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Hyderabad Growth Corridor Limited

ORR/JICA2/Pkg 2/Vol II

HYDERABAD GROWTH CORRIDOR LIMITED

Name of Work

Construction of Eight lane Access Controlled Expressway as


Outer Ring Road to Hyderabad City in the State of Andhra
Pradesh, India in the stretches from Shamirpet to Pedda
Amberpet from Km 61.700 to Km 95.000 (Northern Arc)
(Package-2 from Km 72.000 to Km 83.000 Keesara Ghatkesar)

ORR/JICA2/ Pkg-2/08-09
(Km 72+000 to Km 83+000 Keesara to Ghatkesar)

BIDDING DOCUMENTS FOR ITEM RATE CONTRACT


VOLUME II

CONTENTS

SECTION
5

DESCRIPTION

TECHNICAL SPECIFICATIONS

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PAGE NUMBERS
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SECTION 5
Technical Specifications

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Technical Specifications
1. PREAMBLE
1.1 The Technical Specifications Contained herein shall be read in
conjunction with the specifications for road and Bridge works issued by
Ministry of Road Transport and Highways, Government of India (Fourth
Revision-2001, reprinted in December,03) including up gradation as
given in Para 2.1
1.1.1 General
The Technical Specifications covering the materials and the
workmanship aspects as well as method of measurements and
payments are included in this section. These specifications cover the
items of civil and non-civil works coming under scope of this document.
All work shall be carried out in conformity with the same. These
specifications are not intended to cover the minute details. The works
shall be executed in accordance with good practices followed for
achieving high standards of workmanship, thus ensuring safety and
durability of the construction. All codes and standards referred to in
these specifications shall be the latest thereof, unless otherwise stated.
1.1.2 Inclusive Documents
The provisions of special conditions of contract, those specified
elsewhere in the tender document, as well as execution drawings and
notes, or other specifications issued in writing by the Engineer shall
form part of the technical specifications of this project.
1.1.3 The attention of the Contractor is drawn to those clauses of codes,
which require supporting specification either by the Engineer or by
Mutual' agreement between the 'supplier and purchaser. In such
cases, it is the responsibility of the tenderer/contractor to seek
clarification on any uncertainty and obtain prior approval of the
Engineer before taking up the supply/construction. In absence of such
prior clarification, the Engineers choice/design will be final and binding
on the contractor without involving separately any additional payment.
1.1.4 Measurement And Payment
The methods of measurement and payment shall be as described
under various items and in the Bill of Quantities. Where specific
definitions are not given, the methods described in B.I.S. Code will be
followed. Should there be any detail of construction or materials which
has not been referred to in the Specification or in the Bill of Quantities
and Drawings but the necessity for which may be implied or inferred
there from, or which is usual or essential to the completion of the work
in the trades, the same shall be deemed to be included in the rates and
prices entered by the contractor in the Bill of Quantities.
1.1.5 Defective Works
All defective works are liable to be demolished, rebuilt and defective
materials replaced by the contractor at his own cost and without
involving any time extension.

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1.2 SITE INFORMATION


1.2.1 The information given hereunder and provided elsewhere in these
documents is given in good faith by the Employer but the Contractor
shall satisfy himself regarding all aspects of site conditions and no
claim will be entertained on the plea that the information supplied by the
Employer is erroneous or insufficient.
1.2.2 The area in which the works are located is mostly plain to rolling terrain.
The Project area is located between 170 11/ 39// - 170 36/ 27.13// N
latitude and 780 14/ 15// - 780 41/ 21// E longitude.
1.2.3 General Climatic Conditions
1.2.3.1 The variation in temperature in this region is between 10C and 46C.
1.2.3.2 The annual rainfall in the area is in the range of 790 mm to 1000 mm.
1.2.4 Seismic Zone
The works are located in seismic zone II as defined in IRC-6-2000
2. GENERAL REQUIREMENTS
The Technical Specifications in accordance with which the entire work
described hereinafter shall be constructed and completed by the
Contractor, comprise of the following:
2.1 Part I General Technical Specifications
The General Technical Specifications shall be the Specifications For
Road And Bridge Works (Fourth Revision 2001, Reprint December
2003), as corrected in the original issued by the Ministry of Road
Transport & Highways (MORTH), Government of India and published
by the Indian Roads Congress (IRC), with a cross reference to relevant
Bureau of Indian Standards (BIS) for materials or other aspects not
covered by the IRC.
2.2 Part II Supplementary Technical Specifications
The Supplementary Technical Specifications shall comprise of various
Amendments/Modifications/Additions to the Specifications For Road
And Bridge Works referred as Part I above and Additional
Specifications for particular items of work not already covered in
Part-I.
2.2.1 A particular Clause or a part thereof in Specifications For Road And
Bridge Works(Fourth Revision 2001, Reprint December 2003) as
corrected in the original referred in Part - I above, where
Amended/Modified/Added upon, and incorporated in Part-II, referred to
above, such Amendment/Modification/Addition supersedes the relevant
Clause or part of the Clause.
2.2.2 When an Amended/Modified/Added Clause supersedes a Clause or
part thereof in the said Specifications, then any reference to the
superseded Clause shall be deemed to refer to the
Amended/Modified/Added Clause or part thereof.

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2.2.3 In so far as Amended/Modified/Added Clause may come in conflict or


be inconsistent with any of the provisions of the said Specifications
under reference, the Amended/Modified/Added Clause shall always
prevail.
2.2.4 The Additional Specifications shall comprise of specifications for
particular items of work not already covered in Part - I.
2.2.5 The Clauses and Sub-Clauses of the following Sections in the
Specifications For Road And Bridge Works (Fourth Revision
2001, Reprinted in December,03) have been amended /modified/
added upon:
Sections

Clauses

100

102, 103, 105, 106, 107, 108, 109, 110, 111, 112, 114,
115, 116, 121, 122, 123, 123A, 124, 126

200

201, 202

300

301, 304, 305, 306

400

401, 406, 407, 408,409

500

501, 502, 503, 504, 507, 508, 509, 521

600

601, 602

800

801, 802, 803, 805, 809, 810,812,813, 815

900

901, 902, 903

1000

1002, 1006, 1007, 1008, 1009, 1010, 1012, 1013, 1014,


1015

1200

1202, 1204, 1205, 1207, 1214, 1215

1400

1402

1500

1501, 1502, 1503, 1504, 1505, 1506,1508, 1509, 1510,


1513

1600

1602, 1604, 1605, 1606, 1607

1700

1703, 1704, 1705, 1706, 1707, 1709, 1710, 1712, 1713,


1715, 1716

1800

1801, 1802, 1803, 1804, 1805, 1806, 1807, 1808, 1816

2000

2001, 2004, 2005, 2006, 2009, 2011

2100

2106

2200

2204, 2210

2300

2305

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2500

2504

2600

2602, 2604, 2607, 2609

2700

2702, 2706, 2709

2800

2809, 2811, 2812, 2813, 2814, 2815, 2816, 2817, 2818,


2819, 2820, 2821, 2822, 2823, 2824, 2825, 2826, 2827,
2828, 2829, 2830, 2831, 2832, 2833, 2834

2900

2904, 2906, 2907, 2910, 2911

3000

3001, 3005

3100

Entire clause is revised .

3200

3201, 3202, 3203, 3204, 3205, 3206 & 3207.

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2.2.6

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Additional Specifications
The following Clauses have been added to the Specifications For
Road And Bridge Works(Fourth Revision 2001, Reprint
December2003)
A-01
A-02
A-03
A-04
A-05
A-06
A-07
A-08
A-09
A-10
A-11
A-12
A-13
A-14
A-15
A-16
A-17
A-18
A-19
A-20
A-21
A-22

2.2.7

Diversion of Existing water courses


Plantation of low height shrubs
Interlocking Concrete blocks
Rain water Harvesting Structure
Reinforced Retaining Wall
Specification for Reinforced Earth Retaining Structures
Raised Pavement Markers (Road Studs)
Rumble strips
Speed Breakers
Chute Drains for High Embankment sections
Grating across CRS drain
Traffic Management & Safety during construction operations including
solar traffic safety devices.
Utility Ducts and Crossing
Re-construction of Temples or Religious Places.
Curing using Liquid Membrane Forming compound
Void Former
Water proof cement painting
Filling of Open Wells.
Levelling and Grading Road Side Land
Control Blasting
High Mast Lighting
Lighting Arrangements
In the absence of any definite provisions on any particular issue in the
aforesaid Specifications, reference may be made to the latest codes
and specifications of IRC, BIS, BS, ASTM and AASHTO in that order.
Where even these are silent, the construction and completion of the
works shall conform to sound engineering practice as approved by the
Engineer and in case of any dispute arising out of the interpretation of
the above, the decision of the Engineer shall be final and binding on the
Contractor.
Wherever reference is made in the Contract to specific standards codes
to be met by the materials, plant, and other supplies to be furnished,
and work performed or tested, the provisions of the latest current
edition or revision of the relevant standards and codes in effect up to 28
days prior to the bid opening date shall apply, unless otherwise
expressly stated in the Contract where such standards and codes are
national, or relate to a particular country of region, other internationally
recognised standards which ensure a substantially equal or higher
performance than the standards and codes specified will be accepted
subject to the Engineer's prior review and written approval. Difference
between the standards specified and the proposed alternative
standards must be fully described in writing by the Contractor and
submitted to the Engineer at least 28 days prior to the date when the
Contractor desires the Engineer's approval. In the event the Engineer
determines that such proposed deviations do not ensure substantially

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equal performance, the Contractor shall comply with the standards


specified in the documents.
Technical Specifications for Building works shall be the latest
Specifications volume I to IV, 1995 as published by the Central Public
Works Department, Government of India and deemed to be bound into
this document.
2.3

PART-III Specifications for Buildings, Subways and Miscellaneous


Works
Technical Specifications for Buildings, Subways, and miscellaneous
works shall be the latest Specifications Volume-I to VI for Civil Works
and General Specifications Electrical Works Part I-INTERNAL, PART IIEXTERNAL for Electrical Works as published by the Central Public
Works Department (CPWD), Government of India and deemed to be
bound into this document.

2.4

The latest edition of all specifications/standards till 28 days before the


final date of submission of the bid shall be applicable.

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PART I
GENERAL TECHNICAL SPECIFICATIONS

1. This part shall comprise the Specifications For Road And


Bridge Works (Fourth Revision 2001, Reprint December 2003),
as corrected in the original issued by the Ministry of Road
Transport & Highways (MORTH), Government of India and
published by the Indian Roads Congress (IRC), Jamnagar House,
Shahjahan Road, New Delhi 110 011, all as deemed to be
bound into this document.
1.1 General conditions regarding use of equipment on works:
In addition to the general conditions already indicated in Volume-I
(of Bidding Documents), the following requirements regarding the
use of equipment in works shall be satisfied.
a) The contractor shall be required to give a trial run of the
equipment for specification and tolerance establishing adequacy to
meet the requirements of specifications and completion of work as
per programme before commencement of work;
b) All equipment provided shall be of proven efficiency and shall
be operated and maintained at all times in a manner as specified
by the manufacturers or industry practice. Regular reports on
proper and adequate maintenance shall be submitted to the
Engineer in the format and at intervals as approved by the
Engineer.
c) No equipment or personnel shall be removed from site without
permission of the Engineer.
1.2 Where the term crushed stone is referred to in the
Specification for Road & Bridge Works of the MORTH (Clause
1007) for use as aggregate in construction of pavement layers or
in construction of culverts & bridges or in construction of cross
drainage works it shall mean that the aggregates shall be obtained
through the use of Cone crusher, Vertical Shaft Impactor and
vibratory screens of suitable capacity.
2

Quality Control on Works & Materials.

Quality control on materials and execution remains the primary


responsibility of the Contractor.
Nevertheless, the Engineer will inspect the work from time to time
during and after construction and get the quality of the work tested
(by himself, by his Testing & Quality Control Units and/or by any
other agency deemed fit by him) generally as per the requirements
of the Handbook of Quality Control for Construction of Roads &

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Runways (IRC Special Publication No. 11 & Section-900 of


MORTH Specifications)
3

Surveying & Measuring Equipments

The Contractor for his use shall procure equipment for surveying
and measurement of the work. The same shall also be made
available to the Engineer at site for any work connected with the
Contract without any charge.

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PART II
SUPPLEMENTARY TECHNICAL SPECIFICATION
(AMENDMENTS/MODIFICATIONS/ADDITIONS TO EXISTING
CLAUSES OF GENERAL TECHNICAL SPECIFICATIONS PART - I)
SECTION 100

GENERAL

CLAUSE 102

Definitions
The following abbreviations shall be added in this Clause.

CLAUSE 103

BIS

- Bureau of Indian Standards

CPCB

- Central Pollution Control Board

HDPE

- High Density Polyethylene

MDD

- Maximum Dry Density (as per IS: 2720-Part 8)

MORTH

- Ministry of Road Transport and Highways

HGCL

- Hyderabad Growth Corridor Limited

BOQ

- Bill of Quantities

QA

- Quality Assurance

OGL

- Original Ground Levels

CRMB

- Crumbed rubber modified Bitumen

DLC

- Dry Lean Concrete

PQC

- Pavement Quality Concrete

BM

- Bituminous Macadam

DBM

- Dense Bituminous Macadam

BC

- Bituminous concrete

Add at the end of the clause


The latest editions of these standards till 28 (Twenty Eight)
days prior to the bid opening date shall be adopted.

CLAUSE 105

Scope of Work
WMM

- Wet Mix Macadam

CECRI

- Central Electro Chemical Research Institute

NHAI

- National Highways Authority of India

TMT

- Thermo Mechanically Treated

ASA

- Acrylic Strene Acrylonintrity

HIPS

- High Impact Polystrene

CIL

- Co-efficient of luminous intensity

RPM

- Reflective Pavement Marker

ECB

- Emergency Call Boxes

VMS

- Variable Message Signs

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DP

- Double Pole

ER

- Electrical Resistivity

REC

- Rural Electrification Corporation

APCPDCL- Andhra Pradesh Central Power Distribution


Company Ltd.
SPCB

-State Pollution Control Board

ASTM

-American Society for Testing and Materials

AASHTO

Clause 105.3

-American Association of State Highway and


Transportation Officials

MUV

-Multipurpose Utility Vehicle

SUV

-Sports Utility Vehicle

DCP

-Dynamic Cone Penetration

FIDIC

-Federation Internationale des Ingenieurs


Conseils

MNES

-Minister of Non-Conventional Energy Sources

HYSD

-High Yield Strength Deformed bars

PSV

- Polished Stone Value

WPC

-Wireless Planning and Coordination

AIV

-Aggregate Impact Value

ACV

-Aggregate Crush Value

IRC

-Indian Road Congress

BS

-British Standard

PMC

-Polymer Modified Cementitious

MARV

-Minimum Average Roll Value

ESC

-Environmental Stress Cracking

PP

-Poly Propylene

SMF

-Scaled Maintenance Free

CPWD

-Central Public Works Department

LED

-Light Emitting Diode

ATM

-Asynchronous Transfer Mode

ITS

- Intelligent Transportation System

TIS

-Traffic Information Services

IRI

-International Roughness Index

Add the following below the existing clause:


The Contractor shall establish, adhere to, monitor and
maintain an adequate quality assurance programme (QAprogramme) based on the requirements of EN ISO 9001.
The

Contractor

shall

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institute

and

operate

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Management System complying with SP-47 (Quality Systems


for Road Bridges) and SP-57 (Quality System for Roads). The
quality management system shall be described in a Quality
Assurance Plan that shall be submitted to the Engineer for
acceptance not later than 28 days after the letter of
Acceptance.
The costs associated with preparing
implementing and monitoring the quality management system
shall be deemed to be covered in the scope of the work. The
Quality Assurance Plan shall cover the following items.
The QA-programme shall cover the quality assurance aspects
of all services rendered, all items to be supplied and all
construction activities to be performed under the Contract, also
including temporary structures and equipment which will
influence the quality of the completed works or the progress of
the Contract.
The QA-programme shall as a minimum cover subjects listed
below:
Organisation and Management Responsibility
Document and data control
Construction programme
Method statements
Process control
Working, inspection, testing and documentation
procedures
Safety and emergency procedures
Control and documentation of purchasing and handling of
materials
Product realisation
Non-conformity and corrective / preventive action
Measurement, analysis and improvement
Internal quality audits
Servicing
Education and training of staff
Site Environmental Plan
Competence / skill requirement for Human resources
Customer communication
The general procedures of the QA-programme shall be
submitted to the Engineer for approval not later than twentyeight days after the date of receipt of letter of acceptance. The
special part of the QA-programme shall be submitted
successively to the effect that it shall have been approved
prior to the commencement of the activities to which the
programme shall apply.
Clause 105.5

Add the following as clause 105.5


The Contractor shall take steps to minimize the negative
impact of construction operations on environment.
Hot Mix Plants should be located at least 1-2 Km from the
nearest habitation unless otherwise required by statutory
requirements. Vehicles and machinery used for road

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construction are to be regularly maintained to conform to


SPCB (State Pollution Control Board) norms. Blasting as per
Indian Explosive Act will be adopted. People living near such
blasting site should have prior information of operation hours.
Workers at blasting site will be provided with earplugs.
Vehicle transporting earth materials will be covered. Water
shall be spread to control the dust Degraded materials and
wastewater shall be disposed into the Septic Tank and soak
pits etc. The contractor will make arrangement to clean up the
spoil as soon as the work finishes in a stretch. If such sites are
located outside the ROW, restoration of the site to a level
acceptable to the landowner will be done with in time period
agreed between landowner and the contractor. Spilling of oil
and bituminous products during construction phase will be
avoided to reduce the chances of contamination of surface as
well as ground water. The construction camps shall be
situated at places involving least risks of the nature
considering the factors like ground slopes, under ground water
table and shall confirm to local building regulations, as
applicable.
Construction camps shall be properly located to avoid
contamination of water through wastewater drainage into river
and canals. Seasonal pollution issues may arise when flow of
river is slow. To prevent such contamination, wastewater
generated at campsite will be discharged in soak pits. For
human excreta, proper disposal through Septic Tanks or deep
trenches will be done.
Clause 106

CONSTRUCTION EQUIPMENT
Add the following sub Para (g) and (h) after sub Para (f):
g)

Adequate standby equipment including spare parts


shall be available.

h)

All measuring devices and gauges shall be in good


working condition. Measuring devices that can affect
product quality shall be calibrated prior to use and at
prescribed intervals against certified equipment.
Calibration procedures shall be established,
maintained and documented and corrective actions
taken when results are unsatisfactory. Accuracy and
fitness of measuring devices shall be ensured by
proper maintenance and periodic tests to be carried
out to check the accuracy of all such equipment and
get certificate from the Engineer.

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Clause 107

Contract Drawings

Clause 107.1

Add the following after the end of Para


After careful study of the drawings issued by the Employer, the
Contractor shall prepare where necessary, all supplementary
and working drawings with field / construction information and
shall submit the same to the Engineer for approval prior to
construction. If any change is required, the proposal shall be
submitted to the Engineer prior to construction for his approval
and shall be treated as incidental to the work.

Clause 107.3

Replace the Sub-Clause as Follows:


Two copies of design drawings, on the basis of which actual
execution of the work to be proceeded shall be given to the
contractor by the Engineer progressively according to the work
programme
submitted
by
the
Contractor
and
approved/accepted by the Engineer. Drawings of particular
activity shall be issued to the Contractor at least 21 days in
advance of the scheduled date of the start of the activity.
After careful study of the drawings issued by the Engineer,
The Contractor shall prepare 4 sets of detailed construction
drawings / working drawings with necessary field/construction
information and shall submit the same to the Engineer for
approval along with a construction methodology at least 21
days in advance of the scheduled date of the start of the
activity.
After reviewing the construction drawing, the Engineer shall
issue back 2 sets of drawing to the contractor duly stamped
Good for Construction along with Drawing Number, Revision
Number and date, at least 7 days in advance of the scheduled
date of the start of the activity.
One set of Original Construction drawings shall be kept at
Construction site and Second set shall be kept at contractors
site office under document control section and should be
available for Inspection / Verification at any time. All
Superseded / Obsolete drawing should be clearly marked as
Superseded or Obsolete.
The contractor shall maintain a document control procedure
for Construction Drawings also as per QA Programme in
accordance with provision of Clause 105.3. The contractor
shall include all the above activities in their Construction
Programme which is to be submitted in accordance with the
Provision of Sub. Clause 14.1 of Conditions of Particular
Application.

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CLAUSE 108

Site Information

Clause 108.4

This Sub-Clause shall read as follows:


The Contractor shall identify quarries, borrow areas and other
sources of materials required for the work. He shall satisfy
himself that the required materials are available in adequate
quantities and complying with the requirements of
specifications. No claims shall be entertained on account of
non-availability of materials, and increase in leads, etc.
As far as possible natural sand shall be used for sand/fine
aggregates. If natural sand is not available with in 100Km or
Government has stopped sand mining, the contractor shall
obtain suitable alternative viz. crushed stone, crushed sand,
etc. to substitute the natural sand. All alternative sand shall
confirm to IS: 383 and tests for conformity shall be carried out
as per IS: 2386 (Parts I to VIII). No separate payment will be
made on account of non-availability of natural sand, arranging
crusher sand and increase in leads, etc.
It is the sole responsibility of the contractor to arrange the
quarries, borrow areas etc., on license / lease basis or
otherwise, and study in detail before tendering, the scope of
taking the quarry on lease. Advance information must be
collected by the contractor regarding the procedure laid down
and the consequent delay in arranging the quarries on lease
and must make alternative arrangement to procure the quarry
products from lease holders. No separate payment will be
made for arranging such quarries, borrow areas, etc.

CLAUSE 109

Setting Out

Clause 109.6

The Last Sentence of the paragraph i.e. The contractor,


Engineer, shall be replaced with following sentences.
The Contractor shall, in connection with the staking out of the
centreline, survey the terrain along the road and cross
sections at intervals 20m and 10m in Straight and Curve
portions respectively shall be done as per the following guide
lines.
1. Work request shall be given for joint inspection/survey
for taking of Original ground levels of road cross
sections 7 days in advance before starting of site
clearance.
2. Preliminary site clearance such as removal of shrubs
and bushes has to be done without disturbing the
original ground surface.
3. Joint survey shall be carried out and the Original
Ground levels (OGL) along the road centre line and
cross sections shall be taken jointly.
4. Engineer shall furnish Copy of the approved records of
Centre line co-ordinates & OGL field books to the
Employer for record.

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Clause 109.7

ORR/JICA2/Pkg 2/Vol II

Replace the first sentence of the paragraph with the following


After obtaining approval of the Engineer, work on site
clearance can commence and the profile and cross sectional
OGLs shall form the basis for measurements and payment.

Clause 109.8
109.8.1

Add the following paragraph in the Sub-Clause 109.8


Surveying Equipment and Personnel
The Contractor shall provide the necessary surveying
equipment, accessories, surveyors and labourers required for
setting out and related measurements, including making
available these to the Engineer and his representatives at
different stages of the work. The surveying equipment shall be
of high standard of manufacture as approved by the Engineer,
in good working condition with adequate numbers and shall
include inter alia the following:
i)

Precision automatic level with micrometer attachment


with tripod and levelling staff reading to 5 mm accuracy
by direct observation and to 1 mm accuracy by
estimation or better.

ii)

Theodelite with tripod Electronically operated with


computerised output attachment reading to 20 seconds
of angle accuracy or better.

iii)

Total Station with 2 spare batteries and a charger,


three tripods plus tangents sufficient for a 4 km range,
together with an electronic data reorder, 6 data packs
and all necessary software for operation.

iv)

Precision staffs 4m & 5m type

v)

3 metre straight edge and measuring wedge fitted with


handles, wedges 100 mm height and 1 mm accuracy.

vi)

Field umbrellas

vii)

Ranging rods 50 mm diameter 3 m long straight with a


conical metallic shoe at one end and painted
alternatively black and white at 300 mm C / C along
the length.

viii)

Camber templates 2 lane fitted with handles.

ix)

Steel tape graduated in metres, centimetres and


millimetres

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a)
b)
c)
d)
x)
xi)
xii)

10 m long
20m long
50m long
Reference markers and pegs

Safety Jackets (Reflective)


Bump Integrator (Wheel mounted)
Nails, chalk piece, paints, brushes etc,

The Contractor shall maintain the surveying equipment in


good condition during the full duration of works and replace
the ones which get worn out or otherwise become
unworkable.
The surveying equipment and related resources shall be
provided under the general obligations of the Contractor
requiring no separate payment.
CLAUSE 110

Public Utilities

Clause 110.1

This Clause shall be replaced with the following:


The information provided in the bid documents about public
utilities like water/oil/gas pipelines, sewers, cables etc. may
not be exhaustive, and it shall be the responsibility of the
Contractor to ascertain the utilities that are likely to be
affected by the works through site investigations and
collection of information from the concerned utility owners:
The Contractor shall be responsible to coordinate with service
provider / concerned authorities for cutting of trees, shifting of
utilities and removal of encroachments etc. and making the
site unencumbered from the project construction area
required for completion of work. This shall include initial and
frequent follow-up meetings / actions / discussions with each
involved service provider / concerned authorities. The
Employer shall make payment for cutting of trees and shifting
of utilities as required by the concerned department.

Clause 110.3

This Sub-Clause shall read as under:


Any utility likely to be affected by the Contractors work shall
be brought to the notice of the Engineer and such work shall
be undertaken only after getting written clearance from the
Engineer.

Clause 110.4

Any services affected by the Works must be temporarily


supported by the contractor who must also take all measures
reasonably required by the various bodies to protect their
services and property during the progress of Works. It shall
be deemed to be part of the Contract and no extra payment
shall be made for the same.

Clause 110.5

The Contractor may be required to carry out certain works for


and on behalf of the various bodies and he shall also provide,

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with the prior approval of the Engineer, such assistance to the


various bodies as may be authorized by the Engineer.
Clause 110.6

For Co-ordinating the work of cutting of trees, shifting of


utilities and removal of encroachments, etc., no separate
payment shall be made and these shall be incidental to the
work.

CLAUSE 111

Precautions for Safeguarding the Environment


This whole clause shall be substituted by following:

Clause 111.1

General
The Contractor shall take all precautions for safeguarding the
environment during the course of the construction of works.
He shall abide by all rules, regulations and laws in force
governing pollution and environmental protection that are
applicable to the area where the works are situated.
NOISE:
The Contractor shall militate against any sustained increase in
base line ambient sound levels at sensitive receptors during
construction of work.
All construction operations shall be performed in a manner to
minimise noise and vibration. The parameters for noise are
detailed below.
70 dB (A) for day and night;
50 dB (A) for day and 45 dB (A) for night for sensitive
receptors
If the noise levels are found to be above these standards and
it is determined by the Engineer that these levels are due to
the equipment or plant being deployed by the Contractor, he
shall undertake, at his own cost measures as approved by the
Engineer, to bring these levels down to the specified levels.
Blasting should be done as per Indian Explosive Act. People
living near such blasting sites shall have prior information of
operational hazards. Blasting will not be undertaken at night.
Workers at blasting sites will be provided with earplugs.
Material haulage roads will be properly regulated.
Labour shall be warned against the hunting of wild life, if any.
No archaeological site shall be disturbed.

Clause 111.2

Borrow pits for Embankment Construction


Borrow pits shall not be dug within the Right-of-Way of the
road. Arable lands will not be used for earth borrowing. The
Contractor will ensure that proper excavation techniques are
used to improve stability and safety of the borrow area. The
excavation shall be carried out in such a way that the area
does not inundate during monsoons or generate cesspools of

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water to become mosquito breeding sites. The stipulations in


Clause 305.2.2 shall govern.
Clause 111.3

Quarry Operations
The Contractor shall obtain material from licensed quarries
only after the consent of the forest department or other
concerned authorities. The quarry operation shall be
undertaken within the purview of the rules and regulations in
force. The Contractor shall ensure scheduling the movement
of transport carrying material to and from the site during nonpeak hours. The trucks carrying all the dusty material, red
earth, moorum and fly ash/ pond, ash shall be covered with a
tarpaulin and provided with adequate free board to prevent
spillage. End boards shall be provided in loaders to prevent
spillage. Stockpiling of material shall be properly planned so
as to ensure that no traffic jam takes place on the highway.

Clause 111.5

Precautions against Dust


The Contractor shall take all reasonable steps to minimize
dust nuisance during the construction of the works. All
existing highways and roads used by vehicles of the
Contractor or any of his sub-contractors or suppliers of
materials or plant, and similarly any new roads which are part
of the works and which are being used by traffic shall be kept
clean and clear of all dust / mud or other extraneous material
dropped by the said vehicles or their tyres. Similarly, all dust /
or mud or other extraneous material from the works spreading
on these highways shall be immediately cleared by the
Contractor. Clearance shall be effected immediately by
manual sweeping and removal of debris, or, if so directed by
the Engineer, by mechanical sweeping and clearing
equipment, and all dust, mud and other debris shall be
removed entirely from the road surface. Additionally, the road
surface including haul road from Quarries and Plants shall be
hosed or watered using suitable equipment to avoid dust
pollution. Special care shall be taken to combat dust problem
originating from use of fly ash/pond ash.

Clause 111.6

Pollution from Hot Mix Plant, WMM Plant, Batching Plant


& Crusher and Other Construction Machinery
The Contractor shall ensure the use of a relatively new, well
maintained hot mix plant (batch type) so that any emission
conforms to the CPCB norms and be fitted with a dust
extraction unit to avoid prolonged engine powered equipment
illness. Hot Mix Plant, WMM plant Batching Plant & Crusher
shall be located more than 500 m from any community or
residence. The contractor has to obtain necessary
consent/clearance from State Pollution Control Board to
operate Hot Mix Plant, WMM plant Batching Plant & Crusher
before commencement of works.

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All vehicles, equipments and machinery needed for


construction will be regularly maintained to ensure that
pollution emission levels conform to CPCB norms. All vehicles
should be fitted with silencers.
Construction vehicles, machinery & equipment will move or be
stationed in designated areas to avoid compaction of soil to
ensure the preservation of the top soil for agriculture.
Clause 111.7

Road Safety
The Contractor shall provide adequate circuit for traffic flow
around construction areas, control speed of construction
vehicles through road safety and training of drivers, provide
adequate signage, barriers and flag persons for traffic control.
If there are traffic jams during construction, measures shall be
taken to relieve the congestion with the assistance of traffic
police. Safety of workers undertaking various operations
during construction will be ensured by providing helmets,
masks, safety goggles, etc. One Qualified Safety Officer and
one Safety Supervisor must be available in the contractors
working team for the entire construction period.

Clause 111.8

Sanitation & Waste Disposal in Construction Camp


The Contractor shall ensure that construction camps are
located at a distance of minimum 200m from water sources.
Special attention shall be paid to the sanitary conditions of the
camps. The Contractor shall ensure that sufficient measures
are taken i.e. provision of garbage tanks and sanitation
facilities. Waste in septic tanks shall be cleaned periodically.
Garbage shall be collected in four soakage pits at each
construction site and disposed of daily. The Contractor shall
provide adequate measures for the health care of workers
and arrange their regular medical check-up to ensure that
they do not suffer from any communicable disease. At every
workplace, good & sufficient water supply will be maintained
to avoid waterborne / water related diseases. If any pits are
dug at construction / camp sites which are not filled and then
may turn into mosquito breeding sites during monsoons,
either these shall be filled up properly so that no water
accumulates or sprayed frequently with pesticides to prevent
mosquito breeding.

Clause 111.9

Substance Hazardous to Health


The Contractor shall not use or generate any material in the
works, which is hazardous to the health of persons, animals
or vegetation. Where it is necessary to use some such
substance which can cause injury to the health of the workers,
the Contractor shall provide suitable protective clothing or
appliances to his workers, viz. earplugs, helmets or dust
masks.

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Clause 111.10

Any structural damage caused to the existing roads/structures


by the Contractors construction equipment shall be made
good without any extra cost.

Clause 111.11

Use of Nuclear Gauges


Nuclear gauges shall be used only where permitted by the
Engineer. The Contractor shall provide the Engineer with a
copy of the regulations governing the safe use of nuclear
gauges he intends to employ and shall abide by such
regulations. Without written approval, no such equipment shall
be used at any level of the work.

Clause 111.12

Environmental Monitoring
In order to carry out periodic checks, environmental
monitoring will be carried out by the Engineer as per schedule
and if any parameter is found above the acceptable
standards, mitigation measures / control measures as decided
by the Engineer shall be complied with by the Contractor.

Clause 111.13

Protection of Existing Trees


Some of the existing trees within the right of way are likely to
be cut down by the Employer prior to handing over of the site
to the contractor.
The Contractor shall take all necessary measures to ensure
safety and protection of the remaining trees from any action
whatsoever relating to his construction operations in the
adjoining areas.
Giant neighbourhood trees recognized locally as important
shall be preserved and engineering designs modified to
accommodate these wherever possible.
Adequate supply of fuel (Kerosene, LPG) shall be provided to
the construction labourers to avoid felling of trees for cooking
and other household activities.

Clause 111.14

Disposal of Materials Outside Work Site


Notwithstanding other relevant provisions in the contract, the
excess material generated by dismantling, excavation, waste
material and lubricants, used oil, gasoline and other such
substance etc., shall be removed from site outside the right of
way at regular intervals and site shall kept clean from all such
disposable materials. Grease, cotton and other waste
construction materials shall be disposed off in shallow
soakage wells constructed at each construction site. Such
intervals shall not exceed one month under any
circumstances. The selection of the disposal site shall be the
responsibility of the Contractor and he shall ensure that the
selected site does not result in any claim for damages to the
Employer or violation of any existing laws.

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Clause 111.15

Compliance with the foregoing will not relieve the Contractor


of any responsibility for complying with the requirements of
any highway authority in respect of the roads used by him.

CLAUSE 112

Arrangement for Traffic During Construction

Clause 112.1

General
Delete the last sentence and add the following:
Two weeks before undertaking work which would involve any
obstruction whatsoever to traffic, the Contractor shall submit,
for the Engineers approval, a Traffic Control Plan in
accordance with IRC: SP: 55 2001. The traffic Control Plan
should also comply with the requirements given in Additional
technical Specifications.
The plan shall include:
i) Typical drawings for temporary diversions in
accordance with Sub-Clause 112.3
ii) Typical details of arrangements for construction under
traffic including details of traffic arrangements proposed to
be in place after the cessation of work each day in
accordance with Additional technical Specifications.
Special consideration shall be given in the preparation of the
Traffic Control Plan for the safety of pedestrian and workers
and delineation of the roadway at night.
Temporary diversions will be constructed only with the
approval of the Engineer.

Clause 112.2

Add at the end of second paragraph as follows:


For portions with concentric widening and strengthening of the
existing carriageway where part width of the existing
carriageway is proposed to be used for passage of traffic,
paved shoulder in a width of at least 2.5m shall be provided
on one side of the existing road with the following minimum
requirements to be provided by the contractor:
i) At least one 5.5m lane to remain open to traffic at all
times
ii) The surface used by the through traffic shall at all
times be a firm all weather compacted surface free of pot
holes and other defects
iii) The maximum continuous length over which
construction under traffic diversion may take place shall
be limited to 750 m. However, for longer stretches
passing places at least 50 m long shall be provided at
every 0.75 km interval.

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iv) The treatment to paved shoulders shall consist of


providing 150mm thick granular base course (grading I,
Table 400-1, as per clause-401) covered by 225 mm thick
wet mix macadam layer, 50 mm Bituminous Macadam
(Grading-II) and treated with 25 mm SDBC (Grading-II).
v) Construction activity shall be restricted to only one
side of the existing road.
In case of eccentric widening of existing two lane to four/six
lane, the additional two lanes shall be constructed first upto
the stage of Bituminous Concrete / Cement Concrete
Pavement for a minimum length of 2 km. and traffic diverted
to it and only thereafter the required treatment to the existing
carriageway including construction of median shall be taken
up.
Where it is absolutely necessary that the camber of the
existing road is to be corrected before the commencement of
the additional carriageway in order to avoid ponding of rain
water, the same uni-directional camber has to be provided
first.
Clause 112.3

SL.
No.

Add the following at the end of this Clause.


Where the new highway crosses or joins with an existing state
highway, or an established road or cart track, the highway,
road or cart track shall be kept open at all times. In case the
Engineer specifically orders to construct and maintain
diversion as described below:

Type of Road

Carriageway Width

Earthen
Shoulders
Width
each side
2.5 m

1.

National Highways

14.0 m

2.

State Highways

7.0 m

2.5 m

3.

Major District Roads and other


Roads

7.0 m

1.0 m

179

Pavement composition
(Compacted)
200mm granular sub base
(grading-I, Table 400-1 as per
clause 401).
225mm W.M.M (as per clause
406).
50 mm BM.
25 mm SDBC.
200 mm granular sub-base
(grading-I, Table 400-1 as per
clause 401)
225 mm W.M.M(as per clause
406)
50 mm BM.
25 mm SDBC.
150 mm granular sub-base
(grading-I, Table 400-1 as per
clause 401)
225 mm W.M.M (as per clause
406), 50 mm BM.
25 mm SDBC.

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The granular sub-base/base course and Bituminous


Macadam with prime coat over WMM will be executed as
per clause 401, 404 and 502 & 504. Clause 112.6 of the
Technical Specifications shall govern payment for these
works.
Drainage should be provided as directed by the Engineer.
The alignment and longitudinal section of diversion including
junctions and temporary cross drainage provisions shall be as
approved by the Engineer.
Clause 112.6

2nd Paragraph is to be replaced with the following :


The Construction of Temporary diversion including temporary cross
drainage structures, shall be measured as individual item quantities
and the unit contract rates of those items shall be inclusive of full
compensation for construction (including supply of material, labour,
tools etc.,) maintenance, final dismantling, and disposal.
The execution of works of Earthwork, GSB, WMM, BM and SDBC,
works of temporary cross drainage structures, traffic signs,
barricading, markings and other safety measures required for
temporary diversion as described in Clause 112.2 shall be
executed, measured and paid in the relevant items of work in the
contract. The contractor shall replace torn out, damaged and stolen
equipment immediately.

CLAUSE 114

Scope of Rates for Different Items of Work

Clause 114.2

Item (ii) of Clause 114.2 shall read as follows:


A detailed resources based construction programme (using
computerized critical path network method) in a form which
facilitates control of the progress of the works and consequences of
any changes in terms of time. The programme shall also include
detailed network activities for the submission and approval of
materials, procurement of critical materials and equipment,
fabrication of special products/ equipment and their installation and
testing and for all activities of the Contractor that are likely to affect
the progress of work, etc. including updating all such activities on
the basis of decisions taken at the periodic site review meetings or
as directed by the Engineer. The Contractor shall submit data via
electronic media and hard copy to the Engineer in a form readily
compatible with the Engineers planning system.
Add the following as item (xvii) for sub-clause 114.2:
The Contractor shall prepare detailed working drawings for each
structure as required, on the basis of the drawings given in Bid
Documents and get them approved by the Engineer. The drawings
shall be submitted to the Engineer at least 8 weeks before
commencement of construction of the structures.

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Add the following as item (xvii) for sub-clause 114.2:


Monthly progress report in a format acceptable to the Engineer.
The report shall state the progress which has been achieved
compared with the planned progress, illustrate delays in proportion
to the progress planned, analyze the consequences and state
planned corrective measures. Intermediate progress reports may
also be required.
The first issue of the detailed construction programme including the
detailed description of the system and the procedures shall be
submitted to the Engineer for acceptance not later than 28 days
after the date of receipt of the letter of acceptance.
The Contractor shall submit to the Engineer for approval & consent,
the updated & revised programme at every six months interval or as
such as directed by the Engineer. The updated & revised
programme shall be submitted showing the actual progress
achieved (physical & financial) and the effects of the progress
achieved on the timing of the remaining work including any change
to the sequence of the activities.
Clause 114.4

Add the following as Clause 114.4


If any work executed by the Contractor does not meet the
specifications, it shall be deemed as rejected. The Engineer, in his
sole discretion, may consider a proposal by the Contractor to retain
an element or part of such work. The Contractors proposal shall be
supported by calculations, drawings and other data to prove the
soundness of the proposal and shall clearly describe the additional
measures required to ensure the intended performance of the work.
Rectification / remedial work to bring such work to acceptable
standard shall be executed by contractor at his cost..

CLAUSE 115

Methodology and Sequence Of Work


The Clause shall read as follows:

Clause 115.1

Submission of Method statement


The Contractor shall submit a method statement. The method
statement shall be submitted in two parts.
The General part of the method statement shall describe the
Contractors proposals regarding preliminary works, common
facilities, and items that require consideration at the early stage of
the contract. The General part shall be issued along with the first
issue of the construction programme (refer clause 114.2) and shall
include information on :
a)

b)

Sources of materials like coarse aggregate and fine


aggregate, quantity and quality of materials available in
different sources;
Sources of manufactured materials like cement, steel,
reinforcement, prestressing strands and bearings. Wherever

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c)
d)

e)

f)

ORR/JICA2/Pkg 2/Vol II

possible the Contractor shall identify at least two sources for


each of the items; he shall also submit samples/test
certificates of recently manufactured materials for the
consideration of the Engineer.
Locations of site facilities like batching plant, hot mix plant,
aggregate processing plant, etc.
Details of facilities/approaches for transportation of personnel,
equipment and materials like concrete for construction of
pavements, foundations and substructures in river bed.
Information on procedures to be adopted by the Contractor for
prevention and mitigation of negative environmental impact
due to construction activities.
Any other information required by the Engineer subsequent to
the scrutiny of the method statement submitted along with the
Bid.

The general part of the Q.A. Programme shall accompany the


method statement.
The special part of the method statement shall be submitted to the
Engineer by the Contractor for each important item of work like
construction of embankments and subgrade, pavements, pile
foundations, concreting, prestressing, repair and rehabilitation of
existing structures, concrete superstructure and for any other item
as directed by the Engineer. These statements shall be submitted
at least 4 weeks in advance of the commencement of the activity or
item of work, unless otherwise stipulated in the contract. The
statement shall give information on :
i) Details of personnel both for execution and quality control of the
work.
ii) Equipment deployment with details of number of units, capacity,
standby arrangements.
iii) Sequence of construction, details of temporary or enabling
works like diversions, cofferdams, formwork including
specialised formwork for superstructure, details of borrow areas,
method of construction of embankment and subgrade,
pavements, piles, concreting procedures, details of proprietary
processes and products (e.g. details of prestressing systems,
proprietary piling systems, bearings, expansion joints etc.) and
details of equipment to be deployed. Wherever necessary,
technical literature, design calculations and drawings shall be
included in the method statement.
iv) Testing and acceptance procedures including documentation.
v) Special part of the Q.A. Programme referred in clause 105.3 for
the particular item of work shall be submitted along with the
method statement for the concerned activity.
vi) The Engineer shall examine and approve the method statement
or direct the Contractor to re-submit the statement with required
modifications. The modified statement shall be submitted within
14 days after receipt of Engineers comments.
The sole responsibility for the safety and adequacy of the methods
adopted by the Contractor shall rest on the Contractor irrespective

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of any approval given by the Engineer.


Clause 115.2

Approval of proprietary product/ process/ system


Only proprietary products proven by international usage in
comparable projects shall be permitted to be used. Fully
authenticated details of licensing and collaboration arrangement
shall be submitted by the manufacturer, where relevant.
Within 90 days of award of work the Contractor shall submit the
following information for all proprietary products for approval by the
Engineer.
i)

Name of manufacturer of product/ process/ system.


Complete details of the manufacturer of the product/
process/system shall be furnished. Details of projects where
similar product/process/ system have been successfully used
shall be furnished. Authenticated copies of license/
collaboration agreement shall be furnished.

ii)

General features of the product/product process/ system.


Detailed write-up with methods statement shall be furnished
for each product/ process/ System. This shall include complete
working drawings & installation drawings, technical
specifications covering fabrication, materials, system of
corrosion, protection etc.,

iii)

Details of product development and development testing.

iv)

Acceptance test and criteria.


Manufacturer shall submit a quality assurance system
document. Details of acceptance test and criteria of
acceptance shall be furnished in this document.

v)

Installation procedure.

vi)

Maintenance procedure and schedule.

vii)

Warranty proposal.

The Engineer may order any additional tests required under


relevant codal specifications for the purpose of accepting the
product. The manufacturer shall make the facility for such additional
tests available. The charges of these additional tests shall be borne
by the Contractor.
Clause 116

Crushed Stone Aggregates


This clause shall read as under:
Where the terms crushed gravel/shingle, crushed stone, broken
stone, stone aggregate or aggregate appear in any part of the
Tender document, Drawings issued for work, they refer to
aggregates obtained through the use of Cone crusher, Vertical

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Shaft Impactor and vibratory screens of suitable capacity.

Clause 121

Field Laboratory

Clause 121.1

Description
Replace the words shown in the drawing in the first sentence of
first paragraph of this clause with the words per provisions
indicated in this Clause and at a location approved by the
Engineer.
Replace electric supply etc., to the second sentence of first
paragraph by including uninterrupted power supply etc.,
Delete the first sentence of second paragraph The floor
spacein the drawing and substitute the following.
The floor space required for the field laboratory shall be not less
than 500 sqm.
The fourth sentence of second paragraphs The furnishing in Table
100-2 shall read as under.
A good semi furnished office accommodation shall be provided to
the Material Engineers of the Supervision Team as per the
direction of the Engineer.

Clause 121.2

Add the following at the end of the clause


There shall also be a provision for a concrete paved area for
storing samples adjacent to the laboratory, of about 300 sqm. And
another 200 sqm. Shall be suitably roofed with open sides giving
protection against sun and rain.
Within 14 (fourteen) days of the commencement date, the
Contractor shall prepare and submit a layout plan and details of
the laboratory building and make/supplier of equipment to the
Engineer for his approval.
The field laboratory to be provided under the Contract shall be
handed over to the Engineer in finished and fully equipped
condition not later than 2 months after the receipt of Notice to
Commence work, and the field laboratory with all
equipment/instrument shall be to the entire satisfaction of the
Engineer. During this 2 months period starting from the Notice to
Commence, work, the laboratory tests shall be performed in
another laboratory proposed by the Contractor and approved by
the Engineer.
This facility will be provided and maintained by the Contractor, as
incidental to work and no separate payment shall be made for this
item.

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Clause 121.3

ORR/JICA2/Pkg 2/Vol II

Laboratory Equipment
This Clause shall read as under :
The following items of laboratory equipment procured from
reputed manufacturers duly approved by the Engineer shall be
provided in the field laboratory.
Laboratory equipment shall be provided by the Contractor for the
laboratory sufficient to carry out all the field and site quality
acceptance testing required in the Specifications. List of Laboratory
equipment to be provided and maintained by the Contractor for the
Field laboratory shall be as in Table 100 3.

Table 100-3 List of Laboratory Equipment to be provided and Maintained for


Field Laboratory
A.

General
i) Balance
a)

10 kg capacity semi-self indicating type Accuracy 1 gm

b)

Electronic

1 No.

Mechanical

1 No.

500 gm capacity Accuracy 0.01 gm


Electronic
Mechanical (semi-self indicating)

c)

1 No.
1 No.

Chemical balance (electronic) 100 gm capacity


Accuracy 0.001 gm

d)

1 No.

Pan balance 5 kg capacity


Accuracy 0.5 gm.

3 Nos.

e)

Platform scale 300 kg capacity

1 No.

f)

Triple beam balance 25 kg capacity


Accuracy 1 gm

ii)

iii)

2 Nos.

Ovens electrically operated, thermostatically


thermometer), stainless steel interior

controlled

(including

a)

Temperature range ambient to 300 C, sensitivity 1 C, capacity 120


litre.

1 No.

b)

Temperature range ambient to 150 C, sensitivity 1 C, capacity 250


litre.

1 No.

Sieves : as per
a)

Test sieve set 450 mm internal diameter. as per IS complete with lid
and pan of hole sizes 75 mm, 63 mm, 53 mm, 37.5 mm, 26.5 mm,
13.2 mm, 9.5 mm, 6.7 mm, and 4.75 mm.

185

1 Set

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Test sieve set 200 mm internal diameter (brass frame and steel/or
brass wire cloth mesh) as per IS complete with lid and pan of
aperture sizes 2.36 mm, 2 mm, 1.18 mm, 600micron, 425micron,
300micron, 150micron and 75micron.

2 Set

iv)

Sieve shaker capable of taking 200 mm and 450 mm diameter sieves


electrically operated with time switch assembly

1 No.

v)

200 tonnes compression testing machine electric cum manually operated 2 Nos.
fitted with three gauges 0-2000 KN x 10 KN, 0-1000 KN x 5 KN and 0-500
KN x 2 KN

vi)

Stop watches 1/5 second accuracy

vii)

Glassware comprising beakers, pipettes, dishes, measuring cylinders (100 1 Doz.


to 1000 cc capacity) glass rods and funnels, glass thermometers range 0 Each
C to 100 C and metallic thermometers range up to 300 C.

viii)

Hot plates 200 mm diameter (1500 Watt)

ix)

Enamel trays

b)

2 Nos.

6 Nos.

a)

600 mm x 450 mm x 50 mm

6 Nos.

b)

450 mm x 300 mm x 40 mm

6 Nos.

c)

300 mm x 250 mm x 40 mm

6 Nos.

d)

Circular plates of 250 mm diameter

6 Nos.

x)

Water still, 3 litre/hour. with fittings and accessories

xi)

Aluminium Tins

1 Set

a)

50 mm x 30 mm

36 Nos.

b)

55 mm x 35 mm

36 Nos.

c)

70 mm x 45 mm

36 Nos.

d)

70 mm x 50 mm

36 Nos.

e)

80 mm x 50 mm

36 Nos.

xii)

Riffle box of slot size 50 mm as per ASTM C-136

1 No.

xiii)

Spatula set of 100 mm and 200 mm long

3 Sets

xiv)

Water testing kit

1 Set

xv)

First aid box

1 Set

B.
i)

ii)

For Soils and Aggregates


Liquid limit and plastic limit
a)

Liquid limit device with Cone Penetrometer and as per IS : 2720

2 Nos.

b)

Single point LL device

1 No.

c)

Moisture content cans

50 Nos.

d)

Ground glass plate with rounded edges 600 mm x 600 mm x 10


mm

2 Nos.

Hydrometer analysis

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a)

High speed stirrer with stainless steel beaker

1 No.

b)

Soil hydrometer set including jar to ASTM : E-100 and C-422

1 Set

iii)

Sampling pipettes fitted with pressure and suction inlets, 10ml.


Capacity

1 Set

iv)

Laboratory compaction
a)

Compaction apparatus (Proctor) to the requirements of IST99


complete with collar, base plate and 2.5 kg rammer (automatic
with counter).

1 No.

b)

Compaction apparatus (heavy) to the requirements of IST180


complete with collar, base plate and 4.5kg rammer (automatic
with counter).

3 Nos.

c)

Vibratory hammer to the requirements of Test BS : 14

1 Set

v)

Sand pouring cylinder (150 mm) with conical funnel and top and base
plate (with 152 mm diameter of sand cone) to the requirements of
ASTM : D 1556

4 Sets

vi)

Sampling tins with lids 100 mm diameter x 75 mm height. 1/2 kg


capacity

30 Nos.

vii)

Laboratory C.B.R. testing equipment to the requirements of IS and


consisting of following:

1 Set

a)

Floor mounted electro-mechanical load frame 5 tonne capacity


with automatic strain control

1 No.

b)

CBR moulds complete with collar, base plate, etc.

18 Nos.

c)

Swell stands for holding dial gauge

9 Nos.

d)

CBR plunger with penetration dial gauge holder

1 No.

e)

Surcharge weight with central hole of 2.5 kg weight

40 Nos.

f)

Spacer disc with handle

2 Nos.

g)

Perforated brass swell plate with adjustable cap on handle

18 Nos.

h)

Soaking tank for accommodating 9 CBR moulds

1 No.

i)

High tensile steel calibrated proving rings of 1000 kg, 2500 kg


and 5000 kg capacity

1 Set
Each

j)

Dial gauge, 25 mm travel-0.01 mm/division

12 Nos.

viii)

Standard Penetration Test equipment (IS: 2131) including solid cone


attachment to fit drive and

1 No.

ix)

Dynamic Cone Penetrometer equipment (IS: 4968)

2 Nos.

x)

Nuclear gauge for density and moisture content determination to the


requirements of AASHTO : 238 and 239

2 Sets

xi)

Balloon Testing apparatus for moisture testing

1 Set

xii)

Speedy moisture tester complete with carrying case and supply of


reagent

2 Nos.

xiii)

Sand equivalent apparatus complete along with chemicals to the


requirements of IS : 2720-1966 (Part XXIX)

1 Set

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xiv)

Reagent grade Sodium Sulphate for soundness test of aggregate


chemical Sodium Sulphate to the requirements of AASHTO : T 104

30
KGs.

xv)

Flakiness test gauge to BS : 812

1 No.

xvi)

Post-hole auger with extension

1 Set

xvii)

Core cutter apparatus 10cm diameter, 10/15cm length height complete


with 20kg hammer

1 Set

xviii)

Flakiness and elongation test gauge

1 Set

xix)

Standard measures of 30, 15, 3 litre capacity along with tamping rod

1 Set

xx)

Unconfined compression test apparatus

1 Set

C.

For Bitumen and Bituminous Mixes

i)

Constant temperature bath for accommodating bitumen test specimen,


electrically operated, and thermostatically controlled, stainless steel
interior, 50 litre capacity, temperature range ambient to 80 C

1 No.

ii)

Bitumen penetrometer automatic type including adjustable weight


arrangement, and needles to the requirements of AASHTO : T - 49

1 Set

iii)

Centrifuge type motorized bitumen extraction apparatus to the


requirements of AASHTO : T 164 with stock of solvent & filter paper

1 Set

iv)

Bitumen laboratory mixer planetary action, 2 litre capacity, including


required accessories electrically operated and fitted with heating jacket

1 No.

v)

Marshall compaction apparatus to the requirements of AASHTO : 245


as per ASTM T 1559-62 and complete with electrically operated
automatic loading unit, compaction pedestal, heating unit, head
breaking assembly, flow meter, load transfer bar, specimen moulds 100
mm diameter with base plate, collars, specimen extractor, compaction
hammer 4.53kg x 457 mm fall (excluding constant temperature bath)

1 Set

v)

a)

1 Set

vi)

Dial type thermometer reading 0-200 C range, accuracy 2 C

2 Nos.

vii)

Thin Film Oven Test apparatus to the requirements of AASHTO : T179, including accessories

1 No.

viii)

Ring and Ball Apparatus as per IS : 1205 1978

1 Set

ix)

Asphalt Institute Vacuum Viscometer as per IS : 1206 (Part II) 1978

1 Set

x)

BS UTube Modified Reverse Flow Viscometer IS : 1206 (Part III)


1978

1 Set

xi)

Apparatus for Determination of Ductility Test as per IS 1208 1978

1 Set

xii)

Pensky Martens closed Tester for testing flash and fire point as per
IS : 1209 1978

1 Set

xiii)

Apparatus for Float Test IS : 1210-1978

1 Set

Modified set for DBM

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xiv)

Apparatus for Determination of water content (Dean and Shark Method)


IS : 1211-1978

1 Set

xv)

Apparatus for Determination of Loss on Heating IS : 1212-1978

1 Set

xvi)

Apparatus of Determination of Specific Gravity IS : 1202-1978

1 Set

D.

For control of profile and surface evenness

i)

String line arrangement for paving with sensor pavers

4 Sets

ii)

ROMDAS-Longitudinal profile calibration device

1 No.

iii)

Towed Fifth Wheel Bump Integrator

1 No.

iv)

Camber templates 2-lane/3-lane straight run cross-section as approved


by the Engineer

4 Sets.

E.

For Cement, Cement Concrete and Materials

i)

Vicat needle apparatus for setting time with plungers, as per IS-2691968

ii)

Moulds

1Set

a)

150 mm x 300 mm high cylinder with capping component along


with the capping set and compound as per IS specification

48 Nos.

b)

Cube 150 mm moulds as per IS specification

36 Nos.

c)

Cube moulds of 50 sqcm 70mm x 70mm for cement testing

18 Nos.

d)

Cube moulds of 50mm x 50mm

18 Nos.

e)

Beams 750 mm x 150 mm x 150 mm moulds

18 Nos.

iii)

High frequency mortar cube vibrator for cement testing

1 No.

iv)

Concrete mixer power driven, 1 cu. ft. capacity

1 No.

v)

Variable frequency and amplitude vibrating table size 1m as per the


relevant British Standard

1 No.

vi)

Flakiness index test apparatus as per B.S. 812

1 No.

vii)

Elongation index test apparatus as per B.S. 812

1 No.

viii)

Aggregate crushing value impact test apparatus as per B.S. 812

1 No.

ix)

Los-Angeles Abrasion apparatus as per IS 2386 (Part 4) 1963

1 No.

x)

Flow table as per IS 712- 1973

4 Nos.

xi)

Equipment for slump test (C-143)/compacting factor Apparatus


complete

4 Nos.

xii)

Equipment for determination of specific gravity for fine and coarse


aggregate as per IS : 2386 1963 (Part 3)

4 Nos.

xiii)

Flexural attachment to compression testing machine

2 Nos.

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xiv)

Core cutting machine with 10cm diameter diamond cutting

1 No.

xv)

Needle vibrator

1 No.

xvi)

Air entrainment meter as per ASTM : C 231

1 No.

xvii)

0.5 cft, 1 cft cylinder for checking bulk density of aggregate with tamping rod

As reqd.

xviii)

Soundness testing apparatus for cement (Le Chatliers principle)

1 Set

xix)

Chemicals solutions and consumables

As reqd.

xx)

Chloride testing kit for chemical analysis of chloride content

1 No.

xxi)

ION exchange kit for rapid determination of sulphate content

1 No.

xxii)

Water still

1 No.

xxiii)

Concrete permeability apparatus

1 Set

All equipment shall confirm to accepted international standards and shall be


subject to the approval of the Engineer.
The Contractor shall be responsible for the provision of adequately
experienced and qualified laboratory staff in sufficient number to be able to
meet all testing requirements to the approval of the Engineer, and for all
transportation of staff, testing equipment and samples necessary to allow the
testing to be performed in a time scale compatible with the needs of the Site.
The Contractor shall arrange to maintain the laboratory in satisfactory
manner and will carry stocks of spare equipment and laboratory
consumables until the issue of Taking over Certificate.
Full complement of listed equipment procured from an internationally reputed
manufacturer after procurement and approval of Engineer shall be incidental
to the work and no payment shall be made to the Contractor.
Clause 121.4

This clause stands deleted.

Clause 121.5

This clause stands deleted.

Clause 121.6

This clause stands deleted.

Clause 121.7

This clause stands deleted.

CLAUSE 123

PROVIDING AND MAINTAINING WIRELESS


COMMUNICATION SYSTEM Deleted and replaced
with the following.

Clause 123A

PROVIDING AND MAINTAINING MOBILE PHONE


SERVICE

Clause 123A.1

Scope

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The work covers the provision and maintenance of


Mobile phone communication service to the Engineer /
the Employer as described under Bill of Quantities.
Clause123A.2(a)

Description
The Mobile phones shall be GSM type and may be
Nokia, Samsung or Equivalent and model as decided by
the Engineer. The number of mobile phones to be
provided by the contractor shall be decided by the
Engineer, out of the total provision in the Bill of
Quantities and indicated in writing. The cost of each
Mobile phone is limited to Rs. 15,000/- including taxes.
The contractor shall arrange to supply, within 15 days
from the date of approval by the Engineer, mobile
phones with SIM cards as indicated above. The SIM
card shall be Post Paid type and having National
Roaming, CLIP, SMS, etc. and from an approved service
provider like Cell One, Airtel, BPL, TaTa or equivalent
The usage charge of each mobile is limited Rs. 3,000/per month including cost towards rent, roaming charges,
etc for the outgoing call mobile phones and Rs.1000/per month for within group cell system. But excluding the
cost of Mobile phone, repair, replacement (if any) and
maintenance.

123.A.2 (b)

Maintenance :
The Mobile phones shall be maintained in smooth
working condition. All expenses towards the owning,
operating and maintenance cost shall be born by the
contractor. In the event of any software, hardware or
SIM card problems, the Contractor shall provide
substitute Mobile phone(s) immediately.
The Contractor shall arrange to maintain the mobile
phone and its accessories to the entire project period.
He shall replace the accessory which goes out of order
and attend to all repairs necessary for keeping the
system in satisfactory working condition.
If the Contractor fails to carry out the required
maintenance as directed by the Engineer at any stage of
work, an amount of Rs. 300 per day or part thereof shall
be debited to the Contractor for the period of phone out
of service.

Clause 123A.3

Measurement for Payment


The Measurement for provision of Mobile phone service
to the Engineer/Supervisory staff / the Employer and
maintaining the same shall be on monthly basis and
payment shall be made on lump sum unit basis for every
month after providing the monthly paid bills. As per the

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Engineers directions, some of the Group Cell Sim Cards


may be provided to the contractor for important
communication points such as hot mix plant, batching
plant, laying site etc. and to the key personnel of the
contractor. Payment shall be borne by the contractor
only. If the Contractor fails to carry over the required
maintenance as directed by Engineer at any stage of
work an amount of Rs.300/- per day or part thereof shall
be debited to the Contractor for the period of phone out
of Services. On the issue of taking over certificate the
cellular phones shall be the property of the Contractor.
Clause 123A.4

Rates
The Contract Unit rates for supply and maintenance of
Mobile phone service shall cover all the expenses
towards the cost of GSM mobile phones of approved
make and model with all standard accessories like cell
charger, cover, registration charges, etc. and cost for
arranging post paid SIM card of approved service
provider, monthly usage charges, repair and
maintenance including replacement cost, if any.

CLAUSE 124

PROVIDING AND MAINTAINING VEHICLES FOR THE


ENGINEER
The heading of this clause shall read as under:
PROVIDING AND MAINTAINING VEHICLES FOR
THE EMPLOYER AND ENGINEER

Clause 124.1

Scope
This Clause shall be read as under:
The work covers providing and maintaining
multipurpose utility vehicle (MUV) or sports utility vehicle
(SUV) are equivalent for use by the Engineer and the
Employer as described under the Bill of Quantities.

Clause 124.2

Description
Paragraph 1 of this Clause shall be read as under:
The (MUV) multipurpose utility vehicle or sports utility
vehicle (SUV) are equivalent shall be new A/C vehicles
on hire charges basis, having cylinder capacity more
than 2000 cc for Engineer, Employer and their
representatives. The number of vehicles to be provided
by the contractor shall be decided by the Engineer in
consultation with the Employer out of the total provision
in the Bill of Quantities and indicated in writing.

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Clause 124.4

ORR/JICA2/Pkg 2/Vol II

Withdrawal of Vehicles
The first sentence for this Clause shall be read as under:
The contractor shall withdraw particular vehicle/vehicles
for the non-use by the Engineer/Employer if so directed
by the Engineer/Employer

Clause 124.5

Measurement of Payments
The Payment for providing and maintaining new vehicle
on hire basis shall be on vehicle day basis calculated on
actual number of days the vehicle provided in
satisfactory working order. If the total usage per vehicle
exceeds 4000 Km per month, an amount of Rs.4 per
Km. shall be paid to the contractor for the extra Km used
over and above the initial 4000 Km per month. A log
book shall be maintained in each vehicle by the
Contractor in the form acceptable to the Engineer. No
Payment shall be made for the period of withdrawal as
per Clause 124.4 irrespective of the fact whether vehicle
was available or not. No payment shall be made for
vehicle break down days, Contractor should arrange for
a substitute vehicle of above mentioned capacity for the
break down vehicles immediately. Not operated days are
not considerable for payment.

Clause 124.6

Rate
Add the words and Employer after the word Engineer
in second line.

CLAUSE 126

Supply of Video Cassettes and Digital CDs (VCDs /


DVDs)

Clause 126.1

The clause shall read as:


The work consists of taking video films of important
activities.

The Contractor shall arrange to make complete


video coverage of the entire existing contract stretch
before start of actual execution of work.
Video filming of important activities of the work as
directed by the Engineer during the currency of the
project shall be carried out and shown to Engineer.
Video filming of the substantially completed sections
of the project.
Video filming of the project after final completion of
the work.
Editing them to a video film of playing time not less
than 60 minutes and upto 180 minutes as directed
by the Engineer. It shall contain narration of the
activities in English by a competent narrator. The

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edition of the video film and the script for narration


shall be as approved by the engineer.
The video CDs / DVDs shall be of acceptable quality and
the film shall be capable of producing colour pictures.
Clause 126.2

Measurements for payment


The clause shall read as:
The measurement shall be number of sets of edited
VCDs each with four copies thereof.

Clause 126.3

Rates
This clause shall read as:
The contract unit rate shall include all expenses for
making video films with the help of a professionally
competent photographer, editing, narration and supply
the final edited master VCDs along with four copies
thereof.

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SECTION 200

SITE CLEARANCE

Clause 201

Clearing and Grubbing

Clause 201.1

Scope
Replace with following paragraph:
This work shall consist of cutting, removing and
disposing of all materials such as trees of girth up to 300
mm., bushes, shrubs, stumps, roots, grass, weeds etc.
and top soil minimum 100 mm but not exceeding 150mm
in thickness, rubbish, etc., which in the opinion of
Engineer is unsuitable for incorporation in the work
including draining out stagnant water, if any, from the
area of road land, drains, cross drainage structures and
other area as specified in the drawings or as directed by
the Engineer. It shall include necessary excavation by
harrow discs or any other suitable equipment, back filling
the excavated area up to a maximum depth of 150mm
and also complete filling of the pits resulting from
uprooting of trees & stumps by suitable/approved soil
and making the surface in proper grade by suitable
equipment and compacted by power roller to required
compaction as per Section 300. The work also includes
keeping the cleared material in stock pile within the
ROW not less than 500m in distance, keeping the stock
pile till completion of bituminous work, re-using the top
soil in turfing and disposal of unsuitable material.
Clearing and grubbing shall be performed in advance of
earthwork operations and in accordance with the
requirements of these specifications. Areas as well as
depth requiring clearing and grubbing shall be
determined by the Engineer.

Clause 201.3

Replace the 3rd paragraph with the following


All Excavations below original ground level arising out
of the clearing and grubbing and also for removal of
trees, stumps, etc., shall be filled with suitable material
and compacted thoroughly so as to make the surface fit
for the next layers in accordance with the section 300 of
Specifications.

Clause 201.4

In the Second Paragraph, Replace upto a lead of


1000m with all leads

Clause 201.5

Measurements for Payment


Replace the first sentence of the first paragraph with the
following
Clearing and grubbing for road embankment, drains and
cross drainage structures shall be measured as areas in
plan basis in terms of hectares.

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Replace the last sentence of the first paragraph with the


following
Cutting including removal of foundations of sign boards,
hoarding boards, concrete posts, kilometre/hectometre
stones, boundary stones, back filling to required
compaction up to general original ground level and of
any pits shall be measured and paid in respective item of
BOQ.
Clause 201.6

Rates

Clause 201.6.1

Delete this clause and replace with the following


The Contract unit rates for the various items of clearing
and grubbing shall be payment in full for carrying out the
required operations including full compensation for all
labour, materials, tools equipment and incidentals
necessary to complete the work. These will also include
cutting of trees and uprooting the stumps up to a girth of
300 including roots as well as stumps left over after
cutting of trees carried out by another agency,
excavation and back filling to required density,
excavation up to a maximum depth of 150mm and
backfilling to required compaction with suitable material
to restore the original ground level with all lifts and
leads.

Clause 201.6.2

The Contract unit rate for cutting (including removal of


stumps and roots) of trees of girth above 300mm shall
include excavation and backfilling to required
compaction, handling, salvaging and stack piling and
disposing of the stocked materials with all lifts and
leads.

CLAUSE 202

DISMANTLING CULVERTS, BRIDGES AND OTHER


STRUCTURES / PAVEMENTS.

Clause 202.3

Dismantling of Pavement
Add at the end of the 2nd para:
The existing bituminous pavement surface, base and
sub-base courses shall be removed by ripping,
pavement breaker or any other suitable equipment, or
any other suitable means as approved by the
Engineer.
Dismantling of existing base, sub-base and surface
courses shall be measured by taking cross-sections at
200 m intervals before dismantling by making 30 cm
wide trench in full width and depth and computing the
volumes in cum. by the method of average crosssectional areas".

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Clause 202.4

ORR/JICA2/Pkg 2/Vol II

Back-filling
After "operations" add "and wells encountered in the
alignment" in 1st line of this clause.
Add at the end of this clause
"The wells may be capped thereafter if directed by the
Engineer. The filling of wells and capping will be paid
separately in the relevant item of earth work, concrete,
RCC works as the case may be.

Clause 202.5

Disposal of Materials
Substitute lead of 1000 m by With all leads, wherever
appearing in this clause.
The first paragraph of the sub clause shall read as
below:
All materials obtained from dismantling/milling shall be
the property of the Employer and the Contractor may
use this material in work or sell/dispose off the material
(with all leads and lifts), for which he shall quote a rate
for rebate against the respective items of BOQ.
However, such use of dismantled material in work shall
have the prior approval of the Engineer. Contractor may
use dismantled / milled road crushed material by
suitably modifying the material, or by crushing the
material, or by breaking the material, and screening the
same, after effecting due rebate in the BOQ, provided it
meets the specifications and is approved by the
Engineer.
Delete the last paragraph of this clause.

Clause 202.6

Measurements for Payment


Add the following items after item (vi):
(vii)
(viii)

(x)
(xi)

Clause 202.7

Dismantling of signboard/ Bill boards .


Nr
Dismantling of dry/grouted stone pitching
.
Cu.m
(ix)
Removal
of
hume
pipe
.
Lm
Dismantling of granular pavement .
Cu.m
Dismantling of 5th Kilometer stone, Kilometer
stone, Hectometer stone, delineator and guard
stone .
Nr.

Rates
Delete the last sentence of the paragraph and replace

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with:
These will also include excavation, back filling with
required compaction where necessary and for handling,
piling and disposal of the dismantled materials with all
lifts and leads as specified in Sub-Clause 202.5. The
cost of cartage of materials with no salvage value to
disposal sites with all leads and lifts is deemed to be
included in the rates for dismantling.
The contract unit rates for various items of rebate shall
be on the full quantities obtained from dismantling taking
into account all the operations for reuse of salvaged
materials and disposal of the balance of material within
all leads and lifts.

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SECTION 300

EARTHWORK, EROSION CONTROL AND DRAINAGE

CLAUSE 301

EXCAVATION FOR ROADWAY AND DRAINS

Clause 301.1

Scope
Insert the following between the words roadway and
side drains in the second line :
road shoulders/paved shoulders, verge, medians,

Clause 301.2.1

Classification:
Add sentence (f) after (e) and read it as below;
(f) Hard Rock (requiring controlled blasting)
Hard rock requiring blasting as described under (c) but
where blasting would damage abutting structures like
building, bridge foundations, etc. and excavation has to
be carried out by controlled blasting without causing any
detrimental damage to near by structures and in
accordance with Additional Technical Specifications .

Clause 301.3.3

Excavation - General:
Delete the last two sentences of Para 5 of this clause.
The following paragraph is added to the sub-clause
301.3.3
Temporary support to the sides of the excavation
necessary to support the foundation of adjoining
structures and to prevent any ground movement shall be
provided by the Contractor. Where temporary supports
are provided these shall be designed and removed such
that no ground movement occurs on removal. The
Contractor shall submit his proposal in this respect to the
Engineer for approval prior to commencement of the
excavation. If any damage occurs the Contractor shall be
liable to restore the property at its own position. No extra
payment will be made against works under this sub
clause.

Clause 301.3.7

This Clause shall be read as under:


In works involving widening of existing pavements or
providing paved shoulders, the existing paved
shoulders/hard
shoulder/earthen
shoulders/verge/median shall be removed to its full width
and depth up to the Subgrade bottom level shown on
drawings or as indicated by the Engineer, preparation of
cut formation as per clause 305 supporting
subgrade/embankment. Method of benching shall be
followed with each successive top layer of existing
pavement layer cut at least 250 mm wider than bottom

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layer. While doing so care shall be taken to see that no


portion of the existing pavement designated for retention
is loosened or disturbed. If the existing pavement gets
disturbed or loosened, it shall be dismantled and cut to a
regular
shape
with
side
vertical
and
the
disturbed/loosened portion be removed completely and
re-laid as directed by the Engineer, at the cost of the
Contractor.
If the existing material below the sub base level up to a
depth of 500mm or more is suitable for Subgrade (with
soaked CBR not less than 10 %) shall be retained. The
cut formation shall be prepared to support the sub-base
as per Clause 305. Any unsuitable material encountered
in this portion of subgrade shall be removed and
replaced with suitable material and compacted in
accordance with Clause 305.
Clause 301.3.11

Disposal of excavated materials


Delete this Sub-Clause and replace with:
All the excavated materials shall be the property of the
Employer. Suitable material obtained from the
excavation of the roadway, shoulders, verges, drains,
cross drainage works, etc. shall be used for:
i)

Filling roadway embankment and Subgrade with all


lifts and leads.

ii)

Filling existing pits/ ponds in the right of way as


directed by the Engineer, including levelling and
spreading, with all lifts and leads.

iii)

For landscaping of the road as directed by the


Engineer, including levelling and spreading, with all
lifts and leads.

Excavated rock shall be utilised by the contractor in the


manner as he desires (other than the above items of
work) duly affording the rebate for the entire quantity of
rock excavated.
The Rebate is to be given towards the salvage value for
the Hard Rock excavated.
Unsuitable and surplus material, which, in the opinion of
the Engineer cannot be used in the works, shall be
removed from site by the Contractor and disposed of at
the nearest dip or other approved location with all lifts
and leads in accordance with all statutory requirements.

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Clause 301.8

ORR/JICA2/Pkg 2/Vol II

Measurement for Payment


Delete the first sentence of the first paragraph and
replace with:
Excavation for roadway shall be measured by taking
cross-section volume calculated in accordance with
Clause109
Delete item (v) of last paragraph.

CLAUSE 301.9

RATES

Clause 301.9.1

In para (ii) the words lead upto 1000m or as otherwise


specified shall be substituted by all leads.
Add the followings after item (vi):
(vii) The removal from site and disposal of all surplus or
unsuitable materials obtained from excavation operations,
which, in the opinion of the Engineer cannot be used in the
Works, shall be included in the Contract rate.
(viii) Arrangement for safety of the property as mentioned
in sub clause 301.3.3 of this specification, shall be
included in the Contract Rate.

Clause 301.9.5

Replace , but leads upto 1000m with and all leads in


the sentence

Clause 301.9.6

Delete this Sub Clause.

CLAUSE 304

EXCAVATION FOR STRUCTURES

Clause 304.3.4

Preparation of Foundation
In Paragraphs 2 and 3 of Clause 304.3.4, substitute
concrete of M15 grade in place of lean concrete (1:3:6
nominal mix).

Clause 304.3.7

Backfilling
Delete the word Mechanical tamper in line 7 and
substitute it with Roller

Clause 304.5.1

Delete upto 1000 m or as otherwise specified; and in


item (v)

Clause 304.5.3

Delete beyond the initial lead of 1000 m and replace


with for all leads.

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CLAUSE 305

EMBANKMENT CONSTRUCTION

Clause 305.2

Materials and General Requirements

Clause 305.2.1

Physical requirements

Clause 305.2.1.1

Replace the sentence Clay having liquid limit exceeding


70 and plasticity index exceeding 45; with the sentence
Clayey soils and other soils having liquid limit exceeding
40 and plasticity index exceeding 18;

Clause 305.2.1.2

This Clause shall be read as under:


Expansive soils such as CH, MH or OH exhibiting
marked swell and shrinkage properties (free swelling
index exceeding 50 per cent when tested as per IS:
2720-Part 40) shall not be used in construction of any
subgrade or embankment.

Clause 305.2.1.4

Delete second sentence of clause 305.2.1.4.

Clause 305.2.1.5

Add the following at the end of first sentence:


The material to be used in subgrade should satisfy the
requirement of the 4 day soaked design CBR of 10%
when tested as per IS: 2720 (Part 16) at 97% maximum
dry density (IS: 2720 (Part 8)).

Clause
305.2.2.2

Borrow materials

Paragraph 1 of this Clause shall be read as under:


No borrow area shall be made available by the Employer
for this work. The arrangement for the source of supply of
the material for embankment and subgrade meeting the
prescribed specifications as well as compliance to the
different environmental requirements in respect of
excavation and borrow areas as stipulated, from time to
time, by the Ministry of Environment and Forest,
Government of India and the local bodies, as applicable
shall be the sole responsibility of the Contractor.

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THE TABLE 300-2 SHALL BE READ AS UNDER:


COMPACTION REQUIREMENTS FOR EMBANKMENT
AND SUBGRADE

SL.
No.
1.
2.
3.
4.

Type of Work/Material

Subgrade and earthen


shoulders
Embankment
High embankment
(exceeding 6m height)
Expansive clays

Relative compaction
as percentage of
maximum laboratory
dry density as per
IS: 2720 (Part 8)
Not less than 97
Not less than 95
Not less than 97
Such material is not
allowed

Paragraph 8 of this Clause given below Table 300-2 shall


read as under:
The contractor shall at least 7 working days before
commencement of construction of embankment and the subgrade; submit the following to the Engineer for approval:
i)

The values of maximum dry density and optimum


moisture content obtained in accordance with IS: 2720
(Part 8) for each fill material proposed to be used in the
construction of embankment and sub-grade.

ii)

The graphs of Density plotted against moisture content


from which each of the values in (i) above of maximum
dry density and optimum moisture content were
determined.

iii) The dry density-moisture content-CBR relationships,


heavy compaction efforts conforming to the IS 2720 (part
8) for each of the fill material proposed to be used in the
sub grade.
The above information shall form the basis for compaction
only upon its approval by the Engineer.
Clause 305.3

Construction Operations

Clause 305.3.4

Compacting ground supporting embankment/ subgrade


Para 1 of this clause shall be read as:

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Where necessary the original ground shall be levelled,


scarified, mixed with water and then compacted by rolling to
facilitate placement of first layer of embankment so as to
achieve minimum dry density as given in Table 300-2.
Add at the end of Para 2
Backfilling layers in pits, trenches and below the original
ground are to be compacted to the relative natural ground
density. The natural ground density shall be determined by
conducting field density tests at three spaced locations
along the central line of the proposed additional
carriageway at a depth between 0.5m to 1.0m. Samples of
natural ground are collected at each location, and are
tested in accordance with IS: 2720 (Part 8). The relative
density (i.e. the percentage of the field dry density to the
laboratory maximum dry density) is assessed for each
sample, and the greatest relative density obtained is
selected as the natural ground density. If the natural
ground density is less than 85% then these are to be
compacted after necessary watering so as to achieve not
less than 85% of relative compaction.
Where necessary to facilitate compaction of the subgrade to
97% relative compaction as stated above, a further depth of
maximum thickness of 0.2m shall be loosened, watered and
compacted in accordance with Sub Clause 305.3.5 and
305.3.6 to not less than 95% of dry density determined in
accordance with IS: 2720(Part-I).
Clause 305.3.5.1

Replace the first sentence of the paragraph as follows:


The embankment and subgrade material shall be spread
in layers of uniform thickness, provided demonstrated
successfully and approved by Engineer, not exceeding 250
mm compacted thickness over the entire width of
embankment by mechanical means, finished by a motor
grader and compacted as per clause 305.3.6.

Clause 305.3.5.2

Spreading materials in layers


appropriate moisture content.

and

bringing

to

In para 3, delete "IS: 2720 (Part 7 or)" .


Clause 305.3.6

Compaction
The second para of this Clause shall read as under:
"Vibratory roller of not less than 80-100 KN static weight with
plain or pad foot drum or pneumatic tyre roller of 300 KN
weight having tyre pressure of at least 7 kg/sqcm shall be
used for compaction.

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Insert the following sentence before the last sentence of


Paragraph 5:
The co-relation between sand replacement densities and
nuclear gauge densities shall be based on trials with
minimum 30 coherent density measurements
Clause 305.4.4

Embankment and Subgrade around structures


In the last line of paragraph-3, substitute compacted
thoroughly to the requirements of Table 300-2 by
compacted thoroughly to not less than 97% MDD
In the last line paragraph 4, substitute 2504 for 2502

Clause 305.4.6

Add the following at the end of clause


Construction of embankments in marshy and boggy
soil:
The area where the embankment has to be constructed
shall be dewatered. After removing the slush and boggy
soil from the area it will be filled with sand upto a height of
500 mm above ponding water level upto toe of
embankment. 300 mm thick layer of stone dust shall be
filled over the sand layer and compacted.

Clause 305.4.8

Delete the clause and read as stated below


For stage construction of high embankments, controlled
rate of filling shall be carried out as indicated below.
The embankment shall be constructed over a drainage
layer and in the first month the total height should be limited
to maximum 6.0 (six) metre only. The balance embankment
construction should be done after a rest period of 2 (Two)
months for strength gain and consolidation. The rest period
need not be given in case where the construction of the
initial 6 metre height of embankment takes more than 4
months.
However, based on the available subsoil data the
contractor may suggest his loading schedule or any other
method to take care of the excessive settlement problem
for approval of the Engineer.

Clause 305.8

Measurements for Payment


Add the following para at the commencement of the clause.
In case of marshy land, slush will be removed till firm
ground is reached and depression caused thereby will be
filled with approved full materials and duly compacted in
layers till the formation reaches the original natural ground
level. The formation so built will be considered as Built up

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Original Ground Level which will be considered for


computation of volume of earthwork at such location.
Separate payments for removal of slush and filling upto
Built up Original Ground Level will be admissible to the
Contractor.
Para 1 shall be read as:
"Earth embankment/sub-grade construction shall be
measured separately by taking cross sections at intervals
after clearing and grubbing and if necessary compaction of
original ground before the embankment work starts and
after its completion and computing the volumes of
earthwork in cubic metres by the method of average and
areas."
Clause 305.9.1

Add new sub section as (xiv) slush removal


Insert including removal and replacement of marshy soil
after words unsuitable material appearing in the second
line of item (iii).
Add including removal of top soil after word material
appearing in first line of item (v)

Clause 305.9.6

Substitute upto a Lead of 1000 m or as otherwise


specified by leads

CLAUSE 306

SOIL EROSION AND SEDIMENTATION CONTROL

Clause 306.4

Measurement for payment


Substitute Clause 306.4 as follows:
All temporary sedimentation and pollution control works
shall be deemed as incidental to the earthwork and other
items of work and, as such, no separate payment shall be
made for the same.

Clause 306.5

Rates
This Clause shall be deleted.

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SECTION 400

ORR/JICA2/Pkg 2/Vol II

SUBBASES, BASES (NON-BITUMINOUS) AND


SHOULDERS
General
Sub clause (i) of clause 401.8 stands deleted and
remaining sub para (ii) to (v) are renumbered as (i) to (iv).
Sub clause (i) of clause 405.7.1 stands deleted and
remaining sub paras (ii) to (iv) are renumbered as (i) to (iii).
The provision of clause 401.8 (i) to (v) be read as Clause
401.8 (i) to (iv) in the sub clauses 402.8, 403.8, 404.7,
407.7 and 410.7

Clause 401

GRANULAR SUB-BASE

Clause 401.1

Scope
Add the following at the end of this clause:
A site trial shall be performed in accordance with clause
903.3.

Clause 401.2

Materials

Clause 401.2.1

Paragraph 1 of this Clause shall read as under:


The material to be used for the work shall be crushed
granite stone, depending upon the grading required. The
material shall be free from organic or other deleterious
constituents and conform to the Grading 1 given in Table
400-1.
Delete last sentence of para 2 and replace it by following:
For drainage layer, grading requirement shall be according
to Grading I of Table 400-2.

Clause 401.2.2

Physical Requirements
The Clause shall read as under:
The materials shall have a 10% fines value of 50 KN or
more (for sample in soaked condition) when tested in
compliance with BS 812 ( Part-3). The water absorption of
the coarse aggregate shall be determined as per
IS:2386(Part-3). If this value is greater than 2% on the
material delivered as per IS:383 , Soundness Test shall be
carried out in accordance with IS:2386 (Part-5) 1963. The
average loss of weight of coarse aggregate after 5 cycles
shall not exceed 12% when tested with sodium sulphate
and 18% when tested with magnesium sulphate as
specified in IS:383.

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Clause 401.3

ORR/JICA2/Pkg 2/Vol II

Strength of sub-base
The clause shall read as follows:
It shall be ensured prior to actual execution that the
material to be used in the sub-base has a minimum CBR
value of 30% when compacted and finished.
When directed by Engineer, this shall be verified by
performing tests in the laboratory. The CBR tests shall be
conducted on specimen soaked for 4 days and compacted
to 98% of the maximum dry density as per IS:2720 (Part 8).

Clause 401.4.2

Spreading and Compacting


The second paragraph of this clause shall read as follows.
"When the sub-base materials consist of combination of
materials mentioned in Clause 401.2.1 mixing shall be done
mechanically in plant".
The fifth Para of this Clause shall read as under:
Immediately thereafter, rolling shall start. If the thickness of
the compacted layer does not exceed 100 mm, a smooth
wheeled roller of minimum 100 KN static weight may be
used. For a compacted single layer upto 225 mm thickness,
the compaction shall be done with the help of a vibratory
plain drum or pad foot drum roller of minimum 100 KN static
weight or with a heavy pneumatic tyred roller of minimum
300 KN static weight having a minimum tyre pressure of 0.7
MN/m2. The rolling should commence at the lower edge
and proceed towards the upper edge longitudinally for
portions having unidirectional cross fall and super elevation
and shall commence at the edges and progress towards
the center for portions having cross falls on both sides.

CLAUSE 406

WET MIX MACADAM SUB-BASE/BASE COURSE

Clause 406.1

Scope
Delete in one or more layers and replace with in two
uniform layers in the last sentence of first paragraph.
Read 125mm in place of 200mm in the last sentence of
second paragraph.

Clause 406.2

Materials

Clause 406.2.1.1

Physical Requirements:
Delete the second sentence beginning with "If crushed
gravel and ending with . fractured faces." and add as
under:

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The constituents of the aggregates shall be produced by


integrated crushing and screening plant (Impact or Cone type
of capacity 200T/hour) and, unless otherwise instructed by
the Engineer, crushing shall be carried out in at least two
stages. The fraction of material passing through 4.75mm
sieve shall also be crusher run screening only.
Add the following at the end of the last paragraph:
Soundness test shall be carried out in accordance with IS:
2386 (Part- 5), 1963. The average loss of weight of coarse
aggregate after 5 cycles shall not exceed 12% when tested
with sodium sulphate and 18% when tested with
magnesium sulphate as specified in IS: 383-1970
From the Table No. 400-10 replace the wording against
single asterik as under:
The aggregate should satisfy both the tests a) Los Angeles
Abrasion Value b) Aggregate Impact Value.
Clause 406.3.3

Preparation of Mix
Para 1 of Clause 406.3.3 shall be read as under:
Wet mix Macadam shall be prepared in an approved Wet
Mix Macadam mixing plant of 200T/ hour capacity having
provision for controlled addition of water and forced/ positive
mixing arrangement.

Clause 406.3.4

Spreading of Mix
Replace the first and second sentence of second
paragraph as follows:
The mix shall be spread by Electronic Sensor Paver
Finisher only, with guide wire arrangement preferably in full
width of the pavement including hard shoulder.
Delete third paragraph.

Clause 406.3.5

Compaction
Delete second sentence of first paragraph.
Read 125mm in place of 200mm in the third sentence of
first paragraph from 1st para delete the sentence If the
thickness of single compacted layer does not exceed 100
mm, a smooth wheel roller of 80 to 100 kN weight may be
used.

Clause 406.4

Opening to Traffic
The clause shall read as:

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No vehicular traffic of any kind should be allowed on the


finished wet mix macadam surface till it has dried and
covered upto the 2nd layer of DBM.
CLAUSE 407

SHOULDERS, ISLANDS AND MEDIAN

Clause 407.1

Scope
Replace the Sub-Clause with the following:
The work shall consist of constructing shoulder
(hard/paved/earthen) on either/one side of the pavement,
median in the road dividing the carriageway into separate
lanes and islands for channelising the traffic at junctions in
accordance with the requirements of these specifications
and in conformity with the lines, grades and cross sections
shown on the drawings or as directed by the Engineer.

Clause 407.2

Materials
Replace the first paragraph by the following paragraph:
Hard shoulder on either/ one side of the road shall be of
Granular
Sub base conforming to the requirements of
Clause 401. Earthen shoulder on either/ one side of the
road shall be of selected earth conforming to requirements
of Clause 305. The material to be used should satisfy the
requirement of the 4 days soaked design CBR of 10%
when tested as per IS: 2720 (Part 16) at 97% maximum dry
density (IS:2720 (Part 8)).
The median / Islands shall be of selected earth conforming
to requirements of Clause 305.
Delete second, third and fourth sentence of the third
paragraph.

Clause 407.4.3

Delete this sub-clause

Clause 407.6

Measurements for Payment


This Clause shall read as under:
Construction shall be measured as finished work in
position as below:

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a)

ORR/JICA2/Pkg 2/Vol II

Shoulders (Hard / Paved / earthen)


(i)
(ii)
(iii)
(iv)
(v)
(vi)

b)

For Excavation in cu. m.


For Earthwork in cu. m.
For Granular sub-base in cu. m.
For sub-base, base, surfacing courses in
units of respective items.
For kerb in Running meters
Item (vi) is deleted

Island / Median
(i)
(ii)
(iii)

For Earthwork in cu.m


For kerb in running meter.
For sub base, base and tile finish in square
metre complete as per Clause 409.

Clause 407.7

Delete with brick or stone block edging

CLAUSE 408

CEMENT CONCRETE
CHANNEL

Clause 408.5

Construction Operations

Clause 408.5.1

Substitute first sentence of Clause 408.5.1 as under:

KERB

AND

KERB

WITH

For the new carriage way, Kerb shall be laid on firm


foundation and extending inside the median as shown in
drawings.
Clause 408.5.2

Add the words or to accommodate drainage pipes at the


end of the paragraph after the words drainage openings.

Clause 409

FOOTPATHS AND SEPARATORS

Sub-Clause 409.2

Materials
Parts (c) of this Sub-Clause 409.2 shall be deleted.

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SECTION 500

BASE AND SURFACE COURSES (BITUMINOUS)

Clause 501

General Requirements for Bituminous Pavement


Layers

Clause 501.2.2

Coarse Aggregates
The first sentence of paragraph 1 shall read as:
The course aggregates shall consist of crushed rock and
shall be obtained through the use of Cone crusher, Vertical
Shaft Impactor and vibratory screens of suitable capacity.
The third paragraph of this Clause shall be deleted

Clause 501.3

Mixing
Para 1, Line 3 and 4, replace the word, Adequate Capacity
with Hot mix plant of``` Batch mix type of Minimum capacity
of 120T per hour.

Clause 501.5.3

Spreading
Replace the first sentence of paragraph 1 as follows:
Bituminous mix shall be spread with paver fitted with
electronic sensing device and string line arrangement
(supported by steel pegs @ 5m apart) on either side of
paving width for automatic levelling, surface evenness and
profile control. Use of string lines is compulsory to provide
signal to electronic sensing device fitted with a Paver
Finisher". The width of the paver shall not be less than 9
mts.

Clause 501.6

Compaction
Replace the last two sentence of paragraph 2 as follows:
The intermediate rolling shall be done with a smooth
wheeled tandem vibratory roller of 8-10 tonne weight
followed by a pneumatic tired roller of 12-15 tonnes weight
having nine wheels, with a tyre pressure of at least 5.6
kg/sq.cm. The finish rolling shall be done with 8 -10 tonnes
smooth wheeled tandem rollers.
Add at the end of 6th paragraph:
Rolling shall be continued till the density achieved satisfies
the requirements of Clause 903.4.2 and all roller marks are
eliminated.

Clause 501.8

Preparation of Surface

Clause 501.8.3.2

In the last sentence replace 1000m with all leads.

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Clause 501.8.3.4

Laying the profile corrective course

Clause 501.8.3.4.1

This Clause shall be read as under:


The surface on which profile corrective course is to be laid
shall be thoroughly swept clean of dust and any other
extraneous material using mechanical broom and dust
collected, removed or blown off using compressed air
except in places where mechanical means cannot reach.
After preparing the granular surface as in Clauses
501.8.3.1., 501.8.3.2 and 501.8.3.3, the profile corrective
course with materials as per Clause 501.2.3/501.2.4 shall
be laid and compacted to the requirement of particular
specification clause. Where a bituminous profile corrective
course is to be laid over primed granular surface, a tack
coat conforming to Clause 503 shall be applied prior to
laying the profile corrective course.

Clause 501.8.3.4.2

This Clause shall be read as under:


An existing bituminous surface shall be prepared as per
Clauses 501.8.3.3 and 501.8.3.4.1. The bituminous profile
corrective course shall be laid after applying tack coat
conforming to Clause 503, and compacted to the
requirement of specification Clause.

Clause 501.8.7.5

1.

The profile corrective course upto 40mm average


thickness shall be laid with Dense bituminous
macadam only.

2.

The profile corrective course shall be laid with


Bituminous macadam for average thickness more
than 40mm and upto 150mm.

3.

If the profile corrective course average thickness is


more than 150mm, the existing Bituminous surface
shall be removed completely and subsequent road
crust layer shall be laid with wet mix macadam.

Tack Coat
This clause shall be read as under:
Tack coat is to be measured and paid for on a per square
metre basis.

Clause 501.8.8.1

In the last sentence replace 1000m with all leads and


lifts.

Clause 501.8.8.2

Sub para (i) of this clause stands deleted and remaining


sub paras (ii) to (xi) are renumbered as (i) to (x)

Clause 502

Prime Coat Over Granular Base

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Clause 502.1

ORR/JICA2/Pkg 2/Vol II

Scope
The clause shall be read as under:
The work shall consist of the application of single coat of
low viscosity Bitumen Emulsion @ 0.6Kg to 0.9Kg per
square metre to a granular surface preparatory to the
superimposition of bituminous treatment or mix.

Clause 502.2.3

Choice of primer
This Clause shall be read as under:
"Primer: The primer used for prime coat shall be bitumen
emulsion complying with IS: 8887 and CSS I Grade
conforming to ASTM D 2397/ AASHTO M 140, and shall be
refinery produced. The particular grade to be used for the
work shall be got approved by the Engineer.

Clause 502.8

Delete the second sentence from the paragraph as under:


Payment shall be........................... in Clause 502.4.3.

CLAUSE 503

TACK COAT

Clause 503.2

Materials
This Clause shall be read as under:
"Binder: The binder used for tack coat shall be bitumen
emulsion complying with IS: 8887 and CSS I Grade
conforming to ASTM D 2397/AASHTO M 140, and shall be
refinery produced. The particular grade to be used for the
work shall be got approved by the Engineer.

Clause 503.8

Replace The rate shall cover..accordingly by


The rate for tack coat shall cover provision of bituminous
emulsion @ 0.275 kg per sqm for primed granular surface
and @ 0.225 kg per sqm for bituminous surface.

Clause 504

BITUMINOUS MACADAM

Clause 504.2

Materials

Clause 504.2.1

Bitumen
This Clause shall be read as under:
The Base binder shall be paving bitumen of penetration
grade 60/70 as per Indian Standard Specification for
Paving Bitumen IS: 73.

Clause 504.2.2

Coarse Aggregates
The first sentence of paragraph 1 shall read as:

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The coarse aggregates shall consist of crushed rock and


shall be obtained through the use of Cone crusher, Vertical
Shaft Impactor and vibratory screens of suitable capacity.
The third paragraph of this Clause shall be deleted
Clause 504.2.3

Fine Aggregates
Delete or naturally occurring material, or a combination of
the two.

Clause 504.2.5

Proportioning of materials
Add below Table 500-4 of Clause 504.2.5 as under:
Grading-I shall be used for compacted thickness of a layer
of 75 mm and above while Grading-2 shall be used for
compacted thickness of a layer of less than 75 mm
thickness.

Clause 504.8

Rate
Add the words except for the item of tack coat after the
words required operations in second line.
The item (viii) of Clause 501.8.8.2 shall be substituted as
under for BM.
The rate shall include any variation in the bitumen content
in excess of percentage by weight of bituminous mix given
in Table 500-4 and no adjustment on this account shall be
admissible.

Clause 507

DENSE BITUMINOUS MACADAM

Clause 507.2

Materials

Clause 507.2.1

Bitumen
This Clause shall be read as under:
The Base binder shall be paving bitumen of penetration
grade 60/70 as per Indian Standard Specification for
Paving Bitumen IS: 73.

Clause 507.2.2

Coarse Aggregates
Delete the words crushed gravel or other hard material
from the first sentence of 1st para of this clause.
Delete Para 2 of this clause.
From the Table 500-8, replace at the bottom of the table
against asterisk Aggregate may .. two tests
as under:

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Aggregate should satisfy both the tests (i) Los Angeles


Abrasion Value and (ii) Aggregate Impact Value
Sub-Clause 507.2.3

Delete the words or naturally occurring mineral material, or


a combination of the two appearing in the first sentence of
the clause.

Sub-Clause 507.2.4

The first sentence of this clause shall read as Filler shall


consist of finely divided hydrated lime or cement as
approved by the Engineer.

Clause 507.2.5

Aggregates grading and binder content


Add following between first and second sentence:
Grading-I shall be used for compacted thickness of a layer
of 75 mm and above while Grading-2 shall be used for
compacted thickness of a layer of less than 75 mm
thickness. The Contractor shall give job mix formula for the
mix design indicating mix properties. The laying of mix shall
be done after approval of the Engineer.
Read 65 instead of 65 or 90 for Bitumen grade in Table
500-10.
Read Modified Marshall method in place of Marshall
method in the Note: 2 of Table 500-10.

Clause 507.3

Mixture Design

Sub-Clause 507.3.1

Requirement for the Mixture


Add the following requirements to the list of Table 500-11:

Clause 507.3.2

Water sensitivity (ASTM D1075): Retained stability


(Ratio of Marshal Stability for 24 hour Immersion and
30 min Immersion in water at 60 degree centigrade
temperature) = not less than 75 %
Stability to flow ratio = 205 to 410
Filler- Bitumen ratio = 0.6 to 1.2

Binder content
Delete Marshall method and replace with Modified
Marshall method in the 3rd line of first paragraph.
Replace the second paragraph by the following paragraph:
The modified Marshall method described in Asphalt
Institute Manual MS-2 requires modified equipment and
procedures; particularly the minimum stability value in
Table 500-11 shall be multiplied by 2.25, and the minimum
flow shall be 3mm.

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Clause 507.3.3

ORR/JICA2/Pkg 2/Vol II

Job mix formula


Insert the following paragraph between existing paragraph
3 & 4:
Mix design shall be carried out in accordance with the
modified Marshall method described in Asphalt Institute
Manual MS-2.

Clause 507.4.9

Rolling
Add after the last paragraph:
Rolling shall be continued till the density achieved is at
least 98% of the Marshall Density.

Clause 507.9

Rate
This Sub-Clause shall be substituted as under:
The Contract unit rate for Dense Bituminous Macadam
shall be payment in full for carrying out the required
operations except for the item of tack coat including full
compensation for all components listed in Clause 501.8.8.2
(i) to (xi) except (viii).
The item (viii) of Clause 501.8.8.2 shall be substituted as
under for DBM.
The rate shall include any variation in the bitumen content
in excess of 4.5 percent by weight of bituminous mix and
no adjustment on this account shall be admissible.

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CLAUSE 508

SEMI-DENSE BITUMINOUS CONCRETE

Clause 508.1

Scope
The last sentence of this Clause shall read as:
A single layer shall be 25mm to 40mm in thickness.

Clause 508.2.1

Bitumen
This Clause shall be read as under:
The Base binder shall be paving bitumen of penetration
grade 60/70 as per Indian Standard Specification for
Paving Bitumen IS: 73.

Clause 508.2.5

Aggregate grading and binder content


This Sub clause shall be read under:
When tested in accordance with IS: 2386 Part I (Wet
sieving method), the combined grading of the coarse and
fine aggregates and added filler shall fall within the limits
shown in Table 500-15 for grading 2.

Clause 508.4.8

Add after the last sentence


Rolling shall be continued till the density achieved is
atleast 98% of the Marshall Density.

Clause 508.9

Rate
This Sub-Clause shall be substituted as under:
The Contract unit rate for Semi-Dense Bituminous
Macadam shall be payment in full for carrying out the
required operations except for the item of tack coat
including full compensation for all components listed in
Clause 501.8.8.2 (i) to (xi).
The item (viii) of Clause 501.8.8.2 shall be substituted as
under for SDBC.
The rate shall include any variation in the bitumen content
in excess of 5% by weight of bituminous mix and no
adjustment on this account shall be admissible.

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CLAUSE 509

BITUMINOUS CONCRETE

Clause 509.1

Scope
The last sentence of this Clause shall read as:
A single layer shall be 25mm to 65mm in thickness.

Clause 509.2.1

Bitumen
This Clause shall be read as under:
The Base binder shall be paving bitumen of penetration
grade 60/70 as per Indian Standard Specification for
Paving Bitumen IS: 73. Modified Bitumen confirming to
IRC SP-53-2002 shall be used which is compatible with
the base binder and which allows the properties given in
Clause 521 to be achieved. The modifier, in the required
quantity shall be blended at the refinery / centralised plant
capable of producing modified binder as approved by the
Engineer. Technical specification clause 521 for modified
binder and IRC: SP-53-2002 shall be referred to.

Clause 509.2.4

The clause shall be read as under


Filler 2% by weight of mix shall consist of finely divided
cement / hydrated lime as approved by Engineer.

Clause 509.2.5

Aggregate Gradation
This Sub Clause shall be read under:
When tested in accordance with IS: 2386 Part I (Wet
grading method), the combined grading of the coarse and
fine aggregates shall fall within the limits shown in Table
500-18 for grading - I.
The grading of the aggregate mix as used in the work shall
be a smooth curve within the envelope in Table 500-18.

Clause 509.3

Mixture Design

Sub Clause 509.3.1

Requirements the Mixture Design


Add the following requirements to the list of Table 500-19:

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Clause 509.4.8

ORR/JICA2/Pkg 2/Vol II

Water sensitivity (ASTM D1075): Retained stability


(Ratio of Marshal Stability for 24 h Immersion and
30min Immersion in water at 60 degree centigrade
temperature) = not less than 75 %
Swell Test (Asphalt Institute, MS-2, No.2), maximum =
1.5%

Spreading
This Clause shall be read as under:
The provisions of Sub-Clauses 501.6, 501.7 and 507.4.9
shall apply, as modified by the approved laying trials.

Clause 509.9

Rate
This Sub-Clause shall be substituted as under.
The Contract unit rate for bituminous concrete shall be
payment in full for carrying out the required operations
except for the item of tack coat including full compensation
for all components listed in Clause 501.8.8.2(i) to (xi)
The item (viii) of Clause 501.8.8.2 shall be substituted as
under for BC.
The rate shall include any variation in the bitumen content
in excess of 5.0 percent by weight of bituminous mix and
no adjustment on this account shall be admissible.

Clause 521

MODIFIED BINDER

Clause 521.2.2

Modifier
The last sentence of this Clause shall read as:
The modifier shall be compatible with the base binder and
which allows properties given in clause 521.3 to be
achieved. The modifier in the required quantity shall be
blended at the refinery/centralised plant capable of
producing modified binder as approved by the Engineer.

Clause 521.6

Measurement for Payment


Replace the Sub-Clause with the following:

SECTION 600

Modified binder supplied in the contract shall not be


measured separately. The cost of modifier used in
Bituminous works shall deemed to be included in the
particular item of the works.
CONCRETE PAVEMENT

CLAUSE 601

DRY LEAN CEMENT CONCRETE SUB-BASE

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Clause 601.2

Materials

Clause 601.2.1

This Clause shall read as follows


Source of Materials
Provisions of Clause 1002 of these specifications shall
apply to sources of material

Clause 601.2.2

Cement
The clause shall read as follows:
"Any of the following type of cements, capable of achieving
the Design strength may be used with the prior approval of
the Engineer, but preference shall be to use 43 grade.
1.Portland cement 33 grade conforming to IS: 269
2.Portland cement 43 grade conforming to IS: 8112
If the soil around has soluble sulphates exceeding 0.5% the
cement used shall be sulphate resistant and conform to IS:
12330.

Clause 601.2.4

Water
This item shall read as under:
Water used for mixing and curing concrete shall conform
to Clause 1010 of Section 1000.

Clause 601.5

Construction

Clause 601.5.4

Placing
Add in the beginning of Clause 601.5.4:
One day before placing of the dry lean cement concrete
sub-base, the surface of the drainage layer shall be given a
fine spray of water and rolled with a smooth wheeled roller
after a lapse of 2-3 hours after watering. The Engineer
may instruct another fine spray of water to be applied just
before placing of the dry lean cement concrete sub-base.

Clause 601.5.7

Curing
Add the following in last.
Method a shall be adopted.

CLAUSE 602

CEMENT CONCRETE PAVEMENT

Clause 602.1

Scope
Add the following at the end of this Clause:

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A site trial shall be performed in accordance with Clause


901.16.
Clause 602.2

Materials

Clause 602.2.2

Cement
Replace the last para of Clause 602.2.2 with:
It is the responsibility of the Contractor to test and propose
the type of cement which will result in a concrete complying
in all respects with the specifications.

Clause 602.2.4.2

Coarse Aggregate
Add following para at the end of clause:
The Stone Polishing Value, as measured by BS: 812 (Part
114), shall not be less than 55.

Clause 602.2.4.3

Fine Aggregate
Add the following at the end of this Clause:
The fine aggregates shall be natural sand conforming to
the grading Zone-II as per IS: 383.
Add the following as Clause 602.2.4.4

Clause 602.2.4.4

Combined All-In Aggregate


The grading limits for all-in aggregates shall be as per IS:
383 for 20mm nominal size aggregates and as given under:
IS Sieve Designation
40mm
20mm
4.75mm
600 micron
150 micron

Sub-Clause 602.2.5

Percentage Passing
100
95-100
30-50
10-35
0-6

Water
This clause shall read as under:
Water used for mixing and curing shall conform to Clause
1010 of Section 1000.
Water for preparation of concrete during hot weather shall
be from water chilling plant installed at site.

Sub-Clause 602.2.7

Premoulded Joint Filler


Replace Clause 602.2.7 with:

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Joint filler board for expansion joints shall be of the same


thickness as the specified joint width within a tolerance of
+ 1.5mm and shall comply with the requirements of IS:
1838 or BS Specification No.2630. The filler for each joint
shall be furnished in a single piece for the full depth and
width required for the joint. Holes to accommodate dowel
bars shall be accurately bored or punched to give a sliding
fit on the dowel bars.
Sub-Clause 602.2.8

Joint Sealing Compound


Replace Clause 602.2.8 with:
The joint sealing compound shall be hot applied
elastomeric type, complying with AASHTO M282 for joints
in asphalt pavements or joints between asphalt and
concrete pavements, and cold applied polyurethane or
polysulphide type complying with BS: 5212 1990 for joints
in concrete pavements.
The joint sealant shall be resistant to age hardening and
shall have flexibility to accommodate movements of
minimum 25% of the joint width as shown in the drawings
without risk of breaking of the sealant or adherence failure.
The dimensions shall be so proportioned; that the
adherence to the groove walls is fully intact within the
movements limits.
Suitable primers as recommended by the manufacturers of
each type of joint sealant shall be used.
Each lot or batch of joint sealant compound and primer
shall be delivered to the job-site in the manufacturer's
original sealed container. Each container shall be marked
with the manufacturer's name, batch or lot number, date of
manufacturer, storage life, safe heating temperature for hot
applied sealant, and shall be accompanied by the
manufacturer's certification stating that the compound
meets the requirements of these specifications.
The manufacturer's health and safety precautions shall be
available at the job- site for each joint sealing compound
and primer and it is the responsibility of the Contractor to
ensure that all precautions are met.

Clause 602.3

Proportioning of Concrete

Clause 602.3.3

Concrete Strength

Clause 602.3.3.1

Replace the entire Clause 602.3.3.1 with:


The pavement concrete shall be a class M-40 concrete
with a minimum 28 days compressive characteristic
strength of 40 MPa and a minimum flexural characteristic

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strengths of 4.5 MPa.


While designing the mix in the laboratory, correlation
between flexural and compressive strengths of concrete
shall be established on the basis of at least thirty tests on
samples. However, quality control in the field shall be
exercised on the basis of flexural strength. It may,
however, be ensured that the materials and mix proportions
remain substantially unaltered during the daily concrete
production. The water content shall be the minimum
required to provide the agreed workability for full
compaction of the concrete to the required density as
determined by the trial mixes or other means approved by
the Engineer and the maximum free water cement ratio
shall be 0.45.
Clause 602.3.3.2

Replace the entire Clause 602.3.3.2 with:


The ratio between the 7 and 28 days strength shall be
established based on the results of the design mix trials,
refer Clause 602.3.5.1. The average flexural strength of the
7 days cured specimens shall be divided by the average
strength of the 28 days cured specimens for each batch,
and the ratio between 7 days and 28 days flexural strength
R7 shall be determined to an accuracy of three decimal
places.
If, during the construction of the trial length or during
normal working, the average value of any six consecutive 7
days test results divided by R7 falls below 4.50+1.65Xs
MPa, (where s is the standard deviation of the group) then
the Contractor shall stop paving and propose for the
approval of the Engineer corrections to the mix to improve
the flexural strength. The Contractor shall provide
evidence, that the proposed corrections result in the
required flexural strength before paving operations may be
resumed by producing minimum six beams with the
proposed corrected mix and testing these for 7 days
flexural strength. No additional payment will be made for
any changes to the mix."

Clause 602.3.5

Design Mix
Add the following at the end of sub-clause 602.3.5.1
Following parameters shall be used
i)
i)
ii)
iii)

Clause 602.5

Characteristics flextural strength at 28 days = 4.5 Mpa


Target mean strength at 28 days = 5.80 Mpa
Water cement ratio = 0.45 maximum
Slump as per IS:1199 = 31+15 mm.

Separation Membrane
Replace the sub clause with the following:

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A separation membrane shall be used between the


concrete slab and the sub-base. Separation membrane
shall be impermeable plastic sheet 125 microns thick laid
flat without creases. It shall be white in colour 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 300mm and any
damaged sheeting shall be replaced at the Contractors
expense. The separation membrane may be nailed to the
lower layer with concrete nails.
Clause 602.6

Joints

Clause 602.6.2

Transverse Joints

Clause 602.6.2.1

Replace the first para as follows:


"Transverse joints shall be 'contraction and expansion
joints. Contraction joints shall be provided at 4.5 m
intervals, except where expansion joints are provided.
Expansion joints shall be provided at the junction of the
approach slabs of bridges and the rigid pavement.
Furthermore, transverse joints shall be provided at special
locations like transitions to structures, transition to flexible
pavements, off carriageway areas as shown on the
drawings. The exact position of transverse joints shall be
coordinated with adjoining construction packages and shall
be proposed by the Contractor in writing for the approval of
the Engineer. Transverse joints shall be straight within the
following tolerances along the intended line, which is the
straight line perpendicular to the longitudinal axis of the
carriageway at the position of the joint."

Clause 602.6.2.2

Contraction Joints
Replace the entire Clause 602.6.2.2 with
"Contraction joints shall be as shown in the drawings.
The crack inducing joint groove, as indicated in the drawing
and to 1/3 depth of the slab shall be cut as soon as the
concrete is hard enough to take the load of the joint sawing
machine without causing damages to the slab. The
Contractor shall furnish a method statement, which
describes his proposed methods for determination of the
time period available for sawing the crack inducing joint
grooves together with the capacity and number of sawing
machines for the approval of the Engineer. The, method
statement shall include establishment of maturity-strength
relationships in the laboratory and measurement of the insitu maturity of the concrete by maturity meters (COMAMeter by Germann Instruments A/S or similar) or other
internationally recognized methods."

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Sub-Clause 602.6.2.3

ORR/JICA2/Pkg 2/Vol II

Expansion Joint
Add new para at the end of this sub-clause :
Joints at the junction of rigid and flexible pavements:
Joints shall be provided at the junctions of rigid and flexible
pavement with transition slab as shown in drawings. Where
due to unavoidable reasons, the joints cannot be
constructed at the junction of the two contract packages
dowel bars shall be provided in the rigid pavement and
other measures as directed by the Engineer taken. Joints
between bituminous pavement and concrete pavements (at
locations other than junction between contract packages)
shall be constructed.

Sub-Clause 602.7.2

Concreting in Hot Weather


Add to the first para :
"If the concrete temperature exceeds 70C during
hardening, the Contractor shall -at his own expense -prove
to the Engineer that durability parameters are unaltered (for
example micro cracking, compressive strength of sawn
cylinders or other as agreed with the Engineer).

Sub-Clause 602.9

Construction

Sub-Clause 602.9.1

General
Add new para at the end of Clause 602.9.1 as follows:
"Paving shall be carried out in full carriageway width,
Including paved shoulders, where required. The paver
should run at least at an average -uniform speed of 1 m per
minute".

Sub-Clause 602.9.3.2

Batching Plant and Equipment


Add at the end of the Clause:
"Batching Plant should have output capacity at least 20%
more than output required to meet the paving speed of 1m
per minute. The Contractor shall not use more than two
plants to meet the daily output requirement of concrete.
The batching plant should have suitable devices for
adjusting the slump of the mix and should have facility for
the computer printouts of every batch produced".

Sub-Clause 602.9.4.1

Insert in the ninth line after uniform speed of at least 1 m


per minute".

Sub-Clause 602.9.4.7

The new para to Clause 602.9.4.7 as follows:


The marking shall be located on the horizontal surface at

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the edge of the paved shoulder and shall be carried out


using prefabricated template figures approximately 80mm
high and 5mm thick as approved by the Engineer. The
figures shall be fixed to a plate which shall be inserted
approximately 2mm into the plastic concrete by vibration
and left in place until the concrete has hardened.
Sub-Clause 602.9.8

Surface Texture
Replace the sub-clause with the following:
Surface texturing/mechanical tining of concrete pavement
shall begin immediately after finishing of the concrete
before application of curing membrane. Texturing/Tining
shall be done with a specified machine specially designed
for the purpose for providing grooves at an uniform spacing
(c/c) of 18mm to 21mm, depth (3mm to 4mm) and width
(3mm), parallel to the centre line of roadway extending over
the entire roadway width but within 75 mm of pavement
edge & omitting within +/- 20mm of the sawed longitudinal
joints.

Sub-Clause 602.10

Trial Length

Sub-Clause 602.10.2

Add new para to Clause 602.10.2 as follows:


"All trials shall be carried out using the same paving width
and slab thickness as ~used in the permanent works."

Sub-Clause 602.10.4

Replace the entire Clause 602.10.4 with:


Transverse joints and longitudinal joints of each type that
are to be included in the pavement work shall be
constructed and assessed in the trial length.

Sub-Clause 602.10.5.3

Density
Replace the entire Clause 602.10.5.3 with:
"(v)

Sub-Clause 602.10.5.5

In-situ density shall be assessed as described in


Clause 903.5.2.2 from at least 3 cores drilled when
the concrete is not less than 7 days old. Should any of
the cores show honey-combing in the concrete, the
trial length shall be rejected and further use of the
spreading and compacting unit shall not be permitted
until further trials have shown that modification can be
made which will result in adequate compaction."

Strength
Add new clause as under:
"Minimum of thirty (30) beams for flexural strength and
thirty (30) cubes for compressive strength shall be prepared
from the concrete delivered to the paving plant. Each pair

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of beams and cubes shall be from a different batch of


concrete. Compressive and flexural strength shall be tested
after 28 days curing.
At the age of 28 days thirty (30) cores with diameter 150
mm shall be saw cut from the slab. The cores shall be saw
cut in both ends to provide a specimen height of 300 mm +
5 mm and shall be tested for compressive strength at the
age of 28 days.
The concrete strength shall be deemed satisfactory if:
the average flexural strength exceeds 4.50 + 1.65*s (MPa),
where s is the standard deviation of the thirty tests, and the
strength of any sample is not less than characteristic
strength less 1.65 times standard deviation.
the average compressive strength of the cores divided by
0.8 is equal to or exceeds the average compressive
strength of the thirty cubes.
Sub-Clause 602.10.5.6

Temperature Measurements
Add new clause as under :
The temperature development in the concrete slab during
hardening shall be recorded. The temperature shall be
measured in the middle of the slab (vertically) at a
horizontal distance of at least 1000 mm from any free edge.
The temperature shall be recorded every 3 hours after
instalment of the thermometer and the temperature-age
relationship shall be determined. The maximum recorded
temperature shall not exceed 70C. If the temperature
exceeds 70C the trial length shall be condemned and the
Contractor shall propose methods to reduce the
temperature development and carry out a new trial length
at his own expense.

Sub-Clause 602.11

Preparation and Sealing of Joint Grooves

Sub-Clause 602.11.3

Sealing with Sealant

Sub-Clause 602.11.3.1

Replace first sentence with:


"Prior to application of the sealant the primer recommended
by the manufacturer shall be applied."

Clause 602.11.3.3

Replace the entire Clause 602.11.3.3 with:


Sealant complying with Clause 602.2.8 shall be used. Cold
applied sealant shall be mixed and applied within the time
limit specified by the manufacturer. Primers shall be
applied neatly with an appropriate brush or as
recommended by the manufacturer.

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Sub-Clause 602.11.4

ORR/JICA2/Pkg 2/Vol II

Testing of applied Sealant


Replace the entire Clause 602.11.4 with:
"Each delivery of joint sealant compound and primer shall
be tested in accordance with AASHTO M282 for hot
applied joint sealant and BS : 5212: Part 2 for cold applied
sealant at a recognised independent laboratory. In case
deliveries are made more frequent than every three
months, testing may be reduced to every three months.
The laboratory shall be approved by the Engineer in
advance."

Sub-Clause 602.13

Opening to Traffic
Replace the entire Clause 602.13 with:
"No vehicular traffic (including the Contractor's vehicles)
shall be allowed on the finished surface until a field flexural
strength of minimum 4.50 MPa has been achieved. It is the
responsibility of the Contractor to produce a sufficient
number of series of test specimens to verify the field
flexural strength.
Each series of test specimens for measurement of field
flexural strength shall consists of minimum 3 test
specimens. The specimens shall be cured at conditions
similar to the field conditions. The method for curing and
storing of the test specimens in order to imitate field
conditions shall be proposed by the Contractor and
approved by the Engineer. The required minimum field
flexural strength of 4.50 MPa is achieved when the average
flexural strength of minimum 3 specimens exceeds 4.50 +
1.65*s, where s is the standard deviation of the group.
Prior to opening to traffic the joints shall be sealed and
areas adjacent to the pavement shall be completed to a
degree that will ensure traffic safety. Opening to traffic shall
not constitute a final acceptance of the pavement."

SECTION 800

TRAFFIC SIGNS, MARKINGS & OTHER ROAD


APPURTENANCES

Clause 801

TRAFFIC SIGNS

Clause 801.1.2

This Clause shall read as follows:


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

Clause 801.2.6

This Clause shall read as follows:

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The aluminum sheets used for signs shall be 2mm thick.

Clause 801.3

Traffic Signs having Retro-reflective Sheetings

Clause 801.3.1

General Requirements
The fifth sentence of this clause should read as under:
The reflective sheeting shall be of High Intensity grade with
encapsulated lens.
Delete last sentence of this clause.

Clause 801.3.6

This clause shall read as under:


Cut-out messages and borders, wherever used, shall be
made out of retro-reflective sheeting as per Clause 801.3.2,
except those in black which shall be of non-reflective
sheeting.

Clause 801.3.7

Add the following at the end of this clause:


All the facility information and place identification signs shall
have Blue (Indian Standard Colour No. 166: French Blue)
background and white letters.

Clause 801.3.11

Warranty and Durability


The first and second sentences of this clause shall read as
under:
The Contractor shall obtain from the manufacturer a sevenyear warranty for satisfactory field performance including
stipulated retro-reflectance of the retro-reflective sheeting of
high intensity grade and submit the same to the Engineer. In
addition, a seven year warranty for satisfactory in-field
performance of the finished sign with retro-reflective
sheeting of high intensity grade, inclusive of the screen
printed or cut-out letters/legends and their bonding to the
retro-reflective sheeting shall be obtained from the
Contractor/Supplier and passed on to the Engineer.

Clause 801.4.1

The third and fourth sentences of this clause shall read as


follows:
Signposts shall be of MS pipe 80mm dia (NB-MW) or as
shown in the drawings. Post shall be embedded in concrete
(M-15) for safeguard against theft. The cost of signpost and
its foundation complete including excavation & concrete shall
be deemed to be included in the rate of signboard.

Clause 801.4.2

Add following at the end of this clause:


The sign back shall be painted with two coats of grey colour
epoxy paint. The signpost shall be painted in black & white

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alternate bands with two coats of epoxy paint.


CLAUSE 802

OVERHEAD SIGNS

Clause 802.5

Materials

Clause 802.5.3

Replace 1.5mm with 2.0mm in the last sentence

Clause 802.5.6

This Clause shall be read as under:


All road signs shall be of retro-reflectorised type and made
of high intensity grade with encapsulated lens type
reflective sheeting vide Clause 801.3, fixed over aluminium
sheeting as per these specifications.

Clause 802.9

Rates
This clause shall read as under:
The contract unit rate shall include
1.

Full compensation for the cost of structure including


furnishing all
labour, materials, tools, equipment,
excavation, fabrication, installation, painting and all
other incidental costs necessary to complete the work
as given in the drawings and as approved by Engineer.
Modifications in the structural dimensions and
foundation details as required by site conditions shall be
deemed to be incidental to the work of overhead signs.

2. Full compensation for providing retro reflective sheeting


of the specified size conforming to Clause 801 including
the cost of screen printing of message and fixing the
reflective sheeting to the overhead structure as shown
in drawings and as approved by Engineer.

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CLAUSE 803

ROAD MARKINGS

Clause 803.2

Materials
This Clause shall read as under:
Road markings shall be hot applied thermoplastic compound
and the materials shall meet the requirements as specified in
Clause 803.4.
The road markings shall be laid in one layer with appropriate
road marking machine approved by the Engineer. Before the
road-marking machine is used on the permanent works, the
satisfactory working of the machine shall be demonstrated on
a suitable site which is not part of the permanent works. The
rate of application shall be checked and adjusted as
necessary before application on a large scale is commenced,
and thereafter everyday it is applied.

Clause 803.3

Ordinary Road Marking Paint


This Clause shall be deleted.

Clause 803.5

Reflectorised Paint
This Clause shall be deleted.

Clause 803.6

Application

Clause 803.6.1

Delete first and second sentences of this clause and add


The road markings shall be laid with appropriate road
marking machinery as approved by the Engineer.

Add the following new Sub-Clause at the end.


Clause 803.6.6

Tolerances
i)

General

Road traffic markings shall be constructed to accuracy within


the tolerances given below:

The width of lines and other markings shall not deviate


from the specified width by more than 5%.
The position of lines, letters, figures, arrows and other
markings shall not deviate from the true position
specified by more than 20 mm.
The alignment of any edge of a longitudinal line shall not
deviate from the true alignment by more than 10 mm in
15 m.
The length of segments of broken longitudinal lines shall
not deviate from the specified length by more than 150
mm.

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In broken lines, the length of segments and the gap between


segments shall be as indicated on the Drawings. If these
lengths are altered by the Engineer, the ratio of the lengths of
the painted sections shall remain the same.
Line and curves, whether broken or unbroken, shall not
consist of chords but shall follow the correct radius.
ii) Faulty Workmanship or Materials:
If any material not complying with the requirements is
delivered at the Site or used in the Works, or if any substandard work is carried out, such material or work shall be
removed, replaced or repaired as required by the Engineer,
at the Contractors own cost. Rejected traffic markings and
paint that has been splashed or has dripped onto the
surfacing, kerbs, structures or other such surfaces shall be
removed by the Contractor at his own cost, in such a way that
the markings of split paint will not show up again later.
CLAUSE 805

ROAD DELINEATORS

Clause 805.2

This clause shall read as follows:


(a)

Triangular Object Marker shall be 300mm side with


four red reflector, made out of 2mm thick aluminum
sheet, face to be fully covered by high intensity grade
white retro reflective sheeting of encapsulated lens
type as per clause 801. The background/ border/
symbols shall be made by screen-printing of desired
colour as per sign details. The sign plate shall be fixed
with 6mm dia. aluminium rivets on MS angle iron
frame. The angle iron frame shall be made with angle
of size 40mmx40mmx5mm. The sign shall be fixed with
nut-bolts & welding on MS pipe 50mm dia (NB-MW)
and 500mm high or as shown in the drawings.

(b)

Rectangular hazard marker 600mm x 300mm made


out of 2mm thick aluminum sheet, face to be fully
covered by high intensity grade white retro reflective
sheeting of encapsulated lens type. The background/
border/ symbols shall be made by screen-printing of
desired colour as per sign details. The sign plate shall
be fixed with 6mm dia aluminium rivets on MS angle
iron frame. The angle iron frame shall be made with
angle of size 40mmx40mmx5mm. The sign shall be
fixed to 80mm dia (NB-MW) MS pipe or as shown in
the drawings.

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(c)

Roadway Indicators shall be 1000mm high made with


100 mm dia. NB medium weight MS pipe. One reflector
of high intensity grade retro reflective sheeting with
encapsulated lens shall be provided on top of the
reflector. The white & red reflector shall be provided
alternatively of 40mm width, so that total width of
reflector shall be 150mm. A wire mesh cover of 150mm
height shall be provided on top or as shown in the
drawings.

(d)

All components of sign and supports shall be


thoroughly descaled, cleaned, primed and painted with
two coats of epoxy paint. The sign backside shall be
with grey colour and post shall be white
colour/alternate white & black bands. The post below
ground shall be painted with three coats of red lead.

CLAUSE 809

CONCRETE CRASH BARRIER

Clause 809.2.2

This clause shall be read as below :


The concrete barrier shall be constructed with grade and
concrete as indicated in the drawing and with thermo
mechanically treated (TMT) deformed bars of grade S 415
conforming to IS-1786.

Clause 809.3.2

Add and culverts after the word bridges in the first


sentence.

CLAUSE 810

METAL BEAM CRASH BARRIER

Clause 810.1.2

Replace this clause by The design, materials to be used


and the location for Metal beam crash barrier shall conform
to relevant drawings or as directed by Engineer

Clause 810.2

Materials

Clause 810.2.1

This Clause shall be read as under:


Metal beam is a W profiled corrugated beam as specified
in drawings made out of cold roll forming from steel strip of
3.0mm thick using high strength steel of IS: 5986 Fe 510
grade with hot dip galvanised 550 gm per square meter.
The beam after forming shall have formed width of 312 mm
and depth of 83 mm and shall have punched holes for
fixing as specified in drawings.
The metal crash barrier posts and spacer shall consist of
C channel section made out of 5 mm thick sheet by cold
roll forming process of steel conforming to IS: 5986 Fe360
grade with hot dip galvanised 550 gm per square meter .
All bolt nuts and washers as specified in drawings shall
conform to IS: 1367 & IS: 1364 unless otherwise specified

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and are hot dip galvanised 550 gm per square meter.


The Guard rail reflector shall be made of material and
placed in position as shown in drawings. The body of it
shall be hot dip galvanized 550 gm per square meter.
Beams to be erected on a radius of 50 m or less shall be
shop curved to the appropriate curvature of the installation.
The mechanical properties of the base metal for Beam shall
conform to the following requirements:
a)
b)
c)

Ultimate Tensile Strength (Min.)


Yield stress (Min.)
Elongation (Min.) in 50mm

483 Mpa.
345 Mpa.
12%

Test specimens for mechanical properties and coating shall


be prepared and tested as specified in relevant IS codes.
Clause 810.2.3

Add at the end of this Clause:


The size of the concrete foundation block for embedding
the posts and grade of concrete shall be as shown on the
drawing.

Clause 810.4

Installation of Posts
The sub-clause 810.4.1, 810.4.2, 801.4.3 and 810.4.4 are
replaced as below:
The guard posts shall be embedded in the concrete footing
of size and the grade of concrete along with the depth of
the embedment of post or as indicated in the drawing.

Clause 810.4.5

Add and end section in the first line after posts.

Clause 810.5.3

Add at the end of Para 1: The guard rail reflector shall be


bolted replacing splice washer at the interval as indicated in
the drawing or as directed by the Engineer.

Clause 810.7

Measurement for Payment

Clause 810.7.1

The 2nd sentence Terminals ..for by numbers shall


be deleted.

Clause 810.7.2

The first sentence of this clause shall be substituted as


below:
No separate measurement for payment shall be made for
Terminals / Anchors of various types required for the work
and the replacement washers for fixing Guard Rail
Reflectors as specified in the drawing. The cost of these
elements shall be deemed to be included in the rate quoted
by the contractor.

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Clause 810.7.3

The words or backfilling shall be substituted as and


concreting

Clause 810.8

Rates
Add and drawings at the end of last sentence of Clause.

CLAUSE 815

Solar powered road safety signals with LED modules


for U turn/ Keep Left / Pedestrian crossing /
Intersection
Signal panel:
Material

: Glass Fibre Reinforced


Polyester conforming to
DIN 16911 type 834-834.5

Protection class

: IP 66 (EN 60 529)

Impact Resistance

: > 7 Nm (EN 50 014)

Flammability

: Self extinguishing (UL 94


V0)

Protective Insulation

: Fully Insulated ( VDE 0100)

Seal Polyurethane Foam

: - 40 C to + 100 C, Endless

Dielectric Strength

: > 10 Kv /mm.

Water absorption

: Max. 0.7% (ASTM D 570)

Toxicity

: Halogen free

Surface

: > 10 12 ohm (DIN 53482)

Dimensions
mm.

: 600 mm x 420 mm x 220

Number and arrangement of LEDs: To be got approved


by engineer
Pole : Galvanised pole with corrosive resistant paint with
alternate black and white stripes. Pole to withstand wind
load.
Solar Panel : 30 Wp (U Turn) / 20 Wp (Keep Left) / 50
WP (Pedestrian Crossing) / 15 Wp (Intersection)
Wattage
: 84 watt (U Turn) / 54 watt (Keep Left) / 132
watt (Pedestrian Crossing) / 36 watt (Intersection)
Foundations

: As required

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Warranty Requirements in favour of HGCL


1. LEDs

: 10,000 hrs

2. Battery (SMF Lead Acid)

: 5 years

3. Solar Panel

: 15 years

4. Other accessories

: The supplier should


give an undertaking to
change any other
damaged part within
48 hours of intimation.

Measurement for Payments:


Unit: The unit of measurement shall be in Numbers
Rate: The unit cost of signals is inclusive supply and
erection of signals with all the equipment and full
compensation for labour and material including meeting the
warranty requirements. 50 % of cost is payable after trial
run of 1 week and the balance after 6 months.

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CLAUSE 900

QUALITY CONTROL FOR ROAD WORKS

Clause 901

General

Clause 901.1

This Clause shall read as under:


All materials to be used, all methods adopted and all works
performed shall be strictly in accordance with the
requirements of these Specifications. The Contractor shall
set up a field laboratory at locations approved by the
Engineer and equip the same with adequate equipment and
personnel in order to carry out all required tests and Quality
Control work as per Specifications and/or as per Clause 121
and/or as directed by the Engineer. The list of laboratory
equipment and the facilities to be provided shall be as per
Clause 121 and shall be approved by the Engineer in
advance.

Clause 901.5

This Clause shall be read as under:


The Contractor shall provide necessary co-operation and
assistance in obtaining the samples for tests and carrying
out the field tests as required by the Engineer from time to
time. This may include provision of laboratory, equipment,
transport, consumables, personnel, including labour,
attendants, assistance in packing and despatching and any
other assistance considered necessary in connection with
the tests.

CLAUSE 902

CONTROL OF ALIGNMENT, LEVEL AND SURFACE


REGULARITY

Clause 902.3

Surface Levels
Add and or thickness after the word levels in the 1st line
of the first paragraph.
Add at the end of first sentence or as desired by the
Engineer in the last paragraph.
Add the following sentence at the last: Towed fifth wheel
Bump Integrator Test is to be conducted on the Bituminous
surfaces to evaluate the surface regularity. Results are to
be taken on Electronic Graph. In Each lane, at four locations
longitudinally, in uni-direction, this bump integrator test is to
be done.

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CLAUSE 903

QUALITY CONTROL TESTS DURING CONSTRUCTION

Clause 903.4

Tests on Bituminous Constructions


Add at the end of this Clause:
The density test shall be carried out by 100 mm diameter
core cutter machine on Dense Bituminous Macadam and
Bituminous Concrete as per the frequency specified.
In Table 900-4, Serial No. 6 for Dense Graded Bituminous
Macadam/ Semi Dense Bituminous Concrete/Bituminous
Concrete, modify the Frequency (Minimum) values for Item
No. (vii), (ix) and (xviii) as under:
Type of
S.
Constructio
No.
n
6
Dense
Bituminous
Macadam
/Semi
Dense
Bituminous
Concrete/
Bituminous
Concrete

Test

Frequency (Minimum)

(vii)
Sand Three
tests
on
Equivalent
aggregates for each
Test
400 t of mix subject to
two tests per plant per
day.
(ix) Polished Initially one set of three
Stone Value representative
(PSV)
specimens for each
source
of
supply.
Subsequently
when
warranted by changes
in the quality of
aggregates.
(xviii) Density One test per 250 m2
area subject to the
of
condition that 10% of
Compacted
density tests shall be
Layer
done on the edges.

Add the following at the end of Table 900-4:


Note:
1. The laboratory and field tests shall be performed on
materials and works at the frequency values indicated
against each. The Supervision Personnel shall ensure
that there are no deviations in this regard.
2.

The Contractor shall prepare a detailed manual for


Quality Assurance including the methodology for the
respective tests, the data formats and the methodology
for the analysis and interpretation of test results based
on the reference Standards and Practices indicated in
the Technical Specifications and obtain the approval of
the Engineer.

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3.

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Daily, Weekly and Monthly Reports on the testing done,


results obtained thereof must be prepared indicating the
location of sampling and testing, deviations from the
acceptance norms for materials and works and actions
taken in respect of removal of defective works must be
prepared by the Contractor and authenticated by the
Supervision Personnel that these tests were done in
their presence and that the testing has been carried out
as per the prescribed methodology.

Characteristics to be tested on completed Bituminous


Layers
The characteristics to be tested on completed bituminous
layers are:

Relative compaction
Layer thickness

For testing the above characteristics, the following sampling


criteria shall apply:
a)

Random Sampling

b)

When testing any lot, or an isolated section, which is


obviously defective or exhibits abnormal variation of the
characteristics under consideration, all samples shall be
taken in a random pattern.
Lot Size
The lot size shall normally be a section laid and
compacted in one process and for which essentially the
same materials had been used. Where production is on
a continuous basis, a lot shall normally mean one-day
production and shall not exceed two full days production.

However, the Engineer for investigating compliance with the


specifications may order a lot of any smaller size, if:

The factors affecting the characteristics under


investigation exhibit abnormal variation within the normal
lot size
The area is obviously defective or of poorer quality that
of the rest;
The rate of production is very high.
Bituminous mix shall be spread with paver fitted with
electronic sensing device and string line arrangement
(supported by steel pegs @ 5m apart) on either side of
paving width for automatic levelling, surface evenness
and profile control. Use of string line is compulsory to
provide signal to the electronic sensing device fitted
with a Paver Finisher.

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a)

b)
c)

ORR/JICA2/Pkg 2/Vol II

Bituminous works, shall be tested immediately after


laying/finishing for:
Thickness (compacted) measured by extracting cores
and shall be dealt in accordance with MORT&H
Specifications Section 900.
Density (compaction) test as performed on the
extracted cores
Workmanship test by measuring roughness of the
finished layer by duly calibrated Towed Fifth Wheel
Bump Integrator

Note: Contractor shall arrange the core extraction machine


at his cost and shall take cores of the executed
bituminous works jointly with Engineer without any
extra cost.
The result of tests shall be compared with the prescribed
acceptable values. The payment of all such works executed
shall be based on the test results. In case test results for (b)
and (c) above fall below the required values in accordance
with specifications, the deductions as specified below shall
be worked out and applied, limiting to Nil payment for the
executed bituminous works. Separate deduction shall be
made for each attribute i.e. density test and workmanship
test.
b)

Density (compaction) Test: Basis of Deduction


Core Density

Deduction
in the
payable
rate
@ 5%
@ 15%

Less Upto 1% of requirement


Less above 1% and upto 2% of
requirement
Less above 2% and upto 3% of
@ 30%
requirement
Less above 3% of requirement
@ 100%.
Such works
shall be
rejected
and NIL
payment
shall be
made.

The minimum deduction in the payable rate shall be made


for an area not less than 250 sqm. for each failure of density
(compaction) test.
c)

Workmanship Test : Roughness measured


longitudinally
The finished bituminous layers (DBM and BC) shall
be tested for workmanship (immediately before
allowing
traffic)
by
measuring
roughness,

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longitudinally, separately for each lane with the


Calibrated Towed Fifth Wheel Bump Integrator.
Calibration of Bump Integrator device shall be carried
out using the procedure recommended in the World
Bank Technical Publication No. 46. The measured
roughness shall not exceed a value of 2000 mm/km.
for finished DBM and B.C. layers.
In case DBM is laid in two separate lifts, the roughness shall
be measured on the final DBM layer. Any completed layer
(DBM and BC) having roughness in excess of the value
2000 mm/km shall be paid in accordance with the
Deduction Formulae as specified below:

Measured Roughness
-

Deduction in the
payable rate
Nil

Upto 5% more than the


requirement
More than 5% and upto @ (10%+1% for
30%
more
than
the every 1% in excess
requirement
of 5% of prescribed
limit)
More than 30% and upto
40%
more
than
the
@50%
requirement
Above 40% of more than
@100% (i.e. Nil
the requirement
payment)

The area for which deduction in the payable rate apply,


shall be determined by the Engineer based on analysis of
roughness results. However, regardless of any other
consideration, the minimum deduction applicable shall not
be less than one lane for one km. Surface area, i.e., 3500
sqm.

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SECTION 1000

MATERIALS FOR STRUCTURES

Clause 1002

SOURCES OF MATERIAL
This Clause shall be substituted as under:

The Contractor shall identify the sources of materials like


coarse aggregate and sand and notify the Engineer
regarding the proposed sources prior to delivery.
Samples of material from the source shall be tested, in the
presence of Engineers representative, for conformity to
specifications. It shall also be ensured that the variation in
test results of different samples is within acceptable limits. If
the product from the approved source proves unacceptable
at any time, the Contractor shall provide new sources of
acceptable material from other sources at his own expense
conforming to specifications.
For manufactured items like cement, steel reinforcement,
prestressing strands, the Contractor shall intimate the
Engineer details of the source (plant where the material is
manufactured), testing facilities available with the
manufacturer and arrangements for transport and storage of
material at site. If directed by the Engineer, the Contractor
shall furnish samples and test results of recently
manufactured material. The Engineer, at his discretion, may
require the Contractor to test the materials in an
independent laboratory approved by the Engineer, and
furnish test certificates. The cost of these tests shall be
borne by the Contractor. The sampling and test procedures
shall be as laid down in Indian Standards or where these are
not available as per the directions of the Engineer. Only
material from the sources approved by the Engineer shall be
brought to the site. If the material from the approved sources
proves unacceptable at any time, the Contractor shall
provide new sources of acceptable material conforming to
specifications from other sources at his own expense.
For proprietary items like bearings, metal beam crash
barriers, Signboards, expansion joints refer clause 1015.1.
Clause 1006

CEMENT
This clause shall read as follows:
Cement to be used in bridge structures shall conform to the
following requirements:
Any of the following types of cement may be used with prior
approval of competent authority.

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Sl No.

Type

1
2
3
4
5
6

Ordinary Portland Cement 33 Grade


Ordinary Portland Cement 43 Grade
Ordinary Portland Cement 53 Grade
Rapid Hardening Portland Cement
Sulphate resistant Portland Cement
Portland Pozzolana Cement

7
8

Portland Blast Furnace Slag cement


Low Heat Portland Cement

Conformi
ng to
IS: 269
IS:8112
IS:12269
IS:8041
IS:12330
IS:1489Part-I
IS: 455
IS: 12600

Notes: (1) Use of Portland pozzolana cement may be


permitted only in plain concrete members.
(2) Under severe condition of sulphate content in subsoil
water, special literature on precautions to be taken with
regard to the use of special types of cement with low C3A
content may be referred to. Durability criteria like minimum
cement content and water cement ratio, etc. should also be
given due consideration.
Minimum cement content mentioned elsewhere from
durability considerations shall not be reduced. From strength
considerations, these cements shall be used with a certain
caution as high early strengths of cement in the 1 to 28 day
range can be achieved by finer grinding and higher
constituent ratio for C3S/C2S, where C3S is Tricalcium
Silicate and C2S is Dicalcium Silicate. In such cements, the
further growth of strength beyond say 4 weeks may be much
lower than that traditionally expected. Therefore, further
strength tests shall be carried out for 56 and 90 days to fine
tune the mix design from strength considerations as directed
by the Engineer.
Total chloride content in cement shall not exceed 0.05
percent by mass of cement. Total sulphur content calculated
as sulphuric anhydride (SO3) shall in no case exceed 2.5
percent and 3 percent when Tri-calcium aluminate percent
by mass is upto 5 or greater than 5 respectively.
Cement procured from non B.I.S. license firms will not be
allowed.
The Contractor has to purchase the cement on the name of
work and on the name of the contractor. The cement
without mentioning the above two names will not be
accepted.
Manufactures test certificate shall be submitted to the
Engineer by the Contractor for every consignment of
cement. The certificate should cover all the tests for
chemical requirements, physical requirements and chloride
content as per the provisions of IS:8112/ IS: 12269.

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Independent tests of samples drawn from the consignment


shall be carried out at the site laboratory or in an
independent laboratory approved by the Engineer,
immediately after delivery. The following properties shall be
tested.
i)
ii)

Setting Time
Compressive Strength

The cost of the tests shall be borne by the Contractor. In


case the cement is stored beyond 90 days from the date of
delivery at site, the following tests shall be carried out at the
site laboratory before the cement is used.
i) Setting Time
ii) Compressive strength.
Lot size for independent testing of cement at site shall
be the quantity received at site on any day subject to a
maximum of 500 tonnes.
CLAUSE 1007

COARSE AGGREGATES
Delete from the first sentence crushed gravel
.inert material appearing in 4th and 5th line of
Para 1.
Add the following at the end of Para 2.

Costs of all tests shall be borne by the Contractor.


Add the following at the end of the Clause:
"Integrated stone crusher with Primary and Secondary
(Cone or Impact Type) crushers shall be deployed for
getting proper size and grading of coarse aggregates."
The alkali aggregate reactivity should be measured and
reported for getting approval for the source aggregates at
the beginning of the work using methods given in IS: 2386.
The tests may be repeated if the source, or the type of rock
being exploited for winning aggregates, changes.
CLAUSE 1008

SAND/FINE AGGREGATES
Add the following at the end of 2nd paragraph:
The alkali aggregate reactivity should be measured and
reported for obtaining approval for the source.
Add the following paragraph at the end of the clause:
As far as possible natural sand shall be used for sand/fine
aggregates. If natural sand is not available within 50 Km or
government has stopped sand mining, the contractor shall

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obtain suitable alternative viz. crushed stone, crushed sand


etc. to substitute the natural sand. All alternative sand shall
confirm to IS:383 and tests for conformity shall be carried
out as per IS:2386 (Parts I to VIII). No separate payment will
be made on account of non-availability of natural sand,
arranging crusher sand and increase in leads, etc
Clause 1009

STEEL

Clause 1009.2

Steel For Prestressing


Add (e) to the list of prestressing steel:
e) Stress relieved low relaxation seven ply strand for
prestressed concrete - IS: 14268.

Clause 1009.3

Reinforcement / Untensioned Steel


Replace Table 1000.3 with the following:
Reinforcement shall consist of the following grades of
reinforcing bars, designated by their characteristic strength,
where characteristic strength fy shall be taken as that
specified in governing IS specifications listed in Table 3 as the
minimum value of 0.2% proof stress or yield stress.
Grade
Designation

Bar Type conforming Charecteri Elastic


to
governing
IS stic
modul
specifications
strength
us
(fy MPa)
(GPa.)
Fe 240
IS:432 Part I Mild 240
200
Steel
415
200
Fe 415
IS:1786 Thermo
mechanically treated
(TMT) High yield
strength deformed
bars (HYSD)
500
200
Fe 500
IS:1786 Thermo
mechanically treated
(TMT) High yield
strength deformed
bars (HYSD)
Note: Wire fabrics conforming to IS: 1566 can be used.
Any other reference to HYSD bars in the specifications shall
be read as TMT bars.
Delete the last Para of the Clause
CLAUSE 1010

Water
Delete the Clause and substitute as given below:

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Water used for mixing and curing shall be clean and free
from injurious amounts of oils, acids, alkalis, salts, sugar,
organic materials or other substances that may be
deleterious to concrete or steel.
In case of doubt regarding development of strength, the
suitability of water for making concrete shall be ascertained
by the compressive strength and initial setting time tests.
The sample of water taken for testing shall represent the
water proposed to be used for concreting, due account
being paid to seasonal variation. The sample shall not
receive any treatment before testing other than that
envisaged in the regular supply of water proposed for use in
concrete. The sample shall be stored in a clean container
previously rinsed out with similar water.
Average 28 days compressive strength of at least three 150
mm concrete cubes prepared with water proposed to be
used shall not be less than 90 per cent of the average of
strength of three similar concrete cubes prepared with
distilled water. The cubes shall be prepared, cured and
tested in accordance with the requirements of BIS: 516
The initial setting time of test block made with the
appropriate cement and the water proposed to be used shall
not be less than 30 minutes and shall not be more than + 30
minutes from the initial setting time of control test block
prepared with the same cement and distilled water. The test
blocks shall be prepared and tested in accordance with the
requirements of BIS: 4031 (Part 5).
The pH value of water shall be not less than 6. Potable
water is generally considered satisfactory for mixing
concrete. As a guide the following concentrations represent
the maximum permissible values:
a)

To neutralise 100 ml sample of water, using


phenolphthalein as an indicator, it should not require
more than 5 ml of 0.02 normal NaOH. The details of
test are given in 8.1 of BIS : 3025 (Part 22).

b)

To neutralise 100-ml sample of water, using mixed


indicator, it should not require more than 25 ml of 0.02
normal H2SO4. The details of test shall be given in
Clause 8 of BIS: 3025 (Part 23).

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Permissible limits for solids shall be as given in following


table:
Tested as per

Permissibl
e Limit
(mg)
200 mg/lit

Organic

BIS 3025 (Pt. 18)

Inorganic

BIS 3025 (Pt. 18)

3000
mg/lit

Sulphates (as SO3)

BIS 3025 (Pt. 28)

400 mg/lit

Chlorides (as CL)

BIS 3025 (Pt. 32)

Suspended matter

BIS 3025 (Pt. 17)

2000
mg/lit for
concrete
work not
containing
embedde
d steel
and 500
mg/lit for
prestressed /
reinforced
concrete
work.
2000
mg/lit

Mixing or curing of concrete with seawater is not permitted


because of presence of harmful salts in seawater.
Water found satisfactory for mixing is also suitable for curing
concrete. However, water used for curing should not
produce any objectionable stain or unsightly deposit on the
concrete surface. The presence of tannic acid or iron
compounds is objectionable.
CLAUSE 1012

CONCRETE ADMIXTURES
Add the following at the end of paragraph 2 of Clause
1012.1:

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Admixtures shall not impair the durability of concrete; they


shall not combine with the ingredients to form harmful
compounds or endanger the protection of reinforcement
against corrosion. Only chloride free admixtures shall be
used.
Paragraph 3 of 1012.1 shall read as follows :
For all admixtures being used the packing shall be marked
with the name of the supplier/manufacturer, brand name
(name of product) and main effect, a certificate for the
admixture in question shall be submitted.
The certificate shall include the following information:
General
a)
b)

c)
d)
e)

f)
g)
h)
i)

Chemical name of the active component in the


admixture.
Values of dry material content, ash content and relative
density of admixture, which can be used for uniformity
tests.
Chloride ion content expressed as a percentage of
weight of cement.
pH value and colour.
Normal side effects e.g. whether the admixture leads to
air entrapment at recommended dosage and if so to
what extent.
Side effects when overdosed.
If two or more admixtures have to be used in one mix,
their compatibility.
Increase in risk of corrosion to reinforcements and
embodiments due to the use of admixture.
Latest date of test and name of test laboratory.

B)

Storing

a)
b)
c)

Shelf life.
Max. & min. allowable temperature.
Other instructions (e.g. requirements of stirring).

C)

Dosage

a)

Maximum and minimum to be specified as a


percentage of weight of cement.

Add the following at the end of the clause:


After selecting a few acceptable brands & types of
admixture based on the manufacturer's data/technical
literature, independent acceptance tests should be carried
out for the same using the approved combinations of
cement /sand/aggregates intended for use in the Project.
After establishing the basic acceptability using strength

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criteria (compression & tensile strengths) a number of trial


mixes be designed using different proportions of
admixtures/cement/water etc. to establish the data bank on
the behaviour of the admixture for the project site conditions.
A spectroscopic signature of accepted product should be
obtained and preserved for comparison for acceptance of
the production lots.
Retrials should be conducted with change in source/type of
cement.
Workmanship
The dosage should be finalised on the basis of field trial and
special mechanical devices should be used for dispensing
the admixture in the batching/mixing plant. No addition of
admixture after dosage is permitted (including addition in
transit mixers).
Manufacturer's
experts
should
be
available
for
consultation/trouble-shooting of problems associated with
their product. The conditions of storage, shelf life etc., as
specified by the manufacturer should be strictly observed.
The manufacturer's Quality Assurance Plan during process
of production should be obtained and filed for
reference/record.
CLAUSE 1014

STORAGE OF MATERIALS

Clause 1014.3

Aggregates
The following shall be added to this Clause:
"Aggregates shall be stored or stockpiled in their respective
size in such a manner that the various sizes will not become
intermixed before proportioning. They shall be stored,
stockpiled and handled in such a manner that will prevent
contamination by foreign materials."

CLAUSE 1015

TEST AND STANDARDS OF ACCEPTANCE


Add following after paragraph 2:
Independent testing of prestressing steel shall be carried
out by the contractor for each consignment from each
source at site in the laboratory approved by the Engineer
before use. The tests shall be carried out for the properties
as listed in clause 7.2.1 of BS-5896: 1980. These tests are
in addition to the tests carried out by the manufacturer.

SECTION 1200

WELL FOUNDATIONS

Clause 1202.2

Substitute 1st sentence of this clause At least one


.commencement of work with As soil investigation has
already been carried out for foundation of bridge for the

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design, confirmatory bore holes shall be carried out for


foundation of bridge at least at one location or as instructed
by the Engineer at well foundation location, which shall be
considered incidental and no separate payment will be
made.
Note:
1) Wherever both borehole and electrical resistivity (ER)
methods are proposed, atleast one ER shall be
conducted in the vicinity of one borehole to calibrate the
ER results with actual sub-soil findings and nature.
Other ER shall be carried out except locations of
proposed borehole.
Electrical Resistivity method shall be conducted at
location decided by the Engineer using either
Schlumberger or Wenner arrangement in accordance
with IS:3043 or EM 1110-1-1802.
Calibration of
equipment shall be submitted to the Engineer prior to the
test. Specialist Geophysicist shall be responsible for
conducting and preparation of recommendations and
reports. The test results along with inference and
conclusions with supporting documents as regards to
sub-soil profiling and conditions with depth (upto atleast
twice the width of foundation below founding level) shall
be provided to Engineer within 3 days of testing.
CLAUSE 1204

CUTTING EDGE

Clause 1204.3

Para (1) of this clause shall read as under:


The cutting edge shall be laid 300 mm above the prevalent
water level or at top of well cap level as specified in the
drawings, in case the river bed is dry.

CLAUSE 1205

WELL CURB

Clause 1205.1

Following paras shall be added after Para 1:


The well curb shall be placed truly in position and level.
When the curb is to be laid in dry bed, the site shall be
leveled by open excavation before the cutting edge is
placed.
For wells, which are to be placed in water, on earthen/sand
island where possible shall be constructed and curb placed
or cast on this island. In case of any deep or fast flowing
water where an island may not be possible, as a special
measure, the precast curb/steel caisson may be floated and
lowered in its final position with the help of necessary
equipment.

CLAUSE 1207.9

Add the following sentence


Rock anchors provided in the steining of the well as shown
in the drawings shall only be measured for payment in

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pneumatic methods of sinking only. For all other methods


seating of wells is incidental to the well sinking.
CLAUSE 1214

Measurement for payment


Add the following at the end of Para (a):
Earthwork in excavation above bottom of cutting edge shall
be measured in cubic meters and shall be carried out and
paid in accordance with section 300 of these specifications.
POINT C OF THIS CLAUSE SHALL BE SUBSTITUTED
AS UNDER.
The measurement for well sinking shall be made in running
metres for different depths as specified in the Contract. The
depth of sinking shall be measured from the bottom level of
the well cap and to the final founding level.
In case, the sinking of well could not be made possible to
reach the founding level as designated due to incidental
obstructions or by any valid reasons or as directed by the
Engineer, then the measurement of sinking of well shall be
limited up to the actual achieved level only.

CLAUSE 1215

Rate
Add the following at the end of Para (a)
Diversion of active water channel for
construction shall be incidental to work.
Para (e) of this clause shall read as under:

carrying

out

The contract unit rate for sinking shall include the cost of
labour, tools and plant and for operation required, such as
formation of island, dewatering, excavation and bailing out
material, providing and placing kentledge on top of well and
removing the same, sand filling and contingencies
warranting provision of temporary top plug or cap in the
event of floods being expected at site making further sinking
not possible, and also other incidental works to sink well to
the level shown on the drawings, the cost of confirmatory
bore hole indicated in clause no.1202.2. It shall also include
blasting or use of divers for removal of obstacles from under
the cutting edge of the well. The rate shall specify the strata
such as soil (all types of soil including boulders) and types of
rock.
SECTION 1400

STONE MASONRY

CLAUSE 1402

MATERIALS
Replace this clause by following:

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Stone to be used, besides quarry stone, shall be obtained


by dressing the boulders of average diameter not less than
300 mm and at least five faces shall be chiselled. All other
materials used in stone masonry shall confirm to Section
1000 except cement mortar which shall confirm to clause
1304.
SECTION 1500

FORM WORK

CLAUSE 1501

DESCRIPTION
This Clause shall be read as under:
The Contractor shall prepare a formwork mobilization and
utilization plan and submit the plan for Engineers approval
at least 21 days before the commencement of construction
of structures. The requirement of formwork shall be worked
out considering the overall construction program of all the
structures to be cast in one or more stages, as specified in
the drawings. The plan shall take into account the time
required for erection of formwork, retention in position,
stripping, and removal and subsequent use in the next and
subsequent structures.
Notwithstanding Engineers approval of mobilisation plan, if
due to any reason, Contractor has to arrange additional
formwork, to meet the requirements of the construction
program, it shall be done by the Contractor without any extra
cost to the Employer.

CLAUSE 1502

MATERIALS
This Clause shall read as under:
All materials shall comply with the requirements of IRC-87.
Materials and components used for formwork shall be
examined for damage or excessive deterioration before use
/ reuse and shall be used if found suitable after necessary
repair.
Only steel formwork shall be used. The steel used for forms
shall be of such thickness that the forms remain true to
shape. All bolts should be countersunk. The use of
approved internal steel ties or plastic spacers shall be
permitted. Structural steel tubes used as support for forms
shall have a minimum wall thickness of 4 mm.

CLAUSE 1503

DESIGN OF FORMWORK

Clause 1503.2

The following shall be added to this clause :


For distribution of load and load transfer to the ground
through staging, an appropriately designed base plate must
be provided which shall rest on firm sub-stratum.

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CLAUSE 1504

WORKMANSHIP

Clause 1504.1

The following shall be added to the end of this sub-clause :


The loading from the formwork shall be distributed to the
soil or the permanent works below (e.g. pile cap) in such a
manner that any total or differential settlements are within
acceptable limits. Subsoil characteristics shall be taken into
account while designing the staging to avoid untoward
failures. All the pipes etc. used for staging shall be free from
kinks, bends etc.

Clause 1505

Substitute the following Clause in place of the existing


clause:
Formed & Unformed Surface Finishes
The surface finishes for formed and unformed surfaces are
classified and defined as below. Surface irregularities
permitted for the various classes of finishes are termed
either 'abrupt' or 'gradual'. Fins or offsets caused by
displaced or misplaced form sheeting, lining or form
sections, by loose knots in form lumber or by otherwise
defective form lumber are considered abrupt irregularities.
All other cases are described as gradual irregularities.
Gradual irregularities will be measured with a template
consisting of a straight edge for plain surfaces or its
equivalent for curved surfaces. The length of template for
testing gradual irregularities on formed surfaces shall be 1.5
m in length, the permissible gradual irregularities being
measured over this length of the template.
Finish F1, F2 and F3 shall describe formed surfaces.
Finish U1, U2 and U3 shall describe unformed surfaces.
Class F1 Finish
The class F1 finish shall apply to all formed surfaces for
which class F2 or F3 is not specified. It shall generally be
formed by steel frame mounted with steel sheet. It shall be
so constructed that there shall be no loss of material from
the concrete during placement and compaction. After
hardening, the concrete shall be in the required positions
and shall have the shape and dimensions called for in the
drawings. Any abrupt irregularities shall not exceed 10mm.
All fins and drifts in excess of the above limits shall be made
good by chipping and grinding if required by the Engineer.
Small blemishes caused by entrapped air or water may be
expected but the surface shall be free from voids,
honeycombing or other large blemishes. Class F1 finish
shall be generally specified for all surfaces buried in ground
or not visible during service or for surfaces that are to
receive further rendering treatment such as plastering etc.

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Class F2 Finish
Class F2 finish shall be obtained by use of properly
designed forms with steel sheet lining. The abrupt
irregularities shall not exceed 5mm and gradual irregularities
shall be less than 8mm. Small blemishes caused by
entrapped air or water may be permitted but the surface
shall be free from honeycombing, voids and large
blemishes. Surface irregularities in excess of those
stipulated shall be removed by chipping or rubbing with
abrasive stone. Class 2 finish shall apply to exposed
surface of pier and abutments, pier cap and abutment caps.
Class F3 Finish
Class F3 finish shall be formed by specially designed close
jointed rigid forms having lining. The surface irregularities
shall be limited to nil for abrupt irregularities and 3 mm for
gradual irregularities. Class F3 finish may be obtained from
class F2 finish by carefully removing all abrupt irregularities
including fins and projections by rubbing/grinding. If steel
forms are used they shall have steel sheet backing faced
with plywood.
In addition, finish F3 shall include filling air holes with mortar
and treatment of the entire surface with sack rubbed finish. It
shall also include clean up of loose and adhering debris. For
a sack rubbed finish, the surface shall be prepared within
two days after removal of the forms. The surface shall be
wetted and allowed to dry slightly before mortar is applied by
sack rubbing. The mortar used shall consist of one part
cement to one and one half parts by volume of fine (I.S.No.
16 mesh) sand. Only sufficient mixing water to give the
mortar a workable consistency shall be used. The mortar
shall then be rubbed over the surface with a fine burlap or
linen cloth so as to fill all the surface voids. The mortar in the
voids shall be allowed to stiffen and solidify after which the
whole surface shall be wiped clean with clean burlap such
that all air holes etc., are filled and the entire surface
presents a uniform appearance without air holes,
irregularities etc. Class F3 finish shall apply to all exposed
surfaces of superstructure.
Class U1 finish
This is the screeded finish used on surfaces over which
other finishes such as wearing coats etc., are to be placed.
It is also the first step in the formation of U2 and U3 finishes.
The finishing operation consists of levelling and screeding
the concrete to produce an even and uniform surface so that
the gradual irregularities are not greater than 5 mm. Surplus
concrete should be removed immediately after consolidation
by striking it off with a sawing motion of a straight edge or
template across a wooden or metal strip that has been set

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as guide. Unless the drawings specify a horizontal surface


or show the slope required, the tops of narrow surfaces,
such as stair treads, walls, curbs and parapets shall be
sloped approximately 10 mm per 300 mm width. Surfaces to
be covered with concrete topping, terrazzo, and similar
surfaces shall be smooth screeded and levelled to produce
even surfaces, irregularities not exceeding 5mm.
Class U2 Finish
This is a floated finish used on all outdoor-unformed
surfaces not prominently exposed to view such as tops of
piers etc. The floating may be done by hand or power driven
equipment. It should not however be started until some
stiffening has taken place in the surface concrete and the
moisture film or 'shine' has disappeared. The floating should
work the concrete no more than is necessary to produce a
surface that is free from screed marks. All joints and edges
should be finished with edging tools. It shall include the
repair of gradual irregularities exceeding 5 mm. All abrupt
irregularities shall also be repaired unless a roughened
texture is specified.
Class U3 Finish
This is a travelled finish used on all surfaces exposed to
view at close quarters such as tops of parapets and kerbs
etc. Steel travelling should not be started until after the
moisture film and 'shine' have completely disappeared from
the floated surface and the concrete has hardened enough
to prevent an excess of fine material and water from being
worked to the surface. Excessive travelling, especially if
started too soon, tends to produce crazing and lack of
durability. Too long a delay will result in a surface too hard
for proper finishing. Steel travelling should be performed
with a firm pressure that will flatten and smooth the sandy
surface free of blemishes, ripples and travel marks. It shall
include the repair of all abrupt irregularities and the repair of
gradual irregularities exceeding 5 mm. It shall also include
finishing the joints and the edges of concrete with edging
tools.
CLAUSE 1506

PRECAUTIONS
Add the following as items (vii) to (ix) to the end of this
clause:
vii.

Adequate support against sideway and lateral loads


due to construction operations and wind shall be
provided.

viii.

Forms shall be rigid and of adequate section to


reduce deflections. Forms shall have sufficient
rigidity to resist horizontal pressures caused by
flowing
concrete
resulting
from
use
of

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superplasticisers. The formwork shall resist the


lateral pressure caused due to fast rate of placement
by concrete pumps.
ix. In case cantilevers are supported directly from the
ground, the supports for cantilevers shall be
removed simultaneously with main supports only
after approval for the same by the Engineer.

CLAUSE 1508

REMOVAL OF FORMWORK
Add the following at the end of paragraph 3 of Clause 1508
Field cure cubes strength to be checked for respective
structural items before removing their for work.
Add the following as paragraph 5 to Clause 1508.
For prestressed units, the side forms shall not be released
before initial setting time (or) as decided by the Engineer
and the soffit forms shall permit, without restraint,
deformation of the member, when prestressing is applied.
Form supports and forms for cast-in-situ members shall not
be removed until sufficient prestressing has been applied to
carry the dead load and any formwork supported by the
member and anticipated construction loads.

CLAUSE 1509

RE-USE OF FORMWORK
This Sub-Clause shall be substituted as under:
After forms are stripped, all materials to be reused shall be
thoroughly cleaned. Holes bored through sheathing for form
ties shall be plugged by driving in common corks or foamed
plastics. Patching plaster may also be used to fill small
holes. After cleaning and before re-fixing, each formwork
shall be got approved by the Engineer.
Formwork and staging shall be so used as to maintain
quality of the exposed surface. However, if in the opinion of
the Engineer, any particular panel/member has become
unsatisfactory for use at any stage, the same shall be
rejected.
All bent steel props shall be straightened before reuse. The
maximum deviation from straightness shall not exceed
1/600 of length. Engineer will decide the suitability of props
for reuse depending on their condition. Decision of the
engineer regarding acceptability of props shall be final. The
maximum permissible axial loads in used props shall be
suitably reduced depending upon their condition.

CLAUSE 1510

SPECIALISED FORMWORK

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Replace the words slip-form work by climbing formwork in


the first sentence of this clause.
The first sentence of Para 2 of this clause shall read as
follows:
Slip forming is not permitted.
Replace the word plywood by marine plywood in the
fourth paragraph of this clause.
CLAUSE 1513

RATE
Add the following at the end of the first paragraph:
The unit rate shall also include all costs for preparation of
erection scheme, designs of false work and formwork and
their approval.

SECTION 1600

STEEL REINFORCEMENT (UNTENSIONED)

CLAUSE 1602

GENERAL
Paragraph 2 of Clause 1602 shall read as follows:
Reinforcements shall be thermo mechanically treated
(TMT) deformed bars of grade Fe 415 conforming to IS:
1786. Only uncoated steel shall be used as reinforcement
unless specified.

CLAUSE 1604

BENDING OF REINFORCEMENT
The first paragraph of this Clause shall read as under:
The reinforcement shown on the drawings shall be
considered merely symbolic representations of the shape
and position and shall not be used by the Contractor to
justify any deviation from the stipulated requirements. Bar
bending schedules and any supplementary drawings as may
be required shall be furnished by the Contractor and got
approved by the Engineer before start of work. The bending
schedules shall state the number, shape and length of bar
and weight in respect of each type. System of bar
referencing should be coherent and systematic and conform
to SP: 34 (SNT) 1987 published by BIS. A separate bar
bending schedule shall be prepared for auxiliary bars like
spacers chairs etc

CLAUSE 1605

PLACING OF REINFORCEMENT
Paragraph I (i) of clause 1605 shall read as follows:
Cover blocks shall be made of concrete or cement mortar
with the same durability properties as the surrounding
concrete and with the same type of constituents. In visible
surfaces, the cover blocks shall be of the same colour and
texture as the surrounding concrete. The Contractors

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proposal for cover blocks shall be submitted to the Engineer


for acceptance.
Add the following as sub para (f) to this clause
Tolerances:
1.

Tolerance of cover: Deviation shall not exceed +10 mm.


No negative tolerance is allowed.

2.

Tolerance in position: Tolerance for deviation from the


positions shown in the drawings shall not exceed the
following:

Structural depth d (mm)


d < 1000
1000 < d < 2000
2000 < d
CLAUSE 1606

BAR SPLICES

Clause 1606.1

Lapping

Tolerance(mm)
< 10
< 0.01d
< 20

First sentence of Clause 1606.1 shall read as follows:


To the extent possible, all reinforcement shall be provided
in full lengths as indicated in drawings.
Add the following as paragraph 2 of Clause 1606.1:
The location of joints in continuous reinforcing bars, not
shown in drawings, shall be submitted to the Engineer for
acceptance. If nothing contrary has been specified, the
number of bars to be joined in any cross-section shall not
exceed one-third of the total.
Clause 1606.2

Welding

Clause1606.2.1

Add the following at the end of the paragraph:


In prestressed concrete members, when welding of
untensioned reinforcement is permitted by the Engineer, it
shall be carried out before insertion of the prestressing
tendons.

CLAUSE 1607

TESTING AND ACCEPTANCE


Add the following as the last paragraph of Clause 1607:
Manufacturers test certificate regarding compliance with
Indian Standards for each lot of steel shall be obtained and
submitted to the Engineer. If required by the Engineer, the
Contractor shall carry out confirmatory tests in the presence
of a person approved by the Engineer. Cost of these tests
shall be borne by the Contractor. The sampling and testing

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procedure shall be as laid down in I.S.1786-1985. However


if any test piece selected from a lot fails, no re-testing shall
be done and the lot rejected.
SECTION 1700

STRUCTURAL CONCRETE

CLAUSE 1703

GRADES OF CONCRETE

Add the following at the end of this Clause.


Concrete mixes leaner than M15 shall be called as nominal
mix concrete.
Nominal mix concrete is that concrete for which concrete
is not to be designed by tests and in which the proportions
of materials are in accordance with the drawings and the
specification Clause mentioned below:
i)

All the materials for this concrete shall conform to


section 1000 of MOSRTH Specification

ii)

Minimum cement content and maximum water cement


ratio for above said nominal mix concrete shall conform
to Clause 1703.2 and Table 1700-3(A) of MOSRTH
Specification.

iii) Mixing of above-said nominal mix concrete shall


conform to Clause 1708 of MOSRTH Specification.
iv) Transporting, Placing and Compaction of above said
nominal mix concrete shall conform to Clause 1709 of
MOSRTH Specification.

CLAUSE 1704

PROPORTIONING OF CONCRETE
Last sentence of paragraph 1 shall be as follows :
Other type of admixtures shall be used with the approval of
the Engineer.

Clause 1704.1

Read the item No. 5 of Table 1700-4 as under:

5.

Clause 1704.2

TYPE
SLUMP (mm)
Underwater concreting through
100-150
tremie e.g. bottom plug, cast-insitu piling.

Add the following at the end of Table 1700.5 :


Concrete Grade
M60

260

Current Margin Target Mean


(MPa)
Strength (MPa)
14
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Add the following at the end of this Clause:


In proportioning concrete, the quantity of both cement and
aggregate shall be determined by weight. Where the weight
of cement is determined by accepting the manufacturers
weight per bag, a reasonable number of bags shall be
weighed separately to check the net weight. Where cement is
weighed from bulk stock at site and not by bag, it shall be
weighed separately from the aggregates. Water shall either be
measured by volume in calibrated tanks or weighed. All
measuring equipment shall be maintained in a clean and
serviceable condition. Their accuracy shall be periodically
checked.
It is most important to keep the specified water-cement ratio
constant and at its correct value. To this end, moisture content
in both fine and coarse aggregates shall be determined as
frequently as possible; frequency for a given job being
determined by the Engineer according to the weather
conditions. The amount of mixing water shall then be
adjusted to compensate for variations in the moisture content.
The determination of moisture content in the aggregates shall
be done as per IS: 2386 (Part III). Suitable adjustments shall
also be made in the weight of aggregates to allow for the
variation in weight of aggregates due to variation in their
moisture content.
Clause 1704.4

Additional Requirements
In Para (a) substitute "0.06%" for "0.1%"; "0.06%" for "0.2%;
and 0.1%" for "0.3% for the three items respectively.

Clause 1704.6

Add the following as clause 1704.6


Materials for pumped concrete:
Materials for pumped concrete shall be batched consistently
and uniformly. Maximum size of aggregate shall not exceed
one-third of the internal diameter of the pipe.
Grading of aggregate shall be continuous and shall have
sufficient ultra fine materials (materials finer than 0.25 mm).
Proportion of fine aggregates passing through a 0.25 mm
sieve shall be between 15% and 30% and that passing
through 0.125 mm sieve shall not be less than 5% of the
total volume of aggregate. Admixtures to increase
workability can be added. When pumping long distances
and in hot weather, set retarding admixtures can be used.
Fluid mixes can be pumped satisfactorily after adding
plasticisers and super plasticisers. Suitability of concrete
shall be verified by trial mixes and by performing pumping
tests.

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CLAUSE 1705

ORR/JICA2/Pkg 2/Vol II

ADMIXTURES
This Clause shall be read as under:
Duly tested admixtures / additives conforming to IS: 6925
and IS: 9103 (without replacement of cement) may be used
subject to satisfactory proven use, with the approval of the
Engineer. The strength of the mix so designed using
admixtures is to be tested for conformity with that of
controlled concrete as per IS 9103. Admixtures generating
hydrogen or nitrogen and containing chlorides, nitrates,
sulphides, sulphates and any other material liable to
adversely affect the steel or concrete, shall not be permitted.
The general requirements, physical and
requirements shall be as per Clause 1012.

CLAUSE 1706

chemical

SIZE OF COARSE AGGREGATES


This Clause shall be read as follows:
The size (maximum nominal) of coarse aggregates for
concrete to be used in various components shall be given as
Table 1700-7

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Table 1700-7

SNo.

Components

Maximum
nominal
size of
Coarse
aggregate
(mm)
20

a.

RCC Well Curb.

b.

RCC / PCC well steining, PCC below


foundations and approach slab,
annular filling around foundations.

c.

Well cap or pile cap; solid wall type


abutments, piers, median walls,
splayed wing walls and their
foundations.

40

40

d.

RCC works in T-beam and slab /


solid slab / voided slab and box
girder superstructure, wearing coat,
kerb, crash barrier, approach slab,
dirt walls, coping on masonry wing
walls, hollow abutments and piers,
pier / abutment caps, pedestals, dirt
walls, piles, all components of
counter
fort
type
abutments,
columns, cantilever return walls etc.

e.

All PSC works

f.

Any other item

20

20
As specified
by the
Engineer

Maximum nominal size of aggregates shall also be restricted


to the following :
The maximum size of the coarse aggregate may be as large
as possible within the limits specified, but in no case greater
than one quarter of the minimum thickness of member or 10
mm less than the minimum lateral clear distance between
individual reinforcements or 10mm less than the minimum
clear cover to any reinforcement.
The proportions of the various individual size of aggregates
shall be so adjusted that the grading produces densest mix
and the grading curve corresponds to the maximum nominal
size adopted for the concrete mix.
CLAUSE 1707

EQUIPMENT
Paragraph 1 of this Clause shall be read as under:

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Unless specified otherwise, equipment for production,


transportation and compaction of concrete shall be as
under
a)

For Production of Concrete:

i)

Batching and mixing of the concrete shall be done in


concrete batching and mixing plant fully automatic of
40 cum per hour minimum capacity. The plant shall
be approved by the Engineer

ii)

In special case, for culverts, the Engineer may allow


mixing of concrete for small pours (< 5 cu. m.) by a
diesel or electrically operated mechanical mixer with
integrated weigh batching facility having a capacity of
0.5 cum. and automatic water measuring system.

Paragraph 3 of this clause shall read as follows:


The accuracy of measuring devices shall fall within the
following limits:
Measurement of Cement

+1% of the quantity


cement in each batch.

Measurement of Water

+1% of the quantity of water


in each batch.

Measurement of Aggregate

+ 2% of the quantity of
Aggregate in each batch.

Measurement of Admixture

+1% of the quantity of


Admixture in each batch.

of

Paragraph 3(b) & 3(c) shall remain unchanged.


Add the following paragraph at the end of the clause:
Batching, mixing transportation and placing concrete.
Once the concreting of a section is started, it has to be
completed as a continuous operation. Before starting an
important placement, the Contractor shall submit to the
Engineer an equipment list to ensure that sufficient
equipment is available for batching, mixing, transporting and
placing concrete and once the concreting of a section is
started, it can be completed as a continuous operation
within a reasonable time.
CLAUSE 1709

TRANSPORTING, PLACING AND COMPACTION OF


CONCRETE
Replace the last sentence of paragraph 1 with the following
sentence:

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Concrete shall not be freely dropped into place from a


height exceeding 2.0 metres
Add the following paragraph at the end of the clause :
For Placing Concrete with Pumps: Pipe lines from the
pump to the placing area should be laid out with a minimum
of bends. For large concrete placements, standby pumps
shall be available. Suitable valves (air release valves,
shutoff valves, etc.) shall be provided as per the site needs.
The pumping of concrete shall be preceded by a priming mix
to lubricate the pump and pipeline. A rich mix of creamy
consistency shall be required for lubricating the pipelines.
Continuous pumping shall be done to the extent possible.
After concrete has been placed the lines and all related
equipment shall be cleaned immediately. A plug sponge ball
shall be inserted in the end near the pump and shall be
forced through the line by either water or air pressure. Pipes
for pumping should not be made from materials, which can
harm concrete. Aluminium alloy pipelines shall not be used.
CLAUSE 1710

CONSTRUCTION JOINTS
Amendments to Appendix 1700/I
In the first paragraph under the heading Preparation of the
Surface of the Joint, after the second sentence "The
surface shall be roughened." insert the following sentence:
The coarse aggregate shall be made visible to a depth of
5mm to 10mm.
At the end of the third paragraph under the heading
Preparation of the Surface of the Joint add the
following:
"Bush hammering is not permitted since it loosens the
coarse aggregate and results in extensive micro cracks."
Under the heading "Concreting of Joints" add the
following at the end of para 3:
"At vertical construction joints, a fine mesh on the inner
surface of the stopping board shall be placed, if directed by
the Engineer, to facilitate removal of laitance."

CLAUSE 1712

ADVERSE WEATHER CONDITION

Clause 1712.2

Hot weather Conditions


Add the following at the end of paragraph 1 of the above
clause:

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Where the Contractor proposes to use ice to cool the


concrete or mixing water or any of the ingredients, the
Contractor shall provide a refrigeration plant to avoid use of
contaminated ice.
CLAUSE 1713

PROTECTION AND CURING

Clause 1713.1

Water Curing
Replace the last paragraph with the following:
The concrete should be kept constantly wet for a minimum
period of 14 (fourteen) days except for rapid hardening
cement concrete when it can be reduced to 5 (five) days.
Water should be applied on unformed surfaces as soon as it
can be done without marring the surface and on formed
surfaces immediately after the forms are stripped. The
concrete shall be kept constantly wet by ponding or covered
with a layer of sacking, canvas, Hessian or a similar
absorbent material and kept constantly wet.
After placing and during the first stages of hardening
concrete shall be protected from harmful effects of sunrays,
drying winds, cold, running water, shocks, vibrations, traffic
including construction traffic etc.
Approved concrete curing compounds should be preferred
where water curing cannot be done reliably.

CLAUSE 1715

TOLERANCES

Clause 1715.1

Sectional Dimensions
Add the following as the second sentence of the Clause:
In the absence of any information in drawings or
specifications, for particular cases, the following limitations
shall apply:

Dimension (mm) a
a 200

Clause 1715.2

Tolerances (mm)
a = (anominal aactual)
a <5

200 < a 2000

a <3 .5 + 0.0075a

2000 < a

a <16.5 + 0.001a

Deviations from Position etc.


Deviation from specified position in plan
a) Variation in levels at top

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b) Variation of reduced levels of bearing areas

+ 5 mm

c) Variation in plumb over full height of piers

+10 mm

d) Surface irregularities measured with 3m straight


edge
(i)

All surfaces except bearing areas

+ 5 mm

(ii)

Bearing areas

+ 3 mm

e) Variation in length of superstructure overall +10mm or


and length between bearings
+0.1% of
the span
length,
which ever
is lesser.
Clause 1716

TESTS AND STANDARDS OF ACCEPTANCE

Clause 1716.2.5.

Acceptance Criteria
Compressive Strength
Substitute Clause 1716.2.5 (a) with the following:
The mean strength determined from any group of four
consecutive samples should exceed the specified characteristic
compressive strength by 3 MPa.

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SECTION 1800
CLAUSE 1801

ORR/JICA2/Pkg 2/Vol II

PRESTRESSING
General
Add the following as the last paragraph of this clause:
Prestressing system shall conform to FIP RecommendationRecommendations of acceptance of post-tensioning systems
June 1993.

CLAUSE 1802

Materials

Clause 1802.2

Sheathing

Clause 1802.2.1

1st para is modified as follows.


The sheathing shall be of corrugated type.
High-density polyethylene pipe conforming to IRC 18-2000
shall only be provided. The wall thickness shall not be less
than 2.3 + 0.3mm. If there is a difficulty in arranging the HDPE
pipes and the engineer is fully convinced of this difficulty the
engineer may permit the usage of cold rolled, cold annealed,
mild steel conforming to IS 513 intended for mechanical
treatment and surface refining but not for quench hardening or
tempering instead of HDPE sheathing.
Third para 1st line is modified as follows.
The thickness of metal sheathing in case it is used shall not be
less than 0.3 and 0.4mm for sheathing ducts having internal
diameter upto 75mm and 90mm respectively. For larger
diameter of ducts thickness of sheathing shall be based on
recommendations of pre-stressing system supplier.

Clause 1802.2.2

Replace existing Clause with the following:


The internal area of the sheathing duct shall be in accordance
with the recommendations of the system manufacturer. In
case of 7T13, 12T13, and 19T13 sizes of tendons, the inner
diameter of the sheathing shall not be less than 55 mm, 75 mm
and 85 mm respectively or those shown in the drawing,
whichever is greater. These dimensions are for post-threaded
cables.

Clause 1802.3

Add the following at the end of the Clause:


Prestressing accessories like jacks, anchorage, wedges, block
plates, etc. being patented items shall be obtained from
authorised manufacturers only. The prestressing components
and accessories shall be subjected to an acceptance test prior
to their actual use on the works (guidance may be taken from
BS:4447).

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CLAUSE 1803

ORR/JICA2/Pkg 2/Vol II

TESTING OF CABLE/ ANCHORAGE ASSEMBLY


Add following Paragraphs to the section.
All samples shall be representative of the lot and in the case of
wire or strand shall be taken from the same master roll. At least
5.0m length shall be selected from each lot for testing. Also two
anchorage assemblies, complete with distribution plates of
each size or types to be used, shall be tested.
Testing of anchorage cable assemblies shall be carried out in
accordance
with
procedures
in
FIP
document
Recommendations for the acceptance of Post Tensioning
systems June 1993.
The frequency of such tests should be as follows:
1)

For acceptance of the tendon at the stage of submission of


tendons, the manufacturers certificate together with the
data of previously conducted and most recent test results
of Acceptance Testing is acceptable subject to further
testing as given below.

2)

Acceptance Testing for the works


a) Static load test for tendon-anchorage assembly

A series of three tests using the proposed


combination of anchorage systems and the prestressing strand/wire/bars. All the tests should meet
the following requirements.
Residual deformations of anchorage components
after the test should confirm the reliability of the
anchorage.
The increase in the displacements between the
anchorage components as well as between the prestressing steel and anchorage components should
not be disproportionate to the increase in tendon
force.
The above relative displacements during the 0.8Fpk
load stage should stabilise within the first thirty
minutes of the load duration of 1 hour.
The mode of failure of tendon should be by the
fracture of the prestressing steel. Failure of the
tendon should not be induced by the failure of
anchorage components.
The measured anchorage efficiency should be:
A = Ftu 0.95 (Refer CEB/FIP Guidelines for Fpm
details).
The total elongation u in free length of the tendon
under the load Ftu should be u 2 %

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b)

ORR/JICA2/Pkg 2/Vol II

Load Transfer Test

A series of three successful tests shall be carried out for


acceptance of the system.
Requirement:

Crack width upon first attainment of upper force 0.8 Fpk


(load point 4) should be 0.10 mm.
Crack width upon last attainment of lower force 0.12 Fpk
(load point n-1) should be 0.10 mm.
Crack width upon final attainment of upper force 0.8 Fpk
(load point n) should be 0.25 mm.
Readings of longitudinal and transverse strains should
have stabilised during cyclic loading. The strains can
be assumed to have stabilised if the increase of strain in
the last two load cycles is less than 5 %.
Readings of crack widths should have stabilised during
cyclic loading. The crack widths can be assumed to
have stabilised if the crack width does not increase by
more than 0.02 mm in the last two load cycles.
The measured failure load Fu must meet each of the
following requirements:

Fu Fpk

fcm.e
fck.o

and Fu 1.1 Fpk

(Refer CEB/FIP Guidelines for details)


Clause 1804.5

Insert following para after 1st Para


Mixture of water-soluble oil such as Dromas B and Water is
to be flushed through empty metallic ducts if used before
threading of cables, and after threading of cable at frequency
of at least once in a month. The layer of oil formed on
sheathing/ prestressing steel shall be fully flushed out by using
clean water before final grouting by cement grout.

CLAUSE 1805

The Clause shall be read as follows:


Prestressing operation and grouting shall be entrusted to only
specifically trained and qualified personnel. All prestressing
accessories shall be procured from authorised manufacturers
with in-house testing facilities. Contractors shall also be
required to engage specialised agencies who should also be
entrusted with the total service contract for fabrication of
cables, certificates shall also be accorded by such specialised
agencies that the work has been carried out in accordance with
prescribed specifications. In exceptional cases where the
client is convinced that the contractor of the bridge itself is well
experienced and has qualified personnel and sufficient track
record to substantiate his performance in the particular system
of prestressing being adopted, the prestressing and grouting
operations could be entrusted to the contractor.

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CLAUSE 1806

ORR/JICA2/Pkg 2/Vol II

TENSIONING EQUIPMENT
Add the following at the end of para 2.
Jack and Pump shall be calibrated by an approved laboratory
prior to use and then at intervals not exceeding three months.

CLAUSE 1807

Add the following at the end of this clause:


The Contractor shall submit fabrication drawings, detailing
prestressing cables, anchorages, couplers, chairs and
supports, templates or forms holding anchorage assemblies
etc. for Engineers approval at least one month before
commencement of work in superstructure. Stressing schedules
shall be prepared by the Contractor and submitted to Engineer
for approval.

CLAUSE 1808

Add the following at the end of clause1808.


Where directed by the Engineer the Contractor shall perform
full-scale site test to determine the adequacy of grout mix,
equipment and grouting method. The Contractor shall submit a
method statement detailing the test procedure.
Special Attention is directed to Appendix 1800/III of the
Standard Specifications.
Contractor shall arrange for testing of all grout components and
of the mix, prior to the start of grouting and whenever the
source of any component is changed, to ensure that the grout
is free of anything that could promote shrinkage or cracking of
the grout or corrosion in the tendons. Further samples of grout
and its components shall be obtained for each day of grouting
at each site where grouting is carried out and a full chemical
analysis shall be performed on the samples.
Add the following at the end of Para 3.1
It is therefore necessary that the grout be continuously mixed
in a colloidal mixer with a minimum speed of 1000 rpm and
have discharge not exceeding 15m per second.

CLAUSE 1815

RATE
Add at end of Para 4:
Cost of fixing anchorages / sheathing for dummy cables and
future pre-stressing cables shall be incidental to work and shall
not be measured / paid extra. No additional cost shall be
payable for stressing of cables for compensation of short fall of
pre-stress or for any other reason.

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CLAUSE 1816

ORR/JICA2/Pkg 2/Vol II

JOINTS IN CONSTRUCTION WITH PRE-CAST UNITS


Add new clause
Joints between a series of pre-cast concrete units, which are to
be pre-stressed together by post-tensioning, shall be such as
to ensure even transfer of compression from one unit to
another.
Whatever be the method of jointing, the holes of the prestressing steel shall be accurately made and shall meet one
another in true alignment at ends. Jigs shall always be used.
Care shall be taken to ensure that the jointing material does
not enter the duct or press the sheath against the pre-stressing
steel.
Jointing by application of mortar on the face of a unit and then
placing another unit against it shall not be permitted.
Suitability and effectiveness of the method should be got
confirmed from a suitably designed mock-up.

SECTION 2000

BEARINGS

CLAUSE 2001

DESCRIPTION
Add the following as paragraph 2 of this clause:
Within 90 days of award, the Contractor shall submit detailed
specifications, designs and drawings including installation
drawings and maintenance manual, for the approval of the
Engineer. Designs shall also include review and modifications
of designs and drawings of bearing pedestals and other
elements required for installation. The installation of bearings
shall be carried out under the supervision of the manufacturer
of the bearings. The Contractor shall provide the bearings only
from the manufacturers approved and enlisted by the Ministry
of Shipping, Road Transport & Highways. In addition to routine
testing of the materials and bearings at manufactures
premises, the Contractor shall arrange at his own cost testing
of random samples of 1 % (Minimum 1 no. of each type) of
bearings from independent agencies, other than manufactures
own facilities, duly approved by the Engineer. The bearings
shall be selected by the Engineer / his authorised
representative and duly sealed in his presence for dispatch to
the independent agency.

CLAUSE 2004

SPECIAL BEARINGS

Clause 2004.1

Spherical Bearings:
The clause shall read follows:

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Spherical Bearings: Spherical Bearings shall conform to the


requirements of sections 9.1 and 9.2 of BS 5400. However
materials of bearing elements may conform to Indian
Standards nearest to the specifications stated in the above
sections of BS: 5400.
CLAUSE 2005

ELASTOMERIC BEARINGS

Clause 2005.3

Acceptance Specifications
In Para 5, substitute the words "Engineer or his authorised
representative" for the word "Inspector".

Clause 2005.3.5

Inspection Certificate
Substitute the words "Engineer or his authorised representative"
for the word "Inspector".

Clause 2005.3.6

Quality Control Certificate


Delete the words /Inspector in the third paragraph.

CLAUSE 2006

POT BEARINGS
The clause shall read follows:
Pot Bearings shall conform to the requirements of IRC: 83
(Part III)-2002.

Clause 2006.1

General

Clause 2006.1.2

Add after 2nd sentence Provisions of IRC:83 (Part III) shall be


applicable for POT, POT cum PTFE, PIN and Metallic Guide
Bearings

CLAUSE 2009

Measurement for Payment


Add the following after Para 2:
"Tar Paper bearings shall be measured in square meters."

Clause 2011

TAR Paper Bearing


Add clause 2011 after the clause 2010 as under
Paper bearing shall be reinforced bitumen laminated kraft
paper confirming to the requirements of IS-1398

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SECTION 2100

OPEN FOUNDATIONS

Clause 2106

TOLERANCES
Reference to Tolerance shall be made to Clause 1715.

SECTION 2200

SUB-STRUCTURE

Clause 2204

PIERS AND ABUTMENTS


Para 2 is replaced with:
Slipforming will not be allowed.
Add the following paragraph at the end of this clause:
Where necessary suitable cofferdams or other means shall be
provided to exclude water from the construction area. The
Contractor shall provide necessary pumping equipment for
dewatering in working areas.

Clause 2210

RATE
This Clause shall read as follows:
"The contract rate for masonry, concrete and reinforcement in
substructure shall include all works as given in respective
sections and cover the cost of incidental items like providing
cofferdams, dewatering, providing special form work, where
necessary, and all other items for furnishing and providing
substructure as mentioned in this section.
The necessary material (thermocole, bituminous fibrous board
or equivalent material), labour, tools etc. required for
maintaining 20 / 40 mm gap between faces of various
structures (old / new) wherever required / as shown in drawing
shall be incidental to work and shall not be measured / paid
separately"

SECTION 2300

CONCRETE SUPER-STRUCTURE

Clause 2305

PRESTRESSED CONCRETE CONSTRUCTION

Clause 2305.1

PSC Girder and Composite RCC Slab


The heading of this clause shall read as follows:
PSC Solid Slab & PSC Girder and Slab
This Clause shall read as follows:

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Hyderabad Growth Corridor Limited

Clause 2305.1.1

ORR/JICA2/Pkg 2/Vol II

PSC Solid Slab


Casting of the slab shall be done in a single stage without
construction joints.
The portions of deck near expansion joints shall be cast along
with reinforcements and embodiments for expansion joints.
The deck slab shall be finished rough, but true to lines and
levels as shown in drawings.
Bearings shall be set as shown in drawings.

Clause 2305.1.2

PSC Girder and Slab


The Contractor shall, in his methods statement, indicate
location of construction joints for the Engineer's approval.
The surface finish of deck shall be finished rough, but true to
lines and levels as shown in drawings.
Bearings shall be set as shown in drawings

Clause 2305.2

Box Girder
Add the following at the end of paragraph 1:
"The Contractor shall, in his methods statement, indicate
construction joints for Engineer's approval."

SECTION 2500

RIVER TRAINING WORKS AND PROTECTION WORKS

Clause 2504

PITCHING/REVETMENT ON SLOPES
The heading of this Clause shall be read as follows:
PITCHING/REVETMENT ON SLOPES AND FILTER MEDIA

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Hyderabad Growth Corridor Limited

Clause 2504.2.2

ORR/JICA2/Pkg 2/Vol II

Filter Media
Add the following sentence at the end of the third paragraph of
this clause:
The material for filter media behind abutment shall conform to
general guidelines given in Appendix 6 of IRC- 78 (Standard
Specifications and Code of Practice for Road Bridges
Section: VII).
Add the following at the end of the clause

When the filter media is to be used behind abutment, wing


wall, retaining wall and return wall, then wire mesh and
coarse aggregate are to be provided on wall face all around
the weep holes to prevent escape of filter media. Provision of
wire mesh and coarse aggregate shall be considered
incidental to the work of providing filter media behind
structures with weep holes.
Clause 2600

EXPANSION JOINTS

Clause 2602

GENERAL
Paragraph c,d,e deleted.
Add the following at the end of the clause:
The expansion joints shall be procured only from those
manufacturers/suppliers of expansion joints who are empanelled
with MoRT&H.
The provisions of the MoRT&H (formerly Ministry of Surface
Transport) issued modified interim specifications for expansion
joints vide letter dated 31/03/97 and revised vide letter No.
RW/NH-34059/1/96 S&R dated 30/11/2000 and issued
corrigendum of same circular dated 15/01/2001, as reproduced
below, shall be adopted.

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SUITABILITY CRITERIA FOR ADOPTION OF DIFFERENT TYPES OF


EXPANSION JOINTS
(Annex-I of above said circular)
Sl.
No
1.

Type of
Expansion
Buried Joint

Suitability for Adoption of


Joint
Simply supported spans upto
10 meters

Expected
Service Life
10 Years

2.

Filler Joint

10 Years

3.

Asphaltic
Plug Joint

Fixed end of simply


supported spans with
insignificant movement or
simply supported spans not
exceeding 10 meters
Simply supported spans or
right or skew (upto 20
degree), moderately curved
or wide deck with maximum
horizontal movement not
exceeding 25 mm. Ambient
temperature should be in the
range of 5 degree to 50
degree Celsius

4.

Compressio
n Seal
Joint*
(Chloropren
e Seal &
Closed Cell
Foam Seal)
Elastomeric
Slab Seal
Joint*

Simply supported or
continuous spans, right or
skew (up to 30 degree),
moderately curved with
maximum horizontal
movement not exceeding 40
mm.
Simply supported or
continuous spans, right or
skew (less than 20 degree),
moderately curved with
maximum horizontal
movement up to 50 mm.
Moderate to large simply
supported cantilever /
continuous construction
having right skew or curved
deck with maximum
horizontal movement up to70
mm

10 Years

5.

6.

Single Strip
Seal Joint*

277

10 Years

10 Years

25 Years

Special Consideration
Only for decks with
bituminous / asphaltic
wearing coat. Steel plate
may need replacement, if
found corroded or distorted
at the time of relaying /
renewal of wearing coat.
The sealant and joint filler
would need replacement if
found damaged.

Only for decks with


bituminous / asphaltic
wearing coat. Not suitable
for bridge with longitudinal
gradient more than 2% and
cross camber / super
elevation exceeding 3%.
Not suitable for curved
spans and spans resting
on yielding supports.
Chloroprene / Closed Form
Seal may need
replacement during
service.

Liable to excessive wear


and tear under high traffic
intensity. Not suitable for
bridges located in heavy
rainfall area and spans
resting on yielding support.
Electrometric seal may
need replacement during
service.

Hyderabad Growth Corridor Limited

Sl.
No
.
7.

Type of
Expansion

ORR/JICA2/Pkg 2/Vol II

Suitability for Adoption of


Joint

Expected
Service Life

Special Consideration

25 Years
Electrometric seal may
Large to very large
need replacement during
continuous / cantilever
service.
construction with right deck
having maximum horizontal
movement in excess of 70
mm
25 Years
Electrometric seal may
8. Special *
For bridges having wide
need replacement during
joints for
decks and large span length
service. Provision of these
special
involving complex
joints may be made with
conditions
movements / rotations in
prior approval of the
different directions / planes,
Ministry.
provision of special type of
modular expansion joints
such as Swivel Joists joints
may be made.
*
These are proprietary items for which 10 years warranty shall be insisted upon from the
suppliers. The contractor shall submit all relevant information as per clause 115.1
Modular
Strip / Box
Seal Joint*

The clause 2604 be replaced fully as below:


Clause 2604

BURRIED, ASPHALTIC PLUG and COMPRESSION SEAL


JOINTS

Clause 2604.1

BURIED JOINT
a)
This joint shall consist of continuously laid
bituminous/asphaltic surfacing over the joint gap bridged
by a steel plate resting freely over the top surface of the
deck concrete.
b)
The width of the joint gap shall be kept as 20 mm.
c)
The st late shall conform to weldable structural steel as
per IS: 2062. The plate shall be 12 mm thick and 200 mm
wide. The plate shall be made of minimum number of
pieces (not exceeding two pieces per traffic lane width)
welded together to form the required length.
d)
8 mm dia, 100 mm long nails, spaced at 300 m centers
along the center line of the plate shall be welded to the
bottom surface of the steel plate to protrude vertically into
the joint gap in order to prevent dislodging of the plate.
e)
The plate and the nails shall be protected against
corrosion by galvanizing or any other approved
anticorrosive coating with a minimum thickness of 100
micron. These shall be completely free of oil, rust, loose
paint or other similar material before application of
anticorrosive coating.
f)
The concrete surface shall be free from any loose
material and cleared of any grease, oil, paint etc. and the
surface shall be sand blasted, clean of all laitance and
level true, prior to placement of the steel plate.
g)
The plate shall be placed symmetrical to the center line
of the joint and it shall be ensured that the plate does not

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get displaced from its position while laying the wearing


course.
Clause 2604.2

ASPHALTIC PLUG JOINT

Clasue2604.2.1

Asphaltic plug joint shall consist of a polymer modified bitumen


binder, carefully selected single size aggregate, closure/bridging
metallic plate and heat resistant foam caulking/ backer rod.

Clause 2604.2.2

General Requirements
a)

b)

c)

d)
e)
f)

Clause 2604.2.3

The joints shall extend to the full depth of the wearing


course down to structural concrete. Where needed, a
recess may be cut into the deck slab concrete to
accommodate the minimum required depth of the joints.
The joint shall be provided in the entire width of the
structure including kerb and / or footpath. A recess in the
kerb and / or footpath shall be made to allow the joint to
pass beneath them. The expansion gap in the adjoining
kerbs and / or footpaths shall be sealed with a suitable
sealant such as polysulphide sealant.
Expansion joint shall cater for a horizontal movement of
25 mm & vertical movement of 2 mm. This shall be
certified by the manufacturer / supplier of the joint.
The minimum width (in traffic direction) of the joint shall
be 500 mm and maximum width shall be 750 mm.
Minimum depth of joint shall be 75 mm and maximum
depth shall not exceed 100 mm.
The joint shall be capable of performing satisfactorily,
within the temperature (ambient) range of 5 to +50
degree C.

Material
a) Binder:
The polymer modified bitumen binder shall have the capacity to
fill the gaps and voids between single size aggregate and to
impart flexibility to accommodate various design movements. It
shall be patented blend of bitumen, synthetic polymer, fillers and
surface active agent and shall be so formulated as to combine
necessary fluidity for the installation process, low temperature
flexibility and flow resistance at high ambient temperatures.
The binder shall satisfy following requirement:
Softening point
: 100 deg. C minimum
Core penetration at 25 deg.
: 100 mm max.
C., 0.1 mm (BS 2499)
Flow resistance at 70 deg.
: 3 mm max.
C., 5 hours (BS 2499)
Extension Test
: 5 cycle of extension to 50
(blocks prepared to ASTMD
per cent at a rate of 3.2
1190 and tested to limits BS
mm/hour at 25 deg.C
2499)
Safe heating temperature
: 210 deg. C

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b) Aggregates:
The aggregate shall be single size aggregate chosen from
basalt, granite, grit stone or gabro group. The nominal size of
aggregate shall be 12.5 mm for depths of joints upto 75 mm and
20 mm for joints of more depths of joint. The aggregate shall not
be flaky and the Flakiness Index shall not be more than 25 per
cent. The aggregate shall satisfy following grading
requirements:

IS Sieve Designation

26.5 mm
19.9 mm
13.2 mm
09.5 mm
06.3 mm
02.3 mm
600 micron
75 micron

Nominal Size of Aggregate


20 mm
12.5 mm
Percent by weight passing the
sieve
100
-85-100
100
0-35
85-100
0-7
0-35
-0-7
0-2
0-2
----0-1
0-1

The aggregate should have good (i) Polished Stone Value


(PSV), (ii) Aggregate Abrasion Value (AAV), (iii) Aggregate
Impact Value (AIV) and (iv) Aggregate Crush Value (ACV). In
addition, surface characteristics should promote proper
adhesion. The following are the required values:
PSV > 60
AAV < 05
AIV < 18
ACV= 1025
c) Closure Plate
The closure plate shall be weldable structural steel conforming
to IS 2062. The minimum thickness of steel plate shall be 6 mm
and the width shall not be less than 200 mm. Closure plate shall
be provided with as large length as possible and welded
together to form the required length. The number of pieces shall
not be more than two per traffic lane width. It shall be provided
with equidistant holes at a maximum spacing of 300 mm centers
for anchorage to the caulking/ backer rod along the longitudinal
center line of the plate. The plate shall be protected against
corrosion by galvanizing or any other approved anti-corrosive
coating paint with a minimum thickness of 100 micron.

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d) Foam caulking/ Backer rod


A closed-cell polyolefine or open cell polyurethene foam
cylindrical caulking or backer rod having diameter equal to 150
per cent of the joint opening shall be provided. It shall be heat
resistant and possess good flexibility and recovery
characteristics with density of 25 to 30 Kg/cum.
Clause 2604.2.4

Installation
a)
b)

c)

d)

e)
f)

g)
h)

i)

j)

Clause2604.2.5

The Expansion joint shall be installed by the


manufacturer / supplier.
The block out for the joint shall be marked and
constructed to the dimensions as indicated in the
drawing or recommended by the manufacturer /
supplier.
The recess for the block out shall thoroughly cleaned of
any loose or foreign material wire brushing and air
blowing and dried with hot compressed air.
The recess in the deck slab, if required, shall be
repaired with epoxy mortar and cleaned and dried
again.
The foam caulking/backing rod shall be placed about
25 mm down into the joint opening.
The aggregate shall be washed, cleaned and heated to
a temperature between 120-180 deg.C prior to
placement.
The binder shall be preheated to temperature of 170 190 C before application.
While sealing the joint opening with preheated binder,
care shall be taken that the binder does not spill on to
the joint surface of the deck.
The joint shall not installed when the ambient
temperature goes below + 5 deg. C or above + 35 deg.
C. or while it is raining / snowing. (Planning for
installation must take into account the weather
condition.)
When clement weather resumes, the joint installation
may be continued after the upper layer and / or
exposed surface of the partially completed joint has
been reprepared by heating and / or coating with binder
as necessary.

Handling and Storage


All the aggregates and binder shall be pre-bagged and clearly
marked. All the material shall be stored on concrete platform at
150 mm above the ground in covered enclosures to avoid
contamination.

Clause 2604.2.6

Tests and Standard of Acceptance


The material shall be tested in accordance with these
specifications and shall meet prescribed criteria. The

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manufacture/ supplier shall furnish the requisite certificates from


the recognized testing laboratory of India or abroad.
The work shall conform to these specifications and shall meet
the prescribed standards of acceptance.
Clause 2604.3

COMPRESSION SEAL JOINT

Clause 2604.3.1

Compression seal joint shall consist of steel armoured nosing at


two edges of the joint gap suitably anchored to the deck
concrete and a performed chloprene elastomer or closed cell
foam joint sealer compressed and fixed in to the joint gap with
special adhesive binder.

Clause 2604.3.2

Material
a) Steel nosing
The steel nosing shall be of angle section ISA 100 x 100
conforming to weldable structural steel as per IS: 2062. The
thickness of legs shall not be less than 12 mm. The top face of
the angle shall be provided with Bleeder holes of 12 mm
diameter spaced at a maximum 100 mm centers so as to
ensure that there are no voids in the concrete beneath the
angle.
b) Anchorage
The anchorage steel shall conform to IS: 2062 or equivalent.
The steel nosing shall be anchored to the deck by reinforcing
bars or anchor plates cast in concrete or a combination of
anchor plates and reinforcing bars. Anchor bars shall engage
the main structural reinforcement of the deck and in case of
anchor plates and anchor loops, this shall be achieved by
passing transverse bars through the loops or plates.
The minimum thickness of anchor plate shall be 12 mm. Total
cross sectional area of bars on each side of the joint shall not be
less than 1600 sq. mm per metre length of the joint and the
center to center spacing shall not exceed 250 mm. The ultimate
resistance of each anchorage shall not be less than 600 KN/m
in any direction.
c) Corrosion Protection
All steel section shall be protected against corrosion by hot dip
galvanizing or any other approved anticorrosive coating with a
minimum thickness of 100 micron.
d) Joint Seal
i)

The sealing element shall be a performed continuous


chloroprene or closed cell from seal with high tear
strength, insensitive to soil, gasoline and ozone. It shall

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have high resistance to ageing and ensure water


tightness. The seal should be vulcanised in a single
operation for the full length of the joint required for
carriageway, kerbs and footpaths, if any. The seal shall
cater for a horizontal movement up to 40 mm and vertical
movement of 3 mm.
ii)

The physical properties of chloroprene / closed cell foam


sealing element shall conform to the following:

Chloroprene Seal
Shall be performed extruded multi web cellular section of
chloroprene of such a shape as to promote self removal of
foreign material during normal service operations. Chloroprene
of joint seal shall conform to clause 915.1 of IRC: 83 (Part - II)
and satisfy the properties stipulated in Table 2: Strip Seal
Element Specifications of these specifications except in respect
of the working movement range of the sealing element which
shall be as specified in Clause 2604.3.2 d (i) above.
Closed Cell Foam Seal
Shall be of performed non extruded non cellular section made
from low density closed cell crossed linked ethylene vinyl
acetate, polyethylene copolymer that is physically blown using
nitrogen. The material shall possess properties as indicated in
Table-1 below:
TABLE-1
S.
No.
i)

Property

Specified Value

Density

41.7 51.3 kg/ cum

ii)

Compression Set on 25 mm

50 percent compression
samples (ASTM D 3575) for 22
hours at 23 degree Celcius, 2
hour recovery; 13 percent set.

iii)

Working temperature

-70 to +70 deg. C.

Iv)

Water absorption (total


immersion for 3 months)
(ASTM 3575)
Tensile strength

0.09766 Kg/ sq.m

v)
vi)

Elongation at break (ASTM


D 3575)

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0.8 Mpa
195 +/- 20 percent

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e) Lubricant cum Adhesive


The type and application of material used in bonding the
performed joint seal to the steel nosing and concrete shall be as
recommended by the manufacturer / supplier of the seal system.
Clause 2604.3.3

Handling and Storage


a) The expansion joint material shall be handled with care and
stored under cover.
b) All joint material and assemblies shall be protected from
damage and assemblies shall be supported to maintain
true shape and alignment during transportation and
storage.

Clause 2604.3.4

Installation
a) The expansion joint shall be installed by the manufacturer/
supplier or their authorized representative, who will ensure
compliance of installation procedure and instructions.
b) The dimension of the joint recess and the width of the gap
shall conform to the approved drawing.
c) Anchoring steel shall be welded to the main reinforcement
in the deck maintaining the level and alignment of the joint.
d) Concreting of pocket/ recess shall be done with great care
using proper mix conforming to same grade as that of the
deck concrete but not less than M30 grade in any case.
The water cement ratio shall not be more than 0.40. If
needed, suitable admixtures may be used to achieve the
workability. The width of pocket shall not be less than 300
mm on either side of the joint. Care shall also be taken to
ensure efficient bonding between already cast/ existing
deck concrete and the concrete in the joint recess.
e) At the time of installation, joint shall be clean and dry and
free from spalls and irregularities, which might impair a
proper joint seal.
f) Concrete or metal surfaces shall be clean, free of rust,
laitance, oils, dirt, dust or other deleterious materials.
g) The lubricant cum adhesive shall be applied to both faces
of the joint and joint seal prior to installation in accordance
with the manufacturer's instructions.
h) The joint seal shall be compressed to the specified
thickness for the rated joint opening and ambient
temperature at the time of installation, which shall be
between +05 to +35C.
i) The joint seal shall be installed without damage to the seal.
Loose fitting or open joints shall not be permitted.

Clause 2604.3.5

Acceptance Criteria
a) All steel elements shall be furnished with corrosion
protection system.
b) For the joint seal the acceptance test shall conform to the
requirements stipulated in Clause 2604.3.2 d above. The
manufacturer/ supplier of this type of joint shall produce a

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test certificate to this effect conducted in a recognized


laboratory in India or aboard.
c) Prior to acceptance 25 percent of the completed and
installed joints, subject to a minimum of one joint, shall be
subjected to water tightness test. Water shall be
continuously ponded along the entire length for a minimum
period of 4 hours for a depth of 25 mm above the highest
point of deck. The width of ponding shall / be at least 50
mm beyond the anchorage block of the joint on either side.
The depth of water shall not fall below 25 mm anytime
during the test. A close inspection of the underside of the
joint shall not reveal any leakage.
Clause 2604.3.6

Tests and Standards of Acceptance


The material shall be tested in accordance with these
specifications and shall meet the prescribed criteria. The
manufacturer/ supplier shall furnish the requisite certificates
from the recognized testing laboratory of India or abroad.
The work shall conform to these specifications and shall meet
the prescribed standards of acceptance.

The clause 2607 be replaced fully as below:


Clause 2607

STRIP SEAL AND MODULAR / BOX SEAL JOINTS

Clause 2607.1

STRIP / BOX SEAL EXPANSION JOINT

Clause 2607.1.1

Components
Strip seal expansion joint shall comprise of the following items:
a) Edge Beam
This shall be either extruded or hot rolled steel section or cold
rolled cellular steel section with suitable profile to mechanically
lock the sealing element in place throughout the normal
movement cycle. Further the configuration shall be such that the
section has a minimum thickness of 10 mm all along its cross
section (flange & web). Thickness of lips holding the seal shall
not be less than 6 mm. The minimum height of the edge beam
section shall be 80 mm. The minimum cross sectional area of
the edge beam shall be 1500 sq. mm.
b) Anchorage
Edge beam shall be anchored to the deck by reinforcing bars or
anchor plates cast in concrete or a combination of anchor plate
and reinforcing bars. Anchor bars shall engage the main
structural reinforcement of the deck and in case of anchor plates
or loops, this shall be achieved by passing transverse bars
through the loops or plates.

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The minimum thickness of anchor plate shall be 12 mm. Total


cross sectional area of bar on each side of the joint shall not be
less than 1600 sq. mm. per metre length of the joint and the
center to center spacing shall not exceed 250 mm. The ultimate
resistance of each anchorage shall not be less than 600 KN/m
in any direction.
Clause 2607.1.2

Material
a) The steel for edge beams shall conform to any of the steel
grade corresponding to RST 37-2 or 37-3 or 52-3 (DIN),
ASTM A36 or A588, CAN/CSA Standard G 40.21 Grade
300 W or equivalent.
b) Anchorage steel shall conform to IS: 2062 or equivalent.
c) All steel sections shall be protected against corrosion by
hot dip galvanizing or any other approved anticorrosive
coating with a minimum thickness of 100 micron;
d) Chloroprene of strip seal element shall conform to Clause
915.1 or IRC: 83 (Part-II). The properties of chloroprene
shall be as specified in Table-2 below:

TABLE 2: STRIP SEAL ELEMENT SPECIFICATION


PROPERTY
Hardness*
DIN 53505
ASTM D 2240 (Modified)
Tensile Strength*
DIN 53504
ASTM D 412
Elongation at fracture*
DIN 53504
ASTM D 412
Tear Propagation Strength
Longitudinal
Transverse
Shock Elasticity
Abrasion
Residual Compressive Strain
(22 h/70 deg. C/30 per cent
strain)
Ageing in hot air
(14 days / 70 deg. C)
Change in hardness
Change in tensile strength
Change in elongation at fracture
Ageing in ozone
(24 h/50 pphm/ 25 deg. C / 20
per cent elongation )
Swelling behavior in Oil
(168h/25 deg. C)
ASTM Oil No.1
Volume Change

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SPECIFIED VALUE
63 + 5 Shore A
55 + 5 Shore A
Min 11 MPa
Min 13.8 MPa
Min 350 Per cent
Min 250 Per cent

Min 10 N/mm
Min 10 N/mm
Min 25 Per cent
Min 220 Cu. mm
Max 28 per cent

Max + 7 Shore A
Max 20 per cent
Max 20 per cent
No Cracks

Max + 5 per cent


Max 10 Shore A

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Change in Hardness
ASTM Oil No. 3
Volume Change
Max + 25 per cent
Change in Hardness
Max + 20 Shore A
Cold Hardening Point
Max 35 deg. C
*
Only one set of specification viz. ASTM or DIN shall be
followed
depending on the source of supply
Clause 2607.1.3

Fabrication (Pre-installation)
a) The strip seal joint system and all its component parts
including anchorages shall be supplied by the
manufacturer / system supplier.
b) The width of the gap to cater for movement due to thermal
effect, prestress, shrinkage and creep, superstructure
deformations (if any) and sub-structure deformation (if any)
shall be determined and intimated to the manufacturer.
Depending upon the temperature at which the joint is to be
installed, the gap dimension shall be preset.
c) Each strip seal expansion joint system shall be fabricated
as a single entity unless stage construction or excessive
length prohibits monolithic fabrication. It shall fit the full
width of the structure as indicated on the approved
drawing. The system shall be pre-set by the manufacturer
prior to transportation. Presetting shall be done in
accordance with the joint opening indicated on the drawing.
d) The finally assembled joint shall then be clamped and
transported to the work site.

Clause 2607.1.4

Handling and Storage


a) For transportation and storage, auxiliary brackets shall be
provided to hold the joint assembly together.
b) The manufacturer/supplier shall supply either directly to the
Engineer or to the Bridge Contractor all the materials of
strip seal joints including sealants and all other accessories
for the effective installation of the joints.
c) Expansion joint material shall be handled with care. It shall
be stored under cover on suitable lumber padding.

Clause 2607.1.5

Installation
a) The joint shall be installed by the manufacturer/supplier or
their authorized representative who will ensure compliance
to the manufacturer's instructions for installation.
b) Taking the width of gap for movement of the joint into
account, the dimensions of the recess in the decking shall
be established in accordance with the drawings or design
data of the manufacturer. The surfaces of the recess shall
be thoroughly cleaned and all dirt and debris removed. The
exposed reinforcement shall be suitably adjusted to permit
unobstructed lowering of the joint into the recess.

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c) The recess shall be shuttered in such a way that


dimensions in the joint drawing are maintained. The
formwork shall be rigid and firm.
d) Immediately prior to placing the joint, the presetting shall
be inspected. Should the actual temperature of the
structure be different from the temperature provided for
presetting, correction of the presetting shall be done. After
adjustment, the brackets shall be tightened again.
e) The joint shall be lowered in a pre-determined position.
Following placement of the joint in the prepared recess, the
joint shall be leveled and finally aligned and the anchorage
steel on the one side of the joint welded to the exposed
reinforcement bars of the structure. Upon completion, the
same procedure shall be followed for the other side of the
joint. With the expansion joint finally held at both sides, the
auxiliary brackets shall be released, allowing the joint to
take up the movement of the structure.
f) High quality concrete shall then be filled in to the recess.
The packing concrete must feature low shrinkage and have
the same strength as that of the superstructure, but in any
case not less than M-35 grade. Good compaction and
careful curing of concrete is particularly important. After the
concrete has cured, the movable installation brackets and
shuttering still in place shall be removed.
g) The neoprene seal shall be field installed in continuous
length spanning the entire roadway width. To ensure
proper fit of the seal and enhance the ease of installation,
dirt, spatter or standing water shall be removed from the
steel cavity using a brush, scrapper or compressed air. The
seal shall be installed without any damage to the seal by
suitable hand method or machine tools.
h) As soon as the concrete in the recess has become initially
set, a sturdy ramp shall be placed over the joint to protect
the exposed steel beams and neoprene seals from the site
traffic. Expansion joint shall not be exposed to traffic before
the carriageway surfacing is placed.
i) The carriageway surfacing shall be finished flush with the
top of the steel sections. The actual junction of the
surfacing / wearing coat with the steel edge section shall
be formed by a wedge shaped joint with a sealing
compound. The horizontal leg of the edge beam shall be
cleaned beforehand. It is particularly important to ensure
thorough and careful compaction of the surfacing in order
to prevent any premature depression forming in it.
Clause 2607.1.6

Acceptance Criteria
a) All steel elements shall be finished with corrosion
protection system.
b) For neoprene seal, the acceptance test shall conform to
the requirements stipulated
in Table
1. The
manufacturer/supplier shall produce a test certificate
accordingly, conducted in a recognized independent
laboratory in India or abroad.

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c) The manufacturer shall produce test certificates indicating


that anchorage system had been tested in a recognized
laboratory to determine optimum configuration of
anchorage assembly under dynamic loading.
d) Prior to acceptance 25 percent of the completed and
installed joints, subject to a minimum of one joint, shall be
subjected to water tightness test. Water shall be
continuously ponded along the entire length for a minimum
period of 4 hours for a depth of 25 mm above the highest
point of deck. The width of ponding shall be at least 50 mm
beyond the anchorage block of the joint on either side. The
depth of water shall not fall below 25 mm anytime during
the test. A close inspection of the underside of the joint
shall not reveal any leakage.
e) Investigation of fatigue strength of the edge beam section
with anchorages to withstand 2 x 106 load change cycles of
85 KN vertical load and 10 KN of horizontal load without
showing sign of distress shall be required. The supplier
shall produce a test certificate in this regard conducted in a
recognized laboratory in India or abroad.
f) As strip seal type of joint is specialized in nature, generally
of the proprietary type, the manufacturer shall be required
to produce evidence of satisfactory performance of this
type of joint.
Clause 2607.1.7

Tests and Standards of Acceptance


The materials shall be tested in accordance with these
specifications and shall meet the prescribed criteria. The
manufacturer/supplier shall furnish the requisite certificates from
the recognized testing laboratory of India or abroad.

Clause 2607.2

MODULAR STRIP/BOX SEAL JOINT

Clause 2607.2.1

A modular expansion joint shall consist of two or more


modules/cells to cater to a horizontal movement in excess of 70
mm. It shall allow movements in all 3 directions and rotation
about all 3 axes as per design requirements. It shall ensure that
during all movement cycles of the joint, opening and closing
(gaps) of all modules are equal.

Clause 2607.2.2

Component
a) The structural system consisting of two edge beams, one
or more central/separation beams or lamellas and cross
support bars supporting individual or multiple central
beams to transfer the loads to the bridge deck through the
anchorage system.
b) Resilient or shock absorption support system for central
beams as well as support bars to dampen dynamic loading
thus reducing the forces transmitted to the substructure
and anchorages and also to accommodate vertical and
transverse movements apart from longitudinal movement.

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c) Sliding or control system which allows closing and opening


of the joint and also ensures that all modules open and
close equally.
d) Mechanically locked sealing system of chloroprene which
provides watertight, noiseless and easy replacement
system.

Clause 2607.2.3

Materials
a) Edge and Central Beams
These shall be either extruded or hot rolled steel sections or
cold rolled cellular steel sections including continuously shop
welded sections for central beams with suitable profile to
mechanically lock the sealing element in place throughout the
normal movement cycle. Further, the configuration shall be such
that the section has a minimum thickness of 10 mm all along the
cross section (flange & web). The thickness of lips holding the
seal shall not be less than 6mm. The cold rolled cellular sections
shall be relieved of any locked in stresses through annealing
process. These shall be closed at both ends and be air tight
after installation of seal to prevent ingress of moisture in the
hollow portion. The minimum height of edge beams and central
beam sections shall be 80 mm. Minimum cross sectional area of
edge beam shall be 1500 sq. mm. The material shall conform to
any of the steel grade corresponding to RST 37-2 or 37-3 or 523 (DIN), ASTM A36 OR A588, CAN/CSA Standard G 40.21
Grade 300 W or equivalent. The material for support bars may
be same as that of edge/central beams or as per manufacturer's
recommendations.
b) Chloroprene Seal
This shall be performed extruded single strip or cellular section
of chloroprene of such a shape as to promote self removal of
foreign material during normal joint operation. The seal shall
possess high tear strength and be insensitive to oil, gasoline
and ozone. It shall have high resistance to ageing and ensure
water tightness.
Chloroprene seal shall conform to clause 915.1 of IRC: 83 (partII). The properties of chloroprene shall conform to Table 2
Strip Seal Element Specification of these specifications.
c) Anchorage
The anchorage steel shall conform to IS: 2062 or equivalent.
Edge beam shall be anchored to the deck by anchor plates cast
in concrete or a combination of anchor plate and reinforcing
bars. Anchor plates or loops shall be anchored by passing
transverse bars through the loops or plates.

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The minimum thickness of anchor plate shall be 12mm. Anchor


bars on each side of the joint shall not be less than 1600 sq. mm
per metre length of the joint and the center anchor bars to
center spacing shall not exceed 250 mm. The ultimate
resistance of each anchorage shall not be less than 600 KN/m
in any direction. The anchor loop at the edge profiles should be
at right angle to the joint. Planned deviations of this direction are
allowable only for the range of 900 +/- 200. (The anchoring
reinforcement of the construction must lie parallel to the anchor
loops.)
d) Support and Control System
The overall system and components of the resilient/shock
absorption system and sliding / control system shall conform to
the specifications recommended by the manufacturer. The
center to center spacing of transverse support bars shall not
exceed 1.75 m.
e) Corrosion Protection
All steel section shall be protected against corrosion by hot dip
galvanizing or any other approved anti corrosive coating with a
minimum thickness of 100 micron.
Clause 2607.2.4

Fabrication (pre-installation)
a) The modular expansion joint system and all its component
parts including anchorages shall be supplied by the
manufacturer.
b) The width of the gap to cater for movement due to thermal
effect, prestress, shrinkage and creep, superstructure
deformations (if any) and sub-structure deformation (if any)
shall be determined and intimated to the manufacturer.
Depending upon the range of temperature at which the
joint is likely to be installed, the gap dimension shall be
preset.
c) Each modular expansion joint system shall be fabricated as
a single entity free from any joint in the longitudinal
direction unless stage construction or excessive length
prohibits monolithic fabrication. It shall fit the full width of
the structure as indicated on the approved drawing. The
system shall be pre-set by the manufacturer prior to
transportation. Pre-setting shall be done in accordance with
the joint opening indicated on the drawing.
d) The finally assembled joint shall then be clamped and
transported to the work site.

Clause 2607.2.5

Handling and Storage


a) For transportation and storage, auxiliary brackets shall be
provided to hold the joint assembly together.
b) The manufacturer / supplier shall supply either directly to
the Engineer or to the Bridge Contractor entire assembly of

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Modular Strip / Box Seal joints including sealants and all


other accessories for the effective installation of the joints.
c) Expansion joint material shall be handled with care. It shall
be stored under cover on suitable lumber padding.
Clause 2607.2.6

Installation
a) The joint shall be installed by the manufacturer/supplier
only.
b) Taking the width of gap for movement of the joint into
account, the dimensions of the recess in the decking shall
be established in accordance with the drawings or design
data of the manufacturer. The surface of the recess shall
be thoroughly cleaned and all dirt and debris removed. The
exposed reinforcement shall be suitably adjusted to permit
unobstructed lowering of the joint into the recess.
c) The recess shall be shuttered in such a way that
dimensions in the drawings are maintained. The formwork
shall be rigid and firm.
d) Immediately prior to placing the joint, the presetting shall
be inspected. Should the actual temperature of the
structure be different from the temperature provided for
presetting, correction of the presetting shall be done. After
adjustment, the brackets shall be tightened again.
e) The joint shall be lowered in a pre-determined position.
Following placement of the joint in the prepared recess, the
joint shall be leveled and finally aligned and the anchorage
steel on one side of the joint welded to the exposed
reinforcement bars of the structure. Upon completion, the
same procedure shall be followed for the other side of the
joint. With the expansion joint finally held at both sides, the
auxiliary brackets shall be released, allowing the joint to
take up the movement of the structure.
f) Controlled concrete having strength not less than that in
superstructure subject to the minimum of M-35 shall be
filled into the recess. The packing concrete must feature
low shrinkage. Good compaction and careful curing of
concrete is particularly important. After the concrete has
cured, the movable installation brackets and shuttering still
in place shall be removed.
g) The chloroprene seal shall be field installed in continuous
lengths spanning the entire roadway width. To ensure
proper fit of the seal and increase the ease of installation,
dirt, spatter or standing water shall be removed from the
steel cavity using a brush, scraper or compressed air. The
seal shall be installed without damage to the seal by
suitable hand method or machine tools.
h) As soon as the concrete in the recess has become initially
set, a sturdy ramp shall be placed over the joint to protect
the exposed steel beams and neoprene seals from site
traffic. Expansion joint shall not be exposed to traffic
loading before the carriageway surfacing is placed.
i) The carriageway surfacing shall be finished flush with the
top of the steel sections. The actual junction of the
surfacing / wearing coat with the steel edge section shall

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be cleaned beforehand. It is particularly important to


ensure thorough and careful compaction of the surfacing in
order to prevent any premature depression forming in it.
Clause 2607.2.7

Acceptance Criteria
a) All steel elements shall be finished with corrosion
protection system.
b) For Chloroprene seal, the acceptance test shall conform to
the requirements stipulated in clause 2607.1.2 (d).
c) The manufacturer shall produce a test certificate
accordingly, conducted in a recognized laboratory, in India
or abroad.
d) Fatigue strength of internal beams and support connection
shall be investigated to withstand 2 million cycles of vertical
load of 85 KN and a horizontal load of 10 KN without
showing signs of distress. The supplier shall have to
produce a test certificate in this regard conducted by a
recognized laboratory from India or abroad.
e) The manufacturer shall produce test certificates indicating
that anchorage system had been tested in a recognized
laboratory to determine optimum configuration of
anchorage assembly under dynamic loading.
f) Prior to acceptance 25 percent of the completed and
installed joints, subject to a minimum of one joint, shall be
subjected to water tightness test. Water shall be
continuously ponded along the entire length for a minimum
period of 4 hours for a depth of 25 mm above the highest
point of deck. The width of ponding shall be at least 50 mm
beyond the anchorage block of the joint on either side. The
depth of water shall not fall below 25 mm anytime during
the test. A close inspection of the underside of the joint
shall not reveal any leakage.
g) As Modular strip / box seal type of joint is specialized in
nature, generally of the proprietary type, the manufacturer
shall be required to produce evidence of satisfactory
performance of his product.

Clause 2607.2.8

Tests and Standards of Acceptance


The materials shall be tested in accordance with these
specifications and shall meet the prescribed criteria. The
manufacturer / supplier shall furnish the requisite certificates
from the recognized testing laboratory in India or abroad.
The work shall conform to these specifications and shall meet
the prescribed standards of acceptance.

Clause 2609

MEASUREMENT FOR PAYMENT


Insert the following as the second sentence of this clause:
The expansion joint shall be measured along the width of the
deck slab from one end to the other, including length through
footpaths and parapets.

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SECTION 2700

WEARING COAT AND APPURTENANCES

CLAUSE 2702

WEARING COAT

Clause 2702.1

Bituminous Wearing Coat

Clause 2702.1.1

This Clause shall read as follows:


Wearing coat shall be constructed as shown in drawings.

Clause 2702.1.2

This following shall be added under this sub-clause:


Measurement: The unit of measurement shall be square
metres.
Unit Rate: The contract unit rate for wearing coat shall include
the cost of prime coat, 15 mm thick mastic asphalt, overlaid
with 50 mm thick BC and all labour, material, tools and plants
and other costs necessary for construction of the work as per
specifications.

CLAUSE 2703

RAILINGS AND PARAPETS

Clause 2703.3

Cast-in-Situ Concrete Railings.


The heading shall be read as follows:
Cast-in-Situ Railings and parapets
Last sentence of the third paragraph shall be replaced by the
following.
Location of construction joints shall be determined in advance
and approved by the Engineer
Add new sub-clause as follows.

CLAUSE 2703.5

CONCRETE CRASH BARRIER BRIDGES

Clause 2703.5.1

General
This work shall consist of construction, provision and
installation of concrete crash barrier on the bridge deck /
approach slab / approaches locations and of dimensions as
shown in the drawings or as directed by the Engineer.

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Clause 2703.5.2

ORR/JICA2/Pkg 2/Vol II

Materials
All materials shall conform to Section 1000, as applicable, and
relevant clauses in Section 1600 shall govern the steel
reinforcement. The concrete barriers shall be constructed
either by the cast-in-place with fixed forms method or the
estrusion or slip form method or a combination thereof with
the approval of the Engineer. Where extrusion or slip form
method is adopted, full details of the method and literature
shall be furnished.
Grade of concrete for crash barrier shall be as per BOQ or as
directed by Engineer.
An expansion joint with Polysulphide Joint sealants and
bituminous fibreboard shall be provided in the crash barriers
at the location of expansion joints / gaps on the bridge,
approaches etc.,

Clause 2703.5.3

Construction Operations
The location of crash barrier shall be strictly adhered to as
shown in the drawing and as directed by the Engineer.
Concrete crash barriers shall present a smooth, uniform
appearance in their final position, conforming to the horizontal
and vertical lines shown on the plans or as ordered by the
Engineer and shall be free of lumps, sags or other
irregularities. The top and exposed faced of the barriers shall
conform to the specified tolerances, as defined in Clause
809.4, when tested with 3m straight edge, laid on the surface.

Clause 2703.5.4

Tolerance
The overall horizontal alignment of crash barrier and rails shall
not depart from the road alignment by more than +30mm, nor
deviate in any two successive lengths from straight by more
than 6mm and the faces shall not vary more than 12mm from
the edge of a 3m straight edge. Barriers shall be at the
specified height, as shown in the plans, above the edge of the
nearest adjacent carriageway or shoulder, within a tolerance
of +30mm.

Clause 2703.5.5

Measurements for Payment


All barriers will be measured in running metre. The sealing of
opening in crash barrier at expansion joints with polysulphide
rubber sealant and bituminous fibreboard as per sub-clause
2703.6 shall be incidental to work. The painting over crash
barrier shall not be measured / paid separately and is
incidental to the work. The cost of GI pipe over crash barrier,
MS plate and painting over GI pipe shall be incidental to the
work.

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Clause 2703.5.6

ORR/JICA2/Pkg 2/Vol II

Rate
The Contract unit rate shall include full compensation for
furnishing all labour, materials, tools, equipment and incidental
costs necessary for doing all the work involved in constructing
the concrete barrier complete in place in all respects as per
these Specifications.
Add new sub-clause as follows:

Clause 2703.6

Polysulphide Rubber Joint Sealant


Polysulphide Joint Sealants with bituminous fibreboard shall
be provided in the expansion joints / gaps in crash barriers.
Before Joint it shall be ensured that the top of the fiber board
and the concrete faces are dry, sound, free from dirt, grease
and other loose foreign matters. A thin coat of primer shall be
applied only on the concrete faces with a brush. The primer
shall be allowed to air dry before applying sealant. The
components of the sealant i.e., base and hardener shall be
mixed in the slow speed mechanical mixer till uniform clor is
obtained. Placement of the mixed sealant shall be done with
either catridge of fully enclosed gun barrels within 30 minutes
of mixing. Manufactures recommendation shall be followed.
The sealing compound shall be two packs, low modulus of
elasticity, polysulphide elastomer having no tar or bituminous
ingredients such as Cico T-680 or equivalent with following
properties of the cured compound.
Tensile strength
Modulus of elasticity
Elongation
Hardness

Operating temperature
Shrinkage
Permanent dynamic movement
Capability

: 0.4 Mpa +10%


: At 100% elongation:
.15 Mpa
: Elongation at break
550%
: Shore A hardness
22+3 @250C
: -200C to + 800C
: Less than 1%
: + 25%

Polysulphide material shall be approved by the Engineer prior


to procurement and use.
Measurements for Payment
Cost for providing Polysulphide Joint sealants and bituminous,
fibreboard in the Expansion Joints in Crash Barriers shall be
deemed to be included in the unit rate of Crash Barrier and
shall not be measured separately.

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Clause 2704

ORR/JICA2/Pkg 2/Vol II

APPROACH SLAB
Replace first paragraph of this clause with the following:
Provision of approach slab shall be in accordance with Guide
lines regarding approach slab for bridges given in MOST
circular no. RW/NH-34015/2/86-S&R dated 22 June 1994.
Delete second sentence of the last paragraph of this clause.

CLAUSE 2706

WEEP HOLES
This Clause shall be read as under:
Weep holes shall be provided in solid plain
concrete/reinforced concrete, brick or stone masonry
abutments, wing walls, return walls as shown on the drawings
or as directed by the Engineer to drive moisture from the back
filling. Weep holes shall be provided with 100 mm diameter
A.C. pipe and shall extend through the full width of concrete
with slope of about 1 vertical: 20 horizontal towards the
draining face.
The spacing of weep holes shall generally be 1 m in either
direction or as shown on the drawing with the lowest at about
150 mm above the low water level or ground level whichever
is higher or as directed by the Engineer.

CLAUSE 2709

RATE
The Second paragraph shall read as follows:
The contract unit rate of parapets and railings shall include
the cost of all labour, materials, tools and plants required for
completing the unit in accordance with these specifications.

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SECTION 2800

Repair of Structures

Clause 2809

DISMANTLING OF CONCRETE WEARING COAT


Read title as follows:
DISMANTLING OF EXISTING WEARING COAT, EXPANSION
JOINTS AND DRAINAGE SPOUTS

Clause 2809.1

Commencement of Dismantling
Add the following as item (iv)
(iv) The existing wearing coat, concrete as well as bituminous
overlay, shall be removed for the entire length including
approach slab for all minor bridges with solid slab
superstructure. Only damaged portion of wearing coat shall be
removed for major bridges and minor bridges with T-Beam and
slab superstructure.

Clause 2809.2

This Clause shall read as follows:


The removal operations shall be carried out mechanically using
pavement breakers and compressors. Removal shall be done
carefully to avoid damage to any part of the existing structure. In
delicate locations, for example around spouts, removal shall be
done by manual methods. After removal, the concrete deck
surface shall be closely inspected for identifying any distress
such as cracks, pockets of loose or honeycombed concrete etc.
The deck surface shall be thoroughly cleaned with special
efforts to remove any loose material. Expansion joints and
spouts shall be removed carefully so that deck concrete is not
damaged.

Clause 2809.3

Precautions During Dismantling Work


Add the following at the end of this clause:
Dismantled material shall not be stacked on the deck nor shall
it be thrown below the bridge. It shall be neatly piled at points
designated by the Engineer with all leads and lifts. Materials,
which can be used or auctioned, shall be stored in neat piles at
locations designated by Engineer with all leads and lifts.
New clauses 2811 to 2831 shall be added after Clause 2810
as given below and existing clauses 2811, 2812 and 2813
shall be renumbered as 2832, 2833 and 2834

Clause 2811

DISMANTLING
OF
EXISTING
RAILINGS,
KERBS,
FOOTPATH SLABS, PART OR COMPLETE DECK SLABS,
APPROACH SLABS AND DAMAGED CONCRETE IN WING
WALLS/RETURNS, PIERS AND ABUTMENTS, RCC/BRICK
MASONRY, ENCLOSURES OF BEARINGS

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Railings, kerbs, footpath slabs, part or complete deck slabs,


approach slabs and damaged concrete in wing walls/returns,
piers and abutments, RCC/Brick Masonry, Enclosures of
Bearings of the existing structures shall be dismantled as shown
in drawing or as directed by the Engineer.
The work shall be executed in accordance with Section 200
clause 202. All damaged concrete in wing walls, returns, piers
and abutments shall be thoroughly inspected to identify the
extent of dismantling. The decision of the Engineer regarding
extent of dismantling shall be final. Care shall be taken to avoid
damage to any part of the existing structure. Dismantling work
for railings and kerbs shall be done carefully such that the
existing reinforcement, which will project into the new work, is
not damaged or lost. Reinforcement shall be cleaned
thoroughly.
Dismantled material shall not be stacked on the deck nor shall it
be thrown below the bridge. It shall be neatly piled at points
designated by the Engineer with all leads and lifts. Materials,
which can be used or auctioned, shall be stored in neat piles at
locations designated by Engineer with all leads and lifts..
Water shall be sprayed to reduce dust while dismantling work is
in progress. Dismantling work shall not be carried out at night,
during storms or heavy rain.
Goggles and gas masks shall be worn at the time of
dismantling. Leather gloves shall be worn by the workers at the
time of dismantling. Screens made of G.I. sheets shall be placed
wherever necessary to prevent the flying pieces from injuring
the workers.
Damage caused to any component of the bridge structure
during removal operations shall be restored by the Contractor at
his cost. The service lines, if any, shall be disconnected/diverted
before dismantling work commences.
Clause 2812

DISMANTLING OF EXISTING DAMAGED BRICK / COARSE


RUBBLE MASONRY IN WING WALLS/RETURNS, PARAPET
ETC.
Damaged brick / coarse rubble masonry in wing walls / returns
and all brick / coarse rubble parapets shall be dismantled as
shown in drawings or as directed by the Engineer.
The work shall be executed in accordance with Section 200
clause 202. Damaged brick / coarse rubble masonry in wing
walls / returns shall be thoroughly inspected to identify the
extent of dismantling. The decision of the Engineer shall be
final. Care shall be taken to avoid damage to any part of the
existing structure.
Dismantled material shall not be stacked on the deck nor shall it
be thrown below the bridge. It shall be neatly piled at points

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designated by the Engineer with all leads and lifts. Materials,


which can be used or auctioned, shall be stored in neat piles at
locations designated by Engineer with all leads and lifts.
Leather gloves shall be worn by the workers during dismantling.
Screens made of G.I. sheets shall be placed, wherever
necessary, to prevent the flying pieces from injuring the workers.
Damage caused to any component of the bridge structure
during removal operations shall be restored by the Contractor at
his cost.
Clause 2813

DISMANTLING
OF
EXISTING
WING
WALL
FOR
CONSTRUCTION OF ADJACENT 2 LANE BRIDGE (a)
BRICK / COARSE RUBBLE MASONRY (b) CONCRETE
Existing brick / coarse rubble masonry / concrete wing wall shall
be dismantled for construction of adjacent 2 lane bridge as
shown in drawings or as directed by the Engineer.
The work shall be executed in accordance with Section 200
clause 202. Only portions which interfere with the construction
of the wing wall/return/median wall of the adjacent 2-lane bridge
shall be dismantled. The decision of the Engineer regarding
extent of dismantling shall be final.
During dismantling all precaution shall be taken to prevent
failure of the retained earth of the approaches.
Dismantled material shall not be stacked on the deck nor shall it
be thrown below the bridge. It shall be neatly piled at points
designated by the Engineer with all leads and lifts. Materials,
which can be used or auctioned, shall be stored in neat piles at
locations designated by the Engineer with all leads and lifts.
Goggles and gas masks shall be worn at the time of
dismantling. Leather gloves shall be worn by the workers.
Screens made of G.I. sheets shall be placed wherever
necessary to prevent flying pieces from injuring the workers.
Damage caused to any component of the bridge structure
during removal operations shall be restored by the Contractor at
his cost.

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Clause 2814

ORR/JICA2/Pkg 2/Vol II

FIXING DOWEL BARS IN DECK SLAB AND GROUTING


WITH NON-SHRINK FREE FLOW CEMENT GROUT
1 Scope
The work shall consist of fixing TMT bars in the existing
concrete deck slab/other concrete components to facilitate
bonding of a structural component with an existing one.
At least 14 days before start of the work, the Contractor shall
furnish detailed methodology of construction including sources
of supply of material, tools, equipment and appliances be
used on work, details of personnel and supervision.
The Contractor's personnel shall be qualified and experienced
in repair and rehabilitation work of such nature.
2 Materials
TMT bars shall conform to Section 1000 and IS-1786.
The grout material used for fixing TMT bars in drilled holes in
concrete shall be obtained from a reputed manufacturer and
grout mix shall be prepared in conformity with the
manufacturer's recommendations. The material shall be either
of the following:
(a) Two/three component low viscosity epoxy resin system,
having required characteristics of bonding with concrete
and resistance to moisture penetration (Resicrete 21 or
Resicrete 212 of MIS Structural Waterproofing Co. or
SIKADUR BTP of MIS Sika Qualcrete or equivalent).
(b) Cement grout in powder form consisting of cement, good
quality sand and admixtures when mixed with required
amount of water forms a pourable mix to be used for
bonding TMT bars in concrete (EXCEM - E1
manufactured by MIS Structural Water Proofing Company
or MIS SIKADUR or equivalent).
The epoxy resin system shall conform to Clause 2803.
The cement grout shall basically be shrinkage compensated,
chloride free and of very high strength (50 MPa at 28 days).
The mix should be capable of pumping or pouring and shall
have excellent bond strength with concrete and steel (bond
strength of 15 MPa with TMT bars at 28 days).

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3 Construction Operations
The construction operation shall be in the following sequence,
and shall be supervised by the Contractor's engineer well
experienced in such works:
(i)

Drill holes of required diameter and depth at desired


locations as shown on Drawings.

(ii)

Clean the hole with air blast through air nozzle of 6-mm
dia connected to air compressor to remove the drilled
powder, which may remain inside the drilled hole.

(iii)

Mix the required quantity of grout so that the work could


be completed within the normal setting time as specified
by the manufacturers.

(iv)

Pour required quantity of mixed grout in the holes.

(v)

Insert the dowel rod in the hole where grout has been
placed. Move the rod up and down several times to drive
out entrapped air, if any.

(vi)

Allow the curing


specifications.

time

as

per

manufacturer's

(vii) Inclined dowels shall be straightened to match their


intended profile only after the grout has finally set and
required strength has been achieved
4 Measurements for Payment
Measurement for fixing TMT bars in concrete involving drilling
in concrete and fixing TMT bar with suitable fixing agent shall
be measured in number of such TMT bars fixed in position.
5 Rate
The contract unit rate for fixing of TMT bars in existing
concrete slab/other components shall include cost of all
material, labor, tools and plants, drilling required diameter hole
in concrete, placing in position, temporary works, testing and
curing and other incidental expenses for the satisfactory
completion of the work as per the specifications.
Clause 2815

RAILINGS/PARAPETS
Cast-in-situ railings/parapets shall be constructed in accordance
with the requirements of structural concrete Section 1700. The
reinforcement shall conform to Section 1600. The formwork
shall conform to Section 1500. The work in general shall
conform to Section 2700 clause 2703.

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The reinforcement of the railings/parapets shall be welded with


the existing reinforcement of the deck slab and with the dowel
bars as shown in the drawings or as directed by the Engineer.
In case there are no old dowel bars, fresh dowel bars shall be
fixed into deck slab as per clause 2814.
Clause 2816

REPAIR OF CORRODED REINFORCEMENT


Repair of corroded reinforcement (where corrosion has reduced
the diameter of the bar by more than 20%) shall be done by
providing new reinforcement, which is either welded or firmly
secured with the old reinforcement.
1 Material
Steel which is to be used as additional reinforcement where the
diameter of existing main longitudinal reinforcement has been
reduced to 80% of the original, should satisfy the requirements
of IS: 226-1975 or IS: 1786-1976. However, the BRC fabric or
weld mesh, which are to replace/strengthen the corroded
stirrups, or tie bars, should be from reputed manufacturers.
2 Repairing Procedure
The exposed reinforcement showing signs of deterioration by
corrosion shall be cleaned by grit blasting.
When corrosion products have been removed, the diameter of
the reinforcement shall be measured. If the diameter of the
reinforcement is found to be reduced to 80% of the original, then
additional reinforcement of equivalent diameter free from rust
shall be firmly secured with the old reinforcement, preferably by
welding, if existing reinforcement can be welded or with a lap of
at least 40 times the dia of the bar.

Clause 2817

PROVIDING AND FIXING DRAINAGE SPOUTS INCLUDING


SEALING WITH WATER PROOFING MATERIAL
For all existing bridge decks drainage spouts shall be replaced
and new drainage spouts shall be provided as shown in the
drawings.
The waterproofing material shall be provided around the area of
drainage spout from the top of the deck.
The work shall be executed in accordance with Section 2700
clause 2705 except to the extent modified below.
The work shall be carried out after the wearing coat is removed.
The existing spouts shall be removed carefully with minimum
damage to surrounding concrete. The pocket formed shall be
sufficiently large to ensure good flow and compaction of nonshrink cement grout around the new spout. In case the earlier

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spouts were provided in railing kerb, holes shall be drilled in slab


without excessively damaging surrounding concrete.
Clause 2818

REPAIR TO
CONCRETE

LEACHED,

HONEYCOMBED,

SPALLED

Leached, honeycombed, spalled concrete (area of damage <


0.5 sq. m.) shall be repaired with 50mm thick (average) PMC
mortar in two or more layers with a bond coat of PMC slurry
between two successive layers.
All loose concrete shall be chipped off with a chipping machine
so that loose layers of concrete are removed exposing the
reinforcement. All loose concrete sticking with the reinforcement
shall be removed. Where reinforcement bars are already
exposed, the chipping shall continue so as to expose half the
diameter prior to further treatment. The concrete surface shall
be thoroughly cleaned with wire brush and oil free air blast.
Where the damaged area is large, sand blasting shall be done
to clean the reinforcement and surrounding concrete. If
reinforcement is exposed, the same shall also be cleaned
thoroughly. The reinforcement shall be coated with PMC slurry
within one hour of cleaning to prevent rusting. The PMC slurry
shall be brush applied on the cleaned reinforcement ensuring
that full surface area is covered in accordance with the
manufacturers recommendation.
Before applying PMC repair mortar, the prepared concrete
substrata shall be thoroughly soaked with clean water. Free
surface water shall be removed before priming. The substrata
shall be primed with PMC slurry.
The specifications for polymer modified cementations (PMC)
mortar / debonding slurry are as under:
The anti corrosive polymer latex, which is to be used should
consist of water based QA-Acrylic polymer incorporated with
non-alcoholic bipolar corrosion inhibitor. The polymer to be used
shall be MONOBOND-2000 or equivalent.
Colour: Milky white liquid
Solid content: The polymer solid content shall be 36 1
percent. The particles shall be of nearly spherical shape with a
diameter of 0.35 0.05 micrometer. The manufacture shall
certify the above requirements about solid content & grain size.
In order to keep control over quality, the manufacture shall
provide infrared absorption spectrum analysis for the material to
be supplied by them.
Mixing proportion: Anti-corrosive polymer modified mortar
Cement
Monobond 2000
Mix no. 10 Silica Sand

304

- 100 parts by weight


- 40 parts by weight
- 300 parts by weight

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The sand, which is to be used for constituting the PMC repair


mortar, should be silica sand as the basic material, which is
categorized in two groups.
a)
b)

Coarse Silica and


Fine Silica

The grading of the above groups should follow the limits


provided below.
Quartz sand mix No. 10
I.S. Sieve
No.
10 mm
4.75 mm
2.36 mm
1.18 mm
600 microns
300 microns
150 microns
75 microns

Percentage passing by
weight
100
100
100
85 - 90
45 - 55
15 - 20
5 - 10
0-3

In the event of using local sand, the sand to be used must


satisfy the limits of deleterious materials & the requirements of
soundness as given in Clause 3.2.1 & Clause 3.6 respectively of
IS: 383. Confirmatory test shall be conducted by the contractor
and sample kept for comparison by the engineer.
Curing:
Anti-corrosive polymer modified mortar curing procedure apply
to normal weather conditions. Under hot weather, precautions
shall be taken to avoid drying. PMC work should be carried out
at a temperature below 40o C.
Under unusual condition weather conditions e.g. high humidity
and / or high wind velocity or imposed constraints, special curing
procedure shall be followed for which approval shall be obtained
from the Engineer.
Air-drying shall be considered to have taken place only during
favourable uninterrupted weather condition existing throughout
the recommended drying period. Some judgments shall be
made in this respect and if conditions are deemed unfavourable
for drying to occur, then drying must be prolonged for the
recommended full period after the weather clears.
As PMC work proceeds, precautions shall be taken to prevent
rapid drying of the PMC repair mortar. This is usually
accomplished by covering the filled surfaces with an
impermeable sheet shortly after the work has been done. The
sheet shall be kept in place until further work is carried out over

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the mortar or in case where the mortar is likely to be disturbed,


the sheet shall be kept in place for 24 hours.
No foot traffic for further work shall be allowed over mortar until
12 hours from the time of the completion of work.
Curing compound may also be used as curing membrane. Care
shall be taken to ensure complete covering particularly around
the interface with the host concrete.
For the first day, the repaired concrete patch shall be protected
from harsh environment by laying a polythene sheet over it,
lapping down the edges.
Mixing PMC:
Methods of Mortar mixing
To mix PMC, it is necessary to have the following items:

A suitable sized non-ferrous mixing container, preferably


plastic;
A high-speed drill with mixing paddles; and
Promark batching containers for measuring out
components to be mixed.

Pour all the liquid polymers latex into mixing container.


Shake the latex to disperse the solid uniformly throughout the
liquid before use.
Begin mechanical mixing and while doing so, slowly add the dry
components, i.e. cement & sand.

Mix for about 5 minutes until solids have been well dispersed.
The resulting mix should look uniform, feel creamy and be free
from lumps & grits.
Precautions shall be taken not to entrap an excessive amount of
air into the mix during mixing.
Since the desired consistency depends on type & brand of
cement as well as weather conditions, start a trial mix with a
reduced amount of cement. Once all components are mixed,
add cement if necessary to achieve the desired consistency.
Record the amounts of cement required and use this for
subsequent mixes. Do not reduce the quantity of cement noted
in the Mix Proportions.
In case the slurry sets before application of mortar, a fresh coat
of slurry shall be applied. Under no circumstances, water shall
be added in PMC repairs mortar mix. Unused mortar or mortar
which has partially set, shall not be re-mixed & used.

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Mechanical Strength of Mortar:


Anti-corrosive polymer modified mortar shall have the following:

Compressive
strength
Flexural strength
(IS 5816 1959)
Split tensile
strength
(IS 5816 1959)

7 days
18 N/mm2

28 days
38 N/mm2

10 N/mm2

6 N/mm2

For anti corrosion polymer modified bonding slurry:


The anti-corrosive polymer modified bonding slurry shall be QA
Acrylic base MONOBOND 2000 or equivalent.
The bonding slurry should remain in tacky state prior to placing
of the freshly mixed concrete or mortar with mechanical strength
of polymer modified bonding slurry.
Mixing proportions of Bonding Slurry shall be as follows:
Cement
weight
MONOBOBD 2000
Fine Silica sand

100 parts by

40 parts by weight
100 parts by weight

The fine silica sand, which is to be used for consistency in anticorrosive polymer modified bonding slurry, should be with fine
silica sand with following sieve sizes.

I.S. Sieve No.


10 mm
4.75 mm
2.36 mm
1.18 mm
600 icrons
300 crons
150 icrons
75 microns

Percentage passing by weight


100
100
100
100
90-100
40-60
0-10
0-3

Mechanical Strength of Bonding Slurry


Bond Strength
WET
DRY

3-4 N/mm2
7-8 N/mm2

Above bonding slurry should conform to the following properties:

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Clause 2819

ORR/JICA2/Pkg 2/Vol II

ASTM-C1059-86 (Latex agents for bonding fresh to old


concrete)

ASTM-C1042-86 (Bond strength of latex system with


cement)

Pot life: 1 hour for 5 kg bonding slurry mix.

REPAIR TO VOID IN ARCHES WITH PMC MORTAR


The voids created in the masonry arches by dislodged stones
shall be filled with PMC mortar.
The surface shall be thoroughly cleaned with wire brush and oil
free air blast. Before applying PMC repair mortar the prepared
substrata shall be thoroughly soaked with clean water. Free
surface water shall be removed before priming. The substrata
shall be primed with PMC slurry. Repair mortar shall be applied
before primer has set i.e. within 20-30 minutes. The mortar shall
be applied with trowel and shall be well worked inside and
compacted. The surface shall be smooth finished to match the
adjacent surface. Unused mortar or mortar which has partially
set shall not be used. Mortar shall be applied in layers to avoid
sagging. Manufacturers recommendation shall be followed.

Clause 2820

SEALING OF CRACKS IN CONCRETE IN PIER / ABUTMENT


CAPS, SLABS, GIRDERS, PEDESTAL WALLS ETC. WITH
EPOXY RESIN INJECTION
The work is to seal all cracks in concrete in pier/abutment caps,
slabs. girders, pedestal walls etc.
The work shall be executed in accordance with Section 2800,
clauses 2803 & 2804.
The cracks shall be sealed with epoxy mortar prior to injection.
Epoxy for mortar shall be Resicrete 2115 or equivalent. Epoxy
for injection shall be Resicrete 21 or equivalent.
The epoxy resin material shall be approved by the Engineer
prior to procurement and use.

Clause 2821

INSPECTION & CLEANING OF BRIDGE BEARINGS AND


GREASING OF STEEL ROCKER-ROLLER
/ PLATE
BEARINGS AND REMOVAL OF ALL DEBRIS AROUND
BEARINGS
The work shall consist of inspection of bearings to check
whether the bearings are functioning properly and if any parts of
the bearing or nuts and bolts are missing, to replace them. The
work shall also include cleaning of bearings and oiling and
greasing of metallic bearings, wherever required. Realignment /
readjustment of bearings, and replacement of missing parts of
metallic bearings, requiring jacking up of superstructure is
excluded from the scope of work. Replacement of existing

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bearings with new bearings is also excluded from the scope of


the work.
The area around the bearings and their pedestals shall be
cleared of all debris, vegetation, dust etc. and cleaned for proper
inspection.
When grease boxes are fixed around the metallic bearings, (a)
the same shall be permanently removed along with old grease
and (b) bearings shall be cleaned for proper inspection.
In case of elastomeric bearings, these shall be inspected for
their proper seating, rotation, bulging, cracking, splitting etc. and
a record thereof shall be provided to the Engineer for necessary
instructions.
In respect of metallic bearings, fresh graphite grease as
approved by the Engineer shall be applied to the surfaces,
which are sliding, rotating or moving due to movements in
bearings. The materials, specially, graphite grease, required for
oiling and greasing of metallic bearings, wherever required, shall
be as per approval of the Engineer. Grease used shall be such
that it retains its properties for long life and shall not affect the
bearing parts.
All other surfaces of the metallic bearings shall be cleaned of all
rusts, corrosion and a coat of anti corrosive oil paint applied as
per directions of the Engineer.
Missing parts of metallic bearings, nuts and bolts etc. shall be
replaced by the Contractor at no extra cost to the Employer.
Clause 2822

CONTROLLED JACKING UP OF SUPER STRUCTURE,


RESETTING / REPLACEMENT OF ROCKER AND ROCKER
CUM ROLLER BEARINGS, SEGMENTAL BEARINGS AND
ELASTOMERIC BEARINGS
The work shall be executed before laying of new wearing coat
and expansion joint. The superstructure shall be jacked up
nominally at abutment end for resetting of the bearings. Jacking
up of superstructure is a specialised work. Contractor shall
furnish a methodology statement with his proposal for
resetting/repair of bearings. Lifting shall be done through
hydraulically operated jacks. The jacks shall be placed under
cross diaphragm. Adequate distribution plates shall be placed at
top and bottom of the jack to reduce the stress on concrete. If
the soffit of the cross diaphragm is weak, the same shall be first
repaired with epoxy mortar and/or epoxy injection and lifting will
commence only after such repair is fully cured. In addition to
jacks, the span will also be supported on packing plates which
shall be placed under the cross diaphragm between the jacks.
The extent of lifting shall be decided by the Engineer.
Only proven type of jacks shall be used. These jacks shall be
provided with lock-nut system. The jacks shall be randomly

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tested for 1.5 times the capacity. In lifted condition the span will
be supported on the lock-nut arrangement of the jacks with no
pressure on the hydraulic circuit. The contact stress on concrete
shall not exceed 30 MPa. Suitable M.S. distribution plates have
to be provided at top and bottom of the jack for this purpose. All
jacks shall be connected to a common pump and it will be
ensured that the deck is rifted equally upstream & downstream.
For monitoring this, dial gauges shall be provided. Only steel
packing plates shall be used. Specifications for epoxy
mortar/epoxy injection shall be followed for repair to soffit of
cross diaphragm.
The cross diaphragms shall be closely watched during lifting
and also for the entire duration when the span is supported on
jacks and packings. If development of cracks is observed, the
lifting will be stopped and alternate arrangement for supporting
the superstructure shall be made subject to approval of the
Engineer.
The cost of all operations under this clause including all tools
and plants. Materials, jacks, pumps, labour etc. shall be
incidental to cost of resetting / replacement of bearings.

Clause 2823

APPLYING 1:3 CEMENT MORTAR TO EXPOSED SURFACE


OF MASONRY OF EXISTING WING WALLS / RETURNS,
ABUTMENT AND PIERS
All exposed masonry surface of existing wing walls /returns,
abutments, piers etc. shall be provided with 20mm thick plaster
in two layers.
The work shall be in accordance with Section 1300.

Clause 2824

BUILDING UP OF EXISTING WING WALLS / RETURNS AND


RETAINING WALL AT SIDES OF APPROACH SLABS WITH
BRICK MASONRY AND FINISHING WITH 1:3 CEMENT
MORTAR 20mm THICK
Existing wing walls and returns wherever deficient shall be built
up and retaining walls shall be constructed at sides of the
approach slabs as shown in the drawings or as directed by the
Engineer.
The work shall be done in accordance with Section 1300.
Masonry for construction of short retaining walls at sides of
approach slab shall be laid over a 100mm thick M 15 PCC
leveling course.

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Clause 2825

ORR/JICA2/Pkg 2/Vol II

SEALING OF WIDE GAPS AT JUNCTION OF WING WALL


AND ABUTMENT WITH BRICK BATS AND FINISHING WITH
1:3
CEMENT
MORTAR
INCLUDING
PROVIDING
BITUMINOUS DEBONDING LAYER
Due to settlement of wing wall, the gap created at the junction of
the wing wall and the abutment, shall be sealed by filling with
brickbats and finishing with plaster.

Clause 2826

The abutment face of the gap shall be coated with one layer of
bituminous compound. The gap shall be filled with bricks bats
and rammed. The vertical exposed surface of the gap shall be
plastered. Thereafter cement slurry shall be poured from the top
under gravity till refusal. The top surface of the gap shall then be
plastered and finally finished.
EARTH FILLING BELOW APPROACH SLAB
This should include:
(a) Excavating the embankment, sub-grade etc. to the
required depth
(b) Refilling with suitable sub-grade fill, pavement base or sub
base to specifications
The work shall be executed in accordance with Standard
Specifications Section 300 Clause 305. The cavities formed
below the approach slabs shall be filled with approved back fill
material. The filling shall be done in layers not exceeding
150mm. The masonry retaining wall shall also be built up in
companion layers of 150mm. The compaction shall be done
with the help of suitable equipment after necessary watering
Measurement for Payment
Measurement for payment shall be as per clause 305.8 of
standard Specification Section 300.
Rate
Rate shall be as per clause 305.9 of standard Specification
Section 300.

Clause 2827

CASTING OF APPROACH SLAB


The grade of concrete shall be as indicated in drawings / Bill of
Quantities / as directed by the Engineer.
Approach slabs which are cracked, missing or otherwise
damaged shall be recast.
The work shall be executed in accordance with Section 2700
clause 2704. The approach slab shall be laid over lean concrete
as per drawing. The base shall be consolidated to proctor
density 98%.

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Measurement for Payment


The measurement shall be in cubic metre.

Rate
The contract unit rate for approach slab shall include the cost
of all reinforcement, labour, material, tools and plant and other
cost necessary for completion of the work as per these
Specifications. The rate for base shall include cost of all
reinforcement, labour, material, tools and plant required,
including preparation of surface and consolidation complete in
all respects

Clause 2828

STONE PITCHING ON SLOPES, 300mm THICK, GROUTED


WITH 1:3 CEMENT MORTAR
Slope protection with stone pitching shall be provided at
abutments.
The work shall be executed in accordance with Section 2500.
Slope protection with stone pitching shall be provided at
abutments of particular bridge wherever disturbed or required.
This will include removing the disturbed slope pitching and
restoring the same and strengthening if required
Measurement for Payment
The stone pitching shall be measured in cubic metre.
Rate
The contract unit rate shall be as per Clause 2510 of
standard Specification Section 2500.

Clause 2829

PROVIDING AND PLACING IN POSITION MECHANICALLY


FABRICATED GABION WALL AROUND ABUTMENT AND
PIERS INCLUDING EXCAVATION AND BACKFILLING
The work shall be executed in accordance with Section 2500
clause 2503. Excavation and back filling shall be done in
accordance with Section 300.
Gabions shall consist of a double twisted Zinc & PVC coated
wire mesh container of variable sizes, uniformly partitioned into
internal cells. interconnected with other similar units, and filled
with stone at the site to form flexible, permeable, monolithic
structures. Mechanically fabricated double twisted hexagonal
mesh type gabion such as Maccaferri or equivalent conforming
to ASTM/ BS specifications shall be used.

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Mechanically fabricated double twisted hexagonal mesh shall be


approved by the Engineer prior to procurement and use.
Clause 2830

COMPRESSIBLE
PRE-MOULDED
BOARD IN LONGITUDINAL JOINTS

ASPHALT

FILLER

The work shall be done in longitudinal joint between existing and


new bridge.
2 mm dia. wire shall be sewn on one face of the filler board as
shown in the drawings. The wire shall be at least 300 mm in
length and shall be tied to reinforcement wherever possible. The
other face shall be glued to the central verge concrete of the
existing bridge with approved adhesive. The filler board shall be
positioned vertically 25 mm below the top of the verge.
Premoulded filler board shall be 50mm thick with a tolerance of
1.5mm and of a firm compressible material and complying with
the requirements of IS : 1838 or BS Specification clause No.
2630.
Filler board material shall be approved by the Engineer prior to
procurement and use.
Clause 2831

POLY-SULPHIDE RUBBER JOINT SEALANT


The work shall be done in longitudinal joint between existing and
new bridge.
Before application it shall be ensured that the top of the fiber
board and the concrete faces are dry, sound, free from dirt,
grease and other loose foreign matters. A thin coat of primer
shall be applied only on the concrete faces with a brush. The
primer shall be allowed to air dry before applying sealant. The
components of the sealant i.e. base and hardener shall be
mixed in a slow speed mechanical mixer till uniform color is
obtained. Placement of the mixed sealant shall be done with
either cartridge of fully enclosed gun barrels within 30 minutes of
mixing. Manufacturer's recommendation shall be followed.
The sealing compound shall be two packs, low modulus of
elasticity, polysulphide elastomer having no tar or bituminous
ingredients such as Cico T -680 or equivalent with following
properties of the cured compound.
Tensile strength
Modulus of elasticity
Mpa
Elongation
Hardness
@ 25C
Operating temperature
Shrinkage
Permanent dynamic movement

313

0.4 Mpa 10%


At 100% elongation: 0.15

Elongation at break 550%


Shore' A' hardness 223

-20C to +80C.
Less than 1%.
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capability
Polysulphide material shall be approved by the Engineer prior to
procurement and use.
Clause 2832

The existing clause 2811 of the Specifications shall be


renumbered as 2832.

Clause 2833

The existing clause 2812 of the Specifications shall be


renumbered as 2833.
Add the following as items (i) to (dd)
i)
Dismantling of existing railings, kerbs, footpaths,
approach slabs etc. shall be measured in cubic meter of
concrete dismantled;
j)
M-35 Concrete parapet with/ without footpath and steel
handrail shall be measured in linear meters;
k)
Dismantling of existing damaged brick masonry shall be
measured in cubic metres of brick masonry dismantled;
I)
Dismantling of wing walls shall be measured in cubic
metres;
m)
Provision of dowel bars shall be measured in numbers;
n)
Repair of corroded reinforcement shall be measured in
terms of weight of steel/reinforcement used, in tonne;
o)
Drainage spouts shall be measured in numbers;
p)
Repairs to concrete with PMC mortar shall be measured
in square metres with average thickness of 20 mm of
mortar applied;
q)
Sealing of cracks in masonry by cement grouting shall
be measured in terms of weight of cement consumption
in kg;
r)
Building up of existing wing walls/return walls/returning
walls shall be measured in cubic metre;
s)
Repair of voids in arches shall be measured in cubic
metre of mortar applied;
t)
Sealing of cracks in piers, slabs etc. shall be measured
in kgs. of epoxy actually consumed for mortar and
injection;
u)
Sealing of gaps between abutment and wing walls shall
be measured in square metres of surface area in
elevation i.e. height x width of gap;
v)
Earth fill below approach slabs shall be measured in
cubic metre;
w)
Concrete M-30 in approach slab shall be measured in
cubic metre;
x)
Premoulded filler boards shall be measured in square
metre;
y)
Polysulphide joint sealants shall be measured in linear
metres;
z)
Cleaning and greasing of bearings shall be measured in
numbers;
aa)
Jacking up superstructure will be measured as a lump
sum;
bb)
Applying cement mortar to exposed surface of masonry
shall be measured in square metres;

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cc)
dd)
Clause 2834

ORR/JICA2/Pkg 2/Vol II

Stone pitching shall be measured in cubic metre;


Gabion walls shall be measured in cubic metre.

Existing Clause 2813 shall be renumbered as 2834.


Add the following at the end of the Clause.
i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

The contract unit rate for dismantling of existing railing


shall include the cost of all materials, labour, tools,
plants, disposal of dismantled materials, safety
measures and all other incidental expenses necessary
for completion of work as per specifications.
The contract unit rate for dismantling of existing wing
walls shall include the cost of all materials, labour, tools,
plants, disposal of dismantled materials, safety
measures and all other incidental expenses necessary
for completion of work as per specifications.
The contract unit rate for dismantling of existing railing,
kerbs, footpath slabs, approach slabs and damaged
concrete in wing walls/returns, piers and abutments shall
include all labour, tools, plants, disposal of dismantled
materials, safety measures and all other incidental
expenses necessary for completion of work as per
specification.
The contract unit rate for dismantling of existing
damaged brick masonry in wing walls/returns, parapets,
etc. shall include all labour, tools, plants, disposal of
dismantled materials, safety measures and all other
incidental expenses necessary for completion of work as
per specification.
The contract unit rate for dismantling of existing wing
wall for construction of adjacent 2-lane bridge a) Brick
masonry b) Concrete shall include all labour, tools,
plants, disposal of dismantled materials, safety
measures and all other incidental expenses necessary
for completion of work as per specification.
The contract unit rate for dowel bars shall include the
cost of all materials excluding steel reinforcement bars,
labour, tools and plant, placing dowel bars in position,
wastage, sampling, testing and all other incidental
expenses necessary for completion of work as per
specifications.
The contract unit rate for providing drainage spouts shall
include the cost of all materials, labour, tools, plants,
disposal of dismantled materials, safety measures and
all other incidental expenses necessary for the
completion of work as per specification. The cost of PMC
brush topping shall not be paid separately.
The contract unit rate for Repair of corroded
reinforcement shall include the cost of all materials,
labour, tools, plants, disposal of dismantled materials,
safety measures and all other incidental expenses
necessary for the completion of work as per
specification.

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ix)

x)

xi)

xii)

xiii)

xiv)

xv)

xvi)

xvii)

xviii)

xix)

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The contract unit rate for repair to leached,


honeycombed, spalled concrete shall include the cost of
all materials, labour, tools, plants, disposal of dismantled
materials, safety measures and all other incidental
expenses necessary for the completion of work as per
specifications. The cost of PMC brush topping shall not
be paid separately.
The contract unit rate for applying cement mortar to
exposed masonry surfaces shall include the cost of all
materials, labour, tools, plants, scaffolding, sampling,
testing, curing and all other incidental expenses
necessary for completion of work as per specifications.
The contract unit rate for building up of existing wing
walls / returns and retaining walls at sides of approach
slabs with brick masonry and finishing with 1:3 cement
mortar, 20 mm thick, shall include the cost of all
materials, labour, tools, plants, scaffolding, sampling,
testing, curing and all other incidental expenses
necessary for completion of work as per specifications.
The contract unit rate for sealing of gaps with cement
mortar shall include the cost of all materials, labour tools,
plants, scaffolding, sampling, testing, curing and all other
incidental expenses necessary for completion of work as
per specifications.
The contract unit rate for earth filling below approach
slabs shall include the cost of all materials, labour, tools,
plants, and all other incidental expenses necessary for
completion of work as per specifications.
The contract unit rate for approach slabs shall include
the cost of all materials, labour, tools, plants, and all
other incidental expenses necessary for completion of
work as per specifications.
The contract unit rate for providing compressible
premoulded asphalt filler board shall include the cost of
all materials, labour, tools, plants, safety measures and
all incidental expenses necessary for completion of work
as per specifications.
The contract unit rate for providing polysulphide joint
sealant shall include the cost of all materials, labour,
tools, plants, and all other incidental expenses
necessary for completion of work as per specifications.
The contract unit rate for cleaning of bearing shall
include the cost of all materials, labour, operations, tools,
plants, and all incidental expenses necessary for
completion of work as per specifications.
The contract unit rate for controlled jacking up of bridge
superstructure shall include the cost of all materials,
Iabour, operations, tools, plants, safety measures and all
other incidental expenses necessary for completion of
work as per specifications,
The contract unit rate for stone pitching shall include the
cost of all materials, labour, tools, plants, and all other
incidental expenses necessary for completion of work as
per specifications.

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xx)

ORR/JICA2/Pkg 2/Vol II

The contract unit rate for gabion walls shall include the
cost of all materials, labour, tools, plants, and all other
incidental expenses necessary for completion of work as
per specifications.

SECTION 2900

PIPE CULVERTS

Clause 2904

Bedding for Pipe


Delete the word rammed in line 6 of paragraph (i) and
substitute it with by Roller/or plate vibrator.

Clause 2906

JOINTING
Delete the first and second sentences of Para 1 of this Clause
and Substitute.
The pipes shall be jointed by collar. The collars shall be of
RCC 150 to 200mm wide and having the same strength as
the pipes to be jointed.

Clause 2907

Backfilling
The Second sentence of this clause shall be replaced as
below:
The backfill shall be with selected granular material of
approved quality.

Clause 2910

Measurement for payment


The first line of second para of this Sub Clause shall be read
as:
Selected granular material for pipe bedding shall be
considered incidental to work and cement concrete bedding
shall be measured separately.

Clause 2911

Rate
The first paragraph under this Sub Clause shall be read as:
The Contract unit rate for the pipes shall include the cost of
pipes including loading, unloading, hauling, storing, laying in
position, jointing and all incidental costs to complete the work
as per these specifications.

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SECTION 3000

MAINTENANCE OF ROAD

Clause 3001

General
This Clause shall be read as under:
"The Specifications shall apply to all items of road
maintenance works as required to be carried out under the
Contract or as directed by the 'Engineer'. The works shall be
carried out in conformity with the relevant Specifications to the
required level, grade and lines using approved materials. The
works shall be carried out using light duty machinery or
manual means provided the quality of the end product does
not suffer. In execution of maintenance works, a reference is
made to the IRC publications: "Manual for Maintenance of
Roads" and "Code of Practice for Maintenance for Bituminous
Surfaces of Highways, IRC 82 - 1982" for guidance and
compliance wherever applicable. Wherever the Specification
is not clear, good engineering practice shall be adopted in the
construction to the satisfaction of the Engineer."

Clause 3005

THIS CLAUSE SHALL BE DELETED.

SECTION 3100

REINFORCED SOIL EARTH STRUCTURES

Section 3100

This Clause shall be substituted by Additional Specification.

Add new section 3200


SECTION 3200

UTILITY DUCTS

Clause 3201

Scope
The work shall consist of laying and jointing of RCC pipe NP-4
utility ducts in accordance with the requirements of Section
2900.

Clause 3202

Laying of Pipes
Laying of Pipes shall be carried out in accordance with clause
2905.

Clause 3203

Jointing
The provisions of clause 2906 of the specifications shall be
followed to the extent applicable. The Engineer's decision shall
be final and binding.

Clause 3204

Backfilling
Back filling, where directed by the Engineer, shall be carried out
in accordance with clause 2907 of the specifications.

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Clause 3205

ORR/JICA2/Pkg 2/Vol II

Closing of ends
The ends of pipes shall be closed with plastic covers to prevent
ingress of foreign materials after the construction.

Clause 3206

Measurement for Payments


The utility ducts shall be measured from end to end in linear
metres.

Clause 3207

Rate
The contract rate for ducts shall include the cost of pipes
including collars and covers, handling and storing of pipes,
laying in positions and jointing complete and all incidental works
necessary for completion. Excavation including back filling,
where necessary, shall not be measured and paid separately
and shall be included in the rate for Utility ducts.

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ADDITIONAL TECHNICAL SPECIFICATIONS

Clause A-1

DIVERSION OF EXISTING WATER COURSES

Clause A-1.1

Scope
The work shall consist of excavation of new channels for
diverting watercourses existing along the road way alignment
or at cross drainage structures and depositing the excavated
materials for closing the existing channels. The location and
the extent of work to be carried out shall be shown on the
Drawings or as directed by the Engineer.

Clause A-1.2

Construction Operations
Excavation of new channels and deposition of excavated
material shall be carried out in accordance with Clause 301.
The excavation shall be carried out to such widths and depths
and at such locations as shown on Drawings or as directed by
the Engineer. Deposition of the excavated material on the
existing channels shall be carried out in such a manner that
the latter gets closed and becomes non-operational. Any
surplus material, if found suitable shall be made use of in
embankment construction or sent to spoil as directed by the
Engineer.

Clause A-1.3

Measurement of Payment
The excavation of new channels shall be measured in cum. as
road way and drain excavation in accordance with Clause
301.

CLAUSE A-2

PLANTATION OF LOW HEIGHT SHRUBS

Clause A-2.1

Scope
The work shall consist of:
a) Planting of saplings in median.
b) Planting of low height shrubs with in median area.

Clause A-2.2

Sapling for Low Height Shrubs


The saplings (not less than 300mm in height) shall be of
draught resistant variety normally grown for hedges in the
area, approved by the Engineer.

Clause A-2.3

Planting of Low Height Shrubs


The low height shrubs saplings shall be planted in two rows,
one each along each edge of the median. Bed for the saplings
shall be prepared with necessary manuring, and the live
saplings shall be planted in lines parallel to the median edge to

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the directions of the Engineer. Spacing between saplings in a


row shall be such that a thick shrub can be grown, and this
shall generally be not farther away than 3m. The planting shall
be completed soon after completion of the medians.

Clause A-2.4

Maintenance
The saplings of low height shrubs planted shall be watered
and maintained by the Contractor till issue of final taking over
certificate. Maintenance shall also include watering, weeding
out of undesirable plants, and replacement of dead plant,
manuring and trimming of the hedges.

Clause A-2.5

Measurement for Payment


Planting of low height shrubs along median edges including
maintenance shall be measured in kilometres.

Clause A-2.6

Rates
The contract unit rate for planting of shrubs shall include the
cost of all labour and material involved in all the operations
described above including cost of saplings and maintenance
as mentioned above, the cost of supplying and stacking the
requisite quantity of manure and other incidentals.

CLAUSE A-3 INTER LOCKING CONCRETE BLOCKS


Clause A-3.1

Scope
The scope of work involves laying of interlocking concrete
blocks laid on 30 mm thick prepared sand bed conforming to
IRC: SP: 63 2004 and laid as shown in the drawings and as
directed by Engineer. The shape of blocks, the source of
supply, the methodology for laying of blocks shall be got
approved from Engineer.

Clause A-3.2

Unit of measurement
The unit of measurement shall be the area of the finished item
of work of interlocking blocks measured in plan in sq m.

Clause A-3.3

Rate
The unit cost includes full compensation for laying the sand
bed and laying the interlocking tiles including the cost of sand
and tiles.

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Clause A-4

ORR/JICA2/Pkg 2/Vol II

RAIN WATER HARVESTING STRUCTURE


1.

Scope
This work shall consist of construction of Rain Water
Harvesting Structures along roadside drains and other
locations intended for ground water recharging, as shown in
the drawings or as ordered by the Engineer and in
accordance with the requirements of these Specifications.

2.

Materials
All materials shall meet commercial grade standards and
shall be approved by the Engineer before being used in the
work.

3. Construction Operations
General
Prior to the start of the relevant construction, the Contractor
shall submit to the Engineer for approval his schedules for
carrying out construction of Road Side Drains and Rain Water
Harvesting Structures. He shall also submit for approval of his
proposed method of construction.
Trench Excavation
Trench for rainwater harvesting structure shall be excavated
to the specified lines, grades and dimensions shown in the
drawings. Where unsuitable material is met with at the trench
bed, the same shall be removed to such depth as directed by
the Engineer and backfilled with approved material which
shall be thoroughly compacted to the specified degree.
Filter Material for Trench
Filter material shall be provided to the dimensions as shown
in the drawing and directions of the Engineer. The grading of
filter material shall be as per the table given below.
Table 1: Grading for 6 mm to 12 mm material
Sieve Size

Percent Passing by weight

13.2

100

11.2

90 100

9.5

70 100

5.6

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Table 2: Grading for 12 mm to 20 mm material


Sieve Size

Percent Passing by weight

26.5

100

13.2

40

Sand shall be of coarse graded type with silt content not


more than 8 %.
3.1 Trench Slope Protection
The sloping sides of water courses along the trench shall,
where shown on the Drawings, be protected against the
action of water by rubble paving to form flat or curved surface
as indicated. The protection shall consist of rough dressed
square stones of size not less than 250 mm in depth nor less
than 0.02 cum in volume and no rounded boulders shall be
used.
4 Measurements For Payment
The work for rainwater harvesting trenches as stated above
shall be measured in terms of unit specified in Bill of
Quantities.
5 Rate
The Contract unit rate for rainwater harvesting structure shall
be payment in full for carrying out all the required operations
including full compensation for all materials, labour, tools and
incidentals.

Clause A-5

REINFORCED CONCRETE RETAINING WALLS


1

Description
This work shall consist of stone masonry and reinforced
concrete retaining walls of the sizes and dimensions shown
on the drawings or as approved by the Engineer, installed at
the locations shown on the drawings or as directed by the
Engineer in accordance with these Specifications.

Materials

2.1 Concrete
Plain cement concrete shall be of grade M15 below the
foundation of the retaining wall as per Clause 1704 of
MOSRTH Specifications.

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Structural concrete shall be of grade M30 as per Clause


1704 of MOSRTH Specifications.
2.2

Steel Reinforcement
The reinforcement for concrete structure shall be as shown
on the drawings or as directed by the Engineer and in
accordance with Clause 1009 of MOSRTH Specifications.
Formwork material shall conform to Clause 1500 of
MOSRTH Specifications.

2.4 Stone Masonry


Materials for stone masonry work shall conform to the
Clause 1004 of MOSRTH Specifications.
2.5

Mortar Materials
Portland cement shall conform to the requirements of
Clauses 1006 and 1304 of MOSRTH Specifications.

3
3.1

Construction
Excavation and Backfill
Excavation shall be performed in accordance with the
requirements of Clauses 304 of MOSRTH Specifications.
Backfill shall be performed in accordance with the
requirements of Clauses 305.4.4 of MOSRTH Specifications.

3.2

Formwork
Formwork shall be supplied and fixed in the position required
for the concrete to be cast as shown on the drawings or as
required by the Engineer and shall be supplied, erected and
removed as specified in Clause 1500 of MOSRTH
Specifications.

3.3

Steel Reinforcement
Steel reinforcement shall be furnished, bent and fixed where
shown on the drawings or where required by the Engineer
and its furnishing, bending and fixing shall be done in
accordance with Clause 1601 of MOSRTH Specifications.

3.4

Structural Concrete
Structural Concrete grade M30 and Plain cement concrete
grade M15 shall be supplied, placed, finished and cured as
specified in Clause 1700 of MOSRTH Specifications.

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4.

ORR/JICA2/Pkg 2/Vol II

Measurement and Payment


The excavation shall be measured in cubic metres and paid
as per Bill of Quantities.
.
Backfilling the trenches with excavated materials and
selected materials shall be measured in cubic metres and
paid as per Bill of Quantities
The quantity of Plain cement concrete shall be measured in
cubic metres and paid as per Bill of Quantities
The structural concrete shall be measured in cubic metres
and paid as per Bill of Quantities.
The steel required shall be measured in tonnes and paid as
per Bill of Quantities.
The payment shall be in full compensation for furnishing and
placing all materials including mortar, formwork and for all
labour, tools, equipment and incidentals necessary to
complete the work prescribed in this section.

Clause A-6

REINFORCED SOIL/ EARTH STRUCTURES

1.0

SCOPE

1.1

All elements comprising the reinforced soil/ earth structure


such as the facia units, the reinforcement with
accessories/fittings and the select backfill material shall all be
laid in conformity with the specifications and in compliance with
the lines, grades, design and dimensions as per the approved
drawings.

1.2

The reinforced soil/ earth structures shall be designed for a


service life of 100 years. The guarantee period for all types of
Reinforced Soil/ Earth Structures shall be ten (10) years from
the date of completion of flyover, underpass, overpass,
interchange, bridge works irrespective of defect liability period
specified elsewhere in the tender document. The contractor(s)
shall furnish the guarantee bond as directed by the Engineerin-Charge.

1.3

The work shall be done in conformity with the MORT&H


Specifications for Road and Bridge works, Reprint 2002. The
design shall ensure internal and external stability of the
reinforced soil/ earth wall, meeting the requirements of B.S.
8006-1995. For external and internal stability analysis under
seismic loading French Standard NF 94-220 and AASHTO/ US
Federal Highway Administration (FHWA) design guidelines
(FHWA-NHI-00-043) shall be followed.

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1.4

ORR/JICA2/Pkg 2/Vol II

Traffic live loads, traffic impact loads on vehicle safety barrier


system shall be taken in accordance with the design
requirements and earthquake loads as per IS: 1893-2002.
The Contractor shall submit within one month from the date of
commencement to the Engineer, the complete design,
computation and working drawing, and also the methodology
proposed to be adopted for the works.
The submission shall include the following:
i.Existing ground levels including cross-sections that have been
verified by the contractor for each location involving the
construction wholly or partially in the original ground.
ii.Layout of walls, detailed design calculations and drawings,
material specifications and construction methodology
including quality control and quality assurance of different
components.
iii.Earthwork requirements, specifications for materials and
compaction of fill.
iv.Details of drainage systems and any other facilities.
v.Test results of soil reinforcing structural element from
manufacturers/ suppliers.
vi.Test results of various materials from a reputed independent
laboratory in India or abroad.
vii.Detail sub-soil investigation report including field and
laboratory test results in complete.
viii.Any other information required in the plans or special
provisions or requested by the Engineer.

2.0

Eligibility Conditions
Reinforced soil/ earth structure being a specialized technology,
the contractor shall furnish design for approval by the engineer
and make his own arrangements to secure the supplies and
services needed. The past experiences and credentials in
details of the specialized agency executing the reinforced wall
construction shall be submitted well in advance for the
approval of the Engineer.
The reinforced soil/ earth structure technology shall have a
proven adoption with regard to durability. The approved agency
shall furnish documentary proof of satisfactory performance of
their proposed methodology for at least 10 years. The
approved executing agency shall have successfully completed
at least one project of construction of reinforced soil structures
of height not less than 8.0 m. and a total minimum 30,000
sq.m. of reinforced soil structures in India. He should provide
authenticated details of licensing and collaboration
arrangement, where relevant for prior approval.

3.0

REINFORCED SOIL/EARTH BACKFILL

3.1

The reinforced earth backfill shall be a select granular fill


having high frictional resistance, low compressibility and free
draining. Coarse-grained soils with limited fines adequately

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satisfy these requirements. Thus, the select granular fill may


contain fines content (passing 75 micron sieve) not exceeding
15%. Co-efficient of uniformity (Cu) of the backfill shall be
greater 2 and the peak angle of internal friction should be
greater than or equal to 320. The plasticity index shall not
exceed 5%.

3.2

The backfill shall also be free from organic or otherwise


deleterious materials so as not to cause corrosion of the soil
reinforcement and the facia panels. It shall conform to the
following physicochemical requirements.
Where metal reinforcement is proposed to be used, the backfill
material shall have a resistivity of 5000 ohm-cm or more
determined based on standard test as directed by Engineer
and materials with resistivity less than 1000 ohm-cm are
inadequate and shall not be used.
Materials with resistivity between 5000 & 1000 ohm-cm are
acceptable provided that in water extracted from soil-water mix,
the content of chlorides does not exceed 200 ppm, the content
of Sulphate does not exceed 1000 ppm, and the Ph value is in
the range of >5<10.
The foundation soils electrochemical requirements should also
meet the above criteria. If not, special consideration will be
given to the design of reinforcing element and facing material.
The above criteria applicable only for metal strip reinforcement.

3.3

The select backfill shall be compacted to ensure achieving


peak angle of friction not lower than 32 as established from
test as per Annexure C, BS 8006 1995. For design, effective
cohesion of backfill shall be taken as zero.

3.4

The compacted layer should not be more than 200mm thick.


The compaction of backfill material shall be 98% of maximum
laboratory density obtained from modified proctor compaction
test performed as per IS 2720 (Part-8).

3.5

Where metal reinforcement is proposed to be used, water used


for compaction of the select fill should have minimum resistivity
exceeding 700 ohm-cm.

3.6

Quality Control
For every 3000 cum of reinforced earth backfill material or
whenever the approved source is changed, one sieve analysis,
one measurement of resistivity, angle of internal friction and
modified Proctor density shall be carried out. Any further tests
on soil to confirm its suitability as reinforced earth backfill can
be decided based on the results of these tests. However,
organic and deleterious content, Ph, sulphate and chloride
content shall be carried out as decided by Engineer.

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4.0

REINFORCING ELEMENTS

4.1

Either of the reinforcing materials such as high adherence hot


dip galvanized steel or polymeric geosynthetics may be used
for reinforcing the select fill. The reinforcement may be in the
form of steel strips, for steel reinforcement and geogrids in
case of polymeric geosynthetic reinforcement. The selection of
suitable reinforcing element shall be as per specifications
given in the document and shall be approved by the Engineer.

4.1.1

Hot Dip Galvanised Soil Reinforcing Strips & Tie Strips


All metallic components buried in soil shall be made of
electrolytically compatible materials. Where this is not possible,
effective electrical insulation of durability equal to the service
life of the structure shall be provided between different
materials. Shapes and dimensions of these elements shall be
as shown on the approved drawings. The minimum width of
the individual steel strip must be 40mm and minimum
thickness must be 5 mm. Tie strips and High Adherence
Reinforcing (HAR) steel strips shall be hot rolled. Their
physical and mechanical properties shall conform to European
norms BSEN 10025 or equivalent IS 2062.
Tie strips shall be fabricated from the plain strips of 40 x 4mm
with same specification as of reinforcing strips.
Reinforcing and tie strips shall be cut to the lengths and
tolerances shown on approved drawings. Holes for bolts shall
be punched in the locations shown. They shall be carefully
inspected to ensure they are true to size and free from defects
that may impair their strength or durability.

Bolts and nuts shall be hexagonal in shape and high strength


screw conforming to European norm E25100 Class 10.9 or
equivalent IS. They shall be 12mm in diameter 40mm in length
with shank, hot dip galvanized conforming to BS 729 or ASTM
A153 or equivalent IS.
The manufacturer shall provide the test results of all physical
and mechanical properties of metallic reinforcement for each
lot or as required by Engineer.
4.1.2

Geosynthetics
The maximum allowable design load of the geogrid type shall
be higher than the required tensile load defined by the stability
analysis in the Design of the wall structure. The
manufacturers of geosynthetic materials must be able to
supply creep test data/ results for the period of minimum 10
years over a temperature of 40o C minimum (Facing
temperature attained in most tropical Indian climates/
locations where geosynthetics is connected to the modular
block or facia panel). The post construction strains in

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geosynthetics must be restricted below 1.0% for approach


highway retaining walls and 0.5% for abutments (mixed or
pure type) to meet serviceability state requirements.
All quantity control strength of geosynthetics must represent
minimum average roll values (MARV) only corresponding to
95% confidence limit. Testing of geosynthetic for tensile
strength shall be performed in accordance with ASTM D 4595
for every 5000 m2 and test data for each lot of material shall
accompany shipments.
4.1.2.1

Geogrid Reinforcement
The geogrid shall be made from high molecular weight and
high tenacity polyester (PET) yarn or high-density
polyethylene (HDPE). Materials should be confirming to BIS,
ISO 9002, BBA or FHWA. The PET geogrids should satisfy
the following electrochemical conditions:

Minimum molecular weight no.


> 25000

Maximum carboxyl end group no. (CEG)


< 30

Minimum mass per unit area (ASTM D 5261) > 250 g/


sqm
Polyester geogrids shall be quoted with a protective PVC
coating to maximize the resistance to hydrolysis and enhance
durability during construction and in service.
High-density polyethylene geogrids shall be manufactured by
extruded, drawn sheets and by punched and orientation
process in one direction so that the resulting ribs shall have a
high degree of molecular orientation, which is continued
through the integral transverse bar. It shall contain adequate
stabilisers to enhance stability to environmental stress
cracking (ESC), photo oxidation (UV exposure) and thermal
oxidation. Materials should be confirming to ISO 9002, BBA,
and FHWA etc. HDPE geogrids must possess 100% junction
efficiency of QC strength (in accordance to GR1-GG2-87 test
requirements) between longitudinal ribs and transverse bars
for efficient load transfer mechanism. Minimum mass per unit
area (ASTM D 5261) of HDPE geogrids shall be 500 gsm.
The roll width shall be minimum 5m.

4.1.2.2

Partial Factors
Partial factors as specified in BS 8006: 1995 shall be used to
calculate the long term design strength of geosynthetic
materials of any type proposed to be used as reinforcement.
HDPE
PET Based
Minimum partial FOS for
based
Geogrids
calculation of 100 years long
Geogrids
term design strength (LTDS) in
accordance with BS 8006:1995
requirement
1. Partial FOS for creep
2.6 5.0
1.6 2.5
deformation (Tu/Tcs)

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2.

3.

4.

5.

ORR/JICA2/Pkg 2/Vol II

Partial FOS for variations in


manufacture from control
specimens (fm 11)
Partial FOS for extrapolation
of creep test data (fm 12)

Partial FOS for construction/


installation damage
(susceptibility to damage)
(fm 21)
Partial FOS for potential
chemical (at 40C) and
biological degradation
(environment) (fm 22)

1.10 (10
years creep
test results
at 40C)

1.00 (use
only
MARV)
1.10 (10
years creep
test results
at 40C)

1.18

1.22

1.10

1.15

1.0 (use
only MARV)

In all cases, the long term design strength (LTDS) shall be


calculated by using the values of material partial factor of
safety based on 100 years service design life. All partial
factors for any type of geosynthetic material proposed in the
reinforced soil/ earth systems shall be provided by the
manufacturer and these shall be certified by a competent
independent certifying agency such as British Board of
Agreement (BBA). The specialist agency supplying geogrids
shall provide such certificate, before approval for the material
is accorded by the Engineer.
In the absence of values of partial factors as per BS 80061995, as specified above, the minimum partial factors as
given in table shall be used in the design, as default values.
5

FACIA UNITS
The fascia units, which help maintain a vertical face of the
reinforced soil/ earth structure, control erosion of the fill and
provide aesthetic appearance to the reinforced soil/ earth
structure, shall be of the pre-cast reinforced concrete
slabs/panels or pre-cast cement concrete blocks or any other
proprietary material that may be approved by the engineer
and/ or as indicated in the drawings. The type and shape of
the facia units to be finally adopted shall be subject to
approval by the Engineer.

5.1

Pre-cast Reinforced Concrete Panels/ Slabs


The pre-cast concrete facing units will be a discrete panel
having maximum longitudinal, transversal and rotational
flexibility to cater high static and dynamic loads, and ground
movements.
Pre-cast concrete facing elements shall conform to the details
and dimensions shown on the approved drawing. Concrete
shall be of grade shown on the drawings and shall conform to
the requirements as specified in section 1700 Structural
Concrete of MORT&H Specifications.

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The nominal thickness of the panel shall be 18 cm including


facing textures and design. The grade of concrete shall be
minimum M-35.
Reinforcement in panels shall be designed for the
connections with soil reinforcing structural elements and shall
be placed as shown on the drawing and shall conform to the
requirements specified in Section 1600 of the MORT&H
Specifications.
5.1.1

Casting
The elements shall be cast on a flat area. Tie-strips
connecting pins, PVC pipes and lifting anchors shall be set in
plate to the dimensions and tolerances shown on the drawing
and reinforcing elements guides shall be set on the rear face,
prior to casting. The concrete in each unit shall be placed
without interruption and shall be compacted by the use of an
approved vibrator supplemented by such hand-tamping as
may be necessary to ensure that the concrete reaches into
the corners of the forms and prevent formation of stone
pockets or cleavage plans. Clear form oil of the same
manufacturer shall be used throughout the casting operations.

5.1.2

Curing
The precast elements shall be cured for a sufficient length of
time as approved by Engineer so that the concrete develops
the required compressive strength. Only fresh potable water
shall be used for curing.

5.1.3

Removal of Forms
The forms shall remain in place until they can be removed
without damaging the elements. The scheme of removal of
formwork shall be as per relevant MORT&H Secifications.

5.1.4

Scribing
The date of manufacture, batch number and panel
designation shall be clearly scribed on the rear face of each
unit.

5.1.5

Concrete Finish
The front (exposed) face of the elements shall have the finish
approved by the Engineer and painted with cement based
waterproof paint or as decided by the Engineer. The rear face
shall have the finish of unformed surface and shall be roughly
screened to eliminate open pockets of aggregates.

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5.1.6

ORR/JICA2/Pkg 2/Vol II

Tolerances
All elements shall be manufactured within the following
tolerances:
- All dimensions within: 5mm
- Evenness of the front face: 5 mm over 1500mm
- Difference between lengths of two diagonals: maximum
5mm.
- Thickness: 2 mm

5.1.7

Handling Storage and Transporting


All elements shall be handled, stored and transported in such
manner as to eliminate the danger of chipping, cracks,
fracture and excessive bending stresses. Elements in storage
shall be supported on firm blocks to be located adjacent to the
reinforcing elements to avoid bending.

5.1.8

Acceptability
Acceptability of the precast elements shall be determined on
the basis of compression tests, as per MORT&H
Specifications.

5.1.9

Rejection
Elements shall be subject to rejection in case of failure to
meet any of the requirements specified above. In addition,
defects, which indicate imperfect molding, or defects
indicating honeycombed or open textured concrete, shall be
sufficient cause for rejection.

5.1.10

Pre-cast Cement Concrete Blocks

5.2.1

The facia material of geosynthetic reinforced soil retaining


wall shall be modular concrete block units, as alternate to
discrete slab/ panel facing.
Pre-cast Cement Concrete blocks shall conform to the details
and dimensions shown on the approved drawings. In case of
hollow blocks, the outer side of the block have a minimum
thickness of 95mm and inner side 50mm. The hollow area
shall not exceed 40% of the cross sectional area
(perpendicular to the wall) of the block. The grade of Concrete
shall be minimum M-35 as per IRC guidelines and the
minimum depth (perpendicular to wall) of these units shall be
300mm.
Casting
Modular concrete facing units will be manufactured by dry
casting process by block making machine to ensure
consistent quality of concrete, dimensional tolerance, good
finish and aesthetic appearance.

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5.2.2

ORR/JICA2/Pkg 2/Vol II

Curing
The pre-cast blocks shall be cured for a sufficient length of
time as approved by Engineer so that the concrete develops
the required compressive strength. Only fresh potable water
shall be used for curing. Steam curing is desirable.

5.2.3

Scribing
The date of manufacture and batch number shall be clearly
scribed on the rear face of each unit.

5.2.4

Concrete Finish
All units shall be sound and free of cracks or other defects
that would interfere with the proper placing of the unit or
significantly impair the strength of permanence of the
construction. Any block units with cracks or chips observed
during construction shall be rejected from use.

5.2.5

Tolerance
Modular concrete block units dimension shall not differ more
than 2.5mm except height, which shall not differ more than
1.5mm.
Modular concrete block units shall match the colour, surface
finish and dimension for height, width, depth and batter
between 1.50 to 50 to vertical.

5.2.6

Handling, Storage and Transporting


All elements shall be handled, stored and transported in such
manner as to eliminate the danger of chipping, cracks,
fracture and excessive breaking stresses. Elements in storage
shall be supported on firm blocking.

5.2.7

Acceptability
Acceptability of the pre-cast element shall be determined on
the basis of compression tests, as per MORT&H
Specifications.

Drainage
The drainage provision shall be strictly followed as per the
approved working drawing and Technical Specification Clause
305. Drainage outlets at the bottom level joints of panels with
provision of non-woven geotextile as per IRC-SP-59 and
backing shall be provided as per approved design and
drawing along the fascia for drainage redundancy. The
retained fill shall have the drainage way, 600 mm wide with
well graded crushed aggregate (materials of 19.5mm to
9.1mm size as per IS: 383) to allow free drainage of the
reinforced fill along with the retained fill. The panel joints

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above 300 mm of existing ground level shall be filled with joint


filler as per clause 7.5 of these specifications.
7.0

Construction Requirements
The construction of Reinforced Soil/ Earth Structures shall be
carried out in accordance with the specifications and in
conformity with the lines, grades, design and dimensions
shown on the approved drawings.

7.1

Excavation
The Plan area of the of Reinforced Soil/ Earth Structures shall
be excavated in accordance with the requirements of General
and Special Specifications and in reasonably close conformity
to the limits and to the lines and grades during construction
stages as shown on the approved drawings. The contractor
shall take precautions to minimise over- excavation.
Excavation support, if required shall be designed by the
Contractor.

7.2

Foundation Preparation
The foundation for Reinforced Soil/ Earth Structures shall be
graded level for width equal to or exceeding the length of
reinforcing geosynthetics. Prior to wall construction, if required
by the Engineer, the foundation shall be compacted with a
smooth wheeled roller. The depth of foundation below the
finished ground level shall not be less than as specified in BS
8006-1995 or 600mm, whichever is greater.

7.2.1

Ground Improvement
Where foundation soil is found to be unsuitable, either
removal and replacement technique or ground improvement is
required to be carried out, as required by the Engineer. The
need for ground improvement, design and ground
improvement methodology shall be verified and approved by
the Engineer prior to construction.
Suitable ground improvement technique shall be identified
based on the results of subsoil exploration. Foundation
preparatory works and foundation treatment/ improvement
shall be treated as integral part of the reinforced soil structure
and accordingly Contractor shall arrange for detailed sub-soil
investigation works and employ his resources to design and
construct the foundation/ ground improvement treatment,
wherever necessary to satisfy the requirements of reinforced
soil structure. The design check and validation for foundation
treatment/ ground improvement and the methodology shall be
verified and approved by the Engineer prior to construction.

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7.3

ORR/JICA2/Pkg 2/Vol II

Leveling Concrete
A leveling concrete pad shall be provided under the walls and
seat beams (for bridge abutments). Concrete shall have a
minimum grade M-15 (150 kg/cm2). Maximum size of
aggregates shall be 20mm and the pad shall be cured for at
least 48 hours before placement of panels.
In case of facia panel, the foundation may be made trough
shaped, so that the first panel is placed in the trough. After
placing the panels, the gap in the trough, may be filled with
mixture of sand and bitumen.

7.3.1

Batter
The reinforced earth/ soil wall face may be provided with an
initial inward batter specified by the system supplier or as
given in the drawings. Initial inward batter is required to
counter the outerward tilt that will occur as the wall height is
built up and also due to construction process. As a guideline
the initial batter is generally in the range of 40 to 60.

7.4

Erection

7.4.1

All reinforcements shall be installed at the proper elevation


and orientation as shown in the wall details of approved
drawings or as directed by the Engineer. The reinforcement
strips shall be placed normal to the face of the wall unless
otherwise shown on the drawings.

7.4.2

Pre-cast Concrete Facia Panels/ Slabs


Pre-cast concrete slabs/ panels shall be placed vertically with
the aid of a light crane. For erection, panels are handled by
means of lifting devices set into the upper edge of the panels.
Panels shall be placed in successive horizontal lifts in the
sequence shown on the drawings as backfill placement
proceeds. As fill materials is placed behind a panel, the
panels shall be maintained in vertical positions by means of
temporary wooden wedges placed in the joint at the junction
of the two adjacent top rows of panels during construction. As
construction proceeds, and a fourth row is erected, the lowest
row of wedges can be removed and so on.
External bracing may also be needed for the initial lift.
However, bracings shall be placed in an area not more than
1.5m wide beyond the outer face of panels.
Vertical tolerances (plumbness) and horizontal alignment
tolerance shall not exceed 25mm when measured along a 3
m straight edge. The maximum allowable offset in any panel
joint shall be 25mm.

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7.4.3

ORR/JICA2/Pkg 2/Vol II

Cement Concrete Hollow Block units


These units will be dry stacked (without mortar) one over the
other in a running bond configuration, vertically. Adjacent
units shall be connected by dowels, shear keys or shear pins
to ensure positive connection with the reinforcing
geosynthetic.
Tongue and groove type connections are not acceptable.
Hollow area in the blocks shall be filled with aggregate of 10
to 18mm nominal size during constructions.
Dowels or pins used by the retaining wall supplier to
interconnect block units shall consist of a non-degrading
polymer or galvanized steel and be made for the use with the
block unit supplied.
All materials shall be installed at the proper elevation and
orientation as shown in the wall details on the construction
plans or as directed by the Engineer. The drawings shall
govern in any conflict between the two requirements.
Broken chipped, stained or otherwise damaged units shall not
be placed in the wall unless they are repaired and the repair
method and results are approved by the Engineer.
The spacing between primary reinforcing geosynthetic shall
not be more than 600mm or two block units, whichever is
greater.
Overlap of the geogrid in the design strength direction shall
not be permitted. The design strength direction is that length
of geogrid reinforcement perpendicular to the wall face and
shall consist of one continuous piece of material. Adjacent
sections of geogrid shall be placed in a manner to assure that
the horizontal coverage shown on the plans is provided.
Geogrid reinforcement should be installed under tension. A
nominal tension shall be applied to the reinforcement and
maintained by staples, stakes or hand tensioning until the
reinforcement has been covered by at least 200mm of soil fill.

7.5

Joint Fillers
Fillers of vertical joints between panels shall be flexible open /
close cell polyurethane foam strips or non-woven fabric strips
(the latter used as joint cover instead of filter) as approved by
Engineer. Bearing pads for horizontal joints between panels
shall be made of elastomer with vulcanised EPDM.

7.6

Reinforced Earth Backfill Placement


The reinforcing elements shall be laid free from all kinks,
damage and displacement during deposition, spreading,
leveling and compaction of the fill. The programme of filling

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shall be such that no construction plant runs directly on the


reinforcement. It shall be ensured that the exposure of soil
reinforcement to ultraviolet rays is minimal and should be
covered with earth within one day of placement.
All construction plant having a mass exceeding 1000 kg shall
be kept at least 1.5m away from the face of slope or wall. In
this area (upto 1.5m from the face of slope or wall), the
following compaction plant shall be used.
i)

ii)
iii)

Vibratory roller having a weight per meter width of roll


not exceeding 1300 kg with total weight not exceeding
1000 kg.
Vibratory plate compactor of maximum weight 1000 kg.
Vibro tamper having a weight not exceeding 75 kg.

During construction of reinforced backfill, the retained material


beyond the reinforcement at the rear of the structure shall be
maintained at the same level as reinforced fill. The entire
works related to compaction should be carried out generally in
a direction parallel to the facing. Fill placement methods near
the facing shall ensure that no voids exist below the
reinforcing elements.
Temporary formwork shall be used to support the construction
as per specified details given in the drawing. The forms,
scaffolding and props shall be sufficient in numbers to allow
taking up of a sectoral construction schedule as specified in
the design.
At the end of each days operations, the contractor shall
shape the last level of backfill as to permit run-off rainwater
away from the wall face.
7.7

Drainage Fill Placement


Drainage fill shall be placed to the minimum finished thickness
and widths shown on the construction plans or as modified by
the Engineer. During placement and compaction of drainage
material, care must be taken to ensure that there is no
contamination with undesirable materials. Vertical layers of
drainage layer material shall be brought up at the same rate
as the adjoining fill material.
Drainage collection pipes shall be installed to maintain gravity
flow of water outside of the reinforced soil zone. The drainage
collection pipe should discharge into a storm sewer, manhole
or along a slope at an elevation lower than the lowest point of
the pipe within the aggregate drain.
The main collection drainpipe just behind the precast facing, if
used, shall be a minimum of 150mm in diameter. The
secondary collection drain pipes should be sloped a minimum
of two percent to provide gravity flow into the main collection
drainpipe. Drainage laterals shall be spaced at a maximum 15

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meters spacing along the wall face. The drainage collection


pipe shall be a perforated or slotted, PVC or corrugated
HDPE pipe. The pipe and drainage aggregate shall be
wrapped with a geotextile that will function as a filter.
More efficient drainage system, if possible, may be suggested
by the proprietary Supplier/ Contractor for the review and
approval of Engineer.
7.8

Cap Block Placement


The cap block and or top concrete block unit shall be bonded
to the modular concrete block units below using cap adhesive.

8.0

Design, Working Drawing, Detailing and Supervision


The scope of work will also cover the supply of detailed
design, engineering submission of working drawings by the
specialized agency for reinforced soil/ earth works. The
designs and drawings shall be got approved from the
Engineer and/or its representative before execution of work.

9.0

Inspection
Engineer and/or the representative shall verify the materials
supplied by the contractor to ensure that all the requirements
of the specifications are satisfactorily met with. This includes
all submittals and proper installation of the system.
The reinforced soil/ earth structure system supplier shall
provide one qualified and experienced representative at site
on full time basis during the entire working phase to ensure
that the quality of the works performed by the Contractor is in
accordance with the specifications and to assist the
Contractor regarding proper wall installation.
The Contractors field construction supervisor shall have
demonstrated experience and should be qualified to direct all
work at the site. All expenses relating to this presence on site
shall be deemed to have been included in the rate and no
extra claim on this account shall be admissible.

10.

Testing of Materials
Testing shall be done as stated elsewhere in this specification
on all materials required for reinforced soil/ earth structure
construction. The tests shall be done from a reputed
independent agency as approved by Engineer as and when
required. Tests on materials and during construction shall not
be limited to the following types.
i)

Testing of soils for evaluating their index and


engineering properties. Soil report may be consulted
with regard to this requirement.

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ii)

Testing of friction angle between the reinforcement and


soil using direct shear test.

iii)

Testing of Reinforcements
(a) For design of reinforced soil/ earth structure, tensile
strength, yield stress, elongation and modulus of
elasticity of the reinforcement material are required.
Both these properties for the steel reinforcement can
be obtained from standard tensile test.
(b) For connection strength between geogrid /metallic
reinforcement and facing where connection strength
should have appropriate factor of safety against the
connection load calculated as per BS 8006: 1995.
(c) The geosynthetic properties can be determined using
standards as summarized below:

Tensile
strength
test

ASTM 1682,
1975
BS 2576
IS 1969-1985

Grab
tensile
test
Wide
width
tensile
test

ASTM 1682,
1975

Tear
Tests

ASTMD 453385

Mullers
Burst test

ASTMD 378677 & BS 4768

Ball burst
test

ASTMD 378777

CBR
push
through
test

ASTM STP
952 P.57-68

ASTM D-4596

A 50mm x 300mm sample clamped to


give a gauge length of 200mm and
stretched at constant rate of 200mm per
minute till breakage. Breaking load and
extension at breakage are recorded.
200mm wide sample with gauge length
of 100mm is tensioned at constant rate
until failure.
A sample of 200mm or 500mmx200mm
clamped across width to give a gauge
length of 100mm, which is tensioned at
200mm per minute breaking load and
extension at breakage recorded.
Fabrics resistance to propagating a tear
is given by this test.
Burst resistance is the resistance of the
fabric to withstand the localized
pressure.
-DO-DO-

Note: Although some of the above tests are applicable to


geo-textiles, the use of geo-textiles is envisaged as only
filter fabric.
11.

Measurement for Payments

11.1

The measurement for Reinforced Earth Structures, Reinforced


soil, Mechanically Stabilized Earth or similar soil reinforcing

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system of Reinforced Soil Retaining wall shall be measured as


follows:
a)
Measurement for facia material (Panel or Blocks) shall
be in vertical Sq. meters. This shall
be measured on
each face of the ramp and closing wall from top of the
levelling concrete to bottom of the crash barrier.
b)
Measurement of backfill placement and compacting for
the reinforced soil/ earth wall shall be in cubic meters for
compacted soil. This shall be measured separately by taking
cross sections at intervals in the original position before the
work starts and after its completion.
11.2

The payment for excavation, foundation concrete, reinforcing


element, fasteners, filter media, drainage layer, drainpipe,
coping beam and other accessories shall not be measured
separately. It is deemed to have been included in the facia
material rates for the project.

11.3

The measurement for crash barrier and friction slab at


reinforced
soil/
earth
structure
location
including
reinforcement shall be measured in running meter in relevant
item of BoQ.

12.

Rate

12.1

The overall rate for reinforced earth shall include detailed


engineering including designs, drawings, all specified quality
control tests, approval from Engineer, furnishing, fabricating
and providing all materials for the walls including fascia
panels, reinforcing elements and all its accessories,
excavation and foundation construction; setting out and
erection of wall materials including fascia panels with all joint
fillers/ materials, reinforcement etc., supplying and placing of
drainage works, filter medium and filter fabric, foundation pad
including any supplementary arrangement to receive the first
panel and capping beam, any foundation treatment/ ground
improvement as deemed necessary and approved by the
Engineer etc. Cost involved for any field investigation and
sub-soil exploration as directed by the Engineer to determine
the extent of ground improvement shall be borne by the
Contractor. The rate shall include the cost of labour, plant/
machinery, material storage and handling expenses, as
required for all the above activities for completing the works.
The rate shall also cover the cost of all materials, castings,
curing, and quality control tests, stacking, transporting and
placing of facia. Cost of joints, all necessary temporary
formwork, scaffolding and all lifts and leads complete as per
approved design/ drawing of the specialised firm shall also be
included.
The rate shall also include material cost, all transportation
costs and storage of the same as per special provisions for
reinforcement element. The rate shall also include cost of
quality control tests, laying of the reinforcing elements

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including all overlaps, jointing or stitching, heat bonding or


extension and jointing them with reinforcing elements of
concrete discrete panels along with all accessories.
The rate also shall include all items of excavation, concrete,
reinforcing steel, formwork, curing etc for foundation and
capping beam.
The rate shall also cover providing, placing and compacting
drainage aggregate, filter medium including drainage
collection pipe, filter fabric and conducting quality control tests
etc for drainage.
The rate shall also include patentee charges (if any) and
supervision by the specialised supplier (manufacturer /
agency).
12.2

The rate for soil fill shall include selection, supply, placing,
compaction, and quality control tests etc. for approved earth
fill. The rate shall also include the cost of labour, plant/
machinery, transportation for all leads and lifts etc. as
required for the completion of the works, dressing and
levelling of slopes, including special measures for edge
reinforcement in accordance with the drawings.

12.3

The rate for crash barrier and friction slab shall include the
cost of all materials, labour, plant/ machinery, transportation
for all leads and lifts etc. as required for completing the work.

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CLAUSE A-7

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REFLECTIVE PAVEMENT MARKERS (ROAD STUDS)


1 GENERAL
Reflective pavement marker (RPM) or road stud is a device
which is bonded to or anchored within the road surface for
lane marking and delineation for night-time visibility. It
reflects incident light in directions close to the directions
from which it came
2 DEFINITION
2.1 DESCRIPTION
STANDARD

OF

TERMS

SPECIFIC

TO

THIS

2.1.1 Coefficient of luminous intensity (CIL) or specific intensity


the ratio of luminous intensity of the retro-reflector in the
direction of observation to illuminace at the retro-reflector on
a place perpendicular to the direction of the incident light
expressed in terms of millicandelas per incident lux (mcd/lx).
2.1.2 Horizontal entrance angle the angle in the horizontal plane
between the direction of incident light and the normal to the
leading edge of the marker.
2.1.3 Observation angle the angle at the reflector between the
illumination axis and observation axis.
2.1.4 Retro-reflection reflection in which the radiation is returned
in direction close to the directions from which it came. This
property being maintained over wide variations of the
directions of incident radiation.
2.1.5 Head that part of a road stud which is above the road
surface when the road stud is fixed in position in the road.
2.1.6 Upper surface that part of the external surface of road stud
which is visible when the road stud is fixed in position in the
road.
2.1.7 Anchorage that part of a road stud which is below the road
surface when the road stud is fixed in position in the road.
3 MATERIAL
3.1 Plastic body of RPM / road stud shall be moulded from ASA
(Acrylic Strene Acrylonitrite) or HIPS (Hi-impact Polystyrene)
or ABS or any other suitable material approved by the
Engineer-in-Charge. The markers shall support a load of
13635 kg tested in accordance with ASTM D4280.
3.2 Reflective panels shall consist of number of lenses
containing single or dual prismatic cubes capable of
providing total internal reflection of the light entering the lens
face. Lenses shall be moulded of methyl methecrylate

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conforming to ASTMD 788 or equivalent.


4 DESIGN
4.1 The slope or retro-reflecting surface shall preferably be 35 +
5 degree to base.
4.2 The area of each retro-reflecting surface shall not be less
than 13.0 sqcm.
5.0 Optical Performance
5.1. Unidirectional and bi-directional studs
5.1.1 Each reflector or combination of reflectors on each face of
the stud shall have a C.I.L. not less than that given in Table
1.
Table 1- Minimum C.I.L. Values for category A Studs
Entrance angle

Observation
angle

00U 50 L&R
0

0 U 10 L&R

220

110

44

0.50

120

60

24

Note: The entrance angle of 00U corresponds to the normal aspect of the reflectors
when the reflecting road stud is installed in horizontal road surface.
5.1.2 A stud or pavement marker that incorporates one or more
corner cube reflectors shall be considered to be included in
category A. A stud that incorporates one more bi-convex
reflectors shall be considered to be included in category B.
5.1.3 OMNI-DIRECTIONAL STUDS
Each omni-directional stud shall have a minimum C.I.L. of
not less than 2 mcd/1x.

5.2 TESTS
5.2.1 Coefficient of luminance intensity can be measured by
procedure described in ASTM E 809 Practice for Measuring
Photometric Characteristics or as recommended in BS :
873 Part 4: 1973.
5.2.2 Under test conditions, a stud shall not be considered to fail
the photometric requirements if the measured C.I.L. at any
one position of measurement is less than the values
specified in Table 1 provided that
(i)

Red

0.3

White

C.I.L. in mcd/1x
Amber

the value is not less than 80% of the specified

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(ii)

ORR/JICA2/Pkg 2/Vol II

minimum, and
average of the left and right measurements for the
specific angle is greater than the specified minimum.

6. FIXING OF REFLECTIVE MARKERS


6.1 Requirements
6.1.1 The enveloping profile of the head of the stud shall be
smooth and the studs shall not present any sharp edges to
traffic.
6.1.2 The reflecting portions of the studs shall be free from crevice
or ledges where dirt might accumulate.
6.1.3 All road studs shall be legibly marked with the name,
trademark or other means of identification of the
manufacturer.
6.1.4 Marker height shall not exceed 20 mm.
6.1.5 Marker width shall not exceed 130 mm.
6.1.6 The base of the marker shall be flat within 1.3 mm. If the
bottom of the marker is configurated, the outermost faces of
the configurations shall not deviate more than 1.3 mm from
a flat surface.
6.2 Placement
1. The reflective marker shall be fixed to the road surface using
the adhesives and the procedure recommended by the
manufacturer. No nails shall be used to affix the marker as
nails are hazardous for the roads.
2. Regardless of the type of adhesive used, the markers shall
not be fixed if the pavement is not surface dry and on new
asphalt concrete surfacing until the surfacing has been
opened to traffic for a period of not less than 14 hours.
3. The portions of the highway surface, to which the marker is
to be bonded by the adhesive, shall be free of dirt, curing
compound, grease, oil, moisture, loose or unsound layers,
paint and any other material which would adversely affect
the bond of the adhesive.
4. Use a wire brush, if necessary to loosen and remove dirt,
then brush or blow clean.
5. The adhesive shall be placed uniformly on the cleaned
pavement surface or on the bottom of the marker in a
quantity sufficient to result in complete coverage of the area
of contact of the market with no voids present and with a
slight excess after the market has been lightly pressed in
place.

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6. For epoxy installations, excess adhesive around the edge of


the marker, excess adhesive on the pavement and adhesive
on the exposed surfaces of the markers shall be
immediately removed. Soft rags moistened with mineral
spirits or kerosene may be used, if necessary to remove
adhesive from exposed faces of pavement markers.
7. Warranty and durability
The contractor shall obtain from the manufacturer a twoyear warranty for satisfactory field performance including
stipulated retro-reflectance of the reflecting panel and
submit the same to the Engineer. In addition, a two-year
warranty for satisfactory infield performance of the finished
road marker shall also be given by the contractor who
carries out the work of fixing of reflective road markers. In
case the markers are displaced, damaged, get worn out or
lose their reflectivity compared to stipulated standards, the
contractor would be required to replace all such markers
within 15 days of the intimation from the Engineer at his own
cost and with no extra cost to be paid for such works.
8. Measurement for Payment
The measurement of reflective road markers shall be in
numbers of different types of markers supplied and fixed.

9. Rate
The contract unit rate for reflective road markers shall be
payment in full compensation for furnishing all labour,
material, tools, equipment including incidental costs
necessary for carrying out the work at site conforming to the
specifications complete as per approved drawings or as
directed by the Engineer.

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CLAUSE A-8

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RUMBLE STRIPS
1. Scope
The scope of work involves provision of 15 numbers of
rumble strips across minor roads meeting the Outer Ring
Road with DBM material and providing thermoplastic
markings on either side of the rumble strips as shown in the
drawing and as directed by Engineer.
2. Unit of measurement
The unit of measurement is per linear meter of the road
across which speed breaker and markings are provided.
3. Rate
The unit rate for includes full compensation for providing
speed breaker and providing thermoplastic pavement
markings as shown in the drawings and as directed by
Engineer.

CLAUSE A-9

SPEED BREAKERS
1. Scope
The scope of work involves provision of speed breaker
across minor roads meeting the Outer Ring Road with DBM
material and providing thermoplastic markings on either side
of the speed breaker as shown in the drawing and as
directed by Engineer.
2. Unit of measurement
The unit of measurement is per linear meter of the road
across which speed breaker and markings are provided.
3. Rate
The unit rate for includes full compensation for laying, to the
required shape and compacting speed breaker as shown in
the drawings and as directed by Engineer and providing
thermoplastic pavement markings on either end.

CLAUSE A-10

CHUTE DRAIN FOR HIGH EMBANKMENT SECTIONS


1. SCOPE
This work shall consist of construction of chute drain on the
slope of the road embankment including erosion protection
works at the locations and to dimensions shown on the
Drawings or as directed by Engineer. Schedule of works
shall be so arranged that the drains are completed in proper
sequence with roadway to ensure that no damage is caused
due to lack of drainage.

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2. MATERIALS
The drains shall be of half round pipe of 300mm dia. formed
by joining half RCC pipe of NP2 type as shown in the
drawings. The RCC work shall conform to the relevant
clauses of these specifications.
The toe wall below ground level shall be of Plain cement
concrete of M15 grade conforming to clause 1700, as
shown in the drawings.
Dumped riprap for erosion protection at ground level, it shall
be constructed as shown in the drawing with hard,
unweathered and durable rubble stone of size 150 to 250
mm.
3. CONSTRUCTION OPERATIONS
At the locations where the chute drains are to be installed, a
rectangular cut on the side slope of the embankment along
the line of the chute drain shall be made. The Concrete bed
with PCC M15 shall be laid with semi circle in the middle.
The laying & jointing of pipe shall be done with Cement
Mortar 1:3, when concrete in bed is still green. The sloping
bed of the drain shall be to a regular line and suitably
compacted to provide a firm bed.
The water collection arrangement shall be constructed with
cement concrete of grades as shown in drawings at
shoulder edge between two chutes for guiding the surface
water into the chute.
The Toe wall shall be constructed with PCC M15 as shown
in drawings. The Rip-Rap/ Stone pitching 300mm thick shall
be constructed upto 1m. on either sides of the drain and at
ground level as shown in the drawings.
4. Measurements for Payment
The Chute drain shall be measured and paid in running
metre. The contract unit rates specified for chute drain shall
be inclusive of all leads and lifts for excavations, concreting
of pipe bed, placing and jointing of pipes with cement
Mortar, Construction of PCC toe wall, rip-rap/stone pitching
for erosion protection and drainage arrangement between
two chutes at shoulder edge, etc. for completing the chute
construction.
CLAUSE A-11

GRATING ACROSS DRAIN


1 Scope
The scope of work includes provision of mild steel gratings
across drain provided near petrol pumps, service stations and
other locations as directed by Engineer.

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The material used for grating and welding procedure should


conform to Clause 1900 and the dimensions of the steel flats
used in the gratings should conform to the drawings or as
directed by Engineer. Suitable anti theft mechanism as
approved by Engineer has to be provided for the gratings.
2 Unit of measurement
The unit of measurement shall be area of the finished grating
measured in Sq. m.
3 Rate
The unit of payment shall be full compensation for the cost of
material, fabrication, welding, and transportation to site and
installation including the cost of anti theft mechanism.
CLAUSE A-12

TRAFFIC
MANAGEMENT
AND
CONSTRUCTION OPERATIONS

CLAUSE A-12.1

TRAFFIC MANAGEMENT AND SAFETY

SAFETY

DURING

Any construction activity on the project will pose a hazardous


situation to the road users. For least disturbance to safe
passage of public traffic appropriate traffic management and
safety measures should be adopted throughout the
construction period. In this regard, the construction zone in
which conflict from safety angle may arise between the road
users on one hand and the construction activities on the other
shall be divided into 4 sub zones, and safety measures as
appropriate for each sub-zone shall be ensured. The subzones and the safety measures to be adopted therefore shall
be as described hereunder:
a. Advance Warning Zone
This warning sub-zone is meant to inform, alert and prepare
the approaching driver well in advance by providing information
regarding the distance and extent/type of hazard ahead so that
he is able to reduce the speed and be in readiness to carry out
the necessary manoeuvres as he meets with the changed
situation. For the operating speeds on the project road, length
of this sub-zone shall be 100mtr. And 500m, in plain and hilly
terrain respectively. Information in this sub-zone will be
conveyed through a series of traffic signs, which will include
Men at Work and the speed reduction signs at the start and
middle of this sub-zone.
b. Transition Sub-Zone
This sub-zone is the area in which the traffic is steered and
guided into and out of the diverted path around the work subzone. This is the most crucial subzone from safety angle as
vehicles have to be guided on to the diverted path, and most of
the movements will be of turning type. The elements for

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designing this sub-zone are speed of the vehicles, extent of


lateral shift and elevation difference between the normal and
the diverted paths. The essential safety measures shall include
delineation of the travel path and prevention of wayward
movements of vehicles by means of barricades, channelizers,
red cones, red lamps during hours of darkness etc., as
appropriate.
In the design of this sub-zone adequate attention shall be paid
for providing necessary turning radius of the curves, grade to
permit for safe passage of animal driven vehicles, drainage
and dust-proofing. Where necessary traffic control shall be
effected through manual flagging and by battery operated
traffic lights during hours of darkness. Where vehicles have to
wait, the waiting area shall be demarcated by stop lines.
Length of the sub-zone will generally be between 50 and
100m.
c. Work Sub-Zone
This is the area where construction activity takes place, and
the main concern relates to safety of workers as also
prevention of public traffic from entering the work area. In this
sub-zone, path of traffic shall be clearly delineated to avoid
intrusion of public traffic moving on to the work area or
construction equipment moving on to the public traffic. It shall
be ensured that adequate distance is available between 2
consecutive work zones
(2 km. on urban section and 5-10
km. in rural sections) so that vehicles get sufficient breather
space for overtaking slow vehicles, lane adjustment etc. Traffic
across this sub-zone shall be guided through with the help of
various traffic control devices, such as signs, delineation of
travel path by cones/drums, barricades, luminous tapes etc. as
appropriate.
d. Termination Sub-zones
The sub-zone is intended to inform the road users of the end of
the construction zone. This shall be effected through suitable
informatory sign boards.
CLAUSE A-12.2

TRAFFIC CONTROL DEVICES


Traffic control devices in the construction zones perform the
crucial task of warning, informing and alerting drivers apart
from guiding the vehicle movements so that the drivers of the
vehicles as well as the workers on site are not faced with
situations posing surprise/hazard, and safe passage to traffic is
effected.
The primary traffic control devices used in work sub-zones are
signs, delineators, barricades, cones, pylons, pavement
marking, flashing lights etc. They shall be such that they are
easily understood without any confusion, are clearly visible
during day and night, conform to the prevailing speeds in

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immediate vicinity, stable against sudden adverse weather


conditions and are easy in installation, renewal and
maintenance. Broad details of the different devices are
hereunder:
a) Signs
The construction signs fall into 3 major categories namely,
regulatory signs, warning signs and guide or informatory sign
as defined and detailed in IRC:67-1977, Code of Practice for
Road Signs. These signs shall be placed on the left hand side
of the travel path.
The common Regulatory signs used in the construction zones
are No Entry, Road Closed, Speed Limit etc. These shall
be used in consultation with the local police and / or authorities.
The warning signs to alert the drivers of the possible danger
ahead in the construction zones are Lane Closed, Diversion
to other carriageway, Divided carriageway Starts, Divided
carriageway Ends, Two way Traffic etc. It will be advisable to
explain the signs with the help of a rectangular definition plate
of size of appropriate to the size of warning triangle and placed
0.15m. below, from the bottom of the triangle.
Guide signs in construction zones shall have different
background colour than the normal informatory signs of
IRC:67-1977, These signs shall have black messages and
arrows on yellow (Traffic Yellow of IS: 5-1978) background.
The guide signs to be commonly used are Diversion, Road
Ahead Closed, Sharp Deviation of Route etc.
The commonly used temporary signs during construction are
depicted in the Drawings. These should preferably be of
reflectorised type to be visible during hours of darkness.
b) Delineators
Delineators are channelising devices such as cones, traffic
cylinders, tapes, drums etc. which are placed in or adjacent to
the roadway to guide the driver along a safe path and to control
the flow of traffic. These shall normally be retro-refelectorised
for night visibility. IRC:79-1981 (Recommended Practice for
Road Delineators) gives details of some of the delineators. The
other types of delineators commonly used are traffic cones,
drums and barricades.
c) Traffic Cones
Traffic cones shall normally be 0.5m to 0.75m high and 0.3m to
0.4m diameter or in square shape at the base. These shall be
made of plastic or rubber with retro reflectorised red and white
band and have suitable anchoring so that they are not easily
blown over or displaced. The cones shall be placed close
enough together (spacing 3-9m) to give an impression of the

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continuity. Larger size cones shall be used for high speeds or


where more conspicuous guidance is required.
d) Empty Bitumen Drums
Empty bitumen drums can be used as channelising device
since they are highly visible, give the appearance of being
formidable objects, thereby commanding the respect of the
drivers. These drums can also be of plastic which are lighter,
easy to transport and store. As delineators, these drums shall
be painted in circumferential strips 0.10m to 0.15m wide,
alternatively in black and white colours.
e) Barricades
When ever the traffic has to be restricted from entering the
work areas such as excavations or material storage sites so
that harzardous locations are barred for public and protection
to workers is provided, or there is need for separating the two
way traffic, barricades shall be used. The barricades may be of
portable or fixed type and can be made of wooden planks,
metal or other suitable material. The horizontal component
facing the traffic shall be made of 0.30m wide wooden planks
joined together and painted in alternate yellow and white strips
of 0.15m width and sloping down at an angle of 45 in the
direction of traffic. Suitable support or ballasting shall be
provided so that they do not over turn or are not blown away in
strong winds. In case of fixed type barricades, a gate or
moveable section shall be separately provided to allow the
movement of the construction/supervision vehicles.
Sketches of typical portable and fixed barricades are provided
in drawings document.
f) Flagmen
In large construction sites, flagmen with flags and sign paddles
shall be effectively used to guide the safe movements. The
flags for andal ing shall be 0.60m x 0.60m size, made of
good red cloth and securely fastened to a staff of
approximately 1 meter in length. The sign paddles shall
conform to IRC:67-1977 and provided with a rigid handle. For
one-way operation at a time during hours of darkness, battery
operated red/green lights shall be used at either end of the
affected section.
g) Solar Blinkers
The following technical specifications shall be adopted. The
Number of blinkers shall be installed as per the approved
drawings and as directed by the Engineer.

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Solar Module
High efficiency Mono/Multi-crystalline 40Wp Solar Module
Battery
Maintenance free VRLA Batteries
Provides 2 days autonomy
LAMP

Cluster of High intensity Ultra bright LEDs


Visibility greater than 500 mts.
Size of the light source 200mm/300mm diameter
(Typical)
Red or Amber Option available
Flashing duty cycle upto 50%

Electronics Regulator

Rating 5A Charging 5A Load.


Nominal system voltage 12V DC.
Automatic over charge & deep discharge protection for
battery.
Discharge of battery through array during night time.

Aspect

Weather proof construction with hinged door


Powder coated sheet metal body

Pole & Structure

Galvanised pipe with corrosion resistant paint.


Designed to meet 145kmph wind load.

Operating temperature 0o to 50o C


Humidity: 95% rh ( N.C.)
Solar Powered Flasher 24 Hours of single aspect &
double aspect.

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h) Solar Stud
Supply and installation of solar studs of size 125 mm x 125 mm
x 90 mm or any suitable dimensions comprises of ultra bright
LEDs with micro controller, all electronics and reflector strip
housed in the cast. The stud should be unidirectional with three
LEDs. The system shall be water proof and withstand the weight
of fully loaded tuck-trailer and provide 35-40 per minute with two
years warranty. The system shall work in weather condition in
temperature range of -4oC to +55oC necessary structure to be
provided for mounting the stud on the road. The system shall
comply with the technical specification provided in the contract
agreement.

Automatic dusk to dawn operation required.


The stud should be of unidirectional with three LEDs.
Ultra bright LEDs are required to give the clear vision.
Colours shall be RED/ AMBER in colour as required.
Controller shall be of micro controller based.
Visibility shall be minimum 800 mtrs at test condition.
It Shall withstand all weather conditions with aluminium die
cast.
All electronic and LEDs shall house in the case with reflector
strips in addition with to LEDs.
The system shall be completely waterproof.
It shall withstand the weight of fully loaded truck- trailer.
Flashing rate shall be 35 to 40 flashes per minute.
The working temperature shall be of 4oC to + 55oC.
Each unit shall be independent unit.
Each stud shall have anti-twist ribs for firm grip.
Size shall be 125mm x 125mm x 90mm or any suitable
dimensions.
Battery voltage shall be 2 volts.
Solar Panel voltage shall be 2 volts.
Warranty two years.

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CLAUSE A-12.3

ORR/JICA2/Pkg 2/Vol II

SAFETY AND MANAGEMENT PRACTICES


Measures for providing safe movement of traffic in some of
the most commonly occurring work-zones on highways shall
be as follows:
a) Detour on Temporary Diversion
In certain situations during the project construction period it
may become necessary to pass the traffic on temporary
diversion constructed parallel to highway.
A temporary diversion road shall basically satisfy the
following requirements
It shall have smooth horizontal and vertical profile for
easy negotiation by vehicles.
It shall not get overtopped by flood or drainage discharge
under any circumstances.
It shall have adequate capacity to
cater for the diverted traffic.
It shall be dust free and shall ensure clear visibility at all
times of the day and night.
Pavement and riding surface for the diversion will depend
on the duration over which the diversion will be used, and
shall be as directed by the Engineer. The commonly used
specifications are SDBC surfacing over 150-200mm thick
WMM constructed on completed sub-grade.
It shall be provided with the required safety standards and
the warning for the construction ahead shall be provided
by the sign Men at Work about 1 km. in advance of the
work zone. In addition a supplementary plate indicating
Diversion 1 km. Ahead and a sign Road closed Ahead
shall be placed. It shall be followed by Compulsory Turn
right / Left Sign. The Detour and Sharp Deviation sign
shall be used to guide the traffic on to the diversion.
Hazard markers shall be placed where the railings for the
cross drainage structures on the diversion start.
b) Partial Closure of Existing Two Lane Carriageway
Such an eventuality will arise only in a special situation where
the existing 2 lanes in use for the main traffic need
emergency repairs and the new lanes under construction are
not available for diversion of the traffic. It will become
necessary to carryout special repairs through partial closure
of the existing 2 lane facility. In such a situation care shall be
taken that the traffic is guided away from the closed lane into

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the operating lane without conflicting with the traffic from


opposite direction. The warning sign for Men At Work shall
be the first sign to be seen by the drivers of the approaching
vehicles. This sign shall have supplementary plate also
showing the distance of work zone. The next warning sign
shall be for the Road Narrowing (depending upon the lane
closure). Compulsory Keep Right or Keep Left sign
depending upon the situation shall be provided at the
beginning of the transition zone and taper. The point where
traffic is to deviate from its normal path, the channel for the
traffic shall be clearly marked with the aid of painted drums of
traffic cones. The traffic lane or carriageway closed sign
shall also be provided at the barricades along with the Keep
Right / Left sign.
c) Switch over of traffic from widened to unwidened section
and vice-versa
In the course of construction, widening of the carriageway will
have to be taken up in stretches with intervening space
between two such stretches. This will bring about the
situations in which the traffic passing through the widened
road would have to pass on and merge with the un-widened
section and vice-versa.
For such cases, apart from Men At Work signs with
distance plate in the advance warning zone, the signs
indicating Road Narrowing or Road widening as
appropriate shall be installed.
The arrangement to be made while the service roads are
under construction in urban stretches is shown in the
Drawings.
d) Switch over of traffic when the New Highway crosses the
National Highway or State Highway or Cart track
In Certain situations during the project construction period,
when the ORR crosses the existing National Highway/ State
Highway/ Car track, it may be necessary to construct a
temporary diversion for the existing highway to allow the
traffic on the existing roads with out any disruption to the
traffic.
Where the New Highway crosses /Joins with an existing
National Highway or State highway or cart track, the highway
road or cart track shall be kept open at all times duly
providing and maintaining the diversion roads.
It shall be provided with the required safety standards and
the warning for the construction ahead shall be provided by
the sign Men at Work about 1 km. in advance of the work
zone. In addition a supplementary plate indicating Diversion
1 km. Ahead and a sign Road closed Ahead shall be
placed. It shall be followed by Compulsory Turn right / Left

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Sign. The Detour and Sharp Deviation sign shall be used


to guide the traffic on to the diversion. Hazard markers shall
be placed where the railings for the cross drainage structures
on the diversion start.
After completion of the main carriageway of the project
highway according to plans, the existing road shall be
brought back to the original standards and the main traffic
from the cross roads shall be restored on them.
CLAUSE A-12.4

PRECAUTIONS FOR SAFETY


The following general precautions shall apply to all the work
sites.
a) General Measures
(i) All the signs and delineators shall be maintained in
a clean and brightly painted conditions at all times.

(ii) Adequate lighting arrangements shall be made for


proper visibility during night travel through the work
area.
(iii) Adequate arrangements for frequent sprinkling of
water shall be made to keep the area dust free.
b) For Safety of Workmen
(i) Workmen shall be trained in use of tools and plant.
(ii) Bitumen handling labour shall be given gum boots,
spectacles etc.
(iii) First aids kits shall be provided.
(iv) Workers required on site during night hours shall be
provided with
fluorescent jackets with reflective
tapes.
c) For Safety of Road User
(i) As far as possible ,the material, equipment and
machinery shall be installed parked in places
sufficient away from the berms in the available road
land. Only in avoidable cases the same be allowed
near the edge of berms.
(ii) Machinery shall be parked at appropriate places
away from the path of public traffic, and shall be
provided with red flags and red lights.
(iii) Only minimum quantity of material required for the
construction operations shall be collected at site
near the public travelled way.

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CLAUSE A-12.5

ORR/JICA2/Pkg 2/Vol II

SAFETY AUDIT
Safety audit shall be conducted periodically on the safety
measures adopted during the constructions operations. The
main aspects to be covered shall include:

Manpower and their safety


Machinery
Temporary works
Equipment &Vehicles
Material storage and handling
Construction procedures
Environment
Site safety guidelines
Miscellaneous services

The Contractor shall constitute special teams from his staff


for the above audit, and shall take appropriate corrective
measures to the directions of the Engineer.
CLAUSE A-12.6

MEASUREMENTS FOR PAYMENT


Construction of service roads shall be measured for the
involved work items such as earth work, sub base, WMM
base, SDBC surfacing etc. according to respective
specifications
Traffic management and safety during the construction shall
be measured as per the items provided in the Bill of
Quantities. For items which are not covered in the BOQ are
deemed to be included under other items of work provided
in the Bill of Quantities.

CLAUSE A-12.7

RATES
The rate for traffic management and safety during
construction will be in full compensation for providing all the
necessary
arrangements
as
described
in
these
specifications or as ordered by the Engineer, including
provision and installation of signs, pavement markings,
delineators, barricades, flagmen, red lamps/ blinking lights
etc. The rate will also include for removal of the above
installation after completion of the construction work in a
particular stretch.
Payment for traffic management and safety during
construction shall be regulated in 2 stages as follows:
Stage 1: Number and type of safety devices shall be as per
the requirement shown in the drawings or as
directed by the engineer during construction and
maintenance of the same for the entire period of
particular construction zone.

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Stage 2: Continuous maintenance of the above, with all


barricades, traffic cones, reflective tapes, signs,
flagmen, lamps/blinkers etc., as per the drawings
or as directed by the engineer. Measurement shall
be made on the basis of respective units shown in
the BOQ for the periods the safety equipment are
maintained in a condition deemed satisfactory by
the Engineer. In the event of removal of required
signs or other safety fixtures, or not replacing the
damaged safety fixtures with the new ones during
the construction, proportionate payment shall be
deducted from the contractors bill or otherwise,
Engineer himself may arrange to install those signs
or safety fixtures by deploying any other agency
and the cost incurred thereof shall be deducted
from the contractors bill for not maintaining
properly.

CLAUSE A-12.8

SOLAR POWERED BLINKER SIGNAL


Scope of work
Supplying and installation of Solar Powered Blinker Signals
with LED Signal Array of ultra bright silicon based LED signal
with amber in colour, the dia of the signal shall be 300mm for
clear vision with the distance of visibility not less than 800 m,
life of LED signal greater than 10 years, system shall be with
complete automatic mechanism including provision for onsite modification, complying with Electronic Specifications
that the system shall operate for
24 hours, designed for
48 Volts, temperature range of working is -4C to +55C ,
frequency of blinking shall be 24 to 30 cycles per minute for
clear vision with open circuit protection, with Solar Photo
Voltaic Modules with panel capacity of 48 V, each module
shall contain manufacturers name, trade mark, model name,
model number, serial number, date of manufacture, etc., the
model shall either crystalline or amorphous based, warranty
on life of panel shall be 10 years with Sealed Maintenance
Free (SMF) storage Battery of capacity 48 V, single pack and
the LED signal module shall be protected against dust and
moisture intrusion as per the requirements of NEMA
Standard 250 -1991. Material used for the lens and signal
module shall conform to ASTM specification for the materials.
Pole should be 5 m height for distant vision with arrangement
for the panel to rotate for the appropriate direction and the
structure shall be vapo cured finish to protect against rust
with provision for mounting the battery at the bottom of the
pole with vandal proof structure. Blinker shall comply with
specifications and drawings provided in the Contract
Agreement.

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TECHNICAL SPECIFICATIONS SOLAR POWERED


BLINKER SIGNAL
L.E.D SIGNAL ARRAY

LED signal should be ultra bright silicon based LED signal


with amber in colour.
The diameter of the signal should be 300mm for clear
vision
The distance of the visibility should be greater than 800 m
Life of LED signal should be greater than 10 years
System should operate completely with automatic
operation
Provision should be given for on-site modification.
The signal array should contain manufactures name,
trade mark, model number, serial number, date of
manufacture.

Electronic Specifications

The system should operate for 24 hours.


The system should be designed for 48 Volts.
Charge controller should be 24 / 36 V, 18 Amps.
The inbuilt charge controlling should be provided for
better life of battery. The battery high, battery low should
be provided with the charge controller.
The temperature compensation should be designed such
that -6Mv / C raise in temperature.
No load current of the system should not exceed 5m Amp
Temperature range of working is -4C + 55C
Enough time to be given for LEDs to cool down for normal
temperature by giving 50% on cycle.
Frequency of blinking should be 24 to 30 cycles per
minute for clear vision.

Protection

Open circuit protection, short circuit, over load protection


required
Protection for reverse polarity of battery is required
Protection for reverse polarity of panel is required

Solar Photo Voltaic Module Specification

Panel capacity should be 48 V, 80 Watt.


Each module should contain manufacturers name, trade
mark, model name, model number, serial number, date of
manufacture, etc.
The model should either crystalline or amorphous based.
Warranty on life of panel should be 10 years
Peak power, peak current, open circuit voltage should be
mentioned on panel

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Storage Battery

Battery should be either Sealed Maintenance Free (SMF)


or Lead Acid Type with aqua turf vent plug with indication
of electrolyte.
Capacity of battery should be 48 V.
The battery should be of low discharge type are C/20 type
Terminal voltage should be of 48 V only in a single pack.
Autonomy of battery should be two / three days.
Maximum depth of discharge less than 80%.

Environmental Requirement

The LED signal module shall be rated for use in the


operating temperature range of -4C to +55C. The
modules shall meet all specifications throughout this
range.
The LED signal module shall be protected against dust
and moisture intrusion as per the requirements of NEMA
Standard 250 -1991 for Type 4 enclosures to protect all
internal components

Standard specification for Enclosure


Enclosure / Housing
Material

NEMA 12/ IP 66 Standard


Glass Fiber reinforced
polyester
/ MS steel
box
Impact Resistance
> 7 Nm
Flammability
Self extinguishing
Protective insulation
Fully insulated
Seal
-40 C + 100 C
Dry electric strength
> 10 Kv per mm
Water absorption
maximum 0.7%
Surface resistance
> 1012 ohm
Colour
Traffic amber
Construction

The LED signal module shall be a single, self contained,


inside the module. The circuit board and power supply
shall be contained inside the module.

The assembly and manufacturing process for the LED


signal assembly shall be designed to assure all internal
components are adequately supported to withstand
mechanical shock and vibration from high winds and
other sources.

Materials

Material used for the lens and signal module construction


shall conform to ASTM specification for the materials.

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Enclosure containing either the power supply or electronic


components of the signal module shall be made of
UL94VO flame retardant materials. The lens of the signal
module is excluded from this requirement.

Mounting structures

Pole should be 5 mtr height for distant vision


Provision should be provided for mounting the panel and
to rotate for the appropriate direction.
Structure should be vapour cured finish to protect against
rust.
Provision should be provided for grouting the pole.
Provision should be provided mounting the battery at the
bottom of the pole with vandal proof structure.

Measurement for Payments:


Unit: The unit of measurement shall be in Numbers
Rate: The unit cost of Solar Powered Blinker Signal is
inclusive supply and erection with all the equipment
and full compensation for labour and material, cost of
foundation, fabrication, welding and transportation to
site and installation, testing including cost of anti-theft
mechanism and all incidental charges necessary for
carrying out the work at site confirming to the
specifications complete including meeting the warranty
requirements. 75% of cost is payable after trial run
of 1 week and the balance 25% after 6 months.

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CLAUSE A-13
1.1

ORR/JICA2/Pkg 2/Vol II

UTILITY DUCTS AND CROSSING


Utility Ducts
Utility ducts should be laid below the footpath, shall comprise
of a set of 8 nos. of 110mm. dia. HDPE pipes (5.3 mm thick) of
approved quality for carrying the utility cables on one side and
160 mm dia HDPE pipes (7.7 mm thick) shall be laid on the
other side of the service road for carrying the electrical cables
separately, which shall be laid in appropriately shaped granular
bed and compacted, as shown in the drawing or as directed by
the Engineer.
Specifications of the Permanently lubricated HDPE telecom
ducts shall conform to the generic requirements no. G/CDS08/01.DEC 99 specified by the Telecommunication
engineering centre, Delhi.
The installation of the ducts along the highways shall also
require supply and installation of RCC utility chambers as
shown in the drawings. The contractor shall make the provision
of providing 1 No. of utility chamber at every 1 Km. for each
ducts as shown in the drawings. Specifications of the RCC
Utility chambers shall conform to the section 1700 of the
MOST specification.
Utility ducts of 160mm diameter HDPE pipes (7.7 mm thick)
shall be laid in the median and 110mm diameter HDPE pipes
(5.3 mm thick) in both the earthen shoulders of the main
carriageway, on compacted and appropriately shaped granular
bed as shown in the drawing or as directed by the Engineer.
Care should be taken to compact the fill material above and
around the duct pipe with power rammer.

1.2

Utility Crossing
For cross connection, two (2) numbers of utility ducts shall be
provided at an interval of 500m for cross connection. A
provision shall be made with 0.6m diameter pipe of NP-4
grade, for facilitating crossing of utilities from one side to the
other. Location, size and design of the cross pipes for utilities
shall be finalized at the detailed design stage in consultation
with the Independent Consultant and HGCL and shall confirm
to IS: 458-2000 and MoRTH specification Clause 2100.
At all junctions, provision shall be made for 0.6m diameter NP4 pipe for facilitating crossing of utilities from one side to the
other. Location, size and design of the cross pipes for utilities
shall be finalized at the detailed design stage in consultation
with the Independent Consultant and HGCL and shall confirm
to IS: 458-2000 and MoRTH specification Clause 2100.

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1.3

ORR/JICA2/Pkg 2/Vol II

Utility Protective Work


The contractor shall carry out the protective work for the
underground utilities to be retained as decided by the
engineer. The work shall be taken up with the express
approval of the Engineer and under strict supervision of
respective line agencies. The work shall comprise digging
trenches around the underground cables to the size and depth
required to accommodate the RCC half pipes (arches). The
grade and size of the arches shall be as directed by the
Engineer and should confirm to the specifications of full RCC
pipe of NP-4 grade. The foundation and bedding concrete shall
confirm to IS: 458-2000 and MoRTH specification Clause
2100.

CLAUSE A-14

RE-CONSTRUCTION
PLACES

OF

TEMPLES

OR

RELIGIOUS

1.1.

For the Temples or Religious places of worship falling in the


project alignment a new structure shall be constructed at a
new location within a distance of 1000 meters. The Engineer
shall finalize the new location after consultation with the local
representatives of the area.

1.2.

The contractor shall take photographs of existing religious


structures and maintain a record of specification of existing
structure before dismantling.

1.3.

The construction of the new structure shall be carried out as


per drawing and Specifications for Building works of Central
Public Works Department.

1.4.

The following items of work are included to be executed:


a) The plinth height of the structure shall be 1.5 meters
above G.L. The walls shall be constructed in R.R. Stone
masonry in C.M. 1:4.
b) Flooring shall be of marble stone topping laid over
cement concrete base of 1:2:4.
c) Plaster shall be in cement mortar 1:4 with andal coat.
d) Shikar shall be constructed as per drawing.
e) The idol (Murti) of God shall be shifted from the original
Temple/Religious structure to the new location with full
religious rites.
f) Steel grill / wooden gates shall be provided.
g) Electric fittings shall be provided inside the structure.
h) Polished stone pavement shall be provided all around the
pedestal in a width of about 3 meters.

1.5.

Mode of Payment
The mode of payment shall be the outer plan plinth
measurements of the structure in sq meters. The complete
work shall be executed as per drawing and direction of the

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Engineer. The rate should include the works specified in para4 including cost material, labour, equipment and incidentals.
CLAUSE A-15

1.1

CURING USING LIQUID MEMBRANE FORMING


COMPOUND
General
Liquid membrane forming compound are sometimes permitted
to be used by the engineer for curing concrete for part or whole
of the total curing period as specified in sections dealing with
concrete construction. These membranes reduce the loss of
water from concrete during early hardening period and some
type of compounds also help in reducing the temperature-rise
of concrete exposed to the radiation from the sun. These
specifications cover the type and use of such compounds.
However, the use of the same will need specific permission
from the engineer, who may require a number of tests to be
carried out for establishing the conformity of the product to
these specifications and to establish that the curing compound
and its method of use does not have any unacceptable effect
on the quality of concrete. The cost of the initial acceptance
testing and the quality control testing will be borne by the
owner, if the method has been specified as a requirement by
the engineer. If on the other hand, it is suggested by the
contractor as an alternative to wet-curing, the full cost of
testing will be borne by him and deemed to be included in his
rates for concreting. The cost of curing in any case will be
deemed to be part of the concrete rates and will not be paid
extra.
All equipment, material etc., needed for curing and protection
of concrete shall be at hand and ready for installing before
actual concreting beings. Detailed plans, methods and
procedures shall be firmly established, shall be settled and got
approved in writing from the Engineer-in-charge sufficiently in
advance of the actual concreting.
The equipment and method proposed to be utilised shall
provide for adequate control and avoid interruption or damage
to the work of other agencies.

1.1.1

Curing Compound
The curing compound shall be conforming to ASTM-C-309-81,
Type-2, white pigmented compound. The solids dissolved in
vehicle shall be either A (no restrictions) or Class B (resin as
defined in ASTM D-883) as approved by the engineer.
White pigmented compound (Type-2) shall consist of finely
divided white pigments and vehicle solids, ready mixed for
immediate use without alteration. The compound shall present
a uniform white appearance when applied uniformly to a fresh
concrete surface at a specified rate of application. It shall be of
such consistency that it can be readily applied by spraying to
provide uniform coating at temperatures above 4C. If two

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coats are to be applied then it should be applied at an interval


of approximately one hour. They shall adhere to freshly placed
concrete that has stiffened or sufficient resist marking during
the application and to damp hardened concrete and shall form
a continuous film when applied at a rate of 5 m/litre. When
dry, the covering shall be continuous flexible and without
visible breaks or pin holes and shall remain as unbroken film at
least 28 days after application. It shall not react deleteriously
with the concrete.
The compound shall meet with the requirement of water
retention test as per ASTM designation C-156-80. The loss of
water in this test shall be restricted to not more than 0.55 kg/m
of exposed surface in 72 hours.
The white pigmented compound (Type 2) when rested as
specified in accordance with method E-79 of ASTM shall
exhibit a day light reflectance of not less than 60% of that of
magnesium oxide.
It shall fulfil the requirement of drying time when tested in
accordance with ASTM-C-309-81. The compound applied shall
be dry to touch in not more than 4 hours. After 12 hours it shall
not be tacky or tack off (peel off) concrete when walked upon
nor it shall impart a slippery surface.
The liquid compound should be of a sprayable consistency.
1.1.2

Supply and Testing


Acceptance Testing
Prior to the approval of the bran/trade name of compound and
the source of supply and manufacturer acceptance testing
shall be carried out to demonstrate the conformance of the
compound to Clause 5502. In addition, testing shall be
performed to demonstrate that on adverse/undesirable change
in quality of concrete or concrete surface takes place as a
result/by-product of the use of the compound. These tests
should be designed to check properties such as loss of
strength at 28 days of surface layer, or of concrete cube,
change in surface texture, change in adhesion to subsequently
applied layers like plaster, flooring, tiling etc. The type and
number of tests are to be as specified by the engineer.

1.1.3

Routine Testing
1. The liquid membrane forming curing compound should be
brought in the manufacturers original clear containers. Each
container shall be legibly marked with the name of the
manufacture, the trade name of the compound, the type of
compound and class of vehicle/solids, the nominal percentage
of volatile material and batch or lot number. The lot numbers
will be assigned to the quantity of compound mixed, sampled
and tested as single product. The manufacturer shall exercise
the care in filling the container so that all are equally
representative of the compound produced.
2. Curing compound to be used on site shall be got tested at
least 14 days in advance so that the result of water retention

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tests, reflectance test, drying etc, are available before it can


bee permitted for use. All of the filled containers represented
by the approved sample shall then be sealed to prevent
leakage, substitution or dilution. The engineer-in-charge or
authorised representative should mark each container
represented by the samples with a suitable identification mark
for later identification and correlation and shall be kept in store
with double lock arrangements. One key shall be kept with the
Contractor and the other with Engineer. Random samples shall
be collected from every batch of the compound. Frequency of
random sampling shall be done as directed by the Engineer.
The contractor shall provide samples and labour for collecting
samples free of cost. Testing shall be carried out by agency
approved by the engineer and in presence of his
representative.
1.1.4

Method of Application
The compound shall be sprayed using mechanical sprayer of
approved design to ensure uniform and continuous membrane
on the concrete surface. The coverage shall be at the rate
specified by the manufacturer or at the rate of 4m per litre or
as specified by the manufacturer and approved by the
engineer. Field trials shall be conducted to decide effective
coverage rate, which depends upon surface finish. The
engineer after verification of the field trails and based on the
actual experience shall order the rate of application as needed
for achieving the proper curing. With a view to ensure thorough
and complete coverage, approximately one half of the
compound for a given area should be applied by moving the
spray gun back and forth in one direction and the remaining
half at right angles to this direction. In case the application is
still not found uniform, the contractor shall have to apply the
second coat as and when directed by the Engineer. If a second
coat is to be applied, it should be applied approximately after
an interval of one hour. The curing compound shall generally
be applied as soon as the bleeding water or shine disappears,
leaving dull appearance.

If surface treatment by roughing, hand brushing etc., is


required (e.g. as in case of road pavements) the curing
compound should be applied immediately after the same.
Equipment for spraying curing compound shall be of pressure
tank type (5 to 7 kg/cm) with provision of continuous agitation.
A curing jumbo with multiple travelling spray fans shall be
provided for effective spray. Spraying on concrete lining shall
be done in such a way that the green concrete is not disturbed
or damaged or any foot impression left. Necessary schemes or
spraying by mechanised means shall be got approved by the
Engineer-in-charge. However, in emergency for very small
areas/ patches) it can be applied with wire or bristled brush.

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CLAUSE A-16

ORR/JICA2/Pkg 2/Vol II

VOID FORMER
Void formers are to be supplied with suitable end blockers to
seal the void former ends.
Specialised form work shall be manufactured by use of form
lining materials with ring stiffeners as per design requirements.
The form lining may either be Marine Plywood, PVC/HDPE
sheet or steel sheet of appropriate thickness and the ring
stiffeners should preferably be of structural steel sections.
Manufactured void formers shall be absolutely leak proof.
The contractor may use PVC/ HDPE pipes, Galvanised
corrugated light metal tubes of required sizes from market or
specially manufactured for use as void formers. However, the
specifications & design for such pipes/ tubes shall be
submitted for approval of Engineer.
The Void Formers shall be strong enough to withstand all
pressure, ramming and vibration during placing of concrete
and handling / erection stresses. The void formers shall be
placed and tied in position so that they are not displaced
during concreting.
All the steel surfaces shall be painted with Zinc Rich Paint in
accordance with Section 1900 of the Technical Specification,
before use of Void Formers.
Standard R.C.C. Hume pipes are not to be used as void
formers.
The contractor shall furnish the design and drawing along with
detailed specifications of the proposed Void Formers for
approval of Engineer before taking up the work.
The payment for void former shall not be made separately. It
is deemed to have been included in the concrete rates for
voided slab which shall include cost of supply of void formers,
transport, fitting fixing in position and all other incidental
expenditure complete.

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CLAUSE A-17

ORR/JICA2/Pkg 2/Vol II

WATER PROOF CEMENT PAINTING


Water proof cement paint shall be mixed in such quantities as
can be used up within an hour of its mixing as otherwise
mixture will set and thicken affecting flow and finish. Water
proof cement paint shall be mixed with water in two stages.
The first stage shall comprise of two parts of water proof
cement paint and one part of water stirred thoroughly and
allowed to stand for 5 minutes. Care shall be taken to add the
water proof cement paint gradually to the water and not vice
versa. The second stage shall comprise of adding further one
part of water to the mix and stirring thoroughly to obtain a liquid
of workable and uniform consistency.
The surface shall be thoroughly cleaned of all mortar
droppings, dirt, algae, grease and other foreign matter by
brushing and washing. The surface shall be thoroughly wetted
with clean water before the water proof cement paint is
applied.
The solution shall be applied on the clean and wetted surface
with brushes or spraying machine. The solution shall be kept
well stirred during the period of application.

CLAUSE A-18

FILLING OF OPEN WELLS


Scope
The work shall consist of removal and disposal of all unsuitable
and obstructing materials, demolition of well lining, placing of
selected materials in layers, and compaction in layers for filling
of open wells originally used as sources for potable water. The
work shall be carried out in accordance with the Specifications
and as directed by the Engineer.
These specifications would be applicable for open wells over
which the road embankments would be built. These would not
be applicable for plugging of open wells, which are outside the
limits of embankments. These open wells would require
plugging using suitable materials so as to protect against
contamination of water. These specifications would also not be
applicable for filling of ponds and water reservoirs.

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Classification of Wells
The open wells shall be classified as under:
Unlined
Lined
The casing/lining of wells may be of masonry, burnt clay,
concrete rings or any other type.
Materials
The fill materials shall be sand, gravel, selected soil and such
materials free from logs, stumps, roots, rubbish, compressible
materials or any other ingredient likely to deteriorate, or affect
the filling and shall be free from any hazardous material such
as harmful chemicals, sewage etc., which could cause
contamination of ground water. A mixture of sand and gravel
would be acceptable as filling material because little settling
would occur afterwards.
The types of material to be used shall be as per Table-1 and as
directed by the Engineer.

Table-1: Material for Filling of Open Wells


SL.
No.
1

Description

Material Type

Well with
standing
water

Mixture of sand and gravel upto 1.5m


height below natural ground level. The
selected granular soil with Plasticity
Index (PI) < 6 for the remaining depth
of well. To achieve the desired
compaction, the top 1.5m shall be
executed by lowering the standing
water level by more than 1.5m below
natural ground level.

Dry well with


depth

Mixture of sand and gravel upto 1.5m


height below natural ground level. The
selected granular soil with Plasticity
Index (PI) < 6 for the remaining depth
of well.

Note:
(1)
Materials for filling of wells of sizes less than 1m in
diameter shall be mixture of natural sand and gravel.
(2) The selected materials (soils and sand-gravel mixtures)

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shall have MDD (as per IS2720, Part-8) not less than 16.0 Kn/m3.
The sand-gravel mix shall be as per sub clause 2504.
The size of the coarse material in soil shall not exceed 25 mm. In
case of sand-gravel mixtures, the maximum particle size shall not
be more than 75 mm. Sand-gravel mixtures with excessive
amounts of gravel (>30%) shall not be permitted
These should be capped with 300 mm thick M-15 grade PCC
slab on granular material.
1.

Construction Operations

(a) Removal of Obstructing Materials


(i)

All debris such as pump, metal wires and rods, pipes, any
other equipment, floating materials and logs, degradable
and also not degradable materials that would cause
incomplete filling of the voids shall be removed from the
bed of wells so that the selected fill materials do not slump
or settle afterwards. The removal and disposal shall also
cover all plastic materials (e.g. used polythene bags, pipes
etc.), sewage, dead animals, boulders etc. as directed by
the Engineer.

(ii) All debris such as pump, metal wires and rods, pipes, any
other equipment, floating materials and logs, degradable
and also not degradable materials that would cause
incomplete filling of the voids shall be removed from the
bed of wells so that the selected fill materials do not slump
or settle afterwards. The removal and disposal shall also
cover all plastic materials (e.g. used polythene bags, pipes
etc.), sewage, dead animals, boulders etc. as directed by
the Engineer.
(iii) In case of lined open wells, the lining shall be dismantled
up to the level of natural ground level or one metre in
height, whichever is higher.
(b) Disinfect Standing Water in Open Wells
All open wells with standing water shall be disinfected to kill
micro organisms. This can be accomplished using by adding
chlorine bleach @ 5 litres of chlorine bleach for every 2,500
litres of standing water and as directed by the Engineer.
(c) Removal of Well Lining
The upper 1m of well casing/lining shall be removed when the
fill material reaches within 1m of the existing ground surface
(d) Placing and Compaction

(i) The placing and compaction operations would commence


after completion of the preceding tasks, (a) and (b), to the
satisfaction of the Engineer.

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(ii) The fill material as specified in Table-1 above shall be


placed in the well in layer of 500 mm using shovels and as
directed by the Engineer. Dumping of materials from dump
trucks and front-

(iii) end loaders into the abandoned wells shall not be allowed.
(iv) Each layer of fill material shall be compacted with the help
of plate compactor or power hammer and as directed by
the Engineer.

(v) Before allowing the next layer, it shall be ensured that the
earlier layer is at the desired compaction and as directed
by the Engineer.

(vi) It shall be ensured that no further consolidation/settlement


takes place while in service after filling of open wells. The
site over the filled open well shall be shaped as directed by
the Engineer to stop ponding of water and also to absorb
any settling of filling material.

(vii) These should be capped with 300 mm thick M-15 grade


PCC slab on granular material.
2. Measurements
Measurement of well filling shall be in cum for finish work for
the following items.
(b) Mixture of sand, gravel and selected granular soil.
(b) PCC M 15 grade.
3. Rates
The contact unit rates for filling of open wells shall include
removal of debris, dismantling of lining, cost of fill materials,
machinery, labour, all compaction works, environmental
protection works, if so directed by the Engineer, and disposal
of unsuitable materials complete with all leads and lifts and as
directed by the Engineer.
CLAUSE A 19

Levelling and Grading Road side Land


1 Description
The work shall consist of levelling and grading of roadside land
for purposes of chaining the land and as a landscaping
measure in accordance with the requirements of these
specifications or as directed by the Engineer.
2 Construction Operations
The construction operations shall follow the following sequence

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(1)

The roadside land from the toe of the road embankment


to the outer open drain shall be cleaned and grubbed in
accordance with Clause 201. Except for trees and largesized plants designated to be retained, all shrubs and
plants shall be removed.

(2)

The land area shall be levelled by cutting high spots and


filling low spots, and sloped towards the outer drain by
means of dozer/grader. The graded slope shall at least
be 0.5% falling towards the ROW boundaries. Grading
shall be in such a manner that the rainwater from the
roadway and roadside land gets drains into the outer
open drains. The graded area shall be rolled with at
least two passes of 8-10 ton roller, and the areas
finished clean and tidy.

(3)

In case the land contours require construction of lateral


drains to drain out the water, the same shall be
excavated as excavation in ordinary soil to Clause 301.

3 Measurement for Payment


The work of levelling and grading the roadside land shall be
measured as area over which the work is performed in sq.m.
Cleaning and grabbing the area shall be measured and paid for
under Clause 201.
4 Rates
The contract unit rate for levelling and grading roadside land
shall be payment in full for all the operations including all
labour, equipment and incidentals required to complete the
work to the requirements of the specification.
CLAUSE A 20

CONTROLLED BLASTING
GENERAL
The specifications for excavation in rock are covered by
MoRT&H Specifications for Road & Bridge Works (4th revision
2001), vide section 300. The following specifications are
additional and supplementary to the same.
CONTROLLED BLASTING
Whenever required by the Engineer, the rock blasting shall be
controlled so that vibration generated during the blasting do not
cause damage to the building and installation around built up
areas. Similarly, the rock pieces should not fly off the pits and
thus damage the buildings and installation and life and limb of
people around. Apart from the general precautions mentioned
in the MoRT&H specifications, following protective measures
and limits for use of explosives are suggested as guidelines.

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PROTECTIVE MEASURES
a) Short delay blasting with light charges shall be used.
b) The blast hole shall be covered with 0.6 to 1.0 sq.m. Mild
steel plate of minimum 6 mm thickness.
c)

Reinforcement rod mesh not less than 20 mm dia at 150


mm centers in both directions shall be placed over the
steel plates.

d) Steel plate and reinforcements shall be inspected after


every blasting operation and all twists shall be removed
before reuse to the satisfaction of the Engineer.
e) The thickness of the covering plate and the kind of dead
weight is to be duly approved by the Engineer.
f)

When blasting is necessary adjacent in partially of


completely built structures the contractor shall take all
precautions necessary to prevent flying rock from causing
damage to the structures.

BLASTING WITHIN CERTAIN LIMITS


No blasting shall be allowed for any of the excavation until
freshly placed concrete of nearby structures has reached a
minimum strength of 7 Mpa.
Normally, blasting shall be resorted to only after 7 days of
concreting work in case of OPC (10 days in case of PPC) in
adjacent structures.
In no case shall blasting be allowed closer than 15m to any
structure after concrete placing has started
When minor blasting is necessary after concrete placing has
started in any structure, the maximum size of charge for
distance from 100m and above shall be limited to the following:

Distan
ce in
m

Safe particle velocity 10


mm/sec. Charge in kgs per
delay

100
150
200
250
300
350
400
450
500

10.7
24.2
43.0
67.3
96.9
131.9
172.3
218.2
269.3

373

Safe particle
velocity 3 mm/sec.
Charge in kgs per
delay.
2.6
5.8
10.3
16.7
23.2
31.6
41.2
52.2
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Any deviation in the above-recommended limits will be adopted


only after the specific approval of the Engineer. The contractor
shall submit the scheme with charges and delays he proposed
to use for blasting, for approval of the Engineer.
It is generally recommended that where the blasting is to be
done, within 20 m of the nearest point of permanent building,
the area shall be line drilled on periphery before blasting.
The Contractor shall be responsible for all damage caused by
blasting whether to permanent or temporary structures and
shall replace or repair the structures at his own cost.
PRECAUTIONS AFTER BLASTING
After the blast, the supervisor must carefully inspect the work
and satisfy himself that all the charges have exploded. After
the blast takes place in underground works, the workmen shall
not be allowed to go to the face till toxic gases have
disappeared from the face.
If it is suspected that part of the blast has failed to fire or is
delayed, sufficient time shall be allowed to elapse before
entering the danger zone. When fuse and blasting caps are
used, a safe time should be allowed and then the supervisor
alone shall leave the shelter to inspect the blasting zone.
None of the drillers are to work near the misfired hole until one
of the two following operations have been carried out by the
Supervisor:
Either (i) the Supervisor should very carefully (when the
tamping is of damp clay) extract the tamping with a wooden
scraper or jet of water or compressed air (using a pipe of soft
material) and withdraw the fuse with the primer and a fresh
detonator with fuse should be placed in these holes and fired
out, or (ii) the hole may be cleared of 30 cm of tamping and its
direction then be ascertained by placing a stick in the hole.
Another hole may then be drilled at least 60 centimeters away
and parallel to it and about 30 cm less in depth, this hole shall
them be charged and fired. The balance of the cartridges and
detonators found in the muck shall be removed.
Before leaving his work, the Supervisor of the concluding shift
shall inform the Supervisor of the relieving shift of any case of
misfires and should point out the position with a red cross
denoting the same and also stating what action, if any, he has
taken in the matter.
The Supervisor should also at once report at the office of the
Contractor and the Engineer all cases of misfire, the cause of
the same and what steps were taken in connection with these.
The names of the day and night shift Supervisors must be noted

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daily in the Contractors office.


If a misfire has been found to be due to a defective detonator of
dynamite the whole quantity or box from which the defective
article was taken, must be thoroughly inspected by the
Contractor.
Drilling in holes not completely exploded by blasting shall not be
permitted.
PERSONNEL
Excavation by blasting will be permitted only under the personal
supervision of competent and licensed blasters and trained
workmen.
All supervisors and workmen in-charge of preparation, handling,
storage and blasting work shall be adequately insured by the
Contractor.
Storage shall be in charge of a very reliable person approved by
the Engineer, who may, if necessary conduct police enquiries as
to his reliability, antecedents etc. The contractor shall have to
produce a security for the person in-charge of the explosives, if
and when required by the Engineer, of the civil authorities of the
district.
The Contractor shall make sure that his supervisors and
workmen are fully conversant with all the rules to be observed in
storing, handling and use of the explosives. It shall be ensured
that the supervisors in charge are thoroughly acquainted with
the details of the handling of explosives and blasting operations.

Clause A-21

1.0

INSTALLATION, TESTING AND COMMISIONING OF HIGH


MAST LIGHTING
Scope
The work of Supply, Installation and commissioning of 20 Meters
High Mast complete with 12 Nos.2x400 Watts Metal Halide flood
light luminaries, Electrical Connections and electrical cables,
foundations with foundation accessories, lamp carriage with
pulley and stainless steel wire ropes, compensating disc, double
drum winch, provision for attaching power tool (with power tool),
Lighting arrestor, aviation light earthing, including foundations
etc. shall be carried out as per IS-1944 and other relevant IS
codes for the same and as per drawings supplied by the
Concessionaire and approved by the Engineer.

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Materials
a) 20 Meters long, High Mast, in two sections made from special
steel plates as per BSEN 10025/IS S986 with excellent ultimate
tensile strength, yield stress and elongation and corrosion
Resistance properties and suitable weldability. Plates to be cut
and folded to form a telescopic polygonal cross section (20
sides) and welded longitudinally as per IS 9595/IS10178 and
continuously tapered, and having no circumferential welds.
b) Hot Dip Galvanisation of both internal and external surface with
minimum 86 Microns more than 600 gm/m2 as per IS
specification.
c) The thickness of sections shall be 6mm. for bottom section and
5mm top section. With a bottom diameter than 480mm and top
diameter than 200mm.
d) The two sections should fit telescopically and the length of
overlap shall be at least 1.5times the diameter.
e) The stress slip fit jointed without any welding at site and length
of overlap should be at least 1.5 times the Diameter.
f) The high mast shall be designed as per IS 875 (Part-Ill) to
withstand a wind pressure of 250 Km/Hr with maximum gust
speed time of 3 seconds.
g) The factor of safety for wind load shall be at least 1.25 and for
other loads shall be 1.15
h) The base plate shall be made of hot-rolled MS. Plate as per
IS:2062 and of minimum 700mm diameter and 30 mm. thick
with at least 8 Nos. foundation Bolts of high tensile steel of
1200mm Length and M30 Category with Nuts for grouting in
concrete.
i) The high mast shall be provided with lantern carriage of 1200
mm diameter made out of 75mmx400mm MS Channel or
60mmx60mm Square tube in 3 segments and having Rubber
Padded Guide ring as buffer between carriage and Mast with a
load carrying capacity of 750 Kgs, raising and lowering type
with three wire suspension system with a double drum winch for
optimum balancing of the lantern carriage and self lubricating
winch gear assembly made of phosphor bronze.

j) The Wires used shall be of Stainless steel, minimum diameter


of 6mm and breaking load capacity of 2350 Kgs. per SS wires.
k) Three nos. of SS wires shall be used for lantern carriage and 2
Nos. for Double Drum Winch.

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l) The luminaries shall be mounted on the lantern carriage by


mounting arm assembly to achieve desired lighting
performance.
m) The mast shall be provided with lighting arrestor with spikes and
aviation obstruction light
n) The high mast shall also be provided with compensating disc
and safety wires for maximum safety and flexibility.
3.0

Earthing
Installation and fixing of 2 Nos. Standard earthing with 50mm
dia G.l. pipe, Class B, Medium Quality, 3 meters long and the
pipe shall have 12mm diameter holes at 15 Cms c/c up to a
height of 2.5 meters from the bottom and a clamp made out of
40mmx5mm G.l. flat at the top for taking earth connection
complete with excavation of earth pit chamber of depth
3000mm in all kind of soil including rock of all variety,
installation of earth electrode and masonry work for earth pit
chamber
with
brick
cast
iron
cover
of
size
300mmx300mmxl0mm thick for covering the earth pit chamber.
The pit shall have alternate layer of 105mm of charcoal and
50mm of salt up to a height of 465mm from the bottom of the pit
and the rest shall be filled up with charcoal to a further depth of
2035mm. and the balance shall be filled up with earth. (The
earth pit chamber shall be erected after the earth has settled
and has became firm. Otherwise the earth shall be watered and
rammed to make it compact and then the masonry work shall
be done with 1:6 cement sand mortar and 1st Class bricks shall
be plastered with 1/2
thick plaster of cement mortar both
inside and outside the chamber. Further the level of the Cast
iron Cover shall be same as adjacent ground / pavement level
including connection with the help of 40mmx5mm GI strip from
earth electrode to earth electrode and from earth electrode to
the high mast.

4.0

Fixing and Installation


12 Nos. 2x400watts, Metal Halide Lamp, High efficiency low
glare asymmetrical floodlighting luminaries complete with 2x400
watts, Metal Halide lamp, housing made of die-cast aluminium
with black powder coated finish and the lamp compartment
consisting of electro chemically brightened, high purity, preanodised aluminium reflector, heat resistant toughened front
glass fixed to the housing with specially designed hinged
mechanism for quick and easy lamp replacement, complete
with external / internal control gear box consisting of energy
efficient, low watt loss, open construction copper ballast, power
factor improvement capacitor, ignitor etc., including power tool
for lowering and raising the lamp carriage the High mast with
movable packing and all tools and accessories complete.

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Measurement and Rates


The payment shall be made on number of High Masts fixed in
position.
All fitments such as High Mast, Luminaries, Accessories and
Cables etc shall be approved by the Engineer along with the
manufaturers details. The Firm must submit the details of the
manufacturers of fitments proposed to be used in the works
along with the other supporting documents to the Engineer for
approval before execution.
The unit rate includes all necessary materials and other fixtures,
earthing, wires, lighting lamps, tools and plants, equipment
required to complete the work. The required excavation and
fixing of High Mast and backfilling and concreting etc., shall be
considered incidental to work. No extra payment shall be
admissible.

CLAUSE A-22

LIGHTING ARRANGEMENTS
Scope :
The work of supplying, installing, testing and fixing properly in
position external light poles including clamps, fixtures, cables
earthing etc., shall be carried out as per relevant I.S. codes for
the same and as per detailed drawings supplied by the
Contractor and approved by the Engineer as indicated below.

1)

Poles and Cross arms:


a) MS. Galvanised Octagonal Poles with base plate fabricated from
special steel plates as per BSEN 10025/IS 5986 with excellent
ultimate tensile strength, yield stress and elongation and
corrosion resistance properties and suitable weldability. Plates to
be cut and folded to form a octagonal cross section and welded
longitudinally as per IS 9595/1S10178. The pole shall withstand
wind pressure of 180 Km/Hr as per IS:875 and of 9.5 Meters
Length in single section, continuously tapered profile for stability
and aesthetics with face to face dimension being 190mm at
bottom and 90mm at top and 4.5mm wall thickness with
foundation base plate made of Hot rolled M.S. Plate as per
IS:2062 and 300mmx300mmx2Omm thick duly welded to the
base of the pole with foundation Bolts of 800mm Length and M24
Category with Nuts for grouting in concrete.
b)

Hot Dip Galvanisation of both internal and external surface with


minimum 86 Micronsmore than 600 gm/m2 as per IS
specification.

c) 1500mm long (Galvanised as above) Cross arms made out of


60mm outer diameter MS. G.l. tubular pipes of Class B and
welded with a cap to fit the top of the above pole and MS Plate
for rigidity between cap and pipe with provision of passing the
electrical cable from the pole to the end of cross arm for
connection of the luminaries.

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d) Electrical Termination box fixed at a height of 500mm from the


bottom of pole, made out of weather resistant fibre glass having
arrangement for fixing the box on the pole with clamps, 4 way 25
Amps / 400 Volts connector, 6/10 Amps / 230 Volts / 10 KA, SP,
MCB, Cable gland at bottom of suitable size for entry & exit of 16
Sq-mm, 4 Core, Armoured Aluminium Cable with 6/10 Amps
e)

2)

Excavation of Pole pit in all kind of soil including rock of all


variety of size 600mmx600mm and depth 1200mm with filling of
sand to a height of 300mm and then laying foundation of
Reinforced cement concrete (1:2:4) of 600mm x 600mm x
900mm high with granite metal of nominal size 20mm to 25mm
including side shuttering and grouting of foundation bolts and
supply and erection of pole as specified above including watering
and ramming it as required including provision for passage of
Cables and finishing the surface with 1:4 ratio cement plaster
Luminaries :
Supply, Installation and Commissioning of 250 Watts, Metal
Halide/H.P.S.V. Street light luminaries including lamps as
specified below on the ends of cross arms mounted on the MS
tubular poles complete with connection from terminal box at the
pole base to the luminaries with the help of 1.5 Sq-mm, 650/1100
Volt grade, twin core, flexible copper wire, PVC insulated and
sheathed conforming to IS:694, complete with supply of all
materials such as luminaries with control gear, lamp, connecting
wires and all accessories and sundries as required for the work
and as per direction of Engineer as detailed below.

a) The housing shall be made of single piece pressure die cast LM6
aluminium / aluminium alloy with low copper content and epoxy
powder coated finish from outside.
b) The lamp compartment shall consist of electrochemically
brightened and anodized, high purity STEP Precision Optics
Tech (POT) reflector.
c) The luminaries shall have a Heat-resistant toughened flat glass
cover for the lamp compartment to ensure ingress protection of
IP66 for the lamp compartment and IP65 for control gear
compartment.
d) The luminaries shall be complete with control gear such as
energy efficient, low watt loss, open construction copper ballast,
power factor improvement capacitor, ignitor etc.
3)

Highmast lights:
Supply, Installation and commissioning of 20 Meters High Mast
complete with 12 Nos.2x400 W Metal Halide flood light
luminaries, Electrical Connections and electrical cables,
foundations with foundation accessories, lamp carriage with
pulley and stainless steel wire ropes, compensating disc, double

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drum winch, provision for attaching power tool (without power


tool), Lighting arrestor, aviation light earthing etc. as detailed
below complete with all materials, accessories and sundries as
required for the work and as per the direction of Engineer as
detailed below.
a) 20 Meters long, High Mast, in two sections made from special
steel plates as per BSEN 10025/IS 5986 with excellent ultimate
tensile strength, yield stress and elongation and corrosion
Resistance properties and suitable weldability. Plates to be cut
and folded to form a telescopic polygonal cross section
(20
sides) and welded longitudinally as per IS 9595/IS10178 and
continuously tapered, and having no circumferential welds.
b) Hot Dip Galvanisation of both internal and external surface with
minimum 86 Microns-more than 600 gm/m2 as per IS
specification.
c) The thickness of sections shall be 6mm. for bottom section and
5mm top section. With a bottom diameter not less than 480mm
and top diameter not less than 200mm.
d) The two sections should fit telescopically and the length of
overlap shall be at least 1.5times the diameter.
e) Stress slip fit jointed without any welding at site and length of
overlap should be at least 1.5 times the Diameter.
f) Shall be designed as per IS 875 (Part-Ill) to withstand a wind
pressure of 250 Km/Hr with maximum gust speed time of 3
seconds.
g) The factor of safety for wind load shall be at least 1.25 and for
other loads shall be 1.15
h) The base plate shall be made rolled MS. Plate as per IS:2062
minimum 700mm diameter and 30mm. thick with at least 8 Nos.
foundation Bolts of high tensile steel of 1200mm Length and M30
Category with Nuts for grouting in concrete.
i) Shall be provided with lantern carriage of 1200 mm diameter
made out of 75mmx400mm MS Channel or 60mmx60mm
Square tube in 3 segments and having Rubber Padded Guide
ring as buffer between carriage and Mast with a load carrying
capacity of 750 Kgs, raising and lowering type with three wire
suspension system with a double drum winch for optimum
balancing of the lantern carriage and self lubricating winch gear
assembly made of phosphor bronze.
j) The Wires used shall be of Stainless steel, minimum diameter of
6mm and breaking load capacity of 2350 Kgs. per SS wires.
k) Three nos. of SS wires shall be used for lantern carriage and 2
Nos. for Double Drum Winch.
l) The luminaries shall be mounted on the lantern carriage by

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mounting arm assembly to achieve desired lighting performance.


m) Shall be provided with lighting arrestor with spikes.
n) Shall be provided with aviation obstruction light.
o) Shall be provided with compensating disc and safety wires for
maximum safety and flexibility.
p) Installation and fixing of 2 Nos. Standard earthing with 50mm dia
G.l. pipe, Class B, Medium Quality, 3 meters long and the pipe
shall have 12mm diameter holes at 15 Cms c/c up to a height of
2.5 meters from the bottom and a clamp made out of
40mmx5mm G.l. flat at the top for taking earth connection
complete with excavation of earth pit chamber of depth 3000mm
in all kind of soil including rock of all variety, installation of earth
electrode and masonry work for earth pit chamber with brick cast
iron cover of size 300mmx300mmxl0mm thick for covering the
earth pit chamber. The pit shall have alternate layer of 105mm of
charcoal and 50mm of salt up to a height of 465mm from the
bottom of the pit and the rest shall be filled up with charcoal to a
further depth of 2035mm and the balance shall be filled up with
earth. (The earth pit chamber shall be erected after the earth has
settled and has became firm. Otherwise the earth shall be
watered and rammed to make it compact and then the masonry
work shall be done with 1:6 cement sand mortar and 1st Class
bricks shall be plastered with 1/2 thick plaster of cement mortar
both inside and outside the chamber. Further the level of the
Cast iron Cover shall be same as adjacent ground / pavement
level including connection with the help of 40mmx5mm GI strip
from earth electrode to earth electrode and from earth electrode
to the high mast.
q) 12 Nos. 2x400watts, Metal Halide Lamp, High efficiency low
glare asymmetrical floodlighting luminaries complete with 2x400
watts, Metal Halide lamp, housing made of die-cast aluminium
with black powder coated finish and the lamp compartment
consisting of electro chemically brightened, high purity, pre
anodised aluminium reflector, heat resistant toughened front
glass fixed to the housing with specially designed hinged
mechanism for quick and easy lamp replacement, complete with
external / internal control gear box consisting of energy efficient,
low watt loss, open construction copper ballast, power factor
improvement capacitor, ignitor etc.
4)

Power Tool :
Supplying of Power tool for lowering or raising the lamp carriage
the High Mast as at Sl. No. 3 above, complete with movable
packing and all tools and accessories.

5)

Multicore Cables :
Supplying and Laying of round multi core armoured cable of
Aluminium / copper conductor as per lS:1554(Pt-l) of 1988 of

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sizes as mentioned below in ground in cable trench of depth


900mm and width 300 mm. (The bottom of the Gable trench shall
be filled with 150mm of sand then cable laid and then filled with
sand to further height of 300mm and then the balance with
excavated earth and in pre laid pipes for road crossings from the
Transformers L.T. Panel to the Feeder panel and from feeder
panel to the pole terminal box complete with all materials &
connections, accessories and sundries as required for the work
and as per the direction of Engineer.
a) Supplying and laying of 16 Sq-mm, 4 Core, Aluminium Armoured
cable as above from transformer panel to feeder panel
b) Supplying and laying of 16 Sq-mm, 4 Core, Armoured cable of
Aluminium as above from feeder panel to pole terminal box and
loop cable from pole to pole.
6)

End Terminations of Cables:


Crimpling / soldering and end socketing with proper sockets of
cable of various sizes and cores as mentioned below including
provision of double compression brass glands
a) End termination of 16 Sq-mm, 4 core, Aluminium
Armoured cable as above.
b) End termination of 16 Sq-mm, 4 core, Aluminium
armoured cable as above.

7)

Transformer with D.P. Structures


Supply, Erection, Testing, Commissioning of 11KV/415V 100
KVA, 50Hz Delta/Star connected outdoor Transformer with tap
changer on HV side and distribution panel. The transformer
should be oil cooled with tappings + 5% to -5% in 4 steps of
2.5% each, with HT bushings, LT gland cable box suitable for
120 Sqmm x 4 core PVC insulated armoured aluminum cable
and the transformer shall be designed and manufactured as per
IS 2026 of 1977 and will be supplied with first filling of
transformer oil conforming to IS 335 of 1993 and as per the
specification given below
Rated KVA
Service
Mounting
Wound
Type
Cooling
Temp raise

:
:
:
:
:
:

Vector group
Primary connection
Primary Volts
Primary frequency
Primary phases
Primary wires

:
:
:
:
:
:

382

100 KVA
Outdoor
DP
Double
Core
ONAN
500C of oil
550C of winding
DYNII
Delta
11000 V
50 hz
3
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Secondary connection
Secondary volts
Secondary phase
Secondary wires
Taps
on
primary
winding
Terminal arrangement
H.V

:
:
:
:
:

LV

:
:

Star
415
3
4
+ or 2.5 %

Three bare terminal sturdy through


weather proof porcelain bushings
Three terminology one separate
neutral terminal for earthing with
cable terminal box and with
required fittings and accessories of
the Transformer.

The Guaranteed max losses of No Load condition are 195 watts


and Full Load condition is 1650 watts.
1) The LT bushings of the CSP Transformers shall be so located
that even under the hottest condition the level of the
Transformer oil shall be below the opening meant for fixing
the LV bushing.
2) For 100 KVA the four walls of the tank shall be made of two
L shaped sheets (without joints) and shall be fully welded
from inside and outside of tank withstand a pressure of 1
kg/cm2 for 10 minutes.
a) Installation and Commissioning of 11/0.4 K.V., 100 KVA, SubStation for Power, supply to Street lighting on the stretch of outer
ring road including liaison for obtaining permission from
APCPDCL and Office of the Electrical inspector for Power
Supply to the above and energising the Sub-Station
b) Installation and Commissioning of 11/0.4 K.V., 100 KVA, SubStation, D.P. Structure to be erected below the existing 11 K.V.
line, 2 Nos. H.T., G.l. Stay Sets for each sub-Station if required,
including cost for supplying all materials, labour, T&P and
Sundries, Storage, Transportation of material to site of work and
all accessories as required for smooth completion of the work
and as detailed below and including cost of 11/0.4 K.V., 160 KVA
transformer and outdoor Electrical Panel
c) Supplying and fixing of 11 K.V. V cross arm made out of
75mmx40mm size MS. Channel as per R.E.C. Construction
Standard A-6, Complete with supply and fixing of back clamp for
cross arm with required numbers of nuts and bolts of size 16mm
diameter and of required length, all duly painted with two coats of
Aluminium paint over a coat of red-oxide paint (paints to confirm
to relevant ISS) with fixing of the same on 12.00 Meters long MS.
Pole top of DP Structure.
d) Supplying and fixing of 11 K.V. lines pole top bracket made out
of 50mmx8mm MS. Flat as per R.E.C. Construction standard A7, complete with all accessories duly painted with coats of

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Aluminium paint over a coat of red-oxide paint (paints to confirm


to relevant ISS) with fixing of the same on 12.00 Meters long MS.
Pole top of DP Structure.
e) Supplying and fixing of 11 K.V. Insulators and hardware fittings
complete with all accessories, required for fixing of the insulator
of various types as specified below [as per R.E.C. Specification
3/1971 (as amended upto date) for insulators and IS:2486 (Pt1/1993 and IS:2486 (Pt-ll)/1989 (as amended upto date)] on 11
K.V. V Cross arm/ Pole top bracket / D.P. Structure etc.
i)

11 K.V. Pin insulator complete with all hardware fitting and


accessories.

ii) 11 K.V. String / Disc insulator (T&C type) complete with all
hardware fitting and accessories
f)

Supplying, Fabrication and erection of Double Pole Structure for


11/0.4 K.V., Sub-Station, complete with the following members of
R.S. joists, MS. Channels, MS. Angles, Nuts, Bolts and washers
etc. of various sizes and lengths including fabrication and
erection as detailed below with all the members of the D.P.
Structure duly painted with two coats of Aluminium paint over a
coat of red-oxide paint (paints to confirm to relevant ISS)

g)

Excavation of Pole pit in all kind of soil including rock of all


variety of size 600x900m and depth 1800mm with filling of sand
to a height of 150mm and then laying base pad of cement
concrete (1:3:6) of 150mm thickness with granite metal of
nominal size 20mm to 40mm and supply and erection of 12.00
Meters long (or as required at site) R.S. joists of size
200mmx100mm for D.P. Structure in the pit above the base pad
and filling the rest of the pit with cement concrete of 1:3:6 ratio
with granite metal as specified above including watering and
ramming it as required2 numbers, at a distance of 2800mm
(approx.) from each other.
The work of fabrication & Erection of D.P. Structure
involves:

i) MS. Channel of size 100mx50mm of length 3000mm (approx)


10 Numbers, fixed in pairs of two each on the D.P. Structure for
fixing String Disc Insulator, Lighting Arrestor, transformer and
A.B. Switch.
ii) MS. Channel of size 100mx50mm of length 250mm (approx.)-20
numbers, fixed as supports to channels for mounting A.B. Switch
and Lighting Arrestor.
iii) MS. Channel of size 75mmx40mm of length 1000mm (approx.)-2
Numbers, fixed on 11.00 Meters long R.S. Joist as cantilever
projection for mounting HG. Fuse unit 2 Numbers, one on
each Joist.
iv) MS. Angle of size

50mmx50mmx6mm

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(approx.)-2 Numbers fixed as bracing for supporting H.G. Fuse


unit.
v) MS. Channel of size 75mmx40mm of length 3000mm (approx.)
4 Numbers fixed on the Cantilever projection for mounting the
H.G. Fuse unit and mounting the 100 KVA Transformer.
vi) MS. Angle of size of 50mmx50mmx6mm length 3000mm
(approx.) - 2 Numbers to be fixed on R.S. Joists as clamping of
transformer.
vii) Clamp made out of 50mm x 6mm MS. Flat for fixing the MS.
Angle to the joist (used as bracing for supporting the H.G. Fuse
unit)-2 Numbers.
viii) Supplying and fixing of one number in each sub one-station 12
K.V., 400 Amps. out door type, manually gang operated A.B.
Switch, triple pole, 3 post pin type insulator per bar mounted in
horizontal position on existing MS. Channel of size 100mx50mm
on D.P. Structure for 11/0.4 K.V. Sub-Station, complete with
supplying and fixing of adequate length of G.l. Pipe as operating
handle erected on extended square shaft and supported by
external bushy bearing with locking arrangement at a suitable
height from ground level and with all hardware fittings like Nuts,
Bolts and washers etc. (The A.B. Switch shall generally confirm
to R.E.C. Specification No.43/1987 and ISS:9920 (Pt.I to IV) as
amended upto date).
ix) Supplying and fixing of 11 K.V., 200 Amps outdoor type HG.
Fuse Set of 3 Nos. as per R.E.C. Construction Standard F-6 and
F-7, mounted horizontally on existing MS. Channel of Size
75mmx40mm and 2800mm long on D.P. Structure for 11/0.4
K.V. Substation, complete with all hardware fitting like nut, Bolt
and washer etc. and base channel of size 75mmx40mm for HG.
Fuse.
x) Supplying and fixing of 12KV. Lighting Arrestor set of 3 Nos.
confirming to IS:3070 /1974, mounted on D.P. Structure for
11/0.4 K.V. Sub-Station complete with all hardware fitting like
Nut, Bolt, Clamp etc.
xi) Supplying and Installation and fixing of Six Numbers (in each
sub-Station) Standard earthing device with 50mm dia G.l. pipe,
Class-B Medium Quality, 3000mm long and the pipe shall have
12mm dia. holes at 15 cms c/c upto a height of 2500mm from the
bottom and with a clamp made out of 40mmx6mm G.l. flat with
G.l. Nuts, Bolts and Washers at the top for taking earth continuity
connection complete with excavation of earth pit chamber
3000mm deep in all kind of soil including rock of all variety &
installation of earth electrode as above in the pit. The pit shall
have alternate layer of 105mm of charcoal and 50mm of salt upto
a height of 465mm from the bottom of the pit and the rest shall
be filled up with charcoal to a further depth of 2035mm
(measured from the bottom of the pit) and the balance shall be
filled up with earth.

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xii) Supplying and fixing of required length of 40mm x 6mm size G.l.
Flat for earth connection between two earth electrode and from
earth electrode to D.P. Structure, Body of Transformer etc.
complete with all connections with G.l. Nuts, Bolts and washers
etc. with supply of G.l. Nuts, Bolts, Washers etc. complete with
all other accessories.
xiii) Supplying and fixing of required length of No. 4 S.W.G. G.l. wire
as earth connection from earth electrode/bus to the body of the
transformer, all lightning arrestor, all members of the D.P.
structure including the joist from top to bottom, Neutral of the
transformer, L.T. Panel Box etc. All the terminals end of the G.l.
wire shall be soldered to cable Sockets / lugs of Copper of
proper size and the connection made with proper size of Nut,
Bolt and washer etc. complete with all other accessories and
connections.
xiv) Supply, Installation, testing and commissioning of 11/0.4 K.V.,
100 K.V.A, transformer, Delta/Star, oil cooled type (Natural
Cooled) with Copper winding on the DP Structure (as mentioned
in this schedule elsewhere) with proper alignment and providing
all connections on 11 K.V. side of the Sub-Station from Insulators
on the D.P. Structure to the H.T. (11 K.V.) bushing of the
transformer through Lightning arrestor, A.B. Switch, HG. Fuse
Set etc. with the help of A.A.C./A.C.S.R. Conductor for
connections as above
xv) Supply and fixing of 95 Sq.mm, 3-1/2 Core, Armoured cable from
the L.T. Bushing of the Transformer to the M.C.C.B in the L.T.
out-door Panel for transformer.
Installation of Out-Door type Electrical Panel consisting of 160
Amps, 400 Volts, 50 KA, Four Pole MCCB for transformer
protection on the DP Structure:
xvi) Excavation of Foundation Trench along the boundary of the SubStation Area and erection of 10 thick and 2 deep retaining wall
all along the periphery of the Sub-Station, the top of such wall
shall be 300mm or 12 high than the surrounding ground level
and Cleaning, Dressing and levelling of the Ground in the 11/0.4
K.V. Sub-Station area and supplying and spreading machine
broken Granite metal of 20mm to 40mm Nominal size on the
ground to a thickness of 100mm within the boundaries of the
Sub-Station.
xvii)

Supply and erection of 11 KV HT Metering unit complete with


energy meter, metering CTs and control cable.
Panels :
Supply, Installation, testing and commissioning of pole mounted
panel to be fixed on the DP consists of:
Supplying and Fabrication of Out door electrical Panel , Pole /
Plinth Mounting type with slope roof and double door type made

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out of 16 SWG Steel sheets, duly painted with one coat of red
oxide paint and two coats of smoke grey enamel paint spray
painted after fabrication and due treatment of sheets with acid to
remove any rust and dust. The Panel doors must have thumb
screws with bakelite knob and rubber gaskets so as to render the
panel dust and vermin proof. The clearance between the various
phases and the earth should be minimum 30mm and that from
the body of the panel should be at least 30mm. The Bus Bars
shall be mounted on cast resin insulators of drum type and
should be properly insulated with insulating tape/sleeve of proper
colour i.e. Red, Yellow and Blue for Phases and Black for
Neutral. The panel shall also have a base fabricated out of
75mmx40mm MS. channel of light category (ISJC category).
(Before fabrication the final drawings should be approved by the
Engineer. Any fabrication done without the approval of drawing
shall be at the risk of the panel manufacturer) The panel shall
consist of the following incoming and outgoing:
(i) : INCOMING:
one number 160 Amps., 400 Volts, 50 KA Breaking Capacity,
Four Pole MCCB for each transformer protection. The Incoming
of the MCCB shall be from the top and the out going i.e.
connection to the outgoing shall be from the bottom only.
(ii) : OUTGOING for each Transformer:
a) One number 160 Amps, 400 Volts Contactor with 1NO+1NC
auxiliary contact after the MCCB
b) One number 24 Hours timer controlling the ON-OFF position of
the contactor
c) One number 20 Amps, 400 Volts, 10 KA TP&N, MCB for
outgoing feeders of High Mast.
d) Six Numbers 63 Amps, 230 Volts, 10 KA, SP&N, MCB for
outgoing feeders.
9

Earthing of the Poles comprises of:


Supplying and fixing of Coil Earthing (as per REC Construction
Standard J-1) with No.8 SWG G.l. wire closely wound in form of
helical coil of 50mm diameter and having 115 Nos. turns with
excavation of earth pit at a distance of 0.5 meter from the pole in
all kind of soil including rock of all variety of size 600mmx600m
and upto a depth of 1500mm, installing the coil earth, filling of pit
with available excavated earth in the pit and connecting the coil
to the earth nut of the street light pole complete with all
accessories and including cost of all material and labour with
necessary T&P and sundries etc. as required for the work.

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HDPE Pipes:
(a) Supply, delivery and laying of 50mm internal diameter HDPE
pipe inside road for road crossing of cable by Hydraulic Drilling
Device without opening of the road top surface laid at a depth of
at least 900mm below the road surface from the transformer
feeding point to the feeder pillar box in meridian including cost of
all accessories, masonry inspection chamber at both ends etc.
complete with for road crossing for laying of cables as in item
No.5 above for cable protection.
(b) Supply, delivery and laying of 50mm internal diameter HDPE
pipe in median laid at a depth of at least 900mm below the
ground surface by excavation of earth and refilling the same after
laying of pipe and cable from pole to pole for laying of cable in
meridian including cost of all accessories, masonry inspection
chamber at both ends etc. complete with for road crossing for
laying of cables as in item No. 5 above for cable protection.

11

Other Charges:
Liaison Charges and Statutory charges for Inspection by the
Electrical Inspector and obtain necessary clearance certificate to
energise the Sub-Station, building and Liaison and statutory
charges for obtaining clearance for power supply from
APCPDCL, excluding deposits to be paid to APCPDCL are all
inclusive.

12

Notes:
1. The Highway Crossing by the Hydraulic Drilling Device Boring
and the construction of manholes for all types of cable laying
through HDPE Pipe, if any, would be incidental to the work and
no extra charges will be borne by Hyderabad Growth Corridor
Limited. It is to be noted that Open Digging is strictly prohibited
under the road crust.

2. The streetlights, Transformers and High Masts shall be handed


over directly to the Hyderabad growth corridor limited along with
all warrantees obtained from the firms. Till the section is handed
over all the maintenance including electricity charges shall be
borne by the Contractor and is incidental to the work.
3. All fitments such as Poles, Luminaries, Accessories, High Masts,
and Cables etc. shall be approved by the Engineer along with the
Manufacturers details. The firm must submit the details of the
manufacturers of the fitments proposed to be used in the work
along with the other supporting documents to the Engineer for
approval.

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4. The agencies should take utmost care to protect the


beautification work in the median such as plantation, lawn etc.
and should replace the damaged parts, if any within seven days
from the date of damage without claiming any extra cost from
Hyderabad Growth Corridor Limited. to the satisfaction of the
Engineer.
5 The staff of the contractor shall wear safety jackets, shoes,
helmets, shock proof hand gloves etc.
13

Measurement of Payment
The various items of Street Lighting shall be measured as
follows:
a) Poles with single cross arm and double cross arm shall be in
numbers.
b) The Measurement for High Mast shall be in numbers.
c) The Measurement for power tool for lowering or raising the lamp
carriage of the high mast shall be in numbers.
d) The Measurement for Metal Halide street light fittings with starter
connections bulbs shall be in numbers.
e) The Measurement for HPSV light fittings with starter connections
bulbs shall be in numbers.
f) The Measurement for Street light control box with timer and all
other accessories shall be as each number.
g) The Measurement for Armoured Aluminium Cables and PVC
armoured cables and other cables shall be in running meters.
h) The Measurement for Pipes shall be in running meters.
i) The Measurement for making of cable end terminations with
necessary glands, lugs shall be in numbers.
j) The Measurement for Transformers including all accessories
shall be in numbers.
k) The Measurement for DP structure including all accessories shall
be in numbers.
l) The Measurement for run of earth lead shall be in running
meters.
m) The Measurement for Copper Plate Earth station including brick
pedestal meshed funnel, CI cover shall be in numbers.

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Rates
The contract unit rate for items of street lighting shall be the
payment in full for carrying out required operations including all
equipment, plant, tools, spares, labour, supervision, overheads,
consumables, materials, erection, maintenance, testing of input
material delivered, profit, taxes and duties together with all
general risks, patent charges (if any) and supervision by the
specialized
supplier/manufacturer/agency,
liabilities
and
obligations set out and implied in the Contract and other
incidentals to comply with the requirement of Technical
Specifications.

A-23

Highway/Advanced Traffic Management Systems (ATMS):

A real time system working round the clock shall be established for informing
the road users of the road, traffic, and weather conditions on the Project
Highway; for making interventions as required for smooth, safe and efficient
traffic operation; and for providing rescue and relief to the users in distress.
The system shall be capable of (i) acquisition of data from various sources
such as the road, the users, the maintenance and operation patrol, the
ambulance, and the intervention team (ii) three way communication between
the data source and a Central Control Room, the Control Room and the data
sources and display units, and between the maintenance and operation
teams, through a transmission system, and (iii) A Central Control Room to
process all data and control the highway operation.

The systems and equipment of ATMS shall meet the following main climatic
and environmental requirement as specified in IS-9000
(i)
(ii)
(iii)

Temperature Range of Operation - Low of 0 Celsius (3 C) to high of


60 Celsius ( 2 C)
Relative Humidity of 95%
Vibration Frequency Range of 10 Hz 55 Hz

Data acquisition system: This shall consist of (a) Automatic Traffic Counter
and Classifier (ATCC), with an in-road loop detectors and treadles. (b) Video
cameras installed on road with such pan and tilts that a length of 2 km road is
captured for video monitoring of traffic, (c) Emergency Call Boxes installed at
every 2 km to enable any user to be instantly in contact with the Control
Room, (d) Meteorological sensors for capturing data on temperature,
weather, wind, (e) Mobile radios for patrol vehicles and ambulances to be in
communication with Central Control Room and among themselves.

Emergency call boxes (ECBs) with loud speaker, micro phone, activation
button with LED indicating conversation, shall be housed in a vandal proof
casing and operate in full to play mode in noise level of up to 95 decibels with
in built diagnostic features for automatic detection in case of damage by any
object. Mobile communication system shall comprise the mobile radio base
stations and control centre equipments. It shall have provision for mounted
mobile set on ambulances, trains & patrolling vehicles. The system shall have
the facility to connect mobile to mobile, mobile to controller, and controller to

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mobile along with the systems for waiting, holding, and transfer of calls. The
system shall use a pair of frequencies to be allotted to the concessionaire
with the approval of wireless planning & coordination (WPC), Deptt. of
Telecommunications and shall operate for full duplex mode. One number per
Km to be provided in staggered.
5

The design for the Variable Message Signs (VMS) will be modular with sign
panels using LEDs / High-Gain Trans Reflective LCDs for outdoor ambient
lights. The sign panel should be such that a display is legible from a distance
of about 200m. For this purpose, panels shall have minimum dimensions of
3m length x 1.8m depth. The minimum height of the characters shall be 300
mm. The contrast ratio shall be more than 30 perpendicular to the bold face
and more than 10 at an angle of 70 degrees to the perpendicular. The
equipment shall be capable of storing minimum 10 frames that can be
triggered on receiving the tele-command. The sign panels shall be installed
on the structure in such a manner that they are aesthetically pleasing and can
withstand wind pressures. The equipment shall be capable of storing
minimum semi-duplex mode and other known forces. The minimum vertical
clearance available at VMSs shall be 5.5 m from the road surface. Power
supply shall be fed from the integrator locations. Two numbers to be provided
for each package.

The meteorological sensors shall comprise thermocouple / pyrometer,


humidity meter, anemometer, visibility meter and sensor for measuring
pavement surface temperature. They shall be installed on a single pole with a
specific
attachment
and
power supply fed from the integrator. They shall have the facility to
communicate on Polythene Insulated Jelly Filled copper cables (PIJF)
/Optical Fibre Cable. One number to be provided for each package

The Automatic Traffic Counter-cum-Classifier (ATCC) shall be capable of


detecting and recording all categories of vehicles plying on the Project
Highway based on their length and no. of axles. The system shall be robust
and capable of operating with minimum maintenance and may be either
piezo-electric or infrared. It should have minimum accuracy level of 99%. The
logic units shall be microprocessor based. The system should be able to
record and store vehicle data for a period of at least two weeks with a Daily
Traffic Volume of up to 1,00,000 vehicles. The system shall have compatibility
to transfer the data on PIJF/Optical Fibre Cable/by using any of the available
communication mode like GSM (Global System for Mobile Communications) /
GPRS (General Packet Radio Service), landline modem, CDMA (Code
Division Multiple Access) depending upon the effective and economic
operation of the particular mode available, at the site. The system shall be
electric/solar power operated depending upon the availability of source. Two
numbers to be provided for each package.

The Closed Circuit Television (CCTV) Surveillance shall comprise video


camera, its housing and pan, and Tilt Heads, The video camera shall be
mounted at a height so as to cover the target length of highway and the
housing shall be able to withstand adverse weather conditions. It shall have a
360 degree angular travel in the horizontal plane and a tilt of 90 degrees
down from 0 degrees horizontal. It shall have zoom lens with minimum power
of 30 X, auto iris and infrared filter, infrared compatibility for night operation
and remotely selectable operating modes. It shall have compatibility with co-

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axial cable/optical fibre cable. Three numbers to be provided for each


package.
9

The main control centre shall be designed for round-the-clock operations of


monitoring, on-line information acquisition and processing the same for
decision making. The Main Control Centre shall have equipment of central
computer, call centre, terminal junction box, uninterrupted power supply
(UPS) , counsel operator with monitors and joy sticks, rack accommodation,
large display board, line printer and general purpose office computer with
monitor, printer, fax and telephone. The system shall also have Network
Management system (NMS) or real-time monitoring of Emergency Call Boxes
(ECBs) and network diagnostics.

10

Transmission System: This shall consist of a backbone Optical Fiber


Transmission system, cable system, interface system, network management
system, repeater/ amplification system, and power supply system. There shall
be 3 or 4 sub-centres (as appropriate) housing all the interface equipment
apart from the Control Centre, provided with, as appropriate, cables,
interface, terminals (such as optical line terminals and interface, network
management system equipment, optical fiber cable interface equipment and
control centre interface equipment, data acquisition system interface, etc).
The cables from ECBs, VMS, meteorological data systems, ATCC shall be
Polythene Insulated Jelly filled (PIJF) copper cables and those from CCTV
cameras shall be coaxial cables. Repeaters/amplifiers shall be used to
maintain the quality of signals. All the cables shall have at least 20 % spare
capacity to allow for expansion. The interface system shall be capable of
handling the composite audio, video and data signals at various interface
levels and process them.

11

Central Control Room (Control Centre): The Central Control Room (CCR)
shall be the repository of all the data acquired from the field and their
processing, storing, and archiving. All the information for real time monitoring
of the Project Highway shall be generated at the CCR and the relevant
information shall be disseminated to the users through Variable message
signs, and to the operation and management teams through mobile radio
communication system for appropriate intervention. Another important
function to be performed at the Control centre shall be the operation and
management of the ATMS itself along with its various sub systems.
CCR shall have the following minimum equipment, hardware and software:
(1)

A Central Computer Server with integrated ATMS and ATMS software

(2)

Traffic Managers Terminal for operation of the integrated traffic


management system

(3)

Call system equipment comprising Operator PC along with subsystems and digital voice recorder.

(4)
terminal

Mobile radio terminal comprising Operator PC and engineering

(5)

Computers for Network Management System (NMS) for Fiber Optic


Communication System.

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(6)

CCTV Console Equipment

(7)

Computers for VMS, AVCC, MET, Traffic Control

(8)

A large size screen

(9)

A line Printer

(10)

An Office Computer

(11)

A Power Supply and back up system

Dissemination of information: Information generated at the Control Centre


shall be disseminated in the following manner:
(a)

To the users: By displays on the Variable Message signs, via internet


web pages, and by creating a node at the way side amenities to
display the relevant information.

(b)

To the Operation and maintenance teams: By mobile phones

(c)

To the ambulances: By mobile phones

(d)

To the Trauma centres: Via ambulances

A-23

Highway/Advanced Traffic Management Systems (ATMS):

A real time system working round the clock shall be established for informing
the road users of the road, traffic, and weather conditions on the Project
Highway; for making interventions as required for smooth, safe and efficient
traffic operation; and for providing rescue and relief to the users in distress.
The system shall be capable of (i) acquisition of data from various sources
such as the road, the users, the maintenance and operation patrol, the
ambulance, and the intervention team (ii) three way communication between
the data source and a Central Control Room, the Control Room and the data
sources and display units, and between the maintenance and operation
teams, through a transmission system, and (iii) A Central Control Room to
process all data and control the highway operation.

The systems and equipment of ATMS shall meet the following main climatic
and environmental requirement as specified in IS-9000
(i)
(ii)
(iii)

Temperature Range of Operation - Low of 0 Celsius (3 C) to high of


60 Celsius ( 2 C)
Relative Humidity of 95%
Vibration Frequency Range of 10 Hz 55 Hz

Data acquisition system: This shall consist of (a) Automatic Traffic Counter
and Classifier (ATCC), with an in-road loop detectors and treadles. (b) Video
cameras installed on road with such pan and tilts that a length of 2 km road is
captured for video monitoring of traffic, (c) Emergency Call Boxes installed at
every 2 km to enable any user to be instantly in contact with the Control
Room, (d) Meteorological sensors for capturing data on temperature,

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weather, wind, (e) Mobile radios for patrol vehicles and ambulances to be in
communication with Central Control Room and among themselves.
4

Emergency call boxes (ECBs) with loud speaker, micro phone, activation
button with LED indicating conversation, shall be housed in a vandal proof
casing and operate in full to play mode in noise level of up to 95 decibels with
in built diagnostic features for automatic detection in case of damage by any
object. Mobile communication system shall comprise the mobile radio base
stations and control centre equipments. It shall have provision for mounted
mobile set on ambulances, trains & patrolling vehicles. The system shall have
the facility to connect mobile to mobile, mobile to controller, and controller to
mobile along with the systems for waiting, holding, and transfer of calls. The
system shall use a pair of frequencies to be allotted to the concessionaire
with the approval of wireless planning & coordination (WPC), Deptt. of
Telecommunications and shall operate for full duplex mode. One number per
Km to be provided in staggered.

The design for the Variable Message Signs (VMS) will be modular with sign
panels using LEDs / High-Gain Trans Reflective LCDs for outdoor ambient
lights. The sign panel should be such that a display is legible from a distance
of about 200m. For this purpose, panels shall have minimum dimensions of
3m length x 1.8m depth. The minimum height of the characters shall be 300
mm. The contrast ratio shall be more than 30 perpendicular to the bold face
and more than 10 at an angle of 70 degrees to the perpendicular. The
equipment shall be capable of storing minimum 10 frames that can be
triggered on receiving the tele-command. The sign panels shall be installed
on the structure in such a manner that they are aesthetically pleasing and can
withstand wind pressures. The equipment shall be capable of storing
minimum semi-duplex mode and other known forces. The minimum vertical
clearance available at VMSs shall be 5.5 m from the road surface. Power
supply shall be fed from the integrator locations. Two numbers to be provided
for each package.

The meteorological sensors shall comprise thermocouple / pyrometer,


humidity meter, anemometer, visibility meter and sensor for measuring
pavement surface temperature. They shall be installed on a single pole with a
specific
attachment
and
power supply fed from the integrator. They shall have the facility to
communicate on Polythene Insulated Jelly Filled copper cables (PIJF)
/Optical Fibre Cable. One number to be provided for each package

The Automatic Traffic Counter-cum-Classifier (ATCC) shall be capable of


detecting and recording all categories of vehicles plying on the Project
Highway based on their length and no. of axles. The system shall be robust
and capable of operating with minimum maintenance and may be either
piezo-electric or infrared. It should have minimum accuracy level of 99%. The
logic units shall be microprocessor based. The system should be able to
record and store vehicle data for a period of at least two weeks with a Daily
Traffic Volume of up to 1,00,000 vehicles. The system shall have compatibility
to transfer the data on PIJF/Optical Fibre Cable/by using any of the available
communication mode like GSM (Global System for Mobile Communications) /
GPRS (General Packet Radio Service), landline modem, CDMA (Code
Division Multiple Access) depending upon the effective and economic
operation of the particular mode available, at the site. The system shall be

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electric/solar power operated depending upon the availability of source. Two


numbers to be provided for each package.
8

The Closed Circuit Television (CCTV) Surveillance shall comprise video


camera, its housing and pan, and Tilt Heads, The video camera shall be
mounted at a height so as to cover the target length of highway and the
housing shall be able to withstand adverse weather conditions. It shall have a
360 degree angular travel in the horizontal plane and a tilt of 90 degrees
down from 0 degrees horizontal. It shall have zoom lens with minimum power
of 30 X, auto iris and infrared filter, infrared compatibility for night operation
and remotely selectable operating modes. It shall have compatibility with coaxial cable/optical fibre cable. Three numbers to be provided for each
package.

The main control centre shall be designed for round-the-clock operations of


monitoring, on-line information acquisition and processing the same for
decision making. The Main Control Centre shall have equipment of central
computer, call centre, terminal junction box, uninterrupted power supply
(UPS) , counsel operator with monitors and joy sticks, rack accommodation,
large display board, line printer and general purpose office computer with
monitor, printer, fax and telephone. The system shall also have Network
Management system (NMS) or real-time monitoring of Emergency Call Boxes
(ECBs) and network diagnostics.

10

Transmission System: This shall consist of a backbone Optical Fiber


Transmission system, cable system, interface system, network management
system, repeater/ amplification system, and power supply system. There shall
be 3 or 4 sub-centres (as appropriate) housing all the interface equipment
apart from the Control Centre, provided with, as appropriate, cables,
interface, terminals (such as optical line terminals and interface, network
management system equipment, optical fiber cable interface equipment and
control centre interface equipment, data acquisition system interface, etc).
The cables from ECBs, VMS, meteorological data systems, ATCC shall be
Polythene Insulated Jelly filled (PIJF) copper cables and those from CCTV
cameras shall be coaxial cables. Repeaters/amplifiers shall be used to
maintain the quality of signals. All the cables shall have at least 20 % spare
capacity to allow for expansion. The interface system shall be capable of
handling the composite audio, video and data signals at various interface
levels and process them.

11

Central Control Room (Control Centre): The Central Control Room (CCR)
shall be the repository of all the data acquired from the field and their
processing, storing, and archiving. All the information for real time monitoring
of the Project Highway shall be generated at the CCR and the relevant
information shall be disseminated to the users through Variable message
signs, and to the operation and management teams through mobile radio
communication system for appropriate intervention. Another important
function to be performed at the Control centre shall be the operation and
management of the ATMS itself along with its various sub systems.
CCR shall have the following minimum equipment, hardware and software:
(1)

A Central Computer Server with integrated ATMS and ATMS software

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(2)

Traffic Managers Terminal for operation of the integrated traffic


management system

(3)

Call system equipment comprising Operator PC along with subsystems and digital voice recorder.

(4)
terminal

Mobile radio terminal comprising Operator PC and engineering

(5)

Computers for Network Management System (NMS) for Fiber Optic


Communication System.

(6)

CCTV Console Equipment

(7)

Computers for VMS, AVCC, MET, Traffic Control

(8)

A large size screen

(9)

A line Printer

(10)

An Office Computer

(11)

A Power Supply and back up system

12

Dissemination of information: Information generated at the Control Centre


shall be disseminated in the following manner:
(a)

To the users: By displays on the Variable Message signs, via internet


web pages, and by creating a node at the way side amenities to
display the relevant information.

(b)

To the Operation and maintenance teams: By mobile phones

(c)

To the ambulances: By mobile phones

(d)

To the Trauma centres: Via ambulances

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