided throughout the
length of the dam at the downstream toe of earth dam as
indicated in the drawings and as per the details shown therein.
The layer of horizontal filter under the casing portion of dam
shall be extended in the toe drains to specified thickness. The
filter shall be watered and tamped with hand tampers.
2. The useful excavated material out of the toe drain shall be
suitably utilised on the dam as directed by the Engineer-in-
Charge.
11. SURFACE DRAINS:

1. This work shall consist of constructing surface drains, Schedule
of work shall be so arranged that the drains are completed in
proper sequence with canal excavation works as necessary
subsequently or no damage is caused to these works due to lack of
drainage.
2. Surface drains shall be excavated to the specified lines, grades,
levels and dimensions. The excavated soils shall be removed from
the area adjoining the drains. and is found suitable utilized in
embankment construction. All unsuitable soils shall be disposed
off as directed.
3. The excavated bed and sides of drains shall be dressed to bring
these in close conformity with the specified dimensions, levels and
slopes.
4. All works on drain constructions shall be planned and executed
in proper sequence with other works as approved by Executive
Engineer with view to ensure adequate drainage for the area.
12. Side drains:

1. The location, grades and sections of the drains shall be as shown
on the drawings and or as directed. Measurement of excavation
for the above drains will be made to the lines shown on the
drawings or as directed.
13. ROAD SURFACES AND PARAPETS

1. Road shall be constructed at the top of the embankment and at
other locations as indicated in the drawing. The roadway shall be
as indicated in drawing. The construction shall be as specified for
the highway by I.R.C. or as directed by the Engineer-in-Charge.
2. The parapets shall also be constructed after allowing sufficient
time for the embankment to undergo the usual post construction
settlement in order to avoid cracking of the walls due to
differential settlement.
14. PROTECTION:
1. The contractor shall take all precautions necessary for the
protection of the work by diversion of stream local surface
drainage, rain water etc. if these are likely, to damage the work.
Any damage to earth work due to any reason what so ever shall
be made good by the contractor at his cost till the work is
certified as completed and takeover by the Superintending
Engineer/Engineer-in-Charge.
15. ROADS AND RAMPS:

1. The contractor shall construct, operation, and maintenance roads
and earth ramps adjacent to the canal and structures at his own
expanses. Suitable materials from excavation or borrow areas
shall be placed as embankment for the roads and ramps. The
width of the road shall be not less than 4.25M.
39 (a) rip-rap on the upstream slope of embankment

Hand Placed Rip-Rap
vi. Rip-rap shall be hand placed on the upstream slope of the dam embankment over
backing of specified filter layers. The thickness of rip-rap layer shall be as indicated in
the drawings.
vii. Stone for rip-rap shall be hard and durable and shall not crumble on long exposure to
water, frost and air.
viii. Procedure for Placing Rip-Rap .- The hand placed riprap shall consist of one man
stones laid on edge. Starting at the bottom of the slope the stones shall be laid
compactly with staggered joints and so matched and inter-locked that they shall be
keyed together with a minimum of joint space. Rock fragments and spell shall be
driven into interstices to wedge the rip-rap in place. The wedging shall be done with
the largest chip practicable, each chip being well driven home with a hammer so that
no chip can be removed by hand. Very irregular projections shall be knocked off so
that the rip-rap presents a reasonably uniform surface free of loose stones.
ix. Hand placed riprap should preferably be laid in one course such that the layer
thickness is same as the stone size. However, at least 80 percent of the area of riprap
should have stones weighing more than 45kg. Such stone should be spread uniformly
in the area. Where such stones are not sufficient to cover the entire thickness of riprap,
the same may be laid in two layers.
If two layers of stones are used, header stones extending throughboth layers and
spaced at about 1.5 m, shall be used. Also, of the two layers, the top layer shall be of
large stones. The size of the smallest side of the heater stone shall not be less than 150
mm and its length shall be equal to the thickness of the riprap plus 150 mm so that the
header stone would project above the general top surface of the riprap by about 150
mm. Such a projection will break the wave force and would also facilitate easy
identification of the header stones. If header stones of full length are not available
from the quarry, concrete blocks of necessary size, length and shape may be
manufactured for the purpose.
In case of stone of requisite size are not available and smaller stones/ boulder locally
available are required to be used, the riprap should be laid in panels furmaed by
constructing profile walls. A portion of the area between the panels may be grouted by
pouring fluid cement mortar worked into the riprap. Hand placed riprap may be laid
flat or laid with projections (Needles).
x. The riprap shall be placed along with the fill so that a minimum of breakdown will
occur during placing and spreading.
2. Dumped Rip- Rap
iv. The minimum thickness of dumped rock riprap and average rock size shall be shown in Table
1. The thickness of riprap shall in no case be less than 450 mm.
TABLE 1: MINIMUM THICKNESS OF DUMPED RIP-RAP
Maximum wave height Minimum average rock size Minimum riprap Thickness
(D50)
(m) (mm)
(mm)
0 to 1.5 300 600
1.5 to 3.0 400 750
Above 3.0 700 1000
v. The most important criteria in Table 1 is the minimum average rock size (D50)of
riprap. For example, for waves of 2 m in height, the riprap should be composed of
rocks, half of which by weight are equal to or larger than more or less
equidimentiaonal rock with average diameter of 400 mm. The rock used for riprap
shallbe well graded from a maximum size roughly equal to 1.5 times the average size
to 50mm.
vi. Procedure for placing rip-rap. - Dumped riprap shall consist of boulders or blasted
rock fragments. It shall be dumped in place mechanically on a property graded filter
layer. The full thickness of dumped riprap shall be dumped in one layer. It shalll either
be dumped over the upstream face from the embankment. Level as the embankment is
being raised up or after the embankment had been completed. When placed during the
construction, the riprap layer should be kept a few metres lower than the construction
surface when placed after the embankment is completed, the rock should be taken to
the crest of the dam in trucks and than lowered down the slope by suitable mechanical
device. The rock shall not be allowed to drop down the slope in a chute or be pushed
down the slope., since these operations result in excessive segregation. After dumping
the rock should be worked manually with bars or other equipment to achieve a well
packed and tidy surface.
3. Graded Filter Underneath Rip-Rap
v. Graded filter shall consist of at least two layers of filter material (coarse and fine), the
thickness of each layer 'shall be as specified in the drawing.
vi. The graded filter shall consist of sand and crushed stone as shown in the drawing.
Sand used shall be clean, sound and durable and shall be free from silt, roots, brush
wood and other impurities. Sand used shall be of size passing 4.75 mm screen.
Crushed stone used for filter shall consist of rock, fragments reasonably graded upto 1
5 cm in maximum dimension.
vii. Gradation requirement for the coarse filter material with respect to riprap material
should conform to the criteria that D85 size of the coarse filter material shall not be
less than 1/10 of D15 size of the riprap material. The gradation requirements for the
fine filter with respect to embankment material should conform to the criteria that D15
size of the fine filter material shall not exceed 5 times the D85 size of the retained
embankment material. The two layers of filter shall also satisfy these criteria with
respect to each other. Where the embankment material satisfy this criteria with respect
to coarse filter, fine filter could be omitted.
viii. Before placing of filter material, the embankment shall be trimmed neatly to the slope
and grades as indicated on the drawing. The filter-material shall be placed in layers of
uniform thickness and care shall be taken to avoid segregation of coarse & fine
material in each layer, formation of pockets and mixing of material of one layer with
material of another layer of earthfill.
4. Tolerance. -
The tolerance on the nominal thickness of rip-rap enforced on the performed profile shall be
10 percent.
9. Dry Stone Pitching :

cum as specified in the appropriate item of USR or other size as
stones being quarried. The small size stones/spalls required for
2. Placing
Backing of filter and/or spalls where specified on drawing shall be placed only after the
underlying slope shall be trimmed neatly to the slopes and grades established on the
drawings. The lowest course of pitching shall be started from the toe wall or the line of pin
headers at the toe of the slope as may be specified on the drawing and the pitching laid course
by course up the slope.
Projecting corners shall be knocked off with the hammer so as to make a rough joint at the
base. The stones shall be laid on end with broadest base down and length normal to the slope
and carefully bonded in all directions and firmly bonded on the backing of filters where
provided. The stones shall be packed with hammer of mallet closed against each other, their
general line being approximately perpendicular to the slope of the underlying surface.
After the stones have been fixed as above, the interstices shall be filled with well fitting chips
driven home.
The general face slope of the pitching when completed shall be as specified in the drawing
subject to the tolerance as given in para 39.3 below. The final surface of the pitching shall be
clear off all refuge.
1. Tolerance : The tolerance on the nominal thickness of rip-rap
enforced on the performed profile shall be 10 (Ten) percent.
10. Dry Picked up boulder pitching
1. The boulders used in this type of pitching shall consists of the
rolled rock masses directly picked up in their natural form from
the river or the nalla beds. The boulders shall be hard, dense and
resistant to abrasion. The size of the boulders in at least one
direction should not normally be less than 22 cm. Also the least
dimension of such boulders in any direction should not be less
than 10 cm. The smaller size boulders/gravels required for
packing and wedging shall be brought to the site only to the
required extent and shall not be used in two or more layers as a
substitute for the boulders of full thickness.
2. Placing :
Over the backing of filter as may be specified in the drawing, the boulders shall be placed
such that the direction in which the size of boulder is around 22 cm is placed normal
to the surface of under layer. Also the boulders shall be laid with broadest base down
and carefully bonded in all directions.
After the boulders have been fixed as above, the interstices shall be filled with well fitting
smaller size boulders / gravel driven home.
The general face sloe of the pitching when completed shall be as specified in the drawing
subject to the tolerance as given in para 39.3. The final surface of the pitching shall be
clean off all refuge.
9. Dry Quarried Boulders Pitching

1. The specification as in Clause 39 shall be followed except that the
boulders of required size shall be obtained by breaking big size
boulders.
cum as specified in the appropriate item of USR or other sizes as
stones being quarried. The small size stones/ spalls required for
3. Placing : Backing of filter and/or spalls where specified on
drawing shall be placed only after the underlying slope shall be
trimmed neatly to the slopes and grades established on the
drawings. The lowest course of pitching shall be started from the
toe wall or the line of pinheaders at the toe of the slope as may be
specified on the drawing and the pitching laid course by course
up the slope.
1. Projecting corners shall be knocked off with the hammer so as to
make as rough joint at the base. The stones shall be laid on end
with broadest base down and length normal to the slope and
carefully bonded in all directions and firmly bonded in all
directions and firmly bonded on the backing of filters where
provided. The stones shall be packed with hammer of mallet closed
against each other their general line being approximately
perpendicular to the slope of the underlying surface.
2. After the stone have been fixed as above, the interstices shall be
filled with well fitting chips driven home.
3. The general face slope of the pitching when completed shall be as
specified in the drawing subject to the tolerance as given in para
39.3. The final surface of the pitching shall be clean off all refuge.
10. ROCK TOE

1. The rock fill shall consist of free draining mixture of rock
fragments of sizes from 75mm to 250mm. A large amount of
material may be obtained from required excavation for other
parts of the work. Additional, as required shall be obtained from
rock quarries.
2. Successive loads of material shall be dumped as to secure the best
practicable distribution of materials. The large rock fragments
shall be placed on the outer slopes and the smaller fragment shall
be placed towards the earth fill side. In general, the downstream
toe shall be placed in the manner to be approved by the Engineer-
in-Charge.
3. The rock fill shall be placed in horizontal layers not exceeding 90
cm in thickness. The completed fill shall be stable and no large
unfilled spaces shall be present in the fill.
4. Large voids, shall not be allowed on the downstream face of the
rock toe, so as to prevent choking by the spilling of earth, rain
cuts, etc. during and after construction. Such voids shall be
properly packed with stone chips of suitable sizes. The surface of
the rock toe shall be kept clear of all earth and debris so as not to
choke its full drainage capacity.
5. The filter layers to be provided behind and below the rock toe
shall satisfy the requirements of as below
6. BASE FILTER BLANKETS:
6. As and where indicated in the approved drawings, filter blanket should be laid
on the base, under the down stream portion of the canal embankment. The
number of layers in the filter blankets and the thickness of each layer shall be
as specified in the drawings. Sand shall be placed and compacted to an
average relative density of 85% with a minimum relative density of 70%. The
filter shall be placed and tamped in to place in such a manner that mixing of
filter with foundation or backfill materials will not occur. The filter materials
should satisfy the following criteria.
1. The filter material shall consist of clean, sound and well graded
aggregate. The material shall be free from debris, wood, vegetable
matter, decomposed rock and other deleterious matter. The
gradation of each filter layer shall meet the following requirements
with respect to the material to be protected and also with respect to
the adjacent filter layers.
i) D. 15 of Filter material > 4 < 20
D. 15 base material
Provided the filter does not content more than 5% of material finer
than 0.07 mm (No. 200 Sieve).
ii) D. 15 of Filter material < 5
D. 85 base Material
iii) D. 50 of Filter material < 25
D. 50 base material
iv) Coefficient of Curvature CC = (D.30)2 >/<3
D.10 x D. 60
V) Co-efficient of Uniformity : Cu = D.60 > 6 for SW
D.10
and Cu = D.60 > 4 for GW
D.10
Where
SW: Sand well Graded and
GW. Aggregate well graded.

7. The base filter materials should be well graded so as to satisfy the above
mentioned criteria. The grain size curve of the filter shall be roughly parallel
to that of base materials. In the above D-15 is the size at which 15% of total
soil particles are smaller. The percentage being by weight as determined by
mechanical analysis. The D-85 size is that at which 85% of the total soil
particles are smaller. It shall be laid in single layer or in layers as per the
drawing. If more than 1 filter layer is required the same criteria shall be allow.
The final filter is considered as the base material for selection of the gradation
of the coarse filter especially in the fine range. Filter materials should not
contain more than 5% of fines i.e. materials finer than 0.075 mm. (passing
through sieve No- 2000 I.S. sieve 75 micron) and fines should be cohesion
less to ensure that filter does not sustain a crack. The filter should not have
particles larger than 75mm. so as to minimise the segregation.
8. D. 15 is the size at which 15% of the total soil particles are smaller, the
percentage being by weight, is being propped, to be determined by mechanical
analysis. D.85 size is that at which 85% of the total soil particles are smaller.
As more than one filter layer is required, similar criteria is followed in each
case, viz., the finer filter is considered as base materials for the selection of the
gradation at the coarser filter.
9. The requirement for grading of the filter shall be established by the tests
conducted in the filed laboratory on the basis of mechanical analysis of
adjacent materials, Mechanical analysis shall be performed of all samples,
which have been compacted by the methods equivalent to compaction by
roller, so that the individual particles are broken to their field condition in the
embankment.
10. The filter materials shall be compacted to an average relative density of 85%
with minimum relative density of 70% as determined by the standard U.S
Bureau of Reclamation (Relative density test for cohesionless free draining
soils)
Dd = emax e
e - max -e min.
Where e = In place void ratio
e max = void ratio in loosened state
e min = void ratio in most compacted state, and
void ratio = Volume of Voids
Volume of solids
The relative density may also be computed using the maximum and min.
density as follows.
Dd = Yd max (Yd-Y min)/Yd (Yd max-Yd. min)
Where Yd Max = Maximum dry density of soil as obtained by the laboratory
procedure
Yd min = Minimum dry density dry density of soil as obtained by
the laboratory procedure.
Yd = The dry density at which the soil is to be placed or the in place dry
density.
The thickness of each filter layer shall be less than 150mm.
42.7 Seepage Drains
The seepage drains shall be excavated to the size and bed grad as shown in the drawings so as
to allow for easy flow of seepage from the hearing toe to the open drains. These shall be
refilled with layers of sand, gravel or broken metal and boulders as shown in the drawings. In
this case greatest care will have to be taken to see that filter media do not get mixed up.
42.8 Chimney Filter
Vertical inclined filter of the dimension specified in drawings shall be constructed on the
downstream face of impervious core. The thickness of chimney filter shall be as shown in the
drawings. Materials used shall be clean, sound and durable and shall be free from silt, roots,
bush and other impurities. Filter materials shall be laid in 30 cm layers and shall be
thoroughly wetted and compacted by pneumatic tyred rollers or other approved equipment.
Materials for filter shall be compacted to obtain a minimum relative density of 70%. The
filter shall satisfy the filter criteria as given in para 42.6.1 for filter blankets.
9. BORROW AREAS
1. All materials required for the construction of impervious, semi
pervious or pervious zones of embankment, which are not
available from excavation and surplus material from other
reaches shall be obtained from designated borrow areas as shown
in drawings or as designated by the field laboratory.
The limits of each borrow areas to be used in the various zones of

embankment shall be flagged in the field and material from each
borrow area shall be placed only in the zones for which it has been
specified.
The depth of cut in all borrow areas will be designated by the Executive
Engineer and the cuts shall be made to such designated depths only.
Shallow cuts will be permitted in the borrow area, if unstratified
material with uniform moisture contents are encountered. Each
designated borrow area shall be fully exploited before switching over to
the next designated borrow pits. Haphazard exploitation of borrow area
shall not be permitted. The type of equipment used and the operations
in the excavation of materials in borrow areas shall be such as will
produce the required uniformity of mixture of materials for the
embankment.
Borrow pits shall not be opened within a distance of ten times the height of the
embankment from the toes (on either side). Borrow pits shall be
operated so as not to impair the usefulness or mar the appearance of
any part of the work or any other property. The surface of wasted
materials shall be left in a reasonable smooth and even condition.
9. Preparation of Borrow Areas

1. All areas required for borrowing earth for embankment shall be
cleared off all trees and stumps, roots, bushes rubbish and other
objectionable material. Particular care shall be taken to exclude
all organic matter from the material to be placed in the dam
embankment. All cleared organic materials shall be completely
burnt to ashes or disposed off as directed. The cleared areas shall
be maintained free of vegetable growth during the progress of the
work.
10. Stripping of Borrow Areas

1. Borrow area shall be stripped of topsoil, sod and any other matter
which is unsuitable for the purpose for which the borrow area is
to be excavated. Stripping operations shall be limited only to
designated borrow areas. Materials from stripping shall be
disposed off in exhausted borrow areas or in the approved
adjacent areas, as directed.
11. BORROW PITS

1. The borrow pits shall not normally be more than 25M in length,
and 10M in width and 11/2 M. depth. A clear spacing of one meter
between each pit shall be left out.
2. The depth of the pits shall be so regulated that their bottom does
not cut the hydraulic gradient line having a slope 4:1 from the top
edge of the embankment.
3. In no case the pits shall be located within 10H from the toe of the
embankment.
4. If the contractor excavated the pits near to the toe against to the
above clauses and the same is observed at any time during or
after the execution of work, the contractor has to fill the same pits
with the soils suitable for hearting zone of embankment and
compact to 98% proctors density at the cost of contractor.
12. Borrow Area Watering
1. Borrow area watering if needed based on laboratory tests will be
done by the contractor as decided by the Engineer-in-Charge.
The placement moisture content for proper compaction of earthwork should

be as near as practicable to optimum moisture content as decided by
laboratory tests. However, depending upon the site condition, the nature
of the earth of the borrow area, the season of the year, the moisture
content of the earth of borrow area will vary over a wide range. Thus it
would be necessary to add water to bring the moisture content of
borrow area earth to as near OMC as practicable. In irrigation
projects, watering in borrow area may be done where watering at the
place of fill does not yield required results. Wherever practicable and
specially during dry months periodical watering of the borrow area by
tankers and mobile units may be done to the extent possible as decided
by Engineer-in-Charge.
9. DRILLING AND BLASTING

1. Blasting where required will be permitted only when proper
precautions have been taken for the protection of persons and
property in accordance with I.S. 4081-1967(Indian Standard
Specification for safety code for blasting and related drilling
operations). While carrying out excavations, adequate
precautions in accordance with I.S. 3764-1966(Indian Standard
Specifications for safety code for excavation work) shall be taken.
2. Explosive such as gelatin, detonators and fuse coils etc., required
for the rock blasting are to be procured by the Contractor at his
cost. It shall be responsibility of the Contractor to store the
explosives purchased by him in accordance with the rules of the
explosives act and other rules framed by Government of India.
3. Contractor shall also furnish the following details:-
Capacity License No. and date Validity period
4. The contractor shall acquaint himself with all the applicable laws
and regulations concerning storing, handling and the use of
explosives. All such laws, regulations and rules, as prevalent from
time to time shall be binding upon the contractor.
5. The provisions detailed in the Specifications are supplementary to
the above laws; rules and regulations are also applicable. Further,
the Engineer may issue modifications, alterations and new
instructions from time to time. The contractor shall comply with
the same without these being made a cause of any claims.
6. List I.S Codes applicable is furnished below.
01 IS. 4081-1986 Safety Code blasting and related drilling operations.

02 IS. 4668-1985 Ammonium nitrate for explosives.
03 IS. 6609-19 (part 1 to5) Method test for commercial blasting explosives and
accessories.
04 IS. 7632-1975 Detonators.
05 IS. 5454-1986 Portable pneumatic Drilling machine.
06 IS. 3764-1966 Safety code for explosives work.
In addition to the above I.S codes, the specifications of A.P.S.S. and manual for
Quality control and inspection shall also be complied with.
1. Excavation by blasting will be permitted only under the personal
supervision of competent and licensed persons and trained
workmen employed. by the contractor at his cost. All supervisors
and workmen incharge of, handling, storage and blasting work
shall be adequately insured by the Contractor.
2. The person incharge of the explosive magazine shall be very
reliable and shall be approved by the Engineer.
3. The contractor shall make sure that his supervisor workmen are
fully conversant with all the rules to be observed in storing,
handling and use of the explosives. It shall be assured that the
Supervisor incharge, is thoroughly acquainted with all the details
of handling and the blasting operations.
10. USE OF EXPLOSIVES

1. For the transport of the explosives and detonators between the
store and the site, closed and strong container made of soft
materials such as timber, zinc, copper, leather shall be used.
2. Explosives and detonators shall be carried in separate boxes. For
the conveyance of primer, special container shall be used.
3. The boxes and containers used, shall be kept closed. Explosives
shall be stored and used chronologically, earlier received shall be
used first . A make up house shall be provided at each working
place in which cartridges will be made up by competent and
licensed men as required for the work. The make up house shall
be separated from other buildings. Only electric storage battery
lamps shall be used in this house.
4. No smoking shall be allowed in the make up house or generally
while dealing with explosives.
11. DISPOSAL OF DETERIORATED

EXPLOSIVES
1. All deteriorated explosives shall be disposed of in approved
manner the quality of the deteriorated explosives to be disposed
of shall be intimated to the Engineer prior to its disposal.
12. PREPARATION OF PRIMERS

1. The primers shall not be prepared near open flames or fire. The
work of preparation of primers shall always be entrusted to the
same personal. Primers shall be used as early as possible after
they are ready.
13. CHARGING OF HOLES

1. The work of charging of holes shall not commence before all the
drilling work at the site is completed and the Contractors
supervisor shall satisfy himself to that effect by actual inspection.
While charging, open lamps shall be kept away. For charging
with powered explosives, a naked flame shall not be allowed. Only
wooden tamping roads, without any kind of metal on the rod shall
be allowed to be used. The tamping roads shall have cylindrical
ends. Bore hole must be of such size that the cartridges can easily
pass down them, they shall not however be too big.
2. Only one cartridge shall be inserted at a time and gently pressed
into the hole with the tamping rods. The sand, clay or other
tamping materials used for filling the holes completely shall not
be tamped too hard.
14. BLASTING
1. Blasting shall be carried during the fixed hours of the day which
shall have the approval of the Engineer. The hours once fixed
shall not be altered without prior written approval of the
Engineer-in-charge.
2. The site of blasting operations shall be prominently demarcated
by red danger flags. The order to fire shall be given only by the
contractors supervisor incharge of the work and this order shall
be given only after giving the warning signal three times, so as to
enable all the labour, watchmen etc., to reach safe shelters.
3. A whistle/biggle with distinctive note shall be used to give the
warning signals. The biggle shall not be used for any other
purposes. All the labour shall be made acquainted with the sound
of the biggle and shall be strictly warned to leave their work
immediately at the first warning signal and to move for safe
shelters. They are not to leave the shelters until all clear signal
has been given.
4. All the roads and footpaths leading to the blasting areas shall be
watched.
5. In special cases, suitable extra precautions shall be taken. The
engineer-in-charge may however permit blasting for under
ground excavation, without restriction of fixed time, provided
that he is satisfied that proper precautions are taken to give
sufficient warning to all concerned and that the work of other
agencies on the site is not hampered. For lightning the fuse, a
lamp with a strong flame such as a carbide lamp shall be used.
6. The contractors supervisor shall watch the required time for the
firing of the fuses and shall see that all the workmen are under
safe shelters in good time.
15. ELECTRICAL FIRING

1. Only the Contractors supervisor incharge shall posses key of the
exploder and short firing accessories and he shall keep it always
with himself. Special apparatus shall be used as a source of
current for the blasting operations; power lines shall not be
tapped for the purpose.
2. The detonators shall be checked before use. For blast in Series,
only detonators of the same manufacture and of the same group
of electrical resistance shall be used. Such of the electrical lines as
could constitute danger for work of charging shall be removed
from the site. The firing cables shall have a proper, insulating
cover so as to avoid short circuiting due to contact with water,
metallic parts of rock etc.,
3. The firing cables shall be connected to source of current only
when nobody is in the area of blasting. Before firing, the circuit
shall be checked by a suitable apparatus. After firing with or
without an actual blast, the contact between the firing cable and
the source of current shall be cut off before any one is allowed to
leave the shelters. During storm rain the blasting operation shall
be suspended.
16. PRECAUTIONS AFTER BLASTING
1. After the blast, the Contractors supervisor must carefully inspect
the work and satisfy himself that all the charges have exploded.
After the blast has taken place in the underground works,
workmen shall not be allowed to go to the place till the toxic gases
are evacuated from the place.
2. MISFIRES:- If it is suspected that part of the blast has failed to
fire or is delayed sufficient time shall be allowed to elapse before
entering the danger zone. When fuse and blasting caps are used, a
safe time should be allowed and then the Contractors supervisor
along shall leave the shelter to see misfire.
3. None of the drillers are to work near this hole until one of the two
following operations have been carried out by the Supervisor.
Either (i) the supervisor should very carefully (when the tamping is of damp clay)extract the
tamping with a wooden scraper or jet of water or compressed air (using pipe of soft
materials) and withdraw the fuse with the primer and detonator attached after which a
fresh primer and detonator with fuse should be placed in this hole and fired out or (ii)
the hole may be cleared of 300mm, of caping and the direction and then be
ascertained by placing a stick in the hole. Another hole may be drilled at least 225mm
away, and parallel to it. This hole should then be charged and fired. The balance of the
cartridge and detonators found in the muck shall be removed.
4. Before leaving his work, the contractors supervisor should

inform the supervisor of the relieving shift of any case of misfires
and should pointout the position with red cross denoting the
same, also stating what action if any, he has taken in the matter. A
register of misfires and their location and how they were dealt
with shall be maintained by the contractor.
5. The contractors supervisor should also at once report at the
contractors office all cases of misfires, the cause of the same and
steps were taken in connection there with.
6. The names of the day and night shift supervisors of the
contractor must be noted daily in the contractors office. If
misfire has been found to be due to a defective detonator, or
dynamite, the whole quantity of box from which the defective
articles was taken must be returned to the contractors office for
inspection, and shall be disposed of.
7. Drilling in the holes not completely exploded by blasting shall not
be permitted.
8. The contractor should produce the firers license and furnish the particulars in the
following statement.
Sl. Name No. of firers Validity
license & date period
No.
9. Blasting operation, when considered necessary shall be resorted

to only with the written permission of the Engineer-in-charge.
Prior inspection shall be carried out for the safety of the public
property. Blasting operations in the proximity of over-head power
lines, communication lines, utility lines or other structures shall
not be carried out until the operator or the owner or both of such
lines have been notified and precautionary measures deemed
necessary have been taken.
9. Before Compaction
1. Materials delivered to the fill shall be visually examined and their
properties estimated by way of inspection. These checks shall
include:
(a) Borrow Areas

iv. Excavation of borrow areas shall be limited in extent and depth as indicated on
plans.
v. Estimation of moisture content of materials by visual examination and feel.
vi. Samples shall be taken for laboratory analysis in case the soil is of different
characteristics.
These inspection checks shall be supplemented by sampling the materials at
prescribed minimum intervals and by testing the samples in the laboratory for
gradation and moisture content.
(b) Embankment
i. Water content tests shall be carried out in the laboratory while placing the fill
materials.
ii. Moisture content shall be controlled by adding water or aerating the soil
according to laboratory test.
iii. It shall be ensured that the methods of dumping, spreading and moisture
conditions are such that which results in reducing segregation and/or variation
of moisture content to a minimum.
9. During Compaction
It is intended that the checks on operations during compaction shall verify :-
iv. That the layer thickness of the materials is as specified.
v. That the fill is compacted by the specified number of passes of the specified
machinery.
vi. That no excessive rutting, weaving or a scaling of the fill occurs during compaction.
9. After Compaction
The condition of the fill after compaction shall be observed and recorded particularly
with respect of rutting or weaving. However, the properties of materials after
compaction shall be determined primarily by field density tests. Dry density attained
shall satisfy the compaction standards as per appendix I.
9. Frequency of Testing
1. The frequencies for various tests for earthwork shall be in
accordance with Appendix 6.02 of the M.P.W.D. manual 1983,
Vol. II, Part II.
2. Special attention shall be given to the following locations where
insufficient compaction is likely to occur:-
i. The junction between areas of mechanical tamping and rolled embankment
along abutments or cut off walls.
ii. Areas where rollers turn during rolling operations.
iii. Areas where too thick a layer is being compacted.
iv. Areas where improper water content exists in a material.
v. Areas where less than specified number of roller passes were made.
vi. Areas where dirt-clogged rollers are being used to compact the materials.
vii. Areas where oversized rock which has been over looked is contained in the
fill.
viii. Areas where materials have been placed when they contained minor amounts
of frost, or at nearly freezing temperatures.
ix. Areas that were compacted by rollers that have possibly lost part of their
ballast.
x. Areas containing materials differing substantially from the average.
9. Record and Reports

Record of borrow area materials and embankment placing operations be maintained in
order to have a continuous check on the suitability and availability of fill materials
and quality of the fill. Thus, it will be possible to have complete description of
materials in any portion of the embankments. The records shall be maintained in the
form specified in Appendix II.
9. Field Test Data

1. Records of field test data results should be presented in the form
of statistical analysis sheets and summary sheets in order to
provide control required for enforcement of statistical
requirements of the specifications.
2. The test data summary sheets and inspection reports be used to
form the basis of construction control report, which should be
issued from the site at fortnightly intervals during construction
season. The report would contain narrative accounts of the
progress and problems of fill construction, statistical analysis of
test data and photographs of the fill operations.
9. EMBANKMENT TEST SECTION :
Placing of compaction methods specified will, have to be verified by test embankment
section to be built prior to starting of fill operations or at an early stage of dam
construction. The initial stage of dam construction itself could be made to serve the
purpose of test embankments. The sections referred herein shall be used to establish :-
1. Layer thickness of fill materials.
2. Optimum practicable moisture content.
3. Number of passes of sheep foot roller, or weight of vibratory roller vis-
-vis number of passes for effective compaction.
When an appreciable change in material occurs, additional test sections shall be made
during construction. The procedure for construction of test embankment sections is as
follows :
i. Select a location on the embankment where uninterrupted placing operations
are being performed. This area 15 m by 30 m should be carefully worked and
referenced so that its limits will be easily recognized. In order to expedite the
determination of moisture content to be used, more than one test section may
be established on the embankment at the same time.
ii. During construction of the test section which will most probably continue for
several shifts, a complete record of the procedure should be kept. This record
should include the number of layers placed, the spread thickness of each layer,
the moisture content, at which the materials were rolled, the designation (No.
1, No. 2, etc.) of the rollers used, the condition of the rollers (clean or dirty),
the action of the materials being rolled (such as wavy under the rollers, the
amount of penetration of the roller teeth after different number of roller trips
etc.) and the borrow pit location from which the materials came.
iii. Check the rollers to make certain that they meet all the requirements of the
specifications.
iv. Determine the required spread thickness of layer that will compact to the
specified thickness after rolling specified number of times and maintain this
thickness as long as number of roller passes is kept the same.
v. Using the available data from borrow pit investigations of the materials to be
used in the test section, the optimum moisture content as determined by
laboratory tests will be known and 3 percent less than this moisture content
should be used in the first 3 or 4 layers rolled.
vi. After 3 or 4 layers have been placed at 3 percent less than the laboratory
optimum moisture content, field density test should be made throughout the
section. These tests should be made for at least each 93 sqm of test section
area, and should be distributed over the area that they will detect the effects of
different compaction conditions encountered during construction. For
example, if the section is located near an abutment, certain parts of the area
will receive more compaction from track travel than others; hence some tests
should be made in the portion compacted only by the rollers and so reported.
vii. The next step is to compact another 3 or 4 layers at the moisture content
slightly higher (1 percent or 2 percent) than the moisture content previously
used, maintaining the same rolled thickness of layer and number of roller
passes as in above. Field density tests are again made over the test section.
viii. If the resulting field dry densities (of material passing the No. 4 sieve) from
(vii) above shown an increase with increase of moisture, again by another 1
percent or 2 percent, repeat the test. If an increase in moisture results in a
decrease in field density, then place the next layers slightly dry of the original
moisture content used and repeat the test. This procedure is nothing more than
developing on the embankment a moisture density relation or compaction
curve for a certain roller, thickness of layer, and a given number of roller trips.
If special studies during investigation have indicated that the material being
tested should be placed within certain moisture limits, or if the moisture limits
to be used have been specified, the procedure outlined above should include
tests at these moisture contents or at moisture contents both greater and
smaller than the specified.
ix. The roller compaction curve is now compared with the standard laboratory
compaction curve. If the field density of materials passing the No. 4 sieve
(from the roller curve) is greater than the standard compaction density at the
specified moisture content, the test section should be continued decreasing the
number of roller trips while maintaining the specific desirable moisture
content until the most economical compactive effort is determined. When the
roller trips are decreased, the required spread thickness of layer that will
compact to the specified thickness of compacted material should be reckoned.
x. All works connected with the embankment test section will be done
departmentally and shall be allowed without hindrance.
9. Turfing
After the slope has been dressed to line, it shall be slightly roughened to bond and hold a
surface dressing consisting of a 150mm layer of good soil. The layer shall then be raked and
lightly rolled with hand roller or hand tamped as directed by the Engineer-in-Charge. The
entire slope surface shall then be covered with a layer of turf sod. The sod shall include a mat
of roots and earth atleast 50mm thick. Sod containing an excessive amount of obnoxious
growth shall be excluded. Sods shall be carefully handled in transportation and transplanting
so that a minimum amount of obnoxious growth shall be excluded. Sods shall be carefully
handled in transportation and transplanting so that a minimum amount of earth will be lost
from the root mass. The strips of blocks of sod shall be laid on the slope in c\lose contact and
then tamped firmly in place so as to fill and close the joints between the blocks. The interval
of time between cutting and laying shall be kept to a practicable minimum and sod shall not
be permitted to dry out. Immediately after placing, the sodded slope shall be thoroughly
wetted and kept moist for 10 days. The sodded slope shall be periodically moistened, if
necessary, for a sufficient period to reestablish the plant growth. Humus sod shall be
transplanted only during an approved season. Alternatively the down stream slopes shall be
topped with a 150 mm layer of good top soil and seeded with approved grass seed as directed.
4.18 Transverse Contraction Joint In Dam/Barrage :
average thickness of 40mm plaster gives smooth plumb surface.
4.18.2
4.18.2 Waterstops Across Transverse Contraction Joint :
4.18.2.1 Materials :
respectively.
viz, Z and M shapes shown in Fig.A of PLATE : 1/CH-4.*
and shall meet the test requirement given in relevant parts of IS:3660.
IS:8543. The rubber/PVC Waterstop shall meet the requairements given in Table 2.
Table-2 : Performance Requirements of Rubber/PVC Waterstops
S. Characteristics Unit Value
No.
i. Tensil Strength N/mm 11.6 min
ii. Ultimate Elongation % 300 min
iii. Tear Resistance N/mm 4.9 min
iv. Stiffness in Flexure N/mm 2.46 min
v. Accelarated Extraction
(a) Tensil Strength N/mm 10.5 min
(b) Ultimate Elongation % 250 min
vi. Effect of Alkali (7 Days)
(c) Hardness Change Point 5
vii. Effect of Alkali (28 days)
(c) Dimension Change % 1
*For figure See Specifications Published by Engineer-in-charge
Fig.B of PLATE : 1/CH-4*
(c) Asphalt Waterstop Recommended specifications of asphalt are given below-
(a) Density 1015 - 1065 Kg/m
(b) Penetration at 25C 200 300
(c) Softening point (Ring and ball test) 80-90C
(d) Brittleness test on 22mm specification at
5C energy absorbed 0.97 Kg/m

PLATE : 1/CH-4*
4.18.2.2 Installation of Waterstops :

4.18.2.2.2 The metal waterstop shall be erected in place with the help of anchor rods.
concreting block.
capped as in the drawing (Fig.B of PLATE : 2/CH-4 and Fig. of PLATE : 3/CH-4)*
interface.
embedded vertically in the block-out concrete.
joint.
masonry in the lower of the two adjacent blocks by more than 1.5m.
PLATE : 4/CH-4*.
3. Jointing :
shall be jointed carefully by heat sealing.
respectively so as to form a continuous water tight diaphragm.
4.19 DIAPHRAGM WALL :
2. Materials :
relevant paras of Chapter 7 & 16.
size of aggregate may be used.
bentonite slurry shall be free from salinity and other deleterious impurities.
in IS:456-1978.
steel sections conforming to IS:226-1975 shall be used.
relevant paras of Chapter 7 &16 and para 4.19.7.3 of this chapter.
suitably processed with chemicals.
designed and tested according to requirement of the structure.
cement clay grout if required.
4.19.2 Equipment and Accessories -
choosen.
centrifuges for cleaning the bentonite slurry for reuse may be employed.
desired speed.
grabs as necessary.
when they are required to work on a site with restricted space or head room.
4.19.3 Specification of Bentonite Slurry -
by weight of bentonite powder in water.
used in diaphragm walling.
Type of Test Method of Test Permissible Value at 20C
Density Mud balance or hydrometer 1.04 to 1.10 g/ml
PH Value PH indicator paper strips 9.5 to 12
Viscosity Marsh cone method 30 to 90 seconds
10-minute gel Shearometer or vane shear apparatus 1.4 to 10 N/m,
strength
(14 to 100 dya/cm)
percentage by mass and the density Ys is given below.
Ys = 1.0 + 0.006 C
There may be some variations of bentonites. Laboratory calibration may be
prepared for the bentonite sample actually used.
blending of freshly mixed bentonite slurry with previously used bentonite slurry.
carried out.
equipment employed.
required density is achieved.
contaminated slurry at the bottom of trench by fresh bentonite slurry.
4.19.4 Bentonite Slurry and Additives :
of slurry. The temperature of water used and of the slurry used shall not be less than 5C.
for a period of minimum 12 hours after it is mixed thoroughly.
very small amount of 0.1 to 0.5 percent by mass of the slurry.
(i) Ferrochrome lignossulphonate in combination with soda ash or bichromate of
soda may be used for effective bentonite hydration if hardness of water
exceeds 200 PP.
(ii) Sodium carboxymethyl cellulose (S.C.M.C.) is yet another additive some times
used. It protects slurry against effects of electrolytes, accelerates filter cake
formation and reduces fluid loss by increasing the viscosity of slurry.
(iii) Cement contamination may be counteracted by phosphates. The calcium gets
removed and clay solids dispersed. Phosphates decrease PH value there by
lowering viscosity and yield value of slurry.
v. Carboxymethyl cellulose, gums or pre-sheared asbestos may be used, to increase

viscosity and reduce filter loss.
vi. To remove fine silty solids and clay solids from the slurry flocoulants may be used.
Vinyl acetate maleic anhydride co-polymer or polyacrylamides may be used. Gaur
gum can flocculate clays, carbonates etc.
vii. Pregelatinised starch may be employed as a fluid loss control. It may also be used as a
protective colloid against the effect of electrolytes.
viii. Stability of slurry filled trenches should be worked out as per procedure described
under Appendix-II.
5. Guide Wall/Pre-Trench :
operation.
of pre-trench level will be minimum 1.5m above the high water table.
Mesh or cage reinforcement shall be used in guide walls.
(on both sides of the wall).
be done continuously.
progress, the level of bentonite slurry will be maintained by addition of bentonite slurry.
4.19.6 Methods of Construction :
to 6m are usually adopted.
4)*.
4.19.6.3 Alternate Panel Method :
a secondary panels.
panels.
primary panels.
which are described below.
4.19.7 Stages of Construction :
4.19.7.1 Excavation of Trench (boring Operation) :
described below.
4.19.7.1.2. Direct Circulation Method :
vii. This method is used with rotary or percussion type rigs where drilling fluid (bentonite
slurry) is pumped through the drilled rods. It can be used for successive panel or
alternate panel construction. The stages of construction are shown in Fig of PLATE :
8/CH-4 Simple trenching rigs for excavation may be used.
viii. The trench panel may be excavated in the ground by making over lapping bore holes
with bentonite slurry jet in combination with percussion and to and from rotary
motion of jetting pipe having a suitable cutter at the tip.
ix. A special semi-circular cutter shall be used for providing appropriate shale at each
panel end to form a suitable joint.
x. The operation of filling bentonite slurry in the trench shall be as described under para
4.19.5.5 and lowering of reinforcement shall be done as described under para 4.19.7.2
xi. For thicker walls that is 40cm and more suitable modified semi-circular jointing cutter
may be used.
xii. This method is suitable for shallow depths and bringing up lighter cuttings.
4.19.7.1.3 reverse Circulation Method -
iv. The reverse circulation method with in percussion shall be used to make trench panel
in the ground as shown in Fig.A of PLATE : 9/CH-4*. Forward and backward
movement of the rig from one end of the panel to the other and shall increase the
depth of panel in zigzag manner.
v. High capacity pumps shall be used to suck the loosened soil in this slurry filled
trench. Separators or sedimentation tanks shall be used to retain the soil cuttings, and
to pass the slurry for circulation and reuse.
vi. This method is suitable for greater depths and to bring up heavier cuttings.
4. Other Requirements during boring operation :
vii. Solids in the settling tank shall be removed and kept along side. When the grabs or
Kelly method is used for boring bored muck from the grab will be left along side.
viii. For overcoming any underground obstruction or boring through all types of rocks
such as soft rock, weathered rock, disintegrated rock, hard rock, boulder etc. The use
of chisel grab will be made in case of grab type equipment. In case of reverse
circulation equipment the cutting tool itself will execute chiseling operation in above
mentioned strata.
ix. The width of cutting tool will be more or less as that of the disphragm wall. The
trench shall be finished upto founding level in the final stage of preparation by using a
cutting tool having a width of not less than 600mm before commencing placement of
concrete.
x. Boring shall be continued in the manners described above upto foundation level.
Depth of the trench will be determined by taking sounding. Diaphragrm wall shall
penetrate about 0.6 metre into sound rock which shall be ensured by careful soundings
taken and certified by engineer-in-charge. If there is difference of more than one
metre or more in the rock level at two ends of the panel, suitable stepping as decided
by Engineer-in-Charge shall be provided.
xi. Before removing the equipment, the bottom of the trench will be cleaned by reverse
circulation equipment.
xii. Form tubes will be lowered at each end of primary panels in case of construction by
alternate panel method and reinforcement cage shall then be lowered in the trench
panel and suitably supported.
2. Reinforcement :
xi. Reinforcement in each panel should form a cage and the vertical ends of the cage
should match with the type of joints of the panel. For ease of handling and good
workmanship the cage should be made rigid. Clear distance between reinforcement
bars should not be less than 100mm for easy flow of concrete.
xii. The length of the cage will be governed mostly by the depth of panel and the length of
rods available. The cage shall however be built up preferably in two fabricated
matching pieces but in no case in more than three pieces. Each subsequent
reinforcement cage after the first cage shall be securely fastened and tack welded to
the lower cage before the assembly is lowered to the trench. The steel reinforcement
cages shall be clearly marked to indicate its correct orientation for proper insertion
into the trench.
xiii. The gap in the main bars should not be staggered more than 50 cms to avoid
difficulties in handling the cage and dropping the cage.
xiv. Suitable gape in the reinforcement cage will be provided for accommodating the
tremie required during concreting operation.
xv. The reinforcement cage will be suitably strengthened at regulat intervals and
generally the bars will be tack welded.
xvi. In case the reinforcement cage is heavy, angle iron frames may be utilized.
xvii. The concrete cover for reinforcement shall be maintained by the use of spacers.
Circular roller cement concrete cover blocks using 1:1-1/2:3 cement concrete mix
shall be provided at suitable intervals preferably one block per square metre on both
sides of the cage and suitably staggered. The diameter of spacer block will depend
upon clear cover required for the reinforcement.
Boxes or inserts for formation of recesses or for ground anchors shall be

lowered along with the cage to correct position and levels. Circular cover
blocks are considered essential to the reinforcement so that they will roll
along the trench without damage and maintain adequate cover.
xviii. The hooks for lifting the reinforcement cage will preferably be of Mild steel, and
diameter and number should be adequate to withstand the weight of the cage.
xix. The reinforcement cage should be kept hanging over pre-trench to provide a minimum
cover of 10mm at the bottom of trench and it shall be maintained in position during
the concreting of each panel.
xx. Rock grout pipes shall be fixed with suitable spacer bars at specified intervals.
shall be provided.
both directions with a cover of 75 to 100mm at faces and at end of elements.
4.19.7.3 Concreting :
than 0.6.
segregation of the ingredients.
practicable to 0.6.
through, for tremic pipe used in concreting.
extra cement added for under water work for laying concrete by other than tremie.
4.19.7.3.5 Concrete Classifications :
strengths and shall conform with the requirements setout in table below.
S. Location Classification Slump
No.
1 Concrete in RCC Diaphragm Walls M-20 150 to 200mm
2 Concrete in RCC Capping M-20 50 to 75mm
Exact mix design however, shall be determined by laboratory tests.
carried out as and when directed.
Chapter 7 & 16.
4.19.7.3.10 Placing and Compacting for Diaphragm Wall :
iii. The concreting shall be done by tremie pipes and the tremie diameter will be
minimum 200mm. It is preferable to use threaded tremie pipes in suitable lengths. The
tremie pipes shall be clean and water tight. Depending upon the length of panels one
or more tremie pipes should be used. The elliptical or oblong tremie pipe shall be used
for concrete having aggregate of 20mm and smaller. This shall be used for walls of 20
to 30cm thickness. For walls of greater thickness a circular tremie pipe may be used.
iv. Prior to placing concrete in any panel it should be ensured that heavily contaminated
bentonite slurry has not accumulated in the bottom of trench which can impair free
flow of concrete. The contaminated bentonite slurry shall be identified by taking a
sample of the slurry from near the bottom of the trench and carry out a density test on
this using a mud balance. Density as measured shall not be greater than 1.25 gm/ml.
Before pouring the concrete through tremie pipes, the bottom of the concreting funnel
should be closed through a steel plate. The tremie should extend to the bottom of
trench excavation prior to the commencement of concrete pouring and care shall be
taken to ensure that bentonite slurry which may have entered the tremie is expelled
from the tube during the initial charging process. After funnel is filled with concrete,
the plate is removed and concrete is discharged. Thereafter concreting is done in a
continuous manner upto required level. Care should be taken during placing to avoid
contamination of the concrete where two or more pipes are used in the same panel.
Simultaneously, care should be taken to ensure that the concrete level at each pipe is
maintained.
11. For Cap Work :
iii. Before placing cap concrete extra concrete already placed ruing concreting of the
diaphragm walls above designed cut off level shall be removed by chiseling manually
or by pneumatic tools. In case concrete below the designed cut off level is found to be
inferior or contaminated not conforming to specifications, the same should also be
removed until concrete of prescribed specifications is met with. Minimum 15 cms (6
inches) should preferably be removed. The chipping shall be done in such a manner as
not to loosen, crack or shatter any part of the work beyond the approved levels at or
below the cut off level. The surface shall be cleaned thoroughly of all loose
fragments, dirt, laitaree and any other objectionable materials and shall be sound and
hard in such conditions as to ensure good bond between the old and new concrete.
iv. After the surface has been cleaned and dampened as specified, surface construction
joints shall be covered wherever practicable with a layer of mortar approximately
15mm to 20m thick. The mortar shall have the same proportions of water air
entraining agent, cement and fine aggregate as the concrete mixture to be placed upon
it. The water cement ratio of the mortar in place shall not exceed that of the concrete
placed upon it and the consistency of the mortar shall be suitable for being spread
uniformly and worked, thoroughly into the irregularities of the surface. Concrete shall
be placed immediately upon the fresh mortar.
groups of coarse aggregate being separated from the concrete mass.
not possible or would be inadequate.
harmful effects of exposure to sunlight, wind and rain, as directed.
cracking.
4.19.8 Types of Joints :
the ends of the primary panels to form suitable joints with secondary panels.
4.19.9 Wall of Precast RCC Panels :
panels shall be supported in the trench by using special supports.
compound.
and impermeability.
that achieved by tremie concrete method.
4.19.10 Grout Cut-off Walls :
used to provide an impermeable cut-off wall.
may be used for diaphragm walls which are primarily meant as impermeable cut-offs.
4.19.11 Tolerances :
from a straight line or a specified profile shall not exceed 25mm in 3m.
2. Diaphragm Wall :
vertical within a tolerance of 1:80.
concrete cast shall be between 150-500mm above the specified wall levels.
and horizontal tolerance of 150mm.

relation to top of guide wall shall be 50mm.
4.19.12 Rock Grouting under the Diaphragm -
4.19.12.1 Specification for this work shall be as per Chapter 22.

reinforcement.
equipment.
the flow in the particular rock media (laminar or turbulent).
media, the test at the particular packer position will be considered as completed.
permeability.
conducting some trial tests at the site.
The pressure which will be generally allowed for grouting will be as follows :
1 PSI for every foot of rock above the packer.
75 PSI for every foot of overburden above rock.
1971. Grouting of Rock Foundation in River Valley Projects.
4.19.12.2 Grouting under the Diaphragm wall joints by Tube-A Manchette Method
the diaphragm wall the area near the diaphragm wall joints will be grouted.
using the mud circulation process.
every 33 cms) covered by rubber sleeve which acts as a one way valve.
enough to allow upward leakage along the tube A Manchette pipe.
the second stage grouting.
grouting of sand between the two walls is not necessary.
4.19.13 Permeability test for Concrete of the Diaphragm Wall :

the panel.
be done through these pipes for a depth of 3cm to 60cms below the bottom of the pipe.
completed can be applied while carrying out this test by using compressed air.
cm per year at pressure equivalent to a hydrostatic head of 40 metres.
4.19.14 Inspection of Works :
be taken in construction and operation of these walls.
4.19.15 Testing Efficiency of Diaphragm Wall :
wall and seepage measured all round the year.
APPENDIX - I
CRITERA FOR CONTROL OF COMPACTED DAM EMBANKMENT
Type of Percentage percentages based on minus nO.4 fraction

Material of No.+4 50 Feet or Less in Height Greater than 50 Feet Height
fraction by Minimum Desirable Moisture Minimum Desirable Moisture
dry weight Acceptabl Average Limits Acceptable Average Limits
of total e Density Density W0-Wf Density Density Wo-Wf
material
1 2 3 4 5 6 7 8
Cohesive 0-25 D=95 D=98 -2 to +2 D=98 D=100 2 to 0
Soil 26-50 D=92.5 D=95 D=95 D=98 (Note 2)
Controlled by More than D=90 D=93 D=93 D=95
the Proctor Test 50
(Note-1)
Cohesion Fine sands Dd=75 Dd=90 Soils Dd=75 D=90 Soils
with should be should
Less soils very wet be very
0-25 wet
Controlled by Medium Dd=70 Dd=85 Dd=70 D=85
the relative sands with
density test
0-25
Coarse Dd=65 Dd=80 Dd=65 D=80
sands with
0-100
gravels
Wo- Is the difference between optimum water content and fill water content in
Wt percent of dry weight of soil.
D Is fill dry density divided by Proctor maximum dry density in per cent.
.
Dd Is relative density
NOTES :
permeability of the total material if used as a water barrier.
prepared.
Appendix II
(Para 4.19 A (VI)
STABILITY OF SLURRY FILLED TRENCHES

The bentonite slurry filled in the trench imparts stability by mainly
applying hydrostatic pressure on the wall, against the impermeable thin
film formed along the wall. Secondly the slurry filled in the trench provides passive
resistance against failure of the trench, and thirdly, the shearing resistance of the slurry
saturated zone and the plastering effects of the filter cake formed also contribute towards
trench stability. The hydrostatic pressure along represents 65 to 80 percent of the total
stabilizing forces. If the density of slurry used is such that it can provide a factor of safety of
one due to hydrostatic pressure, then the factor of safety of the actual trench shall be between
1.25 to 1.50. Therefore taking only hydrostatic pressure and considering F=1, the density of
slurry may be calculated as indicated by the following formula. This formula should be used
as a guide only.
Where
H = depth of the trench
Cu = undrained shear strength of clayey soil
Y = natural density of saturated soil
Ys = density of the slurry needed for the trench, and
horizontal as well as vertical directions See Figures below :
For sandy
Where
KA =
Y = effective unit weight of the sandy soil
= submerged unit weight
= saturated weight weight of water
= Y sat Yw
THE VALUE OF A DEPENDS UPON RATIO OF THE TRENCH (SEE FIG. ABOVE).
the water level.
VOLUME III
SECTION - 6
GATES
INDEX
TENDER DOCUMENT 49
TURNKEY TENDER 49
2SURVEY 58
4FINAL REPORT 68
APPENDIX I 69
ETC. 69
APPENDIX II 71
71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
APPENDIX IV 77
1 GENERAL 162
2. STANDARDS 162
3. SCOPE: 163
4. PLANNING: 163
EMBANKMENT 165
13 EXCAVATION 169
16DEWATERING 171
24MATERIAL 178
29DOWEL BANKS: 186
33TOE DRAINS : 187
35SIDE DRAINS: 188
37PROTECTION: 188
42ROCK TOE 192
43 BORROW AREAS 195
46 BORROW PITS 196
53BLASTING 198
62 TURFING 203
1 GENERAL 139
2. STANDARDS 139
3. SCOPE: 140
4. PLANNING: 140
EMBANKMENT 142
66 EXCAVATION 146
69DEWATERING 148
77MATERIAL 155
82DOWEL BANKS: 163
86TOE DRAINS : 164
88SIDE DRAINS: 165
90PROTECTION: 165
95ROCK TOE 169
96 BORROW AREAS 172
99 BORROW PITS 173
106BLASTING 175
115 TURFING 180
1 GENERAL 163
GATES 163
5SCOPE 165
(GATES) 165
10 PAINTING 172
INSTALLATION 177
1. REFERENCES : 303
2. TERMINOLOGY 305
4 ANCHORAGES 334
1 INTRODUCTION 256
8SURFACE DRAINS 258
11 SHOULDER 263
13 INTRODUCTION 274
14PRE-REQUISITE 274
SECTION - 7 : GATES
1 General
Classification of Gates
The gates shall be classified on the basis of water head above the sill level as below:
1. High head gates - A gate which operates under a water head of 30 M and above.
2. Medium head gates - A gate which operates above a water head of 15M but less than
30M.
3. Low head gates - A gate which operates under a water head of less than 15M.
1. types of Gates
2.1 Under all water head conditions, different types of gates under use in river
valley projects shall be of following types :
a) slide gates
4. fixed wheel gates

5. Stoney or roller gates
6. Caterpillar gates
7. Radial gates
8. Single faced sluice gates
2.2 Vertical Lift Gates
a) slide gates
b) fixed wheel gates
c) Stoney or roller gates
d) Caterpillar gates
2.3 Radial gates or Tainter Gates
Spillway gates
2.4 Gates for Hydropower Pruposes
a) Penstock or Conduit Gates
b) Draft Tube Gates

c) Bulk Head Gates
2.5 Stop logs or Guard Gates
2. Components & Material Specifications for different

gates
The material to be used in the fabrication / manufacturer of gates shall confirm
to relevant latest Indian Standards. For other items viz. castings/foreging,
manufactures test certificates shall be checked to ensure quality, if prescribed
by the department. For bought out items viz, motor, wire ropes, bearings,
bushings, seals etc. department shall specify in advance the required quality
standards. The general components of various gates shall have following
material qualifications.
a) For fixed wheel gates - As per Appendix A
b) For slide gates - As per Appendix B
a) For radial gates - As per Appendix C
3. Design Criteria
The general design consideration for all kinds of gate, lays down that
1. The gates shall be self closing type under its own weight
2. The gates shall be power operated or manually operated (if provided)
3. In case of regulations requirement, the gates shall be capable of being
held in partially open position without cavitation and under vibration.
4. The gates should be reasonably water tight within the specified limits
of 5 to 10 litre / minute/meter length of seal.
Following Indian Standards shall be referred for design aspects of various gates:-
a) Fixed wheel gates - IS: 4622 1992
b) Slide gates - IS: 5620 1978
c) Single faced sluices - IS: 3042 1965
gates (200-1200mm)
d) Radial gate - IS: 4623 - 1990
4. Typical installation of various types of gates.

Following diagrams showing the typical installation of various types of gates are
given:
Fig. 1: Typical arrangement of various components of fixed wheel gates
Fig. 2A: Typical diagram showing low head slide gates (full face gate frame)
Fig. 2B: Typical diagram showing low head slide gate leaf.
Fig. 2C: Typical diagram showing embedded frame of low head slide gate.
Fig. 2D: Low head slide gate showing gate & frame.
Fig. 2E: Low head slide gate sealing arrangements (Stop log with rubber seal)
Fig. 2F: Low head slide gate sealing arrangements (Stop log with wood seal)
Fig. 2G: Low head slide gate (with rubber & wood seal)
Fig. 3A: Radial gate with parallel arm
Fig. 3B: Radial gate with inclined arm
Fig. 4A: Dimensions of single faced sluices 200 mm to 600 mm (rising type)
Fig. 4B: Dimensions of single faced sluices 200 mm to 600 mm (non-rising type)
Fig. 4C: Dimensions of single faced sluices 200 mm to 1200 mm (rising type)
Fig. 4D: Dimensions of single faced sluices 200 mm to 1200 mm (non-rising type)
Fig. 4E: Dimensions of single faced sluices 300x375 mm to 1050x1200 mm (rising

type)
5. SCOPE
The scope of the specifications laid down herein after is to make recommendations
and issue guidelines in respect of hydraulic structures used on river valley projects for
controlled released of water. These gates are the steel structure and are manufactured
through Standard codes of practices involving selection of materials fabrication under
specified tolerance by welding / riveting inspection of manufactured assemblies and
their accuracies, erection of gate component through embedment , with the help of
embedded parts, into the civil structures and finally testing the installation and final
checks involved.
Following stages have been discussed in these specifications in all types of gates.
a) General Workmanship
b) Manufacture / fabrication of gates structure / components, embedded parts.
c) Shop assembly.
d) Erection inspection & testing
6. General specifications for workmanship, welding /

riveting, finishing and painting of steel structures
(Gates)
1. Straightening
All materials shall be straight and if necessary before being worked shall be
straightened and or flattened by pressure, unless, required to be of curvilinear form
and shall be free from twists.
2. Cutting
1. Cutting may be affected by shearing, chopping or sawing. Gas
cutting by mechanically controlled torch shall be permitted for
mild steel only. Gas cutting of high tensile steel shall also be
permissible provided special care is taken to leave sufficient metal
to be removed by machining so that all metals that has been
hardened by flame is removed. Hand flame cutting shall be
permitted subject to the approval of purchaser.
2. Shearing, Chopping and gas cutting shall be clean, reasonably
square and free from distortion. The edges shall be grounded
afterwards if considered necessary.
3. Holing
1. Holes through more than one thickness of the material for
members such as compound stanchion and girder flanges, where
possible, be drilled after the members are assembled and tightly
clamped or bolted together. The punching shall be permitted
before assembly, provided the holes are punched 3 mm less in
diameter than the required size and reamed after assembly to the
full diameter. The thickness of the material punched shall not be
greater than 16 mm.
2. When the holes are drilled in one operation through two or more
separable parts, these parts when so specified by the purchaser
shall be separated after drilling & burrs removed. (IS: 800-1991)
3. Matching holes for rivets and black bolts shall register with each
other so that a gauge of 1.5 mm or 2 mm (as the case may be,,
depending on whether the diameter of rivets or bolts is less than or
more than 25 mm) less in diameter than the diameter of the hole
will pass freely through the assembled members in the direction at
right angle to such member. Finished holes shall not be more than
1.5 mm or 2 mm (as the case may be) in diameter longer than the
diameter of the rivet or black bolt passing through them, unless
otherwise specified by the purchaser.
4. Holes for turned and fitted bolts shall be drilled to a diameter
equal to a nominal diameter of the shank or batter subject to HB
tolerance specified in IS: 919-1990. Recommendations for
engineering preferably, parts to be connected with close tolerance,
shall be firmly held together by tacking bolts or clamps and holes
drilled all the thickness at one operation & subsequently reamed to
size. All holes not drilled at one operation shall be drilled to a
smaller diameter and reamed out after assembly. Where this is not
practicable, the parts shall be drilled separately through hard
bushed steal jigs.
4. Riveting
1. The rivets shall be heated uniformly through their length, without
burning or excessive sealing and shall be of sufficient length to
provide a head of standard dimension. They shall, when driven fill
the holes completely and if countersunk, the countersinking shall
be fully filled by the rivet, any protruedness of the countersunk
head be dressed off flush, if required.
2. Riveted members shall have all joints firmly drawn and held
together before and during riveting and special care shall be taken
in this respect for all single or multiple riveted connections.
3. All loose, burned, or otherwise defective rivets shall be cut out and
replaced before the structure is loaded and special care shall be
taken to inspect single riveted connection.
4. Where practicable, machine riveting shall be carried out by using
machines of the steady pressure type.
5. Bolting
1. Where necessary, washers used shall be tapered or otherwise
suitably shaped to give the heads and nuts of bolts a satisfactory
bearing.
2. The threaded portion of each bolt shall project through the nut at
least one thread.
3. In all cases where full bearing area of the bolt is to be developed,
the bolt shall be provided with a washer of sufficient thickness
under the nut to avoid many threaded portions of the bolt being
within the thickness of parts bolted together.
6. Welding
1. For welding of any particular type of joint, welders shall give
evidence of having satisfactorily completed appropriate tests as
described in the following relevant Indian Standards:
a) IS: 817-1991- Code of practice for training and testing of metal arc welders.
b) IS: 7318-1974- A qualifying tests for metal arc welders engaged in structural
welding.
c) IS: 1393-1991 Code of practice for training and testing of oxygen-acetylene

welders.
2. All welding shall be in accordance with any of the following

standards as appropriate.
a) IS: 816-1992-Code of practice for use of metal are welding for general instruction in mild
steal.
b) IS: 819-1992- Code of practice for resistance spot welding for tight assemblies in mild
steal.
c) IS: 822-1991- Code of practice for inspection of welds.
d) IS: 823-1964- Code of procedure for metal are welding of mild steel.
e) IS: 1024-1992- Code of practice for use of welding in bridges and structures subject to
dynamic loading.
f) IS: 1323-1987-Code of practice for Oxygen-Acetylene welding for structural work in mild
steel.
7. Casting and Forgings

1. The castings and the forgings are the bought out items used in the
gate installation and as such these are intended to be strictly as per
the specified drawings. All such work shall be laid out to secure
good matching between adjoining unfinished surfaces. Castings
shall be cleaned and shall be chipped and ground free from
projections. Defects in castings involving repair by welding, shall
preferably be disallowed in case of large discrepancies. Castings
with minor defects may be repaired by welding, but shall
necessarily be stress-relieved according to the requirement.
2. The casting or forgings of ferrous or non ferrous nature shall
conform to the following Indian Standards as appropriate:
a) The Stainless steel (Corrosion resistant steel) used for pins embedded parts
shall confirm to
IS: 1570 1991

IS: 6911 1992
b) IS: 210 1991 (Gray Iron castings (III revision)
c) IS: 306 1988 Tin Bronze ingots and castings.
d) IS: 1030 1989 - Carbon steel castings for general engineering purposes.
e) IS: 1570 1991 Schedule for wrought steels for general engineering purposes.
f) IS: 2004 1991 Carbon steel forgings for general engineering purposes.
g) IS: 2062-1992 Structural steel (fusion welding quality)
h) IS: 2595 - 1991 Code of practice for radiographic testing.
i) IS: 2825 1984 Code of procedure for stress relieving of welded joints.
8. Tolerances
1. Fits and tolerances of various components and parts shall
be accounting to the best shop practice keeping in view the
functional requirement of the parts. Tolerances and
allowances of the matching parts during manufacturing
and erection have been recommended in relevant paras and
also at appendix D and E.
9. Painting
1. The code of practice laid down hereinafter is to be adopted for
protection of iron and steel structures against atmospheric
corrosion under all climatic conditions.
10.Surface preparation
1. The surface shall thoroughly cleaned and roughened by
compressed air blasting or centrifugal blasting with a suitable
abrasive grit. Immediately before spraying the surface shall be free
from grease, scale, rust moisture or other foreign matter.
2. The roughness of blasted surface shall be specified by the
department or a criterion of acceptability shall be laid down by the
department of basis of the adhesion test the method of which is
laid down in para 5.3.1 of IS : 5805 1991.
11. Spraying
1. The metal spraying shall be carried out without delay after the
surface has been prepared by suitable grit blasting, but in any case
within such period that the metal is sprayed on to a surface which,
is still completely clean, dry and without visible oxidation.
If deterioration in the surface to be coated is observed, the surface preparation
treatment shall be prepared on the surface in question.
2. The coating metal and its purity requirement shall be specified by

the department as conforming to the IS: 2590-1992 and IS:209-
1992.
3. The surface to be sprayed shall be coated of uniform texture and
free from lumps, coarse areas and loosely adherent powder. The
nominal thickness of the coating shall be specified by the
purchaser with the limits of 100 to 300 mm. The minimum local
thickness, determined by the magnetic method described in
IS:3203-1992 shall not be less than 75% of the specified nominal
thickness.
4. Sealing and finishing coats wherever applied on zinc and
alunminium to provide additional protection, shall be applied
without undue delay. Contamination of the sprayed surface with
oil, grease, dirt, finger marks etc. shall be avoided.
5. The schedule of painting during different stages of manufacturers,
assembly, erection shall be specified by the department. The type
of paint, number of coats, coverage rate, surface to be painted shall
also be specified by the department. The methods of painting viz.,
hand brushing, metal spray, painting and metal paint
qualifications shall be specified by the department in the tender
specifications.
7. Fixed Wheel and Slide gates Manufactures.

For proper functioning of gates, the manufacturer shall lay down a quality control
programme for each and every stage of manufacture. Certain criteria have been laid
down which will facilitate proper installation and assembly, better maintenance and
efficient working of the gates.
1. Materials
1. All materials and components required for the fabrication /
manufacture of gate structures shall conform to the requirement of
latest relevant Indian Standards. In absence of Indian Standard
for any material or component, specifications must be laid down
by department who may also specify the specifications for bought
out items like bearings, castings, forgings, seals etc. However
original manufacturers test certificate for bought out item shall be
referred.
2. All castings or forgings shall conform to the relevant Indian
Standards.
3. Visual examination shall be carried out to find out the general
soundness of casting and may if required be subjected to non -
destructive tests.
4. All forgings shall be suitably heat treated (if required) and shall be
smooth and free from tool marks.
2. Welding
1. All welding shall conform to the relevant Indian Standards.
Qualified welders according to IS:7318-1974 shall be employed for
welding work. Welding procedure for all major welds shall be
drawn up and carried out. Test pieces may be made to ensure the
soundness of welding, if necessary.
2. Visual examination shall be carried out of all welded joints to
ensure that welding is free from:
a) Cracks on the surface of joints or parent metals located in the heated zones of the
joint.
b) Undercuts in the parent metals.
c) Sponginess porosity in the welding metal
d) Non-uniform width of fillet joints
e) Mis-alignment and distortion of welded member and
f) Irregular reinforcing beads of weld.
1. All major stress carrying parts of all welds shall be examined by

non-destructive tests namely, X-ray, ultrasonic etc. The stress
relieving of part, if deemed necessary, shall be done as per
procedure laid down in IS: 2825 1984.
2. Manufacturing Tolerances
The embedded parts and the gates shall be manufactured to such accuracy as are
required for the safe and efficient operation of the gates. As a general guide following
tolerances may be used.
1. Embedded Parts.
1. Deviation of any point on the face of seal seats or wheel track from a 2.0 mm
machined straight edge held against it shall not exceed 0.5 mm.
2. Variation in distance between the face of the seal seat and the face of its
respective wheel track shall not exceed 1.0 mm.
3. Deviation from straightness of the guide track shall not be more than 2.0 mm in 2
metre length.
4. There shall be no off-sets or gaps at any adjoining field joints between seal
seats, wheel track and guide tracks.
2. Fixed Wheel Gates.
These gates shall be so assembled than when a machined straight edge is held against all the
wheels on either side in zero position it will not be possible to insert a feeder gauge thicker
than 1.5 mm between any of the wheel and straight edge.
The distance between the side guide block or guide roller on one side of the gate to the
corresponding guide block or guide roller on the other side shall not vary from the dimension
shown on the drawing by more than 1.5 mm.
3. Slide Gates.
The gate and the components shall be so manufactured that on assembly the top side and top
seal bases are in common plane within the tolerances as given below
a) When a straight edge is held against seal bases, it shall not be possible to
insert a 0.2 mm feeder gauge between the seal base and the straight
edge.
b) When a machined straight edge is held against the metallic seal faces (after
fixing metallic seals) it shall not be possible to insert 0.2 mm feeder
gauge between seal face and the straight edge at any point.
c) The distance between the side guide blocks or the guide rollers on either side
of the gate shall not exceed the dimensions shown on the drawing by
more than 1.5 mm.
7. Shop Assembly & testing for Gates and Embedded

Parts
1. The manufacturing tolerance shall include surface finish
tolerance (when specified) as specified under IS: 696-1960.
> - 80 Microns
-40-80
-16-40
-Upto 16 Microns
(One Micron = 0.001 mm)
1. Shop assembly of embedded parts shall necessarily be done for

high head gates. For medium and low head gates, it shall be done,
if required.
2. Gate shall be assembled complete with seals, wheels and guides
either in horizontal or vertical position for proper alignment and
inspection.
3. Side guide blocks and rollers may be shimmed, if necessary, to
maintain required tolerance.
4. Variation in the distance between axes of each pan of seal seats,
wheel tracks or side guide tracks for any gate shall not exceed 1.5
mm.
5. Embedded parts shall be so assembled that the deviation of their
axes from the respective alignment shall not exceed 1.5 mm.
6. All the wheel of the gate shall rotated several times to ensure free
movement.
7. The marketing and match marking shall be made before actual
dispatch of the components.
8. Painting
1. All the metal surfaces of the gate after thorough cleaning shall be given one coat of
primary paint immediately. Each coat shall be allowed to dry or hardened thoroughly
before the succeeding coat is applied.
2. Bronze, finished ferrous surfaces and hoist rope shall not be painted.
3. The unfinished interior surfaces of oil tank, and the unfinished surfaces of gears that
will run in oil, shall be given 8 coats of oil resistant paint.
4. All finished surface of ferrous metal, including screw, threads, that will be exposed
during transport shipment or while awaiting installation shall be cleaned as specified
and given a heavy uniform coating of gasoline soluble rust preventive compound.
5. Field painting should be carried out at each stage step by step as it will be convenient
with proper appropriate paints and the final painting shall be done after the complete
assembly of gates.
7. Fixed Wheel and Slide Gates Rope Drum Hoist

These specifications shall be applicable for rope drum hoists for all types of gates viz.
Radial, Fixed wheel or slide gates etc.
1. Material
1. All materials and components used in the manufacture or

assembly of the hoist shall conform to the latest Indian
Standards. The duty of the hoist shall be specified by the
purchaser. The purchaser has to specify the quality and
standard of such material and components.
2. All materials used shall be of tested quality. Original
manufactures test certificates for bought out items like the
castings, forgings, worm reducers, wire ropes, motor and
brakes etc. shall be furnished by the manufacturer of the
hoist on demand.
3. All casting and forgings used shall conform to relevant
Indian Standards, Any repair to castings, if necessary, shall
be carried out in accordance with the relevant Indian
Standards. Forgings shall free from any defect, tool mark
and shall have smooth surfaces. Forgings shall be heat
treated where deemed necessary.
2. Hoist Unit of gates and Checking.
Following components of the hoist unit shall be checked:
1. Drive unit consisting of gear box, motor, brake, all mounted on a base frame.
2. Hoist drum and gear reduction unit mounted on a base frame and connected to drive
unit by line shafts, limit switches and dial indicators.
3. Hoist rope, rope fixtures with accessories.
4. Arrangement for manual operation of gate.
5. Control panel.
6. Any other components.
3. Drive unit gear box

1. It shall be checked for proper seating arrangement of the shafts
and oil in gear box.
4. Hoist motor
1. It shall be of approved manufacture capacity insulation and speed
(r. p. m.). It shall conform to IS: 325-1991 unless otherwise
specified and shall be checked for its performance. Manufacturers
test certificate shall be furnished for motor by supplier to
purchaser.
5. Brake
It shall be of approved manufacture capacity. It shall be checked for
alignment and tightness. Brake liners shall be of approved manufacture
and shall conform to the approved specifications.
1. Base frame
1. The base frame for mounting of drive unit/gear reduction unit
with hoist drum shall be checked for the dimensional accuracy.
2. Hoist Drum
1. This shall be checked for dimensional accuracy. Cast iron/cast steel
drums shall be checked for blow holes, cracks etc. specially at
groove centers. Fabricated drums shall be checked for stress
relieving in approved manner. Rope grooves shall be checked for
orientation. Arrangement of rope attachment to the drum shall be
checked for security.
3. Reduction unit gear box

1. It shall be checked for proper assembly, dimensional accuracy,
sealing, finish of machined parts, and surface preparation for
painting gears, pinions and other internal components shall be
checked for alignment Meshing of gear and pinion teeth shall be
checked for alignment. It shall also be checked for contact surface
and backlash by suitable method such as applying a thin film of
paint or grease on either pinion or gear wheel and running the
assembly and noting the impression. Gears and pinions shall be
checked for hardness. Tolerances of gears and pinions shall
conform to IS: 919-1987 and backlash shall conform to IS: 4460-
1991.
4. Line Shaft
1. It shall be checked for straightness and other dimensions. The
straightness shall be in accordance with relevant Indian
Standards. Mounting of couplings shall be checked for alignment.
5. Limit Switch
1. It shall be checked for satisfactory operation. It shall be weather
proof.
6. Dial Indicators
1. It shall be checked for satisfactory operation and accuracy.
7. Hoist Rope
1. It shall be of approved manufacture and shall conform to relevant
Indian Standards. The rope shall be checked for diameter, length,
freedom and kinks, proper thimble end, connections and splicing.
If the wire ropes are of galvanized type, the galvanization shall be
in accordance with class II of IS: 1573-1991. Manufacturers test
certificates shall be furnished on demand by supplier for hoist
ropes.
8. Rope Fixtures
1. It shall be checked for dimensional accuracy and their corrections.
9. Arrangement for manual operation

1. It shall be checked for satisfactory operation. It shall be ensured
that the gates are kept at required position during their travel for
specified speed as envisaged in the design and specified for
operational requirements of the gate.
10.Control panel
1. Panels shall be checked for their suitability for the purpose
envisaged in the specification. The checks shall include items such
as weather proofing of conducting wires, proper construction of
panels, high voltage tests, insulation resistance of cable, calibration
of meters, earthing of installation, checking of connections and
concealment if required.
11. Lubrication of Gears and Bearings

1. For gears and pinions, lubricating oil/grease or lubricating
compound used shall be of approved grade and quality.
2. Bearings closed from outside and open from inside shall be
checked for splash lubrication and bearing covers shall be free
from leakage. For bearings closed from both sides, proper injection
of grease of approved quality and grade shall be checked.
12.Inspection of hoist assembly and checks

1. The Assembled hoist shall be checked for the following :-
1. Quality of workmanship
2. Overall dimensions.
3. Optimum sound and vibrations.
4. Speed of operation allowing for variation in accordance with Indian Standards.
5. Any mechanical jamming.
1. Painting of different components of hoist shall be according to

relevant Indian Standards.
8. fixed wheel and slide gate erection

1. General Inspection : It shall be ascertained that the gate parts
received at the site of erection have been
manufactured/fabricated according to the drawings and have
necessary markings of shop inspection. It shall be ensured that all
exposed surfaces of embedded parts are protected by painting,
greasing etc. The surfaces of embedded parts in contact with
concrete shall be free from greases, paint etc. for better bonding
with concrete. A coating of cement wash/cement latex may be
given, if necessary.
2. Dimensional differences, if any, shall be accounted for before
erection and the drawings corrected accordingly for erection.
Critical dimensions shall be worked out from the drawings.
3. The reference lines, center line of openings and levels relations to
the completed civil structure shall be established on site so as to
facilitate erection at proper locations.
4. It shall be ensured that the various components of the hoisting
arrangement such as motors, reduction gear assembly, switches,
wire ropes and shafting are provided according to the
specifications.
9. Inspection of block outs

1. Concreting behind the gate groove may be done in one or two
stages. If done in two stages, it shall be ensured that correct block
outs are kept for accommodating the gate parts as manufactured
according to the specifications/drawings. It is also to be ensured
that the required dowel bars having adequate lengths are left out
in the block outs. The entire block-out is roughened to ensure
proper and necessary bondage to the second stage concreting.
10. Inspection of embedded parts

1. It shall be ensured that the sill beam is correctly positioned both
in level and location. All the nuts and bolts of anchorages of sill
beam shall be tightened so as to prevent dislocation during and
after concreting.
2. The embedded parts that is track plates, guides, seal seats, gate
groove lining etc. shall be checked when all parts are in final
position at least upto double the gate height, in one operation.
The check shall be carried out both in location and levels, with
respect to sill beam already established in the position. Each part
shall be checked first individually and thereafter relatively with
the other parts. It shall be ensured that the manufacturing
tolerances, as specified are considered while creating these parts
and even after accounting these tolerances, the erection work is
carried out according to the provisions in design and drawings.
3. The track plates and seal seats shall be absolutely in true
alignment. The alignment shall be checked by means of plump
bob and feeler gauge or micrometer, preferably at each 300 mm
intervals from bottom to top side of the gate opening.
Alternatively, diagonal checking or any other satisfactory method
may be adopted for checking the alignments. (This check requires
special attention).
4. After having checked the track plates and seal seats on both sides,
it shall be ensured that they are in their respective planes. It shall
also be checked that top seal seat, wherever provided, shall also
be in the required plane. (This check requires special attention).
5. Guide and counter guides, if provided, shall be checked for true
location and alignments.
6. Groove liners and corner protection angles, when provided, shall
be checked for true location and alignment.
7. Following critical dimensions shall be checked at intervals of 300
mm from bottom to double the gate height. (See Fig. A & B).
1. Centre to center distance of track plates.

2. Center to center distance of side seal seats.
3. Face to face distance of guides.
4. Face of track plate to face of the side seal seat &
5. Face of track plate to center line of guide.
Note1 : Use of suitable template for checking (d) & (e) (See Fig. A & B) is recommended to
maintain corresponding portions of vertical embedded parts from sill level up to
top of embedded parts.
Note 2 : Above double the gate height, the checking interval may be increased to one metre.
Note 3 : In case, top seal is provided the dimensions between the face of the track plate and
face of top seal seat shall also be checked.
1. Eccentricity or some such arrangement, if provided to a gate for

its fine adjustment in the groove, shall not be accounted for while
erecting embedded parts.
2. Anchorages shall be fastened or welded rigidly, after final
adjustment of embedded parts so as to prevent dislocation of
parts while pouring second stage concrete.
3. The gate groove concreting shall be done only after satisfying for
all these details and keeping proper records thereof. Rechecking
of embedded parts shall be done after concreting
8. Inspection of the gate at site of erection

1. The gate which is received at site duly inspected in workshop
shall be re-inspected at site before lowering into the gate groove.
Overall dimensions shall be checked to ensure that the gate fits
correctly in the gate groove. It shall also be ensured, before
lowering, that the gate has been painted according to
specifications.
2. Following critical dimensions shall be checked at an interval of

300 mm, wherever applicable.
1. Center to center distance between wheel treads.
2. Center to center distance between side seal/bases.
3. Face to face distance between guide shoes/rollers.
4. Face to seat base to wheel tread.
5. Center line of guide shoes/rollers to wheel tread in zero position.
1. The seals & seal bases shall be checked to ensure that they are
coplanar. All the wheels shall be adjusted to ensure that wheel
treads are in their proper alignment. The wheel pins shall be
locked after making the adjustment.
2. The seal bolts shall be tightened adequately and uniformly.
3. The gate wheels shall be checked for free rotation to ensure that
they are not jammed during transport/handling. To check
effectiveness of the seal, actual seal interference shall be
compared with that provided in design, because on this aspect
will depend to a great extent the efficiency of sealing arrangement
and easy operation of gate.
4. In case of counter weighted gate or gates with ballast, it shall be

ensured that correct weight is added.
8. FIXED WHEEL AND SLIDE GATES INSPECTION
OF COMPLETE GATE INSTALLATION
1. It shall be ensured that the installation of various parts of the
hoisting arrangements have been done to specified location and
alignment particularly in respect of correct positioning and
attachment of rope / stem of the gate as well as hoist.
2. There are several type of hoisting arrangement and the following

considerations shall be looked into at the time of erection and
subsequent inspection.
1. Connections like shaft couplings, connections of wire ropes to the drum and to the
gates, connection of the stem rod to the gate and hoist, connection of stem links,
connections of hoist components to the base etc. have been properly made.
2. Intermediate supports for stem rods are provided the required levels and permit free
movement of stem rod for the entire gate travel.
3. In case of double stem hoists both the hoists shall be properly synchronized.
4. The ends of wire ropes are properly looped and sufficient U clamps shall be
provided.
5. The rope is not loose and has been tightly wound over the rope drum. The rope shall
be properly lubricated and shall have no kinks.
6. The wire rope or chains at both ends of the gate and counter weight (if provided) shall
have equal initial tension.
7. Electrical installation shall be properly earthed.
8. The limit switches shall be properly adjusted to the operational requirements.
9. This may be checked by patting a spirit level on the horizontal top surface of gate or
weight. The babble of sprit level should be in the centre with the weight gate is hung
and not resting on the sill or plate-form.
1. It shall be ensured that the gate groove, sill and the embedded
parts are thoroughly cleaned and no foreign material is present in
the groove. Before lowering the gate it shall be perfectly ensured
that the gate groove is free from any obstruction.
2. The hoist provided for the operation of the gate shall first be
allowed to run under no load (without connection to gate) to
ensure its satisfactory working and that there is no undue
temperature rise due to friction in the rotating / moving
components.
8. FIXED WHEEL AND SLIDE GATES TESTING

1. The gate shall be tested first in the dry condition with the hoist
duly connected to the gates. The gate shall be moved up, and
down in the groove to ensure its smooth working and that there is
no obstruction and no undue effort required for its operation. In
case the gate is not going down of its own weight or found tight in
some position,, reasons shall be investigated and remedied instead
of forcing the gate down. While testing the gate in dry condition
the rubber seals should be kept wet by water jetting or other
suitable methods to avoid damage and to wear to the seals.
2. The testing of the gate seals in dry conditions shall be done by

viewing the contact surface against a tight source. It shall be
ensured that the top seal rides smoothly over the top seal seat at
the time of its approach to the latter.
3. In case of rubber seals, water should be poured over the seals so

that there shall not be dry friction of the seals. In case of metal
contact oil or grease is to be used. No grease or lubrication to be
used for rubber seals.
4. There shall be no noise of friction, any other noise, no signs of

excessive friction, no jerky performances, no dug in any position,
no dangling of the gate, no twist in the rubber seals, top seal does
not leave its plane and the rubber seals are not overpressed.
5. The gate, after lowering, is to be kept resting on the sill beam, i.e.
in close position. The leakage test may be taken in this position by
using suitable pump with necessary arrangement of jetting water
at 1.5 times the designed pressure on sealing positions from
bottom to top. Particularly all corner joints and other joints, if
any are to be tested to ensure perfect working of the gate.
6. The gate shall be fully opened or closed to ensure full opening and
satisfactory closing. The time needed for 300 mm opening or
closing of the gate is to be recorded for calibration purposes at
the time of actual operation.
7. In rope drum hoists, it is to be tested that the gate is going down

of its own weight, or with Ballast provided, and no additional
force is needed. The gate is also going down or coming up
vertically and there is no uneven pull to the gate. Also winding of
rope over the drums is uniform and is according to the design
provisions.
8. The tests as provided from 16.1 to 16.4 shall also be performed

against water load when conditions permit.
9. The torque required for movement of the gate on load shall be

measured and checked against designed value.
10.Under the designed water head conditions the leakage through

the gate should not exceed 15 litres/minute/meter length of the
seal.
11. When the gate is operated under water load, it is to be ensured

that there is no vibration to the gate, hoist or civil structures at
various gate openings.
12.By pass arrangement made for water and air vent, when provided
shall be checked for proper working of the system.
VOLUME - III
SECTION 7 HYDRO-MECHANICAL EQUIPMENT.
INDEX
ARTICLE NO.DESCRIPTION OF ARTICLE
1. GENERAL
1. SCOPE OF WORK
2.2 GENERAL DESCRIPTION OF EQUIPMENT
2.2.1 Spillway
2.3 SPECIFICATIONS AND TECHNICAL
REQUIREMENTS
2.4 ANNEXURE I
2.5 ANNEXURE II
2.0 GENERAL
Control of water at dam of the Project is envisaged through hydro mechanical

equipment as detailed below.
Units of measurements
The following units of measurements and abbreviations shall be used:
Unit Abbreviation
Metre m
Square metre m2
Cubic metre m3
2.14 Tonne T
Number No.
Lumpsum L.S.
Kilogram kg.
Kilometre km.
Hours hrs.
2.1 SCOPE OF WORK
The broad scope of works to be more fully defined by the bidder in the documents to
be submitted shall include the following:
(1) Design manufacture, inspection, shop assembly, testing, painting.
(2) Delivery at port of disembarkation, marine transportation, transit insurance,
collection of equipment and custom clearance, inland, transportation to
site.
3. Site storage, transportation and handling ,site erection, painting, testing and
commissioning including provision of labour, plant and material for the above.
3. Handing over to owner, supply of necessary spares for 5 years trouble free operation
and supply and installation of all incidentals not specified but are necessary for proper
completion and satisfactory functioning of the system.
(5) Guarantee of the following permanent equipment, alongwith all auxiliary

equipment in the designated location of the project as specified in the
following sections of technical specifications.
It is not the intention of these specifications to specify complete details of equipment.
However, the contractor shall supply the equipment which will meet in all
respects, the requirements of owner in regard to performance, durability and
satisfactory operation. All the equipment supplied shall conform to the
relevant Indian Standard. Wherever Indian standards are non-existent or silent,
relevant International Standards (as agreed between the owner and the
contractor) shall be followed. The sizes and numbers of units in each case are
based upon owners preliminary design and may vary to suit site conditions
and design requirements.
2.1.2 SPILLWAY
a) Eight 12.00 m width x 9.15 m high radial gates to pass 7079 cumecs of discharge.
b) Eight sets of embedded parts and anchorage for radial gates.
c) Sixteen hydraulic hoist cylinder (2 for each radial gate) with independent power
pack for individual gates and controls.
d) One sets of 12.00 m width x 9.35 m high wheeled stoplog
e) Eight sets of embedded parts for stoplogs including dogging arrangement and One
storage bay.
f) One No. lifting beam for spillway stoplogs.
g) One traveling gantry crane for handling the stoplogs along with rails etc.
6. HEAD REGULATOR GATES:
Suitable number of openings and gates have to be provided for canal outlet to
discharge 13.90 cumecs water through Control Structure (head regulator) with
sill level at 613.85m.
2.1.7 MICROPROCESSOR BASED REMOTE CONTROL SYSTEM

Microprocessor based Remote control system for operation of spillway radial gates
and head regulator gates to be housed in Regulation Room at Dam complex.
The system shall also include and monitor the following transducers
instrumentation at various locations:-
Gate position indicators for spillway radial gates and intake gates and head regulator
gates
Water level indicators One each near intake end and on other side of spillway and
One each near draft tube and tailrace outlet.
Discharge monitors for discharge through spillway radial gates and sluices.
2.1.9 SPARES
a) Mandatory spare parts for gates, hoists and cranes.
b) Additional spares recommended by bidder for 5 years trouble free operation.

2.1.10 TOOLS
Two sets of tools and equipment including special tools required for repair and
maintenance.
2.1.11 OPERATION AND MAINTENANCE MANUAL
Twenty sets of operation and maintenance manual including drawings as built, all
catalogue and brochures (for bought out items).
2.2 GENERAL DESCRIPTION OF EQUIPMENT:
2.15 2.2.1 SPILLWAY
2.2.1.1 RADIAL GATES

Seven radial gates of size 12.00 m x 9.15 m shall be of welded steel fabrication with
Cylindrical skin plate supported by stiffeners, main girders, arms and trunnion
assembly designed to withstand and operate against the Normal unbalanced
upstream full reservoir level. Provision should also be made to approach
various components of the gate through ladders for inspection and
maintenance. The trunnion shall be equipped with self lubricated bushings
(lubrite or equivalent), or spherical plain bearings. The fabrication should be
such that easy exchangeability of sealings is possible. The gates shall be
provided with a minimum of four-guide roller assembly on each side. The
trunnion assembly shall be supported by trunnion bracket resting on trunnion
beams/yoke girder and rest beams. The gates shall be designed to close under
their own weight for all operating conditions. The main vertical girder shall
transmit the design load to radial trunnion arms without warping or undue
deflection.
All the spillway crest radial gates shall be provided with overflow hoods. The
minimum width of the chord of the hood shall be 1.5 times of the depth of the
horizontal girder of the gates. The side seals will be provided on both sides of
the hood to protect the end arms and hydraulic cylinders from water spillage
and floating debris. The end arms of the gate, the location of the side seals
and the length of the hood etc. shall be suitably located during the detailed
design stage. A minimum of four nos. of flow breakers, 200 mm high each
and spanning over full width of the hood shall also be provided.
2.2.1.2 EMBEDDED PARTS
The radial gate embedded parts shall consist of steel sill beams and fabricated radial
pier guides members with stainless steel faced sealing surfaces (curved) and
roller support beams (curved). It shall also include erosion plates if required
(from civil design consideration), dogging devices and the trunnion bearing
foundation plates, post tensioned trunnion anchor rods, sleeves, nut,
frames/supports etc. Embedded parts shall include anchor bolts, plate & nuts
for all beams, roller paths, sealing faces, dogging devices, erosion plates (if
necessary) etc.
2.2.1.3 HOISTING EQUIPMENT FOR RADIAL GATES
2.15.1 For each gate, the operating equipment shall consist of One hydraulic
cylinders and One power pack. The power pack shall consist of One
pumps, One motors and all other required equipment. Each gate shall
also be provided with local control panel. Gate position indicator shall be
located at top of the Dam. Provision shall also be made for lifting the
cylinders in case of any maintenance. Provision for hydraulic dogging of
the piston rod at the end of the stroke and mechanical dogging device for
holding the gate for maintenance shall also be made. Necessary provision
for maintenance of the hydraulic cylinder shall be made. The hydraulic
system of each pair of adjacent gates shall be interconnected so as to
operate either of the gate at full speed or both the gates at half the speed.
One sets of mobile gasoline engine operated power pack alongwith
hydraulic quick acting connecting/ disconnecting hoses shall be provided
for the purpose. Each set shall be capable of operating One gate
independently. A selector switch for local or remote operations, and all
necessary provisions of transducers & instrumentation as well as
provision for connection to remote control system, in accordance with the
requirements of remote control system shall be provided.
The hydraulic cylinders shall be supported on cardenic suspension system

mounted on the piers about which, it can swivel and shall be connected to the
gate on the piston rod end through clevis eye. The upper end of the cylinder
shall be connected through cardenic suspension hinged at elevation designed
level. The suspension bracket assembly will be' held in position by means of
suitable numbers of load bearing anchors. Each anchor rod will be embedded
in first stage concrete to transfer the imposed loads from the cylinders. The
rotating parts will consist of cardenic link plate in the form of steel ring held
in position by a pin (material stainless steel) and a bush assembly (material
bronze) which shall rotate along with the cylinder for various position of the
gate. Suitable approach shall be provided from the downstream side for
maintenance of the pin and bush assembly.
Main Data
1.Number of gate : 8
2.Type of hoist : Hydraulic
3.Clear width : 12.00 m
4.FRL : 623.50 m
5.Gate Height : 9.15 m (including free board)
6.Maximum Water Level : 625.00 m
7.Crest Level : 614.350 m
8.Sill level : 613.85
9. No. of portable gasoline engines : 3
2.2.1.4 SPILLWAY STOPLOGS
One set of Stoplog units suitable for 12.00 m width clear openings and comprising
suitable fabricated sections making up an overall height of 9.35 m with
upstream skin plate, stiffeners, girders, upstream seal assemblies, wheel
assemblies, lifting attachments, side guide rollers, filling-in valves etc. The
stoplog will be designed to withstand the head corresponding to FRL suitable
for lowering under its own weight under balanced No-flow conditions.
Each section shall be fitted with bottom seal, side seal elements, track and guide roller
assembly. In addition, each unit except the bottom units, shall be provided
with an integral filling in valve system operated by the lifting beam hooks, for
ensuring operation of the stoplogs under balanced no flow conditions at
different reservoir level conditions upto FRL. A probe unit shall be installed
to give indication when the water pressure on both the sides of stoplog unit is
equalized. A probe unit to facilitate for disengagement of the hook locking
system only after it is properly seated on sill or over the lower unit shall be
incorporated in each stoplog unit.
2.2.1.5 EMBEDDED PARTS
Eight sets of fabricated steel embedded parts for 12.00 m clear span openings
comprising embedded guides complete with roller paths, erosion plates, if
required (from civil design consideration), lateral seal paths, sill beams,
storage bay units, if necessitated, and anchors for primary and secondary
concrete for twenty one water passage openings, dogging devices, etc.
Stoplog will be provided with manually operated dogging devices which will enable
a section to be stored at pier level in each of the 12.00 m span. Spillway
openings supported on pads integral with the embedded side guide members.
Suitable arrangements shall be made for storage of the stoplog units, in
storage bays, if required. Sections will be stored above water level. Suitable
locking devices shall be provided to lock the stoplog units over dogging
devices.
2.2.1.6 TRAVELING GANTRY
One, Electrically operated Traveling Gantry crane specifically for handling the
spillway stoplog units with an automatic lifting beam and complete with
stops, anchors and rail track with all necessary controls.
The operation of the gantry will be from an enclosed cabin with the maximum
possible unrestricted view. The gantry will be provided with all necessary
brakes, (viz. electromagnetic brake, as well as thruster brake ) storm anchors,
overload protection and for hoisting motion interlock devices etc.,
electromagnetic brakes for L.T., limit switches for extreme positions of hoists,
long travel as well as for centering the crane at centre line of each bay. All
drive and hoist gearing will be fully enclosed and housed as appropriate.
Additional inching controls shall be provided on the L.T. drive.
The main gantry structure will be of welded steel construction with bolted
connections, with smooth architectural lines of pleasing overall appearance,
incorporating adequate access facilities.
2.16 The gantry will be provided with an ancillary jib hoist with a
suitable grappling device and hoist to facilitate removal of logs
and heavy debris from reservoir. Extension of track shall be
suitable to handle the units from storage bay also. The power
supply to crane shall be suitably planned from central location of
its travel and a suitable trench along the rails shall be provided
for cable movement. The bidder may suggest any other suitable
arrangement for Power supply to the traveling gantry.
2.2.1.7 LIFTING BEAM

Three lifting beam for spillway stoplogs shall be of fabricated steel construction
suitable for handling by the traveling gantry and equipped with One
positively engaging type hooks with lifting lugs of stoplog units. It shall be
suitable for automatic engaging and disengaging the units.
Main Data :
2.16.1.1.1.1 Number of stoplogs : 3 set
2.16.1.1.1.2 Clear span of opening : 12.00 m
2.16.1.1.1.3 Total height of stoplogs : 9.35 m
No. of stoplog units : 3 Set

Number of filling in valve
in top of each unit : 3
Size of filling in valves
in stoplog : Not less than 300mm dia.
FRL : EL 623.50 m.
Sill level : 613.85
2.2.4 REMOTE CONTROL SYSTEM FOR GATES
The remote control system which is microprocessor control based shall consist of One
operator stations. One operator station shall be located in regulation room
provided at Dam top and shall be supplemented by a second operator station
provided at power house control room. The system shall be used for the
following:
Control and operation of spillway radial gate, intake gate and head regulator gate.
Gate position indication and monitoring of spillway radial gates, draft tube gates and
head regulator gate.
Water level indication and monitoring alongwith necessary alarms provided One at
other end of spillway One at head regulator gate.
Monitoring and indication of discharge measurements for discharge through spillway

radial gate.
Differential pressure measurement and indication across trash rack/ screens.
All the necessary transducers and instrumentation for the above at various locations
shall be provided and incorporated in the remote control system.
Each operator station shall include operator's consoles which comprises colour C.R.T.
with push buttons for operation and mimic panel which indicate the gate
movement. The operator shall be able to view the gate positions or any gate
status with the help of graphic display in the C.R.T.
One of the operator stations shall have One controllers each backing up the other so
that failure of One of the controller shall Not cause any discontinuity in the
control system and shall ensure that No loss of data takes place during change
over. The system shall also have a printer for printing various logs, instructions
and reports. Interlocking shall be provided between both the operator's stations
and between the local control panels and the operator station. System design
should be such that the operation can be dOne from local control panels, only
with the permission of operator station.
All the input display from field including water level of reservoir shall be displayed at
both the C.R.T. The system should continuously monitor the reservoir level
and depending upon this level it shall be able to calculate the input discharge
into the reservoir. In addition to this the gate openings of spillway gates, intake
gate should be displayed in the form of graphic displays. The system shall be
able to display the output discharge through spillway radial gates and canal
head regulator gates so that the operation of spillway gates can be carried out
in auto mode.
The system shall include various instruments like water level transmitters, sensors for
spillway gates, intake gate, height (opening) measurements.
The communication between the controllers and operator station shall be through
optical fibre data highway or any other reliable system.
One uninterruptable power supply (UPS) system to provide back up to the system in
case of failure of the main power supply to equipment shall also be provided.
2.3.2 DESIGN AND STRESS LEVELS
The hydro-mechanical equipments shall be designed in accordance with the
requirements of Indian standards. The bidder shall clearly indicate the standard
to which these equipment shall be designed.
For worst loading conditions such as earthquake conditions or gates jammed
conditions, storm wind conditions and under brake down torque conditions of
the hoist, the permissible design stresses shall be increased by 33-1/3% over
the Normal stress but limited to 80% of the yield point. In case of fasteners,
the increase in stress for worst loading cases shall be limited to 25% only.
The allowable design stress level for various components of hydraulic hoist shall
conform to the requirement of IS 10210. However for buckling of piston rod
of hydraulic cylinder, a factor of safety of 3.5 shall be adopted.
The embedded parts of gates shall be designed to limit the bearing pressure on 2nd
stage concrete to 25% of compressive strength of the concrete. An increase of
33-1/3% over the above stress is permitted in the case of worst loading cases.
Permissible stresses for field welds shall be considered from relevant I.S.
Codes. All the embedded parts shall be taken below the sill for at least 300 mm
distance. Downstream faces of gate grooves shall be provided with suitable off
sets as per ICOLD-1979 or model studies.
All the gates, stoplogs and bulkheads shall be equipped with side guide rollers
(200 mm dia) instead of guide shoes.
The gates, stoplogs and bulkheads having roller/sliding track and seal seat on same
side shall be provided with leaf springs on other side to provide adequate force
for proper pre-compression.
Pin of side guide rollers shall have hard chromium plating of 40microns.
Various lifting/operating equipment and their supporting structure including
that of trash rack cleaning machine shall be designed for Normal as well as
storm wind conditions as per Indian Standards IS 875.
The impact factor for various structures shall be in accordance with relevant Indian
standards. However minimum impact factor of 30% shall be considered for the
design of dogging devices, Hoist and crane structures, with Normal allowable
stresses. A corrosion allowance of 1.5 mm shall be adopted for penstocks.
2.3.3 SEISMIC CONDITIONS
The seismic coefficient has been approved for preliminary design purpose
from National Committee on Seismic Design Parameters .Horizontal
acceleration (PGA) equal to 0.134g (DBE) and vertical acceleration equal to
0.120g (DBE). The response spectra of the project site are available.
2.3.4 EMBEDDED PARTS
All the sealing faces in the embedded frame shall be of stainless steel. The wheel
tracks and sliding tracks shall be of corrosion resisting steel. The BHN of
wheel tracks shall be 50 points higher than the wheel rim. All the tracks (wheel
as well as sliding)and seal seats shall be machined after welding is completed.
The minimum thickness of seal seats after machining shall Not be less than 10
mm and thickness of roller/sliding path plate shall Not be less than 20 mm
after machining. Roller path, seal paths and guide track shall be provided upto
the heights indicated below.
Guide Track - full range of travel of gate.(including Maintenance position)
Track - unbalanced operation- twice the gate height + 1M
Track - balanced operation - gate height +1 m.
Seal seats - From sill level to One gate height and upto lintel seal seat unless
otherwise specified.
2.3.5 WHEEL ASSEMBLIES
Gate wheel shall be of cast-steel/forged steel and without any flanges and suitably
hardened. Each wheel shall be bored and provided with a self aligning type
roller bearing. The design of wheel assembly shall be such that any wheel
assembly can be removed and replaced without further gate disassembly. The
axis of wheel assemblies shall be of solid stainless steel and shall be provided
with a minimum eccentricity of +5 mm to facilitate wheel alignment. The
wheel assembly shall be provided with complete sealing arrangement and o-
rings to prevent ingress of water/silt into the bearing. Suitable greasing system
shall be incorporated in the wheel assembly.
2.3.6 GATE SEALS
All gate stoplog units and bulkhead shall be provided with natural rubber/ Neoprene
sealing elements in a section appropriate to the functional requirements and
gate type. In cases where low frictional resistance is necessary, the seals will
be provided with a PTFE insert bonded during the moulding process.
Thickness of bottom seal shall Not be less than 20mm and this shall be of
wedge type. All corner seals between lintel seals and side seals shall be of
continuous moulded piece. All seals will be clamped to gate units by stainless
steel fasteners. Suitable chamfer shall be provided in the base plate and clamps
of seal assembly. The properties of natural rubber /Neoprene seals shall be as
under:-
a) Shore A durometer hardness 65+5
b) Minimum elongation 450%
c) Ultimate tensile Strength (Minimum) 14.5 N/mm2
d) The rubber compound shall Not absorb more than 10% by weight, of water in 7 day
test
e) The tensile strength of the test specimen, after being subjected to an accelerated
ageing test of 48 hours in oxygen at 70o C and 2.1N/mm2 pressure, shall
be Not less than 80% of the strength of the test specimen before ageing.
2.3.7 FRICTIONAL RESISTANCE
The following frictional resistance co-efficient shall be adopted in the Design of gates
and associated equipment.
StaticDynamic
1. Rubber seal on Stainless steel 1.5 1.2
2. Seals with PTFE inserts 0.2 0.15
3. Roller bearing Factor 0.015 0.01
4. Self-lubricating bearings 0.2 0.15
5. Plain bearings 0.4 0.3
6. Steel on steel 0.6 0.4
7. Brass or bronze on steel 0.5 0.3
2.3.8 OPERATING EQUIPMENT

The capacity of the hoist and crane for various gates and stoplog units be calculated
on the basis of self weight of the gate, weight of lifting beam(where
applicable) frictional forces (including static seal friction, wheel/trunnion
friction, hoist friction, silt load etc.) and down pull forces. The hoist capacity
thus arrived at shall be increased by 20 percent to cater for reserve hoist
capacity.
Similarly in the case of gates designed for closing under self weight, the downward
forces closing the gate while lowering shall be at least 20% higher than the
forces opposing down ward motion. However the sealing pressure shall Not be
less than the values mentioned in the IS code.
The electric power for traveling cranes shall be provided by means of a trailing cable
and reeling drum arrangement. Suitable trenches shall also be provided for the
travel of the cable along the crane.
2.3.9 GATE SEAL LEAKAGE
The leakage be allowance for gate shall Not be greater than an overall average of 6
litres/minute/meter of seal length which covers for small areas such as
corners being in excess of the average. In the case if stoplogs and bulkheads
the average permissible leakage shall be 10 litres/minute/meter of seal
length.
2.3.10 HYDRAULIC HOISTS

The hydraulic hoisting equipment consists of hydraulic servo motors, oil pumps, and
all necessary piping, valves, controls and other accessories. The servo motor
consists of hydraulic cylinder and the piston stem. The material of cylinder
shall be St.52 and the piston stem material shall conform to 22 Cr.Ni.17. In
addition, piston rod shall be hard chromium plated to a thickness of
50microns. Sealing of the piston and the rods shall be achieved by means of
chevron packing. The cylinder bore shall be honed. The piping shall be of
heavy duty seamless steel tube. The couplings and connection shall be as per
International Standard.
The gate and cylinder base suspension shall be effected by maintenance free hinged
bearings. All the hydraulic hoist cylinder shall be provided with hydraulic
locking device to hold the piston along with the gate to facilitate
maintenance of the gate, creep prevention devices, speed damping devices
at the end of stroke and limit switches for both end positions and dogging
position of the gate. Wherever specified limit switch shall also be provided
for crack opening of the gate. Position transmitter shall be vibration proof
and free from humid atmosphere. The power pack unit shall comprise of
One parallel pump motor sets, One acting as stand by complete with
associated hydraulic and electrical control. Facilities shall be provided in
local control panel to allow remote control/Indication. Manual operation
shall be provided in all the power pack to lift the gates during power
failure. Pump motor set of power pack shall be provided with Space
heaters. In hydraulic pipings either couplings or flanged connections shall
be used to ensure leak proof joints. (Ferrule joints are Not acceptable)
2.3.11 GANTRY CRANES AND HOISTS
E.O.T. gantry cranes and hoists for handling the various stoplogs bulkhead and gates
shall be designed and shall conform to requirements of applicable to Indian
codes. Cranes will be classified according to its specific duty, service life and
load status covering the structure and gear mechanism. The winding drums
shall have single layer of rope, as far as practical.
Gantry cranes shall be supplied complete with rails equipped with necessary
anchorage to withstand wind and seismic loads transmitted from the gantry
structure. Electromechanical hoist shall consist of wire ropes, drums, reduction
gear, couplings, brakes, electric motors, limit switches. Both electro magnetic
and thruster brakes shall be provided on hoist drives where LT and CT drives
shall be equipped with electro magnetic brakes. Necessary provisions for
connections to remote control system shall be provided on local control panels.
2.3.13 LIFTING BEAMS
The lifting beams for handling the stoplog sections will be of the automatic type,
being preset to release or engage the hooks prior to lowering. Presetting is by
manual positioning of a central counterweight system, and an interlock
arrangement prevents premature release of the hooks during lowering. A probe
rod incorporated in each stoplog unit releases the locking arrangement when
the section is fully lowered, enabling the hooks to disengage.
2.3.14 ROPE DRUMS AND WIRE ROPES
The rope drums and wire ropes shall conform to the Indian Standards in general. The
ropes shall conform to IS2266 improved plow steel and fibre core extra
flexible high grade improved wire rope. The ropes shall have a factor of
safety of six(6).
The drums shall be made of cast steel or fabricated from steel plates and shall be
reinforced to sustain concentrated loads due to rope tension. The drums shall
have a diameter Not less than 20 times the rope diameter and shall have
sufficient length to adopt full length of rope of specified lift and number of
falls, in One layer plus One idle turns at each fastening end and minimum
One extra groove. The drums shall be checked for crushing and combined
stress as per IS-6938.
2.3.15 ELECTRICAL EQUIPMENT
All electrical equipment, including motors, starters, control panels, sole Noids and
associated instrumentation shall be of international standard and shall be
suitable for the climatic conditions prevailing at the project site and shall
be provided with all necessary anti-condensation heaters and other
protection against the ingress of dirt and insects.
All motors shall be induction type with water tight terminals, anti-friction bearings
and built in totally enclosed fan ventilated enclosures. All motors have speed
Not exceeding 1500 rpm. Creep speed motors shall also be continuously
rated. All hoists including crane hoists shall be provided with atleast One sets
of brakes working on different principles viz electromagnetic, thrustor, eddy
current braking system etc.
All motions shall be provided with limit switches at both extreme ends of travel. For
hoist motion the system shall be provided with overload limit switches and
slack rope limit switches. Master controllers for E.O.T. gantry crane, trash
raking machine shall be of the joy stick type located in the operators cabin.
Indications and protections shall be provided on the control panel.
2.3.16 INSPECTION & TESTS
All materials shall be of tested quality and all work performed shall be subject to rigid
inspection and No articles or materials shall be dispatched until all tests,
analysis and shop inspection have been completed or certified copies of
reports or results of tests and analysis have been accepted. Duplicate copies of
manufacturer's test certificates including chemical analysis and mechanical
properties shall be made available for all materials. In case test certificates are
Not available for any of the material the same shall be got tested and only
those materials which fulfill the requirements of these specifications shall be
used. From any part/item, it should be possible to locate its manufacturer's
batch/lot mark, which shall be achieved by transferring the batch marks
before parting the materials.
All castings shall be annealed and forging shall be Normalized.
2.3.17 SHOP ASSEMBLY AND TESTING
During the course of manufacture, the equipment included in the scope of supply shall
be subject to rigorous inspection and testing.
All components, sub-assemblies and assemblies will be dimensionally and
functionally checked against the relevant drawing.
All spillway radial gates shall be fully shop assembled with skin plate assembly,
horizontal girders, end girders, arms, trunnions, bracing etc. to ensure that all
parts fit properly true to line and that required dimensions, clearance and
tolerances have been achieved.
Other gate units shall also be fully shop assembled (with temporary bolting where
necessary),and checked for dimensional and flatness checks with all
fitments such as wheels, guides, seals, bypass valves etc., attached. The
correct C.G. shall be established during shop assembly before Preliminary
welding of lifting lugs.
Reception frames and guides shall be assembled on the shop floor for dimensional and
straightness checks, also alignment of connecting members within the required
tolerances.
In all cases the various connecting parts shall be match marked to facilitate site
erection.
Hoisting units shall be fully assembled on the hoist platform and test run to atleast 20
minutes and load tested to 1.25 times the rated capacity. All lifting beam shall
be shop assembled and hooks will be similarly load tested. Automatic
engaging and dis-engaging of lifting beam hooks shall also be tested in the
shop. During test run all the components of the hoist shall be tested for their
performance.
Each hydraulic hoist cylinder complete with all packings, pistons, supports etc., shall
be pressure tested to 1.5 times the working pressure and maintained at this
pressure for atleast 30 minutes. Each hoist cylinder shall be moved for its full
stroke length.
The hydraulic hoist control units, pumping units, valves, piping etc., shall be pressure
tested to 1.25 times the working pressure and maintained at this pressure for
atleast 30 minutes.
The gantry crane and hoist shall be fully shop assembled and tested to 1.25 times the
rated capacity. The hoist shall be operated for 15 to 30 minutes in slowest
speed to demonstrate that equipment has been designed for continuous duty.
The gantry Crane shall be made to travel for a distance of 30 m if so permitted
or otherwise the driving wheels shall be rotated under power, by jacking of
wheel carriage/crane.
2.3.18 SITE TESTING AND COMMISSIONING
All embedded reception frames and support frames etc., shall be erected and checked
for dimensional accuracy and alignment in accordance with the assembly
drawing within the required tolerances and level limits before and after
concreting.
After site assembly of the gate units within their respective reception frames, all gates
will be checked for roller alignment, seal compression and guide clearances.
The operating equipment will be checked for correct positioning and alignment, and
undergo full functional tests over the operation range of the particular gate,
checking operating speeds and performance of the hydraulic and electrical
control systems.
Hydraulic systems will be pressure tested to 1.5 times the maximum rated operating
pressure.
Gantry cranes and hoisting winches shall be load tested, all in accordance with
standard's requirements, and all hoist and travel motions checked, including
brakes, interlocks and safety devices.
All lifting beams will be checked for correct functioning in conjunction with bypass
valves and interlock probe systems.
All gates shall be dry tested before impounding of water to ensure that there is No
clearance between seals and seal seats, all rollers are in contact with roller
path, the clearance between guide rollers and guide is within the prescribed
limits and the gate travels smoothly in the groove up and down without
excessive sway throughout the travel.
Wet test of all gates and associated equipment after impounding will include checking
of seal efficiency and full operational test under maximum design water load.
2.3.19 NON DESTRUCTIVE TEST
The fabricated gate/stoplog units, embedded parts, penstocks, hoist components and
other load carrying members. shall be subjected to the following Non
destructive tests.
2.3.19.1 Steel
i) Butt welds Radiography 100%
ii) All fillet welds Magnetic 100%
in the gate beam, particle
end plate and
lifting point
iii) Other fillet welds Magnetic particle 10%
iv) Root runs of Dye-penetrant 100%
important load
bearing joints.
v) For penstocks
a) longitudinal joints. Radiography 100%
b) Circumferential Radiography 100%
joints of bends
and T joints.
c) Circumferential Ultrasonic 100%
joints enclosed
in concrete and
Not tested by
radiography-
straight ferrules.
d) Plates Ultrasonic 100%
2.3.19.2 Castings and Forgings
Castings Ultrasonic Level I SA 603 ASME Sec.V Forgings Ultrasonic SA388 ASME
Sec.V 2.3.20
2.3.20 PRESSURE TEST
Each fabricated ferrule of penstocks and each segment of bend fabricated for field
erection shall be pressure tested individually to a pressure equal to 1.5 times
the design internal pressure subject to a limit of 0.8 times the yield point of
the material.
Suitable test bed with accessories shall be provided at site by the bidder for testing
purposes. Bulkheads for testing of bends as fabricated shall also be provided
and Nothing extra shall be payable on this account.
The test pressure shall be applied and released one times successively and after each
application shall be held steady for atleast 15 minutes or till such time all
welded joints and plates can be examined for defects, leaks etc.
2.3.21 STRESS RELIEVING
Trunnion bearing hub casting prior to machining shall be stress relieved, if welded.
Yoke girder and the anchor girders shall also be stress relieved. Elsewhere
welded plates thicker than 28mm will also be stress relieved. The procedure
for stress relieving shall be as per ASME section VIII Division 1.
2.3.22 SURFACE PREPARATION AND PAINTING
All exposed and under water steel works including liners shall be sand blasted to at
least Sa 2 1/2 quality of Swedish Standards. SIS055900. The bidder shall
clearly indicate the painting system proposed by them for under water as well
as exposed surfaces of steel works including liners indicating the type of
primers, protective coatings, No. of coats proposed and their dry film
thickness. However, the dry film thickness should be around 70-80 microns
for primer protections and 400 microns (in One coats) for Preliminary
paintings.
23. GENERAL
The bidder shall include necessary ladders, platforms, handrails in and around gate
installations in order to provide approach for inspection and maintenance.
Removable steel covers shall also be provided on gate openings at deck level
wherever required.
Necessary cabling (within his scope of work) for various hoist installations including
remote control system shall be provided by the bidder without additional cost
to the Owner.
The bidder shall prepare detailed technical specifications, design calculations, general
arrangement, assembly, subassembly and detailed fabrication drawings and
inspection drawings for various components of works and submit the same
for the approval of the owner. Fabrication shall be taken up only after
approval of the above by the owner. All schematic wiring diagrams, control
circuit, drawings, hydraulic piping and installation drawings and hydraulic
circuit diagrams along with detailed write up shall also be submitted for
approval.
The metre, kilogram, second (MKS) System shall be used for this contract where
manufacturers products are produced in imperial sizes, substitutions shall
be made to nearest metric size. All drawings, calculations, design data and
instructions manuals shall be in MKS units. For manufacturer's
convenience imperial measurements may be placed in brackets after the
MKS units.
2.16.2 LIST OF I.S.CODES REQUIRED IN GENERAL
Sl.No. Description IS Number

________________________________________________________
1. Recommendation of structural
design of fixed wheel gates IS 4622
2. Recommendation of structural
design of Radial gates IS 4623
3. Recommendations for structural
design criteria for low head
slide gates IS 5620
4. Recommendation for structural
design of medium & high head
slide gates IS 9349
5. Code of practice for design of
rope drum and chain hoists for
hydraulic gates. IS 6938
6. Code of practice for electric
overhead Traveling cranes and
gantry cranes other than steel
works cranes IS 3177
7. Code of practice for design
manufacture erection & testing
of cranes & hoists. IS 807
8. Code of practice for use of
structural steel in general
building construction. IS 800
9. Design criteria for hydraulic
hoists for gates. IS 10210
10. Recommendation for inspection
testing & maintenance of fixed
wheel & slide gates. IS 7718
(Part I)
11. -do- (Part II)
12. -do- (Part III)
13. Recommendation for Inspection, IS 10096
testing & maintenance of Radial (Part-I)
gates & their hoists.
14. -do- IS 10096
(Part II)
15. -do- IS 10096
(Part III)
16. Approval test for welding pro- IS 7307
cedures (Part I) (Part I)
17. Approval testing of welders working IS 7310
to approved welding procedures (Part I)
18. Approval tests for welders when IS 7318
welding procedures approval is
Not required.
19. Code of practice for liquid IS 3658
penetrant flow detector
20. Code of practice for Ultrasonic
tube echo testing by contact and IS 3664
immersion methods.
21. Code of practice for magnetic
flow detector IS 3703
22. Code for unfired pressure vessels IS 2825
23. Code of practice for radiographic testing IS 2595
24. Code of practice for structural
safety of bldgs: Loading Std. IS 875
25. Code of practice for plain &
reinforced concrete IS 456
26. Sluice valves & Gate valves IS 780
27. Criteria for Earthquake
resistant design of structures IS 1893
28. Steel wire ropes for General
Engg. Purposes IS 2266
Bidder shall indicate the approximate weight of the various components of
each gates and its hoists.
1)Weight of gates/stoplogs/bulkhead
2)Weight of embedded parts
3)Weight of hoists/cranes and its capacity
4)Weight of hoist supporting structure.
5)Weight of lifting beams

2.4 SPECIFICATION OF MATERIAL Annexure I
2.4.1. Materials for various components of Hydro- Mechanical equipment shall
conform to the requirements given below. The bidder shall indicate the exact
specification of material proposed by them in the bid.
S.No. COMPONENT MATERIAL SPECIFICATION

CONFORM TO OF MATERIAL
PROPOSED BY
BIDDERS.
1. Gate, Embedded parts,
groove-liner, bonnets etc.
a) Steel Plate Mild steel-
weldable quality
b) Rolled section Mild Steel-
Weldable quality.
2. Main rollers,
Guide roller,
Cast steel
Forged Steel
3. Trunnion Hub Forged steel.
4. Self-lubricating "Lubrite" or
bearings and approved equal
washers
5. Main and guide Corrosion-resistant
roller axles Steel.
6. Side guides
a) Steel plate Mild steel- weldable
quality
b) Rolled Sections Mild steel-Weldable
quality
7. Main Roller Corrosion-resistant
track steel
8. Side and back Carbon steel
roller track
9. Sealing surfaces Corrosion-resistant
steel
10. Seal fasteners Corrosion-resistant
steel
11. Structural members
of hoist platforms,
columns etc.
a) Steel plate Mild steel-weldable
quality
b) Rolled sections Mild steel-weldable
quality
12. Hoist drums and Steel platge-weldable
achieve quality, cast steel
13. Gears Cast steel
14. Pinions Forged steel
15. Pins, shafts, Cold rolled steel
sheave, axles, corrosion resistant
less than 75mm steel, carbon
dia steel
above 75mm dia Carbon steel
Forged steel
Corrosion resistant steel
16. Wire rope 6x37 construction
17. Bearing Pedestal Cast steel
18. Bronze bush other Plain bronze

than specified above
19. Hydraulic Hoist St 52 or equal
cylinder tube
20. Flange plate St 52-3 or equal
21. Connecting eye Forged steel
Cast steel
22. Piston Bronze
23. Piston rod 22 cr Ni 17
24. Lifting pins Carbon steel
Corrosion resistant steel
25. Bolts for corrosion-resistant
connecting Steel.
flange plates of
Hydraulic Hoist.
26. Pipes for Heavy duty seamless
Hydraulic Units
27. Coupling for International standard
Hydraulic pipes
28. Manifold for Steel
Hydraulic Units
29. Spherical/ SKF,FAG or approved
roller bearings equal
30. Machine bolts Carbon steel
and nuts
31. Steel plate for Pressure vessel quality plate
penstocks
Annexture- II
The following data shall be furnished alongwith the bid:
1. Design Codes To Conform to
a) For Gate & Embedded Parts
b) For Gate rollers and roller path.
c) Electro-mechanical Hoist
d) Hydraulic Hoist
e) Crane
f) Electrical design
PS: Copies of Design standard (other than IS) shall be submitted along with the bid.
2. Sand Blasting and Painting System proposed for
1. Gates, Embedded Parts Trashracks.
b) Mechanical portion of Electro-Mechanical Hoists.

c) Supporting structure for Electro-Mechanical Hoists.
d) Cranes/Trashracks cleaning machine
e) Hydraulic Hoists.
f) Penstock
3. Hydraulic Hoists
a) Type of pump
b) Working pressure
c) Test pressure for cylinder
d) Test pressure for piping & valves.
e) Mounting of cylinder
f) Surface finish of Piston rod
g) Type of limit switch
h) Type of position indicator
4. Trash rack cleaning machine
a) Capacity of rake
b) Overload protection
c) Type of limit switch
d) Type of motor for different operation
5. Remote control system
a) Position transmitter for various gates
b) Transmitter for water level measurement
c) Size of CRT screen
d) Capacity of printer
e) Capacity of controllers
f) Duration of UPS
g) Language used in software
6. Electro-Mechanical Hoists
a) Type of motor
b) Type of Brake
d) Type position indicator
7. Cranes
1. Type of motor for different operations
2. Type of brake
26.10 RADIAL GATES-MANUFACTURING
26.10.1 General
This part of chapter lays down the recommendations for inspection, assembly testing of radial
gates at the manufacturing stage. The hoisting equipment viz. ropes drum hoists have been
covered in the later part of this chapter.
26.10.2 Material
26.10.2.1 All Materials used shall conform to latest Indian Standards as detailed in Appendix-
C.
26.10.2.2 All materials used shall be of tested quality. Original manufacturer's test certificates
for bought out items such as castings forgings and seal be asked for ensuring quality.
26.10.2.3 All castings/forgings shall conform to the latest Indian Standards. Visual
examination/inspection shall be done to ensure the soundness and surface smoothness. It
required, non destructive tests shall be conducted.
26.10.3 Welding
26.10.3.1 The selection of electrodes, welding procedure, investigation of defects and testing
of welds shall be in accordance with procedure laid down in para 26.4.3.
26.10.3.2 Any part of electrodes, welding procedure, investigation of defects and testing of
welds shall be in accordance with procedure laid down in para 26.4.3.
26.10.3.2 Any part of item may be stress relieved according to the requirement and procedure
laid down in IS:2825-1984. General following items require stress-relieving.
a) Yoke/trunnion girders, anchor girder, and trunnion brackets, where heavy welding is
involved.
b) Trunnion hub if part of the arm (structural portion) is welded to the casting.
26.10.4 Manufacturing tolerances
The gates and embedded parts shall be manufactured to such accuracy and tolerances as are
required for the safe and efficient operation of gates. Following tolerances shall be
maintained as a general guidance.
26.10.4.1 Embedded Parts
26.10.4.1.1 Deviation of any point on the face of seal seat from 2.0 M machined straight edge
held against it shall not exceed o.5 mm.
26.10.4.1.2 Deviation from straightness of the wall plate shall not be more than 2.0 mm in 2.0
m length.
26.10.4.1.3 Offsets and gaps at any adjoining joints between seal seats, guides etc. shall not
exceed o.5 mm.
26.10.4.1.4 When Yoke girder and anchor girder are inter connected by the flats or tie rods
the linear dimensions shall be within the limits specified under IS 21-2-1991 (Allowable
deviations for dimensions without Special tolerances).
26.10.4.2 Gates
26.10.4.2.1 The gate leaves with stiffners shall generally be manufactured on a jig and
fixture. The tolerances on the gate shall be 1/1000 of radius or + 10mm whichever is less.
26.10.4.2.2 The distance between the side guide roller/guide shoes on one side of the gate to
the corresponding guide roller/ guide shoes on the other side shall not vary from dimension
shown in the drawings by more than + 0.000 mm to 2.00 mm.
26.10.4.2.3 Parallel distance of centre line of both the trunion bearing from upstream bottom
edge of skin plate shall not vary more than 13.0 mm.
26.10.4.2.4 The horizontal distance between the centre to centre of trunnions shall not vary
from the dimension shown in the drawings by more than 13.0 mm.
26.10.4.23 Connections - At all splices, the holes shall be match drilled. If fit bolts are
provided, the holes shall be reamed at assembly.
26.10.5 Shop assembly and testing (Gate & Embedded Parts)

26.10.5.1 The anchor girder together with the tie bars of convenient length for testing and
yoke girder shall be load tested equivalent to 1.5 times the design load before crection. The
load shall be applied gradually by means of hydraulic jacks and the assembly shall remain
under load the enable all the observations required by test procedure to be made.
26.10.5.2 Assembly of wall plates and sill beams shall be done at the shop.
26.10.5.3 Gates shall be assembled complete with guide rollers and trunnions for proper
alignment and inspection. All the specified dimensions in para 26.9.4.1 and 26.9.4.2 and other
central dimensions shall be checked on assembly.
26.10.5.4 Side guide rollers may be shimmed if necessary, to miantain the required tolerances
as specified in para 26.9.4.2.
26.10.6 Seals
Seals may be assembled either at shop or during erection according to the convenience. The
holes in seals shall be match drilled with seals base and clamps. The seals used shall conform
to specifications at Appendix-F.
26.10.7 Match-marking
All erection marks shall be hand punched. All the components shall be match marked before
dismantling.
26.10.8 Cleaning & Painting
Surface shall be cleaned thoroughly, preferably by sand/shot blasting. Painting shall be as

specified and the procedure shall be recommend by the paint manufacturer and as per
procedure described under para 26.4.6.
26.11 RADIAL GATES - ROPE DRUM HOIST
26.11.1 Service requirement
Rope Drum Hoists for crest radial gates shall be capable of lifting and closing the gates under
full unbalance head for which the gates are designed.
While computing hoist capacity, 20% reserve hoist capacity may be taken in to consideration.
The lifting speed for the hoist shall be 0.30 m per minutes.
26.11.2 General arrangement
The rope drum hoists, shall be electrically operated. They shall be installed on the hoist
bridges to be provided for them. The hoist shall be provided with local & remote control gate
position indicators.
26.11.3 The seller shall furnish details of erection facilities for handling the parts furnished
under, this work upto its final installed location if any these devices are to be specially
fabricated, detailed drawings and specifications thereof shall be furnished by the seller
without any additional cost to the buyers.
26.11.4 Operating Characteristics
26.11.4.1 All hoists shall be operated either from hoist bridge located on top of the piers or
from remote control cabin.
26.11.4.2 The control system shall fully open or close the gate at the minimum speed of 0.3
m/min.
26.11.4.3 All electrical switches shall be push button type and shall be flush mounted. All
internal wiring of the control of the power cabinet shall be furnished by the seller.
26.11.5 Design Criteria
26.11.5.1 Design data- All important design data shall be specified which interalia may
include the following information (a) Location of radial gages (b) number of hoists (c) MWL
& FRL (d) Hoist capacity (e) Gate travel (f) Raising and lowering speed of the gate (g)
Permissible stresses.
26.11.5.2 The allowable stresses for some of the materials are as stated as per para 5.0 of this
volume. Where the allowable stresses have not been specified they shall be taken one half
(1/2) of the yield stress or 1/5th of the ultimate tensile stress whichever is less.
26.11.5.3 In case any material conforming to different equivalent specifications is used, if

permitted, the stresses allowed shall not exceed, the allowable stresses previously got
approved from the buyers.
26.11.6 Manufacturing details
26.11.6.1 Wire ropes- The steel wire ropes shall be of 6 x 37 const. fibre core conforming to
I.S. specifications for steel wire ropes for general engineering purposes (IS:7266-1991). The
wire rope shall be provided with a device that would take care of unequal streach of rope. The
minimum factor of safety of the wire rope shall be under normal operating condition and 3
under break down torque condition.
26.11.6.2 Rope drum - The drum shall be made from cast steel (27-54 grade) conforming to
Indian Standards on topic "Specifications for steel castings for general engineering purposes"
IS:1030-1989).
26.11.6.3 Gears - All Spur gear wheels shall be cast steel (27-54) grade conforming to
IS:1030-1989 and pinion shall be forged steel (class 3 A) conforming to IS::2004-1991.
26.11.6.4 Shafts - All shafts shall be made of carbon steel conforming to Indian Standard
Schedules for wrought steel Part V stainless and heat resisting steels (I revision) (with
amendment No. 1) IS:1570 (Pt.V) 1991.
26.11.6.5 Bush Bearings - Drum shafts shall be provided with bush bearings of aluminum
bronze confirming to IS Specifications for aluminum bronze ingets and castings (second
revision) IS:305-1991.
26.11.6.6 Couplings - All couplings shall be cast steel (27-54 grade) conforming to IS:1030-
1989 and forged steel (class 3 A) conforming to IS:2004-1991).
26.11.6.7 Gear Boxes - Gear boxes shall be of rigid construction filled with inspection covers
and lifting handles. The gear boxes shall be so designed that the gears can easily be removed
or replaced and shall be such that the gears are suitable lubricated. Facilities for oil filling and
draining connection for oil level indicating and adequate breathing shall be provided. The
gear box shall be made of structural steel conforming to IS:726-1990/IS:2062-1992.
26.11.6.8 Gate position indicators - Local indication of the gate position shall be provided on
the rope drum hoist. Remote indication shall also be provided at remote control cabin.
26.11.6.9 Access ladder & platform - A permanent access ladder for providing access to the
top of each rope drum hoist alongwith support platform of not less than 8 mm chequered
plate & guard railing shall be provided on the hoisting bridge. These shall permit approach to
the top at each rope drum hoist for inspection, maintenance and operation of the hoist.
Hoisting bridge for hoist assembly etc. shall be provided by the seller.
26.11.6.10 Hoist Assembly & Test - Fabrication of the parts shall be carried out under strict
supervision on trained technical personal. If the buyer desires to inspect the work during the
course of fabrication the same shall be done during working hours at the workshop. The work
done in the workshop shall be subjected to inspection from time to time from the buyer. The
seller shall provide all faciliteis required for such inspection of materials, fabrication of
component testing of materials parts at the place of manufacture and erection. The seller shall
before shipment make such assembling and tests of the various parts of the hoists and
hoisting accessories and of the controls as may be required in his workshop to ensure that all
parts fit and operate properly and that all dimensions and all tolerances requirement are in
accordance with the specifications and drawings. The seller shall demonstrate and operate the
equipment for the inspection of the buyer before disassembly and preparation for shipment.
26.11.7 Electric equipment
26.11.7.1 General requirement - All electric equipments covered under these specifications
shall conform to Indian Standard specifications and of high quality and suitable for
application for duty and function which the particular accessories shall be required to perform
in the operation of the crest radial gates. The type manufacture's name, type performance and
readings of all such items shall be given for each of the electrical equipments. The power
supply shall be 400/440 volts, 3 phase 50 c/s, AC and 230/240 volts single phase 50c/s AC.
26.11.7.2 Schedule of requirement- Control cabinet in the control chamber for each crest
radial gate hoist shall be acquired with the following equipments located suitably in the
cabinet.
1. Electric motor.
2. Convenient size heaters for motor with operating switch.

3. Convenient size heaters with operating switch for control cabinet.
4. Motor starters
5. Circuit breaker backed by short circuit fuses for motor
6. Current transformer
7. Local control selector switches (double pole, two positions stay put mechanical locking
type)
8. Control switches - Raise/lower
9. Push button "Stop"
10. Electric motor starter relay
11. Resistors for various lamp indication circuit
12. Red lamps for closed position of crest radial gate
13. Green lamps for open position of crest radial gate
14. Amber lamp for crest radial gate in movement
15. Control circuit supply heating lamp indication
16. Control circuit supply tripped lamp indication
17. Blue lamp for crest radial gate partly opened/closed position.
18. Electronic type transmitters alongwith electronic type digital receiver for indication of
gate travel position in the remote control cabinet located in non overflow block.
19. Any equipment not mentioned in the list but the buyer/seller feels essential.
26.11.7.3 Control Cabinets- Every rope drop hoist shall have separate control cabinet. The
control cabinet in the control chamber shall be of sufficient size so as to hearty &
methodically addommodate all the required electrical equipment and appurtances. Each
cabinet shall have two compartments. The lower compartment shall accommodate circuit
breakers for power supply to motor & control circuit, starters, heater switches, control
switches, stop push button and indicating lamps. Each compartment shall be provided with
independent lockable doors. All equipments shall be flush mounted. The location of mounting
brackets and tapped holes and layout of the equipments in the control cabinets shall suit in
particular commercial equipment furnished, all necessary bolts, screws & other fastners for
mounting commercial equipment, shall also be furnished by the seller. The control cabinet
shall be completely assembled wired & tested in shop. The suitable insulation wiring shall be
adequately designed, neatly installed and fastened. Electrical connection shall be made only
at apparatus terminal blocks. The splices or laps shall be permitted between terminal
connections. Terminal field connections shall be accessible without distrubance to internal
wiring. To prevent condensation of moisture, each cabinet shall be provided with single phase
230/250 volts cartidge heater. All wiring shall be weather proof & suitable for tropical
climate and highly humid atmosphere, where necessary wiring shall be covered in metal
conduits. All power & controlled wiring shall be furnished by the seller. Each control cabinet
shall be not less than 3 mm. thick steel sheet, suitably reinforced where required. The
assembled cabinet shall have neat appearance and all exterior sharp corners, welds
& surface irregularities shall be ground smooth. The doors shall swing freely on hinges and
shall close without sticking. All the locks of the cabinets shall be keyed alike with keys
removable either locked or unlocked position. Four sets of keys shall be supplied of each
cabinet.
26.11.7.4 Electric Motor - One electric motor, shall be provided for each type drum hoist.
The electric motor shall be 400/440 volts, 3 phase, 50 c/s eqipped cage, non reversing type
with high starting torque characteristics and shall conform to Indian Standard specifications
for one phase indication motor (Fourth Revision) IS:325-1991 as regards rating,
characteristics & tests unless otherwise specified herein. The motor shall be totally enclosed,
Fan cooled & suitable for use in tropical climate and highly humid atmosphere.
The electric motor shall be of sufficient capacity to carry continuously the maximum possible
load likely to develop under all stipulated conditions without exceeding the name plate
ratings.
The insulating materials, for electric motor shall conform to the I.S. Classfications of
insulating materials for electric machinery & apparatus in relation to their thermal stability in
service IS:1271-1990.
The maximum temperature of the wiring, when the electric motor is delivering the rated
output continuously at the rated voltage and frequency shall not exceed 70C above the
ambient temperature of 280C. The temperature rise of others parts of the motor shall be in
accordance with the IS:325-1991.
The electric motor shall be furnished duly coated by the protective material approved by the
Buyer to prevent formation of rust & corrosion due to affects of moisture. All electric motors
shall be of the same make & latest model.
All electric motor bearings shall be self lubricating type which shall be properly sealed
against loss of lubricant or entrance of dust.
To prevent condensation, the electric motor shall be equipped with 230/250 volts, single
phase heaters nominated in or on the phase. The loads of the electric motor and the
anticondensation heater shall be brought out in a terminal box on the motor suitable cable
entry lugs.
26.11.7.5 Wiring - All wirings of power control cabinets shall be neatly installed, conected
and securely anchored in poles in a workman like manner. Electric connections shall be neat,
mechanically tight and secure and shall be made of apparatus terminals & terminal blocks.
Terminals for field connections shall be accessible freely. The insulation of control wiring
shall be of polyvinyl chloride or similar synthetic insulation of 650 volts grade. All
conductors connected to restore or otherwise subject to abnormal heat shall be 650 volts
grade heat resistant installation. All wiring shall be weather proof
and suitable for tropical climate and highly humid atmosphere. Wherever necessary the
wiring shall be carried in metal conducits. All electrical conduits shall be heavy gauge and
shall be hot dip galvanized and shall conform to Indian Standard Rigid steel conduits (with
Amendment No. 1) IS:9537 (Part II) 1990 and Indian Standard "Rigid plain conduits of
insulating materials" IS:9537 (Part III) 1990.
26.11.7.6 Flexible coupling - The flexible coupling, between the motor and worm gear
reducer shall be an all metl type suitable for accommodating radial and angular misalignment,
the coupling shall be of adequate capacity to drive the worm gear reducer and shall be
accurately bored and key seated to lift the motor and line shaft.
26.11.7.7 Circuit breaker- One air insulated triple ple circuit breaker, shall be provided for
the control of each motor. It shall be suitable for use as back up protection against short
circuit current and in accordance with Indian Standard Specification for alternating current
circuit breakers requirements and tests, Section 1 voltages not exceeding 100 VAC or 1200
VDC (first revision) I.S.2516 (Part I & II)/Scection I-1991. The circuit breaker shall be
provided with thermal air load release. The intersecting capacity of the circuit breaker shall
not be less than 5000 amps. Provision shall exists on the circuit breaker for the adjustment of
trip setting to suit the requirements of Electrical motor.
26.11.7.8 Motor Starter - For each motor one magnetic motor starter of suitable capacity
rated for 400/440 Volts, one phases 50 C/S/ AC & direct on the line staring service shall be
provided.
The Starter shall be suitable for working in conjunction with the control relay for thermal
overload single phasing protection and shall have no volt release coils. Preferably the starter
shall be of same make & model as the Electrical motor.
26.11.7.9 Control switch - For raising the gate spring loaded control switch of self resetting
type shall be provided. The switch shall be provided momentory contact when its handle is
operated to position (R) for raising the gate. The control switch shall be of heavy duty type
having silver plated contacts and suitable for flush mounting on a panel. The rating shall be 5
amps, 230/250 Volts, 50 C/S A.C.
26.11.7.10 Push button - For stopping the gate at an intermediate position, spring loaded
push button shall be proved. The push button shall be heavy duty type having silver plated
contacts and suitable for flush mounting on the panel. The push button shall have normally
closed contacts. The rating shall be 5 amps, 230/250 Volts, 50 C/S. A.C. supply.
26.11.7.11 Indicating lamps - To indicate the gate at exteram positions and other positions,
indicating lamps shall be provided as under:-
i. Gate fully opened Green indicating lamp
ii. Gate fully opened Red indicating lamp
iii. Gate intermediate Blue indicating lamp

iv. Gate in moving position Amber i indicating lamp
The indicating lamps shall be watertight rated, for heavy duty type 230/250 volts AC and
suitable for flush mounting on the control cabinets.
26.11.7.12 Heater Switch - Suitable single pole disconnecting heater switch shall be
provided for the heater in each electric motor in the control cabinets. It shall be heavy duty
type rated for 5 amps, 230/250 Volts AC supply.
26.11.7.13 Control Relay - For overload and single phasing protection of motor, 3 control
relay shall be provided. The overload device shall be set or adjusted to trip the starter between
115%-120% of the rated normal full load running current of the motor. The relay shall be
capable of resetting manually.
26.11.7.14 Gate Selector Switch - Gate selector switches composed of one single pole, 3
position roatry type switches installed in tandem and operated by a common switch rated for
5 amps, 230/250 volts 500 hertz supply and suitable for flush mounting on panels shall be
provided to select a gate for operation.
26.11.7.15 Gate position contact - The site of electrical contacts which shall operate at
position corresponding to the position of the gate shall be provided. These contacts shall be
utilized in the control circuit for automatic starting or stopping of electric motor for obtaining
light indication for various travels of the gate.
The contacts shall be heavy duty rated for 5 amps, 230/250 volts 50 c/s A.C. Supply,
operation of the contacts shall be as follow-
Contact 1-2 Normally Opens when gate started
closed raising
Contact 3-4 Normally Closes when gate fully
open raised
26.11.7.16 Limit Switch - The limit switch shall be suitable for service under conditions of
extreme moisuture. It shall be drilled and tapped for conduits and shall be suitably designed
to be wired and serviced after being mounted in position. It shall have single pole, double
break contacts to operate at 230/250 volts single phase 50 c/s A.C. supply.
26.11.7.17 Electronic type transmitter with electronic type Digital receiver- Electronic
type transmitter with electronic type digital receiver for indication in the remote control
cabinet shall consist of a transmitter and a receiver set and shall be used for remote indication
of the gate position for each crest Radial gate. The transmitter shall be suitably mounted on
the respective gate and the receiver shall be housed in the remote control cabinets. The
transmitter and receiver sets shall be minutely synchronised to have absolute identical
performances.
26.11.7.18 Remote Control - The seller shall provide complete arrangement including
control cabinets, switches and all electrical accessories including complete wiring for the
entire arrangement. The seller shall submit detailed drawings showing layout of the complete
arrangement, sizes of proposed panels and shall furnish operational circuit diagrams, details
of electrical items and accessories used and illustrative pamphlet of proposed transmitting
and receiving units. The seller shall also furnish details of erection including foundations of
the control cabinets.
26.11.7.19 Electromagnetic Brake - The electro magnet brake shall be of spring set, shoe
type. It shall be operated and continuously rated. The brake shall be capable of over coming
atleast 140% of the full load torque exerted by the motor. The brake shall set automatically
when the current is cut off from the motor and it shall be electrically released when the
current is applied to the motor. The brake shall be equipped with a hand operated release
lever.
26.11.7.20 Hand Operation Arrangements- Provision shall also be made for operating the
hoist manually in case of failure of power supply. Electrical inter locks shall be provided to
prevent operation by electrical power when the manual drive is engaged. Manual operation
shall be as per Indian Standard IS:6938-1989.
26.11.7.21 Lubrication - The lubrication of the motor, gear reducers, roller and bush
bearings shall be as specified by the manufacturer of the respective equipment. The points of
lubrication of the bearings and journals shall be readily accessible. Grease grooves shall be
provided in the bearing surfaces for satisfactory distribution of the lubricant. A level type
hand compressor for forcing the lubricant to the bearings shall be provided by the seller. The
hand compressor shall be equipped with heavy duty flexible metallic hose and coupling
suitable for the industrial bottom type fittings.
1. Hoist Motor It shall be of approved manufacture, capacity,

insulation and speed (R.P.M.). It shall conform to IS: 325-1991
unless otherwise specified and shall be checked for its
performance. Manufacturers test certificates shall be furnished
for motor by supplier to purchaser.
2. Brake It shall be of approved manufactures and capacity. It shall
be checked for alignment and tightness. Brake liners shall be of
approved manufacture and shall conform to the approved
specifications.
3. Base Frame The base frame for mounting of drive unit/gear

reduction unit with hoist drum shall be checked for the
dimensional accuracy.
4. Hoist Drum This shall be checked for dimensional accuracy. Cast

iron/cast steel drums shall be checked for blow holes, racks etc.
specially at groove centres. Fabricated drums shall be checked for
stress relieving in approved manner. Rope grooves shall be checked
for orientation. Arrangement of rope attachment to the drum shall
be checked for security.
5. Reduction unit gear box It shall be checked for proper assembly,

dimensional accuracy, sealing, finish of machined parts, and
surface preparation for painting gears, pinion and other internal
components shall be checked for alignment. Meshing of gear and
pinion teeth shall be checked for alignment. It shall also be
checked for contact surface and backlash by suitable methods such
as applying thin film of paint or grease on either pinion or gear
wheel and running the assembly and noting the impression. Gears
and pinions shall be checked for the hardness. Tolerance of gears
and pinions shall conform to IS: 911-1987 and backlash shall
conform to IS: 4460-1991.
6. Line shaft It shall be checked for straightness and other

dimensions. The straightness shall be in accordance with relevant
Indian Standards. Mounting of couplings shall be checked for
alignment.
7. Limit Switch It shall be checked for satisfactory operation. It

shall be weather proof.
8. Dial Indicators It shall be checked for satisfactory operation and

accuracy.
9. Hoist rope It shall be of approved manufacturer and shall

conform to relevant Indian Standards. The rope shall be checked
for diameter, length, free from bends and kinks, proper thimble
end, connections and splicing. If the wire ropes are of galvanized
type, the galvanization shall be in accordance with Class II of IS:
1573-1991 Manufacturers test certificates shall be furnished on
demand by supplier for hoist ropes.
10. Rope Fixtures It shall be checked for dimensional accuracy and

their corrections.
11. Arrangement for manual operation It shall be checked for

satisfactory operation. It shall be ensured that the gates are kept at
required positions during their travel for specified speed as
envisaged in the design and specified for operational requirements
of the gate.
12. Control Panel Panels shall be checked for their suitability for the
purpose envisaged in the specification. The checks shall include
items such as weather proofing of conducting wires, proper
construction of panels, high voltage tests, insulation resistance of
cable, calibration of meters, earthing of installation, checking of
connections and concealment if required.
2. Lubrication of gears and bearings
1. For gears and pinions, lubricating oil/grease or lubricating

compound used shall be of approved grade and quality.
2. Bearings closed from outside and open from inside shall be
checked for splash lubrication and bearings covers shall be free
from leakage. For bearings closed from both sides, proper injection
of grease of approved quality and grade shall be checked.
3. Inspection of hoist assembly and checks
1. The assembled hoist shall be checked for the following :-
1. Quality of workmanship.
2. Overall dimensions
3. Optimum sound and vibrations
4. Speed of operation allowing for variation in accordance with Indian Standard.
5. Any mechanical jamming.
1. Painting of different components of hoist shall be according to
relevant Indian Standards.
2. General Inspection
1. It shall be ascertained that the gate parts received at erection site

have been manufactured according to the drawings and have
necessary marking of shop inspection as prescribed. It shall be
ensured that all exposed surfaces of the embedded parts have been
protected by painting, greasing etc. as specified. The embedded
parts in contact with concrete shall be free from grease, paint etc.
For better bonding with concrete, a coating of cement wash/cement
latex may be applied, if prescribed.
2. The reference/centre lines of piers and bays and the levels having
relations to complete, civil structure shall be established at site so
as to facilitate erection at proper locations.
3. It shall be ensured that the various components of the hoisting

arrangement, such as meters, reduction gear assembly, switches,
wire ropes etc. are provided according to the manufacturers
instructions and erected according to the hoist suppliers drawings
remitted by the purchaser.
4. The permissible tolerances for the embedded parts and the

components of gate shall be in accordance with the appendix D of
IS: 4623-1990.
5. Inspection of blockouts It shall be ensured that correct blockouts

are kept for accommodating the embedded parts as manufactured
according to the design and drawing approved by the purchaser.
6. Block out The block out should have sufficient gap left out in the
concrete, so that a hand with spanners etc. should be able to work
freely inside the block out. The minimum block out gap for first
stage concrete in the sill beam portion should be 800x600 mm and
for second stage concrete it should be 600x400 mm. Similarly for
wall plate the gap should be 750x650 mm and for second stage
concrete it should be 750x250mm. It shall also be ensured that the
required dowel bars having adequate lengths are left out in the
block outs during first stage concrete. The entire block out is
roughened properly for further concreting to give necessary
bondage to second stage concreting.
3. Inspection of pier anchorage
1. The inspection of pier anchorage shall be carried out at following

stages:
1. Trunnion bracket and support girder.
2. Load carrying anchors or ties and embedded girder (if insulated anchors or ties
are used).
3. Anchor girder of yoke girder.
4. Thrust block / trunniom tie.
2. The pier anchorages shall be checked with respect to the centre

line of the pier and the trunnion axis (line parallel to the crest axis
and passing through the centre line of trunnion pins.) Control
survey marks shall be given on each pier to check the location /
alignment of pier anchorages. These shall include the lines parallel
to the end at right angles to the dam/barrage axis and a bench
mark for level.
3. Centre to centre distance of the adjacent piers shall be checked by

a steel tape. It will be preferable to put a steel girder across the
span for taping the distance over the span.
4. The trunnion bracket/supports shall be placed on the top of a steel

and kept in opposition with the help of struts and their position
shall be checked with respect to centre line of pier and trunnion
axis. A dummy trunnion assembly may be used to check the
distance between centre line of trunnion and sill beam centre. The
slope of trunnion assembly shall be checked with the help of an
inclination gauge. The two trunnion assemblies for each gate shall
be checked with respect to each other.
5. The yoke girder/anchor girder shall be checked for its alignment

and slope in both directions. For this checking holes may be picked
up from dummy trunnion bearing.
6. Before erection the tie bars/rods shall be checked on a level

platform for straightness and defect, if any, shall be rectified
forthwith. After erection the slope and spacing of the tie bars/rods
shall be checked. For checking the spacing, a spacer gauge shall be
used. After assembly the entire pier anchorages shall be checked.
The two anchorages for each gate shall be checked with respect to
each other.
7. The length of the anchor flat or bolt should be 0.6 R where R is the
radius of the curvature of the radial gate.
8. The measurement of 0.6 R may be measured to the face of the

anchor. Girder to the face of the pier i.e. the total embedded
portion should be 0.6. R.
The inclination of anchor flat or tie bar or the flat should be checked with the
inclination of the arm of the gate, that they should not interfere at the time of opening
of the gate.
9. Before concreting the pier after erection of pier anchorages, it is

necessary that a second check of all the parts is made to ensure
against any possible displacement during welding, riveting etc. For
safety of erected anchorages, the grouting/ concreting operations
shall be commenced after minimum possible intervals. For
insulated anchors/ties, the insulation shall be provided and
checked the before starting the grouting/concreting operations. To
allow for the elongation of the insulated load carrying anchors and
trunnion tie if used to trunnion bracket shall be so fixed so as to be
able to slide on the anchorage girder. Bronze pads shall be used for
this purpose on the top of the anchorage girder and at the bottom
of the trunnion bracket as shown in fig. 3 C.
10. Anchor bolts shall be provided in the first stage concrete with
suitable blockout opening, to hold the track base and seal seat
assemblies. The anchor bolts shall be with double nuts and
washers. For adjustment purposes enclosed holes in the seal base
parts shall be provided so as to allow for misalignment of anchor
bolts. The minimum size of holes shall not be less than that given in
table 1. The first stage and second stage concrete should be one
grade above than the concrete of surroundings crest of piers.
Table 1 Holes and washers for anchor bolts

Bolt Hole in member Hole in washer Washer
Dia (mm) Dia (mm) Dia (mm)
12 28 14 502 x 6
14 29 16 502 x 6
16 30 18 502 x 6
18 32 20 602 x 6
20 34 22 602 x 6
22 36 24 652 x 6
Bolt Hole in member Hole in washer Washer
Dia (mm) Dia (mm) Dia (mm)
24 40 26 752 x 10
27 45 29 752 x 10
30 50 32 802 x 10
33 55 35 902 x 10
36 60 38 902 x 10
39 65 42 1002 x 12
42 70 46 1052 x 12
45 75 50 1102 x 12
48 80 54 1202 x 12
1. Inspection of sill beam
1. Before erection, centre line of the sill beam shall be marked on the
pier faces. The centre line of the gates shall be inscribed on the
crest shifted by 300 mm or so on upstream side. The sill beam
centre line shall be checked in relation to the trunnion centre line.
2. After erection, the alignment and the angular setting of the sill
beam shall be checked. For the angular setting of sill beam 3 to 5
frames may be used.
3. After aligning the sill beam, all the bolts and nuts shall be put in
position. The reinforcement bars and dowels be welded with
anchor bolts so that the complete assembly is firmly held in
position and is not disturbed during concreting / grouting.
4. The aggregate used for concreting / grouting shall not be more
than 20 mm. The concrete mix shall be hand compacted by using
rods. No mechanical vibrators shall be used.
2. Inspection of wall plates (side seal seats)

1. The wall plates shall be in true alignment with respect to centre
line of trunnion pin. The dummy trunnion assembly with extension
rods shall be used for checking the alignment of wall plates. The
verticality of the wall plates shall be checked to ensure that wall
plates are truly vertical.
2. After setting of wall plates, all the bolts and nuts shall be put in
position. The reinforcement bars and dowels in the block out shall
be accurately welded to the side seats in such a manner that wall
plates are not displaced during concreting or otherwise.
3. The shuttering planks for concreting the wall plates shall be at
least 1.5 to 3 mm clear from the metal parts of wall plate.
Maximum aggregate size used for concreting the block outs shall
not exceed 20 mm. All concrete mix shall be hand compacted and
done in conversant stages as the shuttering progress in the upward
direction. Compaction may be done by 20mm rods. No mechanical
vibrators should be used.
3. Inspection of gates
1. The sub-assemblies of the gate which are received at site duly
inspected in workshop shall be re-inspected at site before lowering
of assembly in the bay.
2. Checking of all dimensions of the gate shall be done after skeleton
assembly of each gate is made and before final welding/riveting is
allowed. This dimensional check shall be repeated after welding is
done.
3. Visual inspection of all welds and bolts/rivets shall be made to the
extent of 100 percent.
4. Following critical dimensions shall be checked :
1. Centre to centre distance between side guide rollers and shoes.
2. Centre to centre distance between the side seal and bases.
3. Distance to bottom seal/base from centre line of trunnion pin.
1. The seal bolts shall be tightened adequately and uniformly and the
guide wheels be checked for free rotation.
2. To check the effectiveness of the seals, active seal interference shall
be compared with that provided in the design, because on this
aspect will depend to a great extent the efficiency of sealing
arrangement and easy operation of gate.
3. Inspection of complete gate installation and hoists including
electrical items.
4. Visual inspection of all gates and hoists shall be carried out as per
the detailed drawing. It has to be ensured that the erection
tolerances have been maintained during and after erection.
5. In case of hoists, following point shall be looked into :-
1. Connections like shaft coupling, connections of wire ropes to drum and gate,
connections of hoist components to the base etc. have been properly made.
2. In case of double hoists both hoists are properly synchronized.
3. Intermediate supports at required intervals are provided to permit free
movement of shaft.
4. The ends of the wire rope are properly looped and sufficient U clamps have
been provided. The rope has been tightly wound over the drum, has no links
and is properly lubricated.
5. The wire ropes or chains at both ends of the gate and counter weight have
equal initial tension.
6. Electric installations have been properly earthed and the limit switches have
been properly adjusted.
1. The hoist provided for the operation of the gate shall first be
independently checked and tested when it is connected to the gate
to ensure its satisfactory working.
2. It shall be ensured that the gate sill, wall plates and other
embedded parts are thoroughly cleaned and no foreign matter is
present to obstruct the movement of the gate.
3. Before operation of the gate the following final checks shall be
made :-
1. Electrical connections and fuses.
2. Overload relay, if provided, to see that it trips the starter.
3. All bearings and wire ropes for proper greasing.
4. All bolt, of gear boxes, hoists drum and shafts, couplings for tightness.
5. The oil level in gear reduction unit.
1. Testing
1. The gate shall be tested in a dry condition with hoist duly
connected for its smooth working. The gate shall be fully
closed or fully opened and it shall be ensured that there is
no obstruction and no undue effort required for its
operation. If the gate is not going down of its own weight or
found tight in some position, reasons shall be investigated
and remedied instead of forcing the gate down. While
testing the gate in dry condition, the rubber seals should be
kept wet by water jetting or suitable methods to avoid
damage to the seals.
2. The testing of gate seals shall be checked in the same
manner as explained in case of fixed wheel or slide gates.
3. Under the designed water head conditions, the leakage
through the gate shall not exceed 15 litres/minute/metre
length of the seal.
4. The gate is to be kept on the sill beam, that is in closed
position. The leakage test, (if provided in the terms of
execution of work), can be done in the position by using
suitable pump with necessary arrangements of jetting
water at 1.5 times, the designed pressure, on sealing
positions from bottom to top. All joints, if any, shall be
tested to ensure perfect working of the gate.
5. The arrangement provided for preventing the travel of the
gate or hoist beyond the designed limit are tested and
checked for proper working. The time required for 300 mm
opening or closing of the gate shall be recorded for
calibration purposes.
6. The full load current required for the movement of the gate
on load shall be measured and checked against the
designed value.
7. When the water starts overflowing, the gate shall be lowered to
hold water to half the height of gates. In this position the seals may
be tested and any leakage shall be attended. The gate shall be
operated up and down under these loading conditions to observe
the operation of the hoist. The gate shall also be checked in a
similar way against full water load.
8. Following observations shall be recorded for testing of gate under
dry condition and under water pressure.
1. Movement of gate and indication of jamming if any.

2. Effective stop is achieved by the gate stops wherever provided.
3. Speed of opening and closing and the current requirement at specified voltage.
4. Operation of brakes and limit switches.
5. Manual operation of gate, if provided.
6. Efficiency of guide rollers to check the side swaying of the gate.
7. Correctness of indication by local position indicators, if provided.
8. Synchronization of remote position indicators, if provided.
9. Vibration of gate, hoist and civil structures.
7. Single faced sluice gates (200 to 1200 mm size).

1. General
1. These specifications cover the single faced sluices from 200mm to
1200mm sizes of different shapes with rising (sliding) and non-
rising (rotating) spindles.
2. The specification is limited to sluices which are suitable for general
use only and for the following types of special use :
1. For wall mounting in situations where small and medium volumes of raw or
filtered water, storm water or sewage are to be controlled and a single faced
seal is required on the waterway for isolating purposes.
2. For water supply draw off and purification works, sewage plants, ordinary
land drainage and irrigation canals, hydro-electric collecting aqueducts and tail
races.
3. For unbalanced head restricted to 15 meters, tending to push the door on to the
frame and there by helping stanch leakage past sealing face.
4. For manual operation by hand wheel/toe-key/frame or floor mounting head
stocks with or without gearing.
2. Classification
1. Single faced sluices are of class 1 or class 2 types. Class 1 covers
sluices suitable for a maximum sealing unbalanced head of 6
meters of water. Class 2 covers sluices suitable for maximum
sealing unbalanced head of 15 meters of water.
2. Shapes and types of sluices may be circular, square or rectangular
and may either be with rising or non-rising spindle.
3. Nominal sizes and dimensions. Single faced sluices shall be
manufactured according to the nominal sizes and dimensions as
given in Table No. 2. Tolerances on the dimensions shall be closely
taken into account and the manufacturing shall be as close to
nominal dimensions as possible. The range and ratings of different
types with rising and non-rising are given in Table No. 3.
3. Materials
Materials for manufacturing of gates and components shall conform to relevent latest
IS codes.
4. Manufacture & Workmanship

1. Frame : The frames shall have a robust spigot of an appropriate
length, cast integral at the back for case of support in the
waterway and to provide an effective seal. Sluices having circular
opening or waterway may have a spigot dimensions conforming to
IS: 1538-1976. For square and rectangular openings the
dimensions shall be as per the tendered specifications.
2. The back of the frame shall be flat. The frame for non-rising
sluices shall have a machined face on the top to support the thrust
plate.
3. A cast iron side guide strip having a machined taper face on the
underside shall be fixed to the frame on each side by mild steel
studs and extending over the height of the waterway to provide
effective guide throughout the travel of the door. A stopper shall be
casted integrally immediately below the waterway and centre with
it to limit the travel of the door.
5. Door
1. Door shall have reinforcement ribs integral at the back for
strength. On each side there shall be tapered sungs or gunmetal or
bronze tape strips not less than one, machined to match similar
taper faced side guide strips on the frame.
2. Two integrally cast luge drilled to take mild steel bearing pin shall
be provided on doors for use with rising spindles. Integrally cast
pocket suitably reinforced to accommodate a nut shall be provided
on doors with non-rising spindle.
3. A stopper to match that on the frame shall be casted integrally at
the bottom.
6. Face (Door) and seat (Frame) rings

1. Facings for different types of sluices shall conform to the
dimensions given in table 4 to 8 read with figures 4A, 4B, 4C, 4D &
4E.
2. Facings shall be so secured by brass rivet pins in the machined
grooves of the frame and door and machined and hand finished,
that with the door fully shut a satisfactory water tight seal is
formed on the waterway. The contact between the facings shall be
sufficiently close at every point in the perimeter so as to produce a
uniform bearing all around.
3. The attachment of the facings to the frame and door shall be so
carried out that when finished they shall remain in place free from
distortion or loosening during effective life of the sluice.
4. Face rings and seat rings used shall be as per shape and sections
given below:
S.No. Sluice gate Type of section of a Type of section

face ring of seat ring
1. Sluice upto & below L Section L Section
300mm
2. Sluices above 300mm Rectangular Section Strips / rings of
rectangular
section
7. Guides
Guides shall be adequately secured to the main frame by stud bolts and provision shall
be made for appropriate longitudinal movement to adjust degree of welding consistent
with sealing property. There shall belittle lateral movement and tongues, keys,
shoulders or lugs may be provided for the purpose.
8. Spindles
1. Rising/sliding type The dimensions shall conform to those
specified in table No. 4, 6 & 8 and shall terminate at the top of the
sluice door and operated through either frame or floor mounted
head stock. The threaded portion of the spindle shall be completely
clear of the liquid being handled and shall be accessible for
lubrication.
2. Non rising/retaining type These shall conform to the dimensions
given in table No. 5 & 7 and shall be threaded at the bottom. They
shall be restrained axially by a thrust plate on the top of the sluice
frame and shall work in a nut located in a pocket on the top centre
of the door. The screeded portions of the spindles shall have
machine cut square or some thread.
3. The length of road may very for each installation, the number of
couplings required may be computed from the table No. 9. for
lengths exceeding 6 meters, it is recommended that only sliding
rods be employed, but if the prevailing conditions do not permit
their use the rotating type may be considered.
4. Thrust bearings For non rising spindles, bearings shall be
provided in the yoke of the frame of a design that will develop and
safely transmit the full thrust at the time of opening or closing the
door.
9. Operating mechanism
1. Provision may be made in the tender specification for operation of
sluices by hand, electric, hydraulic or pneumatic power.
2. Hand Wheels For gates having rising or non-rising spindles the
diameter of hand wheel is dependent on the factors viz.
unbalanced load, type of actuating gear employed (spur or worm),
length of operating rod. The diameter of hand wheel suitable for
use on ungeared hand stocks are given in table No. 11 for general
guidance.
3. Height of sluices The overall heights and the dimensions of the
sluice frame and doors shall be in accordance with table No. 12.
4. Workmanship All castings shall be clean, sound and without
defect of any kind. They shall be free from sand and no casting
shall be burned, plugged, stopped, patched or welded and no
repairs of defects shall be permissible. All foundry and machine
work shall be done in accordance with best modern practice and
all component parts shall be carefully and accurately machined to
jigs and templates so as to make, them fully interchangeable on site
without any additional work.
5. Painting Immediately after casting and before machining, all cast
iron parts shall be thoroughly cleaned and before rusting
commences, these shall be coated by atleast two coats of bitumastic
rust proof compound of satisfactory quality and specification. The
final coats shall be applied to the exterior surfaces, machined
portion, after assembly and testing.
6. Testing After completion each sluice gate shall be tested in the
shop for smooth working of the component parts including
operating gear.
APPENDIX - A
MATERIALS FOR THE COMPONENTS OF FIXED-WHEEL GATES
S.NO. Component Part Recommended materials Reference

1 2 3 4
i. Wheel Cast steel IS: 1030-1989
Cast iron IS: 210-1991
Wrought steels IS: 1570-1987
Forged steel lS:2004 1991
ii. Bushing Bronze
iii. Wheel pins or axis Chrome nickel steel IS: 1570-1987
or corrosion resisting IS:2004.1991
Steel,mild steel with IS:20621992
nickel or chromium IS: 1060-1992
platting. IS: 1337-1991
iv. Structural parts Structural steel IS:2062 1992
gate leaftrack IS:8500- 1992
base etc.
v. Seal Rubber Appendix- F
vi. Wheel trach a) Stainless Steel IS: 1570(Pt.V)
b) Corrosion resisting steel 1991
c) Cast Steel IS: 1570-1987
d) Structural Steel IS: 1030-1989
e) Corrosion resisting cast iron IS:2749-1991
Material (a) to (e) may be
specified depending upon the
actual rements of wheel loads.
S.NO. Component Part Recommended materials Reference
1 2 3 4
vii. Seal seat Stainless steel plate or stainless steel IS:1570Pt.V)1991
clad plate
viii. Seal base, Seal seat Structural steel of convenient shape IS:2062-1992
IS:8500-1992
ix. Seal clamp Structural steel IS:2062-1992
Stainless steel IS:8500-1992
IS:6527-1992
IS:6603-1991
x. Guide Structural steel or corrosion IS:2062-1992
resisting steel
IS:8500-1992
IS:6527-1991
xi. Springs Spring Steel IS:1570-1987
IS:6527-1992
xii. Anchor bolts Strucutural steel IS:2062-1992
IS:8500-1992
xiii. Guide rollers and Structural steel or corrosion IS:2062-1992
guide shoes resisting steel, cast, steel or forged
steel IS:8500-1992
IS:210-1991
IS:1030-1989
IS:2004-1991
Note: 1. Grade of the material conforming to the specifications mentioned above shall be
specified by the designer to suit to the particular requirement.
Note : 2. Cast iron shall not be used for wheel and tracks for high head gates.
Note : 3 The choice of material is governed by th&lypo of installation,accessibility for

maintenance, reservoir water properties silt, etc.
1. Specifications for carbon steel castings for general engineering purposes (second revision)
2. Specifications for grey iron castings (second revision)
3. Schedule for wrought steels for general engineering purposes.
4. Specifications for carbon steel forgings for general engineering purposes (first revision)
5. Specifications for structural steel (Standard quality) (first revision)
6. Specifications for structural steel (Fusion welding quality) (second revision)
7. Electroplated coatings of nickel and chromium on iron and steel (First revision)
8. Specifications for hard Chromium electripumped coatings on iron and steel (first revision)
9. Weldable structural steel, medium and high strength quality.
10. Specifications for stainless and heat resisting steels(First revision)
11. Specifications for stainless iron castings (First revision)

12. Specifications for stainless steel wire rod.
13. Specifications for stainless steel bars and flats.
APPENDIX- B
RECOMMENDED MATERIALS FOR VARIOUS COMPONENTS
(FOR LOW BEAD SLIDE GATES)
DETAILS OF MATERIALS
The recommended materials for various components are given below:
a) Gate leaf
Cast iron IS:210-1991
Structural steel IS:2062-1992
15:8500-1992
Cast steel IS:1030-1989
b) Gate frames
Structural steel IS:2062- 1992
IS:8500-1992
c) Seal Plates/Seals IS: 306-1988
Bronze IS: 1458-1991
IS: 318-1991
Brass IS:291-1989(Grade I)
Wood (commercial good quality)
Stainless steel IS:1 570(Pt. V) 1991
IS:6911-1992
Rubber Appendix - F
d) Seal seats/Bearing Plates
Bronze IS: 306-1988

IS: 318-1991
IS: 1458-1991
Brass 15:291-1989 (Grade 1)
Steel IS: 226-4992
IS:8500- 1992
IS:2062- 1992
Stainless steel clad plate or 15:6911-1991
Stainless steel IS:1570-(Pt. V)1991
C) Guides.
IS:8500- 1992
Corrosion resisting steel IS:6603-1991
1. Specifications for grey iron castings (second revision)
2. Specifications for structural steel (Standard quality) (Fifth revision)
3. Specification for structural steel (Fusion welding quality) (second revision)
4. Specifications for weldable structural steel, medium and high strength quality.
5. Specifications for carbon steel castings for general engineering purposes (second revision)
S. Specifications for tin bronze (second revision) ingots and castings.
7. Specifications for loaded tin bronze ingots and castings (Revised)
8. Specifications for railway bronze ingots and castings (Revised)
9. Specifications for naval brass rods and Sections (Suitable for machining and gorging
(second revision)
10. Schedules for wrought steels Part V Stainless and heat resisting steels (first revision)
11. Specifications for stainless steel plate sheet and strip. Specification for stainless steel bars
and flats.
APPENDIX - C
MATERIALS FOR PARTS OF THE RADIAL GATES.
S.No. Component part. Recommended materials Reference
i) Skin plate, stiffers, Structural steel
horizontal girders, arms IS:808-1989
bracings, tie members IS:2062-1992
anchorage girder, yoke IS: 8500-1992
girder, embedded girder
rest girder, load carrying anchors.
ii) Guide rollers Cast steel IS:1030-1989
forged steel IS:1875-1992
IS: 1004-1991
Wrought steel IS: 1570-1987
Cast steel IS:210-l991
iii) Trunnion, hub and Cast steel IS: 103 0-1989
bracket Structural steel IS:2062-1992
iv) Pin Structural steel* IS:2062- 1992
IS:8500-]992
Cast Steel* IS:1030-1989
Forged steel* IS:1875-1971
IS:2004-1991
Corrosion resisting IS: 1570- 1987
Steel
v) Bushing Bronze
v) Seal seat, sill Stainless steel plate 15:1570 (Pt.V) -
beam or stainless steel. 1991
clad plate.
Vii) Seal base and Structural steel IS:2062-1992
base 15:8500-1992
viii) Seal Rubber Appendix - F
Note I - Grade of the material conforming to specification mentioned above shall be specified
by the designer to suit the particular requirement.
Note 2 - Where materials marked with * are used for making pins, they will be electroplated
with chromium in accordance with IS: 1068 - 1968
1. Specifications for structural steel standard quality (First revision).
2. Specifications for rolled steel beam, channel and angle sections (revised)
3. Specifications for structural steel (fusion welding quality) (first revision).
4. Weldable structural steel (medium and high strength qualities).
5. Specifications for carbon steel coatings for general engineering purposes (second revision)
6. Specifications for carbon steel forgings for general engineering purposes (first revision).
7. Specifications for carbon steel billets, bloonjs,slabs and bars for forgings(fourth revision).
8. Schedule for wrought steels for general engineering purposes.
9. Schedule for wrought steels for general engineering purposes: Part V Stainless and heat-
resisting steels (first revision)
10. Specification for grey iron castings (second revision)
11. Electroplated coatings of nickel and chromium on iron and steel (first revision)
APPENDIX-D
TOLERANCES FOR EMBEDDED PARTS AND IN COMPONENTS OF GATE
(FOR FIXED WHEEL AND LOW

HEAD SLIDE GATES)
Components Classification
Low High Head
and med,
head
A. Embedded Parts
1. Track Plates
1.1 Alignment plane parallel + 1.0 + 0.5
to flow
1.2 Distance between centre line +1.5 +1.0
Of opening and track
1.3 Coplanerness +1.0 +1.0
2. Guide
2.1 Alignment plane parallel +1.0 +1.0
of opening and face of guide
Side Seal Seats
3.1 Alignment plane parallel +2.0 +1.0
to flow
of opening and face of guide
Side Seal Seats
3.3 Coplanerness +1.0 +0.5
(FOR FIXED WHEEL AND LOW

HEAD SLIDE GATES)
Low High Head
and med,
head
4. Top Seal Seat
4.1 Alignment +2.0 +1.0
4.2 Weight above sill +3.0 +2.0
4.3 Coplanerness with aids steel +1.5 +1.0
seat
5. Critical Dimensions
5.1 Centre to centre distance + 3.0 + 2.0
between track plates
5.2 Centre to centre distance + 3.0 + 2.0
between side seal seats
5.3 Face to face distance between +2.0 + 2.0
guides
5.4 Face to track to face of aids
seal seat +1.0 + 1.0
+0.0 + 0.0
5.5 Face of track to centre line + 2.5 + 2.0
of guide
6. Gate
I. Wheels
1.1 Alignment of treads in Zero 1.5 1.5
Eccentricity position
(FOR FIXED WHEEL AND LOW HEAD SLIDE GATES)
Low High Head
and med,
head
2. Side and Top Seal Base.

2.1 Alignment 1.0 0.5
2.2 Coplanerness 1.0 0.5 V
3. Critical Dimensions
3.1 Centre to centre distance 2.0 1.0
between sealbases
3.2 Centre to centre distance 2.0 l.0
between centre line wheel treads.
3.3 Face to face distance between 3.0 2.0
faces of guide shoes or guide
rollers.
3.4 Face to face distance between 2.0 1.0
wheel tread to side seal base. - 0.0 - 0.0
3.5 Distance between faces of 2.5 .5
wheel tread and centre line
of guide shoe/roller
APPENDIX- E
TOLERANCE FOR EMBEDDED PARTS AND COMPONENTS OF GATE
(FOR RADIAL GATES)
COMPONENTS TOLERANCES
A. EMBEDDED PARTS
1) Wall Plate and Sill Plate + 0.00
a) Distance between centre line of opening 0.00 mm
and face of wall plate at sill end -2.00 mm
b) Distance between centre line of opening + 2.00
and face of wall plate at top end. - 0.00 mm
c) Straightness of face of wall plates and Offset at joints
sill plates to be around smooth
d) Normally face of wall plate to + 0.01
gate sill and centre line of trunnion 0.00
bearings.
e) Alignment of sill plate in horizontal 0.25 mm
plane.
B. COMPONENTS OF GATE
1) Guide Roller/Guide Shoe
a) Distance between centre line of gate 1.0 mm
and face of guide roller! guide shoe
b) Horizontality of centre lines of both 0.25 mm
the trunnion bearings.
c) Parallel distance of centre line of both the 0.25 mm
tmnnion bearings from upstream mm
bottom edge of skin plate.

(FOR RADIAL GATES)
COMPONENTS TOLERANCES
d) Tolerances in diameters of pin bush To suit diameter and
hub and, bracket of trunnion assembly required fits
2) Side seal
a) Distance between centre line of 1.0 mm
gate and face of side seal.
3) Trunnjon Bearing 0.25 mm
a) Colinearing of lines of both
the trunnion bearings
APPENDIX - F
SPECIFICATION FOR RUBBER FOR SEAL
DETAILS OF SPECIFICATIONS (As per IS 11855 - 1990)
The rubber seals shall be moulded from natural or synthetic rubber containing not less than
one percent by weight of copper inhabiter, and shall have the following physical properties:
a) Minimum Shore A durameter hardness .......... 65 + 5
b) Minimum elongation .......................................450 percent
c) Ultimate tensile strength (minimum) ..........14:5 N/mm2
d) The rubber compound shall not absorb more than 10 percent, by weight of water in a 7
days test and
e) The tensile strength of the test specimen,, after being subjected to an acceleration against
test of 48 hours in oxygen at 70 c and 2.1 N/mm2 pressure, shall not be less than 80 percent
of the strength of the test specimen before ageing.
TYPES OF RUBBER SEALS RECOMMENDED FOR DIFFERENT CLASSES OF

GATES.
a) High Head - double atom type (preferably with cladding) Medium head - solid bulb note
type, and
c) Low Head - hollow/solid bulb music note type or flap or premoulded L - type
NOTE - Wedges type seal may be used at the bottom of the gate when it comes to rest on the
sill. If the gate slides on the face of an opening, musical note or double atom type seals may
be used.
TYPES OF SEALS USED IN RADIAL GATES.
The types of seals to be used for variou classes of gates shall be as follows:
a) For crest gates the following types maybe used.
1. Side seals:
i) Hollow bulb music note type,
ii) Solid bulb music note type, and
iii) I-shaped type.
2. For bottom seals, the wedges type may be used.
b) For conduit gates the following types are recommended.
1. Side and top seals - The seals may be of the session type and maypreferably be fixed to the
embedded metal of the gate and pressurized by reservoir water to ensure better sealing. The
seals maybe of plain rubber or of rubber clad with brass, bronze fluoro-carbon or stainless
steel.
2. Bottom seal - Wedge type seal may be used.

TABLE 1 : HOLES AND WASHERS FOR ANOTHER BOLTS (RADIAL GATES)
(All dimensions in millimeters)
BOLT DIA HOLE IN MEMBER HOLE IN WASHER WASHER

DIA DIA
(mm) (mm) (mm) (mm)
12 28 14 502 x 6
14 29 16 502 x 6
16 30 18 502 x 6
18 32 20 602 x 6
20 34 22 602 x 6
22 36 24 652 x 6
24 40 26 752 x 10
27 45 29 752 x 10
30 50 32 802 x 10
33 55 35 902 x 10
36 60 36 902 x 12
39 65 42 1002 x 12
42 70 46 1052 x 12
45 75 50 1102 x 12
48 80 54 1202 x 12
TABLE 2 : NOMINAL SIZES AND DIMENSIONS OF SINGLE FACED SLUICES
SHAPE SIZE REF. TO FIG.
(1) (2) (3)
Circular 200 to 600 4A(1), 4B(1)
200 to 1200 4C(1), 4D(1)
Square 200 to 600 4A(2), 4B(2)
200 to 1200 4C(2), 4D(2)
Rectangular 300 x 375 4E
to
1200 x 1050
TABLE 3 : RANGE AND RATING OF SLUICES
(With rising and non-rising spindles)
CLASS SPINDLE TYPE SIZE WATER REFERENCE
PRESSURE TO FIG.
(SEATING) IN
M HEAD MAX.
(1) (2) (3) (4) (5)
1 Rising 200 to 300 6 4A(1) and
350 and 450 4.5 4A(2)
500 to 600 3
1 Non Rising 200 to 300 6 4B(1) and
350 and 450 4.5 4B(2)
500 to 600 3
2 Rising 200 to 1200 15 4B(1) and
4B(2)
2 Non Rising 200 to 1200 15 4D(1) and
4D(2)
2 Rising 300 x 375 15
to
1050 x 1200
TABLE 4 : DIMENSIONS OF FACINGS AND SPINDLE DIAMETER CIRCULAR
AND SURFACE SINGLE FACED SLUICES
FIG. 4 (A)
Water Face Thickness Face Breadth Spindle
Circular or
Square Rising diameter
X r X r X r
(1) (2) (3) (4) (5) (6) (7)
200 4 5 16 16 30 30
250 4 5 20 20 30 40
300 5 5 20 20 40 40
350 6 6 20 20 40 40
450 6 6 20 20 45 40
500 6 6 22 22 45 50
550 6 6 22 22 50 50
600 6 6 22 22 50 55
X = Circular Waterway
r = Square Waterway
TABLE 5 : DIMENSIONS OF FACINGS, SPINDLE DIAMETERS AND
DIMENSIONS OF TAPERED SQUARE ON SPINDLES FOR CIRCULAR AND
SQUARE SINGLE FACED SLUICES
(FIG. 4B)
(All Dimensions in Millimeters)
Waterway Face Face Dia Tapered Square on spindle
Thickness Breadth Meter Non-Rising
X r X r Top Bottom Length
Sqre.
(1) (2) (3) (4) (5) (6) (7) (8) (9)
200 4 5 16 16 35 22 27 50
250 4 5 20 20 35 22 27 50
300 4 5 20 20 35 22 27 50
350 6 6 20 20 45 24 29 50
450 6 6 20 20 45 24 29 50
500 6 6 22 22 50 29 29 65
550 6 6 22 22 50 29 29 65
600 6 6 22 22 50 29 29 65
r = Square Waterway
TABLE 6 : DIMENSIONS OF FACINGS AND SPINDLE DIAMETER FOR
CIRCULAR AND SQUARE SINGLE FACED SLUICES
FIG. 4 (C)
Waterway Face Thickness Face Breadth Spindle Rising
Circular or Diameter
Square
X r X r X r
(1) (2) (3) (4) (5) (6) (7)
200 4 5 20 20 32 32
250 4 6 20 25 32 40
300 4 6 25 25 40 40
450 6 6 25 25 45 48
600 6 6 25 25 50 55
750 6 6 25 25 55 58
825 6 6 25 25 58 58
900 6 6 25 25 58 60
1050 6 6 32 32 60 65
1200 6 6 32 32 65 65
r = Square Waterway
TABLE 7 : DIMENSIONS OF FACINGS SPINDLE DIAMETERS AND
DIMENSIONS OF TAPERED SQUARE ON SPINDLES FOR CIRCULAR AND
SQUARE SINGLE (FIG. 4D) FACED, SLUICES (NON RISING TYPE)
Waterway Circular Face Face Dia Tapered Square on
or Square Thickness Breadth Meter spindle Non-Rising
Spindle
X r X r Top Bottom Length
Sqre.
(1) (2) (3) (4) (5) (6) (7) (8) (9)
200 4 5 20 20 35 22 27 50
250 4 6 20 25 40 22 27 50
300 6 6 25 25 40 22 27 50
450 6 6 25 25 50 35 42 67
600 6 6 25 25 58 35 42 67
750 6 6 25 25 58 35 42 67
825 6 6 25 25 58 35 42 67
900 6 6 25 25 58 35 42 67
1050 6 6 32 32 65 40 46 75
1200 6 6 32 32 65 40 46 75
r = Square Waterway
TABLE 8: DIMENSIONS OF FACINGS AND SPINDLE DIAMETERS FOR
RECTANGULAR SINGLE FACED SLUICES (FIG. 4E)
WATERWAY FACE THICKENSS FACE BREATH SPINDLE RISING
Width (A) x Depth DIA
(A2)
(1) (2) (3) (4)
300 x 375 6 25 40
450 x 300 6 25 45
375 x 450 6 25 47
525 x 375 6 25 47
450 x 525 6 25 50
600 x 450 6 25 50
525 x 600 6 25 53
675 x 525 6 25 53
600 x 675 6 25 53
750 X 600 6 25 53
675 x 750 6 25 55
825 x 675 6 25 55
750 x 825 6 25 55
900 x 750 6 25 60
825 x 900 6 25 60
1050 x 900 6 30 62
900 x 1200 6 30 62
1200 x 900 6 30 62
1050 x 1200 6 30 62
1200 x 1050 6 30 62
TABLE 9 : CLASS 1 AND CLASS 2 SLUICES COUPLINGS FOR RISING AND
NON-RISING SPINDLES AND WALL BRACKETS FOR NON-RISING SPINDLES.
DISTANCE BELOW BASE OF COUPLINGS
HEADSTOCK
m No.
Up to 3.5 0
Over 3.5 to 8 1
Over 8 to 12.5 2
Over 12.5 to 17 3
Over 17 to 21.5 4
Over 21.5 to 26 5
Over 26 to 30.5 6
Note : Where the length of rod below base of headwork exceeds 3.5 m, one coupling is
required and for every 4.5 m thereafter, an additional coupling. The table is intended
to facilitate calculation.
TABLE 10 : WALL GUIDE BRACKETS FOR TENSION RODS
DISTANCE OF RODS BELOW BASE OF BRACKETS
HEADSTOCK
M No.
Up to 2 Nil
Up to 2 to 3.5 1
Over 3.5 to 6.5 2
Over 6.5 to 9.5 3
Over 9.5 to 12.5 4
Over 12.5 to 15.5 5
Over 15.5 to 18.5 6
Over 18.5 to 21.5 7
Over 21.5 to 24.5 8
Over 24.5 to 27.5 9
Over 27.5 to 30 10
Note : Wall guide brackets are required for tensional rods at a maximum of 4.5 m centres, and
for tensional rods at a maximum of 3 m centres, the distance to the top most guide
bracket not exceeding 4 m and 2 m respectively below base of headstock. However,
for tensional rods more than 3 m in length, the distance of the topmost guide bracket
below the headstock base is generally reduced to one foot, and the rod and bracket are
arranged to eliminate tensional strain in the rod.
TABLE 11 : DIMENSION OF HAND WHEELS FOR USE ON UNGEARED
HEADSTOCKS AND DETAILS OF LENGTHENING RODS.
(All dimensions in mm)
Waterway Class 1 (Fig. 4A & 4B) Class 2 Fig. 4C, 4D & 4E
Type of H/W Dia. Rod Type of H/W Rod Dia.
spindle Dia. Dia. Dia.
used
(1) (2) (3) (4) (5) (5) (7)
200 dia NR 375 30 NR 375 30
R 225 28 R 225 30
200 Square NR 375 35 NR 375 35
R 225 28 R 225 30
250 dia NR 375 35 NR 375 35
R 225 28 R 225 30
250 Square NR 350 38 NR 600 38
R 375 38 R 375 38
300 dia NR 450 38 NR 600 40
300 x 375 Rect. R 375 38 R 375 38
300 Square NR 600 40 NR 750 40
R 375 38 R 450 38
350 dia NR 600 40 NR 750 40
R 375 38 R 450 38
350 Square NR 600 45 - - -
R 375 38 R 525 38
450 Dia NR 750 47 NR - -
375 x 450 Rect. R 450 45 R 675 45
450 Square NR 750 47 - - -
R 450 45 R 525 45
500 Dia NR 750 47 - - -
525 x 375 Rect. R 450 45 R 525 45
500 Square R 600 45 R 750 45
550 Dia NR 750 50 - - -
450 x 525 Rect. R 525 45 R 600 45
550 Square R 750 - R 600 -
600 Dia R 600 45 R 750 45
600 x 450 Rect.
600 Square R 750 50 Ungeared headstock cannot be
used
650 Dia R 750 50 R 900 50
650 x 525 Rect.
675 x 525 Rect.
650 Square R 750 50 Ungeared headstock cannot be
600 x 675 Rect. used
700 Dia R 750 50 -- do --
750 Dia . R 750 50 -- do --
750 x 600 Rect.
675 x 750 Rect.
825 Dia. R 900 50 Ungeared headstock cannot be
750 Square used
825 x 675 Rect.
NR = Non-Rising R = Rising H/W = Hand Wheel
Note : Ungeared head stock will not be suitable for higher sizes.
TABLE 12 :HEIGHTS OF SINGLEFACED SLUICES
(All dimensions in mm)
a) CLASS 1 FOR A MAXIMUM SEATING UNBALANCED PRESSURE OF 6 m HEAD
SIZE OF WATERWAY HEIGHT OF FRAME

Figure 4A (1) or 4A(2) Rising Type
200 615
250 720
300 845
350 1010
450 1210
500 1350
550 1450
600 1550
Figure 4B (1) or 4B (2) Non rising types
200 730
250 835
300 960
350 1120
450 1315
500 1475
550 1580
600 1675
SIZE OF WATERWAY FIG 4C(1) OR RC (2) Fig. 4D(1) or 4D(2) Non-rising
Rising types, Height of Top types, Heights of frame.
of Frame from Invert.
200 700 700
250 700 700
300 800 800
450 1130 1130
600 1445 1445
750 1765 1765
825 1920 1920
900 2070 2070
1050 2425 2565
1200 2715 2880
SIZE OF WATERWAY HEIGHT OF FRAME
WIDTH X DEPTH (Figure 4D) Rising Type
300x375 975
450x300 800
375x450 1130
525x375 975
450x525 1280
600x450 1130
525x600 1445
675x525 1280
600x675 1600
750x600 1450
675x750 1765
825x675 1600
750x825 1920
900x750 1765
825x900 2070
1050x900 2070
900x1050 2450
1200x900 2070
900x1200 2715
1200x1050 2450
1050x1200 2715
VOLUME III
Section- 8 STONE MASONARY (IN DAM AND APPURTENANT WORKS)
CONTENTS
8B.1 References
8B.2 General
8B.3 Masonary Classification
8B.4 Materials
8B.5 Cement Mortar
8B.6 Preparation of Foundation / Surface for Placing Masonary
8B.7 Masonary Construction
8B.8 Truncated Construction
8B.9 Protection of Masonary
8B.10 Permeability Test on Masonary
8B.11 Weather Condition
8B.12 Curing
Appendix - I Masonary Classification and Location Details
Appendix - II Permeability Testing Procedure for Masonary
CHAPTER 8
STONE MASONRY ( IN DAM AND APPURTENANT WORKS)
REFERENCE
IS No. Title
269-1989 Ordinary Portland cement. 33 Grade (Fourth revision)
455-1976 Portland slag cement ( third revision)
456-1978 Code of practice for plain and reinforced concrete
(third revision)
460-1985 Test sieves
1121(Pt 1)- 1974 Compressive Strength ( first revision)
1122-1974 Methods of tests for determination of true specific gravity of natural building
stones ( first revision) (reaffirmed 1987)
1124-1974 Method of test foi determination of water absorption apparent specific brevity
and porosity of nature& building stones (first revision)
1126-1974 Method of test for determined of durability of natural building stones (first
revision)
1344-1981 Calcined clay pozzolana (second revision)
1489-976 Portland POzzolana cement (second revision)
1727-1967 Methods of test for Po1entc materials ( first revision)
2116-1980 Sand for masonry mortars ( first revision)
2250-1981 Preparation and use of masonry mortars( first revision)
2386(Pt II-1963) Estimation of deleterious meterials and organic impurities.
2386 (Pt III)-1981 Specific gravity, density, voids, absorption and bulking.
3812- 1981 Fly ash for use as pozzolana and admixture (first revision)
4082-1977 (Recommendations on stacking end storage construction materials at site (first

revision)
5529( Pt II) - 1985 Tests In Bedrocks
6909-1973 Supersuiphated cement
8605-1977 Construction of masonry in dams
9103-1979 Admixtures for concrete
11216-1985 Permeability test for masonry during and after construction
Rejghat dam project specification Rejghat
8 B.2 GENERAL
Masonry for the dam and appurtenant works shall be composed of atone pieced In a matrix of
cement, sand water end any other admixture: specified Tests shall be made or the masonry as.
well as the mortar matrix at specified intervals during. the progress of the work and the mixes
modified as necessary in order to consistently secure the required strength, workability ,
density end !impermeability together with maximum possible economy. lt is contemplated
that he mortar far. Masonry may ran in arctei from a lean mix of strength 18N/mm2 to a rich
mix a1: strength 18N/mm2 The water cement ratio for the mortar wil be regulated by the
requirements of strength, durability. workability and permeability.
8 B.3 MASONRY CLASSIFICATIONS
Masonry classification Is related to the type of and the specified 28 days compressive
strength of 50 mm cube of mortar to be used and shall conform with the requirements as set
out In the Appendix-I. The grade of mortar will be defined by Its compressive strength in
N/mm2 at the age of 28 clays. In case where approved pzalano is used as pert replacement of
cement, the poo1ane mortar shell designed to attain the some 365 days strength as would be
attained at the end of 365 days by a corresponding neat cement mortar. corresponding neat
cement mortar.
8 B.4 MATERIALS
8 B.4.1 Cement
8 B.34.1.1 Portland cement, Portland slag cement, Portland pozzolene cement end super
suphated cement shall, be used for plain and reinforced concrete work end stone masonry
work in dams end other massive structures and shell comply with the requirements of IS:2C
1989, IS:45S:1976 and IS:6909-1973 respectively. Special cements m n ne specified for use
in dam masonry.
8 B.34.1.1 Portland cement, Portland slag cement end portl&d lena cement that has been in
storage for rnre than 120 days counted after the date of despatch from factory shall not be
used without a special inspection testing and approval. Transport, storage, sg d testing shel
by the speciftic for ue of cement detailed in Chapter 7.
8B.4.2 Water
Water used for mixing mortar, grout, and also for washer ha stone end curing masonry shell
conform to the requirement of IS: 4561978. The water used shall be clean and free from
injurious amount of oil, acid, akjakli, salts and organic materiel or other substances that may
be deleterious to mortar.
8.4.3 Sand
88.4.3.1 The term sand is usri to designate fine aggregate with maximum size pf particles
4.75 mm. The sand shall consist of natural sand, crushed stone sand or crushed gravel sand or
a combination of any of these. The send shell consist of hard, dense, durable uncoated rock
fragments and shall be free from injurious amounts on dust, lumps of clay, soft or flaky
particles, shale, alkali, icam, mics and other deleterious substances. The amount of
deleterious substances by weight shall not below.
S.NO. Deleterous Substances Percentage
(by weight)
1- Shale 1.0
2- Coal & Lignite 1.0
3- Clay Lamps 1.0
4. Cinders & Clinkers 0.5
5. Material passing I.S. Sieve I

(Screen Opening 0.0 mm.) 3.0
6. Total of other deleterious substances
such as alkali, mica and coated grains
flaky particles etc. 2.0
the laboratory as par tS : 2386 (Part II) 1963. The sand used shall be of coal& category
conforming to S:2 116 1980. The sand or fine segregate shall be investigated for sulphate
content and it shall be ensured that it is free from this hazard. Where sand from different
sources are being used one mixer at the same time, they shall be so silenced to ensure
uniform grading in successive batches. The send as batched, shall be well graded within the
limits specified below:
I.S. Sieve Designation Percentage Passing by Weight'
4.75 mm 100
2.36 mm 90 to 100
1.18 mm 70 to 100
800 micron 40 to 100
300 micron 5 to 70
150 micron 0 to 15
8B.4..3.2 A sand whose grading falls outside the specified limits due to excess or deficiency
of coarse or fine particles may be processed to comply with the standard by screening
through a suitably sized sieve bending with required quantities, of suitable sizes of sand
particles. Based on test results and in the. light of practical experience with the use of local
materials deviation in grading of sand given in table above may be considered by the
Superintending Engineer.
8B..4.3.3 The various sizes of particles of which the sand is composed shall be uniformly
distributed .throughout the mess.. The mechanical analysis curve of sand shall indicate
uniform gradation Without predominance of my one or more size. The fineness modulus shall
preferably loan towards the coarser range in the limit fixed. A gap graded sand requires more
cement and may promote permeability if adequate care Is not taken. Remedial measures as
specified above still be taken to ensure uniform graduation.
8B4.3.4 For natural sand the fineness modulus shall be greater than 2.2 and less tan 2.8.
8B.4.3.5 The grading of the sand shell be controlled such that the fineness modulus of at least
nine out of ten consecutive test samples of finished sand, when samples are taken at
frequencies premised In item 2 of appendix- 6.02 of M.P.W.D Manual 1983 (Pt II ) will not
very more then 0.25 from the average fineness modulus of the tan consecutive test samples. ,
8B.4.4Resistance to Sulphate Attack
8B8.4.4. 1 The following could be source of sulphate attack:
(a) Sulphate contained in the sand or line aggregate used In the mortar.
(b) Sulphate from soil in the case of masonry in contact with soil.
(c) In exception& circumstance suiphete derived from the calcine clay pozzolana.
8&4.4..2 The cement in the mortar will undergo expansive reaction in the presence of
sulphate, which will lead to cracks in the mortar. Where serious sulphate attack is expected,
portland slag cement or portland pozzolana cement may preferably be used instead of of
ordinary portland cement. Other general precautions she be taken as given in Appendix 0 of
Chapter 7 Concrete end Chapter 16 : RCC and form work. Necessary precaution should be
exercised when opting for super sulphate cement. It should be borne in mind that sulphate
attack is a hazard for which there is no satisfactory solution and the problem should rather be
avoided then outing to use remedial measures.
8B.45 Admixtures
8B.4.5.1 Admixtures Including pozzolanas, air entraining agents, wetting agents, etc. shall be
used only under specific authorization end wherever so permitted; the pitortions and methods
of. use shall be specified by the Engineer in charge.
8B.4.5.2 Materials permitted as admixture shall have established merit for improving any
specific quality of the mortar without c: deleterous effects.
8B.4.5.3 Air Entrain Admixtures - Air entraining admixtures, satisfying the criteria in
13:9103 1979 shall only, be used if permitted by the Engineerincharge. The percents
of air entrained, shall be tasted by the Engineerincharge or his designate. The percentage
of air entrained shall normally be8 TO 12% of cement mortar.
8B.4.6 Pozzolana
8B.4.6.1 Fly ash pozzolena suitable for incorporation in cement mortar and concrete end in
lime pozzolena mixture shell be grade II (as designated in IS: 38121981 ) and shall
conform IS:3812-1981.
8B.4.6.2 Claimed dlay pozzolena suitable for incorporation unblended cement mortar and
concrete end in lime pozzolene mixture, shell be grade II (as designated in IS:1344-1981) end
shall be manufactured in a manner as specified IS:1344-1981.
8B.4.6.3 Pozzlane (fly ash and calcined clay) shall conform to the physical requirements
given in following table when tested in accordance with IS:1727-1967.
S.No. Characteristics Requirement
1. Fineness- Specific surface in m2/kg 250

by Blaine's permeability method, min
2. Lime reactivity - Average compressive
strength in n/mm2 min 3.0
3. Drying shrinkage, max 0.1
8B.4.6.4 Pozzlolane shall be such that it will agree with the cement used and in no way
promote or increase the sulphate attack.
8B.4.6.3 Storage- It shall be free from any admixture of clay dust, or foreign matter and shall
be stacked on a brick, wood or other suitable platform so as to be adequately protected from
such admixture. Storage of materials shall be in accordance with IS:4082-1977.
8B.4.7 Stone
8.4.7.1 The stones for masonry shell be hard dense for masonry shall be hard, Dense durable,
tough, sound and clean. They should be free from decav. weathered faces, soft seams. veins,
flows, cracks stains and other defects and shall have, as far as possible uniform colour and
texture. Stones not uniform in colour texture and or with stains may be permitted after proper
tests.
8.4.7.2 The Stone for Random Rubble Masonry - The size of the stones shall normally
vary from 0.05 to 0.01 mm. No stone larger than the maximum specified size of 0.05 cum
should be used. the stones shall be taken from quarries approved from geological and
engineering consideration. No stone shall weight less than 25 kg. The stone used in be
hearting shall be roughly cubical in shape. No stone weighing between 75 kg and 150 kg
shall be less than 225 mm in any direction and no stone weighting between 25 kg and 75 kg
shall be less than 150 mm in any direction.
8B.4.7.2.1 Spalls with minimum dimension of 200 mm to 100 mm shall be used to wedge
into thick mortor. They shall not normally exceed 10% of the volume of stone masonry.
8B.4.7.3 Stone for Chisel Dressed Coursed Rubble Masonry
8B.4.7.3.1 The height of the stone for face work shall be uniform and is recommended to be
300 mm including mortar joint. The length (parallel to axis) depth shall not be less than the
height of the stone. stone. At least 5O of the stones shell have length more theft 1.5 times the
height or the stone. At least on third of the remaining stones shall be bond stones projecting
not less than two and half times the height into the masonry. The remaining shall be header
stones with depth not less than one and half times the height of the stone.
8B.4.7.3.2 The stones shall be hammer dressed on face and one line chisel dressed on bed,
top end sides for a minimum depth of 75 mm up to which the stones shall be true and
rectangular. Beyond 75 mm depth, the stones may be tapered but the tail end of the stones
shall have at least half the area of the faces. Bushing on the faces of the stones shell not
project more than 40 mm.
8B.4.7.3 Header stones- shell not be less then 300 mm in length and one and a half times the
height in depth.
8B.4.7.4 Stretcher Stones - The stretcher stones shall not be less than 450 mm in length and
not less than its height in depth.
8B.4.7.5 Bond Stones- The bond stones shall not be less then 300 mm in length and two end
a half time its height in depth.
8B.4.7.6 Quoin stones - shell be of the same height as the face stones but shell be true and
rectangular on two faces with one line dressing for 75 mm depth in beds end sides. The
stones shop be at least 300 mm long on one face and 50mm on the other face.
8.B.4.7.4Stone For Dressed Coursed Rubble Masonry
8.B.4.7.4.1 Stones for hammer dressed coursed rubble masonry shall rat the requirement of
stones for chisel dressed coursed rubble masonry (See. pare 8B.4.7.3) except that the stones
shell be only hammer dressed. The stones shafl be nearly rectangular.
8.B.4.7.5 Random Rubbble Masonry With Selected Stones - Stones for random rubble
masonry with selected stones for face work shall be with minimum dimension of 225 mm in
length as well as height. The depth of at least 5O stone shall not be less than 225 mm. The
depth of at least one sixth stones shall not be less then 400 mm and depth of rest stones shell
not be less then 150 mm. The stone need be hammer dressed on face.
8.B.4.7.6 Tests For Masonry Stones - The following tests shell be carried out In accordance with
Indian Standards mentioned against each to ensure suitability of stones or masonry.
S.No. Name of test Relevant Indian Standard

I Compressive strength test IS : 1121 (Pt. 1) -1974
II Specific gravity test IS : 1122 1974
III Water absorption test IS : 1124 1974
IV Durability (Soundness) test IS : 1126 1974
The compressive strength test shall be conducted with the load parallel to the bedding plane
and also perpendicular to the bedding plane. The percentage of water absorption of stone
samples shall not exceed 5%.
8B.5 Cement mortar :
8B.5.1 General
8B.5.1.1 The cement mortar shall consist of cement, sand and other approved admixtures, as
required, each complying with its respective specifications in accordance with para 8B. 4.1 to
8B 4.6 mixed in the proportions as may be defined. The proportions of material entering into
the mortar shall be based on laboratory studies. The moisture content of the sand and tis
gradation, as available for use, shall be taken into account in proportioning the mix.
Pozzolanic material may also be mixed, if directed, in proportions fixed by the Engineer in
charge. If directed, suitable air entraining agent may be used to improve the quality and
workability of the mortar. The exact proportions of air entertainment shall be determined by
actual tests.
8B.5.1.2 All materials forming the mortar should be measured by weight except for water
which may be by weight or by equivalent volume. Periodical calibration of the measuring
instruments shall be carried out. Where weight batching is not possible, due consideration
to bulkage of sand and its water content shall be given.
8B.5.2 Batching
8B.5.2.1 The prescribed amount of various materials for mortar including water, cement,
admixtures and sand shall be controlled within the limits of accuracy. The amount of cement
and sand shall be determined by weighing. The quantity of water may be weight or by
equivalent volume. In case of sand, the surface moisture shall be determined in accordance
with the method prescribed. Where volume batching has been revised from time to time and
taken into account. Where volume batching has been permitted, due considerable to bulkage
of sand and its water content shall be given.
8B.5.2.2 The proportion of the various materials shall be changed as directed in order to
maintain the desired quality of mortar. The batching equipment shall be calibrated and
operated so that the combined inaccuracies in feeding and measuring the materials will not
exceed one and a half percent for water cement or pozzolene and 2 percent for sand.
8B.5.2.3 The operating performance of each scale or other measuring devices shall be
checked by test weights and the tests shall cover the ranges of measurements involved in the
batching operations. Tests of equipment in operation shall be made atleast once every
fortnight and adjustments, repairs or replacement made as necessary to meet the specified
requirement for accuracy of measurement.
8B.5.2.4 Sand shall not be batched for mortar when water is dripping form it.
8B.5.3. Mixing
8B.5.3.1 The mortar ingredients shall be mixed thoroughly in batch mixers of satisfactory
type and sizes which are so designed as to ensure uniform distribution of all component
materials throughout the mass at the end of mixing period. The plant shall be so designed and
operated that all material entering the mixer can be accurately proportioned and readily
controlled. the entire batch within mixer shall discharged before recharging. Mixers should
not be loaded in excess of 10% more than the manufactures rated capacity.
8B.5.3.2 The mixing time for each type of mixer shall be reckoned after all materials except
the full amount of water are in the mixer. The thoroughness of mixing and adequacy of
mixing time so as to give a uniform mortar shall be tested at the start of the and at such
intervals as may be considered necessary. The uniformity of mortar is reliable indication of
the thoroughness of mixing and adequacy of mixing time. Retampering requiring the addition
of water to preserve the required consistency shall be avoided. The minimum mixing time
generally specified is as follows :-
Capacity of Mixer (m3) Time of mixing (min)
1.50 or less 1.50
2.50 2.00
3.00 2.50
4.00 2.75
4.50 3.00
For any one mix, the variation in the air free unit weights shall not exceed the following :
For one batch 35 kg / m3
Average of 3 batches 25 kg / m3
8B.5.3.3 Use of same mixer for different mortar mixes consecutively shall be avoided.
8B.5.3.4. The first mortar batch at the start of the work after every cleaning operation of the
mixer drum shall be made richer by addition of 10 percent extra cement over and above that
required for the mix.
8B.5.3.5. It should be preferable to use the mixer having a timing device for indicating the
completion of the mixing period. The actual time of mixing shall be checked at least twice
during each shift and the timing shall be adjusted if in error. The timing device shall be so
interlocked with the discharge gate of the batch hopper that timing does not start until the
discharge gate is fully closed and all ingredients are in the drum. Strict manual control in
recording the time should be followed where the mixers do not bear the time device. The
RPM of the mixer shall be kept 16 to 20. The full contents of the drum shall be discharged
quickly so as to avoid segregation. The minimum mixing periods are conditioned on the
materials being fed into the mixer in a manner which will facilitate efficient mixing and on
operation of the mixer at its design speed. The following sequence of charging the mixer shall
be adopted.
(i) Five to ten percent of the total quantity of water required for mixing, adequate to
wet drum thoroughly shall be introduced before the other ingredients in order
to prevent any caking of the cement on the blades or sides of the mixer.
(ii) All dry ingredients (cement, pozzolana and sand) shall be simultaneously ribboned
into the mixer in such a manner that the period of flow for each ingredient is
about the same. Eighty to ninety percent of the total quantity of water required
for mixing shall be added uniformly alongwith dry ingredients.
(iii) The remaining quantity of water shall be added after all the other ingredients are
in the mixer.
(iv) Water shall be added prior to, during and following the mixer charging
operations. Excessive over mixing consistency will not be permitted. Mortor
which has been kept un-utilized for more than 30 minutes after the addition
of water shall be wasted unless mortar continuous to be in such a workable
condition that its use is specifically permitted.
(v) When the mixer is stopped, before placing again any ingredient in the mixer, or all
hardened mortar shall be removed from the inner surface of the mixer.
(vi) The retempering of partially hardened mortar requiring renewal mixing with or
without the addition of cement, sand or water shall not be permitted.
8B.5.4. Tests and Acceptance Criteria

8B.5.4.1 Tests on mortar shall be regularly conducted and shall comprise compressive
strength and permeability tests.
8B.5.4.2 Tests for compressive strength Compressive strength of the mortar shall be tested
in accordance with the procedure specified in IS : 2250-1981. In special cases where
specimens of different sizes are used such as 15 cm x 30 cm cylinder / 15 cm cube, necessary
correlation shall be established, and such tests may be adopted for quality control.
8B.5.4.2.1 The compressive strength of cement mortar used shall be as specified for the
particular job. The strength of one sample shall be taken as the average of at least three test
specimens taken from single batch of mortar. If the individual specimen result differs by more
than + 15 percent of the average of 3 specimens, the average of the remaining two specimens
shall be worked out or the test may be repeated. If the individual test results of two specimens
of mortar do not come within + 15 percent of the average and where repeat tests are not
possible, the whole set of results shall be rejected from the analysis. Over a given period of
time not more than 10 percent of the specimens tested shall have a compressive strength less
than 80 percent of the required strength and the average of all tests shall equal of exceed the
required strength. The exact proportions for the, cement, sand and water for mortars shall be
fixed after conducting tests for compressive strength.
8B.5.4.2.2 The frequency of sampling of mortar separately for each mix proportion shall be
as follows :-
(i) upto 100 m3 of masonry work per day, one sample per shift per mixer and
(ii) for every additional 100 m3 of masonry work per day, one sample per shift per
mixer.
8B.5.4.3 Tests for permeability The permeability tests on mortar specimen shall be
conducted in accordance with the procedure specified in IS : 1727 1967 as described in
brief in Appendix II. Mortar as used on work shall not give a coefficient of permeability
greater than 2.5 x 10-8 mm/sec for rich mortar and 4.8x10-8 mm/sec for lean mortar.
8B.5.5 Transporting Mortar
8B.5.5.1 Mortar shall be transported from the mixer to the place of placing in position as
rapidly as practicable by methods that will prevent loss of ingredients or consistence or in air
content of more than two percent, before the mortar is placed on the work. Whenever the
length of haul from the mixing plant to the place of deposit is said that the mortar unduly
compacts, suitable agitators shall be installed in the conveying system.
8B.5.5.2 Where the time of haul exceeds 20 minutes, mixed mortar shall be transported under
cover and protected from evaporation.
8B.5.5.3 Chutes used for conveying mortar shall be of such size and shape as to ensure a
steady uniform flow in 8 compact mass and shall be protected from wind and sun where
necessary to prevent loss of consistency, evaporation and shall be furnished with a discharge
hopper. The free fall or drop of mortar shall be limited to 150 cm. Buckets shall be of the
bottom drum type permitting an even controlled flow into the site of placing or hopper
without undue splashing or segregation. Cars and trucks shall be designed to facilitate
uniform delivery rather than quick dumping.
8B.5.5.4 The chute sections shall be made of or lined with metal and all runs shall have
approximately the same slope not falter than one vertical to two and a half horizontal. The
required consistency of the mortar shall not be changed in order to facilitate chutting. Where
it becomes necessary to change the consistency, the mortar will be completely redesigned.
Where there is a free fall within the conveying system, suitable baffle plates, splash boards or
down spouts shall be provided to prevent segregation or loss of ingredients. All chutes shall
be thoroughly cleaned before and after each run.
8B.5.5.5. Equipment used for transporting mortar from mixer to the place of masonry shall be
maintained free from deposits of the mortar and leakage of mortar.
8B.6. Preparation of foundation / surface for placing masonry
8B.6.1 Masonry in contact with foundation
8B6.1.1 After completion of rough excavation of foundation, scaling and trimming for final
removal of all slabby or drummy rock or any loosened mass shall be done by chiseling,
picking , barring and wedging. Any weathered or decomposed rock remaining should be
removed, the doubtful areas cleaned out to sufficient depth and back filled with concrete or
masonry in richer mortar. If foundation conditions permit, consolidation grouting may be
carried out before laying masonry. In case steps are required to be provided in the foundation
of any individual block, stepping should not exceed 5 m with 9 maximum difference in
elevation of 10 m.
8B.6.1.2 Masonry shall not be placed until embedded parts, if any, are all installed and
checked and surface prepared for placing. All surface of submitted material that have become
encrusted with dried mortar or grout shall be cleaned thoroughly before the surrounding or
adjacent masonry is placed. No masonry shall be placed until the foundation has been
inspected and approved.
8B.6.1.3 Immediately, before placing masonry all surfaces of foundation upon or against
which masonry is to be placed, shall be free from standing water, mud and debris. All
surfaces or rock upon which or against which masonry is to be placed shall in addition to the
foregoing requirements, be cleared and freed from oil, objectionable coating and loose
semidetached or unsound fragments. The cleaning and roughening of the surface of rock shall
be performed by the use of high velocity air water jet, wet sand blasting, stiff brooms, picks
or by other effective means. The washing and scrubbing process shall be continued until the
wash water collecting in puddles is clear and free from dirt. In the final cleaning process, the
wash water may have to be removed by sponges. If any drilled hole is left in the foundation
surface which are no longer needed, the hole shall be cleaned with air water jetting and filled
up, completely with cement slurry. The preparation of the foundation as specifies above shall
be done not earlier than 72 hours before starting masonry work on it.
8B.6.1.4 The surfaces of absorptive foundation upon or against which masonry is to be
placed shall be kept sufficiently wet for atleast 24 hours immediately prior to placing so that
moisture will be drawn from the freshly placed cement slurry and mortar.
8B.6.1.5 If for any reason construction on the foundation surface, thus proposed is delayed,
the area shall be examined thoroughly for any defects and rectifications carried out. The
foundation shall then be kept moistened for 24 hours prior to masonry placement.
8B.6.1.6 Immediately preceding the placement of masonry on foundation rock, the cleaned
up surface shall be moistened and coated with a thick layer of cement slurry (comprising one
cement : about two thirds of water by volume). The slurry shall be spread only on a small
area of about half a square metre at a time and the layer of mortar (which has to follow) shall
be spread immediately thereafter but in no case later than five minutes after the slurry coat is
given in order to avoid stiffening up of cement slurry which may prevent satisfactory
bonding. The layer of the rich mortar 50 mm to 75 mm thick shall be spread over the slurry
and worked into all the irregularities of the foundation surface by trowels, bars and brushes.
The composition of this mortar shall be the same as used in the
masonry work being placed over it. The stone of the first course of masonry shall be carefully
pressed into the mortar immediately so as to force the mortar around the corners. The layer of
mortar shall be made thicker if stones larger than 0.06 cubic metre are placed.
8B.6.1.7 Water from any springs or leakage through the surrounding area shall be kept out of
the foundation area and from masonry till the later has set. Where pumping is resorted to care
shall be taken to ensure that no work already carried out is disturbed or damaged.
8B.6.2 Masonry in Contact with Masonry
Surface of masonry shall be treated as follows before laying fresh masonry over it loose
stones, if any, shall be removed. Mortar joint shall be scraped with iron rods and the exposed
faces of stone shall be wire brushed. The surface shall be cleaned with air water jet. The
water collected in the depressions of masonry shall be removed by sponge or cloth.
8B.6.3 Masonry in contact with old masonry
Surface of old masonry has been exposed for a long time, that is, more than 28 days, shall be
treated as follows. Loose stones, if any, shall be removed old mortar joints shall be scraped to
a depth of 15 mm or wet sand blasted and washed with air-water jet. Immediately prior to
placing of masonry, the old masonry surface shall be treated in the same way as for
foundation masonry described in para 8B.6.1.6.
8B.6.4. The clean up of construction joints in running masonry, work can be accomplished
with case, if a freshly placed layer is gone over with air-water jet just after a lapse of 3 to 4
hours when the mortar will have set hard enough to withstand any erosion. The period may
have to be varied to suit conditions arising form the type of cement used and the weather.
8B.7 Masonry Construction
8B.7.1 General
8B.7.1.1 The masonry work shall be so arranged that a layer of masonry once laid is not
subjected to any disturbance either from the placement of subsequent layers or from any
incidental traffic on the block from the time the mortar in the first layer has lost its plasticity
(workability) to atleast 24 hours from its placement.
8B.7.1.2 The details of all openings, block outs, measuring instruments embedded parts and
piping shall be ascertained and all fixtures positioned in the area before the masonry work is
done in the area.
8B.7.1.3 The structure shall be true to level line, plumb or curved or as directed in a workman
like manner, suitable aids like templates, scaffolding etc, shall be used. The joints shall be
minimum possible and spalls shall be used to minimize mortar requirements in thick joints.
Masonry shall be kept wet for atleast 21 days after being built and at no time and on no
account shall be allowed to be dry in this period. If stones, once kept, in position, are to be
adjusted they shall be lifted clear and reset, they shall not be moved one over the other.
Walkways are necessary to ensure that the green masonry is not disturbed before it sets.
8B.7.1.4 The maximum height of masonry allowed to be constructed at a time shall be 0.6 m
in one or more layers. No fresh masonry shall be laid within 24 hours over time masonry
previously laid.
8B.7.1.5 In the same block (monolith) the difference in level of masonry layers should
normally be not more than 1.5 m to be negotiated in steps 3H : IV. In no case the difference in
level shall be permitted in rich cement mortar face and random rubble masonry work.
8B.7.1.6 The quarried stones shall be thoroughly cleaned and washed before they are brought
to the block for placement.
8B.7.1.7 The following rules shall be observed to ensure efficient construction :
(a) Do not place mortar which bleeds excessively,
(b) Keep the surface continuously moist,
(c) Clean the old masonry surface, prior to starting masonry on it, by wet sand
blasting or chiseling and washing.
(d) Thoroughly and effectively broom into the old surface a layer of mortar and build
the masonry course on it immediately, and
(e) Masonry work should invariably be done during day light hours.
8B.7.1.8 In case of long stoppage of work, suitable depressions of about 2 m x 2 m should be
left to be depth of one or two courses for proper keying and effective boundage with the new
masonry. Work shall be started first in these depressions.
8B.7.2 Face Masonry
8B.7.2.1 Coursed Rubble Masonry The face masonry shall be of selected stones and
dressed and dressed, as described in para 8B.4.7.3 and 8B.4.7.4. The work shall be in parallel
courses of about 300 mm thickness in each courses stones shall be laid in head and stretcher
fashion and joint shall break in courses above and below by atleast half the height of the
courses. The joint in face work shall not be thicker than 15 mm for single line chisel,
dressed stones or 20 mm for hammer dressed stones. Bond stone in each course shall be so
provided that every 6th stone or third header stone is a bond stone. The bond stone shall be
staggered. The face masonry work shall preferably be constructed simultaneously with the
hearting masonry. The content of Mortar in face shall not be less than 33% and not more than
35% of masonry.
8B.7.3 Random Rubble Masonry with Selected stones
The random rubble masonry with selected stones shall be of selected stones as specified in
para 8B.4.7.5 and shall be laid in parallel courses of about 250 mm thickness. The joints shall
break in courses above and below by atleast half the height of course. The joints shall not be
thicker than 35 mm. The stones of different depth shall be suitably staggered.
8B.7.4 Random Rubble Masonry (Uncoursed Rubble Masonry)
8B.7.4.1 The hearting shall be of the random rubble masonry. The mortar to be used for each
class and location of masonry shall confirm to the particular specifications for that class of
mortar and the specifications of the materials used therein.
8B.7.4.2 The stones as specified in para 8B.4.7.2 shall be set on their flat beds as received
from the quarry and without further dressing except knocking out week corners and sharp
edges. Spalls as specified in para 8B.4.7.2.1 shall be used to wedge into thick mortar space
and shall not exceed 10 percent in volume of the total stones utilized. All stones, spalls etc.
shall be washed with water jet and wire brushes before use to ensure clean surface for mortar
to adhere to and water shall be sprinkled before actually placing the stone in position in the
work to prevent absorption of water from the mortar. The mortar placed above the underlying
course of masonry / rock surface shall be worked out by a trowel to a quacky mass and the
stone laid on flat bed shall be shaken by 1 m long 25 mm dia plain MS bar (one end of rod
may be made slightly flat for proper insertion between two stones) to sink into mortar
squeezing excess mortar from all sides. The other stones shall be placed as close as possible
to the adjacent stones and the joints all around the stone shall be filled with mortar. The
stones should be carefully laid so as to break joints as much as possible and solidly bedded
with close joints. After placing at least two stones all around the central stone is manually
vibrated in the lateral direction by insertion of a rod vertically. Simultaneous to this operation
of vibration the joints between the stones shall be packed by a packing rod (12 mm dia. and
0.60 m long plain MS bar) and as trowel. This operation of lateral vibration shall be
continued to the extent necessary to bring up all excess mortar and entrapped air in the
mortar. The spalls shall than be wedged into mortar by hammering down by a wooden mallet
so as to reduce the thickness of the mortar joints. The chips shall not be put flat at the top as
these tend to get dislodged but these should be driven end wise. Also these shall be as rough
as possible to secure good bond between successive layers. Further the spalls shall not be
inserted in space between stones, before it is filled up with mortar. The thickness of the joint
shall not exceed 35 mm. The content of mortar in random rubble masonry shall not be less
than 40% and not more than 45% of the masonry.
8B.8 Truncated Construction
Truncation of masonry section should be avoided. However, if is unavoidable, the following
precautions shall be taken :
(i) The truncated section should satisfy the design criteria adopted for full section for
that particular stage of construction.
(ii) Truncated faces shall be constructed in steps embedding enough dowel bars to
ensure proper bond between old and new masonry.
(iii) The later construction on the truncated sections shall be started after giving
treatment to the truncated face in the same way as for masonry in contacty
with old masonry described in 8B.6.3.
(iv) In case concrete is used for constructing truncated section, shear keys shall be
provided in both horizontal and vertical faces of the truncated section, and
(v) The joint between old concrete and masonry constructed later shall be grouted
after raising the masonry to sufficient height.
8B.9 Protection of Masonry
The fresh masonry shall be protected against vibrations or any other movement which might
injure it before it has reached its final set. Stones shall not be allowed to be dumped over the
masonry which has not taken its final set. Mortar and fresh masonry shall be protected from
rains.
8B.10 Permeability test on masonry
Permeability test on masonry shall be carried out in accordance with Appendix-II (During
and after construction). The permeability shall be determined in Lugeons which shall be
shall be defined as the water loss in liters per minute per metre depth of the drill hole under a
pressure of 10 atmosphere maintained for 10 minutes in ad drill holes of 46 to 76 mm
diameter.
8B.11 Weather condition
8B.11.1 Masonry work shall be temporally suspended during excessively hot of rainy
weather when conditions are such that the masonry cannot be properly placed and cured.
8B.11.2 Whatever necessary, exposed surfaces, of fresh masonry shall be shaded from direct
rays of the sun and protected against premature setting of the mortar or drying by being cured
under continuous sprays of water. All Freshly placed masonry shall be covered and protected
against surface wash.
8B.12 Curing
Arrangement shall be made to protect the fresh masonry against rapid drying and to cure the
masonry. The masonry shall be cured after 8 to 12 hrs of construction and water shall be
gently sprayed so as to avoid damage. All exposed surfaces of masonry shall be kept
continuously moist for a minimum period of 21 days.
APPENDIX - I
MASONRY CLASSIFICATION AND LOCATION DETAILS
S.No. Location of use Classification details

28 days minimum
Type of Masonry
compressive strength
of 50 mm mortar
cube in N/mm2
1 2 3 4
1 0.60 thickness in u/s fact of Coursed rubble masonry (a) 14 (upto 50 m high
over flow & non over consisting of face stone dam )
flow sections. with one line chisel
dressed stone 75 mm on (b)18 (for darn higher
all four sides. than 50m)
2 2.4 m thickness in u/s face Random rubble masonry. (a)14 (upto 50 m high
of overflow and non- dam)
overflow sections at the
back of face work. (b)18(for dam higher
than 50m)
3 1.0 m depth of foundation Random rubble masonry. (a)14 (upto 50 m high

for the full section of dam)
except area covered by
items above in both (b)18(for dam higher
overflow and non than 50 m)
overflow sections.
4 Down stream face of non (a) Random. Rubble 10.50

over flow section: masonry with selected.
stones. 10.50
(a) from one metre above
foundation upto 0.5 m (b) Hammer dressed
below wrap around line coursed rubble masonry.
along the masonry face
(thickness 0.30 ml.
(b) above item 4(a)

(thickness 0.45 m)
1 2 3 4
5 Heartlngin both overflow Random rubble masonry 10.50

and non- overflow
sections,
6 Contraction joints Random rubble masonry (i)14 upto 3 m from u/s

with selected stones. face.
(a) upto 50 m high dam (ii) 10.5 beyond 3 m

from u/s face.
(b) for dam higher than
50 m (i) 18 upto 3 m from u/s
face
(ii) 10.5 beyond 3 m

from u/s face.
7. Training Wall
(a) 0.45 m Thickness on Hammer dressed coursed 10.5

star face. rubble masonry.
8.0
(b) 0.45 m thickness onrear Hemmer dressed coursed
face from 0.5 m below the rubble masonry. 8.0
earth line along masonry
masonry of masonry. Random rubble masonry
(c)Other than (a)&(b)
APPENDIX-II
PERMEABILITY TESTS AND STANDARDS OF IMPERMEABILITY
1 PERMEABILITY TESTS
1.1 Frequency of Test
1.1.1 Masonry - Permeability test for the masonry shell be conducted regularly and at
frequent intervals to judge quality end maintain uniformity. The permeability tests for
masonry shall be conducted every 6 to 8 m rise of each block. Every block where fresh
masonry is laid shall be tested at least every year.
1.1.2 Mortar Permeability tests on mortar shall normally be carried out once in a week.
Specimens 1 00 mm die and 50 mm high or similar size prepared from mortar as used on
work shall be used for testing.
1.2 Testing Procedure For Masonry
Test holes 50 to 80 mm in diameter and of appropriate depth (say 6 to 8 m) shell be drilled

ore the built up masonry after 28 days handening. Drilling shall be done by wet percussion
method. However, in special circumstances above drilling may be resorted to. The holes shell
be kept 300 to 600 mm above the bottom level of the masonry to be tested. These holes shall
be drilled vertically in two rows. One row shop be at 1.5 in from the axis of the dam. The
second row shall be nt about one-third of the width of the dam from the rear face excluding
the front impervious face. The holes shell be provided staggered and it should be seen that at
least one hole each in upstream and downstream portion in each block is provided. The holes
may be closer if found necessary on the basis c the permeability test results. In locating the
holes, position of any embedded parts, instruments, galleries and other opening snail be kept
in view, The holes thus drilled shall be cleaned, filled with water end saturated for 48 hours.
Then these holes shall be subjected to a water loss test to determine. "Lugeon".
Notwithstanding the test pressures specified for higeon values, the actual test pressures
should not be so high as to cause disturbance to masonry. The test pressure shall however be
kept between 0.10 to 0.25 kg/cm2 per metre depth. Then assuming linear variation of water
loss with respect to the pressure applied, the water loss in ugeons may be interpreted For
details of procedure and test equipments reference may be made to lS:5529( Part 2)-1985.
1.2. 1 When a concrete membrane is used on the upstreem face of masonry dam, the upstream
hole for water loss test shall be drilled one metre downstream of the junction of concrete
membrane with masonry.
1.2.2 After the water loss rests the holes shall be grouted to refusal with neat cement and the
results of grout intake recorded.
1.3 Testing Procedure for Mortar
Permeability tests on mortar specimen shall be conducted in accordance with the procedure
specified in IS: 1727-1967.
2. STANDARDS OF IMPERMEABILITY
2.1 Masonry
Standard of impermeability aimed at shall be a water loss of not more than 2.5 and 5 lugeons
in the upstream and downstream portion of the dam respectively.
2.1.1 Permissible water loss in holes drilled in accordance with 1.2 shall be not more than 2.5
or 5 lugeons depending on the mortal mix used for masonry at that location
(rich or lean respectively).
2.1.2 The values of water loss obtained from the test is the overall value of masonry including
loss into cracks, joints, etc. It provides an approximate estimate of the possible
leakage that may take place through specific zones of masonry.
2.2 Mortar
Mortar as used on work shall not give of permeability greater than 2.5 x 10-8 mm/sec for rich
mortar and 4.8x10-8 mm/sec for lean mortar.
2.3 If test holes in a block indicate water loss greater than acceptable, measures in the form of
adequate core drilling and grouting shall be done as directed by the Engineer-
in-Charge.
VOLUME III
SECTION - 9
STEEL AND IRON WORK
INDEX
TENDER DOCUMENT 49
TURNKEY TENDER 49
2SURVEY 58
4FINAL REPORT 68
APPENDIX I 69
ETC. 69
APPENDIX II 71
71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
APPENDIX IV 77
1 GENERAL 162
2. STANDARDS 162
3. SCOPE: 163
4. PLANNING: 163
EMBANKMENT 165
13 EXCAVATION 169
16DEWATERING 171
24MATERIAL 178
29DOWEL BANKS: 186
33TOE DRAINS : 187
35SIDE DRAINS: 188
37PROTECTION: 188
42ROCK TOE 192
43 BORROW AREAS 195
46 BORROW PITS 196
53BLASTING 198
62 TURFING 203
1 GENERAL 139
2. STANDARDS 139
3. SCOPE: 140
4. PLANNING: 140
EMBANKMENT 142
66 EXCAVATION 146
69DEWATERING 148
77MATERIAL 155
82DOWEL BANKS: 163
86TOE DRAINS : 164
88SIDE DRAINS: 165
90PROTECTION: 165
95ROCK TOE 169
96 BORROW AREAS 172
99 BORROW PITS 173
106BLASTING 175
115 TURFING 180
1 GENERAL 163
GATES 163
5SCOPE 165
(GATES) 165
10 PAINTING 172
INSTALLATION 177
1. REFERENCES : 303
2. TERMINOLOGY 305
4 ANCHORAGES 334
1 INTRODUCTION 256
8SURFACE DRAINS 258
11 SHOULDER 263
13 INTRODUCTION 274
14PRE-REQUISITE 274
SECTION 9
STEEL AND IRON WORKS
1. REFERENCES :
IS:226-1975 Structural steel (standard quality) fifty revision (with amendment Nos. 1
to 5)
IS:278-1978 Galvanized steel barbed wire for fencing (third revision), (with
amendment NO. 1 & 2).
IS: 280-1978 Mild steel wire for general Engineering purposes (third revision), (with
amendment No. 2)
IS: 432 (Pt. I) Mild steel and medium tensile steel bars (third revision).
1982
IS: 456-1978 Code of practice for plain and reinforced concrete (third revision) (with
amendment No. 1)
IS: 800-1984 Code of practice for general construction in steel (second revision) (with
amendment No.2).
IS: 813-1961 Scheme of symbols for weldings.
IS: 814 (Pt. 1 & Covered electrodes for metal arc welding of structure steel.
III) 1974
IS: 816-1969 Code of practice for use of metal arc welding for general construction in
mild steel, (first revision), (with amendment Nos. 1 & 2).
IS: 818-1968 Code of practice for safety and health requirements in electric and gas
welding and cutting operations (first revision).
IS: 822-1970 Code of procedure for inspection of welds.
IS: 1038-1983 Steel doors, windows & ventilators (third revision).
IS: 1081-1960 Code of practice for mixing and glazing of metal (steel and aluminium)
doors, windows and ventilators (with amendment o.1)
IS: 1148-1982 Hot rolled steel rivet bars (upto 40mm diameter) for structural purposes
(third revision).
IS: 1161-1979 Steel tubes for structural purposes (third revision).

IS: 1361-1978 Steel windows for industrial buildings (first revision) (with amendment
No. 1 & 2).
IS: 1363 (Pt. I, II Hexagonal hard bolts, screws & nuts of product grade C.
& III) 1984
IS: 1566-1982 Specification for hard drawn steel wire fabric for concrete reinforcement,
(second revision).
IS: 1732-1971 Dimensions for round and square steel bars for structural and general
engineering purposes (first revision) (with amendment No.1).
IS: 1786-1985 High strength deformed steel bars and wires for concrete reinforcement
(third revision).
IS: 1852-1979 Rolling and cutting tolerances for hot rolled steel products (third
revision).
IS: 1977-1975 Structural steel (ordinary quality) second revision) (with amendment
Nos. 1 to 3).
IS: 2061-1984 Weldable structural steel (fusion welding quality) third revision), (with
amendment No.1.
IS: 2140-1978 Standard galvanized steel wire for fencing (first revision) Reaffirmed
1986.
IS: 2502-1963 Code for practice for bending and fixing of bars of concrete
reinforcement.
IS: 2721-1979 Galvanized steel chain link fence fabric (first revision) (Reaffirmed
1986).
IS: 2751-1979 Code of practice for welding of mild steel plain and deformed bars for
reinforced concrete construction (first revision).
IS: 3386-1979 Wooden fence posts (first revision).
IS: 4082-1977 Recommendations of stacking and storage of construction materials at

site (first revision).
IS: 4351-1976 Steel door frames (first revision) (with amendment No. 1).
IS: 4454(I)-1981 Steel wires for cold springs-patented and cold drawn steel wires
unalloyed (second revision).
IS: 4948-1974 Welded steel wire fabric for general use (first revision) (with amendment
No.1)
IS: 4996-1984 Reinforced concrete fence posts (first revision).
IS: 6248-1979 Specification for metal rolling shutters and rolling grills.
IS: 8629 (Pt. I to Code of practice for protection of iron and steel structures from
III)-1977 atmospheric corrosion.
IS: 9077-1979 Code of practice for corrosion protection of steel reinforcement in RB

and RCC construction.
IS: 9417-1979 Recommendations for welding cold worked steel bars for reinforced
concrete construction.
IS: 9595-1980 Recommendations for metal arc welding of carbon and carbon
manganese steel (with amendment No. 1) (reaffirmed 1987).
IS: 10521-1933 Collapsible gates.
IS: 21-1979 Standard Specifications and code of practice for Road Bridges-Section
III; cement Concrete (plain & reinforced) (first revision).
SP: 24(S & T) Explanatory Hand Book on Indian Standard Code of Practice of Plain
and reinforced concrete.
Standard specifications 77 of CPWD, Maharashtra PWD

specifications.
Standard specifications of National Buiding Organisation.
Design of concrete Members with Ribbed Tor steel by R. Chandra.
2. TERMINOLOGY
Bottom Lock Plate : The fabricated bar inserted at the bottom of rolling shutter
curtain, so as to lie against the steel, including the slide bolts, pulling handles etc.
Bracket plates : The supporting plates at either end on the top, together with the U-
shaped clamps supporting the entire moving mechanism of the rolling shutter.
Bundle : Two or more coils or a number of lengths properly bound together.
Coil : One continuous bar as rolled in the form of a coil.
Composite Window : A window comprising of two or more sashes joined together
with one or more coupling members.
Coupling : Joining door, window or ventilator units, side by side or one on the top of
another or any combination of these units with mullions or transoms.
Crank Handle : the Winding handle used for raising and lowering mechanical gear
operated rolling shutters through a bevel gear box.
Curtain : The main apron of the rolling shutter consisting of the assembly of lath
sections, end locking clips and the connecting pieces at the top.
Elongation : the increase in length of a tensile test piece under stress. The elongation
at fracture is conventionally expressed as a percentage of the original gauge length of
a standard test piece.
Fixing : Securing metal door, window or ventilator to prepared structural or masonry
surrounds and fixing of fittings and accessories.
Flange : The flange of the metal section on the inside is called inner flange and the
flange exposed to the outside is called the outer flange.
Glazing : securing of glass in the metal door, window or ventilator.
Glazing Bead : Strips of metal or timber used for glazing in addition to putty.
Guide channels : The channels on either side in which the shutter moves up and
down.
Holdfast : A metal lug used for fixing door, window or ventilator.
Hood Cover : A sheet metal cover bent into a suitable shape for covering the roller.
Jamb : the vertical sides of the door, window or ventilator.
Lath sections : The individual rolled interlocking laths or slats with which the
rollingshutter curtain is assembled.
Longitudinal Rib : A rib or uniform cross-section, parallel to the axis of the bar/wire
(before cold working. If any).
Mastic : A weather proofing compound usually with a putty base which remain
pilliable and plastic.
Mesh size : The pitch or centre distance of main wires by the pitch of centre to centre
distance of cross wires.
Nominal Diameter of Size : The diameter of a plain round bar/wire having the same
uses per metre length as the deformed bar/wire.
Nominal Perimeter of a Deformed Bar/Wire : 3.14 times the nominal diameter.
Nominal Mass : The mass of the bar/wire of nominal diameter and of density 0.007
Kg/mm2 per metre run.
Over all Height : The distance between the sill and the top of the bracket plate of the
rolling shutter plus an allowance of not more than 150mm.
Over all Width : The outer distance between the two guide channels of the rolling
shutter.
Proof stress : The stress which is just sufficient to produce, under load, a permanent
deformation equal to a specified percentage of the original gauge length.
0.2 Percentage Proof Stress : The stress at which a non-proportional elongation
equal to 0.2 percent of the original gauge length takes place.
Pulling Hook : The steel rod shaped into a hook at one end and into a right at the
other, used for raising and lowering self coiling type rolling shutters.
Putty Bedding : Putting which is placed in the glazing rebate of the door, window or
ventilator into which glass is bedded.
Putty Back : Portion of the bedding putty remaining between the glass and rebate
after the glass has been pressed into position in the glazing rebate of the section.
Putty Front : Putty forming a mitred filling between the surface of the glass and the
front edge of the section.
Rendering : Plastering of the outside face of the wall and the outer reveal.
Reveal : the depth of the wall revealed beyond the frame in the sides of the opening.
The reveal on the inner sides is called the inner reveal and reveal exposed to outside
is called the outer reveal.
Plush Reveal : A reveal which is not rebated.
Rebated Reveal : A reveal which forms an angle or sometimes a groove into which
the outer flange of the steel window section fits.
Roller : the entire rolling portion at the top of the shutter including the suspension
shaft, the pulleys, the springs and ball bearing, if any.
Sash : A complete industrial window unit, whether of the fixed or opening type.
Sill : The lower boundary of a door, window or ventilator openings.
Stopper Height : The stopper height of a rolling shutter shall be the height as
measured from the sill to the bottom of the lock plate, when the rolling shutter is in
the full open position.
Tensile strength : The maximum load reached in a tensile test divided by the
effective cross sectional area of the test piece. Also termed as ultimate tensile stress.
Threshold : The portion of the door frame which is fixed to floor.
Transverse Rib : Any rib on the surface of a bar/wire other than a longitudinal rib.
Ventilator : The opening part of a sash. It consists of an inner frame and an outer
frame.
Centre Hung Ventilator : A ventilator horizontally pivoted at the centre of each side,
with the top half opening inwards and the bottom half opening outwards.
Top Hung Ventilator : A ventilator hinged at the top, and opening outwards.
Yield Stress : Stress (that is, load per unit of cross sectional area) at which elongation
first occurs in the test piece without increasing the load during tensile test. In the case
of steels with no such definite yield point, the yield stress is the stress under the
prescribed testing conditions at which the observed increase in the gauge length is
1/200 of the gauge length when the rate at which the load applied is not more than 5
N/mm2 when approaching the yield stress.
3. REINFORCEMENT :
1. General : This work shall consist of furnishing and placing steel
reinforcement of the shape and dimensions indicated in the
drawings and as specified in these specifications.
1. All steel used for reinforcement shall be clean, free from oil,
greese, paints, dust, mortar, scales, kinks, rust or any
rolling defects or bends other than those required as per
drawings or as directed by the Engineer-in-Charge.
2. Quality of Reinforcement :
3.2.1 The steel reinforcement shall be, any of the following, as may be
specified for the job in question.
1. Mild steel and medium tensile bars conforming to IS: 432-1982 as amended from
time to time.
2. Cold twisted bars conforming to IS: 1786-1985 as amended from time to time.
3. Hard drawn steel wire fabric conforming to IS: 1566-1982 as amended from time to
time.
3.2.2 The ultimate tensile stress, yield stress and percentage elongation of
reinforcing steel shall be as given in Appendix I.
3.2.3 In case of material purchased from re-rollers or other than authorised

suppliers of manufacturer, the supplier shall furnish manufacturers
certificate containing the results of all the required tests on samples taken
from the delivered material. For each bundle/coil of bars, a tag shall be
attached indicating cast No., Lot No., Grade & Size.
3. Stacking and Storage : Steel reinforcement shall be stored in such

a way as to prevent distortion, deterioration and corrosion.
Reinforcing bars shall not be left in direct contact with the
ground but they shall be stacked on top of an arrangement of
timber sleepers or the like suitable racks shall also be used for
stacking reinforcement in tiers. Bars of different classifications,
sizes and lengths shall be stores separately to facilitate issues in
such sizes and lengths as to minimize wastage in cutting from
standard lengths.
4. Cutting and Bending :
3.4.1 Bars bent during transport or handling shall be straightened
before being used on work; they shall not be heated to facilitate
bending.
3.4.2 Reinforcement bars shall be of the size prescribed and shall be

accurately cut to length and bent to shape and fixed in position as
shown on the drawings or as directed by the Engineer-in-Charge
and shall conform to IS: 2502-1963 as revised form time to time.
The tolerance for bending and cutting shall be as given in Table
1.
Table 1 Permissible Bending and Cutting Tolerances
Length Tolerance
Over Upto and Plus Minus

Including
Cm Cm Mm Mm
For bent bars - 75 3 5
75 150 5 10
150 250 6 15
250 - 7 25
For straight Bars All - 25 25

lengths
3. einforcement bars shall be bent cold, but bars larger than 25mm in
size may be bent not at cherry red heat (not exceeding 850oC)
except those bars which depend for their strength on odd working.
Hot bars shall not be cooled by quenching. Bars shall not be
straightened or bent in a manner that will injure or weaken the
material.
4. Bars of 12mm diameter and under may be bent by simple tools

such as a claw. For bars upto 16mm a simple hand machine
(without gears) is recommended. For larger diameter, a geared bar
bending machine (hand operated) will be suitable. For bars 36mm
and above, and where large quantities of bars are to be bent,
power operated benders may be used advantageously.
5. Unless otherwise specified a U-type hook shall invariably be

provided at the end of each bar. The radius of the bend shall not
less than twice the diameter of the round bar and the length of the
straight part of the round bar. Deformed bars may be used without
hooks.
5. Joint and Splicing :
1. Lapped Splices :
3.5.1.1 All reinforcement shall be furnished in full length indicated in the

drawings as far as possible. Splicing bars, except as shown in the
2.16.3drawings shall not be permitted without written approval of the
Engineer-in-Charge.
2. Where splices are provided in the reinforced bars, they

shall conform the requirements contained in Design Series
Technical Circular No. 24 appended at Appendix II.
2. Welded Splices :
1. Reinforcement in structure shall not be welded except

where shown in the drawing. All welding procedures shall
be subject to the approval of the Engineer-in-Charge in
writing.
2. Welding of reinforcements shall be done in accordance with

the recommendations of the following Indian Standards :-
13. IS:2751-1979 gives the requirements of weldings of mild round and deformed
bars conforming to grade-I of IS:432(Part 1)-1982 and IS: 1786-1985.
14. IS:9417-1979 gives requirements of welding of cold worked steel bars

conforming to IS: 1786-1985.
15. The M.S. electrodes used for welding shall conform to IS: 814-1974.
3. Joints welding procedures which are to be employed shall

invariably be established by a procedure specification and shall
be qualified prior to use by tests as prescribed in IS: 2751-1979
and IS: 9417-1979. All welders and welding operators to be
employed shall have to be qualified by tests prescribed in IS:
2751-1979 and IS: 9417-1979. Inspection of weld shall conform
to IS: 822-1970 and destructive and non destructive testing may
be undertaken when deemed necessary. Joints with weld defects
detected by visual inspection or dimensional inspections shall
not be accepted.
4. Reinforcement bars upto and including 20mm in diameter should
be lap welded and those larger than 20mm diameter should be
butt welded.
As far as possible in concrete structures subjected to large numbers of repetition of

substantial loads welding should be avoided.
5. Welds shall be avoided at bends or in curved parts of the

reinforcing bars and shall be located atleast at a distance of 50
times the diameter from bends.
6. The design strength of a welded splice or mechanical connection
shall be taken as equal to 80 percent of the design strength of the
bar for tension splices and 100 percent of the design strength for
compression splices. However, 100 percent of the design strength
may be assumed in tension when the spliced area forms not more
than 20% of the total area of steel at the section and the splices
are staggered at least 60 cm.
Note : Welded joints or mechanical connections in reinforcement may be used but in all cases
of important connections, tests shall be made to prove that the joints are of
the full strength of bars connected.
1. Deformed bars shall not be lap welded at splices except where

lap welding is shown on the drawings or otherwise specifically
approved. In the welds of lapped joints, the shear strength of the
filler materials should be taken as 0.38 times its yield or proof
stress as given in appropriate standards. The length of weld
should be sufficient to transmit the design load in the bar, that is,
the cross sectional area of (parent) bar x 0.87 fy should be equal
to effective length of weld throat thickness x the shear strength of
the filler material. The length of a run of weld should not
normally exceed five times the size of the bar. If a longer length of
weld is required, it should be divided into sections and the space
between runs made not less than five times, the size of the bar.
2. Butt welding of reinforcement bars shall be performed under
cover from the weather and may be performed either by the gas
pressure or flash pressure welding process or by electric arc
methods. The following shall apply for all welding of
reinforcement bars including butt welding and the preparation of
welded reinforcement mats.
xiii. The ends of the bars to be butt welded by gas pressure or flash pressure
welding shall be squared off by an abrasive disc cutter. Any accumulation
of dirt or oxide film formed after the cutting operation shall be removed
by sand blasting or buffing prior to welding. Ends of bars to be joined by
flash pressure welding shall be cleaned off all rust and projections on the
end faces and for a distances of about 15 cm from the ends, if necessary
to prevent arching. Care shall be taken in aligning and separating the
ends of the bars to be joined by arc welding and the ends of the bars shall
be matched accurately and shall be retained firmly in position during the
welding operations. For pressure welding, the bars shall be accurately
held in position with the prescribed pressure applied prior to heating
and during heating and welding.
xiv. Where bars are to be joined by electric arc welding the weld metal shall
be deposited in successive layers and each layer shall be thoroughly
cleaned before subsequent layer is deposited.
xv. All structural welds shall have complete fusion and freedom from
imperfections. Defective pressure welded joints shall be separated by
flame cutting and rewelded.
Defective arc welds shall be chipped to sound metal and resulting cavities shall
be filled in the same manner as the original grooves were filled or the
bars shall be flame cut and rewelded.
(xvi) Tack welding of reinforcement bars, for fixing bars in place or for
preparation of mats shall be carried out by competent operators
using approved techniques. The work shall be so performed that
there are no short discontinuities or loss of cross section in the
jointed bars at or adjacent to the weld.
5. Binding and Placing :

1. Before reinforcement is placed, the surfaces of the reinforcement
and the surfaces of any metal supports shall be cleaned of heavy
flaky rust, loose mill scale, dirt, greese, coats of paints, oil or other
foreign substances which may destroy or reduce bond. Heavy flaky
rust can be removed by rubbing with gunny (burlap) or equivalent
treatment. A note on rust over reinforcement is given at Appendix
III for general guidance.
2. Reinforcement bars shall be placed accurately in the positions

indicated in the drawing and maintained in these positions. When
delay occurs between assembling the steel and depositing the
concrete, the placing of the reinforcement shall be again carefully
checked immediately prior to concreting.
3. Reinforcement after being placed in position shall be maintained in

a clean condition until completely embedded in concrete. Special
care shall be exercised to prevent any displacement of
reinforcement in concrete already placed.
4. When reinforcement bars are bent aside, at construction joints and

afterwards bent back into their original positions, care should be
taken to ensure that at no time the radius of the bend is less than 4
bar diameters for plain mild steel or 6 bar diameters for deformed
bars. Care shall also be taken when bending back bars, to ensure
that the concrete around the bars is not damaged.
5. Bars crossing each other should be secured by annealed binding

wire of size not less than 0.90mm and conforming to IS: 280-1978
in such a manner that they will not slip over each other at the time
of fixing and concreting.
6. The bars shall be kept in position by the following materials :-
1. In case of beam and slab construction, precast cover blocks in cement mortar
1:2 (1 cement : 2 sand) about 4 cm x 4 cm section and of thickness equal to the
specified cover shall be placed between the bars and shutterings, so as to
secure and maintain the requisite cover of concrete over reinforcement;
2. In case of cantilevered and doubly reinforced beams or slabs, the vertical
distance between the horizontal bars shall be maintained by introducing chain
spacers or support bars of steel at 1m or at shorter spacing to avoid sagging;
3. In case of columns and walls, the vertical bars shall be kept in position by
means of timber templates with slots accurately cut in them; or with block of
cement mortar (1:2) suitably tied to the reinforcement if, templates are used,
they shall be removed after the concreting has progressed to a level just below
them;
4. In case of R.C.C. structures, such as arches, domes, curved profiles of
spillways, falls, training walls, etc. cover blocks, spacers and templates, shall
be used as directed by the Engineer-in-Charge.
1. Chairs, spacers, hungers, supporting wire or other approved
devices at sufficiently close intervals may also be used as approved
by Engineer-in-Charge. All materials used for positioning the steel
shall be non-corrodible material. Supports shall not extend to the
surface of concrete except where shown on drawings.
2. All the bars protruding from concrete and to which other bars are
to be spliced and which are likely to be exposed for an indefinite
period shall be protected by a thick coat of neat cement grout.
3. Reinforcement will be inspected for compliance with requirements

as to size, shape, length, spacing and position after it has been
placed.
6. Substitution :
1. Substitution of size of bars, different from specified in the drawing

shall be allowed only with the permission of Engineer-in-Charge.
Substitution of the same type and grade such as plain bars and
deformed bars of various grades say F415, F500 shall be used as
main reinforcement in a structural member. However,
simultaneous use of two different typeof steel for main and
secondary reinforcement respectively is permissible. Guide lines
for substitution are given in Appendix IV.
2. While permitting substitution of bars, the Engineer-in-Charge

shall satisfy himself regarding the design requirements in respect
of bond, spacing between bars, and minimum cover etc. as given in
IS:456-1978 and IS:3370 (Pt. II) 1965. The relevant clauses are
given below for guidance:
(i) Bond : 25.2 of IS: 456-1978
(ii) Spacing : 25.3 of IS: 456-1978
(iii) Cover : 25.4 of IS: 456-1978 and 7.2 of IS:3370-1963

5. Bundling of Bars :
1. The bundles of bars may be provided in the original
design/drawing or may be necessitated as requirement of
substitution. The bars shall be bundled in shapes of
triangular, square or L-shaped to act as one unit of
reinforcement. The bar diameters in a bundle shall be
limited to two nearest sizes. Bundled bars shall be tied
together to ensure the bars remaining together. Bars larger
than 36mm dia shall not be bundled except in columns.
2. Curtailment : Bars in a bundle shall terminate at different

points spaced apart by not less than 40 times the bar
diameter except for bundles stopping at a support.
When all bars in a bundle are carried to the support, the increased development
length (based on single bar) for bundles as given in para 2.2 of Appendix IV
should be used for checking of the development of stress.
1. Diameter of bundled Bars : Where spacing limitations and

minimum concrete cover are based on bar of diameter, a group of
bars bundled in contact shall be treated as a single bar of diameter
derived from the total equivalent area.
2. The minimum free distance between groups of bundled bars
should be at least the maximum of the followings :
i. C+1.5 cm where, C = maximum size of aggregate (cm).

ii. The diameter of the largest size of bar used.
iii. 3 cm.
1. If more than one layer of bundled bars are used, then the groups
should be placed one over the other.
2. Bundles shall not be used in a member without stirrups.
3. For column where large amount of bundled bars are used (2 to

3%) the spacing of tie should be reduced to half the normal tie
spacing (1/2 the minimum lateral size of the member).
4. STRUCTURAL STEEL & IRON WORK

4. Materials
1. Steel : All finished steel shall be well and cleanly rolled to the
dimensions and weight specified by ISI subject to permissible
tolerances as per IS: 1852-1979. The finished materials shall be
reasonably free from cracks, surface flaws, laminations, rough and
imperfect edges and all other harmful defects. Steel sections, shall
be free from excessive rust, scaling and pitting and shall be well
protected.
he mechanical properties and chemical composition of the structural steel shall be as per
Appendix V & VI. The following varieties of steel should be used for structural
purposes:
1. S.T. 42-S : The standard quality steel designated as ST-42-S,
conforming to IS:226-1975 shall be used for all the types of
structure (riveted or bolted) including those subject to dynamic
loading and where fatigue, wide fluctuation of stresses, reversal
of stresses and great restraint are involved as for example crane
gantry girders, road and rail bridges etc.
It is also suitable for welded structures provided that the thickness of materials does not
exceed 20 mm.
1. ST 42-W : The fusion welding quality steel designated as S.T.
42-W, conforming to IS: 2062-1984 shall be used for structures
subject to dynamic loading (Wind load is not to be considered
as dynamic for this purpose) where welding is employed for
fabrication and where fatigue, wide fluctuation of stress,
reversal of stress and great restraint are involved as for
example, crane gantry girders and road and rail bridges.
2. ST 42-O : The ordinary quality steel designated as S.T. 42-O,
conforming to IS: 1977-1975 shall be used for structures not
subjected to dynamic loading other than wind loads where
welding is not employed or/and structures not situated in earth
quake zones or/and design has not been based on plastic theory.
3. S.T. 32-O : The ordinary quality steel designated as S.T. 32-O
conforming to IS: 1977-1975 shall be used for doors, window
frames, window bars, grills, steel gates, hand railing, builders
hardware, fencing post, tie bars etc.
2. Rivets : Rivets shall be made from rivet bars of mild steel as per IS
: 1148-1982. The tolerance on diameter of bars shall be as given in
table 2 :
TABLE -2
Diameter of Bars (mm) Maximum Tolerance (mm)

Below 20 (-) 0.40
20 (-) 0.45
22 and 24 (-) 0.50
Over 24 (-) 2 percent on diameter

3. Black Bolts : These are also known as machine bolts and are made
from rods as they come from the rolling mills and are not finished
to exact size.
4. Turned And Fitted Bolts : These bolts are turned to exact diameter
in automatic lathe.
5. Electrodes : The electrodes required for metal arc welding shall be

covered electrodes and shall conform to IS : 814-1974.
The size of the electrode shall be designated by the diameter of the core wire
expressed in mm.
The contact end of the electrodes shall be bare and clean to a length of 20 to 30
mm. The arc striking end of the electrode permit easy striking of arc. Where the
end is bare, the distance from the arc end to the first point where the full cross
section of the covering prevails shall not exceed the 2/3rd of the diameter of the
core wire, subject to a maximum length of 2.5mm.
The electrodes shall be of three types, namely :-
1. Normal penetration electrodes,
2. Deep penetration electrodes, and
3. Electrodes suitable for deep penetration and normal penetration.
1. Covering : The covering shall be sufficiently robust to withstand
without damage, normal conditions of handling and storage and
shall be free from defects which would interfere with satisfactory
performances of the electrodes. The covering shall fuse and/or
burn evenly.
2. Steel work in Single Section Fixed Independently / With

Connecting Plate
The steel work in single sections of R.S. joists, flats, tees, Angles fixed independently,
without connecting plate and the steel work in single section fixed with connecting
plate or angle cleats as in main and cross beams, hip and jack rafters purlins
connected to common rafters and the like shall be covered by the provisions in these
paras.
1. Fabrication : The steel sections as specified or required, shall be

straightened and cut square and to correct lengths and measured
with a steel tape. The cut ends exposed to view shall be finished
smooth. No two pieces shall be welded or otherwise jointed to
make up the required length of member.
All straightening and shaping to form, shall be done by pressure. Bending or

cutting shall be carried out in such a manner as not to impair the strength of the
metal.
1. Paintings :
1. All surfaces which are to be painted, oiled or otherwise treated
shall be dry and thoroughly cleaned to remove all loose scale and
loose rust.
2. Surfaces not in contact but inaccessible after shop assembly, shall
receive the full specified protective treatment before assembly.
This does not apply to the interior of sealed hollow sections.
3. Parts to be encased in concrete shall not be painted or oiled.
4. Shop contact surfaces need not be painted unless so specified. If
so specified, they shall be brought together while the paint is still
wet.
2. Erection : Steel work shall be hoisted and placed in position
carefully without any damage to itself and other building work and
injury to workmen. Where necessary, mechanical appliance such
as lifting tackle, winch etc. shall be used. The suitability and
capacity of all plant and equipment used for erection shall be to
the satisfaction of Engineer-in-Charge.
2. Steel Work in Built Up sections (Rivetted and Bolted) :
The steel work in built up sections (Rivetted and bolted), such as in

trusses, framed work etc. shall be covered by the provisions in these paras.
1. Laying out : Steel structure shall be laid out on a level platform to

full scale. This may be done to full size or in parts, as shown on
drawings or as directed by the Engineer-in-Charge. A steel tape
shall be used for measurements.
2. Fabrication : Fabrication shall be done as described in subsequent
paras.
1. Strengthening, shaping to form and cutting : The steel sections as

specified or required, shall be straightened and cut, square and to
correct lengths and measured with a steel tape. The cut ends
exposed to view shall be finished smooth. No two pieces shall be
welded or otherwise jointed make up the required length of a
member.
All straightening and shaping to form, shall be done by pressure. Bending or

cutting shall be carried out in such a manner as not to impair the strength of metal.
In major works or where so specified, shop drawings giving complete information

for the fabrication of the component parts of the structure including the location,
type size length and details of rivets, bolts or welds, shall be prepared in advance
of the actual fabrication and approved by the Engineer-in-Charge. The drawings
shall indicate the shop and field rivets, bolts and welds. The steel members shall
be distinctly marked or stenciled with paint with the identification marks as given
in the shop drawings.
Great accuracy shall be observed in the fabrication of various members, so that

these can be assembled without being unduly packed, strained or forced into
position and when built up, shall be true and free from twist, kinks, buckles, or
open joints.
Wooden or metal sheet templates shall be made to correspond to each member and
rivet holes shall be marked accurately on them and drilled. The templates shall be
laid on the steel members, and holes for riveting and bolting marked on them. The
ends of the steel members shall also be marked for cutting. The base of steel
columns and the position of anchor bolts shall be carefully set out.
All stiffeners shall be formed by pressure and where practicable the metal shall
not be cut and welded in making these.
2. Making Holes : Holes through more than one thickness of

material for members such as compound stanchion and girder
flanges shall, where possible, be drilled after the members are
assembled and tightly clamped or bolted together. Punching may
be permitted before assembly, provided the holes are punched 3
mm less in diameter than the required size and reamed after
assembly to the full diameter. The thickness of material punched
shall be not greater than 16mm.
Black bolt/Rivet Holes : The diameter for rivets and black bolt holes shall be
taken as the nominal diameter of a rivet plus 1.5 mm for rivets of nominal
diameter less than or equal to 25mm and 2.0mm for rivets of nominal diameter
exceeding 25mm, unless specified otherwise. Holes for turned and fitted bolts
shall be drilled or reamed large by 0.2 to 8 mm depending upon the dia of bolts as
shown in Appendix VIII.
Holes shall have their axis perpendicular to the surface bored through. The drilling
or reaming shall be free from burrs, and the holes shall be clean and accurate.
Holes for rivets and bolts shall not be formed by gas cutting process.
Holes for Counter : Sunk bolts shall be made in such a manner that their heads sit
flush with the surface after fixing.
3. Assembly : The component parts shall be assembled in such a
manner that they are neither twisted nor otherwise damaged,
and shall be so prepared that the specified cambers, if any, are
provided. Before making holes in individual members, for
fabrication the steel work intended to be rivetted or bolted
together shall be assembled and clamped properly and tightly so
as to ensure close abutting, or lapping of the surfaces of the
different members. All stiffeners shall bear tightly both at top and
bottom without being drawn or caulked. The abutting joints shall
be cut or dressed true and straight, and fitted close together.
Web plates of girders, which have no cover plates, shall have their ends flush with
the tops of angles unless otherwise required. The web plates, when spliced shall
have clearance of not more than 5 mm. The erection clearance for cleated ends of
members connecting steel to steel shall preferably be not greater than 1.5 mm. The
erection clearance at the ends of beams without web cleats shall not be more than
3 mm at each end but where for practical reasons, greater clearance is necessary
suitably designed seating shall be provided.
Column splices and butt joints of struts and compression members depending on
contact for stress transmission shall be accurately machined and close butted over
the whole section. In column caps and bases, the ends of shafts together with the
attached gussets angles, channels, etc. after riveting together shall be accurately
machined so that the parts connected, butt against each other over the entire
surfaces of contact. Connecting angles or channels shall be fabricated and placed
in position with great accuracy so that they are not unduly reduced in thickness by
machining.
The ends of all bearing stiffeners shall be machined or ground to fit tightly both at
top and bottom.
4. Riveting :
Rivets shall be used, where so provided in the drawings. Riveted members shall
have all parts firmly drawn and held together before and during riveting, and
special care shall be taken, in this respect for all single riveted connections. For
multiple riveted connections, a service bolts shall be provided in every third or
fourth hole.
The riveting shall be carried out by using machines of the steady pressure type.
However, where such facilities are not available hand riveting may be permitted
by Engineer-in-Charge. The rivets shall be heated red hot, care being taken to
control the temperature of heating so as not to burn the steel. Rivets of diameter
less than 10 mm may be driven cold. Rivets shall be finished neat, with heads full
and of equal size. The heads shall be central on shanks and shall grip the
assembled members firmly. All loose, burnt, or badly formed rivets with eccentric
or deficient heads shall be cut out and replaced. In cutting out rivets, care shall be
taken so as not to injure the assembled members. Caulking and recupping shall not
be permitted.
For testing rivets hammer weighing approx 0.25 Kg. Shall be used. Both heads of
the rivet (specially the machine head) shall be tapped. When so treated the rivets
shall not give a hollow sound and a jar. Where so specified further test shall be
carried out to ensure the soundness of rivets.
5. Bolting :
The nominal length of the bolt shall be the distance from the underside of the head
to the further end of the shank. The nominal diameter of the bolt shall be the
diameter at the shank above the screwed threads. Bolts, nuts and washers shall be
thoroughly cleaned and dipped in double boiled linseed oil, before use. All bolt
heads and nuts shall be hexagonal unless specified otherwise. The screwed threads
shall conform to IS: 1363: (Pt. I to III) 1984 and the threaded surface shall not be
tapered. The bolts shall be of such length as to project at least one clear thread
beyond the nuts when fixed in position, and these shall fit in the holes without any
shake. The nuts shall fit in the threaded ends of bolts properly.
Where necessary, washers shall be tapered or otherwise suitably shaped to give
the heads and nuts of bolts a satisfactory bearing. In all cases where the full
bearing area of the bolt is to be developed, the bolt shall be provided with a
washer of sufficient thickness under the nut.
Where there is risk of the nuts being removed or becoming loose due to vibrations
reversal of stresses, these shall be secured from slackening by the use of locknuts,
spring washers or cross cutting as directed by the Engineer-in-Charge.
3. Erection :
1. Steel work shall be hoisted and erected in position carefully,
without any damage to itself, other structure and equipment and
injury to workmen. The method of hoisting and erection
proposed to be adopted shall be got approved from the Engineer-
in-Charge. Proper equipment such as derricks, lifting tackles,
winches ropes etc. shall be used.
2. The work may be erected in suitable units as may be directed by
the Engineer-in-Charge. Fabricated members shall be lifted at
such points as to avoid the deformation or excessive stress in
members. The structure or the part of it place in position shall be
secured against overturning or collapse by suitable means.
During execution the steel work shall be securely bolted or
otherwise fastened and when necessary, temporarily braced to
provide for all loads to be carried safely by the structure during
erection including those due to erection equipment and its
operations. The steel work shall be placed in proper position as
per approved drawings. Final riveting or permanent bolting shall
be done only after alignment has been obtained.
3. Trusses shall be lifted only at nodes. The trusses above 10 m in
span shall not be slinged at the apex, as it will develop
compression stresses in the bottom tie member. They shall be
lifted by slinging at two mid points of rafters, which shall be
temporarily braced by a wooden member of a suitable section.
After the trusses are placed in position, purlins and wind
bracings shall be fixed as soon as possible.
The ends of the truss which faces the prevailing winds shall be fixed holding
down bolts, and the other end kept free to move. In case of trusses of spans upto
10 m the free end of the truss shall be laid on lead sheet or steel plate as per design
and the holes for holding down bolts shall be made in the form of oblong slots so
as to permit the free movement of the truss end. For larger spans, the truss shall be
provided with bearing as per design.
4. Columns and stanchions shall be erected truly vertical with
necessary cross bracings etc. as per drawing and the base shall be
properly fixed with the foundation concrete by means of anchor
bolts etc. as per design.
5. Anchor bolts shall be placed in the concrete foundation. These
should be held in position with a wooden template. The anchor
bolts shall be provided with suitable timber mould or pipe sleeve
to allow for adjustment. The timber mould or pipe shall be
removed after initial set of concrete. The spaces left around
anchor bolts shall have a sloping channel leading to the side of
the pedestal and on the underside of the base plate to allow the
spaces being grouted up after the base plate is fixed in the
position alongwith the column footing. Grouting shall be of
cement mortar 1:3 (1 Cement 3 coarse sand) or as specified.
6. Bedding of Column, Stanchions, Etc. : Bedding shall not be carried
out until the steel work has been finally levelled, plumbed and
connected together. The stanchion shall be supported on steel
wedges and adjusted to make the column plumb. For multistoried
buildings, the bedding shall not be done until sufficient floor
beams are fixed in position. The base plates shall be wedged clear
of the bases by M.S. wedges and adjusted where necessary to
plumb the columns. The gaps under the base plates upto 25mm
shall then be pressure grouted with cement grouts.
With small columns, if permitted by the Engineer-in-Charge, the columns base

shall be floated on a thick cement grout on the concrete pedestal. The anchor bolts
holes in the base plate may be made about 10 to 15mm larger than the bolts. In
such cases suitable washers shall be provided.
APPENDIX I
PHYSICAL PROPERTIES OF REINFORCING BARS
(Para 4.3.2.2)
Nominal Ultimate Elongation
S.No. Type of Size of Characteristic tensile Composition of Gauge
Reinforcement Bars strength (yield stress of Steel length of
stress or 2 Conforming 5.65
(mm) percent proof (N/mm2) to IS No. (area)0.5
stress)
(N/mm2) (%)
(1) (2) (3) (4) (5) (6) (7)

5,6,8,10,
432 Mild Steel 250 410 IS:226-1975 23
(Part (Grade-I) 12,16,20
I)
1982
22,25,28
240 410 -- do -- 23
32,36,40
45,50
5,6,8,10
Mild Steel 225 370 Fe 410.0 (St 23
(Grade II) 12,16,20 42.0) of IS:
1977-1175
22,25,28
215 370 -- do -- 23
32,36,40
45,50
5,6,8,10
Medium tensile 350 540 (St. 55-HTW) 20
steel 12,16 of IS:961-
1975
20,22,25
340 540 -- do -- 20
28,32
36,40,45
330 510 - do - 20
50
6,8,10,12 C-0 30%
1786- High strength 415 (for Fe 10% more (Max.) 14.5
1985 deformed steel 16,18,20, 415) than the S-0.060%
actual 0.2
proof
22,25,28 stress P-0.060%
32,36,40, S&P-0.11%
45,50
C-0 30%
500 (for Fe 8% more 12
500) than the S-0.055%
actual 0.2 P-0.055%
proof
stress S&P-0.105%
1566- Hard-drawn (See note) As per IS: 432 - - -

1982 Steel fabric (Part II) 1982
Note- 1: Mild steel bars are supplied in the following grades:
1. Mild Steel Bars Grade-I : Steel or Mild steel reinforcement bars Grade-I shall be
manufactured and have the chemical composition in accordance with the requirements
of steel St-42 of IS: 226-1975 St-42-S shall be used for all the type of structures
including those subjected to dynamic loadings and where fatigue, wide fluctations of
stress, reversal of stresses and great restrain are involved as for example crane, gentry,
girders, road and railway bridges etc.
2. Mild steel bars grad II : Ordinary quality steel shall be manufactured and have the
chemical composition in accordance with the requirements of steel St-32-0 IS:1977-
1975. The grade II quality of steel designated as St-42-0 shall be used for structures,
not subjected to dynamic loadings, other than wind load, where welding is not
employed or/and structures not situated in earthquake zones or/and design has not
been based on Plastic Theory.
3. Ordinary Quality Steel Ordinary quality steel shall be manufactured and have the
chemical composition in accordance with the requirements of steel St-32-0 shall be
used for doors, windows, window frames, window bars, grills, steel gates, hand
grilling, fencing posts, tie bars etc.
2. Basically the material for deformed mild steel and medium tensile steel
bars is the same as for plain mild steel and medium tensile steel bars.
Therefore, the specifications for use of deformed bars has to be, as far
as possible, in line with the specification for plain mild steel and
medium tensile steel bars.
3. Basically the material for cold twisted steel bars is same as for plain or
deformed mild steel bars. The specification for use of cold twisted steel
bars shall therefore, be as far as possible, in line with the respective
mild steel bars.
4. Hand drawn steel wire fabrics shall be manufactured and have the
properties in accordance with the requirement of IS: 1566-1982 and
shall be used for floor slabs (hollow block, ribbed), for secondary
reinforcement in developing fire resistance and in some precast
concrete products like pipes.
APPENDIX II
ANCHORING AND SPLICING OF REINFORCING BARS
Copy of Design Series T.C. No. 24 (Issued vide No. 125/BODHI/R&C/TC11/89 dated
20.2.90)
(Para 4.3.5.1.2 & 4.3.5.1.6)
1. General : When an R.C.C. member is loaded, the transfer of force between concrete and
embedded steel reinforcement takes place only by virtue of the grip of bound between
the two materials. The bond between concrete and steel must be sufficient to make
them act jointly. In case the bond between the two materials is not proper and
adequates the R.C.C. member, when loaded, will fail as the steel reinforcement on
account of imperfect bond will slip and will not contribute to resist any stresses
developed in the member. The bond depends upon the grade of concrete, type and size
of reinforcing bars, the length of embedment of bars and the cover of concrete to the
reinforcement.
1. Development (Bond) Length :
2.1 For a safe design of R.C.C. member, it is necessary that the designed tension or
compression at any section in any reinforcing bar shall be balanced by the equal bond
strength developed by the sufficient length of the bar embedded in the concrete
beyond that section on either side. The length, thus, required is known as bond length
or development length.
Bond length or development length Ld (in mm) is given by the following expression.
Ld = C.K.N.
Where, C = Constant depending upon the grade of steel & nature of
stress (i.e., tension or compression).
K = Constant depending upon the grade of concrete.
N = Diameter of bar (O) in mm x maximum permissible
stress at
section in N/mm2. Value of C&K should be adopted from table A & B respectively.
TABLE A
Value of C
S.No. Type of Steel Nature of Stress
(Yield stress in Tensile Compressive

N/mm2)
1. Tor-steel (415) 1.0 0.80
2. Mild-steel (250) 1.40 1.12

TABLE B
VALUE OF K
Grade of concrete M15 M20 M25 M30 M35 M40
Value of K 0.30 0.22 0.20 0.18 0.16 0.15
2.2 Bars Bundled in Contract : The development length of each bar of bundled bars shall be
that for the individual bars as calculated in para 2.1, increased by 10% for two bars in
contract, 20% for three bars in contract, and 33% for four bars in contact.
3. Anchoring Reinforcing Bars :
3.1 Anchoring Bars in Tension : Hooks should invariably be provided for palin bars in
tension. Deformed bars may be used withou end anchorages provded development length
requirement is satisfied. In case, this requirement is not satisfied deformed bars may be
provided with end hooks. While calculating the anchorate values as specified in para 3.1.1
below should be adopted.
3.1.1. Bends & Hooks : Bend and hook should conform to shape and dimensions given in
Fig. 1 The anchorage value of bend and hooks should be considered as follows :-
(i) Bends : the achorage value of bend should be taken as 4 times the diameter of the bar for
each 450 bend subject to a maximum of 16 times the diameter of the bar.
(ii) Hooks :- The anchorage value of a standard U type hook should be equal to 16 times the
diameter of the bar.
3.2 Anchoring Bars in Compression : The anchorage length of straight bars in compression
should be equal to the development length of bars in compression as specified in para
2 above. The projected length of hook, and
straight lengths beyond bend, if provided, for a bar in compression should be
considered for development length.
3.3 Mechanical Devices for anchorage : Any mechanical or other device capable of
developing the strenght of the bar without damage to concrete may be used as
anchorage with the approval of the designer.
3.4 Anchoring Shear Reinforcement :

3.4.1 Inclined Bars : The development length shall be as for bars in tension, this length shall
be measured as under :-
(i) In tension zone, from the end of the sloping or inclined portion of the bars (See Fig
2(a) & (b).
(ii) In the compression zone from the mid depth of the beam, see Fig. 2(c).
2. Stirrups : In case of secondary reinforcement, such as stirrups and

transverse ties, complete development lengths and anchorages shall be
deemed to have been provided when the bar is bent through an angle of
atleast 90o round a bar of atleast its own diameter and is continued
beyond the end of curve for a length of atleast eight bar diameter.
Note : Thin concrete cover over the 90o hook in a stirrup may lead to spelling of cover
concrete as the 90o hook has a tendency to straighten out under over load. To
avoid this type of failure, a cover of atleast twice the dia of stirrup bar shall be
provided. Where this is impracticable, the hook shall have a 135o bend.
4. Reinforcement Splicing :
1. General arrangements and provisions : As far as possible, bars of full length as
per drawing should be used. In case this is not possible, over lapping in bars in
the manner prescribed below should be provided.
i. When practicable, over lapping bars should not touch each other, but be kept apart by
concrete between them by 25mm or 1.25 times the maximum size of the coarse
aggregate whichever is greater.
ii. When arrangement as per 4.1(i) above is not practicable overlapping bars should be
bound with annealed steel wire not less than 0.9mm (20 SWG) thick twisted tight.
iii. Splices in tension zone of flexural members should, as far as possible:-
1. Be away from the sections of maximum stress and be staggered.
2. Should not be at sections where the bending moment is more than 50 percent
of the moment of resistance and not more than half the bars shall be spliced at
a section.
iv. In tension zones, where more than one-half of the bars are spliced at a section or
where splices are made at points of maximum stress, special precautions should be
taken, such as increasing the length of lap as per Table C or using spirals or closely
spaced stirrups around the length of the splice.
Table C Percentage increases in Lap length
Splice stress (percentage of designed Percentage of bars spliced at one point

stress).
50 or less More than 50
(a) 50% or less. 0 30
(b) More than 50% 30 70

(v) In compression, zone, all the compression bars may be lapped at the same
section.
4.2 Lap Splices :
(a) Lap splices shall not be used for bars larger than 36 mm, for larger diameters bars may be
welded, in case where welding is not practicable, lapping of bars larger than 36 mm dia. may
permitted, in which case additional spirals should be provided around the lapped bars.
(b) Lap splices shall be considered as staggered if the centre to centre distance of the splices
is not less than 1:3 times the lap length calculated as described in para 4.2(c). The individual
splices of bars within the bundle should be staggered by 1.3 times the increased lap lengths as
per para 4.2(c) read with para 2.2
(c) Lap length including anchorage value of hook in flexible tension shall be Ld or 30 dia
whichever is greater and for direction tension 2 Ld or 30 dia. whichever is greater. The
straight length of the lap shall not be less than 15 dia. or 20 cm. (Dia. denotes diameter of
reinforcing bar and Ld denotes the development length as per para 2 suitably modified as per
para 4.1 (iv). Splices in tension members should be enclosed in spirals made of bars not less
than 6 mm diameter with pitch not more than 100 mm and the spliced bars should end in
hooks even in the case of ribbed or deformed bars.
(d) The lap length in compression shall be equal to the development length in compression,
calculated as described in para 2 but not less than 24.
(e) When bars of two different diameters are to be spliced, the lap length shall be calculated
on the basis of diameter of the smaller bar.
(f) When splicing of welded wire fabric is to be carried out, lap splices of wires shall be made
so that overlap measured between the extreme cross wires shall be not less than the spacing
of cross wires plus 10 cm ad detailed in Fig.-3.
4.3 Welded Splices : Welding should not usually be preferred in splicing of the bars, chiefly
because of the difficulty of detecting a faulty weld. In case it is unavoidable the
relevant IS:456-1978. IS: 2751-1979 & IS: 9417-1979 may be referred.
5. This circular supersedes Instructions and all other circulars and Technical Memorandum
issued on this subject in the past.
Sd/ (O.N. THAPAR) Sd/- (P.C. AGARWAL)
Engineer-in-chief
Chief Engineer BODHI, Bhopal W.R. Deptt. Bhopal (M.P.)
APPENDIX III
A NOTE ON RUST OVER REINFORCEMENT
(Para 4.3.6.1)
1. Some rust is not harmful to the bond between concrete and steel and no
benefits is gained by removing all the rust. However, any rust and mill
scale which is not firmly attached should be removed, to ensure the
development of good bond.
2. Rust increases the normal roughness of the steel surfaces and tends to
augment the holding capacity of the bar, but it may reduce the effective
area of the bar.
3. Usually normal handling is sufficient for removal of loose rust and
scale prior to embedment of reinforcement steel. However, in some
instances, it may be necessary to rub with a coarsely woven sack
(gunny) or use of wire brush.
4. Sand blasting etc. which were in vogue are not required. The procedure
of cleaning shall be as decided by the Engineer-in-Charge.
5. Bars that appear to have rusted beyond usefulness may be checked by
cleaning and weighing them for conformance with specifications.
APPENDIX IV
GUIDE LINES FOR SUBSTITUTION
1. Substitution by adjusting Bar Spacing :
1. Normally substitution should be on basis of adjusting the spacing of bars
according to available diameter of bar wherever possible as per formula given
below:-
Spacing or substituted bar of = Sx(da/do)2x(spacing of original bars
Available dia and grade of steel being substituted).
2. Where it is desired for direct substitution without change in spacing of bars,
the specified arrangement may be substituted either with single bar of higher
grade steel having equivalent area or with bundle of bars of same grade steel
rendering equivalent area as the case may be, the equivalent area may be
computed as per formula:
Required equivalent area = 1/Sx(Area of original bar or bars in a bundle).
Of available grade of steel
In formula given in 1.1 & 1.2 above, da = dia of available bar
do = dia of original bar
S = Constant to be obtained From
table 1.
TABLE I Value of S
Value of S
Case
Hydraulic Structure Non hydraulic structure
(i) Form M.S. to Tor. 1.300 1.360
(ii) Form Tor to M.S. 0.660 0.566
(iii) (a) From M.S. to M.S. 1.000 1.000
(b) From Tor to Tor 1.000 1.000

1.2.1 In case where only diameter of specified M.S. bars needs to be substituted with
deformed bars (Fe 415) without change in bar spacing, the following table 2 may be
used.
TABLE 2
Dia of M.S. Dia of deformed bar (grade- Fe 415)

bars
For tension For compression
Non Hydraulic Non Hydraulic

Hydraulic Hydraulic
1 2 3 4 5
10 8 10 8 8
12 10 12 10 12
16 10 2x10 2x10 2x10
18 2 x10 16 16 10+12 or 16
20 16 18 2+12or 18 2+21 or 18
22 18 or 2x12 20 or 12+16 20 20
25 20 22 22 or 2x16 22 or 2x16
28 22 25 or 2 x 16 16+18 or 25 16+18 or 25
32 25 2x20 18+20 or 28 18+20 or 28
36 28 32 or 20+22 2x22 or 32 2x22 or 32
40 32 2x25or 22+25 2x25 or 36 2x25 or 36

APPENDIX V
AREAS AND WEIGHTS OF STEEL SECTIONS ROUND AND DEFORMED
BARS
(Para 4.3.7.3)
Dia Weight Sectional Perimeter Dia Weight Sectional Perimeter

per metre area per metre Area
1 2 3 4 5 6 7 8
mm Kg Sq. cm Cm mm Kg. sq. cm Cm

5 0.154 0.196 1.571 20 2.47 3.14 6.286
6 0.222 0.283 1.886 22 2.98 3.80 6.914
8 0.395 0.503 2.514 25 3.85 4.91 7.857
10 0.617 0.785 3.143 28 4.83 6.16 8.800
12 0.888 1.13 3.771 32 6.31 8.04 10.050
16 1.58 2.01 5.029 36 7.99 10.2 11.314
18 2.00 2.54 5.657 40 9.85 12.6 12.571

Note : The unit weight given may be used as a guide. Actual weight of the lot of steel may be
used for working out unit weight for actual use/consumption.
APPENDIX VI
MECHANICAL PROPERTIES OF SRUCTURAL STEEL
(Para 4.4.1.1)
Steel Class of steel Nominal Tensile Yield Percentage

Designation project Thickness / dia. strength stress Min. Elongation
5.65 x (Gauge length)
(Area)
Mm Kgf / mm2 Kgf/mm2
Bend test only shall be required

410-530 250 23
ST-42-W & Plates, sections Below 6 upto & 410-530 230 23
STYLE=" (for examples, including 20
42-S angles, tees, over 20 upto 410-530 220 23
beams, channels, including 40
etc.) and flats over 40

Below 10 410-530 250 23
Bars (round, 10 upto &
square and including 20 410-530 230 23
hexagonal)
over 20

Below 6 410-530 250 23
ST-42-0 Plates, sections 410-530 240 23
(for example, 6 upto &
angels, tees, including 20 410-530 220 23
beams, channels, over 20 upto &
etc.) and flats. including 40
over 40

Below 10 410-530 250 23
Bars (round,
square and 10 upto & 410-530 240 23
hexagonal) including 20
over 20
Below 6
ST-32-0 Plates, sections 310-430 -- 26
(for example, 6 & above
angles, tees,
beams, channels,
etc.) and flats

Below 10
Bars (round 310-430 -- 26
square and 10 & above
hexagonal)
APPENDIX VII
CHEMIAL COMPOSITION OF STEEL
(Para 4.4.1.1)
Steel Designation Max. Percentage
Carbon Sulphur Phosphorous
ST-42-W 0.200 0.055 0.055
ST-42-S 0.23/0.25* 0.055 0.055
ST-42-0 -- 0.070 0.070
ST-32-0 -- 0.070 0.070

* - 0.23 for thickness or dia 20 mm & below 0.25 for thickness or dia over 20 mm.
APPENDIX VIII
HOLES FOR TURNED AND FITTED BOLTS
(Para 13.4.3.2.2)
Bolt diameter Hole diameter Bolt diameter Hole diameter
(1) (2) (3) (4)

1.6 1.8 (39) 42
2 2.4 42 45
(2.2) 2.6 (45) 48
2.5 2.9 48 52
3 3.4 (52) 56
(3.5) 4.0 (56) 62
4 4.5 (60) 66
(4.5) 5.0 64 70
5 5.5 (68) 74
6 6.6 72 78
(7) 7.6 (76) 82
8 9.0 80 86
10 11.0 (85) 91
12 14.0 90 96
(14) 16.0 (95) 101
16 18.0 100 107
(18) 20.0 105 112
20 22.0 110 117
(22) 24.0 (115) 122
24 26.0 120 127
(27) 30.0 125 132
30 33.0 (130) 137
(33) 36 140 147
36 39.0 (150) 158

Note : (1) All dimension are in milimeters.
(2) Diameters are to be treated as second preference.
5 SPECIFICATION OF PRESTRESSED STEEL
1. DESCRIPTION
Structural concrete containing prestressed steel reinforcement to introduce

precompression is termed as prestressed concrete.
The work shall be carried out in accordance with the drawing and these specifications
or as approved by the Engineer.Concrete and untensioned steel for the construction of
prestressed concrete members shall conform to the requirements of sections 5 and 8
for Structural Concrete and Steel Reinforcement respectively in so for as the
requirements of these Sections apply and are not specifically modified by
requirements set forth herein.
2. MATERIALS
All materials shall conform to section 5 except steel for

prestressing.The prestressing steel shall conform to either
of the following:Plain hard drawn steel wire conforming
to IS: 1785 (Part I) and IS: 1785 (Part II).Cold drawn
indented wire conforming to IS: 6003High tensile steel
bar conforming to IS: 2090Uncoated stress relieved
strands conforming to IS: 6006.
3. SHEATHING
1. The sheathing ducts shall be of the spiral-corrugated type. Unless otherwise

specified, the materials shall be Cold Rolled Cold Annealed (CRCA) Mild
Steel conforming to IS: 513 intended for mechanical treatment and surface
refining but not for quench hardening or tempering.
2. The material shall normally be bright finished. Either galvanized or lead-

coated mild steel strips shall be used.
3. The thickness of sheathing shall be as shown on the drawing, but shall not be
less than 0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts having internal
diameter of 50 mm, 75 mm and 90 mm respectively. For bigger diameter of
ducts, thickness of sheathing shall be based on recommendations of
prestressing system supplier or as directed by the Engineer-in-Charge.
4. The sheathing shall conform to the requirement as per tests specified in

Appendix - I.Where sheathing ducts joints ate unavoidable, such joints shall be
made slurry tight by the use of corrugated threaded sleeve couplers which may
be tightly screwed onto the side of the sheathing ducts.
5. The length of the coupler should not be less than 150 mm but should be
increased upto 200 mm where practicable. The joints between the ends of the
coupler and the ducts shall be sealed with adhesive sealing tape to prevent
penetration of cement slurry during concreting. The couplers of adjacent ducts
should be staggered wherever practicable. As far as possible, couplers should
not be located in curved zones.
6. The internal area of the sheathing ducts shall be in accordance with the
recommendations of the system manufacturer and shall be about three times
the area of the tendons. In case of 6T13, 12T13 and 19T13 sizes of tendons
comprising 12/32 mm dia strands, the inner diameter of the sheathing shall not
be less than 50 mm, 75 mm and 90 mm respectively or those shown in the
drawing, which ever is greater.
7. Where prestressing tendons are required to be threaded after concreting the

diameter of sheathing shall be about 5 mm larger than that required as above.
8. In severe environment, cables shall be threaded after concreting. In such cases

a temporary tendon shall be inserted, in the sheathing or the sheathing shall be
stiffened by other suitable method during concreting.
4. Anchorages
1. Anchorages shall be procured from authorised manufacturers only.
Anchorages shall conform to BS: 4447. Test certificates form a laboratory
fully equipped to carry out the tests shall be furnished to the Engineer-in-
Charge. Such test certificates shall not be more than 12 months old at the time
of making the proposal for adoption of a particular system for the work.
2. No damage anchorages shall be used. Steel parts shall be protected from
corrosion at all times. Threaded parts shall be protected by greased wrappings
and tapped holes shall be protected by suitable plugs until used. The anchorage
components shall be kept free from mortar and loose rust and other deleterious
coating.
3. Swages of prestressing strand and button heads of prestressing wire, where
provided shall develop a strength of at least 95 percent of the specified
breaking load of the strand or wire as the case may be. Where swaging / button
heading is envisaged, the contractor shall furnish details of his methodology
and obtain approval of the Engineer, prior to his taking up the work.
4. Untensioned steel reinforcement, around anchorages shall conform to the
details of prestressing system and as shown on the drawings.
5. TESTING OF PRESTRESSING STEEL AND

ANCHORAGES
1. All materials specified for testing shall be furnished free of cost and shall be
delivered in time for tests to be made well in advance of anticipated time of
use.
2. All wire, strand or bars to be shipped to the site shall be assigned a lot number
and tagged for identification purposes. Anchorage assemblies to be shipped
shall be like-wise identified.
3. All samples submitted shall be representative of the lot to be furnished and in
the case of wire or strand, shall be taken from the same master roll. The
Contractor shall furnished samples of at least 5.0 m length selected from each
lot for testing. Also, two anchorage assemblies, complete with distribution
plates of each size or types to be used shall be furnished alongwith short
length of strands as required.
6. WORKMANSHIP
6.1 Cleaning
Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other deleterious
substance.
Cleaning of the steel may be carried out by immersion in suitable solvent solutions, wire
brushing or passing through a pressure box containing carborudum powder. However,
the tendons shall not be brought to a polished condition.
6.2 StraighteningHigh tensile wire and strand shall be supplied in coils of sufficiently large
diameter such that tendons shall retain their physical properties and shall be straight
as it unwinds from the coil. Tendons of any type that are damaged, kinked or bent
shall not be used. The packing of prestressing wire/strand shall be removed only just
prior to making of cable for placement. Suitable stands shall be provided to facilitate
uncoiling of wires/sans without damage to steel. Care shall be taken to avoid the
possibility of steel coming into contact with the ground.
5. Positioning
7.1 Post-Tensioning
1. Prestressing tendons shall be accurately located and maintained in

position, both vertically and horizontally, as per drawings.
2. Tendons shall be so arranged that they have a smooth profile without

sudden bends or kinks.
3. The locationing of prestressed cables shall be such as to facilitate easy

placement and vibration of concrete in between the tendons. High
capacity tendon shall be used to reduce the number of cables thereby
eliminating the necessity of grouping. The selected profiles of the
tendons shall be such that their anchorage are not located in the top
deck surface. Where two or more rows of cables have to be used, the
cables shall be vertically in line to enable easy flow of concrete. The
clear vertical and horizontal distance between any two cables shall in
no case be less than 100 mm anywhere along the length of the
superstructure. Where precast segments are used, the clear distance
shall be at least 150 mm.
4. Sheathing shall be placed in correct position and profile by providing
suitable ladders and spacers. Such ladders may be provided at intervals
of approximately 1.0 m. Sheathing shall be tied rigidly with such
ladders/spacer bars so that they do not get disturbed during concreting.
5. The method of supporting and fixing shall be such that profile of

cables is not disturbed during vibrations, by pressure of wet concrete,
by workmen or by construction traffic.
6. Sheathing in which the permanent tendon will not be in place during

concreting shall have a temporary tendon inserted or shall be stiffened
by some other method of the approval of the Engineer-in-Charge. The
temporary tendon shall be pulled out before threading the permanent
tendon into place by a special threading machine or other contrivance.
7. Where possible tendons shall not be placed until immediately prior to

stressing. Tendons shall be handled with care to avoid damage or
contamination, to either the tendon or the sheathing. Any tendons
damaged or contaminated shall be cleaned or replaced.
8. Pre-Tensioning:
8.1 Prestressing steel shall be accurately located and maintained in position, both vertically
and horizontally, as per drawings.
8.2 Each anchorage device shall be set square to the line of action of the corresponding
prestressing tendon and shall be positioned securely to prevent movement during
concreting.
8.3 The anchorage device shall be cleaned to the satisfaction of the Engineer-in-Charge prior
to the placing of concrete. After concrete, any mortar or concrete which adheres to
bearing or wedging surface, shall be removed immediately.
9. Cutting
9.1 Cutting and trimming of wires or strands shall be done by suitable mechanical or flame
cutters. When a flame cutter is used, care shall be taken to ensure that the flame does
not come in contact with other stressed steel. The location of flame cutting of wire or
strand shall be kept beyond 75 mm of where the tendon will be gripped by the
anchorage or jacks.
9.2 In post-tensioning the ends of prestressing steel projecting beyond the anchorages, shall
be cut after the grout has set.
10. Protection of Prestressing Steel
1. Prestressing steel shall be continuously protected against corrosion, until
grouted. The corrosion protector shall have no deleterious effect on the steel or
concrete or on the bond strength of steel to concrete. Grouting shall conform
to these specifications or as directed by the Engineer-in-Charge.
2. In the case of external prestressing, steel shall be encased in suitable
polyethylene pipes before grouting.
11. Sheathing
1. The joints of all sheathing shall be watertight. Special attention shall be paid to
the junction at the anchorage end, where the sheathing must tightly fit on the
protruding trumpet end of anchorage and thereafter sealed preferably with heat
shrink tape, to make it water-proof.
2. The heat-shrink tape is supplied in the form of bandage rolls, which can be
used for all diameters of sheathing ducts. The bandage is coated on the
underside with a heat sensitive adhesive so that after heating the bandage
material shrinks on the sheathing duct and ensures formation of a leak proof
joint. The heating is effected by means of a soft gas flame.
3. The sheathing and all joints shall be water tight. Any temporary opening in the
sheathing shall be satisfactorily plugged and all joints between sheathing and
any other part of the prestressing system shall be effectively sealed to prevent
entry of mortar, dust, water or other deleterious matter. Sheathing shall be
neatly fitted at joints without internal projection or reduction of diameter.
4. Enlarged portions of the sheathing at couplings or anchorages shall be of
sufficient length to provide for the extension of the tendons.
12. Grout vents
12.1 Grout vents of atleast 20 mm diameter shall be provided at both ends of the sheathing
and at all valleys and crests along its length. Additional vents with plugs shall also be
provided along the length of sheathing such that the spacings of consecutive vents do
not exceed 20 m. Each of the grout vents shall be provided with a plug or similar
device capable of withstanding a pressure of 1.0 MPa without the loss of water, air
pressure or grout.
13. Anchorages
1. All bearing surfaces of the anchorages shall be cleaned prior to concreting and
tensioning.
2. Anchor cones, blocks and plates shall be securely positioned and maintained
during concreting such that the centre line of the duct passes axially through
the anchorage assembly.
3. The anchorages shall be recessed from the concrete surface by a minimum
cover of 100 m.
4. After the prestressing operation are completed and prestressing wires/strands
are cut, the surface shall be painted with two coats of epoxy of suitable
formulation having a dry film thickness of 80 microns per coat and entire
recess shall be filled with concrete or non-shrink/pre-packaged mortar or
epoxy concrete.
14. SUPERVISIONAll prestressing and grouting operations shall be undertaken by trained
personnel only. A representative of Engineer-In-Charge & of the prestressing system
shall be present during all tensioning and grouting operations and shall ensure,
monitor and certify their correctness.
15. TENSIONING EQUIPMENT
1. All tensioning equipment shall be procured from authorised manufacturers
only. Where hydraulic jacks are used, they shall be power-driven unless
otherwise approved by the Engineer-in-Charge. The tensioning equipment
shall satisfy the following requirements :
2. The means of attachments of the prestressing steel to the jack or any other
tensioning apparatus shall be safe and secure.
3. Where two or more wires/strands constitute a tendon, a single multipull
stressing jack shall be used which is capable of tensioning simultaneously all
the wires/strands of the tendon. Suitable facilities for handling and attaching
the multipull jack to the tendons shall be provided.
4. The tensioning equipment shall be such that it can apply controlled total force
gradually on the concrete without inducing dangerous secondary stresses in
steel, anchorage or concrete; and
5. Means shall be provided for direct measurement of the force by used of
dynamo-meters or pressure gauges fitted in the hydraulic system itself to
determine the pressure in the jacks. Facilities shall also be provided for the
linear measurement of the extension of prestressing steel to the nearest mm
and of any slip of the gripping devices at transfer.
6. All dynamo meters and pressure gauges including a master gauge shall be
calibrated by an approved laboratory immediately prior to use and then at
intervals not exceeding 3 months and the true force determined form the
calibration curve.
7. Pressure gauge shall be concentric scale type gauges accurate to within two
per cent of their full capacity. The minimum nominal size of gauge shall be
100 mm. The gauge shall be so selected that when the tendon is stressed to 75
per cent of its breaking load, the gauge is reading between 50 per cent and 80
per cent of its full capacity.
8. Suitable safety devices shall be fitted to protect pressure gauges against
sudden release of pressure.
9. Provision shall be made for the attachment of the master gauge to be used as a
check whenever requested for by the Engineer-in-Charge.
16. POST-TENSIONING
1. Tensioning force shall be applied in gradual and steady steps and carried out in
such a manner that the applied tensions and elongations can be measured at all
times. The sequence of stressing, applied tensions and elongations shall be in
accordance with the approved drawing or as directed by the Engineer-in-
Charge.
2. It shall be ensured that in no case, the load is applied to the concrete before it
attains the strength specified on the drawing or as stipulated by the
prestressing system supplier, whichever is more.
3. After prestressing steel has been anchored, the force exerted by the tensioning
equipment shall be decreased gradually and steadily so as to avoid shock to
the prestressing steel or anchorage.
4. The tensioning force applied to any tendon shall be determined by direct
reading of the pressure gauges or dynamo-meters and by comparison of the
measured elongation with the calculated elongation. The calculated elongation
shall be invariably adjusted with respect to the modulus of elasticity of steel
for the particular lot as given by the manufacturer.
5. The difference between calculated and observed tension and elongation during
prestressing operations shall be regulated as follows:(a) If the calculated
elongation is reached before the specified gauge pressure is obtained, continue
tensioning till attaining the specified gauge pressure, provided the elongation
does not exceed 1.05 times the calculated elongation. Of 1.05 times the
calculated elongation is reached before the specified gauge pressure is
attained, stop stressing and inform the Engineer-in-Charge.(b) If the calculated
elongation has not been reached at the specified gauge pressure, continue
tensioning by intervals of 5 kg/sq. c.m. until the calculated elongation is
reached provided the gauge pressure does not exceed 1.05 times the specified
gauge pressure.(c) If the elongation at 1.05 times the specified gauge pressure
is less than 0.95 times the calculated elongation, the following measures must
be taken, in succession, to determine the cause of this lack of discrepancy, (i)
Check the correct functioning of the jack, pump and leads.(ii) Detension the
cable. Slide it in its duct to check that it is not blocked by mortar which has
entered through holes in the sheath. Retension the cable if free.(iii) Re-
establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.If the required elongation is still not obtained, further
finishing operations such as cutting or sealing, should not be undertaken
without the approval of the Engineer-in-Charge.(d) When stressing from one
end only, the slip at the end remote from the jack shall be accurately measured
and an appropriate allowance made in the measured extension at the jacking
end.A complete record of prestressing operations along with elongation and
jack pressure data shall be maintained in the format given in Appendix II. The
number of stages of prestressing and grouting shall be reduced to a minimum,
preferably 2 in the case of simply supported girders.
17. GROUTING OF PRESTRESSED TENDONSGrouting shall conform to Appendix III.
A record of grouting operations shall be maintained in the format given in Appendix IV.18.
PRE-TENSIONING
18.1 General : The planning and construction aspects of the tensioning bed, tensioning
bench, abutments at location of anchorage, steam curing system, formwork of the
concrete elements and arrangements for de-moulding, lifting, stacking and
transportation of the pre-tensioned concrete elements are all specialized items and
shall be entrusted to engineers specifically experienced in this type of work.
19. Stressing Bed for Pre-tensioning
1. The abutments and bed for pre-tensioning of tendon shall be designed to
withstand the total tensioning force.
2. A notice shall be displayed adjacent to the stressing bed showing the
maximum tensioning force permitted.
3. Where concrete elements are cast and prestressed individually, the stressing
bench or moulds shall be rigid enough to sustain the reaction of the
prestressing force without distortion.
4. In the long line method of prestressing, sufficient locator plates should be
distributed throughout the length of the bed to ensure that the wires are
maintained in their proper position during concreting. The moulds shall be free
to slide in the direction of their length and thus permit the transfer of the
prestressing force to all the concrete elements along the whole line.
5. Sufficient space shall be left in between the ends of concrete elements to
permit access for cutting the strands/wires after transfer. Hold-downs or
deflectors shall be used for holding or deflecting the tendons in required
position firmly. Deflectors which are in contact with the tendon shall have a
diameter not less than the tendon or 15 mm, whichever is greater.
6. The tensioning force required to be applied as stated on the drawings shall be
the force remaining in the strands/wires after all strands/wires have been
anchored to the abutments of the stressing bed and after the anchorage slip has
already taken place. The tensioning force shall be determined by direct reading
of the pressure gauges or dynamo-meters and by the measured elongation after
slip.
7. The contractor shall submit method of tensioning the tendons including the
arrangement and layout of prestressing beds and all tendon deflection points to
the Engineer-in-Charge for approval before manufacture commences.
8. The contractor shall carry out trial stressing operations to establish the
frictional resistance offered by the hold-downs and the slip during anchoring.
9. Where sheathing of pre-tensioning tendons is required to prevent bond over a
specified length, it shall consist of plastic tubing or other material approved by
the Engineer and shall be of a quality, diameter and thickness such that bond
shall be effectively prevented. The tubing shall be fastened to the tendon in
such a manner that cement mortar cannot enter. The Engineer may order that
the pull-in of the tendon be measured during the transfer of prestress.
10. The Contractor shall also submit calculations showing that the hold-downs
have been designed and constructed to withstand concentrated loads resulting
form the application of the tensioning force.
20. Tensioning Procedure
20.1 The tensioning of the wires and strands shall be done not too much in advance of
concreting.
2. The tensioning force shall be applied gradually and uniformly.

3. In order to remove slack and to lift tendons off the bed floor, an initial force
approved by the Engineer shall be applied to the tendons. Allowance shall be
made for this force in calculating the required elongation.
4. Tendons shall be marked for measurement of elongation after the initial force
has been applied. When required by the Engineer-in-Charge, tendons shall be
marked at both the jacking end and dead end of the stressing bed and at
couplers if used so that slip and draw-in may be measured.
5. Where deflected strands have been specified the Engineer-in-Charge may

direct the elongation or strain gauge measurement be taken at various
positions along the tendon to determine the force in the tendon at those
positions.
21. Transfer of Prestress

1. While the process of tensioning can be accomplished by means of hydraulic
jacks, some positive mechanical means shall be provided to maintain the
tension during the entire period between the tensioning of the wires/strands
and transfer of the prestressing force to the concrete element.
2. Transfer of prestress shall not proceed until the Engineer-in-Charge has
approved the proposed method. Tendons and deflection devices shall be
released in such a pre-determined order that unacceptable tensile stresses are
not induced in the concrete.
3. Prior to transfer of the force to the units, all tendons shall be tested for
tightness and any loose tendon shall be reported to the Engineer-in-Charge
who will decide whether the units affected shall be rejected.
4. The Engineer-in-Charge may require that tendon be marked at each end of any
unit to allow measurement of the pull-in of the concrete.
5. Tendons shall be released gradually and preferably simultaneously.
6. Under no circumstances shall tendons be cut while under tension.
7. On completion of the transfer of prestress, the projecting lengths of tendon
shall be cut off flush with the end surface of the unit, unless otherwise shown,
by a method approved by the Engineer-in-Charge.
8. In no case shall the transfer of prestressing force to the concrete elements take
place before concrete attains the strength specified in the drawings. To
determine the specified strength, additional cube testing shall be undertaken at
the Contractors cost. In case steam curing is employed, the cubes shall be
placed in the same environment as the concrete elements to obtain an accurate
assessment of concrete strength at the time of transfer.
9. The sequence of transfer of prestressing force shall be done strictly as
indicated in the drawings and ensuring that eccentricities of the prestressing
force in the vertical and horizontal directions of the concrete element is a
minimum during the entire sequence.
10. The maximum slip of any tendon during transfer shall not exceed 3 mm at any
end of the concrete element. In case this slip is exceeded, the concrete element
in question shall be rejected.
22. Protection of Ends
1. The exposed ends of the tendon and the concrete surface of the ends of the
units shall be wire brushed clean of all rust, loose mortar, grease and dirt.
2. The exposed ends of the tendons and concrete surface within 50 mm of
tendons shall be then abraded to provide a clean sound surface. An epoxy tar
paint suitably formulated to give a dry film thickness of 80 microns per coat
shall then be immediately applied over the ends of the tendons unless
otherwise directed.A second coat of paint shall be applied prior to the drying
out of the first coat.
23. SAFETY PRECAUTIONS DURING TENSIONING
23.1 Care shall be taken during tensioning to ensure the safety of all persons in the vicinity.
23.2 Jacks shall be secured in such a manner that they will be held in position, should they
lose their grip on the tendons.
23.3 No person shall be allowed to stand behind the jacks or close to the line of the tendons
while tensioning is in progress.
23.4 The operations of the jacks and the measurement of the elongation and associated
operations shall be carried our in such a manner and form such a position that the
safety of all concerned is ensured.
23.5 A safety barrier shall be provided at both ends to prevent any tendon, which might
become loose from recoiling unchecked.
23.6 During actual tensioning operation, warning signs shall be displayed at both ends of the
tendon.
23.7 After prestressing, concrete shall neither be drilled nor any portion cut nor chipped away
nor disturbed, without express approval of the Engineer.
23.8 No welding shall be permitted on or near tendons nor shall any heat be applied to
tendons. Any tendon which has been affected by welding, weld spatter or heat shall be
rejected.
24. TRANSPORTATION AND STORAGE OF UNITS
1. Precast girders shall be transported in an upright position. Points of support
and the direction of reactions with respect to the girder shall approximately be
the same during transportation, and storage as when the girder is placed in
final position.
2. When members are to be stacked, they shall be firmly supported at such
bearing positions as will ensure that the stressed induced in them are always
less than the permissible design stresses. Further, inclined side supports shall
be provided at the ends and along the length of a precast girder to prevent
lateral movements or instability.
3. Care shall be taken during storage, hoisting and handling of the precast units
to prevent their cracking or being damaged. Units damaged by improper
storing or handling shall be replaced by the Contractor at his expense.
25. TOLERANCE
25.1 Permissible tolerance for positional deviation of Prestressing tendons shall be limited to
the following:
a) Variation from the specified horizontal profile : 5mm
b) Variation from the specified vertical profile : 5mm
c) Variation from the specified position in member : 5mm
26. TESTS AND STANDARDS OF ACCEPTANCE
26.1 The materials shall be tested in accordance with these Specifications and shall meet the
prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.
Appendix I
TEST ON SHEATHING DUCTS
All test specified below shall be carried out on the same sample in the order given below.
At least 3 samples for on lot of supply (not exceeding 7000 meter length) shall.
The tests are applicable for sheathing transported to site in straight lengths where test/testing
cable is threaded inside the sheathing prior to concreting. There tests are applicable for
sheathing not for coiled cable and transported to site as a assembled not for sheathing ducts
placed in position without threading of prestressing cable a concreting.
(A) WORKABILITY TEST :
A test sample 1100mm long is soldered to a fixed base plate with a soft solder (Fig.F-1) The
sampel is then bent to a radius of 1800 mm alternately on either side to 3 cycles.
Thereafter the sealing joints will be visually inspected to verify that no failure/fixing has
takne place.
(B) TRANSERVE LOAD RATING TEST
The test ensures that stiffness of the sheathing is sufficient to prevent permanent portion
during site handling.
The samples is placed on a horizontal support 500 mm long so that the sample is sorted at all
points of outwards corrugations.
A load as specified in Table 1 is applied gradually at the centre of the supported on through a
contract surface 12mm long. It shall be ensured that the load is applied approximately at the
centre of two corrugations. Fig. 1800/1-2. The load as specified is fixd in increments.
TABLE 1
(mm) 225-35 35-45 45-55 55-65 65-75 75-85 85-90
(N) 250 400 500 600 700 800 1000

The sample is considered acceptable if the permanent deformation is less than 5 per m. of the
diameter of the sheathing.
(C) TENSION LOAD TEST
A test specimen is subjected to a tensile load. The hollow core is filled with a wooden door
piece having a diameter of 95 per cent of the sample to ensure dr profile during test loading.
Fig. 1800/1-3.
A coupler is screwed on and the sample loaded in increments, till reaching the load specified
in Table 2. If so deformation of the joints nor slippage of couplers is noticed, All test shall be
considered satisfactory.
TABLE 2
(mm) 25-35 35-45 45-55 55-65 65-75 75-85 85-90
(N) 300 500 800 1100 1400 1600 1800

(D) WATER LOSS TEST
The sample is sealed at one end. The sample is filled with water and after sealing, the end is
connected to a system capable of applying a pressure of 0.05 MPs. Fig.- 1800/-1-4, and kept
constant for 5 minutes using a hand pump with pressure gauge or stand pipe system can be
used.
The sample is acceptable if the water loss does not exceed 1.5% of the volume.
Fig 1800/I-4:Dimension are in mm
High tentile steel (UTS) . kg/cm2 Last Date of concreting
..
Cube Strength: at 28 days . kg/cm2 Date of Prestressing
.. Guages
Max. Jack pressure not to exceed under any circumstance kg/cm2
Column 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 2021 22 23 24 25
s1
Gauge InitialTotalDevia Net Devia Exce

Gauge
mark elongelong tion elong tion ss or
mark
readings ation ationc1-c7 ation after short
reading of
Cable of uptoc7=c5 mm c8=e7draw- fall
Calculate extension
stressin extensio Reading at
100 - -S in c2- in
d in mm at Slip (draw-in)
g n in mm instant of
kg/cmc3+c6 mm e8 devi
elongatio the mm
sequenc at the locking 2 mm ation
n mm pressure
e pressure c6=(C after
of
of 4-C3) draw
200kg/cm
100kg/c mm in
2
m2 (c2-
c8x
SequCabBefoBefoABC3-ABC4-APABPBC5= ImmedAfterTotal 100)
ence le re re A 1 1 A1 2 kg/ 2 Kg/A2 iately 24 Dra / c2
MKdrawdraw + + mmcmmmcm + after Hrs. w-
D ing 1ing 2 B B1 2 2 B2 lockin in
mm g
SASBSASBSaS
A+
SB+
SA1
+
Sb2
Signature of Officers present during prestressing Client Contraction System supporte

APPENDIX III
SPECIFICATIONS FOR GROUNTING OF POST-TENSIONED CABLES IN
PRESTRESSED CONCRETE.
1. GENERAL
1.1 The recommendations cover the cement grouting of post-tensioned tendons of prestressed
concrete members of bridges. This also covers some of the essential protective measures to be
adopted for minimizing corrosion in PSC Bridges.
1.2 The purpose of grouting is to provide permanent protection to the post-tensioned steel
against corrosion and to develop bond between the prestressing steel and the surrounding
structural concrete. The grout ensures encasement of steel in an alkaline environment for
corrosion protection and by filing the duct space, it prevents water collection and freezing.
2. MATERIALS
2.1 Water
Only clean potable water free from impurities conforming to section 1000 shall be permitted.
No sea or creek water is to be used at all.
2.2 Cement
Ordinary Portland cement should be used for preparation of the grout. It should be as fresh as
possible and free of any lumps. Pozzolana cement shall not be used.
2.3 Sand
It is not recommendation to use sand for grouting of prestressing tendons. In case the internal
diameter of the ducts exceeds 150mm, use of sand may be considered Sand, used, shall
conform to IS:383 and shall pass through IS Sieve No. 150. The weight of sand in the grout
shall not be more than 10 per cent of the weight of cement, unless proper workability can be
ensured by addition of suitable plasticizers.
2.4 Admixtures
Acceptable admixtures conforming to IS : 9102 may be used if tests have shown that their use
improves the properties of grout, i.e. increasing fluidity, reducing bleeding, entraining air or
expanding the grout. Admixtures must not contain chlorides, nitrates, sulphides, sulphates or
any other products which are likely to damage the steel or grout. When an expanding agent is
used, the total unrestrained expansion should not exceed 10 per cent. Aluminium powder as
an expanding agent is not commended for grouting because its long terms effects are not free
from doubt.
2.5 Sheathing
2.5.1 For specifications of sheathing, section 1800 may be referred.
2.5.2 Grout openings or vents.
a) All ducts should have grout openings at both ends. For this purpose special openings
should be provided where such openings are not available at end an-chorages. For draped
(curved) cables vents shall be provided at all crown and valley points. It is a good practice to
provide additional air vents at suitable intervals not exceeding 20m. All grout openings or
vents should include provisions for preventing grout leakage.
b) Standard details of fixing couplers, inlets, outlets and air vents to the duct/ anchorage shall
be followed as recommended by the supplier of the prestressing system.
2.5.3 Ducts should be securely fastened at close intervals. All unintended holes or openings in
the duct must be repaired prior to concrete placing. The joints of the couplers and the
sheathing should be made water proof by use of adhesive tape or similar suitable system
capable of giving leak proof joints. Grout openings and vents must be security anchored to
the duct and to either the forms or to reinforcing steel to prevent displacement during
concreting operations due to weight, buoyancy and vibrations.
2.5.4 Ducts require very careful handling as, being of thin metal, they are susceptible to
leakage due to corrosion in transit or storage, by tearing/ripping in handling particularly when
placed adjoining to reinforcing steel, by pulling apart at joints while inserting tendons prior to
concreting, or by accidental puncturing while drilling for form ties/inserts. Ducts are also
liable to damage by rough use of internal vibrator and sparks from welding being done close
by.
3. EQUIPMENT
3.1 Grout Mixer and Agitator
It is essential that the grout is maintained in a homogenous state and of uniform consistency
so that there is no separation. The mixer should have an additional storage device with an
agitator to keep the grout moving continuously before it is pumped in the duct. Positive
reciprocating type grout pumps should be used.
3.2 Grout Pump
The pump should be a positive displacement type and should be capable of ejecting the grout
in a continuous operation and not by way of pulses. The grout pump must be fitted with a
pressure gauge to enable pressure of injection to be controlled. The maximum pressure at
which grout should be pumped shall be 0.3 MPa and the grout pump must have a relief
arrangement for bypass of the grout in case of built up of pressure beyond 1 MPa The
capacity of the grout pump should be such as to achieve forward speed of grout of around 5
to 10 meters per minute. The slower rates are referable as they reduce the possibility of
occurrence of voids. If the capacity of the pump is large, it is usual to grout two or more
cables simultaneously through a common manifold.
Use of hand pump for grouting, is not recommended . Use of compressed air operated
equipment for injection is prohibited, as it is likely that there will be some air trapped in
grout.
3.3 Water Pump
Before commencement of grouting, a stand by direct feed high pressure water pump should
be available at site for a emergency. In case of any problem in grouting the ducts, such pump
shall immediately be connected to the duct and all grout flushed by use of high pressure water
flushing. It is therefore, necessary to have adequate storage of clean potable water for
operation of the water pump for such emergencies.
3.4 Grout Screen
The grouting equipment should contain a screen having a mesh size of 106 micron size of
150 microns if sand is used). Prior to introduction into the grout pump, the grout should be
passed through such screen. This screen should be easily accessible for inspection and
cleaning. This screen should be easily accessible for inspection and cleaning.
3.5 Connection and air Vents.
Standard details of fixing inlets, outlets and air vents to the sheathing and/or anchorage
should be followed as recommended by specialist supplier of the system of prestressing. In
general, all connections are to be of the Quick Couple type and at change of diameters
suitable reducers are to be provided.
4. PROPERTIES OF THE GROUT
4.1 Water/cement ratio should be as low as possible, consistent with workability. This ratio
should not normally exceed 0.45.
4.2 Before grouting, the properties of the grout mix should be tested in a laboratory
depending on the facilities available. Tests should be conducted for each job periodically. The
recommended teset is described below.
4.3 Compressive Strength
The compressive strength of 100 mm cubes of the grout shall not be less than 17 MPa at 7
days. Cubes shall be cured in a moist atmosphere for the first 24 hours and subsequently in
water. These tests shall be conducted in advance to ascertain the suitability of the grout mix.
5. MIXING OF GROUT
5.1 Proportions of materials should be based on field trials made on the grout before
commencement of grouting, but subject to the limits specified above. The materials should be
measured by weight.
5.2 Water should be added to the mixer, first followed by Portland cement and sand, if used.
Admixture if any, may be added as recommended by the manufacturer.
5.3 Mixing time depends upon the type of the mixer, but will normally be between 2 and 3
minutes. However, mixing should be for such a duration as to obtain uniform and thoroughly
blended grout, without excessive temperature increase or loss of expansive properties of the
admixtures. The grout should be continuously agitated until it is injected.
5.4 Once mixed, no water shall be added to the grout to increase its fluidity.
5.5 Hand mixing is not permitted.
6. GROUTING OPERATIONS
6.1 General
(a) Grouting shall be carried out as early as possible but not later than 2 weeks of stressing a
tendon. Whenever this stipulation cannot be complied with for unavoidable reasons,
adequate
temporary protection of the steel against corrosion by methods or products which will
not impair the ultimate adherence of the injected grout should be ensured till grouting.
The scaling of the anchorage ends after concreting is considered to be a good practice
to prevent ingress of water. For structures in aggressive environment, sealing of the
anchorage ends is mandatory.
Notes :
i) Application of some patented water soluble oils for coating of steel/VPI powder
injection/sending in of hot, dry, oil-free compressed air through the vents at frequent intervals
have shown stone good results.

ii) Some of the methods recommended for scaling of anchorages are to seal the openings with
bitumen impregnated gunny bag or water proof paper or by building a brick pedestal
plastered
on all faces enclosing the exposed wires outside the anchorages.
iii) Any traces of oil if applied to steel for preventing corrosion should be removed before
grouting operation.
iv) Ducts shall be flushed with water for cleaning as well as for wetting the surfaces of the
duct walls. Water use for flushing should be of same quality as used for grouting. It
may, however, contain about 1 percent of slaked lime or quick lime. All water should
be drained thorough the lowest vent pipe or by blowing compressed air through the
duct.
v) The water in the duct should be blown out with oil free compressed air.
Blowing out water from duct for cables longer than 50 m draped up at both ends by
compressed air is not effective, outlet/ vent provided at or near the lowest point shall be used
to drain out water from duct.
vi) The connection between the nozzle of the injection pipe and duct should be such that air
cannot be sucked in.
vii) All outlet points including vent openings should be kept open prior to commencement of
injection grout.
viii) Before grouting, all air in the pump and hose should be expelled. The suction circuit of
the
pump should be air-tight.
6.2 Injection of Grout
a) After mixing the grout should be kept in continuous movement.
b) Injection of grout must be continuous and should not be interrupted.
c) For vertical cable or cables inclined more than 60 degrees to the horizontal, injection
should be effected from the lowest anchorages or event of the duct.
d) The method of injection should ensure complete filling of the ducts. To verify this, it is
advisable to compare the volume of the space to be filled by the injected grout with the
quantity of grout actually injected.
e) Grouting should be commencement initially with a low pressure of injection of upto 0.3
MPa
increasing it until the grout comes out at the other end. The grout should be allowed to flow
freely from other end until the consistency of the grout at this end is the same as that of the
grout at the injection end. When the grout flows at the other end, it should be closed off and
building up of pressure commenced. Full injection pressure at about 0.5 MPa shall be
maintained for at least one minute before closing the injection pipe. It is recommended for at
least one minute before closing the injection pipe. It is recommended practice to provide a
stand pipe at the highest point of the tendon profile to hold all water displayed by
sedimentation or bleeding. If there is a built up of pressure much in excess of 1 MPa without
flow of grout coming at the other end, the grouting operation should be discontinued and the
entire duct flushed with high pressure water. Also, the bypass system indicated in para 3.2
above is essential for further safety.
f) In the case of cables draped downwards e.g. in cantilever construction simultaneous
injection
from both ends may be adopted Fig. 1800/III-1
g) Grout not used within 30 minutes of mixing should be rejected.
Appendix I
TEST ON SHEATHING DUCTS
All test specified below shall be carried out on the same sample in the order given below.
At least 3 samples for on lot of supply (not exceeding 7000 meter length) shall.
The tests are applicable for sheathing transported to site in straight lengths where test/testing
cable is threaded inside the sheathing prior to concreting. There tests are applicable for
sheathing not for coiled cable and transported to site as a assembled not for sheathing ducts
placed in position without threading of prestressing cable a concreting.
(A) WORKABILITY TEST :
A test sample 1100mm long is soldered to a fixed base plate with a soft solder (Fig.F-1) The
sample is then bent to a radius of 1800 mm alternately on either side to 3 cycles.
Thereafter the sealing joints will be visually inspected to verify that no failure/fixing has
taken place.
(B) TRANSERVE LOAD RATING TEST
The test ensures that stiffness of the sheathing is sufficient to prevent permanent portion
during site handling.
The samples is placed on a horizontal support 500 mm long so that the sample is sorted at all
points of outwards corrugations.
A load as specified in Table 1 is applied gradually at the centre of the supported on through a
contract surface 12mm long. It shall be ensured that the load is applied estimately at the
centre of two corrugtions. Fig. 1800/1-2. The load as specified is fed in increments.
TABLE 1
(mm) 225-35 35-45 45-55 55-65 65-75 75-85 85-90
(N) 250 400 500 600 700 800 1000

The sample is considered acceptable if the permanent deformation is less than 5 per m. of the
diameter of the sheathing.
(C) TENSION LOAD TEST
A test specimen is subjected to a tensile load. The hollow core is filled with a wooden door
piece having a diameter of 95 per cent of the sample to ensure dr profile during test loading.
Fig. 1800/1-3.
A coupler is screwed on and the sample loaded in increments, till reaching the load specified
in Table 2. If so deformation of the joints nor slippage of couplers is noticed, All test shall be
considered satisfactory.
TABLE 1
(mm) 25-35 35-45 45-55 55-65 65-75 75-85 85-90
(N) 300 500 800 1100 1400 1600 1800

h) Disconnection is facilitated if a short length of flexible tube connects the duct and injection
pipe.
7. PRECAUTIONS AND RECOMMENDATIONS
FOR EFFECTIVE GROUTING
a) In cold and frosty weather, injection should be postponed, unless special precautions are
taken.
If frost is likely to occur within 48 hours after injection, heat must be applied to the
member
and maintained for at least 48 hours after injection so that the temperature of the grout
does
not fall below 5 degrees Celsius. Prior to commencement of grouting. Care must be
taken to
ensure that the duct is completely free of frost/ice by flushing with warm water, but
not with steam.
b) The temperature of the grout shall not exceed 25 degrees Celsius. For increasing the
workability of grout, its temperature may be lowered by use of chilled water or by
putting ice outside the grout storage container.
c) When the cables are threaded after concreting, the duct must be temporarily stiffened
during concreting by inserting bunch of strands, wires or reinforcement or a rigid
PVC pipe or any
other suitable method.
d) During concreting, care shall be taken to ensure that the sheathing is not damaged Needle
vibrators shall be used with extreme care by well experienced staff only, to ensure
against such damage.
e) It is a good practice to more the cables in both directions during the concreting
operations.This can easily be done by light hammering the ends of the wires/strands
during concreting. It is also advisable than 3 to 4 hours after concreting the cable
should be moved both ways through a distance of about 20 cms. With such
movement, any leakage of mortar which has taken place in spite of all precautions,
loses bond with the cables, thus reducing the chance of blockages.
This operation can also be done by fixing prestressing jacks, at one end pulling the
entire cable and then repeating the operation by fixing the jack at the other end.
f) The cables to be grouted should be separated by as such distance as possible.
g) In case of stage prestressing, cables tensioned in the first stage should not remain
ungrouted till all cables are stressed. It is good practice, while grouting any duct in
stage prestressing, to keep all; the remaining ducts filled up with water containing 1
percent lime or by running water through such ducts till the grout has set. After
grouting the particular cable, the water in the other cables should be drained and
removed with compressed air to prevent corrosion.
h) Care should be taken to avoid leaks from one duct to another at joints of precaust members
in particular.
i) End faces where anchorages are located are vulnerable points of entry of water. They have
to be necessary protected with an effective barrier. Recesses Should be packed with
mortar concrete and should preferably be painted with water proof paint.
j) After grouting is completed, the projecting portion of the vents should be cut off and the
face protected to prevent corrosion.
VOLUME III
SECTION - 10
ROAD WORKS
INDEX
TENDER DOCUMENT 49
TURNKEY TENDER 49
2SURVEY 58
4FINAL REPORT 68
APPENDIX I 69
ETC. 69
APPENDIX II 71
71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
APPENDIX IV 77
1 GENERAL 162
2. STANDARDS 162
3. SCOPE: 163
4. PLANNING: 163
EMBANKMENT 165
13 EXCAVATION 169
16DEWATERING 171
24MATERIAL 178
29DOWEL BANKS: 186
33TOE DRAINS : 187
35SIDE DRAINS: 188
37PROTECTION: 188
42ROCK TOE 192
43 BORROW AREAS 195
46 BORROW PITS 196
53BLASTING 198
62 TURFING 203
1 GENERAL 139
2. STANDARDS 139
3. SCOPE: 140
4. PLANNING: 140
EMBANKMENT 142
66 EXCAVATION 146
69DEWATERING 148
77MATERIAL 155
82DOWEL BANKS: 163
86TOE DRAINS : 164
88SIDE DRAINS: 165
90PROTECTION: 165
95ROCK TOE 169
96 BORROW AREAS 172
99 BORROW PITS 173
106BLASTING 175
115 TURFING 180
1 GENERAL 163
GATES 163
5SCOPE 165
(GATES) 165
10 PAINTING 172
INSTALLATION 177
1. REFERENCES : 303
2. TERMINOLOGY 305
4 ANCHORAGES 334
1 INTRODUCTION 256
8SURFACE DRAINS 258
11 SHOULDER 263
13 INTRODUCTION 274
14PRE-REQUISITE 274
SECTION - 10 : ROAD WORK
CONSTRUCTION AND SPECIFICATIONS
1 Introduction
1.1 The performance of roads is directly linked with quality of construction.
Road construction techniques have been upgraded recently and use of
new and alternate materials have been advocated for all type of roads.
It is logical to see that the purpose of road construction is to provide a
firm, durable and even surface of the pavement, which could stand the
stress imparted due to traffic and climatic conditions. The road
construction activity starts for earthwork for embankment and
completes with high quality surface finish with bituminous or concrete
construction. Each component of the road has appropriate construction
requirements and specification to be followed. This Chapter deals with
details of construction techniques and specifications for various
pavement course involving use of traditional as well as alternate and
locally available materials for all-weather roads.
2. Materials and source:

1. The quality of materials, lead to the borrow areas and climatic
conditions are key factors for cost effective construction.
3. Construction Techniques:
1. Conventional construction methods are typically labour based
and most of the construction operations are done manually. In
case of mechanized method of construction, most of the
operations are done with machines like grader, bulldozer, and
paver, etc. Vibratory roller may also be used for compaction. The
selection of construction methodology will be based on various
considerations. No doubt, a modern mechanized method will lead
to larger and faster output and will also help in maintaining the
better quality of construction.
2. The construction of roads in some areas requires extensive

blasting and the roads have to be carved through very steep and
vertical rock faces. Thus exclusive dependence on manual labour
for work in hilly areas has associated safety hazards.
4. Machinery and tools:

1. In India, road construction activities are accomplished in various
stages. The tools, appliances and equipment required for different
construction activities may also be classified as manual and
mechanised method. Most of the tools and appliances used by
manual labour for various phases of construction are
conventional tools and appliances common to all the activities and
phases of construction. Special tools, appliances and equipment
are also used for special construction activities like bituminous
work and construction of concrete road, etc. Some
machines/equipments, like, dozers, compressors, crushers, loader
and load carriers are also common to most of the construction
activities where mechanised methods are adopted. The list of tools
appliances and equipment required for semi mechanized method
is given in Appendix I. On major projects, the work of bulky
and repetitive nature can be done more economically and
efficiently by well-designed machines. Practically every operation
in construction of roads can be performed by different types of
equipment, but under and given set of conditions only a
particular type of machine would be most effective. Thus
selection of machine for any particular phase of construction
requires detailed study about brand, model and specification of
the various equipment available and their suitability for
particular phase of construction. IRC publication MOST
Handbook on Road Construction Machinery, may be referred
for further details. The surface evenness and compaction are
generally checked with camber board/template, straight edge,
depth gauge and density measuring kit. Recently unevenness
indicator and nuclear density meters have also been introduced
for exercising quality control is given in Appendix - II.
5. Embankment and Subgrade

1. Construction of embankment and preparation of subgrade are
part of earthwork. The main activities associated with
construction are, soil survey and identification of borrow areas,
construction of embankment and subgrade. The details are
discussed in the following paragraphs.
6. Embankment with conventional earth:

1. The height of road embankment depends on the highest flood
level (HFL) in area generally 0.6 to 1.0 m height above HFL is to
be ensured. The embankment may be constructed by rolling in
relatively thin layers. Each layer should be compacted by suitable
roller to a desired density before the next layer is placed.
Compaction should be carried out at optimum moisture content
so as to take advantage of maximum dry density using a specified
compacting effort and equipment. The thickness of each
compacted layer may vary between 150 to 300 mm depending
upon various factors such as soil type, compaction equipment and
specifications. Using ordinary 8-10 tonne rollers, compacted
thickness shall not exceed 150 mm IRC:36, IRC:56, IRC:75 may
be referred for construction of embankments.
2. For identification of suitable borrow area, samples may be

collected at different depths from the test pits dug open in borrow
areas from where the embankment material is to be obtained.
The soil for processing should be brought to proper moisture
content, so that the needed degree of compaction can be imparted
with least effort. Needed amount of water should be quite
uniformly dispersed in the entire soil mass. Depending upon the
weather conditions and time gap between sprinkling of water and
commencement of rolling, an allowance of 3 to 4 per cent for
evaporation should be made in the quantity of water to be added
during summer when temperature is greater than 350C, in winter
this allowance may be reduced to 1 to 2 per cent. For earthwork
construction, the loose thickness of the soil layer should not
normally exceed 200 mm when ordinary 8-10 tonne rollers are
used.
3. When the earthwork has reached a stage where the general form
of the final shape of the embankment has been obtained, the
spreading of earth should be done in straight reaches to a
crowned shape, and to appropriately banked profile if the reach
is on a curve. The moisture content in the laid soil should be the
optimum moisture content subjected to the permitted tolerance.
Highly expansive soils such as black cotton soil should be
compacted at the specified moisture content, which is usually on
the wet side of the optimum moisture content. The tolerance
limits of variation from the specified moisture content OMC are
normally + 1 per cent to 2 per cent for sandy/silty soils and
Optimum Moisture Content (OMC) to +2 per cent for
clayey/black cotton soils. Earth to be used should be good soil,
free from slumps, roots and leaves of trees, plants and rubbish.
The Clods should be broken to less than 75 mm size. The
equipment for compaction of earthwork should be an 8-10 tonne
smooth wheeled power roller. However, if such a power roller is
not available, the use of lighter rollers of 6 to 8 tonne weight may
be permitted. In such cases, the thickness of loose soil layer
should be suitably reduced and the number of passes needs to be
increased to achieve the desired density.
4. Densities to be aimed at the compaction process shall be chosen

with due regard to factors such as soil type, height of
embankment, drainage conditions, position of individual layers
and type of available compaction machinery. Each compacted
layer shall be tested in the field for density and compacted fully
before the operations for the next layer commence. The minimum
field density in case of the embankment shall not be less than 97
per cent Standard Proctor compaction (IS:2720 (Part 7) 1980).
The overall profile should be improved with each successive layer
so that the subgrade level is approached. The profile of the
formation is as per lines and grades.
7. Subgrade with natural earth

1. The preparation of subgrade includes all operations before the
pavement structure could be laid over it and compacted. Thus the
preparation of subgrade would include site clearance (if the
formation already exists), grading (embankment or cut section)
and compaction to desired density at optimum moisture. The
subgrade may be situated on embankment or excavation or at the
existing canal bank. In all the cases, site should be cleared off and
the top soil consisting of grass, roots, rubbish and other organic
matter are to be removed. The grading operation is started
thereafter so as to bring the vertical profile of the subgrade to
designed grade and camber. Bulldozers, tippers and blade
graders are useful equipment to speed up this work. Highly
clayey and black cotton soil shall not be used directly as a
subgrade material. In such case a capping layer of 100 mm
thickness shall be provided with material of CBR higher than 10
per cent or geo-textile shall be used as a filter material, if found
economical. In case the reach is in cutting and in-situ soil is to be
used for subgrade, the method consists in loosening of the soil to
appropriate depth to compact to a thickness of 300 mm bringing
the moisture to required level and compacting it with a suitable
roller to 100 per cent Standard Proctor compaction density. The
compaction process should commence at the edges and progress
towards the centre except at super-elevated portions where it
shall commence from lower edges and progress towards higher
edge. When the reach is in fillings, it is necessary to ensure that at
least the top 300 mm of the embankment constituting the
subgrade of the pavement should be compacted to 100 per cent of
Standard Proctor compaction density in at least two layers at
optimum moisture content. The subgrade should be finished to
the desired profiles; a camber board should be used to check the
cross slope.
8. Surface drains
1. The fast disposal of runoff on the road surface is achieved by
surface drainage. Surface drains shall be excavated to the
specified lines, grades, levels and dimensions based on the type of
the drain. The excavated material shall be removed from the area
adjoining the drains and if found suitable, utilised in
embankments or subgrade construction. All unsuitable materials
shall be disposed of as dirtected. The excavated bed and sides of
the drains shall be dressed to bring this in close conformity with
the specified dimensions, levels and slopes.
9. Sub Base (Granular)

1. Sub-base is an intermediate layer between subgrade base course.
The function of this layer is as a drainage layer for the pavement
to avoid excessive wetting and weakening of subgrade. Various
materials and techniques are used for construction of sub base
course. Various type of construction for sub-base, which are
appropriate for rural road, are detailed here.
2. Granular sub-base (GSB):
1. The grading for coarse graded GSB for construction of sub-base

course shall be as given in Table after conducting the wet sieve
analysis.
Table: Grading for Coarse Graded Granular Sub Base Materials (Wet Sieve Analysis)
IS Sieve Percent by weight passing the IS sieve

Designation
Grading I Grading II Grading III
75 mm 100 - -
53 mm - 100 -
26.5 mm 55-75 50-80 100

4.75 mm 10-30 15-35 22-45
75 < 10 < 10 < 10

Note: The material passing 425 micron sieve for all the three grading when tested
according to IS: 2720 (part 5) shall be having liquid limit and plasticity index not more
than 25 and 6 respectively. The material with CBR>15 percent shall be accepted for
construction of GSB course. (MORTH Specifications for Road and Bridges works.)
1. Immediately prior to the laying of sub-base, subgrade shall be prepared
with the help of a motor grader of adequate capacity. The granular
material for sub-base shall be preferably natural. Mixing of ingredients
to make granular sub-base may be undertaken under strict quality
control. Manual methods shall be permitted only where the width of
laying is not adequate for mechanical operations or in small sized jobs.
Moisture content of loose material shall be checked in accordance with
IS:2720 (part 2). After water has been added (at +1 percent to -2
percent of OMC as per IS:2720 (part 8) 1983), the material shall be
processed by mechanical or other approved names line disc harrows,
rotavators until the layer is uniformly wet. Immediately thereafter,
rolling shall start. The thickness of single compacted layer shall not
exceed 100 mm.
2. Rolling shall commence at the lower edge and proceed towards the
upper edge longitudinally for portions having unidirectional cross fall
and super elevation. It shall commence at the edge and progress
towards the centre for portion having cross fall on both sides. Each
pass of the roller shall uniformly overlap not less than one-third of the
track made in the preceding pass. Rolling shall be continued till the
density achieved is at least 98 per cent of the IS heavy compaction
density for the material as per IS:2720 (Part 8)-1983. The surface of
any layer of material in completion of compaction shall be well closed,
free from movement under compaction equipment and from
compaction plane, ridges, cracks or loose material.
2. Coarse sand sub-base
1. The coarse to medium sand sub-base gives comparatively more

effective drainage to pavement, where the embankment is clayey
or black cotton soil. Sand layer shall be provided as a part of sub-
base over the compacted subgrade layer where annual rainfall is
more than 1000 mm. The sand layer shall normally be in 100 to
150 mm compacted thickness (necessary arrangements shall be
made for local confinement of sand). The coarse to medium sand
for construction of a drainage layer shall conform to grading given
in Table below.
TABLE. GRADING OF COARSE TO MEDIUM SAND FOR SUB-BASE
IS Sieve Per cent Passing

11.2 100
5.6 mm 80-100
2.36 mm 70-90
180 micron <5
1. The sand conforming to the grading as given in Table above shall

be spread uniformly and evenly upon the prepared subgrade in
required quantities from stockpiles along the side of the road or
directly from tippers. Immediately following the spreading of the
sand, watering shall be done and rolling shall be started with
vibratory roller of approved type at optimum moisture condition
decided before construction or through saturation/vibration.
2. Base Course (Granular)
1. The following specifications are recommended for construction of
granular base course
1. Water Bound Macadam
2. Crusher Run Macadam
3. Use of Alternate Macadam
2. Water Bound Macadam (WBM)
(a) Grading:
WBM may be used as sub-base as well as base course and also surface course of rural
roads. In each case, it shall be constructed in conformity with line, grades and cross-
section shown on the drawings. The existing surface of the subgrade, sub-base of base to
receive WBM course, shall be prepared to the required grade and camber and cleaned of
all dust. Any ruts or soft yielding places that have appeared due to improper drainage of
surface under traffic or season shall be corrected and rolled. The grading of aggregates
shall conform to requirements given in the Tables belows. The quantity of binding
materials, where it is to be used will depend on the type of screenings. Generally, the
quantity required for 75 mm compacted thickness of water bound macadam will be 0.06-
0.09 cum/10 sqm. The quantity shall be in the range of 0.08-0.1 cum/10 sqm for 100 mm
compacted thickness. Necessary arrangements shall be made for the lateral confinement
of aggregates. There may be construction of side shoulders in advance to a thickness
corresponding to the compacted layer of the WBM course. After shoulders are ready,
inside edges may be trimmed vertical and included area cleaned of all spilled material
thereby setting the stage for spread of coarse aggregates. Table below gives the quantities
of materials (loose) required for 10 sqm for sub-base/base course with compacted
thickness of 100 or 75 mm.
TABLE: GRADING REQUIREMENTS OF COARSE AGGREGATES FOR WBM
Grading No. Size Range (mm) IS Sieve Designation Per cent by weight
(mm) passing
125 100
1. 90 to 45
90 90-100
63 25-60
45 0-15
22.4 0-5
90
2. 63 to 45
63
53
45
22.4
63 100
3. 53 to 22.4
53 95 100
45 65 90
22.4 0 10
11.2 05
TABLE: GRADING REQUIREMENTS FOR SCREENING FOR WBM
Size Range, mm IS Sieve Designation

Grading Percent by weight
No. (mm) (mm) passing
13.2 100
A 13.2
11.2 95-100
5.6 15-35
0.180 0-10
11.2 100
B 11.2
5.6 95-100
0.180 15-35
TABLE: QUANTITITES REQUIRED FOR 75MM AND 100 MM COMPACTED

WBM COURSE
Grading Size Compacted Loose Screenings

No. Range, Thickness, Quantity of
(mm) (mm) coarse Stone Screening Crushable Type, such
Aggregate, as, Moorum or
cum Gravel, cum
Size, mm Quantity,
cum
1 90-45 100 1.21 to 1.43 Type A 0.27 to Not 0.30 to

13.2 0.30 Uniform 0.32
2. 63 to 45 75 0.91 to 1.07 Type A 0.12 to Not 0.22 to 0.24

13.2 0.15 Uniform
Type B 0.20 to Not 0.22 to 0.24

11.2 0.22 Uniform
3. 53 to 75 0.91 to 1.07 Type B 0.18 to Not 0.22 to 0.24

22.4 11.2 0.21 Uniform
The compacted thickness for layer with grading 1 shall be 100 mm while with grading 2
and 3 shall be 75mm. Grading 2 and 3 shall be preferably used for construction of
Water Bound Macadam for rural roads.
2. Spreading and rolling of coarse aggregates: The coarse aggregates shall be spread
uniformly and evenly upon the prepared base in required quantities from stockpiles
along the side of the road or directly from vehicle.
In no case shall these dumped in heaps directly on the area where neither these are to
be laid nor shall their hauling over a partly completed base be permitted. The
aggregates shall be spread to proper profile by using templates placed across the road
about 6m apart. Where possible approved mechanical devices shall be used to spread
the aggregates uniformly so as to minimize the need for their manipulation by hand.
The WBM course shall normally be constructed in layers of not more than 75 mm
compacted thickness. However, for aggregates of grading NO. 1 the compacted
thickness shall be 100 mm. No segregation of large or fine particles shall be allowed.
The coarse aggregates, as spread shall be of uniform gradation with no pockets of fine
material. Immediately following the spreading of the coarse aggregates rolling shall
be started with 3 wheeled power roller of 8-10 tonne capacity or tandem or vibratory
roller of approved type.
The type of roller to be used shall be approved by the Engineer-in-Charge based on
trial run. Except on superelevated portions where the rolling shall proceed from inner
to the outer edge, rolling shall begin from the edges gradually progressing towards the
centre. First the edges shall be compacted with roller running forward and backward.
The roller shall then move inwards parallel to the centre line of the road, in successive
passes uniformly overlapping preceding tracks by at least one half of the width.
Rolling shall be discontinued when the aggregates are partially compacted with
sufficient void space in them to permit application of screenings. However, where
screenings are not to be applied as in the case of crushed aggregates like brick metal,
laterite and kankar, compaction shall be continued until the aggregates are thoroughly
keyed. During rolling slight sprinkling of water may be done, if necessary. Rolling
shall not be done when the sub-grade is soft or yielding or when it causes a wave like
motion in the sub-grade or sub-base course. The rolled surfaced shall be checked
transversely and longitudinally with templates and any irregularities corrected by
loosening the surface by adding or removing necessary amount of aggregates and re-
rolling until the entire surface conforms to the desired camber and grade. In no case
shall the use of screenings be permitted to make up depressions.
2. Application of screenings : After coarse aggregates have been rolled, screenings

shall be applied gradually over the surface to fill the interstices. Dry rolling shall be
done when the screenings are being spread so that the jarring effect of roller causes
them to settle into the voids of the coarse aggregates. The screenings shall not be
dumped in piles but applied uniformly in successive thin layers either by spreading
motion of hand shovels, mechanical spreaders or directly from trucks. Trucks plying
over the base course to spread screenings shall be equipped with pneumatic tyres and
so operated as not to disturb the coarse aggregates. The screenings shall be applied at
a slow rate in three or more applications as necessary. Rolling or brooming shall
accompany this. In no case shall the screenings be applied so fast and thick as to form
cakes or ridges on the surface making the filling of voids difficult or preventing the
direct bearing of roller on the coarse aggregates. After the application of screenings,
the surface shall be copiously sprinkled with water, swept and rolled. Hand brooms
shall be used to sweep the wet screenings into voids and to distribute them evenly.
The sprinkling, sweeping and rolling operations shall be continued and additional
screenings applied where necessary until the coarse aggregates are well bounded and
firmly set. Grout of screenings and water formed ahead of the wheels of rollers shall
be taken out so that the base or sub-grade does not get damaged due to addition of
excessive quantities of water during the construction.
2. Application of binding material: After the application of screenings, binding

material (PI=4-6) that is required to be used shall be applied at a uniform rate in two
or more successive thin layers. After each application of binding material, the surface
shall be sprinkled with water and the resulting slurry swept in with brooms so as to fill
the voids properly. After final compaction, the road shall be allowed to cure overnight.
Next morning, hungry spots shall be filled with screenings or binding material lightly
sprinkled with water, if necessary it may be also rolled. No traffic shall be allowed till
the macadam sets. In the case of WBM base course to be provided with bituminous
surfacing, the latter shall be laid only after the WBM course is completely dry and
primed before allowing any traffic on it.
3. Crusher run macadam (CRM) : The work shall consist of
furnishing, placing and compacting crushed stone aggregate sub-
grade and base courses constructed in accordance with the
requirements set forth in this specification and in conformity with
the lines, grades, thicknesses and cross sections shown on the plan
or as directed by the Engineer-in-Charge. The grading shall
conform to the grading and quality requirements shown in Table
below.
Table: Aggregate Grading Requirement for Crusher Run Macadam
Sieve Size, mm Percent Passing by Weight
53 mm max, size 37.5 mm max. size

63 100 -
45 87-100 100
22.4 50-85 90-100
5.6 25-45 35-55
0.710 10-25 10-30
0.90 2-9 2-9
The aggregate shall be uniformly deposited on the approved subgrade by means of the
hauling vehicle with or without spreading devices. Aggregates will be distributed over
the surface to the depth specified on the plans or as directed by the Engineer-in-
Charge. After the base course material has been deposited, it shall be thoroughly
mixed to full depth of layer by alternately blading the entire layer to the centre and
back to the edges of the road. It shall then be spread and finished to the required cross
section by means of a motor grader. Water shall be applied prior to and during all
blading and processing operations to moisten the material sufficiently to prevent
segregation of the fine and coarse particles. Water shall be applied in sufficient
quantity during construction to assist in compaction. Compaction shall commence
immediately after the spreading operation. If the thickness of single compacted layer
does not exceed 100mm, a smooth wheel roller of 8-10 tonne weight may be used.
For a compacted single layer upto 200mm, the compaction shall be done with the help
of vibratory roller of minimum of 8-10 tonne or equivalent capacity. The speed of the
roller shall not exceed 5 km/h. Each layer of material shall be compacted to not less
than 98 percent of the IS heavy compaction density as per IS: 2720 (Part 8) 1983.
11. Shoulder
1. Shoulder gives adequate side support to the pavement and also
drains off surface water from the carriageway to the road side
drain.
2. Construction of Shoulders: The construction shall be done in

layers each matching the thickness of adjoining layer. Only after
a layer of WBM, shoulder shall be laid and compacted. Next
corresponding layers in pavement shall be taken up after the
completion of first layer of WBM and shoulder. This procedure
shall be followed upto the surface course. In the case of
bituminous courses, work on shoulder shall start only after the
pavement course has been laid and compacted. The compaction
requirement of earthen shoulder shall be 100 percent of Standard
Proctor compaction density as per IS:2720 (Part 7) 1980.
During all stages of shoulder construction, the required cross fall shall
be maintained to drain off surface water. Regardless of the method of
laying all shoulder construction material shall be placed on the
shoulder. Any spilled material dragged on to the pavement surface shall
be immediately removed without damage to the pavement.
12. Bituminous Constructions

1. Rural roads are expected to have very low traffic, and therefore,
any all weather surfacing will provide the needed connectivity.
But, where there is reasonable volume of motorized traffic, thin
bituminous surfacing will be desirable. This section deals with
construction of all different bituminous construction required for
flexible pavement. The basic objective of providing thin
bituminous surfacing on rural roads is to seal granular surface
cost effectively and to reduce maintenance efforts.
2. Prime coat on granular surfaces: Prime coat is a spray

application of low viscosity liquid bituminous material on top of
the top most granular layer of the base course. Prime coat
performs following important functions.
o Coats and bonds loose mineral particles of granular surface.
o Water proofs the surface of the base by plugging capillary or interconnected

voids.
o Provides adhesion or bond between the granular base and bituminous layers.
The primer shall be a slow setting bitumen emulsion complying with IS:8887-1995,
or medium curing cut back as per IS:217-1983. The use of medium curing cut back
shall be restricted to sub zero temperature conditions only. The procedure for
preparation of cut back for primer is given in Appendix-III. The requirement of
viscosity and quantity of liquid bituminous materials to be used for priming shall be
as given in Table below.
TABLE: REQUIREMENT OF VISCOSITY AND QUANTITY OF LIQUID

BITUMINOUS MATERIALS FOR PRIMING
Porosity Type of Surface Viscosity at 60oC saybolt Quantity per 10 sqm

Furol (Seconds) (Kg.)
Low WBM 14-28 6-9
Medium Stabilished base 33-66 9-12
High Gravel base 117-234 12-15
The primer can be applied using one of the following equipments as decided by
Engineer-in-Charge.
o Self propelled distributor

o Towed bitumen pressure sprayer
o Hand sprayer (for small works)
Prior to applying the primer, the surface shall be carefully swept or brushed clean of
dust and loose particles. The desirable range of temperature of cutback as primer for
grades, viz. MC-30, MC-70, MC-250 shall be 30 to 55oC, 50 to 80oC and 75 to 100oC
respectively. Emulsion as primer can be sprayed at 20 to 60oC. A primed surface shall
be allowed to cure for atleast 24 hours before application of next bituminous layer.
Emulsion for priming always requires dilution with water in 1:1 ratio (water :
Emulsion). A very thin layer of clean sand may be applied to the surface of the primer
to prevent the primer picking up under wheels of paver or trucks delivering material
for construction of bituminous layer.
3. Tack Coat application: Tack coat is a very light application of

liquid bituminous material on a bituminous layer when a new
layer is to be laid over it. It is used to create a bond between a
new bituminous layer to be placed on the existing bituminous or a
primed granular layer. The following types of liquid bituminous
materials can be used for tack coat applications:
o Rapid or medium or slow setting type emulsion (IS:8887-1995)
o RC-70 or MC-70 grade cutback bitumen (IS:217-1988)
o Hot bitumen.
The existing surface shall be made slightly damp in case of tack coat using emulsion
and dry if bitumen or cutback bitumen is used. Hot bitumen or cut back bitumen may
be used in special case, where it is felt necessary for climatic reasons. The tack coat
may be sprayed by one of the following equipments:
o Self propelled pressure distributor.

o Towed bitumen sprayer.
o Pressure hand sprayers
o Perforated cans for small area.
The surface to be tack coated must be clean, free of loose material and dust. In case
emulsion is used for tack coat, the bituminous layer is placed after complete braking
of emulsion as indicated by change in colour from brown to black. The recommended
quantities of liquid bituminous material for tack coat are as given in table below
TABLE: RECOMMENDED QUANTITITES OF LIQUID BITUMINOUS

MATERIAL FOR TACK COAT
Types of Surface Quantity per 10 sqm

Granular (Primed) 3.0 Kg.
Bituminous Surface 2.5 Kg.
If, the existing surface is a freshly laid bituminous layer, a tack coat is not mandatory
and it may not be required at all.
1. Open graded premix carpet with seal coat: The open graded
premix carpet construction involves use of mixed bituminous
material laid in compacted thickness of 20mm followed by a seal
coat. The aggregate quality for premix carpet shall conform to
requirements. In case water absorption exceeds 1 percent, the
polished stone value as measured by the test in BIS: 812 Part II
shall be less than 55. The binder shall be paving bitumen
conforming to IS:73-1992 or emulsion conforming to IS: 8887-1995
specifications or modified bitumen conforming to IRC:SP:53. The
quantity of materials needed for 10 sqm road surfaces for 20mm
compacted thickness of open graded premix carpet are given in
Table below.
Table: Material Requirements for Open Graded Premix Carpet
Aggregate Bitumen, Kg. per 10 Emulsion Kg. per

sqm 10 sqm.
Size, mm Quantity, cum per 10

sqm
22.4-11.2 0.18
14.6 20-23
13.2-5.6 0.09
Any hot mix plant or spot mixer of appropriate capacity and type shall be used for
preparation of mixed material. The temperature of ingredients and mix shall be as
given in Table below.
Table: Temperature of Ingredients and Mix
Grade of Temperature oC
Bitumen
Bitumen at Aggregate at Mix delivered at Mix at the time of rolling
Mixing mixing site
S-35 165-170 170-175 135-155 > 100
S-65 155-165 160-170 130-150 > 95
S-90 150-160 155-165 125-145 > 90
The construction operations, like, mixing, spreading and rolling shall be same as
described in Appendix-V. In case of construction of open graded premix carpet using
bitumen emulsion premixing of cationic emulsion shall be carried out in a suitable
mixing device such as cold mix plant as per IS: 5435 (Revised) or concrete mixer. The
other details regarding mixing, spreading and rolling are given in Appendix-V. The
surface shall be sealed with suitable seal coat.
2. Seal Coat: These types of construction are undertaken for sealing

open graded premix carpet surface or a pervious surface of
bituminous macadam. The binder shall be S-90 grade conforming
to IS:73-1992. The grading and quantities of binder shall be as
given in Table below.
Table: Requirements of Materials for Seal Coat
Type Aggregate Bitumen Emulsion
Specification Quantity, Specification Quantity, Specification Quantity,

size, mm cum Kg/10 sqm Kg/10 sqm
A 11.2-2.36 0.09 S-65 9.8 RS 15.0
B 2.36-0.18 0.06 S-90 6.8 SS 10.0
The type A seal coat shall be used for high rainfall areas (over 1500mm) and type B
seal coat for other climatic conditions.
Appendix I
Tools, Appliances and Equipments Required for Manual Methods
A. Road Alignments Reconnaissance Survey and Trace Cut, Layout
i. Abbey level/quick setting level

ii. Ghat tracer
iii. Prismatic Compass and Theodolite, where required
iv. Dumpy level with staff
v. Altimeter
vi. Measuring chain with arrows/tape
vii. Ranging rods, flags, pegs and nails
viii. Sharp knife
ix. Pick axes, crow bars, shovels and spades
x. Felling axes sledges and Dahs
xi. Rope and masons thread
B.Formation Cutting/Embankment/Jungle Clearance
i. Hand saws, felling axes and dahs

ii. Anchor bars and rope
iii. Flags and measuring tape
C. Excavation/Embankment
i. Pick axes, crow bars, shovels and spades

ii. Cane baskets and wheel barrows
iii. Sledges and chisels
iv. Rammers and compactors
v. Flags and rope
vi. Water cans, empty drums for storage of water and hose pipe
vii. Sheep foot roller with prime mover

viii. Template, straight edge 3 meters long and Engineers sprit level
ix. Masons thread and other tools as required for surface dressing or making camber
D. Blasting Tools
i. Auger/Crow bar - Made of steel for drilling holes in rocks
Jumping bar
ii. Stemming rod - Made of wood to charge and steam the holes for blasting
iii. Scraper - Made of brass to clean the holes
iv. Pricker - Made of bars, aluminum or wood to prick the cartridge prior to inserting
detonator or detonating fuses.
v. Crimper - Made of non-ferrous, non-sparking material for rimping the detonator to

fuse.
E. Protective and Drainage Work
Layout and Construction
i. Measuring boxes, water measures and sieves

ii. Spades and shovels
iii. Mortar pans, cane baskets and wheel barrows
iv. Iron rammers and wooden tampers
v. Dressing hammers and chisels
vi. Masons tools including trowel, float, spirit level, straight edge and thread etc.
vii. GI buckets 6 to 12 liters
viii. Empty drum or GI storage tank 2000 litres capacity
ix. GI sheet for mixing mortar/concrete
x. Vibrator and concrete mixer
xi. Tools for making scaffolding
Curing
i. Hessian cloth and polyethylene sheets

ii. Buckets, cans and hose pipe
iii. Empty drums or water storage tanks 2000 litres capacity

F. Pavement Work
Picking or removing old pavement
i. Pick axes, crow bars, hammers and chisels
Cleaning the surface
i. Wire brushes
ii. Coir brushes
iii. Brooms and old gunny bags
Handing and spreading materials
i. Baskets lines with gunny cloth and wheel barrows

ii. Bucket GI 6 to 12 litres capacity
iii. Empty drums or GI storage tank 200 litres capacity
iv. Heating trays, wheel barrows
v. Hammer and cutter for opening bitumen drums
vi. 15 to 30 liters capacity containers for measuring aggregate
vii. Shovels and spades
viii. Rakers with small and long handle
ix. Spring balance 10 and 25 kg
x. Bitumen boiler
xi. Chain pulley arrangement for lifting drums
xii. Tractor or other arrangement to pull the bitumen boiler (Road Roller may also be able
to do this)
Checking profile and quality control
i. Thermometer dial type range 00 2500C

ii. Thermometer mercury in glass range 000 2500C
iii. Straight edge meter
iv. Camber board/template
v. Depth gauge
Special tools for pavement surfacing
i. Manually operated sprayers

ii. Road rollers 3 wheeled smooth, tandem, vibratory and pneumatic as per
specification of component layers of pavement
Appendix - II
Plant and Equipment Required for Different Phases of Mechanized Construction
1. Formation Cut/Embankment
Jungle Clearance
i. Crawler tractor with bulldozer attachment.

ii. Power saw.
iii. Tactor mounted winch
iv. Rooters.
Formation Cutting, excavation/embankment
i. Scraper, tractor/motorized or towed.

ii. Crawler tractor with bulldozer/angle dozer/riper and wheel dozer.
iii. Excavator with shovel/drag-line attachment.
iv. Pay loader (Front end loader)
v. Disc harrow
vi. Rotary tillers
vii. Water lorries
viii. Water pump
ix. Motor grader
x. Compactor sheep foot with prime mover, Vibratory roller and smooth wheel roller
(8/10 tonne capacity).
Blasting
i. Air compressor
ii. Wagon drill
iii. Jack hammer with accessories
iv. Exploder with shot firing cable
v. Ohm meter
vi. Winch for suspending scaffolding

1. Protective and Drainage Works
i. Excavator
ii. Back hoe ripper with prime mover/tractor
iii. Concrete mixer
iv. Tripod pulley block/crane
v. Truck mounted mixers
vi. Vibrators Internal and screed type.
vii. Fork lift
viii. Water lorries
ix. Bar bending machine
x. Water pump
xi. Load carriers (Dumper/Tipper & Trucks)
1. Flexible Pavement 0 (Pavement with Bituminous Surfacing)
Crushing of aggregate
i. Stone crusher
ii. Granulators
iii. Air Compressor
iv. Jack hammer with accessories
v. Blasting accessories
vi. Tractor with dozer attachment, wheel dozer
vii. Pay loader (front end loader)
viii. Load carriers (Dumper/Tipper & Trucks)
ix. Generator
Laying base/sub-base course
i. Motor/Grader
ii. Water bowser with water sprinkling system
iii. Disc harrow / rotary tillers
iv. Paver finisher
v. Compactor 3 wheeled smooth 8/10 tonne capacity roller
vi. Mixer for wet mix macadam
vii. Plate compactor for compacting narrow widths
viii. Load carriers (Dumpers/Tippers)
2. Bitumen Work
Bituminous spraying and mixing equipment
i. Mechanical Broom
ii. Bitumen pressure distributor
iii. Gritter (Grit spreader)
iv. Hot mix or cold mixing plant of appropriate capacity with all accessories as laid down
in IRC: 72 and IRC:43 (for cement concrete roads)
v. Dumper/Tippers and Trucks
Spreading and laying bituminous courses
(i) Paver finisher
1. Rolling Equipment and Pavement Marking Equipment
i. Three wheeled roller, 8-10 tonne
ii. Tandem roller
iii. Vibratory roller
iv. Pneumatic tyre roller
v. Pavement marker
1. Tools for Checking Surface Evenness and Compaction
i. Profilometer
ii. Density meter
1. Tools for Checking Surface Evenness and Density/Compaction

i. Profilometer
ii. Density meter
F. Rigid Pavement Cement Concrete Roads
i. Motor grader
ii. Compactor 8/10 tonne steel wheeled roller, vibratory roller, tandem roller
iii. Water lorry with water sprinkling arrangement
iv. Hydraulic hammer
v. Hydraulic concrete cutter for cutting/dressing the concrete pavement neatly etc.
vi. Screed vibrator
vii. Mixer
G. Preparation of Concrete Mix and Laying
i. Concrete weigh batching plant of suitable capacity

ii. Trucks/dumpers/tippers
iii. Mixer mounted on truck (transit mixer)
iv. Water bowser/water lorry
v. Cement silo
vi. Concrete laying appliances
vii. Joint sealing machine
viii. Joint cutting machine
ix. Fork lift for shifting at work site
x. Water pump
xi. Concrete vibrators internal type and screed type.
H. Tools and Appliances for Safety during Construction
i. Road barriers
ii. Diversion and Caution Boards
iii. Red flags
iv. Field tent and accessories

v. Gum boots, gloves and Goggles
vi. First aid box

Appendix V
Mixing, Transportation and Laying of Hot Mixed Bituminous Materials
Hot mixed bituminous materials shall be made with following methods and precautions :
i. Premixed bituminous materials which includes bituminous macadam, open graded

premix carpet and closely graded premix carpet shall be prepared in a hot mix plant of
adequate capacity capable of yielding a mix of uniform quality with respect to grading
and binder content. The difference in temperature of bitumen and aggregate shall not
exceed 14oC. The temperature of binder shall not exceed 175oC in any case.
ii. A batch type of continuous type or a spot mixer may be used for preparation of mix as
decided by Engineer-in-Charge. If a continuous mixing plants to be used for mixing,
contractor must demonstrated by laboratory analysis that cold feed combined grading
is within permissible grading limits and binder content is in compliance to job mix
formula. The maximum permitted variations in binder content of mix is 0.3 percent.
iii. The surface shall be cleaned of all loose and extraneous matter by a mechanical
broom or any other means like high pressure air jet etc. Laying of bituminous mixture
shall not be carried out when air temperature is below 10oC or the wind blowing
exceeding 40 Km/h.
iv. Excluding the areas, where mechanical paver can not access, bituminous material
shall be spread, leveled and tamped by self propelled paver finisher. The rate of
delivery of material to the paver shall be regulated to enable paver to run continuously
without any break in paving process. The hand paving of premixed material shall be
permitted in following circumstances.
o Small laying area
o Patch work and paving of footpaths
o Locations where it is impractical for a paver to operate.
v. Compaction shall be completed before the temperature falls below the minimum
specified rolling temperature, i.e., 100oC. The initial and breakdown rolling shall be
done with 8-10 tonne dead weight smooth wheeled rollers followed by intermediate
rolling with the same roller or a vibratory roller. The final rolling shall be done with a
light roller smooth wheeled tandem roller. The roller shall first compact materials
adjacent to joints then lower to upper side of layer, over lapping on successive passes
by at least one third of the width of the rear roll. In case of rolling in super elevated
and uni-directional camber, the rolling shall progress from lower to upper edge after
the edge has been rolled.
vi. The minimum thickness of material laid in each paver pass shall be maintained in
accordance with minimum value given in the specifications. When laying of wearing
course approaches an expansion joint, machine laying shall be stopped 300 mm
before start of the joint. The pavement area upto joint and beyond it shall be hand
paved.
vii. During the period of construction, arrangements for traffic shall be made in
accordance with provisions of Clause 112 of the MoRT&H of the Specifications for
Road and Bridge Works.
QUALITY CONTROL IN CONSTRUCTION
13. Introduction
1. Quality should conform to the customer need or users
requirement in all activities and projects. However, quality is
considered as conformance to specifications particularly in
construction sector. The quality control is an essential
requirement for all weather rural road construction by adopting
IRC/MoRT&H Specifications and construction methods for
creating durable and longer lasting assets for rural India. The
overall quality control of rural road works must cover controlling
of quality of materials and the work at site with the help of
objective tests performed at a reasonable, pre-determined
frequency with affecting progress or works. It is always tests
performed at a reasonable, pre-determined frequency without
affecting progress of works. It is always advantageous to have
separate quality control unit, independent of construction staff to
control and monitor the work. The guidelines in this regard are
contained in IRC:SP:11, Handbook of quality Control for
Construction of Roads and Runways, Clause 900 Specifications
for Road and Bridge Works of MoRT&H specifications and
IRC:SP:57, Guidelines for quality systems for Road
Construction.
14. Pre-Requisite
Pre-requisite for quality control shall be as follows:
All materials to be used, all methods to be adopted and all works performed shall be
strictly in accordance with requirement of specifications. Requirement of quality
control tests and required frequency shall be mentioned in the tender document.
In view of low traffic volume on rural roads and smaller size of projects, the
requirement of quality control with respect to frequency of test may be reduced as
compared to requirements indicated in MoRT&H Specifications. Further, reduction in
frequency of testing without compromising quality assurance is likely to expedite
progress of the work. However, the Engineer-in-Charge may decide a higher test
frequency for larger size projects.
The contractor shall set-up a field laboratory of minimum needed equipments (camber
board, sieve sets, core cutter with accessories and balance with weights upto 0.1 gm
accuracy) and a oven to facilitate analysis of gradation, moisture and field density at
locations approved by the Engineer-in-Charge and depute needed personnel in order
to carryout all required tests at specified frequency and as per the requirements
mentioned in tender of as directed by the Engineer-in-Charge. For conducting the
other required tests, arrangements may be made with other organizations/laboratories
also to meet the requirements of quality control and quality assurance. In case of
larger size projects, contractor may be requested to set up a better laboratory at site or
use facilities created at any other place nearby. The list of equipments and the quality
control facilities shall be got approved from Engineer-in-Charge in advance before
start of work. The laboratory shall be manned by a qualified Materials
Engineer/Scientists assisted by experience Laboratory Assistants/Technicians.
For satisfying himself verification about the quality of the material or work, quality
control tests will also be conducted by the Engineer-in-Charge himself or quality
control unit or any other technical agency at a pre-decided frequency. Additional tests
may also be conduced where, in the opinion of Engineer, need for such tests is felt.
15. Specifications and Codes of Practice

1. The specifications and codes of practice laid down by Indian
Roads Congress, Ministry of Road Transport and Highways, and
Bureau of Indian Standards are required to be followed in
construction of roads.
16. Earth Work and Granular Layer

1. The materials supplied and the works carried out by the
contractor shall conform to the specifications prescribed. For
ensuring the requisite quality of construction, the materials and
works shall be subjected to quality control tests, as described
hereinafter. The testing frequencies indicated are the desirable
minimum and the Engineer-in-Charge shall recommend for
additional tests whenever felt necessary, to ensure compliance
with the appropriate specifications. Some of the important test on
soil, aggregate and bituminous materials are described in
Appendices-III, IV and V respectively. For details, relevant code
of practice may be referred as per list given at Appendix I.
1. Borrow material: Grid the borrow area for earthwork at 50m

centre to centre (or closer, if the variability is high) to full depth of
proposed working area. The tests representative samples shall be
carried out as indicated in Table below).
Table Frequency of Test for Borrow Material
Test No. Description Test Method Frequency
EW-1 Sand content IS: 2720 (Part 4) One tests per 4000 cum of
soil
EW-2 Plasticity index IS: 2720 (Part 5) One tests per 4000 cum of
soil
EW-3 Natural moisture content IS: 2720 (Part 2) One tests per 500 cum of
soil
EW-4 Compaction test IS: 2720 (Part 7) One tests per 4000 cum of
soil
EW-5 CBR test on materials to IS: 2720 (Part 16) One CBR test for every
be used in the subgrade. 5000 cum of soil.
2. Earthwork and compaction control : The frequency of testing for

earthwork at construction site shall be as indicated in table below.
Table: Frequency of Test for Earthwork
Test No. Description Test Method Frequency
EW-6 Moisture content prior IS: 2720 (Part 2) One test for every 250 m3 of soil
to compaction subject to minimum of 4 test/day.
EW-7 Thickness of layer - Regularly
EW-8 Degree of the IS: 2720 (Part 28) One set of the test per 2000 m2 area
compaction comprising 5-6 measurement.
The test locations for compaction control shall be chosen only through random
sampling techniques. The guidelines are indicated in Fig. . Acceptance shall be based
on mean value of a set of density determinations. If considerable variations are
observed between individual density results, the minimum number of tests in one set
of measurement shall be increased to 10. The acceptance criteria shall be subjected to
the condition that the mean density (MD) is not less than the specified density plus X.
Where X = 1.65 1.65 . x (standard deviation)
(No of samples)0.5
The minimum value of mean field density shall be 97 percent of standard proctor
density in case of embankment and 100 percent of Standard Proctor density for
subgrade layer.
3. Granular sub-base and bases : The tests and their frequencies for
the different types of base and sub-base shall be as given in Tables
below. The evaluation of density results and acceptance criteria for
compaction control shall be on lines similar to those set out in
section 16.1.2. However, the compaction density to be complied to
for sub-base shall be as per MoRT&H guidelines, i.e., 98 percent.
Further, it must fulfill the statistical criteria given for subgrade
compaction. The guidelines for location of test points are given in
Fig.
Table: Frequency of Test for Granular and Stabilished (mechanical Sub-Base and
Gravel Road
Test No. Test Test Method Frequency
SB-1 Gradation IS: 2720 (Part 4) Two tests per 500 cum or per day
SB-2 Atterberg limits IS: 2720 (Part 5) Two tests per 500 cum or per day
SB-3 Moisture content prior IS: 2720 (Part 2) Two tests per 500 cum or per day
to compaction.
SB-4 Density of compacted IS:2720 (Part 28) One set of test per 2000 sqm
layer
SB-5 Thickness - Regularly
Table: Frequency of Test for Stabilished (Lime/Cement / Lime-GBFS/Lime-Fly Ash)

Sub-Base
SB-6 Purity of lime/cement IS:1514/IS:269 / 1 tests per 5000 Kg. or/lot

455/IS:1489
SB-7 Degree of pulverization - Regularly
SB-8/9 CBR or unconfined IS: 2720 (Part 16) 1 tests per 100 cum of mix
compressive strength IS: 4332 (Part 5)
test on a set of 3
specimens.
SB-3 Moisture content prior IS: 2720 (Part 2) 2 tests per 500 cum or per day
to compaction
SB-4 Density of compacted IS: 2720 (Part 28) 1 set of test per 2000 sqm
layer
SB 5 Thickness - Regularly
Table: Frequency of Test for Water Bound Macadam (Sub-Base, Base Course and
Surface Course)
GB-1 Aggregate impact value IS: 2386 (Part 4) 1 tests per 250 cum or source
GB-2 Grading of aggregate IS: 2386 (Part 1) 2 tests per 250 cum or per day
and screening
GB-3 Flakiness index and IS: 2386 (Part 1) 1 tests per 250 cum or per day
elongation index
GB-4 Atterberg limits of IS: 2720 (Part 5) 1 tests per 50 cum or per day
binding material
GB-5 Water absorption IS: 2386 (Part 3) 1 test per source
GB-6 Thickness - Regularly
In case of use of special materials, like, lime flyash, cement, lime GBFS (granulated blast
furnace slag) and stabilized sand to be used in sub-base and base course construction, the type
and frequency of tests shall be same as for conventional materials. Gravel and WBM also
may be accepted as wearing coarse for unsurfaced roads. In such cases, the quality control
methods and frequency of test will be as indicated here.
17. Bituminous courses

1. Bituminous materials can be used for construction of prime coat,
tack coat modified penetration macadam, bituminous macadam,
open graded premix carpet with seal coat, and closely graded
premix carpet (mix seal surfacing, etc.). The modified penetration
macadam and bituminous macadam shall be used only at special
locations where traffic is heavy and requirement of strengthening
by bituminous course is essential.
1. Prime coat and tack coat : The applications of prime coat and tack
coat over granular course is essential before providing a
bituminous surfacing. The quality control tests and their minimum
frequency for prime coat and tack coat applications shall be as
given in Table below
Table: Frequency of Test for Prime Coat and Tack Coat
BL-1 Quality of binder IS: 73/217/8887 1 test per lot or per 10 tonne
BL-2 Temperature of binder Appendix VI Regularly
BL-3 Rate of spread of Appendix VII 2 tests per day or per 1000 sqm
binder
2. Bituminous macadam and modified penetration macadam: The

construction of bituminous macadam and modified penetration
macadam can be undertaken in special cases where it is felt
essential as a design requirement. The tests and minimum
frequencies for these bituminous works pertaining to base course
construction shall be as given in Tables below.
Table: Frequency of Test for Bituminous Macadam
BL-4 Aggregate impact value IS: 2386 (Part 4) 1 test per 250 cum/source
BL-5 Flakiness index IS: 2386 (Part 1) 1 test per 250 cum
BL-6 Stripping of aggregate IS: 6241-1971 1 test per source
BL-7 Water absorption IS:2386 (Part 3) 1 test per source
BL-8 Grading of aggregates IS: 1286 (Part 1) 1 test per 100 cum
BL-9 Binder content Appendix VIII 2 test per day
BL-10 Thickness - Regularly
BL-11 Density of compacted Appendix IX 1 test per 1000 sqm area or per day
layer
1. Bituminous surface course: The following bituminous surface

courses are generally recommended for rural roads construction:
o Surface dressing
o Opening graded premix carpet with seal coat
o Closely graded premix carpet or mix seal surfacing
The various tests and their minimum frequencies for different types of bituminous
works for surface course are given in Tables below.
Table: Frequency of Test for Surface Dressing
BL-4 Aggregate impact value IS: 2386 (Part 4) 1 test per 250 cum per source
BL-5 Flakiness index IS: 2386 (Part 1) 1 test per 250 cum per day
BL-3 Rate of spread of Appendix VII 1 tests per 1000 sqm

binder
BL-12 Rate of spread of Appendix X 1 test per 1000 sqm

aggregate
Table: Frequency of Test for Open Graded Premix Surfacing or Closely Graded Premix
Surfacing or Mix Seal Surfacing
est No. Test Test Method Frequency

BL-4 Aggregate impact value IS: 2386 (Part 4) 1 test per 250 cum per source
BL-5 Flakiness index IS: 2386 (Part 1) 1 test per 250 cum per day
BL-8 Grading of aggregates IS: 2386 (Part 1) 1 test per 50 cum
BL-13 Soundness IS: 2386 (Part 5) 1 test per source
(Magnesium and
sodium sulphate)
BL-14 Binder content Appendix VIII 2 test per 500 cum or per day
BL-10 Thickness - Regularly
Appendix - III
Laboratory Testing for Properties of Soil (IS: 2720)
Soil is one of the principal materials of construction for embankments and stabilized soil base
and sub-base courses. Some important tests on soil as an engineering material are as under :-
1. Plasticity Index (IS: 2720-Part 5).
i. Liquid Limit (LL).
The test is carried out in a standard Casagrande Liquid Limit Device in which
a cup containing a grooved specimen is made to fall on a rubber plate. The
number of blows to close the groove to a length of about 12.5 mm is
determined for different moisture content. The moisture content corresponding
to 25 blows is determined from a plot between number of blows and moisture
content.
ii. Plastic Limit (PL).
The moisture content at which a soil water mix when rolled into a thread on a
glass plate starts crumbling at 3 mm dia gives the plastic limit of the soil.
iii. Plasticity Index (PI).
The numerical difference between liquid limit and plastic limit is the plasticity
index. Thus, it is determined from the liquid limit and plastic limit and plastic
limit value of soil. A rough estimate of this can also be made using Uppals
Syringe. A soil paste is made by adding water to soil such that water is above
the plastic limit of soil. This paste is put into the syringes and pushed out
through the holes in the cap. Depending upon the texture of the thread, the PI
can be estimated.
2. Sieve Analysis (IS:2720-Part 4).
The particle size distribution is by far the simplest way of broadly classifying a soil in
terms of its being granular, medium grained and fine grained. The sieve analysis
consists simply in taking weighed quantity of the sample, soaking it in water
overnight and washing out the finer fraction through 75 micron IS Sieve. The fraction
retained is dried and then passed through a series of sieves. However, for the rural
road works, a set of 7 sieves is recommended. To be able to broadly evaluate the
particle size distribution of a soil even three sieves namely 2.36 mm, 425 micron and
75 micron may suffice. While a mechanical shaker is generally used in well equipped
laboratories, manual shaking of sieves is considered sufficient if carried out for a
period not less than three minutes. In case of dry cohesionless soil such as sand, dry
sieve analysis may be carried out.
3. Proctor Compaction (IS:2720-Part7).

This test is conducted to determine the achievable density in field and the optimum
moisture required for compaction. It is conducted in a proctor mould (IS:2720 Part 7 -
1980) apparatus. The soil sample is compacted in three layers giving 25 blows on
each side by a standard rammer at five different moisture contents. From the plot
between moisture content and dry density, the optimum moisture content and
maximum dry density are determined. In case of heavy compaction method (IS: 2720
Part-8 1983), soil sample is compacted in five layers (depending on the size of the
mould) giving 56 blows using a IS heavy rammer.
4. CBR (IS: 2720 Part 16).
It is extensively used for the design of flexible pavements in India. The test is carried
out on a sample compacted at optimum moisture content to maximum dry density and
soaked for 4 days. In case of stabilized specimen, the specimen is cured for 7 days in
wet sand and then subjected to the 4 days soaking. The CBR of the specimen is
computed from the load needed for 2.5mm/5.0mm penetration of a standard plunger
determined from the graph between penetration and load. If required the zero
correction is applied for penetration while computing the load for 2.5mm/5.0mm
penetration.
Appendix - IV
Laboratory Testing for Properties of Road Aggregates (IS: 2386)
The performance of pavement depend to a great extent on the correct choice of quality and
quantity of aggregates as they from the major constituent of road construction materials.
Since the aggregates have to bear the brunt of traffic, strength or resistance to degradation of
aggregates as well as structural stability offered by mechanical interlock of aggregate
particles in a layer from are important factors. IS:2386-1963 (Parts I to VIII) gives the
methods of tests for aggregates for road construction.
Great care is necessary in taking out samples of aggregates for testing unless the samples are
true representative, the results of various tests may not reflect accurately their characteristics.
For sampling of coarse aggregates, fine aggregates and filler, use of a flat shovel is preferable
when working on a flat surface to ensure that a representative proportion of fines is picked
up. The aggregates should be surface dry. Suitable form of sample divider is the riffle box. In
case, a sample divider is not available, the representative sample may be obtained by
quartering. For more details on sampling, IS: 2386-1963 (Part I) may be referred to.
Some of the important tests on aggregates for road construction are given in the following
paragraphs:
Sieve Analysis: The test procedure is described in IS: 2386-1963 (Part I). The required
quantity of sample of aggregates is sieved manually or mechanically on a standard set
of sieves depending upon the maximum size of aggregates and the percentage retained
on each sieve is determined. The test results are expressed as percent by weight passing
each sieve. Sieve analysis test gives the particle size distribution in a sample of
aggregate.
Shape of Aggregates: Aggregates have three different shapes, viz. cubical, flaky and
elongated. While cubical aggregates are good for development of mechanical interlock
between aggregate particles and consequently for achieving structural stability in a
bituminous mix, flaky and elongated aggregates are considered to be undesirable due to
their greater susceptibility to fracture and larger surface area per unit volume requiring
higher quantity of bitumen for coating. The presence of some quantity of flaky and
elongated particles in an aggregate mass is inevitable, as these are bound to be produced
in the aggregate crushing operation. But appropriate standards have been prepared to
limit the quantity of such particles in an aggregate mass depending upon a particular use
of such aggregates. The weight of flaky (or elongated) particles expressed as percent of
total sample of aggregates and weight of long particles as a percent of non-flaky
material is known as flakiness and elongation index respectively.
A flaky particle is one whose least dimension (thickness) is less than 0.6 times its mean
dimension. The test is not applicable to aggregates of sizes smaller than 6.3mm.
An elongated particle is one whose greatest dimension (length) is greater than 1.8 times
its mean dimension. The test procedure is given in IS: 2386-1963 (Part 1). The
elongation test is not applicable to aggregates of sizes smaller than 6.3 mm.
Specific Gravity: Specific gravity is the ratio of the mass of a given absolute volume of
aggregates to the mass of an equal volume of water at a specified temperature. The test
procedure is given in IS:2386-1963 (Part 3). The specific gravity value of aggregates is
required in computation of voids in bituminous mix design. For coarse aggregates, the
wire basket method is used for determination of specific gravity, while for fine
aggregates, the pyknometer method is used. For filler materials, specific gravity bottle
is used.
Water Absorption : Water absorption is the difference in weight of aggregates between 24

hours water saturated surface-dry condition and oven-dry condition expressed as
percentage of the latter. The test procedure is given in IS:2386-1963 (Part 4). Water
absorption is high for porous aggregates. It is necessary to provide extra binder in a
bituminous premix at the rate of 0.5 percent for every 1 percent water absorption in
excess of 2 percent.
Aggregates Impact value: Number of tests are used to evaluate strength characteristics of
aggregates. A simple test, which is also correlated with other tests, is the Aggregate
Impact Test. The test procedure is given in IS: 2386-1963 (Part 4). The aggregate
impact value gives a measure of resistance of aggregates degradation due to impact,
which differs from characteristics value of resistance to crushing under slow
compressive load. In the aggregate impact test, 12.5 to 10mm size clean dry aggregates
of specified volume are subjected to 15 blows of a 13.5 to 14.0 Kg. hammer falling
from a height of 380 + 5 mm. The weight of the sample of aggregates passing 2.36mm
sieve after the test expressed as percentage of the original weight is the aggregate
impact value. The lower the aggregate impact value, the higher is its strength.
Soundness: This test indicates the susceptibility of aggregates to disintegration under the
action of water containing sodium and magnesium sulphates. The test procedure is
described in IS:2386-1963 (Part 5). Washed and dried aggregates of specified sizes are
immersed in saturated solution of sodium sulphate / magnesium sulphate for 16 to 18
hours. The sample is then removed and dried to constant weight. This forms one cycle.
The test is repeated for 5 cycles. After 5 cycles, the sample is washed, dried in an oven
and re-sieved on those very sieves, which were used before the test. The material
retained on each sieve is recorded. The cumulative difference between the amounts of
material retained on each sieves before and after the test is the loss due to disintegration
and is expressed as percentage of total initial weight of the sample. The permissible
value for loss in sodium sulphate and magnesium sulphate after 5 cycles are 12 percent
and 18 percent respectively. If the loss is more, then the aggregates are likely to
disintegrate by water containing such salts.
Stripping value : Stripping is the displacement of bitumen film from a coated road aggregate
particle in the presence of water. The details of test procedure are given in IS:6241-
1971. In this test, 20 to 12.5mm size aggregates are coated with 5 percent bitumen
under specified conditions and immersed in distilled water at 40oC for 24 hours. The
average percent area of aggregate surface stripped is assessed visually, while the
aggregates are under water. The amount of stripped area expressed as percent, is the
stripping value.
Appendix V
Testing of Bituminous Materials
IS: 73-1992 specify the requirements of penetration grade bituminous binders. All the tests
are detailed in IS: 1201, IS:1220, IS: 10512 and IS: 9381, IS: 8887-1995 has specified
requirement of cationic bitumen emulsions. A few important tests and their significance are
briefly described below :
1. Tests on Bitumens
i. Specific Gravity : Details of test are given in IS: 1202-1978. It is defined as the ratio
of the mass of a given volume of the bitumen to the mass of an equal volume of water
at 27oC. It is used to compute the volume of bitumen and determination of voids in
compacted bitumen mixture in Marshall method of mix design. It is determined by
pyknometer.
ii. Water Content Test : This test is specified in IS: 1211-1978. Water content is
determined using Dean and Stark method. It is desired that bitumen should contain
minimum water content. The maximum limit is 0.2 percent as per IS:73-1992. Water
Content more than the specified limit causes frothing during heating.
iii. Flash and Fire Point by Cleveland Open Cup : This test is specified in IS:1209-
1978. It is defined as the lowest temperature in oC at which the vapour from heated
bitumen catches fire momentarily in the form of flash. The fire point is the lowest
temperature in oC at which the vapour of bitumen ignite on application of flame at
least for 5 second. The heating rate is 5oC/minute. This test is indicative of fire hazard,
if a bitumen is heated beyond flash point. The fire point is usually 5-10oC higher than
flash point. The minimum limit of flash point is 220oC.
iv. Softening Point Test (Ring and Ball) : Details of apparatus and procedure are given
in IS:1205-1978. Softening point, is a temperature measured in oC, at which a
bituminous binder attain a particular degree of softness under specified test
conditions. Distilled water is used as bath medium for bitumens with softening point
value below 80oC and glycerol for value beyond 80oC. The temperature of bath is
raised at 5oC minute from 50 in case of water and from 35oC in case of glycerol. The
temperature, at which, a standard steel ball (3.5 g) placed over bitumen touches a base
plate 25 mm below the ring is recorded as softening point. It signifies the temperature
at which bitumen passes from semi-solid state to liquid state and indicate the
atmospheric temperature at which the bitumen is likely to bleed. Hence, softening
point of a bitumen should be 5-10oC higher than the maximum atmospheric
temperature.
v. Penetration Test : This test is specified in IS: 1203-1978. It is conducted to measure
consistency and identify the grade of bitumen. It is defined as vertical distance
traversed by a standard needle in 0.1mm unit under a known load (100g), at a fixed
temperature (25oC), for a known time (5 second). The distance in 0.1mm units is
known as penetration of needle, the softer the bitumen. For each test three
measurements are needed at 10mm apart on bitumen surface.
Repeatability : If penetration is less than 50, 1 unit
If penetration is more than 50, 3 percent of mean
Reproducibility: If penetration is more than 50, 4 units
If penetration is more than 50, 8 percent of the mean
vi. Ductility Test : Standard test procedure is described in IS: 1208-1978. Ductility is
measured in cm and is defined as the distance in cm to which a briquette bitumen
specimen will elongate before breaking when it is pulled apart at 5 cm/min. rate at
27oC. The cross section at minimum width of specimen is 10mm x 10mm. Sample is
to be prepared in standard mould and to be placed at 27oC for minimum 90 minutes. It
signified the property by virtue of which a bitumen can exist in a thin film without
breaking.
vii. Viscosity Test : Viscosity of bitumen plays a vital role for different operations of
bituminous road construction. The suggested viscosity values are given below :
Operation Viscosity, cST
Pumping 600-800
Spraying 50-200
Mixing 150-300
Laboratory mixing 150-190
Laboratory compaction 250-310
Rolling 1000-10000
From the viscosity temperature relationship, the appropriate temperature for

various operation of bituminous road construction can be determined. It is a
standard test specified in IS: 1206-1978. Viscosity is defined as resistance to
flow due to internal friction of bitumen. In Industrial units, it is measured by
time in second taken by specified volume of bitumen/cutback
bitumen/emulsion to flow from 10mm/4mm orifice cup of standard tar
viscometer or saybolt-furol viscometer. There are several cup viscometers
available which differs mainly in the size of opening through which bitumen is
drained. Absolute viscosity = flow time x density x K. The value of K for 4
mm cup (STV), 10mm cup (STV), and saybolt furol viscometer are 0.0132,
0.400 and 0.00218 respectively. The test results may be expressed as :
kinematic viscosity = flow time x K. It can measure viscosity between 320-
5600 cSt. Kinematic viscosity is expressed in Stocks, which can be obtained
by dividing absolute viscosity by density. It is measured by recording time in
seconds required for fixed quantity of material to flow through a glass
capillary viscometer at a given temperature. The product of time flow and
calibration factor gives the kinematic viscosity.
viii. Loss on Heat Test : this test is specified in IS: 1212-1978. it is defined as the percent
loss in weight (exclusive of water content) of volatiles, when a sample of bitumen (50
g) is heated at a standard temperature (163oC) under specified test conditions. Sample
is prepared in a penetration cup (55 mm dia and 35mm depth) and placed in an oven
for 5 hours on a rotating shelf (5-6 revolutions per minute). Penetration test is also
conducted on the sample before and after heating. This test signified the resistance of
a bitumen to hardening during construction. The loss in weight and percent retained
penetration values are reported.
Percent loss in weight = Wt. of bitumen before heating Wt. of bitumen after heating
--------------------------------------------------------------------------------- x 100
Wt. of bitumen before heating
Retained Penetration, percent = Penetration after heating
---------------------------------- x 100
Penetration, before heating
ix. Solubility in Trichloroethylene (TCE) : Details of test are given in IS: 1216-1978. It
is a measure of the purity of bitumen (1-2g) in the solvent and separating the
insolubles by filtering over asbestos mat in gooch crucible. The limit for solubility of
bitumen in TCE is minimum 99 percent.
x. Stripping Test : Stripping (IS: 6241-1971) is the displacement of bitumen film from
coated road aggregates in the presence of water. In this test 20-12.5 mm size
aggregates are coated with 5 percent bitumen under specified conditions and
immersed in distilled water at 40oC for 24 hours. The average percentage area of
aggregate surface stripped is assessed visually. The amount of stripped area expressed
as percent, is the stripping value. The permissible maximum limit is 15 percent.
Stripping value of different types of aggregate is invariable. A higher value

indicates possibility of loss of adhsion between aggregate and bitumen in
presence of water. The stripping depends upon type aggregate shape, size,
grain size, surface texture, mineralogical composition, moisture, acidity and
alkalinity.
1. Tests on Bitumen Emulsions (IS:8887)
i. Sieve test on IS 600 Micron Sieve : This test complements the settlement test. It is a
stability test, used to find out amount of bitumen in the form of larger globules in a
emulsion, which cannot be determined by settlement test. The larger drops can clog
spraying equipment and will not provide uniform coating. A specified amount of
sample is poured through a IS 600 micron sieve. After rinsing with distilled water, the
sieve and bitumen are dried in oven. The amount of retained bitumen is determined by
weighing and reported as residue on sieving.
ii. Binder Content : The binder content in bitumen emulsion can be determined by a
distillation test. A specified quantity of emulsions sample (50g) is distilled under
specified test conditions. The binder content is determined by substracting percentage
of water content from 100. The residue is used for further testing to check the quality
of bitumen in a emulsion.
iii. Stability to mixing with Coarse Aggregates : This test has a three fold purpose. It
determines the ability (i) to coat the aggregate (ii) to withstand mixing action while
remaining as a film on aggregates and (iii) to resist washing action of water after
completion of mixing. The method is used to determine coagulation value using
aggregate (200g) and emulsion (50g).
iv. Viscosity by standard Saybold Furol Viscometer (IS:3117) : Viscosity is defined
as a fluids resistance to flow. In the case of emulsion, the saybolt furol viscosity test
is used as a measure of consistency. Results are reported in Saybolt Furol seconds.
The viscosities of Rs. (Rapid setting) and MS (Medium setting) emulsions are
determined in seconds at 50oC and of SS (Slow Setting) emulsions at 25oC
respectively.
v. Storage Stability Test : This test is used to determine the ability of an emulsion to
remain as a uniform despersion during storage. A measured quantity of sample is
placed in two cylinders (stoppered) and allowed to stand for 24 hours. A specified
sample is siphoned from the top and placed in oven for a set time at a specified
temperature. They are removed, allowed to cool and weighted after the top sample is
removed but a small portion of bitumen emulsion remaining in each cylinder is
siphoned off. A specified portion that is left is just through the same procedure as for
the top sample. The storage stability is expressed as the numerical difference between
the average percentage of bituminous residue found in two top samples and two
bottom samples.
vi. Particle Charge : The particle charge test is conducted to identity cationic emulsion by
its positive charge. It is performed by immersing two copper Pates 25x75mm which
are connected to a 12 volt circuit. At the end of specified period of 2 minutes, an
appreciable quantity of bitumen is deposited on cathode indicating cationic emulsion.
vii. Miscibility with Water : This test finds, if MS and SS emulsion can be mixed with
water. It is not applicable for RS emulsions. After adding and stirring with distilled
water, the emulsion sample is allowed to stand for two hours. It is then examined for
any appreciable coagulation of the bitumen droplets in an emulsion. This test is a
measure of quality of emulsion.
viii. Stability with Cement : The cement mixing does the same for SS emulsion, as the test
does for RS emulsions. In the cement mixing test, a sample is mixed with finely
ground Portland cement and mixture is washed over a IS 1.4 mm sieve. The amount
of material retained may be recorded as percent coagulation.
ix. Test on Residue : Penetration, ductility and solubility in trichlorothylene tests are
conducted after distillation test to check the quality of bitumen. These tests are
conducted as per procedures specified in IS:1201-1220.
Appendix VII
Determination of Temperature of Binder
The temperature of bituminous binder shall be determined with the help of calibrated
standard mercury thermometer or any other type of standard thermometer. The range of
thermometer for different type of bituminous materials and their accuracy shall be as under:
1. Melted Bitumen : ambient to 200oC accuracy + 1oC
2. Cutback bitumen : ambient to 100oC accuracy + 0.5oC
3. Melted Bitumen : ambient to 80oC accuracy + 0.5oC

Appendix VIII
Determination of Bitumen Content in Bituminous Mix
The test is intended for determination of bitumen content in the bituminous mix by cold
solvent extraction method . The mineral aggregates recovered from the test can be used for
checking their gradation. A representative bituminous mix sample of about 500 gm by weight
is accurately weighted and placed in the bowl of extraction apparatus and covered with
commercial grade of trichloroethylene. Sufficient time (not more than one hour) is allowed
for dissolving the bitumen in solvent. The filter ring of the extractor is dried, weighed and
then fitted around the edge of the bowl. The cover of the bowl is clamped tightly. A beaker is
placed under the drain to collect the extract. The machine is revolved slowly and then
gradually the speed in increased to a maximum of 3600 rpm. The speed is maintained till the
solvent ceases to flow from the drain. The machine is allowed to stop, 200ml of solvent is
added and the above procedure is repeated. A number of 200ml solvent additions (not less
than three) are used till the extract is clear and not darker than a light straw colour. The filter
ring from the bowl is removed, dried first in air and then in oven at 115oC to constant weight,
and weighed. The fine materials that might have passed through the filter paper are collected
back from the extract preferably by centrifuging. The material is washed and dried to constant
weight as before. The percentage of binder in the bituminous mix sample is calculated as
follows :
W1 (W2 + W3 + W4)
Percentage of Binder = --------------------------------------------- x 100
W1
Where,
W1 = Weight of sample, gm
W2 = Weight of sample after extraction, gm
W3 = Weight of fine material recovered from the extract, gm
W4 = Increase in weight of filter ring, gm

Appendix - IX
Determination of In-Situ Density of Bituminous Course
The metallic tray of the field density unit is kept on a level spot of the bituminous surface and
a hole, 10 cm in diameter, is cut up to the full thickness of the layer. All bituminous materials
removed from the hole are carefully collected and weighed. The thickness of the layer is also
recorded.
A known weight of dry standard sand passing 600 micron sieve and retained on 300 micron
sieve, is taken in the sand pouring cylinder. The cylinder is kept directly over the hole, and
the shutter of the cylinder is released without any jerk and closed when the hole is filled with
the sand. The quantity of the residual sand in the cylinder as well as the quantity filling the
cone of the cylinder are separately weighed.
The in situ density of the layer is calculated as follows :
In situ density = (A*D)/(W-(W1+W2)) gm /cc
Where,
A = Weight of bituminous materials removed from the hole cut in the layer, gm
B = Initial weight of sand taken in the cylinder, gm
W1 = Weight of sand filling the cone of the cylinder, gm
W2 = Weight of sand remaining in the cylinder, gm
D = Bulk density of sand, gm/cc.
Prior calibration for depth of hole, is necessary.

Appendix X
Rate of Spread of Aggregates in Surface Dressing
The rate of spread of aggregates by the aggregate spreader or any other suitable means can be
checked by measuring the area covered by each lorry/truck/any other device of known
capacity. This can also be checked by removing the spread aggregates from small areas of the
road surface and weighing them. A 20cm square metal frame is laid on the new surface
dressing, and all the aggregates within the enclosed area are collected, washed in solvent to
remove bitumen and then weighed, and the rate of spread of aggregates is calculated. It is
measured along the road at intervals of between 4 m to 8 m. The variation in the rate of
spread of aggregates should be within + 20 percent of the mean.
Appendix - XI
Checking of Surface Regularity Using a Straight Edge
The procedure to be followed for checking the surface regularity with a straight edge is as
follows :
i. The 3 metre straight edge may be made of steel or seasoned hard wood. When made
of wood, it may be 75mm wide and 125mm deep and its test face should preferably be
lined with a metallic plate. The edge should be perfectly straight and free from warps,
rots or defects of any kind.
ii. Periodically, the straight edge should be checked for its trueness with a string or a
metallic master straight edge. The straight edge should be rectified or replaced as soon
as the same has lost its trueness.
iii. The depressions under the straight edge are to be measured with a graduated wedge.
The wedge should be preferably be metallic but may alternatively be of seasoned upto
25mm with a least count of at least 3mm.
iv. For recording depressions in the longitudinal profile of the road surface, the straight
edge is placed longitudinally, parallel to the centre line of the road. Measurements
along two parallel lines may normally be sufficient for a single land road.
v. The straight edge has limitations as regards the measurement of undulations at vertical
curves. Additional templates or straight edges may be made for this purpose specially
if the curves are sharp.
vi. The straight edge may be placed at the starting point with the wedge inserted between
it and the test surface, where the gap is maximum, and the reading is taken. The
wedge may then be slided forward by about 1.5 m distance and the wedge reading is
recorded. This process is continued. The straight edge need not always be moved
forward to record the maximum depression existing at a location. Locations with
depressions in excess of the specified magnitude should be marked on the surface.
A team of three persons consisting of two workmen and a supervisor would be required for
one straight edge and two graduated wedges. The two workmen will operate the
straight edge, while the supervisor will record measurements with the wedges and
do the markings on the road.
VOLUME - III
Section - 11 Drilling And Grouting
CONTENTS
Sl.No. Contents
22.1 References
22.2 Terminology
22.3 Drilling
22.3.1 General
22.3.2 Guide line factors affecting selection of drilling equipment
22.4 Diamond Drilling
22.4.1 Equipment
22.4.2 Drilling Procedures
22.4.3 Drilling Observations
22.4.4 Record of Observations
22.4.5 Selection & Care of Core Bits
22.4.6 Core Barrels
22.4.7 Spindle Speed
22.4.8 Bit Pressure and Water Pressure
22.4.9 Core Recovery
22.4.10 Handling of Equipments
22.4.11 Core Box Arranging & Indexing of Cores
22.4.12 Storage of Cores
22.5 Calyx Drilling
22.6 Percussion Drilling
22.6.1 Drilling with Jack Hammer
22.6.2 Drilling with wagon Drill
22.6.3 Drilling with Drifter
22.7 Grouting Rock
22.7.1 Coordination with Design Requirement
22.7.2 Coordination with other construction activities
22.7.3 Relation of Geology in Grouting and the Importance of Foundation, Exploration &
initial Experimentation.
22.7.4 Grouting methods
22.7.5 Pattern & depth of Holes & Sequence of Grouting
22.7.6 Materials
22.7.7 Drilling & Grouting Equipments
22.7.8 Drilling
22.7.9 Washing Holes
2.7.10 Water Testing of Holes
22.7.11 Water Connections
Sl.No. Contents
22.7.12 Grouting or Rock Foundations
22.7.13 Back Filling / Packing of Grout Holes
22.7.14 Uplift gauge (Upheaval Gauge or Foundation Displacement indicator)
22.7.15 Drainage Holes
22.7.16 Repair & Cleanup
22.7.17 Technical Field Records
Appendix - I
Appendix - II
Appendix - III
Appendix - IV
Appendix - V
Appendix -VI
Appendix -VII
15:6909-1990 Super sulphated cement
15:6926-1990 Code of practice for diamond core drilling for site investigation for river valley
projects.
15:6935-1973 Method of determination of water level in borehole.
IS:10135-1982 Code of practice for drainage system for gravity dams.
IS: 12330-1988 Sulphate resisting cement.
2.1722.2 TERMINOLOGY
22.2.1 Blanket or Consolidation (Area\ Grouting - Blanket or area of consolidation

grouting refers to grouting of an area through shallow holes for improving the foundation
condition by bonding together the jointed or shattered rock into more or less a monolithic
mass.
222.2 Curtain Grouting - Cuitain grouting refers to grouting of one or more lines of deep
holes in order to create a barrier against seepage. This is sometimes referred to as high
pressure grouting.
22.2.3 Full depth grouting - A method ofgrouting in which the entire depth of a hole is
grouted in one operation by connecting the grout supply lin to the manifold at the top of the
hole.
22.2.4 Stage - A partial depth of hole, treated or to be treated.
22.2.5 Stage Grouting - A method of grouting in which a hole is deepened and grouted in a
descending sequence of stages.
22.2.6 Packer - The device used in the hole to segregate a part of hole for grouting installed
at suitable elevation for maintaining pressure in the hole.
22.2.7 Packer Grouting A method of grouting of a hole which has drilled to its final depth,
in any desired sequence of section which are isolated by use of packers from the ungrouted
sections.
22.2.8. Single Packer method Method in which one Packer is used in the drill hole, in this
case the test section is between the bottom of the bore hole and the packer(see fig 1 A)
22.2.9 DOUBLE PACKER METHOD METHOD IN WHICH TWO PACKERS ARE USED IN THE
DRILL HOLE. IN THIS CASE THE TEST SECTION IS BETWEEN THE TWO PACKERS (SEE
FIG 1B)
22.2.10 SPLIT SPACING GROUTING METHOD- A SEQUENCE OF DRILLING AND GROUTING

HOLES IN WHICH WIDELY SPACED HOLES ARE DRILLED AND GROUTED INITIALLY AND
THE SPACING IS SUBDIVIDED BY INTERMEDIATE HOLES . THE INITIAL SET OF HOLES
ARE CALLED PRIMARY HOLES AND INTERMEDIATE HOLES ARE TERMED SECONDARY
ETC. ACCORDING TO THE SEQUENCE OF SUBDIVISION.
22.2.11 SLUSH GROUTING- APPLICATION OF CEMENT SLURRY TO SURFACE ROCK AS A MEANS

OF FILLING CRACKS AND SURFACE IRREGULARITIES OR OPEN JOINTS TO PREVENT
LEAKAGE AND SLACKING.
22.2.12 Contact Grouting -Contact grouting is a sealing operation intended to bring abmt as
nearly as possible a Thily bonded contact between any concrete stnicture and the adjacent
rock.
22.2,13 Washing -Washing of the walls of the grout bole by water under pressure after
completion of drilling bit before grout injection.
22.2.14 Jetting - Systematic washing of groups of holes in order to remove the erodible
material in the intervening rock mass.
22.2.15 Circulating System - The piping arrangement by which grout is conveyed from the
grout pump to the grout bole and through a return line from the hole to the grout pump.
22.2.16 Single Line System -The piping arrangement by which grout is conveyed from a
grout pump to the grout hole through a single line of pipe without a return line.
22.2.17 Collar of hole - The opening of hole at surfae or opening of stand pipe, protruding
out of ground level is called collar of hole.
22,2.18 Grout Nipple - A short length of pipe, installed at the top of a grout hole through
which drilling is done and/or to which the grout header is attached for the purpose of
injection by grout.
22.2.19 Agitator -A machine employed for agitating an already mixed grout to maintain the
grout in. colloidal/suspended state, during storage or grouting operation.
22.2.20 Manifold or Reader - The piping arrangement at the top of the hole for connecting
the supply line to the-bole.
22.2.21 Patterns - Arrangement of boles in plan and vertical section.
22.2.22 Grout Refusal - When rate of grout intake of a hole or stage reduces beyond a
specified limit, averaged over a given time, at a particular pressure, the hole is said to have
attained a state of grout refusal and grouting of a hole is said to be completed.
22.2.23 Percolation Test -Pumping of water into a hole through a direct connection or a
packer to measure water acceptance under pressure. .
22.2.24 Lugeon - It is the water absorption during the test in lit/min/metire depth conducted
under a standard pressure of 10kg/cm2 or normalized value in proportion to the test pressure
when tested at lower pressure.
22.3 DRILLING
22.3.1 General
Drilling shall be done by one of the following methods as specified :-
(a) Percussion Drilling - In this method rock is broken by impact from the repeated blows. It
includes drilling using jack hammer, Drifter, Wagon drilllt also includes down the hole
hammer- drilling.
(b) Rotary Drilling- In this method the drill grind the rock into small particles through
abrasive effect of bit that rotates in the hole. It includes drilling rigs using diamond bits, etc.
and calyx drilling.
22.3.2 Guideline Factors Affecting Selection of Drilling Equipment:

Holes are drilled for several purposes such as for exploration, for-injection of grout and for
receiving charge of explosive for blasting etc. Among the many factors that affect the
selection of equipment, the important ones are as follows:
(i) The purpose of the hole, such as blasting, grout injection, etc.
(ii) The size and required depth of hole.
(iii) The nature of terrain. Rough surface may require jack hammer.
(iv) The type and hardness of rock
(v) The extent to which the rock is broken or fractured.
(vi) Overall size of the project
(vii) Availability of water for drilling purposes, lack of water favours
dry drilling.
(viii) The extent to which rock is to be broken for handling.
(ix) Overall economy
22.3.2.1 Percussive drilling methods are generally more economical in all types of rocks.. For
deep holes it may be advantageous to use the overburden drilling equipment. By virtue of the
separate rotation drive, greater speed and economy can be achieved, also by virtue of the
greater rigidity of the casing tube combined with the drill rods, better control on inclination of
holes can generally be achieved in the overburden drilling equipment. Down the hole hammer
is also capable of maintaining a better control on the inclination. However, the hammer may
get clogged when the drill cutting forms slush in soft saturated strata and cannot be removed
by air flushing.
22.3.2.2 During percussive drilling in stratified rocks where the resistance of the rocks is
prone to variation the holes may get curved and control on inclination may be lost. In such
cases guide tubes may be used for ensuring verticality of the holes (or alternatively) rotary
drilling may be used.
22.3.3 Irrespective of whether air or water is used for flushing of the hole during drilling,
thorough cleaning by water flushing is essential before starting grouting operations.
22.4 DIAMOND CORE DRILLING
22.4.1 Equipment
22.4.1.1 Rotary Diamond Core Drilling Machine -The machine shall be capable of
providing a rotary motion and using drilling bits. The feed or thrust to the drilling tool is
actuated by hydrant i.e. mechanical, manual or other suitable means. The machine shall also
be capable of drilling angular holes where required .by prevailing geological site conditions.
22.4.1.2 Water Pump or Drilling Mud Pump- The pump shall he capable of delivering
sufficient volume and pressure for the size of the hole to be drilled,
22.4.1.3 Core Barrels - The type of core barrels shall depend upon the type of formation to
be drilled through. For soft rock or fractured hard rock the use f i double tube core barrel is
recommended.
Note :- The outer diameter of single and double tube core barrels and the corresponding hole
and core diameters shall be as given in table below:
TABLE -1 CORE BARREL OUTER DIAMETERS AN!) HOLE
AND CORE DIAMETERS
Size designation Outer Diameter of Hole Diameter mm Core Diameter mm

single Tube Type A or core barrel mm
Type B (G or M
Design)
(1) (2) (3) (4)
AW 46.0 48.0 30.0
BW 57.9 59.4 42.0
NW 73.8 75.6 54.7
Note :- Larger core barrels to give core diameters upto 151.6 mm are available from
manufacturers.
22.4.1.3:1 Single Tube - This shall consist of a hollow steel tube, with the bead at the upper
end threaded for drillrod, and fitted at the lower end with a blank or set reaming shell, a core
lifter, and a core bit.
22.4.1.3.2 Double Tube Swivel Type, Type A -(Commonly referred to as G design)The

double tube, swivel tube, Type. A shall have an outer tube and a concentric inner tube. The
latter is suspended from the core barrel head on ball or roller bearing and is positioned at the
bottom by the reamer shell. Ball or roller bearing suspension of the inner tube makes rotation
of inner tube independent of the barrel.
22.4.1.3.3 Double Tube Swivel Type, B (Commonly referred to as M design) This is similar
to double tube type A with the important difference that core lifter is contained in a lifter case
attached to the bottom of the inner barrel. The lifter case extends down close to the bit face
for protecting the core from water washing at any time. To accommodate this additional
length on the inner tube, the bit is longer and has a female connection. The short length
reamer shell has male threads on both ends.
22.4.1.3.4 Triple Tube - With split inner tube or plastic inner tube
22.4.1.4 Core Bits - These shall be set with diamonds, tungsten carbide or similar hard
materials or impregnated bits appropriate to the hardness of materials being drilled.
Note :- In a set bit as the name indicates the diamonds are set in a material embedding
material on the surface and the diamonds protrude out from the matrix. Impregnated bits
contain uniformly sized and graded diamonds evenly distributed through - out the matrix.
Impregnated bits are throw away type and they should be used until all the diamonds are
consumed.
22.4.1.5 Reaming Shell- It joints the drill bit to the core barrel It is either blank or set either
with diamonds or tungsten carbide appropriate to the hardness of the materials being drilled,
to act as a reamer and so enlarge the hole slightly. I be outer diameter over the diamonds set
on the reamer shells will be slightly more than the outer diameter of the core barrel so that the
diamonds on. the reamer shell may ream the drill hole sides- and thus prevent the barrel
rubbing against the wall rock and wear prematurely.
22.4.1.6 Drive Pipe Or Casing - Standard weight or extra heavy pipe, as required by the
nature of overburden or the drilling method shall be famished, where necessary for driving
through overburden to bedrock. The casing or pipe shall be of a diameter to take the largest
size core barrel to be employed. The inside of the casing or pipe shall be free of burrs and
obstructions.
22.4.1.7 Casing -The casing pipe shall be of mild steel and seamless. When it is necessary 10
case through formations already penetrated by the drill or when no drive easing has been
employed, auxiliary casing shall be provided that will fit inside the hole and permit the use of
the next smaller bid ad core barrel.
NOTE: The outer and diameters of casings are given in Table 3.
\TABLE :3 DIAMETERS OF CASINGS
Size designation Outer Diameter mm Inner Diameter

mm
(1) (2) (3)
EX 46 38
AX 57 48
BX 73 60
NX 89 76
44x37mm 44 37
54x47mm 54 47
64x57mm 64 57
74x67mm 74 67
84x77mm 84 77
22.4.1.8 Drill Rods - The drill rods shall be of such diameter to permit adequate flow of the
drilling fluid (dril1in mud or water) and to provide sufficient upward velocity of the fluid
between the rod and the hole wall, to remove and recover the cuttings effectively and
completely.
NOTE : The outer and inner diameter of drill rods are given in Table 4.
TABLE 4: DIAMETER OF DRILL RODS
Size designation Outer Diameter mm Inner Diameter mm

(1) (2) (3)
EW 34.9 25.4
AW 43.6 34.1
BW 53.9 44.4
NW 66.6 57.1
NOTE :- Larger drill rods upto 88.9 mm outer diameter and 77.7 mm inner diameter are
available.
22.4.1.9 Retrieving Toots - Special retrieving tools for casing, rods, core barrels, bits, other
small objects, lost pieces of core etc. shall be furnished. -
22.4.1.10 Auxiliary Equipment - Auxiliary equipment shall be furnished as required by the

work including tripod, roller bits, fishtail bits, wrenches, equipment for mixing the drilling
mud, etc.
For inclined bore holes it will be necessary to obtain suitable equipment for measuring the
inclination of bore holes. In the absence of this equipment the method of etching by glass
tube with hydrochloric acid lowered in the hole shall be followed:
22.4.2 Drilling Procedure
22.4.2.1 In any drilling for surface exploration the endeavour should be to get the maximum
core size to maximum depth for obtaining maximum core recovery as well as optimum data
for interpretation, -
22.4.2.2 The core drilling procedure shall be used when formations are encountered which
are too hard to be sampled by soil sampling methods. A penetration of 30 cm or kss for 50
blows according to IS:2131-1992 Method for Standard penetration for soils shall be
considered as indicating that soil sampling methods are not applicable and core drilling shall,
be adopted. In sothe cases the use of dry drilling techniques with Tungston carbide bits may
be advantageous. If even this technique indicates no penetration wet drilling techniques shall
be adopted with diamond bits.
22.4.2.3 The casing shall be seated firmly on the bed rock or the hard material where found
necessary to prevent caving of the hole, to prevent loose materials froiu entering the hole, and
to prevent the loss of drilling fluid. The surface f rock or hard material shall be levelled when
necessary by the use of a fish tail or other bits for proper seating of the casing.
22.4.2.4 Core drilling shall begin using the Type A or Type B (NWG or NWM) double tube
swivel core barrel. After drilling the required run, the core barrel shall be removed from the
hole and the core shall be taken out. If the core blocks the flow of the drilling fluid during
.drilling, the core shall be removed by withdrawing the core barrel immediately.
22.4.2.5 The core and the cuttings shall be logged by a geologist:

22.4.2,6 The core cuttings shall be placed in the core box in a accordance with specification
under para 22.5.1.
22.4.2.7 When soft materials are encountered which produce less than 50 perent recovery,
core drilling shall be stopped. If soil samples are desired, such samples shall be secured in
accordance with the procedures described in IS:2131-1963 or IS:2132-1992. Diamond core
drilling shall be resumed when refusal materials are again encountered.
22.4.2.8 Special care shall be taken to record occurrence of seams, fissures, cavities and
broken areas etc. If such broken rock or cavities prevent the advance of the boring, action
shall be taken to (a) cement the hole, or (b) ream and case, or (c) case and advance with next
smaller size core barrel as the conditions warrant. Same procedure shall be followed where
fissures are encountered causing loss of drilling water return.
22.4.2,9 In soft, seamy or otherwise unsound rock, where core recovery is poor, the Type B
(M design) or the triple tube core barrel with bottom discharge bits shall be employed. In
hard, sound rock, the single tube core barrel shall be employed, if the core recovery is poor
double tube core barrel shall be preferred.
22,4.3 Drilling Observations
22.4.3.1 Behavior of Drill Water
22.4.3.1.1 The colour of the return drill water and the depth at which changes in regard to
these characteristics shall be recorded at frequent intervals. The return water brings with it the
cuttings at the strata through which the drilling is in progress and provides information with
regard to the litho logy and the general nature of the strata through which the drilling bit is
progressing. For example, drilling through ham and structurally sound quartzite's may,
generally, give clean water, with only a few particles, whereas, return drill water thickly laden
with cuttings, may be recovered while drilling through comparatively soft, interceded shale
strata or clay filled seams or shear zones. Excessively mud-laden water, containing a lot of
cuttings, may also be correlated with poor recovery of core at that depth and indicate
probable reason for the core loss.
22.4.3,1.2 The depth at which dull water is lost or returned filly or partially shall also be
recorded, as it may indicate the existence of open joints or any other special geological
feature, such as cavities and faults which may have caused the loss of water in the drill hole
at the specified depths, subsequent recovery of drill water, especially upon placement of
casing and/or grouting across the leaky zone, may indicate the extent of the leaky zones.
Approximate water intake values in the zone where total or partial water loss is observed
shall be assessed and recorded.
224.3.1.3 Where hot water is encountered during drilling, the temperature of the water, depth
of occurrence and amount of flow shall be recorded in remarks column of daily drilling report
Appendix I.
22.4.3.2 Rate of Penetration
22.4.3.2.1 The rate of penetration gives indication as to the comparative physical nature of
the strata through which the bit is passing. For example, in bard quartzite bands, the rate of
penetration is generally slow compared to the progress in shale bands. Therefore, the depth
through which a uniform rate of penetration was maintained and the depth at which it showed
a marked change shall be noted as this will help in locating the depth at which the actual
change of strata occurred, although, due to the loss of core in the softer formation, it may not
be possible to precisely locate its vertical extent from the examination of the core alone.
22.4.3.2.2 Any sudden fall of the drill rod and the depth at which such a fall occurs shall also
be carefully recorded. This may give an indication of the existence of any open seam or
cavity in the drilled strata or of any markedly weak or softer zone therein, if the fall of the
drill rod is also accompanied by highly muddy return drill water.
22.4.3.3 Core Loss
22.4.3.3.1 The depth at which a core loss might have taken place, as adjudged by the behavior
of the drill machine while drilling, shall be recorded. This will enable the geologist
interpreting the observations to give probable reason for the loss. In this connection, blockage
of drill bit during drilling and the recovery of redrilled and rounded core pieces shall be
recorded in the daily drill report.
Poor core recovery may be due to various causes, such as poorly consolidated nature of the
rock, presence of highly sheared zones, clay-filled seams, as well as inclination of the hole
with respect to the foliation of the rock and even due to the techniques of drilling.
Sludge samples often give important clues to adjudge causes for poor core recovery. These
samples shall be kept for all runs where poor core recovery is anticipated (see para
22.4.11.3.4)
Core recovery may be ruined by careless operation by drilling too fast, over drilling a run,
dropping core and grinding it or not pulling out the tools when the barrel is jammed and
thereby grinding the core. Vibration in the drill string also causes poor core recovery.
22.4.3.4 Vibration and Torque - Any heavy vibration or torque noted during the drilling
shall be recorded together with the depth of drilling at which these phenomenon are noticed.
Any remedial measures taken and their effect on vibration and torque shall also be recorded.
The record of vibration and torque shall be integrated with the type of formation crossed,
nature of core breakage and the amount of core recovered.
21.4,3,5 Ground Water Level In The Hole - The ground water level in the drill holes shall
be recorded day, both before and after the drilling and any fluctuations in the levels observed
therein shall be noted. In cases where considerable divergence in the levels is noticed it may
be necessary to bail out the water and record the level as recuperated to equilibrium value.
This information will give an indication as to the ground water table conditions, if this is
intercepted by the drill hole. It may also indicate the degree of tightness or otherwise of the
rocks drilled through, when studied in conjunction with the pressure percolation test data,
22.4.3,6 Other Special Condition to be Noted - Any other conditions which may be peculiar
to individual cases shall be noted. Some of the special conditions which are likely to occur
are given in 22.4.3.6.1 to 22.4.3.6. (see also Drill Observers Remarks under Appendix I).
22.4.3.6.1 Depth at Which Hole was Grouted - The depth at which grouting of the hole had
To be done shall be recorded for effectively interpreting the foundation conditions under an
engineering structure. Grouting of the hole may sometimes be necessary while the drilling is
being done through broken strata, as the sides of the hole collapse frequently due to the poor
physical condition of the substrata. Also, in those cases where the drill water is continuously
being lost and a flushing-of the cutting from the drill hole is not observed. grouting of the
hole may have to be resorted to avoid the jamming of the bit inside the hole in either case.
Necessity for grouting is an important indication of the ethological) and the physical nature of
rock being drilled through. If the hole is grouted or stabilized by using bent mite slurry the
fact shall be recorded.
22.4,3.6,2 Artesian Conditions - Wherever artesian conditions are observed, they shall be
recorded carefully. As far as possible accurate observations shall be made with regard to the
depth. the pressure and the volume of outflow of water from such artesian horizons, by using
water meters or by diverting the flow to a measured container. The piezornetric head of each
horizons as observed at the ground surface at each drilling point shall also be noted.
The piezometric head shall be determined by using a sensitive pressure gauge to the drill pipe
or casing. The alternative but approximate, method of determining the piezometrtc head h
fixing a pipe above the top of the hole as soon as an artesian horizon is encountered and
recording the rise of water level in the pipe may also be used. In order to accurately
determine the piezometric head of individual artesian horizons pierced by the bole, packers
shall be fixed at the top and bottom of the horizon in the hole prior to the recording of the
piezometnc head above the ground surface at the drilling point
22.4.3.6.3 Gas Discharge - Where subterranean gases like methane are encountered either
with the return water or gas bubbles or as gas shown at specific depths this information shall
be recorded. Samples of gas shall be collected and preferably analyzed at site. Where this is
not possible special precautions shall be taken to send the samples in hermetically sealed
containers for subsequent chemical analysis.
2Z,4.3.6.4 Permeability Test - These tests are necessary for properly evaluating the
permeability of the strata over which the proposed engineering structure will be founded and
to plan seepage control measures, These tests shall be conducted in accordance with
IS:5529(Part I)4990, IS:5529(Part II)-1990 (Also refer Appendix lV).
22.4.3.6.5 Deviation of Inclined Drill Holes - The deviation of inclined drill holes, if any,
during drilling shall be recorded in each run by using a bore hole clinometer, In the absence
of a bore hole clinometer, measuring of inclination of the hole with the help of etching by
hydrofluoric acid. of a glass tube lowered suitably in the hole, shall be undertaken.
224.3.7 Other Observations - Details of casings and bits used, depth at which blasting was
done, if any, for driving of casing, types of barrel (single, double or triple) and bits, depth at
which in situ tests were done mineralization, if any, encountered, supplies like petrol, diesel,
etc., used and other details given in Appendix I shall also be recorded.
22.4.4 Record of observations
22.4.4.1 The observations and other details shall be recorded in. the profonna given in
Appendix I Suitable notes shall be recorded for special observations.
22.4.4.2 One sheet of the proforma given in Appendix I shall be used for one shift of drilling
only. Drilling observers shall be present whole time on the drilling job. Copies of the
proformas duly filled in, shall be kept with the cores and, shall also be sent to the concerned
engineering geologist through the Engineer-in-Charge.
22.4.5 Selection and care of core bits:
22.4.5.1 Fast progress and good core recovery are not combined. In foundation
investigations, the emphasis shall be on good core recovery.
224.5.2 Diamond Set Bits:
22.4.5.2.1 The harder and more fine grained the rock is, the smaller diamonds shall be used.
Bits with big demimondes (5 to 15 stones per carat) are suited for soft rocks and for fractured
rocks of all types. Bits with 15 to 30 stones per carat are intended for hard fractured rocks and
bits with 30 to 60 stones per carat are mostly used in hard solid rocks. The diamonds that may
be used for different types of rocks are given, in Appendix II for guidance. The bits indicated
with cross (X) shall normally be used. In some cases other types of bits may be considered..
22.4.5.2.2 Bits of bigger diameter give a better core recovery and less disturbed core. The
diameter of the bits shall be decided by the demands of the drilling programme.
22,4..5.2.3 Precautions to be taken with new bits:
(a) It is preferable to use an old bit to start a hole.
(b) Speed, and bit pressure should be low to avoid vibration, and loss of diamonds (See also
para 22.4.7 & 22.4.8)
(c) As tools are lowered near bottom of the hole, water circulation should be started to
washout settled cuttings which usually extend up some distance from bottom.
(d) A new bit should never be pushed to the bottom of a bole, since an old bit is usually under
gauge, a new bit should be stopped 5 to 10 cm from the bottom and drilled. When the bottom
is readied, the new bit should be rim at a moderate rate and. slow feed for 3 to 5 cm to give
the diamonds a chance to seat themselves. This prevents the sharp points from being broken
off
(e) Wrench Jaws should not be allowed to touch the diamonds in a-bit. This applies also to
the reaming shells.
(f) When bits and shells are not in use they should be well oiled over their entire surface and
packed in a separate box used only for this purpose. Each diamond set tool should be
protected by waste, rags or other soft packing to prevent damage to the diamonds.
(g) When drilling through very hard, fine-grained, siliceous rock, the diamonds may get
polished after drilling only about a metre or more. When this happens the diamond bit cannot
be expected to make any further progress in that particular kind of rock and should be
removed from service and used later, either in another hole or in that same hole in some
different kind foundation. Very often a slight change in the grain or hardness of the formation
will remove the polish from the stones and render the bit useful for much additional drilling.
(h) When, drilling through highly abrasive rocks, there is tendency for the metal to wear away
from the diamonds. In these cases when the diamonds become exposed approximately one-
third of their size, the bits should be removed and reset. After one-third of the bulk of each of
the diamonds extends from the metal there is danger of further wearing away of the metal to
the point where: the diamonds will drop out.
(i) Burnt bits are sometimes caused by not tightening dull rods before lowering into the hole
and depending on torque when starting to drill to do so. Because of wash water escaping
through the joints the bit may run dry and hot in the mud and sludge at the bottom of the hole.
The bit will also get burnt if it gets into the accumulated sludge at the bottom of the hole and
drilling is started without cleaning the bottom of the hole.
22.4.5.2.4 Reselling of Bits - Items containing diamonds should be properly handled and
maintained as any erroneous use may easily cause expensive damage to the equipment and/or
limper drilling operations. Diamond set bits have to be reset at intervals, that is, the diamonds
are salvaged and replaced in a fresh mart Bits shall be checked after each run. Resetting
should be done on any of the following indications:
(a) If the matrix is worn out to the extent that more than 30 to 40 per cent, of diamonds are
exposed. This may indicate that too soft matrix has been used; the bit may be reset in a harder
matrix
(b) If the cutting edges of the diamonds are polished, the diamonds have a glare and are
shiny. This is an indication that the bit has been run with insufficient water pressure. In such
cases water pressure should be adjusted.
(c) if more than. 30 per cent, of the diamond paints are broken. This often occurs in highly
fractured rock where the diamonds are apposed to impacts which will break their points. In
hard rock, vibrations in the rod string may have the same results. In such cases the spindle
speed should be reduced or impregnated bits should be used.
(d) If some diamonds are missing. If the bit is continued to be used without resetting, more
diamonds will fall out and the rolling at the cutting face and destroying this bit as well as
other bits inserted in the hole. Further more the diamonds are lost and have to be replaced at
great cost.
22.4.52.5 Impregnated Bits: These bits are self sharpening and are designed to be run to
destruction. They are mostly used in very hard rock, for example hard granite, gneiss
pegmatite, hard sandstone, quartzite, and flint stone (see also appendix II). In highly fractured
rock the impregnated bits are often more resistant then diamond set bits. The pre-requisite for
the use of impregnated bits is that the dulled rock is abrasive, that is, hard particles of the
sludge will wear away the mett1 of the matrix thus exposing the embedded diamonds.
Impregnated bits will become polished if used in wrong type of rock or at low bit pressure in
connection with low spindle speed. In very hard and fine crystalline rocks they may get
polished by using a too high spindle speed. Impregnated bits should never be run in rocks
limestone, marble, dolomite, or serpentine which create an adhesive sludge without any
abrasive particles. If an impregnated bit does not cut, it can be sharpened by a gentle tapping
of the cutting surface with the edge of a big file.
22.4.5.3 Tungsten Carbide Tipped Bits (Saw-Tooth) - These are used for planning of the
rock surface before the more expensive diamond bits are used. They can also be used for
drilling in very soft rock and in overburden (See Appendix II). They should be retargeted at
intervals with silicon carbide disc.
22.4.5.4 Reaming Shells and Casing Shoe Bits - These should be reset under the same
conditions.
22.4.5.5 With each order for resetting there shall be indication for the matrix (its hardness),
carat content of diamonds in the bit (to define amount of additional diamonds) and diamond
size (stones per carat).
22.4.6 Core Barrels:
Single tube core barrels shall be used only in. solid unfractured rock and for the first 25 to 70
cm when a new hole is started. In fractured and/or soft rock, the use of single tube core barrel
will cause the core to be grounded jammed or washed away. Double tube core barrels shall
always be used in fractured and/or soft rocks. In very friable rocks Type B core barrels with
bottom discharge bits shall be used at slow speed and low bit and water pressures. Long core
barrels may be used in solid rocks and short ones in fractured rock. The runs shall never
completely fill the core barrels but leave a few centimeters.
22.4.7 Spindle Speed:
22.4.7.1 Diamond Set Bits - High spindle speed gives rapid progress. but the core recovery
will be hampered, especially in soft rocks. The spindle speed should therefore be regulated to
the properties of the rock. At small diameters and holes down to 180 m the spindle speed may
reach. but should rarely exceed 1500 rev/ruin while 100 to 200 rev/ruin is average at great
diameters and for deep holes. As an spindle speed should be 100 to 750 rev/min for NX bits
and 5 to 15 stones/carat; and for small diameter bits with 30-60 stones/carat, spindle speeds
of 500 to 1500 rev/mm are suitable: The bit speeds suitable for various types of rocks are
given in Appendix II
22.4.72 Impregnated Bits - The impregnated bits can work within a large range of spindle
speeds and high speeds give more: rapid progress. However, the spindle speed should never
be so high as to cause vibration in the rods. The highest V spindle speed should not exceed
that giving a periphery speed of the bit equal to 2.3 mis, which gives maximum speeds of
1000 rev/ruin for AX bits, 700 rev/ruin for BX bits and 550 rev/ruin for NX bits
22.4.8 Bit Pressure and. Water Pressure:
The bit pressure (feed pressure plus weight of the rods) should be low (160 to 315 kg) when a
new bit is put into operation to prevent too rapid wear or break of the cutting points of the
diamonds. As the polishing of the diamonds proceeds the cutting speed is reduced which can
be made up for by increasing the feed pressure. The requirement for resetting the bit gives
generally the limit for the pressure. However, the strength of the rods and the rig itself will
mostly impose the maxim pressure, 900 to 1130 kg with A-rods. If a worn out bit is operated
at high pressure, there is a danger of deviation of the hole. (incidence on bit pressure and
water pressure for various rock types is given in Appendix II.
22.4.9 Core Recovery:
Regardless of the careful supervisor an engineer may give to the driller the responsibility for
good core recovery which is largely in the bands of drill operators. Generally this may be
assured by adopting correct drilling techniques and special coring equipment. In this
connection the use of double tube or triple tube core barrel with bottom discharge bits would
be found useful in ensuring the maximum possible core recovery in soft rock or fractured
bard rock Special drilling techniques in such. cases may call for short inns of drilling and
judicious control of water supply and speed of drilling Core recovery may be ruined by
drilling too fast over if rifling a run, or dropping core and grinding it, or not pulling out the
tools when the barrel is jammed arid thereby grinding the core. This also damages the bit.
Vibration in the drill string causes poor core recovery, diamond wear and diamond losses in
bits and shells, wear and tear on drills and loss of footage. Guidance on. the causes of
vibration and the measures to be taken for controlling vibration are given in Appendix III.
22.4.10 Handling of Equipment:
22.4.10.1 All equipment whether at store or at work site shall be kept in a shed in. proper
order, preferably in racks and protected by grease; Expensive equipment shall be kept under
lock when not used. Diamond items and all threads shall be first prettied by soft wrapping.
22.4,10.2 Tools shall be used with care and for the intended purpose. There are special
wrenches for core barrel outer and inner tubes, for core barrel head coring bits and reaming
shells. Pipe wrenches are used for pipe & casings. Wrenches shall not be used wrenches of
wrenches also includes a risk of dropping the drill string with consequent damage to bits and
difficulties for retrieving the dropped equipment. Safety foot clamps shall always be used at
lifting and lowering operations.
22.4.11. CORE BOX ARRANGING AND INDEXING OF CORES :
24.4.11.1 GENERAL : AT THE SITE OF DRILLING, THE CORES, IMMEDIATELY ON THEIR

WITHDRAWAL FROM THE CORE BARREL SHALL BE PLACED IN CORE TRAY AND
THEN TRANSFERRED TO CORE BOXES SPECIALLY MADE FOR THIS PURPOSE.
22.4.11.2 Core Box These boxes should be made of seasoned specified timber or any other
durable material. If made of timber the top lid of the box shall be made up of a
maximum of twol planks. If two planks are used the lid should be stengthened by
means of battens. Battens should also be provided at each end at the bottom to
facilitate handling. There should be different sizes of compartments to accommodate
different sizes of cores. It is desirable to provide grooves on the inside of the
widthwise sides of the box corresponding to the widths of compartments for the AX,
BX and NX size cores (see Note 2 under Fig. 2) so that the partitions for the
compartments can be slide in easlily. The boxes will be of good workmanship, doords
fitting snugly with hinges and locks of specified quality approved by engineer in
charge
.
Note :- 1 - Indicates depth at which cores were obtained.
V DH = drill hole
RL = reduced level
Note :- 2 - This figure gives typical details of a box for 54.7 mm. diameter core. The box with
the same overall dimensions may be used for cores of diameter 42.0 and 30.0 mm. by
dividing the inside of the box into 5 or 6 compartments respectively instead of the 4
compartments shown in the figure for 54.7 nun, core giving the following compartment
width:
Core Diameter Width of compartment
in the Core Box
(mm) (mm)
54.7 61
42.0 48
30.0 36
The 54.7, 42.0 and 30.0 mm. are generally designated as NX, BX and AX cores respectively.
22.4.11.3 Arranging and Indexing of Cores:
22.4.11.3.1 The cores shall be arranged starting from the side nearest to the hinge from the
left to the right end of the box in the order of increasing depth from the surface, in a manner
very similar to the lines on the pages of a book (see Fig.2). All core pieces shall be numbered
serially, omitting very small pieces in the run. An arrow mark (---->) towards increasing
depth shall be marked on every piece of core.
22.4.11.3.2 The core shall be separated at the end of the runs, either by inserting cross
partitions of wood or by using the side supports in the case of the end of the core box, and the
depths shall be clearly marked with paint, indelible ink or copying pencil. For each run, the
pieces of core should be tightly packed together, as nearly as possible to its original condition
in the ground. The cross partitions of wood wherever used, shall be of suitable size and fixed
tightly to fit in the longitudinal partitions in the core box. (The cross partitions should be
about 50 mm in width and of length and depth to fit tightly into the compartments.)
22,4.11.3.3 In case there is no core recovery in an entire run, part of a run or in consecutive
runs, separate wooden filler blocks, preferably a wooden dummy equal in length to the core
loss, shall be inserted for each of the core loss sections and marked with paint, indelible ink
or copying pencil thereon. The appropriate depths shall be marked on the wooden partitions
on each flank of the core loss run. Each core loss dummy filler shall be arranged in a position
in the core box corresponding with the position of core loss in the ground. If the position of a
core loss within a run is not known (and this is often the case) then, by convention, the core
loss dummy filler may be placed at the bottom of the run.
22.4.11.3.4 For reaches where core recovery is anticipated to be poor, the return drill water
shall be collected in bowls and the settled sludge shall be recovered and suitably packed in
polythene bags and kept in the core box with separating wooden blocks on either side marked
with .the depths and the inscription washings*. Attempt shall be made to collect the cores, as
far as possible, even in the runs made in the overburden section at a drilling site.
22.4.11.3.5 Cores at the drilling sites shall be kept at a clean and dry place. The core boxes
shall be closed immediately after a core run is kept and the necessary indexing has been done,
in order to avoid any infiltration of extraneous material and the consequent spoiling of the
core surfaces, all of which may render proper interpretation of the cores difficult later on. The
cores shall be so packed in the core boxes that they are not damaged in transit. Packing
material like thy straw, cotton waste etc., shall be used to make the cores tight in the box.
Latches shall then be secured on each of the core boxes and, before they are transported to the
place of detailed examination and storage, it shall be ensured that the latches are well fixed
and that there is no possibility of mixing of the cores during their transit from the field to the
place of examination and then to the core shed.
22.4.11.3.6 The drill hole number, the box number and the engineering feature for which the
hole had been made shall be noted on the top of the lid of the indivi4ual core boxes at the
drilling site itself so as to avoid any possibility of the mixing-up of the core boxes. A suitable
core box or a set of core boxes for each bore hole shall be kept to avoid mixing of cores front
different holes. when there are more than one core box for a single bole, these shall be
numbered indicating the numerator as serial number and denominator as total number of core
boxes for that hole (for example 1/3, 213 and 3/3 for three core boxes for a hole)
22.4.11.3.7 The engineer-in-charge shall arrange, if possible, a Geological Assistant to

supervise and log when the drilling is in progress. The Agency for drilling shall afford all
facilities for his logging and collecting information. In cases, a geologist cannot be arranged
to be present during drilling, on completion of drilling of each hole, the cores shall be logged
by an engineering geologist who should also check the 4oaily Drill Report; and discuss with
the concerned driller any peculiarities or uncertainties recorded during the drilling of the hole.
The core boxes shall be finally shifted to a place of storage (a sited or building equipped With
racks, etc) for the purpose.
22,4.11.3.8 Three copies of each of the daily drill reports shall be sent along with the core
boxes, one for study in connection with the preparation of the detailed geological logs of the
drill holes by the site geologist and another for being kept as a record in the place of storage
for cores and the third for recording in Engineer-in-Charge office.
22.4.12 Storage of cores
22.4.12.1 Cores shall be maintained at medium and major river valley projects for at least 10
years after the completion of construction of the project so that it may be possible to check
the sub-surface conditions and to study. the. problematical foundation features which may
occasionally arise dining the construction phase or the post-construction maintenance phase
of the project. After this period, cores may be destroyed only on the Specific orders of Chief
Engineer. The place of storage shall be well ventilated aid lighted to facilitate proper
examination of cores. Spare core boxes and painting materials shall be stored in convenient
place in the place of storage of cores for ready use.
22.4.12.2 Immediately on their arrival in the place of storage the core boxes shall be cleaned
and painted. The paint shall be of such a nature as to be durable and water resistant. After
primary coating of the paint on the outside surfaces of the core boxes the top lid of the boxes
shall be inscribed in a well contrasted paint colour with the feature of the project for which
the drill hole, total length of the cores contained in the box and the box number (see fig.. 2).
The sides of the core boxes shall fritter be inscribed with the drill hole number, the length of
the cores contained in the box and the serial number of the box, for easy reference when the
boxes are kept in the racks. No painting is necessary inside the core box, except along the in
of the box, on the inserted dummy blocks and the partitions separating the individual runs,
which should be inscribed with the reason for core loss and the lengths of the runs as marked
earlier on the field.
22.4.12.3 In the case of cores which are liable to disintegrate on exposure suitable
representative samples as mistrusted by Engineer-in-charge shall be taken and preserved by
waxing or by any other suitable method. A copy of record of drilling information of the bore
hole and the details of cores suitably prepared using the preformed given in Appendix lV,
shall be compiled and kept in the place of storage (core library). If such samples are taken, a
record to that effect shall be kept at the corresponding section of the run, in the core box.
22.4.12.4 If any portion of the core is removed from the box for testing or other examination
this should also be recorded by insertion of suitable remarks on a square section of timber
painted white, kept in the core box.
22.4.12.5 A series of racks shall be arranged at the place of storage (core library) and the
boxes after being painted and suitably captioned, shall be arranged in the racks according to
the serial order and area of exploration.
The daily drill reports received from the field shall also be available for ready reference in the
place of storage.
22.4.12.6 A certificate as follows shall be furnished by S.D.O, in barge for every calendar
year before end of December-
"Certified that I have personally inspected the upkeep of core boxes, which are maintained in
identifiable, and good condition. The core boxes are counted by me and no box is missing.
22,5 CALYX DRILLING
22.5.1 This is a rotary abrasive type drill in which core can be obtained.
22,5,2 For drilling in hard rock shorbit is used. The shorbit at the bottom of the drill pipe
assembly is connected to a core barrel. The core barrel plug is between them. The drill rods
are hollow seamless steel tubes available generally in lengths varying from one to three
meters. The core drills incorporate all other features of the rotary rig, the rotating mechanism,
the derrick, the winch drum operated by the main shaft the mud pump
AND THE MECHANICAL ARRANGEMENT FOR APPLYING PRESSURE ON THE BIT. THE DRILLING
OUTFIT, HOWEVER, IS GENERALLY LESS SOPHISTICATED THAN A CONVENTIONAL DIRECT
ROTARY RIG. THE CHILLED STEEL SHOTS (CALYXITE) ARE FED THROUGH THE WATER LINE.
DURING DRILLING THE CALYXITE IS GROUND BY THE SHOT BIT. PRESSURE IS APPLIED ON THE
BIT IN ADDITION TO THE WEIGHT OF THE DRILL PIPE ASSEMBLY. WATER IS USED AS A DRILL
FIELD TO LUBRICANT THE DRILL AND REMOVE LOOSE DEBRIS. AS THE DRILLING PROCEEDS,
CYLINDRICAL ROLLERS ARE CUT THROUGH AND COLLECTED IN THE CORE BARREL WHICH IS
REMOVED AT FREQUENT INTERVALS. THE OPERATION IS NOT CONTINUOUS AND HENCE IT IS
TIME CONSUMING.
22.5.3 FOR ARRANGING AND INDEXING OF CORES AND STORAGE OF CORE BOXES,
SPECIFICATIONS UNDER PARA 22.4.11 SHALL BE APPLICABLE.
22.6 PERCUSSION DRILLING :
In this type of drilling process the rock is broken by impact from repeated blows. Therefore,
core cannot be otained by the method.
22.6.1 Drilling with Jack Hammer
It is an air operated percussion type portable drill. It is mostly used for drilling vertical
shallow holes upto 6 m in depth.
A complete drilling unit consists of a hammer, drill-steel and a bit, As the compressed air
flows through a hammer, it causes a piston to reciprocate at a specified speed which produces
the hammer affect. Jack hammers for occasional use may be used dry, but for a continued use
wet drilling is used to keep down the dust.
22.6.2 Drilling with Wagon Drill
The wagon drill is a larger jack hammer mounted on a mast supported by two or more wheels
to provide portability. Their performance is better than jack-hammer. They are used to drill at
any angle from vertical to slightly above horizontal. They are self feeding and automatic
rotating and can be operated wet or dry.
22.6.3 Drilling With Drifters
A drifter is an air operated percussion type drill similar to a jack hammer, but so large that it
requires mechanical mounting. They are used for drilling vertical, horizontal or up holes.
They are capable of drilling boles upto 12 cm diameter. It is extensively used in tunH2e work.
Either, air or water may be used to remove the cutting. They are mounted on columns or bars.
22.7 GROUTING OF ROCK
22.7,1 Co-ordination with Design Requirement
22.7.1.1 Rock grouting is normally carried out to fill discontinuities of cavities or voids in
rock mass by a suitable material. The grouting program should aim at satisfying the design
requirement economically and in conformity with the rest of the construction schedule. The
basic design requirement generally involve the following:
(a) Impermeabilization of the rock mass to control the quantity of the seepage and/or to help
control the hydrostatic uplift by means of grouting above or in conjunction with drainage
measures:
(b) Reduce the deformability of jointed or shattered rook; and
(c) To fill construction voids i.e. to seal the gap between concrete structure and the adjacent
rock, e.g. abutments, tunnel crowns, etc.
22.7.1.2 Before deciding upon details for any particular job, the design requirement shall be
established and the primary objective defined, as described in preceding para. The depth,
spacing and pattern of grout boles, the choice of method of grouting, materials injected and
consumption limit as well as control on pressure depend on the objectives as described in
preceding para. These controls and criteria shall have to be established by trials.
22.7.1.3 The criteria for appraisal of efficacy of grouting are results of water percolation test
in bore holes and specific absorption of the grout material per stage or per metre of the hole.
Percolation tests (see Appendix V) may fail to provide a reliable indication unless they are
standardized and uniform procedures are used in testing rock before and after grouting. In no
case shall testing be done in holes where grout had entered due to leakage or grouted for
integration of the water loss or lugeon value.
22.7,1.4 The following criteria are suggested for deciding whether to grout any particular
zone or portion of rock. The criteria described in 22.7.1.4.1 and 22.7.1.4.2 are to be used with
caution and overall design requirements as well as geological conditions shall be kept in mind
before applying the criteria in any given case.
22.7,1.4.1 Curtain Grouting
(a) Dam exceeding 30 m height, curtain grouting should be carried out when the water
absorption exceeds one lugeon; and
(b) Dams under 30 m height, curtain grouting should be carried out where the water
absorption exceeds 3 lugeon.
(c) Curtain grouting should be asserted to after carrying out experimental grouting on a test
patch with set of holes depending upon geological formation.
22.7.1.42 Consolidation Grouting- :The extent of consolidation grouting will be governed by

the presence or otherwise of filling material in the joints or seams. and nature of filling
material. When it is decided to remove the filling material by washing, the extent of the, zone
grouted will be determined by the efficacy of the washing procedure. On the other hand, if is
decided not to wash and remove the material fifing the joints or seams; the criteria for
grouting will be the grout ability of the stratum.
22.7.2 co-ordination with other construction activities.
22.7.2.1 Grouting operations are generally interdependent with other construction operations;
for example, excavation and blasting in the vicinity of the area that is being grouted may
cause leakage of grout and render the grouting operation ineffective. In anther cases, it may
be necessary to complete the grouting operations to enable start to be made of other
operations, such as concreting or masonry work. Sometimes it may be necessary to carry out
grouting before removal of the overburden to obtain the necessary load of surcharge over the
zone required to be grouted. In other case removal of the overburden may be necessary to
facilitate scaling of the cracks prior to grouting. Drainage holes shall always be drilled only
after grouting is completed within the expected distance of grout level Generally it is
preferable to complete blasting before taking up grouting operations, If blasting after grouting
is unavoidable, thorough testing and rerouting shall be essential after blasting.
22.7.2.2 A drainage and grouting gallery is a device commonly used to facilitate grouting
after placing the masonry or concrete in the foundation and ensure that the necessary cover of
concrete is obtained to enable the desired grouting pressure to be developed. Sometimes holes
are drilled in the foundation, black steel pipes are left in place through the masonry or
concrete which is raised and the foundation grouted through these pipes later.
22.7,2,3 . It is difficult to make general stipulations regarding the coordination of grouting
and other. construction activities;, but it would be evident from the above comments that
careful planning of all associated construction activities, such as excavation, concreting till
placement drilling of drainage holes and their coordination with grouting is essential for
successful execution of the grouting programme.
22.7.3 . Relation of Geology to Grouting the importance of Foundation Exploration and

Initial Experimentation:
22.7.3.1 The sub-surface conditions shall be investigated by core drilling the number of holes
in the foundation area Percolation tests should be conducted in the holes and the open area of
the foundation chartered for Use in planning the grout treatment When investigation holes
have served their purpose, they shall be completely filled with grout.
22.7.3.2 The grouting programme shall be conducted in such a manner that the initial
experimentation covers all the typical geological situations.
22.7.3.3 The depth, spacing and orientation of grout holes shall be related to the geological
features; for example inclined holes shall be preferred when the rock permeability is
primarily due to closely spaced vertical system of joints. It is sometimes necessary to evolve
a pattern of holes consisting of different sets of holes appropriate to each type of discontinuity
such as bedding planes, system of joints and lava contacts.
22.7.4 Grouting Methods
22.7.4.1 Rock grouting consists essentially of drilling a series of grout holes in rock and
injecting grout under pressure which eventually sets in the openings and voids in the rock.
The drilling and grouting operations can be carried out either to the lull depth in one
operation or in successive depths either by stage grouting or by packer grouting.
Grouting in the valley shall normally proceed from river bed towards abutments.
22.7.4.2 Full Depth Grouting - in the full depth method each hole shall be drilled to the full
desired depth, washed, pressure tested and grouted in one operation. This method is usually
limited to short holes 5 m or less in depth or holes upto 10 m that have only small cracks and
joints and there is no risk of surface leakage. in deep bore holes high grouting pressures may
have to be used to achieve proper penetration of the grout at an economic spacing of holes.
As the depth grouting involves the risk of disturbance in the upper elevations, it is not
generally considered suitable for grouting deep holes. For grouting in heterogeneous strata,
where the nature of rock discontinuities is subject to large variations in relation to the depth
full depth grouting is. not recommended and stage grouting is preferred to packer grouting in
such cases.
22.7.4.3 Stage Drilling And Grouting
22.7..4.3.1 Stage grouting is conducted to permit treatment of various zones individually by

grouting successively increasing depths after sealing the upper zones. Stage grouting, in
descending stages, can be carried out by adopting the following procedure.
22.7,4.3.2 For stage grouting the connection at the top of the hole can be made directly to the
header or. by seating a packer at the top of the hole in the casing pipe. Alternatively, it is
sometimes advantageous to install a packer immediately above the stage that is being grouted
in order to isolate the upper portion of the hole. Higher pressures can then be permitted for
grouting of the lower stage without causing heave and upheaval in the higher stages.
22.7.4.3.3 An alternative, procedure would be to withdraw the grout pipe, after completing
the grouting operation, by a distance equal to the depth of the stage grouted. After the initial
set occurs, that is, about half an hour, the portion of the hole above the stage grouted may be
washed. In this method the grout sets in the length of one stage and it is necessary to red rill
one stage before proceeding with further grouting. . it is more convenient to install the packer
at the top of the hole when one-stage redialing procedure is adopted.
22.7,4,4 Choice Of Method Of Grouting
22.7.4.4..1 Grouting with double packer is suitable where a few well defined seams or zones
exist and the packers can be seated above and below such zones. Rotary drilling method is
preferred when double packers are used.
22.7.4.4.2 When packers can be seated and there is no risk of upheaval grouting can be
carried out with single packer in ascending stages.
22.7.4.4.3 However, it is frequently the experience that packers may function yet grout may
over travel and cause upheaval in the .zones above the section being grouted. The method of
stage grouting in descending order is therefore a more dependable method for badly jointed
and fissured strata vulnerable to upheaval.
22.7,4.4.4 In relatively compact rocks it may be more convenient to seat the packer at the top
of the stage being grouted. The hole may then be washed, as soon as the period of initial set
of cement is over, to the entire depth of the hole upto the bottom of the stage in progress.
22.7.4.4.5 On the other band in strata vulnerable to upheaval, it may be necessary to allow the
grout to set and form a sheath around the hole in order to enable high pressures to be used in
the lower portions of the hole. in such cases, the washing and single stage redialing procedure
would have to be adopted.
22.7.5 Pattern and Depth of Holes and Sequence of Grouting
22.7.5.1 The pattern and depth of holes is governed primarily by the design requirements and
the nature of the rock. When the purpose is consolidation, the holes are arranged in a regular
pattern over the entire surface area required to be strengthened and the depth is determined by
the extent of broken rock as well as the structural requirements regarding the deformability
and strength of the foundation. When the purpose is imp remobilization, the grout holes are
arranged in a series of lines to form a curtain approximately perpendicular to the direction of
seepage. The depth of holes is dependent on design considerations as also on the depth of
pervious rock and the configuration of zones of relatively impervious strata.
22.7.5.2 Pattern Of Holes For Curtain Grouting

22.7,5,2.1 Single line grout curtains are effective only in rocks having a fairly regular
network of discontinuities with reasonably uniform size of openings. In such cases a curtain
of adequate width can be achieved by grouting a single line of boles. In massive rocks with
fine fissures, uplift control is primarily achieved by drainage and the grout curtain is used
only as a supplementary measures to avoid concentrations of seepage which may exceed the
cap acuity of the drainage system. Single. line curtain may serve this limited objective in
comparatively tight rock formations.
22.7.5.2.2 In single line curtains it is customary to drill a widely spaced system of primary
holes, subsequently followed by secondary and tertiary boles at a progressively smaller
spacing. The usual practice is to split the spacing from primary to the secondary and
secondary to tertiary phase. One of the criteria for deciding on the primary spacing is the
length of expected intercommunication of grout between boles. The initial spacing usually
varies between 6 to 12 in but the choice of spacing should be based on the geological
conditions and on experience. At every phase of the grouting operation, the results of
percolation tests and grout absorption data shoul4 be compared with the previous set of holes
in order to decide whether a further splitting of the spacing of holes is worthwhile. When no
significant improvement is noticed either in terms of decrease of the grout absorption or
water percolation, careful review should be made of the rock features, the nature of the rock
and its relations to the pattern of holes. Sometimes it may be more advantageous to drill
another line of holes at a different angle and orientation than to spit the spacing further.
Spacing below one meter, are rarely necessary and the requirement of a spacing closer than
one meter may often indicate an unsuitable orientation and inclination of holes. Possibly
multiple line curtains may b necessary.
If the area is too limited, the setting time of the grout becomes important since it is not
desirable to drill too close to a freshly grouted hole. Before pressure growing is started,
drilling of all the holes should be completed within a distance of 20.0 m of the hole to be
grouted.
22.7.5.2.3 Multiple Line Curtains - In rocks with a wide range of sizes of openings, cavities
and discontinuities which are also irregularly distributed, a single line curtain may not be
effective. The larger openings may absorb excessive volumes of grout if high pressures and
thin grouts are used. On the other hand thicker grouts (1:1 or thicker or grout with fillers)
used for sealing the larger openings may block the sides of holes and prevent penetration of
finer cracks. In such cases it may be advantageous to use a multiple line curtain consisting of
outer lines which are drilled and grouted initially with thicker grouts. It may sometimes be
difficult to treat the outer rows of holes to refusal and grouting may have to be stopped after
injecting a limiting volume of grout which may be arrived at on the basis of experience
and/or initial trials. After completing the grouting of the outer holes. intermediate line or lines
of holes may be drilled and grouted at comparatively higher pressure with thinner grouts.
Grouting of the outer rows which is carried out initially facilitates containment of grout and
thus ensures effective subsequent treatment of inner cracks at higher pressure through the
central row or rows of holes. The final spacing of inner and outer rows may be different in a
multiple line pattern, the spacing in each row being governed by the nature of rock
discontinuity, intended to be treated by the particular row. In any case in the central row the
split spacing method should be followed until the desired degree of impermeabilization is
achieved.
22.7.5.3 Pattern Of Holes For Consolidation Grouting

22.7,5.3.1 The choice of pattern of holes, for consolidation grouting depends on whether it is
necessary to wash and jet the hole systematically (see 22.7.9.3). When washing has to be
carried out in a hexagonal pattern (see flg.4) it would be preferred as
THIS ADMITS FOR FLOW REVERSAL. WHEN SYSTAMATIC WASHING AND JETTING IS
CARRIED OUT TO REMOVE ALL SOFT MATERIAL IN SEAMS IT IS GENERALLY NOT
NECESSARY TO USE A PRIMARY AND SECONDARY SYSTEM OF HOLES.
22.7.5.3.2 WHEN IT IS DESIRABLE TO TEST THE EFFICACY OF CONSOLIDATION GROUTING BY

COMPARING THE GORUT ABSORPTION IN PRIMARY AND SECONDARY HOLES A
RECTANGLUR OR SQUARE PATTERN (SEE FIG. 4) OF HOLES WOULD BE
PREFERRED. THIS IS GENERALLY THE CASE WHEN THE JOINTS ARE IRREGULAR
AND RELATIVLY FREE FROM IN FILLING OR IT IS NOT NECESSARY TO REMOVE
THE MATERIAL FILLING THE JOINTS.
22.7.5.4 NUMBERING OF GREAT HOLES :
22.7.5.4.1 EACH HOLE WOULD BE ASSIGNED A NUMBER WHICH WOULD BE USED FOR ALL
FURTURE REFERFERENCES. NUMBER WOULD INCLUDE DETAILS VIZ. BLOCK
MUMBE, STAGE, SERIAL SERIAL NUMBER OF THE
hole and phase (Primary secondary-tertiary etc.) For an example; a grout hole in Masonry
block 17 is numbered as under:
1 7/GI5(P)
Where: 17 = Block 17,
G =Grout hole
I= I st stage
5 = Serial number of hole
P = Primary hole (Thus their would be Secondary, S, and
Tertiary, T, if deemed necessary).
In addition the holes (primary, secondary & tertiary) shall be shown on a drawing showing
location and number of these holes in plan.
22,7..5.4..2 Special grout holes proposed on geological considerations would have prefix RG
instead of G
22.75.4.3 All grouting operations would follow in sequence according to serial numbers of
the hole:
22.7..5.5 Sequence Of Grouting
22.7.5,5,1 While carrying out grouting \operations it is necessary to ensure that no hole is
drilled so close to a hole being grouted that inter connections develop. Spacing between
primary holes is generally so selected that the drilling could be carried out without
interference from grouting due to inter-connections from adjoining holes. Sometimes a
situation arises when drilling of upper stages of secondary holes may be in progress
concurrently with the grouting of the deeper stages of primary holes. In such cases,
interconnections would not be prevented if a sufficient cover of rock is not available between
the portion which is being grouted and the zone in which the drilling of secondary holes may
be in progress. As a rule the drilling of secondary holes in any zone of the foundation shall
not be taken until su1Thient cushion of already grouted stages of primary holes in the same
area is not available.
22.7.5.5.2 In multiple line curtains relative sequence of outer and inner rows shall also be
strictly followed as described in 22.7.5.2.3.
22.7.5.5.3 When grouting in rock overlain by pervious soil it is necessary to complete

grouting of the contact zones of the rock and solid before commencing the grouting of the
rock otherwise grout would escape into the soil and it may not be possible to control or detect
excessive leakage.
22.7.6 Materials
22.7.6.1 Grouting materials
(i) General - Rock routing shall usually be performed with a mixture of neat cement and
water. Other solid materials as well as soluble chemicals has also been used for economic or
other reasons.
(ii) Cement - The cement to be used should be ordinary Portland (IS:269:1989) or IS

8112:1989 or IS: 12269:1987, Portland puzzling IS 1489 (Pt.7th):1991, Portland slag
(IS:455:1989), supersuiphated plated cement (IS 6909:1990), sulphate resisting cement
(IS:12330: 1988)
(iii) Sand - Coarse & fine sand sometimes required as filter in the grout shall conform to the
specifications of sand for concrete as given in specifications of Chapter 7 & 16 with the
limitation that sizes above No.10 IS sieve shall be excluded.
(iv) Water . Water for mixing grout shall be clean & free from injurious amounts of oil, acid,
alkali, salts, silt, organic matter and other deleterious substances.
(v) 1 kg of 200 mesh bentonite per sack of cement may be used with bentonite as admixture
where required.
(vi) Pipe and pipe fittings for grouting permanently incorporated into the work shall be of
standard weight black steel pipe and fittings conforming to IS:1239 (Pt.l) 1979.
22.7.7 Drilling and Grouting Equipments
22.7.7.1 General.- Sufficient drilling and grouping equipment with necessary auxiliary
quotient and accessories to complete the various types of drilling and grouting required shall
be arranged. The equipment shall be maintained in first class operating condition at all times.
2,7.7.2 Percussion drills for drilling grout holes shall be capable of drilling boles of the sizes
and to the depths specified iii rock or through concrete while continuously washing the holes
during drilling. Such drills shall be provided with the following:
(i) A water supply at a minimum pressure of 8.5 kg/cm2 at the drill with the drill operating;
(ii) An auxiliary water swivel installed between the drill chuck and the rods;
(iii) Drill rods and bits having oversize water passages.
22.7.7.3 Grouting Equipments
22.7.7.3.1 General Equipments - The grouting equipment should meet the following
requirements:
(a) Be of sufficient size to the maximum demand for grout;
(b) Be capable of prolonged operation at anticipated maximum pressures;
(c) Be of sufficiently rugged construction to minimize delays from failure of some essential
part;
(d) Permit quick cleaning by washing; and
(e) Provide quick access to key parts in case of mechanical failure.
Continuity of operation is necessary not only for efficiency, but also effectiveness of the
grouting.
22.7.7.3.2 Grouting equipment shall be capable of effectively batching, mixing and
maintaining grout mixes in suspension as specified, and of delivering and pumping grout into
the grout holes and concrete joints through grout connections in a continuous uninterrupted
flow at any constant pressure upto the limiting pressures specified. However each grouting
installation supplied for the work shall include the following minimum equipment -
(i) Operating and one stand by pump each capable of operating at a maximum discharge
pressure of 25 kg/cm2 and of pumping and injecting grout, including grout to which sand has
been added if required as specified, at rates upto at least 0.15 m3 per minute without pressure
fluctuations at the collar of the bole. A suitable water connection shall be installed on the
intakes of the pumps to facilitate flushing of the system and injection of water into the grout
holes.
(ii) A high speed (Colloidal) type mixer designed primarily for mixing grout materials,
including grout to which sand has been added if required and capable of mixing a minimum
of 0.3m3 per minute of grout mixture.
(iii) An agitator consisting of a mechanically agitated sump graduated in cubic meters and
measuring to an accuracy of .01 cum and capable of maintaining the solids in the grout in
suspension. The agitator shall be equipped with adequately sized screens to remove from the
grout entering the agitator from the mixers and the grout return line any hardened grout or
foreign material not passing a 150 micron Indian standard sieve if a non- sanded mix is being
used or a 1.18 mm Indian standard seive if a standard mix is used. The capacity of the
agitator shall not be less than that of the mixer.
(iv) An approved water meter graduated in tenths of 0.03 m3.
(v) All valves, water flow meters, grout flow meters, pressure gauges including pressure
hosepipe, flush-coupled diamond drill casing where applicable, sleeves, packers, fittings and
small tools necessary to complete the grouting as specified. An accurately calibrated high
precision pressure gauge shall also be arranged for checking accuracy of all pressure gauges
used in the grouting system.
(vi) Packers consisting of pneumatic or hydraulic expansible tubes, or of mechanically

manipulated rings of rubber, leather or other suitable material which can be set singly in a
grout hole at any depth required upto a maximum of 76 in or, where required by the
Engineer-in-Charge in pairs to isolate a section of hole. Packers shall be so designed that they
can he expanded to seal the holes at the specified elevations and that when expanded, they
shall be capable of withstanding without leakage, for a period of at least 10 minutes, water
pressures equal to the maximum expected grout pressures which they will have to withstand.
The arrangement of the grouting equipment shall be such as to provide a continuous

circulation of grout of uniform consistency through out the grouting system and to permit
accurate pressure control at the collar of the hole being grouted at all rates of grout in take.
Pressure gauges and valves shall be supplied at the pump. at each hole being grouted and
elsewhere as required to ensure the necessary control of grouting.
A flow meter in the supply line and a flow meter in the return line shall be arranged in such a
manner that a continuous and accurate record of the amount of liquid flowing to the each hole
and being returned to the agitator can be obtained.
22.7.8 Drilling
22.7.8.1 Holes for grouting shall be drilled at the location, to the depths (and of sizes) shown
on the relevant drawing and as required by site conditions.
22.7.8.2 The minimum diameter of each grout hole shall not be less than that produced by the
commercial standard Ex-size drill i.e. approximately 38 mm. The size of the holes specified
are the minimum diameters required at the bottom of the boles. The grout holes may be
drilled using either diamond or wet percussion drills as specified. Whenever diamond core
drilling is carried out for grouting, cores from such holes shall be recovered, logged properly
and preserved in core boxes as specified in para 22.4. 11.
22.7.8.3 Holes shall be drilled vertically or at an inclination to the vertical as shown on the
drawings, or as directed by the Engineer-in-Charge. Exploratory boles shall not deviate from
the required directions by more than one per cent of the length of the holes, as measured at
the point of maximum penetration. All measurements relating to the depth of the hole shall be
made from the ground collar of the hole.
Grout hole and check holes shall be drilled wet and a constant flow of return water shall be
maintained at all times. Use of lubricants other than water as an aid to drilling grout holes
shall not be permitted.
Where packers are to be used any bole for grouting or water testing every precaution shall be
taken during drilling to maintain a smooth wall in the hole, in order that the packers can be
set properly at any desired location.
22.7.8.4 When drilling of a grout hole or, check hole, has been completed to its final depth or
to the bottom of a stage, the hole shall be washed to remove all drill cuttings sediments,
sludge and other loose or foreign materials.
22.78.5 Each grout hole and check hole shall be protected from becoming clogged or
obstructed until it is grouted, by wooden plug or steel cap and where a grout pipe nipple or
pipe fitting is permanently embedded in rock or concrete, a suitable cap for such grout pipe
nipple or pipe fitting shall be provided.
22,7,8.6 Each grout hole and check hole shall be labelled with a metal or plastic tag and each
tag shall be numbered.
22.7.9 Washing Holes.
22.7.9.1 General - The purpose of washing is two fold. First to clean the hole to remove
material deposited on the surface during the drilling operation and second to provoke
deliberate inter connections between adjoining grout holes to remove known seams end
layers or credible material. It should be borne in mind that inter connections between holes
are effective only, if the washing operations are carried out systematically to remove all the
soft material. Isolated interconnections do not serve much useful purposes soft materials may
still remain in position in an unknown and irregular pattern. A distinction is therefore made
between routine washing of holes at the end of the drilling operation (see 22.7.9.2) and
systematic washing of groups of holes in order to remove the erodable material in the
intervening area for which the term jetting or special washing is used (See para 22.7 .9 .3).
22.7.9.2 Routine Washing
22.7.9.2.1 On completion of the drilling of a stage and before injection the holes shall be
washed by allowing the drilling water to run until the return from the hole is reasonably
clean. The quantity of water flowing into the bole during the period shall be adequate and
generally not less than 15 lit/min.
22.7.9.2.2 When no return of drilling or washing water occurs, the holes shall be washed for a
reasonable period based on site experience. This is generally for 20 minutes. If an abrupt loss
of drill water occurs during drilling and similarly when a strong flow of artesian water is
encountered the drilling should be stopped and the hole grouted even if it has not reached its
final depth.
22.7.9.2.3 Should inadvertent connections to adjacent holes take place the washing out should
be continued until the flow of water from the hole to which the connections were made is
clear. Such inter connections between the various holes shall be shown on the drawing
showing location of holes as described in para 22.7.5.4.1 showing the interconnections
between holes. The direction of flow of water or grout shall also be indicated with an arrow
in the appropriate direction on the lines showing such interconnections.
22.7.9.2.4 Where deliberate attempts to obtain connections between adjacent boles are
required in order to remove known deposits of erodable materials the jetting procedures
described in para 22.7.9.3 should be used instead of the washing procedure described in
22.7.9.2.
22.7.9.2.5 In case, reasonably clear water is not obtained on return on washing of a hole
within 30 minutes of washing, it may be presumed that the hole needs special washing, The
special washing as per para 22.7.9.3 shall then be taken up.
22.7,9.3. Special Washing (Jetting)
22.7.9.3.1 The results of routine washing in many cases indicate that special washing
procedures are required in order to remove more intensive deposits of loose or cloyey
materials from fissures fractures or other zones intercepted by grout holes. Special washing
arietta operations are carried out in order to deliberately provoke connections between
boreholes and to remove known deposits of readable materials.
22.7.9.3.2 Special washing or jetting shall be carried out on groups of holes arranged on a
square, triangular or hexagonal pattern known as cells.
22.7,9.3.3 Experience has indicated that the hole spacing within each cell should not exceed
about 1,5 m for successful jetting. The optimum spacing at any site can be arrived by washing
holes in a pattern of primary and secondary cells.
22.7.9.3.4 All holes in a cell shall be fitted with stand-pipes, and then drilled to the level of
the first seam to be treated. Where a network of seams exists, all holes shall be drilled to the
short first stage depth of 3 to 6 meters. The stand-pipes shall then be capped with three-way
plug cocks and the cell is then ready for jetting.
22.7.9.3.5 A manifold shall then be fitted to the first hole, so arranged that compressed air and
high pressure water can be fed to the hole in rapid alternation. Air and water pressures used in
jetting any stage shall not exceed the grouting pressures specified for that stage. Uplift metres
with anchor rods set well below the zone being treated shall be installed for observing any
upheaval.
22.7.9.3.6 All other cocks in the cell shall then be opened and water followed by air applied
alternately until a connection is made. Jetting shall continue on this connection until no
further redouble matter can be removed. Where any other hole connect to the manifold hole
during the operation, its cock should be closed. All the interconnections between various
holes shall be shown in the manner specified in para 22.7.9.2.3.
22.7.9.3.7 When the first connection has been cleaned out, the cock on the connected holes
shall be closed and the process repeated until connections have been established, if possible,
to all holes in the cell from the original hole.
22.7.9.3.8 The following alternative procedure may also be used for washing the cells.
In washing a cell water is connected to one hole and air to the adjacent hole on each side. The
water and air connection are changed at frequent intervals to cause the water flow in every
possible direction through the seam. Application of air and water pressure is continued until
all possible inter connections between adjacent holes are established.
22.7.9.3.9 As many combinations of holes as necessary shall be used to ensure the cleaning of
all seams. The washing of any set of holes shall be continued until all loose materials are
removed from the seams and crevices. It is neither desirable nor practicable to continue
washing until the discoloration in the effluent disappears completely. But it shall be continued
till reasonably clear water emerges from the holes. Washing shall be done generally for a
minimum period of 20 minutes for each hole. In some zones, washing operations may have to
be extended for several hours.
22.7.10 Water Testing of Holes
227.10.1 In order to determine the permeability of the rock and the effectiveness of grouting
operations, water tests in exploratory holes, grout holes and check boles shall be made in
conjunction with drilling and grouting operations.
22,7.10.2 When during drilling, abnormal gain or loss of drill water is observed or caving of
the hole occurs, or the bit and drill rod falls through an open crack or cavity or when
unusually low core recovery is obtained, drilling shall be discontinued and hole shall be water
tested.
22.7.10.3 The procedure for water pressure testing shall be as follows:
(i) Immediately prior to being tested, each hole shall he thoroughly flushed to remove all drill
cuttings, sediments, sludge or other materials from the hole and such flushing shall be
continued until the wash water returns clear.
(ii) If a hole is drilled to fill depth, the Section of the hole to be tested shall be isolated by
sealing it off with packers set at the bottom as well as at the top of the section. If stage
drilling method is used, a single packer shall be, used to isolate the section to be tested.
(iii) The existing water level in the hole to be tested shall be recorded before commencement
of the pressure testing. The hole shall be filled with clean water and the packers tightened.
(iv) Clean water shall be pumped into the hole through such valves and flow meters as are
required to regulate the pressure of the water being injected and to measure the flow into the
hole. The pressure testing apparatus shall be tested before use and shall be periodically tested
for accuracy and satisfactory operations.
(v) Pumping shall be continued until the pressure of water to be injected is maintained with
flow into the hole in a steady state. The pressure test shall be performed in one continuous
operation using the following steps of pressure and times.
Step No. Pressure (P) Elapsed time minutes

1 P1=1/3 P3 5
2 P2=2/3 P3 5
3 P3=Maximum pressure attainded limited to 10
Prescribed grouting pressure
4 P4=2/3 P3 5
5 P5=1/3 P3 5
In some cases after steps 4 & 5, the bole valve shall be closed and the pressure drop observed
and recorded for a maximum period of 3 minutes in each instance.
22.7.11 Grout Connections.
Connections for doing grouting shall be made using expansion type packers specified in para
22.7.7.3.2(VI) except that:
(a) Connections for doing grouting shall be made using removable pipe nipples attached to
pipe fittings embedded in concrete.
(b) Connection shall be made using grout pipe, grout nipples where, in the opinion of the
Engineer-in-charge, rock conditions are such that packers cannot be set directly in holes and
where such nipples are required to be set into springs, crevices in the rock, faults or other
foundations anomalies.
Where grout pipe nipples are used for connections to holes in rock, the size of the pipe nipple
for each hole and the depth into the bole to which it is set shall be adjusted to suit the size and
type of hole drilled and the surface rock conditions. Prior to grouting, the space around the
nipple shall be carefully sealed with a quick setting mortar.
Where grout pipe nipples or fittings for grout connections are permanently embedded in
concrete such pipes, nipples or fittings shall be so embedded that they terminate not less than
7.5 ems from the finished surface of the concrete, ilie pipe shall be standard black (iron) pipe
confirming to IS:1239 (Pt.I)1979 for class I weight A type. The pipe fittings shall be of
malleable iron confirming to IS: 1239(Pt,l)l979.
All pipes and fittings to be embedded in concrete shall be cleaned thoroughly of all dirt,
grease, grout and mortar, immediately before being embedded in the concrete. They shall be
carefully assembled and placed, and shall be held firmly in positions and protected from
damage until the concrete has set.
Grout pipes which leak during grouting operations shall be reset.
22.7.12 Grouting of Rock Foundations
22.7.12..1 The grouting shall be carried out using packer grouting technique or stage grouting
technique as desired by the Engineer-in-Charge depending upon the rock conditions and
results of earlier grouting.
22.7.12.1.1 Packer grouting shall be performed by attaching a packer to the end of a grout
supply pipe into the drill hole until it reaches the nearest part of the farthest stage to be
grouted at a specified pressure, setting the packer and growing the stage beyond the packer at
the required pressure, allowing the packer to remain in place until there is no back pressure,
with drawing the grout supply pipe to the nearest part of the next stage required and grouting
the hole in successive stages as required, by the Engineer-in-Charge.
22.7.12.1.2 In stage grouting the hole will be drilled to a limited depth, pressure tested if
necessary, and then grouted at that depth. After the hole has refused grouting (to the extent
specified hereinafter), it shall be flushed out by washing to its final set (within 2 to 4 hours).
Alternatively the grout may be allowed to harden and redrilling carried out through the
hardened grout as directed by the Engineer-in-charge.
After the grout surrounding the grouting hole has set, the hole may be tested for water
pressure if required. Thereafter successively deeper stages shall be drilled, grouted (and
tested if required) at increasing pressures until the required depth of the hole is completely
drilled and grouted.
22.7.12.1.3 The packers shall be so designed that they can be expanded to seat the drill bole
to a specified elevation and when expanded shall be capable of withstanding without leakage,
water-pressure equal to the maximum grout pressure to be used.
22.7.12.1.4 The depth of each stage shall be 6 to 10 m. but may vary as required by site
conditions. The grouting shall begin with low pressure, say 0.10 to 0.25 kg/cm2, per meter
depth of packer or grout zone measured on the back pressure gauge located at the header. The
pressure will be built up gradually. In no case the pressure will be such as to cause upheaval
of the bed rock. Sensitive upheaval indicators (see para 22.7.11) shall be installed at suitable
locations and shall be carefully watched for any indications of uplift during water pressure
testing and grouting operations.
22.7.12.2 Once the grouting of a stage or group of holes has been commenced it shall be
continued without interruption until completion. In general a stage may be considered
complete when the absorption of grout at the desired limiting pressure is less than 2 lit./min
averaged over a period of 10 minute.
22.7.12.3 As far as practicable a continuous flow of grout shall be maintained at the desired
pressure and the grouting equipment shall be operated to ensure continuous and efficient
performance throughout the grouting operation. The personnel in charge of grouting as well
as the grouting equipment in use shaft respond quickly and effectively to manipulate the
desired changes in the grout mix consistency rate and pressure of injection etc. as directed by
Engineer-in-Charge during grouting operation.
22.7.12.4 Should it be necessary to interrupt injection before it is completed, for instance if

there is a plant breakdown, about 500-1000 liters of clean water should be run into hole and
allowed to stand.
If any stage continues to absorb large quantities of the thickest pump able grout at nil
pressure, grouting shall be stopped when a predetermined limit of consumption is reached.
Alternatively sometimes it is possible to suspend injection overnight and resume the work
next day. Even than the limit of consumption shall apply. When any of the procedures
recommended is adopted the grouting operations should be controlled in accordance with
para 2.2 an4 3 of Appendix VI.
22.7.12.5 When any hole connect to another during injection, the grout shall be allowed to
escape from the coupled hole until it is of the same consistency as that being injected, the
coupled hole shall then be capped and the combined holes brought up to pressure. After the
first hole has been grouted all the other holes shall be successively connected to the grouting
header to subject them to full pressure.
Where leakage of grout occur on the ground surface, they shall be restricted by caulking with
wooden wedges, lead wool, etc. or by thickening the grout followed by re-treatment with
thinner grouts and through fresh holes, if necessary, as directed by the Engineer-in-Charge.
22.7.12.6 Grouting shall be stopped whenever pressure gauges register a sudden drop of
pressure or the rate of grout absorption increases abruptly or there is any indication of
upheaval, disturbance or leakage. Additional holes may have to be drilled and grouted in the
vicinity for sealing fine cracks which may not be effectively treated due to premature
blocking of holes by interruption of grouting operations.
22.7.12.7 The control of grout mixtures is not amenable to rules which can be fixed in
advance and sufficient discretion has to be exercised by the Engineer-in-Charge. (3routing
should normally start with a thin mixture which is gradually thickened until about 75 per cent
of the final desired pressure has been obtained with the pumps operating at normal speed. As
the hole approaches refusal, the thick grout should be replaced with thinner grout and used
until the hole refuses. In appendix VI the guiding principles for controlling pressures and
selecting grout mix proportions are discussed. As a general principle grout mixture shall not
be thickened if pressure starts to rise after continuous injection over a period of 10 minutes.
Hasty changes in the mix proportions are not desirable and the response of the hole to the
selected mix proportion or pressure should be judged only after observing for a sufficient
period. The choice of initial mix proportions should be based on the water intake test.
Experimentation, at the start of the work, should be used to establish the guideline for choice
of mix prop orations. Use of excessively thin mixes in the initial stages is generally
wastefully & may some times cause softening of rocks like shale. Therefore, a starting mix of
5:1 is recommended and in exceptional cases 10:1 may be adopted.
The ratio of water to solids of the grout deposited finally in-situ is generally quite different
from the water content of the mixed grout during injection. For neat cement grouts, with non-
cohesive admixtures it is generally found that the set grouts are very much denser than grout
specimens prepared in the laboratory from the mixed grout; hence due allowance should be
made for the removal of water-in--situ while interpreting the laboratory test data.
22.7.12.8 Should conditions warrant, grout mixes shall be thinned after thickening, and if
necessary to prevent premature stoppage, periodic application of water under pressure may be
made. However, no prolonged application of water shall be permitted.
22.7.12.9 If it is found that a hole will take grout at the rate of the maximum capacity of the
grout pump and no decrease in the rate of grout intake is observed while pumping a mixture
having a water cement ratio of 0.5:1 or, that no resistance can be built by reducing the pump
speed, the grouting of the hole shall be continued for a maximum 1 hour at minimum pump
speed. If the rate of grout intake still does not decrease, the grouting of that hole shall be
discontinued for a minimum of 2 hours to allow the grout to attain initial set. Thereafter the
hole shall be cleaned and after a period of; 6 hours grouting shall be resumed, If it is found
that certain holes cannot be effectively grouted with particular water cement mixture due to
very large cavities or excessive grout intake, thicker grout mixtures may be used when
directed.
22.7.12.10 The amount of sand used in the mix will be increased progressively until the
maximum amount, which the equipment can handle successfully, has been reached. If the
desired results are not obtained with this mix. grouting will be discontinued In such event the
hole shall be cleaned the grout allowed to set, and additional drilling and grouting shall then
be done in this hole or, in the adjacent area, as directed, until the desired pressure is built up.
22.7.12.11 The grouting of each hole shall be continued until the hole refuses to take grout
mixes of 3 to 1 or thicker at the maximum pressure required, or until the hole takes grout
mixes thinner than 3 to I at a rate of less than 0.03 m3 of grout mixture, in 20 minutes if
effective pressure of 3.5 kg/cm2 or less are being used, in 15 minutes if pressure between 3.5
and 7.0 kg/cm2 are being used, in 10 minutes if pressure between 7.0 and 14.0 kg/cm2 are
being used, and in 5 minutes if pressure in excess of 14.0 kg/cm2 are being used. As far as
practicable, the maximum required grouting pressures shall be maintained constant during
grouting injections.
22.7.12.12 After a stage of grouting is completed in any hole or set of holes, the pressure
shall be maintained by stop cocks or other suitable valve devices until the grout has set
sufficiently that it will be retained in the holes. Higher grout pressure may be used in final
reading.
22.7.12.13 The following requirements shall also be met dining grouting: -
(1) Drilling, washing pressure testing or grouting shall not be performed within a distance of
12m. or as may be considered suitable for the site conditions. from a hole being pressure
tested or grouted unless at least one grout hole in between these holes, has been completely
grouted and a period of. 6 hours has elapsed since the completion of such grouting.
(2) On steeply sloping ground, grouting shall invariably proceed from the lower elevation to
the higher.
(3) The arrangement of the grouting equipment shall be such as to provide a continuous
circulation of grout throughout the system and to permit accurate pressure control by
operation of a valve on the grout return line. regardless of how small the grout take may be.
(4) The grouting equipment shall be so located that the agitator is within 30 In. of any hole
being grouted. Pressure gauges and adequate valves will be required to control bye-passes
and shut off.
(5) The equipment and lines shall be prevented from becoming fouled by constant circulation
of grout and by the periodic flushing out of the system with water. Flushing shall be done
with the grout intake valve closed, the water supply valve open, and the pump running at MI
speed.
(6) Any grout which has not been used within 1 hour of the time of mixing shall be wasted.
22.7.12.14 The holes drilled for curtain grouting shall be packer grouted or stage grouted at
pressures which will give an effective pressure at the top of the stage being grouted of 0.23
kg/cm2 per meter of depth below the nearest rock surface, except as otherwise required by
the Engineer-in-Charge. In determining such pressure, the Engineer-in-Charge will take into
consideration the elevation of the grout water and the pressure losses in the grout pipes. The
deep grouting shall be completed by grouting the holes by progressively working up the
abutments.
22.7.12.15 The effectiveness of the grouting work shall be checked as work progresses by
tests performed hi a series of vertical and/or inclined holes drilled along the grout curtain
every 15 m or nearer if required. Pressure tests in these boles, and core recovery, may
indicate that parts of the foundation already grouses required additional grouting. In such
event additional holes shall be drilled and grouted as and when required.
22.7.13 Backfilling/Packing of Grout Holes
Grout holes shall be backfilled with grout having a water-cement ratio of 0.7:1 with 3 per
cent. of bentonite. A minimum 25 mm dia delivery pipe shall be lowered to the bottom of the
hole. Grout shall be pumped in the delivery pipe until it flows from the hole, then the delivery
line shall be slowly withdrawal while pumping continues. If settlement of grout occurs after
initial set, the holes shall again be backfilled with grout.
22.7.14 Uplift Gauge (Up Heave Gauge Or Foundation Displacement Indicator).
The surface bed rock may be particularly sensitive to displacement due to hydraulic pressure
developed during pressure testing or grouting. Such displacement shall be controlled with the
aid of careful observations of uplift gauges specifically installed for the purpose. For this 12
mm diameter pipe or 15 mm dia M.S. bright bar shall be anchored by growing to the bottom
of holes drilled at specific locations indicated at site 3 meters deeper than the proposed grout
holes in the area. Above the anchorage, the pipe shall be encased in a 40 mm asphalt dipped
M.S. conduit and the hole filled up with lean mortar, An iron yoke or bridge shall be
anchored to the surrounding rock or masonry. Measuring tips shall be set at the top of the
pipe and on the underside of the yoke. A standard strain gauge with 0.01 mm least count may
be used for this purpose (Fig.5) The gap between the tips shall be frequently measured during
grouting and pressure testing operations. For any progressive upheaval greater than 0.0254
cm the pressure shall be reduced and grouting operation continued thereafter, if necessary, the
pressure shall be relieved by allowing the grout to flow out of the holes until the gauge show
the settlement has ceased, before continuing the operations. Such instruments may have to be
installed at a minimum interval of 20 meters.
22.7.15. Drainage Holes :

22.7.15.1 Drainage of dam foundation shall be accomplished by a line of holes drilled from
the foundation gallery into the foundation rock. The diameter of the hole shall generally by
NX drill which is 75 mm. The spacing of the hole shall be initially kep as 6 m centre to centre
and may be reduced as required or as decided by the Engineer in charge. If not otherwise
specified, the depth of drainage holes shall be decided by the Engineer in charge on the
basis of the geological conditions and that it would be 20 to 10 percent of the maximum
reservoir depth and between 30 to 75 percent of the curtaining routing depth for preliminary
design. These shall further be reviewed and holes provided at closer intervals are further
deepened on the basis of actual observations after the reservoir is filled. To facilitate this,
additional nipples / pipes as directed shall be embedded in the gallery / concrete.
22.7.15.2 The drainage holes of 75 mm dia shall be drilled through 100 mm dia. black steel
pipe embedded in the masonry / concrete portion in the galleryh. When
drainage holes are drilled through soft foundations, a perforated pipe shall be
placed in the drainage holes and the space between walls of holes and this pipe
shall be filled with pea gravel (passing 10 mm seive and retained on 4.75 mm
seive) (See fig. 6 B). This arrangement would avoid caving in of walls and
the holes could be got washed, if required.
22,7.15.3 Drainage holes shall be drilled after all foundation grouting has been completed
within minimum horizontal distance of 15m. The drainage holes shall be drilled through the
drainage gallery through previously installed black steel pipe extending down to the
foundation rock, Additional drainage holes or curtain grouting shall be provided if uplift
pressure higher than designed values is observed. After drilling, the pipes shall be plugged at
top and seepage water from the hole shall be taken off at a T-joint and led to the gutter of
gallery. (see flg.6A & B ).
22.7.15,4 Where cross galleries, additional foundation galleries and drifts are introduced,
necessary drainage arrangements shall also be provided as directed by the Engineer-in-
Charge.
22.7.15.5 The seepage water from drainage holes shall be monitored from consideration of
quantity, contents of fines and chemicals and remedial action taken, if warranted.
22.7.15.6 All the water shall be removed from the hole when grout is placed. The anchor bars
if required to be provided as per the design shall be forced into place before the grout has
taken. Its initial set, and where practicable shall be vibrated or tapped until the entire surface
of the embedded portion of the bars is in intimate contact with the grout. Special care shall be
taken to ensure against any movement of the bars which have been placed.
2 2.7.16 Repair and Clean up

Concrete surface and foundation surfaces over which grout has flowed shall be cleaned and
restores to their original condition. Upon completion of the grouting all removable grout
nipples shall be removed from grout pipes embedded in concrete. Holes in concrete for such
connections shall be filled and finished as specified. Any grout pipe nipples extending above
the dam zone foundation and, if required by the Engineer-in- charge any other foundation,
shall be cut flushed with the foundation surface.
22.7.17 Technical Field Records
An accurate and up-to-date technical field records of all survey, drilling testing, growing, and
control operations and observations required to be performed in connection with this work,
shall be maintained for each hole in a chronological order in the preformed given in
Appendix VII. Suitable forms shall be used for recording other relevant information not
covered by the proffering given in Appendix VII.
APPENDIX - I
(Para 22.4.3.6, 22.4.37 and 22.4.4.1)
DAILY DRILL REPORT
Project Date
Location Shift: from h to h
Feature
Drilling machine Drill hole
Machine No: Hole No.
Type: Coordinates: Collar elevation:
Feed: Screw/hydraulic Bearing hole: Ground elevation
Angle with horizontal: Depth of water level in the hole
Depth drilled during the shift At start of shift (m)
At end of shift (m)
Pump:
Pump No:
Capacity: From to
Pressure used: (m) (m)
(N/mm2)
Casing Run Lengt Rate of Water Colou Core Recovery Type Remar
Lowered h Penetration Loss r of of ks
Size Depth From To Drille (mm/minut (See Return Lengt Percentag Rock
(mm Fro To (m) (m) d (m) e) Drill Water h (m) e of core
) m (m) Observer' recovery
(m) s Remark
I)
Supplies Bits used
Petrol Diesel Motor Misc Types Depth (Old/New Carat Stones per
(lt) (lt) Oil (lt) and Size From To (m) with lead and Carat
(m) Number Make
Drill ForemanlSuperviser Operator
Office-in-Charge Drill observer
DRILL OBSERVERS MARKS

1. Water loss during drilling may either be recorded as (a) complete, when no water is coming
out, partial or nil water loss; or (b) in percentage of return water (100 per cent, loss
when no water is coming back and no water loss or 0 per cent. when all the drilling
water is coming back) (See 22.4.3.1.2)
2. Rate of penetration in special zones (soft or broken zones) (see 22.4.3.2) and other details
of drilling like heavy vibration and tarque (see 22.4.3.4) recorded during drilling.
3. Reason for heavy core loss (see 22.4.2,3) as integrated with rate of penetration.
4. Any special conditions not recorded, for example, depth at which blasting was done while
driving casing depth at which hole was grouted (see 22.4.3.6.1), artesian water
conditions if any observed during drilling (see 22.4.3.6.2), gas discharge (see
22.4,3.6.3)
5. If water flows are encountered at the collat of the drill, then the pressure head and
discharge at the collar should be recorded. On completion of the hole, the pressure
decline over a period of time should also be recorded.
6. Other details given at 22.4,3.7 should also be observed and recorded.
7. The feel of the driller may be suitably recorded in remarks column.
APPENDIX - II
(Para 22.4.5.2.4.5.2.5, 22.4.5.3, 22.4.7.1 and 22.4.8)
Average data for drilling with N size tools to achieve a concurrence of rapid progress and
good core recovery.
ROCK BIT TYPE Bit

TYPE T.C. Diamond Set Bits Pressure
5 15 30 Diamond Core Bit Water
Impregnated Barrel Speed pressure
15 30 60 Bits Type B rev/min Kg/cm2
1 2 3 4 5 6 7 8 9 10
Laterite X X 100 Light 3.5 to 7
Weathered X X 200 Light 3.5 to 7
granite and
soft gnaiss
Sandstone X X 200 Light 9 to 12.5
Medium
Clay shales X X 200 Light 9 to 12.5
Other X X X 200 Light 9 to 12.5
bedded Medium
sediments
ROCK BIT TYPE Diamond Core Bit Bit Water
TYPE T.C. Diamond Set Bits Impregnated Barrel Speed Pressure pressure
Bits Type B rev/min Kg/cm2
T.C.
Diamond
5 15 30 5
15 30 60 15
1 2 3 4 5 6 7 8 9 10
Hard X 200 Medium 10.5 to 14
sandstone
Black X 400 Medium 10.5 to 14
schist
Basalt X 400 Medium 10.5 to 14
(green
stone)
Prophyry X X 400 Medium 10.5 to 14
Diorite X X 400 Medium 12 to 15.5
Hard basalt X 600 Medium 14 to 17.5
(green heavy
stone)
Hard X X 600 Medium 14 to 17.5
perphyry heavy
Hard X X 600 Heavy 14 to 17.5
diorite
granite,
gneiss
Bit type : TC=tungsten carbide saw tooth bits.
5, 15, 30, 30, 60 = Diamond set bits with stones per carat within the limits indicated
The bits indicated with a cross (X) should normally be used

When using other size of coring equipment, multiply with factor given below:
Size Factor
Feed Pressure Water Pressure Bit Speed
NX 1 1 1
BX 0.7 0.7 1.3
AX 0.5 0.5 1.6
EX 0.3 0.3 1.9
APPENDIX - III
(Para 22.4.9)
VIBRATION IN DRILLING
1. CAUSES OF VIBRATION
1.1 Causes of vibration for which the operator is responsible are the following:
(a) Excessive rotational speed;
(b) Excessive feed rate of pressure;
(c) Excessive water pressure or volume;
(d) Low water pressure or volume, resulting in slow removal of cuttings;
(e) Drilling when the core barrel is filled;
(f) Drilling over dropped core; and
(g) Careless handling of drill rod. Bent rods cause vibration deviation in holes and damage to
bits.
Rods can be bent through:
(1) Rough handling of rods;
(2) Their improper use as crow bar or as lever arm, and
(3) Hoisting and lowering rods with pipe wrench instead of using safety clamps.
1.2 Causes of vibration controllable by the operator are the following:
(a) Unsatisfactory setting up of drilling rig;

(b) Incorrect size of rods and core barreI inrelation to the size of hole;
(c) Bent core barrel and rods;
(d) Bit with missing stones or damaged bits;
(c) Lack of rod grease;
(f) Unsatisfactory condition of drilling equipment, such as won out spindle and bearing of
swivel bead; and
(g) Off-centre tightening of the chuck.
1.3 Causes of vibration not fully controllable by drillers are the following:
(a) Worn out rod couplings;
(b) Core bits with flat faces that 'w' lk in certain formations:
(c) Crooked drill holes due to unfavorable geological features:
(d) Cavities in the rock, allowing wide sway of the rod string; and
(e) Variable hard and soft layers, such as lime - stone with chert or shale with hard quartzite
layers.
Note.- All causes of vibration listed have serious effects on core recovcry and
wear on bits and equipment.
2. REMEDIES FOR VIBRATION
2.1 Remedies for vibration are the following:
(a) The use of rod grease on bottom rods;
(b) Drill rods of maximum size for hole being drilled;
(c) Use of drill collars;
(d) The use of sharp bits;
(e) The use of straight rod and core barrel, concentrically threaded;
(f) Maintenance of rods, coupling, core barrel and drill itself in first class condition ; and
(g) Proper control of feed, rotational speed and drill bit pressure:
In coring operations as many of the adverse conditions which tend to induce rod vibrations as
is physically and economically possible shall be climinated.
APPENDIX - V
(Para 22.7.1.3)
IN SITU PERMEABILITY TESTS IN BED ROCK IN DRILL HOLES:
(Pumping-in Type Test)
I. EQUIPMENT
The following equipments shall be used for water percolation tests in drill holes
1.1 Drilling Equipment. - A drill rig and/or accessories for lowering and driving the easing
pipe.
1.2 Water meter.- Capable of reading up to 0.5 of a liter. The water meter should be
periodically checked and calibrated.
1.3 Pressure gauge.- Choice of pressure gauge of range 4 or 10 or 16 kg/cm2 should be

made dependent on the maximum pressure desired for testing. This will give suitable least
count reading for test accuracy. Where centrifugal pumps are not available and reciprocating
pumps have to be used, they should be used with syphon or air-dome attachment in order to
enable correct measurement of testing pressure.
1.4 A pump.- Preferably a centrifugal pump of minimum capacity 500 It/mm capable of
producing pressure up to 30 kg/cm2.
1.5 Water pipes, connections and swivels. - See Note under 1.8.
1.6 Drill Rods, Perforated Rods and Other Fittings.- See Note under 1.8.
1.7 Packers (Washers, Pneumatic or Hydraulic Type). See Note.
Note.- Leather cup packers are generally used in rock formation where holes drilled retain
their proper size. Mechanical packers are commonly used in moderately hard formations
wherein the holes drilled are upto 20% over size, Pneumatic packers, can be used for all types
of formations, are generally preferred for soft rock formations wherein the holes drilled are
20% over size.
1.8 Equipment for Measuring Water Level in the Drill Holes.- See IS: 6935 - 1973.
Note- When drilling is in progress, no additional water pipes, swivel, etc. will be necessary.
The drill rods and other equipment as used in drilling may be used for conducting percolation
tests.
1.9 A Stop Watch, - Having a measuring capacity up to one hour and a least count of one
second.
2. QUALITY OF WATER TO BE USED FOR THE TEST
In the pumping in test, unless clear water is used, the tests are invalid and may be grossly
misleading. The presence of even small amounts of silt or clay in water used in the test will
result in plugging of the test section and give permeability results that are too. low.
By means of settling tank or a filter, efforts should be made to assure supply of clear water. It
is also desirable, where the climatic conditions demand, to raise the temperature of added
water to one higher than ground temperature so as to preclude the creation of air bubbles in
the ground which may greatly reduce the acceptance of water by the test section.
3. PROCEDURE PUMPING-IN TYPE OF TESTS

The water percolation tests should be conducted in uncased and ungrouted sections of the
drill holes.
3.1 Single (Single packer - method) or double (double packer method) packers are
employed to conduct these tests (See fig. 1). Examination of drill cores and the results
of water tests obtained during drilling will usually indicate whether a double packer test
in any isolated section or sections of the drill hole is required. In certain form ations, it
may not be possible to use the packer or there is a danger of the packer being stuck in.
the holes. In such cases, a better method will be to grout the earlier stage, extend the
bore hole and carry out the test. The tests are based on. measuring the amount of water
accepted by the test section (of the hole) confined by a packer/packers while water is
pumped into it. The lay out for the test is shown in figure 7.
The single packer method (Fig. IA) is useful where the full length of the hole cannot stand
uncased/ungrouped in soft rocks, such as sand rock (soft and stone), clay shale or due to
highly fractured and sheared nature of the rocks or where it is considered necessary to have
permeability values side by side with drilling (for example where multiple aquifers are
present). Where the rocks are sound and the fill length of the hole can stand without
casing/grouting double packer method (Fig. 1B) may be adopted. The specific advantage of
double packer method is that critical rock zones can be tested by confining the in along with
packers. The disadvantage of the double packer method is that leakage through the lower
packer can go unnoticed and lead to over estimation of water loss. Wherever time permits,
single packer method would be preferable.
3.2 Single packer method : In this method the hole should be drilled to a particular, depth
desirable for the test. The core barrel should then be removed and the hole cleaned
with water until, clear water returns. The packer should be fixed at the desired level
above the bottom of the hole and the test performed in accordance with the procedure
laid down in Para 3.5, after performing the test, the entire assembly should be
removed. The drilling should then be proceeded with till the next test section has been
drilled for performing the next test. In this manner the entire depth should be tested
side by side with the drilling.
3.3. Double packer method - In this method the hole should be drilled to the final depth
desired and cleaned with water until clear water returns. Two packers connected to the end of
a perforated drill rod of a length equivalent to the test section should be fixed in the drill hole.
The bottom of the perforated rod should be plugged before the double packer tests are
proceeded with.
The tests may be done from bottom upwards or from top downwards. However, it is
convenient to start the test from the bottom of the hole and then work upwards.
3.4 To verify the presence of ground water table the water level in the hole should be
depressed either by evacuation with compressed air or boiling by sand. After this operation is
completed, if three consecutive readings of the water level taken at 10 to 15 min intervals is-
constant, then this water level may be taken as the ground water level. The time interval may
have to be increased to 30 min in less permeable formation.
3.5 The tests are recommended to be performed in 1.5 or 3m test sections so that the entire
hole is covered, depending Upon the geological conditions; as for example in sections
passing through a shear zone or a highly jointed zone, a lesser length of section should be
used (see also para 4.3). The test length should not, however, be less than 5 times the
diameter of the bore hole. The test section should be confined by means of a packer or
packers (see para 3.2 & 3.3). The water level in the hole/test section should be determined
using electrical device as given in IS:6935 - 1973.
The measurements of the water level should be noted at short intervals of time (usually 10 to
15 mm) till three consecutive readings show constant values. The constant readings should be
taken as the depth of water table. This measurement is done for determining the hydrostatic
pressure in the test zone and this value is used for calculating the permeability of the horizon.
If these measurements indicate that there is no water table or piezometric head, this fact
should be mentioned in the report/noted on the Drg. showing the logs of bore holes.
Under piezometric conditions, the piezonietric head in separate horizons shall be ascertained
by measurement of water level after installation of packer in the hole.
generally limited to the following:-
Rock Type Limit of Test Pressure applied to

the Test Zone in g/cm2 per metre
of Rock Load (See Note)
(i) Unconsolidated or poorly 115
consolidated sedimentary
formations.
(ii) Consolidation horizontally bedded 175
sedimentary formations.
(iii) Hard irrigation and metamorphic 230
rocks
Note :- These pressures are applicable for testing in exploratory holes for determining the in-
situ permeability. For testing to determine the groutability of the formation higher
pressure may be needed (see IS:6066-1984).
3.7 Cyclic Test In special circumstances cyclic tests are performed to evaluate the
washability and grouting of joints or rock or their extent. Cyclic tests for assessment
of permeability are useful in competing lugeon value. These tests are started at low
pressures, the test pressures, the test pressures built up to the maximum capable
pressure by increments and decreased in the same order until the original pressure is
reached. Generally, for the performance of the cyclic tests, 4 ranges of pressure should
be chosen which may be fixed at 25 percent, 50 percent, 75 percent and 100 percent
of the pressures selected for the test section based either on suitable rock cover or
maximum equivalent of reservoir head whichever is applicable (see para 3.6).
In addition to performing the permeability tests at regular intervals of the
strata, it is desirable to test critical bedrock zones by confining them alone with
packers.
4. PRECAUTIONS IN CONDUCTING THE TEST
4.1 On completion of drilling, the holes shall be immediately capped or plugged and shall be
protected from entry of dirt, muck, grout or any kind of waste.
4.2 Water level in the drill shall be recorded before proceeding with the water percolation
tests.
4.3 Normally a 1.5 or 3 m section is considered suitable for performing the tests. However,
the length of the test section should be selected according to the total thickness of the
permeable stratum and geological conditions and varied locally to seat the packer(s)
properly. Short test sections of 1.5 m would be preferred in thin bedded and
heterogeneous strata. When the intake of water in the test section is more than that
which the pump can deliver it is advisable to reduce the section. Under normal
circumstances test sections longer than 3 m are not recommended.
4.4 The hole should be thoroughly flushed with clear water before the tests are commenced.
Where core recovery is good (greater than 70 per cent) holes should be flushed with water
under pressure, until the wash water is clear. When the recovery is poor (less than 70 percent)
and the holes are liable to collapse by the disturbance caused by. washing the holes may be
cleaned by gentle surging (by moving a rubber block up and down the hole) followed by
gentle flushing.
4.5 Drill rods or 32 mm pipes may be used for conducting the permeability tests. It would
here're, always be better to use a large diameter rod when the alternative is available so that
friction losses may be reduced to the minimum possible.
4.6 The water swivel used in the test should preferably have a uniform inside diameter, to
minimize loss of head,
4.7 Locations of the pressure gauge between the pump and the water meter or the water meter
and the swivel may not measure the actual pressure acting in the test. In order to et a better
and representative figure of the pressure acting, it is recommended that the gauge be located
between the swivel and the packer (see Fig.7).
4.8 Unnecessary bends in the pipe lines from the pump to the swivel should be avoided.
4.9 The water used for the test should be clear and free from silt (see para 2).
4.10 All joints and connections between the water meter and the packer, it should be assured
that the packer/packers are not, leaking. A leaking packer usually causes the rise of water
level in the hole or even the water strata overflowing from the nipple.
4.11 Every opportunity should e taken- of comparing the permeability observations in open
pits, shafts and trenches with the results of tests in bore holes.
5. COMPUTATION OFEQU1VALENT PERMEABILITY FROM PERMEABILITY TEST

DATA.
5.1 THE COEFFICIENT OF PERMEABILITY SHOULD BE COMPUTED USING THE FORMULAE

GIVEN IN FIG.9. THE COEFFICIENT CU AND CS IN THESE FORMULAE MAY BE TAKEN
FROM THE GRAPHS GIVEN IN FIG. 10 AND FIG. 11. FOR WATER PERCOLATION TESTS
CONDUCTED ABOVE THE WATER TABLE, THE POSITION OF THE BASE OF ZONE I
SHOULD BE FOUND FROM THE CURVE GIVEN IN FIG.12. THE - FRICTION LOSS OF
HEAD (L) SHOULD BE CALCULATED OR OBTAINED FROM FIG.8A, 8B OR 8C. THIS
HEAD SHOULD BE DEDUCTED FROM THE COMBINED HEAD DUE TO GRAVITY AND
THAT DUE TO APPLIED PRESSURE. NUMERICAL EXAMPLES ILLUSTRATING THE USE OF
THE FORMULAE ARE GIVEN IN PARA 5,2,
Limitations Q / A < 0.10 S > 10 in method II : Thickness of each packer should be 10.
A = LENGTH OF TEST SECTION, IN M.

A = SURFACE AREA OF TEST SECTION, IN M2 (IN METHOD 1, A IS AREA OF WALL PLUS AREA OF
BOTTOM)
CU = CONDUCTIVITY COEFFICIENT UNSATURATED BED (SEE FIG. 10)
Cs = conductivity coefficient saturated bed (see fig. 11)
D = distance from ground surface to bottom of hole, in m.
H = effective head = H2 + H3 L, in m
below water table, distance between swivel and water table, in m.
H3 = applied pressure at collar, in m of water.
cm/s)
pipe, it may be ignored.
Q = Steady flow into well in 3/s.
r = radius of test hole, in m.
S = THICKNESS OF SATURATED MATERIAL, IN M.
TU = U D + H
U = THICKNESS OF UNSATURATED MATERIAL, IN M.
X = PERCENT OF UNSATURATED STRATUM TU X 100 (SEE FIG. 12)
FIG. 9 FORMULAT FOR CALCULATION OF COEFFICIENT OR PERMEABILITY

5.2 CALUCATION OF PERMEABILITY COEFFICIENT USING PRESSURE PERCOLATION TEST IN
BEDROCK
ZONE 1 :
U = 23 M D = 7.6 M A = 3 M
R = 0.15 M H2 = 10 M H3 = 1.75 KG/CM2
= 17.5 M
Q = 0.0013 M3/S
L USING 32 MM PIPE AT 0.0013 M3/S
= 23 CM LOSS PER 3.05 M SECTION
DISTANCE FROM SWIVEL TO BOTTOM OF PIPE 6.7 M
6.7 X 0.23
HEAD LOSS = 3.05 = 0.514 M
H = (10+17.5-0.51) M = 26.99 M, SAY 27 M
TU = U D + H = 23-7.6 + 27 M = 42.4 M
H 27 X 100
X = TU X 100 = 42.4 = 63.6 PERCENT

Tu 42.4
.........................=.........................=14.1
A3
Tu
Point .................................., X on Fig.12 is in Zone 1
H 27
.........................=......................... =180
r 0.15
A3
.........................=......................... =0.11
H 27
Cu from (Fig. 10) = 62
Q 0.0013x100
K = .........................= .........................cm / s per unit gradient
Cur H 62x0.15x27
= 0.00052 cm/s per unit gradient
ZONE II:
U = 23m D = 20m A=3m
r = 15cm H2 = 22m
h = 1.75 kg/cm2 = 17.5 m Q= 0.001 3 m3/s
L using 32 mm pipe at 0.001 3 m3/s
= 23cm loss per 3.05 m section
Distance from swivel to bottom of pipe 19.6 m
19.6
Head loss = ..............................x 0.23 m = 1.5m
3.05
H32+ 17.5- 1.5=38m
Tu = 23 -20+38=41 m
38
X=___________x 100= 92.5 percent
41
Tu 41
__________=_________ = 13.7
A3
A3
__________=_________ =20
r 0.15
Cs (From Fig. 11) 39
Tu
Point _______________, X on Fig. 12 is in Zone II
Method I
2 Q 0.0026x100
K=_______________=________________
(Cs +4) (Tu + H-A) (43x 0.15) (41+38-3)
= 0.00053 cm/s per unit gradient
Method II
2 Q 0.0026x100
K=_______________=______________________
(Cs +4) (Tu + H-A) (39x 0.15) (76)
0.000 583 cm/s per wilt gradient
ZONE III
U =23 in S=18m
D=30m A=3m
r=0.15m H2= 25 in
H3= 1.75kg/cm2 =175m
Q= 0.0013 m3/s
L using 32 in pipe at 0.001 m3/s = 23 cm loss per 3.05 in section
Distance from swivel to bottom of pipe =30 m
30
Head loss ------- x 0.23 = 2.26
3.05
H = 25+17.5..2.26 40.24m
A3
--------------= ------= 20
r 0.15
Cs(fromFig.11)=39
Method I
0.001 3x 100
k_____________________=0.0005cm/sperunitgradient
(39 + 4)(0.15 x40.24)
METHOD II
0.001 3x100
K= -------------------- = 0.00055cm/sperunit
39x0.15x 40.24 gradient
5.3 In hard-rock when the permeability tests are conducted the water intake is generally due
to joints and fractures and not due to intergranular voids. In such cases, the permeability
computed from these tests would correspond to that of the joints and fractures and would
represent the equivalent permeability of a homogeneous isotropic material
5.4 The water loss may also be expressed in Lugeons which is defined as the water loss of
one liter per minute per meter of the drill bole under a pressure of 10 atmospheres maintained
for 10 min a drill hole of 46 to 76 mm diameter.
As it is difficult to build up without upheaval/deformation pressure of 10 atmospheres at

depths of less than 30 to 45 m in hard massive rock a unit coefficient of water loss (one liter
per minute per meter per atmosphere) herein after designated as a deci-Lugeon may be
adopted for direct evaluation of the order of water tightness of the rock.
6. SIGNIFICANCE OF PERMEABILITY VALUE IN BED ROCK
6.1 The direct values of water loss (which may be preferably expressed 111* Louganis) is a
useful guide to assess the competency of the foundation, determine the necessity or otherwise
of grouting requirements and to settle the foundation grades of darn foundation. Therefore, it
is customary to note the water loss values along with the plotting of the log of bore holes.
6.2 It is customary also to note the values, of water loss at a water pressure of
1.5 to 2times the rosewood head to which the bed rock at that level is likely to he subjected.
6.3 The water loss indicate the aquifer zones that are more permeable and against which
slotted pipes are to be placed in tube well construction.
6.4 The equivalent permeabilities of rock are some guide in ground water yield - studies. But
in ground water studies more reliance is placed on pumping tests with mother well
surrounded by auxiliary wells.
APPENDIX-VI
(Para 22.7.12.4 & 22.7.12.7)
CONTROL OF GROUTING OPERATION
1. PRESSURE
The pressure should be adequate to achieve the desired grout and the pressure should be
limited so, as to avoid disturbance and upheaval of the ground.
1.1 For structures on rock foundations, it is a basic requirement that no disturbance should be.
caused to the surface zones of the foundation by the grouting operation. When grouting is
undertaken below an existing structure no upheaval of the foundation can be allowed as it
would have very harmful consequences on the structure and/or equipment.
1.2 In general, the disturbance caused by grouting is dependent more on the manner in which
the pressure is developed and the nature of the rock than on the absolute magnitude of
pressure. Relatively higher pressures can be sustained without damage to the foundations,
when pressure is built up gradually, as resistance to flow is developed by deposition of grout.
On the other hand, when pressure are raised hastily, damage could occur even, at relatively
low pressures. In general horizontal particularly stratified or low dipping rocks are more
vulnerable to disturbance by grouting pressure than fractured igneous or metamorphic rocks
or steeply dipping sedimentary rocks. Rocks previously subjected to folding and fracturing or
rocks in the process of adjustment after removal of overburden load are also more vulnerable
to disturbance.
1.3 It is always advisable to begin with a low initial pressure say 0.10 to 0.25 kglcm2/m of
overburden and build up pressure gradually. Initially the rate of intake may be 20 to 30
lit./min. hi order to avoid the premature build of high pressure a general guideline should be
followed that the pressure shall be raised only when the intake rate falls below 5 liter/minute
when surface leaks develop, pressure shall be immediately reduced. Subsurface cracking may
sometimes be indicated by as abrupt rise in the rate of intake after grouting at a constant
value of pressure for a considerable period.
1.3.1 The most common difficulty experienced in consolidation grouting is surface leakage. It
is therefore customary to pipe through the required height of concrete or masonry and carry
out the growing after the rock has been completely covered. This not only eliminates surface
leakage but permits use of higher pressure so that even the smaller seams can be grouted
effectively,
1.3.2 The true pressure at any depth should take into account the pressure head caused by the
weight of the grout in the hole. This correction in kg/cm2 may be computed by
multip1yingthe depth of the ho! in meters by factors relative to the water- cement ratio given
in Table 1 and ,added to the pressure gauge reading at the top of the grout hole.
TABLE 1 - MULTIPLYING FACTORS
Water-Cement Factor Water-Cement Factor

Ratio (2) Ratio (2)
(1) (1)
0.75 0.151 2.50 0.118
1.00 0.140 2.75 0.117
1.25 0.131 3.00 0.112
1.50 0.127 4.00 0.110
1.75 0.123 5.00 0.107
2.00 0.121 10.00 0.102
2.25 0.119
1.4 Control of pressure should be exercised according to the following guidelines:
(a) The 1imitin value of pressure for each zone and depth of stage may be established initially
from the results of trial grouting, along with observations of upheaval by uplift gauge. Figure
13 may be used as a guide, subject to verification by trial grouting;
(b) Pressure limits may be decided by analyzing the result of Cyclic Percolation Test.
(c) Limiting pressures may be decided by continuous review of the trends of pressure and rate
of intake during grouting operations.
taken as initial values to be confirmed by trial and observation.
test thus constitutes a basis of verification or rock categorization as per Fig. 13.
1.4.1.1 Interpretation of water test :
principles :
cyclic test.
SOMETIMES THE RESISTANCE TO FLOW INCREASE DISPROPORTIONATELY TO THE INCREASE IN

PRESSURE AND THEREFORE THE RISE OF FLOW RATES IS NOT COMMENSURATE WITH THE
INCREASE IN PRESSURE. THIS MAY BE ATTRIBUTED TO DEVELOPMENT OF TURBULENT FLOW
REGIME AND IS INDICATED BY LUGEON VALUES DECREASING WITH INCREASE OF PRESSURE.
(B) Hydraulic fracturing is indicated by a disproportionate increase of flow with reference to
pressure and the percolation at the end of the cyclic test is higher than the initial
values at equal pressure.
(B) Hydraulic fracturing is indicated by a disproportionate increase of flow with reference to

pressure and the percolation at the end of the cyclic test is higher than the initial values at
equal pressure.
Sometimes, flow rates tend to decrease with passage of time and the flow rate at the end of
cyclic test is smaller than the initial flow rate at equal pressure. This is categorized as a
condition of void filling.
Sometimes, a phenomena similar to hydraulic fracturing occurs when lugeon values at the
end of the test arc higher than the initial values at equal pressures.
However, if the test is repeated, a normal trend is indicated. Such cases are categorized a
washout. 1 lie difference between the hydraulic fracturing and washout category is that in
case f hydraulic fracturing a progressive increase of flow rates will occur with each cycle as
the cycles are performed.
1.4.2 The pressure limits initially established as per 1.4.1 should be feather reviewed by
examining trends of grout intake and pressures during initial stage of actual grouting
operations. The method of interpretation of trends of grouting pressure is described in para
1.4.2.1. It should be recognized that the resistance to flow of grout pres sores are built up
gradually. Consequently higher pressures may be used in water tests without causing
hydraulic fracturing. Normally, the aim should be to obtain A type trends. This trend
signifies increase of resistance of flow as the joints / cracks I cleavages are filled by the grout
response. Grouting with B type trends can be permitted since they-imply a fluctuating
response. Grouting with W type trend may be continued till the limit of consumption is
attained or recital may be attained eventually by restricting the pressures or by thickening the
grout when B trends develop. B trends thus constitute a permissible deviation from the
ideal which should be minimized by careful control. When pressure limits are properly
chosen A type trends would predominate. Under no circumstances C type trends should be
permitted since they imply hydraulic fracturing. The pressure control criteria initially chosen
as per 1.4 should be modified on the basis of the analysis of the trends of gratuity pressure
and intake. The chosen pressure limits ensure that A trends are achieved generally and C
trends are eliminated.
1.4.2.1 Method of Interpretation of Trends of Grouting. - The categorization should be done
as follows by competing the ratio of rate of grout intake and grating pressure and examining
trend of variation as the grouting operation continues -
Rate of grout intake
(a) Ratio of __________________________Decreasing 'A' trend
Grouting Pressure
(b) Ratio of _______________________Constant B trend*
Grouting Pressure
(c) Ratio of ____________________________increasing C trend
Grouting Pressure
* In this case the rate of intake and pressure may fluctuate while the ratio would remain
constant for a prolonged period and grouting may be stopped if consumption limit is attained.
Alternatively the operation may end with a decreasing ratio which implies A trend towards
closer.
1.5 Situations arise in practice when hydraulic fracturing may occur before uplift is observed
or surface leakage is noticed. This is attributable to developments of localized high strains. In
rock associated with hydraulic fracturing up heavily may be noted only when sufficient
volume of grout is injected into the fractured zones to cause dig-. placements in the surface
zones.
2.0 GROUT MIX. Grout mixture ranging from mixture of 0.5:1 upto 10:1 (ratios by weight
of water and cement) have been used. Recommended range of mixture falls from 5:1 to 0.8:1.
It is only in exceptional circumstances that mixtures leaner than 10:1 need be used. The
choice of grout mixture may be based on results of percolation tests conducted prior to
grouting (See 1.4). The ideal would be to conduct a percolation tests in each hole, for each
stage. However, the number of percolation tests may be reduced if extent of zones of different
types of rock and rock characteristics can be established on the basis of geological evidence
and results of initial experimental grouting operation. It is inadvisable to relax the
requirements of percolation testing in the initial stages of grouting and grout absorptions at
low water-cement ratio are a poor substitute for water percolation tests.
2.1 If grout is too thick, passage of grout travel may get obstructed at a short distance and the
fine seams may not be filled up. On the other hand if injection with the grout is continued for
a too long time, the grouting operation may get unduly prolonged and may be rendered
unduly expensive. If openings are large and grout is thin, grout consumption will be
excessive even with. low pressure. h the case of fine cracks additions of betonies say 2 to 3
per cent hi a grout mix: will have lubricating action. No general rules can be stipulated
regarding the manner in Which the thickening of the grout is to be carried out. The
appropriate sequence for every site may be decided after a review of tIIe% results of initial
grouting; a judgment about the efficacy of a particular sequence may be had by comparing
the grout consumption of the primary and secondary or secondary and tertiary holes. As a
guide, the mix should be thickened if there is no Increase in the pressure after a continuous
grouting of about 10 min.
2.2 When multiple line grout curtains are used the control of grouting operation, would differ
from single line curtains. In the outer lines thick grouts may be used to prevent over travel
and to block the more pervious zones. In the inner or central lines grouts may be thickened
very gradually and comparative thinner grout may be used at the start. Similarly the
thickening of grouts may be carried out more gradually in tertiary holes as compared to
primary and secondary holes. In order to prevent over travel of grout in the case of wide
joints, sodium silicate is sometimes added, while for increasing the flow ability in the case of
thin joints 2 to 3 per cent betonies is added.
2,3 It has been the practice of some organizations to dilute the grout by increasing the water
content at the end of the grouting operation. The advantages of this procedure are
controversial: however, the thinning of the grout may be helpful in preventing abrupt rise in
pressure and/or clogging of the equipment at the end of the grouting operation. Thinning of
the grout is not permissible When stable grout suspensions are used that do not allow
exclusion of the excess water by filtration. If such grouts are diluted, the strength and
imperviousness may be compromised. Alternatively it is recommended to keep more than one
grout design ready with the use of clay - cement, bentonite-cement, bentonite-chemical etc.,
so that these mixes can he used without change of mix design.
2.3.1 A recommended method is also to arrange for grout refusal to occur while a thin mix is
being pumped even though 3:1 to 1:1 mixes were used temporarily.
2.3.2 While packer grouting and thin beginning mixes, the section of hole just completed is
automatically exposed to the new beginning mix. This of course does not apply to the last or
top section of the hole. In special cases, such as a large opening into- which a lot of standard
grout has been pumped or in a zone in which refusal was specially difficult to obtain or again
in the case of deep interconnection, this process might not be performed and thin mixes may
be omitted for 6 in or so overlying the trouble some zone, or the section might be allowed to
rest for a few hours before higher sections are treated.
3. CONTIOL OF GROUT CONSUMPTION-
When pressure does not. built up even after groin's a thick grout that is, grout with water
cement ratio smaller than 0.6:1 by weight or richer or by grouts with fillers, such as clay,,
sand and, betonies, it is desirable to stop grouting after the predetermined limit of
consumption is reached. The choice of the limit of consumption will depend on the length of
a, stage and size of the cavities, open joints and fissures. After grouting a hole in which
grouting has to be stopped because the consumption limit was reached it is necessary to drill
additional holes in the vicinity and grout them with more fluid grout in order to penetrate the
finer cracks and joints which may not be grouted in the initial operation. In such situations a
multiple line curtain, may be used with advantages and the sequence of grouting shall be as in
2.2.
APPENDIX VII
(PARAA 22.7.17)
PRESSURE GROUTING RECORD
Hole No Grout cap Up Lift Gauges
Co-Ordinates Width Bottom Elevation
Diameter Depth Top Elevation
Elevation Casing Pipes (Space for Sketch)
nature Ground Depth
Type of Hole Diameter
s. Hole Type Stag Da Ti Water Pressure Gro Pressure Grout Up Ob Extt Lea Re
N log of es of te me Test ut grouting Consi lit t s ent kage mar
o Partic Grou Grou pra Pres Test mix use Inta Cem stancy obs poi of from ks
ulars ting ting ssur sure inta by d ke ent poi nt leak near
Log e used ke Volu pre litre cons nt No age by
spe Litr me ssu s umed No . 2 fro hole
cifi es re per .1 m s
ed per min surf Hole
min ute ce No.
utes joint
&
fiss
ures
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Notes 1. Skatch on the top right hand corner shall show the location of the hole beibg grouted
together with location and condition of nearby boles. Holes that have been
drilled will be indicated by 'D' with the number showing the deopth of the hole
such as 'D-25'. The hole has been grouted will be indicated by the letter BG in
similar manner. Position of upheaval indicators shall also be shown.
2. Column 1 & 2 will also show the ground water table level.
3. Column 5 & 5 will record the date & time of any significant event in the operation. The
change pressure & intake in the water pressure test and each change in grout
mix, pressure of intake in the grouting operation will be recorded.
4. The rate of intake in column 13 shall be recorded for each pressure of grout mix change.
5. Cement consumption in column 13 shall be recorded for each pressure of grout mix
change.
6. Column 15 & 16 will show readings of uplift observation points at the beginning of the
operations and at every noticeable change.
7. Under 'Remarks' In column 19 shall be recorded any change or incident affecting the
grouting operation such as 'Tight Hole' Leak caulked' Hole No.....Capped.
'Grout pump down, Grouting suspended due to............ Hole Completed and so
forth.
water resources Department Page 219
2. GEOTECHNICAL INVESTIGATION
The contractor will have to carry out detailed subsurface Geo Technical
Investigation by taking boreholes at every 500 m spacing along the
alignment of the canal. The holes will be drilled below one meter the
bed level of the canal. The contractor will lavel in position of structure
or 1.2 m below the foundation level. The contractor will submit detailed
engineering Geo Technical and rock mechanics analysis report
based on bore hole data and shall prepare Geo Technical L-Section
along the canal alignment that will decide lining of the canal system.
The contractor will then prepare detailed design and submit for
approval of the Engineer before commencement of actual work of
construction.
2.1 Exploration by Pits/Trenches/Drifts/Adits and Shafts
Open test pits, trenches, drifts and shafts are features accessible for visual
examination in sub surface exploration and exploration and afford the most complete
information on the ground penetrated. Location of pits, trenches, drifts and shafts
shall preferably be decided in consultation with an engineering geologist; invariably
to be followed for the medium and major irrigation projects.
2. Exploration by Test Pits
1. Pits are dug manually but mechanical equipment may also be used for
the purpose upto shallow depths. N dry ground, pits are economical in
comparison to bore holes upto a depth of about 5 m depending upon
the location. As the depth increases, the cost of excavating a it
increases very rapidly and it is seldom that unsupported pits are dug to
a depth exceeding 6 m except in the case of hard soils. The top of a pit
shall be kept large enough so that the dimension of the pit at the
bottom may be at least 1.2 m x 1.2 m which are sufficient to provide
necessary working space. Additional space for sheeting and timber
supports, hoisting arrangements and ladder, etc. shall be provided. A
recommended proforma for the recording of information obtained from
trial pits is given in Appendix II (A).
2. For deep pits in soil, the walls shall be supported by timber. Typical
sheeting and bracing to be adopted in such cases in shown in Plate 2-
P/3. Instead of sheeting and bracing, cribbing with 75x150 mm timber
may be used and the arrangement is shown in plate 2 P/4. In loose
materials, it is advisable to keep the space between the pit walls and
the cribbing at a minimum and also to pack the space with hay or wood
shavings, and to keep the bottom of cribbing close to the bottom of the
pit. The material from such pits is removed by buckets operated from a
hoist or windlass which should be equipped with a ratchet devise for
safety. During excavation, the bottom of the pit should be kept fairly
level and of full selection so that each lift may represent the
corresponding portion of the deposit in quality and quantity. The
excavated material should be placed round the pits as stock piles,
separated when significantly different materials are encountered, and
marked stackes should be driven into the stockpiles to indicate the
depth from which the materials were excavated in order to facilitate
logging and sampling later on. The excavated material should be
placed round the pits in the manner it is received from the excavation,
preferably in a clockwise direction. The deposits of excavated material
from the pit at every change in strata should be dumped separately in
the manner described above. Samples from these deposits should be
taken as soon as material comes out of the pit and the natural water
content of the excavated material determined.
3. Test pits left open for inspection shall be provided with covers or
barricades for safety. Pits and trenches shall be suitably fences.
Trenches and pits should be filled back properly when exploration and
physical inspections are completed and the relevant records have been
obtained.
4. When water is encountered in a pit, a suitable dewatering system may
be required for further progress. Where suction pumps are used it is
desirable that the suction hose be 10 mm larger in diameter than the
discharge opening of the pump and the suction head not more than 4.5
m. This required resetting the pump in the pit (on a frame attached to
the cribbing) at intervals of about 3.5 m. When an internal combustion
engine is used in the pet. It would be necessary to lead the exhaust
gases well away from the pit.
5. Undisturbed samples may be obtained from open pits from each
stratum if the nature of the deposit permits. For this purpose a pillar of
suitable dimensions, say, 40x40 cm should be left undisturbed at the
centre of the pit to collect undisturbed samples of required size from
each layer showing a change of for mation. If the thickness of each
layer exceeds 2 m, a second sample may be taken. These undisturbed
samples will be useful for the determination of several characteristics
of the in situ materials. Special care shall be taken to preserve the
natural moisture content of the samples.
3. Hand Auger Borings

1. Augur boring is the most common, economical and rapid
method for relatively shallow exploration of fine-grained
materials above the water table. Hand augers become
awkward and cumbersome beyond a depth of
approximately 6 m. If the work is done carefully, the layers
of different soils may be accurately located, identified and
suitable distributed samples obtained.
2. In making auger borings it is often necessary to add water to
soften a hard, dry, clayey soil so that the auger will penetrate the
soil. Also, if dry sands or silts are encountered the addition of
water will make the soil slightly cohesive and easier to pick up by
the auger. Cohesive soils can be augered successfully below the
ground water table. However, if clean non cohesive silts of
sands are encountered below the water table, they are very
difficult to extract from the hole and such material will cave unless
the hole is cased.
4. Rotary Drilling
Rotary Drilling shall be carried out with or without coring. For rotary drilling with
coring, double core barrels giving core diameters of at least 52 mm shall be used. The
radial deviation of boreholes shall not exceed 5% of the borehole depth.
1. Wherever necessary, and as approved by Engineer-in-Charge drill
holes shall be provided with casings through overburden and in rock of
poor quality. The length through overburden may be drilled without
coring. Filling of part of the hole with grout and subsequent re-drilling
shall be carried out as necessary in zones of poor rock quality.
2. In specific case, as approved by Engineer-in-Charge drill holes shall
remain open. In those cases the upper end of the hole and the part of
the hole extending through the overburden shall be provided with a
pipe closed by a cap.
3. During drilling with coring the rotation speed, feeding pressure and
amount of flushing water shall be adopted to the rock properties, so as
to obtain cores of the best possible quality.
4. Cores shall be placed in core boxes of wood or metal. The depth of
each run shall be noted in the box and core losses marked by pieces of
wood of corresponding length. The core boxes shall be transported to
and kept in a core store.
5. The water levels in the drill holes shall be measured when first
encountered and at the beginning and end of each shift. An electrical
device, including spares, shall always be available for this purpose.
6. Records of core drillings shall be submitted on daily basis within 24
hours and shall comprise.
7. Core recovery per run, as well as all core losses, Rock Quality
Designation and fracture spacing.
- Depth of each run
- Water level in the drill hole when encountered at the beginning and end of the shift.
- Length of casing, lengths grouted and re-drilled.
The form of the record shall be as agreed with the employers
3. supplementary conditions
3.1 The Contractor, shall assume full responsibility of Engineering adequacy,
coordination and timely completion of investigation, designs, drawings
and detailed estimates including all other activities with their own
modern equipment, man power and other services required connected
to the work.
3.2 The Contractor shall be fully responsible for designing and estimating of
all the connected and component works of the project. The
responsibility of the Contractor shall be,
1. To study in detail all the Engineering and design features.

2. to prepare technical specifications which are necessary for
execution of works.
3. The Contractor shall be responsible for furnishing the most
technically suitable and economical proposals. The Contract
price quoted shall include the cost of investigation, alternative
investigation, site surveys, designs, alternative designs,
estimates etc., to arrive at most economically and technically
sound and suitable proposals. No separate payment shall be
made for study of alternatives.
4. The designs and specifications are to be drafted by the
Contractor.
5. Cost of estimate.
The Contractor shall submit a complete cost estimate adopting prevailing market rates
and with current rates of prevalent U.S.R For adopting the market rates, the
quotations from the reputed firms are to be obtained and enclosed for the
items not covered by the U.S.R.
6. Preparation of all designs, drawings, estimates, command area
registers and land acquisition schedules as may be required for
complete and correct execution of all works which are included
in the scope of the work for the block, and should conform to
I.S.I specifications. All the above plans and documents shall be
supplied in 5 copies to the Executive Engineer incharge of the
work for onward submission to the competent authority i.e.,
Chief Engineer, Dhasan Ken Besin Sagar, Superintending
Enigneer, Water Resources Circle Chhatarpur (M.P.) for
approval. It is obligatory for the Contractor to make any
modifications or alternations for designs & drawings as
required by the Department and also in the proposals without
any extra payment.
7. The department shall not provide the village maps/and other
particulars to Contractor. The Contractor shall have to procure
the connected village maps and revenue records from Officers
of Revenue Department i.e. Patwari, Inspector, and Niab
Tehsildar etc. and settlement department of the restrictive area
at their own cost village Patwari. Necessary authorization letter
recommending for the issue of the above maps will be issued
by the Engineer-in-Charge.
8. Investigation of PAWAI Irrigation Project dam land &
properties survey of F.R.L. & properties survey upto M.W.L.
conducting site survey for, preparation of estimates of Dam and
its Components.
1.0 Block command Plans with 1.00M interval contours as applicable to the block.
Block command Plans are to be prepared by conducting the following items of
work.
1.1 Reconnaissance survey of PAWAI irrigation Project with the command area F.R.L.
& M.W.L. etc. verifying the village plans and topo-sheets.
1.2 By fixing the base lines and boundary lines of the area with total station and GPS
Software.
1.3 Conducting block levelling by taking levels at 100m intervals and duly taking the
net levels at closer intervals viz., 30m, 15m, 5m etc., wherever the sudden
changes of the ground occur such as nalla, rivers, mounds, ponds, dips etc., to
obtain the clear and defined configuration of the same.
1.4 Plotting C.S net levels or block levels on the concerned village plans of 1:4000
Scale, and drawing the contours at 1.00M intervals and marking the block
command plans in serial numbers as per G.S.I topo sheets pattern.
3. Detailed Survey:
Detailed survey shall be conducted for fixing the alignment of Main Dam / Subsidiary
Dam and its all components as follows:
1. Chaining
2. Taking L.S levels at 5m intervals and Cross sections shall be taken @
3m intervals along the Dam alignment and C.S. levels on the C.S at
3M intervals to a width of 90m or more on either side of the alignment
for main Dam and its components depending upon the actual
requirement.
3. Fixing of Centre Line stones of size 750mm x 150mm x 150 mm as per
the drawing enclosed at every 15m intervals along the alignment and at
every tangent points of the curve and @ I.P points etc. The Centre Line
Stones, I.P. Stones and stones at tangent points should be painted with
different colours for each, for clear identification fixing of F.R.L. stone
and MWL at every 150 m interval with different colours.
4. Painting of the stones with good quality of paint approved by the
Engineer-in-Charge.
5. Preparation of Hydraulic Particulars may be taken up only after
approval of alignment by competent authority i.e., Chief Engineer,
Dhasan Ken Besin Sagar (M.P.).
4. Drilling of Bore-Holes/ Trail pits for Dam and its Components:
1. Boreholes shall be drilled at every interval along the centerline of
the Dam and its Components for excavations.
2. Classifying the soils and noting the classification of soils in T.P /
Bore Hole Register
3. Bore holes shall also be drilled 10m beyond the maximum scour
level, or up to hard strata which ever is less for all the dam
components and core-samples of distrurbed and un-disturbed soils
are to be tested in the laboratory, to find out the bearing capacity
of soils; and the samples are to be preserved for verification by the
Engineer-in-Charge. Minimum 3 Numbers of bores one at center
of crossing, the other two on u/s and D/s of crossing are to be
drilled for each structure. Extra Bores are to be drilled wherever
necessary, depending upon the magnitude of the structure Log
book of the bores drilled shall be maintained at site, during
progress of drilling, besides preserving the core samples in wooden
core boxes at site.
5. Preparation of Estimates:
1. Earth Work Excavation:
1. The estimate of PAWAI Irrigation Project Project including earthen dam, composite
dam (central spillway) non overflow portion, radial gate, instrumentation, lighting of
gallery and top of dam, 33 KV station, dewatering pump in gallery with river
diversion work and all other connecting work.
2. The estimates for excavation and formation of PAWAI Irrigation Project Dam are to
be prepared based on the approved Hydraulic particulars and based on classification
of soils as per bore hole/ Trail pits data.
3. Cross sectional area of Dam and its components are to be worked out as per cross
sections plotted at 5m intervals.
4. Quantities of different soils may be worked out separately based on the areas
computed by preparing earth work area statements.
5. Necessary leads and lifts are to be calculated for different types of soils.
6. Rate analysis may be worked out as per current U.S.R 2009.
7. Abstract estimate may be prepared for the earth work estimates.
8. Report accompanying the estimate as per investigation standards covering all the
necessary points shall be prepared, and all salient features shall be thoroughly
discussed in the report.
3. Final Report
4.1Final report is to be prepared for each village separately covering the
following points.
4.2 F.R.L. survey with land acquisition case of land and properties.
4.3 M.W.L. survey with land acquisition case of properties.
4.4 Maintenance and operation manual with all relevent record and drawing
including as per direction of engineer-in-charge. ,
4.5 CHECKING OF SURVEY WORK:
4.5.1 The checking of field survey work, Longitudinal Section of canals and F.C and
establishment of Bench Marks to an extent of about 25% of the total work will
be carried out concurrently or separately by the department during progress of
survey. Necessary equipment and labour for carrying out such checking by the
Department shall be provided by the contractor / Tenderer.
APPENDIX I
TOPOGRAPHICAL SURVEYS, EXTENT, SCALES, CONTOUR INTERVAL, ETC.

of surveys
(1) (2) (3) (4) (5) (6) (7)
1. River surveys (i) L-Section 1 :10,000 1:100 - Leveling at 50m or
less interval along
(a) Major Upstream-L- the fair weather deep
project Section upto channel. Following
MWL + 5m or items shall be
to a point upto indicated on the L-
which the back Section:
water effect is
likely to extend (i) Date of survey of
from the axis of the particular
the structure, reach and water
whichever is level on that day.
less in case of
any head works (ii) Deep pool and
situated rapids, rock out
upstream crops etc.
within MWL +
5m or far these (iii) Max. Historical /
points affected observed HFL
by back water,
L-Section to be
taken upto head
works.
Downstream - 1:10,000 1:100 - - do -
10 km. from the
axis of
structure or
upto nearest
head work
whichever is
less
(ii) Cross 1:2500 1:100 - Leveling at the 50m
section : or less interval.
Following items
Upstream -X- shall be shown on
section @200m the cross-section
interval upto
MWL + 5m or i. Date of
1km. on either survey and
side of the firm water level
of surveys
(1) (2) (3) (4) (5) (6) (7)
bank whichever on the day.
is less and for a ii. Maximum
distance of water level.
2Km. from the
axis of the iii. Maxi
structure and historical /
thereafter at 1 observed
Km. interval HFL
corresponding
to the length of iv. Rapids and
the L-section. rock out
crops etc.
2. Reservoir Contour plan 1:2500 - 1 to 2 or 3m Contour interval for
covering on stone less then 10 to
(a) Major area upto an horizontal - 1 m,
Project elevation of slope 10 to 30, 2m,
MWL + 5m and slope more than
30 - 3m.
3. Dam and Grid plan with 1:2500 - 1 or 2 or 3m Contour intervals as
Dyke : contours of the per i`tem 3(a) above
site covering block leveling to be
(a) Major the area upto on 10m grid basis.
project 250m upstream
and 500m m
downstream of
the axis
extending upto
an elevationof
MWL + 5m or
more depending
upon the site
conditions (tail
channel) are
shall be
adequately
covered).
4. Soil Plan of area 1:10000 - 10m or less This may be carried
Conservation subject to or 1: out for major and
Survey erosion, slides 50000 medium projects
and slips. depending upon the
location of the area.
5. Geological Reservoir and Same as recommended under -
Maps river valley each item above or otherwise as
structure (dams, stated in the Geological report.
Barrage,
of surveys
(1) (2) (3) (4) (5) (6) (7)
Tunnel, Power
House
Penstocks,
Water
Conductor
System and
important
structures on
Canal.
6. Foundation Plan : 1:2500 - As specified Showing location of
Investigation above for the structures, bore
Maps Major 1:2500 corresponding holes, trial pits, drifts
Medium, 1:1000 structure. and points where in-
situ tests were
Minor conducted etc.
Cross Section : 1:2500 1:100 - Showing logs of bore
holes, trial pits, drifts
Major 1:2500 1:100 etc. and other feature
Medium 1:1000 1:100 of the foundation.
Minor
7. Borrow area Plan : 1:2500 - 0.5 or 1m Showing location of
and Quarries different materials of
Major construction pit/ drill
holes.
Sections : 1:2500 1:100 - Showing profile
along the grid lines
Major upto the depth
explored.
8. Soil Surveys Plan : 1:10,000
or
Major 1:15,000
APPENDIX II
Structure Minimum pattern of drilling

Spacing of Drill Holes/Pits/Drifts Depth of Drill Holes/Pits/Drifts
(1) (2) (3)
(a) Earth & Drill holes along the axis 150 m or Depth equal to half the height of the
rock fill dam less apart, with intermediate pits to
embankment at the elevation of the
delineate weak and vulnerable hole or five meter in the fresh rock
strata with a minimum number of (proved by the geo-physical or any
three to five holes in the gorge other suitable method) whichever is
portion and additional to on each less. About two holes to be extended
abutment parallel to the flow deep (equal to the maximum height
Drifts on each abutment at about 60 of the embankment in the absence of
m elevation interval with a rock at higher elevation) in the gorge
minimum of one abutment. portion and one each in abutments.
Drifts to be extended 5 m in
geologically sound strata for keying
the embankment in the absence of
rock.
(b) Masonary Drill holes along the axis at 100 m 110 m in fresh rock (proved by geo-
& concrete interval or less apart to delineate physical or any other suitable
dam / structure weak and vulnerable strata with a method) About two holes to be
minimum number of 3 to 5 holes in extended deep (equal to the
the gorge portion and additional maximum height of the embankment
two on each abutment parallel to in the absence of rock at higher
the flow. elevation) in the gorge and one each
Drifts on each abutment at about abutments.
60m elevation interval with a 10m in fresh rock (proved by
minimum of one each abutment. geophysical or any other suitable
method).
Note:
1. A minimum pattern of drilling holes and excavation of pits and drifts

has been above. Addition holes shall be drilled and pits/drifts
excavated in consultation with the Geologist/Research laboratory to
bring out clearly the foundation and abutment characteristics especially
the weak zones requiring special treatment.
2. Disturbed and/or undisturbed soil samples, foundation of rock samples, etc shall be
collected and tested at an interval of 1.5 m depth or change of strata for
laboratory tests. In situ permeability tests shall be carried out in the selected drill
holes in the different strata at different elevations. Other in-situ tests shear tests
etc shall be carried out in the holes or other suitable locations depending up on
the nature of the strata and design requirements.
3. The bearing capacity test and in-situ testing of the foundation rock shall be carried
out for item (f) to (g) at average foundation level.
4. The plans and cross section shall be prepared on the scale as indicated in Appendix
I
5. the Logs of the holes/pits/drifts shall be prepared as per Appendix II(A) to II(B)
enclosed.
APPENDIX II (A)
LOG OF TEST PIT BORROW AND FOUNDATION
INVESTIGATIONS
Feature Project . Test pit No. ..
Area designation . Co-ordinates . Ground Elevation .. Depth to ground water level ..
Method of excavation Approximate dimensions of hole Dates of excavation Hole
logged by.
Classific Dept Size Classifica Volum Weigh Percent Weigh Percent Weigh Percent Locati
ation h and tion and e of t of 0 age by t of 75 age by t of age by on of
Symbol (M) type Descripti Hole to volume to volume Plus volume in situ
Letter of on of Sampl 75mm of 0 to 125m of 75 to 125m of plus tests
Graphics Samp Material ed (M) Materi 125mm m 125mm m 125mm
le (give al in material Materi material Materi material
Taken Geologic Sampl al in . al in
al and in e sampl sampl
place e e
descriptio (K.G.)
n for
Foundatio
n
Investigat
ion)
Remarks
Record after water has reached its natural level.

This may be done as given in IS: 1498-1970 Classification and identification of soil for
general Engineering purposes (First revision)
(Weight of rock sampled X 100)/(Bulk specified gravity of rock) x (volume of hole sampled).
Record water test and density test data, if applicable, and also bulk specific gravity stating
how obtained (measured or estimated) under remarks.
APPENDIX II(B)
DAILY DRILL REPORT
Project Location Feature
Drill No. and type Pump No.
Collar elevation : Capacity and pressure used :
Ground elevation: Hole No. :
Date : Co-ordinates:
Shift: From . H to . H: Bearing of hole:
Depth of Water level Angle with vertical:
Depth drilled during the shift:
From to ..
At start of shift :
At end of shift :
Run Length Type Colour Type Water Core recovery Rate of Remark
Drilled and of of Loss penetration s
mm size Return soil/ with mat/min
of water Rock Depth
hole
From To Length Percentage Sl.
No. of
M M Cores
1 2 3 4 5 6 7 8 9 10 11 12
Supplies Casing Lowered Bits Used

Petrol Diesel Motor Misc. Size From To Type and From To Old or new
Oil Depth depth Size Depth depth with number
Drill Foreman/Supervisor Operator

Officer-in-Charge Drill Observer
DRILL OBSERVERS REMARKS
(1) Water loss during drilling may either be recorded as :
i. Complete when no water is coming out : partial : or nil water loss : or
ii. In percentage of return water (100 percent loss when no water is coming back and no
water loss (0 percent) when all the drilling water is coming back).
2. Penetration speed to special zones (soft or broken zones) and other details of
drilling like heavy vibration recorded during drilling.
3. Reasons for heavy core loss as integrated with speed of drilling;
4. Any special conditions not recorded for examere depth at which blasting was
done while driving casing, depth at which note was ground antesian water
conditions (if any observed) during drilling.
5. If water flows are encountered at the collar of the drill, then the pressure head
and discharge at the collar should be recorded. On completion of the hole, the
pressure decline over a period of time should also be recorded.
APPENDIX III
INVESTIGATIONS FOR ESTABLISHING
SUITABILITY OF CONSTRUCTION MATERIALS
1. EARTH FOR DAM
Following investigations shall be carried out :
i. The plans and sections of the borrow area shall be made on a scale of 1:2500 with
contour interval of 0.5m, showing the location and logs of test pits, bore holes spaced
about 150m apart and demarcating different types of soil. The lead for different types
of soil from the site of work for different borrow areas shall also be indicated. The
borrow areas shall be located as near the dam site as possible but not less than five
times the head of water (H) away from the toe or heel of the dam for major dams and
not less than 10 H away from the toe or heel of the dam for medium and minor dams.
ii. Soil samples shall be tested for mechanical analysis, atterberg limits, Proctor
compaction, permeability, triaxial shear tests with pore pressure measurements under
O.M.C. and saturation conditions, and suitability tests in soils with high soluble
content.
iii. The sand and gravel to be used for filters shall be tested as for concrete aggregate.
iv. Units of earthwork sampling for suitability shall be taken as per the following table :
S.No. Particulars Major Project
1. Profile E/W Quantity Above 1400 thousand cubic metre
2. Borrow are E/W quantity Above 2100 thousand cubic metre
3. Units fo profile E/W sampling 20 thousand cubic metre
4. Units of borrow area quantity 30 thousand cubic metre
5. Sampling Number of samples Minimum 100 and maximum 200
samples.
APPENDIX IV
CONSTRUCTION MATERIALS
1. Concrete Structures
Following investigations shall be carried out

i. Geological and related characterization of aggregates including type of
deposits, classification and characteristics of rocks, chemical suitability of
aggregates and strength tests.
ii. Investigations for the availability of natural artificial pozzolana with their
characteristics
iii. The construction material shall be tested for petrographic analysis of sand and
rock samples, grading and physical tests of sand and rock samples to assess
their suitability, presence of reactive aggregates in the area, pozzolana
materials and strength of permeability test
2. Earthwork/Embankment
Following investigation shall be carried out

i. The plans and sections of the barrow area shall be made on scale of
1:2500 with contour interval of 0.5 m showing the location and logs of
test pits, bore holes spaced about 150 m apart and demarcating
different types of soil. The lead for different types of soils from the site
of work for the different borrow areas shall also be indicated. The
borrow areas shall be located as near the embankment as possible but
not less than five times the head of water (H) away from the toe of
major embankment and ten times the head of water (H) for medium
and low size of embankment.
ii. Soil samples shall be tested for mechanical analysis, Atterberg limits,
Procter compaction, permeability, triaxial shear tests with pore
pressures measurements under OMC and saturation conditions, and
suitability tests in soils with high soluble contents.
iii. The sand and gravel to be used for filters shall be tested as for concrete
aggregates.
iv. Units of earthwork sampling for suitability shall be taken as per the
following tables
S. Particulars Minor Project Medium Projects Major projects
No.
1. Profile E/W Quantity 140 thousand 140 thousand
Above 1400
cubic meter cubic meterthousand cubic
meter
2. Borrow area E/W Quantity 210 thousand 210 to 2100 Above 2100
cubic meter thousand cubic thousand cubic
meter meter
3. Units of profile E/W 5.5 thousand 14 thousand cubic 20 thousand
sampling cubic meter meter cubic meter
4. Units of borrow area 8.5 thousand 21 thousand cubic 30 thousand
quantity cubic meter meter cubic meter
5. Sampling Number of Minimum 10 Minimum 25 Minimum 100
samples samples samples and maximum
samples
APPENDIX -
LOCATION AND NUMBER OF M.M.
Standard / Permanent Ordinary or temporary

S.No. Particulars B.M. B.M.
Location & No. Location & No.
(1) Major Dam One on either bank i. Dam alignment excluding
along the alignment river portion @10 chains
&
located D/S at a distance
Medium Dam of five times the height of
the dam away from the
C/L of the dam.
ii. One on waste weir at a
distance of 2 chains from
the mid point of the C/L
of the alignment.
iii. Spill channel & approach
channel alignment one @
every 10 chains.
(2) Minor Dam One on one bank - Same as for Sl. No. 1 above -
VOLUME III
SECTION - 3
LAND ACQUISITION
THE LAND ACQUISITION CASES ARE TO BE PREPARED AND SUBMITTED IN
THE FORMATS PRESCRIBED BY THE AUTHORITY COMPETENT TO PASS THE
ENFORCED TIME TO TIME ARE TO BE STRICTLY FOLLOWED.
VOLUME III
SECTION - 4
EXCAVATION
CONTENTS

TENDER DOCUMENT 49
TURNKEY TENDER 49
50
SECTION 7: GATES 51
Volume - III 52
Section I 52
GENERAL 52
Volume III 53
Section - 2 53
Preparatory Work 53
INDEX 53
2 Survey 58
2.5 ACCURACY 60
4 Final Report 68
APPENDIX I 69
APPENDIX II 71
NOTE: 71
APPENDIX II (A) 73
APPENDIX II(B) 74
APPENDIX III 76
MATERIALS 76
APPENDIX IV 77

Technical Specification Pawai Irrigation Project

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ECHNICAL SPECIFICATION PAWAI IRRIGATION PROJECT

GOVERNMENT OF MADHYA PRADESH

WATER RESOURCES DEPARTMENT

PAWAI irrigation project

Execution of PAWAI Irrigation Project complete including construction of earth dam,

DHASAN KEN BESIN SAGAR

WATER RESOURCES DEPARTMENT

TENDER DOCUMENT CONTAINS FOLLOWING VOLUMES

2. Tender document for Turnkey contract : Volume II

3. Technical Specifications : Volume III

4. Drawings and Design Parameters : Volume IV

5. Quality Control Manual : Volume V

Description Page No.

Description Page No.

THE SPECIFICATIONS CONTAINED UNDER DIFFERENT SECTIONS IN THIS

2.4Survey Instruments and Personnel

2.4.1Total Station Instrument

It is an instrument for precise measurement of horizontal and vertical angles. These

These conforming to specifications of IS: 1779-1961 shall be used.

2.4.6Metric Surveying Chains

These shall conform to specifications of IS: 1492-1970

These conforming to specifications of IS: 2288-1963 shall be used.

2.4.8Vertical Staff Gauges

Surveying chain pins conforming to specifications of IS: 1842-1961 and powrahs

2.4.11Centre line stone

2.4.12M.S. Plate with Anchor Bolts for permanent B.M.

2.4.13Ordinary Bench Mark of Stone or R.C.C.

2.4.14Other Materials like pegs, paints etc.

2.6Reconnaissance and Study of Maps

2.6.1Before starting the reconnaissance it is necessary to thoroughly understand the

i. Previous history of the area,

2.7Guidelines for Survey investigation of Dam System

i. Topographical surveys including preparation of survey plans to cater to the

2.8For chain and compass survey, generally no jungle clearance is required to

2.10Chaining of Final Alignment

It shall be done with due precision after setting of curves.

2.11Marking on village maps

2.13DAG BAILING IN ALL TYPES OF SOIL

2.1 Exploration by Pits/Trenches/Drifts/Adits and Shafts

2. Exploration by Test Pits

3. Hand Auger Borings

1. To study in detail all the Engineering and design features.

4.5 CHECKING OF SURVEY WORK:

S.No. Description Area to be Scale Contour Remark

Structure Minimum pattern of drilling

1. A minimum pattern of drilling holes and excavation of pits and drifts

Record after water has reached its natural level.

Supplies Casing Lowered Bits Used

Drill Foreman/Supervisor Operator

Following investigations shall be carried out

Following investigation shall be carried out

Standard / Permanent Ordinary or temporary

GOVERNMENT OF MADHYA PRADESH 48

2.1 UNDER ALL WATER HEAD CONDITIONS, DIFFERENT TYPES OF

1.2 Construction and maintenance of diversions in case diversion of existing

5. Setting out Work

5.3 Except the mathematical and surveying instrument which shall be

6 ClearinG, GRUBBING AND PREPARATION OF

7. STRIPPING, BENCHING AND FURROWING AND

8. BENCHING UNDER EMBANKMENT

9. EXCAVATION OF CUTOFF OR PUDDLE TRENCH

10. RECORDING OF CROSS SECTIONS.

11. CLASSIFICATIONS OF EXCAVATED

Soft or Ordinary Soil