Government of the People’s Republic of Bangladesh

Ministry of Road Transport and Bridges

Roads and Highways Department

STANDARD TENDER DOCUMENTS

SECTION-7

GENERAL SPECIFICATIONS
(TECHNICAL SPECIFICATIONS)

January 2025
(2nd Draft)
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

DIVISION 1
GENERAL AND SITE FACILITIES

CONTENTS

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

DIVISION 1 – GENERAL AND SITE FACILITIES

1.1 Maintenance and Protection of Traffic ............................................................... 1

1.1.1 General
3
1.1.2 Access to Adjacent Property and Intersecting Roads .......................................... 4
1.1.3 Width of Carriageway for Detours and Diversions ............................................. 4
1.1.4 Assistance to Public ........................................................................................... 5
1.1.5 Night, Weekend and Holiday Traffic ................................................................. 5
1.1.6 Barriers
5
1.1.7 Plant and Equipment .......................................................................................... 6
1.1.8 Maintenance of Traffic Control Devices ............................................................ 6
1.1.9 Effective Traffic Control with Road Maintenance .............................................. 6
1.1.10 Specifications and Measurement for The Construction & Maintenance
of Detours and Diversion for Typical Situations and Maintenance of
Existing Road .................................................................................................... 7
1.1.10.a Detours Away from Existing Road Embankment and Diversions for
Cross Drainage Structures................................................................................... 7
1.1.10.b Diversions in the existing embankment when road construction is taken
up on the half width beyond proposed centreline. ............................................... 9
1.1.10.c Maintenance of existing road where works have not commenced or is
not required ......................................................................................... 10
1.1.10.d Maintenance of completed half width of road and shoulder opened to
traffic: ........................................................................................................ 11
1.1.10.e Maintenance of Traffic on exposed granular layer in carriageway under
construction: ..................................................................................................... 12
1.1.11 Dust and Mud or Extraneous Materials on Roads .............................................. 12
1.1.12 Measurement and Payment ............................................................................... 12
1.2 Field Office for The Engineer and Other Facilities to Be Provided by
The Contractor ................................................................................................. 13
1.2.1 Field Office for the Engineer and his Staff ........................................................ 13
1.2.2 Sanitation
14
1.2.3 Office Equipment and Consumables ................................................................. 14
1.2.4 Sign Boards
15
1.2.5 Survey Equipment
15
1.2.5.a Levels and Levelling Staffs ............................................................................... 16
1.2.5.b Theodolites ....................................................................................................... 16
1.2.5.c Electronic Distance Measurer (EDM) ................................................................ 16
1.2.6 Insurance of Engineer’s Field Office, Furniture and Equipment ........................ 17
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.2.7 Progress Photographs ........................................................................................ 17

1.2.8 Measurement and Payment ............................................................................... 17
1.3 Testing of Materials ......................................................................................... 18
1.3.1 Contractor’s Site Laboratory ............................................................................ 18
1.3.2 Materials Testing by Independent Laboratories ................................................ 19
1.3.3 Special and Additional Testing ........................................................................ 19
1.3.4 Staff for Materials Testing ............................................................................... 20
1.3.5 Sampling and Testing ...................................................................................... 20
1.3.6 Measurement and Payment .............................................................................. 21
1.4 Transport for The Engineer .............................................................................. 22
1.4.1 General
22
1.4.2 Items of Transport
22
1.4.3 Measurement and Payment .............................................................................. 22
1.5 Relocation of Public Utilities ........................................................................... 24
1.5.1 Description
24
1.5.2 Measurement and Payment .............................................................................. 24
1.6 Contractor’s General Obligations ..................................................................... 25
1.6.1 Site Establishment, Maintenance and Demobilization ...................................... 25
1.6.2 Provision of Performance Security................................................................... 25
1.6.3 Provision of Insurances .................................................................................... 25
1.6.4 As-Built Drawings
25
1.6.5 Measurement and Payment .............................................................................. 25

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.0 Introduction
All divisions of this specification shall apply to road, bridge and other supporting works
required to be executed under GoB and other contracts or otherwise as directed by the
Engineers. In every cases, the work shall be carried out to satisfy the Engineer and shall
confirm to the location as specified in the contract and dimensions, grades, cross sections
as specified in the approved drawings or otherwise directed by the Engineer. All the
ongoing and completed works under GoB contracts shall ensure the RHD Quality
Assurance Plan, 2005 or the updated approved version, whichever is available. The works
under foreign aided project shall conform to the quality assurance plan approved by
respective Engineer. In all GoB or foreign aided projects, the contractor shall prepare the
quality assurance plan as recommended above to submit to the Engineer prior to the
commencement of work to cover all stages of works such as setting out, selection or
approval of construction material, method, equipment or plant, quality assurance tests
(methods as described in RHD standard test procedures or this specification or as
approved by the Engineer).
1.1 Scope of the Works
The work to be conducted under the contract contains various items described in the
contract documents as well as in the Bill of Quantities of that documents.
1.1.1 Conformity with Drawings
All works completed and all materials furnished shall conform the lines, grades, typical
cross sections, layout, dimensions, material and other requirements along with
tolerances (if mentioned any) shown in the drawings. The drawings in the tender
documents shall be used as reference and contractor shall ensure that the price quoted by
him in the Bill of Quantities cover the complexity of the nature of the works during the
full process of construction. The drawing shall include the location drawings for each
contract with start and end point of the work under contract documents. In the absence
of topographical mapping and plan layouts, every contract must include the location and
extent of the major work items showing the start and end chainages (in bar chart form).
Where surface water drainage is required and is to be included in a works contract, a
longitudinal plan showing the gradients and outfalls shall be included within the contract
documents. This can be in diagrammatic form but must show the relevant information
required by the Contractor for the drainage to be constructed by him.

The contractor shall, based on proper surveys and site investigation, submit the working
drawings (hard and soft copy) to the Engineer of each activity prior to atleast 30 days
before the commencement of that activity. If any modification is proposed in the
working drawings, it shall be examined by the Engineer to make necessary approval
steps (if needed) as mentioned within the contract documents or Engineers authority as
stipulated in other approved documents of RHD. Examination or approval of these
drawings by Engineer shall not relieve the contractor of his liabilities under the contract.

1.1.2 Bills of Quantities

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

For every item of work within a contract where an estimate has to be made of the
quantities involved and supported by appropriate field measurements, calculations shall
be made that are checked and approved by the Engineer and filed in the document
control system. All BQ items must correspond to the relevant pay items in the RHD
Specification or the Particular Specification for the Contract.

1.1.3 General and Particular Specification

The approved general specification must form the basis of all RHD road contracts
supplemented where necessary by a Particular Specification for an individual contract.
Accordingly, it is essential that in the preparation of Tender Documents, latest and
current version of the Standard Tender Documents shall be used for the type of contract
to be undertaken. These Standard Tender Documents and the contract specific details
are to be checked and approved by the Engineer prior to the floating of tenders.

1.1.4. Site Information and Setting Out

The site information included in the Tender documents is given to the contractor in good
faith for guidance only, whereas the contractor shall be responsible to satisfy himself
regarding the site conditions before commencement of works. The contractor shall
establish working bench mark tied with Reference bench mark (as indicated in the tender
documents) after taking possession of the site. The no of working bench marks shall be
four per km and near all drainage structure, overpass or underpass and it shall be checked
and approved by the Engineer.

The lines, grading, level of formation, side slopes, drainage works, carriage way with right
off area shall be carefully set out with correct gradients and cross section whenever
necessary by the contractor and regularly checked for any adjustments.

1.1.3 Quality Assurance Plan

All GoB works will be covered by RHD Quality Assurance Plan whereas foreign funded
projects can have their own plan approved by concerned Engineer. The Quality Assurance
Plan will cover all the process starting from document preparation prior to construction
work and during the construction work process. The contractor shall conform to all actions
are taken in terms of planning, management and execution of the work in accordance with
that quality assurance plan during the construction period. The contractor will submit a
quality assurance plan to the Engineer covering all the aspects of setting out, selection of
material at source, plant and equipment with capacity as indicated in the tender
documents, staff personnel, document and data control, construction program,
arrangement for traffic maintenance during construction, construction methodology,
quality control tests, site laboratory and other facilities in accordance with RHD Quality
Assurance Plan, 2005, or as instructed and approved by the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.2 Maintenance and Protection of Traffic

1.2.1 General
From the date of Commencement of the works as provided in the contract, the Contractor shall
be responsible for maintaining an uninterrupted and safe passage for vehicles and pedestrians
along the project road, detours, diversions and temporary structures. During construction due
attention shall be paid by the Contractor to the maintenance and riding comfort of all such
roads, detours, diversions and temporary structures therein at all times during day or night. In
view of that, the contractor shall provide, erect, operate and maintain all necessary signs,
signals, lights, markings, barricades, diversions, detours and temporary structures with utmost
care and diligence.

This section of the specification includes provision for pedestrian and vehicular traffic on:

 Sections of existing road where work has not commenced or is not required;
 Sections of existing road where work is in progress;
 Detours required in accordance with the drawings or as ordered by the Engineer or as otherwise
required by the Contractor's work method.

The types of maintenance situations described below include:

(i) Construction and maintenance of detours away from existing road that are required because the
full width of the existing road is under construction or where works on cross drainage structures
requires the provision of a detour;

(ii) Construction and maintenance of diversions along an existing embankment where road
construction is underway at half width beyond the proposed centerline;

(iii) Maintenance of existing road where works have not commenced or is not required;

(iv) Maintenance of completed half width of the project road and shoulder opened to traffic;

The Contractor's responsibility shall include the necessary rectification of any deterioration or
damage to the road, intersections or driveways and drainage structures due to passage of traffic
or rains or flood. The specific location of any detour or diversion shall depend upon the
Contractor's method of working and the Contractor shall be deemed to have covered all the cost
of the same while quoting his price.

The Contractor shall so conduct his operations as to offer the least possible obstruction and
inconvenience to the traffic movement. He shall have under construction no greater length or
amount of work than he can properly handle at a time without affecting the free flow of traffic.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Unless stated otherwise in this specification, all traffic shall be permitted to pass through the
sections of the works which have been already completed and opened to traffic in accordance
with the contract.

Areas of existing public roadway, traffic diversions or detours shall not be obstructed or used in
any way by the Contractor for the dumping or stockpiling of materials or parking of
Contractor's equipment.

At least l5 days before commencing work on any section of the project works, the Contractor
shall submit to the Engineer proposals for the maintenance of traffic including the Working
Drawings for traffic control arrangements, road signs, and any temporary road works including
detailed typical cross sections of the proposed detours/diversions indicating clearly the type of
diversion, construction materials and thickness of the pavement structure and surfacing not
inferior to the specifications stated hereinafter and a program showing the time over which the
detour/diversion is required to be operational to provide a smooth and safe passage through the
construction area.

The Engineer may require changes to such proposals of temporary works prior to approving the
proposal and program. The standard of road surfacing required may depend on the duration that
the detour/diversion is required to be operational. Approval to the Contractor's proposal shall
not take away the Contractor's obligation to provide for an uninterrupted passage of vehicles
and pedestrians at all times. Where necessary the Contractor shall strengthen by the addition of
extra pavement layers or by additional compaction or any other means any detours or diversions
that may be found inadequate for traffic with no extra cost to the contract.

1.2.2 Access to Adjacent Property and Intersecting Roads

Construction operations shall be conducted in such a manner as to cause as less inconvenience
as possible to the abutting property owners. At all times and at no extra cost to the contract,
access to private entrances and buildings along the line of the work shall be maintained and
temporary approaches to any intersecting roadways shall be provided and kept in safe and
trafficable condition. Existing approaches from intersecting roads or private entrances, which
may temporarily be damaged or rendered ineffective by the works, shall be repaired or
reconstructed as the case may be and maintained according to the approval of the Engineer until
the permanent access required in the works is completed.

1.2.3 Width of Carriageway for Detours and Diversions

Where construction or maintenance operations interfere with the traffic, the Contractor shall
keep open not less than a 6.0 m wide (two-way) carriageway unless otherwise specified or
approved by the Engineer. Where-ever practicable, the Contractor shall widen the existing road
embankment so that the required carriageway width of 6.0 m can be provided while
construction works on the other half of the road embankment is progressing.

Where it is not practicable to provide for 6.0 m width as described above, for example, the
approach to an existing culvert where work has been taken up over half of its width, not less
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

than 3.0-meter clear carriageway width shall be made available for one-way traffic. The length
over which the road may be closed for half width and one-way traffic provided shall not exceed
400 meter and the passage of traffic shall be controlled in one way operation by the Contractor
either manually or by using automatic signals, which shall be supported at all time by man in
case of failures.

1.2.4 Assistance to Public

No diversion shall be opened to traffic without ensuring a prompt availability at all time of men
and equipment to remove any stranded vehicle from the diversion/detour sections.

The Contractor at all times shall be prepared to render immediate assistance to pedestrians or to
the drivers or passengers of any vehicles who may be delayed, obstructed or stranded while on
the sections of the works under his control.

1.2.5 Night, Weekend and Holiday Traffic

At night and during weekends and public holidays, where construction or maintenance
operations interfere with traffic, provision shall be made for vehicles and pedestrians to have an
un-restricted and safe use of a 6.0m wide carriageway. Should an emergency occur so that a
6.0m wide carriageway is not available, the contractor must employ all safety measures possible
as directed by the Engineer. The cost of such emergency measures will not result in extra
payment, and are deemed to have been included in the contractor’s quoted price.

1.2.6 Barriers
The Contractor shall provide and erect all lights, signs, equipment and barriers required to
ensure complete control of traffic, the safety of public and workmen employed in the works.
Barriers shall be used for closing of lanes or roads, the protection of workmen and regulation of
vehicular traffic. The main requirements are:

a) Barriers shall be constructed of steel tubes and concrete or of other material (New Jersey
Barriers either of concrete or plastic one filled with water or sand can be used) subject to
approval of the Engineer. The barriers shall be conforming to the design, dimensions and color
of the barrier shown in the approved Working Drawings submitted by the Contractor or such
other design as may be approved by the Engineer.

b) Trestles supporting barriers shall be neatly and stoutly constructed of sawn timber, concrete or
other material subject to the approval of the Engineer. Trestles shall serve as firm supports for
the barriers but the bases shall not protrude beyond the ends of the boards.

c) Provision shall be made for the attachment of warning lamps to the trestles or barriers where the
barrier is to be left in position overnight.

d) Where part-width of the road is to be closed to traffic and the closed strip is not required for
actual working, additional barriers shall be erected across the closed portion of the road. The
Contractor shall take positive measures, including the use of centerline lane barriers and
manned gate barriers, to prevent traffic from forming double line queues at stop signs.
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

e) Where work is actually in progress on part of the road, a line of barriers shall be erected
between the work area and that portion of the carriageway which is available for traffic.

f) Advance warnings shall be erected and barricades shall be provided at the entry/departure point
of the detour in such a way as to completely obstruct and prevent traffic from entering
incomplete sections of the works or bridges/culverts under dismantling and reconstruction.
Barriers or barricades shall be constructed as required for the situation to the satisfaction of the
Engineer.

1.2.7 Plant and Equipment

During the day, if working in a position adjacent to traffic, plant items having projections
beyond the normal width of the item (e.g. a grader blade) shall have a red cotton flag attached
to the outer end of the projection for traffic safety.

At night where traffic is permitted to use the whole or portion of the existing road, all plant
items and similar obstructions shall be removed from the normal path of vehicles to provide a
lateral clearance of at least 3 m if practicable and with an absolute minimum of 1.5 m.

Plant and equipment, within 150 mm of the edge of the pavement or detour or side-track, shall
be lit at night by not less than two amber lamps suspended vertically from the point of the
obstruction nearest to a traffic lane and one amber lamp at each end of the obstruction on the
side furthest away from the traffic lane.

1.2.8 Maintenance of Traffic Control Devices

All Traffic control devices shall be maintained in good working condition and in the correct
position at day and night. They shall be neat and clean; all traffic signs shall be clear and legible
at all time. Sidetracks shall be maintained in good order at all time. Except otherwise permitted
by the Engineer, all traffic-controlled sections of the road shall be manned at all time. Outside
normal working hours, the Contractor shall maintain a duty officer and a labor gang with
transport on call at all time to take care of urgent repairs or alterations to traffic control systems
and/or equipment whenever required. He shall keep the Engineer's Representative and the
nearby Police Station informed of the Duty Officer so that they could communicate in case of
any emergency.

1.2.9 Effective Traffic Control with Road Maintenance

The maintenance of the existing road, detours or diversion with effective control of traffic shall
be considered a prime responsibility of the Contractor. If in the opinion of the Engineer, a
situation has arisen where lack of maintenance is creating hindrance to free flow of traffic or
causing distress to travelling public, the Engineer shall be free to engage, after giving 3 day’s
written notice to the Contractor, any agency or agencies to undertake the work causing such
hindrances.

All costs associated with taking such action will be recovered from the amount that is or that
may become due to the Contractor. It shall be explicitly understood that recoverable amounts
may not be limited to the rates quoted by the Contractor or any pay item against such
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 SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

maintenance works. The decision of the Engineer regarding the amount to be deducted from the
Contractor shall be final and binding upon the Contractor.

The Contractor shall provide only such labor on traffic control as have been properly trained or
have previous experience. They shall be persons of proven comprehension and competence in
the courteous and efficient control of the vehicular traffic.

Persons controlling traffic shall wear distinctive brightly colored (yellow, orange or similar)
uniforms and shall be provided with waterproof clothing in easily visible colors and weather
shelters when required.

1.2.10 Specifications and Measurement for Construction & Maintenance of Detours and
Diversion for Typical Situations and Maintenance of Existing Road

1.2.10.a Detours Away from Existing Road Embankment and Diversions for Cross-Drainage
Structures.
(i) Specification
A detour shall be constructed away from the existing road where the full width of the road is
under construction or where cross drainage structural works requires its provision. The
provisions under this clause shall also apply for diversions constructed for structures under re-
construction or rehabilitation works. No detours and/or diversion will be approved in cases
where the new carriageway is to be constructed on a different alignment to the existing
carriageway.

Detour shall be so constructed that its pavement surface always remains at least 0.5m above
the expected water level during its whole service period. The surface shall be shaped,
adequately compacted, leveled, and graded to provide a trafficable pavement to the
satisfaction of the Engineer and shall contain temporary cross drainage pipes/culverts,
wherever is required, to ensure uninterrupted passage to traffic during the execution of the
works. Connection to existing roads and tracks shall be graded to provide smooth junctions.
The pavement shall be properly maintained in a smooth, hard and serviceable condition at all
times. The detour construction shall be of a minimum carriageway width of 6.0 m plus l.0 m
earth shoulder on each side.

The pavement structure for the detours shall be provided in view of the length of time and
season of the year it is proposed to carry the traffic load and subject to the approval of the
Engineer. When a detour is required to be operational for more than 3 months, the following
specification shall be considered.

(a) a well compacted soil sub-grade covered with a minimum 300 mm thick improved sub-
grade of soil sand mix compacted to 95% MDD (AASHTO: T-180) overlaid with 200
mm Sub Base, 100 mm Type 1 Aggregate Base and 50 mm Bituminous Base Course, to
be decided by the Engineer depending on site condition.

If the diversion required to serve the traffic for period of 3 month, Herring Bone Bond
(HBB) over Brick Flat Soling (BFS) constructed with approved picked Jhama bricks or
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

equivalent materials with their joints filled with approved sand.

All costs shall have been included in the pay items for construction of diversions/detours.
No traffic will be released over a diversion until inspected and approved by the
Engineer's Representative. The Contractor shall maintain the detour so constructed to the
satisfaction of the Engineer. Any potholes or undulations may appear in
detour/diversions constructed with granular layer shall be repaired with granular
materials and bituminous treatment as necessary.

The detours and diversions for drainage structures shall be maintained with utmost care
and diligence for the full-service period and any damage and defect shall be repaired
forthwith to the satisfaction of the Engineer.

Temporary bridge detours shall be constructed on permanent bridge construction site.

These temporary bridges will be capable of safely carrying all road traffic and may be of
one lane width. The contractor must submit design calculations and plans of all
temporary bridge proposals for the Engineer’s approval before the construction
commences. Also, the contractor must obtain the Engineers approval of the temporary
bridge constructed before traffic is allowed to use it. The same conditions shall apply for
road detours regarding attendance on traffic and maintenance of the temporary bridge.

The Contractor will be permitted to use any land within the right of way for the purpose
of constructing detours/diversion roads. However, where the land available is unsuitable
or insufficient in any way, the Contractor shall make all arrangements and pay all costs
incurred in obtaining the temporary use of any land outside the right of way. Such costs
shall be deemed to have been included in the rates for the pay items for all works for
detours including their removal after their period of service.

As soon as possible after the completion of any part or whole of the works and prior to
the issue of a Taking over Certificate as per Clause 48 of General Conditions of Contract
(GCC), all detours, diversions or passing places that have been constructed shall be
restored to their original conditions at no additional costs.

ii. Measurement
Construction and maintenance of detours away from an existing road embankment shall
be measured in km. The construction of diversions and detours for cross-drainage
structures shall be measured in meter when they have been constructed ready to accept
traffic and to the engineer’s satisfaction. No separate measurement will be made for
temporary culverts in diversions and detours as they shall be deemed to be included in
the measured km or meter amount. Temporary bridges constructed as part of detours on
bridge sites shall be measured in meter length as approved for construction by the
Engineer. The measurement for maintenance of diversions and detours including
temporary bridges of any cross-drainage structure described above shall be measured in
“m-month” when completed to the satisfaction of the Engineer and shall be considered
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

for payment up to the period the traffic is allowed. Such period shall not be considered
more than that allowed for the intended life of the diversion/detour as per the approved
work program.

1.2.10.b Diversions in the existing embankment when road construction is taken up on the half
width beyond proposed centreline.
(i) Specification

Except where the Contractor is authorized to construct a detour, the construction work
on an existing carriageway shall generally be taken up in part widths. Roadway
excavation and/or the earthwork in embankment fill required for the construction of the
diversion shall be taken up in such a manner so as to provide a reasonably smooth and
even profile for the satisfactory use of traffic.

The total width of carriageway for the diversion including the available part width of the
existing embankment or carriageway shall not be less than 6.0m with 0.5m shoulder at
the inner side and 1.0m wide earth shoulder on outer side. However, it shall be noted that
part width of the existing carriageway may or may not be available for the diversion
depending on the position of the proposed centerline. If additional embankment fill is
required specifically for the diversion (temporary works), the placement of temporary fill
and its removal, after its service period shall be deemed to have been included in the
related pay item for the diversion works. The cost of embankment construction that
forms part of the permanent Works shall be included under pay item for Earthworks as
applicable. The earthwork in embankment stated above may also be replaced with
earthwork in cutting depending upon the site conditions.

If it becomes impractical to provide the desired width, a narrower width may be

considered but only with the explicit prior approval of the Engineer.

The composition of the new pavement structure to be constructed alongside the existing
pavement, as part of total 6.0m wide carriageway for the diversion (temporary works)
shall be considered commensurate with the length of time and season of the year it is
proposed to carry the traffic subject to approval by the Engineer. For a diversion required
to serve the traffic for periods in excess of 3 months, the following specification for the
pavement shall be considered:

(a) a well compacted soil sub-grade covered with a minimum 300 mm thick improved sub-
grade of soil sand mix compacted to 95% MDD (AASHTO: T-180) overlaid with 200 mm
Sub Base, 100 mm Type 1 Aggregate Base and 50 mm Bituminous Base Course, to be
decided by the Engineer depending on site condition.
When part of diversion is constructed with granular layers, the finished surface shall be
primed with cutback bitumen and shall be provided with a premixed bituminous seal coat
to keep the road trafficable. The Seal Coat shall have 0.015 cum of pea-gravels blended
with 0.01 cum of sand (FM 0.8) with 80 kg of bitumen per cum of pea-gravels on 1.0 Sqm

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

road surface and rolled by 8/l0T Steel Roller. No traffic will be released over a diversion
until inspected and approved by the Engineer.

The Contractor shall maintain the diversion so constructed for its service period to the
satisfaction of the Engineer. Potholes and undulations in any part of the diversion
constructed with granular layer shall be repaired with granular materials and bituminous
treatment as necessary. If any width of the existing pavement forming a part of the
temporary diversion, it shall be maintained to the level and specification stated above.

The diversion shall be maintained with utmost care and diligence for its full-service period
and any damage and defect shall be repaired forthwith to the satisfaction of the Engineer.

(ii) Measurement

The measurement for construction of diversion & its maintenance for passing traffic
along a part of the existing carriageway during construction period shall be made in km-
month with no separate measurement to be made for culverts should they be required.

1.2.10.c Maintenance of existing road where works have not commenced or is not required
(i) Specification

Within the limits of the project road, the Contractor shall carry out routine maintenance
work on all sections of existing carriageway and shoulders that are being used by traffic
in a safe and trafficable condition. Potholes, broken edge, pavement defects and
washouts shall be promptly repaired to an acceptable condition all according to the
specifications stated hereinafter and to the satisfaction of the Engineer.

Material falling out on existing carriageway as a result of carting or clearing operations

and other obstructions to traffic including dead animals and crash debris shall be
removed immediately by the Contractor.

Unless otherwise approved by the Engineer, the Contractor shall not by his operations
obstruct any side road or branch track, or break down any fence or obstruct any drain or
water course, nevertheless if such blockages occur, he shall at once remove and repair
the blockages. Should the Contractor neglect to remove such obstructions or repair
damages, the Engineer may take action to have any necessary work carried out and the
cost thereof will be deducted from any amount that may be due or become due to the
Contractor.

The Contractor shall take full care that his construction equipment’s and vehicles do not
cause any damage to the bridge on the works or to the adjacent sections of roads.
Bridges required to carry loads in excess of their apparent capacity shall be propped or
be deck plated where punch through may occur. The Contractor shall be responsible for
the replacement or repair, at his own cost, of any damage to the bridge by his equipment
or activities, and will have no claim on the Employer for any time loss or disruption of

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

work due to collapse of any bridge. In the event of a bridge failure as mentioned, which
severs traffic passage in the contract area, the Contractor will provide a temporary by-
pass without delay and in no case in not more than 24 hours’ time following the breach
of such passage.

The road shall be maintained with utmost care and diligence for its full-service period
and any damage and defect shall be repaired forthwith to the satisfaction of the
Engineer.

(ii) Measurement

The measurement for the maintenance for passing traffic along an existing road where
works has not commenced or where no work is required shall be measured on a monthly
basis provided the Engineer is satisfied that the Contractor has met his obligation under
this clause.

1.2.10.d Maintenance of completed half width of road and shoulder opened to traffic:
(i) Specification

The half-constructed part of the pavement along with the hard shoulder and the
additional diversion part as per the approved Working Drawings shall be considered
together to provide a minimum carriageway width of 6.0m for the temporary passage of
traffic.

The hard shoulder part including additional width shall be scarified and recompacted
adding new materials as necessary to the satisfaction of the Engineer. The hard shoulder
and the diversion shoulder part shall be duly repaired, compacted and mended for any
loss of thickness and potholes, if any, to prepare them to be used by the traffic. After the
other half of the roadway has been constructed, the full width of road will be opened to
traffic.

Any damage to the constructed bituminous pavement in part widths that is opened to
traffic shall be made good to the satisfaction of the Engineer and the cost for such
repairs shall be deemed to have been covered under the Contractor's defects liability of
completed works and making good for any such damage shall reflect no additional cost
to the contract.

Payment for construction of hard shoulder and additional diversion width with sub-base
materials as shown in the typical cross-section in the Contract Drawing or as directed by
the Engineer shall be made under relevant payment clauses and payment for repair and
maintenance work for the period the shoulder being used by the traffic as per the
approved time cycle shall be covered under general obligation of the Contractor.

(ii) Measurement

11
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

No separate measurement will be made for this item. All costs for discharging the
obligations under provision for maintenance and provisions for traffic shall be deemed
to have been included in the rates for the permanent works items associated with this
activity.

1.2.10.e Maintenance of Traffic on exposed granular layer in carriageway under

construction:

No traffic shall be allowed on exposed granular layers in carriageway under construction.

1.2.11 Dust and Mud or Extraneous Materials on Roads

(i) Specification

The Contractor shall take all reasonable measures to minimize dust nuisance during
construction of the works. All existing roads being used by the Contractor’s or Sub-
Contractor’s or Supplier’s vehicle, plant and equipment and similarly the new roads
which are part of the permanent works being used by the traffic, shall be kept clean and
clear of all dust/mud/debris dropped from the vehicles/plant/equipment. Likewise, all
dust/mud/extraneous materials from the works spreading on the road surface shall be
cleared immediately by the Contractor.

The materials shall be removed immediately by manual sweeping, if so, directed by the
Engineer, or by mechanical sweeping and clearing equipment and all dust, mud and
debris shall be completely removed from the road surface. The road surface and
diversion being used by traffic shall be watered daily during dry season to prevent dust
nuisance and the Contractor shall keep provision for water tanker (bowsers) of at least
one tanker for each 10 km project length or part thereof wholly devoted to this purpose.

(ii) Measurement

All these activities shall be deemed to be the General Obligations of the Contractor and
deemed to have included in his rates and no separate payment shall be made.

1.2.12 Measurement and Payment

The work shall be paid at the contract unit rate for the item listed below & shown in the
BOQ. Payment shall be for full compensation for performing work for construction of
diversion and its maintenance works including all labor, carriage, material, tools,
equipment, cutting pavement all complete as necessary for the work, taxes, profit and
overhead.

Pay Items shall be:

BOQ ITEM DESCRIPTION UNIT

12
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1/2/1 Detours 6m wide carriageway. The construction and Lane/Km

maintenance and removal of approved detour/diversion, away
from the existing road embankment, on original ground with
temporary pavement on earthwork and cross drainage, except in
diversions for construction of structures.

1/2/2 The construction and removal of diversion/detours at culverts mm

and bridge sites subject to the Engineer's prior approval
Temporary road diversion 6m wide carriageway
Temporary bridges minimum 3m wide

1/2/3 Construction and maintenance of the diversion road for passing Km-month
traffic along a part of existing carriageway during construction
period including dressing and leveling existing road flanks,
providing temporary signboard, barrier etc. all as per direction
of Engineer.

1/2/4 Maintenance of existing road where Works have not

Month
commenced or is not required

1/2/5 Maintenance of diversion both pavement and temporary bridges

M-month
constructed as per Clause 1.5.10.1 so as to maintain traffic for
the period of construction of both culverts and bridges.

1.3 Field Office for The Engineer and Other Facilities to Be Provided by The
Contractor

1.3.1 Field Office for the Engineer and his Staff

In addition to the office space required for his own use, the Contractor shall provide and
maintain a furnished field office for the use of the Engineer and his staff. Requirements
for the office construction, including overall size, number and size of individual rooms,
and furniture are stated in Particular Specifications Clause 1.2.1 in Section 7 of Volume
1-The Tender.

The field office shall be maintained in a secure and watertight condition by the
Contractor until the completion of the works or as otherwise instructed by the Engineer
and shall be provided with electricity, potable running water and sewerage connections.
All doors shall be fitted with approved locks, and windows shall be provided with
mosquito screens and blinds and shall have interior locking-devices.

13
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Before construction, the Contractor shall submit for the approval of the Engineer, plans
and drawings showing proposed details and location for the field office, including
foundations, access roads, shades, layout of electrical and water supplies and hard
standings thereto. The Engineer may require revision of the plans prior to giving
approval for construction. The Contractor shall also submit details of proposed furniture
and fittings to the Engineer for approval.

The office, complete with furnishings, fittings, access roads and hard standings shall be
ready for occupation by the Engineer within four weeks of the date when the Contractor
first takes over the site.

The Contractor will provide all necessary MLSS (Members of Lower Service Staff) for
the field office, including day and night Security Guards and a Tea Boy. The Contractor
will also provide a competent Computer Operator for office work. Staff considered
unsuitable by the Engineer shall be replaced straight away.

The Contractor shall arrange for the field office to be properly cleaned regularly and for
access roads and hard standings to be maintained in a well-drained and trafficable
condition. All furnishings and fittings in the field office shall also be maintained by the
Contractor in good working condition and to the satisfaction of the Engineer.

All materials recovered from dismantling the office and removing access roads, hard
standings etc. should be stockpiled on site as directed by the Engineer and all furniture
and fittings will be the property of the Employer.

Wherever suitable buildings are available within the general limits of the site of the
works, the Contractor may also propose to the Engineer that the buildings be rented.
The buildings must conform to all the criteria above and if deemed to be satisfactory,
the Engineer may accept that to be used as his office.

1.3.2 Sanitation
The Contractor shall provide adequate water-borne sanitation; refuse collection and
disposal arrangements complying with the existing laws of Bangladesh and local by-
laws to the satisfaction of the Engineer for all office, laboratory, workshop, rest house,
etc. erected on the Site.

1.3.3 Office Equipment and Consumables

The Contractor shall provide and maintain essential office equipment such as Photocopy
Machines, Computers, Printers, Internet Devices, etc. for the Engineer’s Office as listed
in Particular Specifications, Clause 1.2.3 in Section 7 of Volume 1-The Tender.
Equipment supplied will be subject to the approval of the Engineer. The Contractor
shall supply all consumables related to the equipment and arrange for their proper

14
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

maintenance including servicing as recommended by their manufacturers. Upon

completion of the Works or as otherwise instructed by the Engineer, all equipment shall
be the property of the Contractor.
The Contractor shall also provide and maintain in good working condition, as
applicable, all items of kitchen equipment listed in Particular Specifications Clause
1.2.3 in Section 7 of Volume 1-TheTender.

The Contractor shall provide all standard stationery items to the Engineer’s field office
along with kitchen and bathroom consumables as may be required by the Engineer
throughout the duration of the contract.

1.3.4 Sign Boards

The Contractor shall provide identification sign boards of the number and size stated in
Particular Specifications, Clause 1.3.4 in Section 7 of Volume 1, The Tender and
maintain them in good condition. All information on the signboards will be written in
English and Bangla. The signboards will be positioned as directed by the Engineer. The
Contractor shall submit proposals for the materials of the signboards, the text layout and
installation of the signboards to the Engineer for approval. Each sign shall-clearly show:

 Name of the Project;

 Name of the Employer;
 All other details as required by the Engineer.

The Contractor shall remove the sign boards on completion of the works or as instructed
by the-Engineer.

1.3.5 Survey Equipment

The Contractor will be required to provide Survey Equipment for the use of the
Contractor’s and Engineer’s staff. The Specification of the main items required is given
in Sections 1.3.5.1 to 1.3.5.3. The numbers of each item to be provided are stated in
Particular Specifications, Clause 1.3.5 in Section 7 of Volume 1-The Tender. The
Contractor shall provide manufacturer’s published specifications of the proposed survey
equipment for the approval of the Engineer and shall ensure that equipment supplied to
the Site is maintained in good working order.

In addition to the survey equipment specified in Sections 1.3.5.1 to 1.3.5.3, the

Contractor shall supply miscellaneous tools and minor items of survey equipment such
as 30 m and 3 m long steel tapes, ranging rods, spirit levels, plumb bobs, umbrellas,
hammers, knives, wooden stakes, steel pins, string lines, paint, marking crayons, etc. to
be used at Site. These shall be available in reasonable quantities at all times for use.

15
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Ranging rods shall be 1.8 m long with alternate red and white painting. They shall be
true and straight with a steel pointed tip on one end.

The Contractor shall supply the required number of manpower to the Engineer to assist
with the survey and setting out works as and when required.

On completion of the Works or as otherwise instructed by the Engineer, all survey

equipment shall be the property of the Contractor.

1.3.5.a Levels and Levelling Staffs

Levels shall be auto set in carrying cases, complete with centering tripods with
extension legs, and to the following minimum specifications:

Magnification 32 times Stadia 1:100

Aperture 40mm minimum Resolving power 3˝ (sec)
o
Angular field of view1 20' Range of sensitivity ±15 minutes or less
Short Focusing Distance 1m Horizontal circle diameter 75 mm
Addition constant 0 Graduation 10 minutes
Accuracy ±1mm for 1 km double run
Staffs shall be telescopic, aluminum with graduations in Metric units.

1.3.5.b Theodolites
Theodolites shall be double circle Triangulation Theodolites with optical Micrometers.
The instruments shall be in airtight metal/wooden carrying cases with tool
compartments and eyepiece filters complete with centering tripods and extension legs,
to the following minimum specifications. One or more Theodolites suitable for the
attachment of an EDM may be required.

Objective aperture 45 mm Addition constant 0

Shortest focusing distance 1.7 m Sensitivity of collimation level 20"/2 mm
Multiplication constant 100 Graduations 360º

1.3.5.c Electronic Distance Measurer (EDM)

EDM’s shall be supplied with full accessories including legs, reflectors and stands,
rechargeable batteries and charger and shall be to the following minimum specification.

Distance measurement: Range not less than 1500m

Accuracy + (5 mm = 5 pmm) mse
Telescope: Image/Mag:m Erect 30 X
Min focus 1.5 m
Angle Measurement: Method: Electronic or Optical
Direct Reading to 5"

16
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Automatic Vertical Index: Range + 5'

Setting Accuracy + 0.25"
Weight including case: Less than 15kg

1.3.6 Insurance of Engineer’s Field Office, Furniture and Equipment

The Contractor shall insure the Engineer’s field office, furniture, office equipment and
survey equipment against loss or damage by accident, fire or theft for the whole duration of
the Contract.

1.3.7 Progress Photographs

Each month on a date to be agreed with the Engineer, the Contractor shall arrange to take a
series of not less than 20 and not more than 40 color photographs and will keep record of the
progress of the Works.

Two complete sets of prints of approximate size 175 mm x 125 mm with soft copy shall be
supplied to the Engineer by the Contractor within one week of each series of photographs
being taken. A list shall accompany the photographs, indicating the date when the
photographs were taken and a short description of the photographs, against the soft copy
numbers.

The photographs shall be taken by an approved professional photographer, accompanied by

representatives of the Engineer and the Contractor. If, for any reason, the Engineer is not
satisfied with any of the photographs, the Contractor shall arrange at his cost for further
photographs to be taken.

1.3.8 Measurement and Payment

The supply of materials and construction of field office for the Engineer, including all
furniture and fittings, supply of consumables, access roads, car parking shades etc., and the
provision of water, electricity and sewerage facilities and the removal of the field office at
the end of the Contract, as described in Specifications Sections 1.2.1 and 1.2.2 and Particular
Specifications Clause 1.2.1 in Section 7 of Volume 1-The Tender, shall be paid for at a lump
sum price.

The maintenance, cleaning and security of the field office for the Engineer, the provision of
MLSS, Tea Boy, and provision of a computer operator and the cost of water, electricity and
sewerage shall be paid for at a monthly rate.

The provision of office equipment, consumables and insurance, as described in

Specifications Sections 1.2.3 and 1.2.6 and Particular Specifications Clause 1.2.3, shall be
paid for at a monthly rate.

Payment for the provision, maintenance and removal of sign boards, as described in
Specifications Section 1.2.4 and Particular Specifications Clause 1.2.4 in Section 7 of
17
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Volume 1-The Tender, shall be on a Lump Sum basis.

Payment for the provision, maintenance and insurance of survey equipment and the
provision of approval personnel, as described in Specifications Sections 1.2.5 and 1.2.6 and
Particular Specifications Clause 1.2.5 in Section 7 of Volume 1-The Tender, shall be at a
monthly rate.

Payment for the provision of progress photographs as described in Specifications

Section1.2.7 shall be at a monthly rate.

Pay items shall be:

1/3/1 Supply, Erect and Remove Field Office for the Engineer Lump Sum

1/3/2 Maintenance, Staffing, Security and Cleaning of the Field Month

Office for the Engineer
1/3/3 Provision of Office Equipment and Consumables Month
1/3/4 Provision, Maintenance and Removal of Sign Boards Lump Sum
1/3/5 Provision and Maintenance of Survey Equipment Month
1/3/6 Provision of Insurance for the Engineer’s Office, Furniture Month
and Equipment.
1/3/7 Progress Photographs Month

1.4 Testing of Materials

1.4.1 Contractor’s Site Laboratory

The Contractor shall provide and maintain a site laboratory for the use of the Contractor
and the Engineer including furniture, testing equipment and consumable stores necessary
to carry out the tests listed in Particular Specifications, Clause 1.3.1 in Section 7 of
Volume 1-The Tender.

The Laboratory shall be constructed with a reinforced concrete floor (minimum thickness
150mm) and brick walls. The building shall be watertight and provided with electricity,
potable running water and sewerage connections. The location of septic tank and soak-
away is to be approved by the Engineer. Doors shall be fitted with approved locks and
windows shall be provided with mosquito screens and blinds and shall have interior
18
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

locking-devices.

Before construction, the Contractor shall submit for the approval of the Engineer, plans
and drawings of the proposed laboratory indicating location, overall size, construction
details and layout of benches, washing facilities, furniture, testing equipment, sample
storage, etc. The Engineer may require revision of the plans prior to giving approval for
the construction. The Contractor shall also submit details of the proposed Testing
Equipment, furniture and fittings to the Engineer for approval.

It will be the contractor’s responsibility to ensure that all the laboratory equipment are
duly calibrated as per required frequency from an competent agency and the current
calibration charts are available in the laboratory for Engineer’s inspection at all times.

The Contractor shall maintain the laboratory, furniture, fittings and testing equipment for
the duration of the Contract and replace any part or item that is irreparably damaged or
lost. The Contractor shall pay all expenses in respect of water, electricity and other
consumables necessary for the running of the laboratory and shall arrange for the
laboratory to be properly cleaned regularly.

The Contractor shall not be permitted to commence on-site testing of permanent works
until the Site laboratory is complete in all respects unless temporary testing procedures
proposed by the Contractor have been approved by the Engineer.

At the end of the Contract, all materials recovered from dismantling the laboratory
together with all furniture, fittings and testing equipment shall be the property of the
Contractor.

1.4.2 Materials Testing by Independent Laboratories

In addition to the Site testing facilities described in Specifications Section 1.3.1 and
Particular Specifications Clause 1.3.1, in Section 7 of Volume 1-The Tender, the
Contractor shall be responsible for arranging for the field and off-Site laboratory tests
listed in Particular Specifications Clause 1.3.2, in Section 7 of Volume 1-The Tender, and
all other tests indicated as the responsibility of the Contractor in Sections of Divisions 2 to
6 of the Specifications. These should be performed by testing laboratories, for example
BRRL, BUET or other places as approved by the Engineer. The Contractor shall be
responsible for the attendance of the staff from these approved testing laboratories
including, if necessary, the provision of transport for personnel, equipment and test-
specimens.

1.4.3 Special and Additional Testing

19
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

In addition to the testing described in Specifications Sections 1.3.1 and 1.3.2, the Engineer
may require further testing to be carried out. Such special and additional testing shall be
arranged by the Contractor under the direction of the Engineer.

1.4.4 Staff for Materials Testing

The Contractor shall provide qualified laboratory/material engineers, technicians,
assistants, laborer, etc. to carry out sampling and testing of materials in accordance with
Specifications Sections 1.3.1, 1.3.2 and 1.3.3. Employing laboratory staff shall be subject
to the approval of the Engineer and shall be available to assist the Engineer with sampling
and testing as and when required.

1.4.5 Sampling and Testing

The frequency of test requirements for pavement layers, bitumen and concrete mixes
should comply with those in Table 1.4-1.

Table 1.4-1 Frequency of Tests

Max Dry
Washed Atterberg In-situ ACV, 10% Fine, LAA
Density/ CBR
Item Grading Limits Density
(STP 7.7.1, 7.7.2,
(STP 4.3/4.5,
(STP 3.3/7.2) (STP 3.2) (STP 6.2) AASHTO T96)
5.1)

Earthworks - 1/2000 m3 1/2000 m3 1/1000 m2 -

Improved -
1/1000 m3 1/1000 m3 1/1000 m3 3/1000 m2
Sub-Grade

Sub-Base 1/750 m3 1/750 m3 1/750 m3 3/1000 m2 1/2000 m3

Base 1/500 m3 1/500 m3 1/500 m3 3/1000 m2 1/1000 m3

For Bituminous and Concrete Mixes 1 set of tests per 100 cum of aggregate for shape
(STP 7.3), grading (STP 7.2), ACV, 10% Fines and Los Angeles Abrasion Value (STP
7.7.1, 7.7.2 and AASTO T96) should be carried out. If crushed gravel is used as coarse
aggregate, percentage of fractured faces shall be checked 1 test per 100cum.

Water absorption, Soundness and Coating & Stripping Test should be carried out 1 test for
each source/type of aggregate at the start of work and subsequently on every change in
quality of aggregate. Sand Equivalent Value for the fine aggregate for bituminous mixes
shall be determined for minimum 1 test /100 cum.

Grading of filler (STP 7.2) for bituminous mixes should be checked 1 test/20 tons of filler.
Water Sensitivity Test should be carried out on the bituminous mixes as per AASHTO-
T283 at the time of mix design and subsequently as and when required by the Engineer.

20
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Dynamic cone Penetrometer (DCP) and Plate Load Test to determine deformation
modulus Ev2 and Ev1(ASTM 1195/ASTM 1196 and DIN 18134) should be carried out in
addition to the density test for each layer of Embankment and Sub-grade 1 test /1000
Sqm. Testing for Ev2 and Ev1is mandatory; however, it’s important to note that the test
results will not be used as acceptance criteria but solely for record keeping purpose.

The Contractor shall maintain complete records of test results, which may be inspected by
the Engineer at any time. All test results shall be recorded on standard forms approved by
the Engineer and shall be signed by the Contractor’s engineer or technician in charge of
the laboratory. Completed forms shall clearly show the locations of samples, sampling
dates and testing dates. Samples shall be numbered serially at the time of sampling. A
copy of all test results should be submitted to the Engineer immediately after completion
of the test.

The Engineer will be informed prior to any sampling or testing carried out in the
laboratory and will have the right to use the facilities and equipment to make his own
tests. The Contractor shall have the right to witness any sampling or testing carried out by
the Engineer. On completion of the Contract, the original copies of all test results shall be
handed over to the Employer through the Engineer.

1.4.6 Measurement and Payment

The provision of the laboratory, furniture, equipment and services detailed in
Specifications Section 1.3.1 and Particular Specifications Clause 1.3.1, in Section 7 of
Volume 1-The Tender, and the removal of the laboratory, furniture and equipment at the
end of the Contract shall be paid for at a lump sum price. Maintenance of the site
laboratory, furniture and equipment shall be paid for at a monthly rate.

The sampling and testing carried out by the Contractor in accordance with Specifications
Sections 1.3.1, 1.3.2, 1.3.4 and 1.3.5 shall be deemed to have included in the pay items for
the respective work in Divisions 2 to 6 of the Specifications.

Payment for special or additional tests described in Specifications Section 1.3.3, shall be
under a provisional sum, unless the costs of such tests are to be borne by the Contractor in
accordance with Clause 35.4 of Volume 2, the Conditions of Contract.

Pay items shall be:

1/4/1 Provide and Remove Site Laboratory and Equipment Lump Sum

1/4/2 Maintain Site Laboratory Month

1/4/3 Special or Additional Tests Provisional Sum

21
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.5 Transport for The Engineer

1.5.1 General

The Contractor shall provide and maintain road and river transport for the exclusive use of
the Engineer, his representatives and representatives of the Employer.

1.5.2 Items of Transport

Road transport, which shall be used both on and off the Site, shall include saloon cars of
1200 cc capacity, double cabin pick-ups, and four-wheel drive vehicles with a minimum
of 6 seats and motor cycles of 125 cc capacities.

River transport shall be motor boats of minimum length 5 m suitable for carrying out
survey and inspection work and shall have a covered deck area to give protection from the
sun and rain. No one either from the Engineer or from the Contractor other than the
authorized boatman shall be allowed to operate the boats.

The Bill of Quantities indicates the requirements for road and river transport. When items
of transport are out of use for repairs, servicing etc., the equivalent substitutes shall be
provided by the contractor.

Items of transport and drivers/boatmen considered unsuitable by the Engineer shall be

replaced.

1.5.3 Measurement and Payment

The Contractor’s monthly rate for the provision and maintenance of vehicles and motor
cycles shall include fuel, servicing, maintenance, drivers’ wages, taxes, duties,
registration, insurance, etc., as applicable under the current law of the Government of
Bangladesh.

The Contractor’s monthly rate for the provision of motor boats shall include fuel,
servicing, maintenance, boatmen’s wages, taxes, duties, registration, insurance, etc. as
applicable under the current law of the Government of Bangladesh.

All boats shall be provided with life belts, life jackets and navigational and warning lights.
22
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

Pay items shall be:

1/5/1 Saloon Car 1500 cc Capacity Month

1/52 Pick-up (Double Cab) Month

1/5/3 Four Wheel Drive Vehicle minimum 6 seats Month

1/5/4 Motor Cycle 125 cc Month

1/5/5 Motor Boat minimum 5 meter length Month

23
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.6 Relocation of Public Utilities

1.6.1 Description

The Contractor shall be responsible for establishing the locations of all public utilities
within the Site of the Works and for their protection. Where the necessity for permanent
relocation of public utilities has been identified, details of which shall be outlined on the
Drawings.

Should the Contractor consider that the temporary relocation of public utilities is necessary
in order to carry out the Contract works without obstructions, he shall submit details of his
proposals to the Engineer.

Relocation works will normally be undertaken by the concerned authorities, with which
the Contractor will be expected to liaise. The Contractor shall indicate relocation works in
his Contract Program.

1.6.2 Measurement and Payment

The Contractor should include all costs associated with the location and protection of
public utilities and the temporary relocation of public utilities in his pricing.

Payment for the necessary permanent relocation of public utilities will be under a
provisional sum.

Pay items shall be:

1/6/1 Relocation of Public Utilities Provisional Sum

24
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

1.7 Contractor’s General Obligations

1.7.1 Site Establishment, Maintenance and Demobilization

The Contractor shall be liable for the provision, maintenance and removal at the end of the
Contract of all offices, stores, covered workshops, canteens, toilet facilities, etc., required
to execute the Works in accordance with the Contract Documents. In addition, the
Contractor shall be responsible for complying with his obligations for safety, security and
protection of the environment described in the Contract Documents including in Sub-
Clauses 17.1 and 18.1 of Volume 2-Conditions of Contract.

1.7.2 Provision of Performance Security

This item is for the provision by the Contractor of the Performance Security, the
requirements of which are stated in Clause 43 of Volume 2-Conditions of Contract.

1.7.3 Provision of Insurances

This item is for the provision of insurances as required in accordance with Clauses 11, 13
and 53 of Volume 2-Conditions of Contract. The minimum amount of third-party insurance
shall be as stated in the Particular Condition of Contract in Section 4 of Volume1-The
Tender. Failure to provide insurance will result in no interim payments.

1.7.4 As-Built Drawings

The Contractor shall furnish sets of as-built Drawings of the Works to the Engineer,
showing the permanent works as actually constructed, within one month of completion of
the Works. Included in the sets of as-built Drawings there will be revisions of Tender
Document and Drawings supplied to the Contractor, if any, during the Contract as well as
revisions of drawings supplied by the Contractor for the Contract. The As-built drawings
submitted by the Contractor will be subject to the approval of the Engineer. For specific
requirements for the As-built Drawings refer to Particular Specifications Clause 1.6.4 in
Section 8 of Volume 1-The Tender.

1.7.5 Measurement and Payment

Payment for these items shall be included by the contractor in his rates for the Works

25
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 1 – GENERAL AND SITE FACILITIES

unless otherwise provided for in Clause 25 of the Contract Data in Section 4 of Volume 1-
The Tender.

26
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

DIVISION 2
EARTHWORK

` 2.1
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

CONTENTS
DIVISION 2 – EARTHWORK
Page

2.1 CLEARING AND GRUBBING ................................................................................................................................ 1

2.1.1 DESCRIPTION ............................................................................................................................................................ 1
2.1.2 PRESERVATION OF PROPERTY ................................................................................................................................... 1
2.1.3 CONSTRUCTION METHODS........................................................................................................................................ 1
2.1.3.a Clearing ........................................................................................................................................................... 1
2.1.3.b Grubbing ........................................................................................................................................................ 1
2.1.3.c Ownership of Cleared Material ....................................................................................................................... 2
2.1.3.d Existing Drainage........................................................................................................................................... 2
2.1.4 MEASUREMENT ........................................................................................................................................................ 2
2.1.5 PAYMENT ................................................................................................................................................................. 2
2.2 ROADWAY EXCAVATION .................................................................................................................................... 4
2.2.1 DESCRIPTION ................................................................................................................................................................. 4
2.2.2 MATERIALS ........................................................................................................................................................... 4
2.2.3 CONSTRUCTION METHODS........................................................................................................................................ 5
2.2.3.a General .......................................................................................................................................................... 5
2.2.3.b Excavated Material Used in the Works ......................................................................................................... 5
2.2.3.c Unsuitable Material from Roadway Excavation ........................................................................................... 5
2.2.3.d Excess Suitable Excavated Material.............................................................................................................. 5
2.2.3.e Excavation of Unsuitable Soil ..................................................................................................................... 6
2.2.3.f Slopes .......................................................................................................................................................... 6
2.2.3.g Drainage...................................................................................................................................................... 6
2.2.3.h Preparation of Excavated Areas.................................................................................................................. 7
2.2.4 MEASUREMENT ..................................................................................................................................................... 7
2.2.5 PAYMENT ................................................................................................................................................................ 7
2.3 BORROW........................................................................................................................................................... 9
2.3.1 DESCRIPTION ........................................................................................................................................................... 9
2.3.2 ACQUISITION AND USE OF BORROW PITS ................................................................................................................. 9
2.3.2.a Borrow Pits within the Right-of-Way ............................................................................................................. 9
2.3.2.b Borrow Pits Outside the Right-of-Way ........................................................................................................... 9
2.3.3 CONSTRUCTION METHODS ....................................................................................................................................... 9
2.3.4 MEASUREMENT AND PAYMENT.............................................................................................................................. 10
2.4 CHANNEL EXCAVATION ................................................................................................................................... 11
2.4.1 DESCRIPTION ......................................................................................................................................................... 11
2.4.2 MATERIALS ............................................................................................................................................................ 11
2.4.3 CONSTRUCTION METHODS ..................................................................................................................................... 11
2.4.3.a Alignment and Levels ................................................................................................................................... 11
2.4.3.b Excavation .................................................................................................................................................... 11
2.4.3.c Filling of Obsolete Channels ........................................................................................................................ 11
2.4.3.d Unsuitable Excavated Material .................................................................................................................... 11
2.4.3.e Excess Suitable Excavated Material............................................................................................................. 12
2.4.4 MEASUREMENT ...................................................................................................................................................... 12
` 2.2
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.4.5 PAYMENT ............................................................................................................................................................... 12

2.5 EXCAVATION AND BACKFILL FOR STRUCTURES ................................................................................... 13
2.5.1 DESCRIPTION ......................................................................................................................................................... 13
2.5.2 MATERIALS ............................................................................................................................................................ 13
2.5.2.a Foundation Fill Material .............................................................................................................................. 13
2.5.2.b Backfill Material........................................................................................................................................... 13
2.5.3 CONSTRUCTION METHODS ..................................................................................................................................... 13
2.5.3.a Clearing ........................................................................................................................................................ 13
2.5.3.b Excavation .................................................................................................................................................... 13
2.5.3.c Disposal of Excavated Material ................................................................................................................... 15
2.5.3.d Cofferdams ................................................................................................................................................... 15
2.5.3.e Pumping and Bailing ..................................................................................................................................... 17
2.5.3.f Backfilling .................................................................................................................................................... 18
2.5.4 MEASUREMENT ...................................................................................................................................................... 18
2.5.5 PAYMENT ............................................................................................................................................................... 19
2.6 EMBANKMENT ..................................................................................................................................................... 21
2.6.1 DESCRIPTION ......................................................................................................................................................... 21
2.6.2 MATERIALS ............................................................................................................................................................ 21
2.6.3 CONSTRUCTION METHODS ..................................................................................................................................... 21
2.6.3.b Placing Embankment .................................................................................................................................... 22
2.6.3.c Compaction of Embankment......................................................................................................................... 23
2.6.4 MEASUREMENT ...................................................................................................................................................... 23
2.6.5 PAYMENT ............................................................................................................................................................... 24
2.6.6 CLADDING MATERIAL ........................................................................................................................................ 24
2.6.6.a Description .................................................................................................................................................... 24
2.6.6.b Measurement ................................................................................................................................................. 25
2.6.6.c Payment ......................................................................................................................................................... 25
2.7 PREPARATION OF SUBGRADE ........................................................................................................................ 26
2.7.1 DESCRIPTION ......................................................................................................................................................... 26
2.7.2 MATERIALS ............................................................................................................................................................ 26
2.7.3 CONSTRUCTION METHODS ..................................................................................................................................... 26
2.7.4 MEASUREMENT ...................................................................................................................................................... 27
2.7.5 PAYMENT ................................................................................................................................................................ 27
2.8 IMPROVED SUBGRADE ....................................................................................................................................... 28
2.8.1 DESCRIPTION ....................................................................................................................................................... 28
2.8.2 MATERIALS ............................................................................................................................................................. 28
2.8.3 CONSTRUCTION METHODS ..................................................................................................................................... 28
2.8.3.a Preparation of Subgrade .............................................................................................................................. 28
2.8.3.b Spreading ..................................................................................................................................................... 28
2.8.3.c Sprinkling, Rolling and Compacting ............................................................................................................ 29
2.8.4 MEASUREMENT ...................................................................................................................................................... 30
2.8.5 PAYMENT ............................................................................................................................................................... 30
2.9 REMOVAL OF EXISTING STRUCTURES........................................................................................................ 31
2.9.1 DESCRIPTION ......................................................................................................................................................... 31
2.9.2 MATERIALS OBTAINED FROM DISMANTLING ......................................................................................................... 31
2.9.3 BACKFILLING AFTER DISMANTLING OF STRUCTURES ............................................................................................ 32
` 2.3
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.9.4 MEASUREMENT ...................................................................................................................................................... 32

2.9.5 PAYMENT ............................................................................................................................................................... 32
2.10 CONSTRUCTION OF EARTHEN SHOULDERS .............................................................................................. 34
2.10.1 DESCRIPTION ..................................................................................................................................................... 34
2.10.2 MATERIALS ....................................................................................................................................................... 34
2.10.3 CONSTRUCTION METHODS ................................................................................................................................ 34
2.10.3.a Preparation ............................................................................................................................................... 34
2.10.3.b Placing ...................................................................................................................................................... 34
2.10.3.c Compaction of Shoulders .............................................................................................................................. 35
2.10.4 MEASUREMENT ................................................................................................................................................. 35
2.10.5 PAYMENT........................................................................................................................................................... 35
2.11 CONSTRUCTION OF HARD SHOULDERS ...................................................................................................... 36
2.11.1 DESCRIPTION ..................................................................................................................................................... 36
2.11.2 MATERIALS ....................................................................................................................................................... 36
2.11.3 CONSTRUCTION METHODS ................................................................................................................................ 36
2.11.3.b Spreading Hard Shoulder ......................................................................................................................... 36
2.11.3.c Sprinkling, Rolling and Compacting ............................................................................................................. 37
2.11.3.d Surface Tolerance ..................................................................................................................................... 37
2.11.4 MEASUREMENT ................................................................................................................................................. 37
2.11.5 PAYMENT........................................................................................................................................................... 38
2.12 SUBGRADE DRAINS ............................................................................................................................................. 39
2.12.1 DESCRIPTION ..................................................................................................................................................... 39
2.12.2 MATERIALS ....................................................................................................................................................... 39
2.12.3 CONSTRUCTION METHODS ................................................................................................................................ 39
2.12.4 MEASUREMENT ................................................................................................................................................. 40
2.12.5 PAYMENT........................................................................................................................................................... 40
2.13 GROUND IMPROVEMENT FOR WEAK EMBANKMENT FOUNDATION ........................................ 41
2.13.1 SCOPE ............................................................................................................................................................ 41
2.13.2 PREFABRICATED VERTICAL DRAIN (PVD) WITH SURCHARGE. ......................................................... 41
2.13.2.a Materials ..................................................................................................Error! Bookmark not defined.
2.13.2.b Construction and Installation Requirements ................................................Error! Bookmark not defined.
2.13.2.c Measurements for Payment: .............................................................................Error! Bookmark not defined.
2.13.2.d Rate: .............................................................................................................Error! Bookmark not defined.
2.14.1 GEOSYNTHETICS FOR ROAD AND BRIDGE WORKS ......................................................................... 57
2.14.1.a Application and General Requirements ................................................................................................ 57
2.14.1.b Testing, Certification and Acceptance ...................................................................................................... 59
2.14.1.c Marking ..................................................................................................................................................... 59
2.14.1.d Packing, Storage and Handling ............................................................................................................... 59
2.14.2 GEOTEXTILES FOR DRAINAGE, SEPARATION AND EROSION CONTROL .................................. 60
2.14.2.a Scope .......................................................................................................................................................... 60
2.14.2.b Material .................................................................................................................................................... 60
2.14.2.c Construction .................................................................................................................................................. 62
2.14.2.c.1 General........................................................................................................................................................... 62
2.14.2.c.3 Separation ................................................................................................................................................. 63
2.14.2.c.4 Filter Layer under Stone Pitching for Erosion Control ............................................................................ 63
2.14.2.d Measurement for Payment ........................................................................................................................ 64
2.14.2.e Rate ........................................................................................................................................................... 64
` 2.4
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.14.3 GEOGRID ......................................................................................................................................................... 64

2.14.3.a Scope ............................................................................................................................................................ 64
2.14.3.b Materials ....................................................................................................................................................... 64
2.14.3.b.1 General ......................................................................................................................................................... 64
2.14.3.b.2 Sub-base Reinforcement ................................................................................................................................. 64
2.14.3.b.3 Erosion Control ............................................................................................................................................. 65
2.14.3.b.4 Reinforced Soil Slopes and Walls ................................................................................................................ 65
2.14.3.c Installation and Construction Operations .................................................................................................... 65
2.14.3.c.1 Sub-base Reinforcement ............................................................................................................................... 65
2.14.3.c.2 Erosion Control ............................................................................................................................................ 66
2.14.3.c.3 Reinforced Slopes and Walls ........................................................................................................................ 66
2.14.3.d Measurement for Payment ........................................................................................................................... 66
2.14.3.e Rate ........................................................................................................................................................... 66
2.14.4 GEOCOMPOSITE DRAINS ....................................................................... ERROR! BOOKMARK NOT DEFINED.
2.14.4.a Scope ..............................................................................................................Error! Bookmark not defined.
2.14.4.b Materials ........................................................................................................Error! Bookmark not defined.
2.14.4.b.1 Prefabricated Vertical Drains (PVDs)/Band Drains .....................................Error! Bookmark not defined.
2.14.4.c Installation .......................................................................................................Error! Bookmark not defined.
2.14.4.c.1 Prefabricated Vertical Drains (PVD) ..........................................................Error! Bookmark not defined.
2.14.4.d Measurement for Payment ...........................................................................Error! Bookmark not defined.
2.14.4.e Rate ..................................................................................................................Error! Bookmark not defined.
2.14.5 GEOCELL FOR SLOPE PROTECTION .................................................. ERROR! BOOKMARK NOT DEFINED.
2.14.5.a Scope........................................................................................................Error! Bookmark not defined.
2.14.5.b Materials .....................................................................................................Error! Bookmark not defined.
2.14.5.c Strength and Other Requirements of Geocell ..............................................Error! Bookmark not defined.
2.14.5.d Installation and Construction Operations .................................................Error! Bookmark not defined.
2.14.5.e Measurement for Payment ...........................................................................Error! Bookmark not defined.
2.14.5.f Rate ..............................................................................................................Error! Bookmark not defined.
2.14.6 GEOSYNTHETIC MAT .................................................................................................................................. 72
2.14.6.a Scope ......................................................................................................................................................... 72
2.14.6.b Material and Strength Requirements ....................................................................................................... 72
2.14.6.c Installation ................................................................................................................................................ 72
2.14.6.d Measurement for Payment ....................................................................................................................... 73
2.14.6.e Rate ....................................................................................................................................................... 74
2.14.7 NATURAL GEOTEXTILE ..................................................................................................................... 74
2.14.7.a Scope ....................................................................................................................................................... 74
2.14.7.b Strength Requirements .......................................................................................................................... 74
2.14.7.c Installation ................................................................................................................................................... 75
2.14.7.d Measurement for Payment ........................................................................................................................... 75
2.14.7.e Rate ............................................................................................................................................................. 75
2.14.8 PAVING FABRICS/GLASS GRIDS ............................................................................................................... 75
2.14.8.a Scope ............................................................................................................................................................ 76
2.14.8.b Material Requirements .................................................................................................................................. 76
2.14.8.b.1 Paving Fabrics ............................................................................................................................................. 76
2.14.8.b.2 Glass Grids .................................................................................................................................................. 76
2.14.8.b.3 Asphalt Reinforcing Geogrids ....................................................................................................................... 77
2.14.8.c Installation ..................................................................................................................................................... 77
2.14.8.c.1 Weather Limitations ..................................................................................................................................... 77
2.14.8.c.2 Surface Preparation .................................................................................................................................. 77
2.14.8.c.3 Tack Coat ................................................................................................................................................. 78

` 2.5
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.14.8.d Paving Fabric Placement ......................................................................................................................... 78

2.14.8.d.1 Glass Grid Placement ............................................................................................................................... 79
2.14.8.d.2 Overlay Placement .................................................................................................................................... 79
2.14.8.e Measurement ............................................................................................................................................ 80
2.14.8.f Rate ........................................................................................................................................................... 80
2.15 MSE (MECHANICALLY STABILIZED EARTH) WALL FOR RAMP .......................................................... 80
2.15.1 DEFINITION OF MSE WALL ................................................................................................................................ 80
2.15.2 DESIGN .............................................................................................................................................................. 80
2.15.3 MATERIAL REQUIREMENTS ................................................................................................................................ 82
2.15.3.a Reinforced Earth Fill ................................................................................................................................. 82
2.15.3.b MSE Wall Concrete Facing Panels............................................................................................................... 83
2.15.3.c.1 Concrete Quality and Strength ....................................................................................................................... 83
2.15.3.c.2 Facing Finish and Tolerances ........................................................................................................................ 84
2.15.3.d Joint Fillers ..................................................................................................................................................... 84
2.15.3.e Cushion Pad .................................................................................................................................................... 84
2.15.3.f Measurement and Payment…………………………………………………………………………………………… 73

` 2.6
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.1 CLEARING AND GRUBBING

2.1.1 Description
This work shall consist of all clearing and grubbing necessary for the performance of the work
covered by the Contract in accordance with the Specifications.

The clearing and grubbing shall in more detail consist of clearing the designated areas of all
trees, down timber, vegetation, rubbish and any other objectionable materials and shall include
grubbing roots and stumps and disposing of all material resulting from the clearing and
grubbing. It shall also include the demolition, removal and disposal of structures that obtrude
the Works except where provided for in Section 2.9.

Clearing shall be confined to the areas enclosed by the right-of-way limits. Grubbing shall be
confined to areas covered by the Works.

2.1.2 Preservation of Property

Attention is directed to the Contractor’s obligations under the Contract with regard to damage,
particularly with regard to protection of property, gardens and landscape and to responsibility
for damage claims. Existing roads, improvements, facilities, adjacent property, utilities,
services and trees and plants designated for preservation shall be protected from injury or
damage which could result from the Contractor’s operations.

2.1.3 Construction Methods

2.1.3.a Clearing
Clearing shall consist of the removal and disposal of everything above ground level including
overhanging branches except those things the Engineer directs are to be left undisturbed. The
material to be cleared shall include but not necessarily be limited to trees, stumps, logs, brush,
undergrowth, grass, crops, loose vegetable matter and structures unless provided for elsewhere.
Trees and stumps shall be cut to ground level.

Clearing shall also include the removal of existing fences, remnants of buildings and courtyard
pavements etc.

The roadway and adjacent areas shall be left with a neat and finished appearance. No
accumulation of inflammable material shall remain on or adjacent to the right-of-way.

2.1.3.b Grubbing
The original ground surface shall be disturbed as little as possible. Grubbing shall, therefore, be
confined to major roots beneath the embankment, ditches, canal diversions and footing
excavations. In these areas grubbing shall consist of the removal of all major stumps,
embedded logs, tree roots and other material, except as otherwise directed by the Engineer.
1
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Holes left shall be filled with suitable material compacted to comply with Section 2.6 of the
Specification with the cost of this being included in the rate for grubbing. Topsoil shall be
removed as agreed with the Engineer and will be measured as roadway excavation. Grubbing
beneath the embankment shall be at the direction of the Engineer.

In agricultural areas where the ground has been formed into ridges or dikes, the ground shall be
roughly levelled or graded to form a surface suitable for embankment foundation to the
satisfaction of the Engineer.

2.1.3.c Ownership of Cleared Material

All cleared material shall, unless otherwise provided for in the Contract, be the property of the
Employer. Materials shall be stockpiled, or placed, by the contractor on site in a location
agreed by the Engineer.

2.1.3.d Existing Drainage

Existing ditches, drainage channels etc., shall be closed at the embankment foundation
boundary except where pipes or other structures are prescribed. Disused drains below
embankments shall be removed and trenches filled in accordance with Section 2.4.

The Contractor is responsible for undertaking any provisional drainage measures, including
temporary watercourses and ditches, which may be necessary.

2.1.4 Measurement
Neither the work of clearing nor grubbing disposal sites, material sites, nor imported borrow pit
sites shall be paid for when such sites are outside the areas designated for clearing or grubbing
and the Contractor is permitted to exercise his own option as to whether he elects to use such
disposal sites or borrow pit sites.

Removal and uprooting of tree having girth size less than 300 mm shall not be measured and
shall be included in measurement of clearing and grubbing. Removal and uprooting of trees of
girth sizes greater than 300 mm shall be measured.
2.1.5 Payment
Clearing and grubbing will be paid by area. The payment shall be full compensation for
furnishing all labour, materials, tools, equipment and incidentals necessary for the clearing and
grubbing the designated areas as specified in these Specifications or as directed by the Engineer
including the removal and disposal of all resulting material.

“Removal and uprooting of trees shall be paid in Number of different girth sizes mentioned in
Pay Items. The rate for removal and uprooting of trees shall include all cost of cutting,
dressing, uprooting, grubbing and carriage to stockyard designated by the Employer.”

2
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Pay items shall be:

2/1/1 Clearing and Grubbing Square Metre

2/1/2a Remove and uproot trees
(Trees with girth 300 mm to 800 mm) Number
2/1/2b Remove and uproot trees
(Trees with girth 801 mm to 1500 mm) Number
2/1/2c Remove and uproot trees
(Trees with girth beyond 1500 mm) Number

3
 SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.2 ROADWAY EXCAVATION

2.2.1 Description
The work shall consist of all the required excavation within the limits of the right of way unless
covered by other Sections of these Specifications. This shall include excavation of side ditches,
where required, the removal, hauling and proper utilisation or disposal of all excavated materials
and shaping of excavation and preparation of exposed surfaces of excavation on the entire length
of the roadway, in accordance with these Specifications and to the lines, levels, grades,
dimensions and cross sections shown on the Drawings or as required by the Engineer. The works
specified shall also include operations in part widths and small areas of roadway where directed
by the Engineer without any extra cost to the Employer.

Roadway excavation shall include the following:

a) All excavation indicated on the Drawings within the limits of the cross sections and
excavation of all materials for side roads and intersections.

b) The removal of existing pavement, sidewalks, kerbs and gutters within the limits of
construction.

c) Excavation for stream and channel changes where not covered under Section 2.4, Channel
Excavation.

d) Excavation required in cuts under embankments below the lowest normal limit of excavation
indicated on the Drawings or below ground line and for the removal of unsuitable material.

Where the layer below the existing pavement and/or shoulders are ordered to be scarified and
recompacted, this work shall be carried out and paid for in accordance with the provisions of
Section 3.1.3.

2.2.2 Materials
Materials from roadway excavations shall be classified as suitable or unsuitable as fill
material, or as road pavement material, by the Engineer. To be suitable as fill material, soil
must not contain roots, sods or other deleterious materials and must conform to the
requirements of Section 2.6.2.

Material excavated from existing road pavements which are to be reconstructed may be used
in the new road pavement provided the material after suitable breaking and mixing satisfies
all requirements of these Specifications.

The existing pavement materials which will include, but not be restricted to bituminous
surfacing, bricks and brick materials, stone, concrete and concrete materials, need not in
4
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

themselves comply fully with the Specifications for the intended use but should be of such
quality to allow the Specifications to be met after breaking, processing and if necessary
mixing with better quality materials. Existing pavement materials containing an excess of
clay, soil or organic material will not normally be considered suitable for reuse in the new
pavement. Fine sands which may be found under some pavements shall not be considered as
part of the road pavement but shall be classed as material suitable for use as fill.

Deduction of the value of excavated pavement material under Pay item No. 2/2/6 shall not
qualify it as suitable for reuse in the Works. Acceptability of the material (after processing as
the case may be) shall be determined by the Engineer and only such material shall be
permitted for incorporation in the permanent works that fully satisfies these Specifications in
all respect.

2.2.3 Construction Methods

2.2.3.a General
All roadway excavation and embankment construction shall be performed as specified here
and in Section 2.6 (Embankment), and the excavation as well as the completed roadway shall
conform to the required alignments, levels, grades and cross sections. Prior to the
commencement of any work, cross sections and measurements should be taken of the
undisturbed roadway. Excavated material shall be deposited so as not to cause damage to
services or property and so as to cause no impediment to the drainage of the site or
surrounding area.

2.2.3.b Excavated Material Used in the Works

Suitable soil from the roadway excavation shall be used so far, as is practicable as fill or top
soil material.

Suitable excavated material, if it is to be reused for the Works, shall be temporarily stockpiled
in suitable and safe areas approved by the Engineer and properly protected from any damage
or loss.

2.2.3.c Unsuitable Material from Roadway Excavation

Excavated material classified as unsuitable as fill material and excavated road pavement
material not approved by the Engineer for use in the new road pavement shall be known as
waste. It shall be the property of the Employer. The Contractor shall stockpile, or place the
material in a location approved by the Engineer.

2.2.3.d Excess Suitable Excavated Material

Suitable material from approved roadway excavation which is in excess of that required for
construction of any part of the Works shall be the property of the Contractor, and it may be
shifted/disposed of by the contractor with prior intimation to the Engineer.
5
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.2.3.e Excavation of Unsuitable Soil

Unsuitable soil shall be excavated below subgrade level in cut and below embankment
foundation level to the depth shown on the Drawings or as directed by the Engineer. The
excavation shall be backfilled in accordance with Section 2.6 of the Specifications where
unsuitable soil is excavated below the normal subgrade level or below embankment
foundations or for benching under embankments.

2.2.3.f Excavation of pavement by Milling Process

During pavement reclamation or maintenance existing pavement can be excavated using
milling machine. Milling is the control removal method of an existing pavement to a desired
depth, using specially designed equipment having replaceable tungsten carbide cutting teeth
mounted on a rotor drum driven by the power supplied by the milling machine.
Important aspects in cold milling are the depth of milling, appropriate milling tools to govern
the size of milled material, control of dust, collection and transportation of milled material, and
stockpiling. Milling processes should be closely examined to make sure that the milled material
is not contaminated with soil, base material, paving geotextiles, or other debris. The milled
surface should also be inspected for “scabbing,” where thin, weakly bonded layers are left in
place. If this is observed, the milling depth should be adjusted to remove the scab layer
because, if allowed to remain in place, the performance of overlay will be poor. The milled
surface should be inspected for uniform texture.
The finished milled surface shall be within 6-8 mm of a true profile grade both in transverse
and longitudinal directions. If the milled surface is to be the final surface of the pavement, it
should have either continuous or intermittent striations or any other pre-approved pattern which
will provide an acceptable level of skid resistance. If pavement is to be constructed over the
milled surface, it shall have a texture which will provide good bondingThe final gradation
required of the reclaimed bituminous materials (RBM) by milling can be obtained by
controlling depth of milling cut, and speed of machine.

2.2.3.g Slopes
All slopes shall be finished in a neat and workmanlike manner as shown in the drawings or
as directed by the Engineer and to an accuracy appropriate to the material, and care shall be
taken that no material is loosened below the required slopes.

2.2.3.h Drainage
During construction, the roadbed and ditches shall be maintained in such condition as to
ensure proper drainage at all times.

Any ditches and channels temporarily required shall be constructed and maintained as to
avoid damage to the roadway section.

6
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.2.3.i Preparation of Excavated Areas

The surfaces of all excavated areas shall be neat and workmanlike and shall have the
required forms, super elevations, levels, grades and cross sections. The surfaces shall be
constructed to the required accuracy to permit the construction of subsequent layers of
material as specified in Section 2.6 and other Sections of these Specifications. The surface
tolerance shall be ±25 mm from the specified levels at any point.
2.2.4 Measurement
All required and accepted roadway excavation including excavation of suitable soil,
unsuitable soil and existing road pavement shall be measured separately in cubic metres by
the average end area method as computed from the initial (prior to excavation) and final
(post excavation) roadway cross sections. For the purpose of measurement all the material
except structures and pavement materials shall be considered as soil.

Preparation of excavated areas will not be measured and paid for separately as this is be
included in the excavation work. Measured roadway excavation shall include removal of
slides, breakages and cave-ins except where caused by carelessness or improper methods of
the Contractor.

2.2.5 Payment
The quantities of roadway excavation in pavement, suitable soil and unsuitable soil
measured as specified above will be paid for at the respective unit price per cubic metre
under the Contract. The price shall include all labour, materials, tools, equipment and
incidentals to complete the work of excavation and stockpiling or disposal at locations
approved by the Engineer, including shaping and preparation of all excavated surfaces and
working in small areas if necessary.

The value of suitable soil recovered from Roadway excavation shall be deducted from
payments due to the Contractor. It shall be determined by multiplying the total quantity of
suitable soil measured in accordance with Section 2.2.4 by the rate inserted by the
Contractor against pay item 2/2/5. No consideration shall be given to weather the whole
quantity of recovered suitable soil could be reused or not in the Works.

The value of the recovered pavement material shall also be deducted from payments due to
the Contractor. It shall be determined from the total quantity of pavement material measured
in accordance with Section 2.2.4, multiplied by the rate inserted by the Contractor against
pay item 2/2/6. No consideration shall be given to weather the whole quantity of excavated
pavement material was determined suitable or not by the Engineer, and also to weather it
could be reused in the works or not.

7
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The measured quantity of recovered pavement material or suitable soil shall include no
allowance for losses during excavating, transporting, mixing, stockpiling, processing and
compaction or for pilferage for the purpose valuation of respective deduction amount.

The pay items in this section of the specifications for roadway excavation shall be full
compensation for all work involved in performing the roadway excavation as shown on the
drawings and as directed by the engineer, including the cost of temporary stockpiling,
selecting and protecting the materials to be reused and the cost of disposal of
unsuitable/excess suitable material.

Pay items shall be:

2/2/1 Roadway Excavation in Unsuitable Soil Cubic Metre

including stockpiling or disposal in a location
agreed by Engineer.

2/2/2 Roadway Excavation in Suitable Soil Cubic Metre

including stockpiling on Site

2/2/3 Roadway Excavation in Existing Pavement Cubic Metre

(Bituminous, Brick, Stone, Unreinforced
Concrete and other Materials Except Reinforced Concrete)
2/2/4 Roadway Excavation in Existing Pavement by
Milling Cubic Metre

2/2/4 Roadway Excavation in Existing Reinforced Cubic Metre

Concrete Pavement

2/2/5 Deduction for Value1 of Suitable Soil Cubic Metre

Recovered from Existing Road.

2/2/6 Deduction for Value2 of Pavement Materials Cubic Metre

Recovered from Existing Road.

Note:
1. Quantity for item no. 2/2/5 shall be taken equal to that of item no. 2/2/2.
2. Quantity for item no. 2/2/6 shall be taken equal to that of item no. 2/2/3.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.3 BORROW
2.3.1 Description
This work shall consist of the clearing and stripping of borrow pits, the excavation and
hauling of materials obtained from approved sources using the material from borrow
pits for constructing embankment, backfill, subgrade, shoulders and other parts of the
work as required under the Contract or by the Engineer.

This Section applies to borrow whether from borrow pits within or outside the
right-of-way.

2.3.2 Acquisition and Use of Borrow Pits

2.3.2.a Borrow Pits within the Right-of-Way

The use, depth, location, and dimensions of borrow pits within the right-of-way shall be
subject to the approval of the Engineer. The Contractor will have to be satisfied himself
before entering into the Contract as to the use of borrow pits within the right-of-way
and to have allowed in the rates for the risk of borrow pits not being permitted in areas
of uncertainty. Notwithstanding any general advice given by the Employer or the
Engineer before the submission of tenders, borrow pits may be prohibited, or restricted
in dimensions and depth by the Engineer where:

a) They might affect the stability or safety of the highway, the railway or structures.

b) They might interfere with natural or artificial drainage or irrigation.

c) They might interfere with adjoining property or future expansion plans for the highway.

2.3.2.b Borrow Pits Outside the Right-of-Way

The Contractor may open borrow pits outside the right-of-way and in such cases the
Contractor shall be fully and solely responsible for the expenses incurred and any legal
consequences.

2.3.3 Construction Methods

All suitable materials removed from borrow sources shall be used as indicated on the
Drawings or as directed by the Engineer. During construction the borrow pits shall be
kept drained as far as practicable and the work shall be carried out in a neat and
workmanlike manner.

Sites of the borrow operations shall be left in a suitable and slightly condition such as to
provide proper drainage where practicable.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.3.4 Measurement and Payment

No payment will be made to the Contractor for borrow and as such it shall not be
measured. Payment under the items of the work in which the borrow material is placed
shall be full compensation for all the necessary tasks and activities to acquire, to
provide and place the material.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.4 CHANNEL EXCAVATION

2.4.1 Description
This work shall consist of excavation for channels for discharging water from side
ditches where shown on the Drawings, required in the Specifications or as directed by
the Engineer. The work shall include the proper utilisation and hauling or disposal of all
excavated materials, and constructing, shaping and finishing of all earthworks.

2.4.2 Materials
Excavated materials shall be classified as unsuitable and suitable soil. To be suitable as
fill material the soil must not contain muck, roots, sods or other deleterious materials
and must conform to the requirements of Section 2.6.2.

2.4.3 Construction Methods

2.4.3.a Alignment and Levels

Channel work shall be constructed in a neat and workmanlike manner correct to
alignments, levels, grades and cross sections required on the Drawings, in the
Specifications or by the Engineer.

2.4.3.b Excavation
Deepening and realignment of existing canals and channels shall be carried out in a way
to allow free flow of the water.

During excavation of new channels these shall as far as possible be kept drained.

All suitable materials removed from the excavation shall be used as far as practicable in
constructing the roadway.

2.4.3.c Filling of Obsolete Channels

Any obsolete canals and channels within the embankment area shall be cleaned up and
back filled with sand to obtain sufficient stability. When sand fill is at a level of 500
mm above water level, compaction shall be carried out as specified in Section 2.6.

2.4.3.d Unsuitable Excavated Material

Excavated material from channel excavations classified as unsuitable as fill material by
the Engineer shall be known as waste. The Contractor, shall stockpile, or place the
material in a location approved by the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.4.3.e Excess Suitable Excavated Material

Suitable material from channel excavation, which is in excess of that, required for
construction of any part of the Works shall be the property of the Employer and shall be
stockpiled on Site as instructed by the Engineer.

2.4.4 Measurement
Payment for backfilling existing channels shall be in accordance with Section 2.6.

Quantities of channel excavation in unsuitable material shall be measured in cubic

metres determined by average end area methods computed from the original and final
geometric cross sections of the authorised and completed excavation.

Excavation of channel in suitable material shall not be measured for direct payment.
The cost shall be included in the rates for the items of the Works in which the excavated
material is placed. The exception to this is excess suitable material which is stockpiled
on Site.

Measured channel excavation shall include for the removal of any slides and cave-ins
which occur in channels except where these have been caused by carelessness or the use
of improper methods by the Contractor.

2.4.5 Payment
This work measured as provided above shall be paid for at the Contract unit price per
cubic metre. The payment shall be full compensation for all excavation, for maintaining
free flow in the channel where necessary and for all labour materials, tools, equipment
and incidentals necessary to complete the work, including stockpiling or disposal off
Site.

Channel excavation of material which is suitable for embankment fill shall not be paid
for separately but shall be paid for at the rate for fill from land as provided for in
Section 2.6.

Pay items shall be:

2/4/1 Channel Excavation in Unsuitable Material Cubic Metre

2/4/2 Channel Excavation in Suitable Material Cubic Metre

including stockpiling on Site (applies to Excess
Suitable Excavated Material only)

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.5 EXCAVATION AND BACKFILL FOR STRUCTURES

2.5.1 Description
This work shall consist of excavation in any material for the foundation of structures,
other than for pipe culverts, not otherwise provided for in the Specifications;
constructing and removing cofferdams, sheeting; pumping, dewatering and bailing;
backfilling of completed structures with suitable material and disposal of excavated
material. Pipes and manholes shall be excavated and backfilled in accordance with
Sections 6.2 and 6.3.

Filling of areas above the natural ground level or above the limits of road excavation or
channel excavation is described in Section 2.6.

2.5.2 Materials

2.5.2.a Foundation Fill Material

Material for foundation fill shall consist of suitably graded sand to one of the grading
envelopes A to C of Section 2.8.2, gravel or stone as shown on the Drawings or as
required by the Engineer, or concrete. Concrete for foundation fill shall conform to the
general requirements of Section 5.1. Concrete to be placed under water shall conform to
the requirements of Section 5.1.3.14. Concrete used as foundation fill in dry excavation
shall be class 15.

2.5.2.b Backfill Material

Backfill materials below top level of pile caps shall consist of sand with not more than
10% of material passing the 75 micron sieve, if not otherwise directed by the Engineer
or stated on the Drawings.

Backfill above top level of pile caps but outside embankment and road areas shall be
excavated material if suitable and approved by the Engineer.

2.5.3 Construction Methods

2.5.3.a Clearing
Prior to starting excavation operations in any area, all necessary clearing and grubbing
shall have been performed.

2.5.3.b Excavation
A) General

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The Contractor shall notify the Engineer sufficiently in advance of the beginning of any
excavation so that cross section elevations and measurements may be taken of the
undisturbed ground. The natural ground adjacent to the structure shall not be disturbed
without permission of the Engineer.

Trenches and foundation pits for structures and structure footings shall be excavated to
the lines, grades and elevations shown on the Drawings or as directed by the Engineer.
The elevations of the bottoms of footings shown on the Drawings are approximate only
and the Engineer may order in writing such changes in the dimensions or elevations of
footings as may be deemed necessary to secure a satisfactory foundation.

Boulders, logs and other objectionable material encountered in excavation shall be

removed. After each excavation is complete the Contractor shall notify the Engineer to
that effect and no footings, bedding material or structure shall be placed until the
Engineer has approved the depth of excavation and the character of the foundation
material.

The foundation material shall be cleared of all loose material and cut to a firm surface,
either level or stepped or serrated, as specified or shown on the Drawings or directed by
the Engineer.

B) Foundation Directly on the Ground

When the footing is to rest on the ground and not on piles, special care shall be taken
not to disturb the bottom of the excavation, and excavation to final grade shall be
deferred until just before the footing is to be placed. When, in the opinion of the
Engineer, the foundation material is soft or otherwise unsuitable, the Contractor shall
remove the unsuitable material and insert foundation fill material or concrete as
specified or shown on the Drawings or directed by the Engineer. If foundation fill
material is required, it shall be placed and compacted in layers not more than 150 mm
thick to the degree of compaction as specified in Section 2.6.

C) Foundation on Piles

When the ground between piles is too soft to support green foundation concrete, the
Contractor shall submit his proposals for a bottom form to the Engineer for his
approval. Extra excavation and foundation fill or concrete fill in such cases will not be
paid for separately.

If the bottom form is achieved by such strengthening of the ground, the Contractor
shall, if requested, submit calculations showing that the pile cap will not be harmed
14
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

during hardening due to differential settlements between the piles and the strengthened
ground.

2.5.3.c Disposal of Excavated Material

Excavated material classified as suitable by the Engineer shall generally be utilised as
backfill or embankment fill. Surplus suitable material shall be stockpiled on Site as
described in Section 2.2.3.4 of these Specifications. Excavated suitable material for use
as backfill shall be deposited by the Contractor in spoil heaps at points convenient for
re-handling of the material during the backfilling operation and approved by the
Engineer.

Excavated material classified as unsuitable as backfill by the Engineer shall be carried

to waste as described in Section 2.2.3.3 of these Specifications.

Excavated material shall be deposited in such places and in such a manner as not to
cause damage to roads, services or property either within or outside the right-of-way
and so as to cause no impediment to the drainage of the site or surrounding area. The
location of spoil heaps shall be subject to the approval of the Engineer who may require
that the reference lines and the traverse lines of any part of the structure be kept free of
obstruction.

2.5.3.d Cofferdams
A) The term “cofferdam” denotes any temporary or removable structure, constructed
to hold the surrounding earth, water or both, out of the excavation, whether such
structure is constructed of earth, timber, steel, concrete or any combination of these.
The term includes earth dikes, timber cribs, sheet piling, removable steel shells and all
bracing; and it shall be understood to include excavation enclosed by pumping wells
and well points.

The cost of cofferdams is always to be included in the tender rates/prices for the
permanent work.

B) The term “caisson” denotes a permanent part of the substructure so constructed as

to sink gradually into place as material is excavated within the area protected by its side
walls. Where the term “well” is used it shall be taken to have the same meaning as
“caisson”.

C) When no provision for caissons is shown on the Drawings, it shall be the intent of
the Contract that suitable cofferdams shall be provided for all excavations where

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

cofferdams may be necessary in order to control water to preclude sliding and caving of
the walls of the excavation.

D) The Contractor shall submit upon request, drawings showing his proposed method
of cofferdam and caisson construction. Approval of the drawings by the Engineer will
not in any way relieve the Contractor of the responsibility for the adequacy of the
design for strength and stability or for the safety of the people working therein.

E) The interior dimensions of cofferdams shall be such as to give sufficient clearance

for the construction and removal of any required forms and the inspection of the
interior and to permit pumping.

F) If possible, cofferdams shall be so designed that no cross bracing shall be left in

place. If this is not possible, bracings left in place shall be of structural steel. The end of
such structural members that would be exposed when the structure is completed shall
be boxed back at least 50 mm behind the concrete face. The resulting holes shall be
completely filled with concrete.

G) In general, sheet piling cofferdams shall extend well below the bottom of the
footing and shall be well braced and as watertight as possible.

H) When foundation piles are to be driven inside a cofferdam and it is judged

impossible to de-water the cofferdam before placing a concrete seal, the excavation
may be extended below the designed level to a depth sufficient to allow for swell of the
material during pile driving operations. Any material that rises to a level above the
design level shall be removed.

I) Where it is possible to de-water the cofferdam, the foundation material shall be

removed to exact grade after the foundation piles are driven.

J) Backfilling in a foundation to compensate for excavation, which has been

extended below the required grade, shall be at the expense of the Contractor.
Backfilling shall be with concrete or foundation fill material as indicated on the
Drawings, or as directed by the Engineer.

If no material is indicated, backfilling shall be concrete of the same kind as required for
the structure to be constructed in the excavation. Unless otherwise permitted no
excavation shall be made outside of caissons or cribs or cofferdams or sheet piling and
the natural streambed adjacent to the structure shall not be disturbed without
permission from the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

If any excavation or dredging is made at the site of the structure before caissons, cribs,
or cofferdams are in place, the Contractor shall after the foundation is in place, backfill
all such excavation to the original ground surface or stream bed with material
satisfactory to the Engineer.

Material deposited within the stream area from foundations or other excavations or
from the filling of cofferdams shall be removed and the stream area freed from
obstruction.

K) Caissons and cofferdams, which have tilted or moved laterally during

construction, shall be corrected as necessary at the expense of the Contractor.

L) Unless otherwise provided cofferdams shall be removed after the completion of

the sub-structure. The removal shall be effected in such a manner as not to disturb or
mar the finished work. The Engineer may order the Contractor to leave any part or the
whole of the cofferdam in place.

M) When conditions which, in the opinion of the Engineer, render it impossible to

de-water the foundation before placing the footing are encountered, the Engineer may
require the construction of a concrete foundation or seal of such dimensions as he may
consider necessary, and of such thickness as to resist any possible uplift. The concrete
for such seal shall be placed as shown on the Drawings or required by the Engineer.
The foundation shall then be de-watered and the footing placed. When weighted cribs
are used and the weight is used to overcome partially the hydrostatic pressure acting
against the bottom of the foundation seal, special anchorages such as dowels or keys
shall be provided to transfer the entire weight of the crib to the foundation seal. When a
foundation seal is placed under water the cofferdam shall be vented at low water as
directed.

Cofferdams shall be constructed so as to protect newly cast concrete from sudden rising
of the water and to prevent damage to the foundation by erosion.

2.5.3.e Pumping and Bailing

Pumping and bailing from the interior of any foundation enclosure shall be done in such
a manner as to preclude the possibility of the movement of water through or alongside
any concrete being placed. No pumping or bailing will be permitted during the placing
of concrete and for a period of a least 24 hours thereafter unless it is done from a
suitable pump separated from the concrete work by a watertight wall or from well
points.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Excavations shall be as dry as possible prior to and during placing concrete. Placing
concrete under water will only be permitted if indicated on the Drawings or approved
by the Engineer.

2.5.3.f Backfilling
All spaces excavated under these Specifications and not occupied by the permanent
structure shall be backfilled. Backfilled material shall fully comply with this
Specification and adequate provision shall be made for drainage. No backfilling shall
commence until permission has been given by the Engineer.

Backfill under top level of pile caps shall always be made with compacted sand fill free
from chemical contamination. Over top level of the pile cap but outside embankment
and road areas, the backfill shall be excavated material if suitable and free from
chemical contamination, and approved by the Engineer. If the excavated material is not
suitable, the Engineer may order sand filling.

Backfill within the embankment and road areas shall be made in accordance with
Section 2.6 of these Specifications.

Special care shall be taken to prevent any unduly high pressure against the structures. In
placing backfill and embankment, the material shall be placed insofar as possible to
approximately the same height on both sides of the structure at the same time. If
conditions require backfilling appreciably higher on one side, the additional material on
the higher side shall not be placed until permission is given by the Engineer that the
structure has enough strength to withstand any pressure created.

Jetting of fill or other hydraulic methods involving, or likely to involve, liquid or

semi-liquid pressure is prohibited. Backfill and embankment fill shall not be placed
behind the walls of bridges or box culverts until the top slab has been placed for at least
three days.

The placing of embankment and the benching of slopes shall continue in such a manner
that at all times there will be a horizontal berm of thoroughly compacted material for a
distance at least equal to the height of the abutment or wall to be backfilled.

2.5.4 Measurement
The volume of excavation and backfill shall be measured in cubic metres of excavated
undisturbed material.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The quantity of excavation for structures to be measured for payment shall include
excavation for all structures except pipe culverts, which will be in accordance with
Section 6.2. The measured volume shall be the excavation plan outline, bounded on the
bottom by the plane of the underside of the brick flat soling to the blinding concrete
under the reinforced concrete footing and on the top by the surface of the existing
ground and on the sides by vertical planes of the footings.

Backfilling with previously excavated material shall not be measured or paid for
separately but shall be deemed included in the rate for excavation.

Backfill with concrete or sand where directed by the Engineer including concrete seals
shall be measured separately as the volume within the plan outline and top and bottom
surfaces. Concrete or sand placed to backfill excavation beyond the excavation required
will not be measured for payment. The plan outline referred to is the excavation plan
outline as defined above.

If sand fill is ordered over top level of pile cap, the fill shall be the specified filling
volume measured on the Drawings up to profiles agreed upon in writing by the
Engineer.

In the case of structures for which a lump sum price is called for, the volume of
excavation as stated above for the work as shown on the Contract Drawings, shall be
subtracted from the volume measured as above, and the price to be paid or deducted
shall be based on the measured increase or reduction of the excavation shown on the
Drawings.

Removal of slides, cave-ins, silting or filling shall not be measured nor paid for.

2.5.5 Payment
This work measured as provided in Section 2.5.4 shall be paid for at the Contract unit
prices per cubic metre for each particular item. The payment shall be full compensation
for all excavation, stockpiling, backfilling and disposal including compaction;
constructing and removing all cofferdams; all dewatering, pumping and bailing; and for
furnishing all materials, labour, equipment, tools, sheeting, bracing, cofferdams, pumps,
and incidentals necessary to complete the work.

Payment for backfilling shall be included in the pay item for “Excavation and Backfill
for Structures” except for sand backfill and concrete backfill. These backfill types shall
be measured as provided in Section 2.5.4 and paid for at the concerned Contract unit
prices, but no compensation in the pay item “Excavation and Backfill for Structures”
shall be made for less backfilling with excavated material or more surplus to waste.
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

All payment for the backfilling and compaction of those areas which were removed, as
structural excavation shall be included in the appropriate unit rates below. Filling or
backfilling of areas above the natural ground level or above the limits of road
excavation or channel excavation section shall be paid for under Section 2.6.

Cofferdams for structures without excavation, for example for pile caps over water shall
be included in the unit prices for the concerned pile cap.

Pay items shall be:

2/5/1 Excavation and Backfill for Structures Cubic Metre

2/5/2 Concrete Backfill for Structures Cubic Metre

2/5/3 Sand Backfill for Structures Cubic Metre

20
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.6 EMBANKMENT
2.6.1 Description
This work shall consist of the construction of embankment and fill by furnishing,
placing, compacting and shaping suitable material of acceptable quality obtained from
approved sources in accordance with these Specifications and to the lines, levels,
grades, dimensions and cross sections shown on the Drawings or as required by the
Engineer.

2.6.2 Materials
All fill materials shall be free from roots, sods or other deleterious material.

Materials for embankments shall be from sources which the Contractor shall propose
and which shall be approved by the Engineer. Approval shall normally be given to the
use of material which, when compacted to 95% of maximum dry density determined in
accordance with STP 4.4 has a 4 day soaked CBR value of not less than 6%.

 Liquid limit of soil fraction passing 0.425 mm sieve not to exceed 40% (STP 3.2)
 Plasticity index of soil fraction passing 0.425 mm sieve not to exceed 10 (STP3.2) and
passing 75µm not to exceed 35% (STP 3.3)

Test and other properties shall meet the requirement as per section 2.8.

2.6.3 Construction Methods

2.6.3. a Preparation of Foundations for Embankment
Prior to placing any embankment upon any area, all clearing and grubbing operations
shall have been completed in accordance with Section 2.1 and excavation under
carriageways shall be carried out in accordance with Section 2.2.

The original ground surface shall be disturbed as little as possible except for levelling of
dikes, terraces and obsolete ditches.

Existing ditches etc., shall be closed at the embankment as described in Section 2.1.3.d.
Embankments in swamps or water shall be constructed as indicated on the Drawings
and as described in these Specifications. The Contractor shall, when ordered by the
Engineer, excavate or displace swamp ground (Section 2.2.3) and backfill with river or
beach sand unless otherwise directed by the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.6.3.b Placing Embankment

A) General

Except as otherwise required by the Drawings, all embankments shall be constructed in

layers approximately parallel to the finished grade of the roadbed. During construction
of embankment, a smooth grade having an adequate crown shall be maintained at all
times to provide drainage.

The placing of fill shall be carried out in successive layers for the full width of fill as
shown on the Drawings with allowance being made for the placement of topsoil if
applicable and in such lengths as are suited to the watering and compaction methods
utilised. Each layer shall not exceed 200 mm in thickness on completion of compaction.
The completed embankment shall have the required form, cross-section, grade and
levels as detailed on the drawings or as directed by the Engineer with a surface
tolerance of 25mm from the specified levels.

Embankment fill placed adjacent to structures shall be in accordance with Section

2.5.3.6.

B) Placing Embankment over Swampy Ground

Where new embankment will overlay existing canals, ditches, ponds or other
waterways, these shall be filled in exclusively with sand in accordance with Section
2.4.3.3. Prior to filling, cofferdams shall be made to allow pumping, and the bed shall
be left to dry until approved by the Engineer for filling.

The Works shall be performed in such a manner and at such times as to avoid
interruption of or interference with the free flow of water in the canals.

Full compensation for conforming to these requirements shall be considered included in

other rates within the Contract items, and no additional payment will be made.

C) Widening of Existing Embankment

Where embankment fill is being carried out to widen an existing embankment the new
fill material shall be fully keyed into the old embankment by means of benching which
shall be in steps each not less than 300 mm high and 600 mm wide. Steps shall be cut in
advance of the filling. Material cut in benches may be used as fill if found to be
suitable.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.6.3.c Compaction of Embankment.

The Contractor can conduct field trial using the same embankment material with
variable moisture content to determine the moisture content needed to achieve the
desired density, otherwise the moisture content should not be more than the Optimum
Moisture Content. The achieved dry density of the embankment after compaction shall
not be less than 98% of maximum dry density determined earlier in accordance with
AASHTO T 180. Static Deformation Modulus Ev2 shall be 60 MPa and Ev2/Ev1 shall
be ≤2.5 (Technical Standards including ASTM 1195/ASTM 1196 and DIN 18134).
Testing for Ev2 and Ev1is mandatory; however, its important to note that the test results
will not be used as acceptance criteria but solely for record keeping purpose.

Dredged sand should be stockpiled outside and not be brought to the roadway. One
density test for each 1,000 square metres of a completed layer will be carried out
according to STP 6.2, unless otherwise directed by the Engineer. If test results show
that the density is less than the required density, the Contractor shall carry out further
compaction to obtain at least the required density. The compacted layer shall be
approved by the Engineer before the Contractor can commence a new layer.

In addition to the density test, one Dynamic Cone Penetrometer (DCP) test shall be
carried out for each 500 sqm of a completed layer; the rate of penetration from the test
should not exceed 38 mm/ blow.

When necessary, each layer, before being compacted, shall be mixed with dry material
or otherwise processed to bring the moisture content sufficiently close to optimum to
make possible its compaction to the required density. The material shall be so worked
as to have a uniform moisture content through the entire layer.

Each layer of material shall be compacted uniformly by use of adequate and appropriate
compaction equipment. The compaction shall be done in a longitudinal direction along
the embankment and shall generally begin at the outer edges and progress toward the
centre in such a manner that each section receives equal compactive effort.

Hauling equipment shall be operated over the full width of each layer in so far as
practicable.

2.6.4 Measurement
Embankment shall be measured in cubic metres based on cross sections of accepted
embankment constructed and completed in accordance with the Specifications, to the
lines, levels and grades required or as directed by the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The cross section to be used will be the area bound by the subgrade (below improved
subgrade or sub-base) the side slopes or edge limits and the original ground line or the
level after excavation of unsuitable material with the net volume being calculated by the
End area method. A deduction of volume will occur when topsoil is placed in
accordance with Section 6.6 of this Specification.

No allowance will be made for material cut in benching operations.

The final volume of embankment fill shall not include the voids for bridges and
box-culverts, but the voids for pipes, manholes, catch basins and the like will however
not be deducted.

Sand backfill to swampy ground shall be measured in cubic metres based on the net
volumes backfilled as directed by the Engineer.

2.6.5 Payment
This work measured as provided above shall be paid for at the Contract unit prices per
cubic metre. Payment shall be full compensation for performing the work, furnishing
the materials and providing all labour, equipment, tools and incidentals necessary to
complete the work.

Partial payment may be made on measured volumes of required embankment fill

actually executed. The Engineer will set terms for deduction in this quantity to
compensate for work not fully completed.

Pay items shall be:

2/6/1 Embankment Fill from Excavation on Site Cubic Metre

2/6/2 Embankment Fill from Borrow Pit in Cubic Metre
Contractor’s Arranged Land
2/6/3 Embankment fill by dredged sand Cubic Metre
2/6/4 Sand Backfill to Swamp for construction Cubic Metre
platform

2.6.6 Cladding Material

2.6.6.a Description
Cladding material use as a part of dredged sand embankments shall be clayey silt with a
plasticity index as determine in accordance with AASHTO T90, of 10 to 20 per cent
and free from all sorts debris, organic materials .
24
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Embankments shall be protected from scour and erosion by a layer of cladding material
as specified in the finished thickness shown on the engineering drawings giving a layer
width of 0.9m to 1.2 m as per direction of engineer. This material shall be spread in
layers not exceeding 200mm loose thickness and compacted by means of suitable size
equipment to a density of 95 per cent of the maximum dry density as determined by
AASHTO T180 and 4 days soaked CBR Value of not less than 4%. Construction of
cladding layer will be integrated with embankment/pavement construction and follow
the procedure describe in relevant section of 2.6. No part shall be left for partly
construction after embankment construction. Care shall be taken to ensure that the
drainage paths of trench drains do not blocked due to cladding construction.

2.6.6.b Measurement
Cladding material shall be measured in cubic meters. The quantity of cladding material
shall be required cladding soil of the designated thickness complete and accepted by the
engineer in charge. When the earthworks do not conform to the required dimension and
side slopes of embankments or excavation requiring cladding soil are of greater area
than required, the area measured shall be there required area as if the earthwork had
conformed to the required dimension.

2.6.6.c Payment
This work measured as provided above, shall be paid for at the Contract unit price per
cubic metre. The price shall be full compensation for furnishing, placing and
compacting all material, including all materials cost and labour, equipment, tools and
incidentals necessary to complete the work.
No payment will be made for cladding soil until it has been grassed.
Pay items shall be:
2/6/5 Cladding Soil - Cubic Meter

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.7 PREPARATION OF SUBGRADE

2.7.1 Description
This work shall consist of the preparation of subgrade in embankment, or in cut by
removing, scarifying, watering, compacting and shaping existing or previously placed
material in accordance with these Specifications and to the lines, levels, grades,
dimensions and cross sections shown on the Drawings or as required by the Engineer.

2.7.2 Materials
Materials for subgrade shall be same as in Section 2.6.2 except the CBR value shall be
8.

2.7.3 Construction Methods

The subgrade shall be prepared over the full width of the embankment including
shoulders. Part width working may be allowed with the prior written approval of the
Engineer.

The subgrade shall be prepared in lengths of not less than 100 metres at any one time,
unless otherwise approved by the Engineer.

Where the subgrade is in embankment, the subgrade layers to the required depth shall
be compacted to achieve dry density not be less than 98% of maximum dry density
(MDD) determined earlier in accordance with Modified Proctor Test (where at top of
Subgrade Static Deformation Modulus EV2 shall be 120 MPa and Ev2/Ev1 shall be
≤2.3, Technical Standards including ASTM 1185/ASTM1196 and DIN 18134) (STP
4.4). Testing for Ev2 and Ev1is mandatory; however, it’s important to note that the test
results will not be used as acceptance criteria but solely for record keeping purpose.

In the case of road sections in cut or in case of full reconstruction of pavements, where
the existing subgrade does not meet the above compaction criteria upto a depth of 300
mm, the material in the upper layer will be first removed and stacked separately. The
bottom layer shall be scarified until the soil is fully loosened; any lumps or clods shall
be removed or broken to pass 50 mm sieve. The layer shall be compacted to achieve the
minimum compaction level as given above, and minimum CBR of 8%. Any unsuitable
material occurring within the layers shall be removed and replaced by approved
materials. The second layer of subgrade shall be laid after testing and approval the first
layer and compacted to similar specifications.

The achieved dry density after compaction of the subgrade layer shall not be less than
98% of maximum dry density as determined in accordance with STP 4.4.

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SECTION 7 GENERAL SPECIFICATIONS
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The material shall be worked as to have a uniform moisture content through the entire
layer.

The subgrade material shall be compacted uniformly by use of adequate and appropriate
compaction equipment. The compaction shall be done in a longitudinal direction along
the embankment and shall generally begin at the outer edges and progress toward the
centre in such a manner that each section receives equal compactive effort.

Samples to determine the compaction shall be taken regularly with a set of three
samples for each 1,000 square metres of finished layer or as decided by the Engineer
will be carried out according to STP 6.2. If the test results show that the density is less
than the required dry density, the Contractor shall carry out further compaction to obtain
at least the required dry density. The compacted subgrade layer shall be approved by the
Engineer before the Contractor can commence a new layer.

The surface of the finished subgrade shall be neat and workmanlike and have the
required form, super elevation, levels, grades and cross section. The finished surface
shall be constructed with a tolerance of 20 mm above or below the specified levels at
any point.

2.7.4 Measurement
Subgrade preparation shall be measured in square metres based on the surface area of
compacted and accepted subgrade actually completed in accordance with the
Specifications, to the lines, levels, grades and cross sections required as directed by the
Engineer. No allowance will be made for overlapping of areas due to half width
working.

No differentiation will be made between subgrade compaction in cut or in fill.

2.7.5 Payment
This work measured as provided above shall be paid for at the Contract unit prices per
square metre. Payment shall be full compensation for performing the work and providing
all labour, equipment, tools and incidentals necessary to complete the work.

The rates shall not include the cost of furnishing the subgrade materials which, if not
existing, shall be included in the quantity for fill material as provided for in Section 2.6.

Pay item shall be:

2/7/1 Preparation of subgrade 300 mm Depth Square Metre

2/7/2 Preparation of subgrade 450 mm Depth Metre Square Metre
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.8 IMPROVED SUBGRADE

2.8.1 Description
This work shall consist of furnishing, placing and compacting improved subgrade
material on a prepared and accepted subgrade in accordance with these Specifications,
and to the lines, levels, grades, dimensions and cross sections shown on the Drawings, or
as required by the Engineer.

2.8.2 Materials
Material shall be a natural or artificial mixture of sand or other mineral aggregates, free
from vegetable matter, soft particles, clay and excess quantities of silt.
Plasticity. The portion of material passing the 0.425 mm sieve shall not to exceed 6, when
tested in accordance with test procedure STP 3.2.”

CBR. The material shall have a soaked CBR value not less than 12, when compacted to
95% of maximum dry density as determined by STP 4.4 (Modified compaction).

Suitable (Passing 75 µm not to exceed 35%) measures shall be taken for protecting the
material from erosion

2.8.3 Construction Methods

2.8.3.a Preparation of Subgrade
Notwithstanding any earlier approval of subgrade, any damage to or deterioration of
subgrade shall be made good before the improved subgrade is laid.

Preparation of the subgrade shall be carried out, unless otherwise agreed by the
Engineer, immediately prior to laying the improved subgrade.

2.8.3.b Spreading
Improved subgrade shall be spread in layers, with uncompacted thickness up to 200
mm, subject to the approval of the Engineer, and the layers shall be as nearly equal in
thickness as possible.

Where the material for shoulders is the same as that used for the improved subgrade
course, the material shall be placed for the full width of the roadbed and the shoulders
simultaneously.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Where the shoulders are not of the same material as the improved subgrade course, then
the improved subgrade shall be spread to give the required compacted depth and the
edge detail shown on the Drawings.

When the improved subgrade course is spread contiguous to concrete kerbs or gutters,
extreme care shall be exercised not to damage the kerbs or gutters. Any damage of
kerbs or gutters resulting from carelessness or negligent construction methods by the
Contractor shall warrant the removal and replacement of said kerbs or gutters at the
Contractor’s sole expense.

2.8.3.c Sprinkling, Rolling and Compacting

Each layer shall be compacted to at least 95% of the maximum dry density as
determined by AASHTO T180. At top of Improved Subgrade Static Deformation
Modulus EV2 shall be 120 MPa and Ev2/Ev1 shall be ≤2.3, Technical Standards
including ASTM 1195/ASTM 1196 and DIN 18134. Testing for Ev2 and Ev1is
mandatory; however, it’s important to note that the test results will not be used as
acceptance criteria but solely for record keeping purpose. Three in situ density tests in
accordance with STP 6.2 shall be taken from each 1,000 square metres of compacted
improved subgrade, or as directed by the Engineer. If the achieved density is less than
the minimum required, the Contractor shall carry out further compaction. Nuclear
Density test can be used with proper calibration.

When commencing work on the improved subgrade the Contractor shall carry out a
field compaction trial to determine the optimum moisture content and the required
number of passes of his particular compaction equipment to comply with the
Specification. This method will be approved by the Engineer and shall be used for all
subsequent compaction of improved subgrade material. Such agreement will not
however relieve the Contractor of his responsibility and in the event that test results
later show that the specified compaction is not being achieved all improved subgrade
work shall cease and not be resumed until a fresh trial has been undertaken and a
revised compaction method approved by the Engineer.

In order to ensure uniform bearing capacity at the finished improved subgrade level,
CBR tests shall be carried out as directed by the Engineer. The CBR shall be such that
the laboratory value obtained in accordance with STP 5.1, at the specified compaction
and after 4 days soaking, shall exceed 12. In areas where these requirements are not
met, correction shall be made by such measures as the Engineer deems necessary.

Immediately after each layer has been spread and shaped satisfactorily, each layer shall
be thoroughly compacted with suitable and adequate compaction equipment approved
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

by the Engineer. Rolling operations shall begin from the outer edge of roadbed toward
the centre, gradually in a longitudinal direction; except on super-elevated curves, where
rolling shall begin at the low side and progress towards the high side.
Improved subgrade material which does not contain sufficient moisture to be compacted
in accordance with the requirements of this Section shall be watered by methods
approved by the Engineer at the Contractor’s own expense. Improved subgrade material
containing excess moisture shall be dried prior to or during compaction by methods
approved by the Engineer, at the expense of the Contractor.

The finished improved subgrade shall follow the required grades and cross sections and
at any point shall not vary more than 20 mm above or below the specified level. The
thickness of the finished improved subgrade shall be:

-not thinner than 20 mm less than the required thickness at any point

-overall not less than the required thickness when five thickness measurements are
averaged in any 100 metres of road.

Improved subgrade which does not conform to the above requirements shall be
reworked, watered and thoroughly re-compacted to conform.

2.8.4 Measurement
Improved subgrade as described in this section shall be measured by the cubic metres of
material compacted in place and accepted. Measurement shall be based on the average
width and thickness of the improved subgrade shown on the Drawings and actual length
measured horizontally along the centreline of the surface of the road.

2.8.5 Payment
This work measured as provided above shall be paid for at the Contract unit rate per
cubic metre for improved subgrade. The payment shall be full compensation for
furnishing all materials, hauling, placing, compacting, sprinkling, finishing and shaping,
and for all labour, equipment, tools and other incidentals necessary to complete the
work specified.

Pay item shall be:

2/8/1 Improved Subgrade Cubic Metre

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.9 REMOVAL OF EXISTING STRUCTURES

2.9.1 Description
This work shall consist of the satisfactory removal and salvage or disposal, wholly or in
part, of existing bridges, structures, substructures, buildings, culverts etc., within the
right-of-way as indicated in the Contract Documents or as required by the Engineer.

The Employer will generally arrange for all structures within the right-of-way, which
are not the property of the Employer to be removed by the respective owners prior to
the Contractor commencing work on site.

Existing structures which are the property of the Employer and which are in the vicinity
of a proposed roadway shall be dismantled or demolished by the Contractor to a level
one metre lower than the proposed road surface elevation. For areas of the Site that will
be used for purposes other than roadways, existing structures shall be dismantled or
demolished to a level lower than the lowest elevation of the finished ground level, as
indicated on the Drawings or directed by the Engineer.

2.9.2 Materials Obtained from Dismantling

The materials in the existing structures may include but are not restricted to structural
steel, reinforced concrete materials, or stone/brick masonry materials, in any
combination. The concrete materials, stone/brick masonry materials obtainable from
dismantling of structure shall be taken to stock-piles by the Contractor for their possible
use in the works when so approved by the Engineer.

The materials salvaged from dismantling may not in itself comply fully with
specifications for intended use in the permanent works. The salvaged material shall be
first sorted out as directed. The materials, which may be used directly in permanent
works, shall be stockpiled separately from those that require processing for reuse. The
materials selected for processing should be of such quality as will meet the
specifications after breaking, screening and / or mixing with better quality materials if
necessary.

Acceptability of the materials (after processing as the case may be) shall be determined
by the Engineer and only such materials that fully satisfy the specifications in all
respects shall be permitted for incorporation in the permanent works.

Structural/reinforcing steel obtained from dismantling of the existing structures is not

considered suitable for use in the permanent works. This will be the property of the
Contractor; it will not be reused for the permanent Works, and shifted/disposed of from
the site with intimation to the Engineer. Structures or portions thereof which are

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

specified in the contract for re-erection shall be stored in separate piles in a location
agreed by the Engineer.

The Contractor shall comply with all laws, ordinances, building regulations etc as
prevailing in Bangladesh.

2.9.3 Backfilling after Dismantling of Structures

As directed by the Engineer, holes and depressions caused by dismantling operations
shall be backfilled with excavated or other approved materials and thoroughly
compacted in line with surrounding areas. The backfilling required for restoring the
ground after dismantling of structures shall not be paid separately as the cost shall be
included in the rate for dismantling structures.

2.9.4 Measurement
The dismantling or rehabilitation, disposal of the material and the backfilling after
dismantling of structures shall be measured as a Lump Sum per structure.

2.9.5 Payment
The Lump Sum (LS) amounts rates for the various items of dismantling or rehabilitation
shall be the full compensation for carrying out the required operations including
excavation backfilling and shaping and providing all labour, materials, tools,
equipment, safeguards and incidentals necessary to complete the work for each
individual structure. These will also include for handling, sorting out, salvaging, and
stock piling usable materials.

All materials from existing structures, which are suitable for use in the road pavement,
shall be stockpiled in a manner approved by the Engineer. The rate per cubic metre
inserted by the Contractor against pay item 2/9/3 shall be deducted from payments due
to the Contractor.

Pay item shall be:

2/9/1 Dismantling existing structure (Box Lump Sum

Culvert/Pipe Culvert/Bridge) including disposal of
spoil and backfilling (Individual Structure to be
stated in Bill of Quantities).

2/9/2 Dismantling portions of existing structure including Lump Sum

Stockpiling of materials (Individual Structure to be
stated in Bill of Quantities)
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2/9/3(a) Deduction of the Value of Recovered Materials Cubic Metre

(Except Reinforcing steel) from Structures

2/9/3(b) Deduction of the Value of Recovered Materials Tonnes

(reinforcing Steel) from Structures

33
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.10 CONSTRUCTION OF EARTHEN SHOULDERS

2.10.1 Description
This work shall consist of the construction of shoulders to the road pavement by
furnishing, placing, compacting and shaping suitable material of acceptable quality
obtained from approved sources in accordance with these Specifications and to the
lines, levels, grades, dimensions and cross sections shown on the Drawings or as
required by the Engineer.

2.10.2 Materials
All shoulder materials shall be free from roots, sods or other deleterious material.

Materials for shoulders shall be from sources, which the Contractor shall propose and
which shall be approved by the Engineer. Approval shall not normally be given to the
use of material from borrow areas which, when compacted to 98% of maximum dry
density in accordance with STP 4.3, has a 4 day soaked CBR value of less than 8%.
Shoulder materials shall conform to the following requirements.

 Liquid limit of soil fraction passing 0.425 mm sieve not to exceed 40% (STP 3.2)

 Plasticity index of soil fraction passing 0.425 mm sieve to be greater than 11 (STP 3.2)

2.10.3 Construction Methods

2.10.3.a Preparation
Prior to placing any shoulder fill, all subgrade preparation and subgrade drainage work
shall be complete.

2.10.3.b Placing
Except as otherwise required by the Drawings, all shoulders shall be constructed in
layers approximately parallel to the finished grade of the roadbed. The layers shall not
exceed 150 mm in thickness on completion of compaction.

Attention is drawn to the requirements for shoulders to be constructed in stages with the
road pavement layers. The finished surface of the soft shoulder shall have a tolerance of
20mm from the specified level for the full width, except that where it adjoins a hard
shoulder then the level at this point must be equal or lower than the finished level of the
approved hard shoulder.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.10.3.c Compaction of Shoulders

The achieved dry density after compaction shall not be less than 98% of the maximum
dry density as determined in accordance with STP 4.3.

Samples to determine the compaction shall be taken regularly, with one sample for each
500 square metres of finished layer, or as directed by the Engineer. Such density tests
will be carried out according to STP 6.2. If test results show that the achieved dry
density is less than the minimum required, the Contractor shall carry out further
compaction. Each compacted layer shall be approved by the Engineer before the
Contractor can commence a new layer.

2.10.4 Measurement
Shoulders shall be measured in cubic metres based on cross sections compacted and
accepted in place. The volume to be measured will be the net volume of required and
accepted shoulder, constructed and completed in accordance with the Specifications, to
the lines, levels, grades and cross sections required or as directed by the Engineer.

2.10.5 Payment
This work measured as provided above shall be paid for at the Contract unit prices per
cubic metre. Payment shall be full compensation for performing the work, furnishing
the materials and providing all labour, equipment, tools and incidentals necessary to
complete the work.

Pay item shall be:

2/10/1 Construction of Soil Earthen Shoulders Cubic Metre

35
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.11 CONSTRUCTION OF HARD SHOULDERS

2.11.1 Description
This work shall consist of the construction of hard shoulders to the road pavement by
furnishing, placing, compacting and shaping suitable material of acceptable quality
obtained from approved sources in accordance with these Specifications and to the
lines, levels, grades, dimensions and cross sections shown on the Drawings or as
required by the Engineer.

2.11.2 Materials
The materials for hard shoulder shall meet the requirements for aggregate base type II
provided for in Section 3.3.2

2.11.3 Construction Methods

2.11.3.a Preparation of Sub-base
The sub-base shall be shaped and compacted in conformity with the provisions of
Section 3.2 to the correct moisture content, and be completed for at least 100 metres
ahead of the placing of the hard shoulder material, unless otherwise approved by the
Engineer.

2.11.3.b Spreading Hard Shoulder

The aggregate and sand shall be mixed thoroughly to obtain a homogenous mix
complying with either grading A or B of Section 3.3.2. Water shall be added during
mixing to keep the mixed material moist so as to prevent segregation during
transportation.

The mixed hard shoulder material, which should be at or near optimum moisture
content shall be spread in two layers of nearly equal thickness so that the compacted
thickness shall conform to that shown on the Drawings or as directed by the Engineer.
All areas of segregation shall be corrected, or removed and replaced with well graded
material.

Where the material for hard shoulders is the same as that used for the base course, the
material shall be evenly spread in layers, as herein specified, for the full width of the
roadbed and the base course and the shoulders should be constructed simultaneously.

At the edge of the hard shoulders the hard shoulder material shall be spread to give the
required compacted depth and the edge detail shown on the Drawings.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.11.3.c Sprinkling, Rolling and Compacting

Immediately after each layer has been spread and shaped satisfactorily, each layer shall
be thoroughly compacted with suitable and adequate compaction equipment approved
by the Engineer.

Hard shoulder material, which does not contain sufficient moisture to be compacted in
accordance with the requirements of this Section, shall be sprinkled with water. The
Contractor shall supply the necessary water at his own expense.

Hard shoulder material containing excess moisture shall be dried prior to or during
compaction. Drying of wet material shall be performed by methods approved by the
Engineer, at the expense of the Contractor.

Each layer shall be compacted to at least 98% of the maximum dry density as
determined by STP 4.5 (Vibrating Hammer). Density of the compacted hard shoulder
shall be determined in accordance with STP 6.2 (150 mm or 200 mm diameter), with at
least one test being made for each 200 linear metres of hard shoulder.

The final shaping and rolling of the soft shoulder to the full width shall be made after
the hard shoulder is completed.

2.11.3.d Surface Tolerance

The finished surface of the hard shoulder shall follow the required grades, levels and
cross-sections and shall not vary from the specified level by more than 10mm. The
finished surface shall also not deviate by more than 10mm from a 3m long straight edge
laid perpendicular and parallel to the road centre-line. Any areas having irregularities
greater than 10 mm, shall be corrected by loosening, adding or removing material,
reshaping and re-compacting.

The minimum thickness at any single point shall be not less than the required thickness
less 10 mm. The hard shoulder shall also have an average thickness not less than the
required thickness when five thickness measurements are averaged in any 100m length
of completed shoulder.

The Contractor shall carry out at his own expense, the reconstruction of areas of hard
shoulder, which are too thin or too variable in thickness to meet this requirement.

2.11.4 Measurement
This item shall be measured as the number of cubic metres of material complete in
place and accepted. Measurements shall be based on the cross section of the hard
37
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

shoulder shown on the Drawings and the actual length measured on the surface of the
road.

2.11.5 Payment
This work measured as provided above shall be paid for at the Contract unit rates per
cubic metre for hard shoulder. The payment shall be full compensation for furnishing all
materials, hauling, placing, compacting, sprinkling, finishing and shaping and for all
labour, equipment, tools and other incidentals necessary to complete the work.

Hard shoulder shall be paid for at the Contract unit rates irrespective of the sources of
material used. All costs of excavating existing pavement or savings to the Contractor
from re-using materials excavated from existing pavements in section 2.2 should be
included under this item.

Pay items shall be:

2/11/1 Construction of Hard Shoulder Cubic Metre

38
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.12 SUBGRADE DRAINS

2.12.1 Description
This work shall consist of excavating, furnishing material, backfilling and finishing
drains to the prepared and accepted subgrade in accordance with these specifications
and the dimensions and cross sections shown on the drawings, or as required by the
Engineer.
2.12.2 Materials
The material for backfilling of subgrade drains shall be clean free draining sand and
gravel, free from any vegetable matter, soft particles, silt or clay.

The grading requirement of the drain backfill material shall conform to that shown in
Table 2.12-1 below:

Table 2.12-1

Sieve size % passing by weight

Min – Max
10 mm 100
5 mm 80-100
2.4 mm 65-95
1.2 mm 50-80
0.6 mm 25-50
0.3 mm 10-20
0.15 mm 0-10
0.075 mm 0-2

The separator material shall consist of suitable approved geotextile membrane. The
separator shall be of adequate strength to protect the drainage material from
contamination during construction of the pavement and shoulder and shall allow the
free passage of water whilst preventing the contamination of drainage backfilling
material with fine soil particles. Samples of proposed materials shall be submitted by
the contractor not less than one month prior to commencement of drainage works. The
Engineer shall order the contractor to carry out tests and field trials necessary to ensure
the adequacy of the material prior to approval. Geo-textile filter fabric used in the works
shall conform to the relevant sub-section of 2.14.

2.12.3 Construction Methods

Subgrade drains shall be excavated neatly by hand in the prepared subgrade to
dimensions and grades and intervals shown on the drawings or directed by the
Engineer. Drains on opposite sides of the road shall be staggered.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The excavation shall be backfilled with material in accordance with Table 2.12-1. The
backfill shall be compacted by hand ramming and struck off level with, or slightly
above, the finished subgrade level.

The finished backfill shall be immediately covered with approved separator material,
which shall extend 150 mm beyond the edges of the drain on all exposed faces. Any
joints in the fabric shall be overlapped by at least 150 mm. Fabric shall be held in place
by suitable means to prevent movement of the separator during construction operations.

Shoulder and pavement materials over the drain and separator shall be carefully placed
by hand for a depth of not less than 100 mm prior to placing and rolling of the general
shoulder pavement materials.

2.12.4 Measurement
Subgrade drains shall be measured in linear metres of drain completed and accepted.

Drains shall extend from a point vertically below the outer edge of the carriageway, or
paved shoulder, to the finished face of the embankment, or side ditch. In the event that
the contractor constructs the embankment to dimensions in excess as those shown on
the plans and sections additional length of subgrade drains shall be at the Contractor’s
expense.

2.12.5 Payment
The work measured as provided above shall be paid at the contract unit rate per linear
metre. Payment shall be full compensation for performing the work and providing all
labour, equipment, materials, tools and incidentals necessary to complete the works.

Pay item shall be:

2/12/1 Subgrade drains (300mm x 500mm) Linear Metre

40
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.13 GROUND IMPROVEMENT FOR WEAK EMBANKMENT

FOUNDATION
2.13.1 Scope
1. The scope for improving the ground of problematic sub-soil conditions comprises of
several alternatives and combination of more than one of the following alternatives.
The improvement may be chosen based on the sub-soil conditions:
2. Using geosynthetic drains (Prefabricated Vertical Drain (PVD) with surcharge to
achieve 90% consolidation of sub-soil within a prescribed time Stone/Sand columns.
3. Sand drain

2.13.2 STEEL SHEET PILES

2.13.2.1 Description
This specification outlines the method and resources involved in installation of sheet
piles to facilitate works related to shore protection and excavation. Any alternate
methods proposed by the contractor shall be at the discretion of Engineer and will have
to be prior approved before commencement of work.

2.13.2.2 Materials
All materials and workmanship shall be in accordance with the appropriate AASHTO,
British Standards, Codes of Practice and other specified standards current at the date of
tender except where the requirements of these Standards or Codes of Practice are in
conflict with this Specification in which case the requirements of this Specification shall
take precedence.

i) Source of Materials

The approved sources of supply of materials shall not be changed until the Contractor has
confirmed that the materials from the new source can meet all the requirements of the
Specifications. Materials failing to comply with the Specifications shall be removed promptly
from the site.

ii) Standard Sheet Piles

Unless specified otherwise, all steel for sheet piles shall be manufactured to ASTM, AISI, GB,
JIS, DIN, BS or any other equivalent standards

iii) Fabricated Sheet Piles and Storage

All fabricated piles, e.g., corners, junctions, box sections, and high modulus sections, shall be
fabricated and supplied to the sheet pile manufacturer's recommendations.
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

iv) Storage

If sheet piles of different grade steel are stored on site, each pile shall be clearly marked as to its
grade and piles of different grades shall be stored separately.

2.13.2.3 Construction Method

The Contractor shall submit all relevant details of the method of construction of the sheet pile
wall and the plant and monitoring equipment he plans to adopt for approval of the Engineer.

i) Ground Condition

The Contractor shall report immediately to the Engineer any circumstances which indicate that
in the Contractor's opinion, the ground conditions differ from the drawings, or which could have
been inferred from the subsurface investigation reports.

ii) Program of Works for Sheet Piles

The Contractor shall submit to the Engineer each day the intended program of sheet pile wall
construction for the following day and shall give 24 hours' notice of his intention to work
outside normal hours and at weekends.

The Contractor shall ensure that during the course of the work, displacement or damage does
not occur to the completed part of the work or any other elements that has already installed and
has been accepted by the Engineer.

iii) Records

The Contractor shall keep records of sheet pile walls and shall submit two signed copies of
these records to the Engineer not later than noon of the next working day after the element was
installed.

Any unexpected driving conditions shall be noted in the records.

iv) Supervision and Control of the Works

The Contractor shall have a competent full-time site supervisor at the site to be in charge for the
sheet pile wall construction or installation.

The site supervisor must be experienced in the sheet pile wall construction necessitated by the
Contract. The whole time of the site supervisor shall be devoted to the sheet pile wall works.
The site supervisor shall not be removed from the Works without the Engineer being notified in
advance with at least one week's notice.

The Contractor shall submit to the Engineer his quality plan one week prior to commencement
of sheet pile work. Subsequent revisions, amendments or additions shall be submitted to the

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Engineer for approval prior to their implementation. Quality assurance and quality control
documentation shall be made available to the Engineer.

v) Ordering of Piles

The Contractor shall ensure that the piles are available at the site for driving for incorporation in
the Works. All piles and production facilities shall be made available for inspection at all time
by the Engineer. Only new piles shall be used for permanent works. Piles shall be carefully
examined at the time of delivery. Damaged piles shall be removed from the site. The records of
testing of the steel used in the piles shall be submitted to the Engineer for his approval prior to
commencing the Works.

vi) Clutch Sealant

The Contractor shall apply a clutch sealant to the piles prior to pitching in accordance with the
manufacturer's recommendations. He shall supply details with his tender of the brand and
properties of the clutch sealant he plans to use.

vii) Tolerances on Setting Out

Marker pins for the sheet pile wall positions shall be set out and installed by the Contractor.
Prior to installation of the sheet pile wall, the element positions shall be checked by the
Contractor and confirmed by the Engineer.

Table 2.13-1. Dimensional Tolerances for Steel Sheet Pile

S1. No. Dimension to which Tolerance Applies Tolerance

Width
1 (a) Single piles ±2%
b) Interlocked piles ±3%
±5%
2 Thickness of section

3 Weight ±5%
4 Length ±50 mm
Squareness of cut for each section
5 a) parallel to line of wall ≤ 2%
b) perpendicular to line of wall ≤10 mm
6 Straightness ≤ 2% of pile length
7 Depth of Section ±4%

viii) Pile Handling and Driving

Pile Handling

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SECTION 7 GENERAL SPECIFICATIONS
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When assembling piles before pitching the Contractor shall ensure that the interlocks are clean
and free from distortion. All storage, handling, transporting and pitching of piles shall be carried
out in such a way that no significant damage occurs to piles and their coatings.

Pile Installation

The Contractor shall satisfy himself that the sheet piles can be installed adequately to the correct
depths through the reported or anticipated soil conditions. The Engineer shall be notified 24
hours before the commencement of driving.

The piles shall be guided and held in position by temporary gates with each pile properly
interlocked with its neighbor. Piles shall not by-pass one another in place of interlocking.

Where sheet piles are driven in panels, the end piles to each panel shall be driven in advance of
the general run of piles. After allowing for initial penetration, no pile in the panel shall be
driven to an excessive lead in comparison with the toe level of the panel in general and where
hard driving is encountered this lead should not exceed 1 m.

At all stages during driving the free length of the sheet pile shall be adequately supported and
restrained. The Contractor shall ensure that the sheet panels are driven without significant
damage or declutching.

The selection of driving and contracting plant shall be made having due regard to the ground
conditions and pile type. The sheet piles shall be driven to the specified level and/or resistance
or if hard driving is experienced, to practical refusal (which shall be defined as when the rate of
penetration is below 100 mm per minute when hammering continuously or 12 blows per 25 mm
movement when using the appropriate equipment), or when visible damage to the pile occurs.
Practical refusal for pile extraction shall be defined generally as when the rate of extraction of a
pile is below 100 mm per minute when back-hammering or pulling (with equipment normally
capable of withdrawing a pile) continuously (after an initial effort of 10 minutes). or when
damage to the pile head occurs. If the piles have not penetrated to the levels specified, or have
encountered obstructions, the Contractor shall submit details as to how he will overcome the
problem.

Pile driving hammers shall be correctly positioned on the pile so that the hammer will be
aligned as near to the axis of the pile as is practically possible. Freely suspended piling
hammers shall be equipped with correctly adjusted leg guides and inserts. Where a hammer is
mounted in a rigid leader, the leader shall be stable. The anvil block or driving plate shall be of
sufficient size to cover as much as possible of the cross-section of pile.

Piles previously driven shall not be used until the Contractor can demonstrate that they can meet
all the requirements of the Specification.

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The Contractor may provide each pile in more than one length. Spliced joints shall be designed
to cater for the combined effects of bearing, shear and bending stresses imposed upon the sheet
piles. Splices shall be located to avoid maximum stress positions. If splices are to be welded,
then these shall be designed in accordance with the guidelines given in AWS/BS 5135 or
equivalent standard and the manufacturer's recommendations. Weld metal shall not encroach
within the interlock areas so as not to interfere with the interlocking of the piles.

viii) Positional and Alignment Tolerance

Unless deflected by obstructions, sheet piles shall be installed within the following tolerances:

 in plan ± 75 mm of the given sheet pile line at commencing surface

 vertical 1 in 75
 level ± 50 mm of required top level.
Pile line dimensions shall be based on the nominal size of piles. Creep or shrinkage of the pile
lines shall not exceed the manufacturer's rolling tolerances.

ix) Welding Standard

For manual metal arc and semi-automatic welding of carbon and carbon manganese steels,
welding of piles and steel framework shall be carried out in accordance with AWS / BS 5135 or
equivalent. Defective welds shall be cut out and replaced. Where steel piles are to be spliced by
butt welding the interlocks shall not be welded unless a sealing weld is required.

x) Durability and Protection

All work associated with surface preparation and coating shall be undertaken inside a
waterproof structure.

xi) Piling Records

The following records shall be kept and a copy shall be submitted to the Engineer:

1. Pile reference number or location;

2. Pile type and grade of steel;
3. Pile length;
4. Type of hammer;
5. Date of driving;
6. Commencing surface level;
7. Depth driven;
8. Length of offcuts;
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SECTION 7 GENERAL SPECIFICATIONS
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9. Length of pile extensions;

10. The measurement of driving resistance at appropriate depths;
11. All information regarding interruptions, unexpected changes in driving characteristics,
obstructions and times taken in overcoming them.

2.13.2.4 Measurement and Payment

Steel sheet pile shall be measured in unit Metric Tonne. For installed piles directed to be cut off
before reaching the penetration depth shown in the Drawing, the portion cut off will not be
measured. Depreciation cost shall be considered for usage of same sheet pile multiple times
under the same contract.

Payment for Steel Sheet Pile shall cover all costs of furnishing, handling, storing and installing
piles including placing, driving, cutting holes and other materials and incidental works as per
the Specifications.

Pay Item shall be:

Pay Item No. Description Unit Measurement

2/13/1 Setting Sheet Piles Tonne

2/13/2 Setting Sheet Piles (Re-used) Tonne

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2.13.3 PRE-FABRICATED VERTICAL DRAIN (PVD)

The following section will replace section 2.13.2 of the draft specification of RHD.

2.13.3.1 Description

This Specification covers the requirements for the supply and installation of prefabricated
vertical drains (PVD) plus the associated works for the purpose of achieving the desired degree
of consolidation settlement at specified locations.

The Contractor shall provide all necessary resources including skilled labor, proper
machine/tools, and materials to complete all the scope of works for the installation of PVD in
accordance with the approved method statement, shop drawings, and this specification. Any
alternate methods proposed by the contractor shall be at the discretion of Engineer and will have
to be prior approved before commencement of work.

Figure 13-1. PVD installation process

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2.13.3.2 Materials

The material and equipment used for testing shall be prior approved by the Engineer

i) Geosynthetic Drain: Geosynthetic strip or band drain shall be manufactured by an ISO

9001 or equivalent certified manufacturer. It shall consist of a corrugated or studded or
3D mesh consisting of an inner core of thick polyester fused at intersection, wrapped in
a non-woven geotextile. Band drain shall be of width and thickness as specified in the
design and shall be a minimum of 100 mm width and 4mm thickness. The core shall
serve as the drainage medium conveying the core water from the soft subsoil to the
drainage layer at the top. The core shall be of three dimensional meshes made of
polyester or equivalent. The filter should be non-woven needle punched adhesive-
bonded fabric. The filter and the core shall be ultrasonically welded together at the edges
to produce a fully integrated product. The drain shall conform to the properties specified
in the table below:

Table 2.13-2. Geometric properties of drain

Property Test Designation Specified Requirements

Dimension of Width - 100 ± 5 mm
PVD Drain Thickness ASTM D5199 ≥4 mm

Table 2.13-3. Physical and Hydraulic Properties of Drain

Property Test Method Proposed Remarks

Values
Tensile Strength (full width of ASTM D4595 or
>2.5 kN
PVD) equivalent
Elongation at 1.0 kN (full ASTM D4595 or
≤ 10%
width of PVD) equivalent
Discharge capacity of new
ASTM D4716 or
straight PVD at 250 kPa & ≥ 500m3/year
equivalent
hydraulic gradients of 1
Tensile strength of filter ASTM D4595 or
>3 kN/m
jacket* equivalent
Apparent opening size of filter ASTM D4751 or < 75 um
jacket (O95 ) equivalent
ASTM D 4833 or
Puncture Resistance > 0.1 KN
equivalent
Coefficient of permeability of ASTM D4491 or
>1x10-4 m/s
filter jacket equivalent
O95/D15 (Opening Size of
Filter/Grain ≥3
Size of Clay)
O50/D50 (Opening Size of
< 24
Filter/Grain
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SECTION 7 GENERAL SPECIFICATIONS
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Property Test Method Proposed Remarks

Values
Size of Clay)
*For installations deeper than 25 m or in difficult soil conditions, a minimum tensile
strength of 6 kN/m in the longitudinal direction for filter jacket may be adopted. (BS
EN 15237:2007 or equivalent).

Test results (ASTM D4595) or equivalent on spliced/joined PVD by independent

ISO/IEC 17025 accredited laboratory shall be included, if relevant.

Engineer reserves the right to take any additional individual samples at any time for
tests by independent ISO 17025 accredited laboratory whenever the PVD is
suspected to be defective.

The drains shall be installed to depths and at spacing as per the design and drawings. The
Contractor shall submit to the Engineer the complete scheme for the installation of vertical band
drains along with the particulars and test results from the manufacturer showing conformance to
the specifications. Unless specified otherwise, the design of the ground improvement measures
shall be to achieve 90 percent consolidation in the time prescribed by the employer. The
equipment and the methodology for installation of the drains shall satisfy the specified
requirement of the prescribed degree of consolidation and the time for achieving the same.

ii) Granular Sand Blanket: After installation of the vertical band drains in the sub-soil, a
blanket of well-draining granular material/coarse sand (natural or crushed) conforming
to grading given in below table of specified thickness compacted to a density of 75 to 80
percent of maximum dry density obtained by heavy compaction shall be provided. The
granular sand blanket shall be exposed to atmosphere at its periphery for dissipation of
pore water pressure.

Table 2.13-4. Gradation of Granular Sand Blanket

Present Passing by Weight (Min-Max)

Sieve Designation Type A Type B Type C
63 mm 100 - 100
37.5 mm 100 100 85-100
25.00 mm 100 -
19 mm 100 - 0-20
9.5 mm 100 45-100 0-5
4.75 mm 85-100 - -
3.35 mm - 25-80 -
2.00 mm 50-100 - -
0.850 mm 25-90 - -
0.600 mm - 8-45 -
0.425 mm 10-75 - -
0.300 mm 0-65 - -
0.150 mm 0-35 0-10 -
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SECTION 7 GENERAL SPECIFICATIONS
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0.75 mm 0-3.0 0-5 -

iii) Geotextile Fabric for Separation and Drainage: The requirements of synthetic geotextile
shall conform to the requirement in geosynthetic section.

2.13.3.3 Construction and Installation Requirements

The Contractor shall prepare and submit method statement for installation of PVD/vertical band
drains and the associated works along with Drawings to the Engineer for prior written approval
before commencement of work

i) Transportation and storage

a. All the PVD drain materials supplied and delivered to site shall be labelled or
tagged for project/sample identification and other quality control purposes. Each
pallet shall be identified by the manufacturer name/logo and lot number, individual
roll number, date of manufacture, manufacturer and product identification of the
filter jacket and core.
b. All PVD delivered to site shall be recorded in site diary and/or in file with delivery
note/order readily for inspection by the Engineer in an approved format.
c. All PVD shall be properly covered and protected by heavy-duty plastic sheet from
sunlight, mud, dirt, dust, debris and other detrimental substances during transport
and on-site storage. The Contractor shall ensure that the PVD is in good condition
and properly stored in a covered area at the worksite. In the event of any damage or
deterioration of the PVD, the Contractor shall be liable to replace the affected
materials at his own cost.
d. All materials which are defective or damaged during transportation, handling or
storage and do not meet the minimum requirements of the PVD drain specifications
shall be rejected by the Engineer. No payment of any kind shall be made on the
rejected product.

ii) Drain Installation

a) PVD shall be located, numbered and pegged out by the Contractor using a baseline and
benchmark indicated by the Engineer. The Contractor shall take all reasonable
precautions to preserve the pegs and is responsible for any necessary re-pegging. The
installed location of the PVD shall not vary by more than 150mm from the plan
locations designated on the approved shop drawings.
b) PVD that are deviated by more than 150mm from the design plan location or are
damaged or improperly installed with machine swinging up and down, will be rejected
and abandoned in place.
c) PVD shall be installed from the working surface to the depth shown on the approved
shop drawings, or to such depth as directed by Engineer who may vary the depths,
spacing, or the number of drains to be installed, and may revise the plan limits for this
work as necessary.
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SECTION 7 GENERAL SPECIFICATIONS
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d) During PVD installation, the Contractor shall provide the Engineer with suitable means
of determining the depth of the advancing drain at any given time and the length of drain
installed at each location/zone by using electronic data logger.
e) PVD shall be installed using a continuous push using static weight. Installation
techniques using driving will not be permitted. Jetting techniques or pre-boring will be
permitted only after receiving written approval from the Engineer.
f) The installation shall be performed, without any damage to the PVD drain during
advancement or retraction of the mandrel. In no case will alternate raising or lowering of
the mandrel during advancement be permitted. Raising of the mandrel will only be
permitted after completion of an installation to the required depth.
g) The mandrel penetration rate should be between 150mm and 600mm per second.
h) Splices or connections in PVD should be carried out in such a manner so that it ensures
continuity of flow. At least 500mm of the previous roll should be overlapped with the
new roll.

Figure 13-1. PVD overlapping

i) The end of PVD shall be provided with a suitable anchor plate to ensure that the drain is
securely anchored at its base providing minimum disturbance to the in-situ soil.

Figure 13-2. Anchor plate at the end of PVD

j) The completed PVD shall be cut off neatly at least 300mm above the working grade, or
as otherwise specified on the drawings.
k) The Contractor may use augering, spudding, or other approved methods to loosen the
soil and any obstruction material prior to the installation of PVD. The obstruction
clearance procedure is subjected to the approval of the Engineer; however, such,
approval shall not relieve the Contractor of his responsibility to clear obstructions in
51
SECTION 7 GENERAL SPECIFICATIONS
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accordance with the specification. If augering is the selected method, the augers shall
have a minimum outside diameter equal to the largest horizontal dimension of the
mandrel, shoe or anchor, whichever is greater.

iii) Additional Surcharge / Pre-Load

a) Addition of surcharge load by approved embankment material shall be placed over the
geotextile layer up to a height as per the design requirement.
b) The addition of surcharge shall be placed with adequate side slope to avoid any slope
failure.
c) The addition of surcharge shall be kept in place for a period as per the design to achieve
desired degree of consolidation. After ascertaining that the desired degree of
consolidation is achieved, the addition of surcharge which is not forming part of
permanent work/ embankment shall be removed to the required level as per drawings
d) Removal of additional surcharge material shall be done without damaging the road
embankment. After removal of additional surcharge, the damaged embankment top, if
any, shall be made good as instructed by the Engineer

iv) Instrumentation and Monitoring

Monitoring the behavior of the sub-soil/ embankment construction shall form part of the work.
The design shall be based on the gain in the shear strength of the subsoil due to consolidation
process. The following critical parameters shall be monitored:

a) Casagrande open standpipe type / Vibrating Wire type piezometer shall be used for
measurement of pore pressure depending upon the requirement of the project and
approval of Engineer in Charge. The detail specifications of the piezometer type along
with calibration certificates as well as method statement for installation and monitoring
will have to be submitted to the Engineer prior to commencement work.
b) Settlements shall be measured by installing platform type settlement gauges, which
consisting of a Wooden base plate of at least 1000 mm square and 50 mm thick; Gl pipe
of at least 25 mm dia fitted to the base plate with a suitable sleeve arrangement and nuts
and bolts and Outer loose-fitting sleeve, to prevent soil form coming into contact with
the inner pipe. Settlement gauges shall be installed at the ground level, before the
starting of the fill construction. These shall be installed locations specified by the
Engineer. The readings of settlement gauges also form the basis to estimate the quantity
of surcharge forming part of permanent work. The number of settlement gauges shall be
decided by the Engineer keeping in view this aspect.
c) The shear strength parameters of the subsoil [unconfined compressive strength (UCS)]
shall be measured at locations specified by the Engineer at the end of specified stage of
surcharge loading in order to compare the actual details with the design assumptions.
Alternate methods for determining shear strength may also be adopted based on
proposal of the contractor subjected to approval of the Engineer.
d) During the placing of the surcharge and compaction, the Contractor shall take utmost
care so that the monitoring instruments are not damaged. Compaction by small vibratory
rollers shall be done for 1.5 m around the monitoring instruments and bigger rollers shall
not be used near the monitoring instruments. Similarly, care shall be taken that
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SECTION 7 GENERAL SPECIFICATIONS
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movement of dumpers does not damage the monitoring instruments.

e) The readings of the piezometers and the settlement gauges shall be recorded at the
following frequency.

 Daily reading shall be taken in stretches where filling/ surcharge operations are in
progress. Weekly readings shall be taken in stretches, where no filling/ surcharge is
being done.

 Weekly readings shall be taken after the desired fill/ surcharge height is achieved, till the
next stage filling commences. All data shall be recorded in a register and maintained
properly.

 The Data from the monitoring instruments provides the background for regulating the
rate of placing the fill/ surcharge as well as the waiting period between stages

The water which will come out from the subsoil through vertical drains will be accumulated at
temporary ditches to be dug at nearby areas and the accumulated water will be dewatered
regularly from the ditches to the outfalls as directed by the Engineer.

f) The water which will come out from the subsoil through vertical drains will be
accumulated at temporary ditches to be dug at nearby areas and the accumulated water will be
dewatered regularly from the ditches to the outfalls as directed by the Engineer.

2.13.3.4 Measurement and Payment

Rate shall include cost of materials, installation, operations involved in pre- loading/additional
surcharge, dewatering, labor, plant hire, material storage and handling expenses for completing
the work including submission of construction drawings and provision of specialist attendance
& supervision at site for (i) geodrain; (ii) sand blanket; (iii) geofabric;(iv) instrumentation and
monitoring; and (v) permanent embankment part of surcharge as described above.

Pay Item No. Description Unit Measurement

2/13/3 Prefabricated Vertical Drains Lin meter
2/13/4 Geo-textile fabric – separation Square meter
(non-woven)
2/13/5 Geo-textile fabric – high Square meter
strength one way (woven)
2/13/6 Geo-textile fabric – high Square meter
strength two way (woven)
2/13/7 Granular drainage blanket. Cubic meter
2/13/8 Settlement measuring Nos.
instrument including plate,
settlement pin, Piezometer,
Inclinometer

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2/13/9 Placement of Preload Cubic meter

(Surcharge) which will be
removed

2.13.4 SAND COMPACTION PILE (SCP)

2.13.4.1 Description

The sand compaction pile (SCP) method is used to strengthen soft/loose ground by installing
sand or a similar material into the soft ground via a casing pipe and vibrating the sand to
produce firmly compacted sand piles in the ground. The method’s basic improvement principles
are “compaction” and “drainage”.

This Specification covers the requirements for the installation of Sand Compaction Pile plus the
associated works for the purpose of creating a composite ground with higher shear strength
values. Meanwhile, while using the application for sandy soil, the method is used for decreasing
void ratio and creating soil with high density, high bearing capacity, and high resistance to
liquefaction.

The Contractor shall provide all necessary resources including skilled labor, proper
machine/tools, and materials to complete all the scope of works for the installation of SCP in
accordance with the approved method statement, shop drawings, and this specification. Any
alternate methods proposed by the contractor shall be at the discretion of Engineer and will have
to be prior approved before commencement of work.

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SECTION 7 GENERAL SPECIFICATIONS
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Figure 2.13-4. Procedure of Sand Compaction Pile

2.13.4.2 Materials

The material and equipment used for testing shall be prior approved by the Engineer
i) Sand: Grading for the Sand Column shall conform to one of the grading envelopes A or
B of Improve subgrade. FM of the sand shall not be less than 0.8.
ii) Steel Casing Pipe: The casing pipe shall be of mild steel. The casing pipe length shall
have at least 2m more length than the Sand Pile.
iii) Drop Hammer: Solid cylinder-shaped drop hammer having at least 1 ton weight and
sectional area that can play within the casing pipe shall be used for compaction.
Diameter of hammer section shall be around 6mm to 8mm lower than the opening of the
casing pipe.

2.13.4.3 Construction and Installation Requirements

The Contractor shall prepare and submit a method statement for installation of Sand
Compaction Pile (SCP) and the associated works along with Drawings to the Engineer for prior
written approval before the commencement of work

a. A two-end open casing pipe of specified diameter and length will be placed
vertically at the designed point of natural ground surface for sand pile construction
b. A small hole of about 50mm / 100mm depth shall be made on the ground with the
hammer. Casing pipe shall be held in a position with the wire rope connected to the
winch, i.e., downward movement of the casing pipe shall be restrained
c. Sand shall be placed within the casing pipe up to a depth of about 1m. Sand placed
at the tip of the casing pipe shall then be compacted to form a solid mass (artificial
shoe) by the hammer holding the casing pipe in position.
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SECTION 7 GENERAL SPECIFICATIONS
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d. Casing pipe shall then be allowed to go downwards with the application of hammer
blows (minimum dropping height of hammer shall be greater than 1.5m) on the
artificial tip and shall be penetrated up to the desired design depth.
e. As the casing pipe reaches the desired depth, the pipe shall be pulled back by about
300mm from the lowest point and then held firmly from the winch. Artificial shoe
shall be then detached from the casing pipe with the hammer blows. Sand shall be
discharged into the casing pipe up to a depth of about 450 – 600mm
f. The discharged sand shall be compacted and enlarged by driving the hammer
numerous times into the sand.
g. After proper compaction, the casing pipe shall be pulled back about 300mm, and
sand shall be discharged and then compacted again.
h. Pipe raising, sand discharging, and hammer driving procedure is repeated numerous
times until the casing pipe reaches the ground surface, forming a complete
compacted sand pile.

Quality Control

a) During the construction, the depth of casing pipe and position of the sand in the
casing pipe are continuously measured for quality control and assurance.
b) The volume of sand measured on the ground, shall be between 135% to 150% of the
designed value.
c) Effect of improvement of the foundation shall be confirmed by SPT or any other
method approved by the Engineer amongst the center of four piles to satisfy the
bearing capacity requirements.

2.13.4.4 Measurement and Payment

The rate shall include the cost of providing all materials, tools, equipment, labor, supervision,
and incidentals necessary to complete the work as per these specifications

Pay Item No. Description Unit Measurement

2/13/10 Execution of sand compaction Linear Meter
pile through displacement
method by using tripod rig,
mechanical winch, dop
hammer (minimum 1 ton),
casing pipe up to a depth of
10m

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2.14.1 GEOSYNTHETICS FOR ROAD AND BRIDGE WORKS

2.14.1.a Application and General Requirements

The specification covers the various applications of geosynthetic materials for use in
road and bridge works including supplying and laying as per contract specifications.
Geosynthetic is a general classification for all synthetic materials used in geotechnical
engineering application. It includes geotextiles, geogrids, geo strips, geomembranes,
recomposites, geosynthetic mats, paving fabric and glass grid etc. Geo fabrics made
from natural fibers such as jute, and coir referred to herein under natural geotextiles
may also be used in different geotechnical engineering applications.
i) Geotextiles: Any permeable synthetic textile used with foundation, soil, rock, earth, or
any other geotechnical engineering-related material as an integral part of a human made
project, structure, or system. The geotextile fabric shall be a woven, non-woven or
knitted fabric consisting of long-chain polymeric filaments or yarns such as
polypropylene, polyethylene or polyester or any combination thereof, formed into a
stable network such that the filaments or yarns retain their relative position to each
other.

There are several application areas for geotextiles requiring specific functions namely
separation, filtration, drainage, reinforcement or a combination thereof.

ii) Geogrids: A deformed or non-deformed netlike polymeric material used with

foundation, soil, rock, earth, or any other geotechnical engineering- related material as
an integral part of human-made project, structure, or system.

Geogrids have relatively high strength, high modulus, and low-creep-sensitive

polymers with apertures varying from 10 to 100 mm in size or more. The
openings/holes in geogrids are either elongated ellipse, near squares with rounded
corners, squares or rectangles. Geogrids can be of uni-axial grid, bi-axial grid or three-
dimensional grids. Geostrip is another form of geogrid, which is used in reinforced soil
structures. It is primarily made of synthetic material in strips and is made from high
tenacity polyester yarn and contained in a suitable polymer sheath.

These are used as reinforcement in pavements and reinforced soil slopes.

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SECTION 7 GENERAL SPECIFICATIONS
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iii) Geomembranes: An essentially impermeable membrane (liner or barrier) used with

foundation, soil, rock, earth, or in any other geotechnical application as an integral part
of human-made project. Geomembranes are made from PVC or polyethylene sheets,
which are duly protected from ultraviolet exposure by carbon black or any antioxidants
and thermal stabilizers. These are used as capillary cut off in roads in water logged
areas.

iv) Geonets: Geonets are used in combination with other types of geosynthetics. These are
usually formed by continuous polymeric ribs at acute angle to one another. When the
ribs are opened relatively large size apertures are formed in a net like configuration.
These are used in combination with other geosynthetic materials to form a composite
material.

v) Geocomposite: A manufactured material, which could be a combination of any two or

more synthetic materials like geotextiles, geogrids, geonets and geomembranes etc., in
laminated or composite form. One of the popular forms of geocomposite is Drainage
Composite. Drainage Composites are formed by combining geotextile or geomembrane
with a core of geonet or serrated/corrugated polymeric materials. Prefabricated Vertical
Drains (PVD)/Band Drains and Fin Drains come under the category of geocomposites.

vi) Geosynthetic Mats: These are two dimensional or three-dimensional mats with
specified thickness, made of multi-filaments, with apertures to allow vegetation growth
for erosion control application. Geosynthetic mat consists of UV stabilized non-
degradable polypropylene/polyethylene or similar polymer fibers that are extruded or
heat bonded to provide a dimensionally stable matrix. A tension element like steel wire
mesh or geogrid shall be included in these mats as reinforcement, where these mats are
required to possess more strength against erosive forces, like in steep slopes or in heavy
rainfall areas. These are used for erosion protection of slopes.

vii) Natural Geotextiles: These geotextiles are made of natural fibers like jute or coir. The
blankets/mats/mesh made of these fibers are sometimes further reinforced with
polymeric nettings to enhance its tensile strength and for holding the fibers intact. The
polymer netting is securely stitched on both sides of the fabric to form a strong quilted
mat. These fabrics have excellent drapability and aid in quick growth of vegetation and
are used for erosion control applications

viii)Paving Fabric and Glass Grids: The paving fabrics are non-woven heat set material,
consisting of at least 85% by weight of polyolefins, polyester or polyamides. They are
heat bonded only on one side.

Glass grids are either a composite glass fiber reinforced geogrid with continuous
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filament nonwoven geotextile chemically /mechanically bonded to the grid, or

bituminous coated glass fiber geogrids with or without adhesive on one side of the grid.

The paving fabric, glass grids and composite of fabric and glass grids are used in
bituminous pavements to act as stress relieving membrane and crack retarding layer
within the pavement structure. The paving fabric also serves the function of water
barrier.

2.14.1.b Testing, Certification and Acceptance

Geosynthetic Materials Shall be Tested and Certified in the Following procedure.
a) The manufacturer shall have ISO certification for manufacturing process and quality
control.
b) The. manufacturer shall provide manufacturer's test certificate for every lot supplied
from the factory.
c) The supplier shall provide third party test reports from an independent laboratory
with valid accreditation for all the test values in Manufacturer's test certificate.
d) Geosynthetics shall be tested in accordance with tests prescribed by either by ASTM,
EN, BS or ISO shall be conducted.
e) The material shall meet the requirements as specified in the contract.

2.14.1.c Marking
Geosynthetic rolls shall be marked with the following information:
a) Manufacturer's name
b) Roll number
c) Grade
d) Length
e) Date of manufacture; and
f) Product identification details

2.14.1.d Packing, Storage and Handling

a) Each geosynthetic roll shall be wrapped with a material that will protect the geosynthetic
from damage due to shipment, water, sunlight and contaminants. The protective
wrapping with a tarpaulin or opaque plastic sheet shall be maintained during periods of
shipment and storage.
During storage, geosynthetic rolls shall be elevated off the ground and adequately
covered to protect from site construction damage, precipitation, prolonged ultra-violet
radiation including sunlight, chemicals that are strong acids or strong bases, flames
including welding sparks, temp temperature in excess of 71 degree centigrade , and any

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other environmental condition that may damage the physical properties of the
geosynthetics.
b) If the outer layer of the geosynthetic is damaged, or exposed to sunlight for a period
beyond that is permitted the outermost wrap of the rolls shall be discarded, and only the
remaining undamaged/unexposed material shall be used. If the geosynthetic rolls
become wet, the water proof cover shall be removed, the rolls shall be elevated off the
ground and exposed to wind in order to dry the fabric. The paving fabric used with
bitumen overlays shall be completely dry prior to installation.

2.14.2 GEOTEXTILES FOR DRAINAGE, SEPARATION AND EROSION

CONTROL

2.14.2.a Scope
The work covers the use of geotextile materials for drainage, separation/filtration and
erosion control works including supplying and laying as per design, drawing and these
specifications.
For drainage/filtration function, geotextile shall be able to convey water across the plane
of the fabric throughout its design life. For separation function the geotextile shall
prevent intermixing of two layers of dissimilar materials, throughout the design life of the
structure.
The geotextile as a filter material below erosion control measures like stone pitching or
stone filled mattresses over the slopes, shall allow the water to flow out and at the same
time prevent the loss of soil under the protective measures.

2.14.2.b Material
a) Strength Requirement
The minimum strength of geotextile in terms of MARV under different installation
conditions shall be as specified in Table 14-1
Table 2.14-1 : Minimum Geotextile Strength Property Requirements
Installation Type Strength Property Requirement (MARV)
Condition Grab Tear Puncture Burst Strength in
Strength Strength in Strength in Newton (N) as per
in Newton Newton (N) Newton (N) ASTM D 3786
(N) as per as per as per
ASTM D ASTM ASTM D
4632 D4533 6241
Elongation at Failure
<50 >50 <50 >50 <50 >50 <50% >50%
% % % % % %
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Harsh Type 1400 900 500 350 2800 2000 3500 1700
installation 1
condition
Moderate Type 1100 700 400 250 2250 1400 2700 1300
Installation II
condition
Less Type 800 500 300 180 1700 1000 2100 950
Severe Ill
Installation
condition

Note:
1) All numeric values in the above table represent Minimum Average Roll Value (MARV)
in weaker principal direction. The MARV is derived statistically as the average value
minus two standard deviations.
2) When the geotextiles are joined together by field sewing, the seam strength shall be at
least 60 percent of the material's tensile strength. All field seams shall be sewn with
thread as strong as the material in the fabric.
b) Ultraviolet Stability Requirements
The material shall satisfy the ultraviolet stability requirements specified in Table: 14-2.
Table 14-2 : Requirements for Ultra Violet Stability
Sl. Properties of Fabric Requirements (Retained Strength)
No.
1) Grab Strength Not less than 70% after 500 hours of
2) Tear Strength exposure
3) Puncture Strength
4) Burst Strength

c) Hydraulic Requirements for Various Applications

i) Subsurface Drainage
The geotextile shall conform to the physical requirements specified in Table 14-3.

Table 2.14-3 : Geotextile Requirements for Subsurface Drainage

ln·situ Passing 0.075 Permittivity, per sec, as per Maximum Apparent
mm Sieve(%) ASTM D 4491 Opening Size, mm ASTM D
4751/1S:14294-1995
<15 0.5 0.43
15 to 5 0.2 0.25
>50 0.1 0.22

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The type of geotextile shall be decided by the Engineer depending upon the
installation conditions.
ii) Separation
The geotextile for different subgrade soil conditions shall conform to the requirements
given in Tables 2.14-4 and 2.14-5.
Table 2.14-4 : Geotextile Requirements for Separation (Subgrades Soaked CBR >3)
S. No. Geotextile Property Requirement

0.02 sec-1 (per

1) Permittivity as per ASTM D 4491 sec)

Maximum Apparent Opening Size as per ASTM D

2) 4751 0.60 mm

Table 2.14-5 : Geotextile Requirements for Separation (Subgrades Soaked CBR≤3)

S. No. Geotextile Property Requirement

1) Permittivity as per ASTM D 4491 0.05 sec-1 (per sec)

Maximum Apparent Opening Size as per ASTM D

2) 0.43
4751

iii) Erosion Control

The geotextile for erosion control shall conform to requirements given in Table 14-6.

Table 2.14-6 : Geotextile Requirements for Erosion Control

ln·situ Soil Passing Permittivity, per sec Maximum Apparent
0.075 mm Sieve(%) ASTM Opening Size, mm ASTM
D 4491 D 4751
<15 0.5 0.43
15 to 5 0.2 0.25
>50 0.1 0.22

2.14.2.c Construction

2.14.2.c.1 General
Exposure of geotextiles to the elements between lay down and cover shall be a maximum
of 14 days to minimize damage potential. In trenches, after placing the backfill material,
the geotextile shall be folded over the top of the filter material to produce a minimum
overlap of 300 mm for trenches greater than 300 mm wide. In trenches less than 300 mm
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SECTION 7 GENERAL SPECIFICATIONS
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wide, the overlap shall be equal to the width of the trench. The geotextile shall then be
covered with the subsequent course. Overlap at roll ends and at adjacent sheets shall be a
minimum of 450 mm, except when placed under water. In such instances, the overlap shall
be a minimum of 1 m. Where seams are required in the longitudinal trench direction, they
shall be joined by either sewing or overlapping. All seams and overlaps shall be subject to
the approval of the Engineer.
Care shall be taken during installation so as to avoid any damage to the geotextile.
Damages, if any, during installation shall be repaired by placing a geotextile patch over the
damaged area and extending it 1m beyond the perimeter of the tear or damage, or as
approved by the Engineer.
2.14.2.c.2 Subsurface Drainage
Construction shall conform to the specifications.

2.14.2.c.3 Separation
After preparation of subgrade as per the specifications along the road alignment,
geotextile shall be rolled out as indicated in the drawings. The entire roll shall be placed
on the sub grade and unrolled as smoothly as possible. Wrinkles and folds in the fabric
shall be removed by stretching as required. Adjacent rolls of geotextiles shall be
overlapped, sewn, or joined as required. For curves, the geotextile shall be folded or cut
and overlapped in the direction of construction. Folds in the geotextile shall be stapled
or pinned approximately 0.6 m centre-to-centre. Before covering, the condition of the
geotextile shall be checked for damage (i.e., holes, nips, tears, etc) by the Engineer.
Before placing the first lift of granular sub-base on the geotextile, a trial stretch of 100
m shall be laid as per roll width to establish a proper construction methodology of
placing and compacting the sub-base in a manner that no damages are caused to the
separation layer of geotextile.

2.14.2.c.4 Filter Layer under Stone Pitching for Erosion Control

The geotextile shall be placed in intimate contact of soil ensuring slight tension, to
avoid wrinkles or folds and shall be anchored on a properly shaped surface as indicated
in drawings and approved by the Engineer. It shall be ensured that the placement of the
overlying material be placed in such a manner that it does not tear/puncture the
geotextile. Anchoring of the terminal ends of the geotextile shall be accomplished as per
drawings through the use of key trenches or aprons at the crest and toe of slope.
The geotextile shall be placed with the machine direction parallel to the direction of
water flow. Adjacent geotextile sheets shall be joined by either sewing or overlapping.
The pitching shall begin at the toe and proceed up the slope. Big sized boulders shall
not be allowed to roll down the slope. Any geotextile damaged shall be either replaced
or repaired with a patch, as directed by the Engineer, at the cost of the contractor.

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2.14.2.d Measurement for Payment

The measurement for payment of Geotextile for sub surface drains shall be in square
metre along with drain construction and drain construction will be separate item.
The geotextile for separation and for filter layer shall be measured in square metres
as per planned dimensions with no allowance for overlapping at transverse and
longitudinal joints. Excavation, back fill, bedding and cover material shall be measured
separately as per relevant clauses of the Contract.

2.14.2.e Rate
The contract unit rate for the accepted quantities of geotextile for drains, separation and
filter layer in place shall be full compensation for furnishing, preparing, hauling, and
placing geotextile including all labour, freight, tools, equipment, and incidentals to
complete the work as per specifications.
2/14/1 Furnishing and installing Geotextile for sub-surface drain Square metre
/separation / filter layer (as detailed in the Drawing or as
directed by the Engineer)

2.14.3 GEOGRID
2.14.3.a Scope
The work covers the use of geogrids in sub-base of pavement, erosion control of slopes,
reinforced soil slopes and reinforced soil walls including supplying and laying as per
design, drawing and these specifications.

2.14.3.b Materials

2.14.3.b.1 General
Geogrids shall be either made from high tenacity polyester yarn jointed at cross points by
weaving, knitting or bonding process with appropriate coating or from polypropylene or
polyethylene or any other suitable polymeric material by an appropriate process. Geogrids
manufactured by extrusion process are integrally jointed, mono or bi-directionally oriented
or stretched meshes, in square, rectangular, hexagonal or oval mesh form. The geogrids
manufactured by weaving/knitting/bonding process shall be formed into a stable network
such that ribs, filaments or yarns retain their dimensional stability relative to each other
including selvages.

2.14.3.b.2 Sub-base Reinforcement

Geogrid for use as reinforcement of sub-base layers of flexible pavements shall meet the
requirement as per the design subject to the minimum requirements as given in Table 14-7.

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2.14.3.b.3 Erosion Control

The geogrid for erosion control application shall have the minimum tensile strength of 4
KN/m, when tested as per ASTM D5035 (Minimum Average Roll Value in Machine
Direction). The aperture opening size shall be minimum 20 mm x 20 mm and average grid
thickness shall be minimum 1.0 mm. Geogrid for erosion control application shall be UV
stabilized. The geogrid shall have ultraviolet stability of 70 percent after 500 hrs exposure
as per ASTM D 4355.
Table 14-7 : Minimum Requirements for Geogrid for Sub-Base of Flexible Pavement
Property Test Method Unit Requirement
Stiffness at 0.5% ≥350; both in machin and cross-machine
strain ISO-10319 kN/m direction
Tensile strength ASTM ≥15% of Tult ; both in machine and cross-
@2% Strain D6637 kN/m machine direction
Tensile strength ASTM ≥20% of Tult ; both in machine and
@5% Strain D6637 kN/m cross-machine direction
Junction Efficiency
for extruded ASTM-WK
geogrids 14256 - 90% of rib ultimate tensile strength
ASTM
Ultraviolet stability D4355 - 70% after 500 hrs exposure

Note:
1) All numerical values in the Table represent MARV in the specified direction.
2) All geogrids shall be placed along machine direction parallel to the centre line of
roadway alignment.

2.14.3.b.4 Reinforced Soil Slopes and Walls

The strength and other requirements shall be as per specification/design .

2.14.3.c Installation and Construction Operations

2.14.3.c.1 Sub-base Reinforcement

Prior to laying of geogrid, the surface shall be properly prepared, cleaned and dressed to the
specified lines and levels as shown on the drawings. The geogrid shall be laid within the
pavement structure as shown on the drawings. Geogrid reinforcement shall be placed flat,
pulled tight and held in position by pins or suitable means until the subsequent pavement
layer is placed. No vehicle shall be allowed on geogrid unless it is covered by at least 150
mm thick sub-base material.

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2.14.3.c.2 Erosion Control

The geogrid for erosion control applications shall be installed in accordance with the
manufacturer's recommendation and as per Clause.

2.14.3.c.3 Reinforced Slopes and Walls

The geogrid for reinforced slopes and walls shall be installed in accordance with the
manufacturer's recommendation.

2.14.3.d Measurement for Payment

The geogrid shall be measured in square metres as per planned dimensions with no
allowance for overlapping at joints, anchoring at toe and crest of the slope. Excavation,
back fill, bedding and cover material shall be measured separately as per relevant clauses
of the Specifications. Reinforced soil slopes and walls shall be measured separately.

2.14.3.e Rate
The contract unit rate for the accepted quantities of geogrid in place shall be in full
compensation for furnishing, preparing, hauling, and placing geogrid including all
labor, freight, tools, equipment, and incidentals to complete the work as per
specifications.
Furnishing
2/14/2and Furnishing and installing Geogrid (as detailed in the Square metre
Drawings or as directed by the Engineer)

2.14.4 GEO-COMPOSITE DRAIN

Specifications of PVD shall conform to specifications outlined under section 2.13.3

2.14.4.1 Description
The work covers the use of geo-composite drainage systems behind retaining walls, slopes,
canals, pavement etc. The Contractor shall provide all necessary resources including skilled
labor, proper machine/tools and materials to complete all the scope of works for installation of
geo-composite drain as per specification based on the approved method statement. Any
alternate methods proposed by the contractor shall be at the discretion of Engineer and will have
to be prior approved before commencement of work.

2.14.4.2 Materials
Geo-composite drains for between fills and retaining wall: The geo-composite drain shall
meet the requirements mentioned in the following table for application behind retaining wall
and between two fills.

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Table 2.14-8. Requirements of geo-composite drains

Properties Test Method Behind retaining Between two
wall fills

A) Geo-composite Drain Non-woven geotextile on both the sides

Draining Core shape Multifilament net Multifilament

or mat net or mat

Thickness at 2 kPa EN 9863-1 or 7 mm (+/-10%) 8.9mm (-10%)

equivalent

Mass per unit area* (This is ISO 9864 or 990 g/m2 (±

720 g/m2 (+/-15%)
not performance parameter) equivalent 10%)

Tensile Strength Machine ISO 10319 or 18 kN/m (- 5) 21 kN/m ( -

Direction equivalent 1kN)

In plane flow capacity MD 3.7 L / (m.s)

2.30 L / (m.s)
(soft/soft
Hydraulic Gradient, i = 1 at ISO 12958 or (rigid/soft contact)
contact) (+/-
20 kPa pressure equivalent (+/-30%)
30%)

ASTM D7361- Note more than

Reduction factor for creep for 07 & ISO Not more than 1.1
100 years at 100kPa 25619-1:2008 1.15
or equivalent

B) Geotextile Filter – Two

Number

EN ISO 10319 9.25 kN/m (-

Tensile Strength MD & CD 8 kN/m (-1.3)
or equivalent 1.7)

EN ISO 12236 1600 (-21%)

Static Puncture Resistance 1400 N (+/-20%)
or equivalent

EN ISO 13433 26 (+6)

Dynamic Puncture Resistance 26 mm (+22)
or equivalent

EN ISO 11058 110 (- 30)

Flux perpendicular to plane 100 l/(m2.s) (-30)
or equivalent

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EN ISO 12956 100 (± 45)

Apparent Opening Size, O90 110 micron (+/-50)
or equivalent

C) Drainage Core

Mass per unit area* (This is EN ISO 9864 or 740 (± 5%)

500 g/m2 (+/-10%)
not performance parameter) equivalent

Geo-composite drain for capillary cutoff: The geo-composite drain shall meet the
requirements mentioned in the following table for capillary cut-off application in pavement and
canal lining.

Properties Test Method Below pavement or horizontal

application of capillary cutoff

Geocomposite (Non-
woven geotextile on
both the sides

Draining Core shape Multifilament net or mat

Thickness at 2 kPa EN 9863-1 or 6 mm

equivalent

Mass per unit area*

(This is not ISO 9864 or
670 g/m2 (± 10%)
performance equivalent
parameter)

Tensile Strength ISO 10319 or 22 kN/m (- 3.0)

Machine Direction equivalent

In plane flow capacity

MD
ISO 12958 or 0.35 L / (m.s) (rigid/soft contact)
Hydraulic Gradient, i =
equivalent
0.1 at 20 kPa pressure

ASTM
Reduction factor for D7361-07 &
creep for 100 years at ISO 25619- Not more than 1.15
100kPa 1:2008 or
equivalent

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B) Geotextile Filter
– Two Number

EN ISO
Tensile Strength MD
10319 or 8 kN/m (-2.0_
& CD
equivalent

EN ISO
Static Puncture
12236 or 1400 N (-20%)
Resistance
equivalent

EN ISO
Dynamic Puncture
13433 or 33 mm (+15)
Resistance
equivalent

EN ISO
Flux perpendicular to
11058 or 100 l/(m2.s) (+/- 30)
plane
equivalent

EN ISO
Apparent Opening
12956 or 110 micron (+/- 50)
Size, O90
equivalent

EN ISO
External Membrane 10319 or 16 kN/m (-2.0)
equivalent

EN ISO 9864
Mass per unit area 120 g/m2 (-10%)
or equivalent

EN ISO
Tensile strength 10319 or 16 kN/m (-2.0)
equivalent

C) Drainage Core

Mass per unit area*

(This is not EN ISO 9864
430 g/m2 (+/- 7%)
performance or equivalent
parameter)

Geo-composite drain shall be tested for long term creep at accredited laboratory like TRI / SGI /
BTTG based on requirement of the Engineer and material having reduction factor for creep
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RFCR only shall be used. Uncertified reduction factors or default reduction factors from any
literature shall not be allowed to be adopted. Geo-composite drain shall be CE certified.

Geo-composite draining core and geotextile filter should not be cut from the drainage composite
for testing purpose. The core and filter should be tested preferably prior to making a composite.
For third party testing cire and filter shall be separately collected from the manufacturer.

2.14.4.3 Construction and Installation Requirements

The Contractor shall prepare and submit method statement for installation of geo-composite
drain before the commencement of work for the approval of Engineer.

a. The geo-composite drain shall be provided in wraps with a protective covering. A

tag or label, or other method of identification shall be attached to each wrapped
package indicating the: Manufacturer Name, Product Name and Style, and Roll
Identification Number. Rolls of geo-composite drain should not be dragged on the
ground, and they must be lifted off the ground before moving them.
b. Geo-composite drain should be adequately protected from ultraviolet (UV) exposure
during storage at the site. The protective wrapping, in which the geo-composite
drain come wrapped from factory, should be kept on till their installation. After
unwrapping, the geo-composite drain should be installed within a maximum of 14
days. If stored outside, they should be elevated from the ground surface and
adequately covered to protect them from site construction damage, precipitation,
UV radiation, including sunlight, chemicals that are strong acid/bases, flames
including welding sparks, temperature in excess of 71ºC, etc.
c. When geo-composite drains are assembled on site, the assemble area shall be clean
and dry. Geo-composite shall have 100mm extra geotextile on side edges for
overlap purpose. Joint parallel to the direction of flow and any exposed edge shall
be protected from the ingress of soil by wrapping with a minimum overlap of
150mm or other measures.
d. Geo-composite drains shall be capable enough of being connected longitudinally
and laterally into pipe systems or outflow purpose. Joint parallel to flow direction
and exposed soil shall be protected from ingress of soil by wrapping with a
minimum overlap of 150mm or other necessary measures

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e. In case of installation behind abutment / retaining wall slotted / perforated pipe may
be provided for horizontal drainage at the bottom, by placing geotextile wrapping
around the pipe

Figure 2.14-1. Details of Geotextile wrapping

f. Installation of geo-composite drains for pavement and linings shall be as per ASTM
D6088-06 (“Standard Practice for installation of geo-composite pavement drains”)
or other approved standards.

2.14.4.4 Measurement and Payment

The geo-composite drain shall be measured in linear meters as per planned dimensions with no
allowance for overlapping at joints, anchoring at toe and crest of the slope/wall/embankment.
Excavation, backfill, bedding and cover material shall be measured separately as per relevant
clauses of the Specifications.
The contract unit rate for the accepted quantities of geo-composite drain in place shall be in full
compensation for furnishing, preparing, hauling, and placing geocomposite including all labor,
freight, tools, equipment, and incidentals to complete the work as per specifications.

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Pay Item Description Unit Measurement

No.

2/14/3 Geo-composite drain Square meter

2.14.5 GEOSYNTHETIC MAT

2.14.5.a Scope
The work covers the use of geosynthetic mats for control of erosion of slopes including
supplying and laying the mat, spreading soil and seeding to promote the design of
vegetation, as per design, drawing and these specifications.

2.14.5.b Material and Strength Requirements

Geosynthetic mat shall be a three-dimensional structure consisting of UV stabilized
non-degradable polypropylene, polyethylene, nylon or similar polymer fibres that are
extruded or heat bonded at the contact points to provide a dimensionally stable matrix
for soil erosion protection. A tension element, i.e. a reinforcing element like geogrid or
steel wire mesh shall be included along with the three dimensional polymeric mats to
provide strength against erosive forces, if specified in the contract
The tensile strength requirements for non reinforced and reinforced three dimension
geosynthetics mat shall meet the minimum requirement as specified in Table 14-10 and
Table 14-11 respectively.

2.14.5.c Installation
Prior to laying of geosynthetics mat on the slope, the surface shall be properly prepared,
cleaned and dressed to the specified lines and levels as shown on the drawings.
Specified trench keys along the crest and at the bottom of slope area shall be provided
to fix the geosynthetics mat in the ground. In case the soil is not fertile, it shall be mixed
with suitable amount of fertilizer or seeds.
Table 2.14-9 : Tensile Strength Requirement for Normal (Non-Reinforced) Three
Dimensional
Geosynthetic Mat for Erosion Control Application (Less Severe Environmental Condition)
Property Test Method Units Minimum
Average Roll
Value
Tensile strength requirement (For ASTM D KN/m 2
0
slopes less than 60 ) 5035
0
For slopes up to 80
Ultraviolet stability at 500h, Retained ASTM D % 80
strength percentage with respect to 4355
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original strength
Thickness ASTM D mm 6.5
6525
Mass per unit area ASTM D gm/m2 250
3776

Table 14-10: Tensile Strength Requirement for Reinforced Three Dimensional

Geosynthetic Mat for Erosion Control Application (Severe Environmental Conditions)
Property Test Method Units Minimum Average
Roll Value
Tensile For slopes up to ASTM D 5035 KN/m 10
0
strength 60
requirement For slopes up to 35
0
80
Ultraviolet stability at 500h, ASTM D 4355 % 80
Retained strength percentage with
respect to original strength
Thickness ASTM D 6525 mm 12
2
Mass per unit area ASTM D 3776 gm/m 500

The work of laying the mat shall begin at the top of the slope providing anchor blankets
in a 300 mm deep and 300 mm wide trench and anchoring with staples/pins. The mat
shall then be unrolled down the slope in the machine direction. The blanket shall not be
stretched but shall have full contact with the soil. The blanket shall be anchored using
staples or stakes.
Edges of adjacent parallel rolls shall be overlapped by approximately 100 mm to 120
mm and anchored with staples at 600 mm to 800 mm spacing depending on the slope.
When blankets have to be spliced, the upper blanket end shall be placed over lower
blanket end (shingle style) with 300mm overlap and anchoring with two staggered rows
of staples at 300mm spacing A minimum cover of soil shall be spread followed by
spreading the seeds and fertilizer In the absence of rain, blankets shall be regularly
watered for viable growth till vegetation sustains on its own. If any damage due to
heavy downpour is noticed, suitable corrective measures shall be taken immediately.
Gully formations, if any, shall be suitably corrected depending upon the site condition.
The treated area shall be protected from the movement of cattle (goat, sheep & cow).
Grazing shall be avoided till the vegetation sustains on its own.

2.14.6.d Measurement for Payment

The geosynthetic mat shall be measured in square metre as per planned dimensions
with no allowance for overlapping at joints, anchoring at toe and crest of the slope.

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2.14.6.e Rate
The contract unit rate for geosynthetic mat for erosion control shall be in full
compensation for furnishing and installing the specified materials and growth of
vegetative cover in accordance with the contract documents including site preparation,
and for furnishing all labor, tools, equipment and incidentals to complete the work as
per these Specifications.
2/14/4 Furnishing and installing geosynthetic mat Square metres
(as detailed in the Drawings or as directed
by the Engineer)

2.14.7 NATURAL GEOTEXTILE

2.14.7.a Scope
The work covers the use of natural geotextile/es for control of erosion of slopes
including supplying and laying the mat spreading soil and seeding to promote the
growth of vegetation, as per design, drawing and these specifications. Natural
Geotextile shall be used to control surface erosion of top cover soil on cut or fill slopes
and to facilitate vegetation to grow.

2.14.7.b Strength Requirements

The natural fibre geotextiles made of Jute shall meet the minimum requirement as
specified in Woven Jute Geotextiles- Specification. However, for coir fibre geotextile, it
shall meet the requirements as specified in Table 2.14-12, when used for erosion control
measures.
Table 2.14-11 : Typical Specifications of Natural Geotextile (MARV*) using Coir
Type Weight Width Thickne Tensile Elong Water Porometr
of (gms) (cm) ss Strength ation Holding y
Price (mm) (kN/m) at Capacity Micron
M CD Break (%)
D (%)

Open
Mesh. 300 120 4.0 5 2.5 20 - -
Fabric
Nonw
7.
oven 450 150 4.0 2.5 30 80 75
5
Fabric

*Minimum average roll value

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2.14.7.c Installation
Prior to laying of natural geotextiles on the slope, the surface shall be properly prepared,
cleaned and dressed to the specified lines and levels as shown on the drawings. Specified
trench keys along the crest and at the bottom of slope area shall be provided to fix the
natural geotextile in the ground. In case the soil is not fertile, it shall be mixed with suitable
amount of fertilizer or seeds. The work of laying the mat shall begin at the top of the slope
providing anchor blankets in a 300 mm deep and 300 mm wide trench and anchoring with
staples/pins. The mat shall then be unrolled down slope in the machine direction. The
blanket shall not be stretched but shall have full contact with the soil. The blanket shall be
anchored using staples or stakes. Edges of adjacent parallel rolls shall be overlapped by
approximately 100-120 mm and anchored with staples at 600-800 mm spacing depending
on the slope. When blankets have to be spliced, the upper blanket end shall be placed over
lower blanket end (shingle style) with 300 mm overlap and anchoring with two staggered
rows of staples at 300 mm spacing.
A minimum cover of soil shall be spread followed by spreading the seeds and fertilizer. A
slow release supplementary fertilizer may be applied to speed up the growth of the
vegetation. In the absence of rain, blankets shall be regularly watered for viable growth till
vegetation sustains on its own. If any damage due to heavy downpour is noticed, suitable
corrective measures shall be taken immediately. Gully formations, if any, shall be suitably
corrected depending upon the site conditions. The treated area shall be protected from the
movement of cattle (goat, sheep & cow). Grazing shall be avoided till the vegetation
sustains on its own.

2.14.7.d Measurement for Payment

The natural geotextile shall be measured in square metres as per planned dimensions with
no allowance for overlapping at joints, anchoring at toe and crest of the slope.

2.14.7.e Rate
The contract unit rate for natural geotextile mat for erosion control shall be in full
compensation for furnishing and installing the specified materials and growth of vegetative
cover in accordance with the contract documents including site preparation, and for
furnishing all labour, tools, equipment and incidentals to complete the work as per these
Specifications.
2/14/5 Natural Geotextile (as detailed in the Drawing Square metre
or as directed by the Engineer)

2.14.8 PAVING FABRICS/GLASS GRIDS

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.14.8.a Scope
This work shall consist of laying geosynthetic materials either non-woven paving fabric or
fibre glass coated grid over existing bituminous surface, including preparation of surface
and joining, stitching or overlapping of geosynthetic fabric etc. as part of highway
pavement strengthening in layers as shown on drawings or as directed by the Engineer.

2.14.8.b Material Requirements

2.14.8.b.1 Paving Fabrics

The paving fabric will be a non-woven heat set material consisting of at least 85 percent by
weight of polyolefins, polyesters or polyamides. The paving fabric shall be resistant to
chemical attack, rot and mildew and shall have no tears or defects which will adversely
alter its physical properties. The fabric shall be specifically designed for pavement
applications and be heat bonded only on one side to reduce bleed-through of tack coat
during installation. The fabric shall meet the physical requirements given in Table 2.14-13.
Table 2.14-13: Physical requirements for Paving Fabrics (Minimum Average Roll Value)
Property Units Standard Requirements Test Method
Grab Tensile
Strength N 450 ASTM D 4632
Elongation % ≥ 50 ASTM D 4632
Mass Per Unit
Area gm/m2 : 140 ASTM D 3776
Asphalt
Retention Kg/10 sq.m 10* ASTM D 6140
o
Melting Point C 150 ASTM D 276
Surface
Texture - Heat bonded on One side Visual inspection
only
Note:* the product asphalt retention property must meet MARV provided by the
manufacturer.

2.14.8.b.2 Glass Grids

These will be either a composite glass fibre reinforced geogrid with continuous filament
non- woven Geotextile chemically or mechanically bonded to the grid; or bituminous
coated glass fiber geogrid with or without adhesive on one side of the grid. The physical
and mechanical properties of glass grid fabric shall conform to the requirements given in
Table 2.14-14.
Table 2.14-14 : Properties of Glass Fibre Grids
Property Units Requirement
Tensile strength both Median and Cross- Machine
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Direction
Tensile strength KN/m ASTM D 6637 50 1000 200
% Elongation at % >4 >4 >4
break
Minimum Mesh size Mm 25x25 12.5x12.5 12.5x12.5
Melting point °C ASTM D 276 >250 >250 >250

2.14.8.b.3 Asphalt Reinforcing Geogrids

These shall be made of high modulus polyester yarns with low creep properties. The grid
shall be connected to low weight non-woven polypropylene fabric. The composite shall
have a bitumen finish. The properties shall conform to the requirements given in Table
2.14-15.

Table 2.14-15: Properties of Asphalt Reinforcement Geogrids

Property Unit Test Method Requirement
Tensile strength in both MD and
CD, Not less than
Tensile strength KN/m IS0-10319 25 50 100
% Elongation at IS0-10319 12.5% 12.5% 12.5%
%
break
Mesh Size 35×35 35×35 35×35
20×20 20×20 20×20
Melting Point °C
>190 >190 >190

2.14.8.c Installation

2.14.8.c.1 Weather Limitations

The air and pavement temperatures shall be at least 100C for placement of hot bitumen and
at least 16°C for placement of asphalt emulsion. The asphalt tack coat or Glass grid shall
not be placed when weather conditions are not suitable.

2.14.8.c.2 Surface Preparation

The pavement surface shall be dry and cleaned of all dirt and oil to the satisfaction of
the Engineer. Cracks wider than 3 mm shall be cleaned and filled with suitable
bituminous material appended by the Engineer. Potholes and locally failed and cracked
pavement sections shall be repaired as directed by the Engineer. If the existing

77
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

pavement is rough or has been milled, a levelling course shall be provided prior to
installation of the Glass grid.

2.14.8.c.3 Tack Coat

The tack coat used to impregnate the fabric and bond the fabric to the pavement shall be
penetration grade Bitumen of 80-100. Glass fiber grids with adhesive on one side may
not require a tack coat.
The tack coat shall be applied using a calibrated distributor spray bar. Hand spraying,
squeegee and brush application may be used only in locations where the distributor
truck cannot reach. The tack coat shall be uniformly applied at a rate to bond the
nonwoven scrim to the existing pavement surface. The tack coat application rate shall
be 1 Kg per square metre or as specified in the contract. When using emulsions, the
application rate must be increased as directed by the Engineer to take into account the
water content in the emulsion. The temperature of the tack coat shall be sufficiently
high to permit a uniform spray. Bitumen shall be sprayed at temperatures between
143oC and 163°C. For emulsions, the distributor tank temperatures shall be maintained
between 55°C and 71oC. The target width of the tack coat application shall be equal to
the Glass grid width plus 100-150 mm. The tack coat shall be applied only as far in
advance of Glass grid installation as is appropriate to ensure a tacky surface at the time
of Glass grid placement. Traffic shall not be allowed on the tack coat. Excess tack coat
shall be cleaned from the pavement.

2.14.8.d Paving Fabric Placement

The paving fabric shall be placed onto the tack coat using mechanical or manual lay
down equipment capable of providing a smooth installation with a minimum amount of
wrinkling or folding. The paving fabric shall be placed before to the tack coat cools and
loses tackiness. After laying the paving fabric, some loose bituminous premix material
shall be sprinkled on it in the wheel path of the paver and the tipper to ensure that the
fabric is not picked up between the wheels. Paving fabric shall not be installed in areas
where the bituminous overlay tapers to a thickness of less than 40 mm. Excess paving
fabric which extends beyond the edge of existing pavement or areas of tack coat
application shall be trimmed and removed. When bitumen emulsions are used, the
emulsion shall be allowed to cure properly such that no water/moisture remains prior to
placing the paving fabric. Wrinkles or folds in excess of 25 mm shall be single-lapped
in the direction of the paving operation. Brooming and/ or pneumatic rolling will be
required to maximize paving fabric contact with the pavement surface. Additional hand-
placed tack coat may be required at laps and repairs as determined by the Engineer to
satisfy bitumen retention of the lapped paving fabric. All areas where paving fabrics
have been placed shall be paved the same day .No traffic except necessary construction
equipment will be allowed to drive on the paving fabric. Turning of the paver and other
vehicles shall be done gradually and kept to a minimum to avoid movement and

78
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

damage to the paving fabric. Abrupt starts and stops shall also be avoided. Damaged
fabric shall be removed and replaced with the same type of fabric. Overlaps shall be
shingle- lapped in the direction of paving. Additional tack coat shall be placed between
the overlap to satisfy saturation requirements of the fabric. Overlap shall be sufficient to
ensure full closure of the joint but not exceed 150 mm. Transverse joints shall be
overlapped in the direction of the pavement by 100 to 150 mm or as per the
manufacturer's recommendations or as directed by the Engineer. Longitudinal joints
shall be overlapped by 20-30 mm or as per the manufacturer's recommendations or as
directed by the engineer. The overlay operations shall be completed at the earliest after
laying the fabric.

2.14.8.d.1 Glass Grid Placement

The glass grid shall be placed on the surface provided by the tack coat using mechanical
or manual lay down equipment capable of providing a smooth installation with a
minimum amount of wrinkling or folding. On curves, the Glass grid must be cut and
realigned to match the curvature. Glass grid shall not be installed in areas where the
bituminous overlay tapers to a compacted thickness of less than 40 mm. When
emulsions are used, the emulsion shall be allowed to cure properly such that no
water/moisture remains prior to placing the glass grid. Wrinkles severe enough to cause
folds shall be slit and laid flat. Brooming and/or rubber-tire rolling will be required to
maximize glass grid contact with the pavement surface. Additional hand-placed tack
coat may be required at overlaps and repairs as required by the Engineer. Turning and
braking of the paver and other vehicles shall be done gradually and kept to a minimum
to avoid movement and damage to the glass grid. Damaged composite shall be removed
and replaced with the same type of composite and a tack coat.
All areas where glass grid has been placed shall be paved the same day. No traffic
except necessary construction traffic shall be allowed to drive on the glass grid.
Overlaps shall be shingle - lapped in the direction of paving. Additional tack coat shall
be placed between the overlap to satisfy saturation requirements of the fabric. Overlap
shall be sufficient to ensure full closure of the joint but not exceeding 150 mm.

2.14.8.d.2 Overlay Placement

Bituminous overlay construction shall closely follow the placement of paving fabric or
glass- grid. Excess tack coat that bleeds through the paving fabric or glass grid shall be
removed by broadcasting hot mix or sand on the glass grid. Excess sand or hot mix shall
be removed before beginning the paving operation. In the event of rainfall prior to the
placement of the asphalt overlay, the fabric must be allowed to dry completely before
the overlay is placed. Overlay asphalt thickness shall meet the requirements of the
contract drawings and documents and shall be carried out in accordance with the
relevant section of 3.10. The minimum compacted thickness of the first lift of overlay
asphalt concrete shall not be Jess than 40 mm.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.14.8.e Measurement
The paving fabric/ glass fibre geogrid shall be measured in Square metres of paved area
covered by the fabric/ glass fibre geogrid. Surface preparation, tack coat and overlay shall
conform to the measurement of section 3.7 and 3.10 .

2.14.8.f Rate
The contract unit rate shall be for the accepted quantities of paving fabric. The rate shall
be full compensation for the work performed and furnishing, preparing, hauling and
placing materials including all labour, material, freight, tools, equipment and incidentals
to complete the work as per contract. Surface preparation, tack coat and overlay shall be
paid separately according to section 3.7 and 3.10 and not included in this section .
2/14/6 Furnishing and installing Paving fabric/glass Square metre
fibre geo grid ( as detailed in the Drawings or
as directed by the Engineer)

2.15 MSE (Mechanically Stabilized Earth) WALL FOR RAMP

2.15.1 Definition of MSE Wall

The work covers the construction of MSE wall structures, together with the construction
of earthwork in layers, assembly and erection of reinforcing elements and placement of
facing panels and all associated components.

Mechanically Stabilized Earth (MSE): An earth retaining structure comprising selected

fill and soil reinforcement that is embedded at regular intervals in both vertical and
horizontal directions within the fill to form a composite structure. The visible face of the
MSE will be decorative or plain structural reinforcement concrete.

2.15.2 Design

Design Life Requirement:

The MSE (Mechanically Stabilized Earth) wall shall have a minimum design life of 75
years.
Design Procedures:
The design of the MSE wall shall conform to the AASHTO LRFD Bridge Design
Specifications (2007), with 2008 and 2009 Interim Revisions.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

The LRFD (Load and Resistance Factor Design) method in various forms is now being
applied throughout the world. The Federal Highway Administration (FHWA) USA has
adopted Mechanically Stabilized Earth Walls and Reinforced Slopes, Design and
Construction Guidelines, by Elias et al. as their current guidelines for MSE wall design
and construction.

MSE used in conjunction with a bridge element shall be independent of the bridge
structure. Vertical and horizontal loads arising from the bridge shall be supported on
piles. Piles shall be surrounded with a compressible material to ensure that horizontal
loads arising from the MSE are not transmitted to the piles.
MSE walls for Bridge Ends (abutments) shall not be allowed. The MSE shall be
designed to support dead and live loads arising from bridge approach roads including
vertical and lateral loads, soil pressures, impact loads from barriers and guard fences
and loads arising from signs and sign support structures.
The Contractor shall determine the allowable bearing pressures and the maximum
settlement of the foundation material under the MSE wall using information obtained
from the site-specific geotechnical investigation.
Subsurface drainage which complies with the specification shall be provided within the
MSE where necessary to intercept groundwater and to prevent the development of
hydrostatic pressure behind the facing panels. A separate drainage system which
complies with the specification shall be provided to collect and discharge surface water
into the storm water drainage system. The specific checks for the strength and service
limit states required for MSE wall design are listed below:

Strength Limit States for MSE walls

External Stability
• Limiting Eccentricity
• Sliding
• Bearing Resistance
Internal Stability
• Tensile Resistance of Reinforcement
• Pullout Resistance of Reinforcement
• Structural Resistance of Face Elements
• Structural Resistance of Face Element Connections

Service Limit States for MSE walls

External Stability
• Vertical wall movements
• Lateral wall Movements

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

Global Stability of MSE walls

• Overall Stability
• Compound Stability

In cases where specific design details for the MSE wall are not provided for a particular
project, the Contractor may refer to the following guidelines. However, it's important to
note that any action taken by the Engineer, including approvals, checks, certificates,
consents, examinations, inspections, instructions, notices, proposals, requests, tests, or
any similar acts, or the absence of disapproval, shall not exempt the Contractor from
their contractual responsibilities. This includes responsibilities related to errors,
omissions, discrepancies, and non-compliance with the contract terms.
The Contractor shall have in place a quality management System, which ensures
compliance with the performance requirements described on the drawings and in the
Specification.

2.15.3 Material Requirements

The component materials of MSE Wall shall consist of the backfill material, MSE Wall
concrete facing panels, reinforcing strips and other accessories.

2.15.3.a Reinforced Earth Fill

The backfill material used in the MSE Wall shall be crushed rock and crusher sand or
coarse river sand (Sylhet Sand) free from organic or other deleterious material. The
material shall conform to the physical, electrochemical and chemical properties detailed
below:

The angle of internal friction of the granular fill under saturated condition shall not be
less than 36o. The Plasticity Index as determined by AASHTO T 90 shall not exceed 6.
The grading requirement of the material shall conform to that shown in the Table
below:

Table 2.15-1: Grading Requirement of Earth fill material

Sieve Size mm Percent passing
14 100
10 70-90
5 48-70
2.36 30-53
1.18 20-40
0.6 12-30
0.3 7-21
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

0.15 4-15
0.075 2-10

The material shall be substantially free of shale or other soft, poor-durability particles.
The material shall have a magnesium sulphate soundness loss of less than 30 percent
after four cycles, measured in accordance with AASHTOT – 104 or a sodium sulphate
loss of less than 15 percent after five cycles determined in accordance with AASHTO T
– 104. For metallic reinforcement Resistivity shall be more than 3000 ohm-cm
(AASHTO T 288), PH shall be 5 – 10 (AASHTO T 289), Chlorides shall be less than
100 parts per million (AASHTO T 291), Sulphate shall be less than 200 parts per
million (AASHTO T 290) and organic content shall be less tha 1 percent (AASHTO T
267). For Geosynthetic reinforcement Polyolefin (PP and HDPE), pH shall be more
than 3 (AASHTO T 289) and Polyester ph shall be more than 3 and less than 9.

2.15.3.a MSE Reinforcing Element

In the current design practices, the recommended length of soil reinforcement is 0.7 H
(H is the height of wall) or not less than 2.4 m according to Federal Highway
Administration (FHWA).
The reinforcing element shall be of geotextile, aluminum alloy strip, copper strip,
carbon steel strip, mats of metal or synthetic grid, or any other proprietary material
which may be approved by the Engineer and indicated on the drawings. Strips
manufactured by Terre Armee is widely in use in MSE in Bangladesh and is
recommended. Horizontal spacing of the strips can be 330 mm and vertical spacing can be 490
mm.

2.15.3.b MSE Wall Concrete Facing Panels

Only pre-cast reinforced concrete panels shall be used as facing. Size of the panel can be
one metre by one metre, of thickness 140 cm. Connectors shall be of galvanized steel.

2.15.3.c.1 Concrete Quality and Strength

Panels shall be made of vibrated concrete with the following requirements:

Characteristic compressive strength at 28 days 30 MPa

Maximum aggregate size 20 mm
Maximum free water/cement rat 0.45

For sea walls or structures facing severe exposure conditions, thicker panels with higher
cement (Sulphate resistant cement) content shall be specifically designed for the
intended purpose.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2.15.3.c.2 Facing Finish and Tolerances

The finish of the exposed face of the panel shall be as shown in the drawings and shall
be free of honeycombs, stains or deep cracks.

Tolerance in dimensions are as follows:

(i) the height of full panels shall be within +/- 5 mm while the height of half panels
shall be within +/- 3 mm.
(ii) the width of all panels shall be within +/- 5mm
(iii) the difference between the lengths of the diagonals shall not exceed 10 mm
(iv) twist or warp shall not exceed 5 mm

2.15.3.d Joint Fillers

The fillers for the vertical and horizontal joints shall be flexible open cell polyurethane
foam strips of 40 mm square cross section.

2.15.3.e Cushion Pad

The cushion pads placed at the horizontal joint shall be made of rubber with shore
hardness 85.

2.15.3.f Measurement and Payment

The measurement for facing wall shall be in square meters. The measurement for crush
barrier and Friction slab shall be in linear meters. Measurement for compacted earth fill
shall be in cubic meters for compacted soil. Rate shall include cost of labor, plant
hire, material storage, cost of labor for ground Improvement needed as per existing
ground conditions and handling expenses for completing the works. Rate for providing
reinforcement elements shall include material cost, all transportation costs and storage
of the same, the rate shall also include cost of laying of reinforcing elements including
all overlaps, jointing or stitching, heat bonded or extension. Rate for facia fixing shall
include cost of joints, all necessary temporary formworks, scaffolding and all lifts and
lead if any, as shown in the drawing. Rate for bed block and capping beam shall include
all items of excavation, concrete, reinforcing steel, formwork, labor and equipment.
Rate for soil till shall include compaction as desired in requisite layers through
mechanical means, cost of hire or labor for plant operations, dressing and levelling
slopes, including special measures for edge reinforcement as shown in the drawing.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 2 - EARTHWORKS

2/15/1 Furnishing and installing Mechanically Square metre

Stabilized Earth (MSE) Wall for Ramp ( as
detailed in the Drawings or as directed by the
Engineer)

Facing Wall Square metre

Engineering Material Fill between face walls Cubic metre
Crush Barriers and Friction Slabs Metre

85
 Division 3

PAVEMENT WORKS
Contents
3.1 Pavement (Minor works & preliminaries) ............................................................................. 1
3.1.1 General ....................................................................................................................................... 1
3.1.2 Preparation and Stockpiling of Materials ................................................................................... 1
3.1.3 Scarification and Preparation of bed under the existing pavement/or Hard Shoulders.............. 1
3.1.4 Repair of Potholes and Damaged Areas of the Existing Bituminous Surfaced Roads .................. 2
3.1.5 Levelling Course .......................................................................................................................... 2
3.1.6 Payment ..................................................................................................................................... 2

3.2 SUB-BASE ............................................................................................................................... 3

3.2.1 Description ................................................................................................................................. 3
3.2.2 Materials .................................................................................................................................... 3
3.2.3.1 Preparation of Subgrade or Improved Subgrade ................................................................................... 5
3.2.3.2 Provision of Lateral Confinement of Aggregates................................................................................... 5
3.2.3.3 Preparation of Mix ............................................................................................................................... 5
3.2.3.4 Spreading of Mix ............................................................................................................................ 6
3.2.3.5 Sprinkling, Rolling and Compacting .................................................................................................... 7

3.2.4 Opening to Traffic ....................................................................................................................... 8

3.2.5 Measurement ............................................................................................................................. 8
3.2.6 Payment ..................................................................................................................................... 8

3.3 LIME TREATED SOIL FOR IMPROVED SUB-GRADE/SUB-BASE ................................................ 9

3.3.1 Scope .......................................................................................................................................... 9
3.3.2 Materials .................................................................................................................................... 9
3.3.3 Construction Methods ............................................................................................................. 10
3.3.3.1 Weather limitations: ........................................................................................................................... 10
3.3.3.2 Degree of pulverisation:...................................................................................................................... 10
3.3.3.3 Soil Pulverisation Requirements for Lime Stabilisation......................................................................... 10
3.3.3.4 Equipment for construction: ............................................................................................................... 10
3.3.3.5 Mix-in-place method of construction: .................................................................................................... 10
3.3.3.6 Construction with manual means: ....................................................................................................... 11
3.3.3.7 Addition of lime: ................................................................................................................................ 11
3.3.3.8 Moisture content for compaction:...................................................................................................... 12
3.3.3.9 Rolling: .............................................................................................................................................. 12

3.3.3.10 Curing: .................................................................................................................................. 12

3.3.4 Strength ................................................................................................................................... 12
3.3.5 Arrangements for Traffic.......................................................................................................... 12
3.3.6 Measurements for Payment .................................................................................................... 12
3.3.7 Payment .................................................................................................................................. 12

3.4 CEMENT TREATED SUB-BASE/BASE ..................................................................................... 13

3.i | P a g e
 3.4.1 Scope ....................................................................................................................................... 13
3.4.3 Materials ................................................................................................................................. 14
3.4.4 Construction Methods ............................................................................................................. 15
3.4.4.2 Degree of pulverisation: ..................................................................................................................... 15
3.4.4.3 Moisture content for compaction: ...................................................................................................... 15
3.4.4.4 Rolling:............................................................................................................................................... 15
3.4.4.5 Curing: .............................................................................................................................................. 15

3.4.5 Strength .......................................................................................................................................... 15

3.4.6 Arrangements for Traffic ................................................................................................................. 15
3.4.7 Measurements for Payment ............................................................................................................ 15
3.4.8 Payment .................................................................................................................................. 15

3.5 WATER BOUND MACADAM SUB-BASE/BASE ..................................................................... 16

3.5.1 Scope ........................................................................................................................................ 16
3.5.2 Materials .................................................................................................................................. 16
3.5.3 Screenings: ...................................................................................................................................... 17
3.5.4 Binding material .............................................................................................................................. 17
3.5.5 Construction Operations ................................................................................................................. 17

3.6 AGGREGATE BASE ............................................................................................................... 18

3.6.1 Description .............................................................................................................................. 18
3.6.2 Materials ................................................................................................................................. 18
3.6.3 Construction Methods .............................................................................................................. 20
3.6.3.1 Preparation of Sub-base..................................................................................................................... 20
3.6.3.2 Provision of Lateral Confinement of Aggregates................................................................................. 20
3.6.3.3 Preparation of Mix ............................................................................................................................ 20
3.6.3.4 Spreading of Mix ............................................................................................................................... 21
3.6.3.5 Compaction....................................................................................................................................... 21
3.6.3.6 Setting and Drying ............................................................................................................................. 22

3.6.4 Opening to Traffic .................................................................................................................... 22

3.6.5 Surface Tolerance ..................................................................................................................... 23
3.6.6 Rectification of Surface Irregularity .......................................................................................... 23
3.6.7 Measurement ........................................................................................................................... 23
3.6.8 Payment .................................................................................................................................. 23

3.7 Geo-fabric Reinforced Seal (GRS) as Strain Alleviating Layer (SAMI) ...................................... 24
3.7.1 Description ............................................................................................................................... 24
3.7.2 Materials ................................................................................................................................. 24
3.7.3 Construction Method................................................................................................................ 26
3.7.3.1 General............................................................................................................................................... 26
3.7.3.2 Sequence of Operations ...................................................................................................................... 26

3.ii | P a g e
 3.7.3.3 Surface Preparation ............................................................................................................................ 26
3.7.3.4 Weather Conditions ........................................................................................................................... 27
3.7.3.5 Equipment ......................................................................................................................................... 27
3.7.3.6 Spraying............................................................................................................................................. 29
3.7.3.7 Bond (tack) coat................................................................................................................................. 29
3.7.3.8 Seal.................................................................................................................................................... 29
3.7.3.9 Placement of Geotextile Fabric........................................................................................................... 29
3.7.3.10 Aggregate Spreading and Rolling ......................................................................................................... 30
3.7.3.11 Trafficking........................................................................................................................................... 30
3.7.3.12 Caution ............................................................................................................................................... 30
3.7.3.13 Reduced Daily Production ................................................................................................................... 30

3.7.4 Maintenance ............................................................................................................................ 31

3.7.5 Measurement ........................................................................................................................... 31
3.7.6 Payment ................................................................................................................................... 31

3.8 BITUMINOUS MATERIALS .................................................................................................... 31

3.8.1 Description .............................................................................................................................. 31
3.8.2 Material ................................................................................................................................... 31
3.8.2.1 Bitumen ............................................................................................................................................. 32

16.D8078 Test Method for Ash Content of Asphalt and Emulsified Asphalt ............................................ 42
3.8.3 Measurement ........................................................................................................................... 42
3.8.4 Payment .................................................................................................................................. 42

3.9 GENERAL REQUIREMENTS FOR BITUMEN BOUND SURFACING (plant method) .................. 42
3.9.1 Description .............................................................................................................................. 42
3.9.1.1 General .............................................................................................................................................. 42
3.9.1.2 General Composition of Mixtures ....................................................................................................... 43
3.9.1.3 Formula for Job-Mix ........................................................................................................................... 43
3.9.1.4 Applications of Job-Mix Formula and Allowable Tolerances ................................................................ 44

3.9.2 Materials ................................................................................................................................. 44

3.9.2.1 Coarse Mineral Aggregate .................................................................................................................. 44
3.9.2.2 Fine Mineral Aggregate ...................................................................................................................... 45
3.9.2.3 Mineral Filler ..................................................................................................................................... 45
3.9.2.4 Bituminous Materials ......................................................................................................................... 46

3.9.3 Construction ............................................................................................................................ 46

3.9.3.1 Weather Limitation ............................................................................................................................ 46
3.9.3.2 Progress of Work ............................................................................................................................... 46
3.9.3.3 Plant and Equipment.......................................................................................................................... 46
3.9.3.4 Preparation and Placing ..................................................................................................................... 51
3.9.3.5 Surface Test of the Pavement.............................................................................................................. 55
3.9.3.6 Control and Testing ............................................................................................................................ 55

3.9.4 Measurement .......................................................................................................................... 56

3.9.5 Payment .................................................................................................................................. 56

3.10 BITUMINOUS PRIME COAT ................................................................................................. 56

3.10.1 Description .............................................................................................................................. 56
3.iii | P a g e
 3.10.2 Materials ................................................................................................................................. 56
3.10.2.1 Bituminous Materials .......................................................................................................................... 56
3.10.2.2 Blotting Material ................................................................................................................................. 56

3.10.3 Construction Methods ............................................................................................................. 56

3.10.3.1 Weather Limitations ........................................................................................................................... 56
3.10.3.2 Equipment .......................................................................................................................................... 56
3.10.3.3 Cleaning Surface ................................................................................................................................. 57
3.10.3.4 Application of Bituminous Material ..................................................................................................... 57
3.10.3.5 Maintenance and Opening to Traffic ................................................................................................... 58

3.10.4 Measurement .......................................................................................................................... 58

3.10.5 Payment .................................................................................................................................. 58

3.11 BITUMINOUS TACK COAT ................................................................................................... 58

3.11.1 Description .............................................................................................................................. 58
3.11.2 Materials ................................................................................................................................. 59
3.11.3 Construction Methods ............................................................................................................. 59
3.11.3.1 Equipment .......................................................................................................................................... 59
3.11.3.2 Cleaning Surface ................................................................................................................................. 59
3.11.3.3 Application of Bituminous Material ..................................................................................................... 59
3.11.4 Measurement .................................................................................................................................... 60
3.11.5 Payment ............................................................................................................................................ 60

3.12 PRIMER SEAL ...................................................................................................................... 60

3.12.1 Description .............................................................................................................................. 60
3.12.2 Materials ................................................................................................................................. 60
3.12.2.1 Bituminous Material ........................................................................................................................... 60
3.12.2.2 Cover Coat Material ............................................................................................................................ 60

3.12.3 Construction Methods ............................................................................................................. 61

3.12.3.1 Cleaning Surface ................................................................................................................................. 61
3.12.3.2 Applying Bituminous Materials............................................................................................................ 61
3.12.3.3 Spreading and Rolling ......................................................................................................................... 61

3.12.4 Measurement .......................................................................................................................... 62

3.12.5 Payment .................................................................................................................................. 62

3.13 BITUMINOUS SURFACE TREATMENT (plant method) ......................................................... 63

3.13.1 Description .............................................................................................................................. 63
3.13.2 Materials ................................................................................................................................. 63
3.13.2.1 Bituminous Materials .......................................................................................................................... 63
3.13.2.2 Bitumen Additive ................................................................................................................................ 63
3.13.2.3 Aggregates.......................................................................................................................................... 63
3.13.2.4 Pre-Coated Aggregate ......................................................................................................................... 64
3.13.2.5 Stockpiling of Aggregates .................................................................................................................... 64

3.13.3 Construction Methods ............................................................................................................. 65

3.13.3.1 Equipment .......................................................................................................................................... 65
3.13.3.2 Weather Limitations and Control of Work ........................................................................................... 66
3.13.3.3 Cleaning and Preparation of Surface ................................................................................................... 66
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 3.13.3.4 Application of Bituminous Material ..................................................................................................... 66
3.13.3.5 Application of Cover Aggregate ........................................................................................................... 69
3.13.3.6 Rolling and Brushing ........................................................................................................................... 69
3.13.3.7 Control of Traffic................................................................................................................................. 69

3.13.4 Measurement .......................................................................................................................... 70

3.13.5 Payment .................................................................................................................................. 70

3.14 DENSE BITUMINOUS SURFACING (plant method)............................................................... 71

3.14.1 Description .............................................................................................................................. 71
3.14.1.1 General............................................................................................................................................... 71
3.14.1.2 General Composition of the Mixture ................................................................................................... 71

3.14.2 Materials ................................................................................................................................. 76

3.14.2.1 General............................................................................................................................................... 76
3.14.2.2 Bituminous Materials .......................................................................................................................... 76
3.14.2.3 Bitumen Additive ................................................................................................................................ 76
3.14.2.4 Coarse Mineral Aggregates ................................................................................................................. 76
3.14.2.5 Fine Mineral Aggregate ....................................................................................................................... 76
3.14.2.6 Mineral Filler ...................................................................................................................................... 76
3.14.2.7 Mixture............................................................................................................................................... 77

3.14.3 Construction Methods ............................................................................................................. 77

3.14.3.1 General............................................................................................................................................... 77
3.14.3.2 Preparation of Bituminous Material .................................................................................................... 77
3.14.3.3 Preparation of Mineral Aggregate ....................................................................................................... 77
3.14.3.4 Preparation of Mixture ....................................................................................................................... 78
3.14.3.5 Spreading and Compaction ................................................................................................................. 78
3.14.3.6 (A) Joints (transverse joint) ................................................................................................................. 78
3.14.3.7 Protection of the Pavement ................................................................................................................ 80
3.14.3.8 Pavement Samples.............................................................................................................................. 80
3.14.3.9 Surfacing Texture ................................................................................................................................ 80

3.14.4 Measurement .......................................................................................................................... 80

3.14.5 Payment .................................................................................................................................. 81

3.15 BITUMINOUS CARPETTING (PLANT METHOD) [APPLICABLE FOR MAINTENANCE AND

EMERGENCY PURPOSES AND NEEDS SPECIAL PERMISSION FROM PROPER AUTHORITY] .............. 82
3.15.1 Description .............................................................................................................................. 82
3.15.1.1 General............................................................................................................................................... 82
3.15.1.2 General Composition of the Mixture ................................................................................................... 82

3.15.2 Materials ................................................................................................................................. 83

3.15.2.1 General............................................................................................................................................... 83
3.15.2.2 Bituminous Materials .......................................................................................................................... 83
3.15.2.3 Coarse Mineral Aggregate ................................................................................................................... 83
3.15.2.4 Fine Mineral Aggregate and Mineral Filler ........................................................................................... 83
3.15.2.5 Mixture............................................................................................................................................... 83

3.15.3 Construction Methods (Plant) .................................................................................................. 84

3.15.4 Measurement .......................................................................................................................... 84
3.15.5 Payment .................................................................................................................................. 84

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3.16 THIN HMA OVERLAYS FOR PAVEMENT PRESERVATION AND LOW VOLUME ASPHALT ROAD
with 4.75 NMAS thickness 19mm to 25mm [APPLICABLE for maintenance and emergency
purposes AND NEEDS special permission from proper AUTHORITY] .............................................. 89
3.16.1 Composition of the Mixture:.................................................................................................... 89
3.16.1.1 Leveling and Patching ......................................................................................................................... 90
3.16.1.2 Thin Overlays and Surface Mixtures ............................................................................................. 91
3.16.2.1 Preparation of Thin Overlay Mixture ................................................................................................... 91
3.16.2.2 A) Joints (transverse joint)................................................................................................................... 92
3.16.2.3 Protection of the Pavement ................................................................................................................ 92
3.16.2.4 Pavement Samples.............................................................................................................................. 92
3.16.2.5 Surfacing Texture ................................................................................................................................ 92

3.16.3 Measurement .......................................................................................................................... 92

3.16.4 Payment .................................................................................................................................. 93

3.17 RECYCLING OF BITUMINOUS PAVEMENTS (REC LAIMED ASPHALT PAVEMENT) ................. 93

3. 17.1 Scope ........................................................................................................................................ 93

3.18 BRICK PAVEMENT ............................................................................................................... 96

3.18.1 Description .............................................................................................................................. 97
3.18.2 Subgrade and Improved Subgrade ........................................................................................... 97
3.18.3 Materials ................................................................................................................................. 97
3.18.4 Brick on End Edging.................................................................................................................. 97
3.18.4.1 Description ......................................................................................................................................... 97
3.18.4.2 Construction Methods. ....................................................................................................................... 97

3.18.5 Single Layer Brick Flat Soling .................................................................................................... 97

3.18.5.1 Description. ........................................................................................................................................ 97
3.18.5.2 Construction Methods. ....................................................................................................................... 97

3.18.6 Brick on Edge Pavement in Herringbone Bond......................................................................... 97

3.18.6.1 Description ......................................................................................................................................... 97
3.18.6.2 Construction Methods ........................................................................................................................ 98
3.18.6.3 Surface Tolerance ............................................................................................................................... 98

3.18.7 Measurement .......................................................................................................................... 98

3.18.8 Payment .................................................................................................................................. 98

3.19 DRY LEAN CEMENT CONCRETE ............................................................................................ 98

3.19.1 Scope ........................................................................................................................................ 98
3.19.1.1 .................................................................................................................................................... 98
3.19.1.2 .................................................................................................................................................... 99
3.19.2 Materials .................................................................................................................................. 99
3.19.2.1 Cement: ................................................................................................................................ 99
3.19.2.3 Water: ................................................................................................................................................ 99

3.19.3 Proportioning of Materials for the Mix ..................................................................................... 99

3.19.3.1 ............................................................................................................................................................... 99

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 3.19.3.2 Moisture content: ............................................................................................................................... 99
3.19.3.3 Cement content:............................................................................................................................ 99
3.19.3.4 Concrete strength:.......................................................................................................................... 99

3.19.4 Construction ............................................................................................................................. 99

3.19.4.1 General: ......................................................................................................................................... 99
3.19.4.2 Batching and mixing:......................................................................................................................... 100
3.19.4.3 Transporting: .................................................................................................................................... 100
3.19.4.4 Placing:......................................................................................................................................... 100
3.19.4.5 Compaction .................................................................................................................................. 100

3.19.5 Trial Mixes .............................................................................................................................. 101

3.19.6 Curing ..................................................................................................................................... 101
3.19.7 Removal of Scaffolding and Formwork........................................................................................ 101
3.19.8 Repair of Concrete .................................................................................................................. 102
3.19.9 Traffic ..................................................................................................................................... 102
3.19.10 Tolerances for Surface Regularity, Level, Thickness and Strength ....................................... 102
3.19.11 Measurements .................................................................................................................... 102
3.19.12 Payment ............................................................................................................................. 102

3.20 CEMENT CONCRETE PAVEMENT ........................................................................................ 102

3.20.1 Scope ...................................................................................................................................... 102
3.20.1.1 ............................................................................................................................................................. 102
3.20.1.2 ............................................................................................................................................................. 102

3.20.2 Materials ................................................................................................................................ 103

3.20.2.1 Cement:............................................................................................................................................ 103
3.20.2.2 Admixtures: ...................................................................................................................................... 103
3.20.2.3 Aggregates: .................................................................................................................................. 103
3.20.2.4 Water: .......................................................................................................................................... 104
3.20.2.5 Admixtures: ...................................................................................................................................... 104
3.20.2.6 High Yield Deformed Steel Reinforcing Bars for dowels and tie bars: ................................................. 104
3.20.2.7 Pre-moulded joint filler: .................................................................................................................... 104
3.20.2.8 Joint sealing compound: ................................................................................................................... 104
3.20.2.9 Storage of materials:..................................................................................................................... 104

3.20.3 Proportioning of Concrete ...................................................................................................... 104

3.20.3.1 ............................................................................................................................................................. 104
3.20.3.2 Cement content:........................................................................................................................... 104
3.20.3.3 Concrete strength: ............................................................................................................................ 105
3.20.3.4 Workability ....................................................................................................................................... 105
3.20.3.5 Design mix ........................................................................................................................................ 105

3.20.4 Separation Membrane ............................................................................................................ 106

3.20.5 Joints ...................................................................................................................................... 106
3.20.5.1 ............................................................................................................................................................. 106
3.20.5.2 Transverse joints............................................................................................................................... 106
3.20.5.3 Transverse construction joint: ........................................................................................................... 107
3.20.5.4 Longitudinal joint .............................................................................................................................. 107

3.20.6 Dowel bars.............................................................................................................................. 107

3.vii | P a g e
 3.20.6.1 ............................................................................................................................................................. 107
3.20.6.2 ............................................................................................................................................................. 108
3.20.6.3 ............................................................................................................................................................. 108
3.20.6.4 ............................................................................................................................................................. 108
3.20.6.5 ............................................................................................................................................................. 109
3.20.6.6 ............................................................................................................................................................. 109
3.20.6.7 Tie bars............................................................................................................................................. 109

3.20.7 Weather and Seasonal Limitations ......................................................................................... 110

3.20.7.1 Concreting during monsoon months: ................................................................................................ 110
3.20.7.2 Concreting in hot weather: ............................................................................................................... 110

3.20.8 Side Forms, Rails ..................................................................................................................... 110

3.20.8.1 Side forms and rails:.......................................................................................................................... 110
3.20.8.2 ............................................................................................................................................................. 111

3.20.9 Construction ........................................................................................................................... 111

3.20.9.1 General:............................................................................................................................................ 111
3.20.9.2 Batching and mixing:......................................................................................................................... 111
3.20.9.3 Equipment for proportioning of materials and paving ....................................................................... 111

3.20.9.4 Hauling and placing of concrete ..................................................................................... 112

3.20.9.5 Construction by fixed form paver ...................................................................................................... 114
3.20.9.6 Construction by slip form paver ........................................................................................................ 114
3.20.9.7 Construction by hand-guided method: .............................................................................................. 115
3.20.9.8 Surface texture ................................................................................................................................. 115

3.20.10 Preparation and Sealing of Joint Grooves ........................................................................... 116

3.20.10.1 General ........................................................................................................................................ 116
3.20.10.2 Preparation of joint grooves for sealing......................................................................................... 117
3.20.10.3 Sealing with sealants .................................................................................................................... 117

3.20.11 Removal of Scaffolding and Formwork: .............................................................................. 118

3.20.12 Repair of Concrete: ............................................................................................................. 118
3.20.13 Measurement of Texture Depth- Sand Patch Method ........................................................ 118
3.20.13.1 The following apparatus shall be used:.......................................................................................... 119
3.20.13.2 Method: ....................................................................................................................................... 119
3.20.13.3 ........................................................................................................................................................... 119

3.20.14 Opening to Traffic ............................................................................................................ 119

3.20.15 Tolerances for Surface Regularity, Level, Thickness and Strength ................................... 119
The tolerances for surface regularity, level, thickness and strength shall conform to the requirements
and Control of quality of materials and works shall be exercised satisfactory to the Engineer.............. 119
3.20.16 Method Statement for concrete pavement construction ............................................... 119
3.20.17 Measurements for Payment ........................................................................................... 123
3.20.17.1 Pavement thickness ...................................................................................................................... 124

3.20.18 Rate .................................................................................................................................... 124

3.viii | P a g e
3.1 Pavement (Minor works & preliminaries)

3.1.1 General

Division 3 of the Specifications covers all requirements for road pavements that will be
incorporated in the Works.
3.1.2 Preparation and Stockpiling of Materials

Materials to be used in pavement works shall be processed and stockpiled only in

designated areas as approved by the Engineer. The Contractor shall make all
arrangements and bear all costs associated with the provision of these storage areas.
Preparation and storage of materials along the alignment will not be allowed.
The designated areas shall be cleared of all vegetation and topsoil prior to commencing
work and the arrival of any materials. The area will be graded with proper slopes,
drained, and well compacted to provide a plane and hard surface for the stockpiling of
materials. The area to be used for stockpiling of concrete/bituminous works aggregates
shall be a surfaced platform with a well compacted 150 mm thick layer of
stone/gravel/brick aggregate or with brick flat soling over a compacted sand bed. The
area of surfaced platform will be sufficient enough to allow stockpiling and handling
operations of aggregates without intermixing of different types of aggregates or spilling
of aggregates outside the surfaced platform at any stage. All necessary measures shall be
taken to prevent contamination of aggregates with silt and clay and other deleterious
materials during the stockpiling and handling operations. If any aggregate has been
stockpiled outside the surfaced platform, the bottom 300 mm of material shall not be
used in the concrete/bituminous works; however, it can be used in other un-important
works with the permission of the Engineer. Similar kinds of precautions shall be taken
during stockpiling and handling of stone boulders to be crushed at the plant site to
prevent contamination of their products. In any case, any contaminated aggregate shall
not be used in the works.
Bricks of different frog marks, different materials and size fractions shall be kept in
separate stockpiles divided as necessary to prevent contamination.
Unless otherwise approved by the Engineer, each stockpile shall be built at least 2
metres high. The Contractor shall supply any planking or other material required in
connection with movement of vehicles over and about the stockpiles.
3.1.3 Scarification and Preparation of bed under the existing pavement/or Hard
Shoulders

The work shall consist of scarifying the bed under existing pavement/or hard shoulders
to a depth up to maximum 200 mm or as ordered by the Engineer and over a width as
indicated on the drawings or as instructed by the Engineer upon excavating pit
holebefore preparing estimate. The excavation of existing pavement/ and hard shoulders
shall be done as instructed in the section 2 of these specifications. The material under the
existing pavement bed shall be thoroughly mixed by means of a motor grader and
homogenised with a pulvimixer or similar approved plant methods. It shall then be
3.1 | P a g e
 spread and compacted, with the addition of water as may be required, in such manner as
to obtain a profile confirming with the lines, grades and cross sections shown on the
Drawings, or as directed by the Engineer.
If there is any suitable surplus material this shall be temporarily stockpiled for
subsequent reuse in the works, as directed by the Engineer.
Any shortage of materials shall be supplied by the addition of material having
engineering characteristics and mix design as specified for the sub-base or base as
appropriate and instructed by the Engineer. The additional material shall be thoroughly
mixed with the scarified and homogenised material, by means of a motor grader, before
compacting.

3.1.4 Repair of Potholes and Damaged Areas of the Existing Bituminous

Surfaced Roads

The Engineer may instruct the Contractor to repair potholes or damaged areas on
existing bituminous surfaced roads including depressions and broken edges.
The Contractor shall remove the bitumen surface as directed. All damaged and unstable
parts of the existing base and sub-base shall be excavated until sound material is reached
on all sides and at the base of the excavation. Unsuitable excavated materials shall either
be disposed of or stockpiled in locations as directed by the Engineer. The shape of the
excavation shall then be made rectangular with vertical sides by cutting the damaged
area in proper shapes both in horizontal and vertical direction.
The excavated material, depending on its nature, shall be:
1) Stocked adjacent to the Works for reuse, if so directed, or
2) Disposed of to spoil, if so instructed in writing by the Engineer.
The bottom of the excavation shall then be shaped, trimmed, watered if necessary, and
compacted to the density required for the appropriate pavement layer. The excavation
shall then be filled with base material of the type directed by the Engineer in layers after
compaction of not thicker than 100 mm. Each layer shall be properly levelled and
watered and carefully rammed or compacted with an approved hand vibratory roller, in
order to achieve the density required in Section 3.7 for Aggregate Base. A bituminous
levelling course or bituminous surfacing will then be placed after applying tack coat to
the bottom layer and outer vertical sides, as directed by the Engineer in accordance with
the procedure as described in Sections 3.11.3.2, 3.11.3.3 and 3.9.3.4.
3.1.5 Levelling Course

Where shown on the Drawings, or as ordered by the Engineer, a levelling course will be
constructed on the existing pavement with the materials required in the Drawings or as
otherwise ordered by the Engineer. The execution, measurement and payment of the
levelling course works shall be in accordance with the relevant provisions of these
Specifications, for the material that will be ordered by the Engineer to be used.
3.1.6 Payment
3.2 | P a g e
 The scarification and preparation of Existing Pavement and/or shoulders will be paid for
at the Contract unit price for each square metre actually scarified in accordance with the
instructions of the Engineer. The price shall be full compensation for all labour,
equipment, tools, plant, etc. for scarifying, mixing, homogenising, spreading, watering
and compacting, or temporary stockpiling for reuse, and all other incidentals necessary
to complete the work specified.
The cost of removing existing layer shall be included in Pay Item No. 3/1/1. The
inventory of damaged portion has to be kept in quantity by taking measurement and then
approval shall be taken from the engineer. The damaged portion shall have to be clearly
marked. If the damaged portion reaches up to the base or sub-base layers, the portion of
base and sub-base layers shall be repaired by appropriate base and sub-base materials
respectively and the cost of repair shall be according to pay items of base and sub-base
construction.
The repair of Potholes and damaged areas of Existing Bituminous Surfaced roads shall
be paid for at the Contract unit rate, on the basis of the volume of excavation filled as
ordered by the Engineer. The rate shall include for all excavation, for disposal or
stockpiling of resulting material, where ordered, for the compaction of the bottom of the
excavation to the specified density, for the supply and placing of sub-base or base
material to the specified density along with the supply and placing of the bituminous
material, and for all charges related to the proper execution of the work prescribed. The
cost of tack coat shall be considered to be included within the rates of this item.
Pay items shall be:
3/1/1 Scarify, Mix and Recompactfor repairing Existing
Pavement and/or Shoulder Square Metre
3/1/2 Repair of Potholes on the Existing Pavement Cubic Metre

3.2 SUB-BASE
3.2.1 Description

This work shall consist of furnishing, placing and compacting sub-base material on a
prepared and accepted subgrade or improved subgrade in accordance with these
Specifications, and to the lines, levels, grades, dimensions and cross sections shown on
the Drawings or as required by the Engineer.
3.2.2 Materials

The Contractor shall submit results of material tests on the proposed sub-base material to
the Engineer for his approval at least seven days in advance of its use. Fresh approval
shall be required when the material is changed.
Material shall be natural or artificial aggregate material (crushed stone, crushed slag etc),
free from vegetable matter, soft particles, clay and excess silt. Natural and artificial
materials may be mixed together provided they fully conform to all requirements of the

3.3 | P a g e
Specification and the proportions are approved by the Engineer in writing. If gravel is
used as coarse aggregate, it shall contain at least 50% particles (by weight) having
broken faces. Natural sand with Fineness Modulus less than 1.0 shall not be allowed to
be used in the sub-base material. Recycled base or sub-base aggregates satisfying the
specification requirements may also be used.
The material for sub-base shall conform to the requirements given below:
a) Grading: The grading (washed method) shall conform to grading envelopes A, B or C
in Table 3.2-1, as specified in the contract; in case the type of grading is not specified
in the contract, it shall be as instructed by the Engineer, whereas grading C may be
used in case of minor roads only(less than 3 million ESAL).
b) Plasticity. The portion of material passing the 0.425 mm sieve shall be shall Be of PI
not more than 6 when tested in accordance with test procedure STP 3.2.
c) CBR. The material shall have a 4-day soaked CBR value not less than 40% when
compacted to 98% of maximum dry density as determined by STP 4.5 (Vibrating
Hammer).
d) Los Angeles Abrasion Value:
In case of Stone aggregate, material when sampled and tested shall have a Los
Angeles Abrasion Value not greater than40% or Aggregate Crushing Value (ACV)
not greater than 30%.
Sub-base layer can be divided into two parts, whereas the lower part can be used as
sub-surface drainage layer or filter layer to serve the drainage purpose as proposed in
the drawings and approved by the Engineer. The filtration compatibility of the sub
base layer must be evaluated to separate the sub grade and sub base layer. Geotextiles
can be used as the separator in some cases, whereas lower part of sub base layer
(dense graded and low permeability) can also be used as the drainage cum filter layer
conforming the grading requirements of the following table containing Grading D
envelope ((Indian Specification of Subbase Envelope VI).

Table 3.2-1
Grading Requirements for Sub-base Material
Percentage by Weight Passing Sieves
Sieve Grading Grading D Tolerance
Size B for mix
Grading (Drainage
Grading A design
(mm) C cum Filter
layer)
50 100 -- 100 100 ±1
80 – 90 – 100
38 --
85 – 100 100
20 55 – 95 100 70 – 90 70 – 95 ±6

3.4 | P a g e
 10 35 – 75 70 – 100 55 – 90 55 – 75 ±7
5 25 – 60 45 - 85 35 – 65 30 – 55 ±6
2.4 15 – 50 30 – 70 25 – 55 10 – 25
0.600 7 – 35 15 – 45 20 – 40 2 - 10 ±2
0.300 6 – 27 7 – 30 10 – 15 0-6
0.075 3 – 15 4 - 20 <5 0-3 ±1
Minimum
CBR 40 40 40 40
Value

3.2.3 Construction Methods

3.2.3.1 Preparation of Subgrade or Improved Subgrade

The subgrade or improved subgrade shall be shaped and compacted in conformity with
the provisions of Specifications Sections 2.7 and 2.8 and completed ahead of the placing
of the sub-base material. Without any earlier approval, any damage to or deterioration of
the subgrade or improved subgrade, including any increase in moisture content above
that permitted to achieve the specified compaction, shall be corrected at the Contractors
expense before sub-base is laid.
Preparation and surface treatment of the subgrade or improved subgrade shall be carried
out only after completion of any specified subgrade drainage and unless otherwise
agreed by the Engineer immediately prior to laying the sub-base. The sequence of
operations shall be as follows:
a) The subgrade or improved subgrade shall be regulated and trimmed so that its
finished profile shall not vary by more than 20 mm above or below the specified
formation level at any point.
b) The trimmed formation shall be rolled by 1 pass of a smooth-wheeled roller having a
load per 100 mm width of roll not less than 214 kg or a vibratory roller having a
static load per 100 mm width of vibratory roll of not less than 71 kg or a vibratory
plate compactor having a static pressure under the base plate of not less than 1,400
kg/m2.

3.2.3.2 Provision of Lateral Confinement of Aggregates

While constructing sub-base, arrangement shall be made for the lateral
confinement/shoulder of sub-base materials. This shall be done by laying materials in
adjoining shoulders along with that of subbase.

3.2.3.3 Preparation of Mix

Mixed materials shall be prepared in an approved mixing plant of suitable capacity
with a provision for controlled addition of water and mixing arrangement like pug-mill
or pan type mixer of concrete batching plant.

3.5 | P a g e
 While adding water, due allowance should be made for evaporation losses. However, at
the time of compaction, water in the wet mix shall be the optimum value of moisture
content. The mixed material should be uniformly wet and no segregation should be
permitted.
The Engineer shall decide whether to utilize a batching plant or manual methods for
laying the aggregate base on the road during preparation of estimate depending
onproject’s value and importance.

3.2.3.4 Spreading of Mix

Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the
prepared sub-gradeor improved subgrade in accordance with the layer depth, with an
un-compacted thickness up to 150 mm, subject to the approval of Engineer. In no case
shall these be dumped in heaps directly on the area where these are to be laid nor shall
their hauling over a partly completed stretch be permitted.
The mix may be spread by a paver finisher. The paver finisher shall be self-propelled of
adequate capacity with following features:
i) Loading hoppers and suitable distribution system, so as to provide a smooth
uninterrupted material flow for different layer thicknesses from the tipper to the
screed.
ii) Hydraulically operated telescopic screed for paving width up to 8.5m and fixed
screed beyond this. The screed shall have tamping and vibrating arrangement for
initial compaction of the layer.
iii) Automatic levelling control system with electronic sensing device to maintain mat
thickness and cross slope of mat during laying procedure.
In exceptional cases where it is not possible for the paver to be utilized, mechanical
means like motor grader may be used with the prior approval of the Engineer. The motor
grader shall be capable of spreading the material uniformly all over the surface.
The surface of the aggregate shall be carefully checked with templates and all high or
low spots remedied by removing or adding aggregate as may be required. The layer may
be tested by depth blocks during construction. No segregation of larger and fine particles
should be allowed. The aggregates as spread should be of uniform gradation with no
pockets of fine materials.
Where the shoulders are of the same as that used for the sub-base course, the material
shall be evenly spread in layers, as herein specified, for the full width of the sub-base
course and the shoulders simultaneously.
Where the shoulders are not of the same material as that of sub-base course, then the sub
base shall be spread to give the required compacted depth and the edge detail shown in
the drawings.
When the sub base is spread contiguous to the concrete kerbs or gutters, extreme care
shall be exercised not to damage them. Any damage of kerbs or gutters resulting from

3.6 | P a g e
 carelessness or negligent construction methods by the Contractor shall warrant their
removal and replacement at the Contractor’s sole expense.
The Engineer may permit manual mixing and /or laying of sub-base mixdepending upon
the quantity of work or importance of the work.

3.2.3.5 Sprinkling, Rolling and Compacting

After the mix has been laid to the required thickness, grade and cross fall/camber the
same shall be uniformly compacted to the full depth with suitable roller. If the thickness
of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 to
100kN weight may be used. For a compacted single layer upto 200 mm, the compaction
shall be done with the help of Vibratory roller of minimum static weight of 80 to 100 kN
with an arrangement for adjusting the frequency and amplitude. An appropriate
frequency and amplitude may be selected. The speed of the roller shall not exceed 5
km/h.
In portions having unidirectional cross fall/super elevation, rolling shall commence from
the lower edge and progress gradually towards the upper edge. Thereafter, roller should
progress parallel to the center line of the road, uniformly over-lapping each preceding
track by at least one-third width until the entire surface has been rolled. Alternate trips of
the roller shall be terminated in stops at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running forward
and backward until the edges have been firmly compacted. The roller shall then progress
gradually towards the center parallel to the center line of the road uniformly overlapping
each of the preceding track by at least one-third width until the entire surface has been
rolled.
Any displacement occurring as a result of reversing of the direction of a roller or from
any other cause shall be corrected at once as specified and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be
thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of
an area without scarifying the surface to permit proper bonding of the added material
shall not be permitted.
If water is required, to bring Sub base material to the correct moisture content, it shall be
sprinkled on the surface. The contractor shall supply and sprinkle the necessary water at
his own expense. Sub-base material containing excess moisture shall be dried prior to or
during compaction. Drying of wet material shall be performed by the methods approved
by the Engineer, at the expense of the Contractor.
The Contractor shall carry out a field compaction trial at the start of constructing the
sub-base to determine the optimum moisture content and the required number of passes
of his particular compaction equipment to comply with the Specification. This trial will
also determine the relationship between the loose and compacted thickness in controlling
the loose thickness at the time of spreading the mix. The method will require to be
approved by the Engineer and shall then be used for all subsequent compaction of sub-
base material. Such agreement will not, however, relieve the Contractor of his
responsibility and in the event that results later show that the specified compaction is not

3.7 | P a g e
 being achieved all sub base work shall cease and not be resumed until a fresh trial has
been undertaken and a revised compaction method approved by the Engineer.
Rolling should not be done when the sub-grade is soft or yielding or when it causes a
wave- like motion in the sub-base/base course or sub-grade. If irregularities develop
during rolling which exceed 12 mm when tested with a 3 m straight edge, the surface
should be loosened and premixed material added or removed as required before rolling
again so as to achieve a uniform surface conforming to the desired grade and cross fall.
In no case shall the use of unmixed material be permitted to make up the
depressions.The thickness of the finished sub-base shall be on average.
- not less than the required thickness when five thickness measurements are
averaged in any 150m length of completed sub-base.
- not thinner than 10mm less than the required thickness at any point.
Sub-base which does not conform to the above requirements shall be corrected by
scarifying the full depth of the affected areas, adding or removing materials and re-
rolling, watering if necessary, until the entire surface conforms to the correct levels and
cross-falls.
Rolling shall be continued till the density achieved is at least 98 percent of the maximum
dry density for the material. Static Deformation Modulus Ev2 shall be 150 MPa and
Ev2/Ev1 shall be ≤2.3 as per technical standards including ASTM 1195/ASTM 1196
and DIN 18134. Testing for Ev2 and Ev1is mandatory; however, it is important to note
that the test results will not be used as acceptable criteria but solely for record keeping
purpose.
After completion, the surface of any finished layer shall be well-closed, free from
movement under compaction equipment or any compaction planes, ridges, cracks and
loose material. Sub-base which does not conform to the above requirements shall be
corrected by scarifying the full depth of the affected areas, adding or removing materials
and re-rolling, watering if necessary, until the entire surface conforms to the correct
levels and cross-falls.
The prepared sub-base layer shall be protected against damage until covered by the base
course.
3.2.4 Opening to Traffic

No Vehicular traffic shall be allowed on the finished sub base surface. Construction
equipment may be allowed with the approval of the Engineer.
3.2.5 Measurement

Sub-base as described in this Section shall be measured by the cubic metres of

compacted material in place and accepted. Measurement shall be based on the
thickness/cross-section of the sub-base shown on the Drawings and area/length
measured on the surface of the road.
3.2.6 Payment

3.8 | P a g e
 This work measured as provided above shall be paid for at the Contract unit rate per
cubic metre for aggregate sub-base, as detailed below. The payment shall be full
compensation for furnishing all materials, hauling, placing, compacting, sprinkling,
finishing and shaping, and for all labour, equipment, tools and other incidentals
necessary to complete the work specified.
Sub-base shall be paid for at the Contract unit rate irrespective of the sources of
materials used for constructing the sub-base. All costs for excavating existing pavement,
or removing existing structures, or savings to the Contractor from re-using materials
excavated from existing pavements or structures shall be deemed already covered under
pay items 2/2/3, 2/2/4, 2/2/5, 2/9/1 and 2/9/2.
Item shall be:
3/2/1 Sub-base Cubic Metre

3.3 LIME TREATED SOIL FOR IMPROVED SUB-GRADE/SUB

-BASE

3.3.1 Scope
This work shall consist of laying and compacting an improved sub-grade/lower sub-base
of soiltreated with lime on prepared sub-grade in accordance with the requirements of
these Specifications and in conformity with the lines, grades and cross-sections shown on
the drawings or as directed by the Engineer. Lime treatment is generally effective for
soils which contain a relatively high percentage of clay and siltyclay, whereas the clay
percentage is at least 15%.
3.3.2 Materials

Soil:
Except when otherwise specified, the soil used for stabilisation shall be the local clayey
soil having a plasticity index greater than 8.
Lime:
Lime for lime-soil stabilisation work shall be commercial dry lime slaked at site or pre-
slaked lime delivered to the site in suitable packing. Unless otherwise permitted by the
Engineer, the lime shall have purity of not less than 70 percent by weight of Quick-lime
(CaO). Lime shall be properly stored to avoid prolonged exposure to the atmosphere and
consequent carbonation which would reduce its binding properties.

Quantity of lime in stabilised mix:

Quantity of lime to be added as percentage by weight of the dry soil shall be as

specified in the Contract. The quantity of lime used shall be related to its calcium oxide
content which shall be specified. Where the lime of different calcium oxide content is to
be used, its quantity shall be suitably adjusted to the approval of the Engineer so that
3.9 | P a g e
 equivalent calcium oxide is incorporated in the work. The mix design shall be done to
arrive at the appropriate quantity of lime to be added, having due regard to the purity of
lime, the type of soil, the moisture-density relationship, and the design CBR/Unconfined
Compressive Strength (UCS) value specified in the Contract. The laboratory CBR/UCS
value shall be at least 1.5 times the minimum field value of CBR/UCS stipulated in the
Contract.

Water:

The water to be used for lime stabilisation shall be clean and free from injurious
substances. Potable water shall be preferred.
3.3.3 Construction Methods
3.3.3.1 Weather limitations:

Lime-soil stabilisation shall not be done when the air temperature in the shade is less
than 10ºC.

3.3.3.2 Degree of pulverisation:

For lime stabilisation, the soil before addition of stabilizer, shall be pulverized using
agricultural implements like disc harrows (only for low volume roads) and rotavators.

3.3.3.3 Soil Pulverisation Requirements for Lime Stabilisation

3.3.3.4 Equipment for construction:

Stabilised soil sub-bases shall be constructed by mix-in-place method of construction or
as otherwise approved by the Engineer. Manual mixing shall be permitted only where
the width of laying is not adequate for mechanical operations, as in small-sized jobs.
The equipment used for mix-in-place construction shall be a rotavator or similar
approved equipment capable of pulverizing and mixing the soil with additive and water
to specified degree to the full thickness of the layer being processed, and of achieving
the desired degree of mixing and uniformity of the stabilised material. If so desired by
the Engineer, trial runs with the equipment shall be carried out to establish its suitability
for work.
The thickness of any layer to be stabilised shall be not less than 100 mm when
compacted. The maximum thickness can be 200 mm, provided the plant used is accepted
by the Engineer.

3.3.3.5 Mix-in-place method of construction:

Before deploying the equipment, the soil after it is made free of undesirable vegetation
or other deleterious matter shall be spread uniformly on the prepared subgrade in a
quantity sufficient to achieve the desired compacted thickness of the stabilised layer.
Where single-pass equipment is to be employed, the soil shall be lightly rolled at the
discretion of the Engineer.

3.10 | P a g e
 The equipment used shall either be of single-pass or multiple pass type. The mixers shall
be equipped with an appropriate device for controlling the depth of processing and the
mixing blades shall be maintained or reset periodically so that the correct depth of
mixing is obtained at all times.
With single-pass equipment the forward speed of the machine shall be so selected in
relation to the rotor speed that the required degree of mixing, pulverisation and depth of
processing is obtained. In multiple-pass processing, the prepared sub-grade shall be
pulverised to the required depth with successive passes of the equipment and the
moisture content adjusted to be within prescribed limits mentioned hereinafter. The
blending or stabilizing material shall then be spread uniformly and mixing continued
with successive passes until the required depth and uniformity of processing have been
obtained.
The mixing equipment shall be so set that it cuts slightly into the edge of the adjoining
lane processed previously so as to ensure that all the material forming a layer has been
properly processed for the full width.

3.3.3.6 Construction with manual means:

Where manual mixing is permitted, the soil from borrow areas shall first be freed of all
vegetation and other deleterious mater and placed on the prepared subgrade. The soil
shall then be pulverized by means of crow-bars, pick axes or other means approved by
the Engineer.
Water in requisite quantities may be sprinkled on the soil for aiding pulverisation. On
the pulverized soil, the blending material(s) in requisite quantities shall be spread
uniformly and mixed thoroughly by working with spades or other similar implements till
the whole mass is uniform. After adjusting the moisture content to be within the limits
mentioned later, the mixed material shall be leveled up to the required thickness so that
it is ready to be rolled.

3.3.3.7 Addition of lime:

Lime may be mixed with the prepared material either in slurry form or dry state at the
option of the Contractor with the approval of the Engineer.
Dry lime shall be prevented from blowing by adding water to the lime or other suitable
means selected by the Contractor, with the approval of the Engineer.
The tops of windrowed material may be flattened or slightly trenched to receive the
lime. The distance to which lime may be spread upon the prepared material ahead of the
mixing operation shall be determined by the Engineer.
No traffic other than the mixing equipment shall be allowed to pass over the spread lime
until after completion of mixing. Mixing or remixing operations, regardless of
equipment used, shall continue until the material is free of any white streaks or pockets
of lime and the mixture is uniform.
Non-uniformity of colour reaction, when the treated material is tested with the standard
phenolphthalein alcohol indicator, will be considered evidence of inadequate mixing.

3.11 | P a g e
3.3.3.8 Moisture content for compaction:
The moisture content at compactionto be determined by trial compaction at site.

3.3.3.9 Rolling:
Immediately after spreading, grading and levelling of the mixed material, compaction
shall be carried out with approved equipment preceded by a few passes of lighter rollers
if necessary. Rolling shall commence at edges and progress towards the centre, except at
super elevated portions where it shall commence at the inner edge and progress towards
the outer edge. During rolling, the surface shall be frequently checked for grade and
crossfall (camber) and any irregularities corrected by loosening the material and
removing/adding fresh material. Compaction shall continue until the density achieved is
at least 98 percent of the maximum dry density for the material.
Care shall be taken to see that the compaction of lime stabilised material is completed
within three hours of its mixing or such shorter period as may be found necessary in dry
weather.
During rolling it shall be ensured that roller does not bear directly on hardened or
partially hardened treated material previously laid other than what may be necessary for
achieving the specified compaction at the joint. The final surface shall be well closed,
free from movement under compaction planes, ridges, cracks or loose material. All loose
or segregated or otherwise defective areas shall be made good to the full thickness of the
layer and recompacted.
3.3.3.10 Curing:

The sub-base course shall be suitably cured for a minimum period of 7 days after which
subsequent pavement courses shall be laid to prevent the surface from drying out and
becoming friable. No traffic of any kind shall ply over the completed sub-base unless
permitted by the Engineer.
3.3.4 Strength

When lime is used for improving the subgrade, the soil-lime mix shall be tested for its
CBR value. When lime stabilised soil is used in a sub-base, it shall be tested for
unconfined compressive strength (UCS) at 7 days. In case of variation from the design
CBR/UCS, in situ value being lower, the pavement design shall be reviewed based on
the actual CBR/ UCS values.
3.3.5 Arrangements for Traffic

During the period of construction, arrangements for traffic shall be provided and
maintained.
3.3.6 Measurements for Payment

Stabilised soil sub-base/ISG shall be measured as finished work in position in cubic

metres.
3.3.7 Payment
3.12 | P a g e
 Sub-base shall be paid for at the contract unit rate irrespective of the sources of materials
used for constructing the sub-base.

Pay items shall be

3/3/1 Lime treated ISG CubicMetres

3/3/2 Lime treated sub base CubicMetres

3.4 CEMENT TREATED SUB-BASE/BASE

3.4.1 Scope

This work shall consist of laying and compacting a sub-base/base course of sand treated
with cement on prepared subgrade/sub-base, in accordance with the requirements of
these Specifications and in conformity with the lines, grades and cross-sections shown
on the drawings or as directed by the Engineer. Mixing and compaction of Cement
Treated Sub Base/Base course:

3.4.2 Methodology

For pavement design, it's crucial to ensure that the Cement Treated Sub base/Base
behaves like a granular material over time, rather than hard concrete, to prevent cracking
that could affect the overlying asphalt concrete layers. Here's a structured approach to
achieve this:

1. Combined Gradation: The combined gradation of aggregates of different sizes in

the laboratory shall be determined. Samples shall be taken from various stockpiles
or sources of soil/aggregates to ensure uniformity and proper distribution of
particle sizes.
2. Material Preparation: Air-dry the materials and mix them in a batching plant.
This ensures proper blending and consistency of the mixture.
3. Placement: Spread the mixed materials evenly on the roadway using a paver.
Proper distribution of the material is essential for uniform compaction and
performance.
4. Additives Placement: Unpack and place packets of cement on top of the placed
materials at predetermined intervals. These additives enhance the strength and
durability of the treated base course.
5. Mixing: Mix all materials thoroughly using a rotavator or similar equipment. This
ensures uniform distribution of additives and aggregates throughout the mixture.
6. Moisture Control: Sprinkle water onto the bed just enough to facilitate
compaction. Proper moisture content is essential for achieving optimal
compaction and ensuring the desired properties of the treated base.

3.13 | P a g e
 7. Compaction: Compact the bed using conventional procedures such as rollers or
compactors. Adequate compaction is critical to achieving the required density and
stability of the treated base course.

The Cement Treated Sub Base/Base can be engineered to behave like a granular base
course, minimizing the risk of cracking and ensuring long-term performance of the
pavement structure following the steps properly.
3.4.3 Materials

The material used for cement treatment shall be soil including sand and gravel, laterite,
kankar, brick aggregate, crushed rock or slag or any combination of these. It shall have
a uniformity coefficient not less than 5, capable of producing a well-closed surface
finish. For use in a base course, the material shall be sufficiently well graded to ensure a
well-closed surface finish and have a grading within the range given in Table 3.4-1. If
the material passing 425 micron sieve is plastic, it shall have a liquid limit not greater
than 45 percent and a plasticity index not greater than 20 percent determined in
accordance with STP.

Cement:
Cement for stabilisation shall either be ordinary portland cement, portland slag cement
or Portland-puzzolana cement.

Table 3.4-1: Grading Limits of Material for Stabilisation with Cement

Percentage by mass passing
Sieve size
Sub-Base/Base Within the range
50.00 mm 100
37.5 mm 95 – 100
19.0 mm 45 – 100
9.5 mm 35 – 100
4.75 mm 25 – 100
600 micron 8 – 65
300 micron 5 – 40
75 micron 0 – 10

Quantity of cement in stabilised mix:

The quantity of cement to be added as percent by weight of the dry mix shall be
specified in the mix design and approved by the Engineer. The mix design shall be done
on the basis of 7-day unconfined compressive strength (UCS) and/or durability test
under 12 cycles of wet-dry conditions. The laboratory strength values shall be at least
1.5 times the minimum field UCS value stipulated in the particular clause of Contract.

3.14 | P a g e
 Water:
The water to be used for cement stabilisation shall be clean and free from injurious
substances. Potable water shall be preferred.
3.4.4 Construction Methods

3.4.4.1 Weather limitations

Stabilisation shall not be done when the air temperature in the shade is less than 10°C.

3.4.4.2 Degree of pulverisation:

For stabilisation, the soil before addition of stabilizer, shall be pulverised, where
necessary.

3.4.4.3 Moisture content for compaction:

The moisture content at compaction to be determined by trial at site.

3.4.4.4 Rolling:
Care shall be taken to see that the compaction of cement stabilised material is completed
within initial setting time of cement used or period as instructed by Engineer in dry
weather.

3.4.4.5 Curing:
The sub-base/base course shall be suitably cured for 7 days. Subsequent pavement
course shall be laid soon after to prevent the surface from drying out and becoming
friable. No traffic of any kind shall ply over the completed sub-base unless permitted by
the Engineer.
3.4.5 Strength
Cement treated soil sub-base/base shall be tested for the unconfined compressive
strength (UCS) value at 7 days, actually obtained in-situ. In case of variation from the
design UCS, in-situ value being on lower side, prior to proceeding with laying of
base/surface course on it, the pavement design shall be reviewed for actual UCS value.
The extra pavement thickness needed on account of lower UCS shall be constructed by
the Contractor at his own cost.

3.4.6 Arrangements for Traffic

During the period of construction, arrangements for traffic shall be provided and
maintained.
3.4.7 Measurements for Payment
Stabilised soil sub-base/base shall be measured as finished work in position in cubic
metres.
3.4.8 Payment
Cement treated Sub-base/ Base shall be paid as cubic meters.

3.15 | P a g e
 Pay items shall be
3/4/1 Cement treated sub base CubicMetres
3/4/2 Cement treated base CubicMetres

3.5 WATER BOUND MACADAM SUB-BASE/BASE

3.5.1 Scope
This work shall consist of clean crushed aggregates mechanically interlocked by rolling
and bonding together with screening, binding material where necessary and water laid
on a properly prepared subgrade/sub-base/base or existing pavement, as the case may be
and finished in accordance with the requirements of these Specifications and in close
conformity with the lines, grades, cross-sections and thickness as per approved plans or
as directed by the Engineer. This specification is meant for repairs and minor works of
widening nature, and also at locations where it is not feasible to lay WMM.
3.5.2 Materials
Coarse aggregates:
Coarse aggregates shall be either crushed or broken stone, crushed slag or any other
naturally occurring aggregates such as kankar and laterite of suitable quality. Materials
other than crushed or broken stone and crushed slag shall be used in sub-base courses
only. If crushed gravel /shingle is used, not less than 90 percent by weight of the
gravel/shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces.
The aggregates shall conform to the physical requirements set forth in Table 3.5-1. The
type and size range of the aggregate shall be specified in the Contract or shall be as
specified by the Engineer. If the water absorption value of the coarse aggregate is
greater than 2 percent, the soundness test shall be carried out on the material delivered to
site.
Table 3.5-1 Physical Requirements of Coarse Aggregates for Water Bound
Macadam for Sub- base/Base Courses.

Test Requirements
Los Angeles Abrasion value 40 percent (Max)
Aggregate Impact value 30 percent (Max)

Combined Flakiness and Elongation Index (Total) 40 percent (Max)

T
The requirement of flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.

Crushed or broken stone:

The crushed or broken stone shall be hard, durable and free from excess flat, elongated,
soft and disintegrated particles, dirt and other deleterious material.

3.16 | P a g e
 Crushed slag:
Crushed slag shall be made from air-cooled blast furnace slag. It shall be of angular
shape, reasonably uniform in quality and density and generally free from thin, elongated
and soft pieces, dirt or other deleterious materials. The weight of crushed slag shall not
be less than 11.2 kNper m3 and the percentage of glossy material shall not be more than
20. It should also comply with the following requirements:
i) Chemical stability
ii) Sulphur content
iii) Water absorption

Grading requirement of coarse aggregates:

The coarse aggregates shall conform to one of the gradings given as specified, provided
in previous
3.5.3 Screenings:
Screenings to fill voids in the coarse aggregate shall generally consist of the same
material as the coarse aggregate. However, where permitted, predominantly non-plastic
material such as moorum or gravel (other than rounded river borne material) may be
used for this purpose provided liquid limit and plasticity index of such material are
below 20 and 6 respectively and fraction passing 75 micron sieve does not exceed 10
percent.
The use of screenings shall be omitted in the case of soft aggregates such as brick metal,
kankar, laterites, etc. as they are likely to get crushed to a certain extent under rollers.
3.5.4 Binding material
Binding material to be used for water bound macadam as a filler material meant for
preventing raveling shall comprise of a suitable material approved by the Engineer
having a Plasticity Index (PI) value of less than 6.
The quantity of binding material 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 m3 per 10 m2.
Application of binding materials may not be necessary when the screenings used are of
crushable type such as moorum or gravel.
3.5.5 Construction Operations
Preparation of base
The surface of the sub-grade/sub-base/base to receive the water bound macadam course
shall be prepared to the specified grade and camber and cleaned of dust, dirt and other
extraneous material. Any ruts or soft yielding places shall be corrected in an approved
manner and rolled until firm surface is obtained.
Where the WBM is to be laid on an existing metaled road, damaged area including
depressions and potholes shall be repaired and made good with the suitable material.
The existing surface shall be scarified and re-shaped to the required grade and camber
before spreading the coarse aggregate for WBM.
3.17 | P a g e
 As far as possible, laying water bound macadam course over existing bituminous layer
may be avoided since it will cause problems of internal drainage of the pavement at the
interface of two courses. It is desirable to completely pick out the existing thin
bituminous wearing course where water bound macadam is proposed to be laid over it.

3.5.6 Measurements

Stabilised soil sub-base/base shall be measured as finished work in position in cubic

metres.

3.5.7 Payment

Sub-base shall be paid for at the contract unit rate irrespective of the sources of materials
used for constructing the sub-base.

Pay items shall be

3/5/1 Water bound macadam sub base CubicMetres
Water bound macadam cement
3/5/2 CubicMetres
treated base

3.6 AGGREGATE BASE

3.6.1 Description
This work shall consist of a base Type I or Type II, composed of crushed aggregate
material placed and compacted on a prepared and accepted sub-base or other base course
in accordance with these Specifications and the lines, levels, grades, dimensions and
cross sections shown on the Drawings or as required by the Engineer. However in case
of National highways aggregate base type II can be omitted and instead of aggregate
base type II, total layer can be constructed as base type I.
3.6.2 Materials
Crushed aggregate shall consist of hard durable particles or fragments of rocks or gravel
crushed to the required size, and a filler of coarse sand (F.M. more than 1.5) or other
finely divided mineral matter. Use of brick aggregate is not allowed in Base Course.
When the stone is produced from crushed rock, it shall be from a source approved in
writing by the Engineer, and crushed and screened to achieve the required grading.
When produced from gravel, not less than 95% by weight of the coarse aggregate shall
be particles having at least one fractured face and not less than 85% by weight of the
coarse aggregate shall be particles having at least two fractured faces and, if necessary to
meet this requirement or to eliminate an excess of filler, the gravel shall be screened
before crushing. Recycled aggregates from base type-I or base type-II may also be used
in either course if they satisfy specification requirements and percentage of the recycled
to be selected on the result of the performed required tests.
The Contractor shall submit results of material tests on the proposed aggregate base
material to the Engineer for his approval at least seven days in advance of its use. Fresh
approval shall be required when the material is changed or as order of the Engineer.

3.18 | P a g e
The material for base shall conform to the requirements given below:
a) Grading. The grading shall conform to one of the grading envelopes A or B, of Table
3.7-2. The material shall be well graded within the envelope with no excess or
deficiency of any size. The grading shall conform to grading envelope A of Table 3.7-2
for base type-I and either envelope A or B for base type-II.

The material shall be well graded within the envelope with no excess or deficiency of
any size; the grading shall not vary from coarser side on one sieve to finer side on
another sieve within the grading envelope. The fraction passing the 0.075 sieve shall be
not greater than one-third of the fraction passing 0.425 mm sieve.

b) Plasticity. The portion of material passing `the 0.425 mm sieve shall be non-plastic,
when tested in accordance with test procedure STP 3.2.
c) CBR. When tested in accordance with STP 5.1, the material shall have a minimum
soaked CBR value at a compaction of 98% of the maximum dry density as determined
by STP 4.5 (Vibrating Hammer) as follows:

Base Type I - 100%

Base Type II - 70%

d) Aggregate Crushing Value/ Los Angeles Abrasion Value (LAA): The coarse part of
material sampled and tested in accordance with STP 7.7.1 and AASHTO T96 shall have
Aggregate Crushing Values (ACV) and Los Angeles Abrasion Value (LAA) as the
following table.

Table 3.6-1:

Los Angeles Abrasion Value

Type of Base ACV (%)
(%)
Base Type-I Less than 25% Less than or equal 30%
Less than 30%
Base Type-II Less than or equal 40%
TPF> 150 kN

Table 3.6-2:

Grading Requirements for Base Material

Sieve Size Percentage by Weight Passing Sieves Tolerance for
mix design
(mm) Grading A Grading B

3.19 | P a g e
 50 100 -- ±1
38 90 – 100 --
20 50 – 85 100 ±6
10 30 – 65 80 – 100 ±7
5 25 – 50 50 – 80 ±6
2.4 15 – 38 35 – 65
0.600 8 – 22 15 – 40 ±2
0.300 6 – 16 10 – 30
0.075 2–8 5 – 10 ±1

3.6.3 Construction Methods

3.6.3.1 Preparation of Sub-base

The sub-base or lower base shall be shaped and compacted in conformity with the
provisions of Section 3.2, to the correct moisture content and be completed for at least
100 metres ahead of the placing of the base material, unless otherwise approved by the
Engineer.

3.6.3.2 Provision of Lateral Confinement of Aggregates

While constructing wet mix macadam, arrangement shall be made for the lateral
Confinement of wet mix. This shall be done by laying materials in adjoining shoulders
along with that of wet mix.

3.6.3.3 Preparation of Mix

Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity
having provision for controlled addition of water and forced/positive mixing
arrangement like pug-mill or pan type mixer of concrete batching plant. The plant shall
have following features.
i) For feeding aggregates- three/four bin feeders with variable speed motor
ii) Vibrating screen for removal of oversize aggregates
iii) Conveyor Belt
iv) Controlled system for addition of water
v) Forced/positive mixing arrangement like pug-mill or pan type mixer.
vi) Centralized control panel for sequential operation of various devices and precise
process control.
vii) Safety devices
Optimum moisture for mixing shall be determined in accordance with STP after
replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to
22.4 mm size. While adding water, due allowance should be made for evaporation
3.20 | P a g e
 losses However, at the time of compaction, water in the wet mix should not vary from
the optimum value by more than agreed limits. The mixed material should be uniformly
wet and no segregation should be permitted. Subject to the approval of the Engineer the
Contractor may prepare and spread the Aggregate Base course at site, provided random
samples taken at site, tested for gradation and found satisfactory.

3.6.3.4 Spreading of Mix

Immediately after mixing, the aggregates shall be spread uniformly and evenly upon the
prepared sub-grade/sub-base/base in required quantities. In no case shall these be
dumped in heaps directly on the area where these are to be laid nor shall their hauling
over a partly completed stretch be permitted.
The mix may be spread by a paver finisher. The paver finisher shall be self-propelled of
adequate capacity with following features:
iv) Loading hoppers and suitable distribution system, so as to provide a smooth
uninterrupted material flow for different layer thicknesses from the tipper to the
screed.
v) Hydraulically operated telescopic screed for paving width upto to 8.5m and fixed
screed beyond this. The screed shall have tamping and vibrating arrangement for
initial compaction of the layer.
vi) Automatic levelling control system with electronic sensing device to maintain mat
thickness and cross slope of mat during laying procedure.
In exceptional cases where it is not possible for the paver to be utilized, mechanical
means like motor grader may be used with the prior approval of the Engineer. The
motor grader shall be capable of spreading the material uniformly all over the surface.
The surface of the aggregate shall be carefully checked with templates and all high or
low spots remedied by removing or adding aggregate as may be required. The layer may
be tested by depth blocks during construction. No segregation of larger and fine
particles should be allowed. The aggregates as spread should be of uniform gradation
with no pockets of fine materials.
The Engineer may permit manual mixing and /or laying of wet mix macadam where
small quantity of wet mix macadam is to be executed. Manual mixing/laying in
inaccessible/ remote Locations and in situations where use of machinery is not feasible
can also be permitted. Where manual mixing/laying is intended to be used, the same
shall be done with the approval of the Engineer.

3.6.3.5 Compaction
After the mix has been laid to the required thickness, grade and crossfall/camber the
same shall be uniformly compacted to the full depth with suitable roller. If the thickness
of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 to
100kN weight may be used. For a compacted single layer up to 200 mm, the
compaction shall be done with the help of Vibratory roller of minimum static weight of
80 to 100 kN with an arrangement for adjusting the frequency and amplitude. An
3.21 | P a g e
 appropriate frequency and amplitude may be selected. The speed of the roller shall not
exceed 5 km/h.
In portions having unidirectional cross fall/super elevation, rolling shall commence
from the lower edge and progress gradually towards the upper edge. Thereafter, roller
should progress parallel to the center line of the road, uniformly over-lapping each
preceding track by at least one-third width until the entire surface has been rolled.
Alternate trips of the roller shall be terminated in stops at least 1 m away from any
preceding stop.
In portions in camber, rolling should begin at the edge with the roller running forward
and backward until the edges have been firmly compacted. The roller shall then
progress gradually towards the center parallel to the center line of the road uniformly
overlapping each of the preceding track by at least one-third width until the entire
surface has been rolled.
Any displacement occurring as a result of reversing of the direction of a roller or from
any other cause shall be corrected at once as specified and/or removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall
be thoroughly compacted with mechanical tampers or a plate compactor. Skin patching
of an area without scarifying the surface to permit proper bonding of the added material
shall not be permitted.
Rolling should not be done when the sub-grade is soft or yielding or when it causes a
wave- like motion in the sub-base/base course or sub-grade. If irregularities develop
during rolling which exceed 12 mm when tested with a 3 m straight edge, the surface
should be loosened and premixed material added or removed as required before rolling
again so as to achieve a uniform surface conforming to the desired grade and crossfall.
In no case shall the use of unmixed material be permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 percent of the
maximum dry density for the material. Density of the compacted aggregate base course
shall be determined in accordance with STP 6.2 (150 mm or 200 mm diameter
depending on the layer thickness) with at least three tests being made for each 1,000
square meters. Besides, Static Deformation Modulus Ev2 shall be 180 MPa and
Ev2/Ev1 shall be ≤2.2 (Technical Standards including ASTM 1195/ASTM 1196 and
DIN 18134). Testing for Ev2 and Ev1is mandatory; however, it’s important to note that
the test results will not be used as acceptable criteria but solely for record keeping
purpose.
After completion, the surface of any finished layer shall be well-closed, free from
movement under compaction equipment or any compaction planes, ridges, cracks and
loose material. All loose, segregated or otherwise defective areas shall be made good to
the full thickness the layer and recompacted.

3.6.3.6 Setting and Drying

After final compaction of wet mix macadam course, the road shall be allowed to dry for
24 hours.
3.6.4 Opening to Traffic
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 No Vehicular traffic shall be allowed on the finished wet mix macadam surface.
Construction, equipment may be allowed with the approval of the Engineer.

3.6.5 Surface Tolerance

The finished surface of the aggregate base shall be checked for level and crossfall and at
any point shall not vary more than +/-10 mm from the specified level. The surface shall
also be checked for irregularities by a 3m long straight edge laid perpendicular and
parallel to the road centerline at intervals not exceeding 20 m. The deviation from the
straight edge shall not exceed 10 mm. Any areas found to be out of tolerance shall be
corrected by loosening, adding or removing material, reshaping and re-compacting.
The thickness of the finished base shall be on average
- Not less than the required thickness when five thickness measurements are
averaged in any 150m length of completed sub-base.
- Not thinner than 10mm less than the required thickness at any point.
The Contractor shall carry out at his own expense, the reconstruction of areas of
aggregate base which are too thin or too variable in thickness to meet the requirement.
3.6.6 Rectification of Surface Irregularity

Where the surface Irregularity of the base exceeds the permissible tolerances or where
the course is otherwise defective due to sub-base material getting mixed with the
aggregates, the full thickness of the layer shall be scarified over the affected area, re-
shaped with added premixed material or removed and replaced with fresh premixed
material as applicable and recompacted. The area treated in the aforesaid manner shall
not be less than 5 m long and 2 m wide. In no case shall depressions be filled up with
unmixed and ungraded material or fines.
3.6.7 Measurement

This item shall be measured as the number of cubic metres of material complete in place
and accepted. Measurements shall be based on the thickness/cross section of the base
shown on the Drawings and the length/area measured on the surface of the road.

3.6.8 Payment
This work measured as provided above shall be paid for at the Contract unit rates per
cubic metre for aggregate base irrespective of the sources of material used. Payments
shall be full compensation for furnishing all materials, hauling, placing, compacting,
sprinkling, finishing and shaping and for all labour, equipment, tools and other
incidentals necessary to complete the work.
All costs of excavating existing pavement, or removing existing structures, or savings to
the Contractor from re-using materials excavated from existing pavements, or structures
shall be deemed already covered under pay items 2/2/3, 2/2/4, 2/2/5, 2/9/1 and 2/9/2.
Pay items shall be:
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 3/6/1 Aggregate Base Type I Cubic Metre
3/6/2 Aggregate Base Type II Cubic Metre

3.7 Geo-fabric Reinforced Seal (GRS) as Strain Alleviating Layer

(SAMI)

3.7.1 Description

GRS is an effective sprayed sealing technique for treating badly cracked and distressed
Pavements particularly where the crack movements are slow.
A GRS is produced by:
a) Spraying a layer of bitumen (bond/tack coat) on to the existing surface
b) Covering the bond coat with an approved fabric and lightly rolling to ensure good
adhesion of the fabric
c) Application of binder
d) Spreading a sealing aggregate
e) Rolling to ensure good adhesion of the aggregate to the fabric.
The fabric is incorporated to add strength to the treatment and provide a seal to cope
with pavement conditions where conventional binder or polymer binder seals are known
to have a reduced life. It can also used be in the bridges in between concrete surface and
asphalt treatment. To minimize the risk of de-bonding of asphalt placed on a GRS, GRS
should be trafficked until it is firmly bonded to the base structure prior to placement of
the asphalt. The length of time that a GRS can be trafficked may be restricted by the
location and service conditions.

3.7.2 Materials

Geotextile Fabric Materials

Geotextiles used for sprayed sealing are conventionally manufactured from polymers,
the most frequently used being polyester and polypropylene. The fabric should be non-
woven, needle-punched and formed from mechanically entangled filaments. Geotextiles
made from continuous filaments are preferred.

Geotextile fabric shall have the properties shown in Table 3.7-1 below.
Table 3.7-1: Geotextile fabric properties
Property Recommended Minimum

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 Light Fabric Grade Heavy Fabric
Grade
Mass (g/m2) 130 175
Thickness (mm) 1.5 1.8
Elongation at 50 50
ultimate strength (%)
G Value 950 950
(Robustness)
Bitumen saturation 0.9 1.1
(L/m2 )
Melting Point (oC) 165 165

A minimum fabric mass of 130 g/m2 is recommended for sealing applications.

However, when a GRS is used on expansive clays or untreated soft pavements, and
larger sized sealing aggregates (e.g. > 10 mm) are proposed, a heavier grade of fabric
with a fabric mass of ≥175 g/m2, should be used to reduce the risk of puncturing of the
fabric.
Storage and Handling of Geotextile Fabric
Geotextile fabrics should be stored in dry areas, in their shipping bags, and away from
direct sunlight for protection from moisture infiltration and UV degradation. The core of
the fabric roll should be a smooth bored PVC pipe and not cardboard. Cardboard cores
are more likely to crush during handling, particularly if affected by moisture. A wet
geotextile fabric should not be used as the potential for aggregate stripping is increased.
Fabric Selection
A minimum fabric mass of 130 g/m2 is used for general sealing applications with 10
mm aggregate. Where larger sealing aggregates are proposed, heavier grades of fabric
(175 to 200 g/m2) should be used. Geotextiles made from polyester are preferred when
using hot bitumen as they have a higher melting point. Where polypropylene fabric is
used the binder temperature should not exceed 170°C.
Other Materials
All other materials are to be as per Section 3.13 Bitumen Surface Treatment.
Pre-sealing Considerations
Pre-sealing requirements for GRS are the same as for conventional seals. The usual
rules for good surface preparation and sealing practices apply. This will ensure the
maximum effective life for the treatment.
Stabilised Heavy Duty Pavements
For stabilised pavements in heavy duty conditions (e.g. > 1x10 7 ESAs or exceeding 500
vehicles/lane/day), the surfacing must be prime sealed, primed and sealed or sealed
prior to the application of the GRS. This will be more effectively anchor the GRS to the
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 base. This also ensures that a rough interface is achieved for both retention of the seal
under traffic and to avoid a slip layer under future asphalt overlays.
Texture Correction
Where the existing surface texture is too coarse for the proposed GRS aggregate or
irregular, then a correction course comprising a small sized aggregate seal or reseal,
should be applied well in advance of a GRS.
When the existing surface is smooth, with little or no texture, or is recently applied
asphalt or slurry surfacing, then a small sized aggregate seal should be applied at least
six weeks in advance to provide a friction key for the GRS.
Pre-spraying of Un-trafficked Areas
Un-trafficked areas, (along the centerline, outer edges and between wheel tracks), may
be pre-sprayed with 0.2 to 0.3 L/m2 bitumen (usually 80/100) in advance of the bond
coat or after the application of the geotextile, particularly if the texture is more hungry
in those areas.
3.7.3 Construction Method

3.7.3.1 General
Generally, construction method shall be as per Section 3.13.3 except where noted
differently below.

3.7.3.2 Sequence of Operations

A typical order of operations is shown in Table 3.7-2. There may be slight variations to
this order for particular circumstances, e.g. if the bond coat bleeds through the geotextile,
a seven mm aggregate may need to be spread prior to or during rolling of the geotextile.
Table 3.7-2: Typical Sequence of Operation for Geotextile Reinforced Seals
Order of Operation
Operations
1 Surface preparation
2 Bond (tack) coat
3 Apply geotextile
4 Roll geotextile
5 Spray binder
6 Apply aggregate
7 Roll aggregate
For a double/double seal the second application
8
would be applied in the normal manner

3.7.3.3 Surface Preparation

For natural surface or clay formations, the relative compaction of the pavement should
comply with the appropriate specifications.

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 Preferred practice for unsealed bases is to first apply a prime or primer seal. Priming is
recommended where a GRS is to be applied to a granular or modified pavement
(particularly stabilised), timber or concrete surfaces.
Before spraying, the surface should be cleaned, swept and given a light spray with water
(if not primed or primer sealed) to promote penetration.
GRSs are used to treat pavements that have the potential to, or are already, extensively
cracked without any pre-treatment, provided the cracks are less than 3 mm in width.
Larger cracks should be pre-treated with one or a combination of the following:
 Fill with emulsion and grit
 Hot or cold modified bitumen crack sealants. (when using this method cracks should
be filled but not over banded)
 Fine asphalt or slurry mixes.
Other defects, e.g. ruts, potholes, shoving, edge defects, etc., should be repaired before
resealing.
As a general rule, any correction seal, crack filling and pavement repairs should be
completed at least six weeks in advance of the application of the GRS to reduce the risk
of bleeding or flushing.

3.7.3.4 Weather Conditions

GRS are specialized treatments and should only be placed in dry warm conditions.
Preferred conditions are:
 Predicted fine weather for next few days
 Little or no wind (to reduce billowing of fabric)
 Dry Pavement
 Dry surface to avoid trapping moisture under the GRS.

3.7.3.5 Equipment
The plant used for conventional sprayed sealing operations can be used for geotextile
reinforced sealing. The use of pneumatic-type multi-wheel rollers of less than 15 t mass
is preferred to lessen the risk of embedment of aggregate and/or crushing the aggregate.
In addition, a fabric applicator such as the one shown in Figure 3.7-1 is required. This is
usually a lightweight frame attached to a loader (smaller, non-articulated loaders are
preferred), or other similar plant item, with a spindle to hold the roll of geotextile. A
spring-loaded broom arrangement and/or tensioning bar is attached at the base of the
frame to press the fabric firmly onto the pavement surface to prevent wrinkling. There
should be a special tension control mechanism to ensure a uniform fabric tension during
application. Frames can be manufactured locally or can usually be hired or purchased
from geotextile suppliers.

3.27 | P a g e
Figure 3.7-1: Schematic of a Fabric Spreader

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3.7.3.6 Spraying
It is accepted practice that the edges of the geotextile are covered by the seal.

3.7.3.7 Bond (tack) coat

The binder used for a bond coat is usually a 80/100 bitumen, ideally without cutter oil.
Where the pavement material is relatively permeable, and where priming or primer
sealing has not been carried out in advance, a small amount of cutter oil (up to 3%) may
be used in the bond coat to promote penetration. If too much cutter oil is used in the
bond coat (e.g. >3%) the evaporation of volatiles will be slow, and in hot weather this
can cause bubbling in the sealed surface.
The bond coat binds the fabric onto the road surface during sealing and the application
rate used ranges between 0.4 and 1.0 L/m2 (cold).
The amount of bond coat applied is part of the total design binder application rate.
The bond coat should be sufficient to secure the fabric during application and sealing
operations, without causing the binder to bleed through the fabric during placement or
subsequent rolling.
Ideally, cutter oil should not be used in bond coats over impermeable pavements such as
clay pavements or heavily bound base materials, as the cutter oil will be trapped in the
geotextile, leading to softening of the seal and possible aggregate stripping. The bond
coat should be sprayed wider than the width of the geotextile to be laid, to allow the
final seal to protect the edges of the geotextile.
If the geotextile is to be placed in two or more adjacent runs, the bond coat should be
sprayed one run at a time, prior to placing each run of geotextile. The overlap width for
the geotextile should be about 100 to 200 mm and must be fully saturated with bitumen
to minimize the potential for aggregate stripping along the join. To achieve this, the
overlap area is sprayed twice – the second spray run overlapping the first run of
geotextile.

3.7.3.8 Seal
The binder is usually Class 85/100 bitumen and may be cutback as per normal sealing
practice. It should be sprayed onto the geotextile at GRS design rate following
placement of the geotextile.
Bitumen should not be sprayed onto the geotextile if the geotextile has become wet, as
the presence of moisture will lead to subsequent seal loss. For this reason, sealing should
not commence unless the seal over the geotextile can be applied well before any rain or
inclement weather occurs.

3.7.3.9 Placement of Geotextile Fabric

The geotextile should be rolled out slowly (using a fabric applicator) immediately after
spraying the bond coat, and as close behind the sprayer as practicable.
The unfurling fabric should be kept as low as possible to the ground to prevent
billowing and should be kept taut to minimize wrinkling. Wrinkles should be broomed
out, or cut and butted where necessary.

3.29 | P a g e
 Adjoining or adjacent rolls should be overlapped by 100 to 200 mm, with the
overlapped join receiving additional binder as described above. Placing of fabrics along
straight alignments is generally problem free.
Where the geotextile is to be placed around a significant curve, it should be ‘cut and
butted’ at regular intervals along the inner side of the curve. Any overlaps should be
hand sprayed with additional bitumen so that the geotextile is fully saturated. Wrinkles
larger than 25 mm should be treated as overlaps.
Care must be taken to ensure overlaps do not occur in the wheel path areas.
On clay formations, the fabric should be laid as wide as possible over the shoulder area
of the pavement, to prevent shoulder erosion and ingress of moisture. For other
applications, the fabric should be applied over the full width of the pavement or
trafficked lane width, as appropriate.
The fabric should be lightly rolled prior to the application of binder.
If rolling and/or construction traffic causes the bond coat to bleed up through the fabric,
a binding coat of 7 mm aggregate may be applied in advance of sealing to prevent pick-
up.
Rollers or vehicles should not stand on the laid fabric as this may lead to a build-up of
binder on the surface of the fabric.

3.7.3.10 Aggregate Spreading and Rolling

Aggregate should be spread onto the binder as soon as possible after spraying. Rolling
should be carried out with a rubber tyred roller with the rolling sequence being from the
middle outwards to the edges

3.7.3.11 Trafficking
Traffic can be used to assist with compaction of the GRS as in conventional sealing
practices. For double/double treatments, slow moving traffic should be allowed onto the
GRS after the first layer of aggregate has been placed. Speed restrictions may be
required until the aggregate and binder are firmly adhered to the geotextile.
For treated pavements, trafficking of the fabric (i.e. no aggregate cover) may be
permitted in extreme circumstances such as plant breakdowns and emergencies,
provided traffic speeds are kept low and the time of trafficking is minimized.

3.7.3.12 Caution
If the exposed fabric becomes wet (unexpected storm or accident) the surface becomes
very slippery and trafficking should be halted immediately and not recommended until
the surface is completely dry. Where practical, a physical barrier should be erected to
prevent trafficking of the wet, exposed fabric.

3.7.3.13 Reduced Daily Production

When programming GRS operations, allowance may be made for reduced area
compared to normal sealing works. This is due to the additional requirements for the
application of the bond coat and geotextile and the additional rolling requirements.

3.30 | P a g e
 3.7.4 Maintenance
Where a clay pavement surfaced with a GRS has been subjected to flooding, it should be
allowed to dry back prior to reopening to traffic. It should then be rolled with a
pneumatic tyred multi tyred roller from the inside (Centre of pavement) to the outside
before being opened to traffic. Premature opening, particularly to heavy vehicles and
four wheel drives, is likely to cause debonding of the GRS from pavement and
pavement deformation.

3.7.5 Measurement
The GRS SAMI works of the type stated in the Bill of Quantities shall be measured in
Square Metres of the completed and accepted works as detailed on the Drawings or as
directed by the Engineer.
3.7.6 Payment
Payment shall be full compensation for trial mixes, furnishing, and placing all materials,
including all labour, equipment, tools and incidentals necessary to complete the Works.
Where defective work is corrected, or additives used which have not been specified or
ordered by the Engineer, no payments will be made in respect of extra work or materials
used in excess of the quantities specified or ordered. The use of adhesive and anti-
stripping agent bitumen additive will not be paid for separately, and any costs involved
should be included within pay item 3/3/1. Pre-coating of chippings shall be carried out
without any additional payment.
Pay items shall be:

Pay Item No. Description Unit Measurement

3/7/1 Single GRS Surface Treatment Square Metres

3/7/2 Bituminous Tack Coat (plant work) Square Metres

Or

Bituminous Tack Coat (labour intensive

3/7/3 Square Metres
work)

3.8 BITUMINOUS MATERIALS

3.8.1 Description
This Section specifies the bituminous materials to be used in the work.

3.8.2 Material

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 The materials shall be as indicated in the Contract Documents. If materials are not
completely described, materials suitable for the purpose and in accordance with
generally recognised good practice should be used. Material shall meet the requirements
for one of the following types.

3.8.2.1 Bitumen

3.8.2.1.1 Penetration Grade Bitumen

Bitumen shall conform to the requirements as ASTM D946-20 (Standard

Specification for Penetration-Graded Asphalt Binder for Use in Pavement
Construction). In all direct pavement construction works and major maintenance, only
bitumen of Penetration Grade 40-50 or 60-70 will be used as specified below.
Penetration Grade 85-100, 120-150 and 200-300 can be used for preparation of
Modified bitumen, sealant and fillers. The samples should be free of water which can
be found through ASTM D95 Test Method for Water in Petroleum Products and
Bituminous Materials by Distillation.

As adjustments to ASTM D946 two additional parameters shall be included for RHD
approved bitumen, which are:

1. Softening Point, ℃ for Pen Grade 40-50 should be 52to 60 (min to max) and for Pen
Grade 60-70 shall be 48-56(min to max) (in place of ASTM D946 specified value of
49 and 46 (min value), respectively.)
2. Specific Gravity for Pen 40-50 and 60-70 bitumen shall be 1.01-1.05, whereas for 85-
100, it will be 0.99-1.04.

Table 3.8-1: ASTM D946 Specification for Penetration Grade Bitumen with adjustments

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 Following ASTM test procedures should be maintained for measurement of above-mentioned
values.

1. Sampling—Practice ASTM D140/D140M.

2. Penetration—Test Method ASTM D5/D5M (same as AASHTO T49)
3. Softening Point—Test Method ASTM D36/D36M.
4. Flash Point—Test Method ASTM D92.
5. Ductility—Test Method ASTM D113.
6. Thin Film Oven Test—Test Method D1754/D1754M OR Rolling Thin Film Oven
Test—Test Method D2872
7. Solubility in Trichloroethylene—Test Method D2042 OR Solubility in N-Propyl
Bromide—Test Method D7553

3.8.2.1.2 Performance Grade Bitumen

The performance grade bitumen is used for the acceptance purposes that must be met under
certain climatic and aging conditions. This standard system is part of the Superpave system.
For specific projects with access to advanced Superpave Performance Grading (PG)
equipment, ASTM D8239-21 (Standard Specification for Performance-Graded Asphalt
Binder Using the Multiple Stress Creep and Recovery (MSCR) Test). For In all direct
pavement construction works and major maintenance, only bitumen of PG High Temperature
Grade 58-XX or above will be used as specified below (exact grade should be selected based
on geological location and climatic condition). For low temperature grade, PG XX-10 should
be selected. MSCR grade requirement should be adjusted based on traffic level and should be
‘S’ grade for routine works with unmodified bitumen.

Table 3.8-2: ASTM D8239 Specification (adjusted for approved grades) for PG Bitumen

Grade range (High temp) PG 58 PG 64 PG 70 PG 76 PG 82

Grade range (Low Temp) -16 -10 -10 -10 -10
Average 7-day maximum pavement design < 58 < 64 < 70 < 76 < 82
temperature (°C)
Minimum pavement design temperature (°C) >−16 >−10 >−10 >−10 >−10
Original binder
Flash-point temperature, D92; min. (°C) 230 230 230 230 230
Viscosity, D 4402: max. 3 Pa × s, test 135 135 135 135 135
temperature (°C)
Dynamic shear, D7175: G*/sinδ, min. 1.00 58 64 70 76 82
kPa; 25 mm plate, 1 mm gap; test
temperature at 10 rad/s (°C)

Rolling thin film oven residue (ASTM D2872)

Mass loss, max. %

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Dynamic shear, D7175: G*/sinδ, min. 2.20 58 64 70 76 82
kPa; 25 mm plate, 1 mm gap; test
temperature at 10 rad/s (°C)

MSCR, D7405, Standard Traffic, ‘S’, 58 64 70 76 82

Jnr3.2, max 4.5 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘H’, 58 64 70 76 82
Jnr3.2, max 2 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘V’, 58 64 70 76 82
Jnr3.2, max 1 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘E’, 58 64 70 76 82
Jnr3.2, max 0.5 kPa-1
Test temp, ℃

Pressure ageing vessel residue (ASTM D6521)

PAV ageing temperature (°C) 100 100 100 100 100
(110) (110) (110)
Dynamic shear, D7175: G* × sinδ, max. 25 31 34 37 40
6000 kPa; 8mm plate, 2 mm gap; test
temperature at 10 rad/s (°C)

Creep stiffness, D 6648: S, max 300 MPa; -6 0 0 0 0

m-value, min. 0.300; test temperature at 60 s
(°C)

Direct tension, D6723: failure strain, min. -6 0 0 0 0

1.0%; test temperature at 1.0 mm/min. (°C)

** In MSCR test, the Standard S grade, traffic < 3 million ESAL; Heavy H Grade traffic >3
million ESAL; for Very Heavy V Grade, traffic > 10 million ESAL and Extreme E grade traffic
>30 million ESAL.

Following ASTM test procedures should be followed for measurement of above-mentioned

values:

1. D92 Test Method for Flash and Fire Points by Cleveland Open Cup Tester
2. D140/D140M Practice for Sampling Asphalt Materials
3. D2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
4. D2872 Test Method for Effect of Heat and Air on a Moving Film of Asphalt (Rolling
Thin-Film Oven Test)
5. D4402/D4402M Test Method for Viscosity Determination of Asphalt at Elevated
Temperatures Using a Rotational Viscometer
6. D6373 Specification for Performance-Graded Asphalt Binder
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 7. D6521 Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging
Vessel (PAV)
8. D6648 Test Method for Determining the Flexural Creep Stiffness of Asphalt Binder
Using the Bending Beam Rheometer (BBR)
9. D7175 Test Method for Determining the Rheological Properties of Asphalt Binder
Using a Dynamic Shear Rheometer
10. D7405 Test Method for Multiple Stress Creep and Recovery (MSCR) of Asphalt
Binder Using a Dynamic Shear Rheometer

3.8.2.1.3 Polymer Modified Bitumen

For high-degree of heat and rut resistance, Polymer modified bitumen (PMB) may be
selected. Using advanced Superpave PG Grading equipment, PMB should be compliant to
ASTM D8239-21 (Standard Specification for Performance-Graded Asphalt Binder Using the
Multiple Stress Creep and Recovery (MSCR) Test). This code is a direct equivalent to
AASHTO M332 specification.

For In all direct pavement construction works and major maintenance, only bitumen of PG
High Temperature Grade 64-XX or above will be used as specified below (exact grade should
be selected based on geological location and climatic condition). For low temperature grade,
PG XX-10 should be selected. Only Elastomeric Polymers, such as SBS, are currently
accepted for use in PMB.

MSCR grade requirement should be adjusted based on traffic level and should be at least ‘H’
grade, when tested at the required High Temperature Grade, found from 7-day maximum
pavement temperature measured over 98% reliability level. ‘V’ or ‘E’ grade should be
selected for high level of traffic, such as 10-30 MESA or 30+ MESA traffic, respectively.
More stringent Jnr value (<0.2 kPa-1) can be selected for extremely high degree of traffic.

Adjustments to ASTM D8239: In addition to the table provided below, PMB should have the
following properties, such as
1. Separation/storage stability, difference in softening point, °C= max 2.2. (ASTM D7173)

Table 3.8-3: ASTM D8239 Specification (adjusted for approved grades) for Polymer
Modified Bitumen

Grade range (High temp) PG 58 PG 64 PG 70 PG 76 PG 82

Grade range (Low Temp) -16 -10 -10 -10 -10
Average 7-day maximum pavement design < 58 < 64 < 70 < 76 < 82
temperature (°C)
Minimum pavement design temperature (°C) >−16 >−10 >−10 >−10 >−10
Original binder
Flash-point temperature, D92; min. (°C) 230 230 230 230 230
Viscosity, D 4402: max. 3 Pa × s, test 135 135 135 135 135
temperature (°C)

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Dynamic shear, D7175: G*/sinδ, min. 1.00 58 64 70 76 82
kPa; 25 mm plate, 1 mm gap; test
temperature at 10 rad/s (°C)

Rolling thin film oven residue (ASTM D2872)

Mass loss, max. %
Dynamic shear, D7175: G*/sinδ, min. 2.20 58 64 70 76 82
kPa; 25 mm plate, 1 mm gap; test
temperature at 10 rad/s (°C)

MSCR, D7405, Standard Traffic, ‘S’, 58 64 70 76 82

Jnr3.2, max 4.5 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘H’, 58 64 70 76 82
Jnr3.2, max 2 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘V’, 58 64 70 76 82
Jnr3.2, max 1 kPa-1
Jnrdiff, max 75%,
Test temp, ℃
MSCR, D7405, Standard Traffic, ‘E’, 58 64 70 76 82
Jnr3.2, max 0.5 kPa-1
Test temp, ℃

Pressure ageing vessel residue (ASTM D6521)

PAV ageing temperature (°C) 100 100 100 100 100
(110) (110) (110)
Dynamic shear, D7175: G* × sinδ, max. 25 31 34 37 40
6000 kPa; 8mm plate, 2 mm gap; test
temperature at 10 rad/s (°C)

Creep stiffness, D 6648: S, max 300 MPa; -6 0 0 0 0

m-value, min. 0.300; test temperature at 60 s
(°C)

Direct tension, D6723: failure strain, min. -6 0 0 0 0

1.0%; test temperature at 1.0 mm/min. (°C)

Following ASTM test procedures should be followed for measurement of above-mentioned

values:

1. D92 Test Method for Flash and Fire Points by Cleveland Open Cup Tester
2. D140/D140M Practice for Sampling Asphalt Materials
3. D2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
4. D2872 Test Method for Effect of Heat and Air on a Moving Film of Asphalt (Rolling
Thin-Film Oven Test)

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 5. D4402/D4402M Test Method for Viscosity Determination of Asphalt at Elevated
Temperatures Using a Rotational Viscometer
6. D6373 Specification for Performance-Graded Asphalt Binder
7. D6521 Practice for Accelerated Aging of Asphalt Binder Using a Pressurized Aging
Vessel (PAV)
8. D6648 Test Method for Determining the Flexural Creep Stiffness of Asphalt Binder
Using the Bending Beam Rheometer (BBR)
9. D7175 Test Method for Determining the Rheological Properties of Asphalt Binder
Using a Dynamic Shear Rheometer
10. D7405 Test Method for Multiple Stress Creep and Recovery (MSCR) of Asphalt
Binder Using a Dynamic Shear Rheometer

In absence of available Dynamic Shear Rheometer, ASTM D5976-00 standard may be

utilized for PMB specification. It should be emphasized that all viable means of getting DSR
access (essential for ASTM D8239) should be exhausted before allowing ASTM D5976-00.
Type I PMB of I-C and I-D is allowed for application in road construction.

Table 3.8-4: ASTM D 5976 Specification for Polymer Modified Bitumen (In absence of
DSR)

Following ASTM test procedures should be followed for measurement of above-mentioned

values:

1. D 5 Test Method for Penetration of Bituminous Materials

2. D 36 Test Method for Softening Point of Bitumen (Ring and-Ball Apparatus)
3. D 92 Test Method for Flash and Fire Points by Cleveland Open Cup
4. D 113 Test Method for Ductility of Bituminous Materials
5. D 140 Practice for Sampling Bituminous Materials
6. D 1754 Test Method for Effect of Heat and Air on Asphaltic Materials (Thin-Film
Oven Test)
7. D 2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
8. D 2170 Test Method for Kinematic Viscosity of Asphalts (Bitumens)
9. D 2872 Test Method for Effect of Heat and Air on a Moving Film of Asphalt (Rolling
Thin-Film Oven Test)
10. D 4957 Test Method for Apparent Viscosity of Asphalt Emulsion Residues and Non-
Newtonian Bitumens by Vacuum Capillary Viscometer
11. D 6084 Test Method for Elastic Recovery of Bituminous Materials by Ductilometer
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2.8.2.1.4 Crumb Rubber Modified Bitumen

Due to lack of previous application in the context on Bangladesh, use of Crumb Rubber shall
not be allowed in present condition.

2.8.2.1.5 Cut-Back Bitumen

Three types of cutback bitumen will be used for RHD usage. They are: Rapid Curing (RC),
Medium Curing (MC) and Slow Curing (SC) Cutback bitumen. Tests performed to exhibit
adherence to specification is valid for 14 days. Specification outlining properties of each
type is given below:

Rapid Curing (RC) Cut-Back Bitumen:

ASTM D2028 shall be adopted as the standard specification for rapid curing cutback
bitumen. Following Table shall be utilized to identify different grades of Rapid Curing
Cutback Bitumen.

Table 3.8-5: ASTM D2028 Specification for Rapid Curing Cutback Asphalt

Medium Curing (MC) Cut-Back Bitumen

ASTM D2027 will be adopted as the standard specification for medium curing cutback
bitumen. Following Table will be utilized to identify different grades of Rapid Curing
Cutback Bitumen.

Table 3.8-6: ASTM D2027 Specification for Medium Curing Cutback Asphalt

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Slow Curing (SC) Cut-Back Bitumen:

ASTM D2026 shall be adopted as the standard specification for slow curing cutback bitumen.
Following Table will be utilized to identify different grades of Rapid Curing Cutback
Bitumen. However, Slow Curing Cutback shall not be used in general pavement application,
except highly specialized usage with proper permission of Engineer in charge.

Table 3.8-7: ASTM D2026 Specification for Slow Curing Cutback asphalt

Following ASTM Test methods should be used for measurement of properties as stated
above.

1. D5 Test Method for Penetration of Bituminous Materials

2. D95 Test Method for Water in Petroleum Products and Bituminous Materials by
Distillation
3. D113 Test Method for Ductility of Bituminous Materials
4. D140 Practice for Sampling Bituminous Materials
5. D402 Test Method for Distillation of Cutback Asphalt
6. D2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
7. D2170 Test Method for Kinematic Viscosity of Asphalts (Bitumens)

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 8. D2171 Test Method for Viscosity of Asphalts by Vacuum Capillary Viscometer
9. D3143 Test Method for Flash Point of Cutback Asphalt with Tag Open-Cup
Apparatus
10. D7553 Test Method for Solubility of Asphalt Materials in N-Propyl Bromide

3.8.2.1.5 Emulsified Bitumen:

Catanionic and anionic emulsion can be used by RHD. Tests performed to exhibit adherence
to specification is valid for 14 days. Depending on the setting tendency and emulsifier
charge, following classifications can be used for emulsions:

Cationic Emulsion:

ASTM D2397 specification will be followed for categorization of Cationic Emulsified

Asphalt.

Table 8: ASTM D2397 Specification

Following ASTM Test methods should be used for measurement of properties as stated
above.

1. D5/D5M Test Method for Penetration of Bituminous Materials

2. D113 Test Method for Ductility of Asphalt Materials
3. D140/D140M Practice for Sampling Asphalt Materials
4. D244 Test Methods and Practices for Emulsified Asphalts
5. D2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
6. D3910 Practices for Design, Testing, and Construction of Slurry Seal
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 7. D6930 Test Method for Settlement and Storage Stability of Emulsified Asphalts
8. D6933 Test Method for Oversized Particles in Emulsified Asphalts (Sieve Test)
9. D6935 Test Method for Determining Cement Mixing of Emulsified Asphalt
10. D6936 Test Method for Determining Demulsibility of Emulsified Asphalt
11. D6997 Test Method for Distillation of Emulsified Asphalt
12. D7226 Test Method for Determining the Viscosity of Emulsified Asphalts Using a
Rotational Paddle Viscometer
13. D7402 Practice for Identifying Cationic Emulsified Asphalts
14. D7496 Test Method for Viscosity of Emulsified Asphalt by SayboltFurol Viscometer
15. D7553 Test Method for Solubility of Asphalt Materials in N-Propyl Bromide
16. D8078 Test Method for Ash Content of Asphalt and Emulsified Asphalt Residues

Anionic Emulsion:

ASTM D977 specification will be followed for categorization of Anionic Emulsified Asphalt
as shown in the following table.

Table 9: ASTM D2028 Specification

Following ASTM Test methods should be used for measurement of properties as stated
above.

1. D5/D5M Test Method for Penetration of Bituminous Materials

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 2. D113 Test Method for Ductility of Asphalt Materials
3. D139 Test Method for Float Test for Bituminous Materials
4. D140/D140M Practice for Sampling Asphalt Materials
5. D244 Test Methods and Practices for Emulsified Asphalts
6. D2042 Test Method for Solubility of Asphalt Materials in Trichloroethylene
7. D3910 Practices for Design, Testing, and Construction of Slurry Seal
8. D6930 Test Method for Settlement and Storage Stability of Emulsified Asphalts
9. D6933 Test Method for Oversized Particles in Emulsified Asphalts (Sieve Test)
10. D6935 Test Method for Determining Cement Mixing of Emulsified Asphalt
11. D6936 Test Method for Determining Demulsibility of Emulsified Asphalt
12. D6997 Test Method for Distillation of Emulsified Asphalt
13. D7226 Test Method for Determining the Viscosity of Emulsified Asphalts Using a
Rotational Paddle Viscometer
14. D7496 Test Method for Viscosity of Emulsified Asphalt by SayboltFurol Viscometer
15. D7553 Test Method for Solubility of Asphalt Materials in N-Propyl Bromide

16.D8078 Test Method for Ash Content of Asphalt and Emulsified Asphalt

3.8.3 Measurement

Measurement of bituminous material shall be either in metric tons or in litres as

indicated in the Contract Documents.
The measured quantity shall be the quantity theoretically required to comply with the
Contract, or shall be the quantity used and accepted, whichever is the less.

3.8.4 Payment
This work shall be paid for as provided in the Section of the Specifications dealing with
the work incorporating the bituminous material and shall be full compensation for
complying with that Section of the Specifications as well as this Section.

3.9 GENERAL REQUIREMENTS FOR BITUMEN BOUND

SURFACING (plant method)

3.9.1 Description

3.9.1.1 General
This work shall cover the general requirements that are applicable to all types of
bituminous bound surfacing irrespective of gradation of mineral aggregate, kind and
amount of bituminous material, or use. Deviations from these general requirements are
indicated in the specific requirements as set forth in the respective Sections of the
Specifications.
Section 3.10 is for Prime Coats
Section 3.11 is for Tack Coats

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 Section 3.12 is for Primer Seal
Section 3.13 is for Bituminous Surface Treatment (Plant Method).
Section 3.14 is for Dense Bituminous Surfacing (Plant Method).
Section 3.15 is for Pre Mix Bituminous Surfacing (Manual Method).
Section 3.16 is for Premix Bituminous Seal Coat (Manual Method).
The work shall consist of one or more courses of pre-mixed bituminous mixtures
constructed on a prepared and accepted base course or other roadbed in accordance with
Sections of these Specifications and in conformity with the required lines, levels, grades,
dimensions and typical cross sections.

3.9.1.2 General Composition of Mixtures

The bituminous mix shall be composed basically of coarse mineral aggregate, fine
mineral aggregate, filler, and bituminous material. The several mineral constituents shall
be sized, uniformly graded, and combined in such proportions that the resulting blend
meets the grading requirements for the specific type under the Contract. To such
composite blended aggregate shall be added bitumen within the percentage limits set in
the specifications for the specific type.

3.9.1.3 Formula for Job-Mix

Before starting work, the Contractor shall submit in writing to the Engineer a job-mix
formula for each type of proposed asphaltic mixture. This shall state the sources and
types of the various materials to be used, the mixing proportions of the various
constituents, the method of mixing, the methods of heating bitumen and aggregates
(including means of temperature control) and the means of transportation, laying and
compaction. The formula so submitted shall stipulate a single definite temperature for
the emptying of the mixture from the mixer, and, for mixtures to be laid hot, a single
definite temperature at which the mixture is to be delivered on the road, all of which
shall fall within the ranges of the general composition and temperature limits. The job-
mix formula for the mixture shall indicate the percentage of aggregate passing each
required sieve size and the percentage of bitumen to be added to the aggregate.
The contractor shall not commence bituminous surfacing work until the job mix formula
has been approved in writing by the Engineer, including any adjustments to the job mix
formula which the Engineer considers are necessary.
Following approval of the mix formulae the Contractor shall produce trial mixes and lay
trial sections of surfacing for each formula. As many samples of the materials shall be
taken and tested as the Engineer considers necessary for checking the required
uniformity of the mixture and ensuring compliance with the Specification. Following
approval of the trial sections by the Engineer in writing the actual surfacing works may
be carried out strictly in accordance with the approved mix formulae and trial sections.
Should a change in a material be encountered or should a change in a source of material
be made, a new mix formula shall be submitted and approved before the mixture
containing the new material is delivered for trials and approval on the surfacing works.

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3.9.1.4 Applications of Job-Mix Formula and Allowable Tolerances
All mixture furnished shall conform to the job-mix formula, within the ranges of
tolerance given below and subject to the maximum temperatures as given in clauses
3.10.3.2 and 3.10.3.4:-
Passing sieves 10 mm and larger ............................................................... ± 5%
Passing sieves between 10 mm and 0.075 mm .......................................... ± 4%
Passing 0.075 mm sieve ............................................................................ ± 1%
Bitumen content (single test result) ........................................................... ± 0.40%
Bitumen content (three consecutive test results) ........................................ ± 0.30%
Temperature of mixture when emptied from mixer ................................... ± 15o C
Temperature of mixture at delivery on road .............................................. ± 15o C
These tolerances are applicable to individual test results. The mean value for a series of
test results should be as close as possible to the approved job mix formula. The grading
shall not be allowed to vary from coarser side on one sieve to finer side on another sieve
within the approved job mix grading envelope.
Each day as many samples of the materials and mixture shall be taken and tested as the
Engineer considers necessary for checking the required uniformity of the mixture. When
unsatisfactory results are obtained the Contractor should take immediate corrective
action. If the Engineer is not satisfied with the actions taken he may halt production,
which will not be allowed to resume until the Contractor demonstrates that the problem
has been corrected.
Job materials will be rejected if they are found not to conform to the requirements of the
Specification.
3.9.2 Materials
3.9.2.1 Coarse Mineral Aggregate
The portion of the aggregate retained on the 5 mm sieve shall be known as coarse
aggregate and shall be crushed stone, or crushed gravel. Only one source of coarse
aggregate shall be used except by written permission from the Engineer. Approval of
sources of supply of aggregate shall be obtained from the Engineer prior to delivery of
the material. Samples and test results shall be submitted for approval of the Engineer at
least 14 days in advance of its use.
Crushed stone and crushed gravel shall consist of clean, tough, durable material free
from coherent coatings, decomposed stone, soft particles, organic matter, shale, clay and
any other substances, which in the opinion of the Engineer may be deleterious to the
mixture. Coarse aggregate shall meet the following requirements.
Table 3.9-1:
Testing Wearing
S.No. Name of Test Base Course
Procedure Course
Aggregate Crushing Less than
1 STP 7.7.1 Less than 20%
Value (ACV) (%) 25%
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 Los Angeles Abrasion Less than
2 AASHTO T96 Less than 20%
(LAA) (%) 20%
Not more than Not more
3 Water absorption STP 7.5.4
2% than 2%
Loss in weight (after 5 cycles)
AASHTO
4 Soundness with Sodium Sulphate solution-
T104
not more than10%
AASHTO
5 Coating & Stripping Test Min. 95% retained coating
T182

When crushed gravel is used, not less than 95% by weight of the particles retained on a 5
mm sieve shall have at least two fractured faces.
The flakiness index as determined in accordance with STP 7.3.1 shall not exceed 25%.

3.9.2.2 Fine Mineral Aggregate

The portion of the aggregate passing a 5 mm sieve shall be known as fine mineral
aggregate, and shall consist of natural sand, stone screenings, or a combination of both.
Stone screenings shall be produced from stone meeting the requirements for coarse
mineral aggregate in Section 3.9.2.1. Fine aggregate shall be composed of clean, hard
durable particles, rough surfaced and angular, free from vegetable matter, soft particles,
clay balls or other objectionable material.
The PI for material passing the 0.425 mm sieve shall be less than 4. Sand Equivalent of
material passing 4.75 mm sieve, when tested in accordance with AASHTO T176, shall
be minimum 50.
When the fine aggregate is tested for soundness as per AASHTO T104, the loss in
weight after 5 cycles with sodium sulphate shall not exceed 15%. Fine Aggregate
Angularity (AASHTO T304-96 ;2000) shall be maximum 45%. This property ensures a
high degree of fine aggregate internal friction and rutting resistance.
Approval of sources of supply of aggregate shall be obtained from the Engineer prior to
delivery of the material. Samples and test results shall be submitted for approval of the
Engineer at least 14 days in advance of its use.

3.9.2.3 Mineral Filler

Mineral filler where required shall consist of limestone dust, dolomite dust, or similar
rock dust, Portland cement, hydrated lime, silica cement or other mineral matter from
sources approved by the Engineer. It shall be non-plastic and free from foreign or other
objectionable material. It shall be dry and free from lumps and when tested by means of
laboratory sieves shall meet the following grading requirements:
Table 3.9-2:

Sieve Percentage by Weight

Designation (STP 3.3)

0.600 mm 100

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 0.150 mm 95 – 100

0.075 mm 65 – 100

Mineral filler shall be considered to include any mineral dust naturally present in the
bitumen.
Approval of sources of supply of mineral filler shall be obtained from the Engineer prior
to delivery of the material. Samples and test results shall be submitted for approval of the
Engineer at least 14 days in advance of its use.

3.9.2.4 Bituminous Materials

Details as to the source and type of bitumen must be submitted for approval at least 14
days before the proposed use of the material and should conform to the requirements of
Section 3.4. The Engineer may instruct for samples of the bitumen to be taken from the
consignment before leaving the place of manufacture and that these should be forwarded
to a laboratory nominated by the Engineer for analysis and testing. The material from
which these samples for testing are taken must be segregated at the place of manufacture
until the satisfactory completion of the aforesaid tests permit release.
Each consignment of bituminous material delivered to the site must be accompanied by
a certificate showing the place of manufacture and the results of standard tests carried
out on the bulk supply from which the material was extracted. No bituminous material
other than that represented by the sample submitted shall be used by the Contractor
except with the written consent of the Engineer. The contractor shall, in accordance with
Specification Clause 1.3.2 and when so directed by the Engineer, arrange for sampling
and testing, at an approved testing laboratory, of all bituminous materials delivered to
and stored at site. Blending of bituminous materials from different refineries shall not be
permitted.
3.9.3 Construction

3.9.3.1 Weather Limitation

Bituminous mixtures shall be placed only when the surface is dry, when rain does not
appear imminent and when the prepared roadbed is in a satisfactory condition. However,
the Engineer may permit, in case of sudden rain, the placing of mixture then in transit
from the plant, if laid at proper temperature and if the roadbed is free from pools of
water. Such permission shall in no way relax the requirements for quality and
smoothness of surface.

3.9.3.2 Progress of Work

No work shall be performed when there is insufficient hauling, spreading or finishing
equipment, or labour, to ensure progress at a rate not less than 75% of the capacity of the
mixing plant.

3.9.3.3 Plant and Equipment

A) Requirements for all Mixing Plants

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All plant used by the Contractor for the preparation of bituminous mixtures shall
conform to all of the requirements below, except that scale requirements shall apply only
where weight proportioning is used; and in addition, any batch mixing plants shall
conform only to the relevant special requirements herein and any continuous mixing
plants shall conform only to the relevant special requirements herein.
The mixing plant, which shall be a batching plant shall have a capacity sufficient to
supply the paver on the road continuously when spreading the bituminous mix at normal
speed and required thickness.
1) Uniformity. The plants shall be so designed, co-ordinated and operated as to produce
a mixture within the job - mix tolerances.
2) Plant scales and weigh house. Scales for any weigh box or hopper may be either of
the beam or spring less dial type and shall be of a standard make and design accurate
to within one-half of 1 percent of the maximum load required.
Scales shall be approved by the Engineer and shall be checked as often as the
Engineer may deem necessary to ensure their continued accuracy.
The Contractor shall provide and have at hand not less than ten 25 kilogram weights
for frequent testing of all scales.
3) Equipment for preparation of bituminous material. Tanks for storage of bituminous
material shall be capable of heating the material under effective and positive control
at all times, to a temperature within the range specified. The circulating system for
the bituminous material shall be of adequate size to ensure proper and continuous
circulation during the entire operating period. Suitable means shall be provided for
maintaining the specified temperature of the bituminous material in the pipe lines,
meters, weigh buckets, spray bars, and other containers or flow lines. The storage
tank capacity shall be sufficient for at least 1 day’s run. Bituminous material may be
partially heated in the tanks and brought to the specified temperature by means of
booster heating equipment between the tanks and the mixer.
4) Feeder for drier. The plant shall be provided with an accurate mechanical means for
uniformly feeding the mineral aggregate into the drier so that uniform production and
uniform temperatures are obtainable.
5) Drier. A rotary drier of approved design for drying and heating the mineral aggregate
shall be provided. The drier shall be capable of drying and heating the mineral
aggregate to the specified temperature.
6) Screens. Plant screens, capable of screening all aggregate to the specified sizes and
proportions and having normal capacities slightly in excess of the full capacity of the
mixer, shall be provided. The screens shall be readily exposed for inspection by the
Engineer.
7) Bins. The plant shall include storage bins of sufficient capacity to supply the mixer
when it is operating at full capacity. Bins shall be divided into at least three
compartments and shall be arranged to ensure separate and adequate storage of
appropriate fractions of the aggregate. For a mineral filler admixture a separate
feeder bin and/or weighing hopper arrangement may be required. Bins shall be so

3.47 | P a g e
 constructed that representative samples can readily be obtained, and the aggregate
level observed.
8) Bituminous control unit. Satisfactory means either by weighing or metering shall be
provided to obtain the proper amount of bituminous material in the mix within the
tolerance specified for the job-mix.
For use with batching plants, it shall provide the designated quantity of bituminous
material for each batch. For continuous mixing plants, the operating speed of the
pump shall be synchronised with the flow of aggregate in the mixer by an automatic
locking control, and the device shall be easily and accurately adjustable. Means shall
be provided for checking the quantity or rate of flow of bituminous material into the
mixer. An accuracy within 1% of the specified amount is required.
9) Thermometric equipment. An armoured thermometer reading from 50C to 200C
shall be fixed in the bituminous feed line at a suitable location near the discharge
valve at the mixer unit.
The plant shall be further equipped with a thermometric instrument so placed at the
discharge chute of the drier as to register automatically or indicate the temperature of
the heated aggregate.
10) Dust collector. The plant shall be equipped with a dust collector constructed to waste
or return uniformly to the elevator all or any part of the material collected. The
material to be returned from the dust collector shall be weighed over the filler scale.
11) Control of mixing time. The plant shall be equipped with accurate positive means to
govern the time of mixing and to maintain it constant unless changed at the direction
of the Engineer. The time of mixing shall be considered as the interval between the
time the bituminous material is spread on the aggregate and the time the same
aggregate leaves the mixing unit.
When bitumen is applied by a spray system, the mixing time shall begin with the
start of the bitumen spray. When the bitumen is not applied by a spray system, a
minimum dry mixing period of five seconds shall precede the addition of the bitumen
to the mix.
12) Safety requirements. Adequate and safe stairways to the mixer platform and guarded
ladders to other plant units shall be placed at all points required for accessibility to all
plant operations. All gears, pulleys, chains, sprockets, and other dangerous moving
parts shall be thoroughly guarded and protected. Ample and unobstructed space shall
be provided on the mixing platform. A clear and unobstructed passage shall be
maintained at all times in and around the truck loading space. This space shall be
kept free from drippings from the mixing platform. Flexible pipe connections
carrying hot bitumen shall be shielded.
B) Special Requirements for Batch Mix Plants
1) Weigh box or hopper. The equipment shall include a means for accurately weighing
each bin size of aggregate in a weigh box or hopper, suspended on scales, ample in
size to hold a full batch without hand raking or running over. The weigh box or
hopper shall be supported on fulcrums and knife edges so constructed that they will

3.48 | P a g e
 not easily be thrown out of alignment or adjustment. All edges, ends, and sides of
weighing hoppers shall be free from contact with any supporting rods, columns or
other equipment that will in any way affect the proper functioning of the hopper.
There shall also be sufficient clearance between hoppers and supporting devices to
prevent accumulations of foreign materials. The discharge gate of the weigh box
shall be so hung that the aggregates will not be segregated when dumped into the
mixer and shall close tightly when the hopper is empty so that no material is allowed
to leak into the batch in the mixer during the process of weighing the next batch.
2) Mixer. The batch mixer shall be capable of producing a continuous uniform mixture
within the job - mix tolerances. It shall be of such design as to permit visual
inspection of the mix.
The mixer shall be equipped with a sufficient number of paddles or blades with
proper arrangement to produce a properly and uniformly mixed batch. The clearance
of blades from all fixed and moving parts shall not exceed 20 mm unless the
maximum diameter of the aggregate particle in the mix exceeds 25 mm.
C) Special Requirements for Continuous Plants
1) Gradation control unit. The plant shall include a means for proportioning accurately
each bin size of aggregate either by weighing or by volumetric measurement.

When gradation control is by volume, the unit shall include a feeder mounted under
the compartment bins. Each bin shall have an accurately controlled individual gate to
form an orifice for volumetrically measuring the materials drawn from each
respective bin compartment. Indicators shall be provided for each gate to show the
respective gate opening in centimetres.
2) Weight calibration of aggregate feed. The plant shall include provision for a
calibration of the gate openings by means of weight test samples so that each of the
materials fed out of the bins through individual orifices may be by-passed
satisfactorily to suitable test boxes, each bin material being confined separately.
The plant shall be equipped to handle conveniently such test samples weighing not
less than 150 kilograms combined weight of samples from all bins, and not less than
50 kilograms for any one bin sample.
3) Synchronisation of aggregate and bitumen feed. Satisfactory means shall be provided
to afford positive interlocking control between the flow of aggregate from the bins
and the flow of bitumen from the meter or other proportioning source. This control
shall be accomplished by interlocking mechanical means or by a positive method
satisfactory to the Engineer.
4) Mixer. The plant shall include a continuous mixer of an approved type capable of
producing a continuous uniform mixture within the job - mix tolerances.
Determination of the mixing time shall be by a weight method, using the following
formula (the weights shall be determined for the job): -
Mixing time in seconds = Pugmill dead capacity in kilograms

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 Pugmill output in kilograms per second
5) Hopper. The mixer shall be equipped with a hopper at the discharge end, of such size
and design that no segregation of mix occurs. Any elevator used for loading mixture
into vehicles shall have an equally satisfactory hopper.
D) Equipment for Hauling and Placing
1) Trucks. Trucks for hauling bituminous mixtures shall have tight, clean and smooth
metal beds that have been sprayed with soapy water, thinned fuel oil, paraffin oil, or
lime solution to prevent the mixture from adhering to the beds. The amount of
sprayed fluid shall however be kept to the practical minimum. Each load shall be
covered with canvas or other suitable material of such size as to protect the mixture
from the weather. Any truck causing excessive segregation of material by its spring
suspension or other contributing factors, or that shows oil leaks in detrimental
amounts, or that causes undue delays, shall upon direction of the Engineer be
removed from the Works until such conditions are corrected. When necessary, in
order that the mixture shall be delivered on the road at the specified temperature,
truck beds shall be insulated to maintain workable temperature of the mixture and all
covers shall be securely fastened.
Trucks or any other equipment leaking petroleum products will not be allowed
admittance to paved areas or areas where paving is under construction.
2) Spreading and finishing equipment. The equipment for spreading and finishing shall
be approved mechanical, self-powered pavers, capable of spreading and finishing the
mixture true to the lines, grades, levels dimensions and cross sections.
The pavers shall be equipped with hoppers and distributing screws of the reversing
type to place the mixture evenly in front of adjustable screeding devices and shall
have reverse as well as forward travelling speeds.
The pavers shall maintain the grade and confine the edges of the pavement to true
lines without the use of stationary side forms. The equipment shall include blending
or joint levelling devices for smoothing and adjusting longitudinal joints between
lanes. The assembly shall be adjustable to give the cross-section shape prescribed and
shall be so designed and operated as to place the thickness or weight per square metre
of material required.
Pavers shall be equipped with activated screeds and devices for heating the screeds to
the temperature required for the laying of the mixture without pulling or marring.
The term “screed” includes any cutting, crowding, or other practical action that is
effective in producing a finished surface of the evenness and texture specified,
without tearing, shoving, or gouging.

If, during construction, it is found that the spreading and finishing equipment in
operation leaves in the pavement surface tracks or indented areas of other
objectionable irregularities that are not satisfactorily corrected by scheduled
operations, the use of such equipment shall be discontinued and other satisfactory
spreading and finishing equipment shall be provided by the Contractor forthwith.
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 Rollers shall be pneumatic tyred rollers and smooth wheel rollers with or without
vibration. The rolling procedure is described in Section 3.5.3.4.
3) Small tools. The Contractor shall provide suitable means for keeping all small tools
clean and free from accumulation of bituminous material. He shall provide and have
ready for use at all times enough tarpaulins or covers, as may be directed by the
Engineer, for use in any emergency such as rain, chilling wind, or unavoidable delay,
for the purpose of covering or protecting any material that may have been dumped
and not spread.

3.9.3.4 Preparation and Placing

A) Preparation of Existing Surface
Where local irregularities in an existing surface would otherwise result in a course more
than 75 mm thick after compaction, the surface shall be brought to uniform contour by
patching with a bituminous mixture to be approved by the Engineer, and thoroughly
tamping or rolling until it conforms to the surrounding surface. The mixture used shall
be the same as that specified for the next course, unless the size of the largest aggregate
in the mixture precludes this when the Engineer will decide the mixture to be used.
Where the existing roadbed is broken or shows instability, the unstable material shall be
removed and disposed of as directed by the Engineer and be replaced with the same
mixture as specified for the next course, compacted to the standard and elevation of the
adjacent surface.
The surface upon which the mixture is to be placed shall be swept thoroughly and
cleaned of all loose dirt and other objectionable material immediately before spreading
the mixture.
B) Preparation of Bituminous Material
The bituminous material shall be heated to the specified temperature in kettles or tanks
so designed as to avoid local overheating and to provide a continuous supply of the
bituminous material to the mixer at a uniform temperature at all times.
C) Preparation of Mineral Aggregate
The mineral aggregates for the mixture shall be dried and heated before being placed in
the mixer. Flames used for drying and heating shall be adjusted properly to avoid
adversely affecting the aggregate and to avoid forming a heavy coating of soot on the
aggregate. The aggregates shall be heated to the temperature specified in the applicable
Section.
The aggregates, immediately after heating, shall be screened into three or more fractions
and conveyed into separate bins ready for combining and mixing with bituminous
material. The fraction of aggregate deposited in any bin shall not contain more than 10%
of material outside the specified size limits for that bin.
D) Preparation of Mixture
The dried mineral aggregates prepared as prescribed above, shall be combined in the
amount of each fraction of aggregate required to meet the job-mix formula for the
particular mixture. The bituminous material shall be measured or gauged and introduced
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into the mix in the amount determined in the job mix formula. The proper amount of
bituminous material shall be distributed over the mineral aggregate and the whole
thoroughly mixed for a period of at least 30 seconds, or longer if necessary to produce a
homogeneous mixture in which all particles of the mineral aggregate are coated
uniformly. For a continuous mixing plant, the mixing time shall be determined from the
formula in Section 3.5.3.3(C)(4) and may be regulated by fixing a minimum gauge in the
mixer unit and/or by other mixing unit adjustment.
E) Transportation and Delivery of Mixture

The mixture shall be transported from the mixing plant to the point of use in vehicles
conforming to the requirements of Section 3.5.3.3(D)(1). Loading and transporting shall
be such that spreading, compaction and finishing shall all be carried out during daylight
hours unless satisfactory illumination is provided by the Contractor.
F) Spreading and Finishing
Upon arrival at the point of use, the mixture shall be spread and struck off to the grade,
elevation, and cross-section shape intended, either over the entire width or over such
partial width as may be practicable. Bituminous mixture pavers conforming to the
requirements of Section 3.9.3.3(D)(2) shall be used for this purpose. The mixture shall
be laid upon an approved surface and only when weather conditions are considered
suitable by the Engineer.
In narrow base widening, deep or irregular sections, turn outs or driveways where it is
impractical to spread and finish the mixture by use of a paver, the Contractor shall use
approved spreading equipment or acceptable hand methods as directed by the Engineer.
On areas where in the opinion of the Engineer, the use of spreading equipment is
considered impractical, the mixture shall be dumped on steel boards then spread, raked
and luted by hand to provide the correct weight or uniform thickness of material without
segregation. Mixture shall not be applied faster than can be properly handled and spread.
G) Compaction of Mixture
1) General. Immediately after the mixture has been spread and struck off, the surface
shall be checked and any inequalities adjusted. The mixture shall then be thoroughly
and uniformly compacted by rolling. Each course shall be rolled as soon after being
placed as the material will support the roller without undue displacement or cracking.
2) Roller Requirements. With each paver, two steel wheeled tandem rollers and one
pneumatic tyred roller will be required.
All rollers shall be self-propelled, capable of being reversed without backlash and
equipped with power steering, dual controls allowing operation from either the right or
left side, water tanks, sprinkler systems and coco-mats to ensure even wetting of rolls or
tyres. The Contractor shall supply to the Engineer for each type of roller a calibration
chart showing the relation between depth of ballast and weight and giving the tare weight
of the roller. Each roller shall be in good condition and worked by a competent and
experienced operative.

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Steel wheeled tandem rollers shall weigh not less than 8 metric tons and each tandem
roller used for final compaction (finish rolling) shall have at least one roll capable of
applying a minimum rolling pressure of 35 kilograms per centimetre of roll width.
Pneumatic tyred rollers shall be of an approved type having not less than seven wheels
with smooth treat compactor tyres of equal size and construction capable of operating at
inflation pressures up to 8.5 kg/cm². Wheels shall be equally spaced along both axle lines
and arranged so that tyres on one axle line track midway between those on the other with
an overlap. Each tyre shall be kept inflated to the specified operating pressure such that
the pressure difference between any two tyres shall not exceed 0.35 kg/cm². Means shall
be provided for checking and adjusting the tyre pressures on the job at all times. Each
roller shall be so equipped that its total weight is adjustable by ballasting allowing the
load per wheel to be varied from 1,500 to 2,500 kilograms. In operation, the tyre
inflation pressure and the wheel load shall be adjusted, as required by the Engineer, to
meet the requirements of each particular application. In general the compaction of any
course with a pneumatic tyred roller shall be accomplished with contact pressures as high
as the material will support.

3) Procedure. Rolling of the mix shall consist of six separate operations as follows:
 transverse joint
 longitudinal joint
 edges
 initial or breakdown rolling
 second or intermediate rolling
 finish rolling

The first rolling of all joints and edges, the initial or breakdown rolling and the final or
finish rolling shall all be done with the steel wheeled tandem rollers.
The second or intermediate rolling shall be done with the pneumatic tyred roller except
on small operations.
Rolling shall start longitudinally at the sides and proceed toward the centre of the
pavement except that on super-elevated curves rolling shall begin at the low side and
progress toward the high side. Successive trips of the roller shall overlap by at least one
half of the width of the roller and alternative trips shall not terminate at the same point.
For initial rolling, the drive roll should be nearest the paver.
The speed of the rollers shall not exceed 4 kilometres per hour for steel wheeled rollers
and 6 kilometre per hour for pneumatic tyred rollers and shall at all times be slow enough
to avoid displacement of the hot mixture. Any displacements occurring as a result of
reversing the direction of the roller or from any other cause shall at once be corrected
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with rakes and fresh mixture where required. Care shall be exercised in rolling not to
displace the line and grade of the edges.
Rolling shall progress continuously as may be necessary to obtain uniform compaction
while the mixture is in a workable condition and until all roller marks are eliminated.
Heavy equipment or rollers shall not be permitted to stand on the newly laid surface until
it has thoroughly cooled.
To prevent adhesion of the mixture to the roller, the wheels shall be kept properly
moistened, but excess water will not be permitted.
Any petroleum products dropped or spilled from the vehicles or equipment employed by
the Contractor upon any portion of the pavement under construction is cause for the
removal and replacement of the contaminated pavement by the Contractor.
Along kerbs, headers, manholes, and similar structures and at all places not accessible to
the roller, thorough compaction shall be secured by means of hot hand tampers or with
mechanical tampers giving equivalent compaction. Each hand tamper shall weigh not
less than 10 kilograms and shall have a tamping face area of not more than 250 square
centimetres.
The surface of the mixture after compaction shall be smooth and true to the established
crown and grade within the tolerance specified. Any mixture that becomes loose and
broken, mixed with dirt, or which is defective in any way, shall be removed and replaced
with fresh hot mixture, which shall be compacted immediately to conform with the
surrounding area. Any area of 1,000 square centimetres or more showing an excess or
deficiency of bituminous material shall be removed and replaced. All high spots, high
joints, depressions, and honeycombs shall be adjusted as directed by the Engineer.
H) Joints
Both longitudinal and transverse joints in successive courses shall be staggered so as not
to be one above the other. Longitudinal joints shall be staggered a minimum of 20cm
and so arranged that the longitudinal joint in the top course shall be at the location of the
line dividing the traffic lanes. Lateral joints shall be staggered a minimum of 100cm
centimetres and shall be straight.
Spreading shall be as nearly continuous as possible and rollers shall pass over the
unprotected end of freshly laid mixture only when authorised by the Engineer. In all
such cases provision shall be made for a properly bonded and sealed joint with the new
surface for the full depth of the course as specified above.
Before placing mixtures against them, all contact surfaces of kerbs, gutters, headers,
manholes etc. shall be given a thin uniform coating of hot bitumen and the joints
between these structures and the surface mixture shall be effectively sealed by the
subsequent spreading, finishing and compaction operations.
When the wearing course is placed adjacent to kerbs to form a bitumen gutter it shall be
sealed with bitumen for a distance of 30 centimetres from the kerb. The seal shall be
evenly applied to the surface by means of hot irons or squeegees so that the surface voids
are completely filled and no excess bitumen remains on the surface. The desired
drainage pattern shall be maintained.

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3.9.3.5 Surface Test of the Pavement
The finished surface of the pavement for both base (binder) and wearing courses shall
not vary from the specified levels and grades by more than 5mm. The surface shall be
also tested by a crown template and 3 metre straight edge, furnished by the Contractor,
applied respectively at right angles and parallel, to the centreline of the road. The
Contractor shall designate some employees to use the template and straight edge under
the direction of the Engineer in checking all surfaces. The crown template shall conform
to the typical cross section shown on the Drawings.
The variation of the surface from the testing edge of the crown template and the straight
edge between any two contacts with the surface shall not exceed 5 millimetres for both
binder and wearing courses.
Tests for conformity with the specified crown and grade shall, when agreed by the
Engineer, be made immediately after initial compaction and variations shall be corrected
by removing or adding materials as may be necessary. Rolling shall then be continued as
specified. After final rolling, the smoothness of the course shall be checked again and
any irregularity of the surface exceeding the above limits and any areas defective in
texture, compaction, or composition, shall be corrected as directed by the Engineer,
including removal and replacement at the Contractor’s expense if so directed by the
Engineer.
The average thickness of the compacted bituminous layer, as computed from 5No
successive determinations for every 400 to 800 m2 of pavement area, shall not be less
than the specified thickness nor shall any particular point be thinner than 5mm less than
the specified thickness. Any section of paving having thickness measurements outside
these limits shall be rectified at the contractor’s expense as directed by the Engineer,
including where necessary removal and replacement. In case of removal and relaying of
the pavement layer a minimum length of 50m shall be removed for its full width.
The edges of the pavement shall follow a smooth alignment and, where not bound by
kerbs or other edgings, shall not deviate from the specified alignment by more than
20mm. Any material laid out of alignment is to be corrected as directed by the
Engineer. Excess material shall be cut off square after final rolling, and disposed of by
the Contractor. Finished pavement surface shall be tested for IRI, the recommended
values/ranges for IRI is 1.75 – 2 m/km for rutting depth 9 – 10 mm and for cracks,
Pavement Condition Rating (PCR) 75 – 80, it is measured on a scale 0 – 100, where 100
means newly paved road.

3.9.3.6 Control and Testing

The Contractor shall supply qualified personnel to be in charge of the tests and controls
required to ensure correct operation of the plant and the manufacture of a satisfactory
product.

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 The Contractor shall keep a diary and maintain records of times, batch numbers, areas
paved and other observations, and he shall follow such instructions as may be given by
the Engineer in order to obtain the required quality of the bituminous bound material.
3.9.4 Measurement
All work prescribed above shall be measured and paid for as provided in the respective
Sections for each type of pavement. The quantity measured and paid for shall always be
the quantity ordered with any permitted excess, or the actual quantity used whichever is
the less.
3.9.5 Payment
The work shall be paid for as provided in the respective Section for each type of
bituminous layer.

3.10 BITUMINOUS PRIME COAT

3.10.1 Description
This work shall consist of the careful cleaning of the surface to be primed and furnishing
and applying bituminous material in accordance with these Specifications to the area
shown on the Drawings or as directed by the Engineer.
3.10.2 Materials

3.10.2.1Bituminous Materials
Bituminous material shall be a MC 30 or MC 70 cut back bitumen and shall conform to
the requirements of Section 3.12.2.2 The bituminous material shall be approved by the
Engineer and may be prepared by cutting back 80/100 penetration bitumen with
kerosene in the ratio of 100 parts by volume of bitumen to 40 – 60 parts by volume of
kerosene depending on the porosity of the surface.

3.10.2.2Blotting Material
Blotting material shall be approved clean dry sand or stone screenings free from any
cohesive materials or organic matter. Not more than 10 per cent of the sand shall be finer
than the 75 micron sieve.
3.10.3 Construction Methods

3.10.3.1Weather Limitations
Prime coat shall be applied at a time when the surface to be treated is dry or slightly
damp, when the ambient temperature is above 13ºC and rising, or above 16ºC if falling,
and when the weather is dry.

3.10.3.2Equipment
The Engineer may approve Construction equipment and methods (including labour
intensive methods) other than those specified hereinafter provided that the contractor can
demonstrate his ability to carry out the work to a satisfactory standard using his proposed
equipment and methods to the complete satisfaction of the Engineer. Such approval shall
be in writing and may be withdrawn at any time if the work is found to be unsatisfactory
in any respect.

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 The equipment used by the Contractor shall include, unless otherwise approved by the
Engineer, a power brush, a pressure bituminous distributor, and, when necessary,
equipment for heating bituminous material.
The distributor shall have pneumatic tyres and shall be so designed, equipped,
maintained and operated that bituminous material at constant temperature may be
applied uniformly on variable widths of surface up to 4 metres at readily determined and
controlled rates of from 0.2 to 2.0 litres per square metre with uniform pressure, and with
an allowable variation from any specified rate not to exceed 0.1 litre per square metre.
Distribution equipment shall include an instrument for measuring the speed of travel
accurately at low speeds, and the temperature of the contents of the tank.
The spray bar on the distributor shall be controlled by a man riding at the rear of the
distributor in such a position that operation of all sprays is in his full view.
The tanks of distributors shall be fitted with accurately calibrated dipsticks or contents
gauges.
All measuring equipment on the distributor shall have been recently calibrated and an
accurate and satisfactory record of such calibration shall be supplied to the Engineer. If,
after beginning the work, the distribution of bituminous material is found to be in error,
the distributor shall be withdrawn from the work and calibrated to the satisfaction of the
Engineer before any further work is undertaken.
The Engineer may require such tests, as he considers necessary to check the performance
of the distributor. As and when directed by the Engineer, the Contractor, at his own
expense, shall make the distributor and its equipment available for field testing and shall
supply any assistance required for this purpose. Any distributor, which does not operate
satisfactorily or conform to the requirements of the Specifications in all respects, may be
rejected by the Engineer for further use on the Works.

3.10.3.3Cleaning Surface
Immediately before applying the bituminous material, all loose dirt and other
objectionable material shall be removed from the surface with a power brush. When so
ordered by the Engineer, a light application of water shall be made just before the
application of bituminous material.

3.10.3.4Application of Bituminous Material

Bituminous material shall be applied at the rate, or rates, either shown in the Contract
Documents or as directed by the Engineer. The rate sprayed can be verified using STP
10.12. This will usually be from 1.0 to 2.5 litres per square metre, and at a temperature
within the range called for in Table 3.4-6 for the particular material being used. Any
prescribed application shall be divided into two applications when necessary to prevent
bitumen flowing off the surface, and additional bituminous material shall be applied
where surface conditions indicate it to be necessary, if the Engineer so directs. No
further courses shall be applied until the prime coat has dried and the solvent evaporated.

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 When so directed, the prime coat shall be applied in lanes of approximately one-half or
less of the width of the completed surface. A lane of prime coat shall be applied, allowed
to penetrate for not less than 48 hours, then covered with blotting material if required,
and opened to traffic before bituminous material is applied to the adjacent lane. In
covering the first primed lane, a strip at least 200 mm wide shall be left uncovered where
it joins the second traffic lane to permit an overlap of the bituminous material.
The surface of structures and trees adjacent to the areas being treated shall be protected
in such manner as to prevent their being splashed or damaged. No bituminous material
shall be discharged into a borrow pit or gutter.

3.10.3.5Maintenance and Opening to Traffic

Traffic shall not be permitted on the primed surface until the material has penetrated and
dried and, in the opinion of the Engineer, will not be picked up by traffic. Where the
Engineer deems it impracticable to detour traffic, the Contractor shall spread the
minimum quantity as determined by the Engineer, of blotting material necessary to avoid
picking up, and traffic shall be allowed to use areas so treated. Any areas containing an
excess or deficiency of priming material shall be corrected by the addition of sand or
bitumen as directed by the Engineer. Such corrections of faulty work shall be carried out
at the Contractor’s expense.
3.10.4 Measurement
The quantity of bituminous material shall be measured for payment in square metres;
however, in the case of plant placed materials a record of the number of Litres of
bituminous material placed will also be kept.
The measured quantity shall be the theoretical required to comply with the Contract, or
shall be the quantity used and accepted. This should be within ± 5% of the theoretical
quantity unless there is a change in the area of coverage.

3.10.5 Payment
This work measured as provided above, shall be paid for at the Contract unit price per
unit of measurement. The prices and payment shall be full compensation for preparation
of the surface and furnishing and placing the materials and application of blotting
materials including all labour, equipment, tools and incidentals necessary to complete the
work prescribed in this Section.
Pay item shall be:
3/10/1(a)Bituminous Prime Coat (plant placed) Square Metre
or
3/10/1(b)Bituminous Prime Coat (hand placed) Square Metre

3.11 BITUMINOUS TACK COAT

3.11.1 Description
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 This work shall consist of furnishing and applying bituminous material to a previously
prepared roadbed, in accordance with the Specifications and to the width and area
required by the Engineer.
3.11.2 Materials
Bituminous material shall be either 60/70 or 80/100 penetration grade bitumen, cut back
bitumen RC 30, RC 70 cut back bitumen RC 30, RC 70, or rapid setting emulsion
conforming to the requirements of Section 3.12.2.2 of these Specifications. The
bituminous material shall be approved by the Engineer.
3.11.3 Construction Methods

3.11.3.1 Equipment
The Engineer may approve Construction equipment and methods (including labour
intensive methods) other than those specified hereinafter provided that the contractor can
demonstrate his ability to carry out the work to a satisfactory standard using his
proposed equipment and methods to the complete satisfaction of the Engineer. Such
approval shall be in writing and may be withdrawn at any time if the work is found to be
unsatisfactory in any respect. The equipment shall be as specified in Section 3.6,
Bituminous Prime Coat.

3.11.3.2Cleaning Surface
The full width of surface to be treated shall be cleaned with a power brush to remove
loose dirt, sand, dust and other objectionable material. The surface to be treated shall be
dry.

3.11.3.3Application of Bituminous Material

Immediately after cleaning the surface, bituminous material shall be applied at the rate
directed by the Engineer, but not to exceed 0.45 litres per square metre and at the
temperature within the range included in Table 3.4-6 for the particular material being
used. The tack coat shall be applied only when the surface is dry.
The tack coat material shall be uniformly distributed over the surface without streaking.
Quantities shall not deviate more than 10% from the quantity prescribed by the
Engineer. Quantities outside the specified tolerances shall be adjusted by the Contractor
at his own expense, to the satisfaction of the Engineer.
The surfaces of structures and trees adjacent to the areas being treated shall be protected
in such manner as to prevent their being splashed or damaged. No bituminous material
shall be discharged into a borrow pit or gutter. The Engineer may direct that emulsions
shall be diluted with clean water in order to control the rate of spread. This shall be done
at the Contractor’s expense.
After the tack coat is applied the Contractor shall protect it from damage until the surface
course is placed. No surfacing layer will be permitted to be placed unless the tack coat is
in a satisfactory condition to receive it and as such the tack coat shall be applied only so
far in advance of surface course placement as is necessary for this to occur.

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 3.11.4 Measurement
The quantity of bituminous material shall be measured for payment in square metres;
however, in the case of plant placed materials a record of the number of Litres of
bituminous material placed will also be kept.
The measured quantity shall be the theoretical required to comply with the Contract, or
shall be the quantity used and accepted. This should be within ± 5% of the theoretical
quantity unless there is a change in the area of coverage.

3.11.5 Payment
This work measured as provided above, shall be paid for at the Contract price per unit of
measurement. The prices and payment shall be full compensation for furnishing and
placing the materials, including all labour, equipment, tools and incidental necessary to
complete the work.

Pay item shall be:

3/11/1(a)Bituminous Tack Coat (plant work) Square Metre

or

3/11/1(b)Bituminous Tack Coat (labour intensive work) Square Metre

3.12 PRIMER SEAL

3.12.1 Description
The work shall consist of an application of bituminous material followed by spreading
of pea-gravel, a cover coat material, in accordance with these Specifications to the area
shown on the Drawings or as directed by the Engineer.

3.12.2 Materials

3.12.2.1 Bituminous Material

Cutback bitumen conforming to the requirements of section 3.4 as appropriate, shall be
used for the purpose. The 80-100 penetration grade bitumen may be converted into
cutback by fluxing and thoroughly mixing 4% diesel with the bitumen after it is heated.
The method of mixing or fluxing for cutback from 80-100 penetration grade bitumen
shall be approved by the Engineer.

3.12.2.2 Cover Coat Material

Cover coat material used for this work shall be screened Pea gravel conforming to the
Specification and graded so that 100% of the materials falls within the size range of 2.4
mm to 6.3 mm. Pea-gravel shall be washed by water, dried and be free from any organic
matter, clay or any other objectionable matter and completely dust free. Samples of the
Pea gravel proposed for use shall be submitted for approval of the Engineer.
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3.12.3 Construction Methods

3.12.3.1 Cleaning Surface

The contractor shall furnish all labour and equipment required for thoroughly cleaning
the surface to be primed. The cleaning shall be done in such a manner as to thorough
remove all mud, dust and other foreign materials. The sweeping on a water bound
surface shall be just sufficient to expose the pattern of the coarse aggregate. Any surplus
bituminous materials shall be removed from the surface.
Special care shall be taken to clean the edges of the road to be primed in order to ensure
uniform application of the bituminous materials, directly on the existing base of
pavement material.

3.12.3.2 Applying Bituminous Materials

Primer seal work shall be carried out only when the surfaces and aggregates are dry and
shall only be commenced in areas which can be completed in dry conditions. Any work
which becomes wet by rain or other causes before rolling is completed may be rejected.
Fluxed bitumen, at a temperature as given in table 3.4-6, shall be applied uniformly to
the prepared surface at a rate of 1.0 L/m2 or as directed by the Engineer.
Application may be approved by labour intensive methods in which case the following
procedure will be adopted.
 The surface to be sprayed will be marked into 1 metre wide strips for the full
width of the pavement.
 Using a container constructed to hold the quantity of bituminous materials
required for the area of 1 strip, apply the fluxed bitumen using a rubber squeegee.
 The contractor shall furnish a thermometer at each mixing unit to ensure that
temperature of cutback bitumen is always within specified range.

3.12.3.3 Spreading and Rolling

Screened pea gravel aggregate, shall be spread uniformly to the required density over the
bitumen prime as soon as possible after application of the bitumen to provide a dense
uniform cover one stone thick. Brooming or other methods shall be used if necessary to
achieve a uniform spread rate. The aggregate application rate will be approximately
10kg/m², or as directed by the Engineer. Rollers shall comply with section 3.9.3 of this
Specification.
The time between application of the bitumen at any location and the completion of
spreading the aggregate over it at that location shall ensure that the bitumen is still
within the specified temperature range and shall not exceed 3 minutes. The aggregate
shall be rolled into the bitumen immediately using a rubber tyred roller for at least 4
passes and the road shall not be opened to traffic if this will cause any damage to the
works.

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3.12.4 Measurement
Surface dressing work shall be measured under this item by the number of square metres
of acceptable work completed.

3.12.5 Payment
The quantity measured as provided above shall be paid for at the contract unit price per
unit of measurement as shown in the Bill of Quantities, or on the drawings. The prices
and payments shall be full compensation for cleaning, application of bitumen,
compaction, furnishing the materials, testing, site trials and for all labour, tools,
equipment and incidentals necessary to complete this item.
Pay item shall be:
3/12/1 Primer Seal Square Metre

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3.13 BITUMINOUS SURFACE TREATMENT (plant method)

3.13.1 Description
Bituminous Surface Treatment shall consist of one or more applications of bituminous
material and cover aggregate to a primed non-bituminous surface, or to a previously
constructed bituminous surface, in accordance with these Specifications and to the area
shown on the Drawings and as directed by the Engineer.
3.13.2 Materials

3.13.2.1 Bituminous Materials

Bituminous material shall be either RC 800 or RC 3000 cut back bitumen, rapid setting
emulsion or, with the agreement of the Engineer 80/100 penetration grade bitumen
conforming to the requirements of Section 3.4 of these Specifications. The bituminous
material shall be approved by the Engineer.

3.13.2.2 Bitumen Additive

An Adhesion and Anti-stripping Agent shall be added to the bituminous material where
so specified or when the Engineer so directs or approves. The additive shall be of a type
approved by the Engineer and the required percentage of additive shall be thoroughly
mixed with the bituminous material in accordance with the manufacturer’s instructions,
or as directed by the Engineer, for such time as is necessary to produce a homogeneous
mixture.

3.13.2.3 Aggregates
Aggregates shall consist of clean, hard, dry, sound, crushed stone or crushed gravel of
uniform quality, free from dust, clay, dirt and other deleterious matter and from excess of
flat or laminated pieces. When crushed gravel is used, not less than 90% by weight of the
particles retained on a 5 mm sieve shall have at least two fractured faces.
Aggregate shall be of such a nature that when thoroughly coated with the bituminous
material proposed for the work, the coating will not be removed upon contact with water.
The aggregate when tested in accorded with STP 7.7.1 and 7.7.2 shall have an Aggregate
Crushing Value less than 25 and a ten per cent fines value greater than175 kN. The
flakiness index as determined in accordance with STP 7.3.1 shall not exceed 25%.
Test results should be submitted to the Engineer for approval. The Engineer may require
that other tests shall be carried out to determine its acceptability for surface treatment.
The grading of the aggregates shall fall within the limits specified in Table 3.9-1 for the
appropriate specified nominal size.

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 Table 3.13-1

Grading Requirements for Cover Aggregate for Bituminous Surface Treatment

Nominal Sieve Size Aggregate Nominal Size
20 mm 14 mm 10 mm
Percentage by weight passing square mesh sieves
20 100 100 100
14 0 - 45 85 - 100 100
10 0-7 0 - 45 85 - 100
6.3 0-2 0-7 0 - 45
2.4 - 0-2 0-7
0.075 0-1 0 – 1.5 0-2

Notes on Table 3.10-1

1) For Single Surface Treatment either 20, 14 or 10 mm nominal size may be specified.
2) For Double Surface Treatment the first course may be either 20 mm or 14 mm
followed by a second course of 10 mm nominal size.
Aggregate shall not contain sufficient moisture to cause uneven distribution of the
pre-coating material and shall not be used in the work until the moisture has evaporated
and the pre-coating material has adhered effectively to the aggregate.

3.13.2.4Pre-Coated Aggregate
Aggregates shall be pre-coated with approved pre-coating material to improve the
adhesion to the bitumen. Pre-coating material shall be thinly and evenly applied by
means of a fine pressure spray to a moving stream of aggregate in an approved mixing
plant so that all particles are fully coated but do not contain excess material. The coating
shall be such that no material will drip from a particle of aggregate suspended between
the fingers.
Pre-coating of aggregate shall not be carried out when rain is imminent unless the
aggregate is adequately covered or unless the mixing of an adhesion agent in the pre-
coating material has been authorised by the Engineer.

3.13.2.5Stockpiling of Aggregates
Stockpiling of aggregates will be permitted only in designated areas approved by the
Engineer. A separate stockpile shall be made for each nominal size of aggregate at each
location.
In areas subject to dusty conditions, pre-coated aggregate shall not be stockpiled for any
period longer than is necessary for moisture to dry out. When there is a visible coating of
dust on the particles, the Engineer may direct that portions of the stockpiles be
pre-coated again.
The site of the stockpile shall be cleared of all vegetation and debris, graded and drained,
and, where the Engineer deems it necessary, the area shall be surfaced with a 100 mm

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 layer of approved stone or with brick flat soling. In any case, the bottom 50 mm layer of
aggregate or any contaminated aggregate shall not be used in the work.
Unless otherwise approved by the Engineer, each stockpile shall be built at least 2
metres high. The Contractor shall supply any planking or other material required in
connection with movement of vehicles over and about the stockpiles.
3.13.3 Construction Methods

3.13.3.1Equipment
Equipment described in this Section will be used for bituminous surface treatments
unless the Engineer approves alternative construction methods proposed by the
Contractor. Alternative construction methods would be particularly applicable to small
areas and to the surfacing of footpaths and hard shoulders.
The Contractor shall supply all the plant and equipment necessary for carrying out the
work in accordance with these Specifications and shall supply details of the make,
model, capacity, weight and such other details of the plant and equipment as may be
required by the Engineer.
For seal coats without cover aggregate, the equipment shall include a power brush, a
self-powered bituminous material pressure distributor and, when necessary, equipment
for heating bituminous material.
For seal coats with aggregate, and surface treatments, the equipment shall include a
power brush, a drag brush, a bituminous material pressure distributor, a self-propelled
pneumatic tyred roller, aggregate spreading equipment, an adequate number of trucks
and, when necessary, equipment for heating bituminous material. A steel wheeled roller
may be used only when so authorised by the Engineer.
In addition, when coated aggregates, bitumen additive or rubberised bituminous
materials are specified, approved mixing plant shall be provided for the particular
application.

Plant and equipment shall comply with the following requirements:

a) The Bituminous Material Distributor shall conform to the requirements of Section
3.10.3.2
b) The Power Brush shall be a rotary brush, towed or self-propelled, designed for
sweeping road surfaces.
c) The Drag Brush shall be capable of distributing unevenly spread aggregate without
disturbing the particles freshly bedded in the binder.
d) The Pneumatic Tyred Roller shall conform to the requirements of Section
3.9.3.4(G)(2).
e) The Steel Wheeled Roller, where this type is permitted, shall have a load per 10 mm
width of roll between 25 and 45 kg.

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 f) The Aggregate Spreader shall be approved mechanical equipment capable of
spreading a uniform layer of cover aggregate of the specified size.
g) Motor Trucks shall be suitable in number and performance for the application of
aggregate in accordance with Section 3.13.3.5.
h) Heating Equipment shall be capable of producing uniform heating to the required
temperature without damage to the bituminous material. An approved instrument for
temperature measurement with an accuracy of 3% shall be provided. Means shall be
provided to drain completely the heating tank or tanks. Suitable fire-fighting
equipment and material shall be conveniently available to the heating equipment at
all times when heating is in progress.

3.13.3.2Weather Limitations and Control of Work

No spraying shall be carried out on a wet pavement, while rain appears imminent or
during high winds. The Engineer may order work to cease temporarily on account of
adverse weather. The Engineer may also order work to cease if the condition of
materials is unsatisfactory, or conditions exist which he considers may affect the work
adversely, for example the equipment or pavement is in unsatisfactory condition. The
work will not be allowed to restart until the contractor has taken the necessary corrective
action.

3.13.3.3Cleaning and Preparation of Surface

No application of bituminous material shall be undertaken until the pavement has been
cleaned to the satisfaction of the Engineer. Loose dirt and other objectionable material
shall be removed from the surface by means of the power brush. If this does not provide
a uniformly clean surface, additional sweeping shall be done by hand, using stiff bass or
similar brushes. Sweeping shall extend at least 200 mm beyond each edge of the area to
be sprayed.
Adherent patches of objectionable material shall be removed from the surface by steel
scraper or other approved method, and where the Engineer so directs, the scraped area
shall be washed down with water and hand brushes.
Where a prime coat has been applied to the surface, any area in which the prime coat has
been insufficiently applied or is defective in any way shall be re-primed as directed by
the Engineer. A period of at least 48 hours or such longer period as may be necessary for
the primer to become completely dry shall elapse before any further bituminous material
is applied.
Before application of the bituminous material, any necessary preliminary patching of the
surface of the road shall have been completed to the satisfaction of the Engineer.

3.13.3.4Application of Bituminous Material

The uniform application of bituminous material at the rate specified or ordered, reference
is made to Table 3.9-2, shall be made by means of the distributor. For small areas, the
Engineer may approve the application by means of hand spray equipment attached to the
distributor.

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For the particular bituminous material being used the application temperature shall be
within the range included in Table 3.4-6. When an adhesion agent has been added to the
bituminous material, the whole of the material in the distributor shall be circulated for at
least fifteen minutes, or such greater time as may be necessary, to achieve a
homogeneous mixture at uniform temperature.

Quantities of bituminous materials in excess of requirements shall not be heated, nor

shall such materials be held within the range of the application temperatures for periods
in excess of ten hours. Any bituminous material which has been heated for an excessive
period of time, or which has been overheated, shall be rejected.
The area to be sprayed with bituminous material at any time shall be limited to that
which can be covered with aggregate at the specified rate within 15 minutes of the time
of spraying in the case of liquid asphalts, or such smaller duration of time as the Engineer
shall direct.
When so directed, the bituminous material shall be applied in lanes of approximately
one-half or less of the width of the completed surface and when so applied, there shall be
a slight overlap of bituminous material along the adjoining edges of lanes. In the case of
multiple surface treatments, succeeding courses shall have the bitumen joint offset by
approximately 200 mm from the joint of the preceding application.
Table 3.13-2

Approximate Quantities of Materials for Surface Treatment per Square Meter

Rate of Application

Nominal Size of Aggregate (mm) Kilograms Litres

Aggregate Bituminous Material

20 20 – 32 1.2 - 2.2

14 12 – 20 0.8 - 1.5

10 8 – 15 0.7 - 1.2

Notes on Table 3.13-2

1. The quantities shown above are a guide only and will vary considerably according to
the type and condition of the surface, the grading, type, shape and absorbency of the
aggregate, the weather conditions and the traffic.
2. The bituminous material may be bitumen, cut back bitumen or bitumen emulsion as
specified elsewhere in the Contract Documents. For seal coats, the Engineer may
direct that emulsions shall be diluted with clean water in order to control the rate of
application. This shall be done at the Contractor’s expense.

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3. In the case of multiple surface treatments a considerable variation of the quantities
shown above for bituminous materials may be found necessary or desirable. The first
application of bitumen may be reduced and subsequent applications increased if this
provides a better result.
4. The rates may be specified by the Engineer, but normally the Contractor will be
required to carry out trials at the Contractor’s expense. These should use materials in
the range indicated in Table 3.9-2, and be on areas other than the Project road
surface, in order to allow the necessary rates to be established. These rates should be
agreed with the Engineer and utilised for the bituminous surface treatment on the
Project road surface and these will produce the actual quantities for the works.
A minimum of two tests for each day’s work shall be carried out by the Contractor,
under the supervision of the Engineer, in order to verify that the actual rate of
application of aggregates and bituminous material complies with the specified rate or
those established by the trials and agreed by the Engineer.If the measured application
rates vary within ±10% of the established rates, the work will be accepted.
Should the measured application rates for bituminous surface treatment be greater than
±10% of the rates ordered, the Engineer shall decide if the concerned work shall be
condemned. Such condemned defective bituminous surface treatment shall be
completely removed, and the work will be carried out again with all abortive and
additional work being at the Contractor’s expense.
When surface treatment is being applied to the shoulders of the carriageway, the
Contractor shall take suitable precautions to prevent contamination of the finished
carriageway surface with bituminous material. However, the bituminous material shall
slightly overlap the adjoining bituminous concrete surface to prevent the ingress of water
along the joint.
During all applications, iron work in the road shall be covered with heavy oil or grease
and the surfaces of adjacent structures and trees shall be protected in such manner as to
prevent their being splashed or damaged.
Suitable paper or metal sheets shall be spread on the ground for a sufficient distance
back from the ends of each application so that flow through the nozzles may be started
and stopped on the paper or metal sheets and so that all nozzles will operate properly
over the entire length being treated. The distributor shall commence moving at a
sufficient distance in advance of the start of the application to ensure that the road speed
for the correct application rate is attained at the commencement of spraying and this
speed shall be maintained until past the finishing point of the application.
After each application, the quantity of material sprayed shall be checked against the area
covered, and any necessary adjustments shall be made to ensure that the specified or
ordered rate of application is maintained in subsequent runs.
Spraying shall cease immediately if any defect develops in the spraying equipment and it
shall not re-commence until the fault has been rectified.

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3.13.3.5Application of Cover Aggregate
Before the bituminous material is applied, sufficient cover aggregate shall be in trucks at
the site of the work to fully cover the area to be sprayed. The application of the
aggregate shall proceed immediately after spraying of the bituminous material and shall
be completed within 15 minutes of the completion of spraying or such smaller period of
time, as the Engineer shall direct.
The aggregate shall be spread uniformly over the bituminous material by means of the
approved aggregate spreader at either the rate specified or as determined by trials. Any
bare or insufficiently covered areas shall be re-run by the mechanical spreader or
covered by hand as necessary to give uniform and complete coverage. Any aggregate
spread in excess of the rate specified or ordered shall be scattered and evenly distributed
on the road or otherwise removed and stockpiled as directed by the Engineer.

3.13.3.6Rolling and Brushing

Immediately after spreading to the satisfaction of the Engineer, the aggregate shall be
rolled with one or more pneumatic tyred rollers or, if permitted by the Engineer, by
approved steel wheeled rollers, until the aggregate is firmly embedded in the bituminous
material. Where required to ensure an even distribution of aggregate, the surface shall be
drag brushed after the initial rolling except that if the drag brush has any tendency to
dislodge aggregate particles bedded in the binder, the Engineer may direct that drag
brushing be deferred or eliminated, and that light hand brushing be substituted. Rolling
shall be continued, as directed by the Engineer, for as long as is necessary to ensure
thorough incorporation of the aggregate into the binder.
Immediately after the binder has hardened to the stage at which, in the opinion of the
Engineer, no more aggregate can be pressed into it by rolling, any remaining loose
particles shall be removed from the pavement and shoulders.
If, after spreading, the aggregate is found to contain moisture and weather conditions are
suitable for drying, the Engineer may allow the rolling of the aggregate to be deferred
for a short time to permit the moisture to evaporate providing that satisfactory adhesion
of the binder to the aggregate is obtained. If the Engineer considers that the adhesion of
the binder to the aggregate is unsatisfactory, he shall reject the work and direct that no
further work be carried out until the conditions improve.

3.13.3.7Control of Traffic
The Contractor shall comply with Section 1.1 of this Specification. In addition the
Contractor shall take all necessary precautions to protect the work from damage until
such time as the seal coat or surface treatment has developed sufficient strength to carry
normal traffic without disturbance of the aggregate. Where it is necessary to allow early
use of the new work to facilitate the movement of traffic, vehicles may be allowed to run
on the work after rolling is completed provided that vehicles are controlled to such slow
speeds that no displacement of aggregate occurs.

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 No traffic shall be permitted to pass the working area during the application of
bituminous material nor shall traffic be permitted to encroach upon the edge of
bituminous material until such time as it is covered with aggregate.
3.13.4 Measurement
The Bituminous Surface Treatment works of the type stated in the Bill of Quantities
shall be measured in square metres of the completed and accepted works as detailed on
the drawings or as directed by the Engineer.
3.13.5 Payment
The quantities, measured as provided above, shall be paid for at the Contract unit price
per unit of measurement, shown in the Bill of Quantities. The prices and payment shall
be full compensation for trial mixes, furnishing, and placing all materials, including all
labour, equipment, tools and incidentals necessary to complete the Works.
Where defective work is corrected, or additives used which have not been specified or
ordered by the Engineer, no payments will be made in respect of extra work or materials
used in excess of the quantities specified or ordered. The use of Adhesive and anti-
stripping Agent bitumen Additive will not be paid for separately, and any costs involved
should be included within 3/9/2. Pre-coating of chippings shall be carried out without
any additional payment.
Pay items shall be:
3/13/1 Single Bituminous Surface Treatment Square Metres
3/13/2(a)Double Bituminous Surface Treatment- Square Metres
20mm nominal size aggregate followed by 10mm
(Machine Method)
3/13/2(b)Double Bituminous Surface Treatment- Square Metres
14mm nominal size aggregate followed by 10mm
(Machine Method)

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3.14 DENSE BITUMINOUS SURFACING (plant method)
3.14.1 Description

3.14.1.1 General
This work shall consist of a surfacing of dense graded bituminous material, constructed
on a prepared aggregate base in accordance with these Specifications, to the lines, levels,
grades, dimensions and cross sections shown on the Drawings, or as required by the
Engineer.
All the provisions of Section 3.5, “General Requirements for Bituminous Surfacing”
shall form a part of this Section of the Specifications unless otherwise stipulated herein.
The surfacing shall consist of one or two layers of the thickness shown on the Drawings.
If the surfacing is of two layers the top layer shall be denoted as the wearing course and
the lower layer as the base course.

3.14.1.2 General Composition of the Mixture

The mixture shall consist of mineral aggregate added with 2% hydrated lime powder or
Portland Cement filler complying with section 3.9.2.3 of these Specifications, if needed,
coated with bitumen with the materials complying with Section 3.9.2 of these
Specifications and with Table 3.10-1. No natural sand shall be allowed in the
Bituminous Mix.
When the total thickness of bituminous surfacing exceeds 90mm, the material may be
laid in two courses if directed by the Engineer.
The base course shall be within the limits set by mix classification 1 in Table 3.14-1and
the wearing course by mix classification 2 in the same table. The mix classification shall
be as specified in the contract; in case the mix classification is not specified in the
contract, it shall be the one instructed by the Engineer.
When the total thickness of bituminous concrete is 50 mm or less the material shall be
laid in a single course within the limits set by mix classification 2 in Table 3.14-1.

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Table 3.14-1

Mix Dense Bituminous Surface-Base Course Dense

Classification Bituminous
Surface-
Wearing
Course

Thickness (mm) 60 -90 50 - 60 40 - 50

Sieve Size (mm) Total % by weight passing (including filler)

37.5 100 100 100

25 75 – 90 100 100

20 65 – 85 85 – 97 100

14 55 -75 70 – 82 75 – 87

10 45 -65 61 – 73 63 – 75

5 30 -50 43 - 55 47 – 57

2.4 21 -38 29 – 38 33 – 42

1.2 14 -30 20 -28 23 – 32

0.60 10 -23 13 – 21 15 – 24

0.30 6 -17 8 -16 10 – 18

0.15 4 -12 5 – 12 6 – 13

0.075 3 -8 3–8 3–8

The ratio of total material passing the 0.075 mm sieve to effective bitumen content shall
be within the range 0.6 to 1.2. The minimum bitumen content shall be 4.0% and 4.5%
for Dense Bituminous Surface Course and Dense Bituminous wearing Course
respectively.
Our gradation table provides a larger scale of aggregate range. To find the more accurate
well graded S-curve, some control points can be selected. The following two tables can
also be used as mix type selection guide for long-life HMA pavements (Newcomb and
Hansen, 2006).
Table 3.14-2
Pavement NMAS, Lift Traffic Level, MESAL
Mix Type 2,3
Layer mm Thickness

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 Range,
mm1
0.3-
<0.3 > 10
10
Dense, Fine 37.5 110-150 ∙∙ ∙∙ ∙∙
25 75-100 ∙∙ ∙∙ ∙∙
Dense
19 60-75 ∙∙ ∙∙ ∙∙
Bituminous
Dense, Coarse 37.5 150-190 ∙∙ ∙∙ ∙∙
Base Course
25 100-125 ∙∙ ∙∙ ∙∙
19 75-100 ∙∙ ∙∙ ∙∙
Dense, Fine 19 60-75 ∙∙ ∙∙ ∙
12.5 40-60 ∙∙ ∙∙ ∙
Dense 9.5 25-40 ∙∙ ∙∙ ∙
Bituminous 4.75 15-20 ∙∙ ∙∙ ∙
Surface
Dense, Coarse 19 75-100 ∙∙
Course
12.5 50-60 ∙∙
9.5 40-50 ∙∙

Notes: 1. Lift thickness conversion is approximate for practical design.

2. MESAL – Millions of Equivalent Sign Axle Loads
3. (∙) Indicates “Recommended,” (∙∙) Indicates “Strongly Recommended,”

To exert more control on the grading requirements to be well graded, relationship

between nominal maximum aggregate size and primary control sieve shall be followed.
If the mix maximum aggregate size has been selected, the percent of passing more than
the corresponding value of the primary control sieve the mix will be fine-graded.

Table 3.14-3

In addition to meeting the requirements of the job-mix formula and the allowable
tolerances in Section 3.9, laboratory samples shall be prepared according to standard
Marshall MethodsinMS 2 of the Asphalt Institute USA75blows for per face. The sample
shall be of approved material to the gradation and bitumen content stated and shall have
the following characteristics.
1. Marshall Stability at 600 50 blows ≤ 1100kg for light traffic road
Marshall Stability at 60075 blows ≤1300 kg for Medium and heavy traffic road
Marshall stability at 60075 blows + Additional number ofblows≤2140 kg for very heavy
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 traffic road
Modified Marshall Method shall be used when required for heavyduty truck loading
road.
2. Marshall Flow not less than 2 mm nor more than 4 mm.
3. Air voids in mix, base course, 3 – 5%’.
4. Air voids in Mix, wearing course, 3 - 5%
5. Voids filled with Bitumen, base course (VFA) 65 - 80%
6. Voids filled with Bitumen, wearing course (VFA) 70 - 80%
7. Voids in Mineral Aggregate (VMA)will be a function of the nominal maximum
aggregate size as following table:
Mixture Nominal Maximum Minimum Design
Aggregate Size, mm VMA, volume %
37.5 11
25.0 12
19.0 13
12.5 14
9.5 15
4.75 16

8. Hamburg Wheel Tracking Device, AASHTO T324-19 Test shall be conducted for
rutting simulation for traffic and waterlogging case. If the Stripping Inflection Point
occurs at a low number load cycles e.g. less than 10000, the bituminous mix shall be
considered susceptible to moisture damage. Recommended maximum rut depth at
10000 load cycles of 4 mm and 10 mm at 20000 load cycles, or as decided by the
Engineer at site. To determine the Creep Compliance and Strength of Hot Mix Asphalt
(HMA) using the Indirect Tensile Test Device as per AASHTO Designation T 322 – 07
(2016).

Table 3.14-4:
Bitumen Grade Temperature Resilient Marshall Stability
Modulus at 60°C
Ambient

20/30 PEN Grade 15°C 16,000-Mpa 3500kg

35/50 PEN Grade 20°C 7000-Mpa
40/50 PEN Grade -- 5000-Mpa
60/70 PEN 25°C 3126 Mpa 1300 kg
grade(unmodified)

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60/70 grade 20°C 12,429 Mpa 2400kg
modified with SBS
85/100 PEN Grade 25°C 1966 Mpa 1022.50 kg
VG-30 grade 25°C 9,651 Mpa 2151.60kg

85/100 pen grade 25°C 1966 Mpa -

PG 64-22 Grade 25°C 7,812 Mpa 3073.88 kg Aged
binder

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 Table 3.14-5:MARSHALL BLOW FOR ASPHALT MIX DESIGN
No of Marshall Blows Traffic volume ESAL
Compaction(number of blows each end of Traffic LevelCategory
specimen)
Marshall blows 75 Medium traffic From104 and106
blows
Marshall blows 75 Heavy traffic above ≥ 106
blows

The bituminous mix for base/wearing course, when subjected to Water Sensitivity Test
as per AASHTO-T283, the loss in strength shall not exceed 20% of the original mix.
This test shall be carried out at the time of mix design and subsequently as and when
required by the Engineer.
3.14.2 Materials

3.14.2.1 General
The materials shall conform to Section 3.9.2 of these Specifications with the additional
requirements noted below.

3.14.2.2 Bituminous Materials

These materials shall conform to the requirements of Section 3.4. The bituminous
material shall be of 60/70 penetration grade.

3.14.2.3 Bitumen Additive

An adhesion and anti-stripping agent shall be added to the bituminous material where so
specified or when the Engineer’s so directs or approves. The additive shall be of a type
approved by the Engineer and the required percentage of additive shall be thoroughly
mixed with the bituminous material in accordance with the manufacturer’s instructions,
or as directed by the Engineer, for such time as is necessary to produce a homogeneous
mixture.

3.14.2.4 Coarse Mineral Aggregates

The provisions of Section 3.9.2.1 shall apply.

3.14.2.5 Fine Mineral Aggregate

The provisions of Section 3.9.2.2 shall apply.

3.14.2.6 Mineral Filler

The provisions of Section 3.9.2.3 shall apply.

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 3.14.2.7 Mixture
Regular checks shall be made on the composition of the mixed material. The Contractor
shall take samples at either the batching plant or at the job site, as directed by the
Engineer, and shall arrange for Marshall Specimens to be prepared (STP 10.9) and tested
for stability and flow. Samples shall also be analysed to determine the mix composition,
by extraction of the bitumen in accordance with STP 10.4 and aggregate grading.
A minimum of three Marshall Specimens shall be prepared for each day or part of a day
that the batching plant is operated and dense bituminous surfacing is laid and a minimum
of two bitumen extractions and aggregate gradings shall also be carried out. If the
contractor can demonstrate good quality control of the plant, through consistent and
acceptable test results being obtained, then less frequent testing may be permitted, at the
discretion of the Engineer.

3.14.3 Construction Methods

3.14.3.1 General
Construction methods shall conform to the requirements of Section 3.9.3 of these
Specifications subject to the following modifications.

3.14.3.2 Preparation of Bituminous Material

Bitumen shall be heated to a temperature between 121°C and 163°C. The Contractor
shall submit a single definite temperature for the Engineer’s approval.

3.14.3.3 Preparation of Mineral Aggregate

The mineral aggregates shall be dried and heated to a temperature between 135°C and
177°C so that the surfaces of aggregates are clean and free of carbon and unburned fuel
oil. The Contractor shall submit a single definite temperature for the Engineer’s
approval.
The mineral aggregates shall be dried so that no steaming, bubbling, foaming, brown
colouring or slumping of the newly produced mixture can be seen when the mix is
loaded on the trucks or placed on the road.
If any traces of insufficient drying are observed, the Contractor shall take such of the
following steps as are necessary to provide properly dried aggregates:
1) Maintain the level of the material in the hot bins above the two-thirds level.
2) Reduce the rate of cold feed.
3) Lower the slope of the drier as much as practicable.
4) Adjust exhaust fan, burner and air intake so as to provide longer flame penetration
into the drier.
If all the preceding steps have been carried out and the mineral aggregate is still not
dried to the satisfaction of the Engineer, double drying will be required for all or part of
the aggregate.

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3.14.3.4 Preparation of Mixture
The mixture shall when emptied from the mixer be at a temperature within the absolute
limits of 135°C and 165°C. A single definite temperature shall be submitted for the
Engineer’s approval in accordance with Section 3.9.1.3.

3.14.3.5 Spreading and Compaction

Unless the bituminous premix is laid directly onto a clean prime coat, a tack coat shall
be applied in accordance with Section 3.11, to the underlying surface prior to spreading
the base and wearing courses.
Non-inclusion of Tack Coat as a separate BOQ item or insufficient quantity of Tack
Coat in the Bill of Quantities (BOQ) shall not relieve the contractor from the obligation
of applying Tack Coat to the underlying surfaces.
For regulation courses the thickness of a compacted layer shall not be less than twice the
maximum stone size.
To avoid traffic disruption, the spreading and compaction is often carried out over half
the road width only. Rollers shall not be allowed to stand on newly laid material that
may be deformed thereby. Sections of newly laid base course shall be kept clean prior to
laying the surface course and no traffic except in connection with laying the surface
course shall be permitted on the prepared base course.
The mixture shall be compacted as soon after being placed as the material will support
the roller without undue displacement or cracking and sufficient compaction plant
should be deployed so that the required degree of compaction is achieved before the
material has cooled to a temperature of 107 oC. Smoothing rolling may continue longer,
if necessary, as long as the temperature of the mat is above 90 oC. The average field
density of any bed of base course and wearing courseshall be between 93 – 98 percent of
theoretical maximum density of the mix (AASHTO T 209 12 – 2016), from the sample
taken behind the paver.No individual density test result shall fall below 97% of the
laboratory density of the Marshall density.

3.14.3.6 (A) Joints (transverse joint)

The work shall be organised so that transverse joints are kept to a minimum and, where
practical, only occur at specified positions (i.e. bridges etc.). All transverse joints are to
be cut back to well compacted full depth material to produce a straight vertical joint
which is to be painted with bitumen before laying of new material.
B) Longitudinal Joint Construction techniques in HMA in Pavements
 LJCT 1 (3:1 Taper Rolled from Hot Side)
The unconfined edge of the first paved lane was constructed with a 3:1 taper at the
proposed joint. Normally, a steel plate is rigidly attached to the screed to give the desired
taper. However, on this project a piece of steel plate was dragged by chain behind the
screed. The resulting taper was not as smooth as would be obtained with a plate rigidly
attached to the screed. The taper was then tacked with bitumen, and a conventional
overlapping technique was used to place the hot side material on the following day. The
end gate of the paver extended about 25 to 38 mm (1 to 1.5 inch) over the top surface of
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 the previously placed material. The height of the uncompacted material above the
previously placed material was about 6 mm (1/4 in.) for each 25 mm (1 inch) of
compacted material placed. Noluting was done. The joint was compacted from the hot
side, overlapping the cold side of the joint approximately 152 mm (6 in.). This type of
compaction, in which the major portion of the roller weight travels on the hot side, is
believed to result into a good bond between the cold and hot sides of the joint.
 LJCT 2 (3: 1 Taper Rolled from Cold Side)
The only difference between this method and LJCT 1 is that the rolling was done with a
major portion of the roller wheel on the cold side with about 152 mm (6 in.) of the roller
wheel on the hot side of the joint. This technique is believed to produce a “pinching”
effect on the joint.
However, timing in this type of rolling is critical. When the roller is operated on the cold
side, the hot side undergoes cooling which can make it difficult to achieve the desired
compaction level.
 LJCT 3 (3: 1 Taper Rolled from Hot Side 152 mm Away)
Compaction in this method was started with the edge of the roller about 152 mm (6 in.)
from the joint on the hot side. Other than that, this method is similar to LJCT 1. The
lateral pushing of the material toward the joint during the first pass of the roller is
believed to produce a high density at the joint. This method is particularly recommended
by some asphalt paving technologists for tender mix or thick lifts, which have the
potential for the mix to be pushed towards the joint.
 LJCT 4 (Taper Removed and Tack Coated)
In this method, the cold side unconfined edge was constructed with a 3:1 taper. Then the
full width of the taper was removed on the following day with a cutting wheel attached
to a motor grader. Since the material had cooled, the cutting was done very carefully,
avoiding any disturbance to the lower lifts. The hot side material was then placed after
applying a tack coat on the vertical face of the cut. Lay down and compaction were
achieved as indicated in LJCT 1, that is, rolling of the joint is accomplished from the hot
side. Initially, cutting could not be done ina straight line because the operator of the
motor grader did not have experience in this operation. Later, a straight line cut is
obtained.
 LJCT 5 (Taper Removed but no Tack Coat)
This type of joint was constructed in the same way as LJCT 4 except that no tack coat
was applied to the vertical face before placement of the adjacent hot lane.
 LJCT 6 (3:1 Taper with 25 mm Offset)
In this method, the cold side unconfined edge was constructed with a 25.4 mm (1 in.)
vertical step (offset) at the top of the joint. The remainder of the joint was constructed
with a 3:1 taper (Figure 2). The vertical face was not tacked, but the taper surface was
tacked, before placement of adjacent hot material and subsequent rolling according to the
method of LJCT 1 (rolling from hot side). The vertical step (offset) is formed by placing
a 610 mm (2 feet) long piece of 51mm x 51 mm (2 in. x 2 in.) angle iron under the drag
device used to form the 3:1 taper.
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  LJCT 7 Asphalt Tack Coat)
The unconfined edge of the first paved lane adjacent to the joint is not provided with any
taper in this experimental section. On the following day, a rubberized asphalt tack coat is
applied on the face of the unconfined edge before placing the adjacent lane. The
thickness of the tack coat is about 3 mm (1/8 in.).Lay down and compaction of the
adjacent lane were achieved following the procedures in LJCT
1 (rolling from hot side).As mentioned earlier, no luting was done on this entire project.
The cores are taken on the joint that the hot lane overlap is about 3 mm to 5 mm (1/8 in.
to 3/16 in.) higher than the cold mat after compaction in most test sections.

3.14.3.7 Protection of the Pavement

Sections of the newly finished work shall be protected from traffic of any kind until the
mixture has cooled to approximately ambient air temperature. Traffic shall not normally
be permitted on the newly laid surface less than 6 hours after completion of the
pavement, except with the approval of the Engineer.

3.14.3.8 Pavement Samples

The Contractor shall, after final rolling and before opening the surface to traffic, cut
samples from the finished work for testing. Samples for the full depth of the course shall
be cores with diameters of 100 or 150 mm, as directed, and cut using an approved coring
machine, from the locations directed by the Engineer.
At least two samples for density measurement shall be taken for each day or part of a
day that the plant operates or if the output exceeds 100 tonnes per day, then at the rate of
two per 100 tonnes or part thereof.
Samples for analysis and other tests shall be taken from the surfacing when the Engineer
so directs. Where samples have been taken from the surface course, fresh material shall
be placed, thoroughly compacted and finished to the satisfaction of the Engineer.

3.14.3.9 Surfacing Texture

The surface finish of the base course shall be close and tight, while the surface finish of
the wearing course shall be equally well bound, though where the mix permits the
surface shall be textured so as to enhance surface friction, but free from dragging cracks
or other surface blemishes. Back casting shall not normally be permitted but when
dragging occurs under the screed of the spreader, fine bituminous material may be cast
over the surface to fill the dragging cracks, providing that this is done before the initial
rolling and providing that rolling is carried out at specified temperature. Should dragging
occur frequently the reason is to be determined and rectified.
3.14.4 Measurement

The quantities of dense bituminous pavement measured for payment shall be the number
of cubic metres of accepted and completed surfacing, of the widths and thickness shown
on the Drawings. However, the Contractor should allow in his rates for additional
material used for forming sloping edges, waste, over spill, joints, cut-backs etc. Should

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 the widths and/or thickness of completed and accepted surfacing be less than indicated
on the Drawings, the quantities measured for payment will be based on the actual widths
and/or thickness. No adjustment in payment will be made where the pavement widths
and thickness as laid and approved are greater than those specified.
The surface profiles of courses will be used in the measurement of course thickness,
unless an alternative method, such as core thickness, is approved by the Engineer.
3.14.5 Payment

The quantities of dense bituminous surfacing measured as provided above shall be paid
for at the Contract unit rates. The rates and payments shall be full compensation for
furnishing and placing all materials including all labour, equipment, tools, trials,
preparation of job-mix formulae, testing, making good test holes and all incidentals
necessary to complete the work. Tack coat shall not be paid for separately except where
specifically provided in the Contract Documents.
When Tack Coat is included as a separate BOQ item in the Contract Document, but the
quantity is not sufficient to cover all the bituminous works under the BOQ, the cost of
quantity of Tack Coat required in addition to the BOQ provision shall be considered to
be included within the rates of bituminous layer. The contractor is advised to make
necessary adjustments accordingly in his rates of bituminous layers.

Pay items shall be:

3/14/1 Dense Bituminous Surfacing - Base Course
(Pen grade bitumen) Cubic Metre
3/14/2 Dense Bituminous Surfacing - Base Course
(Modified bitumen) Cubic Metre
3/14/3 Dense Bituminous Surfacing -Wearing Course Cubic Metre
(Pen grade bitumen)
3/14/4 Dense Bituminous Surfacing - Wearing Course Cubic Metre
(Modified bitumen)

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3.15 BITUMINOUS CARPETTING (PLANT METHOD) [APPLICABLE
FOR MAINTENANCE AND EMERGENCY PURPOSES AND
NEEDS SPECIAL PERMISSION FROM PROPER AUTHORITY]

3.15.1 Description
3.15.1.1 General
This work shall consist of a surfacing of bituminous material, constructed on a prepared
base in accordance with these Specifications, to the lines, levels, grades, dimensions and
cross sections shown on the Drawings or as required by the Engineer.
The provisions of Section 3.9, “General Requirements for Bituminous Surfacing” shall
form a part of these Specifications except that the requirements for plant mixing and
laying by paving machine may be relaxed for smaller works provided that the contractor
proposes and demonstrates effective alternative methods to the full satisfaction of the
Engineer. However, the requirement for plant mixing shall not be relaxed for bituminous
works exceeding 01 km in total length. Such methods shall take account of the total
quantity of material to be mixed and laid within the stipulated programme. Any
alternative methods shall only be employed after receipt of written approval from the
Engineer. Such approval may be withdrawn at any time if the work is found to be
unsatisfactory.
Bituminous carpeting shall consist of one or two layers of binder course of the total
thickness shown on the drawings or as directed by the Engineer.

3.15.1.2 General Composition of the Mixture

The mixture shall consist of mineral aggregate and filler if needed, coated with bitumen,
with the materials complying with Section 3.9.2 of these Specifications.
When the total thickness of bituminous base (binder) course exceeds 50 mm, the
material may be laid in two layers if so directed by the Engineer. The material shall
conform to the mix classification 1 in Table 3.11-1.
The selected job-mixes shall conform to Table 3.15-1, unless with the specific approval
of the Engineer.

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 Table 3.15-1

Mix classification 1 2
Course Base (Binder) Base (Binder)
Thickness (mm) 25 38 or 50
Sieve Size (mm) Total % by weight passing
25 100 100
20 100 75-100
12.5 75-100 60-80
10 60-80 -
5.0 40-60 40-60
¶
2.4 20-35 20-38
0.6 10-20 6-18
0.075 2-8 2-8
Bitumen Content 5.5%± 0.3% 5.2%± 0.3%
% by weight of total mixture. (5.2% - 5.8%) (4.9% - 5.5%)

3.15.2 Materials

3.15.2.1 General
The materials shall conform to Section 3.9.2 of these Specifications with the additional
requirements noted below.

3.15.2.2 Bituminous Materials

These materials shall conform to the requirements of Section 3.4. The bituminous
material shall be 60/70 penetration grade.

3.15.2.3 Coarse Mineral Aggregate

The provision of Section 3.9.2.1 shall apply.

3.15.2.4 Fine Mineral Aggregate and Mineral Filler

The provision of Sections 3.9.2.2 and 3.9.2.3 shall apply.

3.15.2.5 Mixture
The Contractor shall carry out regular checks at frequency to be determined by the
Engineer on the composition of the mixed material and shall submit results to the
Engineer within 3 days of sampling.

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3.15.3 Construction Methods (Plant)

The construction method shall be followed as described in section 3.14.3 and as when
required Manual method shall be followed with the approval of the Engineer applicable
for short road sections/isolated location of road sections
3.15.4 Measurement
The quantity of bituminous carpeting measured for payment shall be the number of
cubic metres accepted and completed surfacing to the width and thickness shown on the
Drawings. Should the widths and/or thickness of the surfacing be less than indicated on
the Drawings, the quantities measured for payment will be based on the actual widths
and/or thickness.
The bituminous carpeting shall be measured as the net dimensions of the top surface of
each course and the Contractor will make allowance in his rate for additional material
used for forming sloping edges and over spill.
3.15.5 Payment

The quantities measured as provided above, shall be paid for at the Contract unit price
rates. The prices and payments shall be full compensation for furnishing and placing all
materials including all labour, equipment, tools, trials, preparation of job-mix formulas,
testing, making good test holes, and incidentals necessary to complete the work. Tack
coat shall not be paid for separately except where specifically provided for in the
Contract Documents.
Pay items shall be:
3/15/1 Premix Bituminous Carpeting Cubic Metre

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3.16 PREMIX BITUMINOUS SEAL COAT (MANUAL METHOD)

3.16.1 Description

3.16.1.1 General

This work shall consist of a premix bituminous seal coal applied to newly laid binder course
of bituminous carpeting, or a prepared and primed granular base course, or existing
bituminous surface in accordance with these Specifications The thickness of the premix
bituminous seal coat shall be 7 mm, 12 mm or 15 mm as directed and shall be to the lines,
levels, garden dimensions and cross sections shown on the Drawings or as required by the
Engineer.

The provisions of Section 3 5, "General Requirements for Bituminous Surfacing shall form a
part of these Specifications except that the requirements for plant mixing and laying by
paving machine may be relaxed for smaller works provided that the contractor proposes and
demonstrates effective alternative methods to the full satisfaction of the Engineer However
the requirement for plant mixing shall not be relaxed for bituminous works exceeding 01 km
in total length. Such methods shall take account of the total quantity of material to be mixed
and laid within the stipulated programme. Any alternative methods shall only be employed
after receipt of written approval from the Engineer Such approval may be withdrawn at any
time if the work is found to be unsatisfactory.

3.16.1.2 Composition of the Mixture

The mixture shall consist of aggregate and sand, coated with bitumen with the materials
complying with Section 3.5.2 of these specifications. The Contractor shall meet the
requirements of the job mix formula in section 3.5.1.3 and the tolerances in Section 3.5.1.4

The maternal shall conform to Table 3.12-1 below, unless otherwise directed by the Engineer
in writing.

Table 3.16-1

Mix Classification Seal Coat Seal Coat

Course Compacted 7 mm 12 or 15 mm
Thickness (mm)
Sieve Size (mm) Total % by weight passing
10 - 100
6.3 100 90-100
5 90-100 75-95
2.4 70-95 20-50
0.6 20-50 5-15
0.075 5-15 2-10

3.16.2 Materials

3.16.2.1 General

The materials shall confirm to Section 3.5.2 of these specifications with the additional
requirements noted below.

3.16.2.2 Bituminous Materials

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 These materials shall conform to the requirements of Section 3.4. The bituminous material be
60/70 or 80/100 penetration grade

3.16.2.3 Mineral Aggregate

Aggregates shall consist of 6.3mm or 10mm down graded pea gravel free from any organic
matter clay and any other objectionable matter.

Where required to achieve the specified grading the aggregate shall be mixed with natural sa
Sand shall be doo plastic, clean and free from any deleterious substances. The minimum FM
sand for the sealing premix shall be between 2.00 to 2.50 and that of sand to be spread over
seal coat as blotting material shall be between 0.80 to 1.00.

The mix of the aggregates and sand combined shall comply with the following grading given
Table 3.12-1

3.16.2.4 Mixture

The Contractor shall carry out regular checks at frequency to be determined by the Engineer o
the composition of the mixed material and shall submit results to the Engineer within 3 days
sampling.

3.16.3 Construction Methods

3.16.3.1 General

Construction methods shall conform to the general requirements of Section 3.5.3 of these
Specifications subject to the following modifications. For smaller works, where the
requirement for plant mixing has been relaxed by the Engineer, the relevant provisions
contained in Section 3.5.3 shall be replaced by those under Sections 3.12.3.2. 3.12.3.3 and
3.12.3.4 of these Specifications.

Following approval of the mix formula the contractor shall undertake short trial sections of
approximately 10 metres length, prior to commencing contract surfacing these trials are b
demonstrate that the contractor and the laying staff understand, and can apply the
specification correctly to produce the quality of work specified on a consistent basis. The
trials will also be used to fine tune the mix design if required.

If the trial works are suitable, they may be accepted in the contract works. If the trial work has
be rejected, they can be permitted to remain in the works until replacement near the end of the
contract, so that unspecified work can be monitored and used to demonstrate to other
contractors and supervision staff the defects that will manifest themselves if work is carried
out using unspecified materials, workmanship or methodology.

Once the Contractor has demonstrated an acceptable procedure he shall submit in writing his
full method statement for the Engineer's approval. No surfacing works will be permitted until
the Engineer's approval has been granted, in writing, and once approved the method shall not
be varied in any way without reference to, and approval of the Engineer.

The Contractor shall furnish a thermometer at each mixing unit to ensure that temperature of
bitumen, mineral aggregates and bituminous mixture shall be within the specified ranges
stipulated in 3.12.3.2 through 3.12.3.5.

3.16.3.2 Preparation of Bituminous Material

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 Bitumen shall be heated in a tar boiler to a temperature between 1210C and 1630C Locally
produced, wood fired boilers are satisfactory, and at the ambient temperatures experienced in
Bangladesh the 80/100 penetration grade bitumen required under the specification can be
poured (albeit slowly) into the tar boiler When the boiler is approximately 30% full the fire
box is filled with wood and the wood ignited. In practice the boilers are generally kept over
50% full during operation by allowing up to two drums of bitumen to drain down through a
manhole, on top of the boiler. Into the main heating tank.

The temperature control at the boiler is critical to the success of this methodology. When the
thermometer within the mass of bitumen in the main tank reaches 1500C the firebox must be
emptied or the fire extinguished. The residual heat within the tar boiler will continue to heat
the bitumen to the required maximum temperature of 163 0C When the temperature is falling
and reaches 1550C he fire box should be refilled with wood and re-ignited as the temperature
will soon fall below 1500C The operation is repeated as the temperature again regains 150 0C
With experience the operator can soon judge how much firewood is required to achieve and
maintain the specified temperatures.

3.16.3.3 Preparation of Mineral Aggregate

Once the aggregates and the job mix has been approved, the Contractor shall construct
gauging boxes to the required size which, when filled and struck off level, deliver the desired
volume for that size of stone.

The pea gravel and sand are batched into a rectangular steel pan with handles at each comer
and heated on top of a metal frame under which heating is provided by firewood and sawdust.
The mixture is continually raked to ensure thorough mixing and even heating. The
temperature of the mixture must reach 1630C after which the pan shall be transferred to an
unheated frame where raking should continue until the mixture temperature has reduced to the
maximum temperature permitted in the specification (1630C)

3.16.3.4 Preparation of Premix Seal Coat

The heated bitumen is drawn off from the tar boiler, decanted into gauge tins and added to the
aggregate in the pan on the unheated frame in the proportion of 1.0kg of bitumen to 0.01m3
aggregate mixture, which shall be laid on 1m2 of road surface for 7mm thickness seal coat.
The proportions will be increased to 1.36kg of bitumen to 0.016m3 of aggregate mixture on
1m2 of road surface for 12 mm thickness seal coat. As the two ingredients are at
approximately the same temperature there is no risk of fire, overheating or the clouds of black
smoke (indicating hot bitumen being applied to very hot aggregates) associated with other
manual methods. The mixing is carried out on the unheated frame and, when satisfactorily
completed, the pan is carried to the adjacent work head for placing.

The mixture shall after mixing be at a temperature within the limits of 135 0C and 1630C The
Contractor shall record and submit the measured temperatures for the Engineer's approval.

3.16.3.5 Spreading and Compaction

The mixed bituminous seal coat shall be placed and spread over the granular base course
which has been primed or bituminous carpeting to a uniform thickness which shall be a
minimum of 25% greater than the specified compacted thickness, and immediately compacted
with a power driven road roller to the satisfaction of the Engineer

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 Static tandem steel wheel rollers will require trials to assess the number of passes to achieve
full compaction. Compaction is generally achieved when all roller marks have been removed
Rollers shall not be allowed to severally achieved material that may be deformed thereby The
mixture shall be compacted as soon after being placed as the material will support the roller
without undue displacement or cracking and sufficient compaction plant should be deployed
so that the required degree of compaction is achieved before the mat has cooled to a
temperature of 107°C

To avoid traffic disruption, the spreading and compaction on sections of existing bituminous
surface is often carried out over half the road width only

Unless the Engineer directs otherwise the seal coat where specified shall be applies
immediately after lying of the bituminous carpeting and the seal coat and bituminous
carpeting shall be rolled together. The combined thickness of the two layers shall not be less
than the sum of the two specified layer thickness.

3.16.3.6 Joints

The work shall be organized so that transverse Joints are kept to a minimum and, where
practical, only occur at specified positions (ie. bridges etc.). All transverse joints are to be cu
back to well compacted full depth material to produce a straight vertical joint which is to be
painted with bitumen before laying of new material.

To attain a strong and even connection in the longitudinal direction, joints shall be pre-heated
in front of laying the adjacent bituminous mix. Alternatively, if approved by the Engineer, the
joint can be cut back and painted with bitumen.

3.16.3.7 Protection of the Pavement

Sections of the newly finished work shall be protected from traffic of any kind until the
mixture has cooled to approximately ambient air temperature. Traffic shall not normally be
permitted on the newly laid surface less than 6 hours after completion of the pavement, except
with the approval of the Engineer.

3.16.3.8 Pavement Samples

If the seal coat is placed on to the carpet course specified in Section 3.11 the Contractor shall
after final rolling and before opening the surface to traffic, cut samples from the finished work
for testing. Samples for the full depth of the course and seal shall be cores with diameters of
100 150 mm as directed, and cut by an approved coring machine, from the locations directed
by the Engineer At least one sample for density and thickness measurement shall be taken for
each 50 m of completed surfacing.

When the seal coat is placed over an existing bituminous surfacing samples for analysis and
other tests shall be taken from the surfacing when the Engineer so directs.

Where samples have been taken from the surface course, fresh material shall be placed
thoroughly compacted and finished to the satisfaction of the Engineer

3.16.3.9 Surface Texture

The surface finish of the finished surfacing shall be close and tight.

3.16.4 Measurement

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 The quantity of bituminous seal coat measured for payment shall be the number of square
metres completed and accepted to the thickness shown on the Drawings or as directed by the
Engineer Bitumen used in the mix shall be deemed to be included and shall not be measured
separately irrespective of its quantity. No price adjustment shall be made if the quantity of
bitumen used increases or decreases due to a change in the job mix formula during the works

3.16.5 Payment

The quantities measured as provided above, shall be paid for at the Contract unit rates. The
prices and payments shall be full compensation for furnishing and placing all materials
including all labour, equipment, tools, trials, preparation of job-mix formulas, testing, making
good test holes, and incidentals necessary to complete the work.

Pay items shall be ;

3/12/1 7mm Compacted Premix Bituminous Seal Coat Square Metre 3/12/2 12mm
Compacted Premix Bituminous Seal Coat Square Metre 3/12/3 15mm Compacted Premix
Bituminous Seal Coat Square Metre

3.17 THIN HMA OVERLAYS FOR PAVEMENTPRESERVATION AND LOW

VOLUME ASPHALT ROAD with 4.75 NMAS (thickness 19mm to 25mm)
[APPLICABLE for maintenance and emergency purposes AND NEEDS special
permission from proper AUTHORITY]

3.17.1 Composition of the Mixture:

AASHTO (specification M 323) specification requirements for4 .75 mm mixtures are
summarized in Table 3.16-1
• An FAA of at least 45 is recommended for over 0.3 million ESALs. Alternatively, the
percentage natural sand should be limited to 15 percent maximum.
• The gradation requirements should be changed to 30-55% passing the 1.18 sieve and 6-13%
passing the 0.075 mm sieve.
Table 3.17-1
Seive size Min %passing MIX-PARAMETERS
12.5 mm 100 Marshall blow 50
9.5 mm 95 FAA(Fine 45
aggregate
angularity
4.75mm 90 SE(Sand 40
Equivalent)
1.18 mm 30 VMA 16
o.075mm 6 VFA 70-80
0.075 12 AIR VOID(Va) 4,0%

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 DENSITY( initial) ≤92.15
Expected extended 13 years
life of pavement
60/70 grade PEN 5.5-6.5%
Binder
ESAL ≤ 3-10 Million

3.17.1.1 Leveling and Patching

Two possible uses for 4.75 mm NMAS HMA mixtures are a leveling course or patching
mix. A leveling course is defined as, a course (asphalt aggregate mixture) of variable
thickness used to eliminate irregularities in the contour of an existing surface prior to
superimposed treatment or construction. A smaller aggregate size mixture is beneficial
for leveling applications where very thin lifts are needed to correct surface defects.
Patches are needed to repair weak areas in pavements, pot holes, or utility cuts. Structural
patches should be designed and constructed with full depth asphalt concrete to ensure
strength equal to or exceeding that of the surrounding pavement structure. Generally,
there are three types of asphalt patching mixtures used: (a) hot mixed, hot laid, (b) hot
mixed, cold laid, or (c) cold mixed, cold laid. Dense graded aggregates are used primarily
for hot mixed, hot laid patching mixtures
Typical gradations of dense graded patching mixtures are presented in Table 3-16-2
which shows that the current AASHTO gradation limits for 4.75 mm NMAS HMA
mixtures would fall within the limits of gradation C. The majority of all patching
mixtures have 9.5 mm or 12.5 mm NMAS gradations (9). However, some agencies do
specify a 4.75 mm NMAS mixture for patching. Larger NMAS mixtures seem to be
preferred because they provide better stability, especially in deeper patches. When
shallow holes are filled, a smaller NMAS mixture is beneficial, especially when the
mixture must be feathered at the edges.

Table:3.17-2 Typical Gradations of Dense-Graded Patching Mixtures

Sieve size Percent passing Percent passing Percent passing
A B C
19 mm 100
12.5 mm 90-100 100
9.5 mm 75-90 90-100 100
4.75 mm 47-68 60-80 80-100
2.36 mm 35-52 35-65 65-100
1.18 mm 24-40 - 40-80
0.600 mm 14-30 - 20-65

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 0.300 mm 9-20 6-25 7-40
o.075 2-9 2-10 2-10

3.17.1.2 Thin Overlays and Surface Mixtures

It may be ideal to use 4.75 mm NMAS mixtures for thin overlays and surface mixtures.
Hansen, stated that HMA overlays are probably the most versatile pavement prevention
techniques available. They can improve structural capacity, improve ride, enhance skid
resistance, reduce noise and improve drainage. However, thin overlays should only be
placed on structurally sound pavements that exhibit surface distresses such as low-
severity transverse and longitudinal cracking. According to NCHRP Report 531, lift
thickness should be at least three to four times the NMAS. For a thin overlay (less than
one inch), a 4.75 mm NMAS asphalt mixture would meet a lift thickness to NMAS ratio
of three to four. The main function of a thin overlay of HMA may not be to provide
strength to the pavement structure, but to protect a deteriorating pavement. If a thin
overlay of 4.75 mm NMAS dense graded HMA is used as a surface mixture, it may
provide a smooth, durable, water-tight surface. However, one possible concern of
applying this type of mixture as surface mix is producing low surface texture. A low
macro texture might lead to poor skid resistance, especially when a surface is wet.

3.17.2.1 Preparation of Thin Overlay Mixture

The mineral aggregates shall be dried and heated to a temperature between 135°C and
177°C so that the surfaces of aggregates are clean and free of carbon and unburned fuel
oil. The Contractor shall submit a single definite temperature for the Engineer’s
approval.
The mineral aggregates shall be dried so that no steaming, bubbling, foaming, brown
colouring or slumping of the newly produced mixture can be seen when the mix is
loaded on the trucks or placed on the road.
If any traces of insufficient drying are observed, the Contractor shall take such of the
following steps as are necessary to provide properly dried aggregates:
1) Maintain the level of the material in the hot bins above the two-thirds level.
2) Reduce the rate of cold feed.
3) Lower the slope of the drier as much as practicable.
4) Adjust exhaust fan, burner and air intake so as to provide longer flame penetration
into the drier.
If all the preceding steps have been carried out and the mineral aggregate is still not
dried to the satisfaction of the Engineer, double drying will be required for all or part of
the aggregate.

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3.17.2.2 A) Joints (transverse joint)
The work shall be organised so that transverse joints are kept to a minimum and, where
practical, only occur at specified positions (i.e. bridges etc.). All transverse joints are to
be cut back to well compacted full depth material to produce a straight vertical joint
which is to be painted with bitumen before laying of new material.

3.17.2.3 Protection of the Pavement

Sections of the newly finished work shall be protected from traffic of any kind until the
mixture has cooled to approximately ambient air temperature. Traffic shall not normally
be permitted on the newly laid surface less than 6 hours after completion of the
pavement, except with the approval of the Engineer.

3.17.2.4 Pavement Samples

The Contractor shall, after final rolling and before opening the surface to traffic, cut
samples from the finished work for testing. Samples for the full depth of the course shall
be cores with diameters of 100 or 150 mm, as directed, and cut using an approved coring
machine, from the locations directed by the Engineer.
At least two samples for density measurement shall be taken for each day or part of a
day that the plant operates or if the output exceeds 100 tonnes per day, then at the rate of
two per 100 tonnes or part thereof.
Samples for analysis and other tests shall be taken from the surfacing when the Engineer
so directs. Where samples have been taken from the surface course, fresh material shall
be placed, thoroughly compacted and finished to the satisfaction of the Engineer.

3.17.2.5 Surfacing Texture

The surface finish of the thin overlay shall be well bound, though where the mix permits
the surface shall be textured so as to enhance surface friction, but free from dragging
cracks or other surface blemishes. Back casting shall not normally be permitted but
when dragging occurs under the screed of the spreader, fine bituminous material may be
cast over the surface to fill the dragging cracks, providing that this is done before the
initial rolling and providing that rolling is carried out at specified temperature. Should
dragging occur frequently the reason is to be determined and rectified.
3.17.3 Measurement
The quantities of thin dense bituminous overlay measured for payment shall be the
number of cubic metres of accepted and completed surfacing, of the widths and
thickness shown on the Drawings. However, the Contractor should allow in his rates for
additional material used for forming sloping edges, waste, over spill, joints, cut-backs
etc. Should the widths and/or thickness of completed and accepted surfacing be less than
indicated on the Drawings, the quantities measured for payment will be based on the
actual widths and/or thickness. No adjustment in payment will be made where the
pavement widths and thickness as laid and approved are greater than those specified.
The surface profiles of courses will be used in the measurement of course thickness,
unless an alternative method, such as core thickness, is approved by the Engineer.

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 3.17.4 Payment
The quantities of thin dense bituminous overlay measured as provided above shall be
paid for at the Contract unit rates. The rates and payments shall be full compensation for
furnishing and placing all materials including all labour, equipment, tools, trials,
preparation of job-mix formulae, testing, making good test holes and all incidentals
necessary to complete the work. Tack coat shall not be paid for separately except where
specifically provided in the Contract Documents.
When Tack Coat is included as a separate BOQ item in the Contract Document, but the
quantity is not sufficient to cover all the bituminous works under the BOQ, the cost of
quantity of Tack Coat required in addition to the BOQ provision shall be considered to
be included within the rates of bituminous layer. The contractor is advised to make
necessary adjustments accordingly in his rates of bituminous layers.
Pay items shall be:
3/17/1 Dense Bituminous Patching----Levelling Course Cubic Metre
3/17/2 Thin Dense Bituminousoverlay – Thin overlay Course Cubic Metre

3.18 RECYCLING OF BITUMINOUS PAVEMENTS (REC LAIMED

ASPHALT PAVEMENT)

3. 18.1 Scope
This work covers the recycling of existing bituminous pavement materials to upgrade an
existing bituminous pavement which has served its initially intended purpose.Materials
to be removed or to be reprocessed from the bituminous layers in pavement can be
termed as Reclaimed Asphalt Pavement (RAP).To introduce environment friendly and
cost effective approaches RAP shall be used as an Asphalt Treated Base (ATB)
conforming the criteria mentioned below. The work shall be performed on such widths
and lengths as shall be directed by the Engineer and may consist of pavement removal,
stockpiling of materials from the old pavement, addition of new bitumen and untreated
aggregates in the requisite proportions, mixing, spreading and compaction of the blended
materials.These specifications cover the hot process.
If criteria of RAP to use in ATB cannot be confirmed rather the quality is lower which
effectively fulfill the requirements of Sub-base material, it can be used as sub base
material. Whereas the RAP containing moss or can be categorized as unsuitable
materials can be discarded as decided and appropriated by the Engineer.
3.18.2 Construction of Asphalt Treated Base (ATB) using RAP

During the process of pavement reconstruction or rehabilitation, it's crucial to assess the
condition of the existing pavement as it often serves as a solid foundation for the new
pavement. In cases where the existing pavement is significantly deteriorated, or when
constraints such as urban road level restrictions or scarcity of road materials are present,
a more innovative approach involves dismantling the existing pavement and using the
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RAP in pavement reconstruction. The dismantled materials i.e. RAP, including aged
asphalt concrete can be pulverized and processed as an Asphalt Treated Base course to
reduce the layer depth of new asphalt layers.

This work shall consist of removing existing bituminous layers by milling machine or
other method as prescribed by Engineer to a depth up to 150 mm, or as ordered by the
Engineer, and over a width as indicated on the Drawings or as instructed by the
Engineer. The material shall be thoroughly mixed by means of a motor grader and
homogenised with a pulvimixer or similar approved plant.

To effectively construct ATB layer, it is essential to engage experienced Materials

Engineers and Technicians equipped with the necessary knowledge and resources. The
process of preparing mix designs incorporating RAP, virgin aggregates, and fresh
bitumen demands meticulous attention and specialized testing. The percentages of
RAPs to be used will be defined by the aggregate properties of RAP to be confirmed as
per that of Dense Bituminous Base Course. Generally in case of Bangladesh 15% to
20% of RAP can be used depending upon the aggregate properties, scope and value of
works stipulated in contract, or as approved by the Engineer upon proper testing.

Trial mixes and field trials should be conducted to assess the performance of RAP
blended with fresh aggregates and fresh bitumen. The process can be utilized with or
without rejuvenator as per the instruction of the Engineer or as assessed by the mix
design trial.

Dense Bituminous Base Course Up to 50mm can be constructed using RAP as ATB
with mix design as instructed or appropriated by the Engineer. For national and regional
highways, a properly designed wearing Base course and wearing surface course should
be employed on ATB to ensure long-term durability and performance.

When conducting mix designs, it is imperative to follow established procedures such as

the Marshall Method. This involves thorough testing of RAP bitumen properties, either
through extraction from existing asphalt or by trial and error methods if extraction
facilities are unavailable.

Additionally, specific gravity tests should be carried out, adhering to standard protocols.
During production in batching plants, strict control measures should be implemented to
maintain temperature levels below 160 degrees Celsius in the drier, and RAP materials
must be adequately air-dried before processing.

In summary, the utilization of RAP offers a sustainable solution for asphalt mixtures,
provided that thorough planning, testing, and quality control measures are implemented
throughout the process. By adhering to best practices and leveraging the expertise of
qualified professionals, the benefits of RAP can be realized while ensuring the integrity
and performance of road infrastructure.

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 Reclaimed Asphalt Pavement (RAP) shall be used in the national highways with
permission from proper authority as sub-base or ATB.

3.18.3 Method Statement for Asphalt Treated Base (ATB) Construction

This method statement outlines the general procedures for constructing Asphalt Treated
Base (ATB) using recycled materials from existing aged asphalt concrete, aggregate
base, and sub base. Specific project requirements and local regulations should be
considered during implementation.

a. Preparation of Existing Pavement:

 Use scarifying and crushing equipment to process the existing pavement.

 Stockpile the crushed mix in designated areas, preventing segregation.

b. Aggregate Testing

 Collect aggregate samples from stockpiles. Ensure proper separation of

aggregates for accurate testing.
 Conduct standard tests to determine aggregate properties such as absorption and
specific gravity.

c. ATB Specifications:

 Adhere to ATB specifications (grading and other requirements to be satisfied as

the specifications of Dense Bituminous Base Course), as instructed by the
Engineer, allowing for a variety of gradations and aggregate qualities.
 Avoid pavement layers thinner than two to three times the nominal aggregate
size to prevent compaction difficulties, tearing under the paver screed, and
potential crushing of large particles during compaction.
 Maintain a maximum aggregate size of 50mm, with passing 75 microns limited
to a maximum of 10%.

d. Mix Design:

 Perform mix design in accordance with the Marshall Method.

e. Batching Plant Operations:

 Maintain a recommended maximum temperature of 160°C in the drier of the batching

plant.
 Follow standard procedures for mixing in the plant and paving on the roadway. Monitor
mix quality throughout the production process.

f. Site Preparation
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  Clear the work area of any obstructions.
 Ensure safety measures are in place, including proper signage and barricades.

g. Paving

 Transport the prepared ATB mix to the designated paving area.

 Use appropriate paving equipment to lay the ATB mix evenly.
 Compact the ATB using rollers to achieve the required density. Density of core samples
taken from the paved area shall be compares with Maximum Theoretical Density Gmm
measured at site laboratory on asphalt mix.
 Ensure proper joint construction and surface finishing.

h. Quality Control

 Conduct regular quality control checks during construction to ensure compliance with
specifications.
 Address any deviations promptly to maintain the integrity of the ATB structure.

i. Completion and Cleanup

 Complete the ATB construction as per project specifications.

 Remove any excess materials and equipment from the site.
 Conduct a final inspection to ensure the work meets quality standards and safety
requirements.
j. Payment
The quantities of Asphalt Treated base course measured as provided above shall be paid
for at the Contract unit rates. The rates and payments shall be full compensation for
stockpiling, excavating, furnishing and placing all materials including all labor,
equipment, tools, trials, preparation of job mix formulae, testing, making test holes and
all incidentals necessary to complete the work. Tack coat shall be paid separately.
Pay items shall be:
3/18/1 Preparation and construction of ATB………………………………..Cubic metre

1. Excavating and rotovating the existing pavement down to bottom of base type
1…………………………………………………………………. Cubic metre
2. Stockpiling and pulverising the scarified material…………………… Cubic metre
3. Compacting the foundation (95% of MDD) ……………………… …. Square metre
4. Asphalt Treated Base course……………………………………………. Cubic metre

3.19 BRICK PAVEMENT

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3.19.1 Description
This work shall consist of furnishing and laying bricks on a prepared and accepted
subgrade or improved subgrade to form brick pavement in accordance with these
Specifications, and to the lines, levels, grades, dimensions and cross sections shown on
the Drawings, or as directed by the Engineer.
3.19.2 Subgrade and Improved Subgrade
The subgrade or improved subgrade shall conform to the provisions of Sections 3.23.1.
3.19.3 Materials
The materials shall consist of first class bricks, which meet the requirements of Section
5.5.2, and sand, which meets the requirements of grading envelope E in Table 2.8-1 of
Section 2.8.2.
3.19.4 Brick on End Edging

3.19.4.1 Description
This work consists of providing and placing brick on end edging along the road adjacent
to the side of the pavement of single layer brick flat soling and herringbone bond brick.

3.19.4.2 Construction Methods.

Bricks shall be laid on end edging with their longest side vertical and shortest side
perpendicular to the road including necessary excavation filling and ramming to the
satisfaction of the Engineer. The completed work shall be true to line and level and
grade as indicated on the Drawings. Interstices between brick edging and adjacent
paving or soling shall be filled by brushing in sand until voids are filled; the edging shall
then be sprinkled with water.

3.19.5 Single Layer Brick Flat Soling

3.19.5.1 Description.
This item consists of providing single layer brick flat soling on accepted subgrade or
improved subgrade.

3.19.5.2 Construction Methods.

The bricks shall be laid flat on a 75 mm thick compacted sand cushion layer over the
prepared subgrade or improved subgrade surface. Bricks shall be laid in a regular and
uniform manner. Interstices of bricks shall be filled with sand, and water shall be applied
by sprinkling. No bricks shall be laid on loose earth or earth filling which has not been
compacted to the required density and no bricks shall be laid on any surface which has
not been inspected and approved by the Engineer.
3.19.6 Brick on Edge Pavement in Herringbone Bond

3.19.6.1 Description
This work shall consist of a base composed of bricks, laid on edge in a herringbone
pattern on a 12 mm sand cushion, placed on a prepared single layer brick flat soling in
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 accordance with these Specifications and to the lines, grades, levels, dimensions and
cross sections shown on the Drawings or as required by the Engineer.

3.19.6.2 Construction Methods

The bricks shall be laid on edge in a single layer in a herringbone pattern to the lines,
grades, levels, dimensions and cross section shown on the Drawings or as required by
the Engineer. The edge of the layer shall be made with cut bricks to produce a line,
which is compatible with brick edging.
The joints shall be filled with sand brushed in and the completed layer shall be sprinkled
liberally with water.

3.19.6.3 Surface Tolerance

In those areas in which pavement is to be placed, any deviation in excess of 10 mm from
a straight edge 3 metres long applied to the surface parallel to the centreline of the road
and 12 mm from a 3 metres straight edge laid transversely, shall be corrected by
removal, reshaping and relaying.

3.19.7 Measurement
Brick on end edging shall be measured in linear metres of completed and accepted work.
Brick flat soling and herringbone bond brick pavement shall be measured in square
metres of completed and accepted work.
3.19.8 Payment
This work, measured as described above shall be paid for at the Contract unit rates
detailed below. The rates shall include the supply of all required materials and all labour,
equipment, tools and incidentals necessary to complete the works as specified.
Pay items shall be:
3/19/1 Brick on End Edging Linear Metre
3/19/2 Single Layer Brick Flat Soling including 75 mm thick
Compacted Sand Cushion Square Metre
3/19/3 Herring Bond Brick Pavement including
12 mm Sand Cushion Square Metre

3.20 DRY LEAN CEMENT CONCRETE

3.20.1 Scope

3.20.1.1
The work shall consist of construction of dry lean concrete sub-base for cement
concrete pavement in accordance with the requirements of these Specifications and in
conformity with the lines, grades and cross-sections shown on the drawings or as
directed by the Engineer. The work shall include furnishing of all plant and equipment,

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 materials and labour including all operations in connection with the work as approved
by the Engineer.
3.20.1.2
The design parameters of dry lean concrete sub-base, viz., width, thickness, grade of
concrete, details of joints, if any, etc. shall be as stipulated in the Contract drawings.
3.20.2 Materials

3.20.2.1 Cement:
Cement shall confirm to the requirements of Section-5.1.2 of General Specifications.
3.19.2.2 Aggregates:
Aggregates shall confirm to the requirements of Section-5.1.2 of General Specifications.

3.20.2.3 Water:
Water shall confirm to the requirements of Section-5.1.2 of General Specifications.

3.20.3 Proportioning of Materials for the Mix

3.19.3.1
The mix shall be proportioned to comply withSection-5.1.2.3 and Section-5.1.2.4 of
General specifications. The water content shall be adjusted to the optimum as per Clause
3.14.3.2 for facilitating compaction by rolling. The strength and density requirements of
concrete shall be determined in accordance with Clause 3.14.5 by making trial mixes.

3.20.3.2 Moisture content:

Moisture content shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.

3.20.3.3 Cement content:

Cement content shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.

3.20.3.4 Concrete strength:

Concrete strength shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.
3.20.4 Construction

3.20.4.1 General:
The place and programme of the lean concrete sub-base construction shall be matching
suitably with the programme of construction of the cement concrete pavement over it.
The dry lean concrete sub-base shall be overlaid with cement concrete pavement only
after 7 days of its construction.
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3.20.4.2 Batching and mixing:
The batching plant shall be capable of proportioning the materials by weight, each type
of material being weighed separately in accordance with Clause 3.15.9.3.2. The cement
from the bulk stock shall be weighed separately. The capacity of batching and mixing
plant shall be at least 25 per cent higher than the proposed capacity for the laying
arrangements. The batching and mixing shall be carried out preferably in a forced action
central batching and mixing plant having necessary automatic controls to ensure
accurate proportioning and mixing. Other types of mixers shall be permitted subject to
demonstration of their satisfactory performance during the trial length. The type and
capacity of the plant shall be got approved by the Engineer before commencement of the
trial length. The weighing balances shall be calibrated by weighing the aggregates,
cement, water and admixtures physically either by weighing with large weighing
machine or in a weigh bridge. The accuracy of weighing scales of the batching plant
shall be within ± 2 per cent in the case of aggregates and ±1 percent in the case of
cement and water.
The design features of Batching Plant should be such that the shifting operations of the
plant will not take very long time when they are to be shifted from place to place with
the progress of the work.

3.20.4.3 Transporting:
Plant mix lean concrete shall be discharged immediately from the mixer, transported
directly to the point where it is to be laid and protected from the weather by covering the
tippers/ dumpers with tarpaulin during transit. The concrete shall be transported by
tipping trucks, sufficient in number to ensure a continuous supply of material to feed the
laying equipment to work at a uniform speed and in an uninterrupted manner. The lead
of the batching plant to paving site shall be such that the travel time available from
mixing to paving as specified in Clause 3.14.5.5.2 will be adhered to.

3.20.4.4 Placing:
Lean concrete shall be laid/placed by a paver with electronic sensor. The equipment
shall be capable of laying the material in one layer in an even manner without
segregation, so that after compaction the total thickness is as specified. The paving
machine shall have high amplitude tamping bars to give good initial compaction to the
sub-base.
The laying of the two-lane road sub-base may be done either in full width or lane by
lane. Preferably the lean concrete shall be placed and compacted across the full width of
the road, by constructing it in one go or in two lanes running forward simultaneously.
Transverse and longitudinal construction joints shall be staggered by 500-1000 mm and
200-400 mm respectively from the corresponding joints in the overlaying concrete slabs.

3.20.4.5 Compaction
3.20.4.5.1
The compaction shall be carried out immediately after the material is laid within the
initial setting time of cement and leveled. In order to ensure thorough compaction,

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 which is essential, rolling shall be continued on the full width till there is no further
visible movement under the roller and the surface is closed.
3.20.4.5.2
The spreading, compacting and finishing of the lean concrete shall be carried out as
rapidly as possible and the operation shall be so arranged as to ensure that the time
between the mixing of the first batch of concrete in any transverse section of the layer
and the final finishing of the same shall not exceed 90 minutes when the concrete
temperature is above 25 and below 30 degree Celsius and 120 minutes if less than 25
degree Celsius. This period may be reviewed by the Engineer in the light of the results
of the trial run but in no case shall it exceed 2 hours. Work shall not proceed when the
temperature of the concrete exceeds 30 degree Celsius. If necessary, chilled water or
addition of ice may be rescued to for bringing down the temperature. It is desirable to
stop concreting when the ambient temperature is above 35°C. After compaction has
been completed, roller shall not stand on the compacted surface for the duration of the
curing period except during commencement of next day's work near the location where
work was terminated the previous day.
3.20.4.5.3
Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static weight
are considered to be suitable for rolling dry lean concrete. In case any other roller is
proposed, the same shall be got approved from the Engineer, after demonstrating its
performance. The number of passes required to obtain maximum compaction depends
on the thickness of the lean concrete, the compactibility of the mix, and the weight and
type of the roller etc., and the same as well as the total requirement of rollers for the job
shall be determined during trial run by measuring the in-situ density and the scale of the
work to be undertaken.
3.20.4.5.4
The final lean concrete surface on completion of compaction and immediately before
overlaying, shall be well closed, free from movement under roller and free from ridges,
low spots, cracks, loose material, pot holes, ruts or other defects. The final surface shall
be inspected immediately on completion and all loose, segregated or defective areas
shall be corrected by using fresh lean concrete and compacted as per Specification. For
repairing honeycombed surface, concrete with aggregates of size 10 mm and below shall
be spread and compacted. It is necessary to check the level of the rolled surface for
compliance. Any level/thickness deficiency should be corrected after applying cement
concrete with aggregates of size 10 mm and below after roughening the surface.
Similarly the surface regularity also should be checked with 3m straight edge. The
deficiency should be made up with concrete with aggregates of size 10 mm and below.
3.20.5 Trial Mixes
Trial Mixes shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.
3.20.6 Curing
Curing shall confirm to the requirements of Section-5.1.3.11 of General Specifications.
3.20.7 Removal of Scaffolding and Formwork
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 Forms and scaffolding shall confirm to the requirements of Section-5.1.3.12 of General
Specifications.
3.20.8 Repair of Concrete
Repair of Concrete shall confirm to the requirements of Section-5.1.3.12 of General
Specifications.
3.20.9 Traffic
No heavy commercial vehicles like trucks and buses shall be permitted on the lean
concrete sub-base after its construction. Light vehicles if unavoidable may, however, be
allowed after 7 days of its construction with prior approval of the Engineer.
3.20.10 Tolerances for Surface Regularity, Level, Thickness and Strength
The tolerances for surface regularity, level, thickness and strength shall conform to the
requirements and Control of quality of materials and works shall be exercised
satisfactory to the Engineer.
3.20.11 Measurements
The unit of measurement for dry lean concrete pavement shall be the unit of volume in
cubic metre of concrete placed, based on the net plan areas for the specified thickness
shown on the drawings or as directed by the Engineer.

3.20.12 Payment
The Contract unit rate payable for dry lean concrete sub-base shall be payment in full
for carrying out the required operations including full compensation for all labour,
materials and equipment, mixing, transport, placing, compacting, finishing, curing,
testing and incidentals to complete the work as per Specifications, all royalties, fees,
storage and rents where necessary and all leads and lifts.
Pay items shall be:

Dry Lean Concrete (as specified in

03/20/01 cu. Metre
Design)

3.21 CEMENT CONCRETE PAVEMENT

3.21.1 Scope
3.21.1.1 The work shall consist of construction of cement concrete pavement in accordance
with the requirements of these Specifications and in conformity with the lines, grades
and cross sections shown on the drawings. The work shall include furnishing of all plant
and equipment, materials and labour and performing all operations in connection with
the work, as approved by the Engineer.

3.21.1.2
The design parameters, viz., thickness of pavement slab, grade of concrete, joint details
etc. shall be as stipulated in the contract drawings.Concrete pavement can be jointed,
jointed reinforced and continuously reinforced concrete. Reinforcement often for crack
control. Rollar compacted concrete and pervious or porous concrete is commonplace.
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 Thicker pavements can carry more loads, because flexural stresses are reduced and
fatigue life of the pavement is increased.
Jointed plain concrete pavement (JPCP), consists of unreinforced concrete slabs 3.6 to
6.0 m in length with transverse contraction joints between the slabs so the pavement
expansions and contractions are addressed through joints. Dowels should be provided
across the joint for load transfer. Dowels are smooth rods, generally plain or epoxy-
coated steel, which are usually greased or oiled on side to allow the joints to open and
close without resistance. JPC pavements, like other conventional concrete pavements,
often use tie bars to connect adjacent traffic lanes. Tie bars are deformed reinforcing
steel and, unlike dowels, are not intended to allow the joints to open and close. JPCP is
the most commonly used type of concrete pavement because it is usually the cheapest to
construct.
Jointed reinforced concrete pavement (JRCP) has typically steel content of 0.01 to 0.25
percent of the cross-sectional area, in the longitudinal direction, with less steel in the
transverse direction. Either individual reinforcement bars or wire febricc and meshes
may be used. Because the steel is paced at the neutral axis or midpoint of the slab,it has
np effect on the flexural performance of the concrete and serves only to keep cracks
together.
Continuously reinforced concrete pavement (CRCP) is characterized by heavy steel
reinforcement and absence of joints. Typically steel content is 0.4 to 0.8 percent by
volume in the longitudinal direction. Steel in the transverse direction is provided in a
lower percentage as temperature steel. Cracks form in CRCP approximately 0.6 to 2 m
apart. The reinforcement holds the cracks tightly together and provides for aggregate
interlock and shear transfer. CRC pavement provides a smoother ride and a longer life
than any other type of pavement.

3.21.2 Materials

3.21.2.1 Cement:
Cement shall confirm to the requirements of Section-5.1.2 of General Specifications.

3.21.2.2 Admixtures:
Admixtures shall confirm to the requirements of Section-5.1.2 of General
Specifications.

3.21.2.3 Aggregates:
Aggregates shall confirm to the requirements of Section-5.1.2 of General Specifications.
Aggregates for concrete shall be tested for determining the reactivity from accelerated
mortar bar test (AASHTO T303) and concrete prism test (ASTM C 1293).

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3.21.2.4 Water:
Water shall confirm to the requirements of Section-5.1.2 of General Specifications.

3.21.2.5 Admixtures:
Admixtures shall confirm to the requirements of Section-5.1.2 of General
Specifications.

3.21.2.6 High Yield Deformed Steel Reinforcing Bars for dowels and tie bars:
Reinforcing bars for dowels and tie bars shall confirm to the requirements of Section-5.2
of General Specifications.

3.21.2.7 Pre-moulded joint filler:

Joint filler board for expansion joints which are proposed for use only at some abutting
structures like bridges and culverts shall be of 20-25 mm thickness within a tolerance of
± 1.5 mm and of a firm compressible' material and complying with the requirements of
BS Specification Clause No. 2630 or Specification for Highway Works, Vol. I Clause
1015.It shall be 25 mm less in depth than the thickness of the slab within a tolerance of
± 3 mm and provided to the full width between the side forms. It shall be in suitable
lengths, which shall not be less than one lane width. Holes to accommodate dowel bars
shall be accurately bored or punched out to give a sliding fit on the dowel bars.

3.21.2.8 Joint sealing compound:

The joint sealing compound shall be of hot poured, elastomeric type or cold
polysulphide type having flexibility, resistance to age hardening -and durability. If the
sealant is of hot poured type it shall conform to AASHTO M282 and cold applied
sealant shall be in accordance with BS 5212 (Part 2).

3.21.2.9 Storage of materials:

Storage of materials shall confirm to the requirements of Section-5.1.3.3 of General
Specifications.
3.21.3 Proportioning of Concrete

3.21.3.1
After approval by the Engineer of all the materials to be used in the concrete, the
Contractor shall submit the mix design based on weighed proportions of all ingredients
for the approval of the Engineer. The mix design shall be submitted at least 30 days
prior to the paving of trial length and the design shall be based on laboratory trial mixes
using the approved materials and methods as agreed to by the Engineer. The mix design
shall be based on the flexural strength of concrete.

3.21.3.2 Cement content:

Cement content shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.

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 3.21.3.3 Concrete strength:
Concrete strength shall confirm to the requirements of Section-5.1.2.3 of General
Specifications.

3.21.3.4 Workability
3.21.3.4.1
The workability of the concrete at the point of placing shall be adequate for the concrete
to be fully compacted and finished without undue flow. The optimum workability for
the mix to suit the paving plant being used shall be determined by the Contractor and
approved by the Engineer. The control of workability in the field shall be exercised by
the slump test as per STP. Usually no slump concrete should be used for pavement
works.

3.21.3.4.2
The workability requirement at the Batching Plant and paving site shall be established
by slump tests carried during trial paving. These requirements shall be established from
season to season and also when the lead from Batching plant site to the paving site
changes. The workability shall be established for the type of paving equipment
available. A slump value in the range of 30 ± 15 mm is reasonable for paving works but
this may be modified depending upon the site requirement and got approved by the
Engineer. These tests shall be carried out on every truck/dumper at Plant site and paving
site initially when the work commences but subsequently the frequency can be reduced
to alternate trucks or as per the instructions of the Engineer.

3.21.3.5 Design mix

3.21.3.5.1
The Contractor shall carry out laboratory trials according to the ACI (American
Concrete Institute) method of concrete mix design with the materials from the approved
sources to be used. Trial mixes shall be made in presence of the Engineer or his
representative and the design mix shall be subject to the approval of the Engineer. They
shall be repeated if necessary until the proportions that will produce a concrete, which
compiles in all respects with this Specification, and conforms to the requirement of the
design/drawings have been determined.
3.21.3.5.2
The proportions determined as a result of the laboratory trial mixes may be adjusted if
necessary during the construction of the trial length. Thereafter, neither the materials nor
the mix proportions shall be varied in any way except with the written approval of the
Engineer.
3.21.3.5.3
The Contractor shall submit results of material tests on the proposedmaterials to the
Engineer for his approval at least seven days in advance of its use. Fresh approval shall
be required when the material is changed or as order of the Engineer.

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3.21.4 Separation Membrane
A separation membrane shall be used between the concrete slab and the sub-base.
Separation membrane shall be impermeable plastic sheeting 125 microns thick laid flat
without creases. Before placing the separation membrane, the sub-base shall be swept
clean of all the extraneous materials using air compressor. Wherever overlap of plastic
sheets is necessary, the same shall be at least 300 mm and any damaged sheeting shall
be replaced at the Contractor's expense. The separation membrane may be nailed to the
lower layer with concrete nails.
3.21.5 Joints

3.21.5.1
The location and type of joints shall be as shown in the drawing. Joints shall be
constructed depending upon their functional requirement as detailed in the following
paragraphs. The location of the joints should be transferred accurately at the site and
mechanical saw cutting of joints done as per stipulated dimensions. It should be ensured
that the full required depth of cut is made from edge to edge of the pavement.
Transverse and longitudinal joints in the pavement and sub-base shall be staggered so
that they are not coincident vertically and are at least 1m and 0.3m apart respectively.
Sawing of joints shall be carried out with diamond studded blades soon after the
concrete has hardened to take the load of the sewing machine and personnel without
damaging the texture of the pavement. Sawing operation could start as early as 6-8
hours depending upon the season.

3.21.5.2 Transverse joints

3.21.5.2.1
Transverse joints shall be contraction and expansion joints constructed at the spacing
described in the Drawings. Transverse joints shall be straight within the following
tolerances along the intended line of joints which is the straight line transverse to the
longitudinal axis of the carriageway at the position proposed by the Contractor and
agreed to by the Engineer, except at road junctions or roundabouts where the position
shall be as described in the drawings:
Deviations of the filler board in the case of expansion joints from the intended line of
the joint shall not be greater than ± 10 mm.
The best-fit straight line through the joint grooves as constructed shall be not more than
25 mm from the intended line of the joint.
Deviations of the joint groove from the best-fit straight line of the joint shall not be
greater than 10 mm.
Transverse joints on each side of the longitudinal joint shall be in line with each other
and of the same type and width. Transverse joints shall have a sealing groove, which
shall be sealed in compliance with Clause 3.15.11.

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3.21.5.2.2 Contraction joints:
Contraction joints shall consist of a mechanical sawn joint groove, 3 to 5 mm wide and
1/4 to 1/3 depth of the slab ± 5 mm or as stipulated in the drawings and dowel bars
complying with Clause 3.15.6.5 and as detailed in the drawings.
The contraction joints shall be cut as soon as the concrete has undergone initial
hardening and is hard enough to take the load of joint sawing machine without causing
damage to the slab.
3.21.5.2.3 Expansion joints:
The expansion joints shall consist of a joint filler board complying with Clause 3.15.2.7
and dowel bars complying with Clause 3.15.6.5 and as detailed in the drawings. The
filler board shall be positioned vertically with the prefabricated joint assemblies along
the line of the joint within the tolerances given in Clause 3.15.6.2.1 and at such depth
below the surface as will not impede the passage of the finishing straight edges or
oscillating beams of the paving machines. The adjacent slabs shall be completely
separated from each other by providing joint filler board. Space around the dowel bars,
between the sub-base and the filler board shall be packed with a suitable compressible
material to block the flow of cement slurry.

3.21.5.3 Transverse construction joint:

Transverse construction joints shall be placed whenever concreting is completed after a
day's work or is suspended for more than 30 minutes. These joints shall be provided at
the regular location of contraction joints using dowel bars. The joint shall be made butt
type. At all construction joints, steel bulkheads shall be used to retain the concrete while
the surface is finished. The surface of the concrete laid subsequently shall conform to
the grade and cross sections of the previously laid pavement. When positioning of bulk
head/ stop-end is not possible, concreting to an additional 1 or 2 m length may be
carried out to enable the movement of joint cutting machine so that joint grooves may be
formed and the extra 1 or 2 m length is cut out and removed subsequently after concrete
has hardened.

3.21.5.4 Longitudinal joint

3.21.5.4.1
The longitudinal joints shall be saw cut as per details of the joints shown in the drawing.
The groove may be cut after the final set of the concrete. Joints should be sawn to at
least 1/3 the depth of the slab ± 5 mm as indicated in the drawing.
3.21.5.4.2
Tie bars shall be provided at the longitudinal joints as per dimensions and spacing
shown in the drawing and in accordance with Clause 3.15.6.6.
3.21.6 Dowel bars

3.21.6.1
Dowel bars shall be mild steel rounds in accordance with Clause 3.15.2.6 with
details/dimensions as indicated in the drawing and free from oil, dirt, loose rust or scale.
They shall be straight, free of irregularities and burring restricting slippage in the
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 concrete. The sliding ends shall be sawn or cropped cleanly with no protrusions outside
the normal diameter of the bar. The dowel bar shall be supported on cradles/dowel
chairs in pre-fabricated joint assemblies positioned prior to the construction of the slabs
or mechanically inserted with vibration into the plastic concrete by a method which
ensures correct placement of the bars besides full re-compaction of the concrete around
the dowel bars.

3.21.6.2
Unless shown otherwise on the drawings, dowel bars shall be positioned at mid depth of
the slab within a tolerance of ± 20 mm, and centered equally about intended lines of the
joint within a tolerance of ± 25 mm. They shall be aligned parallel to the finished
surface of the slab and to the centre line of the carriageway and to each other within
tolerances given hereunder, the compliance of which shall be checked as per Clause
3.16.10.7.
For bars supported on cradles prior to the laying of the slab:
All bars in a joint shall be within ± 3 mm per 300 mm length of bar
2/3rd of the bars shall be within ± 2 mm per 300 mm length of bar
No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300 mm
length of bar in either the horizontal or vertical plane
Cradles supporting dowel bar shall not extend across the line of joint i.e. no steel bar of
the cradle assembly shall be continuous across the joint
For all bars inserted after laying of the slab:
Twice the tolerance for alignment as indicated in (i) above

3.21.6.3
Dowel bars, supported on cradles in assemblies, when subject to a load of 110 N applied
at either end and in either the vertical or horizontal direction (upwards and downwards
and both directions horizontally) shall conform to be within the following limits:
Two-thirds of the number of bars of any assembly tested shall not deflect more than 2
mm per 300 mm length of bar
The remainder of the bars in that assembly shall not deflect more than 3 mm per 300
mm length of bar.

3.21.6.4
The assembly of dowel bars and supporting cradles, including the joint filler board in
the case of expansion joints, shall have the following degree of rigidity when fixed in
position:-
For expansion joints, the deflection of the top edge of the filler board shall be not greater
than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical face of the
joint filler board and distributed over a length of 600 mm by means of a bar or timber
packing, at mid depth and midway between individual fixings, or 300 mm from either

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 end of any length of filler board, if a continuous fixing is used. The residual deflection
after removal of the load shall be not more than 3 mm.
The joint assembly fixings to sub-base shall not fail under the 1.3kN load applied for
testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.
The fixings for contraction joint shall not fail under 1.3 kN load and shall fail before the
load reaches 2.6 kN when applied over a length of 600 mm by means of a bar or timber
packing placed as near to the level of the line of fixings as practicable.
Fixings shall be fail when there is displacement of the assemblies by more than 3 mm
with any form of fixing, under the lest load. The displacement shall be measured at the
nearest part of the assembly to the centre of the bar or timber packing.

3.21.6.5
Dowel bars shall be covered by a thin plastic sheath for at least two-thirds of the length
from one end for dowel bars in contraction joints or half the length plus 50 mm for
expansion joints. The sheath shall be tough, durable and of an average thickness not
greater than 1.25 mm. The sheathed bar shall comply with the following pull-out tests:
Four bars shall be taken at random from stock and without any special preparation shall
be covered by sheaths as required in this Clause. The ends of the dowel bars which have
been sheathed shall be cast centrally into concrete specimens 150 x 150 x 600 mm,
made of the same mix proportions to be used in the pavement, but with a maximum
nominal aggregate size of 20 mm and cured in accordance with IS: 516. At 7 days a
tensile load shall be applied to achieve a movement of the bar of at least 0.25 mm. The
average bond stress to achieve this movement shall not be greater than 0.14 MPa.

3.20.6.6
For expansion joints, a closely fitting cap 100 mm long consisting of waterproofed
cardboard or an approved synthetic material like PVC or GI pipe shall be placed over
the sheathed end of each dowel bar. An expansion space at least equal in length to the
thickness of the joint filler board shall be formed between the end of the cap and the end
of the dowel bar by using compressible sponge. To block the entry of cement slurry
between dowel and cap it may be taped.

3.21.6.7 Tie bars

3.21.6.7.1
Tie bars in longitudinal joints shall be deformed steel bars of strength in accordance
with Clause 3.15.2.6. The bars shall be free from oil, dirt, loose rust and scale.
3.21.6.7.2
Tie bars projecting across the longitudinal joint shall be protected from corrosion for
75mm on each side of the joint by a protective coating of bituminous paint with the
approval of the Engineer. The coating shall be dry when the tie bars are used.
3.21.6.7.3
Tie bars in longitudinal joints shall be made up into rigid assemblies with adequate
supports and fixings to remain firmly in position during the construction of the slab.
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 Alternatively, tie bars at longitudinal joints may be mechanically or manually inserted
into the plastic concrete from above by vibration using a method, which ensures correct
placement of the bars and re-compaction of the concrete around the tie bars.
3.21.6.7.4
Tie bars shall be positioned to remain within the middle third of the slab depth as
indicated in the drawings and approximately parallel to the surface and approximately
perpendicular to the line of the joint, with the centre of each bar on the intended line of
the joints within a tolerance of ± 50mm, and. with a minimum cover of 30 mm below
the joint groove.

3.21.7 Weather and Seasonal Limitations

3.21.7.1 Concreting during monsoon months:

When concrete is being placed during monsoon months and when it may be expected to
rain, sufficient supply of tarpaulin or other water proof cloth shall be provided along the
line of the work. Any time when it rains, all freshly laid concrete which had not been
covered for curing purposes shall be adequately protected. Any concrete damaged by
rain shall be removed and replaced. If the damage is limited to texture, it shall be
retextured in accordance with the directives of the Engineer.

3.21.7.2 Concreting in hot weather:

No concreting shall be done when the concrete temperature is above 30 degree
Centigrade. Besides, in adverse conditions like high temperature, low relative humidity,
excessive wind velocity, imminence of rains etc., if so desired by the Engineer, tents on
mobile trusses may be provided over the freshly laid concrete for a minimum period of 3
hours as directed by the Engineer. The temperature of the concrete mix on reaching the
paving site shall not be more than 30° C. To bring down the temperature, if necessary,
chilled water or ice flakes should be made use of.
No concreting shall be done when the concrete temperature is below 5 degree
Centigrade and the temperature is descending.
3.21.8 Side Forms, Rails
3.21.8.1 Side forms and rails:
All side forms shall be of mild steel of depth equal to the thickness of pavement or
slightly less to accommodate the surface regularity of the sub-base. The forms can be
placed on series of steel packing plates or shims to take care of irregularity of sub-base.
They shall be sufficiently robust and rigid to support the weight and pressure caused by
paving equipment. Side forms for use with wheeled paving machines shall incorporate
metal rails firmly fixed at a constant height below the top of the forms. The forms and
rails shall be firmly secured in position by not less than 3 stakes/pins per each 3 m
length so as to prevent movement in any direction. Forms and rails shall be straight
within a tolerance of 3 mm in 3 m and when in place shall not settle in excess of 1.5 mm
in 3 m while paving is being done. Forms shall be cleaned and oiled immediately before
each use. The forms shall be bedded on a continuous bed of low moisture content lean
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 cement mortar or concrete and set to the line and levels shown on the drawings within
tolerances ± 10 mm and ± 3 mm respectively. The bedding shall not extend under the
slab and there shall be no vertical step between adjacent forms of more than 3 mm. The
forms shall be got inspected from the Engineer for his approval before 12 hours on the
day before the construction of the slab and shall not be removed until at least 12 hours
afterwards.

3.21.8.2
At all times sufficient forms shall be used and set to the required alignment for at least
200 m length of pavement immediately in advance of the paving operations, or the
anticipated length of pavement to be laid within the next 24 hrs whichever is more.
3.21.9 Construction

3.21.9.1 General:
A systems approach may be adopted for construction of the pavement, and the Method
Statement for carrying out the work, detailing all the activities including indication of
lime-cycle, equipment, personnel etc., shall be got approved from the Engineer before
the commencement of the work. The above shall include the type, capacity and make of
the batching and mixing plant besides the hauling arrangement and paving equipment.
The capacity of paving equipment, batching plant as well as all the ancillary equipment
shall be adequate for a paving rate of atleast 300 m in one day.

3.21.9.2 Batching and mixing:

Batching and mixing of the concrete shall be done at a central batching and mixing plant
with automatic controls, located at a suitable place which takes into account sufficient
space for stockpiling of cement, aggregates and stationary water tanks. This shall be,
however, situated at an approved distance, duly considering the properties of the mix
and the transporting arrangements available with the Contractor.

3.21.9.3 Equipment for proportioning of materials and paving

3.21.9.3.1
Proportioning of materials shall be done in the batching plant by weight, each type of
material being weighed separately. The cement from the bulk stock may be weighed
separately from the aggregates and water shall be measured by volume. Wherever
properly graded aggregate of uniform quality cannot be maintained as envisaged in the
mix design, the grading of aggregates shall be controlled by appropriate blending
techniques. The capacity of batching and mixing plant shall be at least 25 per cent
higher than the proposed capacity of the laying/paving equipment.
3.21.9.3.2 Batching plant and equipment:
General- The batching plant shall include minimum four bins, weighing hoppers, and
scales for the fine aggregate and for each size of coarse aggregate. If cement is used in
bulk, a separate scale for cement shall be included. The weighing hoppers shall be
properly sealed and vented to preclude dust during operation. Approved safety devices
shall be provided and maintained for the protection of all personnel engaged in plant
operation, inspection and testing. The batch plant shall be equipped with a suitable non-
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 resettable batch counter, which will correctly indicate the number of batches
proportioned.
Bins and hoppers- Bins with minimum number of four adequate separate compartments
shall be provided in the batching plant.
Automatic weighing devices-Batching plant shall be equipped to proportion aggregates
and bulk cement by means of automatic weighing devices using load cells.
Mixers- Mixers shall be pan type, reversible type or any other mixer capable of
combining the aggregates, cement, and water into a thoroughly mixed and uniform mass
within the specific mixing period, and of discharging the mixture, without segregation.
Each stationary mixer shall be equipped with an approved timing device which will
automatically lock the discharge lever when the drum has been charged and release it at
the end of the mixing period. The device shall be equipped with a bell or other suitable
warning device adjusted to give a clearly audible signal each time the lock is released.
In case of failure of the timing device, the mixer may be used for the balance of the day
while it is being repaired, provided that each batch is mixed 90 seconds or as per the
manufacturer's recommendation. The mixer shall be equipped with a suitable non-
resettable batch counter, which shall correctly indicate the number of batches mixed.
The mixers shall be cleaned at suitable intervals. The pickup and throw-over blades in
the drum or drums shall be repaired or replaced when they are worn down 20 mm or
more. The Contractor shall (1) have available at the job site a copy of the manufacturer's
design, showing dimensions and arrangements of blades in reference to original height
and depth, or (2) provide permanent marks on blade to show points of 20 mm wear from
new conditions. Drilled holes of 5 mm diameter near each end and at midpoint of each
blade are recommended. Batching Plant shall be calibrated in the beginning and
thereafter at suitable interval not exceeding 1 month.
Control cabin- An air-conditioned centralised control cabin shall be provided for
automatic operation of the equipment.
3.21.9.3.3 Paving equipment:
The concrete shall be placed with an approved fixed form or slip from paver with
independent units designed to (i) spread,(ii) consolidate, screed and float-finish, (iii)
texture and cure the freshly placed concrete in one complete pass of the machine in such
a manner that a minimum of hand finishing will be necessary and so as to provide a
dense and homogeneous pavement in conformity with the plans and Specifications. The
paver shall be equipped with electronic controls to control/sensor line and grade from
either or both sides of the machine.
Vibrators shall operate at a frequency of 8300 to 9600 impulses per minute under load at
a maximum spacing of 60 cm. The variable vibration setting shall be provided in the
machine.
3.21.9.4 Hauling and placing of concrete
3.21.9.4.1
Freshly mixed concrete from the central batching and mixing plant shall be transported
to the paver site by means of trucks/tippers of sufficient capacity and approved design in

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 sufficient numbers to ensure a constant supply of concrete. Covers shall be used for
protection of concrete against the weather. The trucks/tippers shall be capable of
maintaining the mixed concrete in a homogeneous state and discharging the same
without segregation and loss of cement slurry. The feeding to the paver is to be
regulated in such a way that the paving is done in an uninterrupted manner with a
uniform speed throughout the days work.
3.21.9.4.2 Placing of concrete
Concrete mixed in central mixing plant shall be transported to the site without delay and
the concrete which, in the opinion of the Engineer, has been mixed too long before
laying will be rejected and shall be removed from the site. The total time taken from the
addition of the water to the mix, until the completion of the surface finishing and
texturing shall not exceed 120 minutes when concrete temperature is less than 25°C and
90 minutes when the concrete temperature is between 25°C to 30°C. Trucks/tippers
delivering concrete shall not run on plastic sheeting nor shall they run on completed
slabs until after 28 days of placing the concrete. The Paver shall be capable of paving
the carriageway as shown in the drawings, in a single pass and lift.
3.21.9.4.3
Where fixed form pavers are to be used, forms shall be fixed in advance as per Clause
3.15.8. of the Specifications. Before any paving is done, the site shall be shown to the
Engineer, in order to verify the arrangement for paving besides placing of dowels, tie-
bars etc., as per the relevant Clauses of this Specification. The mixing and placing of
concrete shall progress only at such a rate as to permit proper finishing, protecting and
curing of the pavement.

3.21.9.4.4
In all cases, the temperature of the concrete shall be measured at the point of discharge
from the delivery vehicle.
3.21.9.4.5
The addition of water to the surface of the concrete to facilitate the finishing operations
will not be permitted except with the approval of the Engineer when it shall be applied
as a mist by means of approved equipment.
3.21.9.4.6
If considered necessary by the Engineer, the paving machines shall be provided with
approved covers to protect the surface of the slab under construction from direct
sunlight and rain or hot wind.
3.21.9.4.7
While the concrete is still plastic, its surface shall be brush textured in compliance with
Clause 3.16.9.8 and the surface and edges of the slab cured by the application of a
sprayed liquid curing membrane in compliance with Clause 3.15.9.9. After the surface
texturing, but before the curing compound is applied, the concrete slab shall be marked
with the chainage at every 100 m interval.

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3.21.9.4.8
As soon as the side forms are removed, edges of the slabs shall be corrected wherever
irregularities have occurred by using fine concrete composed of one part of cement to 3
parts of fine chips and fine aggregate under the supervision of the Engineer.
3.21.9.4.9
If the requirement for surface regularity fails to be achieved on two consecutive working
days, then normal working shall cease until the cause of the excessive irregularity has
been identified and remedied.

3.21.9.5 Construction by fixed form paver

3.21.9.5.1
The fixed form paving train shall consist of separate powered machines which spread,
compact and finish the concrete in a continuous operation.
3.21.9.5.2
The concrete shall be discharged without segregation into a hopper spreader which is
equipped with means for controlling its rate of deposition on to the sub-base. The
spreader shall be operated to strike off concrete upto a level requiring a small amount of
cutting down by the distributor of the spreader. The distributor of spreader shall strike
off the concrete to the surcharge adequate to ensure that the vibratory compactor
thoroughly compacts the layer. If necessary, poker vibrators shall be used adjacent to the
side forms and edges of the previously constructed slab. The vibratory compactor shall
be set to strike off the surface slightly high so that it is cut down to the required level by
the oscillating beam. The machine shall be capable of being rapidly adjusted for changes
in average and differential surcharge necessitated by changes in slab thickness or cross
fall- The final finisher shall be able to finish the surface to the required level and
smoothness as specified, care being taken to avoid bringing up of excessive mortar to
the surface by overworking.

3.21.9.6 Construction by slip form paver

3.21.9.6.1
The slip form paving train shall consist of power machine which spreads, compacts and
finishes the concrete in a continuous operation. The slip form-paving machine shall
compact the concrete by internal vibration and shape it between the side forms with
either a conforming plate or by vibrating and oscillating finishing beams. The concrete
shall be deposited without segregation in front of slip form paver across the whole width
and to a height, which at all times is in excess of the required surcharge. The deposited
concrete shall be struck off to the necessary average and differential surcharge by means
of the strike off plate or a screw auger device extending across the whole width of the
slab. The equipment for striking-off the concrete shall be capable of being rapidly
adjusted for changes of the average and differential surcharge necessitated by change in
slab thickness or crossfall.

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3.21.9.6.2
The level of the conforming plate and finishing beams shall be controlled automatically
from the guide wires installed as per Clause 3.16.8 by sensors attached at the four
comers of the slip form paving machine. The alignment of the paver shall be controlled
automatically from the guide wire by at least one set of sensors attached to the paver.
The alignment and level of ancillary machines for finishing, texturing and curing of the
concrete shall be automatically controlled relative to the guide wire or to the surface and
edge of the slab.
3.21.9.6.3
Slip-form paving machines shall have vibrators of variable output, with a maximum
energy output of not less than 2.5 KW per metre width of slab per 300 mm depth of slab
for a laying speed upto 1.5 m per minute or pro-rata for higher speeds. The machines
shall be of sufficient mass to provide adequate reaction during spreading and paving
operations on the traction units to maintain forward movements during the placing of
concrete in all situations.
3.21.9.6.4
If the edges of the slip formed slab slump to the extent that the surface of the top edge of
the slab does not comply with the requirements of Clause 3.16.14, then special measures
approved by the Engineer shall be taken to support the edges to the required levels and
work shall be stopped until such time as the Contractor can demonstrate his ability to
slip form the edges to the required levels.

3.21.9.7 Construction by hand-guided method:

Areas in which hand-guided methods of construction become indispensable shall be got
approved by the Engineer in writing in advance. Such work may be permitted only in
restricted areas in small lengths. Work shall be carried out by skilled personnel as per
methods, approved by the Engineer. The acceptance criteria regarding level, thickness,
surface regularity, texture, finish, strength of concrete and all other quality control
measures shall be the same as in the case of machine laid work.

3.21.9.8 Surface texture

3.21.9.8.1
After the final regulation of the slab and before the application of the curing membrane,
the surface of concrete slab shall be brush-textured in a direction at right angles to the
longitudinal axis of the carriageway.
3.21.9.8.2
The brushed surface texture shall be applied evenly across the slab in one direction by
the use of a wire brush not less than 450 mm wide but longer brushes are preferred. The
brush shall be made of 32-gauge tape wires grouped together in tufts spaced at 10 mm
centres. The tufts shall contain an average of 14 wires and initially be 100 mm long. The
brush shall have two rows of tufts. The rows shall be 20 mm apart and the tufts in one
row shall be opposite the centre of the gap between tufts in the other row. The brush
shall be replaced when the shortest tuft wears down to 90 mm long.

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3.21.9.8.3
The texture depth shall be determined by the Sand Patch Test as described in Clause
602.12. This test shall be performed at least once for each day's paving and wherever the
Engineer considers it necessary at times after construction as under:
Five individual measurements of the texture depth shall be taken at least 2 m apart
anywhere along a diagonal line across a lane width between points 50 m apart along the
pavement. No measurement shall be taken within 300 mm of the longitudinal edges of a
concrete slab constructed in one pass.
3.21.9.8.4
Texture depths shall not be less than the minimum required when measurements are
taken as given in Table 600-2 nor greater than a maximum average of 1.25 mm.

TABLE 3.21-1
Required
Time Number of
Texture Depth (mm)
of Test Measurements
Specified Value Tolerance
Between 24 hours
and 7 days after the
constn., of the slab An average of 5
1.00 ± 0.25
or until the slab is measurements
first used by
vehicles
Not later than 6
weeks before the An average of 5
1.00 + 0.25-0.35
road is opened to measurements
public traffic.

3.21.9.8.5
After the application of the brushed texture, the surface of the slab shall have a uniform
appearance.
3.21.9.8.6
Where the texture depth requirements are found to be deficient, the Contractor shall
make good the texture across the full lane width over length directed by the Engineer,
by retexturing the hardened concrete surface in an approved manner.
3.21.10 Preparation and Sealing of Joint Grooves

3.21.10.1 General
All transverse joints in surface slabs shall be sealed using sealants described in Clause
3.15.2.8. Joints shall not be sealed before 14 days after construction.

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3.21.10.2Preparation of joint grooves for sealing
3.21.10.2.1
Joint grooves usually are not constructed to provide the minimum width specified in the
drawings when saw cut joints are adopted. They shall be widened subsequently by
sawing before sealing. Depth/width gauges shall be used to control the dimension of the
groove.
3.21.10.2.2
If rough arises develop when grooves are made, they shall be ground to provide a
chamfer approximately 5 mm wide. If the groove is at an angle upto 10 degree from the
perpendicular to the surface, the overhanging edge of the sealing groove shall be sawn
or ground perpendicular. If spalling occurs or the angle of the former is greater than 10
degrees, the joint sealing groove shall be sawn wider and perpendicular to the surface to
encompass the defects upto a maximum width, including any chamfer, of 35 mm for
transverse joints and 20 mm for longitudinal joints. If the spalling cannot be so
eliminated then the arises shall be repaired by an approved thin bonded arris repair using
cemeiititious materials
3.21.10.2.3
All grooves shall be cleaned of any dirt or loose material by air blasting with filtered,
oil-free compressed air. If need arises the Engineer may instruct cleaning by pressurized
water jets. Depending upon the requirement of the sealant manufacturer, the sides of the
grooves may have to be sand blasted to increase the bondage between sealant and
concrete.
3.21.10.2.4
The groove shall be cleaned and dried at the time of priming and sealing.
3.21.10.2.5
Before sealing the temporary seal provided for blocking the ingress of dirt, soil etc.,
shall be removed. A highly compressible heat resistant paper-backed debonding strip as
per drawing shall be inserted in the groove to serve the purpose of breaking the bond
between sealant and the bottom of the groove and to plug the joint groove so that the
sealant may not leak through the cracks. The width of debonding strip shall be more
than the joint groove width so that it is held tightly in the groove. In the case of
longitudinal joints, heat resistant tapes may be inserted to block the leakage through
bottom of the joint.

3.21.10.3Sealing with sealants

3.21.10.3.1
When sealants are applied, an appropriate primer shall also be used if recommended by
the manufacturer and it shall be applied in accordance with their recommendation. The
sealant shall be applied within the minimum and maximum drying times of the primer
recommended by the manufacturer. Priming and sealing with applied sealants shall not
be carried out when the naturally occurring temperature in the joint groove to be sealed
is below 7° C.

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3.21.10.3.2
If hot applied sealant is used it shall be heated and applied from a thermostatically
controlled, indirectly heated preferably with oil jacketed melter and pourer having
recirculating pump and extruder. For large road projects, sealant shall be applied with
extruder having flexible hose and nozzle. The sealant shall not be heated to a
temperature higher than the safe heating temperature and not for a period longer than the
safe heating period, as specified by the manufacturer. The dispenser shall be cleaned out
at the end of each day in accordance with the manufacturer's recommendations and
reheated material shall not be used.
3.21.10.3.3
Cold applied sealants with chemical formulation like polysulphide may be used. These
shall be mixed and applied within the time limit specified by the manufacturer. If
primers are recommended they shall be applied neatly with an appropriate brush. The
Movement Accommodation Factor (MAF) shall be more than 10 per cent.
3.20.10.3.4
The sealants applied at contraction phase of the slabs would result in bulging of the
sealant over and above the slab. Therefore, the Contractor in consultation with the
Engineer shall establish the right temperature and time for applying the sealant.
Thermometer shall be hung on a pole in the site for facilitating control during the
sealing operation.
3.21.10.3.5
Sealant shall be applied, slightly to a lower level than the slab with a tolerance of 5 ± 2
mm.
3.21.10.3.6
During sealing operation, it shall be seen that no air bubbles are introduced in the
sealant either by vapours or by the sealing process.
3.21.10.3.7 Curing:
Curing shall confirm to the requirements of Section-5.1.3.11 of General
Specifications.Concrete temperature should be controlled as delayed ettringite formation
(DEF), is a form of internal sulfate attack that can happen with steam-cured and mass
concrete when internal concrete temperatures exceed 70 0C.
3.21.11 Removal of Scaffolding and Formwork:
Forms and scaffolding shall confirm to the requirements of Section-5.1.3.12 of General
Specifications.
3.21.12 Repair of Concrete:
Repair of Concrete shall confirm to the requirements of Section-5.1.3.12 of General
Specifications.
3.21.13 Measurement of Texture Depth- Sand Patch Method

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3.21.13.1 The following apparatus shall be used:
o A cylindrical container of 25 ml internal capacity
o A flat wooden disc 64 mm diameter with a hard rubber disc, 1.5 mm thick, stuck to
one face, the reverse face being provided with a handle
o Dry natural sand with a rounded panicle shape passing a 300 micron IS sieve and
retained on a 150 micron IS sieve.

3.21.13.2Method:
The surface to be measured shall be dried, any extraneous mortar and loose material
removed and the surface swept clean using a wire brush both at right angles and parallel
to the carriageway. The cylindrical container shall be filled with the sand, tapping the
base 3 times on the surface to ensure compaction, and striking off the sand level with the
top of the cylinder. The sand shall be poured into a heap on the surface to be treated.
The sand shall be spread over the surface, working the disc with its face kept flat in a
circular motion so that the sand is spread into a circular patch with the surface
depressions filled with sand to the level of peaks.

3.21.13.3
The diameter of the patch shall be measured to the nearest 5 mm. The texture depth of
concrete surface shall be calculated from 31000/(DxD) mm where D is the diameter of
the patch in mm.
3.21.14 Opening to Traffic
No vehicular traffic shall be allowed to run on the finished surface of a concrete
pavement within a period of 28 days of its construction and until the joints are
permanently sealed. The road may be opened to regular traffic after completion of the
curing period of 28 days and after sealing of joints is completed including the
construction of shoulder, with the written permission of the Engineer.
3.21.15 Tolerances for Surface Regularity, Level, Thickness and Strength
The tolerances for surface regularity, level, thickness and strength shall conform to the
requirements and Control of quality of materials and works shall be exercised
satisfactory to the Engineer.
3.21.16 Method Statement for concrete pavement construction
3.21.16.1 Introduction:

This method statement outlines the procedure for the construction of concrete pavement.
It covers the steps involved in the preparation, placement, and finishing of concrete to
achieve a durable and ordinary-quality pavement.

3.21.16.2 Scope
This method statement applies to the construction of concrete pavements.

3.21.16.3 Equipment and Materials

The following equipment and materials will be required for the construction of concrete
pavement:

o Compaction equipment (e.g., rollers, plate compactors)

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o Concrete batching plant
o Concrete mixers
o Concrete vibrators
o Steel reinforcement bars (if required)
o Formwork materials
o Concrete testing equipment
o Finishing tools (e.g., screeds, trowels)
o Water source

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3.21.16.4 Procedure:
Site Preparation:

 Clear the construction area from any debris, vegetation, or obstructions.

 Excavate and prepare the subgrade as per the project specifications, ensuring proper
compaction and grading.

 Install any necessary subbase or base layers, if specified.

Formwork:

 Set up formwork along the edges of the pavement, ensuring proper alignment and
adequate support.

 Apply form release agent to the formwork to facilitate easy removal after concrete
placement.

Concrete Mixing and Delivery:

 Set up the concrete batching plant at an appropriate location.

 Ensure that the concrete mix design meets the project specifications, including the
required strength, slump, and any additional admixtures.

 Regularly check and calibrate the batching plant to maintain accurate proportions of
materials.

 Deliver the concrete to the construction site using concrete mixers, ensuring a continuous
supply.

Concrete Placement:

 Pour the concrete into the prepared formwork, taking care to avoid segregation and
honeycombing.

 Use concrete vibrators to consolidate the concrete and remove any air voids.
 Monitor the concrete placement process to maintain a consistent thickness and level.

Finishing:
 Use screeds or laser levelling devices to achieve the desired pavement elevation and
slope.
 Strike off excess concrete using a straightedge or screed, ensuring a uniform surface.
 Finish the surface with trowels to achieve the desired texture and smoothness.
 Cure the concrete using appropriate curing methods such as curing compounds, moist
curing, or curing blankets.

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 Joints and Edges:
 Install contraction joints at predetermined intervals to control cracking and allow for the
expansion and contraction of the concrete.
 Finish the joint edges using appropriate jointing tools or devices.
 Install edge restraints, if required, to prevent the displacement of the pavement.

Quality Control and Testing:

 Regularly sample and test the concrete during construction to ensure it meets the
specified requirements.
 Conduct slump tests, compressive strength tests, and any other required tests as per the
project specifications.
 Monitor the curing process and take necessary measures to maintain adequate moisture
levels.

3.21.16.5 Health, Safety, and Environmental Considerations:

 Provide adequate personal protective equipment (PPE) to all workers.
 Ensure proper ventilation and dust control measures during concrete mixing and
placement.
Follow local regulations and best practices for the disposal of waste materials and excess
concrete.

3.21.17.6 SAMI (Stress Arresting Membrane Interlayer) on Concrete Bridge Decks

Description:

Concrete bridge decks are susceptible to various types of distresses, such as cracking,
spalling, and corrosion, due to factors like traffic loads, temperature fluctuations, and
exposure to environmental elements. To enhance the durability and prolong the service life of
concrete bridge decks, engineers have developed innovative solutions, one of which is the
Stress Arresting Membrane Interlayer (SAMI) system. The Stress Arresting Membrane
Interlayer (SAMI) system offers several benefits for concrete bridge decks, including crack
mitigation, waterproofing, enhanced durability, and improved ride quality. By following the
appropriate application procedure, engineers can effectively incorporate SAMI into bridge
deck rehabilitation and construction projects, enhancing the longevity and performance of
these vital transportation assets.

3.21.17.6.1Application Procedure of SAMI:

Surface Preparation:

The existing concrete bridge deck surface must be thoroughly cleaned and prepared before
applying the SAMI system. This involves removing any loose debris, oil, grease, or other
contaminants that may interfere with the bonding of the SAMI material.

SAMI Material Selection:

Various types of SAMI materials are available, but it is recommended to use polymer-
modified (SBS) asphalt for bridges.

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 Application of SAMI:

The SAMI material is typically applied using spray equipment. It is uniformly sprayed onto
the prepared concrete deck surface to achieve the desired thickness, typically ranging from 3
to 6 millimeters. The application may require multiple passes to ensure complete coverage
and uniformity.

Curing and Overlay Installation:

After the SAMI material is applied, it needs to cure and achieve sufficient strength before the
overlay is placed. The curing time can vary depending on the SAMI material and
environmental conditions. Once cured, the asphalt, is installed on top of the SAMI system. In
some cases a firmly bonded membrane protected with asphalt overlay is used.

Quality Control:

Throughout the application process, quality control measures should be implemented to

ensure proper thickness, uniform coverage, and adherence of the SAMI material. This may
involve periodic testing, visual inspections, and verification of compliance with project
specifications.

3.21.17 Measurements for Payment

Cement Concrete pavement shall be measured as a finished work in square metres with
specified thickness. The volume to be paid for will be calculated on the basis of
thickness and plans shown on the project drawings and adjusted for the deficiency in
thickness. No additional payment shall be made for extra thickness of the slab. The full
payment will be made to this item after 28 days strength of the concrete is found to be
satisfactory.
The unit for measurement for concrete pavement shall be the cubic metre of concrete
placed, based on the net plan areas for the specified thickness shown on the Drawings or
directed by the Engineer. The rate shall include all provisions of this Specification and
shall include the provision of all materials including polythene film, concrete, stock
piling, mixing, transport, placing, compacting, finishing, curing together with all
formwork, and including testing and submission of test certificates and records. No
deduction shall be made in measurement for openings provided that the area of each is
less than 0.5 sq. m. The unit rate as entered in the Bill of Quantities shall also include
the full costs of contraction, expansion, construction, and longitudinal joints. It shall
also include joint filler, keys, caulking rod, debonding strip, sealant primer, joint sealant,
dowel bar and lie rod.

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3.21.17.1 Pavement thickness
All precautions and care shall be taken to construct pavement having uniform thickness
as called for on the plans.
Thickness of the cement concrete pavement shall be calculated on the basis of level data
of the cement concrete pavement and the underlying sub-base taken on a grid of 5 m x
3.5 m or 6.25 m x 3.5 m, the former measurement being in longitudinal direction.
A day's work is considered as a 'lot' for calculating the average thickness of the slab. In
calculating the average thickness, individual measurements which are in excess of the
specified thickness by more than 10 mm shall be considered as the specified thickness
plus 10 mm.
Individual areas deficient by more than 25 mm shall be verified by the Engineer by
ordering core cutting and if in his opinion the deficient areas warrant removal, they shall
be removed and replaced with concrete of the thickness shown on the plans.
3.21.18 Rate
The Contract unit rate for the construction of the cement concrete shall be payment in
full for carrying out the operations required for the different items of the work as per
these Specifications including full compensation for all labour, tools, plant, equipments,
testing and incidentals to complete the work as per Specifications, providing all
materials to be incorporated in the work including all royalties, fees, storage, rents
where necessary and all leads and lifts.
Pay items shall be:
03/21/01 Cement Concrete Pavement (Concrete class-30 ) cu metre
03/21/02 Cement Concrete Pavement (Concrete Class - 35) cu metre
Square
03/21/03 SAMI for Bridge Decks
Meter

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4- FOUNDATIONS

DIVISION 4

FOUNDATION WORK

4.1 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

DIVISION 4 - FOUNDATION WORK

4.1 BORED CAST IN PLACE PILES........................................................................................................4.6

4.1.1 Description .......................................................................................................................................4.6
4.1.2 Materials .................................................................................................................4.6
4.1.2.1 Steel Casing ...........................................................................................................................4.6
4.1.2.2 Concrete ................................................................................................................................4.7
4.1.2.3 Reinforcement .......................................................................................................................4.7
4.1.2.4 Drilling Fluid .........................................................................................................................4.7
4.1.3 Construction Methods ....................................................................................................................4.8
4.1.3.1 General ..................................................................................................................................4.8
4.1.3.2 Setting Out Piles ....................................................................................................................4.9
4.1.3.3 Diameter of Piles ...................................................................................................................4.9
4.1.3.4 Tolerances .............................................................................................................................4.9
4.1.3.5 Boring ....................................................................................................................................4.9
4.1.3.6 Placing Reinforcement ........................................................................................................4.12
4.1.3.7 Placing Concrete ..................................................................................................................4.13
4.1.3.8 Extraction of Temporary Casing .........................................................................................4.15
4.1.3.9 Temporary Support .............................................................................................................4.16
4.1.3.10 Records ...............................................................................................................................4.16
4.1.3.11 Measures in Case of Rejected Piles ......................................................................................4.7
4.1.4 Measurement .....................................................................................................................4.17
4.1.5 Payment ..............................................................................................................................4.17
4.2 PRECAST CONCRETE DRIVEN PILES ............................................................................4.19
4.2.1 Description .........................................................................................................................4.19
4.2.2 Materials ............................................................................................................................4.19
4.2.2.1 Concrete ..............................................................................................................................4.20
4.2.2.2 Formwork ............................................................................................................................4.20
4.2.2.3 Prestressing Steel .................................................................................................................4.20
4.2.2.4 Reinforcement .....................................................................................................................4.20
4.2.3 Production of Piles ..............................................................................................................4.21
4.2.3.1 Casting .................................................................................................................................4.21
4.2.3.2 Tensioning Procedure (Prestressed Piles Only) ..................................................................4.21
4.2.3.3 Curing ..................................................................................................................................4.21
4.2.3.4 Release (Pretensioned Piles Only) ......................................................................................4.21
4.2.3.5 Finishing ..............................................................................................................................4.22
4.2.3.6 Marking of Piles ................................................................................................. …………4.22
4.2.3.7 Handling and Storage of Piles .............................................................................................4.22
4.2.3.8 Spliced Piles ........................................................................................................................4.22
4.2.4 Driving Piles .......................................................................................................................4.22
4.2.4.1 Strength of Piles ..................................................................................................................4.22
4.2.4.2 Leaders and Trestles ............................................................................................................4.22
4.2.4.3 Driving Equipment ..............................................................................................................4.23
4.2.4.4 Driving Procedure and Redrive Checks ..............................................................................4.23
4.2.4.5 Final Set ..............................................................................................................................4.24
4.2.4.6 Driving Sequence and Risen Piles ......................................................................................4.24
4.2.4.7 Jetting ...................................................................................................................................4.24
4.2.4.8 Length of Piles….................................................................................................................4.24
4.2.4.9 Repair or Damaged Pile Heads ...........................................................................................4.25
4.2.4.10 Cut off and Extension ..........................................................................................................4.25
4.2.4.11 Damage to Adjacent Structures and Services ......................................................................4.25
4.2.4.12 Records ................................................................................................................................4.25
4.2.5 Tolerances ..........................................................................................................................4.26
4.2 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.2.5.1 Setting Out ..........................................................................................................4.26

4.2.5.2 Position ...............................................................................................................4.26
4.2.5.3 Verticality ............................................................................................................4.26
4.2.5.4 Rake ...................................................................................................................4.26
4.2.6 Defective Piles.....................................................................................................4.26
4.2.7 Measurement......................................................................................................4.27
4.2.8 Payment ..............................................................................................................4.27
4.3 PRECAST CONCRETE UNITS FOR RIVER TRAININGAND RETAINING
STRUCTURES………………………………………………………………………….4.29
4.3.1 Description ..........................................................................................................4.29
4.3.2 Materials .............................................................................................................4.29
4.3.3 Construction Methods.......................................................................................4.29
4.3.3.1 King Post & Anchor Piles....................................................................................4.29
4.3.3.2 Precast Planks ......................................................................................................4.29
4.3.4 Tolerances ...........................................................................................................4.29
4.3.5 Measurement.......................................................................................................4.29
4.3.6 Payment...............................................................................................................4.30
4.3.7 PILE INTEGRITY TEST………………………………………………4.30

4.3.7.1
Description........................................................................................................4.30
4.3.7.2
Test procedure......................................................................................................4.30
4.3.7.3
Results of Testing................................................................................................4.31
4.3.7.4
Measurement.......................................................................................................4.31
4.3.7.5
Payment ..............................................................................................................4.31
4.4 PILE TEST LOADING .......................................................................................4.32
4.4.1 Descriptions .......................................................................................................4.32
4.4.1.1 General ..........................................................................................................4.32
4.4.1.2 Definitions ...................................................................................................4.32
4.4.2 Supervision .........................................................................................................4.33
4.4.3 Safety Precautions ..............................................................................................4.33
4.4.3.1 General .............................................................................................................4.33
4.4.3.2 Kentledge ..........................................................................................................4.33
4.4.3.3 Tension Piles and Ground Anchors ...................................................................4.34
4.4.3.4 Testing Equipment ...............................................................................................4.34
4.4.4 Construction of a Pilot Pile to be Test Loaded ...............................................4.34
4.4.4.1 Notice of Construction .......................................................................................4.34
4.4.4.2 Method of Construction .....................................................................................4.34
4.4.4.3 Boring or Driving Record ...................................................................................4.35
4.4.4.4 Cut-Off Level .....................................................................................................4.35
4.4.4.5 Pile Head for Compression Tests ......................................................................4.35
4.4.5 Preparation of a Working Pile to be Tested ....................................................4.35
4.4.6 Reaction Systems ...............................................................................................4.35
4.4.6.1 Compression Tests ............................................................................................4.35
4.4.6.2 Working Piles .....................................................................................................4.35
4.4.6.3 Spacing..............................................................................................................4.35
4.4.6.4 Adequate Reaction ............................................................................................4.36
4.4.6.5 Care of Piles ......................................................................................................4.36
4.4.6.6 Loading Arrangement ........................................................................................4.36
4.4.7 Equipment for Applying Load ...........................................................................4.36
4.4.8 Measurement of Load .......................................................................................4.36
4.4.9 Adjustability of Loading Equipment ..............................................................4.36
4.4.10 Measuring Movement of Pile Heads ...............................................................4.37
4.4.10.1 General .............................................................................................................4.37
4.4.10.2 Leveling Method ...........................................................................................4.37
4.4.10.3 Independent Reference Frame .................................................................... 4.37
4.3 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.4.10.4 Other Methods ................................................................................................4.37

4.4.11 Protection of Testing Equipment ......................................................................4.37
4.4.11.1 Protection from Weather ....................................................................................4.37
4.4.11.2 Prevention of Disturbance ..................................................................................4.38

4.4.12 Supervision ...........................................................................................................4.8

4.4.12.1 Notice of Test ....................................................................................................4.38
4.4.12.2 Records .............................................................................................................4.38
4.4.13 Test Procedure ...................................................................................................4.38
4.4.13.1 Proof Test by Maintained Load Test ..................................................................4.38
4.4.14 Presentation of Results ......................................................................................4.39
4.4.14.1 Results to be Submitted .....................................................................................4.39
4.4.14.2 Schedule of Recorded Data ................................................................................4.40
4.4.15 Completion of a Test ..........................................................................................4.41
4.4.15.1 Measuring Equipment .........................................................................................4.41
4.4.15.2 Kentledge ...........................................................................................................4.41
4.4.15.3 Temporary Piles .................................................................................................4.41
4.4.16 Measurement and Payment ..............................................................................4.41

4.5 BITUMEN SLIP LAYER FOR PILES .................................................................4.44

4.5.1 Description ..........................................................................................................4.44
4.5.2 Materials ............................................................................................................4.44
4.5.2.1 Primer .................................................................................................................4.44
4.5.2.2 Bitumen ..............................................................................................................4.44
4.5.3 Field Storage and Installation ...........................................................................4.40
4.5.4 Measurement ......................................................................................................4.45
4.5.5 Payment .............................................................................................................4.45

4.6 DRIVEN BULLAH PILES .....................................................................................4.46

4.6.1 Description ..........................................................................................................4.46
4.6.2 Materials ............................................................................................................4.46
4.6.3 Driving Piles .......................................................................................................4.46
4.6.3.1 Driving Equipment ..............................................................................................4.46
4.6.3.2 Leaders and Trestles .........................................................................................4.46
4.6.3.3 Hammers ..........................................................................................................4.46
4.6.3.4 Length of Piles ...................................................................................................4.46
4.6.3.5 Records .............................................................................................................4.46
4.6.4 Measurement ......................................................................................................4.48
4.6.5 Payment ..............................................................................................................4.48

4.7 WELL FOUNDATION ...........................................................................................4.48

4.7.1 Description ..........................................................................................................4.48
4.7.2 Materials .............................................................................................................4.48
4.7.2.1 Steel cutting edge -----------------------------------------------------------------------4.48
4.7.2.2 Concrete ---------------------------------------------------------------------------------4.49
4.7.2.3 Reinforcement --------------------------------------------------------------------------4.49
4.7.2.4 Sand ---------------------------------------------------------------------------------------4.49
4.7.3 Construction Methods …………………………………………………………4.49
4.7.3.1 Setting Out and Preparations for Sinking --------------------------------------------4.49
4.7.3.2 Cutting Edge Erection -------------------------------------------------------------------4.50
4.7.3.3 Well curb ------------------------------------------------------------------------------4.50
4.7.3.4 Well Steining ------------------------------------------------------------------------------4.50
4.7.3.5 Well Sinking ------------------------------------------------------------------------------4.51
4.7.3.5.1 General ----------------------------------------------------------------------------------4.51
4.7.3.5.2 Sand blows in wells --------------------------------------------------------------------4.52

4.4 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.7.3.5.3 Use of Kentledge as Sinking Load ----------------------------------------------------4.52

4.7.3.5.4 Use of Water Jetting --------------------------------------------------------------------4.52
4.7.3.5.5 Use of Explosives ----------------------------------------------------------------------4.53
4.7.3.5.6 Use of Divers ----------------------------------------------------------------------------4.53
4.7.3.6 Precautions during sinking --------------------------------------------------------------4.54
4.7.3.7 Tilts and Shifts ----------------------------------------------------------------------------4.55
4.7.3.10 Bottom Plug -------------------------------------------------------------------------------4.57
4.7.3.11 Sand Filling -------------------------------------------------------------------------------4.58
4.7.3.12 Top Plug -----------------------------------------------------------------------------------4.58
4.7.3.13 Well cap -----------------------------------------------------------------------------------4.58
4.7.3.14 Tolerances ---------------------------------------------------------------------------------4.59
4.7.3.15 Tests and standards of acceptance -----------------------------------------------------4.59
4.7.4 Measurement ----------------------------------------------------------------------------4.59
4.7.5 Payment ------------------------------------------------------------------------------------4.60

4.8 STEEL SHEET PILES ...........................................................................................4.62

4.8.1 Description ..........................................................................................................4.62
4.8.2 Materials ............................................................................................................................4.62
4.8.3 Construction Methods........................................................................................................4.62
4.8.4 Measurement & Payment...................................................................................................4.66

4.9 REINFORCED EARTH WALLS...........................................................................................4.66

4.9.1 Description .........................................................................................................................4.66
4.9.2 Materials ............................................................................................................................4.67
4.9.3 Construction Methods........................................................................................................4.70
4.9.4 Measurement & Payment...................................................................................................4.73

4.10 PRE CAST SPUN PILES.........................................................................................................4.73

4.10.1 Description .........................................................................................................................4.73
4.10.2 Materials ............................................................................................................................4.74
4.10.3 Construction Methods........................................................................................................4.74
4.10.4 Measurement & Payment...................................................................................................4.79

4.11 STEEL SCREW PILES............................................................................................................4.79

4.11.1 Description .........................................................................................................................4.79
4.11.2 Materials ............................................................................................................................4.79
4.11.3 Construction Methods........................................................................................................4.80
4.11.4 Measurement & Payment...................................................................................................4.81

4.12 LATERAL LOAD TEST..........................................................................................................4.85

4.12.1 Description .........................................................................................................................4.85
4.12.2 Materials ............................................................................................................................4.85
4.12.3 Construction Methods.......................................................................................................4.85
4.12.4 Measurement & Payment...................................................................................................4.87

4.13 PARALLEL SEISMIC TEST..................................................................................................4.87

4.13.1 Description .........................................................................................................................4.87
4.13.2 Materials ............................................................................................................................4.87
4.13.3 Construction Methods........................................................................................................4.88
4.13.4 Measurement & Payment...................................................................................................4.87

4.14 HIGH STRAIN DYNAMIC TESTING OF PILES...............................................................4.87

4.14.1 Description .........................................................................................................................4.87
4.14.2 Equipment...........................................................................................................................4.87
4.5 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.14.3 Construction Methods........................................................................................................4.88

4.14.4 Measurement & Payment...................................................................................................4.87

4.15 ULTRASONIC CROSS-HOLE TESTING............................................................................4.87

4.15.1 Description .........................................................................................................................4.87
4.15.2 Equipment...........................................................................................................................4.87
4.15.3 Construction Methods....................................................................................... 4.88
4.15.4 Measurement & Payment...................................................................................................4.87

4.6 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.1 BORED CAST IN PLACE PILES

4.1.1 Description

This work comprises the construction of bored cast in place piles for bridges, including
the provision of all materials and structures in accordance with these Specifications and
in conformity with the requirements of the Drawings or other parts of the Contract
Documents.

Piles through water and soft upper soil layers shall be provided with a permanent steel
casing if shown on the Drawings.

The pile boring shall be carried out using a temporary steel casing bored to the pile toe
or to a level approved by the Engineer. The temporary casing shall be withdrawn.

Under certain circumstances the Contractor may be permitted to bore all or part of the
pile without casing under water or use drilling fluid to stabilize the borehole as referred
to in Section 4.1.2.4.

The piles shall be concreted and reinforced to resist pile loads and horizontal forces on
the pile caps according to the Drawings and these Specifications.

4.1.2 Materials

4.1.2.1 Steel Casing

This part of the Specifications only deals with the permanent steel casing. For steel
casing used during boring of the pile see Section 4.1.3, Construction Methods.

When permanent steel casing is shown on the Drawings, the steel shall conform to the
AASHTO Standard Specification M 183-79 (ASTM A36) or equivalent.

The minimum thickness of the permanent steel casing shall be 10 mm. However, the
thickness may be waived to 6(six) mm, if specified in Drawings. The minimum length
shall be from 100 mm above the bottom of the pile cap to 5 meter under the riverbed or
into firm strata. If the permanent casing is used in the boring operation or if the
handling and transport require a greater thickness to avoid deformation or buckling, the
increase in thickness shall be provided by the Contractor at his own expense.

The steel casing shall be furnished in appropriate lengths and the joints shall be
approved by the Engineer.

4.7 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

The casing shall be handled and stored in a manner that shall prevent buckling and
other deformation as well as accumulation of dirt, oil and paint. When placed in the
work it shall be free from dirt, oil, grease, paint, mill scale and loose or thick rust.

The outside surface of the permanent casing of piles to river piers, for the depth
indicated on the Drawings from the underside of the pile cap shall receive anticorrosion
tar type paint. The paint shall be approved by the Engineer and its application shall
follow the manufacturer's instructions.

4.1.2.2 Concrete

The concrete shall conform to Section 5.1 of these Specifications. Concrete class 25
with type 1 cement shall be used.

For coastal or saline environments, the type of cement to be used shall be determined as
directed by the Engineer.

Concrete placed under water or drilling mud by tremie shall have a cement content of
not less than 350 kg/m3.
The density and consistency of the concrete shall conform to the tremie casting method
and the maintenance of sufficient workability (slump) of all the concrete during the
casting and casing handling period, including reasonably calculated delays, shall be
secured by a design mix, (including the necessary retarders and plasticizers), tested by
trial mixes prior to the pile construction.

All relevant concrete properties such as slump, time of setting, temperature and strength
shall be measured on the trial mixes.

4.1.2.3 Reinforcement

The reinforcement shall conform to Section 5.2 of these Specifications.

4.1.2.4 Drilling Fluid

The following clauses shall be complied with if bentonite mud is used to stabilize the
boreholes:

A) Supply

The Contractor shall obtain a certificate from the manufacturer of the bentonite powder,
showing the properties of the consignment delivered to the site. This certificate shall be
made available to the Engineer on request. The properties to be given by the
manufacturer are the apparent viscosity range (in centipoises) and the gel strength range
for solids in water.

Any other material proposed by the Contractor for the drilling fluid shall have to be
approved by the Engineer.

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DIVISION 4 - FOUNDATION WORK

B) Mixing

Bentonite and any other material shall be mixed thoroughly with clean water to make a
suspension which shall maintain the stability of the pile excavation for the period
necessary to place concrete and complete construction.

Where saline or chemically contaminated groundwater occurs, special precautions shall

be taken to modify the bentonite in fresh water so as to render it suitable in all respects
for the construction of piles.

C) Tests

The frequency of testing drilling fluid and the method and procedure of sampling shall
be proposed by the Contractor and approved by the Engineer prior to the
commencement of the work. The frequency may subsequently be varied as required
depending on the consistency of the results obtained. The control tests shall cover the
determination of density, viscosity, gel strength and pH values.

The Contractor shall supply all equipment and experienced operators required to carry
out tests on the drilling mud. No additional payment shall be made for these tests which
shall be considered as an essential part of the drilling operations.

4.1.3 Construction Methods

4.1.3.1 General

The Contractor shall demonstrate to the satisfaction of the Engineer that his proposed
construction methods for the piles do not result in the pile shafts being weakened by
contamination of the concrete, by sectional reduction, by washing out of cement, by
breaking during pulling of temporary casings or in any other way, including the
construction of neighboring piles.

A) Assumed Procedure

The following construction procedure has been assumed in the design. The final
construction procedure shall be as approved by the Engineer prior to commencing
piling operations.

1. Place permanent steel casing, if required, in position and embed casing toe
into river bed or firm strata. If no permanent steel casing is specified a sufficient length
of temporary steel casing shall be used to stabilize the upper part of the borehole.

2. Bore and excavate inside the steel casing down to casing toe level, or to a
level approved, and continue excavation to final pile tip level using either temporary
casing under water, or using drilling mud. The fluid level inside casings shall at all
times be at least 2 metres higher than outside the casings.

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3. Carefully clean up all mud or sedimentation from the bottom of borehole.

4. Place reinforcement cage, inspection pipes etc.

5. Concrete continuously under water, or drilling fluid, by use of the tremie

method.

6. Withdraw the temporary boring casing concurrently with concreting to the

instructed level.

7. After hardening, break out the top section of the concrete pile to reach sound
concrete.

B) Approval of Construction Method

In the tender, the Contractor shall describe the construction method he proposes,
including name of proposed Sub-contractor (if any), information on boring equipment,
materials, method of work and control of quality. The Contractor shall submit
references from similar jobs carried out by him and/or his proposed Sub-contractor.

During contract negotiations, the Contractor shall submit all requested supplementary
detailed information in writing.

After the Contract has been awarded, the Contractor shall prepare a detailed programme
and establish a procedure for the pile construction. The detailed programme shall
contain all required information on materials, equipment, methods of work etc. and be
approved in writing by the Engineer. Such approval shall not, however, relieve the
Contractor of his responsibilities for pile construction.

The import of any boring equipment or materials by the Contractor, before he has
received the Engineer’s approval of proposed construction methods, shall be at the
Contractor’s risk.

4.1.3.2 Setting out Piles

The Contractor shall check the casing position for each pile during and immediately
after placing the casing, and agree it with the Engineer.

4.1.3.3 Diameter of Piles

The diameter of a pile shall be not less than the specified diameter.

4.1.3.4 Tolerances

The centre of the completed pile at the cut off level shall not deviate more than 100 mm
from the theoretically correct position shown on the Drawings. The inclination of the
pile shall not deviate more than 1:100 from vertical. The Contractor shall provide

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DIVISION 4 - FOUNDATION WORK

suitable equipment, such as an inverted pendulum, to check the verticality of the

boreholes at intervals during drilling and prior to concreting.

4.1.3.5 Boring

A) Methods
Method of excavation shall be proposed by the Contractor and approved by the
Engineer. Water or air jetting for boring of the piles shall not be allowed. However,
following methods may be considered as general guideline, pending variance imposed
by soil condition or other factors:

Sl. Drilling method Pile Diameter

1 Boring by PERCUSSION METHOD using Direct 400 mm diameter

Mud Circulation (DMC) or Bailer and Chisel
600 mm diameter
technique by tripod and mechanical winch machine.
Tube well boring machine shall not be used 750 mm diameter

900 mm diameter

2 Boring by Skid Mounted Mechanical Table Drive 900 mm diameter

Rotary Boring/ Spindle Type Rotary Drilling
1000 mm diameter
Machine. Tube well boring machine/ Bailer and chisel
technique by tripod and mechanical winch machine 1200 mm diameter
shall not be used.

3 Boring by HYDRAULIC ROTARY METHOD using 900 mm diameter

Crawler mounted, telescopic boom hydraulic piling
rig. Tube well boring machine/ Bailer and chisel 1000 mm diameter
technique by tripod and mechanical winch machine/ 1200 mm diameter
Skid Mounted Mechanical Table Drive Rotary
Boring/ Spindle Type Rotary Drilling Machine shall 1500 mm diameter
not be used.
1800 mm diameter

2000 mm diameter

2500 mm diameter

4 Driven Cast-in-Situ vertical R.C.C. pile of specified 400 mm diameter

diameter and length (length to be measured from the
600 mm diameter
bottom of pile cap to the bottom of shoe), to carry
safe working load not less than specified, including 750 mm diameter
cost shoe & all other materials and labour for casting,
hoisting, driving etc. and also including cost of 900 mm diameter
dummy lengths of pile and of hire charges of all

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DIVISION 4 - FOUNDATION WORK

instruments as necessary but excluding concrete & 1000 mm diameter

reinforcement etc. all complete as per drawing,
1200 mm diameter
specification and direction of Engineer-in-Charge.
1500 mm diameter

B) Boring Near Recently Cast Piles

Piles shall not be bored so close to other piles which have recently been cast and which
contain workable or unset concrete so that a flow of concrete could be induced from or
damage caused to any of the piles. Boring and excavation for a pile shall not be
commenced until 24 hours after completion of any pile within a radius of 6 metres,
centre to centre (Or as directed by the Engineer).

C) Temporary Casings

Temporary casing of approved quality or an approved alternative method shall be used

to maintain the stability of pile excavations, which might otherwise collapse.

Temporary casings shall be free from significant distortion. They shall be of uniform
cross-section throughout each continuous length. During concreting they shall be free
from internal projections and encrusted concrete which might prevent the proper
formation of piles.

D) Stability of Pile Excavation Using Drilling Fluid

Where a borehole is formed without casing under water or using drilling fluid for
maintaining the stability of a boring, the level of the water or fluid in the excavation
shall be maintained so that the water or fluid pressure always exceeds the pressure
exerted by the soils and external ground water. The water or fluid level shall be
maintained at a level not less than 2 metres above the level of the river water level or
any artesian pressure level.

In the event of a rapid loss of water or bentonite suspension from the pile excavation,
the excavation shall be backfilled without delay and the instructions of the Engineer
shall be obtained before excavation at that location is resumed.

E) Disposal of Excavated Material

No excavated material shall be dumped into the river or any connecting waterway
without the written approval of the Engineer. Excavated material shall be removed from
site and dumped either beyond areas affected by dredging, or taken to the Contractors

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DIVISION 4 - FOUNDATION WORK

approved dumping areas on land. The Contractor shall be fully responsible for costs
involved in removing the excavated material to spoil.

F) Pumping from Boreholes

Pumping from a borehole shall not be permitted unless a casing has been placed into a
stable stratum which prevents the flow of water from other strata in significant
quantities into the boring, or unless it can be shown that pumping will not have a
detrimental effect on the surrounding soil or property.

G) Obstructions

Where boulders or other obstructions render it impossible to bore the pile, excavation
operations inside pile casing as directed by the Engineer shall be carried out to remove
obstructions exceeds 200 mm and the obstruction is found more than 2 metres below
river bed.

H) Unexpected Ground Conditions

The Contractor shall report immediately to the Engineer any circumstances which
indicate that in the Contractor's opinion the ground conditions differ from those
expected by him from his interpretation of the site investigation reports.

I) Boring Records

During the boring of the pile, the Contractor shall compile a 'boring log' indicating
depths and types of the various soil layers encountered. Disturbed samples shall be
submitted to the Engineer as requested.

The Contractor shall allow for carrying out sampling and tests to check soil strengths as
required by the Engineer.

J) Final Pile Toe Level

The final pile toe level shall be as indicated on the Drawing or as instructed by the
Engineer after due consideration of the Contractor's proposals, boring logs and test
results.

The final toe level of other piles may subsequently be altered according to the results of
the test loadings detailed in Section 4.4.

K) Inspection and Cleaning Bottom of Excavation

The time between final excavation and bottom cleaning and the start of concreting shall
be kept as short as possible and shall not exceed 6 hours. To achieve this, the final 2

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DIVISION 4 - FOUNDATION WORK

metres of excavation shall not start until all preparations for cleaning, reinforcing and
concreting are finished. In case of unexpected delay the Contractor shall dump sand or
gravel in the bore to 2 metres above toe level.

On completion of the drilling an interval is required, to allow the fine materials to settle
(15 minutes unless otherwise approved by the Engineer). Thereafter the bottom of the
excavation shall be carefully cleaned of mud, sedimentation and other soft material by
an approved method.

The Contractor shall show, to the satisfaction of the Engineer, that the bottom of the
excavation is clean. Sedimentation tests shall be carried out by the Contractor in the
presence of the Engineer.

If boring without casing, the diameter of the boring hole for a representative number of
piles shall be measured by caliper prior to the placing of concrete. The verticality of
boreholes will be checked as directed by the Engineer. These measurements shall be
done by the Contractor using approved equipment and no reimbursement shall be made.

4.1.3.6 Placing Reinforcement

The reinforcement shall be placed as indicated on the Drawings. Reinforcement in the

form of a cage shall be assembled with additional support, such as spreader forks and
lacings, necessary to form a rigid cage. Hoops, links or helical reinforcement shall fit
closely around the main longitudinal bars and be bound to them by approved wire, the
ends of which shall be turned into the interior of the pile or pour. Reinforcement shall
be placed and maintained in position.

The cover to all reinforcement shall be not less than 75 mm.

Joints in longitudinal steel bars shall be permitted unless otherwise specified. Joints in
reinforcement shall be such that the full strength of the bar is effective across the joint
and shall be made so that there is no relative displacement of the reinforcement during
the construction of the pile.

Joints in longitudinal bars in piles with tension (for instance for test loading) shall be
carried out by welding unless another method has been approved by the Engineer.

If the final pile toe level instructed by the Engineer is deeper than that indicated on the
Drawings, the section of the pile deeper than the toe level indicated on the Drawings is
not required to be reinforced, unless otherwise instructed by the Engineer.

4.1.3.7 Placing Concrete

A) Approval

No concreting shall take place before the bottom of the excavation has been cleaned,
the borehole inspected and approval obtained in writing from the Engineer.

The method for placing concrete requires to be approved and conform to the following:
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DIVISION 4 - FOUNDATION WORK

• The method of placing and the workability of the concrete shall be such that a
continuous monolithic concrete shaft of the full cross section is formed.

• The concrete shall be placed continuously, and without such interruption as would
allow the previously placed batch to have hardened. In this respect the Contractor shall
submit details of his contingency plans, standby plant etc. to be utilized in the event of
an equipment failure.
• The use of pumped concrete and the methods in its use shall be approved.

• The Contractor shall take all precautions in the design of the mix and placing of the
concrete to avoid arching of the concrete in a casing. No spoil, liquid or other foreign
matter shall be allowed to contaminate the concrete.

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DIVISION 4 - FOUNDATION WORK

B) Workability of Concrete

Slump measured at the time of discharge into the pile boring shall be in accordance with
Table 4.1-1.

Table 4.1-1

Slump

Piling Mix Minimum Range Typical Conditions of Use

(mm) (mm)
Workability

A 75 75 - 150 Placed into water-free unlined or permanently lined

bore of 600 mm diameter or over, or where casting
level lies below temporary casing: reinforcement
widely spaced, leaving ample room for free
movement of concrete between bars.

B 100 100 - 200 Where reinforcement is not spaced widely; where

cut-off level of concrete is within temporary casing;
where pile bore is water-free and the diameter is less
than 600 mm.

C 150 150 or Where concrete is to be placed by tremie under

more water or drilling mud or by pumping.

C) Placing Concrete Under Water or Drilling Fluid

Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not
be discharged freely into the water or drilling fluid.

Before placing concrete, the Contractor shall ensure that there is no accumulation of silt,
other material, or heavily contaminated bentonite suspension at the base of the boring,
which could impair the free flow of concrete from the pipe of the tremie. A sample of the
bentonite suspension shall be taken from the base of the boring using an approved
sampling device. If the specific gravity of the suspension exceeds 1.25, the placing of
concrete shall not proceed. In this event the Contractor shall modify the mud quality.

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DIVISION 4 - FOUNDATION WORK

The concrete shall be a rich coherent mix of high workability in accordance with Section
4.1.2.2 and shall be placed in such a manner that segregation does not occur.

During and after concreting, care shall be taken to avoid damage to the concrete from
pumping and dewatering operations.

The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall
extend to the base of the boring and a sliding plug or barrier shall be placed in the pipe to
prevent direct contact between the first charge of concrete in the pipe of the tremie and
the water or drilling fluid. The pipe shall at all times penetrate the concrete, which has
previously been placed and shall not be withdrawn from the concrete until completion of
concreting. The bottom of the tremie pipe shall be kept at least 1.5 metres under the
surface of concrete once that amount of concrete has been placed. At all times a sufficient
quantity of concrete shall be maintained within the pipe to ensure that the pressure from it
exceeds that from the water or drilling fluid. The internal diameter of the pipe of the
tremie shall be not less than 150 mm for concrete made with 20 mm aggregate and not
less than 200 mm for concrete made with 40 mm aggregate. It shall be so designed that
external projections are minimized, allowing the tremie to pass through reinforcing cages
without causing damage. The internal face of the pipe of the tremie shall be free from
projections.

The Contractor shall maintain a continuous record of the volume of concrete used and the
level of the concrete in the pile. Any deviations from the theoretical, or expected,
volume/level relationship shall be immediately reported to the Engineer.

4.1.3.8 Extraction of Temporary Casing

A) Workability of Concrete

Temporary casings shall be extracted while the concrete within them remains sufficiently
workable to ensure that the concrete is not lifted.

B) Concrete Level

When the casing is being extracted a sufficient quantity of concrete shall be maintained
within it to ensure that pressure from external water, drilling fluid or soil is exceeded and
that the pile is neither reduced in section nor contaminated. The toe of the temporary
casing shall be kept a minimum of 2 metres under the outlet of the tremie.

No concrete shall be placed in the boring once the bottom of the casing has been lifted
above the top of the concrete; it shall be placed continuously as the casing is extracted
until the desired head of concrete is obtained.

Adequate precautions shall be taken in all cases where excess heads of water or drilling
fluid could be caused as the casing is withdrawn because of the displacement of water or
fluid by the concrete as it flows into its final position against the walls of the shaft.

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DIVISION 4 - FOUNDATION WORK

The pile shall be concreted with a certain over height to allow for chiseling off the top
concrete down to sound hard concrete.

The pile top shall, after clean cutting, be embedded 100 mm in the foundation.

C) Vibrating Extractors

The use of vibrating casing extractors shall be permitted.

D) Reinforcement Cage

During concreting and pulling the casing, the reinforcement cage shall be secured against
uplift and the top shall be kept under close inspection.

E) Supervision

The execution of the pile concreting shall be supervised by a qualified person of the
Contractor's staff, who will keep records on the relation between quantity of concrete
used, level of concrete and withdrawal of casing.

4.1.3.9 Temporary Support

The Contractor shall ensure that free standing piles are temporarily braced or stayed
immediately after driving to prevent loosening of the piles in the ground and to ensure
that no damage resulting from oscillation, vibration or movement of any free-standing
pile length can occur.

4.1.3.10 Records

The Contractor shall keep records as indicated below for the installation of each pile and
shall submit two signed copies of these records to the Engineer not later than noon of the
next working day after the pile was installed. The signed records shall form a record of
the work. The following data are required:

a) Pile location
b) Pile reference number
c) Pile type
d) Nominal cross-sectional dimensions or diameter
e) Date and time of boring
f) Date and time of concreting
g) River bed level at commencement of installation of pile
h) Working level
i) Pile toe level
j) River water levels
k) Pile head level
l) Length of temporary casing
m)Length of permanent casing
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DIVISION 4 - FOUNDATION WORK

n) Soils samples taken and in situ tests carried out

o) Standing water level
p) Length and details of reinforcement
q) Concrete mix
r) Volume of concrete supplied to pile and corresponding levels of concrete and casings
s) All information regarding obstructions, delays and other interruptions to the sequence
of work.

4.1.3.11 Measures in Case of Rejected Piles

If any pile is found unsatisfactory in the opinion of the Engineer for utilization in the
structure, it shall be cut off below the pile cap if so ordered by the Engineer. The pile
shall be replaced as directed by the Engineer.

When the safe bearing value of any pile is found by test to be less than the design load,
longer piles or additional piles shall be installed as ordered by the Engineer.

4.1.4 Measurement
The unit of measurement for bored cast in place piling shall be the linear metre of pile
constructed and accepted in the structure. The payable lengths of the satisfactory bored
piles shall be measured from the toe level to cut off 100 mm above the bottom level of
pile cap. Pile permanent steel casing shall be measured separately in linear metres of the
installed and accepted length of casing. Reinforcement steel shall be measured in
accordance with Specifications Section 5.2.4.

4.1.5 Payment
Bored piles shall be paid for at the Contract unit price per linear metre. The rate shall
constitute full compensation for all materials including temporary casings & concrete and
integrity testing of pile (The integrity test shall be done as per Clause no 4.3.7), but
excluding reinforcement steel and Permanent Steel Casing, which items will be paid for
separately. The rate shall also include boring equipment, standard penetration testing,
split spoon sampling, boring, excavation, concreting, inspection and control, cutting off,
welding, coupling and all related tools, rigs, cranes, jets, frames, leads, labour, and other
incidental equipment and work necessary to complete the work.

Payment for bored cast in place pilot piles (see Section 4.4.1.2(e) for definition of pilot
pile), completed and accepted, shall be made at the Contract unit price per linear metre for
providing piles of the size specified. When pilot piles are incorporated in the foundation
as working piles, no additional payment shall be made for the piles.

Payment for reinforcement steel shall be at the Contractor’s rates per tonne for mild steel
and high yield deformed steel bars.

Payment for Pile Permanent Steel Casing shall be at the Contract unit price per linear
metre. The rate shall constitute full compensation for all materials, labour and plant

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DIVISION 4 - FOUNDATION WORK

necessary for providing and installing the casing, including all jointing, testing and
coatings.

No payment shall be made for unauthorized, defective, unsound or unsatisfactorily piles

or for any costs incurred by the Contractor for such piles.

Payment for testing of piles shall be made separately, as detailed in Section 4.4.

Pay items shall be:

04/01/01(a) Bored Cast in Place Piles (Dia 400mm) Linear Metre

04/01/01(b) Bored Cast in Place Piles (Dia 600mm) Linear Metre

04/01/01(c) Bored Cast in Place Piles (Dia 750mm) Linear Metre

04/01/01(d) Bored Cast in Place Piles (Dia 900mm) Linear Metre

04/01/01(e) Bored Cast in Place Piles (Dia 1000mm) Linear Metre

04/01/01(f) Bored Cast in Place Piles (Dia 1200mm) Linear Metre

04/01/01(g) Bored Cast in Place Piles (Dia 1500mm) Linear Metre

04/01/01(h) Bored Cast in Place Piles (Dia 2000mm) Linear Metre

04/01/01(i) Bored Cast in Place Piles (Dia 2500mm) Linear Metre

04/01/01(j) Boring by PERCUSSION METHOD using Direct Linear Metre

Mud Circulation (DMC) or Bailer and Chisel
technique by tripod and mechanical winch machine
(Dia 400, 600, 750 & 900 mm)

04/01/01(k) Boring by Skid Mounted Mechanical Table Drive Linear Metre

Rotary Boring/ Spindle Type Rotary Drilling
Machine. (Dia 900, 1000 & 1200 mm)

04/01/01(l) Boring by HYDRAULIC ROTARY METHOD Linear Metre

using Crawler mounted, telescopic boom hydraulic
piling rig. (Dia 900, 1000, 1200, 1500, 1800, 2000
& 2500 mm)

04/01/01(m) Driven Cast-in-Situ vertical R.C.C. pile of specified Linear Metre

diameter and length (length to be measured from
the bottom of pile cap to the bottom of shoe), to
carry safe working load not less than specified,
including cost shoe & all other materials and labour
for casting, hoisting, driving etc. and also including
cost of dummy lengths of pile and of hire charges

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DIVISION 4 - FOUNDATION WORK

of all instruments as necessary but excluding

concrete & reinforcement etc. all complete as per
drawing, specification and direction of Engineer-in-
Charge. (Dia 400, 600, 750, 900, 1000, 1200 &
1500 mm)

04/01/03 Mild Steel Reinforcing Bars Tonne

04/01/04 High Yield Deformed Steel Reinforcing Bars Tonne

04/01/05(a) Permanent Steel Casing (6mm thick, dia 400mm) Linear Metre

04/01/05(b) Permanent Steel Casing (6mm thick, dia 600mm) Linear Metre

04/01/05(c) Permanent Steel Casing (6mm thick, dia 750mm) Linear Metre

04/01/05(d) Permanent Steel Casing (10mm thick, dia 600mm) Linear Metre

04/01/05(e) Permanent Steel Casing (10mm thick, dia 750mm) Linear Metre

04/01/05(f) Permanent Steel Casing (10mm thick, dia 900mm) Linear Metre

04/01/05(g) Permanent Steel Casing (10mm thick, dia 1000mm) Linear Metre

04/01/05(h) Permanent Steel Casing (10mm thick, dia 1200mm) Linear Metre

04/01/05(i) Permanent Steel Casing (12mm thick, dia 1500mm) Linear Metre

04/01/05(j) Permanent Steel Casing (16mm thick, dia 2000mm) Linear Metre

04/01/05(k) Permanent Steel Casing (20mm thick, dia 2500mm) Linear Metre

4.2 PRECAST CONCRETE DRIVEN PILES

4.2.1 Description
This work shall consist of precast reinforced or prestressed concrete piles furnished and
driven in accordance with these Specifications and in conformity with the requirements
shown on the Drawings or elsewhere in the Contract Documents.

The type and sizes of piling to be used shall be as indicated on the Drawings. Where
precast concrete driven piles have been used for the design, the Engineer shall consider
and may give approval for the use of alternative types of piling proposed by the
Contractor. The Contractor in submitting an alternative type of pile shall provide design
data, piling experience records and calculations supporting the pile design and any
variations in the substructure.

4.2.2 Materials
4.2.2.1 Concrete

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DIVISION 4 - FOUNDATION WORK

Precast concrete piles shall be constructed in accordance with the details shown on the
Drawings, and of the concrete class, proportions, method of mixing and placing in
accordance with the provisions of Section 5.1. Concrete class shall be minimum 30, and
all cement used shall be type 1 (Sulphate resistant cement shall be used for saline area)
and concrete shall contain not less than 350 kg of cement per m3.

Any face of a pile shall not deviate by more than 6 mm from a straight edge 3 metres long
laid on the face, and the centroid of any cross section of the pile shall not deviate by more
than 1/1,000 of the length of the pile from the straight line connecting the centroids of the
end faces of the pile.

4.2.2.2 Formwork

The formwork for square precast concrete piles shall conform to the general requirement for
concrete formwork as described in Section 5.1.

The head of each square pile shall be square to the longitudinal axis. The corners of the head and
the corners of the pile shaft for a distance of 300 mm from the head shall be chamfered 25 mm x
25 mm.

4.2.2.3 Prestressing Steel

All prestressing steel shall comply with the general provisions of Section 5.3. All prestressing
tendons shall comply with the details shown on the Drawing as to the quality, size, position and
prestressing force introduced to the pile.

4.2.2.4 Reinforcement

Reinforcement steel shall be in accordance with the provisions set out in Specifications
Section 5.2 and positioned as shown on the Drawings.

4.2.3 Production of Piles

4.2.3.1 Casting

Piles shall be cast in a horizontal position. Special care shall be taken to place the
concrete so as to produce a pile free from any air pockets, honeycombing or other defect.

Concrete shall be placed continuously and shall be compacted by vibrating or by other

means satisfactory to the Engineer. The forms shall be slightly overfilled, the surplus
concrete screeded off, and the top surfaces finished to a uniform, even texture similar to
that produced by the forms.

Piles may only be constructed in separate shorter elements with the approval of the
Engineer. Joints made after casting and/or stressing shall be at least as strong as the piles
themselves in every respect.

4.2.3.2 Tensioning Procedure (Prestressed Piles Only)

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DIVISION 4 - FOUNDATION WORK

Tensioning shall be carried out only in the presence of the Engineer, or his representative,
unless otherwise approved in writing.

As used here the word “tendon” shall be defined as any single prestressing element used
to apply prestressed forces to the concrete. For pretensioning this shall be each strand or
straight wire.

All tendons to be stressed in a group shall be brought to a uniform tension of

approximately 500 kilograms per tendon prior to being given their full tension. After this
initial stressing the group shall be stressed to a total tension as required on the Drawings
by means of hydraulic jacks or other approved appliances equipped with gauges
graduated to read directly to 1% of the total load applied, and calibrated to measure
accurately the stress induced in the steel. This induced stress shall be measured by
elongation of the tendons and checked by gauge pressure. The results obtained shall be
within 5% of each other.

Means shall be provided for measuring the elongation to an accuracy of one millimetre in
twenty metres of length between jacking heads. In the event of apparent discrepancies of
more than five percent between stresses indicated by gauge pressure and elongation, the
entire operation shall be checked carefully and the source of error determined and
corrected before proceeding further.

Independent references shall be established adjacent to each anchorage to indicate any

yielding or slippage that may occur between the time of initial stressing and final release
of the tendons.

4.2.3.3 Curing

Curing of the concrete shall be commenced prior to the formation of surface shrinkage
cracks and as the concrete has hardened sufficiently to prevent injury. Curing shall
conform to the requirements of Section 5.1.

4.2.3.4 Release (Pretensioned Piles Only)

For precast pretensioned members the tendon stress shall be maintained between
anchorages until the concrete has reached a compressive strength equal to the “Transfer
Strength” specified on the Drawings. After strength requirements are attained, the tension
in the tendons shall be gradually and simultaneously released and the tendons cut off as
required in such a way as to prevent shock. It shall be the Contractor's responsibility to
transfer the prestress safely and to the Engineer's satisfaction in all respects.

A recess shall be cut at the ends of piles around each tendon to allow cutting off the
tendon and filling the recess with grout so that the cover to the end of the tendon is not
less than 20 mm.

4.2.3.5 Finishing

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

Piles shall present a true, smooth, even surface free from any surface blemishes and true to the
dimensions shown on the Drawings, within the tolerance limits.

4.2.3.6 Marking of Piles

After a pile has been cast, the date of casting, reference number, length and, where
appropriate, the prestressing force shall be clearly inscribed on the top surface of the pile
and also clearly and legibly marked on the head of the pile. In addition, each pile shall be
marked at intervals of 250 mm along the top 3 metres of its length before being driven.

4.2.3.7 Handling and Storage of Piles

The method and sequence of lifting, handling, transporting and storing piles shall be such
that the piles are not damaged. The lifting point of each size of pile shall be proposed by
the Contractor with supporting calculations for approval of the Engineer which verifies
the pile will not be damaged during lifting, handling, transporting and storage. During
transport and storage, piles shall be stored on adequate supports located under the lifting
points of the piles.

Concrete shall at no time be subjected to loading, including its own weight, which will
induce a compressive stress in it exceeding one third of its strength. For this purpose the
assessment of the strength of the concrete and of the stresses produced by the loads shall
be subject to the agreement of the Engineer.

All piles within a stack shall be in groups of the same length. Packings of uniform
thickness shall be provided between piles at the lifting points.

4.2.3.8 Spliced Piles

Where the Drawings do not detail any splices in piles, the Contractor may adopt spliced
piles provided details of the splicing method and drawings are submitted to the Engineer
for approval prior to the manufacture of the piles.

4.2.4 Driving Piles

4.2.4.1 Strength of Piles

Piles shall not be driven until the concrete has achieved the specified 28 day strength.

4.2.4.2 Leaders and Trestles

At all stages during driving and until incorporation in the superstructure, the pile shall be
adequately supported and restrained by means of leaders, or other guide arrangements to
maintain position and alignment and to prevent buckling. These arrangements shall be
such that damage to the pile does not occur. Leaders shall be of sufficient length to make
the use of followers unnecessary.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.2.4.3 Driving Equipment

Before any piling work is commenced the Contractor shall submit to the Engineer full
details of the pile driving equipment and the method he intends to use in carrying out the
work.

For special types of piling, driving head mandrels, or other devices in accordance with
requirements shall be provided so that piles may be driven without injury.

The driving equipment shall be of a type which assures that the energy needed to
penetrate the pile to the required depth is transmitted to the pile head without damaging
the pile. Efficiency factor of the hammer, i.e. the relation between the theoretical energy
developed by the hammer and the energy submitted to the pile, shall be minimum 0.7.

Piles shall be driven with hydraulic machines and/or steam, air, diesel or gravity
hammers. When diesel hammers are used, they shall be calibrated by load tests if
necessary.

When gravity hammers are used for driving concrete piles, the drop of the hammer shall
not exceed 1 metre and the hammer shall have a weight of not less than 80% of the
weight of the pile and the driving head. The fall shall be regulated so as to prevent injury
to the pile.

The minimum energy developed by other types of hammers shall be the same as specified
for gravity hammers.

4.2.4.4 Driving Procedure and Redrive Checks

Each pile shall be driven continuously until the specified or approved set and/or depth has
been reached, except that the Engineer may permit the suspension of driving if he is
satisfied that the rate of penetration prior to the cessation of driving will be substantially
re-established on its resumption or if he is satisfied that the suspension of driving is
beyond the control of the Contractor. A follower (long dolly) shall not be used.

The Contractor shall inform the Engineer without delay if an unexpected change in
driving characteristics is noted. A detailed record of the driving resistance over the full
length of the nearest available pile shall be taken if required.

At the start of work and in a new area or section, sets shall be taken at intervals during the
last 3 metres of the driving to establish the behaviour of the piles.

The Contractor shall give adequate notice and provide all facilities to enable the Engineer
to check driving resistances. A set shall be taken only in the presence of the Engineer
unless otherwise approved.

Redrive checks, if required, shall be carried out to an approved procedure.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.2.4.5 Final Set

The final set of each pile shall be recorded either as the penetration in millimetres per 10
blows or as the number of blows required to produce a penetration of 250 mm.

When a final set is being measured, the following requirements shall be met:

a) The exposed part of the pile shall be in good condition without damage or distortion.
b) The dolly and packing, if any, shall be in sound condition.
c) The hammer blow shall be in line with the pile axis and the impact surfaces shall be
flat and at right angles to the pile and hammer axis.
d) The hammer shall be in good condition and operating correctly.
e) The temporary compression of the pile shall be recorded if required.

4.2.4.6 Driving Sequence and Risen Piles

Piles shall be driven in an approved sequence to minimize the detrimental effects of heave
and lateral displacement of the ground.

When required, levels and measurements shall be taken to determine the movement of
either the ground or of any pile which results from the driving process.

When a pile has risen as a result of adjacent piles being driven, the Contractor shall
submit to the Engineer his proposals for correcting this and the avoidance of it in
subsequent work.

4.2.4.7 Jetting

Water jetting shall not be allowed. Continuous vibratory percussive methods shall be used
to drive a pile to both its design depth as well as the required set where the upper strata
afford high resistance to driving.

4.2.4.8 Length of Piles

The lengths of the piles shown on the Drawings are based on information which has been
obtained from a site investigation prior to the driving of test piles.

Before pile lengths are finally settled, the Contractor shall construct to the lengths shown
on the Drawings such pilot piles as may be found necessary and these piles shall be
driven in the positions specified by the Engineer who shall be notified in advance of the
driving. The Contractor shall furnish the Engineer daily with a detailed record of the pilot
piles for the full depth of driving. After attaining the approved set, driving shall be
continued until the Engineer directs that it shall cease. Length of working pile shall be
reviewed and determined based on load test of pilot piles or service piles, as directed by
the Engineer.

Reference is made to Section 4.4 with regard to load tests on selected pilot piles.

4.2.4.9 Repair or Damaged Pile Heads

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

When repairing the head of a pile, the head shall be cut off square at sound concrete, and
all loose particles shall be removed by wire brushing, followed by washing with water. If
the pile is to be subjected to further driving, the head shall be replaced with concrete of an
approved grade.

If the driving of a pile has been accepted but sound concrete of the pile is below the cut-
off level, the pile shall be made good to the cut-off level with concrete of a grade not
inferior to that of the concrete of the pile.

Repaired piles shall not be driven until the added concrete has reached the specified
characteristic strength of the concrete of the pile.

4.2.4.10 Cut off and Extension

Prestressed concrete piles shall be cut off at such elevation that they shall extend into the
cap or footing as indicated on the Drawings. In the case of hollow core piles starter bars
shall be cast into the core at the top of the piles and extended into the cap or footing, all as
shown on the Drawings. Extensions to prestressed concrete piles shall generally not be
permitted, unless a provision for lengthening prestressed piles was incorporated at the
time of manufacture. Any method for lengthening shall be such that joints are capable of
taking safely the stresses during driving and under load.

4.2.4.11 Damage to Adjacent Structures and Services

The Contractor will take all necessary precautions to avoid damage to any adjacent
structures and services. If during the execution of the work damage is, or is likely to be,
caused to any adjacent structures or services, the Contractor shall submit to the Engineer
his proposals for repair or avoidance of such damage.

4.2.4.12 Records

The Contractor shall keep records as indicated below of the installation of each pile and
shall submit two signed copies of these records to the Engineer not later than noon of the
next working day after the pile is installed. The signed records shall form a record of the
work.

The following data are required:

a) Pile location
b) Pile reference number
c) Pile type
d) Nominal cross-sectional dimensions or diameter
e) Length of preformed pile
f) Date and time of driving or redriving
g) Ground level at commencement of installation of pile
h) Working level
i) Pile toe level

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

j) Type, weight, drop and mechanical condition of hammer and equivalent information
for other equipment
k) Number and type of packing used and type and condition of dolly used during driving
the pile
l) Set of pile in mm per 10 blows or number of blows per 250 mm of penetration
m) If required, the sets taken at intervals during the last 3 metres of driving
n) If required, temporary compression of ground and pile from time of a marked increase
in driving resistance until pile reaches its final level
o) All information regarding obstructions delays and other interruptions to the sequence
of work

4.2.5 Tolerances

4.2.5.1 Setting Out

Setting out shall be carried out from the main grid lines of the proposed structure.
Before installation of the pile, the pile position shall be agreed with the Engineer and
marked with suitable identifiable pins or markers.

4.2.5.2 Position

For a pile cut off at or above ground level the maximum permitted deviation of the
pile centre from the centre point shown on the setting out drawing shall be 75 mm in any
direction. An additional tolerance for a pile head cut off below ground level shall be
permitted in accordance with Sections 4.2.5.3 and 4.2.5.4.

4.2.5.3 Verticality

The maximum permitted deviation of the finished pile from the vertical shall be 1 in
50.

4.2.5.4 Rake

The piling rig shall be set and maintained to attain the required rake. The maximum
permitted deviation of the finished pile from the specified rake shall be 1 in 25.

4.2.6 Defective Piles

The procedure of driving the piles shall not subject them to excessive and undue abuse
producing crushing and spalling of the concrete or deformation of the steel. Manipulation
of piles to force them into proper position, considered by the Engineer to be excessive,
shall not be permitted. Any pile damaged by reason of internal defects, or by improper
driving or driven out of its proper location or driven below the elevation fixed by the
plans or by the Engineer, shall be corrected at the Contractor’s expense by one of the
following methods approved by the Engineer for the pile in question:

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

1) The pile shall be withdrawn and replaced by a new and if necessary, a longer pile.

2) A second pile shall be driven adjacent to the defective or low pile.

3) The pile shall be spliced or built up as otherwise provided herein or a sufficient portion
of the footing extended to properly embed the pile.

4.2.7 Measurement

The unit of measurement shall be the linear metre of pile furnished, driven and accepted
in the structure. The pay lengths of the satisfactorily driven piles shall be measured from
the toe to the cut off.

Cut off lengths shall not be measured for payment.

Reinforcement steel shall be measured in accordance with Specifications Section 5.2.4.

4.2.8 Payment

Precast concrete driven piles shall be paid for at the Contract unit rate per linear metre.
The rate shall constitute full compensation for all materials but excluding reinforcement,
which shall be paid for separately. The rate shall also include all shoes, equipment,
hardware, formwork etc., driving, cutting off, lengthening and splicing, welding and
coupling and all related tools, rigs, cranes, boilers, hammers, leaders, labour and other
incidental equipment and work.

Payment for precast concrete driven pilot piles (see Section 4.4.1.2(e) for definition of
pilot pile), completed and accepted, shall be made at the Contract unit price per linear
metre for providing piles of the size specified. When pilot piles are incorporated in the
foundation as working piles, no additional payment shall be made for the piles.

Payment for reinforcement steel shall be at the Contractor’s rates per tonne for mild steel
and high yield deformed steel bars.

No payment shall be made for unauthorized, defective, unsound or unsatisfactorily driven

piles or for any costs incurred by the Contractor for such piles.

Payment for testing of piles shall be made separately, as detailed in Section 4.4.

Pay items shall be:

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

04/02/01(a) Driven Precast Piles (150mm X 150mm) Linear

Metre

04/02/01(b) Driven Precast Piles (200mm X 200mm) Linear

Metre

04/02/01(c) Driven Precast Piles (300mm X 300mm) Linear

Metre

04/02/01(d) Driven Precast Piles (350mm X 350mm) Linear

Metre

04/02/01(e) Driven Precast Piles (400mm X 400mm) Linear

Metre

04/02/01(f) Driven Precast spliced Piles (300mm X 300mm) Linear

Metre

04/02/01(g) Driven Precast spliced Piles (350mm X 350mm) Linear

Metre

04/02/01(h) Driven Precast spliced Piles (400mm X 400mm) Linear

Metre

Circular pile of dia 300mm, 400mm, 500mm and 600mm Linear

Metre

04/02/02 Driven Precast Pilot Piles (Dimensions as indicated on Linear

the Drawings and stated in the Bill of Quantities) Metre

04/02/03 Mild Steel Reinforcing Bars Tonne

04/02/04 High Yield Deformed Steel Reinforcing Bars Tonne

04/02/04 (b) Grade 60 (420 MPa) Deformed Steel Reinforcing Bars Tonne

04/02/04 (c) Grade 80 (550 MPa) Deformed Steel Reinforcing Bars Tonne

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.3 PRECAST CONCRETE UNITS FOR RIVER TRAINING AND

RETAINING STRUCTURES

4.3.1 Description

This work shall consist of furnishing and placing all precast members of retaining and river
training structures and anchor arrangements, all in accordance with these Specifications and
in conformity with the requirements on the Drawings or of other parts of the Contract
Documents.

The precast structures consist essentially of precast and driven “I” shaped concrete piles
(King Posts) laterally supporting precast concrete planks. The king posts may be laterally
anchored through tie bars to raker piles.

4.3.2 Materials

The king posts and raker piles shall conform to the requirements of Section 4.2.2.

The precast concrete planks shall be constructed in accordance with the details shown on
the Drawings, and in accordance with Sections 5.1 and 5.2. Cement used shall be type 1.

4.3.3 Construction Methods

4.3.3.1 King Post & Anchor Piles

All production and construction methods for king posts and anchor piles shall conform to
Sections 4.2.3 and 4.2.4 except that load testing shall not normally be required.

4.3.3.2 Precast Planks

The precast planks shall be placed between the king posts as shown on the Drawings. The
planks shall be excavated or driven down to the levels indicated on the Drawings or as
otherwise directed. In this connection it may be necessary to clear up the bed to the
prescribed level and make local excavations along the planks as they are lowered. The
method of placing the planks shall be agreed with the Engineer .

4.3.4 Tolerances
The horizontal position of the king posts after being driven shall not deviate from the
correct position more than +10 mm perpendicular to the line of the wall and +10 mm in the
direction of the wall. The precast planks in between the piles are designed to allow for a
longitudinal tolerance of king post position of +10 mm. If the Contractor during
construction establishes that the above tolerance is too small, the Engineer may accept
minor changes in the tolerance. Such changes will require corresponding changes in plank
sizes.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.3.5 Measurement
King posts shall be measured by linear meter in accordance with Section 4.2.7. No
distinction shall be made for different sizes or shapes of king posts which shall be as
shown on the Drawings.

Precast planks shall be measured by square meter of plank used.

Raker piles shall be measured by cubic metre in accordance with Section 4.2.7. No
distinction shall be made for different sizes or rakes of raker piles which shall be as
shown on the Drawings. Tie bars shall not be measured separately but are deemed
included in the rate for raker piles.

Reinforcement steel in king posts and raker piles shall be measured in accordance with
Specifications Section 5.2.4. Reinforcement steel in precast planks shall not be measured
separately.

4.3.6 Payment
The Contractor’s rates for king posts and raker piles will constitute full compensation for
the supply of all materials excluding reinforcement steel, which shall be paid for
separately. The rates shall also include handling, placing and all other related works.

The Contractor’s rate for precast planks will constitute full compensation for the supply
of all materials including reinforcement steel, handling, placing, driving of raker piles and
all other related works.

Stone protection, if required, will be measured and paid for separately in accordance with
Section 6.

Pay items shall be:

04/03/01 King Post Cubic Metre

04/03/02 Raker Piles (including Tie Bars) Cubic Metre

04/03/03 Precast Planks (including Reinforcement Steel) Square Metre

04/03/04 Mild Steel Reinforcing Bars to King Posts and Raker Tonne
Piles

04/03/05 High Yield Deformed Steel Reinforcing Bars to King Tonne

Posts and Raker Piles

4.3.7 PILE INTEGRITY TEST

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.3.7.1 Description

Pile Integrity test is to be performed by the Procuring Entity through BRRL or Bridge
unit Professionals or any reputed organization appointed by the Engineer on a number of
constructed working piles at the location of each abutment and pier position of a structure
to verify the integrity of the installed piles. The apparatus for the Integrity Test shall be
selected and arranged by the testing organization. Tests shall be carried out only under the
direction of experienced and competent professionals conversant with the test equipment
and test procedure.

4.3.7.2 Test procedure

All piles are to be selected for testing. With the permission from the Design unit selected
piles can be tested. The contractor shall provide detailed records as recorded during
installation of each pile which is to be tested. The contractor shall cut down all pile heads
at the cut off level or otherwise prepare the piles for testing as required by the Engineer.
The pile head shall be formed to give plane surface which is normal to the axis of the pile.
The reinforcement of the pile shall be bent in such a way to ease the testing.

4.3.7.3 Results of Testing

Pile Integrity test or sonic test is a quick method to check the continuity of pile shape and
size up to desired level. This method detects pile defects like cracks, Breaking, Necking,
soil intrusion and variation of pile shape. The final length can also be measured
indirectly. If any pile after Integrity test is found unsatisfactory in the opinion of the
Engineer for utilization in the structure, the pile shall be replaced as suggested by the
design unit and directed by the Engineer/Project Manager. All extra expanses shall be
borne by the contractor and payment shall be made in accordance with clause 4.1.3.11 of
these specifications.

4.3.7.4 Measurement

The unit of measurement shall be number of pile tested.

4.3.7.5 Payment

The test performed in the number of piles shall be paid for at the rate charged by the
approved testing organization. The rate shall constitute full compensation for all
materials, equipments and labour for test purpose. The payment shall be made by the
contractor to the test performer and the amount shall be reimbursed to the contractor by
the procuring Entity from the provisional sum as indicated in the bill of quantities.

The bill for integrity test shall not be paid separately to the contractor because it is
already included in the item number 4.1.5.

Pay items shall be:

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

PIT on 10 (ten) nos. piles or less of a single bridge Set

Additional charge on Mobilization & demobilization Per km

beyond 100 km of Dhaka / nearby source to site

PIT on each additional pile after 10(ten) piles tested Each

4.4 PILE TEST LOADING

4.4.1 Descriptions

4.4.1.1 General

This Section deals with the testing of a pile by the application of an axial load or force. It
covers vertical piles tested in compression.

4.4.1.2 Definitions

A) Allowable Load

The load which may be safely applied to a pile after taking into account its ultimate
bearing capacity, negative friction, pile spacing, overall bearing capacity of the ground
below and allowable settlement.

B) Compression Pile

A pile which is designed to resist an axial force such as would cause it to penetrate further
into the ground.

C) Kentledge

The dead weight used in a loading test.

D) Maintained Load Test

A loading test in which each increment of load is held constant either for a defined period
of time or until the rate of movement (settlement or uplift) falls to a specified value.

E) Pilot Pile

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

A pile installed before the commencement of the main piling works or a specific part of
the works for the purpose of establishing the suitability of the chosen type of pile and for
confirming its design, dimensions and bearing capacity. Pilot piles may be utilized as
working piles, subject to the Engineer’s approval.

F) Proof Load

A load applied to a selected pile to confirm that it is suitable for the load at the settlement
specified. A proof load should not normally exceed 200% of the working load on a pile
except in circumstances where Special Provisions are provided for the testing of precast
piles driven to a set. In these circumstances, 300% is specified.

G) Reaction System

The arrangement of kentledge, piles, anchors or rafts that provides a resistance against
which the pile is tested.

H) Tension Pile

A pile which is designed to resist an axial force such as would cause it to be extracted
from the ground.

I) Test Pile

Any pile to which a test loading is, or is to be, applied.

J) Ultimate Bearing Capacity

The load at which the resistance of the soil becomes fully mobilized.

K) Working Load

The load which the pile is designed to carry.

L) Working Pile

One of the piles forming the foundation of a structure.

M) Dynamic Load

4.4.2 Supervision
All tests shall be carried out only under the direction of an experienced and competent
supervisor conversant with the test equipment and test procedure. All personnel operating
the test equipment shall have been trained in its use.

4.4.3 Safety Precautions

4.4.3.1 General
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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

When preparing for, conducting and dismantling a pile test the Contractor shall carry out
the requirement of the various regulations and other statutory instruments that are
applicable to the work for the provision and maintenance of safe working conditions, and
shall in addition make such other provision as may be necessary to safeguard against any
hazards that are involved in the testing or preparations for testing.

4.4.3.2 Kentledge

Where kentledge is used the Contractor shall construct the foundations for the kentledge
and any cribwork, beams or other supporting structure in such a manner that there will not
be differential settlement, bending or deflection of an amount that constitutes a hazard to
safety or impairs the efficiency of the operation. The kentledge shall be adequately
bonded, tied or otherwise held together to prevent it falling apart, or becoming unstable
because of deflection of the supports.

The weight of kentledge shall be greater than the maximum test load and if the weight is
estimated from the density and volume of the constituent materials an adequate factor of
safety against error shall be allowed.

4.4.3.3 Tension Piles and Ground Anchors

Where tension piles or ground anchors are used the Contractor shall ensure that the load is
correctly transmitted to all the tie rods or bolts. The extension of rods by welding shall not
be permitted unless it is known that the steel will not be reduced in strength by welding.
The bond stresses of the rods in tension shall not exceed normal permissible bond stresses
for the type of steel and grade of concrete used.

4.4.3.4 Testing Equipment

In all cases the Contractor shall ensure that when the hydraulic jack and load measuring
device are mounted on the pile head the whole system shall be stable up to the maximum
load to be applied. Means shall be provided to enable dial gauges to be read from a
position clear of the kentledge stack or test frame so that failure in any part of the system
due to overloading, buckling, loss of hydraulic pressure will not constitute a hazard to
personnel.

The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated
under hydraulic pressure shall be capable of withstanding a test pressure of 1.5 times the
maximum working pressure without leaking.

The maximum test load or test pressure expressed as a reading on the gauge in use shall be
displayed and all operators shall be made aware of this limit.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.4.4 Construction of a Pilot Pile to be Test Loaded

4.4.4.1 Notice of Construction

The Contractor shall give the Engineer at least 48 hours notice of the commencement of
construction of any pilot pile, which is to be test loaded.

4.4.4.2 Method of Construction

Each pilot test pile shall be constructed in a manner similar to that to be used for the
construction of the working piles, and by the use of similar equipment and materials. Any
variation shall only be permitted with prior approval.

Extra reinforcement and concrete of increased strength shall be permitted in the shafts of
pilot piles at the discretion of the Engineer.

4.4.4.3 Boring or Driving Record

For each pilot pile which is to be tested a detailed record of the soils encountered during
boring, or of the progress during driving shall be made and submitted to the Engineer daily
not later than noon on the next working day.

4.4.4.4 Cut-Off Level

The pile shaft shall terminate at the normal cut-off level, or at a level required by the
Engineer.

The pile shaft shall be extended where necessary above the cut-off level of working piles
so that gauges and other apparatus to be used in the testing process are not damaged by
water or falling debris.

4.4.4.5 Pile Head for Compression Tests

For a pile that is tested in compression, the pile head or cap shall be formed to give a plane
surface which is normal to the axis of the pile, sufficiently large to accommodate the
loading and settlement-measuring equipment and adequately reinforced or protected to
prevent damage from the concentrated application of load from the loading equipment .

4.4.5 Preparation of a Working Pile to be tested

If a test is required on a working pile the Contractor shall cut down or otherwise prepare
the pile for testing as required by the Engineer in accordance with Sections 4.4.4.4 and
4.4.4.5.

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DIVISION 4 - FOUNDATION WORK

4.4.6 Reaction Systems

4.4.6.1 Compression Tests

Compression tests shall be carried out using kentledge, tension piles or specially
constructed anchorages.

Where kentledge is to be used, it shall be supported on cribwork disposed around the pile
head so that its centre of gravity is on the axis of the pile. The bearing pressure under
supporting cribs shall be such as to ensure stability of the kentledge stack. Kentledge shall
not be carried directly on the pile head, except when directed by the Engineer.

4.4.6.2 Working Piles

Where working piles are used as reaction piles their movement shall be measured to within
an accuracy of 0.5 mm.

4.4.6.3 Spacing

Where kentledge is used for loading vertical piles in compression, the distance from the
edge of the test pile to the nearest part of the crib supporting the kentledge stack in contact
with the ground shall be not less than 1.3 metres.

The centre to centre spacing of vertical reaction piles, including working piles used as
reaction piles, from a test pile shall be not less than three times the diameter of the test pile
or the reaction piles or 2 metres, whichever is the greatest.

4.4.6.4 Adequate Reaction

The size, length and number of the piles or anchors, or the area of the rafts, shall be
adequate to transmit the maximum test load to the ground in a safe manner without
excessive movement or influence on the test pile.

4.4.6.5 Care of Piles

The method employed in the installation of any reaction piles, anchors or rafts shall be
such as to prevent damage to any test pile or working pile.

4.4.6.6 Loading Arrangement

The loading arrangement used shall be designed to transfer safely to the test pile the
maximum load required in testing. Full details shall be submitted to the Engineer prior to
any work related to the testing process being carried out on the Site.

4.4.7 Equipment for Applying Load

The equipment used for applying load shall consist of one or more hydraulic rams or jacks
with the total capacity of the jacks being at least equal to the required maximum load. The
jack or jacks shall be arranged in conjunction with the reaction system to deliver an axial

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load to the test pile. The complete system shall be capable of transferring the maximum
load required for the test.

4.4.8 Measurement of Load

Suitable approved measuring devices for determining the load on the pile shall be supplied
by the Contractor. Certificates of calibration shall be supplied to the Engineer.

In addition, large diameter (i.e. exceeding 1.2 metre) test piles shall be instrumented at 5
different depths to measure the load distribution along the piles. The instrumentation shall
consist of both a mechanical system and strain gauges for measuring the pile deformation.
The mechanical system shall consist of 6 mm steel rods or high tensile steel wires gauge
No. 23, placed in steel tubes down to the various depths, and connected to dial gauges at
the top. The strain gauges shall be of a stable type, wholly protected by a steel capsule.
They shall be welded to the steel reinforcement, 2 gauges at each depth.

The Engineer shall approve the type of gauges to be used and other details on the
instrumentation.

4.4.9 Adjustability of Loading Equipment

The loading equipment shall be capable of adjustment throughout the test to obtain a
smooth increase of load or to maintain each load constant at the required stages of a
maintained loading test.

4.4.10 Measuring Movement of Pile Heads

4.4.10.1 General

In a maintained load test movement of the pile head shall be measured by two of the
methods as described below. One method for settlement measurements, the other method
for control.

4.4.10.2 Levelling Method

An optical or any other leveling method by reference to an external datum may be used.

Where a level and staff are used, the level and scale of the staff shall be chosen to enable
readings to be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile
cap may be used instead of a leveling staff. At least two datum points shall be established
on permanent objects or other well-founded structures, or deep datum points shall be
installed. Each datum point shall be situated so that only one setting up of the level is
needed.

No datum point shall be affected by the test loading or other operations on the site.

Where another method of leveling is proposed this shall be approved in writing.

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4.4.10.3 Independent Reference Frame

An independent reference frame may be set up to permit measurement of the movement of

the pile. The supports for the frame shall be founded in such a manner and at such a
distance from the test pile, kentledge support cribs, reaction piles, anchorages and rafts
that movements of the ground in the vicinity of the equipment do not cause movement of
the reference frame during the testing. Check observations of any movements of the
reference frame shall be made and a check shall be made of the movement of the pile head
relative to an external datum during the progress of the test. In no case shall the supports
be less than three test pile diameters or 2 metres, whichever is the greater, from the centre
of the test pile.

The measurement of pile movement shall be made by two dial gauges rigidly mounted on
the reference frame that bear on surfaces normal to the pile axis fixed to the pile cap or
head. Alternatively the gauges may be fixed to the pile and bear on surfaces on the
reference frame. The dial gauges shall be placed in diametrically opposed positions and be
equidistant from the pile axis. The dial gauges shall enable readings to be made to within
an accuracy of 0.1 mm.

The reference frames shall be protected from sun and wind.

4.4.10.4 Other Methods

The Contractor may submit for approval any other method for measuring the movement of
pile heads.

4.4.11 Protection of Testing Equipment

4.4.11.1 Protection from Weather

Throughout the test period all equipment for measuring load and movement shall be
protected from the weather.

4.4.11.2 Prevention of Disturbance

Construction equipment and persons who are not involved in the testing process shall be
kept at a sufficient distance from the test to avoid disturbance to the measurement
apparatus.

4.4.12 Supervision

4.4.12.1 Notice of Test

The Contractor shall give the Engineer at least 24 hours notice of the commencement of
the test.

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4.4.12.2 Records

During the progress of a test, the testing equipment and all records of the test as required
in Section 4.4.14.2 shall be available for inspection by the Engineer.

4.4.13 Test Procedure

4.4.13.1 Proof Test by Maintained Load Test

The maximum load, which shall be applied in a proof test, is shown on the Drawings. The
loading and unloading shall be carried out in stages as shown in Table 4.4-1 or as required
by the Engineer.

Following each application of an increment of load the load shall be held for not less than
the period shown in Table 4.4-1 or until the rate of settlement is less than 0.25 mm/hour
and is slowing down. The rate of settlement shall be calculated from the slope of the curve
obtained by plotting values of settlement versus time and drawing a smooth curve through
the points.

Each stage of unloading shall proceed after expiry of period shown in Table 4.4-1.

For any period when the load is constant, time and settlement shall be recorded
immediately on reaching the load and at approximately 15 minute intervals for 1 hour, at
30 minute intervals between 1 hour and 4 hours, and at 1 hour intervals between 4 hours
and 12 hours after the application of the increment of load.

The Engineer may require that the full loading, or any portion of the loading, be
maintained on the pile for periods longer than shown in Table 4.4-1.

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Table 4.4-1

Loading Sequence

Load as Percentage of Working Load Minimum Time of

Bored Piles Driven Piles Holding Load

25 50 1 hour

50 100 1 hour

75 125 1 hour

100 150 1 hour

75 125 10 minutes

50 100 10 minutes

25 50 10 minutes

0 0 1 hour

100 150 6 hours

125 200 1 hour

150 250 6 hours

175 275 1 hour

200 300 24 hours Proof

Load

175 275 10 minutes

150 250 10 minutes

125 225 10 minutes

100 200 10 minutes

75 150 10 minutes

50 100 10 minutes

25 50 10 minutes

0 0 1 hour

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4.4.14 Presentation of Results

4.4.14.1 Results to be submitted

Results shall be submitted as:

a) A summary in writing to the Engineer, unless otherwise directed, within 24 hours of

the completion of the test, which shall give for a proof test by maintained load for each
stage of loading, the period for which the load was held, the load and the maximum
settlement or uplift recorded.

b) The completed schedule of recorded data as in Section 4.4.14.2 within seven days of
the completion of the test.

4.4.14.2 Schedule of Recorded Data

The Contractor shall provide information about the tested pile in accordance with the
following schedule where applicable.

A) General

1) Site location
2) Contract identification
3) Proposed structure
4) Date of test

B) Pile Details

1) Identification (number and location of the test pile)

2) Ground level at pile position
3) Head level as which test load is applied
4) Type of pile
5) Length in ground
6) Level in ground
7) Level of toe
8) Details of Permanent casing

C) Installation Details

1) Dates and times of boring, driving and concreting of test pile and adjacent piles
2) Date and time of casting concrete
3) Driven length of pile or temporary casing at final set
4) Hammer type, size or weight
5) Dolly and packing, type and condition before and after driving
6) Driving log (depth, blows per 250 mm, interruptions or breaks in driving)
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7) At final set and at redrive set, for drop or single acting hammers, the length of the drop
or stroke, for diesel hammers the length of the stroke and the blows per minutes, for
double-acting hammers the number of blows per minute
8) Condition of pile head or temporary casing after driving

D) Test Procedure

1) Weight of kentledge
2) Tension pile, ground anchor or compression pile details
3) Plan of test arrangement showing position and distances of kentledge supports, rafts,
tension or compression piles and reference frame to test pile
4) Jack capacity
5) Method of Load measurement
6) Method(s) of penetration measurement
7) Relevant dates and times

E) Test Results

1) In tabular form
2) In graphical form: loads plotted against movements and time

4.4.15 Completion of a Test

4.4.15.1 Measuring Equipment

On completion of a test all equipment and measuring devices shall be dismantled,

checked and either stored so that they are available for use in further tests or removed
from the Site.

4.4.15.2 Kentledge

Kentledge and its supporting structure shall be removed from the test pile and stored so
that they are available for use in further tests or removed from the Site.

4.4.15.3 Temporary Piles

On completion of a preliminary test, temporary tension piles shall be cut off below
ground level, removed from the Site and the ground made good with approved material as
specified.

4.4.16 Lateral Load Test

Performing Lateral load test for test load of 1.5 times of the working lateral load in
accordance with ASTM D 3966 (Standard Test Methods for Deep Foundations under
Lateral Load) on working pile including the cost of arranging kenteldge, jacks, platform,
reaction frame with required anchorage, island where required, preparing the pile head if
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DIVISION 4 - FOUNDATION WORK

necessary, dial gauges, joist and all other necessary arrangement, loading and unloading,
submission of the result, removal of all arrangement after completion, cost of all labour,
material, carriage, leads and lift etc. complete as per approved drawing, Technical
specification and as directed by the Engineer-in-charge.

Before commencing load test, Contractor shall submit methodology for conducting load
test to the E-I-C for approval. The Testing firm will be selected taking prior approval of
procuring entity. The methodology of lateral load test and driving logs/ boring & pouring
logs shall be the part of test report. Lateral Load Test and Report shall be conducted
under the supervision of personnel from BRRL or a professional Geotechnical Engineer
registered in the Bangladesh Professional Engineers Registration Board (BPERB),
Institute of Engineers Bangladesh (IEB)

4.4.17 Measurement and Payment

Load tests on large diameter (i.e. exceeding 1.2 metre) cast in place bored piles shall normally be
carried out on working piles using other working piles as anchor piles. The test pile and
anchor piles will be paid for at the normal rates for working piles as provided in Section
4.1. Separate payments will be made for carrying out each load test, individual rates shall
be provided for different proof loads, which are specified in the Bill of Quantities.
Payment for load tests on large diameter cast in place bored piles shall include provision
of special instrumentation to test piles, anchor bars to reaction piles, provision of all
testing equipment, carrying out of the tests, dismantling of equipment and removal from
site, breaking out pile heads etc. in accordance with the requirements for working piles,
preparation of all reports etc.

Load tests on pilot driven piles shall normally be carried out using temporary anchor piles
or kentledge. The pilot pile will be paid for at the rates provided for pilot piles in Section
4.2. Separate payment shall not be made for anchor piles. Separate payments will be made
for carrying out each load test and individual rates shall be provided for different proof
loads, which are specified in the Bill of Quantities. Payment for load tests on pilot driven
piles shall include provision of anchor piles or kentledge, provision of all test equipment,
carrying out of the tests, dismantling of equipment and removal from site, cutting off
below level of temporary anchor piles, preparation of all reports etc.

Load tests on pilot cast in place piles, less than 1.2 metre diameter, shall normally be
carried out using temporary anchor piles or kentledge. The pilot pile will be paid for at the
rates provided for pilot piles in Section 4.1. Separate payment shall not be made for
anchor piles. Separate payments will be made for carrying out each load test and
individual rates shall be provided for different proof loads, which are specified in the Bill
of Quantities. Payment for load tests on pilot piles shall include provision of anchor piles
or kentledge, provision of all test equipment, carrying out of the tests, dismantling of
equipment and removal from site, cutting off below level of temporary anchor piles,
preparation of all reports etc.

Pay items shall be:

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DIVISION 4 - FOUNDATION WORK

04/04/01(a) Load Test on Cast in Place Working Pile (Proof load Number
to be specified in BoQ) 50 Ton

04/04/01(b) Load Test on Cast in Place Working Pile (For 100 Number
Ton)

04/04/01(c) Load Test on Cast in Place Working Pile (For 200 Number
Ton)

04/04/01(d) Load Test on Cast in Place Working Pile (As Number

specified in Drawings & BoQ)

04/04/02 Load Test on Cast in Place Pilot Pile (Proof load to Number
be specified in BoQ)

04/04/03 Load Test on Pilot Driven Pile (Proof load to be Number

specified in BoQ)

04/04/04 Lateral Load Test

04/04/04(a) Lateral Load Test (Up to 50 MT capacity pile) Number

04/04/04(b) Lateral Load Test (Above 50 MT capacity pile) Number

4.5 BITUMEN SLIP LAYER FOR PILES

4.5.1 Description

This work shall consist of a bitumen slip layer placed on the upper part of concrete piles
before driving.

Bitumen slip layer is provisional, and shall be used only if directed by the Engineer. The
use of a slip layer to reduce negative skin friction on the piles will be evaluated after
completion of pile load tests.

The bitumen layer shall be used on the upper part of the pile through soft and medium
stiff clay. Any shorter length may be decided by the Engineer. This part of the pile shall
be primed and uniformly coated with a bituminous material as specified below. No
priming or coating shall be allowed below the designated elevation of the installed pile.

4.5.2 Materials

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4.5.2.1 Primer

Before priming, the pile shall be completely clean and dry. The primer shall consist of the
relevant bitumen for the slip layer and a petroleum solvent, or RC 250 as decided by the
Engineer. The bitumen and the solvent shall be suitably blended to produce a liquid
coating which may be applied cold, and which produces a suitable bond between the pile
surface and the asphalt enamel. The primer shall have good spraying, brushing and
leveling properties and a minimum tendency to produce bubbles during application. It
shall be homogeneous and free from water.

The amount of primer shall be 0.2 litre/m2, applied with brushing or spraying to achieve a
uniform continuous film.

The primer shall be allowed to set thoroughly, for minimum 6 hours or more as needed,
before the slip layer is applied.

4.5.2.2 Bitumen

The bitumen slip layer shall consist of a straight run bitumen, penetration grade 80-100.

The bitumen shall be heated to a liquid state, which is approximately 200°C, and applied
by brushing or other approved means. The thickness shall be minimum 3 mm.

Special measures such as wrapping sprayed surfaces with suitable paper or plastic sheet
shall be taken to prevent the bitumen from flowing and stripping and from damage during
handling and storage. During storage the piles shall be protected from sun-heat, and if
necessary cooled with spraying of water.

4.5.3 Field Storage and Installation

Precautions shall be taken to prevent damage to the bitumen slip layer during installation
as deemed necessary by the Engineer.

Piles shall not be placed directly on the ground: wood sleepers shall always be used. The
sleepers shall be placed beneath the uncoated end parts. When lifting piles the wire rope
should not be in direct contact with the bitumen slip layer.

4.5.4 Measurement
The unit of measurement shall be square meters of pile covered by bitumen slip layer and
accepted by the Engineer. Cut off lengths shall not be measured for payment.

4.5.5 Payment
This work measured as provided above shall be paid for at the Contract unit prices per
square metre. The unit rate shall constitute full compensation for all materials, equipment
and workmanship necessary to provide the slip layer and the protective layer inclusive of
protective metal rings if required, and the additional costs incurred during handling and
driving of the piles.

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Payment shall only be made if bitumen slip layer is selected and ordered in writing by the
Engineer.

Pay item shall be:

04/05/01 Bitumen Slip Layer to Concrete Piles Square Meter

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4.6 DRIVEN BULLAH PILES

4.6.1 Description
This work shall consist of providing and driving wooden piles in accordance with these
Specifications and in conformity with the requirements of the Drawings or the Engineer’s
instructions.

4.6.2 Materials
Bullah piles shall consist of best quality timber; Sal, Sundari, Garzon or equivalent
approved by the Engineer. The diameter shall be 200-250 mm and the length shall be
such that not less than 4.5 metres of acceptable pile can be driven. Each pile shall be fitted
with a metal shoe.

4.6.3 Driving Piles

4.6.3.1 Driving Equipment

Before any piling work is commenced the Contractor shall submit to the Engineer full
details of the pile driving equipment and the methods he intends to use in carrying out the
work.

4.6.3.2 Leaders and Trestles

At all stage of driving the pile shall be adequately supported and restrained by means of
leaders or other guide arrangements to maintain position and alignment. These
arrangements shall be such that damage to the pile does not occur.

4.6.3.3 Hammers

Any kind of hammer may be used provided that it is of a type which assures that the
energy needed to penetrate the pile to the required depth is transmitted to the pile head
without damaging the pile. When gravity hammer are used the drop shall not exceed 1.0
meter. The fall shall be regulated so as to prevent damage to the pile. The efficiency
factor of the hammer, i.e., the relationship between the theoretical energy developed by
the hammer and the energy transmitted to the pile, shall be a minimum of 0.7.

4.6.3.4 Length of Piles

The length of piles to be driven shall be as shown on the Drawings or as approved or

directed by the Engineer. Piles shall be neatly cut off at the specified level.

4.6.3.5 Records

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The Contractor shall keep records as indicated below for each pile and submit two signed
copies to the Engineer not later that the next working day that a pile is driven.

a) Pile Location
b) Pile Reference Number
c) Pile Type and Diameter
d) Date and Time of Driving
e) Ground Level
f) Details of Hammer and Drop
g) Details of any Delay or Interruptions

4.6.4 Measurement
The unit of measurement shall be the linear metre of pile furnished, driven and accepted
in the structure. The pay length of the satisfactorily driven piles shall be measured from
the toe to the cut off.

Cut off lengths shall not be measured for payment.

4.6.5 Payment
The work measured as provided above shall be paid for at the Contract unit rate per linear
meter. The rate shall constitute full compensation for all materials, equipment, driving,
cutting off and all related tools, rigs, cranes, hammers, leaders and other incidental
equipment and work.

No payment shall be made for unauthorized, defective, unsound or unsatisfactorily driven

piles or for any costs incurred by the Contractor for such piles.

Pay item shall be:

04/06/01(a) Driven Bullah Piles (Dia 125-150mm) Linear Meter

04/06/01(b) Driven Bullah Piles (Dia 150-175mm) Linear Meter

04/06/01(c) Driven Bullah Piles (Dia 175-200mm) Linear Meter

04/06/01(d) Driven Bullah Piles (Dia 200-225mm) Linear Meter

Linear Meter

4.7 Well Foundations

4.7.1 Description
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DIVISION 4 - FOUNDATION WORK

This work shall consist of construction of well foundation, taking it down to the founding
level through all kinds of sub-strata, plugging the bottom, filling the inside of the well,
plugging the top and providing a well cap in accordance with the details shown on the
drawings and as per these Specifications, or as directed by the Engineer.

Wells may have a circular, rectangular or D-shape in plan and may consist of one, two or
more compartments in plan. The outer wall of the well, known as well Steining may be
cellular.

The process of taking down the well to the founding level is known as well sinking. After
reaching the founding level, the hollow inside the well, (“dredge hole”) is plugged at the
bottom by concrete (“bottom plug”). The dredge hole is then filled with approved filling
up to the level indicated on the drawings and provided with a concrete plug (“top plug”).

To facilitate sinking of well, steel cutting edge is fabricated and connected to a concrete
well curb of required shape. On top of the well curb, adequate height of well Steining is
cast and the process of sinking is carried out. After a portion of the well has been sunk,
another height of well Steining is cast on top of the previous section and further sinking
carried out. This process is continued till the bottom level of the well reaches the
founding level.

At the top of the well Steining, “well cap” is laid which transmits the loads and forces
from the sub-structure (piers or abutments) to the foundations.

At least one bore-hole must be available/carried out in accordance with these

specifications at each well foundation location, prior to commencement of work. The
depth of bore-holes should extend up to a depth equal to one and a half times the outer
diameter/ least dimension of the well below the anticipated founding level. In case the
well foundation is to rest on a rocky strata, it may be necessary to undertake additional
borings/probings prior to commencement of work to ascertain the actual profile and the
quality of the rocky strata, at the level at which the well has to be seated, etc.

4.7.2 Materials
4.7.2.1 Steel cutting edge

The mild steel cutting edge shall be made from structural steel sections and shall be
strong enough to facilitate sinking of the well through the type of strata expected to be
encountered. The weight of the cutting edge shall not be less than 40 kg per metre length
and be properly anchored into the well curb, as shown in the drawing.

When there are two or more compartments in a well, the bottom end of the cutting edge
of the inner walls of such wells shall be kept at about 300 mm above that of outer walls.

In V shaped cutting edge, the inclined plate should meet the vertical plate in such a way
that full strength connection by welding is feasible.

4.7.2.2 Concrete
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DIVISION 4 - FOUNDATION WORK

The concrete for well curb/Steining, Bottom &Top plug, and well cap shall conform to
section5.1 of these specifications.

4.7.2.3 Reinforcement

The reinforcement shall conform to section 5.2 of these specifications.

4.7.2.4 Sand

Sand for filling the inside of well shall be non-plastic and free from vegetable matter , soft
particles and clay. It shall conform to either grading b or grading C of table 2.8-1 of these
specifications.

4.7.3 Construction Methods

4.7.3.1 Setting Out and Preparations for Sinking

Necessary reference points shall be fixed, away from the zone of blow-ups or possible
settlements resulting from well sinking operations. Such reference points shall be
connected to the permanent theodolite stations with the base line on the banks. The center
of the individual wells shall be marked with reference to these stations. The distance,
wherever practicable, shall be checked with the help of accurate tapes and precision
distomat. Reference points shall also be fixed to mark X-X axis (usually traffic direction)
and Y-Y axis (normal to X-X axis) accurately. A temporary bench mark shall also be
established near the well foundation, away from the zones of blow-ups or possible
settlement. The bench mark shall be checked regularly with respect to the permanent
bench mark established at the bridge site.

For wells which are to be located in water, an earthen or sand island shall be constructed.
Sand islands are practicable for water depths of about 5 m under stable bed soil
conditions. For greater depths or in fast flowing rivers or for locations where soil is too
weak to sustain Sand Island, floating caissons may have to be adopted.

The plan dimensions of sand islands shall be such as to have a working space of at least 2
m all around the Steining. The dimension of the sand islands shall however be not less
than twice the dimension in plan of the well or caisson. Sand islands shall be maintained
to perform their functions, until the well is sunk to a depth below the bed level at least
equal to the depth of water.

Sand Island shall be protected against scour and the top level shall be sufficiently above
the prevailing water level to be decided by the Engineer so that it is safe against wave
action.

While sand islands are constructed at well location, floating caissons are generally
fabricated at or near the banks on dry land or dry docks. Floating caissons are towed into
position in floating condition.

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DIVISION 4 - FOUNDATION WORK

For well placed in the banks of the river or in the dry area, the bed may be prepared by
excavating the soil up to 1.5 m followed by leveling and dressing before placing the
cutting edge.

4.7.3.2 Cutting Edge Erection

The parts of cutting edge shall be erected on level firm ground. Temporary supports shall
be provided to facilitate erection and maintaining the assembly in true shape. The
fabrication may be carried out in the shop or at site. Steel sections shall not be heated and
forced into shape. However, “V” cuts may be made in the horizontal portion, uniformly
throughout the length, to facilitate cold bending. After bending, such “V” cuts should be
closed by welding. Joints in the lengths of structural sections, unless otherwise specified
shall be filler welded using single cover plate to ensure the requisite strength of the
original section.

4.7.3.3 Well curb

The well curb shall be such that it shall offer minimum resistance while sinking, but shall
be strong enough to be able to transmit superimposed loads from the Steining to the
bottom plug. The shape and the outline dimension of the curb as given in Appendix -3
(Fig. 2) of IRC: 78 may be referred for guidance. The internal angle of the curb as shown
in Appendix 3 shall be about 30o to 37o, depending upon geotechnical data.

The well curb may be pre-cast or cast-in-situ. The well curb shall be reinforced concrete
of mix not leaner than M 25 with minimum reinforcement of 72 kg/cu.m excluding bond
rod. The steel shall be suitably arranged to prevent spreading and splitting of curb during
sinking. Steel formwork for well curb shall be fabricated strictly in conformity with the
drawing. The outer face of the curb shall be vertical. The bottom ends of vertical bond
rods of Steining shall be fixed securely to the cutting edge with check nuts or by welds.
The formwork on outer face of curb may be removed within 24 hours after concreting.
The formwork on inner face shall be removed after 72 hours. All concreting in the well
curb shall be done in one continuous operation.

In case blasting is anticipated, the inner faces of the well curb shall be protected with the
steel plates of thickness not less than 10 mm up to the top of the well curb. If it is desired
to increase the steel lining above the well curb then the thickness in the extended portion
can be reduced to 6 mm. This extra height of the steel shall not exceed 3 m, unless
specific requirement exists, as decided by the Engineer. The curb in cases involving
blasting, shall be provided with additional hoop reinforcement consisting of 10 mm dia
mild steel or deformed bars at 150 mm spacing which shall also extend up to a height of
liner.

4.7.3.4 Well Steining

The dimensions, shape, concrete strength and reinforcements of the well shall strictly
conform to those shown on the drawings. The formwork shall preferably be of M.S.

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DIVISION 4 - FOUNDATION WORK

sheets shaped and stiffened suitably. In case timber forms are used, they shall be lined
with plywood or M.S. sheets.

Steining built in the first lift above the well curb shall not be more than 2 m and in
subsequent lifts it shall not exceed the diameter of the well or the depth of well sunk
below the adjoining bed level at any time. For stability, the first lift of steining shall be
cast only after sinking the curb at least partially for stability. Concreting of steining may
be carried out in subsequent lifts of about 2 to 2.5 m. Attempts should be made to
minimize the number of construction joints. The concreting layers shall be limited to 450
mm restricting the free fall of concrete to not more than 1.5 m. Laitance formed at the top
surface of a lift shall be removed to expose coarse aggregates before setting of concrete at
the proposed construction joint. As far as possible, construction joints shall not be kept at
the location of laps in the vertical steining bars.

The steining of the well shall be built in one straight line from bottom to top such that if
the well is titled, the next lift of steining will be aligned in the direction of the tilt. The
work will be checked carefully with the aid of straight edges of lengths approved by the
Engineer. Plumb bob or spirit level shall not be used for alignment. After sinking of a
stage is complete, damaged portions, if any, of steining at top of the previous stage shall
be properly repaired before constructing the next stage.

The height of steining shall be calibrated by making at least 4 gauges (preferably in traffic
direction and in a direction normal to traffic direction) distributed equally on the outer
periphery of the well each in the form of a 100 mm wide strip painted on the well, with
every metre mark shown in black paint. The gauges shall start with zero at the bottom of
the cutting edge. Marking of the gauges shall be done carefully with a steel tape.

After reaching the founding level, the well steining shall be inspected to check for any
damage or cracks. The Engineer will direct and the Contractor shall execute the remedial
measures before acceptance of the well steining. In case the well cannot be accepted even
with any remedial measure, then the well shall stand rejected.

4.7.3.5 Well Sinking

4.7.3.5.1 General

The well shall as far as possible be sunk true and vertical through all types of strata.

Sinking or loading of the well with kentledge shall be commenced only after the steining
has been cured for at least 48 hours or as specified in the drawings.

No well shall be permitted to be placed in a pre-dredged hole.

The well shall be sunk by excavating material uniformly from inside the dredge hole. Use
of water jetting, explosives and divers may be adopted for sinking of wells through
difficult strata with prior approval of the Engineer.
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DIVISION 4 - FOUNDATION WORK

Normally dewatering of well should not be permitted as a means for sinking the well. It
shall never be resorted to if there is any danger of sand blowing under the well.
Dewatering shall however be done when well is to be founded into rock. Pneumatic
sinking may have to be resorted to where obstacles such as tree trunks, large size
boulders, etc. are met at the bottom or when there is a hard stratum which cannot be
removed by open dredging. The necessity for pneumatic sinking shall be decided by the
Engineer.

Sinking history of well shall be maintained in the format given bellow:

4.55 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

Chart of Sinking

LOWEST BED LEVEL----------- LOWEST WATER LEVEL -------------

HIGHT OF FLOOD LEVEL --------------- FOUNDATION LEVEL --------------

HEIGHT OF CURB -------------- HEIGHT OF CUTTING EDGE ---------

---

STEINING SINKING DEPTH OF STRATAMET KENTLEDGE QUANTITY REPORT REPORT REMARKS SIGNATU
WITH ANY
SPECIAL
REDUCED RL OF TOP RL OF TOP HEIGHT TOTAL RL. OF INITIAL FINAL SINKING RL. OF SUMP WEIGHT ECCENTRICITY OF REGARDI RE OF
OF OF OF HEIGHT REFERANCE GAUGE ECCENTRICITY DREDGED NG
STEINING STEINING MATERIAL METHOD
LEVEL AFTER GAUGE DURING BOTTOM OF BELOW TONNES ALONG X AXIS CUBIC OF SUPERVIS
(RL) CASTING STEINING OF LEVEL READING ALONG Y METRE OBSTACL
BEFORE STEINING AXIS
CUTTING CUTTING SINKING ING
(INCLUDIN READING THE METRE
OF CAST (AT WHICH METRE DAY EDGE ES OR
G CURB
BOTTOM CASTING CUTTING METRE
AND EMPLOYE
METRE EDGE OFFICER
CUTTING SAND
(COL.4 – EDGE (COL.9 -
OF EDGE IS
(COL.7COL.8) D
CUTTING
EDGE COL.3) (COL.4-COL.2) COL.8) BELOW
PLACED)
METRE
DURING

SINKING
DATE

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

4.7.3.5.2 Sand blows in wells

Dewatering shall be avoided, if sand blows are expected. Any equipment or men working
inside the well shall be brought outside the well as soon as there are any indications of sand
blow. Sand blow often can be minimized by keeping the level of water inside the well
higher than the water table and also by adding heavy kentledge.

4.7.3.5.3 Use of Kentledge as Sinking Load

Kentledge shall be placed in an orderly and safe manner on the loading platform and in
such a way that it does not interfere with the excavation of the material from inside the
dredge hole and also does not in any way damage the steining of the well.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

Where tilts are present or there is a danger of well developing a tilt, the position of the load
shall be regulated in such a manner as to provide greater sinking effort on the higher side of
the well.

4.7.3.5.4 Use of Water Jetting

Water jetting and jack down method may be employed for well sinking as per requirement.

4.7.3.5.5 Use of Explosives

Mild explosive charges may be used as an aid for sinking of the well only with prior
permission of the Engineer. Blasting of any sort shall only be done in the presence of the
Engineer and not before the concrete in the steining has hardened sufficiently and is more
than 7 days old. When likelihood of blasting is predicted in advance, protection of the
bottom portion of the well shall be done as per these Specifications.

After blasting operations are completed, the well curb and steining should be examined for
any cracks and remedial measures taken.

If blasting has been used after the well has reached the design foundation level, normally
24 hours shall be allowed to lapse before the bottom plug is laid.

The charges shall be exploded well below the cutting edge by making a sump so as to
avoid chances of any damage to the curb or to the steining of the well. A minimum sump
of 1 m depth should be made before resorting to blasting. Use of large charges, 0.7 kg or
above, may not be allowed except under expert direction and with the permissions from
the Engineer. Suitable pattern of charges may be arranged with delay detonators to reduce
the number of charges fired at a time. The burden of the charge may be limited to 1 m and
the spacing of holes may normally be kept as 0.5 to 0.6 m.

All prevalent laws concerning handling, storing and using of explosives shall be strictly
followed.

All safety precautions shall be taken as per IS: 4081 “Safety Code for Blasting and related
Drilling Operations”, to the extent applicable, whenever blasting is resorted to. There
should be no equipment inside the well nor there any worker in the closed vicinity of the
well at the time of exploding the charges.

If rock blasting is to be done for seating of the well, the damage caused by flying debris
should be minimized by covering blasting holes by rubber mats before blasting.

4.7.3.5.6 Use of Divers

Use of divers may be made both for the sinking purpose like removal of obstructions, rock
blasting and for inspection. All safety precautions shall be taken as per any acceptable
safety code for sinking with divers or any statutory regulations in force.

Only persons trained in the diving operation shall be employed and shall be certified to be
fit for diving by an approved doctor.
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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

They shall work under expert supervision. The diving and other equipments shall be of
acceptable standard and certified to this effect by an approved independent agency. It
shall be well maintained for safe use.

Arrangement for ample supply of low pressure clean cool air shall be ensured through an
armored flexible hose pipe. Standby compressor plant shall be provided in case of
breakdown.

Separate high pressure connection for use of pneumatic tools shall be made. Electric lights,
where provided, shall be at 50 volts (maximum). The raising of the diver from the bottom
of wells shall be controlled so that decompression rate conforms to the rate as laid down in
appropriate regulations.

Size of different types of Well:

1. 12750mm X 5500mm (RCC Well)

2. 7940mm X 4270mm (Brick Well)
3. 10000mm X 5000mm ( Brick Well)

Size may differ based on designer requirement.

4.7.3.6 Precautions during sinking

a) When the wells have to be sunk close to each other and clear distance between them is
not greater than the diameter of wells, sinking shall be taken up on all wells and they
shall be sunk alternately so that sinking of wells proceeds uniformly. Simultaneous
and even dredging shall be carried out in the wells in such a manner that the difference
in the levels of the sump and cutting edge in the adjacent wells does not exceed half
the clear gap between them. Plugging of all the wells shall be done together.

b) During sinking of dumb-bell or double D-shaped wells, the excavation in both the
dredge holes should be carried out simultaneously and equally.

c) Bore chart shall be referred to constantly during sinking for taking adequate care while
piercing different types of strata. The type of soil as obtained during the well sinking
should be compared with bore chart so as to take prompt decisions.

d) Before seasonal floods, all wells on which sinking is in progress shall be sunk to
sufficient depths below the designed scour level. Further, they shall be temporarily
filled and plugged so that they do not suffer any tilt or shift during the floods.

e) All necessary precautions shall be taken against any possible damage to the
foundations of existing structures in the vicinity of the wells, prior to commencement
of dredging from inside the well.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

f) The dredged material shall not be allowed to accumulate over the well. It shall be
dumped and spread, as far away as possible, and then continuously and simultaneously
removed, as directed by the Engineer. In case the river stream flows along one edge of
the well being sunk, the dredged material shall not be dumped on the dry side of the
bank but on the side on which the river current flows.

g) Very deep sump shall not be made below the well curb, as it entails risk of jumping
(sudden sinking) of the well. The depth of sump shall be generally limited to one-sixth
of the outer diameter/least lateral dimension of the well in plan. Normally the depth of
sump shall not exceed 3.0 m below the level of the cutting edge unless otherwise
specially permitted by the Engineer.

h) In case a well sinks suddenly with a jerk, the steining of the well shall be examined to
the satisfaction of the Engineer to see that no damage has occurred to it.

i) In pneumatic sinking, the well shall not, at any time, be dropped to a depth greater than
500 mm by the method of “blowing down”.

j) Dewatering shall be avoided if sand blows are expected. Any equipment and men
working inside the well shall be brought out of the well as soon as there are any
indications of a sand-blow.

k) Sand blowing in wells can often be minimized by keeping the level of water inside the
well higher than the water table and also by adding heavy kentledge.

l) In soft strata prone to settlement/creep, the construction of the abutment wells shall be
taken up only after the approach embankment for a sufficient distance near the
abutment has been completed.

4.7.3.7 Tilts and Shifts

The inclination of the well from the vertical is known as tilt and the horizontal
displacement of the center of the well at the founding level from its theoretical position is
known as shift.

Unless otherwise specified, the tilt of any well shall not exceed 1 (horizontal) in 80
(vertical), and the shift at the well base shall not be more than 150 mm in any resultant
direction.

Tilts and shifts shall be carefully checked and recorded in the format vide Appendix
1200/II regularly during sinking operations. For the purpose of measuring the tilts along
the two axes of the bridge, reduced level of the marks painted on the surface of the
steining of the well shall be taken. For determination of shift, locations of the ends of the

4.59 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

two diameters shall be precisely measured along the two axes, with reference to fixed
reference points.

Whenever any tilt is noticed, adequate preventive measures like placing eccentric
kentledge, pulling, strutting, anchoring or dredging unevenly and depositing dredge
material unequally, putting obstacles below cutting edge. Water jetting etc., shall be
adopted before any further sinking. After correction, the dredged material shall be spread
out uniformly.

A pair of wells close to each other has a tendency to come closer while sinking. Timber
struts may be introduced in between the steining of these wells to prevent tilting. The chart
of tilt and shifting of well is given below:

CHART OF TILT AND SHIFTING IN WELL NO:

DATE TOTAL TOTAL REDUCED LEVELS (RL’S) OF GAUGE MARKS TILT SHIFT ACTION REMARKS SIGNATURE
OF

STEINING SINKING ALONG X-AXIS ALONG Y-AXIS TILT TILT RESULTANT TILT ALONG ALONG (COL13 2- TAKEN
(COL10 2+COL11 2 XAXIS YAXIS COL14 2)1/2 FOR SUPERVISIN
WITH WITH
(PLACE) (PLACE) DIFFERENCE (U/S) (D/S) DIFFERENCE ALONG ALONG
X- Y- RECTIFI G OFFICER
END END
DERECTION DERECTION
(COL.5- (COL.8-
COL.4) COL.7) AXIS AXIS CATION
METRE METRE

COL.6 COL.6

METRE METRE
DIVIDED DIVIDED

METRE METRE
BY WELL BY
DIA WELL

DIA

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18

Tilts occurring in a well during sinking in dipping rocky strata can be safeguarded by
suitably supporting the curb.

In the event of a well developing tilt or shift beyond the specified permissible values, the
Contractor shall have to carry out, at his own cost, suitable remedial measures to the
satisfaction of the Engineer, to bring the tilt and shift within permissible values.

If the resultant tilt and / or shift of any well exceed the specified permissible values,
generally it should not exceed 1 in 50 and 300 mm respectively. The well so sunk shall be
regarded as not conforming to specifications and a sub-standard work. The Engineer in his
sole discretion may consider accepting such a well, provided:

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

i) Calculations for foundation pressures and steining stresses, accounting for the actual
tilt and shift furnished by the Contractor show that the well is safe. Remedial measures
required to bring the stresses within permissible values (such as increase in the
dimension of the well cap, provision of dummy weights on the well cap etc.), shall be
carried out by the Contractor at his own cost.

ii) The Contractor shall be subjected to reduction in rates as a penalty in accordance with
Clause 4.7.5(g).
In case the Engineer, in his discretion, rejects the well, the Contractor shall dismantle
the rejected well to the extent directed by the Engineer and remove the debris. Further,
the Contractor shall, at his own risk and cost, complete the bridge with modified span
arrangement acceptable to the Engineer.

4.7.3.8 Floating caissons

Floating caissons may be of steel, reinforced concrete or any suitable material. They shall
have at least 1.5 m free board above the water level and increased, if considered necessary,
in case there is a possibility of caissons sinking suddenly owing to reasons, such as scour
likely to result from lowering of caissons, effect of waves, sinking in very soft strata, etc.

Well caissons should be checked for stability against over-turning and capsizing while
being towed and during sinking, due to the action of water current, wave pressure, wind
etc.

The floating caisson shall not be considered as part of foundation unless proper shear
transfer at the interface is ensured.

4.7.3.9 Seating of Wells

The well shall be uniformly seated at the founding strata. It shall be ensured by test
borings that the properties of the soil encountered at the founding strata and up to a depth
of one and a half times the well diameter is identical to that adopted in the design. The
procedure for test borings shall satisfy the provisions of these specifications. In case the
soil encountered is inferior to that adopted in design, the well shall be re-designed by the
Engineer adopting the soil properties actually encountered and the founding level
intimated to the Contractor, who shall carry out the work accordingly.

In case of seating of wells in hard rocky strata, where the rock profile is steeply sloping,
pneumatic methods of sinking may be adopted to seat the well evenly as directed by the
Engineer. The decision of adopting pneumatic sinking shall be taken by the Engineer. The
cutting edge may also be embedded for a suitable depth in the rocky strata, as decided by
the Engineer keeping in view the quality of rock. As an additional measure of safety, the
well shall be anchored to the rocky strata by anchor bars provided in the steining of the
well, as shown on the drawing irrespective of the fact that tension develops or not at the
base of the well under design loads. After the well has been evenly seated on good hard
rock, arrangements shall be made to facilitate proper inspection in dry and visible
conditions before the bottom plug is laid.
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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

4.7.3.10 Bottom Plug

The bottom plug shall be provided in all wells and the top shall be kept not lower than 300
mm in the centre above the top of the curb, as shown in Appendix-3 of IRC:78. A suitable
sump shall be below the level of the cutting edge. Before concreting the bottom plug, it
shall be ensured that it’s inside faces have been cleaned thoroughly.

The concrete mix used in bottom plug shall have a minimum cement content of 330 kg per
cu.m with a slump about 150 mm to permit easy flow of concrete through tremie to fill up
all cavities. Concrete shall be laid in one continuous operation till the dredge hole is filled
to the required height. For under water concrete, the concrete shall be placed by tremie
under still water condition and the cement content of the mix be increased by 10 percent.
Admixtures, if required may be added to the concrete to achieve the required
characteristics.

In case of grouted concrete, the grout mix shall not be leaner than 1:2. It shall be ensured
that the grout fills up all interstices up to the top of the bottom plug by suitable means such
as, controlling the rate of pumping etc.

Any dewatering required, shall be done 14 days after concreting of bottom plug.

The concrete production equipment and placement equipment should be sufficient to

enable under water concreting within stipulated time. Necessary standby equipment should
be available for emergency situation.

Before commencing plugging, all loose material from the bottom of the well shall be
removed.

Concreting shall be done in one continuous operation till the dredge hole is filled up to the
required height and thereafter sounding shall be taken up to ensure that the concrete has
been laid to the required height.

Least disturbance shall be caused to the water inside the well while laying concrete in the
bottom plug.

Concrete shall not be disturbed in any way for at least 14 days.

In order to check any rise in the level of the bottom plug soundings should be taken at the
close of concreting and once every day for the subsequent 3 days.

The soundness of the bottom plug may be tested by dewatering the well by 5 m below the
surrounding water level and checking the rise of water. The rate of rise shall preferably be
less than 10 cm per hour. In case the rate is higher, suitable remedial measures as directed
by the Engineer, shall be taken by the Contractor at his own cost.

4.7.3.11 Sand Filling

Sand filling shall commence after a period of 14 days of laying of bottom plug. Also, the
height of the bottom plug shall be verified before starting sand filling.
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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

Sand shall be clean and free from earth, clay clods, roots, boulders, shingles, etc. and shall
be compacted as directed. Sand filling shall be carried out up to the level shown on the
drawing or as directed by the Engineer.

4.7.3.12 Top Plug

After filling sand up to the required level a plug of 300 mm thick concrete shall be provided over it
as shown on the drawing or as directed by the Engineer.

4.7.3.13 Well cap

A reinforced cement concrete well cap will be provided over the top of the steining in
accordance with the drawing. Formwork will be prepared conforming to the shape of well
cap. Concreting shall be carried out in dry condition. A properly designed false steining
may be provided where possible to ensure that the well cap is laid in dry condition.

The bottom of the well cap shall be laid preferably as low as possible but not below the
LWL, taking in to account for this purpose, the water level prevalent at the time of casting,
where the bed level is higher than the LWL, the bottom of the well cap may be suitably
raised. Bond rods of steining shall be anchored into the well cap.

4.7.3.14 Tolerances

The permissible tilt and shift shall not exceed 1 (horizontal) in 80 (vertical) and the shift at
the well base shall not be more than 150 mm in any resultant direction.

For the well steining and well cap, the permissible tolerances shall be as follows:

a) Variation in dimension : +50 mm, –10 mm

b) Misplacement from specified position in plan : 15 mm

c) Surface irregularities measured with 3 m

straight edge : 5 mm

d) Variation of level at the top : ± 25 mm

4.7.3.15 Tests and standards of acceptance

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.

4.7.4 Measurement
All quantities shall be measured from the drawing, or as ordered by the Engineer, except
those required to be provided by the Contractor at his cost.
4.63 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

a) The cutting edge shall be measured in tonnes based on the net weight of metal used in
it.
b) The concrete in curb, well steining and well cap shall be measured in cubic metres in
each of the items as per Section 5.1.4. The reinforcements shall be measured in tonnes
separately in each of the items, as per Section 5.2.4.
c) The measurement for well sinking shall be made in running metres for different depths
and in different types of strata (for example, predominantly sand/clay soil, soft rock,
hard rock, etc.) as specified in the Contract. The depth of sinking shall be measured
from the level specified in the Contract. If no level has been specified in the Contract,
sinking shall be measured from the low water level or from the level at which the
cutting edge was laid, whichever is higher.
d) The quantity of concrete in bottom and top plug shall be measured in cubic metres as
per Section 5.1.4.
e) The quantity of sand filling shall be measured in cubic metres.
f)
4.7.5 Payment
All quantities shall be measured from the drawing or as ordered by the Engineer,
excepting those required to be provided by the Contractor at his cost.

a) The Contract unit rates of cutting edge shall cover all costs of labour, material, tools,
plant and equipment, including placing in position, sampling and testing, and,
supervision, all as per respective Section of Structural Steel Work and as described in
this section.

b) The Contract unit rates for concrete in curb, steining, bottom plug, top plug and well
cap, shall cover all costs of labour, material, tools, plant and equipment, formwork and
staging including placing in position, sampling and testing, and, supervision, all as per
respective Section of Structural Concrete and as described in this section.

c) The Contract unit rates for reinforcement in curb, steining, and well cap, shall cover all
costs of labour, material, tools, plant and equipment, including bending to shape,
placing in position, sampling, testing and supervision, all as per respective Section of
Steel Reinforcement and as described in this section.

d) The Contract unit rates for sand filling shall cover all costs of labour, material, tools,
plant and equipment, including placing in position, sampling testing and supervision,
all as described in this section.

e) The Contract unit rates for sinking shall cover the costs of labour, tools, and equipment
and plant and for all operations and other incidentals for sinking of well including
seating excepting provisions of pneumatic sinking as described in this Section. The
unit rates shall specify the strata such as types of soil, rock, etc. The rate shall cover all
testing and supervision required for the work.

g) Reduction in contract unit rates for sinking as a penalty, in pursuance of Clause

4.7.3.14
4.64 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

If any well with tilt and/or shift exceeding the permissible values is accepted by the
Engineer, the Contractor shall be subjected to a reduction in the rates for payments as
follows:

Sl. Amount of tilt and/or shift Percent deduction on the rate

(s) for sinking of whole well
No.

1. Tilt exceeding the specified permissible value but 5 percent

equal to or within 1 in 60

Tilt exceeding 1 in 60 but equal to or within 1 in

2. 50 10 percent

3. Tilt exceeding 1 in 50 20 percent

4 Shift exceeding the specified permissible value but 2 percent

equal to or within 200 mm

5. Shift exceeding 200mm but equal to or within 5 percent

300mm

6. 10 percent
Shift exceeding 300 mm

Pay items shall be:

04/07/01 Cutting Edge (Well Shoe) Ton

04/07/02 Class-20 Concrete for RCC Well cum

04/07/03 Concrete in Top/Bottom Plugging cum

4/07/04(a) Labor for Well Sinking (Size 5000mm X 10000mm) Depth 0m-6m Metre

4/07/04(b) Labor for Well Sinking (Size 5000mm X 10000mm) Depth 6m-12m Metre

Labor for Well Sinking (Size 5000mm X 10000mm) Depth 12m-

4/07/04(c) Metre
18m

Labor for Well Sinking (Size 5000mm X 10000mm) Depth 18m-

4/07/04(d) Metre
24m

4.65 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 4 - FOUNDATION WORK

Labor for Well Sinking (Size 5000mm X 10000mm) Depth Above

4/07/04(e) Metre
24m

4/07/04(f) Labor for Well Sinking (Size 4270mm X 7940mm) Depth 0m-6m Metre

4/07/04(g) Labor for Well Sinking (Size 4270mm X 7940mm) Depth 6m-12m Metre

4/07/04(h) Labor for Well Sinking (Size 4270mm X 7940mm) Depth 12m-18m Metre

4/07/04(i) Labor for Well Sinking (Size 4270mm X 7940mm) Depth 18m-24m Metre

Labor for Well Sinking (Size 4270mm X 7940mm) Depth Above

4/07/04(j) Metre
24m

04/07/05 Sand Filling cum

04/07/06 High Steel Reinforcement Bars Ton

4.66 | P a g e
 4.8 STEEL SHEET PILES

4.8.1 Description

This specification outlines the method and resources involved in installation of sheet
piling to facilitate works related to shore protection and excavation. Any alternate
methods proposed by the contractor shall be at the discretion of Engineer and will have to
be prior approved before commencement of work.

4.8.2 Materials

All materials and workmanship shall be in accordance with the AASHTO, Codes of
Practice and other current specified standards at the date of tender except where the
requirements of these Standards or Codes of Practice are in conflict with this Specification
in which case the requirements of this Specification shall take precedence.

i) Source of Materials

The approved sources of supply of materials shall not be changed until the Contractor has
confirmed that the materials from the new source can meet all the requirements of the
Specifications. Materials failing to comply with the Specifications shall be removed
promptly from the site.

ii) Standard Sheet Piles

Unless specified otherwise, all steel for sheet piles shall be manufactured to ASTM, BSTI
(BDS ISO) or any other equivalent standards.

iii) Fabricated Sheet Piles and Storage

All fabricated piles, e.g., corners, junctions, box sections, and high modulus sections, shall
be fabricated and supplied to the sheet pile manufacturer's recommendations for approval
of the Engineer.

iv) Storage

The methodology of storage for Sheet piles shall have prior approval from the Engineer. If
sheet piles of different grade steel are stored on site in corrosion preventive manner, and
each pile shall be clearly marked as to its grade and piles of different grades shall be stored
separately.

4.8.3 Construction Methods

The Contractor shall submit all relevant details of the method of construction of the sheet
pile wall and the plant and monitoring equipment he plans to adopt for approval of the

July 2011 Page 6. 67

Engineer.

i) Ground Condition

The Contractor shall report immediately to the Engineer any circumstances which
indicate that in the Contractor's opinion, the ground conditions differ from the drawings,
or which could have been inferred from the subsurface investigation reports.

ii) Program of Works for Sheet Piles

The Contractor shall submit to the Engineer each day the intended program of sheet pile
wall construction for the following day and shall give 24 hours' notice of his intention to
work outside normal hours and at weekends.

The Contractor shall ensure that during the course of the work, displacement or damage
does not occur to the completed part of the work or any other elements that has already
installed and has been accepted by the Engineer.

iii) Records

The Contractor shall keep records of sheet pile walls and shall submit two signed copies
of these records to the Engineer not later than noon of the next working day after the
element was installed.

Any unexpected driving conditions shall be noted in the records.

iv) Supervision and Control of the Works

The Contractor shall have experienced full-time site supervisor (s) at the site to be in
charge for the sheet pile wall construction or installation.

The Contractor shall submit to the Engineer his quality plan one week prior to
commencement of sheet pile work. Subsequent revisions, amendments or additions shall
be submitted to the Engineer for approval prior to their implementation. Quality
assurance and quality control documentation shall follow the Quality Assurance Plan of
RHD.

v) Ordering of Piles

The Contractor shall ensure that the piles are available at the site for driving for
incorporation in the Works. All piles and production facilities shall be made available for
inspection at all time by the Engineer. Only new piles shall be used for permanent works.
Piles shall be carefully examined at the time of delivery. Damaged piles shall be removed
from the site. The records of testing of the steel used in the piles shall be submitted to the
Engineer for his approval prior to commencing the Works.

July 2011 Page 6. 68

 vi) Clutch Sealant

The Contractor shall apply a clutch sealant to the piles prior to pitching in accordance
with the manufacturer's recommendations subject to the approval of the Engineer. Brief
of clutch sealant or refer to other established document.

vii) Tolerances on Setting Out

Marker pins for the sheet pile wall positions shall be set out and installed by the
Contractor. Prior to installation of the sheet pile wall, the element positions shall be
checked by the Contractor and confirmed by the Engineer.

Table 1. Dimensional Tolerances for Steel Sheet Pile

S1. No. Dimension to which Tolerance Applies Tolerance

Width
1 (a) Single piles ±2%
b) Interlocked piles ±3%
±5%
2 Thickness of section

3 Weight ±5%
4 Length ±50 mm
Squareness of cut for each section
5 a) parallel to line of wall ≤ 2%
b) perpendicular to line of wall ≤10 mm
6 Straightness ≤ 2% of pile length
7 Depth of Section ±4%

viii) Pile Handling and Driving

Pile Handling

When assembling piles before pitching the Contractor shall ensure that the interlocks are
clean and free from distortion. All storage, handling, transporting and pitching of piles
shall be carried out in such a way that no significant damage occurs to piles and their
coatings.

Pile Installation

The Contractor shall satisfy himself that the sheet piles can be installed adequately to the
correct depths through the reported or anticipated soil conditions. The Engineer shall be
notified 24 hours before the commencement of driving.
The piles shall be guided and held in position by temporary gates with each pile properly
interlocked with its neighbor. Piles shall be interlocked properly according to the
approved design.

July 2011 Page 6. 69

 Where sheet piles are driven in panels, the end piles to each panel shall be driven in
advance of the general run of piles. After allowing for initial penetration, no pile in the
panel shall be driven to an excessive lead in comparison with the toe level of the panel in
general and where hard driving is encountered this lead should not exceed 1 m.
At all stages during driving the free length of the sheet pile shall be adequately supported
and restrained. The Contractor shall ensure that the sheet panels are driven without
significant damage or declutching.
The selection of driving and contracting plant shall be made having due regard to the
ground conditions and pile type. The sheet piles shall be driven to the specified level
and/or resistance or if hard driving is experienced, to practical refusal (which shall be
defined as when the rate of penetration is below 100 mm per minute when hammering
continuously or 12 blows per 25 mm movement when using the appropriate equipment),
or when visible damage to the pile occurs. Practical refusal for pile extraction shall be
defined generally as when the rate of extraction of a pile is below 100 mm per minute
when back-hammering or pulling (with equipment normally capable of withdrawing a
pile) continuously (after an initial effort of 10 minutes). or when damage to the pile head
occurs. If the piles have not penetrated to the levels specified, or have encountered
obstructions, the Contractor shall submit details as to how he will overcome the problem.

Pile driving hammers shall be correctly positioned on the pile so that the hammer will be
aligned as near to the axis of the pile as is practically possible. Freely suspended piling
hammers shall be equipped with correctly adjusted leg guides and inserts. Where a
hammer is mounted in a rigid leader, the leader shall be stable. The anvil block or driving
plate shall be of sufficient size to cover as much as possible of the cross-section of pile.

Piles previously driven shall not be used until the Contractor can demonstrate that they
can meet all the requirements of the Specification.

The Contractor may provide each pile in more than one length. Spliced joints shall be
designed to cater for the combined effects of bearing, shear and bending stresses imposed
upon the sheet piles. Splices shall be located to avoid maximum stress positions. If
splices are to be welded, then these shall be designed in accordance with the guidelines
given in AWS/BS 5135 or equivalent standard and the manufacturer's recommendations.
Weld metal shall not encroach within the interlock areas so as not to interfere with the
interlocking of the piles.

viii) Positional and Alignment Tolerance

Unless deflected by obstructions, sheet piles shall be installed within the following
tolerances:
 in plan ± 75 mm of the given sheet pile line at commencing surface
 vertical 1 in 75
 level ± 50 mm of required top level.
Pile line dimensions shall be based on the nominal size of piles. Creep or shrinkage of the
pile lines shall not exceed the manufacturer's rolling tolerances.

July 2011 Page 6. 70

 ix) Welding Standard

For manual metal arc and semi-automatic welding of carbon and carbon manganese steels,
welding of piles and steel framework shall be carried out in accordance with AWS / BS 5135
or equivalent. Defective welds shall be cut out and replaced. Where steel piles are to be
spliced by butt welding the interlocks shall not be welded unless a sealing weld is required.

x) Piling Records

The following records shall be kept and a copy shall be submitted to the Engineer:
Here is a well-structured table format for piling records:
S.
Record Parameter Details/Notes
No.
Pile Reference Number or Unique identifier or location
1
Location coordinates of the pile.
Specify the type (e.g., steel, concrete)
2 Pile Type and Grade of Steel
and grade used.
Total length of the pile (in meters or
3 Pile Length
feet).
Model and type of hammer used for
4 Type of Hammer driving (e.g., drop hammer, hydraulic
hammer).
5 Date of Driving Exact date the pile was driven.
Ground level at the start of the piling
6 Commencing Surface Level
operation.
Total depth the pile was driven into the
7 Depth Driven
ground.
8 Length of Offcuts Length of discarded sections of the pile.
Length of any extensions added to reach
9 Length of Pile Extensions
the required depth.
Driving resistance recorded at specific
10 Driving Resistance
depths (e.g., blows per meter).
Interruptions/Unexpected Notes on issues faced, obstructions, and
11
Changes/Obstructions methods to resolve them.
This format can be filled for each pile and included in a piling report for submission to
the Engineer. You may also consider adding a column for remarks or additional
observations, if required.

4.8.4 Measurement and Payment

Steel sheet pile shall be measured in unit Metric Tonne. For installed piles directed to be
cut off before reaching the penetration depth shown in the Drawing, the portion cut off

July 2011 Page 6. 71

 will not be measured. The temporary sheet piles shall be considered as the property of
the Contractor.

Payment for Steel Sheet Pile shall cover all costs of supplying, furnishing, handling,
storing and installing piles including placing, driving, cutting holes and other materials
and incidental works as per the Specifications.

Pay Item shall be:

Pay Item Description Unit Measurement
No.
Setting Sheet Piles (temporary) Tonne
Setting Sheet Piles (Re-used) Tonne
(Temporary)
Setting Sheet Piles Tonne
(Permanent)
Setting Sheet Piles (Re-used) Tonne
(Permanent)

4.9 REINFORCED EARTH WALLS

4.9.1 Description

The specification covers construction of reinforced soil structures together with the construction
of earthwork in layers, assembly and placing of reinforcing elements and facia elements during
the construction process and all associated works. Any alternate methods proposed by the
contractor shall be at the discretion of Engineer and will have to be prior approved before
commencement of work.

The work shall include the design and construction of the reinforced soil structure and ground
improvement measures required, if any.

Reinforced soil structures with a slope face angle steeper than 70° are categorized as reinforced
soil walls, and those with a slope face angle less than 70° are considered as reinforced soil
slopes.

4.9.2 Material

(i) Reinforcing Elements

The reinforcing element shall be metallic in the form of ties (galvanized steel bars/tendons) or
mats of metal (steel grids, woven and welded steel wire meshes) or synthetic (PET, HDPE, PVA,
PP) reinforcement in the form of grid or strip or strap or combination of metallic or synthetic or
any other proprietary material which shall be approved by the Engineer and shown on the

July 2011 Page 6. 72

drawings.

Carbon steel ties shall comply with BS EN 10025 / IS: 2062 or any other equivalent standard and
have a silicon content of not more than 0.55 percent. The fabricated element shall be galvanized
in accordance with IS 4759 and IS 2629 or any other equivalent standard, and the minimum zinc
coating weight shall not be less than 1000gm/sq.m

The steel ties with minimum bearing and shear strength of 490N/mm2 shall comply with the
requirements of BS EN 10025, Grade S 355 JR, or IS: 2062 grade Fe 490 or any other equivalent
standard except for the elongation (on base metal) for which minimum 22% is acceptable.

The panel lugs shall be manufactured from hot-rolled steel ties with the same steel quality and
grades as specified above, except that the minimum zinc coating weight not less than 600
gm/sq.m.

All permanent metallic connectors (exposed to soil), tie strips, and lugs shall be hot dip
galvanized. Nuts/ bolts (fasteners) shall be galvanized as per requirements of IS: 1367-Part 3.
Nuts/ bolts (fasteners) shall be grade 10.9 or any other equivalent standards.

For all metallic components, where holes or penetrations are made through the reinforcing
elements to accommodate connections such as bolts, pins, or other, the cross-section thickness
and/or width of metallic component shall be increased to account for section loss caused by the
hole or penetration. The manufacturer of geogrids, geotextiles, geostrips, polymeric strips or
straps, polymeric ties or any other geosynthetic material, including any proprietary geosynthetic
material, for use as reinforcing element shall fulfill the following requirements:
- Shall have ISO (ISO-9001) / CE Certification or any other equivalent certification for
manufacturing process and quality control,
- The product shall have certification for use as soil reinforcing material from an agency
accredited for certifying geosynthetic reinforcement products.
- The manufacturer shall provide test reports from an independent laboratory with valid
accreditation, for all the tests needed to establish all the reduction factors listed below
RFCR - Reduction factor for creep.
RFID - Reduction factor for installation damage
RFW - Reduction factor for weathering
RFCH - Reduction factor for chemical/ environmental effects.
fs - Factor for the extrapolation of data
All the above factors shall be determined in accordance with the provisions of ISO/TR 20432-
“Guide to the determination of long-term strength of geosynthetics for soil reinforcement. Or,
any other equivalent standard.

(ii) Earth Fill and Environmental Conditions

July 2011 Page 6. 73

The fill in the reinforced soil zone shall have drained or effective angle of friction not less than
30°, measured in accordance with IS: 2720 (Part 13) or equivalent, by conducting a drained
direct shear test. In case the fill material has 25 percent or more particles of 4.75 mm or larger,
drained shear test using large shear box may be conducted (IS: 2720: Part 39: Section 1 or
equivalent) . The gradation of fill soil shall be as per following limits.
Sieve Size Percentage passing
75mm 100%
425 micron 0-60%
75 micron less than 15

Materials with more than 15 percent passing 75 micron sieve, but less than 10 percent of
particles smaller than 15 microns are acceptable provided PI is less than 6 and angle of friction is
not less than 300.
The fill material used in the reinforced soil zone shall be free from organic or other deleterious
materials and shall not react adversely (chemically, electrically or biologically) with the
reinforcement material and / or facia material.
Properties of fill soil in the reinforced zone, unreinforced zone (or retained/back fill) soil and the
foundation soil shall be determined accurately during the construction phase, as per quality
assurance plans and directions of Engineer so as to ensure that these are the same as those
considered in the design phase.
The fill soil in the unreinforced zone shall conform to the requirements specified in the design.
Where galvanized steel reinforcement is used, the fill material shall be free draining granular
material and shall meet the following requirements as per table below
Table 2. Recommended Limits of Electrochemical Properties for Reinforced Fills with Steel
Reinforcement
Property Criteria Test Method
Resistivity > 3000 ohm-cm AASHTO T-288 or
equivalent
pH > 5 and < 10 AASHTO T-289 or
equivalent
Chlorides < 100 PPM ASTM D 4327 or
equivalent
Sulphates < 200 PPM ASTM D 4327 or
equilvalent

(iii) Facing Material

The facing system shall be one of the following
- Precast reinforced concrete panels

July 2011 Page 6. 74

- Precast concrete blocks and precast concrete hollow blocks.
- Gabion facing
- Wrap around facing using geosynthetics
- Metallic facing, prefabricated in different shapes including welded wire grid and
woven steel wire mesh
- Other proprietary and proven systems

Facing shall be sufficiently flexible to withstand any deformation of the fill and foundations. The
facia units to be adopted in the project shall be shown in the drawings and shall be approved by
the Engineer.

Facia type adopted shall be given in the design and shown with complete details in the drawings.
The system supplier shall provide any test data to satisfy the Engineer regarding the properties
and suitability of the facia system adopted, if so required.

Where facia such as wrap around or mechanically woven gabion or welded wire and woven steel
wire mesh facings have been used and where climate conditions are appropriate, a green finish
shall be provided where specified.

Connection between the facia panels and the reinforcing element shall be by using either nut or
bolt, HDPE inserts with bodkin joint, hollow embedded devices, polymeric/ steel
strips/rods/pipes, fibre glass dowels or any other material shown in the drawings. Connection
between facia panel and reinforcing element shall not rely only on concrete strength and must
have direct load sharing by steel reinforcing bar. Hollow sleeves where reinforcement is passed
and relying on only on concrete strength shall not be permitted. The connection between the
panel and the reinforcement shall provide for 100 % of the long term design strength of the
reinforcing element in continuity.

In case of modular block facia and other type of facia such as gabion facia, where the
reinforcement is held by friction between the facia block and the reinforcement, the results of
pullout test as per ASTM D 6638 “Standard Method of Test for Determining Connection
Strength between Geosynthetic Reinforcement and Segmental Concrete Units” shall prevail. The
hollow concrete blocks must have mechanical connection and friction-based connection shall not
be allowed.

The available connection strength shall satisfy the design requirements and shall not be less than
the maximum possible tensile force that the reinforcement layer under consideration may be
subjected to.

4.9.3 Construction Methods

July 2011 Page 6. 75

(i) Depth of Foundation

A strip footing, minimum 350mm wide and 150mm thick in 15Mpa grade plain concrete, shall
be provided at founding level to receive the facia or the bottom most reinforcement.

The depth of embedment below the outer finished roadlevel at the foot of the wall shall not be
less than 500 mm or as per site condition subject to the design. In case rock is met above
founding level, the depth of embedment shall be adjusted as per ground conditions.

(ii) Laying of Reinforcement

The reinforcing elements shall be placed at right angles to the face of the wall or design axis,
with greater cross-sectional dimension in the horizontal plane and the length shall be as shown in
the drawings. Reinforcing elements such as geogrids, shall be stretched and held taut by driving
nails or pegs at the farther end. Reinforcing element as such as geostrips shall be laid in V shape
fashion from face to rear end and shall be anchored with steel hooks. Without steel hooks the
polymeric reinforcement shall not be allowed.

Add for steel tendon

(iii) Facing Batter

It may be necessary to set facing unit at an additional batter than as provided in the drawings
since there is a tendency for initially positioned units of facia to lean outward as the fill material
is placed and compacted. Care and caution shall be taken to accommodate this phenomenon. At
the end of the construction, the face may have a slight residual inward batter.

(iv) Drainage

Drainage bay shall be provided. The width of the drainage bay shall be 600 mm behind the
facing element. The drainage material shall conform to the specifications of the filter media as
outlined below:

- Filter design may not be required if embankment consists of CH or CL soils with liquid
limit greater than 30, resistant to surface erosion. In this case, if a layer of material is used
as bedding for pitching, it shall be well graded, and its D 85 size shall be at least twice
the maximum void size in pitching
- In the foregoing, D 15 means the size of that sieve which allows 15 percent by weight of
the filter material to pass through it and similar is the meaning of D 50 and D 85 (15
being replaced with 50 and 85 respectively).
- If more than one filter layer is required, the same requirement as above shall be followed
for each layer. The finer filter shall be considered as base material for selection of coarser
filter.
- The filter shall be compacted to a firm condition. The thickness of filter is generally of
the order of 200 mm to 300 mm. Where filter is provided in two layers, thickness of
each layer shall be 150 mm

July 2011 Page 6. 76

Alternatively, geo-composite drain of specifications mentioned as per Clause of RHD
specifications shall be adopted.

(v) Laying and Compaction

The reinforcing elements shall be laid free from all kinks, damage and displacement during
placing, spreading, leveling and compaction of the fill. The programme of filling shall be such
that no construction plant moves directly on the reinforcement.

All construction plant having a mass exceeding 1500 kg shall be kept at least 2.0m away from
the face of slope or wall.

In the area up to 2.0 m from the face of slope or wall, the following compaction plant shall be
used:
- Vibratory roller having a weight per meter width not exceeding 1300 kg with total weight
not exceeding 1500 kg
- Vibratory plate compactor of maximum weight 1000 kg
- Vibro tamper having a weight not exceeding 75 kg

Before allowing the movement of vehicles over the reinforcement, a minimum compacted
thickness of 150mm or as per field condition, shall be provided over the reinforcement and the
speed of the vehicles shall be restricted to 10 km/hr.

During construction of reinforced fill, the retained material beyond the reinforcement at the rear
of the structure shall be maintained at the same level as reinforced fill.

Fill shall not be placed on surface that contains mud, organic soil or area that have not met
compaction requirement.

The thickness of compacted layer shall not be more than 200 mm, compacted to at least 95 per
cent of maximum laboratory density.

(vi) Construction Serviceability and Tolerances

The construction tolerances shall be as per the following:

Casting of pre-cast RCC panels: All elements shall be manufactured within the following
tolerances:

- All dimensions within ±5 mm

- Evenness of the front face: ± 5 mm over 1500mm
- Difference between lengths of two diagonals: 5mm max.
- Thickness: + 5 mm (-) 0 mm

July 2011 Page 6. 77

 Description Tolerance

± 50 mm – metallic reinforcement
Location of plane of structure
± 75 mm – synthetic reinforcement
Bulging (Vertical) and Bowing (Horizontal) ± 20 mm in 4.5 m template (Metallic)
± 30 mm in 4.5 m template (Synthetic)

Steps at joints ± 10 mm

Dimensions of modular concrete blocks shall not differ more than ±2.5 mm for length and
width and ± 1.5 mm in height.

Minimum vertical movement capacities required for facing systems to cope with vertical
internal settlement of reinforced fill shall be as below:

Structural form Minimum vertical movement Differential Alignment from

capacity of system settlement from EN 14475 or
EN 14475 or equivalent
equivalent

Discrete panels Joint closure of 1 in 150 ~ 1% with panel ± 25mm

relative to panel height aspect ratio ≈ 1 to
~ 0,5% with
larger ratios.

Full height panels Vertical movement capacity ≤ 0.5% ± 25mm

of connections 1 in 150
relative to panel height

Concrete blocks ~ 0.5% ± 50mm

Semi-elliptical facings Vertical distortion of 1 in 150 ~ 2% ± 100mm

relative to panel height

Geotextile/Geogrid No specific limit except for ~ 2% ± 100mm

wrap-around facings appearance or serviceability
considerations

Gabion facings No specific limit except for ~ 2% ± 100mm

appearance or serviceability

July 2011 Page 6. 78

 considerations

4.9.4 Measurement and Payment

The unit of measurement for furnishing and fabricating the materials for the RE walls, including
concrete facing panels, soil reinforcements, attachment devices, fasteners, bearing blocks and
shims, joint materials and incidentals shall be the square meter of wall surface area. The wall
surface area shall include the surface area of nominal panel joint openings and wall penetrations
such as pipes and other utilities. The quantity to be paid for shall be measured on the basis of
wall surface area supplied including all associated cost.

Pay Item shall be:

Pay Item No. Description Unit Measurement

Xxxxxxx Reinforced Earth Wall sqm
Xxxxxxx Earth fill for RE Wall Cubic meter

4.10 PRE-CAST SPUN PILES

4.10.1 Description

This specification for driven of spun piles generally describes the method used for the
installation of driven precast with various size diameter of spun piles ranging from Grade 60MPa
– 120 MPa. This specification describes the procedures of driven piles, penetration, or set that is
required within the given scope of works. Any alternate methods proposed by the contractor
shall be within stipulated cost and at the discretion of Engineer and will have to be prior
approved before commencement of work.

The design, materials and workmanship of the precast pretensioned spun concrete piles shall
comply with the relevant clauses of BS 8004 :1986, BS 8110 : 1997, JIS A 5337 :1993 or
equivalent standard and is to be read in conjunction with the condition of contract and drawings. 1

4.10.2 Materials

The materials used in the manufacture of the precast prestressed spun piles shall comply with the
following specifications or requirements:

a. Cements — The cement shall be ordinary Portland Cement and shall comply with MS 522 or
equivalent standards.

July 2011 Page 6. 79

b. Steel Reinforcements — Steel reinforcement shall comply with the following specifications:
(1) Rolled steel bars and hard-drawn steel wire shall comply with MS 144, MS 146 or equivalent
standards

(2) Prestressing steel shall comply with JIS C3109 or BS 4486 and BS 5896 or equivalent.
c. Aggregates — Aggregates shall be clean, durable and comply with MS 29 or equivalent.
Maximum size of aggregate shall be 20mm.

d. Water — Water shall be free from harmful amount of matter injurious to concrete and its
reinforcement and shall comply with MS 28 or equivalent

e. Admixture — Admixture shall comply with MS 922 or equivalent. Calcium chloride shall not
be used.

f. Test certificates for cement, reinforcement and admixture from approved laboratory shall be
available for inspection by the Employer’s Representative.

4.10.3 Construction Method

i) Equipment and resources

The contractor shall ensure appropriate piling rig, hydraulic hammer, mobile crane, welding sets
are used based on prior approval of the Engineer before commencement of work.

ii) Setting Out

Pile setting out shall be carried out jointly with the site engineer, and shall include any additional
reference points necessary, to enable immediate checking and cross-referencing for any
problematic pile positioning.

iii) Piling Platform

Pier pile positions shall be installed over a suitable pile installation platform, whether they be on
firm ground or on an elevated staging. Any platform/staging established shall be robust and
stable enough to handle weights of piling machine, additional cranes as necessary and the
working forces that will develop during pile driving. The platform must be of known elevation to
enable the control of pile penetration and/or pile setting when necessary.

iv) Pile Driving Termination Criteria

1. Pile set shall be decided through a test pile installation.

2. If pile set is the criteria, the required working load shall be agreed, and stoppage of pile
driving shall be based on Hiley’s pile driving formula. The graphical “set over 10-blow

July 2011 Page 6. 80

 readings” shall be obtained. Subsequent calculation using agreed driving parameters shall
determine adequacy of driving.
Hiley formula:

Hammer Efficiency A
Mass of Hammer W
Drop of Hammer h
Safety Factor f
Pile Working Load L
Total Mass P
Coefficient of Restitution e
Temporary Compression C
3. The actual set values will be recomputed at site based on the variable parameters of actual
pile length installed and the actual temporary compression recorded. If pile penetration is the
criteria, the outcome of the test pile installation shall be a guide to the required depth of
penetration.

v) Pile installation

Piles shall be lifted from its stacked position utilizing its two designated lifting points. Canvass
padded slings shall be used for spun piles.

The toe end of the starter piles shall be pitched/planted to its exact position manually by
suspending the pile from its driven end.

With the toe position fixed, the required pile inclination shall then be adjusted to the required
angle while the guide rails and required back supports are firmly secured.

Counter checks shall be made through two survey stations, preferably at right angles to each
other, to confirm the position at the pile base and inclination of pile shaft. The stations should be
situated at least 30m away.

Pile driving shall utilise the most suitable hammer for driving the type of pile to the set without
damage to the pile head. The type (static, vibration or dynamic), weight and mechanism (diesel,
hydraulic etc.) of the hammer shall be approved by the engineer.

July 2011 Page 6. 81

When driving commence, the first few blows and meter of penetration shall be closely monitored
to enable any initial deviation to be physically corrected.

Large deviations in terms of position and inclination (in excess of specified tolerances) shall
merit an extraction and re-drive at this stage if forcible corrections are not adequate.

For deviations that inevitably occur at deeper penetrations, only measurements in the final set
position shall dictate, amongst other factors, the pile acceptance or otherwise.

Where driving depths go below the piling rig’s base level, a suitable dolly or temporary pile
extension of known length and material properties shall be used to enable proper computation of
the pile set.

vi) Pile Driving Records

Pile driving shall be recorded through an agreed format and shall detail all the relevant
information including times for driving and jointing.

The records shall be comprehensive to discount any uncertainty or reservations as to the piles’
integrity to be part of the permanent structure.

File Code Ref:

Pile Driving Record

Work Item Location

Pile No. Hammer Type
Driving Date Hammer Weight (striking or impact part) kg
Start Time Drop Height cm
Finish Time Striking Energy Kg.m
RC Pile Size cm Length m Casting
Date
Extension Casting
cm Length m
Pile Size Date
Connection Weld
Welding m mm
Box Thickness

Pile Driving Results

No. of Penetration Drop No. of Penetration Drop Pile Tip
Pile Tip
blows (cm) Heigh blows (cm) Height Depth
Depth (m)
t (cm) (cm) (m)

July 2011 Page 6. 82

 Design Actual
Elevation of pile Tip (pile nose) (m)
Elevation of bottom of pile cap (m)
Pile Length (m)
Final Refusal (cm)
Transverse Tolerance (Y axis)
Longitudinal Tolerance (X axis)

Other Remarks:

For Subcontractor: For Engineer: For Client’s Representative

vii) Pile Jointing and Splicing

Piles shall be joined at the specified position using the recommended method or propriety
systems as required.

The required setting and hardening times for primers and epoxies, where used, shall be adhered
to when pile joints are made, to ensure a safe and effective joint.

When welding joints, no gaps shall be allowed and full bearing at the connecting plates between
the driven and the extended length shall be ensured. Pile driving will then be resumed after the
required setting/hardening times for the weld to develop its strength.

viii) Pile Cut-Off

July 2011 Page 6. 83

Piles shall only be cut-off after securing the directive and acceptance by the engineer in charge.
This is to ensure that any re-driving work that would be required can still be carried out when
such situations warrant.

The value for pile cut-off level must be formally agreed and any piles that need to be ‘brought
up’ to the required cut-off level must meet the contractual agreement and specification
guidelines.

Where pile cut-off levels are below ground, excavation sides shall either be sloped or protected
by an earth retaining structure to prevent collapse of the excavated pit.

Where pile cut-off levels are below water level, suitable enclosing structures (e.g. cofferdams)
shall be installed to exclude water from the works.

ix) Fabrication of Pile Plug

Stripping of piles and fabrication of pile heads for concrete piles shall be carried out in
accordance to the Drawings. The lengths of stripping and reinforcement to be provided shall be
adequate to anchor the pile into the pile cap to be constructed.

4.10.4 Measurement and Payment

Payment shall be made for for all costs incurred related to testing including, but not limited to
procurement, preparation and installation, conductions of the tests, and subsequent reporting of
the results.

Pay Item No. Description Unit Measurement

Xxxxxxx Installation of Pre-stressed m
Concrete Spun Piles of
specified material strength and
diameter

4.11 STEEL SCREW PILES

4.11.1 Description

This specification consists of materials, equipment, fabrication, testing, and construction of

Screwed Steel Pile in accordance with relevant standards, drawings, or as directed by the
Engineer. Any alternate methods proposed by the contractor shall be within stipulated cost and at
the discretion of Engineer and will have to be prior approved before commencement of work.1

July 2011 Page 6. 84

4.11.2 Material

Steel pipe piles used for Screw Steel Piles shall conform to the requirements of JIS A 5525,
ASTM A252, ASTM 53, EN10217, EN10219, BS, or equivalent standards.

Physical-mechanical properties of steel material for steel pipe pile

Grade Yield Point Tensile strength Elongation

(N/mm2) (N/mm2) (%)
SKK400/ ASTM 235 or more 400 or more 18 or more
1006 or equivalent
SKK490/ASTM 315 or more 490 or more 18 or more
1006 or equivalent

Steel for the blade of the pile tip shall conform to the requirements of ASTM A572 / JIS G 3106,
Physical-mechanical properties of steel material for the blade of pile tip:

Grade Yield Point Tensile strength Elongation

(N/mm2) (N/mm2) (%)

(16mm＜ｔ≦40mm) 315 or more 490‐610 21 or more
(Testing specimen type
1A)
(40mm＜ｔ≦75mm) 295 or more 490‐610 23 or more（1）
(Test specimen type 4)

(75mm＜ｔ≦100mm) 295 or more 490‐610 23 or more

(Test specimen type 4)

Note(1):

In the case, if testing specimen type 1A is used for more than 40mm and less than 50mm,
elongation 21% or more shall be applied.

(a) The pile tip blade shall be selected from among certified blade.
(b) The welding of pile tip blade and steel pipe pile shall follow JIS A 5525,
ASTM A252, ASTM 53, EN10217, EN10219, BS, or any other equivalent standard and
adopt full penetration welding method.
(c) The Contractor shall submit to the Engineer for approval of steel certificate from the
Manufacture (test results of physical-mechanical properties of the steel) for fabrication of
steel pipe, Quality Control Program, method of manufacturing including welding detail of
joint of piles, quality testing of welding, and experience of manufacturing, supplying steel
pipe piles.

July 2011 Page 6. 85

4.11.3 Construction Method

The Contractor shall submit all relevant details of the method of construction of the steel screw
pile wall and the plant and monitoring equipment he plans to adopt for approval of the Engineer.

i) General
a. Piling of Rotation steel piles shall be executed in the presence of the Engineer or his
representative. All piling shall be carefully located on the lines and spacing as
indicated in the Drawings and shall be installed vertically.
b. The piling of Screw Steel Piles shall be executed by using the dedicated casing
rotation machine. The contractor shall take full responsibility in selecting capable
rotation machine to ensure proper construction and schedule of the project. The
operator of the casing rotation machine shall be properly trained and have experience
of operating the machine. Rotating force shall be applied from the casing rotation
machine to a Screw Steel Pile by gripping the pile body directory through the collar
with high-strength serrate plate.
c. If piles hit any obstructions or encounter difficulty to penetrate hard soil before
reaching proper bearing layer expected from the nearest soil investigation data, the
Contractor shall report the situation to the Engineer without delay and remove the
obstructions with approval by the Engineer.
d. The soil condition shall be foreseen by the Contractor. In case of difficulty to remove
the obstructions, the pile shall be rotated in reverse to pull it out. Then an auxiliary
method can be used to remove the obstructions. Auxiliary methods include pre-
boring by the earth-auger method, casing excavation using a casing rotator with
hammer grab, or excavating inside soil of the Screw Steel Pile with a hammer grab
and no additional payment will be made for it.
e. The Contractor shall report immediately to the Engineer any circumstances which
indicate that in the Contractor's opinion the ground conditions differ from the
drawings, or which could have been inferred from the subsurface investigation
reports.

ii) Daily Record

On completion of installation of each Screw Steel Pile the Contractor shall submit daily records
to the Engineer within 24 hours giving the information listed in Table below.

General Record Installation of Rotation Steel Pile

- Date - Foundation No.
- Weather condition - Pile identify number, coordinates for
- Working group (organization, determining location of the pile
personnel) - Natural ground level
- Equipment and machineries - Soil condition
- Detail of working time - Pile head elevation.
- Progress report - Pile tip elevation.
- Safety report - Construction equipment

July 2011 Page 6. 86

 - Detail of acceptance of steel pipe, pile tip
- Detail of joint welding (position, time and
conditions)
- Construction time
- Detail of any obstacles
- Auxiliary method if used (Hammer grab,
others)
- Fully record of rotating force, rotating
torque, weight of counterweight to each
meter in depth
- others

iii) Trouble and Failure Report

If the Contractor causes any damage to utilities or adjacent structures during the works, the
Contractor shall submit the report of the damage without delay with the proposed plan for the
repair and improvement to avoid repetition of such damages to the Engineer.

iv) Storage and Handling

a) The units of Screw Steel Pile shall be stored above the ground by timber supports
placed on firm ground, which is not liable to subside, whether wet or dry, under the
weight of the units. Where the units are stacked in layers, they shall not be stacked
more than three (3) layers high, with timber supports placed between each layer.
Supports for each layer shall be placed on those of the preceding layer and shall be
placed not more than 20 % of the length of the unit from each end.
b) The Contractor shall attach hanging hooks to the Screw Steel Pile segments to allow
vertical lifting of the segments. A minimum of two (2) hanging hooks are required
for vertical lifting. The method of attachment shall not cause damage to the Screw
Steel Pile segment during attachment, lifting of the segment, and removal of
attachment. The method of attachment and location of the attachment points shall be
included in the method statement. Only the approved hanging hooks shall be used
during lifting, and Screw Steel Piles shall be stored and transported not to damage
these hanging hooks. Piles damaged during handling shall be replaced at the
Contractor’s own expense.

iv) Monitoring of Operation

During the execution of the Screw Steel Pile, working torque, penetration rate, and vertical load
shall be monitored for all the piling works to evaluate the correlation of sub-ground soil
condition and working torque. The monitored record of Screw Steel Pile shall be submitted to the
Engineer within 48 hours after completion of all Screw Steel piles for each foundation.

July 2011 Page 6. 87

v) Finish Piling Operation

a) The Contractor shall request the approval of the Engineer when the Contractor
finishes the piling works.
b) Working torque and other measured data shall be used to confirm that the pile tip has
reached the bearing layer. To stop piling operation, the following conditions shall be
satisfied.
- The pile tip has reached the design elevation.
- Measured data has suggested that the pile has reached the bearing layer.
- Necessary penetration depth to the bearing layer (in principle, 1.0 diameter of pile or
more) has been confirmed.
c) If required penetration has not been obtained due to an extremely hard bearing layer,
the Contractor shall finish the piling subject to the approval of the Engineer.
d) In this case, top of Screw Steel Upper Pile shall be cut off by oxyacetylene cutting or
other adequate method at the elevation approved by the Engineer.
e) Following information shall be documented and submitted to the Engineer.
- Foundation number and pile number.
- Pile specification (diameter, thickness, length etc.);
- Record of completion situation (finishing working torque, elevation of the bearing
layer, penetration length into the bearing layer, etc.);

vi) Tolerance
Tolerance of Screw Steel Pile shall comply with “Quality Control Standard of Steel Pile
Foundation” by Ministry of Land, Infrastructure, Transport and Tourism. Detail of tolerance of
completed pile shall be given in the Table below.

Item Tolerance
- Position of pile center - Dp/4 or less and ±100mm
- Elevation of Pile top - ± 50 mm
- Inclination of pile - 1/100 or less
- Penetration length into the - 1.0 Dp or more
bearing layer

Note: Dp = Diameter of pile

vii) Site Welding Work

a) The joint of Screw Steel Piles shall be welded in complete penetration butt weld with
suitable mild steel backing ring plates provided. Site welding method shall be semi-
automatic arc weld or other weld method approved by the Engineer. The ends of the
sections shall be suitably prepared for welding. The welding procedures shall comply
with all requirements of the following welding specifications. The bead for
temporary welding shall be longer than 80mm at more than six locations (Outside
pile diameter from 700mm to 1000mm) in one ring welding line.
b) When the segments are welded together, the seam of one segment shall be located at
a distance of more than one-eighth of the segment circumference from the seam of

July 2011 Page 6. 88

 another.
c) The Contractor shall assign the qualified welding engineer for quality control, who
has experience the site welding of steel pipe and shall be responsible for all of
welding works. The Contractor shall submit his qualifications for the Engineer’s
approval.
d) Welders hired for this purpose shall be successful passers of examination necessary
for site welding of piles or other licensing examinations equivalent or superior to it as
provided in AWS D1.1, JIS Z 3801, JIS Z 3841, WES 8106 or equivalent and have
already been engaged in welding operations for six (6) month or longer.
e) The joints of the Screw Steel Pile shall be welded in accordance with AWS D1.1 or
equivalent
f) For welding the Screw Steel Pile at the site, the following information shall be
documented and reported to the Engineer.
- Pile number and position of the welding area;
- Welding data, weather conditions including temperature, rain and wind condition;
- Name of welder;
- Method of welding (posture, voltage, current, type of electrode, etc.);
- Time record for welding.
g) Tolerance of the assemblage of components shall be in accordance with the
followings.
- Root opening shall be from 1 mm to 4 mm
- Dislocation between joining piles shall be 3 mm (Outside pile diameter from 700mm
to 1000mm) or under in accordance with relevant ASTM / JIS standards
h) Cleaning and drying of the welding line in both components prior to welding.
- There shall be no black skin, rust, paint or grease present at the welding area
- Welding line shall be thoroughly dried
i) Attachment and removal of hanging hooks, etc.
- Welding of parts such as hanging hooks for lifting shall be carried out in the shop. If
site welding is unavoidable, the welding shall be conducted under adequate control.
- Removal of temporary parts such as hanging hooks from the piles shall be
performed by oxy-acetylene cutting or other adequate method with great care to
prevent damage to the base metal of the piles.

viii) Inspection for the site Welding Work

a) The inspection of site welding shall be carried out by using ultrasonic test method
throughout with frequency 1 per about 20 welding joints probing from 4 directions,
30 cm circumferential length per direction. However, if necessary, the Engineer can
request more ultrasonic test to verify welding quality.
b) There shall be no cracks appearing in or near the weld beads. The inspection shall be
carried out by visually.
c) Butt welding joints shall be free of weld pits on the bead surface. There shall be no
height difference exceeding 5 mm. The depth of undercut shall not exceed 0.3 mm.
There shall be no overlap.

In order to verify the capacity of Screw Steel Piles, specified number of static tests shall be

July 2011 Page 6. 89

carried out on pilot piles in accordance with the instruction of the Engineer.

4.11.4 Measurement and Payment

Payment shall be made for design, installation and completion of screwed steel piles including
all associated costs to carry the designated working loads including the pile cap weight and also
satisfying the load test criteria all as per design.

Pay Item No. Description Unit Measurement

xxxxxxx Supplying, handling, Liner meter
transporting, pitching and
driving piles

4.12 LATERAL LOAD TEST

4.12.1 Description

This Work shall consist in performing Lateral Load Test on Pile in conformance with ASTM
03966 or equivalent standard as approved by the Engineer. Any alternate test methods proposed
by the contractor shall be at the discretion of the Engineer and within stipulated costs and will
have to be prior approved before commencement of work.

4.12.2 Materials

The standards for all materials (concrete, rebar etc.) used in the construction of the load test shall
conform to the relevant drawings, project specifications and RHD Technical Specifications, 2022
or other applicable standards and methods acceptable to the Engineer.

4.12.3 Construction

i) Method of Load Application

Lateral load testing shall begin after Axial Compressive Load tests are completed on the relevant
test piles.
The Contractor shall provide the required test loads shown on the Drawings by jacking between
two test piles simultaneously using one or more jacks. The minimum distance between the test
pile and the reaction pile(s) shall be five test pile diameters. The minimum distance between the
test pile and the reaction may be greater than five test pile diameters if not testing the piles
simultaneously. The Contractor shall submit method statement of conducting to Lateral Load
Test to the Engineer for his review and approval.

July 2011 Page 6. 90

The Contractor may request approval for supplying the reaction for the lateral load test by
another method. In that case, the Contractor shall submit alternative method statement with
appropriate detailed representative Drawings for the approval by the Engineer.
ii) Load Application System
The load shall be applied by means of one or more hydraulic jacks having a total capacity of at
least two times the maximum loads shown on the Drawings and in the project specific
specifications. The jack load shall be transferred to the test piles by means of steel bearing plates
that bear firmly against the test piles. Bearings and bearing plates shall be of steel and of
sufficient size to accommodate the testing equipment used and to transmit the applied loads
without detrimentally high unit pressures. The heads of the piles shall be capped so as to provide
plane vertical bearing surfaces for the bearing plates, or the bearing plates shall be set in high-
strength grout or adequately welded to the sides of the piles using suitable filler material to
provide full bearing against the piles.

All instrumentation and hydraulic jack(s), load cell(s), pump etc. shall be approved by the
Engineer.

A. Reference Beam

The reference beam for LVDTs (linearly variable differential transducers) or dial gauges shall be
supported on supports firmly anchored at a minimum clear distance of 3 m or as shown on the
Drawing from the test piles. The reference beam shall be oriented perpendicular to the line of
load application and located at a sufficient distance from the test piles to avoid interference with
the test piles throughout the test. The surfaces on which the gage stems bear shall be smooth
finished, such as glass or sheet acrylic, attached by a suitable adhesive.

B. Measurement of Lateral Movement of Pile Top

A primary and a secondary movement of test pile shall be measured with an inclinometer or
other approved instrument.

iii) Load Procedure

The loading procedure shall be the Standard Loading Procedure specified in ASTM D 3966 and
as outlined in the Table below.

Percentage of Design Load Duration

Load (minutes)
0 -
25 10
50 10
75 15
100 20
125 20
150 20

July 2011 Page 6. 91

 170 20
180 20
190 20
200 60
150 10
100 10
50 10
0 -

Additional cycles of loading or unloading using similar procedures may be required by the
Engineer following the completion of the initial test cycle. The Engineer shall decide to
terminate the test if an unsafe eccentric loading condition develops as a result of high or out of-
line pile movements. The Contractor shall be responsible for the safety and structural stability of
the test.

Tolerance

To determine lateral load capacity, a lateral load test shall be performed with at least two times
the proposed design working load as specified in the drawings. Allowable lateral capacity based
on BNBC 2020 shall satisfy the following criteria. The safe load on single pile for the initial test
should be least of the following:

˗ 50% of the lateral load at which the pile head displacement is 12mm or lateral load
specified to any other specified displacement as per project requirement for performance
evaluation.

˗ Final load at which the total displacement corresponds to 5mm.

˗ Load corresponding to any other specified displacement at specified locations in single or

group piles as per performance requirement.

4.12.4 Measurement and Payment

Lateral Load Test shall be measured in number of Lateral Load Tests completed and accepted by
the Engineer.

The payment shall be the full compensation for furnishing all labor, materials, and equipment
necessary to satisfactorily complete the work including everything to assemble, install, conduct
and remove the lateral load test equipment, as well as all report preparation, costs associated with
the procurement, fabrication, and installation of the test piles including procurement and
installation of the instrumentation.

Pay Item No. Description Unit Measurement

xxxxxxx Lateral Load Test Nos.

July 2011 Page 6. 92

4.13 PARALLEL SEISMIC TEST

4.13.1 Description

This work shall consist in performing parallel seismic logging of deep foundation in
conformance with ASTM D8381/D8381M-21 or equivalent standard as approved by the
Engineer. Any alternate test methods proposed by the contractor shall be within stipulated cost
and at the discretion of Engineer and will have to be prior approved before commencement of
work.

4.13.2 Equipment

In the PS method, the receiver response must be recorded. The equipment needed to perform the
data collection includes the following:
1. Digital signal analyzer (or PC-based data acquisition) system with at least two channels with
at least 4096 data points per channel.
2. Instrumented impulse hammers weighing 1.4–5.5 kg to impart and measure the impact force.
This signal is also used to trigger the data acquisition on impact.
3. Hydrophone receivers are required for borehole-based PS tests

4.13.3 Construction

In order to conduct the test, a vertical plastic tube is installed into a hole in the ground. The tube
should be parallel to the Pile or Pier or Foundation Element to be tested. The horizontal distance
between the tube and foundation element should not exceed 0.5m. The diameter of the tube
should not be less than 40 mm and it should be installed up to the depth which is 3 m greater
than the expected lowest level of the foundation element under consideration. When the tube is
installed in dry soil, the annular space between the tube and the hole is filled with cement grout
from top to bottom of the tube.

At the beginning of the test, the plastic tube is filled with clear water, because hydrophone is
lowered down the tube to capture P-waves (Compressional Wave). The tube is capped at the top
and bottom to avoid ingress of debris and any leakage of water from the tube until the test is
completed.

The hydrophone is sensitive to audio frequencies and it is kept at every 0.5m depth (from EGL)
to receive P-wave data, as the hammer hits the nearby structural component supported by the
foundation being tested. The depth of the hydrophone, placed at different depths inside the tube,
is obtained by the depth meter. The test is carried out from the top to bottom of the tube.

At each depth, the top of the foundation element or an appropriate spot on the superstructure is
hit with the hammer. The location of the hammer striking point is kept constant all through the
test. The hammer stroke creates longitudinal waves that travel down the foundation element and
then through the soil, and the hydrophone (placed inside the tube) receives the P-wave travelling
through the soil. The waves that arrive at the hydrophone are transmitted to the PSI and recorded

July 2011 Page 6. 93

in the computer which is connected to it. Upon completion of the test, a profile of P-wave forms
with depth is obtained by compiling the recorded waves to the respective wave receiving depths
by the hydrophone.

Thus, FAT-Depth Plot has two straight lines with two different slopes. The depth corresponding
to the intersecting point of these two lines is considered the lowest depth of the foundation
element.
Summary of the PSI Test Outcome
Item Unit Value
The point where the slopes of the straight
M
lines in the FAT-Depth Plot changes
Extended Length of tube above EGL M
Estimated Pile Length M
Wave Velocity in pile m/sec
Wave Velocity in soil m/sec

4.13.4 Measurement and Payment

Parallel Seismic Test shall be measured in number of tests completed and accepted by the
Engineer.

Payment for Parallel Seismic Test shall be full compensation for Pile Instrumentation, labor,
transportation, professionals, recording, and reporting including all incidentals necessary to
complete the test.

Pay Item No. Description Unit Measurement

xxxxxxx Parralel Seismic Test Nos.
(PST)

4.14 HIGH STRAIN DYNAMIC TESTING OF PILES

4.14.1 Description

This test method obtains the force and velocity induced in a pile during an axial impact event.
Force and velocity are typically derived from measured strain and acceleration. The Engineer
may analyze the acquired data using engineering principles and judgment to evaluate the
integrity of the pile, the performance of the impact system, and the maximum compressive and
tensile stresses occurring in a pile. This Work shall consist in performing a High Strain Dynamic

July 2011 Page 6. 94

Load Test on Pile in conformance with ASTM D4945 or equivalent standard as approved by the
Engineer. Any alternate test methods proposed by the contractor shall be within stipulated cost
and at the discretion of Engineer and will have to be prior approved before commencement of
work.

4.14.2 Material

The standards for all materials (concrete, rebar, etc.) used in the construction of the load test
shall conform to the relevant drawings, project specifications, and RHD Technical
Specifications, 2022, or other applicable standards and methods acceptable to the Engineer.

4.14.3 Construction

i) Pile Driving Modeling

The engineer who performs the driving modeling and signal matching shall have a minimum of 5
years of dynamic pile testing and analysis experience. Hammer specifications that will be used
for testing shall be prior approved by the Engineer. The contractor shall perform preconstruction
wave equation analyses and prepare a summary report of the results. The acceptability of the
wave equation report and the adequacy of analyses will be determined by the Engineer.

ii) Testing Operations

Dynamic pile testing field measurements shall be carried out using approved equipment,
software and recording equipment. The data collected at the end of initial driving and the
beginning of re-strike shall be analyzed using approved signal matching techniques and software.

The equipment required to be attached to the pile shall be appropriately positioned and fixed to
the approval of the Engineer.

The hammer and all site equipment used shall be capable of delivering an impact force sufficient
to mobilize the specified nominal axial resistance indicated in the design without damaging the
pile.

The testing equipment shall monitor pile stresses during driving to prevent pile damage and
ensure pile integrity and capacity. If the testing equipment indicates overstressing or damage to
the pile, immediately discontinue driving.

iii) Dynamic Measurement and Analysis

Monitoring of pile driving shall begin when pile driving begins unless otherwise approved by the
Engineer. The data shall be recorded and processed immediately in the field by the pile driving
monitoring equipment and software. Unless monitoring indicates that additional driving will
damage the pile, pile driving, and monitoring shall continue until both the specified pile tip
elevation and the required nominal axial resistance are reached. For each pile tested, pile driving
analysis using signal matching techniques shall be performed for a selected blow at the end of

July 2011 Page 6. 95

driving to determine the relative resistance from end bearing and skin friction along the pile.

On completion of all field work, the specialist engineer shall prepare a final report covering all
aspect of pile load-settlement behaviour including ultimate tip resistance and ultimate shaft
resistance. This final report shall incorporate results of the PDA monitoring, and results of all
CAPWAP computer analyses. The results of CAPWAP analysts shall be compared to the PDA
results and correlations shall be drawn between the CAPWAP results and the PDA field
monitoring results.

4.14.3 Measurement and Payment

High Strain Dynamic Test shall be measured in number of tests completed and accepted by the
Engineer. Payment for High Strain Dynamic Test shall be full compensation for Pile
Instrumentation, Accelerometer, Strain transducer, Pile Driver Analyser, Impact Pile Driving
Hammer, labor, transportation, professionals, recording, and reporting including all incidentals
necessary to complete the test.

Pay Item No. Description Unit Measurement

xxxxxxx High Strain Dynamic Test Nos.

(HSDT)

4.15 ULTRASONIC CROSS-HOLE TESTING

4.15.1 Description

This test method covers procedures for checking the homogeneity and integrity of concrete in
deep foundation such as bored piles, drilled shafts, concrete piles, or auger-cast piles. This
method can also be extended to diaphragm walls, barrettes, dams, etc. The test measures the
propagation time and relative energy of an ultrasonic pulse between parallel access ducts (cross-
hole) or in a single tube (single hole) installed in the deep foundation element. This method is
most applicable when performed in tubes that are installed. Any alternate test methods proposed
by the contractor shall be within stipulated cost and at the discretion of Engineer and will have to
be prior approved before commencement of work.

4.15.2 Material

The material and equipment used for testing shall be prior approved by the Engineer. The table

July 2011 Page 6. 96

below indicates the materials required to be incorporated into the work and approved by the
Engineer.

Description Remarks
Sonic tube and fittings Pipe, Coupler, End closure
Joint clamp For joining Tubes
Steel U clips For joining Tubes to the cage

The table below indicates the equipment required to be incorporated into the work and approved
by the Engineer:

Description Remarks
Depth Wheel / Counter
Cable
Microprocessor based For recording and displaying data, converting data from
system analogue to digital format, analyzing receiver responses,
and printing logs.
DC battery power source

The following documents shall be submitted after product delivery.

- Catalogue and calibration certificate of all equipment’s
- Dimensional inspection list (for tubes)

4.15.3 Construction

The Contractor shall submit all relevant details of the method of conduction of cross-hole sonic
load tests and equipment he plans to utilize for approval of the Engineer.

i) General
a. In this test, the transit time of an ultrasonic compressional wave (or p-wave) signal
from a signal source in one access tube to a receiver in another access tube is
measured from the bottom to the top of a foundation.
b. Then, knowing tube separation distance, the p-wave velocity is calculated for each
depth horizon which results in a profile plot of velocity with respect to depth.
c. In a nominal foundation with uniform, "good" quality concrete, the acoustic travel
time between equidistant tubes will be relatively constant over the depth of the
foundation which varies within 3,600 m/sec ~ 4,400 m/sec. Poor quality concrete
containing defects (for example, soil inclusion, gravel, water, drilling mud, bentonite,
voids, contaminated concrete, or excessive segregation of the constituent particles)
has a comparatively lower P-wave speed. By measuring the transit time of an
ultrasonic P-wave signal between an ultrasonic transmitter and receiver in two
parallel water-filled access ducts cast into the concrete during construction and
spaced at a known distance apart, such anomalies may be detected.
d. On the other hand, an improper concrete mix, voids, or other non- cemented intrusive
materials can cause decreased-velocity anomalies. Complete loss of signal may
indicate a severe defect.

July 2011 Page 6. 97

ii) Testing Arrangement
a) Sonic tubes are supplied and installed around the perimeter of the reinforcement
cage that is installed in the drilled shaft(s) to be tested.
b) These tubes provide the source and receiver probes with access to the full foundation
length from top to bottom.
c) After placing concrete during pile construction and waiting a minimum of 72 hours
for concrete curing, CSL tests can be performed.
d) Sonic tubes placed on the reinforcement cage should have a minimum concrete
cover of diameter approximately 50mm.
e) Round tubes with a regular internal diameter free of defects and obstructions,
including any tube joints, shall be used to permit the free, unobstructed passage of
the probes.
f) Tubes shall be watertight and free from corrosion with clean external faces to ensure
a good bond between the concrete and the tubes.
g) Tubes may be extended with mechanical couplings. Duct tape or other wrapping
material to seal the joints and butt-welding of joints should not be used.
h) When couplings are used, it is required to record their location.
i) The piling contractor should install tubes such that the CSL probes pass through the
entire length of the tube without binding.
j) It is also required to ensure that the access tubes are plumb and verify that
unobstructed passage of the probes is achievable before the CSL.
k) The tubes should be fit with a watertight shoe on the bottom and a removable cap on
the top. Tubes shall be secured to the interior of the reinforcement cage at regular
intervals.
l) Tubes shall be installed uniformly and equidistantly around the circumference such
that each tube is spaced parallel for the full length and at the maximum distance
possible from each end tube.
m) Tubes shall not be damaged during installation of the reinforcement cage.
n) Tube tops shall be capped to prevent debris from entering the access tubes. No
excessive torque, hammering or other stresses is applied, which could break the bond
between the tube and concrete when removing caps from the tubes.
o) Number and spacing of vertical sonic pipes dependent on the size of the bored pile
shall be specified by the contractor.

iii) Test Procedure

a) Standard CSL test is to be carried out keeping source and receiver probe in the same
horizontal plane.
b) Both the transducer and receiver are to be lowered to the bottom of two separate tubes
before the test is started.
c) The tubes are attached to the rebar structure in the drilled shaft prior to pouring concrete.
d) During piling period the tubes are filled with water and capped so that concrete doesn't
get inside the tube which is cut off after completion of piling and the water is driven out
using water jet cleaning the tube before starting the test.
e) The tubes are then again filled with water which acts as a coupling agent between a

July 2011 Page 6. 98

 transducer and the drilled shaft.
f) The transducer generates an ultrasonic signal that propagates through the concrete.
g) The cables attached to the probes are simultaneously hand-pulled over the depth wheel to
steadily bring the probes to the surface.
h) Prior to pulling, any slack in the cables is removed to ensure accurate depth
measurements in the CSL records.
i) While traversing a tube pair, CSL acoustic travel time and signal energy measurements
made at certain intervals should be specified by the contractor.
j) These measurements are plotted as depth vs. relative energy and depth vs. first arrival
time (FAT). After completion of the test, the pipe is exerted and the hole is filled using
non-shrinkable grout having the same concrete strength as the pile or more.
k) Grout pressure to be applied is considered to be between 0.3MPa to 1.0MPa depending
on the viscosity and density.
l) While in the field, testing agency personnel evaluate the measured data as well as the
derived sonic velocities in terms of completeness and accuracy.
m) A preliminary evaluation of the integrity of the concrete in the foundations tested can
generally be provided in the field.

iv) Tolerance

Results of the CSL shall be presented in a written report shall be submitted within (5) working
days of completion of testing. The report shall include presentation of CSL logs for all tested
tube pairs including:

1. Presentation of the traditional nested signal peak (e.g., “waterfall”) diagram as a function
of time plotted versus depth.
2. Computed pulse first arrival time (FAT) or pulse wave speed versus depth.
3. Computed relative pulse energy or amplitude versus depth.

A CSL log shall be presented for each tube pair. The rating of the shaft integrity considers the
increases in “first arrival time” (FAT) and the energy reduction relative to the arrival time or
energy in a nearby zone of good concrete.

The criteria for evaluation of the concrete from the CSL test shall follow:

Description Remarks
FAT increase 0 to 10% and Energy Reduction < 6 db Good (G)
FAT increase 11 to 20% and Energy Reduction of < 9 db Questionable (Q)
FAT increase 21 to 30% or Energy Reduction of 9 to Flaw (F)
12 db
FAT increase >31% or Energy Reduction > 12 db Defect (D)

Flaw or Defect zones, if any, shall be indicated on the logs, listed in a table, and their horizontal
and vertical extent and location discussed in the report text. Flaws must be addressed if they
affect more than 50% of the profiles. Defects must be addressed if they affect more than one
profile (a profile is the result of complete investigation from bottom to top between two tubes)

July 2011 Page 6. 99

at the same cross section. Flaws or Defects covering the entire cross section define a full layer
concern requiring repair. “Addressing” a Flaw or Defect means as a minimum, an evaluation by
tomography if the concern is localized (e.g. not across the full section), and/or, depending on
the depth to the concern, additional measures like core drilling, repair or replacement, repeat
tests after a long waiting time or testing by other methods (gamma-gamma, low strain, high
strain).

4.15.4 Measurement and Payment

Payment shall be made for all costs incurred related to testing including, but not limited to
procurement, preparation and installation, conductions of the tests, and subsequent reporting of
the results.
Pay Item No. Description Unit Measurement
xxxxxxx Conduction of Cross-hole Nos
sonic load test on xxx diameter
pile including reporting of the
results

July 2011 Page 6. 100

SECTION-7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

DIVISION 5
STRUCTURES
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

DIVISION 5 - STRUCTURES

Table of Contents
DIVISION 5 - STRUCTURES ..........................................................................................................................ii

5.1 CONCRETE FOR STRUCTURES ............................................................................. 1

5.1.1 Description 1
5.1.2 Materials 1
5.1.2.1 Specifications for Materials ............................................................................................................1
5.1.2.2 Testing of Materials 3
5.1.2.3 Composition of Concrete ...............................................................................................................4
5.1.2.4 Control of Concrete Quality .............................................................................6
5.1.3 Construction Methods ..................................................................................................................9
5.1.3.1 General 9
5.1.3.2 Scaffolding and Formwork ...............................................................................9
5.1.3.3 Care and Storage of Concrete Materials .......................................................11
5.1.3.4 Preparations before Casting ..........................................................................12
5.1.3.5 Measuring Materials 12
5.1.3.6 Mixing Concrete 12
5.1.3.7 Handling and Placing Concrete .....................................................................15
5.1.3.8 Perforations and Embedment of Special Devices .........................................18
5.1.3.9 Finishing Concrete Surfaces .........................................................................18
5.1.3.10 Construction Joints 20
5.1.3.11 Curing Concrete 21
5.1.3.12 Removal of Scaffolding and Formwork .........................................................21
5.1.3.13 Repair of Concrete 21
5.1.3.14 Depositing Concrete under Water .................................................................22
5.1.3.15 Factory Made Precast Concrete Elements ....................................................22
5.1.3.17 Grouting of Ducts for Prestressing Tendons .................................................23
5.1.3.18 Loading 26
5.1.3.19 Backfill to Structures 26
5.1.3.20 Cleaning Up 26
5.1.4 Specifications for higher strength Concretes (40, 45 & 50 MPa) ................................................26
5.1.5 Measurement 27
5.1.6 Payment 27
5.2 REINFORCEMENT 29
5.2.1 Description 29
5.2.2 Materials 29
5.2.2.1 Bar Reinforcement 29
5.2.2.2 Wire Mesh 30
5.2.2.3 Binding Wire 30
5.2.2.4 Bar Sizes 30
5.2.2.5 Ordering Material 31
5.2.2.6 Additional Tests 31
5.2.3 Construction Methods .......................................................................................32
5.2.3.1 Protection and Storage .....................................................................................32
5.2.3.2 Cutting and Bending 32
5.2.3.3 Placing, Supporting and Fastening ...............................................................32
5.2.3.4 Splicing 32
5.2.3.5 Substitutions 33
5.2.4 Measurement 33
5.2.5 Payment 33

5.3 PRESTRESSING REINFORCEMENT ..................................................................... 35

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

5.3.1 Description 35
5.3.1.1 General 35
5.3.1.2 Definitions 35
5.3.2 Materials 35
5.3.2.1 Tendons for Post Tensioning Systems ..........................................................35
5.3.2.2 Anchorage Assemblies ..................................................................................35
5.3.2.3 Sheathing 36
5.3.3 Construction Methods .......................................................................................36
5.3.3.1 General 36
5.3.3.2 Storage of Materials 37
5.3.3.3 Manufacture of Tendons ...............................................................................37
5.3.3.4 Placing Tendons and Sheathing ...................................................................37
5.3.3.5 Placing Anchorages 38
5.3.3.6 Jacks for Prestressing 38
5.3.3.7 Post-tensioning Procedure ............................................................................38
5.3.3.8 Grouting 39
5.3.3.9 Finishing off Tendons 39
5.3.3.10 Pre-Tensioning 40
5.3.4 Measurement 40
5.3.5 Payment 40

5.4 EXISTING CONCRETE ........................................................................................... 41

5.4.1 Description 41
5.4.2 Materials 41
5.4.2.1 Concrete 41
5.4.2.2 Reinforcement 41
5.4.2.3 Prestressing Reinforcement ..........................................................................41
5.4.2.4 Cement Grout and Mortar .............................................................................41
5.4.2.5 Resin Repair Mortars 41
5.4.3 Construction Methods .......................................................................................41
5.4.3.1 General 41
5.4.3.2 Workmanship 43
5.4.4 Measurement 43
5.4.5 Payment 43

5.5 BRICKWORK ......................................................................................................... 44

5.5.1 Description 44
5.5.2 Materials 44
5.5.2.1 Specifications for Materials ...........................................................................44
5.5.2.2 Specifications for Mortar ................................................................................45
5.5.3 Construction Methods ......................................................................................45
5.5.3.1 General 46
5.5.3.2 Workmanship 47
5.5.3.3 Brick Drainage Layers 47
5.5.4 Measurement 47
5.5.5 Payment 47

5.6 PAINTING METAL STRUCTURES ......................................................................... 48

5.6.1 Description 48
5.6.2 Materials 48
5.6.2.1 General 48
5.6.2.2 Prime Coat 49
5.6.2.3 Undercoat 49
5.6.2.4 Finish Coat 49
5.6.3 Construction Methods .......................................................................................49
5.6.3.1 Cleaning of Surfaces 49
5.6.3.2 Number of Coats and Colour .........................................................................51

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

5.6.3.3 Weather Conditions 51

5.6.3.4 Mixing of Paint 51
5.6.3.5 Application 51
5.6.3.6 Painting Galvanized Surfaces .......................................................................52
5.6.4 Measurement 52
5.6.5 Payment 52
5.6.6 Cold Galvanizing Compound for Galvanic Protection............................................................52
5.6.6.1 General 52
5.6.6.2 Materials 52
5.6.6.3 Construction Procedure: .................................................................................................................53
5.6.6.4 Application of Cold Galvanizing Compound: .....................................................................................53
5.6.6.5 Measurement: 54

5.7 BRIDGE STEELWORK........................................................................................... 56

5.7.1 Description 56
5.7.2 Materials 56
5.7.3 Construction Methods .......................................................................................56
5.7.3.1 Unit Bridging 56
5.7.3.2 Steel Beams for Composite Bridges .................................................................................................57
5.7.4 Measurement 57
5.7.5 Payment 57

5.8 MOVEMENT JOINTS ............................................................................................. 59

5.8.1 Description 59
5.8.2 Materials 59
5.8.2.1 Expansion Joints 59
5.8.2.2 Bridge Deck Joints 60
5.8.2.3 Joint Performance Requirements ..................................................................60
5.8.2.4 Storage of Materials and Protection against Corrosion .................................60
5.8.2.5 Construction Methods .......................................................................................60
5.8.2.6 Measurement 61
5.8.2.7 Payment 61
5.9 DRAINAGE OF STRUCTURES ..........................................................................63
5.9.1 Description 63
5.9.2 Materials 63
5.9.2.1 Bridge Gullies 63
5.9.2.2 Cast Iron Piping 63
5.9.2.3 PVC Pipes 63
5.9.2.4 Cleaning Boxes 63
5.9.2.5 Catch Basins 63
5.9.2.6 Culvert Pipes 63
5.9.2.7 Inserts 63
5.9.2.8 Fittings and Other Incidentals ........................................................................63
5.9.3 Construction Methods .......................................................................................63
5.9.3.1 Storage and Handling of Materials ................................................................63
5.9.3.2 Bridge Gullies 64
5.9.3.3 Cast Iron Piping 64
5.9.3.4 PVC Pipes 64
5.9.3.5 Cleaning Boxes 64
5.9.3.6 Catch Basins 64
5.9.3.7 Culvert Pipes 64
5.9.3.8 Weep Holes 64
5.9.3.9 Inserts 65
5.9.4 Measurement 65
5.9.5 Payment 65

5.10 INSERTS AND FITTINGS IN STRUCTURES ......................................................... 65

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

5.10.1 Description 65
5.10.2 Materials 65
5.10.3 Construction Methods .......................................................................................65
5.10.4 Measurement 66
5.10.5 Payment 66

5.11. BRIDGE BEARINGS (ELASTOMER)...................................................................... 67

5.11.1 Descriptions 67
5.11.2 Materials 67
5.11.2.1 Elastomer 67
5.11.2.2 Steel Laminates 67
5.11.2.3 Bond 67
5.11.3 Fabrication and Installation ..............................................................................68
5.11.3.1 General 68
5.11.3.2 Fabrication tolerances ...................................................................................68
5.11.3.3 Permission for fabrication ..............................................................................69
5.11.3.4 Testing facilities for fabrication ......................................................................69
5.11.3.5 Quality control certificate ...............................................................................69
5.11.3.6 Sample Testing of Bearings ..........................................................................70
5.11.4 Installation 70
5.11.4.1 Cement Mortar Bearings pad ........................................................................70
5.11.4.2 Bearings 71
5.11.4.3 Maintenance 71
5.11.5 Measurement 71
5.11.6 Payment 71
5.12 BRIDGE BEARINGS (POT BEARING) ............................................................................................73
5.12.1 Description 73
5.12.1.1 Design and Applicable Codes .....................................................................73
5.12.1.2 Manufacturers 73
5.12.1.3 Substituted Bearings .....................................................................................73
5.12.2 Materials 73
5.12.2.1 Metals 73
5.12.2.2 Poly tetra fluoro ethylene (PTFE) ..................................................................74
5.12.2.3 Elastomer 74
5.12.2.4 Coal Tar Epoxy 76
5.12.2.5 Preformed Fabric Pads .................................................................................................................76
5.12.2.6 Sealing Rings 76
5.12.2.7 Grouts 77
5.12.3 Design Requirements ........................................................................................77
5.12.3.1 Elastomeric Disc 77
5.12.3.2 Sliding Surfaces 77
5.12.3.3 Rotation 78
5.12.3.4 Movement 78
5.12 .3.5 Welding 78
5.12.3.6 Submission of shop drawings .........................................................................................................78
5.12.4 Certifications 78
5.12.5 Fabrication 78
5.12.5.1 PTFE 78
5.12.5.2. Bolts and Bolt Holes ....................................................................................................................79
5.12.5.3 Welding 79
5.12.5.4 Protective Measures 79
5.12.6 Testing 79
5.12.6.1Testing facilities for fabrication .........................................................................................................80
5.12.6.2 Sample testing: Procedures and Compliance .................................................................................80
5.12.7 Products Delivery Storage and Handling .....................................................................................81
5.12.7.1Assembly and Marking .....................................................................................................................81
5.12.7.2 Care and Protection 81
5.12.8 Installation 81

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

5.12.8.1 General 81
5.12.8.2 Tolerances 82
5.12.9 Shock Transmission Units ..............................................................................................................82
5.12.9.1 General 82
5.12.9.2 Model Testing of Yielding shock Transmission Unit ......................................82
5.12.10. Other types of bearings ................................................................................................................83
5.12.10.1 Steel-laminated Elastomeric/Neoprene bearings .........................................................................83
5.12.11 Measurement 83
5.12.12 Payment 83

5.13. BEARING REPLACEMENT .................................................................................... 84

5.13.2 Construction 84

5.14. BRIDGE SUPER-STRUCTURE (PRECAST PRESTRESSED CONCRETE

GIRDERS) .............................................................................................................. 86
5.14.1 Description 86
5.14.2 Materials 86
5.14.2.1 Girder 86
5.14.2.2 Bearings 86
5.14.2.3 Non-Shrink Grout 86
5.14.3 Construction 86
5.14.3.1 General 87
5.14.3.2 Handling and Transportation of Girders ........................................................87
5.14.3.3 Temporary Work 88
5.14.3.4 Installation of Bearings ..................................................................................88
5.14.3.5 Erection of Girder 88

5.14. BRIDGE SUPER-STRUCTURE (PRE-CAST/ CAST IN-SITU VOIDED SLAB) ........ 91

5.14.1 Description 91
5.14.2 Construction 91

5.15. BRIDGE SUPER-STRUCTURE (PRE-CAST/ CAST IN-SITU SEGMENTAL

BRIDGE)................................................................................................................. 93
5.15.2.1 General 94
5.15.2.1 Casting Works 94
5.15.2.1 Embedded Elements 94
5.15.2.1 Tolerances 95
5.15.2.1 Erection 95

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

5.1 CONCRETE FOR STRUCTURES

5.1.1 Description
This work shall consist of the construction of all or portions of structures of cement concrete,
of the required grades and types, with or without reinforcement, prestressed reinforcement
and with or without admixture, in accordance with these Specifications and to the lines,
levels, grades and dimensions shown on the Drawings and required by the Engineer.
Cement concrete shall consist of a mixture of cement, water and coarse and fine aggregate
with or without admixture.

5.1.2Materials

5.1.2.1 Specifications for Materials

A) Cement
Cement shall conform to the requirements of AASHTO Standard Specification M 85 type
1, normal Portland cement, unless other types are indicated on the Drawings or specified
by the Engineer.
Cement shall be sampled and tested in accordance with STP Sections 2.6 and 8.
Bagged or bulk cement which has partially set or which contains lumps of caked cement
shall be rejected. The use of cement reclaimed from discarded or used bags shall not be
permitted.

B) Water
The water used in mixing and curing concrete shall be tested by methods described in
AASHTO Test Method T 26. All water shall be clean and free from salt, oil, acid,
vegetables or other harmful substances. The use of river water will be subject to the
approval of the Engineer.

C) Admixtures
Admixtures or any other additions shall not be used except with the written approval of
the Engineer.
Admixtures, if specified or permitted, shall fully conform to the requirements of
AASHTO Standard Specification M 194-74.

D) Coarse Aggregate
Coarse aggregate for all types of concrete with the exception of blinding concrete shall
consist of hard durable crushed or broken rock and generally conform to the requirements
of AASHTO Standard Specification M 80. Coarse aggregate shall be clean, free from
dust and other deleterious materials and shall be in Saturated Surface Dry (SSD)
condition.
The amounts of deleterious substances shall not exceed the following limits:
1) Soft fragments; 2% by mass
2) Clay lumps; 0.25% by mass
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

3) Material Passing the 0.075 mm sieve; 0.50% by mass if clay, 1.50% by mass if
fracture dust
In addition, coarse aggregates shall comply with the following:
1) Thin or elongated pieces; Flakiness Index (STP 7.3.1) less than 30
2) The aggregate crushing value (STP 7.7.1) shall be less than 30% and the ten
percent fines value (STP 7.7.2) shall be greater than 150 kN.
The grading of coarse aggregate of Nominal maximum size 20 mm shall conform to
Table 5.1-1 below. The grading of 40 mm maximum size coarse aggregate shall be in
accordance with AASHTO Standard Specification M 80.

Table 5.1-1
Grading Requirements for 20 mm Nominal Maximum Size
Coarse Aggregate
Sieve Size (mm) % Passing by Weight
25 100
20.0 90 - 100
12.5 20 - 55
10.0 5 - 20
5.0 0-5
2.4 -
1.2 -
In heavily reinforced structures with difficult casting conditions, smaller size aggregates
may be used if approved by the Engineer.

E) Fine Aggregate
Fine aggregate shall consist of natural sand and fine aggregates from different sources of
supply shall not be mixed or stored in the same pile.
The amounts of deleterious substance when tested in accordance with STP 3.4 shall not
exceed the following limits:

1) Friable Particles; 0.5% by mass

2) Coal and Lignite; 0.5% by mass
3) Material passing the 0.075 mm sieve; 3.0% by mass; corresponding FM shall
be checked by the Engineer before use
4) Any other deleterious materials shall not cause a strength reduction of the
concrete of more than 5% in relation to the strength of concrete free of the
concerned deleterious material.

The grading shall normally be in accordance with Table 5.1-2. In the event that it is not
possible to obtain regular supplies of sand conforming to this grading, the Engineer may
approve the adoption of a grading conforming to the requirements of table 4 with
additional limits of either C or M of BS 882: 1992. However, any additional costs
resulting from changes in aggregate proportions or additional cement contents required to

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

achieve the specified strengths, when using these alternative gradings, shall be borne by
the Contractor and shall not be reimbursed.

Table 5.1-2
Grading Requirements for Fine Aggregate
Sieve Size (mm) % Passing by Weight
10.0 100
5.0 95 – 100
1.2 45 – 80
0.30 10 – 30
0.15 2 – 10

5.1.2.2 Testing of Materials

A) Cement
Cement shall be in accordance with AASHTO M 85. The Contractor must provide the
Engineer with manufacturer’s certificates indicating compliance.
Cement shall be sampled and tested for fineness, setting time and strength in accordance
with STP 8.1, STP 8.2 and STP 8.3, respectively, at the Contractor’s expense. The
Contractor shall notify the Engineer of delivery dates so that there will be sufficient time
for sampling the cement, either at the mill or upon delivery. If this is not done, the
Contractor may be required to re-handle the cement in the store for the purpose of
obtaining the required samples.
Sampling shall normally be instructed by the Engineer for every batch of cement prior to
this cement being incorporated in the Works.

B) Water
The water proposed by the Contractor to be used in mixing or curing concrete shall be
tested by methods described in AASHTO Test Method T 26.
In sampling water for testing, care shall be taken that the containers are clean and that
samples are representative.
When comparative tests are made with a water of known satisfactory quality, any
indication of unsoundness, marked change in time of setting, or a reduction of more than
10 percent in mortar strength, shall be sufficient cause for rejection of the water under
test.
The water shall be tested at a recognized laboratory approved by the Engineer. The test
result shall be signed by the laboratory. The water shall be tested before commencement
of work or if the source is changed or at any time required by the Engineer. All testing
shall be carried out at the Contractor’s expense.

C) Admixtures
The Contractor shall submit specifications and samples of any admixtures or additives
that he proposes to use to the Engineer at least 28 days before the commencement of
construction or manufacture of the particular structure on which he intends to use such
admixtures.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

Any tests the Engineer may require on concrete mixes on account of the Contractor’s
proposal to use additives shall be carried out at the expense of the Contractor.

D) Aggregates
1) Selection and Approval
From the aggregate materials proposed by the Contractor, samples shall be selected
according to STP Section 2.4 and in the presence of the Engineer. The samples shall be
tested at the site laboratory or at an approved testing laboratory for conformance with
Section 5.1.2.1 of these Specifications.

2) Quality Control
The quality control of the aggregate shall be as directed by Engineer. Gradings shall
normally be checked daily.
Moisture contents of fine aggregate shall be determined daily and at any time when a
change in moisture content is expected.

If the Contractor proposes to change the source of aggregate, the Engineer shall be
informed in advance and in no case less than 3 weeks before the new aggregate shall be
used.

5.1.2.3 Composition of Concrete

A) Classes of Concrete
Concrete for incorporation in the Works shall be of the classes indicated on the Drawings
and shall comply with Table 5.1-3.

Table 5.1-3
Concrete Characteristic Nominal
Minimum
Strength Maximum
(N/mm2 @ 28 days) Size of
Cement
Coarse
Concrete Cylinder Cube Content
Aggregate
(150
Class (150 x 300 mm) (mm) (Kg/m3)
mm)
10 10 13 40 210
20 240
15 15 19 40 250
20 280
20 20 25 40 300
20 320
25 25 31 40 340
20 360
30 30 37 40 370
20 400
35 35 44 40 400
20 430
40 40 50 40 400
20 430
40 400
45 45 56
20 430
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

40 400
50 50 62
20 430
*Mix design shall conform the target strength as mentioned in the design.

B) Proportioning
When designing the concrete mix, the Contractor shall consider the following conditions:
1) Strength
The class of the concrete is to be as shown on the Drawings. The class is the specified
characteristic cylinder strength at 28 days. Concrete mixes shall be designed to comply
with Specifications Section 5.1.2.4.

2) Water/Cement Ratio
The ratio of free water to cement when using saturated surface dry aggregate shall be
maintained at minimum level for hydrationand not exceeding 0.50 by weight for all
concrete, except for blinding concrete where it shall not exceed 0.6, unless approved
by the Engineer.
For concrete in barriers, edge beams and bridge decks directly exposed to traffic or
concrete in pile caps or abutments in contact with the ground, the water cement ratio
shall not exceed 0.40, unless approved by the Engineer.

3) Minimum Cement Content

As indicated for the respective class in Table 5.1-2 or as specified in the Job Mix
Formula.

4) Minimum Filler Content

Filler content (fine aggregate less than 0.25 mm and cement) shall not be less than as
follows (except for mass concrete).
Maximum coarse (mm) 20 40
aggregate size

Minimum filler content (kg/m3 435 350

of
concrete)

5) Coarse Aggregate
The maximum size of coarse aggregate will generally be stated on the Drawings;
either 40 mm or 20 mm, in accordance with Table 5.1-1. Grading and quality is to
comply with the requirements of Section 5.1.2.1(D).

6) Fine Aggregate
The grading and quality is to comply with the requirements of Section 5.1.2.1

7) Workability

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

The concrete shall be of suitable workability to obtain full compaction. Slumps

measured in accordance with STP 9.1 shall not exceed 75 mm unless otherwise
indicated on the Drawings or approved by the Engineer.

C) Trial Mixes
After the Contractor has received approval for the cement and aggregate to be used, he
shall prepare trial mixes with concrete of designed proportions to prove and establish
workability, strength, water cement/ratio, surface criteria etc. Methods of transporting
fresh concrete and the compaction equipment shall be considered. The trial mixes shall be
made and compacted in the presence of the Engineer, using the same type of plant and
equipment as will be used for the Works.
From each trial mix, cylinders or cubes shall be made and tested in accordance with
Section 5.1.2.4.
From the same mix as that from which the test specimens are made, the workability of the
concrete shall be determined by the slump test in accordance with STP 9.1. The
remainder of the mix shall be cast in a wooden mould and compacted. After 24 hours the
sides of the mould shall be struck and the surface examined in order to satisfy the
Engineer that an acceptable surface can be obtained with the mix.
The trial mix proportions should be approved if the required strength is obtained from
tests carried out in accordance with Section 5.1.2.4 and the consistency and surface is to
the satisfaction of the Engineer.
When a mix has been approved, no variations shall be made in the mix proportions, or in
the type, size, grading zone or source, of any of the constituents without the consent of
the Engineer, who may require further trial mixes to be made before any such variations
are approved.
Until the results of trial mixes for a particular class have been approved by the
Engineer, no concrete of the relevant class shall be placed in the Works. If the
Concrete mix achieves minimum 75% of the target strength as specified in design, in
7 days, the Job Mix Formula may be provisionally approved by the Engineer.

When the Contractor intends to purchase factory-made/ready mix concrete units, trial
mixes may be dispensed with evidence provided to satisfy the Engineer that the factory
regularly produces concrete which complies with the Specifications. The evidence shall
include details of mix proportions, water/cement ratios, slump tests and strengths
obtained at 7 and 28 days.

5.1.2.4 Control of Concrete Quality

A) General
The Contractor shall assume the full responsibility for the quality of the concrete
conforming to these Specifications and this responsibility shall not be relieved by the
testing carried out and approved by the Engineer.
The Contractor shall thus at his own discretion establish additional testing procedures as
necessary.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

B) Control of Concrete Production

1) Materials
Materials used shall be tested in accordance with Section 5.1.2.2.

2) Plant and Equipment

Batching plants shall be calibrated and tested at standard intervals by any recognized
institution arranged by the Contractor subject to approval by the Engineer before any
major concrete casting,orat any other time if requested by the Engineer.

3) Fresh Concrete
The frequency of slump tests shall be as directed by the Engineer, with at least one
test per truck/transit of concrete mix.

C) Control of Strength
1) Sampling and Testing
Cube tests may be substituted for cylinder tests if acceptable to both the Engineer and
the Contractor. If cube tests are adopted, the concrete characteristic strengths shall be
as shown in Table 5.1-2. All other requirements of the Specifications shall equally
apply to cubes or cylinders.
The Contractor shall take samples of the concrete for testing. The number, frequency
and location shall be decided by the Engineer. A minimum of 3 concrete
cubes/cylinders should be taken for each day’s casting, or for every 15 m³ of concrete
cast in large pours. The slump of concrete samples shall be measured. The procedures
for sampling and making cubes/cylinders and testing them shall be as described in
STP 9.2.

2) Strength Requirement
The results of the testing shall conform to the strength requirements according to
British standard BS5400: Part 7, as given below, or to any mathematically correct
statistical test for each casting section.

D) Target Mean Strength

The concrete mix should be designed to have a mean strength greater than the
required characteristic strength by at least the current margin.
The current margin for each particular type of concrete mix shall be determined; it
may be taken as having the smaller of the values given by (1) or (2) below.
1) 1.64 times the standard deviation of tests on at least 100 separate batches of
concrete of nominally similar proportions of similar materials and produced over a
period not exceeding 12 months by the same plant under similar supervision.
2) 1.64 times the standard deviation of tests on at least 40 separate batches of
concrete of nominally similar proportions of similar materials and produced over a
period exceeding 5 days but not exceeding 6 months by the same plant under
similar supervision.

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

Where there are insufficient data to satisfy (1) or (2) above, the margin for the initial
mix design should be taken as two-thirds of the characteristic strength for concrete.
This margin should be used as the current margin only until sufficient data are
available to satisfy (1) or (2) above. However, when the required characteristic
strength approaches the maximum possible strength of concrete made with a
particular aggregate, a smaller margin may be permitted by the Engineer for the initial
mix design.

E) Testing Plan
Each cube shall be made from a single sample taken from randomly selected batches of
concrete.
Compliance with the specified characteristic strength may be assumed if:
1) The average strength determined from any group of four consecutive test cubes
exceeds the specified characteristic strength by not less than 0.75 times the current
margin, and
2) Each individual test result is greater than 95% of the specified characteristic
strength.

The current margin should be taken to be two-thirds of the specified characteristic

strength for concrete, unless as mentioned above a smaller margin has been established to
the satisfaction of the Engineer.
If only one cube result fails to meet the second requirement then that result may be
considered to represent only the particular batch of concrete from which that cube was
taken provided the average strength of the group satisfies the first requirement.
If more than one cube in a group fails to meet the second requirement or if the average
strength of any group of four consecutive test cubes fails to meet the first requirement
then all the concrete in all the batches represented by all such cubes shall be deemed not
to comply with the strength requirements. For the purposes of this sub-Section, the
batches of concrete represented by a group of four consecutive test cubes shall include the
batches from which samples were taken to make the first and the last cubes in the group
of four, together with all the intervening batches.

F) Action to be taken in the Event of Non-Compliance with the Testing Plan

When the average strength of four consecutive test cubes fails to meet the first
requirement in (F), above, the mix proportions of subsequent batches of concrete shall be
rejected.The mix designs shall be reviewed and modified to increase the strength.
The action to be taken in respect of the concrete which is represented by the test-cubes
which fail to meet either of the requirements (or not by correct statistical proof can be
verified to have the required strength) shall be determined by the Engineer.
The Engineer may also instruct the Contractor to prove statistically the strength, by
cutting/taking cores and testing them according to a programme approved by the
Engineer at Contractor’s expense. The age of the concrete and degree of hardening at the
time of the new testing shall be considered. The equivalent cylinder/cube strength shall
comply the minimum characteristic strength or as decided by the Engineer.
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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 5- STRUCTURES

G) Control of Hardening
If the Contractor wants to remove forms and scaffolding earlier than specified herein,
extra test specimens shall be cast by the Contractor in accordance with the instruction of
the Engineer. These specimens shall be tested the day before removal of the form. On the
basis of the test results the Engineer shall take the final decision on the time for the
removal of forms.
For prestressed concrete, extra test specimens shall be cast by the Contractor in
accordance with the instructions of the Engineer, to determine the time for tensioning the
tendons. On the basis of the test results, the Engineer shall decide upon the time for
prestressing the concrete.

5.1.3 Construction Methods

5.1.3.1 General
The Contractor shall in due time and as soon as possible present and discuss his
construction methods and work programme with the Engineer and shall obtain his
approval before commencement of any work.
The Contractor shall maintain an adequate number of trained and experienced supervisors
and foremen at the Site to supervise and control the work.
All construction, other than concrete, shall conform to the requirements prescribed in
other Sections of the Specifications, for the particular items of work comprising the
complete structure.

5.1.3.2 Scaffolding and Formwork

A) Scaffolding
Details, plans and structural calculations for scaffolding shall be submitted by the
Contractor to the Engineer for approval, but in no case shall the Engineer’s approval
relieve the Contractor of his Contract responsibilities. All scaffolding shall be designed
and constructed by the Contractor to provide the necessary rigidity and to support dead
and live loads without deflection or deformation. The Engineer may require the
Contractor to employ screw jacks or hardwood wedges to take up any settlement in
scaffolding and formwork, either before or during the placing of concrete.
Tests may be required by the Engineer of materials proposed by the Contractor for
scaffolding. Test loadings of the completed scaffolding may also be required for the
determination of flexibility and strength. All expenses associated with testing shall be
borne by the Contractor.
Scaffolding which cannot be founded on a satisfactory footing shall be supported on
piles, which shall be spaced, driven and removed in a manner approved by the Engineer.
When the Contractor wishes to support scaffolding on existing structures, he shall submit
his proposals in due time to the Engineer, in writing, including loads from the scaffolding.
The Engineer will consider the proposals and respond in writing.
Scaffolding shall be set to give the finished structure a camber, if indicated on the
Drawings or specified by the Engineer.
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Scaffolding shall remain in place for periods which shall be determined by the Engineer.

B) Formwork
Formwork shall include all temporary or permanent moulds for forming the concrete.
Formwork shall be of wood, metal or other approved materials and shall be built mortar
tight and rigid enough to maintain the concrete in position during placing, compacting,
setting and hardening.
Formwork for exposed surfaces (“wrought form”) shall be made of dressed lumber of
uniform thickness with or without a form liner of an approved type or shall be of metal
sufficiently rigid in itself with no surface blemishes that will impair the quality of the
concrete surface finish. No rusty or bent metal forms shall be used. Exposed concrete
arises shall be provide with formed chamfers, as indicated on the Drawings or instructed
by the Engineer.
Rough lumber may be used for surfaces that will not be exposed in the finished structure
(“rough form”).
All lumber shall be sound, free from warps and twists, sap, shakes, large or loose knots,
wavy edge or other defects affecting the strength or appearance of the finished structure.
All forms shall be set and maintained true to the line designated until the concrete is
sufficiently hardened. Forms shall remain in place for periods, which shall be determined
by the Engineer. When forms appear to be unsatisfactory in any way, either before or
during the placing of concrete, the Engineer may order the work stopped until the defects
are corrected.
If requested, the Contractor shall submit to the Engineer working drawings of the forms
and also, if requested, calculations to verify the rigidity and strength of the forms.
The shape, strength, rigidity, water tightness and surface smoothness of reused formwork
shall be maintained at all times. Any warped or bulged lumber must be re-sized before
being reused. Formwork that is unsatisfactory in any respect shall not be reused.
Metal ties or anchorages within the form shall be so constructed as to permit their
removal to a depth of at least 50 mm from the face without injury to the concrete. All
fittings for metal ties shall be of such design that, upon their removal, the cavities which
are left will be of the smallest possible size. The cavities shall be filled with cement
mortar and the surface left sound, smooth, even and uniform in colour.
Formwork shall be so constructed that easy cleaning out of any extraneous material inside
the formwork can be achieved without disturbing formwork already checked and
approved by the Engineer.
Formwork shall be treated with approved non-Steining oil or saturated with water, to
facilitate formwork removal. The Engineer may require trials to be carried out before
approval is given for the use of a particular type of oil, to ascertain that the oil proposed
by the Contractor does not discolour or injure the finished concrete face in any way.
Before placing any concrete, all shavings, loose binding wires, soil, rubbish and all
foreign matter shall be removed from the formwork and the formwork shall be carefully
and thoroughly washed with water. If not indicated otherwise, the following tolerances of
the finished concrete structures shall apply:
Foundations: horizontally + 30 mm; vertically + 20 mm
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Piers: Horizontally + 20 mm, vertically + 10 mm, inclination 1:400

Dimensions of other structural members: + 10 mm, -5 mm
Edge beams and parapets shall be made to such accuracy that no deviations from the
correct alignment are visible.
The cross sectional areas of the superstructure of bridges shall in no place deviate
more than 3% from the theoretically correct cross sectional areas.
Anchors for bearings, expansion joints, railings, etc. shall be placed within the
tolerances indicated on the Drawings or specified by the Engineer.

C) Blinding Concrete
A leveling layer of blinding concrete shall be provided as the permanent bottom form for
all concrete structures that will directly bear on prepared soil, whether this blinding
concrete is shown on the Drawings or not. The leveling layer of blinding concrete shall be
of thickness not less than 75 mm.

D) Approval of Scaffolding and Formwork

If plans and calculations of scaffolding and formwork are requested by the Engineer, no
construction of such scaffolding and formwork shall take place before approval by the
Engineer, in writing. Such approval shall not relieve the Contractor of his responsibilities
under the Contract for the adequacy of scaffolding and formwork.
The Engineer shall have reasonable time for his examination of the Contractor’s plans
and calculations, especially if scaffolding is introducing temporary loading on new
structures. The Contractor shall not be allowed extensions of Contract time due to
awaiting such approval.
The Engineer shall inspect all formwork and scaffolding and no concrete shall be placed
until the Engineer’s approval has been given. Such approval shall not relieve the
Contractor of any of his responsibilities under the Contract for the successful completion
of the structure.

5.1.3.3 Care and Storage of Concrete Materials

A) Storage of Cement
All cement shall be stored in suitable weatherproof buildings or silos which will protect
the cement from dampness. These buildings or silos shall be placed in locations approved
by the Engineer. Provisions for storage shall be ample, and the shipments of cement as
received shall be separately stored in such manner as to provide easy access for the
identification and inspection of each shipment. Storage buildings shall have a capacity for
the storage of a sufficient quantity of cement to allow sampling at least 14 days before the
cement is to be used. Cement shall meet the test requirements at any time and any cement
stored for an elongated time shall be checked and tested before use regardless of whether
it has previously been tested.

B) Storage of Aggregates
Aggregates shall be so stored as to prevent the inclusion of foreign material. Aggregates
shall not be placed upon the finished roadbed. Aggregates of different sizes and kinds
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shall be placed in different stockpiles. Stockpiles of blended coarse aggregates shall be

built up in successive horizontal layers not more than 1 meter thick. Each layer shall be
completed before the next is started. Should segregation occur, the aggregates shall be
recombined to conform to the grading requirements.
Washed aggregates and aggregates produced or manipulated by methods which involve
the use of water shall be allowed to drain at least 12 hours before use.

5.1.3.4 Preparations before Casting

Before any major casting, the Contractor shall prepare a complete “casting programme”
describing staff and labor, consumption of materials, plant, tools and equipment, reserves
of materials, standby plant and equipment, proposed means of handling and placing the
concrete, quality controls etc.
No concrete shall be mixed and placed until the Contractor’s casting programme has been
approved in writing by the Engineer.
Equipment and tools necessary for handling materials and performing the work, and
satisfactory to the Engineer as to design, capacity, and mechanical condition, shall be at
the site of the work before casting is started.
If any equipment is not maintained in full working order, or if the equipment as used by
the Contractor proves inadequate to obtain the result prescribed, such equipment shall be
repaired or other suitable equipment substituted or added at the discretion of the
Engineer.

5.1.3.5 Measuring Materials

All material in the mix shall be proportioned by weight or volume, subject to the approval
of the Engineer.
When volume batching is proposed by the Contractor, the exact proportions must be
converted from trial mix weights to volumes, from bulk densities determined in the
laboratory. Written approval from the Engineer is required.

5.1.3.6 Mixing Concrete

A) General
All concrete shall be mixed in batch mixers, either at the site of construction, at a central
plant, or in transit. Each mixer shall have attached to it in a prominent place, a
manufacturer’s plate showing the capacity of the drum in terms of mixed concrete and the
speed of rotation of the mixing drum.

B) Mixers at Local Site of Construction (for minor works)

Mixers at local sites shall be approved drum-type capable of combining the aggregate,
cement, and water into a thoroughly mixed and uniform mass within the specified mixing
period and of discharging the mixture without segregation. The mixer shall be equipped
with a suitable charging hopper, water storage and a water measuring device, accurate
within 1%. Controls shall be so arranged that the water can be applied only while the
mixer is being charged. Suitable equipment for discharging the concrete shall be

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provided. The mixer shall be cleaned at suitable intervals. The pickup and throw-over
blades in the drum shall be replaced when they have lost 10% of their depth.

The mixer shall be operated at a drum speed of between 15 and 20 revolutions per
minute. The batched materials shall be so charged into the drum that a portion of the
water shall enter in advance of the cement and aggregates and the water shall continue to
flow into the drum for a minimum time of 5 seconds after all the cement and aggregates
are in the drum. Mixing time shall be measured from the time all materials except water
are in the drum and shall, in the case of mixers having a capacity of 1 cubic meter or less,
not be less than 50 seconds nor more than 70 seconds. In the case of dual drum mixers,
the mixing time shall not include transfer time. The contents of an individual mixer drum
shall be removed before a succeeding batch is emptied therein. Any concrete mixed less
than the specified minimum time shall be discarded and disposed of by the Contractor at
his own expense.
The volume of concrete mixed per batch shall not exceed the mixer’s nominal capacity in
cubic feet or cubic meters as shown on the manufacturer’s guaranteed capacity standard
rating plate on the mixer; except that an overload up to 20% of the mixers nominal
capacity may be permitted provided concrete test data for strength, segregation and
uniform consistency are satisfactory, and provided no spillage of concrete takes place.
Retempering concrete by adding water or by other means shall not be permitted. Concrete
which is not of the required consistency at the time of placement shall not be used and
shall be discarded and disposed of by the Contractor at his own expense.

C) Central Plant Mixers

These mixers shall be of approved drum type capable of combining the aggregate, cement
and water into a thoroughly mixed and uniform mass within the specified mixing period
and of discharging the mixture without segregation. Central plant mixers shall be
equipped with an acceptable timing device that will not permit the batch to be discharged
until the specified mixing time has elapsed. The water system for a central mixer shall be
either a calibrated measuring tank or a device and shall not necessarily be an integral part
of the mixer.
The mixers shall be cleaned at suitable intervals. This shall be examined daily for changes
in interior condition. The pick up and throw-over blades in the drum shall be replaced
when they have lost 10% of their depth.

In addition to the requirements for mixers at local sites detailed above, central plant
mixers which have a capacity of between 2 and 5 cubic meters, or greater than 5 cubic
meters, should have a minimum mixing time of 90 and 120 seconds respectively,
provided tests indicate that the concrete produced is equivalent in strength and uniformity
to that attained as stated in the preceding paragraphs.
Mixed concrete shall be transported from the central mixing plant to the site of work in
agitator trucks or, upon written permission of the Engineer, in non-agitator trucks.
Delivery of concrete shall be so regulated that placing is at a continuous rate unless
delayed by the placing operations. The intervals between deliveries of batches shall not
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be so great as to allow the concrete in place to harden partially, and in no case shall such
an interval exceed 30 minutes.
D) Agitator Trucks
Unless otherwise permitted in writing by the Engineer, agitator trucks shall have
watertight revolving drums suitably mounted and shall be capable of transporting and
discharging the concrete without segregation. The agitating speed of the drum shall not be
less than two or more than six revolutions per minute. The volume of mixed concrete
permitted in the drum shall not exceed the manufacturer’s rating nor exceed 80% the
gross volume of the drum.
Upon approval by the Engineer, open-top, revolving-blade truck mixers may be used in
lieu of agitating trucks for transportation of central plant mixed concrete.
Gross volume of agitator bodies expressed in cubic feet or cubic meters shall be supplied
by the mixer manufacturer. The interval between introduction of water into the mixer
drum and final discharge of the concrete from the agitator shall not exceed 45 minutes.
During this interval the mix shall be agitated continuously.

E) Non-Agitator Trucks
Bodies of non-agitating equipment shall be smooth, water-tight metal containers equipped
with gates that will permit control of the discharge of the concrete. Covers shall be
provided when needed for protection against the weather.
The non-agitating equipment shall permit delivery of the concrete to the site of the work
in a thoroughly mixed and uniform mass with a satisfactory degree of discharge.
Uniformity shall be satisfactory if samples from the one-quarter and three quarter points
of the load do not differ by more than 30 mm in slump. Discharge of concrete shall be
completed within 30 minutes after the introduction of the mixing water to the cement and
aggregate.

F) Truck or Transit Mixers

These shall be equipped with electrically actuated counters by which the number of
revolutions of the drum or blades may readily be verified and the counters shall be
actuated at the commencement of mixing operations at designated mixing speeds. The
mixer when loaded shall not be filled to more than 60% of the drum gross volume. The
mixer shall be capable of combining the ingredients of the concrete into a thoroughly
mixed and uniform mass and of discharging the concrete with a satisfactory degree of
uniformity.
Except when intended for use exclusively as agitators; truck mixers shall be provided
with a water measuring device to measure accurately the quantity of water for each batch.
The delivered amount of water shall be within plus or minus 1% of the indicated amount.
Truck mixers may be used for complete mixing at the batch plant and as truck agitators
for delivery of concrete to job sites, or they may be used for complete mixing of the
concrete at the job site. They shall either be a closed watertight revolving drum or an
open top revolving blade or paddle type.
The amount of mixing shall be designated in number of revolutions of the mixer drum.
When a truck mixer is used for complete mixing, each batch of concrete shall be mixed
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SECTION 7 GENERAL SPECIFICATIONS
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for between 70 and 100 revolutions of the drum or blades at the rate of rotation
designated by the manufacturer of the equipment as the “mixing speed”. Such designation
shall appear on a metal plate attached to the mixer. If the batch is at least 0.5 cubic meters
less than guaranteed capacity, the number of revolutions at mixing speed may be reduced
to not less than 50. Mixing in excess of 100 revolutions shall be at the agitating speed. All
materials, including the mixing water, shall be in the mixer drum before actuating the
revolution counter which will indicate the number of revolutions of the drum or blades.
When wash water (flush water) is used as a portion of the mixing water for the
succeeding batch, it shall be accurately measured and taken into account in determining
the amount of additional mixing water required. When wash water is carried on the truck
mixer, it shall be carried in a compartment separate from the one used for carrying or
measuring the mixing water. The Engineer will specify the amount of wash or flush
water, when permitted; any may specify a “dry” drum if wash water is used without
measurement or without supervision.
When a truck is used for complete mixing at the batch plant, mixing operations shall
begin within 30 minutes after the cement has been added to the aggregate. After mixing,
the truck mixer shall be used as an agitator, when transporting concrete, at the speed
designated by the manufacturer of the equipment as agitating speed. Concrete discharge
shall be completed within 45 minutes after the addition of the cement to the aggregates.
Each batch of concrete delivered at the job site shall be accompanied by a time slip issued
at the batching plant, bearing the time of departure therefrom. When the truck mixer is
used for the complete mixing of the concrete at the job site, the mixing operation shall
begin within 30 minutes after the cement has been added to the aggregates.
The rate of discharge of the plastic concrete from the mixer drum shall be controlled by
the speed of rotation of the drum in the discharge direction with the discharge gate fully
open.

5.1.3.7 Handling and Placing Concrete

The temperature of concrete at the time of placing shall not exceed 35 oC. In preparation
for the placing of concrete all sawdust, chips and other construction debris and extraneous
matter shall be removed from the interior of forms. Struts, stays and braces, serving
temporarily to hold the forms in correct shape and alignment, pending the placing of
concrete at their locations, shall be removed when the concrete placing has reached an
elevation rendering their service unnecessary. These temporary members shall be entirely
removed from the forms and not buried in the concrete.

Concrete must reach its final position in the forms within 20 minutes of the completion of
mixing, or as directed by the Engineer.Concrete shall be placed so as to avoid segregation
of the materials and the displacement of the reinforcement. The use of long troughs,
chutes and pipes for conveying concrete from the mixer to the forms shall be permitted
only on written authorization of the Engineer. In case an inferior quality of concrete is
produced by the use of such conveyors, the Engineer may order discontinuance of their
use and the institution of a satisfactory method of placing.

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Open troughs and chutes shall be of metal or metal lined. Where long steep slopes are
required, the chutes shall be equipped with baffles or be in short lengths that reverse the
direction of movement.
All chutes, troughs and pipes shall be kept clean and free from coatings of hardened
concrete by thoroughly flushing with water after each run. Water used for flushing shall
be discharged clear of the structure.
When placing operations would involve dropping the concrete more than 1.5 m, it shall
be deposited through sheet metal or other approved pipes. As far as practicable, the pipes
shall be kept full of concrete during placing and their lower ends shall be kept buried in
the newly placed concrete. After initial set of the concrete, the forms shall not be jarred
and no strain shall be placed on the ends of reinforcement bars which project.
Concrete, during and immediately after depositing, shall be thoroughly compacted. The
compaction shall be done by mechanical vibration subject of the following provisions:
1) The vibration shall be internal unless special authorization of other methods is
given by the Engineer or as provided herein.
2) Vibrators shall be of a type and design approved by the Engineer. They shall
be capable of transmitting vibration to the concrete at frequencies of not less than
4,500 impulses per minute.
3) The intensity of vibration shall be such as to visibly affect a mass of concrete
of 20 mm slump over a radius of at least 450 mm.
4) The Contractor shall provide a sufficient number of vibrators to properly
compact each batch immediately after it is placed in the forms.
5) Vibrators shall be manipulated to thoroughly work the concrete around the
reinforcement and embedded fixtures, and into the corners and angles of the forms.
Vibration shall be applied at the point of deposit and in the area of freshly deposited
concrete. The vibrators shall be inserted and withdrawn from the concrete slowly. The
vibration shall be of sufficient duration and intensity to thoroughly compact the
concrete, but shall not be continued so as to cause segregation. Vibration shall not be
continued at any one point to the extent that localized areas of grout are formed.
Application of vibrators shall be at points uniformly spaced and not further apart than
twice the radius over which the vibration is visibly effective.
6) Vibration shall not be applied directly or through the reinforcement to sections
or layers of concrete which have hardened to the degree that the concrete ceases to be
plastic under vibration. It shall not be used to make concrete flow in the forms over
distances so great as to cause segregation, and vibrators shall not be used to transport
concrete in the forms.
7) Vibration shall be supplemented by such spading as is necessary to ensure
smooth surfaces and dense concrete along form surfaces and in corners and locations
impossible to reach with the vibrators.
8) The provisions of this Section shall also apply to precast piling, concrete
cribbing and other precast members except that, if approved by the Engineer, the
manufacturer’s methods of vibration may be used.

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Concrete shall be placed in horizontal layers not more than 600 mm thick except as
hereinafter provided. When less than a complete layer is placed in one operation, it shall
be terminated in a vertical bulkhead. Each layer shall be placed and compacted before the
preceding batch has taken initial set to prevent injury to the green concrete and avoid
surfaces of separation between the batches. Each layer shall be compacted so as to avoid
the formation of a construction joint with a preceding layer which has not taken initial set.

When the placing of concrete is temporarily discontinued, the concrete, after becoming
firm enough to retain its form, shall be cleaned of laitance and other objectionable
material to a sufficient depth to expose sound concrete. To avoid visible joints as far as
possible upon exposed faces, the top surface of the concrete adjacent to the forms shall be
smoothed with a trowel. Where a “feather edge” might be produced at a construction
joint, as in the sloped top surface of a wing wall, an inset form shall be used to produce a
blocked out portion in the preceding layer which shall produce an edge thickness of not
less than 150 mm in the succeeding layer. Work shall not be discontinued within 450 mm
of the top of any face, unless provision has been made for a coping less than 450 mm
thick, in which case, if permitted by the Engineer, a construction joint may be made at the
underside of the coping.

Immediately following the discontinuance of placing concrete all accumulations of mortar

splashed upon the reinforcement steel and the surfaces of forms shall be removed. Dried
mortar chips and dust shall not be puddle into the unset concrete. If the accumulations are
not removed prior to the concrete becoming set, care shall be exercised not to injure or
break the concrete-steel bond at and near the surface of the concrete, while cleaning the
reinforcement steel.

For simple spans, concrete shall preferably be deposited by beginning at the centre of the
span and working from the centre toward the ends. Concrete in girders shall be deposited
uniformly for the full length of the girder and brought up evenly in horizontal layers. For
continuous spans, the concrete placing sequence shall be as shown on the plans or agreed
on by the Engineer.

Concrete in slab and girder haunches less than 1.0 meter in height shall be placed at the
same time as that in the girder stem.

Concrete in slab spans shall be placed in one continuous operation for each span unless
otherwise provided.

Concrete in T-beam or deck girder spans may be placed in one continuous operation if
permitted by the Engineer.

Concrete in columns and pier shafts shall be placed in one continuous operation, unless
otherwise directed.

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SECTION 7 GENERAL SPECIFICATIONS
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Unless otherwise permitted by the Engineer, no concrete shall be placed in the

superstructure until the column forms have been stripped sufficiently to determine the
character of the concrete in the columns. The load of the superstructure shall not be
applied to the supporting structures until they have been in place at least 14 days, unless
otherwise permitted by the Engineer.

Pneumatic placing of concrete shall be permitted only if authorized by the Engineer. The
equipment shall be so arranged that vibration does not damage freshly placed concrete.

Where concrete is conveyed and placed by pneumatic means the equipment shall be
suitable in kind and adequate in capacity for the work. The machine shall be located as
close as practicable to the place of deposit. The position of the discharge end of the line
shall not be more than 3 meters from the point of deposit. The discharge lines shall be
horizontal or inclined upwards from the machine. At the conclusion of placement the
entire equipment shall be thoroughly cleaned.

Placement of concrete by pumping shall be permitted only if authorized by the Engineer.

The equipment shall be so arranged that vibrations do not damage freshly placed
concrete. Where concrete is conveyed and placed by mechanically applied pressure, the
equipment shall be suitable in kind and adequate in capacity for the work. The operation
of the pump shall be such that a continuous stream of concrete without air pockets is
produced. When pumping is completed, the concrete remaining in the pipeline, if it is to
be used, shall be ejected in such a manner that there is not contamination of the concrete
or separation of the ingredients. After this operation, the entire equipment shall be
thoroughly cleaned.
5.1.3.8 Perforations and Embedment of Special Devices
The Contractor is responsible for determining in advance of making any concrete pours,
all requirements for perforation of concrete sections or embedment therein of special
devices of other trades, such as conduits, pipes, weep holes, drainage pipes, fastenings,
etc. Any concrete poured without prior provision having been made, shall be subject to
correction at the Contractor’s expense.
Special devices to be embedded:
• Expansion joints
• Drain outlets including fixing bolts for down pipes
• Bolts and inserts for sign posts
• Bolts and inserts for various purposes regarding inspection and maintenance
as directed by the Engineer
Other devices not mentioned above shall be shown on the Drawings, or directed by the
Engineer. The inserts and fittings should conform to Sections 5.9 and 5.10 of this
Specification.

5.1.3.9 Finishing Concrete Surfaces

One of the following types of finishing shall be applied to concrete surfaces:

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SECTION 7 GENERAL SPECIFICATIONS
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Type A - Concrete Decks

Immediately after placing concrete, concrete decks shall be struck off using templates to
provide proper crowns and shall be finished smooth to the correct levels. Finish shall be
slightly but uniformly roughened by brushing. The finished surface shall not vary more
than 10 mm from a 3 meter straight edge placed in any direction on the roadway.

Type B - Kerb and Sidewalk Surface

Exposed faces of kerbs and sidewalks shall be finished to true lines and grades. The kerb
surface shall be wood floated to a smooth but not slippery finish. Sidewalk surfaces shall
be slightly but uniformly roughened by brushing.

Type C - Ordinary Finish

An ordinary finish is defined as the finish left on a surface after the removal of the forms
when all holes left by form ties have been filled, and any minor surface defects have been
repaired. The surface shall be true and even, free from depressions or projections.
The concrete in bridge seats, caps, and tops of walls shall be struck off with a straight
edge and floated to true grade. Under no circumstances shall the use of mortar topping for
concrete surfaces be permitted.

Type D - Rubbed Finish

After the removal of forms the rubbing of concrete shall be started as soon as its
condition permits. Immediately before starting this work the concrete shall be kept
thoroughly saturated with water for a minimum period of three hours. Sufficient time
shall have elapsed before the wetting down to allow the mortar used in patching to have
thoroughly set. A medium coarse carborundum stone shall be used for rubbing a small
amount of mortar on the face. The mortar used shall be composed of cement and fine
aggregate mixed in the same proportions as that used in the concrete being finished.
Rubbing shall be continued until all form marks, projections, and irregularities have been
removed, all voids filled, and a uniform surface has been obtained. The paste produced by
this rubbing shall be left in place at this time. The final finish shall be obtained by
rubbing with a fine carborundum stone and water until the entire surface is of a smooth
texture and uniform colour.
After the final rubbing has been completed and the surface has dried, burlap shall be used
to remove loose powder. The final surface shall be free from unsound patches, paste,
powder and objectionable marks.

Type E - Bushhammer Finish

Bushhammering shall be carried out by treating the surface with an approved heavy duty
power hammer fitted with a multi-point tool which shall be operated over the surface to
remove 5 to 6 mm of concrete paste and expose maximum areas of coarse aggregate.
Aggregate left embedded shall not be fractured or loose. 25 mm wide bands at all corners
and arrises shall be left as cast. The finish surface shall be even and of uniform
appearance and shall be washed with water upon completion.
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SECTION 7 GENERAL SPECIFICATIONS
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Type F - Ribbed Finish

Ribs shall be vertical and to the dimensions shown on the Drawings. The direction of the
grain of the timber forming the ribs shall be vertical.

Type G–fair-faced finish

Cast-in-place fair-faced concrete works with f'cr=33.5 MPa and f'c=25 MPa at 28 days on
standard cylinders by using 75% of OPC and 25% of white cement conforming to BDS
EN-197-1-CEM-I, 52.5N, best quality Sylhet sand or coarse sand of equivalent F.M. 2.2,
20 mm down and well graded stone chips conforming to ASTM C-33 (Aggregate grading
as per table shown in technical specification) at mix ratio of 1:1.5:3, adding coloring
pigment admixture (satisfying ASTM C979) as per architectural design, conforming to
the standard practice of code ACI / BNBC / ASTM including conducting necessary tests,
screening sand and chips through proper sieves, washing, making and placing shutter in
position maintaining true to plumb, making shutter water tight properly, placing
reinforcement in position, including pouring ofconcrete in form, compacting by vibrator
machine and curing at least for 28 days, removing centering-shuttering after specified
time approved; including cost of water, electricity, other charges etc. all complete,
approved and accepted by the Engineer-in-charge.

5.1.3.10 Construction Joints

A) General
Construction joints shall be made only where located on the plans or shown in the
pouring schedule, unless otherwise approved by the Engineer.
If not detailed on the plans, or in the case of emergency, construction joints shall be
placed as directed by the Engineer. Shear keys or inclined reinforcement shall be used
where necessary to transmit shear or bond the two sections together.

B) Bonding
Before depositing new concrete on or against concrete which has hardened, the forms
shall be re-tightened. The surface of the hardened concrete shall be roughened as required
by the Engineer, in a manner that does not leave loosened particles of aggregate or
damaged concrete at the surface. It shall be thoroughly cleaned of foreign matter and
laitance, and saturated with water. To ensure an excess of mortar at the juncture of the
hardened and the newly deposited concrete, the cleaned and saturated surfaces, including
vertical and inclined surfaces, shall first be thoroughly covered with a thin coating of
mortar or neat cement grout against which the new concrete shall be placed before the
grout has attained its initial set. Bonding agent may be used as per instruction of the
Engineer.
The placing of concrete shall be carried continuously from joint to joint. The face edges
of all joints which are exposed to view shall be carefully finished true to line and
elevation.

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SECTION 7 GENERAL SPECIFICATIONS
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5.1.3.11 Curing Concrete

All concrete surfaces shall be kept thoroughly wet for at least 7 days after placing. Bridge
deck and sidewalk slabs shall be covered with wet thick cloth made with jute or suitable
geotextileimmediately after final finishing of the surface. This material shall remain in
place for the full curing period or may be removed and replaced with sand when the
concrete has hardened sufficiently to prevent marking. In both cases the materials shall be
kept thoroughly wet for the entire curing period. All other surfaces if not protected by
forms, shall be kept thoroughly wet, either by sprinkling or mud curing (pond created by
wet clay and surface covered by wet soil necessarily immediate after the initial setting
time) or by the use of wet burlap until the end of the curing period. The wood forms are
allowed to remain in place during the curing period, but they shall be kept moist at all
times to prevent openings at joints.
After a period of 7 days, the concrete shall be watered daily at certain intervals approved
by the Engineer to avoid drying out of the surface. This shall take place during the
following 2 weeks. The water used shall be the same as used in concrete mixes unless
otherwise approved by the Engineer.
Curing agents may be used as per instruction of the Engineer.
Any proposal from the Contractor for the use of liquid membrane curing compound shall
be subject to the approval of the Engineer.

5.1.3.12 Removal of Scaffolding and Formwork

Forms and scaffolding shall not be removed without the approval of the Engineer. The
Engineer’s approval shall not relieve the Contractor of his Contract responsibilities. Any
ken ledge blocks and bracing shall be removed at the same time as the forms and in no
case shall any portion of the wood forms be left in the concrete.
Forms used on exposed vertical faces shall remain in place for periods which shall be
determined by the Engineer and normally not less than 3 days.
Supporting scaffolding and forms under slabs, beams and girders shall normally remain in
place until the full required strength of the concrete has been obtained. If a shorter period
is requested, this may be permitted by the Engineer. In such case, special test specimens
(see Section 5.1.2.4) shall be cast to monitor the hardening. Removal methodology of
scaffolding and formworks shall be proposed the contractor and approved by the
Engineer.

All structures shall be fully stripped before adjacent structures are cast.

5.1.3.13 Repair of Concrete

As soon as the form has been stripped, the Contractor shall advise the Engineer who shall
inspect the concrete before any improvement of the surface takes place.
All wire or metal devices used for securing the formwork which project from or appear
on the surface of the finished concrete shall be removed or cut back to at least a depth
equal to the required reinforcement cover. All holes and pockets so formed shall be filled
with cement mortar mixed in the same proportions as the fine aggregate to cement of the
concrete mix used for that particular section of the structure, after the surface to be
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SECTION 7 GENERAL SPECIFICATIONS
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patched has been thoroughly cleaned and wetted to receive the patch. In case of cracks
developed acceptable to the Engineer shall be repaired using epoxy-based grout as
approved by the Engineer.

Excessive honeycombing shall be sufficient to cause rejection of portions of the structure

containing this honeycombing. The Contractor, on receipt of written orders from the
Engineer, shall remove and rebuild such portions of the structure at his own expense.
Smaller honeycombing and other defects can be repaired if permitted by the Engineer.
Structural, maintenance and aesthetical points of view shall be taken into consideration
before such approval, if any, may be given. The method of repair shall be approved by the
Engineer and an extension of period for a certain part of the performance bond may be
required.

5.1.3.14 Depositing Concrete under Water

Concrete shall not be deposited in water except with the approval of the Engineer and
under his immediate supervision; and in this case the method of placing shall be as
defined in this Section.
Concrete placed under water shall be carefully placed in a compact mass, in its final
position, by means of a tremie tube and shall not be disturbed after being deposited.
Special care must be exercised to maintain still water at the point of deposit. Concrete
shall not be placed in running water. The method of depositing concrete shall be so
regulated as to produce approximately horizontal surfaces.
Concrete seals shall be placed in one continuous operation. When a tremie tube or pipe is
used, it shall consist of a tube or pipe not less than 150 mm in diameter. All joints in the
tube shall be watertight. The means of supporting the tremie tube shall be such as to
permit free movement of the discharge end over the entire top of the concrete and to
permit its being lowered rapidly when necessary to choke off or retard the flow. The
tremie tube shall be filled by a method that prevents washing of the concrete. The
discharge end shall be completely submerged in concrete at all times and the tremie tube
shall be kept full. Concrete slump shall not be less than 150 mm.
Dewatering shall proceed only when the concrete seal is considered strong enough to
withstand any pressure to be exerted upon it. This time shall be decided by the Engineer.
All laitance or other unsatisfactory material shall be removed from the exposed surface by
scraping, jetting, chipping or other means, which do not injure the seal unduly.

5.1.3.15 Factory Made Precast Concrete Elements

Any supplier of precast concrete elements (concrete blocks, piles, paving blocks etc.)
shall be approved in writing by the Engineer. Such approval can be withdrawn at any
time.
Concrete work in precast concrete elements shall fully conform to all relevant Sections of
these Specifications.
The supplier shall maintain laboratory facilities of the same standard as the site
laboratory.

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Unless otherwise approved by the Engineer, precast concrete members shall not be
moved from the casting position until the concrete has attained a compressive strength of
80% of the specified 28 day strength, nor transported until it has developed a strength of
90% of the specified 28 day strength.

Extreme care shall be exercised in handling and moving precast concrete members.
Precast girders and slabs shall be transported in an upright position. Shock shall be
avoided and the points of support and directions of the reactions with respect to the
member shall be approximately the same during transportation and storage as when the
member is in its final position. If the Contractor deems it expedient to transport or store
precast units in other than this position, this shall be at the Contractor’s risk, after
notifying the Engineer of his intention to do so. Any rejected unit shall be replaced at the
Contractor’s expense by an acceptable unit.
Proposed details on the handling and transportation of precast concrete members shall be
submitted in writing by the Contractor, to the Engineer, for his approval.
Each precast member is to be uniquely and permanently marked so as to show its type,
date of casting and any other information required by the Engineer.

5.1.3.16 Control of Heat in Structures

In structures of major dimensions i.e., pile caps, etc. the heat deriving from the hardening
of the concrete shall be controlled by the Contractor. Temperature gradients introducing
risk of cracking shall not occur and the temperature shall not exceed 70 oC.
To control heat of hydration cold water circulation method shall be used as per instruction
of the Engineer.
The Contractor shall submit timely proposals with details methodology for avoiding
excessive heat generation, such as the cooling of aggregates before mixing, to the
Engineer for approval.

5.1.3.17 Grouting of Ducts for Prestressing Tendons

A) General
The purpose of grouting is to provide permanent protection to the post-tensioning steel
and to achieve bond between the prestressing steel and the concrete.
The time of commencement of grouting shall be approved by the Engineer. The
Contractor shall give timely notice of grouting to the Engineer.

B) Definition of Terms
1) Admixture. Any material added to the grout other than Portland cement and
water.
2) Duct. The hole or void provided in the concrete for the tendon used in post-
tensioning, formed by sheathing.
3) Grout. A mixture of cement and water with or without admixtures.
4) Grout opening or vent. An inlet, outlet or vent in the duct for grout, water or
air.

C) Grout Openings or Vents

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SECTION 7 GENERAL SPECIFICATIONS
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All ducts shall have grout openings at both ends. For draped cables, all high points should
have a grout vent except where cable curvature is small, such as in continuous slabs. All
grout openings or vents shall include provisions for preventing grout leakage.

D) Equipment
1) The grouting equipment shall include a mixer capable of continuous
mechanical mixing which will produce a grout free of lumps and undispersed
cement. The equipment shall be able to pump the mixed grout in a manner
which will comply with all provisions of the recommended practice.
2) Accessory equipment which will achieve accurate solid and liquid measures
shall be provided to batch all materials.
3) The pump shall be a positive displacement type and be able to produce an
outlet pressure of at least 10.5 kg/cm². The pump should have seals adequate
to prevent introduction of oil, air or other foreign substances into the grout and
to prevent loss of grout or water.
4) A pressure gauge having a full scale reading of no greater than 21 kg/cm² shall
be placed at some point in the grout line between the pump outlet and the duct
inlet.
5) The grouting equipment shall contain a screen having clear openings of 3.2
mm maximum size to screen the grout prior to its introduction into the grout
pump. If a pump with a thixotropic additive is used, a screen opening of 4.8
mm is satisfactory. This screen shall be easily accessible for inspection and
cleaning
6) The grouting equipment shall utilize gravity feed to the pump inlet from a
hopper attached to and directly over it. The hopper must be kept at least
partially full of grout at all times during the pumping operation to prevent air
from being drawn into the post-tensioning duct.
7) Under normal conditions, the grouting equipment shall be capable of
continuously grouting the largest tendon on the Works in no more than 20
minutes.

E) Materials
1) Portland Cement: Portland cement shall confirm to one of the following:
Specifications for Portland cement - AASHTO M 85, type 1, 2 or 3.
Cement used for grouting shall be fresh and shall not contain any lumps or
other indication of hydration or “pack set”.
2) Water:The water used in the grout shall be potable, clean and free of injurious
quantities known to be harmful to Portland cement or prestressing steel.
3) Admixtures:Admixtures, if used, shall impart the properties of low water
content, good flowability, minimum bleed and moderate expansion. Their
formulation shall contain no chemicals in quantities that may have harmful
effects on the prestressing steel or cement. Admixtures containing chlorides,
fluorides, sulphites and nitrates shall not be used.

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SECTION 7 GENERAL SPECIFICATIONS
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Aluminium powder of the proper fineness and quantity or other approved gas
evolving material which is well dispersed through the other admixture may be
used to obtain 5 to 10 percent unrestrained expansion of the grout.
All admixtures shall be approved by the Engineer and used in accordance with
the instructions of the manufacturer.

F) Mixing of Grout
1) Water shall be added to the mixer first, followed by Portland cement and
admixture, or as required by the admixture manufacturer.
2) Mixing shall be of such duration as to obtain a uniform thoroughly blended
grout, without excessive temperature increase or loss of expansive properties
of the admixture. The grout shall be continuously agitated until it is pumped.
3) Water shall not be added to increase grout flowability which has been
decreased by delayed use of the grout.
4) Proportions of materials shall be based on tests made on the grout before
grouting is begun, or may be selected based on prior documented experience
with similar materials and equipment and under comparable field conditions
(weather, temperature, etc.). The water content shall be the minimum
necessary for proper placement and when type 1 or 2 cement is used shall not
exceed a water/cement ratio of 0.45.
The water content required for type 3 cement shall be established for a particular brand
based on tests. The pumpability of the grout may be determined by the Engineer in
accordance with the U.S. Corps of Engineers Method CRD-C79. When this method is
used, the efflux time of the grout sample immediately after mixing shall not be less than
11 seconds. The flow cone test does not apply to grout which incorporates a thixotropic
additive.
Trial mixes shall be carried out on site with the selected constituents to demonstrate the
physical properties of the grout.

G) Grouting
Preparation of duct:
• Flushing of metal ducts shall be carried out, if considered necessary by the
Engineer.
• The pumping pressure at the tendon inlet shall not exceed the value which may
develop cracking in surrounding concrete.

• If the actual grouting pressure exceeds the maximum recommended pump pressure,
grout may be injected at any vent which has been or is ready to be capped, as long
as one-way flow of grout is maintained. If this procedure is used, then the vent,
which is to be used for injection, shall be fitted with a positive shutoff.
• When one-way flow of grout cannot be maintained as outlined above, the grout
shall be immediately flushed out of the duct with water.

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SECTION 7 GENERAL SPECIFICATIONS
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Grout shall be pumped through the duct and continuously wasted at the outlet pipe until
no visible slugs of water or air are ejected. To ensure that the tendon remains filled with
grout, the outlet and/or inlet shall then be closed. Plugs, caps or valves thus required shall
not be removed or opened until the grout has set.

H) Temperature
Grout shall not be above 35°C during mixing or pumping. If necessary the mixing water
shall be cooled.

5.1.3.18 Loading
No superstructure load shall be placed upon finished bents, piers, or abutments until the
Engineer so directs but in no case shall any load of any kind be placed until the concrete
has completed curing.
The Contractor shall not place any temporary loads on deck slabs unless allowed by the
Engineer in writing (see Section 5.1.3.2). Bridge deck slabs shall be opened to traffic only
when so directed by the Engineer and generally not sooner than 28 days after the placing
of the concrete has been completed.

5.1.3.19 Backfill to Structures

All spaces which have been excavated and the volumes of which are not occupied by the
concrete structure shall be backfilled and compacted with acceptable material in
accordance with the provisions of Section 2.5 as directed by the Engineer.

5.1.3.20 Cleaning Up
Upon completion of a structure and before final acceptance, the Contractor shall remove
all forms and scaffolding etc. down to 0.5 meters below the finished ground line.
Excavated, or useless materials, rubbish etc. shall be removed from the Site and the Site
shall be left in a neat and tidy condition satisfactory to the Engineer.

5.1.4 Specifications for higher strength Concretes (40, 45, 50, & 60 MPa)
Providing and laying Cement Concrete works with minimum cement content as per
standard practice of Code AASHTO/ ASTM and cement conforming to BDS EN 197-1 :
2003 CEM-I 52.5N / ASTM C150 Type-1, silica fume conforming to ASTM C 1240,
high range water reducing admixture of complying type F/ G under ASTM C 494 (Doses
of admixture to be fixed by the mix design) for smart dynamic concrete (i.e. Low fines
self-compacting concrete), sand of minimum FM 2.80 and 20mm down well graded
crushed stone chips broken from boulders (LAA value not exceeding 25) conforming to
ASTM C 33 , including breaking stone boulders into chips, screening through proper
sieves, making and placing shutter in position, making shutter water-tight properly,
placing non prestressing reinforcement, HT Strand, sheath, anchorage in position, mixing
in mechanized batch mix plant & pumping using line pump or boom placer, maintaining
allowable slump of 75mm to 100mm, casting in forms, compacting by mechanical
vibrator machine, curing at least for 28 days, removing shutter after specified time period,
finishing, launching, shifting & placing in position etc. including cost of water,
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SECTION 7 GENERAL SPECIFICATIONS
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electricity, other incidental charges etc. all complete as per design, drawing, specification
& direction of E-I-C. The Mix Design shall have to be approved by the Engineer.

5.1.5 Measurement
Concrete shall be measured by the number of cubic meters of class and maximum coarse
aggregate size indicated on the Drawings complete in place and accepted by the Engineer.
In computing quantities, the dimensions used shall be those shown on the Drawings. No
deduction from the measured quantity shall be made for drainage, , conduits, chamfers,
reinforcement bars, prestressing tendons, water stops or pile heads embedded in
concrete.
Reinforcing and prestressing steel shall be measured for payment as described in
Specifications Sections 5.2 and 5.3.
Formwork, scaffolding, construction joints and surface finishes shall Not be measured
separately but shall be an integral part of the concrete items unless otherwise specified.
Blinding concrete for concrete structures bearing directly on prepared soil shall be
measured in cubic meter. . The measured area will be the same as that of the base area of
the concrete structure.

5.1.6 Payment
Concrete of the classes and maximum coarse aggregate sizes shown on the Drawings and
measured as provided in Section 5.1.4 shall be paid for at the Contract unit prices per
cubic meter. The Contractor’s rates shall include all trial mixes (as specified in Section
5.1.2.3), mixing, transporting, placing and compacting the concrete. The rates shall also
include all concrete finishing, the supply, placing and building in of weep pipes or pipe
sleeves, forming construction joints, forming holes or pockets not exceeding 0.15 m³
each.
The Contractor’s rates shall be fully inclusive of the cost of all labor and materials in
providing and erecting all formwork, falsework and centering and for their subsequent
removal.
Payment for precast units shall include all concrete, prestressing tendons, formwork,
finishing, transport and erection and where applicable any bolts, bedding or other devices
necessary to fix them in their permanent position.
Payment for single layer brick flat soling shall include the supply of all required materials
and all labor, equipment, tools and incidentals necessary to complete the work.

Pay items shall be (the rates shall be inclusive of scaffolding and formworks):

05/01/02(a) Concrete Class as Detailed on Drawings (Class 10) cu meter

05/01/02(b) Concrete class as Detailed on Drawings (Class 20) cu meter

05/01/02(c) Concrete class-25 (Foundation i.e. Pile, Well, etc.) cu meter
05/01/02(d) Concrete class -25 (Vertical member i.e. Pier Column, Abutment cu meter
Wall, Wing Wall etc)
05/01/02(e) Concrete class -25 (Culvert, Retaining Wall, Toe wall etc) cu meter

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SECTION 7 GENERAL SPECIFICATIONS
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05/01/02(f) Concrete class-25 (Abutment Pile cap, Pier Pile cap, Pier Cap, cu meter
Girder, cross girder, diaphragm, beam etc)
05/01/02(g) Concrete class-25 (Side walk, wheel guard, curb, Rail & Post etc cu meter

05/01/02(h) Concrete class - 25 (RCC Pavement work) cu meter

05/01/02(i) Concrete class-35 (Deck slab, side walk, wheel guard, curb etc) cu meter
05/01/02(j) Concrete Class - 35 as Detailed on Drawings cu meter
05/01/02(k) Concrete Class – 40 (Pre-stressed Girder) cu meter
05/01/02(l) Concrete Class – 45 (Pre-stressed Girder) cu meter
05/01/02(m) Concrete Class – 50 (Pre-stressed Girder) cu meter
05/01/02(n) Concrete Class – 60 (Pre-stressed Girder) cu meter

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SECTION 7 GENERAL SPECIFICATIONS
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5.2 REINFORCEMENT

5.2.1 Description
This work shall consist of furnishing and placing bars of the grade, type and size shown in
accordance with these Specifications and in conformity with the requirements shown on the
Drawings.

5.2.2 Materials

5.2.2.1 Bar Reinforcement

All mild steel bars shall have a yield stress not less than 240 N/mm² and shall conform to
ASTM A615 or ASTM A706 or BDS ISO 6935-2:2016 or the latest such equivalent
standard or specification in force that is considered by the Engineer to apply.
All high yield steel bars shall be deformed bars with a yield stress not less than 400
N/mm²and shall conform to ASTM A615 or ASTM A706 or BDS ISO 6935-2:2016orthe
latest such equivalent standard or specification in force that is considered by the Engineer
to apply.
The production process of the reinforced bar is at the discretion of the manufacturer, as
described in BDS ISO 6935-2: 2016.However, various types of deformed bars will be
permitted, as mentioned in following table:

Ribbed or deformed bar reinforcement

Grade 300 (B 300DWR): Ribbed or Deformed bar produced and marked as per
BDS ISO 6935-2:2016 with minimum yield strength, fy (ReH) = 300 MPa, but the
tested yield strength shall not exceed fy by more than the 90MPa and the ratio of
tested ultimate strength, fu (Re) to tested yield strength (fy) shall be at least 1.25
and minimum elongation after fracture (A5.65) & minimum total elongation at
maximum force (Agt) is 17% and 8% respectively.
Grade 400 (B 400DWR): Ribbed or Deformed bar produced and marked as per
BDS ISO 6935-2:2016 with minimum yield strength, fy (ReH) = 400 MPa, but the
tested yield strength shall not exceed fy by more than the 120MPa and the ratio of
tested ultimate strength, fu (Re) to tested yield strength (fy) shall be at least 1.25
and minimum elongation after fracture (A5.65) & minimum total elongation at
maximum force (Agt) is 17% and 8% respectively.
Grade 420 (B420DWR): Ribbed or Deformed bar produced and marked as per
BDS ISO 6935-2:2016/ ASTM A706M - 16 with minimum yield strength, fy
(ReH) = 420 MPabutfy(ReH)not exceeding 540 MPa, the ratio of ultimate tensile
strength, fu(Rm) to actual yield strength, fy (ReH) shall be at least 1.25 and
minimum elongation in 200mm shall be at least 14% for bar sizes 10mm through
20mm, at least 12% for bar sizes 22mm through 32mm and at least 10% for bar
sizes 40mm and 50mm.
Grade 500 (B 500CWR): Ribbed or Deformed bar produced and marked as per
BDS ISO 6935-2:2016 with minimum yield stress, fy(ReH) = 500 MPa, the ratio of

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SECTION 7 GENERAL SPECIFICATIONS
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ultimate tensile strength, fu(Rm) to actual yield strength, fy (ReH) shall be at least
1.15 andminimumtotalelongation after fracture (A5.65) &minimumelongation at
maximum force (Agt) is 14% and 7% respectively. [This reinforcement shall be
selected as per instruction given in the drawing & after getting approval from
Design unit, RHD.]
Grade 500 (B 500DWR): Ribbed or Deformed bar produced and marked as per
BDS ISO 6935-2:2016 with minimum yield stress, fy(ReH) = 500 MPa, but
fy(ReH)not exceeding 650 MPa, the ratio of ultimate tensile strength, fu(Rm) to
actual yield strength, fy (ReH) shall be at least 1.25 and minimum total elongation
after fracture (A5.65) &minimum elongation at maximum force (Agt) is 13% and
8% respectively. [This reinforcement shall be selected as per instruction given in
the drawing & after getting approval from Design unit, RHD.]
Fusion Bonded Epoxy Coating Reinforcement (FBECR): Extra over reinforcing
bar items as above for providing Fusion Bonded Epoxy Coating (FBEC) to
reinforcement bars as per ASTM A775/ BDSISO 14654: 2013 specification for a
coating thickness (after curing) of 175 to 300 microns for 10mm to 16mm and 175
to 400 microns for 20mm to 50mm re-bars including extra cost on account of
careful handling during straightening, cutting, bending & placing, extra cost on
account of using PVC coated binding wire instead of G.I. wire, extra cost on
account of touch-up material (All cut edges/weld areas and bend locations where
coating has been damaged touch up shall be done with same Coating, the upper
thickness limit shall not apply to repaired areas of damaged coating) supplied by
coating agency and repair work, extra cost on account of transportation to and fro
from steel yard to plant and plant to work site by trailer (if required), loading,
unloading, flexibility & holiday testing, etc. complete to ensure proper resistance of
FBE against corrosive environment.
[Fusion Bonded Epoxy Coating to be proposed only in Coastal Area/Severe
Exposure Condition with prior approval of Design Unit, RHD.]

5.2.2.2 Wire Mesh

Wire mesh shall conform to the requirements of AASHTO Standard Specification M 55 -
Welded Steel Wire Fabric for Concrete Reinforcement.

5.2.2.3 Binding Wire

Reinforcement binding wire shall be best black annealed mild steel wire, approximately
1.6 mm in diameter. PVC coated binding wire instead of G.I. wire have to be used for
FBECR as recommended by the FBECR manufacturer.

5.2.2.4 Bar Sizes

AASHTO Standard Specifications refer to the Imperial measurement system. However,
metric sizes of steel are shown on the Drawings and shall be used.

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SECTION 7 GENERAL SPECIFICATIONS
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5.2.2.5 Ordering Material

The name of the proposed supplier (or names of proposed suppliers) of the reinforcement
shall be submitted as soon as possible to the Engineer for his approval. The Contractor
shall also submit all relevant data on the steel required by the Engineer, such as breaking
strength, yield strength, characteristics on elongation, chemical composition etc. Copies
of orders placed shall be submitted to the Engineer.
Bar reinforcement shall be transported in standard bundles, tagged and marked in
accordance with the Code of Standard Practice of the Concrete Reinforcing Steel
Institute. No steel shall be delivered without a manufacturer’s certificate guaranteeing the
yield stress, which shall be submitted to the Engineer. The steel shall be stored on Site
and marked in a way that later enables identification of the steel corresponding to each
certificate.

5.2.2.6 Additional Tests

The Contractor shall cut out steel samples as directed by the Engineer and these shall be
tested according to the Engineer’s instructions by an approved Testing Institution.
Expenses incurred for additional tests in connection with cutting out, transporting and
testing of the samples shall be paid for by the Contractor. In general, two samples shall be
tested from each batch of a particular size of reinforcement delivered to the site.

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SECTION 7 GENERAL SPECIFICATIONS
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5.2.3 Construction Methods

5.2.3.1 Protection and Storage

Reinforcement for structures shall be handled and stored in a manner that will prevent
bending out of the desired shape and any accumulation of dirt, oil and paint. When placed
in the works it shall be free from dirt, oil, grease, paint, mill scale and loose or thick rust.

5.2.3.2 Cutting and Bending

Bars shall be cut and bent cold to the dimensions indicated and with equipment and
methods approved by the Engineer.
Stirrups and tie bars shall be bent around a pin having a diameter not less than four times
the minimum thickness of the bar. Bends for other bars, where full tension in the bar may
occur, shall be made around a pin having a diameter not less than twenty times the bar
diameter. Hooks shall conform to American Concrete Institute Standard Building Code
Requirements for reinforced concrete ACI 318-83ACI 318-19, or as shown on the
Drawings.

5.2.3.3 Placing, Supporting and Fastening

All bar reinforcement shall be placed, supported and secured prior to any concreting
operations. The reinforcement shall be checked and approved by the Engineer before
pouring of concrete.
Cover blocks required for ensuring that the reinforcement is correctly positioned shall be
as small as possible, consistent with their purpose, of a shape and material acceptable to
the Engineer, and designated so that they will not overturn when the concrete is placed. If
made of concrete, the maximum size of aggregate shall be 6 mm and the mix proportion
shall be one part of Portland cement to 2 parts of sand by weight. Wire shall be cast in the
block for the purpose of tying it to the reinforcement. The wire must not be closer than 30
mm from the concrete surface. The use of small stones or wood blocks shall not be
permitted.
The reinforcement shall be held securely in place at the exact position and at the exact
spacing as indicated on the Drawings by the use of wire ties at bar intersections, supports
and cover blocks. Wire ties shall be securely tied and folded so that they do not project
beyond the planes formed by the reinforcing bars. The adequacy of the supports and ties
to secure the reinforcement properly shall be subject to the approval of the Engineer.

5.2.3.4 Splicing
Reinforcement shall be furnished in the lengths indicated on the Drawings. When the
Contractor wishes to use more splices than are indicated and/or necessary, the Contractor
shall furnish Working Drawings to the Engineer for approval in accordance with the
guidelines provided on the Contract Drawings. If such additional splices are approved,
the extra weight occasioned by such splices shall not be included in the measurement of
reinforcement for payment.
All splices for high yield deformed steel bars and mild steel plain steel bars shall have lap
lengths as shown on the Drawings. Lap splices shall generally be located at points of
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SECTION 7 GENERAL SPECIFICATIONS
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minimum tension in bars. Except where otherwise shown on the Drawings lap splices
shall be made with the bars placed in contact and securely wired together.
Welding of reinforcing steel shall be done only if detailed on the Drawings or approved
in writing by the Engineer. Before the Engineer may approve of such welding, the
Contractor shall submit and test any samples as the Engineer may require and make due
allowance for the time elapsing before results are available.

5.2.3.5 Substitutions
Substitutions of bars shall be permitted only with specific authorization by the Engineer
and at the expense of the Contractor. If bars are substituted they shall have a cross
sectional area equivalent to the design area, or larger. If substitutions of bars are
permitted, the Contractor shall produce working drawings and reinforcing detailing at his
own expense and to the approval of the Engineer.

5.2.4 Measurement
The quantity of reinforcement to be measured under this Section shall be the computed
weight in tonnes of material used and accepted as shown on the Drawings provided that
the quantity shall not include the reinforcement in any item of work for which the basis of
payment includes the reinforcement. In computing the weight to be measured, the
theoretical weights of bars of the cross section shown on the Drawings or authorized,
shall be used. The weight shall be calculated based on a constant mass of 0.00785
kg/mm² per meter run.
The computed weight shall not include the extra material incurred when bars larger than
those specified are used, or the extra material necessary for splices when bars shorter than
those specified are used with the permission of the Engineer, or the weight of any devices
used to support or fasten the reinforcement in the correct position including any necessary
chairs.
However, payment shall be allowed for lap splices not shown when the bars are longer
than 12 meters. Only one lap splice per every 12 meters will be paid for.
5.2.5 Payment
This work measured as provided above, shall be paid for at the Contract unit price per
metric tonne of reinforcement of the particular type. The payment shall be full
compensation for furnishing and placing reinforcement of any size and for all labor,
binding wire, equipment, tools and incidentals necessary to complete the work prescribed
in this Section.
Pay items shall be:
05/02/01 Mild Steel Reinforcing Bars Tonne
05/02/02 High Yield Deformed Steel Reinforcing Bars
05/02/02(a) High Yield Deformed Steel Reinforcing Bars (Grade Tonne
300: 300 MPa)
05/02/02(b) High Yield Deformed Steel Reinforcing Bars (Grade Tonne
400: 400 MPa)
05/02/02(c) High Yield Deformed Steel Reinforcing Bars (Grade Tonne
420: 420 MPa)
05/02/02(d) High Yield Deformed Steel Reinforcing Bars (Grade Tonne
500CWR: 500 MPa)
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SECTION 7 GENERAL SPECIFICATIONS
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05/02/02(e) High Yield Deformed Steel Reinforcing Bars (Grade Tonne

500DWR: 500 MPa)
05/02/02(f) High Yield Deformed Steel Reinforcing Bars (Grade Tonne
550: 550 MPa)
FBECR : Extra cost for FBEC over item 05/02/02(a) to
05/02/02(g) 05/02/02(e) Tonne
05/02/02(h) For Re-bar diameter: 8mm to 12mm Tonne
For Re-bar diameter: 16mm to 50mm
05/02/03 Wire Mesh Reinforcement Tonne

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SECTION 7 GENERAL SPECIFICATIONS
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5.3 PRESTRESSING REINFORCEMENT

5.3.1 Description

5.3.1.1 General
This work shall consist of the furnishing and placing, pre-tensioning or post-tensioning of
bars, strands or wires as specified on the Drawings and these Specifications.

5.3.1.2 Definitions
Post tensioning is defined as any method of prestressing concrete in which the tensioned
reinforcement is tensioned after the concrete is placed.
Pre-tensioning is defined as any method of prestressing concrete in which the tensioned
reinforcement is tensioned before the concrete is placed.
Prestressing reinforcement is defined as any reinforcement to which prestress is applied
by post tensioning or pre-tensioning.
Non-prestressing reinforcement (“ordinary reinforcement” or only “reinforcement”) is
defined as any reinforcement to which no prestressing tension is applied externally.

5.3.2 Materials

5.3.2.1 Tendons for Post Tensioning Systems

Prestressing steel shall be Stress-Relieved Wire according to AASHTO M 204, Stress
Relieved Strand according to AASHTO M 203 or High-Strength Steel bar according to
ASTM A 722.
The Contractor may propose any other internationally acknowledged prestressing steel
subject to approval of the Engineer. Detailed drawings showing the tendon arrangement
and calculations shall be submitted, which verify that the proposed tendons introduce into
bridge structures the prestressing effect equivalent to the original design shown on the
Drawings.
No tendons shall be used in the construction before testing has been carried out and
approved by the Engineer.

5.3.2.2 Anchorage Assemblies

The end anchorages (stressing anchorages and dead end anchorages) shall be especially
designed for the actual type of tendon and must have been used on other similar work and
thus have demonstrated proper functioning and durability for this purpose.
Allowance shall be made to test anchorages to destruction. The anchorages shall be
capable of fixing the prestressing steel at a load of not less than 95% of the specified
minimum tensile strength of the prestressing steel.
The manufacturer shall submit appropriate test certificates from an approved testing
laboratory.
Information on all details of the design and the steel quality of the anchorages shall be
submitted to the Engineer.

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5.3.2.3 Sheathing
All sheathing shall be of the metallic corrugated type, galvanized and fully mortar tight.
The sheathings shall be strong enough to maintain their shape under such forces as may
be expected to act on them.
All information on proposed sheathings shall be submitted by the Contractor to the
Engineer for his approval.

5.3.3 Construction Methods

5.3.3.1 General
The Contractor shall provide a technician skilled in the use of the actual system of
prestressing to supervise the work to the satisfaction of the Engineer.
The Contractor shall provide all equipment necessary for the construction and the
prestressing. Prestressing shall be done with approved jacking equipment. If hydraulic
jacks are used they shall be equipped with accurate reading pressure gauges. The
combination of jack and gauge shall be calibrated and a graph or table showing the
calibration shall be furnished to the Engineer. Should other types of jacks be used,
calibrated proving rings or other devices shall be furnished to accurately establish jacking
forces.
If alternative systems are adopted, the Contractor shall submit, for the approval of the
Engineer, drawings and calculations which show the arrangements of tendons, anchorage
assemblies, etc. and verify that the prestress occurring at every section is equal to that
produced by the system originally used in the design.

A) Pre-Tensioning Systems
Prestressing strand and wire to precast piles shall be seven wire strand and wire in
accordance with ASTM A 416-74.
Prestressing tendons can be directly substituted by other types of equivalent strength
tendons conforming to JIS G 3109-1971, BS 3617-1971 and BS 2691-1969.

B) Certificates
Manufacturer’s test certificate for breaking strength shall be obtained for each delivered
coil or bundle and a stress/strain diagram shall be obtained for every fifth coil or bundle.
Each coil or bundle of prestressing steel shall be delivered with charge No. and markings
to allow identification of the corresponding tests carried out.
Copies of the manufacturer’s dated test certificates of his Routine Testing shall be
submitted to the Engineer for his approval.

C) Tests
Tests in addition to those to be carried out by the manufacturer as specified herein will be
required.
Supervised by the Engineer, the Contractor shall cut out samples (approximately 1.0m
long) for each 25 tons of steel, or as directed by the Engineer. The breaking load, 0.2%
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SECTION 7 GENERAL SPECIFICATIONS
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proof load and elongation tests shall be carried out according to ASTM A 370, by an
approved independent testing laboratory.
Expenses incurred in connection with cutting out, transport and testing of the samples
shall be borne by the Contractor.
No tendons shall be used in the construction before the testing has been carried out and
approved by the Engineer.

5.3.3.2 Storage of Materials

Coils and bundles of prestressing steel shall be stored flat on a floor raised off the ground
and under full cover from the weather. They shall be protected from damage, oil,
corrosion or any deleterious matter, and shall not be opened until required. Before being
fabricated into prestressing tendons the strands or bars shall be cleaned of loose rust and
any deleterious matter, and inspected by the Engineer for approval. Prestressing steel
reinforcement which shows signs of pitting or has any surface defects such as splits,
roughness or necking is not to be used, and any lengths of wire or strand so affected shall
be cut off and rejected.
Corrugated sheathing is to be delivered to the site coiled on to large diameter wooden
drums, securely fastened and protected from damage. They shall be stored on site under
cover from the weather, and shall be protected from rusting, damage, oil or any other
deleterious matter and shall be clean and free from all such matter before being used in
the Works.
5.3.3.3 Manufacture of Tendons
Prestressing cables shall be prepared on site from coils of wires or strands. Tendons,
which consist of a number of high tensile steel strands, shall be formed in a manner
approved by the Engineer. In estimating the length of all cables, extra allowance must be
made for applying either one or two tensioning jacks.
Sheathing shall be carefully examined prior to use and any damaged lengths shall be cut
away and rejected.
Suitable spacers shall be provided, if required, to hold the strands or bars in correct
position in the sheathings to ensure that there is sufficient space around each wire or
cable to allow proper grouting.
Joints in corrugated sheathing shall be formed by the use of couplers and/or by wrapping
the joints with tape. They shall be so designed as to prevent the ingress of concrete or
other material during casting. All joints in sheathing shall be approved by the Engineer.

5.3.3.4 Placing Tendons and Sheathing

Tendons shall be carefully handled so as to avoid sharp bends or kinks. The sheathing
and/or the tendon shall be rigidly supported in the exact positions as shown on the
Drawings so that no movement can take place during casting of elements to be
prestressed.
The tendons shall be placed with the following tolerances:
Vertical ± 10 mm, horizontal ± 20 mm.
The tendons shall be supported by special supporting arrangements as proposed by the
Contractor and approved by the Engineer. If the sheathing is supported by reinforcement
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bars, they shall be plain round bars of mild steel. The supports shall be placed at adequate
centres to ensure the tendons in all positions are placed along the prescribed curve. Care
must be taken to prevent the supports from penetrating into the sheathings and if
necessary special means must be used.

5.3.3.5 Placing Anchorages

Anchor cones, blocks and plates shall be positioned and maintained during concreting so
that the centreline of the duct passes axially through the anchorage assembly.
All bearing surfaces of the anchorage shall be clean prior to concreting and tensioning.
The anchorage itself shall be adequately protected against corrosion following the
completion of the final stressing operation.

5.3.3.6 Jacks for Prestressing

All jacks used for prestressing shall be of the type applicable to the system adopted.
The accuracy of all load measuring equipment shall be checked to the satisfaction of the
Engineer at the start of work each day it is to be used and whenever the equipment is
moved to a different jack.

5.3.3.7 Post-tensioning Procedure

1) Prior to construction work, the Contractor shall submit a table which shows
the tensioning order of all tendons to be tensioned at each construction stage,
pressure of hydraulic jacks or pumps, anchor pull-in and elongation of each
tendon. This proposed post-tensioning procedure is subject to approval by the
Engineer. The Contractor shall carry out tensioning tests on a few tendons
designated by the Engineer, and the results shall be taken into consideration
for the table preparation. The result of the tensioning work for each tender
shall be submitted in a form designated by the Engineer.

2) Tensioning shall be carried out only in the presence of the Engineer unless
permission in writing has been obtained to the contrary.

3) Immediately before tensioning, the Contractor shall prove that all tendons are
free to move between jacking joints and that members are free to
accommodate the horizontal and vertical movements due to the application of
prestress.

4) Unless otherwise described in the Contract, concrete shall not be stressed until
it has reached at least the age at which two test cylinders taken from it attain
the specified transfer strength. The test cylinders shall be made and tested in
accordance with Section 5.1.2.4. The Contractor shall cast sufficient additional
cylinders to demonstrate that the required strength of the concrete at transfer
has been reached.

5) Where members consist of jointed elements, the strength at transfer of the

jointing material shall be at least equivalent to the specified transfer strength
of the member.

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SECTION 7 GENERAL SPECIFICATIONS
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6) The Contractor shall establish the datum point for measuring extension and
jack pressure to the satisfaction of the Engineer.

7) The Contractor shall add to the forces described in the Contract an allowance
for anchorage friction and jack losses. The total forces and calculated
extensions shall be agreed with the Engineer before stressing is commenced.

8) Immediately after anchoring, the stresses in the prestressing tendons shall not
exceed 70% of their specified characteristic loads. During stressing the value
shall not exceed 80%.

9) The tendons shall be stressed at a gradual and steady rate. The forces in the
tendons shall be obtained from readings on two load cells or pressure gauges
incorporated in the equipment. The extensions of the tendons under agreed
total forces shall be within 5% of the agreed calculated extensions.

If the required elongation cannot be reached, the jacking force may be

increased to 80% of the specified characteristic load of the tension. If the
difference between the measured and calculated elongation is more than 10%,
however, no further tensioning shall be made until the calculations and the
equipment is checked.

10) When stressing tendons with stressing anchorage at both ends, the pull-in at
the ends remote from the jack shall be accurately measured and the
appropriate allowances made in the measured extensions at the jack ends.

11) When the prestressing has been applied to the satisfaction of the Engineer, the
tendons shall be anchored. The jack pressures shall then be released in such a
way as to avoid shocks to the anchorages or tendons.

12) If the pull-in of the tendons at completion of anchoring is greater than agreed
by the Engineer, the loads shall be released at a gradual and steady rate and
tensioning carried out afresh.

13) The Contractor shall keep full records of all tensioning operations including
the measured extensions, pressure gauge or load cell readings and the amount
of pulling at each anchorage. Copies of these records shall be supplied to the
Engineer within 24 hours of each tensioning operation.

14) The men employed shall be experienced in this class of work. Every
precaution shall be taken to ensure the safety of the workmen during the
tensioning period.

5.3.3.8 Grouting
Grouting shall be carried out as specified in Section 5.1.3.17.

5.3.3.9 Finishing off Tendons

After grouting, the ends of the anchorages and any projecting ends of cut-off tendons
shall be covered by concrete or special mortar mix.

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5.3.3.10 Pre-Tensioning
The specified force shall be maintained by the use of fixing devices at the ends of the
tensioning steel during concreting and curing until the concrete has attained the specified
strength or other strength approved by the Engineer. The tensioning steel shall then be
released gradually and uniformly.
All details and function of the “prestressing bed” shall be approved by the Engineer.
The amount of tensioning shall be as shown on the Drawings or as instructed by the
Engineer.
The amount of jacking force and the elongation shall be measured on each strand wire or
bar in a way approved by the Engineer.
Test specimens manufactured and cured in accordance with Section 5.1.2.4 may be
requested for the verification of the concrete strength before releasing the tensioning
steel.

5.3.4 Measurement
The quantity to be measured shall be the theoretical weight in metric tons of the
prestressing steel as shown on the Drawings without sheathings, anchorages etc., and
measured between the outer faces of the anchorage blocks.

5.3.5 Payment
The work measured as provided above shall include all works as specified including
provision of sheathings, anchorages, couplers, spirals, supports for the tendons,
tensioning, grouting and finishing works.

Pay item shall be:

05/03/01 Prestressing Wire or Strand (as detailed on the Drawings) Tonne

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SECTION 7 GENERAL SPECIFICATIONS
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5.4 EXISTING CONCRETE

5.4.1 Description
This work shall consist of the construction of small extensions; reconstruction of
localized defective concrete; rehabilitation of existing concrete facing; reinforcing,
anchoring, tying and nominal stressing together of concrete elements; ground
anchors; and sealing and treatment of structural cracks in various forms of members,
all in accordance with these Specifications and the lines, levels, grades, dimensions
and locations shown on the Drawings and as required by the Engineer.

5.4.2 Materials

5.4.2.1 Concrete
Concrete shall comply with the requirements of Section 5.1 of these Specifications.

5.4.2.2 Reinforcement
Reinforcement shall comply with the requirements of Section 5.2 of these Specifications.

5.4.2.3 Prestressing Reinforcement

Prestressing reinforcement shall comply with the requirements of Section 5.3 of these
Specifications.

5.4.2.4 Cement Grout and Mortar

Cement grout and mortar shall comply with the requirements of Section 5.1 of these
Specifications.

5.4.2.5 Resin Repair Mortars

Epoxy resins, unsaturated reactive polyester resins or unsaturated acrylic resins specified
on the Drawings and detailed in the Bill of Quantities shall conform to the requirements
of the Manufacturers recommendations or other suitable alternatives, subject to the
approval of the Engineer, where it can be demonstrated that the proposed alternatives are
at least equivalent to the materials proposed.

5.4.3 Construction Methods

5.4.3.1 General
The Contractor shall in due time and as soon as possible present and discuss his
construction proposals and work programmers for nominal extensions to existing concrete
structures; for implementing repairs to existing structural cracks in concrete structure; for
implementing repairs to existing concrete surfaces and for the rehabilitation of existing
defective concrete.
The details of Works shall cover the requirements specified on the Drawings and as
directed by the Engineer at each location. The scope of new Works shall be as confirmed
by the Engineer. The precise extent of all concrete extensions or repairs shall be jointly
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surveyed by the Contractor and the Engineer at the commencement of the Works and the
locations of all extensions, repairs or strengthening shall be recorded and carefully
marked in paint on each structure to permanently identify the Works to be implemented.
In locations where existing concrete sections are to be extended or joined, the existing
concrete shall be carefully broken back at the locations where sections are to be joined.
The breaking will be done to ensure the damage to existing concrete is the absolute
minimum. Sufficient concrete will be removed to expose where appropriate the
reinforcement of the existing section. Sufficient reinforcement will be exposed to enable
additional reinforcement to be lapped to the existing steel. The reinforcement will be
carefully cleaned and all loose concrete shall be removed. The existing concrete will be
cleaned of all dust and a construction joint shall be prepared accordingly on the exposed
face to ensure a good feature can be obtained between the new work and the existing
concrete section. Concrete and reinforcement for the construction of the new section shall
conform in all respects to Sections 5.1 and 5.2 respectively.
Defective concrete on the front face of substructure walls such as piers, abutments etc.,
particularly adjacent to the water line; and in soffits to beams, slabs and other
superstructures; on the wet faces of main beams and other superstructures shall be
carefully removed in a sequence and in accordance with the strict instructions of the
Engineer. Such works shall be permanently supervised by a technical representative of the
Engineer and the Contractor shall also ensure technical staffs are permanently available
on the Site to receive specific instructions. The existing structural integrity of existing
members shall not be impaired during this operation and the Contractor shall be fully
responsible for ensuring strict procedures are followed. Defective concrete on main
structural members shall be carefully and cleanly removed by manual methods using
hammers and chisels to expose the main and secondary reinforcement. This reinforcement
shall be carefully cleaned using wire brushes unless the Engineer gives alternative
instructions. The concrete shall also be carefully broken back and the surface shall be
cleaned of all dust and loose material. The removed defective concrete shall be replaced
by a method proposed by the Contractor that shall be subject to the approval of the
Engineer. In this respect, the Contractor shall propose and clearly demonstrate that the
method he proposes to adopt is capable of giving a guaranteed facing of concrete that
would be equivalent in all respects to the workmanship standards that would be accepted
in new works. Depending on the extent of the repair works, sprayed concrete or gunite
will be allowed provided acceptable procedures are proposed. Traditional formwork
methods with “letter boxes” will also be allowed for large volume repairs.
Strategic structural cracks on highly stressed structural members such as shear cracks at
scarf joints or shear cracks in beam webs shall be sealed by resin repair mortars. The
Contractor shall ensure temporary access is provided to effectively implement critical
repairs. The final decision of the repair resin will be made on completion of the inspection
immediately prior to undertaking the sealing operation. Initially, cracks will be cleaned of
all dust and debris in accordance with manufacturer’s recommendations once the resin to
be adopted has been identified. Depending on the method to be adopted, nipples shall be
inserted along the cracks or vacuum impregnation procedures shall be prepared to enable

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SECTION 7 GENERAL SPECIFICATIONS
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grout to be effectively injected into the structural cracks. The Engineer shall assess the
effectiveness of crack repairs, generally on the basis of the quantity of resin injected.
Structural concrete members that exhibit cracking and relative movement may be
anchored or tied in accordance with the Engineer’s instructions. Wing walls and
abutments shall be tied and anchored at the locations and to the details indicated on the
Drawings and as specified in the Bill of Quantities. Prior to commencing any of the work,
the Contractor shall obtain the approval of the Engineer of the methods to be adopted for
all temporary arrangements. This shall cover the provision of temporary stages; the
proposed drilling methods; proposed safety measures; proposed anchoring methods and
subsequent testing for ground anchors to ensure tie bars are capable of carrying twice
working load; proposed stressing methods and ultimate grouting of anchor bars. The
Contractor shall take instructions from the Engineer on the precise requirements for the
provision; installation and anchoring of all tie bars incorporated in the Works.

5.4.3.2 Workmanship
Repairs and the like to existing concrete shall be constructed as shown on the Drawings or
as may be required, by skilled and experienced personnel well versed in this type of work.
The Contractor shall clearly demonstrate that his workforce proposed to be used on
concrete repair works have a capability to complete this form of work to a satisfactory
standard. Such demonstrations may take the form of pilot repair works not directly
associated with the Works.

5.4.4 Measurement
Concrete Extensions and Repairs shall be measured in either cubic meters or square
meters depending on the form of work ordered, placed and accepted. In computing
quantities, the dimensions of concrete extensions where appropriately shown on the
Drawings for new work and extensions shall be used as the basis for measurement.
Remedial repairs of defective concrete face work and replacement of defective concrete
shall be measured by the area of square meters ordered, marked up and accepted. The
sealing of cracks with resin repair mortars shall be measured by the weight of resin used
in the injection process of cracks ordered to be repaired, marked up and accepted. The
sealing of cracks with cement mortar shall be measured by the cumulative length of
cracks ordered to be repaired, marked up and accepted. The provision of tie bars and
ground anchors, and installation (including fixing, drilling, grouting in stages, stressing
etc.) shall be measured by the weight of bar ordered, installed and accepted.
No incidental works necessary to perform the repair works shall be measured; the
Contractor shall include in the payment items for all necessary temporary works to
undertake and complete every operation.

5.4.5 Payment
The Work measured as provided above shall be paid for at the Contract unit prices per
cubic meter of concrete or square meter of concrete refacing. Resins used in cracks shall
be paid for at the Contract unit prices per kg of material used. Anchor and tie bars shall be
paid for at the Contract unit prices per tonne of bar used. Concrete cracks filled with
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SECTION 7 GENERAL SPECIFICATIONS
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cement mortar shall be paid for at the Contract unit prices per length of crack required.
The rates shall be fully inclusive of all cost of all labor and materials temporary works
and equipment to complete the works in a professional manner.

Pay items shall be:

05/04/01 Modifications to Existing Concrete Cubic Meter
05/04/02 Concrete Surface Repair Works Square Meter
(Superstructures)
05/04/03 Concrete Surface Repair Works Square Meter
(Substructures)
05/04/04 Resin Repair Mortars Kg
05/04/05 Cement Mortar in Cracks Linear Meter
05/04/06 Anchor and Tie Bars Tonne

5.5 BRICKWORK

5.5.1 Description
This work shall consist of the construction, reconstruction, rehabilitation, face work repairs
and repointing of brickwork structures, also the construction of brick drainage layers, in
accordance with these Specifications and the lines, levels, grades, dimensions and locations
shown on the Drawings or as required by the Engineer.

5.5.2 Materials

5.5.2.1 Specifications for Materials

A) Bricks
First class bricks shall be made from good brick earth, free from saline deposits, and shall
be sand-moulded. They shall be thoroughly burnt by coal without being vitrified, of
uniform and good colour, shall be regular and uniform in size, shape and texture with
sharp square edges and parallel faces. They must be homogeneous in texture and emit a
clear metallic ringing sound when struck one against the other. They shall be free from
flaws, cracks, chips, stones, modules of lime or kankar and other blemishes. A first class
brick shall not absorb more than 1/6th of its weight of water after being soaked for one
hour, and shall show no sign of efflorescence on drying. First class bricks not meeting
these requirements shall not be used under any circumstances.
Jhama bricks are those which are so overburnt as to become vitrified or distorted, so as to
be unsuitable for exact brickwork. Jhama bricks may be broken and used for aggregate in
roadworks provided the vitrified mass has not become porous or spongy as a result of
over burning and the aggregate satisfies the requirements of these Specifications.
Perforated bricks should be of uniform size and colour with sharp edges, square and
parallel faces and have a standard number of perforations. They must be standard
commercial products of approved manufactures and shall be approved by the Engineer.

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SECTION 7 GENERAL SPECIFICATIONS
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Machine made pressed bricks shall be of the size shown on the Drawings and shall be
standard commercial products of approved manufacturers. The use of machine made
pressed bricks shall be approved by the Engineer prior to use in the Works.
First class bricks should have the following dimensions after burning: 242 mm x 115 mm
x 70 mm. Picked Jhama bricks may have dimensions slightly below those for other brick
but not less than 235 mm x 110 mm x 70 mm. The unit weight determined in accordance
with STP 7.8.3 of 1st class bricks shall not be less than 1,100 kg/m3 and the unit weight of
Jhama bricks shall not be less than 1,200 kg/m3.

The crushing strength of bricks shall be tested in accordance with STP 7.8.4. The average
crushing strength of first class bricks shall not be less than 17 N/mm². The average
crushing strength of Jhama Bricks shall not be less than 20 N/mm².

B) Cement
Cement shall be as specified in Section 5.1.

C) Fine Aggregate
Fine aggregate shall be as specified in Section 5.1. The fineness modulus of sand shall not
be less than 1.50.

D) Water
Water shall be as specified in Section 5.1.

E) Steel Reinforcement in Anchors

Steel and anchorages shall be as specified in Sections 5.2 and 5.3.

5.5.2.2 Specifications for Mortar

Cement mortar shall consist of a mixture of one part by weight of cement to two parts by
weight of sand. The cement and sand shall be mixed dry and in the specified proportion
until the colour of the mixture is uniform. Approved water shall then be added sparingly,
only the minimum necessary being used to produce a workable mixture of normal
consistency. The water/cement ratio in no case shall exceed 50% by weight, or as directed
by the Engineer. The mixing shall be done on a clean board or platform with tied joints,
to avoid leakage. At the close of each day’s work the mixing trough and pans shall be
thoroughly cleaned. Cement mortar shall be mixed in such quantities as can be used in the
work within 30 minutes. Mortar, which has taken initial set, shall not be used nor shall it
be remixed with fresh mortar and such mortar shall be discarded and removed from the
working site.

5.5.3 Construction Methods

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SECTION 7 GENERAL SPECIFICATIONS
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5.5.3.1 General
The details of Works shall cover the requirements specified on the Drawings or as
directed by the Engineer at each location. The scope of new Works shall be as indicated
on the Drawings and as confirmed by the Engineer. The precise extent of all brickwork
extensions, repairs to defective brickwork, rehabilitation of brickwork and repointing of
mortar joints shall be surveyed by the Contractor and the Engineer at the commencement
of the Works and the locations of all repairs shall be recorded and carefully marked in
paint on each structure to permanently identify the Works to be implemented.
The Contractor shall in due time and as soon as possible present and discuss his
construction proposals and work programme for building new brickwork structures;
brickwork extensions to existing structures; brickwork repairs to defective bricks and
rehabilitation of existing structures; and the repointing of defective joints in existing
brickwork.
Excavations for new brickwork extensions such as wing walls shall be conducted to the
requirements of Division 2. Blinding concrete shall be provided in accordance with the
requirements of Section 5.1 Brickwork shall be constructed in accordance with the
requirements specified hereunder, to the lines and levels on the Drawings and as directed
by the Engineer.
Extensions to existing brickwork shall be achieved by the careful removal of existing skin
courses as directed by the Engineer to the lines and levels specified and marked in paint.
The old brickwork and joints shall be carefully prepared and cleaned to enable new
brickwork to be constructed on and adjacent to the old courses.
Defective brickwork in the front faces of abutment walls, particularly adjacent to the
water line, and in brick arches shall be carefully removed in a sequence as instructed by
the Engineer. The existing stability of walls and arches shall not be impaired during this
operation and the Contractor shall be fully responsible for ensuring that temporary
supports are provided to guarantee that the full structural integrity of the walls, arches etc.
is at all times retained. This may entail the temporary provision of struts and beams to
existing arch rings, spandrel walls and retaining walls. The defective brickwork shall all
be removed on an incremental basis if this is deemed desirable and new brickwork shall
be carefully constructed to guarantee that the structural integrity of the element is
returned to its original condition.
Weak and defective mortar in existing brickwork shall be carefully removed from the
joints to a depth instructed by the Engineer. The extent of mortar to be removed from
existing joints shall also be instructed by the Engineer and shall be marked in point on
existing brickwork faces. All joints shall be carefully cleaned prior to repointing with a
cement mortar. The composition of the mortar will be as directed by the Engineer and
will take into account the existing strength of joints that are not to be repaired. Existing
joints shall be repointed in a workmanlike manner to ensure full depth penetration is
attained and the finish is trimmed and flush with the face of the brickwork.
Cracks in existing brickwork shall be treated similarly to joints. Defective material shall
be carefully removed and the cracks shall be filled with cement mortar.
Tie bars and pattress plates shall be incorporated in accordance with the Drawings or the
instructions of the Engineer, where existing brickwork can be effectively anchored to
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other structural features. Tie bars and pattress plates shall be painted in accordance with
the requirements of these Specifications and shall be placed and positioned before
brickwork extensions are commenced. This would be specifically appropriate for the
strengthening and tying of brick spandrel walls to existing brick arches that are to be
either elevated or extended. The anchors to the tie bars should be nominally tightened
prior to the construction of the brickwork and subsequently nominally stressed after
completion of the structural work and compaction of filling.

5.5.3.2 Workmanship
Brickwork shall be built plumbed, curved or battered as shown on the Drawings or as
may be required, by properly supervised skilled masons and workmen. Bricks shall be
cleaned and if necessary, they shall be scrubbed. Bricks shall be soaked in water for at
least three hours before use.
Where new work joins previous work, the latter shall be well cleaned and thoroughly
watered. All face work bricks shall be specially selected regarding size, shape and edges.
Unless otherwise specified bricks shall be laid in English Bond, with frogs upward. All
horizontal joints shall be parallel and level. Vertical joints in alternate courses shall come
directly over one another. Joint thickness shall be 6 mm and shall in no case exceed 8
mm. The height of four courses including 4 bed joints shall rise 300 mm. Walls shall
always be carried up regularly along their entire length throughout the structure unless
otherwise directed by the Engineer. The brickwork shall be cured for at least seven days.
Fixtures such as clamps, pipe brackets etc. shall be provided in the brickwork during
execution.

5.5.3.3 Brick Drainage Layers

Brick drainage layers to abutments, wing walls and other structures shall be constructed
of “dry-laid” bricks as indicated on the Drawings and with vertical joints not exceeding a
width of 10 mm.

5.5.4 Measurement
Brickwork shall be measured by the number of cubic meters that is ordered, placed and
accepted. In computing quantities, the dimensions of brickwork shown on the Drawings
for new work and extensions shall be used as the basis for measurement. Remedial repairs
of defective brick and replacement of defective brickwork shall also be measured by the
number of cubic meters ordered as indicated on the Drawings or marked up and accepted.
No measurements will be taken on the defective brickwork that it is necessary to remove.
The repointing of existing brickwork joints shall be measured by the number of square
meters of repointing that is ordered, marked up and accepted. No measurements will be
taken on the amount of defective mortar it is necessary to remove.
Tie bars and pattress plates indicated on the Drawings or ordered by the Engineer shall be
measured by the Tonne.
No measurements will be taken of any temporary works.

5.5.5 Payment
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The work measured as provided above shall be paid for at the Contract unit prices per cubic
meter of brickwork or square meter of repointing.
The Contractor’s rates shall include for all temporary measures to retain structural adequacy
of an existing structure; all preparatory work in breaking out defective brickwork and
removal of the same; for mixing mortar; for placing brickwork on/against prepared surfaces
to the lines, levels as indicated on the Drawings or as instructed by the Engineer; for finished
joints in a neat and professional manner. The Contractor’s rates shall be fully inclusive of all
cost of labor and materials in providing brickwork with sound mortar joints that will satisfy
the structural criteria of the elements of the whole.
The Contractor shall be paid at the Contract unit rate for tie bars and pattress plates installed
and accepted.

05/05/01 New and Extended Brickwork Cubic

Meter
05/05/02 Brick Drainage Layer Cubic
Meter
05/05/03 Replacement of Defective Existing Cubic
Brickwork Meter
05/05/04 Repointing of Existing Brickwork Square
Joints Meter
05/05/05 Steel Tie Bars and Pattress Plates Tonne

5.6 PAINTING METAL STRUCTURES

5.6.1 Description
This work shall consist of, unless otherwise provided in the Contract, the preparation
of the metal surfaces on existing structures, the application, protection and drying of
the paint coatings and the supplying of all tools, tackle, scaffolding, labor and
materials necessary for the entire work as shown on the Drawings.

5.6.2 Materials

5.6.2.1 General
All paints to be used for the painting system shall be obtained from one manufacturer.
Paint shall be supplied in sealed containers of not more than 5 litres capacity and
these shall be used in strict order of delivery. The paint shall be adequate in all
respects for the intended purpose and shall be obtained from the manufacturer ready
for the use specified.

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Paint shall be stored in sealed containers in a lock-up store where it is not exposed to
extreme temperature. Any special storage conditions recommended by the
manufacturer shall be observed.
Paint not used within the shelf life period specified on the containers, or within 18
months of the date of manufacture, shall be replaced.
At the end of a working period, paint with a limited pot life or any two pack primers
etc. shall be discarded. Other types of paint shall be returned to the store and kept in
sealed containers.

5.6.2.2 Primer Coat

The primer coat of paint for metal shall be a red lead paint and shall conform to the
AASHTO Specification for Red Lead Ready-Mixed Paint, M 72.
Red lead pigment in the dry form or as a paste in oil shall conform to ASTM D 83.
The 97% grade shall be specified for dry pigment.
In mixing for paint, raw linseed oil (ASTM D 234) may be replaced with boiled
linseed oil (ASTM D 260) to the extent of 50% of the total oil content.
The paint, preferably, shall be factory mixed. As an alternative the pigment shall be
furnished in the form of red lead paste.

5.6.2.3 Undercoat
The undercoat shall be red lead paint as specified above, tinted light brown with lamp
black in an amount not exceeding 1/32 kilogram per litre of linseed oil. Dry film
thickness shall be 50 micron.

5.6.2.4 Finish Coat

The finish coat shall be as shown on the Drawings or as specified by the Engineer. It
shall conform to one of the following AASHTO Specifications:
1) Foliage Green Bridge Paint M 67
2) Black Bridge Paint M 68
3) Aluminium Paint (Paste-Mixing Vehicle) M 69
4) White and Tinted Ready-Mixed Paint (Lead and Zinc Base) M70

5.6.3 Construction Methods

5.6.3.1 Cleaning of Surfaces
A) General
Surfaces of metal to be painted shall be thoroughly cleaned, removing rust, loose mill
scale, dirt, oil or grease and other foreign substances. Unless cleaning is to be done by
sand blasting, all weld areas, before cleaning is begun, shall be neutralized with a
proper chemical, after which they shall be thoroughly rinsed with water.

Cleaning may be carried out by hand, mechanical means, chemically, sand blasting or
by flame cleaning. The method used in any area shall be approved by the Engineer.
Methods of cleaning are described as follows. All cleaning shall be approved by the
Engineer before the application of any paint.
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B) Hand Cleaning
The removal of rust, scale and dirt shall be done by the use of metal brushes, scrapers,
chisels, or hammers or other effective means. Oil and grease shall be removed by the use
of gasoline or benzene. Bristle or wood fibre brushes shall be used for removing loose
dirt.

C) Mechanical Cleaning
Steelwork shall be mechanically cleaned using power driven tools such as carborundum
grinding discs, chipping hammers and needle guns, followed by steel wire brushing,
washing and dusting to remove all loosened material. Excessive burnishing of the metal
through prolonged application of rotary wire brushes shall be avoided. Any visible peaks
and ridges produced by the use of mechanical cleaning tools shall be removed.

D) Sandblasting
The sandblasting shall remove all loose mill scale and other substances down to the bare
metal. Special attention shall be given to cleaning of corners and re-entrant angles. Before
painting, sand adhering to the steel in corners and elsewhere shall be removed. The
cleaning shall be approved by the Engineer prior to any painting, which shall be done
within 2 hours and before rust forms.

E) Flame Cleaning
Metal shall be flame cleaned in accordance with the following operations:

1) Oil, grease and similar adherent matter shall be removed by washing with a
suitable solvent. Excess solvent shall be wiped from the work before proceeding
with subsequent operations.
2) The surface to be painted shall be cleaned and dehydrated (free of occluded
moisture) by the passage of oxyacetylene flames which shall have an oxygen to
acetylene ratio of at least one. The inner cones of these flames shall have a ratio of
length to port diameter of at least 8 and shall be not more than 3.7 mm centre to
centre. The oxyacetylene flames shall be traversed over the surfaces of the steel in
such manner and at such speed that the surfaces are dehydrated; and dirt, rust,
loose scale in the form of blisters or scabs, and similar foreign matter are freed by
the rapid, intense heating by the flames. The flames shall not be traversed so
slowly that loose scale or other foreign matter is fused to the surface of the steel.
The number, arrangement and manipulation of the flames shall be such that all
parts of the surfaces to be painted are adequately cleaned and dehydrated.
3) Promptly after the application of the flames, the surfaces of the steel shall be wire
brushed, hand scraped wherever necessary, and then swept and dusted to remove
all free materials and foreign particles. Compressed air shall not be used for this
operation.
4) Paint shall be applied within 2 hours after the steel has been cleaned and while the
temperature of the steel is still above that of the surrounding atmosphere, so that
there will be no re-condensation of moisture on the cleaned surfaces.
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5.6.3.2 Number of Coats and Colour

All steel shall be painted with one prime coat, and with not less than two field coats. The
thickness of the prime coat shall not be less than 75 microns and the total thickness of the
two field coats shall not be less than 125 microns.
The colour shall be as specified or determined by the Engineer. The coats shall be
sufficiently different in colour to permit detection of incomplete application.

5.6.3.3 Weather Conditions

Paint shall not be applied when the air is misty, or when, in the opinion of the Engineer,
conditions are otherwise unsatisfactory for the work. It shall not be applied upon damp
surfaces.
Material painted under cover in damp weather shall remain under cover until dry or until
weather conditions permit its exposure in the open. Painting shall not be done when the
metal is hot enough to cause the paint to blister and produce a porous paint film.

5.6.3.4 Mixing of Paint

Paint shall be factory mixed. All paint shall be re mixed before applying in order to keep
the pigments in uniform suspension.

5.6.3.5 Application
A) General
Painting shall be done in a neat and workmanlike manner. Paint may be applied with hand
brushes or by spraying except that aluminum paint preferably shall be applied by
spraying. By either method, the coating of paint applied shall be smoothly and uniformly
spread so that no excess paint collects at any point. If work done by spraying is not
satisfactory to the Engineer, hand brushing shall be required.

B) Brushing
When brushes are used, the paint shall be so manipulated under the brush as to produce a
smooth, uniform, even coating in close contact with the metal or with previously applied
paint, and shall be worked into all corners and crevices.
On all services, which are inaccessible for paint brushes, the paint shall be applied by
spraying or applied with sheepskin daubers, to ensure thorough covering.

C) Spraying
Power spraying equipment shall apply the paint in a fine, even spray without the addition
of any thinner. Paint, when applied with spray equipment, shall be immediately followed
by brushing when necessary to secure uniform coverage and to eliminate wrinkling,
blistering and air holes.

D) Removal of Paint
If the painting is unsatisfactory to the Engineer, the paint shall be removed and the metal
thoroughly cleaned and repainted.

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E) Thinning Paint
Paint as delivered in containers when thoroughly mixed is ready for use. If it is necessary
to thin the paint in order that it shall spread more freely, this shall be done only by heating
in hot water or on steam radiators, and liquid shall not be added nor removed unless
permitted by the Engineer.

5.6.3.6 Painting Galvanized Surfaces

For the purpose of conditioning the surface of galvanized surfaces for painting, the
painting shall be deferred as long as possible in order that the surface may weather.
Before painting galvanized surfaces they shall be treated as follows:
In 1 gallon of soft water dissolve 2 ounces each of copper chloride, copper nitrate, and sal
ammoniac, then add 2 ounces of commercial muriatic acid. This should be done in an
earthen or glass vessel, never in tin or other metal receptacle. Apply the solution with a
wide flat brush to the galvanized surface, after which it will assume a dark, almost black,
color, which on drying becomes a grayish film. The Contractor may propose any
alternative process as a method of treatment subject to the approval of the Engineer.

5.6.4 Measurement
The quantity of work done under this section shall be measured in square meters to
include all painting required on each structure or structural unit.

5.6.5 Payment
Payment will be made for the work, materials, labor and equipment as detailed on the
Drawings and as specified in the Bill of Quantities.
Pay item shall be:
05/06/01 Preparation and Painting of Existing Square Meter
Structures

5.6.6 Cold Galvanizing Compound for Galvanic Protection

5.6.6.1General
This work shall consist of, unless otherwise provided in the Contract, the preparation of
the metal surfaces on existing structures, the application, protection and drying of the
coatings and the supplying of all tools, tackle, scaffolding, labor and materials necessary
for the entirework as shown on the Drawings.

5.6.6.2 Materials
 Cold Galvanizing Compound is a metallic coating which contains 95% - 96% zinc
(Dust) in its dry film.
 Dry galvanized film should not contain any toxic elements.
 Specific Weight of the compound should be 2.50 – 3,0 g/ml.

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 Solid content should be 86% by weight (± 1%) and 52% by volume (±1%)
according to ASTM D1475.
 Temperature resistance of dry film should be minimum -400C and maximum
6500C.
 pH resistance in atmospheric condition should be 4.5 pH to 10.5 pH.
 It must have excellentUV resistance capacity.

5.6.6.3 Construction Procedure:

a) Preparation of the Surface:
Surface of the metal to be coated shall be thoroughly cleaned. Cleaning will be done with
appropriate power tools or Green Rust Convertor or blasting method. Before
coating the rich, zinc product, cleaning and blasting must be done according to SA -1,
SA- 2, SA- 2.50, SA- 3.00 (Swedish standard internationally recognized surface
preparation method) ISO – 8501.

i. SA – 1, Light blast cleaning: Through this process of cleaning, there it could be

done 20 micron to 39 micron thickness of coating.
ii. SA – 2, Thorough blast cleaning: Through this process of cleaning, there it could
be done 39 micron to 59 micron thickness of coating.
iii. SA – 2.50 Very thorough blast cleaning: Through this process of cleaning, there it
could be done 60 micron to 99 micron thickness of coating.
iv. SA – 3.00 Blast to visually clean steel: Through this process of cleaning, there it
could be done 100 micron to 360 micron thickness of coating.

Surface Cleaning could be done in three (3) ways.

1) With appropriate power tools & Green rust Convertor.
2) Wet vapor blasting (Dustless)
3) Abrasive grit blasting or sand blasting.

a) New metal surface: Steam clean or high pressure wash-down all surface, followed by
using appropriate power tools or Green rust convertor or a grit slurry vapor blasting
to obtain the roughness.

b) Old, previously galvanized, painted or rusty surface: Steam clean to remove all
contaminations from porous surfaces. Allow to dry off and blast clean as normal.

c) Galvanized steel in good condition: Steam clean the surface, followed by a light
sweep blast to remove the zinc salt layer.

5.6.6.4 Application of Cold Galvanizing Compound:

a) Apply the content of Cold Galvanizing Compound as soon as possible on the prepared
metal surface before any contamination or corrosion occurs before coating. Otherwise the

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surface must be prepared again. The stipulated time for coating is within 2 (two) hours
after completion of the blasting and cleaning.

b) It can be applied on a clean surface by roller, brush and conventional spray gun or by
airless spray.

c) Stripe coat: It is always recommended to treat corners, sharp edges, nuts and bolts
before applying a uniform coat by brush.

d) Stirring: It must be thoroughly mechanically stirred to achieve a homogeneous liquid

before application. After a maximum of 20 minutes, re-mixing is necessary.

e) Cleaning: Before and after using the spraying equipment, it must be rinsed with fresh
thinner. Brushes and rollers should also be rinsed with thinner. Never use white spirit.

f) Dilution: For Brush or roller, use 5% Mineral Spirit or Aromatic

hydrocarbon/appropriated thinner to dilute the content. For conventional spray, use 15%
Mineral Spirit or Aromatic hydrocarbon/appropriated thinner to dilute the content. For
Airless spray, use 7% Mineral Spirit or Aromatic hydrocarbon/appropriated thinner to
dilute the content.

g) Application: Once thoroughly mixed, the content can be applied by using a normal
paint-brush, a short-fiber roller (not for first coat) or a conventional spray-gun or an
airless spray-gun. When applying contents by spraying it must only be thinned by
Mineral Spirit or Aromatic hydrocarbon/appropriated thinner.

h) Temperature: The application surface temperature range is from 150C to 600C, where
condition allows with a maximum humidity of 97%. Like all coatings the substrate
surface should be free from all types of contaminations.

i) Reloading: When a new coat is applied on to an existing layer to form a single

homogeneous layer, the old layer does not need to be removed before re-coating with a
new layer. A removal of contamination is required though.

j) Drying time: The content of film galvanizing system should be touch dry and dust free
in about 10 (ten) minutes at 200C (40 micron DFT).

5.6.6.5 Measurement:

a) The quality of work done under this section shall be measured in square meters to
include all coatings of Cold Galvanizing Compound required on each structure,
structural unit and all components.
b) For thickness measurement Digital coating thickness gauge shall be used.

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5.6.6.6 Payment:
Pay Item shall be

05/06/02 40 Micron Cold Galvanizing Compound for minimum 10 years Sqm

protection against rust and corrosion
05/06/03 60 Micron Cold Galvanizing Compound (Duplex) including Sqm
Polyurethane (PU) or Urethane or Polysiloxane continued with
Micaceous Iron Oxide (MIO), Aluminum and Magnesium Silicate
fot minimum 13 years protection against rust and corrosion
05/06/04 60 Micron Cold Galvanizing Compound for minimum 13 years Sqm
protection against rust and corrosion.
05/06/05 80 Micron Cold Galvanizing Compound for minimum 15 years Sqm
protection against rust and corrosion
05/06/06 100 Micron Cold Galvanizing Compound for minimum 18 years Sqm
protection against rust and corrosion
05/06/07 120 Micron Cold Galvanizing Compound for minimum 20 years Sqm
protection against rust and corrosion.
05/06/08 140 Micron Cold Galvanizing Compound for minimum 23 years Sqm
protection against rust and corrosion.
05/06/09 160 Micron Cold Galvanizing Compound for minimum 26 years Sqm
protection against rust and corrosion
05/06/10 180 Micron Cold Galvanizing Compound for minimum 30 years Sqm
protection against rust and corrosion
05/06/11 360 Micron Cold Galvanizing Compound for minimum Life time Sqm
protection against rust and corrosion.

Note: There is data on the life expectancy of G60 hot-dip galvanizing in the specific
environment in question, then an application of Cold Galvanizing Compound to a minimum
dry film thickness of 3.0 mils or 80 Micron, in the same environment, will give the same life
expectancy of the G60 hot-dip galvanizing.

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5.7 BRIDGE STEELWORK

5.7.1 Description
This work shall consist of the carriage of unit bridging, steel beams/ girders and other items
of bridge steelwork and ancillaries from a port to the bridge site, storage on site and
installation/erection in accordance with the manufacturer’s standard procedures or as shown
on the Drawings.
Elastomeric bearings for composite bridge construction, materials for temporary works and
other ancillary materials shall be provided by the Contractor.

5.7.2 Materials
Materials provided to the Contractor shall be collected by him from the port. The Contractor
shall meet any demurrage costs at the port arising from his failure to provide the requisite
loading equipment and/or transport. The Contractor shall exercise great care in loading,
transporting, unloading, storing and installation/erection of all components. Any damage
shall be repaired by the Contractor at his expense and to the satisfaction of the Engineer. If
any component is damaged beyond repair, the Contractor shall bear all direct and indirect
costs associated with replacement. Similarly, the Contractor shall make good any shortfall
due to loss or theft.
The Contractor shall submit detailed proposals of elastomeric bearings for composite bridges
to the Engineer, for approval, prior to procurement. The proposals shall be based on the
design requirements and dimensions indicated on the Drawings.
Other materials for the permanent works provided by the Contractor shall be of the quality
and type shown on the Drawings, subject to the approval of the Engineer.

5.7.3 Construction Methods

5.7.3.1 Unit Bridging

Unit bridging shall be assembled and installed by the Contractor in accordance with the
standard procedures provided by the manufacturer. Bearings for unit bridging shall be
installed in accordance with the Drawings and the manufacturer’s instructions.

The method of erection shall be subject to the approval of the Engineer.

If the bridging is to be erected by cantilevering, the Contractor will be responsible for

providing any necessary kentledge, rails for access and any other materials required for
temporary works.

If the bridging is to be erected in position on wooden bullah trestles, these shall be

designed and constructed to provide the necessary rigidity and to support the loads
without settlement or deformation. The Contractor shall submit detailed drawings and
designs for the proposed trestles and false works to the Engineer for his approval. The
Engineer’s approval shall not however relieve the Contractor of his responsibility for
ensuring the adequacy of his proposals and for the successful erection of the bridging.

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When bridge parapet steelwork consisting of posts and barrier is provided with unit
bridging, the fixing to reinforced concrete deck slabs shall be in accordance with the
manufacturer’s recommendations. The Contractor shall however submit his proposals for
installation to the Engineer, for approval, prior to installation.

5.7.3.2 Steel Beams/ Girders for Composite Bridges

The Contractor shall submit proposals for the installation of elastomeric bearings and
steel beams/ girders as shown on the Drawings to the Engineer for approval.

5.7.4 Measurement
Carriage of unit bridging, steel beams and other items of bridge steelwork and ancillaries
from the port to site shall be measured by the tonne.
The fixing of bearings for unit bridging which are supplied to the Contractor shall be
measured by number. The supply and fixing of elastomeric bearings for composite bridge
construction shall be measured by number.
The assembly and installation of unit bridging shall be measured by the linear meter of
bridge. Parapet steelwork fixed to reinforced concrete deck slabs shall be measured by the
linear meter of parapet.
The installation of steel beams/ girders for composite bridge construction shall be measured
by the tonne.

5.7.5 Payment
Payment for carriage of bridge steelwork and ancillary items shall include for all materials,
labor and equipment for loading at the port, transporting and unloading at the site.
Payment for the fixing of bearings for unit bridging and the supply and fixing of elastomeric
bearings for composite bridge construction shall include the provision of all additional
materials such as shims and mortar and the provision of all labor and incidentals to complete
the work.

The Contractor’s rates for the assembly and installation of unit bridging and steel parapet
shall include all labor, temporary works and equipment required to complete the work.
The Contractor’s rate for the installation of steel beams and ancillary steelwork items for
composite bridge construction shall include all labor, temporary works and equipment
required to complete the work.
Pay items shall be:

05/07/01 Carriage of Bridge Steelwork from Port to Tonne

Site
05/07/02 Fixing of Bearings for Unit Bridging Number
05/07/03 Supply and Fixing of Elastomeric Bearings Number
for Composite Bridge Construction
05/07/04 Assembly and Installation of Unit Bridging Linear Meter
05/07/05 Installation of Steelwork for Composite Tonne
Bridge Construction
05/07/06 Installation of Steel Post and Barrier Parapet Linear Meter
to Reinforced Concrete Deck Slab
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5.8 MOVEMENT JOINTS

5.8.1 Description
This work shall consist of furnishing and installation of materials for expansion joints in
reinforced concrete structures and the furnishing and installation of fabricated bridge deck
joints.
All expansion joints shall be products which have a proven successful performance record.
The contractor shall submit for the approval of the engineer full details of the proposed joints.
This shall include lists of projects in which the proposed product has been incorporated in
similar structures and climatic conditions. The contractor shall submit substantiating
information on previously installed units of the same type supporting the durability and
periods free of maintenance claimed by the manufacturer.
The Design of the joint system shall facilitate inspection and replacement. Epoxy nosing
joints shall not be permitted.

a) The Contractor shall furnish and install bridge deck expansion joints and accessories
as shown on the Drawings or directed by the Engineer. The accessories shall include
bold assemblies, welding, metal work, elastomers and sealants as required.
b) Should the proposed deck joints require changes to the basic concrete outline of the
bridge decks, the Contractor shall also submit all relevant details to the Engineer for
approval.
c) Grout or dry pack concrete for metalwork shall be mixed in the proportions and to the
consistency approved by the Engineer. The Contractor shall furnish all cement and
fine aggregate for grout of dry pack complying with the requirements of
Section5.1.2.1 (A) and Section-5.1.2.1(D). The cost of all work in connection with the
grouting or dry packing operations and the cost of the cement and fine aggregate for
grout shall be included in the rates tendered in the Bill of Quantities for furnishing
and installing the various items of metal work for which the grout or dry pack is
required. Before placing grout of dry pack, the surfaces of existing concrete on which
the grout or dry pack will be placed shall be roughened and shall be cleaned of all
laitance, loose or defective concrete, coatings and other foreign material by effective
means followed by thorough washing. Such surfaces shall be kept moist immediately
prior to the placing of the grout of dry pack.

5.8.2 Materials

5.8.2.1 Expansion Joints

The materials for expansion joints will be as detailed on the Drawings. Typically these
will include compressible joint filler board, dowel bars and two part polysulphide sealant.
Ancillary materials necessary for use with polysulphide sealant, such as primer and bond
breaker tape shall be provided in accordance with the sealant manufacturer’s
recommendations. The Contractor shall obtain the Engineer’s approval of all proposed
materials prior to procurement.

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5.8.2.2 Bridge Deck Joints

These shall be fabricated in accordance with the details shown on the Drawings. The
Contractor shall obtain the Engineer's approval of any fillers and paints necessary to
complete the joints, prior to procurement.

5.8.2.3 Joint Performance Requirements

a) The joints shall be completely watertight. Special attention shall be paid to the
detailing to ensure full water tightness at the faces of the parapets.
b) All metal work shall be galvanized in accordance with Standard Drawing.
c) The movement capacity of deck expansion joints shall be as shown on the
Drawings.

5.8.2.4 Storage of Materials and Protection against Corrosion

The Contractor shall propose the corrosion protection system for components of
movement joints, full details of which shall be submitted for the approval of the Engineer.
All materials for movement joints delivered to site shall be stored under cover, on
platforms above the surface of the ground, to the satisfaction of the Engineer. They shall
be kept free from dirt, oil, grease and other foreign substances. Any materials unused
prior to the manufacturer's "use by" date shall be removed from site by the Contractor,
unless written approval to the contrary is obtained from the Engineer.

5.8.2.5 Construction Methods

All materials and fabrications shall be installed in accordance with details shown on the
Drawings and where applicable, in accordance with the manufacturer's instructions and
recommendations. The joint gap and pre-setting to suit ambient temperatures at the time
of installation shall be as directed by the Engineer.

a) Not less than 30 days prior to placing an order for a proprietary joint, of 60 days
before commencing installation of the deck joints, the Contractor shall submit for
approval, complete shop drawing showing details of fabrication and installation.

b) Expansion deck joints as shown on the Drawings have been located on the bridge
decks showing the longitudinal movement in the bridge decks due to shrinkage, creep
and thermal effects in either the precast beams or the concrete deck slab as zero. The
Contractor shall take into account at the time of installation of the deck joints the
actual movement that has taken place in the bridge deck and shall take such measures
as directed by the Engineer to ensure that the deck joint openings as installed are
satisfactory.

c) Joints shall be of uniform width and shall be accurately set, finished and aligned flush
with the finished carriageway level to provide a smooth ride free from tyre slap and
impact loading, all to the satisfaction of the Engineer.

5.8.2.5 Recommendation type for Expansion Joint

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Following types of expansion joint can be recommended as per requirement of expansion

or contraction amount:

SL. Expansion or Contraction amount Expansion Joint

1. Less than 25mm Angle Plate Type Joint

2. 25mm to 50mm Elastomeric Single Strip Seal
3. More than 50mm but less than or Finger Type Expansion Joints
equal to 125mm with drainage seal
4. More than 125mm Modular Sealed Expansion
Joint

5.8.2.6 Measurement
Expansion joint shall be measured by the linear meter of complete joint installed,
measurement being along a straight line from base to top of a wall or one side of a slab to
the other, etc. The measured length may therefore include a sealant length of over twice
this value if several faces of the concrete are sealed. Bridge deck joints shall be measured
by the linear meter of joint installed.

5.8.2.7 Payment
Expansion joints measured in accordance with section 2.6 shall be paid for at the contract
unit prices for providing joints in the locations indicated on the Drawing and described in
the Bill of Quantities. Payment shall be full compensation for furnishing and installing all
materials, including all labor, tools, equipment and incidentals necessary to complete the
work.
Bridge deck joints measured in accordance with Section 2.6 shall be paid for at the
Contract unit price. Payment shall be full compensation for furnishing all materials,
fabrication either on or off site and labor, tools, equipment and incidentals necessary to
complete the work shown on the Drawings.

Pay items shall be

5/8/1 Expansion Joint Complete as Detailed on Linear Meter
the Drawings in the Location
Described in the bill of Quantities

5/8/2 Bridge Deck Joint Complete as Detailed Linear Meter

on the Drawings

Materials shall comply with the following or equivalent as agreed with the Engineer:
a) Structural Steel - BS4360
b) Fixing to Bridge Structure - HSFG bolts to BS 4395
c) Elastomer - similar to elastomeric bridge bearing

Exposed steel plate shall have a 2 mm non-skid surface coating in accordance with the
manufacturer’s recommendations, details of which shall be submitted to the Engineer.
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5.9 DRAINAGE OF STRUCTURES

5.9.1 Description
This work consists of furnishing and erection of drain outlets on bridge decks and drainage of
other structures including PVC piping, cleaning boxes, catch basins, concrete drains, erosion
protection, inserts, fittings and other incidental parts necessary to provide for further supports
of drain pipes in accordance with the lines, levels, grades, sizes, dimensions and types shown
on the Drawings.

5.9.2 Materials

5.9.2.1 Bridge Gullies

The size and strength of bridge gullies shall be as indicated on the Drawings.

5.9.2.2 Cast Iron Piping

Cast Iron Piping shall comply with AASHTO Standard Specification M129 or other
approved standards.

5.9.2.3 PVC Pipes

All PVC pipes shall comply with ISO R 161 “Pipes of Plastic Materials for the Transport
of Fluids”, or with BS 3505 “Unplasticized PVC Pipes for Cold Water Services”.

5.9.2.4 Cleaning Boxes

The Contractor shall submit to the Engineer for his approval details of boxes with
cleaning lids made of approved material to be installed in the locations indicated on the
Drawings.

5.9.2.5 Catch Basins

To comply with Section 6.3 of these Specifications.

5.9.2.6 Culvert Pipes

To comply with Section 6.2 of these Specifications.

5.9.2.7 Inserts
Inserts shall be made of steel conforming to AASHTO Standard Specification M 183
(ASTM A 36).
5.9.2.8 Fittings and Other Incidentals
Materials should be as indicated on the Drawings or as approved by the Engineer.

5.9.3 Construction Methods

5.9.3.1 Storage and Handling of Materials

The steel and PVC parts shall be carefully handled and stored under cover on blocking,
racks or platforms so as not to be in contact with the ground and the steel parts shall be
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protected from corrosion. Materials shall be kept free from dirt, oil, grease and other
foreign matter.

5.9.3.2 Bridge Gullies

Bridge gullies are to be cast into the structure at the location as indicated on the
Drawings. Special care must be taken to avoid displacement of gullies during concreting
operations.

5.9.3.3 Cast Iron Piping

Special jointing instructions relevant to the purchased types of pipe will be issued by the
Engineer. The pipes shall be embedded in the locations as indicated on the Drawings.
During casting of concrete the piping shall be kept in the correct position by means
approved by the Engineer.

5.9.3.4 PVC Pipes

The jointing shall be of a type recommended by the manufacturer of the pipes. Bends
shall be of long sweep, free from kinks. Embedded pipes shall be cast into the structure in
the locations as indicated on the Drawings. During casting of concrete the piping shall be
kept in the correct position by means approved by the Engineer.
Exposed pipes shall be parallel to or at right angles to walls, slabs and girders. All
exposed pipes shall be attached to concrete, steel, masonry or timber by galvanized
malleable iron or galvanized steel straps, clamps or hangers of an approved type, held at
not less than two points by galvanized steel bolts or lag screws. The runs shall be
supported at not greater than 1 metercentres on horizontal or near horizontal runs, unless
otherwise specified and not less than 50 mm clear of the supporting members.
All ends of pipes installed during construction shall be closed against the intrusion of
foreign material.

5.9.3.5 Cleaning Boxes

To be installed by methods proposed by the Contractor and approved by the Engineer.

5.9.3.6 Catch Basins

To comply with Section 6.3 of these Specifications.

5.9.3.7 Culvert Pipes

To comply with Section 6.2 of these Specifications.

5.9.3.8 Weep Holes

While constructing abutment, wing wall and return wall weep holes shall be provided
therein unless shown otherwise in the relevant drawings and filter layer approximately 1m
wide right up against the wall to its full height shall be provided. Unless otherwise shown
the weep holes shall be of concrete pipe of 100 mm diameter and shall extend through the
full width of the wall with slope of about 1 vertical to 20 horizontal towards the drawing
face. The spacing of weep holes shall be generally 1.5 m in either direction and shall be
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staggered. The lowest ones shall be located at about 300 mm above the low water level or
ground level whichever is higher, or as directed by the Engineer. In general, one weep
hole per 1.5 square meter of vertical surface shall be provided.

5.9.3.9 Inserts
To comply with Section 5.10 of these Specifications.

5.9.4 Measurement
The individual items shall not be measured and will be paid for as a lump sum.

5.9.5 Payment
Drainage work to a particular structure or to several structures, as defined in the Bill of
Quantities, will be paid for at the Contract lump sum price.
The price and payment shall constitute full compensation for furnishing all materials as
indicated on the Drawings including delivery, erection, surface treatment and finishing and
for all labor, equipment, tools and incidentals necessary for the completion of the work.
The payment of Catch Basins and Culvert Pipes shall be paid within Sections 6.3 and 6.2
respectively.
Pay item shall be:
05/09/01 Provision and fixing of drainage to structure(s) as Lump Sum
detailed on the Drawings and defined in the Bill of
Quantities
5.10 INSERTS AND FITTINGS IN STRUCTURES

5.10.1 Description
This work consists of furnishing and embedding of inserts, fittings and other incidental parts
into bridgeworks necessary to provide for further supports for utility pipes and cables and the
like. The type, size and location will be indicated on the Drawings, or instructed by the
Engineer.

5.10.2 Materials
Unless otherwise indicated on the Drawings, the inserts shall be made of steel conforming to
AASHTO Standard Specification M 183 (ASTM A 36). Material to be as indicated on the
Drawings or as approved by the Engineer.

5.10.3 Construction Methods

The inserts and fittings shall be embedded at the locations indicated on the Drawings or as
instructed by the Engineer. During casting of concrete in structures, the inserts and fittings
shall be kept in the correct position by means approved by the Engineer.
The inserts and fittings shall be plugged or pressed against the formwork in a way that no
mortar from the concrete may enter the thread of the inserts or fittings.
After removal of the formwork, the Contractor shall clean the surface of the insert and fittings
to the approval of the Engineer.

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5.10.4 Measurement
The individual items shall not be measured and will be paid for as a lump sum.

5.10.5 Payment
This work will be paid for at the Contract lump sum price, which shall be fully inclusive of
all working drawings, materials, installation including labor, equipment, tools and incidentals
necessary to complete the work.

Pay item shall be:

05/10/01 Embedment of Inserts and Fittings Lump Sum

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SECTION 7 GENERAL SPECIFICATIONS
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5.11. BRIDGE BEARINGS (ELASTOMER)

5.11.1 Descriptions
This work shall consist of furnishing and installation of elastomeric bearings. Elastomeric
bridge bearing shall be manufactured and furnished in accordance with this Specifications
and Drawings and shall be installed at the locations shown on the Drawings or directed.
Throughout this Section the term 'elastomeric bearing' shall refers to a rubber bearing
consisting of one or more vulcanized natural rubber slabs bonded to metal plates to form a
sandwich arrangement and caters for translation and / or rotation of infrastructure by elastic
deformation of elastomer.

5.11.2 Materials

5.11.2.1 Elastomer
The raw elastomer shall be virgin neoprene. Natural rubber shall comply with AASHTO
M251-92.The elastomer compound whose nominal hardness falls within the ranges of 46-
55, 56-65 and 66-75 are classified as types A, B and C, respectively. The elastomer
compound shall meet the minimum requirements of table 5.11.2.3 when test specimens
are cut from the finished product, the physical properties shall be permitted to vary from
those specified in table 5.11.2.3 by 10 %

5.11.2.2 Steel Laminates

Steel laminates used for reinforcement shall be made from rolled mild steel conforming to
ASTM A36 or A570, Grade 36 or ASTM A611, Grade 40. The laminates shall have a
minimum nominal thickness of 16 gages. The steel plates separating the elastomeric
layers will be completely bonded by vulcanization to the elastomeric material on all
surfaces using special metal to rubber bonding adhesive.

5.11.2.3 Bond
The vulcanized bond between fabric and reinforcement shall have a minimum peel
strength of 5.2KN/m. Steel laminated bearings shall develop a minimum peel strength of
6.9 KN/m2. Peel tests shall be performed by ASTMD429 Method B.

Table 5.11.2.3
TestMethod Properties of Elastomer unit Type A Type B Type C

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D2240 Physical Hardness(shore a Durometer) IRHD 50+5 60+5 70+5

D412 Minimum Tensile Strength N/mm2/MPa 15.52 15.52 15.52
Minimum Ultimate Elongation 400 350 300

D573 Accelerated Ageing(70 hours at 100 dc

+1dc) IRHD 15 15 15
Maximum Change in Durometer % -15 -15 -15
Hardness % -40 -40 -40
Maximum change in Tensile strength
Maximum change in Ultimate
elongation
D395 Compression set 22 Hours % 35 35 35
Method B @100dc,Maximum
D1149 Ozone Resistance No No No
Test after 100 hours at 100 pphm ozone Cracks Cracks Cracks
in air by volume, 20% strain, 38dc +1dc
ASTM D Ash Content % 5 5 5
297

ASTM D Shear Modulus of Elasticity MPa

4014 Minimum value 0.8 0.8 0.8
Maximum Value 1.2 1.2 1.2

5.11.3 Fabrication and Installation

5.11.3.1 General
Bearing with steel laminates shall be casted as a single unit in a mould and vulcanized
under heat and pressure. Casting of elements in separate units and subsequent bonding
shall not be permitted, nor shall cutting from larger size cast be permitted.
Bearing of similar size to be used in particular bridge shall be produced identical process
and in one lot as far as possible. Phased production only resorted to when the total
number of bearings is large enough.
The moulds used shall be sand blasted, clean of all mill scales and shall be free from all
contaminations prior to bonding by vulcanization. Rusted plates with pitting shall not be
used. . All edges of plate shall be rounded.
Spacers used in moulds to ensure cover and location of laminates shall be of maximum
size and number practicable. Care shall be taken to ensure uniform vulcanizing conditions
and homogeneity of elastomer through the surfaces and body of bearings.

5.11.3.2 Fabrication tolerances

Laminated bearings shall be built to the specified dimensions within the following
tolerances and should comply with AASHTO M251-92.

1. Overall Height
Design thickness 32mm or less -0, +3mm
Design thickness over 32 mm -0, +6mm
2. Overall horizontal Dimensions -0, +6mm
3. Thickness of Individual Layers of Elastomer +/-20% of design
value, Max+/- 3mm
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4. Edge cover -0, +3mm

5. Thickness of Top and Bottom cover layer -0, smaller of 1.5mmand
20% of nominal
cover layer thickness
6. Position of Exposed Connection Members -0, +3mm
7. Parallelism with opposite Face
Top and Bottom 1 in 200
Sides 1 in 50

5.11.3.3 Permission for fabrication

At least 30 days before manufacture of the bearings is commenced, the Contractor shall
submit, for approval, certificates of tests performed on natural rubber to be used in the
bearings. The tests shall be in accordance with AASHTO M251-92.
Manufacture of the bearings shall not commence until the Contractor has received
preliminary approval of these details.

5.11.3.4 Testing facilities for fabrication

The manufacturer shall have his plant for all the test facilities required for the process and
acceptance control tests. The test facilities and their operation shall be open to inspection
by the Engineer on demand. Acceptance testing shall be commenced with the prior
submittal of testing program by the manufacturer to the Engineer and after obtaining his
approval. The Contractor shall inform the Engineer at least one month in advance of the
date and place of manufacture and test facilities of the bearing. The Contractor shall make
necessary arrangement for the Engineer to inspect the manufacturing process of tests. If
the place of manufacture or testing is located overseas, the Contractor shall allow the cost
for all expenses incurred by two officers nominated by the Employer for the inspection
and testing of bearings. The Contractor shall provide the Engineer with all facilities at the
places of manufacture and necessary for such inspection.

5.11.3.5 Quality control certificate

A lot under acceptance shall comprise all bearings, including a pair of extra test bearings
of equal or nearly equal size produced under identical conditions of manufacture to be
supplied for a particular project. The manufacture shall certify for each lot of bearing
under acceptance:
That an adequate system of continuous quality control was operated in his plant
That the entire process remained in control during the production of the lot of bearings
under acceptance as verified from the quality control records /charts which shall be open
to inspection of the Engineer on demand.
A certified copy of results of process control testing done on samples of elastomer used in
the production of the lot shall be appended and shall include at least the following
information.
Composition of the compound-raw elastomer and ash content, the grade of raw elastomer
used (including name, source, age on self).Test results of hardness, tensile strength,
elongation at break, compression test, accelerated ageing etc.

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An information card giving the details for the bearings duly certified by the manufacturer
shall be appended.
The manufacturer of the bearings shall have not less than 5 (five) years successful
experience in manufacturing similar type and capacity bearings.

5.11.3.6 Sample Testing of Bearings

a) No bearings shall be installed until tests in accordance with AASHTO M251-92 have
been completed by an approved laboratory on randomly selected bearings and the
bearings, having achieved all requirements, have been approved.
b) Bearings for testing shall be selected by the Engineer and the Engineer shall be
present at any testing. The rate of testing of bearings shall be in accordance:
Bearing Rate of Testing
Type A 1 in 4
c) Each bearing shall be indelibly marked with white paint with an identifying number
asdirected by the Engineer on the side. This number shall be the bearing identification
number for test certificates.
Any bearing which fails to pass these requirements shall be indelibly marked
'FAILED' and shall not be used in the works. 'FAILED' bearings will not be paid for.
d) Each bearing which passes these tests and complies with this Specification in
all other respects shall be indelibly marked 'PASSED'.
e) The Contractor shall submit, for approval, a copy of a test certificate giving test
results of the bearings which have passed the tests.
f) Notwithstanding anything to the contrary contained in this Specification, the
inspection, examination and testing of bearing samples by the Engineer and any consent
to proceed with the manufacture of the bearings resulting from such acts shall not prohibit
the Engineer from making further inspection, examination, or tests on the bearings
subsequently and rejecting any bearings if shown to be in non-compliance with this
Specification. The Engineer may reject any bearing with flaws or irregularities.

5.11.4 Installation

5.11.4.1 Cement Mortar Bearings pad

The cement mortar shall have a minimum compressive strength at 7 days of 30 MPa and
shall be composed of one part of cement to 2 parts of sand, unless otherwise approved.
All of the sand used in preparation of the mortar shall pass a 4.75 mm sieve.
Before placing the cement mortar bearing pads, the Contractor shall prepare a trial mix of
his proposed cement mortar mixture. The equipment used to make the trial mix shall be
the equipment to be used during the Contract.
Three standard 95 mm test cubes shall be cast for compression strength testing and cured
for 7 days to the satisfaction of the Engineer. The cubes will be air cured on site in a
sheltered location.
The three cubes shall be tested for compressive strength at 7 days and each cube shall
have a compressive strength of at least 30 MPa. Construction of the bearing pads shall not
be started until the strength of the proposed mix has been approved.
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The provision of all necessary equipment and carrying out of the sampling of the mortar,
the casting, on-site curing and testing of specimens shall be done by the Contractor at his
cost.

5.11.4.2 Bearings
The contractor shall supply, fix in position and maintain the bearings strictly in
accordance with the drawings and designs of the contract. Care shall be taken in packing,
Transportation, storage and handling to avoid any mechanical damage, contamination
with oil, grease and dirt, undue exposure to sunlight and installation of multiple bearings
one behind the other on a single line of support shall be of identical dimensions.
Bearings shall be placed between true horizontal surfaces (Maximum tolerance 0.2%
perpendicular to load) and a true plan position of their centre lines marked on receiving
surfaces (maximum tolerances+/-3mm). The level of the top surface of the elastomeric
bearing when installed shall not vary from that shown on the Drawings by more than 3
mm.
Concrete surfaces shall be free from local irregularities (maximum tolerance+/-1mm in
height)
If the Cement mortar bearing pads do not meet these tolerances may be repaired by either
grinding the surfaces which will be in contact with the bearings to achieve the desired
tolerances or by roughening these surfaces and casting a layer of an approved mortar over
the complete surface to a minimum of 3 mm and grinding as necessary. If the above
tolerances are not achieved, the Engineer may direct that the bearing pad be removed and
replaced by a new pad with the specified tolerances.
For cast in place concrete construction of superstructure, where bearings are installed
prior to its concreting the forms around the bearings shall be soft enough for easy
removal. Any mortar contamination of the bearings during concreting shall be completely
removed before setting.

The contractor shall ensure the presence of an authorized expert of the manufacturer
during commencement of the construction activities.

5.11.4.3 Maintenance
After installation routine maintenance, inspection of all bearings shall be made till the
expiry of the maintenance period to check for any surface cracking or signs of damage.
Damaged bearings shall be replaced immediately. To avoid difference, all adjacent
bearings on the same line of support shall also be checked and removed if necessary.

5.11.5 Measurement
Measurement for payment of furnishing and installing elastomeric bearing shall be made
of the number of bearings furnished and installed as shown on the Drawings or directed
by the Engineer.

5.11.6 Payment
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The unit rate for elastomeric bearing shall include all costs of materials, labor, tools and
plants, fabrication, testing, installation and maintenance as per drawing etc all complete.
Pay items shall be
05/11/01(a) Supply and Installation of Elastomeric bearings Number
05/11/01(b) Supply and Installation of Elastomeric bearings Number
05/11/01(c) Supply and Installation of Elastomeric bearings Number
05/11/01(d) Supply and Installation of Elastomeric bearings Number

Different Size of Elastomeric bearing as below:

a) 300mm x 400mm x 72mm
b) 400mm x 500mm x 72mm
c) 450mm x 500mm x 72mm
d) 500mm x 500mm x 72mm
Size may differ based on designer requirement.
Size of different type of bearing will be as per approved drawing.

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SECTION 7 GENERAL SPECIFICATIONS
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5.12 BRIDGE BEARINGS (POT BEARING)

5.12.1 Description
The work specified in this Sub-Section includes the supply, manufacture and installation of
pot type bearings.

5.12.1.1 Design and Applicable Codes

The bearings shall be designed, manufactured and installed in accordance with this
specifications and the applicable requirements of the following standard Codes and
Specifications:-
Standard specification for Highway Bridges adopted by AASHTO Part I&IIOr equivalent

5.12.1.2 Manufacturers
The bearing manufacturer proposed as supplier for the bearings shall have not less than
5 years successful experience in manufacturing similar type and capacity bearings and
shall be subjected to the approval by the Engineer.

5.12.1.3 Substituted Bearings

The contractor may submit alternative pot bearings based on pot bearings of similar
design to that shown for consideration and approval by the Engineer provided they
comply with the following:-
(a) Equal or better load carrying and movement capacity;
(b) Fabricated by an approved manufacturer;
(c) All control dimensions are maintained ; no change in overall height; bearing must
fit within limits of detailed masonry plate;
(d) Use unfilled Polytetrafluoroethylene (PTFE) ;
(e) Use elastomeric material as a confined medium within the pot;
(f) Equal or better than the bearings shown on the drawings in all structural respects.

5.12.2 Materials

5.12.2.1 Metals
(a) Stainless steel : Stainless steel sliding surface shall either be stainless clad steel plate
or solid stainless steel meeting the following requirements;-
Stainless steel clad plate shall conform to the requirements of BS 1449: Part 2. The grade
of material for sliding surfaces shall be 316 S16. The backing steel of base metal shall be
of Grade 43A to BS 4360. The stainless steel and based metal shall be mill rolled under
heat and pressure until they are integrally bonded over their entire interface.Solid
stainless steel plate shall conform to the requirements of Bs 1449: Part1.

(b) Structural Steel: Structural steel components of the bearing shall comply with
requirements of B5 4360. For pot bearings, the bases pot shall be machined from a solid
steel plate. All ferrous metal (other than stainless steel) shall be fabricated from the grade
steel specified above with the additional requirements that the steel shall contain 0.35 to
0.5% copper to enhance its weathering characteristics.
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Anchor bolts, Hex Nuts And Washers

Anchor Bolts, Hex Nuts and Washers shall be fabricated from the steel Grade 43 and
complying with the requirements of BS 4360 and be sized and threaded in conformance
to the requirements of BS 3692 for Anchor Bolts and Hex Nuts and BS 4320 for washers.

(c) Anchor Bolts, Nuts And Washers : Anchor Bolts, Nuts and Washers shall be
galvanized and complying with the requirements of BS 729.

(d) Countersunk Screws :Countersunk Screws shall be carbon steel (equivalent to alloy
43, BS 4360) cylindrical head cap screws, meeting the applicable requirements of BS
4933.

(e) End Welded Shear Studs: End Welded shear studs shall be fabricated to the
requirements of BS 4360.

5.12.2.2 Poly tetra fluoro ethylene (PTFE)

PTFE resin shall be 100 per cent virgin material meeting the requirements of BS 3784:
Grade A.
The composition of filled PTFE shall be such that its coefficient of friction is not more
than twice the coefficient of friction of pure PTFE when measured under the same
conditions.
(a) Filler material
Filler material, when used, shall be milled glass fibers, carbon or other approved inert
filler materials.
(b) Adhesives
Adhesives for bonding PTFE to Backing Plates shall produce a bond with minimum
peel strength of 4N/mm width when tested in accordance with BS 5350: Part C9.
They shall be resistant to the action of lubricants, atmospheric and biological agents
and temperature to which bearing may be subject;
(c) Lubricant
The lubricant used shall retain its properties within the temperature range of -270 to +
47 0C. It shall not change its consistency or affect the constituent parts of the bridge
bearings. The lubricant shall have the following properties:-
(i) Worked penetration range of 240 to 280 determined in accordance with BS 5296
(ii) a solidification point < A40 0C
(iii) a bleeding < 4% when tested in accordance with BS 5297 using 150 0C for 24
hour.

5.12.2.3 Elastomer
(a) Elastomer material shall be good quality natural rubber complying with the
requirements of MS 3.51 SMR 5 Grade or better shall be used. All ingredients
shall be uniformly dispersed.
(b) the physical properties of the vulcanized rubber when tested according to BS 903
shall conform to the requirements the following physical properties of rubber.
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(c) physical properties of Rubber

The physical properties of the vulcanized rubber when tested according to
appropriate standard shall conform to the requirements of Table 2.11 Bearings
whose nominal hardness falls within the ranges of 46-55, and 66-75 are classified
as types A, B and C respectively and the properties of the vulcanizates shall
conform to the requirements of the respective types. However in all cases the
hardness of a single size and design of bearings shall be within a maximum range
of ±5 IRHD. For the purpose of verifying that the bearings conform to the
requirements of this clause, all test specimens of ozone resistance shall be taken
from an outside surface of a bearing and all other test specimens shall be taken
from and outside and middle third of a bearing.

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Table 5.12.2 Physical Properties of Elastomer

Type A Type B Type C Methods of
Tests
1 Nominal Hardness 46 to 55 56to 65 66 to 75 ISO 48
(IRHD)
2 Tensile strength 21 17 14 ISO37
(N/sq.mm)min
3 Elongation at Break (%), 550 450 300 ISO37
min
4 Compression set after 30 30 30 ISO 815
24 hours at 700c and 25
Compression (%) Max.
5 Ozone resistance test No No No ISO 1431
after 96 hours at 25 visible visible visible Part 1
pphm ozone, 400C 20% cracks cracks cracks
strain
6 Accelerated ageing for ISO188(air
168 hours at 700C oven)
6.1) Change in tensile ±15 ±15 ±15 ISO37
strength(%)
6.2) Change in A20 A20 A20 ISO48
elongation at break,(%)

5.12.2.4 Coal Tar Epoxy

Coal Tar Epoxy shall comply with the requirements of BS5493 Ref Kf 3B.

5.12.2.5 Preformed Fabric Pads

Preformed Fabric Pads shall be compressed of multiple layers of 227 gram cotton duck
impregnated and bound with high quality natural rubber or of equivalent and equally
suitable materials compressed into resilient pads of uniform thickness the number of
splices shall be subs as to produce the specified thickness after compression and
vulcanizing. The finished pads shall withstand compression loads perpendicular to the
plane of the laminations of not less than 69KN sq.mm without detrimental reduction in
thickness of extrusion.

5.12.2.6 Sealing Rings

Sealing rings for containing the confined medium in pot bearings shall meet the following
requirements:-
(a) Non-corrosive Materials;
(b) Withstands or transmit all impose loads;
(c) Allow free movement of the piston;
(d) Contains the confined medium within the pot under the maximum static dynamic
loading;
(e) Prevents contamination of the confined medium with foreign matter.

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(f) Designed to be flushed with the outside surface of the Elastomer to ensure proper
sealing.

5.12.2.7 Grouts
Non shrink grouts for setting anchor bolts shall be of an approved quality and tested in
accordance with the requirements of BS 1881,BS 4550, BS4551 and BS 5075: Part 2.

5.12.3 Design Requirements

Design parameters shall comply with the following requirements:-

5.12.3.1 Elastomeric Disc

The maximum design compressive stress shall be 40 N/sq.mm.

5.12.3.2 Sliding Surfaces

Sliding surface shall accommodate translation by sliding of a hard mating surface of
stainless steel across a PTFE surface.

(a) Stainless steel

Stainless steel sliding surface shall be accurate, flat surface with Brinnell hardness of
125 minimum it shall comply with the following requirements
(i) Stainless steel sliding surface shall completely cover the PTFE surface in all
operating positions of the bearing.
(ii) Stainless steel sliding surface shall be positioned so that the sliding movement
causes the dirt and dust accumulation to fall from the surface of the stainless steel
without contaminating the PTFE.

(b) PTFE Sliding Surface

Holes in PTFE sliding surface shall not be permitted.

(c) Coefficient of Friction

Unless otherwise specified the minimum coefficient of friction used in the design
shall be as Table 5.12.

Table 5.12-1 Coefficient of Friction for Sliding

Bearing stress Coefficient of

(N/sq.mm) Friction
5 0.08
10 0.06
20 0.04
30 and over 0.03

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5.12.3.3 Rotation
The rotation of pot bearings about a horizontal axis shall not exceed 0.15.

5.12.3.4 Movement
The pot bearings shall accommodate the expansion and contraction movements, as shown on
the Drawings.

5.12 .3.5 Welding

Welding to steel plate has a bonded PTFE surface may be permitted provided welding
procedures are established which restrict the maximum temperature reached by the bond area
to less than 1500 (as determined by temperature indication wax pencils or other suitable
means approved by the Engineer)

5.12.3.6 Submission of shop drawings

The Contractor shall, before the fabrication of any bearings, submit shop drawings to the
Engineer for approval the shop drawings shall include

(a) Plan and elevation of the bearing ;

(b) Complete details and sections showing all materials incorporated with the bearing;
(c) All B5, ASTM or other material designations;
(d) Vertical and horizontal load capacity;
(e) Rotation and translation capacity;
(f) Compression stress on all sliding surfaces, as well as on the surfaces of the confines
medium, at maximum and minimum design loads;
(g) Complete design calculations to demonstrate compliance with the specification;
(h) Details of corrosion properties to metal components;
(i) Details of fixing to both the superstructure and the substructure;
(j) Method of installation;
(k) All other information required by the Engineer to facilitate his consideration of the
contractor’s proposal.

The Contractor’s submission shall be made at least one month prior to the date by which
approval of his proposals is required. The contractor shall be responsible for ensuring that
sufficient time is allowed for the submission and approval of his proposals; and for the testing
and delivery of the bearings, to avoid delaying the works.

5.12.4 Certifications
The Contractor shall furnish Certified Test Reports, Material Certificates and a Certificates
of Compliance for each bearing in accordance with the Engineer’s instructions.

5.12.5 Fabrication
5.12.5.1 PTFE
(a) Bonded PTFE: The surface of PTFE to be bonded shall be prepared for
bonding in accordance with B5 5350: Part A1. The minimum bond strength between
the PTFE and its backing plate, when tested in accordance with BS 5350: Part C9,
shall be 4N/mm width
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(b) Confined PTFE: shall be recessed into metal backing plate. The shoulders of
the recess shall be sharp and secure to restrict the flow of PTFE. The thickness of the
PTFE and its protrusion from the recess shall be related to its maximum plan
dimension in accordance with Table 5.12.1

Table 5.12.5.1: Thickness and Protrusion of PTPE

Maximum Minimum Maximum
dimension of Thickness projection
PTFE (diameter (mm) above
or diagonal) recess
(mm) (mm)

<600 4.5 2
>600, <1200 5 2.5
>1200, <1500 6 3

5.12.5.2. Bolts and Bolt Holes

Bolt holes shall be drilled or reamed. Where specified by the Engineer, bolts or
screw shall be of a vibration resistant type. Taper washers of the correct angle of taper
shallbe provided under all heads and nuts bearing on beveled surfaces.

5.12.5.3 Welding
(a) General
Welding procedure shall be as such as to minimize distortion of the bearing
components and to avoid damage to finished work or bonded materials
(b) Aluminums
Metal-arc welding of aluminum shall be in accordance with the recommendation of
BS 3019: Part 1
(c) Stainless Steel
Welding of stainless steel sheet to a mild steel backing plate shall be by an inert gas
shielded metal-arc tungsten inert gas metal-arc process. Electrodes used with that
former method shall be austenitic steel electrodes complying with BS 2926.

5.12.5.4 Protective Measures

Permanently exposed surface shall be protected against corrosion as specified
approved by the Engineer.
(a) Dissimilar Materials: Care shall be taken to prevent electrolytic action
between dissimilar metals in contact by the use of suitable insulation and prevention
of moisture penetration
(b) Damaged Areas: Any damaged area of protective treatment shall be made
good to the satisfaction of the Engineer or the damaged parts replaced.

5.12.6 Testing

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5.12.6.1Testing facilities for fabrication

The manufacturer shall have his plant for all the test facilities required for the process and
acceptance control tests. The test facilities and their operation shall be open to inspection
by the Engineer on demand.
Acceptance testing shall be commenced with the prior submittal of testing program by the
manufacturer to the Engineer and after obtaining his approval. The Contractor shall
inform the Engineer at least one month in advance of the date and place of manufacture
and test facilities of the bearing. The Contractor shall make necessary arrangement for the
Engineer to inspect the manufacturing process of tests. If the place of manufacture or
testing is located overseas, the Contractor shall allow the cost for all expenses incurred by
two officers nominated by the Employer for the inspection and testing of bearings. The
Contractor shall provide the Engineer with all facilities at the places of manufacture and
necessary for such inspection.

5.12.6.2 Sample testing: Procedures and Compliance

(a) Load Testing
Both vertical and horizontal loads shall be applied to the bearing in the most adverse
combinations as specified on the Drawing or in the Schedule of Bearings. Load transfer
due to tilting of bearing shall be taken into account. Before recorded measurements, the
bearing shall be embedded in by applying a load equal to the serviceability limit state and
then releasing it. The test loads shall then be applied in increments and load deflection
measurements shall be recorded for each increment. The rate of loading shall be slow
enough to avoid any adverse shock effects and the maximum load shall be maintained
until any obvious short-term creep has ceased.
The load shall then be removed in decrements and load deflection measurements made
each decrement. After complete unloading, the amount of set shall be checked and if
significant, the loading and unloading cycle shall be repeated. If the set is shown to be
progressive, then the bearing is deemed not to comply with this Specification.
For compliance, tested bearing shall show no sign of visible damage or permanent
deformation of any part due to loading cycles subsequent to the initial bedding in cycle.

(b) Friction
Friction testing of sliding surfaces shall be carried out as follows:-
(i) A vertical load equal to the permanent load specified on the drawing or listed
the schedule of Bearings shall be applied to a pair of sliding surface mounted back to
back between the plates of a compression testing rig. A horizontal force shall be
applied to the pair of sliding plates sufficient to cause movement of not less than
25mm between the stainless steel and PTFE sliding surface. The maximum force
required to cause this movement shall be recorded. The load shall then be removed
from the rig and inspected.
(ii) The coefficient of friction shall be calculated as (maximum horizontal force)
/22x vertical load for each test position and shall in no case exceed Table2.11-2
(iii) After testing the stainless steel shall be checked for flatness, which must be
within the specified limits. The bond to the backing plate shall be unaffected. The
PTFE shall be free from mechanical damage

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(iv) The tests shall be carried out at room temperature. The PTFE surface shall be
lubricated with the lubricant to be used in service. For compliance, tested bearing
shall show no apparent surface flaws.

5.12.7 Products Delivery Storage and Handling

5.12.7.1Assembly and Marking
Each pot bearing shall be assembled at the plant, marked for identification and delivered
to the construction site as a complete unit. Each bearing shall be marked to indicate the
normal position of the bearing

5.12.7.2 Care and Protection

During handling, transport, storage and installation, bearings shall be kept clean and
protected from mechanical damage, heat, contaminates and other deleterious effects.

5.12.8 Installation

5.12.8.1 General
Bearings which have been pre-assembled shall not be dismantled except with the prior
approval of the Engineer if for any reason the bearing has been dismantled, it shall be
done under expert supervision and the manufacturer’s assistance shall be sought. All
bearings whether require providing horizontal restraint or not, shall be fixed to the
superstructure with the mechanical fixings or similar. Reliance on the friction between the
bearing and the superstructure or substructure to resist part of the horizontal may be
permitted provided faces of safety of not less than 1 1½ is applied to the proven
coefficient of friction. The worst combination of vertical load and horizontal load shall be
considered.
The Contractor shall carefully check the level of any surface, plinth or bed upon which a
bearing will rest and he shall make due allowance for any difference in the depth the
bearing to be installed from that assumed on the Drawing. If necessary he shall adjust the
levels of the substructure to ensure that the level of the superstructure will be at the
required level on completion.
Unless specified all bearings shall be installed with bottom plate horizontal. For case
where tapered top plate is required to take up the longitudinal elevation, welding of
bolting to the top of the bearing is not allowed. The tapered top plate must be machined
on the bearing itself.
Any temporary lock devices for bearings shall be removed before a post-tensioned case in
place superstructure is stressed. For other type of superstructures, the Engineer shall agree
the time for removal of any locking devices shall be agreed by the Engineer.
Care shall be taken to avoid displacing bearings during formwork erection, steel fixing
and concreting.

The contractor shall ensure the presence of an authorized expert of the

manufacturerduring commencement of the construction activities.

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5.12.8.2 Tolerances

(a) Bearings shall be located so that their centerlines are within ±3mm of their correct
position. The level of bearings shall be within tolerance of ±0.0001 times the
adjacent span or lesser of the adjacent spans, but shall not exceed ±5mm. Bearings
shall be set to their correct inclination within a tolerance of 1 in 200mm in any
direction.
(b) Departure from the plane between twins or multiple bearings shall be within
tolerance specified on the drawing.
(c) Bearing shall be installed so that the directions of their horizontal axis are within
tolerance of ±0.005 radian from their correct alignment.

5.12.9 Shock Transmission Units

5.12.9.1 General
Steel components of shock transmission unit with transverse restraint bearings shall
comply with the general requirements except as otherwise stated herein. Other
components shall comply with Clauses 2.11. Protection of steelwork against corrosion
shall be as specified in SIS 0559000,BS 729, BS 6044, BS 2992, BS 3900, BS 2569
Part1, BS 4921, ISO 8503/Part-2, SSPC Paint, SSPC SP-2, SSPC SP-3 Seismic shock
transmission devices shall comply with Clause 3.4.
Details of shock transmission unit shall be as shown on the working Drawings.
The design of the restraints shall make provision facilitate inspection of the device if
construction incorporates the robust steel pintle restraint shown on the Consultant’s
reference Designs then replacement is not anticipated during the designs life of the
structure. If, in the opinion of the Engineer, an accepted alternative device may require
replacement during the design life of the bridge, then design shall facilitate replacement.

5.12.9.2 Model Testing of Yielding shock Transmission Unit

Scale model rests shall be carried out on shock transmission unit designed to yield under
seismic loading.
The Contractor shall submit to the Engineer for approval full details of his proposals for
such testing including where the tests are to be carried out and curricula vitae for the key
personnel involved.
The Engineer shall be given access to inspect testing at all times and shall have the
authority to instruct further amended tests at his discretion.
Factual reports including all results shall be submitted to the Engineer within one week of
the completion of each test. An interpretative report shall be submitted to the Engineer for
his approval within one week of the completion of testing.
The models shall not be smaller than one fifth of the size of the actual restraint.
A minimum of six clearly identified test specimens shall be prepared. A minimum of
three specimens shall be subjected to the nominal test sequence; a minimum of two
specimens shall be subjected to an arbitrary 30% excess deformation and one further
specimen tested to a deformation history chosen in the light of the other test results.

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Allowance shall be made for a minimum of six further specimens and having different
details to assist in design optimization.
The models shall accurately represent the transmission and it’s fixing arrangements.
Materials tests shall be carried out to relate the material strength and ductility to the
materials in the actual transmission.
The nominal test sequence shall accurately represent the deformation history expected for
actual transmission. This shall cover both magnitude and rate of deformation
The maximum force developed in each direction of deformation shall be recorded for
every cycle, and the force deformation relationship recorded for the first three cycles and
thereafter every fifth cycle. The physical appearance of the specimen after the test shall
be carefully recorded.

5.12.10. Other types of bearings

5.12.10.1 Steel-laminated Elastomeric/Neoprene bearings
Supplying, fitting and fixing steel-laminated Elastomeric/Neoprene bearings
(preferably from Mageba, VSL, Tensa, Watson or equivalent) in exact positions as per
drawing, specifications and direction of the E-I-C including cost of all materials, labor,
carrying etc. The set shall be of 100% virgin Chloroprene Rubber (CR), grades of raw
elastomer of proven use in elastomeric bearings, with low crystallization rates and
adequate shelf life viz. Neoprene WRT, Neoprene W, Bayprene 110, Bayprene 210,
Skyprene B-5, Skyprene B-30, Denka S-40V and Denka M-40, shall be used. No
reclaimed rubber or Vulcanized wastes or natural rubber shall be used. Use of synthetic
rubber-like materials such as Ethyl Propylene Dimonomer (EPDM), Isobutane Isoprene
Copolymer (IIR) and Chloro-Isoprene Copolymer (CIIR) shall not be permitted.
Laboratory test to be performed from certified laboratory for compliance according to
special provisions for different types of bearings determined in accordance with relevant
standards.

5.12.10.2 Spherical Bearing

Supplying, fitting & fixing in position true to line and level cast steel spherical/cylindrical
type bearing with stainless steel plate with PTFE sliding surface as per AASHTO
specifications [ASTM D5977-15: Standard Specification for High Load Rotational
Spherical Bearings for Bridges and Structures], complete with all accessories as per
drawing & direction of E-I-C and including cost of all material installation. One set must
be taken as extra for laboratory test which to be performed from BUET.

5.12.11 Measurement
The method of measurement for payment shall be in number for each Bearing and for each
shock Transmission Unit with Transverse Restraints.

5.12.12 Payment
The Contract unit rate for the items shown in the BOQ shall include cost of all materials,
equipment and other incidental charges for supply, installation and fixing in all respects per
these specifications and as shown in the drawing.

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Pay items shall be

5/12/01 Supply and Installation of Pot bearings Number
05/12/01(a) Supply and Installation of Pot bearings Number
(500mm X 500mm X 72mm)
05/12/01(b) Supply and Installation of Pot bearings Number
(500mm X 450mm X 72mm)
05/12/01(c) Supply and Installation of Pot bearings Number
(400mm X 300mm X 72mm)
5/12/02 Supply and Installation of Shock
Transmission units
05/12/02(a) Supply and Installation of Shock Number
Transmission units
(up to 50 MT of horizontal load)
05/12/02(b) Supply and Installation of Shock Number
Transmission units
(Above 50 MT of horizontal load)
5/12/03 Supply and Installation of Steel- Number
laminated Elastomeric/Neoprene
bearings
5/12/04 Supply and Installation of Spherical Number
bearings
Size of different type of bearing will be as per approved drawing.

5.13. BEARING REPLACEMENT

5.13.1 Description

This work consists of furnishing all labor, tools and equipment for jacking and supporting the
existing beams/slab while removing the bearing assembly. The Contractor is responsible for
the complete design of the bridge lifting procedures and the materials used. The Contractor
shall furnish and place all bracing, shoring, blocking, cribbing, temporary structural steel,
timber, shims, wedges, hydraulic jacks, and any other materials and equipment necessary for
safe and proper execution of the work. The Contractor shall remove and dispose of the
bearings according to the Standard Specifications.

The bridge deck, substructure and bearings shall be designed and detailed to permit future
bearing replacement of each and every bearing and jacking points shall be clearly shown
onthe drawings.

• No reduction in traffic loading shall be considered during bearing replacement.

• A maximum jacking movement of 10mm shall be assumed for bearing replacement.

5.13.2 Construction

The Contractor shall submit details and calculations of his/her proposed jacking systems and
temporary support procedures for approval by the Engineer before commencing work. If
unforeseen field conditions preclude the execution of the approved jacking plan, the Engineer
may require the Contractor to provide additional supports or measures. All changes to the
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jacking plan shall be approved by the Structural Engineer that sealed the jacking plan.
Neither added precautions nor the failure of the Engineer to order additional protection will in
any way relieve the Contractor of sole responsibility for the safety of lives, equipment and
structure.

(a) Jack and Remove Existing Bearings with bridge deck in place. Jacking and cribbing under
and against the existing diaphragms, if applicable, will not be allowed. The Contractor's
jacking plans and procedures shall be designed and sealed by a Licensed Structural
Engineer.In all cases, traffic shall be removed from the portion of the structure to be jacked
prior to and during the entire time the load is being supported by the hydraulic pressure of the
jack(s). The minimum jack capacity per beam shall be as noted in the plans. Whenever
possible, traffic shall be kept off that portion of the structure during the entire bearing
replacement operation. The shoring or cribbing supporting the beam(s) during bearing
replacement shall be designed to support the dead load plus one half of the live load and
impact shown in the plans. If traffic cannot be kept off that portion of the structure during the
bearing replacement, then the shoring or cribbing supporting the beam(s) shall be designed to
support the dead load and full live load and impact shown in the plans. No jacking shall be
allowed during the period of placement and cure time required for any concrete placed in the
span(s) contributing loads to the bearings to be jacked and removed. Jacking shall be limited
to 1/8 in. (4 mm) maximum when jacking one bearing at a time. Simultaneous jacking of all
beams at one support may be performed provided the maximum lift is 1/4 in. (7 mm) and the
maximum differential displacement between adjacent beams is 1/8 in. (4 mm). Suitable
gauges for the measurement of superstructure movement shall be furnished and installed by
the Contractor.

(b) Jack and Remove Existing Bearings when entire bridge deck is removed. Jacking and
bearing removal shall be done after the removal of the existing bridge deck is complete. The
Contractor’s plans and procedures for the proposed jacking and cribbing system shall be
designed and sealed by a Licensed Structural Engineer unless jacking can be accomplished
directly from the bearing seat under the beams or girders.

Jacking shall be limited to 1/4 in. (7 mm) maximum when jacking one beam at a time.
Simultaneous jacking of all beams at one support may be performed provided the maximum
lift is 3/4 in. (19 mm) and the maximum differential displacement between adjacent beams is
1/4 in. (7 mm). When staged construction is utilized, simultaneous jacking of all beams shall
be limited to 1/4 in. (7 mm) unless the diaphragms at the stage line are disconnected, in
which case the maximum lift is 3/4 in. (19 mm). Suitable gauges for the measurement of
superstructure movement shall be furnished and installed by the Contractor.

The Contractor shall be responsible for restoring to their original condition, prior to jacking,
the drainage ditches, pavement, or slope wall disturbed by the cribbing footings.

The contractor shall ensure the presence of an authorized expert of the manufacturer during
commencement of the construction activities.

5.13.3 Payment

This work will be paid for at the contract unit price each for jack and remove existing
bearings.

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xxxxxxxx Jack and Remove Existing Bearing Nos

5.14. BRIDGE SUPER-STRUCTURE (PRECAST PRESTRESSED

CONCRETE GIRDERS)

5.14.1 Description
This specification relates to transportation, loading, unloading and erection of precast
prestressed concrete girders. The specification outlines work associated with transportation,
material proposal, erection, tolerance criteria, temporary works as well as measurement of
payment for the girders.

A precast prestressed concrete girder shall be used for bridge in straight alignment and for
curved bridges where the radius of the horizontal curve is very large. The span of the girder
shall be 20m to 55m. For a span of more than 50m the girder shall be cast in place over the
pier or abutment.

5.14.2 Materials

5.14.2.1 Girder

Precast Prestressed Concrete Girders will be supplied by the Contractor at the precast
Fabricator’s yard. The precast fabricator will load the girders onto the contractor’s
hauling equipment. Pick-up of girders shall be during the Fabricator’s normal working
hours unless other or otherwise mutually satisfactory arrangements are made between the
Contractor and the Fabricator. The Contractor shall be responsible for the security and
integrity of the girders during transportation to site, and during unloading, storage and
erection on site. Girders damaged during any of these operations shall be replaced or
repaired to the satisfaction of the Engineer before final approval is granted. The decision
to repair or replace the damaged girders will be entirely at the discretion of RHD.

5.14.2.2 Bearings

The Contractor shall supply bearings in accordance with the requirements of the
specification and details on the Drawings and as per approved material proposal
submitted by the contractor.

5.14.2.3 Non-Shrink Grout

The contractor shall submit a material proposal for non-shrink grout for the grout pads
which must be approved by the Engineer.
.

5.14.3 Construction

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5.14.3.1 General

Transportation, unloading and erection of the precast prestressed concrete girders shall be
under the direction of a Professional Engineer, registered and licensed to practice. The
Professional Engineer shall be experienced in bridge girder transportation and erection
and be present for all stages of girder loading, unloading and erection. The precast
prestressed concrete girders shall be picked up only by the lifting devices installed by the
Fabricator.

During storage and transportation, the girders shall be maintained in an upright position
and shall be supported within 500 mm of the bearing areas. The machined surfaces of
steel bearing components cast into the girders shall be protected from damage at all times.

5.14.3.2 Handling and Transportation of Girders

The Fabricator shall load, and the Contractor shall transport all of the girders in
accordance with the following unless and other-wise any alternate method statements
approved by the Engineer in charge:
i) The Contractor shall be responsible for the design, supply, installation and removal of
temporary bracing for girders as may be required during the Contractor’s handling and
transportation of the girders. Should the Contractor choose to transport the girders to a
temporary storage location, he shall be responsible for additional loading, transporting,
unloading and storage procedures. The submission of design calculations and Shop
Drawings for the temporary bracing to the Engineer shall in no way relieve the Contractor
of the full responsibility for the success or failure of the design.
ii) The Contractor shall submit his proposed route for transporting the girders including
traffic control procedures as part of the proposed Transportation Plan. In all traffic control
situations, the flagman must be trained and properly attired in flagman’s vest and
approved headgear with approved flagman’s stop/slow paddle or fluorescent red flag. The
proper advance signing must also be in place.

When transporting bridge girders using equipment other than a flatbed trailer, the
Contractor shall be responsible for ensuring the following:
- Travel speed not to exceed 80 kph.
- Travel only in daylight between sunrise and sunset; and
- Travel will not be allowed on weekends or statutory holidays unless authorized by
the Engineer.
- When transporting bridge girders, the Contractor shall be responsible for ensuring
that all of the required permits have been acquired and the conditions of all
permits are met.
- Extreme care shall be exercised during the handling and transportation of the
precast girders to avoid twisting, cracking or other distortion that may result in
damage to the girder. The Contractor shall be responsible for protecting the
girders at restraint points on the vehicle. All damaged corners or surfaces of the
girders will be regarded as honeycomb and shall be repaired as directed by the
Engineer.
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- No loose timber blocking will be permitted for use in temporary works for any
aspect of girder handling and transportation.
- It is the Contractor’s responsibility to ascertain the actual weight of the girders.
The concrete in the precast prestressed girders may be denser than regular
concrete and the girders contain a high percentage of reinforcing steel and
stressing strands which also tend to increase theweight of the girders.

5.14.3.3 Temporary Work

Temporary works including work bridges and platforms, barges, erection bracing,
wind bracing, and lateral stability bracing required for handling, transportation and
erection of precast prestressed concrete girders shall be installed and constructed in
accordance with the Contractor’s approved design and Shop Drawings.

5.14.3.4 Installation of Bearings

The Contractor shall install bearings in accordance with the requirements of the
specification and details on the Drawings and as per approved method statement
submitted by the contractor.

5.14.3.5 Erection of Girder

Before erecting the girders, the Contractor shall verify that the lengths of the girders, the
layout of the substructure units, the elevations of the bearing seats, and the location of the
anchor bolts are as shown on the Drawings. All discrepancies discovered by the
Contractor shall be brought immediately to the attention of the Engineer.
It is essential that the girders be erected with utmost attention being given to girder
positioning, alignment and elevation. The Contractor shall adjust girder position, bearing
location, and bearing elevation in order to achieve as closely as possible the lines and
grades shown on the Drawings. The Contractor shall minimize any differential camber
(girder to girder), and the sweep of the girders by jacking, loading of girders, winching, or
whatever means are necessary, and shall provide the necessary temporary attachments to
hold the girders in position. The Engineer shall approve all proposed methods of jacking,
loading, winching, etc. prior to the work being undertaken.
The maximum dimensional deviation in mm, of erected precast prestressed concrete
girders from that as detailed on the Drawings shall not exceed the following:
Sweep (NU Girders) 1 mm/m
Sweep (Other Girders) Deviation from true, 20 mm x length (m) / 50

Approved the erected positions of the girders, all lifting hooks shall be cut off 50 mm
below the top surface of the girder and all lifting hook pockets shall be filled with an
approved high strength non-shrink grout. In cases where a concrete deck is going to
be cast over the lifting hook locations, the lifting hooks are to be cut off flush with the
top of the girders. All lifting holes shall be filled with an approved high strength non-
shrink grout.

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Temporary erection bracing, wind bracing and lateral stability bracing shall be designed and
installed in order that it will not interfere with the forming and pouring of the diaphragms and
deck and shall remain in place until seven (7) days after the pouring of the diaphragms.

The different possible lifting methods of girder are outlined below:

Girder lifting by Crane

Beams should be picked up and supported only at the designated pick-up points, unless the
plans state otherwise. These pick-up points are loops extending out of the tops of the beams
(one near each end). The pick-up cable should maintain a safe slope. A safe maximum
amount would be 1:1.5. If a flatter slope is used, the beam may be damaged. Contractors may
use more than one crane if necessary. The plans for the pickup position and lifting method
according to girder shape shall be approved be the Engineer in charge.

Girder lifting by Grid launcher

Beam / Grid Launcher is used in the erection of precast beam bridges for span by span
method of construction for precast beam girders like U-beam, T-beam, I-beam, etc. This
mainly consists of main beam, cantilever beam, under guide beam, front and rear support
legs, auxiliary outrigger, hanging beam crane, jib crane and electro-hydraulic system.
Designed for precast beam assembly without crane assistance the Beam Launcher is widely
used for plain construction, can also meet the requirement for mountain building highway
slope, small radius curved bridge, skew bridge and tunnel bridge. There are 2 types of Beam/
Grid Launchers: the single-box type and the double-truss type. Launcher types are used
depending on the requirements of the project and with transport trolleys either on rails or with
tyres depending on gradient and length of the bridge. The Beam/ Grid Launcher gives a good
stability, high efficiency, safety and reliability, easy to adjust variable cross and easy to
operate. It has three methods for picking up the precast beam: from rear end of the beam
launcher on the deck level, from below on ground level, or from the bridge side. The launcher
can accomplish the girder carrying with erecting at the same time. It can also erect 4 pieces of
girders with another two cranes one day, saving construction cycles. It comprises a main
beam, cantilever, under guide beam, front and rear legs, auxiliary outrigger, hanging beam
crane, cantilever crane and electro-hydraulic system. The methodology for lifting using Grid
Launcher shall be approved by the Engineer in charge.

Girder lifting by Gantry cranes

Gantry cranes can be equipped to lift precast beams, or a single crane with double spreaders
to lift precast beams. The lifting weight of two cranes that lift at the same time is generally
450 tons, and the lifting weight of a single crane may be up to 900 tons. The crane is
composed of outriggers, crane running and lifting mechanism, which can realize all-round
mechanized action. This gantry crane for bridge construction is mainly used to lift and move
the precast beam from the beam-making platform to the beam storage platform. After the
precast beam is maintained, it will be lifted from the beam storage platform to the beam

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transport vehicle. The gantry crane can complete the assembly and disassembly of the bridge
erector, and it is also used to erect dry bridges with low piers.
The lifting system in gantry cranes adopts a four-point fixed lift beam, which is balanced by
the load to ensure the safety of the concrete box girder and the lifting system’s structure.
Through the vertical and horizontal fine adjustment of the lifting mechanism, the accuracy of
box girder erection can be achieved. The methodology for using Gantry Cranes shall be
approved by the Engineer in charge.

Girder lifting by Segment lifter.

Segment lifter can be best utilized for Balanced cantilever construction where pre-casting is
possible and the segment can be transported below the span. This Equipment allows the
erection of industrialized segments and faster erection and is therefore addressed to bridges
with a great number of spans. Since these are very specialized equipment, the fabrication is
mostly done at the centralized fabrication unit and it’s being shipped to various sites. A
segment lifter is launched through a hydraulic system which gives a safe launching for the
equipment. The segment lifter allows faster erection and is therefore addressed to bridges
with a great number of spans. It is equipped with two electric hoists for lifting the precast
segments and adjusting the cross-fall. Segment lifters are usually designed to install segments
in ramps, in tight locations, or in areas that are generally difficult to access. It incorporates
two primary hydraulic systems providing both lifting of segments and moving of the frame
itself during construction when high lifting speeds are required, tandem lifting units or winch
systems are utilized on segment lifter. The methodology for using Segment Lifter shall be
approved by the Engineer in charge.

5.13.3.6 Measurement

The delivery of precast prestressed concrete girders will be measured on a unit basis
and the number to be paid for will be the total number of girders delivered and
accepted by the engineer. The erection of precast prestressed concrete girders will be
measured on a unit basis and the number to be paid for will be the total number of
girders erected and accepted by the Engineer.

5.13.3.7 Payment

Delivery of precast prestressed concrete girders will be paid for at the Contract Unit
Price per girder for “Delivery of Precast Prestressed Concrete Girders”, measured as
specified herein, which price will be payment in full for performing all operations
herein described and all other items incidental to the work including in this
Specification.

Erection of precast prestressed concrete girders will be paid for at the Contract Unit
Price per girder for “Erection of Precast Prestressed Concrete Girders”, measured as
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specified herein, which price will be payment in full for performing all operations
herein described and all other items incidental to the work as approved by the
Engineer.

Pay Item Description Unit

No. Measurement
xxxxxxx Delivery and Erection of nos
Prestressed Concrete
Girders

5.15. BRIDGE SUPER-STRUCTURE (PRE-CAST/ CAST IN-SITU

VOIDED SLAB)

5.15.1 Description

A voided concrete slab is a system that removes the non-working or excess concrete from the
structural slab and replaces it with void formers. Voided slabs can be either in reinforced
concrete or in prestressed concrete.

Voids can be either circular or rectangular in shape. Void formers may be manufactured from
steel sheets, fibre-reinforced cement, expanded polystyrene, HDPE, etc. They are generally
corrugated to attain sufficient rigidity in order to prevent distortion or collapse during
concrete. They should also be leak tight.

Void formers shall be suitably tied down in order to prevent flotation during concreting. Care
shall be taken during placement of concrete to ensure that the concrete flows fully into the
space beneath the void formers.

A cast-in-place voided slab shall be used as a superstructural system for the via-duct portion
of the bridges, especially in a short span curved portion of the alignment. This type of slabs
may be used in sharp curved portions where superelevation and transient curves are
introduced. The appropriate span length for this type of slab may be in between 10m to 15m.

5.15.2 Construction

The construction shall be carried out according to the contractors’ proposed method
statement approved by the Engineer. The following criteria shall be followed for
tolerance of girder during the construction:

Precast Concrete Superstructure

a) Variations in thickness of top and : ± 5 mm to bottom slab for box girders, top and
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bottom flange for T-girders and slabs

b) Variations in web thickness : -5 mm to +10 mm
c) Variations in overall depth or width : ± 5 mm
d) Variation in length overall and length : shall not exceed ± 10 mm between bearings or
± 0.1 percent of the span length, whichever is less
e) Permissible surface unevenness in : 5 mm deck slab when measured with a 3 m
straight edge or template

Cast In-Situ Superstructure

a) Variations in thickness of top and : -5 mm to +10 mm bottom slab for box girders,
top and bottom flange for T-girders and slabs
b) Variations in web thickness : -5 mm to +10 mm
c) Variations in overall depth or width : ± 5 mm
d) Variation in length overall and length : shall not exceed ± 10 mm between bearings or
± 0.1 percent of the span length, whichever is less
e) Permissible surface unevenness in : 5 mm deck slab when measured with a 3 m
straight edge or template

5.15.3 Measurement

Structural concrete shall be measured in cubic meters. In reinforced or prestressed

concrete, the volume occupied by reinforcement or prestressing cables and sheathing
shall not be deducted. The slab shall be measured as running continuously through and
the beam as the portion below the slab. Based on the quantity ordered or as shown on
the approved drawings.

Steel reinforcement shall be measured in length including hooks, if any, separately for
different diameters as actually used in work, excluding overlaps. From the length so
measured, the weight of reinforcement shall be calculated in tonnes. Wastage
overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed
steel wire or other methods for binding and place, shall not be measured and the cost
of these items shall be deemed to be included in the rates for reinforcement based on
the quantity ordered or as shown on the drawings. Concrete Superstructure High
tensile steel (prestressing) in superstructure shall be measured in cubic meters. The
volume occupied by mild steel reinforcement/HYSD bars, high tensile steel, sheathing
and anchorages shall not be deducted.

High tensile (prestressing) steel shall be paid for separately. Its length, as actually
incorporated in the finished work, shall be measured and weight calculated therefrom
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in tonnes on a theoretical basis, for payment. Anchorage devices, the additional length
of cables for attaching jack, ducts or sheathing, grouting, non-prestressed steel
reinforcement fixed to the anchorage devices, making of recesses and filling the same,
protection by painting with epoxy and furnishing samples for testing, shall all be
deemed to be incidental to and included in the item of high tensile steel and shall not
be measured separately, based on the quantity ordered or as shown on the drawings.

5.15.4 Payment
The contract unit rates for concrete, steel reinforcement (untensioned) and high tensile
steel (prestressing) shall include all works as given in respective Sections of these
Specifications and cover all incidental items for furnishing and providing
superstructure as mentioned in this Section and as shown on the drawings.

Pay Item Description Unit

No. Measurement
xxxxxxx Concrete of specified cum
grade
xxxxxxx Reinforcing steel bar tonne
xxxxxxx High tensile tonne
prestressing steel

5.16. BRIDGE SUPER-STRUCTURE (PRE-CAST/ CAST IN-SITU

SEGMENTAL BRIDGE)

5.16.1 Description
Fabricate, store, transport and erect precast structural concrete superstructure and/or
substructure segments on a prepared foundation, to the established lines and grades, in
accordance with the design, dimensions and details shown on the drawings and in
accordance with this section.

A pre-cast or cast-in-situ segmental bridge shall be constructed where a large span

bridge span is required. The applicable length of the main span is 80m to 110m. The
length of the end span may vary from 0.6 to 0.75 times the main span length
depending on the design requirements. This type of construction method is appropriate
where staging is not possible due to substantial velocity of water flow or busy traffic
condition under the main span.

5.16.2 Construction

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5.16.2.1 General

The contractor shall use methods and procedures providing adequate safety to the general
public from construction/erection activities and/or falsework placed over or adjacent to
travelled roadways, navigational or recreational waterways or any existing commercial,
industrial or another facility.

All work shall be carried out based on approved shop drawings, method statements and
material proposals approved by the Engineer.

5.16.2.1 Casting Works

The casting works for specification involve a comprehensive set of procedures and
requirements for the fabrication of segments in a casting yard. The contactor shall
outline the layout of the casting yard setup and operation of casting cells, use of
rain and sunshades, geometry control stations, rebar cage storage and handling,
and other related aspects.

Additionally, detail calculations and procedures for lifting, storing, and stacking
segments within the casting yard shall be included in the method statement
submitted by the contractor. Established procedures for erection mark and segment
identification shall be outlined at an early stage. Segment transport plan from
casting yard to construction site will need prior approval from competent authority.
Adherence to material conformance as per material specification shall be ensured
prior to construction

Detailed guidelines shall be provided for forms, geometry control, preparation for
match, casting, embedded items, concrete placement, consolidation, finishing,
curing, removal of forms, and testing samples at various stages.

All associated works shall be prior approved by the Engineer in charge.

5.16.2.2 Embedded Elements

Embedded items, as outlined in the specifications, must comply with the

requirements for prestressed and post-tensioned construction. For embedded post-
tensioning ducts, accuracy in positioning is crucial, and positive methods should
be employed to prevent displacement or damage during concrete placement.
Adequate securing of ducts to the reinforcement cage is required, with closer
supports for small or flexible ducts. Sealing duct ends is mandatory to prevent
water and debris entry, and verification of unobstructed ducts is essential before
and after concrete pours. Anchorage plates and castings must be fixed, connected,
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and sealed before concrete placement, ensuring rigidity for correct alignment.
Regarding reinforcing steel, adherence to plans, proper alignment with post-
tensioning ducts, and meticulous placement within specified tolerances are
emphasized, with any necessary replacements subject to Engineer approval.

5.16.2.3 Tolerances

The following tolerances apply to the fabrication of precast components:

Superstructure Box Segments

Width of Web ±6.35 mm

Depth of bottom slab ±4.7625 mm
Depth of top slab ±4.7625 mm
Overall depth of segment ±4.7625 mm
Overall width of segment ±6.35 mm
Length of segment ±9.525 mm
Diaphragm dimensions ±9.525 mm

(2) Precast Box Pier Segments

Height (Individual Element) ±6.35 mm

Width and Breadth (Individual Element) ±6.35 mm
Thickness (wall) ±6.35 mm
(3) All Fabricated Segments

Ends (deviation from a plane per 6m width or depth ±6.35 mm inch per 6m not to exceed 12.7 mm
Flat Surface (deviation from a plane at any location) ±2 mm/m not to exceed a total of ±6.35.

5.16.2.4 Erection

Before commencing erection operations, submit proposals for all segment erection operations to the
Engineer for approval. This submittal must be in the form of an “Erection Manual” and include but
not necessarily be limited to:
1. A detailed step-by-step sequence for the erection of each segment including all intermediate
procedures relating to erection equipment, temporary and permanent post-tensioning and the
making of closures between spans and/or cantilevers and another required sequencing.
2. Positioning, use and sequencing of falsework, jacking and/or releasing of falsework, temporary
towers, supports, tie-downs, counterweights, closure devices and the like.
3. Positioning, use and sequencing of erection equipment such as cranes, beam and winch devices,
gantries, trusses and the like, both on and off the structure, including the movement, introduction
and/or removal of any supports onto or connections with the structure. Include drawings and
calculations for the structural effects of erection equipment on the structure.

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4. Detailed scheduling of all temporary and permanent post-tensioning operations and sequences in
accordance with the segment erection and closure operations and other required scheduling.
5. Stressing forces and elongations for post-tensioning.
6. Sequencing of filler injection operations.
7. A method for the field survey control for establishing and checking the erected geometry
(elevations and alignments) with particular attention to the setting of critical segments such as, for
example, pier segments for balanced cantilever erection. This information may be included in the
Erection Manual or may be submitted later as a supplementary or separate document.
8. Any other relevant operations as required and applicable to the structure type and construction
method.
No erection shall commence without prior approval of the method statement by the Engineer in
charge

5.16.3 Measurement

Precast superstructure segment concrete, including cast-in-place concrete for closure and wet
joint pours, will be measured by volume according to the quantities represented by the
dimensions of the segments and cast-in-place pours on the approved shop drawings.

All reinforcement in precast superstructures, cast-in-place closures and wet joints will be
measured by weight according to the quantities represented by the reinforcement details
approved shop drawings.

All permanent post-tensioning in the superstructure will be measured by weight according to

the quantities represented by the details in the approved shop drawings.

5.16.4 Payment

Payment for precast superstructure segment concrete will be at the contract bid prices per
cubic meter for the various classes of concrete called for such prices and payments will be
full compensation for manufacture, storage, transport, assembly, and erection of the segments
complete and in place, including filling all concrete blackouts and similar miscellaneous
details. These prices and payments will also include the furnishing and the application of
epoxy bonding agent and finish coating when specified in the drawings, providing temporary
and permanent segment access details, material testing, special erection equipment,
temporary post-tensioning, tools, labor and incidental items necessary for completing the
work in accordance with the specifications and approved shop drawings.
No additional payment will be made for extra concrete necessitated by approved
modifications to the segments or structure needed to accommodate the Contractor’s
construction methods.
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Payment for reinforcement in precast segments, closure pours, wet joints and other cast-in-
place concrete joints and details will be at the Contract bid price per tonne for reinforcing
steel (superstructure) and for reinforcing steel (substructure).

No additional payment will be made for extra reinforcement necessitated by approved

modifications to the segments or structure for the purposes of the Contractor’s construction
methods.

Pay Item No. Description Unit Measurement

xxxxxxx Concrete of specified grade cum

xxxxxxx Reinforcing steel bar tonne

xxxxxxx High tensile prestressing steel tonne

5.17. COUPLER

5.17.1 Description

This work shall consist of furnishing and placing of coupler or mechanical splice with
Specifications and in conformity with the requirements mentioned in AASHTO, BNBC, ISO
or any other equivalent standards. The mechanical splice is defined as complete assembly of
a coupler or an end-bearing sleeve including any additional intervening material or other
components providing a splice of two reinforcing bars. Reinforcement coupler is termed as
coupling sleeve or threaded coupler for mechanical splices of reinforcement bars for the
purpose of providing transfer of axial tension and/or compression from one bar to the other
bar where,
- coupling sleeve is a device fitting over the ends of two reinforcing bars,
- threaded coupler is a threaded device for joining reinforcing bars with matching threads .

5.17.2 Material and requirements

The requirements apply to the coupler even though the check of the properties of the coupler
is carried out on a mechanical splice that has been installed in accordance with the
manufacturer's written instructions.

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The technical requirements for couplers are related to the following properties wherei)
and ii) are mandatory while iii) and iv) are related to categories defined in ISO 15835-1 Sec
5.2
i) Strength and ductility under static forces:

Strength and ductility of the mechanical splice shall be verified by testing to satisfy the
requirements of both ISO 15835-1:2018, Sec 5.3.2 and Sec 5.3.3 or any other equivalent
standard. A reference bar from the same heat of steel shall be tested to verify that its
measured strength and ductility satisfy the minimum values specified in the product standard
of the bar.

It is preferable that the test splice and the reference bar come from the same length of
reinforcing bar.

For surveillance testing, if all samples of the mechanical splice tensile strength tests fail
outside the length of the mechanical splice and the mode of failure of the bar is ductile
(including necking), and the measured tensile strengths comply with the product standard of
the bar, no verification of the ductility of the mechanical splice is required. If couplers are
used to connect bars of different sizes, the strength and ductility requirements shall be based
on the smaller reinforcing bar diameter.

Strength: The tensile strength of the mechanical splice shall be at least ReH × (Rm/ReH)spec.
If Rmspec is the value specified in the reinforcing bar standard, the tensile strength of the
mechanical splice shall be at least Rm, spec.

Ductility: Requirements for the ductility of spliced bars are to ensure that the use of the
mechanical splice maintains a minimum ductility in the reinforcement. The ductility of the
coupler itself is not subject to testing.

The minimum Agt measured in accordance with ISO 15630-1:2018 on the reinforcing bar
outside the length of the mechanical splice shall not be less than 0,7Agt, where Agt is the
specified characteristic value of the reinforcing bar taken from the product standard of the
reinforcing bar.
Where Agt is not specified for the reinforcing bars, a minimum value of 3 % shall be attained
in the bar outside the mechanical splice before failure of the test piece.

ii) slip under static forces;

The median value of all test results shall not exceed 0.10 mm. The outlier values shall,
however, not exceed the maximum allowable slip by more than 0.05 mm.

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NOTE 1: Slip requirement is important for limitation of crack widths in exposed reinforced
concrete structures.
NOTE 2: The purpose of using the median value for the evaluation of results is to filter-out
questionably high and low values, as this test is performed by a multitude of measurement
devices and fixtures that are not yet covered by a standard. For couplers longer than 100 mm,
a slip greater than 0,10 mm may be accepted.

NOTE 3: The reason for this provision is that the longer the coupler, the larger the volume of
concrete through which the coupler slip will dissipate.

iii) properties under high cycle fatigue loading in the elastic range;

The largest diameter of mechanical splices of category F shall be tested in fatigue. The
manufacturer may sub-divide the product range in several groups of diameters and test the
largest diameter of each group in order to characterize the performance.
NOTE 1: When tested in air, the worst fatigue results normally occur on the largest diameter.
NOTE 2: The fatigue performance of a mechanically spliced bar will usually be lower than
that of the un-spliced bar.

Fatigue performance
Mechanical splices of category F shall sustain a fatigue loading of at least 2 million cycles
with a stress range, 2σa, of 60 MPa without failure. The maximum stress, σmax, in the test
shall be 0,6ReH, spec.
The tests shall comply with the following acceptance criteria.
— If all test pieces do not fail before reaching two million cycles, the test is passed.
— If one test piece fails the test, three additional test pieces from the same batch shall be
tested. If all three additional test pieces pass, the test is passed.
— If two or more test pieces fail the fatigue test, the test is failed.

iv) properties under low cycle reverse loading in the elastic-plastic range.

Mechanical splices of category S shall be tested in reverse elastic-plastic loading. The

performance requirements for mechanical splices subject to tension and compression tests
simulating an earthquake are the average residual elongation after the first 20 cycles u20
shall not exceed by more than 0,3 mm the equivalent residual elongation of an un-spliced
reference length from the same bar, measured on the same gauge length,

— the mechanical splice shall survive the strain cycles in stages 2 and 3 of the test, and

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— the ultimate tensile strength shall exceed the value specified in the specification clauses:
Rm, spec or ReH × (Rm/ReH)spec

The requirement on u20 may be disregarded if allowed in national provisions and agreed
between the purchaser and the supplier.

Testing of these properties shall be carried out in accordance with ISO 15835-2 or equivalent
standards.

5.17.3 Construction

i) Cutting: Only saw cutting of bars are allowed. Shear cutting, gas cutting, or any other cutting
method is strictly prohibited.
• Holding width of the machine’s vice shall be adjusted to fit the bar size.
• A trial cutting shall be performed to ensure smooth operation.
• Saw blades must be inspected regularly and be in good condition. Worn or damaged blades shall be
re-sharpened or replaced.

ii) Forging: The contractor shall select the right die grips/ die pockets according to the rebar
diameter. Both sides of the Die grips/pockets from the same batch. The roller height needs to be
positioned in accordance with the operation manual. The correct height is reached when the rebar is
almost touching the roller when the clamp is closed. Pressure setting and forging length must be
adjusted correctly as per the machine’s operation manual to ensure the diameter after forging is
within the specifications. A trial forging shall be performed to ensure that the correct diameter after
forging as per “Machine setting table” is achieved and operation runs smoothly.

iii) Threading: The cutting head and carriage clamp must be aligned. The threading speed shall be
adjusted in accordance with the recommendations given in the operation manual. The shift guides
shall not be worn out and in good condition. Chaser condition needs to be inspected at regular
intervals and re-sharpened when damaged or worn. The thread diameter needs to be set in
accordance with the bar diameter used. Use the setting gauge or a thread sample corresponding to the
thread core diameter in accordance with the operation manual. The threading length needs to be set
in accordance with the given tolerances. The setup shall be checked on a test piece.

5.17.4 Measurement

Since the type and size of coupler may vary based on requirement purpose hence,
measurement for the couplers to be quantified in nos.

5.17.5 Payment

This work shall be paid for at the Contract unit price per piece of coupler for the particular
type and size.
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Pay Item No. Description Unit Measurement

xxxxxxx Coupler of specified type and Nos
size

5.18. WELDED WEIR REINFORCEMENT (WWR)

5.18.1 Description

This work shall consist of furnishing and placing of welded wire reinforcement (WWR) or welded
fabric with Specifications and in conformity with the requirements mentioned in BNBC,ISO or
equivalent standard.

5.18.2 Material and requirements

The BDS ISO 6935-3:1992 specifies technical requirements for factory made sheets or rolls of
welded fabric, manufactured from steel wires or bars with diameters from 4 mm to 16 mm and
designed for the reinforcement of concrete structures and the ordinary reinforcement of prestressed
concrete structures. For the purpose of BDS ISO 6935-3:1992, the term “wire” also includes bars.
The fabric shall be made of either
˗ Cold-reduced wires with nominal diameters in the range from 4 mm to 16 mm (recommended:
4.5 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, 10 mm and 12 mm) and with mass and geometry
complying with IS0 10544 or equivalent
˗ Plain bars with nominal diameters of 6 mm, 8 mm, 10 mm, 12 mm or 16 mm (recommended:
6 mm, 8 mm, 10 mm and 12 mm) and with mass complying with BDS IS0 6935-1:2009 or
equivalent.
˗ Ribbed bars with nominal diameters of 6 mm, 8 mm, 10 mm, 12 mm or 16 mm
(recommended: 6 mm, 8 mm, 10 mm and 12 mm) and with mass and geometry complying
with BDS ISO 6935-2:2016 or equivalent.

All fabric shall be machine made, and the joints at the intersections of the longitudinal and transverse
wires shall be made by electrical resistance welding to provide shear resistant connections.

Each sheet of fabric shall contain the number of wires appropriate to its specified length, width,
spacing and overhang dimensions. The number of broken welds shall not exceed either 1 % of the
total number of cross-welded joints in the sheet or half the number of cross-welded joints along any
one wire.

Fabric shall be free from any defect which can be shown to affect adversely the mechanical
properties of the steel. Fabric including butt-welded wires shall be permitted and missing wires
resulting from test sampling in accordance with clause 3 (Testing of WWR) shall not be considered
as defects.
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The longitudinal wires may be single or twin wires. The transverse wires shall be single wires. The
dimensions of the fabric shall be specified as gross length in both directions. The permitted
geometric deviation for fabric are:
length and width: ± 25 mm or ± 0.5 %, whichever is greater.
Wire spacing: ± 10 mm or ± 7.5 %, whichever is greater.

The recommended spacing of longitudinal wires is a multiple of 50 mm and preferably not less than
50 mm. The recommended spacing of transverse wires is a multiple of 25 mm and preferably not less
than 25 mm.

5.18.3 Construction

(i) Handling, Shipping, Unloading and Storage of WWR

Welded wire reinforcement sheets are bundled in quantities depending on size of sheets and
corresponding weights in accordance with customers’ requirements. The bundles are bound together
using steel strapping or wire rod ties.
Once sheets are bundled, they are transported to storage or loading areas by forklift trucks or by
overhead cranes or any the convenient method decided by the manufacturer. After the sheet bundles
are loaded onto the flatbed trailers or vehicles, they are secured to the flatbed using chains and
binders, nylon straps, steel strapping or a combination of these devices or any convenient method
decided by the manufacturer.

The bundles of welded wire reinforcement sheets are unloaded at job site in the same manner in
which it was loaded. The manufacturer can choose any convenient method to unload the sheets at job
site.

Welded wire reinforcement (WWR) shall be handled and stored in a manner that will prevent any
accumulation of dirt, oil and paint. When placed in the works, it shall be free from dirt, oil, grease,
paint, mill scale and loose or thick rust. If a rust stain is spotted on wwr, it shall be cleaned by
brushing or soft grinding.

(ii) Installation Method

The engineer or consultant or respective personnel from authority specifies the amount of
reinforcement required and the correct position for the reinforcement within a structural element. To
ensure proper performance of the reinforcement, it is essential that the welded wire reinforcement
sheets be placed on supports to maintain their required position during concrete placement. The
supports (either concrete blocks, steel or plastic “chair” devices, or a combination of these) must be
appropriately spaced in order to work effectively. The concerned engineer from the implementing
authority can take decision based on the site requirements.

5.18.4 Measurement
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This work measured as provided above shall be paid for at the Contract unit price based on weight
(in kilograms) of Welded wire reinforcement (wwr).

5.18.5 Payment

The payment shall be full compensation for furnishing and placing of Welded wire reinforcement
(wwr) of any size and for all labor, unloading, placing, handling, shipment, equipment, tools, and
incidentals necessary to complete the work prescribed in this Section.

Pay Item No. Description Unit Measurement

xxxxxxx Welded Wire Reinforcement kg

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DIVISION 6

MAINTENANCE

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 6 - MAINTENANCE

Table of Contents
6.1 Repair of Potholes by Brick Flat Soling (Auto Bricks) ................................................................................ 1
6.1.1 Description ...................................................................................................................................... 1
6.1.2 Construction Methods ..................................................................................................................... 1
6.1.2.1 Surface Tolerance ........................................................................................................................ 1
6.1.3 Measurement ................................................................................................................................. 1
6.1.4 Payment.......................................................................................................................................... 1
6.2 Repair of Potholes by HBB (Auto Bricks) .................................................................................................. 3
6.2.1 Description ...................................................................................................................................... 3
6.2.2 Construction Methods ..................................................................................................................... 3
6.2.2.1 Surface Tolerance ........................................................................................................................ 3
6.2.3 Measurement ................................................................................................................................. 3
6.2.4 Payment.......................................................................................................................................... 3
6. 3 Herring Bond Brick Pavement i/c sand cement filler (Machine Made)..................................................... 5
6.3.1 Description ...................................................................................................................................... 5
6.3.2 Construction Method ...................................................................................................................... 5
6.3.2.1 Surface Tolerance ........................................................................................................................ 5
6.3.3 Measurement ................................................................................................................................. 6
6.3.4 Payment.......................................................................................................................................... 6
6.4 Khoa Grouting ......................................................................................................................................... 7
6.4.1 Description ...................................................................................................................................... 7
6.4.2 Materials ......................................................................................................................................... 7
6.4.2.1 Where Apply ............................................................................................................................... 7
6.4.3 Construction Method ...................................................................................................................... 7
6.4.4 Measurements ................................................................................................................................ 7
6.4.5 Payment.......................................................................................................................................... 7
6.5 Jungle / Vegetation Removal................................................................................................................... 8
6.5.1 Description ...................................................................................................................................... 8
6.5.2 Payment.......................................................................................................................................... 8
6.6 Cleaning Grass, Soil, Sand from Road Median .......................................................................................... 9
6.6.1 Description ...................................................................................................................................... 9
6.6.2 Payment.......................................................................................................................................... 9
6.7 Unsuitable / hazardous materials removal ............................................................................................ 10

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SECTION 7 GENERAL SPECIFICATIONS
DIVISION 6 - MAINTENANCE

6.7.1 Description .................................................................................................................................... 10

6.7.2 Materials ....................................................................................................................................... 10
6.7.3 Work Method ................................................................................................................................ 10
6.7.4 Measurement ............................................................................................................................... 10
6.7.5 Payment........................................................................................................................................ 10
6.8 Verge profile correction ........................................................................................................................ 11
6.8.1 Description .................................................................................................................................... 11
6.8.2 Materials ....................................................................................................................................... 11
6.8.3 Construction Method .................................................................................................................... 11
6.8.4 Measurement ............................................................................................................................... 11
6.8.5 Payment........................................................................................................................................ 11
6.9 CLEANING OF BRIDGE OR CULVERT ....................................................................................................... 12
6.9.1 Description .................................................................................................................................... 12
6.9.2 Work Method ................................................................................................................................ 12
6.9.3 Measurement and Payment .......................................................................................................... 13
6.10 REMOVAL OF OBSTRUCTION TO WATERFLOW ...................................................................................... 14
6.10.1 Description .................................................................................................................................... 14
6.10.2 Work Method ................................................................................................................................ 14
6.10.3 Measurement and Payment .......................................................................................................... 14
6.11 REMOVAL OF OBSTRUCTION TO WATERFLOW ...................................................................................... 15
6.11.1 Description .................................................................................................................................... 15
6.11.2 Work Method .................................................................................................................................... 15
6.11.3 Measurement and Payment .......................................................................................................... 15
6.12 PARTIAL REPAIR OF GABION MESH ....................................................................................................... 16
6.12.1 Description .................................................................................................................................... 16
6.12.2 Work Method ................................................................................................................................ 16
6.12.3 Measurement and Payment .......................................................................................................... 16
6.13 PATCHING OF CONCRETE SPALLING .................................................................................................. 17
6.13.1 Description .................................................................................................................................... 17
6.13.2 Work Method ................................................................................................................................ 17
6.13.2.1 Material specification ............................................................................................................ 17
6.13.2.2 Work requirement ................................................................................................................. 18
6.13.3 Measurement and Payment .......................................................................................................... 19

iii
SECTION 7 GENERAL SPECIFICATIONS
DIVISION 6 - MAINTENANCE

6.14 TOUCHUP PAINTING ............................................................................................................................. 20

6.14.1 Description .................................................................................................................................... 20
6.14.2 Work Method ................................................................................................................................ 20
6.14.2.1 Application criteria ................................................................................................................ 20
6.14.2.2 Material................................................................................................................................. 20
6.14.2.2 Work Requirement ................................................................................................................ 21
6.14.3 Measurement and Payment .......................................................................................................... 22
6.15 CRACK INJECTION ................................................................................................................................. 23
6.15.1 Description .................................................................................................................................... 23
6.15.2 Work Method ................................................................................................................................ 23
6.15.2.1 Material................................................................................................................................. 23
6.15.2.2 Work requirement ................................................................................................................. 24
6.15.3 Measurement and Payment .......................................................................................................... 26
6.16 CRACK FILLING ...................................................................................................................................... 27
6.16.1 Description .................................................................................................................................... 27
6.16.2 Work Method ................................................................................................................................ 27
6.16.2.1 Material................................................................................................................................. 27
6.16.2.2 Work requirement ................................................................................................................. 27
6.16.3 Measurement and Payment .......................................................................................................... 29
6.17 HAND APPLIED MORTAR ....................................................................................................................... 30
6.17.1 Description .................................................................................................................................... 30
6.17.2 Work Method ................................................................................................................................ 30
6.17.2.1 Material................................................................................................................................. 30
6.17.2.2 Work requirement ................................................................................................................. 30
6.17.3 Measurement and Payment .......................................................................................................... 32

iv
6.1 REPAIR OF POTHOLES BY BRICK FLAT SOLING (MACHINE
MADEBRICKS)

6.1.1 Description
This item consists of providing single
layer brick flat soling by machine made
bricks on accepted damaged pavement
bed for repair of potholes.

6.1.2 Construction Methods

Cutting Potholes edge into square shape by hand tools or excavator (if necessary) and leveling
the bed by loose aggregate and sand (50% Khoa and 50% Sand) and then compacting by hand
tools/rollers/plate compactors.The machine madebricks shall be laid flat on 75mm thick
compacted aggregate sand layerover damagedpavement. Bricks shall be laid in a regular and
uniform manner. Interstices of bricks shall be filled with sand, and water shall be applied by
sprinkling. No bricks shall be laid on loose surface which has not been compacted to the
required density or compaction criteria and no bricks shall be laid on any surface which has not
been inspected and approved by the Engineer. Joint shall be repaired by bituminous materials
with proper tack coat and sand.

6.1.2.1 Surface Tolerance

In those areas in which pavement is to be placed, any deviation in excess of 10mm from a
straight edge, 3meters long applied to the surface parallel to the centerline of the road and
12mm from a 3 meters straight edge laid transversely, shall be corrected by removal,
reshaping and relaying as per satisfaction of the Engineer.

6.1.3 Measurement
Repair of Potholes by Brick Flat Soling shall be measured in square meters of completed and
accepted work.

6.1.4 Payment
This work, measured as described above shall be paid for at the unit rates detailed below. The
rates shall include the supply of all required materials and all labor, equipment, tools and
incidentals necessary to complete the works as specified.

Pay items shall be:

06/01/01 Repair of Potholes by Brick Flat Soling (machine Square Meter

madebricks)including 75mm thick aggregate sand layer

1
2
6.2 REPAIR OF POTHOLES BY HBB (MACHINE
MADEBRICKS)

6.2.1 Description
This item consists of providing single layer
Herringbone bond (HBB) by machine made bricks
on accepted damaged pavement bed for repair of
potholes.

6.2.2 Construction Methods

Cutting Potholes edge into square shapeby hand tools or excavator (if necessary) and
leveling the bed by loose aggregate and sand (50% Khoa and 50% Sand) and then
compacting by hand tools/rollers/plate compactors. The machine made bricks shall be laid
at an angle of 45° to the direction of the row, instead of horizontally. Alternate courses lie
in opposing directions, resulting in a zigzag pattern on 75mm thick compacted aggregate
sand layer over damaged pavement. Bricks shall be laid in a regular and uniform manner.
Interstices of bricks shall be filled with sand, and water shall be applied by sprinkling. No
bricks shall be laid on loose surface which has not been compacted to the required density
or compaction parameter and no bricks shall be laid on any surface which has not been
inspected and approved by the Engineer. Joint shall be repaired by bituminous materials
with proper tack coat and sand.
6.2.2.1 Surface Tolerance
In those areas in which pavement is to be placed, any deviation in excess of 10mm from a
straight edge 3 meters long applied to the surface parallel to the centerline of the road and
12mm from a 3 meters straight edge laid transversely, shall be corrected by removal, reshaping
and relaying as per satisfaction of the Engineer.

6.2.3 Measurement
Repair of Potholes by Herringbone Bond Brick (HBB) Pavement shall be measured in square
meters of completed and accepted work.

6.2.4 Payment
This work, measured as described above shall be paid for at the unit rates detailed below. The
rates shall include the supply of all required materials and all labor, equipment, tools and
incidentals necessary to complete the works as specified.

Pay items shall be:

3
06/02/01 Repair of Potholes by Herringbone Bond Brick (HBB) Square Meter
(machine madebricks) including75mm thick aggregate
sand layer

4
6. 3 HERRINGBONE BOND BRICK PAVEMENT WITH

SAND CEMENT FILLER

6.3.1 Description
This work shall consist of a base composed of machine made machine made bricks, laid on
edge in a herringbone pattern on 25mm cement concrete bed, placed on prepared single layer
machine machine made brick flat soling in accordance with these specifications and to the lines,
grades, levels, dimensions and cross sections shown on the drawings or as required by the
Engineer.

6.3.2 Construction Method

The bricks shall be laid on edge in a single layer in a herringbone pattern to the lines, grades
levels, dimensions and cross section shown on the drawings or as required by the Engineer. The
edge of the layer shall be made with cut bricks to produce a line, which compatible with brick
edging.

The joints shall be filled with sand cement (2:1) mortar.

6.3.2.1 Surface Tolerance

In those areas in which pavement is to be placed, any deviation in excess of 10mm from a
straight edge 3 meters long applied to the surface parallel to the centerline of the road and
12mm from a 3 meter straight edge laid transversely, shall be corrected by removal,
reshaping and relaying as per satisfaction of the Engineer.

5
6.3.3 Measurement
Brick on end edging shall be measured in linear meters of completed and accepted work. Brick
flat soling and herringbone bond brick pavement shall be measured in square meters of
completed and accepted work.

6.3.4 Payment
This work, measured as described above shall be paid for at the unit rates detailed below. The
rates shall include the supply of all required materials and all labor, equipment, tools and
incidentals necessary to complete the works as specified.

Pay items shall be:

06/03/01 Brick on end edging linear Metre

06/03/02 Herringbone Bond Brick Pavement including Square Meter

sand cement (2:1) mortar

6
6.4 KHOA GROUTING

6.4.1 Description
This work shall consist of reshaping damaged/depressions area into regular shape, cleaning,
applying tack coat, placing aggregate, applying bitumen, compacting aggregate and apply fine
aggregate.

6.4.2 Materials
40mm downgraded dust free Brick Khoa from machine made brick plant having ACV greater
than 30, LAA Value less than 35 andwater absorption less than 15. Hot Bitumen of 60/70 grade
heating up to 1600CStone Chips of 12 mm down grade.

6.4.2.1 Where Apply

Potholes and depression of greater than depth of 75 mm, broken edge repair. Normally
apply on hard base layer or on bituminous layer. Not to apply on loose surface.

6.4.3 Construction Method

Cut the surface into regular shape. Clean the damaged surface properly. Apply hot bitumen of 1
kg/m2 in the dustless dry aggregate layer not more than 100 mm thick in the proper level. Roll
the aggregate properly. Apply hot bitumen of 2kg/m2. Applying stone chips for filling the gap
over the bitumen rolling the surface. If depression or potholes are greater than 100mm thick
then apply it into two layers.

6.4.4 Measurements
Measurement shall be taken as average thickness of depression of potholes area and volume of
work done shall be measured by multiplying length width and depth of depression or potholes.

6.4.5 Payment
This work shall be included of cutting, cleaning, tack coat, placing of aggregate, rolling,
applying bituminous layer, applying fine aggregate and finally rolling.

Pay items shall be:

06/04/01 Khoa Grouting Cubic Metre

7
6.5 REMOVAL OF VEGETATION/JUNGLE/BUSH

6.5.1 Description
This item includes removal or cutting of vegetation or jungle (road side vegetation which
obstructs vision of head on vehicles) by hand tool or cutting machine as per satisfaction of the
engineer and dispose the waste intosafe system and in a safe distance, in own arrangement, with
Engineer’s consent.Objective of this item shall be to remove undesirable roadside vegetation in
order to maintain required sight distances, control roadside growth, ensure proper drainage, and
to provide a reasonably neat appearance to the highway right-of-way.

6.5.2 Construction Method

All vegetation, including bushes, shrubs, jungle growth, and other greenery, shall be cleared
and disposed of in an appropriate manner. This process may involve removal, mulching, or
chipping, ensuring the highway right-of-way maintains a clean and aesthetically pleasing
appearance. In areas where mechanical equipment cannot be used due to the presence of traffic,
pedestrians, or nearby structures, manual hand-cutting tools shall be employed for vegetation
control. The installation of temporary signage and traffic control measures is essential to ensure
safety and smooth operations during the course of this work.

6.5.3 Payment
Payment shall be done by the area of removal or cutting.The removal of large quantities of
brush, shrubs and small trees using hand tool or mechanically self-propelled equipment.
Pay item shall be:

06/05/01 Removal of Vegetation/Jungle/Bush Square Meter

8
6.6 CLEANING GRASS, SOIL, SAND FROM ROAD MEDIAN

6.6.1 Description
This Item includes Cleaning Grass, Soil, Sand from Road Median, Road Side Vegetation which
deposited on road median by hand tools, blower, cutter or other mechanical means and dispose
the waste into safe system and safe distance, in own arrangement, with Engineer’s consent.
6.6.2 Payment
Payment shall be done by the area of cleaning.

Pay item shall be:

06/06/01 Cleaning Grass, Soil, Sand from Road Median Square Meter

9
6.7 REMOVAL OF UNSUITABLE/ HAZARDOUS MATERIALS

6.7.1 Description
This item includes excavation of unsuitable road side garbage,unsuitable debris, spoil and any
other garbage. These materials shall be excavated and removed in full as directed by the
Engineer. Garbage material includes domestic and industrial waste material, solid waste, liquid
waste, food waste, hazardous substances etc. The Engineer may order to refill the excavated
place with suitable soil, this backfilling procedure will follow the Division-2: Earthwork
specifications.All of these excavated materials shall be kept and disposed in a safe system and
safe distance, in own arrangement, as per satisfaction of the Engineer.

6.7.2 Materials
Generally road side garbage / unsuitable / hazardous materials those are caused due to
unauthorized dumping by different entities or bodies or organizations.

6.7.3 Work Method

Excavate roadside garbage by excavator loading into dump truck, carrying materials to safe
distance and dumping.

6.7.4 Measurement
Volume of excavated materials shall be measured into cubic meter depending on the length of
disposal from the worksite

6.7.5 Payment
Payment shall be:

06/07/01 Up to 5 Km carried Cubic Meter

06/07/02 Beyond 5 Km carried Cubic Meter

10
6.8 MAINTENACE OF SHOULDER OR VERGE PROFILE
CORRECTION

6.8.1 Description
This item consists of cutting / modifying / correctingearthen shoulder, filling nearby low
shoulder and carrying excess materials into safe system and safe distance. The item also
pertains to the scope of repairing or restoring washouts and low shoulders on paved or non-
paved shoulders by adding new gravel or recycled asphalt or using existing material. Objective
of this item is intended to ensure an acceptable shoulder surface, proper slope, and to provide a
smooth transition from the edge of pavement to thetoe of the embankment or right of way
(ROW).

6.8.2 Materials
Generally earth materials to be cut from raised earthed shoulder or nearby sources.

6.8.3 Construction Method

Excavation of raised earthen shoulder should be done by hand tools/excavator then disposal of
excavated materials by truck to safe system and safe distance. In case of nearby low earthen
shoulder then filling by suitable materials. Finally rolling should be to the loose excavated /
filling shoulder by roller.

6.8.4 Emergency Disaster Management

Erosion and washouts are the loss of shoulder material. This condition usually occurs during
rain storms, flood, sea surges or extreme weather events. The most common problem areas are
where guardrail has been installed, along and/or at the bottom of steep grades, and inside of
turns.All washouts and low shoulders shall be repaired, low shoulders exist when the shoulder
material is not flush with the edge of the pavement. This condition usually occurs due to
insufficient granular material.All washouts adjacent to the edge of travelled lane and any low
shoulders that pose a potential hazard to the traveling public shall be counter measured as soon
as possible.

6.8.5 Measurement
Volume of excavated materials in cubic meter shall be measureddepending on the length of the
disposal from worksite

6.8.6 Payment
Payment shall be:

06/08/01 Up to 5 Km carried Cubic Meter

06/08/02 Beyond 5 Km carried Cubic Meter

11
6.9 CLEANING OF BRIDGE OR CULVERT OR UNDERPASS

6.9.1 Description
The work shall consist of cleaning of the dust, sand, soil, gravel, rubbish, vegetation, debris,
other foreign materials etc. accumulated at different components of a bridge, namely deck
surface, curbs and sidewalks, expansion joints, pier caps, abutment caps, trusses and their web
members, lower flanges of beams and girders, wind bracings and drains curb or felloe guard;
cleaning of parapet/guard; catch basin on the bridge and/or drainage pipe; expansion joints;
steel or concrete girder ends including removal of obstruction to flow of small bridge, box or
pipe culverts.The work shall also include cleaning of vegetation under/around the bridge,
ramps, viaducts and slope retaining works.

6.9.2 Work Method

Overall methodology for the cleaning work including equipment and manpower mobilization,
disposal plan, traffic diversion plan etc.shall have to be submitted to the Engineer for approval.
for the cleaning of the bridge components, the watershall be clean and free from unwanted
foreign materials such as sediments, salt contaminants, chemicals, grease, oil, rubbish and other
substances which are harmful to the bridge components. The contractor shall obtain necessary
approvals of the source of water to be used for cleaning. Engineer’s approval shall be taken on
the source and quality of water. All necessary tests shall be performed on water samples at
laboratories to be specified by the Engineer, and test certificates shall be provided as required.

All accumulated foreign materials shall be removed from bridge sidewalks, bridge decks, top
of curbs, beam flanges, gusset plates, abutment bridge seats, top of pier, truss joints, deck drain
systems, and other locations specified and as directed by the Engineer, prior to cleaning with
water pressure. Removal shall be performed using hand brooms, hand shovels, scrapers,
vacuum cleaners or other methods acceptable to the Engineer. The removed materials shall be
collected and disposed at an approved waste area in accordance with governing local
regulations. Excavated, recovered or excess materials shall not be disposed into the
river/canals/water bodies or on dry land portions below the bridge.

Salt contaminants, dirt, and other detrimental foreign matters shall be removed without
damaging or peeling the paint from any structural steel. If high-pressure water is used, the
maximum water pressure shall not be so high that any paint is damaged. The cleaning operation
shall be discontinued if the foreign materials have not been easily removed or if cleaning
operation is causing damage to existing paint coating. In this situation, the high-pressure water
shall be adjusted to clean the surface without damaging the paint coating.

All deck drains and its accessories shall be flushed with high-pressure water after the
accumulated foreign material has been properly removed. Drain systems may have to be
disassembled to remove large blockages of accumulated foreign material. Should this be

12
necessary, these shall be returned to their original configuration immediately after cleaning.
Drainage systems shall drain properly after cleaning.

The Contractor shall flush out the interior surfaces of all girders and truss members using high-
pressure water. This flushing shall continue until such time that clear water is being draining
out. The exterior surfaces of all truss members, miscellaneous structural steel connecting the
truss members, and floor beam ends projecting outwardly from the row of exterior stringers
shall be thoroughly washed down using high-pressure water.

The Contractor shall obtain approval of the source of water used. They shall use freshwater
which is free of sediments and salt contaminants and be responsible for allexpenses involved in
securing the approved water.

The surface areas of a steel bridge should be cleaned and washed by brushing with freshwater
or using high pressure water blasting, including the top and bottom flanges, webplates,
diaphragms, lateral members and gusset plates. For convenience, inspection vehiclemay be
utilized to carry out cleaning of the bridge soffit.
All surface areas of the bridge deck should be cleaned including the curbs, expansion
joints,drain pits and railings. This may be performed by manual shoveling/sweeping or using
highpressure water blasting.

All areas under the superstructure should be cleaned, including the bearing shoe bed,concrete
diaphragms and pier caps. This may be done by manual shoveling/sweeping orusing high
pressure water blasting. Accessing the top of piers, a higher ladder or hangladder will be useful
and an inspection vehicle can be utilized, if possible.

Vegetation shall be removed from the components of the bridges as well as from near the
bridgesif it is found that they affect the soundness of the structure in course of time.

6.9.3 Measurement and Payment

This payment shall be considered as full compensation for supplying all materials, labor, and
equipment and for the performance of all works necessary for the flushing, washing, cleaning,
and removal and disposal of all foreign materials and debris, in accordance with the contract
documents.

Pay items shall be:

6/9/1 Cleaning of Bridge or Culvert Lump Sum

or Underpass

13
6.10 REMOVAL OF OBSTRUCTION TO WATERFLOW
6.10.1 Description
The work shall consist of removal of floating debris, drifting shrubs, weeds, vegetation, wood,
etc. are transported byflowing water in the stream which pile up around the pier and adjacent to
abutments and disposal to a designated area as per satisfaction of the Engineer

6.10.2 Work Method

The contractor shall take all necessary permissions for the works beforecommencement of
activities. Permission from private property owners, if required, shall be takenlawfully when it
is necessary to remove debris from public/private property.

Floating debris, driftwoods etc. shall be removed and disposed properly to a designatedplace. It
may be necessary to cut the large driftwoods into pieces for disposal.Burning of the removed
materials within the right of way is not permitted. Thedisposed material should be stockpiled at
a designated area and dried. The contractorshall address all environmental issues associated
with removal and disposal of debrisfrom bridge sites. The water reservoir shall be kept intact
after conducting this work.

6.10.3 Measurement and Payment

Pay items shall be:

6/10/1 Removal of Obstructions to the Lump Sum

Waterflow

14
6.11 REPAIRING OF PROTECTION WORKS DUE TO SCOURING

6.11.1 Description
The work shall consist of restoration of missing stones/bricks from masonrywork, gabion
mattress and protection works, caused by the scouring effect of flooding.

6.11.2 Work Method

(a) Filling material
Partially or fully missing bricks / stones in the damaged masonry work shall beplaced by
installing new brick / stone masonry following the alignment anddimensions indicated in
the drawings or as per instruction of the Engineer.

(b) Mortar masonry

All loose, imperfect or unsound bricks / stones and mortar joints, panels, etc. in theexisting
works shall be removed. The substrata shall then be compacted to achieve asound base to
receive the new bricks/stones. The slope line shall be carefully preparedand repair work
shall be executed in accordance with the drawings and as per siterequirements.

(c) Supplemental masonry

Where new stone masonry is placed into the existing masonry wall, joints shall bepartially
or completely set. Exposed surface of the existing stone masonry shall becleaned with wire
brush and lightly moisten so as to attain best possible bonding withthe new work.

(d) Curing
After laying of the bricks / stones into the existing mortared masonry work, curingwith
water shall be done after the initial setting of the mortar at the joints, and shallbe
continuously cured for 7 days.

6.11.3 Measurement and Payment

This work will be paid based on a unit price per cubic meter or lump-sum to compensate for
cutting, loading, hauling,disposing of existing stone/brick/concrete block masonry work and
subsequent cleaning etc. at each location and for all labor, equipment, tools, and other
necessary accessoriesto complete the work.

Pay items shall be:

6/11/1(a) Repairing Stone masonry Cubic metre (m3)
6/11/1(b) Repairing Stone masonry Lump sum (LS)
6/11/2(a) Repairing Mortar masonry Cubic metre (m3)
6/11/2(b) Repairing Mortar masonry Lump sum (LS)

15
6.12 REPAIR OF GABION MESH

6.12.1 Description
The work shall consist of restoration of the Gabion mattresses used for protection of river
banks, bed as well as for protection ofabutments and piers by replacing the damaged wires.

6.12.2 Work Method

Proper access arrangement for the work shall be ensured. The damaged/unacceptable portions
of gabion wires shall be cut and removed carefully. While removing the damaged wires, care
shall be exercised not to disturb the existingportion of the gabion work which is in intact
condition.

Any missing infill material (stones/bricks/concrete blocks) in the gabion mattressshall be

replaced by the same infill material as per the specification by insertingthrough the openings
made by cutting the damaged wires as mentioned above. Thenew infill material shall be
properly inserted and made to level with the existingsurface so that the new work does not
unduly protrude beyond the existing surface.

New gabion wire mesh shall be placed over the existing damaged mesh. The new mesh shall
betied to the existing with steel wires as used in original gabion works. Care shall betaken to
fully cover the damaged portions leaving no space for the infill materials tocome out.Upon
completion of works, all material, tools and equipment shall be removed from the site.

6.12.3 Measurement and Payment

This work shall include fullcompensation for cutting, loading, hauling, disposing of existing
stone/brick/concreteblock masonry work and subsequent cleaning, etc. at each location and for
all labor,equipment, tools, and other necessary accessories to complete the work.

Pay items shall be:

6/12/1(a) Repair of gabion mesh Cubic meter (m3)

6/12/1(b) Repair of gabion mesh Lump sum (LS)

16
 6.13 PATCHING OF CONCRETE SPALLING
6.13.1 Description
The work shall consist of patching of spilling including minor honey comb and potholes in
deck. The will be applicable to spilling of concrete having width less than 300 mm and depth
less than 50mm.

6.13.2 Work Method

The work shall comprise application of polymer cement repair mortar on the spilled portion
ofconcrete after treating the area with suitable bonding agent and after applying
anticorrosionpaint on the surfaces of the corroded rebar, if any. The work requires adequate
curing.

6.13.2.1 Material specification

The material shall be approved by the Engineer through mill certificate of the supplier.

(a) Polymer Cement

Polymer cement mortar shall conform to the requirements of the specifications shownin
Table 9-1 or equivalent ASTM Specifications.

Table 6.13-1 Specification of Polymer Cement for Patching

Property Test Method Specification
Initial setting time - above 60 minutes
Shrinkage ASTM D2566 below 0.05 %
Thermal expansion ASTM C531 2.0x10-5 mm/mm/oC
Slant shear bond to ASTM C882 Concrete failure above 15 N/mm2
concrete
Compressive strength ASTM above 20 N/mm2
D695M

(b) Epoxy bonding agent

The epoxy bonding agent to concrete surface shall conform to the requirements of
thespecification indicated in Table 6.13-2. (Anti-corrosion zinc rich primer shall beapplied
to exposed rebar).

Table 6.13-2 Compressive strength ASTM D695M 70 N/mm2

Property Test Method Specification
Compressive strength ASTM D695M 70 N/mm2
Flexural strength ASTM D790M 40 N/mm2
Tensile strength ASTM D638M 30 N/mm2
Tensile shear bond to steel ASTM 1002 15 N/mm2
Slant shear bond to mortar ASTM C882 15 N/mm2
Bond Strength of Cured ASTM D7274 15 N/mm2
Concrete to Fresh Concrete

(c) Zinc Rich Primer

17
 The zinc rich primer to rebar shall be in accordance with the requirements of the
specifications in Table 6.13-3.
Table 6.13-3 Specification of Zinc Rich Primer for Rebar
Property Test Method Specification
Gloss @ 60°Angle ASTM D 523 Flat
Adhesion ASTM D 3359 Minimum 3A
Salt Spray Resistance ASTM D3-37 Excellent
%Zinc by Weight in Dried FilmTest - 87.5±2 percent

6.13.2.2 Work requirement

(a) General
Patching repair works using Portland cement mortar shall be carried out in
accordancewithprovisions of relevant standards and manufacturer’s specifications.
Patching, as a minor pair work, should be carried out using an appropriate means to access
the repair area before the defect worsens. Patching repair work method using polymer
cement mortarshall be carried out as follows.

(b) Marking of patching area

The surface area to be patched will be evaluated using hammer for hollow sounding
delaminated area(or by using instruments to detect unsound concrete).The area to be patch-
repaired will be marked with paint or marker and complete coverage of the
Damage area will be ensured.

(c) Tipping damaged concrete off

Using a small sledge hammer and chisel, alldamaged concrete at the edges and corners of
area tobe repairedshall be removed. Loose debris shall be removed using a wire brush.Care
should be taken to ensure that no reinforcementis damaged.Surface shall be cut to expose
the reinforcement and to reach the sound concrete substrate,without breaking the concrete
behind the reinforcement. If rebar is exposed, anticorrosionagent coating should be applied
on the bar surface prior to patching. All works shall besubjected to the approval of the
Engineer.Patch areas that are within 600 mm of each other should be combined into a
single largepatch.If necessary, formwork around the damaged concrete shall be provided to
straighten the edges of thedamaged section.

(d) Coating tipping area

Concrete surfaces to receive repair mortar shall be prepared by mechanical scrubbing
toremove loose materials, surface laitance, organic contaminants and moss. The clean
anddust free surface shall then be coated by a bonding primer.Care shall be taken to ensure
that vibration associatedwith the repair works does not cause delimitation ofexisting
adjacent plaster or concrete.

(e) Applying bonding agent and anti-corrosion paint

18
 Bonding agent to the damaged area shall be applied in order forthe patch material to
adhere. Additionally, concretenails/bids may be set to reinforce the repair.If rebar is
exposed, anticorrosion coating should be applied on the bar surface prior topatching.

(f) Patching mortal

The mortar mix shall be prepared in a bucket using equipmentapproved by the Engineer. A
trowel shall be used to spreadfresh mortar over the area, covering the concretenails driven
halfway in the old concrete. The mortar shall be leveled by using a towel. Polymer
cementmortar is suitable for both vertical and horizontalsurface applications, with a thin
coating of up to 15 mm.

(g) Finishing
As may be required, the mortar surface can be smoothened using a trowel or broom
finished. The texture of the finish of the final repair mortar layer shall match the finish of
the existing surface. There pair mortar application shall be built up to the original surface
profile in layers not exceeding 20mm with the final layer not exceeding 15 mm, unless
otherwise recommended by the manufacturer and approved by the Engineer. The Engineer
may approve repair mortar application thickness of up to 50 mm for light weight mortars,
provided the mortar manufacturer furnishes technical data to justify a layer thickness of
greater than 20 mm.

(h) Curing
All types of concrete repair with repair mortar need thorough and continuous curing
todevelop strength and impermeability. Curing also minimizes drying shrinkage while
bondstrength is developing. Curing of the repair mortar shall be in accordance with
themanufacturer's instructions related to the polymer modified additive. Where curing
agentshare specified by the manufacturer, they shall be applied immediately after the
surfaceshave been scarified for the next repair mortar layer, or toweled to a finish.

6.13.3 Measurement and Payment

Area prepared for patching shall be measured in square meter after removal of concrete
ofrequired thickness over the marked area of delaminated concrete identified by the Engineer.

Payment shall be made based on per square meter rate which shall include identificationand
removal of deteriorated concrete, cleaning and preparation of surface to receive repairmortar,
furnishing and placing of all materials including finishing, curing, formwork, labor,equipment,
tools and necessary access arrangement, as well as removal of formwork,staging, scaffolding
and all other temporary works after completion, complete as specifiedand directed by the
Engineer.

Pay items shall be:

6/13/1 Patching Squaremeter (m2)

19
6.14 TOUCHUP PAINTING
6.14.1 Description
The work shall comprise touchup painting on steel members atlocalized areas including surface
preparation and other associated works. This section shall cover only painting on relatively less
affected areas which can be carried out with the useof machine tools / hand tools. Painting of
larger areas requiring sand blast cleaning whichshould be carried out in accordance with the
specifications covered under major repairs.

6.14.2 Work Method

6.14.2.1 Application criteria

Touchup painting shall be done locally on partially rusted steel surfaces. Depending on
thearea affected by corrosion, two different surface preparations will be needed.

Table 6.14-1 Degree of rusting and surface preparation

Affected Description of degree ofrusting Surface preparation
Area
10-20 % Grade-1: Corrosion is partially Remove old coating film, rust with
visible but not severe. Peeled-off disk grinder, scraper and wire brush
coating film is partially visible
20-30% Grade-2: Corrosion is partially Remove old coating film, rust with
severe on steel surface and scraper and wire brush partially
coating film is almost visible but revealing the steel
partially deteriorated due to texture
corrosion

If the paint condition is identified as Grade-1 (affected surface 10-20%), aluminum

paintshall be applied with a similar shade.Where condition of paint is evaluated as Grade-2
(affected surface 20-30%) with loss ofsection within 20%, special anticorrosion paint shall
be applied to restrict corrosion fromprogressing further.

Galvanized and heavily corroded steel surfaces shall also be treated with
specialanticorrosion paint systems. Patch repair with ordinary aluminum paint is not
suitable forrepair of corrosion affected galvanized steel surfaces (Old steel truss bridges
manufacturein USA are made up of galvanized metal). As shown in the photos, special
anticorrosionpaint shall be applied to heavily corrode steel portions.

6.14.2.2Material

Aluminum paint material shall be in accordance with the manufacturer’s specifications

andas approved by the Engineer.For special anticorrosion paint, the materials shall satisfy
the test requirements indicated inthe relevant ASTM specifications as follows.

20
 Table 6.14-2 Specification of Aluminum paint
Tests Test Specifications
Reference
Adhesive ASTM 7days 1.0 N/mm2, 28days 1.5 N/mm2
test D7234
Elongation ASTM C190 7days 0.40 %, 28days 0.40 %
Saltwater ASTM No defection
test D6943

6.14.2.2 Work Requirement

(a) Scaffolding
Scaffolding shall be installed for close access to the corrosion affected surfaces of thesteel
members to be repaired. Standard scaffoldings may be used, however
mobilescaffolding/inspection vehicle may be found suitable as it allows for free movement
inmost cases and provides access with convenience to various parts of a bridge,particularly
for bridges with high elevation or deep river crossings.

(b) Preparation of Steel Surface

Surface preparation shall conform to the paint manufacturer’s specifications. Hand orpower
tools shall be applied for cleaning the surfaceGroves and ridges formed on the affected
surface shall be removed with power grinder.Where appropriate, as an alternative, epoxy
resin filler may be used to fill the surfaceto a smooth and even finish. Where depth of
roughness is within 0.5 mm, paintadequacy and durability can be achieved without
application of multiple coats ofsurface leveling paints. Thickness of each coat shall not
exceed the limiting valuerecommended in the paint manufacturer’s specifications.

Application of aluminum paint material shall be in accordance with the

manufacturer’sspecifications and as approved by the Engineer.

(c) Application of Touchup Paint

Paint shall be applied with brush or roller. The paint shall be applied in such a way thata
uniform and smooth surface is formed without wrinkles, runs, streaks, sags, or anyother
defects. Components of the paint shall be mixed in accordance with themanufacturer’s
instructions and the application shall also conform to such instructionsand specifications.
Paint shall be applied immediately after the surface preparation,preferably within 4 hours.

Total dry film thickness for special anticorrosive paint shall be 500 m (equivalent1.5kg/m2)
consisting of two layers of coating as follows:
‐Layer-1: 250 m
‐Layer-2: 250 m
Anticorrosion paint shall be applied in accordance with the stipulations of
paintmanufacturer’s specifications. Minimum total film thickness for aluminum paint
shallbe not less than 125 m.

21
 Ronal paint is recommended for galvanized member touchup painting.

Total dry film thickness for Ronal paint shall be 80 m (equivalent 0.5kg/m2)consisting of
two layers of coating as follows:
‐Layer-1: 40 m
‐Layer-2: 40 m
Ronal paint shall be applied in accordance with the stipulations of paint
manufacturer’sspecifications.

6.14.3 Measurement and Payment

The work shall be measured as the accepted surface area treated and painted, in squaremeters.
Payment shall be made based on unit price per square meter area of field touchuppainting
complete in all respect and approved, including all labor, services of technicalservice advisor,
equipment, tools, materials and work incidentals including allnecessary storage and hauling to
and from the bridges as repaired, and collection andstorage of all materials within the work
area.

Pay items shall be:

6/14/1 Touchup painting Square metre (m2)

22
6.15 CRACK INJECTION
6.15.1 Description
Thework shallcomprise crack repairs to any concretestructures, particularly todeck slab. The
works include preparation of concretesurface, insertion of pipe fittings bonded with
adhesive,injection of epoxy, curing and conducting performancetest.Crack injection for
concrete requires highly skilledprocess and its effectiveness depends mostly on theproficiency
of the certified technician. The technicianshould be qualified based on his experience
andapproved by the Engineer-in-Charge.

6.15.2 Work Method

6.15.2.1 Material
The material shall be approved by the Engineer through Manufacturer’s Test Certificate
(MTC) from the supplier.

(a) Epoxy Resin

The epoxy resin shall be compatible with the concrete of structure and shall have
theproperties shown in Table 6.15-1. Testing of said properties shall be in accordance
withthe relevant standards shown in Table 6.15-1, or equivalent ASTM Specifications.

Table 6.15-1 Specification of Epoxy Resin (for Deck Slab)

Property Test Method Unit Specification
Viscosity (cPs) ASTM D2393 mPa.s 500/below
Potlife - min 30
Specific Gravity ASTM D792 - 3.30 ± 0.1
Compressive Strength ASTM D695M N/mm2 20 /above
Flexural Strength ASTM D790M N/mm2 10/above
Tensile Shear Bond to Steel ASTM D1002 N/mm2 15 /above
Slant Shear Bond Strength to ASTM C882 N/mm2 15/above
Concrete
Bond Strength to Concrete Dry / Wet ASTM D7234 N/mm2 1.5

(b) Sealant
The epoxy-based sealant material shall be compatible with the injection material and shall
have the properties listed in Table 6.15-2 below. Testing of materials shall be in accordance
with the listed standards or equivalent ASTM Specifications.

23
 Table 6.15-2Specifications of Sealant (Putty) for Crack Injection (for Deck Slab)
Property Test Method Unit Specification

Specific Gravity ASTM D792 - 1.50±0.30

Bond Strength ASTM C882 N/mm2 15/above
Compressive Strength ASTM D695M N/mm2 50 /above
Flexural Strength ASTM D790M N/mm2 15 /above
Tensile Shear Bond Strength ASTM D1002 N/mm2 10 /above

6.15.2.2 Work requirement

The Contractor shall submit the Work Procedure/Statement to the Engineer for approval
comprising material approval, injection procedure, quality assurance plan, equipment
deployment, skilled/semi/unskilled manpower, diversion planning, or any other pertinent
documentsbefore commencement of the work.

(a) Clean the cracks

All loose debris such as dirt, concrete fine particlesand contaminants (oil, grease, etc.) shall
be removedfrom the cracks using high-pressure water, orspecial solvent. The residual water
orsolvent in the crack shall be blown away with filtered (dust and oil free) compressed air
and adequate time will be allowed for dryingair.
The intention of this work is to fill and seal these cracks, particularly those found
onconcrete bridges. The extent of the cracks shall be indicated by the Contractor and
shownon drawings. The detail of the quantities shall be marked out on the concrete
elements and agreed with the Engineer prior to proceeding. The Engineer may adjust
theextent of the work as the project proceeds, based on actual conditions.
Loose or spilled concrete, grease, traces of paints, oil or other contaminants shall bemarked
out and removed using wire brushes, grinding wheels or power brush.
All cracks shall be thoroughly cleaned using clean, oil-free compressed air. Both
theconcrete surface and the cracks shall be allowed to dry thoroughly before
commencingthe crack injection.

(b) Adhesion of pipe fitting

The terminal of the injector shall be connected to the pipefittings. Pipe fittings are bonded
with the adhesive tothe crack center for injecting epoxy. Spacing of thepipes varies between
150mm to 500 mm, dependingon the width and depth of the cracks. The first andlast pipe
fitting shall be set at or near the bottom and top respectively.The pipe fittings shall be fixed
at certain intervalsalong the length of each crack. The distance betweeneach fitting shall be
as shown on the drawings,considering the width and depth of crack, forapproval of the
Engineer.
The surface sealant shall be moisture tolerant puttywith good adhesion to concrete. This is
supplied intwo components namely, the base resin and thehardener. These are weighed
according to thespecified mix proportions of the manufacturer. Themixing process is
continued until a uniform paste isobtained.The mixed surface sealant shall be applied to the
24
metal base of each pipe fitting. Theyshall be pressed firmly into place and held until
secured. In this way, all the fittings shallbe fixed along the length of the crack. The surface
of the cracks between the fittings shallbe sealed with a band of surface sealant, measuring
50 mm wide and 2 to 3 mm thick. A complete seal shall be made around the metal bases of
each pipe fitting. The repairedcracks shall be allowed to cure for at least 12 hours.

(c) Epoxy Injection

Epoxy shall be injected using air-activated injecting guns. Injection is performed on the
pipe fitting. Duration of the injection operation shall be inaccordance with the supplier’s
instructions.

If the crack is vertical, the injection of epoxy shall be commenced at the lowest pipe fitting,
untilthe epoxy exudes from the pipe fitting above. For horizontal cracks, the injection shall
be carried out from one end of the crack to the other, in a similar manner. Using a 5
cmwidth strap, epoxy sealant shall be applied on the area around the pipe fitting and
cracksallowing it to harden.
Each crack shall be treated in a single, continuousoperation. Sufficient materials shall
therefore bereadily available prior to the commencement ofwork. The preparation, mixing
and application of thematerials shall be undertaken in strict compliancewith the
manufacturer’s recommendations andapproved by the Engineer. Before the
workscommence, the Contractor shall ensure that allnecessary tools and equipment are on
site.
The materials shall not be used without the approvalof the Engineer when the ambient
temperature is ator below 5 degree Celsius or is above 35 degree Celsius. Only intact
packageof epoxy resin shall be used for each injectionpurpose. No part packs or on-site
batching shall beallowed under any circumstances.
In all operations of storage, mixing and application, the Contractor shall comply with
thehealth and safety standards of the Engineer and the relevant governing rules
andregulations as well.

(d) Curing
The epoxy system shall be allowed to curium disturbed for twenty four (24) hours. The
pipefittings and bands of surface sealant shall then beremoved. Any damaged areas shall be
made good tothe satisfaction of the Engineer-in-Charge.

(e) Performance Test

Low Frequency Pulse Velocity Ultrasonic Inspection will be determined if the epoxy resin
has penetrated the full depth of the crack. If incomplete penetration is revealed from
thistest, the work has to be repeated on the Contractor’s expense.

25
6.15.3 Measurement and Payment
The method of measurement to determine payment for the crack injection works on cracksshall
be based on the total the lengths of the cracks or the works as lump sum, which are identified
by the Engineer.

The contract price paid per meter or in lump sum for this work item shall include full
compensation forsupplying all labor, materials, tools, equipment, and incidentals, and for
performing all theworks involved in the preparation and injection of epoxy on cracks in the
existing concretecompletely in place as shown on the plans and as specified in the standard
specifications,special provisions and as directed by the Engineer-in-Charge.

Pay items shall be:

6/15/1 Crack Injection Linear Meter (m)

6/15/2 Crack Injection Lump Sum

26
6.16 CRACK FILLING
6.16.1 Description
Thework shallcomprise crack repairs to concretestructures by filling the cracks with flexible
sealant. Crack widths should be more than 0.5 mm with depth of less than 300 mm.

6.16.2 Work Method

6.16.2.1 Material
The material shall be approved by the Engineer through Manufacturer’s Test Certificate
(MTC) from the supplier.Testing of materials shall be in accordance with the relevant
standards shown or equivalentASTM Specifications.

(a) Epoxy bonding primer

Epoxy bonding primer shall conform to the Specifications as shown in Table 6.16-1below.

Table 6.16-1 Specifications of Epoxy Bonding Primer

Property Test Method Unit Specifications
Compressive Strength ASTM D695M N/mm2 70
Flexural Strength ASTM D790M N/mm2 40
Tensile Strength ASTM D638M N/mm2 30
Tensile Shear Bond to Steel ASTM D1002 N/mm2 10
Slant Shear Bond to Mortar ASTM C882 N/mm 15

(b) Sealant
The epoxy-based sealant material shall be compatible with the injection material and shall
have the properties listed in Table 6.16-2.

Table 6.16-2 Specification of Epoxy Based Sealant

Test Specificatio
Property Unit
Method ns
Specific Gravity ASTM D792 - 1.5±0.3
Elongation ASTM D638 % 50
2
Bond Strength to Concrete Dry /Wet ASTM C882 N/mm 3.0

6.16.2.2 Work requirement

The Contractor shall submit the Work Procedure/Statement to the Engineer for approval
comprising material approval, injection procedure, quality assurance plan, equipment
deployment, skilled/semi/unskilled manpower, diversion planning, or any other pertinent
documentsbefore commencement of the work.

(a) Preparation of concrete

All loose debris such as dirt, concrete fine particles and contaminants (oil, grease,etc) shall
be removed from the cracks using high-pressure water, or special and effective solvent. The
27
residual water or solvent in the crack shall be blown away with filtered (dust and oil free)
compressed air and adequate time shall be allowed for drying air. The intention of this work
is to filland seal these cracks, particularly those foundon concrete bridges. The extent of the
cracksshall be indicated by the Contractor and shownon drawings. The detail of the
quantities shall bemarked out on the concrete elements, andagreed with the designated
Engineer prior top proceeding.The Engineer may adjust the extent of the work as the
project proceeds, based on actualconditions.
Loose or spilled concrete, grease, traces of paints, oil or other contaminants shall bemarked
out and removed using wire brushes, grinding wheels or power brush as cleaningdevices.
All cracks shall be thoroughly cleaned using clean, oil-free compressed air. Both
theconcrete surface and the cracks shall be allowed to dry thoroughly before
commencingthe injection.

(b) Preparation of Groove

Using a concrete saw, hand tools or pneumatic tools, a minimum 10 mm wide x 10
mmdeep V-groove or U-groove shall be prepared at the surface along the crack. The groove
shall be cleaned with an oil free air jet or wire brush before placing the bonding coat.

(c) Applying bonding coat

The concrete surface of groove to which the bonding coat is to be applied shall be wet
using potable water to achieve a moisture condition such that the concrete will not absorb
moisture from the mortar. The wetting period will depend upon the substratacondition and
the bonding coat manufacturer's recommendations, subject to Engineer’s satisfaction.

The surface shall then be left wet until the free water has evaporated before thebonding coat
is applied. Using a brush, the coat shall be applied to the exposedconcrete surface.

(d) Caulking epoxy sealant

The mixed sealant shall be applied into the groove along the cracks by a caulking gun. A
complete seal shall be made around the metal bases of each port. The applied sealant as a
caulking shall be allowed to cure for at least 12 hours.
The sealant material shall be selected inconsideration with the crack movement which
should be calculated considering the applied loads, shrinkage and temperature variations.
The Contractor shall propose suitable sealant material based on the study on the crack
movement, subject to Engineer’s approval. The preparation, mixing and application of the
sealant materials shall be undertaken in strict accordance with the manufacturer’s
recommendations.
The Contractor is to ensure that all necessary tools and equipment are on site until the
works commence. In all operations of storage, mixing and application, the Contractor shall
comply with the health and safety recommendations of the Engineer and therelevant
governing rules and regulations.

(e) Curing
28
 After the crack is sealed the sealant shall be allowed to cure for twelve (12) hours and shall
be let undisturbed for this time.

(f) Performance test

Low Frequency Pulse Velocity Ultrasonic Investigation shall be used to determine if the
epoxy sealant has penetrated to the base of the groove. If incomplete penetration is revealed
by investigation, such conditions shall be reworked at cost to the Contractor.

6.16.3 Measurement and Payment

The method of measurement to determine payment for the Filling works shall be based on the
total lengths of the cracks or works as lump sum, which are identified by the Engineer-in-
Charge.
The contract price paid per meter or lump sum for this work item shall include full
compensation for supplying all labor, materials, tools, equipment, and incidentals, and for
performing all the works involved in the preparation and injection of epoxy on cracks in the
existing concrete, completely in place, as shown on the plans and as specified in the standard
specifications, special provisions, and as directed by the Engineer.

Pay items shall be:

6/16/1 Crack Filling Linear Meter (m)

6/16/2 Crack Filling Lump Sum

29
6.17 CONCRETE SURFACE REPAIR BY HAND APPLIED MORTAR
6.17.1 Description
The works shall include Hand applied Mortar (Patching) repair performed to restore small
areas where sound concrete is damaged by spilling, scaling and/or impact. The patch thickness
is limited to a maximum of 100 mm depth of hollow surface.
The work shall be applied to defects without exposed rebar’s [Hand applied Mortar (A)] and/or
to surfaces with exposed rebar’s [Hand applied Mortar (B)].(B) is applied to surfaces with
exposed rebar’s.

6.17.2 Work Method

6.17.2.1 Material
The material shall be approved by the Engineer through Manufacturer’s Test Certificate
(MTC)fromthe supplier. Testing of materials shall be in accordance with the relevant
standards shown or equivalentASTM Specifications.

(a) Epoxy bonding primer

Epoxy bonding primer shall conform to the Specifications as shown in Table 6.17-1below.

Table 6.17-1 Specifications of Epoxy Bonding Primer

Property Test Method Unit Specifications
2
Compressive Strength ASTM D695M N/mm 70
2
Flexural Strength ASTM D790M N/mm 40
Tensile Strength ASTM D638M N/mm2 30
2
Tensile Shear Bond to Steel ASTM D1002 N/mm 10
Slant Shear Bond to Mortar ASTM C882 N/mm 15

(b) Sealant
The epoxy-based sealant material shall be compatible with the injection material and shall
have the properties listed in Table 6.17-2.

Table 6.17-2 Specification of Epoxy Based Sealant

Property Test Method Unit Specifications
Specific Gravity ASTM D792 - 1.5±0.3
Elongation ASTM D638 % 50
2
Bond Strength to Concrete Dry /Wet ASTM C882 N/mm 3.0

6.17.2.2 Work requirement

The Contractor shall submit the Methodology (procedures) of the Work to the Engineer for
his review and approval before commencement of the work.

(a) Preparation of concrete

All loose debris such as dirt, concrete fine particles and contaminants (oil, grease,etc) shall
be removed from the cracks using high-pressure water, or special and effective solvent. The
30
residual water or solvent in the crack shall be blown always with filtered (dust and oil
free)compressed air and adequate time shall be allowed for drying air. The intention of this
work is to fill and seal these cracks, particularly those foundon concrete bridges. The extent
of the cracksshall be indicated by the Contractor and shownon drawings. The detail of the
quantities shall bemarked out on the concrete elements, and agreed with the designated
Engineer prior toproceeding.The Engineer may adjust the extent of the work as the project
proceeds, based on actualconditions.
Loose or spilled concrete, grease, traces of paints, oil or other contaminants shall bemarked
out and removed using wire brushes, grinding wheels or power brush as cleaningdevices.
All cracks shall be thoroughly cleaned using clean, oil-free compressed air. Both
theconcrete surface and the cracks shall be allowed to dry thoroughly before commencing
the injection.

(b) Preparation of Groove

Using a concrete saw, hand tools or pneumatic tools, a minimum 10 mm wide x 10
mmdeep V-groove or U-groove shall be prepared at the surface along the crack. The groove
shall be cleaned with an oil free air jet or wire brush before placingthe bonding coat.

(c) Applying bonding coat

The concrete surface of groove to which the bonding coat is to be applied shall be wet
using potable water to achieve a moisture condition such that the concrete will not absorb
moisture from the mortar. The wetting period will depend upon the substrata condition and
the bonding coat manufacturer's recommendations, subject to Engineer’s satisfaction.
The surface shall then be left wet until the free water has evaporated before the bonding
coat is applied. Using a brush, the coat shall be applied to the exposed concrete surface.

(d) Caulking epoxy sealant

The mixed sealant shall be applied into the groove along the cracks by a caulking gun. A
complete seal shall be made around the metal bases of each port. The applied sealant as a
caulking shall be allowed to cure for at least 12 hours.
The sealant material shall be selected inconsideration with the crack movement which
should be calculated considering the applied loads, shrinkage and temperature variations.
The Contractor shall propose suitable sealant material based on the study on the crack
movement, subject to Engineer’s approval. The preparation, mixing and application of the
sealant materials shall be undertaken in strict accordance with the manufacturer’s
recommendations.
The Contractor is to ensure that all necessary tools and equipment are on site until the
works commence. In all operations of storage, mixing and application, the Contractor shall
comply with the health and safety recommendations of the Engineer and therelevant
governing rules and regulations.

(e) Curing

31
 After the crack is sealed the sealant shall be allowed to cure for twelve (12) hours and shall
be let undisturbed for this time.

(f) Performance test

Low Frequency Pulse Velocity Ultrasonic Investigation shall be used to determine if the
epoxy sealant has penetrated to the base of the groove. If incomplete penetration is revealed
by investigation, such conditions shall be reworked at cost to the Contractor.

6.17.3 Measurement and Payment

The method of measurement to determine payment for the filling works shall be based on the
total lengths of the cracks or as lump sum, which are identified by the Engineer.
The contract price paid per meter or lump sum for this work item shall include full
compensation for supplying all labor, materials, tools, equipment, and incidentals, and for
performing all the works involved in the preparation and injection of epoxy on cracks in the
existing concrete, completely in place, as shown on the plans and as specified in the standard
specifications, special provisions, and as directed by the Engineer.

Pay items shall be:

6/17/1 Concrete Surface Repair by Linear Meter (m)

Hand Applied Mortar
6/17/2 Concrete Surface Repair by Lump Sum
Hand Applied Mortar

6.18 DUST CONTROL

32
6.18.1 Description
The application of dust control product to control airborne dust created by traffic.To mitigate
the negative effect of airborne dust with respect to visibility and nuisance dust.
6.18.2 Work Method
The work for this activity involves the contracted supply and/or mechanical application of
water over the road surface, typically using a water bowser. To enhance stabilization, dust
control agents such as calcium or magnesium chloride can be mixed with the water and
sprayed. In areas with higher traffic volumes or where additional stabilization is required,
increased amounts of water may be applied based on local conditions.
6.18.3 Measurement and Payment
This work shall be paid based on a unit price per kilometer to fully compensate for equipment,
materials, labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/18/1 Dust Control Kilometer

6.19 ASPHALT PATCHING

6.19.1 Description
Asphalt patching involves repairing surface defects in paved areas using hot or cold mix
asphalt, applied either manually or with an automatic/semi-automatic patching machine. This
process covers patching potholes, depressions, pavement edge defects, distressed areas, and
asphalt gutters. The main goal is to remove traffic hazards by filling holes, leveling surface
depressions, and improving the overall riding quality of the pavement.
6.19.2 Work Method
For pothole repairs, miscellaneous patching, and asphalt gutter installation, any preparatory
tasks, including the removal of asphalt and/or gravel and the placement of granular material up
to 300 mm deep, are part of this activity. Cold mix asphalt is typically used when hot mix
asphalt is unavailable. Potholes that do not meet the minimum criteria outlined in the "Pothole
Criteria and Response Time Table" must be repaired during the construction season. This work
should be coordinated with other maintenance activities occurring near the pothole.

33
(Source: Highway Maintenance Standards, Department of Transportation and Infrastructure, Nova Scotia, Canada)

34
When planning asphalt patching work or setting priority lists, the following types of defects
should be considered:
 High concentration of small potholes.
 Segregation/Raveling: Loss of pavement material resulting in surface voids.
 Wheel rutting: Longitudinal depressions in the wheel paths deeper than 20 mm.
 Rippling: A wavy or washboard-like surface across the pavement.
 Cracking: Includes longitudinal, transverse, alligator, and edge cracks.
 Edge loss: Deterioration of the pavement surface near the shoulder.
 Distortions: Any changes in the pavement's original shape.
 Flushing: Polished surface or visible asphalt cement on the pavement.
 Water ponding: Water accumulation on the roadway.
 Repairs around structures such as catch basins, manholes, bridge approaches, and bridge
drains..

6.19.3 Measurement and Payment

This work shall be paid based on a unit price ton per day to fully compensate for equipment,
materials, labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/19/1 Asphalt Patching Ton per day

35
6.20 EXTREME WEATHER EVENT DAMAGE MITIGATION

6.20.1 Description
Damage to departmental roads, highways, structures, or other infrastructure resulting from
severe weather events and/or natural disasters. The goal is to repair and/or restore these
infrastructures to their pre- and post-storm conditions while ensuring public safety during and
after the event, whenever feasible.
6.20.2 Work Method
This activity includes all labor, equipment, materials, and contracted services required for
cleanup, repair, and public protection following severe weather events or natural disasters. It
can only proceed with the Procuring Entity’s approval. After a major event, the Engineer will
conduct an inspection to assess damage and prioritize the necessary repairs. All available
equipment, labor, and materials must be mobilized to minimize the impact of storm damage.
The required work must be carried out with the same safety precautions as standard roadwork.
Method statements, a priority list, and a checklist of tasks must be submitted. Emergency
repairs will be prioritized based on network redundancy and the severity of the damage.
6.20.3 Measurement and Payment
This work shall be paid based on Lump Sum to fully compensate for equipment, materials,
labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/20/1 Extreme weather events Lump sum
damage mitigation

36
6.21 WASTE, DEBRIS AND LITTER CLEAN-UP
6.21.1 Description
This activity involves the physical removal of unwanted items from the road surface and right-
of-way, followed by their proper disposal. These items include, but are not limited to, roadside
rubbish, dead animals, illegal signs, fallen trees, loose brush, and fallen rocks on the road and
shoulders, particularly in the Chittagong Hill Tracts. Debris and litter cleanup is essential to
prevent damage or injury to the traveling public and maintenance personnel or equipment.
Additionally, such debris can harm road structures and cause blockages in drainage systems.
6.21.2 Work Method
All debris must be cleared from the road surface, shoulders, and right-of-way and disposed of in
accordance with department policy and current governmental and municipal regulations. Dead
animals found on the traveled portion or shoulder of the right-of-way must be properly removed
and disposed of.
6.21.3 Measurement and Payment
This work shall be paid based in meters to fully compensate for equipment, materials, labours,
efforts and other necessary accessories to complete the work.

Pay items shall be:

6/21/1 Waste, debris and litter cleanup Meter

37
6.22 CLEANING DRAINS, CHUTES, AND DRAINAGE STRUCTURES

6.22.1 Description
Drain maintenance involves clearing debris and materials from drains, storm sewers, chutes, as
well as pipes and outfall structures. It also includes repairing any structural defects and leaks
within the system. The primary goal of this task is to ensure smooth water flow and maintain
the system’s capacity to handle peak water flows effectively.
6.22.2 Work Method
This system comprises drains, sewers, connections, junction chambers, laterals, manholes, and
outfall structures. An "outfall" structure is built at the pipe outlet of a storm sewer system to
facilitate the transition between the pipe and a watercourse while preventing erosion at the
outlet or in the outfall channel. Storm sewers and outfall structures will be cleaned or repaired
as needed to address any potential deficiencies. These deficiencies may include hazards to
public safety, flow restrictions, or negative impacts on highway infrastructure.
6.22.3 Measurement and Payment
This work shall be paid based on meter per day to fully compensate for equipment, materials,
labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/22/1 Cleaning Drains, Chutes, And Meter per day
Drainage Structures

38
6.23 MAINTENANCE OF CULVERTS

6.23.1 Description
Culvert maintenance involves repairing existing culverts, cleaning both the ends and full
lengths, fixing rip rap, excavation, backfilling, and adding surface gravel. It also includes any
ditching work within 3 meters of each culvert end. The objective is to ensure efficient water
flow and maintain the functional and structural capacity of the culvert to handle peak water
flows and meet traffic demands.
6.23.2 Work Method
Existing drainage structures will be maintained to ensure efficient water flow and preserve their
functional capacity to handle peak flows. Any culverts that pose or have the potential to create
unsafe conditions for the traveling public, adjacent properties, or highway infrastructure will be
cleaned as necessary. Immediate removal of obstructions that are causing damage to the culvert,
ditch, roadbed, shoulders, or nearby properties, or that pose a safety risk to the public, is
required. The contractor is also responsible for ensuring proper driveway installations in line
with permit regulations. If conventional methods, such as high-pressure water flushing, fail to
clear blocked culverts, specialized techniques may be employed. Additionally, any hand-laid or
grouted rip-rap around culvert ends that is damaged or eroded will be repaired, and displaced
material replaced as needed.
6.23.3 Measurement and Payment
This work shall be paid based on square meter of culvert area to fully compensate for
equipment, materials, labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/23/1 Maintenance of Culverts Square meter

39
6.24 MAINTENANCE OF HIGHWAY TRAFFIC SIGNS-SIGNALS
POSTS, POLES, FRAMES, AND GANTRIES

6.24.1 Description
Sign Maintenance and Repair involves maintaining signs and posts, including tasks such as
repairing, repainting, and cleaning existing signs and posts. It also includes replacing signs or
posts that are missing or damaged beyond repair. The goal is to maintain the integrity of the
signs, ensuring they effectively communicate traffic regulations, warn of road conditions, and
provide essential information for route selection to highway users.
6.24.2 Work Method
Signs are devices that may be regulatory, warning, or informational, installed or maintained to
provide important information and ensure the safety of the traveling public on highways. Sign
Maintenance and Repairs will include, but are not limited to, the following:
 Repair or clean signs that are illegible due to issues such as mud, fading, poor
reflectivity, bending, improper orientation, twisting, vandalism, or damage (broken or
cracked).
 Replace missing signs or posts, as well as those that are beyond repair, bent, improperly
oriented, twisted, broken, or cracked.
 Report all vandalized or stolen signs to the appropriate authority, along with an estimate
of the replacement cost.

6.24.3 Measurement and Payment

This work shall be paid based on Lump Sum to fully compensate for equipment, materials,
labours, efforts and other necessary accessories to complete the work.

Pay items shall be:

6/24/1 Maintenance of Culverts Lump Sum

40
41
 Table of Contents
7.1 TRAFFIC SIGNS ............................................................................................................. 9
7.1.1 General ........................................................................................................................... 9
7.1.2 Materials ............................................................................................................................ 11
7.1.2.1. Sign Posts .............................................................................................................. 11
7.1.2.2. Sign Plates .............................................................................................................. 11
7.1.2.3. Frames and Stiffening........................................................................................... 11
7.1.2.4. Fixture and Fittings .............................................................................................. 12
7.1.2.5. Preservatives, Paints and Finishes for Posts and Fittings ................................. 13
7.1.3 Sign Fabrication and Installation ................................................................................. 15
7.1.4 Overhead Sign Materials..................................................................................................... 18
7.1.5 Installation of Overhead Sign ............................................................................................. 18
7.1.6 Warranty and durability ..................................................... Error! Bookmark not defined.
7.1.7 Measurement ................................................................................................................ 20
7.1.8 Payment........................................................................................................................ 20
7.2 REMOVAL OF EXISTING TRAFFIC SIGNS ......................................................... 21
7.2.1. Description ......................................................................................................................... 21
7.2.2. Construction Method ......................................................................................................... 21
7.2.3. Measurement ...................................................................................................................... 21
7.2.4 Payment............................................................................................................................... 21
7.3 ROAD MARKINGS ..................................................................................................... 22
7.3.1 Hot Applied Thermoplastic Road Marking ........................................................................ 22
7.3.1.1 Reflectorizing glass beads ...................................................................................... 24
7.3.2. Cold Applied Reflective Paint ........................................................................................... 28
7.3.4. Measurement ...................................................................................................................... 33
7.3.5. Payment .................................................................................................................... 33
7.4 Audible and Vibratory Pavement Markings .................................................................... 33
7.4.1. Description ......................................................................................................................... 33
7.4.2. Materials ............................................................................................................................ 33
7.4.3. Application......................................................................................................................... 34
7.4.4. Measurement ...................................................................................................................... 36
7.4.5 Payment............................................................................................................................... 36
7.5. Road Stud ........................................................................................................................... 36
7.5.1 General ................................................................................................................................ 36
7.5.2 (A) Reflective Pavement Markers (Road Studs)................................................................. 37
7.5.2.1 Material ................................................................................................................... 37
7.5.2. (B) Solar Powered Road Markers (Solar Studs) ................................................................ 39
7.5.2.1 Material ................................................................................................................... 39

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7.5.3. Placement ........................................................................................................................... 39
7.5.4. Warranty and durability ..................................................................................................... 40
7.5.5. Measurement ...................................................................................................................... 40
7.5.6 Payment............................................................................................................................... 40
7.6 Removal of old Thermoplastic Road Markings ......................................................... 40
7.6.1. Description ......................................................................................................................... 40
7.6.2. Construction Method ......................................................................................................... 40
7.6.3 Measurement ....................................................................................................................... 41
7.6.4 Payment............................................................................................................................... 41
7.7 Traffic Control and Safety Devices in Construction Zone .............................................. 41
7.7.1. General ............................................................................................................................... 41
7.7.2 Traffic Cones ...................................................................................................................... 42
7.7.2.1 General .................................................................................................................... 42
7.7.2.2 Measurement .......................................................................................................... 42
7.7.2.3 Payment ................................................................................................................. 42
7.7.3. Drums................................................................................................................................. 42
7.7.3.1. General ................................................................................................................... 42
7.7.3.2. Measurement ......................................................................................................... 43
7.7.3.3. Payment ................................................................................................................. 43
7.7.4 Barricades ........................................................................................................................... 43
7.7.4.1. General ................................................................................................................... 43
7.7.4.2. Material .................................................................................................................. 43
7.7.4.3. Application............................................................................................................. 44
7.7.4.4 Measurement .......................................................................................................... 45
7.7.4.5. Payment........................................................................................................................... 45
7.7.5. Flagman and STOP/GO Portable Boards........................................................................... 45
7.7.5.1. Materials ................................................................................................................ 45
7.7.5.2. Application............................................................................................................. 46
7.7.5.3. Measurement ......................................................................................................... 46
7.7.5.4. Payment ................................................................................................................. 46
7.7.6. Reflective Clothing ...................................................................................................... 46
7.7.6.1. Materials ................................................................................................................ 46
7.7.6.2. Application............................................................................................................. 46
7.7.6.3. Measurement ......................................................................................................... 47
7.7.6.4. Payment ................................................................................................................. 47
7.8. Conspicuity tape ................................................................................................................. 47
7.8.1. General ............................................................................................................................... 47
7.8.2. Materials ............................................................................................................................ 48
7.8.3. Application......................................................................................................................... 48

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7.8.4. Measurement ...................................................................................................................... 48
7.8.5. Payment.............................................................................................................................. 48
7.9 Delineators ........................................................................................................................... 49
7.9.1 General ................................................................................................................................ 49
7.9.1.1. Categories .............................................................................................................. 49
7.9.2. Material .............................................................................................................................. 51
7.9.2.1 Post .......................................................................................................................... 51
7.9.2.2 Reflector .................................................................................................................. 52
7.9.3 Construction and Installation .............................................................................................. 53
7.9.3.1. Erecting Delineator Posts and Brackets .............................................................. 53
7.9.3.2. Installing Delineators ............................................................................................ 53
7.9.3.3. Temporary Delineators......................................................................................... 54
7.9.4. Warranty ............................................................................................................................ 54
7.9.5. Measurement ...................................................................................................................... 54
7.9.6. Payment.............................................................................................................................. 54
7.10 Rumble Strip Median ................................................................................................... 55
7.10.1. Description ....................................................................................................................... 55
7.10.2. Materials .......................................................................................................................... 55
7.10.3. Construction Method ....................................................................................................... 55
7.10.3.1. Surface preparation ............................................................................................ 55
7.10.3.2. Application of Tack Coat ................................................................................... 55
7.10.3.3. Placing of Bituminous Mixture .......................................................................... 56
7.10.3.4. Compactions of Bituminous Mixture ................................................................ 56
7.10.4 Measurement ..................................................................................................................... 56
7.10.5 Payment............................................................................................................................. 56
7.11 Solid concrete Interlocking Paving Blocks Pavement on footpath ........................... 57
7.11.1. Description ....................................................................................................................... 57
7.11.2. Material requirements ...................................................................................................... 57
7.11.2. 1 Cementitious Materials....................................................................................... 57
7.11.2.2. Aggregates ........................................................................................................... 57
7.11.2.3. Chemical admixtures .......................................................................................... 57
7.11.2.4. Physical Requirements ....................................................................................... 57
7.11.2.5. Spacer Nibs and Chamfers ................................................................................. 58
7.11.2.6. Manufacturing / Casting .................................................................................... 58
7.11.2.7. Tolerances ............................................................................................................ 58
7.11.2.8 Sampling and Testing .......................................................................................... 58
7.11.2.9 Visual Inspection .................................................................................................. 59
7.11.3. Construction Method ....................................................................................................... 59
7.11.3.1 Basic Paving operations ....................................................................................... 59

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 7.11.3.2 Edge Restraint ...................................................................................................... 59
7.11.3.3 Laying course........................................................................................................ 59
7.11.3.4 Screeding to Level ................................................................................................ 60
7.11.3.5 Surcharge .............................................................................................................. 60
7.11.3.7 Laying.................................................................................................................... 60
7.11.3.8 Compaction of road bed/paving blocks with plate vibrator ............................. 61
7.11.3.9 Edging ................................................................................................................... 61
7.11.4. Measurement .................................................................................................................... 61
7.11.5 Payment ................................................................................................................... 62
7.12 Pre-cast Kerbs for Median/ NMT Lane Separator/ Roundabout/ Footpath ............... 62
7.12.1 Description ........................................................................................................................ 62
7.12.2 Materials ........................................................................................................................... 62
7.12.2.1 Cementitious Materials........................................................................................ 62
7.12.2.2 Aggregates ........................................................................................................... 62
7.12.2.3 Chemical Admixtures .......................................................................................... 62
7.12.2.4 Steel Reinforcement – .......................................................................................... 63
7.12.2.5 Physical Requirements ........................................................................................ 63
7.12.2.6 Manufacturing/Casting ....................................................................................... 63
7.12.2.7 Finish and Color ................................................................................................... 64
7.12.2.8 Testing ................................................................................................................... 64
7.12.3 Construction Methods ....................................................................................................... 64
7.12.3.1 Construction of median / NMT lane separator / roundabout / footpath ......... 64
7.12.3.2. Installation of Pre-cast Kerbs ............................................................................ 64
7.12.4 Measurement ................................................................................................................ 65
7.12.5 Payment............................................................................................................................. 65
7.13 Backfilling of Median/NMT Lane Separator/Roundabout ....................................... 65
7.13.1 Description ........................................................................................................................ 65
7.13.2 Materials ...................................................................................................................... 65
7.13.3 Construction ...................................................................................................................... 66
Earth filling of median/ Lane divider/ Roundabout ..................................................................... 66
7.13.4 Measurement ................................................................................................................ 66
7.13.5 Payment............................................................................................................................. 66
7.14 Dismantling Damaged Kerb Stones and Re-use of Kerb Stones .............................. 66
7.14.1 Description ................................................................................................................... 66
7.14.2 Construction ................................................................................................................. 66
7.14.3 Measurement ................................................................................................................ 67
7.14.4 Payment........................................................................................................................ 67
7.15 Painting of Median/NMT Lane Separator/Roundabout ........................................... 67
7.15.1 Description ................................................................................................................... 67

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7.15.3 Method of Application of Paint ........................................................................................ 67
7.15.4 Measurement ..................................................................................................................... 68
7.15.5 Payment............................................................................................................................. 68
7.16 Demolition and Removal of Existing Median ............................................................. 68
7.16.1 Description ........................................................................................................................ 68
7.16.2 Method ......................................................................................................................... 68
7.16.3 Measurement ................................................................................................................ 68
7.16.4 Payment........................................................................................................................ 69
7.17 Crash Barriers .................................................................................................................. 69
7.17.1 General .............................................................................................................................. 69
7.17.2. Placement ......................................................................................................................... 70
7.17.3. Materials .......................................................................................................................... 71
7.17.3.1 Concrete Crash Barrier/New Jersey Barrier..................................................... 72
7.17.3.2 Metal Beam Crash Barrier/W-Beam ................................................................. 73
7.18 Flexible Wire Rope Barriers ............................................................................................ 77
7.18.1. General ............................................................................................................................. 77
7.18.2. Material ............................................................................................................................ 78
7.18.3. Installation........................................................................................................................ 79
7.18.4. Measurement .................................................................................................................... 79
7.18.5. Payment............................................................................................................................ 79
7.19 Water Filled Plastic Movable Barriers with Reflectors................................................. 80
7.19.1. Description ....................................................................................................................... 80
7.19.2. Use/Application ............................................................................................................... 80
7.19.3. Materials &Properties ...................................................................................................... 80
7.19.4. Construction ..................................................................................................................... 81
7.19.5. Warranty .......................................................................................................................... 81
7.19.6. Measurement .................................................................................................................... 81
7.19.7. Payment............................................................................................................................ 81
7.20 Cones with Retro-Reflective Sheets and connected by Ropes ....................................... 82
7.20.1. Description ....................................................................................................................... 82
7.20.2 Use/Application ................................................................................................................ 82
7.20.3 Materials & Properties ...................................................................................................... 82
7.20.4 Construction ...................................................................................................................... 82
7.20.5 Warranty ........................................................................................................................... 83
7.20.6 Measurements ................................................................................................................... 83
7.20.7 Payment............................................................................................................................. 83
7.21 Fencing for Footpath / NMT Lane Separator ................................................................ 83
7.21.1 Description ........................................................................................................................ 83
7.21.2 Materials ........................................................................................................................... 83

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7.21.3 Installation......................................................................................................................... 83
7.21.4 Measurement ..................................................................................................................... 84
7.21.5 Payment............................................................................................................................. 84
7.22 Raised Pedestrian Crossing on Speed Table/ Speed Hump .......................................... 84
7.22.1 Description ........................................................................................................................ 84
7.22.2 Materials ...................................................................................................................... 85
7.22.2.1 Tack Coat .............................................................................................................. 85
7.22.2.2 Bituminous Mixture ............................................................................................. 85
7.22.2.3 Form Work ........................................................................................................... 85
7.22.3 Construction Methods ....................................................................................................... 85
7.22.3.1 Surface Preparation ............................................................................................. 85
7.22.3.2 Application of Tack Coat ................................................................................... 85
7.22.3.3 Placing of Bituminous Mixture .......................................................................... 86
7.22.3.4 Compaction of Bituminous Mixture .................................................................. 86
7.22.4 Measurement ................................................................................................................ 86
7.22.5 Payment............................................................................................................................. 86
7.23 Rumble Strip (Thermoplastic) ......................................................................................... 87
7.23.1 General .............................................................................................................................. 87
7.23.2. Material ............................................................................................................................ 88
7.23.3. Placement ......................................................................................................................... 88
7.23.4. Measurement .................................................................................................................... 88
7.23.5. Payment............................................................................................................................ 88
7.24 Rumble Strip Tape ............................................................................................................ 89
7.24.1. General ............................................................................................................................. 89
7.24.2 Installation......................................................................................................................... 89
7.24.3. Measurement .................................................................................................................... 89
7.24.4 Payment............................................................................................................................. 89
7.25 Convex Mirror .................................................................................................................. 89
7.25.1General ............................................................................................................................... 89
7.25.2 Material ............................................................................................................................. 90
7.25.3 Installation......................................................................................................................... 91
7.25.4. Measurement .................................................................................................................... 91
The quantity to be measured for payment shall be the number of each Convex Mirror .............. 91
7.25.5 Payment............................................................................................................................. 91
7.26 Anti-Glare Systems ........................................................................................................... 91
7.26.1 Description ........................................................................................................................ 91
7.26.2. Material ............................................................................................................................ 91
7.26.3 Application........................................................................................................................ 92
7.26.4. Measurement .................................................................................................................... 92

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7.26.5. Payment............................................................................................................................ 93
7.27 Sound Barrier ................................................................................................................... 93
7.27.1 General .............................................................................................................................. 93
7.27.2 Materials ........................................................................................................................... 93
7.27.3 Constructions .................................................................................................................... 94
7.27.4 Measurement ..................................................................................................................... 94
7.27.5 Payment............................................................................................................................. 94
7.28 Street Lightning ................................................................................................................ 94
7.28.1 General .............................................................................................................................. 94
7.28.2 Material and Equipment .................................................................................................... 95
7.28.3 Constructions .................................................................................................................... 96
7.28.4 Warranty ........................................................................................................................... 96
7.28.5 Measurement ..................................................................................................................... 96
7.28.6 Payment............................................................................................................................. 96
7.29 Distance Marker (KM Post) ............................................................................................. 96
7.29.1 Description ................................................................................................................... 96
7.29.2 Materials ...................................................................................................................... 97
7.29.3 Construction Methods .................................................................................................. 97
7.29.4 Measurement ................................................................................................................ 97
7.29.5 Payment........................................................................................................................ 97
7.30 Traffic Impact Attenuators .............................................................................................. 97
7.30.1 General .............................................................................................................................. 97
7.30.2 Material ............................................................................................................................. 97
7.30.3 Application........................................................................................................................ 98
7.30.4 Measurement ..................................................................................................................... 99
7.30.5 Payment............................................................................................................................. 99
7.31 Semi Automatic Toll Collection System .......................................................................... 99
7.31.1 Automatic Vehicle Counter cum Classifier (AVCC) System ........................................... 99
7.31.2. Automatic Boom Barrier ................................................................................................ 100
7.31.3 Contactless Smart Card Readers/Writers ........................................................................ 102
7.31.4 Close Circuit Television (CCTV) System ...................................................................... 103
7.31.5 Digital Video Recorder (DVR) ....................................................................................... 103
7.31.6 Lane Controller ............................................................................................................... 103
7.31.7 User’s Fare Display Unit................................................................................................. 104
7.31.8 Traffic Light System ....................................................................................................... 104
7.31.9 Lane Communication System ......................................................................................... 105
7.31.10 Overhead Lane Signs (OHLS) ...................................................................................... 105
7.31.11 Toll Management System (TMS) ................................................................................. 107
7.32 Advanced Traffic Management Systems (ATMS) ....................................................... 108

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7.32.1 General ............................................................................................................................ 108
7.32.2 Environmental/Climatic Requirements ...................................................................... 110
7.32.3 Emergency Call Box ....................................................................................................... 111
7.32.4 Mobile Radio Communication System ........................................................................... 113
7.32.5 Variable Message Signs .................................................................................................. 114
7.32.6 Automatic Traffic Counter cum Classifier................................................................ 122
7.32.7. Payment ................................................................................................................ 139

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 7.1 TRAFFIC SIGNS
7.1.1 General

The color, configuration, size and location of all traffic signs for the District Highways,
Regional Highways, National Highways, and Expressways shall be as specified in the
drawings and relevant Specifications or as directed by the Engineer. Specified traffic sign
shall be in accordance with the Road Safety Engineering Manual of Roads and Highways
Department or as shown on the drawings.

Where the competent authority advises to make the meaning of a sign or symbol more
explicit or in the case of mandatory signs limits their application to certain categories of
road users or for specific time periods then an inscription shall be placed below the traffic
sign in a rectangular definition plate of suitable size. The definition plate shall be retro-
reflective with color-code provided in Road Safety Engineering Manual of Roads and
Highways Department. Numerals and word messages shall be in Bengali and English
languages as necessary.

Solar Road Signs

Solar Road Signs can play a vital function in a modern, advanced traffic management
system. These signs are strongly illuminated and therefore easy to read, making them much
more suitable for the purpose of ensuring the attention of road users. In addition, solar road
signs have considerable benefit of conserving energy due to its environmentally conscious
solar technology.

Signs must be used where they are required. Warning signs has to be placed during ongoing
road works and then removed to use in required location without disrupting movement on
nearby footpaths. The speed sensors built into most solar powered road signs are very
sensitive and so it has to be assured that the solar power is only used when traffic is on the
road. In the period when the traffic flow is smooth, the sign is not illuminated and therefore
uses no power.

Signs are also used for indicating to the drivers about road condition through flickering
automatically and warn the drivers to be carefully. They help to reduce the traffic accidents
and fatalities. Signs are mainly used at rural-urban fringe zone and in locations where the
sunshine is strong.

Solar traffic flash light can also be used as indicator in the central divider edge between the
normal & express lane. It would give the flash warning light at night capturing the driver's
attention reducing the possibility of vehicles collision and also act as a warning system for
pedestrians.

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(a) Informatory, cautionary and mandatory signs

Informatory, cautionary and mandatory signs shall be manufactured using layout method
with inscriptions or cut letters with colored retro reflective sheeting on different types of
road in accordance with Road Safety Engineering Manual of Roads and Highways
Department.

(b) Overhead signs

Overhead signs may be used instead of or in addition to kerb mounted signs in places where
the situation warrants in order providing proper information and guidance to the road users
The following conditions may be considered while deciding about the provision of
overhead signs:

 Traffic volume at or near capacity

 Complex interchange design
 Three or more lanes in each direction
 Restricted sight distance
 Closely spaced interchanges
 Multi-lane exits
 Large percentage of commercial vehicles
 High speed vehicular movement
 Insufficient space for ground mounted sign
 Background of street lighting
 Distances of important places along the highways at suitable intervals

From safety and aesthetic considerations, overhead signs shall be mounted on overhead
bridge structures. Where these are required to be provided at some other locations, the
support system should be properly designed based on sound engineering principles, to
safely sustain the dead load, live load and wind load on the completed sign system. For this
purpose, the overhead signs shall be designed to withstand a wind loading of 150 kg/m2
normal to the face of the sign and 30 kg/m2 transverse to the face of the sign. In addition to
the dead load of the structure, walkway loading of 250 kg concentrated live load shall also
be considered for the design of the overhead sign structure. The height and lateral offset
will be provided as per Road Safety Engineering Manual of Roads and Highways
Department.

Number of Signs at an Overhead Installation

In no case shall there be more than three signs displayed at any one location, including
regulatory or warning signs, either on the overhead structure or on its support.

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 7.1.2 Materials

7.1.2.1. Sign Posts

Contractor shall provide all Sign Posts sufficiently strong enough so that the signs can
withstand in all conditions and even against strong wind during storm. Mounting post for
signs shall be in the standard form of heavy galvanized round steel tubes of not less than 50
mm internal diameter or 75 mm external diameter with minimum 2 mm wall thickness or
other approved sections of adequate tensile, bending, compression strength and impact,
hardness and torsional rigidity, complying with the appropriate specifications (ASTM
A370, A938) of the American Society for Testing Materials.

When necessary, due to sign board area additional posts or vertical backside supports must
be used to ensure required strength against wind pressure. The stresses generated in the post
due to a wind pressure of 150 kg per square meter on the sign face shall not exceed the
allowable working stresses in the tube material.

The portion of the mounting post lying within ground and 0.20 meter above ground level
shall be given protective bituminous coating both inside and outside. Hollow posts or other
hollow sections used as mounting post shall be provided with post caps of approved cast or
sheet metal or a suitable weather resisting plastics material.

7.1.2.2. Sign Plates

Sign plates and supplementary plates, on which reflective sheeting will be placed shall be
manufactured from aluminum sheet, complying with BS1470 or ASTM B209 or equivalent
internationally recognized specification acceptable to the Engineer. The minimum thickness
of the plate shall be 2 mm.

Sign plates and panels shall be accurate to the shapes and sizes specified in the Engineering
Drawings read in conjunction with BRTA Traffic Signs Manual, March 2000. All mounting
holes shall be accurately located and, after drilling or punching, all burrs, rough spots and
loose material if any must be removed. In place where painting is required, all holes shall
be drilled before the painting is applied.

7.1.2.3. Frames and Stiffening

Sign plates requiring frames or stiffening shall have adequate ribs or flanges as an integral
part of the sign plate or shall be provided with frames or stiffening members. The metal
used for frames and stiffening shall be mild steel with proper protective paining for
corrosion resistance or otherwise be compatible with the metal used for the face plate so as
not to cause corrosive activity (aluminum or stainless steel frame is recommended for
aluminum plates). Except where ribs or flanges are integral parts of the sign plate and

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provide the necessary stiffening, sheet metal sign plates exceeding 500 mm in any
dimension shall be stiffened by the attachment of a frame or stiffening member (s) to the
back of the sign plate. The frame or stiffening members shall be corrosion resistant, and
made of a material which does not affect adversely the serviceability or durability of the
sign plates.

The frame for a sign plate shall be simple and easy to fabricate and erect but shall provide
required stiffness. Frame of a sign plate shall have form of flanges round the edges of a
sign, welded ribs and made of steel or aluminum sections compatible with the type of the
material used for the sign plate itself, with a minimum thickness of 3 mm. Where flanges
are provided, they shall be uniform on all edges of the sign plate.

Where metal frame members join, these shall be welded or joined with suitable brackets,
bolt and rivets. For welding of steel, AWS D1.1/D1.1M: Structural Welding Code – Steel,
and for welding of aluminum plates and frames, AWS D1.2/D1.2M - Structural Welding
Code for Aluminum by American Welding Society (AWS) shall be followed. Direct
welding between steel and aluminum is generally avoided due to technical difficulties and
the resulting weak joint. In all cases the joints shall be strong enough to withstand the
stresses occurs therein due to a wind pressure of 150 kg/m2 acting in any direction on the
sign face.

7.1.2.4. Fixture and Fittings

The method of fixing sign plates, frames and brackets to posts shall be such that will
facilitate their removal for replacement or maintenance purposes and at the same time
ensure that the sign and any framing shall be held firmly enough to withstand the specified
loads. Signs mounted on single posts shall be so fixed as to prevent the forced rotation of
the signs on the posts. Clips and brackets shall be shaped to secure a firm hold on the post
without placing any bending strain on the sign plate.

Where dissimilar metals will be joined together, precautions shall be taken to prevent any
electrolytic action leading to galvanic corrosion, differential thermal expansion and melting
points, formation of intermetallic compound etc. Alternative to welding joint, different
adhesive bonding, or using bimetallic transition inserts shall be considered to achieve a
strong, reliable connection between dissimilar metals like steel frames and aluminum
plates. In the case of mechanical fastening (bolts, screws, rivets, or other fasteners), such
issues shall be overcome by using paint, lacquer or other suitable means to eliminate metal
to metal contact. A suitable alternative for such jointing would be the combined use of
riveting and adhesive (where adhesive alone may not be sufficient).

Brackets used in erection of signs, may be manufactured from sheet or cast or extruded
aluminum, alloy, or may be fabricated from steel sections taking into account compatibility
with sign plate materials so as not to cause corrosion. The minimum thickness of material
for brackets shall be 3mm. Welded joints (if used) shall be sound, with smooth surfaces.

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Holes shall be drilled before painting and shall be accurately located. Steel or aluminum
strip used for clip shall not be less than 2 mm thick.

Screws and bolts shall not be less than 8 mm (5/16 inch) in diameter and of adequate
length, but without excessive projection of the screwed ends. In a situation where the entire
assembly would be insecure for absence of a screw, these screws shall have at least four
full threads protruding when it is tight and shall be fitted with a locknut.

Where hollow rivets are used to connect sign plates to frames or fixings, the holes shall be
effectively blocked to prevent light shining through. Screw, bolt or rivet heads on the face
of a sign shall be unobtrusive and each shall match the color of the part of the sign where it
is located.

Caps for posts of hollow section shall be shaped to shed rainwater to the outside of the
posts and adequate means of securing the caps to the posts shall be provided.

The material, forms and arrangements of fixtures and fittings shall be submitted by the
contractor and agreed to by the Engineer as part of the prior approval of sign fabrication.

7.1.2.5. Preservatives, Paints and Finishes for Posts and Fittings

Exposed steel surfaces shall be painted with an anti-corrosive primer as approved by the
Engineer. All coatings, paints, varnishes and enamels used in the preparation and finish of
the posts and fittings shall be of the best quality and made for the purpose intended to serve,
and of brands and types acceptable to the Engineer. To ensure compatibility, primers,
undercoats and finishing coats shall wherever possible, be of the same manufacture. All
materials shall be stored and used within such time limits, as specified or recommended by
the manufactures or in accordance with the directions of the Engineer.

For longer durability, especially against corrosion, all steel parts used shall have zinc
coatings (hot-dip galvanizing, thermal spray, zinc-rich paints) which shall comply the
coating thickness, performance requirements, and applicability requirements with ASTM
Specification A 123 (for larger steel products and components like column, beam, plates
etc.) or A 153 (for smaller hardware and fasteners), as appropriate. Such zinc coated parts
shall not require painting unless indicated in the drawings. Where painting of steel parts is
required, the paint shall be of high zinc oxide content coating material of approved
formulation coating material. The color of the primer shall be different from those of
succeeding coatings. Alternatively, epoxy paint with UV-resistant top coat can be
considered for high durability against corrosion (ASTM D 1763 – 00 can be followed for
required tests).

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 If painting of aluminum alloy parts is noted in the drawings, the priming paint shall be
pigmented with chromates or chromes (excluding lead chromes). No painting shall be done
on sign faces.

7.1.2.6. Traffic Signs having Retro-Reflective Sheeting

General requirements: The retro-reflective sheeting used on the sign shall consist of the
white or other colored sheeting having a smooth outer surface which has the property of
retro-reflection over its entire surface. It shall be weather-resistant and show colorfastness.
It shall be new and unused and shall show no evidence of cracking, scaling, and pitting,
blistering, edge lifting or curling and shall have negligible shrinkage or expansion. A
certificate of having tested the sheeting as per ASTM D 4956-09, for co-efficient of retro-
reflection, day/night time color luminous property, outdoor weathering, shrinkage,
flexibility, linear removal, adhesion, impact resistance, specular gloss and fungus resistance
and its having passed these tests shall be obtained from a reputed or Government
Laboratory, by the manufacturer of the sheeting.

Retro-reflection Requirements:
The requirements for classes, types, coefficient of retro-reflection, applicability, warranty
periods with minimum retention of coefficient of retro-reflection of retro-reflective sheeting
on different types of highways shall be followed from the Highway Safety Engineering
Manual 2024.

Color:

Unless otherwise specified, the general Color scheme and properties shall be as stipulated
in ASTM 4956–16(b). The Colors shall be durable and uniform in acceptable hue when
viewed in day light or under normal headlights at night and in inclement weather
conditions. The indicative pictorial depiction is given in Table 7.1-3.

Table 7.1-3 Indicative Pictorial Depiction of Colors for Sheeting

.

Adhesives:

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The sheeting shall have either a pressure-sensitive adhesive of the aggressive-tack type
requiring no heat, solvent or other preparation for adhesion to a smooth clean surface, or a
tack free adhesive activated by heat, applied in a heat- vacuum applicator, in a manner
recommended by the sheeting manufacturer. The adhesive shall be protected by an easily
removable liner (removable by peeling without soaking in water or other solvent) and shall
be suitable for the type of material of the base plate used for the sign. The adhesive shall
form a durable bond to smooth, corrosion and weather resistant surface of the base plate
such that it shall not be possible to remove the sheeting from the sign base in one piece by
use of sharp instrument. In case of pressure-sensitive adhesive sheeting, the sheeting shall
be applied in accordance with the manufacturer’s Specifications. Sheeting with adhesives
requiring use of solvents or other preparation for adhesive shall be applied strictly in
accordance with the manufacturer’s instructions.

Messages/borders:
The messages (legends, letters, numerals etc.) and borders shall either be screen-printed or
of cut-outs from durable transparent overlay or cut-out from same type of reflective
sheeting (excluding for black Color) for the cautionary/ mandatory signs. Screen printing
shall be processed and finished with materials and in a manner specified by the sheeting
manufacturer. For the information and other signs, the messages (legends, letters, numerals
etc.) and borders shall be cut-out from durable transparent overlay film or cut out from
same reflective sheeting only. Cut-outs shall be bonded with the sheeting in the manner
specified by the manufacturer. Both the screen-printed areas and cut-out messages sheeting
and cut-out durable transparent overlay film shall be covered under the warranty period of
the sheeting type, issued by the sheeting manufacturer.

Refurbishment:

Where existing signs are specified for refurbishment, the sheeting shall have a semi-rigid
Aluminum backing or materials as per Clause 7.1.2, pre-coated with aggressive-tack type
pressure sensitive adhesive. The adhesive shall be suitable for the type of material used for
the sign and should thoroughly bond with that material.

7.1.3 Sign Fabrication and Installation

Sign Fabrication

The contractor shall submit on site sign drawings with design calculations and details of
sign fabrication process (including materials and equipment to be used) to the Engineer for
approval. Fabrication process of signs shall be such that all sign plates, fittings and fixtures,
etc. can be assembled and erected without requiring modification during installations. The
installation of signs shall not interfere with traffic movement and safety including
foundations for sign posts.

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If desired by the Engineer the contractor will arrange at his own cost practical
demonstration of the proposed fabrication process. The Engineer will accord approval of
the proposed fabrication process in writing if the fabrication process becomes satisfactory
to him. After getting approval of the Engineer in writing only, the contractor shall
immediately start fabrication of all the signs.

Mounting Posts and Foundations

Sign posts shall be adequate in number, size and strength to hold the signs in position
without allowing any displacement or tilting within the defect liability period. Number and
rigidity of sign posts shall be fixed based on the size of the signs. The sign posts shall be
made of steel tube or mild steel sections or as approved by the Engineer. The posts shall be
adequately strong enough to withstand a wind pressure of 150 kg per square meter on sign
face. If necessary additional posts or vertical backside supports must use on sign boards to
ensure strength against wind pressure.

The lengths of posts shall be provided as shown in the drawings. The base plates shall be
not less than 4.5 mm thick and shall have an area not less than five times the outer plan area
of the post or as shown the drawing.

For a wind speed of 50 meters per second across the sign plate, factor of safety for the
integrity and stability of the sign post-foundation shall not be less than 1.5.

Where a post has to be sited close to a wall, either the top of the post shall be angled away
from the wall to provide adequate clearance for the sign or an adequate bracket shall be
provided from the post for this purpose. In either case the post shall be of adequate strength
and rigidity to withstand the additional bending moments and torsion resulting from such
arrangement.

All open-ended posts, or other hollow sections used in construction shall be effectively
capped to prevent the entry of water.

For the case of signs having areas of more than 2.0 square metre, the contractor shall
submit, prior to start of the foundation works of the signs, design calculations to the
Engineer for approval.

Embedment of Sign Posts in Concrete Foundations

The base of posts shall be embedded in concrete foundations. Concrete shall be rammed
round the base of the posts such that the post will be firmly held in position immediately
after completion of placing and compaction of concrete.

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The minimum thickness of concrete embedment and its height shall be as per drawings or
as directed by the Engineer based on specific design consideration taking into account the
ground conditions.

The post shall be carefully positioned and plumbed and struts and stays applied as
necessary to hold it in position during embedment. The concrete shall then be placed under
and round the post in uniform lifts not exceeding 200 mm and each lift thoroughly rammed.
Care shall be taken to avoid contamination of the concrete from the surrounding surface
and soils. Any contaminating material falling into the concrete shall be immediately
removed along with the contaminated concrete itself.

All the concrete embedment for a post shall be provided in one operation and the surface of
the concrete embedment shall be formed to present a neat and tidy appearance and sloped to
shed water away from the post.

Installation of LED solar signs

Sign Fabrication and Installation will be same as to the Sign Fabrication and Installation
section under Traffic Signs having Retro-Reflective Sheeting but note that due to having
solar panel, Retro-Reflective Sheeting is not required.

Major steps of installations of LED solar signs shall be -

a) To embed the T-shaped screw into lead rail, to vise the poling tighter with anchor ear,
to hold the T-shaped screw with the nut, to fix the LED traffic signal, and to connect to
the solar panel.
b) To turn on the power switch ensuring the signal work well: to cover the solar panel
with covering to test the night-condition, then if LED sign is flickering well, put the
covering away and test whetherflickering stops in day-control.
c) To adjust the angle and direction of the solar panel. The tilt angle of the solar panels
should generally be equal to the latitude of the location to optimize solar gain
throughout the year. Bangladesh’s latitude ranges from approximately 20°N to 26°N.
Solar panels in Bangladesh should face south. For locations closer to the southern part
of Bangladesh (around 20°N), set the tilt angle at about 20°. For locations further north
(around 26°N), the tilt angle should be closer to 26°.
d) In city areas, solar products shall not be installed under high building and shade, as the
solar panel will not work, if it shade a part. ideally, solar products shall be installed in
the place where the sun shine strongly.

Care and Cleaning

a) Clean the solar panel every three months to make sure it absorbs the sunshine well.
b) Clean the reflective sheeting and LED snoot to make sure it is clear to be seen.
c) Turn off the power switch in order to protect the battery in long rainy days until the
battery have reserved 80% capacity after three-days charging.

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 7.1.4 Overhead Sign Materials

Aluminum alloy or galvanized steel to be used as truss design supports shall conform to
relevant ASTM/BS standards. These shall be of sections and type as per structural design
requirements as shown on the plans.

After steel trusses have been fabricated and all required holes punched or drilled on both
the horizontal truss units and the vertical and support units, they shall be galvanized in
accordance with this Specification.

Where Aluminum sheets are used for road signs, they shall be of smooth, hard and
corrosion resistant Aluminum alloy conforming to ASTM/BS standards. The thickness of
sheet shall be related to the size of the sign with minimum thickness of sheet as 1.5 mm.

Plates and support sections for sign posts shall conform to section 7.1.2.

The overhead signs shall be of micro prismatic retro reflective sheeting (Type-XI).

Size and Locations of Signs

The size of the signs, size of letters, letter fonts, sign dimensions, layout and their
placement on different types of highways shall be as per instructions represented in RHD
Road Safety Engineering Manual 2024.

In the absence of details or for any missing details in the Contract documents, the signs
shall be provided as directed by the Engineer.

7.1.5 Installation of Overhead Sign

The supporting structure and signs shall be fabricated and erected as per details given in the
plans and at locations directed by the Engineer.

Sign posts, their foundations and sign mountings shall be so constructed as to hold signs in
a proper and permanent position to adequately resist swaying in the wind or displacement
by vandalism.

The work of construction of foundation for sign supports including excavation and backfill,
forms, steel reinforcement, concrete and its placement shall conform to the relevant
Specifications given in this Chapter . The structures shall be erected with the specified
camber and in such a manner as to prevent excessive stresses, injury and defacement.

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 Brackets shall be provided for mounting signs of the type to be supported by the structure.
For better visibility, they shall be adjustable to permit mounting the sign faces at any angle
between a truly vertical position and three degrees from vertical. This angle shall be
obtained by rotating the front lower edge of the sign forward. All brackets shall be of a
length equal to the heights of the signs being supported.

Before erecting support structures, the bottom of each base plate shall be protected with an
approved material which will adequately prevent any harmful reaction between the plate
and the concrete.

The end supports shall be plumbed by the use of leveling nuts and the space between the
foundation and base plate shall be completely filled with an anti-shrink grout.

Anchor bolts for sign supports shall be set to proper locations and elevation with templates
and carefully checked after construction of the sign foundation and before the concrete has
set.

All nuts on aluminium trusses, except those used on the flanges shall be tightened only until
they are snug. This includes the nuts on the anchor bolts. A thread lubricant shall be used
with each aluminium nut.

All nuts on galvanized steel trusses, with the exception of high strength bolt connections,
shall be tightened only to a snug condition.

Field welding shall not be permitted.

After installation of signs is complete, the sign shall be inspected by the Engineer. If
specular reflection is apparent on any sign, its positioning shall be adjusted by the
Contractor to eliminate or minimize this condition.

Warranty for solar panel

a) Solar panel lifetime should be more than 10 years
b) Battery should be High temperature resistant lead-acid maintenance-free
c) battery lifetime should be more than years
d) Other parts warranty may differ from product wise
e) Should be provided according to authority requirements.

7.1.6 Size and Location of Signs

The size of the signs, size of letters, letter fonts, sign dimensions, layout and their
placement on different types of highways shall be as per instructions represented in RHD
Road Safety Engineering Manual 2024.

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In the absence of details or for any missing details in the Contract documents, the signs
shall be provided as directed by the Engineer.

7.1.7 Measurement

The work shall include the supplementary plate, aluminum back plate/primary sign(s),
conforming classes and types of reflective sheeting as per highway categories on sign
faces, posts (also additional axes or vertical supports if required), foundations, bracings,
erection and fixing in position inclusive the costs of necessary steel/aluminum frames,
support structures and fittings & fixtures, etc.. Traffic signs shall be measured in numbers
(standard size traffic signs) and in square meters (bigger signs than standard size).

7.1.8 Payment

Cost of Traffic Signs, measured as above, shall be paid in the following pay items. The
rates of traffic signs shall comprise costs of construction, erection and mounting posts
vertically in cement concrete (1:2:4) foundation, costs of primary sign, supplementary
plate, posts, foundation, backing aluminum plate, sign facing with standard class of
sheeting, fixing signs with post, enamel painting/galvanization on frames and posts, fittings
& fixers, erection of overhead sign post and gantry, cost of all labor, transportation,
loading/unloading, fittings & fixers, auxiliary materials, tools, equipment, excavation and
backfilling and other incidentals and cost of maintenance, repair and replacement, if
required, during defect liability period up to satisfaction of the Engineer.

Payable items shall be:

Pay Description Unit

Item
7.1.1 Standard size Traffic sign 750 mm a. Type I No.
diameter, 750 mm triangle height or b. Type II No.
area up to 0.7 m2 including c. Type III No.
supplementary plate, frame, post and d. Type IV No.
foundation etc. e. Type IX No.
f. Type XI No.
7.1.2 Standard size Traffic sign 900 mm a. Type I No.
diameter, 900 mm triangle height or b. Type II No.
area up to 0.7 m2 including c. Type III No.
supplementary plate, frame, post and d. Type IV No.
foundation etc. e. Type IX No.
f. Type XI No.
7.1.3 Traffic signs and sign boards above g. Type I Sq. m
0.7 m2 including plate, frame, h. Type II Sq. m
fasteners & foundation etc. ` Type III Sq. m
Type IV Sq. m
Type IX Sq. m
Type XI Sq. m

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 7.1.3a Steel for double posts Kg
7.1.3b Steel for one side cantilever post Kg
7.1.3c Steel for gantry Kg

7.1.4 Solar Sign/Flashing light No.

Note: “Type” indicates the selected type of retro-reflective sheeting.

7.2 REMOVAL OF EXISTING TRAFFIC SIGNS

7.2.1. Description

This work shall consist of removal of existing traffic signs. The existing unspecified /
damaged traffic signs shall be removed and disposed of as per direction of the Engineer.

7.2.2. Construction Method

The construction work shall include all necessary excavation to take out the existing sign
and posts with its foundation and disposed off from the site. The back filling of the
excavated hole shall be made with selected soils and be compacted. Unused spoils will be
the property of the contractor.

7.2.3. Measurement

The measurement for removal of the traffic sign shall be in Number.

7.2.4 Payment

The work is measured above shall be paid in the following items. The payment shall be full
compensation of the excavation and taking out the sign post with foundation, filling and
compacting the holes with selected soil, cost of all labor, equipment, transporting the post
with foundation and all other incidentals to complete the work.

Pay item shall be:

Pay Item Description Unit

7.2.1a Removal of existing unspecified / damaged traffic No.
signs on single and double posts
7.2.1b Removal of existing unspecified / damaged traffic No
signs on one side cantilever post
7.2.1c Removal of gantry mounted existing unspecified / No
damaged traffic signs

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 7.3 ROAD MARKINGS

General

The color, width and layout of road markings shall be in accordance with RHD Road Safety
Engineering Manual 2024, and as specified in the drawings or as directed by the Engineer.

Road markings shall be hot applied thermoplastic compound, reflectorized paint or cold
applied reflective paint as specified in the item and the material shall meet the requirements
as specified in these Specifications.

7.3.1 Hot Applied Thermoplastic Road Marking

General

a) The work under this section shall consists of marking traffic stripes using a
thermoplastic compound meeting the requirements specified herein.
b) The thermoplastic compound shall be screeded or extruded on to the pavement surface
in a molten state by suitable machine capable of controlled preparation and laying with
surface application of glass beads at a specific rate. Upon cooling to ambient pavement
temperature, it shall produce an adherent pavement marking of specified thickness and
width and be capable of resisting deformation by traffic.
c) The color of the compound shall be white or yellow other than the parking area as
specified in the drawings or as directed by the Engineer.
d) Where the compound is to be applied to cement concrete pavement, a sealing primer as
recommended by the manufacturer, shall be applied to the pavement in advance of
placing of the stripes to ensure proper bonding of the compound. On new concrete
surface any laitance and/or curing compound shall be removed before the markings are
applied.

Thermoplastic material

The thermoplastic material shall be homogeneously composed of aggregate, pigment, resins

and glass reflectorizing beads.

Requirements

a) Composition: The pigment, beads, and aggregate shall be uniformly dispersed in the
resin. The material shall be free from all skins, dirt and foreign objects and shall
comply with requirements indicated in Table 7.3-1

Table 7.3-1 Proportions of Constituents of Marking Material (Percentage by weight)

Page | 22
 Component White Yellow
Binder 18.0 min. 18.0 min.
Glass Beads 30-40 30-40
Titanium Dioxide 10.0 min. —
Calcium Carbonate and Inert
Fillers 42.0 max. See Note below
Yellow Pigments — See Note below

Note: Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the
manufacturer, provided all other requirements of this Specification are met.

b) Properties : The properties of thermoplastic material, when tested in accordance with

ASTM D36/BS-3262-(Part I), shall be as below:

a. Luminance:
White: Daylight luminance at 45°-65 percent min. as per AASHTO M 249.

Yellow: Daylight luminance at 45°-45 percent min. as per AASHTO M 249.

b. Drying time:
When applied at a temperature specified by the manufacturer and to the required
thickness, the material shall set to bear traffic in not more than 15 minutes.
c. Skid resistance:
Not less than 45 as per BS: 6044.
d. Cracking resistance at low temperature:
The material shall show no cracks on application to concrete blocks.
e. Softening point:
102.5oC + 9.5oC as per ASTM D 36.
f. Yellowness index (for white thermoplastic paint) :
Not more than 0.12 as per AASHTO M 249.

c) Storage life: The material shall meet the requirements of these Specifications for a
period of one year. The thermoplastic material must also melt uniformly with no
evidence of skins or un-melted particles for the one year storage period. Any material
not meeting the above requirements shall be replaced by the manufacturer/
supplier/Contractor.

d) Reflectorization: Shall be achieved by incorporation of beads, the grading and other

properties of the beads shall be as specified in Sub-section 7.3.1.1.

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 e) Marking : Each container of the thermoplastic material shall be clearly and indelibly
marked with the following information:

a. The name, trade mark or other means of identification of manufacturer

b. Batch number

c. Date of manufacture

d. Color (white or yellow)

e. Maximum application temperature and maximum safe heating temperature.

f) Sampling and testing: The thermoplastic material shall be sampled and tested in
accordance with the appropriate ASTM/BS method. The Contractor shall furnish to the
Engineer a copy of certified test reports from the manufacturers of the thermoplastic
material showing results of all tests specified herein and shall certify that the material
meets all requirements of this Specification.

7.3.1.1 Reflectorizing glass beads

General:
This Specification covers two types of glass beads to be used for the production of
reflectorized pavement markings.
Type 1 beads are those which are a constituent of the basis thermoplastic compound vide
Table7.3.2 and Type 2 beads are those which are to be sprayed on the surface.
The glass beads shall be transparent, colorless and free from milkiness, dark particles and
excessive air inclusions.
These shall conform to the requirements spelt out in Clause shown below:

Specific requirements
a. Roundness: The glass beads shall have a minimum of 70 percent true spheres.
b. Refractive index: The glass beads shall have a minimum refractive index of 1.50.
c. Gradation: The glass beads shall meet the gradation requirements for the two types as
given in Table.7.3-2.

Table 7.3-2. Gradation Requirements for Glass Beads

Percent retained
Type 1 Type 2
Sieve size
1.18 mm 0 to 3

850 micron 5 to 20 0 to 5

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 600 –do- — 5 to 20
425 –do- 65 to 95 —
300 -do- — 30 to 75
180 –do- 0-10 10 to 30
Below 180 micron — 0 to 15

Free flowing properties:

The glass beads shall be free of hard lumps and clusters and shall dispense readily under
any conditions suitable for paint striping. They shall have to pass the free flow-test.
Test methods: The specific requirements shall be tested with the following methods:
a. Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass dish.
Place the dish in a 250 mm inside diameter desiccator which is filled within 25 mm of
the top of a desiccator plate with sulphuric acid water solution (specific gravity 1.10).
Cover the desiccator and let it stand for 4 hours at 20°C to 29°C. Remove sample
from desiccator, transfer beads to a pan and inspect for lumps or clusters. Then pour
beads into a clean, dry glass funnel having a 100 mm stem and 6 mm orifice. If
necessary, initiate flow by lightly tapping the funnel. The glass spheres shall be free
of lumps and clusters and shall flow freely through the funnel.
b. The requirements of gradation, roundness and refractive index of glass beads and the
amount of glass beads in the compound shall be tested as per BS: 6088 and BS: 3262
(Part I).
c. The Contractor shall furnish to the Engineer a copy of certified test reports from the
manufacturer of glass beads obtained from a reputed laboratory showing results of all
tests specified herein and shall certify that the material meets all requirements of these
Specifications. However, if so required, these tests may be carried out as directed by
the Engineer.

Application properties of thermoplastic material

The thermoplastic material shall readily get screeded or extruded at temperatures specified
by the manufacturers for respective method of application to produce a line of specified
thickness which shall be continuous and uniform in shape having clear and sharp edges.

The material upon heating to application temperatures shall not exude fumes which are
toxic, obnoxious or injurious to persons or property.

Preparation of Road Surface

The material shall be applied only on a surface, which is clean and dry. It shall not be laid
over loose deleterious materials like mud or similar extraneous matter, or over an old paint
marking or an old paint marking or an old thermoplastic marking which is faulty or
incompatible with the material being applied. New surfaces must be allowed to weather and
compact for at least 72 hours before applying the marking. When using thermoplastic

Page | 25
 material, smooth polished surfaces e.g., smooth concrete, old asphalt surfacing with smooth
polished surfaces stones, and/or where the method of application requires or the Engineer
directs, a tack coat shall be applied to the surface prior to the application. The tack coat
shall be as recommended by the manufacturer of the thermoplastic material and to the
approval of the Engineer. Faulty and old markings shall be removed before applying new
marking. Removal of old marking shall have separate pay items.

Preparation and placing of Road Markings

Preparation

The material shall be melted in accordance with the manufacturer’s instructions in a heater
fitted with a stirrer to give a smooth consistency to the thermoplastic and such that local
overheating shall be avoided. The temperature of the mass shall be within the range
specified by the manufacturer and shall in no account be allowed to exceed the maximum
temperature stated by the manufacturer. The molten material shall be used as expeditiously
as possible and for thermoplastics which have natural resin binders or are otherwise
sensitive to prolonged heating, the material shall not be maintained in a molten condition
for more than 4 hours.

Laying

Markings may be applied by hand-screening, hand propelled machine or by self-propelled

machine as approved by the Engineer. After transfer to the laying apparatus, the material
shall be maintained within the temperature range specified by the manufacturer and stirred
to maintain the right consistency for laying.

Road marking shall be applied in accordance with the manufacture’s recommendation and
BS 3262 as continuous or intermittent lines, arrows, figure and symbol of the types and
colors and dimensions in the Drawings, or as otherwise directed by the Engineer.

Thermoplastic paint with glass beads shall be laid to the thickness.

a. Screed line not less than 3 mm.
b. The method of thickness measurement shall be in accordance with appendix H BS
3262.

The contractor shall state the maximum safe heating temperature, the temperature range of
the apparatus and the method of laying process to be used.

The thermoplastic marking shall be screed or spray applied in cooperating Ballotini and
also has surface application of Ballotini applied evenly at the rate of 500 ± 50 g/m 2. The
minimum thickness specified is exclusive of surface applied solid glass beads. Road
marking materials shall only be applied to surface which is clean and dry. Marking shall be
free from raggedness at their edges and shall be uniform free from streaks. Carriageway
lane and edge lines shall be laid by approved mechanical means to a regular alignment.

Page | 26
Trial area for Road Marking

The contractor shall undertake trial area of a representative sample of the road markings to
demonstrate the suitability of his proposed method and equipment and the competence of
his operatives to the satisfaction of the Engineer.

Tolerance

The completed paint work shall have a neat appearance with sharply defined edges and the
markings shall be within the tolerance specified below:
a. Lines and other markings shall not deviate from specified width by more than 5%.
b. The position of lines, letters, figures, arrows and other markings shall not deviate
from the specified positions by more than 20 mm.
c. The edges longitudinal lines shall not deviate from the true edge by more than 10 mm
in 15 meter.
d. The length of broken lines in the longitudinal direction shall not deviate from the
specified length by more than 100 mm.

After the application of the paint, the road markings shall be protected against damage by
traffic or other causes. The contractor is responsible for the faulty workmanship or
substandard work. The paint which has been splashed or dripped on the surfacing,
structures or other surfaces shall be removed by the Contractor at his own cost.

The contractor shall not proceed with the marking work until the equipment, method of
application, and rate of application, as established by a test section, have been approved by
the Engineer.

The work shall be carried out very carefully to a regular alignment in accordance with the
Drawings. Straight edges and templates shall be used if required by the Engineer.

Re-use of Thermoplastic Material

At the end of the day’s work, as much as possible of the material remaining in the heater
and/or laying apparatus shall be removed. This may be broken and used again, provided
that the maximum heating temperature has not been exceeded and that the total time during
which it is in a molten condition does not exceed the requirements.

Defective Materials or Workmanship

Materials which are defective or have been applied in an unsatisfactory manner or to

incorrect dimensions or in a wrong location shall be removed, the road pavement made
good and the materials replaced, reconstructed and/or properly located, all at the
Contractor’s expense and to the satisfaction of Engineer.

Protection of Traffic

Page | 27
 The Contractor shall protect pedestrian, vehicular and other traffic adjacent to the working
area against damage or disfigurement by construction equipment, tools and materials or by
splatters, splashes and smirches of paint or other construction materials and shall during the
course of the work provide and maintain adequate signs and signals for the warning and
guidance of traffic.

The Contractor shall be fully responsible to ensure protection of new work till its maturity
& till such time, it herdens fully to permit traffic without any damage. It is binding upon the
Contractor to replace such damaged work at his own cost & responsibility.

7.3.2. Cold Applied Reflective Paint

General

The work shall consist of marking traffic stripes using a solvent based cold applied paint,
which shall be applied on the asphalt/cement concrete road surface by brush or by Road
Marker (Spray equipment capable of spraying the paint on the road). Glass beads shall be
subsequently spread pneumatically on to the paint when it is still wet so that the beads will
be firmly held by the paint after drying. Color of the paint shall be white or yellow as
specified in the RHD Road Safety Engineering Manual 2024 or drawings or as directed by
the Engineer.

Material

The cold applied paint material shall be homogeneously composed or binder, pigment,
extenders and other additives as required for the formulation.

Composition:

The pigments and extenders shall be uniformly dispersed in the binder medium dissolved in
organic solvents. The material shall be free from skin, dirt and foreign objects and shall
comply with requirements indicated in Table 7.2-3

Table 7.2-3 Proportions of Constituents or Paint (Percentage by weight)

Component White Yellow

Binder 25.0 min. 18.0 min.

Titanium Dioxide 20.0 min. —

Calcium Carbonate

and Inert Fillers 16.0 min. 29.0 min.

Yellow Pigments —— 14.0 min.

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 Note: Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the
manufacturer, provided all other requirements of this Specification are met.

Properties: Non-Volatile Matter content by weight shall be a minimum of 65 percent as

determined in accordance with test method ASTM D1644. The liquid paint shall have a
density of 1.3 minimum as determined in accordance with test method ASTM D1475.

Appearance: Drying Time of the paint as determined by the test method ASTM D711 shall
be a maximum of 20 minutes at a wet film thickness of 350 micron. The paint shall set to
bear traffic after 40 minutes when the ambient temperature is higher than 24ºC. The paint
shall not be applied when the surface temperature of the road is higher than 40ºC.

Properties of the dried paint film: When tested using a sand abrasion tester as described
in ASTM D968, the quantity of sand required for removal of a 75 micron thick unbeaded
dry film shall be greater than 65 liters.

Elongation: The unbeaded dry film shall pass the test in accordance with ASTM D 1737
and ASTM D 2205.

Water Resistance: The unbeaded dry film shall pass the test in accordance with ASTM
D1647 and ASTM D2205.

Skid resistance: Skid resistance for the beaded dry film shall be not less than 45 as per BS
6044.

Storage life: The material shall meet the specifications for a period of one year. During this
period, the paint material when stored in an airtight container shall not form skin. The
material shall also not form a cake at the bottom of the container.

Minimum thickness of the Unbeaded Cold Applied Paint Coat: The minimum thickness
of the wet unbeaded coat of paint shall not be less than 400 micron, and the minimum
thickness of the dry unbeaded coat of paint shall not be less than 200 microns.

Retro-reflective Properties:

The minimum co-efficient of retro-reflection as per British Standards BS EN 1436: 1998 shall
be as under:

For white paint (Beaded) – 300 mcd/m2/lux on application

–100 mcd/m2/lux after defect liability period
of one year

For yellow paint (Beaded) – 200 mcd/m2/lux on application

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 – 100 mcd/m2/lux after defect liability period
of one year

The minimum luminous co-efficient as per British Standards BS EN 1436:1998 shall be as

under

For white paint (Unbeaded) – 100 mcd/m2/lux on application

For yellow paint (Unbeaded) – 80 mcd/m2/lux on application

Marking

Each container of the cold-paint shall be clearly and indelibly marked with the following
information:

a. The name, trade/patent mark

b. Batch No.

c. Month of Manufacture

d. Color (White or Yellow)

Sampling and testing

The cold applied reflective road marking paint shall be sampled and tested in accordance
with appropriate ASTM/BS test methods.

The contractor shall furnish to the Engineer a copy of certified test methods from the
manufacturer of cold applied reflective road marking paint showing the results of:

a) No pick up time as per ASTM D 711.

b) Resistance to wear as per ASTM D4060 or as per ASTM D968 from

approved laboratories.

c) Material safety data sheet shall be obtained from the manufacturer and
kept with the paint materials.

Reflecting glass beads

General: Reflection is achieved by pneumatically spreading glass beads on to the paint

when it is still wet. The beads will be firmly held by the paint after drying.

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 The glass beads shall be transparent, colorless and free from milkiness, dark particles and
excessive air inclusions. These shall conform to the requirements spelt out below.

Specific requirements

a. Gradation: The glass beads shall meet the gradation requirements as per No. 4 of BS:
6088 as given in Table 7.2-4.
Table 7.2-4 Gradation Requirements for Glass Beads

Sieve Size Percentage Retained

250 micron 0-10

150 micron 80-100

< 150 micron 0-20

b. Roundness: The glass beads shall have a minimum of 70 per cent true Spheres.

c. Refractive Index: The glass beads shall have a minimum refractive Index of 1.50.

d. Free flowing properties: The glass beads shall be free of hard lumps, clusters and shall
dispense readily under any conditions suitable for paint striping. They shall pass the free
flow-test as given below.

Test Methods: The specific requirements shall be tested with the following methods:

a. Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass dish.
Place the dish in a 250 mm inside diameter desiccator which is filled within 25 mm of the
top of a desiccator plate with sulphuric acid water solution (specific gravity 1.10). Cover
the desiccators and let it stand for 4 hours at 20ºC to 29ºC. Remove sample from
desiccator, transfer beads to a pan and inspect for lumps or clusters. Then pour beads into
a clean, dry glass funnel having a 100 mm stern and 6 mm orifice. In case it is required
flow can be initiated by lightly tapping the funnel. The glass spheres shall be free of lumps
and clusters and shall flow freely through the funnel.

b. The requirements of gradation, roundness and refractive index of glass beads and the
amount of glass beads in the compound shall be tested as per BS:6088 and BS:3262 (Part-
1).

c. The Contractor shall furnish to the Engineer a copy of certified test reports from the
manufacturer of glass beads obtained from a reputed laboratory showing results of all tests
specified herein and shall certify that the material meets all requirements of these
Specifications. However, if so required, these tests may be carried out as directed by the
Engineer.

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Application

Marking shall be done by machine. For locations where painting cannot be done by
machine, approved manual methods shall be used with prior approval of the Engineer. The
Contractor shall maintain control over traffic while painting operations are in progress so as
to cause minimum inconvenience to traffic compatible with protecting the workmen.

The cold applied paint shall be applied on the asphalt/cement concrete road surface by
brush or by Road Marker/Spray equipment capable of spraying the paint on the road
surface. Glass beads @ 300gms per square metre shall be subsequently spread
pneumatically on to the paint when it is still wet so that the beads will be firmly held by the
paint after drying.

The pavement temperature shall not be more than 40ºC during application. All surfaces to
be marked shall be thoroughly cleaned of all dust, dirt, grease oils and all other foreign
matter before application of paint.

The material, when formed into traffic stripes, must be readily renewable by placing an
overlay of a new material directly over an old line. Such new material shall so bond itself to
the old line that no splitting or separation takes place.

Cold applied paint shall be applied in intermittent or continues lines of uniform thickness of
at least 200 micron of unbeaded dry film thickness unless specified otherwise. When
arrows or letters are to be provided, cold applied paint may be applied manually. In
addition to the beads recommended for, a further quantity of 300 gms of glass beads per
square meter conforming to the specification shall be sprayed uniformly in to a mono-layer
on to the cold paint line in quick succession of the cold paint spraying operation. The
minimum thickness is exclusive of surface applied glass beads.

The finished line shall be free from ruggedness on sides and ends and be parallel to general
alignment of the carriage way.

The upper surface of the lines shall be of uniform level and free from streaks.

Preparation: The cold applied reflective road marking paint shall be stirred well to form
homogeneously with the thinner recommended/supplied by the manufacturer and put into
the machine with the consistency level recommended by the machine manufacturer by
using proper viscometers. The thinner shall not be added more than that recommended by
the manufacturer to avoid bleeding.

Properties of finished road marking:

a. The stripe shall not be slippery when wet.

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 b. The marking shall not lift from the pavement in freezing weather.

c. After application and proper drying, the stripe shall show no appreciable deformation or
discoloration under traffic and under road temperatures up to 60ºC.

d. The marking shall not deteriorate by contact with sodium chloride, calcium chloride or
oil drippings from traffic.

e. The stripe or marking shall maintain its original dimensions and position. Cold ductility
of the material shall be such as to permit normal movement with the road surface without
chopping or cracking.

7.3.4. Measurement

The painted markings shall be measured in sq. meters of actual area marked (excluding the
gaps, if any).

In respect of markings like directional arrows and lettering, etc., the measurement shall be
by numbers.

7.3.5. Payment
Pay items shall be:

Pay Item Description Unit

7.3.1 Hot thermoplastic road markings Sq. m
7.3.2 Cold thermoplastic road markings Sq. m
7.3.3 Hot thermoplastic road markings for directional No
arrows and lettering
7.3.4 Cold thermoplastic road markings for No
directional arrows and lettering

7.4 Audible and Vibratory Pavement Markings

7.4.1. Description
.
The work shall involve application of audible and vibratory pavement markings in
accordance with the drawings or the direction of the Engineer

7.4.2. Materials

Thermoplastic: Thermoplastic material shall meet the requirements of Clause 7.1.2 of

these Specifications.

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Glass Spheres: Use glass spheres meeting the requirements of Clause 7.1.2. The Engineer
will take random samples of glass spheres in accordance with ASTM D1214 and the
Department’s Sampling, Testing and Reporting Guide schedule.

Equipment
The equipment capable of providing continuous, uniform heating of the striping material to
temperatures exceeding 200ºC, mixing and agitating the material in the reservoir shall be
used to provide a homogenous mixture without segregation. Equipment will maintain the
striping material in a plastic state, in all mixing and conveying parts, including the line
dispensing device until applied. Equipment shall be capable of producing a consistent
pattern of transverse bars positioned at regular and predetermined intervals. It shall meet
the following requirements:

a) capable of traveling at a uniform rate of speed, both uphill and downhill, to produce a
uniform application of striping material and capable of following straight lines and
making normal curves in a true arc.
b) capable of applying glass spheres to the surface of the completed stripe by automatic
sphere dispensers attached to the striping machine such that the glass spheres are
dispensed closely behind the installed line. The glass sphere dispensers should be
equipped with an automatic cut-off control that is synchronized with the cut-off of the
thermoplastic material and applies the glass spheres uniformly on the entire traffic
stripe surface with 50 percent to 60 percent embedment equipped with a special kettle
for uniformly heating and melting the striping material.
c) Equipped with special kettle for uniformly heating and melting the stripping material.
The kettle must be equipped with an automatic temperature control device and
material thermometer for positive temperature control and to prevent overheating or
scorching of the thermoplastic material.
d) Meets the requirements of the fire safety standards.

7.4.3. Application

General: Before applying traffic stripes and markings, any material that would adversely
affect the bond of the traffic stripes shall be removed by a method approved by the
Engineer.

Before applying traffic stripes to any Portland cement surface, a primer, sealer or surface
preparation adhesive of the type recommended by the manufacturer shall be applied.
Longitudinal lines should be offset by at least 50 mm from construction joints of Portland
cement concrete pavement.

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Traffic stripes or markings shall be applied only to dry surface, and when the ambient air
and surface temperature is at least 10ºC and rising for asphalt surfaces and 16ºC and rising
for concrete surface.

Striping shall be applied to the same tolerances in dimensions and in alignment. When
applying traffic stripes and marking over existing markings, ensure that not more than 50
mm on either end and not more than 25 mm on either side of the existing line is visible.

Thickness: Base lines shall be applied having a thickness of 2 mmto2.2 mm exclusive of

the transverse audible bars, when measured above the pavement surface at the edge of the
base line.

As an alternative to the flat base line, a profiled baseline meeting the following dimensions
may be applied. The profiled baseline shall have a minimum height of 4 mm, when
measured above the pavement surface at the edge of the inverted rib profile. The thickness
in the bottom of the profile marking shall be 0.9 mm to 1.3 mm. The individual profiles
shall be located transversely across the full width of the traffic stripe at approximately 25
mm. and on center, with a bottom width between 2.5 mm and 8 mm.

Dimensions of Transverse Audible Bars: The raised transverse bars shall be applied with
a profile such that the leading and trailing edge are sloped at a sufficient angle to create an
audible and vibratory warning,

Transverse bars on shoulder and centerline markings shall have a height of 11 mm to

14mm, including the base line. The height shall be measured above the pavement surface at
the edge of the marking, after application of drop-on glass spheres. The bars shall have an
approximate length of 65 mm. The bars may have a drainage channel on each bar; the
width of each drainage channel will not exceed 6.5 mm at the bottom of the channel. The
longitudinal distance between bars shall be 750 mm.

Retro-reflectivity: White audible and vibratory markings shall attain an initial retro
reflectance of not less than 300 mcd/1x.m2 and yellow audible and vibratory markings shall
attain not less than 250 mcd/1x m2, respectively.

Glass spheres: Apply glass spheres to all markings. The manufacturer shall determine if a
single or double application of glass spheres is used and the recommended drop rates for
each application.

Protection of newly applied audible and vibratory markings

Traffic shall not be allowed onto or vehicles permitted to cross newly applied pavement
markings until they are sufficiently dry. Any portion of the pavement markings damaged by
passing traffic or from any other cause shall be removed and replaced.

Observation period

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Pavement markings shall be subject to a 180 day observation period under normal traffic.
The observation period will begin with the satisfactory completion and acceptance of the
pavement marking work. The pavement markings shall show no signs of failure during the
observation period. The Contractor shall replace, at his own cost, any pavement markings
that do not perform satisfactorily under traffic during the 180 day observation period, shall
be replaced by the Contractor at his own cost.

7.4.4. Measurement

Audible and vibratory pavement markings shall be measured in linear meter. The work
shall cover all work specified in this Section, including, all cleaning and preparing of
surfaces, furnishing of all materials, application, curing and protection of all items,
protection of traffic, furnishing of all tools, machines and equipment, and all incidentals
necessary to complete the work.

7.4.5 Payment
Audible and vibratory pavement markings shall be measured in linear meter. Payments will
be full compensation for all work specified in this Section, including, all cleaning and
preparing of surfaces, furnishing of all materials, application, curing and protection of all
items, protection of traffic, furnishing of all tools, machines and equipment, and all
incidentals necessary to complete the work. Final payment will be withheld until all
deficiencies are corrected.

Pay Item Description Unit

7.4.1 Audible and Vibratory Pavement Markings ln. m

7.5. Raised Pavement Markers (Road Studs)

7.5.1 General

a. Raised Pavement Markers remain highly visible at night and in rainy weather.
b. Micro-prismatic optics provide excellent wet and dry reflectivity
c. Durable construction
d. Rumble effect for added awareness

Benefits
a. Durable, lightweight and impact resistant
b. Provides both wet and dry reflectivity
c. Easy to install and maintain
d. Rumble effect for added awareness
e. Nylon shanks offer excellent anchoring

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 7.5.2 (A) Reflective Pavement Markers (Road Studs)

Raised pavement markers should conform to EN1463 (EU) or equivalent standard. Markers
may be depressible or non-depressible. They may be embedded, surface-bonded with
adhesives or anchored by shear pins. The maximum height above the pavement surface
should be 20mm and up to 25mm for depressible markers.
Raised pavement markers should be unidirectional on dual carriageway roads and
bidirectional on undivided roads. Bidirectional markers may be used to deter wrong-way
driving at critical locations.
A good quality road surface is required for installation. Markers should not be provided
over pedestrian crossings and at stop lines as they could be slippery.

Color and Spacing

Raised pavement markers should be in different colors to indicate different line marking
types. Their spacing is related to speed limit, curve radius and the need to highlight the road
conditions. The casing should have a neutral color such as natural metallic finish, white or
black. They may have the same color of the reflector if used for unidirectional traffic.
The work cover the providing and fixing of reflective pavement marker (RPM) or road
stud, a device which is bonded to or anchored within the road surface, for lane marking and
delineation for night-time visibility. It reflects incident light in directions close to the
direction from which it came.

7.5.2.1 Material

Plastic body of RPM/road stud shall be molded from ASA (Acrylic-Styrene-Acrylonitrile)

or HIPS (Hi-impact Polystyrene) or Acrylonitrile Butadiene Styrene (ABS) or any other
suitable material approved by the Engineer. The markers shall support a load of 13,635 kg
tested in accordance with ASTM D4280.

Reflective panels shall consist of number of lenses containing single or dual prismatic
cubes capable of providing total internal reflection of the light entering the lens face.
Lenses shall be molded of methyl methecrylate conforming to ASTM D 788 or equivalent.

Design

The slope or retro-reflecting surface shall preferably be 35 ± 5° to base and the area of each
retro-reflecting surface shall not be less than 13.0 square centimeter.
Unidirectional and bi-directional studs

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Each reflector or combination of reflectors on each face of the stud shall have a Coefficient
of Luminous Intensity (C.I.L) not less than that given in Table 7.5-1 or Table 7.5-2 as
appropriate.

Omni-directional studs

Each Omni-directional stud shall have a minimum (C.I.L) of not less than 2 mcd/lx.

Table 7.5-1 Minimum C.I.L. Values for Category ‘A’ studs

Entrance angle Observation angle C.I.L. in mcd/lx

White Amber Red
0o U 5o L &R 0.3o 220 110 44

0o U 10oL&R 0.5o 120 60 24

Table 7.5-2 Minimum C.I.L. Values for Category ‘B’ studs

Entrance angle Observation angle C.I.L. in mcd/lx
White Amber Red
0o U 6o L &R 0.3o 20 10 4
0o U 10o L&R 0.5o 15 7.5 3

Note: a) The entrance angle of 0oU corresponds to the normal aspect of the reflectors
when the reflecting road stud is installed in horizontal road surface.
b) The stud incorporating one or more corner cube reflectors shall be included
in category ‘A’. The stud incorporating one or more bi-convex reflectors
shall be included in category ‘B’.

Tests

Co-efficient of luminance intensity can be measured by procedure described in ASTM E

809 “Practice for Measuring Photometric Characteristics” or as recommended in BS: 873-
Part 4: 1973.

Under test conditions, a stud shall not be considered to fail the photometric requirements if
the measured C.I.L. at any one position of measurement is less than the values specified in
Table 7.5-1 or Table 7.5-2 provided that

a. the value is not less than 80 percent of the specified minimum, and

Page | 38
 b. the average of the left and right measurements for the specific angle is greater than the
specified minimum.

7.5.2. (B) Solar Powered Road Markers (Solar Studs)

7.5.2.1 Material

The solar studs shall be made of Aluminum alloy and poly carbonate material which shall
be absolutely weather resistance and strong enough to support a load of 13,635 kg tested in
accordance with ASTM D4280. Its color may be white, red, yellow, green or blue or
combination as directed by the Engineer. It should be water resistant against water ingress.

The dimensions of solar studs shall not be less than 100 mm x 100 mm x 10 mm. It shall
have super bright LEDs so as to provide long visibility from a distance of more than 800 m.
Its flashing rate shall not be less than 1 Hz. It should be able to give the prescribed
performance in the temperature range of -40ºC to +55ºC. Its life shall be not less than 3
years.

Fixing of Reflective Markers Requirements

The enveloping profile of the head of the stud shall be smooth and the studs shall not
present any sharp edges to traffic. The reflecting portions of the studs shall be free from
crevices or ledges where dirt might accumulate. Marker height shall not be less than 10mm
and shall not exceed 20 mm. and its width shall not exceed 130 mm. The base of the marker
shall be flat within 1.3 mm. If the bottom of the marker is configured, the outermost faces
of the configurations shall not deviate more than 1.3 mm from a flat surface. All road studs
shall be legibly marked with the name, trade mark or other means of identification of the
manufacturer.

7.5.3. Placement

The reflective marker shall be fixed to the road surface using the adhesives and the
procedure recommended by the manufacturer. No nails shall be used to affix the marker so
that they do not pose safety hazard on the roads. Regardless of the type of adhesive used,
the markers shall not be fixed if the pavement is not surface dry and on new asphalt
concrete surfacing until the surfacing has been opened to traffic for a period of not less than
14 hours. The portions of the highway surface, to which the marker is to be bonded by the
adhesive, shall be free of dirt, curing compound, grease, oil, moisture, loose or unsound
layers, paint and any other material which would adversely affect the bond of the adhesive.
The adhesive shall be placed uniformly on the cleaned pavement surface or on the bottom
of the of the marker in a quantity sufficient to result in complete coverage of the area of
contract of the marker with no voids present and with a slight excess after the marker has
been lightly pressed in place. For epoxy installations, excess adhesive around the edge of

Page | 39
the marker, excess adhesive on the pavement and adhesive on the exposed surfaces of the
markers shall be immediately removed.

7.5.4. Warranty and durability

The Contractor shall submit a two year warranty for satisfactory field performance
including stipulated retro-reflectance of the reflecting panel, to the Engineer. In addition, a
two year warranty for satisfactory infield performance of the finished road marker shall
also be given by the Contractor who carries out the work of fixing of reflective road
markers. In case the markers are displaced, damaged, get worn out or lose their reflectivity
compared to stipulated standards, the Contractor would be required to replace all such
markers within 15 days of the intimation from the Engineer, at his own cost.

7.5.5. Measurement

The measurement of reflective road markers shall be in numbers of different types of

markers supplied and fixed.

7.5.6 Payment

The contract unit rate for reflective road markers shall be payment in full compensation for
furnishing all labor, material, tools, equipment including incidental costs necessary for
carrying out the work at site conforming to the specification complete as per approved
drawings or as directed by the Engineer.

Pay Item Description Unit

7.5.1 Raised Pavement Markers Nos
7.5.2 Solar Powered Road Markers Nos

7.6 Removal of old Thermoplastic Road Markings

7.6.1. Description

This work shall consist of removal of existing old road markings from the road surface
before application of new thermoplastic road marking. Removal shall be done by the
approved method to a satisfaction of the Engineer. Removal of old thermoplastic road
markings shall be done only outside of the rescaled junction area to ensure correct guidance
to road users’ or to a satisfaction of the Engineer.

7.6.2. Construction Method

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 Old road marking shall be removed from the road surface with a milling method by milling
existing lane marking, arrow etc. away from the road surface to the depth maximum 1 mm.
The Engineer may approve other removal method after contractor’s trial section.
Width of the milled area shall not exceed from the width of the removed marking more than
1 cm both side of the removed marking.
Inside the junction area old thermoplastic road markings shall be covered with premix
bituminous resealing layer while leveling the existing junction.

7.6.3 Measurement

The measurement of removal of existing old thermoplastic marking shall be in square meter.

7.6.4 Payment

The payment shall be full compensation of all labor, equipment, material, tools, machinery
and all other incidental necessary to complete the work to a satisfaction of the Engineer.

Pay items shall be:

Pay Item Description Unit

7.6.1 Removal of old thermoplastic road markings Sq. m

7.7 Traffic Control and Safety Devices in Construction Zone

7.7.1. General

Traffic Control Devices in the construction zone comprise signs, delineators, traffic cones,
drums, barricades, longitudinal barriers, warning tapes, flagmen, reflective jackets,
headgears.

Signs: Traffic signs shall be in accordance with BRTA Traffic sign manual or as directed
by the Engineer. It’s material and other requirements shall be in accordance with Clause 7.1
of these Specifications.

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Delineators: Delineators in constructions zone are in form of vertical posts, cones, traffic
cylinders, tapes, drums etc. Vertical posts shall be in accordance with the provisions
contained in BRTA Traffic sign manual or as directed by the Engineer.

7.7.2 Traffic Cones

7.7.2.1 General

Traffic cones may be of height 500 mm, 750 mm and 1000 mm, and 300 to 500 mm in
diameter or in a square shape. They shall be of brilliant red/orange/yellow, ultraviolet
stabilized color for maximum visibility and fade resistance under all weather conditions and
ambient working temperature of -30ºC to +140ºC. The material shall be Linear Low
Density Polyethylene (LLDP), plastic or rubber so that there is no damage to the vehicle
when they are stuck. Cone and base are to be of one continuous layer to prevent tearing and
base separation they should be non-crushable/flexible/tear resistant and UV stabilized and
made from non-fading colors. They should return to their original shape in just 20 seconds
after being crushed. The bases of cones shall be loaded with ballast (but they should not
present a hazard if the cones are inadvertently struck) or anchored to check their being
blown away. Their base should be designed for easy stacking without sticking. They may
have retro reflective white band and mounted flashing warning light for enhanced night
visibility. All traffic cones shall conform to BS: 873 (Part 8) 1985 Catalogue A and the
provisional European Standard EN 13422.
7.7.2.2 Measurement

The measurement shall be for each piece.

7.7.2.3 Payment

Pay items shall be:

Pay Item No. Description Unit of

Measurement
7.7.2.1 Traffic cones Nos

7.7.3. Drums

7.7.3.1. General

The drums shall be of size 800 mm to 1000 mm in height and 300 mm in diameter. They
shall be constructed of lightweight, flexible, and deformable materials of LLDP or plastic
so that no damage is caused to the vehicle when stuck. Steel drums shall not be used. They
may be of bright red, yellow or white colors. They should be portable enough to be shifted
from place to place within a temporary traffic control project to accommodate changing
conditions but would remain in place for a prolonged period. The markings on drums shall
be horizontal, circumferential, alternative orange and white retro reflective stripes 100 to
150 mm wide. Each drum shall have a minimum of two orange and two white stripes. Any

Page | 42
non-retro reflective spaces between the horizontal orange and white stripes shall not exceed
50 mm wide. Drums shall have closed tops that will not allow collection of roadwork or
other debris. Drums should not be filled with sand, water, or any material to an extent that
would make them hazardous to motorists, pedestrians, or workers. When they are used in
regions susceptible to freezing, they should have drainage holes in the bottom so that water
will not accumulate and freeze, causing a hazard if struck by a motorist. Ballast shall not be
placed on top of drum.

7.7.3.2. Measurement

The measurement shall be for each piece

7.7.3.3. Payment
The payment for each piece, for providing and maintenance at site shall be as per the
direction of the Engineer.

Pay items shall be:

Pay Item Description Unit

7.7.3.1 Drums Nos

7.7.4 Barricades

7.7.4.1. General

The barricades may be portable or permanent. Barricades may be of wooden, metal or other
suitable material panels. They shall be stable under adverse weather conditions and appear
significant but not to cause damage to the vehicle if they are stuck. They can be classified
in 3 types, namely Type-I, Type-II and Type-III. Type-I and Type-II are portable and Type-
III permanent. Because of their vulnerable position and the hazard they could create, they
should be constructed of lightweight materials and should have no rigid stay bracing for A-
frame designs.

7.7.4.2. Material

7.7.4.2.1. Type-I and Type II barricade: The rail/panel length shall be 2000 mm to 2500
mm for Type I and 1000 mm to 1200 mm for Type II barricade. The width of rails shall be
200 mm to 300 mm. The rails shall be painted in alternate yellow and white stripes of 150
mm width each, sloping away at an angle of 45° in the direction of traffic. The support shall
be on an “A-Configuration” or otherwise at the top to permit convenient folding and
staking for transportation. Their stability can be improved by ballasting. On highways or in
other situations where barricades may be susceptible to overturning in the wind, sandbags
should be used for ballasting. Sandbags may be placed on lower parts of the frame or stays

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 to provide the required ballast but shall not be placed on top of any striped rail. Barricades
shall not be ballasted by heavy objects such as rocks or chunks of concrete.

7.7.4.2.2. Type-III barricade: Type-III is the permanent type and may be made of wood,
metal or other suitable material. The typical configuration shall include 3 or more
panels/rails, of minimum 1000 mm length (maximum length as per site requirement) and
300 mm width each, painted with alternate yellow and white stripe of 150 mm width
flopping at an angle of 45°. They shall be supported and secured on 2 or more vertical
supports of same material. On highways or in other situations where barricades may be
susceptible to overturning in the wind, sandbags should be used for ballasting. Sandbags
may be placed on lower parts of the frame or stays to provide the required ballast but shall
not be placed on top of any striped rail. Barricades shall not be ballasted by heavy objects
such as rocks or chunks of concrete.

7.7.4.3. Application

Type I or Type II barricades are to be used in situations where traffic is maintained through
the temporary traffic control zone. They may be used singly or in groups to mark a specific
condition, or they may be used in a series for channelizing traffic. Type I barricades
normally would be used on conventional roads or urban streets and arterials. Type II
barricades have more retro reflective area and are intended for use on highways and
expressways or other high-speed roadways.

Type III barricades be used for road closure and may extend completely across a roadway
or from kerb to kerb. Where provision is made for access of authorized equipment and
vehicles, the responsibility should be assigned to a person to ensure proper closure at the
end of each work day.

When a highway is legally closed but access must still be allowed for local traffic, the Type
III barricade should not be extended completely across a roadway. A sign with the
appropriate legend concerning permissible use by local traffic shall be mounted.

Signs may be erected on barricades, particularly those of the fixed type, that offer a most
advantageous facility for this purpose. The ROAD CLOSED and DETOUR or ARROW
signs, and the large arrow warning signs, for example, can be mounted effectively on or
above the barricade that closes the roadway.

Longitudinal Safety Barriers

Longitudinal channelizing barricades are light weight channelizing devices that can be used
singly as Type-I, II or III barricades, or connected so that they are highly visible and have
good target value. They should be interlocked to delineate or channelize the traffic flow and
mark the work zone. The inter-locking barricade wall should not have gaps that allow
pedestrians or vehicles to stray from the channelizing path. Longitudinal channels

Page | 44
barricades are located adjacent to traffic and therefore, are subject to impact by errant
vehicles. Because of their vulnerable positions, longitudinal channelizing barricades should
be constructed of lightweight materials and be crash worthy. They shall be of high density
polyethylene, non-fading, and high impact and U.V. resistant. They shall be of orange,
white or custom colors. Their size should be minimum 1500 mm in length, 1000mmin
height, and 600 mm in width. They could be filled with water through an aperture on the
top and emptied by removing a plug at the base.

On roads with low speed traffic, GI sheets material could be considered for longitudinal
barricades. They shall be firmly secured to vertical support system with no sharp edges to
pose any hazard when struck. Their configuration shall be as per the drawing or as directed
by the Engineer.

7.7.4.4 Measurement
Measurement shall be per running meter of longitudinal barrier

7.7.4.5. Payment

Payment for the running meter of complete job of providing, installation and maintenance
at site as per the drawing/direction of the Engineer.

Pay items shall be:

Pay Item Description Unit

7.7.4.1 Barricades(Type I/II) ln.m
7.7.4.2 Barricades(Type III) ln. m

7.7.5. Flagman and STOP/GO Portable Boards

7.7.5.1. Materials
The flagmen or flaggers shall be deployed where:
a. Workers or equipment intermittently block an unprotected traffic lane,
b. One lane is used for two directions of traffic,
c. It is considered necessary to guide, warn or control traffic is considered necessary.

The flagman should be alert, intelligent and capable to effectively perform the assigned
duties. Flagman shall be provided with hand signaling devices such as flags and sign
paddles. Flagmen must be provided with and must wear warning garments, safety headgear,
footwear and gloves for their protection and for conspicuity, while flagging. Warning

Page | 45
garments worn at night must be of reflective material. Flags for signaling shall be minimum
450 mm by 450 mm and made of good red cloth and securely fastened to a staff of
approximately of 1 m. in length.

7.7.5.2. Application
STOP/GO (Thamoon and Chaloon) Portable Sign paddles should be at least 600 mm
Diameter provided with a rigid handle of minimum 1.5 m. The background Color of STOP
should be red and its shape shall be octagonal conforming to BRTA Traffic Sign manual.
The word STOP would be in white color. Background of SLOW sign should be green with
black letters.

7.7.5.3. Measurement

The measurement shall be for each piece

7.7.5.4. Payment
Pay items shall be:

Pay Item No. Description Unit of

Measurement
7.7..5.1 STOP/GO Portable Boards Nos

7.7.6. Reflective Clothing

7.7.6.1. Materials
In the work zones and construction sites, all the workers, supervisors and inspecting
officers shall wear high visibility fluorescent clothing with retro reflective material, so that
their presence is conspicuous from a distance of 300 m. Clothing may be in form of vests,
T-shirts, jackets, pants and raincoats etc., depending upon weather conditions and ease of
usage. They shall be of bright colors of fluorescent red-orange or fluorescent yellow-green.

The reflective clothing’s shall have reflective bands of width appropriate for the garments
viz. vests, T-shirts, jackets, pants and raincoats. It shall have 360º visibility with at least one
retro reflective band encircling the torso, There shall be appropriate separation distances of
vertical and horizontal bands placed on torso, sleeves and trouser areas. The garment shall
be free of roughness and sharp edges so as not to cause excessive irritation and the wearer
should get the best possible degree of comfort and protection.

7.7.6.2. Application

The reflective clothing shall meet the requirements of standards given in EN 471:2003The
material shall be tested for color and luminance, colorfastness with cracking, perspiration,
laundering and UV light exposure. The material shall meet the requirements of brightness

Page | 46
 after rainfall performance, temperature variation, abrasion resistance, flexing, cold folding
and variation in temperature.

7.7.6.3. Measurement

Measurement shall be for the unite piece of clothing

7.7.6.4. Payment
Payment for providing and maintaining at site shall be as per direction of the Engineer.

Pay items shall be:

Pay Item No. Description Unit of Measurement

7.7.6.1 Reflective clothing Nos

Personal Protection Equipment for Workers

All the workers, exposed to moving roadway traffic or equipment in road construction
zones shall wear Reflective Material high-visibility safety vest 105 g/sqm polyester 100%
(such as Flu Red/Orange or Flu Yellow /Lime 3M2925 or equivalent) and other similar
apparel, helmet-headgear, steel-toe-boots, gloves, masks (such as 3M N95 and 3M 9913V
or equivalent), fall-protection harness (half and full) and other protective gears for their
protection.

The safety apparel shall be in accordance with Clause related to reflective clothing. The
safety headgear or protective helmet shall protect the wearer against falling objects and
possible serious injury. It shall address requirements of shock absorption, resistance to
penetration, flame resistance, chin strap anchorages, comfortable wearing and shall meet
the requirements of EN 397.

The safety shoes or boots shall provide personal protection from any possible hazard posed
by the activity being done and provide comfortable wearing without giving any hindrance
in the expected tasks. The work gloves shall provide protection against any personal injury
that could be caused by the activities to be performed and comfort in wearing without
giving any hindrance in the expected tasks. If the worker is to be exposed to dust in the
work zone, he shall have respiratory protection by dust mask. Depending upon the task,
workers engaged in welding operations shall have eye protection through passive welding
sheet meeting the requirements of EN 175 or auto darkening sheet meeting the requirement
of EN 379 / EN 169.

7.8. Conspicuity tape

7.8.1. General

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 Conspicuity tape is basically highly reflective, micro prismatic sheeting with pressure
sensitive adhesive for easy application to trucks, trailers and large vehicles to enhance
visibility and detection distance.

7.8.2. Materials

It is designed to clearly outline the side and rear perimeter of curtain and rigid sided trucks
and enhance visibility and detection to up to 1,000m at night. Marking vehicles will
provide enhanced safety for drivers and help to reduce accidents and save lives. This
product is suitable for Buses, Caravans, emergency vehicles, Tankers, Trailers, Trucks and
Inspection vehicle. It should have superior reflectivity, excellent durability and ease of
application.

7.8.3. Application

Requirement
Compliant with Regulation ECE104
Adhesive Type Pressure-sensitive, Solvent free
Applications Buses, Caravans, Emergency & vehicles, Tankers, Trailers, Trucks
Construction Flexible, Micro prismatic
Length 50 m
Performance Level Diamond Grade
Width 50 mm

Color of marking material

Rear marking red or yellow

Side marking yellow or white

Constructions
Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge.

7.8.4. Measurement
Measurement shall be per running meter of longitudinal barrier

7.8.5. Payment

Pay items shall be:

Pay Item Description Unit

7.8.1 Conspicuity tape Ln M

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 7.9 Delineators
7.9.1 General

Delineators generally consist of reflectors or retro-reflective strips attached to ground-

mounted posts or reflectors mounted directly onto safety barriers. Delineators are
particularly beneficial for roads without road lighting and where the performance of road
markings is unsatisfactory.

The work covers supplying and fixing roadway indicators, hazard markers and object
markers. Roadway indicators shall be properly installed to indicate the horizontal alignment
and vertical profile of the roadway so as to outline the vehicle path for safe driving.

7.9.1.1. Categories

Alignment Delineator Highlighting road alignment and curves

Access Delineator Demarcating accesses and intersections
Lane Delineator Separating opposing traffic or slow traffic
Hazard Marker Highlighting roadside hazards which cannot be
reasonably removed
Diverge Gore Delineator Highlighting diverge gores on high speed roads

Delineators are normally provided as vertical posts with an overall height shown in BRTA
Traffic sign manual. They should consist of reflectors and are clearly visible at night time.
The reflector should be mounted more than 0.7m above the road surface to minimize
masking by plants. The appearance and color of different categories of delineators should
be distinctly different and consistently applied according to their functions.

7.9.1.1.1. Alignment Delineator

Alignment delineators should be used on road sections with increased risks of an errant
vehicle leaving the road such as curves, zones of narrowing or lane reduction and merging
or diverging areas. The recommended color is white with a black color area surrounding the
reflector. Table 7.9-1 provides a guide to the spacing of alignment delineators.

Table 7.9-1 Spacing of Alignment Delineators (ref: BRTA Traffic sign manual)

Spacing (m)
Curve Radius (m) Outside of curves Inside of curves*
< 100 6 12
100- 199 10 20
200- 299 15 30

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 300- 399 20 40
400- 599 30 60
600- 799 40 60
1200- 1199 60 60
1200- 2000 90 ** 90 **
> 2000 and Straight 150 # 150 #
* Position to match delineator on opposite side
** Adopt 60m in areas susceptible to fog
# Adopt 75m in areas susceptible to fog and 90m where low beam light is
used, adopt 90m where wire rope safety barriers are used

7.9.1.1.2. Access Delineator

Access delineators are provided at direct frontage accesses and intersections to highlight
their presence and position. They are generally not required for major intersections where
the layout is clearly defined by signs and markings.
At least one access delineators is required on each side of an access. For larger
intersections, it is desirable to install two or more units to reveal the layout. A possible
color scheme is white with a red color retro reflective strip wrapping around the post.

7.9.1.1.3. Hazard Markers

Hazard markers preferably have a rectangular sign face in stripes. Hazard markers are used
to alert drivers of roadside hazards with the risk of frontal collisions. They should generally
be positioned 0.5m to 1m ahead of hazard and may be preceded by alignment delineators
guiding approach traffic to avoid the hazard.
Additionally, it could be desirable to apply reflective paints in strips of yellow and black
color directly onto the hazard e.g. ending of bridge parapet or drainage structures. If the
hazard presents relatively low risk, painting alone may substitute the hazard marker.

7.9.1.1.4. Lane delineators

Lane delineators are circular flexible posts installed along centerlines of undivided roads.
They are also appropriate for installation over narrow traffic islands separating opposing
traffic lanes, slow vehicle lanes or parking areas. Lane delineator may be used along both
straight sections and curves to deter overtaking in addition to solid line markings.
The main purposes of lane delineators are
a. Deterrence of corner cutting along curves
b. Deterrence of overtaking on straight sections or curves
c. Prevention of wrong-way traffic
d. Highlighting the presence of traffic islands

7.9.1.1.5. Diverge Gore Delineator

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 Diverge gores are generally delineated by chevron road markings and raised pavement
markers without the need for delineators. However, it could be desirable to provide
delineators on the approach to serve as an additional buffer zones for diverge gores which:
a. are located on curves
b. have poor visibility
c. have a high risk of collisions
Delineators for diverge gores may be of a distinct color or based on lane delineators.

7.9.2. Material
The design, materials to be used and the location of the road delineators (roadway
indicators, hazard markers and object markers) shall conform to BRTA Traffic sign
Manual, and to relevant drawings or as otherwise directed by the Engineer.

7.9.2.1 Post
7.9.2.1.1 Flexible guide post
A guide post which deflects when impacted by a vehicle and then returns to a vertical
position, without maintenance intervention.
Furnish delineator units consisting of an approximately 3 inch (75 mm) circular
hermetically sealed, acrylic plastic prismatic, reflex reflector, housed in embossed
aluminium, and provided with a single grommet mounting hole or provide a flexible plastic
post from the department's approved products list, complete with a 3 inch (75 mm) x 9 inch
(225 mm) reflective sheet conforming to 7.1.2.5.
Obtain the engineer's approval for the type and quality of acrylic plastic reflex reflectors
used.

7.9.2.1.2 Rigid guide post

Rigid guide post is a type of guide post which either fractures or remains intact and straight,
but not vertical, when impacted by a vehicle.

7.9.2.1.3 Concrete Posts

The precast concrete posts shall be cylindrical shaped (150 mm dia and 1.5m long) and
shall be excavated to the levels indicated on the Drawing or other parts of the Contract
Documents.

7.9.2.1.4 Steel Delineator Posts

Provide a flanged channel section post weighing 1.67 kg/m per linear foot or more before
zinc coating, and made of steel with the following properties:

Minimum tensile strength 50 ksi (345 MPa)

Minimum tensile yield strength 36 ksi (250 MPa)
Minimum Elongation 5.0 percent in 2 inches (50 mm)

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 Provide posts the length, and with mounting holes the size and spacing the plans show.
Ensure the posts are symmetrical, well rolled, and free from defects that impair their
strength or appearance.
Hot-dip zinc coating of the posts after completing all forming, cutting, punching or drilling.
Perform zinc coating according to AASHTO M 111.

7.9.2.2 Reflector

The delineators shall be retro reflectorized as shown on the drawings or as directed by the
Engineer. The reflectors on the delineators shall be of retro reflective sheeting with
encapsulated lens and with the visibility of 300 m under clear weather conditions, when
illuminated by the upper beam of the car headlights.

Reflectors should enable a delineator to be clearly visible 300m ahead when illuminated by
a high beam light in clear conditions. They should have a size equivalent to at least 75mm
or 100mm diameter and are mounted at heights in the order of 800mm to 1200mm
irrespective of the mounting method.

Characteristics:

a. Having a clear plastic base

b. Seven square inches (4500 mm2) of reflective area, called the lens
c. A heat sealable plastic or plastic-coated metallic foil back, fused to the lens under heat
and pressure around its perimeter and the central mounting hole to form a unit sealed
against dust, water, and vapor
d. For reflector color, use the color as per direction of Engineer in charge.

Provide a lens with a smooth front surface; free from protrusions or indentations, other than
a central mounting hole and identification, with a prismatic pattern on the rear surface that
result in total internal reflection of light. Ensure that the manufacturer's trademark is
molded legibly in the lens face.

7.9.2.2.1. Barrier mounted Reflectors (Double Sided)

Reflectors consisting of top retro reflective unit exposed area of 125 cm2 white color &
bottom retro reflective unit exposed area of 35 cm2 red color wide angle cube corner micro
prismatic nonmetallic retro reflective sheeting conforming to the retro reflection values as
per ASTM D 4956-16b Type XI table specification. The tubular delineator shall have a core
and shell construction, shell shall be made of tough, high impact resistant, injection-
molded, thermoplastic outer body & the inner core shall consist of powder coated or
painted Mild steel of minimum thickness 1.0mm on which retro reflective sheeting is
pasted on one side such that at least 60% of exposed area is a flat surface & core-shell
structure shall be of height not less than 800 mm above the ground and width not less than
80 mm. The metallic core of the delineator shall extend 300mm beyond the shell length
from bottom for installing in the ground.

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 7.9.2.2.2 Delineator Brackets
Provide either structural steel or aluminum brackets (conform to ASTM B 221), for
mounting delineators on concrete barriers or other structures.

7.9.2.2.3. AFP (Aluminum flexible prismatic) Sheeting

AFP Sheeting flexible prismatic sheeting shall be of 0.9 m width and laminated at the back
with a 50-micron thick Aluminum (Al) foil with pressure sensitive adhesive and liner,
further this flexible prismatic sheeting shall have screen printed arrow /slant line pattern in
black Color on top in continuous roll format. Neither AFP sheeting nor the flexible
prismatic sheeting used shall crack when slowly bent in second time around a 1/8th inch
mandrel after being conditioned for 24 hrs. at 0 degrees and tested as per section S2.2.2 of
ASTM, D 4956-16b. The AFP sheeting with the liner removed shall be applied with a
neoprene contact adhesive with polychloroprene as base viscosity of 200-450 cps and solid
content of 20-30 % once applied the edges of the product shall be extremely resistant to
peel off.

7.9.3 Construction and Installation

7.9.3.1. Erecting Delineator Posts and Brackets

a. Erect steel or flexible plastic posts to support delineators or small signs
b. Provide zinc coated steel or aluminum angles or brackets to support delineators
mounted on concrete barriers or other structures
c. Set the posts and steel or aluminum brackets for the delineators at the locations and
offsets the plans show or the engineer directs
d. Erect the posts to a true vertical position by driving with equipment that does not
damage the post. The contractor shall remove and replace all posts bent or damaged
otherwise by own operations at no expense to the department. Drive the posts into the
ground according to plan details, unless specified otherwise
e. Mount delineator brackets with stainless steel bolts, anchors, and gaskets if required,
according to plan details
f. The curved side of the post is to face in the direction of travel on the roadway

7.9.3.2. Installing Delineators

a. Erect reflector units on steel or wood marker posts, or on structures

b. Assemble the delineators in the field, for mounting according to the plans
requirements, as single delineators or double delineators
c. Mount the center of the top delineator unit at the height the plans show
d. Attach each delineator unit securely to the supporting steel post. If placing on
structures, mount according to plan details
e. If required, attach delineator units to marker posts with aluminum screw-nails
according to plan details

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 f. Notch the marker post to accept the delineator unit or units, and drill or saw the base
of the post if required, all as the plans show.

7.9.3.3. Temporary Delineators

Provide, install, and remove temporary delineators and temporary delineator posts.

7.9.4. Warranty

Pre-qualification warranty of at least 2 years for field performance shall be submitted by the
Contractor for technical qualification in the tender. Two Years Warranty Certificate for
Delineator for the quantity installed and a certified copy of test reports from an independent
test laboratory conforming to mechanical properties shall be obtained from the
Manufacturer by the Contractor and submitted to the Engineer-In-Charge.

7.9.5. Measurement

The measurement shall be for each piece of Post

7.9.6. Payment

Delineator Posts and Delineator Brackets

(a) The department will measure Delineator Posts Steel, Concrete, Delineator Posts
Flexible, and Delineator Brackets by each individual post or bracket acceptably completed.

Delineators and Temporary Delineators

(a) The department will measure Delineators and Temporary Delineators by each individual
reflector acceptably completed.

The department will pay for measured quantities at the contract unit price under the
following bid items:

Pay Item No. Description Unit

7.9.1 Delineator Posts Steel Nos
7.9.2 Delineator Posts Flexible Nos
7.9.3 Concrete posts Nos

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 7.10 Rumble Strip Median
7.10.1. Description

The item shall consist of providing rumble strip median to carriageway for separating
traffic flow. Rumble strip median shall be constructed by implementing longitudinal strips
both side of the road’s middle line and connect strips with transverse diagonal to each other
as shown in the drawings or instructed by the Engineer.

7.10.2. Materials

Liquid asphalt for tack coat shall be rapid-curing type cutback grades RC-2 or RC-4 or as
directed by the Engineer, and shall conform to the requirements of sub-clause 3.7.3 of this
specification. Bituminous tack coat shall be applied on the surfaces where rumble strips /
raised pedestrian crossing will be constructed.
The bituminous mixture for rumble Strips Median shall conform to the requirements for
clause 4.5 premix bituminous carpeting of this specification.
3% of cement shall be used in bituminous mixture as filler to improve the strength of
completed Rumble Strips Median.
Steel forms shall be used for construction of Rumble Strips Median. Forms shall be placed
on the road surface tightly so that shape of the works is obtained as per drawings.

7.10.3. Construction Method

7.10.3.1. Surface preparation

Contractor shall mark the middle line of the road section to ensure correct alignment of
rumble strip median and measure and mark the location of longitudinal strips as shown in
the drawings.

Immediately prior to the application of the tack coat, the bituminous surface shall be
cleaned free of all dirt, dust, and other foreign substances which, would prevent proper
bonding of the tack coat.
7.10.3.2. Application of Tack Coat

Immediately after the surface has been cleaned and approved by the Engineer, the tack coat
shall be applied to the area of construction where premix bituminous material shall be
applied on the existing bituminous surface. The tack coat shall be sprayed with approved
mechanical or hand-spraying equipment. The rate of application shall be as shown on the
plans or as ordered by the Engineer, but in no case shall exceed one-quarter (1/4) liter per
square meter. The tack coat shall be applied uniformly and to the satisfaction of the
Engineer.

Page | 55
 7.10.3.3. Placing of Bituminous Mixture

Contractor shall prepare steel forms with the correct dimension for the construction of
rumble strip median as shown in the drawing. As soon as the tack coat has settled, hot
bituminous mixture (according to the sub-clause 4.5) shall be placed and consolidated in to
the form by approved working method. After the mixture is settled, the form shall be
removed.
To complete rumble strip median rain transverse diagonal strips to 45odegree angle after
every 2.0 meter shall be constructed to connect longitudinal strips together as per drawings.
During the construction of rumble strip median rain water gap in transverse direction must
be included in every 2.0m interval with 50 mm gap width. Dimension of rain water gap
must follow the contract drawing or as per direction of Engineer.

7.10.3.4. Compactions of Bituminous Mixture

Compaction shall be done with approved method by the Engineer to ensure correct
alignment, shape and height of the longitudinal strips as shown in the drawing. Height and
alignment must be rechecked after the compaction. Before thermoplastic marking is
applied, all strips must be cleaned from dirt and dust to ensure bonding of marking.

7.10.4 Measurement

Rumble strips median constructed by premix bituminous carpeting materials with seal coat
at the same time will be measured in linear meter actually constructed and accepted in
conformity with size and details as shown on drawings or as directed by the Engineer.
Bituminous tack coat shall be measured separately as stated under the item 3.7.1 of these
specifications.
Thermoplastic road marking on the top of rumble strip median shall be measured in the unit
of square meter as described under the item 7.3.4.
Rumble strips median constructed by premix bituminous carpeting materials with seal coat
measured above shall be paid for at contract unit rate linear meter, which shall be payable
in full compensation for furnishing all labor, carriage, material, tools, equipment and all
other incidental necessary to complete the work.

7.10.5 Payment

Thermoplastic road marking on the top of the rumble strip median shall be paid at the
contract unit rate of square meters and it shall be paid under the pay item 7.3.1 or 7.3.2
Bituminous tack coat shall be paid separately under the pay item 3.7.1.

Pay item Description Unit

7.10.1 Rumble Strips Median Lin.m
3.7.1 Bituminous Tack Coat Sq. m
7.3.1 Hot thermoplastic road markings Sq. m

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 7.3.2 Cold thermoplastic road markings Sq. m

7.11 Solid concrete Interlocking Paving Blocks Pavement on

footpath
7.11.1. Description

This work shall consist of furnishing all materials, like interlocking paving blocks for
construction of footpath surface, including sand laying course under the block for
installation.

7.11.2. Material requirements

7.11.2. 1 Cementitious Materials

Cementitious Materials shall conform to the following applicable ASTM specifications

a. Portland cements - Specification C 150

b. Blended cements - Specification C595/C 595. Types IS or IP
c. Silica fume - Specification C 1240

7.11.2.2. Aggregates

Aggregates shall conform to the ASTM C-33

a. Normal Weight - Specification C33
b. Lightweight - Specification C331

7.11.2.3. Chemical admixtures

Chemical admixtures shall conform to the following applicable ASTM specifications.

a. Air-entraining admixtures - Specification C 260
b. Water reducing, retarding and accelerating admixtures - Specification C 494
c. Pigments for integrally Colored concrete - Specification - C979

7.11.2.4. Physical Requirements

a. Units shall be of specified or approved shape, size and thickness, capable of being
fitted and placed with one hand, and shall have an exposed face area less than or
equal to 0.065 m2 (100.75 in 2), and their aspect ratio (that is, overall length
divided by thickness) shall be <4. The minimum thickness shall be 60 mm (2.375
in).
b. Concrete units covered by this specification may be made from lightweight or
normal weight aggregates or mixed lightweight and normal weight aggregates.

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 c. Compressive strength - at the time of delivery to the work site, the average
compressive strength of the test samples shall be not less than 49N/mm2
d. Cement component of the compacted concrete shall not be less than 380 kg/m3
e. Absorption - The maximum average absorption of the test samples shall not be
greater than 5% with no individual unit greater than 7%.
f. Resistance to freezing and thawing - If directed by the Engineer, the Contractor
shall strictly satisfy the Engineer either by proven field performance or a
laboratory freezing-and-thawing test that the paving units gave adequate
resistance to freezing and thawing. If a laboratory test is used, when tested in
accordance with test methods C67, specifications shall have no breakage and not
greater than 1.0% loss in dry mass of any individual unit when subjected to 50
cycles of freezing and thawing. This Test Method shall be conducted not more
than 12 months prior to delivery of units.
g. Abrasion Resistance - when tested in accordance with Test Methods C 418,
specimens shall not have a greater volume loss than 15 cm3 / 50 cm2 (0.195 in3 /
7.75 in2) The average thickness loss shall not exceed 3 mm (0.118in)
h. Dimensional Tolerance - Length or width of units shall not differ by more than
+1.6 mm (+1/16in) from approved samples. Heights of units shall not differ more
than ± 3.2 mm (±1/8 in) the specified standard dimension.

7.11.2.5. Spacer Nibs and Chamfers

a. A projection on vertical face of unit intended as an aid to laying should be

provided in the Interlocking Paving Units.
b. A chamfer around the wearing surface shall be desirable and the work size of the
width and depth of any chamfer shall have to be prior approved by the Engineer.

7.11.2.6. Manufacturing / Casting

The solid concrete Interlocking paving Unit/Blocks shall be factory made "Pressed" type of
approved quality, uniform texture and color, manufactured by employing a pressure not less
than 5 NM/m2 over the entire surfaces receiving the pressure.

7.11.2.7. Tolerances

The maximum dimensional deviations from the stated work sizes for the paving blocks
measured shall be as follows:
Length = ± 2 mm
Width = ± 2 mm
Thickness = ± 0 mm

7.11.2.8 Sampling and Testing

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 a. The Engineer/Engineer's representative shall be accorded proper facilities to inspect
and sample the units at the place of manufacture form the lots ready for delivery
b. Sample and testing shall be in accordance with Test Methods C140. except as
required in 4.5 Units tested in compression shall be whole. If the testing, machine
does not have sufficient force to break a whole unit, then the unit shall be cut in half
along the shortest axis and one half tested. Units with protruding, smaller ends shall
have the ends saw cut and the remaining larger pieces tested. This specimen shall be
symmetrical about two axes.

7.11.2.9 Visual Inspection

All units shall be sound and free of defects that would not interfere with the proper placing
of the units or impair the strength or performance of the construction.

7.11.3. Construction Method

There are three layers in an Interlocking block paving:

a. Improved Sub-grade: Laid as for a conventional road, the thickness of improved sub-
grade will be minimum 20 cm and other requirement will fulfill the specification of
clause no. 3.8
b. The laying course - a layer of carefully screeded compacted minimum thickness 5 cm
of "Sylhet" coarse sand of Fineness Modulus ≥ 1.8
c. The surface course - the interlocking paving blocks themselves of approved size,
shape, Color, texture and finish.
In additional edge restraint is essential to prevent the blocks from moving sideways and
becoming loose.
It is normally provided by standard pre-cast concrete kerbs.

7.11.3.1 Basic Paving operations

(a) Place and screed the laying course
(b) Place the blocks
(c) Complete the edges
(d) Vibrate the surface

7.11.3.2 Edge Restraint

a. This is normally provided by pre-cast kerbs which are laid prior to paving.
b. It is essential that the kerb foundation should not project in front of the kerb as the
surplus concrete will prevent blocks from being laid properly. Similar care must be
taken with the hunching to gully and manhole surrounds.
c. Edge restraint is still need even where special edge blocks are used.

7.11.3.3 Laying course

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The laying course, about 50 mm thick after vibration consists of washed sharp "Sylhet"
sand containing not more than 3% of silt and clay by weight and with not more than 15%
retained on a 2.3.6 mm sieve. To achieve the best regularity in the finished road surface, the
sand should be uniform in type and moisture content, spread to a smooth level without
uneven pre-compaction.
To help maintain uniformity, the sand should be obtained from a single source, allowed to
drain before use and sheeted over to minimize moisture changes.

7.11.3.4 Screeding to Level

Screeding is done by traditional methods. On roads & footways of up to 5m wide,

screeding can be done from the kerbs. For wider roads, or over large areas, temporary
screed rails set to level can be used.
It is essential to take care with screeding, not only because it gives a better footpath surface
but also because it help as the block layer.
A cambered screed broad is needed for roads or footways with a cambered cross-section.

7.11.3.5 Surcharge

After final vibration, the blocks will be lower than their initial level because the laying
coarse sand has been compacted and some has moved up into the joints between the blocks.
Thus the sand has to be laid to a surcharge, the amount of which depends on the type and
moisture content of the sand but is normally in the range of 5 to 15 mm. For ensuring that
the surcharge is correct, the final road level should be checked after completion of the first
few meters and then at frequent intervals. After checking if it is found that the final level is
incorrect, the blocks may be lifted and stacked and the sand thoroughly raked and
rescreeded at a new level.

7.11.3.6 Surface course

The positioning of the initial blocks demands extra care. To give the required laying pattern
the blocks must be placed at the correct angle against after starting edge such as a row of
concrete channel blocks.
Each block has to be placed very carefully so as not to disturb its neighbors and it is not
until three or four rows have been placed that the normal rapid laying rate can be achieved.
However, with a herringbone pattern where the blocks are at 90" to the centerline half
blocks should be fitted at the starting line.

7.11.3.7 Laying

Each block must be placed firmly against its neighbors, being held slightly above the laying
course so as not to disturb the sand until the block is in its correct place. Any damaged
blocks should be rejected.

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All blocks must be laid so that they fit closely together. If joints begin to open, the blocks
should be knocked together with a hide mallet. Care must be taken not to till the blocks on
the leading edge of the laying face by standing or kneeling on them.
Block-laying is continued until enough area has been laid to make vibration worthwhile -
say, 15 to 20 square meters. Men or light equipment can move over the blocks before they
have been vibrated. This may cause an uneven surface which may be 'Ironed out by the
plate vibrator.

7.11.3.8 Compaction of road bed/paving blocks with plate vibrator

Plate vibrator shall be used for compacting road bed just before the placement of paving
blocks. Plate vibrator shall also be used to get the paving blocks initially set. A plate
vibrator shall have the plate area between 0.2 and 0.3 square meters and a centrifugal force
of approximately 1.0 tonne.

7.11.3.9 Edging

Where blocks do not fit at the edges the spaces are filled with cut blocks, Cutting machines
are available to split blocks, but very small pieces are best chipped off with a bolster and
hammer.
Where the gaps are small, with a dimension less than 40mm, they can be filled with a 4:1
sand mortar.

7.11.3.10 Filling the Joints

After the initial vibration, sand as per following grading is brushed over the surface of the
blocks, and is vibrated into the joints by a further two or three passes of the Plate vibrator.
After all the joints are filled, surplus sand can be swept away.

Table 7.11-1 for Joint Filling Sand Grading

Sieve Size mm % Passing by Weight
2.36 100
1.18 90 - 100
0.600 60 - 90
0.300 30 - 60
0.150 15 - 30
0.075 5 - 10

7.11.4. Measurement
The unit of measurement shall be in square meters of footpath covered by solid concrete
Interlocking Paving Blocks of specified thickness.

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 7.11.5 Payment
The payment shall be the full compensation for the cost of factory made interlocking
paving units, labor, laying course, cement sand mortar as mentioned above, transportation
and cost of all materials, tools and plants, compaction costs and all other incidental costs
necessary to complete the work.

Pay Items Description Unit

No.
7.11.1 Procurement and construction of footpath with 60 mm Sq. meter
thick solid concrete interlocking Paving Blocks including
5 cm compacted coarse sand laying course.

7.12 Pre-cast Kerbs for Median/ NMT Lane Separator/ Roundabout/

Footpath

7.12.1 Description

The work shall consist of construction of median / NMT lane separator / roundabout /
footpath with pre-cast factory made ‘Pressed’ kerbs, including end protection of median or
NMT lane separator as shown in the drawings or instructed by the Engineer, in conformity
with lines, levels, typical cross sections and locations shown in engineering drawings and
these technical Specifications or as instructed by the Engineer.

7.12.2 Materials

7.12.2.1 Cementitious Materials

Cementitious Materials shall conform to the following applicable ASTM specifications

a. Portland cement – Specification C 150
b. Blended Cements – Specification C595/C 595 M. Type IS or IP.
c. Silica Fume – Specification C 1240
7.12.2.2 Aggregates
Aggregates shall conform to the ASTM C-33
a. Normal Weight – Specification C 33
b. Lightweight – Specification C 331

7.12.2.3 Chemical Admixtures

Chemical Admixtures shall conform to the following applicable ASTM specifications
a. Air-entraining Admixtures – Specification C 260
b. Water reducing retarding and acceleration admixture – Specification C 494

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 c. Pigments for integrally Colored concrete specification C979

7.12.2.4 Steel Reinforcement –

Steel reinforcement must follow ASTM A615 or ASTM A617M or ASTM A706M as
specified in drawings or as directed by the Engineer.

7.12.2.5 Physical Requirements

a. The pre-cast kerbs shall be of specified or approved shape, size and thickness –
factory manufactured with approved materials in accordance with the specifications
and in conformity with lines, level and typical sectional details as shown on drawings
or as directed by the Engineer.
b. Concrete units covered by this specification may be made from light weight or normal
weight aggregates or mixed lightweight and normal weight aggregates.
c. Compressive strength – at the time of delivery to the work site, the average
compressive strength of the test samples shall be not less than 30N/mm2 with no
individual unit less than 25.8 N/mm2
d. Cement component of the compacted concrete shall not be less than 350 Kg/m3
e. Absorption – The maximum average absorption of the test samples shall not be
greater than 3.2% with no individual unit greater than 5% when tested within one
months after manufacture and between 2.8 to 2.4% when tested after two months of
its manufacturing.
f. Resistance to freezing and thawing – If directed by the Engineer, the contractor shall
strictly satisfy the Engineer either by proven field performance or a laboratory
freezing and thawing test that the kerbs and edging have adequate resistance to
freezing and thawing. If a laboratory test is used, when tested in accordance with test
methods C67, specimens shall have no breakage and not greater than 1.0% loss in dry
mass of any individual unit when subjected to 50 cycles of freezing and thawing. This
test method shall be conducted not more than 12 months prior to delivery of kerbs
g. Dimensional Tolerance – All kerbs, shall be manufactured according to the profiles
shown on drawings and in typical sectional details. When sampled at random and
measured for length, width or height, the average dimensions of the twelve values
obtained from the four measurements on each of the three units sampled shall be
within ± 4mm of the specified dimensions but none of the original values shall vary
from the average by more than ± 2mm.
h. Angles and Arises – All angles of the products, with the exception of angles resulting
from the splayed or chamfered face shall be right angles, subject to the tolerances as
stated sub-clause 4.6
i. The Arise shall be clean and with the exception of the rounded arises, sharp. The
wearing surfaces shall be true and out of winding, subject to the tolerances in above
sub-clause.
7.12.2.6 Manufacturing/Casting

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All solid concrete kerbs shall be factory made “Pressed” type of approved quality, uniform
texture and color, manufactured by employing a pressure not less than 5 MN/m2 over the
entire 4 surfaces receiving the pressure.

7.12.2.7 Finish and Color

Surface Finishes – Unless specified otherwise, all surfaces which are exposed in service
shall be clean. Free from dents, bulges, depressions and completely smooth of uniform
natural color, texture and free from any marks or stains.

7.12.2.8 Testing

Contractor must supply latest test results from manufacturer or he must arrange new tests
to satisfy these requirements. Result should not be older than 3 months. It shall be the
responsibility of the contractor to arrange testing equipment and instrumentation and carry
out the periodic testing of the products in accordance with Engineer’s directions.

7.12.3 Construction Methods

7.12.3.1 Construction of median / NMT lane separator / roundabout / footpath

The median / NMT Lane separator / Roundabout shall be constructed as per drawing. The
median/NMT Lane separator / roundabout shall be constructed on the existing carriageway
and requires excavating existing pavement as shown on the drawing. All joint and concrete
work shall be cured properly for a minimum period of 7 (seven) days.

7.12.3.2. Installation of Pre-cast Kerbs

a. Only good quality kerbs is allowed to use for median / NMT lane separator /
roundabout / footpath

b. The pre-cast units shall be fixed or placed in position as per the details indicated in
typical sectional details.

c. The bedding concrete shall be class – 15 with stone aggregates as per the Technical
Specifications and the vertical mortar joints shall be in cement sand mortar (at 1:3
proportion) finished with regular recessed pointing as per approved sample or
direction of Engineer.

d. All pre-cast concrete units to be fixed in concrete shall be presoaked and moist to the
satisfaction of the Engineer, before placing the same over bedding concrete or before
placing cement sand mortar (1:3) in joints. All concrete work and joints shall be cured
for a period not less than 10 days.

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 7.12.4 Measurement

Kerb shall be measured in linear meters actually constructed and accepted in conformity
with size and shape as shown on drawing or as directed by the Engineer. The length shall
be measured at center line of top of finished surface. Payment for the installation of pre-cast
Kerbstone shall be paid at the contract unit price per linear meter under the pay item 7.12.2
(Type K2, dimensions xxx) or under the pay item 7.12.3 (Type K3, dimensions xxx).
Backfilling shall be measured and paid separately under clause 7.13.

7.12.5 Payment

Kerb as measured above, shall be paid for at the contract unit rates in linear meter, which
shall be payment in full compensation for furnishing all labor, carriage, material, tools,
equipment, excavation, cutting pavement, provisions of side offset kerb detail, vehicular
access drop kerb arrangement, together with bed, haunch, fixing concrete, construction of
end protection to median or NMT lane separator and all other incidentals necessary to
complete the work to the satisfaction of the Engineer.

Pay Item No. Description Unit of

Measurement
7.12.1 Procurement and installation of pre-cast kerb Type Lin. m
“K1” for median, NMT lane separator and roundabout
7.12.2 Procurement and installation of pre-cast kerb Type Lin. m
“K2” for footpath
7.12.3 Procurement and installation of pre-cast Kerb Type Lin. m
“K3” for footpath

7.13 Backfilling of Median/NMT Lane Separator/Roundabout

7.13.1 Description

The item shall consist of backfilling of constructed median/NMT lane separator

/roundabout as shown in the drawings or instructed by the Engineer.

7.13.2 Materials

Earth free from roots, stones and other bigger particles, which may cause severe injuries in
case of vehicle hit to a Median/NMT Lane separator/roundabout, shall be used for
backfilling.

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 7.13.3 Construction
Earth filling of median/ Lane divider/ Roundabout

The space in the medians/NMT Lane separator / roundabout constructed shall be field with
earth. The placing of earth shall be carried out in successive layers for the full width of fill
as shown on the drawings and in such lengths as are suited to the watering and compaction
methods utilized. The layer shall not exceed 150 mm in thickness on completion. Earth
should be free from roots, soda or other deleterious and foreign materials.

7.13.4 Measurement

Backfilling of median / NMT lane separator / roundabout shall be measured in cubic meters
of materials completed and accepted on the site.
Excavation and removal of flexible pavement shall be measured in cubic meters in its
original location and volume determined in cubic meters by the average end area method.

7.13.5 Payment

Backfilling of median / NMT lane separator / roundabout with earth shall be paid for at the
contract unit rate cubic meters. Payment shall be the full compensation of materials, labor,
equipment and all other incidentals necessary to complete the work.
Excavation and removal of flexible pavement shall be paid at the contract unit rate cubic
meters. The payment shall be full compensation to completion of work.

Pay Item Description Unit Measurement

7.13.1 Earth filling in the road median / NMT lane Cubic Meters
separator / roundabout
7.13.2 Roadway Excavation and the removal of existing Cubic Meters
flexible pavement structure.

7.14 Dismantling Damaged Kerb Stones and Re-use of Kerb Stones

7.14.1 Description

The work shall consist of furnishing all necessary tools, equipment and materials for
dismantling of damaged kerbstones or cleaning and recovering kerbstones in accurate
condition for reusing in construction work.

7.14.2 Construction

The existing kerb stones shall be recovered from the kerbstones area being dismantled
mechanically or manually and during dismantling care shall be taken so that considerable
numbers of kerb stones are saved. After necessary cleaning, these kerbstones shall be
installed to the same locations or to other location as per drawings.

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The joints of kerb stone shall filled with cement mortar in the proportion of 1 parts of
cement to 4 parts of sand. Curing by water to these works shall be done for at least 7 days.

7.14.3 Measurement

The completed work of dismantling and reinstallation of kerbstones shall be measured in

linear meter along the center line of the kerbstones line. The measurement shall be recorded
before dismantling and after installing separately. If all the kerbstones are not used in the
new work the surplus dismantling kerbstones shall be stocked piled and handed over to
RHD.

7.14.4 Payment
The work measured above shall be paid for at the contract unit rate in linear meters. The
payment shall be full compensation for furnishing materials, labor, tools, equipments and
incidentals necessary for the proper completion of work as specified in the contract
documents or as directed by the Engineer.
Pay item shall be:

Pay Item Description Unit

7.14.1 Dismantling of existing kerbstones Lin. m
7.14.2 Reinstallation of kerbstones Lin. m

7.15 Painting of Median/NMT Lane Separator/Roundabout

7.15.1 Description

This shall consist of furnishing all necessary tools, materials, labor etc. for painting road
median / NMT lane separator / roundabout with reflective as shown in the drawings or
instructed by the Engineer.

7.15.2 Materials

The primer coat of plastron sealer or an approved equivalent material of known paint
manufacturer shall be used on concrete surface or plastered brick surface.
Reflective paint shall be of high intensity grade and as approved by the Engineer.

7.15.3 Method of Application of Paint

Reflective paint shall be used as recommended by manufacturer. First primer shall be used
on the surface after necessary cleaning is completed. Then 1st and 2nd coats of painting
shall be applied as per recommendation of the manufacturer. Two coats of reflective paint
with one prime coat of plastron sealer shall be applied on the specified surface. At best after
one day, the 2nd coat shall be applied. The application of paint may be by brush/spray or
roller as per convenience of the work.

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 Reflective painting of alternate black and white color shall be applied on face of the road
medians / NMT lane separator / roundabout as shown in the drawings or instructed by the
Engineer.

7.15.4 Measurement

The reflective painting of median / NMT lane separator / roundabout shall be measured in
square meters of the painted area completed and accepted by the Engineer.

7.15.5 Payment
The quantities as measured above shall be paid for at the contract unit prices per square
meter. The payment shall be full compensation for material, equipment, tools and incidental
necessary to complete the work.
Pay item shall be:

Pay Item Description Unit Measurement

No.
7.15.1 Reflective painting of road medians / NMT lane Sq. m
separator / roundabout

7.16 Demolition and Removal of Existing Median

7.16.1 Description

This item shall include demolition of different type of road medians, like kerbstone median,
concrete median or New-Jersey Barrier as shown in the drawings or as directed by the
Engineer and removal of demolished material from the site.
Item includes also removal of existing filling material either to disposal site or temporary
stock pile for reuse as instructed by the Engineer.

7.16.2 Method

The demolition of existing road medians shall be done as per approved method or as
instructed by the Engineer. The contractor must submit demolition method to Engineer for
approval one week before commencing the work.
Only required sections shall be demolished and remaining part of median must remain
undisturbed.
Safety Precautions
The contractor shall comply with all safety measure while demolishing the medians against
traffic flow on the road.

7.16.3 Measurement

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 Demolition and removal of existing road medians shall be measured in linear meter actually
demolished and accepted.

7.16.4 Payment

Quantities measured as stated above shall be paid at the contract unit price per linear meter.
The payment shall be full compensation for furnishing all required tools, machines, labor,
materials, removal of demolished median and filling material for disposal or stock pile and
incidentals for completion the work.

Pay Item No. Description Unit

7.16.1 Demolition and removal of existing median (including Linear Meter
filling material)

7.17 Crash Barriers

7.17.1 General

The work shall consist of construction, provision and installation of crash barriers as shown
in the drawing or as directed by the Engineer. The crash barrier is provided to absorb the
impact energy and reduce the severity of accidents involving vehicles leaving the traveled
way. It should be installed where the severity of accidents due to striking the barrier, which
is shielding the hazard, is lower than what it will be without the barrier.

The crash barriers can be classified as flexible, semi-rigid, or rigid. The flexible system is
the most yielding type, which may be composed of wire rope fencing. Semi-rigid barriers
offer requisite resistance to control the deflection of longitudinal member to an acceptable
limit; metal beam crash barriers give this system. Rigid system does not deflect on impact
but causes the maximum severity of impact; concrete crash barrier is the rigid system.

They are generally longitudinal roadside crash barriers and median barriers. Some of the
commonly encountered roadside obstacles are bridge piers, abutments and railing ends,
roadside rock mass, culverts, pipes and headwalls, cut slopes, retaining walls, lighting
supports, traffic sign and signal supports, trees, and utility poles. Median barriers are
provided to check head-on-collisions, especially on highways with narrow medians, caused
by out-of-control vehicles jumping across the medians.

Raised curbs or drains should not be provided between the traveled way and the barriers.
These destabilize the vehicle balance and disturb its equilibrium before it strikes the barrier,
thus defeating the essential purpose of safety and redirection of the impacting vehicle.

Categories:

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Category Application Containment for
P-1: Normal Containment Bridges carrying expressway, 15 kN vehicle at 110 km/h,
or equivalent and 20 degree angle of
impact

P-2: Low Containment All other bridges except 15 kN vehicle at 80 km/h,

bridge and
over railways 20 degree angle of impact

P-3: High Containment At hazardous and high risk 30 kN vehicle at 60 km/h,

locations, over busy railway and
lines, complex interchanges, 20 degree angle of impact
etc.

7.17.2. Placement

Placement recommendations determine the exact layout of the barrier and should be made
by the design engineer keeping in view the lateral offset of the barrier and flare rate. The
final layout shall be a site specific combination of these factors. The barriers should be as
far away from the traffic as possible and should preferably have uniform clearance between
the traffic and the hazard.

As far as possible the safety barrier should be placed beyond 2.5 m of the traveled way. For
long and continuous stretches, this offset is not critical. The distance between the barrier
and the hazard should not be less than the deflection of the barrier by an impact of a full
sized vehicle. In case of embankments, a minimum distance of 60 cm should be maintained
between the barrier and the start of embankment slope or a hazard to prevent the wheels
from dropping over the edge.

Flatter flare rates may be used particularly where extensive grading would be required to
ensure a flat approach from the traveled way subject to the availability of right of way.

At locations, where the two adjacent carriage ways are at the same level, the barrier shall be
placed in the center of the median, duly taking into consideration, the drainage
requirements. The placement of median barriers in cases where the two carriageways are at
different levels is a function of the slopes between the two medians.

Crash barriers should be provided with reflectors to enhance their visibility in the night
time.

Warrants
The crash barriers shall be provided at following locations.

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 a. Where the height of embankment is 3m or more,

b. Where the embankment is retained by retaining structure,

c. Where the median is depressed, flushed or having the width of less than 4.5 m. The
barriers shall be for both directions of travel,

d. On valley side of highway in mountainous and steep terrain,

e. Between the main carriageway and footpath on bridges,

f. At hazardous locations, as per the direction of the Engineer.

g. On the highways with ADT more than 20,000 PCUs and with medians width less
than 9m, median barriers are required. The probability of a vehicle crossing across
the median is relatively low and median barriers in such cases are optional.

h. Median barriers to shield fixed objects in narrow median. If necessary, median

barriers should be flared to encompass a fixed object, which may be a lamp post,
foundation of overhead signs, bridge pier etc.

i. Any hazardous location as directed by the Engineer.

Medians with width between 9 and 15 m do not warrant a barrier unless there is an
adverse history of median crossovers. Median barriers may be impractical where a
road has a large number of closely spaced median openings since the barrier needs
to be terminated with an end treatment at these points. An evaluation of the number
of median openings, accident history, alignment, sight distance, design speed,
traffic volume and median width requires to be made prior to taking a decision on
installation of a median barrier.

7.17.3. Materials

The concrete barriers shall be constructed either by the “cast-in-place with fixed forms”
method or the “extrusion or slip form” method or a combination thereof at the Contractor’s
option with the approval of the Engineer. Where “extrusion or slip form” method is adopted
full details of the method and literature shall be furnished.

Concrete barriers shall be constructed with M 20 grade concrete or as indicated in the

drawing and with thermo mechanically treated (TMT) deformed bars of grade S415

An expansion joint with pre-molded asphalt filler board shall be provided at the junctions
of crash barrier on structure and crash barrier on the fill. The crash barrier on the fill shall

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be constructed in pieces of length not exceeding 20 m, with pre-molded asphalt filler board
joints.

7.17.3.1 Concrete Crash Barrier/New Jersey Barrier

7.17.3.1.1Construction operations

The location of crash barrier shall be strictly adhered to as shown on the drawing and/or as
directed by the Engineer. Concrete crash barriers shall present a smooth, uniform
appearance in their final position, conforming to the horizontal and vertical lines shown on
the plans or as ordered by the Engineer and shall be free of lumps, sags or other
irregularities. The top and exposed faces of the barriers shall conform to the specified
tolerances.
Based on evaluation of vehicle direction, sight distance, structural stability and the
psychological effect of barrier height on driver reaction, the most desirable height of the
median barrier is 80 cm. ‘New Jersey’ type is the most common shape of concrete crash
barrier. Variations up to 50 mm in height of barrier can be made in the total height of the
barrier to meet the site requirements. It is however important to maintain the height of
lower slope between 20 cm and 35 cm so as to reduce the chances of overturning of the
vehicles.

The concrete barrier may be precast in lengths up to 6 m depending upon the feasibility of
transport and lifting arrangements. The minimum thickness of foundation may be 25 mm
thick cement concrete or hot mix asphalt placed at the base of barrier to provide lateral
restraint. Where more than 75 mm thick overlay on the road pavement is anticipated, the
foundation step may be increased to 125 mm. However, longitudinal roadside concrete
barrier should have elaborate footing design which is structurally safe unless sufficient
earth support is available. Backfilling to the concrete barriers shall be compacted in layers
to the compaction of the surrounding earthwork.

Tolerance: The overall horizontal alignment of rails shall not depart from the road
alignment by more than + 30 mm, nor deviate in any two successive lengths from straight
by more than 6mm and the faces shall not vary more than 12 mm from the edge of a 3 m
straight edge. Barriers shall be at the specified height as shown in the plans above the edge
of the nearest adjacent carriageway or shoulder, within a tolerance of + 30 mm.

End Treatment, Paint and One - way/ Two-Way Reflectors: The road side concrete
barrier shall be provided with an end treatment by tapering the height of terminating end
within a length of 8 m to 9 m. Median crash barrier shall be terminated sufficiently away
from the median opening. It shall be provided with an end treatment, which shall be
obtained by tapering the height of terminating end of the median barrier within a length of 8
m to 9 m.

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Barriers should be painted Yellow/Black as per the approved pattern. One - way/ Two-Way
Reflectors (Red/White on edge-barriers and Yellow/Yellow on Median) should be installed
at spacing’s as per the approved drawing.

7.17.3.1.2 Measurements for payment

All barriers will be measured by linear meters of completed and accepted length in place,
corresponding end to end along the face of concrete barriers including approach and
departure ends.

Rate

The Contract unit rate shall include full compensation for furnishing all labor, materials,
tools, equipment and incidental costs necessary for doing all the work involved in
constructing the concrete barrier complete in place in all respects as per these
Specifications.

7.17.3.2 Metal Beam Crash Barrier/W-Beam

7.17.3.2.1 General

This work shall consist of furnishing and erection of metal beam crash barrier of
dimensions and at locations as shown on the drawing(s) or as directed by the Engineer.

Metal beam crash barrier shall generally be located on approaches to bridge structures, at
locations where the embankment height is more than 3 m and at horizontal curves.

7.17.3.2.2 Materials

Metal beam rail shall be corrugated sheet steel beams of the class, type, section and
thickness indicated on the plans. Railing posts shall be made of steel of the section, weight
and length as shown on the plans. All complete steel rail elements, terminal sections, posts,
bolts, nuts, hardware and other steel fittings shall be galvanized. All elements of the railing
shall be free from abrasions, rough or sharp edges and shall not be kinked, twisted or bent.

The “W” beam type safety barrier shall consist of a steel post and a 3 mm thick “W” beam
rail element, spaced away from the posts. The steel post and the blocking out spacer shall
both be channel section of 75 x150 mm size 5 mm thick. The rail shall be 70 cm above the
ground level and posts shall be spaced 2 m center-to-center.

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The thrie-beam safety barrier shall have posts and spacers similar to the ones mentioned
above for “W” beam type. The rail shall be placed at 85 cm above the ground level. This
barrier has a higher initial cost than the “W” beam type but is less prone to damages by
vehicle collisions especially for shallow angle impacts.

The “W” beam, the thrie beam, the posts, spacers and fasteners for steel barriers shall be
galvanized by hot dip process (zinc coated, 0.55 kg per square meter; minimum single spot)
unless otherwise specified. The galvanizing on all other steel parts shall conform to the
relevant Specifications. All galvanizing shall be done after fabrication.

7.17.3.2.3 Construction operations

The line and grade of railing shall be true to that shown on the plans. The railing shall be
carefully adjusted prior to fixing in place, to ensure proper matching at abutting joints and
correct alignment and camber throughout their length. Holes for field connections shall be
drilled with the railing in place in the structure at proper grade and alignment.

Unless otherwise specified on the drawing, railing steel posts shall be given one shop coat
of paint (primer) and three coats of paint on structural steel after erection, if the sections are
not galvanized. Any part of assembly below ground shall be painted with three coats of red
lead paint.

Splices and end connections shall be of the type and designs specified or shown on the
plans and shall be of such strength as to develop full design strength of the rail elements.

Installation of posts

Holes shall be dug or drilled to the depth indicated on the plans or posts may be driven by
approved methods and equipment, provided these are erected in proper position and are free
from distortion and burring or any other damage.

All post holes that are dug or drilled shall of such size as will permit proper setting of the
posts and allow sufficient room for backfilling and tapping.

Holes shall be backfilled with selected earth or stable materials in layers not exceeding 100
mm thickness and each layer shall be thoroughly tamped and rammed. When backfilling
and tamping are completed, the posts or anchors shall be held securely in place.

Post holes that are drilled in rock and holes for anchor posts shall be backfilled with
concrete.

Page | 74
 Posts for metal beam guardrail on bridges shall be bolted to the structure as detailed on the
plans. The anchor bolts shall be set to proper location and elevation with templates and
carefully checked.

Erection

All guard rail anchors shall be set and attachments made and placed as indicated on the
plans or as directed by the Engineer.

All bolts or clips used for fastening the guardrail or fittings to the posts shall be drawn up
tightly. Each bolt shall have sufficient length to extend at least 6 mm through and beyond
the full nut, except where such extensions might interfere with or endanger traffic in which
case the bolts shall be cut off flush with the nut.

All railings shall be erected, drawn and adjusted so that the longitudinal tension will be
uniform throughout the entire length of the rail.

End treatment for steel barrier and Two-way Trapezoidal Reflectors

End treatments shall form an integral part of safety barriers which should not spear, vault or
roll a vehicle for head-on or angled impacts. The two end treatments recommended for steel
barriers are “Turned-down-guardrail” and “Anchored in back slope”.

Turned-down guardrails have the “W” or thrie section reduced from full height to ground
level with a gentle slope over a distance of 8 to 9 m. The turned down rail is intended to
collapse on impact, allowing the vehicle to pass over it without becoming airborne or
unstable. In order to locate the barrier terminal away from the traveled way and to minimize
drivers’ reaction to hazard near the road by gradually introducing a parallel barrier
installation or to transition a roadside barrier nearer the roadway such as a bridge parapet or
a railing, the turned down rail should be flared away from the roadway. Suggested flare
rates depending upon the design speed and type of barrier are given in Table 7.17-01.

Two-way Trapezoidal Reflectors (Red/White) should be installed at spacing as per the

approved drawing.

Table 7.17-01 Suggested Flare Rates

Design speed (km/h) Flare rates
Rigid barriers Semi-rigid barriers
100 17:1 13:1
80 14:1 11:1
65 11:1 9:1
50 8:1 7:1

The posts in the end treatment should have the same cross section as provided in the main
barrier.

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 At road cross sections in cutting or if the road transitions from cut to fill, the barriers can be
anchored in back slopes. The back slope covering the anchored portion of the barrier should
be graded flat, with side slopes preferably not steeper than 10:1. The anchored portion
should develop a tensile strength in the rail element to prevent the rail from pulling out of
the anchorage. The barrier can also be anchored in an earth beam specially constructed for
this purpose provided the new beam itself is not a hazard to the traffic. The earth beam
should be made impervious to erosion. No flaring is to be provided for a “Turned-down-
guardrail” end treatment.

Tolerance
The posts shall be vertical with a tolerance not exceeding 6mm in a length of 3 m. The
railing barrier shall be erected true to line and grade.

7.17.3.2.4 Measurements for payment

Metal beam railing barriers will be measured by linear meter of completed length as per
plans and accepted in place. Terminals/anchors of various types shall be paid for by
numbers.
No measurement for payment shall be made for projections or anchors beyond the end
posts except as noted above. Furnishing and placing anchor bolts and/or devices for guard
rail posts on bridges shall be considered incidental to the construction and the costs thereof
shall be included in the price for other items of construction.
No measurement for payment will be made for excavation or backfilling performed in
connection with this construction.

7.17.3.2.5 Payment
The Contract unit rate shall include full compensation for furnishing of labor, materials,
tools, equipments and incidental costs necessary for doing all the work involved in
constructing the metal beam railing barrier complete in place in all respects as per these
Specifications.

Pay Item No. Description Unit

7.17.1 New jersey Barrier lin m
7.17.2 Metal Beam/W-Beam Barrier Linear Meter

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 7.18 Flexible Wire Rope Barriers

7.18.1. General
Flexible Wire Rope Safety Barrier (WRSB) is a type of roadside or median safety traffic
barrier/guard rail. It consists of steel wire ropes mounted on weak posts. As is the case with
any roadside barrier, its primary purpose is to prevent a vehicle from leaving the travelled
way and striking a fixed object or terrain feature that is less forgiving than itself. Also
similar to most roadside barriers, cable barriers function by capturing and/or redirecting the
errant vehicle. The system is more forgiving.

There are two types of cable barrier systems in use today, low-tension and high-tension.
High-tension cable is preferable as when a vehicle impacts the high-tension system under
normal conditions, the cable deflects as little as 8 ft from its original location.

High-tension cable consists of three or four pre-stretched cables supported by weak posts.
During installation, the cables are placed on the posts, and then tightened to a specific
tension according to temperature. The tensions values range between approximately 2,000
and 9,000lb. Due to this tightening, the cable installations can be of indefinite length. In
fact, the lengths of the runs are usually only limited by the presence of obstacles such as
median openings or bridge columns.

The inherent tension within the system also allows the cables to remain strong, even after
an impact that removes several posts, thus allowing the remainder of the run to function
normally. But a lack of proper installation and testing has led to severe collisions and even
death.

Characteristics
Tension – High tensioned WRSB are generally tensioned to app. 2.5t during installation
(subject to weather conditions, type of WRSB, and other factors). Low tensioned WRSB
are not as common as they used to be, the tension is generally very low and close to 0.

Containment or Deflection – based WRSB. Deflection aimed WRSB could be tensioned to

slightly higher tension and will most probably use 4 wires (ropes). The overall length of the
barrier tends to be shorter. Containment based WRSB will have wire ropes spread further
apart from each other (approximately 150mm - 60mm), to increase the catchment area.

Test level- FWRB systems should be approved at TL-4 test level.

Slopes-Cable barrier is intended for use on slopes with a 1:6 vertical to horizontal ratio.

Clearance-Cable barriers deflect between 2.5 m and 3.6 m upon impact. Given these
relatively large deflections, cable barrier systems are not usually considered appropriate to
shield fixed objects closer than 2.5 m offset of the travelled way. Even when the available

Page | 77
 clearance exceeds 2.5 m, the public seems to have a greater level of confidence in a more
robust barrier.

7.18.2. Material

The system should comply with European (EN) 1317-2 standards or Australian (AS)
standards.
(A) POST –
Size– Post shall be 100x55x5mm (Z shaped) hot deep Galvanized.
Height – 1430mm (4.70 Feet) with appropriate length is embedded in underneath concrete
for stability.
POST SPACING – Generally 3-5 meter (10.5 Feet) centre to centre, depends on shape of
the road. The distance from Final Post to End Anchor is 2 meters (6.5 Ft).As per field
condition, supplier will propose the spacing with details and approval needs to be taken
from the Engineer in charge.

(B) ROPE -
19mm 3 x 7 strand pre-stretched by 35%
Height of the top Ropes from Road Surface - 790-930 mm [+/- 30mm]
Weight – 1.17 kg/meter.
Minimum Tensile Strength – 1370 N/mm2.
Minimum Breaking Load is - 17.7 Tonnes.

(C) Foundation Pit -

The Foundation Pit size for Posts are 350 mm (1.20 Ft) Diameter x 750 mm (2.460 Ft)
deep.

Foundation Pit size for End Anchors are 2000 x 1000 x 3000 mm Diameter or 1500 x 1500
x 1500 mm or between 3 to 6 cubic meters in volume depending upon the soil conditions.

Concrete strength needs to be 25Mpa.

A typical drawing is given below-

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 7.18.3. Installation

The tension is applied using a tension machine and hand-pump, to achieve the correct level
of tension on the wire ropes, during installation. All other installation procedure will be
according to EN 1317-2 standards or AS or Manufacturer standard procedure, as
recommended by the Engineer in Charge.

End protection, painting and Delineators

2-way (red and white) Reflectors should be installed on all posts or top of all posts should
also be painted with red-colour reflective paint. Also Glare Protection and a tough plastic
sheet have to be provided post to post to reduce motor-cycle rider casualties.
Post caps shall be fitted with 50 x 100 mm Class 1A retro: reflective material or placed on
the front top of the post above the wire ropes. Delineators shall be installed at
approximately 12.5 to 15 m spacing. Delineators shall not be placed on flared sections.

All other safety measures will be according to EN 1317-2 standards or AS or Manufacturer

standard procedure, as recommended by the Engineer in Charge.

7.18.4. Measurement

The quantity to be measured for payment shall be the number of linear meters of Wire rope
Barrier completed, including the supply and installation of all ropes, posts, anchorages and
fixings as specified.

7.18.5. Payment

This work measured as provided above will be paid for at the Contract rate for Wire rope
Barrier. The rate and payment will be full compensation for furnishing and installing all
materials, including labor, equipment, tools and incidentals necessary to complete the work.

Pay Item No. Description Unit

7.18.1 Wire Rope Barrier Linear Meter

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 7.19 Water Filled Plastic Movable Barriers with Reflectors
7.19.1. Description

Since our water filled barriers are constructed with high-quality Polyethylene plastic, the
hollow construction is perfect for any construction site. The water filled barrier is
lightweight when empty but provides excellent stability and energy absorption when filled
with water. Since we know that your construction project demands the best equipment, we
have designed our barriers to be highly durable and resistant to splitting, cracking, and
deterioration even in inclement weather. Water filled barriers are a great alternative
to traditional barricades because they provide energy absorption for
Oncoming traffic in a way that provides increased safety for both drivers and workers.
These practical and economical applications make water filled obstacles one of the most
popular options for work zone places nowadays. In virtually any construction zone there is
always an essential balance to be struck between protecting motorists and protecting
workers. The forces from impact having a water barricade upon passengers and automobile
are significantly lower compared to the choice that is concrete, yet a barricade that is
ballasted does the occupation of protecting workers in the area. Water filled barriers are a
great alternative to traditional barricades because they provide energy absorption
for oncoming traffic in a way that provides increased safety for both drivers and workers.
These practical and economical applications make water filled obstacles one of the most
popular options for work zone places nowadays.

7.19.2. Use/Application

Road Safety Barriers are used on Roads to control the Motorists to not to move to Restricted
areas, it is also used to stop the vehicle, to direct the vehicles to other path, in construction
sites etc.
Water filled barriers can be used in the following situations
a. Construction areas
b. Work zones
c. Crowd control
d. Temporary road blocks
e. Public works projects
f. Special events/sporting events
g. Traffic Channelizing

7.19.3. Materials &Properties

Plastic water filled barrier, Reflector tape

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 7.19.4. Construction

The construction crews will appreciate how easy it is to transport and set up the water filled
barriers. All tasks can be easily be carried out by a two-man team is afforded by the
lightweight of empty obstacles and is ideal when temporary restrictions are needed fast.
Deploying water filled barriers allows for rapid response in emergency situations, as well as
adequate security on a temporary basis.
To ensure maximum safety for traffic and construction crews, our barriers are made using
highly visible colors to be seen in all weather and conditions. Particularly essential for
temporary obstacles, which frequently present an ‘unexpected’ element for motorists and
pedestrians, for example when used to delineate diversions and temporary closings and
reflectors.
Using their range of high visibility colors, water filled barriers are certainly evident from a
safe space, to improve safety in comprehension, along with accessibility.

7.19.5. Warranty

a. Length: 1000 mm
b. Height: 800 mm
c. Width: 500 mm
d. Maximum Capacity of Water: 20 Liters
e. Material Pure HDPE,
f. UV Protected
g. Reflectors on Water filled Road Barrier.

7.19.6. Measurement

The quantity to be measured for payment shall be the number of linear meters

7.19.7. Payment

Pay Item No. Description Unit

7.19.1 Plastic Movable Barriers Linear Meter

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 7.20 Cones with Retro-Reflective Sheets and connected by Ropes

7.20.1. Description

Safety Cones are also called as Traffic cones, Construction cones, Witch’s hat, Road cones
which is generally a conical marker used on roads or highways. Traffic cones are generally
placed on roads to warn drivers not to drive too close to an area where work is being done.
Safety Traffic Cones are used in directing traffic, indicate special routes, use at sporting
events. Safety Cones are also used to delineate short-duration maintenance and utility work.
By using the Safety Cones Traffic management can be done and happening of unnatural
incidents near maintenance and utility works can be avoided.

7.20.2 Use/Application

Specifically designed to be provided on roads and highways to fulfill a variety of

application from safety point of view like Lane dividing, Road diversion, Parking areas,
Men at work zone, Traffic channelization.

7.20.3 Materials & Properties

a. Made of special PVC material that makes them highly flexible and durable.
b. A high reflective sleeve is fixed on the cone for better visibility in all weather
conditions.
c. It also has provision for fixing of “O” Ring, plastic chain or caution tape.
d. Uniquely designed base absorbs impact, grips the road and won’t easily blow off with
fast traffic or winds.
e. Brilliant fluorescent red Color which is UV tempered and attracts immediate
attention.
f. Textured interior surface prevents stacked cones from sticking together.
g. Provision of holes for fixing plastic chain, Bright color UV stabilized, Reflective
sleeve for day night visibility, excellent flexure strength, Sturdiness, Durability,
Widely used for road safety.

7.20.4 Construction

It is portable.

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 7.20.5 Warranty

a. Material: Premium grade 100 % PVC

b. Height: 750 mm
c. Base: 320 mm
d. Rubber Base Thickness: 25.4 mm
e. Reflective Sleeve: White PVC Sleeve of width 100 mm
f. Weight: 1.9 Kgs

7.20.6 Measurements

The quantity to be measured for payment shall be the number of each cone

7.20.7 Payment

Pay Item Description Unit

7.20.1 Cones Nos

7.21 Fencing for Footpath / NMT Lane Separator

7.21.1 Description
The work consists of furnishing all materials for constructing fencing concrete foundations.
The work includes the furnishing and placing of foundation concrete and all other
incidental necessary and devices used to fix and erect the fencing as per contract drawings
or directed by the Engineer.

7.21.2 Materials

A mild steel to be used in such to AASHTO standard: M 183-93. Fencing for footpath /
NMT lane separator should be painted and finished with two coats of synthetic enamel
paint of approved color and quality over one coat of anti-corrosive primer to provide a
smooth painted appearance.

7.21.3 Installation

The fencing shall be carefully adjusted, installed or erected over 1:2: 4 cement concrete
foundation blocks of specified dimensions truly vertical and in longitudinal profile as
approved by the Engineer. The same shall be supported and protected appropriately at least
for 3 (three) weeks, till foundation concrete hardness after full curing during this period is
attained.

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 7.21.4 Measurement
The footpath / NMT lane separator fencing shall be measured in linear meters actually
constructed and accepted in conformity with size, shape and design/details as shown on the
drawings or as directed by the Engineer. The length, however, shall be measured along the
centre line of top of the fencing.

7.21.5 Payment

Fencing as measured above shall be paid in the contract unit price linear meter. Rate shall
be the full compensation for furnishing all labor, carriage, all materials, tools and plants,
welding and painting excavation, cutting pavements, cement concrete foundation curing
and protection of works, disposing off of surplus excavation material, backfilling and all
other incidentals necessary to complete the work.

Pay Item Description Unit

7.21.1 Fencing for Footpath, height 1.5m Lin. m
7.21.2 Fencing for NMT lane separator, height 1.5m Lin. m

7.22 Raised Pedestrian Crossing on Speed Table/ Speed Hump

7.22.1 Description

Raised pedestrian crossings on Speed tables are also used as speed reducer to the vehicles
.Speed tables are trapezoidal devices over an extended width enabling traffic to pass
through at higher speeds ranging from 30km/h to 60km/h. They consist of a flat top and
two approach ramps. In view of this raised pedestrian crossings are provided in the selected
bazar areas, in front of the School, College and University where vehicles pass at
considerable speed. Besides, raised pedestrian crossings are also provided in some critical
areas where vehicles have the options of passing at high speed.
The width of pedestrian crossings is generally in the order of 3m to 5m. Pedestrian
crossings may be located on or in between speed tables. Where traffic flow is heavy and
speed is around 30km/h, pedestrian crossings on speed table are particularly attractive if
there is already a footpath. Where traffic flow is heavy and speed is around 40 to 50km/h,
pedestrian crossings may be located between speed tables. Where traffic flow is moderate
and speed is low with busy pedestrian activities, pedestrian crossings may not be required.

Speed humps are sinusoidal device over an extended width enabling traffic to pass through
at higher speeds ranging from 30km/h to 60km/h.

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 7.22.2 Materials

7.22.2.1 Tack Coat

Liquid asphalt for tack coat shall be rapid-curing type cutback grades RC-2 or RC-4 or as
directed by the Engineer, and shall conform to the requirements of sub-clause 4.4.2 of this
specification. Bituminous tack coat shall be applied on the existing bituminous surfaces
where rumble strips/raised pedestrian crossing will be constructed.

7.22.2.2 Bituminous Mixture

The bituminous mixture for Raised Pedestrian Crossing shall be Premix Bituminous
Carpeting shall conform to the requirements for clause 4.5 premix bituminous carpeting of
this specification.
3% of cement shall be used in bituminous mixture as filler to improve the strength of
completed Raised Pedestrian Crossing.

7.22.2.3 Form Work

Steel forms shall be used for construction of Raised pedestrian Crossing. Forms shall be
placed on the road surface tightly so that shape of the works is obtained as per drawings.

7.22.3 Construction Methods

7.22.3.1 Surface Preparation

Immediately prior to the application of the tack coat, the bituminous surface shall be
cleaned free of all dirt, dust, and other foreign substances which, in the opinion of the
Engineer, would prevent proper bonding of the tack coat. For the case of rumble strips
chipping shall be done on the existing road surface for ensuring bond up to satisfaction of
the Engineer.

7.22.3.2 Application of Tack Coat

Immediately after the surface has been cleaned and approved by the Engineer, the tack coat
shall be applied to the area of construction where premix bituminous material shall be
applied on the existing bituminous surface. The bituminous material shall be applied by
means of approved hand-spraying equipment. The rate of application shall be as shown on
the plans or as ordered by the engineer, but in no case shall exceed one-quarter (1/4) liter
per square meter. The tack coat shall be applied uniformly and to the satisfaction of the
Engineer.

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 7.22.3.3 Placing of Bituminous Mixture

As soon as the tack coat has set hot bituminous mixture shall be placed in the forms and
consolidated by approved hand methods and struck flush with the top of the form.

7.22.3.4 Compaction of Bituminous Mixture

For the case of rumble strips bituminous mix shall be consolidated by hand compactor/hand
roller. Forms of rumbles strips shall remain in place until the premixed bituminous
materials has properly consolidated and pre-compacted so that shape of the rumble strips is
not distorted after removal of the Forms. Rumble strips damaged partially or fully during
removal of the Forms and allowing vehicles passing over, the contractor shall redo the
rumble strips at his own cost.
For the cases of speed reducers and raised pedestrian crossings bituminous mixture shall be
compacted with different method. After the bituminous mixture has been placed in the form
and consolidated, the form shall be carefully removed from the roadway and rolling
operations shall immediately be started with an approved pneumatic roller/vibrating roller
as per direction of the Engineer, Rolling shall be continued until the desired compaction is
obtained. Turning of roller on the work shall not be permitted. After completion of rolling
operations, all visible tack coats if any shall be blotted with sand.

7.22.4 Measurement

Raised Pedestrian Crossings shall be measured in contract unit rate per cubic meters
actually completed and accepted by the Engineer. Dimensions of rumble strips and raised
pedestrian crossings shall be measured after acceptance.
Bituminous tack coat shall be measured separately as stated under the item 3.7.1 of these
specifications.

7.22.5 Payment

The payment shall be the full compensation for all materials, labor, equipment, tools,
supplies and incidentals for completion of the work.

The pay items shall be:

Pay Item Description Unit

7.22.1 Raised Pedestrian Crossing Cubic Meter
7.22.2 Speed Hump Cubic Meter
3.7.1 Bituminous Tack Coat Square Meter

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 7.23 Rumble Strip (Thermoplastic)
7.23.1 General

A rumble strip is an installation on the pavement consisting of indentations which generate

an audio-tactile effect to alert drivers when it is driven over. When a vehicle drives over
them, they make a loud rumbling sound and vibration. They can be placed across traffic
lanes to alert drivers that they are approaching a potentially hazardous location, such as a
work zone or an isolated intersection. They are used along the shoulders or centerlines of
highways to alert drivers that they are leaving their traffic lane.

Types of rumble strips

a) Longitudinal rumble strip

Longitudinal rumble strips provide an effective warning to road users who may stray away
from their travel paths due to fatigue, inattention, errors in judgment or poor visibility in
rain or fog. If not corrected in time, this could lead to the vehicle crashing onto the roadside
or colliding with a stopped vehicle on the shoulder. Rumble strips are particularly
beneficial in a rural environment and may be installed along:

a. edge lines and shoulder lines

b. centerlines and wide center lines
c. chevron markings preceding a diverge gore

However, it should not be placed on the shoulder of a roadway that is used by bicyclists
unless a minimum clear path of 1 meter is also provided on the shoulder. On divided
highways, rumble strips are sometimes installed on the median side (left-hand side) shoulder
as well as on the outside (right-hand side) shoulder. On two-way roadways, rumble strips are
sometimes installed along the center line.

b) Rumble strip median

Rumble strip median is provided to carriageway for separating traffic flow. It is constructed by
premix bituminous carpeting materials with seal coat at the same time will be measured in
linear meter actually constructed and accepted in conformity with size and details as shown
on drawings or as directed by the Engineer.

c) Transverse rumble strip

The main purpose of transverse rumble strips is to reduce traffic speeds and raised awareness
on the approach to intersections, roundabouts, pedestrian crossings and urbanized sections
etc. They are also useful on the approach to sharp curves, tunnels and toll plazas on free-flow
sections of single and dual carriageway roads. They should be used in conjunction with
traffic signs unless the hazard is self-explaining.

Page | 87
Detailed dimensions of transverse rumble strips are given in the Engineering drawings.
Rumble strips shall be provided on the Highways to aware the drivers about speed reducer,
raised pedestrian crossing and rail crossing ahead. 6-9 strips shall make a set of rumble strips
and two sets of rumble strips shall be required. Distance of the Rumble Strips from the
obstructions and distance in between each set of Rumble Strips vary depending upon speed
limits of the vehicles. Table 07.23-01 shows the distances at different speed limits.

Table 07.23-01 Distance of the Rumble Strips from the obstructions and in between
each set of Rumble Strips

Speed Distance (L) in between the strips (Vehicles Clear distance (L1) in between
Limit will cross first) and the obstruction. two sets of Rumble Strips.
(km/hr) Distances are in meter (m) Distances are in meter (m)
40 100 25
50 125 30
60 150 35
70 175 40
80 200 45

Before commencing the physical works of the Rumble Strips the contractor shall give
layouts of the required rumble strips and get approval of the Engineer. The Engineer has the
authority to change the above distances and number of strips.

7.23.2. Material

Same as 7.5.2 from this specification

7.23.3. Placement

Same as 7.5.3 from this specification

7.23.4. Measurement

Same as 7.5. 5from this specification

7.23.5. Payment
Same as 7.5.6 from this specification

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 7.24 Rumble Strip Tape/ Pavement Marking Tape
7.24.1. General

Pavement Marking Tape is a high visible and durable reflective tape. Pavement marking
tape with a polyurethane top coat is applied for long term high dry brightness to retain
whiteness and a reinforced netting for added long life. These tapes can be applied without
surface preparation adhesive during the typical pavement marking season. These tapes are
ideal for use on asphalt or concrete surfaces and on dark roads where reflectivity is critical
during the night. These are preformed reflective tapes for permanent-type applications such
as lane and center lines, edge lines, gore markings, crosswalks, stop bars, symbols and
legends.

Requirements

Adhesive Type Permanent

Average Daily Traffic High, Medium
Construction Pre-formed patterned tape
Design Pattern Raised diamond pattern
Surface Type Asphalt, Concrete
Width 100 mm

7.24.2 Installation
Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge.

7.24.3. Measurement

The quantity to be measured for payment shall be linear meter

7.24.4 Payment

Pay Item Description Unit

7.24.1 Rumble strip tape Lin Meter

7.25 Convex Mirror

7.25.1General

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 Convex mirrors are used for safety reasons to overcome sight restriction problems. Their
use is now widely accepted in low-speed vehicle and pedestrian conflict areas. Convex
mirrors are typically used where the lateral sight distance is poor at locations such as
obscured T- junctions, concealed driveways, acute bends of a narrow road, such as hairpin
bends in mountain passes, parking areas with acute exit driveways, or approaches to
skewed railway level crossings. The convex mirror is also known as the spherical mirror,
wide-angle mirror, it is mostly placed or installed in a variety of corners and junctions. It
can expand the driver’s vision so as to detect the corners across the vehicle early to reduce
the occurrence of traffic accidents. And it also can serve as a monitor if installed in the
street corridors and shops.

Precaution

However, convex mirrors should not be used as the first option when sight distance is
restricted. Convex mirrors should only be used in low-volume, low-speed road
environments. The traffic being viewed in the mirror should have an 85th percentile speed
of 60 km/h or less.
Convex safety mirrors shall not be installed:

a) On public roads where alternative traffic management measures or engineering

measures such as improvements to sight distance and road-realignment are
available in the short term.
b) To enhance the safety of pedestrian crossing movements. Other solutions should be
considered, such as relocation of the crossing point or strategically located
pedestrian refuges.
Convex mirrors are not for general use and should only be installed as a traffic safety
device if there is a severe problem with sight distance and there are no other viable options
available. A road safety audit should be conducted before a decision is made to install a
convex mirror on a public road.

7.25.2 Material

Properties
Convex mirrors should have following features:
a. offer bright reflection
b. unbreakable and unalterable
c. easy to install
d. durable
e. vandal resistant
f. weather proof material
g. resistant against abrasion
h. corrosion resistance

Material/ Product Details

Page | 90
Body Material highly polished stainless steel or polycarbonate
Size 45 cm/60 cm/80 cm/100 cm
Lens Polycarbonate with Hood
Shape Circular

7.25.3 Installation

Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge. These mirrors can be fixed in different angles as per the need, used to
see the images of vehicles from blind spot and prevent accidents.
The ‘DISTORTED IMAGE’ written sign must be installed below the mirror. An advance
sign ‘CONVEX MIRROR AHEAD’ also be required if the location of the convex mirror is
not obvious.

7.25.4. Measurement
The quantity to be measured for payment shall be the number of each Convex Mirror

7.25.5 Payment

Pay Item Description Unit

7.25.1 Convex Mirror Nos

7.26 Anti-Glare Systems

7.26.1 Description

Anti-glare systems are facilities to limit the glare of headlights from opposing vehicles or
other external light sources. Anti-glare screens are installed on the roads and designed to
prevent a driver against glare from headlights of an oncoming vehicle. The main reasons
for using and installation of anti-glare screens on the roads are road sections with dangerous
and sharp turns, accidents at dusk and at night, unfavorable terrain.

7.26.2. Material

Materials should confirm European standards EN 12676-1, EN 12676-2 or as per Clients

requirement.

The main structural element is a robust blown plate made of low pressure high molecular
weight polymer which is painted with non-fading stain and resistant against UV radiation.

Page | 91
 a. Plate height: 600 mm, 900 mm, 1200 mm.
b. Plate width: 220 mm, 267 mm.
c. Wear-resistant, resistant against corrosion and UV radiation, various chemical agents,
various environmental influences. Product operation is acceptable at the temperatures
between -40 and +60 degrees.
d. Wind load on the system structure is 150 km/h.
e. Anti-glare screens have no sharp corners on which the people can get hurt.

7.26.3 Application

Anti-glare systems should be considered mainly on Expressway and National Highway

roads in the following situations:
1. Narrow Median width
2. Relatively heavy night time traffic
3. Low standard horizontal curves and sag curves
4. Opposing traffic at a different level smaller than 2m
5. Existence of a parallel road with opposing traffic
6. Near tunnel portals where tunnel tubes are at close proximity
7. Glare from other light sources

At intersection, median openings and pedestrian crossings, anti-glare systems have to be

terminated well in advance to satisfy visibility requirements.

Requirements
The height of anti-glare systems is generally in the order of 1,400mm above the pavement.
The width of anti-glare screen is in the range of 80 to 250mm at a spacing of 0.5m to 1.0m.

Anti-glare screens should be able to shield opposing traffic headlamps at an angle not less
than 8 degrees. On horizontal and vertical curves, the minimum angle should be increased
to the range of 8 to 15 degrees.
Anti-glare facilities on curves should not result in unacceptable forward visibility required
for the prevailing operating speeds of traffic. Otherwise, the median has to be adequately
widened.

Precaution
Anti-glare screens or nets should not be made of reflective materials. They may be attached
onto safety barriers without compromising their normal safety function.

7.26.4. Measurement

Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge.

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 7.26.5. Payment
The quantity to be measured for payment shall be in linear meter

Pay Item Description Unit

7.26.1 Anti-Glare Screen Lin Meter

7.27 Sound Barrier

7.27.1 General

Modern highways are a source of noise of rather a high frequency rate (ranging from 63 to
8000 Hz) that significantly exceeds the acceptable sanitary and hygienic norms for
surrounding areas. There are a lot of scientific works on the issue of the harm of noise loads
for living forms; therefore noise screens within populated places, recreation spaces and
other adjacent inhabited areas are compulsory.

Requirements and conditions

a. Acoustic design
 correct acoustic calculations to determine the geometric dimensions,
configuration and location of barriers

b. Construction design
 according to the requirements of acoustic design for the barrier geometry taking
into account the geology, geodesy and wind region norms, an economical
version of the foundation should be developed;

c. Using of high-quality structural elements

 mandatory anti-corrosion protection for all metal parts
 acoustic elements in the barrier structure should have an acoustic insulation
factor not less than 24 dBA

d. Installation
 correct installation is an important factor under assembly of barrier structure
 Need to avoid discontinuity in the barrier body (the exception – using of
additional acoustic barriers), cracks and gaps both in the structure itself, and
between the structure and the roadbed.

7.27.2 Materials

Materials with Types

Noise barrier is a structure composed of:

a. Foundation;
b. Metal supports;
c. Acoustic structural elements;

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 d. Seals and fasteners.

Noise barriers are divided into two types – noise reflective (transparent and non-
transparent) and noise absorbing (non-transparent, with a mineral wool filling) systems.

Noise Barrier Screens

The main structural unit is a noise barrier panel. The panel is made of galvanized metal
from 0.7 to 1.2 mm thick and later it is coated with a polymeric coating. The panel has the
shape of a box and is filled with mineral wool (with density ranging from 75 to 175kg/m 3)
in a waterproof film.

The noise barrier panel may have no perforations or may have a perforated front side that
increases the absorption ability (absorption factor).

Reflective Noise Screen

The main structural unit is a reflective sound case manufactured of acrylic glass or
monolithic polycarbonate (with a fatigue limit not less than 60MPa and a light-transmitting
ability not less than 88%). Due to the high light-transmitting ability the reflective noise
screens allow surveying and prevent from the tunneling effect.

Combined Screens
The construction includes noise barrier panels combined with reflective sound boxes.

7.27.3 Constructions

Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge.

7.27.4 Measurement

The quantity to be measured for payment shall be in linear meter

7.27.5 Payment

Pay Item Description Unit

7.27.1 Sound Barrier Lin Meter

7.28 Street Lightning

7.28.1 General

Street lighting should be provided as a priority:

a. Within built-up areas and their peripheries

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 b. For road sections with sub-standard alignment
c. For road sections with heavy traffic at night time
d. For road sections with regular pedestrians or slow traffic at night time
e. For grade-separated pedestrian or slow vehicle facilities
f. At major interchanges or intersections with heavy traffic at night time
g. Through tunnels, long bridges and their immediate approaches
h. At toll plazas and immediate approaches to ports or border control points

General Requirements

The recommended luminance performance of street lighting is given in Table 7.28-1.

Table 7.28-1: Recommended Luminance Performance of Road Lighting

Recommended Average Overall Longitudinal Road Categories

Luminance Luminance Uniformity Uniformity
Performance Level Ratio U0 Ratio U1
Category L (cd/m2)
1 1.5 0.4 0.7 Expressway and
National Highway
Roads with speed
limit >= 70km/h
2 1.0 0.4 0.5 Other rural or
urban roads
3 0.5 0.4 0.5 Connecting roads
of less importance

L: Average luminance over a defined area of the road surface viewed from a specified
observer position
U0: Ratio of the minimum to average luminance of a defined area of the roadway
U1: Ratio of the minimum to the maximum luminance along a longitudinal line drawn
through the observer position

7.28.2 Material and Equipment

a. Urban Traffic Routes, Main Distributor Roads – Generally 10 meter mounting

height column supporting LED luminaires as appropriate to meet the requirements
for the appropriate ME lighting class.

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 b. Industrial Estate, Local Distributor and Access Roads – Generally 8-10 meter
mounting height column supporting LED luminaires to meet the requirements for
the appropriate lighting class.
c. Residential Roads Access Roads and Footpaths – Generally 6 meter mounting
height column supporting LED/ as appropriate to meet the requirements for the
appropriate S lighting class.

7.28.3 Constructions

All public lighting systems installed and maintained should fully comply with BS 7671:
Regulations for Electrical Installations 1992 and other related Legislation and Regulations
(Highways Act 1925, Electrical Department guidelines etc.)

Installation will be done as per Manufactures standard guidelines or as per instruction of the
Engineer in charge.

7.28.4 Warranty

Provide a written five year on‐site replacement warranty covering material, fixture finish,
and workmanship.
On‐site replacement includes transportation, removal, and installation of new products.
Finish warranty shall include warranty against failure or substantial deterioration such as
blistering, cracking, peeling, chalking, or fading. Provide a written five year replacement
material warranty for defective or non‐starting LED source assemblies. Provide a written
five‐year replacement material warranty on all drivers (power supplies). Provide a written
five year replacement warranty for luminaires exhibiting inadequate lumen maintenance at
end of warranty period. Warranty period shall begin on date of possession. The supplier
will provide the site Owner with appropriate signed warranty certificates. The site Owner
shall receive certificates prior to final payment.

7.28.5 Measurement
The quantity to be measured for payment shall be after completed work

7.28.6 Payment

Pay Item Description Unit

7.28.1 Road Lighting On Completed work

7.29 Distance Marker (KM Post)

7.29.1 Description

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This work shall consist of furnishing and installation of concrete kilometre posts as detailed
on the Drawings and at locations indicated on the Drawings or as directed by the Engineer.

7.29.2 Materials

Concrete kilometre posts shall be precast using concrete conforming to the requirements of
Section 7.10.2.1.3. Reinforcement steel shall conform to the requirements of related
Section. Paint, if indicated on the Drawings, shall be of the appropriate type and color and
to the approval of the Engineer.

7.29.3 Construction Methods

Construction, fabrication and installation of concrete kilometre posts shall be as shown on

the Drawings.

7.29.4 Measurement
The quantity measured for payment shall be the actual number of concrete kilometre posts placed and
accepted.

7.29.5 Payment
This work measured as provided above shall be paid for at the Contract rate for each
monument and post. The price and payment shall be full compensation for furnishing and
placing, including all materials, labour, equipment, tools, and incidentals necessary to
complete the work.

Pay Item Description Unit

7.29.1 Concrete Kilometer Posts On Completed Work
Each Nos

7.30 Traffic Impact Attenuators

7.30.1 General

The work shall include configuration, furnishing and installing traffic impact attenuation
devices at hazardous locations (for example gore areas between diverging roadways)
conforming to the details shown in the drawings/plans or as directed by the Engineer; so as
to act as energy observers. The traffic impact attenuators or crash cushions shall be
installed for speeds greater than 50 kmph. They may be composed of sand barrels or of ‘w’-
beam fender panels supported by diaphragm with trigger mechanism.

7.30.2 Material

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 The system shall consist of a group or series of free standing plastic barrels configured in
increasing weights from the impact point towards the object. The array shall be designed to
transfer the vehicle’s momentum to the increasing masses of sand in the barrels and to
provide a gradual deceleration. Each barrel is to be designed with a specific weight of
unbagged sand to absorb the energy of an errant vehicle. The lighter barrels shall be placed
near the front of arrays to gradually slow the smaller vehicles. Heavier barrels shall be
placed further back in the array to slow the larger vehicles. The standard module weights
are 90 kg, 180 kg, 315 kg, 640 kg and 950 kg, as recommended by AASHTO. The axis of
symmetry of the arrays should be directed along the most likely direction. Approach for an
errant vehicle for gore areas could be back towards the intersection of the edges of
pavement. For roadside hazards, the angle between access of the array and the edge of the
travelled way should not 10°. Obstacles in narrow median should be shielded on both ends
and the modules placed on the ends (to shield opposite direction traffic) should be placed
flushed with downstream edge of the obstacle to avoid wrong way hits. The modules
should be placed on a concrete or asphalt surface with maximum slope of 5 percent in any
direction. Each barrel’s location and weight of sand should be carefully spray painted on
the surface at the position that will be covered by the barrel to ensure that the array will be
correctly reconstructed after an accident.

7.30.3 Application
The total length and width of the array shall be designed depending upon the expected
speed of approaching vehicle. The typical lay out for approach speed of 100 kmph would
have total length of 10 m, width of 2.5 m accommodating 14 barrels arranged in 9 rows
with one barrel in first 4 rows and 2 barrels in next 5 rows. The Contractor shall furnish a
copy of the manufacturer’s installation instructions for whatever particular brand of sand-
filled impact attenuator is to be used. The sand-filled impact attenuator arrays shall be
inspected to ensure that the array is set up as shown in the standard plans and filled in
accordance with the manufacturer’s recommendations. Sand barrels are essentially one-hit
systems requiring complete replacement of impacted barrels. Their use, therefore, is
suitable at sites where impact frequency is expected to be low. The arrangement shall be
first designed and the layout drawing got approved by the Engineer.

Proprietary Attenuator System

The Proprietary Attenuator Systems essentially comprise a series of w- beam fender panels
supported by diaphragms with a trigger mechanism at nose, which, when hit, releases a
‘front assembly’ to absorb the energy of impact. When impacted, the system shall telescope
rearward to absorb the energy so as to bring the errant vehicle to a controlled stop. The
refurbishment shall involve the replacement of damaged unit with repair done, off site. The
contractor/supplier of such system shall furnish the certificate that the system to be installed
has been tested in accordance with the NCHRP 350 and performs effectively at design
speeds up to 100 kmph

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 7.30.4 Measurement

The quantity to be measured for payment shall be after completed work

7.30.5 Payment

The traffic impact attenuator system shall be measured and payment made for design and
installation of the system as complete job at each location.

Pay Item Description Unit

7.30.1 Impact Attenuator on completed work

7.31 Semi Automatic Toll Collection System

The Integrated Semi-Automatic Toll Collection System shall comprise following main
subsystems:

a. Automatic Vehicle Counter cum Classifier (AVCC)

b. Automatic Boom Barrier
c. Contactless Smart Card Systems
d. Ticket Printer
e. User Fare Display unit
f. Close Circuit Television System (CCTV)
g. Lane Controller
h. Traffic Light System
i. Intercom System
j. Over Head Lane Signs
k. Integrated Toll Management Software

All equipment shall have built - in or external surge protection devices.

7.31.1 Automatic Vehicle Counter cum Classifier (AVCC) System

General
The AVCC system shall be able to distinguish between the categories of vehicles using the
highway and as defined by the Ministry’s Toll Rules. This class information shall be
transmitted to the Lane Computer on completion of the post Automatic Vehicle

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 Classification (AVC). The Lane Computer shall check that this information matches the
classification entered by the toll collector. If there is a discrepancy between the two
classifications, the Lane Camera shall be triggered to capture a digital image of the vehicle
together with details of the class discrepancy message, transaction number with its date and
time, lane number and toll collector. The digital image and discrepancy information shall
be communicated to the supervisory console for further processing by the toll supervision
staff. In case of network or Lane computer failure, the AVCC system shall function
independently and feed data directly to the Plaza Server and the system shall be able to
detect the vehicle moving in wrong direction. The system shall also assist in auditing the
toll collection operation. It shall be in modular unit with capability for various modules and
functions to perform independently at different levels of toll collection operation. The
Central AVCC data base system shall be part of this audit function. It shall be a standalone
device with control access where the data cannot be changed or altered in any way. The
reports from this system shall assist in identifying problems with operations, fraud or over/
under collection of tolls. This central AVCC database System shall be able to operate
independently of the Toll Lane System, even if the Toll Lane Controller is non-operational.
Any new technology, meeting the requirements specified in these Specifications should not
be excluded.
Technical requirements
Each lane shall be equipped with an AVC controller (different from the lane controller)
interface to classification sensors. The classification sensors can be any or combinations of
the following types:
a. Fiber-optic treadles
b. Laser classifiers
c. Optical height sensors
d. Optical axle counters
e. Infrared Light curtains
f. Magnetic Sensors
g. Resistive Sensors

AVCC processing unit shall be a real-time processing unit shall be the trigger source for
Lane Camera system and shall have standby power supply capable of operations for a
period of at least 4 hours. The AVC controller should be metallic, vandal-proof with IP 65
protection. It shall have System accuracy (calculated on a base of 10,000 vehicles)

a) For vehicle counting: 99% minimum.

b) For vehicle classification: 98% minimum.

7.31.2. Automatic Boom Barrier

General

The barriers are to be used to control the traffic through the lane. The operation of boom
barrier shall be linked to the lane computer and shall allow the vehicle to pass through after

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 a successful financial transaction. The system shall consist of a fixed housing and a
movable arm. The boom shall be of 3000 mm length for a normal lane and more than 3500
mm for extra wide lane. The housing shall contain the motor and control units and shall be
installed on the left side of the lane. The boom barrier should be electrically operated
barrier gate for Toll Lane application. The barriers shall have presence detectors
independent to the AVC system to prevent barrier arms coming down on vehicles while
passing. This shall be in the form of infrared units, dedicated embedded loops or any other
sensors. The finish of its housing may be Powder Coated Orange, RAL 2000 and that of the
boom with powder Coated White RAL 9010 with reflective strips. All housing and internal
parts shall have rust and corrosion free metals or alloys of high strength with suitable epoxy
coating as applicable. The Housing base frame shall be of Stainless Steel so as to protect
the housing from rusting from the bottom.

Technical requirement

The power supply shall be through 230+/-10%V AC, 50Hz with 100 percent duty cycle. Its
Logic Control shall be with Technology to ensure that opening and closing timings remain
constant under variation of wind and speed. It shall have smooth landing of boom without
swaying at the end positions. The response time shall be 1.5 seconds, for boom length of up
to 3000 mm and 2 sec. for boom length more than 3500 mm. The mean time before failure
(MTBF) shall be 5 million cycles (1 Cycle = 1 open and close). It should be able to operate
between the temperature ranges of -5oC to 55oC.

Lane Camera

General
The camera installed at convenient location shall be capable of capturing images of the
following vehicles:

a) In case of class discrepancy between the class detected by the AVC

and that entered by the toll collector
b) Exempt users
c) Vehicles with Smart card
d) All transaction of vehicle with special events
e) Offending vehicles
f) When the alarm footswitch is activated by the toll collector.

System Configuration

The camera should be installed at convenient location to capture images of the vehicles; it
shall produce clear images of the front view along with the number plates of the vehicles
even during night. The resolution of the images should be such that the registration number
of the vehicles can be easily read. The camera should have waterproof housing with a hood
to protect from direct sunlight. The protection shall be in accordance with IP65. The stand

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 for the camera shall be made in steel tube that will not swing or twist under gutter speed of
strong wind.

7.31.3 Contactless Smart Card Readers/Writers

General
The Contactless Smart Card Readers/Writers are used for managing electronic Toll
Collection in conjunction with a compatible Contactless Smart Card. The Contactless Smart
Card Readers/Writer is linked to a micro-controller or a PC which is typically the lane
computer. It allows the vehicle to pass through after a successful financial transaction. Card
reader/writer shall be “single-package” type, combining electronics and antenna in one
package.

Installation requirement

The Contactless Smart Card Readers/Writers shall be installed on the right side of all the
lanes of the Toll Plaza. The orientation of the Contactless Smart Card Readers/Writers shall
be wall mounting type, to be at a suitable height on the toll booth wall, to accommodate all
types of vehicles e.g. separate readers for trucks/buses and cars/jeeps. This is to ensure that
a successful ‘Readers/Writers’ is achieved with a Contactless Smart Card. Readers/Writers.

Technical requirements

The reader shall have the ability to read the smart card from a distance, ranging from 0 cm
to 10 cm with a transaction time of less than 0.5 seconds for read/write. Contactless Smart
Card Readers/Writers shall be wall mounting type and all transactions shall be secured with
modern and industry standard cryptographic techniques or those based on DES/3DES
mechanisms to resist fraud and to deter theft or misuse. The reader/writer shall conform to
ISO Standards: 14443A and shall be sealed to a NEMA 4/IP65. It should have transmit
frequency of 13.56 MHz The operating temperature of the Smart Card Readers/Writer
should be -5oC to +55oC and operating humidity of up to 95 percent non-condensing.

Contactless Smart Cards

General

The Contactless Smart Card is used for storing money value for the purpose of Toll
Collection in conjunction with a compatible Contactless Smart Card Readers/Writers. The
Contactless Smart Card allows the Readers/Writers to increment/decrement user fee from
the stored money value. It allows the vehicle to pass through after a successful financial
transaction. The Contactless Smart Card, the card Readers/Writers shall be in a single
technology configuration. The Smart Card shall be able to store the money value in prepaid
mode.

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Technical requirements

The card shall meet the ISO 14443A standards for contactless smart cards. The memory of
the smart card shall be >=1KB. It shall be warranted against defects in materials and
workmanship for 3 years. The Operating Temperature of the Smart Card should be -10ºC to
60oC.

7.31.4 Close Circuit Television (CCTV) System

General

The System shall be provided to monitor the activities of toll collection booth operations in
the toll plaza. It shall comprise Video Camera and Video Camera Housing at the toll Plaza
and 42’’ LCD Monitor and Digital Video Recorder (DVR) at the control centre. The Video
Cameras shall be conveniently mounted so that full view of the Toll Plaza and the booth
operations are captured.

Technical requirements

The Video Camera shall be of dome type to avoid pilferage, be resistant to vandalism and
be weather-proof. The mounting and equipment housing shall be able to withstand adverse
weather conditions the camera shall provide a minimum of 520 TV lines horizontal
resolution. The camera shall provide a useable picture at a minimum illumination of 0.02
Lux. The weighted signal to noise (SN) ratio shall be greater than 50 dB at 1.0 V p-p, 75
ohms. The Cameras shall have MTBF (Mean time between failures) of at least 50,000
hours of operation.

7.31.5 Digital Video Recorder (DVR)

The Digital recorder shall be stand alone and have the facility to record images on the hard
disk and also on external recording devices such as DVD, Hard Disk etc. The digital
Video Recorder shall have enough data storage capacity to store video of 15 days from all
the cameras and shall have interface to archive the data on to the DVD/Tape for back-up.
The DVR shall have sufficient video signal inputs to cater for all cameras. It shall have
Capability alarm/event based recording and the facility for high speed searching based on
inputs such as date, time, etc. The Digital recorder shall have functionality to display
multiple video images simultaneously on a single Monitor/Screen.

7.31.6 Lane Controller

General

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 The Lane Controller shall be provided to control and monitor all the sub systems of the toll
lane. It shall consist of CPU and power supply, Data Communication ports, Digital I/O
port, Circuit breakers, Terminal blocks, Relays LAN port, IP 65 enclosure with high
security locking mechanism. All the peripheral devices in the lane shall be hardwired to the
Lane Controller.

Technical requirements

The system shall be modular with Input/output Card having adequate channels catering to
interfacing of all the peripherals devices with a provision for adding extra two devices. The
system shall be housed in a metallic enclosure and installed inside the toll booth. All the
peripheral devices in the lane shall be hardwired to the Lane Controller.

7.31.7 User’s Fare Display Unit

General
The Fare Display Unit shall be in the form of a variable message sign, controlled
automatically by the lane computer, to indicate the category of the vehicle and the amount
payable by the road user. The system shall be LED based. It shall be installed outside the
booth, near the payment window so that the road user will have clear view of the fare
payable.

Technical requirements

a) Power Supply : 220V/50 Hz AC

b) Communication : RS232
c) Operating Temperature : -10oC to + 55oC
d) Protection : IP 65
e) LED Reliability : 100,000 hrs

7.31.8 Traffic Light System

General

LED based light signal, installed at the toll lane towards the exit side shall be connected to
the lane controller. The traffic sign glowing red would indicate that the motorist has to stop
and pay the user fee. After successful transactions, the traffic sign would turn green to
indicate that the motorist can proceed onwards. Traffic lights shall be installed on a pole of
about 2 m above the road surface on the right side of each lane. The Contractor shall decide
the appropriate height taking into account other equipment to ensure clear/unobstructed

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 visibility and control through lane controller. The system shall work in synchronization
with the boom barrier and shall have in-built night dimming function.

Technical requirements

a) Size of the display Approx. 200 mm diameter with sun visor

b) LED Industry standard, Red and Green
c) Housing Corrosion resistant material
d) Environmental protection IP 65
e) Intensity Day light visibility > 1000 mcd for Red, >1600
mcd for Green

f) Operating temperature -100C to + 650C

7.31.9 Lane Communication System

Voice communication installed in the toll booths shall provide “hands free” two-way verbal
communication between the supervision staff in the toll control room and the toll collectors.
The toll collector shall be able to attract the attention of the Supervisor in the control room
by pressing a single button on the intercom slave unit in the toll booth. The equipment shall
also have the facility to allow the supervision staff to monitor communication in the toll
booth between the toll collector and the user or between any of the tollbooths without
alerting the toll collector. The voice communication system shall operate independently of
the Lane Computer system. It shall also be implemented in various rooms of the plaza
building and at building access points. Two-way communications shall be possible as soon
as the Supervisor responds by selecting the appropriate lane button on the Master
Communication unit. One-way communication shall be possible from the Control Room
intercom to all lanes simultaneously (broadcast).

7.31.10 Overhead Lane Signs (OHLS)

The overhead lane signs OHLS shall be mounted on the leading edge of the canopy
covering the toll lanes above the center of the lane to indicate to the User whether the toll
lane is open or closed for the processing of vehicles. A Red Cross signal would indicate
that the lane is closed, whilst a green arrow would indicate that the lane is open to traffic.

Technical requirements

The OHLS shall be made of green and red LEDs. Signs shall be sufficiently bright and
directed to indicate to a motorist approaching the toll plaza, at a distance of 250 m on a
bright cloud free day that lanes are available for use. The cross and allow aspects shall be
larger than 300 mm. The sign shall be fitted with a sun-hood to screen the effect of the
sunlight. The enclosure of the OHLS shall be constructed from a corrosion resistant

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 material. The enclosure shall have an IP 65 rating and be ventilated to dissipate internal
heat. The system shall have night dimming function.

UPS System

UPS system shall be supplied for individual lanes and plaza systems separately. Each UPS
system shall be designed for 125 percent of the total connected load. The power supply to
all electronic equipment (indoor and outdoor) shall be fed from UPS which shall have
minimum 2 hours backup. The power budget calculation is to be submitted to the Engineer.

Violation Alarm
The siren operates in conjunction with a violation and acts as a warning device. The
purpose of the siren is to alert the plaza staff of a run-through through the lane. Visual
indication is via a strobe light. It shall meet the following requirements:

i) Technology Motor driven

ii) Audible rating 112 dB at 1 m
iii) Hearing distance 500 m
iv) Environmental Protection IP 65

Computer Hardware

Plaza server shall have following minimum Specification:

a) Intel Xeon 3.0 GHz or higher with Intel EM64T/1 MB Cache/ 800 MHzFSB
b) 2 GB ECC DDR2 RAM upgradeable to 12 GB
c) Dual Channel U320 SCSI Controller
d) 6x36 GB (10K rpm) HDD, Hot-pluggable, with RAID-5 Support
e) CDRW – DVD Combo Drive
f) Dual Gigabit 10/100/1000 Ethernet
g) Redundant Power Supplies, Redundant Fans
h) Anti-virus pre-loaded
i) Server Management Software – with remote management features onboard
j) 20/40 GB DAT Drive
k) Certifications: ACP V1.0 B Compliant PCI 2.2 Compliant, PXE Support, WOL
support, Microsoft Windows 2000/2003, Linux, PCI-X1.0 Compliant
l) Operating Conditions: Operating Temperature Range: 0ºC-50ºC
m) Relative Humidity: 20 percent - 90 percent, non-condensing
n) AC Voltage : 207V AC to 253V AC @ 47-63Hz

Bar code reader

The bar code reader shall be used to scan unique identification bar codes imprinted on
media such as paper and plastic medium such as smart cards etc. The bar code reader shall

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 be equipped with easily visible LEDs and audible beeps that indicate the scanner’s
operation status. The barcode reader shall have a rugged protective boot with an adjustable
stand and be mounted to a countertop or be left free standing for handheld scanning. The
barcode readers shall conform to IS: 14700: Part 6: Sec 3; 2002. The bar code reader shall
be IP54 protected.

Receipt printer
The receipt printer shall be a compact thermal printer able to print, as a minimum, toll
payment receipts (text and graphics) and barcodes. The receipt printer shall use thermal
fixed head technology. The print speed shall not be less than 150 mm/s for both text and
graphic and at a minimum resolution of 203 dpi (8 dots per mm). It shall be able to support
paper thickness of 75 - 80 GSM. The receipt printer shall support programmable English
and Hindi fonts and graphics, including Barcodes of at least Code 128 format. The receipt
printer shall have an automatic cutter with a self-sharpening ceramic rotary knife. The
receipt printer shall be robust for use in a toll booth environment where there is heavy
usage and possible dust and exhaust from vehicles. The auto cutter shall have a reliability
of at least 1.5 million cuts. The receipt printer head shall have a Mean Cycle between
Failure (MCBF) of at least 50 million print lines. The receipt printer shall have a Mean
Time between Failure (MTBF) of at least 360,000 hours. The receipt printer enclosure shall
be IP54 rated.

7.31.11 Toll Management System (TMS)

The Toll Management System (TMS) shall be responsible for processing the data into
information that will be used to verify toll transactions, provide toll collector control, cash-
up and performance facilities, and shall include a host of management tools and reports for
the effective administration of the toll operation. The TMS shall also assist in auditing the
toll collection operation. It shall be a modular unit with the capability for various modules
and functions to perform independently at different levels of the toll collection operation.
The TMS shall have various customized reports to assist in managing the toll facility, and
to provide management tools to assess toll revenues. The TMS shall have financial
management and traffic analysis tools to assist the operator in planning operations. The
Contractor/supplier shall ensure that security updates and latest service packs, “patches” are
loaded. Industry standard operating systems shall be utilized and all user licenses shall be
provided. The database shall be an industry standard database and shall be supplied with all
the latest service packs and patches, including user licenses.

Payment

The payment shall be made for design, configuration, installation and commissioning the
ATMS, as complete job on the identified stretch of highway, as per directions of the
Engineer.

Pay Item Description Unit

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 7.31.1 Semi-Automatic Toll Collection System On Completed Work

7.32 Advanced Traffic Management Systems (ATMS)

7.32.1 General
The work would cover design, supply, installation, commissioning and/or operation and
maintenance of Advance Traffic Management Systems (which is one of the components of
Intelligent Transport Systems - ITS). The system would include out-door equipment
including emergency call boxes, variable message sign systems, meteorological data
system, close circuit TV camera (CCTV) system, traffic counting and classification system
and transmission system. The indoor equipment would comprise a large display board,
central computer (with Network Management System - NMS), CCTV monitor system, call
center system or management of emergency call boxes housed in a control center with
uninterrupted power supply. Any new technology, meeting the requirements specified in
these specifications should not be excluded. The systems shall meet following objectives

a) Smooth and uninterrupted traffic flow

b) Enhance road safety
c) Real time information and guidance to users
d) Emergency assistance round the clock
e) Alerts for abnormal road and weather conditions
f) Reduced journey time and inconvenience
g) ATMS shall provide online recording and reviewing of the voice & visual information
for record and analysis.

System Configuration
The ATMS shall have following sub-systems:

a) Emergency Call Boxes

b) Mobile Communication System

c) Variable Message Signs system

d) Meteorological Data System

e) Automatic Traffic Counter cum Classifier System

f) Video Surveillance System

g) Video Incident Detection System (VIDS)

Availability Requirements

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 a) make emergency calls to Control Centre in case of accidents, breakdown, fire and
ambulance
b) pre-warn the highway users about unusual condition on the road
c) ATMS shall provide the following information/data to traffic managers for efficient
and effective handling of traffic
d) information regarding location of any incident, incoming calls, help required and
messages to be passed to third parties
e) Information regarding traffic congestion, speed and weather conditions
f) ATMS shall provide the following controls to traffic managers
g) change the variable message signs from the Control Centre
h) Mobilize the movement of ambulances, cranes & patrolling vehicles.

The inability to perform any required function, the occurrence of unexpected action or
degradation of performance below the specifications shall be considered as a failure. The
Mean-time-between-failure (MTBF) shall be the average operating time accumulated by
the total population of identical items between failures. The system supplier/contractor shall
submit MTBF and MTTR figures. The ATMS shall have an overall system availability of
better than 99 percent. The ATMS shall be considered unavailable if any of its function
cannot be properly executed and when any of the following conditions persist for more than
8 hours on the entire stretch.

a) Variable Message System Failure: No display/Improper Display of VMS or

failure of their related transmission/control system which would render the
VMS inoperative

b) Emergency Call System Failure: Failure of any three consecutive Call boxes
or failure of their related transmission system which would render the call
boxes inoperative.

c) ATCC Failure: Failure of more than one ATCC or failure of their related
transmission system which would render the ATCC inoperative.

d) Met Failure: Failure of more than one Met or failure of their related
transmission system which would render the Met inoperative.

e) Video Surveillance System Failure: Failure of more than two Video Cameras
or failure of their related transmission/control system which would render the
cameras inoperative.

f) Video Incident Detection System Failure: Failure of more than one Video
Cameras or failure of their related transmission/control system which would
render the cameras inoperative.

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 g) Display at Control Centre: Whenever Control Centre is unable to get display
of messages initiated by the Control Centre in-charge.

In addition to the above the system shall be considered unavailable when failure of the
integrated ATMS Software or its hardware persists for more than 8 hours.

Reliability Requirements
The supplier shall ensure that ATMS supplied shall comply with the following reliability
requirements:

ATMS (Sub-Systems) Mean Time Before Failure - MTBF

Outdoor Equipment 15,000 hours

Transmission System Equipment 15,000 hours
Control Centre Equipment 15,000 hours
Power Supply Equipment 15,000 hours

Maintainability Requirements

The Mean-Time-to-Repair (MTTR) of the ATMS to full normal operation following a

failure shall be less than 8 hours all inclusive.

System Safety Requirements

The ATMS is classified as a safety related system and a minimum of CENELEC standards
EN50128 software integrity level 2 shall apply. All equipment must comply with and be
installed in accordance with IEC 65, IEC 364. All metal enclosures shall be provided with
an earthing terminal and earthing of all equipment shall be carried out in accordance with
overall earthing policy.

7.32.2 Environmental/Climatic Requirements

7.32.2.1 Indoor equipment :
Temperature (Operating) 0oC to + 50oC
Relative Humidity Up to 95% (non-condensing)
7.32.2.2 Outdoor Equipment
Temperature (Operating) 5oC to + 60oC
Relative Humidity Up to 95% (non-condensing)

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 The system and the equipment used as a minimum shall meet the following climatic and
environmental requirements

Tests Severities
Change of Temperature Low Temp 0°C + 3°C
(Temp cycling) High Temp 60°C + 2°C
Rate of cooling and heating 1°C/m
Duration of each cycle 3 hours
No of Cycles : 3
Damp heat (Cyclic) test Upper Temp 40°C + 2°C
variant 1 Lower Temp 25°C
One Cycle12 h
Relative humidity 95 percent
No. of Cycles : 6
Vibration Freq. range10 Hz – 55 Hz
(Sinusoidal) test Vibration0.35 mm
Amplitude
Duration of 20 sweep cycles endurance (10 Hz – 55
Hz) for sweep
No of axes 3 co-ordinate axis
Duration at 30 min+1 min resonant frequency

7.32.3 Emergency Call Box

The apparatus is a communication medium to be installed on the highway and to be used by

the road users to make alarm call to the Control Centre in case of accidents and other
emergency problems on the road or any incident. The Emergency Call Boxes shall be
located in pairs on opposite sides of the highway. Main ECB unit (Master) shall be located
on one side and the secondary unit (Slave) on the opposite side.

System Configuration

The Emergency phone shall comprise loud speaker, microphone, activation button, ringing
tone to indicate progress of call when button is pressed, confidence tone to indicate call is
still connected when on hold, recorded message in case the line is busy and LED indication
during conversation. These components shall be provided in FRP (Fibre Reinforcement
Plastic)/stainless steel/Aluminium Alloy housing.

General requirements

The ECB shall be designed for hands free operation. It shall be identified by reflective
guide sign placed approx. 10 m ahead of the ECB. It shall have a provision for mounting on
a concrete base with cast-in bolts, nuts and washers and the whole shall be installed so as

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 the persons using the instrument will normally be facing the oncoming traffic. The
enclosure shall be equipped with retro reflective sticker that is clearly visible at night. The
sticker shall read ‘SOS’ along with a telephone symbol. It shall have provision for the
instructions of operation to be written clearly on the outside surface in two languages.
Voice Logger Software shall be provided to handle and log all calls from the network.
There shall be up to four programmable auto dial numbers associated with the push button.
The ECB shall automatically dial subsequent numbers if the first number is busy or
unavailable.

Technical requirements

The ECBs shall work on DC supply and operate in full duplex mode. It shall be able to
operate in a noise level of up to 95 db. The ECB should be suitably protected against
external EMI/ESI interference through shielding or grounding. It shall have in-built
programming port/ feature for addressing. The same must be capable of being addressed
using Laptop or Palmtops in fields. The ECB Central software shall use this address for
identification of ECB. The ECB shall use latest components and a micro controller of
adequate capacity to meet the system requirements. It shall have in-built fault diagnostics
features for on-site maintenance and have extant protection against lightning. It shall be
powered from the communication cable/solar panel. The solar panel and battery shall be
adequately rated to support the ECB working under idle conditions and a talk time of
minimum 90 minutes over 3 days in succession under worst climatic conditions. At each
location one ECB shall be Master and the other Slave. The master ECB shall be equipped
with fibre optic interface, solar panel, battery back-up and voice communication
mechanism and shall also comply with all the requirements specified in this section for
ECBs. The slave ECB shall be equipped at least with
– activation button, vandal sensing mechanism, call progress indication LED,
Microphone, Speakers, Handicapped operation activation – in a weather proof housing
as detailed in these Specifications. The system shall detect vandalism and give audio-
visual alarm at the control center. The ECB system shall have a product support
guarantee of 10 years from the manufacturer. The ECB central system shall
communicate with the Central Traffic Management System and all the events and
alarms shall also be displayed and stored in the Central Traffic Management server.

The ECBs shall meet the specification as per the following:

a) Electromagnetic compatibility: be suitably protected against external EMI/ESI
Interface through shielding/grounding.
b) Lightning Protection: to be suitably protected.
c) Drop and topple: BS2011 or equivalent.
d) Enclosure: IP 65.
The equipment shall conform to all applicable electrical standards in India.

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 7.32.4 Mobile Radio Communication System

General

The mobile communication system shall be provided to establish voice communication on

radio between the Control Centre and the emergency mobile vehicles such as ambulances,
cranes and patrolling vehicles. The system shall comprise base station unit, repeater unit,
mobile radio unit and control center equipment. Its Base Station Unit shall comprise
transmitter, receiver antenna switch, radio engineering terminal, radio data terminal, radio
operator terminal and power supply. Its Repeater Unit shall comprise transmitter, receiver,
antenna, repeater and power supply. Its Mobile Radio Unit shall comprise transmitter,
receiver, antenna, control unit and power supply. The Control Centre Equipment shall have
Network Management System.

General requirements
The system shall cover the entire route. The system design shall be modular in concept.
The system shall be compact and rugged in design having ease of maintenance and shall
work satisfactorily under adverse conditions like storm, rain and vandalism resistant. The
system shall neither affect functioning of other telecom equipment installed adjacent or
along it, nor get affected by the presence of other equipment/systems. The Mobile Radio
shall have provision for mounting the mobile set on ambulances, cranes and patrolling
vehicles. The repeater station equipment and antenna shall be installed at sub centers. Each
mobile unit shall have a unique address code. The system equipment shall work on re-
chargeable batteries with 24 hr back-up.

The control panel of mobile unit and base station unit shall have the following features:

a) Power ON-OFF switch

b) Emergency calling button
c) Adjustment of loudspeaker volume
d) Digital display
e) Functional buttons

Functional requirements

The modulation shall be either frequency or phase type (FSK) and shall operate in semi-
duplex mode. The equipment shall have provision to eliminate collision of data. It shall
have facility to configure the network for individual, sub-group or broadcast mode of
operation for both selective calling and group calling operation. All components used in the
assembly of equipment shall be of industrial grade specification. The equipment shall
conform to ETS European standards and shall be suitably protected through shielding/
grounding against external EMI/ESI Interference, and shall be immune to RFI, ESD and
lightning.

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Technical requirements

The system shall have the facility to connect mobile to mobile, mobile to controller and
controller to mobile. The system shall have the facilities for waiting calls, holds calls and
transfer calls. The system shall have a facility such that the Control Centre can select
between the call modes of individual call, group/all-call and call to mobiles listed in the
queue. The system shall use primary channels for calling from mobiles to the Control
Centre and vice-versa whereas the secondary channels shall be used for mobile to mobile
connection. The system shall have the facility to terminate the mobile to mobile connection
under the following conditions:
a) One of the two parties hangs up

b) One of the two parties receives a call from the Control Centre

c) The duration of the conversation exceeds 5 minutes limit.

In case of emergency, the system shall have the facility to receive alarm calls from mobile
radio. The mobile radio shall be integrated with the Fibre Optic Communication system.
The system shall use frequencies to be obtained by the contractor from WPC in the
complete stretch as per scope. The system shall have the provision for communication on
the PSTN Network. The system shall have suitable voting system to select the better signal
at base stations as well as mobile units. The system shall have provision to handle calls
from/to at least 20 mobile sets. The system shall have self-diagnostic features. The system
shall be protected against any damage due to power supply fluctuations, transients and
surges.

7.32.5 Variable Message Signs

VMS Solution is a fully automated solution that provides real time, contextual updates to
motorists in an automated fashion without the need for any manual intervention.

This solution helps increase Road Safety & enhances Road User Experience. A Smart
VMS seamlessly integrates with a host of IOT (Internet of Things) nodes thereby
enabling a host of applications such as Weather, Parking, Air Quality Monitoring,
Disaster Management, Vehicle Monitoring & counting, etc. The solution is powered by
3M’s Analytics Engine which is designed to provide automated traffic & congestion
updates & predictive analytics to road users in real time thereby helping reduce
congestion.

Key Features:
a) Provides Real Time, Contextual & Useful Updates to Road users in an
automated fashion

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 b) Integrates with a host of third party sensors to allow applications such as
Parking, Air Quality Monitoring, Weather, etc
c) Instant citizen communication tool for disaster management.
d) Highly secure solution providing you best in class security & encryption

e) Robust solution that works seamlessly even in the event of control room
failure.

f) In built Analytics Engine provides powerful traffic and congestion

analytics

Function

The Variable Message Signs (VMSs) shall provide to road users the advance en-route
traveler information of road conditions ahead in real time. VMS shall generally provide:

a) Advance information on incidents such as accidents, traffic diversions,

incident management and notice for road work, adverse weather and road
conditions and operation with lane control signals;

b) Traveler information such as display of road construction activity in near

future, messages for testing of the system and special events that affect the
traffic flow;

c) Public service announcements like messages relating to driver safety

campaign.

Fixed VMS

Fixed VMS shall be mounted on a sturdy and aesthetically pleasing gantry structure
whereby the vertical clearance of at least 5.5 m is available from the road. Safety barriers
shall be provided at gantry support column(s) for their protection and for safety of road
users. The concrete pedestal for support column should be flushed with ground but in no
case should protrude for more than 1.5 m.

The minimum distance of VMS on expressways should be 1.5 km prior to decision point
and that for National Highways it should be 1 km. The signs should be visible from a
distance of 250 m. It should not be located on a curve and on a highway sections having
grade exceeding 4 percent.

There should be clear distance between existing sign and VMS. The minimum distance
between road signs and VMS should be at least 250 m on expressways and 150 m on
National Highways.

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Portable VMS

Portable signs can be mounted at the back of the truck or similar vehicle. The portable
VMS signs mounted on a truck could be powered by solar energy or battery and show the
sign of ‘men at work’ and/or speed limits in the construction zone. They shall be so placed
that they are effective. The placement must give adequate time to the motorists to react to
the message and take corrective action. On Expressways and National Highways placement
of these at 2 km prior to the decision points should be done with repetition at every 500 m.
It should provide a sight distance of 300 m and should not interfere with other traffic
control devices. If the portable VMS set-up and a message are not to be required for a
period of next four hours or more, the sign panel should be turned away from the traffic,
parallel to the road center line. Non blank signs should be facing the drivers for an extended
period.

Under no circumstances shall VMS be used for advertising of any kind. It would be in
blank mode when traffic, roadway, environment or pavement conditions or public service
announcements do not warrant the display of message or messages.

Type of messages through VMS

The average driver or motorized vehicle at high speed can comprehend two message
panels. Each panel should be complete phrase and each phrase should be independent of the
other. The messages should consist of:
Type of Statement Example
A problem statement Road work/accident ahead
An effect statement Delay/congestion
An attention statement for certain group Motorist
An action statement Take the next carriageway

Some typical messages are as given below:

Accident Ahead, Road Closed, Take Diversion;

‘Accident Ahead’ followed by some typical messages like ‘Expect Delays’, Merge Right’,
Merge Left’, ‘All Traffic Exit’ can be displayed.

Maximum Speed:—————kmph

Speed Limit strictly enforced;

Construction Work, Road Closed; Signal Ahead; Sharp Curve Ahead; Congestion Ahead;

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 Bad weather conditions like ‘Heave Fog Ahead’, ‘Poor Visibility Ahead;
Trucks use Left Lane; Watch for Stopped Traffic; Watch your speed; Watch for Falling
Rocks: (In the case of landslide prone areas);

Two Way Traffic Ahead (this message can be displayed where the road section abruptly
changes from four/six lane divided section to two lane bi-directional carriageways);

No Mobile When Driving; Drunken Driving Prohibited;

Technical requirements

The design of the system shall be modular. The system shall use LEDs/high gain Tran
reflective LCDs for outdoor full sunlight. The failure of one LED module should not affect
the output of any other LED cluster. Its design shall be such that the display is legible from
a distance of 300 m on Expressways and from 250 m on other highways.

The equipment will comply with the following:

a) Overall Size Board Length minimum 3000 mm

Height minimum 1800 mm
Depth 200 mm

b) Number of Display Lines 3

c) Number of Characters per line 15

d) Height of Characters minimum 400 mm
e) Language Bilingual
f) Contrast Ratio > 30:1 perpendicular to the board face
>10:1 at an angle of + 70° to
perpendicular.
g) Memory Capable of storing minimum 10 frames
that can be triggered on receiving the
tele-command.
h) Housing or other Powder coated housing with IP54
equivalent international standard for
protection and easing against dust,
sprayed water and winds.

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i) Mounting Pole mounted as gantry or cantilever
with vertical clearance of 5.5 m from the
surface.

j) Interface Standard RS422 and RS485 interfaces

with compatibility on Ethernet.

k) Special Features Automatic diagnostic and reporting of

failure/ fault of arrays/ rows
l) Additional Features and humidity Incorporation of temperature sensor
sensor.
m) Luminous Intensity (LED) 3000 mcd
n) Life of Components of VMS > 10 years

Elaborate Fault diagnostics shall be provided as per EN 12966 or other equivalent

international standards. Each pixel shall be monitored and feedback shall be provided for
the health status. Minimum of following shall be provided:

a) Power Failure at VMS

b) Processor PCB Failure

c) LED Cluster Failure

d) Loss of incoming message/data not properly received.

e) Temperature monitoring.

The controller unit shall provide brightness control facility. In order to monitor ambient
temperature of the housing the controller shall be capable of automatically diagnosing and
reporting component failure or any electronic fault. The controller shall be provided with a
test port for local diagnostics via laptop. It shall be possible to perform fault diagnostics
from the central control room via the software. The LED Clusters shall be mounted suitably
for providing better viewing angle. Each display module shall have its own display
interface to the Central processor. VMS shall be designed to comply with the following
protocols:

NMCS2, MESSAGE CONTROL, TR2070D, NTCIP Version 2 or other equivalent

international protocols.

Testing

The equipment shall be tested for functional requirements as below:

Messages shall be displayed using the central software and local terminal. The fault
conditions shall be simulated. Messages/fault logs shall be checked for:

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 a) LED FAULT
b) Communication failure
c) Power failure
d) Brightness of Pixels

Installation requirements
The structure on which the VMS is mounted shall be sturdy and aesthetically looking and
capable of bearing wind loads up to 200 kmph. The lowest hung part of the display board
shall have vertical clearance of at least 5.5 m from the road level. It shall be provided with a
walkway to allow at least six persons to carry out maintenance of the VMS without
obstructing the carriageway.

Transmission System

General
The Transmission system provides connectivity between Control Centre and outdoor
equipment such as Emergency Call Boxes, Variable Message Signs, Meteorological Data
System, Video Cameras, Traffic Sensors, etc. The system shall comprise Cable System,
Interface System and Optical Fibre Transmission System.
Cable system

The system shall comprise copper cable, Backbone Optical fibre cable (for connectivity
between the sub-centers and main control centre) and auxiliary fibre optic cable for
connectivity of the road side equipment to the sub-centre and Coaxial cable. The cable
system along with interface equipment shall work satisfactorily under adverse conditions
like storm, etc. The Optical Fibre Cable system shall interconnect with the defined optical
transmission sources and also if required with associated network devices for signal
transmission without any impairment. A separate and independent (auxiliary) Optical Fibre
Cable system shall be used for the transmission of video signals; data signals form the
equipment locations to the sub-centers where copper cable has limitations for transmission
of signal

All Optical Fibre Cable shall be of TEC (Govt. of India) approved design.
The Co-axial Cable System shall provide immediate interface to carry signals from CCTV
/VIDS Cameras located at strategic locations to the nearest sub center. Optical Fibre Cable
shall also be used with transmitters and receivers if the distance is large and high quality
signal transmission and reception is not possible using co-axial system. The signals shall,
without any impairment, be routed to the Control Centre via the sub-centers using the
auxiliary Optical Fibre cable.

Interface system
Interface System shall comprise Sensor interface equipment, Optical fibre cable interface
equipment and Control Centre interface equipment The Interface System shall cover the

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 Copper Cable, Co-axial Cable and Optical Fibre Cable System and transmit and process the
composite signals to achieve the desired reliability/availability requirement. The Interface
sub-systems shall be capable of handling the composite audio, video and data signals at
various interface levels and process them. The Interface sub-systems shall be designed
optimally at various levels i.e. from the individual sub-systems level to integrator through
Control Centre.

OFC transmission system

The system shall comprise optical line terminals, interface cards and network management.
The Backbone Optical Fibre Cable System shall interconnect the sub-centre/integrators and
the Control Centre. The Optical Fibre Cable system shall interconnect with the defined
optical transmission sources and also if required with associated network devices for signal
transmission without any impairment. The backbone communication of Cable system shall
be used only to interconnect the sub-centers to the main control centre. This cable shall be
terminated only at the sub-centres and main control centre. It shall not be allowed to
interface any other sub-systems in the field to this cable or any spare cores in the cable
directly or through branching. A separate and independent (auxiliary) Optical Fibre Cable
system shall be used for the transmission of video signals; data signals form the equipment
locations to the sub-centers where copper cable has limitations for transmission of signals.
This would be finalized during approval of detailed design by the successful bidder.
Power supply system
The Power Supply System shall support the requirements of individual sub-systems. The
Power Supply System proposed for individual sub-systems shall take into account the
overall availability/reliability requirements. The Power Supply System design shall take
into consideration local power availability, temperature and other climatic variations, and
easy maintainability.

Meteorological Data System

General

The Meteorological Data System shall consist of wind sensors for monitoring wind speed
and direction, visibility sensors for detection of visibility changes resulting from fog or dust
storm, atmospheric sensors to measure air temperature and humidity and road condition
sensor to read road surface temperature. The system configuration shall therefore comprise
thermocouple/dynamometer, humidity meter, anemometer and visibility meter.

Technical requirements

The Meteorological Data System shall communicate the measurement to the Control
Center. It shall be compact, rugged in design and having ease of maintenance and shall be
capable of detecting and keeping track of the surface temperature of the Highway surface
and initiate appropriate alarms at the Control Centre.

The Sensor shall meet following requirements

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Relative Humidity Sensor

Range : -100%
Minimum Accuracy : ± 2% RH
Resolution : 0.1%
Temperature Range : -5ºC to +60ºC
Sensor Mechanism : The sensor shall be adequately protected against
dust/pollution and shall provide a linear output voltage for 0 –
100% humidity

Air Temperature Sensor

Range :- 30ºC to +70ºC

Sensing Element : should provide a linear output for the entire range of
temperature
Resolution : 0.1% of range
Accuracy : ±0.3% of range
Visibility Sensor Range: 50 to 1500 m
Wavelength : 880nm
Sensor Type : Infrared sensor, source and detector
Accuracy : ±15%

Wind Direction Sensor

Threshold Speed : Less than 0.3 m/s

Accuracy : Better than ±5%
Damping ratio : 0.7

Wind Seed Sensor

Range : Up to 79 m/s
Threshold Speed : Less than 0.3 m/s
Accuracy : ±2%
Output Signals : Average Wind / Average Gust

Road Condition Sensor

Temperature Sensor
Range : -10ºC to +60ºC
Resolution : 0.1ºC
Accuracy : ±0.2ºC

Wet/Dry Sensor
Output : ON/OFF

Data acquisition controller:

The Data Acquisition Controller shall meet the following requirements;

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 a) Be suitable for all the supplied sensors,
b) Have appropriate number and type of inputs in order to service all the
sensors,
c) Incorporate an LCD display to allow local monitoring of the data,
d) Have a memory backup (up to 7 days) to retain data locally in case of
communication failure.

7.32.6 Automatic Traffic Counter cum Classifier

7.32.6.1 General

This system shall be provided for identifying and recording all types of vehicles on the
highway for effective monitoring and data collection at Control Centre. Besides, the system
shall be capable of classifying any other vehicle category as per user needs. Vehicle
classification should be user selectable based on length of vehicle and/or detuning of the
loop inductivity. The system shall be robust and be capable of operating with minimum
maintenance. The system shall interface with the ATMS/ATMS Software for central
monitoring. The indicative classification of common vehicles in India, based on wheel
base, is as given hereafter.

Serial Types of Vehicle Probable Range of Wheel Base (mm)

No
1) Two Wheelers (Motorized) 0-1350
Scooters, Mopeds, Motor Cycle
2) Three Wheelers 1400-1800
(Auto/Tempo)
3) Four Wheelers 1801-2675
Cars, jeeps, vans etc.
4) Light Motor Vehicles 2690-3400
5) Trucks/Buses 3401-5600
6) Multi Axle Vehicles 5000-18000

Vehicle Classification should be user selectable based on length of vehicle and number of
axles. The system shall have the capability of accommodating multiple installations through
installation of detectors/sensors which can be left permanently in place and connected as
required to the recording device when traffic counts are made at that particular location. It
shall also be capable of taking inputs from portable sensors and should be modular in
design. The system shall have capability of interfacing with the integrators for central
monitoring. It shall have suitable interface for transmitting information from ATCC System
to the Control Centre.

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Technical requirements

Sensors: The sensors should be a combination of piezo-electric sensors and inductive

loops, enabling counting/classification of up to 4-lane traffic (expandable to at least 6-lane
traffic) with user set time periods.

Electronics: Vehicle counting/classification interval shall be programmable from one

minute to 1440 minutes (24 hours) and system should accept user programmable recording
intervals to count and classify during a 24 hour period. The system should be able to count
and classify vehicle by each lane.

Data collection: The system shall be capable of sending data to the ATMS/ ATMS
Software which shall enable the ATMS/ATMS Software to classify the vehicles, detect
average speed per lane, vehicle occupancy and headway as a minimum. Data collection
shall be by RS232, RS422 or RS485 interface or IP connection. The system shall be
capable of recording, for later analysis, on an individual vehicle basis, time/date, speed,
direction, number of axles, axle spacing and site identification.

Data storage: The system should be able to record and store vehicle data for a period of at
least two weeks with daily traffic volumes of up to 10,000 vehicles.

Operating language: English

System accuracy: The accuracy of the system in recording speeds and headways/gaps
shall as per Table 7.32-01

Table 7.32-01 System Accuracy Requirements

Parameter Accuracy Conditions

Average Speed 10 There are at least 25 vehicles in the group,

percent individual vehicle speeds are between 10 kmph and
195 kmph with vehicles conforming to normal
highway driving behavior.

Average Headway 10 There are at least 25 vehicles in the group,

percent individual vehicle speeds are between 10 kmph
and 195 kmph, individual vehicle head-ways are
between 1 and 10 seconds and the vehicles conform
to normal highway driving behavior.
Flows 5 percent There are at least 100 vehicles of each category in
group and vehicles conform to normal highway
Driving behavior.

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 Occupancy 10 There are at least 25 vehicles in the group,
percent individual vehicle speeds are between 10kmph
and 195kmph, individual vehicle headways are
between 1 and 10 seconds and the vehicles conform
to normal highway driving behavior.

Data retrieval: The system should have the capability of data retrieval, direct data transfer
through a serial link to computer, Leased line/GSM/CDMA.

Software: Software and manuals to analyze the data from output of vehicle counts,
classification speeds and headways shall be provided. Capability of graphic/tabular
presentation of analyzed data shall also be offered.

Mode of operation: This will be user programmable up to at least 12speed and 15 vehicle
class bins, of vehicles operating in India (user specified). System capability in this regard
may be indicated. Counter shall also bin simultaneously in speed, axle and count or any
combination of the three.

Capability: The system shall have capability of recording vehicle counting and
classification, speed, headway at set interval of 1-10 minutes.

Video Surveillance System

General
The System shall be provided to monitor the movement of vehicles on the highway. System
configuration shall comprise video camera, video camera housing, pan and tilt heads,
optical transmission units for video and data (if required) and mounting poles at camera
locations. The Control centre configuration shall comprise monitors for individual cameras,
matrix switcher, multiplexer and digital video recorder with suitable interface for the
integrated highway package and optical interface units to the backbone communication
system wherever required (where the video and data cannot be transported from camera
location to the Sub-centre on co-axial cable). The Video Camera location shall be easily
identifiable. The Video Camera shall be of dome type to avoid pilferage, be resistant to
vandalism and weather-proof. The mounting and equipment housing shall be able to
withstand adverse weather conditions and the Video Camera shall be capable of working
satisfactorily under worst weather conditions. The Video Camera and associated units shall
be water ingress and dust proof. The Video Camera mounting shall have easy accessibility
for maintenance purposes.

Technical requirements

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 The Video Camera shall meet the following minimum technical as requirements:
a) Image Sensor ¼” CCD with 22 x optical zoom
b) Active Pixels 752(H) x 582(V)
c) Horizontal Resolution Minimum 470 lines
d) Sensitivity 0.02 lux @ 1/1.5 Second shutter speed
e) Focus Automatic (with manual override/preset facility)
f) Signal to Noise >50 dB
g) AGC Automatic with manual override
h) White Balance Automatic with manual override
i) Auto Shutter Yes
j) Signal Format NTSC/PAL
The video camera shall have angular travel as below:
Horizontal: 360º continuous pan
Vertical Tilt: +2º to -92º
The Video Camera shall have speed as below:

Manual Speed
Pan : 1/100 to 800/second (Variable)
Tilt : 1/10o to 400/second (Variable)
Preset Speed
Pan : 2500/second
Tilt : 2000/second

The dome drive shall have 40 presets with labels and shall have an accuracy of +/-0.250
preset accuracy. It shall have built-in protection against Power Line Surge and Lightning
and provision for Onscreen- compass and Tilt display, integral, auto sensing multi- protocol
receiver/drive and provision for Auto-flip dome rotation. There shall be programmable
limit stops for Auto/random/frame scan modes. The Video Camera shall be connected to
the control centre/sub-centre through co-axial cable and data cable/optical fibre cable as per
the site requirement and shall have remotely selectable operating modes and shall be
operated from the Control Centre.
The video images from camera shall be transmitted in real time. The video image shall be
made available at the control centre without any distortion or loss of information. The video
camera system shall have the facility for zone blanking, auto identification of zones when
the pan movement of camera is active and infra-red compatibility for night operation.

Video Incident Detection System

The system shall be an intelligent image detection system using CCTV cameras. The
cameras shall have inbuilt intelligence to ascertain when the image has meaningfully
deviated from the Standard Image originally recorded. On sensing the incident, the system
shall automatically start recording the image at the control centre.
The Incident Detection system shall capable of the following:

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 a) Measurement of traffic flow speed between 0 and 150 km/hr for up to
6-lanes

b) Detection of vehicles driving in wrong direction

c) Automatic detection of 5 types of traffic flow: normal, dense, delayed,

congested, and stop and go
d) Detection of stopped vehicles, within 10 secs and for up to 16 detection zones.
e) Monitor Zone occupancy of the detection area
f) Detection of deceleration
g) Detection of fog/smoke

Alarms for following events:

a) Queue

b) Stop

c) Inverse direction

d) Speed drop

e) Fog/smoke

f) No video signal

g) Error
Control Centre

General

The Control Centre shall accommodate following equipment and software:

i) Central Computer Server (with integrated ATMS/ATMS Software)

ii) Emergency call management system equipment and software

iii) CCTV Console and other Equipment

iv) Mobile radio operator and configuration equipment and software

v) Video incident detection system console and other equipment

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 vi) Backbone communication equipment and NMS for the same.

vii) Large Display Board

viii) Printer

ix) Uninterrupted Power Supply with supply system and back up

x) Power supply equipment.

Emergency call management

Emergency Call Management system located at the Control Centre shall carry out the
following functions:

a) Attend to incoming calls from ECB’s using a PC based console, and navigate
the highway section under supervision using graphical representation of the network
which shall be displayed on the PC monitor.
b) Provide audible and visual alert on the screen for any incoming calls from the
Emergency call boxes. Color of the icon representing the Call boxes on the graphical
map shall change indicating the states of call box (phone) healthy, call box (phone)
faulty, incoming call, conversation in progress and call on hold.
c) Provide for call waiting signal to the ECB and put the call on queue in case of
several calls at the same time.
d) Create log and record all conversations from and to the Control Centre from
the ECBs.
e) Further the system shall automatically check periodically (the interval of
which shall be operator selectable) the health of phones and generate an audio visual
alarm in case of faults.
f) The system shall generate a unique call number for each and every call and
allow the operator to provide annotation.
g) There shall be one Emergency Call Manager’s terminal easily expandable to
more operator stations by connecting more operator terminals.
h) Holding of any call by the operator.
i) Terminating any call by the operator.
j) Seamless configuration on addition/deletion of ECBs on the network.
k) Database generation, display on the monitor and logging of all parameters of
call progress.
l) Recording of communication between the operator and road users.
m) Audio visual alarm in case of vandalism.
n) Audio visual alert in case of operation by handicapped.

Integrated ATMS software

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 The ATMS software shall manage the following on a single server platform:

a) Emergency Communication System

b) Variable Message Signs System
c) Meteorological Data System
d) Automatic Traffic Counter cum Classifier System
e) Video Incident Detection System
f) CCTV Surveillance System.

System architecture

Hardware for central server

The system shall run on a powerful dual-processor server with RAID facilities to provide
continuity of hard disk storage. Storage capacity should be large; and comfortably
sufficient to cater for the demands of a modern traffic management system. The system
shall have client-server architecture so that multiple users may access the system
simultaneously.

Minimum hardware specification shall be as follows:

a) Server from reputed company

b) Dual Core 2.2 GHz Processor or Higher

c) Hard Disc : 5* 146 (RAID 5 Support)

d) 4Gb RAM or higher

e) Operating system : Industry standard

f) The database : Industry standard

g) Tape drive for backup/archive

h) Facility for remote diagnosis and support.

Hardware for work stations/operator console

The workstations shall have the following specifications:

a) Pentium IV 2.0 GHz

b) 512 Mb RAM

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 c) 80GB ; Hard Drive

d) 19’’ TFT monitor

System software

The System software shall run on industry standard Server platform incorporating either
MS Windows or Linux operating system in a client server mode. All the above subsystems
shall be displayed and managed by the Supervisor which will show the status of all the
above subsystems simultaneously as graphic symbols/icons. The graphic operator interface
shall be menu driven for ease of operation. The operator shall be able to configure, set
values, commands, perform database operations, reports, archive using these menus. The
Integrated ATMS software shall monitor and record online all data from ATCC, Met
Sensors, VMS, traffic control system, CCTV, VIDS and ECBs. It shall be possible to
configure the sub-systems as well as add/delete components of the system such as ECB,
VMS, MET sensor, ATCC, VIDS, and CCTV in the ATMS software online seamlessly.

The Integrated ATMS Software shall also have following features:

i) The system server shall be configured so as to minimize the risk of data loss in
the event of system failure of power loss. It shall support client terminals
operating on a LAN, WAN or remote connection. Access to the database and
client terminals shall be username and password controlled. Access level shall
be determined by the system supervisor and shall range from “read only” to
full edit/supervisor rights. The system shall not bypass/violate access rights
setup on slave systems. It shall not be possible to send shut down or “Kill”
commands form the database management system.

ii) For system monitoring it shall be possible to configure a view only user with
access to the map and embedded/linked data only. Such a terminal could be
used by police, highway engineers, emergency services, etc. It shall be
possible to relay urgent faults/incidents/System alarms (supervisor
configurable) to remote operators/staff via an SMS message for any
requirements in future.

iii) The system shall have proven and modular Web interfaces. It should be
possible to integrate the same if required in future for providing highway
information such as CCTV images, traffic flow, journey time, etc., to the
general public via internet web pages.

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 iv) The system shall have proven and modular interfaces to automatic license
plate recognition system. It shall be possible to integrate the same in future if
required.

System functions

Sub-system monitoring and control

The System software shall monitor and control ATMS sub-systems as below:

a) It shall monitor and record online all data from Meteorological Data System
installed on the highway. The data shall be updated every five minutes.

b) It shall monitor and record online all data from the ATCC. The system shall
provide the user with the information/display of traffic flow conditions on the MAP.
The data shall be updated every one minute.

c) It shall monitor health of the Emergency telephones on a continuous basis.

d) It shall monitor and control the variable message signs. The operator shall be
able to generate new messages for signs. The system shall react intelligently and
automatically to the highway conditions and set up suitable messages on the VMS. It
shall also be possible to schedule the pre-defined messages to be displayed on the
VMS. The display period shall be operator selectable. The priorities of the messages
shall also be operator selectable.

e) The System software shall provide information regarding incidents (VIDS)

and store/archive them for future use.

f) The system shall interface with intelligent traffic control systems for traffic
control and monitoring specially at interchanges and access points.

g) The system shall interface to CCTV system to select cameras for display and
control of images.

h) The system shall process above referred data acquired through above system
for decision taking, display information on respective VDU monitors and central
Large Display Board.

i) Provide continuously clear and comprehensive displays and print log of

events.

j) Access to historical data files of ATMS.

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 k) Execution of operator commands with access code security.

l) Generation of reports at specified times (operator selectable)

m) System timekeeping.

n) Connectivity and data transfer to other control centers if required.

Graphic User Interface (GUI)

The GUI for the system shall be map based and menu driven. The changes commands/
menu shall be simple to be executed by the operator. There shall be a screen depicting the
map of the highway along with other equipment installed on the route. The highway map
shall be capable of displaying an overview level showing the whole area covered by the
system. It shall then be possible with no loss of definition, to zoom to a detailed map. It
shall be possible to display both static and dynamic data on the Map. Two level of mapping
shall be supported as a minimum:

a. Highway Overview.

b. Highway section wise detailed view.

Icons shall be placed on the map to identify different equipment types. Both shall be
automatically tagged with grid reference data to allow them to appear in the correct relative
positions at both levels of map. Positioning the mouse pointer over an icon or poly-line
shall display the corresponding equipment status information.

For poly-lines representing route data, the user shall be able to configure a number of
thresholds for the different data types available. An example would be congestion for links
where up to X% percentage thresholds can be defined. Each threshold shall be represented
by a distinct Color or changed shapes. The map shall use this scheme to display the poly-
lines based on comparisons with the current real-time data.

The user shall have the ability to configure the map view to display the data layers of
choice, for example to show Met Sensor only or ATCC together with current incidents.

It shall be possible for the operator to place icons or “active” symbols on the map to
represent

a) Access control/ramp metering system

b) Traffic control system
c) Variable Message signs
d) CCTV cameras

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 e) Incidents such as Accident, Roadwork, Event, Diversion, Breakdown and
Road closure
f) Strategy
g) Weather station data
h) Flow, speed classification information
i) User defined fields

Icons will be either active or non-active. Active icons will link to the associated system and
show their current status change of state (Color or flash) and by displaying detailed
information triggered user action.

Data base management

The database used by the ATMS software shall be an industry standard database like
ORACLE, SQL, dbase etc. The system shall have facility to perform certain selected
database operations only by authorized users.

Data presentation and storage

The presentation of data shall reflect the use of the system as a real time tool for the
operator to monitor and control the highway. It shall be possible to present current data
(day) in comparison with profile data or date comparison (same day last year). It shall be
possible to create predictive traffic data and trends. The data shall be stored in the system in
a format to present weekly and monthly average for congestion and summary flow for
weeks and months. The system shall store at least 12 months of data. Older data may be
archived. However, the system shall provide tools for the retrieval, manipulation and
presentation of data. Data store shall be clearly marked with an indicator to show day or
period type e.g. normal, holiday, weekly off; by reference to the system calendar. It shall be
possible to export data to an external system for further analysis. Transfer shall be available
in .xls, csv or any standard formats. It shall be possible to display data or combinations of
data in graphical manner and to print graphs, e.g., Graphs of current, profile, historic, and
combinations for
a) Flow
b) Occupancy
c) Congestion

Archive and Restore

This facility shall allow the archiving of the database to a tape/External HD/DVD. The data
archived shall then be deleted from the database. Data may only be archived when it is
more than two years old. Only one archive request may be outstanding at a time. Once
archived, part or all of the data may be restored by copying from the tape back onto the
system, where it remains for 30 days. Only one restore request may be outstanding at a
time.

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 It shall be possible to define a series of notification levels which will raise an alarm when
the disk space reaches a specified limit. This is used to alert an operator to the need to
archive data.

Database back-up
The system management procedures for producing daily and weekly back-ups shall not
need any operator intervention.

Reports
The system shall have detailed reports for:
a) Status reports for the sub-systems (alarms, faults etc.)

b) Detailed traffic reports-speed, count, occupancy etc.

c) Detailed weather report for all variables from weather sensor

d) Detailed report of emergency call.

Timetable and calendar

The system shall have a time table facility. The timetable shall allow commands by day of
the week, time of day, day type. The system calendar shall allow days to be marked as
normal, holiday, weekly off, etc.
System log
The system shall retain a log of all events, alarms, timetable actions, and operator actions
(together with operator username). In addition to system generated events the operators
shall have facilities to enter events or incidents into the log. It shall be possible to search the
log by time/date, event type, operator user name, strategy, location.
The log facility shall provide the means to:

a) Record all important events that occur in the operation of the integrated
highway management system, both manual and automatic View and manage
the status of alarm events,
b) Collect and collate incident information from both manual and automatic
sources,
c) Allow the user to record routine operational messages,

d) View all changes and actions taken on the ATMS,

e) Record and view useful contact names and other details.

Asset management

a) The system shall incorporate a facility to store records of assets for ATMS.

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 b) The asset register shall store data relating to location, type, and number of
equipments as well as electricity ratings.

User management

This facility shall provide the means to make user access to ATMS secure. Only the system
administrator(s) shall have access to this facility and will set up details for other users. Each
user shall have a username that needs to be configured so that it matches a PC log-in.
Hence logging on to the PC will automatically mean that access to ATMS is available for
the chosen users. Each user can also be configured to have access to none, some or all of
the ATMS facilities.

Operator interface and control

Fault and alarm management

Fault and Alarm Monitoring (FAM) for ATMS shall have following features:

a) The FAM system shall be provided with the capabilities to monitor system
alarm status on a real-time basis.

b) The FAM system shall have the ability to store alarms in the database for
future enquiries, and to access the fault alarm history database for retrieval of
alarm data in the alarm history memory.

c) All ATMS controlled equipment as well as VMS display boards shall be

provided with fault monitoring and reporting to the FAM system.
Alarm handling

a) The following alarm conditions shall be provided to the FAM system as a

minimum:

o Loss of communication link

o Loss of the entire ATMS facilities at a location

o Loss of interface link with the ECB

o Alarm from MET Sensor-Air Temperature, Visibility, Humidity, Road

Surface temperature, Road Surface wet/dry, Wind Speed, wind
direction etc.
o VMS Faults e.g. Communication Fault, LED Fault, Data parity fault,
Power supply fault, Protocol polling fault to I/O Device, etc.

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 o ATCC faults e.g. Sensor fault, communication link failure etc.

o CCTV faults

o Traffic control system faults-Lamp LED Fault, Sensor fault,

communication link failure, etc.

o Power supply unit failure

o Automatic Message priority conflict.

b) All failure alarms shall be stamped with time and date.

c) All failure alarms shall remain on the active alarm display list until they have
been acknowledged by the operator on the FAM system via the management
workstation.

d) All alarms removed from the active alarm display list shall automatically be
inserted into the alarm history database when they occur.

e) The alarm history database shall be provided with sufficient storage capacity
to store the anticipated alarms for a period of at least four weeks without
carrying out any housekeeping function.

Alarm displays

a) Alarms shall be displayed on the workstation via a detailed full screen alarm
browser application.

b) The alarm Display shall provide as a minimum the following general

capabilities and characteristics for the ABA for alarm display list and alarm
history:

o A Color-coding scheme indicating the alarm severity according to the

alarm classifications.

o The display of the alarms with their associated time stamps.

o Scrolling capabilities to enable the operator to view more alarms that

can be displayed on one single screen.

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 o The facilities to acknowledge alarms.

o The facilities to clear alarms from the display.

Fault diagnostics

The fault diagnostics system shall perform the following diagnostics features as a
minimum.

a. Detect the alarm conditions

b. All fault status information and associated equipment test results shall be
presented to the workstation immediately after the alarms are triggered.

Failure modes

When power is restored following a power failure to the system, the system shall perform
all necessary self-testing processes and then resume functioning fully in the same
configuration as before the shutdown. This shall be completed automatically within 5
minutes of power restoration.

Back bone communication system

The backbone communication system shall connect the sub-centers with the Control
Centre. The auxiliary Optical Fibre communication system shall provide connectivity for
peripheral systems like ATCC, CCTV, mobile radio, emergency call management system,
VIDS, Traffic Control System, Mobile Radio and LAN interface for Tolling Systems to the
Control Centre. There shall be a node for the backbone communication system at every
sub-centre and the Control Centre. The network management system (NMS) shall be
located at main Control Centre. It shall however be possible to connect the NMS at any
sub-center location which houses a communication node. The NMS shall be installed on a
PC.

Large display board

Functions

a) The device shall be used for monitoring the traffic through CCTV/ VIDS to
display the ATMS Graphical User Interface (GUI). The large display board shall be
displayed on the wall of the Control Centre. The Application software shall consist of
a built-in module for display board.

b) It shall be possible to create customized data acquisition screen and drag icons
by simple click of the mouse.

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 c) It shall be possible to create backgrounds using scanned photographs, maps,
one-line diagrams, engineering drawings, etc, using popular graphic or engineering
applications.

d) It shall be possible to create new process diagrams that represent various

sections of the highway at different levels of levels of details using the package.
Equipment

The Large Display Board shall be highly reliable for installation and round the clock
operation in the Control Centre. The Display Board shall be driven by the Central
Computer using the main console. The design of the Display Board system shall be
modular and expandable. The Display Board shall use high gain trans-reflective LCDs for
ambient indoors. The Board shall meet the following specifications:

a) Overall board size Length minimum 3000 mm

Height minimum 1200 mm
b) Display Graphic
c) Contrast Ratio: Minimum 1000:1
d) Housing Structure coated housing with IP54
Protection casing against dust,
sprayed water
e) Interface Standard RS 422, RS 485 (Ethernet compatible)
f) Special Features Automatic diagnostics and failure reporting

Uninterrupted power supply

Functions

The uninterrupted power supply shall be installed at the Control Centre for providing clean
uninterrupted power supply to all the operational Equipment at the centre. The
uninterrupted power supply shall be capable of providing full load for the operational
equipment for a minimum period of 60 minutes. The Control Centre shall be powered from
230V AC from the State Electricity Board (SEB) supply. Any loss of AC power to the
Control Centre from the SEB shall not cause loss of any data on the computers or any
resetting of system parameters. The following requirements will be met:

Features To meet the load requirement

Rating 230 V AC (+10% to -15%)
Input Voltage 50 HZ ± 10%
Input Frequency High frequency switching sinusoidal multiple
Inverter Type Pulse
Output Voltage 230 V
Output Frequency Free running 50 Hz ± 0.1%

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 Tracking bypass ± 2%

Output Voltage Waveform Sinusoidal

Output Voltage Regulation Better than ± 1% for simultaneous variation

of no. to full load and input Voltage to any
extremes. ±

Total harmonic distortion <5%

Inverter efficiency >87%

Transmit Response for 100% step load
Dip-Typical 5% max. <8%
Peak-Typical 5% max. <8%
Recovery to normal up to 60 msec. i.e. 3 cycles.
Overload capacity 125% for 10 msec.

800% on static bypass for 10 msec.

Audible indication <55 dBA at 1 meter distance for

i) Mains OK
ii) Inverter OK
iii) Overload
iv) On battery
v) Low battery
vi) Inverter trip

Four extra LED indications shall be available with automatic bi-directional static switch for
a. By pass OK

b. Load on inverter

c. Load on By Pass

d. By Pass frequency out of range

e. Metering for voltage, frequency and current

f. Battery capacity required for minimum 1-hour back up at full load.

Warranty
The Contractor/Supplier of the Advanced Traffic Management Systems (ATMS) shall
furnish the Warranty/Guarantee for successful commissioning and operation of ATMS for a

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minimum period of 5 years. He shall also furnish the certificate that there is no proprietary
item and that the Systems shall be interoperable. All components and equipment shall be
tested for commissioning. The documents with regard to design, technical details,
installation details, testing and commissioning, details of fault diagnostics, operation and
maintenance manuals and reports shall be submitted to the Engineer by the
Contractor/Supplier.

7.32.7. Payment
The payment shall be made for design, configuration, installation and commissioning the
ATMS, as complete job on the identified stretch of highway, as per directions of the
Engineer.

Pay Item Description Unit

7.32.1 Advanced Traffic Management Systems on completed work

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 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

DIVISION 8

INCIDENTALS
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

DIVISION 8 – INCIDENTALS

8.1 Slope and Streambed Protection ........................................................................................... 8.7

8.1.1 Description ........................................................................................................................................ 8.7
8.1.2 Materials ..................................................................................................................................... 8.7
8.1.2.1 Riprap Protection to Slopes ......................................................................................................................... 8.7
8.1.2.2 Protection to River Bank ........................................................................................................................ 8.7
8.1.2.3 Mortar ................................................................................................................................................... 8.7
8.1.2.4 Concrete Slope Protection .............................................................................................................................. 8

8.1.3 Construction Methods ................................................................................................................ 8.8

8.1.3.1 General .................................................................................................................................................. 8.8
8.1.3.2 Preparation ............................................................................................................................................ 8.9
8.1.3.3 Cut-off Walls ......................................................................................................................................... 8.9
8.1.3.4 Laying ................................................................................................................................................... 8.9

8.1.4 Measurement .................................................................................................................................. 8.10

8.1.5 Payment .......................................................................................................................................... 8.10
8.2 Reinforced Concrete Culvert Pipes .......................................................................................... 8.12
8.2.1 Description ...................................................................................................................................... 8.12
8.2.2 Materials ......................................................................................................................................... 8.12
8.2.2.1 Reinforced Concrete Pipe .......................................................................................................................... 8.12
8.2.2.2 Mortar ....................................................................................................................................................... 8.12
8.2.2.3 Reinforcement........................................................................................................................................... 8.12
8.2.2.4 Bricks .................................................................................................................................................. 8.12

8.2.3 Construction Methods .............................................................................................................. 8.12

8.2.3.1 General ................................................................................................................................................ 8.12
8.2.3.2 Excavation ........................................................................................................................................... 8.13
8.2.3.3 Bedding .................................................................................................................................................... 8.13
8.2.3.4 Installation ................................................................................................................................................ 8.13
8.2.3.5 Backfilling ........................................................................................................................................... 8.14

8.2.4 Measurement ................................................................................................................................... 8.14

8.2.5 Payment ........................................................................................................................................... 8.14
8.3 Drainage and Other Miscellaneous Structures ......................................................................... 8.15
8.3.1 Description ...................................................................................................................................... 8.15
8.3.2 Materials ......................................................................................................................................... 8.15
8.3.3 Construction Methods..................................................................................................................... 8.15

8.3 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.3.3.1 General ..................................................................................................................................................... 8.15

8.3.3.2 Manholes and Catch Basins ....................................................................................................................... 8.15
8.3.3.3 Concrete Side Ditch and U-Drain ......................................................................................................... 8.16
8.3.3.4 Headwalls to Culvert Pipes................................................................................................................... 8.16

8.3.4 Measurement ................................................................................................................................... 8.16

8.3.5 Payment ........................................................................................................................................... 8.16
8.4 Kerb, Gutter and Edge Detail.................................................................................................... 8.16
8.4.1 Description............................................................................................................................... 8.16
8.4.2 Materials ................................................................................................................................... 8.16
8.4.3 Construction Methods .............................................................................................................. 8.16
8.4.3.1 Concrete Kerb and Gutters ........................................................................................................................ 8.16
8.4.3.2 Edge Detail ............................................................................................................................................... 8.17

8.4.4 Measurement ............................................................................................................................ 8.17

8.4.5 Payment ................................................................................................................................... 8.17
8.5 Topsoil ...................................................................................................................................... 8.18
8.5.1 Description ...................................................................................................................................... 8.18
8.5.2 Materials ......................................................................................................................................... 8.18
8.5.3 Construction Methods..................................................................................................................... 8.18
8.5.4 Measurement ................................................................................................................................... 8.18
8.5.5 Payment ........................................................................................................................................... 8.18
8.6 Grassing .................................................................................................................................... 8.20
8.6.1 Description ...................................................................................................................................... 8.20
8.6.2 Materials ......................................................................................................................................... 8.20
8.6.3 Construction Methods..................................................................................................................... 8.20
8.6.4 Measurement ................................................................................................................................... 8.21
8.6.5 Payment ........................................................................................................................................... 8.21
8.7 Concrete Monuments and Posts ........................................................................................... 8.22
8.7.1 Description................................................................................................................................ 8.22
8.7.2 Materials....................................................................................................................................... 8.22
8.7.3 Construction Methods .............................................................................................................. 8.22
8.7.4 Measurement ............................................................................................................................ 8.22
8.7.5 Payment .................................................................................................................................... 8.22

8.4 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.8 Protection of Works .................................................................................................................. 8.23

8.8.1 Scope of Work ................................................................................................................................. 8.23
8.8.2 Bricks for Mattressing .................................................................................................................... 8.23
8.8.2.1 General ..................................................................................................................................................... 8.23
8.8.2.2 Sampling................................................................................................................................................... 8.23
8.8.2.3 Dimension................................................................................................................................................. 8.23
8.8.2.4 Appearance ............................................................................................................................................... 8.23
8.8.2.5 Unit Weight .............................................................................................................................................. 8.23
8.8.2.6 Crushing Strength...................................................................................................................................... 8.23
8.8.2.7 Water Absorption ...................................................................................................................................... 8.23

8.8.3 Geotextile Filter Fabric ................................................................................................................... 8.24

8.8.4 Mattressing ...................................................................................................................................... 8.24
8.8.4.1 General ..................................................................................................................................................... 8.24
8.8.4.2 Bricks ....................................................................................................................................................... 8.24
8.8.4.3 Galvanized Wire Mesh ............................................................................................................................. 8.24
8.8.4.4 Placement ................................................................................................................................................ 8.24

8.8.5 Measurement .................................................................................................................................. 8.25

8.8.6 Payment .................................................................................................................................... 8.25
8.9 Slope Protection Works by Palisading................................................................................. 8.26
8.9.1 Description ...................................................................................................................................... 8.26
8.9.2 Requirement of Wooden Piles ........................................................................................................ 8.26
8.9.3 Construction Methods..................................................................................................................... 8.26
8.9.4 Measurement ................................................................................................................................... 8.26
8.9.5 Payment ........................................................................................................................................... 8.26
8.10 Mobilization for Deck Slab Repairing Work ........................................................................... 8.27
8.10.1 Description .................................................................................................................................... 8.27
8.10.2 Materials........................................................................................................................................ 8.27
8.10.3 Measurement ................................................................................................................................. 8.27
8.10.5 Payment ......................................................................................................................................... 8.27
8.11 Concrete Kilometre Posts .................................................................................................. 8.28
8.11.1 Description ......................................................................................................................... 8.28
8.11.2 Materials........................................................................................................................................ 8.28
8.11.3 Construction Methods ................................................................................................................... 8.28
8.11.4 Measurement ................................................................................................................................. 8.28

8.5 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.11.5 Payment ......................................................................................................................................... 8.28

8.12 RCC Palisading ............................................................................................................... 8.29
8.12.1 Description .................................................................................................................................... 8.29
8.12.2 Materials .................................................................................................................................. 8.29
8.12.3 Construction Methods .............................................................................................................. 8.29
8.12.3.1 RCC Post ................................................................................................................................................ 8.29
8.12.3.2 RCC Grade Beam .................................................................................................................................... 8.29
8.12.3.3 RCC Vertical Wall .................................................................................................................................. 8.30
8.12.3.4 Precast RCC Plate/Planks ........................................................................................................................ 8.30
8.12.4 Tolerances.................................................................................................................................................. 8.30

8.12.5 Measurement ................................................................................................................................. 8.30

8.12.6 Payment ......................................................................................................................................... 8.30

8.6 | P a g e
SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.1 Slope and Streambed Protection

8.1.1 Description
This work shall consist of the provision and installation of protection for stream banks,
riverbanks, embankment slopes, cut slopes and other surfaces composed of erodible materials
where protection is desired. Generally, protection to slopes will form an impervious layer
constructed in or on designated surfaces and shall have at its bottom and ends anti-scour
devices, such as cut-off walls or toe walls. Protection to the riverbanks shall form a graded
aggregate scour protection.
The protection shall be constructed to the shapes and dimensions shown on the Drawings or as
required by the Engineer.

8.1.2 Materials
8.1.2.1 Riprap Protection to Slopes
Stone for riprap shall consist of stone boulders of suitable size and shape. The stone shall be
dense, resistant to the action of air and water, and suitable in all other respects for the purpose
intended. Alternatively concrete blocks manufactured from stone chips maybe used, if shown
on the Drawings.

The minimum thickness of stone shall be 100 mm (measured perpendicular to face of riprap).
No face dimension shall be less than the thickness of the stone. Unless otherwise specified, the
stones shall weigh not less than 10 kilograms each. The minimum thickness of the concrete
block shall be 150 mm with a weight not less than 20 kg, with the concrete being Class 20
manufactured in accordance with Section 5.1 of the Specification.

8.1.2.2 Protection to River Bank

The following materials shall be used:

a. Coarse gravel with sizes ranging from 5 - 40 mm and of approved grading.

b. Cobblestones with sizes ranging from 50 - 100 mm and of approved grading.
c. Boulders with sizes ranging from 100 - 200 mm.

The soundness of gravel and stones shall be approved by the Engineer.

The boulders shall be dense, resistant to the action of air and water and suitable in all other
respects for the purpose intended.

8.1.2.3 Mortar
Mortar shall be composed of one part of cement and two parts of sand by dry loose volume and
sufficient water to make a mortar that can be easily handled and trowelled. Retempering of

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DIVISION 8 - INCIDENTALS

mortar that has not been used for periods of 45 minutes or longer will not be permitted. Cement
for mortar shall conform to the requirement of Section 5.1 of these Specifications.

8.1.2.4 Concrete Slope Protection

Concrete and reinforcement used in the construction of concrete facing for slopes shall be in
accordance with Sections 5.1 and 5.2 of these Specifications, respectively, except where
modified by the Drawings.

8.1.3 Construction Methods

8.1.3.1 General
A) Grouted Riprap

Unless otherwise specified riprap pavement shall always be constructed as an impervious layer
upon designated surfaces. Unless otherwise specified riprap pavement shall have mortared
joints and 40 mm weepholes per 2 m measured in both directions.

B) Loose Stone Riprap

Stone protection shall be carried out as shown on the Drawings.

The stone protection shall consist of the following layers:

Stone Type Grading (mm) Layer Thickness (mm)

Boulders 100 - 200 300

Cobble Stones 50 - 100 200

Coarse Gravel 5 - 40 150

Total 650

C) Concrete Slope Protection

Concrete slope protection shall be carried out as shown on the Drawings. Concrete shall be
Class 20 and the reinforcement shall conform to the requirements of Section 5.2. The
construction methods shall also conform to the requirements of Sections 5.1 and 5.2.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.1.3.2 Preparation
A) Grouted Riprap (stone or concrete blocks) and Concrete Slope Protection

Excavation or construction of embankments shall be processed to planned shapes and

dimensions, as if there were no protection, to allow some excavation immediately prior to the
placing of the protection. The Contractor is responsible for discussing with the Engineer, his
proposed method or constructing embankments in areas to be protected so that the proper
procedure can be agreed.

The areas to be covered shall, at the proper time, be laid out to intended positions, and all
necessary cut and fill stakes, batter boards, and construction lines set up. Every effort shall be
made to have the surfaces in such condition as to require some excavation immediately prior to
the laying of the protection. Where, however, low areas are encountered they shall be backfilled
and thoroughly tamped at the earliest practical time in advance of the laying of masonry, to
avoid settlement after placing riprap. It is not necessary that the entire area to be protected will
be excavated and fine graded in advance of the laying. Work should always be laid upon a
freshly excavated and stable surface.

B) Loose Stone Riprap

Stone protection work shall where possible be carried out during periods when low river levels
allow construction in the dry. Approval of the Engineer shall be obtained prior to placing stone
protection under water.

The area of the stone protection shall be prepared by excavating or dredging to the levels shown
on the Drawings or as directed by the Engineer.

It is not necessary that the entire area to be protected will be excavated in advance of the laying.
Gravel should always be laid upon a freshly excavated surface.

8.1.3.3 Cut-off Walls

Riprap and concrete slope protection shall always be accompanied by a bottom cut-off wall,
unless otherwise instructed by the Engineer.
The cut-off wall shall be constructed of reinforced concrete to the dimensions and details shown
on the Drawings. Concrete shall be in accordance with Section 5.1 and reinforcement in
accordance with Section 5.2.
8.1.3.4 Laying
A) Riprap Protection and Concrete Slope Protection

After cut-off concrete has been placed and accepted, the laying of slope protection shall be
commenced in tight contact with the cut-off concrete and laid from the bottom towards the top.

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DIVISION 8 - INCIDENTALS

In the case of riprap protection the stones, boulders or concrete blocks shall be bedded on 50 -
100 mm of free draining sand or gravel as directed and shall be laid in close contact. The
interstices may be partly filled with spalls or small stones. For the concrete slope protection, the
reinforcing steels shall be laid and the concrete poured according to the requirements described
in Sections 5.1 and 5.2.

Weep holes to riprap pavement shall be covered on the inside with stones and gravel filters
extending 300 mm from the hole in all directions and connecting with the porous bedding
material.

All joints and openings to riprap pavement shall be filled solidly with mortar.

Weep holes for the concrete slope protection and the joints shall be prepared and constructed as
shown on the Drawings.

B) Loose Stone Riprap

All materials shall be transported and laid by methods, which do not cause damage to material
previously laid.

Boulders shall be placed well packed and wedged together without mortar.

8.1.4 Measurement

Riprap and concrete slope protection shall be measured for payment on the basis of the area in
square metres. Linear dimensions will be taken in not less than two directions, and of sufficient
number so that averages can be obtained, and the product of the averages shall be the area
considered for payment. Where slopes exist, measurement will be along the surface of the
slopes.

Loose Stone Riprap shall be measured in cubic metres of stone protection as the total volume
delivered by truck at site.

Concrete for cut-off walls shall be measured for payment on the basis of cubic metres. Length
measurement will be taken along the front of the cut-off wall, while the width and depth will be
the measurements given by the Engineer in writing. Excavation, formwork or reinforcement
shall not be measured separately.

Material so measured shall be directly incorporated in the works or securely stored to the
satisfaction of the Engineer.

8.1.5 Payment

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 SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

The work measured as provided above shall be paid for at the Contract unit prices per linear
metre, square metre or cubic metre. The prices and payment shall be full compensation for
furnishing all material, excavations whether shown or not and whether below water or not,
concrete, reinforcement, forms if necessary, screening, curing, handling, backfilling if any,
mortar, joints, weep holes, gravel filters, porous bedding, equipment, tools, labour and
incidentals necessary to complete the work.

Pay items shall be:

08/01/01 Grouted Riprap Pavement Square Metre

(stone/concrete blocks to be specified)
08/01/02 Concrete Slope Protection Square Metre
08/01/03 Loose Stone Riprap Protection Cubic Metre
08/01/04 Concrete Cut-off Cubic Metre

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.2 Reinforced Concrete Culvert Pipes

8.2.1 Description

This work shall consist of concrete culvert pipes furnished and installed at such locations as are
shown on the Drawings or as directed by the Engineer in accordance with these Specifications
and in accordance with the classes, lines, levels, grades and dimensions shown on the Drawings.

The work shall include the furnishing and construction of such joints and such connections to
other pipes, catch basins, manholes, walls and other items as may be required to complete the
structure as shown on the Drawings. The work shall also include connection of existing drains,
which have been interrupted by the road construction, to the new drainage system as directed by
the Engineer.

8.2.2 Materials

8.2.2.1 Reinforced Concrete Pipe

Reinforced concrete pipes for culverts shall be constructed fully in accordance with the
Drawings and Sections 5.1 and 5.2 of these Specifications.

8.2.2.2 Mortar
Mortar for joints shall contain one part Portland cement and two parts sand by dry volume
unless otherwise required by the Drawings or the Specifications.

The amount of water in the mix shall be such that the consistency of the mortar is suitable for
the purpose intended and to the satisfaction of the Engineer.

All mortar shall be used within 30 minutes of adding the water.

8.2.2.3 Reinforcement
Steel reinforcement shall be in accordance with Section 5.2 of these Specifications, except
where modified by the Drawings.

8.2.2.4 Bricks
Bricks shall be in accordance with Section 5.5 of these Specifications.
8.2.3 Construction Methods

8.2.3.1 General
Pipes shall either be laid in existing ground, or if to be placed under the embankment fill this
shall have been constructed to a height greater than the crown of the pipe in accordance with
Section 2.6, before the Contractor will be permitted to excavate to place the pipes.

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.2.3.2 Excavation
The width of the pipe trench shall be sufficient to permit satisfactory jointing of the pipe and
thorough tamping of the bedding material under and around the pipe.

Before laying, the ground shall be trimmed true to line and grade, as directed by the Engineer,
over sufficient width to permit satisfactory construction of the bedding. Special care shall be
taken to remove any hard or deleterious material from the foundation area.

When soft, spongy or unstable soil is encountered; such soil shall be removed under the pipe for
a width and to a depth as directed by the Engineer and replaced with sand or other suitable
selected material properly compacted to provide adequate support for the pipe.

The prepared surface shall provide a firm foundation of uniform density throughout the length
of the culvert.

Excavated materials classified as suitable should either be utilized as back filling, embankment
fill or if surplus be stockpiled on site as described in Section 2.2.3.d of these Specifications.
Excavated material classed as unsuitable shall be carried stockpiled as described in Section
2.2.3.c of these Specifications.

8.2.3.3 Bedding
Bedding for pipe culverts shall conform to the requirements given below for Class “A” or “B”
bedding, whichever is called for on the Drawings or by the Engineer.

If the class of bedding is not shown, Class “B” bedding shall be provided.

A) Class “A” Bedding - Concrete cradle for pipe culverts shall consist of a continuous
concrete cradle constructed of Class 15 concrete in conformity with the details shown on
the Drawings and the requirements of Section 5.1 of these Specifications.

B) Class “B” Bedding - Class “B” bedding shall be constructed by bedding the pipe
culverts in a trench cut in the natural ground or embankment to a depth as shown on the
Drawings. The pipe culverts shall be bedded on a thickness of bedding material as
shown on the Drawings accurately shaped by a template to fit the lower part of the pipe
culvert exterior.

8.2.3.4 Installation
All concrete culvert pipes shall be laid with reinforced and mortared joints. The pipe shall be
laid carefully and in straight lines. Before succeeding sections of pipe are laid, the lower half of
the groove of the proceeding section shall be plastered on the inside with cement mortar of
sufficient thickness to bring the inner surface of the abutting pipes flush and even. At the same
time the upper half of the succeeding pipe shall be similarly plastered with mortar. After the
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DIVISION 8 - INCIDENTALS

pipe is laid, the remainder of the joint shall be filled with similar mortar, and sufficient
additional mortar shall be used to form a bead around the joint. The inside of the joint shall be
wiped and finished smooth. The mortar on the outside shall be protected with brickwork to
allow backfilling to proceed.

8.2.3.5 Backfilling
Backfilling shall be carried out with material as indicated on the Drawings. It shall be placed in
uniform layers not exceeding 15 centimetres in uncompacted depth and compacted as
embankment fill for layers at the depths concerned below sub-grade. Special care shall be taken
to compact the material under the haunches of the pipe and to ensure that the backfill shall be
brought up evenly on both sides of the pipe.
Sand fill for bedding shall conform to the requirements for backfill of sand to structures in
Section 2.5. Embankment fill shall conform of the requirements of Section 2.6.
8.2.4 Measurement

Culvert pipe shall be measured as the linear metres from end to end of each pipe structure,
complete and accepted in place.
Excavation, bedding or concrete surrounding, backfill and tamped fill as well as cutting of holes
for connection pipes will be considered incidental to the laying of the pipe and will not be
measured as such. Headwalls shall be measured and paid for in accordance with Section 8.3.
8.2.5 Payment

Reinforced concrete culvert pipe measured as provided above shall be paid for at the Contract
unit price per linear metre for the particular size specified on the Drawings. The price shall be
full compensation for furnishing, hauling and installing the pipe, jointing, excavation,
dewatering, pumping and bailing, bedding, backfilling, compaction and for all labour, tools,
equipment and incidentals necessary to complete the work.

Pay items shall be:

08/02/01 Reinforced Concrete Culvert Pipe - Class A bedding Linear Metre (Diameter as
Specified)
08/02/02 Reinforced Concrete Culvert Pipe - Class B bedding Linear Metre (Diameter as
Specified)

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SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.3 Drainage and Other Miscellaneous Structures

8.3.1 Description

This work shall consist of the construction of all kinds of manholes, catch basins, drainage
channels, pipe end walls, head walls and other miscellaneous structures in brickwork or of the
required class or classes of concrete, with or without reinforcement constructed in accordance
with these Specifications and to the lines, levels, grades and dimensions shown on the Drawings
or as required by the Engineer. The work shall also include excavation, bedding and backfilling
with suitable material in accordance with the Drawings and these Specifications. Some standard
drawings has

8.3.2 Materials

Concrete shall conform to the requirements of Section 5.1. The concrete shall be Class 25
unless otherwise indicated on the Drawings.

Reinforcement, where required shall conform to the requirements of Section 5.2.

Brickwork shall conform to the requirements of Section 5.5.

8.3.3 Construction Methods

8.3.3.1 General
Construction methods given under Sections 2.5, 5.1, 5.2 and 5.5 shall apply to this item unless
otherwise described.
8.3.3.2 Manholes and Catch Basins
Manholes shall be completed before the adjacent roadway surfacing is placed. They shall not be
constructed in Embankment areas, until the earthworks have reached sub grade level.

Frames for gratings and covers for manholes and catch basins shall be properly secured as
indicated in the Drawings so as to be held rigidly in place to proper grade and alignment.
Rocking gratings and covers will not be accepted.

Inlet and outlet pipe of manholes shall be set or cut flush with the inside faces of the walls of
such structures and shall extend a sufficient distance beyond the outside faces of the walls to
provide ample room for making proper connections. The joint around the pipe in the structure
wall shall be completely and neatly closed with mortar, or other material as may be specified, so
as to make it watertight.

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 SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

8.3.3.3 Concrete Side Ditch and U-Drain

Concrete Side ditches and U-drains shall be constructed to the dimensions and details shown on
the Drawings.
8.3.3.4 Headwalls to Culvert Pipes
All headwalls to culvert pipes shall be formed in brickwork to the dimensions and details shown
on the Drawings.

8.3.4 Measurement

Manholes, catch basins drains and Headwalls to culvert pipes will be measured for payment by
number of each type as indicated in the Bill of Quantities, completed and accepted in place.

Excavation, side support if necessary, sand bedding, lean concrete inlet pipes, grate bars, slide
gates, covers and gratings, ladder rungs, service pipes and house connection pipes will be
considered incidental to the construction of the manhole and not measured as such.

Concrete side ditches and U-drains will be measured for payment by number of linear metres
completed and accepted in place. Excavation, bedding, formwork, joints, covers etc. will not be
measured separately except for reinforcing bar. The reinforcing bar shall be measured separately.

8.3.5 Payment

This work measured as provided above will be paid for at the Contract unit price for each
particular item, such price and payment constituting full compensation for all material except for
reinforcement, labour, tools, equipment and incidentals necessary to complete the work.

The complete work includes all work associated with the structure as indicated on the Drawings
or in these Specifications. Pay items shall be:

08/03/01 Manhole (Diameter as stated in the Bill of Quantities) Number

08/03/02 Catch Basin (Diameter as stated in the Bill of Quantities) Number

08/03/03 Concrete Side Ditch (As detailed on the Drawings) Linear Metre

08/03/04 Brick Headwall to Culvert Pipe (Pipe Diameter as stated in the Bill of Number
Quantities)
08/03/05 Saucer Drain (Brick Masonry) (As detailed on the Drawings) Linear Metre

08/03/06aU Drain-Brick Masonry (upto 1000mm average height) Linear Metre

(As detailed on the Drawings)

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 SECTION 7 GENERAL SPECIFICATIONS

DIVISION 8 - INCIDENTALS

08/03/06bU Drain-Brick Masonry (upto 1500mm average height) Linear Metre

(As detailed on the Drawings)

08/03/07aU Drain-RCC (upto 1000mm average height) Linear Metre

(As detailed on the Drawings)

08/03/07bU Drain-RCC (upto 2000mm average height) Linear Metre

(As detailed on the Drawings)

08/03/07cU Drain-RCC (upto 2500mm average height) Linear Metre

(As detailed on the Drawings)

05/05/02 High Yield Reinforcing Bar Tonne

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 GENERAL
SPECIFICATIONS
DIVISION 8 - INCIDENTALS

8.4 Kerb, Gutter and Edge Detail

8.4.1 Description

This work shall consist of kerb, gutter, or combination of kerb and gutter, made of concrete
or edging to the road pavement using whole bricks and constructed in accordance with these
Specifications at the locations and in accordance with the lines, levels, grades, dimensions
and types shown on the Drawings.

8.4.2 Materials

Concrete shall be of the grades and types indicated on the Drawings and shall conform to the
requirements of Section 5.1.

Brick shall be selected Class “A” bricks of regular shape free from any defects or distortion.
They shall conform in all respects to the requirements for first class bricks as specified in
Section 5.5.2.1 of these Specifications.

Sand for bedding and infilling gaps between bricks shall be non-plastic and free from
vegetable matter, soft particles and clay. It shall conform to either grading B or grading C of
Table 2.8-1 of these Specifications.

8.4.3 Construction Methods

8.4.3.1 Concrete Kerb and Gutters

Excavation shall be made to the required depth, and the base upon which the kerb, gutter, or
combination kerb and gutter is to be set shall be compacted to a firm, even surface. All soft
and unsuitable material shall be removed and replaced with suitable material.

Kerb and gutter shall be cast in sections 3 metres or less with preformed filler 20 mm in
thickness, to the size as shown on the Drawings.

Concreting shall be in accordance with the requirements of Section 5.1.

Forms shall be removed not less than 24 hours after concrete has been placed. Minor defects
shall be repaired with mortar containing one part of Portland cement and two parts of fine
aggregate.

Repair will not be permitted on the faces and rejected portions shall be removed and replaced
at the Contractor’s expense.

The finished work shall be true to line, grade and level to within 5 mm and shall present a
smooth appearance free from kinks and distortion visible to the eye.

When kerbs are to be placed on minor structures or on rigid pavement, tie bars shall be
inserted in the concrete as shown on the Drawings.

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 GENERAL
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DIVISION 8 - INCIDENTALS

8.4.3.2 Edge Detail

The edge detail shall be as shown in the Drawings or as specified by the Engineer. The edge of
the pavement hard shoulder and soft shoulder must be adequately compacted. Any damage
caused to be the pavement materials by compaction equipment due to the contractors method
ofworking shall be repaired at the Contractors expense.

8.4.4 Measurement

The quantity measured for payment shall be the number of linear metres of the several types
and sizes of concrete kerb, edge kerbs, the combination kerb and gutter or brick edging,
completed in place and accepted. Concrete kerb, combination kerb and gutter and brick edging
shall be measured in place along the front face of the kerb. No deduction shall be made for
flattening of kerbs.

8.4.5 Payment

This work measured as provided above, will be paid for at the Contract unit price per linear
metre for each particular item which prices and payments shall be full compensation for all
excavation, backfilling and tamping, furnishing and placing all materials, including all labour,
tools, equipment, forms, falsework, centering and incidentals necessary to complete the work.

Pay item shall be:

08/04/01 Concrete Kerb (As detailed on the drawings) Linear Metre

08/04/02 Combined Concrete Kerb and Gutter (As Detailed on the Drawings) Linear Metre

8.17 | Page
 GENERAL
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DIVISION 8 - INCIDENTALS

8.5 Topsoil
8.5.1 Description
This work shall consist of furnishing topsoil which has been removed from approved
sources and transporting, spreading and thorough compaction of it on prepared surfaces in
accordance with these Specifications and the Drawings.

8.5.2 Materials
Topsoil furnished by the Contractor shall consist of a natural friable surface soil without
admixture of undesirable soil, refuse or foreign materials. It shall be reasonably free from
roots, hard clay, coarse gravel, stones larger than 50 mm in any dimension, noxious weeds,
tall grass, brush, sticks, stubble or other litter and shall have indicated by a healthy growth
of crops, grasses, trees or other vegetation that it is free-draining and non-toxic.

8.5.3 Construction Methods

The Contractor shall notify the Engineer at least 5 days before he intends to start topsoil
stripping operations. After inspection and approval by the Engineer, and prior to stripping
the topsoil, the Contractor shall remove noxious weeds and tall grass, brush, large stones
and roots.

The topsoil shall be evenly spread on the designated areas to a depth, which after
settlement and compaction shall be that shown on the Drawings. Spreading shall not be
done when the ground or topsoil is excessively wet or otherwise in a condition detrimental
to the work. The roadway surfaces shall be kept clean during hauling and spreading
operations.

After spreading has been completed, any large clods, large stones, roots, stumps and litter
shall be raked up and removed.

To reduce erosion as much as possible, the placing of topsoil and the subsequent grassing
shall be done simultaneously with or immediately after the placing and compacting of the
individual layers of fill.
8.5.4 Measurement
The quantity measured for payment shall be the number of cubic metres of required topsoil
of the designated thickness complete and accepted in place. If side slopes of embankments
or excavation requiring top soil are of greater area than required due to earthworks not
conforming to the required dimension, the area measured shall be the required area as if
the earthwork had conformed to the required dimension.

8.5.5 Payment

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 GENERAL
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DIVISION 8 - INCIDENTALS

This work measured as provided above, shall be paid for at the Contract unit price per
cubic metre. The price shall be full compensation for furnishing and placing all material,
including all labour, equipment, tools and incidentals necessary to complete the work.

No payment will be made for topsoil until it has been grassed according to Section 8.7.

Pay item shall be:

08/05/01 Topsoil Cubic Metre

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 GENERAL
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DIVISION 8 - INCIDENTALS

8.6 Grassing
8.6.1 Description

This work shall consist of furnishing turf and sods as required and planting them to give a
healthy stable covering of grass which will maintain its growth in any weather and prevent
erosion of the material in which it is planted.
8.6.2 Materials

Grass shall be of species native to Bangladesh, harmless and inoffensive to persons and
animals and not of a kind recognized as a nuisance to agriculture. It shall be free of disease
and noxious weeds, deep rooted and sufficiently rapid growing and spreading to give
complete cover over the planted area within the Defects Liability Period.

The term “grass” embraces turf and sods and, if the Engineer permits, may include plants of
other types capable of giving effective protection.

Fertilizer shall be approved lime or mixtures of plant nutrients or both.

8.6.3 Construction Methods

Sodding or surfing shall be done by planting sods or turf, as indicated on the Drawings, to
give continuous cover over the whole area. They shall be planted with their root systems
substantially undamaged, well buried in firm material, and packed around with moist earth in
which they have grown.

Grass shall be planted at such a time and the work shall be done in such a way that at the time
of the final construction inspection all areas to be grassed are substantially covered with
healthy, well established, firmly rooted grass and the planted area is free from erosion
channels.

Surfaces to be planted shall be trimmed in such a way that the ground surface after planting
shall be as shown on the Drawings.

Fertilizer shall be added at the time of planting if necessary to ensure good ground cover
within the required time.

The Contractor shall maintain the grass at his expense until the end of the Defects Liability
Period. Maintenance shall consist of preserving, protecting and replacing grass and such other
work as may be necessary to keep it in a satisfactory condition to prevent erosion and to
present a dense and uniform appearance. The Contractor shall be responsible for satisfactory
growth and shall water, fertilize, and mow the grass at such intervals as will ensure good
ground cover of live grass all through the Defects Liability Period.

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 GENERAL
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DIVISION 8 - INCIDENTALS

8.6.4 Measurement

The quantity measured for payment shall be the number of square metres of turfed or sodded
surface whether horizontal or sloping of required and accepted grassing well established in
place. Fertilizer will not be measured separately.

8.6.5 Payment

This work measured as provided above shall be paid for at the Contract unit rate per square
metre. Payment for grassing shall be made at the termination of the Defects Liability Period.
The payment will be full compensation for furnishing all materials, labour, equipment, tools
and incidentals necessary to complete the work to the satisfaction of the Engineer.

Pay items shall be:

08/06/01 Grass Sodding Square Metre

08/06/02 Grass Turfing Square Metre

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 GENERAL
SPECIFICATIONS
DIVISION 8 - INCIDENTALS

8.7 Concrete Monuments and Posts

8.7.1 Description

This work shall consist of furnishing and installation of concrete monuments and posts as
detailed on the Drawings and at locations indicated on the Drawings or as directed by the
Engineer.
8.7.2 Materials

Concrete monuments and posts shall be precast using concrete conforming to the
requirements of Section 5.1. Reinforcement steel shall conform to the requirements of
Section 5.2. Paint, if indicated on the Drawings, shall be of the appropriate type and color and
to the approval of the Engineer.
8.7.3 Construction Methods

Construction, fabrication and installation of concrete monuments and posts shall be as shown
on the Drawings.
8.7.4 Measurement

The quantity measured for payment shall be the actual number of concrete monuments and
posts placed and accepted.
8.7.5 Payment

This work measured as provided above shall be paid for at the Contract rate for each
monument and post. The price and payment shall be full compensation for furnishing and
placing, including all materials, labour, equipment, tools, and incidentals necessary to
complete the work.
Pay items shall be:

08/07/01 Concrete Monument Number

08/07/02 Concrete Post Number

8.22 | Page
 GENERAL
SPECIFICATIONS
DIVISION 8 - INCIDENTALS

8.8 Protection of Works

8.8.1 Scope of Work
Bridge abutments and culvert inlets shall be protected by brick mattressing laid over
geotextile filter fabric in accordance with the Drawings and these specifications.

8.8.2 Bricks for Mattressing

8.8.2.1 General
This section specifies whole bricks for use in the Works.

8.8.2.2 Sampling
Whole bricks shall be sampled in accordance with Standard Test procedures Clause 1.1.
Samples thus collected will be tested for crushing strength, unit weight and water absorption.
Samples shall be collected from each batch of 5,000 bricks supplied, or more frequently as
the Engineer may direct.

8.8.2.3 Dimension
First Class Bricks should have the following dimensions after burning, 250 mm x 120 mm x
70 mm. Picked Jhama (PJ) Bricks may have dimensions slightly below those for other brick
but not less than 235 mm x 110 mm x 70 mm.

8.8.2.4 Appearance
Bricks shall be uniform in size and colour and shall emit a clear metallic ringing sound when
struck one against another. They should have an even surface without cracks.

8.8.2.5 Unit Weight

The unit weight shall be determined in accordance with STP 7.8.3 (Compacted). The unit
weight of 1st Class broken bricks shall not be less than 1100 kg/m³ and Picked Jhama broken
bricks shall not be less than 1200 kg/m³.

8.8.2.6 Crushing Strength

The crushing strength of bricks shall be tested in accordance with STP 7.8.4. The average
crushing strength of 1st class bricks shall not be less than 17 N/mm² and for PJ bricks shall
not be less than 20 N/mm².

8.8.2.7 Water Absorption

The water absorption shall be determined in accordance with STP 7.8.3 for Material between
38 mm and 10 mm. The water absorption as a percentage of the dry weight shall not exceed
20%, for 1st class bricks or 15% for PJ bricks.

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8.8.3 Geotextile Filter Fabric

Geotextile filter fabric used in the works shall be equivalent to Biddam U44 or Terram 2000
or polyfelt TS 650. The material shall be supplied in rolls and installed completely in
accordance with the manufacturer’s instructions.

8.8.4 Mattressing

8.8.4.1 General
The Contractor shall construct mattressing over geotextile filter fabric consisting of bricks
enclosed by wire mesh, and metal stakes consisting of 16mm diameter round reinforcing bar
as shown on the Drawings to provide scour protection around structures and elsewhere as
directed by the Engineer.

The geotextile fabric shall be placed on a smooth and uniform foundation, cleared and
grubbed and compacted as for roadway embankment, prior to the installation of the
mattressing.

8.8.4.2 Bricks
Brick used in mattressing shall be Picked Jhama bricks complying with the requirements of
Section 8.11.2.

8.8.4.3 Galvanized Wire Mesh

Wire for mattressing shall be mild steel wire conforming to the appropriate British Standard
and hot dip galvanized weaving to the requirements of BS 729.

The wire shall be not less than 2.5 mm in diameter and the minimum weight of zinc coating
shall be 270 grams per square metre. The adhesion of the zinc coating to the wire shall be
such that when the wire is wrapped six turns around a mandrel four times the diameter of the
wire, it shall not flake nor crack to such an extent that any zinc can be removed by rubbing by
fingers.

The mesh shall be hexagonal woven with the size of mesh no greater than 60mm by 80mm
and joints shall be formed by twisting each pair of wires through three half turns. The shorter
dimension shall be taken from centre to centre of the twisted joints and the longer dimension,
which is nominal, from the ends of the twisted joints. The mesh shall be laid so that the
longer dimensions of both the mesh and the bricks are at right angles to each other.

8.8.4.4 Placement
Bricks shall be placed in baskets approximately 2m width by 6m long and 200mm thick.
Picked Jhama whole brick shall be first placed in the baskets so that the 110mm x 240mm
face of the brick is vertical. Broken brick pieces of the size not smaller than 70mm x 57mm x
55mm are required to be randomly packed into the basket. Filling shall be carried out by

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raking the broken bricks to achieve compaction with a slight overfilling so that the mattress
top mesh must be stretched over the bricks and then tied in place. All baskets shall be wired
together to form a continuous mattress with 3mm galvanized tie wire and where the baskets
abut concrete structures they shall be firmly attached to the structure with 3mm galvanized
anchor wire embedded in the structure as shown on the Drawings.

When placed on a slope, mattressing shall be constructed starting from the bottom of the
slope and metal stakes consisting of steel reinforcing bars of the dimensions shown on the
Drawings shall be driven through the mattressing at 1.5m centres.

8.8.5 Measurement

Measurement for payment for installing geotextile filter fabric will be made based on the area
in square metres measured parallel to the face on slopes of mattressing installed as shown on
the Drawings or directed by the Engineer. No additional payment will be made for fabric
used to provide specified laps.

Measurement for payment for furnishing and installing mattressing will be made based on the
area in square metres measured parallel to the face on slopes of mattressing installed as
shown on the Drawings or directed by the Engineer. No extra measurement shall be made for
cut off walls or edge thickening.

8.8.6 Payment
Pay items shall be:

08/8/01 Geo-textile filter fabric (as detailed on the Drawings or as Square Metres
directed by the Engineer)
08/8/02 Furnishing and installing mattress (as detailed on the Square Metres
Drawings or as directed by the Engineer)

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8.9 Slope Protection Works by Palisading

8.9.1 Description
This work shall consist of providing slope protection work by Palisading in accordance with these
Specifications and in conformity with the requirements of the Drawings or the Engineer’s
instructions.

8.9.2 Requirement of Wooden Piles

Wooden piles shall consist of best quality timber, Sal, Sundari or Garzon, the diameter of which shall
be average 150 mm measured at 1/3 depth from the thick end and the length shall be minimum 6
metres.

For local bullah, wooden piles shall consist of best locally available timber, e.g., Gab, the diameter of
which shall be between 150mm and 200mm and the length shall be minimum 6 metres as approved by
the Engineer.

8.9.3 Construction Methods

A 1/3 rd of the length of wooden pile, but not less than 2.0 m below ground level, shall be driven at a
spacing of 600 mm c/c. Two (2) layers of horizontal runners with half sawn bullah and drum sheet
shall be fixed with gazali, nut, bolts etc. necessary tie wire and tie posts shall also be provided.

8.9.4 Measurement

The unit of measurement shall be the linear metre of Palisading works completed as per the drawing
and accepted.

8.9.5 Payment

The work shall be measured as provided above shall be paid at the contract unit rate per linear metre.
The rate shall constitute full compensation for all labour materials, equipment, driving, fitting, fixing
and all related tools, hammers and other incidental equipment and works.

No payment shall be made for unauthorized or unsatisfactory works

Pay item shall be:

08/9/01(a) Bullah Palisading (150mm – 175mm) Lin. Metre

08/9/01(b) Bullah Palisading (Local Bullah: 150mm – 200mm) Lin. Metre

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8.10 Mobilization for Deck Slab Repairing Work

8.10.1 Description
This work shall consist of mobilization of equipment, labour and materials for deck slab
epairing work at locations as directed by the Engineer.

8.10.2 Materials
The materials for construction warning signs shall conform to the requirements of the
Drawings and shall be of the appropriate type and colour and to the approval of the Engineer.

8.10.3 Measurement
The unit of measurement shall be square meters of deck slab actually repaired and accepted.

8.10.5 Payment
This work measured as provided above shall be paid for at the Contract rate for mobilization
of equipment, labour and materials. The price and payment shall be full compensation for
mobilizing equipment, labour and materials necessary to complete the work.

Pay items shall be:

08/10/01 Mobilization for deck slab repairing work etc Square Metre

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8.11 Concrete Kilometre Posts

8.11.1 Description
This work shall consist of furnishing and installation of concrete kilometre posts as detailed
on the Drawings and at locations indicated on the Drawings or as directed by the Engineer.

8.11.2 Materials
Concrete kilometre posts shall be precast using concrete conforming to the requirements of
Section 5.1. Reinforcement steel shall conform to the requirements of Section 5.2. Paint, if
indicated on the Drawings, shall be of the appropriate type and colour and to the approval of
the Engineer.

8.11.3 Construction Methods

Construction, fabrication and installation of concrete kilometre posts shall be as shown on the
Drawings.

8.11.4 Measurement
The quantity measured for payment shall be the actual number of concrete kilometre posts
placed and accepted.

8.11.5 Payment
This work measured as provided above shall be paid for at the Contract rate for each
monument and post. The price and payment shall be full compensation for furnishing and
placing, including all materials, labour, equipment, tools, and incidentals necessary to
complete the work.

Pay items shall be:

08/11/01 Concrete Kilometre Posts Number

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8.12 RCC Palisading

8.12.1 Description
This work shall consist of furnishing and placing Precast RCC posts with-
(i) Precast RCC Plates/Planks with necessary anchoring with the RCC Posts;
(ii) Cast in situ RCC Grade Beam and vertical wall constructed on the RCC Posts.
In accordance with the Specifications and in conformity with the requirements of the
Drawing or as with other parts of the Contract Documents.
The RCC posts consist essentially of precast and driven “I” shaped RCC concrete posts
laterally supporting the precast concrete plate or the cast in situ RCC wall with Grade Beam
constructed on the driven RCC Posts.

8.12.2 Materials
The RCC posts, Grade Beam and RCC wall shall conform to the requirements of Section
4.2.2 and shall be constructed in accordance with the details shown on the Drawings, and
with Sections 5.1 and 5.2.

The precast concrete plate shall be constructed in accordance with the details shown on the
Drawings, and with Sections 5.1 and 5.2.

Cement to be used shall be type 1.

8.12.3 Construction Methods

8.12.3.1 RCC Post
All production and construction methods for RCC Posts shall conform to Sections 4.2.3 and
4.2.4 except that load testing shall not normally be required. For RCC Plate Palisading, the
RCC Posts shall be driven by a monkey/drop hammer or by wash boring, whichever is
suitable to site condition, up to the required depth as per proper grade, alignment and the
approved drawing.

The Precast RCC Posts shall be driven by a monkey/drop hammer or by wash boring,
whichever is suitable, in full length of the Posts as per proper grade, alignment and the
approved drawing.

8.12.3.2 RCC Grade Beam

Construction methods for RCC Grade Beam shall conform to Sections 4.2.3 and 4.2.4.

The grade beam shall be constructed on the pre-cast driven RCC Posts by breaking the heads
of the RCC Posts driven to the ground up to150mm depth, scraping and removing loose

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particles, placing reinforcement with necessary scaffolding, shuttering and then casting the
Grade Beams in situ as per proper grade, alignment and the approved drawing.

8.12.3.3 RCC Vertical Wall

Construction methods for RCC vertical wall shall conform to Sections 4.2.3 and 4.2.4

The RCC vertical wall shall be constructed on the RCC Grade Beam supported by pre-cast
driven RCC Posts after placing reinforcement, scaffolding, shuttering and then casting the
vertical RCC wall up to the designed height as per proper grade, alignment and the approved
drawing.

8.12.3.4 Precast RCC Plate/Planks

The precast concrete Plate/Planks shall be constructed in accordance with the Drawing, and
Sections 5.1 and 5.2.

The precast plates/planks shall be placed between the RCC posts as shown on the Drawings.
The planks shall be excavated or driven down to the levels indicated on the Drawings or as
otherwise directed. In this connection it may be necessary to clear up the bed to the
prescribed level and make local excavations along the planks as they are lowered. The
method of placing the plates/planks and anchoring them with the RCC Posts shall comply in
all respect as per the approved drawing, specification and direction of the Engineer.

8.12.4 Tolerances
The horizontal position of the RCC posts after being driven shall not deviate from the correct
position more than +10 mm perpendicular to the line of the wall and +10 mm in the direction
of the wall. The precast planks in between the piles are designed to allow for a longitudinal
tolerance of RCC post position of +10 mm. If the Contractor during construction establishes
that the above tolerance is too small, the Engineer may accept minor changes in the tolerance.
Such changes will require corresponding changes in plank sizes.

8.12.5 Measurement
The unit of measurement shall be the linear meter of Palisading work completed as per the
approved drawing and accepted by the Engineer in all respect.

8.12.6 Payment
The work shall be measured as provided above and shall be paid at the contract unit rate per
linear meter. The rate shall constitute full compensation for all materials, labours, tools,
equipment, driving, fitting, fixing fabricating, shuttering, casting, curing and all other
incidental charges.
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No payments shall be made for unauthorized or unsatisfactory works

08/12/01(a) RCC Palisading (4m post, 200mm X 200mm) with precast RCC Lin. Meter
Plate/Plank

08/12/01(b) RCC Palisading (3m post, 150mm X 150mm) with precast RCC Lin. Meter
Plate/Plank

08/12/01(c) RCC Palisading (2.67m post, 200mm X 200mm) with cast in situ Lin. Meter
vertical wall

08/12/01(d) RCC Palisading (2m post, 150mm X 150mm) with cast in situ Lin. Meter
vertical wall

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