Road Safety Cell’s Specifications for Traffic Signs and

other Safety-Related Works

September 2003

Based on MoRTH “Specifications for Road and Bridge Works, Fourth Revision”

Note:

These specifications are constantly being improved. Refer to the Road Safety Cell for the
latest version.

No responsibility can be taken for any problems arising from the use of these specifications
by organisations other than Kerala PWD.
Traffic Signs, Markings and Section 800
Other Road Appurtenances

801. TRAFFIC SIGNS

801.1. General

801.1.1. The colour, configuration, size and location of all traffic signs for highways other than
Expressways shall be in accordance with the Code of Practice for Road Signs, IRC: 67-2001 or as
shown on the drawings. For Expressways, the size of the signs, letters and their placement shall be as
specified in the Contract drawings and relevant Specifications. In the absence of any details or for
any missing details, the signs shall be provided as directed by the Engineer.

801.1.2. All road signs shall be made retro-reflective by the application of retro-reflective sheeting
vide Clause 801.3, fixed over aluminium sheeting as per these specifications.

801.2. Materials

The various materials and fabrication of the traffic signs shall conform to the following
requirements:

801.2.1. Concrete: Concrete shall be of the grade shown on the Contract drawings or otherwise as
directed by the Engineer.

801.2.2. Reinforcing steel: Reinforcing steel shall conform to the requirement of

IS: 1786 unless otherwise shown on the drawing.

801.2.3. Bolts, nuts, washers: High strength bolts shall conform to IS: 1367 whereas precision bolts,
nuts, etc., shal1 conform to IS: 1364.

801.2.4. Plates and supports: Plates and support sections for the sign posts shall conform to IS: 226
and IS: 2062 or any other relevant IS Specifications.

801.2.5. Aluminium: Aluminium sheets used for sign boards shall be of smooth, hard and corrosion
resistant aluminium alloy conforming to IS: 736-Material designation 24345 or 1900.

801.2.6. Signs with a maximum side dimension not exceeding 600 mm shall not be less than 1.5 mm
thick. All others shall be at least 2 mm thick. The thickness of the sheet shall be related to the size of
the sign and its support and shall be such that it does not bend or deform under the prevailing wind
and other loads.

801.2.7. In respect of sign sizes not covered by IRC: 67, the structural details (thickness, etc.) shall
be as per the approved drawings.
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801.3. Traffic Signs Having Retro-reflective Sheeting

801.3.1. General requirements: The retro-reflective sheeting used on the sign shall consist of white
or coloured sheeting having a smooth outer surface, which has the property of retro-reflection over
its entire surface. It shall be weather-resistant and show colour fastness. It shall be new and unused
and shall show no evidence of cracking, scaling, pitting, blistering, edge lifting, or curling, and shall
have negligible shrinkage or expansion.
The sheeting and overlay films shall be considered for use only when sufficient evidence exists to
ensure that the material and services offered can be reliably conforming to the technical
specification.
The sheeting shall be part of a family of matched component products required for the manufacture
and imaging of permanent traffic signs. The material (sheeting, overlay films) for use in the
production of finished traffic control devices shall all be from the same manufacturer.
The retro-reflective sheeting shall be of the type specified in the Bill of Quantities or on the
Drawings. There are three types: High Intensity, Micro-Prismatic, and Engineering.

801.3.2. Retro-reflective Sheeting

801.3.2.1. High Intensity Encapsulated Lens Type: This sheeting shall be of encapsulated lens
type consisting of spherical glass lens elements adhering to a synthetic resin and encapsulated by a
flexible, transparent waterproof plastic having a smooth surface. The retro-reflective surface after
cleaning with soap and water and in dry condition shall have the minimum coefficient of retro-
reflection as indicated in Table 800-1(a) conforming to Type III sheeting as specified in ASTM D
4956 - 01 determined in accordance with ASTM Standard E:810.
Table 800-1(a) ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-REFLECTION
FOR HIGH INTENSITY (ENCAPSULATED LENS TYPE) SHEETING (CANDELAS PER
LUX PER SQUARE METRE)

Observation angle Entrance angle White Yellow Green / Red Blue

(in degrees) (in degrees)
0.2 -4 250 170 45 20
0.2 +30 150 100 25 11
0.5 -4 95 62 15 7.5
0.5 +30 65 45 10 5

When totally wet the sheeting shall not show less than 90% of the values of retro-reflection indicated
in Table 800-1 (a). At the end of 7 years the sheeting shall retain at least 75 per cent of its original
retro-reflectance."
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801.3.2.2 Micro-Prismatic Type

This sheeting shall consist of flexible white or coloured prismatic lens elements with a distinctive
interlocking seal pattern and orientation marks visible from the face of a smooth surface. The
sheeting shall have a pre-coated adhesive protected by an easily removable liner.
The retro-reflective surface after cleaning with soap and water and in dry condition shall have the
minimum coefficient of retro-reflection as given in Table 800-1 (b) determined in accordance with
ASTM Standard E-810.

Table 800-1(b) ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-REFLECTION

FOR MICRO-PRISMATIC TYPE SHEETING (CANDELAS PER LUX PER SQUARE
METRE)

Observation angle Entrance angle White Yellow Green Red Blue

(in degrees) (in degrees)
0.1 -4 660 500 66 130 30
0.1 +30 370 280 37 74 17
0.2 -4 380 285 38 76 17
0.2 +30 215 162 22 43 10
0.5 -4 240 180 24 48 11
0.5 +30 115 86 12 17 7

When totally wet the sheeting shall not show less than 90% of the values of retro-reflection indicated
in Table 800-1(b). At the end of 7 years the sheeting shall retain at least 75 per cent of its original
retro-reflectance."

801.3.2.3. Engineering grade sheeting: This sheeting shall be of enclosed lens type consisting of
microscopic lens elements embedded beneath the surface of a smooth, flexible, transparent, water-
proof plastic, resulting in a non-exposed lens optical reflecting system. The retro-reflective surface
after cleaning with soap and water and in dry condition shall have the minimum coefficient of retro-
reflection (determined in accordance with ASTM Standard: E-8l0) as indicated in Table 800-1(c).

TABLE 800-1 (c) ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-

1.1.1 REFLECTION FOR ENGINEERING GRADE SHEETING
(CANDELAS PER LUX PER SQUARE METRE)

Observation angle Entrance Angle White Yellow Orange Green/ Blue

(in degrees) (in degrees) Red
0.2 -4 70 50 25 9.0 4.0
0.2 +30 30 22 7.0 3.5 1.7
0.5 -4 30 25 13.5 4.5 2.0
0.5 +30 15 13 4.0 2.2 0.8

When totally wet, the sheeting shall not show less than 90 per cent of the values, of the values, of
retro-reflection indicated in Table 800-1(c). At the end of 5 years, the sheeting shall retain at least 50
per cent of its original retro- reflectance.
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801.3.4. Message/ Borders: The messages (legends, letters, numerals, etc) shall be made out of
white retro-reflective sheeting (as per Clause 801.3.2), except those in black, which shall be made of
non-reflective film. Black symbols shall also be made of non-reflective film. Red borders and other
secondary coloured areas shall be created by applying coloured overlay film to white retro-reflective
sheeting. Overlay film shall be as specified by the sheeting manufacturer and shall be bonded with
the sheeting in the manner specified by the manufacturer. Creating coloured areas by means of
screen-printing with ink shall not be permitted.

801.3.7. Colour : Colour shall be as specified and conform to the requirements of Table 800-2.
Conformance to colour requirements shall be determined spectrophotometrically in accordance with
ASTM E 1164, with instruments utilising either 45/0 or 0/45 illumination / viewing conditions and
tolerances as described in ASTM E 1164 for retro-reflective materials. The colour shall be durable
and uniform in acceptable hue when viewed in day light or under normal headlights at night”

1.1.1.1.1.1 Table 800-2 CHROMATICITY COORDINATES

Reflectance Limit (y)
Colour X Y X Y X y x y Min. Max.
White 0.30 0.30 0.35 0.35 0.33 0.37 0.28 0.32 40
Yellow 0.48 0.42 0.54 0.45 0.46 0.53 0.42 0.48 24 45
Red 0.69 0.31 0.59 0.31 0.56 0.34 0.65 0.34 3 15
Blue 0.07 0.17 0.15 0.22 0.21 0.16 0.13 0.03 1 10
Green 0.03 0.39 0.16 0.36 0.28 0.44 0.20 0.79 3 9

The four pairs of chromaticity co-ordinates determine the acceptable colour in terms of the CIE 1931
standard colorimetric system measured with standard illumination Source D65 - these colours are
equivalent to those listed in ASTM D 4956 using Source C.

801.3.8. Adhesives: The sheeting shall either have a pressure sensitive adhesive of the aggressive-
tack type requiring no heat, solvent or other preparation for adhesion to a smooth clean surface, or a
tack free adhesive activated by heat, applied in a heat-vacuum applicator, in a manner recommended
by the sheeting manufacturer. The adhesive shall be protected by an easily removable liner
(removable by peeling without soaking in water or other solvent) and shall be suitable for the type of
material of the base plate used for the sign. The adhesive shall form a durable bond to smooth,
corrosion and weather resistant surface of the base plate such that it shall not be possible to remove
the sheeting from the sign base in one piece by use of sharp instrument. In case of pressure-sensitive
adhesive sheeting, the sheeting shall be applied in accordance with the manufacturer's Specifications.
Sheeting with adhesives requiring use of solvents or other preparation for adhesive shall be applied
strictly in accordance with the manufacturer's instructions.

801.3.9. Refurbishment: Where existing signs are specified for refurbishment, the sheeting shall
have a semi-rigid aluminium backing pre-coated with aggressive-tack type pressure sensitive
adhesive. The adhesive shall be suitable for the type of material used for the sign and should
thoroughly bond with that material.
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801.3.10. Fabrication:

801.3.10.1. Surface to be reflectorised shall be effectively prepared to receive the retro-reflective

sheeting. The aluminium sheeting shall be de-greased either by acid or hot alkaline etching and all
scale/dust removed to obtain a smooth plain surface before the application of retroreflective sheeting.
If the surface is rough, approved surface primer may be used. After cleaning, metal shall not be
handled, except by suitable device or clean canvas gloves, between all cleaning and preparation
operation and application of reflective sheeting/primer. There shall be no opportunity for metal to
come in conflict with grease, oil or other contaminants prior to the application of retro-reflective
sheeting.

801.3.10.2. Complete sheets of the material shall be used on the signs except where it is unavoidable;
at splices, sheeting with pressure sensitive adhesives shall be overlapped not less than 5 mm.
Sheeting with heat-activated adhesives may be spliced with an overlap not less than 5mm or butted
with a gap not exceeding 0.75 mm. The material shall cover the sign surface evenly and shall be free
from twists, cracks and folds. Cut-outs to produce legends and borders shall be bonded with the
sheeting in the manner specified by the manufacturer.

801.3.11. Warranty and durability: The Contractor shall obtain from the manufacturer a seven-
year warranty for satisfactory field performance including stipulated retro-reflectance of the retro-
reflective sheeting of prismatic grade and high intensity grade and a five-year warranty of
engineering grade, and submit the same to the Engineer. In addition, a seven-year warranty (five-
years for engineering grade signs) for satisfactory in-field performance of the finished sign inclusive
of the letters / legends and their bonding to the sheeting shall be obtained from the
Contractor/supplier and passed on to the Engineer. The Contractor/supplier shall also furnish a
certification that the signs and materials supplied against the assigned work meets all the stipulated
requirements and carry the stipulated warranty.
The warranty shall also cover the replacement obligation by the sheeting manufacturer as well as the
contractor for replacement/repairing/restoration of the retro-reflective efficiency.
A lot certificate shall be supplied in original from the manufacturer of the retro-reflective sheeting
stating that the material lot being supplied under the purchase order conforms to the standards
specified for retro-reflective sheeting.
The sheeting manufacturer shall provide test data showing that the representative combined
production material (sheeting, overlay films) of the type to be supplied has met the requirements for
36 months of accelerated outdoor weathering. Processed and applied in accordance with the
recommended procedures the retro-reflective material shall be weather-resistant and following the
cleaning shall show no appreciable discoloration, cracking, blistering, or dimensional change and
shall not have less than 50% of the specified minimum reflective intensity values (Table 800-1(a),
800-1(b) and 800-1(c)) when subjected to accelerated outdoor weathering for 36 months. This test
data shall be gathered in accordance with ASTM D 4956 and by an independent agency. The data
submitted shall cover both the retro-reflective sheeting and overlay films manufactured by the
sheeting manufacturer in standard traffic colours. The overlay films shall be tested with the sheeting
to which they are intended to be applied. The data collection shall have been completed no more
than 5 years prior to the offer.
All signs shall be dated during fabrication with an indelible marking to indicate the type of sheeting
used, the name of the manufacturer, and the start date for the warranty. Warranty should be given in
the original and should have legal jurisdiction in India.
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801.4. Installation

801.4.1. Sign posts, their foundations and sign mountings shall be so constructed as to hold these in a
proper and permanent position against the normal storm wind loads or displacement by vandalism.
Normally, signs with an area up to 0.9 sq. m. shall be mounted on a single post, and for greater area,
two or more supports shall be provided. Sign supports shall be of mild steel or galvanised iron
(G.I.). All open-ended posts, or other hollow sections, shall be effectively capped to prevent the
entry of water. Post end(s) shall be firmly fixed to the ground by means of a properly designed
foundation. The work of foundation shall conform to relevant Specifications as specified.

801.4.2. All components of signs and supports other than the reflective portion and G.I. posts and
sections shall be thoroughly de-scaled and cleaned by means of sandblasting or equally effective
method. They shall then be primed using a high zinc oxide content coating material of approved
formulation. The colour of the priming shall be different from succeeding coatings. Two finish
coats of epoxy paint shall then be applied. The first coat shall be completely dry before applying the
second coat.
All painted surfaces shall be considered warranted against peeling, blistering and excessive fading
and as such these effects when noted will be considered as defects.

801.4.3. The signs shall be fixed to the posts by welding in the case of steel posts and by bolts and
washers of suitable size in the case of reinforced concrete or G.I. posts. After the nuts have been
tightened, the tails of the bolts shall be furred over with a hammer to prevent removal.

801.4.4. Except where ribs or flanges are an integral part of the sign plate and provide the necessary
stiffening, sheet metal sign plates exceeding 500mm in any dimension shall be stiffened by the
attachment of a frame or stiffening member(s) to the back of the sign plate. The post or posts
supporting a sign may be taken into consideration for stiffening purposes. A bracket may form the
stiffening frame or part of it. The frame for a sign plate or plates shall be simple in design and shall
have the minimum number of members to give it the required stiffness. The stiffening or frame for a
sheet metal sign plate may take the form of flanges round the edges of a sign, welded ribs or steel or
aluminium sections with a minimum thickness of 2 mm. Where flanges are provided they shall be
uniform on all edges of the sign. Where metal frame members join they may be welded or joined
with suitable brackets and nuts and bolts but in all cases the joints shall be strong enough to
withstand the stresses induced in them.

801.4.5. The method of fixing sign plates, frames and brackets to posts shall be such as will facilitate
removal for replacement or maintenance purposes and permit adjustment in the position of a sign
without detaching it from its post or posts, but the sign and any framing shall be held firmly enough
to withstand the load to which it will be subjected. Signs mounted on single posts shall have a fixing
to prevent the forced rotation of the signs on the posts. Clips and brackets shall be shaped to secure a
firm hold on the post without placing any bending strain on the sign plate.

801.4.6. Where dissimilar metals are joined together, precautions shall be taken to prevent
electrolytic action, particularly in the case of screws and rivets. This may be accomplished by using
paint, lacquer or other suitable means to eliminate metal to metal contact.

801.4.7. Brackets used in the construction of signs may be manufactured from sheet or strip
aluminium alloy, extruded sections, cast aluminium alloy or may be fabricated from steel sections.
The minimum thickness of material shall be 3 mm. Welded joints shall be sound and their surfaces
smooth. Holes shall be drilled before painting and shall be accurately located. Steel or aluminium
strip used for clips shall not be less than 2 mm thick.
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801.4.8. Screws and bolts shall not be less than 8 mm (5/16 inch) in diameter and of adequate length,
but without excessive projection of the screwed ends. In any situation where, if a screw were
removed, the assembly would be insecure, that screw shall have not less than four full threads
protruding when it is tight and shall be fitted with a locknut or a spring washer. All fastening shall be
rust proofed by galvanizing or zinc plating.

801.4.9. Where hollow rivets are used to connect sign plates to frames or fixings the holes shall be
effectively blocked to prevent light shining through. Screw, bolt or rivet heads on the face of a sign
shall be as unobtrusive as possible and each shall match the colour of the part of the sign where it is
located.

801.4.10. Where so indicated on the Drawings the bases of posts shall be embedded in concrete.
Concrete shall be rammed round the base of the post such that the post will be firmly held in position
immediately after completion of placing and compaction. The minimum thickness of concrete
embedment and its height shall be as shown on the Drawings or be a minimum of 0.1 cubic metres of
class M20 concrete.

The post shall be carefully positioned and plumbed, and struts and stays applied as necessary to hold
it in position during embedment. The concrete shall then be placed round the post in uniform lifts not
exceeding 200 mm and each lift thoroughly rammed. Care shall be taken to avoid contamination of
the concrete from the surrounding surface and soils. Any contaminating material falling into the
concrete shall be immediately removed. All the concrete embedment for a post shall be provided in
one operation and where the surface of the concrete embedment is above the level of the surrounding
surface the exposed portion shall be formed to present a neat and tidy appearance and sloped to shed
water away from the post.

801.4.11. Prior to supplying the signs the Contractor shall submit a sample sign, including, plate,
support frame, fixings and post to the Engineer for approval.

801.5. Measurements for Payment

The measurement of standard cautionary, mandatory and information signs shall be in numbers of
different types of signs supplied and fixed, while for direction and place identification signs, these
shall be measured by area in square metres.

801.6. Rate

The Contract unit rate shall be payment in full for the cost of making the road sign, including all
materials, installing it at the site and incidentals to complete the work in accordance with the
Specifications.
Traffic Signs, Markings and Section 800
Other Road Appurtenances

802. OVERHEAD SIGNS

802.1. General

802.1.1. Overhead signs may be used in lieu of, or as an adjunct to, ground signs where the situation
so warrants for proper information and guidance of the road user. The following conditions may be
considered while deciding about the provision of overhead signs:

(1) Traffic volume at or near capacity

(2) Complex interchange design
(3) Three or more lanes in each direction
(4) Restricted sight distance
(5) Closely spaced interchanges
(6) Multi-lane exits
(7) Large percentage of commercial vehicles
(8) High speed traffic
(9) Consistency of sign message location through a series of interchanges
(10) Insufficient space for ground mounted signs
(11) Background of street lighting
(12) Distances of important places enroute highways at suitable intervals.

802.1.2. From safety and aesthetic standpoints, overhead signs shall be mounted on overhead bridge
structures wherever possible. Where these are required to be provided at some other locations, the
support system should be properly designed based on sound engineering principles, to safely sustain
the dead load, live load and wind load on the completed sign system. For this purpose, the overhead
signs shall be designed to withstand a wind loading of 150 kg/m2 normal to the face of the sign and
30 kg/m2 transverse to the face of the sign. In addition to the dead load of the structure, walkway
loading of 250 kg concentrated live load shall also be considered for the design of the overhead sign
structure.

802.2. Height

Overhead signs shall provide a vertical clearance of not less than 5.5m over the entire width of the
pavement and shoulders except where a lesser vertical clearance is used for the design of other
structures. The vertical clearance to overhead sign structures or supports need not be greater than 300
mm in excess of the minimum design clearance of other structures.

1.1.1.2 802.3. Lateral Clearance

802.3.1. The minimum clearance outside the usable roadway shoulder for expressway signs mounted
at the road side or for overhead sign supports either to the right or left side of the roadway shall be
1.80 m. This minimum clearance of 1.80 m shall also apply outside of an unmountable kerb. Where
practicable, a sign should not be less than 3 m from the edge of the nearest traffic lane. Large guide
signs should be farther removed preferably 9 m or more from the nearest traffic lane, unless
otherwise specified. Lesser clearances, but not generally less than 1.80 m, may be used on
connecting roadways or ramps at inter-changes.
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802.3.2. Where a median is 3.6 m or less in width, consideration should be given to spanning over
both roadways without a central support. Where overhead sign supports cannot be placed at a safe
distance away from the line of traffic or in an otherwise protected site, they should either be so
designed as to minimise the impact forces or protect motorists adequately by a physical barrier or
guard rail of suitable design.

802.4. Number of Signs at an Overhead Installation

In no case should there be more than three signs displayed at any one location, including regulatory
or warning signs, either on the overhead structure or on its support.

802.5. Materials for Overhead Sign and Support Structures

802.5.1. Aluminium alloy or galvanized steel to be used as truss design supports shall conform to
relevant IS. These shall be of sections
and type as per structural design requirements as shown on the plans.

802.5.2. After steel trusses have been fabricated and all required holes punched or drilled on both the
horizontal truss units and the vertical and support units, they shall be galvanized in accordance with
IS Specifications.

802.5.3. Where aluminium sheets are used for road signs, they shall be of smooth, hard and corrosion
resistant aluminium alloy conforming to IS 736- Material Designation 24345 or 1900. The thickness
of sheet shall be related to the size of the sign with minimum thickness of sheet as 1.5 mm.

802.5.4. High strength bolts shall confound, to IS: 1367 whereas precision bolts, nuts etc. shall
conform to IS: 1364.

802.5.5. Plates and support sections for sign posts shall conform to IS: 226 and IS: 2062.

802.5.6. The overhead signs shall be reflectorised with high intensity retro-reflective sheeting
preferably of encapsulated lens type.

802.6. Size, Locations, etc. of Signs

802.6.1. The size of the signs, letters and their placement shall be as specified in the Contract
drawings and Specifications.

802.6.2. In the absence of details or for any missing details in the Contract documents, the signs shall
be provided as directed by the Engineer.

802.7. Installation

802.7.1. The supporting structure and signs shall be fabricated and erected as per details given in the
plans.

802.7.2. Sign posts, their foundations and sign mountings shall be so constructed as to hold signs in a
proper and permanent position to adequately resist swaying in the wind or displacement by
vandalism.
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802.7.3. The work of construction of foundation for sign supports including excavation and backfill,
forms, steel reinforcement, concrete and its placement shall conform to the relevant Specifications
given in these Specifications.

802.7.4. The structures shall be erected with the specified camber and in such a manner as to prevent
excessive stresses, injury and defacement.

802.7.5. Brackets shall be provided for mounting signs of the type to be supported by the structure.
For better visibility, they shall be adjustable to permit mounting the sign faces at any angle between a
truly vertical position and three degree from vertical. This angle shall be obtained by rotating the
front lower edge of the sign forward. All brackets shall be of a length equal to the heights of the signs
being supported.

802.7.6. Before erecting support structures, the bottom of each base plate shall be protected with an
approved material which "will adequately
prevent any harmful reaction between the plate and the concrete.

802.7.7. The end supports shall be plumbed by the use of levelling nuts and the space between the
foundation and base plate shall be completely filled with an anti-shrink grout.

802.7.8. Anchor bolts for sign supports shall be set to proper locations and elevation with templates
and carefully checked after construction of the sign foundation and before the concrete has set.

802.7.9. All nuts on aluminium trusses, except those used on the flanges, shall be tightened only until
they are snug. This includes the nuts on the anchor bolts. A thread lubricant shall be used with each
aluminium nut.

802.7.10. All nuts on galvanized steel trusses, with the exception of high strength bolt connections,
shall be tightened only to a snug condition.

802.7.11. Field welding shall not be permitted.

802.7.12. After installation of signs is complete, the sign shall be inspected by the Engineer. If
specular reflection is apparent on any sign, its positioning shall be adjusted by the Contractor to
eliminate or minimize this condition.

802.8. Measurements for Payment

802.8.1. Aluminium or steel overhead sign structure will be measured for payment by the specific
unit (each) complete in place or for each component of the overhead sign structure as indicated in the
Bill of Quantities and the detailed drawing(s).

802.8.2. Flat sheet aluminium signs with retro-reflective sheeting thereon shall be measured for
payment by the square metre for each thickness, complete in place.

802.9. Rate

802.9.1. The structural steel part of the overhead sign shall be measured in tonnes while the sign
board shall be measured in sq. m. Other items like excavation for foundation and concrete in
foundation to be measured and paid in cu. m. separately. The Contract unit rate for overhead sign
structure shall be payment in full compensation for furnishing all labour, materials, tools, equipment,
excavation, fabrication and installation and all other incidental costs necessary to complete the work
to the Specifications.
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802.9.2. The Contract unit rate for aluminium sheet signs shall include the cost of making the sign
including all materials and fixing the same in position and all other incidental costs necessary to
complete the work to the Specifications.

803. ROAD MARKINGS

803.1. General

The colour, width and layout of road markings shall be in accordance with the Code of Practice for
Road Markings with paints, IRC: 35, and as specified in the drawings or as directed by the Engineer.

803.2. Materials

Road markings shall be made with either road marking paint or hot applied thermoplastic compound,
as specified in the Bill of Quantities or on the Drawings. The material shall meet the requirements
specified below.

803.3. Ordinary Road Marking Paint

803.3.1. Ordinary paint used for road marking shall conform to Grade as per IS: 164.

803.3.2. The road marking shall preferably be laid with appropriate road marking machinery.

803.3.3. Laying thickness of road marking paint shall be as specified by the Engineer.

803.4. Hot Applied Thermoplastic Road Marking

803.4.1 General:

(i) The work under this section consists of marking traffic stripes using a thermoplastic
compound meeting the requirements specified herein.

(ii) The thermoplastic compound shall be screeded/extruded on to the pavement surface in a

molten state by suitable machine capable of controlled preparation and laying with
surface application of glass beads at a specific rate. Upon cooling to ambient pavement
temperature, it shall produce an adherent pavement marking of specified thickness and
width and capable of resisting deformation by traffic.

(iii) The colour of the compound shall be white or yellow (IS colour No. 356) as specified in
the drawings or as directed by the Engineer.

(iv) Where the compound is to be applied to cement concrete pavement,

a sealing primer as recommended by the manufacturer, shall be applied to the pavement
in advance of placing of the stripes to ensure proper bonding of the compound. On new
concrete surface any laitance and/or curing compound shall be removed before the
markings are applied.

803.4.2. Thermoplastic Material

803.4.2.1. General: The thermoplastic material shall be homogeneously composed of aggregate,

pigment, resins and glass reflectorizing beads. The thermoplastic material shall be factory mixed,
Traffic Signs, Markings and Section 800
Other Road Appurtenances

from an approved manufacturer, and shall be of a tropical grade suitable for application, by the
means proposed, to the specified road surfaces.
803.4.2.2. Requirements:

(i) Composition: The pigment, beads, and aggregate shall be uniformly dispersed in the resin. The
material shall be free from all skins, dirt and foreign objects and shall comply with requirements
indicated in Table 800-3.

TABLE 800-3. PROPORTIONS OF CONSTITUENTS OF MARKING MATERIAL

(Percentage by weight)

Component White Yellow

Binder 18.0 min 18.0 min
Glass Beads 30-40 30-40
Titanium Dioxide 10.0 min -
Calcium Carbonate
Inert Fillers 42.0max See
Yellow Pigments - Note
Note: Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of the
manufacturer, provided all other requirements of this Specification are met

(ii) Properties: The properties of thermoplastic material, when tested in accordance with ASTM
D36/BS-3262- (part I), shall be as below:

(a) Luminance:

White: Daylight luminance at 45 degrees-65 per cent min. as per AASHTO

M 249
Yellow: Daylight luminance at 45 degrees-45 per cent min. as per AASHTO M 249

(b) Drying time: When applied at a temperature specified by the manufacturer and to the required
thickness, the material shall set to bear traffic in not more than 15 minutes.

(c) Skid resistance: not less than 45 as per BS 6044.

(d) Cracking resistance at low temperature: The material shall show no cracks on application to
concrete blocks.

(e) Softening point: 102.5 t 9.5. C as per ASTM D 36.

(f) F1ow resistance: Not more than 25 per cent as per AASHTO M 249.

(g) Yellowness Index (for white thermoplastic paint): not more than 0.12 as per AASHTO M 249

(iii) Storage life: The material shall meet the requirements of these Specifications for a period of one
year. The thermoplastic material must also melt uniformly with no evidence of skins or
unmelted particles for the one year storage period. Any material not meeting the above
requirements shall be replaced by the manufacturer/ supplier/ Contractor.

(iv) Reflectorisation: Shall be achieved by incorporation of beads, the grading and other properties
of the beads shall be as specified in clause 803.4.3.
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(v) Marking: Each container of the thermoplastic material shall be clearly and indelibly marked with
the following information:

1. The name, trademark or other means of identification of manufacturer

2. Batch number
3. Date of manufacture
4. Colour (white or yellow)
5. Maximum application temperature and maximum safe heating temperature.

(vi) Sampling and testing: The thermoplastic material shall be sampled and tested in accordance
with the appropriate ASTM/BS method. The Contractor shall furnish to the Employer a copy of
certified test reports from the manufacturers of the thermoplastic material showing results of all
tests specified herein and shall certify that the material meets all requirements of this
Specification.

803.4.3. Reflectorising glass beads

803.4.3.1. General: This Specification covers two types of glass beads to be used for the production
of reflectorised pavement markings.

Type 1 beads are those which are a constituent of the basic thermoplastic compound vide Table 800-3
and Type 2 beads are those which are to be sprayed on the surface vide Clause 803.6.3.

803.4.3.2. The glass beads shall be transparent, colourless and free from milkiness, dark particles and
excessive air inclusions.

These shall conform to the requirements spelt out in Clause 803.4.3.3.

803.4.3.3. Specific requirements

A. Gradation: The glass beads shall meet the gradation requirements for the two types as given in
Table 800-4.

TABLE 800-4. GRADATION REQUIREMENTS FOR GLASS BEADS

Per cent retained

Sieve size
Type 1 Type 2
1.18 0 to 3 -
850 50 to 20 0 to 5
600 - 5 to 20
425 65 to 95 -
300 - 30 to 75
180 0 to 10 10 to 30
Below 180 micron - 0 to 15

B. Roundness: The glass beads shall have a minimum of 70 per cent true spheres.

C. Refractive index: The glass beads shall have a minimum refractive index of 1.50.

D. Free flowing properties: The glass beads shall be free of hard lumps and clusters and shall
dispense readily under any conditions suitable for paint striping. They shall pass the free flow-
test.
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803.4.3.4. Test methods: The specific requirements shall be tested with the following methods:

(i) Free-flow test: Spread 100 grams of beads evenly in a 100 rnrn diameter glass dish. Place the dish
in a 250 rnrn inside diameter desiccator which is filled within 25 rnrn of the top of a desiccator
plate with sulphuric acid water solution (specific gravity 1.10). Cover the desiccator and let it
stand for 4 hours at 20 to 29 degree C. Remove sample from desiccator, transfer beads to a pan
and inspect for lumps or clusters. Then pour beads into a clean, dry glass funnel having a 100 mm
stem and 6 mm orifice. if necessary, initiate flow by lightly tapping the funnel. The glass spheres
shall be essentially free of lumps and clusters and shall flow freely through the funnel.
(ii) The requirements of gradation, roundness and refractive index of glass beads and the amount of
glass beads in the compound shall be tested as per BS 6088 and BS 3262 (part I).

(iii) The Contractor shall furnish to the Employer a copy of certified test reports from the
manufacturer of glass beads obtained from a reputed laboratory showing results of all tests
specified and shall certify that the material meets all requirements of this Specification.
However, if so required, these tests may b carried out as directed by the Engineer.

803.4.4 Application properties of the thermoplastic material

803.4.4.1 The thermoplastic material shall readily get screeded/ extruded at temperatures specified by
the manufacturers for respective method of application to produce a line of specified thickness which
shall be continuous and uniform in shape having clear and sharp edges.

803.4.4.2 The material upon heating to application temperatures shall not exude fumes, which are
toxic, obnoxious or injurious to persons or property.

803.4.5 Preparation:

i) The material shall be melted in accordance with the manufacturer;’ instructions in a heater
fitted with a mechanical stirrer to give a smooth consistency to the thermoplastic material
to avoid local overheating. The temperature of the mass shall be within the range
specified by the manufacturer, and shall on no account be allowed to exceed the
maximum temperature stated by the manufacturer. The molten material should be used as
expeditiously as possible and for thermoplastic material which has natural binders or is
otherwise sensitive to prolonged heating, the material shall not be maintained in a molten
condition for more than 4 hours.

ii) After transfer to the laying equipment, the material shall be maintained within the
temperature range specified by the manufacturer for achieving the desired consistency for
laying.

803.4.6 Properties of finished road marking:

a) The stripe shall not be slippery when wet.

b) The marking shall not lift from the pavement in freezing weather.
c) After application and proper drying, the stripe shall show no appreciable deformation or
discolouration under traffic and under road temperature up to 60C
d) The marking shall not deteriorate by contact with sodium chloride, calcium chloride or oil
drippings from traffic.
e) The stripe or marking shall maintain its original dimensions and position. Cold ductility of the
material shall be such as to permit normal movement with the road surface without chopping,
cracking or peeling
f) The colour of yellow marking shall conform to IS Colour No. 356 as given in IS:164
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803.5. Reflectorised Paint

Reflectorised paint, if used, shall conform to the Specification by the manufacturers and approved by
the Engineer. Reflectorising glass beads for reflectorising paints where used shall conform to the
requirement of Clause 803.4.3

803.6. Application

803.6.1. The material shall be applied only on a surface which is clean and dry. It shall not be laid
over loose detritus, mud or similar extraneous matter, or over an old paint marking, or over an old
thermoplastic marking which is faulty. New surfaces must be allowed to weather and compact for at
least 72 hours before applying the marking. In the case of smooth polished surfaces, e.g. smooth
concrete, old asphalt surfacings with smooth polished surface stones, and/or where the method of
application requires or the Engineer directs, a tack coat shall be applied to the surface prior to the
application. The tack coat shall be as recommended by the manufacturer of the thermoplastic
material and to the approval of the Engineer. Faulty thermoplastic markings shall be removed if
required by the Engineer.

803.6.2. The road markings shall be laid with the appropriate road marking machinery as approved
by the Engineer. The thermoplastic material shall be applied hot either by screeding, extrusion or
spraying. After transfer to the laying apparatus , the material shall be laid at a temperature within the
range specified by the manufacturer for the particular method of laying being used. For locations or
markings which are awkward to do by machine, approved manual methods shall be used with the
prior approval of the Engineer. Where the marking material is applied by means of a machine, it
shall be applied in one layer. 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. Adjustment to the machine shall be followed by further testing.

Only when the machine has been correctly adjusted and approved by the Engineer may the machine
be used on the permanent work. The operator shall be experienced in the use of the machine. The
rate of application shall be checked and adjusted if necessary before application on a large scale is
commenced and thereafter daily. The Contractor shall maintain control over traffic while marking
operations are in progress so as to cause minimum inconvenience to traffic compatible with
protecting the workmen.

803.6.3. The pavement temperature shall not be less than 10°C during application. All surfaces to be
marked shall be thoroughly cleaned of all dust, dirt, grease, oil and all other foreign matter before
application of the paint.

The material, when formed into traffic stripes, must be readily renewable by placing an overlay of
new material directly over an old line of compatible material. Such new material shall so bond itself
to the old line that no splitting or separation takes place.

Thermoplastic paint shall be applied in intermittent or continuous lines of uniform thickness of at

least 2.5 mm unless specified otherwise. Where arrows or letters are to be provided, thermoplastic
compound may be hand-sprayed. In addition to the beads included in the material, a further quantity
of glass beads of Type 2, conforming to the above noted Specification shall be sprayed uniformly
into a mono-layer on to the hot paint line in quick succession of the paint spraying operation. These
glass beads shall be applied at the rate of not less than 400 grams per square meter area.
Traffic Signs, Markings and Section 800
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803.6.4. The minimum thickness specified is exclusive of surface applied glass beads. The method of
thickness measurement shall be in accordance with Appendices B and C of BS - 3262 (part 3).

803.6.5. The work shall be carried out very carefully to a regular alignment in accordance with
the Drawings. Straight edges and templates shall be used if required by the Engineer. The finished
lines shall be free from ruggedness on sides and ends and be parallel to the general alignment of the
carriageway. The upper surface of the lines shall be level, uniform and free from streaks.

803.6.6. Tolerances

(i) General

Road traffic markings shall be constructed to an 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.

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.

Lines and curves, whether broken or unbroken, shall not consist of chords but shall follow the correct
radius.

(ii) Faulty Workmanship or Materials

If any materials not complying with the requirements is delivered at the Site or used in the Works, or
if any sub-standard work is carried out, such material or work shall be removed, replaced or repaired
as required by the Engineer, at the Contractor’s own cost. Rejected traffic markings and
thermoplastic road marking material 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 or spilt paint will not show up again later.

803.7. Measurements for Payment

803.7.1. The painted markings shall be measured in sq. metres of actual area marked (excluding the
gaps, if any).

803.7.2. In respect of markings like directional arrows and lettering, etc., the measurement shall be
by numbers.
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803.8. Rate

The Contract unit rate for road markings shall be payment in full compensation for furnishing all
labour, materials, tools, equipment, including all incidental costs necessary for carrying out the work
at the site conforming to these Specifications complete as per the approved drawing(s) or as directed
by the Engineer and all other incidental costs necessary to complete the work to these Specifications.

804. HECTOMETRE/KILOMETRE STONES

804.1. General

The work covers the supply, painting, lettering and fixing of distance measurement stones and shall
include:

(i) Hectometre stones

(ii) Kilometre stones
(iii) 5th Kilometre stones

804.2. The dimensions of the stones and the size, colour, arrangement of letters and script shall be as
per IRC: 26 "Type Designs for 200 Metre Stones" and IRC: 8
"Type Designs for Highway Kilometre Stones".

804.3. The hectometre/kilometre stones may be made of local stones, concrete or any other material
available locally and approved by the Engineer. The stones shall be bedded into the ground with
adequate foundations as indicated in the drawings or in the relevant I.R.C. Specifications or as
directed by the Engineer. The orientation and location of the stones shall be as indicated in the
drawings or in the relevant I.R.C. Specifications or as directed by the Engineer.

804.4. Measurements for Payment

The measurement will be in numbers of 200 metre, kilometre and 5th kilometre stones fixed at site.

804.5. Rate

The Contract unit rate for nectometre/kilometre/5th kilo metre stones shall be payment in full
compensation for furnishing all labour, materials, tools, equipment and making the stones, painting
and lettering and fixing at site and all other incidental costs necessary to complete the work to these
Specifications.

805. ROAD DELINEATORS

805.1. General

The work covers supplying and fixing delineator posts as per the Drawings.

805.2. The delineator posts shall be made of M-20 grade reinforced cement concrete and HYSD
steel reinforcement constructed as shown in Drawing and as per Technical Specification Clauses
1500, 1600 & 1700.

Reflectors of the type specified in the Drawing shall be fixed to the posts in such a manner which
discourages theft and is approved by the Engineer.
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The design, materials to be used and locations of delineators shall conform to Recommended
Practice for Road Delineators, IRC-79 and to relevant Drawings or as otherwise directed by the
Engineer.

Before constructing the delineator posts the Contractor must submit a sample post to the Engineer for
approval.

805.3. Measurements for Payment

The measurement shall be made in numbers of delineators fixed at site.

805.4. Rate

The Contract unit rate for Road Delineators shall be payment in full compensation for furnishing all
labour, materials, tools, equipment for preparing, supplying and fixing at site and all other incidental
costs necessary to complete the work to these Specifications.

806. BOUNDARY STONES

806.1. General

The work comprises of supplying and fixing boundary stones as per designs and Specifications given
in IRC: 25 "Type Designs for Boundary Stones" and at locations indicated in the drawings or as
directed by the Engineer.

806.2. Measurement for Payment

The measurement shall be made in numbers of boundary stones fixed at site.

806.3. Rate

The Contract unit rate for boundary stones shall, be payment in full compensation for furnishing all
labour, materials, tools, equipment for preparing, supplying and fixing and all other incidental costs
necessary to complete the work to these Specifications.

807. FENCING
807.1. General

The work comprises of fixing Mild Steel (MS) posts and providing barbed wire fencing including
necessary stays and entry gates as shown in the drawing (s) and as directed by the Engineer.

807.2. The M.S. posts shall conform to IS: 226 and shall be of angle iron of size indicated in the
drawings. The angle iron shall be embedded in concern to a sufficient depth below ground as
indicated in the drawings. The steel shall be fabricated and painted to conform to Section 1900 of
these specifications.

807.3 The barbed wire shall be o galvanised iron and shall conform to IS: 278

807.4 Entry gate(s) shall be made of M.S rods or other metal as per the design shown in the
drawings.

807.5. Measurement for payment

The measurement shall be in running metre of fencing including the entry gates.
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807.6 Rate

The contract unit rate for fencing shall be payment in full compensation for furnishing all labour,
materials, tools, equipment for fabrication and fixing at site and all other incidental costs necessary to
complete the work to these specifications.

808. GALVANIZED TUBULAR PEDESTRIAN GUARD RAILING

808.1 General

The work shall consist of supplying, fixing and erecting GI Tubular steel railing(s) as shown on the
drawings and as directed by the Engineer.

808.2. The railings shall be tubular steel in conformance to IS:1239. The fabrication and painting
except for the final coat shall be completed before despatch to the site. Prior to the painting, all
surfaces shall be grit blasted to the satisfaction of the Engineer and Pickled. The priming coat of
paint shall be applied as soon as the steel has dried.

808.3. The posts shall be vertical and of the types shown in the drawing with a tolerance not
exceeding 6 mm in a length of 3m. The railing shall be erected true to line and grade.

808.3.1. The vertical posts shall be erected after embedding by at least 425 mm in M20 grade
concrete block of size 300 x 300 x 450 mm placed below formation level.

808.4. Measurements for Payment

The railing shall be measured in linear metre from end to end along the face of the railing, including
end and intermediate posts, with no deductions for gaps as shown on the drawings.

808.5. Rate

The Contract unit rate or GI Tubular steel railing(s) shall be payment in full compensation for
furnishing all labour, materials, tools, equipment and plant required for fabrication, connection,
oiling, painting, temporary erection, inspection, test and final erection at site and all other incidental
costs necessary to complete the work to these Specifications.

809. CONCRETE CRASH BARRIER

809.1 General

809.1.1 This work shall consist of construction, provision and installation of concrete crash barrier at
the edges of the road and median at locations and of dimensions as shown on the drawings or as
directed by the Engineer.

809.1.2. Concrete barrier shall generally be located on approaches to bridge structures, at locations
where the embankment height is more than 3 metres and at horizontal curves.

809.2. Materials

809.2.1. All materials shall conform to Section l000-Materials for Structures 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 "extrusion or slip form"
method or a combination thereof at the Contractor's option with the approval of the Engineer. Where
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"extrusion or slip form" method is adopted, full details of the method and literature shall be
furnished.

809.2.2. Concrete barriers shall be constructed with M 20 grade concrete and with High Yield
Strength deformed reinforcement conforming to IRC: 21.

809.2.3. An expansion joint with pre-moulded asphalt filler board shall be provided at the junction of
crash barrier on structure and crash barrier on the fill. The crash barrier on the fill shall be
constructed in pieces of length not exceeding 20 m, with pre-moulded asphalt filler board joints.

809.3. Construction Operations

809.3.1. The location of crash barrier shall be strictly adhered to as shown on 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 faces of the
barriers shall conform to the specified tolerances, as defined in Clause R09.4, when tested with 3 m
straight edge, laid on the surface.

809.3.2. When concrete barriers are to be constructed on recently completed bridges, the height of
the barriers shall be adjusted to compensate for the camber and dead load deflection of the
superstructure. The amount of adjustment shall be determined by the Engineer and shall be ordered
before the concrete is placed. Such barriers shall be placed after form work has been released and as
long after the superstructure construction as possible without hampering the progress of the work.

809.3.3. Backfilling to the concrete barriers shall be compacted in layers to the compaction of the
surrounding earthwork.

809.4. Tolerance The overall horizontal alignment of rails shall not depart from the road alignment
by more than ± 30 mm, nor deviate in any two successive lengths from straight by more than 6 mm
and the faces shall not vary more than 12 mm from the edge of a 3 m 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 ± 30 mm.

809.5. Measurements for Payment

All barriers will be measured by linear metres of completed and accepted length in place,
corresponding end to end along the face of concrete barriers including approach and departure ends.

809.6. 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.

810. METAL BEAM CRASH BARRIER

810.1. General

810.1.1. This work shall consist of furnishing and erection of metal beam crash barrier of dimensions
and at locations as shown on the drawing (s) or as directed by the Engineer.

810.1.2. Metal beam crash barrier shall generally be located on approaches to bridge structures, at
locations where the embankment height is more than 3 metres and at horizontal curves.
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810.2. Materials

810.2.1. Metal beam rail shall be corrugated sheet steel beams of the class, type, section and
thickness indicated on the plans. Railing posts shall be made of steel of the section, weight and
length as shown on the plans. All complete steel rail elements, terminal sections, posts, bolts, nuts,
hardware and other steel fittings shall be galvanised. All elements of the railing shall be free from
abrasions, rough or sharp edges and shall not be kinked, twisted or bent.

810.2.2. Steel beam elements and terminal sections shall be galvanised (zinc coated, 0.55 kg per
square metre, minimum single spot) unless otherwise specified. The galvanising on all other steel
parts shall conform to the relevant IS Specifications. All fittings (bolts, nuts, washers) shall conform
to the IS: 1367 and IS: 1364. All galvanizing shall be done after fabrication.

810.2.3. Concrete for bedding and anchor assembly shall conform to Section 1700 of these
Specifications.

810.3. Construction Operations

810.3.1. The line and grade of railing shall be true to that shown on the plans.
The railing shall be carefully adjusted prior to fixing in place, to ensure proper matching at abutting
joints and correct alignment and camber throughout their length. Holes for field connections shall be
drilled with the railing in place in the structure at proper grade and alignment.

810.3.2. Unless otherwise specified on the drawing, railing steel posts shall be given one shop coat of
paint (primer) and three coats of paint on structural steel after erection, if the sections are not
galvanised. Any part of assembly below ground shall be painted with three coats of red lead paint.

810.3.3. Splices and end connections shall be of the type and designs specified or shown on the plans
and shall be of such strength as to develop full design strength of the rail elements.

810.4. Installation of Posts

810.4.1. Holes shall be dug or drilled to the depth indicated on the plans or posts may be driven by
approved methods and equipment, provided these are erected in proper position and are free from
distortion and burring or any other damage.

810.4.2. All post holes that are dug or drilled shall be of such size as will permit proper setting of the
posts and allow sufficient room for backfilling and tapping.

8I0.4.3. Holes shall be backfilled with selected earth or stable materials in layers not exceeding 100
mm thickness and each layer shall be thoroughly tamped and rammed. When backfilling and tamping
are completed, the posts or anchors shall be held securely in place.

810.4.4. Post holes that are drilled in rock and holes for anchor posts shall be backfilled with
concrete.

810.4.5. Posts for metal beam guardrails on bridges shall be bolted to the structure as detailed on the
plans. The anchor bolts shall be set to proper location and elevation with templates and carefully
checked.
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810.5. Erection

810.5.1. All guardrail anchors shall be set and attachments made and placed as indicated on the plans
or as directed by the Engineer.

810.5.2. All bolts or clips used for fastening the guardrail or fittings to the posts shall be drawn up
tightly. Each bolt shall have sufficient length to extend at least 6 mm through and beyond the full nut,
except where such extensions might interfere with or endanger traffic in which case the bolts shall be
cut off flush with the nut.

810.5.3. All railings shall be erected, drawn and adjusted so that the longitudinal tension will be
uniform throughout the entire length of the rail.

810.6. Tolerance

The posts shall be vertical with a tolerance not exceeding 6 mm in a length of 3 metre. The railing
barrier shall be erected true to line and grade.

810.7. Measurements for Payment

810.7.1. Metal beam railing barriers will be measured by linear metre of completed length as per
plans and accepted in place. Terminals/ anchors of various types shall be paid for by numbers.

810.7.2. No measurement for payment shall be made for projections or anchors beyond the end posts
except as noted above. Furnishing and placing anchor bolts and/ or devices for guard rail posts on
bridges shall be considered incidental to the construction and the costs thereof shall be included in
the price for other items of construction.

810.7.3. No measurement for payment will be made for excavation or backfilling performed in
connection with this construction.

810.8. Rate

The Contract unit rate shall include full compensation for furnishing of labour, materials, tools,
equipment and incidental costs necessary for doing all the work involved in constructing the metal
beam railing barrier complete in place in all respects as per these Specifications.

811. ROAD TRAFFIC SIGNALS

811.1. General

The traffic signal, its configuration, size and location shall be in accordance with IRC: 93 and IS:
7537 and as shown in the drawings or as directed by the Engineer. Prior to installation of signals, the
Contractor shall submit to the Engineer, for approval, detailed proposals showing the signal type,
sizes, paint and structural details of the signal posts including control system.

811.2. Operation

The traffic signals shall have a microprocessor-based controller capable of operating the signals in
the following modes: automatic, amber flashing, and manual. There shall be a system of interlocking
to prevent conflicting signals from being displayed at the same time. The controller shall be fully
programmable, so that signal plans (timings, phasing, signal linking, etc) can be easily altered after
installation. The controller shall monitor the operation of the signals, and when a fault, such as a
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lamp failure, is detected it shall automatically switch the signals to amber flashing, or, in the event of
a major failure, to OFF.

811.3. Materials

The various materials and fabrication thereof shall conform to the following:

811.3.1. Signal foundation: The signal foundations shall be constructed as per Specifications given
in Clause 13 of IRC: 93 or as shown in the drawings.

811.3.2. Constructional requirements: The constructional requirements for the post, signal head,
signal lamp, visor, supports for overhead mounted signals, equipment housing, locks, inter-
connecting cables, earthing, mains termination, controller, electrical components, power pack, etc.,
shall conform to relevant Clauses of IS: 7537, unless otherwise stated in IRC: 93. The signal
installation, including equipment cabinets, posts, etc., shall be corrosion-proofed, either by the use of
corrosion-resistant materials, or by treatment. It shall also be dust-proof, weather-proof and resistant
to deterioration through the action of direct sunlight. The signal installation together with the
attachment of a backing board shall be capable of withstanding wind velocities of up to 160km/h in
any direction, and temperatures over a range of 00C to 700C. It shall also be designed and protected
so as to minimise problems through casual damage and theft. The signal lamps and their
components shall be adequately supported to withstand mechanical shock and vibration from high
winds and other sources. All posts shall be made of galvanised iron, suitably painted. Cables shall
be laid underground in ducts

811.3.3. Optical requirements: LED (light emitting diode) lamps shall be used. The standard
signal lamps (red, green, amber) shall be 300mm in diameter. The red and amber signal lamps shall
contain a minimum of 150 LEDs. The green arrow signal lamp shall contain a minimum of 50
LEDs. The minimum luminous intensity of the red lamp shall be 40 candelas when measured at
12.50 vertical and horizontal viewing angles. Arrangement of lamps, illumination of lamps, visibility
and shielding of signals, etc., shall be as per relevant Clauses of IRC: 93 and IS: 7537.”

8.11.3.4. Power supply: The signals shall be powered either by mains electricity or a solar power
pack, as specified in the Bill of Quantities or on the Drawings. Where a solar power pack is to be
used it shall be capable of providing sufficient power to operate the signals for three days of low light
conditions. The battery shall be a sealed maintenance-free unit having a minimum working life of
two years.

811.4. Tests

Tests shall be carried out on all components of the traffic signal including tests on the performance of
the complete system as per relevant Clauses of IRC: 93 and IS: 7537. All LED lamps shall be
switched on for a minimum of 24 hours and any that fail during this time shall be rejected.

811.5. Maintenance of Traffic Signals

It shall be the responsibility of the Contractor to provide for the maintenance of the signal system
throughout the warranty period of five years after installation, as per Clause 18 of IRC: 93. The
Contractor shall repair minor faults within 6 hours of their being reported to them, and major faults
within 24 hours.
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811.6. Measurements for Payment

The measurement for traffic signalisation system shall be by unit for complete work as specified and
as per drawings for complete road junction.

811.7. Rate

The Contract unit rate for the traffic signalisation system as a whole shall be payment in full
compensation for furnishing all labour, materials, tools, equipment for preparing, supplying, fixing at
site, testing and maintenance throughout warranty period and all other incidental costs necessary to
complete and maintain the work to these Specifications.

812. ROAD STUDS (RAISED PAVEMENT MARKERS)

812.1. General

Road studs shall be designed to provide effective, long-lasting visibility at night. They shall be
durable and incorporate abrasion-resistant retro-reflective lenses and be suitable for installation on
asphalt and cement concrete road surfaces. They shall show white, red or yellow colour and be uni-
directional or bi-directional as shown on the Drawings, or in the Bill of Quantities, or as otherwise
directed by the Engineer.

812.2. Materials

Road studs shall conform to ASTM D4280 type "H". Each retro-reflective lens element shall be not
less than 10 sq. cm in area and shall be of a corner cube micro prismatic type with an abrasion-
resistant coating or protective layer. The minimum coefficient of retro-reflection shall be as
indicated in Table 800-5.

TABLE 800-5 ACCEPTABLE MINIMUM COEFFICIENT OF RETRO-REFLECTION FOR

ROAD STUDS (millicandelas per lux)
Observation Entrance White Yellow Red
Angle Angle
0.2 0 279 167 69
0.2 20 112 67 28

The Contractor shall supply a certificate from an independent laboratory to the effect that the stud
has been tested and meets the standard.

The body of the stud shall be made of moulded plastic or metal alloy, and shall be able to withstand
heavy loads and impacts. The studs shall not project more than 20 mm above the level of the
surrounding road surface.

The studs shall be designed for direct application to the road surface by means of special adhesive.

The Contractor shall supply a certificate from an independent laboratory to the effect that the stud
has been tested and meets the ASTM D 4280 standard for Luminous Intensity, Compressive Strength
and Abrasion. Prior to supplying the studs the Contractor shall submit samples to the Engineer for
approval.
Traffic Signs, Markings and Section 800
Other Road Appurtenances

812.3. Application

Road studs shall be fixed in the positions indicated on the Drawings or as otherwise directed by the
Engineer. The road studs shall be fixed to the road surface by means of an approved adhesive, in
accordance with the manufacturers instructions. Sufficient adhesive shall be used to give complete
coverage of the contact area and to provide a slight excess. The road studs shall be pressed down on
the prepared area and all excess adhesive pressed out. The excess adhesive shall then be removed
immediately with a suitable solvent. The studs shall be protected against impact until the adhesive
has hardened. Before fixing, the surface shall be thoroughly clean and dry. Road studs shall not be
applied to new asphalt surfacing until the surfacing has been opened to traffic for a period of not less
than 14 days. Road studs must not be applied over thermoplastic or paint road markings.

812.4. Warranty and Durability

The Contractor shall obtain from the manufacturer a two-year 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 road stud shall
also be given by the Contractor who carries out the work of fixing the studs. Studs which become
displaced, damaged, get worn out or lose their reflectivity shall be replaced by the contractor at his
own cost

812.5 Measurement for Payment

The measurement shall be made in numbers of road studs fixed at site

812.6 Rate

The Contract unit rate for road studs shall be payment in full for all materials, labour and tools
required for supplying and fixing of road studs and all other incidental costs for completing the work
to the specifications.

815. PAINTING CONCRETE STRUCTURES

815.1 General

The work shall consist of painting concrete structures such as kerbs and walls. Before applying the
paint, surface shall be cleaned to remove any dust and any other foreign material. In the case of
existing surface having extensive fungus, the surface shall be cleaned thoroughly with Bio-wash.
After cleaning the surface one coat of either sealer or any cement-based primer shall be applied.
Subsequently two coats of elasteromeric paint shall be applied as shown on the drawing or as
otherwise directed by the Engineer.

815.2 Measurement for Payment

The measurement shall be made in square metre of painted surface.

Base and Surface Courses Section 500
(Bituminous)

500. BITUMINOUS WORK

523 RUMBLE STRIPS

Unless directed otherwise rumble strips shall be constructed by fixing formwork to the road surface,
applying a Tack Coat, and then laying and compacting Pre-mix asphalt.

523.1 Pre-mix specification

This shall be a bituminous mixture of chippings and binder conforming to the specifications set out
below. The maximum size of chippings used shall not exceed that for nominal size 10 mm. The
grading shall be as shown in Table 500-23 of the MOST specification aggregate gradation for
bituminous concrete:

The residual binder content (% by Mass of Total Mix) shall be 4.3 - 5.5. Some increase beyond this
range of residual binder content may be permitted for aggregates having unusually high absorption
characteristics.

The Bitumen emulsion shall be Cationic Medium Setting ( MS) grade to the requirement of IS 8887
and having a bitumen content of 6.0% minimum by weight.

523.2 Methods of Producing Pre-mix

Pre-mix should preferably be manufactured at a commercial manufacturing plant, but it may also be
mixed in an approved mechanical mixer. The supplier’s methods of production shall be such as to:
(i) limit segregation of the Pre-mix and loss of materials:
(ii) supply a homogeneous product; and
(iii) result in the required workability and cohesion of the Pre-mix, which is compatible with the
placing equipment, to achieve the specified compaction.
Temperatures of materials shall be maintained in a range sufficient to ensure a homogeneous mix
without causing deleterious effects to binder through overheating.

523.3 Storage of Pre-mix

Pre-mix shall be stored where possible under cover from weather and on a concrete slab and/or in an
appropriate storage bin. Stockpiles shall be constructed in such a manner that no compaction, other
than by weight of the material itself, will result. No equipment of any kind shall be run over the
surface of the stockpile.

523.4 Transport of Pre-mix

The Pre-mix shall be discharged into motor trucks, the bodies of which shall be kept thoroughly
clean and coated with a thin film of release agent to prevent the mix sticking to the body of the truck.
The bituminous mix shall be kept free from contamination and segregation during transportation.
During transport the Pre-mix shall be covered with a suitable cover, held down securely.

523.5 Preparation of road surface

All loose material and foreign matter shall be removed by thoroughly brushing with brooms,
washing or by other acceptable means. All hardened mud or other foreign matter shall be loosened
by scraping and then be swept off. The debris shall be deposited away from the surface to be treated.
Any defect in the surface shall be corrected and no tack coat shall be applied until the Engineer has
approved the surface.
Base and Surface Courses Section 500
(Bituminous)

523.6 Fixing of formwork

Formwork shall be fixed firmly to the surface to conform to the width and height of the rumble strip
specified.

523.7 Tack coating

Once the surface has been prepared an approved bitumen emulsion shall be thinly applied by hand at
the rate 0.2-0.25kg/m2.

523.8 Laying and compaction of Pre-mix

Immediately after the tack coat has been applied and approved, the mixture shall be spread or laid to
line and level without segregation. Compaction shall be done by a pedestrian vibratory roller, power
rammer, a vibratory plate compactor or a hand tamper approved by the Engineer. The maximum
height of the strip shall not exceed 20 mm inclusive of any paint or thermoplastic marking that may
be applied later.
Whilst the Pre-mix is still workable the formwork shall be removed and the edges of the Pre-mix
rounded by compaction so that there is no vertical or near-vertical face exceeding 6 mm in height.

523.9 Traffic
Traffic shall not be allowed to run over the rumble strips until the following day.

523.10 Signing
The construction of rumble strips shall not start until appropriate permanent warning signs have been
installed.

523.11 Measurements for Payment

Rumble strip made of premix shall be measured in Linear metre.

523.12 Rate
The contract unit rate for rumble strip shall be payment in full of providing, laying and compacting
Rumble strip to the required grade and line including full compensation for all material, labour, tools,
equipment and other incidentals to complete the work
Base and Surface Courses Section 500
(Bituminous)

524 ROAD HUMPS

Road humps shall be of the type and design indicated on the Drawings and shall be fixed in the
positions indicated and approved by the Engineer. Unless directed otherwise road humps shall be
constructed by laying and compacting hot pre-mix.

524.1 Pre-mix specification

This shall be a bituminous mixture of chippings and binder conforming to the specifications set out
below. The grading shall be as shown for Grading 2 in Table 500-18 of the MOST specification for
composition of bituminous concrete pavement layers.
The residual binder content and the bitumen grade shall be as shown for Grading 2 in Table 500-18
of the MOST specification.

524.2 Methods of Producing Pre-mix

Pre-mix should preferably be manufactured at a commercial manufacturing plant, but it may also be
mixed in an approved mechanical mixer. The supplier’s methods of production shall be such as to:
(i) limit segregation of the Pre-mix and loss of materials:
(ii) supply a homogeneous product; and
(iii) result in the required workability and cohesion of the Pre-mix, which is compatible with the
placing equipment, to achieve the specified compaction.
Temperatures of materials shall be maintained in a range sufficient to ensure a homogeneous mix
without causing deleterious effects to binder through overheating.

524.3 Storage of Pre-mix

Pre-mix shall be stored where possible under cover from weather and on a concrete slab and/or in an
appropriate storage bin. Stockpiles shall be constructed in such a manner that no compaction, other
than by weight of the material itself, will result. No equipment of any kind shall be run over the
surface of the stockpile.

524.4 Transport of Pre-mix

The Pre-mix shall be discharged into motor trucks, the bodies of which shall be kept thoroughly
clean and coated with a thin film of release agent to prevent the mix sticking to the body of the truck.
The bituminous mix shall be kept free from contamination and segregation during transportation.
During transport the Pre-mix shall be covered with a suitable cover, held down securely.

524.5 Preparation of road surface

All loose material and foreign matter shall be removed by thoroughly brushing with brooms,
washing or by other acceptable means. All hardened mud or other foreign matter shall be loosened
by scraping and then be swept off. The debris shall be deposited away from the surface to be treated.
Any defect in the surface shall be corrected. In order to key in the hump to the adjoining pavement a
500mm by 30mm deep trench shall be excavated across the full width of the existing pavement at the
limits of the hump, or as otherwise indicated on the Drawings. Work shall not proceed until the
Engineer has approved the surface.

524.6 Profile template

It is essential that the hump be constructed to exactly the correct profile. Two identical profile
templates shall be constructed from sawn timber to the dimensions indicated on the Drawings.

524.7 Tack coating

Once the surface has been prepared an approved bitumen emulsion shall be thinly applied by hand at
the rate 0.2-0.25kg/m2.
Base and Surface Courses Section 500
(Bituminous)

524.8 Laying and compaction of Pre-mix

The hump shall be built up using successive layers of Pre-mix. Each layer shall be no more than
50mm thick and shall be compacted before adding the next layer. The first layer shall be spread
immediately after the tack coat has been applied and approved. Compaction shall be done by a
pedestrian vibratory roller, power rammer, or a vibratory plate compactor approved by the Engineer.
The profile shall be checked before spreading the next layer.
A run-on fillet shall be provided to the smooth the transition from the pavement to the hump.

524.9 Traffic
Traffic shall not be allowed to run over the road humps for three hours after the final compaction.

524.10 Signing
The construction of road humps shall not start until the appropriate permanent warning signs have
been installed.

524.11 Measurements for Payment

Road hump made of Pre-mix shall be measured in Linear Metre

524.12 Rate
The contract unit rate for road humps shall be payment in full of providing, laying and compacting
road humps to the required profile including full compensation for all material, labour, tools,
equipment and other incidentals to complete the work