Construction Methodology

National Highways Authority of India (NHAI)
PROJECT
Construction of 4-Lane Greenfield Expressway spur from Delhi-Vadodara

Greenfield expressway near Bandikui to Jaipur in Bharatmala Pariyojana
Phase-I in the state of Rajasthan on Hybrid Annuity Mode
General Methods & Arrangements for

Design and Construction
Revision: R0
(August 2022)
Client Independent Engineer Concessionaire EPC Contractor

M/s GR Bandikui Jaipur M/s G R
National Highways
To be appointed Expressway Private Limited Infraprojects
Authority of India
(GBJEPL) Limited (GRIL)
Construction of 4-Lane Greenfield Expressway spur from Delhi-Vadodara Greenfield expressway near Bandikui
to Jaipur in Bharatmala Pariyojana Phase-I in the state of Rajasthan on Hybrid Annuity Mode
General Methodology & Arrangements for Design and Construction
Table of Contents
1. Introduction ..................................................................................................................................... 3
2. Method Statements .......................................................................................................................... 4
2. 1. Section 1: Road Works .............................................................................................................. 4
2.1.1. Flow Chart for Bituminous work ...................................................................................... 4
2.1.2. Flow Chart for Pavement Quality Concrete (PQC) Works ............................................... 5
2.1.3. Methodology for Survey and Setting Out ......................................................................... 6
2.1.4. Methodology for Clearing and Grubbing (C & G) ............................................................ 7
2.1.5. Methodology for Excavation ............................................................................................. 8
2.1.6. Methodology for Embankment Construction .................................................................. 10
2.1.7. Methodology for Embankment with Fly-ash................................................................... 13
2.1.8. Methodology for Subgrade Construction ........................................................................ 15
2.1.9. Methodology for Granular Sub-base (GSB) for rigid pavement ..................................... 17
2.1.10. Methodology for Wet Mix Macadam (WMM) ............................................................... 20
2.1.11. Methodology for Prime Coat ........................................................................................... 24
2.1.12. Methodology for Dense Bituminous Macadam (DBM) .................................................. 25
2.1.13. Methodology for Tack Coat ............................................................................................ 29
2.1.14. Methodology for Bituminous Concrete (BC) .................................................................. 30
2.1.15. Methodology for Dry Lean Concrete (DLC) ................................................................... 35
2.1.16. Methodology for Pavement Quality Concrete (PQC) ..................................................... 40
2.1.17. Methodology for Thermoplastic Road Marking Paint .................................................... 52
2.1.18. Methodology for Longitudinal Lined Drain .................................................................... 56
2.1.19. Methodology for Median Filling ..................................................................................... 58
2.2. Section 2: Structure Works...................................................................................................... 60
2.2.10. Methodology for Structural Concrete for Bridges and Culverts ..................................... 60
2.2.11. Methodology for Box Culverts ........................................................................................ 63
2.2.12. Methodology for Pipe Culverts ....................................................................................... 65
2.2.13. Methodology for Slab Culverts and Minor Bridges ........................................................ 67
2.2.14. Methodology for Precast Box Culvert ............................................................................. 70
2.2.15. Methodology for Pile Foundation ................................................................................... 72
2.2.16. Methodology for Pile Cap ............................................................................................... 74
2.2.17. Methodology for Casting of Pier/ Abutment shaft .......................................................... 78
2.2.18. Methodology for Casting of Pier Cap/Abutment Cap ..................................................... 80
2.2.19. Superstructure Construction & Concreting ..................................................................... 82
2.2.20. Methodology for Pre-Cast Segment ................................................................................ 87
2.2.21. Methodology of Pre-stressing of Girders ........................................................................ 92
2.2.22. Methodology for Underpass ............................................................................................ 96
2.2.23. Methodology for Kerb Laying......................................................................................... 99
2.2.24. Methodology of Wearing Coat ...................................................................................... 100
2.2.25. Methodology for Approach Slab ................................................................................... 101
2.2.26. Methodology Floor Protection ...................................................................................... 101
2.2.27. Methodology for Backfilling Behind Structures ........................................................... 101
2.2.28. Methodology for Road Signs......................................................................................... 102
2
General Methodology & Arrangements for Design and

Construction
1. Introduction
Table 1- Brief details of the Project
S. No. Particulars Details

Construction of 4-Lane Greenfield Expressway spur from Delhi-Vadodara
1. Project Greenfield expressway near Bandikui to Jaipur in Bharatmala Pariyojana Phase-I
in the state of Rajasthan on Hybrid Annuity Mode
2. Authority National Highways Authority of India
3. Independent Engineer To be appointed
4. Concessionaire M/s GR Bandikui Jaipur Expressway Private Limited (GBJEPL)
5. EPC Contractor M/s G R Infraprojects Limited
Salient Features of the Projects
1. Date of LOA issued 30.03.2022
2. Date of Agreement 14.06.2022

Date of Commencement /
3. TBD
Appointed Date
4. Bid Project Cost Rs. 1368.00 Cr
5. Construction Period 730 days from the Appointed Date
6. Total Length of the Project 66.916 km
7. Length of Connecting/Slip Road Service Road = 1.950 km RHS and Slip Road = 6.470 km including BHS
8. ROBs 1
9. Major Bridge 2
Interchange/Flyover/VUP/LVUP/
10. 3/2/11/0/17
SVUP
11. Minor Bridges 11
12. Box Culverts 141
13. Toll Plaza 5
14. Truck Lay Bye -
15. Bus-Bay / Bus Shelter -
16. Intersections 6
3
2. Method Statements
The method statement is divided into two sections:
1. Section 1: Road Works includes, Survey work, Clearing & Grubbing, Excavation,
Construction of Embankment, Subgrade, Granular Sub-base (GSB), Wet Mix Macadam
(WMM), Prime & Tack Coat, Bituminous Works (DBM and BC), DLC, PQC, Traffic
Signs, Median filling, Road Markings and Road Appurtenances.
2. Section 2: Structure works which includes the Hume Pipe Culvert, Box Culvert (RCC
& Pre-cast), Slab & Minor Bridge, Pile foundation, Pile Cap, Pier &Abutment shaft,
Pier Cap & Abutment cap, Casting of Girder & Precast Box Segment, Underpass, Grade
Separators, and Cross Drainage, Structures & Protection works.
2. 1.Section 1: Road Works

2.1.1. Flow Chart for Bituminous work
Clearing & Grubbing

1
(C & G)
2 Earthwork
3 Subgrade
Cement Treated Subbase

4
(CTSB)
Wet Mix Macadam

5
(WMM)
6 Prime Coat
Dense Bituminous Macadam

7
(DBM)
8 Tack Coat
Bituminous Concrete
9
(BC)
10 Road Marking & Road Furniture’s
4
2.1.2. Flow Chart for Pavement Quality Concrete (PQC) Works
Clearing & Grubbing

1
(C & G)
2 Earthwork
3 Subgrade
Granular Sub-base
4
(GSB)
Dry Lean Concrete

5
(DLC)
6 Separation Membrane
Pavement Quality Concrete

7
(PQC)
8 Texturing
9 Curing
10 Road Marking & Road Furniture’s
5
2.1.3. Methodology for Survey and Setting Out

Scope of Work
The work shall consist of detailed Survey work such as TBM Pillar fixing, establishment of
working benchmark, marking of project centre line, taking of OGL etc.
Reference Documents
1. Contract Agreement
2. IRC: SP: 99-2013
3. Ministry of Road Transport& Highway Specifications (MORT&H -5th Revision)
4. Relevant Drawings/ Approved Coordinates, FRL, Plan and Profile
Instruments / Tools
1. Total Station with all accessories : 1 no.
2. Auto Levels with levelling staff etc. : 1 no.
3. Measuring Tapes : 1 no.
4. Field Book : 1 no.
5. Calculator : 1 no..
Mason thread, nails, hammer, spade, paint, lime powder etc/others as required.
Method of Statement
1. Establishment of working Benchmarks tied with the Reference Benchmark in the area
soon after taking possession of the site. These to be got verify from Engineer. TBM
rechecking to be done in every month/specified interval and will be verify by Engineer.
2. The working Benchmarks shall be at the rate of four per km and also at or near all
drainage structures, over-bridges and underpasses.
3. In order to facilitate the setting out of the works, the centre line of the carriageway or
highway marked. It must then be accurately referenced in a manner satisfactory to the
Engineer, every 50m intervals in plain and rolling terrains and 20m intervals in hilly
terrain and in all curves.
4. NGL to be taken at 10 metre intervals longitudinally in specified offset.
Work Safety
5. Safety aids shall be mobilized in required number to take care of the workers & of the
adjoining road users.
6. Proper safety arrangement to be done during the survey work
7. At the time of survey work at existing road, flag man to be deputed on both side of
instrument placed.
8. Safety cone to be placed at both sides.
9. All Technical and non-technical staff should be in proper safety jackets and shoes.
10. The safety Officer shall make frequent patrols along the highway to ensure the safety of
equipment & signs are operational at all time.
Rectification of Works
Any discrepancies / damage / missing found during checking will be rectified as per instruction
of Concessionaire.
Approval
In the beginning and after a periodic check of TBM/BM lists will be prepared jointly, which will
be referred for future work.
6
2.1.4. Methodology for Clearing and Grubbing (C & G)

Scope of Work
The work shall consist of cutting, excavation, removing and disposing of all materials such as
trees of girth up to 300 mm, bushes, shrubs, stumps, roots, grass weeds, rubbish etc. and top soil
up to 150mm declared unsuitable by the Concessionaire, including draining out stagnant water
if any from the area of road land, drain, cross drainage structure and other area as specified in
the drawing or instructed by Concessionaire. It shall include necessary excavation & back filling
of the pits, by suitable soil, resulting from uprooting of trees & stumps and making the surface
levelled by suitable equipment and compacted by the power roller to required compaction as per
Clause 305.3.4 of MORT&H. The work also includes handling, salvaging and disposal of
cleared material. Clearing and grubbing shall be performed in advance of earthwork operation
and in accordance with requirement of this specification.
Reference
Reference Documents:
2. IRC: SP: 99-2013
4. Relevant Drawings
Preservation of Property / Amenities
Suitable safeguards shall be ensured to protect the roadside amenities, erosion & water pollution
by the exposed surface of slopes & cut formed during the clearing & grubbing operations, shall
be prevented through the use of berms, dikes, sediment basins, slope drains, grasses or other
suitable devices as per Clause 201.2 of MORT&H specifications.
Equipment’s
The following equipment’s shall be used to carry out the Clearing & Grubbing operation.
1. Grader
2. Excavator / J.C.B / Backhoe Loader
3. Tractor Trolley
4. Rollers
5. Water tankers
6. Survey Kit / Instrument
7. Dozer
Method of Operation
1. The toe line shall be established, with reference to the alignment based on the levels taken
earlier. The area for clearing & grubbing shall be demarcated, covering areas of road
embankment, drains, cross drainage structures and such other areas as specified in
relevant approved drawings.
2. Trees up to 300 mm in girth and stumps and roots falling within the construction zone
shall be removed by the suitable equipment’s or by manual labours as per site
requirements.
3. The Grader / Excavator / Dozer shall be deployed to remove all shrubs, bushes,
vegetation, grass, weeds, rubbish, and top organic soil up to 150 mm in thickness, which
is unsuitable for incorporation in the permanent work.
4. The above machines & tools shall be deployed to carry out the Clearing & Grubbing
operation and the bushes, stumps falling within proposed construction shall be cut to the
depth below ground level that in no case these fall within 500 mm of the sub grade. Also,
7
all vegetation and deleterious matters unsuitable for incorporation in the embankment &
subgrade shall be also removed between fill lines.
5. All branches of the trees extending above the highway shall be trimmed.
6. All excavation below the general ground level done to remove the trees stumps shall be
filled with suitable approved material and compacted to the density as required by the
specification.
7. The existing soil of natural ground shall be tested for its suitability. In the event of the
material non-conforming to the MORT&H specifications, it shall be removed and
replaced with the approved material & compacted with Vibratory Roller to achieve the
required density of 95% of MDD.
8. OGL will be taken after clearing, grubbing and compaction.
Disposal of the Materials
1. Materials collected from Clearing and Grubbing is disposed-off to the suitable places.
2. Stacking of cleared stumps, branches & boulders shall be done neatly at the appropriate
location up to a lead of 1000M.
Work Safety
Safety aids shall be mobilized in required number to take care of the workers & of the adjoining
road users.
1. All locations adjacent to the existing road where clearing & grubbing is progressing shall
be provided with visible safety & road signs.
2. Minimum of two flagmen with reflective vests holding a red flag each shall be deployed
to control the traffic wherever required during clearing & grubbing operations.
3. No machines or equipment’s shall be permitted to remain on the existing road or Shoulder
unattended unless it is properly protected &secured in a safe manner.
4. The Safety Officer frequently patrols at construction zones of project highway to ensure
the safety of equipment, workers & road users and safety signs are operational at all time.
Environmental Safety
1. Deleterious matters detrimental to the environment shall be disposed-off as directed by
Contact Aire at the designated locations provided by the Authority.
2. Vehicles tracks shall be kept moist to prevent flying of dust particles with the vehicle
movement.
2.1.5. Methodology for Excavation

Scope of Work
The work shall consist of excavation, removal and disposal of materials necessary for the
construction of roadway, side drains and waterways in accordance with clause 301 of MORT&H
specifications.
Reference
2. IRC: SP: 99-2013
8
Equipment’s
The following equipment’s shall be carried out for the Embankment Construction. If desired the
contractor shall demonstrate the efficacy of the type of equipment to be used, before
commencement of work.
1. Hydraulic Excavator
2. Dozer
3. Dumper (Tipper Trucks)
4. Motor Grader
5. Vibratory Roller
6. Water Tanker
7. Tractor Trolleys
8. Auto Level
9. Total Station
Method of Operation
1. The excavation of cutting shall be carried out in accordance with the drawings and to the
slopes, levels, depths, widths, and heights shown on the drawings.
2. Prior to commencement of the works, surveyor will use the survey data of road alignment
and TBM provided by the Engineer for setting out the extent of cutting in accordance
with the cross sections and put in such pegs, bars, sight rails and reference markers
necessary to control the works.
3. A survey team shall monitor and control each stage of work. All the major setting out
works will be carried out jointly with the Engineer's Surveyor. At the same time, the cut
material below the topsoil level shall be sampled and tested for laboratory compaction,
laboratory CBR, grading and index properties, so that it may be classified as suitable or
not for the various categories of fill. Requests for Approvals for use of that material as
fill will then be submitted. (These works to be carried out well ahead of proposed
commencement of reconstruction to enable the Engineer’s Representative to make
necessary adjustments to the works, if warranted).
4. Before commencement of cut/fill, it will be ensured that the haul roads have sufficient
width for to and from traffic and for smooth movement of the plant. The diversion of
traffic, warning signs, flagmen etc., to the agreed traffic management plan shall be
deployed for the safety of the works, and all necessary ramps be provided to maintain
existing accesses to and off the road.
5. Before starting the mass excavation, the topsoil shall be stripped from the area, either to
a thickness agreed from the soil sampling holes, or as directed on site by the Engineer or
his designated staff, and afterwards measured by levelling. Requests for Approval for
commencement of cutting shall then be submitted.
6. When Approvals are received, the mass excavation shall be started from the top of the
high ground down to the formation levels. At the specified frequency and at any change
of material the Engineer will be notified, and the material will be sampled and tested for
continued suitability of use. If the changed material is considered to be Hard Rock a
Request for Approval for re-classification will be submitted.
7. Slopes in cutting shall be trimmed mechanically to neat and even surfaces in accordance
with the designed gradients. The tolerance for widths of excavations shall not exceed the
dimensions shown on the drawings by more than 150mm or specified limits. Erosion
protection measures if desired by the Engineer shall be carried out after the completion
of trimming.
8. The construction of side drain shall follow closely to the slope trimming and surface
water shall be regulated to discharge to the side drain.
9
9. If directed by the Engineer the slope of cutting shall be cleared of all rock boulders or
rock fragments, which move when, pressed by a crowbar. The formation of sub-grade on
the cut area shall be sampled and tested for lab compaction, lab CBR, and grading and
index properties. If found to be suitable for sub-grade this will be compacted and tested
as to Cl.301 and Cl.305 Request for approval for placing of sub-base will then be
submitted. If there is likely to be a delay in immediately placing the sub-base, then a
protective layer 300mm thick shall be left in place above the sub-grade level for removal
later.
Work Safety
1. During Excavation works, adequate safety and traffic signs shall be installed adjacent to
the road shoulders to protect the ongoing works as per location specific safety plan.
2. For locations where the excavation work is going on, a minimum of 2 flagmen with
reflective vests and holding a red flag each be deployed to control the traffic.
3. All locations adjacent to existing road where Excavation is in progress shall be provided
with safety and road signs.
4. No machines or equipment’s shall always be permitted to remain on the existing road or
shoulder unattended unless it is properly protected and secured in a safe manner
5. The Safety Officer shall make frequent patrols along the highway to ensure that the safety
equipment and signs are operational at all time.
1. Nearby streams, water courses, lakes, reservoir shall be protected from contamination by
the soil erosion from areas exposed during excavation by constructing temporary berms,
dikes, sediment Basins, slopes, drains & by the use of temporary mulches, seeding or
other control devices.
movement.
2.1.6. Methodology for Embankment Construction
Scope of Work
The work shall consist of construction of embankment with approved and specified materials
obtained from approved borrow areas or suitable material obtained from roadway excavation
and drain excavation and in accordance with clause 305 of MORT&H specifications.
Reference
2. IRC: SP: 99-2013
5. IS 2720 Codes.
Setting Out
After completion of site clearance, the limits of embankment shall be marked by fixing pegs on
both sides at regular intervals. The chainage boards and working benchmark shall be set outside
the limits of construction areas.
Selection of Material and Borrow areas
1. Material: The material used in embankment shall be soil, moorum, gravel, reclaimed
material from pavement, fly ash, pond ash, a mixture of these or any other material
approved by the Contact Aire. List of approved borrow areas shall be provided to IE with
10
all requisite details / properties of soil for reference and further checking or verification
at site. It shall be free of logs, stumps, roots, rubbish & any other material likely to
deteriorate or affect the stability of the embankment. The material for embankment shall
be obtained from the approved source with preference to the material becoming available
from nearby roadway excavation or any other excavation under the contract. The material
requirements shall be in accordance with clause 305.2 of MORT&H specifications.
2. Borrow Material: The Borrow Material shall comply the Clause 305.2.2.2 of the
MORT&H specifications.
3. Applicable Permits: Before operating selected borrow area all lease and clearance from
government authority shall be taken.
Equipment’s
The following equipment’s shall be carried out for the Embankment Construction. If desired the
contractor shall demonstrate the efficacy of the type of equipment to be used, before
commencement of work.:
2. Dozer
4. Motor Grader
5. Vibratory Roller
6. Water Tanker
7. Tractor Trolleys
8. Auto Level
9. Total Station
Method of Operation:
1. After completion of site clearance, the limits of embankment shall be marked by fixing
pegs at regular intervals before commencing the earthwork. Construction toe line will be
more than the design toe line to ensure proper compaction on edges.
2. The original ground shall be levelled to facilitate placement of first layer of embankment,
water is sprinkled and then compacted by rolling so as to achieve minimum dry density
as specified in the Table 300-1 of MORT&H specifications. Unsuitable material
occurring in embankment foundation shall be removed and replaced by approved
materials laid in layers and suitably compacted to the required and specified degree of
compaction. Excavation at approved borrow areas shall be carried out with excavator and
transportation of excavated material shall be done by dumpers / tractor trolley.
3. Natural ground soil shall be tested for its suitability. If found unsuitable it shall be
replaced with the suitable material.
4. M.D.D. of natural ground soil shall be determined, and natural ground shall be tested for
dry density, if found less than 95% of M.D.D., the original ground shall be scarified
mixed with water and compacted with vibratory roller to achieve minimum specified dry
density.
5. For construction adjacent to the existing embankment, a continuous horizontal
benching 300 mm wide or as per drawing shall be provided in the existing
embankment.
6. The embankment material shall then be spread in layers up to 250 mm (when compacted using
vibratory roller / compactor) or up to 200 mm (when compacted using 80-100 kN static roller)
thicknesses over the entire area with the dozer and finished by a motor grader. If any clods or
hard lumps of earth larger than 75 mm is found same shall be broken manually. Where the
existing embankment to be widened and slope is steeper than 1 vertical to 4 horizonal continuous
11
benches shall be cut out into the old slope to ensure adequate bond. Where water is required to
be added the same shall be sprinkled from a water tanker fitted with sprinkler, uniformly on the
surface but without flooding and shall be mixed thoroughly in soil by harrowing until uniform
moisture content is obtained throughout the depth of the layer. If the material delivered to the
roadbed is too wet, it shall be dried by evaporation and exposure to the sun till the moisture come
down at/near the OMC level.
7. The compaction shall be done with the help of vibratory roller or 8 - 10 tonne static roller.
Compaction trial shall be carried out on a suitable stretch to determine the no. of passes
required for particular type of soil, dumped for embankment, to achieve densities
specified in the Table 300-2 of MORT&H specifications. Based on the trial actual
compaction will be carried out with required no. of passes of vibratory roller until the
specified density is achieved. Rolling shall progress parallel to the centreline of the road
uniformly overlapping each preceding track by one-third width. Rolling shall be
continued till the specified density is achieved as per Table 300-2. In case specified
compaction is not achieved the material in the soft area shall be removed and replaced
with approved material. Densities shall be tested by sand replacement method/nuclear
density gauge.
8. Testing: Testing of Compacted layer shall be conducted in compliance to frequency
stipulated in section 903.2.1 of MORT&H.
9. Subsequent layers shall be placed only after the finished layer has been tested as per s.no.
7. The top levels of the embankment shall be constructed with the approved drawing
keeping the variation within tolerance limit as per Table 900-1.
10. Different layers of embankment will be marked on pillars fixed outside the toe-line.
11. The construction operations/ requirements shall be in accordance with clause 305.3 of
MORT&H.
Work Safety
1. During construction of widening works, adequate safety and traffic signs shall be
installed adjacent to the road shoulders to protect the ongoing works as per location
specific safety plan.
2. For locations where the dumping of embankment materials by tippers are performed
from the road shoulder, a minimum of 2 flagmen with reflective vests and holding a red
flag each be deployed to control the traffic which may be affected by the unloading
operation.
3. All locations adjacent to existing road where embankment construction is in progress
shall be provided with safety and road signs.
4. No machines or equipment’s shall always be permitted to remain on the existing road
or shoulder unattended unless it is properly protected and secured in a safe manner.
5. The Safety Officer shall make frequent patrols along the highway to ensure that the
safety equipment and signs are operational at all times.
1. Nearby streams, water courses, lakes, reservoir shall be protected from contamination
by the soil erosion from areas exposed during excavation by constructing temporary
berms, dikes, sediment Basins, slopes, drains & by the use of temporary mulches,
seeding or other control devices.
movement.
12
2.1.7. Methodology for Embankment with Fly-ash

Scope
The scope of work includes the details regarding the construction of the embankment with fly-
ash.
Reference Documents
2. IRC SP: 99-2013
3. IRC SP: 58-2001
Setting Out
After completion of site clearance, the limits of embankment shall be marked by fixing pegs on
both sides at regular intervals. The chainage boards and working benchmark shall be set outside
the limits of construction areas.
Material
The materials to be used in embankment construction should be characterised to determine their
physical and engineering properties. The fly-ash conforming to specifications as per IRC SP: 58-
2001 shall be used.
Clearing and Grubbing
This work consists of cutting, removing and disposal of trees, bushes, shrubs, roots, grass,
rubbish, etc., from the alignment and within the area of road land which will accommodate road
embankment, drains, and such other areas as specified on the drawings. During clearing and
grubbing, the EPC Contractor shall take adequate precautions against soil erosion, water
pollution, etc. All trees, stumps, etc., falling within fill area should be cut to at least 500 mm
below ground level and pits shall be filled with suitable material and compacted thoroughly so
as to make the surface at these points conform to the surrounding area.
Stripping and storing of Topsoil
When constructing embankment using fly ash, the topsoil from all areas to be covered by the
embankment foundation should be stripped to specified depth not exceeding 150 mm. Top soil
should not be unnecessarily trafficked either before stripping or when in stockpiles. Also, these
shall not be surcharged, or otherwise loaded and multiple handling should be kept to minimum.
Setting Out
After the site has been cleared, the limits of embankment should be set out true to lines, curves,
slopes, grades and sections as shown on the drawings. The limits of the embankment should be
marked by fixing batter pegs on both sides at regular intervals as guides before commencing the
construction. The embankment should be built sufficiently wider than the design dimensions so
that surplus material may be trimmed, ensuring that the remaining material is of the desired
density and in position specified, and conforms to the specified slopes. Benchmarks and other
stakes should be maintained as long as in the opinion of the engineer, they are required for the
work.
Compacting the Ground supporting Embankment
Where necessary, the original ground should be levelled, scarified, mixed with water and then
compacted by rolling so as to achieve minimum 97 percent of MDD determined as per IS:2720
(Part 8) for the foundation soil.
13
Handling and Transportation of Fly-Ash

Fly ash is typically delivered to the site in covered dumper truck to minimize loss of moisture
and dusting. Fly ash generally contains moisture to prevent dusting.
Spreading and Compaction
Typical cross-sections of fly ash embankment with and without intermediate soil layers are
shown in the figure 1 and 2. The fly ash shall be confined by the selected earth cover from all
the three side as shown in the figure. The top 0.5 m of embankment should be constructed using
selected earth to form the subgrade for the road pavement.
The side soil cover of required width shall be provided along with the core and mechanically
compacted as the embankment progresses upwards. The addition of side cover subsequent to the
construction of the core is prohibited. The fill material should be spread by mechanical means,
finished by motor grader. Smaller vibratory rollers with dead weights of 10 to 15 kN perform
well on loose layer thickness of the order of 100-150 mm. medium weight vibratory rollers with
dead weights in the range 60-100 kN, provide satisfactory compaction for loose layer thickness
of about 250 mm. When vibratory roller of dead weight 80-100 kN are used, loose layer thickness
up to 400 mm can be adopted. When compaction is earned out using only static roller of 80- 100
kN weight, loose layer thickness shall not exceed 200 mm. The cover soil and fly-ash should be
laid simultaneously before compaction, to ensure confinement of fly-ash. Clods or hard lumps
in cover soil shall be broken to have a maximum size of 50 mm.
Moisture content of the fill material shall be checked at the site prior to commencement of
compaction. Moisture content of fly-ash laid for compaction shall normally vary from OMC±
2% (determined as per IS: 2720 (Part 8)). The moisture content limits can be varied depending
on the weather conditions, provided specified compaction is achieved as revealed through actual
site trials and there is no dust problem. At moisture contents higher than the appropriate range,
fly ash may liquefy and would be difficult to handle and compact. Moisture content of cover soil
shall be maintained at its OMC. Where water is required to be added to the fill material, it shall
be sprinkled from a water tanker fitted with a sprinkler capable of applying water uniformly
without any flooding. The water shall be mixed thoroughly by blading, discing or harrowing or
by suitable means until uniform moisture content is obtained throughout the depth of the layer.
14
If the material delivered to the construction site is too wet, it shall be dried by aeration and
exposure to sun, till the moisture content is acceptable for compaction.
Fly ash can be compacted using vibratory or static rollers. Each layer of fly-ash shall be
thoroughly compacted to the specified density. The construction of fly ash core and earth cover
on the sides should proceed simultaneously. Each compacted layer shall be finished parallel to
the final cross-section of the embankment. The minimum dry density after compaction as
percentage of MDD IS:2720 (Part 8) shall be 95% except when used in bridge abutments - for
embankment length equal to 1 .5 times the height of the embankment where 100% compaction
shall be required.
Fly ash embankments should be benched at 4 to 6 m vertical intervals to drain surface water run-
off to the ends of the embankment, rather than allowing full volume of the run-off to travel down
the face of the embankment to the toe. Run-off from pavement surfaces should be collected and
discharged into proper drainage system.
Finishing Operations
Finishing operations shall include the work of shaping and dressing the shoulders/verge/road bed
and side slopes to conform to the alignment, levels, cross-sections and dimensions shown on the
drawing or as directed by the Engineer subject to the tolerance. Both upper and lower ends of
side slopes shall be rounded off to improve appearance and to merge the embankment with the
adjacent terrain.
Quality Control
Quality of compacted material shall be controlled through periodic checks on the compaction
process or the end product, singly or in combination as directed. The end product must conform
to the specifications. The number of tests to be conducted and acceptance criteria shall be as
outlined in MORT&H Specifications for Road and Bridge Works, Section 900.
2.1.8. Methodology for Subgrade Construction

Scope of Work
The work shall consist of construction of Subgrade with approved and specified materials
obtained from approved borrow areas or suitable material obtained from roadway excavation
and drain excavation and in accordance with clause 305 of MORT&H specifications.
Reference
2. IRC: SP: 99-2013
Setting Out
After completion of site clearance/embankment the limits of sub-grade shall be marked by fixing
pegs on both sides at regular intervals. The working benchmark shall be set outside the limits of
construction areas.
Selection of Material and Borrow Areas
1. Material: The material used in Sub-grade shall be soil, moorum, gravel, reclaimed
material from pavement, fly ash, pond ash, a mixture of these or any other material
approved by the Contact Aire. List of approved borrow areas shall be provided to IE with
15
all requisite details / properties of soil for reference and further checking or verification
at site. It shall be free of logs, stumps, roots, rubbish & any other material likely to
deteriorate or affect the stability of subgrade. The material for subgrade shall be obtained
from the approved source with preference to the material becoming available from nearby
roadway excavation or any other excavation under the contract. The material
requirements shall be in accordance with clause 305.2 of MORT&H specifications.
2. Borrow Material: Samples shall be collected from the identified borrow area & tested as
per IS 2720. On confirmation of the suitability material the area shall be properly
demarcated.
Equipment
The following equipment shall be carried out for the subgrade construction. If desired the EPC
Contractor shall demonstrate the efficacy of the type of equipment to be used, before
2. Dozer
4. Motor Grader
5. Vibratory Roller
6. Water Tanker
7. Tractor Trolleys
8. Auto Levels
9. Total Station
Method of Operation
1. After completion of embankment, the limits of subgrade shall be marked by fixing pegs
at regular intervals before commencing the earthwork. Construction toe line will be more
than the design toe line to ensure proper compaction on edges.
2. The embankment top shall be levelled to facilitate placement of first layer of subgrade,
scarified, mixed with water and then compacted by rolling so as to achieve minimum dry
density as specified in Table 300-1 of MORT&H specifications. Subgrade treatment
specified for subgrade shall be carried out as per approved design and drawing.
Unsuitable material occurring in subgrade foundation shall be removed as per direction
and approval of Concessionaire and replaced by approved materials laid in layers and
suitably compacted to the required and specified degree of compaction. Excavation at
approved borrow areas shall be carried out with excavator and transportation of
excavated material shall be done by dumpers.
3. M.D.D. of borrow area soil as determined in lab, and when the same be laid for subgrade
preparation and tested for dry density should not have relative compaction less than 97%
of M.D.D. (as specified in MORT&H specifications Table 300-2), if found less, the layer
shall be scarified mixed with water and compacted to achieve minimum specified dry
density.
4. For construction adjacent to the existing embankment a continued, horizontal benching
300 mm wide or as per drawing shall be provided in the existing embankment.
5. The subgrade material shall then be spread in layers not exceeding 250 mm (when
compacted using vibratory roller / compactor) or up to 200 mm (when compacted using
80-100 kN static roller) thicknesses over the entire area with the dozer and finished by a
motor grader. When the existing subgrade to be widened continuous horizontal benches
shall be cut out into the old slope to ensure adequate bond. Where water is required to be
added the same shall be sprinkled from a water tanker fitted with sprinkler, uniformly on
the surface but without flooding and shall be mixed thoroughly in soil by blending or
16
harrowing until uniform moisture content is obtained throughout the depth of the layer.
If the material delivered to the roadbed is too wet, it shall be dried by evaporation and
exposure to the sun till the moisture content is accepted for compaction.
6. The compaction shall be done with the help of vibratory roller or 8 - 10 tonne static roller.
Compaction trial shall be carried out on a suitable stretch to determine the no. of passes
required for particular type of soil, dumped for subgrade, to achieve densities specified
in the Table 300-2 of MORT&H specifications. Based on the trial actual compaction will
be carried out with required no. of passes of vibratory roller or static roller until the
specified density is achieved. Rolling shall progress parallel to the centreline of the road
uniformly overlapping each preceding track by one-third width. Rolling shall be
continued till the specified density is achieved as per Table 300-2 of MORT&H
specifications. In case specific compaction is not achieved the material in the soft area
shall be removed and replaced with approved material. Densities shall be tested by sand
replacement method.
7. Subsequent layers shall be placed only after the finished layer has been tested as per the
clause 903.2.2 and accepted. The top levels of the subgrade shall be checked with
reference to the longitudinal and cross profile of the road as per drawing to keep the
variation within tolerance limit as per table 900-1.
8. Testing: Testing of Compacted layer shall be conducted in compliance to frequency
stipulated in section 903.2.1 of MORT&H.
Work Safety
1. During construction, adequate safety and traffic signs shall be installed adjacent to the
road shoulders to protect the ongoing works as per location specific safety plan.
2. For locations where the dumping of sub-grade materials by tippers are performed from
the road shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag
each be deployed to control the traffic which may be affected by the unloading operation.
3. All locations adjacent to existing road where sub-grade construction is in progress shall
be provided with visible safety and road signs.
shoulder unattended unless it is properly protected and secured in a safe manner.
equipment and signs are operational at all times.
1. Nearby streams, water courses, lakes, reservoir shall be protected from contamination by
dykes, sediment Basins, slopes, drains & by the use of temporary mulches, seeding or
movement.
2.1.9. Methodology for Granular Sub-base (GSB) for rigid pavement
Scope of Work
This Sub-base is the lowest of all the pavement layers consisting of natural sand, moorum, gravel,
crushed stone or combination thereof necessary to comply with the grading requirements.
Materials shall be laid in one or more layers as per line and level, grade and cross section shown
in the drawing and as per clause 401 of MORT&H specification.
17
Reference
2. IRC: SP: 99-2013
Setting Out
After the layer of Sub-grade has been approved, then line and level are carried out to fix the
granular sub-base layer (herein after called GSB layer). Pegs are fixed at regular intervals on the
safe side of the road edge where blade of grade will not disturb the peg while blending of the
GSB materials. On each peg top level of GSB layer is marked. The chainage boards and working
benchmark shall be set outside the limits of construction areas.
Material
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. Materials like brick metal,
kankar and crushed concrete may be allowed only with the specific approval of the
Concessionaire. List of approved sources shall be provided to IE with all requisite details /
material properties for reference and further checking or verification at site. The material shall
be free from organic or other deleterious constituents and shall conform to the quality standards
as prescribed in the Table 400-1 & 2 of MORT&H specifications and reproduced below.
IS Sieve Percent by Weight Passing the IS Sieve

Designation Grading 1 Grading 2 Grading 3 Grading 4 Grading 5 Grading 6
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
0.075 mm <5 <5 <5 <5 - 0-3
Aggregate Impact
Max 40
Value (AIV)
Liquid Limit Max 25
Plasticity Index Max 6
CBR Value Minimum 30% unless otherwise specified in the contract
18
Equipment
The following equipment shall be carried out for the sub-base construction. If desired, the
Contractor shall demonstrate the efficacy of the type of equipment to be used, before
3. Motor Grader
4. Vibratory Roller
5. Water Tanker
6. Tractor Trolleys
7. Auto Levels
8. Total Station
Construction Operations
1. Prior to laying of GSB material, the sub-grade already finished to clause: 301 or 305 of
MORT&H as applicable shall be prepared. Approved sub-grade layer is rolled with two
passes by smooth wheel roller with slight sprinkle of water.
2. The Sub-base material of the grading specified in the contract and water shall be mixed
mechanically by a suitable mixer equipped with provision for controlled addition of water
and mechanical mixing. So as to ensure homogenous and uniform mix. The dumped GSB
Material is spread with the help of motor grader on the approved layer of Sub-grade.
Samples will be collected from site to check for gradation. Sufficient water is added,
taken into account of evaporation losses. So that at the time of compaction, it is from 1
percent to 2 percent below the optimum moisture content corresponding to IS : 2720 (Part
8).Immediately rolling starts with vibratory roller of 80 to 100 KN static weight with
plain drum rolling is done from lower edge towards upper edge longitudinally for the
portion having unidirectional cross fall and super elevation.
3. Each pass of the roller shall uniformly overlap not less than one third of the track made
in the previous pass. During rolling, grade and cross fall shall be checked and any high
spot or depressions, which become apparent, corrected by adding or removing fresh
materials. The speed of roller shall not exceed 5km/h. Rolling shall be continued till the
density of the layer is achieved at 98% of the Maximum Dry Density
4. Testing: Testing of shall be conducted in compliance to frequency stipulated in section
table 900-3 of MORT&H.
Gradation IS:2720 (Pt 4) 1 Tests/400 m3
Atterberg’s limits IS:2720 (Pt 5) 1 Tests/400 m3
Moisture Content prior to

IS:2720 (Pt 2) 1 Tests/400 m3
compaction
Field Density of compacted layer IS:2720 (Pt 28) 1 Tests/1000 m2
Deleterious content test IS:2720 (Pt 27) As required
CBR IS:2720 (Pt 16) As required
19
Work Safety
2. For locations where the dumping of GSB materials by tippers are performed from the
road shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag each
be deployed to control the traffic which may be affected by the unloading operation.
3. All locations adjacent to existing road where GSB construction is in progress shall be
provided with visible safety and road signs.
1. Nearby Streams, water courses, lakes, reservoir shall be protected from contamination by
dikes, sediment Basins, slopes, drains & by the use of temporary mulches, seeding or
2. Vehicles / tracks shall be kept moist to prevent flying of dust particles with the vehicle
movement.
CTSB – Methodology will be submitted separately
2.1.10. Methodology for Wet Mix Macadam (WMM)

Scope
The work shall consist of laying, spreading and compacting of clean, crushed, well-graded
specified granular materials on a prepared and approved Granular sub-Base. The material is well
mixed with water and rolled to a dense mass. It shall be laid on one or more layers as per line
and level, grade and cross section shown in the drawing or as directed by the Engineer. The
thickness of single compacted Wet Mixed Macadam (WMM) Base shall not be less than 75mm.
Maximum thickness of single compacted layer base can be up to 200mm upon approval of
Engineer.
Reference
2. IRC: SP: 99-2013
4. Relevant drawings
20
Setting Out
After the layer of CTSB has been approved, then line and level are carried out to fix the Wet
Mix Macadam base layer (herein after called WMM Base). Pegs are fixed at regular intervals on
the safe side of the road edge where blade of grader should not disturb the peg while blending of
the Base materials. On each peg’s top level of Base layer is marked. The chainage boards and
working benchmark shall be set outside the limits of construction areas.
Materials
1. Aggregates:
a. 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. If water absorption
of coarse aggregate is greater than 2%, soundness test shall be carried out in
accordance with IS:2386 P-5. The aggregates shall conform to the physical
requirements as per Table 400-12 of MORT&H specifications.
b. Grading Requirements: The aggregates shall conform to the grading given in Table
400-13 of MORT&H specifications and reproduced below.
IS Sieve Designation, mm % by weight passing the IS Sieve

53.00 100
45.00 95-100
26.50 -
22.40 60-80
11.20 40-60
4.75 25-40
2.36 15-30
600.00 micron 8-22
75.00 micron 0-5
Material finer than 425 microns shall have Plasticity Index less than 6.
Equipment
The following equipment shall be carried out for the subbase (WMM) construction. If desired
the Contractor shall demonstrate the efficacy of the type of equipment to be used before
3. Motor Grader
4. Sensor Paver
5. Vibratory Roller
6. Water Tanker
7. Tractor Trolleys
8. Auto Level
9. Total Station
2.1.10.6. Detail of Personnel Deployed
21
a. Personnel Deployed for Execution

1. Engineer 01
2. Site Supervisor 01
3. Surveyor 01
4. Safety Supervisor 01
5. Paver Operator 01
6. Roller Operator As Required
7. Labour As Required
b. Personnel Deployed for Quality Control
1. Lab Technician 01
2. Lab Helper As Required
2.1.10.7. Construction Operations

1. While constructing Wet Mix Macadam, arrangement shall be made for the lateral
confinement of wet mix. This shall be done by laying materials on adjoining shoulder
along with that of WMM layer. The preparation of mix, spreading of mix and compaction
are done sequentially. Preparation of Base: The surface of the sub-base to receive the
Wet Mix Macadam course shall be prepared to the specified grade and camber and
cleaned of dust, dirt and other extraneous material. Any ruts or soft yielding places shall
be corrected in an approved manner and rolled until firm surface is obtained.
2. Wet mix Macadam shall be prepared in an approved WMM mixing plant having
provision for controlled addition of water and forced/positive mixing arrangement.
Optimum moisture for mixing shall be determined in accordance with IS: 2720 (Part8)
after replacing the aggregate fraction retained on 22.4 mm sieve with materials of passing
from 22.4 and retained on 4.75mm. While adding water, evaporation loss shall also be
taken into account. The mixed material should be uniformly wet, and no segregation shall
be permitted.
3. Immediately after mixing, the aggregate shall be spread uniformly and evenly upon the
approved CTSB layer. Materials should neither be dumped in heap nor their hauling over
a partly completed stretch. The mix shall be spread by a WMM paver finisher capable of
paving minimum 4.5m to 9.0m width hydraulically operated telescopic screed. The
screed shall have temping and vibrating arrangement for initial compaction of the layer.
Loading hoppers and suitable distribution system, so as to provide a smooth
uninterrupted material flow for layer thicknesses from the tipper to the screed. Automatic
levelling control system with electronic sensing device to maintain mat thickness and
cross slope of mat during laying procedure. In certain cases where it is not possible for
the paver to be utilizes, motor Grader may be used. The motor grader shall be capable of
spreading the material uniformly all over the surface. Its blade shall have hydraulic
control suitable for initial adjustments and maintaining the same so as to achieve the
specified slope. The layer may be tested by depth block during construction. No
segregation of materials is allowed. The aggregates should be of uniform gradation with
no pockets of fine materials.
2.1.10.8.Compaction
After the mix has been laid on site to the required thickness, grade and camber, then compaction
is carried out with suitable roller to the full depth. For a thickness up to 200mm in a single layer,
compaction shall be done with vibratory roller of 80 to 100 KN static weights with plain drum
or equivalent capacity roller. Rolling is done from lower edge towards upper edge longitudinally
for the portion having unidirectional cross fall and super elevation. Each pass of the roller shall
22
uniformly overlap not less than one third of the track made in the previous pass. During rolling,
grade and cross fall shall be checked and any high spot or depressions, which become apparent,
corrected by adding or removing fresh materials. The speed of roller shall not exceed 5km/h.
Rolling shall be continued till the density of the layer is achieved 98% of the Maximum Dry
Density. Rolling should not be done when the WMM layer is soft or yielding or when it causes
a wave like motion. If irregularities develop during rolling which exceeds 12mm when tested
with 3m straight edge, the surface should be loosened, and premixed materials added or removed
as required before rolling again. In no case the unmixed material be permitted to make up the
depressions.
2.1.10.9.Opening of Traffic
No vehicular traffic of any kind should be allowed on the finished wet mix macadam surface.
Construction traffic may be allowed.
2.1.10.10. Quality Control & Surface Finish
Control on the quality of materials and works shall be exercised by the Concessionaire in
accordance with Section 900. The surface finish of construction shall conform to the
requirements of Clause 902.
2.1.10.11. Rectification of Surface Irregularities
Where the surface irregularity of the WMM 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, re-shaped with added premixed
material or removed and replaced with fresh premixed material as applicable and re-compacted
in accordance with Clause 406.3. The area treated in the aforesaid manner shall not be less than
5 m long and 2 m wide. In no case shall depressions be filled up with unmixed and ungraded
material or fines.
2.1.10.12. Work Safety
2. For locations where the WMM laying paving continue are performed from the road
shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag each be
deployed to control the traffic which may be affected by the paving operation.
3. All locations adjacent to existing road where WMM construction is in progress shall be
provided with visible safety and road signs.
equipment and signs are always operational.
1. Nearby Streams, water courses, lakes, reservoir shall be protected from contamination by
dikes, sediment Basins, slopes, drains & using temporary mulches, seeding or other
control devices.
2. Vehicles / tracks shall be kept moist to prevent flying of dust particles with the vehicle
movement.
23
2.1.11. Methodology for Prime Coat

2.1.11.6.Scope
The work shall consist of application of single coat of low viscosity liquid bituminous material
over prepared WMM surface preparatory to the superimposition of bituminous treatment or mix.
The prime coat shall be applied only on WMM layer over which DBM layers are to be laid.
The priming shall not be carried out if the surface of base layer is wet, or if the weather is foggy,
rainy, windy etc. or the temperature in shade is less than 10ºC.
The rate of spray shall be as specified in section 502.2.2 of the MORT&H specifications i.e., 0.7
to 1 kg/sq. m.
2.1.11.7.Reference
2. IRC: SP: 99-2013
2.1.11.8.Materials
The Emulsion used for prime coat shall be cationic bitumen emulsion (SS 1) complying with
IS 8887.Record of MTC for each lot /load shall be maintained in laboratory. Before using
emulsion from source, credential along with sample test results shall be submitted to IE.
2.1.11.9.Equipment’s
1. Priming shall be carried out by using self-propelled bitumen pressure distributor.
2. The distributor shall ensure that the material is sprayed uniformly and at specified rates
and temperatures.
3. Air Compressor.
4. Mechanical Broom.
2.1.11.10. Preparation of Base
The WMM layer surface to be primed shall be swept clean, made free from dust, and be made
dry. It shall be shaped to the specified grades and levels as per drawings. It shall be free from
any ruts, irregularities, and segregated materials.
If the surface to be primed is so dry and dusty to cause freckling of bituminous material, the
same shall be lightly and uniformly sprinkled with water immediately before priming but priming
shall be done after no surface water is visible.
2.1.11.11. Application
The prime coat shall be sprayed uniformly over the base surface. The temperature of the primer
during application shall be such that the primer could be sprayed effectively through the jets of
the spray bar.
For control of the Quality of material and work it shall be tested in accordance with Table 900-
4
Test Minimum Desirable Frequency
24
Number of Sample per lot and tests as per

Quality of Binder
IS:73, IS:217 and IS:8887 as applicable
Binder Temp At regular close interval
Rate of Spread of binder Three tests per day
2.1.11.12. Curing
After the application of the Prime Coat, the surface shall be allowed to be cured for at least 24
hours to allow the penetration of the Priming Material into the Base course. During this curing
period no traffic of any kind shall be allowed to ply on the surface.
2.1.11.13. Arrangement of Traffic
No traffic will be allowed on priming surface. Diversion road if required will be provided as
required under Clause 112, of the MORT&H specifications.
2.1.12. Methodology for Dense Bituminous Macadam (DBM)

2.1.12.6.Scope
This work shall consist of construction in a single or multiple layer of DBM on a previously
prepared base or sub base. The thickness of single layer shall be between 50 mm to 100 mm or
as per approved design and drawings.
2.1.12.7.Reference
2. IRC: SP: 99-2013
5. Relevant IRC codes
1. Crusher of required capacity for Aggregates/ Crushed Aggregate
2. Hot Mix Plant
3. Batching Plant
4. Paver with sensor arrangement
5. Steel Tandem Rollers with required weight
6. Pneumatic Tandem Roller with required weight
7. Bitumen Sprayer
8. Dumpers
9. Air compressor
10. Pegs for putting levels.
11. Broom (Mechanical)
12. Straight edge
13. Thermometers (0 - 250ºC range)
14. Gauge for checking thickness.
15. Survey Kit / instrument
16. Measuring tape (metal)
17. Core cutting machine.
25
2.1.12.9.Details of Personnel Deployed

1. Sr. Engineer 01
3. Surveyor 01
1. Lab Technician As Required
2.1.12.10. Materials
The source and test report of all material shall be submitted to the Concessionaire for review
prior to use in aforesaid work. List of all the approved materials shall be provided to IE with all
the requisite details for reference and further verification at site.
1. Bitumen: The type & grade of bitumen shall be VG 40 conforming to IS 73.

Every lot of Bitumen shall have MTC & Before accepting the lot testing for softening
point, penetration, viscosity (Absolute & Kinematic) & residue in TCE shall be
conducted according to relevant IS code.
2. Coarse Aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel
or other hard material retained on 2.36 mm sieve. They shall be clean, hard, durable of
cubical shape, free from dust and soft or friable matter, organic or other deleterious
substances. Coarse aggregates shall be procured from the approved quarry and crusher.
The coarse aggregate shall satisfy the specifications requirement set out in sub-clause
505.2.2 and 505.2.5 of the MORT&H specifications as per table 500-8:
Property Test Specification Testing Method
Max 5% passing
Cleanliness Grain Size analysis IS:2386 Part-I
0.075mm Sieve
Flakiness and Elongation Index
Particle Shape Max 35% IS:2386 Part-I
(Combined)
Los Angeles Abrasion Value or Max 35% IS:2386 Part-IV
Strength
Aggregate Impact Value Max 27% IS:2386 Part-IV
Soundness either Sodium Sulphate or Max 12% IS:2386 Part-V
Durability
Magnesium Sulphate Max 18% IS:2386 Part-V
Water Absorption Water Absorption Max 2% IS:2386 Part III
Coating and Stripping of Bitumen Min. Retained Coating

Stripping IS:6241
Aggregate 95%
Water Sensitivity Retained Tensile Strength Min. 80% AASTHO 283
26
Note: If the minimum retained tensile test strength falls below 80%, anti-stripping agent
shall be used.
3. Fine Aggregates: Fine aggregates shall be either crushed or naturally occurring mineral
material, or a combination of the two, passing the 2.36 mm sieve and retained on the 75-
micron sieve. These shall be clean, hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious matter. The fine aggregate shall have a sand
equivalent value of not less than 50 when tested in accordance with the requirement of
IS: 2720 (part 37). The plasticity index of the fraction passing the 0.425 mm sieve shall
not exceed 4, when tested in accordance with IS: 2720 (Part 5).
4. Filler: This shall conform to Clause 505.2.4 of MORT&H specifications. Filler shall
consist of finely divided mineral matter such as rock dust, hydrated lime or cement. The
filler shall be graded within the limits indicated in Table 500-9 of MORT&H
specifications.
IS sieve (mm) Cumulative Percent Passing by weight of Total Aggregate

0.6 100
0.3 95-100
0.075 85-100
5. Aggregate Grading and Binder Content: When tested in accordance with IS: 2386 Part I
(wet sieve method), the combined grading of the coarse and fine aggregate and added
filler for the particular mixture shall fall within the limits shown in Table 500-10 of
MORT&H specifications. Bitumen content shall be determined in accordance with
clause 505.3 of MORT&H specifications.
2.1.12.11. Mix Design
1. Requirement of Mix: Apart from conformity with the grading and quality requirement
for individual ingredients, the mixture shall meet the requirements set out in table 500-
11 of the MORT&H specifications.
2. Mix Design: The binder content shall be optimized to achieve the requirement of the mix
set out in table 500-11. The Marshall method for determining the optimum binder content
shall be adopted as described in MS-2 Asphalt Institute Manual. The Fines to Bitumen
(F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
3. Job Mix Formula: The procedure for formulating the job mix formula shall be generally
as specified in clause 505.3.3 of MORT&H specifications. All relevant testing and Mix
design shall be conducted jointly along with IE. The test results obtained thereafter shall
be submitted to the Concessionaire for approval and trial stretch will be laid based on the
submitted JMF. Further Concessionaire shall submit the JMF to IE for concurrence.
4. Plant Trials: After completion of JMF at lab, plant trial will be carried out to establish
that the plant can be set up to produce a uniform mix conforming to the approved job mix
formula. The permissible variation in job mix formula will be as per the limits specified
in MORT&H specifications Table500-13 and reproduced below.
Description Base/Binder Course

Aggregate Passing 19mm Sieve or larger ±8%
27
Aggregate passing 13.2mm, 9.5mm sieve ±7%

Aggregate passing 4.75mm ±6%
Aggregate passing 2.36mm, 1.18mm, 0.6mm ±5%
Aggregate passing 0.3mm, 0.15mm ±4%
Binder content ±0.3%
Mixing temperature ±10 ºC
2.1.12.12. Construction Operation

1. Weather and Seasonal Limitations: The provisions of clause 501.5.1 MORT&H
specifications shall be followed.
2. Preparation of Base: The base on which DBM is to be laid shall be prepared, shaped and
compacted to the required profile in accordance with clause 501 and clause 902 of
MORT&H specifications and prime coat shall be applied as per clause 502 of MORT&H
specifications.
3. Prime Coat: Where the material on which the DBM is to be laid is other than a bitumen
bound layer, a prime coat shall be applied in accordance with clause 502.
4. Preparation and Transportation of Mix: The provisions of clauses 501.3 and 501.4 shall
apply. The mixing, laying and rolling temperature shall be as per Table 500-2 of
5. Spreading: The provisions of clause 501.5.3 & 501.5.4 of MORT&H shall apply. Laying
shall be done with two nos. of Paver simultaneously to avoid any longitudinal cold joints.
if there are any longitudinal joints left, the same shall be cut vertically using an asphalt
cutter and panted with bitumen emulsion before placing fresh material.
6. Rolling: Compaction shall be carried out in accordance with the provisions of clauses
501.6 and 501.7 The density of the finished paving layer shall be determined by taking
cores, no sooner than 24 hours after laying, or by other approved method. The compacted
layers of DBM shall have a minimum field density equal to or more than 92% of the
density based on theoretical maximum specific gravity (Gmm) obtained on the day of
compaction. Rolling shall be continued until the specified density is achieved or there is
no movement under the roller.
7. Traffic Diversion Plan: Before execution of work an approved diversion, plan shall be
adopted.
8. Work Safety
a. During construction, adequate safety and traffic signs shall be installed adjacent
to the road shoulders to protect the ongoing works as per location specific safety
plan.
b. For locations where the DBM laying paving continue are performed from the road
shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag
each be deployed to control the traffic which may be affected by the paving
operation.
c. All locations adjacent to existing road where DBM construction is in progress
shall be provided with visible safety and road signs.
d. No machines or equipment’s shall always be permitted to remain on the existing
road or shoulder unattended unless it is properly protected and secured in a safe
manner.
28
e. Necessary PPE shall be worn by the workers while handling of laying and rolling
works of Bituminous mix.
f. The Safety Officer shall make frequent patrols along the highway to ensure that
the safety equipment and signs are always operational.
9. Environmental Safety:
a) The excess material and any other excess materials shall be disposed suitably
without polluting streams, water courses.
b) Vehicles tracks shall be kept moist to prevent flying of dust particles with the
vehicle movement.
c) The smoke and dust at plant will be controlled by adopting suitable method.
2.1.12.13. Surface Finish and Quality of work
The surface finish of the completed construction shall conform to the requirement of clause 902.
For control of the quality of materials and the work carried out, the provisions of section 900
shall apply.
2.1.13. Methodology for Tack Coat

2.1.13.6.Scope
The work shall consist of application of single coat of low viscosity liquid bituminous material
over DBM surface by clause 503 of the MORT&H specifications.
The tack coat shall not be carried out if the surface of DBM layer is wet, or if the weather is
foggy, rainy, windy etc. or the temperature in shade is less than 10ºC.
The rate of spray shall be as specified in Table 500-5 of the MORT&H specifications i.e. 0.2 to
0.3kg/sqm.
2.1.13.7.Reference
2. IRC: SP: 99-2013
2.1.13.8.Materials
The binder used for tack coat shall be cationic bitumen emulsion (RS 1) complying with IS 8887
or suitable low viscosity paving bitumen of VG 10 grade conforming to IS: 73.
1. Tack coat shall be carried out by using self-propelled bitumen pressure sprayer for
spraying the material uniformly at a specified rate and temperatures.
2. Air Compressor.
3. Mechanical Broom.
2.1.13.10. Preparation of Base
The DBM layer surface on which tack coat is to be applied shall be swept clean, made free from
dust, and be made dry. It shall be shaped to the specified grades and levels as per drawings. It
shall be free from any ruts, irregularities, and segregated materials.
29
2.1.13.11. Application
The application of tack coat shall be at the rate specified in Table 500-5, and it shall be applied
uniformly. If rate of application of Tack Coat is not specified in the contract, then it shall be the
rate specified in Table 500-5. No dilution or heating at site of RS1 bitumen emulsion shall be
permitted. Paving bitumen if used for tack coat shall be heated to appropriate temperature in
bitumen boilers to achieve viscosity less than 2 poise. The normal range of spraying temperature
for a bituminous emulsion shall be 20°C to 70°C and for cutback, 50°C to 8O°C. The method of
application of tack coat will depend on the type of equipment to be used, size of nozzles, pressure
at the spray bar, and speed or forward movement.
For control of the Quality of material and work it shall be tested in accordance with Table 900-
4
Test Minimum Desirable Frequency

Number of Sample per lot and tests as per
Quality of Binder
IS:73, IS:217 and IS:8887 as applicable
Binder Temp At regular close interval
Rate of Spread of binder Three test per day
2.1.13.12. Curing
The tack coat shall be left to cure until all the volatiles have evaporated before any subsequent
construction is started. No plant or vehicles shall be allowed on the tack coat other than those
essential for the construction.
No traffic will be allowed on priming surface. Diversion road if required will be provided as
required under Clause 112, of the MORT&H specifications.
2.1.14. Methodology for Bituminous Concrete (BC)

2.1.14.6.Scope
This work shall consist of laying, in a single course, a 30 mm to 50 mm thick layer of BC on a
previously prepared bituminous bound surface, as per specified lines & grades and in accordance
with clause 507 of MORT&H specifications.
2.1.14.7.Reference
2. IRC: SP: 99-2013
5. Relevant IRC Codes
1. Crusher of required capacity for Aggregates.
2. Hot Mix Plant
3. Batching Plant
4. Paver with sensor arrangement
30
5. Steel Tandem Rollers with required weight

6. Pneumatic Tandem Roller with required weight
7. Bitumen Sprayer
8. Dumpers
9. Air compressor
10. Pegs for putting levels.
11. Broom (Mechanical)
12. Straight edge
13. Thermometers (0 - 250ºC range)
14. Gauge for checking thickness
15. Survey Kit / instrument
16. Measuring tape (metal)
17. Core cutting machine
1. Sr. Engineer 01
2. Site Engineer 01
3. Surveyor 01
1. QC Engineer 01
The source and test report of all material shall be submitted to the Concessionaire for approval
prior to use in aforesaid work. List of all the approved materials shall be provided to IE with all
the requisite details for reference and further verification at site.
1. Bitumen: The type & grade of bitumen shall be VG 40 conforming to IS 73.
2. Coarse Aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel
or other hard material retained on 2.36 mm sieve. It shall be clean, hard, durable and
cubical shape, free from dust and soft organic and other deleterious substances. The
aggregate shall satisfy the physical requirements specified in Table 500-16 of MORT&H
specifications and reproduced below. Where crushed gravel is proposed for use as
aggregate, not less than 90% by weight of the crushed material retained on 4.75 mm sieve
shall have at least two fractured faces resulting from crushing operation. Coarse
aggregates shall be procured from the approved quarry and crusher. List of approved
sources shall be provided to IE with all requisite details / material properties for reference
and further checking or verification at site. Where the selected source of aggregates has
poor affinity for bitumen, the bitumen shall be treated with anti-stripping agents, as per
the material manufacturer's recommendations.
31
Property Test Specification Testing Method
Max 5% passing
Cleanliness Grain Size analysis IS: 2386 Part-I
0.075mm Sieve
Flakiness and Elongation Index
Particle Shape Max 35% IS: 2386 Part-I
(Combined)
Los Angeles Abrasion Value or Max 30% IS: 2386 Part-IV
Strength
Aggregate Impact Value Max 24% IS: 386 Part-IV
Soundness either Sodium Sulphate or Max 12% IS: 2386 Part-V IS:
Durability
Magnesium Sulphate Max 18% 2386 Part-V
Water Absorption Water Absorption Max 2% IS: 2386 Part III
Coating and Stripping of Bitumen Min. Retained Coating

Stripping IS: 6241
Aggregate 95%
Polishing Polished Stone Value Min 55 BS:812-114
AASTHO T 283
Water Sensitivity Retained Tensile Strength Min. 80%
3. Fine Aggregates: Fine aggregates shall be either crushed or naturally occurring mineral
material, or a combination of the two, passing the 2.36 mm sieve and retained on the 75-
micron sieve. These shall be clean, hard, durable, dry and free from dust, and soft or
friable matter, organic or other deleterious matter. The fine aggregate shall have a sand
equivalent value of not less than 50 when tested in accordance with the requirement of
IS: 2720 (part 37). The plasticity index of the fraction passing the 0.425 mm sieve shall
not exceed 4, when tested in accordance with IS: 2720 (Part 5).
4. Filler: This shall conform to Clause 505.2.4 of MORT&H specifications. Filler shall
consist of finely divided mineral matter such as rock dust, hydrated lime or cement. The
filler shall be graded within the limits indicated in Table 500-9 of MORT&H
specifications.
IS sieve (mm) Cumulative Percent Passing by weight of Total Aggregate

0.6 100
0.3 95-100
0.075 85-100
5. Aggregate Grading and Binder Content: When tested in accordance with IS: 2386 Part I
(wet sieve method), the combined grading of the coarse and fine aggregate and added
filler for the particular mixture shall fall within the limits shown in Table 500-17 of
MORT&H specifications. Bitumen content shall be determined in accordance with
clause 505.3 of MORT&H specifications.
2.1.14.11. Mix Design
1. Requirement of Mix: Apart from conformity with the grading and quality requirements
for individual ingredients, the mixture shall meet the requirements set out in Table 500-
17 of MORT&H specifications. The mix design for BC mixes using modified bitumen
32
shall be done in the same manner as used for conventional bitumen by Marshall Method
of Mix Design (MS2).
2. Mix Design: The binder content shall be optimized to achieve the requirements of the
mixture set out in Table 500-17. The Marshall method for determining the optimum
binder content shall be adopted as described in the Asphalt Institute Manual MS-2. The
Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.
3. Job Mix Formula: The procedure for formulating the JMF shall be generally as specified
in Clause 507.3.3. Mix design will be established jointly and all testing will be conducted
jointly. The result thus obtained will be submitted to the Concessionaire for the approval
and trial stretch will be laid based on the submitted JMF. Further Concessionaire shall
submit the JMF to IE for concurrence.
4. Plant Trials: After completion of JMF at lab, plant trial will be carried out to establish
that the plant can be set up to produce a uniform mix conforming to the approved JMF.
The permissible variation in JMF will be as per the limits specified in MORT&H
specifications Table 500-18.
Description Base/Binder Course
Aggregate Passing 19mm Sieve or larger ±7%
Aggregate passing 13.2mm, 9.5mm sieve ±6%
Aggregate passing 2.36mm, 1.18mm, 0.6mm ±4%
Aggregate passing 0.3mm, 0.15mm ±3%
Aggregate passing 0.075mm ±1.5%
Binder content ±0.3%
Mixing Temperature ±10 ºC
2.1.14.12. Construction Operation

1. Weather and Seasonal Limitations: The work of laying shall not be taken up during rainy
or foggy weather/ the base course is damp or wet or during dust storm or when the
atmospheric temperature in shade is 10ºC or less as specified in the MORT&H
specifications.
2. Preparation of Base: The base surface on which the BC is to be laid shall be clean and
treated with Tack coat. The surface shall be thoroughly swept clean by broom and dust
removed by compressed air.
3. Tack Coat: This shall be as per clause 503 of MORT&H specifications.
4. Preparation and Transportation of Mix: BC shall be prepared in batch in Hot Mix Plant.
The mixing will be done in a twin shaft pug mill, which will produce a homogeneous
mix. The mixture shall be transported from the batching plant in tippers / dumpers
covered with tarpaulin, as and when required, to maintain the temperature, over spillage
and dust and environment hazard.
5. Spreading: The mix shall be transported to the site by the dumpers, which shall slowly
discharge the mix in the paver hopper, while both the tipper and paver will move forward
steadily and slowly. The automatic sensor shall ensure that the mix is being laid to the
proper line, grade and level. The direction of the paver will be guided by the string lines
fixed with the stack & arms on both sides of the edges 0.5 m away from the edge.
33
Transverse & longitudinal joints shall be cut vertically with asphalt cutter and a coat of
hot bitumen shall be applied before placing materials.
6. Rolling & Compaction: As soon as the mix has been laid by the paver, compaction shall
be done with the help of a set of rollers moving at a speed not exceeding 5 km/hour
following close to the paver. Rolling sequence will be as established during laying trial
stretch.
Compaction shall subsequently be completed before the temperature falls below the
minimum rolling temperatures. Rolling of the longitudinal joints shall be done
immediately behind the paving operation. After this, rolling shall commence at the edges
and progress towards the centre longitudinally except that on super elevation and
unidirectional cambered portions, it shall progress from the lower to the upper edge
parallel to the centre line of the pavement. Rolling shall continue until all roller marks
have been removed from the surface.
a. Initial or breakdown rolling shall be done with 80-100 kN dead weight smooth
wheeled rollers.
b. Intermediate rolling shall be done by 8-10 tons dead weight or vibratory roller or
with a pneumatic tired roller of 12 to 15 tons weight having nine wheels, with a
tire pressure of at least 5.6 kg/sq. cm. The finish rolling shall be done with 6 to 8
tons smooth wheeled tandem rollers and the no. of passes required shall be
decided after laying a trial bed.
During rolling, wheels of rollers shall be kept moist by light sprinkling water from the
water storage fitted with the roller to prevent the mix from adhering to the wheels. The
roller shall proceed on the fresh material with rear or fixed wheel leading so as to
minimize the pushing of the mix.
In portions in camber, rolling should begin at the edge with the roller forward and
backward until the edges have been firmly compacted. The roller shall then progress
gradually towards the centre parallel to the centre line uniformly overlapping each of the
preceding tracks by one-third width until the entire surface has been rolled.
Along forms, kerb and walls where rolling cannot be done by rollers, shall be compacted
with mechanical tampers or a plate compactor or rammers as may be feasible.
Any undulations / displacement found as a result of reversing of the direction of a roller

or due to some other reasons shall be rectified as specified or removed.
All the field tests such as checking of compaction by core cutting, surface irregularity by
using a straight edge and checking of cross slope by taking level, rate of spray of tack
coat using trays, temperature of mix using digital thermometer, depth of the layer using
thickness gauge etc. shall be carried out as per the requirement of MORT&H
specifications clause 900.
The compacted layers of BC shall have a minimum field density equal to or more than
92% of the average theoretical maximum specific gravity (Gmm) obtained on the day of
compaction.
34

During the period of construction, arrangements of traffic shall be made in accordance with the
provision of clause 112. of the MORT&H specifications.
2.1.14.14. Opening to Traffic
As per MORT&H specifications Clause 507.5.
2.1.14.15. Safety and Environmental Control
Work Safety
1. During construction, adequate safety and traffic signs shall be installed adjacent to
2. For locations where the DBM laying paving continue are performed from the road
shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag each
be deployed to control the traffic which may be affected by the paving operation.
3. All locations adjacent to existing road where DBM construction is in progress shall
4. No machines or equipment’s shall always be permitted to remain on the existing road
5. Necessary PPE shall be worn by the workers while handling of laying and rolling
works of Bituminous mix.
6. The Safety Officer shall make frequent patrols along the highway to ensure that the
safety equipment and signs are always operational.
Environmental Safety:
a) The excess material and any other excess materials shall be disposed suitably
b) Vehicles tracks shall be kept moist to prevent flying of dust particles with the
vehicle movement.
c) The smoke and dust at plant will be controlled by adopting suitable method.
2.1.14.16. Surface Finish and Quality of work

The surface finish of the completed construction shall conform to the requirement of clause 902.
For control of the quality of materials and the work carried out, the provisions of section 900
shall apply.
2.1.15. Methodology for Dry Lean Concrete (DLC)

2.1.15.6.Scope of work
The work shall consist of construction of DLC sub-base for cement concrete pavement in
accordance with the requirements of MORT&H specifications clause 601 and in conformity with
the lines, grades and cross sections shown on the drawings.
2.1.15.7.Reference
2. IRC: SP: 99-2013
35
2.1.15.8.Setting Out
1. The GSB surface already approved will be given a fine sprayed with water and rolled
with the earth compactor giving a Couple of passes after a lapse of 2-3 hours of watering.
This will stabilize the loose surface. Prior to watering, loose or dislocated spots, if any,
will be identified and they will be rectified by removing loose material and back filling
with appropriate material and compacting to the required degree of Compaction as the
adjoining areas. The GSB surface will be kept ready at least one day in advance of DLC
laying.
2. Before start of laying, it will be ensured that the guide/sensor wires are in position on
both sides or on one side of the Paver depending upon the Paver pressed used for the
work. For SP1600, guide wires will be provided on both sides of the Paver. For normal
sensor Paver guide wires will be provided on one side with slope control provision. There
will be designated entry points for the trucks carrying concrete on to the new carriageway
or prepared GSB layer.
1. Concrete Batching Plant all the required accessories and storage facilities.
2. Tippers.
3. Sensor Paver
4. Excavator / JCB
5. Vibratory Rollers
6. Water tankers
7. Equipment for laboratory and survey
1. Engineer 01
3. Surveyor 01
2.1.15.11. Material
The EPC Contractor shall indicate to the Concessionaire the source of all materials with relevant
test data to be used in DLC work sufficiently in advance and the approval of the Concessionaire
for the same shall be obtained before the schedule commencement of the work in trial length.
List of approved sources shall be provided to IE with all requisite details / material properties
for reference and further checking or verification at site.
1. Cement: Cement to be used may preferably be obtained in bulk form. Cement shall be
transported, handled and stored on the site in such a manner as to avoid deterioration or
contamination. Cement shall be stored above ground level in perfectly dry and watertight
sheds and shall be stacked to a height of not more than eight bags. Wherever bulk storage
containers are used, their capacity should be sufficient to cater the requirement at site.
36
The containers shall be emptied at least once every 3 months. MTC or lab test certificate
shall be maintained for each and every batch of cement received.
Following type of cement may be used with prior approval of the Concessionaire.
S. No Type of Cement Conforming to

1 Ordinary Portland cement (OPC-43 /OPC-53) IS:269
2 Portland Slag Cement IS: 455
3 Portland Pozzolana Cement IS: 1489-Part I
If subgrade soil contains soluble sulphates in a concentration more than 0.5%, sulphate
resistant cement conforming to IS: 6909
2. Fly-Ash: Fly-Ash up to 20 percent by weight of cementitious material (Cement + Fly-

ash) may be used cement may be used to replace OPC cement and in such case the cement
content shall not be less than 120 kg/cum. Fly-ash shall conform to IS: 3812 Part I.
3. Aggregates: Aggregates for DLC 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 forth in table 600-2 of MORT&H specifications.
a. Coarse Aggregates: Coarse Aggregate shall comply with clause 602.2.6.2, except that
the maximum size of the coarse aggregate shall be 26.5 mm, and aggregate gradation
shall comply with Table 600-1.
b. Fine Aggregates: The fine aggregate shall comply with clause 602.2.6.3.
4. Water: Water used for mixing and curing shall comply with Clause 602.2.7.
2.1.15.12. Proportioning of Materials for the Mix
The mix shall be proportioned with a maximum aggregate cementitious material ratio of 15:1
(as per MORT&H). The water content shall be adjusted to the optimum as per clause 601.3.2 for
facilitating compaction by rolling. The strength and density requirements of concrete shall be
determined in accordance with clause 601.7 and clause 601.8 by making trial mixes. Care should
be taken to prevent one size of aggregate falling into other size of the hopper of the feeding bin
while loading the individual size of the aggregates into the bins.
1. Moisture Content: The OMC shall be determined and demonstrated by rolling during
trial length construction and the OMC and degree of compaction shall be got approved
from Concessionaire. IE may further witness or verify the test as per the provisions of
CA. While laying in the main work, the DLC shall have a moisture content between the
optimum and optimum +2 percent, keeping in view the effectiveness of the compaction
achieved and to compensate for evaporation losses.
2. Cement Content: The cement content in the DLC shall be such that the strength specified
in clause 601.3.4 of MORT&H is achieved. The minimum cement content shall be 150
kg/cum of concrete. In case fly-ash is blended at site as part replacement of cement, the
quantity of fly-ash shall not be more than 20 percent by weight of cementitious material
and the content of OPC shall not be less than 120 kg/cu. m.
37
3. Concrete Strength: Clause 601.3.4 of MORT&H shall be applicable. The average

compressive strength of each consecutive group of 5 concrete cubes shall not be less than
10 MPa at 7 days. In addition, the minimum compressive strength of any individual
concrete cube shall not be less than 7.5MPa at 7 days.
4. Sub-Grade: The subgrade shall conform to the grades and cross-sections on the drawings
and shall be uniformly compacted to the modified Proctor density not less than 97%. The
lean concrete sub-base shall not be laid on a subgrade softened by rain after its final
preparation, surface trenches and soft spots, if any, must be properly back-filled and
compacted to avoid any weak spot. A day before placing of the sub-base, the subgrade
surface shall be given a fine spray of water and rolled with one or two passes of a smooth
wheeled roller after a lapse of 2-3 hours in order to stabilise loose surface. If found
necessary, another fine spray of water may be applied just before placing the sub-base.
5. Drainage Layer: A drainage layer conforming to Clause 401 shall be laid above the
subgrade before laying the DLC sub-base.
2.1.15.13. Trial Length
Trial length shall be prepared before commencement of main works which shall incorporate
details of proposed materials, plant ,equipment’s ,mix proportions & procedure for batching ,
mixing , laying , compaction and construction procedure .selection of trial length shall be outside
of main work and shall have length of minimum 100m. preparation of trial length shall be carried
out in two days over 100m stretch to demonstrate transverse construction joints between
hardened and fresh concrete .
2.1.15.14. Construction
1. General: The DLC shall be laid on the prepared granular drainage layer. The DLC sub-
base shall be overlaid with concrete pavement only after 7 days of sub-base construction.
2. Batching and Mixing: The batching plant shall be capable of proportioning the materials
by weight, each type of material being weighed separately in accordance with Clause
602.9.2, 602.9.3.1 and 602.9.3.2 of MORT&H specifications.
3. Transporting: Plant mix DLC shall be discharged immediately from the mixer,
transported directly to the point where it is to be laid and protected from the weather by
covering the tipping trucks with tarpaulin during transit if necessary.
4. Placing: DLC shall be placed by a paver with electronic sensor on the drainage layer. In
roads with carriageway more than 2 Lanes a longitudinal joint shall be provided.
Transverse Butt type joints shall be provided at the end of the construction in a day. The
DLC shall extend beyond the PQC (including that in shoulder, if any) by 0.75 m on either
side.
5. Compaction: 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 surface is well
closed. The minimum dry density obtained shall not be less than 98 percent of that
achieved during the trial length construction in accordance with Clause 601.7. The
densities achieved at the edges i.e. 0.5 m from the edge shall not be less than 96 percent
38
of that achieved during the trial construction. Double drum smooth-wheeled vibratory
rollers of minimum 80 to 100 kN static weight are suitable for rolling DLC.
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 temperature of
concrete is between 25°C and 30°C, and 120 minutes if less than 25°C. This period may
be reviewed by the Concessionaire in the light of the results of the trial run but in no case
shall it exceed 120 minutes. Work shall not proceed when the temperature of the concrete
exceeds 30°C. If necessary, chilled water or addition of ice may be resorted to for
bringing down the temperature. It is desirable to stop concreting when the ambient
temperature is above 35°C. After compaction has been completed, roller shall not stand
on the compacted surface for the duration of the curing period except during
commencement of next day's work near the location where work was terminated the
previous day.
6. Joints: Construction and Longitudinal joints shall be provided as per 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 DLC shall be staggered from the construction butt type
joint in concrete pavement by 800-1000 mm. Longitudinal joint in DLC shall be
staggered by 300-400 mm from the longitudinal joint of concrete pavement.
7. Curing: The curing shall be done by either of the following ways:

a. Curing may be done by covering the surface by gunny bags / hessian, which shall
be kept wet continuously for 7 days by sprinkling water.
b. The curing shall be done by spraying with approved resin based aluminized
reflective curing compound in accordance with clause 602.9.12. As soon as the
curing compound has lost its tackiness, the surface shall be covered with wet
hessian for 3 days.
c. Wax-based white pigmented curing compound may be used to cure the dry lean
concrete. The compound shall be applied uniformly with a mechanical sprayer
and with a hood to protect spray from the wind.
2.1.15.15. Quality Control
Control of quality of materials and works shall be exercised by the Concessionaire in accordance
with Section 601.
2.1.15.16. Repairs
Rectification, if any, will be taken up before overlaying PQC. The low spots, loose material,
potholes, etc., will be made good by using fresh lean concrete material duly compacting the same
as per specifications. For repairing honey combed surface, and any other spots which cannot be
repaired with DLC material, concrete with aggregates of size 10mm and below will be used after
roughening the surface for proper keying in.
2.1.15.17. Safety and Environmental Control.

Work Safety
39
• During construction, adequate safety and traffic signs shall be installed adjacent to
• For locations where the DLC laying paving continue are performed from the road
shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag each
be deployed to control the traffic which may be affected by the paving operation.
• All locations adjacent to existing road where DLC construction is in progress shall
• No machines or equipment’s shall always be permitted to remain on the existing road
• Necessary PPE shall be worn by the workers while handling of laying works of
Concrete mix.
• The Safety Officer shall make frequent patrols along the highway to ensure that the
safety equipment and signs are always operational.
• The excess material and any other excess materials shall be disposed suitably
• Vehicles tracks shall be kept moist to prevent flying of dust particles with the
vehicle movement.
• The smoke and dust at plant will be controlled by adopting suitable method.
2.1.16. Methodology for Pavement Quality Concrete (PQC)
2.1.16.6.Scope
The work shall consist of construction of un-reinforced, dowel jointed, plain cement concrete
pavement in accordance with the requirements of MORT&H specifications and inconformity
with the lines, grades and cross sections shown on the drawings.
2.1.16.7.Reference
2. IRC: SP: 99-2013
1. Batching Plant with and automatic weighting device to proportion aggregate and bulk
cement
2. Pan type reversible type mixers equipped with timing device.
3. Centralized control cabin
4. Wheel loaders
5. Tipper trucks
Slip form paver
2.1.16.9. Details of Personnel Deployed
1. Sr. Engineer 01
3. Surveyor 01
40
1. QC Engineer 01
1. Source of Materials: The EPC Contractor shall indicate to the Concessionaire the source
of all materials to be used in the concrete work with relevant test data sufficiently in
advance. List of all the approved materials shall be provided to IE with all the requisite
details for reference and further verification at site.
2. Cement: Any of the following types of cement capable of achieving the design strength
may be used.
S. No Type of Cement Conforming to

1 OPC 43 / OPC 53 Grade IS:269
2 Portland Slag Cement IS: 455
3 Portland Pozzolana Cement IS: 1489-Part I
3. Admixtures:
a. Chemical Admixtures: Admixtures conforming to IS: 9103 and IS: 6925 shall be
permitted to improve workability of concrete or extension of setting time, on
satisfactory evidence that they will not have any adverse effect on the properties
of concrete with respect to strength, volume change, durability and have no
deleterious effect on steel bars.
b. Mineral Admixtures: Fly-ash up to 20% by weight of cementitious material may

be used in Ordinary Portland cement 43 or 53 grade as part replacement of cement
provided uniform blending with cement is ensured. The fly ash shall conform to
IS: 3812 (Part I) & GGBFS shall confirm (IRC: 15-2017 / IS: 16714-2018). Site
mixing of fly ash shall be permitted, ensuring availability of the equipment’s at
site for uniform blending through a specific mechanised facility with automated
process control like batch mix plants conforming to IS:4925 and IS:4926.
4. Aggregate: Aggregates for pavement concrete shall be natural material complying with
IS: 383 but with Los Angeles Abrasion Test value not exceeding 35 percent. The limits
of deleterious materials shall not exceed the requirements set out in Table 600-2.
a. Coarse Aggregate: The maximum size of coarse aggregate shall not exceed 31.5
mm for pavement concrete. The Los Angeles Abrasion Value shall not exceed
35. The combined flakiness and elongation index of aggregate shall not be more
than 35 percent.
b. Fine Aggregate: The Fine aggregate shall consist of clean natural sand or crushed
stone sand or a combination of the two and shall conform to IS: 383. The fine
41
aggregates shall have a sand equivalent value of not less than 50 when tested in
accordance with requirement of IS: 2720 (Part-37)
c. Combined Gradation of Fine and Coarse Aggregate: The combined gradation of
fine and coarse aggregates shall be as per Table 600-3 of MORT&H
specifications.
5. Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amount of oil, salt, acid, vegetable matter and other substances harmful to the
finished concrete.
6. Steel for Dowels and Tie Bars: Steel shall conform to the requirements of IS: 432 and
IS: 1786 as relevant. The dowel bars shall conform to IS: 432 of Grade I. Tie bars shall
be either High Yield Strength Deformed bars conforming to IS: 1786 and grade of Fe
500 or plain bars conforming to IS: 432 of Grade I.
7. Joint Filler Board: Synthetic Joint filler board for expansion joints shall be used only at
abutting structures like bridges and shall be of 20-25 mm thickness with a tolerance of
±1.5 mm and of a firm compressible material and complying with the requirements of
IS: 1838, with a compressibility more than 25%.
8. Joint Sealing Compound: The joint sealing compound shall be of hot poured,
elastomeric type or cold polysulphide / polyurethane / silicone type having flexibility,
resistance to age hardening and durability as per IRC: 57.
9. Preformed Seals: The pre-formed sealing material shall be vulcanized elastomeric

compound using polychloroprene (Neoprene) as the base polymer.
10. Storage of Materials: All materials shall be stored in accordance with the provisions of
Clause 1014 of MORT&H specifications.
2.1.16.11. Proportioning of Concrete
1. Cement Content: The quantity of cement shall not be less than 360 kg/cum for all types
of cement. In case fly ash grade I (as per IS:3812) is blended at site as part replacement
of cement, the quantity of fly ash shall be up to 20% by weight of cementitious material
and the quantity of OPC in such a blend shall not be less than 310 kg/cum. If GGBFS is
used, minimum OPC content shall not be less than 310 kg/cum.
2. Concrete Strength: The characteristic flexural strength of concrete for 28 days shall not
be less than 4.5 MPa unless specified otherwise. Target mean flexural strength for mix
design shall be more than 4.5 MPa + 1.65s, where “s” is standard deviation of flexural
strength derived by conducting test on minimum 30 beams.
The water content shall be the minimum required to provide the agreed workability for
full compaction of the concrete to the required density as determined by the trial mixes
and the maximum free water cement ratio shall be 0.45 when only OPC is used and 0.50
when blended cement (Portland Pozzolana Cement or Portland Slag Cement or OPC
blended with fly ash or Ground Granulated Blast Furnace Slag, at site) is used IRC 44
shall also be referred regarding the selection of w/c ratio.
The ratio between the 7- and 28-day strength shall be established for the mix to be used
in the slab in advance, by testing pairs of beams and cubes at each stage on at least six
42
batches of trial mix. The average strength of the 7 day cured specimens shall be divided
by the average strength of the 28-day specimens for each batch, and the ratio “R” shall
be determined. The ratio “R” shall be expressed to three decimal places.
3. Workability: The workability of the concrete at the point of placing shall be adequate
for the concrete to be fully compacted and finished without undue flow. The optimum
workability for the mix to suit the paving plant being used shall be determined by the
EPC Contractor and approved by the Concessionaire. The workability shall be
established for the type of paving equipment available. A slump value in the range of 25
± 15 mm is reasonable for paving works but this may be modified depending upon the
site requirement and got reviewed by the IE.
4. Design Mix: The laboratory trials of design mix shall be carried out with the materials
from the approved sources to be used as per IRC: 44. Trial mixes shall be made in
presence of the Concessionaire and the design mix shall be subject to the approval of the
Concessionaire. Further the Concessionaire shall submit the JMF to IE for concurrence.
5. Sub-Base: The cement concrete pavement shall be laid over the DLC sub-base
constructed in accordance with the relevant drawings and specifications. It shall be
ensured that the DLC sub-base is not damaged before laying the concrete pavement. If
the DLC is found damaged at some places or it has cracks wider than 10 mm, it shall be
repaired with fine cement concrete (aggregate size 10 mm and down) before laying
separation membrane layer.
6. Separation Membrane: A separation membrane shall be used between the PQC and the
DLC sub-base. Separation membrane shall be impermeable PVC sheet of 125-micron
thickness or as specified in pavement design, transparent or white in colour laid flat with
minimum creases. Before placing the separation membrane, the DLC sub-base shall be
swept clean of all the extraneous materials using air compressor. Wherever overlap of
plastic sheets is necessary, the same shall be at least 300 mm and any damaged sheathing
shall be replaced. The separation membrane may be nailed to the lower layer with
concrete nails.
7. Tie Bars: Tie bars shall be provided at the longitudinal joints as per dimensions and
spacing shown in the drawing and in accordance with Clause 602.6.6. The direction of
the tie bars at curves shall be radial in the direction of the radius.
8. Dowel Bars: The work shall be done in accordance to the clause 602.6.5 of MORT&H
specifications. Dowel Bars shall be mild steel rounds in accordance with Clause 602.2.8,
details / dimensions as indicated in the drawings and free from oil, dirt, loose rust or
scale. They shall be straight, free of irregularities and burring restricting slippage in the
concrete. The sliding ends shall be sawn or cropped cleanly with no protrusions outside
the normal diameter of the bar.
Unless shown otherwise on the drawings, dowel bars shall be positioned at mid depth of
the slab within a tolerance of ±20 mm, and centred equally about intended lines of the
joint within a tolerance of ±25 mm.
a. For bars supported on cradles prior to the laying of the slab.

i. All bars in a joint shall be within ±2 mm per 300 mm length of bar.
43
ii. 2/3rd of the number of bars shall be within ±3 mm per 500 mm Length of
bar
iii. No bar shall differ in alignment from an adjoining bar by more than 3 mm
per 300 mm length of bar in either the horizontal or vertical plane.
iv. Cradles supporting dowel bar shall not extend across the line of joint i.e.
no steel bar of the cradle assembly shall be continuous across the joint.
b. For all bars inserted after laying of the slab except those inserted by a Dowel Bar
Inserter the tolerance for alignment may be twice as indicated in (a) above.
The assembly of dowel bars and supporting cradles, including the joint filler board in the
case of expansion joints, shall have the following degree of rigidity when fixed in
position:
a. For expansion joints, the deflection of the top edge of the filler board shall be not
greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
face of the joint filler board and distributed over a length of 600 mm by means of
a bar or timber packing, at mid depth and midway between individual fixings, or
300 mm from either end of any length of filler board, if a continuous fixing is
used. The residual deflection after load shall be not more than 3 mm.
b. The fixings for joint assembly shall not fail under 1.3 kN load and shall fail before
the load reaches 2.6 kN when applied over a length of 600 mm by means of a bar
or timber packing placed as near to the level of the line of fixings as practicable.
c. Fixings shall be deemed to fail when there is displacement of the assemblies by

more than 3 mm with any form of fixing, under the test load. The displacement
shall be measured at the nearest part of the assembly to the centre of the bar or
timber packing.
Dowel bars in the contraction joints, construction joints and expansion joints shall be
covered by a thin plastic sheath. The thickness of the sheath shall not exceed 0.5 mm
and shall be tightly fitted on the bar for at least two-thirds of the length from one end for
dowel bars in contraction/construction joints and half the length plus 50 mm for
expansion joints.
2.1.16.12. Joints
The locations and type of joints shall be as shown in the drawing. Joints shall be constructed
depending upon their functional requirement. The location of the joints should be transferred
accurately at the site and mechanical saw cutting of joints done as per stipulated dimensions. It
shall be ensured that the required depth of cut is made from edge-to-edge of the pavement.
Transverse and longitudinal joints in the PQC and DLC shall be staggered so that they are not
coincident vertically and are at least 800 to 1000 mm and 300 to 400 mm apart respectively.
Sawing of joints shall be carried out with diamond studded blades soon after the concrete has
hardened to take the load of the sewing machine and crew members without damaging the texture
of the pavement.
Sawing operation could start as early as 4-8 hours after laying of concrete pavement but not later
than 8 to 12 hours depending upon the ambient temperature, wind velocity, relative humidity
and required maturity of concrete achieved for this purpose.
44
When the Kerb is cast integrally with the main pavement slab, the joint cutting shall also be
extended to the kerb.
1. Transverse Joints: Transverse joints shall be contraction, construction and expansion

joints constructed at the spacing described in the drawings. Transverse joints shall be
straight within the following tolerances along the intended line of joints.
a. Deviations of the performed filler board (IS: 1838) in the case of expansion joints
from the intended line of the joint shall not be greater than ±10 mm.
b. The best fit straight line through the joint grooves as constructed shall be not more
than 25 mm from the intended line of the joint.
c. Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 mm.
d. Transverse joints on each side of the longitudinal joint shall be in line with each other
and of the same type and width. Transverse joints shall have a sealing groove which
shall be sealed in compliance with Clause 602.10.
2. Contraction Joints: The contraction joints shall be placed transversely at pre-specified

locations as per drawings / design using dowel bars. These joints shall be cut as soon as
the concrete has undergone initial hardening and is hard enough to take the load of joint
sawing machine without causing damage to the slab. Contraction joints shall consist of a
mechanical sawn joint groove, 3 to 5 mm wide and one-fourth to one-third depth of the
slab ± 5 mm or as stipulated in the drawings and dowel bars complying with Clause
602.6.5.
3. Expansion Joints: The expansion joint shall consist of a joint filler board complying
with Clause 602.2.9 and dowel bars complying with Clause 602.6.5 and as detailed in the
drawings. The filler board shall be positioned vertically with the prefabricated joint
assemblies along the line of the joint within the tolerances given in Clause 602. 6.2.1.
The adjacent slabs shall be completely separated from each other by the joint filler board.
4. Transverse Construction Joints: Transverse construction joint shall be placed

whenever concreting is completed after a day's work or is suspended for more than 30
minutes. These joints shall be provided at location of contraction joints using dowel bars.
If sufficient concrete has not been mixed to form a slab extending up to a contraction
joint, and if an interruption occurs, the concrete placed shall be removed up to the last
preceding joint and disposed of.
5. Longitudinal Joint: The longitudinal joints shall be constructed by forming or by sawing

as per details of the joints shown in the drawing. Sawed longitudinal joints shall be
constructed when the concrete pavement placement width exceeds 4.5 m. The groove
may be cut after the final set of the concrete. Joints should be sawn to at least one-third
the depth of the slab ±5 mm as indicated in the drawing.
45
2.1.16.13. Concreting during Monsoons

Concreting should be avoided during rainy season. However, when concrete is being placed
during monsoon months and when it may be expected to rain, sufficient supply of tarpaulin or
other waterproof cloth shall be provided along the line of the work. Any time when it rains, all
freshly laid concrete which had not been covered for curing purposes shall be adequately
protected. Any concrete damaged by rain shall be removed and replaced.
2.1.16.14. Temperature Limitation
No concreting shall be done when the temperature of the concrete reaching the paving site is
above 30°C. Besides, in adverse conditions like high temperature, low relative humidity,
excessive wind velocity, imminence of rains etc., tents on mobile trusses may be provided over
the freshly laid concrete for a minimum period of 3 hours as directed by the Concessionaire. To
bring down the temperature, if necessary, chilled water or ice flakes should be made use of.
When the ambient temperature is more than 35°C, no concreting shall be permitted.
2.1.16.15. Fixed Form Paving
1. Side Forms and Rails: These shall be provided in case of fixed form paving. All side
forms shall be of mild steel of depth equal to the thickness of pavement or slightly less
to accommodate the surface irregularity of the sub-base. The forms can be placed in series
of steel packing plates or shims to take care of irregularity of sub-base.
The forms and rails shall be firmly secured in position by not less than 3 stakes/pins for
every 3 m length so as to prevent movement in any direction. Forms and rails shall be
straight within a tolerance of 3 mm in 3 m and when in place shall not settle in excess of
1.5 mm in 3 m while paving is being done.
The forms shall be bedded on a continuous bed of low moisture content lean cement
mortar or concrete and set to the line and levels shown on the drawings within tolerances
±10 mm and ±3 mm respectively. At all times sufficient forms shall be used and set to
the required alignment for at least 300 m. Length of pavement immediately in advance
of the paving operations, or the anticipated length of pavement to be laid within the next
24 hours whichever is more.
2. Slip Form Paving:

a. Use of Guidewires: Where slip form paving is proposed, a guidewire shall be
provided along both sides of the slab. Each guidewire shall be at a constant height
above and parallel to the required edges of the slab as described in the contract
drawing within a vertical tolerance of ±3 mm. Additionally, one of the wires shall
be kept at a constant horizontal distance from the required edge of the pavement
as indicated in the contract drawing within a lateral tolerance of ±10 mm. The
guidewires shall be supported on stakes 5-6 m apart by connectors capable of fine
horizontal and vertical adjustment. The guidewire shall be tensioned on the stakes
so that a 500-gm weight shall produce a deflection of not more than 20 mm when
suspended at the midpoint between any pair of stakes. The ends of the guidewires
shall be anchored to fixing point or winch and not on the stakes. On the curves,
the stakes shall be fixed at not more than 3 m Centre-to-Centre. The stakes shall
be positioned and hammered into the ground and the connectors will be
maintained at their correct height and alignment from 12 hours on the day before
concreting takes place till after finishing of texturing and spraying of curing
compound on the concrete.
46
3. Trial Length
Trial length shall be prepared before commencement of main works which shall
incorporate details of proposed materials, plant, equipment’s, mix proportions &
procedure for batching, mixing, laying, compaction, and construction procedure.
selection of trial length shall be outside of main work and shall have length of minimum
100m. preparation of trial length shall be carried out in two days over 100m stretch to
demonstrate transverse construction joints between hardened and fresh concrete
4. Construction
a. General: A systems approach may be adopted for construction of the pavement, and
the Method Statement for carrying out the work, detailing all the activities, indication
of time-cycle, equipment, personnel etc., shall be got approved from the
Concessionaire before the commencement of the work. This shall include the type,
capacity and make of the batching and mixing plant besides the hauling arrangement
and paving equipment. The capacity of paving equipment, batching plant as well as
all the ancillary equipment shall be adequate for a paving rate of at least 500 m in one
day. The paving speed of slip-form paver shall not be less than 1.0 m per minute. The
concreting should proceed continuously without stops and starts.
b. Batching and Mixing: Batching and mixing of the concrete shall be done at a central
batching and mixing plant, with automatic controls, located at a suitable place which
takes into account sufficient space for stockpiling of cement, aggregates and
stationary water tanks. This shall be located at an approved distance, duly considering
the properties of the mix and the transporting arrangements available with the EPC
Contractor.
c. Equipment for Proportioning of Materials and Paving: Proportioning of materials

shall be done in the batching plant by weight, each type of material being weighed
separately. The cement from the bulk stock may be weighed separately from the
aggregates. Water shall be measured by volume. Specified percentage of plasticizer
in volume will be added by weight of cement. Wherever properly graded aggregate
of uniform quality cannot be maintained as envisaged in the mix design, the grading
of aggregates shall be controlled by appropriate blending techniques.
i. Batching Plant and Equipment:

• General: The batching plant shall include minimum four bins,
weighing hoppers, and scales for the fine aggregates and for each size
of coarse aggregate. If cement is used in bulk, a separate scale for
cement shall be included. There shall be a separate bin for fly ash, if
this additive is specified. The weighing hoppers shall be properly
sealed and vented to preclude dust during operation. The batch plant
shall be equipped with a suitable non-resettable batch counter which
will correctly indicate the number of batches proportioned. A
continuous type of mixing plant can also be used provided the
ingredients are weighed through electronic sensors before feeding.
• Automatic weighing devices: Batching plant shall be equipped to
proportion aggregates and bulk cement by means of automatic
weighing devices using load cells.
47
• Mixer: Mixers shall be pan type, reversible type or any other mixer
capable of combining the aggregates, cement, and water into a
thoroughly mixed and uniform mass within the 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 pick-
up and throw• over blades in the drum or drums shall be repaired or
replaced when they are worn down 20 mm or more. The EPC
Contractor shall have available at the job site a copy of the
manufacturer’s design, showing dimensions and arrangements of
blades in reference to original height and depth, or (2) provide
permanent marks on blade to show points of 20 mm wear from new
conditions.
• Control cabin: An air-conditioned centralized computer control cabin
shall be provided for automatic operation of the equipment.
• The design features of the batching plant should be such that it can be
shifted quickly.
ii. Paving Equipment: The concrete shall be placed with an approved fixed
form or slip form paver with independent units designed to (i) spread, (ii)
consolidate, screed and float-finish, (iii) texture and cure the freshly placed
concrete in one complete pass of the machine in such a manner that a
minimum of hand finishing will be necessary and so as to provide a dense and
homogeneous pavement in conformity with the plans and Specifications.
Vibrators shall operate at a frequency of 8000-10000 impulses per minute

under load at a maximum spacing of 600 mm. The variable vibration setting
shall be provided in the machine.
iii. Concrete Stew: The EPC Contractor shall provide adequate number of
concrete saws with sufficient number of diamond-edge saw blades. The saw
machine shall be either electric or petrol / diesel driven type. A water tank
with flexible hose and pump shall be made available for this activity on
priority basis.
d. Hauling and Placing of Concrete: Freshly mixed concrete from the central batching
and mixing plant shall be transported to the paver site by means of tipping trucks or
transit mixers of sufficient capacity and approved design in sufficient numbers to
ensure a constant supply of concrete. Covers shall be used for protection of concrete
against the weather. While loading the concrete truck shall be moved back and forth
under the discharge chute to prevent segregation. The tipping trucks shall be capable
of maintaining the mixed concrete in a homogeneous state and discharging the same
without segregation and loss of cement slurry.
i. Placing of Concrete: The total time taken from the addition of the water to
the mix, until the completion of the surface finishing and texturing shall not
exceed 120 minutes when concrete temperature is less than 25°C and 90
minutes when the concrete temperature is between 25°C and 30°C.
48
The placing of concrete in front of the PQC paver should preferably be from
the side placer to avoid damage to DLC by concrete tipping trucks. In case of
unavoidable situation, truck supplying concrete to the paver may be allowed
to ply on the DLC with the approval of the Concessionaire.
The paver shall be capable of paving the carriageway as shown in the

drawings, in a single pass and lift.
Where fixed form pavers are to be used, forms shall be fixed in advance as
per Clause 602.8. Before any paving is done, the site shall be shown to the
Concessionaire, in order to verify the arrangement for paving besides placing
of dowels, tie-bars etc., as per the relevant Clauses of these Specifications.
The mixing and placing of concrete shall progress only at such a rate as to
permit proper finishing, protecting and curing of the concrete in the pavement.
While the concrete is still plastic, its surface shall be textured by brush or tines
as per the instructions of the Concessionaire in compliance with Clause
602.9.11. The surface and edges of the slab shall be cured by the application
of a sprayed liquid curing membrane in compliance with Clause 602.9.12.
After the surface texturing, but before the curing compound is applied, the
concrete slab shall be marked with the chainage at every 100 m interval by
embossing.
e. Construction by Slip Form Paver: The slip form paving train shall consist of a
power machine which spreads, compacts and finishes the concrete in a continuous
operation. The slip form paving machine shall compact the concrete by internal
vibration and shape it between the sides forms with either a conforming plate or by
vibrating and oscillating finishing beams. The concrete shall be deposited without
segregation in front of slip form paver across the whole width and to a height which
at all times is in excess of the required surcharge. The deposited concrete shall be
struck off to the necessary average and differential surcharge by means of the strike
off plate or a screw auger device extending across the whole width of the slab. The
equipment for striking-off the concrete shall be capable of being rapidly adjusted for
changes of the average and differential surcharge necessitated by change in slab
thickness or cross fall.
The level of the conforming plate and finishing beams shall be controlled
automatically from the guide wires installed as per Clause 602.8 by sensors attached
at the four corners of the slip form paving machine. The alignment of the paver shall
be controlled automatically from the guide wire by at least one set of sensors attached
to the paver. The alignment and level of ancillary machines for finishing, texturing
and curing of the concrete shall be automatically controlled relative to the guide wire
or to the surface and edge of the slab.
Slip-form paving machines shall have vibrators of variable output, with a maximum
energy output of not less than 2.5 kW per metre width of slab per 300mm depth of
slab for a laying speed up to 1.5 m per minute. The machines shall be of sufficient
mass to provide adequate reaction during spreading and paving operations on the
traction units to maintain forward movements during the placing of concrete in all
situations. Normal paving speed shall be maintained as per Clause 602.9.1.
49
Slip-form pavers with adequate width to pave the entire carriageway width in one go
shall be employed unless specified in the Contract. In situations where full-width
paving is not possible, paving in part widths may be permitted by the Concessionaire.
Paving in part will be avoided, except in unavoidable circumstances. In case of part
width paving, care shall be taken to ensure that while laying the next lane, bond
between the remaining half length of tie bar or subsequently inserted tie bars and the
newly laid concrete is adequately developed. Care shall be taken to avoid damage to
the previous lane.
i. Tube Floating: Upon the instructions of the Concessionaire, EPC Contractor

shall scrape the concrete surface when in plastic state with a 3 m long tube
float fixed with a long and stable handle before texturing. Tube float shall be
of an alloy steel tube of 50 to 60 mm diameter with a long and stable handle.
The length of tube float shall preferably be longer than half the length of slab
i.e., half the distance between two transverse contraction joints.
The tube float shall be placed at the Centre of the slab to longitudinal joint
and pulled slowly and uniformly towards the edges. After the use of float tube,
it shall be frequently cleaned before further use. The slurry removed shall be
discarded.
f. Construction by Fixed Form Paver: The fixed form paving train shall consist of
separate powered machines which spread, compact and finish the concrete in a
continuous operation.
The concrete shall be discharged without segregation into a hopper spreader which is
equipped with means for controlling its rate of deposition on to the sub-base. The
spreader shall be operated to strike off concrete up to a level requiring a small amount
of cutting down by the distributor of the spreader. The distributor of spreader shall
strike off the concrete to the surcharge adequate to ensure that the vibratory
compactor thoroughly compacts the layer.
g. Semi-Mechanized Construction: Areas in which hand-guided methods of

construction become indispensable shall be got approved by the Concessionaire in
writing in advance. Such work may be permitted only in restricted the areas in small
lengths.
h. Transition Slabs: At the interfaces of rigid and flexible pavement, at least 3 m long
reinforced buried slab shall be provided to give a long-lasting joint at the interface.
The details shall be as given in IRC: 15.
i. Surface Texture:
i. Tining: After final floating and finishing of the slab and before application of
the liquid curing membrane, the surface of concrete slabs shall be textured
either in the transverse direction (i.e., at right angles to the longitudinal axis
of the road) or in longitudinal direction (i.e. parallel to the centre line of the
roadway). The texturing shall be done by tining the finished concrete surface
by using rectangular steel tines. A beam or a bridge mounted with steel tines
50
shall be equipped and operated with automatic sensing and control devices
from main paver or auxiliary unit.
ii. Brush Texturing: Alternatively, on the instructions of the Concessionaire,

the brush texturing shall be applied. The brushed surface texture shall be
applied evenly across the slab in one direction by the use of a wire brush not
less than 450 mm wide but wider brushes normally of 3 m length are
preferred. The brush shall be made of 32-gauge tape wires grouped together
in tufts placed at 10mm centres. The tufts shall contain an average of 14 wires
and initially be 100 mm long. The brush shall have two rows of tufts. The
rows shall be 20 mm apart and the tufts in one row shall be opposite the Centre
of the gap between tufts in the other row. The brush shall be replaced when
the shortest tuft wears down to 90 mm long. For texture depth MORT&H 5th
Revision Table 600-5 shall be applicable.
j. Curing: Immediately after the surface texturing, the surface and sides of the slab
shall be cured by the application of approved resin-based aluminized reflective curing
compound which hardens into an impervious film or membrane with the help of
mechanical sprayer. The curing compound shall not react chemically with the
concrete and the film or membrane shall not crack, peel or disintegrate within three
weeks of application.
k. Preparation and sealing of Joint Grooves: All Joints shall be sealed using sealants
described in Clause 602.2.10 and in accordance with clause 602.10.
l. For control of the Quality of material and work it shall be tested in accordance with
Table 900-6
2.1.16.16. Safety and Environmental Control

Work Safety
• During construction, adequate safety and traffic signs shall be installed adjacent
to the road shoulders to protect the ongoing works as per location specific safety
plan.
• For locations where the PQC laying paving continue are performed from the road
shoulder, a minimum of 2 flagmen with reflective vests and holding a red flag
each be deployed to control the traffic which may be affected by the paving
operation.
• All locations adjacent to existing road where PQC construction is in progress shall
• No machines or equipment’s shall always be permitted to remain on the existing
road or shoulder unattended unless it is properly protected and secured in a safe
manner.
• Necessary PPE shall be worn by the workers while handling of laying works of
Concrete mix.
• The Safety Officer shall make frequent patrols along the highway to ensure that
the safety equipment and signs are always operational.
51
• The excess material and any other excess materials shall be disposed suitably
• Vehicles tracks shall be kept moist to prevent flying of dust particles with the
vehicle movement.
• The smoke and dust at plant will be controlled by adopting suitable method.
2.1.17. Methodology for Thermoplastic Road Marking Paint
2.1.17.6.Scope
The work shall consist of providing and laying of pavement marking with hot applied
thermoplastic paints as per Clause 803 of MORT&H specifications.
2.1.17.7.General
This method statement covers providing and laying of pavement marking with hot applied
thermoplastic paints as specified in drawing or as per IRC: 35.
2.1.17.8.Materials
Materials of road marking shall be hot applied thermoplastic compound and the same shall meet
the requirements as specified in clause 803.4 of MORT&H specifications.
1. Composition: The pigment, beads, and aggregate shall be uniformly dispersed in the
resin. The material shall be free from all skins, dirt and foreign objects and shall comply
with requirements indicated following table.
Proportions of constituents of Material (% by weight) (Table 800-9 of MORT&H

specifications)
Component White Yellow

Binder 18 min 18 min
Glass Beads 30-30 30-30
Titanium Dioxide 10 min -
Calcium Carbonate and Amount of yellow pigment, Calcium
42 max
Inert Fillers Carbonate and inert fillers shall be at the
option of the manufacture, provided all other
Yellow Pigments - requirement of MORT&H specifications to
be met.
2. Properties: The properties of thermoplastic material, when tested in accordance with

ASTM D-36 / BS-3262 (Part I) shall be as below:
a. Luminance:
White: Daylight luminance at 45º- 65 percent min. as per AASHTO M 249.
Yellow: Daylight luminance at 45º- 45 percent min. as per AASHTO M 249.
b. Drying Time:
When applied at a temperature specified by the manufacturer and to the required
thickness, the material shall set to bear traffic in not more than 15 minutes.
c. Skid resistance: Not less than 45 as per BS 6044.
52
d. Cracking resistance at low temperature: The material shall show no cracks on

application to concrete blocks.
e. Softening point: 102.5º± 9.5ºC as per ASTM D 36.
f. Flow resistance: Not more than 25 per cent as per AASHTO M 249.
g. Yellowness index (for white thermoplastic paint: not more than 0.12 as per AASHTO
M 249.
3. Storage life: The material shall meet the requirements of these specifications for a period
of one year. The thermoplastic material must also melt uniformly with no evidence of
skins or un-melted particles for the one-year storage period. Any material not meeting
the above requirements shall be replaced by the Manufacture/Supplier/EPC Contractor.
4. Reflectorisation: Shall be achieved by incorporation of beads, the grading and other

properties of the beads shall be as specified in clause 803.4.2 of MORT&H
specifications.
5. Marking each container of the thermoplastic material shall be clearly and indelibly
marked with following information.
• The name, trademark, or other means of identification of manufacturer.

• Batch number
• Date of manufacture.
• Colour (white or yellow)
• Maximum application temperature and maximum safe heating temperature.
6. Sampling and Testing: The thermoplastic material shall be sampled and tested in
accordance with the appropriate ASTM/BS method. The EPC Contractor shall furnish to
the Concessionaire a copy of MTC of the thermoplastic material showing results of all
tests specified herein and shall certify that the material meets all requirements as
mentioned above. IE may witness or verify the test as per the provisions given in CA.
7. Reflective Glass Beads:
a. General: This specification covers two types of glass beads to be used for the
production of reflective pavement marking. Type 1 beads are those which are a
constituent of the basic thermoplastic compound vide table 800-3 of MORT&H
specifications and Type -2 beads are those which are to be sprayed on the marked
surface vide clause 803.6.4 of MORT&H specifications. The glass beads shall be
transparent, colourless, and free from milkiness, dark particles and excessive air
inclusions. These shall conform to the requirements spelt out in Clause 803.4.2.3
of MORT&H specifications.
b. Specific Requirements:
• Gradation: The glass beads shall meet gradation requirements for the two
types as given in the following table:
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Percent Retained (Table 800-10)

Sieve size
Type-1 Type-2
1.18 mm 0 to 3 -
850 microns 5 to 20 0 to 5
600 microns - 5 to 20
425 microns 65 to 95 -
300 microns - 30 to 75
180 microns 0 to 10 10 to 30
<180 microns - 0 to 15
• Roundness: The glass beads shall have a minimum of 70 per cent true
spheres.
• Refractive index: The glass beads shall have a minimum refractive index
of 1.50.
• Free flowing properties: The glass beads shall be free of hard lumps and
clusters and shall dispense readily under any condition suitable for paint
stripping. The y shall pass the free - Flow test.
2.1.17.9.Traffic Arrangement and Control
1. Before taking up of laying markings, program for the diversion of traffic shall be drawn
up and got it approved by the Concessionaire as per clause 112 of MORT&H
specifications and as per IRC SP: 55.
2. Temporary sign boards, barricading, flags, lights, and flagmen will be provided at
working area as per approval of the Concessionaire.
3. On both sides, suitable regulatory/warning signs as approved by the Concessionaire shall

be installed for the guidance or roads users.
2.1.17.10. Work Methodology
1. Equipment’s
a. Pre-Melter
b. Pram-applicator
c. Mechanical Broom
d. Air compressor
e. Truck
f. Water tanker with pipe attachment
g. Survey kit / instrument
h. Infra-Red Thermometer (Laser thermometer)
2. Application
a. Preparation (as per MORT&H specifications Clause: 803.4.4):
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i. The material shall be melted in accordance with the manufacturer’s instructions

in a Heater fitted with a mechanical stirrer to give a smooth consistency to the
thermoplastic material to avoid local overheating. The temperature of the mass
shall be within the range specified by the manufacturer and shall on no account
be allowed to exceed the maximum temperature stated by the manufacturer. The
molten material should be used as expeditiously as possible and for thermoplastic
material which has natural binders or is otherwise sensitive to prolonged heating
the material shall not be maintained in a molten condition for more than 4 hours.
ii. After transfer to the laying equipment, the material shall be maintained within the
temperature range specified by the manufacture for achieving the desired
consistency for laying.
• Cleaning: The surface of the flexible road pavement shall be thoroughly

cleaned form all of dust any other material, grease, oil etc. at the area where
the material shall be applied to mark the pavement with the help of broom and
air compressor.
• Pre- Marking: The reference centreline (Pre-Marking) of the lane marking as

per the drawing shall be made to have temporary marking with chalk
powder/long thin rope, so that the applicator machine pointer in the front of
the machine can be guided to move along this pre-Marked line while material
is being applied on the road. This ensures accurate alignment of the markings
when laid on the road surface.
• Heating of the Material: The road marking material shall be heated in the pre-
Melter as well as pram-applicator machine fitted with mechanical stirrer to
give smooth consistency to the material and to avoid local heating of the
material. For heating, LPG with suitable burner system shall be used to
achieve temperature of 180+/-10 ºC which is the specified application
temperature. The temperature Gauge fitted on the machine as well as the pre-
Melter displays the material temperatures continuously for monitoring the
application temperature.
• Lane Markings: The lane marking shall be made as per the reviewed drawing
for width; length and thickness shall be made with the help of the Screed- Box
attached to the Applicator Machine. The thermoplastic paint shall be applied
in intermittent of continuous lines of uniform thickness of at least 2.5 mm.
Where arrows or letters are to be provided, thermoplastic compound may be
hand sprayed. The tolerances of the width, position alignment and length of
segment of broken lines shall be as per Technical specification sub clause
803.6.6.
• Drop-On Glass Beads Application: The approved glass beads shall be placed
in position from the bead dispenser attached to the machine and the dispersion
is by forced-feed mechanism which works while the machine is applying the
markings with the Screed-Box., simultaneously and before the thermoplastic
material (which is hot applied) becomes dry and cold while achieving road
surface temperature. The type-2 glass beads conforming to the above noted
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specification shall be sprayed uniformly into a monolayer on to the paint line

at the rate of 250 grams per square meter area.
• Weather: The marking shall be done with approved material only on dry
pavement surfaces of minimum Temperature of 10º C.
• Arrow Marking: The arrow marking shall be made using the approved
material with specifically made stencils of shape and size.
• Properties of finished road marking (as Per MORT&H specifications Clause:

803.4.6):
▪ The strip shall not be slippery when wet.

▪ The marking shall not lift from the pavement in freezing weather.
▪ After application and proper drying, the stripe shall show no appreciable
deformation or discoloration under traffic and under road temperatures up
to 60ºC.
▪ The marking shall not deteriorate by Contract with sodium chloride or oil
drippings from traffic.
▪ The stripe or marking shall maintain its original dimension and position.
Cold ductility of the material shall be such as to permit normal movement
with surface without chopping or cracking.
2.1.18. Methodology for Longitudinal Lined Drain

2.1.18.6.Scope
The Scope of this work covers the following activities:
1. After setting out, the excavation necessary for construction of Longitudinal Drain shall
be carried out as per Section 300 MORT&H specifications.
2. The selection of various construction materials, testing of materials, approvals and quarry
selection, testing and approval of various grades of materials etc. conforming to section
1000 MORT&H specifications.
3. The construction of Longitudinal Drain with reference to Section 300, Section 1000,
Section 1500, Section 1700 of MORT&H specifications and IS: 1077.
2.1.18.7.Materials
1. Bricks shall comply Clause 1003 of MORT&H specifications.
2. OPC 53/43 grade conforming to IS 269 or PPC.
3. Coarse Aggregates, Sand / Fine Aggregates as per IS 383 and the tests shall be carried
out as per IS 2386.
4. The formwork material shall comply with IRC 87.
5. Water conforming to section 1010 MORT&H specifications.
2.1.18.8.Plant, Equipment and Machinery
The following plant and equipment are necessary for the planned progress:
1. Batching Plant.
2. Transit Mixers.
3. Needle Vibrators.
4. Slump cone and concrete test cube moulds.
5. Concrete Pump and Crane bucket.
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6. JCB/Excavator.
7. Tippers/Dumpers.
8. Steel Shutters as formwork.
2.1.18.9.Construction operations.
1. Survey & Setting out Works:
The limits for excavations shall be set out true to lines, curves, slopes, grades and sections
as shown on the drawings and using established bench marks / co-ordinates. All the
survey instruments used shall be calibrated periodically as per the Calibration Plan.
Survey check reports and other relevant data shall be maintained in relevant inspection
formats.
2. Detailed drawing submission:

The detailed drawing for the longitudinal drain shall be made with the invert levels shown
with the indication of type of bedding as specified on the working drawing.
Before any construction work is being carried out, the EPC Contractor must submit an
elevation of the invert level showing the length to be constructed and the following details
to be incorporated on the drawing:
a. The existing ground profile.

b. Founding levels at the base.
c. Invert levels of longitudinal drain from one point at downstream to upstream.
d. The invert levels of the longitudinal drain intersecting the disposal outlet.
The Concessionaire will review for the drawing prior start of the longitudinal drain.
3. Construction of Longitudinal Drain

a. Excavation:
The foundation bed for the Longitudinal Drain shall be excavated true to the lines
and grade as set out. It shall be executed to provide sufficient room for steel
shutters.
b. Bedding for Longitudinal Drain:

The bedding surface of filling area must be a firm ground of uniform density
throughout the length of the drain. It shall be compacted and tested so that it is
good for the PCC to be laid on it.
The bedding surface of cutting area shall be clean and free from loose materials.
Then lay the PCC to required thickness and dimensions. The finished surface
should be uniform in thickness.
c. Construction of Longitudinal Drain Base slab (Raft) by Cast in situ Method

i. Clean up any debris in the PCC by blowing out any foreign materials.
ii. The base slab dimensions shall be marked on the PCC
iii. All temporary shuttering shall be checked so that they are securely fixed.
iv. After taking necessary approval from IE pouring of concrete shall be
started.
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v. The concrete should be uniformly vibrated with a needle. Conduct the

routine slump checks and cast test cubes as per prescribed frequency or as
directed by the Concessionaire.
vi. 25mm Expansion joint gap to be provided at every 40 m interval and to
be filled with Shalitex board and filler material (waterproof).
vii. Upon completing the concreting, it is essential to cure the concrete with
potable water on the next day and regularly do so for the minimum next 7
days.
d. Construction of Longitudinal Drain walls

i. Tie the wall reinforcement which were cut and bend as per the bar bending
schedule. When the Contractor is satisfied that the preparation is ready for
inspection, submit a request to the Engineer for reinforcement inspection
by raising a RFI.
ii. Fix the steel shutters forms for the walls for stage 2 concrete after
obtaining approval from the Engineer on the wall reinforcement. The steel
shutters must be properly fixed and fastened together. Attention must be
given to external lateral bracings are sufficient and would prevent bulging
of concrete. Check that all gaps between steel shutters are properly
plugged to prevent leaking of concrete slurry during vibration of the
concrete. Next, when the Contractor is satisfied that the preparation is
ready for inspection, submit a request to the Engineer for inspection by
raising a RFI.
iii. The Engineer carries out his inspection and approval given to proceed.
iv. Order, pour and vibrate the concrete in an acceptable manner specified by
MORT&H Specifications. The concrete should be uniformly vibrated
with a needle. Conduct the routine slump check and make test cubes as
directed by the Engineer.
v. Upon completing the concreting, it is essential to cure the concrete with
water the next day regularly and continuously for the next 7 days
e. Construction of Longitudinal Drain by Precast Drain Method

i. The base of the drain shall be formed with sand compacted to the required
gradient.
ii. The drain centre line shall be maintained with the use of a string tied to
wooden pegs from the downstream end to the upstream end.
iii. The precast drain already lined up along the edge of the trench shall then
be lifted by a JCB, equip with two steel rope (or acceptable slings) for
lifting, and put in place in the trench.
iv. The string shall be the guide in installing the precast drain unit from
downstream to upstream.
v. The joints between drains shall be sealed with cement/sand mortar.
vi. The next step is to construct the upper part where the reinforcement has
been left for overcoming variation in depth of the Longitudinal Drain.
2.1.19. Methodology for Median Filling
2.1.19.6.Scope
This work shall consist constructing of median in the road dividing the carriage way in to
separate lanes to channelize the traffic in accordance with the lines, grades and cross sections
shown on the drawings.
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2.1.19.7.Reference
Section 408 of MORT&H specification
2.1.19.8.Materials
6. Bricks shall comply Clause 1003 of MORT&H specifications.
7. OPC 53/43 grade conforming to IS 269 or PPC.
8. Coarse Aggregates, Sand / Fine Aggregates as per IS 383 and the tests shall be carried
out as per IS 2386.
9. The formwork material shall comply with IRC 87.
10. Water conforming to section 1010 MORT&H specifications.
2.1.19.9.Plant, Equipment and Machinery
The following plant and equipment are necessary for the planned progress:
1. Dumper
2. Motor Grader/Loader
3. Compactor
4. Wooden Rammer
5. Water Tank
1. The materials used in the median shall be soil, moorum, gravel, recycled material, a
mixture of these or any other suitable material approved by the engineer. Such materials
shall be free of logs, stumps, roots or any other materials likely to deteriorate the stability
of the median.
2. The materials shall satisfy the Physical and chemical requirements as per MORT&H
Clause No: 305.2.1.1, 305.2.1.2, and 305.2.1.3.
2.1.19.11. Procedure
1. Unwanted plants, roots, boulders, concrete and bituminous material shall be removed and
got checked by raising RFI prior to start of median filling.
2. Place/Dump the approved borrow material or any other suitable material approved by the
engineer in the median by dumpers. In case of Existing road in used after ensuring road
safety by placing barricades 50m before the spot with adequate information sign boards
and markings.
3. Care shall be taken to avoid spilling of soil over adjacent pavement while dumping.
4. Soil shall be spread in uniform layers of 200mm using motor grader, Dozer, loader or
manually as per the site condition.
5. Water shall be added to the material to achieve the moisture content in the range of +1 %
to -
6. Compaction shall be done with 8-10 Ton roller in 4.5m median where as in 2.5m median
compaction shall be done with 2.5-ton roller or plate compactor for 1.2 m median.
7. The topmost layers shall be compacted lightly in order to facilitate sufficient growth of
roots of grass and plants/shrubs.
8. The filling shall be raised centrally by 3% on either side for easy flow of rainwater to the
adjacent pavement and avoid any water logging in median.
2.1.19.12. Safety
1. All dumpers shall be provided with reverse horn & light.
2. Wherever required, Flagman shall be provided.
3. The speed of construction vehicles plying in stretch shall be restricted to 30kmph.
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4. Any labour, if being used in the job shall be screened and trained.
5. All workmen at work area shall wear PPE’s and reflective jackets.
6. Median filling work shall not disturb the live traffic.
2.2. Section 2: Structure Works

2.2.10. Methodology for Structural Concrete for Bridges and Culverts
2.2.10.6.Scope
The work shall consist of producing and placing the various grade of concrete as per approved
drawings by weigh batching in accordance with the specifications conforming to MORT&H
specifications, IRC: 112 and the work specifications as stipulated in the contract document and
drawings.
2.2.10.7.Reference
2. IRC: SP: 99-2013
4. IRC: 112
After completion of site preparation, alignment of structure is marked on the ground with lime
and or string. With reference to its alignment other points of structures like wing wall, abutment
wall are pegged. For construction purpose temporary benchmarks (TBM) are also established
near by the location of structure. The place of TBM shall be chosen in such a way that it will not
be disturbed by the construction activities and it shall remain in position until all the works are
completed in that location.
2.2.10.9.Material
1. Cement: Cement conforming to IS: 269 shall be used only after ensuring the minimum
required design strength. MTC shall be submitted to the Concessionaire for every
consignment of cement. The certificate shall cover all the tests for chemical requirements,
physical requirements and chloride content. Independent tests of samples drawn from the
consignment shall be carried out at the site laboratory or in an NABL approved laboratory
or Government Engineering College approved by the Concessionaire and further
reviewed by IE immediately after delivery.
2. Coarse Aggregates: Coarse aggregate shall be produced from approved quarry in

required sizes. It shall consist of clean, hard, strong, dense, non-porous and durable pieces
of crushed stone or a suitable combination thereof as specified. Maximum nominal size
of aggregate for various structural components shall conform to the Table 1700-7 of
MORT&H specifications / IS 383.
3. Fine Aggregate: Fine aggregate for structural concrete shall be clean, hard, strong and
durable pieces of crushed stone or suitable combination of natural sand. They shall not
contain dust, lumps, soft or flaky, materials, mica or other deleterious materials in such
a quantity to reduce the durability and strength of concrete. Gradation of fine aggregate
shall conform to Table 1000-2 of MORT&H specifications / IS 383.
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4. Water: Water shall conform to section IS 456 / section 1010 of MORT&H

specifications. Water shall be free from injurious materials like oils, acids, alkaline, salts,
sugar, organic materials or other substance that may be deleterious to the concrete or
steel. Potable water is generally considered satisfactory for construction purpose. Mixing
and curing with seawater shall not be permitted.
5. Reinforcement Steel: Reinforcement steel shall conform to section 1009.3 of MORT&H

specifications. Reinforcement shall be thermo-mechanically treated (TMT) deformed
bars of grade Fe-500 or as mentioned in drawing confirming to IS 1786. Only uncoated
steel shall be used as per shape and size shown on the drawings. It shall conform to the
specification or as approved by the Concessionaire. The Concessionaire shall further
submit the credentials to IE for review and concurrence. Concessionaire shall further
submit the credentials to IE for review and concurrence.
6. Bending of Reinforcement: Bar bending schedule will be prepared and submitted to the
Concessionaire for approval before start of work. Bar bending schedule shall include
number, shape and cutting length of bar and weight in respect of each type. A separate
bar bending schedule shall be prepared for auxiliary bars like spacer, chairs etc.
All the material shall be got approved from Concessionaire prior the utilization in construction
works.
2.2.10.10. Placing of Reinforcement
Reinforcement shall be placed in accordance with the drawing and shall be inspected and
approved by Concessionaire. After getting approval from Concessionaire, immediately pouring
of concrete can be allowed.
Reinforcement shall be tied with binding wire in such a way that it shouldn’t be displaced while
pouring the concrete on it.
Cover blocks shall be made of cement, sand & 10 mm down aggregate with the same grade of
concrete / PVC.
Layers of bar shall be separated by spacer bars kept at approximately 1m interval and min. size
of 12mm, or maximum size of main reinforcement, whichever is greater. Horizontal
reinforcement shall not be allowed to sag between supports.
Necessary auxiliary bars like spacer, chairs, and blocks shall be provided to fix the reinforcement
in its correct position.
2.2.10.11. Proportioning of Concrete
The concreting will be done based on mix design. All measuring equipment shall be in a clean
and serviceable condition. Their accuracy shall be periodically checked. Water cement ratio shall
be maintained constant to its connecting value taking into account moisture content of
aggregates. The amount of water to be added shall be adjusted to compensate the variation in
moisture content due to weather conditions. Proportioning of concrete shall be as per approved
design mix by weigh batching.
2.2.10.12. Trial Mixes
The trial mixes of all grades of concrete shall be prepared by using samples of approved materials
same as that are proposed to use in the works before commencement of work. The initial trial
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mixes shall be prepared at site laboratory. In all cases complete testing of all the constituent
materials proposed in the design mix shall be carried out prior to making trial mixes.
Additional trial mixes shall be carried out before the production, in case of substantial changes
are made in the material or in the proportion of the materials to be used.
2.2.10.13. Equipment’s
Keeping in view of the requirements of the work, equipment proposed to carry out work is as
under:
1. Batching Plant
2. Mixer Trucks / Transit mixer
3. Vibrator
4. Vibrator needles
5. Wheel Loader
6. Excavator
7. Shutter Material
8. Bar Bending & Cutting machine
9. Concrete Pump
2.2.10.14. Transporting, Placing & Compaction of Concrete

Transportation of concrete shall be carried by transit mixer or pumps. Hose pipe from the
concrete pump chutes to the placing area should be laid out with minimum bends. Concrete at
the time of pouring should have temperature in between 5ºC to 40ºC. Placement of concrete shall
not be carried out when the day temperature exceeds 40 ºC.
As a general guidance, permissible free fall of concrete shall be maintained 1.50 to 2.0m, when
free fall of large height involved, self-compacting concrete shall be used in such situation.
2.2.10.15. Formwork
Formwork shall conform to section 1500 of MORT&H specifications. Material and components
used for formwork shall be examined for damage or excessive deterioration before use / reuse
and shall be used only if found suitable after necessary repairs.
The steel / plywood used for forms shall be of such thickness that the forms remain true to shape.
The use of approved internal steel ties or plastic spacers shall be permitted. Structural steel tubes
used as support for forms shall have a minimum wall thickness of 4 mm / or as per design. The
design erection & removal of form work shall conform to IRC: 87.
2.2.10.16. Construction Joints
Construction joints shall be provided as minimum as possible and shall be as per drawings.
Laitance shall be removed before fresh concrete is cast. The surface shall be roughened enough
not to dislodge the coarse aggregate. Concrete may be brushed with stiff brush in its green stage
at the location of construction joint. Fully hardened concrete shall be treated with mechanical
tools to remove the laitance.
2.2.10.17. Curing
Water curing shall be done with water specified in section 1000 of MORT&H specifications.
Exposed surface of concrete shall be kept continuously in a damp or wet condition by spraying
of water or by covering with a layer of sacks, canvas, hessian or similar materials and shall be
kept constantly wet for a period of not less than 14 days from the date of placing the concrete.
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2.2.10.18. Finishing
The finishing shall be done as specified in clause 1713 of Section 1700 of MORT&H
specifications.
2.2.11. Methodology for Box Culverts

2.2.11.6.Scope of Work
The work shall consist of reinforcement cement concrete work and furnishing the structure for
box culvert, slab culvert and minor bridges at the location shown in the drawing or as instructed
by the engineer and in accordance with the requirements of the Technical Specification.
2.2.11.7.Reference Drawings of Precast Box Culverts
Reviewed drawings shall be referred for casting of box culvert
2.2.11.8.Working Drawings
Working drawings, structural drawings along with relevant details will be submitted to the
Concessionaire prior to start of work on site. After review of the above submissions by the
Concessionaire, the setting out of the structures shall be done.
Widening of existing Box Culvert/reconstruction of new Box Culverts as per reviewed drawing.
This work shall consist of Excavation, Foundation, Raft, Walls, Slab, and Return Walls
construction.
2.2.11.10. Reference
2. IRC: SP: 99-2013
2.2.11.11. Setting Out
After completion of site clearance, alignment of Box culvert is surveyed to trace out lines on the
ground with lime and or string for the location of culvert and its structures. For construction
purpose temporary Benchmark (TBM) is also established near by the location of structure. The
place of TBM shall be chosen in such a way that it will not be disturbed by the construction
activities, and it should remain in position until all the structure are completed in that location.
2.2.11.12. Plant & Machineries
• Mixer Machine with Weigh Batcher / Batch Mix Plant & Transit Mixers.
• Hand Rammer / Vibrator.
• Trailer / Open Body Truck.
• Water Tanker.
• Water Pump.
• Shuttering Plate and Stays, etc.
• Backhoe Loader
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Materials: Cement, Mineral Admixtures, Chemical Admixtures, Fine Aggregate, and Coarse
Aggregate & Water shall comply with Clause 1700 of MORT&H Specifications.
Reinforcement: Reinforcement Steel shall be HYSD bars conforming to IS: 1786 and Grade of
Fe 500 or as shown on reviewed drawings.
Concrete: Grade of Concrete shall be as shown on the reviewed drawings. The concrete mix
shall be designed, produced, and transported to site.
Formwork: All materials for formwork shall comply with the requirements of IRC: 87. Only
steel formwork shall be used. All bolts shall be countersunk. The use of approved internal ties
or plastic spacer shall be used. Structural steel tubes used as support for forms shall have a
minimum wall thickness of 4mm.
2.2.11.14. Method of Construction
1. The excavation shall be carried out either manually or by Machine as per site condition.
If machine excavation is carried out, then care shall be taken that there should be no extra
cutting than the required level. The base of the PCC shall be firm surface with required
level.
2. If required, the base shall be sprinkled with water before placing PCC concrete over the
same.
3. Raft layout shall be done for the foundation raft and wall.
4. PCC grade of M15 or as shown in the reviewed drawing shall be laid in the said
foundation after proper layout.
5. Grade of concrete for Raft, Wall, Deck Slab, Return Wall & Curtain Wall shall be used
as per reviewed drawings.
6. Steel reinforcement shall be tied as per reviewed BBS & Drawings.
7. Fixing formwork for base raft of the structure foundation. This formwork includes the
haunch and kick-starter.
8. Concreting shall be poured as described in Clause 1700 of MORT&H Specifications.
9. A post concreting check shall be carried out after stripping and remedial action, if
required any, shall be taken up immediately.
10. Proper water curing arrangements shall be done.
11. The same sequence and precautions, as above, shall be repeated for wall, return walls and
curtain wall.
12. Care shall be taken to provide weep holes as per the Drawing.
13. Scaffolding and formwork for soffit of top slab of box shall be carried out.
14. Steel reinforcement shall be tied as per reviewed BBS & Drawings. Fixing formwork for
sides and inspection shall be carried for concreting.
15. Concreting of top slab carried out.
16. Boulder and pitching work shall be taking up for U/S and D/S aprons. Development of
areas between Return wall and curtain wall.
17. The slab shall be caste along with the wall (after casting the haunch and starter) if the
total height is less than 3 meter.
18. The side shutters of wall &deck slab can be removed after12 hrs of concreting.
19. Do proper curing of deck slab & vertical surfaces of walls by ponding & providing wet
hessian clothes.
20. Remove the soffit staging after required time as per span length.
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21. Floor protection works on both U/s & D/s side shall be carried out as per reviewed GFC
drawings.
22. Traffic Diversion to be done before the starting of this work so that vehicle movement
will be smooth without disturbance to proposed work.
2.2.11.15. Safety
1. During construction of culverts or minor bridges, diversion road is to be built if required
to pass on going public vehicle with adequate safety. Before the diversion of road starts,
retro-reflective traffic signs shall be installed adjacent to the road shoulders to protect the
ongoing works and workers. Clause 112 of MORT&H shall be followed for construction
and maintenance of diversion road.
2. During the night-time, there should be lights on the construction location so that night-
time drivers will be aware of construction activities and they will be alert while driving.
3. No machines or equipment’s shall be permitted to remain on the existing road or shoulder
unattended at any time unless it is properly protected & secured in a safe manner.
4. The safety Officer shall make frequent patrols along the highway to ensure the safety
equipment & signs are operational at all time.
5. While erecting formwork following safety measure shall be ensured:
6. Adequate support against sideway and lateral loads due to construction operation and
wind shall be provided.
7. In case cantilevers are supported directly from ground and the supports will be removed
simultaneous by along with the main support.
8. Form with adequate thickness shall be used to minimize the deflections. Also, it shall be
rigid enough to resist horizontal pressures due to flow of concrete mixed with plasticizer
and lateral pressure due to fast rate of placement by concrete pumps.
9. All Excavated Area shall be barricaded with safety ribbons properly or as to the site
condition.
2.2.11.16. Environmental Safety
Nearby Streams, water courses, lakes, reservoir shall be protected from contamination by the
soil erosion from areas exposed during excavation by constructing temporary berms, dikes,
sediment Basins, slopes, drains & by the use of temporary mulches, seeding or other control
devices.
Vehicles tracks shall be kept moist to prevent flying of dust particles with the vehicle movement.
2.2.12. Methodology for Pipe Culverts
2.2.12.6.Scope
The work shall consist of furnishing and installing required length, type and size of reinforced
cement concrete pipe at the location shown in the drawing or in accordance with the requirements
of the CA.
2.2.12.7.Reference
2. IRC: SP: 99-2013
65
After completion of site clearance, alignment of culvert is surveyed to trace out lines on the
ground with lime and or string for the location of culvert and its structures. For construction
purpose temporary bench mark (TBM) is also established near by the location of structure. The
place of TBM shall be chosen in such a way that it will not be disturbed by the construction
activities, and it should remain in position until all the structure are completed in that location.
Concessionaire prior to start of work on site. After review of the above submissions by the
Concessionaire, the setting out of the structures shall be done.
2.2.12.10. Selection of Material
All materials used in the construction of pipe culverts shall conform to the requirements of
Section -1000 of MORT&H specifications. Concrete pipes to be used in site, shall be inspected,
tested, if necessary and approved by the Concessionaire and provided with manufacturing
certificates.
Pipe used for construction works of pipe culvert shall be tested for conformity in accordance
with IS: 458 and all the concrete used for manufacturing of pipe as well as construction shall be
in accordance with quality norms set forth in section 1700 of MORT&H.
The following equipment’s shall be deployed for the construction.
2. Hydraulic crane / Hydra
3. Dumper
4. Plate compacter, mechanical or pneumatics tamping
5. Water Tanker
6. Tractor trolleys
2.2.12.13. Method of Operation
1. The foundation bed for pipe culverts shall be excavated true to the lines and grades shown
on the drawing or as directed by the Concessionaire. The IE may inspect or verify tests
as per the provisions of the CA. The pipe shall be placed in shallow excavation of the
natural ground or in open trenches cut in existing embankment, taken down to levels as
shown on the drawings. Where trenching is involved its width on either side of the pipe
shall be a minimum of 150 mm or one-fourth of the diameter of the pipe whichever is
more. But in no case it should be more than one third of the diameter of the pipe. The
sides of the trench are kept as nearly vertical as possible. Pipe shall be placed on PCC
bed.
2. The bedding surface is provided with firm foundation of uniform density throughout the
length of the culvert in specified line, levels and grades.
3. After completing foundation, then only pipe is laid in position in required levels and
grades without damage as per approval from the Concessionaire. If many pieces are to
be laid, then clear spacing is maintained at least half the diameter of the pipe to a
minimum of 450 mm. Placing of pipe is carried out beginning from outlet (down slope)
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towards inlet (upslope) in a grade to make invert smooth as specified in drawing. In the
case of bell- mouth pipe, belled end of the pipe should face upstream.
4. The pipes are joined as per the connection details show in the reviewed drawings. For
joining pipe under light hydraulic pressure, the recess at the end of the pipe shall be filled
with jute braiding dipped in hot bitumen or other suitable approved compound. The
bitumen ring of one pipe shall set in to recess of the next pipe. The ring shall be
thoroughly compressed by jacking or by any other suitable methods. All joints should
consistent with the interior surface with the pipes. After finishing, the joints shall be kept
covered and damp for at least four days.
5. Backfilling of trenches shall commence immediately after jointing material has hardened.
The backfill soils shall be clean, free from boulders, large roots excessive amounts of
sods or other vegetables matter, and lumps and shall be approved by the Concessionaire.
Filling of trench is carried out on both side of the pipe to avoid uneven pressure to the
pipe. Backfilling is carried out in layer of not exceeding 150mm, and is thoroughly
rammed, tamped and vibrated in each layer. Approved pneumatic or light mechanical
tamping equipment can be used. Special attention shall be paid on the hunch of the pipe
to consolidate the filling materials.
6. Head walls, wing walls, aprons and other ancillary works shall be constructed in
accordance with the details as shown in the drawings. RCC wall shall confirm to the
section 1500, 1700, 2100, 2200 or 2300 as applicable Aprons shall confirm to the section
2500.
For Pipes: - Load Test & other test will be done at manufacturer’s yard as per IS: 3597.
Control Tests on Structural Concrete as mentioned in methodology for Structural Concrete. Pipes
shall conform to IS: 458.
2.2.12.15. Opening to Traffic
To open the traffic through the culvert, minimum earth cushion required above the top of the
pipe is at least 600 mm.
2.2.13. Methodology for Slab Culverts and Minor Bridges

2.2.13.6.Scope
The work shall consist of reinforcement cement concrete work and furnishing the structure for
slab culverts and minor bridges at the location shown in the drawing or as instructed by the
Concessionaire and in accordance with the requirements of the MORT&H specifications.
2.2.13.7.Reference
2. IRC: SP: 99-2013
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2.2.13.8.Detail of Personnel Deployed
After completion of site preparation, alignment of said culverts or minor bridge shall be marked
on the ground with lime or string. With reference to its alignment other points of structures like
wing wall / return wall, abutment wall is pegged. For construction purpose temporary benchmark
(TBM) is also established near by the location of structure. The place of TBM shall be chosen in
such a way that it will not be disturbed by the construction activities, and it shall remain in
position until all the structure is completed in that location.
2.2.13.10. Working Drawings
Concessionaire prior to start of work on site. After review of the above submissions, the setting
out of the structures shall be done.
2.2.13.11. Selection of Material
1. Formwork: All materials for formwork shall comply with the requirements of IRC: 87.
Only steel formwork shall be used. All bolts shall be countersunk. The use of approved
internal ties or plastic spacer shall be used. Structural steel tubes used as support for forms
shall have a minimum wall thickness of 4mm.
2. Reinforcement: Reinforcement shall be thermo-mechanically treated (TMT) deformed

bars of grade Fe-500 or as shown on reviewed drawing confirming to IS 1786. Steel shall
be used as per shape and size shown on the drawing. It shall confirm to the specification
or as approved by the Concessionaire. Concessionaire shall further submit the credentials
to IE for review and concurrence.
3. Concrete & Brick: All materials for this work i.e. concrete / brick shall confirm to the
section 1000 of MORT&H specifications.
The following equipment’s shall be used for the construction of Minor Bridge and Slab Culverts:
1. Batching Plant
2. Mixer Trucks / Transit mixer
3. Vibrator
4. Vibrator needles
5. Wheel Loader
6. Excavator
7. Shutter Material
8. Bar Bending & Cutting machine
9. Concrete Pump
10. Hydraulic crane
11. Water Tanker
12. Tractor trolleys
1. Site Engineer (Str.) 01
2. Site Supervisor (Str.) 01
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3. Surveyor 01
5. Pump Operator 01
2.2.13.14. Method of Operation
1. Formwork
a. Design of Formwork: Complete design and drawings of formwork for slab super
structure will be submitted for approval before start of work. The design of formwork
shall confirm to the IRC 87.
b. Workmanship: Workmanship shall comply with the clause 1504.2, 1504.4 & 1504.10
of MORT&H specifications. Form shall be made so as to produce a finish concrete
true to shape, line and levels and dimensions as shown on the drawings, subject to
the tolerances specified in respective sections of these specifications, or as directed
by the Concessionaire. All steel tubes are free from kink and bends and it is allowed
to rest on firm base. Subsoil condition is also taken into account while designing the
staging to avoid onto-ward failure.
c. Preparation of Form before Concreting: Contract surfaces of the form shall be

thoroughly cleaned and dried before applying a release agent. It should be ensured
that the release agent is appropriate to the surface to be coated. The form shall be
thinly coated with releasing agent in a sequence first vertical and then horizontal
surface and any excess can be wiped out. The same type and make of release agent
shall be used throughout or similar formwork materials and different type shouldn’t
be mixed. The release agent shall not come in Contract with the reinforcement bar or
the hardened concrete. Release agent should preferably be water based and shall be
got approved by Concessionaire.
d. Removal of Formwork of Slab/ Super Structure: The scheme for removal of form
(i.e. de-shuttering and de-centring) shall be planned on advance and submitted for
review. No formwork shall be removed without prior approval of Concessionaire.
2. Reinforcement
a. Bending of Reinforcement: Bar bending schedule shall be prepared and submitted to
Concessionaire, prepared based on reviewed drawings, for approval before start of
work. Bar bending schedule shall include number, shape and cutting length of bar
and weight in respect of each type. A separate bar bending schedule shall be prepared
for auxiliary bars like spacer, chairs etc.
b. Placing of Reinforcement:
i. Reinforcement shall be placed in accordance with the reviewed drawings and get
inspected and approved by the Concessionaire. Further IE may inspect the work
as per the provisions of the CA. After approval pouring of concrete shall follow.
ii. Reinforcement shall be tied with binding wire in such a way that it won’t be
displaced while pouring the concrete on it.
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iii. Cover block are made of cement, sand and aggregate with the same durability of
surrounding concrete.
iv. Layers of bar shall be separated by space bars kept at approximately 1m interval
and min. size 12mm or maximum size of main reinforcement, whichever is
greater is used. Horizontal reinforcement shall not be allowed to sag between
supports.
v. Necessary auxiliary bars like spacer, chairs, and blocks shall be provided to fix
in its position.
2.2.13.15. Concrete
1. Grades of Concrete: Concrete used in any structure shall be specified by designation. For
all items of work Design Mix shall be used.
2. Proportioning of Concrete: Proportioning of concrete shall be done in computerized
batching plant. All measuring equipment shall be in a clean and serviceable condition.
3. Their accuracy shall be periodically checked. Water cement ratio is maintained constant
to its designated value taking in to account of moisture content of aggregates. The amount
of water to be added shall be adjusted to compensate for the variation in moisture content
due to weather condition.
4. Admixtures: Duly tested admixtures/ additives confirming to IS 6925 and IS 9103 may
be used subject to satisfactory proven use, with the approval of Concessionaire.
5. Size of Coarse Aggregate: Size shall refer to Table 1700-7 of MORT&H specifications.
2.2.13.16. Transporting, Placing and Compaction of Concrete
Transportation of concrete shall be carried by transit mixer or pumps. Hose pipe from the
concrete pump chutes to the placing area should be laid out with minimum bends. Concrete at
the time of pouring should have temperature in between 5ºC to 40ºC. Placement of concrete shall
not be carried out when the day temperature exceeds 40 ºC.
As a general guidance, permissible free fall of concrete shall be maintained 1.50 to 2.0m, when
free fall of large height involved, self-compacting concrete shall be used in such situation.
2.2.13.17. Protection and Curing
Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding
or by covering a wet layer of sacks, canvas, hessian or similar materials and shall be kept
continuously wet for a period of 14 days from the date of placing of concrete.
2.2.14. Methodology for Precast Box Culvert
2.2.14.6.Scope
Pre-casting and erecting of box segments for culverts.
2.2.14.7.References
2. IRC: SP: 99-2013
1. Hydra (12T capacity)
2. Hydraulic crane (50T)
3. Crane bucket
4. Gantry (25MT)
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5. Transit mixer
6. Concrete batching plant
7. Mechanical vibrators
8. Crib shuttering
3. Surveyor 01
5. Pump Operator 01
Casting of Pre-cast Box:
1. The base bottom shutter is fixed to line and level to lay the PCC around bottom shutters
(Bottom shutters are prefabricated with inverted shear keys as per drawings).
2. Inner shutter is mounted and bolted with bottom shutter.
3. Reinforcement of box segment is prefabricated as per BBS and details given in the
drawings (it should be prepared outside of casting bed). The reinforcement is positioned
over bottom shutter.
4. Outer shutter (crib type) is fixed for line, level, wall thickness.
5. Top shear key is fixed (bottom shear is permanently fixed to the bottom shuttering).
6. The concrete of designed grade is poured and vibrated using immersion vibrators. The
pouring is done by Crane bucket using transit mixer.
7. Curing is done after 12 hours by sprinkler, manual pouring etc.
8. De-shuttering is done after 24 hours of casting.
9. The box segment is touched up after De-shuttering if required and number is painted.
10. The box segment is stacked in the yard till it attains the required strength as per
specification.
11. Curing shall be done for a minimum of 14 days.
2.2.14.10. Erection of Pre-cast Box:
1. The alignment of box culvert is marked as per drawings on ground.
2. PCC is laid for fixing the boxes with the required offset and to line and level.
3. Shifting of box segments is done after 28 days or achieved required strength.
4. The boxes are transported with the help of trailer from stacking yard to site.
5. The boxes are positioned as per centre line of box culvert to maintain the line and level.
6. After positioning, jointing the boxes is done using one of the bonding compounds, in the
recommended proportion by manufacturing and design. The bonding compound is
applied in all jointing faces for jointing each other.
7. After completion of jointing the boxes, bonding material is applied on top for resistance
to tearing and abrasions.
8. Back filling behind box is done layer by layer using approval back filling material or
Geo-Composite.
9. The protection works are carried out thereafter.
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2.2.15. Methodology for Pile Foundation

2.2.15.6.Scope
This method statement covers the boring of pile for Major/Minor Bridges / ROB/Flyover in
accordance with the details shown on the relevant drawings and conforming to the requirement
of MORT&H specifications. The work shall be carried out as per IS: 2911 Part 1.
2.2.15.7.References
6. IRC: SP: 99-2013
8. IS: 2911 Part 1
1. The centre line / benchmark of each bridge / structure shall be fixed with reference-to-
reference point / project centre line & get it approved by the Concessionaire. The
reference points to be fixed to mark X-X axis (usually in traffic direction) & Y-Y
direction. For the establishment of above points Total Station may be used.
2. For every bridge / structure at least 2 nos. of permanent benchmark / centre line points
shall be fixed on either side of bridge keeping a safe distance from the construction area
so that in future it should not be disturbed by any means.
3. Centre line / benchmark should be transferred to every pier / abutment location keeping
a safe distance from foundation area in X-X and Y-Y direction.
4. The layout with help of co-ordinates of all Piles coming under the particular
pier/abutment to be made before starting of boring any Pile.
5. These working points should be checked along with Concessionaire and shall be entered
in the site record.
Working drawings, structural drawings, staging drawings and bar bending schedules will be
submitted to the Engineer prior to start of work on site. After approval of the above submissions
by the Engineer/Approval authority, the setting out of the structures shall be done.
Test Pile: Test Pile shall be done as per the reviewed working drawings and clauses 1105 of
2.2.15.10. Material
The basic material shall conform to section 1000 of MORT&H specifications. The structural
steel, concrete shall be used in pile foundations shall conform to Section 1600,1700,1800,1900
of MORT&H specifications. The list of approved materials shall be provided to Engineer/
Approval authority with all the requisite details for reference.
The following equipment’s shall be deployed in the execution of Piling.
1. Piling Rig / Percussion machine and other allied equipment’s.
2. Lifting Crane/Service Crane
3. Dumpers
4. Batching & Mixing Plant
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5. Transit Mixers
6. Concrete Pump/Tremie Pipe with hopper
7. Bentonite/Polymer mixing set up.
8. Mixing tank & pump
9. Vertical pump
10. Sounding chain & measuring tape
11. Vibrators with needles
12. Bar Bending Machine/Cutting & Bending Machine
1. Sr. Engineer/Asst. Manager (Str.) 01
3. Surveyor 01
4. Safety officer 01
5. Pump Operator 01
2.2.15.13. Personnel for Execution & Supervision
A well-trained team who has experience to execute such activity shall be deputed to execute the
above job. Cage inspections shall be done by the Sr. Structural Engineer / Site Engineer / DPM
to ensure the conformance to the working drawings and relevant codes before lowering the cage.
1. Boring
a. The cast-in-situ bored pile shall be done by making bore in the ground and removing
the material.
b. Boring shall be carried out using rotary equipment.
c. The diameter of the finished pile shall not be less than that specified. A continues
record shall be kept as to the volume of concrete placed in relation to the length of
pile that is cast.
d. The drilling mud such as bentonite/Polymer suspension shall be maintained at a level
sufficiently above the surrounding ground water level throughput the boring process,
to ensure the stability of the strata which is being penetrated until the pile has been
concreted.
2. Concerting
a. Wherever practicable, concrete should be placed in a clean dry hole in case of minor
bridge piling.
b. Before concreting of the pile is commenced, it is essential to ensure that no debris
remains at the bottom of the shaft.
c. Reinforcement for the pile as shown on the reviewed drawing shall be tied in place
to form a cage which is lowered into the pile shaft.
d. Where concrete is placed in dry and a casing is present, the top 3m of the pile shall
be compacted using internal vibratos in case of minor bridge.
e. Care shall be taken during concerting to prevent the segregation of the ingredient.
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f. The concrete shall be properly graded, shall be self-compacting and shall not get
mixed with soil, excess water, or other extraneous matter.
g. The placing of concrete with tremie pipe shall be continues process from the toe level
to the top of the pile. To ensure compaction by hydraulic static heads, rate of placing
concrete in the pile shaft shall not be less than 6m (length of pile) per hour.
h. It shall be ensured that bottom of tremie pipe always remains buried in already placed
concrete.
i. Temporary Casing during the concerting shall be done as per the clause 1107.3 of
2.2.15.15. Mixing, Transportation, placing and compaction of Concrete

1. Concrete mixing: Concrete shall be mixed in approved proportions in batching and
mixing plant (clause 1708 of MORT&H specifications).
Batching plant calibration shall be approved by the Concessionaire and witnessed by IE

Mixing time shall be adjusted according to the efficiency of the mixer to ensure the
uniform distribution and a uniform colour of the entire batch. In any case mixing time
shall not exceed two minutes. Mixer which has been out of use for more than 30 minutes
shall be thoroughly cleaned before putting in a new batch. Mixer shall be thoroughly
cleaned before switching over from one type of cement to the other type. Water cement
ratio of the mix shall be maintained to the designed one by recording the moisture content
of the ingredients frequently and adjusting the water quantity of the mix. Suitable
adjustment shall also be made in the weight of aggregate to allow for the variation in the
weight of aggregate due to variation in their moisture content. Aggregate shall be kept
moist or shaded during summer to keep the temperature low. Sand / fine aggregate shall
conform to Table 1000-2 of MORT&H specifications. Approved super plasticizers shall
be used to delay the setting time and increase fluidity of the concrete mix to aid the
pumping and long distances transportation. It shall conform to section 1012 of MORT&H
specifications.
2. Transportation of concrete mix: Concrete shall be transported in transit mixers.

Concrete shall not be poured during the peak temperature hours in summer season to
keep the maximum temperature below 40ºC. In winter concrete shall be avoided during
peak low temperature hours to maintain the minimum temperature more than 5ºC.
3. Placing of concrete: Placing of concrete shall be done with tremie method in accordance
with clause 1107.4 of MORT&H.
2.2.16. Methodology for Pile Cap

2.2.16.6.Scope
This method statement covers the work procedure to be adopted for casting of pile cap as per
Approved drawings including fixing of formwork system, reinforcement, compaction, curing.
The following equipment’s shall be deployed in the execution of Pile cap.
1. Excavator
74
2. Dumpers
3. Batching Plant
4. Transit Mixers
5. Truck / trailer
6. Generator
7. Concrete Vibrators with Needles
8. Jack hammer
9. Compressor
10. Crane / Hydra
11. De-watering Pump
12. Tractor
13. Bar Cutting Machine
14. Bar Bending machine
15. Welding Transformer
16. Drill Machine
17. Concrete Pump
18. Road Roller
* As per site condition it can be increased or decreased.
3. Surveyor 01
5. Pump Operator 01
2.2.16.9. Safety
The preparatory works shall be carried out as per Diversion plans separately submitted for
construction activities.
A width of approx. 8.00 m (outside to outside of barricading) shall be barricaded along road for
purposes of construction of pile caps. This can be increased at specific location with prior
approval of Engineer. Suitable reflectors, blinkers, diversion board, painting of barricade etc.
shall be done to caution the road users and for their safety. Working space shall be well
illuminated during work at night. All site personnel shall wear helmets, safety shoes, jackets and
other safety devices as required.
Proper precautions and safety arrangements shall be used for activities like welding, handling of
reinforcement, fixing of formwork, eclectically operated equipment’s etc.
Proper safety shall be done for all site operations and method of construction for the safety
person’s onsite and for the installations of such facilities as well as protect the works, the public
and the environment from injury on damage.
2.2.16.10. Survey
Before commencing excavation, the pile cap area shall be marked on the ground after carrying
out survey with reference to control points. After excavation the levels of the pit shall be checked
75
for correctness to the drawings and recorded. Longitudinal and transverse centrelines shall be
marked outside the pit for reference for cross checking the pile. The shift of pile shall be recorded
by marking the theoretical coordinates of pile on ground and circle of equivalent to pile diameter
shall be drawn and shift of actual pile will be measured from theoretical edges of pile. The as
built details of the piles shall be recorded jointly. Based on shifted location of pile top, pile cap
/ PCC layout shall be marked to ensure minimum 150 mm offset from outer edge of pile. After
laying of PCC, the layout of the pile cap shall be marked on it with reference to the reference
points to facilitate tying of rebar and erection of shuttering.
2.2.16.11. Excavation
Shoring shall be provided depending upon the stability of the soil found in the area. Shoring shall
be done with the help of old steel plates and props. At road locations the pit shall be excavated
to the dimensions providing working space all around the pile cap, to facilitate fixing of steel&
erection of shuttering as detailed in the drawings. The last 300 mm excavation shall be carried
out manually & levelling course shall be laid down within 36 hrs after completing excavation of
last 200 mm depth. Provision for sump shall be made at the corner of the pit to pump out
underground water of about 750 mm deep from PCC bottom. Also an earthen drain of about 200
mm width if required shall be provided all around pile cap dimension & it shall be connected
with sump to drain off excess rain water / seepage water to ensure that the water table will at
least 300 mm below the lowest level of the excavation before laying PCC. The excavated earth
shall be then disposed by means of trucks / loaders.
2.2.16.12. Removal of Laitance
After excavation the laitance of the piles shall be removed by using Pneumatic Jack Hammers
seven days after casting of pile or manually three days after casting of pile. The top of pile after
striping shall project 50 mm into the pile cap and reinforcements of pile shall be fully anchored
in pile cap as per clause 709.5.2 of IRC: 78. The debris of broken concrete shall be removed
from the pit and disposed-off to approve dumping sites. Exposed bars shall be straightened &
cleaned properly with wire brush.
2.2.16.13. PCC
After levelling the bottom, the pit shall be watered to keep the soil moist. PCC of M15 mix or as
specified in drawing shall be mixed at the centralized batching plant at the casting yard and
transported to site in transit mixers.
The concrete shall directly pour through chutes, shall be spread and levelled manually to the
specified thickness shown in the drawing. PCC edges shall be projected 100 mm more than that
of pile cap as detailed in the drawing to facilitate the fixing of form work and levels of PCC shall
be jointly checked & verified. The PCC shall be cured by sprinkling water.
2.2.16.14. Reinforcement
1. Fabrication: For fabrication of reinforcement, BBS shall be prepared as per reviewed
drawings. The reinforcement shall be cut using cutting machines or manually as required
and bent at rebar yard. The re-bars shall either be transported to location in trailer / truck
or cutting bending may be done at site depending upon the situation.
2. Fixing of Re-bars: The re-bars shall be manually fixed into its position as shown in the
drawings. Reinforcement of pile cap shall be lapped with the reinforcement of pile. Cover
blocks of same grade of concrete in which these are to be embedded shall be provided at
spacing of about 2.0 m c/c to ensure uniform cover as specified in the drawing and tied
together with GI binding wire. After fixing the pile cap rebar, pier shaft rebar shall be
erected. This rebar shall be supported by erecting a suitable staging frame across the
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width of the pile cap. The rebar cage shall be checked as per checklist given in IRC SP
112 and RFI for inspection shall be raised for inspection of Concessionaire. The rebar,
chairs, spacers & laps shall be jointly checked after completion of cage placing. Sufficient
chairs and spacers shall be provided to keep the cage in its proper position. After getting
the clearance, balance shuttering work will be taken up. Pier dowels shall be hold in
position rigidly to prevent it from buckling.
2.2.16.15. Shuttering
Shuttering fabricated as per reviewed drawings shall be placed at locations as per the pile cap
dimensions shown in the good for construction drawing. Reinforcement shall be fixed as per the
drawing and marking the layout on PCC for pile cap. After completing the fixing of rebar cage
shuttering shall be erected & fixed on the layout drawn on PCC. Before fixing, the shuttering
area shall be cleaned with wire brush & approved shuttering oil shall be applied on concrete face.
After fixing of shuttering it shall be checked as per QA checklist and RFI to be raised for
inspection of Concessionaire. For preventing leakages from joints, rubber strip / foam strip shall
be provided at the joints of shuttering plates. Proper side supports/bracings/tie bars shall be
provided to resist lateral pressure of green concrete during pouring.
2.2.16.16. Concreting
The concrete of required grade shall be produced as per the approved design mix at the
centralized batching plant and transported by transit mixers to the pouring location. Before
pouring concrete, slump of 150 mm to 130 mm/ as per design mix shall be checked at pouring
location. The concrete shall be placed by concrete pump / placer boom or by direct chutes.
Concrete placing commences from one end to another in cascading manner till completion. The
drop height of the concrete should not be more than 1.5 m. The concrete shall be vibrated using
60 mm / 40 mm diameter needle vibrators. Concrete cubes shall be taken for testing of
compressive strength as per IRC 21 at pouring location. Concreting should be done in such a
way that next layer of concrete should be laid before initial set of concrete of previous layer to
avoid cold joints. Regular tamping shall be done during & after concreting operation.
2.2.16.17. Curing
Date of concrete shall be written on the concrete surface to ensure curing up to the specified
duration after date of casting. The concrete shall be cured by ponding method. Bunds of cement
mortar of lean mix shall be built after the concrete attains final setting time after casting of
concrete, these bunds shall be filled with water from approved source. The sides of the pile cap
shall be covered with Hessian cloth till back filling is started. Further curing is ensured by
keeping the backfill moist with water.
2.2.16.18. Backfilling
Immediately after de-shuttering, concrete surface shall be checked jointly and get the approval
for backfilling from Concessionaire. The IE may further witness or inspect the site as per the
provisions of the CA. Back filling with local earth available or excavated material shall be carried
out in layers of 150 mm (compacted thickness) (as per clause 304.3.7 of MORT&H
specifications). The compaction shall be done with the help of suitable equipment such as mech.
tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve a density not less
than the field density before excavation.
2.2.16.19. Miscellaneous Works
After backfilling the damaged roads, if any shall be repaired immediately preferably within 15
days of backfilling as per specification before removing of the barricades, the whole area shall
be cleaned after completion of work.
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2.2.17. Methodology for Casting of Pier/ Abutment shaft

2.2.17.6.Scope
This method statement describes the methodology for casting of vertical pier shaft over open
foundations or pile caps up to pier cap bottom for elevated viaduct structures or Abutment Shaft.
2.2.17.7.Deployment of Equipment
1. Batching plant
2. Transit mixer
3. Concrete pump/boom placer
4. Generator
5. Concrete vibrator with Needles
6. Crane
7. Truck/Trailer
The capacity and quantity of above equipment shall be as per the quantum of work as shall
be decided by the Site team during the execution of such works at site.
3. Surveyor 01
5. Pump Operator 01
2.2.17.9.Safety
The preparatory works shall be carried out as per Diversion plans separately submitted for taking
up construction activities in urban areas.
A width of approx.8.00 m (outside to outside of barricading) shall be barricaded along road for
purposes of construction of piers. This can be increased at specific location with prior approval
of Engineer. Suitable reflectors, blinkers, diversion board, painting of barricade etc. shall be done
to caution the road users and for their safety. Working space shall be well illuminated during
work at night. All site personnel shall wear helmets, safety shoes and other safety devices as
required.
Proper safety should be done for all site operations and method of construction for the safety
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2.2.17.10. Work Procedure

1. Survey: The location of piers / abutment shafts and their layout shall be checked once
again with respect to the reference points already established during pile foundation
works of respective pier.
2. Reinforcements: The BBS shall be prepared as per reviewed drawings and the same
shall be submitted to Concessionaire. The bar length shall be cut as per length given in
submitted BBS either manually or by cutting machine and then those shall be bend as per
requirement shown in BBS. The cutting and bending operation shall be done in
reinforcement yard or at site depending upon the case. The reinforcement shall be
properly cleaned before use. After that reinforcement shall be placed and fixed in position
manually or the prefabricated cage can be transported & fixed to reduce the time cycle.
3. Formwork: The form work shall be fabricated in-line with the reviewed drawings in
such way to make standards shuttering and if required special shuttering shall be
fabricated. All the joints shall be connected by bolts and rubber / foam strips shall be
used in all joints to prevent leakage during concreting. Lateral supports/ties shall be
provided at suitable spacing to hold the shutters in position while concreting to counter
act the lateral pressure due to green concrete. Gaps / holes in the form work shall be
plugged with foam / putty or suitable material to make it leak proof.
The surface of all formwork / shutter which shall receive green concrete shall be
thoroughly cleaned and shutter oiled before fixing in position. For adjusting verticality,
anchoring shall be made by using wire ropes from top of shutters to suitable anchor points
on and around ground surface or concrete block support. Turn buckle / chain pulley shall
be attached to the above wire ropes to pull the formwork for ensuring its verticality. Once
the formwork is fixed, the same shall be got checked as per checklist format given in IRC
SP: 112 and RFI shall be raised for checking / inspection by Concessionaire. The
Concessionaire may invite the IE for inspection or verification of the work as per the
provisions of the CA.
4. Concreting: The concrete of required strength shall be prepared at batching plant as per
approved mix design in the site laboratory. The concrete shall be transported in transit
mixers to the pouring location. Slump in concrete shall be kept between 110 mm to 140
mm at pouring location and the slump shall be checked regularly at the pouring location.
The concreting shall be done using concrete pump with flexible hose or with crane &
bucket arrangement and free fall of concrete shall be limited to 1.50 m. The compaction
of concrete shall be done using needle type vibrators with 60 mm / 40 mm diameter
needles. To check the quality of concrete, cubes shall be taken for testing compressive
strength as per clause 1718 of MORT&H specifications at pouring locations. Shear key
of suitable size shall be provided at horizontal construction joint at the interface of older
lift and new lift of concrete. Also, top surface of substructure lift shall be
hacked/roughened to remove laitance for proper bonding between two lifts.
5. De-shuttering: De-shuttering will be done after attaining desired strength of the structure
and shall be done by using the crane. The joints of shuttering to be loosened and bolts are
too opened one by one to take shutter out without damaging the pier ribs.
6. Curing: The concrete shall be cured by putting hessian cloth over the entire surface of
pier shaft except the top surface of pier. The hessian cloth shall be kept moist by
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sprinkling water and for pier top surface water shall be poured directly on the surface to
keep it wet throughout the curing period of 14 days. Curing compound may also be used,
depending upon the necessity.
2.2.18. Methodology for Casting of Pier Cap/Abutment Cap

This method statements deals with casting of pier cap/Abutment Cap over staging erected from
ground level.
2.2.18.7.Work Procedure
1. Survey: Centre line on both directions shall be marked at the top of the pier shafts for
placing formwork for pier cap. After casting of pier shaft, the centreline shall be marked
over the top surface of pier to fix the formwork, reinforcement, and concreting.
2. Staging: Crib staging shall be erected from ground level to support the formwork of pier
cap. Space shall be kept on staging beyond the plan dimension of pier cap on all sides of
the pier cap for making a platform to facilitate fixing of reinforcements, side formwork
and concreting. M.S. railing shall be provided at the edge of the platform and a M.S.
ladder with hand railing shall be fixed for reaching up to platform. Bottom formwork and
platform shall be fixed over the staging before proceeding for other activities.
3. Reinforcements: The BBS shall be prepared as per reviewed drawings and the same
shall be submitted to Concessionaire. The bar length shall be cut as per length given in
submitted BBS either manually or by cutting machine and then those shall be bend as per
requirement shown in BBS. The cutting and bending operation shall be done in
reinforcement yard or at site depending upon the case. The reinforcement shall be
properly cleaned before use. After that reinforcement shall be placed and fixed in position
manually or the prefabricated cage can be transported & fixed to reduce the time cycle.
4. Formwork: The form work shall be fabricated in-line with the reviewed drawings in
such way to make standards shuttering and if required special shuttering shall be
fabricated. All the joints shall be connected by bolts and rubber / foam strips shall be
used in all joints to prevent leakage during concreting. Lateral supports/ties shall be
provided at suitable spacing to hold the shutters in position while concreting to counter
act the lateral pressure due to green concrete. Gaps / holes in the form work shall be
plugged with foam / putty or suitable material to make it leak proof.
The surface of all formwork / shutter which shall receive green concrete shall be
thoroughly cleaned and shutter oiled before fixing in position. For adjusting verticality,
anchoring shall be made by using wire ropes from top of shutters to suitable anchor points
on and around ground surface or concrete block support. Turn buckle / chain pulley shall
be attached to the above wire ropes to pull the formwork for ensuring its verticality. Once
the formwork is fixed, the same shall be got checked as per checklist format given in IRC
SP: 112 and RFI shall be raised for checking / inspection by Concessionaire.
Concessionaire may invite I.E for inspection as per provision of Contract.
5. Concreting: The concrete of required strength shall be prepared at batching plant as per
approved mix design in the site laboratory. The concrete shall be transported in transit
mixers to the pouring location. Slump in concrete shall be kept between 80 mm to 130
80
mm at pouring location and the slump shall be checked regularly at the pouring location.
The concreting shall be done using concrete pump with flexible hose or with crane &
bucket arrangement and free fall of concrete shall be limited to 1.50 m but not more than
2.0m. The compaction of concrete shall be done using needle type vibrators with 60 mm
/ 40 mm diameter needles. To check the quality of concrete, cubes shall be taken for
testing compressive strength as per clause 1718 of MORT&H specification at pouring
locations. Shear key of suitable size shall be provided at horizontal construction joint at
the interface of older lift and new lift of concrete. Also, top surface of substructure lift
shall be hacked/roughened to remove laitance for proper bonding between two lifts.
6. De-shuttering: De-shuttering will be done after attaining desired strength of the structure
and shall be done by using the crane. The joints of shuttering to be loosened and bolts are
too opened one by one to take shutter out without damaging the pier ribs. After shuttering
dimension shall be measured and tolerance shall be recorded in accordance with clause
2307 of MORT&H. if it is found beyond the limit a separate method statement for
rectification shall be submitted and got approved.
7. Curing: The concrete shall be cured by putting hessian cloth over the entire surface of
pier cap except the top surface of pier cap. The hessian cloth shall be kept moist by
sprinkling water and for pier top surface water shall be poured directly on the surface to
keep it wet throughout the curing period of 14 days. Curing compound may also be used,
depending upon the necessity.
2.2.18.8.Deployment of Equipment
1. Batching plant
2. Transit mixer
3. Concrete pump
4. Welding generator
5. Concrete vibrator
6. Vibrator needles
7. Crane
8. Truck/Trailer
9. Bar Bending Machine
The capacity and quantity of above equipment shall be as per the quantum of work as shall be
decided by the Site team during the execution of such works at site.
3. Surveyor 01
5. Pump Operator 01
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2.2.18.10. Safety
The preparatory works shall be carried out as per Diversion plans separately submitted for
construction activities on urban areas.
A width of approx.8.00 m (outside to outside of barricading) shall be barricaded along road for
purposes of construction of piers. This can be increased at specific location with prior approval
of Engineer. Suitable reflectors, blinkers, diversion board, painting of barricade etc. shall be done
to caution the road users and for their safety. Working space shall be well illuminated during
work at night. All site personnel shall wear helmets, safety shoes and other safety devices as
required.
Proper safety should be done for all site operations and method of construction for the safety
2.2.19. Superstructure Construction & Concreting

2.2.19.6.Scope
This section shall cover furnishing and providing of concrete for superstructure and its
construction in accordance with the drawings and as per MORT&H specifications.
2.2.19.7.Material
Material shall conform to Section 1000 of MORT&H specifications.
2.2.19.8.Casting, handling of precast RCC Girder
The main activities and procedure to be followed for the casting and handling of the pre-cast
girders shall be as below:
1. Fixation of formwork: Firm casting beds for girders shall be prepared at the site and side
shutters as per dimensions shown in the reviewed drawings shall be placed in position
and de-shuttering shall be done after concreting of girders by removing side shutters.
Suitable distances have been kept for the side shuttering so that the girders can be
removed from the bed.
2. Preparation & Placing of Reinforcement Cage: A standard BBS shall be prepared as per
the length of the girders. The cutting, bending & binding of the reinforcement shall be
done as per BBS on the platform. The details of the reinforcement placed shall be checked
in accordance with the BBS and recorded as per format. The cover blocks provided shall
be of the approved shape, size and of the same strength as that of the girders as mentioned
in the reviewed drawing.
3. Pouring of concrete: Concrete of required grade shall be mixed at the batching plant as
per the approved mix design, transported to the site by transit mixer, and poured with the
help of chute attached to TM concrete shall be poured up to the full height and shall
proceed from one end to the other. Care to be taken that no cold joint is allowed to occur
during concreting. Compaction shall be ensured by using needle vibrators of size 40 mm
and 60 mm as required. Wooden mallets shall be continuously used for tamping on
shutters to remove any air bubbles.
2.2.19.9.Identification precast RCC Girder
The pre-cast girders shall be marked suitably for identification. These shall have the following
markings on each side of the girder:
1. Date of Casting.
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2. Length of Girder
3. Girder No.
2.2.19.10. Curing and de-position of RCC Girders from Bed
The curing of RCC Girder shall be done as prescribed in MORT&H specifications. The RCC
Girders shall be shifted from the bed after 28 days /as specified.
2.2.19.11. Tolerance
Tolerance shall be as per MORT&H specifications Clause 2307.1.
Variation in thickness of top and bottom flange for T-girders

±5 mm
and slabs.
Variations in web thickness -5 mm to +10 mm
Variation in overall depth or width ±5 mm
Shall not exceed ±10 mm or
Variation in length overall and length between bearings ±0.1% of the span length,
whichever is less.
Permissible surface unevenness in deck slab when measured
5mm
with a 3 m straight edge or template.
2.2.19.12. Pedestals Casting & Bearing Fixing

1. The centre line of bearing should be marked on the pier/abutment cap by the surveyor
and size of pedestal shall be marked accordingly.
2. The size of pedestals over pier/abutment cap shall be cast as per the reviewed drawings.
3. Around bearing there shall be a clear offset of 150 mm beyond the edges of bearings or
the size of pedestals shall be so kept so that bursting/crushing of pedestal does not occur
under the load coming on it.
4. The shuttering shall be erected as per required size of pedestal.
5. For installation of bearing, pockets commensurate with the size of anchors shall be kept
in pedestals during concreting of the same.
6. The pedestal shall be cast approximately 20mm short of the required finished level so
that the required margin for fixing of bearing is available, after that gap shall be filled
with the cement epoxy mortar.
2.2.19.13. Launching of Girders
1. RCC Girders shall be lifted by lifting hook provided in the girder on both ends with the
help of two cranes. Both cranes have to act simultaneously and slowly, and girder shall
be placed directly on already placed bearing as per the drawings.
2. The girders shall be placed in its true alignment & position and in plumb with the help of
Sims and shall be checked for their location, level so that they are as per drawings.
3. Where the gap between the bottom of the girder and pier cap is more, suitable cribs shall
be provided.
4. The girder once in position shall be suitably braced with each other so that there is no
movement in them when staging, shuttering and concreting for deck slab is being done.
2.2.19.14. Staging for Casting of Deck
After placing the required number of girders between two piers, reinforcement and shuttering for
end diaphragm shall be done as per drawing. Concreting of required grade shall be placed in
diaphragm / crossbeam.
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For vibration, needle vibrator will be used. A temporary platform shall first be erected between
girders to enable the workers to fix the shutting forms and scaffolds for pouring concrete for
deck slab. The staging for this shall be made with pipes and working plate form will be made by
challis.
1. For Cantilever Portion:
a. The outer girders shall be provided with hole in the webs in two rows to insert tie
rods for fixing cantilever frame to support centring and shuttering form work for
cantilever portion of deck slab.
b. The frame will be fixed with girder with the help of tie rods threaded at ends and bolts
over which required form work will be placed.
2. For Inner Portion:
a. Staging for deck slab shall be supported from girder flanges and not from ground.
b. First of all, location of wooden block will be masked on bottom flange of the girder.
c. These wooden blocks shall be fixed by 16 mm dia bolts with 200mm x 200mx10mm
plate which is welded with lower pipe of H frame and Wooden blocks shall work as
footing for H frame by making them with suitable slope to properly sit on bottom
flange of girder.
d. The frame shall then be lifted by crane and placed in previously marked position on
bottom flange of girder.
e. Screw Jacks shall be fixed on top of frame to carry a channel ISMC 150.
f. To prevent sliding of the wooden blocks suitable bracing of scaffolding pipe shall be
provided.
g. The bottom shuttering of the diaphragm shall be placed in position with cut-out for
the Bearings.
h. If the gap between the shuttering and the pier cap is very small and may cause
obstruction in its removal, plywood of suitable thickness shall be used as packing.
Thermocoal packing shall be provided under the ply. This will enable the removal of
ply board during de-shuttering.
i. The sides of the shuttering for the diaphragm shall be placed in position only
after the reinforcement has been placed in position the joints between adjacent
shuttering plates shall have 5mm thick foam between them to avoid leakage of cement
slurry.
j. The top level shall be checked to match with the reviewed drawings. The levels shall
be adjusted where required with the help of screw jacks provided over the H-frames.
k. The shuttering surface shall be cleaned, and suitable shuttering agent used for easy
removal of shuttering.
l. Entire shuttering so fixed shall be duly checked and approved by Concessionaire.
2.2.19.15. Reinforcement
1. A bar bending schedule shall be prepared based on the reviewed drawings and shall be
submitted for review.
2. Cutting and bending shall be done and checked for its shape and size before framing the
cage.
3. The reinforcement bar shall be hoisted on to the shuttering and placed in position as
indicated in the drawings.
4. Inserts for rainwater pipes and drainage spouts shall be placed in position. It will be
ensured that during concreting these does not get disturbed.
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5. Suitable cover blocks shall be used to maintain the required cover as shown in the
drawing. Wherever necessary suitable chair shall be provided so that location of the bars
does not get disturbed due to movement of labour and equipment.
6. Wooden block shall be fixed in position to provide recess for fixing of expansion joints
as per reviewed drawing of the manufacturer.
2.2.19.16. Concreting
1. Concreting of the grade as shown in the drawings and as per the approved mix design
shall be used.
2. A slump as required shall be used to achieve the required compaction.
3. Concrete from the batching plant shall be transported to site by transit mixers and pumped
at required location with help of concrete pump / placer boom or crane and bucket
arrangement.
4. The concrete in the diaphragm shall be laid in the layer, each layer not exceeding 500mm.
5. Concrete shall be started from one expansion joint and carried progressively to the other
expansion joint.
6. The concrete pump pipe shall be so laid that by removing each length the Concrete
reaches the required location and addition of pipe are not required.
2.2.19.17. De-shuttering of Deck Slab
Deck slab shuttering will be removed after concrete has achieved 14 days (as per MORT&H
specifications) of designed strength. The shuttering plates along with scaffolding pipe will be
removed manually with the help of chain pulleys/, Manila ropes with pulleys. A temporary
platform used to erection shall be useful for de-shuttering also. Shuttering plates along with
scaffolding rods will be removed and kept on platform. Later these plates and scaffolding rods
will be brought down by chain pulleys / Manila ropes with pulleys.
2.2.19.18. Deployment of machinery
1. Concrete pump
2. Batching plant
3. Transit mixers
4. Vibrators
5. Needles
6. Cube Mould
8. Power Arrangement (Generator/ Electricity)
3. Surveyor 01
5. Pump Operator 01
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2.2.19.20. Method Statement for Installation of Strip Seal type Expansion Joints with
Sinus Plate
1. Before installation material shall be checked for acceptance test in accordance with
clause 2612.2.1 as per table 2600-5 of MORT&H.
2. Expansion joints shall be installed under close supervision of the manufacture’s /
supplier’s engineer in order to ensure the quality of the installation and its function as
intended during the entire life span.
3. Detailed Installation Manual shall be supplied by the Manufacture / supplier.
4. The gap dimensions shall be pre-set depending upon the temperature at which joint is to
be installed.
5. The dimensions of the recess, levels, skew & slope in the deck slab shall be established
in accordance with the drawing or design data as provided by the approved manufacturer.
6. The surfaces of recess shall be thoroughly cleaned.
7. The exposed reinforcement shall be suitably adjusted to permit unobstructed lowering of
the joint into the recess.
8. The recess has to the shuttered in such a way that the dimensions in joint drawing are
maintained. The formwork shall be tight.
9. Immediately prior to placing the joint the pre-setting shall be inspected.
10. The lowering of joint shall be done in a pre-determined position.
11. After placement, the joint shall be levelled and finally aligned and the anchor loops on
one side of the joint welded to the exposed reinforcement bars of the structure.
12. Upon completion, the same procedure shall be following for the other side of the joint.
13. After the above procedures for every joint, the concreting procedure shall follow the
clause 2610.1 (ix) of MORT&H specifications.
14. Proper compaction and curing shall be done.
15. After the concrete has cured, the moveable installation brackets still in place shall be
removed.
16. Rolled up neoprene strip seal shall be cut into the required length and inserted between
the edge beams by using by using a crowbar pushing the bulb of the steel in to the grooves
of the edge beam. Then the sinus plate shall be fixed in position as per details shown in
drawings. The carriage way surfacing shall be finished flush with the top of the steel
sections, the actual junction of the surfacing wearing coat with the steal edge section shall
be formed by a wedge-shaped joint with a sealing compound.
2.2.19.21. Drainage Spouts
1. General:
a. Drainage along longitudinal direction shall be ensured by sufficient numbers of
drainages spouts embedded in the deck slab.
b. The drainage spouts shall be made by corrosive resistant material such as galvanized
steel and shall have a minimum diameter of 100 mm.
c. The spacing of drainage spouts shall not exceed 10 m.
d. The discharge from drainage spout shall be kept away from the deck structure.
2. Fabrication:
a. All material shall be corrosion resistant. Steel components shall be of mild steel
conforming to IS: 226.
b. The drainage assembly shall be seam welded for water tightness and then hot dip
galvanized.
3. Placement:
a. The galvanized assembly shall be given two coats of bituminous painting before
placement.
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b. The whole assembly shall be placed in true position, line and level as shown in the
drawings with necessary cut-out in shuttering for deck slab and held in place firmly.
c. Where the reinforcement of the deck is required to be cut, an equivalent
reinforcement shall be placed at the corners of the assembly.
d. After setting of the deck slab concrete the shrinkage cracks around the assembly shall
be totally sealed with bituminous sealant.
e. Excess sealant should be trimmed to receive the wearing coat.
2.2.20. Methodology for Pre-Cast Segment
2.2.20.6.Purpose / Objectives
To document a suitable methodology for carrying out casting of Pre-cast Segment at casting
yard.
2.2.20.7.Design Codes, Standards & Reference
The design of the casting cell is based on an ultimate limit state design approach. The design
loads used for the structural design of steel work include the following:
• Steel Design: BS 5950 Part 1- 2000: Structural use of steel work in building part 1 code
of practice for design in simple and continuous construction hot rolled section.
• Lateral pressure: Pressure of fresh Concrete
• DIN 18218: On vertical form work
• Complete segment tolerance: Guide specification from design and construction of
segmental concrete bridge
• MORT&H’s Specification: 5th Revision, 2013 Specification for Road and Bridge Works
• IRC SP:65 2018: Guidelines for Design and construction of Segmental Bridges
2.2.20.8.Deployment of machinery
1. Concrete pump
2. Batching plant
3. Transit mixers
4. Vibrators
5. Needles
6. Cube Mould
8. Power Arrangement (Generator/ Electricity)
3. Surveyor 01
5. Pump Operator 01
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2.2.20.10. General Description

Each span of the viaduct is split into certain numbers of field segments and pier segment at both
ends. Each segment is cast successively against the previous segment such that they all fit
together when assembled in sequence at the actual span location.
The casting cell is designed for the short bed method of match casting whereby each completed
segment shifted to forward by one position is such that the next segment is cast in the same place
using the face of the preceding segment to form the joint face.
The casting cell includes all the form panels that form external and internal faces of a segment.
Supporting structures for the form panels and conjugate segment and the transfer cart with which
segment an adjusted and moved.
2.2.20.11. Segment production
• Typical 2 ½ day cycle or as specified, assumed for basic field segment profile.
• Typical 4 days cycle or as specified, assumed for pier segment. These cycles are based
on the condition that prefabricated re-bar cage is used, and three soffit forms/mould is
provided.
2.2.20.12. Component description
In general, the casting cell consists of the following component.
1. Bulkhead panel and support frame with working plat form.
2. Soffit form
3. Outer form
4. Inner form and traveller
5. Transfer cart
The entire components have to assembly on side as complete set of casting cell.
1. Bulk Head
Bulk head panel is steel form panel. Used to form the match casting face the steel skin is
shaped according to the segment section and strengthening by channels and stiffer plates
Following are the types of bulk head panels.
• Field segment
• pier segment
Support Frame Assembling
The shear key forms are welded to the bulk head panel to form the shear keys at the match
casting face. Accesses for the stressing anchorages/ recess formers are provided in the
bulk head panel.
The fixed bulk head is used reference for the geometry control of the new segment it
must be erected truly vertical align, horizontal levelled and perpendicular to the casting
Cell centre line.
The bulk head panel is supported any four supports frames. With four locator pins located
at the top of the form panel two of the support frames (web frames) are located at the
inter section point between web and deck slab.
Working plat form are provided at the top flange level and supported by the bulkhead
support frame.
Match cast face
88
For the very first field segment permanent bulk head will be used to form the match
casting face the cast segment will be use as a conjugate segment for others segment
casting
2. Soffit Form
This steel structure shall form the bottom part of the segment the steel form panel is
supported by a table which equipped with four nos. of screw jakes on supporting legs.
Hence by adjusting the screw jack the soffit panel can be levelled.
Soffit form panel of field segment consist of a main panel and a hinge panel. The hinge
panel shall be swing down when the segment is in the conjugate position to allow over
lapping space with the new soffit form. No hinge panel is required for the pier segment
soffit form.
3. Outer Form
The outer form is a steel form that forms the external part of the web and wing the form
panels are supported by a space from which is equipped with screw jacks as on inner
support leg and turn buckle as on outer support.
Working plat form is provided at both ends of the wing slab and it is designed to provide
the working space for stressing as well.
Outer forms are fixed in the longitudinal direction with adequate overlapping to both
Conjugate segment and bulkhead for casting of various segment lengths.
There are two types of outer form assembling.
4. Inner void form
This steel panels form the internal part of the segment the inner form consists of few form
panels which are web form top slab form, centre form and slab rib form.
The traveller tower is designed to support the self-weight of inner form by the
cantilevered needle beam. Screws jacks are provided at the front support interface
between the traveller tower and needle beam and tie bar with shim at the rear support
interface.
This combination allowed a vertical adjustment to this needle beam. About 11.00 tonnes
or as specified of counterweight are needed to stabilize the traveller tower for overturning
due to cantilever reaction.
The traveller tower is longitudinally moveable with wheels when pulling from the centre
pulling point. This longitudinal movement allows the inner form to travel in longitudinal
direction which is required for the casting work.
Hydraulic jacks and screw jack will be used for all the forms stripping work and turn
buckle will be used on propping for the form panels during casting.
5. Transfer Cart
Transfer cart is designed for the following purpose.
1. Lift up and transfer the cast segment to conjugate position.
2. Lift up and transfer the cast segment to parking area for segment lifting to stock
yard.
3. setting up and levelling the soffit form
4. segment geometry adjustment
The transfer cart consists of carriage frame jacking frame and sliding member. The
carriage frame is a truss structure which is equipped with wheels at the bottom to allow
the movement along the rail when pulling from centre pulling point. The carriage form
is also equipped with four numbers of hydraulic jacks. On top of both hydraulic jacks is
the jacking frame. Two sliding members are installed on top of both transverse members
of the jacking frame and connected to each other with a horizontal jack.
89
The combination of wheels and jack’s system in the transfer cart allow the following
motion:
1. Longitudinal movement - pulling by winch / chain pully
2. Transverse movement - Activated the Horizontal jack in the same
direction
3. Gradient adjust - Activated both front or rear vertical jack
4. Cross fall adjust - Activated both left and right vertical jack
5. Rotation in plan - Activated rear horizontal jack
2.2.20.13. Assembly of Casting Cell
1. The fixed bulk head panel and supports frame must be erected to the correct position. It
is important to make same that the bulk head panel is truly verticals aligned Horizontal
levelled and truly perpendicular to the casting cell centre line
2. The soffit form must be placed at the correct position assisted by the transfer cart the
soffit form must be horizontal levelled and aligned perpendicular to the bulk head panel.
Sufficient 50mm overlap of the soffit form to the bulk head panel must be provided. The
transfer cart has to launch to the stand by position after soffit form setting up.
3. The outer form must be set up at the correct position it needs to be level to the correct
height and aligned parallel to the segment centre line 50mm of overlap of the outer form
to the bulkhead panel must be provided. At this stage the outer form does not need to be
closed to the bulkhead.
4. Assembly the inner form and traveller tower at the stand by position behind the fixed
bulk head. Adjust the screw jack and tie bar of the traveller tower to level the inner form,
the form panels are in the refracted condition at this stage
2.2.20.14. Typical Segment Casting
1. Assume that the segment has been cast and all the form panels have been stripped except
the soffit form conjugate segment have been removed.
2. Activate the transfer cart to bring the cast segment into the approximate conjugate
position.
3. All the form panel faces are cleaned and prepared for the new casting
4. The new soffit table is lifted to position within the mould by crane.
5. Install the rebar cage with pre-cast concrete struct on to the soffit form.
6. The conjugate segment is launch to the position levelling and alignment adjustment are
required to ensure the correct geometry.
7. Close up the outer form to from the space between the bulkhead and conjugate segment.
Install the tie bar to tight the outer form to the soffit table.
8. Launch the inner form through the fixed bulkhead and reach the conjugate segment.
Install the temporary propping to the needle beam to the conjugate segment. Active the
hydraulic jack to expand the inner form panels to form the space between the bulkhead
and conjugate segment. Locked the turn buckle when the inner form panels are in
position.
9. Make sure all the form inner faces are properly sealed by suitable seal materials.
10. The segment is ready for casting.
11. The sequences of concrete shall be as follows:
a) Soffit Slab
b) 1/3 height of web -1
c) 1/3 height of web -2
d) 1/3 to 2/3 height of web -1
e) 1/3 to 2/3 height of web -2
f) 2/3 to top of web -1
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g) 2/3 to top of web -2

h) Top Slab including Cantilevers on both sides.
i. Concreting: After final checking from clients the preparation for Segment concreting
is made at site by arranging all the necessary equipment’s/machineries and place them
in order at their location in working condition. The concrete of required grade and
quantity is produced form the batching plant and transported to the location by transit
mixers. The Segment concreting is done by 30 Cum per hour or as required concrete
pump/Concrete funnel. Maintain the slump of concrete as design and above as
required for pumping concrete. Vibrate the concrete by Shutter vibrators and High
frequency vibrators for proper compaction of the concrete. The concreting shall be
continued without break till it reaches the top level so as to avoid formation of any
cold joint. Required no of cube are to be casted at site for testing of the strength as
per code provisions. Start the curing after final setting of concrete.
ii. Curing: After Segment concrete final setting water curing shall be start and it shall
continue throughout the curing period of 14 days or as specified.
iii. De-Shuttering: Do de-shuttering of Segment after Stressing of Transfers PT in first

stage which is to be done after the concrete strength reach the 20 MPa or as specified.
Do inspection of the exposed concrete for any defects and if any repair the same after
joint inspection of the same with client’s representatives.
1 Survey and record the geometry of the cast/conjugate segment.
2 Check concrete strength.
3 Start 1st stage transverse pre-stressing after getting cube strength 20 MPa or
as specified:
a. Stripping of inner form.
b. Release the turn buckle.
c. Remove the slab rib form by manually.
d. Activate the hydraulic jack and turn buckle subsequence to strip the
bottom struct block form panel form the concrete surface.
e. Remove the temporary propping of needle beam.
f. Activate the hydraulic jack and turn buckle subsequently to strip and
drop the centre form panel from the concrete surface.
g. Activate the hydraulic jack and screw jack subsequently to strip, drop
and retract the top slab form and web form.
h. Back launch the inner form to the standby position.
2.2.20.15. Stripping of Outer form
Release all tie bars. Adjust the turn buckle at the outer support to restart the outer form adjust
the spherical bearing. These operations will Swing away the outer form from the concrete surface
and soffit form. The minimum of 25 mm vertical clearance between the outer form and soffit
form is required for the following stripping work. The screw jack at inner support allows for the
vertical adjustment if necessary.
2.2.20.16. Stripping of conjugate segment
Lowering the front leg of soffit form support table to rotate the conjugate segment in longitudinal
direction. Hence separated the conjugate segment from the new cast segment assisted by transfer
cart transfer the conjugate segment to parking area for segment lifting to storage yard.
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2.2.20.17. Stripping the fixed bulkhead

Lowering the front leg of soffit form support table to rotate the segment in longitudinal direction
hence separated the concrete surface from the bulkhead. This lowering operation must no more
than 25mm to avoid crash with the outer form.
Repeat the above steps for the next segment.
2.2.20.18. First segment casting
In general, the casting of the 1st segment of the project is similar to mentioned above except the
following.
a. Instead of conjugate segment a permanent bulkhead is used to form the match casting
face of the segment. The setting of the bulkhead panel is similar but mirrored from the
fixed bulkhead.
b. Temporary propping of the needle beams needs to be extended to ground level.
c. Stripping of the bulkhead panel at match casting face can be done by back launch the
support frame. Therefore, sliding is allowed to the base plate of the support frame.
1.4.3.7. Tolerances
Finished Segment tolerances should not exceed the following:
a. Length of match-cast segment (not cumulative) ± 5 mm

b. Overall span length between bearings ± 10 mm
c. Web thickness, depths of top and bottom flanges, width of top and
Bottom flanges, overall depth of segment, thickness of diaphragm ± 5 mm
d. Grade of form edge and soffit ± 1.0 mm
e. Tendon hole location ± 3.0 mm
f. Position of shear keys ± 5.0 mm
2.2.21. Methodology of Pre-stressing of Girders
2.2.21.6.Scope
The purpose of pre-stressing is as per design requirement for Post Tensioning of Concrete
Girders at Major Bridge/ROB/Flyover.
This work shall consist of:
1. Profiling
2. Cutting and threading of tendons
3. Stressing of tendons
4. Grouting of tendons
5. End Cap Concreting
2.2.21.7.References
2. IRC: SP: 99-2013
5. Relevant IRC Codes
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3. Surveyor 01
5. Pump Operator 01
2.2.21.9.Procedure
Profiling: Profiling (layout of prestressing tendon) shall be carried out according to the ordinates
given in the reference drawings. Cable supports/Chairs shall be welded to the vertical stirrups
and sheathing will be tied with the help of binding wire so as to avoid displacement of cable
during concreting. However, care should be taken in providing smooth profile and there should
be no sudden kinks.
Precautions during profiling:
1. Between the points given the cable must retain a regular curvature without undulations
or sharp changes in the direction, which will cause entries in the friction loss at the time
of stressing.
2. The cable axis must coincide with anchorage axis for a length.
3. The cable must be placed in the concrete section in such a way so as to allow easy
concreting and sufficient cover.
Step in Profiling:
1. Preparing cone boxes and fixing guides to it.
2. Profiling and fixing of sheathing.
Installation of Tendons:
1. Checking of Identification Tag details.
2. The packing of HTS strands shall be removed just prior to use.
3. The strand shall be de coiled on an elevated platform along its length and the required
length of catch strand shall be marked, cut and recorded in the format correlating the
Cable No. to Coil No. The coils may be mounted on a rotating table to facilitate
unpacking.
4. Cut strands shall be inspected for defects like opening of wires, if any.
5. The cut strands shall be threaded inside the duct for full length.
6. Strand shall be cleaned up before the threading operation.
7. In case any Delay in stressing operation after inserting the strands, the ends of strands
protruding beyond the face of girders should be wrapped with plastic sheets to protect
from water/dust.
Stressing of Tendons:
1. Jack Efficiency test shall be carried out at site before commencement of stressing activity.
2. Pressure gauges third party calibrated certificate shall be made available at site.
3. Pressure gauges shall be calibrated once in 3 months or once for every 200 cables are
stressed.
4. Pressure gauges shall be calibrated either against a master proving ring or preferably by
a dead weight tester at regular intervals. Calibration certificate required for Master
proving ring.
5. The stressing operation shall be undertaken by the pre-stressing technicians.
6. Before commencing the stressing operation, Tube Unit & strands projecting outside the
anchorages shall be cleaned.
7. The Bearing plates, Wedges shall be cleaned and visually checked for any damages
before using.
93
8. Bearing plates shall be assembled on both sides and the threaded strands shall be secured
with compact wedges by tamping with pipe.
9. Multi strand jacks will be fixed at the both ends.
10. The stressing pumps shall be connected to the jack through the hose pipes.
11. The stressing sequence shall be observed as indicated on the post-tensioning drawings.
12. When reaching the design stressing load, measure the elongation.
13. Stressing shall proceed on the indicated elongation.
14. In case elongation reached earlier and corresponding jack pressure is not reached, further
jacking 5% extra elongation or desired jack pressure which earlier, shall be done.
15. In case jack pressure is reached and elongation is not reached, stressing shall be continued
up to a maximum jack pressure of 1.05 times the calculated pressure or desired elongation
whichever obtained earlier.
16. In case of variation more than the prescribed limits, the matter shall be referred to the
design office.
17. Initial slackness in pre-stressing cables shall be removed by applying tension of 1/3 the
maximum pressure.
18. The pressure shall then be increased gradually by intervals of 50kg/Sq.cm and elongation
shall be recorded.
19. When conformity of the design elongation with the measured one are ascertained, the
tendon force shall be anchored.
20. On reaching the Full load, the wedges shall be locked of hydraulically at 250 to 280
kg/Sq.cm lock off Pressure.
21. Upon successfully completed stressing of the tendon, the jacking unit shall be removed
and installed to the next tendon.
22. After removal of jack, a mark shall be done on strands at a distance of 100 mm to observe
24 hrs. for any further wedge slip. If any slip is observed, the observation shall be
submitted to Designer for their review & approval.
23. The strands protruding from the anchor head shall be cut off at a distance of not less than
50 mm from the anchor-head surface by means of an abrasive disc cutter.
24. The 1st stage stressing shall be done after 3 days or on achieving 30N/mm2 or as
specified whichever is later.
25. After checking the slip for 24 hours the Girder shall be shifted from casting bed to
stacking bed.
26. The 2nd stage Stressing shall be done after 21 days or on achieving 45Mpa or as specified
whichever is later.
27. After checking the 24 hours slip the strands protruding from the anchor heads shall be
cut and grouting shall be carried out.
28. A stressing record shall be prepared for each cable to be stressed on which all steps and
occurrences of the procedure are recorded. The stressing record sheet shall be filled up
by the pre-stressing technician in charge of the operation.
Grouting of Tendons:
1. The tendon shall now be prepared for grouting. Between stressing and grouting of a
tendon with in 10days after tensioning, but not before 24 hours after tensioning.
2. Grout vents at least 20 φ shall be provided at both end anchorages for each cable.
3. Grout caps shall be fixed on both sides of anchor heads and tightly secured.
4. Ducts shall be flushed with lime water for cleaning as well as wetting the duct walls. The
entire water shall be drained through lowest drainpipe or by blowing compressed air
through the duct.
5. As soon as flushing is completed the grout operation shall be started.
94
6. The proportions of grout materials shall be based on field trials conducted before
commencement of grouting.
7. Water shall be added in mixer first, followed by cement and admixture.
8. The additive admixture is mixed with cement in proportion as recommended by additive
manufacture.
9. The grout mix shall have water cement ratio not exceeding 0.45(as per IRC 18-2000)
Cebex 100 or as required in right proportion shall be added to the grout mix to avoid the
shrinkage of the grout mix.
10. The compressive strength of 100mm cubes of the grout shall not be less than 17 Mpa at
7 days.
11. The temperature of the Grout shall not Exceed 25 degrees Celsius.
12. Mixing time of grout shall be 2 to 3 minutes so as to obtain uniform and thoroughly
blended grout. The grout shall be continuously agitated with agitator till it is injected.
Water shall not be added once the grout is mixed thoroughly.
13. The locking pressure 5 kg/sq.cm is to be maintained for approximate one minute.
Consistency of grout shall be ensured.
14. Once the desired pressure of injection reaches, the valve at the entry point shall be closed.
15. Records for grouts shall be maintained.
End Cap Concrete:

1. The rebar shall be tied as per the approved drawings.
2. The side formwork shall be placed and secured properly.
3. Before placing the end shutter, Nitobond EP or as specified shall be applied on the old
concrete to achieve proper bonding between old & new concrete.
4. After the concreting is done, it shall be cured to achieve the strength.
5. The formwork shall be removed and now the girder is ready for erection after being
stressed.
2.2.21.10. Safety & Environment
4. Safety stewards shall be engaged for monitoring to avoid unsafe conditions & unsafe
acts.
5. Green helmets shall be provided for safety stewards.
6. All the persons involved shall be given Pep talk before start of the Pre-stressing activity.
7. All the staff and work men shall be provided with necessary personal protective
equipment (Safety helmets, safety hand gloves, safety shoes, safety belts, safety goggles,
retro-reflective jackets etc.) always at site.
8. Drinking water facility shall be provided at site.
9. First aid box with necessary medicines shall be available at site office.
10. General Lighting shall be provided in work place.
11. Only certified plant & machineries shall be put in operation.
12. The operators shall have relevant experience and valid license to operate machineries.
13. A warning sign, “Stressing Operations in Progress” shall be put up at locations where
stressing operations would be carried out.
14. Strand bundle protruding from the bearing plate must be encased in a plastic or sheet
metal pipe to prevent injury by the sharp ends of the strands.
15. During the process of strand cutting, only abrasive disc cutters with guard shall be used,
and goggles shall be worn during the process.
16. Only intact and tight pressure hoses shall be used.
17. No stranger shall be allowed in the immediate vicinity of the stressing equipment during
stressing to avoid injury in event the tendon or concrete should fail.
95
18. The pump and jack shall be securely tied to a solid object when working at an elevated
level.
19. No stressing equipment or accessories shall be used that are not complete as supplied
from the manufacturer or post-tensioning supplier.
20. Stressing shall take place on a proper working platform, as required by the regulation
agency. Hands shall be kept out of jack while stressing operation is taking place and
while retracting.
21. All persons shall stand clear of equipment, hoses or electric cords while stressing is taking
place; always use the remote switch and not the toggle switch located on the pump unit.
If a tendon shall fail or a blowout occur, or the jack grippers fail; the jack, pump, hoses
and electrical cords shall be thrown off the structure. If this occurs anyone standing close
the hoses or cords shall be dragged off the structure with the equipment.
2.2.22. Methodology for Underpass
2.2.22.6.Scope
This method statement covers the construction of underpass and adjacent RCC retaining wall. 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
specifications, technical Specifications Volume II or as directed by the Engineer.
2.2.22.7.References
2. IRC: SP: 99-2013
Working drawings, structural drawings and bar bending schedules will be submitted to the
Engineer prior to start of work at site. After approval of the above submissions by the Engineer,
the setting out of the structures shall be done.
2.2.22.9.Material
Shuttering and Staging Materials: 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 levelled and aligned to the true lines. 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 Engineer’s approval.
Reinforcement Bars: Reinforcement bars shall be procured from the approved Manufactures
Test Certificate shall be obtained with each consignment. On further supplies from the same
source independent laboratory testing shall be done as required by the Engineer.
2.2.22.10. 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 Project specifications Volume II, MORT&H , IS Codes & IRC Codes. Compliance
of the constituents shall be controlled as per the above Codes and Specifications.
96
The following equipment’s shall be deployed in the execution.
1) Excavators
2) Rock breakers
3) Dumpers
4) Batching & Mixing Plant
5) Transit Mixers
6) Vibrators
7) Welding Machines
8) Earth rammer
9) Bending & Cutting machine
10) Concrete pump
2.2.22.12. Personnel for Execution & Supervision
A well-trained team who has experience to execute such activity shall be deputed to execute the
above job. Cage inspections shall be done by the Sr. Structural Engineer / Site Engineer / DPM
to ensure the conformance to the working drawings and relevant codes before lowering the cage.
Setting 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.
Excavation: Excavation shall be done up to 300 mm up from the founding level and balance
portion shall be trimmed to avoid over excavation.
Lean Concrete: Lay out for the structure shall be done with the co-ordinates & survey points.
Form work of the required size and length shall be provided for laying and placing lean concrete
over the approved excavated base. Open foundation shall be constructed in dry condition and
required adequate dewatering arrangements shall be provided to the satisfaction of engineer as
per clause 2104.3 of, MORT&H specification or as directed by the IE.
Reinforcement Fixing: Re-bars 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 by machine. Layers of the reinforcement
shall be separated by chair-bars at convenient c/c length. Cover blocks, spacers, supporting wires
etc. shall be provided as per specification requirements to fix the reinforcement firmly in its
correct position.
Design, Erection & Removal of Form Work: The design and erection of formwork shall be as
per IRC- 87 & conforming to MORT&H 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 and suitable formwork as per design. The inside surface of the forms
shall be coated with release agent to prevent adhesion of concrete to formwork.
The formwork shall be removed in such a way that it does not cause damage to the concrete
surface. Centring 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.
97
Mixing, Transportation, Placing and Compaction of Concrete:
Concrete Mixing: Concrete shall be mixed in approved proportions in batching and mixing
plant or in a concrete mixer (clause 1708 of MORT&H).
The mix shall be approved by the efficiency of the mixer to the uniform distribution and a
uniform colour of the entire batch. In any case mixing time shall not exceed two minutes. If the
mixer has been out of use for more than 30 minutes, it shall be thoroughly cleaned before putting
in a new batch. Mixer shall thoroughly be cleaned before switching over from one type of cement
to the other type. Water cement ratio of the mix shall be maintained to the designed one by
recording the moisture content of the ingredients frequently and adjusting the water quantity of
the mix. Suitable adjustment shall also be made in the weight of aggregate to allow for the
variation in the weight of aggregate due to variation in their moisture content. Aggregate shall
be kept moist or shaded during summer to keep the temperature low.
In case of the pumping concrete, material shall be batched consistently and uniformly. Grading
of ingredients in the mix design shall be selected uniform ensuring sufficient amount of ultra-
fine material.
Gradation of fine aggregate shall conform to Table 1000-2 of MOSRTH specifications.
Approved super plasticizers shall be used to delay the setting time and increase fluidity of the
concrete mix to aid the pumping and long-distance transportation.
Transportation of concrete mix: Concrete shall be transported in transit mixers. Concrete shall
not be poured during the peak temperature hours in summer season to keep the maximum
temperature below 40 degree centigrade. In winter concrete shall be avoided during peak low
temperature hours to maintain the minimum temperature more than 5 degree centigrade. As per
Technical Specifications concreting will not be done when ambient temperature exceeds 40
degree Celsius.
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 from a
height exceeding1.5m .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 450mm when internal
vibrators are used and not exceeding 300mm in all other cases. Concrete shall be thoroughly
compacted using vibrators or other means during placement and worked around reinforcement,
embedded fixtures and into corner of the form work to produce a dense homogeneous, void free
mass having the required surface finish. Over vibration shall be avoided to minimize the risk of
forming a weak surface layer.
2.2.22.14. 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 approval from
Engineer. The joints shall be provided in a direction perpendicular to the member axis or as
shown on Drawing. At vertical construction joint a fine mesh on the stopping board shall be
placed.
2.2.22.15. 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, canvas, Hessian or similar materials and shall be
kept constantly wet for a period of 14 days from the date of pouring concrete .
98
2.2.22.16. Finishing
Immediately after the removal of the shutters, the exposed bars if any shall be cut inside concrete
member at least 50mm below the surface of concrete and the resulting holes filled with epoxy
mortar. All other repairs like honeycomb, corner or other defects shall be repaired with cement
sand mortar using the same aggregate cement ratio as of the structure. Repaired surface shall be
kept moist at least for 24 hours and application of curing compound over that surface.
Special pre-packed standard branded mortar shall be used where specified on drawings. All
construction and expansion joint, in the completed work shall be left carefully tooled and free
from any mortar and concrete.

Frequency and testing of sampling done as per cl no 1717 of MORT&H.

1. During construction of VP/NVP adequate safety & traffic sign shall be installed adjacent
to the road shoulder to protect the ongoing work.
2. During construction of VP/NVP a minimum 2 flagmen with reflective vests and holding
a red flag each shall be deployed to control the traffic, which may be affected by the
construction operations.
2.2.22.19. Environmental Safety

1. All debris shall be disposed at the designated site.
2. Excavation shall be limited to the extent practicable.
3. Any soil erosion or sedimentation that may affect construction operations, damage
adjacent properties or cause contamination of water sources, lakes reservoirs etc. shall be
protected by constructing temporary berms, dikes, sediment basins & slope drains.
2.2.23. Methodology for Kerb Laying

This work shall consist of constructing 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.
2.2.23.7.References
7. IRC: SP: 99-2013
The following equipment’s shall be deployed in the execution.
1. Kerb Machine
2. Transit Mixture
3. Tipper / Tractor Trolley.
4. Water tankers
99
5. Auto Levels
6. Total Station
7. Kerb cutting Machine.
8. Curing compound sprayer
2.2.23.9.Method of Operation
1. Kerb shall be laid on firm foundation of minimum 125 mm thickness of cement concrete
of M15 grade cast-in-situ or on extended width of pavement. The foundation shall have
a projection 50 mm beyond the kerb stone. Before laying the foundation of lean concrete,
the base shall be levelled and slightly watered to make it dump.
2. In the median portions in the straight reaches, the kerb shall be cast in continuous lengths.
In the portions where footpath is provided and/or the slope of the carriage is towards
median (as in case of super elevated portions), there shall be sufficient gap/recess left in
the kerb to facilitate drainage openings.
3. After laying the kerbs and just prior to hardening of the concrete, saw cut grooves shall
be provided at 5 m intervals or as specified by the Engineer.
4. Kerbs on the drainage ends such as along the footpath or the median in super elevated
portions, shall be cast with monolithic concrete channels as indicated in drawings. The
slope of the channel towards drainage pipes shall be ensured for efficient drainage of the
road surface.
5. Vertical and horizontal tolerances with respect to true line and level shall be 6 mm.
The foundation of Kerb shall be provided in cement concrete of Grade M15 and kerb shall be
provided in cement concrete of Grade M20 in accordance with Section 1700 of these
Specifications.
Frequency and testing of sampling done as per cl no 1717 of MORT&H.
1. During construction of works, adequate safety and traffic signs shall be installed adjacent
to the road shoulders to protect the ongoing works as per location specific safety plan.
2. For locations where Kerb laying work is in progress, 2 flagmen with reflective vests and
holding a red flag each be deployed to control the traffic which may be affected by the
unloading operation.
3. All locations adjacent to existing road where Kerb Laying is in progress shall be provided
with safety and road signs.
2.2.24. Methodology of Wearing Coat
A layer of BC 50 mm thick laid in single layer as per Clause 2702.1 (Type-1) of MORT&H
specifications. The cross slope in the deck shall be kept as per reviewed drawings. For the
structures with flat deck surface, camber / super-elevation in the wearing coat shall be achieved
by providing profile making course before laying wearing coat.
100
The profile making course shall be of the same material as of wearing coat. The thickness of
wearing coat at any point shall not be less than that given Clause 2702.1 (Type-1) of MORT&H
specifications.
2.2.25. Methodology for Approach Slab

A reinforced concrete slab covering the entire width of roadway shall be provided as approach
slab.
1. Minimum length of approach slab shall be kept 3.50 m or as per reviewed drawings.
2. Minimum thickness and grade of concrete of slab shall be as per reviewed drawings.
3. The details of slab shall be according to reviewed drawing.
4. The cement concrete and reinforcement shall conform to sections 1600 & 1700 of
5. The base of approach slab shall be as shown in the drawing.
2.2.26. Methodology Floor Protection

2.2.26.6.Apron
1. The surface for apron laying shall be levelled and prepared for length & width as shown
on drawing.
2. The size of stone should conform to clause 5.3.7.2 of IRC: 89.
3. The specific gravity of stones shall not be les then 2.65
4. The size of stone shall be such that the weight of any fragments of stone as not less than
40 kg or as designed on the basis of mean velocity of flow.
5. The stone shall be hand packed within these walls.
2.2.26.7.Curtain Walls
1. First of all, foundation trenches are excavated providing working space as per dimension
provided in drawings for curtain walls.
2. The minimum depth of curtain wall below floor level on upstream side shall be 2.0 m
and on downstream side shall be 2.5 m.
3. The curtain wall shall be according to IRC:89 -1997, 10.2.3.
2.2.27. Methodology for Backfilling Behind Structures
1. Back filling should commence in conformity with Appendix VI of IRC: 78.
2. Back filling shall be done with approved material after concrete is fully set.
3. It should be carried out in such a way as not to cause undue thrust on any part of the
structure.
4. All space between foundation masonry or concrete and the side of excavation shall be
refilled to original surface in layers.
5. The thickness of layer should not exceed 150mm after compaction.
6. The compaction shall be done with the help of suitable equipment such as mechanical
tamper, rammer, plate vibrator etc. after watering.
7. The filter material shall be well packed to a thickness of 300 - 600 mm, gradation of filter
media shall confirm to the requirements of 2504 or table 300-3 of MORT&H.
101
2.2.28. Methodology for Road Signs

This work shall consist of manufacturing, fixing and erection, commissioning, painting of all
type Road signs board, will be provided wherever required in accordance with IRC 67 &
MORT&H -800 section and agreement.
2.2.28.6.References
IRC 67 & MORT&H-800 section
1. Hydra/crane
2. Concrete
3. Bolts-Nut, plates, post etc. with full set of spanners.
2.2.28.8.Procedure
After complete printing of sheet and fitting on board with bolted/welded on post as per IRC-67 the
further work procedure will as follow: -
Sequence of work
1. Manual Excavation for pit.
2. Fixing the support channel / angle.
3. Concreting of the foundation.
4. Fixing the signs with channel / angle and painting with commissioning.
In detail work process
1. Exact location whereby road signs are to be erected, will be marked by surveys in
accordance with the relevant approved drawings.
2. Excavation will be carried out manually to the adequate depth to suit the respective
signboard considering the type & purpose.
3. Steel post of the signboard will be erected using adequate supports to make it vertical.
Care will be taken to ensure the post painted with 3 coats of red lead paint for the portions
below the ground and the remain part is painted according to the required ground level.
4. Concrete of grade M-20 or as specified will be poured & well compacted after making
the earthen surface moist.
5. Next day, the supports will be removed, and signboards will be fixed, and foundation
will be cured.
6. After completing erection direction of board or verticality of post should be checked for
final clearance and approval.
2.2.28.9.Important Safety Precautions:
1. The area shall be restricted from public entrance until final setting of concrete.
2. All truck shall be provided with reverse horns.
3. Only experienced and licensed operators / drivers shall be engaged for excavation and
hauling.
4. Flagmen shall be provided at all working points or near the job to be done.
5. The pit shall be barricaded.
6. Proper access shall be provided for traffic and public movement.
7. During Crain or hydra operation one guide man for machine operation must be available
for safe movement and erection of post.
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National Highways Authority of India (NHAI)

Construction of 4-Lane Greenfield Expressway spur from Delhi-Vadodara

General Methods & Arrangements for

Client Independent Engineer Concessionaire EPC Contractor

General Methodology & Arrangements for Design and

S. No. Particulars Details

3. Independent Engineer To be appointed

4. Concessionaire M/s GR Bandikui Jaipur Expressway Private Limited (GBJEPL)

5. EPC Contractor M/s G R Infraprojects Limited

Salient Features of the Projects

1. Date of LOA issued 30.03.2022

2. Date of Agreement 14.06.2022

4. Bid Project Cost Rs. 1368.00 Cr

5. Construction Period 730 days from the Appointed Date

6. Total Length of the Project 66.916 km

13. Toll Plaza 5

14. Truck Lay Bye -

15. Bus-Bay / Bus Shelter -

2. 1.Section 1: Road Works

Clearing & Grubbing

Cement Treated Subbase

Wet Mix Macadam

Dense Bituminous Macadam

10 Road Marking & Road Furniture’s

2.1.2. Flow Chart for Pavement Quality Concrete (PQC) Works

Clearing & Grubbing

Dry Lean Concrete

Pavement Quality Concrete

10 Road Marking & Road Furniture’s

2.1.3. Methodology for Survey and Setting Out

2.1.4. Methodology for Clearing and Grubbing (C & G)

2.1.5. Methodology for Excavation

2.1.7. Methodology for Embankment with Fly-ash

Handling and Transportation of Fly-Ash

2.1.8. Methodology for Subgrade Construction

IS Sieve Percent by Weight Passing the IS Sieve

Gradation IS:2720 (Pt 4) 1 Tests/400 m3

Atterberg’s limits IS:2720 (Pt 5) 1 Tests/400 m3

Moisture Content prior to

Field Density of compacted layer IS:2720 (Pt 28) 1 Tests/1000 m2

Deleterious content test IS:2720 (Pt 27) As required

CBR IS:2720 (Pt 16) As required

CTSB – Methodology will be submitted separately

2.1.10. Methodology for Wet Mix Macadam (WMM)

IS Sieve Designation, mm % by weight passing the IS Sieve

2.1.10.6. Detail of Personnel Deployed

a. Personnel Deployed for Execution

2.1.10.7. Construction Operations

2.1.11. Methodology for Prime Coat

Test Minimum Desirable Frequency

Number of Sample per lot and tests as per

2.1.12. Methodology for Dense Bituminous Macadam (DBM)

2.1.12.9.Details of Personnel Deployed

1. Bitumen: The type & grade of bitumen shall be VG 40 conforming to IS 73.

Property Test Specification Testing Method

Water Absorption Water Absorption Max 2% IS:2386 Part III

Coating and Stripping of Bitumen Min. Retained Coating

Water Sensitivity Retained Tensile Strength Min. 80% AASTHO 283

IS sieve (mm) Cumulative Percent Passing by weight of Total Aggregate

Description Base/Binder Course

Aggregate passing 13.2mm, 9.5mm sieve ±7%

2.1.12.12. Construction Operation

2.1.13. Methodology for Tack Coat