SPECIFICATION

FOR
GRANULAR SUB BASE,
WET MIX MACADAM
AND
DRY ROLLED LEAN CONCRETE
Item 1: Preparation of granular sub-base by providing close graded material,
conforming to specifications mixing in a mechanical mix plant at OMC,
carriage of mixed material by mechanical transport to work site, for all
leads and lifts, spreading in uniform layers of specified thickness with
mechanical means including neatly leveling & dressing on prepared surface
and compacting with vibratory power roller to achieve the desired density,
complete and as per direction of Engineer-in-charge.

PARTICULAR SPECIFICATION OF GRANULAR SUB BASE

1 Scope

This work shall consist of laying and compacting well-graded material on prepared sub-
grade in accordance with the requirements of these Specifications. The material shall
be laid in one or more layers as sub-base or lower sub-base and upper sub-base
(termed as sub-base hereinafter) as necessary according to lines, grades and cross-
sections shown on the drawings or as directed by the Engineer-in charge.

The thickness of a single compacted GSB layer shall not be less than 75 mm. When
vibrating or other approved types of compacting equipment are used, the compacted
depth of a single layer of the sub-base course may be increased to 200 mm upon
approval of the Engineer-in-charge.
2 Materials

2.1 The material to be used for the work shall be natural sand, crushed gravel, crushed
stone, crushed slag, or combination thereof depending upon the grading required. Use
of materials like brick metal, kankar and crushed concrete shall be permitted in the
lower sub-base. The material shall be free from organic or other deleterious
constituents and shall conform to the grading given in Table 1 and physical requirement
given in Table 2. Gradings III and IV shall preferably be used in lower sub-base.
Gradings V and VI shall be used as a sub-base cum drainage layer. The grading to be
adopted for a work shall be as specified in the contract.

If the water absorption of the aggregate determined as per IS:2386 (Part 3) is greater
than 2 percent, the aggregate shall be tested for Wet Aggregate Impact
Value(AIV)(IS:5640). Soft aggregate like Kankar, brick ballast and laterite shall also be
tested for Wet AIV (IS:5640).

. Table -1. Grading for granular sub-base material

IS Sieve Percent by Weight Passing the IS Sieve
Designation Grading Grading Grading Grading Grading Grading
I II III IV V VI
75.0 mm 100 - - - 100 -
53.0 mm 80-100 100 100 100 80-100 100
26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100
9.50 mm 35-65 50-80 - - 35-65 55-75
4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55
2.36 mm 20-40 30-50 - - 10-20 10-25
0.85 mm - - - - 2-10 -
0.425 mm 10-15 10 -15 - - 0-5 0-8
0.075mm <5 <5 <5 <5 - 0-3

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Table 2: Physical Requirement for Materials for Granular Sub-base.

Aggregate Impact Value(AIV) IS:2386(Part 4) or 40 Maximum

IS:5640
Liquid Limit IS:2720(Part 5) Maximum 25
Plasticity Index IS:2720(Part 5) Maximum 6
CBR at 98% dry density IS:2720(Part 5) Minimum 30 specified
(IS:272-(Part 8) unless otherwise specified
in the Contract

2.2 Strength of sub-base

It shall be ensured prior to actual execution that the material to be used in the sub-
base satisfies the requirements of CBR and other physical requirements when
compacted and finished.

When directed by the Engineer-in-charge, this shall be verified by performing CBR tests
in the laboratory as required on specimens re-moulded at field dry density and moisture
content and any other tests for the “quality” of materials as may be necessary.

3 Construction Operations

3.1 Spreading and compacting

The sub base material of grading specified in the Contract and water shall be mixed
mechanically by a suitable mixture equipped with provision for controlled addition of
water and mechanical mixing so as to ensure homogeneous and uniform mix. The
required water content shall be determined in accordance with IS: 2720(Part-8). The
mix shall be spread on the prepared sub grade with mechanical means of adequate
capacity its blade having hydraulic controls suitable for initial adjustment and for
maintaining the required slope and grade during the operation or other means as
approved by the Engineer-in-charge.

The moisture content of mix shall be checked in accordance with IS:2720 (Part-2) and
suitably adjusted so that at the time of compaction it is from 1-2% below the optimum
moisture content.

Manual mixing shall be permitted only where the width of laying is not adequate for
mechanical operations, as in small-sized jobs. The equipment used for mix-in place
construction shall be a rotavator or similar approved equipment capable of mixing the
material to the desired degree. If so desired by the Engineer-in-charge, trial runs with
the equipment shall be carried out to establish its suitability for the work.

Immediately after spreading the mix, rolling shall be done by an approved roller. If the
thickness of the compacted layer does not exceed 100mm, a smooth wheeled roller of
80 to 100 KN weight may be used. For a compacted single layer up to 200mm, the
compaction shall be done with the help of a vibratory roller of minimum 80 to 100 KN
static weight capable of achieving the required compaction. Rolling shall commence at
the lower edge and proceed towards the upper edge longitudinally for portions having
unidirectional crossfall or on super elevation. For pavement having crossfall on both
sides rolling shall commence at the edges and progress towards crown.

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 Each pass of the roller shall uniformly overlap not less than one third of the track made
in the preceding pass. During rolling, the grade and crossfall (camber) shall be checked
and any high spots or depressions, which become apparent, corrected by removing or
adding fresh material. The speed of the roller shall not exceed 5 Km per hour.

Rolling shall be continued till the density achieved is at least 98% of the maximum dry
density for the material determined as per IS: 2720 (Part 8). The surface of any layer
of material on completion of compaction shall be well closed, free from movement
under compaction equipment and from compaction planes, ridges, cracks or loose
material. All loose, segregated or otherwise defective areas shall be made good to the
full thickness of layer and re-compacted.

4 Surface Finish and Quality Control of Work

4.1 General
All works performed shall conform to the lines, grades, cross-sections and dimensions
shown on the drawings or as directed by the Engineer-in-Charge, subject to the
permitted tolerances described herein-after.

4.2 Horizontal Alignment:

Horizontal alignment shall be reckoned with respect to the centre line of the
carriageway as shown on the drawings. The edges of the carriageway as constructed
shall be correct within a tolerance of ±10 mm therefrom. The corresponding tolerance
for edges of the pavement and lower layers of pavement shall be ±25 mm.

4.3 Surface levels:

The top level of the granular sub-base shall not vary from those calculated with
reference to the longitudinal & cross profile of the pavement shown in the Drawings or
as directed by Engineer-in-Charge, beyond the tolerances mentioned as follow:

S.No. Sub-base Tolerances

1 Flexible pavement ±10 mm
2 Concrete pavement ±6 mm

4.4 Surface Regularity:

The maximum allowable difference between pavement surface and underside of a

3 m straightedge when placed parallel with or at right angles to the centre line of
pavement at points decided by the Engineer –in-charge shall not exceed 8 mm.

4.5 Rectification:

Where the surface regularity fall outside the specified tolerances, the Contractor shall
be liable to rectify the same upto the satisfaction of Engineer-in-Charge. Where the
surface is high, it shall be trimmed and suitably compacted. Where the same is low, the
deficiency shall be corrected to scarifying the lower layer and adding fresh material and
recompacting to the required density.

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4.6 Quality Control:

The following quality control tests shall be carried out at frequencies specified against
each for Granular Sub-base:-

S.No. Test Test Method Frequency (min.)

1 Gradation IS: 2720 (Part –VI) One test per 200 m3
2 Atterberg limits IS: 2720 (Part-V) One test per 200 m3
3 Moisture Content prior IS: 2720 (Part-II) One test per 250 m2
to compaction
4 Density of compacted IS: 2720 (Part-XXVIII) One test per 500 m2
layer
5 Deleterious constituents IS: 2720 (Part-XXVII) As required
6 C.B.R. (On set of 3 IS: 2720 (Part-XVI) As required
specimens)
7 Control of Grade, - Regularly
camber thickness and
suface finish

5 Arrangement of Traffic

No vehicular traffic of any kind shall be allowed on the finished granular sub-base
surface till it has dried and the next course laid. In exceptional cases, construction
traffic may be allowed with approval of the Engineer-in-Charge for short durations once
the course is completely dry provided vehicles move over the full width avoiding any
rutting or uneven compaction. The Contractor will take all precautionary measures to
prevent any damage to the finished surface till next layer is laid over it.

6 Measurements for Payment

The unit of measurement for Granular Sub Base Course shall be cubic meter of mix
placed. This shall be determined from the top levels of the under layer and the final
levels of the consolidated GSBC as mentioned below:

Before laying GSBC, the top levels of under layer shall be taken jointly by the Engineer-
in-Charge or his representative and the contractor at 3 meters intervals both ways or
closer as directed by the Engineer-in-Charge. These levels shall be recorded on the
plan as well as in the level book and record shall be signed by the contractor. The
levels of the consolidated GSBC shall again be taken and plotted on the plan and
recorded in the level book, to determine the average thickness laid, on the basis of
these levels. The volume of mix laid consolidated and finished, shall then be the
product of the measured surface area and the average thickness laid.

The protection of edges of granular sub-base extended over the full formation as shown
in the drawing shall be considered incidental to the work of providing granular sub-base
and as such no extra payment shall be made for the same.

7 Rate

Unit rate of the item shall include the cost of labour, materials and equipment, mix
design, mixing, transportation, placing, compacting, finishing and other quality control
operations, field & lab tests, all royalties, fees, storage, rents, all leads and lifts.

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Item 2: Providing, laying, spreading and compacting graded stone aggregate (size
range 53 mm to 0.075 mm) to wet mix macadam (WMM) specification
including premixing the material with water at OMC in mechanical mix plant,
carriage of mixed material by mechanical transport to site, for all leads &
lifts, laying in uniform layers with mechanical paver finisher in sub- base
/base course on well prepared surface and compacting with vibratory roller
of 8 to 10 tonne capacity to achieve the desired density, complete as per
specifications and directions of Engineer-in-Charge.

PARTICULAR SPECIFICATION FOR WET MIX MACADAM SUB-BASE/BASE

1 Scope

This work shall consist of laying and compacting clean, crushed, graded aggregate and
granular material, premixed with water to a dense mass on a prepared sub grade/sub-
base/base or existing pavement as the case may be in accordance with the
requirements of these Specifications. The material shall be laid in one or more layers
as necessary to lines, grades and cross-sections shown on the approved drawings or as
directed by the Engineer-in-Charge.

The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75
mm. When vibrating or other approved types of compacting equipment are used, the
compacted depth of a single layer of the sub-base course may be increased to 150 mm
upon approval of the Engineer-in-Charge.
2 Materials

2.1 Aggregates

2.1.1 Physical requirements:

Coarse Aggregates shall be crushed stone. If crushed gravel/shingle is used, not less
than 90 percent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall
have at least two fractured faces. The aggregates shall conform to the physical
requirement set forth in table-1.
Table 1: Physical Requirements of coarse aggregates for Wet Mix
Macadam for Sub-base / Base course.
Test Test Method Requirements
Los Angeles Abrasion value IS : 2386 (Part 4) 40 per cent (Max.)
or Aggregate Impact value IS : 2386 (Part 4) or IS:5640 30 per cent (Max.)
Combined Flakiness and IS : 2386 (Part 1) 35 per cent (Max.) *
Elongation Indices (Total)

* To determine this combined proportion, the flaky stone from a representative sample
should first be separated out. Flakiness index is weight of flaky stone metal divided by
weight of stone sample. Only the elongated particles are to be separated out from the
remaining (non-flaky) stone metal. Elongation index is weight of elongated particles
divided by total non-flaky particles. The value of flakiness index and elongation index so
found are added up.

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 If the water absorption value of the coarse aggregate is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per IS: 2386
(Part 5).

2.1.2 Grading requirements

The aggregate shall conform to the grading given in table below:

Table 2: Grading Requirements of aggregates for Wet Mix Macadam

IS Sieve Per cent by weight passing

Job Control Grading Band
designation the IS sieve Tolerances Percent
53 mm 100 0
45 mm 95 – 100 ±5
26.50 mm - -
22.40 mm 60 – 80 ±8
11.20 mm 40 – 60 ±8
4.75 mm 25 – 40 ±8
2.36 mm 15 – 30 ±8
600 micron 8 – 22 ±5
75 micron 0 – 5 ±3

The job control band tolerances in the Table 2 shall be applied to final gradation to
establish a job control grading band. The full tolerance still applies if application of the
tolerances results in a job control grading band outside the design range.
Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.

The final gradation approved within these limits shall be well graded from coarse to fine
and shall not vary from the low limit on one sieve to the high limit on the adjacent sieve
or vice versa.
3 Construction operations

3.1 Preparation of Base:

The surface of the sub grade/sub-base/base to receive the wet mix macadam course
shall be prepared to the specified grade and camber and clean of dust, dirt and other
extraneous material. Any ruts or soft yielding places shall be corrected in an approved
manner and rolled until firm surface is obtained if necessary by sprinkling water.
As far as possible, laying wet mix macadam course over existing bituminous layer may
be avoided since it will cause problems of internal drainage of the pavement at the
interface of two course. It is desirable to completely pick out the existing thin
bituminous wearing course where wet mix macadam is proposed to be laid over it.

3.2 Provision of lateral confinement of aggregates:

While constructing wet mix macadam, arrangement shall be made for the lateral
confinement of wet mix. This shall be done by laying materials in adjoining shoulders
along with that of wet mix macadam layer and following the sequence of operations as
follows:

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 The sequence of operations shall be such that the construction of paved shoulder is
done in layers each matching the thickness of adjoining pavement layer. Only after a
layer of pavement and corresponding layers in paved and earth shoulder portion have
been laid and compacted, the construction of next layer of pavement and shoulder shall
be taken up.
Where the materials in adjacent layers are different, these shall be laid together and
the pavement layer shall be compacted first. The corresponding layer in paved shoulder
portion shall be compacted thereafter, which shall be followed by compaction of earth
shoulder layer. The adjacent layers having same material shall be laid and compacted
together.

3.3 Preparation of mix:

Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity
having provision for controlled addition of water and forced/positive mixing
arrangement like pug mill or pan type mixer of concrete batching plant.
The plant shall have the following features:
i. For feeding aggregates – three/four bin feeders with variable speed motor.
ii. Vibrating screens for removal of oversized aggregates.
iii. Conveyer belt
iv. Control system for addition of water
v. Forced/positive mixing arrangement like pug mill or pan type mixture.
vi. Centralised control panel for sequential operation of various devices and precise
process control
vii. Safety devices.

Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part 8)
after replacing the aggregate fraction retained on 22.4 mm sieve with material of 4.75
mm to 22.4 mm size. While adding water, due allowance shall be made for evaporation
losses. However, at the time of compaction, water in the wet mix shall not vary from
the optimum value by more than agreed limits. The mixed material should be uniformly
wet and no segregation shall be permitted.
For small quantity of WMM work or inaccessible/remote location and in situation of
where use of machinery is not feasible, the Engineer-in-Charge may permit the mixing
to be done in concrete mixers/manual mixing.

3.4 Spreading of mix:

Immediately after mixing, the aggregates shall be spread uniformly and evenly upon
the prepared sub grade/sub-base/base in required quantities. In no case shall these be
dumped in heaps directly on the area where these are to be laid nor shall their hauling
over a partly completed stretch be permitted.
The mix shall be spread by a paver finisher. The paver finisher shall be self-propelled of
adequate capacity with following features:

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 i. Loading hopers and suitable distribution system so as to provide a smooth
uninterrupted material flow for different layer thicknesses from the tipper to the
screed.
ii. Hydraulically operated telescopic screed for paving width upto 8.5 m and fixed
screed beyond this. The screed shall have tamping and vibrating arrangement for
initial compaction of layer.
iii. Automatic leveling control system with electronic sensitive device to maintain mat
thickness and cross-slope of mat during laying procedure.

In exceptional cases where it is not possible for the paver to be utilized, suitable
mechanical means may be used with the prior approval of Engineer-in-Charge.

The surface of the aggregate shall be carefully checked with templates and all high or
low spots remedied by removing or adding aggregate as may be required. The layer
shall be tested by depth blocks during construction. No segregation of larger and fine
particles shall be allowed. The aggregates as spread shall be of uniform gradation with
no pockets of fine materials.

3.5 Compaction:

After the mix has been laid to the required thickness, grade and cross-fall / camber, the
same shall be uniformly compacted, to the full depth with suitable roller. If the
thickness of single compacted layer does not exceed 100 mm, a smooth wheel roller of
80 to 100 KN weight shall be used. For a compacted single layer up to 150 mm, the
compaction shall be done with the help of vibratory roller of minimum static weight of
80 to 100 KN with an arrangement for adjusting the frequency and amplitude. An
appropriate frequency and amplitude may be selected. The speed of the roller shall not
exceed 5 Km/hr.
In portions having unidirectional cross-fall / super elevation, rolling shall commence
from the lower edge and progress gradually towards the upper edge. Thereafter, roller
shall progress parallel to the centre line of the road, uniformly over-lapping each
preceding track by at least one-third width until the entire surface has been rolled.
Alternate trips of the roller shall be terminated in stops at least 1 m away from any
preceding stop.

In portions in camber, rolling shall begin at the edge with the roller running forward
and backward until the edges have been firmly compacted. The roller shall then
progress gradually towards the centre parallel to the centre line of the road uniformly
overlapping each of the preceding track by at least one-third width until the entire
surface has been rolled.

Any displacement occurring as a result of reversing of the direction of a roller or from

any other cause shall be corrected at once as specified and / or removed and made
good.

Along forms, kerbs, walls or other places not accessible to the roller, the mixture shall
be thoroughly compacted with mechanical tampers or a plate compactor or any other
suitable method decided by the Engineer-in-Charge. Skin patching of an area without
scarifying the surface to permit proper bonding of the added material shall not be
permitted.

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 Rolling shall not be done when the sub grade is soft or yielding or when it causes a
wave-like motion in the sub-base/base course or sub grade. If irregularities develop
during rolling which exceed 12 mm when tested with a 3m straight edge, the surface
shall be loosened and premixed material added or removed as required before rolling
again so as to achieve a uniform surface conforming to the desired grade and cross-fall.
In no case the use of unmixed material shall be permitted to make up the depressions.

Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in IS:
2720 (Part - 8).

After completion, the surface of any finished layer shall be well closed, free from
movement under compaction equipment or any compaction planes, ridges, cracks and
loose material. All loose, segregated or otherwise defective area shall be made good to
the full thickness of the layer and re-compacted.

3.6 Setting and drying:

After final compaction of wet mix macadam course, the pavement shall be allowed to
dry for 24 hours.

4 Opening to Traffic

No vehicular traffic of any kind shall be allowed on the finished wet mix macadam
surface till it has dried and the course laid. In exceptional cases, construction traffic
may be allowed with approval of the Engineer-in-Charge for short durations
once the course is completely dry provided vehicles move over the full width
avoiding any rutting or uneven compaction. The Contractor will take all precautionary
measures to prevent any damage to the finished surface till next layer is laid over it.

5 Surface Finish and Quality Control of Work

5.1 Surface Regularity: The maximum allowable difference between pavement surface
and underside of a 3m straightedge when placed parallel with or at right angles to the
centre line of pavement at points decided by the Engineer-in-Charge shall not be more
exceed 8 mm.

5.2 Surface level: The tolerance in surface level for wet mix macadam shall not vary ±10
mm for machine laid and ±15 mm for manually laid with reference to the longitudinal
and cross-profile of the pavement shown on the drawing or as directed by Engineer-in-
Charge.

5.3 Quality Control:

The following quality control tests shall be carried out at frequencies specified against
each for Wet Mix Macadam.

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 S.No. TEST Test Method Frequency
i) Los Angeles Abrasion Value/ IS:2386 (Part IV) One test per 200
Aggregate Impact Value cum. of aggregate.
ii) Grading of mixed aggregate IS:2386 (Part I) One test per 100
cum. of aggregate.
iii) Flakiness Index IS:2386 (Part I) One test per 200
cum. of aggregate.
iv) Plasticity Index IS:2720 (Part V) One test per 200
cum. of aggregate.
v) Moisture content prior to One test per 200
compaction cum. of aggregate.
vi) Density of compacted layer IS:2720(Part-28) One test per 500
sqm.

5.4 The materials supplied and the works carried out by the Contractor shall conform to the
relevant technical specifications and as approved by the Engineer-in-Charge.

For ensuring the requisite quality of construction, the materials and works shall be
subjected to quality control tests, as described above. The testing frequencies set forth
are the desirable minimum and the Engineer-in-Charge shall have the full authority to
carry out tests as frequently as he may deem necessary to satisfy himself that the
materials and works comply with the appropriate specifications.

Test procedures for the various quality control tests are indicated in the respective
Section of these Specifications or for certain tests within this Section. Where no
specific testing procedure is mentioned, the tests shall be carried out as per the
prevalent accepted engineering practice to the directions of the Engineer-in-Charge.

6 Rectification of Surface Irregularity

Where the surface irregularity of the wet mix macadam course exceeds the permissible
tolerances or where the course is otherwise defective due to sub grade soil getting
mixed with the aggregates, the full thickness of the layer shall be scarified over the
affected area, reshaped with added premixed material or removed and replaced with
fresh premixed material as applicable and re-compacted in accordance with Clause 3
above. The area treated in the aforesaid manner shall not be less than 5m long and
2m wide. In no case, the depressions shall be filled up with unmixed and un-graded
material or fines.

7 Measurements for Payment

Wet mix macadam shall be measured as finished work in position in cubic meters by
level computation method. This shall be determined from the top levels of the under
layer and final levels of the consolidated layer as mentioned below:-

Before laying wet mix macadam, the top levels of under layer shall be taken jointly by
the Engineer-in-Charge or his representative and the contractor at 3 meter intervals
both ways or closer as directed by the Engineer-in-Charge. These levels shall be
recorded on the plan as well as in the level book and the record shall be signed by the
contractor. The levels of the consolidated wet mix macadam shall again be taken and
plotted on the plan and recorded in the levels. The volume of mix laid consolidated and

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 finished, shall then be the product of the measured surface area and the average
thickness laid.

The protection of edges of wet mix macadam extended over the full formation as
shown in the drawing shall be considered incidental to the work of providing wet mix
macadam and as such no extra payment shall be made for the same.

8 Rates

Unit rate of the item shall include the cost of labour, materials and equipments, mix
design, mixing, transportation, placing, compacting, finishing and other quality control
operations, field & lab tests, all royalties, fees, storage, rents, all leads and lifts.

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Item 3: Providing and laying dry lean cement concrete with coarse and fine
aggregate conforming to IS:383, the size of coarse aggregate not exceeding
26.5 mm, aggregate cement ratio not exceed 15:1, aggregate gradation
after blending to be as per specification, cement content not to be less than
150 kg/cum, optimum moisture content to be determined during trial length
construction, concrete strength not to be less than 10 MPa at 7 days, mixed
in a batching plant as per mix design, transported to site, laid with a paver
with electronic sensor, compacting with 8-10 tonne vibratory roller, finishing
and curing etc complete as per specification and direction of the Engineer-
in-Charge.

SPECIFICATIONS FOR DRY ROLLED LEAN CONCRETE (DRLC)

1 Scope

1.1 The work shall consist of construction of (zero slump) dry lean concrete sub-base for
cement concrete pavement in accordance with the requirements of these specifications
and shall conform to the lines, grades and cross-sections shown on the drawings or as
directed by the Engineer-in-Charge. The work shall include furnishing of all plant and
equipment, materials and labour and performing all operations, in connection with
work, as approved by the Engineer-in-Charge.

1.2 The design parameters of dry lean concrete sub-base, i.e. width, thickness, grade of
concrete, details of joints, if any, etc. shall be as stipulated in the drawings or as
directed by Engineer-in-Charge.

2 Materials

2.1 Source of Materials: The contractor shall indicate to the Engineer-in-Charge the
source of all materials with relevant test data to be used in the dry lean concrete work
sufficiently in advance and the approval of the Engineer-in-Charge for the same shall be
obtained before start of the work. If the contractor later proposes to obtain the
materials from a different source during execution of work, he shall notify the Engineer-
in-Charge for his approval before such materials are to be used.

2.2 Cement: Any of the following types of cement may be used with the prior approval of
Engineer-in-Charge.

S. No. Type Conforming to

i) Ordinary Portland Cement IS: 8112
ii) Portland Slag Cement IS: 455
iii) Portland Pozzolana Cement IS: 1489-Part-I

If the sub-grade is found to consist of soluble sulphates in a concentration more than

0.5 percent, the cement used shall be sulphate resistant and shall conform to IS: 6909.

2.2.1 Supply of Cement shall be obtained either in bulk form or as per clause 3.1.2.5 of CPWD
specifications Vol-I, 2009. Cement shall be subjected to acceptance tests prior to its
use. Nothing extra shall be paid on this account.

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2.3 Aggregates

2.3.1 Aggregates for lean concrete shall be natural material complying with IS: 383. The
aggregates shall not be alkali reactive. The limits of deleterious materials shall not
exceed the requirements set out in table 1 of IS: 383. In case the aggregates are not
free from dirt, the same may be washed and drained for at least 72 hours before
batching, as directed by the Engineer-in-Charge.

2.3.2 Coarse aggregate: Coarse aggregates shall consist of clean, hard, strong, dense,
non-porous and durable pieces of crushed stone or crushed gravel and shall be devoid
of pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces.
The maximum size of coarse aggregate shall not exceed 26.5mm for lean concrete. No
aggregate which has water absorption more than 2 percent shall be used in the
concrete mix. The aggregate shall be tested for soundness in accordance with IS:2386
(Part-5). After 5 cycles of testing, the loss shall not be more than 12 percent if sodium
sulphate solution is used or 18 percent if magnesium sulphate solution is used. The
Loss Angeles Abrasion value shall not exceed 35. The combined flakiness and
elongation index of aggregate shall not be more than 35 percent.

2.3.3 Fine aggregate: The fine aggregates shall consist of clean natural sand or crushed
stone sand or a combination of the two and shall conform to IS:383. Fine aggregate
shall be free from soft particles, clay, shale, loam, cemented particles, mica and organic
and other foreign matter. The fine aggregates shall have a sand equivalent value of not
less than 50 when tested in accordance with the requirement of IS:2720 (Part 37).

2.3.4 The material after blending shall conform to the grading as indicated in Table 1.
Table 1: Aggregate gradation for Dry Lean Concrete

Sieve Designation Percentage passing

the sieve by weight
26.50 mm 100
19.00 mm 75-95
9.50 mm 50-70
4.75 mm 30-55
2.36 mm 17-42
600 micron 8-22
300 micron 7-17
150 micron 2-12
75 micron 0-10

2.4 Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amounts of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete. It shall meet the requirements stipulated in IS: 456.

2.5 Storage of materials

2.5.1 Cement:

The Contractor shall provide adequate storage facilities to prevent deterioration of

cement during storage due to climate and other causes. Wherever bulk storage
containers are used, their capacity should be sufficient to cater to the requirement at
site. The containers shall be cleaned at least once every 3 months. Cement remaining in
stores for more than one and half month from the date of manufacture must be

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 retested before use and to be rejected, if it fails to conform to any of the requirements
of the specifications.

2.5.2 Aggregates:

a) Stock piles shall be made immediately on receipt of aggregates at site of work.

Aggregates shall be stacked separately according to the nominal sizes of coarse
aggregates. For fine aggregates, separate stacks shall be made.

b) Aggregates shall be stacked on a hard surface so as to exclude the possibility of soil

or grass being mixed up. When stacked in close proximity, the stock piles shall be
separated by bulk heads to prevent the different sizes of aggregates from mixing
together. Special care shall be taken to clean and wash the last layer of aggregates
in contact with ground surface before use.

c) Before batching, the aggregates shall have been stock piled for at least 24 hours to
allow for draining of water, if any. The Contractor shall make adequate provision for
stock piling aggregates to the extent sufficient to meet the needs of the work taking
into account the availability of supplies and rates of delivery etc. and nothing extra
shall be paid for necessary double handling and transport of materials from
stock piles to mixing plant etc.

3 Proportioning of Materials for the Mix

3.1 The mix shall be proportioned with a maximum aggregate cement ratio of 15:1. The
water content shall be adjusted to the optimum as per clause 3.2 for facilitating
compaction by rolling. The strength and density requirement of concrete shall be
determined in accordance with clause 6 and 7 by making trial mixes.

3.2 Moisture Content: The right amount of water for the lean concrete in the main work
shall be decided so as to ensure full compaction under rolling and shall be assessed at
the time of rolling the trial area. Too much water will cause the lean concrete to be
heaving up before the wheels and to be picked up on the wheels of the roller and too
little will lead to inadequate compaction, a low in-situ strength and an open-textured
surface.

The optimum water content shall be determined and demonstrated by rolling during
trial area construction and the optimum moisture content and degree of compaction
shall be got approved from the Engineer-in-Charge. While laying the main work, the
lean concrete shall have a moisture content between the optimum and optimum + 2
per cent, keeping in view the effectiveness of compaction achieved and to compensate
for evaporation losses.

3.3 Cement Content: The cement content in dry lean concrete shall be such that the
strength specified in clause 3.4 is achieved. For the purpose of tendering, the cement
content may be assumed as 150 Kg per cum of finished DRLC.

If the actual quantity of cement required as per laboratory mix design varies from the
quantity assumed above, necessary cost adjustment for deviation in the quantity of
cement as per mix design, if any, shall be done as per the rate of cement in actual
supply voucher from manufacturer /authorized dealer at the time of execution. In the
case of authorized distributor the rate may be authenticated by the manufacturer.
However, under no circumstances the cement content shall fall below 150 Kg per cum.
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 3.4 Concrete Strength: The average compressive strength of each consecutive group of
5 cubes made shall not be less than 10 MPa at 7 days. In addition, the minimum
compressive strength of any individual cube shall not be less than 7.5 MPa at 7 days.
The design mix complying with the above clauses shall be got approved from the
Engineer-in-Charge and demonstrated in the trial length construction.

4 Construction

4.1 General

The pace and programme of the dry lean concrete sub-base construction shall be
matching suitably with the programme of construction of the cement concrete
pavement over it. The dry lean concrete sub-base shall be overlaid with concrete
pavement only after 7 days after sub-base construction.

4.2 Batching and Mixing

4.2.1 A system approach should be adopted for construction of pavement, and the method
statement for carrying out the work, detailing all the activities including indication of
time cycle, equipment, personnel etc. shall be got approved from the Engineer-in-
Charge before the commencement of work. The above shall include the type, capacity
and make of batching and mixing plant beside the hauling arrangement and paving
equipment. The capacity of paving equipment, batching plant as well as all the ancillary
equipment shall be adequate for a paving requirement for day’s work.

4.2.2 Batching and mixing of the concrete shall be done at a central batching and mixing
plant of capacity ……… (not less than 30 Cum/hr) with automatic controls, located at
suitable place which takes into account sufficient space for stock piling of cement,
aggregate and stationary water tanks. This shall be however, situated at an approved
distance, duly considering the properties of the mix and transport arrangements
available with the contractor.

4.2.3 Proportioning of a material shall be done in the batching plant by weight, each type of
material being weighed separately. The cement from the bulk stock may be weighed
separately from the aggregates and water shall be measured by volume. Wherever
properly graded aggregate of uniform quality can not be maintained as envisaged in the
mix design the grading of aggregates shall be controlled by appropriate blending
techniques. The capacity of batching and mixing plant shall be at-least 25% higher than
the proposed capacity for the laying/ paving equipment.

4.2.4 The batching plant shall include preferably four bins, weighing hoppers, and scales for
the fine aggregate and for each size of coarse aggregate. If cement is used in bulk
(after opening bags on platform) a separate scale for cement shall be included. The
weighing hoppers shall be properly sealed and vented to preclude dust during
operation. Approved safety devices shall be provided and maintained for the protection
of all personnel engaged in plant operation, inspection and testing. The batch plant
shall be equipped with a suitable non resettable batch counter which will correctly
indicate the number of batches proportioned.

4.2.5 Bins preferably with four adequate separate compartments shall be provided in the
batching plant.
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4.2.6 Batching plant shall be equipped to proportion aggregates and bulk cement by means
of automatic weighing devices using load cells. The weighing device shall have an
accuracy within + 1% in respect of quantity of cement and water and + 2% in respect
of aggregates and accuracy shall be checked at least once a month.

4.2.7 Mixers shall be pan type, reversible type with single or twin shaft or any other mixer
capable of combing the aggregates, cement and water into a thoroughly mixed and
uniform mass within the specified mixing period and of discharging the mix without
segregation. Each stationary mixer shall be equipped with an approved timing device
which will automatically lock the discharge lever when the drum has been charged and
release it at the end of the mixing period. The device shall be equipped with a bell or
other suitable warning device adjusted to give a clearly audible signal each time the
lock is released. In case of failure of the timing device the mixer may be used for the
balance of the day while it is being repaired provided that each batch is mixed for 90
seconds or as per the manufacturer’s recommendation. The mixer shall be equipped
with a suitable non resettable batch counter which shall correctly indicate the number
of batches mixed.

4.2.8 The mixer shall be cleaned at suitable intervals. The pickup and throw over blades in
the drum or drums shall be repaired or replaced when they are worn down 20mm or
more. The contractor shall have available at the job site a copy of the manufacturers
design, showing dimensions and arrangements of blades in reference to original height
and depth or provide permanent marks on blade to show points of 20mm wear from
new conditions. Drilled holes of 5mm diameter near each end and at mid point of each
blade are recommended. Batching plant shall be calibrated for the each ingredients
upto its maximum quantity being used in the mix at site in the beginning and thereafter
at suitable interval not exceeding one month.

4.2.9 Air-conditioned centralized computer control cabin shall be provided for automatic
operation of the equipment.

4.2.10 The design feature of the batching plant should be such that it can be shifted quickly.

4.3 Transporting

Plant mix lean concrete shall be discharged immediately from the mixer, transported
directly to the point where it is to be laid and protected from the weather by covering
with tarpaulin during transit. The concrete shall be transported by tipping trucks,
sufficient in number to ensure a continuous supply of material to feed the laying
equipment to work at a uniform speed and in an uninterrupted manner. The lead of
the batching plant to the paving site shall be such that the travel time available from
mixing to paving as specified in Para 4.5.2 will be adhered to. Tipping truck shall not
have old concrete sticking to it. Each tipping truck shall be washed with water jet
before next loading as and when required after inspection.

4.4 Placing

Lean concrete shall be laid by a paver with electronic sensor on the sub base layer or as
specified. The equipment shall be capable of laying the material in one layer in an even
manner without segregation, so that after compaction the total thickness is as specified.
The paving machine shall have high amplitude tamping bars to give good initial

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 compaction to the sub-base. One day before placing of the dry lean cement concrete
sub-base the surface of the granular sub-base/drainage layer shall be given a fine spray
of water and rolled with a smooth wheeled roller.

The Dry Lean Concrete shall be laid in such a way that it is at least 750mm wider on
each side than the proposed width including paved shoulders of the concrete pavement.
The extra widening beyond 750 mm width on either side shall be decided based on the
specification of the paver, such that the crawler moves on the Dry Lean Concrete and
the cost of extra width beyond 750 mm on either side, if any, shall be borne by the
Contractor. For small works, the laying of concrete with paver may be dispensed with.
Where laying of PQC is done by manual method, the extra 750 mm width Dry Lean
Concrete on either side for crawler movement is not required.

4.5 Compaction

4.5.1 The compaction shall be carried out immediately after the material is laid and levelled.
In order to ensure thorough compaction, rolling shall be continued on the full width till
there is no further visible movement under the roller and the surface is well closed.
The minimum dry density obtained shall be 98 per cent of that achieved during trial
length construction in accordance with clause 6. The densities achieved at the edges
i.e. 0.5 m from the edge shall not be less than 96 per cent of that achieved during trial
construction.

4.5.2 The spreading, compacting and finishing of the lean concrete shall be carried out as
rapidly as possible and the operation shall be so arranged as to ensure that the time
between 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 between 25 and 30 degree Celsius and 120 minutes if less than 25
degree Celsius. The period may be reviewed by Engineer-in-Charge in the light of the
results of the trial run but in no case shall it exceed 2 hours. Work shall not proceed
when the temperature of the concrete exceeds 30 degree Celsius. If necessary, chilled
water or addition of ice may be resorted to for bringing down the temperature. It is
desirable to stop concreting when the ambient temperature is above 35 degree Celsius.
After compaction has been completed, roller shall not stand on the compacted surface
for the duration of the curing period except during commencement of next day’s work
near the location where work was terminated the previous day.

4.5.3 Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 KN static weight
are suitable for rolling dry lean concrete. In case any other roller is proposed, the same
shall be got approved from Engineer-in-Charge, after demonstrating its performance.
The number of passes required to obtain maximum compaction depends on the
thickness of the dry lean concrete, the compatibility of the mix, and the weight and
type of the roller and the same as well as the total requirement of rollers for the job
shall be determined during trial run by measuring the in-situ density and the scale of
the work to be undertaken.

4.5.4 A preliminary pass without vibration to bed the Dry Lean Concrete down shall be given
followed by the required number of passes to achieve the desired density and, a final
pass without vibration to remove roller with vibration marks and to smoothen the
surface.

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 Special care and attention shall be exercised during compaction near joints, kerbs,
channels, side forms and around gullies and manholes. In case adequate compaction is
not achieved by the roller at these points, use of plate vibrator shall be made, if so
directed by the Engineer-in-Charge.

4.5.5 The final lean concrete surface on completion of compaction shall be well closed, free
from movement under roller and free from ridges, low spots cracks, loose material, pot
holes, ruts or other defects. The final surface shall be inspected immediately on
completion and all loose, segregated or defective areas shall be corrected by using
fresh lean concrete material laid and compacted. For repairing honeycombed/hungry
surface, concrete with aggregate of size 10 mm and below shall be spread and
compacted as per specification. It is necessary to check the level of the rolled surface
for compliance. Any level/thickness deficiency shall be corrected after applying concrete
with aggregate of size 10 mm and below after roughening the surface. Strength test
shall be carried out, and if deficiency in strength is noticed, at least three (evenly
spread) cores of minimum 100 mm dia. per 5000 sqm shall be cut to check deficiency in
strength. The holes resulting from cores shall be restored by filling with concrete of the
specified strength and compacted by adequate rodding.

4.5.6 Segregation of concrete in the tipping truck shall be controlled by moving the dumper
back and forth while discharging the mix into the same or by any appropriate means.
Paving operation shall be such that the mix does not segregate.

4.6 Joints

Construction and longitudinal joints shall be provided as per the drawings. Transverse
butt type joint shall be provided at the end of the construction in a day. Longitudinal
construction joint shall be provided only when full width paving is not possible.
Transverse joints in Dry Lean concrete shall be staggered from the construction butt
type joint in concrete pavement by 800-1000 mm.

Longitudinal joint in Dry Lean Concrete shall be staggered by 300-400 mm from the
longitudinal joint of concrete pavement.

At longitudinal or transverse construction joints, unless vertical forms are used, the
edge of compacted material shall be cut back to a vertical plane where the correct
thickness of the properly compacted material has been obtained.

4.7 Curing

After two to three hours i.e. when concrete has started setting /hardening, the exposed
surfaces shall be kept damp with moist gunny bags, sand or any other material
approved by the Engineer-in-Charge or by sprinkling water. 24 hours after compaction,
the exposed surface shall be kept continuously in damp or wet condition by ponding or
by covering with a layer of sacking, canvas, hessian or similar materials and kept
constantly wet for at least 7 days from the date of laying where Ordinary Portland
Cement is used and this period of curing shall be 10 days from the date of laying when
Portland Pozzolana Cement /Portland slag cement is used.

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5 Trial Mixes

The contractor shall make trial mixes of dry lean concrete with moisture contents like
5.0, 5.5, 6.0, 6.5 and 7.0 per cent using specified cement content and the specified
aggregate grading but without violating the requirement of aggregate-cement ratio
specified in clause 3.1. Optimum moisture and density shall be established by preparing
cubes with varying moisture contents. Compaction of the mix shall be done in three
layers with vibratory hammer fitted with a square or rectangular foot (as in appendix
'A'). After establishing the optimum moisture, a set of six cubes shall be cast at that
optimum moisture for the determination of compressive strength on third and the
seventh day. Trial mixes shall be repeated if the strength is not satisfactory either by
increasing cement content. After the mix design is approved, the Contractor shall
construct a trial section in accordance with clause 6.0.

If during the construction of trial area/patch, the optimum moisture content determined
as above is found to be unsatisfactory, the contractor may make suitable changes in the
moisture content to achieve the satisfactory mix. The cube specimens prepared with
the change mix content should satisfy the strength requirement. Before production of
the mix, natural moisture content of the aggregate should be determined on a day-to-
day basis so that the moisture content could be adjusted. The mix finally designed
should neither stick to the rollers nor become too dry resulting in ravelling of surface.

6 Trial Length

6.1 After finalizing the mix design, trial length/area as decided by the Engineer-in-Charge
shall be prepared.

6.2 After the construction of the trial length, the in-situ density of the freshly laid material
shall be determined by sand replacement method .Three density holes shall be made at
locations equally spaced along a diagonal that bisects the trial length average of these
densities shall be determined. These main density holes shall not be made in the strip
500 mm from the edges. The average density obtained from the three samples
collected shall be the reference density and is considered as 100 per cent. The field
density of regular work will be compared with this reference density in accordance with
clauses 4.5.1 and A.2 of Appendix ‘A’.

6.3 The hardened concrete shall be cut over 3m width and reversed to inspect the bottom
surface for any segregation taking place. The trial length shall be constructed after
making necessary changes in the gradation of the mix to eliminate segregation of the
mix. The lower surface shall not have honey combing and the aggregates shall not be
held loosely at the edges.

6.4 The main work shall not start until the trial length has been approved by the Engineer-
in-Charge. After approval has been given, the materials, mix proportions, moisture
content, mixing, laying, compaction plant and construction procedures shall not be
changed without the approval of the Engineer-in-Charge.

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7 Tolerance for Surface Regularity, Level, Thickness, Density and
Strength

7.1 Surface Regularity: The maximum allowable difference between pavement surface
and underside of a 3 m straightedge when placed parallel with or at right angles to the
centre line of pavement at points decided by the Engineer–in-Charge shall not be more
exceed 10 mm for dry lean concrete.

7.2 Surface level: The tolerance in surface level for dry lean concrete shall not vary ±6
mm with reference to the longitudinal and cross-profile of the pavement shown on the
drawing or as directed by Engineer-in-Charge.

7.3 Thickness, density and strength shall be as per Appendix ‘A’.

7.4 Quality control test on the materials and the work and minimum frequencies shall be as
under:
S. No. Test Test Method Minimum
desirable
frequency
1. Quality of cement IS:269/455/1489 As required
2. Los Angeles Abrasion Value/ IS:2386(Part IV) One test per
Aggregate Impact value 200m3
3. Aggregate gradation IS: 2386(Part I) One test per
100m3
4. Aggregate moisture content/ IS: 2386(Part As required
Water absorption III)
5. Wet analysis of mix IS:1119 As required
6. Control of grade, camber - Regularly
thickness and surface finish
7. Cube strength of material mixed IS:516 One test per
at site (3 samples) 1000 Sqm or
part thereof

7.5 Rectification:

The defective length of the Dry Lean Concrete course shall be removed to full depth and
replaced with material conforming to the specification. Before relaying the course, the
disturbed subgrade or layer below shall be corrected by levelling, watering and
compacting.

8 Traffic

No heavy vehicles shall be permitted on the lean concrete sub-base after its
construction. Light vehicles if unavoidable may, however, be allowed after 7 days of its
construction with prior approval of the Engineer-in-Charge.

9 Measurement for Payment

The unit of measurement for dry lean concrete pavement shall be cubic meter of
concrete placed. This shall be determined from the top levels of the under layer and
the final levels of the consolidated dry lean concrete as mentioned below:-

Before laying dry lean concrete, the top levels of under layer shall be taken jointly by
the Engineer-in-Charge or his representative and the contractor at 3 meters intervals
both ways or closer as directed by the Engineer-in-Charge. These levels shall be

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 recorded on the plan as well as in the level book and the record shall be signed by the
contractor. The levels of the consolidated dry lean concrete shall again be taken and
plotted on the plan and recorded in the level book, to determine the average thickness
laid, on the basis of these levels. The volume of mix laid consolidated and finished, shall
then be the product of the measured surface area and the average thickness laid.

10 Rate

The contract unit rate payable for dry lean concrete sub-base shall be for carrying out
the required operations including all labour, materials and equipment, mixing, transport,
placing, compacting, finishing, curing, rectification of defective surfaces, testing as per
Specifications, all royalties, fees, storage and rents where necessary and all leads and
lifts.

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 Appendix ‘A’

Dry Lean Concrete

A.1 Sampling and Testing of Cubes

Samples of dry lean concrete for making cubes shall be taken from the uncompacted
material from different locations immediately before compaction at the rate of 3
samples for each 1000 Sqm or part thereof laid each day. The sampling of mix shall be
done from the paving site.

Test cubes of 150mm size shall be made immediately from each mix sample.

Cubes shall be made in accordance with the methods described in IS:516 except that
the cubes shall be compacted by means of a vibratory hammer with the moulds placed
on a level and rigid base. The vibrating hammer shall be electric or pneumatic type
fitted with a square or rectangular foot having an area of between 7500 to 14000
Sqmm. The compaction shall be uniformly applied for 60 + 5 seconds with a downward
force of between 300 N and 400 N on to each of the three layers of the lean concrete
material placed into the mould. The surface of each compacted layer shall be scarified
before the next layer is added to give key for the next layer. The final layer shall be
finished flush with the top of the cube mould.

The dry lean concrete shall be cured in accordance with IS:516.

A.2 In-Situ Density

The dry density of the laid material shall be determined from three density holes at
locations equally spaced along a diagonal that bisects each 2000 sqm or part thereof
laid each day and shall comply with the requirements as per Clause 4.5.1. This rate of
testing may be increased at the discretion of the Engineer in case of doubt or to
determine the extent of defective area in the even of non-compliance. Density holes at
random may be made to check the density at edges.

A.3 Thickness

The average thickness of the subbase layer as computed by the level data of sub-base
and subgrade or lower sub-base shall be as per the thickness specified in the contract
drawings. The thickness at any single location shall not be 8mm less than the specified
thickness. Such areas shall be corrected as stated in Clause 4.5.5. Areas which cannot
be repaired should be replaced over full width. The extent of deficient area should be
decided based on cores.

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