GOVERNMENT OF MAHARASHTRA

PUBLIC WORKS DEPARTMENT

REVISED
STANDARD SPECIFICATIONS
2012

VOLUME I
ROADS, BRIDGES AND CROSS DRAINAGE
 INSTRUCTIONS
The Standard Specifications have been grouped under the following sections:-
A. Basic Materials.
B. General Items.
BR. Bridge Work.
CD. Cross Drainage Works.
Rd. Road Works.
Bd. Building Works.
The first two sections cover specifications for Basic materials and General Items pertaining
to all normal construction works. The other sections include specifications for the various
items of work that are required under those respective sections. The specifications under
each section are distinguished by prefix mentioned against each. The list of items under
each section is given at the beginning of that section. Indian Standards have been adopted
and referred to wherever necessary. A list of such Standards referred to, is given at the
beginning of each section. These Standards should be available in divisions. For compliance
of specifications it is advisable to buy samples of required materials especially fixtures etc.
and keep for reference prior to calling tenders. In the general instructions men­tion may be
made that the material shall conform to samples with the Department.
The wording of the items has been standardised to form the basis for preparing the list of
items for the Standard Schedule of Rates. In order to avoid repetition and to keep down
the volume of write up, different alternatives like type of mortar (cement or lime), propor­
tion of mix of each type of mortar etc. which have to be actually used in a particular item of
work have been included in the same item either as alternatives for deleting the unwanted
alternatives or as blanks to be filled in while preparing the list. For purposes of Schedule of
Rates, each item mentioned in the specifications will have to be split up into a number of
separate items to provide for each alternative or combination of alternatives and for each
figure that will have to be filled up in the blanks, where left. Whatever the alternative or
combination of alternatives that may be retained in the item of the schedule and whatever
figures may be included in the blanks for that item, the specifications drawn up for the item
will be applicable for all the split up items.
For every one of such split up items, the number of the specifi­cation to be quoted in the
tender and referred to will be the single number of the corresponding combined item which
provides for all the alternatives and blanks in the Standard Specifications. The reference
should include the prefix of the particular section, letter of the particular group and the serial
number of the item. Thus in Bd.G.5, Bd. will refer to the section of Building work, G will refer
to Brick work group of that section and 5 will refer to the item number 5 in the list of items
in that group.
The specifications for each item covers:
1. General scope of the item,
2. Materials required,
3. Processing of the materials,
4. Construction operations,
5. Finishing,
6. All the elements which are included in the item, and
 7. Mode of measurement, deductions to be made etc, and payment.
If specifications are to be added for any new items, they may be drafted likewise.
The analysis of scheduled rate for any item will be framed to cover all elements included
in that item, as specified in the Standard Specifications. For National Highway Works the
specifications for Roads and Bridge of the Ministry of Surface Transport (Road Wing)
Central Government, published by the Indian Roads Congress shall be adopted.
It is observed that in the case of certain items the DSR provides a rate with limited scope.
These gives rise to meager rate for item of larger scope and vise a versa. While formulating
DSR care is required to be taken to introduce number of items with different scope for the
item.
These specifications shall be thoroughly studied before deciding whether any addition to
the Standard Specifications is required or some portion is required to be modified due to
new materials, differ­ent processing, architectural ornamentation, etc. Such additions or
modifications shall be included in the special provisions to be men­tioned in the specifications
for the particular items, in addition to the reference made to the Standard Specifications.
Where necessary, the specifications have been supplemented by sketches for clarity.
The Engineer shall also supply detailed drawings where required. When, however, any
discrepancy is found between the drawing and the estimates or the specifications, the
Engineer’s deci­sion as to which shall be followed shall be final. “Engineer” shall mean the
Executive Engineer in charge of the work and shall include the superior Engineer Officers
of the Engineering Department of the Government of Maharashtra, i.e. the Superintending
Engineer, Chief Engineer, etc.
Metric system has been adopted throughout these specifications for weights, measures,
etc. Rationalised metric standards have been adopted wherever they have been evolved
or in use.
 SECTION A
Basic Materials
Contents
1. List of Indian Standards referred to
2. Specifications for Basic Materials: -
A.1. Lime.. .. .. .. .. .. .. .. .. .. .. .. .. .. ..
A.2. Cement..... .. .. .. .. .. .. .. .. .. .. .. ..

List of Indian Standards referred to

Wherever revision has taken place the latest revision shall be used for reference.
1. I.S. 75-1967--
Linseed Oil, Raw, for Paints.
2. I.S. 77-1968--
Linseed Oil, Boiled, for Paints.
3. I.S. 77-1968--
Linseed Oil, Pale Boiled, for Paints.
4. I.S. 85-1950-- with Amendment No. I.
Methods of Test for Oil Pastes for Paints.
5. I.S. 86-1950-- with Amendment Nos. I and II.
Oil Pastes for Paints to Indian Standard Colour Nos. 101, 102, 103, 104, 169, 216,
217, 219, 352, 353, 354, 358, 359, 360, 361, 362, 363, 364, 410, 443, 444, 628,
629, 630, 631, 632, 633, 634.
6. I.S. 87-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour No. 105, Oxford Blue.
7. I.S. 88-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour No. 106, Royal Blue.
8. I.S. 89-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour No. 411, Middle Brown.
9. I.S. 90-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour No. 414, Golden Brown.
10. I.S. 91-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour Nos. 218, 220, 222, 223, 224, 225,
226, 227, 221, 267.
11. I.S. 92-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour Nos. 537, 538, 540, 541, 570.
12. I.S. 93-1950-- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour Nos. 445, 446, 448, 449, 451, 473.
13. I.S. 94-1950- with Amendment No. I.
Oil Paste for Paints to Indian Standard Colour Nos. 355, 356, 358, 557.
14. I.S. 95-1950-- with Amendment Nos. I and II.
 Oil Paste for Paints, Exterior, White.
15. I.S. 96-1950-- with Amendment Nos. I and II.
Oil Paste for Paints, Interior, White.
16. I.S. 97-1950-- with Amendment Nos. I and II.
Oil Paste for Paints, Jointing purposes, etc., White Lead.
17. I.S. 98-1950-- with Amendment Nos. I.
Oil Paste for Paints, Zinc Oxide.
18. I.S. 99-1950-- with Amendment Nos. I.
Oil Paste for Paints, Zinc Oxide, Reduced.
19. I.S. 100-1950-- with Amendment No. I.
Oil Paste for Paints for General Purposes, Black.
20. I.S. 101-1964-- with Amendment No. I.
Methods of Test for Ready Mixed Paints and Enamels.
21. I.S. 102-1962-- with Amendment No. I.
Ready Mixed Paint, Brushing, Red Lead, Non setting, Priming.
22. I.S. 103-1962-- with Amendment No. I.
Ready Mixed Paint, Brushing, White Lead, for Priming and Gener­al Purposes.
23. I.S. 104-1962-- with Amendment No. I.
Ready Mixed Paint, Brushing, Zinc Chrome, Priming, for use on Aluminum Light
Alloys.
24. I.S. 105-1950--
Ready Mixed Paint, Brushing, Priming, for Enamels, for use on Metals.
25. I.S. 106-1962— with Amendment No. I.
Ready Mixed Paint, Brushing, Priming, for Enamels, for use on Wood.
26. I.S. 107-1950--
Ready Mixed Paint, Brushing, Red Oxide-Zinc Chrome, Priming.
27. I. S. 109-1968-with Amendment No. 1.
Ready Mixed Paint, Brushing, Priming, Plaster, to Indian Standard Colour
No. 361, Light Stone.
28. I. S. 110-1988-
Ready Mixed Paint, Brushing, Gray Filler, for Enamels, for use over Primers.
29. I. S. 11 1-1950-with Amendment Nos. 1. 2 and 3.
Ready Mixed Paint, Brushing, Undercoating, Exterior to Indian Standard Colour
Nos. 101, 216, 352, 358, 443, 632.
30. I. S. 11 3-1950 - with Amendment Nos. 1, 2 and 3.
Ready Mixed Paint, Brushing, Undercoating, Interior to Indian Standard Colour Nos.
101, 216, 352, 358, 443, 632.
31. I. S. 115-1950--with Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, Undercoating, Exterior, Matt Finish to Indian Standard
 Colour No. 352, Pale Cream No. 632, Dark Admiralty Gray.
32. I. S. 11 7-1964-with Amendment No. 1 -
Ready Mixed Paint, Brushing, Finishing, Exterior, Oil Gloss, for General Purposes to
Indian Standard Colour Nos. 101 to 104, 169, 174 to 216, 217,219, 275, 278, 280,
281, 283, 352, 353, 354, 358 to 365, 384 to 388, 397, 410, 442 to 444, 628 to 632,
634, 635, 692 to 694, 697.
33. I. S. 118-1962-with Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing Oil Gloss, for General Purposes, to Indian
Standard Colour Nos. 355, 356, 368, 557.
34. I. S. 119-1962-with Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, to
Indian Standarad Colour Nos. 218, 220, 221, 222, 223, 224, 225, 226, 227, 267.
35. I. S. 120-1962-with Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, to Indian
Standard Colour Nos. 537, 538, 540, 541.
36. I. S. 121-1962-Amendment-No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, to Indian
Standard Colour No. 414-Golden brown.
37. I. S. 122-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, to Indian
Standard Colour No. 41 1. Middle Brown.
38. I. S. 123-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes. to Indian
Standard Colour Nos. 445, 446, 448, 449, 451, 473, and red oxide.
39. I. S. 124-1952-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss- for General Purposes, to Indian
Standard Colour No. 105, Oxford Blue.
40. I. S. 125-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, to Indian
Standard Colour No. 106, Royal Blue.
41. I. S. 126-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Exterior, Oil Gloss, for General Purposes,
to Indian Standard Colour No. 671, Middle Graphite and Dark Graphite.
42. I. S. 127-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Exterior, Oil Gloss, for General Purposes,
White.
43. I. S. 128-1962-Amendment No. 1.
Ready Mixed Paint, Brushing, Finishing, Oil Gloss, for General Purposes, Black.
44 I. S. 129-1962-with Amendment Nos. 1 to 3.
Ready Mixed Paint, Brushing, Finishing, Interior, Oil Gloss, for General Purposes,
to, Indian Standard Colour Nos. 101 to 104, 169, 216 to 219, 352 to 354, 358 to
364, 410, 443, 444, 628 to 635.
45. I.S. 133-1965-Amendment No. 1.
Enamel, Brushing Interior, (1) Undercoating, (2) Finishing Colour as required.
46. I. S. 137-1965-Amendment No.1.
Ready Mixed Paint, Brushing, Matt Finish, Interior. to Indian Standard Colour Nos.
101 to 104, 169, 216, 217, 219, 352 to 354, 358 to 364, 410, 443, 444, 628 to 635.
47. I. S. 148-1950-Amendment Nos. I and 2.
Ready Mixed Paint, Brushing, Undercoating, Stoving, for Enamels and General
Purposes, Colour as required.
48. I. S. 154-1950-Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, Dead black, for use on Metal.
49. I. S. 155-1950-Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, Matt Black, for use on Wood.
50. I. S. 156-1950-Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, for use on Floors, Colour as required.
51. I. S. 157-1950-Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, Acid and Alkali Resisting, Lead-Free, for General
Purposes, to Indian Standard Colour Nos. 446, 537 and 632.
52. I. S. 158-1968-Amendment No. 1.
Ready Mixed Paint, Brushing, Bituminous, Black, Lead-Free, Acid, Alkali, Water and
Head Resisting, for General Purposes.
53. I. S. 159-1950-with Amendment No. 1.
Ready Mixed Paint, Brushing, Acid Resisting, for Protection against Acid Fumes.
Colour as required.
54. I. S. 161-1950 -Amendment Nos. 1 and 2.
Ready Mixed Paint, Brushing, Matt, Head Resisting Colour as required.
55. I. S. 162-1950-Amendment No. 1.
Ready Mixed Paint, Brushing, Fire Resisting, Silicate Type, for use on Wood Colour
as required.
56. I. S. 164-1951-Amendment No. 1.
Ready, Mixed Paint, Brushing, for Road Marking to Indian Standard Colour No. 356
Golden Yellow and White and Black.
57. I. S. 2339-1963-Amendment No. 1.
Aluminium Paint, Brushing, for General Purposes, in Dual Container.
58. I. S. 167-1950-with Amendment Nos. 1, 2 and 3.
Ready Mixed Paint, Thick White, for Lettering.
59. I. S. 168-1973-Amendment No. 1.
Ready Mixed Paint, Brushing, Quick Drying, Matt, Lead-Free, for General Purposes,
to Indian Standard Colours.
60. I. S. 210-1970-Amendment No. 1.
Grey Iron Castings.
61. I. S. 1521-1972, I. S. 1608-1972, I. S. 1663, I. S. 1894-1972.
Tensile Testing of Metals (Ferrous).
62. I. S. 226-1969-
Structural Steel.
63. I. S. 2107-1962, I. S. 2108-1962.
Malleable Iron Castings.
64. I. S. 269-1967-Amendment No. 1.
Ordinary, Rapid Hardening and Low Heat-Portland Cement.
65. I. S. 280 1972-
Mild Steel Wire.
66. I. S. 287-1973-
Recommendations for Maximum Permissible Moisture Content of Timber used for
Different Purposes in Different Climatic Zones.
67. I. S. 383-1970-
Aggregates from natural sources for concrete.
68. I. S. 432-1966-in two parts with Amendment Nos. 1 and 2 to Part 1.
Mild Steel and Medium Tensile Steel Bars and Hard-Drawn Steel Wire for Concrete
Reinforcement.
69. I. S. 456-1964-Amendment Nos. 1 to 5.
Code of Practice for Plain and Reinforced Concrete for General Building
Construction.
70. I. S. 515-1959-
Natural and Manufactured, Aggregate for use in mass Concrete.
71. I. S. 533-1973-with Amendment Nos. 1 and 2.
Gum Spirit of Turpentine (Oil of Turpentine).
72. I. S. 712-1973-
Building Limes.
73. I. S. 800-1962-Amendment Nos. 1 and 2.
Code of Practice for use of Structural Steel in General Building Construction.
74. I. S. 883-1970.
Code of Practice for use of Structural Timber in Building (Material Grading and
Design).
75. I. S. 1030-1974-
Steel castings for General Engineering Purposes.
76. I. S. 1077-1970-
Common Burnt clay Building bricks.
77. I. S. 1124-1957.
Water absorption of Natural Building-Stone-method of test.
78. I. S. 1141-1973.
Code of Practice for Seasoning of Timber.
79. I. S. 1148-1973-Amendment No. 1.
Rivet Bars for Structural Purposes.
80. 1. S. 1344-1968.
Surkhi for use in mortar and concrete.
81. I. S. 1542-1960.
Sand for plaster.
82. I. S. 1624-1974.
Field testing of Building Lime and Lime Mortar.
83. I. S. 1785-1966-Part I with Amendment No. 1 - Part II—1967.
Plain hard drawn steel wire for prestressed concrete.
84. 1. S. 2090-1962-
High tensile steel bars used in prestressed concrete.
85. 1. S. 3812-1981
Specification for use of fly ash.
86. 1. S. 12894-1990
Specification for use of fly ash-Lime bricks.
87. 1. S. 1489 (Part I) for use of fly-ash-mixed P.P.C.
Recent Y Amendment if any shall be considered
 GENERAL TABLE OF CONTENTS

VOLUME -I

Section A

(1) BASIC MATERIALS­

Items A. 1 to A. 17

Section B

(2) GENERAL ITEMS-

­Items B. 1 to B. 21

Section BR

(3) BRIDGE WORK--

Items BR. 1 to BR. 58

Section CD

(4) CROSS DRAINAGE WORKS-

Items CD. 1 to CD. 24

Section Rd.

(5) ROAD WORKS-

Items Rd. I to Rd. 62

 SECTION A
Basic Materials

CONTENT

Page

1. List of Indian Standards referred to

2. Specifications for Basic Materials: -

A.1. Lime

A.2. Cement

A.3. Neeru

A.4. Water

A.5. Fine Aggregate

A..6. Coarse Aggregate

A.7. Stone for masonry

A..8 Bricks

A..9 Mild steel bars for reinforcement

a) High Tensile steel bars

b) High Tensile steel wires

A.10. Structural steel

A.11. Mild steel binding wire

A.12. Timber

A.13. Oil Paints

a) Ready mixed paints

b) Oil paints prepared on site

 SECTION A

STANDARD
SPECIFICATIONS
FOR BASIC MATERIALS
 A.2.2.
* 1964, ** 1967, *** 1968

A.1. LIME
A.1.1. General -The Specification covers eminently hydraulic limes (in their hydrated
states) and moderately hydraulic limes and fat limes in their un hydrated and hydrated
states used in building construction.
A.1.2. Classification -As per I.S. 712-*, the Building limes shall be classified as -
Class A.- Eminently Hydraulic lime used for structural purposes.
Class B.- Semi-Hydraulic lime used for masonry work.
Class C.- Fat lime used mainly for finishing coat in plastering, White washing and with
suitable add mixtures such as Surkhi, or any other pozzolanic material, to produce Artificial
hydraulic mortar.
Class D.- Magnesium lime used for finishing coat in plastering, White washing etc.
Class E.- Kankar lime used for necessary mortar.
A.1.3. Chemical Composition -For different classes of limes, the chemical composition
shall be as per I.S. 712-*.
A.1.4. Physical Requirements -They shall comply with I.S. 712-*. All impurities, ashes or
pieces improperly burnt shall be screened or picked out before slaking. The lime shall be
slaked with water not less than one week or more than two weeks before use. The slaked
lime shall be screened through I.S. 240 sieve for mortar used for concrete or masonry and
first coat of plaster and I.S. 120 sieve for second and third coats of plaster.
A.1.5. Storage -Storage shall comply with I.S. 712-*. The slaked lime if stored, shall be
kept in a water-proof and damp-proof closed shed with impervious floor and sides to protect
it against rain, moisture, weather and extraneous materials mixing with it. The lime shall be
used when fresh, i.e., within 14 days of its removal from kiln.
All lime that has been in any way damaged by rain, moisture, dirt, air-slaking or any other
cause shall be rejected and all reject­ed material shall be removed from the work site
forthwith.
A.1.6. Sampling and testing -According to I.S. 712-* Sample of lime shall be got approved
by the Engineer who shall keep it in his office.
A.1.7. Field Testing -According to I.S. 1624-***.
A.1.8. Measurement - When required to be measured, measurement shall be by volume
with cu. metre as the unit.

A.2. CEMENT
A.2.1. Cement -Cement shall conform to I.S. 269-* or I.S. 8112- ****. for Gr. 43 or Gr. 53
cement.
The type of cement as to whether it shall be Ordinary Rapid Hardening or Low Heat shall
be specified. When no type is specified, Ordinary Portland cement shall be used.
A.2.2. The weight of Ordinary Portland cement shall be taken as 144 kg. Per cu. m. and
Rapid Hardening Portland cement as 121 kg. per cu. m. The measurement of proportion
of cement should normally be on the basis of weight and whole bags, each undisturbed
and sealed 50 kg. bag being considered equivalent to 35 litters in volume. When part bag
is required, cement shall be taken by weight. When the basis of mix. is by volume, cement
will be taken by weight, assuming 35 litters to be equal to 50 kg. Care should be taken to
see that each bag contains full quantity of cement.
RED BOOK  VOLUME I  ROADS  2012 15
A.2.3.
A.2.3. Tests -When tests are considered necessary, they shall be carried out as indicated
in I.S. 269-* or I.S. 8113 : 1976. The contractor should ensure that the cement is of sound
and required quality before using it.
A.2.4. Storage -Cement required for use shall be as fresh as possible and stored on planks
raised 15 to 20 cm above the floor and stacked 30 cm away from the walls in suitable
closed weather-proof buildings at the work site or at the selected approved site, in such
a manner as to prevent deterioration by dampness or moist atmosphere or intrusion of
foreign matter. Cement shall be stored in such a way as to allow the removal and use of
cement in chronological order of receipt, i.e. first received being first used. Not more than
15 bags shall be stacked vertically in one pile and maximum width of the piles should not be
more than 3 metres. Any cement that has deteriorated caked or which has been damaged
shall not be used. Cement concerning which there is a doubt shall not be used pending
testing and satisfac­tory results. Cement that is condemned shall be immediately removed
from the work site. When temporarily stored in the open for use within 48 hours, it shall
be kept on a platform of planks about 15cm to 20cm. above ground and covered with a
tarpaulin. Ordinary cement stored for more than 2 months from the date of receipt from the
factory shall be subjected to test and used only if found satisfactory. The cost of tests shall
be borne by the agency responsible for the storage after 2 months from receipt. Different
kinds or brands of cement or cement of the same brand from different mills should be
stored in separate groups and should not be mixed during the use except when directed in
writing by the Engineer. Cement shall be kept in a store under double locking arrangement
so that it can be taken out or fresh stock admit­ted with the knowledge of supervising staff
of the Department. A board indicating stock and daily transactions of cement shall be kept
in each room of the cement store. Daily account of receipt and use of cement bags shall
be maintained by the Contractor in the Performa approved by the Engineer. This shall be
kept in the store for verifi­cation by the supervising Departmental staff. Copies of the records
shall be supplied to the Engineer regularly.
A.2.5. The cement shall not be stored for unduly long periods. It should not be handled in
such a way as to impair its strength or useful characteristics.
A.2.6. Measurement - When required to be measured, measurement shall be by weight
with tonne as the unit.

A.3. NEERU
A.3.1 General -This specification covers neeru to be used for plaster finishes in building
work.
A.3.2 Materials –
1) Lime - Class C lime ( i.e pure fat lime ) as mentioned in I.S.1712-1973 shall be used.
Lime shall comply with specification No. A.1 in all respects.
2) Water - Water shall conform to specification No. A.4.
3) Sand - Sand shall conform to specification No. A.5.
All sand shall pass through I.S. sieve No.50.(0.599 mm)
A.3.3 Preparation -Lime shall be slaked and mixed with suffi­cient water to form a thick
paste. It shall be reduced to a fine paste by grinding. It shall then be passed through a
fine sieve (3mm mesh) to remove all un slaked particles and foreign matter and allowed to
mellow under water for at least 10 days in large slaking tanks. The surplus water on the top
shall be allowed to run off. The slaked lime paste thus formed shall be used for preparing
neeru. Ready lime powder class C conforming to I.S. 1712 may also be used for preparing
neeru.
16 RED BOOK  VOLUME I  ROADS  2012
 A.5.2.
The neeru shall be prepared by mixing together 4 parts of this lime paste and 1 part of fine
sieved sand by volume. Jute fibre finely chopped shall be added to this mortar at the rate of
4 Kg of jute to every Cu.m. of lime sand mixture. The mixture shall then be properly ground
to a fine paste between two stone or a mill. Neeru may also be prepared from ready powder
by intimate hand mixing.
The neeru thus prepared shall be kept moist until used and no more than what can be
consumed in 15 days shall be prepared at a time. In case of neeru prepared from ready
lime powder , it shall be used immediately.
A.3.4 Measurements - When required to be measured the measurement shall be by
volume with Cu.m. as unit.

A.4. WATER
(a) Water for mixing cement/lime mortar or cement/lime concrete - Water for mixing
cement/lime mortar or concrete shall not be salty or brackish and shall be clean, reasonably
clear and free from objection­able quantities of silt and traces of oil, acid and injurious alkali,
salts, organic matter and other deleterious material which will either weaken the mortar or
concrete or cause efflorescence or attack the steel in R.C.C. Water shall be obtained from
sources approved by the Engineer. Sources of water shall be maintained at such a depth
and the water shall be withdrawn in such a manner as to exclude silt, mud, grass or other
foreign materials. Containers for transport, storage and handling of water shall be clean.
If required by the Engineer, it shall be tested by comparison with distilled water. Comparison
shall be made by means of standard cement tests for soundness, time of setting and mortar
strength as specified in I.S. 269-**. Any indication of unsoundness, change in time of setting
by 30 minutes or more, or decrease of more than 10% in strength of mortar prepared
with the water sample when compared with the results obtained with mortar prepared with
distilled water shall be sufficient cause for rejection of water tested. Sea water shall not be
used.
Water fit for drinking will generally be found suitable for mixing cement/lime mortar or
concrete.
(b) Water for curing cement/lime mortar or concrete - Water for curing mortar or concrete
should not be too acidic or too alkaline. It should have a pH value ranging between 4.5 to
8.5. It shall be free of elements which significantly affect the hydration reaction or other­wise
interfere with the hardening of mortar or concrete during curing or those which produce
objectionable stains or other unsightly depos­its on concrete or mortar surfaces. Hard and
bitter water containing more than 100 p.p.m. of sulphates shall not be used for curing pur­
pose.
Sea water and water containing over 3% of chloride salts should not be used for curing
reinforced concrete works.
Potable water will generally be found suitable for curing cement/lime mortar or concrete.

A.5. FINE AGGREGATE

1959 = 1963 =
A.5.1. General - All fine aggregate shall conform to I.S. 383-== and relevant portion of I.S.
515-= as directed by the Engineer.
A.5.2. Sand for use in concrete shall be natural sand or crushed stone screenings. Sand
shall be clean, well graded, hard, strong, durable and gritty particles free from injurious
amounts of dust, clay, kanker nodules, soft or flaky particles, shale, alkali, salts, organic
matter, loam, mica or other deleterious substances and shall be approved by the Engineer.
RED BOOK  VOLUME I  ROADS  2012 17
A.5.2.
The maximum size of particles shall be limited to 5mm. Where the best trap sand available
in the region contains murum or laterite particles, such particles may be allowed up to 5%.
Zeolite crystals may also be permitted up to 4%. If the fine aggregate contains more than
4% of clay, dust or silt shall be washed. When the quality of fine aggregate is doubtful, it
shall be tested for clay, organic impurities and other deleterious substances as laid down
in I.S. 383-==. It shall not contain deleterious materials in such quantity as to reduce the
strength or durability of the mortar or concrete or to attack the reinforcement in the case
reinforced con­crete work. Sea sand shall not be used.
A.5.3. The fine aggregate for concrete shall be graded within limits given in table III or
table IV in paragraph 5-2 of the I.S. 383-==. The fineness modulus may range between
2.6 to 3.6. If substi­tution of a certain quantity of stone screenings will improve the quality of
concrete, the Engineer may allow it.
A.5.4. The fine aggregate for cement mortar for masonry and first coat of plaster should
generally satisfy the following grading:-

I.S. Sieve Percentage by weight

passing sieve
480 100
240 80 - 95
120 70 - 90
60 40 - 85
30 5 - 50
15 0 - 10
The fineness modulus shall not exceed 3.0
A.5.5. The fine aggregate for cement mortar for pointing and second coat of plaster may
have the following grading :-

I.S. Sieve Percentage by weight

passing sieve

480 100
240 100
120 75 - 100
60 40 - 85
30 5 - 50
15 0 - 10
The fineness modulus shall not exceed 1.6.
I.S. 1542-1960 shall generally apply for sand for plaster.
A.5.6. Gradation - The gradation of materials from any one source shall not vary in
composition beyond the range of values that governs, in selecting source of supply. For
determining the degree of uniformi­ty, determination of fineness modulus shall be made
upon representa­tive samples furnished by the contractor from such sources as he proposes
to use. Fine aggregate from any one source having a variation in fineness modulus greater
than -20 to +20 from the average fineness modulus of the representative samples submitted
by the contractor shall be rejected or may be accepted subject to such changes in the
proportion of aggregate as the Engineer may direct.
18 RED BOOK  VOLUME I  ROADS  2012
 A.6.2.
A.5.7. Storage - The fine aggregate should be stacked carefully on a clean, hard surface
so that it will not get mixed up with delete­rious foreign material.
Sand shall not be stacked in high conical heaps so that segrega­tion of heavier particles by
sliding down may be prevented. It shall be placed in layers not thicker than those resulting
from lorry loads dumped on the same plane.
A.5.8. Tests - The aggregate shall satisfy the tests referred to in I.S. 383-****. Samples of
sand to be used for a particular item shall be got approved by the Engineer who shall keep
it in his office for reference.
A.5.9. Royalty - The contractor shall be responsible for observ­ing the laws, rules and
regulations imposed under the Minor Minerals Act and such other laws and rules prescribed
by Government Departments such as Forest and Revenue and by competent Local
Authorities etc. Royalty payable for securing the material shall be paid by the con­tractor
subject to general conditions of contract.
Where rules permit refund of Royalty for use of the materials in Government work the
Engineer will pass a certificate for the quantity so used.
No royalty shall be charged when the material is allowed to be obtained from Departmental
quarry.
A.5.10. Measurement - When required to be measured, measurement shall be by volume
with cu. meter as the unit. No deduction shall be made for the voids.

A.6. COURSE AGGREGATE

A.6.1. Coarse aggregate shall consist of crushed or broken stone and be hard, strong,
dense, durable, clean, of proper gradation and free from skin and coating likely to prevent
proper adhesion of mor­tar. the aggregate shall generally be cubical in shape and as far
as possible flaky, elongated pieces shall be avoided. It shall generally comply with the
provisions of I.S. 383-== and I.S. 515-=. Unless special stones of particular quarries are
mentioned in the special provisions, aggregates shall be broken from the best trap/granite/
quartzite/gneiss stones in that order available in the region and approved by the Engineer.
Stone shall have no deleterious reaction with cement. Shingle of the appropriate grading
may be per­mitted to be substituted for some proportion of the metal without price adjustment
if it is shown that thereby strength of concrete is increased and workability improved.
A.6.2. The maximum size of the aggregates may be upto 80mm. and well graded between
the sizes 5mm to 80mm. in such proportions as to give maximum density to the concrete.
The maximum size should be as large as possible within the above limit but should not
exceed 1/4 of the minimum thickness of the member, provided however this size pres­ents
no difficulty in the case of R.C.C. to surround the reinforcement thoroughly and fill up the
corners of the formwork satisfactorily. In the case of general concrete work, a maximum size
of 40mm is used and in R.C.C. work a maximum size of 20mm will be found satisfactory;
but it should be restricted to 6mm less than the minimum lateral clear distance between
bars or 6mm less than the cover, whichever is small­er.
The crushing strength of aggregate will be such as to allow the concrete in which it is used
to built up the specified strength of the concrete.

RED BOOK  VOLUME I  ROADS  2012 19

A.6.3.
A.6.3. Approximate range in grading of coarse aggregate may be as under :-

PERCENTAGE OF COARSE AGGREGATE FRACTION

MAXIMUM SIZE NOMINAL 40mm to 20mm to 5mm to 10mm to 5mm to

OF AGGREGATE RANGE 80 mm 40 mm 20 mm 20 mm 10 mm
(1) (2) (3) (4) (5) (6) (7)

20mm 100 55—67 33--45

40mm 40—50 50—60 28—40 18--30
80mm 20—36 16—36 35—44 10—30 13--29
Grading tests shall be taken in the beginning and at change of source or machinery or type
of metal. Where required by the Engineer, tests indicated in I.S. 383= and I.S. 456-* shall
be got carried out in an approved laboratory at the contractor’s cost to show the accept­
ability of the material.
A.6.4. Coarse aggregate of a porous nature where absorption of water after 24 hours’
immersion in water, is more than 5% by weight, shall not be used.
A.6.5. Limits of deleterious substances shall not exceed those prescribed in 2.3.1.1 and
2.3.1.2 of I.S. 515-=.
A.6.6. Storage - The aggregates of different sizes shall be stored separately and handled in
such a manner as to prevent intermixing of different sizes of aggregates required separately
for grading purpos­es. No foreign matter shall be allowed to be mixed up with aggregates. If
covered with dust, etc., they washed clean before use.
A.6.7. Royalty - The contractor shall be responsible for observ­ing the laws, rules and
regulations imposed under the Minor Minerals Act and such rules prescribed by Government
Departments such as Forest and Revenue and by competent Local Authorities etc. Royalty
payable in connection with securing the material shall be paid by the contrac­tor subject to
general conditions of contract.
Where rules permit refund of Royalty for use of the materials in Government work the
Engineer will pass a certificate for the quantity so used.
The contractor shall be entirely responsible for operating exist­ing quarries or opening new
quarries including removal of over-burden and shall bear all costs pertaining to them.
In the case of Departmental quarries, operations shall be carried out in such a way that
their further usefulness is not affected. No royalty will be charged when the material is
allowed to be obtained from the Departmental quarry.
When the quarries are not owned by the Department, the contractor shall be responsible
for securing the written consent of the land owners for opening new quarries or working old
ones and for payment of all compensation, Royalty, etc.
Samples of coarse aggregates required for the work shall be got approved by the Engineer
both regarding quality and grading and shall be kept in the Engineer’s office. The coarse
aggregate to be used shall conform to those samples.
A.6.8. Blasting - Blasting shall be carried out according to instructions laid down in
specification No. B.2.
A.6.9. Measurement -  When required to be measured, measurement shall be by volume
with cu. meter as the unit. No deduction shall be made for the voids.

20 RED BOOK  VOLUME I  ROADS  2012

 A.7.6.
A.7. STONE FOR MASONRY
A.7.1. Stone to be used in the masonry shall be trapped, granite, quartzite, gneiss, laterite
or any other type of good stones avail­able locally. In the absence of mention of a special
type in the item or the special provision, good trap, granite, quartzite or gneiss stones in
that order available in the region and known to be satisfac­tory in use in view shall be used.
The stone shall stand weathering well and when immersed in water for 24 hours shall not
absorb water more than 5% of its dry weight when tested according to I.S. 1124-===. The
stone of the required quality shall be obtained from quarries specified in the contract or
quarries approved by the Engineer. All stones shall generally be freshly quarried. Laterite
stone should be compact in texture and the mottled and streaked colours pervading it
should not be very unevenly distributed. Those types in which white clay colours should not
be used as building stones. Laterite stones exposed to weather to harden for some time
should be preferred. It should not be used where subject to great pressure and liable to be
soaked with water.
A.7.2. Quality of face stones - The stones to be used in the face shall be tough, hard,
dense, sound and durable, resistant to weather­ing action, reasonably fine-grained, uniform
in colour and texture and free from seam cracks or other defects which would adversely affect
their strength, durability or appearance. They shall also be free from weathered portion and
skin. The exposed faces shall be entirely free from any type of discolorations. Preferably
stone shall be from a quarry the product of which is known to be of satisfactory quality in
use. Stones shall be freshly quarried with clean faces and sharp edges all round and shall
be of such a character that it can be wrought to such lines and surfaces, whether curved
or plane as may be required. size and shape of stones shall be as per the requirements of
each item.
A.7.3. Quality of rubble stones - Rubble stones for hearting shall be of approved quality,
sound, hard, dense and durable, free from segregation, seams, cracks, and weathered
portions and other struc­tural defects or imperfections tending to affect their soundness and
strength. Stones shall generally be freshly quarried with sharp edges and clean faces. They
shall be free from rounded, worn or weathered surfaces or skin or coating which prevents
the adherence of mortar. Size and shape of stone shall be as per the requirement of each
item.
A.7.4. Quality of other stones - Stones to be used as headers, pin headers, quoins,
coping, etc., shall comply with the requirements of facing and hearting stones as may be
relevant and shall further comply with the requirement of size and shape stipulated under
the relevant item.
A.7.5. Samples - Sample of stones to be used in the work shall be got approved by the
Engineer before the work is started and such samples shall be maintained in the Engineer’s
office.
A.7.6. Royalty, octroi duties, etc. - Royalties, compensation, octroi duties, etc., payable
in connection with securing the stones shall be paid by the contractor subject to conditions
laid down in the general conditions. The contractor shall be responsible for observing the
laws, rules and regulations imposed under the Minor Minerals Act and such other rules etc.,
laid down by Government Departments and Local Authorities.
Where rules permit refund of royalty for use of the materials in Government works, the
Engineer will pass a certificate for the quanti­ty so used. No royalty will be charged when the
materials are allowed to be obtained from the Departmental quarries. In the case of Depart­
mental quarries, operations will be carried out in such a way that their further usefulness is
not affected.

RED BOOK  VOLUME I  ROADS  2012 21

A.7.7.
The contractor will be entirely responsible for operating exist­ing quarries or opening new
quarries including removal of over-burden and shall bear all costs pertaining to them.
Where the quarries are not owned by the Department, the contrac­tor shall be responsible
for securing the written consent of the land owners for opening new quarries or working old
ones and for payment of all compensation, Royalty, etc. The stones whatever their source
shall be of the specified quality.
A.7.7. Blasting - Blasting shall be carried out according to instructions laid down in
specification No. B.2.
A.7.8. Measurement - When required to be measured, measurement shall be by volume,
length of numbers as the case may be with cu. metre, metre and one as the respective unit.
In case of rubble the measurement shall be by volume of stacks without deductions for
voids.
In case of khandkies the measurement shall be by length.
In case of stones such as quoins, arch stones, etc., the measure­ment shall be by
numbers for specified sizes.
In case of stones such as the slabs, coping stones, etc., the measurement shall be by
volumes for specified dimensions.

A.8. BRICKS
A.8.1. First-class Bricks - First-class Bricks shall be of regu­lar and uniform size, shape and
colour, uniformly well burnt through­out but not overburnt. They shall have plain rectangular
faces with parallel sides and sharp, straight and right angled edges. They shall be free from
cracks or other flaws. They shall have a frog of 10mm depth on one of their flat faces.
A.8.1.1. They shall give a metallic ringing sound when struck.
A.8.1.2. They shall show a fine grained, uniform, homogeneous and dense texture on
fracture and be free from lumps of limes, lamina­tions, cracks, air holes, soluble salts
causing efflorescence or other defects which may in any way impair their strength,
durability, ap­pearance or usefulness for the purpose intended. They shall not have any
parts under-burnt. They shall not break when thrown on the ground on their flat face in
a saturated condition from a height of 60cm
A.8.1.3. Size - (a) The size of the conventional bricks may vary from about 22cm x 10cm
x 6.5cm to 23cm x 11cm x 8cm Only bricks of one standard size, shall be used on one
work unless specially permit­ted by the Engineer. The following tolerances are permitted
in the standard conventional size adopted on a particular work :-
Length - plus or minus 3mm.
Breadth - plus or minus 1.5mm.
Depth - plus or minus 1.5mm.
(b) When I S bricks are used they shall comply with I.S. 1077-1966*.
A.8.1.4. Absorption - After immersion in water, absorption by weight shall not exceed
20% of the dry weight of the brick when tested according to I.S. No. 1077-1966*.
A.8.1.5. Crushing strength - The load to crush the brick when dry shall not be less than
44 Kg/sq.cm and when thoroughly soaked, shall not be less than 33 Kg/sq.cm.
A.8.1.6. Tests - When bricks are to be used in high load bearing walls, where the load
coming on the walls is of the order of 4.5 Kg/sq.cm. and more, where there is a doubt
about the crushing strength of the bricks, the Engineer may order the compression tests
as laid down in I.S. 1077-1966*. If different kilns use different materials and methods of

22 RED BOOK  VOLUME I  ROADS  2012

 A.9.3.
burning, one test shall be made for each group of kilns using the same type of materials
and methods of burning. If the aver­age strength is less than that mentioned in A.8.1.5.
The bricks from the kiln represented by the sample shall be rejected. All tests shall be
done at the cost of the contractor.
A.8.2. Second class Bricks - (a) Second class bricks shall be similar to first class bricks
except that they may be slightly over­burnt and may not have very sharp edges. Tolerance
in depth shall be plus or minus 3mm. Absorption of water when immersed in water shall
not exceed 22% when tested according to I.S. 1077-1966*. Crushing strength may be 10%
less than that prescribed for first class bricks.
All other provisions specified for first class bricks shall also apply to second class bricks.
(b) When I.S. bricks are used they shall comply with relative provisions for second class
bricks in I.S. 1077-1966*.

A.9. MILD STEEL BARS FOR REINFORCEMENT

A.9.1. Material - Mild steel reinforcement bars - mild steel bar reinforcement for R.C.C.
work shall conform to I.S. 432-(Part I) and shall be of the tested quality of not less than
Grade I. It shall also comply with the relevant part of I.S. 456-*.
All the reinforcement shall be clean and free from dirt, oil, paint, grease, mill scale or loose
or thick rust at the time of plac­ing.
The contractor shall produce a test certificate of the manufac­turer.
If independent tests are considered necessary, they shall be carried out according to I.S.
1521 and 1608-****. The cost of such tests shall be borne by the contractor if the results
are unsatisfac­tory and by the Department if the results are satisfactory. In case of untested
steel, the cost of the tests shall invariably be borne by the contractor.
Bars of rods rerolled from scrap steel shall not be used unless tests show that they fully
comply with I.S. 432-(Part I).
A.9.2. Storage - Reinforcement steel shall be stored above ground surface upon platforms,
skids or other supports to avoid distortion and sags of long lengths and shall be protected
as far as practicable, from surface deterioration by direct contact with undesirable elements
or by exposure to conditions producing rust and corrosion. All bars of the same designation
shall be stacked separately in racks and dis­tinctly marked.
A.9.3. Measurement -  When required to be measured, measurement shall be by weight
with quintal or tonne as the unit. The bars may be directly weighed or the weight shall be
calculated according to stan­dard weights mentioned in ISI Hand Book correct upto 0.10 Kg.

A.9.(a) HIGH YIELD STRENGTH DEFORMED BARS

The bars shall conform to I.S. 1786-1979 or I.S. 1139-1966. These shall either be cold
twisted or hot rolled deformed bars with the 0.2% proof stress of 415 N/sq.mm. or 500 N/
sq.mm. as per the requirement of the design.
Storage shall conform to A.9.2.
Measurement shall conform to A.9.3.

A.9.(b) HIGH TENSILE STEEL BARS

The high tensile steel bars for use in prestressed concrete work shall conform to I.S. 2090-
1962.
The storage shall conform to A.9.2.
The tensile strength of the high tensile steel bars shall be as specified in the special
RED BOOK  VOLUME I  ROADS  2012 23
A.10.1.
provisions of the item. In the absence of the given strength the minimum ultimate strength
shall be taken as 100 Kg./sq.mm.
Measurement shall conform to A.9.3.

A.9.(c) HIGH TENSILE STEEL WIRES

The high tensile steel wires for use in prestressed concrete work shall conform to I.S. 1785-
**.
The storage shall conform to A.9.2.
The tensile strength of the high tensile steel wires shall be as specified in the special
provisions of the item. In the absence of the given strength the minimum ultimate strength
shall be as given in para 6-1 of I.S. 1785-**.
Measurement shall conform to A.9.3.

A.10. STRUCTURAL STEEL

A.10.1. All structural steel shall conform to I.S.226-**** and I.S.800-****. The steel shall be
free from defects mentioned in I.S.226-**** and shall have a smooth uniform finish. It shall
be straight­ened if necessary, in the mill before shipment. Material shall be free from loose
mill scale, rust-bits or other defects affecting its strength and durability. Rivet bars shall
conform to I.S.1148-*.
A.10.2. Storage - Structural steel shall be stored above the surface of the ground upon
platforms, skids or other suitable supports to avoid distortion of sections in long length and
shall be protected as far as practicable from surface deterioration by direct contact with
harmful elements or exposure to conditions producing rust and corrosion. It should be so
stored and handled that the material will not be subject to excessive stress and damage.
A.10.3. Straightening - All deformed structural material will be properly straightened by
methods which are not injurious prior to being laid off, punched or otherwise worked in the
shop. Sharp kinks and bends shall be cause for rejection.
A.10.4. Tests - When the steel is supplied by the contractor, test certificates of the
manufacturers shall be produced. If further tests be necessary, they will be done according
to I.S. 226-****= and I.S. 1521-*****, 1608-***** ; the cost of such tests will be borne by
the Department if the results are satisfactory and by the contractor if the results are
unsatisfactory.
A.10.5. Measurement - The sections shall be supplied in specified exact lengths,
smoothly cut to the required lines. The lengths of the sections shall be measured correct
to a centimetre and weight calcu­lated on the basis of standard weights prescribed by I.S.
for each relevant section correct up to 0.10 of a Kg. Tolerances mentioned in I.S. 226-
****= shall be applicable unless other tolerances are pre­scribed in the specifications of any
particular item.
The contract rate shall be for a unit of one quintal or one tonne.

A.11. MILD STEEL BINDING WIRE

A.11.1. The mild steel wire shall be of 1.63mm or 1.22mm (16 or 18 gauge) diameter and
shall conform to I.S. 280-*.
The use of black or galvanised wire will be permitted for binding reinforcement bars. It shall
be free from rust, oil, paint, grease, loose mill scale or any other undesirable coating which
will prevent adhesion of cement mortar.
A.11.2. Storage - The wire coils shall be stored above ground on platforms or other

24 RED BOOK  VOLUME I  ROADS  2012

 A.12.4.
supports and protected from surface deterioration by direct contact with harmful elements
or by exposure to conditions producing rust and corrosion.
A.11.3. Measurement and Payment - No measurements will be taken of the wire used for
tying reinforcement bars. The rate for reinforce­ment steel and its fabrication shall include
the cost of the binding wire.
A.11.4. Measurement - When required to be measured, measurement shall be by weight
with quintal or tonne as the unit. The wire shall be weighed correct up to 0.10 Kg.

A.12. TIMBER
A.12.1. General - The specifications cover the requirements of good quality timber to be
used for various works. When the kind of wood is not specially mentioned, good Indian teak
(Tectona Grandis) alone shall be used.
A.12.2. Quality - Timber to be used in building works shall be from the heart of a sound tree
of mature growth, the sapwood being entirely removed. It shall be uniform in substance,
straight in fibre, free from large, loose, dead or cluster knots, flaws, shakes, warp, cup,
spring, twist, bends or defects of any kind. It should be free from spongy, brittle, flaky, or
brushy condition, sapwood and borer holes.
All timber shall be seasoned and be free from decay, rot, harmful fungi and insect attacks
and from any other damage of harmful nature which will affect the strength, durability,
appearance or its useful­ness for the purpose for which it is required.
A.12.3. Colour - The colour should be uniform as far as possible, the darkness of the
colour amongst coloured species of timber being generally a sign of strength and durability.
A.12.4. Kinds - Timber shall be of the species mentioned in the tender items. Normally for
doors, windows, roof, scantlings, trusses, etc., in all permanent and first class works, Indian
Teak Wood (Tecto­na Grandis) of the best quality like that from Dandeli, Ballarshah, and
Bulsar shall be used. Properly seasoned and treated Nana (Lagar­stroemia Lanceolata)
wood can be used as an alternative to teak wood when so specified. Adequately seasoned
and properly treated timber of Haldu (Adma Cardifolia), Anjan (Hardwickia binata) and
Bijasal (Ptero­carpus marsupium) can be used in place of teak for specified items of wood
work when so stipulated in the tender. Seasoned rose wood (Dal­bergia Latifolia) can be
used for internal fittings for first class work and furniture. Where jungle wood or hardwood
is mentioned for interior or temporary works and where economy is the sole considera­tion,
following species of timber may be used:-

Serial No. Trade Name Botanical Name

(1) (2) (3)
1. Poon Calophyllum spp.
2. Pali Dischopsis spp.
3. Silver Oak Grevillea Robusta A(unn).
4. Bija Sal Pterocarpus Marsupium.
5. Sal Sborea Rubusta Gaertn.
6. Kindal Terminalia Paniculata.
7. Laurel or Ain Terminalia Tomentosa.
8. Kalam Mitra gyanana paryifolia.
9. Dhaura Anogeissuc lifolia wall.
10. Haldu Adiona Cordifolia Hoop.
11. White cedar Dyso Xylum Malabaricum.
12. Benteak or Nana Lager spoemia Lanceolata.
RED BOOK  VOLUME I  ROADS  2012 25
A.12.5.
13. Mundani Acrocarpus Trascinefolious.
14. Gurjun Ritecracarpus Indicus.
15. Malabar Red Pine (Piney) (Hardwickia Pinnata).
16. Dhaman Grewia filia folia.
17. Jamba Xylia Xylocarpa.
18. Anjan Hard wickia binata.
19. Salai Boswelia serata Raxb.
The samples of species to be used shall be deposited by the contractor in the office of the
Engineer.
A.12.5. Seasoning - Only properly seasoned timber shall be used for first class work.
Seasoning of timber shall be judged from its moisture contests as laid down in I.S. 287-
****. The timber should be well seasoned in the log before being cut into scantlings and
there­after also in scantlings as long as possible. Care must be taken to see that warping or
cracking does not set in during seasoning.
The maximum permissible moisture contents for timber for various purposes shall be as
under :-
Climatic Zones as per I.S. 287-*****
Zone I Zone II Zone III Zone IV
Dry area Moderately Moderately Humid area
Annual Dry area Humid area Annual
Rainfall Annual Annual Rainfall
Below Rainfall Rainfall over
50.0 cm. 50-100 cm. 100-200 cm. 200 cm.
Moisture content (% of, over dry weight of timber)
(1) (2) (3) (4) (5)

(a) For roof and floor 12 14 17 20

timbers, roof and weather
boarding and other
carpenter’s work.
(b) For joinery including 10 12 14 16
frames, stair-cases,
moulding and other
joiner’s work.
(c) Floor and match 08 10 10 12
boarding
Note -- The above limits may be relaxed for timber intended for temporary construction
such as shoring from work, bullies, and the like.
A.12.6. Grading - Grading for structural timber shall be as per clause 5 of I.S. 883-****.
A.12.7. Stacking - As soon as foundations of a building are laid, all necessary timber
scantlings shall be brought to site and stacked as laid down generally in I.S. 1141-**** and
kept under cover and allowed to remain till required.
A.12.8. Inspection - Timber for building work shall not be wrought until seen and approved
by the Engineer, who may reject defec­tive timber which shall be immediately removed from
the site of work. Any effort like plugging, painting, using any adhesives or resinous materials
to hide defects shall render the pieces rejectable by the Engineer. Timber presented for
inspection shall be clean and free from dust, mud, paint or other material which may conceal

26 RED BOOK  VOLUME I  ROADS  2012

 A.13.a.1.
the defects. Cut off ends for protection can be done after inspection with raw linseed oil or
any other material approved by the Engineer. No timber work shall be painted, tarred or
oiled without the previous permission of the Engineer.
A.12.9. Sawing - All scantlings, planks, etc., shall be sawn in straight lines and planes
and of uniform thickness and of full meas­urement from end to end and shall be sawn in the
direction of the grain. They shall be sawn with such sufficient margin as to secure specified
dimensions, lines and planes after being wrought.
A.12.10. Tolerances - The Engineer may allow tolerances in the defects permissible as per
I.S. 883-*****, clause 5.2 and table II in it, if in his opinion any particular permissible defect
does not reduce the usefulness of the piece for the purpose it is required. The tolerances
for defects shall be mentioned in the specifications for individual item of wood work.
Maximum slope of grain shall range between 1 in 10 and 1 in 20 as per I.S. 883-*****,
clause 4.2.3.
A.12.11. Rejected timber - Any timber rejected shall at once be removed from the site of
the works.
A.12.12. Classification - Timber shall be classified as :-
(a) Logs, round, square or rectangular when the felled timber is not at all processed
or when it is only partially hewn to a square or rectangular shape on the outside.
Quantity is measured in cubic meters.
(b) Pole or post-natural felled timber without any processing is classified according to
the midgirth or middiameter according to the girth or diameter at top and bottom
excluding bark in each case. These are measured in meters in groups of each girth
or diameter.
(c) Planks - When the thickness of the sawn scantling is less than 5cms. and width more
than 5cm., they are classified as planks.
(d) Battens - When the thickness and width are each less than 5cm. these are classified
as battens and supply is measured in meters only and completed item in sq. metres.
(e) Scantlings - Sawn scantlings of dimensions other than the above. These are
measured in cubic meters.

A.13. OIL PAINTS

General - The specifications cover the requirements for oil paint to be used as a finishing
material with respect to its composition, form, condition and tests to be carried out. Unless
expressly permit­ted in the special provisions or directed by the Engineer, nothing but ready
mixed (factory mixed) paints satisfying the I.S. specifications for the particular paint shall
be used. But in cases when the Engineer permits use of stiff paints, the procedure for
preparing paints shall be described in the specifications given below in A.13.b.
All paints, thinners, etc., should preferably be kept in a sepa­rate store that is well ventilated
and free from excessive heat, sparks, flame or direct rays of the sun.
A.13.a READY MIXED PAINTS
A.13.a.1. Material - The paint shall be of the specified colour and approved by the
Engineer. The paint shall comply in all respects with relevant Indian Standard from :-
I.S. 105,107,111 to 116, 130 to 132, 134, 149 to 153, and 163- 1950.
I.S. 108, 135, 136 - 1952.
I.S. 102 to 104, 106, 118 to 129- 1962.

RED BOOK  VOLUME I  ROADS  2012 27

A.13.a.1.
I.S. 117- 1964.
I.S. 133, 137, 148, 154 to 157- 1965.
I.S. 109, 110, 158, 161, 162- 1968.
the exact reference depending on choice of paint, the specified pur­pose to be served
such as under-coating, finishing, exterior or in­terior painting and mode of application
of paint like spraying and brushing. The detailed specifications for any item on painting
shall mention the mode of application of paint. If mode is not mentioned application shall
be with brushes.
 Except as otherwise required in the cited specifications, all paints shall meet the
following general requirements :-
(1) The paint shall not show excessive settling in a freshly opened full can and shall
easily be redispersed with a paddle to a smooth, homogeneous state. The paint shall
show no curdling, livering, caking or colour separation and shall be free from lumps and
skins.
(2) The paint as received shall brush easily. possess good lev­elling properties and
show no running or sagging tendencies when applied to smooth steel vertical surfaces
at a rate of 10 sq. m. per litre.
(3) The paint shall not skin within 48 hours in a three quarters filled closed container.
(4) The paint shall dry to a smooth uniform finish free from roughness, grit, unevenness
and other surface imperfections. The paint shall show no streaking or separation when
flowed on clean glass.
(5) All vehicles shall be free from rosin and rosin derivatives. They may contain additional
agents such as anti-skinning and wetting aids.
The paints shall be supplied in strong, substantial containers, clearly marked with the
ready mixed weight and volume of paint content together with colour the name and
address of the manufacturer. They shall not be opened until actually required for use.
Paints from containers which have been opened shall be used first.
A.13.a.2. Use -  Ready mixed paint shall be used exactly as re­ceived from the
manufacturer and according to their instructions and without any admixtures whatsoever
except with the previous approval of the Engineer.
A.13.a.3. Tests -  In case of doubt regarding the quality, the paints supplied by the
contractor shall be tested in an approved laboratory as described in I.S. 101-1964 if
considered necessary by the Engineer.
A.13.b. OIL PAINTS PREPARED ON SITE
A.13.b.1. Material -
(1) Oil paste - Oil pastes to be used to prepare oil paints shall comply in all respects
with the Indian Standard I.S. 96 depending on the choice of colour and requirement in
respect of chemical composi­tion.
(2) Linseed oil -  Raw linseed oil shall comply with the I.S. 75-1973. Boiled linseed oil
shall comply with I.S. 75-1950 and pale boiled linseed oil shall comply with I.S. 77-****.
(3) Turpentine - Turpentine shall comply with I.S. 533-****.
 Oil paste, linseed oil and turpentine shall be supplied in strong and substantial
containers, clearly marked with the name, weight and volume of content of material
together with colour the name and ad­dress of the manufacturers.
A.13.b.2. Preparation of Paint -  The oil paste shall be mixed with a mixture of (pale

28 RED BOOK  VOLUME I  ROADS  2012

 A.13.b.4.
boiled, boiled or raw) linseed oil and turpen­tine (mixed in proportion of about 3:1). Mixing
shall be done thor­oughly so as to produce a paint of uniform consistency suitable for
application by brushing. If there are any undissolved particles or impurities, the paint
should be screened through an approved strainer or canvas cloth to exclude them.
The brushing consistency shall be such that when the paint is applied to a smooth and
clean vertical steel surface, there shall be no running, streaking and sagging of the paint
during the time required to dry. In case a flat finish is de­sired for the final coat, a little
more turpentine shall be added to the paint.
A.13.b.3. Tests -  In case of doubt regarding the quality, the oil pastes shall be tested
as described in I.S. 85-1950 and linseed oil and turpentine shall be tested as described
in the respective I.S. mentioned above. The cost will be borne by the Department if the
material satisfies the specifications and by the contractor if other­wise.
A.13.b.4. Measurement -  When required to be measured, measurement shall be by
volume with litre as the unit for liquid and semi liquid paints and by weight with kg. as
unit for stiff pastes.

RED BOOK  VOLUME I  ROADS  2012 29

30 RED BOOK  VOLUME I  ROADS  2012
 M S PLATES (PLAIN)

Thickness is mm Weight in kg. Thickness in mm Weight in kg.

per sqm. per sqm.

5 39.25 16 125.60

6 47.10 18 141.30

8 62.80 20 157.00

10 78.50 22 172.70

12 94.20 25 196.25

14 109.90

FLATS
Width Weight Kg per metre length for thickness in
mm.
in mm 3 4 5 6 8 10 12 16 18 20 25 32 40
10 0.2 0.3 0.4 0.5 - - - - - - - - -

15 0.4 0.5 0.6 0.7 0.9 - - - - - - - -

20 0.5 0.6 0.8 0.9 1.3 - - - - - - - -

25 0.6 0.8 1.0 1.2 1.6 2.0 2.4 - - - - - -

30 0.7 0.9 1.2 1.4 1.9 2.4 2.8 3.8 - - - - -

35 0.8 1.1 1.4 1.6 2.2 2.8 3.3 4.4 5.0 5.5 - - -

40 0.9 1.3 1.6 1.9 2.5 3.1 3.8 5.0 5.6 6.3 - - -

45 1.1 1.4 1.8 2.1 2.8 3.5 4.2 5.6 6.4 7.1 - - -

50 1.2 1.6 2.0 2.4 3.1 3.9 4.7 6.3 7.1 7.8 9.9 - -

55 1.3 1.7 2.2 2.6 3.4 4.3 5.2 6.9 7.8 8.6 10.8 - -

60 1.4 1.9 2.4 2.8 3.8 4.7 5.6 7.5 8.5 9.4 11.8 15.1 -

65 - - - 3.1 4.1 5.1 6.1 8.2 9.2 10.2 12.8 16.3 20.4

70 - - - 3.3 4.4 5.5 6.6 8.8 9.9 11.0 13.7 17.6 22.0

75 - - - 3.5 4.7 5.9 7.1 9.4 10.6 11.8 14.7 18.8 23.6

80 - - - 3.8 5.0 6.3 7.5 10.0 11.3 12.6 15.7 20.1 25.1

90 - - - 4.2 5.6 7.1 8.5 11.3 12.7 14.1 17.7 22.6 28.3

100 - - - 4.7 6.3 7.8 9.4 12.6 14.1 15.7 19.6 25.1 31.4

RED BOOK  VOLUME I  ROADS  2012 31

 INTEGRATED PLANT FOR TMT STEEL

The various conditions & I.s. specifications for the TMT steel are as under :

A) Steel to be used shall be TMT (Thermo mechanically treated) of grade Fe-415. All
specifications, mechanical, properties like 0.2% proof stress, ultimate stress elongations,
bend, rebend test and chemical composition of carbon. Manganese, Carbon equivalent,
Sulphur, Phosphorus, Nitrogen shall be strictly confirming to respective grades of steel
as per I.S. 1786.

B) The TMT Steel shall be procured stricly from the integrated steel plant. The term
integrated steel plant shall meant.
a) The plants have its own mines to procure the virgin raw iron ores.
b) That the plants have its modern facility of blast furnace and basic oxygen steel
making facility.
c) That plant is making raw material (billets) in house confirming the chemical
composition of carbon, manganese, sulphur and phosphorus strictly as per
composition recommended by I.S. 2061 & 2062.
d) That plant has its rolling under strictly computer numeric control observing exactly
the tolerance limits of rolling as specified by I.S. 1786.
e) That plant is issuing its Test Certificate of chemical & mechanical properties of
rolled steel of each batch of large tonnage quantity, (more than min. 100 Ton)

The manufacturers/suppliers complying above requirements shall be selected and their names
shall be listed and registered with the Executive Engineer, P.W. Division, Nashik. A certificate
wil be issued to them in token of their listing.

Only such listed manufacturers /suppliers will be liable for the supply of TMT steel against the
requirement for the various P.W.D. works.

Presently R.I.N.L. TATA STEEL, SAIL are having integrated plants.

32 RED BOOK  VOLUME I  ROADS  2012

 Number Width of Width of Length of line Length of gap on Remarks
of Traffic carriageway centre line sagment in m. NH/SH
lanes in m. in cm.
Straight Curved On On curved
reach reach & straight reach &
near reach near
intersection intersection

2 7.0 10.00 4.50 3.0 7.50 3.00 On Single

curves Broken
where sight line white
distance is
inadequate
provide solid
lines

3 --- 10.00 4.50 3.0 7.50 3.00 On Single

curves Broken
where sight line
distance is
inadequate
provide solid
lines

4.6 & 8 --- 2 lines --- --- --- --- Solid

lines

RED BOOK  VOLUME I  ROADS  2012 33

34 RED BOOK  VOLUME I  ROADS  2012
 SECTION B

STANDARD
SPECIFICATIONS
FOR GENERAL ITEMS

RED BOOK  VOLUME I  ROADS  2012 35

36 RED BOOK  VOLUME I  ROADS  2012
 B.1.5.
B.1. EXCAVATION
Excavation for foundation including shoring and strutting as necessary and disposing of
excavated stuff as directed.
General - The excavation will generally refer to open excavation of foundation wet or dry.
B.1.1. Clearing site - The site on which the structure is to be built shown on the plan and
the area required for setting out and other operations should be cleared and all obstructions,
loose stones, materials and rubbish of all kinds, stumps, brush wood and trees removed
as directed, roots being entirely grubbed up. The materials obtained will be the property
of Government and materials pronounced useful by the Engineer will be conveyed and
properly stacked as di­rected within the specified lead. Useless materials will be burnt or
otherwise disposed off as directed by the Engineer.
B.1.2. Setting out - After clearing the site, the centre lines will be given by the Engineer
and it will be the responsibility of the contractor to install substantial reference marks, bench
marks, etc., and maintain them as long as required true to line, curve, level and slopes. the
contractor will assume full responsibility for alignment, elevation and dimension of each
and all parts of the work. Labour, materials, etc., required for setting out and establishing
Bench Marks and other reference marks shall be arranged by the contractor at his own
cost.
B.1.3. Excavation - Foundation excavation shall include removal of all materials of
whatever nature and whether wet or dry, necessary for the construction of the foundation
and substructure exactly in accordance with the lines, levels, grades and curves shown
on the plans or as directed by the Engineer. It shall be taken to the exact width of the
lowest step of the footing and the sides shall be left plumb where the nature of soil admits
it. Unless there is a specific extra provision in the contract for shoring or for cutting side
slopes, contractor shall at his own cost do the necessary shoring or cutting of slopes to a
safe angle or both as approved by the Engineer when the strata need such treatment. The
contractor shall notify the Engineer before starting excavation to enable him to take cross
sec­tional levels for purposes of measurements before the ground is dis­turbed.
B.1.4. Preparing the foundation for footing - The bottom of foundation shall be levelled
both longitudinally and transversely or stepped as directed by the Engineer. Before footing
is laid, final surface should be slightly watered and rammed. If any soft patches come to
light on inspection or ramming, these shall be dug out and dealt with as ordered by the
Engineer. No filling will be allowed to bring the foundation to level. If by the contractor’s
mistake, excava­tion is made deeper than shown on the plans or ordered by the En­gineer,
the extra depth shall be made up with masonry of the founda­tion grade as directed by the
Engineer and at the cost of the contrac­tor. All rock or other hard foundation shall be cleaned
of all soft and loose material and cut to a firm surface, either level, stepped or serrated
as directed by the Engineer. The elevation of the bottom of foundation shown on the plan
will be considered as approximate only and the Engineer may order such changes in
the dimensions and eleva­tion of the foundation as may be deemed necessary to secure
satisfac­tory foundation.
After each excavation is completed the contractor shall notify the Engineer to that effect
and no footing will be allowed to be laid until the Engineer has approved the depth and
dimensions of excavation and the nature of the foundation material and the levels and/or
meas­urements are recorded.
B.1.5. Shoring - Unless separately provided in the contract, excavation of slopes to
prevent falling in of sides or providing, fixing, maintaining and removing shoring, bracing,

RED BOOK  VOLUME I  ROADS  2012 37

B.1.5.
etc., shall not be paid for. The contractor shall be responsible for the design of the shoring
for the excavation to be properly upheld. Shoring shall be of sufficient strength to resist
side pressure and ensure safety from slips and blows and to prevent damage to work and
property and injury to persons. It shall be removed as directed after all items for which it is
required are completed.
B.1.6. Protection - Near towns and all frequented places founda­tion pits, well pits and
similar excavation shall be strongly fenced and marked with red lights at night in charge
of watchman to avoid accidents. Adequate protective measures shall be taken to see that
the foundation excavation does not affect or damage adjoining structures. All measures
required for the safety of the excavation, the people working in and near the foundation
trenches, property and the people in the vicinity shall be taken by the contractor at his own
cost, he being entirely responsible for any injury to life and damage to prop­erty caused by
his negligence or accident due to his constructional operations.
B.1.7. Disposal of excavated materials - No materials excavated from the foundation
trenches of whatever kind they may be, are to placed even temporarily nearer than 1.5 m.
or greater distance pre­scribed by the Engineer from the outer edge of the excavation. All
materials excavated will remain the property of Government. Rate for excavation, includes
sorting of useful materials and stacking them separately as directed within the specified
lead. Materials suitable and useful for backfilling or other use shall be stacked on convenient
places but not in such a way as to obstruct free movement of men, animals and vehicles
or encroach on the area required for construc­tional purposes. It shall be used to the extent
required to completely backfill the structure to original ground level or the elevation shown
on the plans or as directed by the Engineer. For backfilling, the materials shall be placed
in 15 cm. to 20 cm. layers, moistened and well compacted. Materials not useful in any way
shall be wasted as directed by the Engineer. If useful excavated rubble is required by the
contractor for use in other items, it shall be paid for at the rate fixed in the tender and if
not so provided, at the rate in the Divisional schedule current at the time of tendering or at
mutually agreed rate if there is no rate in the Divisional schedule. The site shall be left clean
of all debris on completion.
B.1.8. Dewatering - Unless specially provided for as a separate item in the contract, the
excavation rate shall include bailing or pumping out all water which may accumulate in
the excavation during the progress of the work either from seepage, springs, rain or any
other cause and diverting surface flow if any, by bunds or other means. The bunds shall be
removed after their purpose is served.
Pumping out water from any foundation enclosure or trenches shall be generally in such a
manner as to preclude the possibility of any damage to the foundation trenches, concrete
or masonry or any adjacent structure. The excavation shall be kept free from water (1)
during inspection and measurement, (2) When concrete and/or masonry are in progress
and till they come above the natural water level, and (3) till the Engineer considers that the
mortar is sufficiently set.
B.1.9. Slips and blows - If there are any slips or blows in the excavation they shall be
removed by the contractor without cost to the Department so as to provide the correct
dimensions required for the foundation.
B.1.10. Backfilling - All timber shoring and form-work shall be removed after their necessity
ceases and trash of any sort shall be cleaned out from the excavation. All space between
foundation masonry or concrete and the sides of excavation must be refilled to the origi­nal
surface with approved materials, in layers of 15 cm. to 20 cm. in thickness, watered and
rammed.

38 RED BOOK  VOLUME I  ROADS  2012

 B.1.12.
The filling shall be done after concrete or masonry is fully set and done in such a way as
not to cause undue thrust on any part of the structure. Where suitable excavated material
is to be used for refill­ing it shall be brought from the place where it was temporarily depos­
ited and used in refilling.
B.1.11. Blasting - Blasting shall be carried out according to specification No. B.2.
B.1.12. Classification -  All materials encountered in the excava­tion shall be mainly
classified in the following groups :-
(1) Soils of all sorts, sand, gravel, soft murum and other simi­lar soft or loose materials.
(2) Hard murmur.
(3) Hard murmur and boulders.
(4) Soft rock.
(5) Hard rock (blasted).
(6) Hard rock (chiseled, wedged or line drilled).
(7) Laterite.
(1) Soils of all sorts, sand, gravel, soft murmur and other simi­lar soft or loose materials
-  Soils of all sorts, sand, gravel, soft murmur, softman, chopan, yellow soil, etc.,
shall include all materials of earthy or sandy nature which can be easily ploughed or
small shin­gle and gravel which can be easily removed. Removal of small boulders
not exceeding 0.03 cu. m. or 30 litres occurring in such strata will be included in the
rate for this item.
(2) Hard murmur - This shall include all kinds of disintegrated rock or shale or indurated
clay free from boulders larger than 0.03 cu. m. or 30 litres and can be removed with
pick and shovel though not without some difficulty.
(3) Hard murmur and boulders - This shall include all kinds of disintegrated rock or shale
or indurated clay intterspersed with boulders less than half a cubic metre and larger
than 0.03 cu. m. or 30 litres which do not normally need blasting and can be removed
with pick, bar, wedges, and hammer. Boulders bigger than 1/2 cu. m. will be paid for
as soft or hard rock according as it is soft or hard rock.
(4) Soft rock -  This shall include all material which is rock or hard conglomerate, all
decomposed and weathered rock, highly fissured rock, old masonry and also soft
rock, boulders bigger than 1/2 cubic metre and other varieties of rock which would
normally be removed with pick, crow bars, wedges and hammer with some difficulty.
(5) Hard rock (blasted) -  This shall include all rock occurring in masses or boulders
bigger than half cubic metre each, which can best be removed by blasting and
where, in the opinion of the Engineer, blasting is necessary. Manjrya rock shall be
considered as hard rock.
(6) Hard rock (chiselled, wedged or line drilled) - This shall include all rock occuring in
masses which can best be removed by blasting but which owing to the proximity of
structures, possibility of shattering the rock below or for any other reason should be
cut by means of cold chisels or wedges or line drilling.
(7) Laterite - This shall include laterite rock soft and hard which can be removed with
Dhokans or blasting. Lateritic murum which has not hardened into stone shall be
classified as hard murum.
The classification of the excavation shall be decided by the Engineer and his decision shall
be final and binding on the contrac­tor.

RED BOOK  VOLUME I  ROADS  2012 39

B.1.13.
Merely the use of explosives in excavation will not be considered as a reason for higher
classification unless blasting is clearly necessary in the opinion of the Engineer.
Rock referred to above shall include trap, granite, quartzite, gneiss, laterite and other types.
B.1.13. Item to include - The rate for the item of excavation will include: -
(1) Clearing site.
(2) Setting out works, profiles, etc., according to sanctioned plan or as ordered and
setting up Benchmarks and other reference mark.
(3) Providing and subsequently removing shoring and strutting or cutting slopes except
when, separately provided for in the tender.
(4) Bailing and pumping out water when separate provision does not exist for it in the
tender.
(5) Excavation and removal of all materials of whatever nature wet or dry and necessary
for the construction of foundation including materials like explosives, removal of
blows and slipsand use of tools, plant and equipment necessary for satisfactory
completion of the item and preparing bed for foundation.
(6) Sorting out of useful excavated materials, conveying them up to the specified lead
clear beyond the structure and stacking them neatly for backfilling or reuse and
wasting useless materials as directed by the Engineer.
(7) Backfilling the trenches alongside masonry or concrete with approved material up to
the natural ground level.
(8) Necessary protection including labour, materials and equip­ment to ensure safety and
protection against risk or accident.
(9) Supply of facilities for inspection and measurements at any time by the concerned
Government officials.
(10) Compensation for injury to life and damage to property if any caused by the
contractor’s operations concerned with this item.
(11) Small drill holes to explore the nature of substratum if necessary.
B.1.14. Measurement and payment - The payment for respective class of excavation shall
be made at the unit contract rate per cubic meter for the quantity acceptably excavated,
limited to the dimensions shown in the sanctioned plans or as directed by the Engineer.
Excava­tion to dimensions in excess of the above will not be measured nor paid for and if so
ordered by the Engineer the contractor shall have to fill up the excess depth with cement
concrete or U.C.R. masonry specified for foundation without extra payment.
Driving of sounding bars, or jumping small drill holes to explore the nature of substratum up
to a total length of one meter distributed in 2 or 3 places in each foundation if necessary,
will be considered incidental work and will not be paid for separately.
Removal of slips and blows in the foundation trenches will not be measured nor paid for.
If it is necessary in the opinion of the Engineer to carry foun­dation below the levels shown
in the plans, the excavation for the first 1.5 m. of additional depth will be included in the
quantity for the particular classification at tendered rate. The excavation below this additional
depth of 1.5 metres will be paid for as extra work at the rate to be decided under general
conditions of the contract unless the contractor is willing to accept payment at tendered
rates. For all depths less than the designed depth plus 1.5 metres the excavation will be
paid for at tendered rates.
Dimensions shall be measured correct to two places of decimals of a metre and individual

40 RED BOOK  VOLUME I  ROADS  2012

 B.2.4.
quantity shall be calculated correct to two places of decimals of a cubic metre.

B.2. BLASTING
B.2.1. General - Blasting shall be carried out only with the written permission of the Engineer.
All the laws, regulations, rules etc. pertaining to the acquisition, transport, storage, handling
and use of explosives shall be rigidly followed. The magazine for the storage of explosives
shall be built to the designs and specifications of the Explosives Department and located
at the approved site. No unauthorised person shall be admitted into the magazine and
when not in use shall be kept securely locked. No matches or inflammable mate­rial shall
be allowed in the magazine. The magazine shall have an effective lighting conductor. The
following shall be hung in the lobby of the magazine :-
(a) A copy of rules both in English and in the language with which the workers concerned
are familiar.
(b) A statement of up-to-date stock in the magazine.
(c) A certificate showing the last date of testing of the light­ing conductor.
(d) A notice that smoking is strictly prohibited.
In addition to these, the contractor shall also observe the following instructions and any
further instructions which may be given by the Engineer and shall be responsible for
damage to property and any accident which may occur to workmen or the public due to any
and all operations connected with storing and handling or use of explo­sives and blasting.
The Engineer shall frequently check the contra­ctor’s compliance with the precautions.
B.2.2. Materials, tools and equipment - The black powder, explo­sives, detonators,
fuses, tamping materials, electrical firing equip­ment, if used, tools for drilling holes and
tamping shall be subject to the approval of the Engineer. The Engineer may specify type
of explosives to be allowed in special cases. The fuse to be used in wet locations shall be
sufficiently water resistant as to be unaffected when immersed in water for 30 minutes.
The rate of burning of the fuse shall be uniform and definitely known to permit such a safe
length being cut as will permit sufficient time to the firer to reach safety before explosion
takes place. Detonators shall be capable of giving effective blasting of the explosives. The
blasting powder, explosives, detonators, fuses etc. shall be fresh and not damaged due
to damp, moisture or any other cause. They shall be inspected before use and damaged
articles shall be discarded totally and removed immediately.
B.2.3. Personnel - The blasting operation shall remain in charge of competent and
experienced supervisor and workmen who are thoroughly acquainted with the details of
handling explosives and blasting opera­tions.
B.2.4. Blasting operation - The blasting shall be carried out during fixed hours of the day
preferably during the midday luncheon hour or at the close of the work as ordered in writing
by the En­gineer. The hours shall be made known to the people in the vicinity. All charges
shall be prepared by the man in charge only.
Red danger flags shall be displayed prominently in all directions during the blasting
operations. People except those who actually light the fuse shall be prohibited from entering
into this area. The flags shall be stationed at 200 metres from the blasting site in all direc­
tions and all persons including workmen shall be excluded from the flagged area at least 10
minutes before the firing, a warning whistle being sounded for the purpose.
The charge holes shall be drilled to required depths and in suitable places.
When the blasting is done with powder, the fuse cut to the re­quired length shall be inserted
into the hole and the powder dropped in. The powder shall be gently tamped with copper
rods with rounded ends. The explosive powder shall then be covered with tamping material
RED BOOK  VOLUME I  ROADS  2012 41
B.2.5.
which shall be tamped lightly but firmly.
When blasting is done with dynamite and other high explosives, dynamite cartridges are
prepared by inserting the square end of a fuse into the detonator and finishing it with
nippers at the open end, the detonator gently pushed into the primer leaving 1/3rd of the
copper tube exposed outside. The paper of the cartridge is then closed up and securely
bound with wire or twine. The primer shall be housed into the explosive. Bore holes shall be
of such size that the cartridge can easily pass down. The holes shall be cleared of all debris
and explo­sive inserted. The space for about 20 cm. above the charges is then filled with
dry clay, pressed home and the rest of the tamping is formed of any convenient material
gently packed with a wooden rammer.
At a time not more than 10 such charges will be prepared and fired. The man in charge shall
blow a whistle in a recognised manner for cautioning the people. All the people shall then
be required to move to safe distances. The charges shall be lighted by the man in charge
only. The man in charge shall count the number of explosions. He shall satisfy himself that
all the charges have been exploded before allowing the workmen to go to the work site.
B.2.5. Misfire - In case of misfire the following procedure shall be observed:-
Sufficient time shall be allowed to account for the delayed blast. The man in charge shall
inspect all charges and determine the missed charge.
If it is blasting powder charge it shall be completely flooded with water. A new hole shall be
drilled at about 45 cm. from the old hole and fired. This should blast the old charge. Should
it not blast the old charge, the procedure shall be repeated till the old charge is blasted.
In case of charges of gelignite, dynamite etc. the man in charge shall gently remove the
tamping and the primer with the detonator. A fresh detonator and primer shall then be used
to blast the charge. Alternatively the hole may be cleared of one foot of tamping and the
direction then ascertained by placing a stick in the hole. Another hole may then be drilled 15
cm. away and parallel to it. This hole shall then be charged and fired when the misfired hole
should explode at the same time. The man in charge shall report to the office at once all
cases of misfire, the cause of the same and what steps were taken in connection therewith.
If a misfire has been found to be due to defective detonator or dynamite, the whole quantity
in the box from which the defective article was taken must be sent to the authority directed
by the En­gineer for inspection to ascertain whether all the remaining materials in the box
are also defective.
B.2.6. Accidents - The contractor shall be solely responsible for any accident during the
entire procedure of handling explosive and blasting and shall pay necessary compensation
to persons affected or damage to lands or property, etc., due to the blasting without extra
claims.
B.2.7. Account - A careful and day-to-day account of the explo­sives shall be maintained
by the contractor in an approved register and in an approved manner and shall be open to
inspection of the Engineer at all times. Surprise visit may also be paid by the Engineer to
the storage and in case of any unaccountable shortage or unsatis­factory accounting, the
contractor shall be liable to be penalised by forfeiture of part or whole of his security deposit
or by cancellation of tender in which case he shall not be entitled for any compensation.

B.3. LIME MORTAR

B.3.1 Materials –
(1) Lime - Lime for structural purposes classi­fied as class A and lime for masonry works
as class B, both shall conform to Specification No. A.1.

42 RED BOOK  VOLUME I  ROADS  2012

 B.3.7.
(2) Water -  The water shall generally conform to the requirements laid down in
specification No. A.4. for water.
(3) Fine Aggregate - Fine aggregate to be used for lime mortar for structural purposes,
masonry work and plaster shall conform to specification No. A.5. The grading of fine
aggregate shall be suitable for the purpose of the item.
B.3.2. Proportion of mix for Mortar - Mortar shall consist of such proportions of slaked
lime and sand as may be specified in the item. The slaked lime and sand shall be measured
by volume. If moist sand is used, necessary allowance shall be made for bulking. Lime
mortars used for structural work shall not be weaker than 1 : 3.
B.3.3. Preparation of mortar - The lime mortar shall be prepared by wet process. Bullock
driven Ghani or power driven mill may be used. The Bullock ghani shall be normally fitted
with a Beale’s Telltale.
The slaked lime is to be first placed in the mill in an even layer and ground for 180 revolutions
with a sufficiency of water. the water shall be added as required during grinding. Care
being taken not to add more water than will bring the mixed materials to a consistency of
stiff paste. Thoroughly wetted sand is then to be added evenly and the mixture ground for
another 180 revolutions. When two stones are used, the number of revolutions for each
stone shall 90 for each part of the grinding. The mortar shall be stirred continuously during
the grinding process, particularly in the angles of the ghani. The sides of ghani shall be
maintained in good order.
Hydraulic lime mortar shall be ground a second time when used for plaster.
B.3.4. Storage - Mortar shall always be kept damp and protected from sun and rain till
used up.
B.3.5. Use - All mortar shall be used as soon as possible after grinding. As a rule it should
be used on the day on which it is pre­pared. But in no case should mortar made earlier than
36 hours be permitted to be used or remain at the site of the work.
B.3.6. Rejection of mortar - Mortar more than 36 hours old or damaged mortar, or mortar
which has once set or caked shall be con­demned and removed from the site by the
contractor at his own expense. No retempering of rejected mortar shall be permitted.
B.3.7. Tests -  Field testing as per I.S. 1924-1960* shall be carried out for each class of
limes when obtained from a new source.

Mix Cement Fine aggregate Coarse aggregate Water

(1) (2) (3) (4) (5)

1:1:2 50kg. bag 35 litres 70 litres 23-27 litres

(35 litres)
1:1.5:3 - Do - 52.5 litres 105 litres 23-30 litres
1:2:4 - Do - 70 litres 140 litres 27-32 litres
1:3:6 - Do - 105 litres 210 litres 37.5-45 litres
1:4:8 - Do - 140 litres 280 litres 47.5-57 litres
1:5:10 - Do - 175 litres 350 litres 56-68 litres
In case of slabs special mixes with smaller size aggregates shall be taken out and placed
below bottom steel to obtain dense cover.
The ratio of the volumes of the fine and coarse aggregates may be varied within limits of

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B.5.4.
1:1.5 to 1:2.5 as directed by the Engineer to suit the maximum size of coarse aggregate,
the grading, density, workability and strength without extra cost. But the sum of the volumes
of the fine and coarse aggregates so adjusted shall however be equal to the sum of the
volumes of fine and coarse aggregates given above for a particular mix.
The quantity of water shall be just sufficient, but not more than sufficient, to produce a
dense concrete of required workability for its purpose. An accurate control shall be kept on
the quantity of mixing water.
An allowance shall be made for surface moisture present in the aggregates when computing
water content as indicated in I.S. 456-1978.
In the case of reinforced concrete work, the workability shall be such that the concrete will
surround and properly grip all the rein­forcement. Water cement ratio will such as will give
concrete just sufficiently weight to be placed and compacted without difficulty.
For vibrated concrete, water content may be reduced by 15% to 20% to give the required
reduced slump.
B.5.4. Mixing - For all important works concrete shall be mixed in mechanical mixer at the
site of work. Care shall be taken to see that the mixer and other accessories are in first class
working condi­tion especially the blades which have to extend right up to the bottom of the
drum. Trial mix shall be taken out to ensure good mixing. Mixing shall be continued till there
is uniform distribution of the materials and a uniform colour is obtained and each individual
parti­cle of the coarse aggregate shall show a complete coating of mortar containing its
proportionate amount of cement. In no case mixing shall be done for less than 1.5 minutes.
The water cement ratio shall range between 0.55 to 0.64 for 1:2:4 mix.
When the Engineer permits hand mixing it shall be done on a smooth watertight platform
large enough to allow efficient turning over of the ingredients of concrete before and after
adding water. Mixing platform shall be so arranged that no foreign matter shall get mixed
with concrete nor the mixing water shall flow out.
The cement in required number of bags shall be placed in a uni­form layer on top of the
measured quantity to fine aggregate required, also spread in a layer of uniform depth in
the mixing platform. Dry sand and cement then shall be mixed thoroughly by turning over
to get a mixture of uniform colour. Enough water shall then be added gradual­ly through
a rose and the mass turned over till a mortar of required consistency is obtained. The
measured quantity of coarse aggregate shall then be placed on a mixing platform and
wetted and the mortar added and the entire mass turned and returned until all the particle
of the coarse aggregate are fully covered with mortar and mixture is of a uniform colour and
required consistency. In hand mixing, quantity of cement shall be increased by 5% above
that specified in para. B.5.3 with out any extra cost.
Concrete shall have a consistency such that it will be workable in the required position and
in the case of R.C.C., flow around rein­forcing steel also.
For vibrated concrete, slump shall range between 2.5 cm. to 5 cm. For hand tamped
concrete, slump shall range between 8 cm. to 13cm.according to the type and nature of the
concrete item. The slump shall be least permitted by workability and maintained throughout
the concreting operation of a member.
The concrete shall be placed in its final position and rammed, vibrated and finished within
30 minutes of adding water to cement. Remixing of partially hardened concrete shall not
be permitted.
B.5.5(a) Scaffolding - All scaffolding, hoisting arrangements and ladders, etc., required
for the facility of concreting shall be pro­vided by the contractor at his own expense and

44 RED BOOK  VOLUME I  ROADS  2012

 B.5.5.(b).4.
removed on the comple­tion of work. The scaffolding, hoisting arrangements and ladders,
etc., shall be strong enough to withstand all live, dead and impact load expected to act
and shall be subjected to the approval of the En­gineer. However the contractor shall be
solely responsible for the safety of scaffolding, hoisting arrangement, ladders, work and
workmen. The contractor shall pay the necessary compensations arising out of the use of
the scaffolding hoisting arrangements and ladders and for damages to work, properties and
injuries to persons.
The scaffolding, hoisting arrangements and ladders shall allow easy approach to work spot
and afford easy inspection.
B.5.5.(b) Forms - Forms shall generally comply with I.S.456-1964, para.7.2.
B.5.5.(b).1. Design - The detailed design of the formwork and falsework shall be
prepared by the contractor and got approved by the Engineer well in time. Such an
approval however will not relieve the contractor of his responsibility for the adequacy
and strength of the formwork and falsework.
B.5.5.(b).2. Materials - The forms and false work shall be made of wood or metal. The
timber from which the forms are prepared should preferably be partially seasoned as too
dry a timber will swell for absorption of moisture while green timber will dry and shrink. It
shall be free from sap, shakes, loose knots, wormholes or other defects. The plants and
scantlings shall be sawn straight and all edges and planes shall be straight and free from
warps. Partially seasoned soft wood is generally preferable for formwork as it is difficult
to drive nails in hard wood. The dimensions of scantlings should conform to the design.
The strength of the wood shall not be less than that assumed in the design.
 In metal form, steel sheets of designed gauge strengthened with framing of angle or
other sections shall be used.
Wooden forms may also be lined with thin steel sheets or plywood to give the required
surface or finish.
B.5.5.(b).3. Fabrication - The timber plans and scantlings of designed dimensions shall
be used in the formwork with appropriate spacing of studs, yokes, joists, girders, etc., as
provided in the design. All timber in contact with concrete shall be wrought on one face
and two edges, the unwrought face being on the outside. The joints should be made
mortar tight. This may be done either by providing tongued and prooved or rebated
joints or by caulking or nailing metal strips or applying adhesive tape on the joints.
The forms shall be built with sufficient strength and rigidity and held in shape by bolts,
clamps, ties, nails, wales or other contrivance to prevent distor­tion or collapse due to
pressure of concrete and other loads inciden­tal to the construction operations. The nuts
and bolt heads inside the formwwork adjoining the concrete should be countersunk.
The formwork should allow finish concrete to have a smooth surface and conforms to
the shapes, lines and dimensions shown on the plans and true to line and grades. The
effect of vibration shall be taken into account in the design and fabrication of forms and
falsework.
 Forms shall be so designed and constructed as to be removable in sections without
damaging the surface of the concrete and with facili­ties of removal in the ascending
order of removal time, without dis­turbing the remaining forms required to be removed
later.
B.5.5.(b).4. Treatment of inside of forms -  Before placing con­crete, the inside of the
forms which comes in contract with concrete shall coated with mineral oil or any other
suitable material approved by the Engineer which will prevent adhesion to concrete to
the forms but will not discolour the concrete. When oil is used, it shall be applied before

RED BOOK  VOLUME I  ROADS  2012 45

B.5.5.(b).9.
reinforcement is placed. Care shall be taken to see that reinforcement does not came in
contact with the coating. All chipping, saw dust and other rubbish shall be removed from
the interi­or of the forms before concrete.
B.5.5.(b).5. Falsework -  Falsework shall be built on foundation or base of sufficient
strength to carry the loads without settlement. Falsework which can not be founded on
solid footing must be supported by piles or other similar devices. Falsework shall be
designed to carry the full loads including that due to construction operations coming
upon it.
B.5.5.(b).6. Erection - Falsework and formwork shall be erected with an eye for absolute
safety of the formwork and concrete work before, during and after pouring concrete.
Watch must be kept to see that the behaviour of centering and formwork is satisfactory
during concreting. Erection should also be such that it would allow removal of forms in
proper sequence without damaging either the concrete or the forms to be removed later.
If there is failure of falsework and/or formwork the contractor shall be responsible for all
the consequent damages to work, injury to life and damage to property.
B.5.5.(b).7. Inspection -  The forms and falsework will be in­spected, checked and
approved by the Engineer before concreting is commenced. But this will not relieve the
contractor of his responsi­bilities for strength, adequacy and safety of the formwork and
false­work.
B.5.5.(b).8. Removal of forms - Formwork shall be removed care­fully without damaging
the concrete or giving sudden shocks. It should be ascertained from the exposed sides
of concrete that it has gained adequate strength before the bottoms and supports of the
formwork are removed.
 Unless otherwise specified in the special provisions, forms of concrete work using
ordinary Portland cement may be struck after expiry of the following periods in normal
circumstances :-
(1) Vertical faces of all structural 28 hrs. to 48 hrs. members, wall
(2) Slabs (props left under) 3 days
(3) Beam soffits (props left under) 7 days
(4) Slabs spanning upto 4.5 m. 7 days
(5) Slabs spanning over 4.5 m. 14 days
(6) Beams spanning upto 6 m. 14 days
(7) Beams spanning over 6 m. 21 days
For Pozzolana Grade 43 or Grade 53 and other types of cements the striking period may
be suitably modified.
In important structures, the sequence of striking formwork shall be approved by the Engineer.
B.5.5.(b).9. Reuse - Before reuse, all forms shall be thoroughly scraped and cleaned,
joints gone over and repaired and the insides retreated to prevent adhesion, all to the
entire satisfaction of the Engineer. The shape, strength, rigidity, mortar tightness and
surface smoothness of reused forms shall be maintained at all times.
B.5.6. Transporting - The concrete shall be handled from the place of mixing to the final
position as quickly as practicable by methods which will prevent segregation and loss of
ingredients. In no case shall the operation take more than 15 minutes.
B.5.7. Placing - The concrete shall be placed into its final position, compacted and finished
within 30 minutes of mixing the water and before setting commences. The method of placing
shall be such as to avoid segregation. Placing shall be done in a balanced manner to avoid

46 RED BOOK  VOLUME I  ROADS  2012

 B.5.9.
eccentric loads on formwork.
As far as practicable the concrete for a particular portion shall be done in one continuous
operation. The construction joints when required shall be made only where located on
the plans or shown in the pouring schedule unless otherwise approved by the Engineer.
The joint shall be regular and vertical and shall be made by placing a bulk head at the
joint. Before commencing subsequent concreting, all loose particles, laitance, etc., shall be
removed and the surface shall then be covered by thick cement slurry as part of placement.
Care shall be taken during
The concrete shall be normally laid in the dry. If the area is under water, it shall be pumped
dry and kept so while placing concrete and till it sets. Where it is necessary to deposit
concrete under water, it shall be done as per I.S. 456-1964* para. 13.2. No extra payment
will be made for the special arrangements, plant, etc., need for the purpose or for the
additional 10% cement required to be the placing not to disturb the forms or the reinforce­
ment. Concrete compacted manually, shall preferably be laid in layers of 15 cm. to 20 cm.
the layers being decided by the time lapse between the successive layers. The time of
laying one layer shall not exceed 30 minutes. The successive layers shall commence within
30 minutes.
When work is to be resumed on a surface which has hardened, such a surface shall be
roughened and scrubbed with brushes to remove laitance, care being taken to avoid
dislodgement of coarse aggregate, swept clean, thoroughly wetted and covered with 6mm.
thick mortar layer composed of cement and sand in the same proportion as the cement
and sand in the concrete, immediately before the commencement of concrete, for securing
good bond.added.
B.5.8. Compacting - The concrete shall be thoroughly compacted during depositing to get
a dense concrete and thoroughly worked into the edges and corners of the formwork as
also along its faces and around reinforcement in the case of R.C.C., by means of suitable
tools such as spades and rods to get a good cast finish without honey comb­ing. Concrete
shall not be disturbed once it is set.
For important or big works where stiffer mix with less slump is adopted, use of mechanical
vibrators is essential. The vibrators shall have not less than 3600 and preferably about
5000 impulses per minute and shall be worked at an interval of about 60cm. It shall be
worked in one place for only such time as will allow formation of dense concrete without
sinking and segregation of the coarse aggregate. Over vibration shall be avoided. Vibration
shall be aided by spading and rodding.
B.5.9. Curing - The concrete shall be initially protected from damage on account of impact,
undue pressure, excessive heat of sun, rain, etc., and covered with wet sacking, hessian
or similar absorbent material soon after the initial set. After the final set the concrete shall
be kept continuously wet preferably by pounding water for a period of not less than 14
days from the date of placement. On Sun­days, holidays and days of cessation of work,
arrangement shall be made to keep the concrete continuously watered.
Should the contractor fail to water the concrete continuously, the Engineer may provide
labour, materials and equipment required for watering and recover the cost from the
contractor.
When atmospheric temperature exceeds 40oC (104oF) following precautions should be
taken:-
(1) Stacking aggregates under shades and keeping them moist.
(2) Using cold water.

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B.5.10.
(3) Reduce the time between mixing and placing to the minimum.
(4) Cooling formwork by sprinkling water.
(5) Starting curing before concrete dries out.
(6) Restricting concreting to mornings and evenings.
B.5.10. Finishing - Immediately after the removal of forms, any undulations, depressions,
cavities, honeycombing, broken edges or corners, high spots and other defects shall be
made good and finished with cement mortar 1:2 But the necessity of such finishing must
be exceptional and the total surface requiring finishing shall not exceed 1 per cent. on an
average. If the initial experience shows that this percentage is exceeded the method of
working itself should be changed to get the required cast finish.
Where the concrete surface is to receive plaster, the surface shall roughened immediately
after removal of forms and within a day thereof to secure a hold for the plaster. The rate
for concrete is inclusive of this roughening and finishing. Concrete after finishing shall be
cured for the full period.
B.5.11. Retempering - Concrete shall be mixed only in such quan­tities as are required
for immediate use and any concrete which has developed initial set shall not be used.
Concrete which is partially hardened shall not be retempered or re-mixed but shall be
destroyed or thrown away.
B.5.12. Sampling and Testing - Sampling of materials and concrete shall be done carefully
by the contractor under the direct supervision of the Departmental staff as per I. S. 456-
1978 at the cost of con­tractor. All necessary labour, materials, equipments, etc., for sam­
pling, preparing test cubes, curing, etc., shall be provided by the contractor. Testing of the
materials and concrete will be arranged by the Department in an approved laboratory at
the cost of the contrac­tor. No plea will be entertained later on the ground that casting of
the test specimen was faulty and that the result of the test specimen did not give a correct
indication of the actual quality of concrete. Compressive strength of ordinary concrete shall
not be less than those specified below :-

No. Mix Works test on 15cm. cubes

Kg./sq.cm. at 7 days Kg./sq.cm. at 28 days
1 1:1:2 160 250
2 1:1.5:3 130 200
3 1:2:4 100 150
4 1:3:6 66 100
5 1:4:8 48 70

One set of six 15cm. cubes shall be prepared from the concrete to be used in the work
for compression test on each of the three days operation and thereafter for every 60 cu.
m. of concrete or three days’ work whichever is less, by the contractor in the presence of
a responsible officer of the Department of a rank not less than that of an overseer. If the
source of aggregate or grading is changed, one set of six test cubes shall be taken for each
changed batch. Three cubes shall be used for test at 7 days’ age and three at 28 days.
After the relation between strength at 7 days and 28 days is reliably established for the
particular set of materials for the same sources, subsequent tests may be carried out only
on three cubes at 7 days and above. 20% of the tests results may be less than the average
strength given above. If the average strength of the cubes show ul­timate compressive

48 RED BOOK  VOLUME I  ROADS  2012

 A.13.b.4.
strength less than the above the Engineer shall have right to order a change in the mix
or water content for the remaining concrete without extra cost. Defective concrete having
strength below 80 % of the required strength is liable to be rejected. Concrete of strength
up to 80% of the required strength may be accept­ed as substandard work at a reduced rate
provided such weak concrete is restricted to such members and in such quantities as will
not endanger the safety of the structure.
B.5.13. Keeping record - A day to day record authenticated by a responsible officer of
the department and the representative of the contractor, in the proforma approved by the
Engineer shall be main­tained by the contractor on the work site and kept open for inspec­
tion. This shall contain important information such as receipt of cement on the work site,
daily use with details of use on various items, time of starting concreting and closer, number
of batches through the mixer, source of water, water cement ratio of concrete, slump, dates
of erection of formwork, passing of formwork by the competent authority, dates of striking
of forms, periods, and method of curing and other events worthy of note. On completion of
the work, the record shall be handed over to the Department.
B.5.14. Item to include –
(1) All labour, materials, use of equipment, tools and plant, installing and removal of
scaffolding, falsework and forms and bracing necessary for the satisfactory comple­
tion of the item except the reinforcement steel.
(2) Providing cement concrete of specified proportion including transporting, placing
and compacting, curing, finishing to the dimen­sions and shapes shown on the plans
or as ordered by the Engineer.
(3) Necessary sampling and tests for material and concrete.
(4) Compensation for injury to persons and damages to work or property.
B.5.15. Mode of measurement and payment - The contract rate shall be for a unit of
one cubic metre of concrete. The concrete shall be measured for its length, breadth and
depth, limiting dimensions to those specified on the plan or as ordered by the Engineer. No
deduc­tion shall be made for reinforcement in concrete in R.C.C. work. Individual dimension
shall be measured correct to one cm. and quanti­ties shall be worked out correct upto three
places of decimals of a cubic metre.

B.6. DESIGN MIX CEMENT CONCRETE

Design mix concrete is that concrete in which proportion of aggregates, cement and water
are determined by the preliminary tests of the materials to be actually used to obtain the
specified strength with the use of minimum quantity of cement. It shall generally comply
with relevant provisions in I.S. 456-1964*.
B.6.1. Materials - Ordinary Portland cement, fine aggregates, coarse aggregates and
water shall comply with specifications laid down for the respective items in specification
No. B.5. for ordinary con­crete.
B.6.2. The design mix shall be obtained from an approved labora­tory or institution and
shall be further got approved from the En­gineer in charge.
B.6.3. Tests - Tests shall conform to the specification laid down in I.S. 456-1978. Tests shall
be got done in an approved laboratory at the cost of the contractor.

RED BOOK  VOLUME I  ROADS  2012 49

B.6.3.1.
B.6.3.1. Works tests - Works tests shall be taken for quantities of concrete as indicated
below :-

Quantity of concrete in cu.m. No. of samples (each sample

shall have three cubes).

1 - 5 1
6 - 15 2
16 - 30 3
31 - 50 4
51 and above One additional sample for every 50 cu. m.
Depending on the quantity of concrete for each element, random samples as indicated
above shall be taken. The required number of samples shall be decided in advance.
The random samples should be taken such that whole of the concrete in that element is
uniformly represented.
 The strength of a sample shall be the average of three cubes of the sample. The
variation in the strengths of a particular sample shall not be more than -15% to +15% of
the average of that sample.
 Standard deviation as defined in I.S. 456-1978 shall be worked out periodically or
atleast once in a month. The maximum standard deviation shall be as under :-

Grade of concrete Maximum standard deviation

N/sq.mm.
M 10 2.3
M 15 3.5
M 20 4.6
M 25 5.3
M 30 6.0
M 35 6.3
M 40 6.6
B.6.3.2. Acceptance criteria - The acceptance criteria shall be as per I.S. 456-1978
cl. 15 according to which every sample (average of three specimen) shall have strength
equal to or more than characteris­tic strength. One or more samples may have strength
less than charac­teristic strength, in which case such strength shall not be less than
0.8 times characteristic strength and the average strength is - [1.65 - {1.65/(number of
samples)^1/2}] x Standard deviation or more. The strength of any sample shall also not
be less than characteristic strength minus 1.35 times the standard deviation.
 For concrete not complying with these requirements acceptance shall be subject to
further provisions of I.S. 456-1978 cl. 15.
B.6.4. Field mix - The actual proportions of the fine and coarse aggregates will be
determined by preliminary tests. In the works tests, bulkage of sand due to moisture if
any, should be allowed for different batches according to the moisture actually present at
the time of mixing. This moisture will be taken into account in control­ling the mixing water
also. The proportions once fixed by preliminary tests shall not be changed so long as the
materials are the same, subject only to the quantities of fine aggregate and water being
adjusted to compensate for bulkage due to the moisture in sand and free water in fine
aggregate at the time of use.

50 RED BOOK  VOLUME I  ROADS  2012

 B.6.9.
No change of materials shall be allowed unless fresh tests with new materials show
satisfactory results.
Water and cement content per batch of concrete as determined by preliminary tests shall
be maintained constant except for suitable allowances to be made for surface moisture of
the aggregates at the time of actual use.
The minimum quantity of cement to be used shall be as under :-
Exposure Plain concrete Reinforced concrete
1. Mild 220 Kg/cu.m. 250 Kg/cu.m.
2. Moderate 250 Kg/cu.m. 290 Kg/cu.m.
3. Severe 310 Kg/cu.m. 360 Kg/cu.m.
For greater details I.S. 456-1978 Appendix - A shall be referred.
For any particular item, compressive strength required to be attained by the concrete at
28 days in the preliminary and works tests on 15 cm. cubes, minimum cement content
required to be used and ap­proximate proportions of approved fine and coarse aggregates
shall be specified in the special provisions. These particulars will be only for the guidance
of the contractor for quoting rates.
Immediately upon the receipt of the award of the contract, the contractor shall inform the
Engineer the exact location of the sources of the acceptable materials which he proposes to
use and get the materials approved. The mix with the actual approved materials to be used
shall be got designed in an approved laboratory by the contractor with minimum quantity
and cement to give the specified strength in the preliminary tests and the proportions
got approved by the Engineer in writing. These proportions shall be used so long as the
materials continue to be of the same quality and from the same sources subject only to
slight changes in the relative quantities of fine and coarse aggregates for the purpose of
promoting workability provided the works tests also show the required strengths.
If such preliminary tests involve change in the theoretical cement factor originally set forth
in the special provisions upto 2% on the higher or lower side, no adjustment in the cost of
the item to be paid to the contractor shall be made. if such alterations change the theoretical
cement factor by more than 2% on the higher or lower side the source and quality of
aggregate remaining the same, payment will be adjusted for against the contractor in
whatever amount the total cost of cement to the contractor has been increased or decreased
by more than 2%. The amount of such increase or decrease shall be calculated on the basis
of quantity of cement determined and pre­scribed in the special provisions. In adjusting the
cost, only the cost of cement shall be considered and handling or other charges which shall
be prepared as incidental to the item.
If during the progress of the work, the contractor wishes to change the materials, the
proportions shall be fixed on the basis of fresh preliminary tests to give the required strength
after the En­gineer is satisfied that the materials satisfy the specifications. No adjustment
of cost shall be made for change of proportions of cement fixed in the original preliminary
tests.
B.6.5. Mixing - Mixing shall comply with specification No. B.5.4. Mixing shall be done only
by mechanical mixers.
B.6.6. Forms - Forms shall comply with specification No. B.5.5.(b).
B.6.7. Transporting - Transporting shall comply with specifica­tion No. B.5.6.
B.6.8. Placing - Placing shall comply with specification No. B.5.7.
B.6.9. Compacting - Compacting shall comply with specification No. B.5.8.
RED BOOK  VOLUME I  ROADS  2012 51
B.6.10.
Compaction shall necessarily be done by mechanical vibrators. No hand compaction will
be permitted except (i) to supplement vibration near the edges and faces of forms, to fill the
corners completely and to prevent honeycombing or (ii) in members where vibration is not
possible nor desirable in the opinion of the Engineer.
B.6.10. Curing - Curing shall comply with specification No. B.5.9.
B.6.11. Finishing - Finishing shall comply with specification No. B.5.10.
B.6.12. Retempering - Specification No. B.5.11. shall be fol­lowed.
B.6.13. Sampling and testing - Sampling and testing shall comply with B.6.3. above, special
provision in the tender and relevant provi­sion of B.5.12.
B.6.14. Keeping records - Records shall be maintained and dealt as per specification No.
B.5.13.
B.6.15. Item to include - All the provisions prescribed in speci­fication No. B.5.14. and also
the preliminary laboratory tests to determine the exact proportions of the concrete mix to
give the speci­fied strengths and control tests during the concreting operations.
B.6.16. Mode of measurement and payment - Measurement and payment shall be as
per specification No. B.5.15. Where adjustment of cost is necessary for use of more or less
cement, only actual cost of cement shall be considered and not handling or other charges.
Cement content of the concrete shall be as specified in the spe­cial provisions.
In the absence of special provisions the cement requirement shall be taken as under :
M 15 - 6.4 Bags/cu.m
M 20 - 7.8 Bags/cu.m
M 25 - 9.2 Bags/cu.m
M 30 - 9.6 Bags/cu.m
M 35 - 10 Bags/cu.m
If the initial preliminary tests before starting work indicate varia­tion of cement actually
necessary to be within a range of +2% of the quantity specified in the special provision,
no adjustment shall be made in the cost for such variations. If the variation of the cement
content is more than + 2%, the cost of concrete shall be adjusted for or against the contractor
by whatever amount the total cost of cement to the contractor at work site is increased or
decreased above or below 2% respectively per unit of finished concrete for which the rate
is quoted in the tender. In case of revision in the mix due to change in materials any extra
cement required over the original mix design shall not qualify for additional payment. In the
case the cement contents are reduced, the cement contents as per the original mix design
shall continue.

B.7. BURNT BRICK MASONRY FIRST CLASS

IN LIME/CEMENT MORTAR
Burnt brick masonry first class in lime/cement mortar of speci­fied proportion including
necessary scaffolding, watering masonry, etc., complete.
B.7.1. Materials - Bricks - First Class Bricks shall be used for this item and shall comply
with specification No. A.9.1. Sample shall be got approved by the Engineer who will keep
it in his office for reference.
Mortar - Mortar shall conform to specification No. B.3.(a). for lime mortar/ B.5.(a). for cement
mortar. The quantity of mortar to be used in one cu. metre of masonry shall vary from 0.24
cu. metre or 240 litre for thin masonry to 0.26 cu. metre or 260 litres for massive masonry

52 RED BOOK  VOLUME I  ROADS  2012

 B.7.3.
of conventional bricks and 0.25 cu. metre or 250 litres for thin masonry and 0.27 cu. metre
or 270 litres for thick masonry for I.S. bricks. The proportion of lime/cement mortar shall be
as speci­fied in the item and special provisions of the tender.
B.7.2. Construction Details -
B.7.2.1. Size - Bricks of different dimensions will not be al­lowed on the same work
except when specially permitted by the En­gineer.
B.7.2.2. Face work - Bricks of entirely uniform colour and of best shape and which have
greater resistance to weathering and pene­tration by rain should be selected for the face
work when it is not to be plastered.
B.7.2.3. Soaking -  All bricks shall be immersed in water for two hours before being
put into work so that they will be saturated and will not absorb water from the mortar.
Immersion will also assist in removing dirt and dust. The surfaces should just be moist
but not too wet at the time of laying.
B.7.2.4. Bats - No bats or but bricks shall be used in the work unless absolutely necessary
around irregular openings or for adjusting the dimensions of different courses and for
closers, in which case, full bricks shall be laid at corners, the bats being placed in the
middle of the courses.
B.7.2.5. Laying -  The bricks shall be laid in mortar to lime, level and shapes shown
on the plans, slightly pressed and thoroughly bedded in mortar and all joints shall be
properly flushed and packed with mortar so that they will be completely filled with mortar
and no hollows left anywhere. Bricks shall be handled carefully so as not to damage
their edges. They should not also be thrown from any height to ground but should be put
down gently. All courses shall be laid truly horizontal and all vertical made truly vertical.
Vertical joints in one course and the next below shall not come over one another and
shall not normally be nearer than quarter of a brick length. For battered faces bedding
shall be built in at places shown in the plans while laying the course only and not later
by removal of bricks alrea­dy laid.
 Care should be taken during construction to see that edges of bricks at quoins, sills,
heads, etc., are not damaged.
The verticality of the walls and horizontality of the courses shall be checked very often
with plumb-bob and spirit-level respec­tively.
B.7.2.6. Bond -  Bond used shall be English or such other as may be ordered and
shall be carried throughout the work. All the corners, alternate courses of brick work
shall be laid header strecherwise as seen on the face so as to secure good bond. The
arrangement of bond at quoins shall be symmetrical.
B.7.2.7. Joints -  Joints shall not exceed 10m. in thickness and this thickness shall be
uniform throughout. The joints shall be raked out not less than 10mm. deep when the
mortar is green and pointing is to be done. Otherwise joints shall be struck flush with
face at the time of laying.
B.7.2.8. Uniform raising - Brickwork shall be carried up regular­ly in all cases where the
nature of work will admit, not leaving any part 60 cm. lower than another. But where
building at different levels is necessary, the brakes shall be stepped so as to give later
a uni­form level and effectual bond. Horizontal courses should be to line and level and
even and face plumb to batter as shown on the plan. The rate of laying masonry may
be up to a height of 60cm. per day if cement mortar is used and 45 cm. if lime mortar is
issued. Greater heights may be built only if permitted by the Engineer in writing.
B.7.3. Scaffolding - S
 caffolding is double or single as is war­ranted for the particular work.

RED BOOK  VOLUME I  ROADS  2012 53

B.7.3.
The ends of pole if required to rest on the brick work shall be located at convenient places.
Scaffolding shall be erected with bullies, steel sections, pipes or bamboos of adequate
strength so as to be safe for all the dead, live and impact loads likely to come on them due
to construction operations. The contractor shall take all measures to ensure the safety of
the work and working people. Any instructions of the Engineer in this respect shall also be
complied with. The contractor shall be entirely respon­sible for any damage to property or
injury to persons resulting from ill erected scaffolding, defective ladders and materials, or
otherwise arising out of his default in this respect. Proper scaffolding shall be provided to
allow easy approach to every part of a work. Overhead work shall not be allowed.
Put log holes shall be made good by bricks to match the face work when put logs are
removed after ensuring that the holes behind are solidly filled in with 1:4:8 cement concrete.
B.7.4. Dewatering - Where water is meet with, the work space shall be kept free of water
by the contractor while the brick work is in progress and until the Engineer considers
the mortar has suffi­ciently set. Dewatering shall also be done when required for taking
measurements, etc. Dewatering shall be carried out in such a manner as not to injure
masonry in any way. Dewatering will be included in the rate of brick work unless separately
provided in the tender.
B.7.5. Watering -  The brick work shall continuously be kept well watered for 14 days
after laying. Brick work laid shall be initially protected against hot sun if necessary by wet
stacking or straw or similar absorbent materials. At no time during the curing period shall
the mortar be allowed to dry. Initial watering should be done careful­ly through a rose so as
not to disturb or wash out mortar. On Sundays or holidays or at the close of day’s work or
other periods of cessa­tion of work, the masonry shall be kept well watered by employing
sufficient number of labour. Should the contractor fail to water the work as specified, the
Engineer may employ the requisite labour, mate­rials and equipments to water the work
properly and change the cost to the contractor.
B.7.6. Final finish - If the brick work is not to be plastered, the face. After pointing is properly
cured, shall be washed down and all stains and adhering mortar lumps removed. Put log
holes, etc, shall be solidly filled in the interior with cement concrete 1:4:8 and the face with
bricks to match adjoining work.
B.7.7. Bad work - Should the mortar perish, i.e., become dry or powdery through neglect of
watering or masonry be hollow or the work not done according to plan and specifications,
the work shall be pulled down and rebuild at contractors expense. If hollows or other
defects are suspected a brick may be removed here and there for con­firmation. If hollows
or other defects are confirmed such portions shall be dismantled and rebuild at the cost of
the contractor.
B.7.8. Item to include –
(1) All labour, materials, use of tools, equipment and other items incidental to the
satisfactory completion of brick masonry.
(2) Erecting and removing all scaffolding, leaders and plant required for the execution of
the work to the height and depths and shapes as shown on the plan or as ordered
by the Engineer.
(3) Dewatering required for completing of this item and till the mortar of masonry, pointing,
plastering is properly set, unless sepa­rately provided in the tender.
(4) Constructing brick work to lines, levels, batters, curves and to any position or shape,
to the height and depth shown on the plans or as ordered by the Engineer including
striking joints and taking out joints and housing frames, fixtures, etc and rectifying
defective work.
54 RED BOOK  VOLUME I  ROADS  2012
 B.8.2.
(5) Watering masonry work.
(6) Clearing the site round the brick work so as to restore the area to its original condition.
B.7.9. Measurement and payment - The contract rate shall be for a unit one cubic meter
of Brick masonry fully completed. The quantity of Brick work to paid under this item shall
be in number of cubic metres measured for completed work and to the limiting dimensions
not exceeding those shown on the plan or as order in writing by the En­gineer. Battered,
tapered and curved portions shall be measured net. Dimensions shall be measured and
quantity of individual item work out correct to two places of decimals of a metre and a cubic
metre respec­tively.
No deduction shall be made for (1) ends of dissimilar materials like girders, beams, lintels,
rafters, etc., up to 500 sq. cm. in section and (2) opening up to 0.1sq. m. in face area.
When the brick work is to plaster, measurements will be exclusive of plaster.
Brick work shall normally be measured as under :-
Half brick wall shall be measured in sq.m. stating the thickness.
Brick walls upto and including three brick in thickness shall measured in multiples of half
bricks which shall be deemed to be inclusive of the mortar joints, as under :-

width for width for

conventional modular I.S.I.
bricks bricks
One brick wall shall be measured as 23 cm. 20 cm.
One and half brick shall be measured as 25 cm. 30 cm.
Two brick shall be measured as 47 cm. 40 cm.
Two and half brick shall be measured as 60 cm. 50 cm.
Three brick shall be measured as 71 cm. 60 cm.

Width of more than three bricks in wall will be actually and limited to the width specified.
Where the fractions of half bricks occur due to architectural or other requirements the
measurement shall be taken as actual.

B.8. BURNT BRICK MASONRY SECOND CLASS

IN LIME/CEMENT MORTAR
Burnt brick masonry second classes in lime/cement mortar of speci­fied proportion including
necessary scaffolding, water masonry, etc., complete.
B.8.1. Materials -
B.8.1.1. Bricks - Brick shall comply with specification No.A.9.2. for second class bricks.
B.8.1.2. Mortar -  Mortar shall conform to specification No. B.3. for lime mortar/B.5 for
cement mortar. Quantity of mortar to be used in one cu. m. of masonry shall vary form
0.30 cu. m. or 300 litre for thin masonry to 0.32 cu.m. or 310 litres for thin masonry to
0.33 cu.m. or 330 litres for massive masonry of I.S.I. bricks.
B.8.2. Joints - Joints shall not exceed 12mm.in thickness and this thickness shall be
uniform throughout.
All other specifications of first class B.B. masonry shall apply to this class of masonry also.

RED BOOK  VOLUME I  ROADS  2012 55

B.9.1.
B.9. STONE MASONRY (GENERAL)
B.9.1. General - The following instructions are to be complied with for all classes of stone
masonry.
B.9.2. Materials -
B.9.2.1. Building stone - Building stone shall comply with the specifications detailed in
A.8. Stones of the specified type and quality shall be obtained from the quarries defined
in the special provisions or from other sources approved by the Engineer. The size of
the stones shall be as specified for the item. The stone shall be kept free from dirt, dust,
oil or any other injurious materials which may attack the stone or mortar or prevent
adhesion of mortar. Stones with skins shall not be used.
 Different categories of stones such as face stones headers, quoins, etc., shall be
collected in advance to suffice atleast for a week’s requirement and shall be stacked
separately categorywise.
B.9.2.2. Mortar - The mortar to be used shall be of the type and proportion maintained
in the item or special provisions. Lime mortar if used, shall comply with specification No.
B.3. Cement mortar if used shall comply with specification No. B.5. Water for curing shall
comply with specification No.A.4.
B.9.3. Dressing - Different type of dressing . The stone shall be dressed to one of the
following types specified for the item or as detailed in the specification for the particular
item itself.
(a) Rough tooled dressing - Rough tooled surface shall have series of band, 4 to
5cm. wide, more or less parallel to tool marks all over the surface. These marks may
be either horizontal, vertical or at an angle of 45øas required. The dressed stones may
have depressions on the surface, the depth of gap between the surface and the straight
edge held against it shall not exceed 3mm. This is also called as “ one line dressing “.
(b) Chisel or punch dressing -  A chisel dressed surface shall have series of parallel
ridges. Chisel marks shall be left all over the surface. This dressing shall be more even
than the rough tooled dressing. The depth of the gap between the surface and a straight
edge held against the surface shall not exceed 2mm. This surface dressing is also called
“ two line dressing “.
(c) Close punch or picked dressing - A closed punched surface shall be closer dressed
further giving finer surface than the chisel or punch dressing.The depth of gap between
the surface and the straight edge held against it shall not exceed 1mm. This is also
called “ three line dressing “.
(d) Fine tooled dressing -  A fine-tooled dressing is one that is finer than the close
punch dressing such that all the unevenness is removed and a fairly smooth surface
is obtained. The surface shall have 5 to 4 lines per centimeter width. Other types of
dressing may also be specified in the special provisions.
(e) Samples - Samples of each category of stones of the speci­fied quality and dimensions
dressed to the specific requirements shall be got approved by the Engineer who will
keep them in his office for reference.
B.9.4. Method of laying stone - The masonry shall be laid to lines levels, curves and
shapes shown in the plans. Fixtures, plugs, frames etc. if any, shall be built in at places
shown on the plan or directed by the Engineer while laying the masonry and not latter by
removing the stones already laid :-
(a) Stones in the hearting shall be laid on their broadest face which gives better

56 RED BOOK  VOLUME I  ROADS  2012

 B.9.4.
opportunity to fill the space between stones.
(b) Stratified stones must be laid on their natural beds. All bed joints shall be normal to
the pressure upon them.
(c) In battered walls, the beds of stone and the plane of cours­es should be at right angles
to the batter.
(d) The courses of masonry shall ordinarily be pre-determined. They shall generally be
of the same height. Where there is to be variation in height of courses, larger courses
are to be placed at the lower levels, the height of courses decreasing gradually
towards the top of the wall, unless plans specify otherwise due to architectural
requirements.
(e) The stones shall be wetted before laying in mortar. The contractor with a vessel full
of water shall supply each mason and a tumbler for wetting stones, care being taken
not to spill any water on green masonry. The bed, which is to receive the stone,
shall be cleaned, wetted and covered with a layer of fresh mortar. All stones shall be
laid full in mortar both in bed and vertical joints and settled carefully in place with a
wooden mallet immediately on place­ment and solidly bedded in mortar before it has
set. Clean chips and spalls, carefully selected to fit in the spaces shall be wedged
into the mortar joints and beds wherever necessary, to avoid thick beds or joints of
mortar. When the foundation masonry is laid directly on rock, the face stones of the
first course shall be dressed to fit into the rock sungly when pressed down in the
mortar bedding over the rock. No dry or hollow space shall be left anywhere in the
masonry and each stone shall all the embedded faces completely covered with the
mortar. If a portion of Masonry is dismantled, every stone must be found with mortar
adhering fast to all its embedded surfaces and there shall be no hollows. This will
be one of the tests in deciding if the masonry is good or bad if need arises. Where
hollows or other defects are suspected a stone here or there may be removed for
confirmation. If these are confirmed such portions shall be dismantled and rebuilt at
the cost of the contractor.
(f) Face work and hearting shall be brought up evenly but the top of each course shall
not be leveled up by flat chips.
(g) In case any stone already set in mortar is disturbed or the joint broken, the stone shall
be taken out without disturbing the adjoining stones and joints, the mortar thoroughly
cleaned from the joints and stone and the stone reset in fresh mortar. Attempts must
never be made to slide one stone over another already laid.
(h) Shaping and dressing shall be done before the stone is laid in the work. No dressing
and hammering which will loosen the masonry will be permitted after it is once placed.
(i) There shall be good collection of stones and spalls within easy reach of each mason
to enable proper selection of stones for individual location while laying. The stones
shall be continuously replenished.
(j) Bond –
1) To give sufficient lateral bond a stone in any course shall break joint with the stone in
the course below or above about half the height of the course and generally not less
than 8cm., i.e., joints parallel to the pressure in courses above and below shall not
lie to closely near the same vertical line.
2) To give sufficient bond, the prescribed number of headers shall extend from front
to back of thin walls up to a width of 60cm. or prescribed number of lines of over-
lapping headers from face to back of walls over 60cm. thick. Overlaps shall be 15cm.

RED BOOK  VOLUME I  ROADS  2012 57

B.9.5.
at each end. To ensure provision of full number of headers of the required size, they
shall be kept at specified intervals in each course in advance of starting masonry and
then embedded in mortar. Their position in each course shall be staggered, so that
each will be near about the middle of the two in the courses below and above. Their
faces shall be marked distinguishing signs to identify them.
3) To bond work at all angle junctions of walls, the stones at each alternate course shall
be so carried into each of the respective walls as to join the work thoroughly. Quoins
shall be laid header and stretcherwise when seen on each side of the wall.
4) When new work has to be started on the old or one completed a long while ago or in
the previous working season, care shall be taken to roughen and clean old surface
satisfactorily without disturbing the masonry before laying the new. It shall be wetted
before laying the bedding mortar.
5) Where practicable the whole of the masonry in any structure shall be carried out up
to a uniform level throughout. But where breaks are unavoidable in carrying up the
work continuously in hori­zontal courses, sufficiently long step shall be left out to join
the courses to be laid later. All junctions of wall shall be formed at the time the walls
are being built; cross walls should be carefully bonded into the main walls.
6) The practice of building two thin faces tied with two occa­sional through stones and
filling up the middle with dry packing and putting mortar on top must be strictly
guarded against. Putting dry chips in the joints of stones before filling them with
mortar shall not be permitted.
7) For ensuring good bond masonry shall be left uneven at the top of each course.
B.9.5. Treatment of joints - When joints are to pointed, they shall be raked to a depth not
less than their width when the mortar is still green. When pointing is not to be done, the
mortar in the joints shall be placed and trowelled smooth while masonry is being laid. If this
is not done, joints shall be raked when the mortar is green as mentioned above, cleaned
and wetted filled with 1:3 cement mortar, pressed and trowelled smooth. Joints shall be
raked when plastering is to be done.
B.9.6. Watering - All masonry built in lime or cement mortar shall be initially protected
form sun, rain, etc., by wet hessian or straw till set and thereafter kept continuously wet
for 14 days from the date of laying, unless other length of period is ordered in the special
provisions. Watering shall be done carefully in beginning through a rose so as not to wash
the mortar out of the joints. On Sundays, holidays, at the close of day’s work and other
periods of cessation of work, the masonry is kept continuously wet for the specified period
of curing and labourers are to be employed for the purpose. Should the contractor fail to
water the work to the satisfaction of the Engineer, the latter may supply requisite men,
materials and equipment to water the work prop­erly and charge the cost to the contractor.
B.9.7. Bad work - Should the mortar perish, i.e., become dry white or powdery through
neglect of watering or if the masonry shows hollow joints or non-adherence of mortar to the
work or if the work does not conform to plans and these specifications, the work must be
pulled down and rebuilt at the contractor’s expense.
B.9.8. Final finish -  All masonry shall be washed down on comple­tion and all stains
adhering mortar removed from the face as the scaffolding is lowered and removed.
B.9.9. Iron, stone, concrete or other fixtures, buttresses, etc. - All iron, stone, concrete
or other fixtures, shall be built and bonded into the work in proper place as work proceeds
not inserted or joggled on after the masonry is advanced.

58 RED BOOK  VOLUME I  ROADS  2012

 B.9.(a).3.2.
B.9.10. Wet foundations - In wet foundations, or other situa­tions where water is met with,
the work place shall be kept free of water by the contractor while the masonry is in progress
and until the Engineer considers the mortar has sufficiently set. Dewatering shall be carried
out in such a way as not to injure the concrete or masonry in any way. Dewatering shall
also be done when required for taking checking measurements, passing foundations, etc.
Dewatering will be included in the rate of masonry unless separate provision is made in the
tender.
B.9.11. Scaffolding - the contractor at his expense shall provide Scaffolding required for
facility of construction.
Scaffolding will be double or single as is warranted for the particular class of masonry. But
the ends of poles should not be in the position of header stones. Scaffolding shall be erected
with steel sections or pipes, bullies or bamboos of adequate strength so as to be safe for
all construction operations. The contractor shall take all measures to ensure the safety of
the work and working people. Any instructions of the Engineer in this respect shall also be
compiled with. The contractor shall be entirely responsible for any damage to property or
injuries to persons resulting from ill erected scaffold­ing, defective ladders and materials or
otherwise arising out of his default in this respect. Proper scaffolding shall be provided to
allow easy approach to every part of the work. Overhead work shall not be allowed.
Put log holes shall be made good by stones to match the face work when scaffolding is
being removed after ensuring that all holes behind are solidly filled in with 1:4:8 cement
concrete.
Clauses of this General Specification shall be applicable in all pertinent points to the
specifications for all classes of masonry.

B.9.(a). RANDOM RUBBLE MASONRY 1ST SORT

Random rubble masonry 1st sort in cement/lime mortar of specified proportion including
striking joints, scaffolding, curing etc., com­plete.
B.9.(a).1. General - Specification No. B.9. for stone masonry (general) shall apply in all
pertinent particulars. Random Rubble masonry shall also comply with the following in
addition.
B.9.(a).2. Materials - Materials shall conform to Specification No. B.9.2.
B.9.(a).3. Dressing and size.
B.9.(a).3.1. Face stones - Height shall not be greater than breadth of face and no stone
shall have its length less than 1.5 times its height. All the sides of the stones on the face
shall be dressed in straight lines and all the sides on the face shall be in one plane.
The stone face shall be roughed tooled (one line dressed) and the sides shall be rough
tooled square up to and afford a bearing of atleast 5cm. (average) from face. Individual
stones shall have gener­ally a face area of not less than 0.05 sq.m. Face stones shall
gener­ally with Specification No. A.7. The face stone shall be selected from the mass of
quarry stones for their larger size, good beds, close grain and uniform colour. 50% of the
stones shall be more than 0.010 cu.m. or 10 litres in walls up to 50 cm. in thickness and
0.015 cu.m. or 15 litres in thicker walls. They shall be as far as possible of equal size on
the face and rough tooled.
B.9.(a).3.2. Through stones -  One through stone shall be provided per half square
metre of facing evenly distributed in a staggered pattern. They shall be about 0.05 sq.m.
in face and shall have a tailing of full width of the masonry when the width is 60 cm. or
less. If the wall or masonry be over 60 cm.thick a line of headers overlap­ping each other

RED BOOK  VOLUME I  ROADS  2012 59

B.9.(a).3.2.
by atleast 15 cm. shall be laid right through the wall from face to back. The length of the
interior headers shall not be less than 45 cm.and their average cross sectional area shall
not be less than 0.03 sq.m. Header shall be distinctly marked on its face.
B.9.(a).3.3. Vertical headers - For massive work with a width of a metre and more, vertical
headers 45 cm. long or depth of two courses whichever is more shall be provided at the
rate of one for every sq.metre of area in plan. For every course a new set of headers
shall be introduced at this rate in a staggered pattern. The average sec­tional area of
each should not be less than0.03sq.m.
B.9.(a).3.4. Hearting and backing stones - These stones shall comply with specification
No.A.8.3. These stones shall not be less than 15 cm. in any direction. In walls of 50 cm.
and less about 30% of stones shall not be less than 0.015 cu.m. or 15 litres. Backing
shall conform to U.C.R. masonry when it is to be plastered.
B.9.(a).3.5. Quoins - Quoins shall be of selected stone and shall have rough/fine tooled
dressing. They shall be cut to the required size and shall normally have a height of
one course. If the plans show a height equal to two courses they shall be provided
accordingly. The beds and tops shall be square to the face and rough tooled to 10 cm.
from the face and vertical joints square and rough tooled to 4 cm. from the face. The
length of the quoins shall not be less than twice the height or 45 cm. whichever is more
on the longer face nor less than the height on the shorter face. In the embedded portion
the length of the side shall not be less than that of the side opposite by more than 8 cm.
for the longer side and 5 cm. for the shorter side.
B.9.(a).4. Scaffolding - Scaffolding shall comply with specifica­tion no. B.9.11.
B.9.(a).5. Wet foundation - To comply with specification no. B.9.10.
B.9.(a).6. Construction details.
B.9.(a).6.1. Laying - Specification in B.9. shall generally apply.
The face stones shall be laid absolutely without any pinnings on the exposed faces. In
each course the headers or lines of headers as the case may be, shall be kept in position
at specified intervals and with specified lapse where such lapse are required before the
masonry of the layer is commenced to ensure that they are being laid properly and in
required numbers and intervals. They shall be embedded in mortar as masonry in that
layer progresses.
Quoins shall be laid stretcher and headerwise as seen on each face and shall correspond
to the arrangement of quoins in the same course.
The quantity of mortar for one cu.m. of thin and massive masonry shall range from 0.25
cu.m. to 0.30 cu.m. and for water retaining masonry from 0.44 cu.m. to 0.46 cu.m.
B.9.(a).6.2. Joints -  No face joints shall exceed 6 mm. in thick­ness. Stones shall be
arranged to break joint as much as possible and long vertical lines of jointing shall be
carefully avoided in the face work.
B.9.(a).6.3. Striking joints -  The face joints should be properly struck while the mortar
is fresh. Joints which cannot be so struck at the time of laying, shall be prepared for it
by raking joints to a depth of not less than 6 mm. when the mortar is fresh. These joints
should be properly cleaned of loose particles, wetted throughly and filled with good fresh
cement mortar 1:3 and finished off by being trowelled smooth.
B.9.(a).6.4. Rate of raising masonry - The rate of raising random rubble masonry brought
up in uniform levels may be limited to a height of 60 cm. per day in case of cement
mortar and 45 cm. in case of lime mortar. But no fresh course shall be laid over masonry

60 RED BOOK  VOLUME I  ROADS  2012

 B.9.(a).8.
previously laid within 4 hours of its laying for cement mortar and 8 hours for lime mortar.
B.9.(a).7. Item to include -
1) Random rubble stone masonry first sort laid in cement/lime mortar of specified proportions,
built in any position to any height or depth and to lines, levels, curves and batters shown on
the plans or as offered by the Engineer with headers, quoins etc., including striking joints
and curing. Cutting grooves holes, etc., for fixing frames, fixtures, etc., is also included.
2) Erecting and removing all scaffoldings, ladders and use of plant required for execution
of the item, safety of the labour and inspection of the work including compensation for any
injury, damage, etc.
3) Dewatering to allow construction in the dry and proper setting of masonry unless
separately provided in the tender.
4) Clearing the site round the masonry and backfilling so as to restore it to the original
condition.
5) All labour, use of tools, materials and other items incidental to satisfactory completion of
the item.
B.9.(a).8. Mode of measurement and payment - The quantity of random rubble masonry
to be paid under this item shall be in number of cubic metres of the completed work including
quoins, etc., and with the limiting dimensions not exceeding those shown on the plans or
as fixed by the Engineer. The contract rate shall be based on a unit of one cubic metre of
masonry. Dimensions shall be measured correct to a centimetre and individual quantities
shall be calculated upto two places of decimals of a cubic metre.

B.9.(b). RANDOM RUBBLE MASONRY 2ND SORT

Random Rubble Masonry 2nd sort in cement/lime mortar of specified proportion including
striking joints, scaffolding, curing etc., com­plete.
The specification for this item shall be exactly same as standard specification B.9.(a). for
Random Rubble masonry 1st sort except for the following changes :-
1) Faces shall be only hammered dressed as explained below. The bed and the joint
faces shall afford a square bearing of 2.5 cm. average from face by hammer dressing
or chiselling.
The flat end of the scabbing or spalling hammer shall knock off the sharp and irregular
projections on the stone face. Lifting the hammer and then allow­ing the pointed end
to drop on the surface freely shall further dress the surface. This process shall be
continued till a fairly uniform and even stone surface is obtained.
Chisel may be used to obtain straight edges for the sides and square surfaces for the
beds and joints.
2) The width of the joints shall not be more than 12 mm.
If pointing or plastering is to be provided the joints shall be raked to not less than 12
mm. when the mortar is green. Otherwise they shall be struck.
3) The quantity of mortar for one cubic metre of masonry shall range from 0.30 cu.m. to
0.35 cu.m. for thin and massive masonry respectively and 0.46 cu.m. to 0.48 cu.m.
for water retaining masonry.

B.9.(c). COURSED RUBBLE MASONRY 1ST SORT

RED BOOK  VOLUME I  ROADS  2012 61

B.9.(c).1.
Coursed Rubble masonry 1st sort in cement-mortar/lime mortar of specified proportion
including scaffolding, curing etc., complete.
B.9.(c).1. General - Specification No. B.9. for stone masonry (general) shall apply in all
pertinent particulars. C.R. masonry 1st sort shall also comply with the following in addition
:-
B.9.(c).2. Materials - Materials shall conform to specification No. B.9.2.
B.9.(c).3. Dressing and size -
(a) face stones - 
(i) Khandki - The khandki stones received from quarry shall be dressed so as to have
the vertical and horizontal sides perfectly straight, parallel and right angles to adjacent
sides. The four sides of the stone on the face shall lie in one plane. Brush­ing on the face
of the stones shall not project more than 4 cm. The beds and tops shall be square to the
face and rough tooled to atleast 8 cm. from the face. The side vertical joint faces shall
be squared to the face and rough tooled to atleast from the face. The face shall have no
depression below the plane of the sides.
All the khandki stones shall be more in breadth than in height and shall run back into the
masonry for not less than 1.5 times the height 30% of the khandkis shall have tailing of
twice their height. 30% of these face stones shall not be less than 0.02 cu.m. or 20 litres.
 The height of the khandki shall not be less than 15 cm. or speci­fied for the particular
item.
 (ii) These khandkis shall be provided for the interior face also when it is to remain
exposed or so specially provided.
(b) Hearting and backing stones -  When interior face is to be plastered or otherwise
permanently remaining covered, backing stones shall be as specified for U.C.R. masonry.
Hearting and backing stones shall be as big as possible 30% of these stones shall not
be less than 0.010 cu.m. or 10 litres for walls 50 cm. or less in thickness and for walls
thicker than 50 cm. 30% of them shall not be less than 0.015 cu.m. or 15 litres.
(c) Quoins -  The quoins shall be selected stone and shall normal­ly be of the same
height as that of the course in which they are to be used. If the plans show a height
of two courses they shall be provided accordingly. The faces of quoins shall be rough
tooled or hammer dressed as directed by the Engineer. A chisel draft of about 40 mm.
shall be provided on each side of the exposed corners.
The beds and the tops shall be dressed square to the face and rough tooled to 10 cm.
from the face and the vertical joints similarly dressed to 4 cm. from the face. The length
of the quoins shall not be less than twice their height or 45 cm. whichever is more on
the longer face or less than their height on the shorter face. In the embedded portion the
length of the side shall not be less than that of the exposed side opposite by more than
8 cm. for the longer side and 5 cm. for the shorter side.
(d) Through stones -   The height of the through stones shall be the full height of the
course and width shall not be less than the height. The face, beds and joints shall be
dressed similar to khand­kis.
 They shall be about 0.05 sq.m. in face and shall have a tailing of full width of the
masonry when the width is 60 cm. or less. If the wall or masonry be over 60 cm. thick a
line of headers overlapping each other by atleast 15 cm. shall be laid right through the
wall from face to back. The length of the interior headers shall not be less than 45 cm.
and their average cross sectional area shall not be less than 0.03 sq.cm. Face header

62 RED BOOK  VOLUME I  ROADS  2012

 B.9.(c).10.
shall be distinctly marked on its face.
(e) Vertical headers -  For massive work with a width of a metre and more, vertical
headers 45 cm. long or depth of two courses whichever is more shall be provided. The
average sectional area of each should not be less than 0.03 sq.m.
B.9.(c).4. Construction - The stones shall be laid in horizontal course or not less than 15
cm. height. The stones in each course shall be of equal height and all courses shall be of
the same height unless otherwise specified or directed by the Engineer. But no course shall
be thicker than any course below it unless otherwise shown on the plans or directed. The
height of different courses shall be predeter­mined and shall match with the corresponding
courses in other parts of the structure.
Khandki stones shall be provided for faces, remaining exposed.
The through stones shall be placed 1.5 metres apart in the clear in every course before
starting the construction of that course and finally embedded in the course.
Vertical headers shall be provided in the case of massive masonry where the thickness of
the masonry is one metre or more at the rate of one for every sq. metre of area in plan. For
every course, a new set of headers shall be introduced shall be introduced at this rate, in
a staggered pattern.
Quoins shall be laid stretcher and headerwise as seen on each face of the wall and shall
correspond to the arrangement of quoins in the same course.
The faces of masonry to be plastered or remaining permanently unexposed shall conform
to U.C.R. masonry unless otherwise directed.
The thickness of joint shall not exceed 10 mm. Where pointing is to be done, the joints shall
be raked to a depth of not less than 10 mm. when the mortar is green.
The quantity of mortar for one cu.m. of thin and massive masonry shall range from 0.25
cu.m. to 0.30 cu.m. and from 0.44 cu.m. to 0.46 cu.m. for water retaining masonry.
B.9.(c).5. Rate of raising masonry - The rate of raising masonry in cement mortar shall
be limited to 60 cm. and in lime mortar shall be limited to 45 cm. per day. But no fresh
course shall be laid over masonry previously laid within 4 hours of its laying for cement
mortar and 8 hours for lime mortar.
B.9.(c).6. Striking joints - The joints of non-exposed face when pointing is not to be done
shall be neatly struck while the mortar is green. Joints which cannot be so struck at the time
of laying, shall be prepared first by raking joints to a depth of not less than 10 mm. when the
mortar is fresh. These joints shall be properly cleaned of loose particles, wetted thoroughly
and filled with good fresh cement mortar 1:3 and finished off by being trowelled smooth.
B.9.(c).7. Cement pointing - When cement pointing is included in the item, it shall be done
according to specification no. B.13.
B.9.(c).8. Scaffolding - Scaffolding shall conform to specifica­tion no. B.9.11.
B.9.(c).9. Wet foundations - To comply with specification no. B.9.10.
B.9.(c).10. Item to include -
1) Coursed rubble masonry first sort laid in cement mortar/lime mortar of specified
proportions, built in any position to any height or depth and to lines, levels, curves
and batters shown on the plans or as ordered by the Engineer including striking
joints, raking out joints and curing for the specified peri­od. Chisel drafting, chamfering
and dressing the stones to lines, shapes and curves shown on the working drawings,
cutting grooves etc., for fixing frames, fixtures, etc., headers and rough tooled quoins

RED BOOK  VOLUME I  ROADS  2012 63

B.9.(c).11.
are also included.
2) Erecting and removing all scaffoldings, ladders and use of plant required for execution
of the item satisfactorily, including compensation for any injury, damage, etc.
3) Inspection facilities.
4) Dewatering unless separately provided for in the tender.
5) Cost of all labour, materials, use of tools and equipment and incidental items required
for satisfactory completion of the item.
6) Clearing the site round the masonry.
B.9.(c).11. Mode of measurement and payment - The contract rate shall be for a unit of
one cubic metre of masonry completed in all respects, in place and accepted. The quantity
of coursed rubble mason­ry to be paid under this item shall be in number of cubic metres of
the finished work and the limiting dimensions shall not exceed those shown on the plans or
as ordered in writing by the Engineer.
Dimensions shall be measured and individual quantities shall be calculated upto two places
of decimals of a metre and cubic metre respectively.
Battered, tapered or curved portions shall be measured net.

B.9.(d). COURSE RUBBLE MASONRY 2ND SORT

Coursed Rubble masonry 2nd sort in cement-mortar/lime mortar of specified proportion
including scaffolding, curing etc., complete.
The specification for this item shall be exactly the same as standard specification B.9.(c).
for the coursed rubble masonry 1st sort except for the following changes :-
1) Two stones may be used for height in one course upto 50%, for the face area.
2) The thickness of joint shall not exceed 12 mm.
3) Backing shall be of U.C.R. masonry, when unexposed or plas­tered. B.9.(e).7
4) The quantity of mortar for one cu.m. of thin and massive masonry shall range from 0.28
cu.m. to 0.33 cu.m. and from 0.46 cu.m. to 0.48 cu.m. for water retaining masonry.
5) The faces of quoins shall be roughed tooled or provided the same type of dressing
as Khandkies as directed by the Engineer. A chisel draft of about 40 mm. shall be
provided on each side of the exposed corner.

B.9.(e). COURSE RUBBLE MASONRY 3RD SORT

Coursed Rubble masonry 3rd sort in cement-mortar/lime mortar of specified proportion
including scaffolding etc., complete.
B.9.(e).1. General - Specification No. B.9. for stone masonry (general) shall apply in all
pertinent particulars. C.R. masonry 3rd sort shall also comply with the following in addition
:-
B.9.(e).2. Materials - Materials shall conform to specification No. B.9.2.
B.9.(e).3. Dressing and size - Stones to be set in the work shall be as received from the
quarry after merely knocking off weak corners and edges with a mason’s hammer. All the
sides of the stones on the face shall be dressed in straight lines and all these sides shall
be in one plane. The beds and joints shall afford a bearing of at least 2.5 cm. average.
Individual stones shall have a width of not less than 20 cm. in its thickest part and no stone
shall be less in width than height and less in length than 1.5 times its height. Each stone
shall be about 0.015 cu.m. or 15 litres or more.

64 RED BOOK  VOLUME I  ROADS  2012

 B.9.(e).11.
B.9.(e).4. Face stones shall generally comply with specification no. A.8. The face stone
shall be selected from the mass of quarry stones for their larger size, good beds, close
grain and uniform colour. 50% of the stones shall be more than 0.015 cu.m. or 15 litres in
walls up to 50 cm. in thickness and 0.02 cu.m. or 20 litres in thicker walls.
B.9.(e).5. Through stones - Each through stone on the face shall have its width not less
than the height and shall tail into the work atleast three times its height.
One through stone shall be provided per half square metre of facing evenly distributed
in a staggered manner. Through stones of successive courses should not be placed one
above the other. They shall be about 0.05 sq.m. in face area and shall have a tailing of 60
cm. or the width of the wall whichever is less. If the wall of masonry be over 60 cm. thick
a line of headers overlapping each other by atleast 15 cm. shall be laid right through the
wall from face to back. The length of the interior headers shall not be less than 45 cm.and
their average cross sectional area shall not be less than 0.025 sq.m. Face header shall be
distinctly marked on its face.
C.C. 1:2:4 headers may be used if so permitted in writing by the Engineer in charge.
B.9.(e).6. Vertical headers - For massive work with a width of a metre and more, vertical
headers 45 cm. long shall be provided at the rate of one for every sq.metre of area in plan.
For every course a new set of headers shall be introduced at this rate in a staggered pat­
tern. Their average sectional area shall not be less than 0.03 sq.m.
B.9.(e).7. Hearting and backing stones - These stones shall comply with specification
No.A.8.3. These stones shall not be less than 15 cm.in any direction. In walls of 50 cm.and
less about 30% of stones should not be less than 0.010 cu.m. or 10 litres and for thic­cker
walls about 30% of the stones shall not be less than 0.015 cu.m. or 15 litres.
B.9.(e).8. Quoins - Quoins shall be of selected stone and shall normally be 20 cm. x 25
cm. x 40 cm. or as directed by the Engineer. The faces of quoins shall be rough tooled or
provided the same type of dressing as that of the face stones as directed. Chisel draft of
about 40 mm. shall be provided on each side of the exposed corner.
The beds and tops shall be dressed square to the face and rough tooled to 10 cm. from the
face and vertical joints similarly dressed to 4 cm. from the face. In the embedded portion
the length of the side shall not be less than that of the exposed side opposite by more than
8 cm. for the longer side and 5 cm. for the shorter side. The sizes of quoins shall be unifrom.
Use of 1:2:4 c.c. blocks or brick-work quoins may be done if so permitted by the Engineer
in charge in writing. No extra payment shall be made in such cases.
B.9.(e).10. Wet foundation - To comply with specification no. B.9.10.
B.9.(e).11. Construction details - Laying - Specification in B.9. for stone masonry shall
generally apply. The face stones shall be laid without any pinnings on the exposed faces.
The edges of adjoining stones shall be parallel to allow joints of fairly uniform width. In
each course, the headers or lines of headers as the case may be, shall be kept in position
at specified intervals and with specified lapse where such lapse are required before the
masonry of the layer is commenced to ensure that they are being laid properly and in
required numbers and intervals. They shall be embedded in mortar as masonry in that layer
progresses.
A horizontal joint shall be introduced at intervals specified on the drawings or as ordered by
the Engineer throughout the masonry. The height of the course shall be a whole multiple of
the height of the quoins.
Quoins shall be laid stretcher and headerwise as seen on each face and shall correspond

RED BOOK  VOLUME I  ROADS  2012 65

B.9.(e).12.
to the arrangement of quoins in the same course.
Where the height of courses is less than 20 cm. 30% of the face area shall be made up of
stones of full height of the course. In the remaining area not more than 3 stones shall be
used to make up the height.
Where the height of courses is between 20 cm. and 40 cm. 30% of the face area shall be
made up by stones each with a face area of not less than 0.30 cu.m. and for the remaining
area the stones shall have a face area of not less than 0.015 sq.m.
The quantity of mortar for one cu.m. of thin and massive masonry shall range from 0.30
cu.m. to 0.35 cu.m. respectively and for water retaining masonry from 0.46 cu.m. to 0.48
cu.m.
Joints - The face joint width shall not exceed 16 mm.
Striking joints - The face joints shall be properly struck while the mortar is fresh. Joints
which cannot be struck at the time of laying, shall be prepared for it by raking joints to a
depth of not less than 15 mm. when the mortar is fresh. These joints should be properly
cleaned of loose particles, wetted thoroughly and filled with good fresh cement mortar 1:3
and finished off by being trowelled smooth.
Rate of raising masonry - The rate of raising coursed rubble 3rd sort masonry per day shall
be limited to a height of 60 cm. or the height of course whichever is less in case of cement
mortar and 45 cm. in case of lime mortar. But no fresh course shall be laid over masonry
previously laid within 4 hours of its laying for cement mortar and 8 hours for lime mortar.
B.9.(e).12. Item to include -
1) Coursed rubble stone masonry third sort laid in cement/lime mortar of specified
proportions, built in any position to any height or depth and to lines, levels, curves and
batters shown on the plans or as ordered by the Engineer including headers, quoins etc.
and striking joints and curing.
2) Erecting and removing all scaffoldings, ladders and use of plant required for execution of
the item satisfactorily, safety of the labour and inspection of the work including compensation
for any injury, damage, etc.
3) Dewatering unless separately provided in the tender.
4) Clearing the site round the masonry.
5) All labour, use of tools, materials and other items incidental to satisfactory completion of
the item.
B.9.(e).13. Mode of measurement and payment - The contract rate shall be for one cubic
metre of finished masonry including quoins, etc.
The dimensions shall be limited to the dimensions shown on the plan or as ordered by the
Engineer.
Dimensions shall be measured correct to a centimetre and cubic contents calculated correct
upto two places of decimals of a cubic metre.

B.9.(f).UNCOURSE RUBBLE MASONRY

Uncoursed Rubble masonry in cement/lime mortar of specified proportion including striking
joints, scaffolding, watering etc., complete.
B.9.(f).1. General - Specification No. B.9. for stone masonry (general) shall apply in all
pertinent particulars. U.C.R. masonry shall also comply with the following in addition :-
B.9.(f).2. Materials - Materials shall conform to specification No. B.9.2.

66 RED BOOK  VOLUME I  ROADS  2012

 B.9.(f).11.
B.9.(f).3. Dressing and size - Stones to be set in the work shall be as received from the
quarry after merely knocking off weak corners and edges with a mason’s hammer. In the
case of face stones all the sides of the stones shall be dressed in straight lines and all the
sides shall be in one plane. Individual stones shall have a thickness and width of not less
than 15 cm. in its thickest part and no stone shall be less in length than 1.5 times its height.
B.9.(f).4. Face stones - Face stones shall generally comply with specification no. A.8.
The face stone shall be selected from the mass of quarry stones for their greater size, good
beds, close grain and uniform colour. 50% of the stones shall be more than 0.010 cu.m. or
10 litres in walls up to 50 cm. in thickness and 0.015 cu.m. or 15 litres in thicker walls. The
beds and joints shall have an average bearing of not less than 2 cm.
B.9.(f).5. Through stones - One through stone shall be provided per half square metre
of facing evenly distributed. They shall be about 0.03 sq.m. in face area and shall have a
tailing of full width of the masonry when the width is 60 cm.or less. If the wall of masonry be
over 60 cm. in width line of headers overlapping each other by atleast 15 cm. shall be laid
right through the wall from face to back. The length of the interior headers shall not be less
than 45 cm.and their average cross sectional area shall not be less than 0.025 sq.m. Face
header shall be distinctly marked on its face.
C.C. 1:2:4 headers may be used if so permitted in writing by the Engineer in charge.
B.9.(f).6. Vertical headers - For massive work with a width of a metre and above, vertical
headers 45 cm. long or depth of two courses whichever is more shall be provided at the
rate of one for every sq.metre of area in plan. For every course a new set of headers shall
be introduced at this rate in a staggered pattern. Their average sectional area shall not be
less than 0.03 sq.m.
B.9.(f).7. Hearing and backing stones - These stones shall comply with specification
No.A.8.3. In walls of 50 cm.and less about 30% of stones shall not be less than 0.010 cu.m.
or 10 litres and for thicker walls about 30% of stones shall not be less than 0.015 cu.m. or
15 litres.
B.9.(f).8. Quoins - Quoins shall be of selected stone and shall normally be 20 cm. x 25
cm. x 40 cm. or as directed by the Engineer. The faces of quoins shall be rough tooled or
provided the same type of dressing as that of the face stones as directed. Chisel draft of
about 40 mm. shall be provided on each side of the exposed corner.
The beds and tops shall be dressed square to the face and rough tooled to 10 cm. from the
face and vertical joints similarly dressed to 4 cm. from the face. In the embedded portion
the length of the side shall not be less than that of the exposed side opposite by more than
8 cm. for the longer side and 5 cm. for the shorter side.
Use of 1:2:4 c.c. blocks or brick-work quoins may be done if so permitted by the Engineer
in charge in writing. No extra payment shall be made in such cases.
B.9.(f).9. Scaffolding - Scaffolding shall comply with the specification No. B.9.11.
B.9.(f).10. Wet foundation - To comply with specification no. B.9.10.
B.9.(f).11. Construction details - Laying - Specification in B.9. for stone masonry (general)
shall generally apply.
The face stones shall be laid without any pinnings on the exposed faces. In each course
the headers or lines of headers as the case may be, shall be kept in position at specified
intervals and with speci­fied lapse where such lapse are required before the masonry of the
layer is commenced to ensure that they are being laid properly and in required numbers
and intervals. They shall be embedded in mortar as masonry in that layer progresses.

RED BOOK  VOLUME I  ROADS  2012 67

B.9.(f).12.
Quoins shall be laid stretcher and headerwise as seen on each face and shall correspond
to the arrangement of quoins in the same course.
The quantity of mortar for one cu.m. of thin and massive masonry shall range from 0.30
cu.m. to 0.35 cu.m. respectively and for water retaining masonry from 0.46 cu.m. to 0.48
cu.m.
Joints - No face joints shall exceed 15 mm.
Striking joints - The face joints should be properly struck while the mortar is fresh. Joints
which cannot be struck at the time of laying, shall be prepared for it by raking joints to a
depth of not less than 15 mm. when the mortar is fresh. These joints should be properly
cleaned of loose particles, wetted thoroughly and filled with good fresh cement mortar 1:3
and finished off by being trowelled smooth.
Rate of raising masonry - The rate of raising uncoursed rubble masonry brought up in
uniform levels may be limited to a height of 60 cm.per day in case of cement mortar and 45
cm. in case of lime mortar. But no fresh course shall be laid over masonry previously laid
within 4 hours of its laying for cement mortar and 8 hours for lime mortar.
B.9.(f).12. Item to include -
1) Uncoursed rubble masonry laid in cement/lime mortar of speci­fied proportions, built in
any position to any height or depth and to lines, levels, curves and batters shown on
the plans or as ordered by the Engineer including headers, quoins etc. and striking
joints and curing.
2) Erecting and removing all scaffoldings, ladders and use of plant required for execution
of the item, safety of the labour and inspection of the work including compensation
for any injury, damage, etc.
3) Dewatering to allow construction in the dry and proper setting of masonry unless
separately provided in the tender.
4) Clearing the site round the masonry.
5) All labour, use of tools, materials and other items incidental to satisfactory completion
of the item.
B.9.(f).13. Mode of measurement and payment - The quantity of uncoursed rubble
masonry to be paid under this item shall be in number of cubic metres of the finished
work including quoins, etc., and with the limiting dimensions not exceeding those shown
on the plans or as fixed by the Engineer. The contract rate shall be based on a unit of one
cubic metre of finished masonry. Dimensions shall be measured and individual quantities
calculated correct upto two places of decimals of a cubic metre respectively.

B.9.(g). LATERITE MASONRY

Providing and constructing laterite stone masonry in cement mortar/lime mortar of specified
proportions, including scaffolding striking joints, raking out joints, curing, etc., complete.
B.9.(g).1. General - Specification No. B.9. for stone masonry (general) shall apply in all
pertinent particulars. Laterite stone masonry shall also comply with the following in addition
:-
B.9.(g).2. Material -
B.9.((g).2.1. Mortar - Cement mortar/lime mortar shall be of proportion as mentioned
in the wording of the item or special provi­sions and shall comply with specification No.
B.5./B.3.
B.9.(g).2.2 Stones -  The laterite stone shall comply with speci­fication No.A.7 in all

68 RED BOOK  VOLUME I  ROADS  2012

 B.9.(g).6.
respects. Laterite of specified quality shall be obtained from the quarries defined in the
contract or from other sources approved by the Engineer. It shall be the best procurable
in the region, known for soundness and satisfying the specification No. A.8 for laterite
stone. Laterite shall be dug from the approved quarry and allowed to harden as long as
possible before being placed in the work.
B.9.(g).3. Dressing and size -
1) The stone shall be quarried in blocks and dressed true and square to the sizes ordered.
The least thickness of stones shall not be less than 15 cm. and breadth shall not be
less than the thickness and length not less than twice the thickness, unless other
sizes are ordered.
2) In walls 50 cm. thick and under, the header shall run right through the wall.
B.9.(g).4. Scaffolding - Shall comply with specification No. 9.11.
B.9.(g).5. Construction -
1) The stones dressed according to the architectural details shown on the drawings or
as directed by the Engineer shall be laid regular courses not less than shown on the
plan or specified. All the courses shall be of same height unless otherwise shown on
the plan or specified. No courses shall be thicker than any course below it, unless
specially shown on the drawings. Each stone must be fitted into its place dry in order
that any inaccuracy of figure may be discovered and corrected before it is finally laid
in mortar and settled in its bed.
2) The stones shall be laid in the work header and stretcher alternately to break joints
atleast 8 cms., the joints being no case more than 12 mm. in thickness. Each stone
shall be carefully laid in place in mortar to bring it to solid bearing both as to bed and
joint.
The quantity of mortar for one cu.m. of masonry shall be about 0.18 cu.m. to 0.20
cu.m.
3) Courses shall be horizontal and side joints vertical through­out unless otherwise
indicated on the drawings.
4) The joints in the face shall be struck smooth while laying the masonry only.For face
of masonry for which pointing or plastering has to done later on, the joints shall be
raked to a depth not less than 12mm. when the mortar is green.
B.9.(g).6. Item to include -
1) Erecting and removing scaffolding, ladders, and use of plant required for execution
of item.
2) Constructing the Laterite masonry as specified above to lines, levels, batters and
shapes as per working drawings or as directed by the Engineer.
3) Striking and raking out joints.
4) Watering the masonry for the specified period.
5) All labour, materials, use of tools, equipment, tackle, re­quired to complete the item as
specified.
6) All chamfering, rebates, holes, etc., required to dressed as per drawings or required
to be cut for fixtures, frames, dowels, railing, bars, anchors, etc.
7) Dewatering where necessary unless separately provided in the tender.
8) Clearing the site round the masonry.

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B.9.(g).7.
B.9.(g).7. Mode of measurement and payment - The contract rate shall be per cubic
metre of the work finished as specified above. Any stone masonry constructed in excess of
the dimensions shown on the drawings or as directed by the Engineer will not be measured
and paid. The linear dimensions shall be measured and total quantity worked out correct
up to two places of decimals of a metre and cubic metre re­spectively.

B.10. MILD STEEL BAR REINFORCEMENT FOR R.C.C. WORK

B.10.1. General - The item provides for the supply of mild steel bars, cutting, bending,
binding with galvanised iron wire and erecting in position for reinforcement in R.C.C.
B.10.2. Materials -
1) Mild steel bar shall conform to the specification No. A.9.
2) The binding wire shall conform to the specification No. A.11.
B.10.3. Supply - When the supply is made by the Department, the contractor shall convey
the mild steel bars from the place of delivery mentioned in schedule `A’ of the tender to
the site of work. The contractor shall be solely responsible for any damage during the
conveyance and till it is used.
When the contractor supplied mild steel reinforcement bars ob­tained from the market they
shall be supplied to the site of work without damage.
B.10.4. Fabrication - Reinforcing steel shall be thoroughly cleaned of all coatings of any
characters that would destroy or reduce the bond.
Bending reinforcement shall conform accurately to the dimensions and shapes shown on
the plans or as directed by the Engineer. Bars shall not be bent or straightened in a manner
that will injure the material. Bars with kinks, bends or cracks shall not be used. Bars shall
be bent cold to the shapes and dimensions shown on the drawings or as directed by the
Engineer in writing. Bar bender may be used to attain proper radii of bends and shapes.
Bars which may be bend in transport or handling shall be properly straightened before
being placed in work without heating them. Bending bar by heating to cherry red heat not
exceeding 815øc may be allowed for only M.S. bars larger than 25mm. diameter except
for bars which depend for their strength on cold working . Hot bars shall not be cooled by
quenching. HYSD bars shall not be heated for bending.
B.10.4.1. Details of length, sizes, laps and bending diagrams shall be got approved by
the Engineer. This is to secure additional precautions against errors.
B.10.5 Splicing and lapping - All reinforcement shall be fur­nished in full lengths indicated
on the plans as far as possible. splicing bars except as shown on the plans will not available,
bars shall be spliced. spliced of tensile reinforcement at points of maxi­mum stress and of
adjacent bars at the same place shall be avoided. Splices shall be staggered as far as
possible and located at suitable points. A welded or mechanical connection if adopted, shall
develop the full strength of the bars . Welding of HYSD bars shall not be done. However
welding of HYSD bars may be done with written permission of the Engineer in charge by
special methods as may be suitable. Unless otherwise shown on the plans, bars shall
be lapped as specified in I.S. 456-1964* with due regard to the grade of concrete. In lap-
splices, bars shall be placed in contact and just wired together to keep in place.
B.10.6 Coupling - Whenever plans and specifications call for the use of coupling-boxes or
bottle nuts to join bars, they shall have sufficient cross section to transmit the full strength
of the bars. The ends of the bars which are jointed by coupling shall be upset for a sufficient
length so that effective cross section after cutting the screw threads shall not be less than
the normal cross section of the bars. Screw threads shall be standard Whitworth threads.

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 B.10.9.
Coupled joints will be paid for separately. Number of tensile test shall be as indicated in
specification No. B.10.7.
B.10.7. Welding - Whenever plans and specifications call for the welding of joints in
reinforcement bars in lieu of lapping them, the bars shall be butt-welded so as to transmit
their full strength. Welding shall generally conform to specification No.B- 18 and I.S. 456-
1964* except as modified below and when otherwise directed by the Engineer. Welded
joints shall be so staggered that in any one section equal to the lap length of the bars,
not more than 33% of the bar are welded. Electric arc welding or oxyacetylene process
of welding, using a process that will exclude air from the molten metal and conforming
to any special provisions for the welding as laid down by the Engineer in writing will be
accepted. Suitable means shall be provided for holding the bars securely in position during
the process of welding. The ends of the bars shall be cleaned of all loose scale, rust,
grease, paint, and other foreign matter and clean original metal exposed before welding.
Only competent and experienced welder shall be
employed on the work. Preliminary test of the weld shall be carried out at the contractor’s
cost to see that the actual field welding method is satisfactory and gives the required
strength. Two welds in 100 welds or a minimum of 2 welds shall be made on the site on
the test pieces under conditions exactly similar to the field welding of actual reinforcement
bars and tested for their tensile strength. The strength of the welded joint shall not be less
than that of the origi­nal bar. If the tests are not satisfactory, change of welding proce­dure
and the Engineer may order further tests. Bars welded along with the welded samples,
found unsatisfactory on tests shall be cut and rewelded. Additional welds if required on this
account shall not be paid for. All the tests shall be at the cost of the contractor.
When welded joints are required they will be paid for separately.
No part of the reinforcement embedded in concrete shall be used for conducting electric
current.
B.10.8. Substitution - Substitution of size of bars different from those specified will be
permitted at the request of the contrac­tor only if authorised by the Engineer. The steel
substituted shall have area not less than the designed area provided further that the safe
bond stress is not exceeded. If such substituted steel has larger area than that originally
specified, such excess weight due to larger area will not paid for.
B.10.9. placing and fastening - All reinforcement shall be accurately placed in position with
spacing and cover shown on the plan and firmly held so during the placing and setting of
concrete. Bars shall be tied at all intersections. Binding wire of 1.63m. or 1.22mm diameter
shall be used. Alternatively the Engineer may permit spot welding instead of tying wire.
Spacing of bars shall be maintained by means of stays, blocks, ties, spacers, hangers or
other approved supports at suffi­ciently close interval so that bars will not sags between
supports nor be displaced during placing, vibrating or compacting concrete or by any other
operation. Metal supports which extends to the surface of the concrete except where shown
in the plans and wooden supports shall not be allowed. Placing bars for reinforcement on
a layer of fresh concrete as the work progress, will not be permitted. The use of pieces of
broken stones or bricks or wooden blocks for maintaining spacing or cover shall not be
permitted. Layers of bars shall be separated by pre cast cement mortar blocks, spacer bars
or other approved devices. Special care shall be taken to prevent any distur­bance of the
reinforcement in concrete that has already been placed. Reinforcement after being placed
in position shall be maintained in a clean condition till it is completely embedded in the
concrete. All bars protruding from concrete to which other bars are to be spliced and which
are likely to be exposed for an indefinite period shall be protected from rusting from rusting
by a thin coat of cement wash.

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B.10.10.
B.10.10. Inspection -  Full details of the numbers, sizes, lengths, weights, laps, welds,
spacing of the bars placed in position in different parts of the work shall be recorded,
certified and signed by the Engineer to show that all reinforcement has been placed cor­
rectly as per the sanctioned drawings or as ordered by the Engineer in writing before placing
concrete. No concrete shall be deposited until the Engineer has inspected and certified the
correctness of reinforce­ment, recorded the steel measurements and given permission to
place the concrete in writing. After the approval of reinforcement by the Engineer it will be
the contractor’s responsibility to see that the reinforcement spacing and arrangements are
not tempered with in any way before or during concreting.
B.10.11. Tests -  When the contractor supplies his own steel, he shall produce the test
certificate. If there is any doubt about the quality, tensile and cold bend tests shall be
carried out according to I.S. 432 - 1978 in an approved laboratory and the cost of the tests
shall be borne by the contractor if the results are unsatisfactory and by the Department if
the results are satisfactory.
B.10.12. Item to include -
1) Cost of labour, material, use of tools, plant and tackle and other incidental items to
complete the work included under the item satisfactorily.
2) Supplying, conveying, cleaning, cutting, bending, binding with 1.63 mm. or 1.22 mm.
(16 or 18 gauge) wire or spot-welding and placing reinforcement in position and
maintaining it clean and in position till the concrete is laid.
3) Cost of sampling and testing.
B.10.13. Measurement and payment - The contract rate shall be on weight basis for 1
quintal of mild steel reinforcement. The weight of steel reinforcement incorporated in the
concrete will be measured in quintal based on the total computed weights for the sizes and
lengths of bars, as shown on the plan or as ordered by the Engineer. The lengths of the
bars shall be measured correct to two planes of deci­mals in metres and the weight payable
would be worked out on the following basis correct to 0.10 of a Kg.
Diameter of bars in millimeters Weight in Kg. per metre
(1) (2)
6 0.22
10 0.60
12 0.90
16 1.60
20 2.50
22 3.00
25 3.80
28 4.80
32 6.30
36 8.00
40 9.90
The steel will be issued to the contractor on the actual weigh­ment. However, while paying
for the item of reinforcement, the weight of steel used on the work will be calculated on the
basis of running length and standard weight per unit length. Claims on account of difference
in actual weights and weights calculated on the basis of length will not be entertained.
The wire for tying and devices for supporting bars and maintain­ing various clearances will

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 B.11.5.
not be measured or paid.
No payment will be made for clips, binding wires, tack welding done in lieu of tying,
separators, wire chairs and other materials used for fastening and supporting reinforcement
in place. If the bars are substituted at the contractor’s request and as a result more steel
is used than specified, only the quantity specified shall be paid. Authorised lap lengths
shall be paid for. If the lengths of bars contemplated in the designs are not available and
the Engineer certi­fies the fact, steel involved in more number of laps will be paid for. When
laps are made for splices other than those shown on the plans for the convenience of the
contractor or lengths of laps more than indi­cated above, the extra steel will not be paid for.
Any extra lengths of bars over the design if used (as shown on the plans) shall not be paid
for.
When splicing of main tensile bars is required to be done by welding or by coupling boxes,
such joints will be paid for separately in terms of numbers for the diameter of the bars
jointed.
When the steel is supplied by Government, the pieces of the bars will not be taken back
by the Department. Such wastages then shall be the property of the contractor and the
contractor will be permitted to dispose off the same with the permission of Iron and Steel
Controller or in accordance with the prevailing orders of the Government. Surplus steel (
full length bars only ) out of the steel issued to the con­tractor will be taken back at the rate
which it was issued to the contractor, the conveyance to the place of original issue for such
steel being at the contractor’s cost.
When steel is supplied free by Government, the rate will include all the items except supply
of steel bars in available lengths at the place of delivery specified. If wastage of steel is
more than the minimum possible, the cost of steel wasted in excess shall be recov­ered
from the contractor at the Divisional issue rate plus a penal rate as decided by the Engineer.

B.11 CEMENT PLASTER

Plastering concrete, stone, or brick masonry surface in cement mortar of specified proportion
and specified thickness including, scaffolding, curing, etc., complete as deducted.
B.11.1. Materials - Cement mortar - Cement mortar shall have the proportion of cement
to sand as mentioned in the wording of the item or in the if the special provisions and shall
comply with specification No. B.5.(a) for cement mortar for plaster.
B.11.2. Scaffolding - Shall be as per B.9.11.
B.11.3. Preparatory work - All joint in the face work that is to be plastered shall be raked
out to depth equal to not less than the width of the joints or as directed by the Engineer.
The raking shall be done taking care not to allow any chipping of masonry. In new work the
raking out shall be done in mortar in the joint is still green. Smooth surfaces of concrete,
old plaster, etc., must be suitable roughened to provide necessary bond for the plaster. All
dirt, soot, oil, paint or any other material that might interfere with satisfac­tory bond shall be
removed. In the case of stone masonry, bushing on the walls to receive the plaster shall not
be more than 12 mm. The surface to be plaster shall be cleaned and scrubbed with fresh
water and kept wet 6 hours prior to plastering. It shall be kept damp during the progress of
the work. The plastering shall not be commenced unless the preparatory work is passed in
writing by the Engineer.
B.11.4. Gauges - Patches of plaster 15 cm.x 15 cm. shall be put on about 3 m. apart as
gauges to ensure even plastering in one plane.
B.11.5. Plastering - In all plaster work mortar shall be firmly applied with some what more

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B.11.5.
than the required thickness and well pressed into the joints and on the surface and rubbed
and leveled with a flat wooden rule to give required thickness. Long straight edge shall be
freely used to ensure the perfectly plane and even surface. All corners must be finished
to plane or curved surfaces as shown on the plan or directed by the Engineer and shall
present a neat ap­pearance.
The mortar shall adhere to the masonry surface intimately when set and there should be
no hollow sound when struck. Cement plastering should be done in squares or strips as
directed. Plastering shall be done from top downward.
B.11.6. Finishing - In any continuous face of a wall, finishing treatment of any type should
be carried out continuously and day to day breaks made to coincide with architectural
breaks in order to avoid unsightly junctions.
B.11.7. Moulding - All moulding shall be worked true to template and drawn neat, clean and
level. All exposed angles and junctions with door frames, etc., shall be carefully finished
and shall be beaded if ordered.
B.11.8. Watering and curing - All plaster work shall be kept damp continuously for a period
of 14 days. to prevent excessive evaporation on the sunny or windward side of the buildings
in hot, dry weather, matting or gunny bags may be hung over the outside of the plaster in
the beginning and kept moist.
B.11.9. Item to include -
1) Erecting, dismantling and removing the plastering.
2) Preparing the surface to receive the plaster.
3) Providing cement plaster of the specified average thickness with specified number of
coats.
4) Dewatering if necessary if not separately provided in the tender.
5) All labour materials, use of tools and equipment to complete the plastering as per
specification.
6) Curing for 14 days.
7) Any moulding work shown on the drawings or as specified unless separately provided
in the tender.
B.11.11. Mode of measurement and payment - The contract rate shall be per square
metre of plastering of specified thickness. All work shall be measured net in square metres.
Dimensions shall be measured and quantity worked out correct up to two places of decimals
in metre and square metre respectively. If the average thickness of plaster provided by the
contractor is more than what is specified on any account, no extra payment is made.
B.11.(a). Cement plaster in one coat - The above specification in B.11 will apply in all
pertinent particulars besides following -
In case of stone masonry the bushing on the walls to receive the plaster shall be removed
to within 12 mm. before laying in masonry ad the plaster shall cover all projections by
atleast 6 mm.
 he plaster shall then be laid on the somewhat more the required thickness and pressed
T
and levelled with a flat wooden rule or float to required thickness. The average finished
thickness of plaster shall be as required in the wording of the item. The surface shall be
rubbed smooth after floating with a thick coat of pure portland cement while the base coat
is still fresh. If neeru finish is specified floating with neat cement will not be required.
B.11.(b). Cement plaster in two coats - Specification No.B.11 will apply in all pertinent

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 B.13.3.1.
particulars.
When plaster is to be laid in two coats, the average thickness of first coat of plaster is
generally 10 mm.on Brick work and 20 mm. on rubble masonry. The first coat is applied
as per B.11.(a) but the surface is not floated or polished or roughened to give the key
to second coat of plaster. Before the first coat hardens, it shall be combed in wavy lines
about 12 mm. apart and 3mm. deep. The first coat shall be kept damp for at least 2 days
immediately following its application.It shall then be allowed to become thoroughly dry.
Before starting to apply the second coat the surface of the first coat shall be damped evenly
the finishing coat shall be of such thickness as to make the total average finished thickness
equal to the required plaster thickness as per item. The finished surface shall be true and
even and present a uniform texture throughout and all joining marks shall be eliminated.

B.12. LIME PLASTER

Plastering concrete, brickwork or stone masonry surfaces in lime mortar of specified
proportions and specified thickness, including scaffolding, curing, etc., complete as directed.
B.12.1. Materials - 1) Lime mortar - Lime mortar of proportion as mentioned in the wording
of the item or in the special provisions shall comply with specification No. B.3.
B.12.2. Scaffolding - Shall be as per B.9.11.
B.12.3. Preparatory work - Shall be as per B.11.3.
B.12.4. Gauges - Shall be as per B.11.4.
B.12.5. Plastering - Shall be as per B.11.5. Lime mortar shall be used instade of cement
mortar.
B.12.6. Finishing -  Shall be as per B.11.6. During the process of finishing, neeru as
specified in specification No. A.3 of the consist­ency of thick cream should be applied and
rubbed in to give a smooth and even surface when neeru finish is specified in the item or
special provisions.
B.12.7. Moulding - Shall be as per B.11.7.
B.12.8. Watering and curing - Shall be as per B.11.8.
B.12.9. Bad work - Shall be as per B.11.9.
B.12.10. Item to include - Shall be as per B.11.10. except that the lime mortar shall be used
instade of cement mortar.
B.12.11. Mode of measurement and payment - Shall be as per B.11.7.

B.13. CEMENT POINTING

Cement pointing with mortar of specified proportion to stone masonry or brickwork including
raking out joints, watering, etc., complete.
B.13.1. Materials - Cement mortar - Cement mortar for pointing shall be of the specified
mix and be as per specification No.B.4.
B.13.2. Scaffolding - Scaffolding to be as per specification No.B.9.11.
B.13.3. Construction details -
B.13.3.1. Unless other types of pointing are specified in the item or the special provisions,
pointing shall be of grooved type. The joints in the masonry shall be raked out to a
depth not less than a width of the joint or as directed in the special provisions or by the
Engineer, when the mortar is green. The joints are to be brushed clean of dust and loose

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B.13.3.1.
particles with a stiff brush. The area shall then be washed and the joints thoroughly
wetted before pointing commenced.
B.13.3.2. The raked out joints shall be filled with mortar of the specified mix and required
consistency and well pressed and rubbed smooth.
B.13.3.3. A semicircular depression 3 mm. diameter shall be made in the joint by
pressing a clean string with trowel keeping the string exactly horizontal and on the
centre line of the joint. The vertical joints shall be similarly marked. These depressed
lines will then be immediately rubbed with a nayla till they become uniformly 6 mm.
deep and 6 mm. wide and assume fairly blackish colour. Intersection of the vertical and
horizontal joints shall be finished neatly with a verti­cal line just touching the horizontal
line but not crossing it. Where the joints are not horizontal or vertical as in the case of
uncoursed rubble masonry, the pointing shall be made along the centre line of actual
joints and the junctions of pointing made neatly. The pointing mortar shall not spread
over the adjoining stones. Mortar pointing shall be restricted to the width of the joint and
all superfluous mortar shall be removed with the trowel.
B.13.4. Watering - The pointed face shall be kept continuously wet for 14 days after initial
set.
B.13.5. Item to include - Cement pointing shall include erecting and removal of scaffolding,
all labour, materials and equipment inci­dental to complete the pointing, dewatering if
necessary till the mortar is set unless separately provided for, raking out joints, clearing,
watering, filling with mortar, trowelling, pointing with nayla and watering.
B.13.6. Measurement and Payment - The contract rate shall be per square metre of cement
pointing. The dimensions measurement shall be correct up to a centimeter and quantity
calculated correct up to two places of decimals of a square metre.

B.14. RCC. CAST-IN-SITU PILES THROUGH DRIVEN SHELLS

Providing RCC. cast-in-situ piles of specified capacity place through steel shells driven
to the required depth in all strata except rock including driving the shells, concreting,
compaction, cast-iron shoes and reinforcement and withdrawing the shell.
B.14.1. General - Cast-in-situ RCC. piles shall be of the design shown on the plans or to
the designs of the Patentee subject to the approval of the Engineer. They shall consist of
concrete cast in steel shells driven to the required depth and / or set and filled with specified
quality of concrete after laying the reinforcement cage. The concrete shall be compacted
as the shell is withdrawn.
B.14.2. Equipment - Equipment will consists of heavy shells and steam or air hammer with
all other necessary accessories and plant or as may be proposed by the Patentee subject
to the approval of the Engineer.
B.14.2.1. Steel shells - The shell shall be of substantial thick­ness and of sufficient
strength and rigidity to permit their driving with heavy steam hammers and to prevent
their distortion caused be soil pressure or the driving of adjacent piles until filled with
concrete. The shells shall have their internal diameter equal to the specified diameter
of the pile and shall be sufficiently watertight to exclude water during the placing of
concrete. The shell shall be equipped with detachable heavy cast-iron shoes or driving
points. A watertight gasket usually of hemp dipped in coaltar shall be provided between
the shoe and the shell.
B.14.2.2. Hammer -  The steel shell shall be driven with the steam or air hammer of
sufficient weight. In no case shell the total energy developed by the hammer be less
than 2,200 Kg. metre per blow.

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 B.14.6.
B.14.2.3. Leads -  Pile driven leads shall be constructed in such a manner as to afford
freedom of movement of the hammer and they shall be held in position by guys and / or
steel braces to ensure rigid lateral support to the shell during driving. Inclined leads shall
be used in driving battered piles.
B.14.3. Driving - The shell with the shoe shall be driven in the correct position with
steam or air hammer to the required depth and/or set on shown on the plan or directed
by the Engineer, true and plumb or to the required batter and to give the designed set
for the last ten blows. Accurate record of number of blows required for the last 30 cm.
whenever possible shall be kept in the required proforma for the guidance of the Engineer
in determining allowable load on the pile. Where driving is interrupted before the final
penetration is reached, the record for final penetration shall not be taken until at least 20
blows are given on resumption of driving. If the required penetration is not obtained driving
will be done more intensively with more blows per minute. As soon as the shell is founded
to be sufficiently deep in hard strata, start will be made for taking the set. The set shall
be 12 mm. or less for the last 10 blows of the hammer. After the speci­fied set is obtained
10 more shall be given to the shell and the set recorded. If during these blows, the set in
10 blows is found to be more than 12 mm. the driving shall be continued further till the
specified set is obtained. If during the process of driving piles, foundation masonry of old
structure or boulder is met with, they shall be removed by the contractor by excavation for
which no extra payment will be made. If any water pipe lines or drainages are encoun­tered
while driving pile shells, the necessary diversion of drainage or water pipe shall be carried
out as per municipal requirements and as directed by the Engineer, by the contractor at his
expense. The item will cover driving the shell through all strata softer than rock.
The contractor will not be entitled to any compensation or extra rate if the depths to which
the piles are required to be driven are increased or decreased, unless specially provided
in the tender.
The contractor will be held responsible for any injury to persons and any damage that may
be caused to the work or neighbouring struc­ture or property due to the operation of driving
piles.
B.14.4 Tolerances - Utmost care shall be taken to see that the shell is driven true and
plumb or to the required batter as far as possible. Unless remedial measures are necessary
due to design re­quirements a shift up to 15 cm. in position and a cant up to 2 per 15 cm.
appropriate additional construction as approved by the Engineer shall be provided at the
contractor’s expense.
B.14.5. Reinforcement - Steel reinforcement shall conform to specification No.B.10.
Longitudinal bars of the required size, shall be assembled into a cage spiral or stirrups
accurately tied according­ly to the design or plan or according to the design of Patentee
ap­proved by the Engineer. Splicing of the longitudinal bars may be lap. The stirrups or
spirals shall be tied to the longitudinal bars with 1.63 mm. diameter (16 guage) wire. The
longitudinal bars shall extend 60 cm. over the top of the pile or as shown on the plans for
being connected to the steel of the pile cap or foundation fitting. the exposed length of
reinforcement shall not be measured or paid. After driving the shell to the required depth,
the cage of reinforcement bar shall be lowered into the shell and held in such a way that the
cage remains truly in the direction of the axis of the shell with designed cover of concrete
all round during pouring of concrete. The reinforce­ment of the cage shall be got approved
in writing by the Engineer before placing it in the shell.
B.14.6. Concrete - Concrete shall comply with specification No. B.6 for ordinary portland
cement concrete of 1:1.5:/1:2:4 proportion. The maximum size of aggregate shall be 20 mm.

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B.14.6.
The contractor shall be responsible to see that all the materials to be used including those
supplied by the Department are of specified quality at the time of use and not damaged in
storage. As the concrete is to be poured into the shell, water sufficient to allow flow of the
concrete shall be provid­ed. In case the surrounding area is dry, extra water ill have to be
added to enable water absorbed from the concrete by the ground , to be made up. The
amount of extra water will be decided by the Engineer. The ground around the pile shall
also be thoroughly wetted for 6 hours in advance of concreting and kept so for 3 days.
In waterlogged ground special care shall be taken to ensure that the soundness of concrete
is not affected due to sub-soil water.
When the concrete is being poured, compaction shall be done by approved means either
by vibrators or by vibration of the shell itself as it is being withdrawn. The bottom shell
shall be maintained not less than 30cm. below the top of the concrete during withdrawal
of shell and pouring operations, unless otherwise permitted by the En­gineer. Separation
of the concrete during withdrawal operations shall be avoided by hammering or otherwise
vibrating the shell. In the later case, separate vibration of the concrete during pouring will
not required.
Concrete shall be placed in one continuous operation/from the shoe to the correct pile cap
evaluation and shall be carried on in such a manner as to avoid segregation.
No shell may be driven nearer than 1.5 metres or 4.5 times the diameters of the pile
whichever is grater, to a pile filled within 7 days unless it is substantially proved that no
damage can take place to the pile due to vibration.
All the piles shall be cast to a level previously fixed and any extra length of pile cast above
that level shall not be paid for. This extra length of pile shall be cut carefully by chiselling
in such a way that no damage result to the pile itself. The tops of pile shall be dressed to
a plain surface. Both these operation when necessary will be carried out by the contractor
at his own cost.
B.14.7. Defective piles - If the shoe has filed before the re­quired depth is reached or the
cant and shift are more than permissi­ble, the concrete is of a poor quality the load test is
unsatisfactory or there is any defect which in the opinion of the Engineer will affect the
strength or life of the pile, the pile will be rejected or the following or other corrective methods
approved by the Engineer, shall be adopted for the pile in question at the contractor’s
expense:-
1) One or more additional piles shall be driven adjacent to the defective one to take the
designed load.
2) The pile cap shall be redesigned and extended to properly embed the piles to take
the design load.
All the pile shells pushed up by the driving of adjacent piles or by any other cause, shall be
driven down again.
B.14.8. Test of concrete - One test of three 15cm. cubes shall be made for the concrete
poured on the first day and thereafter one for every fifteen piles cast and not less than one
test of three 15cm. cubes for each week’s operations. The age of test shall be 28 days but 7
days’ test may be used if the relation between strength at 28 days and 7 days is established
by a sufficient number of test. These cubes shall be got tested in an approved laboratory.
All the expenses of materials, moulds, labour, transport, test etc., shall be borne by the
contractor. If any test cube result show strength of concrete below the minimum specified,
the piles represented by the sample shall be liable to rejected.
B.14.9. Load test -  Load test shall be carried out on the pile indicated by the Engineer.

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 B.15.3
The load test shall be carried out accord­ing to the specification No. B.17. If the test are
not satisfactory the pile may be rejected or if it is possible in the opinion of the Engineer
to adopt corrective measures by driving additional piles and redesign the pile cap such
measures will be provided by the contrac­tor without any extra cost to Department. The load
test will be paid for separately.
B.14.10. Item to include -
1) All labour, materials and use of equipment including shoes, use of driving equipment
and driving shell, concrete, reinforcement, compaction and withdrawal of the shell
required for completing the pile in all respects.
2) Compensation for any injury to persons and damage to property due to the operation
of piling.
3) Correction of defective piles.
Load test will be paid for separately.
B.14.11.Measurement and Payment - The contract rate shall be per square metre of
pile of specified diameter and capacity driven and concreted to the full depth and accepted
including reinforcement.
Quantity of cast in situ RCC, piles to be paid for, shall be actual number of linear metres of
pile cast and left in place in the completed and accepted work. He measurement shall be
made from the point of shoe of the pile to the bottom of the pile cap or bottom of the footing
as the case may be. Pile shoe will not be paid separately. Quantity will be measured correct
up to a centimeter.
The tendered unit shall apply even if the actual length is more or less than shown on the
plans or specified.

B.15. RCC. CAST IN SITU BORED PILE

Providing RCC. cast in situ bored piles of specified capacity founded on the suitable strata
including reinforcement and compaction of concrete.
B.15.1. General - Cast in situ RCC, piles shall be of the design and layout shown on the
plans or as proposed by the Patentee and approved by the Engineer. After the casing is
sunk to the required depth in a suitable hard strata or rock, the reinforcement cage shall be
lowered into the casing. Cement concrete of specified quality is then poured into the casing
and compacted and the casing gradually withdrawn.
B.15.2. Equipment - The equipment shall consists of heavy steel casing sections with
screwed ends for connection and various types of percussion or rotary boring tools for
boring and lifting the bored materials and water if any, from the casing, worked mechanically
with suitable machinery. Arrangement for driving the casings boring pro­ceeds within it shall
also be provided. The casing shall be of suit­able thickness, sufficient strength and rigidity
to permit driving the heavy hammers and to prevent its distortion due to soil pressure until
filled with concrete.
B.15.3 Driving - The boring tool shall be centred at exact pile location Boring and driving
shall then proceed alternately till the appropriate strata is reached. When the casing is
being driven in, care shall be taken to check that it is truly vertical. Sequence of boring and
driving or vice versa will depend upon the strata passed through. The item will cover boring
and driving the casing through all strata softer than rock. The contractor will not be entitled
to any compensation or extra rate if the depths to which the piles are re­quired to be driven
are increased or decreased.

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B.15.4.
Contractor will be responsible for any compensation that may have to be paid due to injury
to persons or damage to work and property caused by his pile driving operations.
When the boring is done to a satisfactory strata according to plan or as approved by the
Engineer and the casing fully driven to the required depth, all loose material existing at
the bottom of the hole after completing the operation shall be removed before pouring the
concrete.
Water may be used in the boring operations only to the extent absolutely necessary for
facilitating the boring. All necessary steps shall be taken to prevent surface water from
entering the hole and all water which may have infiltrated into the hole shall be removed
before pouring the concrete. If necessary the inside of the shell shall be inspected by
lowering the light and it should be seen that any materi­al like earth, clay, etc., sticking to
the casing is removed.
B.15.4. Tolerances - Utmost care shall be taken to see that the shell is driven true
and plumb as far as possible. Unless remedial measures are necessary due to design
requirements a shift of 8 cm. in position and a cant up to 2 % of height will be permitted. If
the cant is more than 2 % and shift more than 8 cm. appropriate remedial meas­ures by way
of redesigning the pile caps and/or driving additional piles as approved by the Engineer
shall be provided by the contractor without extra expense.
B.15.5. Reinforcement - Steel reinforcement shall conform to specification No.B.10.
Longitudinal bars of the required size shall be fabricated into a cage spiral or stirrups
accurately according to the design or plan or according to designs of the Patentee approved
by the Engineer. Splicing of longitudinal bars may be by lap. The stirrups or spirals shall be
tied to the longitudinal bars with 1.63 mm. diameter (16 guage) wire. The longitudinal bars
shall extend 60 cm. over the top of the pile or as shown on the plans for being connected
to the steel of the pile-cap or foundation- footing. The exposed length of reinforcement
shall not be measured or paid. After driving the casting to the required depth the cage
of reinforcement bar shall be lowered into the shell and held in such a way that the cage
remains truly in the direction of the axis of the shell with designed cover of concrete all-
round during pouring concrete. The reinforcement of the cage shall be got approved in
writing by the Engineer before placing it in the casting.
B.15.6. Concrete - Cement concrete shall comply with specifica­tion No. B.6. for ordinary
portland cement concrete of 1:1.5:3 propor­tion. The maximum size of coarse aggregate
shall be 20 cm. The con­tractor will be responsible to see that all the materials to be used
including those supplied by the Department are of specified quality and not damaged in
storage. The inside of the casting shall be cleaned if necessary before concrete is poured.
As the concrete is to be poured into the casting, water sufficient to allow flow of the con­crete
shall be provided. In case the surrounding area is dry, extra water will have to be added to
enable water absorbed from the concrete by the ground , to be made up. The amount of
extra water will be decided by the Engineer. Surrounding area shall also be well watered
for 6 hours before concreting and kept well watered for 3 days. In waterlogged ground care
shall be taken to ensure that the soundness of concrete is not affected by sub-soil water.
When the concrete is being poured, compaction shall be made by approved means. The
bottom of the shell shall be maintained not less than 30cm. below the top of the concrete
during withdrawal of casting and pouring operations, unless otherwise permitted by the
Engineer.
Concrete shall be placed in one continuous operation from the bottom of the bored hole to
the bottom of the pile-cap and shall be carried on in such a manner as to avoid segregation.
If water is met with, it shall be removed. If it is impossible to remove it, concrete shall be

80 RED BOOK  VOLUME I  ROADS  2012

 B.15.11.Measurement
laid by tremie.
All the piles shall be cast to a level previously fixed and any extra length of pile cast above
that level shall not be paid for. This extra length of pile shall be cut carefully by chiselling
in such a way that no damage result to the pile itself. The tops of pile shall be dressed to
plain surface. Both these operation when necessary will be carried out by the contractor at
his own cost.
B.15.7. Defective piles - If the cant and shift are more than permissible, the concrete is
of a poor quality, the load test is unsatisfactory or there is any defect which, in the opinion
of the Engineer, will affect the strength or life of the pile, the pile will be rejected or the
following or other corrective methods approved by the Engineer shall be adopted for the
pile in question at the contra­ctor’s expense:-
1) One or more additional piles shall be cast adjacent to the defective pile and so
arranged as to take the designed load.
2) The pile-cap or the footing shall be redesigned and extended to properly embed the
pile to take the designed load.
B.15.8. Test of concrete - One test of three 15cm. cubes shall be made for the concrete
poured on the first day and thereafter one for every fifteen piles cast or one for each week’s
operation whichever is more. The age of test shall be 28 days; but 7 days’ test may be used
if the relation between strength at 28 days and 7 days is established by a sufficient number
of test. These cubes shall be got tested from an approved laboratory. All the expenses
of materials, moulds, labour, transport, test etc., shall be borne by the contractor. If any
test cube result show the strength of concrete below the minimum specified, the piles
represented by the sample shall be liable to rejected.
B.15.9. Load test - Load test shall be carried out on the pile indicated by the Engineer.
They shall generally be about 1 % of the total number of piles . The load test shall be
carried out according to the specification No. B.17.
If the test are not satisfactory, the pile may be rejected or if it is possible to adopt corrective
measures by driving additional piles and redesigning the pile-cap in the opinion of the
Engineer such measures shall be provided by the contractor without any extra cost to
Department. The load test will be paid for separately.
B.15.10. Item to include -
1) All labour, materials and use of equipment such as casting, boring and driving
equipment, boring, providing concrete, reinforce­ment, compaction and withdrawal of
the casting including dewatering.
2) Compensation for any injury to persons and damage to property due to the operation
of pile driving.
3) Test of concrete.
4) Correction of defects if any.
Load test will be paid for separately.
B.15.11.Measurement and Payment - The contract rate shall be for a unit of one linear
metre of pile finished and accepted including reinforcement.
Quantity of RCC. cast in situ piles to be paid shall be actual number of linear metres of pile
left in place in the completed and accepted work. The measurement shall be made from the
bottom of the bored hole to the bottom of the pile-cap or bottom of the footing as the case
may be to correct up to one centimeter.

RED BOOK  VOLUME I  ROADS  2012 81

16.1
In case the length of the bored hole is more than pile length + 1.5 m. the length in excess
shall be paid as empty bore under a sepa­rate item.

B.16. UNDER REAMED PILES

Providing under reamed piles dia. with single/double bulb.
16.1 General - The under reamed pile shall be of the dia as specified in the working of the
item and shall have single or double bulbs as indicated in the working of the item. these
piles shall be form by suitable equipment as per the requirement of IS 2911 (Part III) -1980.
B.16.2 Equipment - The piles shall be formed by manual operation of the equipment which
shall comprise
a) An auger
b) An under-reamer with bucket
c) Boring guide
d) Accessories like extension rods, cutting tool, rotating bar, concreting funnel etc.
e) portable tripoid, hoist with manually operated winch.
B.16.3 Boring - The hole shall bored by auger operated manually care shall be taken to
see that the bore is vertical. For softening the soil water may be used to small extent at the
bottom of the hole. Harder lumps etc shall be knocked by cutting tool. The augured material
shall be carried to a safe distance beyond the work area and disposed off or stacked
as directed. The bore shall extend to the depth as per the design. In the absence of the
mention the depth shall be as per the table included in the specification. The boring shall be
done taking due care to avoid accidents or injury. The contractor shall be fully responsible
for any injury to any person or damage collapse of bore etc. Extra boring if any done shall
not be filled. But shall be con­creted. The contractor shall not be entitled for payment for
such extra length.
B.16.4. Forming Bulb - The bulb shall be formed as per the design requirement or
accompanying guide lines as directed by the special equipment. Care shall be taken to see
that no loose soil spills the bucket. Such spilled soil shall be promptly removed by auger. In
case of two bulbs the upper bulb shall be formed when the length of the bore reaches the
required level which shall not be the full length. the upper bulb will be formed by the under
reamer. After the upper bulb is formed further boring of the hole shall be continued to reach
the final level. Care shall be taken to see that the upper bulb is not damaged during the
further operations.
The boring and forming bulb for particular pile shall not be done as a continuous operation
and no bore or fully formed pile bore in­cluding bulbs left unconcreted for long period. The
concrete shall be any case be done before the walls of bores dry up tending to scaling of
soil. In any case the concreting shall not be postponed beyond 5 days of boring of the hole.
However if any collapse of bore hole side or other damage takes place due to the hole
remaining unconcreted it shall be the responsibility of the contractor and he shall not be
entitled for any compensation.
B.16.5. Tolerance - The pile shall not deviate more than 75 mm from the centre. The
tolerance for verticality shall be 1.5%. Rectification or revision of the design may be
necessary due to defective piles not conforming the requirements. Any such modification
as may be directed by the Department shall be carried out by the contractor at his cost.
B.16.6. reinforcement - The steel bar reinforcement shall be as per the design. In the

82 RED BOOK  VOLUME I  ROADS  2012

 B.17.1.
absence of design the steel shall be provided as per the details in this specification. The
steel shall be measured and paid for sepa­rately. The fabrication of reinforcement shall
conform to specifica­tion No. B.10.
B.16.7. Concreting - The concrete shall be 1:2:4 concrete and shall conform to specification
No. B.6.
Before starting concreting any loose material at the bottom of the hole shall be cleared. The
reinforcement cap shall be lowered in the hole. Care shall be taken to see that the cage
does not rub against the wall causing falling of soil from the wall. The cage shall be suitably
hung from the ground level to obtain a minimum cover of 50 mm at bottom. The side cover
shall be 20 mm. The concrete shall have adequate slump to allow easy placing through
the funnel. Sufficient water shall be used so that the loss of water due to absorption by soil
is compensated. The surrounding area shall be watered for 3 days. The concrete shall be
placed carefully so as not to disturb the bore hole wall. Gentle tamping shall be done by
rod to obtain dense con­crete. The concrete shall be suitably pushed side ways to avoid any
hollows being left beyond the cage.
B.16.8. Load Test - Load test if ordered due to suspected defect shall be car­ried out as
directed. The cost of the test shall be borne by the contractor if the pile is found defective.
The cost of the test shall be borne by the Department if the pile is found to be acceptable.
Any rectification required due to defective piles shall be carried out by the contractor at his
cost as approved by the Department.
B.16.9. Item to Include -
1. All labour, materials (excluding reinforcement),use of equipment.
2. Extra length of pile due to contractors default.
3. Compensation due to injury or damage.
4. Load test of pile if the pile is proved to be defective.
5. Correction required due to defective pile.
B.16.10. Measurement and payment - The contract rate shall be for one metre length of
pile excluding steel reinforcement. the length shall be measured from bottom of the bore
hole (restricting the length to design length) to the bottom of the ground beam. The length
shall be measured correct upto one cm.
B.16.11. Details of under reamed piles

Dia. Size Underreamed Length Reinforcement

in cm. dia. in cm.
single double Longitudinal 6mm
Rings
20 50 3.5 m 3.5 m 3 of 10 mm 18mm c/c

25 62.5 3.5 m 3.5 m 4 of 10 mm 22mm c/c
30 75 3.5 m 3.5 m 4 of 12 mm 25mm c/c
37.5 94 3.5 m 3.75 m 5 of 12 mm 30mm c/c

B.17. LOAD TEST OF PILES

Carrying out loading tests of pile or pile group including con­struction of test caps, accessories
and instruments, dismantling the caps after test, etc., complete.
B.17.1. General - The load test shall be carried out on any particular pile or pile-group

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B.17.1.
selected by the Engineer after period of not less than 28 days after casting. The load test
shall be carried out by applying a series of test loads as specified below on a test cap or
suitable platform over the pile or group of piles unaided by any other support. Direct loading
or application of pressure by hy­draulic jacks with gauges or any other suitable methods
may be adopted as approved by the Engineer. Before any load test is made, the pro­posed
apparatus and procedure shall be got approved by the Engineer. Readings shall have to
be recorded with the help of deflectometers from to sides of the cap or platform, precision
levels or any other suitable device approved by the Engineer. Reference points for measur­
ing pile settlement shall be sufficiently removed from the test pile to preclude the possibility
of disturbance. A complete record of all load test shall be filed with the Department.
B.17.2. Procedure of test - The pile or pile-group to be tested shall be loaded by a method
which will maintained constant load under increasing settlement. The test load shall be
150% of the proposed safe working load on the pile or the pile-group. The load shall be
applied in equal increment of 10 tonnes at interval of half an hour till the full test load is
reached. Full test load shall remain for a period of 48 hour. During the period of test, careful
observation shall be made for settlement taking place before and after each incre­ment of
load.
The test load shall be removed in decrements not exceeding 10 tonnes with intervals of
not less than 15 minutes. The rebound will be recorded after each decrement. The final
rebound shall be recorded 24 hours after entire test load has been removed. Reading of
settlements and rebound shall be referred to a pucca Bench Mark. These shall also be
recorded to 0.25mm for each increment or decrement of load by means of deflectometer.
The contractor shall himself arrange to provide the necessary loads, R.S. joints, apparatus,
test caps or platform and all other materials and equipment, power and labour necessary
for successfully carrying out the test to the satisfaction of the Engineer. The contractor shall
be responsible for any injury to the life and property, if any, caused during or due to the test.
After the test load is removed, the head of the pile should be carefully examined for any
damage. Damage, if any, shall be made good to the satisfaction of the Engineer.
If the pile fails to comply with the requirement, due to defec­tive pile or defective driving, the
pile will be rejected unless it is possible to carry out effective remedial measures which will
be done at the cost of the contractor. The cost of testing such defective piles shall be borne
by the contractor.
In the case of precast piles, if the piles sink under test load due to weak strata, the pile shall
be extended and driven to the required depth to obtain the specified loading capacity.
B.17.3. Item to include -
1) Building up of test cap or platform or any other arrangement approved by the Engineer
for satisfactorily loading of the pile or pile-group with the test load and removal.
2) Necessary suitable material for loading in specified batches up to the total test load
or necessary arrangement for applying the test load by hydraulic jack with suitable
yokes and tested pressure gauges.
3) Suitable apparatus for accurately measuring the test load, the settlement or rebound
of the pile under each increment or decrement of load.
4) All labour, equipment, power, material incidental to making the loading test satisfactorily
as directed by the Engineer.
5) If the reinforcement bars projecting beyond the top of the pile are required to be cut
for test purposes, the item will include chipping off the pile to the required length to
uncover the reinforc­ing bars for securing sufficient lap length for the bars required to

84 RED BOOK  VOLUME I  ROADS  2012

 B.18.(a).I.
be added and rebuilding the pile to the required level, curing, etc.
6) Clearing the site after test.
B.17.4. Measurement and payment - Test one pile or pile-group shall be measured as
one test and payment will be made at the rate quoted in the tender for one loading test.

B.18. WELDING
B.18.1. General - The specifications given hereunder shall apply to welding as applied to
new and existing mild steel structures and mild steel reinforcement for R.C.C. work welding
may be adopted in R.C.C. work in the following cases :-
a) Fillet welding for placing the reinforcement in correct posi­tion or for providing cross
bars in lieu of hooks.
b) Butt welding for reinforcing bars. Welding shall be made by the metal process unless
oxyacetelyne gas welding is specially permit­ted by the Engineer in writing. The
specifications for the former have been given in B.18.(a) and for the later in 18.(b).
B.18.2. Welding contract -
1) The welding work shall not be given to a contractor who does not produce satisfactory
evidence of his ability to handle the work in competent manner. The contractor
shall also prove the ability of the operators employed by him to produce welding
connection of the re­quired strength.
2) The contractor shall employ a competent welding supervisor or charge-hand to ensure
that the standard of workmanship is satisfac­tory.
3) The Engineer shall have a free access to the work being car­ried out by the contractor
at all reasonable times and facility shall be provided so that during the course of
welding he may be able to inspect any layer of weld metal. He shall be at liberty to
reject any work not conforming to the relevant specifications; defective welds shall
be cut out and rewelded.
B.18.3. Safety requirements and health provisions - The contrac­tor shall make all safety
and health provisions for his welders as are laid in I.S. 818-*** i.e. code of practice of safety
and health re­quirements in electric and gas welding and cutting operations.

B.18.(a). METAL ARC WELDING

B.18.(a).I. Metal arc welding in structural work -
Material - Electrode - Electrodes used for strength welds shall conform to I.S. 814-****.
They shall be of shape and size approved by the Engineer. They shall be preserved from
oxidation and shall be kept in clean condition.
Welding - The size of the weld and the position where the weld shall be placed shall be
entirely as per the drawing supplied or as directed by the Engineer.
Design of welds, drawings , permissible stresses in welds, weld­ing in compression and
tension members, welding in plate girderd lacing, battening, weld equipment, electrodes
shall be as per I.S. 816-****. Code of practice for the use of metal arc welding for gener­al
construction in mild steel.
Welded fabrication of structural steel shall be on the lines given in I.S. 800-1962.
The following instructions shall also be followed from point of view of workmanship :-
1) Welders and work shall as far as possible be protected from wind and weather.
2) Welds should be made flat in position wherever possible.

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B.18.(a).II.
3) Adequate steps shall be taken to maintain the correct arc length, rate of travel, current
and polarity for the type of electrode and nature of work.
4) Structural steel shall not be painted or oiled on any areas where welding is to be done
and shall be well cleaned to remove any paint, scab, rust and expose original clean
metal surface immediately before welding.
5) The member shall be securely held in positions by means of tack welds, service bolts,
clamps or jigs before commencing welding so as to prevent relative movement due
to distortion, wind or other causes. When the wind or manual handling is liable to
cause distor­tion, the work shall be securely held in approved frames or jigs.
6) Freedom of movement of one member of the joint shall be al­lowed wherever possible.
No butt joint shall be welded without allow­ing one component freedom of movement
of the order of 2 mm.
7) The sequence of welding shall be such that when possible, the member which offers
greater resistance to compression are welded first.
8) The welding of the joint shall be so arranged that resulting tensile and compressive
stress produced by each portion of the weld tend to balance each other. The step
back method shall be adopted for continuous run.
9) Fusion faces must be cut to the required shape by shearing, chipping, machining
or machine gas cutting. Hand cutting by gas may be substituted for machine gas
cutting only if the latter is impractica­ble; the cutter shall be adequately guided so that
the cut edge is clean and uniform If the fusion face is rough it shall be dressed by
chipping, filing or grinding in a satisfactory manner.
10) Welds showing slag, inclusions, porosity or lack of proper penetration shall be cut
out and rewelded. Overlap of the toe of the weld and under cutting of the parent
metal should be avoided and where present to a serious extent shall be rectified.
11) All slack shall be removed from each run before another run is superimposed and
from the final run. When cold, the final run shall be protected with cleaned boiled
linseed oil and shall not be painted until approved by the Engineer.
12) Grinding of finished weld is permitted provided the weld is not reduced below the
prescribed section.
13) All welds which have not been ground shall be scrubbed with a 10% solution of
hydrochloric acid which shall be satisfactorily washed off with water before the paint
is applied, unless alkali resistant paint is used.`
B.18.(a).II. Metal arc welding of M.S. bar reinforcement in RCC. works -
Materials - Electrode shall comply with I.S. 814-****. They shall be of shape and size of as
approved by the Engineer. They shall be preserved from oxidation and shall be in clean
condition. Electrode shall be of heavy coated type The electrode shall satisfy the follow­ing
mechanical properties :-
a) Ultimate strength not less than 44 kg./sq.mm.
b) Yield point not less than 31 kg./sq.mm.
c) elongation of a length equal to 3.54 times the diameter of the rod, not greater than
20%, and
d) Izod impact test 4kgm.
Maximum size of electrode shall be based on following table: -

86 RED BOOK  VOLUME I  ROADS  2012

 B.18.(a).II.
Maximum size of Amperage corrosponding to
Diameters of bars in mm. Electrodes Max. size of mm. Electrodes
(1) (2) (3)
S.W.G. mm.
12 to 25 10 3.25
25 to 32 8 4.06 As specified by
10 3.25 the manufacturer
32 to 50 10 3.25 of Electrodes.
8 4.06
25 to 50 8 4.06
6 4.88
The forms of butt weld shall be made in one of the following form :-

No. Type Diameter Minimum gap. Angle of V Root face Details

range in mm.(g) (a) (E) of welds
mm.(D)
(1) (2) (3) (4) (5) (6) (7)
Single V
1 12 to 40 D/4 60 to 70 None
Butt weld
Double V
2 Butt weld 3 to 6 --- 60 to 70 None
28 and above
The form and dimensions of weld surface shall be such as will provide access for the
electrode to be welded and enable the welder to see clearly the work in progress.
A butt weld shall be built up so that the effective throat dia­meter is greater than the diameter
of the bars joined. such increase in diameter shall not be less than 10% and not more than
25% of the diameter of the bars joined. Such increase in diameter shall not be less than
10% and not more than 25% of the diameter of the bars joined.
Workmanship -
1) The surface to be welded and the surrounded material for a distance of at least 12 mm.
from the weld shall be freed from scale and cleaned so as to remove dirt, grease, paint,
heavy rust or other surface deposit, wire brushing being used necessary.
2) Fusion faces must be cut to the required shape by shearing, chipping, machining or gas
cutting.
3) All the bars to be butt welded should be aligned and set in position with their axes in
one straight line. This should be done either by wiring to the other reinforcement or by
attachment in a jig or clamp or by use of standards and guides and chairs on a prepared
platform. One of the bars shall have freedom of movement in the direc­tion of its axis to
avoid residual stresses. Turning or rotating the bar till half the bar is welded should be
avoided. Turning or rotating the bar shall be done without disturbing the alignment and
without introducing any twist in the bar during the process of welding.
4) The welding current shall conform with respect to voltage and amperage (and polarity if
direct current is used) to the recommenda­tions of the manufactures of the electrodes being
used. The arc length, voltage and amperage shall be suited to the diameter of the bar to
be welded.

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Test
i) A single layer of weld metal whether deposited on one pass or made up of several
parallel beads shall not exceed 3mm. in thickness.
ii) The electrode manipulation during welding shall ensure that,-
a) complete fusion between the base metal and the deposited weld metal is obtained.
b) the melted base metal is replaced by the weld metal so that no under cut remains
along the edges of finished welds,
c) the melted weld metal makes all slag, oxide and gases float to the surface behind the
advancing arc. All the slag should be removed from each run before another run is
superimposed and from the final run by hammering lightly and wire brushing.
d) full penetration into the root of the weld is obtained, and
e) surface of the weld shows regular and even ripples and edges of the weld merge
thoroughly with the base metal.
5) Welder shall be provided with such staging and necessary, with protection as will
enable them to perform the welding operation prop­erly.
6) All welding shall be in good condition and capable of enabling the welder to provide
and maintain the correct arc at all times.
Test - Two welds in 100 welds or a minimum of two welds shall be made on the site on test
pieces under condition exactly similar to the field welding of actual reinforcement bars and
tested for their strength. The strength of the welded joints shall not be less than that of the
original bar i.e. failure shall be in the parent metal and not in a welded joint.
If the tests are not satisfactory change in welding procedure or personnel may be ordered
by the Engineer. Bars welded along with the welded samples found unsatisfactory on test
shall be cut and rewelded. The test shall be got made at the cost of the contractor.

B.18.(b) Oxyacetylene Welding -

B.18.(b).I. Oxyacetylene welding in structural steel work -
Material - Filler rods - Filler rods shall conform to I.S. 1278-****. They shall be preserved
from oxidation and shall be in a clean condition.
The design method of welding, workmanship in oxyacetylene welding shall be as per I.S.
1923-****, code of practice for oxyacetylene welding for structural work in mild steel. The
instructions given in B.18(a) regarding workmanship shall also be adhered to in this type
of welding.
B.18.(b).II. Oxyacetylene welding for M.S. reinforcement bars in R.C.C. work -
Materials - Filler rods - Filler rods shall conform to I.S. 1278-****. They shall be preserved
from oxidation and shall be in clean condition. They shall satisfy the same mechanical
properties as mentioned for electrode in B.18.(a)II.
Welding - Shapes of the ends of the bars at the weld shall be the same as laid down in
B.18(a)II. unless other shapes are permitted by the Engineer in writing.
Workmanship - Same as for B.18.(a).II in all relevant particu­lars.
Test - Same as for B.18.(a).II.

B.19. STRUCTURAL STEEL WORK

B.19.1. General - This specification covers the requirements of providing fabrication and
erection of structural steel work including painting.
B.19.2. Materials - Structural steel sections - This shall comply with specification No. A.10.

88 RED BOOK  VOLUME I  ROADS  2012

 B.19.9.
Rivets - Shall conform to I.S. 1148-**** and I.S. 800-**** .
Bolts - These shall comply with I.S. 1148-**** and I.S. 800-****.
B.19.3. Fabrication and erection - Cutting, holding, assembly, riveting, machining,
bending, marking and erection shall be carried out in accordance with approved plans and
as directed by the Engineer from time to time and shall comply with I.S. 800-****
B.19.4. Damaged members -  any material found damaged or defective shall be stacked
separately and shall marked in distinctive colour. Such material is to dealt with expeditiously
under the orders of the Engineer.
B.19.5. Riveting, welding and bolting –
1) Riveting or welding shall not be started until such time as the Engineer as personally
satisfied himself that the alignment is correct, the vertical plumb, the camber correct
with all camber jacks screwed tight, all joints and cover plates fixed tight with service
bolts and filled rivet holes coinciding. While assembling, holes in different components
shall be made concentric with the use of drifts before service bolts are fixed.
2) Welding if required to be done, shall conform to specification No. B.18.
3) All permanent machine-fitted or other bolt must be perfectly tight and should be burred
or otherwise checked, to prevent nuts from becoming loose. No unfilled rivet or bolt
hole are to left to any part of the structure.
4) Fitting and riveting (or welding) of connections of steel section, in cases where pieces
are short or of full length shall be done in such a manner that the metal not unduly
strained or cracks caused.
5) Care shall be taken to see that cracks are not filled with paint, putty, cinders, dirt, oil
or fillings for the purpose of decep­tion.
6) Particular care must be taken to ensure free expansion and contraction wherever
provided for in drawings or as the Engineer directs.
7) Chipping of rivets, angle flanges, and edges of plates must be done without breaking
out the metal. Chipped edges shall be fin­ished off with a file and all concave corners
shall be rounded off.
B.19.6. Painting - Painting shall generally comply with I.S. 800-**** and I.S.1477(Part I)-
**** subject to such additions or altera­tions as may be prescribed in the special provisions
for any particu­lar item. It shall also comply with relevant part of specification No. B.21. One
priming coat of red lead shall be applied immediately after fabrication. Two coats of oil paint
of approver shade shall be applied after complete erection.
Structural steel work to be encased in concrete shall not be painted
B.19.7. Inspection and testing - These shall be carried out in conformity with I.S.800-****.
B.19.8. Item to include -
1) The item shall include supply fabrication and erection in position at site of all
structural steel sections of the required dimensions and labour, materials, and
use of equipment required for all operations of fabrications, hoisting, erection and
satisfactory completion of the item.
2) Item shall also include labour, materials and use of equipment required for painting
the structural steel work.
B.19.9. Mode of measurement and payment - The contract rate for the item shall be one
quintal or one tonne.

RED BOOK  VOLUME I  ROADS  2012 89

B.20.1.
In the case of rolled sections length shall be measured correct to a cm. and weight
calculated on the standard weight per metre tabu­lated in the I.S.I. Hand Book for structural
steel sections limited to the length shown on the plans correct up to 0.10 of Kg. weight of
steel plates of each thickness shall be calculated separately on the basis of actual shape
provided without taking in to account wastage or cut off. In case of bolted work, weight of
bolts, nuts, and washers, shall be added in full and no deduction shall be made for bolt
holes. In riveted work only the weight of rivet heads shall be added. No deductions shall be
made for rivet holes. No increase in weight shall be allowed in welded work due to welding.

B.20. GENERAL WOOD WORK

B.20.1. General - The specifications refer to wood work in gener­al, including carpentry
and joinery work in roofs, floors, verandahs, staircases, door and window frames, bridges,
coffer dams, shores, struts, large gates, etc.
B.20.2. Materials -
1) Timber shall comply with specification No. A.12 in all re­spects.
2) Species of timber - The species of timber to be used shall be mentioned in the items.
Where no species is mentioned, good Indian teak (Tectona Grandis) alone shall be
used. In case a particular jungle wood species has to be changed the Engineer’s
decision about the alternative shall be final.
Engineer may inspect all logs and scantling previous to use and reject any which he
consider defective in the requirement of specifi­cation.
3) Glue - Glues are of two types (i) organic type which glue shall be from skin or bone
material, and (ii) synthetic type. It shall be such material that it may be used without
causing harm and odour. A freshly prepared hot solution shall be of a clear amber
colour, trans­lucent, free form black or cloudy spots and shall swell considerably
when immersed in cold water without dissolving.
Organic type shall comply with specification No. I.S. 852-**** and synthetic shall comply
with I.S. 851-**** in all respect.
4) Nails, Screws, etc - Nails, screws, ties, straps, bolts, etc, shall of the material, make the
pattern specified in the item or the special provisions and approved by the Engineer.
B.20.3. Precaution against decaying -
B.20.3.(1) The contractor must be in all cases obtain order from the Engineer regarding
time at which he shall do painting or oiling to wood work and permission of the Engineer
before he paints, oils or otherwise treats wood work.
B.20.3.(2) All parts of woodwork resting on or set in masonry shall be well painted with
2 coats of hot boiled tar approved by the Engineer. The tar shall be so applied as not to
appear on the exposed timber. No extra payment shall be made for such tarring. Timber
buried in the ground shall be well coated with tar
When the end of a beam or joist is embedded in masonry and air space of 6 mm. shall
be left at the end and sides wherever practicable and necessary in the opinion of the
Engineer.
B.20.4. Workmanship - All woodwork shall be neatly and truly finished to the exact
dimensions required. Unless otherwise required in the special provisions, woodwork which
will remain exposed to view when the work is completed shall be accurately planed to the
required dimensions perfectly smooth and to lines, planes or curves as re­quired. Unless
otherwise specified all joints shall be simple tenon and mortise joints with the end of the
tenon exposed to view. All mortise, tenon and other joints shall fit truly and fully without

90 RED BOOK  VOLUME I  ROADS  2012

 B.20.9.
wedging or filling, in a workmanlike manner. Only where specially required, the end of the
shall not show. All joints shall be of the types shown on the drawing or specified for the item
and as directed by the Engineer. Where no specific instructions are given to the contractor,
he shall observe the following principles in forming joints :-
1) To cut the joints and arrange fastenings so as to weaken as little as possible the
pieces of timber they connect.
2) To place each abutting surface in a joint as nearly as possi­ble perpendicular to the
pressure it has to transmit.
3) To form and fit accurately ever pair of surfaces that come in contact.
All framed joinery, for external work shall be put together with white lead and joints pinned
with hardwood or bamboo pins. for inter­nal work where joints are not likely to be affected by
moisture, the joints may be glued and similarly pinned. Where ordered, the butt joints shall
be cross tongued and tongues cut at right angles or diagonally to the grain of the wood. All
moulding shall be cleaned and accurately finished and all metres, etc., shall be properly
met. Where turning is required it shall be done to the exact shapes shown in the drawings.
B.20.5. Framing - Framed woodwork includes all sawing, cutting, planing, jointing, framing,
supply and use of all straps, bolts, hold fasts, nails, trenails, spikes, screws, etc., necessary
for framing and fixing.
Framing and trussing are to be done in the best possible manner and all necessary ties,
straps, bolts, screws, etc., fitted as shown on the drawings or as directed by the Engineer.
Holes of correct size shall be drilled before inserting screws. Driving in or starting the
screws with hammer is prohibited. All screws shall be dipped in oil before inserted in the
wood. the kind of nails and screws shall be to the approval of the Engineer. The heads of
nails or screws shall be sunk or dealt with as the Engineer may direct.
B.20.6. Scaffolding - The contractor will provide all labour, scaffolding ladders and tackle
necessary for hoisting and fixing wood­work in position and afford facilities for its inspections
during constructions. He is also responsible to see that the tackle and scaffolding, etc., are
of the requisite strength and that the work is secured in a proper manner during inspection.
The contractor shall be responsible for the safety of the work, workman and for action or
compensation that may arise in this connection.
B.20.7. Iron work - All iron-work connected with woodwork and going to be embedded in
masonry shall before erection, receive 2 coats of hot coaltar. If it is to be painted, it shall
be given t5he first 2 coat on the ground before being fixed in position and the third coat
afterwards.
B.20.8. Precautions against fire - No woodwork of any kind shall be laid within 60cm. of
a fire place or fuel. During the progress of work all shavings, cutting and other rubbish shall
be cleaned away as the work progresses, and all precaution shall be taken against fire. No
rubbish shall be left under floor boards or in other concealed position on the job.
B.20.9. Inspection - All woodwork shall be inspected and pass by the Engineer before
being put in to the work. The Engineer shall not be barred from rejection any wrought timber
on account of defective quality by reason of his having previously passed the same before
had been worked upon. In no case woodwork shall be painted or otherwise treated before
it is inspected and approved by the Engineer.
All woodwork in a building shall after it has been passed by the Engineer, have the primary
coat of paint put on or otherwise treated before being fitted in position. The subsequent
coat of paint or other finish shall be applied after the woodwork is fixed in position.

RED BOOK  VOLUME I  ROADS  2012 91

B.20.10.
B.20.10. Defective-work - If within three month after the work is completed any under
shrinkage or bad workmanship is discovered the contractor shall forthwith replace or refix
the same to the satisfac­tion of the Engineer without extra charge.
B.20.11. Item to include –
(1) Supply of specified species of timber sawn to requisite sizes without any defect,
wrought, framed and fixed in position with the required standard of workmanship
including supply and fixing of fixture, straps, bolts, holdfasts, spikes, nails, screws,
etc., applying contractors glue or other joining material, coal-tarring embedded parts
and painting joints.
(2) All material, labour. scaffolding, use of equipment etc., for forming and fixing and
completing the item as specified.
(3) Applying two coats of double boiled linseed oil to internal woodwork unless other
types of finishing is specified in the special provisions.
B.20.12. Mode of Measurement and payment - This will depend upon the item in the
tender for which woodwork is executed. All woodwork when put up shall be of the dimensions
shown on the drawings or as directed by the Engineer. Woodwork will be paid by net
measurements and no allowance will be made for wastage or for dimensions supplied
beyond those specified. But the length of each piece shall be measured overall so as to
include projection for tenons or scarfs. For curved pieces cut out of the solid, the minimum
overall dimensions of the required original rectangular section of scantling will be allowed
in the measurements. The3 dimensions of sectional measurement shall be taken correct
up to 2mm. and the length will be measured correct up to places of decimal of a metre. The
quantity shall be calculated to three places of decimal of a cubic metre. When the schedule
calls for supply of wrought timber, the rate shall as in all other cases include carriage to and
delivery at the site of work.

B.21. OIL PAINTING

B.21.1. Material and accessories -
B.21.1.1. Oil paints - Oil paints shall conform to specification No. A.17. All paints shall
be thoroughly stirred with a clean stick before use. While being used the paint shall be
stirred often to keep the pigment in uniform suspension. Ready mixed (factory mixed)
paints only shall be used unless other type are specifically mentioned. Sample colour
boards shall be prepared by the contractor and got approved by the Engineer before
painting is started.
B.21.1.2. Brushes - Unless other methods of application like spraying are specified paint
shall be applied with brushes. On no account shall be rags be used in the application
of paints. The size of brushes to be used for painting of various works shall be got
approved by the Engineer. All brushes shall be either round or oval shaped. Flat brushes
when specifically authorised by the Engineer in writing shall not be over 8cm. wide.
B.21.1.3. Containers - The paint while being applied shall be kept in shallow pans and
not in deep cans and must be kept well stirred. All paint cans must be cleaned out at the
end of each day’s work.
B.21.2. Scaffolding - Scaffolding if necessary shall be as per B.9.11.
B.21.3. Precautions in using lead paints –
(1) White lead, sulphate and all products containing those pigments (but not while
pigments containing not more than 2 per cent. of lead) shall be used in internal
painting of building except for priming coat and artistic painting or fine lining work.

92 RED BOOK  VOLUME I  ROADS  2012

 B.21.(a)
They shall be as far as possible used in painting operations in the form of paste or
ready mixed paint and measures shall be taken whenever practicable, to prevent
danger aris­ing from the application of the paint in the form of spray or by dust caused
by rubbing down and scraping.
(2) Paint workers must be warned to avoid getting smeared with the above paints.
B.21.4. Cleaning - Cleaning operations shall precede painting so that paint may be
applied to clean surfaces. The work shall be carried out in such a manner that dirt and
matter removed by cleaning will not come in contact with freshly applied paint. The method
to be applied for cleaning and preparing surfaces for painting shall be mentioned in the
specifications for each type of surface. When not so mentioned, any suitable method
approved by the engineer for exposing the original surface without damage shall be adopted.
B.21.5 Application - The primer coat of paint shall be applied as soon as possible after
the surface has been cleaned before deteriora­tion of the surface by rust(in case of steel
surfaces) and contamina­tion of the surface by dust, dirt or any other foreign material for all
surfaces. Preferably painting should be done immediately; after cleaning on the surface
with salts, acids, alkali or other harmful materials before the painting coat is applied and
between the applica­tion of the remaining coats of paints, the surfaces shall be cleaned
again.
Paints shall not be applied when the air is misty or atmospheric conditions are such as
to promote condensation or in the opinion of the Engineer, the conditions are otherwise
unsatisfactory for the work. Painting shall normally be done only in dry weather. It shall not
be applied upon damp and moist surfaces:
Spraying or bushing may apply paint. Unless otherwise specified paint shall be applied with
brushes. Paint shall be worked into all crevices and corners where possible and surfaces
not accessi­ble to brushes shall be painted by sheepskin or spray or any other method
approved by the Engineer. All runs or sags shall be brushed out. Painting shall be one in
a neat and workmanlike manner. Paint shall be applied so as to produce a uniform even
coating over the entire surface, free from streaks, pitting, wrinkles or other irregu­larities.
The number of priming and finishing coat shall be as specified for the particular item.
Sufficient time shall be allowed for one coat of paint to dry before the next is applied.
B.21.6 Protection - Painted surface shall be protected from sun, rain, condensation,
contamination or surface damage until it is dry to the fullest extent. Boards indicating “ Wet
Paints” shall be put up where necessary.
B.21.(a) Painting Iron and Steel work - In addition to specifi­cations for oil painting “ General”
the following shall apply for painting Iron and Steel Work:-
B.21.(a).1.  Operation and workmanship for painting Iron and Steel work shall be as
per I.S. 1477 (Part I)-1959. code practice for fin­ishing of Iron and Steel in Buildings,
painting and allied finishes : subject to the following:-
(1)  The method of preparation of the surface for paint­ing shall be as specified in the
special, provisions for each item and as in B.21.4. Where Iron and Steel woks need
repainting ( as main­tenance), instructions detailed in clause 8 of I.S.1477 (part I)
shall be followed.
(2) Red lead paint shall be used for primer coat unless other paints are specified. The
number of primer coats shall be given in detailed specifications for each item. When
not given it shall be one coat.
(3) Intermediate protective treatments ( pre-treat­ments) shall be omitted unless specified

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B.21.(b).
in the special, provisions.
(4) The finishing coats shall be of the paint as speci­fied for each item by the Engineer.
The number of finishing coats of the required shade of colour shall also be specified
for each item separately. They shall be two when the number is not specified.
(5)  Actual date of painting girders, steel tanks and other steel structures shall be
neatly marked by the contractor on the structure according to the instructions of the
Engineer.
B.21.(b). Painting New Wood Work - In addition to specifications for `oil painting General`,
the following specifications shall also apply for painting new woodwork:-
B.21.(b).1. Paint shall not be applied to a woodwork which is not well seasoned. The
surface to be painted must be thoroughly dry, clean, and smooth Woodwork must be
passed by the Engineer before any paint is applied.
B.21.(b).2. Preparation of surface - Before any paint is applied the woodwork shall be
finished smooth with the plane. The surface shall then be rubbed smooth with sand
paper first with coarse grade about 2+1/2 and then finished with a medium grade paper
say 1+1/2. Sand papering must be finished with grain. when finished, no scratches from
the coarse paper should show.
 Before priming coat is applied, the knotting shall be done by one of the following
methods as directed by the Engineer:-
(1) Ordinary or size knotting:- This shall be applied in two coats. the first to be made by
grinding red lead in water and mixing it with strong glue size, used hot. The second
coat shall be of red lead ground in linseed oil and thinned with boiled linseed oil and
turpentine.
(2) Lime coating:- Cover the knot with hot lime and leave on for 24 hours; then scrape
off and coat the surface with size knotting as above.
(3) Patent knotting:- This consists of 2 coats of a varnish made by dissolving shellac in
methylated spirit of wine.
B.21.(b).3 Printing coat - After preparing the surface of wood­work as above, priming
coat shall be applied.
Priming coat shall be as follows:-
(a) On inside woodwork:- It shall consists of 0.25 kg of red lead + 4 kg of white lead +
1.14 litres of boiled linseed oil + 0.57 litre raw linseed oil + 40 gm. of litharge or patent
driers and shall be applied before the woodwork is fixed in place.
(b) On outside woodwork:- It shall consists of 4.5 kg of white lead + 2.28 litres of raw
linseed oil + 27 gm of red lead + 54 gm of litharge or patent driers and shall be
applied before the wood­work in fixed place.
B.21.(b).4. Stopping - After priming, all small holes, cracks, open joints and similar
minor defects of every kind if already allowed by the Engineer to remain, shall be stopped
with putty made from pure whiting mixed to the proper consistency with raw linseed oil,
a little white lead being worked in after mixing to help the hardening of the putty. On no
account putty is to be used before the priming coat is put on.
B.21.(b).5. Additional coats -  After applying priming coats, the work shall be lightly
rubbed down smooth with sand paper and the subsequent coats of paint of the specified
shade approved by the Engineer, shall be applied. The paint shall be applied with
brushes. It shall be spread as smoothly as possible with brush by means of crossing
( at right angles to the grain) and then laying of with the brush in the direction of the

94 RED BOOK  VOLUME I  ROADS  2012

 B.21.(d).4.
grain over the crossing. the final coat shall be very carefully crossed and laid off so that
the brush marks are not visible. Each coat of paint shall be allowed to dry thoroughly
and shall lightly rubbed down before the next is laid. Every coat shall be passed by the
Engineer before the next is laid on it. The finished surface shall not show any hair marks,
ridges, or dry patches of paints, and no puddles shall be left in the corners of panels,
and angle of moulding.
 For new wood work exposed to the weather unless the number of coats of paint is
mentioned in the special provisions three coats of paints shall be applied exclusive of
the priming coat. In the interior of the building 2 coats shall suffice.
B.21.(b).6. Embedded timber - The outsides of the chowkats of the doors and windows
as also other timber embedded in masonry shall be given two coats of hot coal-tar
before erection. This is incidental to the item and shall not be paid separately.
B.21.(c). Repainting old wood work - In addition to specification for “ oil painting General
“ the following specification shall also apply for repainting old wood work:-
B.21.(c).1. Cleaning the surface - All the paint shall be re­moved either by scraping,
burning or by a paint remover as ordered by the Engineer. Following precautions shall
be taken :-
(1) While removing paint by burning by using a blow lamp, particular care shall be
taken to avoid burning wood work. If any wood work is found to be charred it will be
replaced at the cost of the contractor.
(2) In the event of a paint remover containing alkali being used, the surface, shall
subsequently be washed down with a weak acid such as dilute vinegar, so as to
neutralise he alkali.
(3) While removing paint by scraping, care shall be taken not to damage the underlying
surface of wood.
The surface shall then be rubbed down smooth with sand paper.
B.21.(c).2. Priming coat - the priming coat shall then be ap­plied as specified for
painting in B.21.(b).
B.21.(c).3. Stopping - After priming, the defects shall be stopped with putty .
B.21.(c).4. Finishing -  The surface shall again be lightly rubbed smooth with sand
paper and specified number of coats of required shade of paint shall then be applied as
specified above or ordered by the Engineer.
B.21.(d). Painting plastered surface - In addition to the speci­fications for “ Oil painting
General” the following specifications shall also apply for painting plastered surfaces:-
B.21.(d).1. New plaster shall not be primed or painted till it is completely dry and hard.
B.21.(d).2. Preparation of surface - The surface shall be care­fully rubbed smooth and
thoroughly cleaned with clean fresh water. Supplementary specifications if any, will be
laid down in the special provisions for the item according as the particular nature of the
surface to be painted, requires. The surface shall be dry, smooth, clean, and free from
dirt.
B.21.(d).3. Priming coat - This shall consist of equal parts of white and red lead mixed
in boiled linseed oil to the required con­sistency applied uniformly over the surface. When
this coat is dry, all cracks, holes and other such defects shall be filled with a mix­ture of
one part white lead and three parts ordinary putty. the sur­face shall then be rubbed
down with sand paper and dusted clean.
B.21.(d).4. Finishing coats -  It may be necessary to give four coats of paints over the
priming coat. The first coat shall be thin so that plaster may be thoroughly saturated. The

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B.21.(d).4.
second coat shall be thicker and shall contain a small quantity of turpentine with some of
the colouring pigment. The third coat also shall be thicker having equal parts of linseed
oil and turpentine. The last coat shall be as specified for each item of painting. Walls and
ceilings shall be given a flat finish as glossy finishing coat shows up the irregularities in
the plaster.
The paint shall be applied with brushes. It shall be spread as smoothly as possible.

96 RED BOOK  VOLUME I  ROADS  2012

 STANDARD SPECIFICATIONS FOR CEMENT
SPECIAL TESTS
Sr. Name of test Specified results Frequency and Remarks
No. OPC PPC

Ratio of percentage > 1.02 Since cement leaving the

of lime to percentage < 0.66 factory undergoes Q.C.
of silica Alumina and tests generally cement is
iron oxide not required to be tested
chemically. However, in
Ratio of % alumina < 0.66 case of doubtful quality,
to that of iron oxide the cement may be got
tested chemically
Weight of insoluble > 1.5 % * < x+2.0(100-x)
residue 100

Weight of magnesia > 6% < 6 %

Total sulphur content > 2.75 % < 2.75 %

Calculated as suphuric SO3

anhydride

Total loss on ignition > 5 % 5 %
* Where X(i) declared percentage
of pozzolona in given cement.
SPECIAL TESTS OPC PPC

Fineness Test

a) After sieving the As per requirement.

residue by weight
on 90 micron / Indian
standard sieve > 10 % > 5%

Blaines air < 22.50 < 3000 As per requirement.
permeability method
specific surface Cm2/gm

RED BOOK  VOLUME I  ROADS  2012 97

 OPC PPC

Soundness test by Le Chatelier > 10 mm > 10 mm The Le Chatelier method may be

method Expansion used for cement having magnesia
content of less than 3%. For
magnesia of more than 3% the
cement will be tested by Auto
Clave Test where expansion. > 0.8%

Setting time by Vicats apparatus < 30 minutes < For 30

each consignment of cement
a) Initial Setting time in minutes minutes

b) Final setting time minutes For each consignment of cement

< 600 minutes < 600 minutes

Compressive strength of at
least 3 mortar cubes ( area of
face 50 Sq.Cm.) composed of
one part of cement 3 parts of
standard sand and P/4 + 3 %
( of Combined mass cement
plus sand) water Where P = %
of water required to produce a
paste of standard consistency.
< 160Kg/Cm2
a) 72 Hr. + 1 Hrs.
< 220Kg/Cm2 < 220
b) 168 Hr. + 2 Hrs. Kg/Cm2

c) 672 Hrs. Not specified < 310 Kg/Cm2

If single size Encore sand is For PPC average drying shrinkage

used. of mortar shall not be more than
< 115 Kg/Cm2 0 - 15 %
a) 72 Hr. + 1 Hrs.

< 175 Kg/Cm2

b) 168 Hr. + 2 Hrs.

98 RED BOOK  VOLUME I  ROADS  2012

 FIELD TEST ON CEMENT

[A] FIELD TESTS FOR FINDING OUT ADULTERATION OF CEMENT WITH STONE
OR COAL DUST

1) Purpose of the test - The aduiteration tests are required to be done to ascertain that
cement is free from any adulteration.

a) A sample of cement shall be heated on a steel plate for 20 minutes on a stove. The
adulterated sample changes its colour.

b) A normal solution of HCL shall be added to an equal volume of water and the resultant
soultion shall be slowly added to small quantity of cement of about 10 gms taken in
a test tube. If any large insoluble residue is noticed it indicates presence of siliceous
materials. Efflorescence and frothing indicates presence of admixture of lime stone dust.

c) A small quantity of cement is taken in a test tube or a measuring cylinder and water
added till the container is half full. The mixture is shaken and allowed to settle for few
minutes. The Cement particles settle down and the coal ash particles are found to be
floating or in suspension as they are lighter.

27

RED BOOK  VOLUME I  ROADS  2012 99

100 RED BOOK  VOLUME I  ROADS  2012
 SECTION BR

STANDARD
SPECIFICATIONS
FOR BRIDGE WORK

RED BOOK  VOLUME I  ROADS  2012 101

102 RED BOOK  VOLUME I  ROADS  2012
 CONTENTS
Serial No. Item Pages
(1) (2) (3)
BR.1 Constructing and maintaining temporary road diversion
including barricading the existing road, maintaining night
watchmen, red lights, etc. as directed till the completion of the
work.

BR.2 Dismantling the existing structure including sorting out useful

materials and stacking them within the specified lead neatly as
directed and disposing off the unsuitable materials.

BR.3 Excavation for foundation including shoring and strutting as

necessary and disposing off excavated stuff as directed

a) earth, soils of all types, sand, gravel, soft murum etc.

b) hard murum

c) hard murum and boulders

d) soft rock

e) hard rock (blasted)

f) hard rock (chiselled and wedged or line drilled)

g) laterite

BR.4 Dewatering including diversion of stream, providing coffer

dams, bunds, etc., as may be necessary for foundation and
other parts of the work and bailing out and pumping out water
during and after excavation as required.

BR.5 Providing and laying in situ : : / cement concrete in foundations

including necessary form work, compacting and curing.

BR.5(a) Providing and laying in situ : : / cement concrete with lums

in foundations including necessary form work, compacting and
curing.

BR.6 Providing uncoarsed rubble masonry in cement mortar 1:-

for foundations of piers, abutments, wings, etc., including
dewatering, stricking joints and watering complete.

BR.7 Providing island for laying steel-curb or cutting-edge of wells.

BR.8 Providing, fabricating, launching, floating and grounding in

position steel-curbs for wells with necessary steel bracings
and steel cutting-edges as shown on the detailed drawings.

RED BOOK  VOLUME I  ROADS  2012 103

BR.9 Providing and laying in situ : : / cement concrete in the hollow
of the steel curbs including compaction by vibrating and curing
complete.

BR.10 Providing, fabricating and setting out mild steel cutting edges
for R.C.C. well curbs as shown on the detailed drawings.

BR.11 Providing, cutting, bending, hooking, laying in position and

tying mild steel reinforcement bars in position for well curbs
and steining complete as per detailed drawings.

BR.12 Providing and laying in situ cement concrete for R.C.C. well
curbs including necessary shuttering, laying compacting by
vibrating, finishing and curing complete (excluding mild steel
reinforcement).

BR.13 Providing and laying in situ cement concrete in well steining

including shuttering, compacting by vibrating, finishing and
curing complete (excluding mild steel reinforcement).

BR.14 Sinking the wells for foundations through all strata except rock
by approved methods including removal of obstacle and use of
necessary plant, machinery, divers, etc., and proper seating of
the well.

BR.15 Providing steel anchor dowels at the base of the well including
drilling holes, placing the dowels in position and effectively
grouting the hole.

BR.16 Providing and laying in situ / cement concrete for the bottom
plugs of wells in the dry or under water including compaction
and curing where necessary.

BR.17 Providing and filling in wells with sand/rubble and sand/shingle

and sand including compaction between the top and bottom
plugs.

BR.18 Providing and laying in situ / cement concrete for top plugs
of wells including compaction by vibration and curing.

BR.19 Providing cast in situ R.C.C. bored piles of 1:1.5:3/M20

concrete for a capacity of ....... tonnes sunk to the required
depth through all strata except rock including compaction of
concrete and provision of reinforcement.

BR.20 Carrying out loading test of pile or pilegroup including

construction of test caps, accessories and dismantling them
after test.

BR.21 Providing, cutting, bending, hooking, laying in position and

tying reinforcement for R.C.C. well/pile caps as detailed in the
drawings including shear pins.

104 RED BOOK  VOLUME I  ROADS  2012

BR.22 Providing and laying in situ cement concrete for R.C.C. well/
pile caps including necessary centering, formwork, compaction
by vibrating, finishing and curing complete (excluding mild
steel reinforcement).

BR.23 Providing coursed rubble masonry in cement mortar 1: for

abutments, returns, wings, etc., with khandki facing and pointing
with cement mortar 1:3 for all khandki faces and rubble facing
with struck joints for rubble backing including scaffolding and
watering masonry complete.

BR.23 a) Providing coursed rubble masonry in cement mortar 1: for piers,

with khandki facing and pointing with cement mortar 1:3 on all
sides including cut and ease waters, dewatering, necessary
scaffolding and watering masonry complete.

BR.24 Providing and laying cement concrete for cast-in-situ piers,

abutments, returns, wings, etc., including provision of V shaped
false joints to form suitable panels on the faces to approved
design and necessary centering, shuttering, scaffolding,
compacting by vibrating, finishing and curing complete.

BR.24 (a) Providing and laying cement concrete for cast-in- situ piers,
abutments, returns, wings, etc., including provision of V shaped
false joints to form suitable panels on the faces to approved
design and necessary centering, shuttering, scaffolding,
compacting by vibrating, finishing and curing complete.

BR.25 Providing, cutting, bending, hooking, laying in position and

tying bars for reinforcement for pier and abutment caps and
for concrete piers and abutments as detailed on the drawings.

BR.26 Providing and laying in situ cement concrete for R.C.C.

caps over piers and abutments including necessary scaffolding,
centering, formwork, compaction by vibrating, finishing and
curing complete. (excluding mild steel reinforcement).

BR.27 Providing and laying in situ M20/M25/M30 cement concrete

for R.C.C. concrete block below the bearing including
necessary centering, formwork, scaffolding, compaction by
vibrating, finishing and curing complete. (excluding mild steel
reinforcement).

BR.28 Providing, cutting, bending, hooking, laying in position and

tying bars for reinforcement as per detailed drawings for -

a) Solid/deck slab,

b) main girders/arch ribs,

c) cross girders,

d) arches.

RED BOOK  VOLUME I  ROADS  2012 105

BR.29 Providing welded joints for mild steel reinforcement bars for-

a) 25 mm diameter and under,

b) 28 mm diameter,

c) 32 mm diameter,

d) 36 mm diameter,

e) 40 mm diameter,

BR.30 Providing bottle-nut joints for the mild steel reinforcement round
bars of 25 mm diameter and above.

BR.31 Providing and laying in situ concrete for R.C.C. work

including centering, formwork, scaffolding, ramming, vibrating,
finishing and curing complete in -

a) Solid/deck slab,

b) main girders/arch ribs,

c) cross girders,

d) arches (excluding reinforcement).

BR.32 Providing expansion joints as per detailed drawings.

BR.32a) Providing neoprene expansion joint as per detailed drawing.

BR.33 Providing and laying in situ 1:4:8 cement concrete for haunch
filling including compacting, curing and scaffolding complete.

BR.34 Providing rubble filling over haunches and arches including

hand packing.

BR.35 Providing and laying in situ / cement concrete including

compacting, finishing, curing and filling the joints with bitumen
complete for -

a) wearing course 8 cm thick.

b) approach slab ( excluding mild steel )

BR.36 Providing vent holes in slab and wearing course with iron grill
at the top and galvanised iron pipe at bottom as per drawing.

BR.37 Providing, cutting, bending, hooking, laying in position and

tying reinforcement bars as per detailed drawings for ballast
walls, kerbs, returns, approach slab etc.

BR.38 Providing and laying in situ cement concrete for R.C.C.

work of ballast walls, kerbs, box returns etc. including
necessary scaffolding, centering, formwork, compaction by
vibrating, finishing and curing complete. (excluding mild steel
reinforcement)

106 RED BOOK  VOLUME I  ROADS  2012

BR.39 (a) Providing R.C.C. parapet with cement concrete with cast-
in-situ/precast panels as per detailed drawings including
reinforcement, scaffolding, centering, formwork, compaction
by vibrating, finishing and curing complete

BR.39 (b) Providing railing of mild steel angle/I/tee posts and galvanised
iron pipes as per detailed drawings including scaffolding and
painting.

BR.39.(c) Providing railing of cast in situ R.C.C. posts with 1:2:4 cement
concrete of trap/granite/quartizite/gness metal and chains as
per the detailed drawings including reinforcement scaffolding,
centering, formwork, compaction, finishing and curing complete.

BR.39 (d) Providing collapsible railing with mild steel channel posts and
removable galvanised iron pipes as per the detailed drawings
included scaffolding and painting.

BR.39 (e) Providing railing of cast in situ R.C.C. posts with 1:2:4 cement
concrete and chains as per the detailed drawings including
reinforcement scaffolding, centering, formwork, compaction,
finishing and curing complete.

BR.39 (f) Providing collapsible railing with channel posts, flats, and
angles as per the detailed drawings including scaffolding and
painting.

BR.40 Providing and fixing in position to exact profile prestressing high

tensile steel of specified ultimate strength including bending,
cutting, laying in sheathing and providing necessary standard
anchorages as per detailed drawing including use of necessary
plant, machinery prestressing etc, complete.

BR.41 Providing galvanised iron 150 mm diameter water spouts as

per drawings.

BR.42 Providing and fixing marble tablet of size and description as

per detailed drawings including moulded marble/ 1:2 cement
mortar border.

BR.43 Providing rubble filling behind the abutments, returns or wings.

BR.44 Carrying out load test of bridge.

BR.45 Providing and fixing neoprene bearing as per detailed drawing.

BR.46 Providing and applying anticorrosive treatment to reinforcement

bars.

BR.47 Providing and laying Bitumen mastic wearing course of 25/40

mm thick over road pavement/ bridge deck including supplying
and conveying of all materials, labour, preparing bitumen
mastic, laying, joining, finishing etc., complete.

RED BOOK  VOLUME I  ROADS  2012 107

108 RED BOOK  VOLUME I  ROADS  2012
 BR.1.5.
BR.1. Constructing and maintaining temporary road diversion including barricading
the existing road, maintaining night watchmen, red-light, etc., as directed till the
completion of the work.
BR.1.1 General - The item provides for constructing temporary diversion road, temporary
stream crossings, closing the existing road, providing barricades, signs, watchmen and
red lights, maintaining the diversions and crossings in a condition satisfactory for the use
of traffic till the completion and opening of the work to traffic and restoring the land to the
original condition on completion of the work.
BR.1.2. Alignment -If the alignment of the diversion is specified on the drawing, the
same shall be adopted without any deviations unless found necessary and permitted by
the Engineer. In the absence of such specified alignment, the contractor shall align the
diversion suitably and obtain approval of the engineer before constructing the same.
BR.1.3. Lands - The contractor shall be allowed to, if possible, and convenient to the
Department to make use of the Departmental land free of royalties, rents, etc. In case
the diversion is required to be routed over other than the Department land, the contractor
shall be responsible for obtaining the consent of the owner and payment of royalties, rents,
compensations, etc., arising out of the use of such lands and shall not be entitled for extra
claims. The Department shall remain indemnified in these matters.
BR.1.4. Construction - .The diversion shall be constructed to the satisfaction of the
Engineer on the approved alignment with an eye to the safety and convenience of the
traffic at all times and shall –
1. not have gradient steeper than 1 in 10,
2. have a width not less than 7.5 metres in case of two- way traffic and 3.75 metres in
case of one-way traffic,
3. not have radius of curves less than 30 metres,
4. have vertical curves allowing a vision of over 50 metres,
5. have banks not more than 1.5 metres high where higher banks are avoidable, and
6. have sides in cuts and banks to stable slopes.
The Engineer may permit in writing deviations in the above if circumstances justify.
The land for the road width shall be cleared of all debris, bushes, stumps of wood, logs,
boulder and all other obstructions.
The bank shall be formed in layers of 15 cm. to 20 cm and where necessary shall be so
consolidated so as to enable traffic to negotiate without risk at a speed not exceeding
15 Km/hr. The road in cutting shall have an even road surface. The 7.5 metres width for
two-way and 3.75 metre width for one-way traffic shall be provided with top dressing of
murum or other suitable material approved by the Engineer to give a reasonably even and
hard surface satisfactory for the use of traffic at all times if it is not naturally firm and well
compacted. Diversion shall include stream crossings also. At stream crossings, the diversion
shall be provided with temporary crossings, or hard bed as and when necessary where the
depth of water exceeds 30 cm. or the nature of stream bed does not allow the traffic to pass
without inconvenience. The crossing shall be designed for one-way traffic and for loading
corresponding to vehicle loading permitted on the road. Water-way to be allowed and the
details of crossing shall be subject to the approval of the Engineer. Protective measures
such as railing shall be provided where necessary as directed by the Engineer.
BR.1.5. Arrangement for traffic -  The existing road should be closed only after the
diversion is completed and ready to take the traffic and then also only after getting prior

RED BOOK  VOLUME I  ROADS  2012 109

BR.1.5.
approval of the Engineer. The traffic shall be guided properly over the diversion which shall
be clearly marked by white-washed stones or other such means. In case of one-way traffic
the flow of vehicles shall if necessary, be regulated alternately from each end by watchmen
and signalers. Caution and “GO SLOW “ signs approved by the Engineer, shall be erected
as directed by the Engineer. The old or existing road shall be adequately barricaded and
properly closed at both ends. Red lights shall be displayed during the night time to indicate
the diversion. Warning signals shall be erected on the existing road at about 70 m from
both ends of the diversion. All diversion signs shall be clearly visible by night and day.
The contractor’s men and material shall not cause any impediment to the traffic on the
diversions. If speed limit is necessary it should be enforced after obtaining sanction from
the competent authority.
BR.1.6. Maintenance - The contractor shall maintain the diversion in a reasonably
good condition till the work is over. The traffic should be able to pass over the diversion
without inconvenience at a speed not exceeding 15 Km/hr.He shall also be responsible to
reconstruct it or part of it if damage due to monsoon or any other cause without extra claims
for the same. The wearing surface shall also be maintained by carrying out repairs to it as
and when necessary. During the monsoon, road side gutters shall be provided wherever
necessary to drain off the surface water if it is likely to damage the diversion road.
If the contractor fails to repair the diversion and crossings in a satisfactory manner, even
after being required by the Engineer to do so within a specified period in writing, the
Engineer will be free thereafter and keep the diversions during the crossing in satisfactory
condition at the cost of the contractor.
BR.1.7. Closing - After the traffic is allowed to pass over the newly constructed or repaired
road surface, bridge or culvert, the diversion road shall be closed for traffic and all the
barricades, signs, signals, etc., removed. The land over which diversion is taken out shall
be restored to its original condition. The crossings shall be dismantled.
BR.1.8. Special points - The contractor shall be responsible thus for -
1. aligning the diversion suitably when no route is specified.
2. obtaining valid written consent of land owners and payment of compensation to them
and indemnifying Government in this connection,
3. construction of the temporary diversion road including temporary stream crossings
where necessary for safe and satisfactory passage of traffic,
4. providing adequate and necessary barricades, sign boards, signalers, signals, and
red lights,
5. control of traffic over the diversion,
6. maintenance of diversion in good condition,
7. accidents over or due to diversion if caused by bad condition and compensation if
any in that connection,
8. reconstruction of diversion when damaged,
9. restoring the land to the original on abandoning the diversion,
10. making good any damage to the existing road due to the diversion.

BR.1.9. Items to include –

(i) All labour, materials, use of equipment, tools and plant necessary for aligning,
constructing, operating, maintaining and closing the diversion satisfactorily.

110 RED BOOK  VOLUME I  ROADS  2012

 BR.2.3.
(ii) All sorts of compensations and responsibilities arising out of the diversion.
BR.1.10. Mode of measurement and payment - The contract rate shall be for the job.
The payment shall be for the entire job including the maintenance till the road, bridge or
C.D. work under construction is opened to traffic. Part payment may be made through the
running account bills at the discretion of the Engineer.
BR.2. Dismantling existing structure including sorting out useful materials and
stacking them within the specified lead neatly as directed and disposing off the
unsuitable materials.
BR.2.1. General - The item provides for the complete removal of the existing structure
except such portions as may be required or permitted in place as shown on the drawing
or as directed by the Engineer, clearing the site, sorting out useful materials and stacking
them neatly within a lead of 100 m. or on the bank indicated by the Engineer whichever is
more and wasting the non-useful materials.
BR.2.2. Preliminaries - If necessary and directed by the Engineer the contractor shall
have to erect screens of canvas or other suitable materials and/or to water the structure
and area to avoid nuisance of dust before and during dismantling. Care shall be taken to
see that dismantling is done in such sequence and manner as to prevent all avoidable
damage to usable materials and any damage to nearby property or injury to life.
In case of structures which are to be removed for re-erection, all members shall be properly
match-marked with paint. The pins, nuts, plates, structural steel members, timber etc., shall
be similarly marked for identification of their position in the entire assembly. All machined
surfaces, pinholes, etc. shall be coated with grease.
Any inventory of all possible serviceable material shall be kept on record and signature of
contractor obtained in token of his acceptance. Any doubt or non-agreement with the same
shall be reported by the contractor before starting the removal.
Portions required to be kept in tact shall be clearly marked before dismantling.
If no separate provision exists in a tender for necessary diversion, the contractor shall
never the less invariably be responsible for the construction and maintenance of adequate
barriers watchmen and/or lights at the ends of portions of the road closed by construction,
to the satisfaction of the Engineer at his (contractor’s) cost, diversion itself being treated as
extra work.
A register shall be opened by the contractor on the work site to show day-to-day account of
the turn out, salvage materials and whether properly stacked or wasted. It shall be signed
by the representative of the contractor and the responsible member of the Department
supervising staff every day.
BR.2.3. Dismantling and removal - The structure shall be dismantled carefully and the
materials removed without causing damage to the serviceable material to be salvaged,
the part of the structure to be retained or any properties nearby. Any avoidable damage
to articles to be salvaged and part of the structure to be retained and any damage to
nearby property or structure shall be made good by the contractor without extra claims. The
contractor shall be responsible for any injury to workers or the public.
Unless otherwise specified the structure shall be removed upto 45 cm. below the ground
level and the portion which interferes in any way with the new construction shall be removed
entirely. Removal of overlaying or adjacent materials, if required, for the dismantling of the
structure, shall be included in the item.
Where existing bridge is to be extended or otherwise incorporated in the new work, only
such part or parts of the existing structure shall be removed as are necessary to provide

RED BOOK  VOLUME I  ROADS  2012 111

BR.2.4.
a proper connection to the new work. The connecting edges shall be cut, chipped and
trimmed to the required lines and grades without weakening or damaging the part of the
structure to be retained.
Blasting if required, may be resorted to with the written permission of the Engineer. In such
a case blasting shall be carried out as specified in B.2. All blasting operations shall be
finished before the new construction is commenced.
Equipment and methods which might damage members, portions of the structures to be
preserved or adjacent construction or structure shall not be used.
If sewers or drains are removed or disturbed , the contractor shall at once remove the
foul matter. If sewer or drains have to be temporarily removed the contractor shall provide
temporary passage for the flow or redo the sewer or drain without extra claims. If existing
sewers or drains are required to be removed permanently and rebuilt to altogether new
alignments, they shall be paid as extra work, if there is no provision in the tender for such
work.
BR.2.4. Disposal - All the materials obtained from the removal of the structure shall be
the property of the Government. Useful material shall be stacked neatly in such a manner
as to avoid deterioration and in places as directed by the Engineer within a lead of 100 m.
or on the other bank indicated by the Engineer whichever is more. Different categories of
material shall be stacked separately.
Unless otherwise provided, excavated materials shall be used in backfilling excavation
made in removing the structure, in constructing embankment or otherwise disposed off as
directed within 100 m. free of Cost.
Useful materials will be issued to the contractor for use in new work or elsewhere at the
rates provided in the tender or when not so provided at the rates agreed upon by the
Engineer and the contractor.
Non useful materials shall be wasted by the contractor without causing any damage or
inconvenience.
BR.2.5. Clearance - All rubbish shall be cleared off the site and the ground left clean and
clear. Any damage caused during the operation shall be made good.
BR.2.6. Responsibilities - The contractor shall be responsible for -
1. maintaining register of the salvaged materials,
2. keeping intact the portion not to be removed,
3. avoidable damage to serviceable article to be salvage during dismantling,
conveyance and stacking.
4. blasting operations when necessary,
5. stacking neatly and safe custody of the salvaged materials till handing over to the
Department.
6. disposing off unserviceable material and its consequences,
7. damages to the nearby property and injury to worker and the public due to his
operations.
BR.2.7. Item to include -
1. All labour, materials, use of equipment, tools and plant required for completing the
job satisfactorily,
2. Erecting and removing screens and watering when necessary as directed.
3. Marking the structure suitably.
112 RED BOOK  VOLUME I  ROADS  2012
 BR.3.2
4. Opening register of salvage materials.
5. Providing adequate barricades, signs, lights, etc.
6. Removal of structures.
7. Diverting the existing drains, road etc., temporarily and redoing the same, if not
separately provided.
8. Stacking serviceable materials.
9. Wasting unserviceable materials.
10. Clearing site on completion.
11. Compensation for damaged properties or injuries to persons.
BR.2.8. Mode of measurement and payment - The contract rate shall be a lump sum for
the complete job. Proportionate payment may be made through running accounts bills. Full
payment shall be made on completion of the job in all respects.
BR.3. Excavation for foundation including shoring and strutting as necessary and
disposing off excavated stuff as directed in -
a. earth, soils of all types, sand, gravel, soft murum, etc.,
b. hard murum,
c. hard murum and boulders,
d. soft rock,
e. hard rock (blasted),
f. hard rock (chiseled and wedged or line drilled),
g. laterite.
BR.3.1. General - The excavation shall conform to specification No. B.1. in all respects
subject to following :-
If excavation in rock is done by blasting, the lowest 15 cm. of blasting shall be done by light
charges so as not to shatter or weaken the underlying rock on which the foundation will be
actually laid.
If excavation in rock is done in excess of the dimensions shown on the plans or as directed
by the Engineer, not only no payment will be made for such over break but the contractor
shall at his own cost fill such extra excavation with concrete or of the foundation grade and
cure it properly. If any offsets are left over the footings, the contractor is not liable to fill the
portion above these offsets with concrete free of cost although he is bound to do so free
of cost in the space between a vertical line from lowest footing and the rock over break if
so ordered. This shall be done when it is intended to fill the gap between the permanent
structure and the side of the trenches in rock with concrete or masonry.
All seams and crevices in rock shall be cleaned out and washed.
Useless material obtained from clearing site and excavation shall be wasted as directed by
the Engineer. Useful material obtained from clearing site shall be stacked as directed by
the Engineer within a lead of 100 metres or on the bank whichever is more as directed by
the Engineer. Materials useful for backfilling may be stacked at a convenient place within
a lead of 50 metres for reuse free of cost. Backfilling shall be done after the concrete or
masonry is fully set and shall be done simultaneously on both sides in such a manner as
not to cause any undue or unbalanced thrust on any part of structure. Special care shall be
taken for compacting the fill behind the abutments. Rolling or tamping s
BR.3.2 Mode and measurement of payment - As in specification No.6.15. The

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BR.3.2
measurements shall be taken net for the inside dimensions of the steel curb. No deduction
shall be made for reinforcement, ties, bolts, nuts, rivet heads and bracing.
BR.3.3. Item to include - In addition to item detailed in the specification No B.1.13,
excavation in rock will include filling concrete of the foundation grade in the trenches
excavated to dimensions in excess of those shown in the plans, i.e., overbreak portions
at contractor’s cost as directed by the Engineer instead of filling with excavated material
subjected to the conditions in BR.3.1 above.
All blows, slips, etc., occurring in the excavation shall be removed by the contractor without
any extra cost to the Department. All surplus material from excavation shall be removed
and the site left cleaned on completion of the work.
BR.3.4. Mode of measurement and payment - It shall be as per specification No. B.1.14.
With regards to backfilling of foundation trenches if concrete is to be filled between the
concrete of the structure and the vertical plane of excavation in rock shown in the drawing
it shall be paid for; but no payment shall be made for the concrete laid in the overbreak
portion.
BR.4. Dewatering including diversion of stream, providing cofferdams, bunds etc.,
as may be necessary for foundation and other parts of the work and bailing out and
pumping out water during and after excavation as required.
BR.4.1 General - The foundation trenches shall be kept dry by resort to pumping alone or
pumping in combination with diversion channels, cofferdams and bunds, diversion weirs,
drainage channels, well points or any other satisfactory method to suit local conditions at
the choice of the contractor. The contractor shall supply the details of his proposals for
approval of the Engineer, but such approval shall in no way release the contractor from the
responsibility for the adequacy of diversion and dewatering arrangement and for the quality
and safety of the work for all of which the contractor shall be responsible.
BR.4.2 Method - The method to be adopted shall be entirely left to the choice of the
contractor provided adequate dewatering is carried out and the schedule programme is
adhered to. The contractor shall plan, construct and maintain satisfactorily necessary
diversion channels and temporary diversions and protective works so as to safely pass the
stream flow and also satisfactorily deal with any sudden rise of flow without damaging the
foundation excavation or works. Where practicable, all substructure shall be constructed
in open excavation and where necessary the excavation shall be shored and braced or
protected by cofferdams. The cofferdam should be carried to adequate depth and heights,
safely designed and constructed with suitable dimensions and protection and shall be
made as water-tight as practicable for facility of construction of the work to be done
inside them. The interior dimensions of the cofferdams shall be such as to give sufficient
clearance for construction and inspection and to permit installation of pumping machinery
etc., inside the enclosed area. The cofferdam is of sufficient heights to [prevent ingress
of water into the foundation pits and to protect green concrete or masonry from tides or
sudden rising of the stream and to prevent damage of the foundation by erosion.
Unless otherwise permitted, no excavation shall be made outside the enclosed area and
the natural stream bed adjacent to the foundation shall not be disturbed without permission
from the Engineer.
Cement grouting or other methods may be used at the discretion of the contractor to prevent
or reduce seepage and to protect the area to be excavated if the soil is porous.
BR.4.3. Pumping - Adequate pumping arrangements shall be made for dewatering
foundation trenches and other areas of construction where dewatering is essential and

114 RED BOOK  VOLUME I  ROADS  2012

 6)
keeping them dry while masonry or concrete or other construction is in progress and till the
concrete or mortar of masonry is sufficiently set and construction can be proceeded without
pumping. Pumps of adequate capacity and in required number shall be provided to ensure
the above. Pumping from foundation trenches or from the interior of the cofferdams or other
areas of construction shall be done in such a manner as to preclude the possibility of the
movement of the water through any fresh concrete or masonry and washing away parts of
concrete or mortar. No pumping will be allowed during placing of concrete or for a period of
atleast 24 hours thereafter unless it is done from outside sump separated from concrete or
masonry by effective means.
The contractor may obtain electric supply from the local supply authorities at his own cost
for operating the pumps. The Department shall render necessary help in obtaining the
supply. The contractor shall bear the entire cost including deposits, connection costs, rents,
energy bills etc.
The contractor should make his own arrangement for necessary labour, materials, and
equipment for cofferdams, pumps engines, and other machinery and devices required for
successful execution of the item of dewatering.
BR.4.4. Desilting - If any foundation pits are full due to floods or flow or blows or slips
during the progress of the work or during the rainy season or due to any other cause, all
pumping required to dewater the pits and to do desilting shall be done without making extra
claims.
BR.4.5. Removal - The cofferdams and other works constructed, for facility or diversion
and/or dewatering shall not cause any damage to property and work and shall be removed
after they have served their purpose in a manner and to the extent directed by the Engineer.
If any excavation is made outside the enclosed area for facility of construction the contractor
shall refill the same with proper ramming after the foundation work is completed so as to
bring the river bed to its original condition and if as directed by the Engineer. Similarly
any material deposited within the stream area for the filling the cofferdam or from any
excavation shall be removed and the stream area made free from obstruction caused
thereby as directed by the Engineer.
BR.4.6. Items to include -
1) Diversion of surface flow, construction of cofferdams, cribs, shoring, struttings, bunds,
dams, service path during construction and removing the same after completion to
bring the river bed to its original condition.
2) All labour, materials, use of equipment or other arrangements necessary for
dewatering during excavation and construction of other items requiring dewatering.
3) Dewatering foundation trenches, excavation and other areas to be built upon to
enable the masonry concrete or other construction work to be done in dry and till the
Engineer considers that the mortar or concrete has sufficiently set.
4) Dewatering till all the items requiring dewatering are fully completed. This shall also
include time required for passing foundation and taking measurements of all the
items requiring dewatering.
5) Removing liquid stuff of any sort which might find access into the trenches by blowing,
slip or any other cause whatsoever from the sides or bottom of the foundation or
excavation or elsewhere during or after dewatering.
6) Compensations, if any required to be paid.
BR.4.7. Mode of measurement
and payment - The payment of dewatering done by any suitable acceptable method of
dewatering approved by the Engineer and for the depths shown on the drawings and upto

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6)
1.5 m below such depth shall be lump sum for the complete job or for each sub-item as
agreed in the tender.
Dewatering required for excavation and other items below this additional depth of 1.5 m.
will be paid for as extra work, rate for which will be fixed according to the terms of contract :-
1. 70 percent of the lump sum cost will be paid when masonry or concrete and other
appurtenant works come up above the natural water level or bed level whichever is
higher.
2. The balance will be paid when all the work is completed.
BR.5. Providing and laying in situ cement concrete in foundations including
necessary form work, compacting, curing and scaffolding complete.
BR.5.1. Preparation of foundation for laying concrete.
BR.5.1.1. Passing foundation - The foundation shall have been prepared according to
specification No. B.1.4 and passed in writing by the Engineer before concreting is started.
Just before starting concrete, the bed of the foundation trenches shall be cleaned of all loose
materials and slightly moistened if dry, to prevent absorption of water from the concrete.
In the case of rock foundation, the bed shall be washed cleaned and excess water if any
removed.
BR.5.1.2 Wet foundation - If the area on which the concrete is to be placed is under
water, it shall be pumped dry and kept so throughout the period of laying concrete and
2 hours after completing concrete, without causing damage to concrete. Concrete with
changed water content may be placed in wet foundations if so directed by the Engineer.
Dewatering shall be done according to specification No. BR 4. Unless dewatering is
separately provided for in the tender the rate of concrete shall also include the cost of
dewatering required. If unusual or unforeseen conditions are met with and it is not possible
nor desirable to dewater, the Engineer may permit the placing of concrete under water as
specified in specification No.B.6.7.
BR.5.2. Cement concrete - The cement concrete shall comply with specification No.B.6.
for nominal mix cement concrete subject to the following. -
BR.5.2.1. Proportion - The proportion shall be as per the mix design for the grade
specified in the wording of the item.
BR.5.2.2. Coarse concrete - Coarse aggregate shall be crushed or broken from sound
stones of specified types available in the region and approved by the Engineer.
 The maximum size of the coarse aggregate shall be 50 mm when the depth of the
concrete footing is 20 cm. or more. For less depths, the maximum size shall not exceed
1/4 th the depth. The aggregate shall be well graded between the maximum size and 5
mm as indicated in specification No.A.7.
BR.5.2.3. Mixing - Cement concrete shall be normally machine mixed. But the Engineer
may permit hand mixing when all due precautions including additional cement laid down
in specification No.B.6.4 shall be observed and uniformly well mixed concrete obtained.
Water content may be within the range mentioned in specification No.B.6.3 or as may
be approved by the Engineer to give the required consistency.
BR.5.2.4. Slump - Slump for manually compacted concrete may not exceed 12 cm and
for vibrated concrete 5 cm.
BR.5.2.5 Placing - Before placing concrete, seams, hollows and crevices if any, shall
be treated with 1:2 cement mortar grout, or filled with 1:3:6 cement concrete if they are
large enough. Grouting will be considered as an incidental item but concrete will be paid

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 BR.5.(a)
for.
BR.5.2.6. Compaction - Compaction shall be started during placing. The concrete will
be normally compacted by immersion vibrators and rodding. The Engineer may permit
manual compaction provided it is effectively done to get a dense concrete.
BR.5.2.7. Forms - If the trenches are dug exactly to the dimensions of the footings, no
forms will be necessary. But the sides and bottom of the trench shall be moistened to the
extent necessary to prevent absorption of water from the concrete. If however, footing
in strata softer than the soft rock are dug to dimensions larger than those shown on the
drawings or as directed by the Engineer, forms complying with specification No.B.6.5
shall be used. The side forms may be removed 24 hours after placement of concrete.
BR.5.2.8. Backfilling - After the concrete is set, space between the concrete and the
excavation sides shall be filled with approved materials in 15 cm layers moistened and
consolidated satisfactorily. In case of extra excavation in rock, the additional space has
to be filled with 1:3:6 cement concrete up to the top level of concrete footing or top of
rock whichever is lower at the cost of the contractor. Relevant provisions of BR.3 shall
also apply.
BR.5.2.9. Tests - If there is doubt regarding the quality of concrete, the Engineer may
arrange to get the concrete tested as specified in B.5.12 for the concrete prepared on
the first day and there-after once every 60 cu.m.
BR.5.3. Vertical headers - In order to allow sufficient bond with masonry above, vertical
headers with an average sectional area of not less than 0.03 sq.m. and not less than 45 cm
in length shall be embedded to half their length in concrete, the other half projecting above
the concrete at the rate of one per square metre within the area to be covered by masonry.
No payment will be made for these vertical headers nor any deduction made in the quantity
of concrete for the embedded part of the vertical headers.
BR.5.4. Interval for starting masonry - Masonry will be allowed to be started on the
concrete 48 hours after completion of concrete. Side filling will also be allowed after 48
hours after completion of concrete. But the material adjoining the concrete shall be kept wet
for the duration of curing period.
BR.5.5 Item to include - In addition to the items mentioned in the general specification
B6.14, item will include the following :-
1. Dewatering if necessary, if not provided as a separated item in the tender.
2. Treating joints, seams, and crevices in rock with 1:2 cement mortar grout.
3. If excavation in rock is done in excess of the dimensions shown on the plan or as
ordered , the extra excavation shall be filled with foundation grade concrete and /or
masonry upto top of rock.
BR.5.6. Mode of measurement and payment - This shall be as per specification
No.B.6.15. Embedded parts of vertical headers will not be deducted from the concrete nor
the vertical headers will be paid for separately. Concrete in the extra excavation in rock
referred to in BR.5.2.8 shall not be paid for.
BR.5.(a) Providing and laying in situ cement concrete with plums in foundations
including form work compacting, curing and scaffolding complete.
The item shall comply in all respects with specification No. BR.5. except that the plums
shall be used as specified in hereinafter.
BR.5.(a).1. Plums - The stones to be used as plums shall conform to B.9.2.1 and shall
be roughly cubical or rounded and shall be about 0.001 cu.m. in volume. They may

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BR.6.1
not have sharp edges and angles. The stones shall be more or less rounded and
without concave surfaces.
BR.5.(a).2. Use - The total volume of solid plums (after deducting 40 percent from the
stack volume) shall not be more than 15 percent of the volume of the concrete alone.
Atleast 60 cm of concrete layer shall first be laid before the plums are used. The
plums shall be placed on the concrete immediately the concrete starts stiffening.
While placing plums care shall be taken to see that the clear distance between two
plums is at least 20 cm. The plums shall be pressed into the concrete such that they
are partly visible on the particular layer. Care shall also be taken to see that the clear
distance between the face of the concrete and plums is not less than 40 cm.
Successive layers of concrete may be about 45 cm. At the top surface of the concrete
the plums shall be entirely embedded in the concrete with a minimum cover of 15 cm
of concrete.
BR.6. Providing uncoursed rubble masonry in cement mortar 1: for foundation of
piers, abutments, wings etc., including dewatering, striking joints and watering
complete.
BR.6.1 General - The masonry shall comply with specification No.B.9.(k) for uncoursed
rubble stone masonry in cement mortar of specified proportion including dewatering,
scaffolding, striking joints, curing etc. complete in all respects subject to the following :-
BR.6.2 Cement mortar - The proportion of cement mortar shall be given in the wording
of the item.
BR.6.3 Stones - The stones shall be of specified type and the best available in the region
and got approved by the Engineer before collecting them. Samples of different categories of
stones of specified sizes and dressing shall be got approved by the Engineer and deposited
in the Engineer’s office by the contractor for reference.
BR.6.4. Weepholes - If provision of weepholes is shown on the drawings or ordered
by the Engineer, they shall be made as provided in specification No.BR.25 with inverted
filters behind. No deduction will be made in the quantity of masonry of the weepholes. No
payment will be made for the weepholes and the inverted filters.
BR.6.5. Dewatering - Dewatering if necessary, shall be done according to the specification
No.BR.4 and shall be covered by the rate of the item unless separately provided in the
tender.
BR.7. Providing islands for laying steel curbs or cutting edge of wells.
BR.7.1. General - When it is necessary to sink the well in water, island of sand or earth or
other suitable material shall be formed.
BR.7.2. Materials - Earth or sand or other approved material for forming the island shall
contain no lumps, clods, stones or other hard material which will obstruct the sinking of the
well or deviate the well from the true line of sink.
 aterial such as rubble, sand bags, bamboos, bullie, stakes, etc., required for the protection
M
of edges and slopes of the islands from erosion as also railing materials for the safety of
workmen shall be provided at the cost of the contractor.
BR.7.3. Construction -  The island shall be formed by depositing approved materials in
uniform layers and shall have a diameter of not less than 3 m. more than the outside
diameter of the well to allow free working space necessary to operate tools and plant and
for movement of labour, etc. The island shall be brought at least 30 cm above the water level
or above such level in case of tidal rivers as will give sufficient time for work as directed.

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 BR.8.1.
The area on which the well curb is to be laid shall be levelled properly and compacted.
The island shall be constructed out of earth or sand or other suitable stuff. Where the
depth of water is shallow, simple island may be prepared by laying rings of sand bags
all round and filling earth or sand within. Side slopes may be provided in place of ring of
sand bags if they are likely to remain stable. Side slopes may be protected from erosion
with pitching or sand bags where necessary.
In greater depths of water where side slopes may not be suitable, two rings of bamboos,
stakes or bullies may be driven as far as they can be hammered in the river bed. Each
of these rings may be lashed round with steel wire rope or tied round with bullies or
bamboos. Closely knit split bamboos may be placed inside the two rings and earth filled
in between. Sand bags may be laid outside these rings for further stability if necessary.
The inside space may be filled with earth or sand to form the island for placing the
cutting edge of curb.
Where the curb is to be floated to the site of sinking, the top of the island shall be kept
at such level as to facilitate the seating of the curb.
 The island shall be maintained throughout the sinking operation and also further if its
use is required for other items of the bridge. If the sinking of the well extends through
and beyond the monsoon, the contractor shall not be entitled for compensation due to
any damage, etc., to the island due to flood or any other cause.
 If so required, the contractor shall have to remove the island entirely or to the extent
necessary on completion of the sinking of the well or completion of the work as directed
by the Engineer.
BR.7.4. Safety - The contractor shall provide suitable railing if it is essential in the opinion
of the Engineer for the safety of the workers. He shall also take such other measures as
are necessary for the safety of the work and work-people and shall be responsible for any
damage, injury or accident and compensation connected there with.
BR.7.5. Item to include -
1) Constructing, maintaining and protecting the island and if so required, full or partial
removal after completion of the work.
2) All labour, materials, use of equipment, tools and plant necessary for satisfactory
completion of the work.
3) Safety measures including compensation for any injury to persons or damage to
work.
BR.7.6 Mode of measurement and payment - The contract rate shall be for one island
constructed and maintained including removal to the extent necessary on the completion of
the work as directed. Payment shall be made for number of such islands. Payment for the
island shall be made on the final completion of the pier. If however, the island is required to
be retained for any other item of the work, only part payment may be made on completion
of the pier and full payment on completion of the work.
BR.8. Providing, fabricating, launching, floating and grounding in position steel
curbs for wells with necessary steel bracings and steel cutting edges as shown in
the detailed drawings.
BR.8.1 Materials - Structural steel shall comply with specification NO.A.10.
BR.8.1. Manufacturing details - Cutting edge shall be fabricated as shown in the detailed
drawing. Cutting, bending, drilling, or punching holes, etc. shall conform accurately to the
dimensions, shapes, and locations shown on the working drawing or as directed by the

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BR.8.1.
Engineer in writing and shall be done by methods approved by the Engineer.
Fabrication and erection shall conform to relevant provisions of specification No.B.19.
BR.8.3 Special points - `V’ cuts may be taken in the horizontal leg of the angle at regular
intervals throughout the length to facilitate bending. The angle shall be cold bent and pressed
to correct shape and the `V’ cuts welded together. The lengths of structural sections shall
be joined together with rivets or bolts or welds with the necessary cover plates to ensure
appropriate strength of original sections.
Holes shall be drilled at points designated on the plans in horizontal leg of the steel member
at the top of the curb for bolting the tie rods for the steining with checknuts.
BR.8.4. Welding - Welding may be resorted to for structurals in place of the rivets or the
bolts and also for ties if so permitted by the Engineer in writing. Welding shall be carried
out by fillet welding with single cover or by any other method approved by the Engineer,
employing suitable qualified and experienced welders. Welding may be done by Metal Arc
or Oxyacetylene process preferably the former.
Care shall be taken while carrying out welding to see that the axes of different members
cut at point indicated on the working drawing. The surfaces to be welded shall be cleaned
thoroughly exposing the original metal immediately before welding. The welded joints shall
develop the full strength of the particular member.
Welding shall be done as per specification No.B.18.
BR.8.5. Layout - Necessary reference points to site the well shall be fixed in a stable manner
in their exact position away from the zone of blows or possible disturbances resulting from
dredging and other operations. These points shall be connected to permanent theodolite
stations on the base lines on the banks. The centre of the individual curbs shall be peg
marked with reference to these stations.
BR.8.6 Preparing the bed - Unless otherwise shown on the drawing. If the river bed is dry,
open excavation as per specification No.BR.3 for the item of excavation shall be carried
down to about 30 cm above the sub soil water level before the well curb is laid.
BR.8.7 Island -Where it is necessary to sink the well in water, an island may be formed as
laid down in specification No. BR.7 and the steel curb shall be towed by barges or carried
by any other suitable means to the site and mounted and sited accurately in the correct
position on the island or bed. The contractor shall be responsible for any loss or damage to
the curb during towing conveyance, grounding, floods etc.
BR.8.8 Pitching of the curb - The area on which the curb is to be laid shall be levelled
properly and compacted. The curb shall be placed in exact location with reference to the
centre peg on closely spaced timber plank grillage of the required width for distributing
the load while concrete is being poured. The curb shall be laid 30 cm above the water
level obtaining at the time of its laying or such level in tidal river as may be convenient
and approved by the Engineer. This level of prepared bed or top of the island will form the
datum for the purpose of measurements for sinking the well. All the vertical rods connected
to the cutting edge shall be temporarily fastened together so as not to disturb the setting of
the curb.
BR.8.9 Safety - Measures shall be taken by the contractor to provide full safety to the
workmen and he will be held responsible for any accidents and compensation in connection
with the item.
BR.8.10 Item to include -
1) Fixing the correct location of the well.

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 BR.10.
2) Open execution for providing island if and where necessary as ordered unless
separately provided in the tender.
3) Providing, fabricating and erecting, floating, launching and grounding the curb
correctly on site.
4) All labour, materials, and use of equipment, tools and plant necessary for carrying
out the item satisfactorily.
5) Safety measures and compensation in case of damage and injury.
BR.8.11 Mode and measurement and payment - the contract rate shall be for one quintal
of structural steel, provided, fabricated completed, and set at the correct position on site
as per sanctioned plan or as approved by the Engineer. The lengths of the steel sections
provided shall be recorded correct upto two places of decimals of metre. The weight shall
be worked out according to the standard weights per unit length laid down by the Indian
Standards Institution correct upto 0.10 Kg.
No separate payment shall be made for rivets, bolts and nuts or for welding. No deduction
shall be made for the holes punched or `V’ cuts taken as explained above.
BR.9. Providing and laying in situ cement concrete in the hollow of steel curbs
including compaction by vibrating and curing complete.
BR.9.1 General - The item shall be carried out generally as per specification No.B.6
subject to following :-
BR.9.2 Proportion - The proportion for cement concrete shall be as per mix design or as
specified in the wording of the item.
BR.9.3 Coarse aggregate - Coarse aggregate shall be crushed or broken from sound
stones of the specified type available in the region and approved by the Engineer. The
maximum size of the coarse aggregate shall be 20 mm and properly graded from 20 mm to
5 mm as indicated in the specification No.A.7 to give a dense concrete. Samples of coarse
and fine aggregates approved by the Engineer shall be deposited, by the contractor in the
Engineer’s office for reference.
BR.9.4 Mixing - Mixing shall be done in a mechanical mixer. Water content may be within
the range specified in specification No B.6.3 or as may be approved by the Engineer to give
the required consistency.
BR.9.5 Slump - Slump may be 5 cm to 8 cm.
BR.9.6 Placing - Before placing concrete in the hollow steel curb, the reinforcement or ties
and connections will be checked by the Engineer and the curb shall be entirely cleared of
all loose stuff and the contact surface of the concrete shall be properly cleaned. Concrete
will be placed thereafter.
BR.9.7 Compaction - Compaction shall be made with vibrators and rods to get a dense
concrete with reinforcement or ties properly embedded and the concrete filled well in the
angles and edges of the steel curbs.
BR.9.8 Item to include - As per specification No.B.6.14.
BR.9.9 Mode and measurement of payment - As in specification No.6.15. The
measurements shall be taken net for the inside dimensions of the steel curb. No deduction
shall be made for reinforcement, ties, bolts, nuts, rivet heads and bracing.
BR.10. Providing, fabricating and setting out mild steel cutting edges for R.C.C. well
curbs as shown on the detailed drawings.
The specification shall be same as for BR.8 except that the steel cutting edge shall replace
RED BOOK  VOLUME I  ROADS  2012 121
BR.11.
steel curb.
BR.11. Providing, cutting, bending, hooking, laying in position and tying mild steel
reinforcement bars for well-curbs and steining complete as per detailed drawings.
BR.11.1 General - The item shall include providing the reinforcement bars, fabricating
them as per sanctioned design or as ordered by the Engineer and placing them in position
ready for the concreting as laid down in specification No.B.10.
BR.11.2 Materials - Steel bars and binding wire shall comply with specification No.A.9.
BR.11.3 Fabrication and placement - Fabrication shall generally comply with specification
No.B.10 The steel reinforcement of the appropriate size and shape shall be properly
assembled and accurately placed in exact position as shown on the drawing or as ordered
by the Engineer including reinforcement to be embedded in the steining of the well for
obtaining proper bond between the curb and the well steining. The tie rods shall be fixed
securely to the horizontal member of the cutting edge/steel curb with check nuts on both
sides. Alternatively the tie rods may be welded to the cutting edge with the approval of the
Engineer. The threaded portion of the bar is to be hammered flat after fixing of the nut into
position.
BR.11.4 Splicing - Where splices are necessary, they shall be staggered as far as possible.
They shall be lapped 45 diameters excluding hooks. Authorised lap length of bars will be
paid for.
All bars protruding from the concrete, to which other bars are to be spliced and which are
likely to be exposed for a considerable period shall be protected from rusting by a thin neat
cement wash.
BR.11.5 Item to include - The item shall include in addition to others mentioned in the
general specification No.B.10 threading of the bars and double check nuts where necessary,
flattening the ends of bars below the nuts and neat cement wash to bars likely to be exposed
for appropriate period.
Welded joints, if approved, in place of laps will be paid in length of bars required for
overlapping. Welding of steining reinforcement bars to the cutting edge, if permitted in lieu
of fixing with bolts, shall be included in the rate and no separate payment will be made for
the same.
BR.11.6 Mode of measurement and payment - As per specification No.B.10.
Threading of bars, providing nuts and checknuts for attaching the reinforcement bars of
cutting edge or welding in lieu shall not be paid for separately.
BR.12. Providing and laying in situ concrete for R.C.C. well curbs including necessary
shuttering, laying, compaction by vibrating, finishing and curing, complete (excluding
steel reinforcement).
BR.12.1 General - The specification for the cement concrete required for the R.C.C. curbs
for the well shall comply with the specification No. B.6 subject to the following. -
BR.12.2 Forms - Forms shall be of mild steel sheets bend to the required shape and
stiffened suitably with mild steel angles. Other types of forms shall be permitted only with the
prior approval of the Engineer in special cases. The forms shall be fabricated in segments
to facilitate easy handling. The form work shall be completely leak proof. The outer forms
may be removed in 48 hours after laying concrete.
The inside forms carrying the weight of the curb shall be removed after 7 days after laying
concrete.

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 BR.13.6
BR.12.3 Proportions - The proportion for the cement concrete for the well curb shall be
as per the mix design or proportions as specified in the wording of the item. Water content
may be within the range laid down in specification No.B.6.3 or as may be approved by the
Engineer to give the required consistency.
BR.12.4. Coarse aggregate - Coarse aggregate shall be crushed from sound stones of
the specified type available in the region and approved by the Engineer. The maximum size
of the coarse aggregate shall be 6 mm less than the cover or 40 mm whichever is smaller.
The aggregate shall be properly graded from the maximum size to 5 mm as indicated in the
specification No.A.7. The contractor shall get the samples of sand and coarse aggregate
approved by the Engineer who will keep them in his office for reference.
BR.12.5 Mixing - The cement concrete shall be mixed in mechanical mixer. Slump may
be 5 cm.
BR.12.6 Placing concrete - The concrete for the curb shall be laid continuously from start
to finish without break. No junctions or joints shall be allowed while laying the concrete.
It shall be laid in the dry. Dewatering if necessary, shall be included in the item unless
separately provided in the tender.
BR.12.7 Compaction - Compaction shall be done by mechanical vibrators and also by
rods so that all reinforcement is properly embedded, all corners are properly filled, honey
combing is avoided and dense concrete is obtained.
BR.13. Providing and laying in situ concrete in well steining including necessary
shuttering, laying, compaction by vibrating and rodding finishing and curing,
complete (excluding mild steel reinforcement).
BR.13.1 General - The concrete for steining of the well shall comply with specification
No.B.7 subject to the following :-
BR.13.2 Forms - The design of the forms shall be such as to build the steining to make
up the lift not exceeding 2 m in height in convenient number of courses. Forms shall be
preferably be of mild steel sheets bent to conform accurately to the required shape and
stiffened suitably with mild steel angles or other sections and shall have no gaps at joints.
The forms shall be fabricated in segments to facilitate easy handlings. If timber forms are
used they shall be lined with plain galvanised iron sheets. The form work shall be completely
leak proof.
The side forms shall be removed 48 hours after the concreting and the surface finished
where necessary immediately thereafter, and kept well watered for the curing period.
BR.13.3 Proportion - The proportion of cement concrete for the well steining shall be as
per the mix design or as specified in the wording of the item.
BR.13.4. Coarse aggregate - Coarse aggregate shall be crushed from sound stones of
the specified type available in the region and approved by the Engineer. The maximum
size of the coarse aggregate shall be 50mm or 6mm less than the cover , The aggregate
shall be properly graded from the maximum size to 5 mm as indicated in the specification
No.A.7
BR.13.5 Mixing - Mixing shall be done in a mechanical mixer. Water content may be within
the range specified in specification No B.6.3 or as may be approved by the Engineer to give
the required consistency.
BR.13.6 Placing concrete - Before building up the steining the planks below the curb if any
shall be removed in such a manner as to maintain reasonably equal pressure of the curb
on its bed without any tilt. After the forms are set up and approved, reinforcement verified

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BR.13.6
and checked, the concrete shall be placed in such a way as not to cause segregations. The
concrete shall be laid continuously all round from start to finish of each course. The building
up of steining shall be proceeded with in convenient lifts as directed by the Engineer as
well is sunk by excavating the inside. The first height shall not exceed 2 m and second 2.5
m. Subsequently height shall be built upto convenient heights not exceeding the diameter
of the well. At any stage the well above the top of the island or bed (if there is no island),
shall not project more than 2 m or half the depth of well sunk below the top of island or
bed, whichever is more. The concrete shall be poured in the best manner possible without
segregation of metal and the steining shall be built up to equal heights around its whole
circumference. The height of the steining from the bottom of the cutting edge shall be
marked continuously by paint and thin incisions at intervals of 25 cm on the inside and
outside of steining so as to facilitate inspection.
BR.13.6 Compaction - Compaction shall be done by immersion type vibrators and rods so
that all reinforcement will be properly embedded, all spaces properly filled to give a dense
concrete and honeycombing is avoided.
BR.13.7 Joints - The top of the well steining at various lifts shall be left rough so as to
develop a good bond between two lifts. The joints between successive stages of concreting
shall be water tight. Before adding a lift, the old concrete surface left rough shall be brushed
with wire brushes to remove laitance and all loose particles and washed cleaned. A uniform
thin coat of 1:3 cement mortar shall be applied to the cleaned surface and concrete of
the upper lift shall be placed immediately thereafter. The upper lift shall be placed after a
minimum interval of 3 days after laying the lower lift. Kentledge shall not be laid before the
concrete develops sufficient strength to bear it.
BR.13.8 Curing - Curing shall be done as per specification No. B.6.
BR.13.9 Sampling and testing - Sampling and testing shall be done as in specification
No.B.6 only if the Engineer doubts the quality of work.
BR.13.10 Cutting steining - If the steining is built to heights greater than those indicated
on the drawings or as directed by the Engineer, the contractor shall cut the extra height
neatly to a uniform plane without damage to the concrete below at his own cost and no
payment will be made for the extra height or for cutting it to the required level.
BR.13.11 Item to include - As per B.6.14.
It shall also include marking heights of steining from the cutting edge upto the top on the
inside and outside of the well and cutting steining, etc., if any as above.
BR.13.12 Mode of measurement and payment - As per B.6.15. Reinforcement will be
paid for separately under item No.BR.11.
BR.14. Sinking the wells for foundations through all strata except rock by approved
methods including removal of obstacles and use of necessary plant, machinery,
divers, etc., and proper seating of the well.
BR.14.1. General - The specification pertains to the well sinking operation proper. Cutting
edge, curb reinforcement and concrete, steining reinforcement and concrete shall be
included and paid for under separate items. Preliminary open excavation or dressing is
required for laying the cutting edge and curbs and providing island shall be included in the
item unless separately provided in the tender.
BR.14.2 Sinking of well - The item provides for sinking of the well through all strata
except rock to the R.L. as shown on the drawing or ordered by the Engineer until desired
foundation stratum is met with.

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 BR.14.2
Programme should be arranged as far as possible in such a way that, every well started
during working is completed, plugged and sealed at the top and the pier or abutment
constructed to a safe level in that season only, so as to be safe during floods. If not, suitable
protective measures shall be taken by the contractor at his own cost.
The contractor may at his own cost, bore holes to ascertain the exact depth to which
particular wells may have to be sunk. If bore results are indicated by the Department,
they shall be taken only as general guide. Government do not bind themselves for the
accuracy of the same. The contractor shall not be entitled to any compensation on account
of variation in strata during actual sinking.
If the river bed is dry, open excavation shall be carried out to about 30 cm above the subsoil
water level before the cutting edge is laid.
Where it is necessary to sink the well in water, an island shall be formed as laid under
specification relevant for laying the cutting edge.
The cutting edge for the curb shall be constructed as detailed under relevant specification.
The steining shall be built up as detailed in relevant specification.
The cutting edge or the curb shall be laid in the exact position on blocking timber. The
blocking timber shall be removed individually in such a manner as to maintain equality of
pressure without any tilt of the cutting edge. The blocking timber shall be pulled out after
loosening the sand underneath. Material within the curb shall be excavated methodically
and evenly over the whole internal area excavating first in the centre and working towards
the circumference uniformly till the curb sinks to about 15 cm above bed. Sand or soil
excavated shall then be back filled to keep the pitched curb in place and stable. The
formwork of steining shall then be set up and then first lift poured.
The well may be adjusted and guided in regard to its direction of sink by temporary
frame work or staging. The staging may be used as platform for handling material and
fixing the dredging equipment thereon. The design and layout of the staging shall require
prior approval of the Engineer although the contractor will not be there-by relieved of his
responsibility for its safety and suitability.
Sinking must not be started till the concrete steining to be sunk has set properly and until
the steining has been passed by the Engineer and commencement of sinking is approved.
The well shall be sunk by excavating the material from the interior methodically and evenly
and removing the material and building up additional sections of steining as the well sinks.
The excavated materials shall be stacked within a lead of 50 m or wasted.
It is essential to see that the curb and the first two lengths of the steining are kept perfectly
vertical and they do not go out of place or plumb materially. The subsequent sinking to
plumb is easier. Any neglect in initial stages will make it more difficult to correct errors.
The contractor shall adopt his own arrangement and method of sinking consistent with
the magnitude of the work, its nature, site conditions ,speed required, etc., and failing
the required progress, the sinking shall be done as ordered by the Engineer. Normally
one of the following methods or combination of two or more of them will be found to work
satisfactorily according to the site conditions :-
1. Manual excavation.
2. Excavation by divers.
3. Excavation by winch and grab, heavy chisels, etc.
4. Excavation by dredgers.
5. Sinking by applying kentledge.

RED BOOK  VOLUME I  ROADS  2012 125

BR.14.3
6. Using light blast with approval of the Engineer.
7. Dewatering.
8. Jetting.
Manual excavation aided by tools to suit the strata may be conveniently resorted to where
there is no much of water or where the water can be easily pumped out.
In deep water, the excavation will have to be done by the aid of winch and grab or a
dredger. Harder strata will have to be loosened by the chisels.
In case of manual excavation under water or removal of obstructions such as boulders, logs,
etc., divers may have to be employed to successfully excavate or remove the obstacles.
When the well does not sink, even after dredging or excavation, kentledge shall be applied
judiciously to effect the sink.
Great care shall be taken from the commencement of sinking operations to ensure that the
well is continuously kept in exact position and perfectly vertical, checking frequently with
the plumb bobs hanging over inside faces of the steining. Daily records of tilts and shifts
shall be kept on site in the requisite proforma. If there are sand blows in the wells they shall
be removed after establishing stable conditions and no claim shall be entertained regarding
removal of the material or difficulties connected therewith.
The tendency of the well to lean to one side over dipping hard strata or in soft soils shall be
countered by providing suitable supports, etc. The levels of excavation in the wells shall be
constantly checked so as to keep the bottom as nearly level as practicable.
Dewatering to the extent necessary shall be done as and when required. Balancing the
water level inside and outside the well shall also be arranged whenever necessary. Jetting
outside may be resorted to when advisable with the approval of the Engineer. All these and
any other measures required to sink the well are included in the item.
In sinking group of wells joined together, the excavation in all the wells in one cluster should
be carried out simultaneously and equally to facilitate even sinking.
Where two separate wells are to be sunk close to each other or the distance between them
is not greater than the diameter of the well, they should be sunk alternately each being sunk
not more than 1/2 the diameter in advance.
BR.14.3 Obstacles - When obstacles such as boulders, logs, hard clay, compacted
material, etc., are met with they shall have to be removed by grabs, dredgers, etc., after
breaking, cutting, jetting, etc., by sending divers if necessary. If this is not successful small
charges of explosives may have to be used with the permission of the Engineer to break
the boulders by sending divers. In no case blasting of any sort shall be done without the
permission of the Engineer in writing and before the concrete in steining has hardened
sufficiently and is more than 7 days old. The contractor shall include in his tender rate, the
eventuality of the cost of the services of divers and all other costs ancillary for removing
boulders, dislodging obstructions below cutting edge and such other operations as may be
required for sinking the well. The method of removal of the obstacles shall be got approved
by the Engineer.
BR.14.4 Kentledge - Kentledge may be used with advantage in sinking the well to over-
come skin friction and buoyancy but shall not be excessive so as to damage the cutting
edge or steining or arranged in such a way as to interfere with the internal excavation.
BR.14.5 Explosives - When other measures are not successful, sinking of wells held up
by skin friction, etc., is some times aided by tremor and vibrations caused by exploding
a small charge of 28 grams or 56 grams of dynamite in the centre of the well. But such

126 RED BOOK  VOLUME I  ROADS  2012

 BR.14.11
explosives shall not be used without the specific approval of the Engineer. Any damage to
the well or adjoining structures due to the blasting shall be made good by the contractor at
his own cost.
BR.14.6 Righting - If the well tilts during sinking it may be righted by -
1. Putting an eccentric loading on the high side of the well.
2. One side excavation at the bottom of wells which is on the higher side.
3. Jetting on the higher side to reduce skin friction.
4. Pulling or pushing the well by approved methods.
5. Any other suitable method.
Methods adopted for righting the well shall require the approval of the Engineer. This shall
however, not relieve the contractor of his responsibility for obtaining satisfactory results.
BR.14.7 Last sink - When the well is approaching final depth and before the last length of
steining is poured in, the exact length required should be decided and the steining should
be built up preferably just less than this length with a view to build it up to the correct level
after the well has been sunk to its final depth.
BR.14.8 Bedding of well - When the well has reached the required level and strata, it
shall be properly seated by levelling the area under the cutting edge. Where uneven or
sloping rock is met with, rock cutting shall be done either after dewatering or by sending
divers to ensure that the periphery of the well rests evenly on rock for more than half the
circumference. Where the difference in level at extreme ends is not more than 30 cm efforts
shall be made to seat the entire well evenly on the rock. Otherwise in the portions where the
well does not rest on rock over-burden on the rock shall be removed and the space filled
with concrete while laying bottom plug. Cutting rock to seat the well properly is included in
the rate of sinking. In cases other than rock bed the well bottom should be embedded into
the strata well below the scour depth to obtain the required stability as shown in the plans
or as ordered by the Engineer.
BR.14.9 Cracks in wells - Vertical and horizontal cracks of a minor nature developed
during sinking for various reasons shall be grouted and finished with neat cement. If the
cracks are appreciable, the well or portion of the well from bottom plug to a section covering
the cracks shall have to be filled with 1:4:8 concrete as directed by the Engineer at the cost
of the contractor.
BR.14.10 Tolerances - The completed well shall not have tilt of more than 1 in 60 of the
depth in any direction and shift of more than 5 percent of the external diameter, unless these
affect the stability of foundations. When the Engineer allows tilt or shifts the dimensions of
the concerned well cap shall be increased so as to cover completely the well tops and the
caps shall be symmetrical with respect to the axis of the piers, abutment and the axis of
the bridge provided that the stresses at the foundation of the well are within permissible
limits. No payment for increase in dimensions of the cap or reinforcement shall be made by
Government. If even with the adjusted location and increased dimensions of the well cap,
the stresses at the foundation level due to tilt and shift do not fall within permissible limits,
the contractor shall have to provide all the additional remedial measures at his own cost. If
due to tilts and shifts and the remedial measures, the span arrangement is required to be
changed, it shall be so done at the cost of the contractor.
BR.14.11 Tests - In case of wells which are not founded on soft or hard rock, load test of
well and bearing capacity of the foundation stratum shall be carried out by the contractor on
any one well as ordered by the Engineer. Loading tests of the well and bearing capacity of
the foundation stratum of the well shall be carried out according to the relevant specification
RED BOOK  VOLUME I  ROADS  2012 127
BR.14.11
and will be paid for separately.
The choice of the well to be tested rests with the Engineer. Additional number of wells may
be tested if so ordered by the Engineer. If the results are found to be unsatisfactory due to
bad concrete or defective sinking, the cost of the test shall be borne by the contractor. All
defective wells shall have to be rectified by the contractor at his own cost.
The contractor shall collect undisturbed and other samples of soil of the foundation stratum
as directed by the Engineer and supply them to the Engineer intact for testing. Cost of
collection of samples will be incidental to sinking and is included in the rate of sinking. Cost
of testing soil samples will be borne by the Department.
BR.14.12 Cleaning - After the well is finally and properly seated the bottom shall be
cleaned and all loose materials removed if necessary, by sending divers before laying
concrete for the bottom plug is permitted. This will be the time to check and verify the levels
and record the depth.
BR.14.13 Safety - The contractor shall be responsible to take all measures for the safety of
the work and workmen and also for any compensation due to injury to persons or damages
to work and property. Well-sinking shall be done in such a way as not to cause any damage
to adjoining structures. The contractor shall be responsible for any such damage.
BR.14.14 Item to include -
i) Open excavation to 30 cm above subsoil water level when no provision for open
excavation is made in the tender.
ii) Sinking of well through all strata except rock by excavation, dredging, loading, etc.,
and, disposing the excavated stuff.
iii) Dewatering, balancing water level.
iv) Righting.
v) Trial bores for deciding the actual depth if required by the contractor.
vi) Removing blows, obstacles, etc.
vii) Clearing the bottom.
viii) Redredging if the work is not completed before monsoon.
ix) Preparing seat by levelling uneven or sloping rock if necessary, for proper seating of
the well.
x) Use of divers.
xi) Collecting samples of materials, staging, use of equipment, tools and plant and other
incidental items necessary for the satisfactory completion of sinking the well.
xii) Safety measures and compensation for injury to persons and damages to work and
property.
BR.14.15 Mode of measurement and payment - The contract rate shall be for one metre
of well sunk through all strata except rock. The depth shall be measured correct upto 5 mm.
The depth of sink shall be measured from the initial level at which the cutting edge was laid
to the bottom of the cutting edge as finally bedded.
If the well is sunk upto 1.5 m. below the level specified on the drawings or even less than
shown on the drawings, actual depth will be paid for at the tendered rate. There will be
no compensation for sinking of wells to less depth than that estimated or shown on the
drawings.
For sinking of well beyond 1.5 m. below the designed level the contractor shall be paid
compensation commensurate with the extra cost involved.
128 RED BOOK  VOLUME I  ROADS  2012
 BR.16.
Variation in strata shall not entitle the contractor for extra claims.
BR.15. Providing steel, anchor dowels at the base of the well including drilling holes,
placing the dowels in position and effectively grouting the holes.
BR.15.1. General - The specification pertains to the provision of dowels to anchor well to
the foundation rock.
BR 15.1.1 Materials - Mild steel dowels shall comply with specification No.B.10 and
shall be of the size and shape shown on the drawings or as ordered by the Engineer. If
the drawing show the dowels to have split bottoms and wedges, they shall be prepared
accordingly.
BR 15.1.2 Sand shall comply with specification No.A5.
BR 15.1.3 Water shall comply with specification No.A4.
BR 15.1.4 Cement shall comply with specification No.A2.
BR.15.1.5 Cement sand grout shall be of 1:1 proportion and of as thick a consistency
as possible to suit the operation and poured in small quantities and rodded all round to
ensure complete embedment of the dowel leaving no hollow in the bore hole.
BR.15.2. Constructional details - Where the well bottom is sufficiently dry or can be
pumped dry, holes shall be drilled in the foundation rock stratum at the locations shown in
the drawings or as directed. The diameter and the depth of the bore shall be as shown on
the plan or as ordered.. The bored holes shall be cleaned and dewatered and kept cleaned
till the dowels are driven and grouted.
Mild steel sections with split bottom and wedges when so shown on the drawing, properly
cleaned of rust, paint etc., shall be inserted and driven in the bores and grouted with 1:1
cement mortar slurry and allowed to set. The dowels shall be embedded in the bottom plug.
Where the well bottom can not be dewatered, the bottom plug shall be laid first and then
holes drilled through the concrete of the bottom plug into the rock stratum on which the well
is founded. Rest of the process shall be similar to the one explained above, the portion of
the bore hole in the plug also being grouted. If any part of the dowel is projecting above the
plug, that portion shall be bent flat before insertion and embedded in 1:2:4 cement concrete
so as to have a cover of 15 cm. all round, concrete shall be cured.
BR.15.3. Item to include -
1) Dewatering.
2) Drilling holes in the foundation rock and also through bottom plug when necessary
as shown on the plans or as directed by the Engineer.
3) Furnishing the mild steel sections with wedges prepared to shapes shown on the
drawings or as directed by the Engineer and placing and/or driving in position.
4) Grouting the dowels and embedding them in concrete above the plug where
necessary.
5) All labour, material, use of equipment, tools and plant, and other incidental items
necessary for the satisfactory completion of the work.
BR.15.4. Mode of measurement and payment - The contract rate shall be for a unit of
one dowel fixed. The dowel shall be of specified section, length and shape, placed along
with the wedge in the hole of required diameter and shape, driven in and grouted and
embedded in concrete where necessary.
BR.16. Providing and laying in situ cement concrete for the bottom plugs of wells in
the dry or under water including compaction and curing where necessary.

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BR.16.1.
BR.16.1. Cement concrete - Cement concrete shall comply with specification No. B.6. for
nominal mix cement concrete subject to following :-
BR.16.1.1 Proportion - The proportion for cement concrete for the bottom plugs shall
be as per the mix design or as specified in the wording of the item.
BR.16.1.2 Coarse aggregate - Coarse aggregates shall be crushed or broken from
sound stone of the specified type available in the region and approved by the Engineer.
The maximum size of the coarse aggregate shall be 50 mm. and well graded from 50
mm to 5 mm. as indicated in specification No. A.7.
BR.16.1.3 Mixing - Mixing shall be done in mechanical mixer. When concrete is to be
laid under water, water content shall be as such to give a slump of not less than 10 cm.
and not more than 18 cm.
BR.16.1.4 Placing - When the concrete is to be laid under water it shall be done
by tremine or any other method as per I.S. 456- para 7.1.7 as may be approved by
the Engineer. When the concrete is laid in dry, water content shall be within the range
specified in specification No. B.6. and approved by the Engineer. When placement is
in the dry compaction shall be done with vibrators and curing done as in specification
No.B.6.
BR.16.2. Details of construction - When the well has reached the foundation rock bed
and properly seated and the inside of the well has been thoroughly cleaned of all rubbish or
loose and soft materials over-lying rock bed concreting will be permitted by the Engineer.
In the case of other softer strata when the well reaches the suitable strata and level to be
founded upon as approved by the Engineer, all loose materials from inside the well shall
be completely removed before placing concrete. If water can not be pumped out, divers
should be sent down to clean the bottom by removing all loose and soft materials before
placing concrete. The depth of the well shall be carefully measured at this stage, verified
and recorded.
If the well can be kept dry without pumping during placing of concrete and during the time
required for its setting, concrete may be laid in the dry and compacted by vibrator.
When the concrete is to be placed under water, the water level in well should be brought up
to its normal steady condition or in level with the water outside the well before concreting
is started. No dewatering is to be done in the well in question nor in any adjacent well at
the time of concreting till it is set. When concreting has to be laid under water, it shall be
deposited in still water by specially designed water tight collapsible or emptying buckets
approved by the Engineer or by tremie. The placing operations shall be continued without
break till the full thickness of the plug is formed to avoid laminations and to effectively seal
the bottom. The mouth of tremie shall all times remain submerged in the concrete. The
consistency of concrete shall be such as to suit the operation as directed by the Engineer.
After depositing, the concrete shall be allowed to set for 14 days during which period it
should not be disturbed in any way. the water shall not be pumped or disturbed during the
period. The concrete should be premeasured before placing on the basis of bag mixes if
it will not be possible to measure the quantity due to the concrete spreading beyond the
cutting edge. In any case, a check on quantity should be kept by premeasuring the mixes.
BR.16.3. Testing - After the concrete has fully set, water shall be pumped out of the well
completely. The plug shall be considered satisfactory if there is no appreciable leakage of
water in the well through or by the side of the plug. If necessary, kentledge shall be applied
to overcome the buoyancy of the well during testing.
If the depth of the well is great and complete dewatering is likely to damage the plug by
upthrust, the test shall be limited to depressing the water level to safe hydrostatic head that

130 RED BOOK  VOLUME I  ROADS  2012

 BR.17.2.
the thickness of plug and buoyancy will permit. The rate of recuperation shall be observed.
If appreciable leakage occurs, the contractor shall be required to remedy the defect by
depositing more concrete to effectively seal the leakage or cement grouting.
These remedial measures shall be entirely at the cost of the contractor.
BR.16.4. Safety - All measures for the work and workmen shall be taken by the contractor
who will be responsible for any injury to life or damage to work or property during the
execution of the item.
BR.16.5. Item to include -
1) Carefully sounding the well bottom including dewatering where possible.
2) Cleaning the inside and bottom of the well thoroughly if necessary by using divers.
3) Pumping out water from the well to the extent possible and necessary when concrete
can be placed in the dry.
4) Bringing the water level in the well to the normal steady condition when concrete has
to be placed under water.
5) Providing and laying the cement concrete as detailed above under water if it can not
be laid in the dry.
6) Testing the bottom concrete plug for leakage including dewatering and apply
kentledge if and as required to counteract hydrostatic pressure.
7) Placing additional concrete or cement grouting till satisfactory results are obtained,
cost of the remedial measures being borne by the contractor.
8) Payment of compensation of injuries to persons or damage to property due to testing
operations, etc.
BR.16.6. Mode of measurement and payment - The rate to be paid for this item shall be
for a unit of one cubic metre of plug concrete actually laid. The cubic quantity of concrete
shall be calculated on the basis of average foundation level and the actual top level of
plug. The dimensions shall be measured correct to two places of decimals in metres and
the quantities shall be worked out correct to three places of decimals in cubic metres. The
volume shall be worked out by the prismoidal formula.
It is likely to be difficult to ascertain the dimensions of the plug laid, the quantity to be paid
shall be pre-measured based on number of 50 Kg. cement bag mixes used including the
concrete required to be laid below and beyond the cutting edge if necessary, to ensure
stability of the well. Bulkage of concrete over the quantity of coarse aggregate shall be
assumed at an average rate of 10 percent.
No deduction shall be made for the steel reinforcement or dowels if used.
BR.17. Providing and filling in wells with sand/rubble and sand/shingle and sand
including compaction between the top and bottom plugs.
BR.17.1 Material - Sand required for filling the well shall be clean, coarse free from clay,
clods, grass roots, etc., and generally obtained from local sources unless found to be
unsuitable. It should not contain more than 5 percent of clay. Rubble should be of trap or
granite or quartzite or gneiss, in that order available in the region, free from weathered,
soft or crumbling portions. Shingle shall be dense, hard and free from weathered, soft or
crumbling portion.
BR.17.2. Construction details - After the bottom plug is laid and tested by pumping, the
well shall be filled up with clean coarse sand or rubble well packed with sand or shingle and
sand as mentioned in the item, in layers of 15 cm. to 20 cm. and each layer compacted to

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BR.17.2.
maximum density up to bottom of top plug. To get this compaction, sand shall be laid under
fully saturated (flooded) condition so that it occupies the minimum volume while being
placed. Rubble or shingle when used, shall be laid in layers and each layer packed with
sand.
BR.17.3. Item to include - Providing filling in layers, watering and compacting the sand or
rubble and sand or shingle and sand as detailed above and all incidental labour, material
and use of tools, scaffolding, etc., required for completion of the item shall be included in
the item.
BR.17.4. Mode of measurement and payment - Before filling in, the depth of the top of
bottom plug shall be measured for verifying the fill and recorded. The contract rate shall be
for a unit of one cubic metre of compacted sand filling.
BR.18 Providing and laying in situ cement concrete for top plug of wells including
compaction by vibration and curing.
BR.18.1. General - The concrete shall conform to specification No.B.5 for nominal mix
cement concrete subject to the following.
BR.18.2. Proportion - Proportion of concrete shall be as per the mix design or as specified
in the wording of the item.
BR.18.3. Coarse aggregate - Coarse aggregates shall be crushed or broken from sound
stone of the specified type available in the region and approved by the Engineer. The
maximum size of the coarse aggregate shall be 50 mm. and well graded from 50 mm to 5
mm. as indicated in specification No. A.6.
BR.18.4 Mixing - Mixing shall be done in mechanical mixer. Water content may be within
the range specified in B.5. as approved by the Engineer.
BR.18.5 Dewatering - If there is water in the space to be concreted it shall be removed and
kept free of water by adopting suitable measures and devices at the cost of the contractor.
Dewatering shall be done according to specification No. BR.4 when necessary.
BR.18.6 Placing concrete - After filling sand, etc., is completed, and approved and its
level checked by the Engineer, the concrete of the top plug shall be placed. It shall be laid
to the correct level as shown on the drawings or as directed by the Engineer. Sand shall be
kept wet so as to occupy minimum volume when concrete is started but the surface shall be
just moist without any surplus water. Concrete shall make thorough bond with the steining.
BR.18.7 Compaction - Compaction shall be done by mechanical vibrators and rods so as
to get dense concrete and intimate contact with the steining.
BR.18.8 Item to include -
1) As per specification No. B.6
2) Keeping the top of sand filling moist but well drained.
3) Dewatering if necessary, when not necessarily provided in the tender.
BR.18.9 Mode of measurement and payment - All dimensions shall be recorded correct
to two places of decimals of a metre and the quantity worked out correct to three places of
decimal of a cubic metre.
The contract rate for the top plug concrete shall be for a unit of one cubic metre of concrete.
BR.19. Providing cast in situ R.C.C. bored piles 1:1.5:3/M20 mix for a capacity of
tones bored to the required depth through all strata except rock including compaction
of concrete.

132 RED BOOK  VOLUME I  ROADS  2012

 BR.22.2
BR.19.1. General - The item shall comply with specification No. B. 15 subject to the
following -
The R.C.C. pile shall have the specified capacity. It shall be circular in shape and have
the designed diameter. Reinforcement cage shall be formed of designed diameter and
Nos. of mild steel bars placed symmetrically along the circumference leaving the designed
cover. The stirrups shall be separate links or helical spirals of the designed diameter bars
as shown on the plans or as directed by the Engineer and tied with 1.63 mm (16 gauge)
or 1.22 mm (18 gauge) mild steel wire. cement concrete shall have a proportion of 1:1.5:3.
Cover shall be as designed.
BR.19.2. Defective piles - If the remedial measures needed to rectify cant, shift or other
defects involve adjustment of span arrangement, it shall also be done by the contractor at
his own cost.
BR.19.3 Item to include - In addition to those mentioned in specification No. B.15.10 cost
of adjustment of spans if any, shall also be borne by the contractor.
BR.20 Carrying out loading test of pile or pile group including construction of test
caps, accessories and dismantling them after test.
The item shall comply with specification No.B.17 in all respects.
BR.21. Providing, cutting, bending, hooking, laying in position and tying HYSD bars
for reinforcement for R.C.C. well/pile caps as detailed in the drawing including shear
pins.
BR.21.1 General - The item shall comply with specification No.B.10 subject to the following.
False work and form work required for R.C.C. work shall have been erected according
to specification No.B.6 to the satisfaction of the Engineer before starting laying out of
reinforcement. Splicing of the main longitudinal bars shall be by lap only. In case of caps
over piles, the main longitudinal bars of the piles shall be tied to the reinforcement of the
pile caps as shown in the plans or as directed by the Engineer. No separate payment will
be made for the protruding bars of piles for splicing them the bars of the pile caps.
In the case of wells, reinforcement bars from the steining shall be anchored into the well
cap as shown in the drawings or as directed by the Engineer. Such protruding bars for the
well steining will be paid for.
Shear pins of 25 mm diameter and 45 cm long shall be embedded in the top of the well
or pile cap for the length of 23 cm leaving the remaining length projecting above the top
of the cap concrete. These shall be fixed at one per sq. metre of area to be covered by
concrete or masonry of the piers and abutments. These pins shall be measured along with
the reinforcement for payment.
The projecting pins shall be encased monolithically with the well or pile caps in 1:2:4 cement
concrete with a 15 cm x 15 cm area at the top level of cap. 44 cm stone headers may be
used as pin headers instead of steel pins encased in concrete. No deduction shall be made
for pin headers or shear pins from the masonry or concrete of piers and abutments nor
separate payments shall be made for headers or concrete casing of shear pins.
BR.22 Providing and laying in situ cement concrete for R.C.C. well/pile, caps,
including necessary centering, formwork, compaction by vibrating, finishing and
curing complete (excluding mild steel reinforcement).
BR.22.1 General - The item shall comply with specification No.B.6 for cement concrete
subject to the following -
BR.22.2 Proportion of concrete - The proportion shall be as per mix design or as specified

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BR.22.2
in the wording of the item.
BR.22.3 Coarse aggregate - Coarse aggregate shall be crushed or broken from sound
and best stones of the specified type available in the region and approved by the Engineer.
The maximum size of the aggregate shall be 40 mm or 6 mm less than the cover whichever
is smaller and well graded form the maximum size to 5 mm according to specification No.
A.6.
BR.22.4 Forms - Wooden or metal forms may be used. Their rigidity and shape shall be
maintained by suitable tie, struts, frame work and lateral supports. They shall be supported
by unyielding centering. They shall be so built as to give the concrete the exact dimension
and shape shown on the drawings or as directed by the Engineer. Stripping off forms shall
be done as laid down in specification No. B.6.
BR.22.5 Reinforcement - The reinforcement of the shapes and dimensions shown in the
drawings shall be placed in the form work with the required spacing and cover and shall be
inspected, passed and measured by the Engineer before concrete is allowed to be started.
Cap reinforcement shall be tied with the reinforcement coming out of the well steining or
piles before concreting. The reinforcement out of the piles and well coming out of the cap
will be dealt with as in specification No. BR.21 as regards payment.
Mild steel bars of 25 mm diameter and 45 mm long shall be embedded for 23 cm in the
concrete with the remaining length protruding above the top level of the top concrete to
serve the shear pins. These shall be fixed at the rate of one for every sq. metre of the area
to be covered by the masonry or concrete of piers and abutments over the pile or well
cap. These will be paid along with the reinforcement. The projecting pins shall be in 1:2:4
cement concrete cast monolithically with the cap with top of 15 cm sq. and bottom of 20
cm sq.
BR.22.6 Scaffolding - All scaffolding required for facility of construction shall be provided
by the contractor at his own expense as also all measures to ensure the safety to the work
and work-people. Any instructions of the Engineer in this respect shall also be complied
with. The contractor shall be entirely responsible for injuries to persons or damages to work
or property in respect of scaffolding, ladders and materials. Proper scaffolding shall be
provided to allow easy approach to the work spot.
BR.22.7 Mixing - Mixing shall be done in mechanical mixer.
BR.22.8 Placing - Placing shall be done in one continuous process without break.
BR.22.9 Compacting - Compaction shall be done by vibrators supplemented by rods to
get-
1. thorough and full embedment of reinforcement bars.
2. dense concrete.
3. corners and angles of the forms thoroughly filled with concrete and,
4. good cast surface on the faces without honeycombing.
BR.22.10. Dewatering - Cost of dewatering if necessary, shall be included in the rate
unless it is separately provided in the tender and it shall be done as per specification No.
BR.4.
BR.22.11. Mode of measurement and payment - According to specification B.6.15. Tops
of piles embedded in the cap shall be treated as part of cap, piles being paid upto the
bottom of the pile-caps. BR.21.1 shall apply regarding pin headers and casing concrete
pins.

134 RED BOOK  VOLUME I  ROADS  2012

 BR.23.7.
BR.23. Providing coarse rubble masonry in cement mortar 1: for abutments, returns,
wings etc. with khandki facing and pointing with cement mortar 1:3 for all khandki
faces and rubble facing with struck joints for rubble backing including dewatering,
scaffolding and watering masonry complete.
BR.23.1. General - The item shall comply with specification No.B.9 for coarse rubble
masonry 2nd sort in cement mortar etc. in all respects except that all stones in each course
shall be of the full height of the course and shall be subject to the following.
BR.23.2. Materials -
BR.23.2.1. Cement mortar - The proportion of cement mortar shall be as specified in
the wording of the item for masonry and one part of cement to three part of sand for
pointing. Water cement ratio shall be such as to give fairly stiff plastic mortar.
BR.23.2.2. Stones - All stones shall be of specified type and best available in the
region and got approved by the Engineer before collecting them. The contractor shall
get dressed sample of all categories of stones required for the work and answering to
the specifications approved by the Engineer for reference.
BR.23.3. Height of the courses - The height of the courses shall not be less than 20 cm
unless specially permitted by the Engineer in writing. The adjustment of the total height
shall usually be made by providing courses of greater height in the lowest portions. The
height of the courses shall be predetermined so as to counting downwards from the top,
the corresponding courses in all piers, abutments, hauches, wings etc. will be at the same
level.
BR.23.4. Face stones - Khandki face stones shall be selected as far as possible for
their longer length on the face. Khandki facing shall be provided for the portion shown
in the drawings or upto 30 cm below the probable depth of exposures of masonry due
to scour or any other cause or as may be decided by the Engineer. Atleast 30 percent of
these stones shall tail into work to twice their height. On the backing, the face shall comply
with specification No.B.9 for uncoursed rubble masonry and the positions of headers shall
correspond with those in the facing.
BR.23.5. Dressing - In order to check the batter of abutments, returns or wings, 5 cm wide
chisel draft shall be provided at the ends of abutments and returns or wings.
BR.23.6. Pointing - Pointing of 1:3 cement mortar shall be done to all the khandki work
and shall comply with specification No.B.13. Cement pointing is included in the rate of
masonry.
BR.23.7. Weepholes - Weepholes shall be kept in the abutments and returns or wings to
drain the moisture from the earth fill behind the masonry. They shall be 8 cm wide and of
the full height of the course in which they are provided and extend through the full width
of the masonry, with a slope of 1 in 20 or so towards the outside draining face. The sides
and bottom of the weepholes in the interior shall be made up with stones having fairly plain
surface to avoid any obstruction to easy flow and the weephole channel will be slabbed
over with stones not less than 15 cm thick and having a bearing of not less than 10 cm
on each side. The weepholes may be spaced about 2 m apart horizontally and about 1 m
vertically in regular staggered positions commencing at about 15 cm above the low water
level or ground level whichever is higher or as directed by the Engineer.
Inverted filter shall be provided behind each weephole extending about 30 cm on all sides
of the hole and shall consists of core of 15 cm layer of 15 cm rubble next to the weephole.
Then 8 cm layer of 20mm metal or gravel covering the rubble layer on all sides and lastly
8 cm layer of sand covering the metal or gravel layer on all sides next to the earth filling.

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BR.
No deduction will be made for weepholes in masonry. Nothing extra will be paid for providing
the weepholes or inverted filters behind the weepholes.
BR. 23.8. Dewatering - Dewatering if required shall be done according to BR4.
BR. 23.9 Item to include -
(1) As in specification No B.9 as modified above and in addition :
(2) Providing chisel drafts.
(3) Pointing all khandki work with 1:3 cement mortar.
(4) If so directed excess excavation in rock shall be filled with concrete or U.C.R.
masonry of the foundation grade in the space outside prescribed dimensions of the
footing in the overbreak portion.
(5) Weephole with inverted filters.
(6) Occasional removal of few stones to see if the masonry is hollow.
(7) Dismantling of defective masonry and rebuilding it properly.
(8) Dewatering if required and not separately provided.
BR.23.10. Mode of measurement and payment - As in specification No.B.9.
No deduction will be made for weepholes and no separate payment will be made for them
and their filters.
BR.23.a). Providing coursed rubble masonry in cement mortar 1: for piers with
khandki facing and pointing with cement mortar 1:3 on all sides including cut and
ease waters, dewatering, necessary scaffolding and watering masonry complete.
BR.23.a).1.General - The specifications for this item shall be the same as in BR.23 subject
to the following -
BR.23.a).2. Face stones - Khandki facing shall be provided all around the piers. It shall
be provided for the depths shown in the drawings or upto 30 cm below the probable depth
of exposure of masonry due to scour or any other cause or as may be decided by the
Engineer. At least 30 percent of khandkies shall tail twice their height into the masonry. 5
cm chisel draft shall be provided at the end of straight portions of the piers near cut and
ease water for checking the batters which shall be uniform without a break.
BR.23.a).3. Cut and ease waters - Cut and ease waters shall be provided exactly to
the shapes shown in the plans and their face work shall correspond to that of the straight
portion of the piers. 5 cm chisel draft shall be provided on both sides of the nose of the cut
and ease waters to check that the batters are uniform. Nose stones shall be laid header
and stretcherwise.
BR.23.a).4. Weepholes - If there are land piers and weepholes are to be provided in them
they shall be provided as in specification No.BR.23 as modified above.
BR.23.a).5. Item to include -
1) As per specification No.BR.23 as modified above and in addition.
2) Providing cut and ease water and khandki facing on all sides.
3) Providing chisel drafts.
BR.23.a).6. Mode of measurement and payment - As in specification No.BR.23.No
deduction shall be made for weepholes if provided, and no payment shall be made for the
weepholes and their filters.
The tender rate shall cover the cut and ease water portions also which shall be measured

136 RED BOOK  VOLUME I  ROADS  2012

 BR.24.8.
nett.
BR.24. Providing and laying cement concrete for cast-in-situ piers, abutments,
returns, wings etc. including provision of V shaped false joints to form suitable panels
on the faces to approved design with necessary centering, shuttering, scaffolding,
laying, compacting by vibrating, finishing and curing complete.
BR.24.1. General - The item shall comply with specification No.B.6 for nominal mix cement
concrete subject to following.
BR.24.2. Proportion - The proportion shall be as per the mix design or as specified in the
wording of the item.
BR. 24.3. Aggregate - Coarse aggregate shall be crushed or broken from sound stones
of the specified type available in the region and approved by the Engineer. The maximum
size of the coarse aggregate shall be 50 mm. or 6 mm less than the cover (in case the
reinforcement is provided) which ever is smaller. The aggregate shall be properly graded
from the maximum size to 5 mm. as indicated in the specification No B.6 to give a dense
concrete. Samples of fine and coarse aggregates approved by the Engineer shall be
deposited in the Engineer’s office for reference.
BR.24.4. Slump - Slump as required for the suitable consistency shall be decided by the
Engineer and the same shall be maintained throughout.
BR.24.5 Mixing - Mixing shall be done in a mechanical mixer.
BR.24.6. Forms - The forms shall be either of timber lined with plain galvanised iron
sheets or steel plates strengthened with suitable mild steel sections as may be found
convenient by the contractor and shall be erected to the exact shape, dimensions, and
RLs indicated on the plans or as ordered by the Engineer. The forms shall be prepared
in panels or boards with V fillets as may be found convenient to obtain easily the false V.
notch joints on the surface of piers, abutments etc. The patterns of joints in abutments,
piers wings etc. shall be same and from the top towards the corresponding joints shall be
at same level unless directed otherwise by the Engineer. The design of forms and pattern
and dimensions of V fillets for false joints shall be furnished in advance by the contractor
for the approval by the Engineer. Any addition or replacement of different members if found
necessary and suggested by the Engineer, shall be provided by the contractor. However
the entire responsibility regarding erection and removal of form work and scaffolding, safety
of work and work-people shall rest on the contractor. The forms may be stripped after
48 hours after concreting. If reinforcement is provided, it shall be inspected, passed and
measured before concreting is allowed.
BR.24.7. Dewatering - If the area of placement is under water, cofferdams and other
necessary devices shall be provided and the water pumped out of the area kept dry
throughout the process of laying concrete and till such time as is required for the setting of
concrete in the opinion of the Engineer. Pumping shall be carried out in such a manner as
to avoid damage by movement of water through green or freshly laid concrete.
If the concrete is required to be laid under water it shall be done as laid down in specification
No.B.6. Water content of concrete should be adjusted in such case.
Cost of dewatering shall be included in the rate of concrete unless separate provision is
made in the tender.
BR.24.8. Scaffolding - Necessary ladders, scaffolding, etc, etc., shall be built up to convey
the concrete to the site of placement. This shall comply with specification No.B.6. Service
bunds, paths, hoists etc. as may be necessary for carrying out the item shall be provided

RED BOOK  VOLUME I  ROADS  2012 137

BR.24.8.
by the contractor at his own cost.
BR.24.9. Placing - The concrete shall be placed in one continuous operation without
break for each lift of concrete. The top of each lift be kept a little uneven to allow bond with
the concrete of upper lift. The height of the layer shall be such as to allow compacting with
immersion type vibrators conveniently. The height of lift to be concreted in one operation in
the case of abutments, wing-walls or returns and piers shall be got approved in advance.
Successive heights shall be laid after three days when the concrete has attained adequate
strength or as approved by the Engineer.
No operation shall be carried out causing vibration in the concrete already laid and partially
set.
24.10. Compaction - The concrete shall be compacted with mechanical vibrators of the
immersion type and also with steel rods worked along the mechanical vibrators to give
a dense concrete. The concrete shall be rodded in all corners, edges, and angles of the
forms and along the form faces while it is being vibrated to get a good surface finish without
honeycombing. Over vibration shall be avoided. Sufficient number of vibrators shall be
provided to compact the concrete sufficiently. The vibrators shall be applied immediately
after placing of concrete . The forms shall not be touched by the vibrators.
BR.24.11. Finishing - Immediately after the removal of forms any undulations, depression,
cavity honeycombing, broken edges or corners, high spots and other defects shall be made
good and finished with cement mortar 1:2. Such finishing is however looked upon only
an exception and the total surface requiring finishing shall not exceed one percent on an
average. If initial inspection shows that this percentage is exceeded, the entire method of
working shall be changed as ordered by the Engineer to get the cast finish.
V grooves as indicated on the drawings or as ordered by the Engineer shall be neatly
finished to give the appearance of panels on piers, abutment, returns, wing wall etc.
BR.24.12. Item to include -
1) As in specification No. B.6.14.
2) Providing V joints.
3) Dewatering if necessary, when not separately provided in the tender.
4) Scaffolding, hoists, service bunds and paths.
BR.24.13 Mode of measurement and payment - As per specification No. B6.15.
No deduction shall be made in the volume of concrete nor any extra payment made
for V grooves or other ornamental work on piers, abutments, wings or returns. Surface
reinforcement where provided shall be paid separately and shall not qualify the concrete
for payment as R.C.C.
BR.24.(a) Providing and laying cement concrete with plums for cast-in-situ piers,
abutments, returns, wings, etc., including provision of V shaped false joints to form
suitable panels on the faces to approved design with necessary centering, shuttering,
scaffolding, compacting by vibrating, finishing and curing complete.
The item shall comply in all respect with specification No. BR.24. except that the plums
shall be use as specified in BR.5(a).
BR.25. Providing, cutting, bending , hooking laying in position and tying mild steel
bars for reinforcement for piers and abutment caps and for concrete piers and
abutments when provided as detailed on the drawings.
BR.25.1 General - The item shall be carried out according to the specification No.BR.21

138 RED BOOK  VOLUME I  ROADS  2012

 BR.26.8.
for providing reinforcement in piers and abutment caps as also in concrete piers and
abutments as shown on the drawings or as ordered by the Engineer. Safe scaffolding as
specified in specification No.BR.26 and approved by the Engineer shall be erected where
necessary.
If anchor bolts, etc., are to be fixed while concrete is being placed, they shall be placed in
correct location and level and secured properly so that they will not be displaced in any way
while placing the concrete or vibrating fixing anchor bolts and other accessories of bearings
shall be covered under the item of bearings.
BR.26. Providing and laying in situ M / nominal mix cement concrete for R.C.C. caps
over piers and abutments including scaffolding, centering, form-work, compacting
by vibrating, finishing and curing complete (excluding steel reinforcement.)
BR.26.1. General - The following specifications from BR.26.2 to 26.10 shall be common
to both nominal mix and design mix cement concrete with due reference to specification
No.B.5 & B.6 for nominal mix and for design concrete mix.
BR.26.2. Coarse aggregate - The maximum size of aggregate shall be 40 mm or 6 mm
less than the cover whichever is smaller. Coarse aggregate shall be broken or crushed
from sound stone of specified type available in the region and approved by the Engineer
and well graded from the maximum size to 6 mm according to specification No. B.6.
BR.26.3. Forms - Wooden or metal forms may be used. Their rigidity and shape shall be
maintained by suitable ties, struts, frame-work, and lateral and bottom supports. They shall
be so built as to give to the concrete the exact dimensions and shape shown on the plans or
as directed by the Engineer. If richer concrete blocks are to be provided below the bearings,
such block spaces shall be isolated by suitable form-work approved by the Engineer to
provide exact dimensions required for the blocks. The forms may be stripped after 24 hours
after concrete is complete.
BR.26.4 Reinforcement - The reinforcement of the shapes and dimensions shown in
the drawings shall be placed in the form-work with required spacing and cover and shall
be inspected, passed and measured by the Engineer before concreting is allowed to be
started. Special reinforcement if any, under the bearings shall be placed in the correct
position. Reinforcement shall be paid separately.
BR.26.5. Scaffolding - All scaffolding required for facility of construction shall be provided
by the contractor at his own expense as also all measures to ensure the safety of the work
and work-people. Any instructions of the Engineer in this respect shall also be complied
with. The contractor shall be entirely responsible for injuries to persons or damage to work
and property resulting form use of scaffolding, ladders and materials or otherwise arising
out of his default in this respect. Proper scaffolding shall be provided to allow easy approach
to work spot.
BR.26.6. Mixing - Mixing shall be done in mechanical mixer.
BR.26.7. Placing - Placing shall be done in one continuous operation without break.
BR.26.8. Compacting - Compacting shall be done by vibrators supplements by rods to
get -
1) thorough and full embedment of reinforcement bars.
2) dense concrete.
3) corners and angles of the forms thoroughly filled with concrete, and
4) good cast surface.

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BR.26.9.
BR.26.9. Bearings - Bearings and anchor bolts of bearings to be fixed in abutment or pier
caps are to be placed correctly with regard to their location and elevation before concrete
is laid. They shall not be disturbed in any way during concreting. Anchor bolts and their
fixing shall be included in the item of providing bearings. Under special circumstances, the
Engineer may permit holes of the required size and depth to be left in the cap for fixing the
anchor bolts of the bearings at the later date and grouting them.
BR.26.10. Dewatering - Cost of dewatering if necessary, shall be included in the rate
unless it is separately provided in the tender.
BR.26.11. Nominal mix cement concrete - Proportioning mix :- Proportioning of the
ingredients for 1:2:4 nominal mix cement concrete shall be done as laid down in specification
No.B.6. Water contents shall be regulated to give the required consistency with a slump of
not more than 5 cm or as directed by the Engineer.
BR.26.12. Design mix cement concrete : Proportioning mix - Before the work is started,
proportions of fine and coarse aggregates and their grading and the minimum quantity of
cement and water required to give a desired compressive strength at 28 days on 15
cm cubes shall be determined by trial mixes in the laboratory. Works tests with the same
proportions shall show a compressive strength as specified.
BR.26.13. All other relevant provisions in specification No B.6. for nominal mix concrete
and B.7 for design mix cement concrete shall apply to the respective concrete used in this
item.
BR.27. Providing and laying in situ M20/M25/M30 cement concrete for R.C.C. concrete
block below the bearing including formwork, scaffolding, compaction by vibrating
and curing complete (excluding mild steel reinforcement.)
BR.27.1. Cement concrete - The cement concrete shall comply with specification No.B.6.
subject to the following:-
BR.27.2. Proportioning mix - Before the work is started, proportion of fine and coarse
aggregates and their grading and the minimum quantity of cement and water required to
give compressive strengths specified at 28 days on 15 cm cubes shall be determined
by trial mixes in the laboratory. Works test with same proportions shall show specified
compressive strength at the same age corresponding. For the purpose of quoting rates
the cement content shall be taken as 7.6/8.5/9.4 bags of 50 kg. per cubic metre .If with
approved aggregates and water cement ratio, minimum cement required is more or less
than specified above for attaining the above strength in the preliminary tests, the cost shall
be adjusted as indicated in specification No.B.7. No adjustment of cost shall be permissible
for change of proportions of aggregates of their grading. The proportions once decided on
the basis of preliminary tests shall be continued until there is a change in the materials. No
adjustments of cost for the contractor shall be made if the subsequent change of materials
requires grater cement content to obtain the specified strength.
BR.27.3 Form work - The open sides of the recesses in the abutment or pier cap concrete
shall be covered by wooden planks or metal sheets suitably strengthened and fixed to
serve as forms for casting of concrete without distortion.
BR. 27.4 Mixing - The concrete shall be mixed in a mechanical mixer.
BR. 27.5 Placing - The surface of the pier or abutment cap concrete to receive the cast-in-
situ concrete block shall be thoroughly cleaned and wetted before placing concrete. Anchor
bolts if not already fixed in the cap, shall be placed in exact positions before the concrete is
deposited and held so till the concrete is laid.

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 BR
BR. 27.6 Compaction - Compaction shall be done by vibrator and rods as concrete is
being poured. The concrete shall be sufficiently rodded to cover the faces of the joints in
cap concrete completely. Care shall be taken to see that anchor bolts are not disturbed by
rodding or by vibrators.
BR. 27.7 Item to include - As in specification No. B.6.15.
Bearing seats, anchors, etc. shall be fixed at the correct level and location.
BR. 27.8 Mode of measurement and payment - As in specification No. B.6.16 No
deduction shall be made for anchor bolts or reinforcement.
BR. 28 Providing, cutting, bending, hooking, laying in position, and tying HYSD bars
for reinforcement as per detailed drawings for
(a) Solid/deck slab.
(b) Main girders/arch ribs
(c) Cross girders
(d) Arches
General - The item shall be carried out according to specification No. B.10 in all respects.
Where thicker bars of the required full length are not available and where they are crowded
as in heavy beams, the bars shall be welded or joined with screwed coupling or bottle nut
as shown on the plans or ordered by the Engineer. In both cases, tests shall be conducted
as specified in specification No. B 10 to see that with the couplings/welds available and the
method of welding proposed to be adopted on the site, the strength of the coupled/welded
joints is not less than the strength of the bar. Payments for such welded and coupled joints
shall be made separately.
Bars necessary for splicing the reinforcement of the R.C.C. parapets, kerbs, etc. shall be
left protruding from the slabs. Where projecting bars form part of an item like parapet for
which the rate is inclusive of reinforcement, the projecting bars will not be paid separately.
BR. 29. Providing welded joints for mild steel reinforcement bars of
(a) 25 mm diameter and under
(b) 28 mm diameter
(c) 32 mm diameter
(d) 36 mm diameter
(e) 40 mm diameter
BR. 29.1 General - The item provides for welding joints in steel round bars 25 mm.
diameter and under and other large diameter bars used for reinforcement in R.C.C. work
and includes necessary welding materials use of specified process and equipment and
tests.
The item shall comply with specification No. B.10.7 in all respects.
BR. 29.2 Item to include -
(1) Cost of all labour, materials like electrodes or filler rods, use of equipment, tools and
plant etc., necessary for the satisfactory completion of the item.
(2) Testing welded joints. If the welding test is unsatisfactory and the bar is cut and
rewelded with an additional joint, such additional joint shall not be paid.
BR 29.3 Mode of measurement and payment - The contract rate shall be per number.
The measurement shall be for the number of joints made, limiting them to the specified

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BR
number or as ordered by the Engineer.
BR. 30. Providing bottle nut joints for the mild steel reinforcement bars of 25 mm.
diameter and above.
BR. 30.1 General - The item provides for the bottle-nuts joints in mild steel bars of 25 mm
diameter and above used for reinforcement in R.C.C. work and include necessary bottle-
nuts, labour, use of equipment and tests.
BR. 30.2 Joints - Whenever plans and specifications call for bottle- nut joints, they shall
be made in lieu of the laps and shall develop full strength of bars.
These joints shall be staggered in such a way that in any one section equal to the lap
length of bars not more than 33 per cent of the bars shall be with bottle-nut joints. Further
care shall be taken to see that the nuts do not prevent concrete from surrounding the bars
completely and affording full cover.
The ends of the bars which are to be joined with bottle nuts shall be upset for a sufficient
length before cutting threads so that the effective diameter after the cutting of threads shall
not be less than original diameter of the bar.
The ends of the bars shall have threads cut on them as shown in the drawings and shall be
cleaned of all loose scales, grease, paint and other foreign matter before fixing the bottle-
nuts.
Tensile tests on test specimen with bottle-nut joint shall be made at the contractor’s cost.
Two joints per 100 joints or a minimum of two joints shall be made on test pieces under
conditions exactly similar to the joints obtained in the field and tested for their strength.
The tensile strength of the joints shall not be less than that of the original bar. If the test
results are unsatisfactory, modifications in the procedure may be done as ordered by the
Engineer. The joints on the reinforcement bars prepared along with the test joints found
unsatisfactory shall be cut and redone. Additional bottle nuts if required in such cases shall
not be paid for. All the tests shall be at the cost of the contractor.
BR. 30.3 Item to include -
(1) Cost of all labour, materials including bottle-nuts, use of equipment, tools and plants,
etc. necessary for the satisfactory completion of the item.
(2) Testing joints.
BR. 30.4 Mode of measurement and payment - The contract rate shall be per number.
The measurement shall be for the number of joints made limiting them to the specified
number or as ordered by the Engineer.
BR. 31. Providing and laying in situ M20/M25/M30/M35 cement concrete for R.C.C.
work including centering, formwork, scaffolding, ramming, vibrating, finishing and
curing complete in
(a) Solid/deck slab,
(b) main girders/arch ribs
(c) cross-girders,
(d) arches (excluding reinforcement).
BR. 31.1 General - This item shall be carried out according to specification No. B.7 subject
to the following:-
BR 31.2 Proportion - The proportions shall be decided by mix design in a recognised
laboratory.

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 BR.
BR. 31.3 Item to include -
(1) Providing, laying, compacting, finishing and curing ordinary cement concrete to the
dimensions and shapes shown in the drawings.
(2) All labour, materials, use of equipment, tools and plant, centering, forms and
scaffolding necessary for the satisfactory completion of the item.
(3) Sampling and testing materials and concrete.
(4) Preliminary and works tests.
BR. 31.4 Mode of measurement and payment -
Solid slabs/Deck slabs - Solid slabs shall be measured net for their full length, width and
thickness. For beam and slab and box girder type construction, the top deck slab shall be
measured overall for the full width. Tapered and cantilevered portions of the slab shall be
measured net as slabs only. Fillets between slab and beam shall not be measured as part
of the slab. The length and the width shall be measured correct upto one cm while the
depth shall be measured correct upto 1/2 cm.
Main girders/Arch ribs - The main girders/arch ribs shall be the beams/ribs supporting the
slab/barrel slab and shall be measured for the dimensions below the soffit of the slab/barrel
slab. The average length of the arch rib shall be measured midway between extrados and
intrados. The length shall be measured correct upto one cm. The depth and width shall be
measured correct upto 1/2 cm. The fillets between slabs and beams/ribs shall be measured
as parts of beams.
In box type girder structures, all the structural elements including webs, bottom members
and connected fillets at bottom and top shall be measured as beams. The top slab shall be
measured as slab.
In case of the bulb type girders, the sectional dimensions shall be measured net correct
upto 1/2 cm.
Cross girders - These shall be measured for their length, width and depth between the
faces of main girders. The length shall be measured correct upto one cm. The depth and
width shall be measured correct upto 1/2 cm.
All the dimensions described above shall be restricted to the dimensions shown on the
drawings or as ordered by the Engineer in writing. In all cases no deductions shall be made
for vent pipes or pipes openings each of 5.0 sq.cm or less in section or for chamfers of less
than 50 mm. Deduction shall be made for bigger chamfers. All quantities shall be calculated
correct to three places of decimals of a cub.m.
The contract rate shall be for a unit of one cubic metre as agreed in the contract.
BR. 32. Providing expansion joints as per detailed drawings.
BR. 32.1 General - The item provides for the expansion joints in the cement concrete of
wearing course.
BR. 32.2 Material - The joints require an assembly of mild steel sections and the bituminous
filling material.
The width of joint shall correspond to the space between the ends of the slabs.
The bituminous filler shall be as under :-
(1) Poured joint filler - The poured joint filler shall be composed of the following ingredients
:-
Clean fine sand 55 percent.

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BR.
Bitumen S. 35 grade of I.S. 73-1961 40 percent.
Asbestos Fiber 5 percent.
The sand and the bitumen shall be heated separately to a temperature of 163o (about 325o
F). Both sand and bitumen shall be mixed intimately after heating. To this shall be added
asbestos fiber and the whole mixed thoroughly. While hot, the mixture shall be poured into
the clean dry joint and allowed to thicken. The mixture shall be laid slightly proud and if
found to be very high, the surplus shall be removed by heated knife or trowel.
When proprietary product from the market is to be used, it shall conform to I.S. 1834-1984.
(2) Pre-moulded joint filler - The joint filler shall be composed of the following ingredients:-
Clean fine sand 60 percent.
Bitumen S 35 grade of I.S. 73-1961 30 percent.
Cement 8 percent.
Chopped Hemp 2 percent.
The sand shall be heated in a flat pan to a temperature of 177o (about 350o F). The bitumen
shall be separately heated to a temperature of 163o (about 325o F). The requisite quantity
of bitumen shall be added to the heated sand and stirred well. The required quantity of
cement and chopped hemp shall be added and the whole mixed intimately. All the materials
shall be measured by weight. The mixture shall be then poured into moulds and allowed to
cool. Width of the moulds shall be such as to fill the U of the copper plate and remain about
25 mm. below the top of the slab. When proprietary product from the market is to be used
it shall conform to I.S. 1838.
BR. 32.3 Construction - The assembly shall be fixed as shown on the drawings and shall
be laid over the R.C.C. deck-slab. The wearing coat concrete shall then be laid leaving
requisite width of the joint in between the two wearing coat-slabs. Part of the slab receiving
the assembly many not be cast with the whole slab. This part may be concreted later.
In case it is so ordered by the Engineer, the joints shall be formed of premoulded joint
fillers and in such a case, this premoulded joint filler shall be placed in immediately before
taking up the concreting of the adjoining slab of the wearing course. These pre-moulded
joint fillers shall remain about 25 mm. below the top of the slab. This gap shall be filled with
poured joint filler.
BR. 32.4 Rate to include -
(1) Fixing in position the expansion joint and filling joint with the bituminous filler,
premoulded and or poured.
(2) All labour, materials, use of equipment required for satisfactory completion of the
item.
BR. 32.5 Mode of measurement and payment - The contract rate shall be either for
one number of such a joint or for one running metre of the joint as may be provided in
the tender. The lineal measurement of the joint shall be recorded correct upto 2 places of
decimals of a metre.
BR.32 (a) Providing and fixing neoprene expansion joints.
BR.32(a).1. General - The item provides for supplying and fixing expansion joints having
neoprene sheet to cover the junction of the adjacent span deckings. The fixing shall
include placing of the expansion joint in true position, maintain it into proper position
while concreting the ends of the deck R.C.C. work either while concreting of the deck or
so left for the purpose of receiving expansion joints.

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 BR.
BR.32.(a).2. Materials - The structural steel and bars required for the purpose shall
comply with I.S. 2062. The neoprene pad shall comply with the requirements for
neoprene as specified in BR.30.
BR.32.(a).3. Expansion joints - The expansion joint shall be fabricated according to the
drawing or as ordered by the Engineer. In case of ready made joints these shall conform
to the manufacturer’s specification. These shall be inspected before being placed for
any damage in transit defect in manufacturer. A sample of the expansion joint shall be
got approved and retained for the references. The expansion joint shall be embedded
into the concreting as specified in the drawing either while concreting of the deck or later
while concreting of the part left for the receiving the expansion joint. Care shall be taken
to see that the joint is not disturbed during the placing operation. Care shall also be taken
to see that the hold-fasts, bolts etc which are provided are thoroughly embedded into
the concrete and no hollows are left. This job shall be entrusted to a qualified person.
Any default shall be rectified by removing and refixing.
BR.32.(a).4. Item to include -
i) All labour, materials, equipment, tools, plant, etc required for satisfactory completion
of the job.
ii) Providing samples.
iii) Rectifying defaults.
BR.(a).5. Mode of measurement and payment - The measurement shall be for the
length of expansion joint so provided as appearing in the plan. The measurement shall
be taken correct upto two places of decimals of a metre. The contract rate shall be for
one metre length.
BR. 33 Providing and laying in situ cement concrete for haunch filling including
compacting, curing and scaffolding complete.
BR. 33.1 General - This item shall be carried out according to specification No. B.5/B.6
for concrete subject to the following :-
BR. 33.2 Proportions - As per B.5/B.6.
BR. 33.3 Coarse aggregate - Coarse aggregate shall be crushed or broken from sound
stones of the specified type available in the region and approved by the Engineer. The
maximum size of coarse aggregate shall be 40 mm. and the aggregate shall be well graded
from 40 mm to 5 mm as indicated in specification No. A.6 to give a dense concrete.
BR. 33.4 Slump - Slump of 5 cm. to 8 cm. as required for the suitable consistency shall
be decided by the Engineer and the same shall be maintained throughout.
BR. 33.5 Mixing - Mixing shall be done in a mechanical mixer.
BR. 33.6 Forms - Ordinarily no forms will be necessary for haunch filling. If, however, they
are found to be necessary, they shall comply with requirements laid down in specification
No. B.6.
BR. 33.7. Placing - The concrete shall be conveyed to the place of deposition without
causing segregation or loss of materials and shall be laid in horizontal layers 38 cm. to
45 cm. when vibrator is used and 15 cm to 20 cm manual compaction. The concrete shall
be placed as far as possible in one continuous operation in the entire haunch filling. The
top of the masonry or the concrete of the arches shall be thoroughly cleaned and wetted
before laying concrete. No operation shall be carried our causing vibration in the concrete
or masonry already set.
In a single span arch, haunch filling shall be carried out simultaneously on both sides of the
RED BOOK  VOLUME I  ROADS  2012 145
BR
arch and filling shall be continued in horizontal layers to conform to the required levels and
shape. In multi span bridges, concreting of the haunches shall be undertaken so as to not
cause unequal stresses in the arches.
BR 33.8 Compaction - In the thicker sections, compacting may be done by vibrator and
rod, but in the thinner and feather edge sections, compaction may be done by ramming
and rodding.
BR. 33.9 Finishing - Any unevenness, depressions, undulations, cavities, etc. shall be
swept clean before finishing.
BR. 33.10. Item to include - As per specification No. B.6.14.
BR. 33.11. Mode of measurement and payment - As per specification No. B.6.15.
BR.34. Providing rubble filling over haunches and arches including handpacking.
BR.34.1. General - The specifications for this item shall be the same as per BR.43 except
for the following :-
The rubble shall be laid carefully by hand over the arches and haunches close to each
other in layers of 15 cm. to 23 cm. with spalls wedged in the interstices for close packing.
The rubble shall not be dumped over the arch or the haunch concrete to avoid injuring the
arch or the concrete. The stones shall be laid gently.
Rubble and spalls shall be arranged at the top 15 cm. in the manner of a reverse filter to
drain away the seepage water through the drainage pipes in the head walls.
No earth or murum shall be allowed to get mixed which will impair the filtering action of the
rubble filling.
BR.34.2. Item to include -
(1) Supply of rubble and spalls, laying in layers and handpacking and providing reverse
filter at top.
(2) All labour, materials, use of tools, scaffolding, etc., necessary for the completion of
the item satisfactorily.
BR.34.3. Mode of measurement and payment - The rubble filling shall be measured net
in cubic metres liming the dimensions to those specified in the plans or as ordered by the
Engineer.
The dimensions shall be measured correct upto two places of decimals of a cubic metre
and the item shall be for one cubic metre. The contract rate shall be for one cubic metre of
rubble laid, handpacked and finished. No deduction shall be made for the voids.
BR.35. Providing and laying in situ cement concrete including compacting,
finishing, curing and filling in joints with bitumen complete for-
(a) Wearing course 8 cm. thick.
(b) Approach slab (excluding mild steel reinforcement).
BR.35.(a).1. Concrete - The concrete hall conform to specification No.B.6/B.7 subject
to the following:-
BR.35.(a).2. Coarse aggregate - Coarse aggregate shall be broken or crushed from
sound stones of the specified type available in the region and approved by the Engineer.
The stone shall be selected as far as possible to stand abrasion satisfactorily. The
aggregate crushing value, vide para. 4.4 of I.S.No. 383 - shall not generally exceed
30 percent. Maximum size of the coarse aggregate shall be 40 mm. The grading of
the aggregate shall be such as shall give dense concrete with the maximum possible

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 BR.35.(a).9.
proportion of the bigger size. Generally the following shall be found to work satisfactorily:-
Metal size ... 25 mm. to 40 mm. 60 to 66 2/3 percent.
Metal size ... 5 mm. to 25 mm. 40 to 33 1/3 percent.
BR.35.(a).3. Proportion - As per B.6
Water cement ratio shall not exceed 0.55 and slump shall not exceed 5 cm.
The proportioning of the mix shall be done as specified in No. B.6.
BR.35.(a).4. Mixing - Mixing shall conform to the relevant provisions in specification
No. B.6.4:concrete shall be mixed in mechanical mixers.
BR.35.(a).5. Forms - The side forms shall be of steel or timber preferably of steel. Their
depth shall be equal to the thickness of the slab. Timber form when permitted shall be
free from warps and shall have sufficient thickness to secure rigidity; their top edge shall
be true to level. Steel form shall be of approved section preferably channels. They shall
be true to line with suitable devices. The forms shall be coated on the inside with oil or
approved material to prevent sticking of concrete. The side forms shall be struck after
24 hours. They shall be removed in a manner not to injure the concrete or to break the
edges. They shall be cleaned and oiled again before reuse.
BR.35.(a).6. Transporting shall conform to the relevant portion of specification No. B.6.6.
BR.35.(a).7. Placing - Placing shall conform to specification No. B.6.7. in general.
The surface to receive the concrete shall be thoroughly swept clean of all dirt, loose
particles and laitance. It shall then be wetted immediately before placing of concrete
with just sufficient water to moisten the surface. The concreting may be done either by
the alternate bay or the continuous method. Care shall be taken to see that the required
thickness of the slab is obtained all over the area. Expansion joints detailed for that
item elsewhere, shall be fixed during the concreting to coincide with the expansion joints
in the decking in width and location. Contraction joint shall be provided at 6m.(about
20o) or at other regular intervals as directed by the Engineer and shall be formed by
making groove 6mm.(about 1/4”) wide with a depth of not less than 1/4th of the depth of
pavement at the thinnest part of the section with a suitable tool. Longitudinal joints shall
be plain butt joints.
BR.35.(a).8. Compacting - Compacting shall conform to the relevant portion of
specification No. B.6.7. Screed board vibrator shall be used for compacting. The tamper
shall weigh not less than 10.5 kg./metre of its length. The bottom shall not be less than
8 cm. wide. The bottom shall be shaped to give the required camber to the wearing
course. It shall be sufficiently strong to withstand working impacts and pressures. It shall
rest on the side forms and shall be moved ahead with a sawing motion. At transverse
joints it shall not be drawn closer than one metre towards the joint. In such a case it
shall be worked from the joint in the reverse direction and the surplus concrete removed.
BR.35.(a).9. Surface finishing -  Immediately after compacting, the surface shall be
inspected for its trueness and rectified where necessary and floated with a wooden band
float of 1.2m.X10cm. The float shall be worked in the transverse direction to the centerline
of the bridge to obtain uniform surface. The surface shall then again be inspected
for its trueness with a straight edges about 3m. long and rectified where necessary.
The surface for a width of at least 15 cm. on each side of the joints shall be floated
simultaneously with a float to produce a level surface across the joints immediately after
initial floating. The surface shall then be finished by a brass fiber broom pulled gently
over the surface in the transverse direction to the centerline of the bridge. The edges
of the slabs and of all transverse and longitudinal joints shall be rounded to a radius of
10mm with an edging tool.

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BR.35.(a).9.
The operation of finishing, brooming etc. shall be done from a bridge spanning across
the width of the concrete to avoid spoiling the surface.
BR.35.(a).10. Curing - Curing shall conform to specification No. B.6.9 sufficient care
shall be taken to protect the edges. Immediately after the initial set the wearing coat
shall be covered with wet empty cement bags. The bags shall be kept wet by sprinkling
water till the final set of the concrete. Soon after the final set of the concrete, bunds or
ridges of earth shall be laid as instructed by the Engineer over the edges and across the
surface to form suitable ponds. These ponds shall be filled with water and kept so far
14 days. The concrete surface shall be protected from any damage till it is completely
cured. After the curing is over, the surface and all the joints shall be completely cleaned
and the expansion joints filled as detailed in specification No. BR. The contraction joints
shall be filled with hot liquid bituminous sealing compound. The traffic may be allowed
after 2 days of filling the expansion joints.
BR.35.(a).11. Sampling and testing - This shall conform to specification No. B.6.12.
BR.35.(a).12. Keeping Records - This shall conform to specification No. B.6.13.
BR.35.(a).13. Item include - This shall be as per specification No. B.6.14. Compaction
shall be done by screed board vibration. Filling joints with bitumen is also included in the
item. Where copper strip expansion joint is not provided in the tender, filling expansion
joints with bitumen, sand and asbestos fiber shall be included in the rate for pavement
concrete.
BR.35.(a).14. Mode of measurement and payment - The contract rate shall be for
one sq. metre of the concrete pavement completed and finished. The concrete shall be
measured for its length and breadth, limiting dimensions to those specified on the plan
or as ordered by the Engineer. Dimensions shall be recorded correct to two places of
decimals of a metre and the area worked out correct to two places of decimals of a sq.
metre. No extra payment will be made if the thickness of the pavement is made more
than that specified. If the thickness provided is less than that specified, the concrete may
be rejected or a reduced rate may be paid as decided by the Engineer. No deduction
shall be made for vent holes.
BR.35.(b). Approach slab -
BR.35.(b).1 Preliminary - The earth work under the approach slab shall have been laid
in layers of 15 cm. to 20 cm. watered and each layer thoroughly consolidated before the
upper is laid. Water bound macadam with at least 15 cm. rubble soling duly hand-packed
shall have been also laid and well consolidated. These items will be paid separately.
 The water bound macadam surface shall be cleaned of all loose materials, blindage,
etc. and brushed clean with fiber brushes. Dust etc. shall be blown off by compressed
air or by waving with gunny cloth.
BR.35.(b).2 Reinforcement - Reinforcement as shown in the drawings or directed by
the Engineer shall be placed as specified in specification No. B.10. Reinforcement will
be paid separately.
BR.35.(b).3 Approach slab concrete - Specification for approach slab concrete shall
be the same as that for cement concrete wearing course. After the reinforcement is
placed, the area to be concreted shall be cleaned of dust and wetted. There shall be
no pools of water. Concrete shall then be laid to the specified depth and camber and
compacted with screed board vibrator and finished and cured and joints treated as in the
case of wearing course.
BR.35.(b).4 Item to include - This shall be as per specification No.B.6.

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 BR.38.5.
BR.35.(b).5 Mode of measurement and payment -This shall be as per specification
No. B.6.15.
BR.36. Providing vent holes in the slab and wearing course with iron grill at the top
and galvanised iron pipe at bottom as per drawing.
BR.36.1. General - The item shall be carried out according to the detailed drawings. The
holes shall be located as shown on the drawing or as ordered by the Engineer.
BR.36.2. Materials -
(1) Galvanised iron pipe 100 mm.diameter of required lengths.
(2) Grill of mild steel plates 6 mm. thick, cut and welded as indicated on the drawings. It
shall be welded to the pipe.
Both combined shall be of such lengths as to be just flush with the top of road slab and
bottom of deck slab.
BR.36.3. Construction - The 100 mm. diameter galvanised iron pipe shall be placed
during the concreting of the deck slab and allowed to project for the required length over the
deck slab so that the top of the grill shall be level with the finished wearing surface.
The edges of the exposed surface of the grill plates shall be neatly ground or filed flush with
the wearing surface so that the wheels of vehicles shall not be injured.
BR.36.4. Item to include -
(1) Galvanised iron pipes.
(2) Grills of mild steel flats or plates welded to the pipes.
(3) Fixing of Galvanised Iron pipes and grill.
(4) All labour, materials, use of equipment, tools etc, necessary for the satisfactory
completion of the item.
BR.36.5. Mode of measurement and payment - The contract rate shall be for one vent
hole provided. Measurement shall be for the number of such vent holes fixed on to the
bridge.
BR.37. Providing, cutting bending, hooking, laying in position and tying HYSD
reinforcement bars as per detailed drawings for ballast-walls, kerbs, returns,
approach, slabs, etc.
This item shall be carried out according to specification No.B.10 in all respects.
BR.38. Providing and laying in situ cement concrete for R.C.C. work of ballast walls,
kerbs, box returns, etc., including scaffolding, centering, formwork, compaction,
finishing and curing complete (excluding mild steel reinforcement).
BR.38.1. General - The item shall be carried out according to specification No.B.6. subject
to the following :-
BR.38.2. Proportion - As per B.6.
BR.38.3. Coarse aggregate - Coarse aggregate shall be broken or crushed from sound
stones of the specified type available in the region and approved by the Engineer. The
maximum size of coarse aggregate shall be 20 mm. and the aggregate shall be well graded
from 20 mm. to 5 mm. as indicated in A.6. to give a dense concrete.
BR.38.4. Formwork - Formwork shall comply with specification No. B.5.5.
BR.38.5. Mixing - Mixing shall normally be done in a mechanical mixer. But manual
mixing with all the precautions necessary to get a uniformly mixed concrete and additional

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BR.38.5.
cement as per specification No.B.5. may be permitted by the Engineer.
BR.38.6. Slump - Slump shall not exceed 10 cm.
BR.38.7. Compaction - Compaction shall be done properly by vibration wherever possible
and by rodding to give a dense concrete, full embedment of reinforcement and a good cast
surface without honeycombing.
BR.38.8. Finishing - Finishing shall be done as required in specification No.B.5.10. Kerbs
and exposed areas of returns shall immediately on stripping of forms and within one day of
such stripping, be finished with 6 mm. thick 1:3 mix smooth or sand faced cement plaster
as directed by the Engineer after roughening the original surface. Finishing shall be done
neatly to lines, levels and curves shown on the plans and shall present a workman-like
appearance. Curing shall be done for 14 days thereafter.
BR. 38.9 R.C.C. Box returns - In the case of R.C.C. box returns, excavation shall be
carried out as indicated on the plans for laying the footing of the R.C.C. returns and paid
for separately under relevant item of excavation. The excavated surface shall be watered
and compacted and lean concrete of the specified thickness laid to the required level for
laying of the R.C.C. return footing. This lean concrete shall be paid for separately under
relevant item. Before casting the concrete of the returns, suitable arrangements shall be
made to leave 100 mm. diameter vents at the designated places in the R.C.C. return to act
as weepholes. These holes shall be slightly sloping towards the outside.
Inverted filters as specified in BR 25.7 shall be provided behind these vents.
No deductions shall be made for the vents nor separate payment made for the inverted
filters behind the vents.
BR.38.10 - Item to include -
(1) As per specification No. B.6.14.
(2) Providing cement plaster finish to kerbs and exposed areas.
(3) Weepholes in the R.C.C. box returns and inverted filters behind them.
BR.38.11 Mode of measurement and payment - As per specification No. B.5.15. The
concrete shall be measured for its length, breadth and depth excluding plaster finish (where
provided) limiting dimensions to those specified on the plans or ordered by the Engineer.
Curved sections shall be measured net. No deduction shall be made for embedded pipes
or other opening less than 500 sq.cm. in sectional area. No payment shall be made for
the pipes if provided and inverted filters provided behind the weepholes in the R.C.C. box
returns.
BR. 39.(a) Providing R.C.C. parapet with cement concrete with cast-in-situ precast
panels, as per the detailed drawings including reinforcement scaffolding, centering,
formwork, compacting, finishing and curing complete.
BR. 39.(a).1. General - The item refers to the provision of R.C.C. parapet with precast or
cast-in-situ panels as per the item as detailed in the working drawings.
BR. 39.(a).2. Material - Mild steel bar reinforcement and wire shall comply with specification
Nos. A.9 and A.15 respectively. The diameter of the bars shall be as shown in the working
drawings.
Cement concrete for R.C.C. shall comply with specification No. B.5/B.6. Proportion of
concrete shall be as per B.5/B.6. Maximum size of coarse aggregate for R.C.C. panels and
railing shall be 6 mm and 20 mm. for the posts. Water content shall be regulated to give
the required consistency for the item within the range specified in specification No. B.6.3 or
as ordered by the Engineer. Mixing and compacting may be mechanical or manual as per
150 RED BOOK  VOLUME I  ROADS  2012
 BR.39.(b).2.
specification No. B.6.4. at the choice of the contractor subject to the production or concrete
of uniform consistency with all coarse aggregates entirely covered with cement mortar and
a dense concrete with good cast finish to the surfaces.
BR. 39.(a).3. Construction - The R.C.C. parapet shall be constructed as per the details
drawings after the centering of decking is removed.
The R.C.C. parapet of the type mentioned in the item shall be built in between cast-in-situ
R.C.C. posts to correct shape, dimensions and spacings specified on the drawings, The
mild steel bar reinforcement of the posts shall be provided as specified under specification
No. B.10 and shown in the drawing and spliced to the bars protruding from the slab or the
kerb.
The concrete shall be cast as per specification No. B.6 to shapes sizes and spacings
shown on drawings. The forms shall be such as to give the exact shape to the concrete
members shown in the drawings or ordered by the Engineer. Cast-in-situ posts panels and
rails shall be plastered neatly with cement mortar of 1:3 mix to 5 mm. thickness and finished
to smooth or sand faced as ordered by the Engineer. Plastering shall be done immediately
after and within one day of stripping the forms after roughening the concrete suitably. The
plaster and concrete shall be well cured for 14 days.
Precast panels shall be cast to the required design with specified reinforcement and tamped
and cured for 14 days. They shall originally present smooth surfaces and shall be filled into
the groves left into the kerb properly supported and grounded. Thereafter the R.C.C. post
and rail will be cast. Precast top rails may also be used along with precast panels in which
case only posts will be cast in situ. The cast-in-situ members shall be plastered with 1:3
cement mortar 6 mm thick to smooth or sand face finish, immediately after and within one
day of stripping the form after roughening and cured for 14 days.
BR.39.(a).4. Item to include -
(1) Providing R. C. C. cast-in-situ posts cast-in-situ/precast concrete panels and cast-
in-situ/precast rails as shown in the drawing including form-work and 6mm. thick
plaster of cement mortar of 1:3 mix for cast-in-situ members.
(2) Reinforcement for precast and cast-in-situ members.
(3) All labour, materials, use of equipment, tools, plant, scaffolding, etc., necessary for
the completion of the item satisfactorily. No separate payment shall be made for
concrete and reinforcement of R.C.C. members, the rate per metre being inclusive
of all the necessary materials like those mentioned above.
BR.39.(a).5. Mode of measurement and payment - The contract rate shall be for one
metre length of the parapet completed to the shape and dimension shown on the drawings.
The parapet shall be measured between the inside of the end pillasters over the abutments.
Where there are only end posts, the parapet shall be measured from outside to outside of
end posts. The length shall be measured correct upto two places of decimals of a metre.
BR.39.(b). Providing railing of mild steel angle /I/ tee posts and galvanised iron pipes
as per the detailed drawings including scaffolding and painting.
BR.39.(b).1. General - The item refers to the provision of mild steel angle, I or tee section
posts and galvanised iron pipe railings as shown on the working drawings.
BR.39.(b).2. Materials -
(1) Mild steel angles, I or tees as per the item, shall be of sizes shown on the plans and
shall comply with specification No.A.10.
(2) Anchor bolts, nuts and check nuts to be as per I.S.No.1148-1973 and of the shape

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BR.39.(b).3.
and size shown in the drawing or ordered by the Engineer.
(3) Galvanised iron pipes of the diameter as shown in the drawings with couplings shall
be of the standard type. The diameter shall be the inside bore diameter.
BR.39.(b).3. Construction - The railing shall be constructed as per the detailed drawings.
There shall be three rows of pipes on each side.
The angle iron, I or tee sections shall be fixed to the protecting anchor bolts which shall
be placed in accurate positions at the time of concreting of the slab and/or the kerb and
fastened securely by means of nuts and check nuts. Three rows of galvanised iron pipes
with couplings shall then be fixed on each side to line, levels and curves as directed by
the engineer and passing through the holes cut in the angles, I or tees. It should not be
possible to remove the pipes easily. All ragged edges of posts shall be smoothened by
filing. The pipes and posts shall then be painted with one coat of red lead and two coats
of approved shade good oil paint. Oil painting shall be done according to specification No.
B.13.
BR.39.(b).4. Item to include -
1) Providing or fixing angles, I or tees, as mentioned in the item, bolts, nuts, galvanised
iron pipes with coupling including painting as shown in the drawings.
2) All labour , materials, accessories, use of equipment, tools, plant, scaffolding, etc.,
necessary for the completion of the item satisfactorily.
BR.39.(b).5. Mode of measurement and payment - The contract rate shall be for one
metre length of the railing completed. The railing shall be measured correct to two places
of decimals of a metre.
BR.39.(c). Providing railing of cast in situ R.C.C. posts with 1:2:4 cement concrete of
trap/granite/quartizite/gness metal and chains as per the detailed drawings including
reinforcement scaffolding, centering, formwork, compaction, finishing and curing
complete.
BR.39(c).1. General - The item refers to the provision of R.C.C. post and chain type railing
as shown in the working drawings.
BR.39(c).2. Materials - Mild steel reinforcement and wire shall comply with specification
No. A.9 and A.15 respectively.
Cement concrete for R.C.C. posts shall comply with specification No.B.6. The maximum
size of coarse aggregate shall be 20 mm. Proportion of concrete shall be one 50 kg bag of
cement : 70 litre of sand : 140 litres of coarse aggregate. Water content shall be regulated
to give the required consistency for the member within the range specified in the B.6.3
as order by the Engineer. Mixing and maintaining may be mechanical or manual as per
specification No.6.4. at the choice of the contractor subject to the production of the concrete
of uniform consistency with all coarse aggregate entirely covered with cement mortar and
dense concrete with good cast finish to the surfaces.
Chains, eyes, hooks to be fixed in the R.C.C. posts shall be of mild steel or wrought iron as
detailed in the drawing or as ordered by the Engineer.
BR.39(c).3. Construction - The railing shall be constructed as per the detailed drawings
in cement concrete of 1:2:4 mix after reinforcement is fabricated and spliced to the bars
protruding from the slab or the kerb according to the specification No. B.10. The forms
shall be such as to give the exact shape and size to the concrete members shown in the
drawings or as ordered by the Engineer. The posts shall be correct to line the levels.
The cast in situ concrete posts shall be finished with plaster of 1:3 cement mortar 6 mm

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 BR.39(d).4.
thick after roughening the surface immediately after and within one day after stripping the
forms. The plaster and concrete shall be cured for 14 days.
The chain of the shape and dimensions shown on the drawings shall be fixed to the eyes
embedded in concrete of the posts indicated on the drawing either with both ends or one
ends fixed. The chain and steel exposed parts shall be painted with one coat of red lead
and two coats of good oil paint of approved shade. Oil painting shall be done according to
the specification No.B.13.
BR.39(c).4. Item to include -
1) Providing R.C.C. cast-in-situ posts with eye embedded in them and providing and
fixing chains shown on drawings with painting for chains and other exposed steel
parts.
2) All labour, material, use of equipment, tools, plant, scaffolding, etc., necessary for
the completing the item satisfactorily.
No separate payment shall be made for concrete and reinforcement of R.C.C. members,
chains, etc. The rate per metre being inclusive of all the necessary materials, accessories,
labours, etc.
BR.39(c).5.Mode of measurement and payment - The contract rate shall be for the one
meter of railing completed. The railing shall be measured between the inside of the under
pillasters over the abutments. Where there are only end posts, the railing shall be measured
from the outside to outside of the end posts. The length shall be measured correct upto two
places of decimals of a meter.
BR.39(d). Providing collapsible railing with mild steel channel posts and removable
galvanised iron pipes as per the detailed drawings included scaffolding and painting.
BR.39(d).1. General - The item refers to the provision of collapsible type of railing as
shown on drawings.
BR.39(d).2. Materials -
1) Channel sections for the posts and cleats shall be of the size and dimensions shown
on the drawings and shall comply with specification No.A.11.
2) Galvanised iron pipes of the diameters shown in the drawings with couplings shall
be of the standard type. The diameter shall be the inside bore diameter.
3) Anchor bolts, nuts, bolts and rivets shall conform to I.S. 1148-1964 and shall be of
the shape and size shown on the drawings.
BR.39(d).3. Construction - The railing shall be constructed as per the detailed drawings.
The channel cleats shall be fixed over the projecting anchor bolts by means of nuts. The
posts shall be fixed to the cleats as detailed on the drawings by means of nuts and bolts.
Three rows of galvanised iron pipes shall be fixed to the posts on each sides through the
holes punched for the purpose. The galvanised pipes shall be painted with one coat of red
lead and two coats of oil paint of approved shade. Painting shall be done according to the
specification No B.13.
BR.39(d).4. Item to include -
1) Providing and fixing collapsible channel posts, cleats, bolts, nuts and galvanised iron
pipes with couplings including anchor bolts, nuts, rivets as per drawings and painting
pipes and steel parts.
2) All labour, material, use of equipment, tools, plant,scaffolding, etc.,necessary for the
completing the item satisfactorily.

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BR.39(d).5.Mode
BR.39(d).5.Mode of measurement and payment - The contract rate shall be for the one
meter of railing completed. The railing shall be measured between the inside of the under
pillasters over the abutments. Where there are only end posts, the railing shall be measured
from the outside to outside of the end posts. The length shall be measured correct upto two
places of decimals of a meter.
BR.39.(e). Providing railing of cast in situ R.C.C. posts with 1:2:4 cement concrete and
chains as per the detailed drawings including reinforcement scaffolding, centering,
formwork, compaction, finishing and curing complete.
BR.39.(e).1. General - The item refers to the provision of R.C.C. post and chain type
railing as shown in the working drawings.
BR.39.(e).2. Materials -
i) Cement concrete shall comply with specification No.B.6.The maximum size of the
coarse aggregate shall not exceed 20 mm. Proportion of concrete shall be one 50 kg
bag of cement : 70 litre of sand : 140 litres of coarse aggregate. Water content shall be
regulated to give the required consistency for the member within the range specified
in the B.6.3 as order by the Engineer. Mixing and maintaining may be mechanical
or manual as per specification No.6.4. at the choice of the contractor subject to the
production of the concrete of uniform consistency with all coarse aggregate entirely
covered with cement mortar and dense concrete with good cast finish to the surface.
ii) Reinforcement bars and binding wires shall comply with specification Nos. A-10 and
A-15.
iii) Standard galvanised iron pipes of the diameter shown on plans with coupling.
Diameter shall be of inside bore.
BR.39.(e).3. Construction - The railing shall be constructed as per the detailed drawings.
There shall be three rows of pipes on each side.
The R.C.C. posts shall be cast to size, shape and spacing as indicated on the drawings
after the reinforcement is put up and spliced according to the specification No. B.10. The
forms shall be such as to give the exact shape and size to the concrete members shown in
the drawings or as ordered by the Engineer. Reinforcement shall conform to specification
No.A.10 and shall be spliced to the bars projecting from the slab or kerb as per the detailed
drawing. Galvanised iron pipes shall be fixed to the post through the holes left tot he posts
for the purpose and shall not be easily removable. Immediately after and within one day
after stripping the forms the concrete surfaces of the post shall be roughened and be
finished with plaster of 1:3 cement mortar 6 mm thick and duly cured for 14 days.The
galvanised pipes shall be painted with one coat of red lead and two coats of oil paint of
approved shade. Painting shall be done according to the specification No B.13. The railing
and posts shall be in line and level.
BR.39.(e).4. Item to include -
1) Providing R.C.C. cast-in-situ posts and galvanised iron pipes with couplings as per
drawings with painting for galvanised iron pipes.
2) All labour, material, use of equipment, tools, plant, scaffolding, etc.,necessary for
the completing the item satisfactorily. No separate payment shall be made for the
concrete and reinforcement of R.C.C. members, pipes, etc., the rate per metre being
inclusive of all the necessary materials, accessories labour etc.
BR.39.(e).5.Mode of measurement and payment - The contract rate shall be for the
one meter of railing completed. The railing shall be measured between the inside of the
under pillasters over the abutments. Where there are only end posts, the railing shall be
154 RED BOOK  VOLUME I  ROADS  2012
 BR.40.2
measured from the outside to outside of the end posts. The length shall be measured
correct upto two places of decimals of a meter.
BR.39.(f). Providing collapsible railing with channel posts, flats, and angles as per
the detailed drawings including scaffolding and painting.
BR.39.(f).1. General - The item refers to the provision of collapsible type of railing as
shown on the drawings.
BR.39.(f).2. Materials -
1) Channel sections of specified sizes and lengths for the posts and bottom channel
shown in the drawings shall conform to the specification No.A-11.
2) Flats of sizes and lengths shown on the plans for the anchorage of the bottom
channels and braces shall conform to the specification No. A-11.
3) Angle of sizes and lengths for the top rail shown on the plan shall conform to the
specification No.A-11.
4) Chain, pin, rivets as shown on the working drawings shall be of mild steel or wrought
iron.
BR.39.(f).3. Construction - The railing shall be constructed as per the detailed drawings.
The bottom rail shall be fixed to the flats embedded in the kerb at the time of the concreting
of the kerb or fixed later. The channel posts shall be fixed at designated points by loose
rivets. Slot shall be cut into the bottom channel and the top angle as indicated on the
drawings. The top angle shall be fixed to the channel posts by the pin with chain fixed to
the posts. The flat braces, the top angles and the channel posts shall be housed into the
bottom channel as indicated on the drawings. The steel members shall be painted with one
coat of red lead and two coats of oil paint of approved shade. Oil painting shall be done
according to specification No. B.13.
BR.39(f).4. Item to include -
1) Providing and fixing the collapsible channel posts, bottom rail, top rail, flat braces
and top angle with necessary accessories and painting.
2) All labour, material, use of equipment, tools, plant, scaffolding, etc., necessary for
the completing the item satisfactorily.
BR.39(f).5.Mode of measurement and payment - The contract rate shall be for the one
meter of railing completed. The railing shall be measured between the inside of the under
pillasters over the abutments. Where there are only end posts, the railing shall be measured
from the outside to outside of the end posts. The length shall be measured correct upto two
places of decimals of a meter.
BR.40. Providing and fixing in position to exact profile and prestressing high tensile
steel of specified ultimate strength including cutting, laying in sheathing fixing it in
exact profile, providing necessary standard anchorages as per detailed drawings
including use of necessary plant, machinery, etc., complete.
BR.40.1 General - The item provides for the prestressing steel including all necessary
accessories, operations, use of tools, plant, machinery etc complete to provide the
prestressing force.
BR.40.2 Materials -
i) High tensile steel shall conform to A.9(b).
ii) Sheathing - This shall be cold rolled cold annealed (CRCA) mild steel for mechanical
treatment and surface refining but not for quenching hardening or tempering. This

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BR.40.3
shall have bright finish. If so specified specially for aggressive environment this shall
be galvanised or lead coated. The thickness of strip shall be 0.24 mm for diameter
upto 51 mm and 0.3 mm for diameter over 51 mm. The sheathing shall conform to
IRC 18-1985.
iii) Anchorages - The anchorage shall be of recognised make and shall be as per
manufacturers specifications. If required the contractor shall conduct necessary
tests at his cost.
iv) Grout - Cement grout shall conform to IRC 18-1985.
BR.40.3 Construction - The steel shall be thoroughly cleaned so as to be free of any
harmful matter on its surface. The reinforcement shall be formed into cables and threaded
through the sheathing. The cable shall be placed into position with suitable arrangement
to hold it in the required profile. Anchorages shall be provided at the two ends in positions
indicated on drawings. The prestressing operations shall be carried out as per the design
requirements and full data shall be recorded regarding extensions and pressures etc. This
shall be made available to the design office. Close liaison shall be kept with the design
office for the requirements and recording.
The prestressing shall be done with approved jacks and in safe manner under the
instructions and guidance of the design office. After achieving the desired extensions the
bars shall be anchored in the anchorages. Whole set of observations shall be supplied to
the design office. After approval to the process, the excess bar lengths shall be cut off. The
cable shall be cement grouted ensuring full grouting. The entire process shall be carried
out under competent supervision. Extra cables if any provided and finally not required, the
steel within shall be removed and the sheathing fully grouted. Such cable shall not qualify
for payment.
BR.40.4 Item to include -
i) All labour, materials, use of tools, plant, machinery.
ii) Sheathing.
iii) Anchorages.
iv) Supporting arrangements.
v) Grout.
vi) All required tests.
vii) Compensation for injury or damage.
vii) Extra cable and removing steel when found to be unnecessary.
BR.40.5 Mode of measurement and payment - The contract rate shall be for one tonne
of steel measured and calculated on the basis of standard weight per metre length. Cut off
lengths shall not be qualify for the payment. Only the steel which has been encorporated
in the structure shall qualify for payment. Anchorages, sheathing, grout shall not be paid
for separately. If the extra cable is finally withdrawn the same shall not qualify for payment.
BR.41. Providing galvanised iron 150mm diameter spouts as per drawings.
BR.41.1. General - The item refers to the provision of 150 mm diameter galvanised iron
pipe water spouts as detailed on the drawings for the draining of water from over the bridge
without fouling the masonry or the concrete.
BR.41.2. Materials - 150mm diameter galvanised iron pipe of required length as indicated
on the drawings.
BR.41.3. Construction - The galvanised iron 150mm diameter pipe shall be cut to the

156 RED BOOK  VOLUME I  ROADS  2012

 BR.43.
length and shape indicated on the drawings and shall be suitably fixed in the masonry or
form-work of concrete symmetrically at 6m. center to center or at other intervals or places
as directed by the Engineer while the masonry is being laid or concreting of the slab is
taken up. These pipes should be placed symmetrically to the span, i.e. at half point or
at 1:3 points or at 1/4 points. The pipes shall be suitably embedded in the masonry or
concrete while masonry or concrete is being laid and not after laying. The inside end of the
pipe shall be neatly shaped and finished to fit in the surface of masonry or concrete without
any projection so as to provide smooth and unobstructed passage for the water to enter.
BR.41.4. Item to include - (1) The cost of pipes, other materials, fastenings, labour, use
of tools, etc. and operations required to complete the item satisfactorily.
BR.42. Providing and fixing marble tablet of size and description as per detailed
drawings including moulded marble/1:2 cement mortar border.
BR.42.1. General - The item provides for the supply of marble slab of the required size,
engraving the emblem, figures and letters as ordered by the Engineer and fixing the same
in position on the bridge as indicated on the drawings or as ordered by the Engineer.
BR.42.2. Materials -
(1) The marble slab shall be 25mm. thick and shall be of good quality milky white shade,
free from veins and unsightly spots etc. It shall have a uniform shade all over the
surface. The surface shall be even smooth and in one plane with edges true and
square. The size of the slab shall be as indicated on the drawings or as ordered by
the Engineer. Marble border if provided in the drawing, shall be of the size, shape
and colour shown therein.
(2) Cement mortar 1:2 shall comply with the specification No.B.4.
(3) Black lead filling.
BR.42.3. Engraving - The border, emblem figures and letters shall be engraved as
indicated on the drawings. The engraving shall be in ‘V’ cut grooves and shall be filled with
black lead tacked in the grooves and flush with the face of the tablet.
BR.42.4. Fixing - The marble tablet shall be fixed securely in position indicated on the
drawings or as ordered by the Engineer in cement mortar 1:2 with marble or mortar
moulding all round according to drawings: mouldings shall be rubbed smooth. Recess
may be left in the concrete or the masonry or may be cut subsequently for the purpose. No
deduction shall be made for the recess left or cut in the masonry or the concrete.
BR.42.5. Item to include -
(1) Supply of marble tablet, engraving and fixing including lead filling and finishing with
moulded border of marble of cement mortar.
(2) Cutting recess in masonry or concrete if necessary.
(3) All labour, materials, use of equipment, tools and plant for completion of the item
satisfactorily.
BR.42.6. Mode of measurement and payment - The contract rate shall be for one square
metre of the marble tablet overall including moulded marble border if provided. Overlaps
of border and tablet shall not be measured. Cement mortar border if provided, shall be
considered as incidental to fixing and shall not be measured. The length and width shall
be measured correct up to two places of decimal of a meter and area calculated correct to
three places of a square meter.
BR.43. Providing rubble filling behind the abutments, returns or wings.

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BR.43.1.
BR.43.1. Materials - The stones to be used shall be broken rubble with fairly regular shape
and not weathered or decayed. Stones shall be selected for their larger size. The stones
shall be about 0.015 cubic m.or 15 litres in size unless otherwise ordered by the Engineer,
having regard to the nature of the stone being quarried. The stones to be used for wedging
in the joints between stones shall be chips of such size as to snugly fill up the interstices in
most cases. All suitable rubble obtained from foundation excavation shall be made use of
first. The rate to be charged for this rubble to the contractor shall be that which is entered
in the schedule A and if not so entered, the Divisional schedule rate current at the time of
tender.
BR.43.2. Details of construction - Dewatering if necessary shall be done according to
specification No.BR.4. The bed on which rubble filling is to be laid shall be cleared of all
loose materials levelled and consolidated and got approved by the Engineer before starting
rubble filling. Rubble filling behind abutments, returns or wings shall be laid in regular
horizontal layers of no more than 30cm. in thickness closely packed and compacted and
firmly set with their broadest face downwards. The interstices between adjacent stones
shall be wedged in with spalls of the proper size, well driven in with hammers or wooden
mallets to ensure tightly packed layers. Such wedging shall be carried on simultaneously
with the placing in position of the largest stones in each layer and shall in no case be
permitted to fall behind. Each layer shall be packed and completed before the upper layer
is started.
Backfilling required to be done if any, on the river-side of the abutment, wings or returns
shall be done simultaneously with the filling on the landside. Special precautions should
also be taken to prevent wedging action against masonry. The masonry shall have been
fully cured before rubble filling.
BR.43.3. Item to include -
(1) Supplying broken rubble and spalls of approved quality and size.
(2) All labour, materials and use of equipment and tools for properly laying hand packing
and compacting the rubble.
(3) Any other incidental charges to complete the work as per sanctioned plan including
dewatering unless separately provided in the tender.
BR.43.4. Mode of measurement and payment - Rubble filling shall be measured in cubic
metres limiting the dimensions to those shown in the plan or as directed by the Engineer.
The dimensions shall be measured to two places of decimals in metres and quantities
worked out to two places of decimals of a cubic metre.
No deduction shall be made for voids.
The contract rate shall be for a unit of one cubic metre.
BR.44. Carrying out load test of bridge.
BR.44.1. General - The item provides for carrying out load test of the bridge including
necessary erection and remove of scaffolding, platform, use of suitable loads, equipments
for application of loads and instruments for measuring deflections, all labour, materials,
etc., necessary for carrying out the test. Load testing shall not be done before 28 days after
concreting. The test shall be on one span or self-contained group of spans connected to
one another in such a way that the loading of one part affects another in the same group.
BR.44.2. Preliminaries - Inspection platform shall be erected for observing deflections,
cracks and behavior of the superstructure under the loading in the selected and designated
spans or units. The platforms shall be so erected as to give easy accessibility close to the
bottom and sides of the deck system, safety and facility of easy movement on them and
158 RED BOOK  VOLUME I  ROADS  2012
 BR.44.8.
shall be totally independent of the structure. During the test, struts strong enough to take
the whole load shall be placed in position leaving a small gap under the members.
Suitable arrangements such as the deflectometer or tested dial gauges shall be provided
to measure the deflections of the designated structural members at designated positions.
These arrangements shall be entirely independent of the inspection platform.
BR.44.3. Test Loading - Test load shall be 125 percent, of the live load including impact.
The test load shall be converted into a uniformly distributed dead load spread over a
suitable length and width so as to produce the bending moment and shear equivalent to
those produced by the test live load. Distributed test load producing the design bending
moment and shear force, shall be applied evenly in the form of sand bags or such other
suitable loads over a predetermined section of the span. Except for this loading, the entire
units shall be cleared of all loads at the time of test.
BR.44.4. Test procedure - The test load shall be applied in increments of 20 percent, or
other suitable increments as directed by the Engineer at an interval of one hour. The behavior
of the deck system shall be observed continuously throughout the test. Deflections shall
be observed before and after the application of the each increment of load. On reaching
the maximum load the same shall be maintained for 24 hours and then the loading shall be
decreased at the same rate and at the same intervals as those of increments of loads and
the deflections shall be observed just before and after the removal of each decrement of
load. The behavior of the deck system shall be observed during this process also.
During the entire test, the behavior of the bearings such as shift and tilt shall be observed
and recorded.
BR.44.5. Recording - The observations of the test shall be recorded in tabular proforma
and the behavior of the structural members recorded in the column of remarks by an officer
of the Department ranking not lower than a Deputy Engineer and signed by the contractor
also:-
(1) Graph of load against deflection shall be plotted both for loading and unloading.
(2) Comparison statement of actual and theoretical deflections shall be prepared. The
two should closely agree with residual deflection not more than 20 percent, of the
maximum.
BR.44.6. Defective Work - If the results and behavior of structural members under the
load test show defective materials and workmanship, the contractor shall take necessary
measures at his own cost to rectify the defects as directed by the Engineer. A fresh loading
test shall be taken after rectification in such a case and payment shall be made only for the
test giving satisfactory results.
BR.44.7. Item to include -
(1) All labour, materials, equipment, tools and plant required for carrying out the bridge
loading test satisfactorily.
(2) Erecting and removal of platforms, scaffolding, etc.
(3) Erecting and removing deflection measuring devices.
(4) Applying test loads and removing.
(5) Recording of observations.
(6) A fresh loading test after rectification if the results of the initial test are unsatisfactory.
BR.44.8. Mode of measurement and payment - Contract rate shall be for carrying our
necessary test on one span or one self-contained group of spans connected to one another
in such a way that the loading of one part affects another in the same group.

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BR.45
The tests shall be recorded as a job and paid for at the contract rate. Test showing
unsatisfactory results due to bad materials or defective workmanship will not be paid for.

TEST RECORD
Sr. Wt.in Time Deflectometer Magnification Actual Computed Remarks
No. tones Hr/Min Reading Factor Deflection
(1) (2) (3) (4) (5) (6) (7) (8)
BR.45 Providing and fixing neoprene bearing as per detailed drawing.
BR.45.1. General - The item provides for supply of neoprene bearings as per the detailed
drawings including fixing in position in location shown on drawings in perfect level. The
bearing shall conform to IRC 83(Part II) 1987.
BR.45.2.Materials -  Chloroprene (C.R.) shall only be used in the manufacture of the
neoprene bearing. No reclaimed rubber or vulcanised wastes shall e used. The raw
elastomer content shall not be less than 60 percent. The ash content shall not exceed 5
percent. The elastomer shall not conform to all the properties given in Table 1 of IRC 85
(Part II) 1987. The shear modulus of the elastomer bearing shall not be less than 0.80 MPa
nor greater than 1.2 MPa. The adhesion strength of elastomer to steel plates shall not be
less than 7 KN/m.
The steel laminates shall conform to IS 226.
BR.45.3. Fabrication - The bearing with steel laminates shall be cast as a single unit in
a mould and vulcanised under heat at pressure. Casting in two or more units and bonding
and cutting from bigger unit shall not be permitted. As a rule all the bearings shall be cast in
one lot unless the number is large and more lots are permitted by the Engineer in charge.
The fabrication shall be true to the shape, size and shall have no surface blemishes. The
steel plates used shall be sand blasted and thoroughly cleaned without mill scales. The
edges shall be rounded. The bearing shall have tolerances as given in Table 2 of IRC 83
(Part II) 1987.
BR.45.4. Testing and acceptance - Two extra bearings per lot of bearings shall be
manufactured for the purpose of testing. Two bearings out of the lot shall be selected by
the Engineer in charge. These bearings shall be tested as per IRC 83 (Part II) 1987 in the
factory in the presence of the representative of the Engineer in charge. These tests shall
be for
i) Determination of shear modulus.
ii) Determination of elastic modulus.
iii) Determination of adhesion strength.
iv) Determination of ultimate compressive strength.
The test results shall conform to standards given in Appendix - 2 of IRC 83 (Part II) 1987.
BR.45.5. Fixing of bearings - The bearing shall be fixed to the pedestal by applying epoxy
layer. Soft pieces of forms shall be used on all sides of the bearing so that after casting of
the superstructure the form work can be taken out without damaging the bearing. The sides
of the forms adjacent to the bearings shall be properly sealed to prevent cement slurry
covering the bearing faces.
BR.45.6 Item to include -
i) Supply of bearing including manufacture, transport etc.
ii) Sampling and testing.
160 RED BOOK  VOLUME I  ROADS  2012
 BR.47.2
iii) Fixing in position.
iv) All labour and materials, equipment, scaffolds required for successful completion of
the item.
BR.45.7 Mode of measurement and payment - The contract rate shall be for one cu.cm.
of the bearing. The measurement shall be outside to outside dimensions measured correct
upto one mm. The dimensions shall be limited to the dimensions shown on the drawings.
BR.46 Providing and applying anti corrosive treatment to the reinforcement to bars.
BR.46.1 General - The item provides for applying anti corrosive treatment to the
reinforcement bars of the make specified in the wording of the item or special provisions
on the drawing or agreement. In absence of such provisions the treatment shall be got
approved from the Engineer in charge and shall be applied as per the recommendations
of the manufactures. The treatment shall be provided at the work site/ specially prepared
yard/ manufacturers factory.
BR.46.2 Preparing steel - The steel shall be thoroughly cleaned to preclude any matter
remaining present on the surface causing non adhesion of the treatment film. If so specified
by the manufacturers cleaning may be done by acids. However after such cleaning the
steel shall be thoroughly washed to remove all acid from the surface and dried.
BR.46.3 Anticorrosive treatment - The treatment should preferably be given to the
reinforcement bars duly cut, bend to required dimensions. However if manufacturers of
the treatment allow application of the treatment to the full bars, it may be done as per
the stipulations of the manufacturers. In case of such bars the cutting and bending shall
be done with extra care to ensure no damage to the film of the treatment. However the
reinforcement thus treated shall be further inspected to identify the damaged surfaces. Such
surfaces shall be then treated further to ensure full coverage. The thickness of the film shall
be as stipulated on the drawings, agreements or the manufacturer’s recommendations.
The treatment shall be given immediately preceding the placing and concreting. In any
case the steel shall not be left without use for more than one month. The steel so treated
shall be carefully stacked on elevated wooden platform or wooden bulleys before use. If
there is time gap for placing and concreting the reinforcement shall be well protected from
weather and any possibility of damage. After placing the reinforcement in place it shall not
be left without concreting for more than one month.
BR.46.4 Item to include -
i) All labour, material, use of equipment, all necessary arrangements for applying the
treatment, transport if so involved, stacking etc. complete.
ii) Necessary sampling and testing.
iii) Compensation for injury, damages etc.
BR.46.5 Mode of measurement and payment - The contract rate shall be for one tonne of
reinforcement treated and placed in the work. The quantity as measured for the reinforcing
steel shall be the basis for the measurement.
BR. 47 Providing and laying Bitumen Mastic Wearing course of 25/40 mm thickness
over road pavement/ bridge deck including supplying and conveying of all materials,
labour, preparing bitumen mastic, laying, joining, finishing etc., complete.
BR.47.1 General - The item provides for laying bituminous mastic wearing course 25/40
mm thick over road pavement / bridge deck.
BR.47.2 Materials -

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BR.47.3
i) Bitumen shall conform to I.S.73. The bitumen shall be S 35 grade or any other
grade approved by the Engineer. The physical properties shall be as under
a) Penetration at 25o (1/100 cm) 20 to 40.
b) Softening point 50o to 80o C.
c) Ductility at 27o C(Minimum) 10 cm.
d) Loss on heating (Maximum) 1%.
e) Solubility in CS2(Minimum) 99%.
ii) Coarse aggregate - Coarse aggregate shall conform to specification No. A.7. subject
to the following
a) Flakiness Index 25% (Max).
b) Asbestos 1% (Max)
c) % in Mastic 30% to 40 %.
Size passing 19 mm 100%
passing 13.2mm 88-96%.
iii) Fine Aggregate - Fine aggregate shall conform to A.5. subject to following.
Passing 2.36 mm sieve 100%
Retained on 75 æm sieve 100%.
iv) Filler - The filler shall be lime stone powder passing 75 æm sieve with a calcium
carbonate percentage of more than 80% by weight. The gradation of fine aggregate and
filler together shall be as under.
Passing Retained % by weight
a) 2.36 mm 600æm 0-25
b) 600 æm 212æm 5-35
c) 212æm 75æm 10-20
BR.47.3 Mix Design - The mix shall be designed to give a hardness of 60 to 80 at 25øC
without coarse aggregate and 10 to 20 at 25 øC after adding coarse aggregate. The
hardness shall be determined in accordance with IS 1195.
BR.47.4 Binder content - The binder content by weight shall be 14% to 17%.
BR.47.5 Job Mix Formula - Based on the materials to be used the contractor shall work
out the mix design for the job. Contractor shall give mix design to the Engineer, giving full
details such as sources of materials, grading physical properties with test results against
the requirements indicated above for the approval at least 20 days in advance.
BR.47.6 Construction - All the necessary arrangements of diversion/ control of traffic
shall be made by the contractor. Any incidence due to the same shall be responsibility of
the contractor.
The bitumen mastic wearing course shall not be laid during the monsoon or during rains,
storms or damp surface. The surface on which the course is to be provided shall be
perfectly dry and clean. The surface shall be thoroughly cleaned by the brooming, dusting
or brushing as may be necessary. The surface shall be inspected for evenness and shape.
Any undulations or deficiencies in shape shall be made good by the material of the surface
course.
Tack coat of bitumen shall be applied at the rate 5 kg/10 sq.m. with suitable grade of
bitumen at temperature suitable for that grade immediately preceding laying of mastic.

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 B.21.(d).4.
The mastic shall be prepared in specially made cookers which shall have arrangements for
continuous heating and mechanical mixing. Appropriate quantity of filler shall be heated in
the cooker to a temperature of 170o to 205o C for one hour. Half the quantity of bitumen
duly heated to 170o C to 205o C shall be added to the heated filler in the cooker. This shall
be thoroughly mixed. The fine aggregate also heated to 170o C to 205o C and remaining
quantity of bitumen heated to 170o C to 205o C shall be added tot he cooker and cooked
further for one hour. During the entire process the temperature shall be maintained between
170o C to 205o C.
If the mix is not intended to be used immediately, this mix shall be cast into blocks of
suitable size will weight approximately 25 kg. These blocks shall be further heated into
cooker to 170o C to 205o C when the wearing course is to be laid. To this mix coarse
aggregate shall be added, duly heated and mixed continuously for one hour. The laying
operation shall be then started with this mix. During the laying process the mix shall be
continuous mixed and heated. The coarse aggregate shall be ensured to be in suspension
and not allowed to settle.
The mix shall be transported to the prepared base in towed mixer transporter and shall be
continuously heated and mixed during transport. The mix shall be spread by the spreaders
to uniform thickness and floated by wooden floats to the required thickness. The mix shall
be laid in strips of not more than one meter in width. Suitable angles or forms shall be
provided to obtain uniform width and thickness. The temperature of the mix at the time of
laying shall be 170o C to 205o C. Bubbles if any during laying shall be punctured and solid
layer obtained.
The joints with adjoining strips shall be neatly made by placing excess mastic and trimming
it to the required thickness getting a flush joint.
The mastic shall be covered with precoated chips of approved quality of 9.5 mm size
(passing 13.2 mm and retained on 6.7mm) at the rate of 0.05 cu.m. per 10 sq.m. and
rolled or pressed into the surface. Precoating shall be done by 2% bitumen by weight of
S-65 to S-90 grade. Pressing of this aggregate shall be done when the mastic is having
temperature of 80o to 100o C.
Traffic shall be allowed after the mastic is cooled to atmospheric temperature. The surface
shall be checked for depressions by a 3m long straight edge. Depressions if any shall not
be more than 4 mm.
BR.47.7 Item to include -
i) All labour, materials, use of equipment, tools, plant for satisfactory completion of the
job.
ii) Designing job mix.
iii) Testing of materials, final product etc.
iv) Cost of tack coat.
v) Surface covering by chips.
vi) Control of traffic during construction.
vii) Compensation for damage or injury.
BR.47.8 Mode of measurement and payment - The contract rate shall be for one
square meter of the wearing course provided. Measurement shall be taken correct upto 2
places of decimals of a meter.

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B.21.(d).4.

164 RED BOOK  VOLUME I  ROADS  2012

 B.21.(d).4.

1100
PILE FOUNDATION

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B.21.(d).4.

166 RED BOOK  VOLUME I  ROADS  2012

 1104.1.
1101. DESCRIPTION
1101.1. This work shall consist of construction of all types of piles for structures in
accordance with the details shown on the drawings and conforming to the requirements of
these specifications.
1101.2. The construction of pile foundations requires a careful choice of the piling system
depending upon sub-soil conditions and loading characteristics and type of structure. The
permissible limits of total and differential settlements, unsupported length of pile under
scour, impact/entanglement of floating bodies and any other special requirements of project
are also equally important criteria for selection of the piling system. The method of installing
the piles, including details of the equipment shall be submitted by the Contractor and got
approved from the Engineer.
1101.3. The work shall be done as per IS: 2911 except as modified herein.

1102. SUB-SURFACE INVESTIGATION

1102.1. The complete sub-surface investigation of strata in which pile foundations are
proposed shall be carried out in advance and by in-situ pile tests. For details of geotechnical
sub-surface explorations reference may be made to Section 2400. At least one bore-hole for
every foundation of the bridge shall be executed. Borings should be carried upto sufficient
depths so as to ascertain the nature of strata around the pile shaft and below the pile tip.
However, depth of boring shall DOI be less than:
i) 1.5 times estimated length of pile in soil but not less than I5 m beyond the probable
length of pile
ii) 15 times diameter of pile in weak /jointed rock but minimum 15 m in such rock
iii) 4 times diameter of pile in sound, hard rock but minimum 3 m in such rock
1102.2. The sub-surface investigation shall define adequately stratification of sub-strata
including the nature and type of strata, its variation and extent and specific properties of the
same. The investigation shall be adequate for the purpose of selection of appropriate piling
system and for estimating design capacities for different diameters and length of piles.
1102.3. Pressure meter tests may be used in the case of rock, gravel or soil for direct
evaluation of strength and compressibility characteristics. Though these tests are of
specialised nature they are most appropriate for difficult/uncertain sub-strata especially for
important projects. .
1102.4. For piles socketed into rocks, it is necessary to determine the uniaxial compressive
strength of the rock and its quality. The investigation shall also include location of ground
water table and other parameters including results of chemical tests showing sulphate and
chloride content and any other deleterious chemical content in soil and/or ground water,
likely to affect durability.

1103. TYPE OF PILES

The piles may be of reinforced concrete, prestressed concrete, steel or timber. The piles
may be of solid or hollow sections or steel cased piles filled with concrete. Concrete piles
may be driven cast- in-situ or precast or bored cast-in-situ or precast piles driven into
preformed bores. The shape of piles may be circular, square, hexagonal, octagonal, “H" or
"I" Section.

1104. MATERIALS
1104.1. The basic materials shall conform to the specifications for materials given in Section

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1104.1.
1000. The specifications for steel reinforcement, structural concrete, prestressed concrete
and structural steel to be used in pile foundations shall be as given in the relevant sections.
1104.2. Concrete in Piles
Grade of concrete to be used in caste-in-situ piles shall not be less than M 20 and the
cement content shall not be less than 400 kg per cubic meter of concrete. Grades of
concrete for precast reinforced and prestressed concrete piles shall not be less than M 25
and M 35 respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ piles and
0.45 for precast piles.
The minimum slump of concrete for driven cast-in-situ piles shall be 100 mm to 150 mm
and that of bored cast-in-situ piles 150 mm to 200 mm. The slump should not exceed 200
mm in any case.
Concrete mix should have homogeneous mixture with required workability for the system
of piling adopted. Suitable and approved admixtures may be used in concrete mix where
necessary.
Where piles are exposed to action of harmful chemicals or severe conditions of exposure
due to presence of sulphate, chloride etc, it may be preferable to opt for higher grades of
concrete restricting water cement ratio to 0.45. Special types of cement, such as sulphate
resistant cement may be used where considered appropriate.

1105. TEST PILES

1105.1. Test piles which are shown on the drawings or specified in the contract or installed
by the Contractor on his own to determine the lengths of piles to be furnished shall
conform to the requirements for piling as indicated in these specifications, if they are to be
incorporated in the completed structure.
Test piles that are to become a part of the completed structure shall be installed with the
same type of equipment that is pr0• posed to be used for piling in the actual structure,
Test piles which are not to be incorporated in the completed structure shall be removed to
at least 600 mm below the proposed soffit level of pile cap and the remaining hole shall be
backfilled with earth or other suitable material.
The piles shall be load tested in accordance with provisions laid down in this section.

1106. PRECAST CONCRETE PILES

1106.1. General
Precast concrete piles shall be of the size and shape as shown in the approved drawings.
If a square section is employed, the corners shall -be chamfered at least 25 mm unless
otherwise specified- on the drawings. The length of pile shall not normally exceed 25
metres. However, where special equipments for handling and installation are available to
the satisfaction of the Engineer, longer length could be permitted.
Piles shall be cast with a driving point and for hard driving, shall be shod with a metal shoe
approved by the Engineer.
1106.2. Stacking, Storing and Handling
Care shall be taken that at all stages of transporting, lifting and handling, piles are not
damaged or cracked. During transport and stacking of piles, they shall be supported at
the same points as those provided for lifting purposes. If the piles are putdown temporarily
during handling, they shall be placed on trestles or blocks located at the same points.
Piles shall be stored at least 300 mm above firm level ground which is not liable to unequal
subsidence or settlement under the weight of the stack of piles. They shall be placed on
168 RED BOOK  VOLUME I  ROADS  2012
 1106.5.
timber supports which are level and spaced so as to avoid bending. The supports shall
be vertically one above the other. Spaces shall be left round the piles to enable them to
be lifted without difficulty. The order of stacking shall be such that the older piles can be
withdrawn without disturbing newer piles. Separate stacks shall be provided for different
lengths of piles. Where piles are stacked in layers, the number of layers shall not exceed
three. Whenever curing is needed during storage, arrangements shall be made to enable the
piles to be watered. For detailed precautions with regard to curing operations specifications
for structural concrete given in Section 1700 shall apply.
Before the operation of handling and driving the piles, the minimum periods counted from
the time of casting shall be allowed for as indicated in Table 1100-1. Prestressed piles shall
not be lifted or handled until fully stressed.

TABLE 1100-1 TIME FOR CURING PRECAST PILES

Minimum periods from time of casting
Strike side- End of Lift from Drive
Type of cement used in shutters wet curing casting bed (days)
casting the pile (hours) (days) (days)
Ordinary Portland 24 7 10 28
Rapid hardeningPortland 12 7 7 I0
1106.3. Lengthening of Piles
Where a pile is to have another length cast on it during driving, the longitudinal reinforcement
shall preferably be joined by full penetration butt welding. The concrete at the top of
the original pile shall be cut down to expose not less than 200 mm of the bars to avoid
spalling of the concrete by heat. The added bars have to be held accurately and rigidly in
position during welding. Where facilities on site are insufficient to make proper butt welding
practicable, the joint may be made by lapping. The reinforcement at the head of pile will
need to be exposed for full anchorage length or 600 mm whichever is greater and the
new bars over-lapped for this distance. Unless otherwise specified, the extension of the
pile shall be formed to the same cross-sectional profile and with concrete of at least the
same strength as that specified for the original pile. The stirrup spacing shall in no case be
greater than 150 mm. Not more than one extension shall be permitted. In case more than
one extension is permitted by the Engineer, only approved mechanical couplers shall be
used.
Driving shall not be resumed until:
(i) The strength of the concrete in the extension is at least equal to the specified
characteristic strength of concrete in pile, and
(ii) The approval of the Engineer has been obtained.
1106.4. Removal of Surplus Length
Any length of pile surplus to that required for incorporation in the structure shall be cut off
neatly and removed. During the process of cutting off, it shall be ensured that projecting
reinforcement to be anchored into the pile cap and the prestressing strands/wires are not
damaged. When stripping prestressed concrete piles, shock release of tendons shall be
avoided. Reference may also be made to clause 7.7.1. of IS:2911 (Part I Section 3) in this
connection.
1106.5. Risen Piles
Level reading should be taken on each pile after driving and again after all the piles are
driven. Piles which are found to have risen due to ground heave or as a result of driving

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1106.6.
adjacent piles shall be re-driven to the original depth or resistance unless re—driving tests
on adjacent piles have shown this to be unnecessary.
1106.6. Manufacture
The pile should be cast in one continuous operation from end to end of each pile. Manufacture
of precast concrete piles shall conform to the guidelines contained in clause Nos. 7.1,7.2
and 7.3 of IS:2911 (Part I, Section 3).
Pile shall be provided with suitable shoe for protecting the point of the pile during driving in
hard ground.
Piles shall not be moved from casting bed until the concrete has hardened sufficiently.
Piles shall not be driven in less than 28 days after casting or unless their strength at the
time of driving is at least that specified for 28 days.
1106.7. Prestressed Concrete Piles
Additional specifications for precast prestressed concrete piles shall conform to those
contained in clause 8 of IS:2911 (Part I Section 3).

1107. CAST-IN-SITU CONCRETE PILES

Cast-in-situ concrete piles may be either installed by making a bore into the ground by
removal of material or by driving a metal casing with a shoe at the tip and displacing the
material laterally. The two types of piles are termed as "bored piles" and "driven piles"
respectively. Cast-in-situ concrete piles may be cast in metal shells which may remain
permanently in place. However, other types of cast-in-situ concrete piles, plain or reinforced,
cased or uncased, may be used if in the opinion of the Engineer the soil conditions permit
their use and if their design and the methods of placing are satisfactory.
The metal casing shall be of sufficient thickness and strength to hold its original form and
show no harmful distortion after it and adjacent casings have been driven and the driving
core, if any, has been withdrawn.
Cast-in-situ concrete driven piles shall be installed using a properly designed detachable
shoe at the bottom of the casing. Certain specific requirements of cast-in-situ driven piles
shall be as per Clauses 1110 and 1111.
Any liner or bore-hole which is improperly located or shows partial collapse that would
affect the load carrying capacity of the pile shall be rejected or repaired as directed by the
Engineer at the cost of the Contractor.
Wherever practicable, concrete should be placed in a clean dry hole. Where concrete is
placed in dry and there is casing pre- sent, the top 3 m of the pile shall be compacted using
internal vibrators. The concrete should invariably be poured through a tremie with a funnel
so that the flow is directed and concrete can be deposited in the hole without segregation.
Where the casing is withdrawn from cohesive soils for the formation of cast-in-situ pile, the
concreting should be done with necessary precautions to minimise the softening of the soil
by excess water. Where mud flow conditions exist, the casing of cast-in-situ piles shall not
be allowed to be withdrawn.
Care shall be taken during concreting to prevent as far as possible the segregation of the
ingredients. The displacement or distortion of reinforcement during concreting and also
while extracting the tube shall be avoided.
If the concrete is placed inside precast concrete tubes or consists of precast sections,
these shall be free from cracks or other damage before being installed.
The concrete shall be properly graded, shall be self-compacting and shall not get mixed

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 1106.7.
with soil, excess water, or other extraneous matter. Special care shall be taken in silty clays
and other soils with the tendency to squeeze into the newly deposited concrete and cause
necking. Sufficient head of green concrete shall be maintained to prevent inflow of soil or
water into the concrete.
The placing of concrete shall be a continuous process from the toe level to the top of the
pile. To prevent segregation, a tube or tremie pipe as appropriate shall be used to place
concrete in all piles.
To ensure compaction by hydraulic static heads, rate of placing concrete in the pile shaft
shall not be less than 6 m (length of pile) per hour.
Bored cast-in-situ piles in soils which are stable may often be installed with only a small
casing length at the top. A minimum of 2.0 m length of top of bore shall invariably be provided
with casing to ensure against loose soil falling into the bore in cases in which the side soil
can fall into the hole, it is necessary to stabilise the side of the bore hole with drilling mud,
or a suitable steel casing. The casing may be left in position permanently specially in cases
where the aggressive action of the ground water is to be avoided, or in the cases of piles
built in water or in cases where significant length of piles could be exposed due to scour.
For bored cast-in-situ piles, casing/liner shall be driven open ended with a pile driving
hammer capable of achieving penetration of the liner to the length shown on the drawing or
as approved by the Engineer. Materials inside the casing shall be removed progressively
by air lift, grab or percussion equipment or other approved means.
Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the casing shall
be kept enough in advance of the boring tool to prevent the entry of soil into the casing,
thus preventing the formation of cavities and settlements in the adjoining ground. The water
level in the casing should generally be maintained at the natural ground-water level for the
same reasons. The joints of the casing shall be made as tight as possible to minimise inflow
of water or leakage of slurry during concreting.
Boring shall be carried out using rotary or percussion type equipment. Unless otherwise
approved by the Engineer, the diameter of the bore-holes shall be not more than the inside
diameter of the liner.
Prior to the lowering of the reinforcement cage into the pile shaft, the shaft shall be cleaned
of all loose materials. Cover to reinforcing steel shall be maintained by suitable spacers.
The diameter of the finished pile shall not be less than that specified and a continuous
record shall be kept by the Engineer as to the volume of concrete placed in relation to the
pile length cast.
Before concreting under water, the bottom of the hole shall be cleaned of drilling mud and
all soft or loose material very carefully. In case a hole is bored with use of drilling mud,
concreting should not be taken up when the specific gravity of bottom slurry is more than
1.2. The drilling mud should be maintained at 1.5m above the ground water level.
Concreting under water for cast-in-situ concrete piles may be done either with the use of
tremie method or by the use of an approved method specially designed to-permit under
water placement of concrete.
General requirements and precautions for concreting under water are as follows :
(a) The concreting of a pile must be completed in one continuous operation. Also, for
bored holes, the finishing of the bore, cleaning of the bore, lowering of reinforcement
cage and concreting of pile for full height must be accomplished in one continuous
operation without any stoppage.
(b) The concrete should be coherent, rich in cement with high slump and restricted water

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1106.7.
cement ratio.
(c) The tremie pipe will have to be large enough with due regard to the size of aggregate.
For 20 mm aggregate the tremie pipe should be of diameter not less- than 150 mm
and for larger aggregate, larger diameter tremie pipes may be necessary.
(d) The first charge of concrete should be placed with a sliding plug pushed down the
tube ahead of it to prevent mixing of water and concrete.
(e) The tremie pipe should always penetrate well into the concrete with an adequate
margin of safety against accidental withdrawal if the pipe is surged to discharge the
concrete.
(f) The pile should be concreted wholly by tremie and the method of deposition should
not be changed pan way up the pile to prevent the laitance from being entrapped
within the pile.
(g) All tremie tubes should be scrupulously cleaned after use.
The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150 mm. Any
defective concrete at the head of the completed pile shall be cut away and made good with
new concrete. The clear cover between the bottom reinforcement in pile cap from the top
of the pile shall be not less than 25 mm. The reinforcement in the pile shall be exposed for
full anchorage length to permit it to be adequately bonded into the pile cap. Exposing such
length shall be done carefully to avoid damaging the rest of the pile. In cases where the pile
cap is to be laid on ground, a levelling course of M 15 nominal .mix concrete 100 mm thick
shall be provided. Defective piles shall be removed or left in place as judged convenient
without affecting the performance of adjacent piles or pile cap. Additional piles shall be
provided to replace the defective piles.

1108. STEEL PILES

Steel piles shall be “H” or "I" sections as shown on the drawings and shall be of structural
steel conforming to- the specifications given in Section 1000.
Steel piles shall be protected by suitable anti-corrosive painting as specified on the drawing.
Piles shall be stored above the ground using protective packing to minimise damage to
surface coating. Each pile shall be supplied preferably in one piece without splices.
At the option of the Contractor, steel piling consisting of structural steel plates welded
together may be substituted for the rolled sections specified, provided that the depth,
width and average thicknesses are at least equal to those of the rolled sections, the steel
plates conform to specification given in Section 1000, the flanges are welded to the web
with continuous fillet welds on either side of the web, and the welding conforms to Clause
1904.8 of these specifications.
The length of the steel pile may be built up in sections either before or during driving
operations. The sections shall be of identical cross-section. Pile splices shall be made with
full penetration butt welds over the whole cross-section. Pile splices shall develop at least
the yield strength of pile. •
The connections shall be made by butt-welding the entire cross- section in accordance with
the provisions in Clause 1904.8 of these specifications. Care shall be taken to properly
align the sections connected so that the axis of the pile will be straight. The number of
welded connections in the length of pile shall be as few as possible.

1109. TIMBER PILES

The Engineer shall stamp each pile on the butt with a stamp which shall make an impression
that is readily legible. Treated timber piles will be inspected by the Engineer after treatment.

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 1111.1.
Untreated timber may be used as test piles.
Untreated timber piles and treated timber piles shall be of approved quality.
Treated timber piles shall be driven within 6 months after treatment.
Timber piles shall be furnished with tip protection and shall be protected by the use of steel
straps as hereinafter specified. Tip protection shall be suitable for use on timber piling of the
size to be driven. Details of tip protection shall be furnished to the Engineer for review and
approval before driving piles. Not less than 2 separate steel straps shall be placed within
600 mm of the butt of each pile after the pile is square cut. Not less than 2 separate steel
straps shall be placed within 300 mm of the tip of each pile. Additional intermediate steel
straps shall be placed at not more than 3 metres centre measured along the length of the
pile.
Timber piles which are to be capped shall be separately cut off so that true bearing is
obtained on every pile. Piles inaccurately cutoff shall be replaced. Splicing of timber piles
shall not be permitted except by written permission of the Engineer.

1110. DRIVING EQUIPMENT

Piles or their casings may be driven with any type of drop hammer, diesel hammer or
single-acting steam or compressed air hammer, provided they penetrate to the prescribed
depth or attain the designed resistance without being damaged. The weight or power of the
hammer should be sufficient to ensure a penetration of at least 5 mm per blow, unless rock
has been reached. It is always preferable to employ the heaviest hammer practicable and
to limit the stroke, so as not to damage the pile. The minimum weight of the hammer shall
be 2.5t. In the case of precast concrete piles the mass of the hammer shall be not less than
30 times the mass of 300 mm length of pile.
Steam or air hammers shall be furnished along with boiler or air compressor of capacity
at least equal to that specified by the manufacturer of the hammers. The boiler or air
compressor shall be equipped with an accurate pressure gauge at all times. The valve
mechanism and other parts of steam, air or diesel hammers shall be maintained in first
class condition so that the length of stroke and number of blows per minute, for which the
hammer is designed, will be obtained. Inefficient steam, air or diesel hammers shall be
removed from the work.

1111. DRIVING
1111.1. General Procedure
Details of the equipment and the method proposed for driving the piles shall be submitted
with the tender for scrutiny and approval of the Engineer. Piles shall be installed from firm
ground or from temporary supports or from fixed platform. The arrangement shall provide
sufficient rigidity to ensure accuracy of pile driving under all conditions of tide, stream flow
or hammer drop.
During driving the top of pile shall be protected by a suitable helmet of substantial steel
construction. The helmet shall provide uniform bearing across the top of the pile and shall
hold the pile centrally under the hammer. No pile shall be driven unless inspected and
approved by the Engineer.
Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of driving
within specified tolerances. Forces producing undue bending or torsional stresses in piles
shall not be applied during driving. The force of the hammer shall be directed centrally and
axially during driving.
The stroke of a single acting or drop hammer shall be limited to 1.2 m unless otherwise

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1111.1.
permitted by the Engineer. A shorter stroke may be necessary when there is danger of
damaging the pile.
Piles shall not be bent or sprung into position but shall be effectively guided and held
on-line during the initial stages of driving. Attempts to correct any tendency for the pile
to run off-line by the application of significant horizontal restraint will not be permitted.
Shortly after the commencement of driving and at regular intervals throughout the driving
operation, checks shall be made to ensure that the pile frame does not exert any undue
lateral force on the pile due to restraint within the helmet
If the indications are that a pile will finish outside the specified tolerances, driving operations
on that pile will cease. The pile shall be withdrawn, the hole filled and the pile re-driven at
no extra cost.
To avoid the possibility of premature "set-up" pile driving shall be continuous in the later
stages, without any deliberate stops. (Delays of an hour or less may lead to significant "set-
up" in piles i.e. resistance to further driving increases after driving is stopped).
If any pile is damaged in any way during driving, it shall be repaired or replaced as directed
by the Engineer, at no extra cost. If during driving, the head of a pile is damaged to the
extent that further driving is not possible, the head shall be cut off and driving continued.
The cost of cutting off shall be borne by the Contractor and where, as a result of such
cutting off the head, the pile is too short, the Contractor, shall, at his own cost, supply and
splice on sufficient length of pile to restore the pile to its correct length.
Piles should be driven to the minimum acceptable penetration shown on the drawings.
This may require preboring and/or jetting as indicated in these specifications with the full
approval of the Engineer.
Piles shall be driven to nominal refusal or the required ultimate dynamic capacity nominated
on the drawings or until the top of the pile is at the level required and specified on the
drawing whichever gives the lowest toe elevation. The Engineer’s decision in these matters
shall be final. Nominal refusal shall be taken as equivalent to 25 mm total penetration for
the final 20 blows using a hammer of driving energy as specified and shall be used as
the criterion for acceptance for piles founded on rock. Severe driving which results in an
average set per blow less than 0.5 mm will not be permitted.
Where hard drilling is encountered because of dense strata or obstructions located above
the predetermined pile tip level, nominal refusal shall not be considered to have been
achieved unless the Engineer is satisfied that the total number of blows, as the average
driving resistance specified for nominal refusal, indicates that further driving will not advance
the pile through dense strata or obstructions.
The pile shall be driven as accurately as possible to the vertical or to specified batter.
Straining the pile into position can damage it and the driving equipment should be adjusted
as much as possible to follow the position of the pile. Any deviation from the proper alignment
shall be noted and promptly reported to the Engineer. If the deviation is to such an extent
that the resulting eccentricity cannot be taken care of by strengthening the pile cap or pile
ties, such a pile shall, at the discretion of the Engineer, be replaced or supplemented by an
additional pile. Unless otherwise specified, the permissible
positional deviation for piles shall be limited to those indicated in Clause 1116.
Care shall be taken not to damage the pile by over-driving. Any sudden change in the rate
of penetration which cannot be ascribed to the nature of the ground shall be noted and its
cause ascertained, if possible, before driving is continued.
When employing a tube which is subsequently withdrawn for the formation of cast-in-situ

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 1111.2.
pile, consideration shall be given to the possibility of doing harm to a pile recently formed by
driving the tube nearby before the concrete has sufficiently set. The danger of doing harm
is greater in compact soils than loose soils. No pile shall be boned or driven within 3 m of a
newly cast pile until at least 24 hours after completion of its installation.
Driving piles in loose sand tends to compact the sand which in turn increases the skin
friction. Therefore, driving a number of friction piles in a group shall proceed outward from
the centre as otherwise it will be difficult to drive the inner piles to the same depth as the
others.
In the case of stiff clay also, the driving for a group of piles shall proceed outward from the
centre. However, in case of very soft soil, the driving may proceed from outside to inside,
so that the soil is restrained from flowing out during driving operations.
If there is a major variation between the depths at which adjacent foundation piles in a
group meet refusal, a boring shall be made nearby to ascertain the cause of this difference.
If the boring shows that the soil contains pockets of highly compressive material below the
level of the shorter pile, it will be necessary to enforce penetration of all the piles to a level
below the bottom of the zone which shows such pockets.
1111.2. Preboring and Jetting
Driving of the piles may be assisted by preboring holes or by the use of jets or both subject
to the approval of the Engineer. These may be used essentially to achieve the minimum
penetration shown on the drawings where such penetration is not reached under normal
conditions of driving indicated in Clause 1111.1.
The diameter of the hole shall not be greater than the diagonal dimension of the pile less
100 mm.
The maximum depth of the preboring shall be such that the specified set (or less) is obtained
when the toe of the pile is at founding level. Preboring shall be as approved by the Engineer
and shall not extend below one metre above the founding level and the pile shall be driven
to at least one metre below the prebored hole. To ensure that the pile is properly supported
laterally in the hole, any space remaining around the pile at the ground level after driving is
finished shall be backfilled with approved granular material.
When water jetting is used, at least two jets shall be attached to the pile symmetrically
when this type of technique is used. The volume and pressure of water at the outlet nozzles
shall be sufficient to freely erode material adjacent to the toe of the pile. The- maximum
depth of jetting shall be such that the specified set (or less) is obtained when the toe of
the pile is at founding level jetting shall cease as directed by the Engineer and shall not
proceed below one metre above the founding level and the pile shall be driven at least one
metre below the pre-bored hole.
To avoid very hard driving and vibration in materials such as sand, jetting of piles by means
of water may be carried out only by express permission of the Engineer and in such a
manner as not to impair the bearing capacity of piles already in place, the stability of the
soil or the safety of any adjoining buildings. Details of the arrangement for jetting shall be
got approved from the Engineer in advance.
If, for jetting, large quantities of water are used, it may be necessary to make provision for
collection of water when it comes to the ground surface, so that the stability of the piling
plant is not endangered by the softening of the ground.
Jetting shall be stopped before completing the driving which shall always be finished by
ordinary methods letting shall- be stopped if there is any tendency for- the pile tips to be
drawn towards the pile already driven owing to the disturbance to the ground.

RED BOOK  VOLUME I  ROADS  2012 175

1113.1.
1112. RAKER (INCLINED) PILES
The maximum rake to be permitted in- piles shall not, exceed the following:
i) 1 in 8 for large diameter cast-in-situ piles viz 0.75 m diameter and above
ii) 1 in 5 for smaller diameter cast-in-situ piles .
iii) 1 in 4 for precast driven piles

1113. PILE TESTS

1113.1. General
The bearing capacity of a single pile may be determined from test loading a pile. The load
test on a concrete pile may not be carried out earlier than 28 days from the time of casting
of the pile.
There shall be two categories of tests_ on piles, namely, initial tests and routine tests.
Initial tests should be carried out on test piles which are not to be incorporated in the work.
Routine tests shall be carried out as a check on working piles. The number _of initial and
routine ` tests on piles shall be as determined by the Engineer depending upon the number
of foundations, span length. type of superstructure and uncertainties of founding strata.
In any case, the initial load tests shall not be less than 2 in number, while the routine load
tests- shall not be less than 2 per cent of the total number of piles in the structure nor less
than 2 in number.
The above stipulations hold good for both vertical as well as lateral load tests on pile
foundations.
However, both initial and routine tests may be suitably increased for structures or cases
with large variation in the sub- surface strata.
The methodology of carrying out load tests and of arriving at safe load on piles shall conform
to IS: 291l (Part IY).
In case of any doubt of workmanship or load carrying capacity of working piles not subjected
to routine tests, or when ordered. by the Engineer, or when provided in the contract, load-
tests on working piles may be supplemented by non-destructive testing. Such tests may
include "Integrity Testing" of concrete in the installed pile and utilisation of "Pile Driving
Analyser" which gives an indication of pile capacity in end bearing and side friction.

1114. PILE CAP

Pile Caps shall be of reinforced concrete. A minimum offset of 150 mm shall be provided
beyond the outer faces of the outer most piles in the group. If the pile cap is in contact with
earth at the bottom, a leveling course of minimum 100 mm thickness of M 15 nominal mix
concrete shall be provided. The attachment of the pile head to the cap shall be adequate
for the transmission of loads and forces. A portion of pile top may be stripped of concrete
and the reinforcement anchored into the cap. Manual chipping may be permitted after three
days of pile casting, while pneumatic tools for chipping shall not be used before seven days
after pile casting. The top of pile after stripping shall project at least 150 mm into the pile
cap. A layer of surface reinforcement may be provided with a cover of 25 mm to retain the
integrity of concrete below the main cap reinforcement which is to be laid 25 mm above the
pile top.
Concreting of the pile cap shall be carried out in dry conditions. The bottom of the pile cap
shall be laid preferably as low as possible taking account of the water level prevalent at the
time of casting.

176 RED BOOK  VOLUME I  ROADS  2012

 1115.2.4.
The top of concrete in a pile shall be brought above cut-off level to permit removal of all
laitance and weak concrete before pile cap is laid. This will ensure good concrete at the
cut-off level.

1115. IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR

DIFFERENT TYPES OF PILES
1115.1. Driven Cast-in-Situ Piles
1115.1.1. Specialist literature and the guidelines from the pile construction industry
shall be consulted regarding the method of installation, equipment and accessories for
pile driving and recording of data.
1115.1.2. During installation of piles the final “set" of penetration of pile per blow of
hammer shall be checked taking an average of last 10 blows.
1115.1.3. The pile shoes which may be of either cast iron conical type or mild steel flat
type shall have double reams for proper seating of the removable casing tube inside the
space between the reams.
1115.1.4. Before commencement of pouring of concrete, it shall be ensured that there is
no ingress of water in the casing tube from the bottom. Further adequate control during
withdrawal of the casing tube is essential so as to maintain sufficient head of concrete
inside the casing tube at all stages of withdrawal.
1115.1.5. Concrete in piles shall be Cast upto a minimum height of 600 mm above the
designed top level of pile, which shall be stripped off at the time of construction of pile
cap.
1115.2. Bored Cast-in-Situ Piles
1115.2.1. While concreting uncased piles, voids in concrete shall be avoided and
sufficient head of concrete is to be maintained to prevent inflow of soil or water into
the concrete. It is also necessary to take precautions during concreting to minimise the
softening of the soil by excess water Uncased cast-in-situ piles shall not be allowed
where mudflow conditions exist.
1115.2.2. The drilling mud such as bentonite suspension shall be maintained at a
level sufficiently above the surrounding ground water level to ensure the stability of the
strata which is being penetrated throughout the boring process until the pile has been
concreted.
1115.2.3. Where bentonite suspension is used to maintain the stability of the bore-
hole, it is essential that the properties of the material be carefully controlled at stages of
mixing, supply to the bore-hole and immediately before concrete is placed. It is usual to
limit:
i) The density of bentonite suspension to 1.05 g/cc
ii) The marsh cone viscosity between 30 and 40
iii) The pH value between 9.5 and 12
iv) The silt content less than 1 per cent
iv) The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing contamination of bentonite
slurry for clay and silt.
1115.2.4. The bores shall be washed by bentonite flushing to ensure clean bottom
at two stages viz. after completion of boring and prior to concreting after placing of
reinforcement cage. Flushing of bentonite shall be done continuously with- fresh

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1115.2.4.
bentonite slurry till the consistency of inflowing and out-flowing slurry is similar.
1115.2.5. Tremie of 150 mm to 200 mm diameter shall be used for concreting. The
tremie should have uniform and smooth cross-section inside, and shall be withdrawn
slowly ensuring adequate height of concrete outside the tremie pipe at all stages of
withdrawal. Other recommendations for tremie concreting are:
(i) The sides of the bore-hole have to-be stable throughout.
(ii) The tremie shall be water-tight throughout its length and have a hopper attached at
its head by a water-tight connection
(iii) The tremie pipe shall be large enough in relation to the size of aggregates. For 20
mm aggregate the tremie pipe shall be of diameter not less than 150 mm and for
larger size aggregate tremie pipe of larger diameter is required.
(iv) The tremie pipe shall be lowered to the bottom of the bore-hole, allowing water or
drilling mud to rise inside it before pouring concrete.
(v) The tremie pipe shall always be kept full of concrete and shall penetrate well into
the concrete in the bore-hole with adequate margin of safety against accidental
withdrawal if the pipe is surged to discharge the concrete.
1115.2.6. For very long or large diameter piles, use of retarding plasticiser in concrete
is desirable.
1115.2.7. For large diameter piles, it may be essential to conduct non-destructive pile
integrity tests to evaluate integrity of the pile.
1115.2.8. Where possible, it may be desirable to grout the base of pile with cement
slurry under suitable pressure after concrete in the pile attains the desired strength. For
this purpose, conduit pipes with easily removable plugs at the bottom end should be
placed in the bore along with reinforcement cage before concreting.

1116. TOLERANCES
1116.1. Permissible Tolerances for Pile
i) Precast Concrete Piles :
a) Variation in cross-sectional dimensions : ± 5 mm
b) Variation in length : ± 25 mm
c) Surface irregularities measured with 3 m straight edge : 5 mm
d) Bow for length in mm : Pile Length in mm
1000
ii) Driven Piles
a) Variation in cross-sectional dimensions : +50 mm, -10 mm
b) Variation from vertical or specified rake : 1 in 50
c) Variation in the final position of the head in plan : 75mm
d) Variation of level of top of piles : ± 25 mm
iii) Bored Piles
a) Variation in cross-sectional dimensions : + 50 mm, -10 mm
b) Variation from vertical or specified rake : 1 in 50 
c) Variation in
the final position : 50 mm
of the head in plan
d) Variation of level of top of piles : ± 25 mm
178 RED BOOK  VOLUME I  ROADS  2012
 1116.2.
1116.2. Permissible Tolerances for Pile Caps .
(a) Variation in dimensions : +50 mm -10 mm
(b) Misplacement from specified position in plan : 15 mm
(e) Surface irregularities measured
with 3 m straight edge : 5 mm
(d) Variation of levels at the top : ± 25 mm

1117. 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.

1118. MEASUREMENTS FOR PAYMENT

For supply of precast concrete, timber or steel piles of specified cross-section, the
measurement shall be in metres of the length of piles ordered in writing by the Engineer
measured from the head to the butt of the shoe or the tapered point. Reinforcement in
precast concrete piles shall not be measured for payment.
For cast-in-situ driven and bored concrete piles of specified cross- section; the measurement
shall be the length in metres of the accepted `pile that remains in the finished structure
complete in place. Reinforcement in cast-in-situ driven and bored concrete piles shall be
measured for payment as per Section 1600. "
Routine and Initial Pile Load Tests shall not be measured for payment.
For installation of the pile, i.e. by driving in the case of precast concrete, timber, steel
and cast-in-situ driven piles, and by boring in the case of cast-in-situ bored piles the
measurement shall be the length in metres that remains in the finished structure complete
in place, limited to that shown on drawings or ordered by the Engineer. No distinction shall
be made for penetration through hard strata or rock and socketing into rock.
For steel liners/casing shown on the drawings to be- permanently left in place, the
measurement shall be by weight in tonnes that remains in the finished structure complete
in place, limited to that shown on drawings or ordered by the Engineer.
For the pile cap, the-quantity of concrete shall be measured in cubic metres as per Section
1700. While reinforcement in pile cap shall be measured in tonnes as per Section 1600.

1119. RATE
The contract unit rate for supplying precast concrete, timber or . steel piles shall include
cost of all labour, materials, tools and equipment, and other work involved in making or
fabricating the pile complete as shown on the drawing, and where required its loading,
transport, delivery to site unloading and stacking it at the place indicated by the Engineer.
The cost of reinforcement as per Section 1600 in precast concrete piles shall be deemed
to be included in the quoted rate for supply of piles.
The contract unit rate for cast-in-situ driven and bored piles shall include the cost of concrete
and all other items as per Section 1700. The contract unit rate shall also include costs of all
labour, materials, equipments and all other incidentals involved in conducting routine and
initial pile load tests including installation of piles for initial load tests.
The contract unit rate for reinforcement in cast-in-situ driven and bored piles shall be as
per Section 1600.

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1116.2.
The contract unit rate for installation of piles shall include full compensation for furnishing
all labour, materials, tools and equipment, and incidentals for doing all the works involved
in driving timber, precast concrete and steel piles, driving or making bores for cast-in-situ
driven and bored concrete piles, cutting off pile heads, all complete in place to the specified
penetration of piles. Providing temporary liner/casing and its withdrawal and placing
reinforcement in position shall also be deemed to be included in the rate for installation of
piles and no additional payment shall be made for the same.
The contract unit rate for permanent steel liners shall include cost of all labour, fabrication
and placing the steel liner to the required depth as shown on the drawings and as ordered
by the Engineer.
The contract unit rate for concrete in pile cap shall cover all costs of labour, materials, tools,
plant and equipment, formwork and staging including placing in position, sampling and
testing and supervision, all as per Section 1700. Reinforcement in the pile cap shall be paid
for separately as per Section 1600.

180 RED BOOK  VOLUME I  ROADS  2012

 1116.2.

1200
WELL FOUNDATIONS

RED BOOK  VOLUME I  ROADS  2012 181

1116.2.

182 RED BOOK  VOLUME I  ROADS  2012

 1203.1.
1201. DESCRIPTION
This work consists 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 drawing and
as per these specifications, or as directed by the Engineer.
In case of well foundations of size larger than 12 m diameter, supplemental construction
specifications will be necessary.

1202. GENERAL
1202.1. 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 is known as well steining
which 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 upto
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, an adequately designed "well cap" is laid which transmits the
loads and forces from the sub-structure (piers or abutments) to the foundations,
1202.2. 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 upto a depth equal to one and a half times the outer
diameter/least dimension of the well below the anticipated founding level. The results of soil
exploration should be presented in accordance with clause 7.4 of IRC: 78. In case the well
foundation is to rest on 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.
1202.3. Blasting may have to be resorted to in order to facilitate sinking through difficult strata,
such as boulders and rocks etc. In. case blasting is anticipated, protective/strengthening
measures specified in clause 710.6 (IV) of IRC: 78 shall be taken. The grade of concrete
in bottom 3 metres of steining shall not be leaner than M 20 or as shown on the drawings.
1202.4. In case the bore hole data shows the presence of steeply dipping rock, chiselling
may have to be resorted to so as to obtain proper seating of the foundation. For this
purpose, the well may require to be dewatered completely under high air pressure inside
the well. This process is known as pneumatic sinking. Pneumatic sinking may also have to
be resorted to in cases where obstacles such as tree trunks, large sized boulders or hard
strata etc. cannot be removed by open dredging. The necessity of adopting pneumatic
sinking shall be decided by the Engineer.
The curb and steining have to be specifically designed for special loadings when pneumatic
sinking is adopted.

1203. SETTING OUT AND PREPARATIONS FOR SINKING

1203.1. 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

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1203.1.
be connected to the permanent theodolite stations with the base line on the banks. The
centre 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.
1203.2. For wells which are to be pitched in water, an earthen or sand island shall be
constructed. Sand islands are practicable for water depths of about 5 metres 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
metres 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.
Floating caissons may be of steel, reinforced concrete or a combination of the two. They
should have at least 1.5 m free board above 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 the lowering of caissons, effect of waves, sinking in very
soft strata etc.
Stability of floating caissons shall be ensured against overturning and capsizing while being
towed and during sinking for the action of water current, wave pressure, wind etc. .
For floating caissons, a detailed method statement for fabrication, floating and- sinking of
caissons shall be prepared and furnished to the Engineer. Such statement shall include the
total tonnage of steel involved, fabrication and welding specifications, list of materials and
plant and a description of operations and manpower required for the work. The caisson
shall be tested for leakages before being towed to site.
1203.3. Equipment
Equipment shall be deployed for construction of well foundation as required and as directed
by the Engineer. Generally, the following equipments may be required for the work:
(a) Crane with grab buckets - capacity 0.5 to 2.0 cum.
(b) Submersible pumps
(c) Air compressors, air locks and other accessories where pneumatic sinking of well is
anticipated.
(d) Chisels of appropriate sizes
(e) Aqua-header for cutting rocky strata
(f) Diving helmets and accessories
(g) Equipment for concrete production, transportation planning and compaction.
184 RED BOOK  VOLUME I  ROADS  2012
 1206.3.
1204. CUTTING EDGE
1204.1. The mild steel cutting edge shall be made from structural steel sections. The
cutting edge shall weigh not 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.
1204.2. 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 fillet welded using single cover plate to ensure the requisite strength of the original
section.
1204.3. The cutting edge shall be laid about 300 mm above prevalent water level.

1205. WELL CURB

1205.1. The well curb may be precast or cast-in-situ. Steel formwork for well curb shall be
fabricated strictly in conformity with the drawing. The outer face of the curb shall be vertical.
Steel reinforcements shall be assembled as shown on the drawings. 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.
1205.2. All concreting in the well curb shall be done in one continuous operation.

1206. WELL STEINING

1206.1. 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.
sheets shaped and stiffened suitably. In case timber forms are used, they shall be lined with
plywood or M.S. sheets.
1206.2. Steining built in the first lift above the well curb shall not be more than 2 metres
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 metres. Attempts should be made to
minimise the number of • construction joints. The concreting layers shall be limited to about
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.
1206.3. The steining of the well shall be built in one straight line from bottom to top such
that if the well is tilted, 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.

RED BOOK  VOLUME I  ROADS  2012 185

1206.4.
1206.4. 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.
1206.5. 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 measures, then the well shall stand rejected.

1207. WELL SINKING

1207.1. 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.
Normally dewatering of well should not be permitted as a means for sinking the well. It also
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 hard strata 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 in Appendix 1200/I.
1207.2. 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.
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.
1207.3. Use of Water Jetting
Water jetting may be employed for well sinking wherever necessary.
1207.4. 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
186 RED BOOK  VOLUME I  ROADS  2012
 1207.6.2.
avoid chances of any damage to the curb or to the steining of the well. A minimum sump of
1 metre 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 permission 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 metre and
the spacing of holes may normally be kept as 0.5 to 0.6 metres.
All prevalent laws concerning handling, storing and using of ex- plosives 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 do any labour in the close 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 minimised by covering blasting holes by rubber mats before blasting.
1207.5. Use of Divers
Use of divers may be made both for 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 for the diving operation shall be employed and shall be certified to be
fit for diving by an approved doctor.
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 armoured 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.

1207.6. Use of Pneumatic Sinking

1207.6.1. General
The Engineer shall familiarise himself with particular reference to caisson diseases and
working of the medical air-lock. A doctor competent to deal with cases of "Caisson Diseases"
or other complications arising as a result of working under high pressure shall be stationed
at the construction site when pneumatic sinking is under progress.
The contractor shall provide complete facilities including the issuing of orders to ensure
strict enforcement of the requirements outlined in these specifications.
Safety provisions as contained in IS: 4138 and in these specifications shall be strictly
followed.
Pneumatic sinking shall be restricted to a depth of 30.0 m.
1207.6.2. Man-Locks and Shafts
Locks, reducers, and shaft used in connection with caissons shall be of riveted construction
throughout. The material used in their manufacture shall be steel plate with thickness not
less than 6 mm.
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1207.6.3.
Shafts shall be subjected to hydrostatic or air pressure test of at least 0.5 MPa, at which
pressure they shall be tight. The pressure at which testing has been done shall be clearly
and visibly displayed.
Shafts shall be provided, with a safe, proper and suitable staircase for its entire length
including landing platforms which are not more than 6 metres apart. Where this is
impracticable due to space constraint, suitable ladders along with landing platforms shall
be installed. These shall be kept clear and in good condition at all times and shall be
constructed, inspected and maintained to the entire satisfaction of the Engineer.
A 1.0 m wide platform with 1.0 m high railing shall be provided all round the caisson air
locks.
Where 15 or more men are employed, caissons shall have two locks, one of which shall be
used as a man lock.
Locks shall be located so that the lowest part of the bottom door shall not be less than 1
metre above high water level.
The supply of fresh air to the working chamber shall at all times be sufficient to permit work
to be done without any danger or excessive discomfort. All air supply lines shall be supplied
with check valves and carried as near to the face as practicable.
A man-lock shall be used solely for the compression or de- compression of persons and not
for _the passage of plant and material and shall be maintained in a reasonably clean and
sufficiently warm state. However, any hand tool or hand instruments used for the purpose
of the work may be carried into the man-lock.
Where it is not reasonably practicable to provide a separate man- _ lock for use by persons
only, the lock when it is in actual use for compression or decompression of a person or
persons shall not be put, simultaneously, to any other use and shall be in a reasonably
clean and sufficiently warm state.
1207.6.3. Valves
Exhaust valves shall be provided, having risers extending to the upper part of the chamber.
These shall be operated, whenever necessary especially after a blast. Precautions shall be
taken that men are not allowed to resume work after a blast until the gas and smoke are
cleared.
1207.6.4. Medical supervision and certification
Every employee absent from work for 10 or more consecutive days due to illness or any
other disability shall be required to pass the regular physical examination by the doctor
before being permitted to return to work.
After a person has been employed continuously in compressed air for a period of 2 months,
he shall be re-examined by the doctor and shall not be permitted to work until such re-
examination has been made and the report is satisfactory. No person known to be addicted
to the excessive use of intoxicants shall be permitted to work in compressed air.
The doctor shall, at all times, keep a complete and full record of examinations made by
him, which shall contain dates of examinations, a clear and full description of the person
examined, his age and physical condition at the time of examination and a statement as to
the period such a person has been engaged in such employment. Records shall be kept
at the place where the work is in progress and shall be subject to inspection by authorised
officers.
Every man lock shall always have a doctor or a responsible person in attendance.
In case the person in charge is not a doctor he must have positive means of promptly
communicating with and seeming the services of a competent doctor in case of emergency.
188 RED BOOK  VOLUME I  ROADS  2012
 1207.6.9.
Such arrangements shall invariably be subject to the approval of the Engineer.
If the air pressure exceeds 0.2 MPa gauge or if 50 or more men are employed, it is obligatory
for the person in charge of medical lock to be a doctor experienced in this type of work.
All cases of compressed-air illness shall be reported and copies of all such reports shall be
kept on tile at the place of work.
1207.6.5. Lighting
All lighting in compressed air chambers shall be operated only by electricity. Two independent
electric lighting systems with independent sources of supply shall be used. These shall be
so arranged that the emergency source shall become automatically operative in case of
failure of the regularly used source. The minimum intensity of light on any walkway ladder,
stairway, or lower working level shall be one-quarter (1/4) candlepower. In all work places,
the lighting shall always be such as to enable workmen to see their way about clearly. All
external parts of lighting fixtures and electrical equipment lying within 2.5 metres above
the floor shall be constructed of non—combustible, non-absorbing insulating materials.
If metal is used it must be effectively earthed. Portable lamp shall have non-combustible,
non-absorbing insulating sockets, approved handles,• basket guards and approved cables.
The use of worn or defective portable and pendant conductors shall be prohibited.
1207.6.6. Safety against fire hazard
No oil, gasoline, or other combustible material shall be stored within 30 metres of any shaft,
caisson, or tunnel opening. However, oil may be stored in suitable tanks in isolated tireproof
buildings, provided such buildings are not less than 15 metres from any shaft, caisson, or
tunnel opening or any building directly connected thereto.
Positive means shall be taken to prevent leaking flammable liquids from flowing into areas
specifically mentioned in the preceding paragraph.
Where feasible, a fire hose connected to a suitable source of -water shall be provided at
the top of every caisson. Where fire mains are not accessible, a supply of water shall be
stored in tanks near the top of every caisson, provided fire pails or suitable pumps are kept
available. Approved fire extinguishers shall also be provided.
1207.6.7. Sanitation
Properly heated, lighted and ventilated dressing rooms shall be provided for all employees
engaged in compressed air work. Such rooms shall contain lockers and benches and be open
and accessible to men during intermission between shifts. Adequate toilet accommodation
of one for every twenty five employees shall be provided.
Care shall be taken to keep all parts of the caissons and other working compartments,
including locker rooms, dry rooms, restrooms, and other equipment in a good sanitary
condition and free from refuse, decaying, or other objectionable matter.
No nuisance shall be tolerated in the air chamber. Smoking shall be strictly prohibited and
all matches and smoking materials shall be left out of the locker rooms.
A separate dry-room shall be provided where working clothes may be dried within reasonable
time.
1207.6.8. Protection against gases
In all cases where gas is expected including alluvium impregnated with decayed vegetable
matter the use of Davy Safety Lamp shall be compulsory.
1207.6.9. Additional safety provisions
a) The weight of the pneumatic platform and that of steining and kentledge, if any,
shall be sufficient to resist the uplift from air inside, skin friction being neglected in
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1207.7.
this case. If, at any section the total weight acting downwards is less than the uplift
pressure of air inside, additional kentledge shall be placed on the well.
If it is not possible to make the well heavy enough during excavation, “blowing down"
may be used. The men should be withdrawn and air pressure reduced. The well
should then begin to move with small reduction in air pressure, "Blowing down"
should only be used when the ground is such that it will not heave up inside the
chamber when the pressure is reduced. When the well does not move with the
reduction in air pressure, kentledge should be added. "Blowing down" should be
in short stages and the drop should not exceed, 0.5 metre at any stage. To control
sinking during blowing down, uses of packings are recommended.
b) The pneumatic sinking plant and other allied machinery shall not only be of proper
design and make, but also shall be worked by competent and well trained personnel.
Every part of the machinery and its fixtures shall be minutely examined before
installation and use. Availability of appropriate spares, standbys, safety of personnel
as recommended in IS: 4138 for working in compressed air must be ensured at
site. Codes for safety and for working in compressed air and other labour laws
and practices prevalent in the country, as specified to provide safe, efficient and
expeditious sinking shall be followed.
c) Inflammable materials shall not be taken into air locks and smoking shall be prohibited.
Wherever gases are suspected to be issuing out of dredge hole, the same shall be
analysed by trained personnel and necessary precautions adopted to avoid hazard
to life and equipment.
d) Where blasting is resorted to, it shall be carefully controlled and all precautions
regarding blasting shall be observed. Workers shall be allowed inside after blasting
only when a competent and qualified person has examined the chamber and steining
thoroughly and found the same to be safe.
1207.7. 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.
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
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 1207.8.
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 metres below the level of the cutting edge unless
otherwise specifically 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 minimised 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.
1207.8. Tilts and Shifts
The inclination of the well from the vertical is known as tilt and the horizontal displacement
of the centre 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 min 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 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.
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, as far as
practicable.
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:
(i) Calculations for foundation pressures and steining stresses, accounting for the actual

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1207.9.
tilt and shift furnished by the Contractor show that the well is safe. Any 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 without claiming for any extra cost.
(ii) The Contractor shall agree to reduction in rates in accordance with Clause 1215(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 expense completes the bridge with modified span
arrangement acceptable to the Engineer.
1207.9. 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 upto 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.
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.

1208. BOTTOM PLUG

For bottom plug, the concrete mix shall be designed (in dry condition) to attain the concrete
strength as mentioned on the drawing and shall contain 10 per cent more cement than that
required for the same mix placed dry, to cater for underwater concreting. However, the total
cement content shall not be less than 363 kg/cu.m. of concrete with a slump in the range
of 150 mm to 200 mm. Admixtures may be added to the concrete to impart the required
characteristics indicated herein.
Concrete for the bottom plug shall be laid by tremie pipe method. Tremie concrete when
started shall be continued without interruption for full concreting in the bottom plug. The
concrete production equipment and placement equipment should be sufficient to enable
under water concreting within stipulated time.Necessa1y 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 upto the
required height and thereafter sounding shall be taken upto 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.

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 1207.9.
The soundness of the bottom plug may be tested by dewatering the well by 5 metres below
the surrounding water level and checking the rise of water. The rate of rise shall preferably
be less than 10 cms 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.

1209. SAND FILLING

Sand filling shall commence after a period of 3 days of laying of bottom plug. Also, the
height of the bottom plug shall be verified before starting sand filling.
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 upto the level shown on the
drawing, or as directed by the Engineer.

1210. TOP PLUG

After filling sand upto the required level a plug of concrete shall be provided over it- as
shown on the drawing, or as directed by the Engineer.

1211. 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 conditions.
The bottom of the well cap shall be laid preferably as low as possible, taking account the
water level prevalent at the time of casting.
Bond rods of steining shall be anchored into the well cap.

1212. 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 levels at the top : ±25 mm

1213. 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.

1214. MEASUREMENTIS FOR 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 own cost.
a) The cutting edge shall be measured in tonnes based on the net weight of metal used
in it, as per Section 1900.
b) The concrete in curb, well steining and well cap shall be measured in cubic metres
in each of the items as per Section 1700. The reinforcements shall be measured in
tonnes separately in each of the items, as per Section 1600.
c) The measurement for well sinking shall be made in running metres for different
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1207.9.
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 1700.
e) The quantity of sand filling shall be measured in cubic metres.
f) Pneumatic sinking, where required shall be paid as a separate item and shall be
measured in cubic metres of material to be excavated.

1215. RATE
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 Concrete 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.
f) The Contract unit rate of material to be excavated by pneumatic sinking shall cover all
costs of labour, material, tools, plant and other equipment and other incidentals and
safety provisions and supervision required for pneumatic sinking as per this Section.
g) Reduction in contract unit rates for sinking as a penalty, in pursuance of clause1207.8.
If any well with tilt and/or shift exceeding beyond permissible values is accepted by the
Engineer, the Contractor shall give a reduction in the rates as follows :
Per cent deduction on
the rate(s) for sinking
S.No Amount of tilt and/or shift of whole well
1. Tilt exceeding the specified permissible value but 5 per cent
equal to or within 1 in 60
2. Tilt exceeding 1 in 60 10 per cent
but equal to or within 1 in 50
3. Tilt exceeding 1 in 50 20 per cent
4. Shift exceeding the specified permissible value but 2 per cent
equal to or within 200 mm
5. Shift exceeding 200 mm but equal to or within 300 mm 5 per cent
6. Shift exceeding 300 mm 10 per cent
Penalties for excessive tilt and shift shall be deducted separately.
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1400
STONE MASONRY

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1207.9.

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 1207.9.
1401. DESCRIPTION
This work shall consist of the construction of structures with stones jointed together by
cement mortar in accordance with the details shown on the drawings and these specifications
or as approved by the Engineer.

1402. MATERIALS
All materials used in stone masonry shall conform to Section 1000 except cement mortar
for stone masonry which shall conform to Clause 1304.

1403. PERSONNEL
Only trained personnel shall be employed for construction and supervision.

1404. TYPE OF MASONRY

The type of masonry used for structures shall be random masonry (coursed or uncoursed)
or coursed rubble masonry (First sort). However, for bridge work generally, course nibble
stone masonry shall be used. The actual type of masonry used for different parts of
structures shall be specified on the drawings.
For facing work, ashlar masonry shall be used where indicated on the drawings.

1405. CONSTRUCTION OPERATIONS

1405.1. General Requirements
The dressing of stone shall be as specified for individual type masonry work and it shall
also conform to the general requirements of IS: 1597 and requirement for dressing of stone
covered in IS: 1129. Other specific requirements are covered separately with respect to
particular types of rubble stone work.
1405.2. Laying
1405.2.1. The masonry work shall be laid to lines, levels, curves and shapes as shown
in the plan. The height in each course shall be kept same and every stone shall be fine
tooled on all beds joints and face full and true. The exposed faces shall be gauged
out, grooved, regulated and sunk or plain moulded as the case may be. The faces of
each stone between the draft be left rough as the stone comes from quarry except
where sacrificial layer is to be provided or plastering is resorted to due to aggressive
environment.
1405.2.2. Stones shall be sufficiently wetted before laying to prevent absorption of
water from mortar. Stratified stones must be laid on their natural beds. All bed joints shall
be normal to the pressure upon them.
Stones in the hearting shall be laid on their broadest face that gives a better opportunity
to fill the spaces between stones.
 The courses of the masonry shall ordinarily be pre-determined. They shall generally
be of the same height. When there is to be variation in the height of courses, the larger
courses are to be placed at lower levels, heights of courses decreasing gradually towards
the top of the wall. The practice of placing loose mortar on the course and pouring water
on it to fill the gaps in stones is not acceptable. Mortar may be fluid mixed thoroughly and
then poured in the joints. No dry or hollow space shall be left anywhere in the masonry
and each stone shall have all the embedded faces completely covered with mortar.
 In tapered walls, the beds of the stones and the planes of course should be at right
angles to the batter. In case of bridge piers with batter on both sides, the course shall
be horizontal.

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1207.9.
The bed which is to receive the stone shall be cleaned, wetted and covered with a layer
of fresh mortar. All stones shall be laid full in mortar both in bed and vertical joints and
settled carefully in place with a wooden mallet immediately on placement and solidly
embedded in mortar before it has set. Clean chips and spalls shall be wedged into the
mortar joints and bed wherever necessary to avoid thick beds or joints of mortar. When
the foundation masonry is laid directly on rock, the face stones of the first course shall be
dressed to fit into rock snugly when pressed down in the mortar bedding over tire rock.
No dry or hollow space shall be left anywhere in the masonry and each stone shall have
all the embedded faces completely covered with mortar. For masonry works over rock,
a levelling course of 100 mm thickness and in concrete M 15 shall be laid over rock and
then stone masonry work shall be laid without foundation concrete block.
 Face works and hearting shall be brought up evenly but the top of each course shall
not be levelled up by the use of flat chips.
 For sharp corners specially in skew bridges, through stones shall be used in order to
avoid spalling of corners.
In case any stone already set in mortar is disturbed or the joints broken, it shall be taken
out without disturbing the adjoining stones and joints. Dry mortar and stones thoroughly
cleaned from the joints and stones and the stones reset in fresh mortar. Attempt must
never be made to slide one stone on top of another, freshly laid.
 Shaping and dressing shall be done before the stone is laid in the work. No dressing
and hammering, which will loosen the masonry, will be allowed after it is once placed. All
necessary chases for joggles, dowels and clamps should be formed before hand.
Sufficient transverse bonds shall be provided by the use of bond stone extending from
the front to the back of the wall and in case of thick wall from outside to the interior and
vice versa. In the latter case, bond stones shall overlap each other in their arrangement.
 In case headers are not available, precast headers of M 15 concrete shall be used.
Cast-in-situ headers are not permitted.
 Stones shall break joint on the face for at least half the height of the course and the
bond shall be carefully maintained through- out.
In band work at all angle junctions of walls, the stones at each alternate course shall be
carried into each of the respective walls so as to unite the work thoroughly.
The practice of building up thin faces tied with occasional through stones and filling up
the middle with small stuff •or even dry packing is not acceptable.
All quoins and the angles of the opening shall be made from selected stones, carefully
squared and bedded and arranged to bond alternately long and short in both directions.
 All vertical joints shall be truly vertical. Vertical joints shall be staggered as far as
possible. Distance between the nearer vertical t joints of upper layer and lower shall not
be less than half the height of the course.
 Only rectangular shaped bond stones or headers shall be used. Bond stones shall
overlap each other by 150 mm or more.
 All connected masonry in a structure shall be carried up nearly at one uniform level
throughout but when breaks are unavoidable the masonry shall be raked in sufficiently
long steps to facilitate jointing of old and new work. The stepping of raking shall not be
more than 45 degrees with the horizontal.
1405.3. Random Masonry (Uncoursed and Coursed)
1405.3.1. Dressing: Stone shall be hammer dressed on the face, the sides and beds to

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 1405.4.2.
enable it to come in proximity with the neighbouring stone. The bushing on the exposed
face shall not be more than 40 mm.
1405.3.2. Insertion of chips: Chips and spalls of stone may be used wherever necessary
to avoid thick mortar beds or joints and it shall be ensured that no hollow spaces are left
anywhere in the masonry. The chips shall not be used below hearting stones to bring
these upto the level of face stones. Use of chips shall be restricted to filling of interstices
between the adjacent stones in hearting and they shall _ not exceed 20 per cent of the
quantity of stone masonry.
1405.3.3. Hearting stones: The hearting or interior filling of the wall face shall consist of
rubble stones not less than 150 mm in any direction, carefully laid, hammered down with
a wooden mallet into position and solidly bedded in mortar. The hearting should be laid
nearly level with facing and backing.
1405.3.4. Bond stones: Through bond stones shall be provided in masonry upto 600 mm
thickness and in case of masonry above 600 mm thickness, a set of two or more bond
stones overlapping each other at least by 150 mm shall be provided in a line from face
to back; In case of highly absorbent types of stones (porous limestone and sandstones,
etc.,) the bond stone shall extend only about two-third into the wall, as through stones in
such cases may give rise to penetration of dampness and therefore, for all thicknesses
of such masonry, a set of two or more bond stones overlapping each other by at least
150 mm shall be provided. One bond stone or a set of bond stones shall be provided for
every 0.50 sq. m. of the masonry surface.
1405.3.5. Quoin stone: Quoin stone i.e. stone specially selected and neatly dressed for
forming an external angle in masonry work, shall not be less than 0.03 cubic metre in
volume.
1405.3.6. Plum stone: The plum stones are selected long stones embedded vertically
in the interior of the masonry to form a bond between successive courses and shall be
provided at about 900 mm intervals.
1405.3.7. Laying: The masonry shall be laid with or without courses as specified. The
quoins shall be laid header and stretcher alternately. Every stone shall be fitted to the
adjacent stone so as to form neat and close joint. Face stone shall extend and bond well
in the back. These shall be arranged to break joints, as much as possible, and to avoid
long vertical lines of joints.
1405.3.8. Joints:  The face joints shall not be more than 20 mm thick, but shall be
sufficiently thick to prevent stone-to-stone contact and shall be completely filled with
mortar.
1405.4. Square Rubble - Coursed Rubble (First Sort)
1405.4.1. Dressing: Face stones shall be hammer dressed on all beds and joints so
as to give them rectangular shape. These shall be square on all joints and beds. The
bed joints shall be chisel drafted for at least 80 mm back from the face and- for at least
40 mm for the side joints. No portion of the dressed surface shall show a depth of gap
more than 6 mm from the straight edge placed on it. The remaining unexposed portion of
the stone shall not project beyond the surface of bed and side joints. The requirements
regarding bushing shall be the same as for random rubble masonry.
1405.4.2. Hearting stones: The hearting or interior tilling of the wall face shall consist of
flat bedded stone carefully laid, on prepared beds in mortar. The use of chips shall be
restricted to the filling of interstices between the adjacent stones in hearting and these
shall not exceed 10 per cent of the quantity of masonry. While using chips it shall be
ensured that no hollow spaces are left anywhere in the masonry.

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1405.4.3.
1405.4.3. Bond stones: The requirements regarding through or bond stone shall be the
same as for random rubble masonry, but these, shall be provided at 1.5 metre to 1.8
metre apart clear in every course.
1405.4.4. Quoin stone: The quoins shall be of the same height of the course in which
these occur and shall be formed of header stones not less than 450mm in length. They
shall be laid lengthwise alternately along each face, square in their beds which shall be
fairly dressed - to a depth of at least 100 mm.
1405.4.5. Face stone: Face stones shall tail into the work for not less than their heights
and at least one-third of the stones shall tail into the work for a length not less than twice
their height. These shall be laid as headers and stretchers alternately.
1405.4.6. Laying: The stones shall be laid on horizontal courses and all vertical joints
should be truly vertical. The quoin stones should be laid header and stretcher alternately
and shall be laid square on their beds, which shall be rough chisel dressed to a depth
of at least 100 mm.
1405.4.7. Joints:  The face joints shall DOI be more than 10 mm thick, but shall be
sufficiently thick to prevent stone-to-stone contact and shall be completely filled with
mortar.
1405.5. Ashlar Masonry (Plain Ashlar)
1405.5.1. Dressing: Every stone shall be cut to the required size and shape, chisel
dressed on all beds and joints so as to be free from all bushing. Dressed surface shall
not show a depth of gap of more than 3 mm from straight edge placed on it. The exposed
faces and joints, 6 mm from the face shall be fine tooled so that a straight edge can be
laid along the face of the stone in contact with every point. All visible angles and edges
shall be true and square and free from chippings. The corner stones (quoins) shall be
dressed square and corner shall be straight and vertical.
1405.5.2. Bond stones: Through bond stones shall be provided in masonry upto 600 mm
thickness and in case of masonry above 600 mm thickness, a set of two or more bond
stones overlapping each other at least by 150 mm shall be provided in a line from face
to back. In case of highly absorbent types of stones (porous limestone and sandstones,
etc.,) the bond stone shall extend only about two-third into the wall, as through stones in
such cases may give rise to penetration of dampness and, therefore, for all thicknesses
of such masonry a set of two or more bond stones overlapping each other by at least
150 mm shall be provided. One bond stone or a set of bond stones shall be 1.5 metres
to 1.8 metres apart clear in every course.
1405.5.3. Laying:  The face stone shall be laid header and stretcher alternately, the
header being arranged to come as nearly as possible in the middle of stretchers above
and below. Stones shall be laid in regular courses not less than 300 mm in height and all
courses of the same height unless otherwise specified. No stone shall be less in width
than its height or less in length than twice its height, unless otherwise specified.
1405.5.4. Joints:  All joints shall be full of mortar. These shall not be less than 3 mm
thick. Face joints shall be uniform throughout, and a uniform recess of 20 mm depth from
face shall be left with the help of a stone plate during the progress of work.
1405.6. Pointing
Pointing shall be carried out using mortar not leaner than 1:3 by volume of cement and
sand or as shown on the drawing. The mortar shall be filled and pressed into the raked out
joints before giving the required finish. The pointing shall conform to Clause 1312.3 of the
specification. The work shall conform to IS:2212. The thickness of joints shall not be less

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 1405.10.
than 3 mm for Ashlar masonry. However, the maximum thickness of joints in different works
shall be as follows:
Random Rubble : 20 mm
Coursed Rubble : 15 mm
Ashlar Masonry : 5 mm
1405.7. Curing
Curing shall conform to Clauses 1309 and 1312.5
1405.8. Scaffolding
For scaffolding Clause 1310 shall apply.
1405.9. Weep Holes
Weep holes shall conform to Clause 2706.
1405.10. Jointing with Existing Structures
For Jointing with existing structures, the specifications given under Clause 1308 shall apply.

1406. ARCHITECTURAL COPING FOR WING/RETURN PARAPET WALLS

Architectural coping for wing/return/parapet walls shall conform to Clause 1313.

1407. TESTS AND STANDARD OF ACCEPTANCE

All work shall be done to the lines and levels as indicated on the drawing or as directed by
the Engineer subject to tolerances as specified in these specifications.
Mortar cubes shall be taken in accordance with IS: 2250 for compressive strength,
consistency of mortar and its water retentivity. The frequency of testing shall be one sample
for every two cubic metres of mortar subject to a minimum 3 samples for a day’s work.

1408. MEASUREMENTS FOR PAYMENT

Stone masonry shall be measured in cubic metres.
In arches, the length of arch shall be measured as the mean length between the extrados
and intrados. The work of pointing shall be measured in square metres.
Architectural coping shall be measured in linear metres.

1409. RATE
The contract unit rate for stone masonry shall include the cost of all labour, materials, tools
and plant, scaffolding, sampling and testing, supervision and other expenses incidental to
the satisfactory completion of the work as described herein above.
The contract unit rate for pointing shall include erecting and removal of scaffolding, all
labour, materials and equipment incidental to complete pointing, raking out joints, cleaning,
wetting, filling with mortar, trowelling, pointing and watering, sampling and testing and
supervision as described in these specifications.
The- contract rate for architectural coping shall include the cost of all labour, materials,
tools and plant, sampling and testing and supervision as described in these specifications.

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1405.4.3.

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1500
FORMWORK

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 1504.3.
1501. DESCRIPTION
Formwork shall include all temporary or permanent forms required for forming the concrete
of the shape, dimensions and surface finish as shown on the drawing or as directed by the
Engineer, together with all props, staging, centering, scaffolding and temporary construction
required for their support. The design, erection and removal of formwork shall conform to
IRC: 87 "Guide1ines for Design and Erection of Falsework for Road Bridges" and these
specifications.

1502. MATERIALS
All materials shall comply with the requirements of IRC: 87. Materials and components
used for formwork shall be examined for damage or excessive deterioration before use /
re-use and shall be used only if found suitable after necessary repairs. In case of timber
formwork, the inspection shall not only cover physical damages but also signs of attacks by
decay, rot or insect attack or the development of splits.
Forms shall be constructed with metal or timber. The metal used for forms shall be of such
thickness that the forms remain true to shape. All bolts should be countersunk. The use
of approved internal steel ties or steel or plastic spacers shall be permitted. Structural
steel tubes used as support for forms shall have a minimum wall thickness of 4 mm. Other
materials conforming to the requirements of IRC: 87 may also be used if approved by the
Engineer.

1503. DESIGN OF FORMWORK

1503.1. The Contractor shall furnish the design and drawing of complete formwork (i.e.
the forms as well as their supports) for approval of the Engineer before any erection is
taken up. If proprietary system of formwork is used, the Contractor shall furnish detailed
information as per Appendix 1500/I to the Engineer for approval.
Notwithstanding any approval or review of drawing and design by the Engineer, the
Contractor shall be entirely responsible for the adequacy and safety for formwork.
1503.2. The design of the formwork shall conform to provisions of IRC: 87. It shall ensure
that the forms can be conveniently removed without disturbing the concrete. The design
shall facilitate proper and safe access to all parts of formwork for inspection.
1503.3. In the case of prestressed concrete superstructure, careful consideration shall be
given to redistribution of loads on props due to prestressing.

1504. WORKMANSHIP
1504.1. The formwork shall be robust and strong and the joints shall be leak-proof
Balli shall not be used as staging. Staging must have cross bracings and diagonal bracings
in both directions. Staging shall be provided with an appropriately designed base plate
resting on firm strata.
1504.2. The number of joints in the formwork shall be kept to a minimum by using large
size panels. The design shall provide for proper "soldiers” to facilitate alignment. All joints
shall be leak proof and must be properly sealed. Use of PVC JOINT sealing tapes, foam
rubber or PVC T-section is essential to prevent leakage of grout.
1504.3. As far as practicable, clamps shall be used to hold the forms together. Where
use of nails is unavoidable minimum number of nails shall be used and these shall be
left projecting so that they can be withdrawn easily. Use of double headed nails shall be
preferred.

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1504.4.
1504.4. Use of ties shall be restricted, as far as practicable. Wherever ties are used they
shall be used with HDPE sheathing so that the ties can easily be removed. No parts prone
to corrosion shall be left projecting or near the surface. The sheathing shall be grouted with
cement mortar of the same strength as that of the structure.
1504.5. Unless otherwise specified, or directed, chamfers or fillets of sizes 25 mm X 25
mm shall be provided at all angles of the formwork to avoid sharp corners. The chamfers,
bevelled edges and mouldings shall be made in the formwork itself. Opening for fixtures
and other fittings shall be provided in the shuttering as directed by the Engineer.
1504.6. Shuttering for walls, sloping members and thin sections of considerable height
shall be provided with temporary openings to permit inspection and cleaning out before
placing of concrete.
1504.7. The formwork shall be constructed with precamber to the soffit to allow for deflection
of the formwork. Pre-camber to allow for deflection of formwork shall be in addition to that
indicated for the permanent structure in the drawings.
1504.8. Where centering trusses or launching trusses are adopted for casting of
superstructure, the joints of the centering trusses, whether welded, riveted or bolted
should be thoroughly checked periodically. Also, various members of the centering trusses
should be periodically examined for proper alignment and unintended deformation before
proceeding with the concreting. They shall also be periodically checked for any deterioration
in quality due to steel corrosion.
1504.9. The formwork shall be so made as to produce a finished concrete true to shape, line
and levels and dimensions as shown on the drawings, subject to the tolerances specified in
respective sections of these specifications, or as directed by the Engineer.
1504.10. Where metal forms are used, all bolts and rivets shall be countersunk and well
ground to provide a smooth, plane surface. Where timber is used it shall be well seasoned,
free from loose knots, projecting nails, splits or other defects that may mar the surface of
concrete.
1504.11. Forms shall be made sufficiently rigid by the use of ties and bracings to prevent
any displacement or sagging between supports. They shall be strong enough to withstand
all pressure, ramming and vibration during and after placing the concrete. Screw jacks
or hard wood wedges where required shall be provided to make up any settlement in the
formwork either before or during the placing of concrete.
1504.12. The formwork shall take due account of the calculated amount of positive or
negative camber so as to ensure the correct final shape of the structures, having regard to
the deformation of false work, scaffolding or propping and the instantaneous or deferred
deformation due to various causes affecting prestressed structures.
1504.13. Suitable camber shall be provided to horizontal members of structure, specially
in long spans to counteract the effects of deflection. The formwork shall be so fixed as to
provide for such camber.
1504.14. The formwork shall be coated with an. approved release agent that will effectively
prevent sticking and will not stain the concrete surface. Lubricating (machine oils) shall be
prohibited for use as coating.

1505. FORMED SURFACE AND FINISH

The formwork shall be lined with material approved by the Engineer so as to provide a
smooth finish of uniform texture and appearance. This material shall leave no stain on
the concrete and so fixed to its backing as not to impart any blemishes. It shall be of

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 1504.14.
the same type and obtained from only one source throughout for the construction of any
one structure. The contractor shall make good any imperfections in the resulting finish as
required by the Engineer. Internal ties and embedded metal parts shall be carefully detailed
and their use shall be subject to the approval of the Engineer.

1506. PRECAUTIONS
(i) Special measures in the design of formwork shall be taken to ensure that it does not
hinder the shrinkage of concrete. The soffit of the formwork shall be so designed
as to ensure that the formwork does not restrain the shortening and for hogging of
bea.ms during prestressing. The forms may be removed at the earliest opportunity
subject to the minimum time for removal of forms with props retained in position.
(ii) Where necessary, form work shall be so arranged that the soffit form, properly
supported on props only can be retained in position for such period as may be
required by maturing conditions.
(iii) Any cut-outs or openings provided in any structural member to facilitate erection of
formwork shall be closed with the same grade of concrete as the adjoining structure
immediately after removal of form work ensuring watertight joints.
(iv) Provision shall be made for safe access on, to and about the formwork at the levels
as required.
(v) Close watch shall be maintained to check for settlement of formwork during
concreting. Any settlement of formwork during concreting shall be promptly rectified.
(vi) Water used for curing should not be allowed to stagnate near the base plates
supporting the staging and should be properly drained.

1507. PREPARATION OF FORMWORK BEFORE CONCRETING

The inside surfaces of forms shall, except in the case of permanent form work or where
otherwise agreed to by the Engineer be coated with a release agent supplied by approved
manufacturer or of an approved material to prevent adhesion of concrete to the formwork.
Release agents shall be applied strictly in accordance with the manufacturer’s instructions
and shall not be allowed to come into contact with any reinforcement or prestressing
tendons and anchorages. Different release agents shall not be used in formwork for
exposed concrete.
Before re-use of forms, the following actions shall be taken :
(i) The contact surfaces of the forms shall be cleaned carefully and dried before applying
a release agent.
(ii) It should be ensured that the release agent is appropriate to the surface to be coated.
The same type and make of release agent shall be used throughout on similar
formwork materials and different types should not be mixed.
(iii) The form surfaces shall be evenly and thinly coated with release agent. The vertical
surface shall be treated before horizontal surface and any excess wiped out
(iv) The release agent shall not come in contact with reinforcement or the hardened
concrete.
All forms shall be thoroughly cleaned immediately before concreting.
The Contractor shall give the Engineer due notice before placing any concrete in the forms
to permit him to inspect and approve the formwork, but such inspection shall not relieve the
contractor of his responsibility for safety of formwork, men, machinery, materials and finish
or tolerances of concrete.

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1504.14.
1508. REMOVAL OF FORMWORK
The scheme for removal of formwork (i.e. de-shuttering and de-- centering) shall be planned
in advance and furnished to the Engineer for scrutiny and approval. No formwork or any
part thereof shall be removed without prior approval of the Engineer.
The formwork shall be so removed as not to cause any damage to concrete. Centering
shall be gradually and uniformly lowered in such a manner as to permit the concrete to take
stresses due to its own weight uniformly and gradually to avoid any shock or vibration.
Where not specifically approved, the time of removal of formwork (when ordinary Portland
Cement is used without any admixtures at an ambient temperature exceeding 10 degrees
Celsius) shall be as under :
a) Walls, piers, abutments : 12 to 48 hours as may be columns and vertical faces decided
by the Engineer of structural members
b) Soffits of Slabs : 3 days (with props left under)
c) Props (left under slabs) : 14 days
d) Softit of Girders : 7 days (with props left under)
e) Props (left under girders) : 21 days
Where there are re-entrant/angles in the concrete sections, the formwork should be
removed at these sections as soon as possible after the concrete has set, in order to avoid
cracking due to shrinkage of concrete.

1509. RE-USE OF FORMWORK

When formwork is dismantled, its individual components shall be examined for damage
and damaged pieces shall be removed for rectification. Such examination shall always
be carried out before being used again. Before re-use all components shall be cleaned of
deposits of soil, concrete or other unwanted materials. Threaded parts shall be oiled after
cleaning.
All bent steel props shall be straightened before re-use. The maximum deviation from
straightness is 1/600 of the length. The maximum permissible axial loads in used props
shall be suitably reduced depending upon their condition. The condition of the timber
components, plywood and steel shuttering plates shall be examined closely for distortion
and defects before re-use.

1510. SPECIALISED FORMWORK

Specialised formwork may be required in the case of slipform work, underwater concreting,
segmental construction etc. Such specialised form- work shall be designed and detailed by
competent agencies and a set of complete working drawings and installation instructions
shall be supplied to the Engineer, The site personnel shall be trained in the erection
and dismantling as well as operation of such specialised formwork. In case proprietary
equipment is used, the supplier shall supply drawings, details, installation instructions, etc.-
in the form of manuals along with the formwork. Where specialised formwork is used, close
co-ordination with the design of permanent structure is necessary.
For slipform the rate of slipping the formwork shall be designed for each individual case
taking into account various parameters including the grade of concrete, concrete strength,
concrete temperature, ambient temperature, concrete admixtures, etc. In the case of
segmental construction, the concrete mix shall be normally designed for developing high
early strength so that the formwork is released as early as possible.
In order to verify the time and sequence of striking/removal of specialised formwork, routine

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 1504.14.
field tests for the consistency of concrete and strength development are mandatory and
shall be carried out before adoption.
For specialised formwork, the form lining material may be either plywood or steel sheet of
appropriate thickness. Plywood is preferred where superior quality of surface is desired,
whereas steel sheeting is normally used where large numbers of repetitions are involved.

1511. 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.

1512. MEASUREMENTS FOR PAYMENT

Unless stated otherwise the rate for concrete in Plain Concrete or Reinforced Concrete or
Prestressed Concrete shall be deemed to include all formwork required in accordance with
this section and shall not be measured separately.
Where it is specifically stipulated in the Contract that the formwork shall be paid for
separately, measurement of formwork shall be taken in square metres of the surface area
of concrete which is in contact with formwork.

1513. RATE
The unit rate of the Plain Concrete or Reinforced Concrete or Prestressed Concrete as
defined in respective sections shall be deemed to cover the costs of all formwork, including
cost of all materials, labour, tools and plant required for design, construction and removal
of formwork and supervision as described in this section including properly supporting the
members until the concrete is cured, set and hardened as required.
Where the contract unit rate for formwork is specifically provided as a separate item, it shall
include the cost of all materials, labour, tools and plant required for design, construction
and removal of formwork and supervision as described in this Section including properly
supporting the members until the concrete is cured, set and hardened as required.

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 1504.14.

1800
PRESTRESSING

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1801. DESCRIPTION
Structural concrete containing prestressed steel reinforcement to introduce precompression
is termed as prestressed concrete.
The work shall be carried out in accordance with the drawing and these specifications or
as approved by the Engineer.
Concrete and untensioned steel for the construction of prestressed concrete members
shall conform to the requirements of sections 1700 and 1600 for Structural Concrete and
Steel Reinforcement respectively in so far as the requirements of these Sections apply and
are not specifically modified by requirements set forth herein.

1802. MATERIALS
1802.1. All materials shall conform to Section 1000.
1802.2. Sheathing
1802.2.1. The sheathing ducts shall be of the spiral corrugated `type. Unless otherwise
specified, the material shall be Cold Rolled Cold Annealed (CRCA) Mild Steel conforming
to IS: 513 intended for mechanical treatment and surface refining but not for quench
hardening or tempering.
 The material shall normally be bright finished. However, where specified, as in case
of use in aggressive environment, galvanised or lead-coated mild steel strips shall be
used.
The thickness of sheathing shall be as shown on the drawing, but shall not be less than
0.3 mm, 0.4 mm and 0.5 mm for sheathing ducts having internal diameter of 50 mm, 75
mm and 90 mm respectively. For bigger diameter of ducts, thickness of sheathing shall
be based on recommendations of prestressing system supplier or as directed by the
Engineer.
 The sheathing shall conform to the requirement as per tests specified in Appendix
1800/I.
 For major projects, the sheathing ducts should preferably be manufactured at the
project site utilising appropriate machines. With such an arrangement, long lengths of
sheathing ducts may be used with consequent reduction in the number of joints and
couplers. Where sheathing duct joints are unavoidable, such joints shall be made slurry
tight by the use of corrugated threaded sleeve couplers which may be tightly screwed
onto the outer side of the sheathing ducts.
The length of the coupler should not be less than 150 mm but should be increased upto
200 mm wherever practicable. The joints between the ends of the coupler and the duct
shall be sealed with adhesive sealing tape to prevent penetration of cement slurry during
concreting. The couplers of adjacent ducts should be staggered wherever practicable.
As far as possible, couplers should not be located in curved zones. The corrugated
sleeve couplers are being conveniently manufactured using the sheath making machine
with the next higher size of die set.
1802.2.2. The internal area of the sheathing duct shall be in accordance with the
recommendations of the system manufacturer and shall be about three times the area
of the tendons. In case of 6T13, 12T13 and 19T13 sizes of tendons comprising 12/13
mm dia strands, the inner diameter of the sheathing shall not be less than 50 mm, 75
mm and 90 mm respectively or those shown in the drawing, whichever is greater.
Where prestressing tendons are required to be threaded after concreting the diameter
of sheathing shall be about 5 mm larger than that required as above.

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1802.2.3.
1802.2.3. In severe environment, cables shall be threaded after concreting. In such
cases a temporary tendon shall be inserted in the sheathing or the sheathing shall be
stiffened by other suitable method during concreting.
1802.3. Anchorages
1802.3.1. Anchorages shall be procured from authorised manufacturers only. Anchorages
shall conform to BS: 4447. Test certificates from a laboratory fully equipped to carry out
the tests shall be furnished to the Engineer. Such test certificates shall not be more than
12 months old at the time of making the proposal for adoption of a particular system for
the project.
No damaged anchorages shall be used. Steel parts shall be protected from corrosion
at all times. Threaded parts shall be protected by greased wrappings and tapped holes
shall be protected by suitable plugs until used. The anchorage components shall be kept
free from mortar and loose rust and any other deleterious coating.
1802.3.2. Swages of prestressing strand and button-heads of prestressing wire, where
provided shall develop strength of at least 95 per cent of the specified breaking load of
the strand or wire as the case may be. Where swaging/button-heading is envisaged, the
Contractor shall furnish details of his methodology and obtain approval of the Engineer,
prior to his taking up the work.
1802.3.3. Untensioned Steel reinforcements, around anchorages shall conform to the
details of prestressing system and as shown on the drawing.

1803. TESTING OF PRESTRESSING STEEL AND ANCHORAGES

All materials specified for testing shall be furnished free of cost and shall be delivered in
time for tests to be made well in advance of anticipated time of use.
All wire, strand or bars to be shipped to the site shall be assigned a lot number and tagged
for identification purposes. Anchorage assemblies to be shipped shall be like-wise identified.
All samples submitted shall be representative of the lot to be furnished and in the case
of wire or strand, shall be taken from the same master roll. The Contractor shall furnish
samples of at least 5.0 m length selected from each lot for testing. Also, two anchorage
assemblies, complete with distribution plates of each size or types to be used, shall be
furnished alongwith short lengths of strands as required.

1804 WORKMANSHIP
1804.1. Cleaning
Tendons shall be free from loose rust, oil, grease, tar, paint, mud or any other deleterious
substance. Cleaning of the steel may be carried out by immersion in suitable solvent
solutions, wire brushing or passing through a pressure box containing carborundum
powder. However, the tendons shall not be brought to a polished condition.
1804.2. Straightening
High tensile steel wire and strand shall be supplied in coils of sufficiently large diameter
such that tendons shall retain their physical properties and shall be straight as it unwinds
from the coil. Tendons of any type that are damaged, kinked or bent shall not be used.
The packing of prestressing wire/strand shall be removed only just prior to making of cable
for placement. Suitable stands shall be provided to facilitate •uncoiling of wires/strands
without damage to steel. Care shall be taken to avoid the possibility of steel coming into
contact with the ground.
1804.3. Positioning

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 1804.5.
1804.3.1. Post-Tensioning
 Prestressing tendons shall be accurately located and maintained in position, both
vertically and horizontally, as per drawings.
 Tendons shall be so arranged that they have a smooth profile without sudden bends
or kinks.
 The locationing of prestressed cables shall be such as to facilitate easy placement
and vibration of concrete in between the tendons. High capacity tendon shall be used to
reduce the number of cables thereby eliminating the necessity of grouping. The selected
profiles of the tendons shall be such that their anchorages are not located in the top
deck surface. Where two or more rows of cables have to be used, the cables shall
be vertically in line to enable easy flow of concrete. The clear vertical and horizontal
distances between any two cables shall in no case be less than l00rnm anywhere along
the length of the superstructure. Where precast segments are used, the clear distance
shall be at least 150 mm.
 Sheathing shall be placed in correct position and profile by A providing suitable
ladders and spacers. Such ladders may be provided at intervals of approximately 1.0
m. Sheathing shall be tied rigidly with such ladders/spacer bars so that they do not get
disturbed during concreting.
The method of supporting and fixing shall be such that profile of cables is not disturbed
during vibrations, by pressure of wet concrete, by workmen or by construction traffic.
 Sheathing in which the permanent tendon will not be in place during concreting shall
have a temporary tendon inserted or shall be stiffened by some other method to the
approval of the Engineer. The temporary tendon shall be pulled out before threading the
permanent tendon into place by a special threading machine or other contrivance.
Where possible tendons shall not be placed until immediately prior to stressing. Tendons
shall be handled with care to avoid damage or contamination, to either the tendon or the
sheathing. Any tendons damaged or contaminated shall be cleaned or replaced.
1804.3.2. Pre-Tensioning. Prestressing steel shall be accurately located and maintained
in position, both vertically and horizontally, as per drawings.
1804.3.3. Each anchorage device shall be set square to the line of action of the
corresponding prestressing tendon and shall be positioned securely to prevent movement
during concreting.
The anchorage devices shall be cleaned to the satisfaction of the Engineer prior to the
placing of concrete. After concreting, any mortar or concrete which adheres to bearing
or wedging surfaces shall be removed immediately.
1804.4. Cutting
Cutting and trimming of wires or strands shall be done by suitable mechanical or flame
cutters. When a flame cutter is used, care shall be taken to ensure that the flame does not
come in contact with other stressed steel. The location of flame cutting of wire or strand
shall be kept beyond 75 mm of where the tendon will be gripped by the anchorage or jacks.
. In post-tensioning the ends of prestressing steel projecting beyond the anchorages, shall
be cut after the grout has set.
1804.5. Protection of Prestressing Steel
Prestressing steel shall be continuously protected against corrosion, until grouted. The
corrosion protector shall have no deleterious effect on the steel or concrete or, on the bond
strength of steel to concrete. Grouting shall conform to these specifications or as directed
by the Engineer.
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1804.6.
In the case of external prestressing, steel shall be encased in suitable polyethylene pipes
before grouting.
1804.6. Sheathing
The joints of all sheathings shall be water-tight. Special attention shall be paid to the junction
at the anchorage end, where the sheathing must tightly fit on the protruding trumpet end of
anchorage and thereafter sealed preferably with heat shrink tape, to make it water- proof.
The heat-shrink tape is supplied in the form of bandage rolls which can be used for all
diameters of sheathing ducts. The bandage is coated on the underside with a heat sensitive
adhesive so that after heating the bandage material shrinks on the sheathing duct and
ensures formation of a leak-proof joint. The heating is effected by means of a soft gas
flame.
A sheath making machine should be positioned at the site of work for large projects so that
sheathing can be prepared as and when it is required for construction.
The sheathing and all joints shall be water tight. Any temporary opening in the sheathing
shall be satisfactorily plugged and all joints between sheathing and any other part of the
prestressing system shall be effectively sealed to prevent entry of mortar, dust, water or
other deleterious matter. Sheathing shall be neatly fitted at joints without internal projection
or reduction of diameter.
Enlarged portions of the sheathing at couplings or anchorages shall be of sufficient length
to provide for the extension of the tendons.
1804.7. Grout Vents
Grout vents of at least 20 mm diameter shall be provided at both ends of the sheathing and
at all valleys and crests along its length. Additional vents with plugs shall also be provided
along the length of sheathing such that the spacings of consecutive vents do not exceed
20 m. Each of the grout vents shall be provided with a plug or similar device capable of
withstanding a pressure of 1.0 MPa without the loss of water, air pressure or grout.
1804.8 Anchorages
All bearing surfaces of the anchorages shall be cleaned prior to concreting and tensioning.
Anchor cones, blocks and plates shall be securely positioned and maintained during
concreting such that the centre line of the duct passes axially through the anchorage
assembly.
The anchorages shall be recessed from the concrete surface by a minimum cover of 100
mm.
After the prestressing operations are completed and prestressing wires/strands are Cut,
the surface shall be painted with two coats of epoxy of suitable formulation having a dry
film thickness of 80 microns per coat and entire recess shall be filled with concrete or non-
shrink/pre-packaged mortar or epoxy concrete.
1804.9. Structural Concrete
Structural concrete shall conform to Section 1700. The formwork shall conform to Section
1500.

1805. SUPERVISION
All prestressing and grouting operations shall be `undertaken by trained personnel only. A
representative of supplier- of the prestressing system shall be present during all tensioning
and grouting operations and shall ensure, monitor and certify their correctness.

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 1804.9.
1806. TENSIONING EQUIPMENT
All tensioning equipment shall be procured from authorised manufacturers only and be
approved by the Engineer prior to use. Where hydraulic jacks are used, they shall be
power-driven unless otherwise approved by the Engineer. The tensioning equipment shall
satisfy the following requirements:
(i) The means of attachments of the prestressing steel to the jack or any other tensioning
apparatus shall be safe and secure.
(ii) Where two or more wires/strands constitute a tendon, a single multiple stressing jack
shall be used which is capable of tensioning simultaneously all the wires/strands
of the tendon. Suitable facilities for handling and attaching the multipull jack to the
tendons shall be provided.
(iii) The tensioning equipment shall be such that it can apply controlled total force
gradually on the concrete without inducing dangerous secondary stresses in steel,
anchorage or concrete; and
(iv) Means shall be provided for direct measurement of the force by use of dynamometers
or pressure gauges fitted in the hydraulic system itself to determine the pressure
in the jacks. Facilities shall also be provided for the linear measurement of the
extension of prestressing steel to the nearest mm and of any slip of the gripping
devices at transfer.
All dynamo meters and pressure gauges including a master gauge shall be calibrated by an
approved laboratory immediately prior to use and then at intervals not exceeding 3 months
and the true force determined from the calibration curve.
Pressure gauges shall be concentric scale type gauges accurate to within two per cent of
their full capacity. The minimum nominal size of gauge shall be 100 mm. The gauge shall
be so selected that when the tendon is stressed to 75 per cent of its breaking load, the
gauge is reading between 50 per cent and 80 per cent of its full capacity. Suitable safety
devices shall be fitted to protect pressure gauges against sudden release of pressure.
Provision shall be made for the attachment of the master gauge to be used as a check
whenever requested for by the Engineer.

1807. POST-TENSIONING
Tensioning force shall be applied in gradual and steady steps and carried out in such
a manner that the applied tensions and elongations can be measured at all times. The
sequence of stressing, applied tensions and elongations shall be in accordance with the
approved drawing or as directed by the Engineer.
It shall be ensured that in no case, the load is applied to the concrete before it attains the
strength specified on the drawing or as stipulated by the prestressing system supplier,
whichever is more.
After prestressing steel has been anchored, the force exerted by the tensioning equipment
shall be decreased gradually and steadily so as to avoid shock to the prestressing steel or
anchorage.
The tensioning force applied to any tendon shall be determined by direct reading of the
pressure gauges or dynamo-meters and by comparison of the measured elongation with the
calculated elongation. The calculated elongation shall be invariably adjusted with respect
to the modulus of elasticity of steel for the particular lot as given by the manufacturer.
The difference between calculated and observed tension and elongation during prestressing
operations shall be regulated as follows:

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1809.1.
a) If the calculated elongation is reached before the specified gauge pressure is
obtained, continue tensioning till attaining the specified gauge pressure, provided
the elongation does not exceed 1.05 times the calculated elongation. If 1.05 times
the calculated elongation is reached before the specified gauge pressure is attained,
stop stressing and inform the Engineer.
b) If the calculated elongation has not been reached at the specified gauge pressure,
continue tensioning by intervals of 5 kg/sq. cm. until the calculated elongation is
reached provided the gauge pressure does not exceed 1.05 times the specified
gauge pressure.
c) If the elongation at 1.05 times the specified gauge pressure is less than 0.95 times
the calculated elongation, the following measures must be taken, in succession, to
determine the cause of this lack of discrepancy :
i) Check the correct functioning of the jack, pump and leads.
ii) Detension the cable. Slide it in its duct to check that it is not blocked by mortar
which has entered through holes in the sheath. Retention the cable if free.
iii) Re establish the modulus of elasticity of steel for the particular lot from an
approved laboratory.
If the required elongation is still not obtained, further finishing operations such as
cutting or sealing, should not be undertaken without the approval of the Engineer.
d) When stressing from one end only, the slip at the end remote from the jack shall be
accurately measured and an appropriate allowance made in the measured extension
at the jacking end.
A complete record of prestressing operations along with elongation and jack pressure
data shall be maintained in the format given in Appendix 1800/II. The number of stages of
prestressing and grouting shall be reduced to a minimum, preferably 2 in the case of simply
supported girders.

1808. GROUTING OF PRESTRESSED TENDONS

Grouting shall conform to Appendix 1800/III. A record of grouting operations shall be
maintained in the format given in Appendix 1800/IV

1809. PRE-TENSIONING
1809.1. General
The planning and construction aspects of the tensioning bed, tensioning bench, abutments
at location of anchorage, steam curing system, formwork of the concrete elements and
arrangements for demoulding, lifting, stacking and transportation of the pre-tensioned
concrete elements are all specialised items and shall be entrusted to engineers specifically
experienced in this type of work.
1809.2. Stressing Bed for Pre-tensioning
The abutments and bed for pre-tensioning of tendons shall be designed to withstand the
total tensioning force.
A notice shall be displayed adjacent to the stressing bed showing. the maximum tensioning
force permitted.
Where concrete elements are cast and prestressed individually, the stressing bench or
moulds shall be rigid enough to sustain the reaction - of the prestressing force without
distortion.
In the long line method of prestressing, sufficient locator plates should be distributed
218 RED BOOK  VOLUME I  ROADS  2012
 1809.4.
throughout the length of the bed to ensure that the wires are maintained in their proper
position during concreting. The moulds shall be free to slide in the direction of their length
and thus permit the transfer of the prestressing force to all the concrete elements along the
whole line.
Sufficient space shall be left in between the ends of concrete elements to permit access for
cutting the strands/wires after transfer. Hold downs or deflectors shall be used for holding
or deflecting the tendons in required position firmly. Deflectors which are in contact with
the tendon shall have a diameter not less than the tendon or 15 mm, whichever is greater.
The tensioning force required to be applied as stated on the drawings shall be the force
remaining in the strands/wires after all strands/wires have been anchored to the abutments
of the stressing bed and after the anchorage slip has already taken place. The tensioning
force shall be determined by direct reading of the pressure gauges or dynamo-meters and
by the measured elongation after slip.
The Contractor shall submit method of tensioning the tendons including the arrangement
and layout of prestressing beds and all tendon deflection points to the Engineer for approval
before manufacture commences.
The Contractor shall carry out trial stressing operations to establish the frictional resistance
offered by the hold-downs and the slip during anchoring.
Where sheathing of pre-tensioned tendons is required to prevent bond over a specified
length, it shall consist of plastic tubing or other material approved by the Engineer and shall
be of a quality, diameter and thickness such that bond shall be effectively prevented. The
tubing shall be fastened to the tendon in such a manner that cement mortar cannot enter.
The Engineer may order that the pull-in of the tendon be measured during the transfer of
prestress.
The Contractor shall also submit calculations showing that the hold- downs have been
designed and constructed to withstand concentrated loads, resulting from the application
of the tensioning force.
1809.3. Tensioning Procedure
The tensioning of the wires and strands shall be done not too much in advance of concreting.
The tensioning force shall be applied gradually and uniformly.
In order to remove slack and to lift tendons off the bed floor, an initial force approved by
the Engineer shall be applied to the tendons. Allowance shall be made for this force in
calculating the required elongation.
Tendons shall be marked for measurement of elongation after the initial force has been
applied. When required by the Engineer, tendons shall be marked at both the jacking end
and dead end of the stressing bed and at couplers if used so that slip and draw-in may be
measured.
Where deflected strands have been specified, the Engineer may direct the elongation or
strain gauge measurements be taken at various positions along the tendon to determine
the force in the tendon at those positions.
1809.4. Transfer of Prestress
While the process of tensioning can be accomplished by means of hydraulic jacks, some
positive mechanical means shall be provided to maintain the tension during the entire
period between the tensioning of the wires/strands and transfer of the prestressing force to
the concrete element.
Transfer of prestress shall not proceed until the Engineer has approved the proposed

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1809.5.
method. Tendons and deflection devices shall be released in such a pre-determined order
that unacceptable tensile stresses are not induced in the concrete.
Prior to transfer of the force to the units, all tendons shall be tested for tightness and any
loose tendon shall be reported to the Engineer who will decide whether the units affected
shall be rejected.
The Engineer may require that tendons be marked at each end of any unit to allow
measurement of the pull-in of the concrete.
Tendons shall be released gradually and preferably simultaneously.
Under no circumstances shall tendons be cut while under tension.
On completion of the transfer of prestress, the projecting lengths of tendon shall be cut off
flush with the end surface of the unit, unless otherwise shown, by a method approved by
the Engineer.
In no case shall the transfer of prestressing force to the concrete elements take place before
concrete attains the strength specified in the drawings. To determine the specified strength,
additional cube testing shall be undertaken at the Contractor’s cost. In case steam curing
is employed, the cubes shall be placed in the same environment as the concrete elements
to obtain an accurate assessment of concrete strength at the time of transfer.
The sequence of transfer of prestressing force shall be done strictly as indicated in the
drawings and ensuring that eccentricities of the prestressing force in the vertical and
horizontal directions of the concrete element is a minimum during the entire sequence.
The maximum slip of any tendon during transfer shall not exceed 3 mm at any end of the
concrete element. In case this slip is exceeded, the concrete element in question shall be
rejected.
1809.5. Protection of Ends
The exposed ends of the tendons and the concrete surfaces of the ends of the units shall
be wire brushed clean of all rust, loose mortar, grease and dirt.
The exposed ends of the tendons and concrete surface within 50 mm of tendons shall be
then abraded to provide a clean sound surface. An epoxy tar paint suitably formulated to
give a dry film thickness of 80 microns per coat shall then be immediately applied over the
ends of the tendons unless otherwise directed.
A second coat of paint shall be applied prior to the drying out of the first coat.

1810. SAFETY PRECAUTIONS DURING TENSIONING

Care shall be taken during tensioning to ensure the safety of all persons in the vicinity.
Jacks shall be secured in such a manner that they will be held in position, should they lose
their grip on the tendons.
No person shall be allowed to stand behind the jacks or close to the line of the tendons
while tensioning is in progress.
The operations of the jacks and the measurement of the elongation and associated
operations shall be carried out in such a manner and from such a position that the safety
of all concerned is ensured.
A safety barrier shall be provided at both ends to prevent any tendon, which might become
loose from recoiling unchecked.
During actual tensioning operation, warning sign shall be displayed, at both ends of the
tendon.

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 1809.5.
After prestressing, concrete shall neither be drilled nor any portion cut nor chipped away
nor disturbed, without express approval of the Engineer.
No welding shall be permitted on or near tendons nor shall any heat be applied to tendons.
Any tendon which has been affected by welding, weld spatter or heat shall be rejected.

1811. TRANSPORTATION AND STORAGE OF UNITS

Precast girders shall be transported in an upright position. Points of support and the
direction of reactions with respect to the girder shall approximately be the same during
transportation, and storage as when the girder is placed in final position.
When members are to be stacked, they shall be firmly supported at such bearing positions
as will ensure that the stresses induced in them are always less than the permissible design
stresses. Further, inclined side supports shall be provided at the ends and along the length
of a precast girder to prevent lateral movements or instability.
Care shall be taken during storage, hoisting and handling of the precast units to prevent
their cracking or being damaged. Units damaged by improper storing or handling shall be
replaced by the Contractor at his expense.

1812. TOLERANCES
Permissible tolerances for positional deviation of Prestressing tendons shall be limited to
the following:
a) Variation from the specified horizontal profile : 5 mm
b) Variation from the specified vertical profile : 5 mm
c) Variation from the specified position in member : 5 mm

1813. 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.

1814. MEASUREMENTS FOR PAYMENT

Prestressed Concrete shall be measured in cubic metres. 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 and its length shall be measured
as actually incorporated in the finished work.
From the length so measured its weight shall be calculated in tonnes on theoretical basis
and paid for. Anchorage devices, additional length of cables for attaching jack, ducts or
sheathing, grout, 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 included in the item of high tensile steel and
shall not be measured separately.

1815. RATE
The contract unit rate for cast-in-place prestressed concrete shall cover the cost of all
materials, labour, tools and plant required for mixing, placing in position, vibrating and
compacting, finishing as per directions of the Engineer, curing and other incidental
expenses for producing concrete of specified strength to complete the structure or its

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1809.5.
components as shown on the drawings and according to specifications. The contract unit
rate shall also include the cost of making, fixing and removing of all centering and forms
required for the work unless otherwise specified in the Contract. For precast prestressed
concrete members, the rate in addition to above shall also include the cost of all materials,
labour, tools and plant required to transport and place these members in their final position
as shown on the drawings and as directed by the Engineer. The contract unit rate for
high tensile steel shall cover the cost of material, labour, tools and plant required for
manufacturing, placing, tensioning, anchoring and grouting the high tensile steel in the
prestressed concrete as shown on the drawings and as per specifications herein above or
as directed by the Engineer. The cost of anchorage devices, additional length of cables for
attaching jack, ducts or sheathing, grout, 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 included in the unit rate. Rate shall
also include payments if any to be made to the supplier of the prestressing system who
has- to monitor, ensure and certify the correctness of all operations.

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 1809.5.

1900
STRUCTURAL STEEL

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1809.5.

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 1903.2.
1901. DESCRIPTION
This work shall include furnishing, fabricating, transporting, erecting and painting structural
steel, rivet steel, cast steel, steel forgings, cast iron and other incidental metal construction
of the kind, size and quantity in conformity with the drawings and these specifications or as
desired by the Engineer.

1902. GENERAL
General requirements relating to the supply of material shall conform to the specifications
of IS: 1387, for the purpose of which the supplier shall be the Contractor and the purchaser
shall be the Engineer. Finished rolled material shall be free from cracks, flaws, injurious
seams, laps, blisters, ragged and imperfect edges and other defects. It shall have a smooth
and uniform finish, and shall be straightened in the mill before shipment. They shall also
be free from loose mill scale, rust, pits or other defects affecting its strength and durability.
The acceptance of any material on inspection at the mill i.e. rolling mills, foundry or
fabricating plant where material for the work is manufactured, shall not be a bar to its
subsequent rejection, if found defective.
Unless specified otherwise, high tensile steel rivet conforming to 18:1149 shall be used
for members of high tensile steel conforming to IS:961 and shall not be used for mild steel
members.
Unless specified otherwise, bolted connection of structural joints using high tensile friction
grip bolts shall comply with requirements of IS: 4000.
Cast iron shall not be used in any portion of the bridge structure, except where it is subject
to direct compression.

1903. MATERIALS
1903.1. All materials shall conform to Section 1000. Special requirements are given below:
Mild steel for bolts and nuts shall conform to IS: 226 but have a minimum tensile strength
of 44 kg/sq. mm. and minimum percentage elongation of 14. High tensile steel for bolts
and nuts shall conform to IS: 961 but with a minimum tensile strength of 58 kg/sq. mm.
High strength friction grip bolts shall be permitted for use only on satisfactory evidence of
performance to the requirements (not covered by these specifications) specified by the
Engineer or included in the special provisions.
For cast steel, the yield stress shall be determined and shall not be less than 50 per cent
of the minimum tensile strength.
Plain washers shall be of steel. Tapered or other specially shaped washers shall be of steel
or malleable cast iron.
Parallel barrel drifts shall have a tensile strength not less than 55 kg/sq.mm. with elongation
of not less than 20 per cent measured on a gauge length of 4√(█(So@)) (So = cross
sectional area).
1903.2. Materials for castings and forgings, fasteners and welding consumables shall be
as under: 1903.2.1. Castings and Forgings: Steel castings and forgings shall comply with
the requirements of the following Indian Standards, as appropriate:
IS:1030 Carbon Steel Castings. for General Engineering purposes
IS:1875 Carbon Steel Billets, blooms, slabs, bars for forgings
IS:2004 Carbon Steel Forgings for General Engineering purposes
IS:2644 High Tensile Steel Casings
IS:4367 Alloy & tool steel forgings for general industrial use
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1903.2.2.
1903.2.2. Fasteners : Bolts, nuts, washers and rivets shall comply with the following or
relevant IS Standards as appropriate :
IS:1929 Hot forged steel rivets for hot closing (12-36mm dia)
IS:2155 Cold forged steel rivets for hot closing (6-16mm dia)
IS:1363 Hexagon head bolts, screw and nuts product grade C
IS:1364 Hexagon head bolts, screw & nuts product grade A & B
IS:1367 Technical supply conditions for threaded steel fastener
(Parts 1 to 18).
IS:3640 Hexagon fit bolts
IS:3757 High tensile friction grip bolts
IS:6623 High strength structural nuts
IS:6639 Hexagon bolts for steel structure
IS:5624 Foundation bolts
IS:7002 Prevailing torque type steel hexagon lock nuts
IS:5369 Plain washers and lock washers - general requirements
IS:5370 Plain washers with outside dia = 3 X inside dia
IS:5372 Taper washers for channels (ISMC)
IS:5374 Taper Washers for I beams (ISMB)
IS:6610 Heavy washers for steel structures
IS:6649 Hardened and tempered washers for high strength structural bolts and nuts
1903.2.3. Welding consumables
Welding consumables shall comply with the following Indian Standards as appropriate :
IS:814 Covered Electrodes for Metal Arc Welding of structural (Part 1) steel for
welding other than sheets
IS:814 For welding sheets (Part 2)
IS:1278 Filler rods and wires for gas welding
IS:1395 Low and medium alloy Steel covered electrodes for manual Metal Arc
Welding
IS:3613 Acceptance Tests for wire flux combinations for sub- merged arc welding of
structural steel IS:7280 Bare wire electrodes for gas shielded arc welding of
structural steel
IS: 6419 Welding rods and bare electrodes for gas shielded arc welding of structural
steel
1S:6560 Molybdenum and chromium-molybdenum low alloy steel - welding rods and
bare electrodes for gas shielded are welding
1903.3. In aggressive environment, corrosion resistant steel can be used. These are low-
alloyed steels containing a total of 1 per cent - 2 per cent alloys, in particular, copper,
chromium, nickel and phosphorous.
1903.4. Paints
All materials for paints and enamels shall conform to the requirements specified on the
drawings or other special provisions laid down by the Engineer.
The type of paints which can be used shall be as follows:

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 1904.2.
a) Ordinary i.e. paints based on drying oils, alkyd resin, modified alkyd resin, phenolic
varnish epoxy
b) Chemical Resistant - one pack type (ready for use) and two pack type
(mixed before use).
c) Vinyl
d) Chlorinated rubber
e) Bituminous
f) Epoxy
g) Polyurethane
h) Zinc rich
Unless otherwise specified, paints shall conform to the relevant IS specifications. The
paints which have been tested for the following qualities as per specifications given in the
relevant IS codes only shall be used :
- Weight test (weight for 10 litre of paint, thoroughly mixed).
- Drying time
- Consistency
- Dry thickness and rate of consumption.

1904. FABRICATION
1904.1. General
All work shall be in accordance with the drawings and as per these specifications with care
being taken that all parts of an assembly lit accurately together. All members shall carry
mark number and item number and, if required, serial number.
Unless specifically required under the contract, corresponding parts need not be
interchangeable, but the parts shall be match marked as required under Clause 1904.7.
Templates, jigs and other appliances used for ensuring the accuracy of the work shall be of
mild steel; where specially required, these shall be bushed with hard steel. All measurements
shall be made by means of steel tape or other device properly calibrated. Where bridge
materials have been used as templates for drilling, these shall be inspected and passed by
the Engineer before they are used in the finished structure.
All structural steel members and parts shall have straight edges and blunt surfaces. If
necessary, they shall be straightened or flattened by pressure unless they are required to be
of curvilinear forms. They shall also be free from twist. Pressure applied for straightening or
flattening shall be such as would not injure the materials. Hammering shall not be permitted.
Adjacent surfaces or edges shall be in close contact or at uniform distance throughout.
The Contractor shall submit his programme of work to the Engineer for his approval at
least 15 days before the commencement of fabrication. This programme shall include the
proposed system of identification and erection marks together with complete details of
fabrication and welding procedures.
The Contractor shall prepare shop drawings for fabricating any member and obtain approval
of the Engineer before the start of work. Complete information regarding the location, type,
size and extent of all welds shall be clearly shown on the shop drawings. These drawings
shall distinguish between shop and field welds.
1904.2. Preparation of Edges and Ends
All structural steel parts, where required, shall be sheared, cropped, sawn or flame cut and
ground accurately to the required dimension and shape.
End/edge planning and cutting shall be done by any one of the following prescribed

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1904.2.
methods or left as rolled:
a) Shearing, cropping, sawing, machining, machine flame cutting.
b) Hand flame cutting with subsequent grinding to a smooth edge.
c) Sheared edges of plate not more than 16mm thick with subsequent grinding to
smooth profile, which are for secondary use such as stiffeners and gussets.
If ends of stiffeners are required to be fitted, they shall be ground, - so that the maximum
gap over 60 per cent of the contact area does not exceed 0.25 mm.
Where flame cutting or shearing is used, at least one of the following requirements shall
be satisfied.
a) The cut edge is not subjected to applied stress.
b) The edge is incorporated in weld.
c) The hardness of cut edge does not exceed 350 HV30.
d) The material is removed from edge to the extent of 2 mm or minimum necessary, so
that the hardness is less than 350 HV 30.
e) Edge is suitably heat treated by approved method to the satisfaction of the Engineer
and shown that cracks had not developed by dye penetrant or magnetic particle test.
f) Thickness of plate is less than 40 mm for machine flame cutting for materials
conforming to IS:226 and IS:2062. The requirement of hardness below 350 HV 30 of
flame cut edges should be specified by the Engineer.
Wherever specified by the Engineer, the flame cut edges shall be ground or machined over
and above the requirement (a) to (f).
Where machining for edge preparation in butt joint is specified, the ends shall be machined
after the members have been fabricated.
Outside edges of plate and section, which are prone to corrosion shall be smoothed by
grinding or filing.
In the case of high tensile steel at least 6 mm of the material from the flame cut edge shall
be removed by machining.
Longitudinal edges of all plates and cover plates in plate girders and built up members shall
be machined except in the following cases:
a) Rolled edges of single universal plates or flats may not be machined.
b) Covers to single flange plates may be left unmachined.
c) Machine flame cutting instead of machining is acceptable for edges of single plates
in compression and for edges of single plates, 25 mm or less thick, in tension.
d) Edges of single shaped plates over 25 mm thick not capable of being machined by
ordinary method may be machine flame cut and the end surface ground.
e) Edges of universal plates or flats of the same nominal width used in tiers may be left
unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12 mm thick and over shall be machined and those
less than 12 mm thick may be sheared and ground.
The ends of plates and sections forming the main components of plate girders or of built-
up members shall be machined, machine flame cut, sawn or hand flame cut and ground.
Where ends of stiffeners are required to be fitted, they shall be machined, machine flame
cut, sawn, sheared and ground, or hand flame cut and ground.
The ends of lacing bar shall be rounded unless otherwise required.
228 RED BOOK  VOLUME I  ROADS  2012
 1904.3.3.
Other edges and ends of mild steel parts may be sheared and any burrs at edges shall be
removed.
1904.3. Preparation of Holes
1904.3.1. Drilling and punching: Holes for rivets, black bolts, high strength bolts and
countersunk bolts/rivets (excluding close tolerance and turn fitted bolts) shall be either
punched or drilled. The diameter of holes shall be 1.5 mm larger for bolts/rivets less than
25 mm dia and 2.0 mm for more than or equal to 25 mm.
All holes shall be drilled except for secondary members such as, floor plate, hand rails
etc. Members which do not carry the main load can be `punched subject to the thickness
of member not exceeding 12 mm for material conforming to IS:226.
 Holes through more than one thickness of material or when any of the main material
thickness exceeds 20 mm for steel conforming to IS:2062 or 16 mm for steel conforming
to IS:961, IS:8500, shall either be sub-drilled or sub-punched to a diameter of 3 mm less
than the required size and then reamed to the required size. The reaming of material
more than one thickness shall be done after assembly.
 Where several plates or sections form a compound member, they shall, where
practicable, be firmly connected together by clamps or tacking bolts, and the holes be
drilled through the group in one operation. Alliteratively, and in the case of repetition
work, the plates and sections may be drilled separately from jigs and templates. Jigs
and templates shall be checked at least once after every 25 operations. All burrs shall
be removed.
 In the case of repetition of spans, the erection of every span shall not be insisted
upon, except where close tolerance or turned bolts are used, provided that methods
are adopted to ensure strict interchangeability. In such cases, one span in ten or any
number less than ten of each type shall be erected from pieces selected at random by
the Engineer and should there be any failure of the pieces to fit, all similar spans shall
be erected complete. In the event of spans being proved completely interchangeable,
all corresponding parts shall carry the same mark so that sorting of the materials at site
is facilitated.
1904.3.2. Block drilling : Where the number of plates to be riveted exceeds three or the
total thickness is 90 mm or more, the rivet holes, unless they have been drilled through
steel bushed jigs, shall be drilled out in place 3 mm all round after assembling. In such
cases, the work shall be thoroughly bolted together.
1904.3.3. Size of holes:  The sizes of holes in millimeters are given in Table 1900-1
below:
TABLE 1900-1 : DIAMETER OF HOLES FOR RIVETS
Nominal dia of Rivets (mm) Dia of Holes (mm)
12 13.5
14 15.5
16 17.5
18 19.5
20 21.5
22 23.5
24 25.5
27 29.0
30 32.0
33 35.0

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1904.3.4.
1904.3.4. Close tolerance bolts and barrel bolts: Holes for close tolerance and turn
fitted bolts. The diameter of the holes shall be equal to the nominal diameter of the bolt
shank minus 0.15 mm to 0.0 mm.
 The members to be connected with close tolerance or turn fitted bolts shall be firmly
held together by service bolts or clamped rand drilled through all thicknesses in one
operation and subsequently reamed to required size within specified limit of accuracy as
specified in IS: 919 tolerance grade H8.
The holes not drilled through all thicknesses at one operation shall be drilled to smaller
size and reamed after assembly.
1904.3.5. Holes for high strength friction grip bolts: All holes shall be drilled after removal
of burrs. Where the number of plies in the grip does not exceed three, the diameters of
holes shall be 1.6 mm larger than those of bolts and for- more than three plies in grip,
the diameters of hole in outer plies shall be as above and dia of holes in inner plies shall
not be less than I-.6 mm and not more than 3.2 mm larger than those in bolts, unless
otherwise specified by the Engineer.
1904.3.6. Removal of burrs: The work shall be taken apart after drilling and all burrs left
by drilling and the sharp edges of all rivet holes completely removed.
1904.4. Rivet and Riveting
The diameter of rivets shown on the drawings shall be the size before heating. Each rivet
shall be of sufficient length to form a head of the standard dimensions as given in IS
handbook on Steel Sections, Part I. It shall be free from burrs on the underside of the head.
When countersunk heads are required, the heads shall fill the countersunk. The included
angle of the head shall be as follows:
a) For plates over 14 mm thickness 90 degrees
b) For plates upto and including 14 mm thickness 120 degrees
The tolerance on the diameter of rivets shall be in accordance with IS: 1148 and IS: 1149
for mild steel rivets and high tensile steel rivets respectively and unless otherwise specified,
the tolerance shall be minus tolerance.
Rivets shall be driven when hot so as to fill the hole as completely as possible and shall
be of sufficient length to form a head of standard dimension. When counter-sunk head is
required, the head shall till the counter-sunk hole. Projection after counter-sinking shall be
ground off wherever necessary.
Rivets shall be heated uniformly to a "light cherry red" colour between 650 degrees Celsius
to 700 degrees Celsius for hydraulic riveting and "orange colour" for pneumatic riveting
of mild steel rivets and shall be red hot from head to the point when inserted and shall be
upset in its entire length so as to fill the hole as completely as possible when hot. Rivets,
after being heated and before being inserted in the hole shall be made free from scale by
striking the hot rivet on a hard surface.
Wherever possible, the rivets shall be machine driven, preferably by direct acting riveters.
The driving pressure shall be maintained on the rivets for a short time after the upsetting is
completed. High tensile steel rivets shall be heated upto 1100 degrees Celsius. Any rivet
whose point is heated more than prescribed shall not be driven.
Where flush surface is required, any projecting metal shall be chipped or ground off.
Before riveting is commenced, all work shall be properly bolted up so that the various
sections and plates are in close contact throughout. Drifts shall only be used for drawing
the work into position and shall not be used to such an extent as to distort the holes. Drifts

230 RED BOOK  VOLUME I  ROADS  2012

 1904.5.6.
of a larger size than the nominal diameter of the hole shall not be used. The riveting shall
be done by hydraulic or pneumatic machine unless otherwise specified by the Engineer.
Driven rivets, when struck sharply on the head by a quarter pound rivet testing hammer,
shall be free from movement and vibrations. Assembled riveted joint surfaces, including
those adjacent to the rivet heads, shall be free from scale, dirt, loose scale, burrs, other
foreign materials and defects that would prevent solid seating of parts.
All loose or burnt rivets and rivets with cracked or badly formed defective heads or with
heads which are unduly eccentric with the shanks, shall be removed and replaced. In
removing rivets, the head shall be sheared off and the rivet punched Out so as not to injure
the adjacent metal and, if necessary, they shall be drilled out. Recupping or recaulking shall
not be permitted. The parts not completely riveted in the shop shall be secured by bolts to
prevent damage during transport and handling.
1904.5. Bolts, Nuts and Washers
1904.5.1. Black bolts (black all over): Black bolts are forged bolts in which the shanks,
heads and nuts do not receive any further treatment except cutting of screw threads.
They shall be true to shape and size and shall have the standard dimensions-as shown
on the drawings.
1904.5.2. Close tolerance bolts:  Close tolerance bolts shall be faced under the head
and turned on the shank.
1904.5.3. Turned barrel bolts: The diameter of the screwed portion of turned barrel bolts
shall be 1.5 mm smaller than the diameter of the barrel unless otherwise specified by
the Engineer. The diameter of the bolts as given on the drawing shall be the nominal
diameter of the barrel. The length of the barrel shall be such that it bears fully on all the
parts connected. The threaded portion of each bolt shall project through the nut by at
least one thread. Faces of heads and nuts bearing on steel work shall be machined.
1904.5.4. High strength friction bolts and bolted connections: The general requirement
shall be as per relevant IS specifications mentioned in clause 5.3 of (Fasteners) of IRC:
24. Unless otherwise specified by the Engineer, bolted connections of structural joints
using high tensile friction grip bolts shall comply with requirements mentioned in IS:
4000.
1904.5.5. Washers: In all cases where the full bearing area of the bolt is to be developed,
the bolt shall be provided with a steel washer under the nut of sufficient thickness to
avoid any threaded portion of the bolt being within the thickness of the bolted together
and to prevent the nut when screwed up, from bearing on the bolt.
 For close tolerance or turned barrel bolts, steel washers whose faces give a true
bearing shall be provided under the nut. The washer shall have a hole diameter not less
than 1.5 mm larger than the barrel and a thickness of not less than 6 mm so that the nut
when screwed up, will not bear on the shoulder of the bolt.
 Taper washers with correct angle of taper shall be provided under all heads and nuts
bearing on bevelled surfaces.
 Spring washers may be used under nuts to prevent slackening of the nuts when
excessive vibrations occur.
Where the heads or nuts bear on timber, square washers having a length of each side
not less than three times the diameter of bolts or round washers having a diameter of 3
1/2 times the diameter of bolts and with a thickness not less than one quarter of diameter
shall be provided.
1904.5.6. Studs: Ordinary studs may be used for holding parts together, the holes in one

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1904.5.6.
of the parts being tapped to take the thread of the stud. Counter-sunk studs may be used
for making connections where the surfaces are required to be clear of all obstruction,
such as protruding heads of bolts or rivets, studs may also be welded on the steel work
in the positions required.
1904.5.7. Service bolts: Service bolts shall have the same clearance as black bolts and
where it is required that there should be no movement prior to final riveting, sufficient
drifts or close tolerance bolts shall be used to locate the work.
1904.5.8. Tightening bolts:  Bolted connection joints with black bolts and high strength
bolts shall be inspected for compliance of codal requirements.
The Engineer shall observe the installation and tightening of bolts to ensure that correct
tightening procedure is used and shall determine that all bolts are tightened. Regardless
of tightening method used, tightening of bolts in a joint should commence at the most
rigidly fixed or stiffest point and progress towards the free edges, both in initial snugging
and in final tightening.
The tightness of bolts in connection shall be checked by inspection wrench, which can
be torque wrench, power wrench or calibrated wrench.
Tightness of 10 per cent bolts, but not less than two bolts, selected at random in each
connection shall be checked by applying inspection torque. If no nut or bolt head is
turned by this application, connection can be accepted as properly tightened, but if any
nut or head has turned all bolts shall be checked and, if necessary, re-tightened.
1904.5.9. Drifts: The barrel shall be drawn or machined to the required diameter for a
length of not less than one diameter over the combined thickness of the metal through
which the drifts have to pass. The diameter of the parallel barrel shall be equal to the
nominal diameter of the hole subject to a tolerance of +0 mm and - 0.125 mm. Both
ends of the drift for a length equal to 1 1/2 times the diameter of the parallel portion of
the bar shall be turned down with a taper to a diameter at the end equal to one-half that
of parallel portion.
1904.6. Pins and Pin Holes
1904.6.1. Pins: The pins shall be parallel throughout and shall have a smooth surface
free from flaws. They shall be of sufficient length to ensure that all parts connected
thereby shall have a full bearing on them. Where the ends are threaded, they shall be
turned to a smaller diameter at the ends for the thread and shall be provided with a pilot
nut, where necessary, to protect the thread when being drawn to place. Pins more than
175 mm in length or diameter shall be forged and annealed.
1904.6.2. Pin holes:  Pin holes shall be bored true to gauge, smooth, straight at right
angles to the axis of the member and parallel with each other, unless otherwise required.
The tolerance in the length of tension members from outside to outside of pin holes
and of compression members from inside to inside of pin holes shall be one millimeter.
In built-up members, the boring shall be done after the members have been riveted or
welded.
 The specified diameter of the pin hole shall be its minimum diameter. The resulting
clearance between the pin and the hole shall not be less than 0.5 mm and not more
than 1.0 mm.
1904.7. Shop Erection and Match Marking
Before being dispatched, the steel work shall be temporarily erected in the fabrication shop
for inspection by the Engineer either wholly or in such portion as the Engineer may require
so that he may be satisfied both in respect of the alignment and fit of all connections.

232 RED BOOK  VOLUME I  ROADS  2012

 1904.3.3.
For this purpose, sufficient number of parallel drifts and service bolts tightly screwed up
shall be employed. All parts shall fit accurately and be in accordance with drawings and
specifications. The steel work shall be temporarily assembled at place of fabrication.
Assembly shall be of full truss or girder, unless progressive_ truss or girder assembly, full
chord assembly, progressive chord assembly or special complete structure assembly is
specified by the Engineer.
The field connections of main members of trusses, arches, continuous beams, spans,
bends, plate girders and rigid frame assembled, aligned, accuracy of holes and camber
shall be checked by Engineer and then only reaming of sub-size holes to specified size
shall be taken up.
After the work has been passed by the Engineer and `before it is dismantled, each part shall
be carefully marked for re-erection with distinguishing marks and stamped with durable
markings. Drawings showing these markings correctly shall be supplied to the Engineer.
Unloading, handling and storage of steel work as per these specifications shall be the
responsibility of the Contractor. The cost of repairs or of rejected material, its removal and
the cost of transporting replacement material to the site shall be borne by the Contractor.
Where close tolerance or turned barrel bolts are used for those cases where interchangeability
is not insisted upon, each span shall be erected and members of each span marked
distinctly.
1904.8. Welding
1904.8.1. All welding shall be done with the prior approval of the Engineer and the
workmanship shall conform to the specifications of IS: 823 or other relevant Indian
Standards as appropriate.
 When material thickness is 20 mm or more, special precautions like preheating shall
be taken as laid down in IS: 823. Surfaces and edges to be welded shall be smooth,
uniform and free from fins, tears, cracks and other discontinuities. Surface shall also
be free from loose or thick scale, slag rust, moisture, oil and other foreign materials.
Surfaces within 50 mm of any weld location shall be free from any paint or other material
that may prevent proper welding or cause objectionable fumes • during welding.
The general welding procedures including particulars of the preparation of fusion faces
for metal arc welding shall be carried out in accordance with IS: 9595.
 The welding procedures for shop and site welds including edge preparation of fusion
faces shall be submitted in writing in accordance with Clause 22 of IS:9595 for the
approval of the Engineer before commencing fabrication and shall also be as per details
shown on the drawings. Any deviation from above has to be approved by Engineer.
Preparation of edges shall, wherever practicable, be done by machine methods.
 Machine flame cut edges shall be substantially as smooth and regular as those
produced by edge planning and shall be left free of slag. Manual flame cutting shall be
permitted by the Engineer only where machine cutting is not practicable.
Electrodes to be used for metal arc welding shall comply with relevant IS specifications
mentioned in IRC: 24. Procedure test shall be carried out as per IS: 8613 to find out
suitable wire-f1ux combination for welded joint.
Assembly of parts for welding shall be in accordance with provisions _of 15:9595.
The welded temporary attachment should be avoided/as far as possible; otherwise the
method of making any temporary attachment shall be approved by the Engineer. Any
scars from temporary attachment shall be removed by cutting, chipping and surface
shall be finished smooth by grinding to the satisfaction of the Engineer.
RED BOOK  VOLUME I  ROADS  2012 233
1904.3.3.
 Welding shall not be done when the air temperature is less than 10 degrees Celsius.
Welding shall not be done when the surfaces are moist, during periods of strong winds or
in snowy weather unless the work and the welding operators are adequately protected.
1904.8.2. For welding of any particular type of joint, welders shall qualify to the satisfaction
of the Engineer in accordance with appropriate welder’s qualification test as prescribed in
any of the Indian Standards. IS:817, IS:1966, IS:1393, IS:7307 (part 1), IS:7310 (Part I) and
IS:7318 (part I) as relevant.
1904.8.3. In assembling and joining parts of a structure or of built- up members, the
procedure and sequence of welding shall be such as to avoid distortion and minimise
shrinkage stress.
All requirements regarding pre-heating of parent material and interpass temperature shall
be in accordance with provision of 15:9595.
1904.8.4. Peening of weld shall be carried out wherever specified by the Engineer:
a) If specified, peening may be employed to be effective on each weld layer except first.
b) The peening should be carried out after weld has cooled by light blows from a power
hammer using a round nose tool. Care shall be taken to prevent scaling or flaking of
weld and base metal from over peening.
1904.8.5. Where the Engineer has specified the butt welds are to be ground flush, the loss
of parent metal shall not be greater than that allowed for minor surface defects. The ends
of butt joints shall be welded so as to provide full throat thickness. This may be done by
use of extension pieces, cross runs or other means approved by the Engineer. Extension
pieces shall be removed after the joint has cooled and the ends of the weld shall be finished
smooth and flush with the faces of the abutting parts.
The joints and welds listed below are prohibited type, which do not perform well under
cyclic loading.
a) Butt joints not fully welded throughout their cross-section
b) Groove welds made from one side only without any backing grip
c) Intermittent groove welds
d) Intermittent fillet welds
e) Bevel-grooves and J-grooves in butt joints for other than horizontal position.
f) Plug and slot welds
1904.8.6. The run-on and run-off plate extension shall be used providing full throat thickness
at the end of butt welded joints. These plates shall comply with the following requirements.
(i) One pair of “run-on" and one pair of "run-off" plates prepared from same thickness
and profile as the parent metal shall be attached to start and finish of all butt welds
preferably by clamps.
(ii) When “run-on" and "run-off" plates shall be removed by flame cutting, it should be
CUI at more than 3 mm from parent metal and remaining metal shall be removed by
grinding or by any other method approved by the Engineer.
1904.8.7. Welding of stud shear connectors: The stud shear connectors shall be welded in
accordance with the manufacturer’s instructions including preheating.
The stud and the surface to which studs are welded shall be free from scale, moisture,
rust and other foreign material. The stud base shall not be painted, galvanised or cadmium
plated prior to welding.

234 RED BOOK  VOLUME I  ROADS  2012

 1904.9.
Welding shall not be carried out when temperature is below 10 degrees Celsius or surface
is wet or during periods of strong winds unless the work and the welder is adequately
protected.
The welds shall be visually free from cracks and shall be capable of developing at least the
nominal ultimate strength of studs.
The procedural trial for welding the stud shall be carried out when specified by the Engineer.
1904.9. Tolerances
Tolerances in dimensions of components of fabricated structural steel work shall be
specified on the drawings and shall be subject to the approval of the Engineer before
fabrication. Unless specified, all parts of an assembly shall fit together accurately within
tolerances-specified in Table 1900-2.
A machined bearing surface, where specified by the Engineer, shall be machined within a
deviation of 0.25 mm for surfaces that can be inscribed within a square of side 0.5 m.

TABLE 1900 - 2 FABRICATION TOLERANCES

A. INDIVIDUAL COMPONENTS
1. Length
a) Member with both ends finished for contact bearing ±1 mm
b) Individual components of members with end plate + 0 mm
connection - 2 mm
c) Other members
i) Upto and including 12 M ±2 mm
ii) Over 12 M ± 3.5 mm
2. Width
a) Width of built-up girders ±3 mm
b) Deviation in the width of members required to be +0 mm
inserted in other members -3 mm
3. Depth
Deviation in the depths of solid web and open web +3 mm
girders -2 mm
4. Straightness
a) Deviation from straightness of columns L/3000 subject to a
maximum of 15 mm where L
is length of member
i) In elevation +5 mm
-0 mm
ii) In plan L/1000 subject to a
maximum of 10 mm.
5. Deviation of centre line of web from centre line of 3 mm
flanges in built-up members at contact surfaces

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1905.1.
6. Deviation from flatness of plate of webs of built- 0.005 d to a maximum of 2
up members in a length equal to the depth of the mm where d is depth of the
member member
7. Tilt of flange of plate girders
a) At splices and stiffeners, at supports, at the top 0.005 b to a, minimum of
flanges of plate girders and at bearings 2mm where b is width of the
member
b) at other places 0.015 b to a, maximum of 4
mm where b is width of the
member
8. Deviation from squareness of flange to web of L/1000, where L is nominal
columns and box girders length of the diagonal
9. Deviation from squareness of fixed base plate (not D/500, where D is the
machined) to axis of column. This dimension shall distance from the column
be measured parallel to the longitudinal axis of the axis to the point under
column at points where the outer surfaces of the consideration on the base
column sections make contactwith the base plate plate
10. Deviation from squareness of machined ends to axes D/1000, where D is as
of columns defined in 9 above
11. Deviation from squareness of machined ends to axes D/1000, where D is as
of beams or girder defined in 9 above
12. Ends of members abutting at joints through cleats or 1/600 of depth of member
end plates, permissible deviation from squareness of subject to a maximum of
ends 1.5 mm

1905. ERECTION
1905.1. General
The provisions of this item shall apply to erection of steel bridge superstructures or main
members of bridge superstructures, composed of steel, which span between supports.
If the sub-structure and the superstructure are built under separate contracts, the department
will provide the substructure, constructed to correct lines, dimensions and elevations
properly finished and will establish the lines and the elevation required for setting steel.
The Contractor shall erect the structural steel, remove the temporary construction, and do
all the work required to complete the construction included in the contract in accordance
with the drawings and the specifications and to the entire satisfaction of the Engineer.
1905.2. Organisation and Equipment
The Contractor shall submit erection plans prepared by the fabricator, showing a method
and procedure of erection, compatible with the details of fabrication.
A detailed scheme must be prepared showing stage-wise activities, with complete
drawings and working phase-wise instructions. This should be based on detailed stage-
wise calculation and take into account specifications and capacity of erection equipment
machinery, tools, tackles to be used and temporary working loads as per Codal provisions.
The scheme should be based on site conditions e.g. hydrology, rainfall, flood timings and
intensity, soil and sub-soil conditions in the river bed and banks, maximum water depth,
temperature and climatic conditions and available working space, etc.
236 RED BOOK  VOLUME I  ROADS  2012
 1905.2.
The scheme should indicate precisely the type of temporary fasteners to be used as also
the minimum percentage of permanent fasteners to be fitted during the stage erection. The
working drawings should give clearly the temporary jigs, fixtures, clamps, spacer supports,
etc.
Unless otherwise provided in the contract, the contractor shall supply and erect all necessary
falsework and staging and shall supply all labour, tools, erection plant and other materials
necessary to carry out the work complete in all respects.
The Contractor shall supply all rivets, bolts, nuts, washers, etc. required to complete
erection at site with an allowance for wastage, etc., of 12 1/2 per cent of the net number of
field rivets, bolts, washers required, or a minimum of five number of each item.
Service bolts and nuts, ordinary platters, washers and drifts for use in the erection of work
shall be supplied at 60 per cent (45 per cent bolts and 15 per cent drifts) of the number of
field rivets per span in each size (this includes wastage). A reduction in the quantities of
service bolts, etc., may however, be specified by the Engineer if more than one span of
each type is ordered.
Prior to actual commencement of erection all equipment, machinery, tools, tackles, ropes,
etc. need to be tested to ensure their efficient working. Frequent visual inspection is
essential in vulnerable areas to detect displacements, distress, drainages, etc.
Deflection and vibratory tests shall be conducted in respect of supporting structures,
launching truss as also the structure under erection and unusual observations reviewed;
looseness of fittings are to be noted.
For welded structures, welders’ qualifications and skill are to be checked as per standard
norms. Non-destructive tests of joints as per designer’s directives are to be carried out.
Precision non-destructive testing instruments available in the market should be used for
noting various important parameters of the structures frequently and systematic record is
to be kept.
Safety requirements should conform to IS: 7205, IS: 7273 and IS: 7269 as applicable and
should be a consideration of safety, economy and rapidity.
Erection work should start with complete resources mobilised as per latest approved
drawings and after a thorough survey of foundations and other related structural work. In
case of work of magnitude, maximum mechanisation is to be adopted.
The structure should be divided into erectable modules as per the scheme. This should be
pre-assembled in a suitable yard/platform and fits matching with members of the adjacent
module checked by trial assembly before erection.
The structure shall be set out to the required lines and levels. The stocks and masses are
to be carefully preserved. The steelwork should erected, adjusted and completed in the
required position to the specified line and levels with sufficient drifts and bolts. Packing
materials are to be available to maintain this condition. Organised "Quality Surveillance"
checks need to be exercised frequently.
Before starting work, the Contractor shall obtain necessary approval of the Engineer as
to the method adopted for erection, the and character of tools and plants. The approval
of the Engineer not relieve the Contractor of his responsibility for the safety of his method
or equipment or from carrying out the work fully in accordance with the drawings and
specifications.
During the progress of work, the Contractor shall have a competent Engineer or foreman in
charge of the work, who shall be adequately experienced in steel erection and acceptable
to the Engineer.

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1905.3.
1905.3. Handling and Storing of Materials Suitable area for storage of structures and
components shall be located near the site of work. The access road should be free from
water logging during the working period and the storage area should be on levelled and
firm ground.
The store should be provided with adequate handling equipments e.g. road mobile crane,
gantries, derricks, chain pulley blocks, which of capacity as required. Stacking area should
be planned and have racks, stands sleeper, access tracks, etc., and properly lighted.
Storage should be planned to suit erection work sequence and avoid damage or distortion.
Excessively rusted, bent or damaged steel shall be rejected. Methods of storage and
handling steel, whether fabricated or not shall be subject to the approval of the Engineer.
Fabricated materials are to be stored with erection marks visible, such as not to come into
contact with earth surface or water and should be accessible to handling equipment.
Small fitting hand tools are to be kept in containers in covered stores.
All materials, consumables, including raw steel or fabricated material shall be stored
specification-wise and size-wise above the ground upon platforms, skids or other supports.
It shall be kept free from dirt and other foreign matter and shall be protected as far as
possible from corrosion and distortion. The electrodes shall be stored specification- wise
and shall be kept in dry warm condition in properly designed racks. The bolts, nuts, washers
and other fasteners shall be stored on racks above the ground with protective oil coating
in gunny bags. The paint shall be stored under cover in air-tight containers. IS: 7293 and
IS: 7969 dealing with handling of materials and equipments for safe working should be
followed. Safety nuts and bolts as directed are to be used while working. The Contractor
shall be held responsible for loss or damage to any material paid for by the Department
while in his care or for any damage to such material resulting from his work.
1905.4. Formwork
The formwork shall be properly designed, substantially built and maintained for all anticipated
loads. The Contractor, if required, shall submit plans for approval to the Engineer. Approval
of the plans, however, shall not relieve the Contractor of his responsibility.
1905.5. Straightening Bent Material
The straightening of plates, angles and other shapes shall be done by methods not likely
to produce fracture or any injury. The metal shall 1é not be heated unless permitted by
the Engineer for special cases, when me heating shall not be to a temperature higher
than that producing •a• dark "cherry red" colour, followed by as slow cooling as possible.
Following the straightening of a bend or buckle the surface shall be carefully investigated
for evidence of fracture. Sharp kinks and bends may be the cause for rejection of material.
1905.6. Assembling Steel
The parts shall be accurately assembled as shown on the drawings and match marks shall
be followed. The material shall be carefully handled so that no parts will be bent, broken or
otherwise damaged.
Hammering which will injure or distort the members shall not be done. Bearing surface or
surfaces to be in permanent contact shall be cleaned, before the-members are assembled.
The truss spans shall be erected on blocking, so placed as to give the proper camber.
The blocking shall be left in place until the tendon chord splices are fully riveted and all
ether truss connections pinned and bolted. Rivets in splices of butt joints of compression
members and rivets in railings shall not be driven until the span has been swung.
All joint surfaces for bolted connections including bolts, nuts, washers shall be free from
scale, dirt, burrs, other foreign materials and defects that would prevent solid seating of
238 RED BOOK  VOLUME I  ROADS  2012
 1905.7.4.
parts. The slope of surface of bolted parts in contact with bolt head and nut shall not exceed
1 in 20, plane normal to bolt axis, otherwise suitable tapered washer shall be used.
All fasteners shall have a washer under nut or bolt head whichever is turned in tightening.
Any connection to be riveted or bolted shall be secured in close contact with service bolts
or with a sufficient number of permanent bolts before the rivets are driven or before the
connections are finally bolted. Joints shall normally be made by filling not less than 50 per
cent of holes with service bolts and barrel drifts in the ratio 4:1. The Service bolts are to
be fully tightened up as soon as the joint is 8SSembled. Connections to be made by close
tolerance or barrel bolts shall be completed as soon as practicable after assembly.
Any connection to be site welded shall be securely held in position by approved methods to
ensure accurate alignment, camber and elevation before welding is commenced.
The field riveting, welding, bolted and pin connection shall conform to the requirements of
Clause 1904 as appropriate.
The correction of minor misfits involving harmless amounts of reaming, cutting and chipping
will be considered a legitimate part of erection. However, any error in the shop fabrication or
deformation resulting from handling and transportation which prevents proper assembling
and fitting up of parts by moderate use of drifts or by a moderate amount of reaming and
slight chipping or cutting shall be reported immediately to the Engineer and his approval
of the method of correction obtained. The correction shall be made in the presence of the
Engineer.
1905.7. Field Inspection
1905.7.1. General
All materials, equipment and work of erection shall be subject to the inspection of the
Engineer who shall be provided with all facilities -including labour and tools required at
all reasonable times. Any work found defective is liable to be rejected.
1905.7.2. No protective treatment shall be applied to the work until the appropriate
inspection and testing has been carried out. The stage inspection shall be carried
out for all operations so as to ensure- the correctness of fabrication and good quality.
Girder dimensions and camber shall not be finally checked until all welding and heating
operations are completed and the member has cooled to a uniform temperature.
1905.7.3. Testing of material: Structural steel shall be tested for mechanical and
chemical properties as per various IS codes as may be applicable and shall conform to
requirements specified in IS: 226, IS:2062, IS:11587, IS:1977, IS:8500 and IS:961, etc.
Rivets, bolts, nuts, washers, welding consumables, steel forging, casting and stainless
steel shall be tested for mechanical and chemical properties in the appropriate IS Code.
 Rolling and cutting tolerance shall be as per IS: 1852. The thickness tolerance check
measurements for the plate and rolled sections shall be taken at not less than 15 mm
from edge.
 Laminations in plates shall be carried out by ultra-sonic testing or any other specified
methods.
Steel work shall be inspected for surface defects and exposed edge laminations during
fabrication and blast cleaning. Significant edge laminations found shall be reported to
the Engineer for his decision. Chipping, grinding, machining or ultrasonic testing shall be
used to determine depth of imperfection.
1905.7.4. Bolted connections: Bolts and bolted connection joints with high strength
friction grip bolts shall be inspected and tested according to IS: 4000.

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1905.7.4.
 Rivets and riveted connection shall be inspected and tested for compliance of codal
requirements.
The firmness of joint shall be checked by 0.2 mm filler gauge, which shall not go inside
under the rivet head by more than 3 mm. There shall not be any gap between members
to be riveted.
Driven rivets shall be checked with rivet testing hammer. When struck sharply on head
with rivet testing hammer, rivet shall be free from movement and vibration.
 All loose rivets and rivets with cracks, badly formed or deficient heads or with heads
which are eccentric with shanks, shall be cut out and replaced.
The alignment of plates at all bolted splice joints and welded butt joints shall be checked
for compliance with codal requirements.
Testing of flame cut and sheared edges is to be done, where the hardness criteria given
in the code are adopted. Hardness testing shall be carried out on six specimens.
1905.7.5. Welding and welding consumables: Welding procedure, welded connection
and testing shall be in compliance with codal requirements.
All facilities necessary for stage inspection during welding and on completion shall be
provided to the Engineer or their inspecting Authority by manufacturer.
Adequate means of identification either by identification mark or other record shall be
provided to enable each weld to be traced to the welder(s) by whom it was carried out.
All metal are welding shall be in compliance with IS: 9595 provisions.
The method of inspection shall be in accordance with IS: 822 and extent of inspection
and testing shall be in accordance with the relevant standards or in the absence of such
a standard, as agreed with the Engineer.
Procedure tests
The Destructive and Non-Destructive test of weld shall be carried out according to IS:
7307 (Part I).
Non-Destructive Testing of Welds
One or more of the following methods may be applied for inspection or testing of weld:
(i) Visual Inspection: All welds shall be visually inspected, which should cover all defects
of weld such as size, porosity, crack in the weld or in the HAZ (Heat Affected Zone)
etc. Suitable magnifying glass may be used for visual inspection. A weld shall be
acceptable by visual inspection if it shows that:
a) The weld has no cracks.
b) Through fusion exists between weld and base metal and between adjacent
layers of weld metal.
c) Weld profiles are in accordance with requisite clauses of IS: 9595 or as agreed
with the Engineer.
d) The weld shall be of full cross section, except for the ends of intermittent fillet
welds outside their effective length.
e) When weld is transverse to the primary stress, undercut shall not be more than
0.25 mm deep in the part that is undercut and shall not be more than 0.8 mm
deep when the weld is parallel to the primary stress in the part that is undercut.
f) The fillet weld in any single continuous weld shall be permitted to under • run
the nominal fillet weld size specified by 1.6 mm without correction provided that
undersize portion of the weld does not exceed 10 per cent of the length of the

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 1904.9.
weld. On the web•to-flange welds on girders, no under run is permitted at the
ends for a length equal to twice the width of the flange.
g) The piping porosity in fillet welds shall not exceed one in each 100 mm of weld
length and the maximum diameter shall not exceed 2.4 mm, except for fillet
welds connecting stiffeners to web where the sum of diameters of piping porosity
shall not exceed 9.5 mm in any 25 mm length of weld and shall not exceed 19
mm in any 300 mm length of weld.
h) The full penetration groove weld in butt joints transverse to the direction of
computed tensile stress shall have no piping porosity. For all other groove welds,
the piping porosity shall not exceed one in 100 mm of length and the maximum
diameter shall not exceed 2.4 mm.
(ii) Magnetic Particle and Radiographic Inspection: Welds that are subject to radio-
graphic or magnetic particle testing in addition to visual inspection shall have no
crack.
Magnetic particle lest shall be carried out for detection of crack and other discontinuity
in the weld according to IS: 5334.
Radiographic test shall be carried out for detection of internal flaws in the weld such
as crack, piping porosity inclusion, lack of fusion, incomplete penetration, etc. This
test mat be carried out as per 15:1182 and 15:4853.
Acceptance Criteria: The weld shall be unacceptable if radiographic or magnetic
particle testing shows any of the type of discontinuities indicated in the code.
(iii) Ultrasonic Inspection: The Ultrasonic testing in addition to visual inspection shall be
carried out for detection of internal flaws in the weld such as cracks, piping porosity
inclusion, lack of fusion, incomplete penetration, etc. Acceptance criteria shall be as
per 13:4260 or any other relevant 1S Specification and as agreed to by the Engineer.
iv) Liquid Penetration Inspection: The liquid penetrant test shall be carried out for detection
of surface defect in the weld, as per IS: 3658, in addition to visual inspection.
The non-destructive testing of following welds be carried out using one of the method
or methods described at (ii), (iii) and (iv) above, as may be agreed to by the Engineer.
a) All transverse butt welds in tension flange
b) 10 per cent of the length of longitudinal and transverse butt welds in tension
flanges.
c) 5 per cent of the length of longitudinal and transverse butt welds in compression
flanges.
d) All transverse butt welds in webs adjacent to tension flanges as specified by the
Engineer.
The particular length of welds in webs to be tested shall be agreed with the Engineer,
in case of (b) or (c).
Where specified by the Engineer, bearing stiffeners or bearing diaphragms adjacent to
welds, flange plates adjacent to web/flange welds, plates at cruciform welds, plates in
box girder construction adjacent to corner welds or other details shall be ultrasonically
tested after fabrication.
 Any lamination, lamellar tearing or other defect found shall be recorded and reported
to Engineer for his decision.
Testing of Welding for Cast Steel: The testing of weld for cast steel shall be carried out
as may be agreed to by the Engineer.

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1904.9.
 Stud Shear Connectors: Stud shear connectors shall be subjected to the following
tests:
a) The fixing of studs after being welded in position shall be tested by striking the side
of the head of the stud with a 2 kg hammer to the satisfaction of the Engineer.
b) The selected stud head stroked with 6 kg hammer shall be capable of lateral
displacement of approximately 0.25 the height of the stud from its original position.
The stud weld shall not show any sign of crack or lack of fusion. The studs whose welds
have failed the tests given in (a) and (b) shall be replaced.
1905.7.6. Inspection requirement: The fabricated member/component made out of
rolled and built-up section shall be checked for compliance of the tolerances given in
Table 1900-2. Inspection of member/components for compliance with tolerances, and
the check for deviations shall be made over the full length.
During checking, the inspection requirement shall be placed in such a manner that local
surface irregularities do not influence the results.
For plate, out-of-plane deviation shall be checked at right angle to the surface over the
full area of plate.
 The relative cross-girder or cross frame deviation shall be checked over the middle
third of length of the cross girder or frame between each pair of webs and for cantilever
at the end of member.
The web of rolled beam or channel section shall be checked for out-of-plane deviation
in longitudinal direction equal to the depth of the section.
During inspection, the component/member shall not have any load or external restraint.
Inspection Stages: The inspection to be carried out for compliance of tolerances shall
include but not be limited to the following Stages:
a) For completed parts, component/members on completion of fabrication and before
any subsequent operation such as surface preparation, painting, transportation,
erection.
b) For webs of plate and box girder, longitudinal compression flange stiffeners in box
girders and orthotropic decks and all web stiffeners at site joints, on completion of
site joint.
c) For cross girders and frames, cantilevers in orthotropic decks and other parts in
which deviations have apparently increased on completion of site assembly.
Where, on checking member/component for the deviations in respect of out-of-plane or
out-of-straightness at right angles to the plate surface, and any other instances, exceed
tolerance, the maximum deviation shall be measured and recorded. The recorded
measurements shall be submitted to the Engineer who will determine whether the
component/member may be accepted without rectification, with rectification or rejected.

1906. PAINTING
1906.1. General
Unless otherwise specified, all metal work shall be given approved shop coats as well
as field coats of painting. The item of work shall include preparation of metal surfaces,
application of protective covering and drying of the paint coatings and supply of all tools,
scaffolding, labour and materials necessary. Coatings shall be applied only to dry surfaces
and the coated surfaces shall not be exposed to rain or frost before they are dry. The
coatings shall be applied to all surfaces excluding shear connectors and inner surfaces

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 1904.9.
of fully sealed hollow sections. Care shall be taken during coating of adjacent surfaces to
build up primer on the shear connectors.
1906.1.1. Types of paints
(i) Ordinary Paints
 These include paints based on drying oils, alkyd resin, modified alkyd resin, phenolic
varnish epoxy, etc. Alkyd resin paints for the protection of steel structures are based
partly on natural oils and partly on synthetic resins. These paints shall be used for steel
structures in atmospheres which are not too aggressive.
Oil based paints can be used for steel structures in cases where the surface preparation
cannot be ideal. Ordinary painting can generally be sub-divided into two groups:
a) Primary Coats This shall be applied immediately after the surface preparation and
should have the properties of adhesion, corrosion inhibition and imperviousness to
water and air.
b) Finishing Coats These are applied over the primary coat and should have the properties
of durability, abrasion resistance, aesthetic appearance and smooth finish.
(ii) Chemical Resistant Paints
The more highly corrosion resistant paints can be divided into two main groups:
a) One pack paints (ready for use)
b) Two pack paints (mixed before use)
 The two pack paints shall be mixed together immediately before use since they are
workable thereafter only for a restricted period of time and dry up as a result of a reaction
between their components and yield hard tough films with resistance to abrasion.
(iii) Vinyl Paints
 These are based on polyvinyl resins such as polyvinyl-chloride (PVC) and polyvinyl-
acetate, etc.
Certain types of vinyl resin paints yield thick, relatively soft and rubber like coatings with
good chemical resistance. They can be repainted without difficulty.
(iv) Chlorinated Rubber Paints
These paints also have good chemical resistance. The main fields of applications shall
be in aggressive environments. In general, chlorinated rubber paints do not have a high
gloss.
(v) Bituminous Paints
 As paint vehicle, bituminous is inferior, but because of the low price, this should be
applied in greater thickness (upto several millimeters) and may be suitable for some
situations. A significant advantage of bitumen paints is their impermeability to ingress of
water. However, bituminous paints do not withstand effectively detrimental effects of oil.
(vi) Epoxy Paints
 These resin paints have good adherence to a well prepared sub- strata. They are
mechanically strong and resistant to chemicals. A disadvantage of epoxy resin paints is
that it can rapidly become dull when exposed to strong sunlight. These disadvantages
do not, however, greatly influence their protective power.
(vii) Polyurethane Paints
 The chemical and mechanical behaviour of polyurethane paint resembles those of
epoxy paint very much. However, polyurethane paint retains its gloss for a longer
period. Because of the high price of polyurethane paint, a combination of the two viz.,
RED BOOK  VOLUME I  ROADS  2012 243
1904.9.
polyurethane and epoxy paints may sometimes be used.
(viii) Zinc Rich Paints
 Instead of introducing an inhibitive pigment into paint, metallic zinc can be used and
such paints can provide cathodic protection to steel.
1906.1.2. Surfaces which are inaccessible for cleaning and painting after fabrication
shall be painted as specified before being assembled for riveting.
All rivets, bolts, nuts, washers etc., are to be thoroughly cleaned and dipped into boiling
linseed oil conforming to IS:77.
All machined surfaces are to be well coated with a mixture of white lead conforming to
IS: 34 and Mutton Tallow conforming to IS: 887.
For site paintings, the whole of the steel work shall be given the second cover coat after
final passing and after touching up the primer and cover coats, if damaged in transit.
1906.1.3. Choice of painting system
The choice of suitable painting system is dependent on factors such as
- Available application methods viz. brush, roller or spray
- Durability in a specific environment
- Availability of skilled manpower
- Cost / benefit etc.
 It is therefore necessary to consult various manufacturers of paint and ascertain the
above aspects while deciding on the appropriate choice of painting system.
1906.1.4. uality of paint: The paints which have been tested for the following qualities as
per the specifications given in the relevant IS codes should only be used:
- Weight Test (weight per 10 litre of paint thoroughly mixed) U
- Drying time
- Flexibility and Adhesion
- Consistency
- Dry thickness and rate of consumption
1906.1.5. Unless otherwise specified, all painting and protective coating work shall be
done in accordance with IS: 1477 (Part 1).
1906.2. Surface Preparation
Steel surface to be painted either at the fabricating shop or at the site of work shall be
prepared in a thorough manner with a view to ensuring complete removal of mill scale by
one of the following processes as agreed to between the fabricator and the Engineer:
a) Dry or wet grit / Sand blasting
b) Pickling which should be restricted to single plates, bars and sections
c) Flame cleaning
Primary coat shall be applied as soon as practicable after cleaning and in case of flame
cleaning, primary coat shall be applied while the metal is still warm.
All slag from welds shall be removed before painting. Surfaces shall be maintained dry and
free from dirt and oil. Work out of doors in frosty or humid weather shall be avoided.
1906.3. Coatings
Prime coat to be used shall conform to the specification of primers approved by the Engineer.

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 1906.4.
Metal coatings shall- be regarded as priming coatings. Primer shall be applied to the blast
cleaned surface before any deterioration of the surface is visible. In any case, the surface
shall receive one coat of primer within 4 hours of abrasive blast cleaning.
All coats shall be compatible with each other. When metal coatings are used, the undercoat
shall be compatible with the metal concerned. The undercoat and finishing coat shall
preferably be from the same manufacturer. Successive coats of paints shall be of different
shades or colours and each shall be allowed to dry thoroughly before the next is applied.
Particular care shall be taken with the priming and painting of edges, comers, welds and
rivets. Typical guidelines for epoxy based paints and the conventional painting system for
bridge girders as given below may be complied with:
a) Epoxy Based Painting
i) Surface preparation: Remove oil/grease by use of petroleum hydrocarbon solution
(IS: 1745) and Grit blasting to near white metal surface.
ii) Paint system: 2 coats of epoxy zinc phosphate primer = 60 micron; Total 5 coats
= 200 micron
b) Conventional Painting System for areas where corrosion is not severe
Priming Coat:
One heavy coat or ready mixed paint, red lead primer conforming to IS: 102
or
One coat of ready mixed zinc chrome primer conforming to IS: 104 followed by one
coat of ready mixed red oxide zinc chrome primer conforming to IS: 2074.
or
Two coats of zinc chromates red oxide primer conforming to 15:2074
Finishing Coats:
Two cover coats of red oxide paint conforming to IS: 123 or any other approved paint
shall be applied over the primer coat. One coat shall be applied before the fabricated
steel work leaves the shop. After the steel work is erected at site, the second coat
shall be given after touching up the primer and the cover coats if damaged in transit.
c) Conventional Painting System for areas where corrosion is severe
Priming Coat : Two coats of ready mixed red lead primer conforming to IS:102
or
One coat of ready mixed zinc chrome primer conforming to IS:104 followed by one
coat of zinc chromate conforming oxide primer to IS: 2074.
Finishing Coats:
Two coats of aluminum paint conforming to IS: 2339 shall be applied over the primer
coat. One coat shall be applied before the fabricated steel work leaves the shop.
After the steel work is erected at site, the second coat shall be given after touching
up the primer and the cover coats if damaged in transit.
1906.4. Painting in the Shop
All fabricated steel shall be painted in the shops after inspection and acceptance with at
least one priming coat, unless the exposed surfaces are subsequently to be cleaned at site
or are metal coated. No primer shall be applied to galvanised surfaces.
Shop contact surfaces, if specifically required to be painted, shall be brought together while
the paint is still wet.

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1906.5.
Field contact surfaces and surfaces to be in contact with cement shall be painted with
primer only. No paint shall be applied within 50mm of designed location of field welds. Paint
shall be completely dried before loading and transporting to site.
Surface not in contact but inaccessible after shop assembly shall receive the fully specified
protective treatment before assembly.
Where surfaces are to be welded, the steel shall not be painted or metal coated within a
suitable distance from any edges to be welded if the specified paint or metal coating would
be harmful to welders or is expected to impair the quality of site welds.
Exposed machined surfaces shall be adequately protected.
1906.5. Painting at Site
Surfaces which will be inaccessible after site assembly shall receive the full specified
protective treatment before assembly. Surfaces which will be in contact after site assembly
shall receive a coat of paint (in addition to any shop priming) and shall be brought together
while the paint is still wet. Damaged or deteriorated paint surfaces shall be first made good
with the same type of coat as the shop coat.
Where steel has received a metal coating in the shop, this coating shall be completed on
site so as to be continuous over any welds, bolts and site rivets.
Specified protective treatment shall be completed after erection.
1906.6. Methods of Application
The methods of application of all paint coatings shall be in accordance with the manufacturer’s
written recommendation and shall be as approved by the Engineer. Spray painting may be
permitted provided it will not cause inconvenience to the public and is appropriate to the
type of structure being coated. Areas hard to gain access to for painting and areas shaded
for spray application shall be coated first by brushing.
Oil based red lead primers must be applied by brush only, taking care to work into all
comers and crevices.
The primer, intermediate and finishing coats shall all be applied so as to provide smooth
coatings of uniform thickness. Wrinkled or blistered coatings or coatings with pinholes,
sags, lumps or other blemishes shall not be accepted. Where the Engineer so directs,
the coating shall be removed by abrasive blast cleaning and replaced at the Contractor’s
expense.
1906.7. Guideline of Specifications for Protective Coating
System in Different Environments
Since the seriousness of the problem of corrosion depends upon atmospheric conditions
and these vary enormously, there is no single protective system or method of application
that is suitable for every situation.
However, as a guide, broad recommendations are given in Table 1900-3 for various types of
coatings in various environmental conditions which should be complied with. Approximate
life to first maintenance is also indicated and can be used as a guide.

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 1906.7.
TABLE 1900-3: RECOMMENDATIONS FOR
TYPES OF PROTECTIVE COATINGS
System Environment
i) Wire brush to remove all loose rust Suitable for mild conditions where
and scale; 2 coats drying oil type appearance is of some importance and
primer; 1 under coat alkyd type paint; where regular maintenance is intended.
1 finishing coat alkyd type. Total dry This system may deteriorate to a marked
film thickness = 150 µm extent if it is exposed to moderate
aggressive atmospheric conditions for
lengthy period
ii) Wire brush to remove all loose rust Similar to (i) but where appearance is
and scale; 2 coats drying oil type not very important provides longer life in
primer; 2 under coats micaceous iron mild condition. Will provide upto 5 years
oxide (MXO) pigmented phenolic life to first maintenance in polluted inland
modified drying oil. Total dry film environment
thickness = 170 µm
iii) Blast clean the surface; coats of Compared to (i), this would provide a
quick drying primer; undercoat alkyd longer life in mild conditions and could
type paint; 1 finishing coat alkyd type. be used in less mild situation e.g. inland
Total dry film thickness: 130 - 150 µm polluted, where maintenance could easily
be carried out at regular intervals
iv) Blast clean the surface; 2 coats of Suitable for general structural steel work
drying type oil primer; 1 undercoat exposed to ordinary polluted inland
micaceous iron oxide pigmented environments where appearance is not
drying oil type paint. Total dry film of primary importance.
thickness: 165 - 190 µm
v) Blast clean the surface; 2 coats of Suitable for structures in reasonably
metallic lead pigmented chlorinated aggressive conditions e.g. near the
rubber primer, 1 undercoat of high coast, Will provide long-term protection
build chlorinated rubber; 1 finishing than (iv) in non-coastal situations. Also
coat of chlorinated rubber. Total dry suitable for aggressive interior situations
film thickness: 200 µm such as industrial areas.
vi) Blast clean the surface; 350 - 450 µm Suitable for sea water splash zones or
thickness. coal tar epoxy. for conditions of occurrence of frequent
salt sprays.
vii) Pickle; hot dip galvanised (Zinc). Total Suitable for steel work in reasonably mild
thickness: 85 µm conditions Life of 15-20 years before first
maintenance could be expected in many
situations
viii) Grit blast, hot dip galvanised. (Zinc). Provides a longer life than. (vii) because
Total thickness = 140 µm of thicker zinc coating
ix) Grit blast; 1 coat of sprayed zinc! Expected to provide long term protection
aluminum followed by suitable sealer approx 15-20 years in aggressive
Total thickness =150 µm atmosphere

1907. TESTS AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with relevant IIS specifications and necessary
test certificates shall be furnished. Additional tests, if required, shall be got carried out by
the Contractor at his own Cost
The fabrication, furnishing, erecting, painting of structural steel work shall be in accordance

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1906.7.
with these specifications and shall be checked and accepted by the Engineer.

1908. MEASUREMENTS FOR PAYMENT

The measurements of this item shall be in tonnes based on the net weight of metal in the
fabricated structure computed on the basis of nominal weight of materials.
The weight of rolled and cast steel and cast iron shall be determined from the dimensions
shown on the drawings on the following basis:
- Rolled or cast steel: 7.84 x 10-3 kg/cu. cm.
- Cast Iron : 7.21 x 10-3 kg/cu. cm.
Weight of structural sections shall be nominal weight
Weight of castings shall be computed from the dimensions shown on the drawings with an
addition of 5 per cent for fillets and over-runs. 530
Weight of weld fillets and the weight of protective coatings shall not be included.
Weight of rivet heads shall be computed by taking the weight of 100 snap heads as given
in Table 1900-4.
When specially agreed upon, allowance for snap heads may be taken a flat percentage
of the total weight. This percentage may be taken as 3 per cent or modified by mutual
agreement.
TABLE 1900-4: WEIGHT OF RIVET HEADS
Dia of Rivet as manufactured Weight of 100 snap heads
mm kg
12 1.3
14 2.1
16 3.4
18 4.45
20 6.1
22 8.1
24 10.5
27 15.0
30 20.5
33 27.2
The Contractor shall supply detailed calculation sheets for the weight the metal in the
fabricated structure.
No additions shall be made for the weight of protective coating or weld fillets.
Where computed weight forms the basis for payment, the weight shall be calculated for
exact cut sizes of members used in the structure, deductions being made for all cuts,
except for rivet holes. Additions shall be made for the rivet heads as mentioned above.
When specially agreed upon, the basis for payment may be the bridge weight complete,
according to specifications included in special visions of the Contract.

1909. RATE
The contract unit rate for the completed structural steel work shall include the cost of all
materials, labour, tools, plant and equipment for fabrication, connections, oiling, painting,
temporary erection, inspection, tests and complete final erection as shown on the drawings
and as specified in these Specifications.

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 1906.7.

2000
BEARINGS

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 2003.1.
2001. DESCRIPTION
This work shall consist of furnishing and fixing bearings in position in accordance with the
details shown on the drawings, to the requirements of these specifications or as directed
by the Engineer.
2002. GENERAL
i) Beating plates, bars, rockers, assemblies and other expansion or fixed devices shall
be constructed in accordance with the details shown on the drawings.
ii) The bearings may either be supplied directly to the Engineer by the manufacturer to
be installed by the Contractor or the Contractor is to supply and install the bearings
as pan of the contract. In the former case, the manufacturer shall be associated with
the installation of the bearings to the full satisfaction of the Engineer, whereas in the
latter case, the Contractor shall be solely responsible for the satisfactory supply and
installation of the bearing. In the detailed description of the specification, a general
reference shall be made to the Contractor or manufacturer and the interpretation
shall be as per terms of contract.
iii) The Contractor shall exercise the utmost care in setting and fixing all bearings in their
correct positions and ensuring that uniformity is obtained on all bearing surfaces.
iv) Bearings shall be handled with care and stored under cover.
v) When bearing assemblies or plates are shown on the drawings to be placed (not
embedded) directly on concrete, the concrete bearing area shall be constructed
slightly above grade (not exceeding 12 mm) and shall be finished by grinding.
vi) It shall be ensured that the bearings are set truly level and in exact position as
indicated on the drawings so as to have full and even bearing on the seats. Thin
mortar pads (not exceeding 12 mm) may even be made to meet with this requirement.
vii) It shall be ensured that the bottoms of girders to be received on the bearings are
plane at the locations of these bearings and care shall be taken that the beatings are
not displaced while placing the girders.
viii) M.S. bearings sliding on M.S. Plates shall not be permitted. For sliding plate bearings
stainless, steel surface sliding on stainless steel plate with mild steel matrix shall be
used. The other option shall be to provide PTFE surface sliding on stainless steel.
ix) Some types of bearings which have been successfully used in various bridges in
India have been covered by these Specifications. For innovative types of structures
or in special cases, special types of bearings to suit the requirements may have to
be provided for which special specifications may be laid down by the Engineer.
2003. STEEL BEARINGS
2003.1. Materials
The material for steel bearings shall conform to the requirements of Section 1000. Some
additional requirements for materials for steel bearings are indicated below:
a) Railway axles (R 19) are also acceptable as forged steel for rollers.
b) For the purpose of checking the soundness of cast steel components, castings shall
be ultrasonically examined following procedures as per IS: 7666 with acceptance
standard as per IS: 9565. The castings may also be checked by any other accepted
method of non-destructive testing as specified in IS: 1030. Quality level of castings
shall be level 3 as per IS: 9565.
The grease for bearings shall conform to the requirements of IS: 503 (Grade 4).

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2003.2.
2003.2. Construction Operations
a) All work shall conform strictly to the drawings and shall be in accordance with the
provisions of this section. Care shall be taken to ensure that all parts of an assembly
fit accurately together. The workmanship shall satisfy all relevant provisions laid
down in Section 1900.
b) Knuckle pins, rolling surfaces of the rollers and bearing surface of the bearing plates
shall be machined and all bolt holes shall be drilled. The whole bearings shall be
fitted and finished as required for good quality machined work to the satisfaction of
the Engineer. However, in case of bearings which are to be grouted or bedded on a
suitable yielding material on any surface which is to be in permanent contact with the
grout or the yielding material may be left unmachined.
c) In prestressed concrete construction where launching of girders is employed, in order
to avoid slipping or jumping of rollers due to vibration or jolts, adequate measures
may be taken to ensure that the roller assembly is not disturbed. It is normal practice
to provide rocker bearings on the launching end and place the beam on the rocker
end slightly in advance of placing on the roller.
d) During concreting of girders, the bearings shall be held in position securely by
providing temporary connection between the top and bottom plates in case of fixed
bearings and between top plate, base plate and saddle plate in case of roller- cum-
rocker bearing or by any other suitable arrangement which prevents the relative
displacement of the components.
e) In prestressed precast girders, where recesses are left on the underside of girders
to receive the anchor bolts, grout holes extending to the beam sides or to the deck
level shall be provided. The cement sand grout shall have a mix of 1:1.
2003.3. Workmanship
a) Fabrication shall be carried out by an organisation experienced and qualified to
undertake precision engineering of this type and be approved by the Engineer.
b) Workmanship shall be of good quality, neatly finished and of good appearance.
c) Castings shall be true to the forms and dimensions shown on the drawings and shall
be free from pouring faults, sponginess, cracks, blow holes and other defects on
position, affecting their appearance or strength. Warped or distorted castings will not
be accepted. Exposed surfaces shall be smooth and dense.
d) All castings shall be cleaned by sand or shot blasting to remove sand or scale and
to present a clean uniform surface.
e) All irregularities, fins or risers shall be ground off flush with the adjacent surface.
Castings with visible cracks, blow holes or similar blemishes shall be rejected if the
imperfections are located in bearing surfaces or cannot be remedied to the approval
of the Engineer.
f) Imperfections which are not located in bearing surfaces shall be cleaned out, filled
with weld metal of the appropriate composition and ground flush.
g) All surfaces of major components like top plates, saddle plates, base plates, rollers
of the bearings shall be machined all over for correct alignment, interchangeability,
proper fitting, etc.
2003.4. Tolerances
Tolerances for its individual components or of the assembled bearings shall be as shown
on the drawings or subject to the approval of the Engineer.

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 2003.5.2.
Unless otherwise specified, the following tolerances shall be maintained:
Diameter of Rollers, Knuckle Pins and Bores
Tolerances on diameter of rollers and all convex surfaces shall conform to K7 of IS: 919.
Tolerances on diameter of all concave surfaces shall conform to D8 of IS: 919.
Height of Bearings
Tolerances on height of any component casting shall not exceed +0.5mm. No minus
tolerance shall be allowed. The edges of all ribs shall be parallel throughout their length.
Base Plate
Tolerance on length and width of the base plate shall not exceed +1.0 mm, tolerance on
the thickness of the plate shall not exceed +0.5 mm. No minus tolerance shall be allowed.
All rocking, rolling and sliding surfaces shall have a machine smooth finish to 20 micron
maximum mean deviation as per IS:3073. Castings
No minus tolerance shall be allowed in the thickness of any part of the castings. The edges
of all ribs shall be parallel through-out their length.
2003.5. Installation of Steel Bearings
2003.5.1. General
a) Bearings shall be placed in the positions as shown on the drawings with all bearing
surfaces in full contact and to the tolerances as specified.
b) Roller and rocker bearings shall be placed so that their axles of rotations are horizontal
and normal to the direction of movement of the members they support. Upper and
lower bearing plates shall be set horizontal in both directions.
c) During installation the bearings shall be I pre-set with respect to the bearing axis to
account for the movement due to the following:
i) Temperature variation between the average temperature prevailing at the time of
installation and the mean design temperature.
ii) Shrinkage, creep and elastic shortening.
d) For bridges in gradient, the bearing plates shall be placed in a horizontal plane.
2003.5.2. Placing
a) On supporting structures, pockets shall be provided to receive anchor bolts; one
side of the pocket shall project beyond the bearing plate. The pocket shall be filled
with mortar of mix 1:1 and the concrete bearing area also shall be finished level by a
thin and stiff mortar pad of mix 1:1 (the thickness not exceeding 12 mm) just before
placing of bearing assemblies or bottom plate on the concrete seat.
b) In case of precast girders a recess of 6 mm shall be provided on the underside with
a level finish for housing the bearing plate. A thin and stiff mortar pad of mix 1:1 with
thickness not exceeding 3 mm shall be provided over the top plate before lowering
the precast beam in position in order to ensure full and even pressure on the plate
surface.
c) It shall be ensured that while placing the girders, the bearings are in their exact
positions as indicated on the approved drawing and not displaced therefrom.
d) All concrete surfaces to be in contact with the mortar shall be thoroughly cleaned
and kept saturated with water for a period not less than 24 hours before placing
mortar and operations are to be carried out when the surface temperatures of the
exposed bearings are the minimum practical.

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2003.5.3.
e) No mortar that is more than 3U minutes old after completion of mixing shall be used.
f) After placing and finishing the mortar, the bearing shall be checked for position
and shims or other temporary supports removed and the mortar made good. If the
bearing has moved, it or the plate shall be lifted, the mortar removed and the whole
procedure repeated.
g) Exposed faces of the mortar shall be cured under damp Hessian for 7 days.
h) Placing of the bearing and mortar shall only be carried out in the presence of the
Engineer.
2003.5.3. Checking, cleaning and lubrication: Before erection, each bearing shall be
uncrated, disassembled and checked. Any damaged parts shall be made good for
approval.
All bearings with sliding surfaces shall be cleaned and lightly lubricated with an approved
lubricant immediately before erection.
2003.5.4. Testing
i) The materials to be used in the bearings shall conform to the specifications laid down
in clause 2003.1.
ii) If required, a suitable number of complete bearings as specified by an accepting
authority shall be tested to 1.25 times the design load. Recovery should be 100 per
cent. Contact surfaces shall be examined by illumination source for any defects,
cracks, etc. Segmental rollers shall be tested for design movements.
iii) For large lots (consisting of 12 sets or more), a quality control report shall be submitted
as detailed below:
a) Unless otherwise agreed upon by the Engineer and the manufacturer, the latter
shall furnish a complete report on the process of quality control. The Engineer may
appoint an authorised inspection agency for inspection purpose on his behalf. Such
an inspection agency shall also submit reports to the Engineer regarding various
tests performed on the bearing or certify the acceptance of the bearings.
b) Test certificates of all raw materials shall be submitted. If manufacturer’s test
certificates are not available for the raw materials, the bearings manufacturer shall
perform the necessary confirmatory tests as per relevant codes of practice and shall
furnish the test results.
c) A detailed quality control system including stage by stage inspection, starting from raw
materials upto the finished bearing shall be submitted by the bearing manufacturer.
d) The Engineer shall reserve the right to witness such inspection at manufacturer’s
works with or without prior permission of the manufacturer. For this, the bearing
manufacturer shall have in-plant testing facilities as far as possible and practicable.
e) The bearing manufacturer shall maintain a list of consumption of raw material for a
period of at least previous one year.
f) Test certificates of bearings manufactured during preceding one year shall be made
available at the manufacturer‘s works.
g) In case the lot size of similar bearings exceeds 12 sets as per the direction of the
Engineer, one extra set of bearings for each 24 sets of bearings or part thereof, shall
be manufactured and the cost of such extra bearings shall be borne by the user.
h) The Engineer shall select the extra bearing(s) at random and shall perform various
tests including destructive testing on it at his discretion, either at the manufacturer’s
works or at any other approved test laboratory, notwithstanding the test reports

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 2004.2.
submitted.
i) In case there is a major discrepancy regarding material, the engineer shall declare the
whole lot of bearings as unacceptable.
j) In case minor defects in fabrication, like welding or machining, is found in the test
bearing before destructive testing and if the test bearing is found to be acceptable
after destructive testing, the minor defects in the test bearings shall not be a bar to
the acceptance of the entire lot.
k) The opinion of the Engineer in cases (i) and Q) above shall be binding on the
manufacturer.

2004. SPECIAL BEARINGS

2004.1. Spherical Bearing
This bearing only takes care of vertical load and horizontal force due to sliding friction. The
bearing will permit uniaxial translatory movement along longitudinal axis of the bridge and
rotation along all axes. The bearing shall consist of the following parts:
Bottom Plate
A bottom plate with concave surface is integrally cast on circular] square plate. The bottom
plate is connected to the sub-structure by means of tight fitted anchor bolts, which are
embedded in concrete. The material of bottom plate shall be cast steel.
Pure unfilled quality dimpled PTFE of specified thickness shall be provided on top of
concave surface of bottom plate in order to allow smooth rotation.
Saddle Plate
A saddle plate with square/circular/rectangular top and convex surface at bottom shall
be placed in the concave surface of bottom plate. The radius of curvature of the convex
bottom of the saddle plate shall be slightly less than that of the concave top surface of the
bottom plate to ensure sufficient contact over a small area. Rotation along all axes shall be
permitted along the contact surface of the saddle plate and the bottom plate. Pure unfilled
quality dimpled PTFE sheet shall be recessed to specified depth of recess over the top of
saddle plate. Suitable elastomeric seal shall be provided on the saddle plate to prevent
ingress of dirt and moisture. The material of saddle plate shall be Cast steel.
Top Plate
The top plate shall have stainless steel plate welded to its bottom which shall slide over
PTFE. The assembly shall be connected to the superstructure by tight fitted anchor bolts.
Translatory movements along longitudinal axis of bridge shall be accommodated at the
PTFE/Stainless steel sliding surface. The material of top plate shall be cast steel.
Guide Plate
Guide Plates shall be welded to saddle plate so as to permit only longitudinal movement.
The material of guide plates should be cast steel.
2004.2. Pin Bearing
Pin bearing shall ensure fixity by arresting translatory movement. The pin bearing shall
not take any vertical load. It will take care of the longitudinal horizontal force of the entire
superstructure unit as well as transverse horizontal force developed at the fixed end.
A pin bearing shall consist of a short height structural built-up column embedded in pier
cap and the protruding length inside soffit of deck shall have rocker plates on all four sides,
which permit rotation. Pin bearing shall resist horizontal force from any direction and will
permit rotation but will not bear any vertical load. The material of pin bearing including

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2004.3.
rocker plates shall be high tensile steel conforming to IS: 961.
2004.3. In general the sliding spherical and pin bearing shall conform to BS: 5400, Parts
9.1 and 9.2 and all relevant clauses of this specification. Bearings shall be guaranteed for
design loads and movements. The term bearing shall include the entire assembly covering
all the accessories • required for operation, erection and dismantling for replacement. All
bearings shall be of replaceable, type. These bearings should be based on their design to
the specifications mentioned/international specifications. The manufacturer should get their
design approved from appropriate authority and the manufacturer should be associated
with installation of bearings.
2004.4. Materials
All materials, particularly the following, shall be original, unused or non-re-cycled conforming
to relevant specifications:
- Cast Steel; Mild Steel, Stainless Steel shall conform to Clause 2003.1.
- Copolymer Poly Tetra Fluora Ethylene (PTFE) unfilled quality shall have required
properties as per BS: 5400 and thickness shall be as specified.
- Anchor Bolts shall be as per relevant IS specifications.
2004.5. Seating of Pin Bearing
i) Backing plate with studs welded on the face opposite to the seating of manufacture
shall be delivered by the manufacturer.
ii) This backing plate shall be accurately positioned on the reinforcement grid of the
pedestal and levelled.
iii) Studs shall be tack welded/tied to the reinforcement to keep the backing plate in
proper location during casting.
iv) Depth of embedment of the backing plate in the concrete shall be as per relevant
drawing.
v) The round base of the pot (bottom) of the pin bearing assembly shall be connected to
the backing plates by anchor screws after concreting of pier cap/pedestal.
vi) In order to ensure successful transfer of large horizontal forces to be resisted by
the Pin bearing, great care shall be taken in detailing the reinforcement in the sub-
structure and the super-structure adjacent to the studs in the backing plate.
2004.6. Acceptance Test on Spherical Bearings
1. All bearings shall be cheeked for overall dimensions
2. All bearings shall be load tested to 1.25 times design vertical load
3. A pair of bearings selected at random shall undergo testing in order to determine
coefficient of friction which shall be less than 0.05.
4. Two bearings selected at random shall be tested for permissible rotation.
2004.7. Acceptance Test on Pin Bearings
1. All bearings shall be checked for overall dimensions.
2. All bearings shall be load tested (if required, for design horizontal load only)

2005. ELASTOMERIC BEARINGS

The term "bearing" in this case refers to an elastomeric bearing consisting of one or
more internal layers of elastomer bonded to internal steel laminates by the process of
vulcanisation. The bearing shall cater for translation and/or rotation of the superstructure

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 2005.1.
by elastic deformation.
2005.1. Raw Material
Chloroprene (CR) only shall be used- in the manufacture of bearing.
Grades of raw elastomer of proven use in elastomeric bearings, with low crystallization
rates and adequate shelf life (e.g. Neoprene WRT, Bayprene 110, Skyprene B-5 and Denka
S-40V) shall be used.
No reclaimed rubber or vulcanized wastes or natural rubber shall be used.
The raw elastomer content of the compound shall not be lower than 60 per cent by its
weight. The ash content shall not exceed 5 per cent. (as per tests conducted in accordance
with ASTM D-297, sub-section 10).
EPDM and other similar candidate elastomers for bridge bearing use shall not be permitted.
Properties .
The elastomer shall comform to the properties specified in Table 2000.1

TABLE 2000-1. PROPERTIES OF ELASTOMER

Value of the
Test Method, IS characteristic
Propertly Unit specification reference specified
1. Physical Properties
1.1. Hardness IRHD IS: 3400 60 + 5
(Part II)
1.2. Minimum Tensile MPa IS:3400 17
Strength (Part I)
1.3. Minimum Elongation Per cent IS: 3400 400
at break (Part I)
2. Maximum Compression
Set Per cent IS: 3400
(Part X)
duration temperature

(h) (deg C)
CR +0 to 00±1 35
24.2
3. Accelerated Ageing
IS: 3400
(Part IV)
duration temperature
(h) (deg C)
CR 70 100±1
3.1 Max change in
Hardness IRHD +15
3.2. Max change in Per cent -15
Tensile Strength
3.3. Max change in
Elongation Per cent -40

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2005.2.
Shear modulus of the elastomer bearing shall neither be less than 0.80 MPa nor greater
than 1.20 MPa. The adhesion strength of elastomer to steel plates determined
according to IS: 3400 (Part XIV) method A shall not be less than 7 kN/m.
For elastomeric bearings (CR) used in adverse climatic conditions the following ozone
resistance test shall be satisfied:
The ozone resistance of elastomer shall be proved satisfactory _ when assessed by test
according to IS: 3400 (Part XX). The strain, temperature, duration and ozone concentration
of the test shall be 20 per cent, 40 ± 1 degree Celsius, 96 h and 50 pphm by volume
respectively.
No cracking detected by visual observation at the end of the test shall be considered
satisfactory. No specific tests for assessment of low temperature resistance- may be
deemed necessary.
NOTE: For use of elastomer in extreme cold climates, the Engineer may specify special
grade of low temperature resistant elastomer in conformity with operating ambient
temperature conditions. The specifications of such special grade elastomer including the
tests for low temperature resistance shall be mutually agreed to by the Engineer and the
producer supplier and are outside the purview of these specifications.
Laminates of mild steel conforming to IS: 226 shall only be per- mitted to be used. Use of
any other material like fibre glass or similar fabric as laminates shall not be permitted.
The manufacturers of elastomeric bearings shall satisfy the Engineer that they have in-
house facilities for testing the elastomer for carrying out the following tests in accordance
with the relevant provisions of ASTM D-297.
a) Identification of polymers: to confirm the usage of Chloroprene (Appendix X-2)
b) Ash content test: to determine the percentage (sub-section 34)
c) Specific gravity test: (sub-section 15)
d) Polymer content test: (sub-section 10)
The Engineer shall invariably get the test (a) performed within his presence or in the
presence of his authorised representative to satisfy the requirement. In case of any disputes
regarding interpretation of results the Engineer may carry out test as per ASTM S-3452-78
(Cinematography test) at the manufacturer’s cost in a recognised test house.
The elastomer specimen to conduct the test shall be obtained from the bearings selected
at random for destructive test. Remaining part of the test bearing shall be preserved by the
Engineer for any test to be done in future, if required.
2005.2. Fabrication
Bearing with steel laminates shall be cast as a single unit in a mould and vulcanised under
heat and pressure.
Casting of elements in separate units and subsequent bonding shall not be permitted, nor
shall cutting from large size cast be permitted.
Bearings of similar size to be used in particular bridge project shall be produced by identical
process and in one lot as far as practicable. Phased production may only be resorted to
when the total number of bearings is large enough.
The moulds used shall have standard surface finish adequate to produce bearings free
from any surface blemishes.
Steel plates for laminates shall be sand blasted, clean of all mill scales and shall be free
from all contaminants prior to bonding by vulcanisation. Rusted plates with pitting shall not

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 2005.3.
be used. All edges of plates shall be rounded.
Spacers used in mould to ensure cover and location of laminates shall be of maximum size
and number practicable. Any hole at surface or in edge cover shall be filled in subsequently.
Care shall be taken to ensure uniform vulcanising conditions and homogeneity of elastomer
through the surface and body of beatings.
The beatings shall be fabricated with the tolerances specified in Table 2000-2.

TABLE 2000-2 TOLERANCES

ITEMS TOLERANCES
1. Overall plan dimensions -0, + 6 mm
2. Total bearing thickness -0, + 5 mm
3. Parallelism
a) Of top surface of bearing with
respect to the bottom surface as datum 1 in 200
b) Of one side surface with
respect to the other as datum I in 100
4a. Thickness of individual internal; ± 20 per cent (max. of 2 mm)
layer of elastomer
b) Thickness of individual outer layer -0, + 1 mm
5a. Plan dimensions of laminates -3mm, +0
b) Thickness of laminates ±10 per cent
c) Parallelism of laminate with
respect to bearing base as datum 1 in 100
The vulcanising equipment/press shall be such that between the plattens of press the
pressure and temperature are uniform and capable of being maintained at constant values
as required for effecting a uniform vulcanisation of the bearing.
The moulding dies utilised for manufacturing the bearings shall be so set inside the platten
of the press so that the pressure developed during vulcanisation of the product is evenly
distributed and the thickness maintained at all places are within acceptable tolerance limits
taking into consideration the shrinkage allowance of vulcanizate.
The raw compound which has been introduced inside the metal dies for vulcanisation shall
be accurately weighed each time and it must be ensured that sufficient quantity has been
put inside the die for proper flow of material at every place so that a homogeneous and
compact bearing is produced without any sign of sponginess or deficiency of material at
any place.
Before any vulcanizate of any batch of production is used for producing vulcanised bearings,
test pieces in the form of standard slab and buttons shall be prepared in accordance with
prescribed standards and salient properties tested and recorded regularly against each
batch of production to monitor the quality of the products.
2005.3. Acceptance Specifications
The manufacturer shall have all the test facilities required for the process and acceptance
control tests installed at his plant to the complete satisfaction of the Engineer. The test
facilities and their operation shall be open to inspection by the Engineer on demand.
All acceptance and process control tests shall be conducted at the manufacturer’s plant.
Cost of all materials, equipment and labour shall be borne by the manufacturer unless

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2005.3.1.
otherwise specified or specially agreed to between the manufacturer and Engineer.
Acceptance testing shall be commenced with the prior submittal of testing programme by
the manufacturer to the Engineer and after obtaining his approval.
Any acceptance testing delayed beyond 180 days of production shall require special
approval of the Engineer and modified acceptance specification, if deemed necessary by
him.
All acceptance testing shall be conducted by the Inspector with aid of the personnel having
adequate expertise and experience in rubber
testing provided by the manufacturer, working under the supervision of the Inspector and
to his complete satisfaction.
Lot by lot inspection and acceptance shall be made.
2005.3.1. Acceptance lot: A lot under acceptance shall comprise _ all bearings, including
the pair of extra test bearings where applicable of equal or near equal size produced under
identical conditions of manufacture to be supplied for a particular project.
The size and composition of acceptance lot shall be got approved by the Engineer.
For the purpose of grading levels of acceptance, testing lots shall be classified as follows:
i) A lot size of 24 or larger number of bearings shall be defined as a large lot
ii) A lot size of less than 24 bearings shall be defined as a small lot
When the number of bearings of equal or near equal size for a single bridge project is large
and phased production and acceptance is permitted, the number of bearings supplied in any
single phase of supply shall comprise a lot under acceptance. When such phased supply
is made, each such lot shall be considered as a large lot for the purpose of acceptance
testing.
2005.3.2. Levels of acceptance inspection: The level of acceptance testing shall
generally be graded into the following two levels depending on lot size:
Level 1 acceptance testing.
Level 2 acceptance testing
Acceptance testing Level 1 is a higher level inspection and shall be applicable to large lots
only, unless otherwise specified. This shall involve manufacture of two extra beatings for
each lot to be used as test bearing and eventually consumed in destructive testing.
Acceptance testing Level 2 shall be applicable to small lots only, (i.e. less than 24 lots) for
which one extra bearing shall be manufactured. Out of the lot one bearing shall be selected
at random carrying out material tests. This bearing shall be excluded from the lot accepted.
Acceptance inspection level 1 may be specified at the sole discretion the engineer taking
into account the special importance of bridge for small lots also under the purview of
special acceptance inspection. The cost of extra bearings, in such cases shall be borne by
the user, while the cost of all other materials, equipment and testing shall be borne by the
manufacturer.
2005.3.3. Testing: Acceptance testing shall comprise general inspection, test on specially
moulded test pieces and test on complete bearings or sections for measurement of various
quality characteristics detailed below:
2005.3.3.1. Acceptance testing level 1
General Inspection
1. All bearings of the lot shall be visually inspected for any defects in surface finish,

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 2005.2.
shape or any other discernible superficial defects.
2. All bearings of the lot shall be checked for tolerances specified in Table 2000- 2.
3. All bearings of the lot shall be subjected to axial load to correspond to cm (i.e. average
compressive stress) = 15 MPa applied in steps and held constant while visual
examination is made to check for discernible defects like :
a) Misalignment of reinforcing plates
b) Poor bond at laminate/steel interface
c) Variation in thickness of elastomer layers
d) Any surface defects
e) Low stiffness
 Deflection under loads between om=5 MPa and om=15 MPa shall be measured and
recorded for all bearings with sufficient accuracy (± 5 per cent), Variation in stiffness of
any individual bearing from the mean of the measured values for all such bearings of the
lot shall not be larger than 20 per cent (of the mean value).
Tests on specially moulded test pieces.
1. Test pieces shall be moulded by the manufacturer with identical compound and under
identical vulcanising conditions as used in the manufacture of the bearings of the
acceptance, lot. The process shall be open to inspection by the Engineer.
2. Test pieces offered for inspection shall be identified by suitable markings and duly
certified by the manufacturer.
3. The quality characteristics to be tested are listed below. The specification references
in parenthesis shall define the corresponding specification for test piece, test method
and criterion for acceptance. Composition (see Note 1 below) Hardness (Table 2000-
1, 1.1)
Tensile strength (Table 2000-1, 1.2)
Elongation at Break (Table 2000-1, 1.3)
Compression Set (Table 2000-1, 2)
Accelerated Ageing (Table 2000-1, 3)
Adhesion Strength (Clause 2005.1)
Ozone Resistance (see Note 2 below)
Note 1.
 For acceptance testing the properties enumerated in Clause 2005.1 and specific
gravity of elastomer of test pieces from test bearing shall be compared with those
for corresponding specially moulded test pieces furnished by the manufacturer. The
following variations shall be deemed maximum acceptable: Specific Gravity ±0.2
Ash Content ± 0.5 per cent
Hardness (Table 2000-1, 1.1)
Tensile strength (Table 2000-1, 1.2)
Elongation at Break (Table 2000-1, 1.3)
Compression Set (Table 2000-1, 2)
Accelerated Ageing (Table 2000-1, 3)
Adhesion Strength (Clause 2005.1)
Note 2.

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2005.2.
Ozone resistance test can be waived by the Engineer for bearings of CR when satisfactory
results of ozone resistance tests on similar • grade of elastomer may be available from
process control records or development test data furnished by the manufacturer.
 Where such process control data are not available or the frequency of testing not
deemed adequate, ozone resistance test shall be mandatory for acceptance of bearings
of CR.
 However, such tests may not be insisted for bearings not located under adverse
conditions of exposure and where the test on accelerated ageing could be considered
as adequate.
Process and acceptance control tests for ozone resistance by an independent testing
agency shall be acceptable.
Tests on Complete Bearings or Sections
1. Two bearings shall be selected at random from the lot as test bearings. These
bearings shall be excluded from the lot accepted.
2. The following tests shall be conducted on test bearings:
Test for determination of shear modulus
Test for determination of elastic modulus
Test for determination of shear modulus (short term loading)
Test for determination of adhesion strength
Test for determination of ultimate compressive strength
The test specifications and acceptance criteria shall conform to those given in Appendix
2 of IRC: 83 (Part II).
2005.3.3.2. Acceptance testing level 2
 General Inspection. This shall conform to the provision in Clause 2005.3.3.1 in all
respects.
 Test on specially moulded test pieces. This shall conform to the provisions in Clause
2005.3.3.1 in all respects.
Test on complete bearings. Test for determination of shear modulus shall be conducted
using two bearings of the lot selected at random and conforming to relevant provisions
of Clause 2005.3.3.1. These bearings shall however be part of the lot accepted. The
remaining tests stipulated in aforesaid clause shall be carried out on all bearings selected
at random which shall be excluded from the lot accepted. 2005.3.4. Special acceptance
inspection: Special acceptance inspection may comprise the following:
1. Acceptance testing by an independent external agency with separate or supplemental
test facilities provided by it.
2. Acceptance testing on test pieces prepared from the surface or body of the test
bearings instead of specially moulded lest pieces.
3. Acceptance tests not covered by these specifications but according to the specifications
laid down by the Engineer.
Special acceptance inspection may be specified under the following conditions:
a) Special contract agreement
b) Unsatisfactory evidence of process or acceptance control
2005.3.5. Inspection certificate: A lot under inspection shall be accepted by the Inspector
and so certified, when no defect is found with respect to any of the quality characteristics

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 2005.3.7
tested on samples drawn from the lot according to specifications laid down in Clause
2005.3.3 covering general inspection tests on specially moulded test pieces and on
complete bearings.
In case of any bearing with defect, the lot shall be rejected by the Inspector and so certified.
In case any bearing is found to be defective with respect to any quality characteristic,
discerned by general inspection tests it specified in Clauses 2005.3.3.1 and 2005.3.3.2,
tests on specially moulded test pieces and complete bearings as applicable according
to Clauses 2005.3.3.1 and 2005.3.3.2 shall nevertheless be completed. If the said lot,
rejected by general inspection, satisfies the acceptance criteria in respect of these other
tests, the lot and individual bearings found defective shall be clearly identified in the
inspection certificate.
The manufacturer shall obtain from the inspector, authorised by the Engineer, immediately
on completion of his inspection, an inspection ff certificate which shall include the details of
a lot or lots accepted/rejected by him and records of all test measurements.
2005.3.6. Quality control certificate:  The manufacturer 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 records/charts which shall be open to inspection of
Engineer/ Inspector 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 i g Shall include at least the following
information: Composition of compound - raw elastomer and ash content, the grade of
raw elastomer used (including name, source, age on shelf), test results hardness, tensile
strength, elongation at break, compression set, accelerated ageing, etc.
A higher level certification of the process quality control shall be it for at the sole discretion
of the Engineer in special cases e.g. where adequate inspection of bearings similar to
those comprising the lot under inspection produced in the same plant is not available the
Engineer or in case of any evidence of process or acceptance being deemed unsatisfactory.
The higher level certification shall comprise submittal of a complete quality control report
as given
in Appendix 3 of IRC: 83 (Part II) supplementing the quality control certificate.
2005.3.7 Acceptance: The manufacturer shall furnish the following to Engineer for the
acceptance judgment:
1. Quality control certificate as laid down in Clause 2005.3.6.
2. Inspection certificate as laid down in Clause 2005.3.5.
The manufacturer shall furnish any supplementary information on the system of quality
control and/or process and acceptance control testing as may be deemed necessary by
the Engineer.
In case of any evidence of process or acceptance control testing being deemed unsatisfactory
by him, Engineer at his sole discretion may call for a special acceptance of the lot according
to specifications laid down by him, without any prejudice to his right to reject the lot. The
entire cost of such supplementary inspection shall be borne by the manufacturer.
The Engineer shall be the sole authority for acceptance of a lot on scrutiny of the certificates
along with any supplementary evidence and complete satisfaction therewith.
In case of rejection of a lot, the Engineer shall reserve the right to call for special acceptance

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2005.4.
inspection for the succeeding lots offered for inspection, according to the specifications
laid down by him. The entire cost of such tightened inspection shall be borne by the
manufacturer.
2005.4. Certification and Marking
Bearings shall be transported to bridge site after final acceptance by Engineer and shall be
accompanied by an authenticated copy of the certificate to that effect.
An information card giving the following details for the bearings, duly certified by the
manufacturer shall also be appended:
Name of manufacturer
Date of manufacture
Elastomer grade used
Bearing dimensions
Production batch no.
Acceptance lot no.
Date of testing
Specific bridge location, if any
Explanation of markings used on the bearing
All bearings shall have suitable index markings identifying the in- formation. The markings
shall be made in indelible ink or flexible paint and if practicable should be visible after
installation. The top of the bearing and direction of installation shall be indicated.
2005.5. Storage and Handling
Each elastomeric bearing shall be clearly labeled or marked. The bearing shall be wrapped
in a cover. They shall be packed in timber crates with suitable arrangement to prevent
movement and to protect comers and edges.
Care shall be taken to avoid mechanical damage, contamination with oil, grease and dirt,
undue exposure to sunlight and weather to the bearings during transport and handling prior
to and during installation.
2005.6. Installation
Installation of multiple bearings one behind the other on a single line of support shall be of
identical dimensions.
Bearings must be placed between true horizontal surfaces (maximum tolerance 0.2 per
cent perpendicular to the load) and at true plan position of their control lines marked on
receiving surfaces (maximum tolerance ±3 mm).
Concrete surfaces shall be free from local irregularities (maximum tolerance ± 1 mm in
height).
Design shall be checked for the actual inclination in seating if larger inaccuracies than
those specified are permitted.
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.
Forms shall also fit the bearings snugly and prevent any leakage of mortar grout. Any
mortar contaminating the bearings during concreting shall be completely removed before
setting.
For precast concrete or steel superstructure elements, fixing of bearing to them may be done
by application of epoxy resin adhesive to interface, after specified surface preparation. The
264 RED BOOK  VOLUME I  ROADS  2012
 B.
specifications for adhesive material, workmanship and control shall be approved by the
Engineer. Care shall be taken to guard against faulty application and consequent behaviour
of the adhesive layer as a lubricant. The bonding by the adhesive shall be deemed effective
only as a device for installation and shall not be deemed to secure bearings against
displacement for the purpose of design.
As a measure of ample safety against accidental displacement, the bearings shall be
placed in a recess as shown in Fig. 9 of IRC: 83 (Part II).
2005.7. Seating of Elastomeric Bearings on a Non-Horizontal Plane
Installation of elastomeric bearings on a Non-Horizontal Plane shall be as follows:
i) Elastomeric bearings shall be delivered with MS backing plate fastened to the bearing
from the manufacturer.
ii) Template of 6 mm M.S. plate and of size same as bearing holding base plate with
matching holes for the anchor screws shall be used. Anchors shall be fitted to
the templates with the anchor screws but with MS washers in place of elastomer
washers. The above template assembly shall be fitted in the formwork at its proper
location and in a vertical plane.
iii) After casting of the pedestal and removal of the formwork, the template is to be
removed.
A. Installation with face plate and without template in•situ casting
i) The sub-assembly of elastomeric bearing with the MS backing plate shall be fitted to
the embedded anchors with anchor screws and elastomeric washers replacing the
steel washer.
ii) A clearance is required between the stainless steel face of the elastomeric bearing
and that of the vertical face of the face plate with stainless steel top installed on
the projection below the soffit. This shall be achieved by inserting removable steel
sheeting of thickness as per the drawing, during preparation of the formwork before
casting of the superstructure.
iii) The face plate with stainless steel top and pack plate shall be assembled with the
anchors with elastomeric washers and anchor screws. The assembly shall be fitted in
the formwork at its proper location and in a vertical plane. The removable steel shims
shall be removed at an appropriate time after the casting of the super-structure.
B. Installation with face plate and with template in-situ casting
i) Template of 6 mm MS plate and of size same as face plate with stainless steel top
and matching holes for the anchor screws shall be used. Anchors shall be fitted to
the templates with the anchor screws but with MS washers in place of elastomer
washers. Separate screws may be used in case of inconvenience of in the length of
original anchor screws. The above template assembly shall be fitted in the formwork
for the super-structure at its proper location and in a vertical plane.
ii) After removal of the superstructure formwork, the template shall be removed.
iii) The face plate with the required thickness of pack plate shall be loosely fitted to
the anchors embedded in the projection below the superstructure, with elastomer
washers and anchor screws.
iv) The sub-assembly of elastomeric bearing with the MS backing plate shall be fitted to
the embedded anchors in the pedestal with anchor screws and elastomeric washers
replacing the steel washer this time.
v) The required clearance between the stainless steel face of the elastomeric bearing

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2006.1.
and that of the vertical face plate installed on the projection below the soffit shall be
checked. After adjustment of the required working clearance the small gap between
the vertical face of the projection below the soffit and the back of the face plate (with
pack plates, if any) shall be grouted with epoxy grout.

2006. POT BEARINGS

2006.1. General
2006.1.1. Pot type bearings shall consist of a metal piston supported by a disc or
unreinforced elastomer confined within a metal cylinder to take care of rotation.
Horizontal movement, if required, shall with a system of sealing rings be provided by
sliding surfaces of PTFE pads sliding against stainless steel mating surfaces. The pot
bearings shall consist of Cast steel assemblies or fabricated structural steel assemblies.
2006.1.2. Provisions of IRC-83 (Part I) shall be applicable for all metallic elements.
Provisions of IRC: 83 (Part II) shall be applicable for all elastomer elements. When any
items are not covered by IRC: 83 (Parts I and H), the same shall be as per guidelines
given hereunder and BS: 5400 (Sections 9.1 and 9.2), except that no natural rubber
shall be permitted. If there is any conflict between BS on the one hand and IRC on the
other, the provisions of IRC will be guiding.
2006.1.3. Combination bearings using any judicious combination and sliding element
shall be permitted. As for example:
Rotation Sliding
Name Element Element Generally for
Pot Pot None Vertical Load
Elastomer Elastomer None* Horizontal Buffer
Pot PTFE Pot PTFE-SS** Vertical Load and
Horizontal Load
Spherical Spherical PTFE-SS** Vertical Load and
Knuckle PTFE Knuckle Horizontal Load
Elastomer PTFE Elastomer PTFE-SS** Transverse Guide
Elastomer SS** Elastomer SS-SS** Transverse Guide
* Elastomer shall permit movement by shear
** Stainless Steel
For special and innovative bridges, new combinations beyond what is shown may be
required. The same may be used after approval by the Engineer.
2006.2. Fabrication
i) The surface mating with the PTFE in the sliding pair shall be corrosion resistant stainless
steel. Normally, the stainless steel shall form the upper component. The stainless
steel shall overlap the PTFE after full movement on all sides. If stainless steel sheet
is used, it should be bonded by continuous welding along the edges. Adhesive or
any other bonding can be approved by the Engineer. The surface shall be prepared
by thorough cleaning to remove grease, dust or any other foreign substance.
ii) PTFE modular sheets of the sliding pair shall be located by confinement assisted
by bonding. Confined PTFE shall be recessed into the metal backing plate. The
shoulders of the recess shall be sharp and square to restrict the flow of PTFE.

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 c)
iii) The thickness of the PTFE shall not be less than 4.5 mm with projection above the
recess not exceeding 2.0 mm. When the piston is subjected to tilting, the seal must
slide along the wall and alter its shape according to the angle of tilt. At the same time,
it must be sufficiently rigid to bridge the gap between the piston and the wall of the
pot. However, the percentage of plan area of The lubrication cavities to the gross
area shall DOL exceed 25 per cent. The depth of the cavity shall not exceed 2.0 mm.
iv) The diameter to thickness ratio of the confined elastomer shall not exceed 15.
The surface of the confined elastomer shall be smooth.
v) A seal shall be provided to prevent extrusion of the confined elastomer between
the piston and the pot wall. The seal should stay functional under the loads - and
rotations acting on it. Additional seal shall be provided to prevent entry of dust- into
the pot. Sealing rings for .pot bearings shall be fabricated from stainless steel. When
the piston is subjected to tilting, the seal must slide along the wall and alter its shape
according to the angle of tilt. At the same time, it must be sufficiently rigid to bridge
the gap between the piston and the wall of the pot.
vi) The hardness of the piston and pot wall at their contact region shall be minimum 350
BHN to reduce wear. The surface finish of the pot base in contact with the confined
elastomer shall be very smooth.
vii) All bearings shall be installed with anchor and anchor screws or some similar device
such that while replacing, the beatings can be removed with minimum lifting of the
superstructure.
viii) The external surfaces of the assemblies shall be completely cleaned by sand
blasting. After sand blasting, dust shall be removed from the surface using clean and
dry compressed air or a clean brush after which suitable coating shall be applied.
ix) Pot bearings including all parts as shown on the drawings shall be fully shop assembled
at the manufacturer's works to ensure proper fitting of all parts.
2006.3. Materials
a) Steel
i) Structural steel shall conform to IS: 226 and IS: 2062, as applicable.
ii) Cast steel shall conform to Gr 280-520W of IS: 1030. 0.3 to 0.5 per cent copper may
be added to increase the corrosion resistance properties.
ii) Stainless steel shall conform to AISI: 304 or XO4Cr18Ni1O of IS: 6911 for ordinary
applications. For applications with adverse/corrosive environment, the stainless
steel shall conform to AISI: 316L or O2Cr17Ni12Mo2 of IS: 6911.
b) PTFE
PTFE (poly tetra fluoro ethylene) shall be of unfilled pure virgin quality. It shall be free
sintered. The mechanical properties of unfilled PTFE shall comply with Grade A of BS:
3784.
c) Elastomer
The confined elastomer inside pot will have the following properties:
a) Hardness IRHD IS: 3400 (Part II) 50 + 5
b) Min tensile MPa IS: 3400 (Part I) 15.5 strength
c) Min elongation at break,) shall be as per Table 2000-I Max compression set and)
“Properties of Elastomer" Accelerated ageing)
For other details, refer to Clause 2005.1.

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2006.4.
2006.4. Workmanship
2006.4.1. Welding
 All welding shall conform to IS: 9595 with electrodes of suitable grade as per 13:814.
Preheating and post weld stress relieving shall be done as per IS: 9595.
2006.4.2. Cast steel assemblies: Cast steel for pot bearing assemblies shall conform
to requirements of relevant I3. Castings shall be true to the forms and dimensions shown
on the drawings, and shall be free from pouring faults, sponginess, cracks, blow holes
and other defects affecting their appearance or their strength. Warped or distorted
castings shall not be accepted. Exposed surfaces shall be smooth and dense.
 All irregularities, fins or risers shall be ground off flush with the adjacent surface.
Castings with visible cracks, blow holes, or similar blemishes shall be rejected if the
imperfections are located on bearing surfaces or cannot be remedied to the satisfaction
of the Engineer.
 Imperfections which are not located on bearing surfaces shall be cleaned out, filled
with weld metal of the appropriate composition and ground flush with adjacent surfaces.
2006.4.3. Structural steel assemblies: Defects arising from the fabrication of the
steel shall be inspected by the Engineer, who will decide whether the materials may be
repaired by the Contractor or will be rejected. The cost of repairs or replacement shall
be borne by the Contractor.
All steel whether fabricated or not, shall be stored above the ground on platforms, skids,
or other supports, and adequately protected against corrosion. Excessively rusted, bent
or damaged steel shall be rejected.
All plates shall be flat and rolled bars and shapes straight before marking out or being
worked. Straightening shall be done by methods which shall not damage the material.
Sharp kinks and bends shall be the cause for rejection.
 Steel may be flame cut to shape and length so that a regular surface, free from
excessive gouges and striations is obtained. Flame cutting by hand shall be done only
with the approval of the Engineer. Exposed corners shall be machined or ground.
2006.4.4. Tolerances
i) U Plan dimensions: -0 to +5 mm
ii) Overall height: -0 to +3 mm
iii) Height of elastomer: ± 5 per cent
iv) Height of any steel component
a) Machined: -0 to +1 mm
b) Unmachined: Class 2 of IS: 4897
v) Stainless steel sliding surface
a) Flatness: 0.0004L, where L = length in
direction of measurement
b) Surface Finish: Ra ≤ 0.25 pm as per IS: 3073
2006.4.5. Painting
i) All non-working surfaces shall be coated with two coats of epoxy primer and one or
more coat each of epoxy intermediate and finish, total thickness ≤ 0.150 µm or any
other painting scheme as approved by the Engineer.
ii) Silicon grease shall be applied at the PTFE/SS interface after testing.

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 2006.6.2.
iii) Anchor sleeves shall be cement coated at the manufacturer’s works.
2006.5. Test
2006.5.1. Raw materials: Necessary test certificates for all raw materials as in Clause
2006.3 above shall be furnished by manufacturers. Reference may also be made to
Clause 2005.1 for tests on elastomers.
2006.5.2. Test on casting: Tests specified in IS: 1030 shall be performed. Castings
shall be ultrasonically tested and certificates submitted. Quality level of castings shall-be
level 3 as per IS: 9565.
2006.5.3. Test on welding: All welding shall be tested by Dye Penetration method. But
welding shall be tested by Ultrasonic method. Soundness of welding shall be certified
by the manufacturer.
2006.5.4. Acceptance test on bearing
i) All bearings shall be checked for overall dimensions.
ii) Ali bearings shall be load tested to 1.1 times maximum design capacity including
seismic force. Bearing tested at higher loads cannot be used.
iii) A pair of bearings selected at random will undergo testing in order to determine the
coefficient of friction “µ". The coefficient of friction shall be ≤ 0.05 at the design load.
iv) Two bearings selected at random shall be tested for permissible rotation.
2006.6. [Installation of POT-cum-PTFE Bearings
2006.6.1. General
i) Care shall be taken during installation of the bearings to permit their correct functioning
in accordance with the design scheme.
ii) To prevent contamination, dismantling of the bearings at site shall not be done.
iii) The load shall be transferred onto the bearings only when the bedding material has
developed sufficient strength. The props for the formwork shall only be removed
after lapse of appropriate time. In special cases, this can be ensured by suitable
devices like jacks, etc.
iv) Temporary clamps and shims (introduced to maintain working clearance) shall be
removed at an appropriate time, before the bearing is required to permit movement.
v) Permitted installation tolerance of the bearing from plane of sliding shall be maintained.
vi) Cement based non-shrink grout with air releasing additive and epoxy based grout,
whichever is specified shall be first tried at the site. For the proprietary grout mixes,
appropriate instructions from the manufacturer shall be followed specially with regard
to the following:
a) Preparation->concrete cleaning, roughening, pre-soaking, etc.
b) Forms->sturdiness, leak proofing, shape, header funnel vents, etc.
c) Bearing Base->cleaning, etc.
d) Placement->mixing, consistency, time period, finishing, etc.
e) Protection->curing, ambient temperature, etc.
2006.6.2. In-situ casting of superstructure
i) Formwork around the bearing shall be carefully sealed to prevent leakage.
ii) Sliding plates shall be fully supported and care taken to prevent tilting, displacement
or distortion of the bearings under the weight of wet concrete.

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2006.6.3.
iii) Bearings shall be protected during concreting operation. Any mortar contaminating
the bearing shall be completely removed before it sets.
2006.6.3. Seating of bearing
A. Using Template
i) Template with required rigidity and matching holes corresponding to the base of the
bearing shall be used.
ii) All the anchors shall be fitted to the lower face of the template using the anchor screws
but with steel washer replacing the elastomer washers. Separate screws may be
used in case of inconvenience in the length of the original anchor screws.
iii) The template assembly shall be located with regard to level and alignment. It shall be
ensured that the top of the anchors lie in a horizontal plane at the required elevation.
The anchors shall be tied/welded to reinforcement to avoid displacement during
concreting.
iv) Concreting of the pedestal/pier cap shall be done to a level leaving a gap of 25-50
mm below the template.
v) The template and steel washers shall be removed prior to placement of the bearing
assembly with temporary clamps. The bearing assembly shall be fitted to the anchors
with the help of anchor screws and elastomer washers. Level at the bearing shall be
checked.
vi) The gap below the bearing assembly shall be grouted with cement based grout.
Reference may be made to Clause 2006.6.1(vi).
B. Without Template with Gap
i) Pockets commensurate with the sizes of the anchors shall be kept in pedestals during
concreting of the same. The pedestal shall be cast approximately 25 mm short of the
required finished level.
ii) Anchors shall be fitted to the bearing bottom with elastomer washers and anchor
screws. The bearing assembly shall be seated in the location on steel chairs/packs.
The anchors fitted below the bearing shall go into pockets in the bed block. Level
and alignment of the bearing shall be checked. It shall be ensured that the bearing
sits in a horizontal plane.
iii) The gap below the bearing assembly including anchor pockets shall be grouted with
cement based grout. Reference may be made to Clause 2006.6.1(vi).
C. Without Template without Gap
Elongated pockets commensurate with the sizes of the anchors shall be kept in pedestals
during concreting of the same. The geometry and location of the anchor pockets (with
tapered funnel extension, if required) shall be such that after placement of the bearing
the pockets can be successfully grouted. The pedestal shall be cast 5 mm - 15 mm short
of the required finished level. The required level shall be achieved by chipping before
placement of the bearing. Careful control shall be exercised to cast at the exact finished
level or 1 mm - 3 mm down from- the required finished level.
D. Seating of bearings shall be as per manufacturer’s instructions.

2007. INSPECTION AND TESTING

Where any patents are used, the manufacturer’s certificate with test proofs shall be
submitted alongwith the design and got approved by the Engineer before their use in work.

2008. TESTS AND STANDARDS OF ACCEPTANCE

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 D.
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.

2009. MEASUREMENTS FOR PAYMENT.

Bearings shall be measured in numbers, according to their capacities and particular
specifications given on the drawings.
The quantity of elastomeric bearings shall be measured in cubic centimetres of finished
dimensions.

2010. RATE
The contract unit rate of each type of bearing shall include the cost of supplying and fixing the
bearings in position complete as specified on the drawings or as decided by the Engineer.
The rate shall also include the cost of samples and their testing when desired by the
Engineer.
In case of steel bearings the rate shall include the cost of all nuts,
bolts, the cost of all tests prescribed in the specifications and shown on the drawings.
Where the Department supplies the bearings, the rate for fixing them shall include the
cost of anchor bolts, their fixing, transport of bearings from the place of supply to the site,
handling and placing them in position as per direction of the Engineer.

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 1906.7.

2300
CONCRETE
SUPER STRUCTURE

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1906.7.

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 2304.1.
2301. DESCRIPTION
The work shall cover furnishing and providing of concrete super- structure in accordance
with the drawings as per these specifications or as directed by the Engineer.
2302. MATERIALS
Materials shall conform to Section 1000 of these Specifications.
2303. GENERAL
2303.1. A method statement for construction, indicating the following, shall be submitted
by the Contractor for approval of the Engineer, well in advance of the commencement of
the construction of superstructure : .
i) Sources of Materials
ii) Design, erection and removal of formwork
iii) Production, transportation, laying and curing of concrete
iv) Prestressing system, if applicable.
v) Personnel employed for execution and supervision
vi) Tests and sampling procedure
vii) Equipment details
viii) Any other point
2303.2. Dimensions, lines and levels shall be set out and checked with respect to
permanent reference lines and permanent bench mark so that the final product is in
accordance with the drawings or as directed by the Engineer.
2303.3. The work shall conform to the following sections besides stipulations in this
section with regard to specific type of construction:
i) Formwork Section 1500
ii) Steel Reinforcement Section 1600
iii) Structural Concrete Section 1700
iv) Prestressing Section 1800
 Additionally, some of the common types of superstructure construction shall have
features as discussed in this Section.

2304. REINFORCED CONCRETE CONSTRUCTION

2304.1. Solid Slabs
Where adjacent span of slab has already been cast, the expansion joint and filler board
shall be placed abutting the already cast span which shall form the shutter on that side of
the new span to be cast. The whole of the slab shall be cast with reinforcement embedded
for the road kerb and railings. No other construction joint shall be allowed except with the
express permission of the Engineer.
Where wearing coat is required to be provided, after the deck slab has been cast, the
surface of the slab shall be finished rough, but true to lines and levels as shown on the
drawings, before the concrete has hardened. The areas of construction joints shall be
treated in the prescribed manner.
The top of the slab shall be covered with clean moist sand as soon as the top surface has
hardened. Curing shall be carried out as per Section 1700.
Where the slab is resting on bearings, the same shall be placed • in position in accordance
with the drawings, before casting of deck slab.

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2304.2.
2304.2. RCC T-Beam and Slab
Provision of construction joint shall conform to the drawings or as per directions of the
Engineer. No construction joint shall be provided between the bottom bulb and the web. If
not indicated on the drawing, construction joint may be provided at the junction of the web
and the fillet between the web and the deck slab with the permission of the Engineer.
The portions of deck slab near expansion joints shall be CBSI alongwith reinforcements
and embedments for expansion joints. For this purpose, the portion of deck slab near
expansion joints may be cast in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels as
shown on the drawings before the concrete has hardened. Care shall be taken for setting
of bearings as indicated on the drawings.

2305. PRESTRESSED CONCRETE CONSTRUCTION

2305.1. PSC Girder and Composite RCC Slab
PSC Girder may be precast or cast-in-situ as mentioned on the drawing or as directed by
the Engineer. Girders may be post-tensioned or pre-tensioned. Where precast construction
is required to be adopted, selection of casting yard and details of methodology and of
equipment for shifting and launching of girders shall be included in the method statement.
In case of cast-in-situ construction, the sequence of construction including side shifting of
girders, if applicable, and placing on bearings shall be in accordance with the drawings.
The PSC girder constituting the top flange, web and the bottom flange shall be concreted
in a single operation without any construction joint.
The portions of deck slab near expansion joints shall be cast along- with reinforcements
and embedments for expansion joints. For this pm-pose, the portion of deck slab near
expansion joints may be cast in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels as
shown on the drawings before the concrete has hardened. Care shall be taken for setting
of bearings as indicated on the drawings.
2305.2. Box Girder
Box girders may be simply supported or continuous. Simply supported box girders shall
have minimum construction joints as approved by the Engineer. In the case of continuous
box girders the sequence of construction and location of construction joints shall strictly
follow the drawings.
The box section shall be constructed with a maximum of one construction joint located in
the web below the fillet between the deck Slab and web. If permitted by the Engineer, one
additional construction joint may be permitted and this construction joint shall be located in
the web above the fillet between the soffit slab and web.
The portions of deck slab near expansion joints shall be cast alongwith reinforcements and
embedments for expansion joints. For this purpose, the portion of deck slab near expansion
joints may be cast in a subsequent stage, if permitted by the Engineer.
The surface finish of the deck slab shall be finished rough but true to lines and levels as
shown on the drawings before the concrete hardened. Care shall be taken for setting of
bearings as indicated on the drawings.
2305.3. Cantilever Construction
Continuity of untensioned reinforcement from one segment to the next must be ensured by
providing full lap length as necessary.

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 2306.2.
The design of the superstructure shall take into account the following aspects which form
an integral part of the construction operations:
a) Stability against over-turning for each statical condition through which the assembly
passes, shall be checked.
b) Stresses at each preceding segment joint with the addition of every segment or
change of statical conditions shall be cheeked. The load of equipment as well as
construction live load shall be taken into account.
c) Precambering of the superstructure during construction shall be done in such a
manner that the finally constructed structure under permanent load attains the final
profile intended in the drawings.

2306. TOLERANCES
2306.1. Precast Concrete Superstructure
Variation in cross-sectional dimensions:
a) upto and including 2m: ± 5 mm
over 2m: ± 5 mm
b) Variation in length overall and length between: shall not exceed ±
10mm
bearings or ± 1 per cent of the
span length, whichever
is lesser
c) Permissible surface irregularities when measured
with a 3 m straight edge or template: 5 mm
2306.2. Cast-in-Situ Superstructure
a) Variations in, thickness of top and bottom slab: -5 mm to +10 mm
for box girders, top and bottom flange for
T-girders or 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 between: shall not exceed ±
10mm
bearings or ± 0.1 per cent of the
span length, whichever
is lesser
e) Permissible surface irregularities when: 5 mm
measured with a 3 m straight edge or template

2307. 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. 580
 

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2306.2.
2308. MEASUREMENTS FOR PAYMENT
Concrete in superstructure shall be measured in accordance with Section 1700, based on
the quantity ordered or as shown on the drawings.
Steel reinforcement (untensioned) in superstructure shall be measured in accordance with
Section 1600, based on the quantity ordered or as shown on the drawings.
High tensile steel (prestressing) in superstructure shall be measured in accordance with
Section 1800, based on the quantity ordered or as shown on the drawings.

2309. RATE
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.

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 2306.2.

2600
EXPANSION JOINTS

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2306.2.

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 2603.2.
2601. DESCRIPTION
This work shall consist of fabrication and placing of expansion joints as indicated on the
drawing and conforming to these specifications or as directed by the Engineer.
2602. GENERAL
a) The expansion joints shall be designed and duly got approved by the Engineer. It
shall cater for expected movement and rotation of the structure at the joints and
provide smooth riding surface. It shall also be easy for inspection, maintenance and
replacement.
b) Expansion joints shall be robust, durable, water-tight and replaceable. Site fabricated
expansion joints shall be prohibited. Expansion joints shall be obtained by the
Engineer either directly or through the Contractor from approved manufacturers and
be of proven type.
c) For bridges with prestressed concrete superstructure, with individual span length more
than 20 m or built with innovative design/construction elastomeric expansion joints of
slab seal or strip seal type shall be provided.
d) For slab type of bridges of spans less than 10 metres continuous surfacing may be
provided across the expansion gaps, supported on a 20 mm thick plate placed and
fixed at the level of the deck slab.
e) For bridges other than those mentioned in (c) above with spans above 10 metres, an
alternative specification of sliding steel plate joint or filled joints with copper plates
may also be adopted if approved by the Engineer, apart from elastomeric expansion
joint of slab seal or strip seal type.
f) Vehicular traffic shall not be allowed over expansion joints after its construction for such
period as may be determined by the Engineer.
g) Proprietary type deck joints offered by the Contractor in lieu of the type specified shall
comply in all respects with the manufacturer’s specifications and meet the required
range of movements and rotations and be fit for the purpose of ensuring satisfactory
long term performance in the bridge.
Where alternative type proprietary deck joints are proposed by the Contractor, the following
information shall be provided.
i) Name and location of the proposed manufacturer.
ii) Dimensions and general details of the joint including material specifications, holding
down bolt or anchorage details and installation procedures
iii) Evidence of satisfactory performance under similar environmental conditions of similar
joints being produced by the manufacturer.
Any acceptance of alternative types will be at the sole discretion of the Engineer.
Such deck joints shall be installed in accordance with the manu-facturer’s recommendations
and to the general requirements of this Specification.
No expansion joint shall be provided only for the width of the carriageway. It shall follow the
profile including the kerb and the footway and facia, if provided. The type of expansion joint
for the latter may be made different from that used for the carriageway expansion joint.
2603. REQUIREMENTS
2603.1. The requirement criterion will be separately applicable for the expansion joint proper
and the transition zone of attachment to the deck.
2603.2. There are two types of performance requirements for the expansion joint proper

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2603.2.
viz. from the necessity of the bridge and from the road users e.g. man, animal and vehicle.
2603.3. P
 erformance Requirement with Respect to Bridges The expansion joint shall:
a) Withstand the imposed load including the impact load from live load and other sources.
b) Allow expansion and contraction movement due to temperature, creep, shrinkage,
prestressing and structural deformations.
c) Permit relative rotation in elevation and plan due to the causes as noted above,
d) Be waterproof. Bridge deck expansion joint seals play a critical role in preventing the
degradation of the structural components of the bridge system. Without effective joint
seals, water passes through the bridge deck and works harmfully to corrode steel
components and cause deterioration of the concrete. Rain water gathers various
corroding additives from the atmosphere and also from the carriageway.
e) Ensure sealing. ln case bridge deck joints are not sealed, apart from loss of
waterproofing, grit and other forms of road debris may enter the joint. Debris, when
impacted with the joint can seriously restrict the movement instead of facilitating the
same. In the case of proprietary joints being accepted for adoption, the sealing shall
be as specified by them,
f) Ensure long life by being resistant to corrosion,
g) Be easy to install,
h) Be easy to maintain. Replaceability of expansion joint shall be one of the basic criteria
for selection of type of expansion joint,
i) Be resistant to the materials likely to collect/spill over the deck in its normal service.
2603.4. Performance Requirement with Respect to User
The expansion joint shall :
a) Provide smooth continuity at the top of the deck for riding comfort,
b) Be of skid resistant surface,
c) Be non-damaging to the rubber tyre,
d) Make minimum noise during vehicular crossing,
e) Ensure that animal paws and hooves should not get entangled where bridges are
used by animal drawn traffic,
i) Permit passing of bullock can steel tyre for bridges where bullock carts ply,
g) Look good aesthetically.
2603.5. Performance Requirement for Transition Zone
It is the zone of connection of joint assembly and the adjoining deck. The expansion joint
shall : •
a) Permit transfer of generated forces without distress, i.e., without getting uprooted. The
purpose will not be served if the bonding is with the wearing coat only. Anchorage must be
provided with the deck structural element,
b) Ensure that surface in the transition zone stays undisturbed during long term service.
2604. STEEL PLATE SLIDING EXPANSION JOINTS
a) In this type of buried joint, the wearing coat shall be made continuous over the joint. The
other alternative shall be to keep a gap in the wearing coat which is filled up with a seal and
filler, to be provided in extremely hot areas;
b) Materials for steel plates shall conform to Section 1900. The exposed metallic components

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 2606.
shall be galvanised or coated with approved anti-corrosive paint. The thickness shall be 20
mm or so for obtaining satisfactory performance.
c) Plates shall be placed to the line, grade and expansion gap shown on the drawings with
any adjustment required for temperature, particular care being taken with the top of the
plates.
d) Plates shall be firmly held in place during concreting by methods approved by the
Engineer. .
e} Any temporary bolts or other fixings which prevent relative movement of the adjacent
parts of the joint shall be removed as soon as the concrete has set sufficiently to hold the
expansion plates in their correct positions. In any case, temporary bolts or other fittings
shall be removed within 6 hours of placing l concrete unless otherwise directed by the
Engineer.
i) Care shall be taken to prevent damage to expansion joint plates or its coating.
g) If any damage occurs, the plates and coatings shall be restored by the Contractor to the
satisfaction of the Engineer.
h) Plates shall be free of oil, rust, loose paint or other similar material before coating.
2605. FILLER JOINTS
a) The components of this type of joint shall be at least 2 mm thick corrugated copper plate
placed slightly below the wearing coat, 20 mm thick compressible fibre board to protect the
edges, 20 mm thick pre-moulded joint filler filling the gap upto the top level of the wearing
coat, sealed with a joint sealing compound.
b) The material used for filling expansion joint shall be bitumen impregnated felt, elastomer
or any other suitable material, as specified on the drawings. Impregnated felt shall conform
to the requirements of IS:1838, and shall be got approved from the Engineer. The joint filler
shall consist of large pieces and assembly of small pieces to make up the required size
shall be avoided.
c) Expansion joint materials shall be handled with care and stored under cover by the
Contractor to prevent damage.
d) Any damage occurring after delivery shall be made good to the satisfaction of the
Engineer and at the expense of the Contractor.
e) Joint gaps shall be constructed as shown on the drawings. Surfaces/of joint grooves
shall be thoroughly cleaned with a wire brush to remove all loose materials and dirt and
debris, then washed or jetted out.
f) Pre-moulded expansion joint filler shall not be placed in position until immediately prior to
the placing of the abutting material. If the two adjacent surfaces of the joint are to be placed
at different times, this type of joint filler shall not be placed until the second face is about to
be placed.
g) Sealants shall be installed in accordance with the manufacturer’s recommendations and
all appropriate requirements for joint face priming.
h) Sealants shall be finished approximately 3 mm below the upper surfaces of the joint.
i) Joint materials spilt or splashed onto finished surfaces of the bridge during joint filling
operations shall be removed and the surfaces made good to the Engineer‘s approval.
j) No joint shall be sealed until inspected by the Engineer and approval is given to proceed
with the work.
2606. ELASTOMERIC SLAB SEAL EXPANSION JOINT

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2606.1.
2606.1. Materials
a) Steel inserts shall conform to IS:226. Use of any other materials like fibre-glass or similar
material shall not be permitted.
b) Elastomer for elastomeric slab unit (ESU) shall conform to clause 915.1 of lRC:83
(Pan II), compounded to give hardness IRHD 60 ±5, subject to the following additional
stipulations :
i) Chloroprene (CR) only shall be used in the manufacture of elastomeric expansion joints.
No reclaimed/natural rubber or vulcanised wastes shall be used. .
ii) The chloroprene material used in the manufacture of elastomeric (expansion jointś) shall
be Neoprene WRT, Bayprene 110, Skyprene B5 or Denka S- 40V.
iii) Chloroprene content of the compound shall not be lower than 60 per cent by weight. The
ash content shall not exceed S pr cent (as per tests conducted in accordance with ASTM
D•297 for (i) and (ii) above.
iv) EPDM and other similar candidate elastomers for expansion joints shall not be permitted.
c) Elastomeric plugs.
d) Spacer bars, marked with centre to centre distance of fixing holes.
e) Fixing bolts and nuts made of stainless steel.
f) Anchor bars comprising hooked anchor stiffeners welded with lower steel inserts and
sinusoidal anchor bars welded with horizontal leg of the edge steel inserts. The elaborate
anchoring arrangements of steel inserts shall be permanently welded tied with the steel
reinforcement.
2606.2. Fabrication
a) Steel inserts shall be grit blasted and provided with epoxy paint.
b) Edges of reinforcing steel sections shall be rounded.
c) Expansion joints shall be fully moulded to the required size in one single vulcanising
operation including the encasing layers as integral and homogeneous part.
d) Tolerances of fabrication shall be as follows :
i) Plan dimension -> ± 5 mm
ii) Total height -> ± 3 mm
2606.3. Supply and Handling
i) The Contractor shall supply all steel-reinforced elastomeric expansion joints including
bolts, nuts, sealant, plugs and all other accessories for the effective installation of the joints
including angled jointing sections for kerbs.
ii) Expansion joint material shall be handled with care and stored under cover by the
Contractor to prevent damage. Any damage occurring after delivery shall be made good at
the expense of the Contractor to the satisfaction of the Engineer.
2606.4. Installation
2606.4.1. E
 xpansion joints shall be installed as per approved drawing. Steel inserts, spacer
bars, concreting of pockets, fixing of elastomer slab unit and presetting, etc., shall be done
as per the following:
a) Steel Inserts
i) Deck casting shall be done leaving pockets or recess for steel inserts and anchors of the
expansion joint as per drawing.

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 2606.4.1.
ii) Steel inserts shall be lowered at the appropriate location inside the pocket.
iii) The top of tl1e insert shall be flush with the finished level of wearing course maintaining
the camber. iv) Spacer bars, duly set appropriately to the month of installation, shall be
fitted under proper supervision.
v) Anchor rods shall be tied/welded with the existing deck main reinforcement, maintaining
level and alignment.
vi) Welding between anchor rods and deck reinforcement is preferable. If welding is not
possible, strong steel tie wires shall be used for fastening, under proper supervision.
b) Space Bar
i) Spacer bars shall be used to ensure proper positioning of bolts and also levelling of the
steel inserts during fixing of the same with the deck reinforcement and casting second
stage concreting in the pocket thereafter.
ii) The 2nd stage concreting operation shall preferably be started within 24 hours of fixing
the steel inserts. In such cases, spacer bars should be removed just after concreting is
finished. lf there is a substantial time lag between fixing of inserts and concreting, then any
one of the following methods shall be adopted, depending on the support condition :
a) For simply supported bridge resting on simple elastomeric bearings, (with no dowel
pins), insert shall be placed in position with spacer bars at every alternate joints. Such
joints shall be called restrained joints hereafter. In other words, inserts shall not be fixed
simultaneously at two ends of one span. lf the above condition is satisfied, inserts with
spacer bars shall be kept in position for a substantially longer period at such restrained
joints. Spacer bars shall be removed after concreting of such restrained joints and inserts
placed in position with spacer bars at the other unrestrained joints thereafter.
b) For bridges resting on other than elastomeric bearings (including bearings with dowel
pins at one end), after placing and aligning the inserts and securing the same, the spacer
bars shall be removed. Concreting shall be done with great care so that inserts are not
dislocated or distorted.
iii) While removing the spacer bar after concreting, one must take care to see that the
concrete is not damaged during withdrawal of spacer bar. H the spacer bar happens to be
snugly fitted, it shall not be pulled by any means; it shall be gas Cut in two pieces and then
removed;
c) Concreting of Pocket
i) Concreting of pocket shall be done with great care using proper mix conforming to grade
similar to that of the deck casting besides ensuring efficient bonding between deck and
steel insert. Also proper care shall be given for ensuring efficient bonding with the already
Cast concrete.
ii) Needle vibrators shall be used. Care shall be taken so that the position of steel insert is
not disturbed during vibration.
iii) Spacer bar shall be removed within an appropriate time before the joint is required to
permit movement.
d) Fixing of Elastomeric Slab Unit (ESU)
i) Special jig shall be used to preset the ESU during installation.
ii) ESU (mounted on the jig, preset) shall be lowered to position.
iii) The line and level on the ESU should be adjusted.
iv) ESU shall be removed and coated with special adhesive

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2606.4.2.
v) ESU shall be placed in position again, ensuring waterproof joining at required faces.
vi) ESU shall be tightened with stainless steel nuts and lock washers in position. Tightened
nuts shall be locked with lock washers.
vi) Special sealant shall be poured inside the plug holes.
vii) The elastomeric plugs shall be pressed in position after applying adhesive on the
appropriate surface.
viii) ESU shall be fitted in position after completion of wearing course. While completing this
part of the wearing course, adequate care shall be taken to ensure a waterproof joining with
the already existing wearing course.
e) Pre-Setting
i) The main purpose of presetting of the steel inserts at the time of its installation is to
ensure as closely as possible the condition that in the long run at the mean average annual
`temperature, the ESU remains at its nominal state.
ii) Major factors responsible for changing the longitudinal length of the bridge superstructure
are indicated below:
a) Temperature variation from annual mean.
b) Changes due to shrinkage of concrete.
c) Changes due to elastic shortening and creep of the prestressed bridge superstructure.
d) Deformation of superstructure and substructure, if any.
Resultant changes in expansion gap due to first factor can occur in both directions from any
pre-selected mean position whereas changes due to creep and shrinkage are unidirectional
such that the expansion gap continuously increases with passage of time.
The steel insert unit of expansion joint can be fixed in any month of the year. As stated
earlier, the expansion gap between bridge superstructure may vary from time to time;
hence the initial fixing distance between fixing points will obviously depend on the month
of installation of steel insert. The c/c distance between stainless steel fixing of bolts as
indicated in the drawing can be taken as only nominal. The same shall be modified by
presetting depending on:
i) The difference between the mean temperature of the month of fixing of steel insert and
the annual average temperature.
ii) The elapsed period between the casting and for prestressing and fixing of steel insert for
calculating the remnant creep and shrinkage.
2606.4.2. Special requirements for installation
i) Prior to construction of bridge deck area adjacent to the joint, the supplier shall provide
detailed working drawings showing the location of all bolts, recesses and holes necessary
for the installation of the joint. Reinforcing bars in superstructure shall be amended as
required to ensure that there will be no interference in the installation of the joint.
ii) All bearing surfaces and recesses which are in contact with the joint assembly shall be
checked with a straight edge to ensure flatness of profile.
iii) No holes shall be drilled for fixing bolts within 7 days of concreting. Holes for the bolts
shall be drilled to the size and depth shown on the drawings.
iv) Sections of the jointing making the completed joint shall follow a straight line.
v) The fixing bolts shall not be placed in a position until at least 4 weeks after stressing is
completed in post-tensioned box or beam and slab structures. Prior to placing sections of

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 2607.1.
jointing, contact surfaces shall be cleaned to remove all grease, tar, paint, oil, mud or any
other foreign material that may affect adhesion of the sealant. .
vi) Sealant shall only be applied to dry contact surfaces. Sufficient sealant shall be applied
to the contact surfaces to cause extrusion of sealant when the jointing is fixed in position.
vii) Final sealing of the finished expansion joint shall be completed immediately after
completion of installation. All exposed ends, joints between units and other areas of possible
leakage shall be filled with sealant. All voids between the sides of the jointing and concrete
or plates shall be filled with sealant.
viii) Bolt cavities shall be cleaned and plugged with neoprene cavity plugs. Prior to placing
the plugs sufficient sealant shall be placed in the cavities to cause extrusion of the sealant
by the plugs.
ix) All excess sealant shall be removed from the jointing and adjacent areas.
2606.5. Acceptance Test
2606.5.1. As per clause 918.7 of IRC-83 (Part II), necessary quality control certification by
the manufacturer in regard to properties of Elastomer and steel will be furnished.
For severe environment, ozone resistance test as per clause 915.2.3 of IRC:83 (Part II),
shall be carried out for elastomer.
The properties of the elastomer shall conform to Table I of clause 915.2 of lRC:83 (Part II).
The acceptance testing for elastomer material shall conform to clause 918.4.1.2 of IRC:83
(Part Il) with additional criteria as stated in Clause 2005.
2606.5.2. The fabricated expansion joint shall be subjected to the following acceptance
tests:
i) Routine test. Each expansion joint shall be tested for at least 100 cycles for a test movement
which shall be 10 per cent more than the design expansion} contraction movement.
ii) In addition to routine test, one out of every 20 expansion joints shall be subjected to the
test movement for 4000 cycles. The lot shall be rejected if the elastomer material shows
signs of fatigue or permanent set or distress in the test. The test piece shall not be used in
the bridge.
iii) The type test for abrasion resistance shall be carried out for one joint out of every 20
nos. as per lS:3400 (Part 3) and the standard deviation shall be within ± 20 per cent
N.B. The manufacturer shall preferably have in-house testing facility. Otherwise, the testing
shall be got done by him at his expense at any testing establishment selected by the
Engineer. A manufacturer who cannot carry out the acceptance test shall not be entitled to
supply elastomeric slab seal joint.
2607. STRIP SEAL EXPANSION JOINT
2607.1. Components
Strip seal expansion joint shall comprise the following items:
a) Edge beams - This special claw leg profiled member shall be of extruded rolled steel
section combining good weldability with notch toughness.
b) Strip seal - This shall be of chloroprene with high tear strength, insensitive to oil, gasoline,
and ozone. It shall have high resistance to aging. This component, provided to ensure
water tightness, shall have bulbous shape of the part of the seal which is inserted into the
groove, provided in the edge beam. The seal should be vulcanised in single operation for
minimum full length of joint.
c) Rigid Anchorage - This shall be welded to the edge beam at staggered distance.
RED BOOK  VOLUME I  ROADS  2012 287
2607.2.
d) Anchor loops - This shall be made of weldable steel connecting the rigid anchorage with
deck reinforcement.
2607.2. Material
a) Edge beams of this special section are at present being directly imported in India. The
steel shall conform to steel grade Rst 37-2 of German Standard or equivalent.
b) Chloroprene of strip seal shall conform to clause 915.1 of lRC:83 (Part II). The properties
of chloroprene shall conform to Table 2600-1.
C) Anchorage steel shall conform to IS:2062.
d) Anchor loop shall conform to lS:2062.

TABLE 2600-1. STRIP SEAL ELEMENT SPECIFICATION

Sealing element is made of chloroprene and must be a extruded section. The working
movement range of the sealing element shall be at least 80 mm. with a maximum of 100
mm at right angles to the joint and $40 mm parallel to the joint.
PROPERTY SPECIFIED VALUE
Hardness 63 ± 5 Shore A
Tensile Strength Min 11 MPa
Elongation at fracture Min 350 per cent
Tear Propagation Strength
Longitudinal Min 10 N/mm
Transverse Min I0 N/mm
Shock Elasticity Min 25 per cent
Abrasion Min 220 mm3
Residual Cornpressive Strain
(22 h/70 deg C /30. per cent strain) Max 28 per cent
Ageing in hot air
(14 days/70 deg C)
Change in hardness Max +5 Shore A
Change in tensile strength Max -20 per cent
Change in elongation at fracture Max -20 per cent
Ageing in ozone
(24 h/50pphm/25 deg C/20 per cent strain) No cracks
Swelling behavior in Oil
(116 h/25 per cent C) ASTM Oil no.
Volume Change Max 5 per cent
Change in hardness Max 10 Shore A
ASTM Oil no.3
Volume Change Max 25 per cent
Change in hardness Max 20 Shore A
Cold Hardening Point Min -35 deg C
2607.3. Fabrication (Pre-installation)
a) Rolled steel profiles for edge beams shall be long enough to cater for a 2-lane carriageway.
These shall be cut to size of actual requirements by means of a mitre box saw. Alignment
of the cut to size steel profiles shall then be made in accordance with the actual bridge

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 2607.5.7.
cross-section on work tables. For this purpose, the contour of bridge cross-section shall be
sketched onto these tables. After the steel profiles are aligned, they will be chucked to the
tables by means of screw clamps and tacked by are welding.
b) Anchor plates shall be cut to the required size by gas cutting. These shall be welded to
the edge beams.
c) Anchor loops shall be bent to the required shape and welded to anchor plates.
d) The finally assembled joints shall then be clamped and transported to the work site.
2607.4. Handling and Storage
a) For transportation and storage, auxiliary brackets shall be provided to hold the joint
assembly together.
b) The manufacturer shall supply either directly to the Engineer or to the Bridge Contractor
all the materials of strip seal joints including sealants and all other accessories for the
effective installation of the jointing.
c) Expansion joint material shall be handled with care. It shall be stored under cover on
suitable lumber padding by the Contractor to prevent damage. Any damage occurring
after delivery shall be made good at the Bridge Contractor’s expense to the satisfaction of
the Engineer.
2607.5. Installation
2607.5.1. The width of the gap to cater for movement due to thermal effect, prestress,
shrinkage and creep, superstructure deformations (if any) and sub-structure deformations
(if any) shall be determined and intimated to the manufacturer. Depending upon the
temperature at which joint is likely to be installed, the gap dimension shall be preset.
2607.5.2. Taking the width of gap for movement of the joint into the dimensions of the recess
in the decking shall be established accordance with the drawings or design data of the
manufacturer. The surfaces of the recess shall be thoroughly cleaned and all dirt and debris
removed. The exposed reinforcement shall be suitably adjusted to permit unobstructed
lowering of the joint into the recess.
2607.5.3. The recess shall be shuttered in such a way that dimensions in the joint drawing
are maintained. The formwork shall be tight.
2607.5.4. Immediately prior to placing the joint, the presetting shall Should the actual
temperature of the structure be different the temperature provided for presetting, correction
of the presetting shall be done. After adjustment, the brackets shall be tightened again.
2607.5.5 The joint shall be lowered in a pre-determined position. Following placement of the
joint in the prepared recess, the joint be levelled and finally aligned and the anchor loops on
one side joint welded to the exposed reinforcement bars of the structure. Upon completion,
the same procedure shall be followed for the other of the joint. With the expansion joint
finally held at both sides, the auxiliary brackets shall be released, allowing the joint to take
up the movement of the structure.
2607.5.6. High quality concrete shall then be filled into the recess. The Packing concrete
must feature low shrinkage and have the same strength as that of the superstructure, but
in any case not less than M 35 grade. Good compaction and careful curing of concrete is
particularly important. After the concrete has cured, the movable installation brackets still
in place shall be removed.
2607.5.7. Rolled up neoprene strip seal shall be cut into the required length and inserted
between the edge beams by using a crow bar pushing the bulb of the seal into the steel

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2607.5.7.
grooves of the edge beams. A landing to a bead shall be formed in the thickened end of
the edges of the seal which would force the thickened end against the steel beam due to
wedge effect when the strip seal is buttoned in place.
2607.5.8. A  s soon as the concrete in the recess has become initially set, a sturdy ramp
shall be placed over the joint to protect the exposed steel beams and neoprene seals from
site traffic. Expansion joint shall not be exposed to traffic loading before the carriageway
surfacing is placed.
2607.5.9. The carriageway surfacing shall be finished flush with the top of the steel sections.
The actual junction of the surfacing/wearing coat with the steel edge section shall be formed
by a wedge shaped joint with a sealing compound. The horizontal leg of the edge beam
shall be cleaned beforehand. It is particularly important to ensure thorough and careful
compaction of the surfacing in order to prevent any premature depression forming in it.
Acceptance Test
i) All steel elements shall be finished with corrosion protection system.
ii) For neoprene seal, the acceptance test shall conform to the requirements stipulated
in Table 2600-I. It shall also be stretch tested. If a manufacturer is to supply this type of
joint, they will have to produce a test certificate accordingly conducted in a recognised
laboratory, in India or abroad.
iii) In view of the importance of the built up edge beams, special investigation of fatigue
strength of this section with anchorages to withstand 2 it 106 load change cycles without
showing signs of damage, will be required. The supplier shall have to produce a test
certificate in this regard, conducted at a recognised laboratory, in India or abroad.
iv) The manufacturer shall produce test certificates indicating that anchorage system had
been tested in a recognised laboratory to determine optimum configuration of anchorage
assembly under dynamic loading.
v) The manufacturer shall satisfy the Engineer that water tightness test for the type of joint
has been carried out in a recognised laboratory to check the water tightness under a water
pressure of 4 bars.
vi) As strip seal type of joint is specialised in nature, generally of the proprietary
type, the manufacturer shall be required to produce evidence of satisfactory performance
of this type of joint.
2608. 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 standards of acceptance.
2609. MEASUREMENTS FOR PAYMENT
The expansion joint shall be measured in running metres. For filled joints, the rate per
running metre shall include the cost of sealant depth provided in this drawing.
2610. RATE
The contract unit rate shall include the cost of all material, labour and other incidental
charges for fixing the joints complete in all respects as per these specifications in the
case of Bridge Contractor supplying the expansion joint. If the manufacturer supplies the
expansion to the Engineer, the cost of installation, handling and fixing shall be borne by the
Bridge Contractor.

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 2610.

2700
WEARING COAT
AND APPURTENANCES

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2607.5.7.

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 2703.1.
2701. DESCRIPTION
This work shall include wearing coat and bridge appurtenances such as railing, approach
slab, drainage spouts, weep holes in conformity with details shown on the drawing and
these specifications or as approved by the Engineer.
2702. WEARING COAT
2702.1. Bituminous Wearing Coat
Specifications for bituminous concrete/bitumen mastic in wearing coat shall conform to
Section 500 except for the special requirements as stated hereinafter.
2702.1.1. Principles of bituminous wearing coat shall comprise the following:
i) A layer of mastic asphalt, 6 mm thick after applying a prime coat over the top of the
deck before the wearing coat is laid. The prime coat and the layer of mastic asphalt
shall be laid as per Clauses 503 and 515 respectively.
ii) 50 mm thick asphaltic concrete wearing coat in two layers of 25 mm each as per
Clause 512
In case of high rainfall intensity areas, the thickness of mastic asphalt layer may be
increased to 12 mm.
2702.1.2. F
or high traffic density, an alternative specification for wearing course
comprising 40 mm bituminous concrete overlaid with 25 mm thick bitumen mastic layer
can be adopted. The work shall be done in conformity with Section 500.
2702.2. Cement Concrete Wearing Coat
Cement concrete wearing coat may be provided in case of isolated bridge construction or
bridges located in remote areas. It shall not be laid monolithic with the deck.
The thickness of wearing coat shall be 75 mm. The minimum grade of concrete shall be M
30 with water cement ratio as 0.4.
Curing of wearing coat earlier than what is generally required may be resorted to, so as to
avoid formation of shrinkage cracks in hot Weather.
All carriageway and footpath surfaces shall have non-skid characteristics.
The cross slope in the deck shall be kept as 2.5 per cent for decks, level in longitudinal
profile.
2702.3. For providing cross camber no variation in thickness of wearing coat shall be
permitted.
2703. RAILINGS
2703.1. General
a) Bridge railing includes the portion of the structure erected on and above the kerb for
the protection of pedestrians and traffic.
b) Railings shall not be constructed until the centering falsework for the span has been
released and the span is self•supporting. For concrete with steel reinforcement,
specifications of the items of controlled concrete and reinforcement mentioned under
relevant sections of these specifications shall be applicable.
c) The type of railing shall be carefully erected true to line and grade. Posts shall be
vertical with a tolerance not to exceed 6 mm in 3 metres. The pockets left for posts
shall be filled up with non-shrinkable mortar.
d) The type of railing to be constructed shall be as shown on the drawings.

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2703.2.
e) Care shall be exercised in assembling expansion joints in the railings to ensure that
they function properly.
f) The bridge railings shall be amenable to quick repairs.
g) Railing materials, particularly metal railings, shall be handled and stored with care, so
that the material and parts are kept clean and free from damage. Railing materials
shall be stored above the ground on platforms, skids, or other supports and kept
free from grease, dirt and other contaminants. Any material which is lost, stolen or
damaged after delivery shall be replaced or repaired by the Contractor. Methods of
repair shall not damage the material or protective coating.
2703.2. Metal Railings
Materials, fabrication, transportation, erection and painting for bridge railings shall conform
to the requirements of section 1900.
All complete steel rail elements, pipe terminal sections, posts, bolts, nuts, hardware and
other steel fittings shall be galvanised or painted with an approved paint.
If galvanised, all elements of the railing shall be free from abrasions, rough or sharp edges,
and shall not be kinked, twisted or bent. If • straightening is necessary, it shall be done by
methods approved by the Engineer.
Damaged galvanised surfaces, edges of holes and ends of steel railing cut after galvanising
shall be cleaned and re-galvanised.
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 drawings, metal railing shall be given one shop coat of
paint and three coats of paint after erection if sections are not galvanised.
Railings shall not follow any irregularity in the alignment of the deck. When shown on the
drawings, the rail elements shall be curved before erection.
2703.3. Cast-in-Situ Concrete Railings
The portion of the railing or parapet which is to be cast in place shall be constructed in
accordance with the requirements for Structural Concrete in Section 1700. The reinforcement
shall conform to Section 1600.
Forms shall either be of single width boards or shall be lined with suitable material duly
approved by the Engineer. Form joints in plane surfaces will not be permitted.
All mouldings, panel work and bevel strips shall be constructed according to the details
shown on the drawings. All corners in the finished work shall be true, sharp and clean-cut
and shall be free from cracks, spalls or other defects. Casting of posts shall be done in
single pour.
2703.4. Precast Concrete Railings
Precast members for railings shall be of reinforced cement concrete and shall conform to
the specifications given in Sections 1600`and 1700. The maximum size of the aggregate
shall be limited to 12 mm and the concrete grade shall be M 30. The precast members shall
be removed from the moulds as soon as practicable and shall be kept damp for a period
of at least 10 days. During this •- period they shall be protected from sun and wind. Any
precast member that becomes chipped, marred or cracked before or during the process of
placing shall be rejected. Special care shall be taken to watch the Surface of the cast-in-situ
portion of the deck.

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 2707.
2704. APPROACH SLAB
Reinforced concrete approach slab covering the entire width of the roadway shall be
provided as per details given on the drawings or as approved by the Engineer. Minimum
length of approach slab shall be 35 m and minimum thickness 300 mm.
The cement concrete and reinforcement shall conform to Sections 1700 and 1600
respectively. The base for the approach slab shall be as shown on the drawings or as
directed by the Engineer.
2705. DRAINAGE SPOUTS
2705.1. This work shall consist of furnishing and fixing in position of drainage spouts and
drainage pipes for bridge decks.
Drainage along l longitudinal direction shall be ensured by sufficient number of drainage
fixtures embedded in the deck slab. The spouts shall be of not less than 100 mm in
diameter and shall be of corrosive resistant material such as galvanised steel with suitable
cleanout fixtures. The spacing of drainage spouts shall not exceed 10 m. The discharge
from drainage spout shall be kept away from the deck structure. In case of viaducts in
urban areas, the drainage spouts should be connected with suitably located pipelines to
discharge the surface run-off to drains provided at ground level.
2705.2. Fabrication
The drainage assembly shall be fabricated to the dimensions shown on the drawings; all
materials shall be corrosion resistant; steel components shall be of `mild steel conforming
to lS:226. The drainage assembly shall be seam welded for water tightness and then hot-
dip galvanised.
2705.3. Placement
The galvanised assembly shall be given two coats of bituminous painting before placement.
The whole assembly shall be placed in true position, lines and levels as shown in the
drawing with necessary cut-out in the shuttering for deck slab and held in place firmly.
Where the reinforcements of the deck are required to be cut, equivalent reinforcements
shall be placed at the corners of the assembly.
2705.4. Finishing
After setting of the deck slab concrete, the shrinkage cracks around the assembly shall
be totally sealed with polysulphide sealant or bituminous sealant as per IS:1834 and the
excess -sea1ant trimmed to receive the wearing coat. After the wearing coat is completed,
similar sealant shall be finished to cover at least 50 mm on the wearing coat surface all
round the drainage assembly.
2706. WEEP HOLE
Weep holes shall be provided in solid plain concrete/reinforced concrete, brick/stone
masonry, abutment, wing wall and return walls as shown on the drawing or directed by the
Engineer to drive moisture from the back filling. Weep holes shall be provided with 100 mm
dia AC pipe for structures in plain/reinforced concrete or brick masonry. In case of stone
masonry, weep holes shall be 80 mm wide, 150 mm high or circular with 150mm diameter.
Weep holes shall extend through the full width of concrete/masonry with slope of about 1
vertical:20 horizontal towards the draining face. The spacing of weep holes shall generally
be lm in either direction or as shown in the drawing with the lowest at about 150 mm above
the low water level or ground level whichever is higher or as directed by the Engineer.
2707. TESTS AND STANDARDS OF ACCEPTANCE
The materials shall be tested in accordance with these Specifications and shall meet the
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2708.
prescribed criteria.
The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.
2708. MEASUREMENTS FOR PAYMENT
The measurement for payment for wearing coat, railings and approach slab shall be made
as given below :
i) Cement concrete wearing coat shall be measured in cubic metres. Asphaltic concrete
wearing coat shall be measured in square metres.
ii) . Railings shall be measured in running metres.
iii) Approach slab and its base shall be measured separately in cubic metres.
iv) `Drainage spouts shall be measured in numbers.
v) Weep holes in concrete/brick masonry structure shall be measured in numbers. For
structures in stone masonry, weep holes shall be deemed to be included in the item
of stone masonry work and shall not be measured separately.
2709. RATE
The contract unit rate for wearing coat shall include the cost of all labour, material, tools
and plant and other cost necessary for completion of the work as per these Specifications.
The contract unit rate of railings shall include the cost of all labour, material, tools and plant
required for completing the work as per these Specifications.
The contract unit rate for approach slab shall include the cost of all labour, material, tools
and plant required for completing the work as per these Specifications. The rate for base
shall include cost of all labour, material, tools and plant required, including preparation of
surface and consolidation complete in all respects.
The contract unit rate for each drainage spout shall include the cost of all labour, material,
tools and plant required for completing the work as per these Specifications. It shall also
include the cost of providing flow drain pipes with all fixtures upto the point of ground drains
wherever shown on the drawings.
The contract unit rate for weep hole shall include the cost of all labour, material, tools and
plant required for completing the work as per these Specifications.

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 PROPERTIES OF STEEL
AREAS, PERIMETERS AND WEIGHTS OF ROUND BARS
Diameter of bar Area Perimeter Weight
mm cm cm.sq. kg.lm.

5 0.20 1.57 0.15

6 0.28 1.88 0.22
8 0.50 2.51 0.39
10 0.79 3.14 0.62
12 1.13 3.77 0.89
16 2.01 5.03 1.58
20 3.14 6.28 2.47
22 3.80 6.91 2.98
25 4.91 7.85 3.85
28 6.16 8.80 4.83
32 8.04 10.05 6.31
36 10.18 11.31 7.99
40 12.57 12.57 9.86
45 15.90 14.14 12.49
50 19.64 15.71 15.41

PROPERTIES OF DEFORMED COLD TWISTED STEEL RODS

Equivalent Sections for Tension Reinforcement
Mild Steel. 8 10 12 16 20 22 25 28 32 36 40 50
(mm)
Deformed
Cold Twisted 6.25 8 10 12.5 16 18 20 22 25 28 32 38
Steel (mm)

Equivalent sections for Compression Reinforcement

Mild steel 12 16 20 22 25 28 32 36 40 50
(mm)
Deformed
Cold Twisted 10 14 2x12 18 20 22 2x18 2x20 32 40
Steel (mm)

SPACING OF REINFORCEMENT
a) Not less than
i) Diameter of bar
ii) 6 mm more than nominal maximum size of course aggregates.

b) Vertical distance between two horizontal reinforcement shall normally be 15 mm. maximum size of
course aggregate or maximum distance of bar whichever is greatest.

c) Pitch of main tensile reinforcement in Solid slab shall be not more than 3 x eff-depth of slab of
600 mm whichever is smaller.

d) Pitch of Distribution bars shall not be more than 35 x eft. depth of 60 mm. whichever is
smaller.

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COVER

a) At each end not less than 25 mm. nor less than twice the dia. of bar.

b) For longitudinal reinforcement in column not less than 40 mm. nor less than the dia of
the bar.

c) For longitudinal reinforcement in beam not less than 25 mm nor less than dia. of the bar.

d) For tensile, compressive, sheer reinforcement in slab not less than 13 mm. nor less than
dia. of bar.

SPLICING

Lapped splicing in the tension shall not be used for bars, larger than 36 mm. such splies shall
preferably welded . Lap length shall be minimum 45 x dia. for bar for hooked bars.

Advantages of ribbed for steel over plain round mild steel reinforcement :

1) Can be used without end books.

2) 65 % greated yield strength.

3) 100% greater bond strength.

4) 20 % more factor of safety due to hyper registance ( continous stress-strain curve)

5) Satisfactorily bondability and weldebility.

6) Net economy in cost of reinforcement upto 40% in tension and 30 in compression.

GALVANISED STEEL SHEETS (PLAIN SHEETS)

WEIGHT IN KILOGRAMS PER SQUARE METER OF SHEET
Description and Class of sheet Thickness of sheets in mm.
1.60 1.25 1.00 0.80 0.63

CLASS-1 (750 G. OF Z (SPELTER) 13.31 10.56 8.60 7.03 5.70

COATING/SaM. both sides
Inclusive)

CLASS-2 (600 G. OF Z (SPELTER) 13.16 10.41 8.55 6.88 5.55

COATING/SaM. both sides
Inclusive)

CLASS-3 (450 G. OF Z (SPELTER) 13.01 10.26 8.30 6.73 5.40

COATING/SaM. both sides
Inclusive)

CLASS-4 (375 G. OF Z (SPELTER) 12.94 10.19 8.22 6.66 5.32

COATING/SaM. both sides
Inclusive)

304 RED BOOK  VOLUME I  ROADS  2012

USEFUL NOTES ON CEMENT

1 ton of Portland cement = 20 bags.

1 cu. ft. of Portland cement weight 90.94 lbs. When lossely filled. Average weight of 1 :2:4 con-
crete, coke bricks aggregate 100 lbs, Per cU.ft; Clinker aggregate 100 lbs cU.ft. brick aggregate
125 lbs, Cu. ft. Ballast aggregate 145 lbs. Per cU.ft.

Average weight of 1 :2:4 reinforced concrete 150 lbs. Per cU.ft. 1 cU.ft. of loose Portland cement
paste will make about.

4.1 cu.ft. of concrete mixed 1 :2:4

5.1 cu.ft. of concrete mixed 1:2 112 : 5 5.8 CU.ft. of concrete mixed 1 :3:6
7.5 cu.ft. of concrete mixed 1 :4:8
1 cu.ft. of 1 loose Portland cement neat as cement paste will cover about 9.5 sq.ft. 1” thick.
1 cu.ft. of 1 loose Portland cement of 2 sand will cover 16.8 sq.ft. 1” thick.
1 cu.ft. of 1 loose Portland cement of 2 sand will cover about 29 sq.ft. 1” thick.
1 cu.ft. of 1 loose Portland cement of 3 sand will cover about 35.7 sq.ft. 1” thick.
1 cu.ft. of 1 loose Portland cement of 6 sand will lay about 410 bricks with 31.2 joint and 527
bricks with 1/4” joints.
Strength of ordinary Portland cement concrete at Various Ages.
Approxiate percentage of strength of ordinary at different ages is comparision with the strength
at 28 days.

7 days old 67%

28 month old 100%
3 month old 122%
6 month old 145%
12 month old 155%

MULTIPLYING FACTOR TO GET PLAIN AREAS FOR PAINTING DONE OVER

IRREGULAR SURFACES

WOOD WORK : DOORS, WINDOWS ETC.

1 . Panelled or framed and braced 1.5 (for each side)
2. ledged and battoned or ledge, battoned 1.5 (for each side)
3. Flush 1.25 (for each side)
4. Part paneled and part glazed or gauzed 1.0 (for each side)
5. Fully glazed or gauzed 0.5 (for each side)
6. Fully venetianed or louvered 1.5 (for each side)
7. Trellis or Jafri work 2 (for painting all over)

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 SECTION CD

STANDARD
SPECIFICATIONS
FOR
CROSS DRAINAGE WORKS

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2708.
CROSS DRAINAGE WORKS
Many of the items for Cross Drainage Works are the same as those for bridge Work. The
specifications of the items of Cross Drainage Works which are identical with those of the
corresponding bridge items may be referred directly to the bridge items as indicated in the
list below.
List of the items which are common to Cross Drainage works and Bridge Work

Serial Item of Cross Drainage Works Identical

No. Bridge Item
(1) (2) (3)
1 Constructing and maintaining temporary road diversion including BR.1
barricading the existing road, maintaining night watchmen, red
lights etc., as directed till the completion of the work.

2 Dismantling the existing structure including sorting out useful BR.2

materials and stacking them within the specified lead neatly
as directed and wasting the useless materials.

3 Excavation for foundation including shoring and strutting as BR.3

necessary and disposing off excavated stuff as directed in:
(a) Earth, soils of all types, sand, gravel,soft murum etc.
(b) hard murum.
(c) hard murum and boulders.
(d) soft rock.
(e) hard rock (blasted).
(f) hard rock (chiseled and wedged or line drilled).
(g) laterite

4 Dewatering including diversion of stream, providing cofferdams, BR.4

bunds, etc., as may be necessary for foundation and other
parts of the work and bailing out and pumping out water
during and after excavation as required.

5 Providing uncoursed rubble masonry in cement mortar 1:- for BR.6

foundations including striking joints and watering complete.

6 Providing coursed rubble masonry in cement mortar 1:- BR.23

for abutment, returns, wings, headwalls, etc., with khandki
facing and pointing with cement mortar 1:3 for all khandki faces
and rubble facing with struck joints for rubble backing including
scaffolding and watering masonry complete.

7 Providing coursed rubble masonry in cement mortar:- BR. .

for piers with khandki facing and pointing with cement mortar
1:3 on all sides including cut and easewaters, necessary
scaffolding and watering masonry complete.

8 Providing, cutting, bending, hooking, laying in position and BR.

tying mild steel bars for reinforcement for the reinforced cement
concrete work as shown on the detailed drawings.

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 2709.
Serial Item of Cross Drainage Works Identical
No. Bridge Item
(1) (2) (3)
9 Providing and fixing expansion joint as per drawing BR.32

10 Providing rubble filling over haunches and arches including BR.34

hand packing.

11 Providing vent holes in the slab and wearing course with iron BR.36
grill at the top and galvanised iron pipe at bottom as per drawing.

12 Providing RCC parapet with cement concrete with cast-in- BR.39(a)

situ/precast panels as per the detailed drawings including
reinforcement, scaffolding, form work, centering, compacting,
finishing and curing complete.

13 Providing railing of mild steel angle/I/tee posts and galvanised BR.39(b)

iron pipes as per the detailed drawings including scaffolding
and painting.

14 Providing railing of mild steel angle/I/tee posts and galvanised

iron pipes as per detailed drawings including scaffolding and
painting.

15 Providing railing of cast in situ R.C.C. posts with 1:2:4 BR.39(c)

cement concrete of trap/granite/quartizite/gness metal and

chains as per the detailed drawings including reinforcement
scaffolding, centering, formwork, compaction, finishing and
curing complete.

16 Providing collapsible railing with mild steel channel posts BR.39(d)

and removable galvanised iron pipes as per the detailed

drawings included scaffolding and painting.

17 Providing railing of cast in situ R.C.C. posts with 1:2:4 cement BR.39(e)
concrete and chains as per the detailed drawings including
reinforcement scaffolding, centering, formwork, compaction,
finishing and curing complete.

18 Providing collapsible railing with channel posts, flats, and BR.39(f)

angles as per the detailed drawings including scaffolding and
painting.

19 Providing galvanised iron 150mm. diameter water spouts as BR.41

per drawings.

20 Providing rubble filling behind the abutments, returns or wings BR.43

The specifications of the items of Cross Drainage Works which are not identical with those
of the corresponding Bridge items or those which are entirely different from the latter are
given hereinafter.

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2708.
List of items of Cross Drainage Works
Serial
No. Item
(1) (2)
1. Providing and laying in situ cement concrete of-
(a) 1 : 3 : 6
(b) 1 : 4 : 8
(c) 1 : 5 : 10
proportion in foundations including necessary formwork,
compacting and curing complete.
2. Providing paving rubble stone 15cm/ 23cm thick in 1:-
Cement mortar over a bedding of 15cm. thick cement concrete
of 1 : 4 : 8 proportion including striking joints and watering
complete.
3. Providing khandki paving of -cm. thickness in :-
Cement mortar over a bedding of 15cm. thick cement concrete
of 1 : 4 : 8 proportion including pointing with cement mortar 1 :
3 and watering complete.
4. Providing uncoursed rubble masonry in cement mortar 1 :-
For piers, abutments, wings, returns head walls parapets, etc.,
including striking joints of the non-exposed faces and pointing
the exposed faces with cement mortar 1 : 3
for exposed faces, scaffolding and watering masonry complete.
5. Providing and laying cement concrete pipe of I. S. NP2/NP3
class of-mm. diameter in proper line, level and slope including
providing, fixing collars in cement mortar 1 : 2 complete.
6. Providing and laying in situ cement concrete including
centering, form work, scaffolding, compacting, finishing and
curing complete in -
(a) R.C.C. Solid / deck slab.
(b) R.C.C. Main and Cross-girders arch ribs.
(c) R.C.C. and plain Arches.
(d) Other R.C.C. elements (excluding mild steel reinforcement).
7. Providing and laying in situ : : cement concrete of for
hunching filling including form work, compacting, curing and
scaffolding complete.
8. Providing hard murmur/selected earth filling including laying
in layers of 15 cm to 20 cm. watering and compacting complete.

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 2709.
Serial
No. Item
(1) (2)
9. Providing and laying in situ : : cement concrete including
compacting, finishing, curing and filling joints with bitumen
compete for :-
(a) Wearing course 8 cm thick
(b) Approach slab (excluding mild steel reinforcement)
10. Providing and fixing in 1:2 cement mortar marble year plate 30
cm x 20 cm in the parapet including cutting border line, figures
and letters and painting complete.
11. Providing and fixing in cement mortar 1 : 2 marble plate 30cm
x 20 cm showing the number of Cross Drainage work and the
direction of flow by arrow including cutting border line, figures,
letters and signs and painting complete.
12. Providing streamlined R.C.C. guard stones including 1:2:4
cement concrete and mild steel bar reinforcement.

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 2709.
CD.1. Providing and laying in situ cement concrete of-
(a) 1 : 3 : 6
(b) 1 : 4 : 8
(c) 1 : 5 : 10
proportion in foundation including necessary formwork, compacting and curing complete.
CD.1.1. General - The item refers to providing and laying cement concrete of the
proportion mentioned in the wording of the item in the foundations.
The specification No. BR.5 shall be applicable to this item with the following modifications:-
(i) The proportion shall be as specified in the wording of the item.
CD.2. Providing stone paving 15cm/23cm thick in 1:- Cement mortar over a bedding
of 15cm. thick cement concrete of 1 : 4 : 8 proportion including striking joints and
watering complete.
CD.2.1. General - The item provides for the rubble stone paving of the specified type of
stones and thickness over 15cm. thick bedding of cement concrete of 1 : 4 : 8 proportion,
after dewatering if necessary and including striking joints and watering. Mortar shall be
of specified proportions.
CD.2.2. Materials - Stones for paving shall conform to specification No. B.9.f.4. The
thickness of the paving shall be made up of one stone only allowing for the mortar
bedding of about 20 mm. Other dimensions of stones shall be more than the thickness.
The coarse aggregate for concrete bedding shall conform to specification No. B.5.2.4
and be broken or crushed from the best stone of specified type available in the region
and approved by the Engineer. The maximum size of the aggregate shall be of 40 mm
and the aggregate shall be well graded from 40 mm. to 5 mm.
CD.2.3. Dewatering - According to specification No. B.9.10.
CD.2.4. Construction -
CD.2.4.1. Concreting - If the bed is sandy or earthy it shall be watered if not originally
wet and the bed made even and compacted manually by rammers if necessary before
laying concrete.
 The 1:4:8 cement concrete shall conform to the relevant provisions of specification
No.B.6 for nominal mix cement concrete and laid evenly and well compacted manually
by rammers to give a finished depth of 15 cm.
The proportion of the cement concrete shall be one bag of 50 kg. of cement : 140 litres
of sand : 240 litres of coarse aggregate.
 The concrete may be mixed manually taking due precautions as specified in B.5.4
regarding increased cement content, etc. The water content may be decided for the
consistency suitable for the work and as directed by the Engineer.
The concrete shall be cured for 14 days or till the stone paving is laid on it whichever is
earlier. The surface of the concrete shall not be smoothened.
CD.2.4.2. Rubble paving - The paving stones shall be laid not earlier than 48 hours
after laying concrete. The stones for the paving shall be used after merely knocking out
weak corners and edges by a mason’s hammer.
The stones shall be wetted before they are laid.
 The paving shall be laid to the levels and shapes as indicated on the drawings or as
ordered by the Engineer in cement mortar of the proportions specified in the item.
The thickness of the paving shall be made up with one stone only.
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The stone shall be laid to have a plain surface level or sloped for the paving at top. The
stones shall be fully bedded on cement mortar which shall be prepared as specified in
B.5(a). Spalls shall be used to fill the voids. There shall be no pinnings at the top surface.
No hollows shall be left in the joints or bedding of the paving. The stones shall break
joints on the surface. The joints shall not exceed 20 mm. The masonry shall generally
conform to the relevant part of specification No. B.9.(f).
The surface joints shall be struck neatly while laying the stones and the paving shall be
watered for 14 days after setting.
CD.2.5. Item to include -
(1) Preparing bed of stream.
(2) Dewatering unless separately provided in the tender.
(3) 1:4:8 cement concrete bedding.
(4) Rubble stone paving laid in cement mortar to levels and shape shown on the drawings
or as ordered by the Engineer.
(5) Striking joints.
(6) Watering.
(7) All labour, materials and use of tools required for completing the item satisfactorily.
CD.2.6. Mode of measurement and payment - The contract rate, shall be for one
square metre of the finished rubble stone paving including the concrete bedding and
striking joints. The dimensions shall be measured correct upto a cm. and the area
worked out correct upto two places of decimals of a square metre.
CD.3. Providing khandki paving of cm. thickness in 1:- Cement mortar over a
bedding of 15 cm. thick cement concrete of 1:4:8 proportion including pointing with
cement mortar 1:3 and watering complete.
CD.3.1. General - The item provides for the khandki paving of specified type of stones
and thickness over 15 cm. thick bedding of cement concrete of 1:4:8 proportion after
dewatering if necessary and including pointing with cement mortar 1:3 and watering.
CD.3.2. Materials - As per B.9.2.
The khandkies shall be dressed to rectangular face with straight edges. The four sides
shall be in one plane. Bushings shall not be more than 2 cm. The sides of khandki shall
be dressed square for at least 4 cm. from the face and further taper shall not be steeper
than 1 in 5.
 All khandkies shall be more in length than the width on face and shall have tailing of
the full specified depth of the pavement. All khandkies shall be of the same width. The
width shall be as shown on the drawings or as ordered by the Engineer according to the
availability of stones but not more than 30 cm. and not less than 15 cm.
The coarse aggregate for concrete bedding shall conform to specification No. B.5.2.4.
and be broken or crushed from the best stone of specified type available in the region
and approved by the Engineer. The maximum size of the aggregate shall be 40 mm. and
the aggregate shall be well graded from 40 mm. to 5 mm.
CD.3.3. Dewatering - According to specification No. B.9.10.
CD.3.4. Construction -
CD.3.4.1. Concreting - According to specification No. CD.1.
CD.3.4.2. Khandki paving - The khandki paving shall be laid not earlier than 48 hours
after laying concrete.

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 CD.5.
 The khandkies shall be wetted immediately before use. The paving shall be laid to
levels, slopes and shapes as indicated on the drawings or as ordered by the Engineer.
The khandkies shall be laid on a bedding of cement mortar so as to embed the bottom
completely in the mortar. Chips and spalls shall be inserted in the mortar joints and beds
wherever necessary. The khandkies shall be laid in strips, rows of khandkies being laid
lengthwise or diagonally as directed by the Engineer.
 The cement mortar shall comply with the specification No. B.5.(a) and shall be of the
proportion mentioned in the item.
No hollows shall be left in the bedding or joints of the paving. The joints at right angles
to the strips (joints formed by the width sides) shall break joints with similar joints in the
adjacent strips.
The joints shall not exceed 12 mm.
The joints shall be pointed with cement mortar 1:3 as specified in B.13 and the paving
shall be watered for 14 days thereafter.
CD.3.5. Item to include -
(1) Preparing bed.
(2) Dewatering unless separately provided in the tender.
(3) 1:4:8 cement concrete bedding.
(4) Khandki paving laid in cement mortar to levels, shape and pattern as shown in the
drawings or as ordered by the Engineer.
(5) Pointing with cement mortar 1:3.
(6) Watering.
(7) All labour, materials and use of tools, etc., required for completing the item
satisfactorily.
CD.3.6. Mode of measurement and payment - The contract rate shall be for one
square metre of the finished paving including the concrete bedding and pointing. The
dimensions shall be measured correct upto a cm. and the area worked correct upto two
places of decimals of a square metre.
CD.4. Providing uncoarsed rubble masonry in cement mortar 1:- For piers,
abutments, wings, returns, headwalls, parapets including striking joints of the non-
exposed faces and pointing the exposed faces with cement mortar 1:3. scaffolding
and watering masonry complete.
CD.4.1. General - The item provides for the uncoarsed rubble stone masonry with
specified type of stones and mortar for the piers, abutments, wings, returns, headwalls,
parapets, etc., including striking joints of the non exposed faces and pointing with cement
mortar 1:3 the exposed faces dewatering, scaffolding and watering with masonry.
The item shall comply with specification No. BR.6 in all respects and further -
(i) the rate of the item shall include pointing with cement mortar 1:3 to the exposed
faces and upto 30 cm. below scour level. This shall comply with the specification No.
B.13, and
(ii) no filling shall be done against the masonry till the mortar has set and permission
given by the Engineer.
CD.5. Providing and laying cement concrete pipe of I.S. NP2/NP3 class of - mm.
diameter in proper line, level and slope including providing and fixing collars in
cement mortar 1:2 complete.

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CD.5.1.
CD.5.1. General - The item provides for the supply and fixing of the spun concrete pipes
of the specified class and diameter in position for the Cross Drainage works including
necessary collars, conveyance and fixing in cement mortar 1:2.
CD.5.2. Materials - Concrete pipes shall be of the class and diameter mentioned in the
item and shall comply with I.S.458.
The collars shall be of the appropriate size for fixing of the concrete pipes specified on
the drawings and shall comply with I.S.458.
 The cement mortar shall comply with the specification No. B.4 proportion of cement
and sand being 1:2.
CD.5.3. Fixing - The handling and laying of the concrete pipes shall comply with I.S. 783
code of practice of laying concrete pipes. para. 9.2. The joints shall comply with para.
10.2.3 and bedding with para. 4.3.3 of the same I.S.
The pipes shall be laid to the lines and levels shown on the drawings and the slope shall
be 1 in 100 towards the down stream unless other slopes are specified on the drawing or
as ordered by the Engineer.
The ends of the pipes shall be flush with face of masonry or bell mouthed if so indicated
on the drawings or ordered by the Engineer. Pipes of non-standard length may be
used when standard length pipes do not fit in between the faces of walls. Otherwise
extra lengths of standard pipes may be left projecting beyond face of masonry on the
downstream. Such extra length will not be paid for.
 Diversions of the road if found necessary, shall be provided according to BR.1 at the
cost of the contractor unless separately provided in the tender.
The collar joints be cured satisfactorily. Till then the filling around shall not be done.
CD.5.4. Item to include -
(1) Supply, conveyance and fixing of the spun concrete pipes including collars, fixing in
cement mortar 1:2 to the line, levels and slope.
(2) All labour materials, use of equipment and tools for completing the item satisfactorily.
CD.5.5. Mode of measurement and payment - The contract rate shall be for providing
one metre of the spun concrete pipe, joined and fixed in position. The measurement
shall be for the length of pipes provided and fixed with collars from the outside of one
face wall to the outside of the other face wall, limiting the length to that specified in the
plan, or ordered by the Engineer.
The length shall be measured correct upto a centimeter. The rate shall be inclusive of
all the projecting lengths, if any, projections being ignored in the measurements.
CD.6. Providing and laying in situ cement concrete including centering, form work,
scaffolding, compacting, finishing and curing complete in -
(a) R.C.C. Solid / deck slab.
(b) R.C.C. Main and Cross-girders arch ribs.
(c) R.C.C. and plain Arches.
(d) Other R.C.C. elements (excluding mild steel reinforcement).
CD.6.1. General - The item provides for the specified type of cement concrete in slabs,
girders, arches and in other elements. It shall comply with the relevant provisions of the
specification Nos. BR. 31.
CD.6.2. Forms - In case of nominal mix concrete, centerings and the forms for small
spans the may be of well compacted earth-filling or stone and mud if found suitable and

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 CD
permitted by Engineer. The top surface of such centering shall be plastered to regular
shape with lime mortar or lean cement mortar. Side forms may be of wood or steel. In
other cases, it shall be as in specification No. B.6/B.7.
CD.6.3. Mixing - For nominal mix cement concrete, mixing may be done manually
with 5 percent, additional cement unless mechanical mixing is specified in the special
provisions. Cement concrete of more than 15 cu.m. in any one job shall be mixed in a
mechanical mixer unless manual mixing is permitted by the Engineer in writing. For the
design mix concrete the mixing shall be done in a mechanical mixer only.
CD.6.4. Compaction - For nominal mix cement concrete involving 15 cu.m. or less in
any one job, compacting may be done manually by rammers and rods when concrete
shall be laid in layers of 15 cm. only unless vibration is specified in the special provisions.
Cement concrete of more than 15 cu.m. in any one job shall be compacted with vibrator
only unless manual compaction with rammers and rods is permitted by the Engineer in
writing. For the design mix cement concrete, compaction shall be done by mechanical
vibrators only.
CD.6.5. Tests - For the nominal mix cement concrete if so permitted by the Engineer,
tests may not be carried out for the compressive strength when quantity of concrete
involved is 15 cu.m. or less.
CD.7.Providing and laying in situ cement concrete of for haunching filling including
form work, compacting, curing and scaffolding complete.
The item shall comply with specification No. BR 33 except that the compaction may be
done manually by reamers and rods.
CD 8. Providing hard murum/selected earth filling including laying in layers of 15
cm to 20 cm. watering and compacting complete.
CD.8.1. Materials - Hard murum shall conform to specification No. Rd. and shall be
supplied at the site of the Cross-Drainage Work.
 Selected earth shall be free from black soil, shadoo, humus and too much of clay.
Granular material shall be preferred.
CD 8.2 Laying - The material shall be conveyed to the site of deposition and laid
in uniform horizontal layers of 15 cm to 20 cm each layer shall be watered and fully
compacted manually before the next layer is laid.
 In the case of filling over arches , each layer shall be laid horizontally to the same
thickness and level simultaneously on both sides, watered and fully compacted manually.
CD 8.3 Item to include -
(1) Supplying hard murum/selected earth, laying it in layers, watering and compacting.
(2) All labour, materials, scaffolding and use of tools and plant necessary to complete
the item satisfactorily.
CD 8.4 Mode of measurement and payment - The contract rate shall be for one cubic
metre of filling laid and compacted. The dimensions shall be measured correct upto a
centimeter in situ and the quantity calculated correct to two places of decimals of a cubic
metre. 10 per cent deduction shall be made in the quantity if measurements are taken
before one monsoon has passed and 5 per cent if taken after one or more monsoons
have passed.
CD 9. Providing and laying in situ : cement concrete including compacting,
finishing, curing and filling joints with bitumen compete for :-
(a) wearing course 8 cm thick

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(b) approach slab (excluding mild steel reinforcement)
 The item shall comply with the specification Nos.BR.35 and respectively except that
the compaction may be done manually with screed board tamper & the concrete shall
be as per B.5.
CD.10. Providing and fixing in 1:2 cement mortar marble year plate 30 cm x 20 cm in
the parapet including cutting border line, figures and letters and painting complete.
The item shall comply with the specification No. in all respects except that the contract
rate shall be per plate and the measurement shall be recorded in numbers.
CD.11. Providing and fixing in cement mortar 1 : 2 marble plate 30 cm x 20 cm
showing the number of Cross Drainage work and the direction of flow by arrow
including cutting border line, figures, letters and signs and painting complete.
The item shall comply with the specification No. BR.42 in all respects except that the
contract rate shall be per plate and the measurement shall be recorded in numbers. There
shall be no border of marble or mortar.
CD.12. Providing streamlined R.C.C. guard stones including 1:2:4 cement concrete
and mild steel bar reinforcement.
CD.12.1 General - The item provides for the R.C.C. streamlined guard stones over
submersible bridge or cause ways including 1 : 2: 4 cement concrete and the mild steel
bar reinforcement.
CD.12.2 Materials -
(i)1:2:4 cement concrete shall conform to specification No. B.5. Maximum size of coarse
aggregate shall be 20 mm.
(ii) Mild steel bar reinforcement shall conform to the specification No. B.10.
CD.12.3 Construction - The reinforcement shall be fabricated and embedded as
indicated on the drawing and guard stone shall be cast to the shape and size as indicated
on the drawings in suitable forms approved by the Engineer. The forms shall be removed
after 48 hours and the concrete surface immediately finished with 1:2 cement mortar if
necessary. The guard stone shall be cured for 14 days. It shall be whitewashed in 3
coats.
CD 12.4 Item to include -
(i) Mild steel bar reinforcement.
(ii) Providing and laying 1:2:4 cement concrete in situ in suitable forms, finishing and
curing.
(iii) Whitewashing in three coats.
CD.12.5 Mode of measurement and payment - The contract rate shall be for one
number of guard stone. The measurement shall be for the number of guard stones
provided. No separate payment shall be made for the reinforcement.

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 CD.12.5

2900
PIPE CULVERTS

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 CD.12.5
2901. SCOPE
This work shall consist of furnishing and installing reinforced cement concrete pipes, of the
type, diameter and length required at the locations shown on the drawings or as ordered by
the Engineer and in accordance with the requirements of these Specifications.

2902. MATERIALS
All materials used in the construction of pipe culverts shall conform to the requirements of
Section 1000.
Each consignment of cement concrete pipes shall be inspected, tested, if necessary, and
approved by the Engineer either at the place of manufacture or at the site before their
incorporation in the works.

2903. EXCAVATION FOR PIPE

The foundation bed for pipe culverts shall be excavated true to the lines and grades shown
on the drawings or as directed by the Engineer. The pipes shall be placed in shallow
excavation of the natural ground or in open trenches cut in existing embankments; taken
down to levels as shown on the drawings. In case of high embankments where the height
of fill is more than three times the external diameter of the pipe, the embankment shall first
be built to an elevation above the top of the pipe equal to the external diameter of the pipe,
and to width on each side of the pipe of not less than five times the diameter of pipe, after
which a trench shall be excavated - and the pipe shall be laid.
Where trenching is involved, its width on either side of the pipe shall be a minimum of 150
mm or one-fourth of the diameter of the pipe whichever is more and shall not be more than
one-third the diameter of the pipe. The sides of the trench shall be as nearly vertical as
possible.
The pipe shall be placed where the ground for the foundation is reasonably firm. Installation
of pipes under existing bridges or culverts Shall be avoided as far as possible. When during
excavation the material encountered is soft, spongy or other unstable soil, and unless other
special construction methods are called for on the drawings or in special Provisions, such
unsuitable material shall be removed to such depth, width and length as directed by the
Engineer. The excavation shall then be backfilled with approved granular material which
shall be properly shaped and thoroughly compacted upto the specified level.
Where bed-rock or boulder strata are encountered, excavation shall be taken down to
atleast 200 mm below the bottom level of the pipe with prior permission of the Engineer
and all rock/boulders in this area be removed and the space filled with approved earth, free
from stone or fragmented material, shaped to the requirements and thoroughly compacted
to provide adequate support for the pipe.
Trenches shall be kept free from water until the pipes are installed and the joints have
hardened.

2904. BEDDING FOR PIPE

The bedding surface shall provide a firm foundation of uniform density throughout the
length of the culvert, shall conform to the specified levels and grade, and shall be of one of
the following two types as specified on the drawings:
(i) First Class bedding: Under first class bedding, the pipe shall be evenly bedded on a
continuous layer of well compacted approved granular material, shaped concentrically
to fit the lower part of the pipe exterior for atleast ten per cent of its overall height or
as otherwise shown on the drawings. The bedding material shall be well graded sand
or another granular material passing 5.6 mm sieve suitably compacted/rammed. The

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CD
compacted thickness of the bedding layer shall be as shown on the drawings and in
no case shall it be less than 75 mm.
(ii) Concrete cradle bedding: When indicated on the drawings or directed by the Engineer,
the pipe shall be bedded in a cradle constructed of concrete having a mix not leaner
than M 15 conforming to Section 1700. The shape and dimensions of the cradle shall
be as indicated on the drawings. The pipes shall be laid on the concrete bedding
before the concrete has set.

2905. LAYING OF PIPE

No pipe shall be laid in position until the foundation has been approved by the Engineer.
Where two or more pipes are to be laid adjacent to each other, they shall be separated by
a distance equal to at least half the diameter of the pipe subject to a minimum of 450 mm.
The arrangement for lifting, loading and unloading concrete pipes from factory/yard and at
site shall be such that the pipes do not suffer any undue structural strain, any damage due
to fall or impact. The arrangement may be got approved by the Engineer.
Similarly, the arrangement for lowering the pipe in the bed shall be got approved by the
Engineer. It may be with tripod-pulley arrangement or simply by manual labour in a manner
that the pipe is placed in the proper position without damage.
The laying of pipes on the prepared foundation shall start from the outlet and proceed
towards the inlet and be completed to the specified lines and grades. In case of use of
pipes with bell-mouth, the belled end shall face upstream. The pipes shall be fitted and
matched so that when laid in work, they form a culvert with a smooth uniform invert.
Any pipe found defective or damaged during laying shall be removed at the cost of the
Contractor.

2906. JOINTING
The pipes shall be jointed either by collar joint or by flush joint. In the former case, the
collars shall be of RCC 150 to 200 mm wide and having the same strength as the pipes to
be jointed. Caulking space shall be between 13 and 20 mm according to the diameter of
the pipe. Caulking material shall he slightly wet mix of cement and sand in the ratio of 1:2
rammed with caulking irons. Before caulking, the collar shall be so placed that its centre
coincides with the joint and an even annular space is left between the collar and the pipe.
Flush joint may be internal flush joint or external flush joint. In either case, the ends of the
pipes shall be specially shaped to form a self centering joint with a jointing space 13 mm
wide. The jointing space shall be filled with cement mortar, 1 cement to 2 sand, mixed
sufficiently dry to remain in position when forced with a trowel or rammer. Care shall be
taken to fill all voids and excess mortar shall be removed. For jointing pipelines under
light hydraulic pressure, the recess at the end of the pipe shall be filled with jute braiding
dipped in hot bitumen or other suitable approved compound. Pipes shall be so jointed that
the bitumen ring of one pipe shall set into the recess of the next pipe. The ring shall be
thoroughly compressed by jacking or by any other suitable method.
All joints shall be made with care so that their interior surface is smooth and consistent with
the interior surface of the pipes. After finishing, the joint shall be kept covered and damp for
at least four days.

2907. BACKFILLING
Trenches shall be backfilled immediately after the pipes have been laid I and the jointing
material has hardened. The backfill soil shall be clean, free from boulders, large roots,
excessive amounts- of sods or other vegetable - • matter, and lumps and shall be approved

326 RED BOOK  VOLUME I  ROADS  2012

 CD.12.5
by the Engineer. Backfilling upto Q 300 mm above the top of the pipe shall be carefully
done and the soil thoroughly rammed, tamped or vibrated in layers not exceeding 150 mm,
Particular care being taken to thoroughly consolidate the materials under the haunches of
the pipe. Approved pneumatic or light mechanical tamping equipment can be used.
Filling of the trench shall be carried out simultaneously on both sides of the pipe in such a
manner that unequal pressures do not occur.
In case of high embankment, after filling the trench upto the top of the pipe in the above
said manner, a loose fill of a depth equal to external diameter of the pipe shall be placed
over the pipe before further layers are added and compacted.

2908. HEADWALLS AND OTHER ANCILLARY WORKS

Headwalls, wing walls, aprons and other ancillary works shall be constructed in accordance
with the details shown on the drawings or as directed by the Engineer. Masonry for the
walls shall •confo1m to Section 1300, 1400 or 1700 as applicable. Aprons shall conform to
Section 2500.

2909. OPENING TO TRAFFIC

No traffic shall be permitted to cross the pipe line unless height of filing above the top of the
pipe line is atleast 600 mm.

2910. MEASUREMENTS FOR PAYMENT

R.C.C. pipe culverts shall be measured along their centre between the inlet and outlet ends
in linear metres.
Selected granular material and cement concrete for pipe bedding shall be measured as
laid in cubic metres. Ancillary works like headwalls, etc., shall be measured as provided for
under the respective Sections.

2911. RATE
The Contract unit rate for the pipes shall include the cost of pipes including loading,
unloading, hauling, handling, storing, laying in position and jointing complete and all
incidental costs to complete the work as per these Specifications. .
Ancillary works such as excavation including backfilling, concrete and masonry shall be
paid for separately, as provided under the respective Clauses.

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3000
MAINTENANCE
OF ROADS

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330 RED BOOK  VOLUME I  ROADS  2012

 3003.1.
3001. GENERAL
The Specifications shall apply to all items of road maintenance works as required to be
carried out under the Contract or as directed by the Engineer. The works shall be carried
out in conformity with the relevant Specifications to the required level, grade and lines using
approved materials. The works shall be carried out using light duty machinery or manual
means provided the quality of the end product does not suffer. In execution of maintenance
works, a reference is made to the IRC publications: "Manual for Maintenance of Roads"
and "Code of Practice for Maintenance for Bituminous Surfaces of Highways, IRC 82-l982"
for guidance and compliance wherever applicable. Wherever the Specification is not clear,
good engineering practice shall be adopted in the construction to the satisfaction of the
Engineer.

3002. RESTORATION OF RAIN CUTS

3002.1. Scope
The work shall consist of earthwork for restoration of rain Cuts in the embankment and
shoulders, using suitable material, and compacting the same.
3002.2. Materials
The material used for restoration of rain cuts shall consist of soil conforming to Clause
305.2.
3002.3. Construction Operation
The area affected by rain cuts shall be cleared of all loose soil and benched. The width of
the benches shall be at least 300 mm and they shall extend continuously for a sufficient
length. The height of the benches shall be in the range of 150-300 mm.
Fresh material shall be deposited in layers not exceeding 250 mm loose thickness and
compacted so as to match with the benching at moisture content close to the optimum.
Compaction shall be carried out using suitable equipment such as plate compactors and
rammers or by suitable implements - handled manually. The finished work shall conform to
alignment, levels and slopes as indicated in the drawing.
3002.4. M
 easurements for Payment The earthwork for restoration of rain cuts shall be
measured in cubic metres.
3002.5.
Rate The Contract rate for the item of earthwork for restoration of rain cuts shall be payment
in full for carrying out the required operation including full compensation for:
(i) Supply of material including all leads and lifts and the cost of arrangement of land;
(ii) Setting out;
(iii) Removal of loose material from the rain cuts;
(iv) Benching of old earthwork; and
(v) Compacting after adding required quantity of water.

3003. MAINTENANCE OF EARTHEN SHOULDER

3003.1. Scope
The work of maintenance of earthen shoulder shall include making up the irregularities/loss
of material on shoulder to the design level by adding fresh approved soil and compacting
it with appropriate equipments or to strip excess soil from the shoulder surface as per the
requirement of this Specification.

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3003.2.
3003.2. Material
The material to be added to the shoulder, if required, shall be a select soil conforming to
Clause 305.
3003.3. Construction Procedure
This work shall involve:
(i) Making up of the earthen shoulder by adding extra soil and compacting the same; and
(ii) Stripping a layer of soil to achieve the required grade and level.
Wherever extra earth is required to be added, the earthen shoulder shall be stripped and
loosened to receive fresh soil. The deficiency of thickness shall be made up in layers of loose
thickness not exceeding 250 mm. Water shall be added, if required, to attain the optimum
amount and the layer compacted by 80 to 100kN smooth wheel roller, vibratory roller, hand
roller, plate vibrator or hand rammer to obtain atleast 94 per cent of the maximum dry
density in accordance with IS : 2720 (Part 8). The finished surface shall have the specified
cross slope and line in accordance with the drawing. The side slopes shall be trimmed to
the required slope with the help of grader or manual methods using hand tools.
Wherever the earth is required to be excavated from the shoulder, this shall be done either
using equipment like grader or by manual means using hand tools. The resulting surface
shall be uniform and have a field density of atleast 94 per cent of maximum density obtained
in accordance with IS:2720 (Part 8). If the surface is not uniformly compacted, it shall be
excavated to a depth of 150 mm and the soil mixed with water if required and compacted
at a moisture content close to the optimum to achieve 94 {per cent of maximum density as
stated above.
3003.4. Measurements for Payment
Maintenance of earthen shoulder shall be measured in sq. metres.
3003. 5. Rate
The Contract unit rate for maintenance of earthen shoulder shall be payment in full
compensation for:
(i) furnishing earth required for making up of shoulders including all leads and lifts, cost
of land and compaction;
(ii) excavation of earth as required and disposal of the earth at the location approved;
and
(iii) all tools, equipments and incidentals to complete the work in accordance with the
above Specification.

3004. BITUMINOUS WORK IN CONNECTION WITH

MAINTENANCE AND REPAIRS
3004.1. General
The scope and type of maintenance to be carried out shall be in accordance with the
provisions of the Contract or as instructed by the Engineer.
In all instances It will have been necessary to identify the causes of defects in order to
permit effective repair. Where investigation work into the causes of defects is included in
the Contract it shall be carried out in accordance with the appropriate provisions of this
Specification.
Maintenance treatments required under the Contract or instructed by Engineer may include
pothole and patch repair, crack-sealing, fog spray, dusting, slimy sealing, surface dressing,

332 RED BOOK  VOLUME I  ROADS  2012

 3004.2.4.
overlays and specialist repairs.
When the pavement to be maintained is intended to carry volumes of traffic in excess of
1 .5 million e.s.a. the constructed materials (particularly patching and overlay materials)
used in maintenance operations shall be of a Standard not less than those specified for the
original construction.
Traffic control during maintenance operations shall conform to the requirements of the
Contract documents.
3004.2. Filling Pot-holes and Patch Repairs
3004.2.1. Scope: This work shall include repair of pot-holes and patching of all types
of bituminous pavement.
The work shall include the removal of all failed material, in the pavement courses and,
if necessary, below the pavement, until the root cause of the failure is removed; the
trimming of the completed excavation to provide firm vertical faces; the replacement
of material of at least as high a standard as that which was originally specified for the
pavement layer; the painting of tack coat on to the sides and bases of excavations prior
to placing of any bituminous materials and the compaction, trimming and finishing of the
surfaces of all patches to form a smooth continuous surface, level with the surrounding
road.
3004.2.2. Materials: A
 ll materials used for the pot-hole and patch repair of bituminous
surface and underlying layers shall be in accordance with this Specification and shall be.
of the same type as specified for the original construction. A mix superior to the one on
the existing surface may also be used for repair work. An emulsified bitumen/modified
bitumen mix compatible with the existing layer shall also be considered appropriate.
 The bituminous mixture used for such patch repairs shall be in accordance with the
appropriate Clause of these Specifications. Materials to be used for patching shall always
be of the same type and standard of construction as, or better than, the material being
patched at the same level of construction. Materials used for patching shall never be of
lesser bearing capacity nor of a greater porosity than the adjacent previous construction.
Non-bituminous material must not be used for patching bituminous materials. Where
modified binder is to be used, Clause 521 of these Specifications shall apply.
The grading of aggregates and bitumen content of the mix used for such patch repair
shall be in accordance with Clause 501. 

3004.2.3.Preparation of the area for pot-hole and patch repair: Each pot-hole and
patch repair area shall be inspected and all loose material removed. The area shall be
cut/trimmed either with jack hammers or with hand tools suitable for the purpose, such
that the defective material `responsible for the failure is all removed and such that the
excavation is of a regular shape.
The edges of the excavation shall be cut vertically. The area shall be thoroughly cleaned
with compressed air or any appropriate method approved by the Engineer to remove
all dust and loose particles. Layers below the level of the bituminous construction shall
be replaced using material of the equivalent specification to the original construction,
which shall particularly include the specified standards of compaction. The area for
bituminous construction shall be tacked or primed with cutback or emulsion depending
upon whether the lower area is bituminous or granular in nature. The sides, however,
are to be painted with hot tack coat material. The prime coat and tack coat shall conform
to Clauses 502 and 503 of these Specifications, respectively.
3004.2.4. Backfilling operation: The mixture to be used in bituminous patching shall
be either a hot mix or a cold mix in accordance with the appropriate Clauses of these
RED BOOK  VOLUME I  ROADS  2012 333
3004.2.4.
Specifications. Mixing shall be done in a plant of suitable capacity. The bituminous
mixture shall be placed in layers of thickness not more than 100 mm (loose) and shall be
compacted in layers with roller/plate compactor/hand roller/rammer to the compaction
standards defined in the appropriate Clauses of these Specifications. While placing the
final layer, the mix shall be spread slightly proud of the surface so that after rolling, the
surface shall be flush with the adjoining surface. If the area is large, the spreading and
levelling shall be done using hand - shovels and wooden straight edges. During the
process of compaction, the surface levels shall be checked using a 3m straight edge.
3004.2.5. Measurement for payment: Filling of pot-holes and patch repair shall be
measured in sq.m. 3004.2.6. Rate : The contract unit rate for filling of pot-holes and
patch repair shall be payment in full for:
(i) furnishing all materials required;
(ii) all works involved including excavation, trimming, back filling with any non-bituminous
layers required, tacking, priming with cutback or emulsion, and back filling with
bituminous materials;
(iii) all labour, tools, equipment and incidentals to complete the work in accordance with
the Specifications.
3004.3. Crack Sealing
3004.3.1. Scope: C  rack sealing shall consist of one or more of the following operations as
instructed under the Contract:
(i) fog seal
(ii) filling cracks with a binder, or a combination of crusher dust and a binder
(iii) by treating the crack sealing as a patch repair.
3004.3.2. Fog seal
3004.3.2.1. Scope: F og seal for use in maintenance work shall conform to the
requirements of Clause 518 of these Specifications, and shall consist of an application
of emulsified bitumen, without any aggregate cover for sealing fine hair-cracks or for
rejuvenating oxidised bituminous surfaces. Areas having cracks with less than 3mm
width shall be considered for this treatment, unless otherwise instructed by the Engineer.
3004.3.2.2. Material : Bituminous emulsion for Fog Seal shall be of a slow setting type.
Where modified binder is to be used, Clause 521 of these Specifications shall apply.
3004.3.2.3. Application : The area to be treated with fog seal shall be thoroughly cleaned
using compressed air, scrubbers, etc. The cracks shall be cleaned with a compressed
air jet to remove all dirt, dust, etc. The fog seal shall be applied at the rate of 0.5-1.0 litre/
sq.m. of emulsion, or as otherwise instructed by the Engineer, using equipment, such
as, a pressure tank, flexible hose and spraying bar or lance. Traffic shall be allowed on
to the surface only after the seal has set to a non-tacky and firm condition so that it is
not picked up by the traffic.
3004.3.2.4. Measurement for payment: T  he fog seal work shall be measured in sq.
metres, calculated from the dimensions of work instructed in the Contract or by the
Engineer.
3004.3.2.5. Rate : The contract unit rate for application of fog seal shall be payment in
full for:
(i) supplying of fog seal material and all the operations for applying it; and
(ii) all the labour, tools, equipment and incidentals to complete the work in accordance
with this Specification.
334 RED BOOK  VOLUME I  ROADS  2012
 3004.5.
3004.3.3. Crack filling
3004.3.3.1. Scope: C
 rack filling shall be carried out using a binder of a suitable viscosity,
normally a slow—curing bitumen emulsion, as instructed by the Engineer. For wider
cracks, in excess of an average of 3 mm in width the application of emulsion may be
preceded by an application of crusher dust, or other fine material acceptable to the
Engineer.
3004.3.3.2. Materials: Bitumen for use in crack sealing shall be of a slow curing type as
instructed by the Engineer. Dust for crack sealing, when used, shall be crusher dust or
some other suitable fine material approved by the Engineer, passing the 4.75 mm sieve
but with a maximum of 10 per cent passing the 0.075 mm sieve.
3004.3.3.3. Construction: if dust is to be used it shall be placed in the cracks before
the application of binder and the cracks filled to a level approximately 5 mm below road
surface level. The surface of the road shall be swept clear of dust prior to the application
of binder- Binder shall be poured into the cracks, taking care to minimise spillage. lf
spillage onto the road surface does occur, dust shall be applied to the excess bitumen
until it is blotted up.
3004.3.3.4. Measurement: Crack sealing shall be paid by the linear metre of crack as
instructed by the Engineer.
3004.3.3.5. Payment: The contract rate for crack sealing shall be payment in full for:
(i) supplying all necessary materials and for the work of applying them;
(ii) all labour, tools, equipment and all incidentals necessary to complete the work
according to these Specifications. 3004.3.4. Crack prevention courses: Clause
522 specifies crack prevention courses. These may be included in substantial
maintenance treatments.
3004. 4. Dusting
3004.4.1. Scope: Dusting shall consist of the application of crusher dust or other fine graded
material approved by the Engineer to areas of road where bleeding of excess bitumen is
occurring.
3004.4.2. Material:  Dust shall consist of crusher dust or other graded fine material
acceptable to the Engineer, and shall generally be finer than 3.0 mm with not more than
l0 per cent passing the 0.075 mm sieve.
3004.4.3. Dust shall be spread by manual application, to the areas of mad defined by
the Engineer. Dust shall generally be applied during the hottest part of the day and, when
so instructed by the Engineer, surplus dust displaced by passing traffic shall be manually
swept back onto the area where further bleeding of excess bitumen is apparent. Dust shall
be applied at a nominal rate of 2.5 kg per square metre.
3004.4.4. Measurement:  Dusting shall be paid for by the square metre of road surface
instructed to be dusted by the Engineer.
3004.4.5. Payment: The Contract unit rate for dusting shall be in payment in hill for:
(i) supplying all necessary materials and for the work of applying them;
(ii) all labour, tools, equipment and all incidentals necessary to complete the work
according to the Specifications.
3004.5. Slurry Seal
Slurry seal for use in maintenance work shall conform to the requirements of Clause 516.
Manual methods of spreading and levelling may be used, subject to the prior agreement of

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3004.6.
the Engineer.
3004.6. Surface Dressing for Maintenance Work.
Surface dressing for maintenance applications shall be carried out in conformity with the
requirements of Clause 510, except that the use of small and portable equipment shall be
permitted provided that it can be demonstrated, to the satisfaction of the Engineer, that it
can produce work consistently in accordance with the requirements of these Specifications.
3004.7. Specialist Repairs
3004.7.1. Specialist repairs include repairs of localized areas of damage to materials
for which repairs using normal hot-mix or cold-mix patching materials are inappropriate.
Such specialist repairs will include repairs to mastic asphalt and stone mastic asphalt.
3004.7.2. In such cases, pot-hole and patch repairs shall be carried out in accordance
with the provisions of Clause 3004.2 above, except that the construction to the mastic
asphalt, stone mastic asphalt or other specialist material layer shall, subject to the
instructions of the Engineer, be carried out in accordance with the provisions of the
appropriate Clause of these Specifications.
3005. MAINTENANCE OF CEMENT CONCRETE ROAD
3005.1. Repair of Joint Grooves with Epoxy Mortar or Epoxy Concrete
3005.1.1 Scope : The work shall consist of repair of spalled joint grooves of contraction
joints, longitudinal joints and expansion joints in a concrete pavement using epoxy
mortar or epoxy concrete.
3005.1.2. Materials : The type/grade of epoxy compatible with the coefficient of thermal
expansion of concrete shall be used with either processed line aggregate or fine stone
chips to produce a dry mix for repairing spalled or damaged edges.
3005.1.3. Repairing Procedure: Spalled or broken edges shall be shaped neatly with
a vertical cut with chisels into the shape of rectangle. Small pneumatic chisels also may
be used, provided the cutting depth can be controlled. The depth of the cut shall be the
minimum to effect repair. After shaping the spalled area, it shall be cleaned and primed.
The epoxy mortar/concrete is then applied using hand tools like trowels, straight edges,
brushes etc. The repaired edge shall be in line with the joint groove and shall be flush
with the concrete slabs. During the repair work, any damage noticed to the joint sealant
shall he made good by raking out the affected portion and resealing.
3005.1.4. Traffic:  Although the epoxy mixes set in 2-3 hours time, it is desirable to
divert the traffic for 12 hours or as per the recommendation of the manufacturers.
3005.1.5. Measurements for payment: Repair of joint grooves shall be measured in
linear metres. 3005.1.6. Rate: The Contract unit rate for repair of joint grooves with _
epoxy mortar or epoxy concrete shall be in full compensation for:
(i) supply and application of epoxy primer, epoxy mortar or epoxy ` concrete;
(ii) all tools, equipment and incidentals to complete the work in accordance with the
above Specification.
3005.2. Repair Involving Removal of Old Joint Sealant and Sealing with Fresh Sealant
in Cement Concrete Pavements
3005.2.1. Scope: The repair of sealant of contraction, longitudinal or expansion joints
shall include removal of the existing sealant-and resealing the joint with fresh sealant
material.
3005.2.2. Material: Sealant material to be replaced shall be either hot poured

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 CD.12.5
rubberised bitumen or polysulphide type of sealant as per Clause - 602.2.8. As per the
recommendation of the manufacturer, appropriate type of primer also shall be applied.
3005.2.3. Repairing procedure: The existing sealant shall be raked out with the help of
a metal raker such that most of the sealant is removed. Subsequently, the sealant stuck
to the sides of the grooves shall be removed thoroughly either by using saw cutting
machine so that grooves may be widened by one mm or by sand blasting. In no case
the old sealant shall be present during resealing operation. If joint grooves are found
inadequate in depth, they shall be deepened as directed by the Engineer.
Before commencing the sealing operation, compressed air shall be used to clean the
joint grooves to clean the joint groove. A heat resistant, paper backed compressible
debonding strip or tape should be inserted in accordance with the requirement of Clause
602.1 l.2. Sealant may be poured either using hand held pourer or using mechanised
sealing machines. Sealants should not be heated directly but in double jacketed
machine. All precautions and arrangements shall be taken not to spill the sealant on
the concrete pavement. The sealant may be poured to a depth of 5 ±2 mm from the
pavement surface. 3005.2.4. Measurements for payment: Repair of joint sealant shall
be measured in linear metres. 3005.2.5. Rate: Contract unit rate for repair of joint sealant
shall be in full compensation for:
(i) removal of old sealant, regrooving or sand blasting the sealing groove and placing of
debonding strip or tape.
(ii) all tools, equipments and incidentals to complete the work in accordance with the
above Specification.

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3004.6.

338 RED BOOK  VOLUME I  ROADS  2012

 3005.2.2.

SECTION RD

STANDARD
SPECIFICATIONS
FOR
ROAD WORK

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3004.6.

340 RED BOOK  VOLUME I  ROADS  2012

 3005.2.2.
List for items for Road Work
Sr.No. Item Page
(1) (2) (3)
Rd.1. Cutting down trees including trunks and branches and
stacking the materials neatly within a lead of 50 m. as
directed with girth -
(a) above 30 cm to 60 cm.
(b) above 60 cm to 90 cm.
(c) above 90 cm to 180 cm.
(d) above 180 cm to 270 cm.
(e) above 270 cm to 450 cm.
(f) above 450 cm.
Rd.1 a) Clearing road land including cutting trees less than 30 cm
in girth clearing brush wood, loose stones, vegetation,
bushes, stumps and mole hills.
Rd.2. Excavation for roadway in earth, soils of all sorts, sand,
gravel, soft murum including dressing section to the
required grade, camber and side slopes and conveying
the excavated materials with all lift upto a lead of 50 m
and spreading for embarkment or stacking as directed.
Rd.3. Excavation for roadway in hard murum including dressing
section to the required grade, camber and side slopes
and conveying the excavated materials with all lift upto a
lead of 50 m and spreading for embarkment or stacking
as directed.
Rd.4. Excavation for roadway in hard murum and boulders
including dressing section to the required grade, camber
and side slopes and conveying the excavated materials
with all lift upto a lead of 50 m and spreading for
embarkment or stacking as directed.
Rd.5. Excavation for roadway in soft rock including dressing
section to the required grade, camber and side slopes
and conveying the excavated materials with all lift upto a
lead of 50 m and spreading for embarkment or stacking
as directed.
Rd.6. Excavation for roadway in hard rock by blasting including
dressing section to the required grade, camber and side
slopes and conveying the excavated materials with all lift
up to a lead of 50 m and spreading for embankment or
stacking as directed.
Rd.7. Excavation for roadway in hard rock by wedging, chiseling
or line drilling including dressing section to the required
grade, camber and side slopes and conveying the
excavated materials with all lift upto a lead of 50 m and
spreading for embankment or stacking as directed.

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3004.6.
Rd.8. Excavation for roadway in laterite rock including dressing
section to the required grade, camber and side slopes
and conveying the excavated materials with all lift up to a
lead of 50 m and spreading for embankment or stacking
as directed.
Rd.9. Excavation catch water gutters in all types of strata to the
specified section including stacking the excavation stuff
in a regular bund and disposing off unsuitable or excess
stuff as directed.
Rd.10. Watering and compacting of embankment formed of
materials obtained from the road cutting within a lead of
50 m to 95 percent of standard proctor density after laying
them in layers of 20 cm to 30 cm.
Rd.11. Conveying materials obtained from road cutting including
all lifts, laying in layers of 20 cm to 30 cm breaking clods,
dressing to the required lines, curves, grades and section,
watering and compaction to 95 % of standard proctor
density for lead of -
(a) Over 50 m. to 300 m. inclusive.
(b) Over 350 m.to 500 m. inclusive.
(c) Over 500 m.to 700 m. inclusive.
(d) Over 700 m.to 1000 m.inclusive.
from the site of excavation to site of deposition.
Rd.12. Providing earthwork for embarkment with approved
materials, obtained from Departmental land or other
sources including all lifts, laying in layers of 20 cm to 30
cm breaking clods, dressing to the required lines, curves,
grades and section, watering and compaction to 95 % of
standard Proctor density complete.
Rd.13 Providing earthwork for embankment with approved
materials, obtained from Departmental land or other
sources including all lifts, laying in layers of 20 cm to 30
cm breaking clods, dressing to the required lines, curves,
grades and section, watering and compaction with power
roller/vibratory roller.
Rd.14 Preparing embankment with approved materials obtained
from the cutting within lead of 50 m. including laying in
layers of 20 cm to 30 cm breaking clods, dressing to the
required lines, curves, grades and section, watering and
compacting with power roller/vibratory roller.
Rd.15 Preparing embankment with approved materials obtained
from the cutting within lead of 50 m. including laying in
layers of 20 cm to 30 cm breaking clods, dressing to the
required lines, curves, grades and section, watering and
compacting with power roller/vibratory roller for a lead of-

342 RED BOOK  VOLUME I  ROADS  2012

 3005.2.2.
(a) Over 50 m. to 300 m. inclusive.
(b) Over 350 m.to 500 m. inclusive.
(c) Over 500 m.to 1000 m.
from the site of excavation to the site of disposition.
Rd.16. Earthwork for embarkment with approved materials,
obtained from Departmental land or other sources including
all lifts, laying in layers of 20 cm to 30 cm breaking clods,
dressing to the required lines, curves, grades and section.
Rd.17. Laying materials obtained from road cutting in layers,
breaking clods, dressing to the required lines, curves,
grades and section for embarkment within a lead of 50 m.
Rd.18. Conveying materials obtained from road cutting including
all lifts, laying in layers of 20 cm to 30 cm breaking clods,
dressing to the required lines, curves, grades and section,
watering and compaction to 95 % of standard proctor
density for lead of -
(a) Over 50 m. to 300 m.
(b) Over 350 m.to 500 m.
(c) Over 500 m.to 1000 m.
from the site of excavation to site of deposition.
Rd.19. Supplying 15 cm/23 cm. rubble at the road side for soling
including conveying and stacking complete.
Rd.19.(a) Supplying 80mm metal at the roadside for soling including
conveying and stacking complete.
Rd.20. Supplying 60mm metal at the roadside including conveying
and stacking complete.
Rd.21. Supplying 50mm at the roadside including conveying and
stacking complete.
Rd.22. Supplying 40mm metal at the roadside including conveying
and stacking complete.
Rd.23. Supplying hard murum/kankar at the roadside including
conveying and stacking complete.
Rd.24. Supplying soft murum/kankar at the roadside including
conveying and stacking complete.
Rd.25. Supplying sand at the roadside including conveying and
stacking complete.
Rd.26. Supplying gravel at the roadside including conveying and
stacking complete.
Rd.27. Laying 15 cm /23 cm rubble soiling including hand packing
with rubble chips complete excluding cost of materials.
Rd.28. Spreading gravel/sand/soft murum/hard murum complete.

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3004.6.
Rd.29. Spreading oversize metal including sectioning complete.
Rd.30. Compacting sub-grade, soling, gravel, oversize metal/
size metal, sand and soft murum layers in wide with power
roller/vibratory roller including artificial watering complete.
Rd.31. Picking and road surface including sanctioning complete.
Rd.32 Compacting the metal layer -- meter wide with power roller/
vibratory roller including necessary labour, materials,
artificial watering and use of equipment etc. Complete. at
the roadside including conveying and stacking for use in
bituminous surfaces
Rd.33. Supplying:-
a) 40 mm.
b) 25 mm.
b) 20 mm.
c) 12 mm.
d) 10 mm.
e) 6 mm.
Rd 34. Supplying bitumen of the I.S.Grades -- at the site of work
including conveying and stacking properly and protecting
it till used.
Rd.35 Laying 50 mm thick full grout bituminous road surface
including preparing the existing road surface, laying the
required thickness of metal layer, heating and spraying
the bitumen, spreading chips and laying seal coat
complete excluding cost of stone aggregate, bitumen and
compaction.
Rd.36 Compacting 50 mm thick full grout surface with power
roller including labour, use of plant etc. complete.
Rd.37 Laying 50 mm thick semi grout bituminous road surface
including preparing the existing road surface, laying the
required thickness of metal layer, heating and spraying
the bitumen, spreading chips and laying seal coat
complete excluding cost of stone aggregate, bitumen and
compaction.
Rd.38 Compacting 50 mm thick semi grout surface with power
roller including labour, use of plant etc. complete.
Rd.39 Laying 40 mm thick premix bituminous carpet including
preparing and cleaning the base, heating bitumen,
applying tack coat at Kg/100 sq.m. mixing bitumen and
aggregate in a bitumen mixer and laying the carpet layers
complete with/without seal coat excluding cost of stone
aggregate, bitumen and compaction.

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 3005.2.2.
Rd.40 Compacting 20 mm thick premix bituminous carpet with
power roller including labour, use of plant etc. complete.
Rd.41 Providing single coat surface dressing including cleaning
the road surface, heating and applying bitumen to the road
surface, spreading chips etc complete excluding cost of
stone chips, bitumen and rolling.
Rd.42 Rolling the single coat bituminous surface with power
roller including labour, use of plant etc. complete.
Rd.43 Providing two coat surface dressing including cleaning the
road surface, heating and applying bitumen to the road
surface, spreading chips etc complete excluding cost of
stone chips, bitumen and rolling.
Rd.44 Rolling the two coat bituminous surface with power roller
including labour, use of plant etc. complete.
Rd.45 Providing bituminous liquid seal coat to black top surface
including preparing the existing road surface, heating and
applying bitumen, spreading chips etc complete excluding
cost of stone chips, bitumen and rolling.
Rd.46 Rolling bituminous liquid seal coats with power roller
including labour, use of plant etc. complete.
Rd.47 Providing 50 mm thick full grout bituminous road surface
including supplying all materials, preparing the existing
road surface laying the required thickness of metal layer
heating and spraying bitumen, spreading chips, laying
seal coats and compacting complete.
Rd.48 Providing 50 mm thick semi grout bituminous road surface
including supplying all materials, preparing the existing
road surface laying the required thickness of metal layer
heating and spraying bitumen, spreading chips, laying
seal coats and compacting complete.
Rd.49 Providing 25 mm thick premix bituminous carpet including
supplying all materials, preparing and cleaning the base,
heating bitumen, applying tack coat at Kg/100 sq.m.
mixing hot bitumen and chips laying the carpet layers and
compacting complete.
Rd.50 Providing 20 mm thick premix bituminous carpet including
supplying all materials, preparing and cleaning the base,
heating bitumen, applying tack coat at Kg/100 sq.m.
mixing hot bitumen and chips laying the carpet layers and
compacting complete.
Rd.51 Providing single coat surface dressing including supplying
all materials, cleaning the road surface, heating and
applying bitumen to the road surface, spreading chips,
use of tools, plant and equipment and rolling complete.

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3004.6.
Rd.52 Providing two coat surface dressing including supplying all
materials, cleaning the road surface, heating and applying
bitumen to the road surface, spreading chips, use of tools,
plant and equipment and rolling complete.
Rd.53 Providing bituminous liquid seal coat to black top surface
including supplying all materials preparing the existing
road surface, heating and applying bitumen, spreading
chips etc complete
Rd. 54. Providing hot mix, hot laid premixed bituminous concrete
25 mm. thick wearing surface over 50 mm. thick premixed
bituminous macadam, including diversion aggregates,
bitumen, etc., heating bitumen and chips, mixing chips
and bitumen in mechanical bitumen mixer, laying the
bituminous macadam base and bituminous concrete
wearing course and compacting the two courses
separately.
Rd. 55. Providing 1:2:4: cement concrete pavement -- mm. thick
including diversion, compacting, finishing, curing, filling in
joins with premoulded and poured bituminous joint filler
and 1:4:8 lean cement concrete.
Rd. 56. Providing and fixing kilometer stone/200 meter stone of
standard size and shape including fixing in a block of
standard size of cement concrete 1:4:8, painting etc.,
complete.
Rd. 57. Providing and fixing guard stones/indicator stones/
boundary stones of standard size and shape including
fixing in ground/in blocks of standard size of cement
concrete 1 : 4 : 8, white washing, etc., complete.
Rd. 58. Providing and fixing stone pinheaders at the toe of the
pitching.
Rd. 59. Providing stone khandki pitching 23 cm. thick.
Rd. 60. Providing dry rubble stone pitching 23 mm thick.
Rd. 61. Providing dry rubble stone masonry.
Rd. 62. Laying 50 mm thick Special grout bituminous road surface
including preparing the existing road surface, laying the
required thickness of metal layer, heating and spraying
bitumen, spreading chips and laying seal coat complete.
Rd. 63. Compacting 50 mm thick special grout surface with power
roller including labour, use of plant, etc. complete.
Rd.64 Providing and laying bituminous bound macadam surface
in 75 mm thick including supplying all materials, spreading
40 mm and 20 mm trap metal layers, heating and spreading
bitumen at the rate of 250 Kg per 100 Sqm and spreading
12 mm size key aggregates and compaction with power
roller including applying tack coat at 50 Kg per 100 Sqm
etc. complete.
346 RED BOOK  VOLUME I  ROADS  2012
 3005.2.2.
Rd.65. Providing and laying 75 mm thick builtup spray grout
including all materials, preparing and cleaning base,
laying metal in two layers, heating and spraying bitumen,
spreading chips, compacting two layers with power roller
etc. complete.
Rd.66. Providing and laying 50 mm/75 mm thick penetration
macadam including all materials, preparing road surface,
laying metal layer, heating & applying bitumen, spreading
chips, compacting etc. complete.
Rd.67. Providing and laying 50 mm/75 mm thick hot laid bituminous
macadam with 4%/3.5%/3%/2.5% bitumen by weight of
total mix including heating chips, bitumen, mixing in plant,
laying with paver compacting etc. complete.(Including
tack coat.)
Rd.68 Providing 20 mm/25 mm thick open graded premix
bituminous carpet including preparing base, tack coat,
heating of bitumen and aggregate, mixing in hot mix
plant laying with mechanical paver and compacting etc.
complete.
Rd. 69 Providing and laying 20 mm thick Mix seal surfacing A
TYPE/B TYPE including preparing base, heating bitumen
and aggregate in hot mix plant, laying the mix by paver
compacting by power roller etc. complete. (including tack
coat.)
Rd. 70 Providing and laying 25 mm/ 40 mm thick bituminous
concrete with 6.25 % bitumen by weight of total mix
including heating bitumen, aggregate, laying with paver
compacting etc complete. (including tack coat.)
Rd.71 Providing and laying 25 mm/ 40 mm thick semi dense
concrete with 5.5 % bitumen by weight to total mix including
all materials, heating of bitumen, aggregate, laying with
paver, compacting etc. complete. (including tack coat.)

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348 RED BOOK  VOLUME I  ROADS  2012

 Rd.
Rd. 1: Cutting down trees including trunks and branches and stacking the materials
neatly within a lead of 50 m. as directed with girths.
a) above 30 cm to 60 cm.
b) above 60 cm to 90 cm.
c) above 90 cm to 180 cm.
d) above 180 cm to 270 cm.
e) above 270 cm to 450 cm.
f) above 450 cm .
Rd. 1.1 General - The item includes cutting of trees having girths specified as above,
measured one meter above the ground and standing within and without the road land as
directed by the Engineer. The trees to be cut shall be duly marked to distinguish them from
the trees not to be cut. The trees 30 cm. in girth and below shall be removed under clearing
site of the particular item and shall not be paid for separately.
Rd. 1.2 Cutting of trees - The trees marked for cutting shall be cut without disturbing or
inconveniencing traffic. Where the cut trees are likely to cause damage to any property,
crops, trees that are to be left standing, road etc., ropes and guys shall be used to cause
the tree to fall in a guided direction in a harmless manner. Where necessary to prevent
injury to structure, road, property or other trees or to avoid damage and obstruction to
traffic, trees shall be cut in section from the top downwards. One cut across the trunk just
near the ground level to a uniform depth shall first be taken and the tree shall then be pulled
by means of ropes so as to separate it from the roots and fall in the guided direction. If
the tree cut falls in a manner to interrupt or obstruct the traffic, necessary diversion shall
be prepared and maintained so as to be safe for the traffic over it till the obstruction of the
tree is entirely removed and the road surface restored to normal condition. Warning single
shall be dis­played on either side of obstruction. If the tree cannot be removed by sunset,
warning red lights to indicate the danger shall be displayed from sunset to sunrise at 50 m.
on either side or the obstruction till it is completely removed. Cost of preparing, maintaining
and operating diversions, providing warning boards, signals, etc. shall be borne by the
contractor. The contractor shall take every precaution to safe­guard the nearby property,
crop and traveling public. If any damage to property or injury to life occurs due to the
contractor’s default in this respect, he shall be liable to compensate such damage or injury.
Rd. 1.3 Grubbing - In road cutting, all stumps and roots shall be removed to a depth of not
less than 30 cm below the graded forma­tion and slopes. Under embankments they shall
be removed to a depth of 15 cm below original ground level or 30 cm below formation level
whichever is more. Outside embankments and cuttings, they shall be removed up to 15 cm.
below ground level. All the excavations made for grubbing shall be filled with excavated
material in 15cm. layers rammed.
Rd. 1.4 Disposal of materials - All the products of cutting trees shall be the property of
Government. All timber from which sawn logs and posts can be produced shall be cut into
merchantable lengths as directed by the Engineer. Such timber will not be required to be
cut to less than 3m. lengths. Other types of trunks and bigger branches shall be cut into
pieces of 1 m. or so and kept in neat stacks as directed within a lead of 50 meters . Smaller
branches and thinner pieces shall be stacked separately and very thin leafy portion de­
stroyed or removed as directed. The contractor shall be responsible for the custody of the
cut materials till handed over to the Depart­ment.
Rd. 1.5 Item to include -
(1) Cutting the trees, grubbing roots and stacking the materials neatly and their safe

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Rd.
custody.
(2) Displaying of warning signals and red lights.
(3) Diversions
(4) Making good any damage to the road surface and compensation for any injury to life
and property due to default of contractor.
(5) All labour, materials and use of equipment required to execute the work satisfactory.
Rd. 1.6 Mode of measurement and payment - Measurement shall be for the number of
trees cut of different sizes having girths of more than 30 cm. The girth shall be measured
at a height of one metre from the ground before cutting and grouped under following size
categories.
Size of trees - The size of the tree shall be determined by the girth at one metre height form
the ground as follows -
a) above 30 cm to 60 cm.
b) above 60 cm to 90 cm.
c) above 90 cm to 180 cm.
d) above 180 cm to 270 cm.
e) above 270 cm to 450 cm.
f) above 450 cm.
Payment shall be made after the cutting is done as specified and the materials handed over
satisfactorily.
The contractor rate shall be per tree of each size category.
Rd. 1 (a) Clearing road land including cutting trees less than 30 cm in girth, clearing
brush wood, loose stones, vegetation, bushes, stumps and molehills in the road
land excluding area covered by the cutting, banks and gutters.
Rd. 1(a) 1. General - The item pertains to the provision of road land clearing including
cutting small trees, vegetation, bushes and clearing stums and molehills in the road land
excluding area covered by the cutting, banks and gutters.
Rd. 1(a) 2. Clearing site - The road land beyond the area covered by cutting and bank of
road and gutters shall be cleared according to Rd. 2.2 The clearance of road land covered
by the cut­tings, banks and cutters shall be covered by the respective items.
Rd. 1(a) 3. Disposal of the stuff removed - All the materials removed as a result of the
clearance shall be the property of Govern­ment. Useful materials shall be stacked properly
at places and as directed by the Engineer within a lead of 50 m. Useless materials shall be
wasted by the contractor without causing nuisance and as approved by the Engineer.
Rd. 1(a) 4. Item to include –
(1) Clearing roadside including cutting trees of girth less than 30 cm. removing
vegetation, grubbing roots, removing loose stones and molehills and disposal of
materials removed.
(2) All necessary labour, materials and use of tools required for carrying out the item.
Rd. 1.(a) 5. Mode of measurement and payment - The contract rate shall be for a sq.
m. The measurement for the length and the width shall be recorded correct up to 10 cm.
limited to those shown in drawings or as directed by the Engineer and the area calculated
cor­rect up to a sq.m.

350 RED BOOK  VOLUME I  ROADS  2012

 Rd.
The width shall be the width actually cleared excluding the roadway, width covered by
slopes, gutters and catch water gutters.
Rd. 2. Excavation for roadway in earth soils of all sorts, sand, gravel or soft murum
including dressing section to the required grade, camber and side slopes and
conveying the excavated materials with all lifts up to a lead of 50 m. and spreading
for embankment or stacking as directed.
Rd. 2.1 General - Roadway and drainage excavation shall consist of excavation, removal
conveyance and satisfactory disposal of materi­als of the strata covered by the wording of
the item for the construc­tion of the road and its drainage including finishing the surface and
the slopes to the required grade, lines, levels, curves and sections shown on the plans or
as directed by the Engineer. The item also covers maintaining the work in finished condition
until taken over by the Department.
Rd. 2.2 Clearing site - The land width required for the road­way, gutters, side slopes and
catch water gutters shall be cleared of all trees having a girth of 30 cm and less, brush
wood, loose stones, vegetation, bushes, stumps and all other objectionable materials. The
roots of trees shall be removed to a depth of 30 cm below the surface of the road formation
and side slopes and the excavation filled up with excavated materials in 15 cm to 20 cm
layers and compacted. Brush wood, stumps, vegetation, etc. shall be cut flush with the
ground. All the materials cleared will be the property of Government. Useful materials shall
be arranged in convenient stacks along the road bound­ary or as directed at places within
a lead of 50 meters and handed over to the Department in convenient sections. Unsuitable
materials shall be burnt or otherwise disposed of by the contractor at his own cost as
directed by the Engineer without causing any nuisance, incon­venience or damage to the
work, property or people in the neighbor­hood. If the material is disposed of outside of
the road land, neces­sary permission from the private land owners shall be taken by the
contractor and royalty, etc. if any paid by him without claiming compensation. In all cases,
the materials shall be disposed of in a neat manner.
Rd. 2.3 Setting out - After clearing the site, the alignment of the road shall be properly set
out true to lines, curves, slope, grade and sections as shown on the plans or directed by the
Engineer. The contractor shall provide all labour and materials such as lime, string, pegs,
nails, bamboos, stones, mortar, concrete, etc. required for setting out, establishing Bench
Marks and giving profiles. The contractor shall be responsible for maintaining the BMs,
profiles, alignment and other stakes and marks as long as they are required for the work in
the opinion of the Engineer. If the contractor defaults in this respect even after direction by
the Engineer within the specified time, they may be restored by the Engineer at the cost of
contractor. Levels and sections of the ground shall be taken and recorded in the presence
of the contractor or his authorised repre­sentative before the excavation is started to serve
as the basis of measurement. The contractor or his representative shall sign the book in
token of his acceptance of the levels, etc. If there is any dis­agreement, the contractor shall
inform of it in writing to the officer concerned with specific reference to the sections before
starting further work. Once further work is started, no cognizance of any complaint shall be
taken, Merely not signing of the book shall not be deemed as disagreement.
Rd. 2.4 Classification of excavation -  The classification of strata mentioned in the
wording shall be as indicated in specification No. B.1.12
Rd. 2.5 Construction methods - Profiles of the section includ­ing the roadside gutters
to be excavated shall be laid at suitable intervals of 10 m. to 50 m. or other intervals
directed by the En­gineer to conform to the curved or straight alignment, sections, grades
and side slopes. The lines of cuts shall be set up with the toe line marked on each side.

RED BOOK  VOLUME I  ROADS  2012 351

Rd.
The roadway section shall first be excavated with vertical sides for each lift and the side
slopes for that lift shall be excavated in steps. These steps shall be smoothened to the
required slope when the excavation reaches the road formation. The contractor shall on no
account excavate beyond the slopes or below the specified grade unless so directed by the
Engineer in writing. If excavations is done below the specified level or outside the section,
it shall not be paid for and the contractor shall be required to fill up at his own cost such
extra excavation in the road portion with approved materials of the embankment grade
in layers of 15 cm to 20 cm. watered and fully compacted to attain maximum density laid
down for the embankment in the same agreement elsewhere. The Engineer may require
measurement ridges and deadment to be left at specified inter­vals or places and kept
intact till ordered to be removed for the purpose of check measurements. The excavation
shall be finished neat­ly, smoothly and evenly to the correct lines, curves, grades, sections
and side slopes as shown on the plans or directed by the Engineer. The sub-grade if loose
shall be scarified, watered and compacted to the same density as the embankment. The
section, side slopes and catch water gutters shall be maintained by the contractor at his
own cost in such a way that the formation and gutters will be well drained by providing
necessary diversions, etc. and not damaged due to obstruc­tion of any drainage. Necessary
passages shall be provided for leading away seepage, springs, surface flow or rain water
safely without damaging the work. If any damage occurs due to default of the contrac­tor
in this respect, he shall make good the damage at his own cost. If it is necessary in the
execution of the work to interrupt existing surface drainage, irrigation channels, sewers or
under drainage, temporary arrangements shall be provided till such time as is neces­sary.
The contractor at his own cost shall make good the interrupted drainage and sewer, etc.
unless separately provided in the tender. Any damage to the existing works or work in hand
caused as a result of his operations or negligence shall be made good by the contractor at
his own cost.
Roadside gutters shall be excavated to the specified sections and shall be measured along
with the main cutting in cubic metres.
Intercepting or catch water gutters where necessary shall be built to the cross-sections
shown on the plans in time to prevent damage to the cuts or banks.
Rd 2.6 Dewatering - If water is met with in the excavation due to springs, seepage, rain
or other causes it shall be removed by suitable diversions, pumping or bailing out and the
excavation kept dry whenever so required or directed by the Engineer. Care shall be taken
to discharge the water so as not to cause damage to the work, crops or any property or any
inconvenience to the property holders in the neighbourhood. Unless separate provision is
made in the tender for dewatering, the cost of dewatering shall be covered by the rate for
excavation.
Rd. 2.7 Slides - If slides occur in the cutting they shall be removed as ordered by the
Engineer. If finished slopes slide into the roadway before the final acceptance of the work,
such slides shall be removed by the contractor and shall be paid for at the contract rate for
the class of excavation involved provided the slides are not due to any negligence of the
contractor. The classification of the materi­al in slides shall conform to its condition at the
time of removal and payment made accordingly regardless of its prior condition.
Care shall be taken to see that excavation is arranged in a safe way so that there will be no
risk to the work or workmen by slides, falling materials, boulders and collapsing sides etc.
Rd. 2.8 Protection - If there is traffic nearby or if there are towns and villages in the
neighbourhood, barricades and/or traffic signals shall be provided day and night for the
duration of the work in such a way as to prevent accidents. Warning signals shall be dis­
played at 70m. from the danger point on both sides to give sufficient warning. If necessary,
352 RED BOOK  VOLUME I  ROADS  2012
 Rd.2.13.
signalers shall be stationed at each end to regulate traffic where it is heavy. Measures
shall be taken to see that the excavation does not affect or damage adjoining structures
or property. If there is damage to property, injury to workers, the members of the public,
animals, etc. due to the negligence of the contractor, he will be responsible and liable to all
the consequences including compensation.
Rd. 2.9 Diversions - If diversions are necessary for the traf­fic they shall be provided and
maintained as specified under specifi­cation No. BR.1.
Rd. 2.10 Disposal of the excavated materials - All the excavated materials shall
be the property of Government. When the useful exca­vated materials is to be used in
embankment within a lead of 50 m. it shall be directly deposited at the required location in
15 cm. to 20 cm layers, the charges for watering and compacting such material being paid
under a separate item. No handling or conveyance charges shall be paid if the material
is temporarily deposited elsewhere and subse­quently conveyed to site of deposition. The
sequence of operations should be arranged properly. Useful excavated material to be used
in embankment beyond 50 may be conveyed directly to the site of use and laid in layers or
first deposited in heaps and conveyed and laid in layers subsequently; the conveyance and
the charges for watering and compaction shall be paid for under a separate item. Materials
required for items other than bank shall be arranged in neat stacks at conveni­ent places
within a lead of 50 m. without interfering with the drain­age in any way. If no Government
land is available but the excavated useful stuff is to be stacked temporarily before use
under the same agreement the contractor shall make his own arrangements for the
stacking of this material temporarily on private lands by paying rents, etc. without claiming
any compensation. Surplus material not required for use on embankment or unsuitable
materials may be used at his own cost to uniformly widen embankment, to flatten slopes
and to fill low places in the road land within a lead of 50m. if so directed by the Engineer.
Material not required for any use whatsoever may be disposed off by the contractor at
his own cost in a manner approved by the Engineer. The excavated material shall not
be deposited within 3 m. from the top edge or slope of toe of the bank unless expressly
permitted by the Engineer in writing. When the excavated material is deposited or disposed
off by the contractor in land not belonging to Government he shall be responsible for any
compensation required to be paid to the private land owner. The leads shall be measured
from approximate center of gravity of the block of cutting to the approx­imate center of
gravity of block of deposited material.
Rd.2.12. Item to include -
(1) Clearing site.
(2) Setting out including necessary labour, material and fixing reference marks.
(3) Diversion unless separately provided in the tender.
(4) Dewatering unless separately provided in the tender.
(5) Protective measures for work, workpeople, public, animals, property, etc.
(6) Excavation to the required lines, curves, sections and grades.
(7) Conveying the excavated materials including all lifts and lead up to 50m. spreading
in layers or stacking as directed and disposing off unwanted materials.
(8) All labour, materials and use of equipment and tools required for completing the item
satisfactorily.
(9) Compensation on account of damages, accidents or use of private lands royally, etc.
Rd.2.13. Mode of measurement and payment - The contract rate shall be for a unit of
one cubic metre for the strata mentioned in the wording of the item of excavation acceptably
RED BOOK  VOLUME I  ROADS  2012 353
Rd.2.13.
completed, limited to the dimensions shown on the plans or as directed by the Engineer.
Excava­tion shall be measured in its original position by taking cross-sections before the
work starts and after it is entirely completed. The quantity shall be worked out by the
average end area method. The individual dimensions and areas of the cutting shall be
measured correct up to two places of decimals of a metre and square metre re­spectively
and the quantity worked out correct up two places of deci­mals of a Cu. metre.
When the classification of the strata changes, the contractor shall bring this to the notice
of the Engineer who will then verify and if necessary take levels for the changed strata for
purposes of measurement.
The Engineer at his option may direct dead-men to be left at such intervals as he may
indicate for purposes of measuring the depths and other dimensions either for initial
measurements or for checking. Deductions shall be made for these dead-men. These
shall be removed when no longer required and the deduction restored thereafter. If the
dead-men are not removed and used in the work or otherwise disposed of as directed by
the Engineer within 15 days of the date of check meas­urement, the Engineer shall have the
right to remove them at the contractor’s cost. If for any reason the dead-men are damaged
at the time of measurement the measuring or check measuring officer shall estimate the
quantity of earthwork at his discretion and such estimate shall be final.
Rd.3. Excavation for roadway in hard murum including dressing section to the
required grade, camber and side slopes and conveying the excavated materials with
all lifts up to a lead of 50m. and spreading for embankment or stacking as directed.
Rd.3.1. General - According to Rd.2.1.
Rd.3.2. clearing site - According to Rd.2.2.
Rd.3.3. Setting out - According to Rd.2.3.
Rd.3.4. Classification of excavation - According to specification No.B.1.12
Rd.3.5. Construction methods - According to Rd.2.5.
Rd.3.6. Dewatering - According to Rd.2.6.
Rd.3.7. Slides - According to 2.7.
Rd.3.8. Protection - According to Rd.2.8.
Rd.3.9. Diversion - According to Rd.2.9.
Rd.3.10. Disposal of excavated materials - According to Rd.2.10.
All the hard murum not intended for use in the bank-work shall be stacked neatly for
further use as directed by the Engineer within a lead of 50m on Government land. If no
Government land is available but the excavated hard murum is to be stacked temporarily
before use under the same agreement, the contractor shall make his own arrange­ments
for the stacking of this hard murum temporarily on private lands for which he shall not
be entitled for any compensation. Surplus hard murum may be used to uniformly widen
embankment, to flatten slopes and to fill low places in the road and within a lead of 50m or
wasted at the cost of the contractor as may be directed by the Engineer.
Rd.3.11. Maintenance - According to Rd.2.11.
Rd.3.12. Item to include - According to Rd.2.12.
Rd.3.13. Mode of measurement and payment - According to Rd.2.13.
Rd.4. Excavation for roadway in hard murum and boulders including dressing
section to the required grade, camber and side slopes and conveying the excavated

354 RED BOOK  VOLUME I  ROADS  2012

 Rd.5.5.
materials with all lifts up to a lead of 50m, and spreading for embankment or stacking
as directed.
Rd.4.1. General - According to Rd.2.1.
Rd.4.2. Clearing site - According to Rd.2.2.
Rd.4.3. Setting out - According to Rd.2.3.
Rd.4.4. Classification - According to specification No. B.1.12.
Rd.4.5. Construction methods - According to Rd.2.5.
If removal of boulders causes depressions in the formation, they shall be filled with approved
materials in layers of 15cm. to 20cm. watered and consolidated. No boulder shall be
allowed to project above the formation.
Rd.4.6. Dewatering - According to Rd.2.6.
Rd.4.7. Slides - According to Rd.2.7.
Rd.4.8. Protection - According to Rd.2.8.
Rd.4.9. Diversion - According to Rd.2.9.
Rd.4.10. Disposal of excavated materials - Hard murum obtained from excavation shall
be dealt with as specified in Rd.3.10. The boulders obtained from the excavation shall be
neatly stacked unless otherwise ordered, in regular stacks on roadsides beyond 3m. of the
edge of the cutting or the toe of the bank up to a distance of 50m. without interfering with
drainage. Suitable boulders, if so ordered, shall be used in the embankment within 50m.
in the lowest or any intermediate layer of the embankment as directed by the Engineer. If
ordered to be disposed off, they shall be disposed off as specified in Rd.2.10.
Rd.4.11. Maintenance - According to Rd.2.11.
Rd.4.12. Item to include - According to Rd.2.12.
Rd.4.13. Mode of measurement and payment - According to Rd.2.13.
Rd.5. Excavation for roadway in soft rock including dressing section to the required
grade camber and side slopes and conveying the excavated materials with all lifts up
to a lead of 50m. and spreading or stacking as directed.
Rd.5.1. General - According to Rd.2.1.
Rd.5.2. Clearing site - According to Rd.2.2.
Rd.5.3. Setting out - According to Rd.2.3.
Rd.5.4. Classification of excavation - According to specification No.B-1.12.
Rd.5.5. Construction methods - According to Rd.2.5. and further as under:-
If necessary, the excavation shall be done by blasting according to specification No. B-2
observing the instructions and the rules and regulations in force regarding storage, transport
and use of explo­sives.
Where excavation is not possible by blasting due to the reasons such as proximity
of structures, possibility of shattering the rock below or for any other reason, then the
excavation shall be done by line drilling and or chiselling and wedging, both manual and
mechani­cal. No Blasting shall be used.
As far as practicable the excavation shall be done so as to leave no undrained pockets in
the surface of the rock. If pockets are formed, the contractor shall at his own cost, provide
drainage ar­rangements for them.

RED BOOK  VOLUME I  ROADS  2012 355

Rd.5.6.
The average side slopes in rock cuts shall be done so as to leave no undrained pockets in
the surface of the rock projecting more than 30cm from the true slope.
Rd.5.6. Dewatering - According to Rd.2.6.
Rd.5.7. Slides - According to Rd.2.7.
Rd.5.8. Protection - According to Rd.2.8.
Rd.5.9. Diversions - According to Rd.2.9.
Rd.5.10. Disposal of excavated materials - Disposal of excavated materials shall
generally comply with specification No. Rd.2.10. All the stuff obtained from the excavation
unless otherwise ordered shall be stacked in regular heaps on the roadside beyond 3m.
of the cutting edge or the toe of the bank within 50m. as directed by the Engineer without
interfering with drainage. If ordered to be wasted, the same shall be wasted as indicated
in Rd.2.10.
If the excavated stuff is ordered to be used for the bank work, it shall be conveyed and used
in the required section of the road or for widening as ordered by the Engineer up to a lead
of 50m or stacked properly for subsequent use.
Rd.5.11. Maintenance - According to Rd.2.11.
Rd.5.12. Item to include - According to Rd.2.12.
Rd.5.13. Mode of measurement and payment - According to Rd.2.13.
The contractor shall remove the overburden so that necessary cross-sections may be taken
for measurement. Boulders more than half a cubic metre in volume shall be measured
individually and volume calculated from average dimensions taken in three directions
perpen­dicular to each other.
All rock excavations shall normally be premeasured on cross-section and check-measured
before starting excavation. The final measurements and quantities shall be based on
cross-section whenever possible.
Stack measurements may be taken for checking and 40 percent deduction made for the
voids in the rubble-stacks, provided the stacks are made up without keeping purposely
made hollows.
When it is impossible to take cross-sectional measurements and the Engineer certifies
to that effect, the measurements in such cases may be taken on stacks and 40 percent
deduction made for voids as above. Stack measurements will not be recorded when
sectional meas­urements can be taken with adequate accuracy.
Rd.6. Excavation for roadway in hard-rock by blasting including dressing section to
the required grade, camber and side slopes and conveying the excavated materials
with all lifts upto a lead of 50m. and spreading or stacking as directed.
Rd.6.1. General - According to Rd.2.1. except that the excavation in rock shall be done by
blasting according to specification No. B-2 and the instructions and the rules and regulations
in force.
Rd.6.2. Clearing site - According to Rd.2.2.
Rd.6.3. Setting out - According to Rd.2.3.
Rd.6.4. Classification - According to specification No. B-1.12.
Rd.6.5. Construction Methods - According to Rd.5.5.
The excavation in rock shall be done by blasting according to specification No.B-2 observing

356 RED BOOK  VOLUME I  ROADS  2012

 Rd.7.10
the instructions and the rules and regulations in force regarding storage, transport and use
of the explosives.
If excavation is done to dimensions larger than the specified, no payment shall be made for
the excavation beyond the specified dimen­sions. If excavation is done to levels lower than
the specified levels the excess excavation shall be made good by rubble and chips packing
them closely by hand up to the designated level. Excavation shall be done as nearly as
possible to the required section.
Rd.6.6. Dewatering - According to Rd.2.6.
Rd.6.7. Slides - According to Rd.2.7.
Rd.6.8. Protection - According to Rd.2.8.
Rd.6.9. Diversions - According to Rd.2.9.
Rd.6.10. Disposal - According to Rd.5.10.
The rubble obtained from blasting shall be stacked neatly in regular heaps as specified in
Rd.2.10. In situations where it is not possible to collect blasted stone, the provision for such
stacking may be waived under the specified authorisation of the Engineer. If the rubble is
required for pitching, soling, masonry, breaking metal ,etc., it will be sold to the contractor
at the rate mentioned in the schedule A of the tender and if not so stated, at the Divisional
schedule rate current at the time of tendering.
Rd.6.11. Maintenance - According to Rd.2.11.
Rd.6.12. Item to include - According to Rd.2.12 and also blasting and all compensations
arising out o the blasting operations.
Rd.6.13. Mode of measurement and payment - According to Rd 5.13.
Rd. 7 Excavation for roadway in hard rock by wedging, chi­selling or line drilling
including dressing section to the required grade, camber and slide slopes and
conveying the excavated materials with all lifts up to a lead 50 m and spreading or
stacking as direct­ed.
Rd. 7.1 General - According to Rd. 2.1
The excavation in rock in the cases wherein no blasting can be allowed due to any reason
such as damages to properties and injuries to people and when so ordered by the Engineer
shall be done by line drilling or wedging and chiselling.
Rd.7.2 Clearing site - According to Rd.2.2
Rd.7.3 Setting out - According to Rd.2.3
Rd.7.4 Classification - According to specification No. B-1.12.
Rd.7.5 Construction methods - According to Rd. 5.5
The excavation in rock shall be done by line drilling and/or chiselling and wedging, both
manual or mechanical. No blasting shall be used.
Rd.7.6 Dewatering - According to Rd.2.6.
Rd.7.7 Slide - According to Rd.2.7.
Rd.7.8 Protection - According to Rd.2.8
Rd.7.9 Diversions -According to Rd.2.9
Rd.7.10 Disposal - According to Rd.5.10

RED BOOK  VOLUME I  ROADS  2012 357

Rd.7.11
Rd.7.11 Maintenance - According to Rd. 5.11
Rd.7.12 Item to include - According to Rd.2.12 Chiselling, line drilling, etc. shall also be
included.
Rd.7.13 Mode of measurement and payment - According to Rd.5.13
Rd.8 Excavation for roadway in laterite rock including dressing section to the
required grade, camber and side slopes and conveying the excavated materials with
all lifts up to a lead of 50 m. and spreading or stacking as directed.
Rd.8.1 General - According to Rd.2.1
The excavation in laterite may be done either by cutting the laterite by ‘dhokans’ or by
pickaxes or by blasting which shall be done according to specification No. B-2 and the
contractor shall ob­serve the instructions, rules and regulations in force for blasting.
Rd.8.2 Clearing site - According to Rd.2.2
Rd.8.3 Setting out - According to Rd.2.3
Rd.8.4 Classification - According to specification No.B.1.12.
Rd.8.5 Construction Methods - According to Rd.6.5
Alternatively the laterite may be excavated by ‘dhokans’ or pickaxes. Even when excavation
is done by blasting, the irregularities shall be dressed with ‘dhokans’ to bring the section to
that shown in the plan.
Rd.8.6. Dewatering -According to Rd.2.6.
Rd.8.7. Slides - According to Rd.2.7.
Rd.8.8. Protection - According to Rd.2.8.
Rd.8.9. Diversions - According to Rd.2.9.
Rd.8.10. Disposal - According to Rd.5.10.
Rd.8.11. Maintenance - According to Rd.2.11.
Rd.8.12. Item to include - According to Rd.2.12.
Rd.8.13. Mode of measurement and payment - According to Rd.5.13.
Rd.9. Excavating catch-water gutters in all types of strata to the specified section
including stacking the excavated stuff in a regular bund and disposing off unsuitable
or excess stuff as directed.
Rd.9.1. General - The item provides for the excavation of the specified section in all strata
and stacking the excavated stuff in a bund and disposing off unsuitable or excess stuff etc.,
as directed.
The item shall comply with relevant portion of the specification Nos. Rd.2 to Rd.8 except
for the following :-
Rd.9.2. Excavation - The gutter shall be excavated to the size, section and grades shown
on the plans or ordered by the Engineer and includes excavation in all strata including rock.
The excavated stuff shall be laid in 15cm. to 20cm. layers and rammed to form regular bund
along the catch-water gutters on the downstream only to prevent spills. Excavated stuff if
found to be useless or in excess, shall be used for strengthening the bund or wasted by the
stuff if found to be useless or in excess, shall be used for strengthening the bund or wasted
by the contractor satisfactorily or as directed. Outside material shall be brought and used
for the bund where necessary.

358 RED BOOK  VOLUME I  ROADS  2012

 Rd.10.6.
The section of the gutter and the bund shall be finished in a workman like manner and such
that there will be no stagnation of water.
Rd.9.3. Item to include -
(1) Clearing site.
(2) Setting out.
(3) Excavation to grade and section in all strata.
(4) Using the excavated and outside material if necessary for forming bund and disposing
off surplus materials.
(5) All labour, materials, use of tools for completing the item satisfactorily.
Rd.9.4. Mode of measurement and payment - The excavation shall be measured in
meters correct up to 10cm. for the length of the catch-water gutter of the specified section
formed by excavating in all strata and putting up bund along the drain.
The contract rate shall be for one metre of the gutter excavated.
Rd.10. Watering and compaction of embankment formed of materi­als obtained from
the road cutting within a lead of 50m. to 95 percent of standard Proctor density after
laying them in layers of 20cm. to 30cm.
Rd.10.1. General - The excavated materials shall have laid in layers of 20cm. to 30cm. to
the required lines, curves, grades and cross-section as shown on the plan or as ordered by
the Engineer within a lead of 50m. under the item of excavation of the particular classification
of stratum. This item refers to clearing site and setting out before laying the material and
breaking clods watering and compacting the material in each layer to the required density
within the lead mentioned in the wording of the item.
Rd.10.2. Clearing site - According to specification No. Rd.12.2.
Rd.10.3. Setting out - According to specification No. Rd.12.3.
Rd.10.4. Materials - All the useful materials such as all types of soils (except the black
or shadoo or greatly shrinkable soils as ordered by the Engineer) sand and shingle mixed
with soils, soft murum, hard murum, small boulders and broken rubble obtained from the
road cutting within the lead mentioned in the wording of the item shall be made use of to the
extent ordered by the Engineer. Some quantity of materials useful for other items may be
ordered to be reserved for such use and in that case shall not be used into the bankwork.
In the absence of any specific orders regarding reserving a portion of the materials, all
the excavated stuff other than the black soil, shadoo or greatly shrinkable soils and other
materials consid­ered by the Engineer as not suitable for bank work shall be put into the
bank. If the contractor, for his own convenience, uses materials other than those from the
road cutting, such quantities of outside materials shall be deemed to have been brought
from the road cutting within the specified leads for the purposes of this item and payments.
Stumps, pieces of wood or other perishable materials shall not be used in the bank. Sods
with humus or grass may be used as surface covering for the bank stops if so permitted by
the Engineer for a depth of not more than 30cm. at the top. Boulders, rubble broken from
large bould­ers and materials obtained from excavating soft and hard rock may be used in
bank work only if permitted by the Engineer.
Rd.10.5. Equipment - According to specification No. Rd.12.5.
Rd.10.6. Construction methods - According to specification No. Rd.12.6
Proper sequence of all operations such as clearing site, setting out, preparing the bed,
laying the excavated materials, watering and compacting each layer shall be maintained to

RED BOOK  VOLUME I  ROADS  2012 359

Rd.10.7.
get unhindered progress.
Rd.10.7. Protection - According to specification No. Rd.12.7.
Rd.10.8. Finishing - According to specification No. Rd.12.8.
Rd.10.9. Maintenance - According to specification No. Rd.12.9.
Rd.10.10. Tests - According to specification No. Rd.12.10.
Rd.10.11. Item to include -
(1) Clearing site.
(2) Setting out alignment including necessary labour and materi­als and maintaining it as
long as required.
(3) Preparing the ground for laying the embankment.
(4) Providing and maintaining diversions unless provided as a separate item in the
tender.
(5) Breaking clods, watering and compacting the materials in each layer laid from the
excavated materials within the lead mentioned in the wording of the item to the
required density.
(6) Carrying out tests.
(7) Finishing the embankment.
(8) Protecting and maintaining the bank.
(9) All labour, materials, use of equipment tools and plant, necessary for completion of
work satisfactorily.
Rd.10.12. Mode of measurement and payment - The contract rate shall be for a unit of
one cubic metre of the finished bank work.
The quantity payable for the bank shall be the quantity of useful road cutting materials,
required to be conveyed and used within a lead of 50m. and measured in situ in cutting.
If the contractor for his own convenience uses materials other those obtained from the
cutting, all such materials used in place of the materials from the road cutting shall be
deemed to have been obtained from the road cutting and paid under this item to the extent
to which useful road cutting materials were available for bank within the specified lead.
If a portion of the road cutting materials is ordered to be reserved for other use, or rejected
as not fit for bank, stack meas­urements of reserved or rejected materials shall be reduced
by adopt­ing following percentage to arrive at solid volumes to be deducted from the total
quantities of relevant excavation items to obtain the quantities put into the banks:-
(i) Earth, soils of all sorts, sand, gravel, soft murum 16 percent.
(ii) Hard murum 16 percent.
(iii) Boulders 40 percent.
(iv) Soft rock 40 percent.
(v) Hard rock 40 percent.
The lead shall be reckoned along the center line of the road from the center of mass of the
road cutting to the center of mass of em­bankment volume where the excavated materials
have been or were to be used irrespective of the actual route of transport.
The quantity of bank shall be paid on the basis of quantity of road cutting used in the bank.
Rd.11. Conveying materials obtained from road cutting includ­ing all lifts laying in

360 RED BOOK  VOLUME I  ROADS  2012

 Rd.12.2
layers of 20cm. to 30cm. Breaking clods, dress­ing to the required lines curves grades
and section, watering and compaction to 95 percent of standard Proctor density for
a lead of-
(a) over 50m. to 300m. inclusive,
(b) over 300m. to 500m. inclusive,
(c) over 500m. to 700m. inclusive,
(d) over 700m. to 1km. inclusive,
from the site of excavation to the site of deposition as directed.
Rd.11.1. General - The work shall consist of conveying the excavated materials including
all lifts to the leads mentioned in the wording of the item, laying in layers of 20cm. to
30cm. breaking clods, dressing to the required section, lines, curves grades watering and
compacting to 95 percent of standard Proctor density.
Rd.11.2. Clearing site - According to specification No. Rd.12.2.
Rd.11.3. Setting out - According to specification No. Rd.12.3.
Rd.11.4. Materials - According to specification No. Rd.10.4.
Rd.11.5. Equipment - According to specification No. Rd. 12.5.
Rd.11.6. Construction methods - According to specification No. Rd. 12.6. and Rd.10.6.
Rd.11.7. Protection - According to specification No. Rd. 12.7.
Rd.11.8. Finishing - According to specification No. Rd. 12.8.
Rd.11.9. Maintenance - According to specification No. Rd. 12.9.
Rd.11.10. Tests - According to specification No. Rd.12.10.
Rd.11.11. Item include - According to specification No. Rd.10.11 including conveyance of
the materials up to leads mentioned in the item.
Rd.11.12. Mode of measurement and payment - According to speci­fication No. Rd.
10.12. except that the excavated materials from cutting have to be conveyed to distances
beyond 50m. as mentioned in the item.
Rd.12 - Providing earth-work in embankment with approved materials obtained from
Departmental land or other sources including all lilts and leads, laying in layers of
20 cm to 30 cm. thickness, breaking clods, dressing to the required lines, curves,
grades and sections, watering and compacting to 95 per cent of standard Proctor
density complete.
Rd.12.1 General - The work shall include preliminaries of clearing site, setting out and
preparing the ground and thereafter forming embankment of the road with approved
materials obtained from Departmental land or other sources, laying them in layers,
watering and compacting to the required density and lines curves, grades, cross section
and dimensions shown on the plan or as directed by the En­gineer with due allowance for
shrinkage.
Rd.12.2 Clearing site - The ground over which embankment is to be formed shall be
cleared of all trees (unless cutting of trees of over 30 cm. girth is provided as a separate
item vide Rd.1.) brush wood loose stones, vegetation, bushes, stumps and all other objec­
tionable materials, under this item, Roots of tree shall be grubbed to a depth of at least
15 cm. below the original ground surface and at least 30 cm below the formation level
whichever is deeper. The holes dug up for grubbing roots etc., shall be filled with excavated

RED BOOK  VOLUME I  ROADS  2012 361

Rd.12.2
materi­als in layers of 15 cm. and compacted. Brush wood, stumps, vegetation etc. shall be
cut flush with the ground materials obtained from clear­ing site shall be dealt with according
to specification No. Rd.2.2.
Rd.12.3 Setting out - After the site is cleared, setting out shall be done as laid down in
specification No. Rd. 2.3. Profiles shall be set up with stout poles to mark the center and
edges of the formation with the top levels of formation clearly marked by paint or cut and
the slopes with strings and pegs at every 30 meters on straight portions and 10 m. or
less on curves or as directed by the Engineer. Toe line may be marked with pick marks.
Longitudinal and cross-section levels shall be taken recorded and checked for measure­
ments and signed by the contractor or his representatives.
All the materials and labour required for this item shall be supplied and profiles. B.Ms. etc.
put up by the contractor. These shall be covered by the rate.
Profiles, pegs, bench marks and other marks shall be maintained without any disturbance
as long as they are required.
Rd. 12.4 Materials - After utilising, for the embankment all the useful and acceptable
materials obtained from the road cutting within the specified leads the contractor shall obtain
additional materials from borrows in Departmental Land or from other suitable sources.
Satisfactory soil murum or a mixture of soil, sand, murum, gravel, small boulders or rubble
shall normally be acceptable. Soils having laboratory dry density of less than 1.44 gm/cc.
may not normal­ly be used in embankments. Soils having laboratory dry density of less than
1.52 gm/cc may not as far as possible be used in embankments exceeding 3 m. in height
or in embankments of any height subject to long periods of innundation. Only the materials
considered suitable by the Engineer shall be used for the bank. Rejected materials shall
not be put into the bank nor brought to the work site. Perishable materi­als such as stumps,
pieces of wood, roots, rubbish, etc. and such other materials as will effect the stability of the
embankment shall not be used. Sods with humus or grass will be permitted to be used as
surface covering for the bank slopes to a thickness of not more than 30 cm.
The material required for embankment shall be obtained in any of the following ways
provided the material is suitable in the opinion of the Engineer :-
(a) From cutting from nearby sections of the road as directed.
(b) From excavation for improving sight distances in nearby curves as directed.
(c) By sectioning any adjacent nalla or waterways as directed.
(d) By excavating cuts to lead water away from the road.
(e) By excavating side drains and catch-water drains.
(f) From waste land outside the road land.
(g) From humps above the general ground level within the road land.
(h) From land acquired temporarily if any, outside the road land.
(i) From borrow pits in Departmental land when permitted and from non Departmental
and private lands when necessary.
The contractor shall follow the priorities fixed by the Engineer for obtaining the materials
from different sources.
All lifts and leads involved in conveying the material to site shall be included in the rate
except when the materials from road cutting or other excavation being paid separately are
to be conveyed for use in banks with different leads under items Rd. 10 and Rd. 11.
No royalty shall be charged if the materials are allowed to be obtained from the borrows
in Departmental land. Borrow pits in De­partmental land shall be excavated according

362 RED BOOK  VOLUME I  ROADS  2012

 Rd.12.6.2.
to direction of the Engineer. If the materials are to be obtained from non-Departmental
and private lands, the contractor shall make his own arrangements and be responsible for
payment of rents, compensation, royalty, etc. and shall not be entitled for extra claims.
The Department shall remain indemnified regarding any claims that may be made by
private owners in this respect.
Roadside borrow pits when permitted shall be rectangular in shape with one side parallel
to the road and shall be dug as near the road boundary as possible. No borrow pits shall
be dug within 5m. of the toe of the final section after making due allowance for future devel­
opment without written permission from the Engineer.
The borrow pits shall be dug as far as possible on the high side of the road. The depth of
borrow pits in road land will depend on the quantity of soil needed to form the embankment
after utilising materials obtained from road cutting etc. and shall not normally exceed 1m.
Borrow pits shall not be dug continuously. Ridges o not less than 8m., width shall be left
at intervals not exceeding 30m. Small drains shall be cut through the ridges to facilities
drainage. To prevent stagnant pools where mosquitoes may breed, the beds of borrow
pits shall be dressed to slope down progressively towards the nearest natural drainage
channel.
In temporarily acquired cultivable lands, the depth of borrow pits shall be such as not
to damage the land permanently. The top soil to a depth of 15cm. may be stripped and
stacked aside. Thereaft­er soil may be dug to a further depth of about 30cm. and used
in forming the embankment. The top soil shall then be spread back on the land in the
excavated portion.
Borrow pits shall not be dug within 500m. of any town or village site. If unavoidable in the
opinion of the Engineer, they shall not exceed 30cm. in depth and shall be well drained.
If all the useful materials available from the road cutting are not used and materials
obtained from other sources are used instead by the contractor for his own convenience,
such materials shall be deemed to have been obtained from the road cutting to the extent
to which useful materials shall be deemed to have been obtained from the road cutting to
the extent to which useful materials were available for bank and shall not be paid for under
this item.
Rd. 12.5. Equipment - Pickaxes, crowbars, phawaras and pans may be used for manual
work. Scrapers, dozers graders, shovel, dumpers, trucks, trolleys, etc. may be used for
mechanized work. Three wheel 8 tonne Power Roller or sheeps-foot roller giving pressure
required to obtain the specified density may be used for compaction. Bullock carts with
tanks or mechanically driven tankers may be used for com­paction. Bullock carts with tanks
or mechanically driven tankers may be used for watering. Vibratory roller shall be used if
95 % standard Proctor density can not be achieved.
Rd. 12.6. Construction Methods -
Rd. 12.6.1. Diversions - If diversions, barricading and signals are found to be necessary,
they shall be provided as detailed in specification No. BR.1.
Rd.12.6.2. Preparing the ground for laying bank - Before any material is laid for the
bank the ground shall be cleared of all rubbish, etc. and the holes, if any, filled up as laid
down in Rd. 12.2. When the embankment is to be laid on hill sides or slopes, the existing
slopes shall be ploughed deeply. If the cross slopes are steeper than 1 in 3, steps with
reverse slope shall be cut into the slopes to give proper hold and seating to the bank as
directed by the Engineer. On surface flatter than 1 in 15 no special surface treat­ment
such as cutting steps shall be necessary. The top 15cm. of soil shall be scarified and
watered if directed and compacted to the same density as specified for the embankment
RED BOOK  VOLUME I  ROADS  2012 363
Rd.12.6.2.
before any material is laid for the bank-work.
 When the embankment is to be paced over an existing road or other hard surface
which is within 15cm. of the finished formation, the road or other hard surface shall be
scarified.
 The rate for embankment includes all the operations for preparing the bed for laying
the bank.
Rd. 12.6.3. Laying the bank - Embankment material shall be placed in successive
horizontal layers of 20cm. to 30cm. depth. ex­tending to the full width of the embankment
including the slopes at the level of the particular layer and 30cm. more on both sides to
allow compaction of the full specified section. The extra loose stuff at the edges shall be
trimmed later after completion of the full specified section. Without extra cost leaving the
correct section fully compacted.
 Keeping the width of the bank initially less and widening it later by dumping loose
earth on the slopes shall not be permitted as the additional width and slopes will remain
loose and uncompacted. Similar procedure to extend the embankment by dumping
the material longitudinally shall also not be allowed. When placing the bank work in
20cm to 30cm layers is not feasible as in water or over slopes too steep to operate
the construction equipment, the embankment may be constructed in one layer to
the minimum level at which equipment can be operated and above such a level, the
embankment shall be made up in layers of specified thickness. When boulders, broken
stones and similar hard materials are mixed with the embankment materials care shall
be taken to see that they are distributed uniformly into the bank and that no hollows are
left near them. No stone or hard materi­al shall project above the top of any layer. Each
layer of embankment shall be watered, leveled and compacted as specified hereinafter,
before the succeeding layer is placed. The surface of the embankment shall, at all times
during construction, be maintained at such a cross fall as will shed water and prevent
ponding. If bridges and culverts on the road are not completed in advance of bankwork,
a length of 15m to 30m from bank shall be left on each side of the structure and these
lengths shall be dealt with later for placing the bank work.
Rd.12.6.4. Watering - If the bank material contains less than the optimum moisture
water shall be added to the material in the borrow pits or alternatively in the loose layers
of embankment to bring the moisture uniformly up to requirement. If some moisture
is likely to be evaporated in transit or in the bank before compaction, adequate water
in excess shall be added to allow for the loss. If the material contains more than the
required moisture, it shall be allowed to dry until the moisture is reduced to the required
extent. If due to wet weather etc., the moisture content of the soil cannot be reduced
to the appropriate amount by exposure, bank work shall be suspended will suitable
conditions prevail without contractor’s claiming any compen­sation.
Water to be used shall be free of harmful elements which may cause heavy efflorescence,
etc., and approved by the Engineer. The contractor shall make his own arrangements
for getting adequate quant­ity of acceptable water.
Rd. 12.6.5. Compaction - When a loose layer is leveled manually or mechanically and
moistened or dried to a uniform moisture content suitable for maximum compaction, it
shall be compacted by power roll­er/vibratory roller/ sheeps foot rollers or heavy hauling
or dozing equipment to give the specified 95% of the standard Proctor density. The
contractor shall do additional compaction necessary to get 95% of the standard Proctor
density. If on testing, the density is found to be less than 95% of the standard Proctor
density the contrac­tor shall do additional compaction to get the specified density after
adding water if required. If the density cannot be improved on rea­sonable efforts, the

364 RED BOOK  VOLUME I  ROADS  2012

 Rd.
work may be accepted as substandard by the En­gineer, if he thinks it not harmful for
the purpose, at a reduced rate. Where the specified density is imperative the work shall
be removed and redone by the contractor at his own cost to give the specified density.
Vibratory roller shall be used to get the required density.
 Where the material allowed to be used is excessively stony or sandy so that it will
not compact to the required density where such material is otherwise acceptable for
embankment construction the Engineer may waive the tests for stony or sandy portions,
provided compaction effort is the same as in non-stony portions where the required test
results are obtained. Each layer shall be completed fully before the next layer is laid.
 Proper sequence of all component operations shall be maintained to give individual
progress.
To allow for subsequent settlement, the finished level of the embankment may be kept
higher than the specified level by 1cm. for each metre of the height of the bank and this,
if provided, will be paid for.
The hauling equipment, animals, labour etc., shall be made to go over the bank as far
as possible, to get the initial compaction.
 Care shall be taken for getting good compaction behind abutments, returns and wing
walls, etc.
Bank-work in areas not accessible to rollers such as those ad­joining bridges, culverts
and other works, shall be carried out inde­pendently of the main embankment and shall
have the layers placed in 10cm to 15cm. height and each layer shall be moistened
and thoroughly compacted with mechanical or manual tempers. Embankment shall be
bought up simultaneously in equal layers on each side and compacted carefully to avoid
unequal pressure, etc.
Rd. 12.7. Protection - Proper care shall be taken to ensure that the method of operation
and compaction of the bank-work does not cause damage or undue strain to any structural
element. Embankment over and around bridges or culverts shall be of approved materials
and careful­ly placed and compacted. The contractor shall take all precautions necessary
for the protection of the bank-work by diversion of streams, local surface drainage, rain
water, etc. likely to damage the bank. Any damage to the bank-work due to no protection or
inadequate protec­tion shall be made good by the contractor at his own cost. Conveyance
of materials shall not cause obstruction or nuisance to the nearby property owners and
traffic.
Rd. 12.8. Finishing - The embankment shall be finished and dressed smooth and even
in conformity with the alignment, levels, cross-sections and dimensions shown on the
drawings with due allowance for shrinkage. On curves, sections shall be provided with
super-elevation and increased widths as shown on the plans or directed by the Engineer.
All damages caused by rain, flood or any other reason shall be made good in the finishing
operations. The road land width shall be cleared of all debris and ugly spots near camping
areas, etc., for which the contractor or his men were responsible.
Rd. 12.9. Maintenance - The contractor shall be responsible for maintaining the bank-
work satisfactorily at his own cost till finally accepted including making good any damages.
Rd. 12.10. Tests –
(a) Tests shall be made to determine the maximum density of the material to be used by
the Protector method before starting the work.
(b) Density tests shall be carried out for the bank-work during the progress of the work.
One set of three core samples for every 1,000 sq.m. area of each layer of bank-work

RED BOOK  VOLUME I  ROADS  2012 365

Rd.
shall be taken and tested. The average density shall not be less than 95 percent of
the standard Proctor density.
A deviation of 80 kg. per cu.m. for fine and 160 kg. per cu.m. for coarse grained soils shall
be permitted in dry density in individual sample if the average density reaches up to 95
percent of standard Proctor density for each set.
Rd. 12.11. Item to include –
(1) Clearing site.
(2) Setting out alignment including necessary labour and materi­als and maintaining it as
long as required.
(3) Preparing the ground for laying the embankment.
(4) Providing and maintaining diversions if necessary unless provided as a separate
item in the tender.
(5) Obtaining the embankment materials including all lifts and leads and laying the bank
in layers, watering, compaction and tests and Royalties, fees, etc., if any.
(6) Protecting and maintaining the bank.
(7) Finishing the embankment.
(8) All labour, materials, use of equipment, tools and plant necessary for completing the
work satisfactorily.
Rd.12.12. Mode of measurement and payment - The contract rate shall be per cu. metre
of the finished bank-work. Measurements shall normally be taken by leveling sections and
chaining distances between them.
The measurements of the sections shall be limited to the dimen­sions shown on the drawings
or those ordered by the Engineer in writ­ing. The dimensions shall be recorded correct upto
two places of decimals of a sq.metre. The sectional areas shall be worked out correct upto
two places of decimals of a cu.m. by the average end area method.
The volume of bank thus calculated shall be reduced by 5 percent for the purpose of
payment when the measurements are taken for running bills and by 1 percent in final
measurements.
If outside materials have been used in the portions of the bank-work where materials from
cutting used according to Rd.11 the outside material shall be deemed to have been obtained
from the cutting as specified in those items and paid for under those items only.
Rd.13. Providing earthwork in embankment with approved materials obtained from
Departmental land or other sources including all lifts and leads, laying in layers of
20cm. to 30cm. thickness; breaking clods, dressing to the required lines, curves,
grades and sections and compacting with power roller/vibratory roller.
Rd.13.1. General - The work includes preliminaries of clearing site, setting out, preparing
the bed where necessary and constructing embankment for the road with materials obtained
from departmental land or other sources, laying them in layers and compacting with a
power roller to the required lines, curves, grades, cross-section and dimen­sions shown on
the plan or as directed by the Engineer with due allow­ance for shrinkage.
The work shall conform in all respects to the specification No. Rd.12 except for the following:-
Rd.13.2. Materials - All types of soils (except the black or shady or greatly shrinkable or
expansive soils as ordered by the Engineer), sand shingle mixed with soils, soft murum,
small boulders and broken rubble may be used. Stumps, pieces of wood or other per­
ishable materials shall not be used in the bank. Sods with humus or grass may be used as

366 RED BOOK  VOLUME I  ROADS  2012

 Rd.14.6
surface covering for the bank slopes to a thick­ness of not more than 30cm. if so permitted
by the Engineer.
The contractor shall obtain these materials from borrows in Government land if set apart for
the purpose or from other suitable sources by making his own arrangement.
The stipulations of Rd.12.4. except the portion in first para referring to densities shall also
apply.
Rd.13.3. Watering - No watering need be done. Scarifying and watering the base are not
necessary.
Rd.13.4. Compaction - The materials shall be laid in layers of 20cm. to 30cm. The layers
shall be compacted with a power roller of 10 to 12 tonnes/vibratory roller. The roller shall
pass at least twice over the same area, once in the forward move and the second time in
the backward move.
As far as possible, the trucks, carts, animals, labour, etc. shall be made to go over the bank
while doing their work to go initial compaction.
Care shall be taken to get good compaction behind abutments, returns, wing walls, etc.
Bank-work in areas not accessible rollers such as those adjoining bridges, culverts and
other works shall be carried out independently of the main embankment and shall have the
layers placed in 10cm. to 15cm. height and each layer shall be thor­oughly compacted with
manual tamper. Embankment shall be brought up simultaneously in equal layers on each
side of the structure and compacted carefully to avoid unequal pressures, etc.
Rd.13.5. Tests - There shall be no density tests but care shall be taken to see that rolling
on each layer is done as specified above.
Rd.13.6. Item to include -
(1) Clearing site
(2) Setting out alignment including necessary labour and materi­als and maintaining it as
long as required.
Rd 13.7 Mode of measurement and Payment - As per Rd.12.13 subject to the following -
The volumes of bank calculated shall be reduced by 10 % for the purposes of payment
when the measurements are taken during the same working season and by 5% if one or
more monsoons have lapsed.
Rd.14 Preparing embankment with approved materials obtained form the cutting
within a lead of 50 m. including laying in layers of 20 cm to 30 cm breaking clods,
dressing to the required lines, curves, grades and sections and compacting with
power roller/vibratory roller.
Rd.14.1 General - The excavated stuff of the approved quality as specified in Rd.10.4 shall
be laid in layers of 20 cm to 30 cm to the required lines, curves , grades and cross sections
as shown on the plans or as ordered by the engineer with in the lead as specified in the
wording of the item and compacted as specified in Rd. 13.4.
Rd.14.2 Clearing site - According to Rd.12.2.
Rd.14.3 Setting out - According to Rd.12.3.
Rd.14.4 Materials - As per Rd.10.4.
Rd.14.5 Equipment - According to Rd.12.5.
Rd.14.6 Construction methods - According to Rd.12.6. except that the compaction shall
be as per Rd.13.4 and no watering need be done.

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Rd.14.7
Rd.14.7 Protecting - According to Rd.12.7.
Rd.14.8 Finishing - According to Rd.12.8.
Rd.14.9 Maintenance - According to Rd.12.9.
Rd.14.10 Item to include - According to Rd.10.11.except for watering and tests.
Rd.14.11 Mode of Measurement and Payment - According to Rd.10.12.
Rd.15. Preparing embankment with approved materials obtained from the road
cutting including laying in layers of 20 cm to 30 cm break­ing clods, dressing to
the required lines, curves, grades and sections and compaction with power roller/
vibratory roller for a lead of -
a) Over 50 m to 300 m. - inclusive.
b) Over 300m to 500 m. - inclusive.
c) Over 500m to 700 m. - inclusive.
d) Over 700m to 1Km. - inclusive.
From the site of excavation to the site of deposition as directed.
Rd.15.1 General - The item shall comply with specification No.14 in all respects except for
the leads specified in the item.
Rd.16 Earthwork in embankment with approved materials obtained from Departmental
land or other sources including all leads and lifts, laying in layers of 15 cm to 20 cm
breaking clods, and dressing to the required lines, curves, grades and sections.
Rd.16.1 General - The work shall consist of preparing embankment for the road with
approved materials obtained from Departmental land or other sources, laying them in
layers in the required lines, curves, grades, cross sections and dimensions shown on the
plan or as directed by the Engineer.
Rd.16.2 Clearing site - According to Rd.12.2.
Rd.16.3 Setting out - According to Rd.12.3.
Rd.16.4 Materials - According to Rd.12.4 except that somewhat inferior local materials
shall be allowed to be used with written permission of the Engineer. Borrow pits shall not be
dug nearer than 3 m from the toe of the bank unless permitted in writing by the En­gineer.
Rd.16.5 Construction methods - Materials from borrow pits may be conveyed by trucks,
carts, donkeys or head loads.
Rd.16.5.1 Diversions - According to Rd.12.6.1.
Rd.16.5.2. Preparing the ground for laying bank - According to Rd.12.6.2 except that
no scarifying, watering and compaction may be done. Surface levels of natural ground
shall be taken and recorded for purposes of measurement.
Rd.16.5.3 Laying the bank - The embankment material shall be placed in successive
horizontal layers of 15 cm to 20 cm extending to the full width of the embankment
including the slopes at the level of the particular layer. When boulders, broken stones
and similar hard materials are mixed up with the embankment materials care shall be
taken to see that they are distributed well and uniformly into the bank and that no hollows
are left. No stone or hard material shall project above the top of any layer. Clods in each
layer shall be broken to about 5 cm size. Suitable allowance shall be made for prob­able
settlement of bank.
Rd.16.5.4 Compaction - The workpeople and/or the animals and the vehicles conveying

368 RED BOOK  VOLUME I  ROADS  2012

 Rd.17.9.
the materials shall pass over the bankwork as uniformly as possible to effect possible
compaction.
 When wearing surface of hard murum is to be laid immediately after completion of
bankwork, the formation shall be dressed to the required section and rolled with a bullock
or power roller, these operations being paid for under separate item for compacting the
hard murum.
 When the hard murum wearing surface is to be laid after the monsoon the formation
shall be left with a little concavity. Earthen bunds on both the edges and cross wise
shall be laid at suitable intervals and maintained throughout the monsoon for ponding
rainwater over the embankment for obtaining maximum compaction and settlement.
This shall not be paid for separately.
Rd.16.6 Protection - According to Rd.12.7.
Rd.16.7 Finishing - According to Rd.12.8.
Rd.16.8 Maintenance - According to Rd.12.9.
Rd.16.9 Item to include - According to Rd.12.11 excepting that no watering compaction
or testing shall be done.
Rd.16.10 Mode of measurement and Payment - According to Rd.12.12 except that the
deduction in quantity shall be 15 % when the measure­ments are taken in the same working
season and 10%if one or more mon­soons have passed.
Rd.17. Laying materials obtained from road cutting in layers, breaking clods, dressing
to the required lines, curves, grades and sections for embankment within a lead of
50 m.
Rd.17.1 General - The work shall consist of preparing embankment for the road with
approved materials obtained from road cutting after breaking clods, conveying, laying in
layers to the required lines, curves, grades, cross section and dimensions shown on the
plans or as ordered by the Engineer in charge.
Rd.17.2 Clearing site - According to Rd.12.2.
Rd.17.3 Setting out - According to Rd.12.3.
Rd.17.4 Materials - As per Rd.10.4.somewhat inferior materials may be allowed for this
item.
Rd.17.5 Construction methods - According to Rd.16.5.
Rd.17.6. Protection - According to specification No. Rd.12.7.
Rd.17.7. Finishing - According to specification No. Rd.12.9.
Rd.17.8. Maintenance - According to specification No. Rd. 12.9.
Rd.17.9. Item to include -
(i) Clearing site.
(ii) Setting out the alignment including necessary labour and materials and maintaining
it as, required.
(iii) Preparing the ground for laying the embankment.
(iv) Providing and maintaining diversions unless provided as a separate item in the
tender.
(v) Spreading the materials for the bank in layers after breaking clods to the required line
curves; grades and section and providing bunds for ponding rain-water.

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Rd.17.10.
(vi) Finishing the road section.
(vii) Protecting and maintaining bank.
(viii) All labour, materials and use of tools and plant for the satisfactory completion of the
item.
Rd.17.10. Mode of measurement and payment - According to Rd.10.12.
Rd.18. Conveying materials obtained from road cutting including all lifts, laying in
layers, breaking clods, dressing to the required lines, curves, grades and section for
a lead of-
(a) over 50m. to 300m.,
(b) over 300m. to 500m.,
(c) over 500m. to 700m.,
(d) over 700m. to 1km.
from the site of excavation to the site of excavation as directed.
Rd.18.1. General - The work shall consist of conveying the exca­vated materials including
all lifts to the lead mentioned in the wording of the item, laying in layers of 15cm. to 20cm.
breaking clods, dressing to the required section, lines, curves and grades as specified in
Rd.17 with additional lead.
Rd.18.2. Clearing site - According to Rd.12.2.
Rd.18.3. Setting out - According to Rd.12.3.
Rd.18.4. Materials - According to Rd. 17.4.
Rd.18.5. Construction method - According to 16.5.
Rd.18.6. Protection - According to Rd.12.7.
Rd.18.7. Finishing - According to Rd.12.8.
Rd.18.8. Maintenance - According to Rd.12.9.
Rd.18.9. Item to include - According to Rd.17.9 and also conveying the materials up to
the specified lead.
Rd.18.10. Mode of measurement and payment - According to Rd.10.12.
Rd.19. Supplying 15cm./23cm. rubble for soling at the roadside including conveying
and stacking complete.
Rd.19.1. General - The item provides for the supply of stone rubble of the specified type
and size at the roadside including ob­taining the rubble from approved sources, conveying
to the site of work including all lifts and leads and stacking in regular heaps as specified
hereinafter uniformly along the roadside.
Rd.19.2. Quarries - Where suitable and approved Departmental quarries exist, the
contractor shall be allowed to obtain the rubble of the requisite quality to the extent
required for the work from these quarries without any royalty. He shall, however, be liable
to pay compensation for any damage caused to the quarries or the Depart­mental land or
property either deliberately or through negligence or otherwise, or from waste of materials
in obtaining the requisite quantity of rubble.
Blasting, if required, shall be done with utmost care according to specification No. B.2
and the contractor shall be fully responsible for all accidents and compensation resulting
therefrom.

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 Rd.
When no suitable Departmental quarries exist or when the full quantity required for the
work cannot be obtained from the Departmen­tal quarries, the contractor shall make his own
arrangements to obtain the rubble. The contractor shall get the sources and the quality
of the rubble approved by the Engineer. The contractor shall be fully responsible for any
and all compensations to be paid as royalty, rents or damages to properties and injuries
to persons etc., caused in obtaining the rubble. No claim on account of any obstruction
caused in collection of materials or difficulties or action arising out of quarrying in private
and non-Departmental land shall be entertained and Government will remain indemnified
with regard to such action and payment.
Quarrying shall be done only from sound portions of approved quarries, the disintegrated
and weathered portions being rejected.
No rubble shall be obtained from within the road land unless so permitted in writing by the
Engineer.
Rd. 19.3. Rubble -
Rd.19.3.1. Quality - The rubble of the specified type of stones shall be hard, tough,
sound, durable, dense, clean, of close texture and free from unsound material, cracks,
decay and weathering. Their water absorption shall be as low as possible but not more
than 5 percent. They shall generally be broken rubble.
Rd. 19.3.2. Size - The shape of the stones shall be as regular as can be obtained by
quarrying without attempt at shaping or dressing. They shall be sufficiently flat bedded.
The stone shall be broken with the smallest dimensions equal to the specified thickness
of soling. The length and breadth should not generally exceed twice its thickness.
Before starting collection, the contractor shall get a sample conforming to the required
quality, shape and size approved by the Engineer who will keep it in his office for
reference.
Rd. 19.3.3. Conveyance to site - Materials shall be brought to site sufficiently in
advance of construction. The contractor shall be responsible to see that vehicles used
for transporting materials do not drop any of the contents on the road and thus cause
nuisance to traffic. The contractor shall also be responsible for any damage or accident
arising out of any such material failing on the road or elsewhere and shall attend to all
complaints in this regard. The Engineer may order the removal of such materials at the
expense of the contractor in case of neglect. Vehicle conveying or depositing materi­als
shall not obstruct traffic. All leads and lifts are included in the rate for the item.
Rd. 19.3.4. Stacking - The rubble shall be stacked uniformly along the roadside in regular
stacks of 6m. * 3m. * 1m. unless other sizes are ordered by the Engineer. Stacking shall
be made without appreciable hollows without making special efforts to hand-pack the
material. The stacks shall be free of earth, rubbish, vegetation, inferior or too much over
size or under size material. Only required number of stacks shall be laid in each of the
200m. section. One stack in each unit section may be of different length if necessary
to make up the total quantity in that particular section. Low and wide stacks with outer
retaining walls and the center filled in loosely shall not be permitted. The material shall
be stacked entirely clear of the carriage way and as far as possible beyond the side
widths and the side drains, on even ground on platforms prepared in advance for the
purpose by the contractor at his cost. If no such land is avail­able, the width of the stack
may be reduced and the stacks may be laid on the side widths with the approval of the
Engineer. Such stacks shall be protected from being disturbed. Necessary precautions
such as barricading, signs and signals shall invariably be taken the con­tractor being
responsible for any accident, injury and compensation due to his negligence in this

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Rd.
respect. On hill roads, material shall be stacked only on stacking berms. In the absence
of such berms within a reasonable distance, stacks shall be made only at places sited
on the side of the road as directed without interfering with free drainage.
 The Engineer may, if required get the stacks coming in the way of or obstructing the
traffic removed at the cost of the contractor and the contractor shall not be entitled to
claim for any loss or damage to the materials on that account. The stacking operations
shall be started at the point farthest from the quarry and carried towards the nearest
point. The stacks shall not be laid at such places where they are likely to be damaged
on account of the traffic, washing out by rains or floods or drainage, slides of the banks
or the slopes of cutting. Any loss on account of these or such other reasons shall be
made good by the contractor without extra claims.
As far as possible the rubble shall be stacked evenly on one side of the road only and in
such quantities per unit length as will be required for that particular length or as ordered
by the Engineer.
Rd. 19.4. Special points - The contractor shall be responsible for obtaining consents
of owners of quarries and lands, payment of royalties, fees, rents, taxes, octroi, etc.,
compensation due to injuries to persons or damages to property in any way connected with
the execution of this item and for loss of materials due to improper stacking etc., and shall
make good the losses without extra claims.
The contractor shall also be responsible for the blasting opera­tions required for obtaining
the rubble as explained in specification No. B.2.
Rd. 19.5. Item to include -
(1) Obtaining rubble of approved quality, shape and size by blasting if required and
payment of royalties, fees, rents, etc., where necessary.
(2) Conveying to roadside including all leads and lifts.
(3) Stacking.
(4) All sorts of compensations involved in the execution of the item.
(5) Opening up of new quarries or reopening old ones including removal of overburden.
Rd. 19.6. Mode of measurement and payment - The contract rate shall be for one cubic
metre of rubble supplied at site in stacks of approved size.
When the rubble is stacked in heaps of one uniform size, smallest heap may be chosen
in the particular km. or unit section and measured for its length, breadth and depth. The
cubic contents of this heap shall be multiplied by the number of such heaps in the km. or
unit section to arrive at the quantity in the particular km. or unit sec­tion. The Engineer may
measure any other heaps also for verification.
When the sizes of stacks are not uniform, each stack shall be measured individually.
The dimensions shall be measured correct to two places of deci­mals of a metre and quantity
worked out correct to two places of decimals of a cubic metre. If there is reason to believe
that the stacks are very loose and are having unduly large hollows and/or materials not
satisfying the specifications, the stacks may be got opened and restacked properly after
removing the inferior material by the Sub-Divisional Officer at the cost of the contractor.
The meas­urements of such a stack shall then be taken and if they are less than those of a
normal heap, the quality of the restacked heap shall be multiplied by the No. of stacks to
arrive at the quantity in the particular unit of length.
No deduction shall be made for voids.
Rubble shall not be used until the full quantity is collected in a Km. and measured. All

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 Rd.20.4.
stacks measured shall be marked with lime wash bands to distinguish them to avoid double
measurement.
All labour, materials, etc., required for measuring, restacking, checking, lime washing, etc.,
shall be at the cost of the contractor.
Rd.19.(a) Supplying 80mm metal at the roadside for soling includ­ing conveying and
stacking complete.
Rd.19(a).1. General - The item provides for the supply of speci­fied type of stone metal
80mm size at the roadside for filling the voids in the soling including obtaining the rubble
from approved sources and breaking to size, conveying to the site of work, including all
lifts and leads and stacking in regular heaps as specified herei­nafter uniformly along the
roadside.
Rd.19(a).2. Quarries - As per Rd.19.2.
Rd.19(a).3. Rubble -
Rd.19(a).3.1. Quality - As per Rd.19.3.1.
Rd.19(a).3.2. Size - The longest dimension May not be more than 100mm. and the
shortest dimension not less than 50mm.
Rd.19(a).3.3. Conveyance to site - As per Rd.19.3.3.
Rd.19(a).3.4. Stacking - As per Rd.19.3.4.
Rd.19(a).3.5. Special points - As per Rd.19.3.4.
Rd.19(a).3.6. Item to include - According to Rd.5.8 and breaking the rubble to the
required size.
Rd.19(a).3.7. Mode of measurement and payment - According to Rd.19.6.
Rd.20. Supplying 60mm. oversize metal at the roadside including conveying and
stacking complete.
Rd.20.1. General - The item provides for the supply of specified type of stone oversize
metal at the roadside including conveying and stacking complete.
Rd.20.2. Quarries - Rubble for breaking oversize metal shall be obtained from quarries as
per specification No. Rd.19.2.
Rd.20.3. Oversize metal - 60mm. size metal is also usually called oversize metal.
Rd.20.3.1. Quality - Quality should satisfy specification No. Rd.19.3.1. The abrasion
value of stones shall not be more than 50%.
Rd.20.3.2. Size - The rubble shall be either manually broken or mechanically crushed
to pieces so as to pass through a square mesh of 80mm internal dimension and retained
on a square mesh of 50mm. Howev­er, the following tolerance should be permitted for
water bound maca­dam. Not more than 20 percent of any sample shall exceed 90mm.
in its greatest dimension. The pieces shall, as far as possible be cubical and have sharp
edges. A sample conforming to the quality, shape and size shall be got approved by the
Engineer before large scale break­ing. The Engineer will keep the sample in his office
for reference. Chura and dust may be allowed up to 15% of the volume of the stack.
The material which will pass through I.S. sieve No.8 will be treated as Chura and dust.
Rd.20.3.3. Conveyance - According to specification No. Rd.19.3.3.
Rd.20.3.4. Stacking - According to specification No. Rd.19.3.4. The heaps may be 6m.
* 3m * 0.5m. as ordered by the Engineer.
Rd.20.4. Special points - According to specification No. Rd.19.3.3.
RED BOOK  VOLUME I  ROADS  2012 373
Rd.20.5.
Rd.20.5. Item to include - Providing and breaking the rubble to metal of the specified size
of 60mm. conveying to roadside and stack­ing including all other relevant items mentioned
in specification No. Rd.19.5.
Rd.20.6. Mode of measurement and payment - According to specifi­cation No. Rd.19.6.
where the heaps in a km. or a unit length are of uniform size one or more heaps in the km.
may be restacked or refilled at the cost of the contractor in places and all the heaps in that
km. or unit length will be taken as equal to the smallest of the restacked heaps and the total
quantity worked out on that basis. In case of stacks suspected to contain inferior, oversize
or undersize material, they shall be opened up and restacked properly at the cost of the
contractor excluding the material not conforming to specifications and shall be measured
on the basis of such restacked heaps as mentioned in specification No. Rd.19.6.
Rd.21. Supplying 50mm. metal at the roadside including conveying and stacking
complete.
Rd.21.1. General - The item provides for the supply of specified type of stone metal of
50mm. size at the roadside including obtaining the metal from approved sources, conveying
to the roadside with all leads and lifts, stacking in regular heaps as specified hereinafter
uniformly along the roadside.
Rd.21.2. Quarries - Rubble for breaking metal shall be obtained from quarries as per
specification No. Rd.19.2.
Rd.21.3. Metal -
Rd.21.3.1. Quality - The stones for breaking metal shall be of the type mentioned in the
item and shall be hard, tough, sound, du­rable, clean, dense, close grained and free from
soft decayed and weathered portions and shall successfully resist weathering, abrasion
and fracture under traffic. Stones should have freshly broken faces. Disintegrated
stones or those with loose skin shall be excluded. the abrasion value of stones shall not
be more than 50%.
Rd.21.3.2. Size - The rubble shall be broken or crushed to pieces to pass through a
square mesh of 60mm internal dimension. All pieces shall be retained on a square mesh
of 40mm. internal dimension. However, the following tolerance shall be permitted for
water bound macadam. Not more than 20 percent of any sample shall exceed 80mm in
its greatest dimension. Chura and dust may be allowed up to 15% of the volume of the
stack. The material which will pass through I.S. sieve no.8 will be treated as Chura and
dust.
 The pieces shall be roughly cubical in shape and more or less of uniform size with
sharp edges for interlocking wit one another and resisting displacement. Rounded, flaky,
thin, elongated material shall not be accepted. Before large scale breaking a sample
conforming to the required quality shape and size shall be got approved by the En­gineer,
who will keep it in his office for reference.
Rd.21.3.3. Conveyance - According to specification No. Rd.19.3.3.
Rd.21.3.4. Stacking - According to specification No. Rd.19.3.4. The heaps may be 5m.
* 2m. * 0.5m. or as ordered by the Engineer.
Rd.21.4. Special points - According to specification No. Rd.19.4.
Rd.21.5. Item to include - Providing and breaking the rubble to metal of the specified
size of 50mm. conveying to roadside and stack­ing including all other relevant items
mentioned in specification No. Rd.19.5.
Rd.21.6. Mode of measurement and payment - According to specifi­cation No.
Rd.20.6.
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 Rd.23.2.
Rd.22. Supplying 40mm. metal at the roadside including conveying and stacking
complete.
Rd.22.1. General - The item provides for the supply of metal of 40mm. size and of the
specified type of stones at the roadside includ­ing obtaining the metal from approved
sources, conveying to the road­side with all leads and lifts, stacking in regular heaps as
specified hereinafter uniformly along the roadside.
Rd.22.2. Quarries - Rubble for breaking metal shall be obtained from quarries as specified
in specification No. Rd.19.2.
Rd.22.3. Metal -
Rd.22.3.1. Quality - Metal shall be broken from approved rubble and shall satisfy
specification No. Rd.21.3.1.
Rd.22.3.2. Size - The rubble shall be broken by hand or crushed mechanically to pieces.
Size of the metal shall be under :-
Standard Percentage passing through square Percentage retained in mesh
size mesh of internal dimension of of internal dimension of
40mm 60mm - 100% 60mm - 0%
40mm - 35 to 70% 40mm - 30 to 65%
12mm - 0 to 5% 12mm - 95 to 100%
However the following tolerance shall be permitted for water bound macadam: Not more
than 20 percent of any sample shall exceed 65mm in its greatest dimension. Chura and
dust may be allowed up to 15% of the volume of the stack. The material which will pass
through I.S. Sieve No. 8 will be treated as chura and dust.
 The pieces shall be roughly cubical in shape and more or less of uniform size with
sharp edges for inter locking with one another and resisting displacement. Rounded,
flaky, thin, elongated material shall not be accepted. Before large scale breaking, a
sample conform­ing the required quality, shape and size shall be got approved by the
engineer, who will keep it in his office for reference.
Rd.22.3.3. Conveyance - According to specification No. Rd.19.3.3.
Rd.22.3.4. Stacking - According to specification No. Rd.21.3.4. Where metal for two
layers has to be stacked, the metal for each layer shall be stacked on the opposite side
of the road or as directed by the Engineer.
Rd.22.4. Special Points - According to specification No. Rd.19.4.
Rd.22.5. Item to include - Providing and breaking or crushing the rubble to metal of the
specified size of 40mm. conveying to roadside and stacking including all other relevant
items mentioned in specifi­cation No. Rd.19.5.
Rd.22.6, Mode of measurement and payment - according to specifi­cation No. Rd.20.6.
Rd.23. Supplying hard murum/kankar at the roadside including conveying and
stacking complete.
Rd.23.1. General - The item provides for the supply of hard murum or kankar as mentioned
in the item, at the roadside including obtain­ing it from approved sources, conveying to
roadside with all leads and lifts, stacking in regular heaps as specified hereinafter uniformly
along the roadside.
Rd.23.2. Quarries - Specifications applicable to rubble in Rd.19.2. will be applicable to
hard murum quarries etc. except that the quarries shall be of hard murum or kankar as
specified instead of stone.
RED BOOK  VOLUME I  ROADS  2012 375
Rd.23.3.
Rd.23.3. Hard Murum/Kankar -
Rd.23.3.1. Quality -
Hard Murum - The hard murum shall be of disintegrated trap, granite, quartzite or
gness rock freshly quarried. It shall be sufficiently hard and free from soft murum, earth,
organic matter or order deleterious or soft material. Before starting collec­tion a sample
should be got approved by the Engineer who will keep it in his office for reference.
The size of the hard murum shall generally be as follows :-
Size (square mesh) percentage passing through,
80mm. 95%
25mm 2%.
Kankar - Kankar shall be as tough as can be procured in the locality. A brown almost
opalescent fracture will generally indicate a good Kankar. It shall not contain any clay in
the cavities between the modules. 100% shall pass through a square mesh of 65mm.
Before starting collection a sample of kankar shall be got approved by the Engineer who
will keep it in his office for reference.
Rd.23.3.2. Conveyance - Specifications applicable to metal in specification No.
Rd.20.3.3 will also be applicable to hard murum or kankar.
Rd.23.3.3. Stacking - Specifications applicable to metal in specification No. Rd.20.3.4
will apply to stacking of hard murum.
Rd.23.4. Special points - The contractor shall be responsible for obtaining consents of
owners of quarries and lands, payment of royal­ties, fee, rents, taxes octroi etc. compensation
due to injuries to persons or damages to property in any way connected with the execution
of the item and for the loss of material due to improper stacking etc. and shall make good
the losses without extra claims.
Rd.23.5. Item to include - Obtaining hard murum or kankar as mentioned in the item of
approved quality and size including payment of necessary royalties, fees, rents, and other
relevant items accord­ing to specification No. Rd.19.5.(2 to 5).
Rd.23.6. Mode of measurement and payment - The stipulations applicable to rubble in
specification No. Rd.19.6 will be applicable to hard murum or kankar also.
Rd.24. Supplying soft murum at the roadside including conveying and stacking
complete.
Rd.24.1. General - The item provides for the supply of soft murum at the roadside including
obtaining the soft murum from approved sources, conveying to roadside with all leads and
lifts, stacking in regular heaps as specified hereinafter uniformly along the roadside.
Rd.24.2. Quarries - Specification applicable to rubble in Rd.19.2 will be applicable to soft
murum quarries also except that the quar­ries shall be of soft murum instead of stone.
Rd.24.3. Soft murum - The soft murum shall be obtained from approved sources and shall
be got approved before starting the supply.
Rd.24.3.1. Quality - Soft murum shall be of granular type free from earth, organic
matter, black cotton soil and any other interior material.
Rd.24.3.2. Conveyance to site - Specifications applicable to metal in specification No.
Rd.20.3.3 will be applicable to soft murum.
Rd.24.3.3. Stacking - Specifications applicable to metal in specification No. Rd.20.3.4.
will also be applicable to soft murum.

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 Rd.26.4.
Rd.24.4. Special points - According to Rd.23.4.
Rd.24.5. Item to include - Collection of soft murum on roadside and relevant items
mentioned in specification No. Rd.19.5.
Rd.24.6. Mode of measurement and payment - The specifications applicable to rubble
in Rd.19.6 shall be applicable to soft murum also.
Rd.25. Supplying sand at the roadside including conveying and stacking complete.
Rd.25.1. General - The item provides for the supply of sand to the roadside including
obtaining the sand from approved sources, conveying to roadside with all leads and lifts,
stacking in regular heaps as specified hereinafter uniformly along the roadside.
Rd.25.2. Source - The contractor shall make his own arrangements from available sources
to obtain the sand.
Rd.25.3. Sand -
Rd.25.3.1. Quality - The sand shall be got approved before start­ing the supply. The
sand shall be free from organic or deleterious matter. The sand shall be coarse, hard
and shall not generally con­tain particles bigger than 6mm. and silt more than 10 percent.
Rd.25.3.2. Conveyance to site - The specification applicable to rubble in Rd.19.3.3.
shall be applicable to sand also.
Rd.25.3.3. Stacking - The specification applicable to metal in Rd.20.3.4. shall be
applicable to sand also.
Rd.25.4. Special points - According to specification No. Rd.23.4.
Rd.25.5. Item to include - Collection of sand on roadside and relevant items mentioned in
specification No. Rd.19.5 so far as they are applicable for sand instead of rubble.
Rd.25.6. Mode of measurement and payment - According to specifi­cation No. Rd.20.6.
Rd.26. Supplying gravel at the roadside including conveying and stacking complete.
Rd.26.1. General - The item provides for the supply of gravel to the roadside including
obtaining the gravel from approved sources, conveying to roadside with all leads and lifts,
stacking in regular heaps as specified hereinafter uniformly along the roadside.
Rd.26.2. Sources - The contractor shall make his own arrangements from available
sources to obtain the gravel.
The sources, the quality and size of gravel shall be got approved before starting the supply.
A sample shall be got approved by the Engineer who will keep it in his office for reference.
The contractor shall be fully responsible for any and all compen­sations, royalty, fees, rents,
taxes, octroi, damage, injury, etc. in obtaining the gravel.
Rd.26.3. Gravel -
Rd.26.3.1. Quality - The gravel shall be free from organic or deleterious matter. The
gravel shall be hard, tough, dense and shall not generally contain particles bigger than
12mm. and silt more than 10 percent.
Rd.26.3.2. Conveyance to site - The specifications applicable to rubble in Rd.19.3.3
shall be applicable to gravel also.
Rd.26.3.3. Stacking - The specifications applicable to metal in Rd.20.3.4 shall be
applicable to gravel also.
Rd.26.4. Special points - According to specification No. Rd.23.4.

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Rd.26.5.
Rd.26.5. Item to include - Collection of gravel on roadside and relevant items mentioned
in specification No. Rd.19.5. so far as they are applicable for gravel instead of rubble.
Rd.26.6. Mode of measurement and payment - According to specifi­cation No. Rd.20.6.
Rd.27. Laying 15cm./23cm. rubble soling including hand packing with rubble chips
complete (excluding the cost of materials).
Rd.27.1. General - The item provides for the labour for laying soling of specified type of
stones in the specified thickness includ­ing preparing the sub grade to proper section by
scraping, dressing, compaction, etc. and hand packing the rubble chips to the required line,
curve, grade and section.
Rd.27.2. Diversion - When the traffic can be allowed on the roadside berms without
much inconvenience to traffic or impediment to the work, this shall be provided by the
contractor at this own cost. He shall provide the necessary barricading, warning boards and
signals and watchmen by day and red lights at night and comply with relevant provisions
of specification No.BR.1. Otherwise, a separate diversion shall be provided according to
specification No. BR.1.
Rd.27.3. Construction -
Rd.27.3.1. Preparation of sub-grade - The sub-grade shall be marked by stakes and
strings for the required width for laying of the soling in line, curve, section and grade
with reference to the center­line. The edge line stakes shall be ranged for a sufficiently
long length to obtain straight lengths and uniform curves. The contractor shall clear off
the area and do the necessary trimming or filling for laying of the soling in line, curves,
grades and section.
 All filling shall be watered and compacted to get maximum consolation. The cam­ber,
super elevation etc. of the sub-grade shall conform in shape to those of the finished
road surface and if in any section of the road surface is loose, undulating or uneven, the
contractor shall at his own cost make it up with suitable materials, water and compact it
and obtain the correct section. Camber boards shall be used to get the required section.
Rd.27.3.2. Laying soling - The rubble collected by the roadside shall be laid with the
largest face downwards and in contact with each other. The stones shall break joint as
far as possible. The full thickness of the soling shall generally be made with one stone
only. The junction of the old road and the new construction shall be diagon­al in plan and
the soling shall be in level with the corresponding course of the old road.
 Unless otherwise provided in the plans or directed by the En­gineer, the width of the
soling shall be 30cm. more than that of the metal above.
Rd.27.3.3. Hand-packing - As the laying of rubble advances the soling shall be hand
packed by wedging and packing with 80mm. metal collected for the purpose in the joints
of the soling and driving them by hammers in place so as to fill the voids as completely
as possible.
The soling shall be laid and hand packed true to grade and section and these shall be
often checked by boning rods, template boards and fish line etc. The grades, section
etc. of the soling shall correspond to those of the surfacing coming on it.
 The soling thus laid shall be finished by knocking out projecting stones and filling
depressions by chips to come up to the grade and camber.
Rd.27.4. Item to include –
(1) Setting out including labour and materials like stakes strings, fish line boning rods,
and camber boards.

378 RED BOOK  VOLUME I  ROADS  2012

 Rd.29.3.
(2) Diversion, barricading, signaling and controlling traffic if necessary unless separately
provided in the tender.
(3) Conveying the rubble from stacks on the roadside and laying the soling to the required
line, curve, grade and section including clearing, sectioning, dressing grades and
section and compacting the sub-grade, breaking rubble, and hand packing with
80mm. metal.
(4) All labour, materials and use of equipment and tools required for carrying out the
work satisfactorily.
Rd.27.5. Mode of measurement and payment - The contract rate shall be for one cubic
metre of soling laid hand packed and finished.
The width and depth shall be restricted to the specified width and depth. The dimensions
shall be recorded correct up to two places of decimals of a metre and the quantity calculated
correct up to two places of decimals of a cubic metre. No deduction shall be made for voids.
Rd.28 - Spreading gravel/sand/soft murum/hard murum.
Rd.28.1. General - The item provides for the labour for conveying grave sand / soft murum
/ hard murum etc. from the roadside stacks and spreading it for filling the interstices and
voids in the rubble soling.
Rd.28.2. Spreading - The gravel etc. shall be conveyed from the stacks on the roadside
and spread evenly over the rubble soling or as blindage or formation as the case may be.
The quantity of gravel to be spread per sq.m. of the rubble soling shall be as directed
by the Engineer. If so ordered, initially less quantity of gravel may be spread and the
remaining spread after words.
If the gravel etc. does not enter the interstices of the soling etc. fully it may be swept by
brooms to fill them if so directed by the Engineer.
Rd.28.3. Item to include -
(1) Conveying the gravel stacked along the roadside and spreading evenly over the
rolled surface and brooming it to fill the voids and interstices.
(2) All labour and use of tools to complete the item satisfactorily.
Rd.28.4. Mode of measurement and payment - According to specifi­cation No. Rd.29.5.
Rd.29. Spreading oversize metal/size metal including sectioning complete.
Rd.29.1. General - The item provides for the labour for conveying the oversize metal/size
metal from the roadside stacks and spreading it for the road crust.
Rd.29.2. Diversions - According to specification No. Rd.27.2.
Rd.29.3. Spreading metal - The metal shall be screened if it contains grass, rubbish or
other deleterious foreign material. The metal shall be spread evenly over the rolled rubble
soling surface by giving a twisting motion to the basket at the time of spreading - Rolling
over soling is included under the rolling of oversize metal true to line, grade and section to
provide the requisite thickness of crust. In order to ensure the correct thickness, the road
area shall be suitably marked so as to receive the contents of one heap for the specified
thickness in the area marked. The unevenness and undula­tions after the spreading shall
be rectified either by thinning the metal or adding it as required. The metal so spread shall
be checked by camber boards and line for the camber and grade at intervals of every
10 metres or so. The edge line stakes shall be ranged for a sufficiently long lengths and
uniform curves.
The sides of the metal shall be held by bunds of murum to prevent metal from spreading if

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Rd.29.4.
side widths are not provided at the time. These bunds shall be of such depth as to support
the metal.
The junction of the existing road and the new construction shall be diagonal in plan.
Between the straight lengths and curves and at the meeting points of convex and concave
portions of reverse curves the change in the camber shall be made very gradually as
directed by the Engineer.
Rd.29.4. Item to include –
(1) Providing bunds of murum, etc. at the edges of metal to one cubic meter of metal.
(2) Conveying the metal from the roadside and spreading evenly to the required depth,
width and section.
(3) Diversion if necessary unless separately provided in the tender.
(4) All labour, materials and use of tools required for the satisfactory completion of the
item.
Rd.29.5. Mode of measurement and payment - The contract rate shall be for spreading
one cubic metre of metal.
The quantity spread shall be arrived at by deducting the quantity in balance on site from the
total collection existing on the roadside before spreading is started. The quantity on site
shall be checked before spreading is started and after completion of spreading.
Rd.30. Compacting sub-grade, soling, gravel, oversize metal/size metal, sand and
soft murum layers in wide with power roller/vibratory roller including artificial
watering complete.
Rd.30.1. General - The item provides for fully compacting the oversize metal/size metal
layer with a power roller of 10 to 12 tonnes weight including compacting the sub-grade,
rubble soling and gravel before spreading the oversize metal and rolling over the oversize
metal surface first dry to refusal and them again after watering and also after spreading of
sand and soft murum blind age necessary la­bour, use of roller etc., complete.
Rd.30.2. Road diversions - According to specification No. Rd.27.2.
Rd.30.3. Rolling over the sub-grade and the soling - The sub-grade shall be rolled after
it is dressed to the required grade and section before laying the soling. The soling after it is
properly laid and hand packed shall be rolled dry with 10 to 12 tonne power roller to refusal
i.e. till the stones n the soling cease to move under the roller and no more compaction can
be achieved. In case of unevenness, high spots shall be knocked out and depressions
filled by spells and recompacted fully. Bunds shall be laid along the edges and compacted
before starting rolling on soling to prevent spreading of stones.
Gravel shall then be spread (To be paid undrer separate item) over the rolled soling and the
surface rolled over again to weigh gravel in the voids of soling.
Rd.30.4 Compaction of over size metal
Rd.30.4.1 General - T he compaction shall be done with 10 to 12 tonne power roller/
vibratory roller. The rolling shall begin with the outside rear wheel covering part of
shoulder and metal. The roller shall be run forward and backward until the shoulder
holds the metal firmly. The rolling shall then progress from edge to the centre in strips
parallel to the center line of the road. Rolling shall be done by lapping each preceeding
strip and shall continue until all the surface has been rolled to refusal. Side bunds shall
be raised before starting to hold the material.
 On super elevation rolling shall be started at the inner edge and carried towards the

380 RED BOOK  VOLUME I  ROADS  2012

 Rd.31.4
outer edge. During and after rolling the sec­tions and grade shall be checked with camber
boards and straight edges and defects corrected. The stretch started on a day shall be
completed the very day. On completion of a day’s work the roller shall be made to stand
on the side width of the road and guarded and protect­ed by barricades. Red light /
reflector shall be hung on the roller to prevent accident.
Rd.30.4.2 Dry rolling of over size metal - Thre rolling shall be completed as described
above till movement under the wheel ceases. This can be judged by -
1. Metal ceases to move.
2. Crushing of metal takes place.
3. Loaded bullock cart leaves no impression.
Rd 30.4.3 Wet rolling - After dry rolling the surface shall be watered freely and rolled
again. Sand shall then be spread to a thick­ness of about 6mm and the rolling done over
the sand. Watering shall be done again and murum blindage spread and the surface
finally rolled lightly.
Rd 30.4.4 The road may be opened to traffic after the macadam has set and in any case
not earlier than 24 hours of rolling. Watering shall be done wherever necessary for 2-3
days after the opening of the road.
Rd. 30.5 Item to include -
1) Rolling over subgrade, soling, gravel including all labour, use of machinery etc.
2) Dry and weight rolling of over size metal including all labour use of equipment etc.
3) Making good unevenness.
4) Final rolling over sand and murum.
5) Watering.
6) Diversion to traffic.
Rd.30.6 Mode of measurement and Payment - The contract rate shall be for 1 Kilometer
of length. The length shall be measured along center line correct upto 10 cm.
Rd.31 Picking the road surface including sectioning complete.
Rd.31.1 General - The item provides for picking and sectioning of the road surface.
Rd.31.2 Diversion - According to Rd.27.2.
Rd.31.3 Picking - All the caked mud, slush, vegetation and other rubbish on the road
surface shall be removed. Where the profile of road is good the surface shall be picked
lightly to loosen the surface metal. Where the profile is uneven the picking shall be done a
little deeper to enable sectioning to the required shape. Picking shall be done sufficiently
ahead of spreading of metal. The edges of picking shall be in true line or curve as required.
The picked surface shall be sectioned to the required grade, camber, superelevation etc.
Templates shall be used to obtain correct profile.
The road surface may be watered for ease in picking. Watering shall not qualify for payment.
The junctions of picked and non picked surfaces shall be digonal.
Rd.31.4 Item to include –
1) Picking.
2) Watering if required.
3) Sectioning.
4) Diversions etc.
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Rd.31.5
5) All necessary labour, material, use of equipment etc. com­plete.
Rd.31.5 Mode of measurement and Payment -
The contract rate shall be for 1 Sq.m.
The dimensions shall be recorded correct upto 1 cm. The length shall be measured along
the center line of road. The width shall be limited to the specified width. The area shall be
worked out correct upto 1 sq.m.
Rd.32 Compacting the metal layer -- meter wide with power roll­er/vibratory roller
including necessary labour, materials, artificial watering and use of equipment etc.
complete.
The specification for this item shall comply with the relevant specifications of Rd.30.
The layers of metal shall not be more than 8 cm.
In order to check the average thickness, trial area shall be laid with a known weight of a
material in order to determined the area cov­ered per tonne and daily checks shall be made
on the coverage obtained with the assessed daily tonnage laid.
Rd.33. Supplying -
a) 40 mm.
b) 25 mm.
c) 20 mm.
d) 12 mm.
e) 10 mm.
f) 6 mm.
aggregate at the road side including conveying and stacking for use in bituminous road
surfaces.
Rd.33.1 General - The item provides for the supply of stone ag­gregate of the specified
type and size at the road side including obtaining the stones of the specified quality from
approved sources, crushing them in mechanical crushers, conveying to the road side with
all leads and lifts, stacking in regular heaps as specified hereinaft­er uniformly along the
road side.
Rd.33.2. Quarries :- Stones of approved type for crushing aggregate shall be obtained
from quarries as specified in specification No. Rd.19.2.
Rd.33.3. Stone aggregates -
Rd.33.3.1. Quality - The aggregates shall be obtained by crush­ing approved stones of
specified type in a mechanical crusher and shall be clean, strong, tough, dense, durable,
close grained and free from soft, decayed and weathered portions and from coating of
dust, dirt or other objectionable matter. They shall preferably have good hydrophobic
characteristics. They shall generally satisfy the follow­ing physical requirement:-
For heavy traffic.
Los Angles abrasion test; per cent, fines maximum 40
Aggregate crushing test; per cent, fines maximum 30
Water absorption by weight after 24 hours
immersion; per cent, not more than 1
Tests shall be carried out according to I.S.383-1970 --
 Tests considered necessary shall be carried out in an approved labora­tory when the
382 RED BOOK  VOLUME I  ROADS  2012
 Rd.34.2.
Engineer considers the quality to be doubtful or there is a dispute about the quality. If
the results are satisfactory, the cost of tests shall be borne by the Department and if
unsatisfactory by the contractor.
Rd.33.3.2. Size - Size of the metal and chips shall be as under:-

Standard Size. Wholly passing through Wholly retained on

square mesh of internal square mesh of internal
dimension dimension
40 mm 50 mm 25 mm.
25 mm. 40 mm 20 mm.
20 mm 25 mm 12 mm.
12 mm 20 mm 10 mm.
10 mm 12 mm 6 mm.
6 mm 10 mm 5 mm.
 Note :- Not more than 20% of any sample shall exceed in its greatest dimension,
standard size plus 25 mm. for 40 mm. standard size, standard size plus 12 mm. for 25
mm., 20 mm. and 12 mm. standard sizes and standard size plus 6 mm. for 10 mm. and
6 mm. standard sizes.
The pieces shall be roughly cubical in shape and more or less of uniform size with sharp
edges for interlocking. Rounded flaky, thin, elongated pieces shall not be accepted.
Before collection, samples of the metal and chips shall be got approved for quality, size
and shape by the Engineer who will keep them in his office for reference. They shall be
completely dry at the time of use.
Rd.33.3.3. Conveyance - According to specification No.Rd.19.3.3
Rd.33.3.4. Stacking - According to specification number Rd.22.3.4. Whenever a
mixture of aggregates of two or more standard sizes is specified for the work, each size
of aggregates shall be stacked separately and entirely clear of the carriageway and
where possible clear of the shoulders also. They shall be stacked in such a manner so
as to prevent mixture, deterioration or contamination.
Rd.33.4. Special points - According to specification No.Rd. 19.4
Rd.33.5. Item to include - Crushing aggregates to the specified sizes from approved
rubble and other items included in specification No. Rd.19.5.
Rd.33.6. Mode of measurement and payment - According to specification No. Rd.19.6
Rd 34. Supplying bitumen of the I.S. Grades -- at the site of work including conveying
and stacking properly and protecting it till used.
Rd.34.1. General - The item provides for the supply of bitumen of the specified grade
conforming to the requirements of the pertinent grade in I.S. No.73-1961. Certain standard
proprietary brands of bituminous materials having the properties conforming to the standard
grades may be specified as the grade acceptable for the type of surfacing and the conditions
in which it is to be constructed. The bitumen shall be supplied in suitable drums including
conveying it to the site of work, stacking properly and protecting till used. Alternatively it
may be supplied by bowsers.
Rd.34.2. Grades and quality - The bitumen shall conform to the grade S.35 with 30/40

RED BOOK  VOLUME I  ROADS  2012 383

Rd.34.2.
penetration of grade S. 90 with 80/100 penetration as specified in I.S. 73-1961. Grade S.
65 with 60/70 penetration shall be used when so ordered.
Rd.34.3. Supply –
(i) When supplied by the Department it shall be issued at the place mentioned in schedule
“A” of the agreement and at the rate mentioned therein. Conveying it to the site shall
be done by the contractor at his cost.
(ii) When not supplied by the Department, the contractor shall make his own arrangement
to obtain at the worksite the bitumen of the specified grade from one of the standard
companies. He shall on demand by the Engineer, obtain and furnish a laboratory
test certificate proving to the satisfaction of the Engineer that the material conforms
to the requirement of the specified grade. Bulk supply in standard tankers may be
arranged at site of work, if approved.
Rd.34.4. Packing and marking - The bituminous materials shall be supplied in non-
returnable drums of such type and strength as will withstand transportation and handling
and such as to have no leakage at any time. The grade of the material, the trade name,
if any, the name of the manufacturer and the weight of the material in the drum shall be
painted on each drum.
Rd.34.5. Handling and transport - Great care shall be taken in loading the drums both
in the case of road and rail transport. Wooden skids or other suitable arrangement shall
be used for rolling the drums up or down to avoid damage in these operations. In no case
shall the drums be thrown down. They shall be conveyed to the site of storage or use very
carefully.
Rd.34.6. Storage - Drums containing different grades shall be kept separate to allow easy
inspection and identification and in such place as will not damage the drums and cause
leakage of the material or intrusion of water and other foreign matter. They shall not be
stored in low lying areas where water is likely to accumulate. As far as possible, the drums
may be stacked on their sides and not on their ends so that the rain-water, if any, will drain
off quickly.
At the site of work the drums shall be stacked properly in suitable localities on the roadside
and protected.
Any damage, loss or wastage in transport, handling and storage due to negligence or any
other cause shall be the responsibility of the contractor and he shall make good the same
without extra claims.
Rd.34.7. Sampling and testing - When the supply is made by the contractor he shall furnish
on demand, laboratory test certificate to show that the material satisfies the requirements
of the specified grade. If there be any doubt about the quality thereafter, the tests shall be
carried out again in an approved laboratory according to the standards specified in I.S. 73-
9161. and the cost shall be met by the Department if the results are satisfactory and by the
contractor if unsatisfactory. Material not satisfying the requirements shall be rejected.
Rd.34.8. Keeping records - The contractor shall keep a day-to-day account of the supply
and use of the bitumen in a separate register and obtain signatures of the responsible
Departmental staff member. The register shall be maintained by the contractor and produced
when so ordered by the Engineer.
Rd.34.9. Return of empty drums - When supply is made by the Department, the contractor
shall return the empty drums in good condition to the place of issue.
If the empty drums are not returned in good condition, compensation at the rate mentioned
in the schedule ‘A’ or special provisions will have to be paid for such drums when the supply
384 RED BOOK  VOLUME I  ROADS  2012
 Rd.35.3.1.
is made by the Department.
Rd.34.10. Item to include -
(i) Obtaining the bitumen from the Department or from a Company.
(ii) Transporting to site.
(iii) Storing and Stacking.
(iv) Protecting.
(v) Keeping record of supply and use.
(vi) Cost of sampling and testing when the results of tests are unsatisfactory.
(vii) Returning or handling over the empty drums in good condition to the Department,
when the supply in drums is made by the Department.
Rd.34.11. Mode of measurement and payment - The contract rate shall be for one
metric tonne of bitumen of the specified grade supplied in non-returnable drums. When
the bitumen is supplied by the Department the drum shall be taken to weigh standard
weight as certified by the Company provided the drums are not leaking or damaged. The
number of drums used by the contractor shall be recorded. The quantity for payment shall
be arrived at by multiplying the number issued by the standard weight. In case of leaking
or damaged drums they will be actually weighted and the standard weight of empty drums
will be deducted to arrive at the net quantity.
When the bitumen is not supplied by the Department the quantity shall be worked out
by multiplying number of undamaged and untempered drums by the standard weight of
bitumen in the drum certified by the company. In case of leaking or damaged rums, they
will be actually weighed and the standard weight of empty drums will be deducted to arrive
at the net quantity. When the supply is made by bowsers the contractor shall produce
weightment slip of the bowser and also the bill of the supplying companies.
Rd.35. Laying 50 mm. thick full grout bituminous road surface including preparing
the existing road surface, laying the required thickness of metal layer, heating and
spraying bitumen, spreading chips and laying seal coat complete excluding cost of
stone aggregate, bitumen and compaction.
Rd.35.1. General - The item provides for the labour for laying the full grout bituminous
road surface of a compacted thickness of 50 mm. including preparing the existing road
surface to receive the full grout course, use of equipment and plant and materials such as
the fuel, etc., but excluding stone aggregate bitument and compaction.
Rd.35.2. Diversions - Diversions shall be taken out and maintained as specified under
item No. Rd. 27.2 by the contractor at his own cost unless separately provided in the tender.
Diversion shall be watered if its dust is likely to blow on the road being bituminised.
Rd.35.3. Construction -
Rd.35.3.1. Materials - The aggregates and bitumen for providing full grout surface of a
compacted thickness of 50 mm. shall comply with specification Nos. Rd.33. and Rd. 34.
respectively and shall normally comply with the following regarding size and quantities
of aggregates and grade and quantities of bitumen : -

Rate of application
MATERIALS for 100 Sq. m.
1 2

RED BOOK  VOLUME I  ROADS  2012 385

Rd.35.3.1.
(a) 40 mm. size metal 6.0 Cu.m.

(b) 12 mm. size chips 1.5 Cu.m.

(c) 10 mm. size chips 1.2 Cu.m.

(d) Bitumen for grouting I.S grade S. 35 500.0 Kg.

with 30/40 penetration or S. 65 with
60/70 penetration.

(e) Bitumen of I.S. grade S.90 seal coat. 170.0 Kg.

The metal and chips shall be entirely dry at the time of spreading. If modifications in the
above quantities are stipulated in the special provisions, the work shall be carried out
according to the requirements of special provisions.
Increase in the use of materials Up to an extent of 10 % shall not entitle the contractor
for extra claims on labour charges, fuel, etc,.
The above quantities are exclusive of patching materials.
The supply of patching materials shall be done and paid for under separate items.
Rd.35.3.2. Preparing the base - Where the section of a water bound macadam road
surface is good except for a few local depressions and unevenness, the surface shall be
bought to the required section by adding suitable patching metal at places as required
and compacting it fully. Such labour will be incidental to the item and shall not be paid
for separately. The road surface shall be swept clean of all dirt, dust, caked mud, slush,
animal droppings and other loose and foreign matter and the blindage shall be brushed
and cleared off to expose the metal surface entirely. If so required by the Engineer, the
contractor shall keep the side widths and nearby diversion watered to prevent dust from
blowing over the surface to be bituminised.
Cement concrete surface shall be cleaned of all foreign matter.
Existing bituminous surface shall be swept clean of all loose and foreign matter.
 There shall always be sufficient length of prepared surface ahead of the bituminous
surfacing operations as directed by the Engineer to keep these operations continuous.
The prepared surface shall be closed to traffic. The contractor shall at his own expense
repair any damage to the prepared base caused by his own operations or use by traffic.
  Edge lines shall be marked with stakes after ranging the line for a sufficiently long
length for spreading the metal and about 30 cm. to 45 cm. wide metal or hard murum
berms formed and compacted to hold the metal from spreading.
Rd.35.3.3. Spreading - The 40 mm size aggregates shall be spread evenly at a rate of
6 cu.m./100 sq.m. or at a rate as ordered by the Engineer to form a uniform layer over
the width of the road specified by the plans. If the aggregate contains dust, grass, etc.,
it shall be screened and if moist, dried before spreading. The section shall be checked
with the camber boards and strings or straight edge. Inequalities shall be made good by
adding reserve aggregate in depressions and removing surplus metal from high spots.
Rd.35.3.4. Compacting - The layer shall be compacted as specified separately under
specification No. Rd.36.
 The compaction shall be covered by that item. Inequalities observed during and after
compaction shall be made good by spreading reserve metal in depression and removing
metal from high spots and compacting.
Rd.35.3.5. Applying bitumen - Bitumen of I.S. grade S. 35, having 30/40 penetration

386 RED BOOK  VOLUME I  ROADS  2012

 Rd.35.5.
shall be heated in a bitumen boiler to a temperature of 177øC. to 191øC. and that
temperature shall be maintained at the time of actual application. The hot bitumen shall
be applied through a pressure sprayer or when permitted, through a can with a nose
to the road surface uniformly at the rate of 500 Kg./100 sq.m. The road surface shall
be divided into suitable rectangles marked by chalk so as to ensure correct rate of
application of the bitumen to penetrate to the full depth of aggregate. Bitumen of I.S.
grade S-65 with 60/70 penetration may be used in cold weather, if so directed. When
supply is made in bulk, pressure sprayers, or ‘Bowsers’ shall be necessarily used.
Rd.35.3.6. Blinding - 12 mm. chips shall then be sprayed evenly over the road surface
at a uniform rate of 1.5 cu.m./100 sq.m. immediately after applying the bitumen when it
is still hot. Brooms shall also be used to ensure uniform thickness of the layer of chips.
Rd.35.3.7. Compacting - The surface shall then be compacted as specified separately
under specification No. Rd.36. This compaction shall be covered by that item.
Rd.35.3.8. Preparing the surface for seal coat - A seal coat shall be applied soon after
the surface is laid and in any case within a month of the laying of the full grout surface.
The surface shall be cleaned of all foreign matter, dust, etc., by brooms, brushes and
gunny bags before applying bitumen for seal coat.
Rd.35.3.9. Applying bitumen for seal coat - Bitumen of I.S. grade S. 90 having 80/100
penetration shall be heated in a bitumen boiler to a temperature ranging between 163 C.
to 177 C. which shall be maintained at the time of actual application. Hot bitumen shall
be applied evenly at a uniform rate of 170 Kg./100 sq.m. with a sprayer or a rose can.
Rd.35.3.10. Blinding - Immediately after the bitumen, the road surface shall be blinded
evenly with 10 mm. size chips at a uniform rate of 1.2 cu. m. /100 sq. m. Brooms shall
be used to ensure the evenness of the layer of chips.
Rd.35.3.11. Rolling - After spreading and evening up the blinding chips, the surface
shall be rolled as specified separately under No. Rd.36. This rolling shall be covered by
that item.
Rd.35.4. Special requirements - Heating of bitumen shall be done in bitumen boilers with
cock unless otherwise permitted by the Engineer. The heated bitumen shall be handled in
iron buckets with handles or sprayers. The labour engaged in handling the heated bitumen
shall use full length gumboots, leather hand gloves and leather jacket with fire proof apron
to cover the chest and the back and reacting up to the knees.
Two thermometers shall be maintained on the site and used for checking the temperature
of the heated bitumen.
Rd.35.5. Item to include -
(1) Diversions unless separately provided in the tender.
(2) Preparing the road surface, including patch-work.
(3) Spreading 40 mm. size aggregates.
(4) Heating bitumen including fuel,etc., and applying to the road surface for grouting.
(5) Blinding the surface with 12 mm. size chips.
(6) Preparing the surface for the seat coat.
(7) Heating and applying bitumen for the seal coat including fuel, etc.
(8) Blinding the surface with 12 mm. size chips for the seal coat.
(9) All labour, materials (excepting bitumen and aggregates) use of tools, plant and
equipment for completing the item satisfactorily.

RED BOOK  VOLUME I  ROADS  2012 387

Rd.35.6.
Rd.35.6. Mode of measurement and payment - The contract rate shall be for 100 sq.
m. (about 1.076 sq. ft.). The measurement shall be for the width of the road as executed
limiting it to the width specified or as ordered by the Engineer and the length measured
along the centre line.
The measurements of dimensions shall be recorded correct up to two places of decimals
of a metre and the area worked out correct up to one place of a sq. m.
Rd.36. Compacting 50 mm. thick full grout surface with power roller including labour,
use of plant, etc., complete.
Rd.36.1. General - The item provides for compaction of full grout surface to a compacted
thickness of 50 mm. with a power roller of 10/12 tonnes including necessary labour,
materials and use of plant.
Rd.36.2. Diversions - According to specification No. Rd.35.2.
Rd.36.3. Compaction general - According to specification No. Rd.30.4.1.
Rd.36.3.1. Initial rolling - The surface on which the grouting is to be laid shall have
been brought to the required section and grade and cleaned under the item No. Rd.35.
preparatory to the spreading of the aggregate. This sub grade shall be rolled if necessary.
The coarse aggregate shall be spread evenly to conform to the required section and
grade as specified in specification No. Rd.35. This layer of metal shall then be rolled
to correct section and grade with a 10/12 tonne power roller to lock the metal without
crushing the aggregate. The surface shall be checked for grade and section during and
after rolling. Any irregularities shall be corrected by loosening the surface and removing
or adding aggregate as required and the spots compacted. Rolling shall be stopped
immediately the aggregate shows signs of crushing.
Rd.36.3.2. Final compaction - Immediately after spraying the bitumen and spreading
the blinding ships as specified in specification No. Rd.35, the surface shall be rolled
with a power toiler to obtain full compaction and to force the blinding chips into the
interstices of the coarse aggregate to pack them tightly. The rolling shall be continued till
the asphalt hardens and the chips stop moving under the roller wheels.
Rd.36.3.3. Rolling over seal coat - The seal coat when laid as specified in Rd.35, shall
be rolled lightly with a power roller so as not to crush the chips.
Rd.36.4. Item to include -
(1) Diversion unless separately provided in the tender.
(2) Compacting the prepared sub-grade surface where necessary.
(3) Initial and final rolling to the correct grade and section.
(4) Rolling over the seal coat.
(5) All labour, materials such as water or oil for applying to the wheels, fuel etc. use of
plant such as power roller necessary for completing the item satisfactorily.
Rd.36.5. Mode of measurement and payment - According to specification No. Rd. 35.6.
Rd.37. Laying 50 mm. thick semi grout bituminous road surface including preparing
the existing road surface, laying the required thickness of metal layer, heating and
spraying bitumen, spreading chips and laying seal coat complete excluding cost of
aggregate, bitumen and compaction.
Rd.37.1. General - The item provides for the labour for laying the semi-grout bituminous
road surface of a compacted thickness of 50 mm. including preparing the existing road

388 RED BOOK  VOLUME I  ROADS  2012

 Rd.37.3.4.
surface to receive the semi-grout course, use of equipment and plant and materials such
as fuel etc., but excluding cost of stone aggregates, bitumen and compaction.
Rd.37.2. Diversions - According to specification No. Rd. 35.2.
Rd.37.3. Construction -
Rd.37.3.1. Materials - The aggregates and bitumen for providing semigrout surface of
a compacted thickness of 50 mm. shall comply with specification No. Rd. 33 and Rd. 34,
respectively and shall normally comply with the following regarding sizes and quantities
of aggregate and grade and quantities of bitumen :-

Rate of application
MATERIALS for 100 Sq.m.
1 2
(a) 40 mm. size metal. 6.0 Cu. m.
(b) 12 mm. size chips. 1.5 Cu. m.
(c) 10 mm. size chips. 1.2 Cu. m.
(d) Bitumen of I.S. grade S. 35 with 275.0 Kg.
30/40 penetration or I.S. grade
S. 65 with 60/70 penetration.
(e) Bitumen of I.S. grade S.90 with 80/100 125.0 Kg.
penetration.
If modifications in the above quantities are stipulated in the special provisions, the work
shall be carried out according to the requirements of the special provision.
 Increase in the use of materials up to an extent of 10 percent shall not entitle the
contractor for extra claims on labour charges, fuel etc.
The supply of these materials shall be done and paid for under separate items.
Rd. 37.3.2. Preparing the base - The road shall be closed to traffic. The edge line shall
be marked with stakes after ranging the line for a sufficiently long length.
 The existing road surface shall be picked to a depth of the top layer of existing metal
uniformly over the full width on which the semi-grout surface is to be laid after edge line
stakes are planted by ranging the edges for a sufficiently long length. The picked up
road surface shall then be brought to the required grade and section. Templates and
strings shall be used to obtain the correct section and grade. If found necessary, soft
murum or gritty material shall be obtained by the contractors and spread evenly to a
thickness of about 12 mm. or as directed by the Engineer to enable hoggin to work up
to about half the thickness of the compacted course. This will be incidental to preparing
the existing road surface and not be paid separately.
Rd.37.3.3. Spreading - The 40 mm. size aggregate collected for the semi-grouting
shall then be spread evenly at the rate of 6 cu .m./100 sq. m. or at the rate as ordered
by the Engineer to form a uniform layer over the specified width. The surface shall be
checked by camber boards and line for the section and grade. Irregularities if any shall
be corrected by adding and removing metal is necessary. If the aggregates contain dust,
grass, etc., they shall be screened before spreading. A small quantity of aggregate shall
be reserved to make up the inequalities.
Rd.37.3.4. Compacting - The layer shall then be compacted as specified separately
under specification No. Rd.38.

RED BOOK  VOLUME I  ROADS  2012 389

Rd.37.3.4.
The compaction shall be covered by that item.
 Inequalities observed during and after compaction shall be made good by spreading
the reserve aggregate in depressions and removing aggregate from the high spots and
by compacting.
Rd.37.3.5. Applying bitumen - Bitumen of I.S. grade S. 35 or S.65 supplied for the
work shall be heated to a temperature of 177oC to 191oC, in a bitumen boiler and that
temperature shall be maintained at the time of actual application. The hot bitumen shall
be applied through a pressure sprayer or can with a nose to the road surface uniformly at
the rate of 275 Kg./100 Sq.m. The road surface shall be divided into suitable rectangles
marked by chalk so as to ensure correct rate of application of bitumen. When supply is
made in bulk, pressure sprayers or “Browsers” shall necessarily be used.
Rd.37.3.6. Blinding - 12 mm. chips shall be spread evenly over the road surface at a
rate of 1.5 Cu.m./100 Sq.m. immediately after applying the bitumen when it is still hot.
Brooms shall also be used to ensure evenness of the layer of chips. Irregularities in
surface shall be corrected by adding or removing chips, applying bitumen, blinding and
compaction.
Rd.37.3.7. Compacting - Immediately after spreading the blinding chips, the surface
shall be compacted as specified separately under specification No. Rd. 38.
The compaction shall be covered by that item.
Rd.37.3.8. Preparing the surface for the seal coat - As specified in Rd. 35.3.8.
Rd.37.3.9. Applying bitumen for seal coat - As specified in Rd.35.3.9.
Rd.37.3.10. Blinding - As specified in Rd. 35.3.10.
Rd.37.3.11. Rolling - After spreading and evening up the blindage chips, the surface
shall be rolled as specified separately under specification No. Rd. 38.
This rolling shall be covered by that item.
Rd.37.4. Special requirements - According to specification No.Rd.35.4.
(1) Diversions if not separately provided in the tender.
(2) Preparing the base including soft murum filter if necessary.
(3) Spreading aggregates of 40 mm. size.
(4) Heating bitumen including fuel etc. and applying to the road surface for semi-grout.
(5) Blinding the surface with 12 mm. size chips.
(6) Preparing the surface for seal coat.
(7) Heating and applying bitumen for the seal coat including fuel etc.
(8) Blinding the surface with 10 mm. size chips for seal coat.
(9) All labour, materials ( excluding bitumen and aggregates ) such as soft murum use of
tools, plant and equipment for completing the item satisfactorily.
Rd.37.5. Mode of measurement and payment - According to specification No. Rd. 35.6.
Rd. 38. Compacting 50 mm. thick semi-grout surface with power roller including
labour, use of plant etc., complete.
Rd. 38.1. General - The item provides for compaction of semi-grout surface to a compacted
thickness of 50 mm. with a power roller of 8/10 tonnes including necessary labour, materials,
use of plant etc.
The specification No. Rd. 36 for the 50 mm. thick full grout-surface compaction shall be
applicable to this item entirely except that watering shall be done to the required extent at
390 RED BOOK  VOLUME I  ROADS  2012
 Rd.
the time of initial rolling of the coarse aggregate to enable the hoggin to rise up to about half
the depth of the course. Metal shall be allowed to dry before applying bitumen.
Rd. 38.2. Item to include -
(1) Diversion unless separately provided in the tender.
(2) Light rolling over the sub-grade if necessary.
(3) Compacting the metal including watering.
(4) Rolling over blinding chips.
(5) Rolling over the seal coat.
(6) All labour, materials, use of tools, plant such as power roller necessary for completing
the items satisfactorily. 

Rd. 39. Laying 20 mm. thick premix bituminous carpet including preparing and
cleaning the base, heating bitumen, applying tack coat at - Kg./100 Sq.m. mixing
bitumen and chips in a bitumen mixer and laying the carpet layer complete with/
without seal coat excluding cost of stone aggregate, bitumen and compaction.
Rd. 39.1. General - The item provides for the labour for laying premix carpet of a
compacted thickness of 20 mm. including preparing the base, heating bitumen, applying
tack coat, mixing chips and the hot bitumen in a bitumen mixer, laying the carpet layer, use
of tools, equipment and plant and materials such as fuel except aggregates, bitumen and
compaction.
Rd. 39.2. Diversions - According to specification No. Rd.34.2.
Rd. 39.3. Construction -
Rd. 39.3.1. Materials - The chips and bitumen for providing the bituminous premix
carpet of 20 mm. thickness shall comply with specification No. Rd. 33. and Rd. 34.
respectively and the quantities shall normally be as under :-

MATERIALS Rate of application for 100 Sq.m.

1 2

(a) 12 mm. size chips. 1.83 Cu. m.

(b) 10 mm. size chips. 0.90 Cu. m.

(c) Coarse sand for dusting. 0.15 Cu. m.

(d) Bitumen of I.S. grade S. 90 with 80/100 156.00 Kg.

penetration or I.S. grade at 56 kg./cu.m. for
carpet.

(e) Bitumen of same grade for tack coat 50.00 Kg.

(i) On bituminous surface. 73.50 Kg.

(ii) On W.B.M. surface. 100.00 Kg.

 Exact quantities to be used for tack coat within the range will be as specified - in the
item.
The chips shall be entirely dry at the time of mixing.
 If quantities of materials per unit stipulated in the special provisions differ from the
above, those in special provision shall be provided. Materials required for patch-work to

RED BOOK  VOLUME I  ROADS  2012 391

Rd.
prepare the base for laying premix carpet are not included in these quantities.
The supply of these materials shall be done and paid for under separate items.
 Increase in the use of materials upto an extent of 10 percent shall not entitle the
contractor for extra claims on labour charges, fuel etc.
Rd 39.3.2. Preparing the base - According to the specification No.Rd.35.3.2.
Rd. 39.3.3. Tack coat - The bitumen shall be heated to a temperature of 163OC to
177OC in a bitumen boiler. Hot bitumen shall be applied to a cleaned surface at the
specified rate by pressure sprayer or if permitted by pouring cans with roses. The tack
coat shall just preceed the laying of the carpet.
Rd. 39.3.4. Carpet - 12 mm. chips and 10 mm. chips shall be put into the bitumen
mixer in 2:1 proportion by volumes and the bitumen of the specified grade heated to a
temperature of 163oC to 177oC in a bitumen boiler shall be added to the chips at the
rate of 56 Kg./cu. m. of the aggregate. The chips and the bitumen shall be mixed in the
mixture till all the chips are uniformly coated.
 The surface shall be suitably marked into rectangular areas to ensure correct rate of
application of the chips. The premixed chips shall be carried in wheel barrows to the site
of deposition without any loss of time and sprayed evenly in a layer of uniform thickness
at the rate 2.73 cu.m./100 sq.m. to get a compacted layer of 20 mm.
Rd. 39.3.5. Compaction - The carpet shall be compact with a 8 to 10 tonne roller as
specified separately under specification No. Rd. 40. and this will be covered by that item.
If any high spots or depressions become apparent during or after rolling, they shall be
corrected by removing or adding premixed chips and compacting.
Rd. 39.3.6. Opening to traffic -  Coarse sand or stone dust shall be sprayed evenly
at the rate of 0.15 Cu.m./100 Sq. m. over the compacted surface, brushed and lightly
rolled.
The traffic shall be allowed to pass over the road after 24 hours of the completion of the
carpet or such time as specified by the Engineer.
Rd. 39.4. Special requirements - According to Rd. 35.4.
Rd. 39.5. Items to include -
(1) Diversions if not separately provided in the tender.
(2) Preparing the base including patch-work.
(3) Heating bitumen.
(4) Applying tack coat.
(5) Mixing chips and bitumen in a bitumen mixer.
(6) Laying carpet.
(7) Spreading stone dust or sand.
(8) All labour, materials ( excluding bitumen and chips ) such as fuel for heating bitumen,
tools, use of equipment and plant for completing the items satisfactorily.
Rd. 39.6. Mode of measurement and payment - According to specification No. Rd. 35.6.
Rd. 40. Compacting 20 mm. thick premix bituminous carpet with power roller
including labour, use of plant etc. complete.
Rd. 40.1. General - The item provides for the compaction of premix carpet to a compacted
thickness of 20 mm. and also over the blinding layer of sand with a power roller of 8/10
tonnes including necessary materials, labour, use of paint, etc. complete.

392 RED BOOK  VOLUME I  ROADS  2012

 Rd.
The item shall comply with general specifications for bitumenous road surfaces. For
compaction of the carpet, light rolling shall be done on the final sand layer also.
Rd. 41. Providing single coat surface dressing including cleaning the road surface,
heating and applying bitumen to the road surface, spreading chips, etc. complete
excluding cost of stone chips bitumen and rolling.
Rd. 41.1. General - The item provides for labour for providing single coat surface dressing
of bitumen including preparing the base, cleaning road surface, heating and applying
bitumen to the road surface, spreading chips, use of tools, equipment, plant and materials
such as the fuel for heating bitumen, etc. complete except stone chips, bitumen and rolling.
Rd. 41.2. Diversions - According to specification
Rd. 41.3. Construction -
Rd. 41.3.1. Materials - The chips and bitumen for providing single coat bitumen dressing
shall comply with specification NO.Rd.33 and Rd.34 respectively and the quantities shall
normally be as under :-
MATERIALS Rate of application for 100 Sq.m.
1 2
A. Over Water bound Macadam.
(a) 12 mm. size chips. 1.50 Cu. m.
(b) Bitumen of I.S. grade S.90 with 80/100 200.00 Kg.
penetration.
B. Over Bituminous surface.
(a) 10 mm. size chips. 1.05 Cu. m.
(d) Bitumen of I.S. grade S. 90 with 80/100 275.00 Kg.
penetration.
The chips shall be entirely dry at the time of spreading.
If modifications in the above quantities are stipulated in the special provisions, the work
shall be carried out according to special provisions.
 Increase in the use of materials up to an extent of 10 per cent shall not entitle the
contractor for extra claims for labour charges, fuel etc.
The supply of these materials shall be done and paid under separate items.
Materials required for patch-work to prepare the base for laying the surface coat are not
included in the above quantities.
Rd. 41.3.2. Preparing the base - If the existing road surface contains local pot holes or
ruts, these shall be repaired by removal of all loose and defective materials and replaced
with corresponding patching material and compacted to produce a tightly bonded even
surface and section conforming with the adjacent area. High spots and depressions
shall be corrected by removal or addition of suitable patching material and compacting.
Such labour shall be incidental to the item and shall not be paid for. The surface shall be
swept clean of all dust, loose and foreign material and kept dry prior to the application
of the bitumen.
Rd. 41.3.3. Applying bitumen - The bitumen of the specified grade shall be heated
to 163oC to 177oC in a bitumen boiler and the hot bitumen shall be applied evenly to
the cleaned road surface at the uniform rate of 200 Kg./100 sq. m. on water bound
macadam surface and 100-125 Kg./100 Sq.m. on a bituminous surface with a pressure
RED BOOK  VOLUME I  ROADS  2012 393
Rd.
sprayer or if permitted with pouring cans with rose. The road surface shall be marked
into rectangular areas so that a measured quantity of bitumen and chips will cover each
such area with uniform thickness as specified. The spraying shall be done along the
longitudinal direction of the road only when the surface is thoroughly dry.
Rd. 41.3.4. Spreading chips - Immediately on applying the hot bitumen to the road,
12 mm. chips shall be sprayed evenly at the rate of 1.5 cu. m./100 sq.m. over the water
bound macadam road surface and 10 mm. chips at the rate of 1.05 cu.m./100 sq.m. on
bituminous road surface.
The surface shall be broomed for ensuring evenness of the layer rolling.
Rd. 41.3.5. Rolling - The surface shall be rolled immediately thereafter as specified
under specification No. Rd. 42. and this will be covered by that item.
Excessive rolling shall be avoided to prevent crushing of the aggregate.
Rd. 41.3.6. Opening to traffic - The surface shall remain closed to traffic 24 hours or
such period as may be specified by the Engineer.
Rd. 41.4. Special requirements - According to specification No.Rd.35.4
The chippings whipped off the road by fast moving traffic shall be collected and spread
back on the surface uniformly till most of these are absorbed in the surface. This shall be
done for 5 days after opening the surface to traffic and shall be incidental to this item.
Rd. 41.5. Item to include -
(1) Diversions if not separately provided in the tender.
(2) Patching up the road surface where necessary.
(3) Cleaning the road surface.
(4) Heating and applying bitumen.
(5) Spreading chips.
(6) All labour, necessary materials, such as the fuel ( excluding bitumen and chips ) use
of tools, equipment and plant.
Rd. 41.6. Mode of measurement and payment - According to specification No.Rd.35.6
Rd. 42. Rolling the single coat bituminous surface dressing of road with a power
roller including labour and use of plant complete.
Rd. 42.1. General - The item provides for the rolling of the single coat bitumen surface
dressing of the road with a power roller 8 to 10 tonnes including necessary materials,
labour, use of plant etc., complete.
Rd. 42.2. Diversions - According to specification No.Rd.34.2
Rd. 42.3. Compaction - General. -- According to specification No.30.4.1.
Rd. 42.4. Rolling - Immediately after spreading the chips the surface shall be rolled lightly
with a power roller of 8 to 10 tonnes capacity without allowing the chips to crush.
Rd. 42.5. Item to include -
(1) Diversions if not separately provided in the tender.
(2) Rolling the surface.
(3) All labour, use of plant such as the roller for completing the work satisfactorily.
Rd. 42.6. Mode of measurement and payment - According to specification No.Rd.35.6.
Rd. 43. Providing two coat bituminous surface dressing including cleaning the road

394 RED BOOK  VOLUME I  ROADS  2012

 Rd.
surface, heating and applying bitumen to the road surface and spreading chips
complete, excluding cost of stone chips, bitumen and rolling.
Rd. 43.1. General - The item provides for the labour for providing two coat surface
dressing of bitumen including preparing the base, cleaning the road surface, heating and
applying bitumen to the road surface, spreading chips, use of tools, equipment and plant
and materials such as the fuel for heating bitumen etc. complete.
Rd. 43.2. Diversions -According to specification No.Rd.35.2.
Rd. 43.3. Construction -
Rd. 43.3.1. Materials - The chips and bitumen for providing two coat surface dressing
shall comply with specification No. Rd.33 and Rd.34 respectively and the quantities shall
normally be as under:-
MATERIALS Rate of application
for 100 Sq.m.
1 2
1st coat :-
(a) 12 mm. size chips. 1.80 Cu. m.
(b) Bitumen of I.S. grade S.90 with 225.00 Kg.
80/100 penetration.
2nd coat :-
(a) 10 mm. size chips. 1.00 Cu. m.
(d) Bitumen of I.S. grade S. 90 with 125.00 Kg.
80/100 penetration.
The chips shall be entirely dry at the time of spreading.
The supply of these materials shall be done and paid for under separate items.
If modifications in the above quantities are stipulated in the special provisions, the work
shall be carried out as stipulated according to the special provisions.
Increase in the use of materials up to an extent of 10 per cent, shall not entitle the contractor
for extra claims on labour charges, fuel, etc.
Materials required for patchwork to prepare the base before laying the surface dressing are
not included in the above quantities.

FIRST COAT
Rd. 43.3.2. Preparing the base - According to specification No.Rd.35.3.2.
Rd. 43.3.3. Applying bitumen - The bitumen of the specified grade shall be heated to
163oC to 177oC in a bitumen boiler and shall be applied uniformly to the cleaned road
surface at the rate of 225 kg./100 sq.m. with a pressure sprayer or if permitted, with
pouring cans with rose. The road surface shall be marked into rectangular areas so
that a measured quantity of bitumen and chips will cover each such area with uniform
thickness as specified. The spraying shall be done in the longitudinal direction of the
road and only when the surface is thoroughly dry.
Rd. 43.3.4. Spreading chips - Immediately on applying the hot bitumen to the road,
12 mm. chips shall be spread uniformly at the rate of 1.8 cu.m./100 sq.m. over the road
surface. The surface shall be broomed for ensuring evenness of the layer. All high and

RED BOOK  VOLUME I  ROADS  2012 395

Rd.
low spots shall be corrected by removing or adding stone chips as required.
Rd. 43.3.5. Rolling - The surface shall be rolled immediately thereafter as specified
under specification No. Rd. The rolling shall be covered by that item.

SECOND COAT
Rd. 43.3.6. Applying bitumen - Before applying the second coat of bitumen the surface
shall be examined and any loose material or foreign matter removed by brooming.
The bitumen shall be applied at the rate of 125 kg./100 sq.m.
Rd. 43.3.7. Spreading chips - Immediately after second application of hot bitumen 10
mm. stone chips shall be spread uniformly at the rate of 1 cu.m./100 sq.m. The surface
shall be broomed to obtain even distribution of the chips.
Rd. 43.3.8. Rolling - Rolling shall be done as in the case of first coat.
Rd. 43.3.9. Opening to traffic - According to specification No.Rd.41.3.6 for single coat
surface dressing.
Rd. 43.4. Special requirements -According to specification No.Rd.41.4 for single coat
surface dressing.
Rd. 43.5. Item to include - Item mentioned in specification No. Rd.42.5 shall be included
for each of the two coats.
Rd. 43.6. Mode of measurement and payment - According to specification No. Rd.35.6 .
Rd. 44. Rolling the two coat bituminous surface dressing with a power roller including
labour, use of plant etc. complete.
Rd. 44.1. General - The item provides for the rolling of the two coat bituminous surface
dressing of the road with a power roller of 8 to 10 tonnes including necessary materials,
labour, use of plant etc. complete.
Rd. 44.2. Diversions - According to specification No. Rd.
Rd. 44.3. Compaction -General -According to specification No.Rd.30.4.1.
Rd. 44.4. Rolling - The first and the second coat of surface dressing shall be lightly
rolled with a power roller of 8 to 10 tonnes capacity separately on each of the two coats
immediately after spreading and brooming the chips, without allowing the chips to crush.
Rd. 44.5. Item to include - According to specification No.Rd.43.5 (for each of two coats).
Rd. 44.6. Mode of measurement and payment - According to specification No. Rd. 35.6.
( Rolling over the two coats separately shall be measured as one for the complete treatment.)
Rd. 45. Providing bituminous liquid seal coat to black top surfaces including
preparing the existing road surface, heating and applying bitumen and spreading
chips complete, excluding cost of stone chips, bitumen and rolling.
Rd. 45.1. General - The item provides for labour for providing liquid seal coat to existing
road surface spreading chips and use of equipment and plant and materials such as the
fuel for heating bitumen etc.
Rd. 45.2. Diversions - According to specification No.Rd. 35.2
Rd. 45.3. Construction -
Rd. 45.3.1. Materials - The chips and bitumen for providing the liquid seal coat shall
comply with specification Nos. Rd.33 and Rd.34 respectively and the quantities shall

396 RED BOOK  VOLUME I  ROADS  2012

 Rd.
normally be as under :-

MATERIALS Rate of application

for 100 Sq.m.
1 2

(a) 6 mm. size chips or coarse sand 0.90 Cu. m.

(b) Bitumen of I.S. grade S.90 with 75-1000.00 Kg.
80/100 penetration.
The chips shall be entirely dry at the time of spreading.
If modifications in the above quantities are stipulated in the special provisions, the work
shall be carried out according to the special provisions.
 Increase in the use of materials up to an extent of 10 per cent, shall not entitle the
contractor for extra claims for labour charges, fuel etc.
The supply of these materials shall be done and paid for under separate items.
 Materials required for patch work to prepare the base for laying the seal coat are not
included in the above quantities.
Rd. 45.3.2. Preparing the base - According to specification No. Rd.41.3.2.
Rd. 45.3.3. Applying bitumen - According to specification No. Rd.41.3.3. except that
the rate of application of hot bitumen to the cleared road surface shall be 100 kg./100
sq. m.
Rd. 45.3.4. spreading chips - Immediately on applying the bitumen to the road surface,
6 mm. chips shall be spread evenly at the rate of 0.9 cu.m. /100 sq.m. over the road
surface. The surface shall be broomed for ensuring evenness of the layer before rolling.
Rd. 45.3.5. Rolling - The surface shall be rolled as specified under specification No.
Rd. 46 and this will be covered by that item.
Rd. 45.3.6. Opening to traffic - The surface shall remain closed to traffic for 24 hours
or such period as may be specified by the Engineer.
Rd. 45.4 Special requirements - According to specification No.Rd.41.4.
Rd. 45.5 Items to include - According to specification No.
Rd. 45.6 Mode of measurement and payment - According to specification No.Rd.35.6.
Rd. 46. Rolling the bituminous liquid seal coat with a power roller including labour,
and use of plant complete.
Rd. 46.1. General - The item provides for the rolling of the liquid seal coat with a power
roller 8 to 10 tonnes including necessary materials, labour, use of plant complete.
Rd. 46.2. Diversions - According to specification No. Rd35.2.
Rd. 46.3. Rolling - The liquid coat shall be rolled with a power roller of 8 to 10 tonnes
capacity immediately after the chips are spread without allowing the chips to crush.
Rd. 46.4 Item to include - According to specification No.Rd.42.5.
Rd. 46.5 Mode of measurement and payment - According to specification No.Rd.35.6.
Rd. 47. Providing 50 mm. thick full grout bituminous road surface including supplying
all materials, preparing the existing road surface, laying the required thickness of
metal layer, heating and spraying bitumen, spreading chips, laying seal coat and
compacting complete.

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Rd.
Rd. 47.1. General - The item provides for material and labour for providing a full grout
bituminous road surface of a compacted thickness of 50 mm. including preparing the
existing road surface to receive the full grout course and use of equipment and plant and
compacting. The item shall comply with all specifications for item No. Rd. 35, and shall also
include supply of all materials and compacting by roller.
Rd. 48. Providing 50 mm thick semi grout bituminous road surface including
supplying all materials, preparing the existing road surface, laying the required
thickness of metal layer, heating and spraying bitumen, spreading chips, laying seal
coat and compacting complete.
Rd. 48.1. General - The item provides for materials and labour for providing a semi
grout bituminous road surface of a compacted thickness of 50 mm. including preparing the
existing road surface to receive the semi grout course, use of equipment and plant and
compacting. The item shall comply with all specifications for item No.Rd.47 and shall also
include supply of all materials and compacting by roller.
Rd. 49. Providing 25 mm. thick premix bituminous carpet including supplying all
materials, preparing and cleaning the base, heating bitumen, applying tack coat,
at 5/10 kg./10 sq.m. mixing hot bitumen and chips, laying the carpet layer and
compacting complete.
Rd. 49.1. General - The item provides for materials and labour for providing a premix
bituminous carpet of a compacted thickness of 25 mm. including preparing and cleaning
the existing road surface to receive the premix carpet,, heating the bitumen, applying tack
coat, mixing chips and hot bitumen, laying the carpet layer compacting and use of plant and
equipment. The item shall comply with specification No. Rd. and shall also include supply
of materials and compaction by roller.
Rd. 50. Providing 20 mm. thick premix bituminous carpet including supplying all
materials, preparing and cleaning the base, heating bitumen, applying tack coat,
at 5/10 kg./10 sq.m. mixing hot bitumen and chips, laying the carpet layer and
compacting complete.
Rd. 50.1 General - The item provides for labour and materials for providing a premix
carpet of a compacted thickness of 20 mm. including preparing the base, heating bitumen,
applying tack coat, mixing chips and hot bitumen and laying the carpet. The item shall
comply with specification No. Rd.34 and shall also include the supply of materials and
compaction by roller.
Rd. 51. Providing single coat surface dressing including supplying all materials,
cleaning the road surface, heating and applying bitumen to the road surface,
spreading chips, use of tools, plant and equipment and rolling complete.
Rd. 51.1. General - The item provides for all materials and labour for a single coat surface
dressing of bitumen including preparing the base, cleaning the road surface, heating and
applying bitumen to the road surface, spreading chips, rolling and use of equipment and
plant. The item shall comply with specification for item No. Rd.36 and shall also include
supply of materials and rolling by a roller.
Rd. 52. Providing two coat bituminous surface dressing including supplying all
materials, cleaning the road surface, heating and applying bitumen to the road
surface, spreading chips, and rolling complete.
Rd. 52.1. General - The item provides for all materials and labour for a single coat surface
dressing of bitumen including preparing the base, cleaning the road surface, heating and
applying bitumen to the road surface, spreading chips, rolling and use of equipment and

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 Rd.
plant. The item shall comply with specification for item No. Rd. 38 and shall also include
supply of materials and rolling by a roller.
Rd. 53. Providing bituminous liquid seal coat to black top surfaces including
supplying all materials preparing the existing road surface, heating and applying
bitumen, spreading chips and rolling complete.
Rd. 53.1 General - The item provides for materials and labour for providing liquid seal
coat to the existing road surface, including use of equipment and plant and rolling by roller.
The item shall comply with specification for item No. Rd.37.3.8 to Rd. 37.6 (relavent part)
and shall include supply of materials and rolling.
Rd. 54. Providing hot mix, hot laid premixed bituminous concrete 25 mm. thick
wearing surface over 50 mm. thick premixed bituminous macadam, including
diversion aggregates, bitumen, etc., heating bitumen and chips, mixing chips and
bitumen in mechanical bitumen mixer, laying the bituminous macadam base and
bituminous concrete wearing course and compacting the two courses separately.
Rd. 54.1. General - The item provides for both the 50 mm. thick bituminous macadam
base and the 25 mm. thick bituminous concrete course. The base course shall be premixed
bituminous macadam and the wearing course shall be of hot mix and hot laid bituminous
concrete. The item includes providing chips, bitumen necessary fuel and heating of bitumen
for base course and chips and bitumen for wearing course, mixing of chips and bitumen for
the two layers in a mechanical mixer, laying and compacting of the base course and the
wearing course separately with a 10 to 12 tonnes power roller, use of equipment tools and
plant and carrying out tests on the bituminous concrete.
Rd. 54.2. Diversions - According to specification No. Rd 35.2.
Rd. 54.3. Construction -
Rd. 54.3.1. Materials - The chips shall conform to Rd.33. and further the sizes and
quantities shall be as specified hereafter.
The bitumen shall conform to the specification No. Rd.34 and shall be of I.S. grade S.
90 with 80/100 penetration.
The requirement of materials for the base coat shall be as under:-

MATERIALS Rate of application

for 100 Sq.m.
1 2

(a) 25 mm. aggregate 3.70 Cu. m.

20 mm. chips 1.65 Cu. m.
12 mm. chips 1.50 Cu. m.
(d) Bitumen of I.S. grade S. 90 with 80/100 penetration :-
For premixing 40 mm. aggregates. 48.10 kg./cu. m.
For premixing 20 mm., 12 mm. chips 56.00 kg./cu. m.
The chips shall be entirely dry at the time of mixing.
Rd. 54.3.1.2. Preparing the base - According to specification No Rd.35.3.2.
Rd. 54.3.1.3. Premixing chips - The bitumen of S. No. 90 grade with 80/100 penetration
shall be heated to 163oC to 177oC. 25 mm., 20 mm. and 12 mm. chips shall be fed into
the mixer in the required proportion. The heated bitumen shall be added to the chips at

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the rate of 48.1 kg./cu.m. for 40 mm. aggregate and 56 kg./cu. m. for 20 mm. and 12
mm. chips and mixed till all the chips are thoroughly coated with bitumen.
 The road surface shall be suitably marked to ensure correct rate of application of the
chips. The premixed chips shall be discharged into wheel barrows and shall be conveyed
to the site with the least loss of time and spread uniformly at the rate of 6.75 cu.m./100
sq.m. immediately. Any irregularities shall be corrected before the rolling commences.
Rd. 54.3.1.4. Compaction - The base course shall be compacted thoroughly with
a 8 to 10 tonne power roller except that it will be done in a single course of 50 mm.
compacted thickness.
Rd. 54.3.2. Hot mix Hot laid wearing course.
Rd. 54.3.2.1. Materials - The aggregate grading including the mineral filler for the
bituminous concrete may be of the following type :-

I.S. sieve No. % passing by weight

12 mm. 100
10 mm. 80-100
480 55-75
240 35-50
60 18-29
30 13-27
15 8-16
8 4-10
Aggregates shall conform to specification No. Rd.33.
 Sand shall conform to the specification No. A.6 and satisfy the requirements of the
grading of the aggregate of the bituminous concrete as stated above or as determined
by preliminary tests.
The filler shall be dry and clean limestone powder or hydrated lime having CaO content
of not less than 60 per cent both passing I.S. sieve No.8. It shall be free from lumps
and loosely bonded aggregation. When tested by laboratory sieves, 100 per cent shall
pass through I.S. sieve No. 15 and 80 per cent shall pass through I.S.sieve No. 8. Filler
shall be added to the aggregate to give the above grading or grading determined by
preliminary tests.
Bitumen shall be of I.S. grade S. 65 with 60/70 penetration.
The actual mix design for the particular job shall be decided by preliminary laboratory tests
by using the approved local aggregates and filler to satisfy the following requirements :--
 Bitumen of I.S. grade S. 65 with 60/70 penetration shall be 6.5 per cent to 8 per cent
by weight of total.
Marshall stability 450 Kg minimum.
% of air voids in total mix. by volume 3 to 5
Rd. 54.3.2.2. Preparing the base - Dirt and dust if accumulated shall be cleared off
leaving the surface entirely clean.
Rd. 54.3.2.3. Mixing and laying wearing course - I.S. grade S. 65 bitumen shall
be heated to a temperature of 163oC to 177oC in a boiler. The aggregate of the grading
given above or as decided by preliminary tests shall be dried and heated in an Aggregate

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Drier to a temperature of 149oC to 177oC and fed into a twin shaft paddle type mixer at
a temperature of not less than 149oC. The bitumen, the aggregate and the filler shall be
measured separately and accurately to the proportions in which they are to be mixed and
mixed intimately till all the particles are completely coated with bitumen. The quantities
of aggregates, bitumen and the filler shall be such as to obtain the per cent. of each as
specified above or decided after tests. Continuous batching and mixing plant shall be
used.
T
 he temperature of bituminous concrete when leaving the mixer shall not be less than
138oC and it shall not be less than 121o C at the time of laying.
 The bituminous concrete shall be transported to the site of work in suitable tipping
vehicles properly insulated and covered with canvas or other suitable material to protect
the mixture from weather condition and to retain the heat. The mixture shall be spread
with a mechanical self powered spreader. The bituminous concrete shall be laid to the
specified line, curve, grade and camber. Any irregularities shall be corrected immediately
and before rolling is started. Before laying the mixture, the faces of the joins shall be
painted with a uniform coating of hot bitumen.
T
 he bituminous concrete shall be laid to such loose depth as to give a compacted layer
of 25 mm.
Rd. 54.3.2.4. Compaction - The bituminous concrete layer shall then be allowed to
cool sufficiently such that it does not spread under the wheel load of a 8/10 tonne power
roller. The compaction shall be done by the roller till no wheel marks are left on the
surface and no further compaction is possible.
Rd. 54.3.2.5. Opening to traffic - The road shall be opened to traffic on cooling of the
concrete to atmospheric temperature.
Rd. 54.3.2.6. Tests - Two specimen per day shall be tested by the contractor in the field
laboratory provided by him for this purpose under the guidance of qualified personnel.
Tests shall be conducted to ascertain stability, bitumen content, air voids and specific
gravity. All expenses pertaining to the laboratory, tests, etc., shall be borne by the
contractor.
 The results shall be supplied to the Engineer everyday for his record and information.
The contractor shall give all facilities for the Departmental staff to inspect the work of
tests being done by him all times.
Rd. 54.3.2.7. Maintenance - The contractor shall be responsible for maintenance of the
surface in good condition for three months after opening the road surface to traffic at his
own cost. Maintenance includes repairing defects occurring in the work.
Rd. 54.4. Special points - According to Rd.35.4.
Rd. 54.5. Item to include -
(1) All materials such as aggregates, bitumen, filler, fuel for heating, for patch work, the
base course and the wearing course.
(2) All labour required to complete all the items of the work as specified satisfactorily
including compaction.
(3) Use of equipment, tools and plant, conveying materials, heating, weighing, mixing,
spreading and compacting.
(4) Maintenance of the road surface for 3 months after opening to traffic.
(5) Sampling and testing.
Rd. 54.6. Mode of measurement and payment - The contract rate shall be for one

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Rd.
sq.m. of the paving as specified, consisting of the base course and wearing course both
considered as one.
The width shall be recorded correct up to a cm. and limited to the width shown on the plans
or directed by the Engineer.
The length shall be measured correct up to a cm. along the center line of the road.
The area shall be calculated correct up to three places of decimals of a sq.m.
Rd. 55. Providing 1:2:4: cement concrete pavement -- mm. thick including diversion,
compacting, finishing, curing, filling in joins with premoulded and poured bituminous
joint filler and 1:4:8 lean cement concrete.
Rd. 55.1. General - The item provides for laying pavement of 1:2:4 cement concrete of
specified thickness with specified type of metal for the road including patching of the sub-
grade to the required section where necessary with 1:4:8 lean cement concrete, vibrating,
finishing and curing and filling the joints with premoulded and poured bituminous joint filler.
Concrete shall generally comply with specification No. B.6 subject to the following:-
Rd. 55.2. Materials -
Rd. 55.2.1. Cement - Cement to be used shall comply with specification No. A.2.
Rd. 55.2.2. Coarse aggregate -Coarse aggregate shall generally comply with
specification No. Rd. 33 and relevant provisions of specification No. A.6. The grading
shall be such as to give dense concrete with maximum of bigger size metal and
lowest possible voids. The maximum size of the standard coarse aggregate shall be
40 mm. Normally the following proportions with slight modifications will be found to be
satisfactory:-
(1) Metal 40 mm. (IRC. Standard) roughly 60 to 66 2/3 per cent.
(2) Metal 20 mm. (IRC. Standard) roughly 40 to 33 1/3 per cent.
(3) Metal 10 mm. (IRC. Standard) roughly 40 to 33 1/3 per cent.
Samples of the materials and their grading shall be tested before the work is commenced
and at intervals during construction when change of materials is indicated by change
of quarry, change of crushing and screening machinery etc. and the precise proportion
of the different grades in the coarse aggregate shall be fixed by the Engineer so as to
secure a well graded material varying from 40 mm. to 6 mm. giving the required strength
of concrete. The grading and testing shall be done at the cost of the contractor who shall
supply the necessary materials, sieves, and screens. They shall be measured in suitable
measuring boxes approved by the Engineer and shall be mixed in approved proportion.
Rd. 55.2.3 Fine aggregate - Fine aggregate shall generally conform to specification
No. A.6. Clean crushed stone screening may be permitted by the Engineer to be used
wholly or in combination with natural sand where suitable natural sands are not available
in required quantity. But they shall satisfy the requirements of grading specified in I.S.
383-1970 and the concrete prepared with it shall give the required strength. The grading
of the particles shall be as laid down in specification A.6 or such other grading as will
enable the concrete in which it is used to have the maximum density and a strength
which shall not be less than specified.
Rd. 55.2.4. Water - Water for mixing and curing concrete shall comply with specification
No. A.4.
Rd. 55.2.5. Reinforcement - Reinforcement when required to be used shall comply
with specification No. B.10.
Rd. 55.2.6. Premoulded joint filler - According to specification No. BR.32.

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 Rd.
Rd. 55.2.7. Poured joint filler - According to specification No. BR.32.
Rd. 55.3. Proportioning of concrete mix - The usual mix to be used in concrete roads
shall be 1:2:4 and the quantities of ingredients based on one 50 kg. bag of cement shall be
as under:-
Ordinary cement 50 kg. bag : 70 liters of sand : 140 liters of coarse aggregate.
The water cement ratio shall not exceed 0.50 for ordinary cement. Slump shall not exceed
40 mm.
Rd.55.4. Equipment -
Rd.55.4.1. General - All equipment, tools and machinery necessary for the proper
preparation of the sub-grade, batching, mixing, conveying, placing, finishing and curing
of the concrete pavement shall be of approved design and kept at site in first class
working condition and shall have been inspected by the Engineer before the contractor
is permitted to start the paving work. They shall be of such capacity and in such numbers
as to insure the required rate of progress. They shall be maintained in satisfactory
working condition throughout the period of construction.
They shall include :-
Rd. 55.4.2. Measuring boxes - When batching is done by volume, the boxes shall
be strongly constructed and provided with handles for convenient lifting and loading
the mixer. The sizes of boxes shall preferably be such as to possible to measure the
required quantity of each size or aggregate in whole boxes or multiples there of and
capable of being lifted by two men. A straight edge shall be provided for striking off after
filling.
Rd. 55.4.3 Mixers - Mechanical concrete mixers of adequate capacity shall be provided
and they shall be of the batch type, of standard design and shall have a rated capacity
of not less than 0.2 cu. m. of mixed concrete.
 The mixers shall have an approved timing device or in its absence, a time piece with
minute and second hands shall be provided by the contractor. The mixer shall also have
approved water measuring device. There shall be approved measures for water in case
measuring device gets out of order for use till the device is repaired.
Pick up and throw over blades in the drum of the mixer which are worn down 20 mm.
or more in depth shall be replaced with new blades.
Rd. 55.4.4. Water supply equipment - The water supply arrangement and equipment
shall be of such capacity and nature as to insure at all the requirements of the work.
Rd. 55.4.5. Sub-grade template or strike board - The template shall be of rigid
construction approximately 10 cm. wide and shall weigh about 45 kg.
Rd. 55.4.6. Scratch template - Scratch template shall be made of strong wooden
scanting rigid enough to keep the shape in working condition and shall be provided with
scratch points placed about 20 cm. apart and set to the exact profile required.
Rd. 55.4.7. Hand tamper - The tamper shall be shaped to the cross-section, of the slab
and shall weigh not less than 10 kg. per metre length. It shall be durably constructed
of 80 mm. timber or of steel channel cross-section, 60 cm. longer than the proposed
width of pavement slab and sufficiently strong and rigid to retain its shape under all
working conditions. If it of timber it shall be shod with steel. The tamper shall be provided
with handles which are resilient and sufficiently long to enable taming operations to
performed by men in standing position.
Rd. 55.4.8. Vibrating screed - Vibrating screed shall be similar to hand tamper but

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Rd.
mounted with a vibrating machine and shall be worked by an engine, compressed air
or electric motor, hand propelled and traveling on side forms. Vibrators shall have a
frequency of not less than 3,600 or preferably about 5,000 impulses per minute.
Rd. 55.4.9. Longitudinal float -  The longitudinal float shall be about 1.2 metres in
length and 10 cm. in width and shall have a suitable handle.
Rd. 55.4.10. Bridges - The bridges shall be so designed that when placed straddling
the forms, no part shall come in contact with the pavement and shall be sufficiently rigid.
Rd. 55.4.11. Brooms - The brooms shall not be less than 45 cm. in width and be made
from good quality bass fiber. The handle shall be at least 30 cm. (about one foot) longer
than half the width of the slab. A minimum of four brooms shall be provided.
Rd. 55.4.12. Three metre straight edge - The straight edge shall be 3 metres long and
shall remain true and rigid under working conditions and shall have suitable handles for
use from bridges across the pavement.
Rd. 55.4.13. Edging tool - The edging tool shall have a radius of 10 mm. The vertical
limb shall extend to the required depth. A minimum of two edging tools shall be provided.
Rd. 55.4.14. Master straight edge - The Master straight edge shall be of known
accuracy for checking other straight edges. It shall be of steel or other suitable material,
of sufficient length and of sufficient rigidity to maintain its accuracy.
Rd. 55.5 Diversions - Diversions shall be provided as per specification No. Rd.27.2.
Unless separate provision is made in the tender for diversion, the rate for concrete shall be
inclusive of diversions.
Rd. 55.6. Preparation of the sub-grade and sub-bases.
Rd. 55.6.1. General - All soft or spongy parts of the sub-grade or base shall be
excavated and refilled with approved material, watered if necessary and well tamped in
8 cm. layers. The rate for concrete shall cover these operations for preparing the base
and no extra payment will be made to the contractor on this account.
Rd. 55.6.2. Macadam sub-base - If there are depressions and hallows in the road
surface they shall be leveled up before concreting by using a lean mix of 1:4:8 concrete
properly compacted before laying of the concrete slab in addition to correcting the
section with such lean concrete.
 After this correction, the section shall be checked for trueness by means of a scratch
template resting on the side forms. The template shall be drawn along parallel to the
center line of the road. The surface irregularities shall be rectified with 1:4:8 lean concrete.
Rd. 55.6.3. Black topped surface - Where concrete slabs are to be laid on the existing
black topped surfaces, no special treatment is necessary where the surface extends
over the required width and is worn uniformly under the traffic.
Rd. 55.6.4. Concrete base - Where concrete is to be placed on the existing base of
concrete, all the joints and cracks in the base slab shall be cleaned and sealed with
suitable bituminous sealing compound.
Rd. 55.6.5. Final finishing of base - Prior to depositing concrete on the base the section
shall be checked with scratch template riding on the side forms and drawn along parallel
to the center line and unevenness corrected with lean concrete as detailed above.
The sub-grade and sub-base shall be completed in accordance with these requirements
in advance of concreting. Correction with lean concrete should be limited to the bay
to be concrete.
 No concrete shall be laid on a freshly laid macadam sub-grade until passed by the

404 RED BOOK  VOLUME I  ROADS  2012

 Rd.
Engineer.
 The existing road surface shall be brushed and all the blindage and loose materials
removed. The surface shall then be uniformly moistened just before laying the concrete
slab with as much water as it will absorb readily without causing pools of standing
water. It may be advisable to have the sub-grade or sub-base sprinkled or thoroughly
wetted from 12 to 24 hours in advance of placing concrete where such procedure seems
necessary.
Rd.55.7 Forms -
Rd.55.7.1 Steel forms - All side forms shall be of mild steel unless use of wooden
sections is specially permitted. The steel forms shall preferably be mild steel channel
sections and shall have the same depth as the edge thickness of the slabs.
 The sections shall have a length of at least 10’ except on curves of less than 50 m.
radius where shorter sections may be used. The use of bent, twisted or worn out forms
will not be permitted. The supply of forms shall be sufficient to permit their remaining in
place not less than 24 hours after concrete has been laid.
Rd. 55.7.2. Wooden forms - Wooden form may be used only when specified in special
provisions. However their use is permitted for all curves having radius of less than 50 m.
Wooden forms shall be 80 mm in thickness and equal in depth to the edge thickness of
the slab and dressed on one side and on top. These forms when used on straight shall
have a minimum length of about 3 m.
Rd. 55.7.3. Setting of forms - The forms shall be set to the exact grade and alignment
at least 60 m. in advance of the point of deposition concrete. The base on which the
forms are to be set shall be well consolidated and rigid so that they will not sink with
the equipment moving on them. Sufficient bracing pins or stakes adequate length shall
be driven into the ground along the outside edge of forms at suitable intervals to obtain
required rigidity. Deviation of more than 6 mm. in a length of 3 m. shall not be permitted.
Rd. 55.7.4. Removal of forms - The forms may be removed 24 hours after laying
concrete. Great care shall be taken during the removal to insure that the concrete and
its edges are not damaged in any way. The forms shall be thoroughly cleaned, repaired
if necessary and oiled each time before reuse.
Rd. 55.8. Joints -
Rd. 55.8.1. Transverse expansion joints - Transverse expansion joints shall be
provided at every 35 m. and shall be of the premoulded type. It shall be 12 mm. thick
and extend to the entire width of the pavement and from the bottom of the slab of 25 mm.
below the surface of the pavement. A bulkhead cut to the exact section of the road shall
be securely staked in place at right angles to the center line of the road. The premoulded
joint filler shall be placed against the bulkhead and held accurately in position by a metal
channel cap or other approved method, during the placing and finishing of the concrete.
When a day’s concreting extends beyond the expansion joint, concrete shall be placed
on both sides of the bulkhead. After the concrete has been compacted and struck off, the
bulkhead shall be removed by lifting it slowly from one end and replacing it with concrete
as it is lifted so that the joint filler will be left in the correct position. The metal channel
cap when used shall be of 10 gauge steel having two equal parallel legs not less than 5
cm. deep. The metal cap shall e placed over the top of the expansion joint material and
the two held in position in the sub-grade by flat metal stakes spaced so closely together
that the joint material will remain straight as the concrete is placed and finished. After the
pavement has been struck off and finished, the metal cap shall be removed.
No concrete shall be left along the expansion joint materials or across the joint at any

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point. Any concrete spanning the ends of the joint next to the forms shall be carefully cut
away after the forms are removed.
No concrete shall be left along the expansion joint materials or across the joint at any
point. Any concrete spanning the ends of the joint next to the forms shall be carefully cut
away after the forms are removed.
When expansion joints are made at the end of the day’s work, they shall be formed by
finishing the concrete to the bulkhead placed across the road. When work is resumed,
the joint filler shall be placed against the hardened concrete with metal channel caps and
held in position by pins until fresh concrete is placed against it. Dowels when provided,
shall be fixed as shown on the plans and shall be paid for separately.
Rd. 55.8.2. Transverse contraction joints - Transverse contraction joints shall be
placed at every 6 m. to 9 m. or as directed by the Engineer and shall be of the weakened
plane or dummy groove type. They shall be formed by making a groove 6 mm. wide with
a depth of not less than 1/4 of the depth of pavement at the thinnest part of the section
with a tee section or suitable tool soon after the concrete is lid.
Rd. 55.8.3. Transverse construction joints - Transverse construction joints shall be
formed whenever placing of concrete is suspended for more than 30 minutes. Except for
emergency stops, construction joints shall be located at the regular site for expansion
or construction in joints. At all construction joints, a bulkhead shall be placed and staked
and concrete surface shall be finished to the face of the bulkhead. An edging tool shall
be used along the bulkhead to make the construction joint a regular and well defined
line.
Rd. 55.8.4. Expansion joint at surfaces - Expansion joints shall be formed about all
structures and features projecting through, into or against the pavement, such joints
shall normally be 12 mm. wide and may be poured or premoulded as directed by the
Engineer.
Rd. 55.8.5. Longitudinal joints - Longitudinal joints shall be plain butt type and shall be
formed by placing the concrete against the faces of the slabs concreted earlier. The faces
of the old concrete slabs shall be painted with bitumen before placing fresh concrete.
Where so provided for slabs thicker than 10 cm., tie bars shall be used at longitudinal
joints. Their dimensions and spacing shall be as shown on the plans. Tie bars shall be
fairly supported so as not to be displaced construction operations. Tie bars shall be
bonded in the slabs across longitudinal joints and while casting the first slabs they may
be bent so that one end of them lies along the forms. After removal of the forms, bars
shall be straightened so that they extend into the concrete placed on the other side of
the joints.
Rd. 55.9. Construction Methods -
Rd. 55.9.1. Mixing - According to specification No. B. 5.
In case of failure of mixer, hand mixing shall be permitted only to complete the particular
slab with the precautions regarding additional cement etc. detailed in specification No.
B.5.4. Such a slab shall be kept under observation for its response to traffic and shall be
paid after the Engineer is satisfied about its performance within a week of opening the
slab to traffic.
Rd. 55.9.2. Placing concrete - Reinforcement when provided shall be placed in
position as shown in the plans and paid for sepa­rately. The concrete shall be deposited
on the previously moistened sub-grade or sub-base. It shall be laid to the required depth
and width of the pavement shown on the plans or directed by the Engineer rapidly in
successive batches in continuous operation without the use of intermediate forms or
406 RED BOOK  VOLUME I  ROADS  2012
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bulkheads between expansion or contraction joints. When consolidated and finished, the
slab thickness required in the plans shall be obtained at all points and the surface shall
not at any point deviate from the grade and section of the required finished surface. The
spreading shall be as uniform as possible to avoid rehan­dling of the concrete. Where
however certain amount of redistribution is necessary, it shall be done with shovels and
not with rakes. While being placed, the concrete shall be rodded with suitable tools or
vibrated so that the formation of voids or honeycomb pockets is prevented along the
faces of the forms. Workmen shall not be allowed to walk on the freshly laid concrete.
 In case of unavoidable interruption in placement of concrete continuously between
transverse expansion joints, a full depth trans­verse construction joint shall be placed at
the point of stopping work by putting a bulkhead provided the section on which work is
suspended shall be at least 3 m. long. Shorter sections shall be removed when work is
resumed, the bulkhead shall be removed, care being taken not to disturb the concrete.
The fresh concrete shall be placed directly against the face of the concrete previously
laid.
Rd. 55.9.3. Compaction and finishing - The sequence of operation shall be -
(a) strike off and compaction.
(b) longitudinal floating and removal of laitance.
(c) straight edging.
(d) finishing at joints.
(e) final finish by brooming.
(f) edging.
(g) finishing sides.
Rd. 55.9.3(a). Strike off and compaction - Concrete as soon as placed shall be struck
off uniformly and screeded with a heavy screeder or tamper to the grade and cross
section shown on the plans and to such level above the base that when compacted and
finished the pavement shall conform to the grade, cross-section and depth indicated by
the plans. The pavement concrete shall be compacted by means of a vibrating screed.
For areas where the width of the slab is very small and tamper cannot be used, hand
compaction and finishing may be adopt­ed subject to the approval of the Engineer.
A hand tamper may be used for screeding and tamping where the work is unimportant
or small i.e., not more than 100 m. The tamper shall rest on the side forms and shall
be drawn ahead with sawing motion in combination with a series of lifts and drops
alternating with lateral shifts, the aim of this operation being compaction and screeding
to the approximate level required. Subsequent tamping should advance about 8 cm.
at a time in the direction in
 which the work is proceeding and in the final stages, tamping should be closer about
12 mm. at a time until a dense and smooth surface is obtained. At trans­verse joints, the
tamper shall be drawn about closer than one metre towards the join and shall then be
lifted and set-down at the joint and drawn backwards away there from. Surplus concrete
if any, shall be taken out with the shovels.
For longer lengths, manually handled vibrating tamper consist­ing of a normal  type of
hand tamper to which pneumatic, mechanical or electric vibrating unit is attached shall be
used for compaction. The concrete shall have been evenly spread to the required level
above the base, making due allowance for compaction. The tamper shall be lowered
vertically on to the concrete surface allowed to remain in position for a few seconds
until compaction is complete, then lifted vertically and lowered on toe adjacent strip of

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uncompacted concrete. The tamper shall again be taken slowly over the surface sliding
with its axis slightly tilted away from the direction of sliding and the operation repeated
until a dense, close knit texture surface is obtained.
 Segregated particles of coarse aggregate which collect in front of the tamper shall be
thrown outside the forms or thoroughly mixed by hand with the mass of concrete already
on the base. Under no circum­stances shall such segregated particles be carried forward
and pushed on to the base in front of the mass.
Compaction by tamping vibrator shall be carried on till the mortar in the mix just works
upto the surface. Care shall be exercised to control the operation of tamping so as
to prevent an excess of mortar and water from being worked to the top. Continuing
vibration beyond what is required to secure necessary compaction and elimination of
voids shall be avoided.
 Immediately after the tamping has been completed and before the concrete has
hardened, i.e., while the concrete is still in a plastic state, the surface shall be inspected
for irregularities with a pro­file checking template and any needed correction made by
adding or removing concrete and tamping.
Rd. 55.9.3.(b). Hand floating -  Soon after the concrete is struck off and compacted,
it shall be further smoothened and laitance removed by means of a longitudinal float
1.2 metre long and 10 cm. wide. It shall be operated by a man sitting on a bridge
spanning clear of slab. The longitudinal float shall be worked on the concrete sur­face
with a sawing motion with its longer dimension parallel to the center line of the road and
passed gradually from one side of the pavement to the other. Movements ahead along
center line of the road­ways shall be in successive advances of not more than one-half
the length of the float.
Rd. 55.9.3.(c). Straight edging and surface correction - After the longitudinal floating
has been completed and excess water if any, has disappeared but while the concrete is
still plastic, the slab surface shall be tested for trueness with a 3 m. straight edge using
two bridges for the purpose. The straight edge shall be held in suc­cessive positions
parallel to the road center line in contact with the surface and the whole area gone over
from one side of the slab to the other. Advance along the road shall be in successive
stages of not more than one-half the length of the straight edge. Any depressions
found shall be filled immediately with freshly mixed concrete, struck, compacted and
refinished. High area shall be cut down, compacted and refinished. The straight edging
and refloating shall continue until the entire surface is found to be free from departures
from the straight edge and the slab has the required grade and section.
 A tolerance of +- 3mm in the straight edges length of 3 m. will be permitted. At the
joint no tolerance shall be permitted. If at any place the departure is more than this, not
more than 3 passes of the vibrating machine shall be allowed for rectification and the
surface tested again. If the departure is still more than the tolerance limit, concrete in the
defective portion will be cut out, fresh concrete placed, compacted and finished to the
required standard without claim­ing any extra payment.
Rd. 55.9.3.(d). Finishing at joints - A suitable float shall be used at all joints. The
device shall be so arranged as to float the surface for a width of at least 15 cm. on each
side of the joint simultaneously and shall be used in such a manner as to produce a level
surface across the joint. If there is any unevenness found after the concrete is set it shall
be ground down flush by the contractor with an approved grinding tool or carborundum
brick and water at the contractor’s cost.
Rd. 55.9.3.(e). Brooming - After hand floating straight edging and finishing the surfaces
at joints and when most of the water sheen has disappeared, the pavement shall be
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 Rd.
given a broom finish with an approved type of bass broom. The broom shall be pulled
gently over the surface of the pavement perpendicular to the center line of the road from
edge to edge in such a manner that the corrugation will be uniform in width and depth.
The depth shall not be more than 1.5 mm . Brooming shall be done when the concrete
is in such condition that the surface will not be torn or unduly roughened by the opera­
tion. Brooms shall be maintained in good serviceable condition at all times by being
washed thoroughly and dried at frequent intervals Coarse or long bristles which cause
irregularities or deep corruga­tions shall be trimmed or entirely cut off. Brooms which are
worn out or otherwise unsatisfactorily shall be discarded.
Rd. 55.9.3.(f). Edging - After brooming has been completed but before the concrete
has taken its initial set, all the edges of the slab shall be carefully finished with an edging
tool to a radius of 10 m. and the pavement edge shall be levelled and floated smooth for
a width of 5 cm. and not broomed.
Rd. 55.9.3.(g). Finishing sides - After the forms are re­moved all the exposed side
face shall be cleaned and honeycombed areas if any, pointed with 1:2 cement mortor
and cured. The sides of the slab shall, thereafter be covered with earth upto the top of
the slab.
Rd. 55.10. Curing -
Rd. 55.10.1. Initial curing - immediately after final finishing operations and after the
concrete has set sufficiently to prevent marring of the surface, the surface and sides of
the concrete slab shall be entirely covered against rapid drying or any other damage
with wet empty cement sacks, wetted burlap or jute mats, etc. and these must be kept
continuously wet by sprinkling water until the concrete has taken its final set and is
sufficiently hard to be walked on without suffering damage. Walking on freshly laid
concrete for placing burlap, etc, will not be permitted.
Rd. 55.10.2. Final curing by ponding - As soon as it is possible to remove the wet
sacking burlap etc, without damaging the surface of the concrete, it shall be removed
and e slab shall be thoroughly wetted and then cured in the following manner :-
 Exposed edges of the slab shall be banked with substantial berms of earth. Upon
the slab shall be spread about 25 mm. thick blanket layer of wet earth transverse and
longitudinal ridges or bunds 8 cm. to 10 cm. high put up over the earth cover making
square panels or 1 m. x 1 m. and the panels filled with water. All portions of concrete
surface shall be so treated and kept continuously saturated with water for 18 days and
left to attain the required strength. The blanket earth layer shall be removed after 21
days of laying the concrete. If the earth covering becomes displaced during the curing
period, it shall be replaced to the original depth and resaturated.
Rd. 55.11. Concreting during rains - Normally no concreting shall be done when there is
rain. When rain is expected while concrete is being placed; a sufficient supply of tarpaulins
or other waterproof covering shall be provided at the actual work site. When it rains, all
freshly laid concrete which has not been covered for curing purposes shall be adequately
protected by means of tarpaulins or other water­proof covering. Any concrete injured by
rain shall be removed and satisfactorily replaced with fresh concrete at the cost of the con­
tractor.
Rd. 55.12. Protection of concrete - Any part of the pavement which is defective or
damaged by traffic or other causes occurring prior to its final acceptance shall be repaired
or replaced by and at the expense of the contractor in a manner satisfactory to the En­
gineer. The contractor shall protect the pavement against both public traffic and the traffic
caused by his own employees and agents.

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Rd.
Rd. 55.13. Cleaning - After the period of curing is over, the earth or other cover may be
removed and pavement thoroughly, washed, brushed, cleaned and allowed to dry.
Rd. 55.14. Sealing of joints - After cleaning the surface all foreign matter in transverse
expansions and contraction joints shall be removed completely. All faces of the joints shall
be cleaned with a wire brush to remove all loose material. If necessary the foreign matter
shall be blown out. The top of the transverse expansion joint shall be thoroughly cleaned
out down to the top of the premould­ed joint filler and the cavity thus formed shall be filled
with an approved poured joint filler. The groove of the transverse contraction joint shall
also be similarly cleaned and filled with the approved poured joint filler. Longitudinal joints
if any shall also be similarly treated. Care shall be taken to see that no stones or pebbles
get into the joints before joint filler has been poured and that the joint filler is not spilled on
the surface of the pavement adjacent to the joint. Any excess filler on the pavement surface
shall be removed immediately and surface cleaned.
Rd. 55.15. Opening to traffic - Traffic shall not ordinarily be allowed on a newly constructed
concrete for a period of twenty one days after placing concrete. This may be extended for
a longer period up to 28 days if the tests of concrete fall short of the specified strength and
indicate that it is advisable to extend the time.
Rd. 55.16. Keeping records - According to specification No.B.5.13
Rd. 55.17. Maintenance - The contractor shall maintain the road at his expense for a
period of three months after opening the pavements for traffic. He shall carry out repairs to
joints as and when necessary, and rectify the defects developed, if any, due to bad work
during the period and perform such other work as my be deemed necessary to carry out the
intent and meaning of these specifications to the satisfaction of Engineer. If the contractor
fails to do this, maintenance may be done by the Department and cost recovered from the
contractor.
Rd. 55.18. Tolerance in thickness - A tolerance of 3 mm. be permitted. If the tolerance
is more than 3 mm. and up to 6 mm. the work may be accepted as substandard and rate
reduced in the proportion of square of the reduced thickness to the square of the designed
thickness. If the thickness is less than the specified by more than 6 mm. that area of the
slab may not be paid for or the rate further reduced as decided by the Engineer.
Rd. 55.19. Sampling and testing - According to specification No.B.5.
Rd. 55.20. Item to include - According to specification No.B.5.14 and (1) preparing
the sub-grade or sub-base for placing cement concrete pavement of specified thickness
including 1:4:8 lean cement concrete for patch-work and correction of camber and
providing diversions. unless these are separately provided in the tender. (2) Providing
cement concrete pavement of specified thickness including compacting, curing, finishing,
providing premoulded and poured joint fillers and maintenance for 3 months after opening
the pavement to traffic. (3) Testing.
Rd. 55.21. Mode of payment and measurement - The contract rate shall be for a unit
of one sq. meter of completed and accepted pavement of concrete of specified proportion,
strength and thickness. The width shall be measured at right angles to the center line of
the pavement from outside to outside of completed pavement limited to that shown on the
plans or as directed by the Engineer correct up to two places of decimals of a metre. The
length will be the actual length measured along the center line of the pavement including
all joints correct to two places of decimals of a metre. The quantity in square metres shall
be calculated correct to two places of a square metre.
Rd. 56. Providing and fixing kilometer stone/200 meter stone of standard size and

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 Rd.
shape including fixing in a block of standard size of cement concrete 1:4:8, painting
etc., complete.
Rd. 56.1. General - The item provides for the supply of kilometer or 200 metre stone of the
type mentioned in the item and standard size and shape according to type plan including
dressing, engraving letters and figures, fixing in a block of 1 : 4 : 8 cement concrete, painting,
etc., complete.
Rd. 56.2. Materials - The kilometer stone or 200 metre stone shall be of the type mentioned
in the item and of the standard size and shape. The stone shall comply with the specification
No. A.8 and shall be in one solid piece. The portion exposed above the ground or platform
shall be chisel dressed as specified in specification No. B.9.3.(b), while the buried portion
may be left undressed.
Figuring and lettering shall be of the size indicated on the type plans and shall be engraved
in V cuts. The depth of cut will be half its width. The particular names and figures to be
engraved on individual stones shall be as ordered by the Engineer.
The 1 : 4 : 8 cement concrete shall conform to the relevant provisions of the specification
No.B.5. Maximum size of coarse ag­gregate shall be 40 mm.
The oil paint for the stones shall be white or other shade approved by the Engineer and that
for lettering and figuring shall be black or other shade approved by the Engineer. The paint
shall conform to the specification No.A.13.
Rd. 56.3. Fixing - The stone shall be fixed in a standard sized block of cement concrete
of 1 : 4 : 8 proportion with the top of the block flush with the ground or road as indicated in
the standard drawing at the designated spot or as ordered by the Engineer.
Any excavation necessary for fixing the stone shall be done by the contractor and the cost
shall be included in the rate.
The exposed part shall be painted with two coats of good oil paint of approved shade
as specified in B.21. The letters and figures shall be painted in black or any other shade
approved by the Engineer.
Rd. 56.4. Item to include -
(1) Supply of kilometer or 200 metre stones.
(2) Dressing and engraving letters and figures.
(3) Fixing in C.C. 1.:4 :8 block including excavating pits.
(4) Painting stone, figures and letters.
(5) All necessary labour, materials, use of equipment and tools, etc., for completing the
job satisfactorily.
Rd. 56.5. Mode of measurement and payment - The contract rate shall be for one
kilometer or 200 metres stones fixed. The measurement shall be for the number of the
kilometer stones fixed in concrete in position and painted.
Rd. 57. Providing and fixing guard stones/indicator stones/boundary stones of
standard size and shape including fixing in ground/in blocks of standard size of
cement concrete 1 : 4 : 8, white washing, etc., complete.
Rd. 57.1. General - The item provides for the supply of guard stones, indicator stones or
boundary stones of specified type and fixing them in position indicated on the drawings or
as ordered by the Engineer in a block of cement concrete 1 : 4 : 8 of 45 cm. X 45 cm. X 45
cm. or ground as mentioned in the item and white washing.
Rd. 57.2. Materials - The guard stone, indicator stone or boundary stone shall be of the
RED BOOK  VOLUME I  ROADS  2012 411
Rd.
specified type of stone and of the standard size and shape shown in the type plans. The
stone shall comply with the specification No. A7. The portions of the stones exposed above
the ground shall be rough tooled as specified in specification NO. B.9.3(a). An arrow mark
shall be engraved on the boundary stones in V cuts as indicated on the type plan. The
depth of the V cut shall be half its width.
The 1 : 4 : 8 concrete when included in the item shall conform to the relevant provisions of
the specification No. B.5. Maximum size of coarse aggregate shall be 40 mm.
Rd. 57.3. Fixing - The guard stone, indicator stone, or boundary stone, shall be fixed in
position as indicated on the drawing or as ordered by the Engineer. It shall be fixed in ground
or in a block of 1 : 4 : 8 cement concrete of size 45 cm. X 45 cm. X 45 cm. as mentioned
in the item with the top of the block flush with the road or ground at the designated spot.
Any excavation necessary for fixing of the guard stone and laying of the cement concrete
bedding shall be done by the contractor at his cost. The exposed part of the stone shall be
given two coats of whitewash.
Rd. 57.4. Item to include -
(1) Supply of dressed guard stone, indicator stone or boundary stone, with arrow mark
engraved on boundary stones.
(2) Fixing the stone in position in 1 : 4 : 8 cement block or in the ground as mentioned in
the item including whitewashing and necessary excavation.
(3) All labour, materials and use of tools and plant required for the completion of the item
satisfactorily.
Rd. 57.5 Mode of measurement and payment - The contract rate shall be for one guard
stone, indicator stone or boundary stone fixed in position in concrete block or ground as
mentioned in the item. The measurement shall be for the number of such stones fixed in
position.
Rd. 58. Providing and fixing stone pinheaders at the toe of the pitching.
Rd. 58.1. General - The item provides for the supply of pinheaders of the specified type
of stone at the toe of the pitching including excavation in ground and fixing the pinheaders.
Rd. 58.2. Materials - The pinheaders shall be of stones complying with the specification
No. A.8. and shall be of the specified type. They shall have an average cross-sectional
area of not less than 0.03 sq. m. The pinheaders shall be at least 60 cm. along with a face
thickness of 20 cm. and a width of 20 cm. or more on the face. The top edges shall be
dressed square or rectangular and the bushing on top face shall not exceed 40 mm. and
the side shall be dressed square for 4 cm. from the top edge.
Rd. 58.3. Fixing -The pinheaders shall be fixed securely at right angles to the bank
slope into the ground after excavating a trench of the required dimensions to have their
top face flush with the plane of the face of the pitching and the lower edge flush with the
ground. They shall be fixed close to each other along the toe of the pitching and the trench
backfilled and compacted before pitching is started. The bed of the trench shall be at right
angles to the slope of the pitching.
Rd. 58.4. Item to include -
(1) Providing pinheaders including excavating trench, fixing them securely and backfilling
along the toe of the pitching.
(2) All labour, materials and use of tool necessary for completing the work satisfactorily.
Rd. 59. Providing stone khandki pitching 23 cm. thick.

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Rd. 59.1. General - The item provides for khandki pitching 23 cm. thick for the bank slope.
Rd. 59.2. Materials - S tone shall comply with specification No. A.7. for face stones. The
khandkies shall be rectangular with straight edges. The four sides shall lie in one plane.
Bushing shall not be more than 40 mm. The beds shall be square to the face for at least 4
cm. and the sides for at least 2 cm. from the face. No special dressing is envisaged in the
remaining position; however, the beds and the joints shall be made as plane as possible
with the aid of a hammer and a chisel.
All khandkies shall be more in breadth than in height on face and shall have a tailing to the
full depth of the pitching. The height of the khandkies shall not be less than 15 cm. and all
khandkies shall be of the same height.
Rd. 59.3. Preparation of the base - The slopes of the bank shall be made up with murum
and trimmed to the required slope and properly compacted under this item. Profiles shall
be put up with pegs and strings at required intervals to ensure that the pitching is laid true
to line, curves, levels, thickness and slopes.
Rd. 59.4. Construction - A line of pinheaders shall be provided when necessary at the
toe to support the pitching ( vide item No.Rd.58.); a masonry toe wall may also be provided
as an alternative, both of which shall be paid separately. The lowest course of pitching shall
be started from the toe wall or the line of headers at the toe of the slope and the pitching
of the specified thickness laid course by course, up the slope. The pitching shall be laid
to lines, curves, levels and slopes indicated in the plans or directed by the Engineer. The
khandkies shall be laid closely in position on the prepared bed and firmly set. The face of
khandkies shall be parallel to the slope and the bedding joints perpendicular to the slope.
The khandkies shall break joint for at least 8 cm. Additional murum bedding if required
for getting proper slope, shall be carried up simultaneously with each course of pitching
watered if necessary and rammed. The interstice in the joints of tailing shall be filed with
spalls of proper size and wedged in with hammers to secure tight packing. Such filling shall
be carried out simultaneously with laying or each course of khandkies. The side joints shall
be as close as possible. There shall be no pinnings on the face.
Rd. 59.5 Item to include -
(1) Preparing the base and putting up profiles.
(2) Laying khandki pitching 23 cm. thick to lines, levels, curves and batters as shown on
the drawings, or as ordered by the Engineer including preparing base, making up,
trimming and compacting the bedding.
(3) All labour, materials, use of tools and plant necessary for the satisfactory completion
o the item.
(4) Repairing disturbed pitching, if any, within three months of completion.
Rd. 59.6 Mode of measurement and payment - The contract rate shall be for one sq.
meter of the finished surface of pitching.
The dimensions shall be measured correct up to a cm. and the area worked out correct up
to two places of decimals of a sq. meter.
Rd. 60. Providing dry rubble stone pitching 23 cm. thick.
Rd. 60.1. General - The item provides for dry rubble stone pitching 23 cm. thick for the
bank work.
Rd. 60.2. Materials - The rubble stones for pitching shall be sound, hard and durable
and fairly regular in shape. The depth of the stones shall be about equal to the specified
thickness of pitching and stone shall generally be not less than 9.9 liters or other size

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ordered by the Engineer having regard to the nature of the stones being quarried. The
smaller size stones required for packing and wedging shall be brought to the site only to
the required extent and they shall not be used in two or more thicknesses as a substitute
for the stones of full thickness.
Rd. 60.3. Preparation of the base - The slopes of the bank shall be made up with murum
an trimmed to the required slope and properly compacted under this item. Profiles shall be
put up with pegs and strings at required intervals for the pitching to ensure that it is done
true to line, curves, levels, thickness and slopes.
Rd. 60.4. Construction - A masonry toe wall or a line of pinheaders when necessary,
shall be provided at the toe to support the pitching and shall be paid for separately vide
specification No. Rd.71. The lowest course of pitching shall be started from the toe wall or
the line of pinheaders at the toe of the slope and the pitching laid course by course up the
slope.
The stones for the pitching shall be used after merely knocking out weak corners and edges
with a mason’s hammer. The stones shall be laid closely in position on the prepared bed
and firmly set with the even face on top. The pitching shall be laid to lines, levels, curves
and slopes as indicated in the plans or as ordered by the Engineer. Each stone shall cover
the full depth of pitching and shall be perpendicular to the sloping bed. The stones shall
be laid breaking joints as far as possible. Additional murum bedding if required for getting
proper slope, shall be carried up simultaneously with each course of pitching, watered, if
necessary and rammed.
The interstices in the joints between adjacent stones shall be filled in with spalls of the
proper size and wedged in with hammers to ensure tight packing. Such filling shall be
carried out immediately after placing larger stones and before the next upper layer is taken
in hand.
Rd. 60.5. Items to include -
(1) Preparing the base and putting up profiles.
(2) Laying dry ruble pitching of the specified thickness to lines, curves, slopes, levels
including preparing base, making up, trimming and compacting the bed and hand
packing.
(3) All Labour, materials and use of tools and plant necessary for the satisfactory
completion of the item.
(4) Repairing disturbed pitching, if any, within three months of completion.
Rd. 60.6. Mode of measurement and payment - The contract rate shall be for one sq.
metre of finished pitching. The dimensions shall be measured correct upto a cm. and
the area worked out correct upto the second place of decimal of a sq. metre.
Rd. 61. Providing dry rubble stone masonry.
Rd. 61.1. General - The item provides for the dry rubble stone masonry of the specified
type of stone for the retaining walls, etc., including scaffolding, etc., complete.
The dry rubble stone masonry shall conform to the specification No. B.9.(f) for U.C.R.
masonry except for the following deviations :-
(1) The masonry shall be without mortar(i.e.,dry).
(2) The quoins may be dressed like khandkies on the face and need not be rough tooled.
(3) The spaces between larger stones shall be filled with spalls as tightly as possible.
Rd. 61.2. Mode of measurement and Payment - According to specification No. B.9.(f).13.

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There shall be no deduction for voids.
Rd. 62. Laying 50 mm thick Special grout bituminous road surface including
preparing the existing road surface, laying the required thickness of metal layer,
heating and spraying bitumen, spreading chips and laying seal coat complete.
Rd. 62.1. General - The item provides for laying the special grout bituminous road surface
of a compacted thickness of 50 mm including preparing the existing road surface to receive
the special grout course use of equipment and plant and materials such as the fuel etc.;
stone aggregate, bitumen and compaction.
Rd. 62.2. Diversions - Diversions shall be taken out and maintained as specified under
item No. 27.2 by the contractor at his own cost unless separately provided in the tender.
Diversion shall be watered if its dust is likely to blow on to the road being bituminised.
Rd. 62.3. Construction -
Rd. 62.3.1. Materials - The aggregate and bitumen for providing special grout surface
of a compacted thickness of 50 mm shall comply with specification Nos. Rd. 33 and
Rd. 34, respectively, and shall normally comply with the following regarding sizes and
quantities of aggregates and grade and quantities of bitumen :-

MATERIALS Rate of application

for 100 Sq. m.
1 2
(a) 25 mm. size metal 6.0 cu.m.
(b) 12 mm. size chips 1.8 cu.m.
(c) 10 mm. size chips 0.9 cu.m.
(d) Bitumen for tack coat, I.S. grade 73.5 kg.
S. 90 with 80/100 penetration.
(e) Bitumen for grouting, I.S. grade 440.0 kg.
S.90 with 80/100 penetration.
(f) Bitumen of I.S. grade S.90 with 73.5 kg. to
80/100 penetration for seal coat 97.5 kg
Note :- For 25 mm. size metal 5 per cent tolerance lower size shall be permitted.
 The metal and chips shall be entirely dry at the time of spreading. If modifications in
the above quantities are stipulated in the special provisions, the work will be carried out
according to the requirements of special provisions.
The above quantities are exclusive of patching materials.
The supply of patching materials shall be done and paid for under separate items.
Rd. 62.3.2. Preparing the base - Where the section of water bound macadam road
surface is good except for a few local depressions and unevenness, the surface shall be
brought to the required section by adding suitable patching metal at places as required
and compacting it fully. Such labour will be incidental to the item and shall not be paid
for separately. The road surface shall be swept clean of all dirt, dust caked mud slush,
animal droppings and other loose and foreign matter and the blindage shall be brushed
and cleared off to expose the metal surface entirely. If so required by the Engineer, the
Contractor shall keep the side widths and nearby diversion watered to prevent dust from
blowing over the surface to be bituminised.
Cement concrete surface shall be cleaned of all foreign matter.

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Rd.
Existing bituminous surfaces shall be swept clean of all loose foreign matter.
 There shall always be sufficient length of prepared surface ahead of the bituminous
surfacing operations as directed by the Engineer to keep these operations continuous.
The prepared surface shall be closed to traffic. The contractor shall at his own expense
repair any damage to the prepared base caused by his own operations or use by traffic.
 Edge lines shall be marked with stakes after ranging the line for a sufficiently long
length for spreading the metal and about 30 cm. to 45 cm. wide metal or hard murum
berms formed and compacted or 5 cm Manila rope for a length of 50 meters on either
side should be used, to hold the metal from spreading.
Rd. 62.3.3. Applying bitumen for tack coat - Bitumen of I.S. grade S. 90 with 80/100
penetration shall be hated to a temperature of 163oC to 177o C in a bitumen boiler and
the hot bitumen shall be applied to the prepared, cleaned road surface at the rate of
73.5 kg per 100 sq.m. Application shall be done by a mechanical pressure sprayer or if
permitted by pouring can with roses. The tack coat shall be applied just before spreading
the aggregates. Application of tack coat shall be done slightly in advance of spreading
the aggregate.
Rd. 62.3.4. Spreading - The 25 mm. size aggregate shall be spread evenly at a rate
of 6 cu.m./100 sq.m. or at a rate ordered by the Engineer to form a uniform layer over
the width of the road specified on the plans. If the aggregate contains dust, grass etc.,
it shall be screened and if moist, dried before spreading. The section shall be checked
with the camber boards and strings or straight edge. Inequalities shall be made good by
adding reserve aggregate in depressions and removing surplus metal from high spots.
Rd. 62.3.5. Compacting - The layer shall be compacted as specified separately under
specification No. Rd. 76.
 The compaction shall be covered by that item. Inequalities observed during and after
compaction shall be made good by spreading reserve metal in depressions and removing
metal from high spots and compacting.
Rd. 62.3.6. Applying bitumen - Bitumen of I.S. grade S.90 having 80/100 penetration
shall be heated in a bitumen boiler to a temperature of 163o C to 177o C and that
temperature shall be maintained at the time of actual application. The hot bitumen shall
be applied through a pressure sprayer or when permitted, through a can with a rose
to the road surface uniformly at the rate of 440 kg./100 sq.m. The road surface shall
be divided into suitable rectangles marked by chalk so as to ensure correct rate of
application of the bitumen to penetrate to the required depth of aggregate. When supply
is made in bulk pressure sprayer or ‘Bowsers’ shall necessarily be used.
Rd. 62.3.7. Blinding - 12 mm. to 10 mm. chips shall then be spread evenly over the
road surface at a uniform rate of 1.8 cu.m./100 sq.ft. immediately after applying the
bitumen when it is still hot. Brooms shall also be used to ensure uniform thickness of the
layer of chips.
Rd. 62.3.8. Compacting - The surface shall then be compacted as specified separately
under specification No. Rd.76. This compaction shall be covered by that item.
Rd. 62.3.9. Preparing the surface for seal coat - A seal coat shall be applied soon
after the surface is laid and in any case within a month of lying of the special grout
surface.
 The surface shall be cleaned of all foreign matter dust, etc. by brooms, brushes and
gunny bags before applying bitumen for seal coat.
Rd. 62.3.10. Applying bitumen for seal coat - Bitumen of I.S. grade S.90 having

416 RED BOOK  VOLUME I  ROADS  2012

 Rd.
80/100 generation shall be heated in a bitumen boiler to a temperature ranging between
163oC to 177oC which shall be maintained at the time of actual application. Hot bitumen
shall be applied evenly at a uniform rate of 73.5 Kg./100 Sq. m to 97.5 Kg./100 Sq. m.
with a sprayer or a rose can.
Rd. 62.3.11. Blinding - Immediately after the bitumen, the road surface shall be binded
evenly with 10 mm size chips at a uniform rate of < 0.9 Cum/100 Sq. m. Brooms shall be
used to ensure the evenness of the layer of chips.
Rd. 62.3.12. Rolling - After spreading and evening up the blinding chips, the surface
shall be rolled as specified separately under specification No. Rd. 76. This rolling shall
be covered by that item.
Rd. 62.4. Special requirements - Heating of bitumen shall be done in bitumen boilers with
lock unless otherwise permitted by the Engineer. The heated bitumen shall be handled in
iron buckets with handles or sprayers. The labour engaged in handling the heated bitumen
shall use all length gumboots, leather hand gloves and leather jacket with fire proof apron
to cover the chest and the back and reaching up to the knees.
Two thermometers shall be maintained on the site and used for checking the temperature
of heated bitumen.
Rd. 62.5. Item to include -
(1) Diversions unless separately provided in the tender.
(2) Preparing the road surface, including patch-work.
(3) Heating bitumen including fuel, etc., and applying to the road surface for tact coat.
(4) Spreading 25 mm size aggregates.
(5) Heating bitumen including fuel, etc., and applying to the road surface for grouting.
(6) Blinding the surface with 12 mm to 10 mm size chips.
(7) Preparing the surface for the seal coat.
(8) Heating and applying bitumen for the seal coat including fuel, etc.
(9) Blinding the surface with 10 mm size chips for the seal coat.
(10) All labour, materials use of tools, plant and equipment for completing the item
satisfactorily.
Rd. 62.6. Mode of measurement and payment - The contract rate shall be for 100 Sq.
m. The measurement shall be for the width of the road as executed limiting it the width
specified or as ordered by the Engineer and the length measured along the center line.
The measurements of dimensions shall be recorded correct upto two places of decimals of
a metre and the area worked out correct upto one plaice of decimal of a Sq. m.
Rd. 63. Compacting 50 mm thick special grout surface with power roller including
labour, use of plant, etc., complete.
Rd. 63.1. General - The item provides for compaction of full grout surface to a compacted
knees of 50 mm with a power roller of 8/10 tonnes including necessary labour materials
and use of plant.
Rd. 63.2. Diversions - According to specification No. Rd. 62.2.
Rd. 63.3. Compaction General - According to specification No. Rd. 36.4.1.
Rd. 63.3.1. Initial rolling - The surface on which the grouting is to be laid shall have
been brought to the required section and grade and cleaned under the item No. Rd.
75. preparatory to the spreading of the aggregate. This sub-grade shall be rolled if

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Rd.
necessary. The coarse aggregate shall be spread evenly to conform to the required
section and grade as specified in specification No. Rd. 75. This layer of metal shall then
be rolled to correct section and grade with a 8-10 tonne power roller to lock the metal
without crushing the aggregate. The surface shall be checked for grade and section
during and after rolling. Any irregularities shall be corrected by loosening the surface
and removing or adding aggregate as required and the spots compacted. Rolling shall
be stopped immediately the aggregate shows sign of crushing.
Rd. 63.3.2. Final Compaction - Immediately after spraying the bitumen and spreading
e blinding chips as specified in specification No. Rd. 75, the surface shall be rolled with a
power roller to obtain full compaction and to force the blinding chips into the interstics of
the course aggregate to pack them tightly. The rolling shall be continued till the asphalt
hardens and the chips stop moving under the roller wheels.
Rd. 63.3.3. Rolling over the seal coat - The seal coat when laid as specified in Rd. 75,
shall be rolled lightly with a power roller so as not to crush the chips.
Rd. 63.3.4. Item to include -
(1) Diversions unless separately provided in the tender.
(2) Compacting the prepared sub-grade surface where necessary.
(3) Initial and final rolling to the correct grade and section.
(4) Rolling over the seal coat.
(5) All labour, materials such as water or oil for applying to the wheels, fuel etc., use of
plant such as power roller necessary for completing the item satisfactorily.
Rd.64 Providing and laying bituminous bound macadam surface in 75 mm thick
including supplying all materials, spreading 40 mm and 20 mm trap metal layers,
heating and spreading bitumen at the rate of 250 Kg per 100 Sqm and spreading 12
mm size key aggregates and compaction with power roller including applying tack
coat at 50 Kg per 100 Sqm etc. complete.
Rd.64.1 General - The work consists of supply of all materials, labour, and use of machinery
required for providing and laying bituminous bound macadam surface for compacted
thickness of 75 mm. This item includes preparing the existing road surface to receive the
bituminous bound macadam course i.e. application of tack coat, spreading of 40 mm size
metal layer in required thickness with compaction with power roller, spreading of 20 mm
chips, compaction with power roller, heating and spraying bitumen with equipment plant
etc. spreading key aggregates 12 mm chips and final compaction with power roller etc.
complete. The work shall be finished in accordance with the requirement of this specification
and in close conformity with grades, lines, cross section and thickness as per approved
drawings or by the Engineer-in-charge.
Rd.64.2 Materials -
Rd.64.2.1 Bitumen :
The bitumen shall be paving bitumen of suitable penetration grade within the range S
35 to S 65 or A 35 to A 65(30/40 to 60/70) as per Indian Standards Specifications for”
Paving Bitumen” IS 73-1961. The actual grade of bitumen to be used shall be decided by
the Engineer in charge appropriate to the region, traffic, rainfall and other environmental
conditions.
Rd.64.2.2 Aggregates :
 The aggregates shall comprise 40 mm size hand broken stones satisfying standard
specification clause Rd 22.3.2, 20 mm size and 12 mm size crushed aggregates satisfy­

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 Rd.64.9
ing standard specification clause 33.3.2, for respective size of crushed metal. The
aggregates shall be clean, strong, durable, fairly cubical in shape and shall be free from
disintegrated pieces, organic or other deleterious matters. The aggregates shall satisfy
the physical requirements set forth in table 500-4 of Ministry of Surface Transport’s
specifications for Road and Bridges. Except that the upper limit of Los Angels abrasion
or value and impact value shall be 50 mm and 40 respectively. The overall gradation
shall conform to table 500-9 of MOST specification.
Rd.64.3 Proportioning of materials
The quantities of the aggregates and bitumen required for the work of 75 mm compacted
bituminous bound macadam is detailed below :
a) 40 mm size hand broken metal 9.00 cmt per 100 sqm.
b) 20 mm size crushed metal 1.50 cmt per 100 sqm.
c) 12 mm size crushed metal 1.80 cmt per 100 sqm.
d) Bitumen including tack coat 250 Kg per 100 sqm.
at 50 Kg per 100 sqm.
Rd.64.4 Weather limitations :
This shall conform to the general specifications for Bituminous Road Surfaces.
Rd.64.5 Preparation of base :
The road surface shall be swept clean of all dirt, dust and other loose and foreign matter.
The work shall be performed on such widths and lengths as directed by Engineer in charge
and may require scari­fying of existing layer, of filling of pot holes etc. The edge lines may
be marked with stakes (formed of murum or metal 25 cm to 30 cm width.)
Rd.64.6 Tack coat :
The tack coat over cleaned surface shall be applied as per clause 503 of specification for
Roads and Bridges by Ministry of Surface
Transport.
Rd.64.7 Spreading and compaction :
Rd.64.8. Spreading of 40 mm size metal :
40 mm size hand broken metal shall be spread evenly at the rate of 9 cubic metres per
100 sqm of area so as to form uniform layer over the width of road specified on plans. Any
foreign matter, organic matter, dust, grass etc. shall be removed immediately. The section
shall be checked with camber board, straight edge batten etc. Any irregularities shall be
made good by adding aggregates in case of depressions and removing aggregates from
high spots.
Rd.64.9 Compaction of 40 mm size metal :
The surface of 40 mm layer after brought to necessary grades and sections shall be
rolled with the use of 8 to 10 tons power roller. Rolling shall commence from the edges
and progress toward the center longitudinally except on super elevated portion it shall
progress form lower to upper edge parallel to the center line of pavement. When the roller
has passed over the whole area as prepared ones, any high spots or depressions which
become apparent shall be corrected by removing or adding aggregates. The rolling shall
then continue till the entire surface has been rolled to desired compaction such as that
there is no crushing of aggregates and all roller marks have been eliminated. The each

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Rd.64.10
pass of the roller shall uniformly over lap not less than one third of the track made in the
preceding pass.
Rd.64.10 Spreading of 20 mm size metal :
20 mm size crushed metal shall be evenly spread at the rate of1.5 cu.m per 100 sqm of
area over the 40 mm size hand broken metal compacted.
Rd.64.11 Compaction after spreading of 40 mm size metal :
The surface of 20 mm metal layer after brought to necessary grades and sections shall
be rolled with the use of 8 to 10 tons power roller. Rolling shall commence from the edges
and progress toward the center longitudinally except on super elevated portion it shall
progress form lower to upper edge parallel to the center line of pavement. When the roller
has passed over the whole area as prepared ones, any high spots or depressions which
become apparent shall be corrected by removing or adding aggregates. The rolling shall
then continue till the entire surface has been rolled to desired compaction such as that
there is no crushing of aggregates and all roller marks have been eliminated. The each
pass of the roller shall uniformly over lap not less than one third of the track made in the
preceding pass.
Rd.64.12 Bituminous application :
Bitumen to be used shall be got approved from Engineer in charge. Bitumen of I.S. grade
S 35 needs heating to a temperature range between 177 degrees to 191 degrees. Bitumen
other than grade I.S. S 35 shall be heated upto a temperature appropriate to that grade.
Bitumen shall be applied through a pressure sprayer uniformly at the rate of 200 Kg per 100
sqm. To ensure correct application of bitumen being sprayed, known dimensioned area be
checked for use of bitumen and accordingly dosage may be increased or decreased as the
case may be.
Rd.64.13 Key aggregates :
On completion of bitumen application, 12 mm size key aggregates shall be sprayed
immediately at the uniform rate of 108 cu.m. per 100sqm of area when entire surface in hot
condition. Broom shall be used to ensure even distribution of key aggregates.
Rd.64.14 Final compaction :
Immediately after spraying of bitumen and spreading of key aggre­gates, the surface shall
be rolled with a power roller to obtain full compaction and to force the blindage of key
aggregates in to interstices of the course aggregate. The rolling shall continue till the
asphalted surface hardens and key aggregates stop moving under power roller.
Rd.64.15 Surface finish and quality control :
The surface finish shall conform to requirements of clause 902 of specification for Roads
and Bridges by Ministry of Surface Trans­port. Quality control test and their frequencies
shall be as per para 5 of table 900-3 on page 228 of specification for Roads and Bridges by
Ministry of Surface Transport.
Rd.64.16 Arrangement of traffic :
During the period of execution, arrangement of traffic shall be carried out according to the
clause 112(excluding last para of 112.6) of specification for Roads and Bridges by Ministry
of Surface Transport.
Rd.64.17 Item to include :
i) Labour and materials, use of equipment required for successful completion of the item.
ii) Applying tack coat.

420 RED BOOK  VOLUME I  ROADS  2012

 Rd.65.3.1
iii) Supplying and spreading and compaction of 40 mm hand broken size metal and 20
mm crushed metal.
iv) Supplying, heating and spraying of bitumen.
v) Supplying, and spreading and compaction of 12 mm crushed metal.
Rd.64.18 Mode of measurement and payment :
The contract unit rate for finished work of bituminous bound macadam shall be for one
sq.m. The finished work shall be measured in square metres.
Rd.65 Providing and laying 75 mm thick builtup spraygrout includ­ing all materials,
preparing and cleaning base, laying metal in two layers, heating and spraying
bitumen, spreading chips, compacting two layers with power roller etc. complete.
Rd.65.1 General - The item provides for laying of 75 mm thick builtup spray grout in two
layer as per the specifications detailed below.
Rd.65.2 Materials -
Rd.65.2.1 Bitumen shall be within the grade S 35 to S 90 or A 35 to A 90 of IS 73-1961.
The actual grade to be used shall be got approved from the Engineer in charge.
Rd.65.2.2 Aggregates -
The aggregates shall be crushed stone. It shall be free from deleterious matter. It shall
conform to the following properties.

S.No. Test Test Method Requirements

1 Los Angles Abrasion Value IS 2386 50% Max.

2 Aggregate Impact Value IS 2386 40% Max.
3 Flakiness Index IS 2386 35% Max.
4 Stripping Value IS 6241 25% Max.
5 Soundness
i) Loss with Sodium Sulphate 5 cycles 12% Max.
ii) Loss with Magnesium Sulphate 5 cycles 18% Max.
6 Water absorption IS 2386 2% Max.

The grading of the coarse and key aggregate shall conform to the following :

Sieve Designation Percent by Weight passing the sieve

Coarse Key

53 mm. 100 --
26.5 mm. 40-75 --
22.4mm. -- 100
13.2mm 0-20 40-75
5.6 mm -- 0-20
2.8 mm 0-5 0-20
Rd.65.3 Construction -
Rd.65.3.1 Weather limitation - As per the special requirements.

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Rd.65.3.2
Rd.65.3.2 Diversion - As per Rd.27.2.
Rd.65.3.3 Preparing the base - As per Rd.35.3.2.
Rd. 65.3.4 Tack coat - Tack coat shall be applied on the prepared base at 5 Kg/10 sqm.
on BT surfaces and 10Kg/10 sqm. shall be heated to 177øC-191øC and applied evenly
through pressure sprayer or through cans with rose if so permitted by the Engineer in
charge. Road surface shall be suit­ably marked to control correct application.
Rd.65.3.5 Spreading and rolling of 1st layer - Immediately after applying tack coat
the coarse aggregate shall be spread uniformly and even preferably by mechanical
means at the rate of 0.5 Cum./10sqm. The surface shall be then brought to the required
grade and camber by checking with templates and correcting the high or low areas by
removing or adding aggregate.
Rd.65.3.6 Rolling - Immediately after spreading the entire surface shall be rolled by a
power roller 8-10 tons. Rolling shall conform to special Require­ments given separately.
Rd.65.3.7 Application of Binder for 1st layer - T he bitumen shall be heated to 177oC-
191oC and applied at the rate of 15 Kg/sqm. uniformly with mechanical sprayers.
Rd.65.3.8 Spreading and rolling of coarse aggregate of 2nd layer -Immediately
after rolling of the 1st layer, aggregate of the 2nd layer shall be spread and rolled as for
the first layer.
Rd.65.3.9. Application of Binder for 2nd layer - Binder shall be heated to appropriate
temperature and applied to the surface at the rate of 15 Kg/10sqm. as per 3.7 above.
Rd.65.3.10 Spreading and rolling of key aggregate -The key aggregate shall be spread
evenly immediately after the 2nd layer of coarse aggregate at the rate of 0.13Cum./10
sqm. The spreading shall be uniform and cover the entire surfaces. Brooms may be
used to ensure uniform application. Rolling by 8-10 tonne roller shall be done as for the
lower layer till the key aggregate is fully pressed into the coarse aggregate layer.
Rd.65.3.11 Testing - Testing shall conform to Sect. 900 of MOST specifications.
Rd.65.4 Item to include -
i) All necessary labour, materials, use of equipment for successful completion of the
item.
ii) Providing and maintaining diversion.
iii) Preparing base.
iv) Tack coat if so included in the wording of the item.
v) Testing of materials and work.
vi) Heating and applying bitumen.
Rd.65.5 Mode of Measurement and Payment - The contract rate shall be for one Cubic
metre of the volume of the layers. The dimensions shall be measured correct upto a cm. The
depth shall be the average depth based on initial levels. The payment shall be restricted to
the specified thickness in case of excess thickness.
Rd.66. Providing and laying 50 mm/75 mm thick penetration Macadam including all
materials, preparing road surface, laying metal layer, heating & applying bitumen,
spreading chips, compacting etc. complete.
Rd. 66.1 General - The item provides for 50 mm/75 mm thick pene­tration Macadam as per
the following specification including all necessary materials, labour, use of equipment etc.
complete. The item includes tack coat and seal coat.

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 Rd.67.2
Rd.66.2 Materials - Materials shall conform to Rd.65.2 with modification of grading of
aggregates as under.

Sieve Designation Percent by Weight passing the sieve

For 50 mm compacted For 75mm compacted
Coarse Key Coarse
Key
Aggregate Aggregate Aggregate Aggregate

63 mm. -- -- 100 --
53 mm. 100 -- --- --
45 mm. -- -- 58-82 --
26.5 mm. 37-72 -- -- 100
22.4mm. -- 100 5-27 50-75
13.2mm. 2-20 50-75 -- --
11.2 mm -- -- -- 5-25
5.6 mm -- 5-25 -- --
2.8 mm 0-5 0-5 0-5 0-5

The Los Angels abrasion value shall be 40 % max and impact value shall be 30%
max.
Quantities of Materials Required for 10 sqm. of Road Surface For Bituminous
Penetration Macadam Base/Binder Course.

Compacted Binder Coarse Key

thickness Aggregate Aggregate
Straight Road Tar
run bitumen RT-4/RT-9

50 mm. 50 kg 60-65 kg 0.60 Cum. 0.15 Cum.

75 mm. 68 kg 82-88 kg 0.90 Cum. 0.18 Cum.
Rd. 66.3 Construction -
This shall conform to Rd.65.3 except that the quantities shall be as specified in Rd.65.2.
Rd. 66.4 Item to include - As per Rd. 65.4.
Rd.66.5 Mode of Measurement and Payment - As per Rd.65.5.
Rd.67. Providing and laying 50 mm/75 mm thick hot laid bituminous macadam with
4% / 3.5% / 3% / 2.5% bitumen by weight of total mix including heating chips, bitumen,
mixing in plant, laying with paver compacting etc. complete.(Including tack coat.)
Rd.67.1 General - The item provides for 50 mm/ 75 mm thick hot laid bituminous macadam
with 4% / 3.5% / 3% / 2.5% bitumen by weight of total mix.
Rd.67.2 Materials - The chips shall conform to Rd.66.2. The grading aggregates shall be
as under

Sieve Designation Percent by Weight passing the sieve

26.5 mm. 100

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Rd.67.3
22.4mm. 75-100
11.2mm. 50-85
5.6 mm 20-40
2.8 mm 5-20
90æm 0-5

Aggregate Grading for 75 mm Compacted

Thickness of Bituminous Macadam

Sieve Designation Percent by Weight passing the sieve

45mm 100
26.5 mm. 75-100
22.4mm. 60-95
11.2mm. 30-55
5.6 mm 15-35
2.8 mm 5-20
90æm 0-5

The bitumen shall conform to Rd.70.2.1.

Rd.67.3 Construction -
Rd.67.3.1 Weather limitations - This shall conform to special requirements Rd.65.3.1.
Rd.67.3.2 Diversion - This shall conform to Rd.27.2.
Rd.67.3.3 Preparing base - This shall conform to Rd.65.3.4.
Rd.67.3.5 Mixing chips -
The mixing of chips & bitumen shall be done in the hot mix plant of adequate capacity
and capable to yield a mix proper and uniform quality. The plant may be of the weigh
batch or volumetric proportion type.
T
 he various units of the plant shall be as per MOST specifi­cation No.504.3.4.
T
 he temperature of bitumen and the aggregate at the time of mixing shall be as under.
Bitumen 150oC to 165oC
Aggregate 125oC to 150oC
 The difference of temperature between the bitumen and the ag­gregate shall not be
more than 25oC.
 The mixing shall be thorough to ensure thoroughly coated chips with homogeneous
mixture. The discharging mixture shall have a temperature of 130oC to 160oC.
The mix shall be transported in suitable tippers. The tippers shall be covered suitably
to prohibit drop in temperature as may be required or directed.
Rd.67.3.6 Spreading - The spreading of the mix shall be done by mechanical pavers.
The paver shall have features as stipulated in MOST specification No.504.3.5.
 The temperature of the mix at the time of laying shall be 120o to 135oC. Longitudinal
joints may be necessary for longer widths. The cross joints in successive layers shall
be staggered. The joints shall have vertical faces & the face shall be covered with hot

424 RED BOOK  VOLUME I  ROADS  2012

 Rd.69.2
bitumen applicable before receiving adjacent layer.
Rd.67.3.7. Rolling - This shall conform to the special require­ments. The rolling shall
consist of three operations viz. break down or initial, second or intermediate and final.
The break down rolling shall be done as soon as rolling is possible without cracking.
The intermediate rolling shall follow as closely as possible to obtain maximum density.
The final rolling shall be done while the mix is still workable. This will be done to remove
rolling marks. The rolling shall preferably be done by vibratory roller with vibrations being
imparted only in the intermediate rolling.
 The entire rolling operations shall be completed before the maximum temperature is
below 80oC.
Rd.67.3.8 Testing -
This shall conform to MOST specification Sect 900.
Rd.67.3.9 Opening to traffic -  The road shall be opened to traffic after the mix
temperature reaches atmospheric temperature.
Rd.67.4 Item to include - This shall conform to Rd.65.4. This also shall include heating of
chips and all operations covered by Rd.67.3.
Rd.67.5. Measurement and Payment - The length shall be recorded correct upto one
centimeter. Depth shall be arrived at on the basis of levels and shall be the average depth
for given length.
The contract rate shall be for one Cu.m. The thickness shall be limited to the specified
thickness.
Rd.68 Providing 20 mm/25 mm thick open graded premix bituminous carpet including
preparing base, tack coat, heating of bitumen and aggregate, mixing in hot mix plant
laying with mechanical paver and compacting etc. complete.
Item shall conform to Rd.39 except that the aggregate and bitumen shall be heated as per
Rd. 67.3.5 & mixed in a hot mix plant. Transportation, laying , compacting shall conform
to Rd.67.3.
The contract rate shall be for sq.m.
Rd. 69 Providing and laying 20 mm thick Mix seal surfacing A TYPE/B TYPE including
preparing base, heating bitumen and aggregate in hot mix plant, laying the mix by
paver compacting by power roller etc. complete. (including tack coat.)
Rd.69.1 General - The item provides for laying of 20 mm thick Mix Seal surfacing of
TYPE A /TYPE B compacting etc. complete as per the following specification.
Rd.69.2 Materials -Bitumen shall conform to Rd.65.2. The aggregate shall conform to
Rd.65.2.2 for quality except that the Los Angels value shall be 40 Max. and impact value
30 Max.

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Rd.69.3
The gradation of aggregate shall be as under.

Sieve Designation Percent by Weight passing the sieve

Type A Type B

13.2mm. --- 100

11.2 mm 100 88-100
5.6 mm 52-88 31-52
2.8 mm 14-38 8-25
90æm 0-5 0-5
Rd.69.3 Construction -
Rd.69.3.1 Proportions - The total quantity of aggregates used shall be 0.27 Cu.m / 10
Sq.m area for type A/type B. Bitumen shall be 22 Kg. and 19 Kg/ 10 Sq.m of area for
type A and type B respec­tively.
Before starting work the contractor shall get the Job Mix Formu­lae for the work approved
from the Engineer in charge.
Rd.69.3.2 Weather Limitations - This shall conform to Rd.67.3.1
Rd.69.3.3 Diversion - This shall conform to Rd.67.3.2
Rd.69.3.4 Preparing Base - This shall conform to Rd.67.3.3
Rd.69.3.5 Tack Coat - This shall conform to Rd.67.3.4
Rd.69.3.6 Mixing Chips - This shall conform to Rd.67.3.5
Rd.69.3.7 Spreading - This shall conform to Rd.67.3.6
Rd.69.3.8 Rolling - This shall conform to Rd.67.3.7
Rd.69.3.9 Testing - This shall conform to Rd.67.3.8
Rd.69.3.10 Opening to traffic - This shall conform to Rd.67.3.9
Rd.69.4 Item to include - This shall conform to Rd.67.4.
Rd 69.5 Measurement and Payments - The measurements shall be recorded correct
upto 1 cm. The contract rate shall be for one Sq.m.
Rd. 70 Providing and laying 25 mm/ 40 mm thick bituminous concrete with 6.25 %
bitumen by weight of total mix including heating bitumen, aggregate, laying with
paver compacting etc complete. (including tack coat.)
Rd.70.1 General - The item provides for laying of the specified layer thickness of bituminous
concrete including all necessary labour, materials, heating of bitumen, aggregate, use of
plant equipment etc. complete.
Rd.70.2. Material - Materials shall conform to Rd.65.2.
The gradation of the aggregate shall be as under.

Sieve Designation Percent by Weight passing the sieve

Grading I Grading II

22.4 mm -- 100
13.2mm. 100 80-100
11.2 mm 90-100 75-95
5.6 mm 60-80 55-75
426 RED BOOK  VOLUME I  ROADS  2012
 Rd.71
2.8 mm 40-55 40-55
710æm 20-30 20-30
300æm 15-25 15-25
180æm 10-20 10-20
90æm 5-11 5-11

Rd.70.3 Construction -
Rd.70.3.1 Job Mix Formula - This shall conform to Rd.69.3.1
The requirement for the mix shall be as under.

Sr.No. Description Requirement
1 Marshall stability determined on 340 Kg. Min.
Marshall specimens compacted by 50
blows on each end.
2 Marshall flow (mm) 2-4
3 Percent voids in mix. 3-5
4 Percent voids in mineral aggregate 75-85
filled with Bitumen
5 Binder content percent by weight of mix 5-7.5

The permissible variation in the Job Mix Formula shall be as under.

Sr.No. Description of Ingredients Permissible variation

by weight of total
mix in percentage.

1. Aggregate passing 5.6 mm + 5.0

sieve and larger
2. Aggregate passing 2.8 mm + 4.0
3. Aggregate passing 710 mm + 3.0
4. Aggregate passing 180 mm + 1.0
and 90æm sieve
5. Aggregate passing Binder + 4.0

Limitations to Item to include shall conform to Rd.69.3 to Rd.69.3.10 & Rd.69.4.

Rd.70.4 Measurement and payment -
The contract rate shall be for one Cu.m. The lengths shall be recorded correct upto one
Cm. The thickness shall be on the basis of levels. The payable thickness shall be restricted
to the actual or specified whichever is less.
Rd.71 Providing and laying 25 mm/ 40 mm thick semi dense concrete with 5.5 %
bitumen by weight to total mix including all materials, heating of bitumen, aggregate,
laying with paver, compacting etc. complete.( including tack coat.)
This item shall conform to Rd.70. with the following modifications:
Aggregate Gradation for Semi Dense Bituminous concrete

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Rd.69.3

428 RED BOOK  VOLUME I  ROADS  2012

 Rd.70.2.

300
EARTHWORK, EROSION
CONTROL AND DRAINAGE

RED BOOK  VOLUME I  ROADS  2012 429

Rd.69.3

430 RED BOOK  VOLUME I  ROADS  2012

 (e)
301. EXCAVATION FOR ROADWAY AND DRAINS
301.1. Scope
This work shall consist of excavation, removal and satisfactory disposal of all materials
necessary for the construction of roadway, side drains and waterways in accordance with
requirements of these Specifications and the lines, grades and cross-sections shown in
the drawings or as indicated by the Engineer. It shall include the hauling and stacking of
or hauling to sites of embankment and subgrade construction, suitable cut materials as
required, as also the disposal of unsuitable cut materials in specified manner, trimming and
finishing of the road to specified dimensions or as directed by the Engineer.
301.2. Classification of Excavated Material
301.2.1. Classification:  All materials involved in excavation shall be classified by the
Engineer in the following manner:
(a) Soil
This shall comprise topsoil, turf, sand, silt, loam, clay, mud, peat, black cotton soil, soft
shale or loose moorum, a mixture of these and similar material which yields to the
ordinary application of pick, spade and/or shovel, rake or other ordinary digging
implement. Removal of gravel or any other nodular material having dimension in any
one direction not exceeding 75 mm occurring in such strata shall be deemed to be
coveted under this category
(b) Ordinary Rock (not requiring blasting) This shall include:
(i) rock types such as laterites, shales and conglomerates, varieties of limestone and
sandstone etc., which may be quarried- or split with crow bars, also including any
rock which in dry state may be hard, requiring blasting but which, when wet, becomes
soft- and manageable by means other than blasting; (ii) macadam surfaces such
as water bound and bitumen/tar bound; soling of roads, paths etc. and hard core;
compact moorum or stabilised soil requiring grafting tool or pick or both and shovel,
closely applied; gravel and cobble stone having maximum dimension in any one
direction between 75 and 300 mm;
(iii) lime concrete, stone masonry in lime mortar and brick work in lime,/cement mortar
below ground level, reinforced cement concrete which may be broken up with crow
bars or picks and stone mansory in cement mortar below ground level; and
(iv) boulders which do not require blasting having maximum dimension in any l direction
of more than 300 mm, found lying loose on the surface or embedded in river bed,
soil, talus, slope wash and terrace material of dissimilar origin. 49.
(c) Hard Rock (requiring blasting)
This shall comprise: -
(i) any rock or cement concrete for the excavation of which the use of mechanical plant
and for blasting is required;
(ii) reinforced cement concrete (reinforcement cut through but not separated from the
concrete) below ground level; and
(iii) boulders requiring blasting.
(d) Hard Rock (blasting prohibited) Hard rock requiring blasting as described under
but where blasting is prohibited for any reason and excavation has to be carried out by
chiselling, wedging or any other agreed method.
(e) Marshy Soil This shall include soils like soft clays and peats excavated below the

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(e)
original ground level of marshes and swamps and soils excavated from other areas requiring
continuous pumping or bailing out of water.
301.2.2. Authority for classification:
The classification of excavation shall be decided by the Engineer and his decision shall be
final and binding on the Contractor. Merely the use of explosives in excavation will not be
considered as a reason for higher classification unless blasting is clearly necessary in the
opinion of the Engineer.
301.3. Construction Operations
301.3.1. Setting out: After the site has been cleared as per Clause 201, the limits
of excavation shall be set out true to lines, curves, slopes, grades and sections as
shown on the drawings or as directed by the Engineer. The Contractor shall provide all
labour, survey instruments and materials such as strings, pegs, nails, bamboos, stones,
lime, mortar, concrete, etc., required in connection with the setting out of works and the
establishment of bench marks. The Contractor shall be responsible for the maintenance
of bench marks and other marks and stakes as long Y as in the opinion of the Engineer,
they are required for the work.
301.3.2. Stripping and storing topsoil:  When so directed by the Engineer, the topsoil
existing over the sites of excavation shall be stripped to specified depths constituting
Horizon "A" and stockpiled at designated. locations for re-use in covering embankment
slopes, cut slopes, berms and other disturbed areas where re-vegetation is desired.
Prior to stripping the topsoil, all trees, shrubs etc. shall be removed along with their
roots, with approval of the Engineer.
301.3.3. Excavation - General: All excavations shall be carried out in conformity with the
directions laid here-in-under and in a manner
 approved by the Engineer. The work shall be so done that the suitable materials
available from excavation are satisfactorily utilized as decided upon beforehand.
 While planning or executing excavations, the Contractor shall take all adequate
precautions against soil erosion, water pollution etc. as per Clause 306, and take
appropriate drainage measures to keep the site free of water in accordance with Clause
311.
 The excavations shall conform to the lines, grades, side slopes and levels shown on
the drawings or as directed by the Engineer. The Contractor shall not excavate outside
the limits of excavation. Subject to the permitted tolerances, any excess depth/ width
excavated beyond the specified levels/dimensions on the drawings shall be made
good at the cost of the Contractor with suitable material of characteristics similar to that
removed and compacted to the requirements of Clause 305.
All debris and loose material on the slopes of cuttings shall be removed. No backfilling
shall be allowed to obtain required slopes excepting that when boulders or soft materials
are encountered in cut slopes, these shall be excavated to approved depth on instructions
of the Engineer and the resulting cavities filled with suitable material and thoroughly
compacted in an approved manner.
After excavation, the sides of excavated area shall be trimmed and the area contoured
to minimise erosion and pending, allowing for natural drainage to take place. If trees
were removed, new trees shall be planted, as directed by the Engineer, The cost of
planting new trees shall be deemed to be incidental to the work.
301.3.4. Methods, tools and equipment:  Only such methods, tools and equipment
as approved by the Engineer shall be adopted/used in the work. If so desired by the

432 RED BOOK  VOLUME I  ROADS  2012

 301.3.9.
Engineer, the Contractor shall demonstrate the efficacy of the type of equipment to be
used before the commencement of work.
301.3.5. Rock excavation:  Rock, when encountered in road excavation, shall be
removed upto the formation level or as otherwise indicated on the drawings. Where,
however, unstable shales or other un- suitable materials are encountered at the formation
level, these shall be excavated to the extent of 500 mm below the formation level or as
otherwise specified. In all cases, the excavation operations shall be so carried out that
at no point on cut formation the rock protrudes above the specified levels. Rocks and
large boulders which are likely to cause differential settlement and also local drainage
problems should be removed to the extent of 500 mm below the formation level in full
formation width including drains and cut through the side drains. Where excavation is
done to levels lower than those specified, the n excess excavation shall be made good
as per Clauses 301.3.3 and 301.6 to the satisfaction of the Engineer.
 Slopes in rock cutting shall be finished to uniform lines corresponding to slope lines
shown on the drawings or as directed by the Engineer. Notwithstanding the foregoing, all
loose pieces of rock on excavated slope surface which move when pierced by a crowbar
shall be removed.
Where blasting is to be resorted to, the same shall be carried out to Clause 302 and all
precautions indicated therein observed.
 Where presplitting is prescribed to be done for the establishment of a specified slope
in rock excavation the same shall be carried out to Clause 303.
301.3.6. Marsh excavation:  The excavation of soils from marshes/ swamps shall be
carried out as per the programme approved by the Engineer.
Excavation of marshes shall begin at one end and proceed in one direction across the
entire marsh immediately ahead of backfilling. The method and sequence of excavating
and backfilling shall be such as to • ensure, to the extent practicable, the complete
removal or displacement of all muck from within the lateral limits called for on the
drawings or as staked by the Engineer, and to the bottom of the marsh, firm support or
levels indicated.
301.3.7. Excavation of road shoulders/verge/median for widening of pavement or
providing treated shoulders:  ln works involving widening of existing pavements or
providing treated shoulders, unless otherwise specified, the shoulder/verge/median
shall be removed to their full width and to levels shown on drawings or as indicated by
the Engineer. While doing so, care shall be taken to see that no portion of the existing
pavement designated for retention is loosened or disturbed. If the existing pavement
gets disturbed or loosened, it shall be dismantled and cut to a regular shape with sides
vertical and the disturbed/loosened portion removed completely and relaid as directed
by the Engineer, at the cost of the Contractor.
301.3.8. Excavation for surface/sub-surface drains:  Where the Contract provides for
construction of surface/sub—surface drains to Clause 309, excavation for these shall be
carried out in proper sequence with other works as approved by the Engineer.
301.3.9. Slides:  if slips, slides, over-breaks or subsidence occur in cuttings during the
process of construction, they shall be removed at the cost of the Contractor as ordered
by the Engineer. Adequate precautions shall be taken to ensure that during construction,
the slopes are not rendered unstable or give rise to recurrent slides after construction. If
finished slopes slide into the roadway subsequently, such slides shall be removed and
paid for at the Contract rate for the class of excavation involved, provided the slides are
not due to any negligence on the part of the Contractor. The classification of the debris

RED BOOK  VOLUME I  ROADS  2012 433

301.3.9.
material from the slips, slides etc. shall conform to its condition at the time of removal A
and payment made accordingly regardless of its condition earlier.
301.3.10. Dewatering: If water is met with in the excavations due to springs, seepage,
rain or other causes, it shall be removed by suitable diversions, pumping or bailing
out and the excavation kept dry whenever so required or directed by the Engineer.
Care shall be taken to discharge the drained water into suitable outlets as not to cause
damage to the works, crops or any other property. Due to any negligence on the part of
the Contractor, if any such damage is caused, it shall be the sole responsibility of the
Contractor to repair/restore to the original condition at his own cost or compensate for
the damage.
301.3.11. Disposal of excavated materials:  All the excavated materials shall be the
property of the Employer. The material obtained from the excavation of roadway,
shoulders, verges, drains, cross- drainage works etc., shall be used for filling up of (I)
roadway embankment, (ii) the existing pits in the right-of-way and (iii) for landscaping of
the road as directed by the Engineer, including leveling and spreading with all lifts and
lead upto 1000 .m and no extra payment shall be made for the same.
All hard materials, such as hard moorum, rubble, etc., not intended for use as above
shall be stacked neatly on specified land as directed by the Engineer with all lifts and
lead upto 1000 m.
 Unsuitable and surplus material not intended for use within the lead Specified above
shall also, if necessary, be transported with all lifts and lead beyond initial 1000 m,
disposed of or used as directed by the Engineer.
301.3.12. Backfilling :  Backfilling of masonry /concrete/hume pipe drain excavation
shall be done with approved material after concrete} masonry/hume pipe is fully set and
carried out in such a way as not to cause undue thrust on any part of the structure and/or
not to cause differential settlement. All space between the drain walls and the side of the
excavation shall be refilled to the original surface making due allowance for settlement,
in layers generally not exceeding 150 mm compacted thickness to the required density,
using suitable compaction equipment such as mechanical tamper, rammer or plate
compactor as directed by the Engineer.
301.4. Plying of Construction Traffic Construction traffic shall not use the cut formation
and finished subgrade without the prior permission of the Engineer. Any damage arising out
of such use shall be made good by the Contractor at his own expense.
301.5. Preservation of Property The Contractor shall undertake all reasonable precautions
for the protection and preservation of any or all existing roadside trees, drains, sewers or
other sub-surface drains, pipes, conduits and any other. structures under or above ground,
which may be affected by construction operations and which, in the opinion of the Engineer,
shall be continued in use without any change. Safety measures taken by the Contractor in
this respect, shall be got approved from the Engineer. However, if any of these objects is
damaged by reason of the Contractor’s negligence, it shall be replaced or restored to the
original condition at his expense. lf the Contractor fails to do so, within the required time
as directed by the Engineer or if, in the opinion of the Engineer, the actions initiated by the
Contractor to replace/restore the damaged - objects are not satisfactory, the Engineer shall
arrange the replacement/restoration directly through any other agency at the risk and cost
of the Contractor after issuing a prior notice to the effect.
301.6. Preparation of Cut Formation The cut formation, which serves as a subgrade,
shall be prepared to receive the sub-base/base course as directed by the Engineer.
Where the material in the subgrade (that is within 500 mm from the lowest level of the

434 RED BOOK  VOLUME I  ROADS  2012

 301.8.
pavement) has a density less than specified in Table 300-2, the same shall be loosened to
a depth of 500 mm and compacted in layers in accordance with the requirements of Clause
305.
Any unsuitable material encountered in the subgrade level shall be removed as directed
by the Engineer and replaced with suitable material compacted in accordance with Clause
305.
In rocky formations, the surface irregularities shall be corrected and the levels brought
up to the specified elevation with granular base material as directed by the Engineer, laid
and compacted in accordance with the respective Specifications for these materials. The
unsuitable material shall be disposed of in accordance with Clause 301.3.11. After satisfying
the density requirements, the- cut formation shall be prepared to receive the sub-base/
base course in accordance with Clauses 310 and 311 to receive the sub-base/base course.
301.7. Finishing Operations
Finishing operations shall include the work of properly shaping and dressing all excavated
surfaces.
When completed, no point on the slopes shall vary from the designated slopes by more
than 150 mm measured at right angles to the slope, except where excavation is in rock
(hard or soft) where no point shall vary more than 300 mm from the designated slope. In no
case shall any portion of the slope encroach on the roadway.
The finished cut formation shall satisfy the surface tolerances described in Clause 902.
Where directed, the topsoil removed earlier and conserved (Clauses 301.3.2 and 305.3.3)
shall be spread over cut slopes, where feasible, berms and other disturbed areas. Slopes
may be roughened and moistened slightly, prior to the application of topsoil, in order to
provide satisfactory bond. The depth of topsoil shall be sufficient to sustain plant growth,
the usual thickness being from 75 mm: to 100 mm.
301.8. Measurements for Payment Excavation for roadway shall be measured by taking
cross—_ sections at suitable intervals in the original position before the work starts and after
its completion and computing the volumes in cu. m. by the method of average end areas
for each class of material encountered. Where it is not feasible to compute volumes by this
method because of erratic location of isolated deposits, the volumes shall be computed by
other accepted methods. At the option of the Engineer, the Contractor shall leave depth
indicators during excavations of such shape and size and in such positions as directed so
as to indicate the original ground level as accurately as possible. The Contractor shall see
that these remain intact till the final measurements are taken.
For rock excavation, the overburden shall be removed first so that necessary cross-sections
could be taken for measurement. Where cross sectional measurements could not be taken
due to irregular configuration or where the rock is admixed with other classes of materials,
the volumes shall be computed on the basis of stacks of excavated rubble after making 35
per cent deduction therefrom. When volumes are calculated in this manner for excavated
material other than rock, deduction-made will be to the extent of I6 per cent of stacked
volumes.
Works involved in the preparation of cut formation shall be measured in units indicated
below :
(i) Loosening and recompacting the loosened material at subgrade cu. m.
(ii) Loosening and removal of unsuitable material and replacing with cu. m.

RED BOOK  VOLUME I  ROADS  2012 435

301.9.
a suitable material and compacting to required density
(iii) Preparing rocky subgrade sq. m.
(iv) Stripping including storing and reapplication of topsoil cu. m.
(v) Disposal of surplus material beyond initial 1000 m lead cu. m.
301.9. Rates
301.9.1. The Contract unit rates for the items of roadway and drain excavation shall be
payment in full for carrying out the operations required- for the individual items including full
compensation for:
(i) setting out
(ii) transporting the excavated materials and depositing the same on sites of
embankments, spoil banks or stacking as directed within all lifts and lead upto 1000
m or as otherwise specified; .
(iii) trimming bottoms and slopes of excavation;
(iv) dewatering;
(v) keeping the work free of water as per Clause 311; and
(vi) all labour, materials, tools, equipment, safety measures, testing and incidentals
necessary to complete the work to Specifications.
Provided, however, where presplitting is prescribed to achieve a specified slope in rock
excavation, the same shall be paid for vide Clause 303.5.
301.9.2. The Contract unit rate for loosening and recompacting the loosened materials
at subgrade shall include full compensation for loosening to the specified depth, including
breaking clods, spreading in layers, watering where necessary and compacting to the
requirements.
301.9.3. Clauses 301.9.1 and 305.8 shall apply as regards Contract unit rate for item of
removal of unsuitable material and replacement with suitable material respectively.
301.9.4. The Contract unit rate for item of preparing rocky subgrade as per Clause 301.6
shall be full compensation for providing, laying and compacting granular base material for
correcting surface irregularities including all materials, labour and incidentals necessary to
complete the work and all leads and lifts.
301.9.5. The Contract unit rate for the items of stripping and storing topsoil and of
reapplication of topsoil shall include full compensation for all the necessary operations
including all lifts, but leads upto 1000 m.
301.9.6. The Contract unit rate for disposal of surplus earth from roadway and drain
excavation shall be full compensation for all labour, equipment, tools and incidentals
necessary on account of the additional haul or transportation involved beyond the initial
lead of 1000 m.
302. BLASTING OPERATIONS
302.1. General
Blasting shall be carried out in a. manner that completes the excavation to the lines
indicated in drawings, with the least disturbance to adjacent material. It shall be done only
with the written permission of the Engineer. All the statutory laws, regulations, rules, etc.,
pertaining to the acquisition, transport, storage, handling and use of explosives shall be
strictly followed.
The Contractor may adopt any method or methods of blasting consistent with the safety

436 RED BOOK  VOLUME I  ROADS  2012

 302.4.
and job requirements. Prior to starting any phase - of the operation the Contractor shall
provide information describing- pertinent blasting procedures, dimensions and notes.
The magazine for the storage of explosives shall be built to the designs and specifications
of the Explosives Department concerned and located at the approved site. No unauthorized
person shall be admitted into the magazine which when not in use shall be 'kept securely
locked. No matches or inflammable material shall be allowed in the magazine. The magazine
shall have an effective lightning conductor. The following shall be hung in the lobby of the
magazine:
(a) A copy of the relevant rules regarding safe storage both in English and in the language
with which the workers concerned are familiar.
(b) A statement of up-to-date stock in the magazine.
(c) A certificate showing the last date of testing of the lightning conductor.
(d) A notice that smoking is strictly prohibited.
All explosives shall be stored in a secure manner in compliance with all laws and ordinances,
and all such storage places shall be clearly marked. Where no local laws or ordinances
apply, storage shall be provided to the satisfaction of the Engineer and in general not
closer than 300 m from the road or from any building or camping area or place of human
occupancy. In addition to these, the Contractor shall also observe the following instructions
and any further additional instructions which may be given by the Engineer and shall be
responsible for damage to property and any accident which may occur to workmen or
the public on account of any operations connected with the storage, handling or use of
explosives and blasting. The Engineer shall frequently check the Contractor’s compliance
with these precautions.
302.2. Materials, Tools and Equipment
All the materials, tools and equipment used for blasting operations shall be of approved
type. The Engineer may specify the type of explosives to be allowed in special cases. The
fuse to be used in wet locations shall be sufficiently water-resistant as to be unaffected
when immersed in water for 30 minutes. The rate of burning of the fuse shall be uniform
and definitely known to permit such a length being cut as will permit sufficient time to the
firer to reach safety -before explosion takes place. Detonator-s shall be capable of giving
effective blasting of the explosives. The blasting powder, explosives, detonators, fuses,
etc., shall be fresh and not damaged due to dampness, moisture or any other cause. They
shall be inspected before use and damaged articles shall be discarded totally and removed
from the site immediately.
302.3. Personnel
The blasting operation shall remain in the charge of competent and experienced supervisor
and workmen who are thoroughly acquainted with the details of handling explosives and
blasting operations.
302.4. Blasting Operations
The blasting shall be carried out during fixed hours of the day preferably during the mid-day
luncheon hour or at the close of the work as ordered in writing by the Engineer. The hours
shall be made known to the people in the vicinity. All the charges shall be prepared by the
man in charge only.
The Contractor shall notify each public utility company having structures in proximity to the
site of the work of his intention to use explosives. Such notice shall be given sufficiently
in advance to enable the companies to take such steps as they may deem necessary
to protect their property from injury. In advance of any blasting work within 50 m of any
RED BOOK  VOLUME I  ROADS  2012 437
302.5.
railway track or structures, the Contractor shall notify the concerned Railway Authority of
the location, date, time and approximate duration of such blasting operations.
Red danger flags shall be displayed prominently in all directions during the blasting
operations. The flags shall be planted 200 m from the blasting site in all directions. People,
except those who actually light the fuse, shall be prohibited from entering this area, and
all persons including workmen shall be excluded from the flagged area at least 10 minutes
before the firing, at warning siren being sounded for the purpose.
The charge holes shall be drilled to required depths and at suitable places. Blasting should
be as light as possible consistent with thorough breakage of the material necessary for
economic loading and hauling. Any method of blasting which leads to overshooting shall
be discontinued.
When blasting is done with powder, the fuse cut to the required length shall be inserted
into the hole and the powder dropped in. The powder shall be gently tamped with copper
rods with rounded ends. The explosive powder shall then be covered with ramping material
which shall be tamped lightly but firmly.
When blasting is done with dynamite and other high explosives, dynamite cartridges shall
be prepared by inserting the square cut -end of a fuse into the detonator and finishing it
with nippers at the open end, the detonator gently pushed into the primer leaving 1/3rd of
the copper tube exposed outside. The paper of the cartridge shall then be closed up and
securely bound with wire or twine. The primer shall be housed into the explosive. Boreholes
shall be of such size that the cartridge can easily go down. The holes shall be cleared
of all debris and explosive inserted. The space of about 200 mm above the charge shall
then be gently filled with dry clay, pressed home and the rest of the tamping formed of any
convenient material gently packed with a wooden rammer.
At a time, not more than 10 such charges will be prepared and fired. The man in charge
shall blow a siren in a recognised manner for cautioning the people. All the people shall
then be required to move to safe distances. The charges shall be lighted by the man-in-
charge only. The man-in-charge shall count the number of explosions. He shall satisfy
himself that all the charges have been exploded before allowing the workmen to go back
to the work site.
After blasting operations, the Contractor shall compact the loose residual material below
subgrade and replace the material removed below subgrade with suitable material.
302.5. Misfire
In case of misfire, the following procedure shall be observed:
(i) Sufficient time shall be allowed to account for the delayed blast. The man-in- charge
shall inspect all the charges and determine the missed charge.
(ii) If it is the blasting powder charge, it shall be completely flooded with water. A new
hole shall be drilled at about 450 mm from the old hole and fired. This should blast
the old charge. Should it not blast the old charge, the procedure shall be repeated
till the old charge is blasted.
(iii) In case of charges of gelignite, dynamite, etc., the man-in-charge shall gently remove
the tamping and the primer with the detonator. A fresh detonator and primer shall
then be used to blast the charge. Alternatively, the hole may be cleared of 300 mm
of tamping and the direction then ascertained by placing a stick in the hole. Another
hole may then be drilled 150 mm away and parallel to it. This hole shall then be
charged and fired when the misfired hole should _ explode at the same time. The
man-in-charge shall at once report to the Contractor’s office and the Engineer all

438 RED BOOK  VOLUME I  ROADS  2012

 303.2.
cases of misfire, the cause of the same and what steps were taken in connection
therewith.
lf a misfire has been found to be due to defective detonator or dynamite, the whole quantity
in the box from which defective article was taken must be sent to the authority directed by
the Engineer for ` inspection to ascertain whether all the remaining materials in the box are
also defective.
302.6. Account
A careful and day to day account of the explosive shall be maintained by the Contractor in
an approved register and manner which shall be open to inspection by the Engineer at all
times.
303. PRESPLITTING ROCK EXCAVATION SLOPES
303.1. General
Presplitting is defined as the establishment of a specified excavation slope in rock by the
controlled use of explosives and blasting accessories in properly aligned and spaced drill
holes.
The presplitting technique shall be used for forming rock excavation slopes at locations
shown on the plans or as otherwise decided by the Engineer.
303.2. Construction Operations
Prior to starting drilling operations for presplitting, the Contractor shall furnish the Engineer
a plan outlining the position of all drill holes, depth of drilling, type of explosives to be used,
loading pattern and sequence of firing. The drilling and blasting plan is for record purposes
only and will not absolve the Contractor of his responsibility for using proper drilling and
blasting procedures. Controlled blasting shall begin with a short test section of a length
approved by the Engineer. The test section shall be presplit, production drilled and blasted
and sufficient material excavated whereby the Engineer can determine if the Contractor’s
methods have produced an acceptable slope.
All overburden soil and weathered rock along the top of the excavation for a distance
of about 5 to l5 m beyond the drilling limits, or to the end of the excavation, as decided
by Engineer shall be removed before -drilling the presplitting holes. Particular care and
attention shall be directed to the beginning and end of excavations to ensure complete
removal of all overburden soil and weathered rock and to expose fresh rock to an elevation
equal to the bottom of the adjacent lift of the presplitting holes being drilled.
Slope holes for presplitting shall be drilled along the line of the planned slope within the
specified tolerances. The drill holes shall be not less than 60 mm nor more than 75 mm
in diameter. Drilling operations shall be controlled by the use of proper equipment and
technique to ensure that no hole shall deviate from the plane of the planned slope by more
than 300 mm nor shall any hole deviate from being parallel to an adjacent hole by more
than two-third of the planned horizontal spacing between holes.
The length of presplit holes for any individual lift shall not exceed 9 m.
The spacing of presplit holes shall not exceed 900 mm on centres and shall be adjusted to
result in a uniform shear face between holes.
Auxiliary drill holes along the presplit line, not loaded or stemmed, may be ordered by the
Engineer. Except for spacing, auxiliary drill holes shall conform to the provisions for presplit
holes.
The line of production holes shall be placed inside the presplit lines in such a manner as to
avoid damage to the presplit face.

RED BOOK  VOLUME I  ROADS  2012 439

303.3.
if necessary, to reduce shatter and overbreak of the presplit surface, the first line of the
production holes shall be drilled parallel to the slope line at the top of the cut and at each
bench level thereafter.
Any blasting technique, which results in damage to the presplit surface, shall be immediately
discontinued.
No portion of any production hole shall be drilled within 2.5 m of a presplit plane except as
approved by the Engineer. The bottom of the production holes shall not be lower than the
bottom of the presplit holes.
A maximum offset of 600 mm will be permitted for a construction working bench at the
bottom of each lift for use in drilling the next lower presplitting pattern. The drilling operations
shall be adjusted to compensate for drift of previous levels and for the offset at the start of
new levels to maintain the specified slope plane.
The maximum diameter of explosives used in presplit holes shall not be greater than one-
half the diameter of the presplit hole.
Only standard cartridge explosives prepared and packaged by explosive manufacturing
firms shall be used in presplit holes. These shall be fired as recommended by the
manufacturer. Ammonium nitrate composition blasting agents will not be permitted in
presplitting operations.
Stemming may be required to achieve a satisfactory presplit face. Stemming material shall
be dry free-running material all of which passes 11.2 mm sieve and 90 per cent of which is
retained on 2.80 mm sieve. Stemmed presplit holes shall be completely filled to the collar.
All charges in each presplitting pattern shall be detonated simultaneously.
303.3. Tolerances
The presplit face shall not deviate more than 300 mm from the plane passing through
adjacent drill holes, except where the character of the rock is such that, as determined by
the Engineer, irregularities are unavoidable. When completed, the average plane of the
slopes shall conform to the slopes indicated on the plans and no point on the completed
slopes shall vary from the designated slopes by more than 300 mm. These tolerances shall
be measured perpendicular to the plane of the slope. In no case shall any portion of the
slope encroach on the side drains.
As long as equally satisfactory presplit slopes are obtained, then either the slope face
may be presplit before drilling for production blasting or presplitting the slope face and
production blasting may be done at the same time, provided that the presplitting drill holes
are fired with zero delay and the production holes are delayed starting at the row of holes
farthest from the slope and progressing in steps to the row of holes nearest the presplit
line, which row shall be delayed at least 50 milliseconds. In either case the presplitting
holes shall extend either to the end of the excavation or for a distance of not less than 15
m beyond the limits of the production holes to be detonated.
303.4. Measurements for Payment
The area of presplitting to be paid for will be measured as square metres of acceptable
presplit slope surface.
303.5. Rates
The Contract unit rate for presplitting work shall be payment in full for carrying out the
required operations for obtaining acceptable presplit slope surfaces. The quantity of rock
excavated through the production/presplit holes shall be paid for as per Clause 301.9.1.
304. EXCAVATION FOR STRUCTURES

440 RED BOOK  VOLUME I  ROADS  2012

 Rd.70.2.
304.1. Scope
Excavation for structures shall consist of the removal of material for the construction of
foundations for bridges, culverts, retaining walls, headwalls, cutoff walls, pipe culverts and
other similar structures, in accordance with the requirements of these Specifications and
the lines and dimensions shown on the drawings or as indicated by the Engineer. - The
work shall include construction of the necessary cofferdams and cribs and their subsequent
removal; all necessary sheeting, shoring, bracing, draining and pumping; the removal of all
logs, stumps, grubs and other deleterious matter and obstructions, necessary for placing
the foundations; trimming bottoms of excavations; backfilling and clearing up the site and
the disposal of all surplus material.
304.2. Classification of Excavation All materials involved in excavation shall be classified
in accordance with Clause 301.2.
304.3. Construction Operations
304.3.1. Setting out: After the site has been cleared according to Clause 201, the limits
of excavation shall be set out true to lines, curves and slopes to Clause 301.3.1.
304.3.2. Excavation:  Excavation shall be taken to the width of the lowest step of the
footing and the sides shall be left plumb where the nature of soil allows it. Where the
nature of soil or the depth of the trench and season of the year do not permit vertical
sides, the Contractor at his own expense shall put up necessary shoring, strutting and
planking or cut slopes to a safer angle or both with due regard to the safety of personnel
and works and to the satisfaction of the Engineer.
The depth to which the excavation is to be carried out shall be as shown on the drawings,
unless the type of material encountered is such as to require changes, in which case
the depth shall be as ordered by the Engineer. Propping shall be undertaken when any
foundation or stressed zone from an adjoining structure is within a line of l vertical to 2
horizontal from the bottom of the excavation.
 Where blasting is to be resorted to, the same shall be carried out in accordance with
Clause 302 and all precautions indicated therein observed. Where blasting is likely to
endanger adjoining foundations or other structures, necessary precautions such as
controlled blasting, providing rubber mat cover to prevent-flying of debris etc. shall be
taken to prevent any damage.
304.3.3. Dewatering and protection: Normally, open foundations shall be laid dry. Where
water is met with in excavation due to stream flow, seepage, springs, rain or other reasons,
the Contractor shall take adequate measures such as bailing, pumping, constructing
diversion channels, drainage channels, bunds, depression of water level by well- point
system, cofferdams and other necessary works to keep the foundation trenches dry
when so required and to protect the green concrete/masonry against damage by erosion
or sudden rising of water level. The methods to be adopted in this regard and other
details thereof shall be left to the choice of the Contractor but subject to approval of
the Engineer. Approval of the Engineer shall, however, not relieve the Contractor of the
responsibility for the adequacy of dewatering and protection arrangements and for the
quality and safety of the works.
 Where cofferdams are required, these shall be carried to adequate depths and
heights, be safely designed and constructed and be made as watertight as is necessary
for facilitating construction to be carried out inside them. The interior dimensions of
the cofferdams shall be such as to give sufficient clearance for the construction and
inspection and to permit installation of pumping equipments, etc., inside the enclosed
area.

RED BOOK  VOLUME I  ROADS  2012 441

Rd.69.3
 If it is determined beforehand that the foundations cannot be laid dry or the situation
is found that the percolation is too heavy for keeping the foundation dry, the foundation
concrete shall be laid under water by tremie pipe only. In case of flowing water or artesian
springs, the flow shall be stopped or reduced as far as possible at the time of placing
the concrete.
Pumping 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 any fresh concrete. No
pumping shall be permitted during the placing of concrete or for any period of at least
24 hours thereafter, unless it is done from a suitable sump separated from the concrete
work by a watertight wall or other similar means.
At the discretion of the Contractor, cement grouting or other approved methods may be
used to prevent or reduce seepage and to protect the excavation area. .
 The Contractor shall take all precautions in diverting channels and in discharging the
drained water as not to cause damage to the works, crops or any other property.
304.3.4. Preparation of foundation: The bottom of the foundation shall be levelled both
longitudinally and transversely or stepped as directed by the Engineer. Before footing is
laid, the surface shall be slightly watered and rammed. In the event of excavation having
been made deeper than that shown on the drawings or as otherwise ordered by the
Engineer, the extra depth shall be made up with concrete or masonry of the foundation
at the cost of the Contractor as per Clause 2104.1. Ordinary filling shall not be used for
the purpose to bring the foundation to level.
 When rock or other hard strata is encountered, it shall be freed of all soft and loose
material, cleaned and cut to a firm surface either level or stepped as directed by the
Engineer. All seams shall be cleaned out and filled with cement mortar or grout to the
satisfaction of the Engineer. In the case of excavation in rock, annular space around
footing shall be filled with lean concrete (1:3:6 nominal mix) upto the top level of rock.
 If the depth of fill required is more than 1.5m above the top of the footing, filling upto
1.5m above top of footing shall be done with lean concrete (1:3:6 nominal mix) followed
by boulders grouted with cement.
 When foundation piles are used, the excavation of each pit shall be substantially
completed before beginning pile driving operations therein. After pile driving operations
in a given pit are completed, all loose and displaced materials therein shall be removed
to the elevation of the bottom of the footings.
304.3.5. Slips and slip-outs:  If there are any slips or slip-outs in the excavation, these
shall be removed by the Contractor at his own cost –
304.3.6. Public safety:  Near towns, villages and all frequented places, trenches and
foundation pits shall be securely fenced, provided with proper caution signs and marked
with red lights at night to avoid accidents. The Contractor shall; take adequate protective
measures to see that the excavation operations do not affect or damage adjoining
structures. For safety precautions, guidance may be taken from IS : 3764.
304.3.7. Backfilling: Backfilling shall be done with `approved material after concrete or
masonry is fully set and carried out in such a way as not to cause undue thrust on any
part of the structure. All space between foundation masonry or concrete and the sides
of excavation shall be refilled to the original surface in. layers not exceeding 150 mm
compacted thickness. The compaction shall be done with the help of suitable Equipment
such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as
to achieve a density not less than the field density before excavation.
304.3.8. Disposal of surplus excavated materials: Clause 301.3.11 shall apply.
442 RED BOOK  VOLUME I  ROADS  2012
 305.2.1.1.
304.4. Measurements for Payment Excavation for structures shall be measured in cu. m.
for each class of material encountered, limited to the dimensions shown on the drawings
or as directed by the Engineer. Excavation over increased width, cutting of slopes,
shoring, shuttering and planking shall be deemed as convenience for the Contractor in
executing the work and shall not be measured and paid for separately.
Preparation of rock foundation shall be measured in square metres. Foundation sealing,
dewatering, including pumping shall be deemed to be incidental to the work unless
separate provision is made for in the Contract. In the latter case, payment shall be on
lumpsum basis as provided in the Bill of Quantities.
304.5. Rates
304.5.1. The Contract unit rate for the items of excavation for structures shall be payment
in full for carrying out the required - operations including full compensation for:
(i) setting out;
(ii) construction of necessary cofferdams, cribs, sheeting, shoring and bracing and their
subsequent removal.
(iii) removal of all logs, stumps, grubs and other deleterious matter and obstructions, •
for placing the foundations including trimming of bottoms of excavations; _
(iv) foundation sealing, dewatering including pumping when no separate provision for it
is made in the Contract;
(v) backfilling, clearing up the site and disposal of all surplus material within all lifts and
leads upto 1000 m or as otherwise specified; and
(vi) all labour, materials, tools, equipment, safety measures, diversion of traffic and
incidentals necessary to complete the work to Specification.
304.5.2. The Contract unit rate for preparation of rock foundation shall be full compensation
for cutting, trimming and cleaning the foundation surface and filling/sealing of all seams
with cement grout or mortar including all materials, labour and incidentals required for
completing the work.
304.5.3. The Contract unit rate for transporting material from the excavation for structures
shall be full compensation for all labour, equipment, tools and incidentals necessary on
account of the additional haul or transportation involved beyond the initial lead of 1000 m.
305. EMBANKMENT CONSTRUCTION
305.1. General
305.1.1.Description: These Specifications shall apply to the construction of
embankments including subgrades, earthen shoulders and miscellaneous backfills with
approved material obtained from roadway and drain excavation, borrow pits or other
sources. All embankments, subgrades, earthen shoulders and miscellaneous backfills
shall be constructed in accordance with the requirements of these Specifications and
in conformity with the lines, grades, and cross-sections shown on the drawings or as
directed by the Engineer.
305.2. Materials and General Requirements
305.2.1. Physical requirements:
305.2.1.1. The materials used in embankments, subgrades, earthen shoulders and
miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any other
material approved by the Engineer. Such materials shall be free of logs, stumps,
roots, rubbish or any other ingredient likely to deteriorate or affect the stability of the

RED BOOK  VOLUME I  ROADS  2012 443

305.2.1.1.
embankment/subgrade.
The following types of material shall be considered unsuitable for embankment:
(a) Materials from swamps, marshes and bogs;
(b) Peat, log, stump and perishable material; any soil that classifies as OL, Ol, OH or Pt
in accordance with IS : 1498;
(c) Materials susceptible to spontaneous combustion;
(d) Materials in a frozen condition;
(e) Clay having liquid limit exceeding 70 and plasticity index exceeding 45; and
(f) Materials with salts resulting in leaching in the embankment.
305.2.1.2. Expansive clay exhibiting marked swell and shrinkage properties ("free
swelling index" exceeding 50 per cent when tested as per IS: 272 Part 40) shall not be
used as a fill material. Where expansive clay with acceptable "free swelling index" value
is used as a fill material, subgrade and top 500 mm portion of the embankment just
below subgrade shall be non-expansive in nature.
305.2.1.3. Any fill material with a soluble sulphate content exceeding 1.9 grams of
sulphate (expressed as SO,) per litre when tested in accordance with BS : 1377 Test 10,
but using a 2:1 water-soil ratio shall 'not be deposited within 500 mm or other distance
described in the Contract, of concrete, cement bound materials or other cementitious
materials forming part of the Permanent Works.
 Materials with total sulphate content (expressed as SO,) exceeding 0.5 per cent by
mass, when tested in accordance with BS : 1377 Test shall not be deposited within 500
mm, or other distances described in the Contract, of metallic items forming part of the
Permanent Works.
305.2.1.4. The size of the coarse material in the mixture of earth shall ordinarily not
exceed 75 mm when being placed in the embankment and 50 mm when placed in the
subgrade. However, the Engineer may at his discretion permit the use of material coarser
than this also if he is satisfied that the same will not present any difficulty as regards the
placement of fill material and its compaction to the requirements of these Specifications.
The maximum particle.-size shall not be more than two-thirds of the compacted layer
thickness.
305.2.1:5. O
 rdinarily, only the materials satisfying the density requirements given in Table
300-1 shall be employed for the construction of the embankment and the subgrade.

TABLE 300-1. DENSITY REQUIREMENTS OF EMBANKMENT AND

SUBGRADE MATERIALS

<Table>

Notes: (1) This Table is not applicable for lightweight fill Material e.g. cinder, fly ash etc.
(2) The Engineer may relax these requirements at his discretion taking into account the
availability of materials for construction and other relevant factors.
(3) The material to be used in subgrade should also satisfy design CBR at the dry unit

444 RED BOOK  VOLUME I  ROADS  2012

weight applicable as per Table 300-2.
305.2.2. General requirements:
305.2.2.1. The materials for embankment shall be obtained from approved sources with
preference given to materials becoming available from nearby roadway excavation or
any other excavation under the same Contract.
The work shall be so planned and executed that the best available materials are saved
for the subgrade and the embankment portion just below the subgrade.
305.2.2.2. Borrow materials:  Where the materials are to be obtained from designated
borrow areas, the location, size and shape of these areas shall be as indicated by the
Engineer and the same shall not be opened without his written permission. Where
specific borrow areas are not designated by the Employer/the Engineer, arrangement
for locating the source of supply of material for embankment and subgrade as well as
compliance to environmental requirements in respect of excavation and borrow areas as
stipulated, from time to time by the- Ministry of Environment and Forests, Government
of India and the local ` bodies, as applicable, shall be the sole responsibility of the
Contractor.
Borrowpits along the road shall be discouraged. If permitted by the Engineer, these shall
not be dug continuously. Ridges of not less than 8 m width should be left at intervals not
exceeding 300 tn. Small drains shall be cut through the ridges to facilitate drainage. The
depth of the pits shall be so regulated that their bottom does not cut an imaginary line
having a slope of 1 vertical to 4 horizontal projected from the edge of the final section of
the bank, the maximum depth in any case being limited to 1.5 m. Also, no pit shall be dug
within the offset width from the toe of the embankment required as per the consideration
of stability with a minimum width of 10 m.
 Haulage of material to embankments or other areas of fill shall proceed only when
sufficient spreading and compaction plant is operating at the place of deposition.
 No excavated acceptable material other than surplus to requirements of the Contract
shall be removed from the site. Should the Contractor be permitted to remove acceptable
material from the site to suit his operational procedure, then he shall make good any
consequent deficit of material arising therefrom.
Where the excavation reveals a combination of acceptable and un- acceptable materials,
the Contractor shall, unless otherwise agreed by the Engineer, carry out the excavation
in such a manner that the acceptable materials are excavated separately for use in the
permanent works without contamination by the unacceptable materials. The acceptable
materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the stability of excavation
or tills by the methods of stockpiling materials, use of plants or siting of temporary
buildings or structures.
The Contractor shall obtain representative samples from each of the identified borrow
areas and have these tested at the site laboratory following a testing programme approved
by the Engineer, It shall be ensured that the subgrade material when compacted to the
density requirements as in Table 300-2 shall yield the design CBR value of the subgrade.

TABLE 300-2. COMPACTION REQUIREMENTS FOR EMBANKMENT AND

SUBGRADE

RED BOOK  VOLUME I  ROADS  2012 445

<Table>

 The Contractor shall at least 7 working days before commencement of compaction

submit the following to the Engineer for approval:
(i) The values of maximum dry density and optimum moisture content obtained in
accordance with IS: 2720 (Part 7) or (Part 8), _as the case may be, appropriate
for each of the fill materials he intends to use. (ii) A graph of density plotted against
moisture content from which each of the values in (i) above of maximum dry density
_and optimum moisture content were - determined.
(iii) The Dry density-moisture content -CBR relationships for light, intermediate and
_ _ heavy compactive efforts (light corresponding to IS: 2720 (Part 7), heavy .
corresponding to IS: 2720 (Part S) and intermediate in-between the two) for each of
the till materials he intends to use in the subgrade.
Once the above information has been approved by the Engineer, it shall form the basis
for compaction.
305.3. Construction Operations
305.3.1. Setting out: After the site has been cleared to Clause 201, the work shall be set
out to Clause 301.3.1. The limits of embankment/subgrade shall be marked by fixing batter
pegs on both sides at regular intervals as guides before commencing the earthwork. The
embankment/subgrade shall be built sufficiently wider than the design dimension so that
surplus material may be trimmed, ensuring that the remaining material is to the desired
density and in position specified and conforms to the specified side slopes.
305.3.2. Dewatering: If the foundation of the embankment is in an area with stagnant water,
and in the opinion of the Engineer it is feasible to remove it, the same shall be removed
by bailing out or pumping, as directed by the Engineer and the area of the embankment
foundation shall be kept dry. Care shall be taken to discharge the drained water so as not
to cause damage to the works, crops or any other property. Due to any negligence on the
part of the Contractor, if any such damage is caused, it shall be the sole responsibility of
the Contractor to repair/restore it to original condition or compensate the damage at his
own cost.
If the embankment is to be constructed under water, Clause 305.4.6 shall apply.
305.3.3. Stripping and storing topsoil: In localities where most of the available embankment
materials are not conducive to plant growth, or when so directed by the Engineer, the topsoil
from all areas of cutting and from all areas to be covered by embankment foundation shall
be stripped to specified depths not exceeding 150 mm and stored in stockpiles of height
not exceeding 2 m for covering embankment slopes, cut slopes and other disturbed areas
where re-vegetation is desired. Topsoil shall not be unnecessarily trafficked either before
stripping or when in a stockpile. Stockpiles shall not be surcharged or otherwise loaded and
multiple handling shall be kept to a minimum.
305.3.4. Compacting ground supporting embankment/subgrade: Where necessary,
the original ground shall be levelled to facilitate placement of first layer of embankment,
scarified, mixed with water and then compacted by rolling so as to achieve minimum dry
density as given in Table 300-2. In case where the difference between the subgrade level
(top of the subgrade on which pavement rests) and ground level is less than 0.5 m and the
ground does not have 97 per cent relative compaction with respect to the dry density as
given in Table 300-2, the ground shall be loosened upto a level 0.5 m below the subgrade
446 RED BOOK  VOLUME I  ROADS  2012
 305.3.5.3.
level, watered and compacted in layers in accordance with Clauses 305.3.5 and 305.3.6 to
not less than 97 per cent of dry density as given in Table 300-2.
Where so directed by the Engineer, any unsuitable material occurring in the embankment
foundation shall be removed and replaced by approved materials laid in layers to the
required degree of compaction.
Embankment or subgrade work shall not proceed until the foundations for embankment/
subgrade have been inspected by the Engineer _ for satisfactory condition and approved.
Any foundation treatment specified for embankments especially high embankments, resting
on suspect foundations as revealed by borehole logs shall be carried out in a manner and
to the depth as desired by the Engineer. Where the ground on which an embankment is to
be built has any of the material types (a) to (f) in Clause 305.2.1, at least 500 mm of such
material must be removed and replaced by acceptable fill material before embankment
construction commences.
305.3.5. Spreading material in layers and bringing to appropriate moisture content
305.3.5.1. The embankment and subgrade material shall be spread in layers of uniform
thickness not exceeding 200 mm compacted thickness over the entire width of embankment
by mechanical means, finished by a motor grader and compacted as per Clause 305.3.6. The
motor grader blade shall have hydraulic control suitable for initial adjustment and maintain
the same so as to achieve the specific slope and grade. Successive layers shall not be
placed until the layer under construction has been thoroughly compacted to the specified
requirements as in Table 300-2 and got approved by the Engineer. Each compacted layer
shall be finished parallel to the final cross-section of the embankment.
305.3.5.2. Moisture content of the material shall be checked at the site of placement prior
to commencement of compaction; if found to be out of agreed limits, the same shall be
made good. Where water is required to be added in such constructions, water shall be
sprinkled from a water tanker fitted with sprinkler capable of applying water uniformly with
a controllable rate of flow to variable widths of surface but without any flooding. The water
shall be added uniformly and thoroughly mixed in soil by blading, discing or harrowing until
uniform moisture content is obtained throughout the depth of the layer.
If the material delivered to the roadbed is too wet, it shall be dried, by aeration and exposure
to the sun, till the moisture content is acceptable for compaction. Should circumstances
arise, where owing to wet weather, the moisture content cannot be reduced to the required
amount by the above procedure, compaction work shall be suspended.
Moisture content of each layer of soil shall be checked in accordance with IS: 2720
(Part 2), and unless otherwise mentioned, shall be so adjusted, making due allowance
for evaporation losses, that at the time of compaction it is in the range of I per cent above
to 2 per cent below the optimum moisture content determined in accordance with IS :
272O (Part 7) or IS:2720 (Part 8) as the case may be. Expansive clays shall, however, be
compacted at moisture content corresponding to the specified dry density, but on the wet
side of the optimum moisture content obtained from the laboratory compaction curve.
After adding the required amount of water, the soil shall be processed by means of graders,
harrows, rotary mixers or as otherwise approved by the Engineer until the layer is uniformly
wet.
Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when
being placed in the embankment and a maximum size of 50 mm when being placed in the
subgrade.
305.3.5.3. Embankment and other areas of fill shall, unless otherwise- required in the

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305.3.5.3.
Contract or permitted by the Engineer, be constructed ` evenly over their full width and
their fullest possible extent and the Contractor shall control and direct construction plant
and other vehicular traffic uniformly over them. Damage by construction plant and other
vehicular traffic shall be made good by the Contractor with material having the same
characteristics and strength as the material had before it was damaged.
Embankments and other areas of unsupported fills shall not l be constructed with steeper
side slopes, or to greater widths than those shown in the Contract, except to permit adequate
compaction at the edges before trimming back, or to obtain the final profile following any
settlement of the fill and the underlying material.
Whenever fill is to be deposited against the face of a natural slope, or sloping earthworks
face including embankments, cuttings, other fills and excavations steeper than I vertical
on 4 horizontal, such faces shall be benched as per Clause 305.4.1 immediately before
placing the subsequent fill.
All permanent faces of side slopes of embankments and other areas of till formed shall,
subsequent to any trimming operations, be reworked and sealed to the satisfaction of the
Engineer by tracking a tracked vehicle, considered suitable by the Engineer, on the slope
or any other method approved by the Engineer.
305.3.6. Compaction: Only the compaction equipment approved by the Engineer shall be
employed to compact the different material types encountered during construction. Smooth
wheeled, vibratory, pneumatic tyred, sheepsfoot or pad foot rollers, etc. of suitable size and
capacity as approved by the Engineer shall be used for the different types and grades of
materials required to be compacted either individually or in suitable combinations.
The compaction shall be done with the help of vibratory roller of 80 to 100 kN static weight
with plain or pad foot drum or heavy pneumatic tyred roller of adequate capacity capable of
achieving required compaction.
The Contractor shall demonstrate the efficacy of the equipment he intends to use by
carrying out compaction trials. The procedure to be adopted for these site trials shall first
be submitted to the Engineer for approval.
Earthmoving plant shall not be accepted as compaction equipment nor shall the use of a
lighter category of plant to provide any preliminary compaction to assist the use of heavier
plant be taken into account.
Each layer of the material shall be thoroughly compacted to the densities specified in Table
300-2. Subsequent layers shall be placed only after the finished layer has been tested
`according to Clause 903.2.2 and accepted by the Engineer. The Engineer may permit
measurement of field dry density by a nuclear moisture/density gauge used in accordance
‘with agreed procedure and the gauge is calibrated to provide results identical to that
obtained from tests in accordance with IS: 2720 (Part 28). A record of the same shall be
maintained by the Contractor.
When density measurements reveal any soft areas in the embankment/subgrade/earthen
shoulders, further compaction shall be carried out as directed by the Engineer. If inspite
of that the specified compaction is not achieved, the material in the soft areas shall be
removed and replaced by approved material, compacted to the density requirements and
satisfaction of the Engineer.
305.3.7. Drainage: The surface of the embankment/subgrade at all times during construction
shall be maintained at such a cross fall (not flatter than that required for effective drainage
of an earthen surface) as will shed water and prevent ponding.
305.3.8. Repairing of damages caused by rain/spillage of water: The soil in the affected

448 RED BOOK  VOLUME I  ROADS  2012

 305.4.2.
portion shall be removed in such areas as directed by the Engineer before next layer is
laid and refilled in layers and compacted using appropriate mechanical means such as
small vibratory roller, plate compactor or power rammer to achieve the required density
in accordance with Clause 305.3.6. If the cut is not sufficiently wide for use of required
mechanical means for compaction, the same shall be widened suitably to permit their use
for proper compaction. Tests shall be carried out as directed by the Engineer to ascertain
the density requirements of the repaired area. The work of repairing the damages including
widening of the cut, if any, shall be carried out by the Contractor at his own cost, including
the arranging of machinery/equipment for the purpose.
305.3.9. Finishing operations: Finishing operations shall include the work of shaping and
dressing the shoulders/verge/roadbed and side slopes to conform to the alignment, levels,
cross—sections and dimensions shown on the drawings or as directed by the Engineer
subject to _the surface tolerance described in Clause 902. Both the upper and lower ends of
the side slopes shall be rounded off to improve appearance and to merge the embankment
with the adjacent terrain.
The topsoil, removed and conserved earlier (Clause 301.3.2 and 305.3.3) shall be spread
over the fill slopes as per directions of the Engineer to facilitate the growth of vegetation.
Slopes shall be roughened and moistened slightly prior to the application of the topsoil in
order to provide satisfactory bond. The depth of the topsoil shall be sufficient to sustain
plant growth, the usual thickness being from 75 mm to 150 mm.
Where directed, the slopes shall be turfed with sods in accordance with Clause 307. If
seeding and mulching of slopes is prescribed, this shall be done to the requirement of
Clause 308.
When earthwork operations have been substantially completed, the l road area shall be
cleared of all debris, and ugly scars in the construction area responsible for objectionable
appearance eliminated.
305.4. Construction of Embankment and Subgrade under Special Conditions
305.4.1. Earthwork for widening existing road embankment: When an existing
embankment and/or subgrade is to be widened and its slopes are steeper than 1 vertical on
4 horizontal, continuous horizontal benches, each at least 300 mm wide, shall be cut into
the old slope for ensuring adequate bond with the fresh embankment/subgrade material to
be added. The material obtained from cutting of benches could be utilized in the widening
of the embankment/subgrade. However, ` when the existing slope against which the fresh
material is to be placed is flatter than 1 vertical on 4 horizontal, the slope surface may only
be ploughed or scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit the use of conventional
rollers, compaction shall be carried out with the help of small vibratory rollers/plate
compactors/power rammers or any other appropriate equipment approved by the Engineer.
End dumping of material from trucks for widening operations shall be avoided except in
difficult circumstances when the extra width is too narrow to permit the movement of any
other types of hauling equipment.
305.4.2. Earthwork for embankment and subgrade to be placed against sloping
ground: Where an embankment/subgrade is to be placed against sloping ground, the
latter shall be appropriately benched or ploughed/scarified as required in Clause 305.4.1
before placing the embankment/subgrade material. Extra earthwork involved in benching
or due to ploughing/scarifying etc. shall be considered incidental to the work. For wet
conditions, benches with slightly inward fall and subsoil drains at the lowest point shall be
provided as per the drawings, before the fill is placed against sloping ground. Where the

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305.4.2.
Contract requires construction of transverse subsurface drain at the cut-till interface, work
on the same shall be carried out to Clause 309 in proper sequence with the embankment
and subgrade work as approved by the Engineer.
305.4.3. Earthwork over existing road surface: Where the embankment is to be placed
over an existing road surface, the work shall be carried out as indicated below:
(i) If the existing road surface is of granular or bituminous type and lies within 1 m of the
new subgrade level, the same shall be scarified to a depth of 50 mm or more if specified, so
as to provide ample bond between the old and new material ensuring that at least 500 mm
portion below the top of new subgrade level is compacted to the desired density.
(ii) If the existing road surface is of cement concrete type and lies within 1m of the new
subgrade level the same shall be removed completely.
(iii) If the level difference between the existing road surface and the new formation level
is more than 1m, the existing surface shall be permitted to stay in place without any
modification.
305.4.4. Embankment and subgrade around structures: To avoid interference with
the construction of abutments, wing walls or return walls of culvert/bridge structures, the
Contractor shall, at points to be determined by the Engineer suspend work on embankment
forming approaches to such structures, until such time as -the construction of the latter is
sufficiently advanced to permit the completion of approaches without the risk of damage to
the structure.
Unless directed otherwise, the filling around culverts, bridges and other structures upto a
distance of twice the height of the road from the back of the abutment shall be carried out
independent of the work on the main embankment. The fill material shall not be placed
against any abutment or wing wall, unless permission has been given by the Engineer
but in any case not until the concrete or masonry has been in position for 14 days. The
embankment and subgrade shall be brought - up simultaneously in equal layers on each
side of the structure to avoid displacement and unequal pressure. The sequence .of work
in this regard shall be got approved from the Engineer.
The material used for backfill shall- not be an organic soil or highly plastic clay having
plasticity index and liquid limit more than 20 and 40-respectively when tested according
to.lS:2720 (Part 5). Filling behind abutments and wing walls for all structures shall conform
to the general • guidelines given in Appendix 6 of IRC : 78 (Standard Specifications and
Code of Practice for Road Bridges-Section VII) in respect of the type of material, the extent
of backfill, its laying and compaction etc. The fill material shall be deposited in horizontal
layers in loose thickness and compacted thoroughly to the requirements of Table 300-2.
Where the provision of any filter medium is specified behind the abutment, the same shall
be laid in layers simultaneously with the laying of -fill material. The material used for filter
shall conform to the ` requirements for filter medium spelt out in Clause 2502/309.3.2 (B)
unless otherwise specified in the Contract.
Where it may be impracticable to use conventional rollers, the compaction shall be carried
out by appropriate mechanical means such as small vibratory roller, plate compactor or
power rammer. Care shall be taken to see that the compaction equipment does not hit or
come too close to any structural member so as to cause any damage to them or excessive
pressure against the structure.
305.4.5. Construction of embankment over ground incapable of supporting
construction equipment: Where embankment is to be constructed across ground which
will not support the weight of repeated heavy loads of construction equipment, the first
layer of the till may be constructed by placing successive loads of material in a uniformly
450 RED BOOK  VOLUME I  ROADS  2012
 305.7.2.
distributed layer of a minimum thickness required to support the construction equipment
as permitted by the Engineer. The Contractor, if so desired by him, may also use suitable
geosynthetic material to increase the bearing capacity of the foundation. This exception
to normal procedure will not be permitted where, in the opinion of the Engineer, the
embankments could be constructed in the approved manner over such ground by the use
of lighter or modified equipment after proper ditching and drainage have been provided.
Where this exception is permitted, the selection of the material and the construction
procedure to obtain an acceptable layer shall be the responsibility of the Contractor. The
cost of providing suitable traffic conditions for construction equipment over any area of the
Contract will be the responsibility of the Contractor and no extra payment will be made to
him. The remainder • of the embankment shall be constructed as specified in Clause 305.3.
305.4.6. Embankment construction under water: Where filling or backfilling is to be placed
under water, only acceptable granular material or rock shall be used unless otherwise
approved by the Engineer. Acceptable granular material shall consist- of graded, hard
durable particles with maximum particle size not exceeding 75 mm. The material should be
non-plastic having uniformity coefficient of not less than 10. The material placed in open
water shall be deposited by end tipping without compaction.
305.4.7. Earthwork for high embankment: ln the case of high embankments, the Contractor
shall normally use the material from the specified borrow area. In case he desires to
use different material for his own convenience, he shall have to carry out necessary soil
investigations and redesign the high embankment at his own cost. The Contractor shall
then furnish the soil test data and design of high embankment for approval of the Engineer,
who reserves the right to accept or reject it.
If necessary, stage construction of fills and any controlled rates of filling shall be carried
out in accordance with the Contract including installation of instruments and its monitoring.
Where required, the Contractor shall surcharge embankments or other areas of till with
approved material for the periods specified in the Contract. If settlement of surcharged
fill results in any surcharging material, which is unacceptable for use in the fill being
surcharged, lying below formation level, the Contractor shall remove the unacceptable
material and dispose it as per direction of the Engineer. He shall then bring the resultant
level up to formation level with acceptable material.
305.4.8. Settlement period: Where settlement period is specified in the Contract, the
embankment shall remain in place for the required settlement period before excavating for
abutment, wingwall, retaining wall, footings, etc., or driving foundation piles. The duration
of the required settlement period at each location shall be as provided for in the Contract
or as directed by the Engineer.
305.5. P
 lying of Traffic Construction and other vehicular traffic shall not use the prepared
surface of the embankment and/or subgrade without the prior permission of the Engineer.
Any damage arising out of such use shall, however, be made good by the Contractor at his
own expense as directed by the Engineer.
Surface Finish and Quality Control of Work The surface finish of construction
305.6. 
of subgrade shall conform to the requirements of Clause 902. Control on the quality of
materials and works shall be exercised in accordance with Clause 903.
305.7. Subgrade Strength
305.7.1. It shall be ensured prior to actual execution that the borrow area material to be
used in the subgrade satisfies the requirements of design CBR.
305.7.2. Subgrade shall be compacted and finished to the design strength consistent with

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305.7.2.
other physical requirements. The actual laboratory CBR values of constructed subgrade
shall be determined on undisturbed samples cut out from the compacted subgrade in CBR
mould fitted with cutting shoe or on remoulded samples, compacted to the field density at
the field moisture content.
305.8. Measurements for Payment
Earth embankment/subgrade construction shall be measured separately by taking cross
sections at intervals in the original position before the work starts and after its completion
and computing the volumes of earthwork in cubic metres by the method of average end
areas.
The measurement of till material from borrow areas shall be the difference between the net
quantities of compacted fill and the net quantities of suitable material brought from roadway
and drainage excavation. For this purpose, it shall be assumed that one cu.m. of suitable
material brought to site from road and drainage excavation forms one cu.m. of compacted
till and all bulking or shrinkage shall be ignored.
Construction of embankment under water shall be measured in cu.m.
Construction of high embankment with specified material and in specified manner shall be
measured in cu.m.
Stripping including storing and reapplication of topsoil shall be measured in cu.m.
Work involving loosening and recompacting of ground supporting embankment/subgrade
shall be measured in cu. m.
Removal of unsuitable material at embankment/subgrade foundation and replacement with
suitable material shall be measured in cu.m.
Scarifying existing granular/bituminous road surface shall be measured in square metres.
Dismantling and removal of existing cement concrete pavement shall be measured vide
Clause 202.6.
Filter medium and backfill material behind abutments, wing walls and other retaining
structures shall be measured as finished work in position in cu.m.
305.9. Rates
305.9.1. The Contract unit rates for the items of embankment and subgrade construction
shall be payment in full for carrying out the required operations including full compensation
for :
(i) Cost of arrangement of land as a source of supply of material of required quantity for
construction unless provided otherwise in the Contract;
(ii) Setting out;
(iii) Compacting ground supporting embankment/subgrade except where removal and
replacement of unsuitable material or loosening and recompacting is involved;
(iv) Scarifying or cutting continuous horizontal benches 300 mm wide on side slopes of
existing embankment and subgrade as applicable;
(v) Cost of watering or drying of material in borrow areas and/or embankment and
subgrade during construction as required;
(vi) Spreading in layers, bringing-to appropriate moisture content and compacting to
Specification requirements;
(vii) Shaping and dressing top and slopes of the embankment and subgrade including
rounding of comers;

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 306.3.
(viii) Restricted working at sites of structures;
(ix) Working on narrow width of embankment and subgrade;
(x) Excavation in all soils from borrow pits/designated borrow areas` including clearing
and grubbing and transporting the material to embankment and subgrade site with
all lifts and leads unless otherwise provided for in the Contract;
(xi) All labour, materials, tools, equipment and incidentals necessary to complete the
work to the Specifications;
(xii) Dewatering; and
(xiii) Keeping the embankment/completed formation free of water as per Clause 311.
305.9.2. In case the Contract unit rate specified is not inclusive of all leads, the unit rate for
transporting material beyond the initial lead, as specified in the Contract for construction of
embankment and subgrade shall be inclusive of full compensation for all labour, equipment,
tools and incidentals necessary on account of the additional haul or transportation involved
beyond the specified initial lead.
305.9.3. Clause 301.9.5 shall apply as regards Contract unit rates ` for items of stripping
and storing top soil and of reapplication of topsoil.
305.9.4. Clause 301.9.2 shall apply as regards Contract unit rate for the item of loosening
and recompacting the embankment/subgrade foundation.
305.9.5. Clauses 301.9.1 and 305.8 shall apply as regards Contract rates for items of
removal of unsuitable material and replacement with suitable material respectively.
305.9.6. The Contract unit rate for scarifying existing granular/bituminous road surface
shall be payment in full for carrying out the required operations including full compensation
for all labour, materials, tools, equipment and incidentals necessary to complete the work.
This will also comprise of handling, salvaging, stacking and disposing of the dismantled
materials within all lifts and upto a lead of 1000 in or as otherwise specified. .
305.9.7. Clause 202.7 shall apply as regards Contract unit rate for dismantling and removal
of existing cement concrete pavement.
305.9.8. The Contract unit rate for providing and laying filter material behind abutments
shall be payment in full for carrying out the required operations including all materials,
labour, tools, equipment and incidentals to complete the work to Specifications.
305.9.9. Clause 305.4.6 shall apply as regards Contract unit rate for construction of
embankment under water.
305.9.10. Clause 305.4.7 shall apply as regards Contract unit rate for construction of high
embankment. It shall include cost of instrumentation, its monitoring and settlement period,
where specified in the Contract or directed by the Engineer.
306. SOIL EROSION AND SEDIMENTATION CONTROL
306.1. Description This work shall consist of measures as shown on plans or as directed
by the Engineer to control soil erosion, sedimentation and water pollution, through use
of berms, dikes, sediment basins, fibre mats, mulches, grasses, slope drains, and other
devices.
306.2. Materials All materials shall meet commercial grade standards and shall be
approved by the Engineer before being used in the work.
306.3. Construction Operations P  rior to the start of the relevant construction, the Contractor
shall submit to the Engineer for approval his schedules for carrying out temporary and

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306.3.
permanent erosion/sedimentation control works as are applicable for the items of clearing
and grabbing, roadway and drainage excavation, embankment,/subgrade construction,
bridges and other structures across water courses, pavement courses and shoulders. He
shall also submit for approval his proposed method of erosion/sedimentation control on
service road and borrowpits and his plan for disposal of waste materials. Work shall not be
started until the erosion/sedimentation control schedules and methods of operations for the
applicable construction have been approved by the Engineer.
The surface area of erodible earth material exposed by clearing and grabbing, excavation,
borrow and till operations shall be limited to the extent practicable. The Contractor may be
directed to provide immediate permanent or temporary erosion and sedimentation control
measures to prevent soil erosion and sedimentation that will adversely affect- construction
operations, damage adjacent properties, or cause contamination of nearby streams or
other water courses, lakes, reservoirs etc. Such work may involve the construction of
temporary berms, dikes sediment basins, slope drains and use of temporary mulches,
fabrics, mats, seeding, or other control devices or methods as necessary to control erosion
and sedimentation. Cut and fill slopes shall be seeded and turfed as required on the plans.
The Contractor shall be required to incorporate all permanent erosion and sedimentation
control features. into the project at the earliest practicable time as outlined in his accepted
schedule to minimize the need for temporary erosion and sedimentation control measures.
Temporary erosion/sedimentation and pollution control measures will be used to control
the phenomenon of erosion, sedimentation and pollution that may develop during normal
construction practices, but may neither be foreseen during design stage nor associated
with permanent control features on the Project.
Where erosion or sedimentation is likely to be a problem, clearing and grabbing operations
should be so scheduled and performed that grading operations and permanent erosion or
sedimentation control features can follow immediately thereafter if the project conditions
permit; otherwise temporary erosion or sedimentation control measures may be required
between successive construction stages. Under no conditions shall a large surface area
of erodible earth material be exposed at one time by clearing and grubbing or excavation
without prior approval of the Engineer.
The Engineer may limit the area of excavation, borrow and embankment operations in
progress, commensurate with the Contractor’s capability and progress in keeping the finish
grading, mulching, seeding and other such permanent erosion, sedimentation and pollution
control measures, in accordance with the accepted schedule. Should seasonal limitations-
make such coordination unrealistic; temporary erosion/sedimentation control measures
shall be taken immediately to the extent feasible and justified.
In the event temporary erosion, sedimentation and pollution control measures become
necessary due to the Contractor’s negligence, carelessness or failure to install permanent
controls as a part of the work as scheduled or ordered by the Engineer, these shall be carried
out at the Contractor’s own expense. Temporary erosion, sedimentation and pollution
control work required, which is not attributed to the Contractor’s negligence, carelessness
or failure to install permanent controls, will be performed as ordered by the Engineer.
Temporary erosion, sedimentation and pollution control may include construction work
outside the right-of-way where such work is necessary 35 a result of road construction such
as borrow pit operations, service roads and equipment storage sites.
The temporary erosion, sedimentation and pollution control features installed by the
Contractor shall be acceptably maintained by him till these are needed, unless otherwise
agreed by the Engineer.

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 307.3.2.
306.4. Measurements for Payment.
The soil erosion, sedimentation and pollution control works will be measured in terms of
units specified in the Bill of Quantities for the respective items.
306.5 Rates
The Contract unit rate for different items of soil erosion, sedimentation and pollution
control works shall be payment in full for carrying out all required operations including full
compensation for all labour, tools, equipment and incidentals to complete the works to the
Specifications.
307. TURFING WITH SODS
307.1. Scope
This work shall consist of furnishing and laying of the live sod of perennial turf forming
grass on embankment slopes, verges (earthen - shoulders) or other locations shown on
the drawings or as directed by the Engineer. Unless otherwise specified, the work shall
be taken up as soon as possible following construction of the embankment, provided the
season is favourable for establishment of the sod.
307.2. Materials
The sod shall consist of dense, well-rooted growth of permanent and desirable grasses,
indigenous to the locality where it is to be used, and shall be practically free from weeds
or other undesirable matter. At the ` time the sod is cut, the grass on the sod shall have a
length of approximately 50 mm and the sod shall have been freed of debris.
Thickness of the sod shall be as uniform as possible, with some 50- 80 mm or so of soil
covering the grass roots depending - on the nature of the sod, so that practically all the
dense root system of the grasses is retained in the sod strip. The sods shall be cut in
rectangular strips of uniform width, not less than about 250 mm x 300 mm in size but not
so large that it is inconvenient to handle and transport these without damage. During wet
weather, the sod shall be allowed to dry sufficiently to prevent rearing during handling
and-during dry weather shall be watered before lifting to ensure its vitality and prevent the
dropping of the soil in handling.
307.3. Construction Operations
307.3.1. Preparation of the earth bed: The area to be sodded shall have been previously
constructed to the required slope and cross section. Soil on the area shall be loosened,
freed of all stones larger than 50 mm size, sticks, stumps and any undesirable foreign
matter, and brought to a reasonably fine granular texture to a depth of not less than 25
mm for receiving the sod. Where required, topsoil shall be spread over the slopes. Prior
to placing the topsoil, the slopes shall be scarified to a depth which, after settlement, will
provide the required nominal depth shown on the plans. Spreading shall not be done when
the ground is excessively wet. Following soil preparation and top soiling, where required,
fertilizer and ground limestone when specified shall be spread uniformly at the rate indicated
on the plans. After spreading, the materials are incorporated in the soil by discing or other
means to the depths shown on the plans.
307.3.2. Placing the sods: The prepared sod bed shall be moistened to the loosened depth,
if not already sufficiently moist, and the sod shall be placed thereon within approximately
24 hours after the same had been cut. Each sod strip shall be laid edge to edge and such
that the joints caused by abutting ends are staggered-. Every strip, after it is snugly placed
against the strips already in position, shall be lightly tamped with suitable wooden or metal
tampers so as to eliminate air pockets and to press it into the underlying soil. On side

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307.3.2.
slopes steeper than 2 (horizontal) to 1(vertical), the laying of sods shall be started from
bottom upwards. At points where water may flow over a sodded area, the upper edges
of the sod strips shall be turned into the soil below the adjacent area and a layer of earth
placed over this followed by its thorough compaction.
307.3.3. Staking the sods : Where the side slope is 2 (horizontal) to l (vertical) or steeper
and the distance along the slope is more than 2 m, the sods shall be staked with pegs or
nails spaced approximately 500 to 1000 mm along the longitudinal axis of the sod strips.
Stakes shall be driven approximately plumb through the sods to be almost flush with them.
307.3.4. Top dressing: After the sods have been laid in position, the surface shall be
cleaned of loose sod, excess soil and other foreign material. Thereafter, a thin layer of topsoil
shall be scattered over the surface of top dressing and the area thoroughly moistened by
sprinkling with water;
307.3.5. Watering and maintenance: The sods shall be watered by the Contractor for a
period of at least four weeks after laying. Watering shall be so done as to avoid erosion and
prevent damage to sodded areas by wheels of water tanks.
The Contractor shall erect necessary warning signs and barriers, repair or replace sodded
areas failing to show uniform growth of grass or damaged by his operations and shall
otherwise maintain the sod at his cost until final acceptance.
307.4. Measurements for Payment
Turfing with sods shall be measured as finished work in square metres.
307.5. Rate
The Contract unit rate for turfing with sods shall mean payment in full for carrying out all the
required operations explained above including compensation for
(i) furnishing all the materials to be incorporated in the Works with all leads and lifts; and
(ii) all labour, tools, equipments and incidentals to complete the work in accordance with
these Specifications.
The Contract unit rate for application of topsoil shall be as -per Clause 301.9.5.
308. SEEDING AND MULCHING
308.1. Scope
This shall consist of preparing slopes, placing topsoil, furnishing all seeds, commercial
or organic fertilizers and mulching materials, providing jute netting and placing and
incorporating the same on embankment slopes or other ‘ locations designated by the
Engineer Or shown in the Contract documents.
308.2. Materials
A) Seeds: The seeds shall be of approved quality and type suitable for the soil on which
these are to be applied, and shall have acceptable purity and germination to requirements
set down by the Engineer.
Fertilizer shall consist of standard commercial materials and conform to the grade specified.
Organic manure shall be fully putrefied organic matter such as cow dung.
Mulching materials shall consist of straw, hay, wood shavings or sawdust, and shall be
delivered dry. They shall be reasonably free of weed seed and such foreign materials as
may detract from their effectiveness as mulch or be injurious to the plant growth.
B) Topsoil: Topsoil shall not be obtained from an area known to have noxious weeds growing
in it. If treated with herbicides or sterilents, it shall be got tested by appropriate agricultural

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 308.4.
authority to determine the residual in the soil. Topsoil shall not contain less than 2 per cent
and more than 12 per cent organic matter.
C) Bituminous Emulsion: A suitable grade of bituminous cutback or emulsion used as a
tie down for mulch shall be as described in the Contract document or as desired by the
Engineer. Emulsified bitumen shall not contain any solvent or diluting agent toxic to plant
life.
D) Netting: lute netting shall be undyed jute yam woven into a uniform open weave with
approximate 2.5 cm square openings.
Geonetting shall be made of uniformly extruded rectangular mesh having mesh opening
of 2 cm x 2 cm. The colour may be black or green. It shall weigh not less than 3.8 kg per
1000 sq. m.
308.3. Seeding Operations
308.3.1. Seed-bed preparation: The area to be seeded shall be brought to the required
slope and cross-section by filling, reshaping eroded areas and refinishing slopes, medians
etc. Topsoil shall be evenly spread over the specified areas to the depth shown on the
plans, unless otherwise approved by the Engineer. The seed-bed preparation shall consist
of eliminating all live plants by suitable means using agricultural implements. All stones 150
mm in smallest dimension and larger shall be removed. The soil shall be excavated on the
contour to a depth of 100 mm. All clods larger than 25 mm in diameter shall be crushed
and packed. Where necessary, water shall then be applied. All topsoil shall be compacted
unless otherwise specified or approved by the Engineer. Compaction shall be by slope
compactor, cleared tractor or similar equipment approved by the Engineer. Equipment shall
be so designed and constructed as to produce a uniform rough textured surface ready for
seeding and mulching and which will bond the topsoil - to the underlying material. The
entire area shall be covered by a minimum of 4 passes or 2 round trips of the roller or
approved equipment.
308.3.2. Fertilizer application: Fertilizer to the required quantities shall be spread and
thoroughly incorporated into the soil surface as a part of the seed-bed preparation.
308.3.3. Planting of seeds: All seeds shall be planted uniformly at the approved rate.
Immediately after sowing, the area shall be raked, dragged or otherwise treated so as to
cover the seeds to a depth of 6 mm.
The operation of seed sowing shall not be performed when the ground is muddy or when the
soil or weather conditions would otherwise prevent proper soil preparation and subsequent
operations.
308.3.4. Soil moisture and watering requirements: Soil-moisture shall exist throughout
the zone from 25 mm to at least 125 mm below the surface at the time of planting. Watering
of the seeded areas shall be carried out as determined by the Engineer.
308.4. Mulching, Applying Bituminous Emulsion and Jute Netting! Geonetting
Within 24 hours of seeding, mulching material mixed with organic manure shall be placed
so as to form a continuous, unbroken cover of approximate uniform thickness of 25 mm
using an acceptable mechanical blower. Mulching material shall be held in place and made
resistant to being ‘b1own away by suitable means approved by the Engineer. When called
for in the Contract documents, mulch material shall be anchored in place with bituminous
emulsion applied at the rate of 2300 litres per hectare. Any mulch disturbed or displaced-
following application shall be removed, reseeded and remulched as specified. Jute netting/
Geonetting shall be unrolled and placed parallel to the flow of water immediately following
the bringing, to finished grade, the area specified on the plans or the placing of seed and

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308.5.
fertilizer. Where more than one strip is required to cover the given areas, they shall overlap
a minimum of 100 mm. Jute netting! Geonetting shall be held in place by approved wire
staples, pins, spikes or wooden stakes driven vertically into the soil.
308.5. Maintenance
The Contractor shall maintain all seeded and mulched areas until final acceptance.
Maintenance shall include protection of traffic by approved warning signs or barricades and
repairing any areas damaged following the seeding and mulching operations. If mulched
areas become damaged, the area shall be reshaped and then seeded and mulched again
as originally specified.
308.6. Measurements for payment
Seeding and mulching shall be measured as finished work in square metres.
308.7. Rate
The Contract unit rate for seeding and mulching shall be payment in full for carrying out
all the required operations including full compensation for all materials, labour, tools and
incidentals.
309. SURFACE/SUB-SURFACE DRAINS
309.1. Scope
This work shall consist of constructing surface and for sub-surface drains in accordance
with the requirements of these Specifications and to the lines, grades, dimensions and
other particulars shown on the drawings or as directed by the Engineer.-Schedule of work
shall be so arranged that the drains are completed in proper sequence with road works to
ensure that no excavation of the completed road works is necessary subsequently or any
damage is caused to these works due to lack of drainage.
309.2. Surface Drains
Surface drains shall be excavated to the specified lines, grades, levels and dimensions to
the requirements of Clause 301. The excavated material shall be removed from the area
adjoining the- drains and if found suitable, utilised in embankment/subgrade construction.
All unsuitable material shall be disposed of as directed.
The excavated bed and sides of the drains shall be dressed to bring these in close conformity
with the specified dimensions, levels and slopes.
Where so indicated, drains shall be lined or turfed with suitable materials in accordance
with details shown on the drawings.
All works on drain construction shall be planned and executed in proper sequence with
other works as approved by the Engineer, with a view to ensuring adequate drainage for
the area and minimising erosion/sedimentation.
309.3. Sub-surface Drains
309.3.1. Scope : Sub-surface drains shall be of close-jointed perforated pipes, open-
jointed unperforated pipes, surrounded by granular material laid in a trench or aggregate
drains to drain the pavement courses. Sub-surface drains designed using Geosynthetics
and approved by the Engineer can also be used.
309.3.2. Materials
A. Pipe: Perforated pipes for the drains may be of metal/asbestos cement/cement concrete/
PVC, and unperforated pipes of vitrified clay/cement concrete/asbestos cement. The type,
size and grade of the pipe to be used shall be as specified in the Contract. In no case,

458 RED BOOK  VOLUME I  ROADS  2012

 309.3.4.
however, shall the internal diameter of the pipe be less than 100 mm. Holes for perforated
pipes shall be on one half of the circumference only and conform to the spacing indicated
on the drawings. Size of the holes shall not ordinarily be greater than half of D.; size of the
material surrounding the pipe, subject to being minimum 3 mm and maximum 6 mm. Du
stands for the size of the sieve that allows 85 per cent of the material to pass through it.
B. Backfill material: Backfill material shall consist of sound, tough, hard, durable particles
of free draining sand-gravel material or crushed stone and shall be free of organic material,
clay balls or other deleterious matter. Unless the Contract specifies any particular gradings
for the backfill material or requires these to be designed on inverted filter criteria for filtration
and permeability to the approval of the Engineer, the backfill material shall be provided on
the following lines:
(i) Where the soil met with in the trench is of fine grained type (e.g., silt, clay or a mixture
thereof), the backlill material shall conform to Class I grading set out in-Table 300-3.
(ii) Where the soil met with in the trench is of coarse silt to medium sand - or sandy type,
the backfill material shall correspond to Class II grading of Table 300-3.
(iii) Where soil met with in the trench is gravelly sand, the backfill material shall correspond
to Class Ill grading of Table 300-3.
Thickness of backfill material around the pipe shall be as shown on the drawings subject to
being at least 150 mm all-round in all cases.
Geosynthetics for use with subsurface drain shall conform to the requirements as per
Section 700.

Table 300-3. GRADING REQUIREMENTS FOR FILTER MATERIAL

<Table>

309.3.3. Trench excavation: T  rench for sub-surface drain shall be excavated to the
specified lines, grades and dimensions shown in the drawings provided that width of trench
at pipe level shall not be less than 450 mm. The excavation shall begin at the outlet end
of the drain and proceed towards the upper end. Where unsuitable material is met with at
the trench bed, the same shall be removed to such depth as directed by the Engineer and
backfilled with approved material which shall be thoroughly compacted to the specified
degree.
309.3.4. Laying of pipe and backfilling: Laying of pipe in the trench shall be started at
the outlet end and proceed towards the upper end, true to the lines and grades specified.
Unless otherwise provided, longitudinal gradient of the pipe shall not be less than 1 in 100.
Before placing the pipe, backfill material of the required grading(s) shall be laid for full width
of the trench bed and compacted to a minimum thickness of 150 mm or as shown on the
drawings. The pipe shall then be embedded firmly on the bed.
Perforated pipes, unless otherwise specified, shall be placed with their perforations down
to minimise clogging. The pipe sections shall be joined securely with appropriate coupling
fittings or bands.
Non-perforated pipes shall be laid with joints as close as possible with the open joints
wrapped with suitable pervious material (like double layer of hessian, suitable Geosynthetics
or some other material of not less than 150 mm width) to permit entry of water but prevent
fines entering the pipes. In the case of non-perforated pipes with bell end, the bell shall
face upgrade.
Upgrade end sections of the pipe installation shall be tightly closed by means of concrete
RED BOOK  VOLUME I  ROADS  2012 459
309.3.5.
plugs or plugs fabricated from the same material as the pipe and securely held in place to
prevent entry of soil materials.
After the pipe installation has been completed and- approved, backfill material of the
required grading(s) (sec Clause 309.3.2B) shall be placed over the pipe to the required
level in horizontal layers not exceeding 150 mm in thickness and thoroughly compacted.
The minimum thickness of material above the top of the pipe shall be 300 mm.
Unless otherwise provided, sub-surface drains not located below the road pavement shall
be sealed at the top by means of 150 mm thick layer of compacted clay so as to prevent
percolation of surface water.
309.3.5. Use of geosynthetic in laying of pipe and backfilling:  After excavating the
trench for subsurface drain, the filter fabric shall be placed, the pipe installed and the trench
backfilled with permeable material according to dimensions and details shown on the plans.
Surfaces to receive filter fabric prior to placing shall be free of loose or extraneous material
and sharp objects that may damage the filter fabric during installation. Adjacent rolls of
the fabric shall be overlapped a minimum of 450 mm. The preceding roll shall overlap the
following roll in the direction the material is being spread.
Damage to the fabric resulting from Contractor’s vehicles, equipment or operations shall be
replaced or repaired by the Contractor at his expense.
309.3.6. Drain outlet: The outlet for a sub-drain shall not be under ` water or plugged
with debris but should be a free outlet discharging into a stream, culvert or open ditch. The
bottom of the pipe shall be kept above high water in the ditch and the end protected with
a grate or screen. For a length of 500 mm from the outlet end, the trench for pipe shall
not be provided with granular material but backfilled with excavated soil and thoroughly
compacted so as to stop water directly percolating from the backlill material around the
pipe. The pipe in this section shall not have any perforations.
309.3.7. Aggregate drains: Aggregate drains shall be placed within the verge/shoulders
after completion of the pavement. Depth, thickness and spacing of the aggregate drains
shall be as shown on the plan.
Trenches for aggregate drains shall be excavated to a minimum width of 300 mm and to
the depth shown on the plans or ordered by the Engineer. The bottom of the trench shall be
sloped to drain and shall be free from loose particles of soil. The trench shall be excavated
so as to expose clearly the granular pavement courses to be drained.
Aggregate for the drains shall be durable gravel, stone or slag and shall be free from
vegetable matter and other deleterious substances. The grading requirements are given
at Table 300-4. Type B grading may be used only where the drain is designed to intercept
surface water flowing to the pipe and is likely to get slowly blocked. Type A grading allows
a much wider range.

TABLE 300-4. GRADING REQUIREMENTS FOR AGGREGATE IDRAINS

<Table>
309.4. Measurements for Payment
Measurement for surface and sub-surface drains shall be per running metre length of the
drain. Disposal of surplus material beyond 1000.m shall be measured in cu. m.
309.5. Rates
The Contract unit rates for surface and subsurface drains shall be payment in full for all
items such as excavation, dressing the sides and bottom; providing lining, turfing, pitching,
masonry, concrete and plastering; providing, laying and jointing pipes; providing, laying and

460 RED BOOK  VOLUME I  ROADS  2012

 312.1.
compacting backfill and bed of granular material; providing, fixing and painting of cover etc.
including full compensation for all materials, labour, tools, equipment and other incidentals
to complete the work as shown on drawings with all leads and lifts except for removal of
unsuitable material for which the lead shall be 1000 m. Provision of inlets, gratings, sumps,
outlet pipes, bedding, disbursers etc. wherever required shall be incidental to construction
of drain. The Contract unit rate for disposal of surplus and unsuitable material beyond the
initial 1000 m lead shall be in accordance with Clause 304.5.3.
310. PREPARATION AND SURFACE TREATMENT OF FORMATION
Preparation and surface treatment of the formation, that is top of the 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 or the road base where
no sub-base is required. The sequence of operations shall be as follows:
(a) All surfaces below carriageway, lay byes, footways and hard shoulders shall, after
reinstatement of any soft areas to the required Specifications be well cleaned and freed of
mud and slurry.
(b) The surface shall be compacted by 4 passes of a smooth wheeled roller of 80 to 100kN
weight after spraying requisite amount of water, if required, before the commencement of
rolling.
(c) The formation shall, wherever necessary, be regulated and trimmed to the requirements
of Clause 305.3.9 with motor grader.
(d) The trimmed formation shall be rolled by one pass of smooth wheeled roller of S0 to 100
kN weight after spraying requisite amount of water, if required, before the commencement
of rolling.
Where the completed formation is not immediately covered with sub- base or road base
material, its moisture content shall be maintained to prevent cracking in the formation by
suitable measures as approved by the Engineer. The entire work of surface treatment
`of formation shall be deemed as incidental to the work of sub—base/base course to be
provided on the subgrade and as such no extra payment shall be made for the same.
311. WORKS TO BE KEPT FREE OF WATER.
311.1. The Contractor shall arrange for the rapid dispersal of water collected/accumulated
on the earthwork or completed formation during - construction or on the existing roadway
or which enters the earthwork or any other item of work from any source, and where
practicable, the water shall be discharged into the permanent outfall of the drainage system.
The arrangements shall be made in respect of all earthworks including excavation for pipe
trenches, foundations or cuttings.
311.2. The Contractor shall provide, where necessary, temporary water courses, ditches,
drains, pumping or other means for maintaining the earthwork free from water. Such
provisions shall include carrying out the work of forming the cut sections and embankments
in such manner that their surfaces have at all times a sufficient minimum cross fall and,
where practicable, a sufficient longitudinal gradient to enable them to shed water and
prevent ponding.
The works 'involved in keeping the earthwork or any other item of works free of water shall
be deemed as incidental to the respective - item of work and as such no separate payment
shall be made for the same.
312. WATER COURSES AT CULVERTS
312.1. Excavation carried out in the diversion, enlargement, deepening or straightening

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312.1.
water courses at culverts, where necessary, shall include the operations such as clearing,
grubbing, removal of vegetation, trimming of slopes, grading of beds, disposal of excavated
materials, pumping, timbering etc. necessary for dealing with the flow of water.
312.2. The beds and sloping sides of water courses shall, where shown on the Drawings,
be protected against the action of water by rubble paving to form a flat or curved surface as
indicated. The protection shall consist of large smooth faced stones or of blocks of precast
concrete. Stones for rubble paving shall be roughly dressed square. No stone shall be less
than 255 mm in depth nor less than 0.02 cu. m. in volume and no rounded boulders shall
be used. After completion of construction of culverts, temporary diversion of water- course,
if any, shall be closed and water course restored for flow through the culvert as per the
direction of the Engineer.
312.3. Measurements for Payment
The work for water courses at culverts as stated above shall be measured in terms of units
specified in the Bill of Quantities for respective items. The temporary diversion of channel to
facilitate construction of culverts, its closure and- restoration to original water course shall
be considered incidental to the work of construction of culverts and no I extra payment shall
be made for the same.
312.4. Rates
The Contract unit rates for different items for water courses at culverts shall be payment
in full for carrying out all required operations including full compensation for all cost of
materials, labour, tools, equipment and other incidentals to complete the work to the
Specification.
313. CONSTRUCTION OF ROCKFILL EMBANKMENT
313.1. Scope
In normal circumstances, the embankment should not be constructed with rockfill material.
However, where specifically permitted by the Engineer because of imperative economic
or technical reasons, construction of rockfill embankments shall be in accordance with the
lines, grades and cross-sections as shown in drawings or as directed by the Engineer.
Rocktill shall not be used at least for a depth of 500 mm below the formation level. There
should be a minimum of 500 mm thick earthen cushion over the rockfill.
313.2. Material
The size of rock pieces used in rockfill embankments shall be such that they can be
deposited in layers so as to suit the conditions evaluated in the field compaction trials or
as directed by the Engineer. The rockfill shall consist of hard, durable and inert material,
preferably maximum size not exceeding 300 mm and per cent finer than 125 mm not
exceeding 10 per cent.
Argillaceous rocks (clay, shales etc.), unburnt colliery stock and chalk shall not be used in
rockfill.
The rock fragments and blinding material required for filling the voids shall also satisfy the
above requirements.
313.3. Spreading and Compaction
The material shall be tipped, spread and levelled in layers extending to the full width of
embankment by a suitable dozer. Fragments of rock shall then be spread on the top of
layer to the required extent and layer compacted by minimum of 5 passes of vibratory
roller having static weight 8-10 tonnes. The compacted thickness of each layer shall not
exceed 500 mm. After compaction of each layer, the surface voids shall be filled with
462 RED BOOK  VOLUME I  ROADS  2012
 313.5.
broken fragments. Next layer, where required, shall be placed in the same manner, above
the earlier compacted layer.
The top layer of rockfill, on which normal earth fill will rest, shall be thoroughly blinded with
suitable granular material to seal its surface.
313.4. Measurements for Payment
Measurement shall be made by taking cross-sections at intervals in the original position
before the work starts and after its completion and computing the volume in cu. m. by the
method of average end areas.
313.5. Rate
The Contract unit rate shall be paid in full for carrying out all the above operations including
cost of rockfill, broken fragments and blinding material and shall provide full compensation
for all items as per Clause 305.9.1 and 305.9.2.

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313.4.

464 RED BOOK  VOLUME I  ROADS  2012

 313.5.

400
SUB-BASES,
BASES (NON BITUMINOUS)
AND SHOULDERS

RED BOOK  VOLUME I  ROADS  2012 465

313.4.

466 RED BOOK  VOLUME I  ROADS  2012

 401.2.2.
401. GRANULAR SUB-BASE
401.1. Scope
This work shall consist of laying and `compacting well-graded material on prepared subgrade
in accordance with the requirements of these Specifications. The material shall be laid in
one or more layers as sub-base or lower sub-base and upper sub—base (termed as sub-
base hereinafter) as necessary according to lines, grades and cross-sections shown on the
drawings or as directed by the Engineer.
401.2. Materials
401.2.1. The material to be used for the work shall be natural sand, moorum, gravel,
crushed stone, or combination thereof depending upon the grading required. Materials
like crushed slag, crushed concrete, brick metal and kankar may be allowed only with
the specific approval of the Engineer. The material shall be free from organic or other
deleterious constituents and conform to one of the three gradings given in Table 400—1.
While the gradings in Table 400-1 are in respect of close-graded granular sub-base materials,
one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the corresponding
gradings for the coarse- graded materials for each of the three maximum particle sizes are
given at Table 400-2. The grading to be adopted for a project shall be as specified in the
Contract.
401.2.2. Physical requirements: The material shall have a 10 per cent fines value of 50
kN or more (for sample in soaked condition) when tested in compliance with BS:812 (Part
111). The water absorption value of the coarse aggregate shall be determined as per IS :
2386 (Part 3); if this value is greater than 2 per cent, the soundness test shall be carried
out on the material delivered to site as per IS : 383. For Grading II and III materials, the
CBR shall be determined at the density and moisture content likely to be developed in
equilibrium conditions which shall be taken as being the density relating to a uniform air
voids content of 5 per cent.

TABLE 400-1. GRADING FOR CLOSE-GRADED

GRANULAR SUB-BASE MATERIALS
IS Sieve Designation Per cent by weight passing the IS sieve
Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm 80-100 100 -
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
CBR Value (Minimum) 30 25 20

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401.3.
TABLE 400-2. GRADING FOR COARSE GRADED GRANULAR SUB-BASE
MATERIALS
IS Sieve Designation Per cent by weight passing the IS sieve
Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm - 100 -
26.5 mm 55-75 50-80 100
9.50 mm - - -
4.75 mm 10-30 15-35 25-45
2.36 mm - - -
0.425 mm - - -
0.075 mm <10 <10 <10
CBR Value (Minimum) 30 25 20

Note : The material passing 425 micron (0.425 mm) sieve for all the three gradings when
tested according to IS : 2720 (Part 5) shall have liquid limit and plasticity index not more
than 25 and 6 per cent respectively.
401.3. Strength of sub-base
It shall be ensured prior to actual execution that the material to be used in the sub-base
satisfies the requirements of CBR and other physical requirements when compacted and
finished.
When directed by the Engineer, this shall be verified by performing CBR tests in the
laboratory as required on specimens remoulded at field dry density and moisture content
and any other tests for the "qua1ity" of materials, as may be necessary.
401.4. Construction Operations
401.4.1. Preparation of subgrade : Immediately prior to the laying of sub-base, the
subgrade already finished to Clause 301 or 305 as applicable shall be prepared by removing
all vegetation and other extraneous matter, lightly sprinkled with water if necessary and
rolled with two passes of 80 -100 kN smooth wheeled roller.
401.4.2. Spreading and compacting: The sub-base material of grading specified in the
Contract shall be spread on the prepared subgrade with the help of a motor grader of
adequate capacity, its blade having hydraulic controls suitable for initial adjustment and for
maintaining the required slope and grade during the operation or other- means as approved
by the Engineer.
When the sub—base material consists of combination of materials mentioned in Clause
401.2.1, mixing shall be done mechanically by the mix- in-place method. •
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 mixing the material to the desired
degree. If so desired by the Engineer, trial runs with the equipment shall be carried out to
establish its suitability for the work.
Moisture content of the loose material shall be checked in accordance with IS:2720 (Part
2) and suitably adjusted by sprinkling additional water from a truck mounted or trailer
mounted water tank and suitable for applying water uniformly and at controlled quantities
to variable widths of surface or other means approved by the Engineer so that, at the

468 RED BOOK  VOLUME I  ROADS  2012

 401.8.
time of compaction, it is from 1 per cent above to 2 per cent below the optimum moisture
content corresponding to IS:2720 (Part 8). While adding water, due allowance shall be
made for evaporation losses. After water has been added, the material shall be processed
by mechanical or other approved means like disc harrows, rotavators until the layer is
uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted layer does
not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For
a compacted single layer upto 225 mm the compaction shall be done with the help of a
vibratory roller of minimum 80 to 100 kN static weight with plain drum or pad foot- drum
or heavy pneumatic tyred roller of minimum 200 to 300 kN weight having a minimum tyre
pressure of 0.7 MN/m2 or equivalent capacity roller capable of achieving the required
compaction. Rolling shall commence-at the lower edge and proceed towards the upper
edge longitudinally for portions having unidirectional crossfall and super- elevation and
shall commence at the edges and progress towards the centre for portions having crossfall
on born sides.
Each pass of the roller shall uniformly overlap not less than one— third of the track made in
the preceding pass. During rolling, the grade and crossfall (camber) shall be checked and
any high spots or depressions, which become apparent, corrected by removing or adding
fresh material. The speed of the roller shall not exceed 5 km per hour.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum
dry density for the material determined as per 15:2720 (Part 8). The surface of any layer
of material on completion of compaction shall be well closed, free from movement under
compaction equipment and from compaction planes, ridges, cracks or loose material. All
loose, segregated or otherwise defective areas shall be made good to the full thickness of
layer and re-compacted.
401.5. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.
401.6. Arrangements for Traffic.
During the period of construction, arrangement of traffic shall be maintained in accordance
with Clause 112.
401.7. Measurements for Payment Granular sub-base shall be measured as finished
work in position in cubic metres.
The protection of edges of granular sub-base extended over the full formation as shown in
the drawing shall be considered incidental to the work of providing granular sub-base and
as such no extra payment shall be made for the same.
401.8. Rate
The Contract unit rate for granular sub-base shall be payment in full for carrying out the
required operations including full compensation for:
(i) making arrangements for traffic to Clause 112 except for initial treatment to verges,
shoulders and construction of diversions;
(ii) furnishing all materials to be incorporated in the work including all royalties, fees, rents
where necessary and all leads and lifts;
(iii) all labour, tools, equipment and incidentals to complete the work to the Specifications;
(iv) carrying out the work in part widths of road where directed; and
RED BOOK  VOLUME I  ROADS  2012 469
402.
(v) carrying out the required tests for quality control.
402. LIME TREATED SOIL FOR IMPROVED SUB-GRADE/SUB-BASE
402.1. Scope
This work shall consist of laying and compacting an improved sub- grade/lower sub-base
of soil treated 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 silty Clay.
402.2. Materials
402.2.1. Soil: Except when otherwise specified, the soil used for stabilisation shall be the
local clayey soil having a plasticity index greater than 8.
402.2.2. Lime : Lime for lime-soil stabilisation work shall be commercial dry lime staked 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 per cent by weight of Quick-
time (CaO) when tested in accordance with IS :1514. Lime shall be properly stored to avoid
prolonged exposure to the atmosphere and consequent carbonation which would reduce
its binding properties.
402.2.3. 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 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 CBRIUCS stipulated
in the Contract.
402.2.4. Water:  The water to be used for lime stabilisation shall be clean and free from
injurious substances. Potable water shall be preferred.
402.3. Construction Operations
402.3.1. Weather limitations:  Lime-soil stabilisation shall not be done when the air
temperature in the shade is less than l0° C.
402.3.2. Degree of pulverisation:  For lime stabilisation, the soil before addition of stabiliser
shall be pulverised using agricultural implements like disc harrows and rotavators to the
extent that it passes the requirements set out in Table 400-3 when tested in accordance
with the method described in Appendix 3.

TABLE 400•3. SOIL PULVERISATION REQUIREMENTS

FOR LIME STABILISATION
IS Sieve designation Minimum per cent by weight
passing the IS Sieve
26.5 mm 100
5.6 mm 80
402.3.3. 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
470 RED BOOK  VOLUME I  ROADS  2012
 402.3.6.
operations, as in small-sized jobs. ‘
The equipment used for mix-in—place construction shall be a rotavator or similar approved
equipment capable of pulverising 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 shall be 200 mm, provided the plant used is accepted by the
Engineer.
402.3.4. 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.
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 subgrade 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 stabilising
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.
402.3.5. Construction with manual means: Where manual mixing is permitted, the soil
from borrow areas shall first be freed of all vegetation and other deleterious matter and
placed on the prepared subgrade. The soil shall then be pulverised 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
pulverised 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 levelled up to the required thickness so that it is ready to be rolled.
402.3.6. Addition of lime: Lime maybe 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
RED BOOK  VOLUME I  ROADS  2012 471
402.3.7.
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.
402.3.7. Moisture content for compaction: The moisture content at compaction checked
vide IS :2720 (Part 2) shall neither be less than the optimum moisture content corresponding
to IS: 2720 (Part 8) nor more than 2 per cent above it.
402.3.8. 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 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 per cent of the maximum dry density for the material determined in accordance
with IS: 2720 (Part 8).
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.
402.3.9. Curing: The sub—base course shall be suitably cured for a minimum period of7
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.
402.4. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.
402.5. 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. The extra pavement thickness needed on account of lower CBR/UCS value
shall be constructed by the Contractor at his own cost.
402.6. Arrangements of Traffic
Dining the period of construction, arrangement of traffic shall be ` maintained in accordance
with Clause 112.
402.7. Measurements for Payment
Stabilised soil sub-base shall be measured as finished work in position in cubic metres.
402.8. Rates
The Contract unit rate for lime stabilised soil sub-base shall be payment in full for carrying

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 403.2.5.
out the required operations including full compensation for all components listed in Clause
401.8 (i) to (v).
403. CEMENT TREATED SOIL SUB-BASE/BASE
403.1. Scope
This work shall consist of laying and compacting a sub-base/base. course of soil 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.
403.2. Materials
403.2.1. Material to be stabilised: 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. For use in a sub-base course, the material shall have a grading
shown in Table 400-4; 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 400-4. If the material passing 425 micron sieve is plastic, it shall have
a liquid limit not greater than 45 per cent and a plasticity index not greater than 20 per cent
determined in accordance with IS:2720 (Part 5). The physical requirements for the material
to be treated with cement for use in a base course shall be same as for Grading I Granular
Sub-base, Clause 401.2.2.
403.2.2. Cement:  Cement for cement stabilisation shall comply with the requirements of
IS: 269, 455 or 1489.

Table 400-4. GRADING LIMITS OF MATERIAL FOR STABILISATION WITH

CEMENT
Percentage by mass passing
Sub-base Base
IS Sieve Designation Finer than: Within the range:
53.0 mm 100 100
37.5 mm 95 95-100
19.0 mm 45 45-100
9.5 mm 35 35-100
4.75 mm 25 25-100
600 micron 8 8-65
300 micron 5 5-40
75 micron 0 0-10
403.2.3. Lime: If needed for pretreatment of highly clayey soils, Clause 402.2.2. shall
apply.
403.2.4. Quantity of cement in stabilised mix:  The quantity of cement to be added as
per cent by weight of the dry soil shall be specified in the Contract. Also if lime is used as
pretreatment for highly clayey soils, the quantity as per cent by weight of dry soil shall be
specified in the Contract. 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 Contract.
403.2.5. Water: The water to be used for cement stabilisation shall be clean and free from
RED BOOK  VOLUME I  ROADS  2012 473
403.3.3.
injurious substances. Potable water shall be preferred.
403.3. Construction Operations
403.3.1. Weather limitations : Stabilisation shall not be done when the air temperature in
the shade is less than 10°C.
403.3.2. Degree of pulverisation:  For stabilisation, the soil before addition of stabilizer,
shall be pulverised, where necessary, to the extent that it passes the requirements as set
out in Table 400-5 when tested in accordance with the method described in Appendix 3.

TABLE 400-5. SOIL PULVERISATION REQUIREMENTS FOR CEMENT

STABILISATION
IS Sieve designation Minimum per cent
by weightpassing the IS Sieve
26.5 mm 100
5.6 mm 80
403.3.3. Clauses 402.3.3 to 402.3.5 shall apply as regards spreading and mixing the
stabiliser except that cement or lime plus cement as the case may be, shall be used as the
stabilising material.
403.3.4. Moisture content for compaction: The moisture content at compaction checked
vide IS: 2720 (Part 2) shall not be less than the optimum moisture content corresponding
to IS: 2720 (Part 8) nor more than 2 per cent above it.
403.3.5. Rolling: Clause 402.3.8 shall apply except that care shall be taken to see that
the_c0mpaction of cement stabilised material is completed within two hours of its mixing or
such shorter period as may be found necessary in dry weather.
4033.6. 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.
403.4. Surface Finish and Quality Control of Works
The surface finish of construction shall conform to the requirements of Clause 902.
403.5. Strength Control on the quality of materials and works shall be exercised by the
Engineer in accordance with Section 900.
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.
403.6. Arrangements for Traffic During the period of construction, arrangement of traffic
shall be maintained in accordance with Clause 112.
403.7. Measurements for Payment Stabilised soil sub-base/ base shall be measured as
finished work in position in cubic metres.
403.8. Rates The Contract unit rate for cement treated soil sub-base/base with pretreatment
with lime if required shall be payment in full for carrying "•out the required operations
including full compensation for all components listed in Clause 401.8 (i) to (v).

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 404.2.3.
404. WATER BOUND MACADAM SUB—BASE/BASE
404.1. Scope
404.1.1. 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.
404.1.2. It is; however, not desirable to lay water bound macadam on an existing thin
black topped surface without providing adequate drainage facility for water that would get
accumulated at the interface of existing bituminous surface and water bound macadam;
404.2. Materials
404.2.1. Coarse aggregates: Coarse aggregates shall be either crushed or broken
stone, crushed slag, overburnt (Jhama) brick aggregates 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 per cent 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 400-6. 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 per cent, the soundness test
shall be carried out on the material delivered to site as per IS: 2386 (Part 5).
404.2.2. 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.

TABLE 400-6 PHYSICAL REQUIREMENTS OF COARSE AGGREGATES

FOR WATER BOUND MACADAM FOR SUB-BASE/BASE COURSES
Test Test Method Requirements
1. *Los Angeles Abrasion IS :2386 (Part-4) 40 per cent (Max)
value Or
* Aggregate Impact value IS :2386 (Part-4) or 30 per cent (Max)
IS:5640
2. Combined Flakiness and IS:2386 (Part-1) 30 per cent (Max)
Elongation Indices (Total)
***
* Aggregate may satisfy requirements of either of the two tests.
** Aggregates like brick metal, kankar, laterite etc. which get softened in presence of water
shall be tested for Impact value under wet conditions in accordance with IS: -5640.
*** The requirement of flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.
404.2.3. 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 kN per mg and the percentage of glossy material shall not
be more than 20. It should also comply with the following requirements:
(i) Chemical stability : To comply with requirements of appendix of BS : 1047

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404.2.4.
(ii) Sulphur content : 1 Maximum 2 per cent
(iii) Water absorption : Maximum 10 per cent
404.2.4. Overburnt (Jhama) brick aggregates: Jhama brick aggregates shall be made
from overburnt bricks or brick bats and is free from dust and other objectionable and
deleterious materials.
404.2.5. Grading requirement of coarse aggregates: The coarse aggregates shall conform
to one of the Gradings given in Table 400-7 as specified, provided; however, the use of
Grading No.1 shall be restricted to sub-base courses only.

TABLE 400-7. GRADING REQUIREMENTS OF COARSE AGGREGATES

Grading Size Range IS Sieve Designation
Per cent
No. by wei ght passing
1 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5
2 63 mm to 45 mm 90 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5
3 53 mm to 22.4 mm 63 mm 100
53 mm 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-50
Note : The compacted thickness for a layer with Grading 1 shall be 100 mm while for layer
with other Gradings i.e. 2 & 3, it shall be 75 mm.
404.2.6. 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 home 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 per
cent.
Screenings shall conform to the grading set forth in Table 400-8. The consolidated details
of quantity of screenings required for various grades of stone aggregates are given in Table
400-9. The table also gives the quantities of materials (loose) required for 10 m2 for sub-
base/base compacted thickness of 100/75 mm.
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.

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 404.3.1.
TABLE 400-8. GRADING FOR SCREENINGS
Grading Size of IS Sieve Designation Per cent by weight
Classification Screenings passing
A 13.2 mm 13.2 mm 100
11.2 mm 90-100
5.6 mm 15-35
180 micron 0-10

B 11.2 mm 11.2 mm 100

5.6 mm 90-100
180 micron 15-35

TABLE 400-9. APPROXIMATE QUANTITIES OF

COARSE AGGREGATES AND SCREENINGS REQUIRED FOR 100/75 MM
COMPACTED THICK- NESS OF WATER BOUND MACADAM (WBM)
SUB-BASEIBASE COURSE FOR 10M2 AREA
Classifica- Size Compact- Loose Screenings
tion Range ed thick- Qty. Stone Screening Crushable Type such
ness as Moorum or Gravel
Grading For-WBM Grading Loose
Classifica- Sub-base/ Classifica- Qty.
tion & size base tion & size
course
(Loose
quantity)
Grading 1 90 mm to 100 mm 1.21 to Type A 0.27 to Not 0.30 to
45 mm 1.43 m3 13.2 mm 0.30 m3 uniform 0.32 m3
Grading 2 63 mm to 75 mm 0.91 to Type A 0.12 to -do- 0.22 to
45 mm 1.07 m3 13.2 mm 0.15 m3 0.24 m3
-do- -do- -do- -do- Type B 0.20 to -do- -do-
11.2 mm 0.22 m3
Grading 3 53 mm to 75 mm -do- -do- 0.18 to -do- -do-
22.4 mm 0.21 m3

404.2.7. Binding material : Binding material to be used for water bound macadam as a filler
material meant for preventing ravelling, shall comprise of a suitable material approved by
the Engineer having a Plasticity Index(PI) value of less than 6 as determined in accordance
with IS: 2720 (Part-5).
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 mi/l0m2 and 0.08-0.10m3/10mi for 100 mm compacted thickness.
The above mentioned quantities should be taken as a guide only, for estimation of quantities
for construction etc.
Application of binding materials may not be necessary when the screenings used are of
crushable type such as moorum or gravel.
404.3. Construction Operations
404.3.1. Preparation of base: The surface of the subgrade/sub-base/base to receive the

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404.3.1.
water bound macadam course shall be prepared to the specified lines and crossfall (camber)
and made free of dust and other extraneous material. Any ruts or soft yielding places shall
be corrected in an approved manner and rolled until firm surface is obtained if necessary
by sprinkling water. Any sub-base/base/surface irregularities, where predominant, shall be
made good by providing appropriate type of profile corrective course (levelling course) to
Clause 501 of these Specifications.
As far as possible, laying water bound macadam course over an existing thick 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.
However, where the intensity of rain is low and the interface drainage facility is efficient,
water bound macadam can be laid over the existing thin bituminous surface by cutting 50
mm x .50 mm furrows at an angle of 45 degrees to the centre line of the pavement at one
metre intervals in the existing road. The directions and depth of furrows shall be such that
they provide adequate bondage and also serve to drain water to the existing granular base
course beneath the existing thin bituminous surface.
404.3.2. Inverted choke: If water bound macadam is to be laid directly over the subgrade,
without any other intervening pavement course, a 25 mm course of screenings (Grading
B) or coarse sand shall be spread on the prepared subgrade before application of the
aggregates is taken up. In ease of a fine sand or silty or clayey subgrade, it is advisable
to lay 100 mm insulating layer of screening or coarse sand on top of fine grained soil, the
gradation of which will depend upon whether it is intended to act as a drainage layer as
well, As a preferred alternative to inverted choke, appropriate geosynthetics per- forming
functions of separation and drainage may be used over the prepared subgrade as directed
by the Engineer. Section 700 shall be applicable for use of geosynthetics.
404.3.3. Spreading coarse aggregates: The coarse aggregates shall be spread uniformly
and evenly upon the prepared subgrade/sub-base/ base to proper profile by using templates
placed across the road about 6 m apart, in such quantities that the thickness of each
compacted layer is not more than 100 mm for Grading 1 and 75 mm for Grading 2 and 3,
as specified in Clause 404.2.5. Wherever possible, approved mechanical devices such as
aggregate spreader shall be used to spread the aggregates uniformly so as to minimise
the need for manual rectification afterwards. Aggregates placed at locations which are
inaccessible to the spreading equipment, may be spread in one or more layers by any
approved means so as to achieve the specified results.
The spreading shall be done from stockpiles along the side of the roadway or directly
from vehicles. No segregation of large or fine aggregates shall be allowed and the coarse
aggregate as spread shall be of uniform gradation with no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with templates and all high
or low spots remedied by removing or adding aggregates as may be required. The surface
shall be checked frequently with a straight edge while spreading and rolling so as to ensure
a finished surface as per approved drawings.
The coarse aggregates shall not normally be spread more than 3 days in advance of the
subsequent construction operations.
404.3.4. Rolling: Immediately following the spreading of the coarse aggregate - rolling
shall be started with three wheeled power rollers of 80 to 100 kN capacity or tandem or
vibratory rollers of 80 to 100 kN static weight. The type of roller to be used shall be approved
by the Engineer based on trial run.
Except on super elevated portions where the rolling shall proceed from- inner edge to the

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 404.3.6.
outer, rolling shall begin from the edges gradually progressing towards the centre. First the
edge/edges shall be compacted with roller running forward and backward. The roller shall
then move inward parallel to the centre line of the road, in successive passes uniformly
lapping preceding tracks by at least one half width.
Rolling shall be discontinued when the aggregates are partially compacted with sufficient
void space in them to permit application of screenings. However, where screenings are not
to be applied, as in the case of crushed aggregates like brick metal, laterite and kankar,
compaction shall be continued until the aggregates are thoroughly keyed. During rolling,
slight sprinkling of water may be done, if necessary. Rolling shall not be done when the
subgrade is soft or yielding or when it causes a wave-like motion in the subgrade or sub-
base course.
The rolled surface shall be checked transversely and longitudinally, with templates and any
irregularities corrected by loosening the surface, adding or removing necessary amount of
aggregates and re-rolling until the entire surface con forms to desired crossfall (camber)
and grade. In no case shall the use of screenings be permitted to make up depressions.
Material which gets crushed excessively during compaction or becomes segregated shall
be removed and replaced with suitable aggregates.
It shall be ensured that shoulders are built up simultaneously along with water bound
macadam courses as per Clause 407.4.1.
404.3.5. Application of screenings: After the coarse ' aggregate has been rolled to
Clause 404.3.4, screenings to completely fill the interstices shall be applied gradually over
the surface. These shall not be damp or wet at the time of application. Dry rolling shall be
done while the screenings are being spread so that vibrations of the roller cause them to
settle into the voids of the coarse aggregate. The screenings shall not be dumped in piles
but be spread uniformly in successive thin layers either by the spreading motions of hand
shovels or by mechanical • spreaders, or directly from Lipper with suitable grit spreading
arrangement. Tipper operating for spreading the screenings shall be so driven as not to
disturb the coarse aggregate.
The screenings shall be applied at a slow and uniform rate (in three or more applications)
so as to ensure filling of all voids. This shall be accompanied by dry rolling and brooming
with mechanical brooms, hand- brooms or both. In no case shall the screenings be applied
so fast and thick as to form cakes or ridges on the surface in such a manner as would
prevent filling of voids or prevent the direct bearing of the roller on the coarse aggregate.
These operations shall continue until no more screenings can be forced into the voids of
the coarse aggregate.
The spreading, rolling, and brooming of screenings shall be carried out in only such lengths
of the road which could be completed within one day’s operation.
404.3.6. Sprinkling of water and grouting: After the screenings have been applied, the
surface shall be copiously sprinkled with water, swept and rolled. Hand brooms shall be
used to sweep the wet screenings into voids and to distribute them evenly. The sprinkling,
sweeping and rolling operation shall be continued, with additional screenings applied as
necessary until the coarse aggregate has been thoroughly keyed, well—bonded and firmly
set in its full depth and a grout has been formed of screenings. Care shall be taken to see
that the base or subgrade does not get damaged due to the addition of excessive quantities
of water during construction.
In case of lime treated soil sub-base, construction of water bound _ macadam on top of it
can cause excessive water to flow down to the lime treated sub-base before it has picked
up enough strength (is still "green") and thus cause damage to the sub-base layer. The

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404.3.7.
laying of water bound macadam layer in such cases shall be done after the sub- base
attains adequate strength, as directed by the Engineer.
404.3.7. Application of binding material: After the application of screenings in accordance
with Clauses 404.3.5 and 404.3.6. the binding material where it is required to be used
(Clause 404.2.7) shall be applied successively in two or more thin layers at a slow and
uniform rate. After each application, the surface shall be copiously sprinkled with water, the
resulting slurry swept in with hand brooms, or mechanical brooms to fill the voids properly,
and rolled during which water shall be applied to the wheels of the rollers if necessary to
wash down the binding material sticking to them. These operations shall continue until the
resulting slurry after filling of voids, forms a wave ahead of the wheels of the moving roller.
404.3.8. Setting and drying: After the final compaction of water bound macadam COUISC,
the pavement shall be allowed to dry overnight. Next morning hungry spots shall be filled
with screenings or binding material as directed, lightly sprinkled with water if necessary and
rolled, No traffic shall be allowed on the road until the macadam has set. The- Engineer shall
have the discretion to stop hauling traffic from using the completed water bound macadam
course, if in his opinion it would cause excessive damage to the surface.
The compacted water bound macadam course should be allowed to completely dry and set
before the next pavement course is laid over it.
404.4. Surface Finish and Quality Control of Work
404.4.1. The surface finish of construction shall conform to the requirements of Clause 902.
404.4.2. Control on the quality of materials and works shall be exercised by the Engineer
in accordance with Section 900.
404.4.3. The water bound macadam work shall HOL be carried out when the atmospheric
temperature is less than 0°C in the shade.
404.4.4. Reconstruction of defective macadam: The finished surface of water bound
macadam shall conform to the tolerance of surface regularity as prescribed in Clause 902.
However, where the surface irregularity of the course exceeds the tolerances or where the
course is otherwise defective due to subgrade soil mixing with the aggregates, the course
to its full thickness shall be scarified over the affected area, reshaped with added material
or removed and replaced with fresh material as applicable and recompacted. In no case
shall depressions be filled up with screenings or binding material.
404.5. Arrangement for Traffic
During the period of construction, the arrangement of traffic shall be done as per Clause
112.
404.6. Measurements for payment
Water bound macadam shall be measured as finished work in position in cubic metres.
404.7. Rate
The Contract unit rate for water bound macadam sub-base/base course shall be payable in
full for carrying out the required operations including full compensation for all components
listed in Clause 401.8 (i) to (v) including arrangement of water used in the work as approved
by the Engineer.
405. CRUSHED CEMENT CONCRETE SUB-BASE/BASE
405.1. Scope
This work shall consist of breaking and crushing the damaged cement concrete slabs and
recompacting the same as sub-base/base _ course in one or more layers. Where specified,
480 RED BOOK  VOLUME I  ROADS  2012
 405.4.
it shall also include treating the surface of the top layer with a penetration coat of bitumen.
The work shall be performed on such widths and lengths as may be specified, in accordance
with the requirements of these Specifications and in conformity with the lines, grades and
cross-sections shown on the drawings or as otherwise directed by the Engineer.
405.2. Materials
405.2.1. Coarse aggregate: Coarse aggregate for this work shall be broken cement
concrete slabs crushed to a size not exceeding 75 mm and as far as possible, conforming
to one of the gradings given in Table 400-7.
405.2.2. Key aggregate: Key aggregate for the penetration coat shall consist of crushed
stone, crushed gravel, shingle or other stones. It shall be clean, strong, durable, of fairly
cubical shape and free of disintegrated pieces, organic or other deleterious matter and
adherent coatings. The aggregate shall be hydrophobic and of low porosity.
The- aggregate shall be of 11.2 mm size defined as 100 per cent passing through 13.2 mm
sieve and retained on 5.6 mm sieve and shall satisfy the physical requirements set forth in
Table 500-3.
405.2.3. Binder: Binder for the penetration coat for the top layer shall be bitumen of a
suitable grade, as directed by the Engineer and satisfying the requirements of IS: 73,217
or 454, as applicable or any approved cutback or emulsion, satisfying the requirements of
15:8887.
405.3. Construction Operations
405.3.1. General: Crushed cement concrete sub-base/base course may be constructed
in one or two layers, depending upon the thickness of the concrete slabs dismantled and
crushed. The thickness of each layer shall, however, not exceed 100 mm in case of sub-
base and 75 mm in case of base course. The course shall be constructed as water bound
macadam to Clause 404, using crushed cement concrete as coarse aggregate except that
no screenings or binding material need be applied. Where specified,the top layer shall be
treated with a penetration coat of binder described in Clause 405.3.2.
405.3.2. Application of penetration coat over the top layer: Before the application of
the penetration coat, the surface shall be cleaned of dust, dirt and other foreign matter,
using mechanical broom or any other equipment specified by the Engineer. Dust removed
in the process shall be blown off with the help of compressed air.
The binder shall be heated to the temperature appropriate to the grade of bitumen used
and sprayed on the dry surface in a uniform manner at the rate of 25 kg per 10 m2 area
in terms of the residual bitumen with the help of either self-propelled or towed bitumen
pressure sprayer with self-heating arrangement and spray nozzle capable of spraying
bitumen at specified rates and temperatures so as to provide a uniform, unbroken spread
of bitumen. Excessive deposits of binder caused by stopping or starting of the sprayer or
through leakage or any other reason shall be suitably corrected.
Immediately after the application of binder, the key aggregates, in a clean and dry state
shall be spread uniformly on the surface at the rate of 0.13 m3 per 10 m3 area, preferably
by means of a mechanical gritter, capable of spreading aggregate uniformly at specified
rates or otherwise manually with the approval of the Engineer, so as to cover the surface
completely. Immediately after the application of the key aggregates, the entire surface shall
be rolled to Clause 506.3.8.
405.4. Surface Finish and Quality Control of Works
The surface finish of construction shall conform to the requirements of Clause 902.

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405.5.
Control on the quality of material and works shall be exercised by the Engineer in accordance
with Section 900.
405.5. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be done as per Clause 112.
405.6. Measurements for Payment
Breaking the existing cement concrete pavement slabs, crushing and recompacting the
slab material as sub—base/base course shall be measured ` as a single item in terms of
the volume of sub-base/base laid in position in cubic metres.
Penetration coat shall be measured as finished work in square metres.
405.7. Rates
405.7.1. The Contract unit rate for crushed cement concrete sub- base/base course shall
be payment in full for carrying out the required operations including full compensation for:
(i) making arrangements for traffic to Clause 112 except for initial treatment to verges/
shoulders and construction of diversions;
(ii) breaking the cement concrete slabs, crushing, sieving and recompacting the slab
material as sub-base/base course;
(iii) all labour, tools, equipment and incidentals to complete the work to the I Specifications;
and
(iv) carrying out the work in part widths of road where directed.
405.7.2. The Contract unit rate for penetration coat shall be payment in full for carrying
out the required operations including full compensation for all components listed in
Clause 504.8.
406. WET MIX MACADAM SUB-BASE/BASE
406.1. Scope
This work shall consist of laying and compacting clean, crushed, graded aggregate and
granular material, premixed with water, to a dense mass on a prepared subgrade/sub-
base/base or existing pavement as the case may be in accordance with the requirements
of these Specifications. The material shall be laid in one or more layers as necessary to
lines, grades and cross—sections shown on the approved drawings or as directed by the
Engineer.
The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm.
When vibrating or other approved types of compacting equipment are used, the compacted
depth of a single layer of the sub-base course may be increased to 200 mm upon approval
of the Engineer.
406.2. Materials
406.2.1. Aggregates
406.2.1.1. Physical requirements: Coarse aggregates shall be crushed stone. If crushed
gravel/shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces
retained on 4.75 mm sieve shall have at least two fractured faces. The aggregates shall
conform to the physical requirements set forth in Table 400-10 below.

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 406.3.2.
TABLE 400-10. PHYSICAL REQUIREMENTS OFCOARSE AGGREGATES FOR
WET MIX-MACADAM FOR SUB BASEJBASE COURSES
Test Test Method Requirements
1. *Los Angeles Abrasion 40 per cent (Max.)
value
or
Aggregate Impact value IS: 2386 (Part-4) 30 per cent (Max.)
or IS :5640
2 *Combined Flakiness and IS: 2386 (Part-1) 30 per cent (Max.)**
Elongation indices (Total)
* Aggregate may satisfy requirements of either of the two tests.
** To determine this combined proportion, the flaky stone from a representative sample
should first be separated out. Flakiness index is weight of flaky stone _meta| divided by
weight of stone sample. Only the elongated particles be separated out from the remaining
(non-fIaky) stone metal. Elongation index is weight of elongated particles divided by total
non-flaky particles. The value of flakiness index and elongation index so found are added
up.
If the water absorption value of the coarse aggregate is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part-5).
406.2.1.2. Grading requirements: The aggregates shall conform to the grading given in
Table 400-11.

TABLE 400-11. GRADING REQUIREMENTS OF AGGREGATES

FOR WET MIX MACADAM
IS Sieve Designation Per cent by weight passing the IS sieve
53.00 mm 100
45.00 mm 95-100
26.50 mm -
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well graded from coarse to fine
and shall not vary from the low limit on one sieve to the high- limit on the adjacent sieve or
vice versa.
406.3. Construction Operations
406.3.1. Preparation of base: Clause 404.3.1. shall apply.
406.3.2. 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 macadam layer and following the sequence of operations described in
Clause 407.4.1.

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406.3.3.
406.3.3. Preparation of mix: Wet Mix Macadam shall be prepared in an approved mixing
plant of suitable capacity having provision for controlled addition of water and forced/
positive mixing arrangement like pugmill or pan type mixer of concrete batching plant. For
small quantity of wet mix work, the Engineer may permit the mixing to be done in concrete
mixers.
Optimum moisture for mixing shall he determined in accordance with IS:2720 (Part-8) after
replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to
22.4 mm size. While adding water, due allowance should be made for evaporation losses.
However, at the time of compaction, water in the wet mix should not vary from the optimum
value by more than agreed limits. The mixed material should be uniformly wet and no
segregation should be permitted.
406.3.4. Spreading of mix: Immediately after mixing, the aggregates shall be spread
uniformly and evenly upon the prepared subgrade/sub- base/base in required quantities. In
no case should these be dumped in heaps directly on the area where these are to be laid
nor shall their hauling over a partly completed stretch be permitted.
The mix may be spread either by a paver finisher or motor grader. For portions where
mechanical means cannot be used, manual means as approved by the Engineer shall be
used. The motor grader shall be capable of spreading the material uniformly all over the
surface. Its blade shall have hydraulic control suitable for initial adjustments and maintaining
the same so as to achieve the specified slope and grade.
The paver finisher shall be self-propelled, having the following features:
(i) Loading hoppers and suitable distribution mechanism
(ii) The screed shall have tamping and vibrating arrangement for initial compaction to the
layer as it is spread without rutting or otherwise marring the surface profile.
(iii) The paver shall be equipped with necessary control mechanism so as to ensure that
the finished surface is free from surface blemishes.
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.
406.3.5. 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 100 kN 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 or equivalent capacity roller. The speed of the roller shall not exceed 5 km/h.
In portions having unidirectional cross fall/superelevation, rolling shall commence from
the lower edge and progress gradually towards the upper edge. Thereafter, roller should
progress parallel to the centre line of the road, uniformly over-lapping each preceding track
by at least one third width until the entire surface has been rolled. Alternate trips of the roller
shall be terminated in stops at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running forward and
backward until the edges have been firmly compacted. The roller shall then progress
gradually towards the centre parallel to the centre line of -the road uniformly overlapping
each of the preceding track by at least one-third width until the entire surface has been
rolled.

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 407.1.
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 for removed and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall be
thoroughly compacted with mechanical tampers or a plate compactor. Skin patching of an
area without scarifying the surface to permit proper bonding of the added material shall not
be permitted.
Rolling should not be done when the subgrade is soft or yielding or when it causes a
wave-like motion in the sub—base/base course or subgrade. If irregularities develop during
rolling which exceed 12 mm when tested with a 3 metre straight edge, the surface should
be loosened and premixed material added or removed as required before rolling again so
as to achieve a uniform surface conforming to the desired grade and crossfall. In no case
should the use of unmixed material be permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the maximum
dry density for the material as determined by the method outlined in IS: 2720 (Part-8)
After completion, the surface of any finished layer shall be well- closed, free from movement
under compaction equipment or any compaction planes, ridges, cracks and loose material.
All loose, segregated or otherwise defective areas shall be made good to the full thickness
of the layer and recompacted.
406.3.6. Setting and drying: After final compaction of wet mix macadam course, the road
shall be allowed to dry for 24 hours.
406.4. Opening to Traffic Preferably no vehicular traffic of any kind should be allowed on
the finished wet mix macadam surface till it has dried and the wearing course laid.
406.5. Surface Finish and Quality Control of Work
406.5.1. Surface evenness: The surface finish of construction shall conform to the
requirements of Clause 902.
406.5.2. Quality control : Control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 900.
406.6. Rectification of Surface Irregularity
Where the surface irregularity of the wet mix macadam course exceeds the permissible
tolerances or where the course is otherwise defective due to subgrade soil 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 in accordance with Clause 406.3. The area treated
in the aforesaid manner shall not be less than 5 in long and 2 m wide. In no case shall
depressions be filled up with unmixed and ungraded material or fines.
406.7. Arrangement for Traffic
During the period of construction, arrangement of traffic shall be done as per Clause 112.
406.8. Measurements for Payment
Wet mix macadam shall be measured as finished work in position in cubic metres.
406.9. Rates
The Contract unit rate for wet mix macadam shall be payment in full for carrying out the
required operations including full compensation for all components listed in Clause 401.8.
407. SHOULDERS, ISLANDS AND MEDIAN
407.1. Scope

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407.2.
The work shall consist of constructing shoulder (hard/paved/ earthen with brick or stone
block edging) on either side of the pavement, median in the road dividing the carriageway
into separate lanes and islands for channelising the traffic at junctions in accordance with
the requirements of these Specifications and in conformity with the lines, grades and cross-
sections shown on the drawings or as directed by the Engineer.
407.2. Materials Shoulder on either side of the road may be of selected earth/granular
material/paved conforming to the requirements of Clause 305/401 and the median may be
of selected earth conforming to the requirements of Clause 305.
Median/Traffic islands shall be raised and kerbed at the perimeter and the enclosed area
filled with earth and suitably covered with grass turf/shrubs as per Clause 307 and/or paved
as per Clause 409.3.4 or 409.3.5.
Paved shoulders shall consist of sub-base, base and surfacing courses, as shown in
the drawings and materials for the same shall conform to relevant Specifications of the
corresponding items. Where paved or hard shoulders are not provided, the pavement shall
be provided with brick/stone block edgings as shown in the drawings. The bricks shall
conform to Clause 1003 of these Specifications. Stone blocks shall conform to Clause 1004
of these Specifications and shall be of size 225 mm x 110 mm x 75 mm.
407.3. Size of Shoulders/Median/Islands Shoulder (earthen/hard/paved)/median/traffic
island dimensions shall be as shown on the drawings or as directed by the Engineer.
407.4. Construction Operations
407.4.1. Shoulder: The sequence of operations shall be such that the construction of
paved shoulder is done in layers each matching the thickness of adjoining pavement layer.
Only after a layer of pavement and corresponding layers in paved and earth shoulder
portion have been laid and compacted, the construction of next layer of pavement and
shoulder shall be taken up.
Where the materials in adjacent layers are different, these shall be laid together and the
pavement layer shall be compacted first. The corresponding layer in paved shoulder portion
shall be compacted thereafter, which shall be followed by compaction of earth shoulder
layer. The adjacent layers having same material shall be laid and compacted together.
In all cases where paved shoulders have to be provided along side of existing carriageway,
the existing shoulders shall be excavated in full width and to the required depth as per
Clause 301.3.7. Under no circumstances, box cutting shall be done for construction of
shoulders.
Compaction requirement of earthen shoulder shall be as per Table 300-2. In the case
of bituminous courses, work on shoulder (earthen! hard/paved), shall start only after the
pavement course has been laid and compacted.
During all stages of shoulder (earthen/hard/paved) construction, the required crossfall shall
be maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be placed
directly on the shoulder. Any spilled material dragged on to the pavement surface shall
be immediately removed, without damage to the pavement, and the area so affected
thoroughly cleaned.
407.4.2. Median and islands: Median and Islands shall be constructed in a manner
similar to shoulder up to the road level. Thereafter the median and islands, if raised, shall
be raised at least 300 mm by using kerb stones of approved material and dimensions and
suitably finished and painted as directed by the Engineer. If not raised, the median and
islands shall be differentiated from the shoulder pavement as the case may be, as directed
486 RED BOOK  VOLUME I  ROADS  2012
 408.5.
by the Engineer. The confined area of the median and islands shall be filled with local earth
or granular material or any other approved material and compacted by plate compactor/
power rammer. The confined area after filling with earth shall be turfed with grass or planted
with shrubs and in case of granular fill it can be finished with tiles/slabs as directed by the
Engineer.
407.4.3. Brick/stone block edging: The bricks/stone blocks shall be laid on edge, with
the length parallel to, the transverse direction of the road. They shall be laid on a bed of 25
mm sand, set carefully, rolled into position by a light roller and made flush with the finished
level of the pavement.
407.5. Surface Finish and Quality Control of Works
The surface finish of construction shall conform to the requirements of Clause 902. Control
on the quality of materials and works shall be exercised by the Engineer in accordance with
Section 900.
407.6. Measurements for Payment Shoulder (earthen/hard/paved), island and median
construction shall be measured as finished work in position as below:
(i) For excavation in cu. m.
(ii) For earthwork/granular fill in cu. m.
(iii) For sub-base, base, surfacing courses in units as for respective items.
(iv) For kerb in running metres.
(v) For turfing and tile/slab finish in sq.m.
(vi) For brick/stone block edging in sq.m.
407.7. Rate
The Contract unit rate for shoulder (hard/paved/earthen with brick or stone block edging),
island and median construction shall be payment in full for carrying out the required
operations including full compensation for all components listed in Clause 401.8 (i) to (v)
as applicable. The rate for brick/stone block edging shall include the cost of sand cushion.
408. CEMENT CONCRETE KERB AND KERB WITH CHANNEL
408.1. Scope
This work shall consist of constructing cement concrete kerbs and kerbs with channel in the
central median and/or along the footpaths - or separators in conformity with the lines, levels
and dimensions as specified in the drawings.
408.2. Materials Kerbs and kerb with channel shall be provided in cement concrete of
Grade M20 in accordance with Section 1700 of these Specifications.
408.3. Type of Construction
These shall be cast-in-situ construction with suitable kerb casting machine in all situations
except at locations where continuous casting with equipment is not practicable. In those
situations, precast concrete blocks shall be used.
408.4. Equipment
A continuous kerb casting equipment of adequate capacity and controls, capable of laying
the kerbs in required cross-sections and producing a well-compacted mass of concrete free
of voids and honeycombs, shall be used.
408.5. Construction Operations
408.5.1. Kerb shall be laid on firm foundation of minimum 150 mm thickness of cement
concrete of M10 grade cast in-situ or on extended width of pavement. The foundation shall
RED BOOK  VOLUME I  ROADS  2012 487
409.
have a projection of 50 mm beyond the kerb stone. Before laying the foundation of lean
concrete, the base shall be levelled and slightly watered to make it damp.
408.5.2. In the median portions in the straight reaches, the kerb shall be cast in continuous
lengths. I n the portions where footpath is provided and/or the slope of the carriageway is
towards median (as in case of superelevated portions), there shall be sufficient gap/recess
left in the kerb to facilitate drainage openings.
408.5.3. After laying the kerbs and just prior to hardening of the concrete, saw cut grooves
shall be provided at 5 m intervals or as specified by the Engineer.
408.5.4. Kerbs on the drainage ends such as along the footpath or the median in
superelevated portions shall be cast with monolithic concrete channels as indicated in
drawings. The slope of the channel towards drainage pipes shall be ensured for efficient
drainage of the road surface.
408.5.5. Vertical and-horizontal tolerances with respect to true line and level shall be 1 6
mm.
408.6. Measurements for Payment Cement concrete kerb/kerb with channel shall be
measured in linear metre for the complete item of work.
Foundation of kerb, where separately provided shall be measured in linear metre for
complete item of work.
408.7. Rates
The Contract unit rates for cement concrete kerb/kerb with channel and foundation for kerb
shall be payment in full compensation for furnishing all materials, labour, tools, equipment
for construction and other incidental cost necessary to complete the work. .
409. FOOTPATHS AND SEPARATORS
409.1. Scope
The work shall consist of constructing footpaths and/or separators at locations as specified
in the drawings or as directed by the Engineer. The lines, levels and dimensions shall be as
per the drawings. The scope of the work shall include provision of all drainage arrangements
as shown in the drawings or as directed.
409.2. Materials: The footpaths and separators shall be constructed with any of the
following types:
(a) Cast-in-situ cement concrete of Grade M20 as per Section 1700 of the Specifications.
(b) Precast cement concrete blocks/tiles of Grade M20 as per Section 1700 of the
Specifications. The minimum thickness of the cement concrete block/tile shall be 25
mm and minimum size shall be 300 mm it 300 mm.
(c) Natural stone slab cut and dressed from stone of good and sound quality, uniform in
texture, free from defects and at least equal to a sample submitted by the Contractor
and approved by the Engineer. The minimum thickness of the natural stone slab
shall be 25 mm and minimum size shall be 300 mm x 300 mm.
409.3. Construction Operations
409.3.1. Drainage pipes below the footpath originating from the kerbs shall be first laid in
the required slope and connected to the drains/sumps/storm water drain/drainage chutes
as per provisions of the drawings, or as specified.
409.3.2. Portion on back side of kerbs shall be filled and compacted with granular sub-
base material as per Clause 401 of the Specifications in specified thickness.

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 410.2.
409.3.3. The base shall be prepared and finished to the required lines, levels and dimensions
as indicated in the drawings with the following :-
(a) Minimum 150 mm thick, compacted granular sub-base material as per Clause 401
of the Specifications.
(b) Minimum 25 mm thick cement concrete of Grade M 15.
Over the prepared base, precast concrete blocks/tiles/natural stone slabs and/or cast-in-
situ slab shall be set/laid as described in Clauses 409.3.4 and 409.3.5.
409.3.4. Precast cement concrete blocks/tiles/natural stone slab: The blocks/tiles/
slabs shall be set on a layer of average 12 mm thick cement- sand mortar (1:3) laid on
prepared base in such a way that there is no rocking. The gaps between the blocks/tiles/
slabs shall not be more than 12 mm and shall be filled with cement—sand mortar (1:3).
409.3.5. Cast—in-situ cement concrete: The minimum thickness of the cement concrete
shall be 25 mm and it shall be cast on the prepared base in panels of specified size in
a staggered manner. Construction joints shall be provided as per Section 1700 of the
Specifications.
409.4. Measurements for Payment
Footpaths and separators shall be measured in sq.metre between inside of kerbs.
Rates Contract unit rates shall be inclusive of full compensation of all labour,
409.5. 
materials, tools, equipment and incidentals to construction of footpaths. Cost of providing
pipes and arrangement for their discharge into appropriate n drainage channels shall be
incidental to the construction of footpaths.
410. CRUSHER-RUN MACADAM BASE
410.1. Scope
This work shall consist of furnishing, placing and compacting crushed stone aggregate
sub—base and base courses constructed in accordance with the requirements set forth
in this Specification and in conformity with the lines, — grades, thicknesses and cross-
sections shown on the plans or as directed by the Engineer.
410.2. Materials
The material to be used for the work shall be crushed rock. If crushed gravel/shingle is
used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm
sieve shall have at least two fractured faces. It shall be free from any organic matter and
other deleterious substances and shall be of such nature that it can be compacted readily
under watering and
rolling to form a firm, stable base. The aggregate shall conform to the grading and quality
requirements shown in Tables 400- 12 and 400-13.
At the option of the Contractor, the grading for either 53 mm maximum size or 37.5 mm
maximum size shall be used, except that once a grading is selected, it shall not be changed
without the Engineer’s approval.

TABLE 400.12. AGGREGATE GRADING REQUIREMENTS

Sieve Size Percent passing by weight
53 mm max. size 3 7.5 mm max. size
63 mm 100 -
45 mm 87-100 100
22.4 mm 50-85 90-100

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410.3.
5.6 mm 25-45 35-55
710 micron 10-25 10-30
90 micron 2-9 2-9

TABLE 400-13. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES

FOR CRUSHER-RUN MACADAM BASE
Test Test Method Requirements
1. *Los Angeles Abrasion value IS: 2386 (Part-4) 40 per cent Maximum
or
*Aggregate Impact value IS: 2386 (Part—4) 30 per cent Maximum
or IS :5640
2 Combined Flakiness and
Elongation indices (Total) IS: 2386 (Part-1) 30 per cent Maximum
***
3 ** Water absorption IS : 2386 (Part-3) 2 per cent Maximum
4 Liquid Limit of material passing IS : 2720 (Part-5) Not more than 25
425 micron
5 Plasticity Index of material IS : 2720 (Part-5) Not more than 6
passing 425 micron
* Aggregate may satisfy requirements of either of the two tests.
** If the water absorption is more than 2 per cent, soundness test shall be carried out as
per IS:2386 (Part-5).
*** To determine this combined proportion, the flaky stone from a representative sample
should first be separated out. Flakiness index is weight of flaky stone metal divided by
weight of stone sample. Only the elongated particles be separated out from the remaining
(non-flaky) stone metal. Elongation index is weight of elongated particles divided by total
non-flaky particles. The value of flakiness index and elongation index so found are added
up.
410.3. Construction Operations
410.3.1. Preparation of subgrade: Any nits, deformations or soft yielding places which
occur in the sub-base or subgrade shall be corrected and compacted to the required density
before the aggregate base course is placed thereon.
410.3.2. Spreading, watering, mixing and compaction: The aggregate shall be uniformly
deposited on the approved subgrade by means of the hauling vehicle with or without
spreading devices. Aggregate will be distributed over the surface to the depth specified on
the plans or as directed by the Engineer.
After the base course material has been deposited, it shall be thoroughly blade-mixed to full
depth of the layer by alternately blading the entire layer to the centre and back to the edges
of the road. It shall then be spread and finished to the required cross-section by means
of a motor grader. Water shall: be applied prior to and during all blading and processing
operations to moisten the material sufficiently to prevent segregation of the fine and coarse
particles.
Water shall be applied in sufficient amounts during construction to assist in compaction.
Alternatively, mixing of the crusher run material and water may be done in a mixing plant
as per Clause 406.3.3.

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 410.7.
Compaction shall commence immediately after the spreading operation. If the thickness
of single compacted layer does not exceed 100 mm, a smooth wheel roller of 80 to100 kN
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 or equivalent
capacity roller. The speed of the roller shall not exceed 5 km/h. Each layer of material shall
be compacted to not less than 98 per cent of the maximum density as determined by IS:
2720 (Part-8).
410.4. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902.
Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.
410.5. Arrangements for Traffic
During the period of construction, arrangement of traffic shall be maintained in accordance
with Clause 112.
410.6. Measurements for Payment
Crusher-run macadam base shall be measured as finished work in position in cubic metres.
410.7. Rate
The Contract unit rate for crusher run macadam base shall be payment in full for carrying
out the required operations including full compensation for items as in Clause 401.8
(i) to (v).

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410.3.

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 500
BASES AND
SURFACE COURSES
(BITUMINOUS)

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494 RED BOOK  VOLUME I  ROADS  2012
501. GENERAL REQUIREMENTS FOR BITUMINOUS - PAVEMENT LAYERS
501.1. General
Bituminous pavement courses shall be made using the materials described in the following
Specifications.
The use of machinery and equipment mentioned in various Clauses of these Specifications
is mandatory. Details of the machinery and equipment are available in the Manual for
Construction and Supervision of Bituminous Works. Equipment mandatory for any particular
project shall be in accordance with the Contract Specification for that project.
501.2. Materials
501.2.1. Binder: The binder shall be an appropriate type of bituminous material complying
with the relevant Indian Standard (IS), as defined in the appropriate Clauses of these
Specifications, or as otherwise specified herein. The choice of binder shall be stipulated in
the Contract or by the Engineer. Where penetration grades of bitumen are specified, they
are referred to by a single—figure designation in accordance with IS:73. Thus bitumen
grade 35 refers to bitumen in the penetration range 30 to 40. Where Modified Binder is
specified, the Clause 521 of these Specifications shall apply.
501.2.2. Coarse Aggregates: The coarse aggregates shall consist of crushed rock,
crushed gravel or other hard material retained on the 2.36 mm sieve. They shall be clean,
hard, durable of cubical shape, free from dust and soft or friable matter, organic or other
deleterious matter. Where the Contractor’s selected source of aggregates have poor
affinity for bitumen, as a condition for the approval of that source, the bitumen shall be
treated with approved anti—stripping agents, as per the manufacturer’s recommendations,
without additional payment. Before approval of the source the aggregates shall be tested
for stripping.
The aggregates shall satisfy the physical requirements set forth in the individual relevant
clause for the material in question.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of
the crushed material retained on the 4.75 mm sieve shall have at least two fractured faces.
501.2.3. Fine Aggregates: Fine aggregates shall consist of crushed or naturally occurring
material, or a combination of the two, passing 2.36mm sieve and retained on the 75 micron
sieve. They shall be clean, hard, durable, dry and free from dust, and soft or friable matter,
organic or other deleterious matter.
501.2.4. Source of material: The source of all materials to be used on the project must
be tested to the satisfaction of and be expressly approved by the Engineer. The Engineer
may from time to time withdraw approval of a specific source, or attach conditions to the
existing approval. Any change in aggregate source for bituminous mixes, will require a
new mix design, and laying trials, where the mix is based on a job mix design. Stockpiles
from different sources, approved or otherwise, shall be kept separate, such that there is no
contamination between one material and another. Each source submitted for approval shall
contain sufficient material for at least 5 days work.
501.3. Mixing
Pre-mixed bituminous materials, including bituminous macadam, dense bituminous
macadam, semi-dense bituminous concrete and bituminous concrete, shall be prepared in
a hot mix plant of adequate capacity and capable of yielding a mix of proper and uniform
quality with thoroughly coated aggregates. Appropriate mixing temperatures can be found
in Table 500-5 of these Specifications; the difference in temperature between the binder

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and aggregate should at no time exceed 14°C. In order to ensure uniform quality of the mix
and better coating of aggregates, the hot mix plant shall be calibrated from time to time.
If a continuous mixing plant is to be used for mixing the bituminous bound macadam, the
Contractor must demonstrate by laboratory analysis that the cold feed combined grading
is within the grading limits specified for that bituminous bound material. In the case of
a designed job mix, the bitumen and filler content shall be derived using this combined
grading. Further details are available in the Manual for Construction and Supervision of
Bituminous Works.
501.4. Transporting
Bituminous materials shall be transported in clean insulated vehicles, and unless otherwise
agreed by the Engineer, shall be covered while in transit or awaiting tipping. Subject to the
approval of the Engineer, a thin coating of diesel or lubricating oil may be applied to the
interior of the vehicle to prevent sticking and to facilitate discharge of the material.
501.5. Laying
501.5.1. Weather and seasonal limitations: Laying shall be suspended while free-
standing water is present on the surface to be covered, or during rain, fog and dust storms.
After rain, the bituminous surface, prime or tack coat, shall be blown off with a high pressure
air jet to remove excess moisture, or the surface left to dry before laying shall start. Laying
of bituminous mixtures shall not be carried out when the air temperature at the surface on
which it is to be laid is below l0°C or when the wind speed at any temperature exceeds 40
km/h at 2m height unless specifically approved by the Engineer.
501.5.2. Cleaning of surface: The surface on which the bituminous work is to be laid shall
be cleaned of all loose and extraneous matter by means of a mechanical broom or any
other approved equipment / method as specified in the contract. The use of a high pressure
air jet from a compressor to remove dust or loose matter shall be available full time on the
site, unless otherwise specified in the Contract.
501.5.3. Spreading: Except in areas where a mechanical paver cannot access,
bituminous materials shall be spread, levelled and tamped by an approved self-propelled
paving machine. As soon as possible after arrival at site, the materials shall be supplied
continuously to the paver and laid without delay.
The rate of delivery of material to the paver shall be regulated to enable the paver to
operate continuously. The travel rate of the paver, and its method of operations, shall be
adjusted to ensure an even and uniform flow of bituminous material across the screed, free
from dragging, tearing and segregation of the material. In areas with restricted space where
a mechanical paver cannot be used, the material shall be spread, raked and levelled with
suitable hand tools by experienced staff, and compacted to the satisfaction of the Engineer.
The minimum thickness of material laid in each paver pass shall be in accordance with the
minimum values given in the relevant parts of these Specifications. When laying binder
course or wearing course approaching an expansion joint of a structure, machine laying
shall stop 300mm short of the joint- The remainder of the pavement up to the joint, and the
corresponding area beyond it shall be laid by hand, and the joint or joint cavity shall be kept
clear of surfacing material.
Bituminous material, with a temperature greater than 145°C, shall not be laid or deposited
on bridge deck waterproofing systems, unless precautions against heat damage have been
approved by the Engineer.
Hand placing of pre-mixed bituminous materials shall only be permitted in the following
circumstances:

496 RED BOOK  VOLUME I  ROADS  2012

 (i) For laying regulating courses of irregular shape and varying thickness.
(ii) In confined spaces where it is impracticable for a paver to operate.
(iii) For footways.
(iv) At the approaches to expansion joints at bridges, viaducts or other structures.
(v) For laying mastic asphalt in accordance with Clause 515.
(vi) For filling of potholes.
(vii) Where directed by the Engineer.
Manual spreading of pre-mixed wearing course material or the addition of such material by
hand-spreading to the paved area, for adjustment of level, shall only be permitted in the
following circumstances:
(i) At the edges of the layers of material and at gullies and manholes.
(ii) At the approaches to expansion joints at bridges, viaducts or other structures.
(iii) As directed by the Engineer.
501.5.4. Cleanliness and overlaying: Bituminous material shall be kept clean and
uncontaminated. The only traffic permitted to run on bituminous material to be overlaid
shall be that engaged in laying and compacting the next course or, where a binder course
is to be sealed or surface dressed, that engaged on such surface treatment. Should
any bituminous material become contaminated the Contractor shall make it good to the
satisfaction of the Engineer, in compliance with Clause 501.8.
Binder course material shall not remain uncovered by either the wearing course or surface
treatment, whichever is specified in the Contract, for more than three consecutive days
after being laid. The Engineer may extend this period, by the minimum amount of time
necessary, because of weather conditions or for any other reason. If the surface of the base
course is subjected to traffic, or not covered within three days, a tack coat shall be applied,
as directed by the Engineer.
501.6. Compaction
Bituminous materials shall be laid and compacted in layers which enable the specified
thickness, surface level, regularity requirements and compaction to be achieved.
Compaction of bituminous materials shall commence as soon as possible after laying.
Compaction shall be substantially completed before the temperature falls below the
minimum rolling temperatures stated in the relevant part of these Specifications. Rolling
of the longitudinal joints shall be done immediately behind the paving operation. After this,
rolling shall commence at the edges and progress towards the centre longitudinally except
that on super elevated and unidirectional cambered portions, it shall progress from the
lower to the upper edge parallel to the centre line of the pavement. Rolling shall continue
until all roller marks have been removed from the surface. All deficiencies in the surface
after laying shall be made good by the attendants behind the paver, before initial rolling is
commenced. The initial or breakdown rolling shall be done with 8-10 tonnes dead weight
smooth wheeled rollers. The intermediate rolling shall be done with 8-10 tonnes dead
weight or vibratory roller or with a pneumatic tyred roller of l2 to l5 tonnes weight having
nine wheels, with a tyre pressure of at least 5.6 kg/sq.cm. The finish rolling shall be done
with 6 to 8 tonnes smooth wheeled tandem rollers.
Where compaction is to be determined by density of cores the requirements to__ prove
the performance of rollers shall apply in order to demonstrate that the specified density
can be achieved. In such cases the Contractor shall nominate the plant, and the method
by which he intends to achieve the specified level of compaction and finish at temperatures

RED BOOK  VOLUME I  ROADS  2012 497

above the minimum specified rolling temperature. Laying trials shall then demonstrate the
acceptability of the plant and method used.
Bituminous materials shall be rolled in _a longitudinal direction, with the driven rolls nearest
the paver. The roller shall first compact material adjacent to joints and then work from the
lower to the upper side of the layer, overlapping on successive passes by at last one-third
of the width of the rear roll or, in the case of a pneumatic—tyred roller, at least the nominal
width of 300mm
In portions with super-elevated and uni-directional camber, after the edge has been rolled,
the roller shall progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall not be
permitted to stand on pavement which has not been fully compacted, and necessary
precautions shall be taken to prevent dropping of oil, grease, petrol or other foreign matter
on the pavement either when the rollers are operating or standing. The wheels of rollers
shall be kept moist with water, and the spray system provided with the machine shall be
in good working order, to prevent the mixture from adhering to the wheels. Only sufficient
moisture to prevent adhesion between the wheels of rollers and the mixture should be
used. Surplus water shall not be allowed to stand on the partially compacted pavement.
501.7. Joints
Where longitudinal joints are made in pre-mixed bituminous materials, the materials shall
be fully compacted and the joint made flush in one of the following ways; only method (iii)
shall be used for transverse joints:
(i) by heating the joints with an approved joint heater when the adjacent width is being
laid, but without cutting back or coating with binder. The heater shall raise the
temperature of the full depth of material, to within the specified range of minimum
rolling temperature and maximum temperature at any stage for the material, for a
width not less than 75 mm. The Contractor shall have equipment available, for use
in the event of a heater breakdown, to form joints by method (iii);
(ii) by using two or more pavers operating in echelon, where this is practicable, and in
sufficient proximity for adjacent widths to be fully compacted by continuous rolling;
(iii) by cutting back the exposed joint, for a distance equal to the specified layer thickness,
to a vertical- face, discarding all loosened material and coating the vertical face
completely with 80/100 penetration grade hot bitumen, or cold-applied bitumen, or
polymer modified adhesive bitumen tape with a minimum thickness of 2 mm, before
the adjacent width is laid.
All joints shall be offset at least 300 mm from parallel joints in the layer beneath or as directed,
and in a layout approved by the Engineer. Joints in the wearing course shall coincide with
either the lane edge or the lane marking, whichever is appropriate. Longitudinal joints shall
not be situated in wheel track zones.
501.8. Preparation of Surface
501.8.1. Scope: This work shall consist of preparing an existing granular or black-topped
surface bituminous course. The work shall be performed on such widths and lengths as
shown on the drawings or as instructed by the Engineer. The existing surface shall be firm
and clean, and treated with Prime or Tack coat as shown on the drawings as otherwise
stated in the Contract.
501.8.2. Materials
501.8.2.1. For scarifying and re-laying the granular surface:  The material used shall be
coarse aggregate salvaged from the scarification of the existing granular base course
498 RED BOOK  VOLUME I  ROADS  2012
supplemented by fresh coarse aggregate and screenings so that aggregates and screenings
thus supplemented correspond to Clause 404: Water Bound Macadam or Clause 406: Wet
Mix Macadam
501.8.2.2. For patching potholes and sealing cracks:  Where the existing surface to be
overlaid is bituminous, any existing potholes and cracks shall be repaired and sealed in
accordance with Clauses 3004.2 and 3004.3, or as directed by the Engineer.
501.8.2.3. For profile corrective course:  A profile corrective course for correcting the
existing pavement profile shall be laid to varying thickness as shown on the Drawings,
or as indicated in the Contract Documents. The profile corrective course shall be laid to
tolerances and densities as specified for wearing course if a single layer, or base course, if
it is to be covered with a wearing course layer.
501.8.2.4. Profile corrective course and its application:  The type of material for use as
profile corrective course shall be as shown on the drawings or as directed by the Engineer.
Where it is to be laid as pan of the overlay/strengthening course, the profile corrective
course material shall be of the same specification as that of the overlay/strengthening
course. However, if provided as a• separate layer, it shall be of the specification and details
given in the contract drawings.
(i) Any high spots in the existing surface shall be removed by a milling machine or other
approved method, and all loose material shall be removed to the satisfaction of the
Engineer.
(ii) Where the maximum thickness of profile corrective course will be not more than
40 mm, the profile corrective course shall be constructed as an integral part of the
overlay course. In other cases, the profile corrective course shall be constructed as
a separate layer, adopting such construction procedures and using such equipment
as approved by the Engineer, to lay the specified type of material, to thickness and
tolerance as specified, for the course, to be provided.
501.8.3. Construction Operations
501.8.3.1. Preparing existing granular surface: Where the existing surface is granular,
all loose materials shall be removed, and the surface lightly watered where the profile
corrective course to be provided as a separate layer is also granular. Where the profile
corrective course of bituminous material is to be laid over the existing granular surface, the
latter shall, after removal of all loose material, be primed in accordance with Clause 502.
The surface finish of all granular layers on which bituminous works are to be placed, shall,
unless otherwise specifically instructed by the Engineer, be free from dust. All such layers
must be capable of being swept, after the removal of any non-integral loose material, by
means of a mechanical broom, without shedding significant quantities of material and dust
removed by air jet, washing, or other means approved by the Engineer.
After cleaning the surface shall be correct to line and level, within the tolerances specified
for base course.
501.8.3.2. Scarifying existing bituminous surface: Where specified or shown on the
drawings, the existing- bituminous layer in the specified width shall be removed with care and
without causing undue disturbance to the underlying layer, by a suitable method approved
by the Engineer. After removal, all loose and disintegrated material, the underlying layers
which might have been disturbed should be suitably reworked and compacted to line and
level. After supplementing the base material as necessary with suitable fresh stone, the
compacted finished surface shall be primed in accordance with Clause 502. Reusable
materials shall be stacked as directed by the Engineer within 1000 m of their origin.

RED BOOK  VOLUME I  ROADS  2012 499

501.8.3.3. Patching of potholes and sealing of cracks: Where the existing surface to
be overlaid is bituminous, any existing potholes and cracks shall be repaired and sealed in
accordance with clauses 3004.2 and 3004.3, or as directed by the Engineer.
501.8.3.4. Laying the profile corrective course
501.8.3.4.1. Laying on granular base: After preparing the granular surface in accordance
with Clauses 501.8.3.1 and 501.8.3.2, the profile corrective course shall be laid using
material as described in Clauses 501.8.2.3 and 501.8.2.4 or as otherwise described in the
Contract, and compacted to the requirements of the particular Specification.
501.8.3.4.2. Laying on existing bituminous surface: The existing bituminous surface
shall be prepared in accordance with Clause 501.8.3.3, and after applying a tack coat
conforming to Clause 503, the bituminous profile corrective course shall be laid and
compacted to the requirements of the particular Specification.
501.8.3.4.3. Correction of local depressions: Where local sags or depressions occur in
the existing pavement, a specific filling operation shall be instructed by the Engineer, which
should be laid in accordance with Figure 500-1. Normally, the maximum layer thickness
at any point should not exceed 100 mm. In placing multiple lifts, they should be arranged
according to the correct method as illustrated.
For correction of camber or super-elevation of the existing carriageway, the method shown
in Figure. 500-2 shall be adopted, depending on the profile of the existing carriageway.
501.8.3.5. Covering the profile corrective courses: Profile corrective course particularly
shall be so planned that the layer shall be covered by the designed base/wearing course at
the earliest opportunity, before opening to regular traffic.
501.8.4. Surface finish and quality control of work: The relevant provisions of Section
900.shall apply.
501.8.5. Arrangements for traffic:  During construction operations, arrangements for
traffic shall be made in accordance with the provisions of Clause 112.
501.8.6. Environmental protection: The provisions of Clause 111 and the provision of
Annexure A to Clause 501 shall apply.
501.8.7. Measurement for payment
501.8.7.1. Potholes and cracks: The work of filling potholes shall be measured separately
and be paid for in square metres. The work of filling cracks by applying fog spray or emulsion
slurry seal shall be measured in square metres, for the area covered by the spray.
The work in filling cracks larger than 3mm in width shall be measured and paid for on a
linear metre basis.
501.8.7.2. Scarifying: Scarifying the existing bituminous surface shall be measured on a
square metre basis.
501.8.7.3. Profile corrective course:  Profile corrective course shall be measured as the
volume instructed and compacted in position and measured in cubic metres, or in tonnage,
as stipulated in the Contract. The volume shall be calculated by plotting the exact profile
of profile corrective course as required, and laid, superimposed on the existing pavement
profile. Cross-sectional areas of the profile corrective course shall be measured at intervals
as used in the design, or as determined by the Engineer, and the volume shall be calculated
using the method of end areas.
501.8.7.4 Prime coat:  Prime coat is to be measured and paid for on a per square metre
basis.

500 RED BOOK  VOLUME I  ROADS  2012

501.8.7.5 Tack coat: This is to be a PROVISIONAL item, which may be used in-part or not
at all, at the Engineers direction, and is to be measured and paid for, if used, on a square
metre basis.
501.8.8. Rates
501.8.8.1. Rate for scarifying:  The contract unit rate for scarifying existing bituminous
surfaces, including repairing / reworking disturbed underlying layers and removing and
stacking reusable I unusable materials, shall include for but not necessarily be limited to,
the cost of all labour, supply of materials needed for repair I reworking, hire charges of tools
and plant, and transportation of scarified materials within 1000 m of their origin.
501.8.8.2. Rate for premixed bituminous material:  The contract unit rate for premixed
bituminous material shall be payment in full for carrying out the required operations including
full compensation for, but not necessarily limited to:
(i) Making arrangements for traffic to Clause 112 except for initial treatment to verge,
shoulders and construction of diversions;
(ii) Preparation of the surface to receive the material.
(iii) Providing all materials to be incorporated in the work including arrangement for -
stock yards, all royalties, fees, rents where necessary and all leads and lifts;
(iv) Mixing, transporting, laying and compacting the mix, as specified.
(v) All labour, tools, equipment. plant including installation of hot mix plant, power supply
units and all machinery, incidental to complete the work to these Specifications;
(vi) Carrying out the work in part widths of the road where directed:
(vii) Carrying out all tests for control of quality; and
(viii) The rate shall cover the provision of bitumen at the rate specified in the contract,
with the provision that the variation in actual percentage of bitumen used will be
assessed and the payment adjusted accordingly.
(ix) The rates for premixed material are to include for all wastage in cutting of joints etc.
(x) The rates are to include for all necessary testing, mix design, transporting and testing
of samples, and cores. If there is not a project specific laboratory, the Contractor
must arrange to carry out all necessary testing at an outside Laboratory, approved
by the Engineer, and all costs incurred are deemed to be included in the rate quoted
for the material.
(xi) The cost of all plant and laying trials as specified to prove the mixing and laying
methods is deemed to be included in the Contractor’s rates for the material.
501.8.8.3. Rate for potholes and crack sealing: The rate for patching potholes shall
include for breaking out, trimming edges, cleaning out, painting edges and bottom with
bitumen, and filling and compacting the excavation with the specified material. The rate
should be inclusive of all plant, tools, labour and materials, transport, and disposal of
surplus material,
The contract unit rate for sealing cracks by applying fog spray shall be inclusive of providing
all materials, tools, labour and plant and carrying out the work. The contract unit rate for
sealing cracks by providing emulsion slurry seal shall be as set forth in Clause 516.9.
The contract unit rate for crack sealing 3mm to 6mm cracks with straight run or other
specified bitumen shall be based on either a square metre basis, or linear metre of cracks
as measured, as stipulated by the Contract.
The contract unit rate for cracks between 6mm and 15mm is to be measured on a linear
metre basis, and the rate is to include for all materials, tools, plant, labour, and transport.
RED BOOK  VOLUME I  ROADS  2012 501
 Annexure ‘A’ to Clause 501
Annexure ‘A’
PROTECTION OF THE ENVIRONMENT
1. General
1.1. This section of the Specification sets out limitations on the Contractor’s activities
specifically intended to protect the environment.
1.2. The Contractor shall take all necessary measures and precautions and otherwise
ensure that the execution of the works and all associated operations on site or off-site
are carried out in conformity with-statutory and regulatory environmental requirements
including those prescribed elsewhere in this document.
1.3. The Contractor shall take all measures and precautions to avoid any nuisance or
disturbance arising from the execution of the Works. This shall wherever possible be
achieved by suppression of the nuisance at source rather than abatement of the nuisance
once generated.
1.4. In the event of any spoil, debris, waste or any deleterious ` substance from the Site
being deposited on any adjacent land, the Contractor shall immediately remove all such
material and restore the affected area to its original state to the satisfaction of the Engineer.
2 Water Quality
2.1. The Contractor shall prevent any interference with the supply to or abstraction from,
and prevent any pollution of, water resources (including underground percolating water) as
a result of the execution of the Works.
2.2. Areas where water is regularly or repetitively used for dust suppression purposes
shall be laid to fall to specially-constructed settlement tanks to permit sedimentation of
particulate matter. After settlement, the water may be re-used for dust suppression and
rinsing.
2.3. All water and other liquid waste products arising on the Site shall be collected and
disposed of at a location on or off the Site and in a manner that shall not cause either
nuisance or pollution.
2.4. The Contractor shall not discharge or deposit any matter arising from the execution of
the Works into any waters except with the permission of the Engineer and the regulatory
authorities concerned.
2.5. The Contractor shall at all times ensure that all existing stream courses and drains
within, and adjacent to, the Site are kept safe and free from any debris and any materials
arising from the Works. 2.6. The Contractor shall protect all watercourses, waterways,
ditches, canals, drains, lakes and the like from pollution as a result of the execution of the
Works.
3. Air Quality
3.1. The Contractor shall devise and arrange methods of working to minimise dust, gaseous
or other air-borne emissions and carry out the Works in such a manner as to minimise
adverse impacts on air quality.
3.2. The Contractor shall utilise effective water sprays during delivery i manufacture,
processing and handling of materials when dust is likely to be created, and to dampen
stored materials during dry and windy weather. Stockpiles of friable materials shall be
- covered with clean tarpaulins, with application of sprayed water during dry and windy

502 RED BOOK  VOLUME I  ROADS  2012

weather. Stockpiles of material or debris shall be dampened prior to their movement, except
where this is contrary to the Specification.
3 .3 Any vehicle with an open load-carrying area used for transporting potentially dust
producing material shall have properly fitting side and tail boards. Materials having the
potential to produce dust shall not be loaded to a level higher than the side and tail boards,
and shall be covered with a clean tarpaulin in good condition. The tarpaulin shall be properly
secured and extend at least 300 mm over the edges of the side and tail boards.
3.4 In the event that the Contractor is permitted to use gravel or earth roads for haulage,
he shall provide suitable measures for dust palliation, if these are, in the opinion of the
Engineer, necessary. Such measures may include spraying the road surface with water at
regular intervals.
4. Noise
4.1. The Contractor shall consider noise as an environmental constraint in his planning and
execution of the Works.
4.2. The Contractor shall take all necessary measures so that the operation of all
mechanical equipment and construction processes on and off the Site shall not cause any
unnecessary or excessive noise, taking into account applicable environment requirements.
The Contractor shall use all necessary measures and shall maintain all plant and silencing
equipment in good condition so as to minimise the noise emission during construction
works.
5. Control of Wastes
5.1. The Contractor shall control the disposal of all forms of waste generated by the
construction operations and in all associated activities. No uncontrolled deposition or
dumping shall be permitted. Wastes to be so controlled shall include, but shall not be
limited to, all forms of fuel and engine oils, all types of bitumen, cement, surplus aggregates,
gravels, bituminous mixtures etc. The Contractor shall make specific provision for the
proper disposal of these and any other waste products, conforming to local regulations and
acceptable to the Engineer.
6. Emergency Response
6.1. The Contractor shall plan and provide for remedial measures to be implemented in
the event of occurrence of emergencies such as spillages of oil or bitumen or chemicals.
6.2. The Contractor shall provide the Engineer with a statement of the measures he intends
to implement in the event of such an emergency which shall include a statement of how he
intends to provide personnel adequately trained to implement such measures.
7. Measurement
7.1. No separate measurement shall be made in respect of compliance by the Contractor
with the provisions of this Section of the Specification. The Contractor shall be deemed to
have made allowance for such compliance with these provisions in the preparation of his
prices for items of work included in the Bills of Quantities and full compensation for such
compliance will be deemed to be covered by them.
502. PRIME COAT OVER GRANULAR BASE
502.1. Scope
This work shall consist of the application of a single coat of low viscosity liquid bituminous
material to a porous granular surface preparatory to the superimposition of bituminous
treatment or mix.

RED BOOK  VOLUME I  ROADS  2012 503

502.2. Materials
502.2.1. Primer: The choice of a bituminous primer shall depend upon the porosity
characteristics of the surface to be primed as classified in IRC: 16. These are:
(i) Surfaces of low porosity; such as wet mix macadam and water bound macadam,
(ii) Surfaces of medium porosity; such as cement stabilised soil base,
(iii) Surfaces of high porosity; such as a gravel base.
502.2.2. Primer viscosity: The type and viscosity of the primer shall comply with the
requirements of IS 8887, as sampled and tested for bituminous primer in accordance with
these standards. Guidance on viscosity and rate of spray is given in Table 500-1.
502.2.3. Choice of primer: The primer shall be bitumen emulsion, complying with IS
8887 of a type and grade as specified in the Contract or as directed by- the Engineer. The
use of medium curing outback as per IS 217 shall be restricted only for sites at sub-zero
temperatures or for emergency applications as directed by the Engineer.
502.3. Weather and Seasonal Limitations
Bituminous primer shall not be applied to a wet surface (see 502.4.2) or during a dust storm
or when the weather is foggy, rainy or windy or when the temperature in the shade is less
than 10°C. Surfaces which are to receive emulsion primer should be damp, but no free or
standing water shall be present.
502.4. Construction
502.4.1. Equipment: The primer distributor shall be a self-propelled or towed bitumen
pressure sprayer equipped for spraying the material uniformly at specified rates and
temperatures. Hand spraying of small areas, inaccessible to the distributor, or in narrow
strips shall be sprayed with a pressure hand sprayer, or as directed by the Engineer.
502.4.2. Preparation of road surface: The surface to be primed shall be prepared in
accordance with Clauses 501.8. and 902 as appropriate. Immediately prior to applying the
primer the surface shall be carefully swept clean of dust and loose particles, care being
taken not to disturb the interlocked aggregate. This is best achieved when the surface layer
is slightly moist (lightly sprayed with water and the surface allowed to dry) and the surface
should be kept moist until the primer is applied.
502.4.3. Application of bituminous primer: The viscosity and rate of application of the
primer shall be as specified in the Contract, or as determined by site trials carried out as
directed by the Engineer. Where a geosynthetic is proposed for use, the requirements of
Clauses 703.3.2 and 703.4 shall apply. The bituminous primer shall be sprayed uniformly
in accordance with Clause 501.The method for application of the primer will depend on
the type of equipment to be used, size of nozzles, pressure at the spray bar and speed of
forward movement. The Contractor shall demonstrate at a spraying trial, that the equipment
and method to be used is capable of producing a uniform spray, within the tolerances –
specified
502.4.4. Curing of primer and opening to traffic:  A primed surface shall be allowed
to cure for at least 24 hours or such other period as is found to be necessary to allow all
the volatiles to evaporate before any subsequent surface treatment or mix is laid. Any
unabsorbed primer shall first be blotted with an application of sand, using the minimum
quantity possible. A primed surface shall not be opened to traffic other than that necessary
to lay the next course. A very thin layer of clean sand may be applied to the surface of
the primer, to prevent the primer picking up under the wheels of the paver and the trucks
delivering bituminous material to the paver.

504 RED BOOK  VOLUME I  ROADS  2012

502.4.5. Tack coat: Over the primed surface, a tack coat should be applied in accordance
with Clause 503.
502.5. Quality Control of Work
For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
502.6. Arrangements for
Traffic During construction operations, arrangements for traffic shall be made in accordance
with the provisions of Clause 112.
502.7. Measurement for Payment Prime coat shall be measured in terms of surface area
of application in square metres.
502.8. Rate
The contract unit rate for prime coat with adjustments as described in Clause 502.7 shall
be payment in full for carrying out the required operations including full compensation for all
components listed in Clause 401.8 (i) to (v) and as applicable to the work specified in these
Specifications. Payment shall be made on the basis of the provision of prime coat at an
application rate of 0.6 kg per square metre, with adjustment, plus or minus, for the variation
between this amount and the actual amount approved by the Engineer after the preliminary
trials referred to in Clause 5.02.4.3.
503. TACK COAT
503.1. Scope
This work shall consist of the application of a single coat of low viscosity liquid bituminous
material to an existing bituminous road surface preparatory to the superimposition of a
bituminous mix, when specified in the Contract or instructed by the Engineer.
503.2. Materials
503.2.1. Binder: The binder used for tack coat shall be bitumen emulsion complying with
IS 8887 of a type and grade as specified in the Contract or as directed by the Engineer.
The use of cutback bitumen as per IS 217 shall be restricted only for sites at sub-zero
temperatures or for emergency applications as directed by the Engineer.
503.3. Weather and Seasonal Limitations
Bituminous material shall not be applied to a wet surface or during a dust storm or when
the weather is foggy, rainy or windy or when the temperature in the shade is less than l0°C.
Where the tack coat consists of emulsion, the surface shall be slightly damp, but not wet.
Where the tack coat is of cutback bitumen, the surface shall be dry.
503.4. Construction
503.4.1. Equipment: The tack coat distributor shall be a self- propelled or towed bitumen
pressure sprayer, equipped for spraying the material uniformly at a specified rate. Hand
spraying of small areas, inaccessible to the distributor, or in narrow strips, shall be sprayed
with a pressure hand sprayer, or as directed by the Engineer.
503.4.2. Preparation of base: The surface on which the tack coat is to be applied shall be
clean and free from dust, dirt, and any extraneous material, and be otherwise prepared in
accordance with the requirements of Clauses 501.8 and 902 as appropriate. Immediately
before the application of the tack coat, the surface shall be swept clean with a mechanical
broom, and high pressure air jet, or by other means as directed by the Engineer.
503.4.3. Application of tack coat: The application of tack coat shall be at the rate specified

RED BOOK  VOLUME I  ROADS  2012 505

in the Contract, and shall be applied uniformly. If rate of application of Tack Coat is not
specified in the contract then it shall be at the rate specified in Table 500-2. The normal
range of spraying temperature for a bituminous emulsion shall be 20°C to 70°C and for an
outback, 50°C to 80°C if RC-70/MC-70 is used. Where a geosynthetic is proposed for use,
the provisions of Clauses 703.3.2 and 703.4.4 shall apply. The method of application of the
tack coat will depend on the type of equipment to be used, size of nozzles, pressure at the
spray bar, and speed of forward movement. The Contractor shall demonstrate at a spraying
trial, that the equipment and method to be used is capable of producing a uniform spray,
within the tolerances specified.
Where the material to receive an overlay is a freshly laid bituminous layer that has not been
subjected to traffic or contaminated by dust, a tack coat is not mandatory where the overlay
is completed within two days.
503.4.4. Curing of tack coat: The tack coat shall be left to cure until all the volatiles have
evaporated before any subsequent construction - is started. No plant or vehicles shall be
allowed on the tack coat other than those essential for the construction.
503.5. Quality Control of Work
For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
503.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
503.7. Measurement for Payment Tack coat shall be measured in terms of surface area of
application in square metres.
503.8. Rate
The contract unit rate for tack coat shall be payment in full for carrying out the required
operations including for all components listed in Clause 401.8 (i) to (v) and as applicable
to the work specified in these Specifications. The rate shall cover the provision of tack coat
at 0.2 kg
per square metre, with the provision that the variance in actual quantity of bitumen used will
be assessed and the payment adjusted accordingly.
504. BITUMINOUS MACADAM
504.1. Scope
This work shall consist of construction in a single course having- 50mm to 100mm thickness
or in multiple courses of compacted crushed aggregates premixed with a bituminous binder
on a previously prepared base to the requirements of these Specifications. Bituminous
macadam is more open graded than the dense graded bituminous materials described in
Clauses 507, 508 and 509.
504.2. Materials
504.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration Grade complying
with Indian Standard Specifications for "Paving Bitumen" IS: 73, and of the penetration
indicated in Table 500- 4.
504.2.2. Coarse- aggregates: The coarse aggregates shall consist of crushed rock,
crushed gravel or other hard material retained on the 2.36 mm sieve. They shall be clean,
hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other
deleterious matter. Where the Contractor’s selected source of aggregates have poor

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affinity for bitumen, as a condition for the approval of that source, the bitumen shall be
treated with approved anti-stripping agents, as per the manufacturer’s recommendations,
without additional payment. Before approval of the source, the aggregates shall be tested
for stripping.
The aggregates shall satisfy the physical requirements set forth in. Table 500-3.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of
the crushed material retained on the 4.75 mm sieve shall have at least two fractured faces.
504.2.3. Fine aggregates: Fine aggregates shall consist of crushed or naturally occurring
material, or a combination of the two, passing 2.36 mm sieve and retained on 75 micron
sieve. They shall be clean, hard, durable, dry and free from dust, and soft or friable matter,
organic or other deleterious matter.
504.2.4. Aggregate grading and binder content: When tested in accordance with IS: 2386
Part 1 (wet sieving method), the combined aggregate grading for the particular mixture
shall fall within the limits shown in Table 500-4 for the grading specified in the Contract.
The type and quantity of bitumen, and appropriate thickness, are also indicated for each
mixture type.
504.2.5. Proportioning of material:  The aggregates shall be proportioned and blended to
produce a uniform mixture complying with the requirements of Table 500-4. The binder
content shall be within a tolerance of x 0.3 per cent by weight of total mixture when individual
specimens are taken for quality control tests in accordance with the provisions of Section
900.
504.3. Construction Operations
504.3.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
504.3.2. Preparation of the base:  The base on which bituminous macadam is to be laid
shall be' prepared, shaped and compacted to the required profile in accordance with
Clauses 501.8 and 902.3 as appropriate, and a prime coat, shall be applied in accordance
with Clause 502 where specified, or as directed by the Engineer.
504.3.3. Tack coat :  A tack coat in accordance with Clause- 503 shall be applied as
required by the Contract documents, or as directed by the Engineer. 504.3.4. Preparation
and transportation of the mixture: The provisions of Clauses 501.3 and 501.4 shall apply.
504.3.5. Spreading: The provisions of Clauses 501.5.3 shall apply.
504.3.6. Rolling: Compaction shall be carried out in accordance with the provisions of
Clauses 501.6 and 501.7.
Rolling shall be continued until the specified density is achieved, or where no density is
specified, until there is no further movement under the roller. The required frequency of
testing is defined in Clause 903.
504.4. Surface Finish and Quality Control of Work: The surface finish of the completed
construction shall conform to the requirements of Clause 902. For control of the quality of
materials supplied and the works carried out, the relevant provisions of Section 900 shall
apply.
504.5. Protection of the Layer
The bituminous macadam shall be covered with either the next pavement course or wearing
course, as the case may be, within a maximum of forty-eight hours. If there is to be any
delay, the course shall be covered by a seal coat to the requirement of Clause 513 before
opening to any traffic. The seal coat in such cases shall be considered incidental to the

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work and shall not be paid for separately.
504.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112
504.7. Measurement for Payment
Bituminous macadam shall be measured as finished work in cubic metres, or by weight
in metric tonnes, where used as regulating course, or square metres at the specified
thickness as indicated in the Contract or shown on the drawings, or as otherwise directed
by the Engineer.
504.8. Rate
The contract unit rate for bituminous macadam shall be payment in full for carrying out the
required operations as specified. The rate shall include for, all components listed in Clause
501.8.8.2. (i) to (xi).

505. BITUMINOUS PENETRATION MACADAM

505.1. Scope
The work shall consist of construction of one or more layers of compacted crushed
coarse aggregates with alternate applications of bituminous binder and key aggregates in
accordance with the requirements of these Specifications to be used as a base course on
roads, subject to the requirements of the overall pavement design, in conformity with the
lines, grades and cross-sections shown on the drawings or as directed by the Engineer.
Thickness of an individual course shall be 50 mm or 75 mm, or other as specified.
505.2. Materials
505.2.1. Bitumen: The binder shall be paving bitumen of suitable penetration grade within
the range of S-35 to S-90 or A-35 to A-90 (30/ 40 to 80/ 100) as per Indian Standards
Specifications for "Paving Bitumen” IS :73, or approved outback satisfying the requirements
of IS : 217 or 454. The actual grade of bitumen or outback to be used shall be as specified
or as directed by the Engineer.
505.2.2. Aggregates: The aggregates shall satisfy the physical requirements set out in
Clause 504.2.2. and Table 500-3. The coarse and key aggregates shall conform to the
grading given in Table 500-6.
505.2.3. Quantities of materials: The quantities of materials used for this work shall be
as specified in Table 500-6.
505.3. Construction Operations
505.3.1. Weather and Seasonal Limitations: The provisions of Clause 501.5.1. shall
apply.
505.3.2. Equipment : A mechanical broom, compressor, self propelled or trailed bitumen
heater/distributor, mechanical aggregate spreader and 8 to 10 tonne smooth steel wheel
roller or vibrating roller are required for the preparation of Penetration Macadam.
505.3.3. Preparation of the base: The base on which the Penetration Macadam Course
is to be laid shall be prepared, shaped and compacted to the specified lines, grades and
sections to Clauses 501 and 902 as appropriate, or as directed by the Engineer. A prime
coat, where specified, shall be applied over the base in accordance with Clause 502 or as
directed by the Engineer. A tack coat as per Clause 503 shall be applied.

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505.3.4. Spreading coarse aggregates: The coarse aggregate shall be dry and clean
and free from dust, and shall be spread uniformly and evenly at the rate specified in Table
500-6. It shall be spread by a self- propelled or tipper tail mounted aggregate spreader
capable of spreading aggregate uniformly at the specified rates over the required widths.
The _ surface of the layer shall be carefully checked with camber templates to ensure
correct line and level and cross fall. The spreading shall be carried out such that the rolling
and penetrating operations can be completed on the same day. Segregated aggregates or
aggregates contaminated with foreign material shall be removed and replaced.
505.3.5. Compaction: After the spreading of coarse aggregates, dry rolling shall be carried
out with an 8-10 tonne smooth steel wheel roller.
The requirements given in Clause 501.6 and 501.7 shall apply.
After initial dry rolling, the surface shall be checked with a crown template and a 3 metre
straight-edge. The surface shall not vary more than 10 mm from the template. or straight-
edge. All surface irregularities exceeding the above limit shall be corrected by removing or
adding aggregates as required.
The rolling shall continue until the compacted coarse aggregate has a firm surface true to
the cross section shown on the plans and has a texture that will allow free -and uniform
penetration of the bituminous material.
505.3.6. Application of bituminous material: After the coarse aggregate has been rolled
and checked, the bituminous binder shall be applied, at the rate given in Table 500-6, in
accordance with Clause 501, and at a temperature directed by the Engineer.
At the time of applying the binder, the aggregates shall be surface dry for the full depth of
the layer.
In certain circumstances, depending on the type and size of aggregate used, the Engineer
may direct the placing of a bed of clean sand or quarry fines, not exceeding 10mm in
thickness, on the prepared foundation before placing the coarse aggregate. The sand or
fine material shall be slightly wetted, just sufficient for it to slurry up during the compaction
process. Where cut back is used, if flooding of the binder occurs it should be applied in two
operations, or as directed by the Engineer.
505.3.7. Application of key aggregates: Immediately after the first application of bitumen,
the key aggregates, which shall be clean, dry, and free from dust shall be spread uniformly
over the surface by means of an approved mechanical spreader or by approved manual
methods at the rate specified in Table 500-6.
Where directed by the Engineer, the surface shall be swept and the _ quantity of key
aggregate adjusted to ensure uniform application, with all the surface voids in the coarse
aggregate being filled without excess. The entire surface shall then be rolled with 8- 10
tonnes smooth steel wheel roller (or vibrating roller operating in non-vibratory mode) in
accordance with the procedure specified in Clause 505.3.5.
505.4. Surface Finish and Quality Control: The surface finish of the completed
construction shall conform to the requirements of Clause 9.02. For control of the quality of
materials supplied and the works carried out the relevant provisions of Section 900 shall
apply.
505.5. Surfacing
The Penetration Macadam shall be provided with a surfacing (binder/wearing course) within
a maximum of forty-eight hours. If there is to be any delay, the penetration macadam shall be
covered by a seal coat to the requirements of Clause 513 before opening to traffic. The seal coat
in such cases shall be considered incidental to the work and shall not be paid for separately.

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505.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 1 12
505.7. Measurement for Payment
Penetration Macadam base course shall be measured as finished work in square metres. -
505.8. Rate
The contract unit rate for Penetration Macadam course shall be payment in full for carrying
out the required operations including, but not necessarily limited to, all components listed
in Clause 501.8 8.2.(i) to (xi).
506. BUILT-UP SPRAY GROUT
506.1. Scope
This work shall consist of a two-layer composite construction of compacted crushed
coarse aggregates with application of bituminous binder after each layer, and with key
aggregates placed on top of the second layer, in accordance with the requirements of
these Specifications, to serve as a base course and in conformity with the lines, grades and
cross-sections shown on the drawings or as directed by the Engineer. The thickness of the
course shall be 75 mm.
Built-up spray grout shall be used in a single course in a pavement structure.
506.2. Materials
506.2.1. Bitumen: Clause 504.2.1. shall apply. Where permitted by the Engineer, an
appropriate grade of emulsion complying with IS 8887 may be used.
506.2.2. Aggregates: The coarse aggregate shall conform to Clause 504.2.2.
The aggregate shall satisfy the physical requirements set out in Table 500-3. The coarse
and key aggregates for built—up spray grout shall conform to the grading given in Table
500-7.
506.3. Construction Operations
506.3.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
506.3.2. Equipment: The provisions of Clause 505.3.2 shall apply.
506.3.3. Preparation of base: The base on which the built-up spray grout course is to
be laid shall be prepared, shaped and compacted to the specified lines, grades and cross-
sections in accordance with Clauses 501 and 902 as appropriate. A prime coat shall be
applied in accordance with Clause 502 with approved primer as directed by the Engineer.
506.3.4. Tack coat: Tack coat shall be applied in accordance with • the procedure described
in Clause 503, as directed by the Engineer.
506.3.5. Spreading and rolling coarse aggregates for the first layer: Immediately after
the application of prime or tack coat, the clean, dry and dust free coarse aggregates shall
be spread uniformly and evenly, by mechanical means, at the rate of 0.5 cu.m. per 10 sq.m.
area.
Immediately after spreading of the aggregates, the entire surface shall be rolled with an
8 - 10 tonnes smooth wheel steel roller. Rolling shall commence at the edges and progress
towards the centre except in super- elevated and uni—directional cambered portions
where it shall proceed from the lower edge to the higher edge. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the preceding- pass.

510 RED BOOK  VOLUME I  ROADS  2012

The surface of the layer shall be carefully checked, after rolling, with a template and
straight edge and shall be within the tolerances specified, and any deficiencies corrected
by reworking and recompacting the layer.
Care shall be taken not to over-compact the layer.
506.3.6. Application of binder - first spray: The binder shall be heated to the temperature
appropriate to the grade of bitumen approved by the Engineer and sprayed on the aggregate
at the rate of 15 kg/10 sq.m. (measured in terms of residual bitumen content) at a uniform
rate .of spray by mechanical sprayers capable of spraying bitumen uniformly at the specified
rates and temperatures. Excessive deposits of binder caused by stopping or starting of the
sprayers or through leakage or for any other reason shall be removed and made good.
506.3.7. Spreading and rolling of coarse aggregate for the second layer: Immediately
after the first application of the binder, the second layer of coarse aggregates shall be
spread and rolled in accordance with the procedure detailed in Clause 506.3.5.
506.3.8. Application of binder - second spray: The second aggregate layer shall then be
sprayed with binder at the rate of 15 kg/ 10 sq. m. (measured in terms of residual bitumen
content) in accordance with Clause 506.3.6.
506.3.9. Application of key aggregate: Immediately after the second application of binder,
key aggregates shall be spread uniformly and evenly, preferably by mechanical means, at
the rate of 0.13 cu.m./10 sq.m. so as to cover the surface completely. The key aggregate
shall be clean, dry and free from dust and deleterious matter. If necessary, the surface shall
be swept to ensure uniform application of the key aggregates. The entire surface shall then
be rolled with an 8-10 tonnes smooth wheel steel roller in accordance with Clause 506.3.5.
While rolling is in progress, additional key aggregates, where required, shall be spread by
hand. Rolling shall continue until the entire course is thoroughly compacted and the key
aggregates are firmly in position.
506.4. Surface Finish and Quality Control
The surface finish-of construction shall conform to the requirements of Clause 902. All
materials shall comply with the requirements of the relevant provisions in Section 900 of
the Specifications.
506.5. Final Surfacing
The built-up-spray-grout shall be provided with final surfacing within a maximum of forty-
eight hours. If there is to be any delay, the course shall be covered by a seal coat to the
requirement of Clause 5 13 before it is open to traffic. Where the seal coat is required as
a result of the selected method of performing this operation, then it_ shall be considered
incidental to the work and shall not be paid for separately.
506.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
506.7. Measurement for Payment
Built-up spray grout shall be measured as finished work in square metres.
506.8. Rate
The contract unit rate for built-up spray grout shall be payment _in full for carrying out the
required operations as specified. The rate shall include for, but not necessarily be limited to
the components listed in Clause 501.8.8.2. (i) to (xi).
507. DENSE GRADED BITUMINOUS MACADAM.

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507.1. Scope
This clause specifies the construction of Dense Graded Bituminous Macadam, (DBM), for
use mainly, but not exclusively, in base/binder and profile corrective courses. DBM is also
intended for use as road base material. This work shall consist of construction in a single
or multiple layers of DBM on a previously prepared base or sub-base. The thickness of a
single layer shall be 50mm to 100mm.
507.2. Materials
507.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration Grade complying
with Indian Standard Specifications for "Paving Bitumen" IS: 73, and of the penetration
indicated in Table 500- 10 for dense bitumen macadam, or this bitumen as modified by one
of the methods specified in Clause 521, or as otherwise specified in the Contract. Guidance
on the selection of an appropriate grade of bitumen is given in The Manual for Construction
and Supervision of Bituminous - Works.
507.2.2. Coarse aggregates: The coarse aggregates shall consist of crushed rock,
crushed gravel or other hard material retained on the 2.36 mm sieve. They shall be clean,
hard, durable, of cubical shape, free from dust and soft or friable matter, organic or other
deleterious substances. Where the Contractor’s selected source of aggregates have poor
affinity for bitumen, as a condition for the approval of that source, the bitumen shall be
treated with an approved anti-stripping agent, as per the manufacturer’s recommendations,
without additional payment. Before approval of the source, the aggregates shall be tested
for stripping. The aggregates shall satisfy the physical requirements specified in Table 500-
8, for dense bituminous macadam.
Where crushed gravel is proposed for use as aggregate, not less than 90% by weight of
the crushed material retained on the 4.75 mm sieve shall have at least two fractured faces.
507.2.3. Fine aggregates: Fine aggregates shall consist of crushed or naturally occurring
mineral material or a combination of the two, passing the 2.36mm sieve and retained on
the 75 micron sieve. They shall be clean, hard, durable, dry and free from dust, and soft- or
friable matter, organic or other deleterious matter.
The fine aggregate shall have a sand equivalent value of not less than 50 when tested in
accordance with the requirement of 15:2720 (Part 37).
The plasticity index of the fraction passing the 0.425 mm sieve shall not exceed 4 when
tested in accordance with IS: 2720 (Part 5)
507.2.4. Filler: Filler shall consist of finely divided mineral matter such as rock dust, hydrated
lime or cement approved by the Engineer.
The filler shall be graded within the limits indicated in Table 500-9.
The filler shall be free from organic impurities and have a Plasticity Index not greater than 4.
The Plasticity Index requirement shall not apply if filler is cement or lime. When the coarse
aggregate is gravel, 2 per cent by weight of total aggregate, shall be Portland cement
or hydrated lime and the percentage of line aggregate reduced accordingly. Cement or
hydrated lime is not required when the limestone aggregate is used. Where the aggregates
fail to meet the requirements of the water sensitivity test in Table 500-8, then 2 per cent by
total weight of aggregate, of hydrated lime shall be added without additional cost.
507.2.5. Aggregate grading and binder content: When tested in accordance with IS:2386
Part 1 (wet sieving method), the combined grading of the coarse and line aggregates and
added filler for the particular mixture shall fall within the limits shown in Table 500-10, for
dense bituminous macadam grading 1 or 2 as specified in the Contract. The type and
quantity of bitumen, and appropriate thickness, are also indicated for each mixture type.
512 RED BOOK  VOLUME I  ROADS  2012
507.3. Mixture Design
507.3.1. Requirement for the mixture : Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture shall meet the requirements set out in
Table 500-11.
507.3.2. Binder content: The binder content shall be optimised to achieve the requirements
of the mixture set out in Table 500-ll and the traffic volume specified in the Contract. The
Marshall method for determining the optimum binder content shall be adopted as described
in The Asphalt Institute Manual MS-2, replacing the aggregates retained on the 26.5 mm
sieve by the aggregates passing the 26.5 mm sieve and retained on the 22.4 mm sieve,
where approved by the Engineer.
Where 40 mm dense bituminous macadam mixture is specified, the modified Marshall
method described in MS-2 shall be used. This method requires modified equipment and
procedures; particularly the minimum stability values in Table 500-1 shall be multiplied by
2.25, and the minimum flow shall be 3 mm.
507.3.3. Job mix formula: Tables The Contractor shall inform the Engineer in writing, at
least 20 days before the start of the work, of the job mix formula proposed for use in the
works, and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder type, and percentage by weight of total mixture;
(b) Coarse aggregate/Fine aggregate/Mineral filler as percentage by weight of total
aggregate including mineral filler;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The individual gradings of the individual aggregate fractions, and the proportion of
each in the combined grading.
(v) The results of tests enumerated in Table 500-11 as obtained by the Contractor;
(vi) Where the mixer is a batch mixer, the individual weights of each type of aggregate,
and binder per batch.
(vii) Test results of physical characteristics of aggregates to be used;
(viii) Mixing temperature and compacting temperature.
While establishing the job mix formula, the Contractor shall ensure that it is based on a
correct and truly representative sample of the materials that will actually be used in the
work and that the mixture and its different ingredients satisfy the physical and strength
requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer for
which samples of all ingredients of the mix shall be furnished by the Contractor as required
by the Engineer.
The approved job mix formula shall remain effective unless and until a revised Job Mix
Formula is approved. Should a change in the source of materials be proposed, a new
job mix formula shall be forwarded to the Engineer for approval before the placing of the
material.
507.3.4. Plant trials - permissible variation in job mix formula: Once the laboratory job
mix formula is approved, the Contractor shall carry out plant trials at the mixer to establish
that the plant can be set up to produce a uniform mix conforming to the approved job mix
formula. The permissible variations of the individual percentages of the various ingredients

RED BOOK  VOLUME I  ROADS  2012 513

in the actual mix from the job mix formula to be used shall be within the limits as specified
in Table 500-13. These variations are intended to apply to individual specimens taken for
quality control tests in accordance with Section 900.
Once the plant trials have demonstrated the capability of the plant, and the trials are approved,
the laying operation may commence. Over the period of the first month of production for
laying on the works, the Engineer shall require additional testing of the product to establish
the reliability and consistency of the plant.
507.3.5. Laying Trials: Once the plant trials have been successfully completed and
approved, the Contractor shall carry out laying trials, to demonstrate that the proposed
mix can be successfully laid, and compacted all in accordance with Clause 501. The laying
trial shall be carried out on a suitable area which is not to form part of the works, unless
specifically approved in writing, by the Engineer. The area of the laying trials shall be a
minimum of 100 sq.in of construction similar to that of the project road, and it shall be in
all respects, particularly compaction, the same as the project construction, on which the
bituminous material is to be laid.
The Contractor shall previously inform the Engineer of the proposed method for laying
and compacting the material. The plant trials shall then establish if the proposed laying
plant, compaction plant, and methodology is capable of producing satisfactory results. The
density of the finished paving layer shall be determined by taking cores, no sooner than 24
hours after laying, or by other approved method.
Once the laying trials have been approved, the same plant and methodology shall be
applied to the laying of the material on the project, and no variation of either shall be
-acceptable, unless approved in writing by the Engineer, who may at his discretion require
further laying trials.
507.4. Construction Operations
507.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
507.4.2. Preparation of base: The base on which Dense Graded Bituminous Material is
to be laid shall be prepared in accordance with Clauses 501 and 902 as appropriate, or
as directed by the Engineer. The surface shall be thoroughly swept clean by a mechanical
broom, and the dust removed by compressed air. In locations where mechanical broom
cannot access, other approved methods shall be used as directed by the Engineer.
507.4.3. Geosynthetics: Where Geosynthetics are specified in the Contract this shall be
in accordance with the requirements stated in Clause 70 3.
507.4.4. Stress absorbing layer: Where a stress absorbing layer is specified in the
Contract, this shall be applied in accordance with the requirements of Clause 522.
507.4.5. Prime coat: Where the material on which the dense bituminous macadam is to
be laid is other than a bitumen bound layer, a - prime coat shall be applied, as specified, in
accordance with the provisions of Clause 502, or as directed by the Engineer.
507.4.6. Tack coat: Where the material on which the dense bituminous macadam is to be
placed is a bitumen bound surface, a tack coat shall be applied as specified, in accordance
with the provisions of Clause 503, or as directed by the Engineer.
507.4.7. Mixing and transportation of the mixture: The provisions as specified in
Clauses 501.3 and 501.4 shall apply.
507.4.8. Spreading: The provisions of Clauses 501.5.3 and 501.5.4. shall apply.
507.4.9. Rolling: The general provisions of Clauses 501.6 and 501-7 shall apply, as

514 RED BOOK  VOLUME I  ROADS  2012

modified by the approved laying trials. The compaction process shall be carried out by the
same plant, and using the same method, as approved in the laying trials, which may be
varied only with the express approval of the Engineer in writing.
507.5. Opening to Traffic
The newly laid surface shall not be open to traffic for at least 24 hrs after laying and
completion of compaction, without the express approval of the Engineer in writing.
507.6. Surface Finish and Quality Control of Work
The surface finish of the completed construction shall conform to the requirements, of
Clause 902. All materials and workmanship shall comply with the provisions set out in
Section 900 of this Specification.
507.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112
507.8. Measurement for Payment
Dense Graded Bituminous Materials shall be measured as finished work either in cubic
metres, tons or by the square metre at a specified thickness as detailed on the Contract
drawings, or documents, or as directed by the Engineer.
507.9. Rate
The contract unit rate for Dense Graded Bituminous Macadam shall be payment in full for
carrying out the all required operations as specified, and shall include, but not necessarily
limited to all components listed in Clause 501.8.8.2 (i) to (xi). The rate shall include the
provision of bitumen, at 4.25 per cent by weight of the total mixture.
The variance in actual percentage of bitumen used will be assessed and the payment
adjusted, up or down, accordingly.
508. SEMI-DENSE BITUMINOUS CONCRETE
508.1. Scope
This clause specifies the construction of Semi Dense Bituminous Concrete, for use in
wearing/binder and profile corrective courses. This work shall consist of construction in
a single or multiple- layers of semi dense bituminous concrete on a previously prepared
bituminous bound surface. A single layer shall be 25mm to 100mm in thickness.
508.2. Materials
508.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration grade complying
with Indian Standard Specification for Paving Bitumen, IS:73 and of the penetration
indicated in Table 500-15, for semi dense bituminous concrete, or this bitumen as modified
by one of` the methods specified in Clause 521, or as otherwise specified in the Contract.
Guidance on the selection of an appropriate grade of bitumen is given in The Manual for
Construction and Supervision of Bituminous Works.
508.2.2. Coarse aggregates: The coarse aggregates shall be generally as specified in
Clause 507.2.2, except that the aggregates shall satisfy the physical requirements of Table
500-14.
508.2.3. Fine aggregates: The fine aggregates shall be all as specified in Clause 507.2.3.
508.2.4. Filler: Filler shall be generally as specified in Clause 507.2.4. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table 500-14 then
2 per cent by total weight of aggregate, of hydrated lime shall be added without additional

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cost.
508.2.5. Aggregate grading and binder content: When tested in accordance with IS:2386
Part 1 (Wet sieving method), the combined grading of the coarse and fine aggregates and
added filler shall fall within the limits shown in Table 500-15 for gradings 1 or 2 as specified
in the Contract.
508.3. Mixture Design
508.3.1. Requirements for the mixture: Apart from conformity with the grading and
quality requirements for individual ingredients the mixture shall meet the requirements set
out in Table 500-16.
The requirements for minimum per cent voids in mineral aggregate (YMA) are set out in
Table 500-12.
508.3.2. Binder content: The binder content shall be optimised to achieve the requirements
of the mixture set out in Table 500-16 and the traffic volume as specified in the Contract. The
Marshall method for determining the optimum binder content shall be adopted as described
in the Asphalt Institute Manual MS-2, replacing the aggregates retained on the 26.5mm
sieve and retained on the 22.4mm sieve, where approved by the Engineer.
508.3.3. Job mix formula:  The procedure for formulating the job mix formula shall be
generally as specified in Clause 507.3.3 and the results of tests enumerated in Table 500-
16 as obtained by the Contractors.
508.3.4. Plant trials - permissible variation in job mix formula: The requirements for plant
trials shall be all as specified in Clause 507.3.4, and permissible limits for variation as
shown in Table 500-13.
508.3.5. Laying trials: The requirements for laying trials shall be all as specified in Clause
507.3.5.
508.4. Construction Operations
508.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
508.4.2. Preparation of base: The surface on which the Semi Dense Bituminous material
is to be laid shall be prepared in accordance with Clauses 50l and 902 as appropriate, or
as directed by the Engineer. The surface shall be thoroughly swept clean by mechanical
broom and dust removed by compressed air. In locations where a mechanical broom cannot
access, other approved methods shall be used as directed by the Engineer.
508.4.3. Geosynthetics: Where Geosynthetics are specified in the Contract this shall be in
accordance with the requirements stated in Clause - 70 3
508.4.4. Stress absorbing layer: Where a stress absorbing layer is specified in the Contract,
this shall be applied in accordance with the requirements of Clause 522.
508.4.5. Tack coat: Where specified in the Contract, or otherwise required by the Engineer,
a tack coat shall be applied in accordance with the requirements of Clause 503.
508.4.6. Mixing and transportation of the mixture:  The provisions as specified in
Clauses'50l.3.and 501.4 shall apply.
508.4.7. Spreading: The general provisions of Clauses 501.5.3 and 501.5.4 shall apply.
508.4.8. Rolling: The general provisions of Clauses 501.6 and 501.7 shall apply, modified
by the approved laying trials. The compaction process shall be carried out by the same
plant, and using the same method, as approved in the laying trials, which may be varied
only with the express approval of the Engineer in writing.

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508.5. Opening to Traffic
The newly laid surface shall not be open to traffic for at least 24 hours after laying and the
completion of compaction, without the express approval of the Engineer in writing.
508.6. Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the requirements of
Clause 902. All materials and workmanship shall comply with the provisions set out in
Section 900 of this Specification.
508.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
508.8. Measurement for Payment
The measurement shall be all as specified in Clause 507.8.
508.9. Rate
The contract unit rate shall be all as specified in Clause 507.9, except that the rate shall
include the provision of bitumen at 4.75 per cent, by weight of total mixture. The variance in
actual percentage of bitumen used will be assessed and the payment adjusted up or down,
accordingly.
509. BITUMINOUS CONCRETE
509.1. Scope
This clause specifies the construction of Bituminous Concrete, for use in wearing and
profile corrective courses. This work shall consist of construction in a single or multiple
layers of bituminous concrete on a previously prepared bituminous bound surface. A single
layer shall be 25mm to 100mm in thickness. 509.2. Materials
509.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration grade complying
with Indian Standard Specification for Paving Bitumen, IS: 73 and of the penetration
indicated in Table 500-18, for bituminous concrete, or this bitumen as modified by one of
the methods specified in Clause 521, or as otherwise specified in the Contract. Guidance
on the selection of an appropriate grade of bitumen is given in The Manual for Construction
and Supervision of Bituminous Works.
509.2.2. Coarse aggregates:  The coarse aggregates shall be generally as specified in
Clause 507.2.2, except that the aggregates shall satisfy the physical requirements of Table
500-17.
509.2.3. Fine aggregates: The fine aggregates shall be all as specified in Clause 507.2.3.
509.2.4. Filler: Filler shall be generally as specified in Clause 507.2.4. Where the aggregates
fail to meet the requirements of the water sensitivity test in Table 500-17 then 2 per cent by
total weight of aggregate, of hydrated lime shall be added without additional cost.
509.2.5. Aggregate grading and binder content: When tested in accordance with IS:2386
Part 1 (Wet grading method), the combined grading of the coarse and fine aggregates and
added filler shall fall within the limits shown in Table 500-18 for gradings 1 or 2 as specified
in the Contract.
509.3. Mixture Design
509.3.1. Requirements for the mixture: Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture shall meet the requirements set out in
Table 500-19. The requirements for minimum per cent voids in mineral aggregate (VMA)

RED BOOK  VOLUME I  ROADS  2012 517

are set out in Table 500—12.
509.3.2. Binder content: The binder content shall be optimised to achieve the requirements
of the mixture set out in Table 500-19 and the traffic volume as specified in the Contract.
The Marshall method for determining the optimum binder content shall be adopted as
described in the Asphalt Institute Manual MS-2, replacing the aggregates retained on the
26.5mm sieve and retained on the 22.4mm sieve, where approved by the Engineer.
509.3.3. Job mix formula:  The procedure for formulating the job mix formula shall be
generally as specified in Clause 507.3.3 and the results of tests enumerated in Table 500-
19 as obtained by the Contractors.
509.3.4. Plant trials - permissible variation in job mix formula: The requirements for
plant trials shall be all as specified in Clause 507.3.4, and permissible limits for variation as
shown in Table 500-13.
509.3.5. Laying trials: The requirements for laying trials shall be all as specified in Clause
507.3.5.
509.4. Construction Operations
509.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply.
509.4.2. Preparation of base: The surface on which the bituminous concrete is to be laid
shall be prepared in accordance with Clauses 501 and 902 as appropriate, or as directed
by the Engineer. The surface shall be thoroughly swept clean by mechanical broom and
dust removed by compressed air. In locations where a mechanical broom cannot access,
other approved methods shall be used as directed by the Engineer.
509.4.3. Geosynthetics: Where Geosynthetics are specified in the Contract this shall be in
accordance with the requirements stated in Clause 703
509.4.4. Stress absorbing layer: Where a stress absorbing layer is specified in the Contract,
this shall be applied in accordance with the requirements of Clause 522.
509.4.5. Tack coat: Where specified in the Contract, or otherwise required by the Engineer,
a tack coat shall be applied in_ accordance with the requirements of Clause 503.
509.4.6. Mixing and transportation of the mixture: The provisions as specified in Clauses
501.3 and 501.4 shall apply.
509.4.7. Spreading: The general provisions of clauses 501.5.3 and 501.5.4 shall apply.
509.4.8. Rolling: The general provisions of clauses 501.6 and 501.7 shall apply, as
modified by the approved laying trials.
509.5. Opening to Traffic
The newly laid surface shall not be open to traffic for at least 24 hours after laying and the
completion of compaction, without the express approval of the Engineer in writing.
509.6. Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the requirements of
Clause 902. All materials and workmanship shall comply with the provisions set out in
Section 900 of this Specification.
509.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112
509.8. Measurement for Payment

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The measurement shall be all as specified in Clause 507.8.
509.9. Rate
The contract unit rate shall be all as specified in Clause 507.9, except that the rate shall
include the provision of bitumen at 5.0 per cent, by weight of total mixture. The variance in
actual percentage of bitumen used will be assessed and the payment adjusted up or down,
accordingly.
510. SURFACE DRESSING
510.1. Scope
This work shall consist of the application of one coat or two coats of surface dressing, each
coat consisting of a layer of bituminous binder sprayed on a previously prepared base,
followed by a cover of stone chips rolled in to form a wearing course to the requirements of
these Specifications. For information on the Design of Surface Dressing refer to the Manual
for Construction and Supervision of Bituminous Works.
510.2. Materials
510.2.1. Binder: The binder shall have a kinematic viscosity lying in the range 1x104 to
7x105 centistokes at the expected range of road surface temperatures at the construction
site during the period of laying. The type of binder to be used will be stated in the Contract
documents and shall comply with one of the following:
Paving Bitumen IS:73
Bitumen Emulsion IS:8887
510.2.2. Aggregates: The chips shall conform to the requirements of Clause 504.2.2.,
except that their water absorption shall be restricted to a maximum of 1 per cent and they
shall have a Polished Stone value, as measured by the method given in BS812 (Part 114),
of not less than 60. The chips shall be single sized, clean, hard, durable, of cubical shape,
free from dust and soft or friable matter, organic or other deleterious matter and conforming
to one of the gradings given in Table 500-21.
510.2.3. Rates of spread of binder and chips: For the purpose of pricing the Bill of Quantities
the rates of spread given in Table 500-20 shall be priced.
510.2.4. Anti-stripping agent: Where the proposed aggregate fails to pass the stripping
test then an approved adhesion agent (Appendix 5 for details) may be added to the binder
in accordance with the manufacturer’s instructions. The effectiveness of the proposed anti-
stripping agent must be demonstrated by the Contractor, before approval by the Engineer.
510.2.5. Pre-coated chips: As an alternative to the use of an adhesion agent the chips may
be pre-coated before they are spread except when the sprayed binder film is a bitumen
emulsion. Pre-coating the chips may be carried out in any one of the two methods:
(a) Mixing them with 0.75 to 1.0 per cent of paving bitumen by weight of chips in a
suitable mixer, the chips being heated to 160°C and the bitumen to its application
temperature. The pre-coated chips shall be allowed to cure for at least one week or
until they become non sticky and can be spread easily.
(b) Spraying the chips with a light application of creosote, diesel oil or kerosene at
ambient temperature. This spraying can be done in a concrete mixer or on a belt
conveying the chips from stockpile to gritting lorries.
510.3. Construction operations
510.3.1. Weather and seasonal limitations: Clause 501.5.1 shall apply.

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510.3.2. Preparation of base : The base on which the surface dressing is to be laid shall
be prepared, shaped and conditioned to the specified lines, grade and cross section in
accordance with Clause 501 or as directed by the Engineer. Prime coat, where needed,
shall be provided as per Clause 502 or as directed by the Engineer. Where the existing
surface shows signs of fatting up, the excess bitumen shall be removed by burning off, or
manually, as specified in the Contract or directed by the Engineer. The bituminous surface
to be dressed shall be thoroughly cleaned either by using a mechanical broom and / or
compressed air, or any other approved equipment I method as specified in the Contract or
by the Engineer. The prepared surface shall be dust free, clean and dry, (except in the case
of cationic emulsion where the surface shall be damp).
510.3.3. Application of binder:  The equipment and general procedures shall all be in
accordance with the Manual for Construction and Supervision of Bituminous Works. The
application temperature for the grade of binder used shall be as given in Table 500-22 and
the rate of spray as given in 510.2.3.
510.3.4. Application of stone chips :  The equipment and general procedure shall all be
in accordance with the Manual for Construction and Supervision of Bituminous Works.
For relatively small areas of surface dressing, careful application of chips by hand may
be acceptable if approved by the Engineer. The rate of application of chips shall be as
determined by the procedure given in the Manual for Construction and Supervision of
Bituminous Works. Immediately after application of the binder, clean, dry chips (in the case
of emulsion binder the chippings may be damp) shall be spread uniformly on the surface
so as to cover the surface completely with a single layer of chips.
510.3.5. Rolling:  Rolling of the chips should preferably be carried out by a pneumatic
tyred roller in accordance with Clause 501.6 and Clause 501.7. Traditional steel wheeled
rollers tend to crush the aggregates and if their use cannot be avoided their weight should
be limited to 8 tonnes. Rolling shall commence at the edges and progress towards the
centre except in super-elevated and uni—directional cambered portions where it shall
proceed from the lower edge to the higher edge. Each pass of the roller shall uniformly
overlap not less than one-third of the track made in the preceding pass. While rolling is in
progress additional chips shall be spread by hand in necessary quantities required to make
up irregularities. Rolling shall continue until all aggregate particles are firmly embedded in
the binder and present a uniform closed surface.
510.3.6. Application of second coat of surface dressing:  Where surface dressing in two
coats is specified, the second coat should not be applied until the first coat has been open
to traffic for 2 or 3 weeks. The surface on which the second coat is laid must be clean
and free of dust. The construction operations for the second coat shall be the same as
described in Clauses 510.3.3 to 510.3.5.
510.4. Opening to Traffic
Traffic shall not be permitted to run on any newly surface dressed area until the following
day. In special circumstances, however, the Engineer may allow the road to be opened to
traffic immediately after rolling, but in such cases traffic speed shall be limited to 20 km per
hour until the following day.
510.5. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902.
For control on the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
510.6. Arrangements for Traffic

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During the period of construction, arrangements for traffic shall-be made in accordance
with the provisions of Clause 112.
510.7. Measurement for Payment
Each coat of surface dressing shall be measured as finished work, for the area instructed
to be covered, in square metres.
510.8. Rate
The Contract unit rate for surface dressing, based on the notional rates of spread for binder
and each size of chippings given in Clause 510.2.3, which shall be adjusted, plus or minus,
for the difference between the notional rates of spread and the rates of spread determined
as described in the Manual for Construction and Supervision of Bituminous Works, and
approved by the Engineer, multiplied by the rates entered in the Bill of Quantities for
binder and each size of chipping. The adjusted rate shall be payment in full for carrying
out the required operations including full compensation for all components listed in Clause
501.8.8.2. (i) to (xi).
511. OPEN-GRADED PREMIX SURFACING
511.1. Open-graded Premix Surfacing using Penetration Bitumen or Cutback.
511.1.1. Scope: work shall consist of the preparation, laying and compaction of an open-
graded premix surfacing material of 20 mm thickness composed of small—sized aggregate
premixed with a bituminous binder on a previously prepared base, in accordance with the
requirements of these Specifications, to serve as a wearing course.
511.1.2. Materials
511.1.2.1. Binder : The binder shall be penetration bitumen of a suitable grade as specified
in the Contract, or as directed by the Engineer, and satisfying the requirements of IS: 73.
511.1.2.2. Aggregate: The aggregate shall conform to Clause 504.2.2 except that the
water absorption shall be limited to a maximum of 1 per cent. The Polished Stone Value, as
measured by the test in BS 812- (Part 114), shall not be less than 55.
511.1.2.3. Proportioning of materials: The materials shall be proportioned in accordance
with Table 500-23.
511.1.3. Construction operations
511.1.3.1. Weather and seasonal limitations: Clause 501.5.1 shall apply.
511.1.3.2. Preparation of surface: The underlying surface on which the bituminous
surfacing is to be laid shall be prepared, shaped and conditioned to the specified lines,
grade and cross-section in accordance with Clause 501. A prime coat where needed shall
be applied in accordance with Clause 502 as directed by the Engineer.
511.1.3.3. Tack coat : A tack coat complying with Clause 503, shall be applied over the
base preparatory to laying of the surfacing.
511.1.3.4. Preparation of premix: Hot mix plant of appropriate capacity and type shall be
used for the preparation of the mix material. The hot mix plant shall have separate dryer
arrangement for heating aggregate.
The temperature of the binder at the time of mixing shall be in the range of 150°C to 163°C
and that of the aggregate in the range of 155°C to 163°C provided that the difference in
`temperature between the binder and aggregate at no time exceeds 14°C. Mixing shall be
thorough to ensure that a homogeneous mixture is obtained in which all particles of the
aggregates are coated uniformly and the discharge temperature of mix shall be between

RED BOOK  VOLUME I  ROADS  2012 521

130°C and 160°C.
The mix shall be immediately transported from the mixer to the point of use in suitable
vehicles or hand barrows. The vehicles employed for transport shall be clean and the mix
being transported covered in transit if so directed by the Engineer.
511.1.3.5. Spreading and rolling: The pre mixed material shall be spread by suitable
means to the desired thickness, grades and cross-full (camber) making due allowance for
any extra quantity required to till up depressions, if any. The cross—fall should be checked
by means of camber boards and irregularities levelled out. Excessive use of blades or
rakes should be avoided. As seen as sufficient length of bituminous material has been
laid, rolling shall commence with 8 — l0tonne rollers, - smooth wheel tandem type, or
other approved equipment. Rolling shall begin at the edge and progress toward the centre
longitudinally, except that on super-elevated and uni-directional cambered portions, it shall
progress from the lower to upper edge parallel to the centre line of the pavement. When the
roller has passed over the whole area once, any high spots or depressions, which become
apparent, shall be corrected by removing or adding premixed materials. Rolling shall then
be continued until the entire surface has been rolled and all the roller marks eliminated.
In each pass of the roller the preceding track shall be overlapped uniformly by at least if
3 width. The roller wheels shall be kept damp to prevent the premix from adhering to the
wheels. In no case shall fuel / lubricating oil be used for this purpose. Excess use of water
for this purpose shall also be avoided.
Rollers shall not stand on newly laid material. Rolling operations shall be completed in
every respect before the temperature of `the mix falls below 100° C. Joints along and
transverse to the surfacing laid and compacted earlier shall be cut vertically to their full
depth so as to expose fresh surface which shall be painted with a thin coat of appropriate
binder before the new mix is placed against it.
511.1.3.6. Seal coat: A seal coat conforming to Clause 513 of the type specified in the
Contract shall be applied to the surface immediately after laying the surfacing.
511.1.4. Opening to traffic: No traffic shall be allowed on the road until the seal coat has
been laid. After the seal coat is laid, the road may be opened to traffic according to Clause
513.4.
511.1.5. Surface finish and quality control of work: The surface finish of construction shall
conform to the requirements of Clause 902. For control of the quality of materials supplied
and the works carried out, the relevant provisions of Section 900 shall apply.
511.1.6. Arrangements for traffic: During the period of construction, arrangement of traffic
shall be made in accordance with the provisions of Clause 112.
511.1.7. Measurement for payment I:  Open graded premix surfacing shall be measured
as finished work, for the area instructed to be covered, in square metres. The area will be
the net area covered, and all allowance for wastage and cutting of joints shall be deemed
to be included in the rate.
511.1.8. Rate: The contract unit rate for open-graded premix surfacing shall be payment in
full for carrying out the required operations including full compensation for all components
listed in Clause 501.8.8.2. (i) to (xi).
511.2. Open graded premix surfacing using cationic bitumen emulsion
511.2.1. Scope:  This work shall consist of the preparation, laying and compaction of an
open graded premix surfacing of 20 mm thickness composed of small—sized aggregate
premixed with cationic bitumen.emulsion on a previously prepared surface, in accordance

522 RED BOOK  VOLUME I  ROADS  2012

with the requirements of these Specifications, to serve as a wearing course.
511.2.2. Materials
511.2.2.1. Binder: The binder for Premix wearing course shall be cationic bitumen emulsion
of Medium Setting (MS) grade complying with 1.8.8887 and having a bitumen content 65
per cent minimum by _ weight. For liquid seal coat RS grade of Cationic bitumen emulsion
shall be used. Where expressly specified in the Contract MS grade emulsion shall be used
or otherwise directed by the Engineer. Slow Setting (SS) grade Cationic bitumen Emulsion
shall be used for premix seal coat.
511.2.2.2. Aggregate: The requirements of Clause 511.1.2.2. shall apply.
511.2.3. Proportioning of materials: The materials shall be proportioned as quantities
given in Tables 500-24 and 500-25.
511.2.4. Construction operations
511.2.4.1. Weather and seasonal limitations: Clause 501.5.1 shall apply except that the
minimum air temperature for laying shall be 10°C. `Cationic bitumen emulsions shall not
normally be stored below 0°C.
511.2.4.2. Preparation of surface: The underlying surface on which the premix surfacing
is to be laid shall be prepared, in accordance with the requirements of Clause 504.3.2 for a
newly primed surface, and in accordance with Clause 507.4.2 where an existing bituminous
surface is to be overlaid.
511.2.4.3. Preparation of binder: Before opening, the cationic bitumen emulsion drums
shall be rolled at slow speed, to and fro, at least 5 times, for a distance of about 10 metres,
to distribute any storage sedimentation.
51 1.2.4.4. Tack coat : A tack coat complying with Clause 503, shall be applied over the
surface preparatory to laying of the surfacing where specified in the Contract, or directed
by the Engineer. 511.2.4.5. Preparation of premix : Premixing of cationic bitumen emulsion
and aggregates can be carried out in a suitable mixer such as cold mixing plant as per IS:
5435 (Revised) or concrete mixer or by pay loaders in exceptional cases where approved
by the Engineer. Where specified in the Contract continuous mixing operation shall be done
either in batch or continuous hot mix plant suitable for emulsion mixes.
When using concrete mixer for preparing the premix, 0.135 cu.m. (0.09 cu.m. of 13.2 mm
size _and 0.045 cu.m. of 11.2 mm size) of aggregates per batch shall be used which
quantity will cover 5 sq.m. of road surface with 20 mm average thickness.
The aggregates required for one batch shall be prepared adjacent to the mixer.
First the coarse aggregate of 13.2 mm size shall be placed into the mixer followed by 5 to
6.5 kg of Cationic bitumen emulsion and then the 1 1.2 mm size aggregate shall be added,
followed by 5 to 6.5 kg of Cationic bitumen emulsion. After the materials have been mixed
thoroughly, the mix shall be immediately transported to the laying site in suitable vehicles.
Too much mixing shall be avoided. `
When mixed manually by shovels, with the approval of the Engineer, 0.06 cu.m. of
aggregates can be conveniently mixed in one heap, with appropriate quantity of emulsion.
It is preferable to make the aggregates damp before mixing as it reduces the effort required
for mixing and also helps to get better coating of aggregates. The 13.2 mm size aggregates
and emulsion are mixed first and then the 11.2 mm size aggregates and remaining quantity
of emulsion is added and mixed. Too much mixing shall be avoided.
511.2.4.6. Spreading and rolling: The premixed cationic bitumen emulsion and aggregates
shall be spread within 10 minutes of applying the tack coat. All levelling, raking, etc. should
RED BOOK  VOLUME I  ROADS  2012 523
be completed within 20 minutes of the time of mixing.
The mix should be spread uniformly to the desired thickness, grades and crossfall (camber)
making due allowance for any extra quantity required to fill up depressions, if any. The
crossfall should be checked by means of camber boards and irregularities leveled out. Too
much raking is to be avoided.
The rolling shall start immediately after laying the premix. A smooth wheeled tandem roller
of 8-10 tonnes shall be used, unless other compaction methods are approved by the
Engineer, based on the results of laying trials, if necessary. While rolling, wheels of roller
should be clean and kept moist to prevent the premix from adhering to the wheels. In no
case shall fuel / lubricating oil be used for this purpose. Use of - water for this purpose shall
be strictly limited to an absolute minimum.
Rolling shall commence at the edges and progress towards the centre longitudinally except
in the case of super-elevated and uni—directional cambered sections where rolling shall
be carried out from the lower edge towards the higher edge parallel to the centre line of the
road.
After one pass of roller over the whole area, depressions or uncovered spots should be
corrected by adding premix material. Rolling shall be continued until the entire surface has
been rolled to maximum compaction and all the roller marks eliminated. In each pass of
the roller the preceding track shall be overlapped uniformly by at least 1/3 width. Roller(s)
shall not stand on newly laid material. Joints both longitudinal and transverse to the road
sections laid and compacted earlier, shall be cut vertically to their full depth so as to expose
fresh surface which shall be painted with a thin surface coat of binder before the new mix
is placed against it.
511.2.4.7. Seal coat: A seal coat, conforming to Clause 510 or Clause 513, as specified in
the Contract, shall be applied 4 to 6 hours after laying the premix carpet.
511.2.5. Opening to traffic:  Traffic should not be allowed over the premix surface with
or without seal coat, for 6 to 8 hours after rolling. In case of single lane roads, traffic shall
be allowed onto the surface once it has reached ambient temperature, but speed must be
rigorously restricted to not more thanl6 km per hour. If any premix material is picked up by
vehicle tyres, the spot shall be filled up by new mix. If traffic conditions permit, the road shall
not be opened until a full 24 hours after laying.
511.2.6. Surface finish and quality control:  The surface finish of construction shall
conform to the requirements of Clause 902. For control of the quality of materials supplied
and the works carried out, the relevant provisions of Section 900 shall apply.
511.2.7. Arrangements for traffic:  During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of Clause 112.
511.2.8. Measurement for payment: Open graded premix carpet shall be measured
as finished work, for the area specified to be covered, in square metres at the specified
thickness, in cubic metres, or in tonnes weight as specified in the Contract. The area will be
the net area covered, and all allowances for wastage and cutting of joints shall be deemed
to be included in the rate. .
511.2.9. Rate: The contract unit rate for premix carpet and seal coat shall be payment in
full for carrying out the required operation-s including full compensation for all components
listed in Clause 501.8.8.2. (i) to (xi).
Bitumen quantities are to be as stated in Table 500-23 for premix, 3.0 Kg per 10 sq.m. for
tack coat, 13Kg per 10 sq.m. for liquid seal coat and 11 Kg per 10 sq.m. for premix seal
coat. The rate will be adjusted according to actual material used.

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512. CLOSE-GRADED PREMIX SURFACING/MIXED SEAL SURFACING.
512.1. Scope
512.1.1. This work shall consist of the preparation, laying and compaction of a close-
graded premix surfacing material of 20 mm thickness composed of graded aggregates
premixed with a bituminous binder on a previously prepared surface, in accordance with
the requirements of these Specifications, to serve as a wearing course.
512.1.2. Close graded premix surfacing shall be of Type A or Type B as specified in the
Contract documents.
512.2. Materials
512.2.1. Binder: The provisions of Clause 511.1.2.1 shall apply.
512.2.2. Coarse aggregates: The provisions of Clause 51 1.1.2.2 shall apply.
512.2.3. Fine aggregates: The fine aggregates shall consist of crushed rock quarry sands,
natural gravel I sand or a mixture of both. These shall be clean, hard, durable, un-coated,
mineral particles, dry and free from injurious, soft or flaky particles and organic or deleterious
substances.
512.2.4. Aggregate gradation: The coarse and fine aggregates shall be so graded or
combined as to conform. to one or the other gradings shown in Table 500-26, as specified
in the contract.
512.2.5. Proportioning of materials: The total quantity of aggregates used for Type A or
B close-graded premix surfacing shall be 0.27 cubic metre per 10 square metre area. The
quantity of binder used for premixing in terms of straight-run bitumen shall be 22.0 kg and
19.0 kg per 10 square metre area for Type A and Type B surfacing respectively.
512.3. Construction Operations.
The provisions of Clause 511.1.3.1 through 511.1.3.5 shall apply.
512.4. Opening to Traffic
Traffic may be allowed after completion of the final rolling when the mix has cooled down to
the surrounding temperature. Excessive traffic speeds should not be permitted.
512.5. Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902. For
control on the quality of materials supplied and the works carried out, the relevant provisions
of Section 900 shall apply.
512.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be in accordance with the
provisions of Clause 112.
512.7. Measurements for Payment
Close-graded premix surfacing, Type A or B shall be measured as finished work, for the
area specified to be covered, in square metres at a specified thickness. The area will be
the net area covered, and all allowances for wastage and cutting of joints shall be deemed
to be included in the rate.
512.8. Rate
The contract unit rate for close-graded premix surfacing, Type A or B shall be payment in
full for carrying out the required operations including fill compensation for all components
listed in Clause 501.8.8.2. (i) to (xi).

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513. SEAL COAT
513.1. Scope
513.1.1. This work shall consist of the application of a seal coat for sealing the voids in a
bituminous surface laid to the specified levels, grade and cross fall (camber). 513.1.2. Seal
coat shall be of either of the two types specified below:
(A) Liquid seal coat comprising of an application of a layer of bituminous binder followed
by a cover of stone chips.
(B) Premixed seal coat comprising of a thin application of tine aggregate premixed with
bituminous binder.
513.2. Materials
513.2.1. Binder 1 The requirements of Clauses 511.1.2.1 and 511.2.2.1 shall apply.
The quantity of bitumen per 10 square metres, shall be 9.8 kg for Section 500 Base and
Surface Courses (Bituminous) Type A, and 6.8 kg for Type B seal coat. Where bituminous
emulsion is, used as a binder the quantities for Type A and Type B seal coats shall be 15
Kg and 10.5 Kg respectively.
513.2.2. Stone chips for Type A seal coat: The stone chips shall consist of angular
fragments of clean, hard, tough and durable rock of uniform quality throughout. They should
be free of soft or disintegrated stone, organic or other deleterious matter. Stone chips shall
be of 6.7mm size defined as 100 per cent passing through 11.2 mm sieve and retained on
2.36 mm sieve. The quantity used for spreading shall be 0.09 cubic metres per 10 square
metre areas. The chips shall satisfy the quality requirements in Table 500-3 except that the
upper limit for water absorption value shall be 1 per cent.
513.2.3. Aggregate for Type B seal coat: The aggregate shall be sand or grit and shall
consist of clean, hard, durable, uncoated dry particles and shall be free from dust, soft or
flaky / elongated material, organic matter or other deleterious substances. The aggregate
shall pass 2.36mm sieve and be retained on 180 micron sieve. The quantity used for
premixing shall be 0.06 cubic metres per 10 square metres area.
513.3. Construction Operations
513.3.1. Weather and seasonal limitations: The requirements of Clause 501.5.1 shall
apply.
513.3.2. Preparation of surface: The seal coat shall be applied immediately after laying
the bituminous course which is required to be sealed. Before application of seal coat
materials, the surface shall be cleaned free of any dust or other extraneous matter.
513.3.3. Construction of Type A seal coat : Bitumen shall be heated to 150°C—163°C
and sprayed at the rate specified on the dry surface in a uniform manner with a self-
propelled mechanical sprayer as described in the Manual for Construction and Supervision
of Bituminous Works.
Immediately after the application of binder, stone chips, which shall be clean and dry,
shall be spread uniformly at the rate specified on the surface preferably by means of a
self-propelled or towed mechanical grit spreader so as to cover the surface completely. If
necessary, the surface shall be brushed to ensure uniform spread of chips. .
Immediately after the application of the cover material, the entire surface shall be rolled
with 8 - 10 tonne smooth wheeled steel roller, 8 - 10 tonne static weight vibratory roller,
or other equipment approved by the Engineer after laying trials if required. Rolling shall
commence at the edges and progress towards the centre except in superelevated and

526 RED BOOK  VOLUME I  ROADS  2012

unidirectional cambered portions where it shall proceed from the lower edge • to the higher
edge. Each pass of the roller shall uniformly overlap not less than one-third of the track
made in the preceding pass. While rolling is in progress, additional chips shall be spread
by hand in necessary quantities required to make up irregularities. Rolling shall continue
until all aggregate particles are firmly embedded in the binder and present a uniform closed
surface,
513.3.4. Construction of Type B seal coat: A mixer of appropriate capacity and type
approved by the Engineer shall be used for preparation of the mixed material. The plant
shall have separate dryer arrangements for heating aggregate,
The binder shall be heated in boilers of suitable design, approved by the Engineer to
the temperature appropriate to the grade of bitumen or as directed by the Engineer. The
aggregates shall be dry and suitably heated to a temperature between l50°C and l65°C or
as directed by the Engineer before these components are placed in the mixer. Mixing of
binder with aggregates to the specified proportions shall be continued until the latter are
thoroughly coated with the former.
The mix shall be immediately transported from the mixing plant to the point of use and
spread uniformly on the bituminous surface to be sealed.
As soon as a sufficient length has been covered with the premixed material, the surface
shall be rolled with an 8-10 tonne smooth-wheeled roller. Rolling shall be continued until
the premixed material completely seals the voids in the bituminous course and a smooth
uniform surface is obtained.
513.4. Opening to Traffic
In the case of Type B seal coat, traffic may be allowed soon after final rolling when the
premixed material has cooled down to the surrounding temperature. In the case of Type A
seal coat, traffic shall not be permitted to run on any newly sealed area until the following day.
In special circumstances, however, the Engineer may open the road to traffic immediately
after rolling, but in such cases traffic speed shall be rigorously limited to 16 km per hour
until the following day.
513.5. Surface Finish and Quality Control of Work: The surface finish of construction
shall conform to the requirements of Clause 902.
For control on the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
513.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
513.7. Measurement for Payment
Seal coat, Type A or B shall be measured as finished work, over the area specified to be
covered, in square metres at the thickness specified in the Contract.
513.8. Rate
The contract unit rate for seal coat Type A or B shall be payment in hill for carrying out
the required operations including full compensation for all components listed in Clause
501.8.8.2. (i) to (xi).
514. SUPPLY OF STONE AGGREGATES FOR PAVEMENT COURSES
514.1. Scope
This Specification Clause shall apply to the supply of stone aggregates only. The work

RED BOOK  VOLUME I  ROADS  2012 527

shall consist only of collection, transportation and stacking the stone aggregates and stone
filler for subsequent use in pavement courses. The actual work of laying the pavement
courses shall, however, be governed by the individual Specification Clause for the actual
work, given elsewhere in this Specification. The size and quantities of the aggregates to be
supplied shall be so selected by the Engineer that the grading requirements set forth in the
individual Specification Clauses for the pavement courses, for which the supply is intended,
are satisfied. All the materials shall be procured from approved sources and shall conform
to the physical requirements, specified in the respective
Specification Clauses for the individual items given elsewhere in this Specification.
514.2. Sizes of Stone Aggregates
The stone aggregates shall be designated by their standard sizes in the Contract and shall
conform to the requirements shown in Table 500- 27.
514.3. Stacking
1. Coarse Aggregates: Only the aggregates satisfying the Specification requirements
shall be conveyed to the roadside and stacked. Each size of aggregate shall be stacked
separately. Likewise, materials obtained from different quarry sources shall be stacked
separately and in such a manner that there is no contamination of one source with another.
2. Fine Aggregate: As stated in the individual relevant Specification Clauses.
The aggregates shall be stacked entirely clear of the roadway on even clear hard ground,
or on a platform prepared in advance for the purpose by the Contractor at his own cost
and in a manner that allows correct and ready measurement. If the stockpile is placed on
ground where the scraping action of the loader can contaminate the material with underlying
soil, then the stockpile shall be rejected by the Engineer. Materials shall not be stacked in
locations liable to inundation or flooding.
The dimensions of the stockpiles and their location shall be approved by the Engineer.
Where the material is improperly stacked, the Engineer shall direct complete re-stacking of
the materials in an approved manner at the Contractor’s cost.
Stone filler shall be supplied in a dry state in bags or other suitable containers approved by
the Engineer and shall be protected from the environment, so as to prevent deterioration
in quality.
514.4. Quality Control of Materials
The Engineer shall exercise control over the quality of the materials so as to ascertain
their conformity with the Specification requirements, by carrying out tests for the specified
properties.
Testing shall be to the following frequencies and the Engineer may, at his discretion, direct
these to be modified according to requirements:
Coarse and fine: One test for each specified property per 50 m’ of stone aggregates.
Stone filler: One test for each specified property for every five tonnes, subject to a minimum
of one test for each consignment.
Materials shall only be brought to site from a previously tested and approved source, and
any materials not conforming to the requirements of the Specification shall be rejected by
the Engineer and removed from the work site.
514.5. Measurement for Payment
Coarse and fine aggregates supplied to the site shall be paid for in cubic metres. The actual
volume of the aggregates to be paid for shall be computed after deducting the specified

528 RED BOOK  VOLUME I  ROADS  2012

percentages in Table 500-28, from me volume computed by stack measurements, to allow
for bulking.
Unless otherwise directed by the Engineer, measurements shall not be taken until
sufficient materials for use on the road have been collected and stacked. Immediately after
measurement, the stacks shall be marked by white wash or other means as directed by the
Engineer.
Stone filler as delivered to the site shall be measured in tonnes.
514.6. Rates
The contract unit rates for different sizes of coarse aggregate, line aggregate and stone
filler shall be payment in full for collecting, conveying and stacking or storing at the site
including full compensation for:
i) all royalties, fees, rents where necessary;
(ii) all leads and lifts; and
(iii) all labour tools, equipment and incidentals to complete the work to the Specifications.
(iv) all necessary testing of material, both initial, to approve the source, and regular
control testing thereafter.
515. MASTIC ASPHALT
515.1. Scope
This work shall consist of constructing a single layer of mastic asphalt wearing course for
road pavements and bridge decks.
Mastic asphalt is an intimate homogeneous mixture of selected well- graded aggregates,
filler and bitumen in such proportions as to yield a plastic and void less mass, which when
applied hot can be trowel led and floated to form a very dense impermeable surfacing.
515.2. Materials
515.2.1. Binder: Subject to the approval of the Engineer, the binder shall be a paving
grade bitumen meeting the requirements given in Table 500-29
515.2.2 Coarse aggregate: The coarse aggregate shall consist of crushed stone, crushed
gravel/shingle or other stones. They shall be clean, hard, durable of fairly cubical shape,
uncoated and free from soft, organic or other deleterious substances. They shall satisfy the
physical requirements given in Table 500-3.
The percentage and grading of the coarse aggregate to be incorporated in the mastic
asphalt depending upon the thickness of the finished course shall be as specified in Table
500-B0.
Fine aggregate : The fine aggregate shall be the fraction passing the 2.36 mm and retained
on the 0.075 mm sieve consisting of crusher run screening, natural sand or a mixture of
both. These shall be clean, hard, durable, uncoated, dry and free from soft or flaky pieces
and organic or other deleterious substances.
Filler : The filler shall be limestone powder passing the 0.075 mm sieve and shall have
a calcium carbonate content of not less than 80 percent by weight when determined in
accordance with IS: 1514. The grading of the fine aggregate inclusive of filler shall be as
given in Table 500-31.

515.3. Mix Design

515.3.1. Hardness number: The mastic asphalt shall have a hardness number at the time
RED BOOK  VOLUME I  ROADS  2012 529
of manufacture of 60 to 80 at 25°C prior to the addition of coarse aggregate and 10 to 20 at
25°C at the time of laying after the addition of coarse aggregate.
The hardness number shall be determined in accordance with the method specified in IS:
1195-1978. 515.3.2. Binder content: The binder content shall be so fixed as to achieve the
requirements of the mixture specified in Clause 515.3.1. and shall be in the range of 14 to
17 per cent by weight of total mixture as indicated in Table 500-32.
515.3.3. Job mix formula: The Contractor shall inform the Engineer in writing at least 1
month before the start of the work of the job mix formula proposed to be used by him for the
work, indicating the source and location of all materials, proportions of all materials such
as binder and aggregates, single definite percentage passing each sieve for the mixed
aggregate and results of the tests recommended in the various Tables and Clauses of this
Specification.
515.4. Construction Operations
515.4.1. Weather and seasonal limitations: The provisions of Clause 501.5.1 shall apply,
except that laying shall not be carried out when the air temperature at the surface on which
the Mastic Asphalt is to be laid is below 10°C.
515.4.2. Preparation of the base: The base on which mastic asphalt is to be laid shall be
prepared, shaped and conditioned to the profile required, in accordance with Clause 501 or
902 as appropriate or as directed by the Engineer. In the case of a cement concrete base,
the surface shall be thoroughly power brushed clean and free of dust and other deleterious
matter. Under no circumstances shall mastic asphalt be spread on a base containing a
binder which might soften under high application temperatures. If such material exists, the
same shall be cut out and repaired before the mastic asphalt is laid.
515.4.3. Tack coat: A tack coat in accordance with Clause 503 shall be applied on the
base or as directed by the Engineer.
515.4.4. Preparation of mastic asphalt: Penetration of mastic asphalt consists of two
stages. The first stage shall be mixing of filler and fine aggregates and then heating the
mixture to a temperature of 170"C to 210°C. Required quantity of bitumen shall be heated
to 170°C to 180°C and added to the heated aggregated. They shall be mixed and cooked
in an approved type of mechanically agitated mastic cooker for some time till the materials
are thoroughly mixed. Initially the filler alone is to be heated in the cooker for an hour and
then half the quantity of binder is added. After heating and mixing for some time, the fine
aggregates and the balance of binder are to be added and further cooked for about one
hour. The second stage is incorporation of coarse aggregates and cooking the mixture for
a total period of 3 hours. During cooking and mixing, care shall be taken to ensure that the
contents in the cooker are at no time heated to a temperature exceeding 210"C.
Where the material is not required for immediate use it shall be cast into blocks consisting
of filler, fine aggregates and binder, but without the addition of coarse aggregate, weighing
about 25 Kgs each. Before use, these blocks shall be reheated to a temperature of not less
than 175°C and not more than 210°C, thoroughly incorporated with the requisite quantity of
coarse aggregates and mixed continuously. Mixing shall be continued until laying operations
are completed so as to maintain the coarse aggregates in suspension. At no stage during
the process of mixing shall the temperature exceed 210°C.
The mastic asphalt blocks (without coarse aggregate) shall show on analysis a composition
within the limits as given in Table 500-32.
The mixture shall be transported to the laying site in a towed mixer transporter having
arrangement for stirring and keeping the mixture hot during transportation.

530 RED BOOK  VOLUME I  ROADS  2012

515.4.5. Spreading: The mastic asphalt shall be laid, normally in one coat, at a temperature
between 175°C and 210°C and spread uniformly by hand using wooden floats or by
machine on the prepared and regulated surface. The thickness of the mastic asphalt and
the percentage of added coarse aggregate shall be in accordance with Table 500-30 or as
specified by the Engineer. Where necessary, battens of the requisite dimensions should be
employed. Any blow holes that appear in the surface shall be punctured while the material
is hot, and the surface made good by further floating.
515.4.6. Joints: All construction joints shall be properly and truly made. These joints shall
be made by warming existing mastic asphalt by the application of an excess quantity of
the hot mastic asphalt mixture which afterwards shall be trimmed to leave it flush with the
surfaces on either side.
515.4.7. Surface finish: The mastic asphalt surface can have poor skid resistance after
floating; in order to provide resistance to skidding, the mastic asphalt after spreading, while
still hot and in a plastic condition, shall be covered with a layer of stone aggregate, This
aggregate shall be 13.2 mm size (passing the 19.0 mm sieve and retained on the 9.5
mm sieve) or 9.5mm size (passing the 13.2 mm sieve and retained on the 6.7 mm sieve)
subject to the approval of the Engineer. Hard stone chips, V complying with the quality
requirements of Table 500-17, shall be precoated with bitumen at the rate of 2 ± 0.4% of
IS-65 penetration grade. The addition of 2% of filler complying with Table 500-9 may be
required to enable this quantity of binder to be held without draining. The chips shall then
be applied at the rate of 0.005 cu. m. per 10 sq. m. and rolled or otherwise pressed into
the surface of the mastic layer when the temperature of the mastic asphalt is not less than
100°C.
Opening to Traffic
Traffic may be allowed after completion of the work when the mastic asphalt temperature
at the mid-depth of the completed layer has cooled to the daytime maximum ambient
temperature.
515.6. Surface Finish and Quality Control of Work
The surface finish of the completed construction shall conform to the requirements of
Clause 902.
For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
The surface of the mastic asphalt, tested with a straight edge 3.0m long, placed parallel to
the centre line of the carriageway, shall have no depression greater than 7mm. The same
limit shall also apply to the transverse profile when tested with a camber template.
515.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
515.8. Measurement for Payment
Mastic asphalt shall be measured as finished work in square metres at a specified thickness,
or by weight in tonnes as stated in the Contract.
515.9. Rate
The contract unit rate for mastic asphalt shall be payment in full for carrying out the required
operations including full compensation for all components listed under Clause 501.8.8.2.
(i) to (ix).
516. SLURRY SEAL
RED BOOK  VOLUME I  ROADS  2012 531
516.1. Scope
Slurry seals are mixtures of fine aggregate, portland cement filler, bitumen emulsion and
additional water. When freshly mixed, they have a thick consistency and can be spread to a
thickness of 1.5 — 5 mm. They may be used to seal cracks, arrest fretting and fill voids and
minor depressions, to provide a more even riding surface or a base for further treatment;
they may also be used on top of a single coat surface dressing.
516.2. Materials
The materials for slurry seal immediately prior to mixing shall conform to the following
requirements:
516.2.1. Emulsified bitumen: The emulsified bitumen shall be a cationic rapid setting
type as approved by the Engineer, conforming to the requirements of IS: 8887. Where
special mobile mixing machines are available, Class A4* rapid setting or Class K3*
road emulsions to BS 434: Part 1 should be used to obtain very early resistance to
traffic and rain. Generally, emulsion for slurry seal should be capable of producing slurry
that will develop early resistance to traffic and rain and is sufficiently stable to permit
mixing with the specified aggregate, without breaking during the mixing and laying
processes. If approved by the Engineer, a slow setting emulsion may be used. Guidance
on selection of an appropriate grade of emulsion is given in the Manual for Construction
and Supervision of Bituminous Works. .
516.2.2. Water:  Water shall be of such quality that the bitumen will not separate from
the emulsion before the slurry seal is in place.
The pH of the water must lie in the range 4 to 7, and if the total dissolved solids in the
water amount to more than 500ppm, the Engineer may reject it, or order the Contractor
to conduct a trial emulsion mix to demonstrate that it does not cause early separation.
516.2.3. Aggregate : The aggregate shall be crushed rock, or slag and may be blended,
if required, with clean, sharp, naturally occurring sand free from soft pieces and organic
and other deleterious substances to produce a grading as given in Table 500-33. The
aggregates shall meet the requirements of the film stripping test (IS: 6241), and a
suitable amount and type of anti-stripping agent added, as may be needed (details given
in Appendix 5).
516.2.4. Additives:  It is usual to use ordinary Portland cement, hydrated lime or other
additives to control consistency, mix segregation and setting rate. The proportion of the
additive should not normally exceed 2 per cent by weight of dry aggregates.
*The corresponding grades in IS: 8887 are only broadly classified as RS, MS and SS
and further sub classification is not available at present.
516.3. Mixture Design
A range of residual binder contents for each aggregate grading is given in Table 500-
33. The optimum mixture design for the aggregate, additive, water and bitumen emulsion
mixture should be determined in accordance with ASTM D 3910.
516.4. Construction Operations
516.4.1. Weather and seasonal limitations: Clause 501.5.1 shall apply.
516.4.2. Surface preparation:  Any necessary remedial work to the road surface and
structure shall be completed either prior to or as part of the contract and agreed as
acceptable by the Engineer, according to the provisions of Clause 501.
Before slurry seal is applied, street furniture and, where directed by the Engineer, road
markings, shall be masked using self-adhesive masking material or other material firmly

532 RED BOOK  VOLUME I  ROADS  2012

 secured against the passage of the spreader box or the tools used for hand laying. Any
packed mud or other deposits on the surface shall be removed, all organic growth shall
be removed by suitable means, and the surface shall be swept free of all loose material.
516.4.3. Tack coat: If required by the Engineer, a tack coat may be applied prior to the
slurry seal, with or without grit or chips, in order to seal the existing substrata and enhance
the bond to the existing road surface. Unless otherwise agreed by the Engineer, the rate
of spread of tack coat shall be 0.15 to 0.30 litres/m2 for bituminous surfaces and 0.4 to 0.6
litres/m2 for concrete surfaces
516.4.4. Mixing and transportation of mixture: Mixing (and laying) techniques vary according
to the type of emulsion used. For class A4 rapid setting and K3 emulsions, only special
mobile mixing machines should be used. These carry supplies of aggregate, emulsion,
water and filler (e. g. ordinary Portland cement or hydrated lime) and are fitted with metering
devices to feed the ingredients in their correct proportions to a mixer fitted to the rear of the
machine. From the mixer the slurry is fed into the screed box towed by the machine.
For all other emulsions, mixing may be by hand, concrete mixer or other mixer which
effectively coats the aggregate uniformly and produces a slurry seal of suitable consistency
for satisfactory laying. For large areas, a bulk transit concrete mixer may be used into which
the ingredients (including water) are measured and mixed as the mixer travels to the area
to be treated. A screed box fitted with an adjustable rubber screed should be towed by the
mixer which feeds it during laying.
The special mobile mixing machine, when used, shall be capable of uniform application
to provide a continuous surface without ridges or segregation. Before laying begins, the
Contractor shall provide the Engineer with a test certificate showing test results for rate
of application carried out under the supervision of a competent authority, demonstrating
that the machine has been tested, using the system to be used in the Contract, not more
than six weeks before the commencement of the work. Where the material is to be hand
laid, the slurry may be supplied to site pre-mixed in suitable containers and steps shall be
taken to ensure that the material in each container is of an even consistency throughout the
container immediately prior to use.
516.4.5. Application: Transverse joints for machine laid areas shall be formed with
spreading, starting and finishing on a protective strip not less than 100 mm wide at each
end of the lane length being treated. Transverse joints shall be formed such that there shall
be no ridges or bare strips.
Unless otherwise approved by the Engineer, longitudinal joints shall coincide with lane
markings. Longitudinal joints shall be formed such that there shall be no ridges or bare
strips.
Hand work around street furniture and other obstructions should meet the same performance
requirements and form a homogeneous surface with the rest of the treated carriageway.
Footways and other confined areas may be spread by hand using squeegees and brooms.
Transverse joints shall be formed with spreading, starting and finishing on a protective strip
not less than 100 mm wide at each end of the lane length being treated. Transverse joints
shall be formed such that there shall be no ridges or bare strips. Kerb edges and other
areas not being treated shall be suitably masked with self adhesive masking material.
Footways shall be finished by dragging a dampened broom transversely over the footway
under its own weight.
All voids, cracks and surface irregularities shall be completely filled. In warm dry weather
the surface, immediately ahead of the spreading, shall be slightly damped by mist water
spray applied mechanically, or for hand laying by a hand operated pressure sprayer, unless

RED BOOK  VOLUME I  ROADS  2012 533

otherwise approved by the Engineer.
516.4.6. Rolling: The need for rolling shall be as instructed by the Engineer. Where rolling
is required, a pneumatic-tyred roller having an individual wheel load between 0.75 and 1.5
tonnes shall be used, or as may be directed by the Engineer. Rolling shall commence as
soon as the slurry has set sufficiently to ensure that rutting or excessive movement will not
occur.
516.5. Opening to Traffic
Masking shall be removed after the slurry seal has been applied, without damage to the
edge of the surfacing, and before opening the road or footway to traffic.
The Contractor shall remove surplus aggregate from the treated areas using a method
agreed by the Engineer. The Contractor shall monitor the slurry seal closely for a minimum
period of 2 hours and if necessary the lane shall be swept again. The monitoring shall
continue until the slurry seal has reached sufficient stability to carry unrestricted traffic.
If there are signs of distress, the Engineer shall require the Contractor to reinstate traffic
safety and management procedures or other such remedial action where necessary in
order to prevent further damage.
Further operations to remove subsequently loosened aggregate shall be carried out over
the next 48 hours. The areas treated and adjacent side roads, footways and paved areas
shall be kept substantially free of loose aggregate for a period of 30 days after completion
of the work.
516.6. Surface Finish and Quality Control of Work
Generally, the surface finish of the completed construction shall conform to the requirements
of Clause 902. For control of the quality of materials supplied and the works carried out, the
relevant provisions of Section 900 shall apply.
In addition, the finished slurry shall have a uniform surface texture throughout the work,
without variations of texture within the lane width, or from lane to lane, due to segregation
of aggregates, or due to variations in the emulsion/water content of the mixture.
The finished surface shall be free from blow holes and surface irregularities in excess of
3 mm beneath a 1 metre straight edge due to scraping, scabbing, dragging, droppings,
excess overlapping or badly aligned longitudinal or transverse joints, damage by rain or
frost, or other defects which remain 24 hours after laying.
516.7. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
516.8. Measurement for Payment
Slurry seal shall be measured as finished work as specified, in square metres.
516.9. Rate
The contract unit rate for slurry seal shall be payment in full for carrying out the required
operations including full compensation for all components listed in Clause 501.8.8.2. (i) to
(xi).

517. RECYCLING OF BITUMINOUS PAVEMENT

517.1. Scope
This Clause of the Specifications covers the recycling of existing bituminous pavement
materials to upgrade an existing bituminous pavement which has served its first-intended

534 RED BOOK  VOLUME I  ROADS  2012

purpose. The work shall be performed on such widths and lengths as may be directed by
the Engineer and may consist of pavement removal, stockpiling of materials from the old
pavement, addition of new bitumen and untreated aggregate in the requisite proportions,
mixing, spreading and compaction of the blended materials.
Recycling processes can be categorised into in-situ recycling (where processing takes
place on site), and central plant recycling (where reclaimed material is processed off site).
The processes can be further sub-divided into hot and cold processes. This Specification
covers the hot process only. However, reclaimed aggregate from cold in-situ recycling can
be used in the Bituminous Cold Mix process specified in Clause 519, subject to the resultant
mixes achieving the specified standards.
517.2. Reclaimed Bituminous Materials for Central Plant Recycling
517.2.1. Proportion of reclaimed materials less than 10 per cent: If not more than 10% of
reclaimed bituminous material is to be used in the production of bituminous macadam or
dense graded bituminous base or binder course material, then Clauses 517.2.2 to 517.2.9
do not apply. However:
a) all reclaimed bituminous material shall be pre-treated before use such that the material
is homogeneously mixed and the maximum panicle size of reclaimed material does not
exceed 40 mm.
b) the mixed material shall comply with the requirements of Clauses 504 or 507 as
appropriate.
517.2.2. Proportions of reclaimed materials greater than 10 per cent: Reclaimed bituminous
material of an amount greater than 10 per cent, may be used in the production of bituminous
macadam and dense graded bituminous base and binder course material, subject to the
requirements of Clauses 517.2.3 to 517.2.9 and subject to the satisfactory completion of full
trial investigations in respect of all related materials, layer thickness, machine operations
and finished works on a case-by- case basis entirely at the contractors cost and subject
to the approval of the Engineer. For estimating purposes, a maximum amount not greater
than 30 per cent reclaimed bituminous material should be assumed.
517.2.3. Materials for recycled pavement: The recycled materials shall be a blend of
reclaimed and new materials proportioned to achieve a paving mixture with the specified
engineering properties. The reclaimed materials shall be tested and evaluated to find
the optimum blend meeting the mixture requirements. Such testing and evaluation shall
be carried out on representative samples, either cores sampled from the carriageway
or samples taken from stockpiles in accordance with current practice. The sampling
frequency should be sufficient to determine how consistent the reclaimed material is and
to provide representative samples for composition analysis and measurement of properties
of recovered binder. As an absolute minimum, one sample to represent 500m of lane
carriageway shall be taken.
517.2.4. Bitumen extraction: The procedure described in ASTM D—2172 shall be used to
quantitatively separate aggregate and bitumen from any representative sample of reclaimed
bituminous pavement.
517.2.5. Aggregate evaluation: Mechanical sieve analysis (IS: 2386, Part I, wet sieving
method) shall be performed on the aggregate portion of the reclaimed bituminous pavement
sample to determine the grading. It is essential that the reclaimed materials to be recycled
are consistent, as variable materials will cause problems with the control of quality and
impede the efficiency of the recycling operation. Suitable sources of consistent material of
sufficient quantity for the scheme being considered need to be identified either in existing
pavements, from stockpiled planings of known origin or from another suitable source,

RED BOOK  VOLUME I  ROADS  2012 535

before a decision can be made on the optimum percentage of reclaimed material.
After selecting the proportion of reclaimed materials to be recycled, the grading of the
mixture may need adjustment, to meet Specification requirements, by the addition of
selected aggregate sizes.
517.2.6. Evaluation of bitumen: When the amount of reclaimed bituminous materials to be
used in the mixture exceeds 10%, the penetration value of the recovered binder from the
reclaimed bituminous material, before mixing, shall exceed 15 pen, after recovery of binder
in accordance with the requirements of BS 2000 : Part 397, when tested in accordance
with IS : 1203. Provided the above requirement is met, hardening of the old binder, during
the original mixing process or through ageing, can be compensated for by adding a softer
bitumen, to obtain the appropriate final grade of binder.
The determination of the type and amount of binder required to be added in the final mix is
essentially a trial and error procedure.
After mixing with recycled materials, the binder recovered from the mixture shall have a
recovered penetration value not less than the value specified in Table 500-34.
517.2.7. Rejuvenators: The use of rejuvenators, and a test to measure their effectiveness,
is described in Clause 517.6.3.
517.2.8. Untreated aggregate: If necessary, fresh untreated aggregate shall be added to the
reclaimed bituminous pavement to produce a mix with the desired grading. The aggregate
shall be checked for quality requirements in accordance with Table 500-3 or Table 500-8 as
appropriate. Reclaimed aggregate, if any, or any aggregate normally used for the desired
bituminous mixture, or both, may be used for this purpose.
517.2.9. Combined aggregate grading: The blend of reclaimed and new aggregate shall
meet the grading criteria specified in the relevant parts of` Clause 504 or 507, as appropriate
and as approved by the Engineer. The blend of aggregates shall be checked for resistance
to stripping as specified in Tables 500-3 or 500-8 as appropriate.
517.3. Mixture Design
The combined aggregate grading and binder content shall comply with the relevant tables
in Clauses 504 or 507. For dense graded bituminous mixtures the mixture design shall also
comply with the requirements of Table 500-11.
517.4. Reclaiming Old Pavement Materials
The removal of pavement materials to the required depth shall be accomplished either
at ambient temperature (cold process) or at an elevated temperature (hot process), as
approved by the Engineer.
517.4.1. Cold removal process: In the cold process, the ripping and crushing operations
shall be carried out using scarifiers, grid rollers, or rippers or by any other means as directed
by the Engineer. The removed materials shall be loaded and hauled for crushing to the
required size as directed by the Engineer. Alternatively, cold milling or planning machines
can be used to reclaim bituminous pavement to controlled depths. After the bituminous
layers are removed, any remaining aggregate materials that are to be incorporated in the
recycled hot mixture shall be scarified and removed. When the pavement material removal
is completed, any drainage deficiencies shall be corrected. After that, the base/sub—base
as the case may be shall be cut, graded and compacted to the required profile and density.
517.4.2. Hot removal process: In this process, the road surface shall be heated, by any
suitable means approved by the Engineer, before scarification. A self propelled plant shall
be used, and a milling drum that follows the planer removes the heated soft bituminous
layer. The depth, width and speed of travel shall be adjusted to suit specific requirements

536 RED BOOK  VOLUME I  ROADS  2012

as directed by the Engineer. During the heating process, the surface temperature of the
road shall not exceed 200°C for more than 5 minutes.
517.4.3. Stockpiling: In the cold process, the reclaimed bituminous pavement material shall
be stockpiled with the height of stockpiles not exceeding 3 m. The reclaimed untreated
aggregate base/sub—base material shall be stockpiled in the same manner as new
aggregate. The number and location of stockpiles shall be carefully planned for efficient
operation of the hot-mix plant.
517.5. Mixing and Laying
Generally, the requirements of Clauses 504.3 or 507.4, as appropriate, shall apply.
517.6. In Situ Recycling - The Remix and Repave Processes
These processes are suitable for the production of bituminous concrete wearing course in
accordance with the provisions of Clause 509.
517.6.1. Scope: In the process of repaving, the existing surface is preheated and scarified
but the scarified material is not removed. A layer of fresh bituminous mix material prepared
in the integrated mixing unit of the plant is then spread evenly on the scarified surface to
give a uniform profile. The spread material should be compacted as soon as possible after
laying. In the process the total thickness of the pavement is increased by up to 50mm.
In the remix process, the scarified material should be taken from the mixing unit of the plant
where it is recycled with fresh binder, aggregate and recycling agent. Then the recycled
mixture is spread on the preheated surface and tamped and compacted to the required
profile.
517.6.2. Heating and scarifying: Surfaces to be treated shall be heated by plant with surfaces
insulated and fully enclosed. The heated width of surfacing shall exceed the scarified width
by at least 75 mm on each side, except against the edge of the carriageway or kerb face.
When new surfacing material is spilled onto the road surface it shall be removed before the
existing surface is heated and scarified. Areas of unscarified material shall not exceed 50
mm X 50 mm.
The depth of scarification shall be such that the bottom of the scarified layer is parallel
to and below the finished road surface level by the thickness of wearing course material
specified. A tolerance of x 6 mm is permissible.
Where street furniture and other obstructions occur, these shall be suitably protected or
removed and the void covered. Surface dressing and large areas of road markings shall be
removed by milling, planning, scarifying or by similar approved processes.
The heated surface shall be evenly scarified to comply with the requirements of this Clause.
When street furniture is left in place or raised, the adjacent areas shall be scarified by other
means, with the material either left in place or removed, prior to passage of the machine. If
furniture needs to be repositioned on completion of work, the new wearing course material
shall be used to make good the road surface for a maximum width of 200 mm around the
obstruction.
During the rehearing process the surface temperature of the road shall not exceed 200°C
for more than 5 minutes.
517.6.3. Rejuvenator: For Remix, when required, rejuvenator shall be uniformly sprayed
across the full-width of the processed material. The machine shall incorporate a meter for
continuous verification of quantities which shall be within ± 5% of the specified rate. The
volume of rejuvenator shall vary in relation to the operating speed of the machine, which
shall be related to the volume of material mixed or scarified.
The rejuvenator shall be a non-emulsified aromatic extract. Its properties shall be verified
RED BOOK  VOLUME I  ROADS  2012 537
using the Rolling Thin Film Oven Test.
Rejuvenation of the existing pavement may also be performed by adding new hot-mix
bituminous material containing a soft binder of suitable penetration for restoring the binder
in the existing pavement to the required penetration.
517.6.4. Mixing: When required, new hot-mix material shall be mixed with the heated and
scarified road pavement material in a pugmill within the Remix machine, observing the
mixing temperatures specified in Table 500-5.
After mixing, the recycled bituminous materials shall be automatically fed to a finishing unit,
which spreads and levels the mixture to the specified thickness and cross-section. The new
bituminous concrete wearing course shall be material complying with Clause 509.
517.6.5. Additional material (general): The proportion of new hot- mix bituminous material,
and the proportion of existing bituminous pavement material shall be as directed by the
Engineer, together with the amount the road surface level is to be raised (if any).
The type and quantity of the new hot-mix material shall be determined by using the
Marshall Mix Design procedure specified in The Asphalt Institute Manual MS-2, before work
commences. Remix designs shall incorporate the stated proportion of material sampled
from the existing road surface.
When additional coarse or fine aggregate or filler are required to be added, they shall
comply with the requirements of Clause 509.2. The amount of additional coarse or fine
aggregate or filler to be added to the existing bituminous pavement material shall be notified
to the Engineer.
517.6.6. Additional aggregate (remix process): The coarse
aggregate, fine aggregate and filler added to the Remixed material shall comply with the
requirements of Clause 509.2.
517.6.7. New surfacing (repave and remix/repave processes): New surfacing material
shall be bituminous concrete wearing course complying with Clause 509, or other wearing
course material approved by the Engineer.
The new surfacing material shall be laid on, and compacted with, the reprofiled surfacing,
which shall be at a temperature within the range of 100°C to 150°C.
517.6.8. Binder: The binder shall be recovered from samples taken from each layer of
material laid. The method of recovery shall be in accordance with BS 2000: Part 397 or an
equivalent test. The penetration of the binder shall be in the range 35-70 pen.
517.6.9. Mixture design: The surfacing material shall be sampled from the paver hopper
or augers. Care shall be taken that only the material forming the new surface layer is
sampled. The sample shall be reduced on site by rifling or quartering to approximately 5 kg
and placed loose in an air-tight container. The sample shall only be reheated once whilst
within the container. As soon as the sample reaches the required temperature, the reheated
material shall be remixed and three Marshall test specimens prepared in accordance with
the procedures specified in MS-2.
The bulk density of each specimen shall be measured before Marshall Stability testing.
The mean stability and flow of the three specimens, measured in accordance with the
procedures specified in MS-2, shall comply with the requirements of Table 500-19.
Finally the 3 Marshall specimens shall be combined and the maximum theoretical specific
gravity (Gmm) of the mixture is determined in accordance with ASTM D 2041. This maximum
theoretical specific gravity (Gmm) corresponds to 0% air voids in the mixture. The actual
bulk specific gravity of a Marshall specimen determined in the Laboratory (Gmm) will
naturally be less than Gmm. The percent air voids (Pa) in the specimen of the compacted
538 RED BOOK  VOLUME I  ROADS  2012
mixture given by Pa = Gmm - Gm mb x 100 / Gmm should be the requirements of air voids
laid down in Table 500-19.
517.7; Opening to Traffic
For recycled material forming the base or binder course layer, Clause 504.5 or 507.5 shall
apply as appropriate. For recycled material forming the wearing course layer, Clause 509.5
shall apply.
517.8. Surface Finish and Quality Control
The surface finish of the completed construction shall conform to the requirements of
Clause 902.
For control of the quality of materials supplied and the works carried out the relevant
provisions of Section 900 shall apply.
517.9. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
517.10. Measurement for Payment The recycled pavement work shall be measured in
cubic metres or tonnes of finished work as stated in the Contract,
517.11. Rate The contract unit rate for recycled pavement shall be payment in full for
carrying out the required operations including full compensation for all items as Clause
501.8.8.2. (i) to (xi)
518. FOG SPRAY
518.1. Scope
Fog spray is a very light application of low viscosity bitumen emulsion for purposes of
sealing cracks less than 3mm wide or incipient fretting or disintegration in an existing
bituminous surfacing, and to help reduce loosening of chips by traffic on newly finished
surface dressing.
518.2. Material
The bitumen emulsion shall be as specified in the Contract or as instructed by the Engineer.
The emulsion shall be SS—1h* (SS—1 can be used if the former is not available) complying
with the requirements of ASTM D—977, or; CSS- 1h* (CSS-1 can be used if the former is
not available) complying with the requirements of ASTM D-2397.
Before use these emulsions shall be diluted, 1 part emulsion to 1 part water. Alternatively,
Class A1-40* or K1-40* emulsions complying with the requirements of BS434: Part 1:1984
may be used. These emulsions have a lower viscosity than the above ASTM grades, they
are rapid setting and they do not require to be diluted. Because of their low viscosity they
should be used as soon as possible after delivery. If this is not possible, the drums should
be very thoroughly rolled before use.
518.3. Weather and Seasonal Limitations
Spraying shall not take place when the temperature is below 10°C, nor in windy or dusty
conditions, nor when it is raining or the surface to be sprayed is wet (a damp surface is
acceptable but refer to Clause 518.4.2.).
518.4. Construction Operations
518.4.1. Equipment: The fog spray shall be applied by means of a self propelled or towed
bitumen pressure sprayer complying with the requirements of the Manual for Construction
and Supervision of Bituminous Works. The spray bar should be protected from gusts of
wind by means of a hood.

RED BOOK  VOLUME I  ROADS  2012 539

518.4.2. Preparation of surface: The surface on which the fog spray is to be applied shall be
thoroughly cleaned with compressed air, scrubbers etc. The cracks shall be cleaned with a
pressure air jet to remove all dirt, dust etc.
518.4.3. Application: The fog seal shall be applied at a rate of 0.5 - 1.0 litres/m2, using
equipment such as pressure tank, flexible hose and spray bar or lance.
518.5. Blinding
If specified in the Contract or ordered by the Engineer, the fog spray shall be blinded with
graded grit of 3mm size and under, coated with about 2 per cent of the emulsion by weight.
The pre coated grit shall be
* The grades in IS:8887 are only broadly classified as RS, MS and SS and further sub-
classification is not available at present. allowed to be cured for at least one week or until
they become non-sticky and can be spread easily.
518.6. Quality Control of Work For control of the quality of materials supplied and the works
carried out, the relevant provisions of Section 900 shall apply.
518.7. Arrangements for Traffic
During the spraying operations, arrangements for traffic shall be made in accordance with
the provisions of Clause 112. The surface should not be opened to traffic for 24 hours after
spraying. If pick-up does occur a light blinding of crusher dust or sand should be applied.
518.8. Measurement for Payment
Fog spray and blinding (if used) shall be measured in terms of surface area of application,
for the area covered, in square metres.
518.9. Rate
The contract unit rate for fog spray and blinding (if used) shall be payment in full for carrying
out the required operations including full compensation for all components listed in Clause
501.8.8.2. (i) to (xi) as applicable to the work specified in these Specifications.
519. BITUMINOUS COLD MIX (INCLUDING GRAVEL EMULSION)
519.1. The Design Mix
Bituminous Cold Mix consists of a mixture of unheated mineral aggregate and emulsified
or cutback bitumen. This Specification deals only with plant mix (as opposed to mixed-in-
place). Two types of mix are considered, namely Designed Cold Mix and Recipe Cold Mix.
The Design Mix procedure shall be used unless the Recipe Mix procedure is specifically
approved by the Engineer.
This Specification Clause has been introduced for the first time. Difficulties in using this
Clause and suggestions for improvement may be forwarded to DG(RD), Ministry of Road
Transport & Highways, Transport Bhavan, Parliament Street, New Delhi-110 001. Fax #
3710236
519.2. Designed Cold Mix
This Specification is based on The Asphalt Institute Manual MS-14, which contains
additional information for guidance. These mixes are considered suitable for use as base
course, appropriate to their stability, in new work or major repair work.
519.2.1. Materials
519.2.1.1. Binder: The binder shall be a bituminous emulsion as specified in AASHTO M
140 (ASTM D977)* or AASHTO M 208 (ASTM D2397)*, namely MS-2, MS—2h, HFMS—2,
HFMS-2h, HFMS—2s, SS-1, SS-lh, CMS-2, CMS-2h, CSS-I and CSS-lh. Alternatively, a
cutback bitumen as specified in AASHTO M 82 (ASTM D2027) or ASTM D 2026, namely

540 RED BOOK  VOLUME I  ROADS  2012

MC 70, 250, 800 & 3000 and SC 250, 800 and 3000 may be used, or, if approved by the
Engineer, an equivalent material which conforms with IS:8887 and IS:217.
A general guide for the use of these binders is given in Table 500-35 and in the Manual for
Construction and Supervision of Bituminous Works. However the final selection shall be
made only after laboratory evaluation with the aggregates to be used. The binder with the
highest residual viscosity at ambient temperatures that can reasonably be handled by the
mixing and laying equipment proposed shall be used.
519.2.1.2. Aggregates: The aggregates shall comply with the requirements of Clause
504.2.2. and 504.2.3. If the aggregates are not properly coated with anionic emulsion or
cutback bitumen, a small amount of hydrated lime, an approved antistripping agent (see
Appendix 5) or a change to cationic emulsion shall be proposed by the Contractor, for the
approval of the Engineer.
519.2.1.3. Aggregate grading and binder content: The combined aggregate grading for the
particular mixture, when tested in accordance with 18:2386 Part 1, (wet sieving method),
shall fall within the limits shown in Table 500-36.
519.2.2. Mixture Design
519.2.2.1. Requirements for the mixture: Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture shall meet the requirements set out in
Table 500-37. 519.2.2.2. Binder content: The binder content shall be optimised to achieve
the requirements of the mixture set out in Table 500-41. The method adopted shall be that
described in Appendix F and H of Asphalt Institute’s Manual, MS-14.
519.2.2.3. Job Mix Formula: The Contractor shall inform the Engineer in writing, at least
one month before the start of the work; the job mix formula proposed for use in the works
and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder, as percentage by weight of total mixture;
(b) Coarse aggregate/fine aggregate as percentage by weight of total aggregate;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 500-39 as obtained by the Contractor;
(v) Test results of the physical characteristics of the aggregates to be used;
(vi) Spraying temperature of binder if appropriate.
While working out the job mix formula, the Contractor shall ensure that it is based on a
correct and truly representative sample of the materials that will actually be used in the
work and that the mixture and its different ingredients satisfy the physical and strength
requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer
for which samples selected jointly with the Engineer of all ingredients of the mix shall be
furnished by the Contractor as required by the former.
The approved job mix formula shall remain effective unless and until modified by the
Engineer. Should a change in the source of materials be proposed, a new job mix formula
shall be established and approved by the Engineer before actually using the materials.
519.2.2.4. Permissible variation from the job mix formula: It shall be the responsibility of the
Contractor to produce a uniform mix conforming to the approved job mix formula, subject
to the permissible variations of the individual percentages of the various ingredients in the

RED BOOK  VOLUME I  ROADS  2012 541

actual mix from the job mix formula to be used, within the limits as specified in Table 500-
39. These variations are intended to apply to individual specimens taken for quality control
tests in accordance with Section 900.
519.2.3. Construction operations
519.2.3.1. Weather and seasonal limitations: Construction with cold mix must not be
undertaken when ambient temperatures below l0°C are expected, during rain, in standing
water, or generally when poor weather is predicted. Bitumen emulsions and cutbacks
depend on the evaporation of water and/or solvent for the development of their curing and
adhesion characteristics. Cold weather, rain and high humidity slow down the rate of curing.
Extra manipulation may be required to remove volatiles in cool and humid conditions. Wind
increases the rate of evaporation.
519.2.3.2. Preparation of the base: The base on which cold mix is to be laid shall be
prepared, shaped and levelled to the required profile in accordance with Clauses 501 and
902 as appropriate, and a prime coat, where specified, shall be applied in accordance with
Clause 502 or as directed by the Engineer.
519.2.3.3. Tack coat: A tack coat in accordance with Clause 503 shall be applied over the
base on which the cold mix is to be laid where specified in the Contract.
519.2.3.4. Preparation and transportation of the mixture: Mixing can be carried out using
one of the following types of mixer, which is provided with equipment for spraying the binder
at a controlled rate and, if necessary, for heating the binder to a temperature at which it can
be applied uniformly to the aggregate:
(a) rotary drum type concrete mixer:
(b) single or twin shaft concrete or macadam mixer;
(c) batch or continuous type mixer without dryer or screens other than a scalping screen.
A sufficient number of haul trucks with smooth, clean beds should be available to ensure
continuous operation of the mixing plant. The type of truck used for transporting the
mixture from the mixer to the road site must be suited to the Contractor’s nominated laying
procedure methodology.
519.2.3.5. Spreading: Designed cold mix shall be placed only when the specified density
can be obtained. The mixture shall not be placed on any wet surface or when weather
conditions will otherwise prevent its proper handling or finishing.
If spreading by motor grader, the grader must have a blade that is straight and sharp and
long enough to ensure finishing to close, straight, transverse tolerances and all joints and
linkages must be in good condition. The grader must be heavy enough to hold the blade
firmly and uniformly on the surface while spreading the mixture.
If climatic conditions and aggregate grading permit evaporation of moisture or volatiles
without aeration by manipulation, a conventional self•propel1ed asphalt paver shall be
used to place designed cold mix. Other methods of spreading may be used as approved
by the Engineer.
519.2.3.6. Compaction: Initial compaction of the laid material shall be carried out using a
pneumatic-tyred roller of a weight appropriate to the layer thickness to be compacted with
single layer thicknesses being 25-100mm and all compaction being in accordance with
Clause 501.6 and Clause 501.7. Smooth tyres shall be used. Final rolling and smoothing of
the surface should be completed using steel wheel rollers. The Contractor shall demonstrate
at laying trials that his proposed laying and compaction methods can achieve a satisfactory
result.
519.2.4. Opening to traffic: Traffic shall not be allowed to run on new work until all the water
542 RED BOOK  VOLUME I  ROADS  2012
or volatiles in the mixture have evaporated, as determined by the Engineer. The rate of
evaporation will be influenced by the temperature, humidity and wind conditions.
519.2.5. Surface finish and quality control of work: The surface finish of construction shall
conform to the requirements of Clause 902. For control of the quality of supplied materials
and the works carried out, the relevant provisions of Section 900 shall apply.
519.2.6. Arrangements for traffic: During the period of construction, arrangements for traffic
shall be made in accordance with the provisions of Clause 112.
519.2.7. Measurement for payment: Designed Cold Mix shall be measured as finished
work, for the area covered, in cubic metres, by weight in metric tonnes, or by square metres
at a specified thickness as specified in the Contract.
519.2.8. Rate: The contract unit rate for Designed Cold Mix shall be payment in full for
carrying out the required operations including full compensation for all components listed
in Clause 501.8.8.2. (i) to (xi). The rate shall cover the provision of the specified grade of
cutback in the mix at 5 per cent of the weight of the total mix or emulsion at 8 per cent of
the weight of the total mix, with the provision that the variation of quantity of binder will be
assessed on the basis of the amount agreed by the Engineer and the payment adjusted as
per the rate for cutback or emulsion quoted in the Bill of Quantities.
Recipe Cold Mix
519.3. Recipe Cold Mix
This Specification is based on BS434:Pa1t 2:1984 which contains additional information.
These are premixes made with emulsion binder which are laid immediately after mixing and
while the emulsion is still substantially in an unbroken state. These mixes are considered
suitable for use only for emergency and minor repair work and temporary road surface
improvement.
519.3.1. Materials
519.3.1.1. Binder: Emulsions of sufficient stability for mixing with the particular graded
aggregate should be used. Grades of emulsion quoted are in accordance with BS434: Part
1:1984 but comparable grades to IS or AASHTO specifications may be used. Guidance on
selection of an appropriate grade of emulsion is given in the Manual for Construction and
Supervision of Bituminous Works. The corresponding grades in IS: 8887 are only broadly
classified as RS, MS and SS and further sub- classification is not available at present.
519.3.1.2. Aggregates: Any normal, clean, but not necessarily dry, aggregate can be used,
provided that it has a sufficiently high crushing strength with regard to the traffic to be
carried. Typical gradings are given in Table 500-40.
519.3.1.3 Aggregate grading and binder content: When tested in accordance with IS:2386
Part 1 (wet sieving method)the combined aggregate grading for the particular mixture shall
fall within the limits shown in Table 500-40. The grade and range of quantity of emulsion are
also indicated in this table. The actual quantity of emulsion to be used shall be approved by
the Engineer after seeing the results of trial mixes made in the laboratory.
519.3.2. Construction operations
519.3.2.1. Weather and seasonal limitations: Construction with cold mix must not undertaken
when ambient temperatures below 10°C are expected of generally when poor weather is
predicted. Bitumen emulsion and cutbacks depend on the evaporation of water and/or
solvent for the development of their curing and adhesive characteristics. Cold weather,
rain, and high humidity slow down the rate of curing. Extra manipulation may be required to
remove volatiles in cool or humid conditions. Wind increases the rate of evaporation.

RED BOOK  VOLUME I  ROADS  2012 543

519.3.2.2. Preparation of base: The base on which the cold mix is to be laid shall be
prepared shaped and graded to the required profile in accordance with Clauses 50l and
902 as appropriate, and a prime coat if specified in the contract, or required by the Engineer,
shall be applied in accordance with Clause 502, or as directed by the Engineer.
519.3.2.3. Tack coat: A tack coat in accordance with Clause 503 shall be applied over
the base on which the cold mix is to be laid if specified in the Contract or required by the
Engineer.
519.3.2.4. Preparation and transportation of the mixture: Mixing shall be carried out using
one of the following types of mixer, which is provided with equipment for spraying the binder
at a controlled rate, and, if necessary, for heating the binder to a temperature at which it can
be applied uniformly to the aggregate:
(a) rotary drum type concrete mixer
(b) single or twin shaft concrete or macadam mixer;
(c) batch or continuous type mixer without dryer or screens other than a scalping screen.
A sufficient number of haul trucks with smooth, clean beds should be available to ensure
continuous operation of the mixing plant. The type of truck used for transporting the mixture
from the mixer to the road site must be suited to the chosen laying procedure.
519.3.2.5. Spreading: The mixed material should be spread immediately after preparation.
The mixture shall be placed only when the specified density can be obtained. The mixture
shall not be placed on any wet surface or when weather conditions will otherwise prevent
its proper handling or finishing. If spreading by motor grader, the grader must have a blade
that is
straight and sharp and long enough to ensure finishing to close straight transverse
tolerances and all joints and linkages must be in good condition. The grader must be heavy
enough to hold the blade firmly and uniformly on the surface while spreading the mixture.
On surface courses, the tyres must be smooth.
The methodology for spreading shall be approved by the Engineer prior to laying, and if
required a laying trial conducted to prove the laying method satisfactory before approval.
519.3.2.6. Compaction: Initial compaction of the laid material shall be carried out using a
pneumatic-tyred roller of a weight appropriate to the layer thickness to be compacted with
single layer thicknesses being 25-100mm and all compaction being in accordance with
Clause 501.6 and 501.7. Smooth tyres shall be used. Final rolling and smoothing of the
surface should be completed using steel wheel rollers. The Contractor shall demonstrate
at laying trials that his proposed laying and compaction methods can achieve a satisfactory
result.
519.3.3. Opening to traffic: Traffic shall not be allowed to run on new work until all the water
or volatiles in the mixture have evaporated. The rate of evaporation will be influenced by
the temperature, humidity and wind conditions.
519.3.4. Surface finish and quality control of work: The surface finish of construction shall
conform to the requirements of Clause 902. For control of the quality of materials supplied
and the works carried out, the relevant provisions of Section 900 shall apply.
519.3.5. Arrangements for traffic: During the period of construction, arrangements for traffic
shall be made in accordance with the provisions of Clause 112.
519.3.6. Measurement for payment: Recipe Cold Mix shall be measured as finished work,
for the area instructed to be covered, in cubic metres, by weight in metric tonnes, or in
square metres at a specified thickness, as specified in the Contract.

544 RED BOOK  VOLUME I  ROADS  2012

519.3.7. Rate
The contract unit rate for Recipe Cold Mix shall be payment in full for carrying out the required
operations including full compensation for all components listed in Clause 501.8.8.2. (i)
to (xi). The rate shall cover the provision of the specified grade of emulsion at the lower
quantity in the range for each type of mix indicated in Table 500-44 with the provision that
the variation of quantity of emulsion will be assessed on the basis of the amount agreed
by the Engineer and the payment adjusted as per the rate for emulsion quoted in the Bill
of Quantities.
520. SAND ASPHALT BASE COURSE
520.1. Scope This work shall consist of a base course composed of a mixture of sand,
mineral filler where required and bituminous binder, placed and compacted upon a
prepared and accepted subgrade in accordance with these Specifications and the lines,
levels, grades dimensions and cross sections shown on the Drawings or as directed by the
Engineer,
Note: Sand Asphalt Base course is used in special situations like quality coarse aggregates
not being available within economical leads and/or water needed for conventional base
course not being readily available, as in desert areas.
520.2. Materials
520.2.1. Bitumen: The bitumen shall be paving bitumen of Penetration Grade S65 (60/70)
or S90 (80/100), as specified in the Contract, both as per Indian Standard Specifications
for "Paving Bitumen" IS: 73.
520.2.2. Sand: The sand shall be clean, naturally occurring or blended material free from
any deleterious substances, dry and well graded within the limits given in Table 500-41 and
with other physical properties conforming to the requirements of this table.
520.2.3. Filler: When required, filler shall consist of finely divided mineral matter such as
rock dust, hydrated lime or cement as approved by the Engineer. The filler shall conform
to Clause 507.2.4.
520.3. Mix Design
520.3.1. Requirements for the mixture: Apart from conformity with the grading and quality
requirements for individual ingredients, the mixture shall meet the requirements set out in
Table 500-42.
This Specification Clause has been introduced for the first time, Difficulties in using this
Clause and suggestions for improvement may be forwarded to DG(RD), Ministry of Road
Transport & Highways, Transport Bhavan, Parliament Street, New Delhi — 110 001. Fax
No. # 3710236.
520.3.2. Binder content: The binder content shall be optimised to achieve the requirements
of the mixture set out in Table 500-46. The Marshall method for determining the optimum
binder content shall be adopted as described in The Asphalt Institute Manual MS-2.
520.3.3. Job mix formula: The Contractor shall develop the job mix formula proposed for
use in the works and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable:
(a) Binder, as percentage by weight of total mixture;
(b) Sand/Mineral filler as percentage by weight of total aggregate including mineral
filler;

RED BOOK  VOLUME I  ROADS  2012 545

 (iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 500-46 as obtained by the Contractor;
(v) Test results of physical characteristics of aggregates to be used;
(vi) Mixing temperature and compacting temperature.
While working out the job mix formula, the Contractor shall ensure that it is based on a
correct and truly representative sample of the materials that will actually be used in the
work and that the mixture and its different ingredients satisfy the physical and strength
requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the Engineer for
which joint samples of all ingredients of the mix shall be furnished by the Contractor as
required by the former.
The approved job mix formula shall remain effective unless and until modified by the
Engineer. Should a change in the source of materials be proposed, a new job mix formula
shall be established and approved by the Engineer before actually using the materials.
520.3.4. Permissible variation from job mix formula: The Contractor shall produce a uniform
mix conforming to the approved job mix formula, subject to the permissible variations of the
individual percentages of the various ingredients in the actual mix from the job mix formula
to be used, within the limits as specified in Table 500-43. These variations are intended to
apply to individual specimens taken for quality control tests as described in Section 900.
520.4. Construction Operations
520.4.1. Weather and seasonal limitations: Clause 501.5.1 shall apply.
520.4.2. Preparation of base : The surface on which Sand Asphalt Basecourse Material is
to be laid shall be prepared, shaped and graded to the profile required for the particular
layer in accordance with Clauses 501 and 902 as appropriate or as directed by the
Engineer. The surface shall be thoroughly swept clean free from dust and foreign matter
using a mechanical brush, and the dust blown off by compressed air. In confined locations
where mechanical plant cannot access, other methods shall be used as approved by the
Engineer. A prime coat, where specified, shall be applied in accordance with Clause 502 or
as directed by the Engineer.
520.4.3. Tack coat : A tack coat over the base shall be applied in accordance with Clause
503, or otherwise as directed by the Engineer.
520.4.4. Preparation and transportation of the mixture: The provisions of Clauses 501.3
and 501.4 shall apply.
520.4.5. Spreading: The provisions of Clauses 501.5.2 to 501.5.4. shall apply. Mixing must
be accomplished at the lowest temperature and in the shortest time that will produce a
mixture with complete coating of the aggregate and at a suitable temperature to ensure
proper compaction. The ideal mixing and compaction temperatures for the particular
bitumen in use shall be obtained from the Bitumen Test Data Chart given in the Manual
for Construction and Supervision of Bituminous Works and shall correspond to a viscosity
of 2 Poise (0.2 Pa.s) and 3 Poise (0.3 Pa.s) respectively, based on the original (unaged)
bitumen properties. For guidance, the ranges of acceptable mixing and rolling temperatures
for some typical penetration grade bitumen are shown in Table 500-5.
520.4.6. Rolling: Clause 501.6 shall apply. Generally the initial or breakdown rolling shall
be done with 8-10 tonne deadweight smooth- wheeled rollers. The intermediate rolling shall
be done with 8 -10 tonne deadweight or vibratory rollers or with a pneumatic tyred roller of
12- 15 tonne weight having a tyre pressure of at least 5.6 kg / sq.cm.. The finish rolling shall
be done with 8 • l0 tonne deadweight smooth wheeled tandem rollers. The exact pattern of
546 RED BOOK  VOLUME I  ROADS  2012
rolling shall be established at the laying trials.
520.5. Opening to Traffic
Traffic may be allowed after completion of the final rolling when the temperature of the
mixture at the mid-depth of the completed layer has cooled to the daytime maximum
ambient temperature. When daytime maximum ambient temperatures are in excess of
35°C, great care is needed to ensure that this criterion is met, particularly where slow
moving heavy traffic is involved.
520.6. Surface Finish and Quality Control of Work The surface finish of the completed
construction shall conform to the requirements of Clause 902.
For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
520.7. Arrangements for Traffic During the period of construction, arrangements for traffic
shall be made in accordance with the provisions of Clause 112.
520.8. Measurement for Payment Sand Asphalt Basecourse materials shall be measured
as finished work, for the area covered, in cubic metres, metric tonnes, or in square metres
at a specified thickness, as stated in the Contract.
520.9. Rate
The contract unit rate for Sand Asphalt Basecourse materials shall be payment in full for
carrying out the required operations including full compensation for all components listed
in Clause 501.8.8.2 (i) to (xi). The rate shall cover the provision of 5 per cent of bitumen by
weight of the total mixture.
The variation from the actual percentage of bitumen approved by the Engineer and used
will be assessed and the rate adjusted, plus or minus, using the rate for bitumen in the Bill
of Quantities.
521. MODIFIED BINDER
521.1. Scope
Modified binders comprise a base binder, to which is added either natural rubber, crumb
rubber or a polymer such as Styrene-Butadiene
This Specification Clause has been introduced for the first time. Difficulties in using this
Clause and suggestions for improvement may be forwarded to DG(RD), Ministry of Road
Transport & Highways, Transport Bhavan, Parliament Street, New Delhi- 110.001. Fax No.
# 3710236.
Styrene (SBS), Ethylene-Vinyl-Acetate (EVA) or Low Density Polyethylene (LDPE). The
purpose is to achieve a high performance binder with improved properties, particularly at
extremes of temperature. 521.2. Materials
521.2.1. Base Binder: The base binder into which the modifier is incorporated shall conform
to IS:73. The choice of grade shall be such that it is compatible with the modifier and, when
mixed shall have the properties described in Clause 521.3.
521.2.2. Modifier: The modifier shall be a natural rubber, crumb rubber or any other
polymer which is compatible with the base binder and which allows the properties given in
Clause 521.3 to be achieved. For further details, IRC: SP: 53-1999 may be referred to. The
modifier, in the required quantity shall be blended at the refinery or at the site plant capable
of producing modified binder.
521.3. Modifier Proportions
The quantity of modifier to be added shall be determined by tests on the base binder and

RED BOOK  VOLUME I  ROADS  2012 547

the modified binder and the properties desired. A reference may be made to the Manual for
Construction and Supervision of Bituminous Works for indicative dosage of different types
of modifiers. The properties of the modified binder shall be as given in Table 500-44, 500-
45 or 500-46 according to the requirements of the Contract.
521.4. Mixing
The modifier shall be blended with the base binder so that it disperses thoroughly prior
to use. The type of mixing equipment used shall be suited to the modifier type. Further
guidance is given in the Manual for Construction and Supervision of Bituminous Works.
521.5. Quality Control of Materials
521.5.1. Binder Properties: For control of the quality of the base binder, the relevant
provisions of Section 900 shall apply. Additionally, the modified binder shall be tested for
all the properties listed in Table 500-44, 500-45 or 500-46 as appropriate and certificates
produced prior to use.
During use, the requirements for softening point, penetration and elastic recovery shall be
tested regularly. If the modified binder is produced on site then tests shall be carried out
daily. If pre-blended modified binder is used tests shall be carried out weekly.
521.5.2. Storage Stability : Pre-blended modified binders which are to be stored without
circulation or agitation facility shall be tested for storage stability prior to use, in accordance
with Appendix 1 of IRC:SP:53- 1999. The mean of the differences in softening point, top to
bottom, of not less than three pairs of samples shall not exceed 5°C.
Other pre-blended modified binders shall be stored with appropriate circulation or agitation
facility, according to the manufacturer‘s instructions.
521.6. Measurement for Payment
Modified binder supplied for the Contract shall be paid for in Tonnes.
521.7 Rate
The contract rate for modified binder shall be as per contract agreement.
522. Crack Prevention Courses
522.1. Scope
This clause covers the provision of Stress Absorbing Membrane (SAM) and Stress Absorbing
Membrane Interlayer (SAMI) as measures to inhibit the propagation of cracks. A SAM is an
elastomeric bitumen rubber membrane, which is laid over a cracked road surface, together
with a covering of aggregate chips, in order to extend the life of the pavement before major
treatment is carried out. SAM can be laid as a
This Specification Clause has been introduced for the first time. Difficulties in using this
Clause and suggestions for improvement may be forwarded to DG(RD), Ministry of Road
Transport & Highways, Transport Bhavan, Parliament Street, New Delhi ~ 110 001. Fax
No. 3710236. single coat or a double coat. A SAMI is a layer which is applied to a cracked
pavement surface but which is followed (within 12 months) by the application of an overlay
course. A SAMI may be a material similar to that used for a SAM. It may alternatively
consist of a bitumen impregnated geotextile.
522.2. Materials
522.2.1. Binder: Binder shall be a modified binder complying with the requirements of Clause
523, according to the requirements of the Contract, except that paving grade bitumen of
80-100 penetration complying with the requirements of IS; 73 shall be used in the case of
a bitumen impregnated geotextile.

548 RED BOOK  VOLUME I  ROADS  2012

522.2.2. Aggregate: The requirements of Clause 510.2.2 apply except that the Polished
Stone Value requirement does not apply in the case of a SAMI. Where required by the
contract, aggregate shall be pre- coated using either of the techniques permitted by Clause
510.2.5.
522.2.3. Rates of spread of binder and aggregate: The rates of spread of binder and
aggregate shall be according to one of the size alterative in Table 500-47, as required by
the Contract.
522.2.4. Geotextile: The use of geotextile as prescribed for Sl. No. 7 in Table 500-47 shall
conform to the requirements of Clause 703 .3
522.3. Construction Operations
522.3.1. Weather and seasonal limitations: Clause 501.5.1 shall apply.
522.3.2. Preparation of base: The base on which the SAM, SAMI or bitumen impregnated
geotextile is to be laid shall be prepared, in accordance with Clause 501 and as directed by
the Engineer. The surface shall be thoroughly cleaned either by using a mechanical brush
or any other equipment / method approved by the Engineer. Dust removed in the process
shall be blown off with compressed air.
522.3.3. Application of binder: The equipment and general procedures shall all be in
accordance with the Manual for Construction and Supervision of Bituminous Works.
The application temperature for modified binder shall be 160-170°C. Binder for bitumen
impregnated geotextile shall be applied according to Clause 502.4. The surface on which
the binder is to be applied shall be dry.
522.3.4. Application of aggregates: The equipment and general procedures shall all be
in accordance with the Manual for Construction and Supervision of Bituminous Works.
Immediately after application of the modified binder, clean, dry aggregate shall be spread
uniformly on the surface.
522.3.5. Sweeping: The surface of SAMs and SAM1s shall be swept to ensure uniform
spread of aggregate and that there are no loose chips on the surface.
522.3.6. Two coat SAM or SAMI : Where a two coat SAM or SAMI is required by the
Contract, the second coat shall be applied within 90 days of the first.
522.3.7. Geotextile placement: For bitumen impregnated geotextile, the requirements of
Clause 703.4.5
522.4. Opening to Traffic
Traffic may be permitted over a SAM or SAMI 2 hours after rolling, but the speed shall be
limited to 20 km/h, until the following day. Speed control measures are to be approved by
the Engineer, prior to laying.
522.5. Surface Finish and Quality Control of Work
The surface finish shall conform to the requirements of Clause 902.
For control on the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 shall apply.
522.6. Arrangements for Traffic
During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.
522.7. Measurement for Payment
Each application of SAM, SAMI or bitumen impregnated geotextile shall be measured as
finished work, for the area specified, in square metres.

RED BOOK  VOLUME I  ROADS  2012 549

522.8. Rate
The contract unit rate for SAM, SAMI or bitumen impregnated geotextile shall be payment in
full for carrying out the required operations including full compensation for all components
listed in Clause 501.8.8.2, (i) to (xi).

550 RED BOOK  VOLUME I  ROADS  2012

 TABLE 500-1 VISCOSITY REQUIREMENT AND QUANTITY OF LIQUID BITUNINOUS PRIMER

Type of surface Kinematic Viscosity of Primer Quantity of Liquid Bituminous

at 60oC Material per 10 Sq.m(kg)
(Centistokes)

Low porosity 30 - 60 6 to 9
Medium porosity 70 - 140 9 to 12
High porosity 250 - 500 12 to 15

TABLE 500-2 RATE OF APPLICATION OF TACK COAT

Type of surface Quantity of liquid bituminous

material is kg per sq.m. area

i) Normal bituminous surfaces 0.20 to 0.25

ii) Dry and hungry bituminous surfaces 0.25 to 0.30
iii) Granular surfaces treated with primer 0.25 to 0.30
iv) Non bituminous surfaces
a) Granular base (not primed) 0.35 to 0.40
b) Cement Concrete pavement 0.30 to 0.35

table 500-3 physical requirements for coarse aggregates for bituminous macadam

Property Test Specification

Cleanliness Grain size analysis Max 5% passing 0.075mm sieve

Particle shape Flakiness and Elongation Index Max 30%
(Combined)
Strength Los Angeles Abrasion Value Max 40%
Aggregate Impact Value Max 30%
Durability Soundness
Sodium Sulfate Max 12%
Magnesium sulfate Max 18%
Water Absorption Water absorption Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures 95%
Water Sensitivity Retained Tensile Strength Min 80%

Notes : 1. IS:2386 Part 1 4. IS:2386 Part 5 : 1963

2. IS:2386 Part 1 5. IS:2386 Part 3 : 1963
(The elongation test to be done only non-flaky aggregates in the sample)
3. IS:2386 Part 4* 6. IS:6241 : 1971
7. The water sensitivity test is only to be carried out if the minimum retained coating in the stripping
test is less than 95%.
*Aggregate may satisfy requirements of either of these two tests.

321
RED BOOK  VOLUME I  ROADS  2012 551
 table 500-4 composition of bituminous macadam
Mix designation Nominal Grading 1 Grading 2
aggregate size Layer 40 mm 19 mm
thickness IS Sieve (mm) 80 - 100 mm 50 - 75 mm
Cumulative % by weight of total aggregate passing
45 100 ---
37.5 90-100 ---
26.5 75-100 100
19 --- 80-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10
0.075 0-8 0-8
Bitumen content % by weight 3.1 - 3.4 3.3 - 3.5
of total mixture - 1
Bitumen grade 35 to 90 35 to 90
Notes : 1 Approximate bitumen contents for conditions in cooler areas of India may be upto 0.5%
higher subject to the approval of the Engineer.
table 500-5 manufacturing and rolling temperatures
Bitumen Bitumen Aggregate Mixed Rolling Laying
Penetration Mixing ( C)
o
Mixing ( C)
o
Material ( C)
o
( C)
o
(oC)

35 160 - 170 160 - 175 170 Maximum 100 Minimum 130 Minimum
65 150 - 165 150 - 170 165 Maximum 90 Minimum 125 Minimum
90 140 - 160 140 - 165 155 Maximum 80 Minimum 115 Minimum

table 500-6 composition of penetration macadam

Cumulative percent by weight of total aggregate passing
For 50 mm compacted thickness For 75 mm compacted Thickness
IS Sieve Coarse Key Aggregate Coarse Key Aggregate
Desingation (mm) Aggregate Aggregate
63 --- --- 100 ---
45 100 --- 58 - 82 ---
26.5 37 - 72 --- --- 100
22.4 --- 100 5 - 27 50 - 75
13.2 2 - 20 50 - 75 --- ---
11.2 --- --- --- 5 - 25
5.6 --- 5 - 25 -- --
2.8 0 - 5 0 - 5 0 - 5 0-5
Approx. Loose
aggregate quantities 0.06 0.015 0.09 0.018
cu.m/m2
Binder quantity
(penetration grade 5 6.8
(kg/m2)

Note : 1) If cutback Bitumen is used, adjust binder quantity such that the residual Bitumen is equal to the values in
this table.

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552 RED BOOK  VOLUME I  ROADS  2012
 TABLE 500-7 granding requirements for coarse and key aggregates
for built-up spray grout

IS Sieve Cumulative percent by weight of total aggregate passing

Desingation (mm) Coarse Aggregate Key Aggregate
53.0 100 ---
26.5 40 - 75 ---
22.4 --- 100
13.2 0 - 20 40 - 75
5.6 --- 0 - 20
2.8 0 - 5 0-5

TABLE 500-8 physical requirements for coarse aggregates

for dense graded bituminous macadam
Property Test Specification

Cleanliness (dust) Grain size analysis Max 5% passing 0.075mm sieve

Particle shape Flakiness and Elongation Index Max 30%
(Combined)
Strength* Los Angeles Abrasion Value Max 35%
Aggregate Impact Value Max 27%
Durability Soundness
Sodium Sulfate Max 12%
Magnesium sulfate Max 18%
Water Absorption Water absorption Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures 95%
Water Sensitivity** Retained Tensile Strength Min 80%

Notes : 1. IS:2386 Part 1 5. IS:2386 Part 3 : 1963

2. IS:2386 Part 1 6. IS:2386 : Part 3
(The elongation test to be done only non-flaky aggregates in the sample)
3. IS:2386 Part 4* 7. IS:6241
4. IS:2386 Part 4 8. AASHTO T283**
*Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the stripping
test is less than 95%.
table 500-9 grading requirements for mineral filler

IS Sieve (mm) Cumulative percent passing by weight of total aggregate

0.6 100
0.3 95 - 100
0.075 85 - 100

323
RED BOOK  VOLUME I  ROADS  2012 553
 table 500-10 composition of dense gradeD
bituminous macadam pavement layers

Grading 1 2
Nominal aggregate size 40 mm 25 mm
Layer thickness 80 - 100 mm 50 - 75 mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing

45 100 ---
37.5 95-100 100
26.5 63-93 90-100
19 --- 71-95
13.2 55-75 56-80
9.5 --- ---
4.75 38-54 38-54
2.36 28-42 28-42
1.18 --- ---
0.6 --- ---
0.3 7-21 7-21
0.15 --- ---
0.075 2-8 2-8

Bitumen content % by mass Min 4.0 Min 4.5

of total mix - 2

Bitumen grade (pen) 65 to 90 65 to 90

Notes : 1 The combined aggregate grading shall not very from the low limit on one sieve to the high
limit on the adjacent sieve.
2 Determined by the marshall method.

table 500-11 requirements for dense graded bituminous macadam

Minimum stability (kN at 60oC) 9.0

Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of Blows) 75 Blows on each of the two faces of the
specimen
Percent air voids 3-6
Percent voids in mineral aggregate (VMA) See table 500-12 below
Percent voids filled with bitumen (VFB) 65 - 75

The requirements for minimum percent voids in mineral aggregate (VMA) are set out in table 500-12.

324
554 RED BOOK  VOLUME I  ROADS  2012
 table 500-12 minimum percent voids in mineral aggregate (VMA)

Norminal Maximum Minimum VMA, Percent Related to

Particle Size - 1(mm) Design Air Voids, Percent - 2
3.0 4.0 5.0
9.5 14.0 15.0 16.0
12.5 13.0 14.0 15.0
19.0 12.0 13.0 14.0
25.0 11.0 12.0 13.0
37.5 10.0 11.0 12.0

Notes : 1 The nominal maximum partile size is one size larger than the first sieve to retain more than 10 percent.
2 Interpolate minimum voids in the mineral aggregate (VMA) for design air voids values between those listed.

table 500-13 permissible variations from the job mix formula

Description Permissible variation
Base / binder course Wearing course
Aggregate passing 19 mm sieve or larger + 8% + 7%
Aggregate passing 13.2mm, 9.5 mm + 7% + 6%
Aggregate passing 4.75mm + 6% + 5%
Aggregate passing 2.36mm, 1.18mm, 0.6mm + 5% + 4%
Aggregate passing 0.3mm, 0.15 mm + 4% + 3%
Aggregate passing 0.075mm + 2% + 1.5%
Binder Content + 0.3% + 0.3%
Mixing temperature + 10 oC + 10 oC
TABLE 500-14 physical requirements for coarse aggregates
for semi dense bituminous concrete pavement layers
Property Test Specification

Cleanliness (dust) Grain size analysis-1 Max 5% passing 0.075mm sieve

Particle shape Flakiness and Elongation Index Max 30%
(Combined)-2
Strength* Los Angeles Abrasion Value-3 Max 35%
Aggregate Impact Value-4 Max 27%
Polishing Polished Stone Value-5 Min 55
Durability Soundness-6
Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
Water Absorption Water absorption-7 Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures-9 95%
Water Sensitivity** Retained Tensile Strength-8 Min 80%

325
RED BOOK  VOLUME I  ROADS  2012 555
Notes : 1. IS:2386 Part 1 6. IS:2386 Part 5
2. IS:2386 Part 1 7. IS:2386 Part 3
(The elongation test to be done only non-flaky aggregates in the sample)
3. IS:2386 Part 4* 8. AASHTO T283**
4. IS:2386 Part 4* 9. IS:6241
5. BS:812 Part 114
*Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the stripping test is less
than 95%.

table 500-15 composition of SEMI dense

bituminous CONCRETE pavement layers

Grading 1 2
Nominal aggregate size 13 mm 10 mm
Layer thickness 35 - 40 mm 25 - 30 mm
IS Sieve-1 (mm) Cumulative % by weight of total aggregate passing
45 --- ---
37.5 --- ---
26.5 --- ---
19 100 ---
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 15-30
0.6 --- ---
0.3 9-19 9-19
0.15 --- ---
0.075 3-8 3-8
Bitumen content % by mass Min 4.5 Min 5.0
of total mix - 2
Bitumen grade (pen) 65* 65*

Notes : 1 The combined aggregate grading shall not vary from the low limit on one sieve to the high
limit on the adjacent sieve.
2 Determined by the marshall method.
*Only in exception circumstances, 80/100 penetration grade may be used, as approved by
the Engineer.

326
556 RED BOOK  VOLUME I  ROADS  2012
 table 500-16 requirements for semi dense bituminous pavement layers

Minimum stability (kN at 60oC) 8.2

Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 Blows on each of the two faces of the
specimen
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) See table 500-12 below
Percent voids filled with bitumen (VFB) 65 - 78

table 500-17 physical requirements for coarse aggregates

for bituminous CONCRETE pavement layers

Property Test Specification

Cleanliness (dust) Grain size analysis Max 5% passing 0.075mm sieve

Particle shape Flakiness and Elongation Index Max 30% (Combined)
Strength* Los Angeles Abrasion Value Max 30%
Aggregate Impact Value Max 24%
Polishing Polished Stone Value Min 55
Durability Soundness
Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
Water Absorption Water absorption Max 2%
Stripping Coating and Stripping of Bitumen Minimum retained coating
Aggregate Mixtures 95%
Water Sensitivity** Retained Tensile Strength Min 80%

Notes : 1. IS:2386 Part 1 6. IS:2386 Part 5 : 1963

2. IS:2386 Part 1 7. IS:2386 Part 3
(The elongation test to be done only non-flaky aggregates in the sample)
3. IS:2386 Part 4* 8. AASHTO T283**
4. IS:2386 Part 4* 9. IS:6241 : 1971
5. BS:812 Part 114
*Aggregate may satisfy requirements of either of these two tests.
**The water sensitivity test is only required if the minimum retained coating in the stripping test is less
than 95%.

327
RED BOOK  VOLUME I  ROADS  2012 557
 table 500-20 nominal rates of spread for binder and chippings

Nominal Chipping Size Binder (penetration grade Chips Cum/m2

mm bitumen) kg/m2
19 1.2 0.015
13 1.0 0.010
10 0.9 0.008
6 0.75 0.004

Note : 1) The rates of spread are for pricing purposes – see Clause 510.2.3 and Clause 510.8
2) For emulsion, these rates of spread are for the residual Bitumen and appropriate adjustment must be made
to determine the total quantity.
3) Refer to Manual for Construction and Supervision of Bituminous Works for the procedure of determining
the rates of spread of binder and chips.

table 500-18 composition of bituminous CONCRETE pavement layers

Grading 1 2
Nominal aggregate size 19 mm 13 mm
Layer thickness 50 - 65 mm 35 - 40 mm
IS Sieve-1 (mm) Cumulative % by weight of total aggregate passing
45 --- ---
37.5 --- ---
26.5 100 ---
19 79 - 100 100
13.2 59 - 79 79 - 100
9.5 52 - 72 70 - 88
4.75 35 - 55 53 - 71
2.36 28 - 44 42 - 58
1.18 20 - 34 34 - 48
0.6 15 - 27 26 - 38
0.3 10 - 20 18 - 28
0.15 5 - 13 12 - 20
0.075 2 - 8 4 - 10
Bitumen content % by mass 5.0 - 6.0 5.0 - 7.0
of total mix - 2
Bitumen grade (pen) 65 65

Notes : 1 The combined aggregate grading shall not vary from the low limit on one sieve to the high
limit on the adjacent sieve.
2 Determined by the Marshall method.

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558 RED BOOK  VOLUME I  ROADS  2012
 table 500-19 requirements for bituminous pavement layers

Minimum stability (kN at 60oC) 9.0

Minimum flow (mm) 2
Maximum flow (mm) 4
Compaction level (Number of blows) 75 Blows on each of the two faces of the
specimen
Percent air voids 3-6
Percent voids in mineral aggregate (VMA) See table 500-12 below
Percent voids filled with bitumen (VFB) 65 - 75
Loss of stability on immersion in water at 60oC Min. 75 percent retained strength
(ASTM D 1075)

table 500-21 grading requirements for chips for surface dressing

IS Sieve-1 Cumulative percent by weight of total aggregate passing
Designation mm for the following nominal sizes (mm)
19 13 10 6
26.5 100 --- --- ---
19.0 85 - 100 100 --- ---
13.2 0 - 40 85 - 100 100 ---
9.5 0 - 7 0 - 40 85 - 100 100
6.3 --- 0 - 7 0 - 35 85 - 100
4.75 --- --- 0 - 10 ---
3.35 --- --- --- 0 - 35
2.36 0 - 2 0 - 2 0 - 2 0 - 10
0.60 --- --- --- 0-2
0.075 0 - 1.5 0 - 1.5 0 - 1.5 0 - 1.5
Minimum 65% by Passing 19 mm, Passing 13.2 mm, Passing 9.5 mm, Passing 6.3 mm,
weight of retained 13.2 mm retained 9.5 mm retained 6.3 mm retained 3.35 mm
aggregate

table 500-22 spraying TEMPERATURES for binders

Binder grades Whirling spray jets Slot jets
Min C o
Max C o
Min C
o
Max oC
Penetration Grade
400/500 160 170 140 150
280/320 165 175 150 160
180/200 170 190 155 165
80/100 180 200 165 175

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RED BOOK  VOLUME I  ROADS  2012 559
 Table 500-23 quantities of materials required for 10 m2 of road surface
from 20mm thick open graded premix surfacing
using penetration Bitumen or cutback
Aggregates
(a) Nominal Stone size 13.2mm (passing 22.4mm sieve and 0.18 m3
retained on 11.2mm sieve)
(b) Nominal Stone size 11.2mm (passing 13.2mm sieve and 0.09 m3
retained on 5.6mm sieve).
Total 0.27 m3
Binder (quantities in terms of straight run Bitumen)
(a) For 0.18 m2 of 13.2 mm nominal size stone at 52kg Bitumen 9.5 kg
per m3
(b) For 0.09 m3 of 11.2 mm nominal size stone at 56kg Bitumen 5.1 kg
per m3
Total 14.6 kg

Table 500-24 quantities of aggregate for 10 m2 area

(A) Premix Carpet

(a) Coarse aggregate nominal 13.2 mm size; passing IS 22.4 mm 0.18 m3
sieven and retained on IS 11.2 mm sieve
(b) Coarse aggregate nominal 11.2 mm size; passing IS 13.2 mm 0.09 m3
sieven and retained on IS 5.6 mm sieve
(B) For Seal Coate :
Refer to Clause 513.

Table 500-25 quantities of emulsion binder

For 10 m2 area
(A) For Premix Carpet 20 to 23 kg
(B) For Seal Coat :
(a) For Liquid seal coat 12 to 14 kg
(b) For premix seal coat 10 to 12 kg

Table 500-26 aggregate gradation

IS Sieve Designation (mm) Cumulative percent by weight of total aggregate passing

Type A Type B
13.2 mm --- 100
11.2 mm 100 88 - 100
5.6 mm 52 - 88 31 - 52
2.8 mm 14 - 38 5 - 25
0.090 mm 0 - 5 0-5

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560 RED BOOK  VOLUME I  ROADS  2012
 table 500-27 size requirements for coarse stone aggregates

S. No. Nominal size of Aggregate Disignation of sieve Disignation of sieve ON

through which the which the aggregates shall
aggregate shall wholly pass be wholly retained
(i) 75mm 106mm 63mm
(ii) 63mm 90mm 53mm
(iii) 45mm 53mm 26.5mm
(iv) 26.5mm 45mm 22.4mm
(v) 22.4mm 26.5mm 13.2mm
(vi) 13.2mm 22.4mm 11.2mm
(vii) 11.2mm 13.2mm 6.7mm
(viii) 6.7mm 11.2mm 2.8mm

table 500-28 percent reducted in volume of aggregates

S. No. Standard size of Aggregate Percentage reduction in volume
computed by stack
mesurements to arrive at
the volume to be paid for
1. 75 mm and 63 mm 12.5
2. 45 mm and 26.5 mm 10.0
3. 22.4 mm, 13.2 mm, 11.2 mm and 6.7 mm 5.0
4. Fine aggregate 5.0

table 500-29 requirements for physical properties of binder

Property Test method Requirement
Penetration at 25 oC IS 1203 15 + 5*
Softening point, oC IS 1205 65 + 10
Loss on heating for 5h at 163 oC, % by mass Max. IS 1212 2.0
Solubility in trichloroethylene, % by mass Min. IS 1216 95
Ash (mineral matter), % by mass Max. IS 1217 1.0
* In cold climate regions (temperature < 10 oC), a softer penetration grade of 30/40 may be used.

table 500-30 grade and thickness of mastic asphalt paving and

grading of coarse aggregate

Application Thickness range Nominal size of coarse Coarse aggregate

(mm) aggregate (mm) content % by mass
of total mix

Roads and carriageways 25 - 50 13 40 + 10

Heavily stressed areas i.e. 40 - 50 13 45 + 10
junctions and toll plazas

331
RED BOOK  VOLUME I  ROADS  2012 561
 Nominal size of aggregate 13 mm
IS Sieve (mm) Cumulative % passing by weight
19 100
13.2 88 - 96
2.36 0-5

table 500-31 grading of fine aggregate (inclusive of filler)

I. S. Sieve Percentage by weight of aggregate
Passing 2.36 mm but retained on 0.600 mm 0 - 25
Passing 0.600 mm but retained on 0.212 mm 10 - 30
Passing 0.212 mm but retained on 0.075 mm 10 - 30
Passing 0.075 mm 30 - 35

table 500-32 comosition of mastic asphalt blocks

without coarse aggregate
I. S. Sieve Percentage by weight of aggregate
Minimum Maximum
Passing 2.36 mm but retained on 0.600 mm 0 22
Passing 0.600 mm but retained on 0.212 mm 4 30
Passing 0.212 mm but retained on 0.075 mm 8 18
Passing 0.075 mm 25 45
Bitumen Content 14 17

table 500-33 aggregate grading, binder content and

approximate coverage rate
Sieve Size (mm) Percentage by mass passing finished thickness of sealing
5 mm 3 mm 1.5 mm
9.5 100 --- ---
4.75 90 - 100 100 ---
3.35 --- 80 - 100 100
2.36 65 - 95 75 - 100 95 - 100
1.18 45 - 70 55 - 90 70 - 95
0.600 30 - 50 35 - 70 55 - 75
0.300 18 - 30 20 - 45 30 - 50
0.150 10 - 21 10 - 25 10 - 30
0.075 5 - 15 5 - 15 5 - 15
Quantity of residual binder, 7.5 - 13.5 10 - 6 12 - 20
percentage by mass of aggregate
Approximate coverage rate (kg/m2) 8 - 15 4 - 6 2-4

332
562 RED BOOK  VOLUME I  ROADS  2012
 table 500-34 minimum recovered binder penetration of recycled mixture

Specified Grade of Binder (Penetration) Minimum Recovered Penetration Value of binder

after mixing
45 27
65 39
90 54

table 500-35 uses of bitumen in cold mix

Type of Constructions Emulsifed Bitumen Cutback Bitumen

Anionic Cationic Medium Curing Slow Curing
(MC) (SC)
Cold Laid Plant Mix
Pavent Base and
MS-2h, HFMS-2h
MS-2, HFMS-2

Surface
HFMS-2s

CMS - 2h

CSS - 1h
CMS - 2

CSS - 1
SS - 1h
SS - 1

70
250
800
3000

250
800
3000
Open graded aggregate * * * *
Well graded aggregate * * * * * * * * * * *
Patching, Immediate use * * * * * * *
Patching, Stock pile * * * *

* The corresponding grades in IS:8887 are only broadly classified as RS, MS and SS and further sub-classification
is not available at present
table 500-36 aggregate grading and bitumen content
Nominal maximum (mm) 9.5 13.2 19.0 26.5
Allowable thickness (mm) 25 - 35 36 - 50 51 - 75 76 - 100
IS Sieve (mm) Cumulative % by weight of total aggrgate passing
37.5 --- --- --- 100
26.5 --- --- 100 90 - 100
19.0 --- 100 90 - 100 ---
13.2 100 90 - 100 --- 56 - 80
9.5 90 - 100 --- 60 - 80 ---
4.75 60 - 80 45 - 70 35 - 65 29 - 59
2.36 35 - 65 25 - 55 20 - 50 19 - 45
0.30 6 - 25 5 - 20 3 - 20 5 - 17
0.075 2 - 10 2 - 9 2 - 8 1-7
1-Guide to binder content % by weight of total mixture
Cutback Min 4 to Max 6
Emulsion Min 7 to Max 10
To be determined by the Modified Marshall Test

333
RED BOOK  VOLUME I  ROADS  2012 563
 table 500-37 mixture requirements for designed cold mix

Parameter Emulsion1 Cutback2

Minimum Stability (kN at 22.2oC) Emulsion
(kN at 25oC) Cutback 2.2 for paving 2.2 for maintenance
3.3 for paving
Percent maximum stability loss on soaking 503 254
Minimum flow (mm) 2 2
Compaction level (number of Blows 50 75
Percent air voids 3-5 5
3-5
Percent voids in mineral aggregate (VMA) See Table 500 - 38
Percent minimum coating6 50 ---
Note : 1 Using “Marshall method for emulsified asphalt aggregate cold mixture design”, Appendix F,
MS-14.
2
Using “Marshall method for cutback asphalt aggregate cold muxture design”, Appendix H,
MS-14.
3
With vaccum saturation and immersion.
4
Four days soak at 25oC
5
Refers to total voids in the mix occupied by air and water.
6
Coating Test. Appendix F, MS - 14.

table 500-38 minimum percent voids in mineral aggregate (VMA)

Nominal Maximum Particle Size Minimum VMA (percent)
IS Sieve (mm)
9.5 16.0
12.5 15.0
19.0 14.0
25.0 13.0
37.5 12.0

table 500-39 permissible variations from the job mix formula

Description Permissible variation
Base / binder course Wearing course
Aggregate passing 19mm sieve or larger + 8% + 7%
Aggregate passing 13.2mm, 9.5 mm + 7% + 6%
Aggregate passing 4.75mm + 6% + 5%
Aggregate passing 2.36mm, 1.18mm, 0.6mm + 5% + 4%
Aggregate passing 0.3mm, 0.15 mm + 4% + 3%
Aggregate passing 0.075mm + 2% + 1.5%
Binder Content + 0.3% + 0.3%

334
564 RED BOOK  VOLUME I  ROADS  2012
 table 500-40 composition of recipe mixes
Nominal Size 40 Single 40 Open 14 Open 6 Medium Fine Coated
(mm) course textured base textured textured wearing
Macadam course wearing course course
Allowable 75 - 100 75 - 100 31 - 50 21 - 30 15 - 20
Thickness (mm)
IS Sieve Cumulative % by weight of total aggregate passing
Size mm
45 100 100 --- --- ---
37.5 90 - 100 90 - 100 --- --- ---
26.5 55 - 90 55 - 85 --- --- ---
19 --- --- 100 --- ---
13.2 35 - 55 15 - 35 90 - 100 --- ---
9.5 --- --- 55 - 75 100 ---
6.3 20 - 30 --- 25 - 45 90 - 100 100
3.35 10 - 20 0 - 10 15 - 25 45 - 65 ---
2.36 --- --- --- --- 75 - 100
1.18 --- --- --- 10 - 30 ---
0.60 --- --- --- --- 30 - 55
0.30 2 - 10 --- --- --- ---
0.15 --- --- --- --- 10 - 25
0.075 --- --- 2 - 6 2 - 8 5 - 15

Emulsion grade and quantity

Generally A2 - 57(4) or A2 - 50(4)
Under some --- --- --- A3 A3
circumstances
Quantity(1) 55 to 70 45 to 65 70 to 90 85 to 100 100 to(2)(3)
Liters/tonne 120

Note : (1) For pricing purposes the lower quantity in these ranges should be assumed.
(2) With coarser grading quantity may sometimes be reduced to 80 litres/tonne and with finer grading it may
sometime be increased upto 135 litres/tonne.
(3) Use 0 - 70 litres/tonne of water as necessary.
(4) A2-50 and A2-57 are British grades of emulsion and their grading system is explained in the manual.

335
RED BOOK  VOLUME I  ROADS  2012 565
 table 500-41 sand granding physical requirements

Sieve Size (mm) Cumulative percentage by weight of total

aggregate passing
9.5 100
4.75 85 - 100
2.36 80 - 100
1.18 70 - 98
0.60 55 - 95
0.30 30 - 75
0.15 10 - 40
0.075 4 - 10
Plasticity Index (%) 6 Max.
Sand equivalent (IS:2720:1977, Part 37) 30 Min.
Los Angeles Abrasion Value (IS:2386, Part 4) 40 Max.
Note : Maximum thickness for sand asphalt is 80mm.

table 500-42 requirements for bituminous pavement layers

Parameer Requirement
Minimum stability (kN at 600C) 2.0
Minimum flow (mm) 2
Compaction level (Number of blows) 2 x 75
Percent air voids 3-5
Percent voids in mineral aggregate (VMA) > 16
Percent voids filled with bitumen (VFB) 65 - 75

table 500-43 permissible variations from the job mix formula

Description Permissible variation

Aggregate passing 4.75mm + 6%

Aggregate passing 2.36mm, 1.18mm, 0.6mm + 5%

Aggregate passing 0.3mm, 0.15 mm + 4%

Aggregate passing 0.075mm + 2%

Binder Content + 0.3%

Mixing temperature + 100C

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566 RED BOOK  VOLUME I  ROADS  2012
 TABLE 500-44. REQUIREMENTS OF POLYMER MODIFIED BINDERS
(ELASTOMERIC THERMOPLASTICS AND RUBBER LATEX)

Designation Grade and Requirements Method of Test

PMB 120 PMB70 PMB40

‘Penetration at 25”C, 0.lmm. 90 to 150 50 to 89 30 to 49 IS: 1203-1978

l00g. 5 sec.

Penetration at 4”C, 0.1 mm. 35 22 18 IS:1205-1978

200g, 60 sec., Minimum*

Softening Point, (R&B).”C, Minimum 38 48 59 IS:1205-1978

Fraass Breaking Point. “C, Maximum* -24 -16 -12 IS:9381-1978

Ductility at 27”C. cm, Minimum 75 50 50 IS:1208-1978

Flash Point, COC, “C, Minimum 220 220 220 IS:1209-1978

Elastic Recovery of Half Thread in 70 60 50 ASTM

Ductilometer at 15”C, %, Minimum (50)** (40)** (30)** D5976-1996

Separation, Difference in Softening 4 4 4 ASTM

Point, R&B, “C, Maximum D5976-1996

Viscosity at 150”C. Poise 1-3 2-6 4-8 IS: 1206-1978

Test on Thin Film Oven Test Residue. TFOT (15:9382-1979)

Designation Grade and Requirements Method of Test

PMB120 PMB70 PMB40

Penetration at 4”C, 0.1mm, 200g. 18 15 12 IS: 1203-1978

60 sec .• Minimum*

Loss in Weight, %, Maximum 1.0 1.0 1.0 IS:9382- I 979

Increase in Softening Point, “C, 7 6 5 IS:1205-1978

Maximum

Reduction in Penetration at 25”C, 35 35 35 IS:1203-1978

%.Maximum

Elastic Recovery of Half Thread in 60 40 35 ASTM

Ductilometer at 15°C. %, Minimum (35)** (30)** (25)** D5976-1996

* Relevant to snow bound cold climate areas

** Natural Rubber Modified Bitumen

RED BOOK  VOLUME I  ROADS  2012 567

 TABLE 506-45. REQUIREMENTS OF POLYMER MODIFIED BINDERS
(PLASTOMERIC THERMOPLASTICS)
Designation Grade and Requirements Method of
Test
PMB 120 PMB70 PMB40
Penetration at 25”C, 0.lmm, l00g, 90 to 150 50 to 89 30 to 49 IS:1203-1978
5 sec.
Penetration at 4”C, 0.lmm, 200g, 35 22 18 IS:1205-1978
60 sec., Minimum*
Softening Point, (R&B), “C, Minimum 38 48 59 IS:1205-1978
Fraass Breaking Point, “C, Maximum* -20 -15 -10 15:9381-1978
Ductility at 27”C, em, Minimum 50 40 30 IS: I 208-1978
Flash Point, COC, ·C, Minimum 220 220 220 IS: 1209-1978
Elastic Recovery of Half Thread in 60 50 40 ASTM
Ductilometer at 15”C, %, Minimum 05976-1996
Separation, Difference in Softening 3 3 3 A5TM
Point, R&B, “C, Maximum 05976-1996
Viscosity at 150”C, Poise 1-2 2-4 4-8 IS: 1206-1978
Test on Thin Film Oven Test Residue, TFOT(/S:9382-/979)
Designation Grade and Requirements Method of
Test
PMBl20 PMB70 PMB40
Penetration at 4·C, O.lmm. 2oog. 18 15 12 IS:1203-1978
60 sec., Minimum*
Loss in Weight. %, Maximum 1.0 1.0 1.0 IS:9382-1979
Increase in Softening Point, “C, 7 6 5 IS: 1205-1978
Maximum
Reduction in Penetration at 25”C, 35 35 35 IS: 1203-1978
%,Maximum
Elastic Recovery of Half Thread in 45 35 30 ASTM
Ductilometer at 15”C, %, Minimum 05976-1996
* Relevant to snow bound cold climate areas

568 RED BOOK  VOLUME I  ROADS  2012

 TABLE 500-46. REQUIREMENTS OF POLYMER MODIFIED BINDERS
(TREATED WITH MODIFIED CRUMB RUBBER)
Designation Grade Method of Test
CRMB CRMB CRMB
60 55 50

Penetration at 25°C, 0.1 mm, 50 -70 50-60 40-60 IS: 1203-1978

100 g, 5 sec.
Softening Point, (R&B), °C, 50 55 60 IS:1205-1978
Minimum
Elastic Recovery of Half Thread in 40 35 30 ASTM
Ductilometer at 15°C, % Minimum . D5976 - 1996
Test on Thin Film Oven Test Residue (15:9382 -1979)
Reduction in Penetration at 25°C, %,Maximum 60 60 60 IS:1203 - 1978
Increase in Softening Point (R&B), °C,Maximum 5 5 5 IS:1205 - 1978
Elastic Recovery of Residue of Half 25 20 15 ASTM
Thread in Ductilometer at 15°C, %, D 5976-1996
Minimum

CRMB – Crumb Rubber Modified Bitumen

table 500-47 quantity of materials required for 10sqm. of road surface

for stress absorbing membrane

Sl. Type and Width of Crack Specification of Quantity of Quantity of chipping

No. SAM to be Binder kg/10m2
applied
1.  Hair crack and map cracks Single coat SAM 8 - 10 0.10 m3 of 5.6mm
upto 3mm width or 2nd coat of two chips
coat SAM
2.  Map cracks or alligator cracks Single coat SAM 10 - 12 0.10 m3 of 5.6mm
3mm to 6mm width chips
3. Map cracks or alligator cracks Two coat SAM 12 - 14 0.12 m3 of 5.6mm &
6mm to 9mm width 1st coat 11.2 mm chips in 1:1 ratio
2nd coat 8 - 10 0.10 m3 of 5.6mm chips
4. Cracks above 9mm width and Two coat SAM
cracked area above 50% 1st coat 14 - 16 0.12 m3 of 11.2mm chips
2nd coat 8 - 10 0.10 m3 of 5.6mm chips
5. All types of crack with crack Single coat SAM 8 - 10 0.10 m3 of 5.6mm
width below 6mm as interlayer chips
6. All types of crack with crack Single coat SAM 10 - 12 0.10 m3 of 11.2mm
width above 6mm as interlayer chips
7. Bitumen impregnated
Geotextile
Note : 1) Binder quantities for bitumen impreganted geotextile shall be in the range 0.9 to 1.2 liters/m2. Binder quantities
outside this range are permitted according to the geotextile manufacturer’s instructions and subject to the
agreement of the Engineer.

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RED BOOK  VOLUME I  ROADS  2012 569
570 RED BOOK  VOLUME I  ROADS  2012
 600
CONCRETE
PAVEMENT

RED BOOK  VOLUME I  ROADS  2012 571

572 RED BOOK  VOLUME I  ROADS  2012
 601. DRY LEAN CEMENT CONCRETE
SUB-BASE
601.1. Scope
601.1.1. The work shall consist of construction of dry lean concrete subbase 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,
materials and labour and performing all operations, in connection with the work, as
approved by the Engineer.
601.1.2. 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.
601.2. Materials
601.2.1. Source of Materials: The Contractor shall indicate to the Engineer the source
of all materials with relevant test data to be used in the lean concrete work sufficiently
in advance and the approval of the Engineer for the same shall be obtained at least 45
days before the scheduled commencement of the work. If the Contractor later pro—
poses to obtain the materials from a different source, he shall notify the Engineer for his
approval at least 45 days before such materials are to be used.
601.2.2. Cement: Any of the following types of cement may be used with prior approval
of the Engineer:
(i) Ordinary Portland Cement IS: 269
(ii) Portland Slag Cement IS: 455
(iii) Portland Pozzolana Cement IS: 1489
If the subgrade is found to consist of soluble sulphates in a concentration more than 0.5
per cent, cement used shall be sulphate resistant and shall conform to IS: 6909.
Cement to be used may preferably be obtained in bulk form. It shall be stored in
accordance with stipulations contained in Clause 1014 and shall be subjected to
acceptance test prior to its immediate use.
601.2.3. Aggregates:
601.2.3.1. Aggregates for lean concrete shall be natural material complying with 1S:
383. The aggregates shall not be alkali reactive. The limits of deleterious materials shall
not exceed the requirements set out in IS: 383. In case the Engineer considers that the
aggregates are not free from dirt, the same may be washed and drained for at least 72
hours before batching, as directed by the Engineer.
601.2.3.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be
devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery
pieces. The maximum size of the coarse aggregate shall be 25 mm. The coarse
aggregate shall comply with Clause 602.2.4.2.
601.2.3.3. Fine aggregate: The fine aggregate shall consist of clean, natural sand or
crushed stone sand or a combination of the two and shall conform to IS 1 383. Fine
aggregate shall be free from soft particles, clay, shale, loam, cemented particles, mica,
organic and other foreign matter. The fine aggregate shall comply with Clause 602.2.4.3.
601.2.3.4. The coarse and fine aggregates may be obtained in either of the following
manner:

RED BOOK  VOLUME I  ROADS  2012 573

 (i) In separate nominal sizes of coarse and fine aggregates and mixed together intimately
before use
(ii) Separately as 25 mm nominal single size, 12.5 mm nominal size graded aggregates
and fine aggregate of crushed stone dust or sand or a combination of these two.
The material after blending shall conform to the grading as indicated in Table 600-1.

TABLE 600-1. AGGREGATE GRADATION FOR DRY LEAN CONCRETE

Sieve Designation Percentage passing the
sieve by weight
26.50 mm 100
19.00 mm 80-100
9.50 mm 55-75
4.75 mm 35-60
600.00 micron 10-35
75.00 micron 0-8

601.2.4. Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amounts of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete. It shall meet the requirements stipulated in IS: 456.
601.2.5. Storage of materials: All materials shall be stored in accordance with the
provisions of Clause 1014 of these Specifications and other relevant IS Specifications.
All efforts must be made to store the materials in proper places so as to prevent their
deterioration or contamination by foreign matter and to ensure their satisfactory quality and
fitness for use in the work. The storage place must also permit easy inspection, removal
and storage of materials. All such materials even though stored in approved godowns must
be subjected to acceptance test immediately prior to their use. The requirement of storage
yard specified in Clause 602.2.9 shall also be applicable.
601.3. Proportioning of Materials for the Mix
601.3.1. The mix shall be proportioned with a maximum aggregate cement ratio of
15 : 1. The water content shall be adjusted to the optimum as per Clause 601.3.2 for
facilitating compaction by rolling. The strength and density requirements of concrete shall
be determined in accordance with Clause 601.6 by making trial mixes.
601.3.2. Moisture content: The right amount of water for the lean concrete in the main
work shall be decided so as to ensure full compaction under rolling and shall be assessed
at the time of rolling the trial length. Too much water will cause the lean concrete to be
heaving up before the wheels and picked up on the wheels of the roller and too little will
lead to inadequate compaction, a low in-situ strength and an open-textured surface.
The optimum water content shall be determined and demonstrated by rolling during trial
length construction and the optimum moisture content and degree of compaction shall be
got approved from the Engineer. While laying in the main work, the lean concrete shall
have moisture content between the optimum and optimum +2 per cent, keeping in view the
effectiveness of compaction achieved and to compensate for evaporation losses.
601.3.3. Cement content: The minimum cement content in the lean concrete shall not
be less than 150 kg/cu.m. of concrete. If this minimum cement content is not sufficient
to produce concrete of the specified strength, it shall be increased as necessary without
additional cost compensation to the Contractor.

574 RED BOOK  VOLUME I  ROADS  2012

601.3.4. Concrete strength: The average compressive strength of each consecutive
group of 5 cubes made in accordance with Clause 903.5.1.1 shall not be less than 10 MPa
at 7 days. In addition, the minimum compressive strength of any individual cube shall not
be less than 7.5 MPa at 7 days. The design mix complying with the above Clauses
shall be got approved from the Engineer and demonstrated in the trial length construction.
601.4. Subgrade
The subgrade shall conform to the grades and cross sections shown on the drawings and
shall be uniformly compacted to the design strength in accordance with these Specifications
and Specification stipulated in the Contract. The lean concrete subbase shall not be laid on
a subgrade softened by rain after its final preparation; surface trenches and soft spots, if
any, must be properly back-filled and compacted to avoid any weak or soft spot. As far as
possible, the construction traffic shall be avoided on the prepared subgrade. A day before
placing of the sub-base, the subgrade surface shall be given a fine spray of water and
rolled with one or two passes of a smooth wheeled roller after a lapse of 2-3 hours in order
to stabilise loose surface. If Engineer feels it necessary, another fine spray of water may be
applied just before placing subbase.
601.5. Construction
601.5.1. General: The pace 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 sub-base shall be overlaid with cement concrete pavement only after
7 days after sub-base construction.
601.5.2. 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 602.9.3.2. The cement from the bulk stock shall be weighed separately from the
aggregates. 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 ma chine 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 per cent in the 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.
601.5.3. Transporting: Plant mix learn 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 hatching plant to paving site shall be such that the travel time
available from mixing to paving as specified in Clause 601.5.5.2 will be adhered to.
601.5.4. 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

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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 subbase 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.
601.5.5. Compaction
601.5.5.1. The compaction shall be carried out immediately after the material is laid
and levelled. In order to ensure thorough compaction 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. The minimum dry density obtained shall be 97 per cent of that
achieved during the trial length construction vide Clause 601.7. The densities achieved
at the edges i.e. 0.5 m from the edge shall not be less than 95 per cent of that achieved
during the trial construction vide Clause 601.7.
601.5.5.2. 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 resorted 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.
601.5.5.3. 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 compatibility 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.
601.5.5.4. In addition to the number of passes required for compaction there shall be a
preliminary pass without vibration to bed the lean concrete down and again a final pass
without vibration to remove roller marks and to smoothen the surface.
Special care and attention shall be exercised during compaction near joints, kerbs,
channels, side forms and around gullies and manholes. In case adequate compaction
is not achieved by the roller at these points, use of plate vibrator shall be made, if so
directed by the Engineer.
601.5.5.5. 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

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 or defective areas shall be corrected by using fresh lean concrete material laid 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 concrete with aggregate 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.
601.5.5.6. Segregation of concrete in the dumpers shall be controlled by premixing
each fraction of the aggregates before loading in the bin of the batching plant, by moving
the dumper back and forth while discharging the mix on it and other means. Even paving
operation shall be such that the mix does not segregate.
601.5.6. Joints: Contraction and longitudinal joints shall be provided as per tl1e drawing.
At longitudinal or transverse construction joints, unless vertical forms are used, the edge of
compacted material shall be cut back to a vertical face where the correct thickness of the
properly compacted material has been obtained.
601.5.7. Curing: As soon as the lean concrete surface is compacted, curing shall
commence. One of the following two methods shall be adopted:
(a) The initial curing shall be done by spraying with liquid curing compound. The curing
compound shall be white pigmented or transparent type with water retention index
of 90 per cent when tested in accordance with BS 7542. Curing compound shall be
sprayed immediately after rolling is complete. As soon as the curing compound has
lost its tackiness, the surface shall be covered with wet hessian for three days.
(b) Curing shall be done by covering the surface by gunny bags/hessian, which shall be
kept continuously moist for 7 days by sprinkling water.
601.6. Trial Mixes The Contractor shall make trial mixes of dry lean concrete with moisture
contents like 5.0, 5.5, 6.0, 6.5 and 7.0 per cent using cement content specified and the
specified aggregate grading but without violating the requirement of aggregate-cement
ratio specified in Clause 601.3.1. Optimum moisture and density shall be established by
preparing cubes with varying moisture contents. Compaction of the mix shall be done in
three layers with vibratory hammer fitted with a square or rectangular foot as described in
Clause 903.5.1.1. After establishing the optimum moisture, a set of six cubes shall be cast
at that moisture for the determination of compressive strength on the 3rd and the seventh
day. Trial mixes shall be repeated if the strength is not satisfactory either by increasing
cement content or using higher grade of cement. After the mix design is approved, the
Contractor shall construct a trial section in accordance with Clause 601.7.
If during the construction of the trial length, the optimum moisture content determined as
above is found to be unsatisfactory, the Contractor may make suitable changes in the
moisture content to achieve a satisfactory mix. The cube specimens prepared with the
changed moisture content should satisfy the strength requirement. Before production of the
mix, natural moisture content of the aggregate should be determined on a day-to-day basis
so that the moisture content could be adjusted. The mix finally designed should neither
stick to the rollers nor become too dry resulting in ravelling of surface.
601.7. Trial Length
601.7.1. The trial length shall be constructed at least 14 days in advance of the proposed
date of commencement of work. At least 30 days prior to the construction of the trial length,
the Contractor shall submit for the Engineer’s approval a "Method Statement" giving detailed

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description of the proposed materials, plant, equipment, mix proportion, and procedure
for batching, mixing, laying, compaction and other construction procedures. The Engineer
shall also approve the location and length of trial construction which shall be a minimum of
60 m length and for full width of the pavement. The trial length shall contain the construction
of at least one transverse construction joint involving hardened concrete and freshly laid
sub-base. The construction of trial length will be repeated till the Contractor proves his
ability to satisfactorily construct the subbase.
601.7.2. In order to determine and demonstrate the optimum moisture content which
results in the maximum dry density of the mix compacted by the rolling equipment and
the minimum cement content that is necessary to achieve the strength stipulated in the
drawing, trial mixes shall be prepared as per Clause 601.6.
601.7.3. After the construction of the trial length, the in-situ density of the freshly laid
material shall be determined by sand replacement method with 20 cm dia density cone.
Three density holes shall be made at locations equally spaced along a diagonal that bisects
the trial length; average of these densities shall be determined. These main density holes
shall not be made in the strip 50 cm from the edges. The average density obtained from the
three samples collected shall be the reference density and is considered as 100 per cent.
The field density of regular work will be compared with this reference density in accordance
with Clauses 601.5.5.1 and 903.5.1.2. A few cores may be cut as per the instructions of the
Engineer to check segregation or any other deficiency.
601.7.4. The hardened concrete shall be cut over 3 m width and reversed to inspect the
bottom surface for any segregation taking place. The trial length shall be constructed after
making necessary changes in the gradation of the mix to eliminate segregation of the mix.
The lower surface shall not have honey-combing and the aggregates shall not be held
loosely at the edges.
601.7.5. The trial length shall be outside the main works. The main work shall not start
until the trial length has been approved by the Engineer. After approval has been given,
the materials, mix proportions, moisture content, mixing, laying, compaction plant and
construction procedures shall not be changed without the approval of the Engineer.
601.8. Tolerances for Surface Regularity, Level, Thickness, Density and Strength
The tolerances for surface regularity, level, thickness, density and strength shall conform to
the requirements given in Clause 903.5. Control of quality of materials and works shall be
exercised by the Engineer in accordance with Section 900.
601.9. Traffic
No heavy commercial vehicles like trucks and buses shall be permit- ted 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.
601.10. Measurements for Payment
The unit of measurement for dry lean 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 as directed by the Engineer.
601.11. Rate
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

578 RED BOOK  VOLUME I  ROADS  2012

necessary and all leads and lifts.
602. CEMENT CONCRETE PAVEMENT
602.1. Scope
602.1.1. The work shall consist of construction of unreinforced, dowel jointed, plain 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.
602.1.2. The design parameters, viz., thickness of pavement slab, grade of concrete, joint
details etc. shall be as stipulated in the drawings.
602.2. Materials
602.2.1. Source of materials: The Contractor shall indicate to the Engineer the source of
all materials to be used in the concrete work with relevant test data sufficiently in advance,
and the approval of the Engineer for the same shall be obtained at least 45 days before the
scheduled commencement of the work. If the Contractor later proposes to obtain materials
from a different source, he shall notify the Engineer for his approval, at least 45 days before
such materials are to be used with relevant test data. 602.2.2. Cement: Any of the following
types of cement capable of achieving the design strength may be used with prior approval
of the Engineer, but the preference should be to use at least the 43 Grade or higher.
(i) Ordinary Portland Cement, 33 Grade, IS : 269.
(ii) Ordinary Portland Cement, 43 Grade IS : 8112.
(iii) Ordinary Portland Cement, 53 Grade, IS 1 12269.
If the soil around has soluble salts like sulphates in excess of 0.5 per cent, the cement used
shall be sulphate resistant and shall conform to IS: 12330.
Guidance may be taken from IS: SP: 23, 1-Iandbook for Concrete Mixes for ascertaining
the minimum 7 days strength of cement required to match with the design concrete strength
Cement to be used may preferably be obtained in bulk form. If cement in paper bags are
proposed to be used, there shall be bag-splitters with the facility to separate pieces of paper
bags and dispose them of suitably. No paper pieces shall enter the concrete mix. Bulk
cement shall be stored in accordance with Clause 1014. The cement shall be subjected
to acceptance test just prior to its use. 602.2.3. Admixtures : Admixtures conforming to
IS:6925 and IS: 9103 shall be permitted to improve workability of the concrete or extension
of setting time, on satisfactory evidence that they will not have any adverse effect on the
properties of concrete with respect to strength, volume change, durability and have no
deleterious effect on steel bars. The particulars of the admixture and the quantity to be used
must be furnished to the Engineer in advance to obtain his approval before use. Satisfactory
performance of the admixtures should be proved both on the laboratory concrete trial mixes
and in trial paving works. If air-entraining admixture is used, the total quantity of air in air-
entrained concrete as a percentage of the volume of the mix shall be 5 ± 1.5 per cent for
25 mm nominal size aggregate.
602.2.4. Aggregates
602.2.4.1. Aggregates for pavement concrete shall be natural material complying with
IS:383 but with a Los Angeles Abrasion Test result not more than 35 per cent. The limits of
deleterious materials shall not exceed the requirements set out in IS: 383.
The aggregates shall be free from chert, flint, chalcedony or other silica in a form that can
react with the alkalies in the cement. In addition, the total chlorides content expressed as

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chloride ion content shall not exceed 0.06 per cent by weight and the total sulphate content
expressed as sulphuric anhydride (SO3) shall not exceed 0.25 per cent by weight.
602.2.4.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be
devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery
pieces. The maximum size of coarse aggregate shall not exceed 25 mm for pavement
concrete. Continuously graded or gap graded aggregates may be used, depending on the
grading of the fine aggregate. No aggregate which has water absorption more than 2 per
cent shall be used in the concrete mix. The aggregates shall be tested for-soundness in
accordance with IS z 2386 (Part-5). After 5 cycles of testing the loss shall not be more
than 12 per cent if sodium sulphate solution is used or 18 per cent if magnesium sulphate
solution is used.
Dumping and stacking of aggregates shall be done in an approved manner. In case the
Engineer considers that the aggregates are not free from dirt, the same may be washed
and drained for at least 72 hours ` before batching as directed by the Engineer.
602.2.4.3. Fine aggregate: The fine aggregate shall consist of clean natural sand or
crushed stone sand or a combination of the two and shall conform to IS : 383. Fine aggregate
shall be free from soft particles, clay, shale, loam, cemented particles, mica and organic
and other foreign matter. The fine aggregate shall not contain deleterious substances more
than the following:
Clay lumps 4.0 per cent
Coal and lignite 1.0 per cent
Material passing IS Sieve No. 75 micron 4.0 per cent
602.2.5. Water: Water used for mixing and curing of concrete shall be clean and free
from injurious amount of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete. It shall meet the requirements stipulated in IS: 456.
602.2.6. Mild steel bars for dowels and tie bars : These shall conform to the requirements
of IS : 432, IS : 1139 and IS : 1786 as relevant. The dowel bars shall conform to Grade S
240 and tie bars to Grade S 415 of 1.S.
602.2.7. Premoulded 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 1.5 mm and of a firm compressible material and complying
with the requirements of 15:1838, or 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 1 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.
602.2.8. 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).
602.2.9. Storage of materials: All materials shall be stored in accordance with the
provisions of Clause 1014 of the` Specifications and other relevant IS Specifications.
All efforts must be made to store the materials in proper places so as to prevent their
deterioration or contamination by foreign matter and to ensure their satisfactory quality and
fitness for the work. The platform where aggregates are stock piled shall be levelled with

580 RED BOOK  VOLUME I  ROADS  2012

15 cm of watered, mixed and compacted granular sub-base material. The area shall have
slope and drain to drain off rain water. The storage space must also permit easy inspection,
removal and storage of the materials. Aggregates of different sizes shall be stored in
partitioned stack-yards. All such materials even though stored in approved godowns must
be subjected to acceptance test as per Clause 903 of these Specifications immediately
prior to their use.
602.3. Proportioning of Concrete
602.3.1. 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 per 15:10262 (Recommended Guidelines for Mix
Design) or on the basis of any other rational method agreed to by the Engineer. Guidance
in this regard can also be obtained from IS: SP: 23 Handbook on Concrete Mixes. The
target mean strength for the design mix shall be determined as indicated in Clause 903.5.2.
The mix design shall be based on the flexural strength of concrete.
602.3.2. Cement content: The cement content shall not be less than 350 kg per cu.m. of
concrete. If this minimum cement content is not sufficient to produce in the field, concrete
of the strength specified in the drawings/design, it shall be increased as necessary without
additional compensation under the Contract. The cement content shall, however, not
exceed 425 kg per cu.m. of concrete.
602.3.3. Concrete strength
602.3.3.1. While designing the mix in the laboratory, correlation between flexural and
compressive strengths of concrete shall be established on the basis of at least thirty tests
on samples. However, quality control in the field shall be exercised on the basis of flexural
strength. It may, however, be ensured that the materials and mix proportions remain
substantially unaltered during the daily concrete production. The water content shall be
the minimum required to provide the agreed workability for full compaction of the concrete
to the required density as determined by the trial mixes or other means approved by the
Engineer and the maximum free water cement ratio shall be 0.50.
602.3.3.2. The ratio between the 7 and 28 day strengths shall be established for the mix
to be used in the slab in advance, by testing pairs of beams and cubes at each stage on at
least six batches of trial mix. The average strength of the 7 day cured specimens shall be
divided by the average strength of the 28 day specimens for each batch, and the ratio ‘R’
shall be determined. The ratio ‘R’ shall be expressed to three decimal places.
If during the construction of the trial length or during normal working, the average value
of any four consecutive 7 day test results falls below the required 7 day strength as
derived from the value of ‘R’, then the cement content of the concrete shall, without extra
payment, be increased by 5 per cent by weight or by an amount agreed by the Engineer.
The increased cement content shall be maintained at least until the four corresponding 28
day strengths have been assessed for its conformity with the requirements as per Clause
602.3.1. Whenever the cement content is increased, the concrete mix shall be adjusted to
maintain the required workability.
602.3.4. Workability
602.3.4.1. 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

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approved by the Engineer. The control of workability in the field shall be exercised by the
slump test as per IS: 1199.
602.3.4.2. 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
avail- able. 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.
602.3.5. Design mix
602.3.5.1. The Contractor shall carry out laboratory trials of design mixes 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.
602.3.5.2. 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.
602.3.5.3. Any change in the source of materials or mix proportions proposed by the
Contractor during the course of work shall be assessed by making laboratory trial mixes and
the construction of a further trial length unless approval is given by the Engineer for minor
adjustments like compensation for moisture content in aggregates or minor fluctuations in
the grading of aggregate.
602.4. Sub-base
The cement concrete pavement shall be laid over the sub-base constructed in accordance
with the relevant drawings and Specifications contained in Clause 601. If the sub-base
is found damaged at some places or it has cracks wider than 10 mm, it shall be repaired
with fine cement concrete or bituminous concrete before laying separation V layer. Prior to
laying of concrete it shall be ensured that the separation membrane as per Clause 602.5 is
placed in position and the same is clean of dirt or other extraneous materials and free from
any damage.
602.5. Separation Membrane A separation membrane shall be used between the concrete
slab and the subbase. 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 C0ntractor’s expense. The separation membrane may be
nailed to the lower layer with concrete nails.
602.6. Joints
602.6.1. 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

582 RED BOOK  VOLUME I  ROADS  2012

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 lm and 0.3 m 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 sawing machine and personnel without damaging the texture of the
pavement. Sawing operation could start as early as 6-8 hours depending upon the season.
602.6.2. Transverse joints
602.6.2.1. 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:
(i) 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.
(ii) 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.
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 mm.
(iv) 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 602.11.
602.6.2.2. 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 x 5 mm or as stipulated in the
drawings and dowel bars complying with Clause 602.6.5 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.
602.6.2.3. Expansion joints: The expansion joints shall consist of a joint filler board
complying with Clause 602.2.7 and dowel bars complying with Clause 602.6.5 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 602.6.2.1;
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.
602.6.3. 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 bulk heads 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.

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602.6.4. Longitudinal joint
602.6.4.1. 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.
602.6.4.2. Tie bars shall be provided at the longitudinal joints as per dimensions and
spacing shown in the drawing and in accordance with Clause 602.6.6.
602.6.5. Dowel bars
602.6.5.1. Dowel bars shall be mild steel rounds in accordance with Clause 602.2.6 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 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.
602.6.5.2. 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 602.10.7.
(i) For bars supported on cradles prior to the laying of the slab:
(a) All bars in a joint shall be within ± 3 mm per 300 mm length of bar
(b) 2/3rd of the bars shall be within ± 2 mm per 300 mm length of bar
(c) 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
(d) Cradles supporting dowel bar shall not extend across the line of joint i.e. no I steel
bar of the cradle assembly shall be continuous across the joint.
(ii) For all bars inserted after laying of the slab:
(a) Twice the tolerance for alignment as indicated in (i) above
602.6.5.3. 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:
(i) Two-thirds of the number of bars of any assembly tested shall not deflect more than
2 mm per 300 mm length of bar
(ii) The remainder of the bars in that assembly shall not deflect more than 3 mm per
300mm length of bar.
602.6.5.4. 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:-
(i) 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 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.

584 RED BOOK  VOLUME I  ROADS  2012

 (ii) 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.–
(iii) 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.
(iv) Fittings shall be deemed to fail when there is displacement of the assemblies by
more than 3 mm with any form of fixing, under the test load. The displacement shall
be measured at the nearest part of the assembly to the centre of the bar or timber
packing.
602.6.5.5. 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:
(i) 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 it 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.
602.6.5.6. 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.
602.6.6.Tie bars
602.6.6.1. Tie bars in longitudinal joints shall be deformed steel bars of strength 415 MPa
complying with IS: 1786 and in accordance with the requirements given below. The bars
shall be free from oil, dirt, loose rust and scale.
602.6.6.2. 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.
602.6.6.3. 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. 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 recompaction of the concrete around the tie bars.
602.6.6.4. 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.
602.7. Weather and Seasonal Limitations
602.7.1. 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

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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.
602.7.2. 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.
602.8. Side Forms, Rails and Guidewires
602.8.1. 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. Sideforms 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 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.
602.8.2. 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.
602.8.3. Use of guidewires
602.8.3.1. Where slip form paving is proposed, a guidewire shall be provided along both
sides of the slab. Each guidewire shall be at a constant height above and parallel to the
required edges of the slab as described in the contract/drawing within a vertical tolerance
of ± 3mm. Additionally, one of the wires shall be kept at a constant horizontal distance from
the required edge of the pavement as indicated in the contract/drawing within a lateral
tolerance of ± 10 mm.
602.8.3.2. The guidewires shall be supported on stakes not more than 8 m apart by
connectors capable of fine horizontal and vertical adjustment. The guidewire shall be
tensioned on the stakes so that a 500 gram weight shall produce a deflection of not more
than 20 mm when suspended at the midpoint between any pair of stakes. The ends of the
guidewires shall be anchored to fixing point or winch and not on the stakes.
602.8.3.3. The stakes shall be positioned and the connectors maintained at their correct
height and alignment from 12 hours on the day before concreting takes place until 12
hours after finishing of the concrete. The guidewire shall be erected and tensioned on the
586 RED BOOK  VOLUME I  ROADS  2012
connectors at any section for at least 2 hours before concreting that section.
602.8.3.4. The Contractor shall submit to the Engineer for his approval of line and level, the
stakes and connectors which are ready for use in the length of road to be constructed by 12
hours on the working day before the day of construction of slab. Any deficiencies noted by
the Engineer shall be rectified by the Contractor who shall then re-apply for approval of the
affected stakes. Work shall not proceed until the Engineer has given his approval. It shall
be ensured that the stakes and guidewires are not affected by the construction equipment
when concreting is in progress.
602.9. Construction
602.9.1. 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 time-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 at least 300 m in one day. 602.9.2. 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.
602.9.3. Equipment for proportioning of materials and paving
602.9.3.1. 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.
602.9.3.2. Batching plant and equipment:
(1) General - The batching plant shall include minimum four bins, weighing hoppers, and
scales for the line 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-resettable
batch counter which will correctly indicate the number of batches proportioned.
(2) Bins and hoppers - Bins with minimum number of four adequate separate compartments
shall be provided in the hatching plant.
(3) Automatic weighing devices - Batching plant shall be equipped to proportion aggregates
and bulk cement by means of automatic weighing devices using load cells.
(4) 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

RED BOOK  VOLUME I  ROADS  2012 587

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.
(5) Control cabin - An air-conditioned centralised control cabin shall be provided for
automatic operation of the equipment.
602.9.3.3. 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.
602.9.3.4. Concrete saw: The Contractor shall provide adequate number of concrete saws
with sufficient number of diamond-edge saw blades. The saw machine shall be either
electric or petrol/diesel driven type. A water tank with flexible hoses and pump shall be
made available in this activity on priority basis. The Contractor shall have at least one
standby saw in good working condition. The concreting work shall not commence if the
saws are not in working condition.
602.9.4. Hauling and placing of concrete
602.9.4.1. 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 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 day’s work.
602.9.4.2. 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. 602.9.4.3. Where fixed

588 RED BOOK  VOLUME I  ROADS  2012

form payers are to be used, forms shall be fixed in advance as per Clause 602.8. 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.
602.9.4.4. In all cases, the temperature of the concrete shall be measured at the point of
discharge from the delivery vehicle.
602.9.4.5. 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.
602.9.4.6. 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.
602.9.4.7. While the concrete is still plastic, its surface shall be brush textured in compliance
with Clause 602.9.8 and the surface and edges of the slab cured by the application of
a sprayed liquid curing membrane in compliance with Clause 602.9.9. 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.
602.9.4.8. 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.
602.9.4.9. If the requirement of Clause 902.4. 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.
602.9.5. Construction by fixed form paver
602.9.5.1. The fixed form paving train shall consist of separate powered machines which
spread, compact and finish the concrete in a continuous operation.
602.9.5.2. 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 subbase. 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 over- working.
602.9.6. Construction by slip form paver
602.9.6.1. 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 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

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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.
602.9.6.2. The level of the conforming plate and finishing beams shall be controlled
automatically from the guide wires installed as per Clause 602.8 by sensors attached at the
four corners 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.
602.9.6.3. Slip-form paving machines shall have vibrators of variable output, with
a maximum energy output of not less than 2.5 KW pr 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.
602.9.6.4. 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 602.14, 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.
602.9.7. 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.
602.9.8. Surface texture
602.9.8.1. 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.
602.9.8.2. 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.
602.9.8.3. 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.

590 RED BOOK  VOLUME I  ROADS  2012

 602.9.8.4. 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 : 600-2. Texture Depth

Required Texture
Depth (mm)
Number of Specified Tolerance
Time of Test Measurements Value
1. Between 24 hours and 7 days after An average of 1.00 ±0.25
the constn., of the slab or until the 5 measurements
slab is first used by vehicles.-
2. Not later than 6 weeks before the An average of 5 1.00 +0.25
road is opened to public traffic. measurements -0.35

602.9.8.5. After the application of the brushed texture, the surface of the slab shall have a
uniform appearance.
602.9.8.6. 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.
602.9.9. Curing
602.9.9.1. Immediately after the surface texturing, the surface and sides of the slab shall be
cured by the application of approved resin- based aluminised reflective curing compound
which hardens into an impervious film or membrane with the help of a mechanical sprayer.
Curing compounds shall contain sufficient flake aluminium in finely divided dispersion to
produce a complete coverage of the sprayed surface with a metallic finish. The compound
shall become stable and impervious to evaporation of water from the surface of the concrete
within 60 minutes of application and shall be of approved type. The curing compounds shall
have a water retention efficiency index of 90 per cent in accordance with BS Specification
No. 7542.
602.9.9.2. The curing compound shall not react chemically with the concrete and the film
or membrane shall not crack, peel or disintegrate within three weeks after application.
Immediately prior to use, the curing compound shall be thoroughly agitated in its containers.
The rate of spread shall be in accordance with the manufacturer’s instructions checked
during the construction of the trial length and subsequently whenever required by the
Engineer. The mechanical sprayer shall incorporate an efficient mechanical device for
continuous agitation and mixing of the compound during spraying.
602.9.9.3. In addition to spraying of curing compound, the fresh concrete surface shall
be protected for at least 3 hours by covering the finished concrete pavement with tents
as described in Clause 602.7.2, during adverse weather conditions as directed by the
Engineer. After three hours, the pavement shall be covered by moist hessian and the same
shall then be kept damp for a minimum period of 14 days after which time the hessian may
be removed. The hessian shall be kept continuously moist. All damaged/torn hessian shall
be removed and replaced by new hessian on a regular basis.
602.9.9.4. The Contractor shall be liable at his expense to replace any concrete damaged
as a result of incomplete curing or cracked on a line other than that of a joint.

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602.10. Trial Length
602.10.1. The trial length shall be constructed at least one month in advance of the proposed
start of concrete paving work. At least one month prior to the construction of the trial length,
the Contractor shall submit for the Engineer’s approval a detailed method statement giving
description of the proposed materials, plant, equipment and construction methods. All the
major equipments like paving train, batching plant, tippers etc., proposed in the construction
are to be approved by the Engineer before their procurement. No trials of new materials,
plant, equipment or construction methods, nor any development of them shall be permitted
either during the construction of trial length or in any subsequent paving work, unless they
form part of further, approved trials. These trial lengths shall be constructed away from the
carriage- way but with at least a subbase layer below it.
602.10.2. The Contractor shall demonstrate the materials, plant, equipment and methods
of construction that are proposed for concrete paving, by first constructing a trial length of
slab, at least 60 m but not more than 300 m long for mechanised construction and at least
30 m long for hand guided methods. If the first trial is unsatisfactory, the Contractor shall
have to demonstrate his capability to satisfactorily construct the pavement in subsequent
trials.
602.10.3 The trial length shall be constructed in two parts over a period comprising at
least part of two separate working days, with a minimum of 30 m constructed each day for
mechanised construction and a minimum of 15 m on each day for hand guided construction.
The trial length shall be constructed at a similar rate (speed, around lm/hr) to that which is
proposed for the main work.
602.10.4. Transverse joints and longitudinal joints of each type that are proposed for dowel-
jointed unreinforced concrete slabs in the main work shall be constructed and assessed in
the trial length. If in the trial length the construction of expansion joint and longitudinal joint
is not demonstrated, the first 2 expansion joints and at least the first 150 m of longitudinal
construction joint for mechanised paving in the main work, shall be considered as the trial
length for these joints.
602.10.5. The trial length shall comply with the Specification in all respects, with the
following additions and exceptions:
602.105.1. Surface levels and regularity
(i) In checking for compliance with Clause 903.5 the levels shall be taken at intervals at
the locations specified in this Clause along any line or lines parallel to the longitudinal
centre line of the trial length.
(ii) The maximum number of permitted irregularities of pavement surface shall comply
with the requirements of Clause 902.4. Shorter trial lengths shall be assessed pro•
rata based on values for a 300 m length.
602.10.5.2. Joints
(iii) Alignment of dowel bars shall be inspected as described in Clause 602.10.7 in any
two consecutive transverse joints. If the position or alignment of the dowel bars at one
of these joints does not comply with Clause 602.6.5, if that joint remains the only one
that does not comply after the next 3 consecutive joints of the same type have been
inspected, then the method of placing dowels shall be deemed to be satisfactory.
In order to check sufficient joints for dowel bar alignment without extending the trial
length unduly, the Contractor may, by agreement with the Engineer, construct joints
at more frequent joint intervals than the normal spacing required in the Contract.
(iv) If there are deficiencies in the first expansion joint that is constructed as a trial, the

592 RED BOOK  VOLUME I  ROADS  2012

 next expansion joint shall be a trial joint. Should this also be deficient, further trial
expansion joints shall be made as part of the trial length which shall not form part of
the permanent works, unless agreed by the Engineer.
602.10.5.3. Density
(v) Density shall be assessed as described in Clause 602.3.3. from at least 3 cores
drilled from each part of the trial length.
602.10.5.4. Position of tie bars
(vi) Compliance with Clause 602.6.6 for the position and alignment of tie bars shall be
checked by drilling additional cores from the slab unless they can be determined
from cores taken for density.
602.10.6. Approval and acceptance
602.10.6.1 Approval of the materials, plant, equipment and construction methods shall
be given when a trial length complies with the Specification. The Contractor shall not
proceed with normal working until the trial length has been approved and any earlier
defective mal lengths have been removed, unless that can be remedied to the satisfaction
of the Engineer. If the Engineer does not notify the Contractor of any deficiencies in
any trial- length within 10 days after the completion of that trial length, the Contractor
may assume that the trial length, and the materials, plant, equipment and construction
methods adopted are acceptable.
602.10.6.2. When approval has been given, the materials, plant, equipment and
construction methods shall not thereafter be changed, except for normal adjustments and
maintenance of plant, without the approval of the Engineer. Any changes in materials,
plant, equipment, and construction methods shall entitle the Engineer to require the
Contractor to lay a further trial length as described in this Clause to demonstrate that the
changes will not adversely affect the permanent works.
602.10.6.3. Trial lengths which do not comply with the Specification, with the exception
of areas which are deficient only in surface texture and which can be remedied in
accordance with Clause 602.9.8.6 shall be removed immediately upon notification of
deficiencies by the Engineer and the Contractor shall construct a further trial length.
602.10.7. Inspection of dowel bars
602.10.7.1. Compliance with Clause 602.6.5. for the position and alignment of dowel
bars at construction and expansion joints shall be checked by measurements relative to
the side forms or guide wires.
602.10.7.2. When the slab has been constructed, the position and alignment of dowel
bars and any filler board shall be measured after carefully exposing them in the plastic
concrete across the whole width of the slab. When the joint is an expansion joint, the
top of the filler board shall first be exposed sufficiently in the plastic concrete to permit
measurement of any lateral or vertical displacement of the board. During the course of
normal working, these measurements shall be carried out in the pavement section at
the end of day’s work by extending slab length by 2 m. After sawing the transverse joint
groove, the extended 2 m slab shall be removed carefully soon after concrete has set to
expose dowels over half the length. These dowels can be tested for tolerances.
602.10.7.3. If the position and alignment of the bars in a single joint in the slab is
unsatisfactory then the next two joints shall be inspected. If only one joint of the three is
defective, the rate of checking shall be increased to one joint per day until the Engineer
is satisfied that compliance is being achieved. In the event of noncompliance in two
or more successive joints, the Contractor shall revert to the construction of fresh trial

RED BOOK  VOLUME I  ROADS  2012 593

 lengths and make any necessary alteration to concrete mix, paving plant or methods
until the dowel bar position and alignment are satisfactory.
602.10.7.4. After the dowel bars have been examined, the remainder of the concrete
shall be removed over a width of 500 mm on each side of the line of the joint and
reinstated to the satisfaction of the Engineer. The dowels shall be inserted on both sides
of the 1 m wide slab by drilling holes and grouting with epoxy mortar. Plastic sheath as
per Clause 602.6.5.5 shall be provided on dowels on one of the joints. The joint groove
shall be widened and sealed as per Clause 602.11.
602.11. Preparation and Sealing of Joint Grooves
602.11.1. General
All transverse joints in surface slabs shall be sealed using sealants described in Clause
602.2.8. Joints shall not be sealed before 14 days after construction.
602.11.2. Preparation of joint grooves for sealing
602.11.2.1. 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.
602.11.2.2. If rough arrises 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 IQ 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 arrises shall be repaired by an approved thin bonded arris repair
using cementitious materials.
602.11.2.3. 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
pressurised 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.
602.11.2.4. The groove shall be cleaned and dried at the time of priming and sealing.
602.11.2.5. 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.
602.11.3. Sealing with sealants
602.11.3.1. 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.

594 RED BOOK  VOLUME I  ROADS  2012

 602.11.3.2 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.
602.11.3.3. 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.
602.11.3.4. 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.
602.11.3.5. Sealant shall be applied, slightly to a lower level than the slab with a
tolerance of 5 ± 2 mm.
602.11.3.6. During sealing operation, it shall be seen that no air bubbles are introduced
in the sealant either by vapours or by the sealing process.
602.11.4. Testing of applied sealants: Manufacturer’s certificate shall be produced by
the Contractor for establishing that the sealant is not more than six months old and
stating that the sealant complies with the relevant standard as in Clause 602.2.8. The
samples shall meet the requirement of AASHTO M 282 for hot applied sealant or BS
5212: (Part- 2) for cold applied sealant.
602.12. Measurement of Texture Depth: Sand Patch Method
602.12.1. The following apparatus shall be used:
(i) A cylindrical container of 25 ml internal capacity
(ii) 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
(iii) Dry natural sand with a rounded particle shape passing a 300 micron IS sieve and
retained on a 150 micron IS sieve.
602.12.2. Method: 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.
602.12.3. 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.
602.13. 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.
RED BOOK  VOLUME I  ROADS  2012 595
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.

602.14. Tolerances for Surface Regularity, Level, Thickness and Strength

The tolerances for surface regularity, level, thickness and strength shall conform to the
requirements given in Clause 903.5. Control of quality of materials and works shall be
exercised by the Engineer in accordance with Section 900.

602.15. Measurements for Payment

602.15.1. 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 tie
rod.
602.15.2. 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.
When the average thickness for the lot is deficient by the extent shown in Table 600-3,
the Contract unit price will be adjusted as per this Table.

596 RED BOOK  VOLUME I  ROADS  2012

 TABLE 600-3. PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNESS
Deficiency in the average Per cent of Contract
thickness of day’s work unit price payable
Up to 5 mm 100
6 - 10 mm 87
11 - 15 mm 81
16 - 20 mm 75
21 - 25 mm 70
In the stretch where deficiency of average thickness is more than 25 mm, the section whose
thickness is deficient by 26 mm or more is identified with the help of cores. Such slabs shall
be removed and reconstructed at the cost of the Contractor. During such rectification work,
care shall be taken to replace full slab and to the full depth.
602.16. 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.
603. ROLLED CEMENT CONCRETE BASE
603.1. Scope
603.1.1. The work shall consist of construction of rolled concrete base course 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, material
and labour and performing all operations in connection with the work, as approved by
the Engineer.
603.1.2. The design parameters of rolled cement concrete base course viz., width,
thickness, grade of concrete, details of joints, if any, etc. shall be as stipulated in the
contract drawings.
603.2. Materials
603.2.1. Source of materials: The Contractor shall indicate to the Engineer the source
of all materials to be used in the lean concrete work with relevant test data sufficiently in
advance and the approval of the Engineer for the same shall be obtained at least 60 days
before the scheduled commencement of the work. If the Contractor later proposes to
obtain the materials from a different source, he shall notify the Engineer for his approval
at least 60 days before such materials are to be used.
603.2.2. Cement: Any of the following types of cement may be used with prior approval
of the Engineer.
(i) Ordinary Portland Cement IS : 269, 8112 or 12269
(ii) Portland Slag Cement IS : 455
(iii) Portland Pozzolana Cement IS : 1489
If the subgrade is found to consist of soluble sulphates in a concentration more than 0.5
per cent, cement used shall be sulphate resistant and shall conform to IS : 12230. Cement
RED BOOK  VOLUME I  ROADS  2012 597
 to be used may preferably be obtained in bulk form. It shall be stored in accordance with
stipulations contained in Clause 1014 and shall be subjected to acceptance test prior to
its immediate use.
603.2.3. Aggregates :
603.2.3.1. Aggregates for lean concrete shall be natural material complying with IS:383.
The aggregates shall not be alkali reactive. The limits of deleterious materials shall not
exceed the requirements set out in IS: 383. In case the Engineer considers that the
aggregates are not free from dirt, the same may be washed and drained for at least 72
hours before batching as directed by the Engineer.
603.2.3.2. Coarse aggregate: Coarse aggregates shall consist of clean, hard, strong,
dense, non-porous and durable pieces of crushed stone or crushed gravel and shall be
devoid of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery
pieces. The maximum size of the coarse aggregate shall be 25 mm. The coarse
aggregate shall comply with the Clause 602.2.4.2.
603.2.3.3. Fine aggregate : The fine aggregate shall consist of clean natural sand
or crushed stone sand or a combination of the two and shall conform to IS:383. Fine
aggregate shall be free from soft particles, clay, shale, loam, cemented particles, mica,
organic and other foreign matter. The fine aggregate shall comply with the Clause
602.2.4.3.
603.2.3.4. The coarse and fine aggregates may be obtained in either of the following
manner:-
(i) In separate nominal sizes of coarse and fine aggregates and mixed together intimately
before use.
(ii) Separately as 25 mm nominal single size, 12.5 mm nominal size graded aggregate
and fine aggregate of crushed stone dust or sand or a combination of these two.
The material after blending shall conform to the grading as indicated in Table 600-4
below:

TABLE 600-4. AGGREGATE GRADATION FOR DRY LEAN CONCRETE

Sieve Designation Percentage Passing the
sieve by weight
37.5 mm 100
19.0 mm 80-100
9.5 mm 55-80
4.75 mm 35-60
600 micron 10-35
75 micron 0-8
603.2.4. Water: Water used for mixing and curing of concrete shall be clean and free
from injurious amount of oil, salt, acid, vegetable matter or other substances harmful to
the finished concrete. It shall meet the requirements stipulated in IS: 456.
603.2.5. Storage of materials:  All materials shall be stored in accordance with the
provisions of Clause 1014 of these Specifications, and other relevant IS Specifications.
All efforts must be made to store the materials in proper places so as to prevent their
deterioration or contamination by foreign matter and to ensure their satisfactory quality
and fitness for the work. The storage place must also permit easy inspection, removal

598 RED BOOK  VOLUME I  ROADS  2012

 and storage of materials. All such materials even though stored in approved godowns
must be subjected .to acceptance test immediately prior to their use. The requirement of
storage yard specified in Clause 602.2.9 shall be applicable.
603.3. Proportioning of Materials for the Mix
603.3.1. The mix shall be proportioned with a maximum aggregate: cement ratio of 15:1.
After the approval of all the materials to be used in the concrete, the Contractor shall
submit the mix design based on weighed proportion 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 design shall be done based on the laboratory trials using approved
materials and methods. The water content shall be adjusted to the optimum as per
Clause 603.3.2. for facilitating compaction by rolling. The target mean strength for the
design mix as well as acceptance Specification of concrete shall be in accordance with
Clause 903.5.2. The mix design shall be based on the flexural strength of concrete.
603.3.2. Moisture content: The right amount of water for the rolled concrete in the main
work shall be decided for ensuring full compaction under rolling and shall be assessed
at the time of rolling the trial length. Too much water will cause the concrete to be
picked up on the wheels of the roller and too little will lead to inadequate compaction, a
low in-situ strength and an open textured surface. The optimum water content shall be
determined in accordance with Clause 603.7. and demonstrated by rolling during trial
length construction; and the optimum moisture content and degree of compaction shall
be got approved by the Engineer. While laying, in the main work, the rolled concrete
shall have moisture content between the optimum and optimum + 2 per cent, keeping
in view the effectiveness of compaction achieved and to compensate for evaporation
losses.
603.3.3. Cement content: The minimum cement content in the rolled concrete shall not
be less than 150 kg/cu.m. of concrete. If this minimum cement content is not sufficient
to produce concrete of the specified strength, it shall be increased as necessary without
additional compensation under the Contract.
603.3.4. Concrete strength: The flexural strength as specified shall be the governing
criteria for approval of the mix. While designing the mix in the laboratory, correlation
between flexural and compressive strengths ‘ of concrete shall be established on the
basis of tests on samples for use at a later date to verify the in situ flexural strength of
rolled concrete through testing of cores.
At least a batch of two beam and cube specimens, one each for 3 day and 7 day
strength testing shall be cast for every 100 cum or part thereof of concrete placed during
construction. On each day’s work not less than four beams and four cubes shall be
mane;
A ratio between the 3 and 7 day strengths shall be established for the mix to be used.
This will help in assessing the fall in strength, if any in advance so that corrective action
can be taken for the future work.
603.4. Subgrade
The subgrade shall conform to the grades and cross sections shown on the drawings and
shall be uniformly compacted to the design strength in accordance with these Specifications
and the Specification stipulated in the Contract. The rolled concrete base shall not be laid
on a subgrade softened by rain after its final preparation; any surface trenches, soft spots
etc., must be properly back-filled and compacted to avoid any weak or soft Spot. As far as
possible, the construction traffic shall be avoided on the prepared subgrade. A day before
placing of the sub-base, the subgrade surface shall be given a fine spray of water and

RED BOOK  VOLUME I  ROADS  2012 599

rolled with one or two passes of a smooth wheeled roller after a lapse of 2-3 hours in order
to stabilise the loose surface. If the Engineer feels it necessary, another fine spray of water
may be applied just before placing the base course.
603.5. Construction
Clause 601.5 shall apply.
603.6. Trial Mix
Using the specified cement content and proportioned aggregates, the Contractor shall
make trial mixes at water contents ranging from 5 per cent to 7 per cent by weight of dry
materials at 0.5 per cent intervals using an aggregate/cement ratio of not greater than
15.0. Optimum moisture and density shall be established by preparing cubes with varying
moisture contents. The compaction of mould shall be done in three layers as explained in
Clause 903.5.2.1. The optimum moisture content determined normally gives an indication
about the moisture content which after minor adjustment may provide satisfactory mix
which could be rolled.
After determining the moisture content from the above trial mix, a set of six beams and
cubes shall be prepared for testing them on 3rd and 7th day. If the flexural strength achieved
is lower than the desired strength, the above trial shall be repeated after increasing the
cement content and adjusting the mix appropriately.
During the construction of trial length as per Clause 603.7 minor modifications may have to
be carried out to the moisture content of the mix. But such modified mix shall have to satisfy
the flexural strength requirement. Flexural strength to be achieved shall be the governing
criteria for the design of mix.
603.7. Trial Length
Clause 601.7 shall apply.
603.8. Traffic No heavy commercial vehicles like trucks and buses shall be permitted on
the rolled concrete base after its construction. Light vehicles may be, however, allowed
after 7 days of its construction with prior approval of the Engineer.
603.9. Tolerances for Surface Regularity, Level, Thickness and Strength
The tolerances for surface regularity, level, thickness and strength shall conform to the
requirements given in Clause 903.5. Control of quality of materials and works shall be
exercised by the Engineer in accordance with Section 900.
603.10. Measurements for Payment
The unit of measurement for concrete and rolled concrete pavement shall be the cubic
metre of concrete placed, based on the net plan areas for the specified thickness shown on
the drawings as directed by the Engineer.
603.11. Rate
The Contract unit rate payable for rolled cement concrete for base course 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.

600 RED BOOK  VOLUME I  ROADS  2012

 900
QUALITY CONTROL
FOR ROAD WORKS

RED BOOK  VOLUME I  ROADS  2012 601

602 RED BOOK  VOLUME I  ROADS  2012
901. GENERAL
901.1. All materials to be used, all methods adopted and all works performed shall be
strictly in accordance with the requirements of these Specifications. The Contractor shall
set up a field laboratory at locations approved by the Engineer and equip the same with
adequate equipment and personnel in order to carry out all required tests and Quality
Control work as per Specifications and/or as directed by the Engineer. The internal layout
of the laboratory shall be as per Clause 121 and/or as directed by the Engineer. The list
of equipment and the facilities to be provided shall be got approved from the Engineer in
advance.
901.2. The Contractor’s laboratory should be manned by a qualified Materials Engineer/
Civil Engineer assisted by experienced technicians, and the set-up should be got approved
by the Engineer.
901.3. The Contractor shall carry out quality control tests on the materials and work to the
frequency stipulated in subsequent paragraphs. In the absence of clear indications about
method and or frequency of tests for any item, the instructions of the Engineer shall be
followed.
901.4. For satisfying himself about the quality of the materials and work, quality control
tests will also be conducted by the Engineer (by himself, by his Quality Control Units or by
any other agencies deemed fit by him), generally to the frequency set forth hereinunder.
Additional tests may also be conducted where, in the opinion of the Engineer, need for such
test exists.
901.5. The Contractor shall provide necessary co—operation and assistance in obtaining
the samples for tests and carrying out the field tests as required by the Engineer from
time to time. This may include provision of labour, attendants, assistance in packing and
despatching and any other assistance considered necessary in connection with the tests.
901.6. For the work of embankment, subgrade and pavement, construction of subsequent
layer of same or other material over the finished layer shall be done after obtaining
permission from the Engineer. Similar permission from the Engineer shall be obtained in
respect of all other items of works prior to proceeding with the next stage of construction.
901.7. The Contractor shall carry out modifications in the procedure of work, if found
necessary, as directed by the Engineer during inspection. Works falling short of quality
shall be rectified/redone by the Contractor at his own cost, and defective work shall also be
removed from the site of works by the Contractor at his own cost.
901.8. The cost of laboratory building including services, essential supplies like water,
electricity, sanitary services and their maintenance and cost of all equipment, tools,
materials, labour and incidentals to perform tests and other operations of quality control
according to the Specification requirements shall be deemed to be incidental to the work
and no extra payment shall be made for the same. If, however, there is a separate item in
the Bill of Quantities for setting up of a laboratory and installing testing equipment, such
work shall be paid for separately.
901.9. For testing of samples of soils/soil mixes, granular materials, and mixes, bituminous
materials and mixes, aggregates, cores etc., samples in the required quantity and form
shall be supplied to the Engineer by the Contractor at his own cost.
901.10. For cement, bitumen, mild steel, and similar other materials where essential tests
are to be carried out at the manufacturer’s plants or at laboratories other than the site
laboratory, the cost of samples, sampling, testing and furnishing of test certificates shall be
home by the Contractor. He shall also furnish the test certificates to the Engineer.

RED BOOK  VOLUME I  ROADS  2012 603

901.11. For testing of cement concrete at site dining construction, arrangements for supply
of samples, sampling, testing and supply of test results shall be made by the Contractor
as per the frequency and number of tests specified in the Handbook of Quality Control
for Construction of Roads and Runways (IRC : SP: 11) and relevant IS Codes or relevant
clauses of these Specifications, the cost of which shall be borne by the Contractor.
901.12. The method of sampling and testing of materials shall-be as required by the
"Handbook of Quality Control for Construction of Roads and Runways"(IRC: SP:11),
and these MOST Specifications. Where they are contradicting, the provision in these
Specifications shall be followed. Where they are silent, sound engineering practices shall
be adopted. The sampling and testing procedure to be used shall be as approved by the
Engineer and his decision shall be final and binding on the Contractor.
901.13. The materials for embankment construction shall be got approved from the Engineer.
The responsibility for arranging and obtaining the land for borrowing or exploitation in any
other way shall rest with the Contractor who shall ensure smooth and uninterrupted supply
of materials in the required quantity during the construction period.
Similarly, the supply of aggregates for construction of road pavement shall be from quarries
approved by the Engineer. Responsibility for arranging uninterrupted supply of materials
from the source shall be that of the Contractor.
901.14. Defective Materials
All materials which the Engineer/his representative have determined as not conforming to
the requirements of the Contract shall be rejected whether in place or not; they shall be
removed immediately from the site as directed. Materials, which have been subsequently
corrected, shall not be used in the work unless approval is accorded in writing by the
Engineer. Upon failure of the Contractor to comply with any order of the Engineer/his
representative, given under this Clause, the Engineer/his representative shall have authority
to cause the removal of rejected material and to deduct the removal cost thereof from any
payments due to the Contractor.
901.15. Imported Materials
At the time of submission of tenders, the Contractor shall furnish a list of materials/finished
products manufactured, produced or fabricated outside India which he proposes to use
in the work. The Contractor shall not be entitled to extension of time for acts or events
occurring outside India and it shall be the Contractor’s responsibility to make timely delivery
to the job site of all such materials obtained from outside India.
The materials imported from outside India shall conform to the relevant Specifications of the
Contract. In case where materials/finished products are not covered by the Specifications
in the Contract, the details of Specifications proposed to be followed and the testing
procedure as well as laboratories) establishments where tests are to be carried out shall be
specifically brought out and agreed to in the Contract.
The Contractor shall furnish to the Engineer a certificate of compliance of the tests carried
out. In addition, certified mill test reports clearly identified to the lot of materials shall be
furnished at the Contractor’s cost.
902. CONTROL OF ALIGNMENT, LEVEL AND SURFACE REGULARITY
902.1. General All works performed shall conform to the lines, grades, cross sections and
dimensions shown on the drawings or as directed by the Engineer, subject to the permitted
tolerances described herein-after.
902.2. Horizontal Alignment Horizontal alignments shall be reckoned with respect to the
centre line of the carriageway as shown on the drawings. The edges of the carriageway as
604 RED BOOK  VOLUME I  ROADS  2012
constructed shall be correct within a tolerance of x 10 mm therefrom. The corresponding
tolerance for edges of the roadway and lower layers of pavement shall be ±25 mm.
902.3. Surface Levels
The levels of the subgrade and different pavement courses as constructed, shall not vary
from those calculated with reference to the longitudinal and cross-profile of the road shown
on the drawings or as directed by the Engineer beyond the tolerances mentioned in Table
900-1.

TABLE 900-1. TOLERANCES IN SURFACE LEVELS

1. Subgrade + 20 mm
- 25 mm
2. Sub-base + I0 mm
(a) Flexible pavement - 20 mm
(b) Concrete pavement + 6 mm
[Dry lean concrete or Rolled concrete] - 10 mm
3. Base-course for flexible pavement
(a) Bituminous course + 6 mm
- 6mm
(b) Other than bituminous + I0 mm
(i) Machine laid - 10 mm
+ 15 mm
(ii) Manually laid -15 mm
4. Wearing course for flexible pavement
(a) Machine laid + 6 mm
- 6mm
(b) Manually laid + 10 mm
- 10 mm
5. Cement concrete pavement + 5 mm
- 6 mm *
* This may not exceed 8 mm at 0 - 30 cm from the edges.
Provided, however, that the negative tolerance for wearing course shall not be permitted
in conjunction with the positive tolerance for base course, if the thickness of the former
is thereby reduced by more than 6 mm for flexible pavements and 5 mm for concrete
pavements.
For checking compliance with the above requirement for subgrade, sub- base and base
courses, measurements of the surface levels shall be taken on a grid of points placed at
6.25 m longitudinally and 3.5 m transversely. For any 10 consecutive measurements taken
longitudinally or transversely not more than one measurement shall be permitted to exceed
the tolerance as above, this one measurement being not in excess of 5 mm above the
permitted tolerance.
For checking the compliance with the above requirement for bituminous wearing courses
and concrete pavements, measurements of the surface levels shall be taken on a grid of
points spaced at 6.25 m along the length and at 0.5 in from the edges and at the centre of

RED BOOK  VOLUME I  ROADS  2012 605

the pavement. In any length of pavement, compliance shall be deemed to be met for the
final road surface, only if the tolerance given above is satisfied for any point on the surface.
902.4. Surface Regularity of Pavement Courses The longitudinal profile shall be checked
with a 3 metre long straight _ edge/moving straight—edge as desired by the Engineer at the
middle of each traffic lane along a line parallel to the centre line of the road. The maximum
permitted number of surface irregularities shall be as per Table 900-2.

TABLE 900-2. MAXIMUM PERMITTED NUMBER

OF SURFACE IRREGULARITIES
Surfaces of carriageways Surfaces of laybys, service
and paved shoulders areas and all bituminous base
courses
Irregularity 4 mm 7 mm 4 mm 7 mm
Length(m) 300 75 300 75 300 75 300 75
National Highways/
Expressway 20 9 2 1 40 18 4 2
Roads of lower
category° 40 18 4 2 60 27 6 3
*Category U of each section of road as described in the Contract. The maximum allowable
difference between the road surface and underside of a 3m straight-edge when placed
parallel with, or at right angles to the centre line of the road at points decided by the
Engineer shall be:
for pavement surface (bituminous and cement concrete) 3 mm
for bituminous base courses 6 mm
for granular sub—base/ base courses 8 mm
for sub-bases under concrete pavements 10 mm
902.5. Rectification
Where the surface regularity of subgrade and the various pavement courses fall outside the
specified tolerances, the Contractor shall be liable to rectify these in the manner described
below and to the satisfaction of the Engineer.
(i) Subgrade: Where the surface is high, it shall be trimmed and suitably compacted.
Where the same is low, the deficiency shall be corrected by scarifying the lower layer
and adding fresh material and recompacting to the required density. The degree of
compaction and the type of material to be used shall conform to the requirements of
Clause 305.
(ii) Granular Sub-base: Same as at (i) above, except that the degree of compaction and
the type of material to be used shall conform to the requirements of Clause 401.
(iii) Lime/Cement Stabilized Soil Sub-base: For lime/cement treated materials where
the surface is high, the same shall be suitably trimmed while taking care that the
material below is not disturbed due to this operation. However, where the surface
is low, the same shall be corrected as described herein below. For cement treated
material, when the time elapsed between detection of irregularity and the time of
mixing of the material is less than 2 hours, the surface shall be scarified to a depth of
50 mm supplemented with freshly mixed materials as necessary and recompacted
to the relevant specification. When this time is more than 2 hours, the full depth
of the layer shall be removed from the pavement and replaced with fresh material

606 RED BOOK  VOLUME I  ROADS  2012

 to Specification. This shall also apply to lime treated material except that the time
criterion shall be 3 hours instead of 2 hours.
(iv) Water Bound Macadam/wet Mix Macadam Sub-base/Base: Where the surface
is high or low, the top 75 mm shall be scarified, reshaped with added material
as necessary and recompacted to Clause 404. This shall also apply to wet mix
macadam to Clause 406.
(v) Bituminous Constructions: For bituminous construction other than wearing course,
where the surface is low, the deficiency shall be corrected by addling fresh material
over a suitable tack coat if needed and recompacting to specifications. Where the
surface is high, the full depth of the layer shall be removed and replaced with fresh
material and compacted to specifications. For wearing course, where the surface
is high or low, the full depth of the layer shall be removed and replaced with fresh
material and compacted to specifications. In all cases where the removal and
replacement of a bituminous layer is involved, the area treated shall not be less than
5 m in length and not less than 3.5 m in width.
(vi) Dry Lean Concrete Sub-base/Rolled Cement Concrete: The defective length of
the course shall be removed to full depth and replaced with material conforming
to Clauses 601 or 603, as applicable. The area treated shall be at least 3 m long,
not less than 1 lane wide and extend to the full depth. Before relaying the course,
the disturbed subgrade or layer below shall be corrected by levelling, watering and
compacting.
(vii) Cement concrete pavement: The defective areas having surface irregularity exceeding
3 mm but not greater than 6 mm may be rectified by bump cutting or scrabbling or
grinding using approved equipment. When required by the Engineer, areas which
have been reduced in level by the above operation(s) shall be retextured 342
in an approved manner either by cutting grooves (5 mm deep) or roughening the surface
by hacking the surface. If high areas in excess 6 mm or low areas in excess of 3 mm
occur, exceeding the permitted numbers and if the Contractor cannot rectify, the slab shall
be demolished and reconstructed at the Contractor’s expense and in no case the area
removed shall be less than the full width of the lane in which the irregularity occurs and full
length of the slab.
If deemed necessary by the Engineer, any section of the slab which deviates from the
specified levels and tolerances shall be demolished and reconstructed at the Contractor’s
expense.
903. QUALITY CONTROL TESTS DURING CONSTRUCTION
903.1. General
The materials supplied and the works carried out by the Contractor shall conform to the
specifications prescribed in the preceding Clauses.
For ensuring the requisite quality of construction, the materials and works shall be subjected
to quality control tests, as described hereinafter. The testing frequencies set forth are the
desirable minimum and the Engineer shall have the full authority to carry out additional tests
as frequently as he may deem necessary, to satisfy himself that the materials and works
comply with the appropriate specifications. However, the number of tests recommended
in Tables 900-3 and 900-4 may be reduced at the discretion of the Engineer if it is felt that
consistency in the quality of materials can still be maintained with the reduced number of
tests.
Test procedures for the various quality control tests are indicated in the respective Sections

RED BOOK  VOLUME I  ROADS  2012 607

of these Specifications or for certain tests within this Section. Where no specific testing
procedure is mentioned, the tests shall be carried out as per the prevalent accepted
engineering practice to the directions of the Engineer.
903.2. Tests on Earthwork for Embankment, Subgrade Construction and Cut Formation
903.2.1. Borrow material : Grid the borrow area at 25 m c/c (or closer, if the variability
is high) to full depth of proposed working. These pits should be logged and plotted for
proper identification of suitable sources of material. The following tests on representative
samples shall be carried out:
(a) Sand Content [IS: 2720 (Part-4)]: 2 tests per 3000 cubic metres of soil.
(b) Plasticity Test [IS:2720 (Part-5)]: Each type to be tested, 2 tests per 3000 cub. metres
of soil.
(c) Density Test [IS:2720 (Part8)]:Each soil type to be tested, 2 tests per 3000 cubic
metres of soil.
(d) Deleterious Content Test [IS:2720 (Part-27)]: As and when required by the Engineer.
e) Moisture Content Test [IS: 2720 (Part-2)]: One test for every 250 cubic metres of soil.
(f) CBR Test on materials to be incorporated in the subgrade on soaked/unsoaked
samples [IS: 2720 (Part•16)]: One CBR test for every 3000 cu. m. atleast or closer
as and when required by the Engineer.
903.2.2. Compaction Control : Control shall be exercised on each layer by taking at
least one measurement of density for each 1000 square metres of compacted area, or
closer as required to yield the minimum number of test results for evaluating a day’s work
on statistical basis. The determination of density shall be in accordance with IS: 2720
(Part-28). Test locations shall be chosen only through random sampling techniques.
Control shall not be based on the result of any one lest but on the mean value of a set
of 5-10 density determinations. The number of tests in one set of measurements shall
be 6 (if non-destructive tests are carried out, the number of tests shall be doubled) as
long as it is felt that sufficient control over borrow material and the method of compaction
is being exercised. If considerable variations are observed between individual density
results, the minimum number of tests in one set of measurement shall be increased to
10. The acceptance criteria shall be subject to the condition that the mean density is not
less than the specified density plus:
_ 1.65 times the standard deviation.
1.65
(No. of samples)0.5
However, for earthwork in shoulders (earthen) and in the subgrade, at least one density
measurement shall be taken for every 500 square metres for the compacted area
provided further that the number of tests in each set of measurements shall be atleast
10. In other respects, the control shall be similar to that described earlier.
903.2.3. Cut formation: Tests for the density requirements of cut formation shall be
carried out in accordance with Clause 903.2.2.
903.3. Tests on Sub-bases and Bases (excluding bitumen bound bases) The tests
and their frequencies for the different types of bases and sub-bases shall be as given
in Table 900-3. The evaluation of density results and acceptance criteria for compaction
control shall be on lines similar to those set out in Clause 903.2.2.
903.3.1. Acceptance criteria: The acceptance criteria for tests on the strength of
cement/lime stabilised soil and distribution of stabiliser content shall be subject to the
condition that the mean value is not less than the specified value plus : _

608 RED BOOK  VOLUME I  ROADS  2012

 _ 1.65 times the standard deviation.
1.65
(No. of samples)0.5

TABLE 900-3. CONTROL TESTS AND THEIR MINIMUM FREQUENCY FOR

SUB-BASES AND BASES (EXCLUDING BITUMEN BOUND BASES)
SI.
No. Type of Construction Test Frequency (min.)
1 Granular (i) Gradation One lest per 200 m3
(ii) Atterberg limits One test per 200 m3
(iii) Moisture content prior One test per 250 m2
to compaction
(iv) Density of compacted One test per 500 m2
layer
(v) Deleterious constituents As required
(vi) C.B.R. As required
2. Lime/Cement (i) Quality of lime/ cement One test for each
Stabilised consignment subject to a
minimum of one test per
Soil Sub-base 5 tonnes
(ii) Lime/Cement content Regularly, through
procedural checks
(iii) Degree of pulverisation Periodically as
considered necessary
(iv) CBR or Unconfined As required
Compressive Strength
test on a set of 3
specimens

(v) Moisture content prior One lest per 250 sq. m.

to compaction
(vi) Density of compacted One test per 500 m2
layer
(vii) Deleterious As required
constituents
3. Water Bound (i) Aggregate Impact One test per 200 m3 of
Macadam Value aggregate
(ii) Grading One lest per 100 m3
(iii) Flakiness Index and One test per 200 m3 of
Elongation Index aggregate-

(iv) Atterberg limits of One test per 25 m3 of

binding material binding
material

RED BOOK  VOLUME I  ROADS  2012 609

SI.
No. Type of Construction Test Frequency (min.)
(v) Atterberg limits of One test per
portion of aggregate 100 cubic metre
passing 425 micron of aggregate
sieve

4. Wet Mix Macadam i) Aggregate Impact Value One test per 200 m3 of
aggregate
(ii) Grading One test per 100 m3
of aggregate
(iii) Flakiness and One test per 200 m3
Elongation Index of aggregate
(iv) Atterberg limits of One lest per 100 m3
portion of aggregate of aggregate
passing 425 micron
sieve

(v) Density of compacted One test per 500 m2

layer.
903.4. Tests on Bituminous Construction
903.4.1. Tests and frequency: The tests and their minimum frequencies for the different
types of bituminous works shall be as given in Table 900-4. The Engineer may direct
additional testing as required.
903.4.2. Acceptance criteria : The acceptance criteria for tests on density and Marshall
stability shall be subject to the condition that the mean value is not less than the specified
value plus :
_ 1.65 times the standard deviation.
1.65
(No. of samples)0.5

TABLE 900-4. CONTROL TESTS FOR BITUMINOUS WORKS, AND THEIR

MINIMUM FREQUENCY
SI.
No. Type of Construction Test Frequency (min.)
1. Prime Coat/Track Coat/ (i) Quality of binder Number of samples
Fog Spray per lot and tests
as per IS: 73, IS:
217 and IS:8887 as
applicable.
(ii) Binder At regular close
temperature for intervals
application -
(iii) Rate of spread of One test per 500m;
Binder and not less than two
tests per day.

610 RED BOOK  VOLUME I  ROADS  2012

SI.
No. Type of Construction Test Frequency (min.)
2. Seal Coat/Surface Dressing (i) Quality of Binder Same as mentioned
under Serial No. 1
(ii) Aggregate Impact One test per 50m] of
Value/Los Angeles aggregate
Abrasion Value
(iii) Flakiness Index -do-
and Elongation
Index
(iv) Stripping value Initially one set of
of aggregates 3 representative
(Immersion Tray specimens for each
Test) source of supply.
Subsequently
when warranted
by changes in the
quality of aggregates
(v) Water absorption -do-
of aggregates
(vi) Water sensitivity Initially one set of
of mix 3 representative
specimens for each
source of supply.
Subsequently
when warranted by
changes in the -
quality of aggregates
(if required)
(vii) Grading of One test per 25 m’ of
aggregates aggregate
(viii) Soundness Initially, one
(Magnesium and determination by
Sodium Sulphate) each method for
each source of
supply, then as
warranted by change
in the quality of the
aggregates.
(ix) Polished stone As required
value
(x) Temperature At regular close
of binder at intervals
application
(xi) Rate of spread of One test per 500 m3
materials of work, and, not less
than two tests per
day

RED BOOK  VOLUME I  ROADS  2012 611

SI.
No. Type of Construction Test Frequency (min.)
(xii) Percentage of When gravel is used,
fractured faces one test per 50mi of
aggregate
3. Open-graded Premix Surfacing / (i) Quality of binder Same as mentioned
Close-graded Premix Surfacing under Serial No. 1

(ii) Aggregate Impact Same as mentioned

Value/Los Angeles under Serial No.2
Abrasion Value
(iii) Flakiness Index -do-
and Elongation
Index
(iv) Stripping value Same as mentioned
under Serial No.2
(v) Water absorption Same as mentioned
of aggregates under Serial No.2
(vi) Water sensitivity Same as mentioned
of mix under Serial No. 2
(vii) Grading of Same as mentioned
aggregates under Serial No.2
(viii) Soundness Same as mentioned
(Magnesium and under Serial No.2
Sodium Sulphate)
(ix) Polished stone As required
value
(x) Temperature At regular close
of binder at intervals
application
(xi) Binder content One test per 500rni
and not less than two
tests per day
(xii) Rate of spread of Regular control
mixed material through checks of
layer thickness
(xiii) Percentage of Same as mentioned
fractured faces under Serial No.2
4. Bituminous Macadam (i) Quality of binder Same as mentioned
under Serial No. 1
(ii) Aggregate Impact Same as mentioned
Value/Los Angeles under Serial No.2
Abrasion Value
(iii) Flakiness Index Same as mentioned
and Elongation under Serial No.2
Index

612 RED BOOK  VOLUME I  ROADS  2012

SI.
No. Type of Construction Test Frequency (min.)
(iv) Stripping Value Same as mentioned
under Serial No.2
(v) Water sensitivity -do-
of mix
(vi) Grading of Two tests per day
aggregates per plant both
on the individual
constituents and
mixed aggregates
from the dryer
(vii) Water absorption Same as in Serial
of aggregates No. 2
(viii) Soundness Same as mentioned
(Magnesium and under Serial No,2
Sodium Sulphate)
(ix) Percentage of Same as mentioned
fractured faces under Serial No.2
(x) Binder content Periodic, subject to
and aggregate minimum of two tests
grading per day per plant
(xi) Control of At regular close
temperature intervals
of binder and
aggregate for
mixing and of the
mix at the time of
laying and rolling
(xii) Rate of spread Regular control
of mixed material through
checks of layer
thickness
(xiii) Density of One test per
compacted layer 2501112 of area
5. Bituminous Penetration (i) Quality of binder Same as mentioned
Macadam/Built-up Spray-Grout under Serial No. 1

(ii) Aggregate Impact One test per 200 ml

Value/Los Angeles of aggregate
Abrasion Value
(iii) Flakiness Index -do-
and Elongation
Index -
(iv) Stripping value Same as mentioned
under Serial No. 2

RED BOOK  VOLUME I  ROADS  2012 613

SI.
No. Type of Construction Test Frequency (min.)
(v) Water absorption Same as Serial No. 2
of aggregates
(vi) Water sensitivity
of mix Same as
Serial No. 2
(vii) Aggregate One test per 100 ml
grading of aggregate
(viii) Soundness Same as mentioned
(Magnesium and under Serial No.2
Sodium Sulphate)
(ix) Percentage of Same as mentioned
fractured faces under Serial No.2
(x) Temperature At regular close
of binder at intervals
application
(xi) Rate of spread of Same as mentioned
binder under Serial No.2
6. Dense Bituminous Macadam/ (i) Quality of binder Same as mentioned
Semi Dense Bituminous under Serial No. 1
Concrete Bituminous Concrete
(ii) Aggregate Impact Same as mentioned
Value/Los Angeles under Serial No.2
Abrasion Value
(iii) Flakiness Index -do-
and Elongation
Index
(iv) Stripping Value Same as mentioned
under Serial No.2
(v) Soundness Same as mentioned
(Magnesium and under Serial No,2
Sodium Sulphate)
(vi) Water absorption As in Serial No. 2
of aggregates
(vii) Sand equivalent As required
test
(viii) Plasticity Index As required
(ix) Polished stone As required, for Semi
value Dense
Bituminous
Concrete/
Bituminous Concrete
(x) Percentage of Same as mentioned
fractured faces under Serial No.2

614 RED BOOK  VOLUME I  ROADS  2012

SI.
No. Type of Construction Test Frequency (min.)
(xi) Mix grading One set of tests
on individual
constituents and
mixed aggregate
from the dryer for
each 400 tonnes
of mix subject to a
minimum of two tests
per plant per day
(xii) Stability of Mix For each 400 tonnes
of`mix produced,
a set of 3 Marshall
specimens to be
prepared and tested
for stability, flow
value, density and
void content subject
to a minimum of two
sets being tested per
plant per day
(xiii) Water sensitivity Same as mentioned
of mix (Retained under Serial No,2
Tensile Strength)
(xiv) Swell test on the As required for the
mix Bituminous Concrete
(xv) Control of At regular close
temperature of intervals
binder in boiler,
aggregate in the
dryer and mix at
the time of laying
and rolling
(xvi) Control of binder One test for each
content and 400 tonnes of mix
grading of the mix subject to a minimum
of two tests per day
per plant
(xvii) Rate of spread Regular control,
of mixed material through checks on
the weight of mixed
material and layer
thickness
(xviii) Density of One test per 250 m2
compacted layer area
7. Mastic Asphalt (i) Quality of binder Same as mentioned
under Serial No. 1

RED BOOK  VOLUME I  ROADS  2012 615

SI.
No. Type of Construction Test Frequency (min.)
(ii) Aggregate Impact Same as mentioned
Value/Los Angeles under Serial No.2
Abrasion Value
(iii) Flakiness Index -do-
and Elongation
index
(iv) Stripping Value -do-
(v) Water sensitivity -do- K
of mix
(vi) Grading of Two tests per day
aggregates both per plant
on the individual
constituents and
mixed aggregates
from the dryer
(vii) Water absorption Same as in Serial
of aggregates No, 2
(viii) Soundness Same as mentioned
(Magnesium and under Serial No.2
Sodium Sulphate)
(ix) Percentage of Same as mentioned
fractured faces under Serial No.2
(x) Binder content Periodic, subject to
and aggregate minimum of two tests
grading per day per plant
(xi) Control of At regular close
temperature intervals
of binder and
aggregate for
mixing and of the
mix at the time of
laying and rolling
(xii) Rate of spread of Regular control
mixed material through checks of
layer thickness
(xiii) Hardness One test for each
number 400 tonnes of mix
subject to a minimum
of two tests per day
8. Slurry seal (i) Quality of binder Same as mentioned
under Serial No. 1.

616 RED BOOK  VOLUME I  ROADS  2012

SI.
No. Type of Construction Test Frequency (min.)
(ii) Film stripping test
Initially one set oi`3
. representative
specimens for each
source of supply,
then as warranted
by changes in the
quality of aggregates
9. Recycled material (i) Binder content and Minimum of one test
aggregate grading per 25 mi of recycled
material
(ii) Recovered binder Minimum of one test
penetration per 50m3 of recycled
material
(iii) Mix stability For each 400 tenses
(Remix/ Repave) of mix recycled, a
set of 3 Marshall
specimens to be
prepared and tested
for stability, flow,
density and void
content, subject to a
minimum of two
sets of tests per day
10. Cold Mix (i) Quality of binder Same as mentioned
under Serial No. 1
(ii) Aggregate Impact Same as mentioned
Value/Los Angeles under Serial No.2
Abrasion Value
(iii) Flakiness. Index -do-
and Elongation
Index
(iv) Stripping Value -do-
(v) Water sensitivity -do-
of mix
(vi) Grading of Two tests per day
aggregates per plant both
on the individual
constituents and
mixed aggregates
from the dryer
(vii) Percentage Two tests per day
minimum coating per plant
(viii) Water absorption Same as in Serial
of aggregates No. 2

RED BOOK  VOLUME I  ROADS  2012 617

SI.
No. Type of Construction Test Frequency (min.)
(ix) Soundness Same as mentioned
(Magnesium and under Serial No.2
Sodium Sulphate)
(x) Percentage of When gravel is used,
fractured faces one test per 50mi of
aggregate
(xi) Binder content Periodic, subject
and aggregate to minimum of` two
grading tests per day per
plant
(xii) Mix stability For each 400 tonnes
of mix produced,
one set of 3 Marshall
specimens to be
prepared and tested
for stability, flow,
density and void
content, subject to a
minimum of two sets
of tests per plant per
day
11. Sand Asphalt Base Course (i) Quality of binder Same as mentioned
under Serial No. 1
(ii) Los Angeles Same as mentioned
Abrasion Value under Serial No.2
(iii) Sand equivalent As required
test
(iv) Plasticity Index As required
(v) Mix grading One set of tests
on individual
constituents and
mixed aggregate
from the dryer for
each 400 tonnes
of mix subject to a
minimum of two tests
per plant per day

618 RED BOOK  VOLUME I  ROADS  2012

SI.
No. Type of Construction Test Frequency (min.)
(vi) Stability of Mix For each 400 tonnes
of mix produced,
a set of3 Marshall
specimens to be
prepared and tested
for stability, flow
value, density and
void content subject
to a minimum of two
sets being tested per
plant per day
vii) Control of At regular close
temperature of intervals
binder in boiler,
aggregate in the
dryer and mix at
the time of laying
and rolling
(viii) Control of binder One test for each
content and 400 tonnes of mix
grading of the mix subject to a minimum
of two tests per day
per plant
(ix) Rate of spread of Regular control and
mixed material through checks on
the weight of mixed
material and layer
thickness
(x) Density of` One test per 250 mi
compacted layer area
12. Modified Binder (i) Softening Point Initially on
submission
thereafter daily if site
blended, weekly if
pre-blended
(ii) Penetration at -do-
25"C and 4°C
(iii) Elastic Recovery -do-
(iv) Ductility -do-
(v) Flash Point -do-
(vi) Fraass Breaking Initially on
submission
(vii) Viscosity at -do-
150°C

RED BOOK  VOLUME I  ROADS  2012 619

SI.
No. Type of Construction Test Frequency (min.)
(viii) Thin film oven -do-
test, penetration,
softening point,
elastic recovery of
residue, loss on
heating
13. Geotextiles (i) The requirements
of Clause 704.3,1
of the Ministry’s
Specification for
Road and Bridge
Works (third
revision) shall
apply
903.5. Quality Control Tests for Concrete Road Construction
903.5.1. Dry lean concrete sub-base : •
903.5.1.1. Sampling and testing of cubes: Samples of dry lean concrete for making
cubes shall be taken from the uncompacted material from different locations immediately
before compaction at the rate of 3 samples for each 1000 sq. m. or part thereof laid each
day. The sampling of mix shall be done from the paving site.
Test cubes of 150 mm size shall be made immediately from each mix •sample.
Cubes shall be made in accordance with the methods described in IS:516 except that
the cubes shall be compacted by means of a vibratory hammer with the moulds
placed on a level and rigid base. The vibrating hammer shall be electric or pneumatic
type fitted with a square or rectangular foot having an area of between 7500 to
14000 sq.mm. The compaction shall be uniformly applied for 60 at ‘ 5 seconds with
‘a downward force of between 300 N and 400 N on to each of the three layers of the
lean concrete material placed into the mould. The surface of each compacted layer
shall be scarified before the next layer is added to give key for the next layer. The
final layer shall be • finished flush with the top of the cube mould.
The dry lean concrete cubes shall be cured in accordance with IS: 516.
903.5.1.2.In-situ density: The dry density of the laid material shall be determined from
three density holes at locations equally spaced along a diagonal that bisects each 2000
square metre or part thereof laid each day and shall comply with the requirements as
per Clause 601 .5 .5 .1. This rate of testing may be increased at the discretion of the
Engineer in case of doubt or to determine the extent of defective area in the event of
non-compliance. Density holes at random may be made to check the density at edges.
903.5.1.3. Thickness: The average thickness of the subbase layer as computed by the
level data of sub-base and subgrade or lower sub-base shall be as per the thickness
specified in the contract drawings. The thickness at any single location shall not be 10
mm less than the specified thickness. Such areas shall be corrected as stated in Clause
601 .5.5 .5. Areas which cannot be repaired should be replaced over full width. The
extent of deficient area should be decided based on cores.
903.5.1.4. Frequency of quality control tests: The frequency of quality control tests for
levels, alignment and materials shall be as in Table 900-6. .

620 RED BOOK  VOLUME I  ROADS  2012

903.5.2. Pavement concrete
903.5.2.1. Sampling and testing of beam and cube specimens: At least two beam
and two cube specimens, one each for? day and 28 day strength testing shall be cast
for every 150 cu.m (or part thereof) of concrete placed during construction. On each
day’s work, not less than three pairs of beams and cubes shall be made for each type of
mix from the concrete delivered to the paving plant. Each pair shall be from a different
delivery of concrete and tested at a place to be designated by the Engineer in accordance
with the testing procedure as outlined in Clause 602.3.3. Groups of four consecutive
results from single specimens tested at 28 days shall be used for assessing the strength
for compliance with the strength requirements. The specimens shall be transported in
an approved manner to prevent sudden impact causing fractures or damage to the
specimen. The flexural strength test results shall prevail over compressive strength tests
for compliance.
A quality control chart indicating the strength values of individual specimens shall be
maintained for continuous quality assurance. Where the requirements are not met
with, or where the quality of the concrete or its compaction is suspect, the actual
strength of the concrete in the slab shall be ascertained by carrying out tests on
cores cut from the hardened concrete at such locations. The cores shall be cut at the
rate of 2 cores for every 150 cu. m. of concrete. The results of crushing strength tests
on these cores shall not be less than 0.8 times the corresponding crushing strength
of cubes, where the height to diameter ratio of the core is two. Where height to
diameter ratio is varied, then the necessary corrections shall be made in calculating
the crushing strength of cubes in the following manner.
The crushing strengths of cylinders with height to diameter ratios between 1 and 2 may
be corrected to correspond to a standard cylinder of height to diameter ratio of 2 by
multiplying with the correction factor obtained from the following equation:
f = 0.11 n+0.78
where f = correction factor and
n = height to diameter ratio
The corrected ICSI results shall be analysed for conformity with the specification
requirements for cube samples. Where the core tests are satisfactory, they shall have
precedence for assessing concrete quality over the results of moulded specimens.
The diameter of cores shall not be less than 150 mm. If, however, the tests on
cores also confirm that the concrete is not satisfying the strength requirements, then
the concrete corresponding to the area from which the cores were cut should be
replaced, i.e., atleast over an area extending between two transverse joints where
the defects could be isolated or over larger areas, if necessary, as assessed by
additional cores and their test results. The equivalent flexural strength at 28 days
shall be estimated in accordance with Clause 602.3.3.2.
In order to ensure that the specified minimum strength at 28 days is attained in 99 per
cent of all test beams, the mix shall be proportioned to give an average strength
at 28 days exceeding the specified strength by 2.33 times the standard deviation
calculated first from the flexural strengths of test beams made from the trial mix and
subsequently from the accumulating result of flexural strengths of job control test
beams.
The standard deviation shall be re-calculated from the test results obtained after
any change in the source or quality of materials and the mix shall be adjusted as
necessary to comply with the requirements.

RED BOOK  VOLUME I  ROADS  2012 621

 An individual 28 day test strength below the specified strength shall not be evidence
for condemnation of the concrete concerned if the average 28 day strength of this
beam plus the preceding 5 and succeeding 4 beams exceeds the specified strength
by 2.33 times the standard deviation and provided that there is no other evidence
that the concrete mix concerned is substandard.
Beams shall be made each day in pairs at intervals, each pair being from a different batch
of concrete. At the start of the work, and until such time as the Engineer may order
a reduction in the number of beams required, at least six pairs of beams and cubes
shall be made each day, one of each pair for testing at 28 days for determination of
the minimum permissible flexural strength and the other for testing at an early age
for the Engineer to assess the quality of the mix. When the first thirty number of 28-
day results are available, and for so long as the Engineer is satisfied with the quality
of the mix, he may reduce the number of beams and cubes required.
During the course of construction, when the source of any material is to be changed, or
if there is any variation in the quality of the materials furnished, additional tests and
necessary adjustments in the mix shall be made as required to obtain the specified
strength.
The flexural strengths obtained on beams tested before 28 days shall be used in
conjunction with a correlation between them and the 28 day flexural strengths to
detect any deterioration in the quality of the concrete being produced. Any such
deterioration shall be remedied without awaiting the 28 day strengths but-the earlier
strengths shall not constitute sole evidence of non-compliance of the concrete from
which they were taken.
Concrete shall not comply with the Specification when more than one test beam in a
batch has 28 day strength less than the specified strength and the average 28 day
flexural strength of the batch of beams is less than the specified strength plus 2.33
times the standard deviation of the batch.
Should the concrete fail to pass the Specification for strength as described above, the
Contractor may, all at his own expense, elect to cut cores from the suspect concrete
as the Engineer shall direct. From the relation between cube strength and flexural
strength, the core strength shall _ be converted to flexural strength.
The equivalent flexural strength at 28 days shall be the estimated in-situ strength
multiplied by 100 and divided by the age—strength relation obtained from Table
900-5. .
Any concrete that fails to meet the strength specification shall be removed and replaced
at Contractor’s expense.

TABLE 900-5. AGE - STRENGTH RELATION OF CONCRETE

(RELATED TO 100 PER CENT AT 28 DAYS)
DAYS 0 2 4 6 8
0 - 41.0 60.0 71.0 77.5
10 81.5 85.0 87.5 90.0 92.0
20 94.0 96.0 97.5 98.5 100.0
30 101.0 102.0 103.5 104.5 105.5
40 106.5 107.0 108.0 109.5 110.0
50 110.5 111.0 112.0 112.5 113.0

622 RED BOOK  VOLUME I  ROADS  2012

 DAYS 0 2 4 6 8
60 11.4.0 114.5 115.0 115.5 116.0
70 116.5 117.0 117.5 118.0 118.5
80 119.0 119.5 119.5 120.0 120.5
90 121.0 121.5 122.0 122.0 122.5
100 123.5 123.5 123.5 124.0 124.5
110 125.0 125.0 125.5 125.5 126.0
120 126.0 126.5 127.0 127.0 127.5
130 127.5 128.0 128.5 128.5 129.0
140 129.0 129.5 129.5 130.0 130.0
150 130.5 130.5 131.0 131.0 131.5
160 131.5 131.5 132.0 132.0 132.5
170 132.5 132.5 133.0 133.0 133.5
180 133.5 134.0 134.0 134.5 134.5
190 135.0 135.0 135.0 135.5 135.5
200 135.5 135.5 136.0 136.0 136.5
210 136.5 136.5 137.0 137.0 137.0
220 137.0 137.5 137.5 137.5 138.0
230 138.0 138.5 138.5 138.5 138.5
240 139.0 139.0 139.0 139.5 139.5
250 139.5 140.0 140.0 140.0 140.0
260 140.5 140.5 140.5 140.5 141.0
270 141.0 141.0 141.5 141.5 141.5
280 142.0 142.0 142.0 142.0 142.0
290 142.5 142.5 142.5 142.5 142.5
300 143.0 143.0 143.0 143.0 143.5
310 143.5 143.5 144.0 -144.0 144.0
320 144.0 144.5 144.5 144.5 144.5
330 144.5 145.0 145.0 145.0 145.0
340 145.0 145.5 145.5 145.5 145.5
350 146.0 146.0 146.0 146.0 146.0
360 146.0 146.0 146.5 146.5 146.5
903.5.2.2. In-situ density: The density 0f the compacted concrete shall be such that
the total air voids are not more than 3 per cent. The air voids shall be derived from the
difference between the theoretical maximum dry density of the concrete calculated from
the specific gravities of the constituents of the concrete mix and the average value of
three direct density measurements made on cores at least 150 mm diameter. Three
cores shall be taken from trial lengths and in first two km length of the pavement, while
the slab is being constructed during normal working. The proportions of the mix and the
vibratory effort imparted i.e. the frequency and magnitude of vibration shall be adjusted
to achieve the maximum density.
All cores taken for density measurement in the trial section shall also be checked for
RED BOOK  VOLUME I  ROADS  2012 623
 thickness. The same cores shall be made use of for determining in-situ strength.
In case of doubt, additional cores may be ordered by the Engineer and taken at
locations decided by him to check the density of concrete slab or the position of
dowel/tie bars without any compensation being paid for the same.
In calculating the density, allowance shall be made for any steel in cores.
Cores removed from the main carriageway shall be reinstated with compacted concrete
with mix proportions of 1 part of portland cement : 2 parts of fine aggregate : 2 parts
of 10 mm nominal size single sized coarse aggregate by weight. Before filling the
fine mix, the sides shall be hacked and cleaned with water. Thereafter cement-sand
slurry shall be applied to the sides just prior to filling the concrete mix.
903.5.2.3. Thickness : Thickness shall be controlled by taking levels as indicated in
Clause 902.3. Thickness of the slab at any point checked as mentioned above shall
be within a tolerance of -5 mm to + 25 mm of the specified thickness as per Drawing.
Thickness deficiency more than 5 mm may be accepted and paid for at a reduced rate
given in Clause 602.15.2. In no case, however, thickness deficiency shall be more than
25 mm.
903.5.2.4. Summary of control tests : Table 900-6 gives a summary of f1'eqI.lef1Cy of
lLeSl.II1g of pavement quality concrete.

TABLE 900-6. FREQUENCY OF QUALITY CONTROL TESTS

FOR PAVING QUALITY CONCRETE
1. Levels, alignment and texture
(i) Level tolerance Clause 902.3
(ii) Width of pavement and position of Clause 902.2
paving edges
(iii) Pavement thickness Clauses 902.3 and 903.5.2.3
(iv) Alignment of joints, widths, depths of To be checked @ one Joint per
dowel grooves 400 m length or a day's work
whichever is more.
(v) Surface regularity both transversely and Once a day or one day's work,
longitudinally without disturbing the curing
operation.
(vi) Alignment of dowel bars and their To be checked in trial length
accuracy/tie bars as per Clause 602.10.5.2 and once on
every 2 km.
(vii) Texture depth Clause 602.9.8
2. Quality of Materials and Concrete
Control tests for materials and concrete shall be as under:
1. Cement Physical and IS: 269 Once for each source of
chemical tests IS : 455 supply and occasionally
when called for in
IS : 1489 case of long/improper
IS : 8112 storage. Besides, the
IS : 12269 Contractor also will
submit daily ICSI data on
cement released by the
Manufacturer.
2. Coarse and (i) Gradation IS: 2386 One test for every day’s
624 RED BOOK  VOLUME I  ROADS  2012
 Fine (Pt. 1) work of each fraction of
aggregates coarse aggregate and
{me
aggregate, initially; may
be
relaxed later at the
discretion of the
Engineer.
(ii) Deleterious IS: 2386 -do- _
constituents (Pt. 2)
(iii) Water absorption IS:2386 Regularly as required
(Pt. 3) subject to a minimum of
one
test a day for coarse
aggregate & two tests a
day for
fine aggregate. This data
shall be used for
correcting
the water demand of the
mix
on daily basis.
3. Coarse (i) Los Angeles IS :2386 Once for each source of
Abrasion
Aggregate value or Aggregate (Pt. 4) supply and subsequently
Impact test on monthly basis.
(ii) Soundness IS:2386 Before approving the
(Pt.5) aggregates and every
month
subsequently
(iii) Alkali aggregate IS:2386 -do-
reactivity (Pt. 7)
4. Water Chemical Tests IS:456 Once for approval of
source
of supply, subsequently
only
in case of doubt.
5. Concrete (i) Strength of 1S:516 2 cubes and 2 beams per
concrete l50 m3 or part thereof
(one
for7day and other for 28
day
strength) or minimum 6
cubes and 6 beams per
day’s
work whichever is more.

RED BOOK  VOLUME I  ROADS  2012 625

 (ii) Core strength on IS:516 As per the requirement
of
hardened concrete the Engineer; only in
case of
doubt.
(iii) Workability of S:1199 One test per each
fresh I dumper
concrete-Slump Test load at both
Batching plant
site and paving site
initially
when work starts.
Subsequently sampling
may be
done from alternate
dumper.
(iv) Thickness From the level data
determination of concrete pavement
surface and
sub-base at grid points
of 5f
6.25 in X 3.5 m
(v) Thickness 3 cores per trial
measurement
for trial length .
length.
(vi) Verification of String line or steel forms
level of
string line in the case shall be checked for
of level at
slip form paving and an interval of 5.0 m or
steel
forms in the case of 6.25 m. The level
fixed tolerance
form paving allowed shall be 1 2mm.
These shall be got
approved
1-2 hours before the
commencement of the
concreting activity.
903.5.3. Rolled Concrete Base
903.5.3. 1. Sampling and testing of beams and cubes : C
 lause 903.5.2.1 shall apply .
903.5.3.2. Thickness: T
 hickness shall be controlled by taking levels as indicated in
Clause 903.5.1.3.
903.5.3.3. In-situ density : T
 he dry density of the laid material shall be determined from
three density holes at locations equally spaced along a diagonal that bisects each 2000

626 RED BOOK  VOLUME I  ROADS  2012

 square metre or part thereof laid each day and shall comply with the requirements as per
Clause 601.5.5.1. This rate of testing may be increased at the discretion of the Engineer in
case of doubt or to determine the extent of defective area in the event of non compliance.
Density holes at random may be made to check the density at edges.
903.5.3.4. Summary of control tests: Table 900-6 gives the summary of tests for levels,
alignment and materials.
903.5.4. Summary of rate of sampling and testing:
(i) Strength: 3 beams and 3 cubes for each 100 sq. m, or part thereof laid each day.
(ii) Density: 3 density holes for each 2000 sq.m. or part thereof laid each day.
(iii) Cores: Only when Engineer instructs. They shall not be cut on regular basis.
A relation between flexural strength and compressive strength may be developed by regression
analysis using the available data. This may be updated from time to time.

RED BOOK  VOLUME I  ROADS  2012 627

628 RED BOOK  VOLUME I  ROADS  2012
 ROAD FURNITURE
HIGHWAY KILOMETRE STONES
Script and Sequence of Inscription

Ordinary kilometre stones put up on N.H. /S.H.shall be inscribed either in Hindi or local
language and indicate the name and distance to the next important (i.e. intermediate) town or
the terminal / starting station as the case may be

Fifth kilometre stones on the other hand shall be inscribed only in Roman and show the name
and distance of the terminal starting as well as of the intermediate town.

The place names shall be inscribed in different scripts in the following sequence only one
script being used on any one kilometre stone.

For NH / SH / MDR / And roads leading to Tourist / Archaeological interest / Industrial Area.

Km. No. Script for place names Place to be shown

0 Roman Terminal / starting station and
next important town.
1 Deonagri Script Next important town.
2 Deonagri Script Terminal / Starting station
3 Deonagri Script Terminal / Starting station
4 Roman Terminal / starting station and
next important town.

For other District Road and village roads. The inscription may be in the Devnagri script.
Inscription in Roman script is not necessary unless the road leads to a place of tourist or
archeological interest or there are other good reasons.
In every case the numerals on km stones shall be inscribed in the internal form of indian
numerals. Local or Devnagri numerals shall not be used.

On each kilometre stone its number (zero at the starting station increasing progressively upto
the last kilometre stone at the terminal station) shall be inscribed on the side on the stone
facing the carriageway. In case of this stones made of R.C.C. or some other material. The
digits may be inscribed one below the other starting from the top. Thus 426 will be shown as.

4
2
6

RED BOOK  VOLUME I  ROADS  2012 629

 Letters and numerals on kilometre stones shall be of the following size.
Height of letters for place name 80 mm.
Height of numerals for kilometrage 130 mm.
Height of numerals for Route Numbers 100 mm.
The other edge clearances shall be as follows
Top50 mm
Bottom75 mm
Sides50 mm
Spacing between lines 50 mm.

The background colour of km/5th km stone shall be white with black letters and numerals for
names of stations and distances. The semi circular portion shall be.

Canary yellowFor NH

Brilliant GreenFor SH

WhiteFor MDR and other roads

Route numbers written on the semi-circular portion shall be in black colour on canary yellow
and white backgrounds and in white colour on brilliant green background.

Placement
Normally km. stones shall be located on left handed side of the road as one proceeds form
which the kilometre stone starts on divided roads having a central median, kilometre stones
should be provided at the left on both sides of the road i.e. independently for each direction
of travel.

Kilometre stones shallbe fixed at right angles to the centre line of the carriageway. On
embankments, these shall be located on the edge of the roadway beyond the shoulders,
if necessary on specially erected platforms. In cut sections these shall be fixed clear of the
shoulders as well as the side drains.

630 RED BOOK  VOLUME I  ROADS  2012

 200 METRE STONE
200 metre stones are to be located on the same side of the road as the one having the
kilometre stones. They should be planted securely just beyond the edge of the formation with
their side bearing the inscription facing and parallel to the centre line of the road.

The inscription carried by the stones shall be numerals 2, 4, 6 and 8 marked in ascending
order in the direction of increasing kilometreage away from the starting station. The numerals
shall be 80 mm high. The colour of the numerals shall be black on a white background for all
categories of roads.

Boundary stones
Boundary stones shall be fixed on either side of the road land opposite every 200 metre stone
and kilometre stone. In addition these shall be fixed at all angular points of the boundary.
Where the boundary is on a curve or the land is costly and likely to be encroached upon these
shall be planted closer as necessary in each case.

The letters R.B. indicating road boundary shall be inscribed on each stone and below it the
name of the Authority in which the road land vest i.e. P.W.D. / D.B. etc.

Boundary stones shall project 300 mm above ground with lower 600 mm going into the
foundation.

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638 RED BOOK  VOLUME I  ROADS  2012
 Maintenance of bituminous surfacing

The type of defects in bituminous surfacing are grouped under four categories :
a. Surface defects which include fatty surfaces, smooth surfaces, streaking and hungry / dry surfaces.
b. Cracks which cover hairline cracks, alligator cracks, longitudinal cracks, edge cracks, shrinkage cracks and
reflection cracks.
c. Deformation defects which comprise of slippage, rutting, corrugation, shoving, shallow depressions and
settlements.
d. Disintegration defects which consists of stripping, loss of aggregates, raveling, pot-holes and edge breaking.
The general causes and remedies for these defects are given as below.
a. Surface defects

NATURE OF DEFECT CAUSE REMEDY

Fatty surfaces Excess Bitumen, soft grade of Apply hot dry cover aggregates or
Bitumen, non-uniform spraying and sand and roll gently for removal of
loss of cover aggregates as in surface excess binder; burn it, if necessary or
dressing, heavy axle loads. relay area affected.
Smooth surfaces Polishing of aggregates by traffic, Resurface with premix carpet using
excess binder. hard aggregates or with slurry seal.

Streakings (alternate lean and rich Non-uniform application of binder, Apply new surface dressing with
lines of bitumen in surface dressing) low temperature of binder, manual proper care in spraying of bitumen.
in longitudinal / transverse direction. spraying, mechanical faults during
Hungry / dry surfaces spraying.
Use of insufficient binder, use Apply slurry seal, or for emergency
of absorptive aggregates, loss of repair apply fog seal.
aggregates from surface.
b. Cracks
Hair-line cracks (fine cracks at close
intervals) Insufficient Bitumen, excess filler, Apply fog-seal with Bitumen,
compacting when too hot, over cutback Bitumen or Bitumen
Alligator cracks (interconnected compaction. Emulsion.
cracks forming a series of blocks) Excessive movement of base or sub- Fill crack with Bitumen Emulsion
base layer, base saturation, excessive or cutback Bitumen and apply slurry
leads over weathered surfacing, seal or sand-Bitumen mix, install
inadequate pavement thickness drainage.

RED BOOK  VOLUME I  ROADS  2012 639

CRACKS CAUSE REMEDY
Longitudinal crack (at the joint Contraction or movement of Fill and seal cracks with cutback
between pavement and shoulder or at sub-grade beneath shoulder, lane Bitumen or Bitumen Emulsion,
the joint between two paving lanes) joint crack due to weak joint or apply sand-Bitumen mix, if cracks
differential frost heave along centre- are wider than 3mm.
Edge cracks (parallel to outer edge line.
of pavement 0.3 to 0.5m inside) Rectify drainage system, provide
Lack of lateral support from hard and paved shoulders, fill cracks
shoulder, poor surface drainage, base and lay premix carpet with seal-coat.
saturation shrinkage, frost heave If edge of the pavement has settled,
inadequate pavement width. bring it upto the desired grade with
plant mix patching material.
Shrinkage cracks (transverse
direction or inter-connected cracks in Apply slurry seal, or sand-Bitumen
large blocks) Shrinkage of bituminous layer mix for filling such cracks.
caused by volume change of
bituminous mix with high content of
Reflection cracks (usually in over- hard Bitumen, lack of traffic.
lays over cement concrete or badly Fill cracks and seal suitably
cracked bituminous base) Due to joints and cracks in the depending on size of crack. Apply a
pavement layer underneath. crack relief layer for prevention of
c. Deformation defects such cracks.
Slippage (between top layer and
layer below accompanied by Remove affected area, apply tack
crescent-shaped. Cracks in direction Lack of bond between layers due coat and patch with premix.
of the thrust of wheels). to omission or inadequacy of tack
coat or prime coat, dust or moisture
in between layers, heavy thrust by
Rutting (longitudinal depressions or traffic.
grooves in wheel tracks) Fill ruts with premix carpet and
Heavy channelized traffic, low compact. Relay affected portion with
stability of mix due to inadequate bituminous mix of good stability if
compaction, weak pavement, high necessary.
intensity of load stress as from
Corrugations (regular undulations bullock carts, plastic deformation.
causing shallow wavy surface) Scarify and relay the surface, cut
Lack of stability in mix, excess high spots and fill low spots. Use
binder / fines, soft Bitumen, poor heater-planer to rectify defects.
aggregate interlock, oscillations set
up by vehicles, frequent braking of
vehicles, faulty laying of mix.

640 RED BOOK  VOLUME I  ROADS  2012

DEFORMATION DEFECT CAUSE REMEDY

Shoving (plastic movement within Lack of stability of mix, excess Remove affected portion and relay
surface resulting in localised bulging binder/fines, softer grade of with-premix carpet and compact.
of surface, occurring commonly Bitumen, lack of bond between
at bus stops, inter-sections, sharp layers, heavy traffic with frequent
curves, steep gradients) braking, sharp negotiation of curves
and gradients.

Shallow depressions (localised and Heavier traffic, settlement of lower Fill with premix carpet and compact
limited in size) dipping about 25mm pavement layers, poor construction to desired grade and profile.
or more below desired profile. method.
Excavate defective fill, reconstruct
Settlement (large localised Poor compaction of fill, poor under controlled conditions to
deformation which may or may not drainage in lower layer, inadequate required thickness, provide adequate
be generally followed by extensive pavement thickness, frost heave drainage, strengthen the pavement if
cracks) or swelling effect of moisture on required.
expansive soil.

d. Disintegration defects

Stripping (loss of adhesion between Softer grade of Bitumen, siliceous Use anti-stripping agent in suitable
binder and aggregates type of aggregates, dust and moisture doses in case of siliceous aggregates,
in presence of water) on aggregates, rain, soon after laying use of proper grade of Bitumen for
of surface. coating, provide adequate surface
drainage.

Loss of aggregates (as in surface- Non uniform spraying of binder, Apply liquid seal, fog-seal or slurry-
dressing) delayed spreading of aggregates, seal. Relay, if necessary with liquid
traffic soon after laying, insuffi-cient seal with proper quality control.
binder, ageing of binder.

Ravalling (progressive disintegration Insufficient binder, ageing of If ravalling is not extensive, provide
of premix carpet by loss of binder, overheated bituminous surface dressing, sand-Bitumen
aggregates) mix, improper coating, inferior mix or slurry-seal. For extensive
aggregates, lack of compaction while ravelling, apply renewal coat of
laying, construction during, cold premix carpet.
weather.

Pot-holes (bowl shaped holes Fill pot holes with premix carpet,
of varying sizes on surface and Poor surface drainage, localized after cutting these to regular size
extending to base course resulting defects in bituminous mix, and applying tack coat. Fill deep pot
from localized disintegration) insufficient binder, insufficient layer holes with bituminous penetr-ation
thickness. macadam or storable mix.

Edge breaking (frayed edges) Relay shoulders with good materials

Infiltration of water, softening of and compact, provide adequate
foundation, worn-out shoulders with drainage.
insufficient side support, inadequate
thickness at edge.

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644 RED BOOK  VOLUME I  ROADS  2012
 Carriageway marking

A broken line shall be used for centre line on two and three lane road, and for traffic lane lines.
These lines are for guidance of the drivers and may be crossed at their discretion.

Longitudinal solid lines are used as guiding or regulating lines and are not meant to be crossed
by the driver.

Line to be provided on 2 or more lanes.

a) Road with restricted visibility White centre line to be solid

b) 4 lane undivided road White centre line to be solid

c) edges of road Yellow line to be solid 20-30 cm.h wide 15 cm

from edge in respect of 2 lane road

Yellow line to be solid 15 cm wide. 15 cm from

edge for multi lane road with central verge.

Carriageway width transition White centre line solid 10 cm. thick with
converging lines solid 10 cm, thick for a length
of 20 times the offset distance yellow edge line
30 cm. wide.

Stop Stop line indicates where vehicles should stop

when directed by a traffic officer or a traffic
controlled device on Urban and sub urban roads.

2.0 to 3.0 m. from 20 cm wide located from

pedestrian crossing on rural roads. Solid 30.00
cm. wide.

1.25 to 9.0 m. from nearest carriageway of the

intersecting road.

Pedestrian crossing Width of pedestrian crossing < 2.0 m. > 4.0 m.

White 10 cm wide lines 20 cm c/c.

RED BOOK  VOLUME I  ROADS  2012 645

 RS - SIGN & CAUTION BOARDS

NOTES FOR SIGN & CAUTIONARY BOARD

Boards shall be in accordance with the I.R.C. - 67 1977 and M.O.S.T. Circular No. RW/NH -
33023/31/88 D. O. III dated 2/5/94 and 11/5/94.

Lettering and numerals for informatory sign boards definition plates shall be in accordance with
I.R.C. - 30-1968 “Standard letters and numerals of different heights for use of highway signs” and
that of Marathi (Devnagari) letters shall be in proportion of English letters of different heights.
The numerals shall be in English, even for Marathi (Devnagari) informatory signs.

Stove Enameling shall as per IS - 151 - 1985.

Colours shall be in accordance with I.S. - 5 - 1961 (Since revised IS - 5, 1994).

To check whether the boards is painted with stove enamel, put few drops of Industrial chloroform
on the surface where painting is done and watch for minimum 5 minutes. If the board is painted
with stove enamel surface will not show any effect or otherwise the painted surface will be dam-
aged / peeled off from the metal plate.

Finished sign plates shall be coated with non peelable crystal clear protective transparent coating
on front side to avoid damage retaining 100% reflection for full retro reflective and partial retro
reflective traffic road signs. (Not obligatory)

The sheet and angle iron post should be in one piece and without joints. The sign plate shall be
securely bolted to the post. The remaining portion of the bolt after tightening the nut shall be
hammered to form reverting. The sign plate should never be welded to the post.

The angle iron post shall be fixed in concrete block of size 60cm x 60 cm x 75 cm in C.C. 1:4:8.
The soffit shall be at a height as per the standard requirement above the road top level.

646 RED BOOK  VOLUME I  ROADS  2012

Following are the general guidelines for adopting the type of boards on road of particular standard.

S. No. Description Type of Board Standard of Road

1. RS-A Retro reflective sheeting of Cautionary / Warning signs 2 Lanes and

high intensity grade on aluminium and mandatory regulatory 4 Lanes N.H. section
sheet. Signs.

2. RS-B Retro reflective sheeting of a) Informatory signs N. H. Section

Engineering grade on aluminium b) All signs M.S.H. & S.H. way
sheet. Sections only

3. RS-C Retro reflective sheeting of All signs Less important S.H.

Engineering grade on M.S. sheet way, and M.D.R.
For partial reflective signs.

4. RS-D Complete stove enameled All signs Rural / Village road

board on M.S. sheet

5. RS-E (a) Angle iron / post with All signs N. H. way /

epoxy painting. S.H. way

RS-E (b) Angle iron / post with All signs Less important,
Synthetic enamel painting. S.H. way, MDR and
V.R.

The work should be entrusted to registered contractor in appropriate class in P.W. Department
of Maharashtra State and the Contractor should have following registrations :

a) He should be having his own Small Scale Industry in Maharashtra State having
permanent registration certificate for the item of Traffic Road Sign Boards.

b) He should be an authorised contractor of manufacturer / sole distributor of Retro

Reflective sheeting and should produce a guarantee certificate of Retro Reflective
sheeting on demand to the Department as per M.O.S.T. specifications.

RED BOOK  VOLUME I  ROADS  2012 647

 The Details of sizes & colours of different categories are tabulated below

Discription Size Area Colours for Reference

648
MxM in Sqm
RS-A RS-B RS-C RS-D
Category Category Category Category
1 2 3 4 5 6 7 8
Advanced Direction
Sign / Destination Sign/
Reassurance Sign/
Informatory Sign.

RED BOOK  VOLUME I  ROADS  2012

A -do- 1.20 x 0.75 0.90 Green Background & white message IRC-67-1977
B -do- 1.20 x 0.90 1.08 Green Background & white message IRC-67-1977
C -do- 1.20 x 1.20 1.44 Green Background & white message IRC-67-1977
D -do- 1.80 x 1.20 2.16 Green Background & white message IRC-67-1977
(E) Village name board 0.90 x 0.60 0.54 Green Background & white message IRC-67-1977
(F) Place Identification 0.75 x 0.60 0.45 Green Background & white message IRC-67-1977
Sign
(G) Caution Board 0.90 x 0.60 0.54 White Background & red message IRC-67-1977
Sign
(H) Cautionary plate for 0.30 x 0.90 0.27 White Background & red band IRC-67-1977
railway crossing sign
(I) Facility information 0.60 x 0.80 0.48 Blue White back Blue & white background Blue and White
Sign and White arrow & white arrow letters background &
ground / Black symbol symbol red reflective white arrow letters IRC-67-1977
letters symbol red reflective
(J) (I) Parking Sign 0.60 x 0.60 0.36 Blue back ground and white “P” IRC-67-1977
(ii) Defination Plate 0.60 x 0.30 0.18 White back ground White back ground & White back ground
& black arrow arrow Red Reflective & Black Arrow IRC-67-1977
(iii) Defination Plate 0.30 x 0.20 0.06 White back ground & White back ground & White background &
black symbol of vehicle Red Reflective arrows black symbol
of vehicle IRC-67-1977
 Discription Size Area Colours for Reference
MxM in Sqm
RS-A RS-B RS-C RS-D
Category Category Category Category
1 2 3 4 5 6 7 8
(K) Flood Gauge 0.13 x 2.00 0.26 White, Red & Black White, Red & Black
band with Graduation band with Graduation IRC-67-1977

(L) (i) N. H. route marker 0.60 x 0.45 0.27 Yellow background, Yellow background, border,
border, letters, numerals letters, numerals IRC-2-1968
Red Reflective Red Reflective

(ii) Direction Plate 0.30 x 0.25 0.075 Yellow background, Yellow background, border,
border, arrow arrow Red Reflective IRC-2-1968
Red Reflective

(M) (i) S.H. Route Marker 0.60 x 0.45 0.27 White & Green background, White & Green background,
Black Border, letters, Black Border, letters, IRC-31-1969
Numericals Non Reflective Numericals Non Reflective

(ii) Direction Plate 0.30 x 0.25 0.075 White Background, White Background,
Black Border and Black Border and IRC-31-1969
Arrow Non Reflective Arrow Red Reflective

(N) Stop Sign Octagonal 0.90 0.81 Red background, white border and letters “STOP” IRC-67-1977
in shape

RED BOOK  VOLUME I  ROADS  2012

(O) Defination Plate for 0.60 x 0.20 0.12 White Background, Black White Background, Black White Background,
SPEED-BREAKER letters, Non Reflective letters, Non Reflective Black letters IRC-99-1988

649
 Discription Size Area Colours for Reference

650
MxM in Sqm
RS-A RS-B RS-C RS-D
Category Category Category Category
1 2 3 4 5 6 7 8
(O) (i) Supplying Rodway 0.10 x 1.00 0.10
Front Side white &
indicator Type (A) black bands of 15cm
Size 0.10x1.00 meter & last band black of IRC-79-1981

RED BOOK  VOLUME I  ROADS  2012

10cm & back side
gray stove enamelled

(P) (ii)Supplying Roadway 0.10 x 1.00 0.10 Front side white & back bands
indicator Type (C) of 15cm & last band back of
Size 0.10x1.00 meter 10cm & back side gray stove
enamelled having 12cm x 8cm
white retro reflective band on IRC-79-1981
top black band

(Q) (i) Supplying Hazard 0.20 x 0.60 0.12 Whitebackground

& back side
Marker Type I sqm. grey stove enamelled red retro IRC-79-1981
Size 0.20 x 0.60 reflective 10cm dia. 3 circles
meter bonded to plate

(ii) Supplying Hazard 0.30 x 0.90 0.27 Black background & back side
marker sqm. grey stove enamelled yellow IRC-79-1981
Size 0.30 x 0.90 retro reflective strips of
meter 10cm wide
 Discription Size Area Colours for Reference
MxM in Sqm
RS-A RS-B RS-C RS-D
Category Category Category Category
1 2 3 4 5 6 7 8
R (i) Supplying object 0.30 meter 0.04 White background and back side grey
marker type Triangular sqm stove enamelled. Red retro reflective IRC-79-1981
(A) size 0.30 meter triangle in centre keeping white border
triangular in shape of 2.5cm stove enamelled all around

R (ii) Supplying object 0.30 meter 0.04 White background and back side grey
marker type Triangular sqm stove enamelled having 5cm dia. 6Nos.
(B) size 0.30 meter Red Retro Reflective circle in Triangle IRC-79-1981
triangular in shape keeping Red border of 2.5 cm stove
enamelled all around

R (iii) Supplying object 0.30 meter 0.04 White background and back side grey
marker type Triangular sqm stove enamelled having 7.5cm dia.
(C) size 0.30 meter 3Nos. Red Retro Reflective circle in IRC-79-1981
triangular in shape Triangle keeping Red border of 2.5 cm
stove enamelled all around

R (iv) Supplying object 0.50 x 0.20 0.10 White background and back side grey
marker type sqm stove enamelled having 7.5cm dia. IRC-79-1981
(D) size 0.30 meter 3Nos. Red Retro Reflective circle
rectangular in shape

RED BOOK  VOLUME I  ROADS  2012

651
 General note on ASTM type IX retro reflective sheeting

A very high intensity retro reflective sheeting having highest retro reflectivity characteristics as short
road distances as determined by the Ra value of table 3 at 1-degree observation angle. This sheeting
is typically unmetallized micro prismatic retro reflective element material. Typical applications of this
material are permanent highway signing, construction zone devices and delineators.

Note - 1 :- All retro reflective sheetings, but especially micro prismatic sheetings, may have unique
performance characteristic outside the range of the standard geometries presented in the tables that define
the types. Certain applications may require the use of a particular product within a particular type in order
to achieve a desired level of retro reflectively in a given situation. In this case, information concerning
additional performance characteristics must be obtained.

Table 3 type IX sheeting

Observation angle Entrance angle White Yellow Orange Green Red Blue

0.1 degree - 4 degree 660 550 260 66 130 30

0.1 degree + 30 degree 370 280 140 37 74 17
0.2 degree - 4 degree 380 285 145 37 76 17
0.2 degree + 30 degree 215 162 82 22 43 10
0.5 degree - 4 degree 240 180 90 24 48 11
0.5 degree + 30 degree 135 100 50 14 27 6
1.0 degree - 4 degree 80 60 30 8.0 16 3.6
1.1 degree + 30 degree 45 34 17 4.5 9.0 2.0
A) Minimum coefficient of retro reflection (R.A.) cd.1x -1 m -2

B) Values for 0.1-degree observation angle are supplementary requirements that shall apply only
when specified by the purchaser in the contract or order.

Performance requirements for type IX sheeting

Minimum coefficient of Retro Reflection Table-3 Outdoor weathering 3-6 months daytime luminance
factor as per Table - 9 other requirements when the colors orange, yellow or white are specified for
construction work zone application, the outdoor weathering will be 12 months

Day time colour :- The colour of the sheeting shall confirm to requirements of Table 13 and Table 9 when
tested in accordance with cl 7.4 (ASTM D4956) Daytime of night time colour shall have substantially
the same hue.

652 RED BOOK  VOLUME I  ROADS  2012

 Table No. 13

Colour Specification limits (daytime)

Colour 1. 2. 3. 4

X Y X Y X Y X Y

White 0.303 0.300 0.368 0.366 0.340 0.393 0.274 0.329

Yellow 0.498 0.412 0.557 0.442 0.479 0.520 0.488 0.472
Orange 0.558 0.352 0.636 0.364 0.510 0.429 0.586 0.404
Green # 0.026 0.399 0.166 0.364 0.286 0.446 0.207 0.771
Red 0.648 0.351 0.735 0.265 0.629 0.281 0.565 0.346
Blue # 0.140 0.035 0.244 0.210 0.190 0.265 0.065 0.216
Brown 0.430 0.340 0.610 0.390 0.550 0.460 0.430 0.390
 The four pairs of caromaticity co-ordinates determine the acceptable colour of terms of the CIE-1931

 The saturation limit of Green and Blue may extend to the border of the CIE caromaticity

Table No. 1

Daytime luminance factor (Y %)

Colour Minimum Maximum

White 40 ---
Yellow 24 45
Orange 12 30
Green 3 12
Red 3 15
Blue 1 10
Brown 1 6.0

Accelerated outdoor weathering requirements :-

This retro reflective sheeting shall be weather resistant and show no appreciable cracking, scaling,
pitting, blistering, edge lifting or curling or more than 1/32 in (in (0.8 mm) shrinkage or expansion when
tested in accordance with CI.7.6 ASTM-Density 4956. Conduct retro reflectivity measurements after outdoor
weathering at 0.2 degree observation and -4 degree and -30 degree entrance angles. The minimum coefficient
of retro reflection (RA) after weathering is specified in following table :-

RED BOOK  VOLUME I  ROADS  2012 653

 Outdoor weathering photometric Requirements for all climates.

Type Months Minimum coefficient of

retro reflective (RA)

ASTM IX 36 b 80% of Table 3

B when the colours Orange, Yellow or White are specified for construction work zone applications the
outdoor weather time will be 12 months.

Colour Fastness :- After the specified outdoor weathering the specimen shall conform to the requirements
of Table 13 and Table 9 when tested in accorded with CL7.4 & 7.7 of ASTM D 4956.

Shrinkage :- The retro reflective sheeting shall not shrink in any dimension more than 1/32 in
(0.8mm) in 10 min or more than 1/8 in (3.2mm) in 24h when tested in accordance
with clause 7.8 ASTM D 4956.

Flexibility :- The Sheeting shall be sufficiently flexible to show no cracking when tested in
accordance with CL. 7.9 ASTM D 4956.

Liner Removal :- The Liner, when provided shall be easily removed without soaking in water or other
solutions and shall not break

Adhesion :- When tested in accordance with Cl. 7.5 ASTM D 4956, the adhesive backing of the
retro reflective sheeting shall produce a bond that will support a 1¾ Lb. (0.79kg)
weight for adhesive classes 1, 2 and 3 or a 1 Lb. (0.45kg) weight for adhesive class 4
for 5 minutes without the bond peeling for a distance of more than 2 inches (51mm).

Impact Resistance :- Retro Reflective sheeting shall show no cracking or delamination outside of the
actual area of impact when subjected to the impact test in accordance with Cl. 7.11
ASTM D 4956.

Specular Gloss :- The retro reflective sheeting shall have a specular glass of not less than 40 when
tested as specified in Cl. 7.12 ASTM D 4956.

654 RED BOOK  VOLUME I  ROADS  2012

RED BOOK  VOLUME I  ROADS  2012 655
 EPOXY
95-1 GENERAL
95-1.01 DESCRIPTION
Section 95-1 includes general specifications for mixing and applying epoxy for highway
construction.

Furnish epoxy as 2 components and mix them together at the job site.

The 2 proportioned epoxy components define a kit when packaged together.

95-1.02 SAMPLING AND TESTING

Submit a certificate of compliance for epoxy.

95-1.03 PACKAGING, LABELING, AND STORING

Each component must be packaged in a container of a size that complies with the epoxy
manufacturer’s instructions for proportions.

Component containers must be sealed and not leak. Containers must not react with components.

The container for each component must be clearly labeled by the epoxy manufacturer with the
following information:

1. ASTM C 881/C 881M class and type

2. Component designation, A or B
3. Manufacturer’s name
4. Manufacture date
5. Batch number
6. Expiration date
7. Directions for use
8. Warnings or precautions required by State and federal laws and regulations

Store components at temperatures greater than 35 degrees F.

95-1.04 DIRECTION FOR USE

Mix and apply the epoxy under the manufacturer’s instructions.

Do not use a component if any of the following occur:

1. Evidence of crystallization or thickening

2. Settled pigments that cannot be readily dispersed with a paddle
3. Component is older than the manufacturer’s recommended expiration date

Thoroughly stir each component before mixing a kit. Do not mix partial kits. Do not add solvents.

Automatic mixing equipment must have positive displacement pumps and be capable of metering
a 2-component mix in the specified ratio ± 5 percent by volume of either component.

Mix the 2 components until no trace of black or white streaks is present in the mixed epoxy.

Clean surfaces to receive the epoxy of rust, paint, grease, asphalt, loose, and deleterious material.
Apply the epoxy and place materials to be bonded before the epoxy starts to thicken. Do not use
epoxy that has exceeded its working life.

95-2 TYPES OF EPOXIES

95-2.01 EPOXY BINDER
Epoxy binder must be low viscosity epoxy formulated primarily for use in:

1. Making HS epoxy concrete and epoxy mortar

2. Pressure grouting cracks in concrete

656 RED BOOK  VOLUME I  ROADS  2012

For load bearing applications, the epoxy must comply with ASTM C 881/C 881M, Type IV, Grade 1,
Class B or C.

For nonload bearing applications, the epoxy must comply with ASTM C 881/C 881M, Type I, Grade
1, Class B or C.

Use Class B whenever the surface temperature is from 40 to 60 degrees F. Use Class C whenever
the surface temperature is above 60 degrees F.

Thoroughly mix the components before adding aggregate if the epoxy is used as binder for HS
epoxy concrete or epoxy mortar. The mix proportions must be 1 part epoxy to 4 parts aggregate
by volume. Aggregate must be clean and have a moisture content of not more than 0.50 percent.
Prime surfaces with epoxy immediately before placing epoxy concrete or mortar.

95-2.02 RESERVED
95-2.03 EPOXY ADHESIVE FOR BONDING FRESHLY MIXED CONCRETE TO HARDENED
CONCRETE
Epoxy adhesive for bonding freshly mixed concrete to hardened concrete must comply with ASTM
C 881/C 881M, Type V, Grade 2, Class B or C.

Use Class B whenever the surface temperature is from 40 to 60 degrees F or if a faster cure is
required. Use Class C whenever the surface temperature is above 60 degrees F.

Coat the blast-cleaned concrete surface with epoxy using a brush or roller. Place freshly mixed
concrete while the epoxy is tacky. Apply a new coat of epoxy if the epoxy sets.

95-2.04 RAPID SET EPOXY ADHESIVE FOR PAVEMENT MARKERS

Rapid set epoxy adhesive for bonding pavement markers to concrete and HMA must comply with
ASTM C 881/C 881M, Type IV, Grade 3, Class B or C, except the gel time may be less than 30
minutes.

Use Class B whenever the surface temperature is from 40 to 60 degrees F. Use Class C whenever
the surface temperature is above 60 degrees F.

When tested, epoxy must comply with the requirements for the properties shown in the following
table:

Rapid Set Epoxy Adhesive For Pavement Markers

Property Requirement
Gel time, minutes, maximum, at 77 °F 30
Bond strength to concrete, minutes, maximum to reach not less
than 200 psi
at 77 ± 2 °F 35
at 50 ± 2 °F 45
Slant shear strength, minimum, psi
2 days at 77 ± 2 °F 1,000
14 days at 77 ± 2 °F, plus water soak 1,500
Tensile adhesion and cohesion, minimum, psi
Ceramic marker bottom 700
Ceramic marker bottom, including post cure 700
Retroreflective pavement marker bottom 500
Color of mixed epoxy gray
Glass transition temperaturea, Tg, minimum 86 °F
Before testing samples must be conditioned at 77 °F for 24 hours under ASTM
a

D 4065

RED BOOK  VOLUME I  ROADS  2012 657

95-2.05 STANDARD SET EPOXY ADHESIVE FOR PAVEMENT MARKERS
Standard set epoxy adhesive for bonding pavement markers to concrete and HMA must comply
with ASTM C 881/C 881M, Type IV, Grade 3, Class B or C.

Use Class B whenever the surface temperature is from 40 to 60 degrees F. Use Class C whenever
the surface temperature is above 60 degrees F.

When tested, epoxy must comply with the requirements for the properties shown in the following
table:

Standard Set Epoxy Adhesive For Pavement Markers

Property Requirement
Bond strength to concrete, time, maximum to reach not less
than 200 psi
at 77 ± 2 °F 3.5 hours
at 55 ± 2 °F 24 hours
Slant shear strength, minimum, psi
2 days at 77 ± 2 °F 1,000
14 days at 77 ± 2 °F, plus water soak 1,500
Tensile adhesion and cohesion, minimum, psi
Ceramic marker bottom 700
Ceramic marker bottom, including post cure 700
Reflective pavement marker bottom 500
Color of mixed components gray
Glass transition temperature , Tg, minimum
a
86 °F
Before testing samples must be conditioned at 77 °F for 24 hours under ASTM
a

D 4065

95-2.06–95-2.08 RESERVED
95-2.09 EPOXY SEALANT FOR INDUCTIVE LOOPS
The epoxy for sealing inductive loops and leads imbedded in HMA and concrete must comply with
ASTM C 881/C 881M, Type I, Grade 2.
When tested, epoxy sealant must comply with the values for the properties shown in the following
table:

Epoxy Sealant for Inductive Loops

Property Value
Tensile strength , minimum, psi
a
400
Elongation , minimum, %
a
90
Shore D hardnessa, minimum 45
a
Test on a 0.125-inch cast sheet, cured 18 hours at 77 °F plus 5
hours at 160 °F

658 RED BOOK  VOLUME I  ROADS  2012

95-2.10 RESERVED
95-2.11 EPOXY RESIN ADHESIVE FOR PRESSURE INJECTION GROUTING OF CONCRETE
PAVEMENT
Epoxy resin adhesive for injection grouting of concrete pavement must comply with the values for
the properties when tested as shown in the following table:

Epoxy Resin Adhesive for Injection Grouting of Concrete Pavement

Property California Test 434 Value

Brookfield viscosity, no. 3 spindle at 20 rpm, Part 4, “Brookfield Viscosity” 0.9

poise, maximum, at 77 °F

Gel time, minutes Part 1, “Gel Time” 2–15

Slant shear strength on dry concrete, minimum, Part 5, “Slant Shear 3,000
psi, after 4 days of cure in air at 77 ± 2 °F Strength”a

Slant shear strength on wet concrete, minimum, Part 5, “Slant Shear 1,700
psi, after 4 days of cure in air at 77 ± 2 °F Strength”a

Tensile strength, minimum, psi Part 7, “Tensile Strength and 4,500

Elongation” except test after
4 days of cure at 77 ± 2 °F

Elongation, %, maximum Part 7, “Tensile Strength and 10

Elongation” except test after
4 days of cure at 77 ± 2 °F
a
For slant shear strength on concrete, procedures B-1 and B-5 do not apply. Testing on dry
concrete must comply with item 2 listed in the following. Testing on wet concrete must comply
with both of the following:
1. Soak blocks in water for 24 hours at 77 ± 2 °F. Remove and wipe off excess water.
2. Apply a coat of epoxy 0.010 inch thick to each diagonal surface. Place 4 pieces of
shim stock on 1 block to control final film thickness. Shim stock pieces must be 0.12 by
0.125 inch and 0.012 inch thick. Before pressing the coated surfaces together, leave the
blocks such that the coated surfaces are horizontal until the epoxy reacts slightly to prevent
excessive flow.

RED BOOK  VOLUME I  ROADS  2012 659