CONSTRUCTION METHODOLOGY

Construction of Six Lane Access Controlled Highway

( NH-152D) Starting From Junction With Rewari-Kanina (SH-

CLIENT -NATIONAL HIGHWAY AUTHORITY OF INDIA

Construction of Six Lane Access Controlled Highway ( NH-152D) Starting From Junction With Rewari-
Kanina (SH-24) Near Kanina To Narnaul (CH 200+000 To CH 227+020, Length 27.020 Km) On EPC Mode
Under Bharatmala Pariyojana in the State of Haryana –PKG-8.

EPC CONTRACTOR :M/s Gawar Construction. Ltd.

INDEPENDENT CONSULTANT : M/S FRISCHMANN PRABHU INDIA Pvt. Ltd.

CONSTRUCTION METHODOLOGY FOR HIGHWAY & STRUCTURE

Document No. : GCL/QAP/NH-334B/03

Name Department Signature Date

Prepared By In Charge QA/QC

Reviewed By Head QA/QC

Reviewed by In chargeStructure

Reviewed by GM Highway

Reviewed by Authorized Signatory

Approved By IE / Client

Current Revision Revision History

Revision Number
Date
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Construction of Six Lane Access Controlled Highway

( NH-152D) Starting From Junction With Rewari-Kanina (SH-

GENERALINTRODUCTION

National Highways Authority of India is a premier organization which has been taking up several
challenging highway / Expressway projects. NHAI has now entrusted the Construction of Six Lane Access
Controlled Highway ( NH-152D) Starting From Junction With Rewari-Kanina (SH-24) Near Kanina To
Narnaul (CH 200+000 To CH 227+020, Length 27.020 Km) On EPC Mode Under Bharatmala Pariyojana in the
State of Haryana –PKG-8. While speed is the criteria, quality cannot be ignored under any circumstances.
With this philosophy in view, the QA/QC wing has now prepared Construction Methodology (Highway &
Structure), to be followed for the design & execution of structure and highway of the project.
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Construction of Six Lane Access Controlled Highway

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METHODOLOGIES

Objective: To establish the construction procedure, equipment required for construction of

following activities.

Trial Stretch:

Prior to start of any road activity trial stretch will be prepared with the construction
methodology discussed below and Quality Control test will be done to arrive at a
methodology which produce the required quality of execution as per the technical
specifications. The execution will be carried out only after the trial stretch is approved.

WP -01: METHODOLOGY FOR SURVEY WORKS

(Acceptance Criteria: Ref. Section 109 of MoRT&H)

Equipment / Machinery Requirement:

1. Auto level
2. Total Station

Procedure:

Alignment Fixing:

The primary aim of the proposed topographic survey is to fulfill all the Design
requirements and to supply accurate and adequate spatial data in the form of maps,
drawings, or DTM for subsequent use in the project. To achieve desired accuracy, it
is essential to use proper precision instrumentation, proper observation of drills, rigid
procedures for coding, data collection, data entry etc. One of the fundamental
principles of survey is that, every survey method should be capable of
accommodating independent and built-in checks to ensure collection of quality data
in the field. It is designed as all our field procedures directed to achieve the above
objectives and our field survey engineers stringently follow the drills and technical
instructions.

Various activities involved in the proposed survey and the procedures to be

adopted in each of these activities are described below:

 Map study
 Reconnaissance survey
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Construction of Six Lane Access Controlled Highway

( NH-152D) Starting From Junction With Rewari-Kanina (SH-
 Establishment of Reference Stations / Benchmarks: Traversing
 Running a DT level line connecting reference pillars: levelling
 Generation of longitudinal and cross-sections of existing road
 Detail survey

1. Map Study:

This is the first activity of any survey. Proposed map study essentially
includes:

 Collection of topographical maps of Survey of India covering the entire stretch

of the road to the minimum scale possible i.e., the maximum size of the map,
available with Survey of India.

 Collection of satellite imageries / aerial photographs for the regions of interest

like major towns which may need bypasses.

 Detailed study of these maps in respect of road alignment, topographical

features, possible hindrances, major streams/ bridges etc.

2. Reconnaissance Survey:

The main objective of this survey is to examine the general character of the area. A
preliminary site visit will be made by all the concerned engineers so that the
alternatives for the proposed scheme can be discussed at the site itself. Based on
the map study all the locations of interest will be visited and topographical features
will be studied. A strip plan will be prepared based on the data collected in this
survey.

Various aspects that will be covered during reconnaissance survey are

indicated below:

 Study of general topographical features of the area

 Study of land use pattern along the stretch
 Junctions study: Survey required, proposals/improvements
 Compilation of all the maps, inventory and reconnaissance survey data
for subsequent planning, programming and coordination
 Photographs at all the important locations.
 Collection and identifying the GTS bench marks
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3. Establishment of Reference pillars:

The basic principle of any topographic survey is to “work from whole to part “.
Accordingly points/pillars will be established with different control levels so that a
network of control points is established all along the stretch and detailed survey is
referred to these points any time subsequently.

Various reference points/pillars that are established along the stretch include:

 GPS control points with high degree of accuracy.

 Total station benchmark reference points at every 250m interval as
secondary control points.
 Intermittent temporary reference points, wherever necessary, as tertiary
control points, in the form of nails driven into firm ground/on the carriage
way.

Reference pillars, which form benchmarks for the entire survey are established all
along the stretch. These pillars are of the size 15 x 15 x 45cm which are cast in RCC
of grade M15 with an MS rod erected at the centre of the top surface firmly
embedded into the concrete. These pre-cast pillars are erected in cement concrete
of grade M10 up to a depth of 30 cm into the ground. The balance 15cm which is
above the ground level is painted yellow.

GPS Stations:

These points are the primary control reference points, which form the basis for the
entire survey. These points are always established in pairs so that the line
connecting the pair of these GPS points becomes the base line for any survey to
start with. The location of these points is selected such that they will not get
disturbed and are visible from each other. The interval of these points would be
around 3Km along the existing road. The x and y coordinates of these points are
obtained using high precision GPS instrument. The Z coordinate of these points is
established with reference to GTS benchmarks using high precision Auto levels. An
arrow indicating the location of these reference points will be painted on the edge of
the road. The reference point number and the RL of these points are marked in red
paint on these pillars. A list of these points indicating their x, y and z coordinates and
the description of their location is prepared for future reference.

GPS pillars, established all along the stretch. These pillars are of the size 20 x 20 x
60cm which are cast in RCC of grade M15 with an MS rod erected at the centre of
the top surface firmly embedded into the concrete. These pre-cast pillars are erected
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Construction of Six Lane Access Controlled Highway

( NH-152D) Starting From Junction With Rewari-Kanina (SH-
in concrete CCM10 up to a depth of 45cm into the ground. The balance 15cm which
is above the ground level is painted yellow.

Total station benchmarks & Traversing:

These are secondary level benchmarks, which are established at every 250m
interval alternatively on either side of existing road such that every benchmark is
visible from its preceding and succeeding points. The coordinates of these
benchmarks are generated using Total station instrument by running an open
traverse between two pairs of GPS stations. Thus the traverse is started at a pair of
GPS points and is closed at the next GPS point connecting all the traverse points in
between. The coordinates of the traverse on the closing benchmark are compared
with the actual coordinates of the closing GPS point. And the error, if any, is
distributed among all the traverse points suitably. However if the error is beyond
tolerance limits the traverse is re-run.

4. Leveling:

The height control for the entire topographic survey will be established by connecting
all the benchmarks to the GTS benchmark of Survey of India. For this purpose high
precision Auto levels will be used. All the level lines will be closed back to check for
the error if any. Double tertiary leveling procedure will be adopted to ensure greater
accuracy. Field books/sheets entries and calculations are thoroughly checked and
cross checked before finalizing the reduced levels. The gross error noticed and its
distribution are clearly indicated in the field book. These finalized levels along with
their number are marked on the pillars with red paint.

5. Detail Survey:

This essentially includes collection of details for all features such as structures
(buildings, tanks, towers etc.), monuments, places of worship, existing road and
railway lines, streams /rivers, utilities, electric and telephone installations (both
overhead as well as underground) huts, trees (of girth greater than 0.3m), fencing, oil
and gas lines falling within the extent of survey. The detailed survey will be carried
out in a systematic way by covering all the details in the increased order of road
chainage. Due remarks will be noted in the field notes about the hidden points,
heights of OH lines etc. so as to facilitate drawings generation.

The width of the survey corridor will be such that it covers sufficient area beyond the
centerline of the proposed divided carriageway. Normally the survey extends to a
minimum of 30m on either side of the centerline of proposed carriageway or land
boundary whichever is more. The width of the survey corridor will be widened
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-
appropriately where developments and/ or encroachments have taken place and
also where the existing alignment needs to be improved.

All the features are picked up and recorded by Total station in a coded format. These
codes will be in four alphanumeric characters. First two characters describe the
feature and the last two numbers mention the string number. A list of codes is
enclosed in the Annexure for reference. The purpose of coding is to facilitate
generation of features while survey data is downloaded and plan is generated.

6. Longitudinal and Cross sections of existing road:

In order to generate the longitudinal section of the existing road, x, y and z

coordinates of the following points are picked up using Total station with reference to
the benchmarks established along the road

 at the start and end of each curve.

 at the centre point of each culvert.
 at the start, end and middle point of each bridge.
 at the centre point of intersection/side road junctions.

Cross sections are generated by taking x, y, z coordinates of various points across

the road using Total station at every 10m interval covering a width of 30m on either
side of centre line of existing carriage way or
ROW whichever is more..

Points that will be covered in each of the cross section include centre point of
carriageway (CC01), carriageway edges (CL01, CR01), shoulder edges (SL01,
SR01), toes of embankment (EB03, EB04), side drains (to define drain dimension),
additional points on ground up to ROW as necessary to depict ground profile.
Additional points need to be covered in the following cases:

 Additional points (2 points on each lane) on the carriage way to estimate

profile correcting course where ever required.
 At the location of sharp curves.
 At cross road locations where a major junction is anticipated.
 Cross sections of cross roads will be taken at 10 m interval for a width
of about 30 m from the project road centerline. The width of the side
road that would be covered is 15 m on either side of its centre line upto
a length of 150 m.
 On either sides of curves where the alignment is likely to be improved.
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-

WP-02: METHODOLOGY FOR CLEARING GRUBBING AND DISMANTLING

STRUCTURES DISMANTLING STRUCTURES
(Acceptance Criteria: Ref. Section 200 of MoRT&H)

Scope:

This work shall consists of cutting, removing and disposing of all materials such as
trees, bushes, shrubs, roots, grass, weeds, top organic soil not exceeding150mm
Dismantling of structures acquired within ROW in brick work, stone masonry, plain/
reinforced concrete, timber structures etc. and sorting out dismantled materials,
disposal of unserviceable materials and utilizing the serviceable materials.

Equipment / Machinery Requirement:

1. Dozer
2. Excavator
3. Tippers

Procedure for clearing and grubbing:

1. Before starting the Clearing and grubbing activity, information to the IC is

given through Daily work programme.
2. Top-soil and deleterious material will be dozed and removed up-to
150mmthickness. All the dozed top soil will be removed from toe line and
stacked/displayed away from the area of work.
3. All the trees, shrubs and roots will be removed from the stretch with the help
of manpower / machineries.
4. Backfilling of the pits will be carried out if required with sand, saturated fully
with water.

Procedure for dismantling structures:

1. The structure shall be carefully dismantled and the resulting materials so

removed shall not cause any damage to the serviceable materials and the structures
nearby.
2. The connecting edges shall be cut, chipped and trimmed to the required lines
and grades without weakening or damaging any part of the structure. Due care shall
be taken to ensure that the reinforcement bars which are to be left in place so as to
project into the new work as dowels or ties are not injured during removal of concrete
while extending the existing culverts/bridges.
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Construction of Six Lane Access Controlled Highway

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3. In dismantling pavements, MS pipes, guard rails, kerbs, gutter, and fencing, where
portions of existing construction are to be left in the finished work, the same shall be
removed to an existing joint or cut/chipped true to the lines with face perpendicular to
the existing structure.
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-

WP-03: METHODOLOGY FOR EARTHWORK IN EXCAVATION

(Acceptance Criteria: Ref. Section 300 of MoRT&H)

Scope:

This work shall consist of excavation by mechanical means in all types of strata, in
rock by wedging/rock splitting or line drilling using pneumatic equipment and
expanding agents, chiseling including dressing to final line, level, grades, cross-
section as shown in drawings for roadway, drains, shoulders, median and foundation
for structures, including hauling suitable excavated materials to site for embankment
and sub-grade construction, also disposal of unsuitable cut materials in specified
manner.

Procedure:

1. The excavation shall be set out true to lines, curves, grades and sections as
per drawings.

2. In works involving widening of existing carriage way, shoulders, median shall

be excavated to the full width and to the required levels as shown in drawings
without disturbing the existing pavement. After reaching to the required depth,
200mm below it shall be loosened and compacted at OMC to achieve a minimum of
95 % of MDD and 90 % in case of expansive clays.

3. In works involving excavation for structures for construction of foundations for

bridges, culverts, retaining walls, head walls, cut-off walls, etc. shall be excavated to
required depth or level as shown in drawings. Where the nature of soil, depth of
trench, season does not permits vertical sides, excavation shall be done with
necessary shoring, strutting, planking or cut to slopes with safe angles with due
regard to the safety of personnel and works.

4. The cut formation, which serves as sub-grade has a density less than 17.5
KN/cum shall be loosened to a depth of 500 mm and compacted in layers and any
unsuitable material encountered shall be removed and replaced with suitable
material.

5. While executing excavation all adequate precautions of soil erosion, water

pollution etc. shall be taken and appropriate drainage measures to keep the site free
of water shall be taken. The suitable material obtained from excavation shall be used
for filling of roadway embankment, filling of existing pits in the ROW, land scarping
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-
etc. All other unsuitable and surplus materials shall be disposed off from site and
shall be stacked.

Rock excavation:

1. Rock when encountered shall be removed upto the required slopes, lines,
depthsorlevels as prescribed in the drawings. Unsuitable shale’s and large
boulders which cause differential settlements shall be removed to the extent
of 500mm below the level prescribed in the drawings and shall brought upto
the required cut formation with concrete of approved mix design or with
suitable granular fill.

2. All loose pieces of rock on excavated slope surfaces that move when
pierced by acrow bar shall be removed. In all cases at no point on cut
formation the rock shall protrude above specified levels.
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-

WP-04: METHODOLOGY FOR EMBANKMENT & SUBGRADE CONSTRUCTION

(Acceptance Criteria: Ref. sec.305of MoRT&H)

Scope:

This work consists of construction of embankment including sub-grade, earthen

shoulders, median and rock fill in embankment by mechanical means with approved
materials from roadway excavation or borrow pits.

Equipment/ Machinery Requirement:

1. Excavator
2. Dumper
4. Water tanker
5. Motor grader
6. Roller

Materials:

These materials shall be free from logs, stumps, roots, rubbish or any other
ingredient likely to affect the stability of the embankment and the sub grade. The
materials that have LL less than 50%,PI less than 25 %, free swelling index less than
50% shall be used for embankment construction. The material, which is having lab
MDD 15.2kN/cum, for filling in medians & embankment up to 3 meters height, MDD
16.0 KN/cum for Embankment Exceeding 3 meters height, and for sub-grade &
shoulders, the material having lab MDD 17.5kN/cum. The samples from the
identified borrow areas shall be brought to site laboratory and tested for the above
requirements.

Procedure for Embankment:

1. Toe line will be marked as per clause 305.3.I of MoRT&H to ensure proper
rolling up to the edges of the toe line.
2. The original ground shall be leveled, scarified, mixed with water and
Compactions to be achieve 95 % of laboratory MDD. When the soil of the
Original ground for embankment is not suitable the same shall be removed
up to 500mm and compacted in layers not exceeding 250 mm to achieve
95 % of MDD.
3. Approved material will be placed as per the calculated loose thickness, so
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-
Thatcompacted thickness does not exceed 250 mm, in accordance to clause
305.3.5 &902.3 of MoRT&H.
4. All the roots / deleterious material will be removed if any manually.
5. The dumped material will be spread over the entire width by means of
dozers / graders to achieve specified slopes and grades.
6. Required quantity of water will be sprinkled after calculating the difference
between OMC & NMC + l% for evaporation losses. If any water logging is
observed dewatering will be carried out in accordance to clause305.3.2 of
MoRT&H.
7. Final grading will be done with motor grader to true line and levels.

8. Moisture content will be checked before the rolling commences. (If the
moisture is not in limits, the same will be brought to -2 % to 1% range of OMC
by adding or drying).

9. The compaction shall be done with a vibratory roller of 80 to 100kN static

weight. Therolling shall commence from the lower edge and proceed towards
upper edge. Each pass of the roller shall overlap l/3rd of the preceding pass.

10. The compaction shall be done to achieve minimum of 95 % of MDD.

11. Field dry density will be carried out by sand replacement method.
Same shall be recorded in the format.
12. During the period of construction arrangement of traffic shall be in
accordance withMoRT&H 112.

Procedure for Sub grade:

Generally proposed to do sub-grade of 500 mm in three layers of 1st layer 250 mm

compacted, 2n layer 250 mm compacted thickness.

l. The approved material for sub-grade shall be excavated at borrows areas /

roadwayexcavation by excavators and hauled to site by tippers.
2. The materials shall be spread in layers of uniform thickness not exceeding
250mm compacted for 1st layer and 250mm compacted for 2 ndlayer
respectively over the entire width by means of dozers/ graders to achieve
specified slopes and grades.
3. The moisture contents shall be checked for OMC and if it is less than required
water may be added by sprinkling and if it is more than required, can be
allowed to dry, by exposure to the sun.
4. The moisture content of each layer shall be checked, and an allowance for
evaporation losses of l % above to 2 % below OMC shall be allowed and
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-
then compactions to be achieve97% of MDD for sub-grade & shoulders and
then successive layers shall be placed.
5. Final grading will be done carefully as per required slope and level.
6. The compaction shall be done with a vibratory roller of 80 to 100kN static
weight. The rolling shall commence from the lower edge and proceed towards
upper edge. Each pass of the roller shall overlap 1/3 rd of the preceding pass.
7. The compaction shall be done to achieve minimum of 97% of MDD.
8. Field dry density will be carried out by sand replacement method and recorded
in the format.
9. During the period of construction arrangement of traffic shall be in accordance
with MoRT&H 112.
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( NH-152D) Starting From Junction With Rewari-Kanina (SH-

WP-05: METHODOLOGY FOR CONSTRUCTION OF GRANULAR SUB-BASE

(Acceptance criteria: Ref. Sec.400 of MoRT&H)

Scope:

This work shall consist of laying and compacting well-graded material on prepared
Sub-grade for widening/ new construction of carriageway, hard shoulders, service
roads, etc.

Equipment Requirement:

1.Crusher Plant
2. Wheel loader
3. Tipper
4. Grader
5. Water tanker
6. Roller

Material:

The material to be used for the work shall be natural sand, crushed gravel, crushed
stone, crushed slag, or thereof combination depending upon the grading required.
The material shall be free from organic or other deleterious constituents and confirm
to the Grading given in table 400-1.

Table400-1
% by weight passing the IS sieve
IS sieve
designation
Gr-1 Gr-2 Gr-3 Gr-4 Gr-5 Gr-6
75mm 100 - - - 100 -
53mm 80-100 100 100 100 80-100 100
26.5mm 55-90 70-100 55-75 50-80 55-90 75-100
9.5mm 35-65 50-80 - - 35-65 55-75
4.75mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36mm 20-40 30-50 - - 10-20 10-25
850 micron - - - - 2-10 -
425 mic 10-15 10-15 - - 0-5 0-8
75 mic <5 <5 <5 <5 - 0-3
CBR value (mm) 30 30 30 30 30 30
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"The material to be used shall have wet AIV value not more than 40%. LL not more
than 25 &PI value not more than 6% and if water absorption is more than 2%,
soundness test shall be carried out."

Procedure for construction:

1. The sub-base material shall be spread on the prepared sub-grade with the
help of mechanical means to the required slopes and grades.
2. The moisture content shall be checked and if required any shall be add by
sprinkling, within a range of 1% above and 2 % below OMC.
3. The material shall be then compacted with vibratory rollers.
4. The compacted thickness of layer shall not exceed 200mm.
5. The rolling shall commence form lower edge and proceed towards the upper
edge. Each pass of the roller shall overlap 1/3rd of the preceding. During
rolling the grades, cambers are to be checked and any depressions or high
spots are to be rectified by adding or removing the material.
6. The rolling shall be continued till achieving the compaction of 98% of MDD.
The surface finish of Sub-base shall be ± 10 mm for flexible pavement and ± 6
mm for concrete pavement as per MoRTH Clause 902 and Table 900-1.
7. Field dry density will be carried out by sand replacement method and
recorded.
8. During the period of construction arrangement of traffic shall be in
accordance with MoRT&H 112.

WP-06: METHODOLOGY FOR WET MIX MACADAM

(Acceptance criteria: Ref. Sec.406 of MoRT&H)

Item:
Construction of WMM shall consist of laying and compacting clean, crushed
aggregate premixed with water in two layers on a prepared Granular Sub Base as per
MoRT&H Clause-406.

A) Scope of Work:

The item consist of the construction of WMM in two layers as necessary to lines, grades
and cross sections shown on the approved drawings or as directed by the engineer. The
thickness of single compacted Wet Mix Macadam layer shall not be less than 75mm.

B) References:

1. Specifications for Road and Bridge works, Ministry of Road Transport & Highways
(MoRT&H)- 5th Revision.
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2. IS 2720 codes
3. Reference drawings

C) Machineries/Equipment’s:

Paver finisher, Vibratory rollers, WMM Plant, Water Tanker (with sprinkler), Tippers /
Dumpers, surface discharge pumps, hand tools, steel Peg, String and survey kit etc. will be
used.

D) Traffic Management:

Sequence of road work and traffic management will be done as explained under
Methodology

A) Safety:

1. We shall take adequate precaution against water pollution and generation of dustduring
the operation.
2. Workmen, Engineers, Supervisors and Inspectors associated with the operation shall
wear safety attires.
3. The area where activity of WMM is to be carried out will be properly barricaded using
proper barricades, reflecting tapes and led properly to the barricading pillars.
4. The working area will be fully protected by the installation of cone at regular interval.
5. Two flag men at each end of the working will manage the traffic congestion or any
accidents.
6. Proper temporary signage viz. "MEN AT WORK", "GO SLOW", "SPEED LIMIT" etc. will
be installed.

F) Materials:

According to MoRT&H Clause-406.2.1.1. Coarse aggregate shall be crushed stone. If water

absorption is more than 2%, Soundness test will be carried out in accordance with IS: 2386
(Part 5). The average loss of weight of coarse aggregate after “5 cycles shall not exceed
12% when tested with sodium sulphate and 18% when tested with magnesium sulphate as
specified in IS: 383. Aggregate may satisfy either of the two tests:

1. Los Angles Abrasion Value (IS: 2386-IV) should not more than 40%. or
2. Aggregate Impact Value (IS: 2386-IV) should not more than 30%.

The aggregate shall conform to the grading given in table 400-13.

IS Sieve (mm) % of Passing Remarks

53.0 100
45.0 95-100
22.4 60-80
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11.2 40-60
4.75 25-40
2.36 15-30
0.600 8-22
0.075 0-5

Material finer than 425 micron shall have Plasticity Index (PI) not exceeding 6%.

Setting out & Cross Sections

Setting out will be carried out in accordance with approved drawings. Required cross-
sections will be maintained as per approved drawings.
Cross sections as submitted on the basis of approved survey details and approved
construction drawings shall be used to execute the work.

I) Construction Operation:
4. The execution of Wet Mix Macadam of 250 mm thickness will be executed at site
in the following manner.
i) 1st layer – 125 mm
ii) 2nd layer – 125 mm
iii) Wet Mix Macadam shall be prepared in an approved mixing plant of suitable
capacity having controlled addition of water and mixing arrangement like pug
mill or pan type mixer of concrete batching plant given in clause 406.3.3.
iv) Optimum moisture for mixing shall be determined in accordance with IS: 2720
(Part-8).
v) At the time of compaction, water in the mix should not vary from the optimum
value -2% and +1%.
vi) The mix shall be spread uniformly and evenly upon the prepared granular sub
base in required quantity.
vii) The mix may be spread either by a Paver Finisher. The Paver Finisher shall
be capable of spreading the material uniformly all over the surface given in
clause 406.3.4.
viii) The paver finisher shall be self-propelled, having features given in clause
406.3.4.
ix) No segregation of larger and fine particles should be allowed. The mix as
spread should be of uniform gradation with no pockets of fine material.
x) After the mix has been laid to the required thickness, grade and crossfall /
camber the same shall be uniformly compacted, to the depth with suitable
roller.
xi) 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 200mm, the compaction shall be done with the help of vibratory roller of
minimum static weight of 80 to 100 kN or equivalent capacity roller.
xii) If portion having unidirectional cross fall / super elevation, rolling shall
commence from the lower edge and progress gradually towards the upper
edge. Thereafter, roller should progress parallel to the center line of the road,
uniformly over-lapping each proceeding track by at least one third width until
the entire surface has been rolled.
xiii) In portion in camber, rolling should begin at the edge with the roller running
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forward until the edges have been firmly compacted.
xiv) The roller shall then progress gradually towards the centre parallel to the
centre line of the road as said above.
xv) Rolling should not be done when the sub-grade is soft or yielding or when it
causes a wave-like motion in the sub-base course.
xvi) Rolling shall continue till the density achieved is at least 98% of the maximum
dry density for the material as determined by the method outlined in IS: 2720
(Part-8).
xvii) After completion, the surface of any finished layer shall be well-closed, free
from movement under compaction equipment.

xviii) Plying of Traffic: No vehicular traffic of any kind shall be allowed on the
finished wet mix macadam surface.

xix) Surface finish &Quality Control of Work: The surface finish and quality
control work shall be carried out in accordance MoRT&H clause-902 & 900
respectively but level will be checked at top layer only and all the tests to be
done for WMM as per clause 900, table 900.3

L) Deployment of Manpower: As per requirement and suitable well skilled Manpower

capable of handling the situation shall be deployed.

N) Site Records:

RFI shall be raised by the contractor before the activity and after completion of process and
internally checking the required parameters by the concerned Concessionaire / IE rep. for
approval

WP-07: METHODOLOGY FOR PRIME COAT

(Acceptance criteria: Ref. Sec. 500 of MoRT&H)

1.0 Objective:
This method statement provides the construction methodology for the execution of the
Primer Coat over WMM finished surface.

2.0 SCOPE OF WORK

The scope of work includes application of single coat low viscosity liquid bituminous
material (SS1 Bitumen Emulsion) to WMM finished surface.

3.0 REFERENCE DOCUMENTS

 Specification for Road and Bridge Works (MoRT&H) issued by the Ministry of
Surface Transport and published by The Indian Road Congress.
 Construction Drawing.
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4.0 RESPONSIBILITY:
 Engineer - 1
 Lab Technician - 1
 Bitumen Sprayer Operator - 1
 Helpers - 4

5.0 PLANT & EQUIPMENT

 Bituminous sprayer : 1 No.
 Air Compressor : 1 No.
 Mechanical Broomer : 1 No.

6.0 CONSTRUCTION METHODOLOGY

6.1 PREPARATION OF ROAD SURFACE:

The surface to be primed shall be prepared in accordance with Clause 501.8 and 902 as
appropriate. The surface to be primed shall be swept clean, free from dust and loose
particles, care being taken not to disturb the interlocked aggregate. This is best achieved
when the surface layer is slightly moist and surface should be kept moist until the primer is
applied. It shall also be free from ruts, any other irregularities and segregated materials.

6.2 APPLICATION OF BITUMEN PRIMER:

The Prime coat shall be bituminous emulsion (SS-1) shall be sprayed/distributed uniformly
over the dry surface, using bitumen sprayer. If the surface to be primed is as dry or dusty as
to cause freckling of bituminous material, it shall be lightly and uniformly sprinkled with
water immediately prior to priming; however, the bituminous emulsion shall not be applied
till such time as no surface water visible. The primer shall be applied at the rate of 7-10 kg
per 10 Sqm (MoRT&H Table 500-1). The temperature at the time of application will be 20 oC
to 70oC.

6.3 CURING OF PRIMER AND OPENING TO TRAFFIC:

It shall be allowed to cure for at least 24 hrs. If it is not observed within 24 hrs of application,
sand shall be spread over the surface to blot the excess primer. Traffic will be allowed only
after surface is fully cured.

7.0 TACK COAT:

Over the primed surface, a tack coat should be applied in accordance with MoRT&H Clause
503.

8.0 QUALITY CONTROL OF WORK:

For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 and Nos. of tests to be conducted with reference MoRT&H
specification and as per frequency.

.
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WP-08: METHODOLOGY FOR TACK COAT

(Acceptance criteria: Ref. Sec. 500 of MoRT&H)

1.0 OBJECTIVE:
The purpose of this methodology is to describe the activities and methods which will be
used to carry out Tack Coat works.

2.0 SCOPE OF WORK

The scope of work includes application of a single coat low viscosity liquid Bitumen
Emulsion (RS-1) on treated / bituminous surface.

3.0 REFERENCE DOCUMENTS

 Specification for Road and Bridge Works (MoRT&H) issued by the Ministry of
Surface Transport and published by The Indian Road Congress.
 Construction Drawing.

4.0 RESPONSIBILITY:
 Engineer - 1 No
 Lab Technician - 1 No
 Bitumen Sprayer Operator - 1 No
 Helpers - 4 Nos

5.0 PLANT & EQUIPMENT

 Bituminous sprayer : 1 No.
 Air compressor : 1 No.
 Mechanical Broomer : 1 No.

6.0 CONSTRUCTION METHODOLOGY

6.1 PREPARATION OF ROAD SURFACE:

The surface shall be swept clean, free from dust and shall be dry. It shall be shaped to the
specified grades and section. It shall also be free from ruts, any other irregularities and
segregated materials.

6.2 APPLICATION OF TACK COAT:

The Tack coat shall be slow setting bitumen emulsion (RS-1). The work shall consist of
single coat application over treated surface / bituminous road surface as per specifications /
contract. The tack coat shall only be applied on clean and free from dust, dirt, and any
extraneous materials, dry surface and on accepted bitumen pavement coarse.

The Tack Coat material shall consist of bitumen emulsion which shall be arranged in bulk or
in drums from approved source. The bitumen emulsion shall confirm to specifications laid
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down in Contract Agreement and will be tested in the Laboratory to the required
specifications.

Full width of treated surface/ bituminous road surface shall be swept cleaned with a
mechanical broom, and high pressure air jet, or by other means given in clause 503.4.2

The bitumen emulsion shall be spread on treated surface/ bitumen surface by means of
distributor. Any area inaccessible to the distributor sprayer bar shall be treated by using
hand spreading system. Insufficient tack coated area shall be re-sprayed to make up the
deficiency. The rate of application shall be done as per Table 500-5 of MoRT&H.

The surface of structure, road furniture shall be protected. The bituminous material shall not
be discharged into road drains, footpath etc.

The traffic control arrangements at the time of laying of tack coat will be made accordingly.
The diversion of traffic shall be done by putting barricades and reflectors etc. while doing
tack coat and bituminous work as per requirement.

6.3 OPENING TO TRAFFIC:

Traffic shall not be allowed on tack coated surface.

7.0 QUALITY CONTROL OF WORK:

For control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 900 and Nos. of tests to be conducted with reference MoRT&H
specification and as per frequency.
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WP-09: METHODOLOGY FOR DENSE BITUMINOUS MACADAM

(Acceptance criteria: Ref. Sec. 505 of MoRT&H)

1.0 Scope
This covers laying and compacting of the mix of clean crushed graded aggregates,
with required amount of Bitumen on a previously prepared base to the requirement
as per these specifications in two layers as necessary to lines, grades and cross
sections shown on the approved drawing and in accordance with clause 505 of
MoRT&H. The thickness of compacted layers shall be as per drawing.
1.0 (A) References:

1. Specifications for Road and Bridge works, Ministry of Road Transport & Highways
(MoRT&H) - 5th Revision.
2. IS, IRC, ASTM & MS-2
3. Reference drawings

2.0
2.1.1 Safety
Adequate Road safety precautions shall be taken while executing works. Access to the
work site will be controlled, so that no vehicle can move on DBM surface.
The existing highway bears a regular and dense flow of traffic. To execute the work without
interfering with the present traffic flow, following precautions will be observed.
 The work will be planned in a manner creating least interference with the existing traffic
flow, while consistent with the satisfactory execution of the project, by using
adequate/appropriate road furniture.
 Work will be planned in alternate stretches from the central line of the pavement and
after approval of engineer work will be commenced.
 A suitable stretch on the right hand side of the central line of the pavement and a left
hand side similar stretch ahead will be operated simultaneously.
 To avoid trespassing in to the new construction zone by existing traffic, it is planned to
provide barricades by the sides of the stretches without affecting traffic.
 The change over phase between new and existing zone will be manned with flags,
diversion posts, warning signs etc. Traffic will be regulated between these stretches
during construction.
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 All measures required, like erecting and maintaining barricades, signboards, markings,
flags and flagmen, for the safety of traffic during construction will be provided as and
when required on situations arising at various sites.
 Diversions will be used for traffic at particular locations as and when required to
expedite the work without disrupting the flow of traffic.

2.1.2 Setting out & Cross Sections

Setting out will be carried out in accordance with approved drawings. Required
cross-section based on approved drawings will be maintained for execution of work.
2.1.3 Material and general requirements
Bitumen: The bitumen shall be paving grade bitumen confirming to IS: 73
Coarse Aggregates: The Coarse aggregate shall confirm to the physical
requirement set Forth in Table 500-8 of MoRT&H specification.
Fine Aggregates:The fine aggregates shall be the fraction passing through
2.36mm Sieve and retained on 75 micron sieve, consisting of crusher run stone-
Aggregate screening. The material for the fine aggregates shall be clean, hard,
durable, uncoated, dry and free from injuries, soft or flaky pieces and organic or
other deleterious Substances. Fine aggregates shall have a sand equivalent value
of not less than 50 When tested as per IS: 2720 (Part 37). The plasticity Index of
fraction passing 425 microns Sieve shall not be more than 4 when tested as per
IS: 2720 (Part 5)

Filler: Filler shall consist of finely divided mineral matter such as rock dust,
Hydrated Lime or Cement. The filler material shall be graded within the Limits
Indicated in Table 500-9. It the aggregates fail to meet the requirements ofwater
Sensitivity test, 2% by weight of aggregate, of hydrated lime shall be added.

2.1.4 Aggregate Grading & Binder Content

When tested as per IS-2386 Part-1, combined grading of coarse and fine aggregates
shall be within the limits accordance of Table 500-10 of MoRT&H specification
Apart from grading conformity & quality requirements for individual ingredients, the
mixture shall meet as per Table 500-11 of MoRT&H.
2.1.5 Plant Trials
Once the laboratory job mix formula is approved, the contractor shall upon approval
of the job – mix formula, plant trials shall be carried out to establish production of
uniform mix conforming to the approved job mix formula.
Permissible variations of the individual percentages of the various ingredients in the
mix as per table 500-13 from the job-mix formula to be used shall be within the limits.
2.1.6 Laying Trails
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Upon approval of the plant trials, laying trial shall be carried out for demonstration of
laying & compaction of the mix as per clause 501 of Technical specifications.
Trial shall be carried out on the first available stretch on the carriageway or
alternately at some other location. Trial shall be carried out over a area of minimum
100 sqm.
It shall be established by the laying trials that the plants deployed & methodologies
of work are capable of producing satisfactory results.
Density of finished paving layer shall be determined by taking cores after 24 hours of
laying.

2.20 Construction Methodology

2.2.1 Plant / Equipment’s, tools and tackles:
 This work will be done as per MoRT&H specification clause 505.

1. SUMMARY OF PROPOSED EQUIPMENT:

Following Plants &Equipment’s shall be used for the execution of work.

NOS.
EQUIPMENT CAPACITY / MODEL

Hot Mix Plant 120 or160 TPH 01 Nos.

Tippers 25-30 tons 20 To 25 Nos.
Sensor Paver (upto 9 m wide) 1 No.
Pneumatic Tyre Roller 12-15 T 1 No.
Tandem Vibratory Roller 8-10 T 2 No.
Loader 3 cu.m. 1 No.
Bitumen Distributor 4 MT 1 No.
Mechanical Broom 1 No.
Air – compressor 150 cfm 1 No.
Steel Pegs & String As per requirement
Thickness Gauge 02 Nos.
Thermometer 02 Nos.
Survey Kit 01 No.

2.2.2 Manpower
As per requirement and suitable well trained Manpower capable of handling
the situation shall be deployed

2.2.3. Construction Operation

1. Base on which DBM is to be laid shall be prepared by cleaning thoroughly by
mechanical broom & removal of dust by compressed air, ensuring that
interlocked aggregates are not disturbed.
2. Prime coat as per MoRT&H specifications shall be provided & cured for
minimum 24 hours, on non-bituminous surface.
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3. Tack coat shall be applied on primed & cured non-bituminous surface as per
MoRT&H specifications.
4. Bituminous mix shall be prepared in the approved batch type hot-mix plant as
per approved job-mix formula by maintaining temperatures.
5. Bituminous mix shall be transported from hot-mix plant to the laying site in
clean tippers lubricated lightly with thin coating of diesel. The tippers shall be
covered.
6. Laying shall be carried out only when surface air temperature is 10 C or
more. Laying shall be suspended during rain, fog & dust storms. Bituminous
surface shall be blown off with high pressure air jet to remove excess
moisture after rain. Laying shall be suspended if winds of high speed
exceeding 40 km/hour, at 2 meter height above surface sweep the area.
7. Rate of delivery of mix to the paver shall be regulated for facilitating
continuous paving operations. Paver operation shall be controlled by
maintaining consistent methods under controlled travel speed to ensure
uniform and even spreading.
8. Hand placing shall be done at locations as described in MoRT&H
9. specifications clause 501.5.3.
10. Laying of bituminous mix shall be done by sensor paver operated along a
string line suspended on pegs fixed at 10 meters intervals. Level of the string
line at pegs shall be fixed 200 mm above the required levels and longitudinal
profile of the section will be followed. Levels at pegs shall be checked while
fixing & again before laying.
11. Levels during paving shall be checked for the laid mat including surcharge for
compaction, and adjustments will be made wherever required for achieving
desired levels.
12. Compaction of the laid mix shall be commenced immediately after laying.
Breakdown rolling shall be carried out with a smooth wheeled tandem roller
operated in a static mode, starting from lower edge of pavement, overlapping
each pass by one third width of roller drum and continuing to the centre. At
super elevated portions, rolling will proceed from lower edge to the upper
edge, successively overlapping preceding pass in a direction parallel to the
centre line of the pavement.
13. Intermediate rolling shall be carried out in two passes with pneumatic
tyreroller of 12 to 15 MT weight having with wheels, with a tyre pressure of at
least 5.6 kg/sqm. This will be followed by two passes of vibratory tandem
roller. Final rolling will be carried out by one pass of Tandem roller in static
mode & finished before temperature of mix reaches 90 C. All the rollers shall
be operated with driven wheel nearest the paver at a speed of 3 to 4 Km/hour
and will not stand on uncompacted pavements but keep moving. Nos. of
passes required shall be decided after laying a trial bed. Rolling shall continue
until all the roller makes have been removed from surface. All deficiencies in
the surface after laying shall be made good by the attendants behind the
paver, before initial rolling in commenced.
14. Joints shall be rolled first at start of work.
15. Roller wheels will be kept moist by water spray provided with the machine.
Rollers will be provided with catch tray to prevent oil, grease or other matter
from dropping on to the pavement.
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16. Longitudinal joints shall be made flush by cutting back exposed joint by a
margin equivalent to layer thickness to a vertical face, removing loosened
material, coating vertical face and then laying adjacent layer & its compaction.
17. The finishing rolling shall be done with 6 to 8 tones smooth wheeled tandem
roller.
2.2.4 Opening to traffic
The newly laid surface shall not be open to traffic for at least 24 hours after laying
and completion of compaction.
2.2.5 Surface Finish and Quality Control of Work:
The surface finish of the completed construction shall confirm to the requirements of
Clause 902. All materials testing and workmanship shall comply with the provisions set
out in Section 900 of MoRT&H Specification and all preconstruction tests for aggregates
& Bitumen.
2.2.6 Arrangements for Traffic:

During the period of construction, arrangements for traffic shall be made in

accordance with the provisions of Clause 112.
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WP-10: METHODOLOGY FOR BITUMINOUS CONCRETE

(Acceptance criteria: Ref. Sec.507 of MoRT&H)

1.0 Scope
This covers laying and compacting the Bituminous Concrete mix on a previously
approved Dense Bituminous Macadam Surface to the requirement as per
specifications as necessary to lines, grades and cross sections shown on the
approved drawing.
Reference:
1. Specifications for Road and Bridge works, Ministry of Road Transport & Highways
(MoRT&H) - 5th Revision.
2. IS, IRC & ASTM codes
3. Reference drawings
2.0
2.1.1 Safety
Adequate Road safety precautions shall be taken while executing works. Access to
the work site will be controlled, so that no vehicle can apply on Bituminous Concrete
surface during the process of laying & compacting & cooling of the surface to
ambient temperature.
2.1.2 Setting out & Cross Sections
Setting out will be carried out in accordance with approved drawings and with Total
Station. Required cross-section based on approved drawings will be maintained for
execution of work.
2.1.3 Material and general requirements& IRC SP:53-2010
Bitumen: The bitumen shall be paving grade bitumen confirming to IS: 73
shall be used.
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Coarse Agg: Coarse aggregates will be procured from the approved source.
Coarse aggregates will confirm to the physical requirement set
forth in Table 500-16 of MoRT&H specification.
Fine Aggregates: The fine aggregates will be the fraction passing through 2.36mm
sieve and retained on 75 micron sieve, consisting of crusher run
stone-aggregate screening. The material for the fine aggregates
shall be clean, hard, durable, uncoated, dry and free from
injuries, soft or flaky pieces and organic or other deleterious
substances.
The plasticity Index of fraction passing 425 microns sieve shall not be more than 4 when
tested as per IS: 2720 (Part 5)
Filler: Filler shall consist of finely divided mineral matter such as rock dust,
hydrated Lime or cement. The filler material shall be graded within the Limits
indicated in Table 500-9.
It the aggregates fail to meet the requirements of water sensitivity test, 2% by weight of
aggregate, of hydrated lime shall be added .

2.1.4 Aggregate Grading & binder content

When tested as per IS-2386 Part-1aggregates will be within the limits of Table 500-
17 of MoRT&H specification.
Apart from grading conformity & quality requirements for individual ingredients, the
mixture will meet the limits of Table 500-17 of MoRT&H specification.
2.1.5 Plant Trials
Once the laboratory job mix formula is approved, the contractor shall upon approval
of the job – mix formula, plant trials shall be carried out to establish production of
uniform mix conforming to the approved job mix formula.
Permissible variations of the individual percentages of the various ingredients in the
actual mix from the job-mix formula to be used as per Table 500-18 of MoRT&H.
2.1.6 Laying Trails
Upon approval of the plant trials, laying trial shall be carried out for demonstration of
laying & compaction of the mix as per clause 501 of MoRT&H specifications.
Trial shall be carried out on the first available stretch on the carriageway or
alternately at some other location. Trial shall be carried out over a area of minimum
100 sqmeter.
It shall be established by the laying trials that the plants deployed & methodologies
of work are capable of producing satisfactory results.
Density of finished paving layer shall be determined by taking cores after 24 hours of
laying.

2.20 Construction Methodology

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2.2.1 Plant / Equipments, tools and tackles:
 This work will be done as per MoRT&H specification clause 507.
2. SUMMARY OF PROPOSED EQUIPMENT:
Following Plants & Equipment’s shall be used for the execution of work.

CAPACITY/
EQUIPMENT NOS.
MODEL
Hot Mix Plant 120 / 160 TPH 01 Nos.
Tippers 25-30 tons 20 To 25 Nos.
Sensor Paver (9.0 m wide) 1 No.
Pneumatic Tyre 12-15 T 1 No.
Roller
Tandem Vibratory 8-10 T 2 No.
Roller
Loader 3 cu.m. 1 No.
Bitumen Distributor 4 MT 1 No.
Mechanical Broom 1 No.
Air – compressor 150 cfm 1 No.
Steel Pegs & Strings As per requirement
Thickness Gauge 02 Nos.
Survey Kit 01 No.
Thermometer 02 Nos.

2.2.2 Manpower
As per requirement and suitable well trained Manpower capable of handling
the situation shall be deployed
2.2.4. Construction Operation
1. DBM base on which Bituminous Concrete is to be laid shall be prepared by
cleaning thoroughly by mechanical broom & removal of dust by compressed air.
Surface shall be washed with water & dried by air compressor wherever required.
2. Tack coat shall be applied on cleaned / dried DBM surface as per MoRT&H
specifications.
3. Bitumen tankers will be unloaded immediately on receipt at plant to ensure
that material/component is left in the tanker.
4. Stirring arrangement will be provided at Bitumen storage tank of the Hot
Mix Plant.
5. Bituminous mix shall be prepared in the approved batch type hot-mix plant
as per approved job-mix formula by maintaining temperatures.
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6. Bituminous mix shall be transported from hot-mix plant to the laying site in tippers
cleaned. The tippers shall be covered with tarpaulin during transportation of the
mix from Hot – mix plant to site.
7. Laying shall be carried out only when surface air temperature is more than 10 C.
Laying shall be suspended during rain, fog & dust storms. Bituminous surface
shall be blown off with high pressure air jet to remove excess moisture after rain.
8. Rate of delivery of mix to the paver shall be regulated for facilitating continuous
paving operations. Paver operation shall be controlled by maintaining consistent
methods under controlled travel speed to ensure uniform and even spreading.
9. Laying of bituminous mix shall be done by sensor paver operated along a string
line suspended on pegs fixed at 10 meters intervals. Level of the string line at
pegs shall be fixed 200 mm above the required levels and longitudinal profile of
the section will be followed. Levels at pegs shall be checked while fixing & again
before laying.
10. Levels during paving shall be checked for the laid mat including surcharge for
compaction, and adjustments will be made wherever required for achieving
desired levels.
11. Compaction of the laid mix shall be commenced immediately after laying.
Breakdown rolling shall be carried out with a smooth wheeled tandem roller 8-10
tone operated in a static mode, starting from lower edge of pavement,
overlapping each pass by one third width of roller drum and continuing to the
centre. At super elevated portions, rolling will proceed from lower edge to the
upper edge, successively overlapping preceding pass in a direction parallel to the
centre line of the pavement.
12. Intermediate rolling shall be carried out in two passes of pneumatic tyre roller of
12 to 15 MT weight having with a tyre pressure at least 5.6kg/sqm. This will be
followed by two passes of vibratory tandem roller. Final rolling will be carried out
by one pass of Tandem roller in static mode & finished before temperature of mix
reaches 115 C. All the rollers shall be operated with driven wheel nearest the
paver at a speed of 3 to 4 Km/hour and will not stand on uncompacted
pavements but keep moving.
13. Joints shall be rolled first at start of work.
14. Roller wheels will be kept moist by water spray provided with the machine.
Rollers will be provided with catch tray to prevent oil, grease or other matter from
dropping on to the pavement.

2.2.4 Opening to traffic

The newly laid surface shall not be open to traffic for at least 24 hours after laying
and completion of compaction.
2.2.5 Quality Control:
The surface finish of the completed construction shall confirm to the requirements of
Clause 902. All materials testing and workmanship shall comply with the provisions set
out in Section 900 of MoRT&H Specification.
2.2.6 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.

WP-11: METHODOLOGY FOR DRY LEAN CONCRETE

(Acceptance Criteria: Ref. Sec 600 of MoRT&H)

Scope
The work shall consist of construction of Dry Lean Concrete (DLC) Sub-base for Cement
Concrete Pavement in accordance with the requirement of technical specifications and in
conformity with approved lines, grades and cross-sections.

Equipment / Machinery Requirement:

1. Batching Plant
2. Tipper
3. Sensor Paver
4. Tandem Roller

1. MATERIALS

Test certificates from manufacturer shall be presented for each lot of cement or
cement testing shall be carried out in our site laboratory and result will be submitted.
Joint test shall be carried out for the approval obtained from the Concessionaire / IE
Representative for every 200cum of material. Water shall be tested as per requirement
of IS: 456 and approval obtained in advance.
Cement shall be procured in polyethylene Bags and loaded manually in to hopper of
cement pump. From hopper of pump it will be pumped to the Silo of the Batching Plant.
Combined grading of aggregates (Coarse & Fine) will be carried out at laboratory
attached with the plant, at least once daily and adjustments in Mix proportions will be
made for aggregates components, accordingly.
All approved aggregate shall be stacked separately at plant site in stack 5.00 Meter
clear Distance apart and shall be identified by placards marked ‘APPROVED’ placed on
top of the heap.

2. MIX - DESIGN

The mix shall be proportioned with a maximum aggregate cement ratio 15:1. The
right amount of water will be decided so as to ensure full compaction under rolling
and will be assessed at the time of rolling the trial length. As the too much water
willcause 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 open textured surface, the optimum moisture content and
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degree of compaction shall be determined during the triallength. These
parameters can be decided during the trial length and be approved by the
Concessionaire / IE Rep.

The minimum cement content in the lean concrete shall not be less than 150
kg/cum of concrete. In case fly ash blended at site as part of replacement, the
quantity of fly ash per cum not less than 120 kg/Cum.If the minimum cement
content is not sufficient to produce concrete of the specified strength, it will be
increased as necessary. The average compressive strength of each consecutive
group of 5 cubes made in accordance with clause 903.5.1.1 will not be less than
10Mpa at 7 days. The design mix meeting these requirements will be got
approved from the Engineer and demonstrated in the trial length construction.

Construction Process

Preparation of Surface: Loose patches on the drainage layer shall be watered

and compacted to achieve a firm surface. Prior approval of length of every days
paving shall be obtained in advance. As for as possible the construction traffic
shall be avoided on the prepared surface. A day before placing of the lean
concrete, the sub 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
stabilize the loose surface.

Concrete Production: Concrete shall be produced in the Batching Plant, which

is capable of proportioning the material, by weight, with each type of material
being weighed separately. The batching and mixing shall be carried out in a
forced action central batching and mixing plant, which has automatic control. The
controls are fully computerized so as to ensure accurate proportioning and
mixing. The accuracy of weighing scales of the batching plant will be within +/- 1
percent in the case of the aggregates and +/- 2 percent in the case of cement
and water. Additives will be introduced into the mixture in diluted form. Loaders
will be used to load aggregates from stacks of approved material into bins. Batch
plant bins will have a storage capacity of 35 cum each. Water will be obtained
from the bore wells at the plant site. Water will be stored in the water tank of 120
kl capacity. Mixing time shall be established to the satisfaction of the Engineer’s
Representative. Concrete will not be produced when ambient temperature fall
below 5 deg centigrade of exceeds 35 degcents. Following measures to control
temperature within 30 deg cent will be adopted.
Mechanically water will be sprinkled to cool the aggregate.
Cover will be provided for aggregate to be used in next 24 hours.
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Chilled water will be used for preparation of concrete. For this purpose water
chilling plant of capacity 15000 lt/hour capacity and storage of 50000 lt will be
used.

Transportation:
Plant mix lean concrete shall be discharged immediately from themixer, transported directly
to the point where it is to be laid and protected from the weather by covering the
tippers/dumpers. The concrete will be transported by tippers/ dumpers of 6 cum capacity
and sufficient in number. The number of the tippers beadequate in number so as to feed the
Paver to work at a uniform speed and in an uninterrupted manner.
PLACING:
a) The work will be carried out with sensor Paver for laying of main
carriageway in one pass.
b) Surveyor will fix the alignment for every day’s work, one day in advance,
and get it approved from Engineer’s Representative.
c) Prior to start of paving, string line will be set, approx. 200mm above DLC
top levels on each side, on longitudinal profile, on stakes placed 10 met
apart.
d) Air and concrete temperature shall be measured and recorded in the
concrete docket, at the plant site as well as laying site. No concrete will be
done when the concrete temperature cannot be maintained below 30 deg
cent & and when ambient temperature is more than 35 deg cent. Plant
operation will be stopped based on feedback from laying site.
e) The Dry Lean Concrete shall be laid in such a way that it is atleast 750
mm wider on each side than the proposed width including paved shoulders
of the concrete pavement.
f) Tractability of concrete received from the batching plant will be maintained
by recording data as shown on traceability form. The actual width shall be
decided based on the specification of the paver, such that the crawler
moves on the Dry Lean Concrete (MoRTH Clause 601.6.4)
Compaction:
a) Rolling shall be done by double drum vibratory roller of 80 KN static weight
and shall commence immediately after laying by Paver. First pass of the
roller shall be given in static mode and there after roller shall be operated
in the vibratory mode. Sufficient number of passes would be given till the
density of compacted layer reaches more than 98% of Dry density
achieved in Trial length construction. Areas inaccessible for the roller will
be compacted by plate vibrators. Static roller will be used as stand by in
the event of breakdown of vibratory roller but further work will not be
carried out till the vibratory roller is available in working condition at site.
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b) Honey-combed surfaces shall be corrected by scarifying and repairing with
concrete prepared with aggregate of 10 mm size before start of rolling
operations.
c) Surface regularity during the course of laying will be checked with a 3
meter straight edge. High points of the surface will be corrected by
scarifying & rerolling and the low areas shall be corrected by filling with
fresh materials and rolling.
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 degrees Celsius and 120 minutes
if less than 25 degree Celsius. However, these parameters will be decided in the
trial length.

CURING: As soon as the lean concrete surface is compacted curing shall commence.
Hessian shall be used and will be kept moist for 7 days by regular sprinkling of
water from flexible pipe attached with a water tanker. Water tankers will be deployed
round the clock for providing water for curing. Water will be available from the bore
wells along the length of the road.

3. TRIAL PAVE

a) Trial paving will be conducted at outside the road alignment at approved

location.
b) Target level for the Trial shall be fixed prior to paving.
c) Suitability of moisture content of Mix shall be examined during the trial length
construction to ensure that maximum density and compressive strength
related to corresponding water content are achieved.
d) Density of compacted materials of trial length will be determined as specified
and taken as reference density. Approval of trial length shall be obtained from
the Engineer.
e) 3-meter wide portion of hardened concrete of trial length shall be cut and
reversed for inspection of bottom surface. The entire process of mix design &
trial length shall be repeated if segregation of mix is observed.
f) Achieve levels will be compared with the target levels.
g) Approval of Engineer’s representative will be obtained before proceeding with
the main work.
TESTING: Testing will be carried out as per table enclosed (Encl). Level conformance
of finished DLC will be ensured by taking levels at specified grids and compared with
the target levels. Concrete testing record will be maintained as per format enclosed
(Encl).
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Tolerances: The tolerances for surface regularity, level, thickness, density and
strength shall conform to the requirements given in clause 903.5. Control of quality of
material and work shall conform to the specification as laid down in Section 900 of
MoRT&H Specifications.

TRAFFIC:No heavy commercial vehicles like trucks and buses shall be permitted on
the lean concrete sub-base after its construction. Light vehicles shall be allowed after
7 days of its construction.

MACHINARY AND MANPOWER: Machinery and manpower will be deployed as

detailed in encl.
h) Is representative will be obtained before proceeding with the main work.

4) Environmental Safety
I. Water will be obtained from the bore wells situated at our Camp Sites
so that it will not affect nearby localities.
II. The Batching Plants are situated at our Camp Sites and water
sprinklers will be installed to minimize Dust & Cement in the localities.
III. Fuel Storage and Refueling at Site are in the Camp Sites and strict
supervision will be maintained to stop Spillage or leakage to any
nearby water bodies.
IV. Our Mechanical Staff will maintain Batching plant & other related
equipment’s regularly to reduce Noise & Atmospheric Pollution.
V. The constructions Vehicles, Machineries and Equipment’s will move in
our designated area so it prevents compaction of any type of
vegetation and plants.
VI. All workers will be suitably provided with safety guards at the site.
VII. Safety Signals & Sign boards will be provided at every 200 m at the
Construction Site.

WP-12:METHODOLOGY PAVEMENT QUALITY CONCRETE

(Acceptance Criteria: Ref. Sec 600 of MoRT&H)
Scope

The work shall consist of construction of Dry Lean Concrete (DLC) Sub-base for Cement
Concrete Pavement in accordance with the requirement of technical specifications and in
conformity with approved lines, grades and cross-sections.

Equipment / Machinery Requirement:

1. Batching & Mixing plant

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2. Slip form paver
3. Texturing &Curing Machine
4. Water Tankers
5. Tippers
6. Concrete Saw
7. Cement Pump
8. Front End Loader

1. MATERIALS
Test certificates from manufacturer shall be presented for each lot of cement or
Cement testing shall be carried out in our site laboratory and result will be submitted. Joint
test shall be carried out for the approval obtained from the engineer’s representative for
every 200cum of material. Water shall be tested as per requirement of IS: 456 and approval
obtained in advance.

Cement shall be procured in polyethylene bags and loaded manually in to hopper of cement
pump. From hopper of pump it will be pumped to the Silo of the Batching Plant.

Combined grading of aggregates (Coarse & Fine) will be carried out at laboratory attached
with the plant, at least daily and adjustments in Mix proportions will be made for aggregates
components, accordingly.

All approved aggregate shall be stacked separately at plant site in stack 5.00 Meter clear
distance apart and shall be identified by placards marked ‘APPROVED’ placed on top of the
heap.

2. MIX DESIGN
The Minimum Cement content in the PQC shall be not less than 360 kg/cum of
Concrete. In case Flyash Grade-1 is blended at site as part of replacement, the quantity of
fly ash shall be upto 20% by weight of cementitious material and the quantity of OPC in
such a blend shall not be less than 310 Kg/Cum. If the Minimum Cement content is
sufficient to achieve the desired strength, it will be increased as necessary. The average
compressive & Flexure Strength of each consecutive group of 6 cubes & 6 Beams made in
accordance with Clause 903.5.2.1. The compressive strength of Cubes will not be less than
and 40 MPA at 28 Days. The Flexure strength of beams will not be less than and 4.5 MPA
at 28 Days. Target mean flexural strength of mix design shall be more than 4.5 MPa +
1.65s, where s is the standard deviation. Mix design as per the stipulations of ‘MoRT&H’
and as per IRC 44 & IS: 10262 will be carried out at the Laboratory and will be submitted to
Concessionaire / IE Rep. for approval.
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3. CONSTRUCTION PROCESS

a) Preparation of surface
Manual brooming shall be done to clean DLC surface before laying separation
membrane. Separation membrane will be laid for the first hour of paving before start of
paving works and shall be continuous process thereafter ensuring sufficient membrane
in place at all times of paving. Separation membrane will be fixed on DLC surface by
concrete nails. Separation membrane will be prevented from damage by aggregates
falling from tippers carrying concrete by manual brooming, ensured by close
supervision.

b) Concrete production

Concrete shall be produced in the batching plant, which is capable of proportioning the
material, by weight, with each type of material being weighted separately. The Batching and
mixing shall be carried out in a forced action central batching and mixing plant, which has
automatic control. The control fully computerized so as to ensure accurate proportioning
and mixing. The accuracy of weighing scales of the batching plant will be within +/- 2
percent in the case of the aggregates and +/- 1 percent in the case of cement and water.
Additives will beintroduced into the mixture in diluted form. Loaders will be used to load
aggregates from stacks of approved material into bins. Batch plant bins will have a storage
capacity of 35 cum each. Water will be obtained from the bore wells at the plant site. Water
will be stored in the water tank of 120 KL capacity. Mixing time shall be established to the
Engineer’s representative. Concrete will not be produced when ambient temperature fall
below 5 degree centigrade or exceeds 35 degree C. Following measures to control
temperature within 30 degree C will be adopted.
i. Mechanically water will be sprinkled to cool the aggregate.
ii. Cover will be provided for aggregate to be used in next 24 hours.
iii. Chilled water will be used for preparation of concrete. For this purpose water
chilling plant of capacity 15000 L/hour capacity and storage of 50000 L will be
used.

c) Transportation

Plant mix concrete shall be discharged immediately from mixer, transported

directly to the point where it is to be laid and protected from the weather by covering
the tippers/dumpers. The concrete will be transported by sufficient numbers of
tippers/dumpers of at least 6 cum capacity. The number of the tippers will be adequate
in number so as to feed the paver to work at a uniform speed of 1 RM/min. and in an
uninterrupted manner.
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4. PLACING

a. The work will be carried out with Wirtgen or equivalent Paver of laying capacity.
b. Prepared sub-base course shall be checked before laying of PQC and Cracks
wider than 5mm will be repaired with concrete prepared from aggregates lower
than 10 mm size.
c. Surveyor will fix the alignment for every day’s work, one day in advance, and get it
approved from Engineer’s Representative.
d. Prior to start of paving, string line will be set, approx. 200mm above PQC top levels
on each side, on longitudinal profile, on stakes placed 10 mtr.apart.
e. Air and concrete temperature shall be measured and recorded in the concrete
docket, at the plant site as well as laying site. No concrete will be done when the
concrete temperature cannot be maintained below 30 degree cent & when ambient
temperature is more than 35 degree cent. Plant operation will be stopped based on
feedback from laying site.
f. Ahead of the Paver and will be shifted forward as the work progresses ahead.
g. Concrete production shall be stopped as per advice from paving site.
h. One copy of docket will be handed over to Engineer’s Representative at laying site
and the other copy will retained by us.
i. Tractability of concrete received from the batching plant will be maintained by
recording data as shown on Tractability form.
j. The concrete shall be deposited in front of Paver by the tippers.
k. Concrete shall be spread by JCB placed ahead of the Paver within the paving
area. Then it will be spread by plough of the Paver to the required level of
surcharge.
l. Concrete will be vibrated and compacted by group of vibrators housed in the vibrator
box at the spacing of 40cms. Capable of providing variable output for achieving
required level of compaction.
m. Dowel bar location shall be identified by paint on DLC. Tie bars shall be located by
taking reference from the dowel bar marking.
n. Dowel bars at transverse joints shall be inverted by vibration plastic concrete and
shall be placed at mid depth of the slab by dowel inserter. Similarly tie bars at
longitudinal joints shall be inserted by vibration into plastic concrete and shall be
placed at mid-depth of slab by Tie Bar inserter. Concrete at all these location shall
be simultaneously vibrated & finished.
o. Finishing of concrete surface at the required level shall be carried out by Oscillating
Beam, which will be guided by the sensor.
p. Texturing shall be done by brush operated from texturing machine. Depth of the
surface texture shall be maintained at 1.0 mm, which shall be tested with the
Engineer’s Representative, and his approval shall be obtained.
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q. Rate of evaporation from surface of concrete will be monitored at an interval of 01
hr. during laying. If rate of evaporation exceeds 1kg/sqm / hr., evaporation
retardant will be used to minimize the effect of surface evaporation. If rate of
evaporation exceeds 2kg/sqm / hr., work will be stopped.
r. Barriers will be provided at each end of the paving site to prevent entry of vehicles.
Entry points will be guarded during day and night.

5. CURING

Curing shall commence as soon as the completion of finishing operations of concrete

surface. Curing shall be carried out, by spaying approved curing compound at the spray
rate recommended by manufacturer. After 3 hour of spraying of curing compound, moist
Hessian shall cover concrete surface without causing damage to curing compound film.
Hessian shall be used and will be kept moist for 14 days by regular sprinkling of water from
flexible pipe attached with a water tanker. Water tankers will be deployed round the clock
for providing water for curing. Water will be available from the bore wells along the length of
the road. Hessian of 16-guage thickness shall be use and stock to cover 20000 sq meter
areas will be maintained.

6. JOINT CUTTING & FILLING

I. Joint cutting will commence at the earliest possible as 4-8 hrs after laying of
concrete. (When the pavement can withstand the weight of concrete saw and saw
cutting does not dislodge particles / aggregates from the side of the joint)
II. Initial cut shall be with 3 mm thick diamond saw blade. This cut will be washed out
immediately and a temporary seal shall be installed. 4mm thick Armour board shall
be used as a temporary seal.
III. Widening of the joint to a width of 12 mm will be taken after 2 to 3 weeks by cutting
with 10 mm thick saw blade operated by concrete saw. Widened joints shall be
washed immediately after the cut.
IV. Joints shall be cleaned with compressed air and shall be dried completely before
filling with sealing compound.
V. 15 mm thick Armour board shall be provided at the bottom of the groove and
masking tape shall be fixed on each side of the joint.
VI. Sealant shall then be filled specified depth and finished by tooling specified shape.

7. TRIAL PAVE

I. Trail paving will be conducted at outside the road alignment and at Camp site.
II. Polyethylene film / Separation membrane shall be spread over the prepared DLC
surface.
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III. Paver shall be set up accordingly, by providing stakes guided sensor string line at
the required target levels.
IV. Mix shall be prepared as required by specification and as per approved mix design.
V. Mix shall be carted to the laying site as per approved method in covered tippers.
VI. Spreading, compacting & finishing shall be carried out in the manner approved
before.
VII. Paving shall be carried out over two days and all transverse & longitudinal joints
will be constructed as required by specification.
VIII. Curing shall be carried out as specified & as per approved method. Insertion of
dowel bars / tie bars, surface texturing shall be done as specified and as per
approved method statement.
IX. Target level for the trial shall be fixed prior to paving.
X. Suitability of moisture content of mix shall be examined during the trial length
construction to ensure that maximum density and compressive strength related to
corresponding water content are achieved.
XI. Achieve levels will be compared with the target levels.
XII. Sealing of joints shall be done as specified and as per approved method.
XIII. Tests on trial shall be carried out as specified vide clause 602.10.5 of MoRT&H
specifications. Cores shall be taken to determine density of concrete & to check
segregation.
XIV. Approval of engineer’s representative will be obtained before proceeding with the
main work.

8. TESTING

Testing will be carried out as per MoRT&H Specification. Level conformance of

finished DLC will be ensured by taking levels at specified grids and compared with
the target levels. Concrete testing records will be maintained as per format enclosed.

9. TOLERANCES

The tolerances for surface regularity, level, thickness, density and strength shall
conform to the requirements given in clause 903.5. Control of quality of material and work
shall conform to the specification as laid down in section 900 of MoRT&H Specifications.

10. TRAFFIC
No heavy or light commercial vehicles like trucks, buses etc. shall be permitted on the
PQC sub-baseafter its construction.

11. ENVIRONMENTAL SAFETY

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I. Water will be obtained from the bore wells situated at our Camp Sites so that it will
not affect nearby localities.
II. The Batching Plants are situated at our Camp Sites and water sprinklers will be
installed to minimize Dust & Cement in the localities.
III. Fuel Storage and Refueling Site are in the Camp Sites and Strict Supervision will
be maintained to stop Spillage or Leakage to any nearby water bodies.
IV. Our Mechanical Staff will maintain Batching Plant & other related Equipment’s
regularly to reduce Noise & Atmospheric Pollution.
V. The constructions Vehicles, Machineries and Equipment’s will move in our
designated area so it prevents compaction of any type of vegetation and plants.
VI. All workers will be suitably provided with safety guards &equipment’s at the site.
VII. Safety Signals & Sign boards will be provided at every 250 m at the Construction
Site.

WP-13: METHODOLOGY FOR CONSTRUCTION OFSHOULDERS/MEDIANS/ISLANDS

(Acceptance criteria:Ref. Sec 408 of MoRT&H)
Scope:

The work shall consists of construction of shoulders on either side of pavement,

median in the road dividing carriageway into separate lanes and islands for
channelizing traffic at junctions, in conformity with the lines, grades and cross-
sections shown in the drawing.

Materials:

Materials for shoulders median and islands shall consist of the same materials that
used for embankment construction, sub-grade, sub-bases and wearing courses (in
case of treated shoulders) and shall confirm to the physical requirements of each
individual layers.

Procedure:

1. The sequence of construction operations shall be such that the shoulders,

median and islands are done in layers each matching the adjoining
pavement layers. Where the materials in adjacent layers are different, these
shall be laid together, pavement layer shall be compacted first, later the
shoulder, median or island layers are compacted.
2. In all cases where paved shoulders are to be provided alongside of existing
carriageway, the shoulder shall be excavated to its full width as stated in
drawings, and laid to the grade, camber as stated in drawings.
3. Regardless of method of construction, the materials shall be placed directly
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onshoulders, median and islands; any spilled material on to the pavement
shall be removed, without damage to the pavement.
4. After the surface reached to the road level, if raised, the median and islands
shall be raised at least by 300mm by using kerbstones of approved materials.

WP-14: METHODOLOGY FOR CONCRETE KERB

(Acceptance criteria: Ref. Sec 409 of MoRT&H)

Scope:

This work shall consists of construction of cement concrete kerb and kerb 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.

Equipment / Machinery Requirement:

1. Batching Plant
2. Transit Mixer
3. Kerb Casting Machine (Continuous)
4. Concrete Cutting Machine

Procedure:

1. Surveyor will give line, Level and Layout, before starting the job.
2. Sensor rope will be fixed as per level/line.
3. Concrete of M-20 grade will be used. Slump at site will be maintained between
l0 - 20mm.
4. Concrete Kerb will be provided with grooves (vertical cut) at 5m intervals with
the help of concrete cutter, prior to hardening.
5. Curingof concrete Kerb will be done as required.
6. Casting of cubes will be done at batching plant as per requirement.
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WP-15: METHODOLOGY FOR SLOPE PROTECTION WORKS(SLOPPITCHING)IN

HIGH EMBANKMENTS
(Acceptance criteria: Ref. Sec 2500 of MoRT&H)

Scope:

This work will consist of covering the slopes of guide bunds, training works and road
embankments with stone, boulders, cement concrete blocks or stones in wire crates
over a layer of granular material called filter.

Equipment’s, Tools & Plants Required:

1. Hand Tools
2. Water tanker
3. Dumper
4. Wooden Form work

Procedure:

Slope Preparation:

The compacted layers shall be trimmed to the required slope and profile as per the
approved drawing using line and pegs. Any depression shall be filled up and
compacted thoroughly using wooden rammers.

Placing of filter layer:

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Suitable material (approved as filter material) shall be placed manually over

prepared base and shall be compacted in uniform layer of 150mm maintaining slope
and profile as per the approved drawing.

Dry rubble pitching:

Over the prepared filter layer dry pitching shall be carried out either with stones of
specified quality or concrete blocks (of M15 grade) having an average weight of 45
Kg maintaining slope and profile as per the approved drawing. Pitching shall be
commenced from bottom of the slope and continued to the top. In case of rubble
pitching care shall be taken to minimize void between the stones, which however
shall be filled up with spalls of suitable size.

Construction of chute drain:

Chute drain shall be constructed along the road alignment parallel to the slope of
pitching as per the dimension, slope and profile as mentioned in approved drawing.
Firstly 75mm thick leveling course (M15 grade) shall be placed along the
embankment slope and shall be extended to the Kerb face. The drain wall shall be
constructed with PCC M15 concrete. At junction of chute drain with kerb, the kerb
shall be cut to the required dimension.

Construction of stone masonry Toe drain:

Construction of Toe drain shall be done simultaneously with the slope pitching. Soil
at toe portion shall be trimmed, leveled and compacted to the required shape and
size. Boulder of specified quality shall be laid in CM (1:3) maintaining the
dimensions, slope and profile as mentioned in approved drawing.

Curing:

Curing of concrete shall be continued for 7 days by sprinkling of water.

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WP-16: METHODOLOGY FOR TURFING WITH SODS IN EMBANKMENT SLOPES

(Acceptance criteria: Ref. Sec 307 of MoRT&H)

Scope:

This work shall consist of furnishing and laying of the live sod of perennial turf
forming grass on embankment slopes or other locations shown on the drawings.

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. The length of sod approximately 50mm and
the sod shall free of debris. Thickness of the sod shall be as uniform as possible,
with some 50-80mm. The sods shall be cut in rectangular strips of uniform width, not
less than about 250mm x 300mm.

Procedure:

1. Embankment slopes shall be prepared by trimming to the required slope

andcross section. Trimmed surface shall be loosened and freed of all
stones larger than 50mm size, sticks, stumps and any undesirable foreign
materials shall be removed.
2. Prepared embankment slopes shall be moistened and sods shall be laid from
bottom upwards. Strips of sods shall be lightly tamped with suitable means.
3. After placing and temping the surface shall be cleaned of loose sods, excess
soil or any foreign materials.
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4. The sods shall be watered regularly for a period of 4 weeks after laying.

WP-17:METHODOLOGYFOR THERMOPLASTIC ROAD MARKING

1. GENERAL

The methodology for laying of Thermoplastic paints in this project is detailed here in
under

Technical Information:

Composition : As per MoRT&H Cl.803.4& IRC:35-1997

Colures : White
Drying Time : 5 to 10 Minutes
Luminance 45deg. Angle (% min) : 65
Skid Resistance : 45

Application Data:

Road Temperature : >100 C

Typical Heating Temperature : 180 to 2100 C
Optimum Heating Temperature : 190 to 2000 C

2. PROCEDURE

Before commencing the Road Marking Activity, the pavement temperature shall not
be less than 10 degree centigrade. The asphalt surface shall be thoroughly cleaned
with mechanical or with manual broomer / air compressor for all dust, dirt, grease, oil
and all other foreign matter before application of paint. After cleaning the road, with
the help of white marker / chalk mark the offsets at an every interval of 50m and at
curve portion at every 20m interval. With the help of a string line / thread fix the offset
and nailed it at every 50m / 20m interval. The offsets for paint marking is as per
drawings and technical specifications. The minimum thickness for marking the paint
shall be at least 2.5mm and minimum width will be 100mm. At kerb and shoulder
edges the lines shall be continuous. At center it would be 3m length markings with
6m gaps on straight portions. For median opening, super elevation, bus shelters,
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service roads, Toll plaza and at Junctions the road markings shall be followed as per
the drawings. Where letters or arrows are to be provided thermoplastic compound
may be hand sprayed.

As per the MoRT&H specification the thermoplastic material along with glass beads
shall be melted uniformly with no evidence of skin or unmated particles. Now the
thermoplastic material shall be poured in to the road marking machine or screed
application machine it shall be placed over the string and adjusting the thickness to
2.5mm at least (excluding glass beads) and machine shall be moved slowly, a further
quantity of glass beads of conforming to the specification shall be sprayed uniformly
into a mono-layer on to the hot paint line in quick succession of the paint spraying
operation. The glass beads shall be applied at the rate of 300 grams per sqm. area.

The finished lines shall be free from ruggedness on sides and ends and be parallel to
the general alignment of the carriageway. The upper surface of the lines shall be
level, uniform and free from streaks.

Once the paint marking completed request for inspection of thickness and width as
per drawing should be issued.

Care shall be taken to prevent the traffic flow while laying the paint mark.
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WP-18: FOR INSTALLATION & ERECTION OF SIGN BOARDS

1. GENERAL

The work shall consist of fabrication, Installation & Erection of Sign Boards as
indicated on the technical drawing and conforming to the specifications.

2. Material

All road signs shall be of retro-reflective type and made of high intensity grade with
encapsulated lens type reflective sheeting vide Clause 801.3 fixed over aluminum
sheeting.

3. Installation

Installation of sign posts shall be carrying out as clause 801.4.

4. Post & Mountings

Sign with an area up to 0.90 Sqm. shall be mounted on a single post, and for greater
area two or more supports shall be provided. All components of signs and supports
shall be thoroughly de-sealed, cleaned, primed & painted with two coats of epoxy
paint. Any part of mild steel below ground shall be painted with three coats of Red
Lead paint.

5. Sitting of Signs

The road signs shall be so placed that the drives can recognize them easily and
intime. Normally signs shall be placed on the left hand side of the road. Vertical
height from bottom of sign to road level shall be as per drawing.

6. Orientation of Signs

The signs shall normally be placed at right angles to the line of travel of the
approaching traffic in other cases shall be according to IRC-67 clause-4.
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WP-19: METHODOLOGY FOR PIPE CULVERTS

1.0 GENERAL DESCRIPTION

The work comprises the supply and installation of reinforced concrete pipe culverts,
inclusive of excavation of excavation, backfilling, bedding all in accordance with the
contract specification and the details shown on the drawings.
2.0 MATERIALS
Reinforcement concrete pipes shall be NP-4 type and conform to the requirements
or otherwise specified and shall be supplied by manufactures approved by the
Engineer.
A ratio of 1:2 cement mortar for jointing of reinforced concrete pipe shall conform to
the requirement of the contract specification.
3.0 EQUIPMENT
 Concrete weigh batching plant
 Hydra crane (5 T capacity)
 Transit Truck mixer and dumpers.
 Needle Vibrators (Electrical or petrol drive units)
 Crane 5T capacity for handling shuttering, reinforcement and materials.
CONSTRUCTION METHODS
3.1 The quality of materials used in the manufacture of precast concrete pipes
shall be subject to inspection and approval by the engineer. Pipes shall
comply with the specified requirement and shall not exhibit any of the
following defects at the time of installation. Approval forms shall be submitted
for facilitating approval of each stage of work.
i. Major fractures or cracks, Defects that indicate imperfect proportioning
of the constituent materials.
ii. Surface defects indicating honey combing or open texture.
iii. Damaged ends or distortion which would prevent making of a
satisfactory joint.
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3.2 Pipe culverts which are to be constructed at excising ground level or under an
existing embankment shall have a trench cut excavated to receive the culvert
down to the levels shown on the drawing.
In case of high embankments with height of fill more than 3 times the external
dia. of pipe, embankment shall be built first built to an elevation above the top
of the pipe equal to the external dia. of the pipe, and the width on each side
equal to five times the dia. of pipe, after which the trench can be cut to lay
pipes. The width on either side of the pipe shall be a min 15 cm of ¼ die of
pipe whichever is greater, but not exceeding 1/3 dia. of pipe. The sides of
trench should be a nearly vertical as possible.
3.3 In areas of soft, unsuitable soil where the removal of unsuitable material is
indicated in the drawings or as directed by the engineer,Culverts are to be
constructed at the existing ground level. Prior to the construction of an
embankment and such cases the procedure shall be as follows the unsuitable
material shall be excavated to such length,width and depth directed by the
Engineer.It shall be back filled in specified layers with approved granola fill of
the same standard as specified for granular bedding material, and shall be
compacted to the same specified standards.The prepared surface shall
provide a firm foundation of uniform density throughout the length of the
culvert to receive the pipe bedding.
3.4 Culverts which are to be constructed below existing ground level shall be laid
in a trench excavated from that level. Excavation of the trench shall be to the
width shown on the drawings, the trench bottom shall be trimmed true to line
and level and soft sport and any over break dealt with as described in the
contract specification. Particular care shall be taken where excavation is in
rock to ensure that there is a minimum cushion of 200 mm layer of approved
compacted earth below the pipe.
3.5 Trenches shall be kept free from water until pipes are laid and joints have
hardened.
3.6 Pipes shall not be laid until the foundation and the Engineer has approved the
pipes class, size and length called for at each location.
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3.7 Concrete pipes shall be laid true line & level, each pipe being separately
aligned. Pipes shall be laid from the outlet and preceded towards inlet. Prior to
joining, jointing surfaces shall be cleaned of all contaminants. In pipes with
bell month the spigot of each pipe shall be inserted concentrically in the
socket of the one previously laidand the pipe adjusted and fixed in its correct
position with the spigot accurately centered in the socket. Care shall be taken
to see that the sealant is adequately compressed to seal the joint.
Alternatively joints can be filled with Cm 1.2
3.8 For all culverts constructed in trench, back filling is done with suitable Material
or bedding material as specified and placed in even layers equally on either
side of the pipe to a height of 300 mm above the crown of the pipe. This shall
be placed in layers not exceeding 150mm thick and dull and duly compacted.
Where culverts are constructed in height embankments the surround material
shall be placed and compacted in layers not exceeding 150mm brought
upevenly on both sides of the pipe to a height of 1000mm above the crown of
the pipe. Above this level suitable material shall be placed in accordance with
the contract specification.
3.9 Heavy earth moving and compacting equipment shall not be permitted to
Cross the pipe line until a minimum of 600mm of back fill, sub base or base
course has been placed and compacted over the crown of the pipes or
otherwise specified.
4.0 SITE RECORDS
The Site Engineers in charge of works, shall ensure that the site supervisors
continuously supervisor and observe the construction of the culvert and maintain the
daily site diary sheets each day. The daily site diary sheets shell record the following
information’s.
a. Location of the works.
b. Type of works and operations.
c. Plant and equipment’s used on site.
d. Sub-contractors labour resources, if any.
e. Total length of culvert laid at each location.
f. Weather condition and details of delays, if any.
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The Site Engineers shall ensure that the total length of culvert laid at each location is
measured and recorded in the presence of the Concessionaire / IErepresentative,
immediately after completion of the works.

WP-20: FOR FIXING, PAINTING AND LETTERING OF HECTOMETER / KILOMETER /

5th KILOMETER STONES

1. General

The work covers the supply, painting, Lettering and fixing of distance measurement
stones and shall include.
Hectometer Stones (200m)
Kilometer Stones
5th Kilometer Stones
The dimensions of the stones and the size, colour, arrangement of letter and script
shall be as per IRC-26 “Type Designs for 200 Meter Stones” and IRC-8 “Type
Designs for Highway Kilometer Stones”
2. Material

Hectometer Stones:
Steel Bars: 2 no of 6mm dia each 1400mm long.
5 no of 6mm dia each 375mm long.
Concrete: RCC M-15 Grade concrete
Foundation: PCC M-10 Grade concrete

Kilometer Stones:
Concrete: PCC M-20 Grade concrete
Foundation: PCC M-10 Grade concrete
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5th Kilometer Stones:
Concrete: PCC M-20 Grade concrete
Foundation: PCC M-10 Grade concrete

3. Fixing of Stones

The outer edge of the unpaved shoulder shall be excavated and cleaned thoroughly
as per technical drawing 150mm (100mm in case of Hectometer Stones) thick
concrete bed (M10 Grade of concrete) shall be laid for the bottom. The stones shall
be placed vertically over the concrete bed M10 grade of concrete shall be placed on
four sides of the stones up to the required level. The orientation and location of the
stones shall be as per technical drawings. Later on painting and arrangement of
letter and script shall be done as per IRC-26 “The Type Design of Hectometer
Stones” & IRC-8 “Type Designs of Highway Kilometer Stones”.

WP-21: FOR PROVIDING AND LAYING 300MM THICK STONE BOULDER

PITCHING ON SLOPES

1. Material: Stones, Spalls.

2. Procedure:

The stone pitching shall commence in a trench over the toe of the slope. Stone shall
be placed by hand to the required length, thickness and depth conforming to the
drawings. Stones shall be set normal to the slope and placed so that the largest
dimension is perpendicular to the face of the slope, unless each dimension is greater
than the specified thickness of pitching.
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The largest stones shall be placed in the bottom courses and for use as headers for
subsequent courses.
The stone of flat stratified nature shall be placed with the principle bedding plane
normal to the slope. The pattern of laying shall be such that the joints are broken and
voids are minimum by packing with spalls of the proper size and wedged in with
hammers to ensure tight packing.
When two or more layers of stones must be laid to obtain the design thickness of
pitching, dry masonry shall be used and shall be well bonded.

WP-22: FOR FILTER MEDIA, BACKFILLING & EMBANKMENT BEHIND ABUTMENT

This item of work deals with activities of Filter media, Backfilling and Embankment
behind Abutments with approved materials as per the terms of contract agreement.
1. General
This item of work shall confirm to clause 2504.2.2, 305 of the MoRT&H specifications

Filter Media
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Filter Media is proposed from the tests conducted in the laboratory and checked for its
suitability as per Clause 2504.2.2 of MoRT&H Specification.
Back filling

Back filling will be done with the material from approved borrow areas.

Embankment

Embankment will also be done from the suitable borrow area as per drawings and
MoRT&H specifications Clause 305.
2. Procedure

a. Initially filter media is laid manually with coarse filter towards weep hole of
Abutment and finer material towards earthen side layer by layer as per the technical
requirement.
b. After Completion of each filter media layer to the required suitable height back
filling will be done simultaneously in layers matching the height with the filter media
layer till it reaches the existing ground level behind Abutment and compacted as per
requirement.
c. Embankment construction will also be taken up either separately or
simultaneously along with filter media and back filling layers.
3. Equipment/ Machinery

a. Roller / Plate compactor/ Rammer

WP – 23 : FOR CONSTRUCTION OF DRAINS

This item of work deals with construction of Drains with approved materials as per the
terms of contract agreement.
1. General

The construction shall confirm to the specific alignment, lines and grades given in the
drawing.
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The materials used shall adhere to the section 1000 of MoRT&H specifications. The
concrete used shall be of approved design mix and shall confirm to section 1700 of
MoRT&Hspecifications.

2. Procedure
Setting Out:
 The reference bench mark and all reference control points will be established before
the commencement of the work & approval will be taken for the same.
 RFI will be raised before commencement of the work.
Stages of Execution:
 Checking of Alignment of drain from the center line.
 Earth work excavation.
 Laying of PCC for drain Bed.
 Pouring of RCC drain raft.
 Pouring of drain wall.
 Pouring of drain slab.
Excavation:

 Layout marking will be done as per approved working drawing and ground levels will
be taken and recorded jointly.
 Excavation will be done conforming to the lines, grades, slopes and levels as shown
on the approved working drawings, as per the specification clause 301.3.8.
 If required dewatering will be done as per the specification clause 301.3.10
 All the excavated materials will be disposed such that the working space will not
effect, as per the MoRT&H specification clause 301.3.11
 Excavation in Hard Rock will be done as per MoRT&H specification clause 301.3.5
 The founding levels of the drain are to be inspected and recorded accordingly.
Concreting:
PCC: The PCC of the drain with approved design mix concrete will be done
conforming to the lines, grades, slopes and levels as shown on the approved working
drawings.
Raft: The reinforcement shall be placed in position and shuttering is erected to exact
dimensions of raft and after due checks, raft is concreted to the required thickness as
detailed in drawing.
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Walls: The shuttering is erected to the exact dimension and the walls are cast above
the raft to bottom level of slab. The procedure adopted will be same as raft.
Weep Holes: Weep Holes will be provided at required spacing as shown in the
drawing.
Slab: The shuttering is made to support the top slab of drain and necessary care is
taken to seal the joints to avoid slurry loss from concrete through joints. The steel is
positioned and concreted.
The formwork is removed after due time as per norms and blemishes, if found, are
made good.
The curing of concrete will be start immediately after completion of the concrete.
The necessary back filling will be done after completion of curing works.

3. Equipment/Machinery:
1. Excavator / JCB
2. Auto level with accessories
3. Transit Mixers
4. Needle Vibrators
5. Cube Moulds

WP-24 METHODOLOGY FOR CURING

Machinery Requirement:
a. Water tanker
b. Hessian cloth
Procedure:
1. Arrangements for storing water shall be provided in nearby location for curing
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of concrete.
2. The water used for curing shall be clean and free from injurious amount of
oils, acids, alkalis, salts, sugar, organic materials or other substances that may be
deleterious to concrete or steel.
3. Exposed surface of concrete shall be kept continuously in a damp or wet
condition by pounding, by covering with layer of sacks, canvas, Hessian cloth or
similar material or by continuously pouring water over the exposed concrete surface.
4. The curing period shall not be less than 14 days from the day of casting. To
monitor the curing, date of casting will be marked on the structure.
Curing of individual elements will be done as below Foundation
Foundation will be cured for at least 14 days from the date of casting. Continuous wet
condition will maintained by pounding on the top of foundations.
Wall/ Column/ Piers
Vertical surface of walls will be covered with Hessian cloth and these will be kept
damp throughout the curing period.
Slab
After casting of slab, bunds will be prepared for ponding. The ponding will be
continued till end of the required curing period.
Precast members
Precast members will be cured in a curing tank at precast yard itself. They will be kept
immersed in water for at least 3 days. After three days they will be removed from the
tank and curing by normal methods will be continued for the rest of curing period.
Drain
For curing of concrete temporary water storage facilities will be provided at regular
intervals. Water will be stored in drums/ makeshift water tanks etc. Stone Masonry
drains will be cured with the storage tanks placed at regular intervals. Continuous wet/
damp condition of the RCC drain will be maintained by covering the walls with Hessian
cloth and keeping it wet.

WP-25: FOR CONSTRUCTION OF FORM WORK/ REINFORCEMENT/

STRUCTURAL CONCRETE
(Acceptance Criteria: Ref. Section 1500, 1600 & 1700 of MoRT&H)
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This item of work deals with construction of formwork, reinforcement and placement of
concrete for all structures with approved materials as per the terms of contract
agreement.

1. General:
This item of work shall be dealt in compliance to Section 1500, 1600, and 1700 of
MoRT&H specifications.

The materials shall confirm to section 1000 ofMoRT&H specifications.

Form work:

This work shall consists of furnishing and fixing of form work (shuttering) of approved
quality forecast- in- situ/ precast / pre-stressed plain or reinforced concrete with
necessary props, staging, centring, scaffolding and any temporary construction
required for their support.

Reinforcement:

This work shall consist of furnishing and placing of high yield strength deformed bars
of the shape and dimensions as shown in approved drawings.

Concrete:

This work shall consist of furnishing and placing of plain or reinforced concrete of all
grades with 20mm downgraded aggregates as defined in MoRT&Hspecifications,
machine mixed and mechanically vibrated to the required level, slope, etc. as per
approved drawings.
Materials:

The source of materials (for cement, coarse aggregate, fine aggregate, water,
admixture, reinforcement steel etc.) shall be identified and the sources will confirm to
the specifications mentioned on the drawings and the requirements laid down in the
section 1000 of MoRT&H or to the requirements specified by the Concessionaire / IE.
All the materials will be stored as per MoRT&HSpecification clause 1014.

Cement:
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The cement to be used in the works shall be Ordinary Portland Cement of confirming
to IS 269. The manufacturer test certificate shall be furnished, and cement shall be
stored as per IS 4082.

Water:

The water to be used shall be free from oils, acids, alkalis, salts, sugar, organic
materials or other substances that may be deleterious to concrete and steel. Potable
water generally considered satisfactory. The water to be used shall satisfy the
requirements as per clause 1010 of MoRT&H specifications.

Coarse aggregate:

Coarse aggregate shall consist of clean, hard, strong, dense, non-porous and durable
pieces of crushed stone. All coarse aggregates shall confirm to clause 1107 of
MoRT&H specifications and IS 383, when tested in accordance to IS 2386 P-1 to P-8.

Fine aggregate:

Fine aggregate shall consist of clean, hard, strong, dense, and durable pieces of
crushed stone or natural sand or a combination of both. All fine aggregates shall
confirm to IS 383, when tested in accordance to IS 2386 parts 1 to 8. The fineness
modulus of fine aggregate shall not be less than 2.0 or greater than 3.5. The grading
shall confirm to table 1000-2 of MoRT&H specification.
Admixtures:

Admixtures shall confirm to the requirements of IS 9103. The manufacturer test

certificate shall be furnished for each consignment. As Per Quality Assurance Plan
admixture should be tested by the third party for checking the properties of admixture

Reinforcement:
For plain or reinforced cement concrete or pre-stressed concrete the reinforcement
shall be confirming to IS 1786-2008 HYSD bars. The steel supplied with test certificate
shall be assembled in accordance with approved drawings and shall ensure storing to
avoid deterioration and corrosion. As Per Quality Assurance plan, Reinforcement
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should be tested by the third party for checking the properties of Reinforcement
Quality

2. Procedure:

Formwork:

1. The formwork shall provide a smooth finish of uniform texture and

appearance. This material shall leave no stains on the concrete and so fixed to its
backing as not to impart any blemishes.
2. Ensuring necessary care will be taken, the formwork in true to line, levels,
plumb, etc., rigid, adequately braced both horizontally and vertically. Form joints shall
be as much as minimized and foam should be provided at every joint to avoid the
leakage of slurry from concrete.
3. Required formwork shall be made out of plywood/ steel shutters to suit the
site conditions. Formwork materials shall be rigid, even surface, and sufficiently strong
to prevent deformation during concrete.
4. Releasing agents such as diesel mixed with grease, shuttering oil, etc. shall
be applied before fixing formwork, and shall not allowed to come into contact with any
reinforcement or pre-stressing tendons and anchorages.
5. The formwork shall be cleaned carefully, dried and releasing agents shall be
applied before re-use.
6. The formwork shall be so removed as not to cause any damage to the
concrete. Centring shall be gradually and uniformly lowered so as the concreteto take
stresses due to its own weight uniformly and gradually to avoid any shock or vibration.
7. Before re-use all components of formwork shall be examined for damage and
damage pieces shall be rectified. Before re-use all components shall be cleaned of
deposits of soils, concrete or other unwanted materials. Threaded parts shall be oiled
after cleaning.
8. Before any erection is taken up the design & drawing of complete farm work
(i.e. the farm as well as their supports) as per specification clause 1503 & 1507, has to
be approved by the Concessionaire / IE.
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9. The removal of Farm work shall be done as per specification clause 1508 and
the used farm work will be reused is required as per MoRT&H specification clause
1509

Reinforcement Steel:

1. Bar bending schedule shall be strictly as per approved drawings, and

reinforcement steel shall be cut and bend as per approved bar bending schedule.
Bars shall be bent cold to the specified shape and dimensions, using a proper bar
bender, operated by hand or power to obtain correct radii of bends and shape.
2. Reinforcement bars shall be placed accurately in position as shown in the
drawings. The bars, crossing one another shall be tied together at every intersection
with binding wire, to make the skeleton of reinforcement rigid such that it does not get
displaced during placing of concrete or any other operation.
3. If required Spacer bars at approx. 1m intervals shall separate layers of
reinforcement. The minimum dia. of spacer bar shall be 12mm to a maximum of main
reinforcement or maximum size of aggregate, whichever is greater. Cover blocks of
thickness equal to the specified cover shall be placed between formwork and bars
made of concrete/ cement mortar of specified grade of concrete/ strength as those of
the member.
4. Necessary stays, blocks, chairs, spacers, hangers, etc. or other subsidiary
reinforcement shall be provided and approved by Concessionaire / IE, to fix the
reinforcement firmly in its correct position. Laps shall be staggered.
Concrete:
The grades of concrete shall be as specified in the drawings/ contract. Necessary mix
designs shall be carried out well in advance as per clause 1700 of MoRT&H
specifications.

Mixing:
1. The mixing of concrete shall be done in batch type concrete mixer or by
concrete batching and mixing plant. All measuring devices shall be maintained in a
clean and serviceable condition. Its accuracy shall be checked periodically.
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2. Mixing of concrete shall be continued till the individual particle of coarse
aggregate shows complete coating of mortar containing its proportionate amount of
cement. In no case the mixing done for less than 2 minutes. Corrections in water and
aggregate with respect to moisture present in the aggregates shall be done on day-to-
day basis.

Transportation and placing:

1. Concrete shall be transported and placed as near as practicable to its final

position, so that no contamination, segregation or loss of its constituent materials
takes place. Concrete from batching plants shall be transported by scoop tippers or
transit mixers.
2. The concrete shall be placed gently in position and shall not have a free fall of
1.5m as per specification clause 1709.
3. Concrete shall be placed in horizontal layers to a compacted layer not
exceeding 450mm.
4. All formwork and reinforcement contained in it shall be cleaned and made free
from standing water, dust, etc., immediately before placing concrete.

Compaction:

1. The concrete shall be compacted within 30minutes of its discharge from the
mixer, unless carried by properly designed agitators, operating continuously, when
this time shall be 1hour. When trials show that the periods stated above are
unacceptable, it is necessary to add retarding/plasticiser admixtures. This shall be
controlled by taking slump at batching plant and site.
2. Concrete shall be thoroughly compacted with vibrators or other means during
placing and worked around reinforcement, tendons, and embedded figures and into
corners of formwork to produce a dense homogeneous void-free mass having a
required surface finish.
3. When vibrators are used, vibration shall be done continuously during the
placing of each batch of concrete until expulsion air has practically ceased and in a
manner does not promote segregation. Where immersion vibrators are used contact
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with reinforcement and all inserts shall be avoided. Standby vibrators in serviceable
conditions shall be kept at site so that they can be used in the event of breakdowns.

Construction joints:

1. Construction joints shall be avoided as far as possible, when unavoidable

shall be provided in a direction perpendicular to the axis of the member. The old
surface shall be thoroughly cleaned and soaked with water. Standing water shall be
removed and surface shall be wetted with neat cement slurry if required. Concreting
shall be carried out continuously up to the construction joints.
2. For a vertical construction joint, a supporting board shall be fixed previously at
predetermined position and shall be properly stayed to prevent displacement or
bulging when concrete is compacted against it. Concreting shall be continued right up
to the board.

Curing:

1. Exposed surfaces of concrete shall be kept continuously in a damp or wet

condition by ponding or by covering with a layer of sacks, canvas, Hessian or by
similar materials and shall be kept constantly wet.
2. Curing compounds shall be permitted in special circumstances like PQC, etc.
Curing compounds shall be continuously agitated before use. All concrete cured by
this method shall receive two applications; the first coat immediately after acceptance
of surface finish, and the second coat shall be after first coat has set, on the saturated
surface before the surface water film disappears.

Finishing:

Immediately after removal of forms, exposed bars or bolts, if any, as far as

possible shall be removed, or if necessary, shall be cut inside the concrete member to
a depth at least 50mm below surface of concrete and the resulting hole shall be filled
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by fresh cement mortar. All fins caused by form joints, all cavities produced by
removal of form ties all other holes and depressions, honeycomb spots, broken edges
or corners, and other defects, shall be thoroughly cleaned, saturated with water, and
carefully pointed and rendered true with mortar of cement and fine aggregate mixed in
the proportions used in the grade of concrete. A surface, which has been thus
rendered, shall be kept moist for a period of 24hours.

Quality control tests:

1. Physical tests on cement at a frequency of 1 test per lot (manufacturing week)

MTC (manufacturer’s test certificate) shall be maintained.
2. Tests on water shall be at a frequency of once per source.
3. Physical and chemical requirements of admixtures – MTC (manufacture’s test
certificate) shall be maintained.
4. Tests on reinforcement at a frequency of once per source per diatest
certificate to be maintained.
5. Workability of concrete shall be checked by slump cone test at a frequency of
once per session at concrete batching plant as well as at placing area.
6. The natural origin materials of construction (Aggregate & Sand) and
purchased material like cement and admixture will be tested by site laboratory as per
routine frequencies.
7. The concrete will be prepared by batching plant / mixer machine. In case the
mixer machine is used the required quantity of material as per the design mix will be
established by calibrated weigh batcher on the site of mixing.
8. The weigh batcher will be checked prior to concreting, to establish that it is in
order and is ready for concreting.
9. After completing of above said process the concrete will be started. To
establish the pour height level pegs will be driven.
10. During the concreting the representative samples of concrete shall be taken
and cubes will be cast. The cubes will be marked with date of pour, grade and
identification of structure. The cast cubes will be cured in curing tank constructed near
site of structure.
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11. After de-moulding the cubes will be shifted to the main project lab for further
testing.

3. Tools and Machinery

1. Measuring tape
2. Concrete Batching Plant
3. Concrete Pump/ Crane & Bucket as required
4. Transit Mixers as required
5. Needle Vibrators
6. Cube Mould.

WP – 26: METHODOLOGY FOR BOX CULVERTS

This item of work deals with construction of Box culverts with approved materials as
per the terms of contract agreement.
1. General

The construction shall confirm to the specific alignment, lines and grades given in the
drawing.

The materials used shall adhere to the section 1000 of technical specifications. The
concrete used shall be of approved design mix and shall confirm to section 1700 of
MoRT&H specifications.

2. Procedure
Diversion of Water:
The requisite and efficient methods are adapted to suit the particular need of
diverting the water.
Excavation:

1. Layout marking will be done as per approved working drawing and ground
levels will be taken and recorded jointly
2. Excavation will be done conforming to the lines, grades, slopes and levels as
shown on the approved working drawings, as per the MoRT&H specification clause
304.3.2
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3. If required dewatering will be done as per the MoRT&H specification clause
304.3.3
4. All the excavated materials will be disposed such that the working space will
not effect, as per the MoRT&H specification clause 301.3.11
5. Excavation in Hard Rock will be done as per MoRT&H specification clause
301.3.5
6. Preparation of foundation will be done as per MoRT&H specification clause
301.3.4
7. if there is any slips & slip outs in the excavation will be removed
8. Filling below foundations up to require level and backfilling will be done with
approved material in layers not exceeding 150mm compacted thickness. The
compaction will be done with the help of suitable equipment such as mechanical
tamper, plate vibrator etc. after necessary watering as per MoRT&H specification
clause 301.3.7

Concreting:
Base Slab: The reinforcement shall be placed in position and shuttering is erected to
exact dimensions of base slab and after due checks, base slab is concreted to the top
of bottom haunch and joints is maintained as detailed in drawing.
Walls: The walls are cast to bottom level of upper haunch. The procedure adopted will
be same as base slab.
Top slab: The shuttering is made to support the top slab and necessary care is taken
to seal the joints to avoid slurry loss from concrete through joints. The steel is
positioned and concreted.
The formwork is removed after due time as per norms and blemishes, if found, are
made good.
The inlet & Outlet structures, the aprons and floor protection works are constructed in
similar progression.
The surroundings are cleared of all surplus stocks, waste materials etc., and cleaned.
The structure is finished as per specifications including necessary markings, paints
etc., and completed.
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3. Equipment/Machinery:
1. Excavator / JCB
2. Auto level with accessories
3. Transit Mixers
4. Needle Vibrators
5. Cube Mould

WP-27: CONSTRUCTION OF OPEN FOUNDATIONS

This item of work deals with construction of open foundations with approved materials
as per the terms of contract agreement.
1. General

This item of work shall be dealt in compliance to the clause 2101 of the MoRT&H
specifications.
The construction shall confirm to the specific alignment, lines and grades given in the
drawing.

The materials used shall adhere to the section 1000 of MoRT&H specifications. The
concrete used shall be of approved design mix.

2. Procedure

Survey:

a) The location points were fixed by a Total station from the established survey
interfacing points.

b) The reference pillars will be fixed in such a way that they are not disturbed during
the course of excavation.

Excavation:

a) Excavation will be done to the size of the foundation plus safe working space
including necessary slopes as per site condition.
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b) At some locations if the surface is below sub soil water level requires de-watering,
and then the same will be done by installing adequate capacity pumps. Necessary
cofferdams and cribs shall be constructed and shall be removed after completion. All
necessary sheeting, shoring, bracing if required shall be provided.

c) If hard rock is encountered while excavation, suitable procedures will be adapted

like
1. Pneumatic breaking using compressor and pavement breakers
2. Wedge and hammer method i.e. drilling and splitting of rock
3. Control blasting and de mucking
Any one of the procedures will be adapted to suit the site conditions.

d) Excavation will be carried out to the required depth as per the foundation details
given in the drawings and if there are any obstructions /hindrances are there in the
course of the work then they will be immediately brought to the notice of the
Concessionaire / IEfor their necessary instruction/action.
Surface dressing will be done before doing the PCC.

e) If Excavation done more than required depth, the extra depth of exaction should be
filled with sand or by soil compacted in layers till it reaches the desired level of PCC.

PCC:
Marking will be given as per the drawing on dressed surface by using Total Station.
Side shuttering should be provided of the required thickness and size of the footing
plus offset for PCC
Required grade of concrete should be laid by using Transit Mixtures and chute.
Compaction should be done by hand rammer.
PCC of required thickness and grade will be laid on the dressed surface.

Reinforcement & Form Work:

Marking will be given as per the drawing over PCC by using Total Station.
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Bar Bending schedule should be prepared as per Drawing and IS1786.Fabrication of
Reinforcement should be done as per the BBS.
Reinforcement will be tied over the PCC for footing and substructure as per the
drawings and proper formwork will be fixed to suit the requirement and as per
drawings.

Concreting:
Concreting shall be done either by crane/bucket or by a concrete pump or manually
whichever suits the situation and grade of concrete will be maintained as per
drawings.

3. Tools and Machinery

1. Excavator/ JCB
2. Total Station/ Theodolite with accessories
3. Auto level with accessories
4. Measuring tape
5. Concrete pump/ Crane & Bucket as required
6. Transit Mixers as required
7. Needle Vibrators
8. Cube Mould.

4. Tolerances

1. Variation in dimensions : +50mm -10mm

2. Misplacement from specified position in plan : 15mm
3. Surface irregularities measured with 3m straight edge :+5mm
4. Variation of levels at the top : +-10mm.

WP-28: FOR CONSTRUCTION OF PILE FOUNDATIONS

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Method statement for Piling:

General & Salient Features:
1. The Dia. of Piles & Grade of concrete to be used for piles is as per mentioned in
drawings.
2. The Hydraulic Rig will be used for piling activity
3. Mild steel liner of 8 mm thickness will be used till the start of the up to reusable
strata in Pile bore hole.
4. All the reinforcement for the pile will be approved by the Concessionaire / IE.
5. Circular cover blocks of Concrete with the same strength of Pile concrete will be
used on the sides to maintain the required cover of 75mm to the reinforcement an
appropriate design mix may for M-35 shall be made with which cover blocks will be
cast.
6. The boring will be carried out according to the sub-soil investigation report at that
location. It will be done with Liner, Bentonite or both.

2.1 Pile Installation with Bentonite:

1. Pile installation procedure with bentonite has been described in the following
steps
2. The piling Hydraulic Rig will be mobilized at the approved location for Pile
boring.

3. Pile points shall be marked at exact pile locations as per relevant bridge
structural drawings with Total Station and checked. The center line of the Kelly shaft is
aligned vertically with the center line of the pile.

4. Four reference points (perpendicular to each other) to be marked for checking

center of the pile bore hole during the boring of pile..

5. Initial boring of about 1.5/2.0 meters is to be done using bucket of desired

diameter of pile.
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6. The Temporary guide casing, approximately 2.0 to 3.0 M length with outside
dia. is equivalent to nominal dia. of the Pile, is then lowered in the bore hole.

7. Position/center line of the guide Casing pipe with reference to pile reference
points already fixed around the pile locations shall be checked to shift/adjust the
casing pipe to ensure that drilling will be proceeded at exact pile locations without any
deviations.

8. The dia. of cutting tool/Bucket will be maximum 75 mm less than outside dia.
of casing/guide pipe for free movement of the bucket in the casing pipe during drilling
operation.soil\rock samples from bore shall be collected at every 2m interval or
change observed in strata as directed by the Concessionaire / IE.

9. The bore hole is then filled with Bentonite slurry, fed from Bentonite
installation. Bentonite circulation channel shall be made from bore hole to Bentonite
tank and fresh Bentonite slurry shall be pumped to bore through hose pipes installed.
Bentonite powder is to be mixed in the fresh water tank at least 24 hours prior to start
of Pile boring to ensure that Bentonite is completely dispersed in the water and attains
required density to stabilize the sides of bore hole during drilling. Bentonite slurry of
specified quality shall be circulated continuously during boring process.

10. Bentonite used to stabilize the sides of bore hole should be conforming to
requirements as listed in Inspection and Test Plan. Density of Bentonite solution
should be checked during boring operation to ensure that the density is about 1.05
g/cc to 1.10 g/cc, Marsh Cone Viscosity 30 to 40, pH Value 9.5 to 12.

11. Bentonite slurry is pumped by high-pressure 15 to 20 HP reciprocating

pumps/vertical pump into the bore hole and the same is allowed to overflow the bore
hole. The overflow slurry with bored mud/soil etc. that comes out along with Bentonite
slurry is passed through channels and is collected in sediment tanks where sediments
settle and Bentonite can be re-used. If necessary, the Bentonite may be passed
through the de-sander tank to remove sand particles before it is re-used.

12. Boring is done up to the founding strata as per drawings/ specifications etc.
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13. Depth of Pile shall be checked with sounding chain and exact depth shall be
recorded in the Pile report.

Reinforcement Cage Lowering:

1. Prefabricated reinforcement cage prepared as per the drawings and approved
depths, is brought and kept near pile location while boring is in progress.

2. After getting the permission from the Concessionaire / IE the reinforcement

cage will be gently lifted and lowered by crane into the bored hole. Necessary
concrete cover will be obtained by using the circular cover blocks

3. If the reinforcement cage is very long i.e. not possible to handle in one lift, the
cages will be lifted one by one and spot welded at the lap joints and then lowered
inside the bored hole.

4. It is to be checked whether the reinforcement cage has to be reached upto

bottom of the Pile by measuring from the top of the cage to the ground level.

3.0 Flushing
1. After the cage lowering, 200 mm diameter Tremie pipes in suitable lengths are to be
lowered in the hole. The operation is done by lowering one Tremie pipe after another
and connecting them by threading or bolting to maintain water tightness throughout
its length till the gap between the pile base and the Tromie pipe bottom is between
75 -150 mm. The Tromie pipe is locked / supported from top to maintain the level
and funnel is attached on top.

2. The Tremie Head to be provided to the tremie pipe for the flushing activity.
The bore is flushed by fresh Bentonite slurry through the tremie head. The pumping
for the flushing is done by use of mud circulation pump. Flushing will be done to
remove all the loose sediments which might have accumulated on the founding strata.
Further, the flushing operation shall be continued till the consistency of inflowing and
out-flowing slurry is similar.

4.0 Pile Concreting :

After flushing is completed, Tremie head should be removed and funnel should be
attached to the Tremie pipe,
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1. The slump of concrete will be maintained at 150 mm to 200mm at site.

2. Concreting operation will be carried out using the 200 mm diameter Tremie
pipes.

3. Initial charge of concrete should be given in the funnel using a plug. Total
concrete quantity in the funnel should be more than the volume of the entire pipe plus
free space below the Tremie. This will ensure a watertight concrete pouring through
tremie.

4. Lifting and lowering is repeated keeping sufficient concrete in funnel all the
time. As the concreting proceeds the Tremie pipe are to be removed one by one,
taking care that the Tremie pipe has a minimum embedment of 2m in the concrete
and shall not be withdrawn from the concrete until the whole pipe is concreted.
Whenever transit mixer cannot reach up to the funnel wheel barrows can be used for
transporting concrete.

5. The concrete is poured in the funnel using transit mixer chute. As the concrete
reaches the top of the funnel, the plug is lifted up to allow the concrete to flow
corresponding to the placing of each batch of concrete.

6. The concreting of Pile is to be done up to 1 m above the cut off level to get
good and sound concrete at cut off level. After completion of concreting the excess
concrete above cut off level up to 700-1000 mm to be removed by manually while the
concrete is in green state.

7. After completion of concreting Tremie, hopper, funnel and other accessories

are to be washed properly and kept greased (threading) in proper stacking condition
near next pile location.

Casting of Pile Cap:

1.0 Salient Features:
The excavation of the pile cap can be started immediately after the last pile of the
particular pile cap group is over. Only precaution is to be taken that minimum 48 hrs is
given for excavation surrounding the last pile of the pile group. The reinforcement will
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be placed at site after all the piles of one group are concreted and excavation and
PCC are completed.

2.0 Excavation and PCC

1. Pile cap layout will be done accurately and excavation will start by
mechanically i.e. Excavator / JCB or manually as per accessibility to site.

2. Excavation of the Machine will be done up to bottom level of PCC roughly and
leveling will be done using manual labour.

3. The bottom of the pile cap will be properly rammed using hand rammers. All
the levels will be checked and the center of the pile cap will be marked properly.

4. The projected portion of the piles shall be broken using chisel and hammers
or breakers up to cutoff levels as shown in the drawings. Projected reinforcement from
the piles shall be straightened and given ‘L’ bend as per drawings.

5. For PCC, required grade of concrete will be poured and compacted to achieve
the desired levels. PCC will be poured to get the required thickness as per drawing.
PCC will be done as per dimensions given in the drawings Compactions of the PCC
can be achieved with the help of ramming manually.

3.0 Pile Cap Construction

1. All the reinforcement in the pile cap should be cut bend as per approved BBS
and pre-bend are brought to the site and pre stacked during the PCC operation with
proper care should be taken that the reinforcement should be stacked on wooden
planks/ sleepers or suitable packing above the ground.

2. Once PCC has set, the pile – cap reinforcement can be tied on site. Before
laying the reinforcement layout on the PCC should be carried out.

3. Simultaneously, the side steel shutters for the pile – cap will also be kept and
locked to each other. However for ease of working shutter placing is done after
reinforcement placing and bending is complete.

4. Cover of 75 mm is provided to the reinforcement using appropriate cover

blocks.
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5. All the reinforcement for the pier column/ abutment column also be fixed along
with the pile caps bars after checking the pier center line.

6. Chairs to be provided, so that there is no sagging in the top layer

reinforcement.

7. Reinforcement to be got properly checked by Concessionaire Engineers

including the top layer of dowel bars of the pier before start of concrete.

4.0 Concreting of pile cap:

1. The design mix of the required grade will be used from the Ready Mix
concrete plant. It is to be ascertained that Design mix is approved well in advance.

2. Concreting will be done using direct chuting or if direct chuting is not possible
than by pumping.

3. Concreting will start from far end of the pile cap and after proper vibration
using 60 mm needle vibrators and will be done in layers taking from one corner to the
other. Thickness of the one layer will be generally be 500mm but if total thickness of
pile cap is less than 1000mm than it could done in one layer.

4. Finishing of the Pile cap will be done in with the help of wooden float manually
and top level of the pile cap to be checked before concrete sets.

5. After initial set of concrete in 3-4 hours, wet Hessian cloth is laid on the top of
the surface of the pile cap and constantly watered.

6. All de-shuttering operation are started after the initial set of concrete and
taken to the next pile – cap. Care to be taken so that edges are not damaged during
De-shuttering / stripping operations

7. Curing of Pile cap to be done by ponding for minimum seven days.

Tests to Be Carried

1. Initial & Routine pile Load test to be done as per IS : 2911 ( Part I / Sec-2) -
1979, Code of Practice for Design and Construction of Pile Foundations, Concrete
Piles, Bored Cast in-situ piles, including Amendment No.3
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2. IS: 2911 Part-IV, Load tests on piles.

Site Record to Be Maintained

The site records shall have the following information.

1. Date of construction
2. Component concreted
3. Pile Concreting during the day
4. Concrete test cubes taken/results of previous cubes tested that day.
5. Plant and equipment used
6. Labour deployed
7. Weather conditions
8. Problems encountered, if any.
Materials

1. Mild Steel Liner

2. Bentonite
3. HYSD steel reinforcement bars
4. RCC Concrete as per GFC drawings.
5. Shuttering plates

Major / Minor Equipment’s and Machinery

1. Concrete Batching Plant

2. Transit Mixers
3. Crane/Hydra
4. Tripod Rig / Rotary Rig along will all accessories.
5. Concrete bucket 0.75 M3 capacity
6. Dewatering pumps
7. Air compressor with receiver
8. Flood light system for night work
9. Total station
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10. Auto Level instrument

WP-29: FOR CONSTRUCTION PRE-STRESSING WORKS

(Acceptance criteria: Ref. Sec. 1800 of MoRT&H)

1. General

This work shall carry out in accordance with the drawings and specifications for ROB,
river bridges, minor bridges and elevated structures.

2. Materials

Cement: The cement to be used in the works shall be Ordinary Portland Cement of
43/53 grade confirming to IS 269. The manufacturer test certificate shall be furnished,
and cement shall be stored as per IS 4082.

Water: The water to be used shall be free from oils, acids, alkalis, salts, sugar,
organic materials or other substances that may be deleterious to concrete and steel.
Potable water generally considered satisfactory. The water to be used shall satisfy the
requirements as per clause 1010 of MoRT&H specification.

Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong, dense,
non-porous and durable pieces of crushed stone. All coarse aggregates shall confirm
to IS 383, when tested in accordance to IS 2386 parts 1 to 8. The grading of coarse
aggregate shall confirm to table 1000-1 of MoRT&H specification.

Fine aggregate: Fine aggregate shall consist of clean, hard, strong, dense, and
durable pieces of crushed stone or natural sand or a combination of both. All fine
aggregates shall confirm to IS 383, when tested in accordance to IS 2386 parts 1 to 8.
The fineness modulus of fine aggregate shall not be less than 2.0 or greater than 3.5.
The grading shall confirm to table 1000-2 of MoRT&H specification.

Admixtures: Admixtures shall confirm to the requirements of IS 9103. The

manufacturer test certificate shall be furnished, and shall be approved by the
Concessionaire / IE.

Reinforcement Steel: For pre-stressed concrete the reinforcement shall be

confirming to IS 1786-2008 HYSD bars. The steel supplied with test certificate shall be
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assembled in accordance with approved drawings and shall ensure storing to avoid
deterioration and corrosion.

Pre-Stressing Steel: The material shall confirm to low relaxation Pre-stressing steel
strands of 12.7mm HTS, class-2 as per IS 14628. High tensile steel and strands shall
be supplied in sufficiently large diameter coils, so that the tendon retains its physical
properties.

Sheathing: The sheathing ducts shall be of the high-density polyethylene or similar

non-chloride containing material, spiral-corrugated type. Unless otherwise specified,
the material shall be cold rolled cold annealed (CRCA) mild steel confirming to IS513.
The thickness of sheathing shall be as shown in drawings. Where joints are
unavoidable, such joints shall be slurry tight by use of corrugated threaded sleeve
couplers not less than 150mm in length. The joints shall be sealed with adhesive
sealing tape to prevent penetration of cement slurry. The internal area of the
sheathing shall be in accordance with the recommendations of the system
manufacturer or in case of 12T13 size of tendons, comprising of 12.7mm dia 12nos.
the inner dia of sheathing shall not be less than 75mm respectively or as shown in the
drawing, whichever is greater. Where pre-stressing tendons are required to be
threaded, before concreting the diameter of sheathing can be 5mm less than the
specified above.

Anchorages: Anchorages shall be produced from authorized manufacturers only,

confirming to BS 4447. No damage Anchorages shall be used and all steel parts shall
be protected from corrosion, threaded parts shall be greased, suitable plugging shall
protect tapped holes, until used.

Grouting Cement: The material shall be CONBEX 200 manufactured by Fosroc or

equivalent.

All Tendons, Anchorages, Sheathing-cones, bearings & wedges received

shall be assigned a lot number and tagged for identification. The manufacturer test
certificates shall be maintained for every lot, in addition to these, the data of previously
conducted and most recent results of “Acceptance Testing”, such certificates shall not
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be more than 12 months old at the time of making the proposal for adoption of a
particular system for the project.

3. Procedure:
Preparatory Works:
1. The coils shall be uncoiled with suitable safety arrangements and any
damaged, kinked or bent shall not be used.

2. Strands shall be cut using Disc cutter / Cutting wheel.

3. Calculate the cutting length as per approved drawings and add grip length.

4. Clean the strand with mixture of water-soluble oil such as Dromas-B.

Sheathing, Laying & profiling:

1. Cutting, bending and tying of reinforcement shall be as per Work Procedure
No.WP-10.

2. After completion of reinforcement, the sheaths shall be laid made as per the
profile shown in the drawings on the pre-fabricated saddles, so that the profile of
cables is not disturbed during vibrations, by pressure of wet concrete, by workmen or
by construction traffic.

3. Any reinforcement falling in the line with the sheathing shall be deviated
locally.

4. The sheathing shall be joined with suitable couplers made out of parent
material and sealed by wrapping self-adhesive tapes.

5. Fix the Anchorages on the both ends of the cable, in the end of the cable and
fix the end anchorage reinforce0ment as per approved drawings.

6. Check the alignment of the cone box.

7. Insert the dummy pipe or rope or any other suitable means, inside the duct to
encounter the blocking.

8. Formwork & Concreting shall be done as per Work Procedure No. WP-10.

9. After 4hours of concreting, remove the dummy and clean the duct.
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Cable lifting, threading and anchorage fixing:
 Lifting of cables/strands shall be done manually, safely without causing any damage.

 Thread the cable manually one by one or bunch depending upon the site condition.

Stressing:

1. Stressing shall be done in sequence as per the contract specification/drawing, after

concrete attaining required strength.
2. Make suitable arrangements for jacks & pumps.
3. Before starting the stressing operation, strands projecting outside the Anchorages
shall be cleaned, to be free from oil, dust, etc.
4. Bearing plate shall be cleaned and positioned at both ends of the cable. Wedges
shall be checked for cracks/deformation and free from oil before placing in position.
5. Bearing ring shall be placed over the bearing plate and located on dowel, screwed
into the tube unit.
6. Wedges shall be checked to ensure correct seating.
7. All stressing equipment shall be cleaned and checked before put into the operation.
8. Stressing jack shall be placed at the both ends of the cable and check the proper
seating of master wedges in the jack.
9. Cable shall be stressed to the required load and elongation, and sequence as given
in the approved drawings.
10. Final lock off for wedges shall be done after stressing is complete.
11. All stressing values/ reports shall be recorded in a format.
12. Strands protruding beyond wedges shall be cut 20-40mm away from the wedge face
using cutting wheel after 24hours of stressing operation.

Grouting:
1. After Pre-stressing is completed, sealing of tendons shall be done at the both ends
by means of cement mortar.
2. Union/ ball valve shall be fixed in the inlet end of guide cones.
3. Ducts shall be cleaned with water using compressor.
4. Air shall be flushed in the ducts to make it dry.
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5. Water used for grouting shall be potable, free from impurities and the grouting shall
be fresh and free from any lumps.
6. Water-Grouting cement ratio shall not exceed 0.4 and suitable non-aluminum based
expanding agent of 0.45% by weight of cement shall be added, and the mixing time
of grout shall be 2-3 minutes.
7. Grout in the collection drum shall be kept in continuous slow agitation by means of
agitator until pumped into the duct.
8. Grout shall be pumped into the duct by means of a positive displacement
reciprocating or hand operated grouting pump.
9. Grout shall be pumped and allowed to flow freely from the outlet end until the
consistency is same that of the inlet end is achieved.
10. As soon as the grouting is completed the out let end shall be closed off by means of
key plug.
11. Grout shall be pumped again to fill up the cavities if any, and full injection pressure of
5kg/sq.cm shall be maintained for 1 minute.
12. The inlet end ball valve shall be closed and pressure shall be released from grout
pump.
13. Plugs/ball valves shall be removed after the grout was set.

Corrective & Preventive action:

a) Minimum strength of concrete at the time of tensioning shall be 32Mpa or

as recommended by the system manufacturer, whichever is higher.

b) If elongation achieved before the calculated gauge pressure is attained,

stop stressing and inform the Engineer.

c) If the calculated elongation is reached before the calculated gauge

pressure is obtained, continue tension till attaining the calculated gauge
pressure; provided the elongation does not exceed 1.05 x calculated
elongation.

d) If the calculated elongation has not been reached, continue tensioning by

intervals of 5kg/sq.cm, until calculated elongation is reached; provided the
gauge pressure does not exceed 1.05 x calculated gauge pressure.
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e) If the elongation at 1.05 x calculated gauge pressure is less than 0.95 x
calculated elongation, the following measures shall be taken in
succession, to define the cause of this lack of elongation.

a) Recalibrate the pressure gauge.

b) Check the correct function of jack, pump and leads.
c) De-tension the cable.
d) Slide it in its duct to check that, it is not blocked by mortar, which has entered
through the holes in the sheath.
e) If it is free, re-tension the cable.
1Pre-stressing materials like, sheathing, strand, anchorages, jacks, pumps, hoses
shall be kept under cover.

2Pre-stressing strands shall be stacked over platforms more than 300mm and
covered.

WP – 30: FOR FIXING OF EXPANSION JOINT

(Acceptance Criteria: Ref. Section 600 of MoRT&H)

1. General

The work shall consist of fabrication and placing of expansion joints as indicated on
the technical drawing and conforming to the MoRT&H specification.

2. Material

The specification of materials, fabrications, handling, storage, installation, text and

standards shall be complied with the requirements of MoRT&H.

3. Procedure

 The gap between the steel edge members shall be adjusted depending on the
temperature at the time of installation of the expansion joint using the clamp plate
arrangement.
 The Expansion joint is lowered in position into the block out
 The level and gradation is adjusted. Matching with the final finished level of the deck
slab at the carriage way.
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 The anchor studs are secured to the deck reinforcement adequately by welding.
 Additional steel bar may also be used to achieve integrity with the deck slab
 Necessary farm work is installed.
 Concrete of the specified mix is poured in to the block out ensuring proper
compaction
 Clamp plates are removed.
 Block out are cured properly.
 To maintain a uniform joint opening and extrusion parallelism a string line shall be
used.

WP-31: FOR FIXING OF DRAINAGE SPOUTS

This item of work deals with fixing of drainage Spouts and drainage pipes in bridge
decks as per the terms of contract agreement.

1. General
This item of work shall be dealt in compliance to the clause 2705 of the MoRT&H
specifications.
The drainage spouts shall be of not less than 100mm in diameter and shall be of
corrosive resistant material.
2. Procedure

Fabrication:
The drainage assembly shall be fabricated to the dimensions shown on the drawings,
the components shall be of mild steel confirming to IS: 226 .The drainage assembly
then shall be seam welded for water tightness and then hot-dip galvanized.

Placement:
The galvanized assembly will be placed in the provision made in the deck slab by
using dummy, which is removed in the appropriate time to leave a slot exactly fitting
the galvanized assembly. The galvanized assembly shall be given two coats of
bituminous painting before placement. The whole assembly shall be placed in true
position, lines and levels as shown in the drawing and held in place firmly.

Finishing:
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The gap between the galvanized assembly and the slot are sealed by using
bituminous sealant and the excess sealant trimmed to receive the wearing coat. After
the wearing coat is completed, similar sealant shall be finished to cover at least 50mm
on the wearing coat surface all around the drainage assembly.

3. Tools/Equipment

1. Measuring tape
2. Auto level etc.

WP-32 :METHODOLOGY FOR MINOR & MAJOR BRIDGE

(Acceptance criteria: Ref. IRC &MoRT&H Specification)

1. SCOPE :-
This method statement covers the construction of Minor Bridge at various location. It
shall consist of furnishing and providing plain and reinforced concrete foundation placed
in open excavation, Substructure and Superstructure in accordance with the drawings
as per MoRT&H Specifications & drawing.

2.0 REFERENCES :-

1. Ministry of Road Transport and Highways specification.

2. Relevant drawings.
3. IRC IS Codes and SP 13.

3.0 WORKING DRAWINGS :-

Working drawings, structural drawings and bar bending schedules will be submitted
to the Concessionaire / IE prior to start the work on site. After approval of the above
submissions by the contractor, the setting out of the structures shall be done.

4.0 MATERIAL :-

4.1 Shuttering and staging Material:-

Formwork shall be of steel with steel fixtures. Vertical and horizontal joints shall be
sealed with foam type of material to prevent possible leakage of cement slurry during
concreting. Formwork shall be erected on stay soldiers with the help of tie rods, props
and pipes. Shuttering shall be leveled and aligned to the true lines.
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Staging shall be designed with adequate safety margin to hold the load of the
concrete. Scheme shall be submitted with the design calculations for the
Concessionaire / IE approval.

4.2 Reinforcement bars :-

Reinforcement bars shall be procured from the approved manufactures. Test

certificate shall be obtained with each consignment.
On clearance of the consignment, bars shall be cut and bent to the size and shape
as per approved bar bending schedule and tied on the site as per the relevant
drawings and specifications.

5.0 CONCRETE MIX :-

Approved concrete mixes of the required compressive strength shall be used in the
construction of various elements of the structure. The characteristics of constituents of
the concrete mix shall conform to drawing, MoRT&H, IS Codes & IRC Codes.
Compliance of the constituents shall be controlled as per the above Codes and
Specifications.

6.0 EQUIPMENT DETAILS :

Following equipment’s shall be deployed in the execution of this bridge:

6.1 Excavators
6.2 Dumpers
6.3 Batching & Mixing Plant
6.4 Transit Mixers
6.5 Concrete Pump
6.6 Lifting Crane
6.7 Welding Machines
6.8 Vibrators
6.9 Water pump or other dewatering arrangements

7.0 PERSONNEL FOR EXECUTION & SUPERVISION:

A team comprising of a Manager, Engineer, Assistant Engineer & supervisors shall

be deputed to execute the above job. Stage inspections shall be done by the
Structure site Engineer to ensure the conformance to the MoRT&H Specifications, IS
Codes & IRC Codes.

8.0 CONSTRUCTION SEQUENCE :-

a. Soil Exploration & confirmation of founding level.

b. Excavation of abutments & piers portion 300mm above the founding level.
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c. Water table at founding level will be lowered by excavating pit near the
foundation. The depth of pit will be 1 more below the founding level. Water
pump will be installed at pit to pump water.
d. Construction of raft for all piers.
e. Construction of piers.
f. Annular/Backfilling of the completed stages of the piers up to required level.
g. Erect staging as per the available staging system.
h. Excavation for abutments up to founding level.
i. Casting of raft for abutments.
j. Construction of abutments.
k. Staging arrangement for all spans.
l. Fixing bearing after casting of bearing pedestal.
m. Fixing shuttering and formwork as per approved materials and setting out
checking before placing of reinforcement for slab.
n. Pouring of slab and its arrangement inspected before the start of pouring.
o. Back filing with filter media as per approval section and material.
p. Fixing of expansion joints .
q. Construction of crash barriers and approach slabs.
r. Laying of Wearing coat.

9.0 CONSTRUCTION OPERATIONS: -

9.1Setting out:

After the site has been surveyed and OGL recorded the limits of excavation shall be
set out to true lines, curves, slopes as per the drawings.

9.2 Excavation.

The excavation for founding levels of abutments and piers shall be done in two
stages. Excavation up to 300 mm above the abutment founding levels shall be done
in first stage to keep the founding level for abutments undisturbed, trimming the side
slope to 1 horizontal and 1 vertical if required.
Excavation upto the Founding levels of piers shall be done in the second stage,
trimming the sides slopes to 1.5 horizontal and 1.0 vertical if required or as per true
size.

9.3 Lean Concrete.

Lay out for the structure shall be done. Formwork of the required size and length
shall be provided for laying and placing lean concrete over the approved excavated
base.

9.4 Reinforcement Fixing:

Rebar’s prepared to the shape and size as per approved bar bending schedule shall be
fixed in position and tied using binding wire as per the requirement of the relevant
drawings and got inspected. Bar shall be bent cold to the specified approved shape and
dimensions using proper bar bender operated by hand or machine. Layers of the
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reinforcement shall be separated by spacer bars at approximately 1 meter. The
maximum size of the spacer bar shall be 20mm or equal to maximum size of rebars or
maximum size of aggregate, whichever is greater. Necessary stays cover blocks, metal
chairs, spacers, metal hangers, supporting wires etc. shall be provided as per site
requirements to fix the reinforcement firmly in its correct position.
9.5 Design, Erection & Removal of Form work.

The design and erection of formwork shall be as per IRC- 87 & conforming to
MORTH section 1500. Convenient removal of the shutter without disturbing the
concrete shall be ensured. Design shall be to facilitate proper and safe access to all
parts of formwork.
Staging shall have cross bracing and diagonal bracing in both directions. Staging
shall be provided on firm strata.
The inside surface of the forms shall be coated with approved release
agent supplied by the reputed manufacturer to prevent adhesion of concrete to
formwork. Application shall be strictly as per manufacturer’s instruction and shall not
be allowed to come into contact with any reinforcement other embedment.
The formwork shall be removed in such a way that it does not cause
damage to the concrete surface. Centering shall be lowered gradually and uniformly
to prevent the concrete to take stress due to its own weight uniformly and gradually
to avoid any shock or vibration. Period of removal shall be as per section 1500 of
MoRT&H.

9.6 Mixing, placing and compaction of Concrete.

9.6 (a) Concrete mixing:-

Concrete shall be mixed in approved proportions in batching and mixing plant or in a

concrete mixer (clause 1708 of MoRT&H).

9.6 (b) Placing and compaction of concrete: -

Concrete shall be placed as near as possible to its final position so that no

contamination, segregation, loss of its constituents material take place. It shall not be
freely dropped into place from a height exceeding 1.5m. All formwork and reinforcement
fixed shall be cleaned and made free from standing water and other unsuitable material,
prior to concreting. Concrete shall be deposited in horizontal layers to a compacted
depth of not more than 450 mm when internal vibrators are used

10.0 CONSTRUCTION JOINTS: -

Construction joints shall be avoided as far as possible and in no case the location of
the joints shall be changed or increased from those shown on drawings except with
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approval from Concessionaire / IE. The joints shall be provided in a direction
perpendicular to the member axis or as shown on Drawing.

11.0 PROTECTION AND CURING OF CONCRETE:-

Exposed surfaces of the concrete shall be kept continuously in a damp or wet

condition by ponding or by covering with a layer of sacks, convas, hessian or similar
materials and shall be kept constantly wet for a period of 14 days from the date of
pouring concrete and as per clauses 1713 of MoRT&H.

12.0 SAFETY: -

12.1 During construction of Bridge adequate safety & traffic sign shall be installed adjacent
to the road shoulder to protect the ongoing work.

12.2 Bridge location shall be provided with visible safety & Road signs.

12.3 During construction of Minor Bridge minimum 2 flagman with reflective vests and
holding a red flag each shall be deployed to control the traffic, which may be effected
by the construction operations.

12.4 The Safety Officer shall make frequent patrols of construction site to ensure that the
safety equipments and signs are operational at all time.

12.5 Other safety arrangement shall be as per approved safety manual.

WP-33: METHODOLOGY SUB & SUPER STRUCTURE OF THE BRIDGES

(Acceptance criteria: Ref. IRC &MoRT&H Specification)

SCOPE:

Construction of Substructures and Pre stressed Superstructures.

CROSS REFERENCE:

 Contract specifications.

 IRC - 18 (2000): - Design Criteria for Pre stressed Concrete Road Bridges.

 IRC-83 (2000): - Standard Specifications and Code of Practice for Road Bridges –
Bearings: - Part (I & II)

 IRC-5 (1998) Standard Specifications and Code of Practice for Road Bridges –
Section I –General features of Design (7th Revision)

 IRC-6 (2000) Standard Specifications and Code of Practice for Road Bridges –
Section II – Loads and Stresses (4th Revision)
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 IRC-21 (2000) Standard Specifications and Code of Practice for Road Bridges –
Section III – Cement Concrete (Plain & reinforced) (3rd Revision)

 IRC-78 (2000) Standard Specifications and Code of Practice for Road Bridges –
Section VII-Foundation & Substructure (2nd Revision)

EQUIPMENT/MATERIAL REQUIREMENT:

Equipment’s to be deployed:
The major construction plant and equipment to be deployed for execution will be as follows.

Material requirement
 Reinforcement Steel ( TMT)/HYSD Bars as per grade specified in the contract
Conforming IS :1786 (only uncoated steels shall be used).All reinforcement shall be
free from loose mill scales, loose rust and coat of paints, oil, mud or other coatings
which may destroy or reduce bond (as per IS: 456).
 Aggregates
 Sand
 Cement
 Admixture
 Grout Cement

Pre stressing materials, Bearings and Expansion Joints:

 HT Strands
 Other Pre stressing Materials (Anchorage Cones, Sheathing Pipe, Bearing Plates
and Wedges).
 Expansion Joints
 Elastomeric Bearings
 POT – PTFE Bearings
Approval of manufacturing agency will be taken prior to ordering of material (Viz.: HT
Strand, Other Pre stressing Materials, Expansion Joints, Elastomeric Bearing &
POT-PTFE Bearing). When the material is ready, the Agency will be informed for test
and it will be tested in presence of Concessionaire / IE. Only tested material will be
procured. Testing of materials will be carried out as per Indian Standard
Specification (IS,IRC& MORT&H)

CONSTRUCTION METHODOLOGY:
1) Method of Substructure Construction
2) Method of Superstructure Construction
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METHOD OF SUBSTRUCTURE CONSTRUCTION:

1. Setting Out

2. Fabrication Of Shuttering for Substructure

3. Reinforcement, Shuttering & Concreting for Substructure

4. Time Cycle for Substructure

Setting out:
Centre line pillars of sufficient heights on both side of the structure will be installed & survey
points will be marked over the well cap or pile cap, as applicable, on either direction of the
alignment by total station from control points. A temporary benchmark shall also be
established near the bridge site. The benchmark shall be checked regularly with respect to
the permanent benchmark established at the bridge site.

Fabrication of shuttering for sub structure:

Fabrication of shuttering will be done at centralized fabrication yard as per required size
and shape.

Reinforcement, shuttering & concreting for substructure:

If the pier height is within 2.5m it may be cast in single pour with suitable arrangement like
tremie pipe or proper designated chute. Otherwise it will be cast as per approved Formwork
drawing or as advised by the Concessionaire / IE.

 Clean the concrete surface and reinforcing bars by wire brush & by tamping to
remove loose deleterious material.

 Clean the shuttering plates and apply shuttering releasing agent on the facing
concrete surface. (Shuttering plates shall be cleaned off any traces of previous
concrete).

 Reinforcing bars will be cut and bent at the central rebar yard as per bar bending
schedule approved by Concessionaire / IE and transported to site using suitable
means. Fixing of reinforcement will then be carried out for pier.

 Fix the shuttering for 1st lift. To make the shutter joints leak proof, suitable foam
sheets are fixed between shuttering joints and masking tapes are used at joints to
seal the joints. Formwork shall be erected and all the form panels shall be joined by
bolts to form the true shape, as per the concrete profile. Sufficient supports resting
on hard base will be provided for shuttering.
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 After checking & approval of Concessionaire / IE, concreting for 1st lift will be carried
out. Shear key shall be provided at each lift for vertical construction joint.

 Repeat the above procedure for every lift up to last lift, as per level mentioned in
approved G.A.D (supplementary drawing).

 Weep holes are provided in each lift, as mentioned in supplementary drawing (for
abutments only).

 Survey points for pier cap are marked on pier top after final lift of pier is cast.

 If the cantilever portion of pier / abutment cap is beyond 1.5m length; H Frame
staging may be erected for supporting the cap shuttering. Otherwise, brackets will be
erected on pier / abutment for supporting of cap shuttering.

 Staging arrangement shall be got approval before execution.

 Bottom shuttering will be fixed after necessary staging.

 Reinforcing bars are preferably cut and bent at a central rebar yard as per bar
bending schedule approved by Concessionaire / IE and transported to site using
suitable means. Fixing of reinforcement is carried out for pier cap (Including verticals
of pedestal).

 Side shutters are fixed in position.

 After checking and obtaining required approval, concreting of pier cap is done.

 Pouring of concrete will be done by pump or crane and bucket. Transportation of

concrete will be done by transit mixer from nearest batching plant.

 Side shutters can be removed within 16~24 hrs of concrete, with due approval of
Concessionaire / IE. Cantilever portion of bottom shuttering will be removed when
the concrete attains sufficient strength.

 Vertical face of concrete surface will be covered with Hessian cloth for curing. Water
will be sprayed over top and vertical surface for a minimum of 14 days.

 Transportation & fixing of reinforcement is carried out for remaining pedestal

reinforcement.

 Side shuttering is erected.

 After checking and approval, concreting of pedestal is carried out.

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 Pedestal will be cast over pier / abutment caps as per the drawing.


Under no circumstances the reinforcement with loose mill scales, loose rust and
coats of paints oil, mud or other coating which may destroy or reduce bond should
not be allowed.
METHOD OF CONSTRUCTION FOR SUPERSTRUCTURE:
RCC T-BEAM (With deck slab):
 Locations For RCC T-Beam (with Deck Slab)
 Setting Out
 Fabrication Of Shuttering & Reinforcement for RCC T Beam (with Deck Slab)
 Staging Arrangement
 Bearing Fixing
 Shuttering And Reinforcement
 Checking And Approval
 Concreting
 Time Cycle For RCC T Beam (with Deck Slab)
Setting out:
Centre line pillars of sufficient height on either side of the bridge will be installed and survey
points will be marked over the pier cap on either direction of the alignment by total station
from control points.
A benchmark shall also be established on top of pier cap. The benchmark shall be checked
regularly with respect to the permanent benchmark established at the bridge site and on
centre line pillar.

Fabrication of shuttering and reinforcement for RCC T-beam (with deck slab):

Standard shutters will be procured or required size shutters will be fabricated preferably at
centralized fabrication yard. Reinforcement will be fabricated preferably at centralized yard
and will be transported to site by truck or trailer. Reinforcement will be free from all rust
scaling, dust, oil & all foreign materials etc.

Staging arrangement:

Staging arrangement for all bridges will be H Frame staging over sleepers and other
possible method by cup lock, cribs, even by filling the earth and any other approved
method. Ground on which staging is to be done shall be well compacted and free from
slush and loose material. Drawing and design calculation of staging arrangement will be
submitted for approval.

Bearing fixing:

 Surface of pedestal will be prepared for fixing the bearings with seat
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 Mark the centerline on the top surface of pedestal.

 Elastomeric bearing is fixed in position (using proper adhesive).

 Check the line and level of bearing after fixing.

 Bearings will be fixed when the soffit shuttering is in progress. After fixing the bearings
balance gap of soffit shutters will be filled with wooden planks in levels & true to line.

Shuttering and reinforcement:

 After completion of staging, girder soffit shuttering duly cleaned by cup wire
brush/buffing wheel will be fixed over cross beams in line and level. Shuttering shall be
arranged in such a manner that wooden planks/ply shuttering is least required.

 All the Four girders and cross diaphragm reinforcement will be fixed.

 Fix the deck shuttering along with girder and cross diaphragm side shutters in line and
level.

 Deck shutters will be supported from cross beams of staging, uniformly distributed.

 Fix the deck reinforcement with proper covers.

 Fix the deck side shutters.

 To make the shutter joints leak proof, suitable foam sheets, putty and masking tape will
be used. Suitable shuttering releasing agent will be applied on the surface, facing
concrete.

Checking and approval:

Approval for survey work, shuttering and reinforcement will be taken stage by stage
whenever the activities are completed.

Concreting:

 Concreting shall be done by pump, to be duly vibrated & compacted.

 Concrete will be transported from the nearest batching plant through transit mixers.

 Concrete shall be placed in a continuous pour.

 Remove the side shutters of deck and girders after 7 days.

 Remove girder soffit shutters when the concrete attains full strength
 Keep the provision for expansion joint fixing.

PSC T beam (with deck slab):

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 Locations PSC T-Beam (with Deck Slab)

 Setting Out

 Fabrication Of Shuttering For PSC T Beam (with Deck Slab)

 Construction sequence applicable for Bridges

 Time Cycle For PSC T Beam (with Deck Slab)

 Time Cycle For PSC T Beam (without Deck Slab)

Setting out:

Centre line pillars of sufficient height on either side of the bridge will be installed and survey
points will be marked over the pier cap on either direction of the alignment by total station
from control points. A benchmark shall also be established on pier cap top. The benchmark
shall be checked regularly with respect to the permanent benchmark established at the
bridge site & on center line pillars.

Fabrication of shuttering for PSC T beam (with deck slab):

Standard shutters to fit beam drawing will be procured or required size shutters will be
fabricated at centralized fabrication yard. Reinforcement will be fabricated at centralized
yard and it will be transported to site by truck or trailer. Reinforcement will be free from all
rust, dust scaling, oil and all foreign materials etc.

Construction sequence applicable for Bridges(In-Situ & by side shifting)

 fix the approved staging as explained earlier

 Initially opposite side outer girder, then middle and bed location girder shall be cast.

 Fix one side shutter of 1st span after applying the de-bonding agent.

 Air vent will be provided at middle portion of the span in each cable duct if required.

 Fix the reinforcement steel as per approved bar bending schedule including sheathing
and anchorage cones in profile by providing spacer / support bars.

 To maintain the cover, concrete cover blocks/Polymer will be provided in required

distance.

 Check the cable profile and reinforcement steel (as already approved by
Concessionaire / IE).

 Erect the other side of shutters.

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 Thread the temporary cable or flexible pipe to avoid the blockage of duct just before
concrete and after concreting, remove the same.

 Concrete the first girder with pump duly vibrated & compacted.

 Remove the 1st girder side shutters after 24 hrs.and erect in second span for 1st girder.

 Start the curing after 12 hrs. When the shutters are removed, girder will be covered with
Hessian cloth and water will be sprayed continuously.

 Continue the above activities for next girders.

 Thread the 1st stage cables.

 Stress the 1st stage cables as per pre stressing schedule as mentioned in approved
construction drawing.
 Fix the Pot-PTFE Bearing over the pedestal as per procedure laid down.

 Side shifting procedure of girder will be got approved from consultant prior to the
commencement of work.

 Side shift the girders in position and place over the bearing.

 Cast the middle two girders of both the spans and place them in position over bearing
one after another as per shifting schedule/procedure already approved by
Concessionaire / IE.

 Cast the fourth girder of both the spans directly over the bearings.

 After stressing the 1st stage cables and after three days of completion of grouting,
remove the staging.

 Cut the protruding strands and seal the bearing portion with concrete, keeping the hole
and ball valve for grouting.

 Grout the cables just after prestressing of 1 st stage cables is over with adequate
grouting pressure.

 Erect the cross diaphragms soffits.

 Fix the reinforcement and shuttering for diaphragms as per approved B.B.S.

 Concrete the diaphragm walls with pump duly vibrated & compacted.

 Erect the brackets on girders for cantilever portion to support the deck shutters
(Shuttering arrangement already approved).

 In between two girders deck shutters will be supported on cross beams over bottom
flange. (Shuttering arrangement already approved.)
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 Fix the deck shutters in line and level.

 Fix the reinforcement of deck slab including cantilever portion of gap slab.

 Fix the side shutters of deck slab.

 Check the reinforcement steel as per approved B.B.S.

 Concrete the deck slab with pump & proper vibration & compaction.

 Thread the second stage cables.

 Stress the second stage cables when deck slab concrete attains full strength,

 Cut the protruding strands and seal the bearing portion with concrete keeping the hole
and ball valve for grouting.

 Grout the cables with adequate grouting pressure.

 Erect the gap slab soffit shutters true to line & levels.

 Fix the reinforcement of gap slab (distribution reinforcement).

 Provide stoppers for providing expansion joints.

 Check the reinforcement work and shuttering and do the concrete for gap slab.

 Remove the staging when the concrete attains full strength.

 Recess filling with epoxy motor.

Construction sequence for all Bridges (By Launching Girder)

Casting and launching of PSC girders:

 Launching procedure of girder will be got approved from consultant prior to the
commencement of work.

 Provide trolley / launching arrangements in middle girder portion.

 Erect launching girder in middle girder portion for further spans.

 Fix the one side shutters for 1st girder after applying the debonding agent.

 Air vent will be provided at middle portion of the span in each cable duct if required.

 Fix the reinforcement steel as per approved B.B.S. sheathing and anchorage cones in
profile by providing spacer / support bars (As per schedule of construction drawing).

 To maintain the cover, concrete cover block will be provided at required distances.
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 Check the cable profile and reinforcement steel.

 Erect the other side of shutters

 Thread the temporary cable or flexible pipe to avoid the blockage of duct just before
concrete and after concrete remove the same.

 Concrete the girder with pump duly vibrated & compacted.

 Remove the side shutters after 24 hrs

 Start the curing after 12 hrs when the shutters are removed. Girders will be covered
with Hessian cloth and sprayed with water regularly.

 Erect the same shutter for second bed

 Continue the above activities of girder casting.

 Thread the 1st stage cables.

 Stress the 1st stage cables as per pre-stressing schedule as mentioned in approved
construction drawing.

 Side shift the girders in middle portion and place over the launching trolley and launch
the girders to last span (far end).

 Side shift both out side girders and place over the bearings.

 Cast the middle girder and launch to last span and place over the bearings

 Cut the protruding strands and seal the bearing portion with concrete keeping the hole
and ball value for grouting.

 Grout the cables as per schedule with adequate grouting pressure.

 Remove the last span-launching girder.

 Then cast & launch the further span girders as mentioned above coming from far end to
the 1st span where casting arrangement is made.

 Remove the launching arrangement from the first span.

 Cast the middle girder of 1st span

 Side shifts the girder & place over bearings.

 Cast both outside girders directly over the bearings

 Remove the staging after stressing the 1st stage cables of outside girders.

 Recess filling with epoxy motor.

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Deck slab casting:
 Erect the cross diaphragms soffits after applying the de-bonding agent.
 Fix the reinforcement and shuttering for diaphragms (B.B.S.& soffits arrangement
already approved).
 Concrete the diaphragm wall.
 Erect the brackets on girders for cantilever portion to support the deck shutters.
 In between two girders deck shutters will be supported on cross beams over bottom
flange (Shuttering arrangement already approved).
 Fix the deck shutters in line and level.
 Fix the reinforcement of deck slab including cantilever portion of gap slab.
 Fix the side shutters of deck slab.
 Check the reinforcement steel as per approved B.B.S.
 Concrete the deck slab with pump duly vibrated & compacted.
 Thread the 2nd stage cables.
 Stress the second stage cables when deck slab concrete attains full strength (As per
schedule of supplementary drawing).
 Cut the protruding strands and seal the bearing portion with concrete keeping the hole
and ball valve for grouting.
 Grout the cables as per schedule with adequate grouting pressure.
 Erect the gap slab soffit shutters true to line & level.
 Fix the reinforcement of gap slab (Distribution reinforcement).
 Provide the block out for providing expansion joints.
 Check the reinforcement work and shuttering and do the concrete in gap slab.
 Remove the shutters when the concrete attains full strength.

Pre stressing work:

 Pre stressing Materials.
 Testing of Materials.
 Preparation for Pre stressing Work.
 Post -Tensioning Procedure

Pre stressing materials:

 Sheathing: - As per drawing

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 HT Strands used as per drawing

 Bearing Plates

 Anchorage Cones

 Wedges as per system provider

Testing of material:

Approval of manufacturing agency will be taken prior to ordering the HT strand & other pre
stressing material. Manufacture test reports will be submitted for approval of material. H.T.
Strand and sheathing will be tested in independent laboratory in presence of Bridge
Engineer/M.E as per the frequency set in the MoRT&H.

Preparation for pre stressing work:

 Clean the pre stressing material before use by volatile substance.
 Master wedges are polished & waxed.
 Cut the strands with grip length by mechanical grinders & cutting discs duly cleaned by
cutting oil.
 All bearing surfaces of anchorages shall be cleaned prior to concreting and tensioning
by volatile substances making absolutely free from rust & dust.
 Sheathing duct is cleaned before placing of strands / tendons by cutting oil.
 Fix Bearing plate and permanent wedges duly cleaned.
 Place the multiple jacks in position.
 Place the master wedges in position.
 Hydraulic Jack is connected with pressure gauge.

 Calibrated pressure gauges shall be used.

Post-tensioning procedure:

 Initially RL at mid span shall be taken.

 Divide the loads to be applied in 10 equal intervals.

 Apply some load to remove the slack and take the initial reading

 Start the tensioning of tendons by ten intervals and take the readings of elongation for
every interval.

 Tensioning force applied to the tendons shall be measured by pressure gauge.

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 If the calculated elongation (deducting for slack & slip) is reached before the calculated
gauge pressure is obtained, continue tensioning till the calculated gauge pressure
attained, provided the elongation does not exceed 1.05 times the calculated elongation.

 If the elongation is achieved before the calculated gauge pressure is attained stop
stressing and inform engineer in charge.

 If the calculated elongation is not been reached, continue tensioning by interval of

5kg/cm2 until the calculated elongation is reached provided the gauge pressure does
not exceed 1.05 times the calculated gauge pressure.

 If required elongation is not obtained, further finishing operations such as cutting or

sealing should not be undertaken without the approval of Concessionaire / IE.

 After stressing is completed, again take the RL at the mid span of girder.

 If there is any loss in pre stressing, increase the strands in last cables as required and
make up the losses by increasing the force & extensions.

Note:

1) In P.SC. T.Beam or Box Girder, the pre-stressing shall be done in stages as per pre-
stressing schedule given in supplementary drawing or as per instructions given by
Concessionaire / IE.

2) Load vs Extension readings shall be recorded in prescribed Performa duly approved

by Concessionaire / IE.

3) Load vs extension graph shall be plotted to calculate slack & also to study behavior of
the structure.

Grouting:

 Grouting Material

 Procedure Of Grouting

Grouting material:

 Water

 Cement

 Admixture (Non shrinkage)

Procedure of grouting:

 Grouting shall be carried out as per Appendix 5 of IRC:18 (Latest Revision).

 Cut the protruding strands and seal the bearing portion with concrete keeping the hole
and ball valve for grouting.
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 Clean the cable duct with water mixed with cutting oil and compressed air.

 Prepare the grout in agitator and fill into grout pump through 150 micron sieve.

 Start the grouting from one end & keep the other end and air vent holes open.

 Allow the grout to pass through the open end and when the thick grout comes out,
close the open-end valve.

 Grout will be injected continuously without interruption upto the required pressure.

 For vertical cable or cables inclined more than 600 to the horizontal, injection should be
affected from the lowest anchorage or vent of the duct.

 Close all the outlet valves. Allow the grout to develop the pressure up to the required
pressure.

 Close the inlet valve.

Expansion joint:

 Tested and approved expansion joints will be used for construction.

 The expansion joints will be provided over the full width of superstructure including kerb
and footpath as per approved methodology.

 Fabricated pieces of expansion joint will be erected at site in position, and extension of
pieces will be done by welding.

 Initially, erection of expansion joints will be done preferably, in the presence of

manufacturer’s representative.

 Second stage of concrete will be done after final checking of expansion joint.

Wearing coat:

Wearing coat shall be 65mm thick, comprising of single layers of 40mm thick asphaltic
concrete and one layer of 25mm thick mastic asphalt, or as ordered. It will be laid after kerb
/ crash barrier construction.

Crash barrier:

 Crash barrier will be cast as per the supplementary drawing.

 Main reinforcement will be embedded in.

 Balance reinforcement steel and shuttering will be fixed as per construction drawing.
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 After approval of Concessionaire / IE, concreting shall be carried out.

 Fixtures for handrails will be provided before concreting.

Footpath and Kerb:

 Foot Path will be cast as per the drawing.

 Main reinforcement will be embedded in deck slab concrete.

 Balance reinforcement steel and shuttering will be fixed as per approved drawing.

 After approval of engineer concreting work is to be carried out.

Hand rails (GI):

 Handrails are to be fixed as per the drawing.

Railing (RCC):

 Preferably, pre cast the horizontal beams of railing (Length of rail adjusted as per span
& approved).

 Vertical reinforcement (for post) will be embedded in deck slab.

 Fix the stirrups of column; shuttering and place the precast beams in position before
casting the column.

 Cast the vertical column ensuring so slurry leakage at joints of column & Hand rail.

 Railing will be cast for a length from one expansion joint to another expansion gap.

General Notes:

 Sequence of pre-stressing will be as per construction drawings for super-structures.

 Anchorage recesses will be sealed with epoxy coating and filled with non-shrink mortar.
End face of girder, at locations of anchorage, will be coated with two coats epoxy.

 Recess and necessary inserts for expansion joints will be as per construction drawings
and as per manufacturer’s requirements and will be got approved before casting the
deck slab.

INSPECTIONS AND TESTING PROCEDURE:

Inspection and Test Plans shall be revised whenever there is any change in methodology
and specifications etc. Various Field and Laboratory Test Formats referred in Inspection
and Test Plans shall be maintained as per the frequency mentioned for various activities.
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All the Records shall be properly controlled and maintained in easily identifiable and
traceable manner.

SAFETY AND ENVIRONMENTAL MANAGEMENT PLAN:

Safety and Environmental Management Plan for the Project has been prepared to meet the
various Safety and Environmental Management requirements of this activity & as
mentioned in the Contract.