1

i)

Geometric Standards
Stretches passing through built up areas shall normally be
provided with 4-lane divided carriageway. Such stretches
shall be indicated in Schedule B.

ii) Where there is constraint of ROW width or difficulty in

acquiring the land along the alignment, the Authority may specify
construction of a bypass instead of 4 laning. The bypass shall be
access controlled 4-lane divided carriageway unless otherwise
specified
ii) The geometric design of the Project Highway shall conform to
the standards set out in this section as a minimum.
iii) As far as possible, uniformity of design standards shall be
maintained throughout the length of the Project Highway. In case
of any change, it shall be affected in a gradual manner.

Geometric Standards
iv) Where the existing road geometries are deficient with
respect to minimum requirements and its improvements to the
prescribed standards is not feasible due to any constraint in
acquisition of additional land, such stretches shall be as specified
in Schedule 'B' of the Concession Agreement.

v) Existing horizontal curves which are found deficient in

radius, layout, transition lengths or super-elevation shall be
corrected to the standards specified in this section.
vi) Any deficiencies in the vertical profile in respect of
grades, layout of vertical curves and sight distance shall be
corrected to meet the minimum requirements specified in this
section.

Grade Separated Structures

i) The structures through which the traffic flows at different levels
are called grade separated structures.
ii) A grade separated structure which is provided for crossing of
vehicles under the Project Highway is called as Vehicular
Underpass (VUP).
iii) A grade separated structure which is provided for crossing of
vehicles over the Project Highway is called as Vehicular
Overpass (VOP).
iv) A structure provided below the Project Highway to cross the
pedestrians is called Pedestrian Underpass (PUP).
V) A structure provided below the Project Highway to cross the
catties is called Cattle Underpass (CUP).
vi) A pedestrian/cattle underpass through which light vehicles of
height upto 3 m can also pass is called Light Vehicular
Underpass (LVUP)

Grade Separated Structures - continued

vii) Flyover is synonymous to VUP/VOP/LVUP/PUP/CUP
viii) A structure provided above the Project Highway to cross
pedestrians is called Foot Over bridge.
ix) A structure provided over the railway lines to carry the
Project Highway is called Road Over Bridge (ROB).
x) A structure provided below the railway lines to carry the
Project Highway is called Road Under Bridge (RUB).
xi) A Trumpet interchange is a grade separator structure
provided at major T-junction facilitating uninterrupted flow of
traffic in each direction.
xii) A Cloverleaf is a grade separator structure provided at a
major cross road junction facilitating uninterrupted flow of
traffic in each direction

Design Speed in Km/hour

Nature of
terrain

Cross slope
of the
ground

Plain and
Rolling
Mountainous
and Steep

Design speed (km/hour)

Ruling

Minimum

Up to 25%

100

80

More than
25%

60

40

Short stretches (say less than 1 km) of varying terrain

met with on the road stretch shall not be taken into
consideration while deciding the terrain classification for
a given section of a Project Highway.

Minimum width of median and ROW in 4-Lane stretches

Minimum width of median (m)
Plain and rolling
Mountainous and
Type of section
terrain
steep terrain
Raised

Depressed
Median

Raised

5m

7.0m

2.5m

Built up Area

2.5m

Not
applicable

2.5m

Approach to grade
separated structures

5m

Not
applicable

2.5m

Open country with

isolated built up area

Type and widths of median at various stretches shall be as

indicated in Schedule B.
Right of Way required in 4-lane bits: 60m; Each Lane width: 3.5m
ROW in 2-Lane stretches accommodated within existing ROW

Width of shoulders in Plain and Rolling Terrain

Type of Section
Open country with
isolated built up
area
Built up area 2 lane
Built up Area 4 lane
Approaches to
grade separated
structures
Approaches to
bridges

Width of shoulder (m)

Paved

Earthen

Total

1.5m

2.0m

3.5m

2.5m
-

2.5m
-

2.0m

2.0m

1.5m

2.0m

3.5m

Width of Shoulders in mountainous and steep terrain

(Hilly Area)
Width of shoulder (m)
Type of Section

Open country with

isolated built up
area
Built up area
And Approaches
to grade
separated
structures/bridges

Paved

Earthen

Total

Hill side

1.5m

1.5m

Valley
side

1.5m

1.0m

2.5m

Hill side

0.25m+1.5m
(Raised)

1.75m

Valley
side

0.25m+1.5m
(Raised)

1.75m

Width of Shoulders in mountainous and steep terrain

(Hilly Area)
Notes: i) In case retaining wall with parapet is provided on
valley side, the earthen shoulder may not be provided.
ii) Width of paved shoulder in approaches to grade separated
structures as indicated in table above shall extend on either
side of the structure in the entire length of retaining/RE walls.
The retaining/RE walls on either side shall be abutting the
paved shoulders and shall have crash barriers on top.
iii) In built up area where two lane highway is provided and
extra width is available, the space between paved shoulder
and the footpath cum drains on both sides shall be covered
with paver block flooring. Similarly in stretches between the
carriageway and footpath cum drains shall be covered with
paver block flooring.

Extra width of pavement and roadway

In each carriageway
Radius of curve

extra width

75 - 100m

0.9m

101 - 300m

0.6m

The cross fall on straight portions of road carriageway, paved

shoulders and paved portion of median shall be 2.5% for bituminous surface
and 2.0% for CC surface.
The two lane roads shall be provided with a crown at the centre. On
horizontal curves, the carriageway shall be super elevated.
The crossfall for earthen shoulders on straight portions shall be at
least 0.5 percent steeper than the slope of the pavement and paved shoulder
subject to a minimum of 3 percent. On super elevated sections, the earthen
portion of the shoulder on the outer side of the curve would be provided with
reverse crossfall of 0.5 percent so that the earth does not drain on the
carriageway and the storm water drains out with minimum travel path.

Sight Distances for various speeds

Design
Safe Stopping Intermediate Sight
Speed
Sight Distance
distance
Km/hour

Overtaking sight
distance

100
80

180m
120m

360
240

640m
470m

60
40

90m
45m

180
90

340m
165m

On two lane roads, intermediate sight distance shall be available

throughout. The attempt should be, however, to provide overtaking sight
distance in as much length as possible. In stretches where even the
intermediate sight distance is not available, the safe stopping distance shall be
provided as a last resort.
Requisite sight distance shall be available along the inner side of the
horizontal curve. Where horizontal and summit curves overlap, the design shall
provide the requisite sight distance in both the vertical direction along the
pavement and in the horizontal direction on the inner side of the curve,

Ruling and Limited Gradients

Nature of
terrain
Plain and
rolling

Ruling
gradient

Limiting
gradient

2.5%

3.3%

Mountainous

5.0%

6.0%

Steep

6.0%

7.0%

Long sweeping vertical curves shall be

provided at all grade changes. These shall be
designed as square parabolas.
Design of vertical curves and its
coordination with horizontal curves, shall be in
accordance with IRC:SP: 23.

Minimum radii of horizontal curves

Nature of terrain

Desirable minimum Absolute minimum

Plain and Rolling

400m

250m

Mountainous and
Steep

150m

75m

Super elevation shall be provided in curves as per IRC: 73 and

shall be limited to 7%. It shall not be less than the minimum
specified cross fall/ camber

Design service volume of two-lane highway in PCUs per day

Nature of terrain

Design Service volume in

PCUs per day

Plain

18,000

Rolling

13,000

Mountainous and Steep

9,000

Lateral clearance at Underpasses

i) Full roadway width at the approaches shall be carried
through the underpass. This width shall not be less than 12m (7m
Carriageway + 2 2.5m shoulders) or as indicated in schedule
B.
ii) For Light Vehicular Underpass the lateral clearance shall
not be less than 10.5 m including 1 .5 m wide raised footpath on
either side.
iii) For pedestrian and Cattle underpasses the lateral
clearance shall not be less than 7 m

iv) Guard rails/crash barriers shall be provided for

protection of vehicles from colliding with the abutments and piers
and the deck of the structures

Vertical clearance at Underpasses

1) Vehicular underpass: 5.5m Minimum
2) Light vehicular underpass: 3.5m
3) For pedestrian and cattle under pass:
3.0m (to be increased to 4.5m in case certain categories
of animals such as elephant/camel are expected to cross the
project highway frequently. This will be as specified in Schedule
B)
Note: Wherever existing slab/box culverts and bridges allow
more than 2m vertical clearance, these can be used in dry
season for pedestrian and cattle crossing by providing flooring.
However, these will not be a substitute for pedestrian and cattle
crossings as per requirements.

Vehicular underpass/overpass
The vehicular under/overpass structures shall be
provided at the intersection of the Project Highway with all the
National Highways and State Highways. Such under/over
passes shall also be provided across other categories of roads
as per site requirements for crossing of traffic. The structure
may be either an underpass or an overpass depending upon the
nature of terrain, vertical profile of road and availability of
adequate right of way etc. Decision whether the cross road or
the Project Highway will be carried at the existing level will be
taken at the time of preparing the feasibility report and would be
based on considerations of drainage, land acquisition, provision
of ramps for the grade separated facility, height of embankment
and project economy etc.
The type and location of various grade separated
structures (VUP, LVUP, PUP/CUP, VOP) shall be as specified in
Schedule 'B' of the Concession Agreement

Cattle/Pedestrian Underpass (CUP/PUP) and Foot Over Bridge

These shall be provided as specified in Schedule 'B' of the
Concession Agreement.
i) A PUP/CUP/Foot Over Bridge may not be necessary
within
a
distance
of
2
km
from
Vehicular
underpasses/overpasses and Light Vehicular Underpasses.
ii) The pedestrian crossings (PUP/FOB) shall have
provision for movement of physically challenged persons.
ill) Underpasses shall be preferred to Foot Over Bridges.
iv) Pedestrian underpass/Foot Over Bridge shall also be
provided within a distance of 200 m from a school or hospital or
factory/industrial area.
v) The Bus Bays along with the Bus Shelters shall be
provided at the identified pedestrian Underpass/Foot Over
Bridge locations as specified in this Manual. Such locations shall
be specified in Schedule 'B'.

Utility Corridor
Two meter wide strip of land at the extreme
edge of ROW shall be kept for accommodating utilities,
both over as well as underground. Provisions contained
in IRC:98 shall be followed to accommodate utility
services in built-up areas of Project Highway. Utility
ducts in the form of 600 mm diameter NP-4 Pipe across
the Project Highway along with inspection box/chamber
at a spacing of 1 km shall be provided for crossing of
underground utilities in built up areas.

Safety during Construction and Operation & Maintenance

Before taking up any construction or maintenance operation/work, the
Concessionaire/Contractor shall prepare a Traffic Management Plan for each
work zone and furnish it to the Independent Engineer for comments duly
incorporating the following:
i) Designate a Site Safety Team headed by a qualified Safety Officer.
ii) Traffic safety devices as per 1RC:SP:55 with the following Specifications:
a) Signages of retro-reflective sheet of high intensity grade.
b) Delineators in the form of cones/drums (300 to 500 mm dia and
1000 mm high) made of plastic/rubber having retro reflective red and white
band, at a spacing of maximum 5 m along with a reflective tape (red and
white band) to be tied in between the gaps of cones/drums. A bulb/flasher
using solar energy is to be placed on the top of the cone/
drum for night delineation.
c) Barricades using iron sheet (plain) with adequate iron railing/frame
painted with retro-reflective paint in alternate black and white (or yellow and
black) stripes. Warning lights at 5.0 m spacing shall be mounted on the
barricades and kept lit in the dark hours and night.

Safety during Construction and Operation & Maintenance cont.

iii) The arrangement of traffic during construction and

maintenance shall conform to the requirements of IRC:SP:55, Clause
112 of MORTH Specifications and provisions of the Concession
Agreement. During the construction period, the Concessionaire shall
maintain, at its cost, the existing lane(s) of the Project Highway or
divert the traffic on to an alternative route-diversion road so that the
operating width and safety standards shall be equal to those of
existing lanes (excluding paved shoulders, if any) for each direction.
The crust of such alternative route/diversion road shall be provided for
minimum 10 msa. The drainage of existing road and construction zone
during construction shall be given special attention by the
Concessionaire. Prior to commencement of construction works, the
Concessionaire shall submit to the Independent Engineer, the detailed
construction methodology to meet the aforesaid requirement
including temporary drainage plan of existing road and construction
zone.

Safety during Construction and Operation & Maintenance cont.

iv) Sprinkling of water for dust control at work zones, haul roads and plant
camp sites.
v) Noise/Pollution suppression measures at work zones, haul roads and
plant/camp sites.
vi) Mechanical, electrical and fire safety practices.
vii) Safety measures like PPE (Personal Protection Equipment) for workers
engaged.
viii) First Aid and Emergency Response Arrangements i.e. First Aid Box,
Ambulance, paramedical staff, alarms, etc.
ix) Safety training/awareness programmes. x) Formats to maintain the
accident records/emergency response provided during accidents.
The Concessionaire shall also be responsible for ensuring
compliance of all labour laws and regulations including those relating to the
welfare of workers engaged both directly and indirectly on the Project
Highway, besides their occupational safety and health.
The Concessionaire shall set up field laboratory for testing of
materials and finished products as stipulated in Clause 120 of MORTH
Specifications.
It
shall
make
necessary
arrangements
for
additional/confirmatory testing of any materials/products at the government
accredited laboratory, for which facilities at site laboratory are not available.

Environment Mitigation Measures

The Concessionaire shall carry out tests/monitor various

parameters impacting the environment of the Project Highway
keeping in view the guidelines of the Ministry of Environment
and Forests and submit proposals for mitigation of adverse
environment impact including provision of noise barriers, etc. for
review and comments of the IE, if any and undertake
implementation of the proposals in consultation with the IE. The
type and locations of the Noise Barriers shall be specified in
Schedule 'B'.
Utilities
The details of the new-utilities which are to be constructed
or provided for along or across the Project Highway shall be as
specified in Schedule 'B' of the Concession Agreement. The
Concessionaire shall be responsible for protection of the existing
utilities on the Project Highway that are not required to be
shifted.

MORT&H Table 300-1, Density Requirements of Embankment

and subgrade materials
S.No

Type of work

Maximum laboratory dry unit

weight when tested as per
IS:2720 (part 8)

Embankment up to 3m
height, not subject to
extensive flooding

Not less than 15.2kN/cu.m

Embankments exceeding
3M height or embankments
of any height subject to
long periods of inundation

Not less than 16.0kN/cu.m

Subgrade and earthen

shoulders/ verges/ backfill

Not less than 17.5kN/cu.m

Notes: 1) This table is not applicable for lightweight fill material e.g. for
cinder, fly ash etc. 2) The engineer may relax these requirements at his
discretion taking into account the availability of materials for construction
and other relevant factors.
maximum values for materials of embankment, sub grade and shoulders:
Free Swell Index: 50%, Liquid Limit: 50% and Plasticity index: 25%

MORT&H Table 300-2, Compaction requirements for subgrade

and shoulders
S.No

Type of work/ material

Relative compaction as % of
laboratory MDD as per IS:2720
(part 8)

Subgrade and
shoulders

Not less than 97%

Embankments

Not less than 95%

Expansive clays
a) Subgrade and
500mm portion just
below the subgrade

Not allowed

Expansive clays
b) Remaining portion
of embankment

90% to 95%

MORT&H(5th revision) TABLE 400-1, GSB grading requirements

Percent by weight passing through the IS sieve

IS Sieve
size

Grading I

Grading
II

Grading
III

Grading
IV

Grading V

Grading
VI

75.0mm

100

--

--

100

53.0mm

80-100

100

100

100

80-100

100

26.5mm

55-90

70-100

55-75

50-80

55-90

75-100

9.50mm

35-65

50-80

35-65

55-75

4.75mm

25-55

40-65

10-30

15-35

25-50

30-55

2.36mm

20-40

30-50

10-20

10-25

0.85mm

2-10

0.425mm

10-15

10-15

0-5

0-8

0.075 mm

<5

<5

<5

<5

0-3

MORT&H (5th revision) TABLE 400-2, Physical

Requirements of GSB materials
Aggregate Impact Value IS:2386-part 4 or
(AIV)
IS;5640

40 Maximum

Liquid Limit

IS:2720-part 5

25 Maximum

Plasticity Index

IS:2720-part 5

6 maximum

IS:2720-part 16

Minimum 30
unless otherwise
specified

CBR at 98% dry density

(IS:2720-part 8)

If water absorption is greater than 2%, Wet Aggregate Impact

test shall be done. Grading III and IV are preferrable for LSB.
Gradings V and VI are for USB and drainage layer.

(4th Rev)TABLE 400-1, Grading for Close Graded Granular

Sub-Base

75.0 mm
53.0 mm
26.5 mm
9.50 mm
4.75 mm
2.36 mm
0.425 mm
0.075 mm

Grading I
100
80-100
55-90
35-65
25-55
20-40
10-25
3-10

Grading II
-100
70-100
50-80
40-65
30-50
15-25
3-10

Grading III
--100
65-95
50-80
40-65
20-35
3-10

(4th Rev)TABLE 400-2. Grading For Coarse Graded Grangular

Sub-base Materials
IS Sieve
Designation
75.0 mm
53.0 mm
26.5 mm
9.50 mm

Percent by weight passing

through the IS sieve
Grading I Grading II
100
-100
55-75

50-80

Grading III
-100

4.75 mm
10-30
15-35
25-45
0.075 mm
< 10
< 10
< 10
CBR Value
30
25
20
(Minimum)
Note: CBR depends on type of materials to be used but not
on gradings. Minmum 10% fines value: 50KN, Max LL: 25%

Table 400-13. Grading Requirements of

Aggregates for the Wet Mix Macadam
IS Sieve
Designation

Per cent by weight

passing the IS Sieve

53.00 mm

100

45.00 mm

95-100

22.4 mm

60-80

11.20 mm

40-60

4.75 mm

25-40

2.36 mm

15-30

600 micron

8-22

75 micron

0-5

WET MIX MACADAM

Materials : 40mm, 20mm, 12mm, 6mm &Stone Dust, Mixing at Pug

Mill with Water, Conveyed to Site, Spreading by Paver and Rolling.
Relative Compaction = 98 %
Aggregate Impact Value (IS:2386: part-4) :30% (max). Combined
flakiness and elongation index (IS:2386: part-1) : 35% (max)

502 of MORTH Prime Coat over granular base

Application of single coat of low viscosity liquid bituminous
material (SS 1 Emulsion) to an absorbent granular surface for
any superimposed bituminous treatment

Table 500-3, Quantity of bituminous primer for various

granular surfaces
Type of surface

Quantity /Sq.m
(Kgs)

WMM or WBM

0.7 to 1,0

Stabilised soil bases/ Crusher

Run Macadam

0.9 to 1.2

503 Tack Coat ( MORT & H )

503.4.3: The application of tack coat shall be at the rate
specified in the contract and shall be applied uniformly. If
rate of application of tack coat is not specified in the
contract then it shall be at the rate specified in table 500-2
Table 500-2, rate of application of tack coat
Type of Surface

Bituminous material
Emulsion or cutback in
Kg/10 Sq.M

Normal bituminous surfaces

2.0 to 2.5

Dry and hungry bituminous surfaces

2.5 to 3.0

Granular surfaces treated with primer

2.5 to 3.0

Non- bituminous surfaces:

Granular base (not primed)

3.5 to 4.0

Cement concrete pavement

3.0 to 3.5

Physical Requirements of Coarse Aggregates for

BM/DBM/SDBC/BC
Table 500-6 for BM, table 500-8 for DBM & 500-17 for BC of 5th
Revision. Table 500-14(4th revision) for SDBC
Property

Test

Specification

Code
Reference

Cleanliness

Grain size
analysis

Max. 5% passing
0.075mm sieve

IS: 2386 part

1

Particle
shape

Flakiness and
Elongation
Index

Max. 35%

IS: 2386 part

1

Strength

Los Angeles
Abrasion Value
or

Max 35% for DBM

&30% for BC

IS: 2386 part

4

Aggregate
Impact Value

Max 27%for DBM &

24% for BC

IS: 2386 part

4

Physical requirements continued

Durability

Soundness:
Sodium Sulphate
Magnesium Sulphate

12%
18%

IS: 2386 part 5

Absorption

Water Absorption

2%

IS: 2386 part 3

Stripping

Coating and Stripping

of Aggregate bitumen

95%

IS: 6241

Water
Sensitivity

Retained Tensile
Strength

Min. 80%

to be done if
stripping fails

Polishing

Polished Stone Value

for BC

Min. 55

Bs: 812 part

114

MORTH 505 Table 500-10 Composition of Dense Bituminous Macadam

Grading

Nominal aggregate size

40 mm

25 mm

Layer Thickness

80-100mm

50-75 mm

IS Sieve (mm)

Cumulative % by weight of total aggregate passing

45

100

37.5

95-100

100

26.5

63-93

90-100

19

71-95

13.2

55-75

56-80

4.75

38-54

38-54

2.36

28-42

28-42

0.3

7-21

7-21

0.075

2-8

2-8

Bitumen content % by
mass of total mix

Min 4.0

in 4.5

Table 500-9, Grading Requirements of mineral filler

0.6
0.3

Cumulative per cent

passing by weight of total
aggregate
100
95 - 100

0.075

85 - 100

IS Sieve
(mm)

The filler shall be free from organic impurities and have a Plasticity
Index not greater than 4. The Plasticity Index requirement shall not apply if
filler is cement or lime. When the coarse aggregate is gravel, 2 per cent by
weight of total aggregate, shall be Portland cement or hydrated lime and
the percentage of fine aggregate reduced accordingly. Cement or hydrated
lime is not required when the limestone aggregate is used. Where the
aggregates fail to meet the requirements of the water sensitivity test in
Table 500-8, then 2 per cent by total weight of aggregate, of hydrated lime
shall be added without additional cost.

Table 500-11, Requirements of DBM and BC

Description

Requirements

Minimum stability (KN at 600C)

9.0

Minimum flow (mm)

Maximum flow (mm)

Compaction level (Number of blows)

75 blows on each face of the

specimen

Percent air voids

3-5

Marshal Qutient (Stablity/flow)

2-5

Percent voids in mineral aggregate

(VMA)

See table 500-12

Percent voids filled with bitumen

(VFB)

65-75

Table 500-12, Minimum per cent voids in mineral

aggregate (VMA)

Nominal
Maximum
particle
size

Minimum VMA, per cent related to

design air voids, per cent
3.0

4.0

5.0

26.5

11.0

12.0

13.0

37.5

10.0

11.0

12.0

Note: Interpolate minimum voids in the mineral (VMA)

for design air voids values between those listed

Table 500-13, Permissible variations from job mix

formula for DBM
Description

Permissible variation
Base/binder course

Aggregate passing 19mm sieve or

larger

8%

Aggregate passing 13.2mm, 9.5mm

Aggregate passing 4.75mm
Aggregate passing 2.36mm, 1.18mm,
0.6mm
Aggregate passing 0.3mm, 0.15mm

7%
6%

Aggregate passing 0.075mm

Binder content
Mixing temperature

2%
0.3%
10C

5%
4%

MORTH 507
Table 500-17 Composition of Bituminous Concrete
Grading
Nominal aggregate size
Layer Thickness
IS Sieve (mm)

1
19 mm
50mm

2
13.2 mm
30-40 mm

Cumulative % by weight of total aggregate passing

26.5

100

19

79-100

100

13.2

59-79

90-100

9.5

52-72

70-88

4.75

35-55

53-71

2.36

28-44

42-58

1.18

20-34

34-48

0.6

15-27

26-38

0.3

10-20

18-28

0.15

5-13

12-20

0.075

2-8

4-10

Bitumen content % by
mass of total mix

5.2

5.4

Table 500-18, Permissible variations from job mix formula

for Bituminous Concrete
Description

Permissible variation
Wearing course

Aggregate passing 19mm sieve or

larger

7%

Aggregate passing 13.2mm, 9.5mm

6%

Aggregate passing 4.75mm

5%

Aggregate passing 2.36mm, 1.18mm,

0.6mm

4%

Aggregate passing 0.3mm, 0.15mm

3%

Aggregate passing 0.075mm

1.5%

Binder content

0.3%

Mixing temperature

10C

Recommended Roughness Values for roads

In India in mm/km as per IRC:SP:30-2009
Surface type

good

average

poor

Very poor

Bituminous
Concrete

< 2000 2000 to 3000

3000 to 6000

Over 6000

Surface Dressing

<3500 3500 to 4500

4500 to 7000

Over 7000

Premix Bituminous
carpet/(Open
Graded)

<3000 3000 to 4000

4000 to 6000

Over 6000

Water Bound
Macadam/Gravel

<8000 8000 to 9000 9000 to 10000

Cement Concrete

<2200

2200-3000

3000-4000

Over
10000
Over 4000

MORT&H Table 9001, Tolerances in Surface Levels

20mm

1.Sub-grade
2.Sub-base
a) Flexible pavement

10mm

b) Concrete pavement

6mm

3.Base course for flexible pavement

a) Bituminous course

+6mm to -6mm

b) Granular
i) Machine laid

10mm

ii) Manually laid

15mm

4. Wearing Course for flexible pavement

a) Machine laid

6mm

b) Machine laid

10mm

5. Cement concrete pavement

5mm

MORT&H Table 9002,Maximum permitted number of

irregularities
Surfaces of
carriageways and
paved shoulders

Irregularity
Length(m)

4mm

Surfaces of laybys,
service roads and all
bituminous courses

7mm

4mm

7mm

300 75 300 75 300 75 300 75

National highways/
Expressways

15

40

18

Roads of lower
category

40

18

60

27

ed
at the middle of each traffic lane parallel to the
center line of the road

MORT&H 902.4 : The maximum allowable difference

between the road surface and underside of a 3m straight
edge when placed parallel with, or at right angles to the
center line of the road at points decided by the Engineer
For pavement surface (bituminous
and cement concrete)

3mm

For bituminous courses

6mm

For granular sub-base or base

courses

8mm

For sub-base under concrete

pavements

10mm

For sub-grade

15mm

MORT&H 903.2 Tests on Earthwork for embankment, sub-grade

construction and cut formation for each source
Test type

As per code

Frequency of testing

Sand Content

IS:2720 part 4

2 per 3000 cubic

meters

Plasticity

IS:2720 part 5

2 per 3000 cubic

meters

Density

IS:2720 part 8

2 per 3000 cubic

meters

Deleterious Content

IS:2720 part 27

As and when
required by
engineer

Moisture Content

IS:2720 part 2

2 per 3000 cubic

meter

Soaked/ un-soaked
CBR

IS:2720 part 16

1 per 3000 cubic

meters

MORT&H 900.3 control tests and their minimum frequency

for sub-bases and bases
Type of
Construction

Test

Moisture content prior to

compaction

One test per

400cum
One test per
400cum
One test per
400cum

Density of compacted
layer

One test per

1000sq.m

Deleterious content

As required

CBR

As required

gradation

Atterberg Limits

Granular

Frequency (min)

MORT&H 900.3 control tests and their minimum frequency

for sub-bases and bases
Type of
Construction

Lime/Cement
stabilised soil
sub-base

Test

Frequency (min)

Quality of lime or cement

One test per each consignment

subject to a minimum of 1 test
per 5 tonnes

Lime or cement content

Regularly, through procedural

checks

Degree of pulverisation

Periodically as considered
necessary

CBR or UCS on a set of 3

specimens

As required

Moisture content prior to

compaction

1 set of 2 tests per 500sq.m

Density of compacted layer

1 set of 2 tests per 500sq.m

Deleterious constituents

As required

MORT&H 900.3 control tests and their minimum frequency

for sub-bases and bases
Type of
Construction

Water Bound
macadam

Test

Frequency (min)

Aggregate Impact Value

One test per

1000cum

Grading of Aggregate

One test per

250cum

Combined FIV & EIV

One test per

500cum

Atterberg limits for binding One test per 50cu.m

material
of binding material
Atterberg limits for
screenings

One test per

100cu.m of
screenings

MORT&H 900.3 control tests and their minimum frequency

for sub-bases and bases
Type of
Construction

Wet Mix
Macadam

Test

Frequency (min)

Aggregate Impact Value

One test per

1000cum

Grading of Aggregate

One test per

200cum

Combined FIV & EIV

One test per

500cum

Atterberg limits for material

passing 425 microns

One test per

200cu.m of
aggregate

Density of compacted
layer

One set of 3 tests

per 1000 sq.m

MORT&H 900.4 control tests for bituminous works and their

minimum frequency

Type of
Construction

Test

Frequency (min)

Number of samples per

lot and tests as per
Quality of binder
IS:73, IS:217and
Prime coat/
IS:8887 as applicable
tack coat/fog
At regular close
spray
Binder temperature
intervals
Rate of spread of
3 tests per day
binder

MORT&H 900.4 control tests for bituminous works and their minimum frequency
Type of
Construction

Seal Coat/
surface
dressing

Test

Frequency (min)

Quality of binder

Number of samples per lot and tests as

per IS:73, IS:217and IS:8887 as
applicable

AIV or LAV

One test per 200cum per source

Combined FIV & EIV

One test per 100cum per source

Stripping value of
aggregate

One test for each source

Water absorption of
aggregate

One test for each source

Water sensitivity of mix

One test for each source

Grading of aggregate

2 tests per day

Soundness

One test for each source

Temperatures

At regular intervals

Rate of spread

Same as for item1

% fractured faces

One test per 100cu.m

Stone polishing value

One test of each source

MORT&H 900.4 control tests for bituminous works and their

minimum frequency
Type of
Construction

Open grade
pre-mix
surfacing/ MSS

Test

Frequency (min)

Quality of binder

Number of samples per lot and

tests as per IS:73, IS:217and
IS:8887 as applicable

AIV or LAV

One test per 200cum per source

Combined FIV & EIV

One test per 100cum per source

Stripping value

One test for each source

Water absorption

One test for each source

Water sensitivity of mix

One test for each source

Grading of aggregates

2 tests per day

Soundness

One test per 200cum per source

Polished stone value

One test per 200cum per source

temperatures

regularly

Binder content

2 tests per day

% fractured faces

One test per 100cum of aggregate

MORT&H 900.4 control tests for bituminous works and their minimum frequency
Type of
Construction

Bituminous
Macadam

Test

Frequency (min)

Quality of binder

Number of samples per lot and tests as

per IS:73, IS:217and IS:8887 as applicable

AIV or LAV

One test per 350cum per source

Combined FIV & EIV

One test per 350cum per source

Stripping value of
aggregate

One test for each source

Water absorption of
aggregate

One test for each source

Water sensitivity of mix

One test for each source

Grading of aggregate

2 tests per day

Soundness

One test for each source

Temperatures

At regular intervals

Rate of spread

Same as for item1

% fractured faces

One test per 100cu.m

Stone polishing value

One test of each source

Density of compacted layer

1 test per 100sq.m

Rate of spread of mix

Regular intervals

MORT&H 900.4 control tests for bituminous works dditional

Additional tests over the tests for BM
Type of
Construction

Dense
Bituminous
Macadam/
Bituminous
Concrete

Test

Frequency (min)

Mix Grading

One test for individual constituent and

mixed aggregate from dryer for each
400t of mix subject to minimum of 2
tests per day per plant

Stability, voids
analysis and
theoretical max.
sp.gravity of
loose mix

3 tests for stability, flow value, void

content, density for each 400t of mix
subject to 2 tests per day per plant.

Moisture
Susceptibility of
Mix (AASHTO
T283)

One test for each mix type whenever

there is change in quality or source of
coarse or fine aggregate

Density of
compacted layer

1 test per 700 sq.m area