Road Spec Volume - II PDF

MUNICIPAL CORPORATION OF
GREATER MUMBAI
ROAD DEPARTMENT
VOLUME-II
TECHNICAL SPECIFICATIONS FOR
ROAD WORKS
2013
ROADS SCHEDULE 2013
Foreword
Ever since establishment of Bombay Municipal Corporation (now Municipal Corporation of Greater
Mumbai) in 1888 by the erstwhile British rulers in India, in the last 125 years of the history of its
existence MCGM has catered to every aspect of the citizen of Mumbai that can be conceived of.
Look to heritage buildings like Victoria Terminus (Chhatrapati Shivaji Terminus), Office of Municipal
Corporation, Dadabai Naoroji Road, Dr. Babasaheb Ambedkar Road, Marine Drive (Netaji Subhash
Road), Prince of Wales Museum, Gateway of India, Malabar Hill Reservoir, Nair Hospital, Lokmanya
Tilak Hospital, KEM Hospital etc which are the service centers for the citizens. Municipal Services
have also been provided in the suburban and extended suburban areas merged in 1950 & 1957
respectively. The obligatory duties are performed well but still there is need to improve in quantity
and quality of services to be provided to the citizens.
Ethical governance and righteous work culture will certainly bring positive changes in design and
implementation of projects. One may take an example of the first Municipal Head Quarter Building,
that was completed in year 1893, in four years, designed by F W Stevens and the execution part
was dealt by Project Engineer Shri Rao Saheb Sitaram Khanderrao Vaidya, who executed the
project of 77.70m high structure and saved Rs.68,000/- as against estimated cost of Rs. 11.80
Lakhs.
The need is to work with precision and accuracy. There shall be harmony between planning and
execution so as to evolve best economics with focused goals.
MCGM is one of the largest local self governments in the Asian Continent. In observance of historic
traditions of strong civic activism, with the change in time and living conditions to match with the
urbanization, MCGM has focused in providing variety of engineering services viz, storm water drain,
sewerage, water supply, roads, bridges, solid waste management, environmental services. Beside
this, the Corporation is also providing dedicated services in the Health sector by establishing Major
and Peripheral hospitals.
To update and modernize the mechanism being used for working on related projects from the stage
of conceptualization to execution, the need was realized to revise prevailing “Schedule Of Rates”
along with specifications which were in operation with various departments and being prepared
individually as per their need and revised at different span of time, resulting into various anomalies.
To overcome all these, it was essential to revise the schedule of rates, not only with simple
mechanized revision but incorporating major changes to keep up with the pace of urbanization,
civilization, construction techniques / mechanization and voluminous developments by restructuring
Municipal Corporation of Greater Mumbai

ROADS SCHEDULE 2013
items in the schedule to cover all requirements. This exercise would provide comfort with designs
and field necessities and will assist in effective checks on creation of extra items during execution.
A conscious decision has been taken to prepare Unified Schedule of Rates to keep pace with the
changing time; a first step forward in this direction. Since long time, there have been demands made
by the stake holders like Municipal Engineers and Contractors to remove non-uniformity, anomalies
and discrepancies in various schedules of rates for work contracts of various departments of MCGM.
Every department had its own expertise and way of functioning which got reflected in its independent
schedule of rates, which however, had no linkage with the fair market rates and schedules of other
departments, resulting into extra items and fair rates. In place of earlier 9 Schedule Of Rates, the
Unified Schedule of Rates is an effort and seeks to rectify the defects, discrepancies and non
uniformities which will provide ease and accuracy of estimation to the Engineers.
In view of the enormous and voluminous nature of work, keeping time frame in perspective and
above all, to ensure professionalism, the work of preparation of Unified Schedule of Rates (USR)
was awarded to the eminent consultants M/s. TATA Consulting Engineers Ltd. M/s. TATA Consulting
Engineers Ltd were directed to conduct a integrated factual market research for major materials from
stockists/manufacturers/dealers and to study schedules of rates of Govt. bodies like C.P.W.D.,
P.W.D. etc The new Rate Analysis are based on Factual Market research done by M/s.TATA
Consulting Engineers Ltd.
The anomalies in rate are minimized after extensive market research and collection of quotations
from reputed large scale stockists/dealers, and also after comparison with rates of CPWD, PWD etc.
The Unified Scheduled of Rates is linked with its comprehensive specifications of basic important
activities so as to have clarity in execution. These specifications follow a chronology of general
scope of the item, material required, processing of material, construction operation, finishing and
mode of measurement. Rigid Standard Operating Procedures (SOPs) and complete control on
processes will certainly satisfy quality parameter. The need for checking the quality of construction is
quite apparent and shall be ensured throughout the construction process. To achieve this, the
Unified Scheduled of Rates incorporates quality assurance procedures.
All the rates are also linked to their detailed specifications and wherever required, with drawings.
Though there are about 12500 items, every item is now given a Unique Code No. which will
eliminate the repetition.
It has been our endeavor to include all the necessary modern materials and technologies in Unified
Schedule of Rates, for example, the concept of green building, which will go a long way to have
control on creation of extra items and fair rates. A salient feature of this Unified Schedule of Rates is
'Starring of items' specified categorically which can be used only at certain works or locations.

ROADS SCHEDULE 2013
Another salient feature is 'Dynamic Rate System' which will be based on study of data base of
quantities and bidding prices of awarded contracts on the basis of which necessary corrections can
be applied to the Unified Schedule of Rates at specified intervals. The MCGM will be now be in a
position to revise the Unified Scheduled of Rates every year, after incumbency period of M/s.TATA
Consulting Engineers Ltd of one year, to work with and correct the system as and when necessary.
I am sure that this 'Unified Scheduled of Rates' will be a milestone in civic governance by MCGM.
This publication shall be of great help and guidance to the officers engaged in the project work of
MCGM.
A.M.C. (Project) Municipal Commissioner

STANDARD SPECIFICATIONS FOR ROAD WORKS SP-RW
MCGM STANDARD SPECIFICATION FOR ROADS

INDEX
Part-I
PAGE
SP-RW- DESCRIPTION
NO.
10 Interpretations & Abbreviations 6
20 New Technologies 7
30 Arrangement of Traffic during Construction 7
40 Precautions for Safeguarding the Environment 9
50 Site Details 10
51 Blank
52 Blank
53 Site Information
54 Setting Out
55 Public Utilities
56 Methodology and Sequence of Work
57 Approval of Materials
58 Use of Surfaces by Construction Traffic
60 Measurements & Rates 11
61 General Rules for Measurements
62 Scope of Rates for Different Items of Work
Part-II
100 Road & Drainage Excavation 14
120 Sub-Surface Drains 20
130 Treatment to Sub-Soil 23
131 Mechanically Stabilised Soil
132 Lime Treated Soil
133 Sand Drains
134 Stone Columns
135 Pre fabricated Vertical (Band) Drains
136 Treatment to Water Mains I Sewer Line Trenches
140 Excavation for Structures 28
150 Embankment & Sub-Grade Construction 29
151 Embankment Construction
152 Construction of Embankment & Sub-Grade under
Special Conditions
153 Rock Fill Embankment
154 Stabilised Soil Sub-Grade Constructions
MUNICIPAL CORPORATION OF GREATER MUMBAI Page 1

PAGE
SP-RW- DESCRIPTION
NO.
155 Embankment Construction with Fly ash
200 Granular Sub-Base I Base 42
210 Granular Sub Base 34
220 Base - Water Bound Macadam 44
230 Base - Open Graded Granular Sub Base with Geo-Cell

52
Confinement
235 Base - Crushed Cement Concrete 52
240 Base - Wet Mix Macadam 54
260 Geo-Synthetic Fabric 57
300 Bituminous Mixes 59
301 Properties of Bitumen
302 Properties of Bituminous Mixes
303 Types of Bitumen
304 Grades of Bitumen
305 Bitumen Emulsion
306 Cutback Bitumen
310 Common Materials & Items 63
311 Anti-stripping Compound
312 Modified Binder
313 Prime Coat
314 Tack Coat
315 Paving Fabrics
316 Stress Absorbing Membrane & Stress Absorbing
Membrane Inter Layer
317 Bituminous Cold Mixes
318 Bituminous Hot Mixes
350 Bituminous Base 89
351 Bituminous Macadam
352 Bituminous Penetration Macadam
354 Dense Graded Bituminous Macadam
360 Wearing Coat 102
361 Open Graded premix Surfacing
362 Closed Graded Premix Surfacing
363 Semi Dense Bituminous Concrete
364 Bituminous Concrete
365 Mastic Asphalt
370 Seal Coat 117

PAGE
SP-RW- DESCRIPTION
NO.
375 Slurry Seal 118
380 Recycling of Bituminous Pavement 121
400 Cement Concrete 127
410 Structural Concrete
425 Ready Mix Concrete
430 Paving Tiles
440 Paver Blocks
450 Dry Lean Cement Concrete
500 Road Surface Drainage Components 142
510 Cement Concrete Kerb & Kerb with Channel 142
550 Manholes 142
560 Water Entrances 144
570 Footpaths, Medians, Shoulders, Islands & Road Arboriculture 144
571 Footpaths, Medians & Road Arboriculture
572 Shoulders & Islands
573 Separators
580 Road Markings & Street Furniture 148

590 Reinforced Earthwork 149
Part-III
600 Quality Control 153
610 General 153
611 Horizontal Alignments
612 Longitudinal Alignment
613 Surface Irregularity
614 Rectification
620 Quality Control Test During Construction 154
621 General
622 Tests on Earthwork for Embankment Construction
- Borrow Material
623 Plasticity Tests
624 Tests on Sub-Bases & Bases
625 Tests on Bituminous Construction
626 Quality control tests for Dry lean concrete

MCGM
Technical Specifications for Roads
10 Interpretations & Abbreviations
Interpretations
Order of Priority
Specifications indicated in BOQ
Technical Specifications outlined in MCGM Standard Specifications

Drawings
Specifications of MORT & H - Latest Edition till 30 days before the final
date of submission of the tender
Indian Road Congress Specifications - Latest Edition till 30 days before

the final date of submission of the tender
Bureau of Indian Standard Specifications - Latest Edition till 30 days

before the final date of submission of the tender
British Standard Specifications - Latest Edition till 30 days before the final
date of submission of the tender
The Asphalt Institute, U.S.A. Publication of Specifications - Latest Edition

till 30 days before the final date of submission of the tender
11 Abbreviations
AASHTO : American Association of State Highway and Transportation
Officials
ASTM : American Society for Testing and Materials
BS : British Standard published by the British Standards Institution
BOQ : Bill of Quantities forming part of the contract
CBR: California Bearing Ratio
IRC : Indian Road Congress
IS : Indian Standard published by the Bureau of Indian Standards
WC : Water Cement Ratio
CRRI : Central Road Research Institute
UCS : Unconfined Compressive Strength
WBM : Water Bound Macadam
SAM: Stress Absorbing Membrane
SAMI : Stress Absorbing Membrane Interlayer
MoRTH: Ministry of Road Transport and Highways

20.0 New Technologies I Materials

20.1 New Technologies I Materials are the one that are not incorporated in this or
MoRTH Standard Specifications
New technologies can make use of Newly Invented / patented materials,
equipment or machinery. It can also make use of conventional materials /
equipment with innovative design. In case of New Patented Material a warrantee
from the manufacturer! Contractor for three years and certification from two
Institute like Central Road Research Institute, Indian Institute of Technology for its
acceptance for field application shall be essential. In case of innovative designs, it
is essential for the contractor to indemnify the corporation against loss due to
failure in addition to certification from an Institute like Central Road Research
Institute(CRRI).
20.2 The Engineer, on satisfactory completion of above formalities, will allot a suitable
stretch of road for mock up purposes. Its performance shall be monitored by the
Engineer and Quality Control Cell for one year. Based on the performance, a
decision will be taken regarding qualification of the material design for field
application. The successful performance will qualify Technology Materials to be
incorporated as provisional specifications as alternative to these standard
specifications. The product shall be under observation for five years during which
its performance shall be monitored. On successful completion of the period with
extensions, if any, the product shall be included in the Standard Specifications.
20.3 Measurements & Payment
The unit of measurements shall be as per mutual agreement between the
contractor and the Engineer.
20.4 Rate
The rate shall be derived from data given by the supplier / contractor.
30.0 Arrangement for Traffic During Construction
30.1 General: The Contractor shall at all time carry out work on the roads in a manner
creating least interference to the flow of traffic while consistent with the
satisfactory execution of the same. For all works involving improvements to the
existing roads, the Contractor shall, in accordance with the directives of the
Engineer, provide and maintain, during execution of the work, a passage for
traffic either along a part of the existing carriageway under improvement, or
along a temporary diversion constructed close to the roads. The Contractor shall
take prior approval of the Engineer regarding traffic arrangements during
construction.
30.2 Passage of Traffic along a part of the Existing Carriageway under Improvement:
For widening / strengthening existing carriageway where part width of the
existing carriageway is proposed to be used for passage of traffic, treated
shoulders shall be provided on the side on which work is not in progress. The
treatment to the shoulder shall consist of providing at least 150mm thick granular
base course covered with bituminous surface dressing in a width of at least 1.5m
and the surface shall be maintained throughout the period during which traffic
uses the same to the satisfaction of the Engineer.
In case of widening existing two-lane to four-lane, the additional two lanes would
be constructed first and the traffic diverted to it and only thereafter the required
treatment to the existing carriageway would be carried out. However, in case
where on the request of the Contractor, work on existing two-lane carriageway is
allowed by the Engineer with traffic using part of the existing carriageway,
stipulations as in Para above shall apply. After obtaining permission of the

Engineer, the treated shoulder shall be dismantled, the debris disposed of and
the area cleared as per the direction of the Engineer.
30.3 Passage of Traffic along a Temporary Diversion: In stretches where it is not
possible to pass the traffic on apart width of the carriageway, a temporary
diversion shall be constructed with 7m carriageway and 2.5m earthen shoulders
on each side (total width of roadway 12m) with the following provision for road
crust in the 7m width:
i. 200mm (compacted) granular sub base;
ii. 225mm (compacted) granular base course; and
iii. Premix carpet with Seal Coat / Mix Seal Surfacing.
The alignment and longitudinal section of diversion including junctions and
temporary cross drainage provision shall be as approved by the Engineer.
30.4 Traffic Safety and Control: The Contractor shall take all necessary measures for
the safety of traffic during construction and provide, erect and maintain such
barricades, including signs, markings, flags, lights and flagmen as may be
required by the Engineer for the information and protection of traffic approaching
or passing through the section of the highway under improvement. Before taking
up any construction, an agreed phased programme for the diversion of traffic on
the highway shall be drawn up in consultation with the Engineer.
The barricades erected on either side of the carriageway / portion of the
carriageway closed to traffic, shall be of strong design to resist violation, and
painted with alternate black and white stripes. Red lanterns or warning lights of
similar type shall be mounted on the barricades at night and kept lit throughout
from sunset to sunrise. At the points where traffic is to deviate from its normal
part (whether on temporary diversion or part width of the carriageway) the
channel for traffic shall be clearly marked with the aid of pavement markings,
painted drums or a similar device to the directions of the Engineer. At night, the
passage shall be delineated with lanterns or other suitable light source. One-way
traffic operation shall be established whenever the traffic is to be passed over
part of the carriageway inadequate for two-lane traffic. This shall be done with
the help of temporary traffic signals or flagmen kept positioned on opposite sides
during all hours. For regulation of traffic, the flagmen shall be equipped with red
and green flags and lanterns / lights.
On both sides, suitably regulatory / warning signs as approved by the Engineer
shall be installed for the guidance of road users. On each approach, at least two
signs shall be put up, one close to the point where transition of carriageway
begins and the other 120m away. The signs shall be of approved design and of
reflectory type, if so directed by the Engineer.
30.5 Maintenance of Diversions and Traffic Control Devices: Signs, lights, barriers
and other traffic control devices, as well as the riding surface of diversions shall
be maintained in a satisfactory condition till such time they are required as
directed by the Engineer. The temporary travelled way shall be kept free of dust
by frequent applications of water, if necessary. Wardens for monitoring traffic as
per requirement of traffic police shall be provided by the contractor at his own
cost.
30.6 The minimum curing time required during which the traffic is to be kept off the
surface for different types of layers / materials shall be as mentioned below:
a) Cement / Lime Stabilised Surfaces: Seven Days
b) Earthen Embankment: One Day
c) Granular Layer: Three Days

d) Bituminous Cold Mixes / Seal Coat : Twelve Hours for heavy vehicles and
Eight hours for light vehicles.
e) Bituminous Hot Mixes: Twenty Four Hours for heavy vehicles and eight
hours for light vehicles
f) Slurry Seals: Four Hours
30.7 Measurements for Payment and Rate: All arrangements for traffic during
construction including provision of temporary cross drainage structures, if
required, and treated shoulder as described in clause 30.2 including their
maintenance, dismantling and clearing debris, where necessary, shall be
considered as incidental to the works and shall be the Contractor's responsibility.
The construction of temporary diversion including temporary cross drainage
structures as described in clause 30.3 shall be measured in linear metre and the
unit contract rate shall be inclusive of full compensation for construction
(including supply of material, labour, tools, etc.), maintenance, final dismantling,
and disposal.
40.0 Precautions for Safeguarding the Environment:
40.1 General: The Contractor shall take all precautions for safeguarding the
environment during the course of the construction of the works. He shall abide by
all laws, rules and regulations in force governing pollution and environmental
protection that are applicable in the area where the works are situated.
40.2 Borrow pits for Embankment Construction: Borrow pits shall not be dug in the
right-of-way of the road.
40.3 Quarry Operations: The Contractor shall obtain materials form quarries only after
the consent of the Forest Department or other concerned authorities is obtained.
The quarry operations shall be undertaken within the purview of the rules and
regulations in force.
40.4 Control of Soil Erosion, Sedimentation and Water Pollution: The Contractor shall
carry out the works in such a manner that soil erosion is fully controlled, and
sedimentation and pollution of natural water courses, ponds, tanks and
reservoirs are avoided. The stipulations in Clause 306 of MORT&H.
Specifications shall govern.
40.5 Pollution from Hot-Mix Plants and Batching Plants: Bituminous hot-mix plants
and concrete batching plants shall be located sufficiently away from habitation,
agricultural operations or industrial establishments. The Contractor shall take
every precaution to reduce the levels of noise, vibrations, dust and emissions
from his plant and shall be fully responsible for any claims for damages caused
to the owners of property, fields and residences in the vicinity.
40.6 Substances Hazardous to Health: The Contractor shall not use or generate any
materials in the works which are hazardous to the health of persons, animals or
vegetation. Where it is necessary to use some substances which can cause
injury to the health of workers, the Contractor shall provide protective clothing or
appliances to his workers.
40.7 Use of Nuclear Gauges: Nuclear gauges shall be used only where permitted by
the Engineer. The nuclear gauges shall be calibrated as per the conditions laid
down in the contract document. The Contractor· shall provide the Engineer with a
copy of the regulations governing the safe use of nuclear gauges he intends to
employ and shall abide by such regulations.
40.8 The Contractor must take all reasonable steps to minimize dust nuisance during
the construction of the works.

40.9 All existing roads used by vehicle of the Contractor or any of his subcontractors
or suppliers of materials or plant, and similarly any new roads which are part of
the works and which are being used by traffic, shall be kept clean and clear of all
dust/mud or other extraneous materials dropped by the said vehicles or their
tyres. Similarly, all dust/mud or other extraneous materials from the works
spreading on these roads shall be immediately cleared by the Contractor.
40.10 Clearance shall be effected immediately by manual sweeping and removal of
debris, or if so directed by the Engineer, by mechanical sweeping and clearing
equipment, and all dust, mud and other debris shall be' removed entirely from the
road surface. Additionally, if so directed by the Engineer, the road surface shall
be hosed or watered using suitable equipment.
40.11 Any structural damage caused to the existing roads by the Contractor's
construction equipment shall be made good without any extra cost.
40.12 Compliance with the foregoing will not relieve the Contractor of any responsibility
for complying with the requirements of any Authority in respect of the roads used
by him.
50.0 Site Details
53.0 Site Information:
53.1 The information about the site of work and site conditions in the Tender
Documents is given in good faith for guidance only but the Contractor shall
satisfy himself regarding all aspects of site conditions.
53.2 The location of the works and the general site particulars are as generally shown
on the Site plan I Index plan enclosed with the Tender Documents.
53.3 Whereas the right-of-way to the bridge sites I road works shall be provided to the
Contractor by the Engineer, the Contractor shall have to make his own
arrangement for the land required by him for site offices, labour camps, stores,
etc.
54.0 Setting Out:
54.1 The Contractor shall establish working Bench Marks related with the Town Hall
Reference Bench Mark (THD) in the area soon after taking possession of the
site. The Reference Bench Mark for the area shall be as indicated. The working
Bench Marks shall be at the rate of four per km and also at or near all drainage
structures, over-bridges and underpasses. The working Bench Marks I levels
should be got approved from the Engineer. Checks must be made on these
Bench Marks once every month and adjustments, if any, got agreed with the
Engineer and recorded. An up-to-date record of all Bench Marks including
approved adjustments, if any, shall be maintained by the Contractor and also a
copy supplied to the Engineer for his record.
54.2 The lines and levels of formation, side slopes, drainage works, carriageways and
shoulders shall be carefully set out and frequently checked, care being taken to
ensure that correct gradients and cross-sections are obtained everywhere.
54.3 In order to facilitate the setting out of the works, the centre line of the
carriageway or road must be accurately established by the Contractor and
approved by the Engineer. it must then be accurately referenced in a manner
satisfactory to the Engineer, every 50m intervals in plain and rolling terrains and
20m intervals in hilly terrain and in all curve points as directed by the Engineer,
with marker pegs and chainage boards set in or near the fence line, and a
schedule of reference dimensions shall be prepared and supplied by the
Contractor to the Engineer. These markers shall be maintained until the works
reach finished formation level and are accepted by the Engineer.

54.4 On construction reaching the formation level stage, the centre line shall again be
set out by the Contractor and when approved by the Engineer, shall be
accurately referenced in a manner satisfactory to the Engineer by marker pegs at
the outer limits of the formation.
54.5 No reference peg or marker shall be moved or withdrawn without the approval of
the Engineer and no earthwork or structural work shall be commenced until the
centre line has been referenced.
54.6 The Contractor will be the sole responsible party for safeguarding all survey
monuments, bench marks, beacons, etc. The Engineer will provide the
Contractor with the data necessary for setting out of the centre line. All
dimensions and levels shown on the drawings or mentioned in documents
forming part of or issued under the Contract shall be verified by the Contractor on
the site and he shall immediately inform the Engineer of any apparent errors or
discrepancies in such dimensions or levels. The Contractor shall, in connection
with the staking out of the centre line, survey the terrain along the road and shall
submit to the Engineer for this approval, a profile along the road centre line and
cross-sections at intervals as required by the Engineer.
54.7 After obtaining approval of the Engineer, work on earthwork can commence and
the profile and cross-sections shall form the basis for measurements and
payment. The Contractor shall be responsible for ensuring that all the basic
traverse points are in place at the commencement of the contract and if any are
missing, or appear to have been disturbed, the Contractor shall make
arrangements to reestablish these points. A "Survey File" containing the
necessary data will be made available for this purpose. If in the opinion of the
Engineer, design modifications of the centre line or grade are advisable, the
Engineer will issue detailed instruction to the Contractor and the Contractor shall
perform the modifications in the field, as required, and modify the ground levels
on the cross-sections accordingly as many times as required. There will be no
separate payment for any survey work performed by the Contractor. The cost of
these services shall be considered as being included in the cost of the items of
work in the Bill of Quantities.
54.8 The work of setting out shall be deemed to be a part of general works
preparatory to the execution of work and no separate payment shall be made for
the same.
54.9 Precision automatic levels, having a standard deviation of ±2mm per Km, and
fitted with micrometer attachment shall be used for all double run levelling work.
Setting out of the road alignment and measurement of angles shall be done by
using theodolite with traversing target, having an accuracy of one second.
Measurement of distances shall be done preferably using precision instruments
like Distomat.
55.0 Public Utilities:
55.1 Drawings scheduling the affected services like water pipes, sewers, oil pipelines,
cables, gas ducts etc. owned by various authorities including Public
Undertakings and Local Authorities included in the Contract Documents shall be
verified by the Contractor for the accuracy of the information prior to the
commencement of any work.
55.2 Notwithstanding the fact that the information on affected services may not be
exhaustive, the final position of these services within the works shall be
supposed to have been indicated based on the information furnished by different
bodies and to the extent the bodies are familiar with the final proposals. The
intermediate stages of the works are, however, unknown at the design stage,
these being dictated by the Contractor's methods of working. Accordingly, the

Contractors programme must take into account the period of notice and duration
of diversionary works of each body as given on the Drawings and: the Contractor
must also allow for any effect of these services and alterations upon the Works
and for arranging regular meetings with the various bodies at the
commencement of the Contract and throughout the period of the Works in order
to maintain the required co-ordination. During the period of the Works, the
Contractor shall have no objection if the public utility bodies vary their decisions
in the execution of their proposals in terms of programme and construction,
provided that, in the opinion of the Engineer, the Contractor has received
reasonable notice thereof before the relevant alterations are put in hand.
55.3 No clearance or alterations to the utility shall be carried out unless specially
ordered by the Engineer.
55.4 Any services affected by the Works must be temporarily supported by the
Contractor who must also take all measures reasonably required by the various
bodies to protect their services and property during the progress of the Works.
55.5 The Contractor may be required to carry out certain works for and on behalf of
the various bodies and he shall also provide, with the prior approval of the
Engineer, such assistance to the various bodies as may be authorized by the
Engineer.
55.6 The work of temporarily supporting and protecting the public utility services
during execution of the Works shall be deemed to be the part of the Contract and
no extra payment shall be made for the same.
55.7 The Contractor may be required to carry out the removal or shifting of certain
services I utilities on specified orders from the Engineer for which payment shall
be made to him. Such works shall be taken up by the Contractor only after
obtaining clearance from the Engineer and ensuring adequate safety measures.
56.0 Methodology and Sequence of Work
56.1 Prior to start of the construction activities at site, the Contractor shall, within 15
days after the date of the Letter of Acceptance, submit to the Engineer for
approval, the detailed construction methodology including mechanical equipment
proposed to be used, sequence of various activities and schedule from start to
end of the project. Programme relating to pavement and shoulder from start to
end of the project. Programme relating to pavement and shoulder construction
shall be an integrated activity to be done simultaneously in a co-ordinated
manner. The methodology and the sequence shall be so planned as to provide
proper safety, drainage and free flow of traffic.
57.0 Approval of Materials
57.1 Approval of all sources of material for work shall be obtained in writing from the
Engineer before their use on the project.
58.0 Use bf Surfaces by Construction Traffic
Ordinarily, no construction traffic shall be allowed on pavement under
construction unless authorized by the Engineer. Even in that case the load and
intensity of construction traffic should be so regulated that no damage is caused
to the sub-grade or pavement layers already constructed. Where necessary
service roads shall be constructed for this purpose and the same shall be
considered as incidental to the work.
The wheels or tracks of plant moving over the various pavement courses shall be
kept free of deleterious materials.
Bituminous base course shall be kept clean and uncontaminated as long as the
same remains uncovered by a wearing course or surface treatment. The only
traffic permitted access to the base course shall be that engaged in laying and

compacting the wearing course or that engaged on such surface treatment

where the base-course is to be blinded and I or surface dressed. Should the
base course or tack coat on the base course become contaminated, the
Contractor shall make good by clearing it to the satisfaction of the Engineer, and
if this is impracticable, by removing the layer and replacing it to Specification
without any extra cost.
60.0 Measurements & Rates
61.0 General Rules for the Measurement of Works for Payment
61.1 General: All measurements shall be made in the metric system. Different items of
work shall be measured in accordance with the procedures set forth in the
relevant sections read in conjunction with the General Conditions of Contract.
The same shall not, however, apply in the case of lump sum contracts.
All measurements and computations, unless otherwise indicated, shall be carried
nearest to the following limits:
a) length and breadth 10mm
b) height, depth or thickness of earthwork, 5mm
sub-grade, sub-bases, bases, surfacing
and structural members
c) areas 0.01 Sq. M.
d) cubic contents 0.01 Cu. M.
In recording dimensions of work, the sequence of length, width and height or
depth or thickness shall be followed.
61.2 Measurement of Lead for Materials: Where lead is specified in the Contract for
construction materials, the same shall be measured as described hereunder:
Lead shall be measured over the shortest practicable route and not the one
actually taken and the decision of the Engineer in this regard shall be taken as
final. Distances upto and including 100m shall be measured in units of 50m,
exceeding 100m but not exceeding 1 Km. in units of 100m and exceeding 1 Km.
in units of 500m, the half and greater than half of the unit shall be reckoned as
one and less than half of the unit ignored. In this regard, the source If material
shall be divided into suitable blocks and for each block, the distance from the
centre of the block to the centre of placing pertaining to that block shall be taken
as the lead distance.
61.3 Measurement of Pavement Thickness for Payment on Volume Basis: The
finished thickness of sub-base, base and bituminous courses to be paid on
volume basis shall be computed in the following manner:
Levels shall be taken before and after construction, at grid of points 10m centre
to centre longitudinally in straight reaches but 5m at curves. Transverse levels
shall be taken at an interval of 2 / 2.5 M as directed by the Engineer.
Suitable references for the transverse grid lines should be left in the form of
embedded bricks on either ends or by other means so that it is possible to locate
the grid points for level measurements after each successive course is laid. For
pavement courses laid only over widening portions, at least one line of levels
shall be taken on each strip of widening, or more depending on the width of
widening as decided by the Engineer.
Notwithstanding the above, the measurements may be taken at closer intervals
also, if so desired by the Engineer, the need for which may arise particularly in
the case of estimation of the volume of the material for profile corrective course
(levelling course). The average thickness of the pavement course in any area
shall be the arithmetic mean of the difference of levels before and after

construction at all the grid points falling in that area, provided that the thickness
of finished work shall be limited to those shown on the drawings or approved by
the Engineer in writing.
As supplement to level measurements, the Engineer shall have the option to take
cores/make holes to check the depth of construction. The holes made and the
portions cut for taking cores shall be made good by the Contractor by laying
fresh mix / material including compacting as required at no extra cost
immediately after the measurements are recorded.
61 .4 Checking of Pavement Thickness for Payment on Area Basis : Where payment
for any bituminous course in Section 300 is allowed to be made on area basis,
the Engineer may have its thickness checked with the help of a suitable
penetration gauge at regular intervals or other means as he may decide.
61.5 Measurement of Bituminous Courses for Payment on Weight Basis: Plant-mixed
bituminous materials for pavement courses where designated to be paid on
weight basis shall be weighed on accurate scales approved by the Engineer.
Approved scales shall mean scales that area of size, capacity, kind and type
suitable for the weighing to be done, and these shall be properly and adequately
installed and maintained. Prior to the use of the scales and as frequently
thereafter as the Engineer may deem necessary to ensure accuracy, the scales
shall be checked and approved by the Engineer, or the Engineer may direct the
Contractor to have the scales checked by other competent agency at the cost of
the Contractor.
Location of the scales shall be as designated by the Engineer. Trucks used for
hauling the material to be weighed shall be weighed empty daily at such times as
the Engineer directs, and each truck shall bear a plainly legible identification
mark.
For materials specified to be measured by weight, the Engineer will have the
option to make measurements of the finished work by volume and such volumes
shall be converted into weight for payment purposes. The factor for conversion
from volume measurement to weight measurement shall be computed from the
representative density of the compacted material at site determined at locations
approved by the Engineer.
62.0 Scope of Rates for Different Items of Work
For ·item rate contracts, the contract unit rates for different items of work shall be
payment in full for completing the work to the requirements of the Specifications
including full compensation for all the operations detailed in the relevant sections
of these Specifications under "Rates". In the absence of any directions to the
contrary, the rates are to be considered as the full inclusive rate for finished work
covering all labour, materials, wastage, temporary work, plant, equipment,
overhead charges and profit as well as the general liabilities, obligations,
insurance and risks arising out of General Conditions of Contract.
The item rates quoted by the Contractor shall, unless otherwise specified, also
include compliance with I supply of the following:
a) General works such as setting out, clearance of site before setting out and
clearance of works after completion,
b) A detailed programme for the construction and completion of the work
(using CPM/PERT techniques) giving, in addition to construction activities,
detailed network activities for the submission and approval of materials,
procurement of critical materials and equipment, fabrication of special
products I equipment and their installation and testing, and for all activities
of the Employer that are likely to affect the progress of work, etc. including

updating of all .such activities on the basis of the decisions taken at the
periodic site review meetings or as directed by the Engineer;
c) Samples of various materials proposed to be used on the Work for
conducting tests thereon as required as per the provisions of the Contract;
d) Design of mixes as per the relevant Clauses of the Specifications giving
proportions of ingredients, sources of aggregates and binder along with
accompanying trial mixes as per the relevant Clauses of these
Specifications to be submitted to the Engineer for his approval before use
on the Works;
e) Detailed design calculations and drawings for all Temporary Works (such
as formwork, staging, centering; specialized constructional handling and
launching equipment and the like);
f) Detailed drawings for templates, support and end anchorage, details of pre-
stressing cable profiles, bar bending and cutting schedules for
reinforcement, material lists for fabrication of structural steel, etc;
g) Mill test reports for all mild and high tensile steel and cast steel as per the
relevant provisions of the Specifications;
h) Testing of various finished items and materials including bitumen, cement,
concrete, bearings as required under these Specifications and furnishing
test reports/certificates;
i) Inspections Reports in respect of formwork, staging, reinforcement and
other items of work as per the relevant Specifications;
j) Any other date which may be required as per these Specifications for the
Conditions of Contract or any other annexures / schedules forming part of
the contract;
k) Any other item of work which is not specifically provided in the Bill of
Quantities but which is necessary for complying with the provisions of the
Contract;
I) All temporary works, formwork and false work;
m) Establishing and running a laboratory with facilities for testing for various
items of works as specified in Section 600 and other relevant Clauses,
where there is no separate item in the Bill of Quantities for establishing and
running a laboratory;
n) Cost of in-built provisions for Quality Assurance;
o) Cost of providing "as-built drawings" in original and two sets of prints and
C.D.
Portions of road works beyond the limits and / or any other work may be got
constructed by the Employer directly through other agencies. Accordingly, other
agencies employed by the Employer may be working in the vicinity of the Works
being executed by the Contractor. The Contractor shall liaise with such agencies
and adjust his construction programme for the completion of work accordingly
and no claim or compensation due to any reason whatsoever will be entertained
on this account. The Employer will be indemnified by the Contractor for any
claims from other agencies on this account.

100.0 Road and Drainage Excavation

101.0 Description :
Roadway and drainage excavation shall consist of excavation removal and satisfactory
disposal of all excavated materials and necessary for the requirements of those
specifications and in the lines, grades and cross-sections shown on the drawings
of indicated by the by the engineer. This work shall include the hauling and
stacking or of hauling to sites of embankment construction of suitable cut
materials as required, as also the disposal of unsuitable cut materials in specified
manner and the trimming and finishing of the road way.
102.0 Classification of excavations: All materials involved in excavation shall be
classified by engineer either under two groups as 102.1 and 102.2 or as per sub
classes of these groups as stated in the contract.
102.1 General Classification: This shall comprise of excavation in soils, road metal,
made ground, clays, moorum, boulders, sand, masonry or concrete in
foundation, plinths and walls and all other material including whatever description
not requiring to be blasted.
102.1.1 Soil
This shall comprise of topsoil, sand, silt, loam, clay, mud, marine clay, loose
moorum, or similar material which yields to the ordinary application of pick,
spade and / or shovel. Removal of gravel or any other nodular material having
dimension not exceeding 75 mm occurring in such strata shall be deemed to be
covered.
102.1.2 Soft rock
This shall include : Macadam surfaces, soling or hard core of roads, stabilised
soil, compact moorum gravel, cobble stone having maximum dimension between
75 & 300 mm, masonry work, concrete , boulders etc which can be removed with
JCB.
102.1.3 Marshy Soil
This shall include soils like marine clays, peats below original levels of marshes
and swamps requiring continuous pumping or bailing out of water
102.2 Rock Excavation: This shall comprise of rock, big boulders more than 0.25
cubic meters (8 c ft). In volume, very hard stone or littoral concrete or any
material requiring to be blasted by an explosive or broken into small pieces by
iron wedges or chisels. The rock excavation shall have two classes
102.2.1 Rock Excavation by Blasting: This shall comprise boulders, hard rock, RCC,
cement concrete for excavation of which the use of blasting is required.
102.2.2 Hard Rock (Blasting Prohibited): Due to restrictions, where excavation in rock
cannot be done by blasting and chiseling, weighing or mechanically chisels,
pavement breakers·are required to be used.
102.3 In case of any question arising as the class of excavation, the engineer shall
determine under which category and that to what extent any particular
excavation shall be classed.
103.0 Construction Operations:
103.1 After the site has been cleared, the limits of excavation shall be set out true lines,
curves, slopes grades and sections as shown on the drawings or as directed by
engineer. The Contractor shall provide all labour, survey instruments and
materials, such as strings pegs, nails, bamboo, stones, lime, mortar, concrete,
etc. required in connection with the setting out of works and establishment of

bench marks. The Contractor shall be responsible for the maintenance of bench
marks and stokes as long as they are required for the work in the opinion of the
Engineer.
103.2 Excavation-General: All excavation shall be carried out in conformity with the
directions laid here in under and in a manner approved by the engineer. The
work shall be so planned that the suitable materials available from excavation
are satisfactorily utilised as decided upon of the Engineer.
The excavation shall conform to the lines, grades, side slopes and levels shown
on the drawings or as directed by Engineer. The contractor shall not excavate
outside the slopes or below the established grades or loosen any material
outside the limits of excavation. Subject to the permitted tolerances, any excess
depth excavated below the specified levels on the roadway shall be made good
at the cost of the contractor with suitable material of similar characteristics to that
removed and compacted to the requirements of clause 150.
All debris and loose material on the slopes of cutting shall be removed. No back
filling shall be allowed to obtain required slopes except when boulders or soft
pockets are encountered in cut slopes these shall be excavated to approved
depth on instructions of the Engineer and regulating cavity filled with suitable
material and thoroughly composted in as approved manner.
103.3 Rock Excavation:
103.3.1 Rock when encountered in roadway excavation, shall be removed upto the
subgrade level or as otherwise indicate on the drawings. Where however
unstable material is intersected at the subgrade level, these shall be excavated
to the extent of 500mm below the subgrade level or as otherwise specified. In all
cases, the excavation operation shall be so carried out that at no point on cut
foundation the rock protrudes above the specified levels, provides however that a
negative tolerance of 150 mm shall be permissible.
Where excavation is done to levels lower than this specified, the excess
excavation shall be made good by hand packing with rubble and chips to
designate level and compacting to the satisfaction of the Engineer.
Slopes in rock cuttings shall be finished to uniform lines corresponding to slope
lines shown on the drawing or as directed by the Engineer. Notwithstanding the
foregoing all loose pieces of rock on excavated slope surface, which move when
prised by a crow bar, shall be removed.
Where blasting is to be resorted to, the same shall be carried out to clause
103.3.2 and precautions indicated there in observed.
103.3.2 Blasting:
103.3.2.1 Blasting shall not be done without the previous consent of the Engineer and shall
be restricted to the hours which he may prescribe. If in the opinion of the
Engineer, blasting would be dangerous to persons or adjacent structure, or is
being carried on in a reckless manner, the rock shall be excavated by other
means.
103.3.2.2 Storage of Explosives: The contractors shall obtain the previous permission of
the Chief of Fire Services for the site, manner and method of storing explosives
near the sites of works. All handlings of explosives, including storage and
transporting shall be carried out under the rules approved by the Explosives
Department of the Government.
103.3.2.3 In carrying out rock blasting, the Contractors shall take all necessary precaution
by the use of screens weighted down and other means for the protection of life
and property and shall strictly comply with all rules and regulations that may be
laid down by the Commissioner of Police, by the Engineer or by other regularly

constituted authority having jurisdictions relative to handling, storing and use of

explosive.
103.3.2.4 In order to ensure the safety of surrounding property and persons no charge
shall be used which is larger than necessary properly to start the work and rock
excavation contiguous to any structure shall be carried on so as not to cause
damage to such structure.
103.4 Marsh Excavation: The excavation of marshes \ swamps \ waterlogged areas
shall be carried out to clause as per the programme laid down by the Engineer.
The Excavation of such portions shall begin at one end and proceed in one
direction across the entire marsh immediately ahead of back filling. The method
and sequence of excavating and back filling shall be such as to assure , to the
extend practicable , the complete removal or displacement of all muck from
within the lateral limits called for on the drawings or as directed by the Engineer
and to the bottom of the marsh, firm support or Levels indicated
103.5 Excavation of Road shoulders for widening pavement: In works involving
widening of existing pavements, unless otherwise specified the shoulders shall
be removed to their full width and to levels shown on the Drawing or as directed
by the Engineer. While doing so, care shall be taken to see that, no portion of the
existing pavement, designated to retained, is loosened or distributed.
104.0 Dewatering: If water is met in the excavations due to springs, seepage, rain or
other causes, it shall be removed by suitable diversions, pumping or baling out
and the excavations kept dry whenever so required or directed by Engineer.
Care shall be taken to discharge the drained water in such a manner as not to be
retained, is loosened or distributed.
The contractors shall provide and work at their own cost all pumps engines and
machinery requisite to keep the trenches for the sewers, drains or foundation and
other excavation clear of water, whether subsoil water, storm water or leakages
from tanks, wells, drains sewers of pipes so that there may be no accumulations
of such water and that no setting out may be done, no masonry may be laid, no
concretes deposited, no joints made no measurements taken the water. The
pumping shall be continued so long after execution of any portion of the work
and repeated often as the Engineer may consider necessary. The pumps and
power applied must be such as the Engineer may determine to be sufficient at
any particular time, or he may himself supply pumps and power at the
contractor's cost or he may stop the work altogether until he is satisfied and also
impose a fine upon the contractors. No nuisance shall be caused to the traffic
and residents at the place due to the dewatering operations etc.
105.0 Disposal of Excavated Material:
105.1 All the excavated materials shall be the property of the Corporation.
The excavated materials shall be utilised without any extra charge in forming the
bank of the road as specified in that behalf or filling in trenches, low lying ground
or wells or shall be deposited in such places and to such heights and levelled as
the Engineer may direct within a distance of 30 metres (100 Ft.) from any edge of
the proposed road site in the contract.
If there be any stone in the excavated materials, suitable for rubble packing, road
metal or for building or any other Municipal purposes, it shall be separated and
deposited as stated above, also without any extra charges.
If any excavation in the road metal or rubble packing be carried out in connection
with pipes sewers, drains, manholes, etc. the road metal or the rubble packing
shall be first stripped of for the whole width of the trench and for the whole extent
of the chamber required and separately deposited to be again utilized as the

Engineer may direct while the other material from the excavation shall be
disposed of a specified herein above or same, as may be necessary to prevent
the weight of the materials from causing the sides of trench to slip or fall.
In case where the Engineer decides that the width of the road or lane where work
of excavation is to be carried out is so narrow as to warrant stacking excavated
material away from the site of the work the contractors shall have to remove the
same if so directed within a lead of 300 metres (1000 Ft.). The excavated stuff
shall be brought back from any edge of the proposed work site, for refilling the
trenches when required. The surplus material shall be removed as directed. No
claims for stacking the excavated stuff away from the site of work or bringing it
back for refilling trenches shall be entertained.
105.2 Disposal of Surplus Material : The surplus earth, stones, boulders and other
materials that will be left after using them for embankments in filling in hollows,
wells and rubble packing etc. within the limits of the work, shall be removed to a
place with the distance quoted in tenders and as directed by the Engineer. The
rate for removal of surplus material to any given place, shall include fencing and
lighting at site, loading and unloading spreading in layers not more than 25cms
(10") thick at dumping ground or stacking in depots of suitable sizes wherever
required, as directed by the Engineer. It must be thoroughly understood that this
shall be paid upon the quantity of space, the material will occupy after excavation
and also after deducting the quantity of earth that may have been used on work
for filing in embankment hollows, wells, and other low lying grounds within the
limits of the work. This shall also include the removal of surplus material from
trenches taken by any Public utility company or by other department of the
Municipal Corporation.
106.0 Preservation of Property:
106.1 The contractor shall take all reasonable precautions for the protection and
preservations of any or all existing road side trees, drains, sewers or other
subsurface drains pipes, conducts and any other structure under or above
ground, which may be affected by constructions, operations and which in the
opinion of the Engineer shall be continued in use without any charges.
Safeguards taken by the contractors in this respect shall be got approved by him
from the Engineer. However, if any of these objects is damaged by reason of the
contractor's negligence, it shall be replaced or restored to the original condition at
his expense.
106.2 Precaution : If the work which the excavation shall have been made be not
completed by the 20th day of May next following or the settling on of rain or
before the day fixed by the Engineer for filling in any excavation on account of
the Mohorrum, or Diwali or other holiday or of any special occasion or ceremony,
the contractors shall refill any such excavation or the Engineer may refill and
compact at their expenses, notwithstanding the non-completion of the work as
aforesaid and in no such case shall the contractor have any claim for such
excavation, refilling or compaction or for any such incomplete work but on the
other hand, the contractors shall bear the cost of road repairs in respect of such
excavations at such time, together with the cost of such procedure as may be
adopted by the Engineer. The contractors may be permitted to continue to work
up to 21 st May on sewers passing through open land or unpaved road or roads
not carrying heavy traffic and wide enough to permit reinstatement being carried
out after setting in of rain without affecting traffic movement.
106.3 Lighting of Excavations : All excavations, trenches, obstructions, materials, etc.
taken, kept or deposited in connection with the work would be sufficiently lighted
at night in order to guard against any damage or danger to the traffic and to take

all precautions to keep all the lamps lighted whole night for the guidance of the
traffic in the following manner:
106.4 All lamps must be kept at a height of about 1 m to 1.25m at strategic points.
a) All lamps should be red in colour.
b) All lamps across, the direction of traffic should be spaced at a distance of not
more than 2m apart.
c) The lamps along the line of traffic should be spaced not more than 9m to 15m
apart.
d) To take such other measures as may be directed by the Engineer from time to
time for the safety of the traffic.
e) The contractor shall make all proper provision for protecting the work by
providing portable traffic barricade with flashers otherwise known as Blinkers.
Specification of Blinkers are as follows:
Series 6,100 blinker unit consisting of a solid state oscillator - dryer circuit using
silicon transistors, tropicalised printed circuit card, driving a 2.4 watt filament
lamp in a screw holder. The unit contains four flashlight cells (type D, 1.5 V) in a
battery compartment in the base. Removable bottom to facilitate quick battery
change.
The assembly is housed in a specially shaped handy box, MS fabricated, painted
in attractive traffic yellow with regulation strips on the visible base. Bakelite
handles on top for carrying. The sides fitted with pre-focused moulded
polystyrene lenses red or amber having prismatic inner surface for efficient light
transmission. Visibility approximately 150 metres on dark night.
106.5 In the event of the contractors not complying with the provisions of this clauses,
the Engineer may without notice to the contractors put up the barricade or
improve upon the same or provide or improve the lighting to adopt such other
measures as he may deem necessary and all the cost of such procedure as may
be adopted by the Engineer shall be borne by the contractors shall be charged a
penalty of Rs.100/- per day till compliance of this requirement.
107.0 Finishing Operations:
107.1 Finishing operations shall include the work of properly shaping and dressing all
excavated surfaces.
When completed, to point on the slopes shall vary from the designated slopes by
more than 150mm measured at right angles to the slope except where
excavation is in rocks (hard or soft) where no point shall vary more than 600mm
from the designated slope. In no case shall any portion of the slope encroach on
the roadway.
The finished cut formation shall satisfy the surface tolerances described in
Clause 610 & 620.
When directed, the top soil removed earlier and conserved, shall be spread over
out slopes, berms and other disturbed areas. Slopes may be roughened and
moistened slightly, prior to the application of top soil, in order to provide
satisfactory bond.
107.2 Laying of Sub-Grade (Preparation of Cut Formation):
The subsoil shall be levelled approximately to proper level and camber by filling
depressions with excavated material and cutting off protuberances. The subsoil
shall be made to have as nearly as practicable a uniform bearing power and all
hard spots therefore be properly excavated and refilled.
All soft and spongy parts of the subsoil shall also be excavated and refilled with
approved materials in 15cm (6") layers for the same reason. (The cost of this

excavation will be paid after under the item for excavation). The subsoil shall be
watered adequately as directed before a roller as put on it. Proper accesses
should be prepared for the roller to get to the subsoil and all manholes frames
and covers should be removed by plates free of cost whenever they interface
with the free rolling of the subsoil.
After rolling, the camber super elevation and longitudinal slope etc. of the subsoil
shall conform in shape to those of the finished road surface. This should be
checked with the help of level stakes, strings and camber board if necessary.
107.3 In rocky formations, the surface irregularities shall be corrected and the levels
brought up to the specified elevation with granular base material as directed by
the Engineer, laid and compacted in accordance with the respective
Specifications for these materials. The unsuitable material shall be disposed of in
accordance with Clause 105.2. After satisfying the density requirements, the cut
formation shall be prepared to receive the sub-base / base course in accordance
with Clauses 107.2 to receive the sub-base/base course.
108.0 Measurements & Rates
108.1 Works involved in the preparation of cut formation shall be measured in units
indicated below:
i. Loosening and re-compacting the loosened material
at sub-grade. Cu. M.
ii. Loosening and removal of unsuitable material and
replacing with a suitable material and compacting
to required density Cu. M.
iii. Preparing rocky sub-grade Sq. M.
iv. Stripping including storing and reapplication of top soil Cu. M.
v. Disposal of surplus material beyond initial 1000m lead Cu. M.
108.2 The rates for excavation shall be held to include and cover without extra charge
all the stipulations contained in every portion of clause with regard to shoring,
pumping, shaping the trenches, filling grounds or embanking with the excavated
materials, or removing surplus materials, and separating stones suitable for
Municipal Work, maintenance of pipes, drain and other work, fencing, lighting,
watching, ramming foundation and all matters and things connected with a or
rendered necessary or otherwise involved by the excavation.
The excavation for the road work will be paid on the basis of sectional
measurements irrespective of the work.
In case of rock excavation, where cross-sectional measurements are not
possible due to irregular configuration or where the rock is admixed with other
classes of materials, the volumes shall be computed on the basis of stacks of
excavated rubble after making 40% deduction due to voids therein.
If in any place, the Engineer may consider that on account of the nature of
subsoil, additional foundations of concrete, rubble otherwise are necessary, or if
in any place, he may require the excavation, for any purpose whatsoever, not
shown on plans or described in the specification, the excavation shall be carried
out as may be ordered by the Engineer and such additional works shall be
measured and paid for the contractors.
The disposal of surplus material shall be measured and paid extra or shall be
part of the excavation item as per the provisions of the Bill of Quantities.

108.2.1 The Contract unit rates for the items of roadway and drain excavation shall be
payment in full for carrying out the operations required for the individual items
including full compensation for:
i. Setting out,
ii. Transporting the excavated materials and depositing the same on sites of
embankments, spoil banks or stacking as directed within all lifts and lead
upto 1000 m or as otherwise specified,
iii. Trimming bottoms and slopes of excavation,
iv. Dewatering,
v. Keeping the work free of water
vi. All labour, materials, tools, equipment, safety measures, testing and
incidentals necessary to complete the work to Specifications.
1082.1.1 The Contract unit rate for loosening and re-compacting the loosened materials at
sub-grade, if provided separately in the contract, shall include full compensation
for loosening to the specified depth, including breaking clods, spreading in
layers, watering where necessary and compacting to the requirements.
108.2.1.2 Clauses 108.2.1, 153.2 and 153.3 shall apply as regards Contract unit rate for
item of removal of unsuitable material and replacement with suitable material
respectively.
108.2.1.3 The Contract unit rate, if provided separately, for item of preparing rocky sub-
grade as per Clause 107.2 shall be full compensation for providing, laying and
compacting granular base material for correcting surface irregularities including
all materials, labour and incidentals necessary to complete the work and all leads
and lifts.
108.2.1.4 The Contract unit rate, if provided separately, for the items of stripping and
storing topsoil and of reapplication of topsoil shall include full compensation for
all the necessary operations including all lifts, but leads as stated in the contract.
108.2.1.5 The Contract unit rate, if separately provided in the contract, for disposal of
surplus earth from roadway and drain excavation shall be full compensation for
all labour, equipment, tools and incidentals necessary on account of the
additional haul or transportation involved beyond the initial lead provided in the
respective item of excavation.
120.0 Sub-Surface Drains:
120.1 Scope: Sub-Surface drains shall be of close-jointed perforated pipes, open-
jointed unperforated pipes, surrounded by granular material laid in a trench or
aggregate drains to drain the pavement courses. Subsurface drains designed
using Geo-synthetics and approved by the Engineer can also be used.
120.2 Materials:
120.3 Pipe : Perforated pipes for the drains may be of metal I asbestos cement I
cement concrete I PVC, and unperforated pipes of I cement concrete I asbestos
cement. The type, size and grade of the pipe to be used shall be as specified in
the Contract. In no case, however, shall the internal diameter of the pipe be less
than 100mm. Holes for perforated pipes shall be on one half of the circumference
only and conform to the spacing indicated on the drawings. Size of the holes
shall not ordinarily be greater than half of D85 size of the material surrounding
the pipe, subject to being minimum 3mm and maximum 6mm. D85 stands for the
size of the sieve that allows 85 per cent of the material to pass through it.
120.3.1 Backfill Material: Backfill Material shall consist of sound, tough, hard, durable
particles of free draining sand-gravel material or crushed stone and shall be free

of organic material, clay balls or other deleterious matter. Unless the Contract
specifies any particular grading for the backfill material or requires these to be
designed on inverted filler criteria for filtration and permeability to the approval of
the Engineer, the backfill material shall be provided on the following lines:
120.3.2 Where the soil met with in the trench is of fine grained type (e.g. silt, clay or a
mixture thereof), the backfill material shall conform to Class I grading set out in
Table 100.1.
120.3.3 Where the soil met with in the trench is of coarse silt to medium sand or sandy
type, the backfill material shall correspond to Class II grading of Table 100.1.
120.3.4 Where soil met with in the trench is gravelly sand, the backfill material shall
correspond to Class III grading of Table 100.1. Thickness of backfill material
around the pipe shall be as shown on the drawings subject to being at least
150mm all-round in all cases. Geo-synthetics for use with subsurface drain shall
conform to the requirements as per Section 260.
Table 100.1 Grading Requirements for Filter Material
Per cent passing by weight
Sieve Designation
Class-I Class-II Class-III
53mm - - 100
45mm - - 97-100
26.5mm - 100 -
22.4mm 95-100 58-100
11.2mm 100 48-100 20-60
5.6mm 92-100 28-54 4-32
2.8mm 83-10 20-35 0-10
1.4mm 59-96 - 0-5
710 Micron 35-80 6-18 -
355 Micron 14-40 2- -
180 Micron 3-15 - -
90 Micron 0-5 0-4 0-3
120.4 Trench Excavation: Trench for sub-surface drain shall be excavated to the
specified lines, grades and dimensions shown in the drawings provided that
width of trench at pipe level shall not be less than 450mm. The excavation shall
begin at the outlet end of the drain and proceed towards the upper end. Where
unsuitable material is met with at the trench bed, the same shall be removed to
such depth as directed by the Engineer and backfilled with approved material
which shall be thoroughly compacted to the specified degree.
120.5 Laying of pipe and backfilling: Laying of pipe in the trench shall be started at the
outlet end and proceed towards the upper end, true to the lines and grades
specified. Unless otherwise provided longitudinal gradient of the pipe shall not be
less than 1 in 100.
Before placing the pipe, backfill material of the required grading(s) shall be laid
for full width of the trench bed and compacted to a minimum thickness of 150mm
or as shown on the drawings. The pipe shall then be embedded firmly on the
bed.
Perforated pipes, unless otherwise specified, shall be placed with their
perforations down to minimize clogging. The pipe sections shall be joined
securely with appropriate coupling fittings or bands.

Non-perforated pipes shall be laid with joints as close as possible with the open
joints wrapped with suitable pervious material (like double layer of Hessian,
suitable Geo-synthetics or some other material of not less than 150mm width) to
permit entry of water but prevent fines entering the pipe. In the case of non-
perforated pipes with bell end, the bell shall face upgrade. Upgrade end sections
of the pipe installation shall be tightly closed by means of concrete plugs or plugs
fabricated from the same material as the pipe and securely held in place to
prevent entry of soil materials.
After the pipe installation has been completed and approved, backfill material of
the required grading(s) (see Clause 120.2.2) shall be placed over the pipe to the
required level in horizontal layers not exceeding 150mm in thickness and
thoroughly compacted. The minimum thickness of material above the top of the
pipe shall be 300mm.
Unless otherwise provided, sub-surface drains not located below the road
pavement shall be sealed at the top by means of 150mm thick layer of
compacted clay so as to prevent percolation of surface water.
120.6 Use of Geo-synthetic in laying of pipe and backfilling: After excavating the trench
for sub-surface drain, the filter fabric (Geo- Textile as per clause 262) shall be
placed, the pipe installed and the trench backfilled with permeable material
according to dimensions and details shown on the plans. Surfaces to receive
filter fabric prior to placing shall be free of loose of extraneous material and sharp
objects that may damage the filter fabric during installation. Adjacent rolls of the
fabric shall be overlapped a minimum of 450mm. the preceding roll shall overlap
the following roll in the direction the material is being spread.
Damage to the fabric resulting from Contractor's vehicles, equipment or
operations shall be replaced or repaired by the Contractor at his expense.
120.7 Drain Outlet : The outlet for a sub-drain shall not be under water or plugged with
debris but should be a free outlet discharging into a stream, culvert or open ditch.
The bottom of the pipe shall be kept above high water in the ditch and the end
protected with a grate or screen. For a length of 500mm from the outlet end, the
trench for pipe shall not be provided with granular material but backfilled with
excavated soil and thoroughly compacted so as to stop water directly percolating
from the backfill material around the pipe. The pipe in this section shall not have
any perforations.
120.8 Aggregate Drains: Aggregate Drains shall be placed within the verge / shoulders
after completion of the pavement. Depth, thickness and spacing of the aggregate
drains shall be as shown on the plan.
Trenches for aggregate drains shall be excavated to a minimum width of 300mm
and to the depth shown on the plans or ordered by the Engineer. The bottom of
the trench shall be sloped to drain and shall be free from loose particles of soil.
The trench shall be excavated so as to expose clearly the granular pavement
courses to be drained.
Aggregate for the drains shall be durable gravel, stone or slag and shall be free
from vegetable matter and other deleterious substances. The grading
requirements are given at Table 100.2. Type B grading may be used only where
the drain is designed to intercept surface water flowing to the pipe and is likely to
get slowly blocked. Type A grading allows a much wider range.
Table 100.2 Grading Requirements for Aggregate Drains
Sieve Size Per cent passing by weight
Type A Type B
63mm - 100

37.5mm 100 85-100

19mm - 0-20
9.5mm 45-100 0-5
3.35mm 25-80 -
600 Micron 8-45 -
150 Micron 0-10 -
75 Micron 0-5 -
120.9 Measurements for Payment: Measurement for surface and sub-surface drains
shall be per running meter length of the drain. Disposal of surplus material
beyond a lead mentioned in the contract shall be measured in Cu.M.
120.10 Rates: The Contract unit rates for surface and sub-surface drains shall be
payment in full for all items such as excavation, dressing the sides and bottom;
providing lining, turfing, pitching, masonry, concrete and plastering, providing,
laying and jointing pipes, providing, laying and compacting backfill and bed of
granulated material; providing, fixing and painting of cover, etc. including full
compensation for all materials, labour, tools, equipment and other incidentals to
complete the work as shown on drawings with all leads and lifts except for
removal of unsuitable material for which the lead shall be 1000m. Provision of
inlets, gratings, sumps, outlet pipes, bedding, disbursers, etc. wherever required
shall be incidental to construction of drain. The Contract unit rate for disposal of
surplus and unsuitable material beyond the initial 1000m lead shall be in
accordance with Clause 108.2.1.5.
130.0 Treatment to Sub-Soil
131.0 Mechanically Stabilised Soil:
The In-situ soil, found weak to support pavement and traffic load, then it shall be
stabilized by mixing it with granular material.
131.1 Materials:
131.1.1 Blending Material for Mechanical Stabilisation: This may be gravel, crushed
stone, crushed slag, brick-mental, soft aggregates like laterite and kankar,
natural sand or clay depending upon the grading requirements. The grading of
mixed material shall as far as possible conform to one of the three gradings in
Table 100.3.
Table 100.3 Grading of Mixed Material for Mechanical Stabilisation
Sieve Designation Percent by Wt. Passing the Sieve
20mm 60-30 80-100 100

10mm 45-65 55-80 80-100
4.75mm 30-50 40-60 50-75
2.36mm - 30-50 33-60
600 Micron 10-30 15-30 15-35
75 Micron 0-10 0-10 0-10
Notes:
a. Not less than 10% should be retained between each pair of successive
sieves specified for use excepting the large pair.
b. The material passing 425 Micron Sieve when tested according to IS:2720
(Part-V) shall have liquid limit and plasticity index of not more than 25 and 6
respectively.

c.. The soaked CBR value of the compacted material shall not be less than 10
d; Moisture Content For Compaction - The moisture content at compaction
checked vide IS2720 (part 2) shall neither be less than optimum moisture
content corresponding to IS2720 (part 8) nor more than 2% above it.
131.1.2 Construction Operation
The mixing shall be carried out by using a mechanical mixer. The mix shall be
spread and compacted by using three wheeled power or tandem roller of 80 to
100 KN capacities.
(a) Measurements for Payment: Stabilised soil sub-base/base shall be
measured as finished work in position in cubic metres.
(b) Rates : The contract unit rate for cement treated soil sub-base / base
with pre-treatment with lime if required shall be payment in full for
carrying out the required operations.
132.0 Lime Treated Soil:
132.1 Materials:
132.1.1 Lime: Lime for lime-soil stabilization work shall be commercial dry lime slaked at
site or pre-slaked lime delivered to the site in suitable packing. Unless otherwise
permitted by the Engineer, the lime shall have purity of not less than 70 per cent
by weight of Quick-lime (CaO) when tested in accordance with IS:1514. Lime
shall be properly stored to avoid prolonged exposure to the atmosphere and
consequent carbonation which would reduce its binding properties.
132.1.2 Water: The water to be used for lime stabilization shall be clean and free from
injurious substances. Potable water shall be preferred.
132.2 Quantity of Lime in Stabilised Mix: Quantity of lime to be added as percentage
by weight of the dry soil shall be as specified in the Contract. The quantity of lime
used shall be related to its calcium oxide content which shall be specified. Where
the lime of different calcium oxide content is to be used, its quantity shall be
suitably adjusted to the approval the Engineer so that equivalent calcium oxide
as incorporated in the work. The mix design shall be done to arrive at the
appropriate quantity of lime to be added, having due regard to the purity of lime,
the type of soil, the moisture-density relationship, and the design
CBR/Unconfined Compressive Strength (UCS) value specified in the Contract.
The laboratory CBR/UCS value shall be at least 1.5 times the minimum field
value of CBR / UCS stipulated in the Contract.
132.3 Construction Procedure: The following procedure for mix in place soil-lime
stabilization is recommended.
The soil, to be stabilized, shall be laid to a uniform loose thickness of 9" over the
prepared sub-grade. Clods or other gravel over 4.75mm diameter shall be either
removed or pulverized to within the above size.
The surface area shall then be divided into convenient panels, preferably of 3M x
3M.
Pre-calculated quantity of lime, required for the quantity of soil contained in the
panel, shall be made to thin fine slurry by mixing the same with sufficient quantity
of water in a drum.
Furrows shall be made in the soil by means of pickaxes, their edges going to the
full depth of the loose soil layer. These shall be made in the longitudinal,
transverse and again longitudinal directions and in that order. One third of the
lime slurry shall be added to the furrows, every time.
As far as possible, alternate panel method shall be adhered to, for a better field
control.

After the excess moisture content in the soil-lime mix gets evaporate, the same
shall be dressed to a uniform layer and rolled.
The layer shall then be cured, i.e., the rolled surface shall be maintained in a
moist state by sprinkling water at intervals till the next layer is laid over it.
132.3.1 Moisture Content for Compaction: For mechanical stabilizations, moisture
content at compaction shall be within the range of 1 % above of 2% below the
optimum moisture content corresponding to IS: 2720 (Part-VIII) whereas for
cement / lime stabilization it shall not be Jess than O.M.C. nor more than 2%
above it. The moisture content shall be adjusted during the mixing operations
(making allowance for evaporation losses) and checked before rolling starts.
132.3.2 Rolling: A power roller shall, as a rule, be not less than 10 tonnes but if at any
time still heavier rollers are required on the works, the contractors shall have to
bring them as may be directed by the Engineer. In case of trenches not more
than 8' in width, an earth master or any other similar equipment manually or
machine operated, shall be invariably employed.
Rolling shall progress from edges to the centre of the road in strips parallel to the
centre line of the road.
Rolling shall be done by lapping uniformly each proceeding rear wheel track by
at least one half width of the track.
On super elevations, rolling shall be started at inner edge and shall progress
towards outer edge. During and after rolling, the surface shall be checked for
grade and camber. Rolling shall be started worked or stopped without jerks.
Rolling shall not normally be done in length less than 100m (300ft).
On completion of day's work, the roller shall be made to stand on the side width
of the road and shall be guarded by a watchman. A red lantern shall be hung on
the roller at night so as to be visible from both sides of the road.
Care shall be taken to see that the compaction of cement stabilized material is
completed within two hours of its mixing or such
132.3.3 Curing:
132.3.4 The sub-base course, stabilized with lime or cement shall be suitably cured for 7
days or less if so desired by the Engineer soon after which subsequent
pavement courses shall be laid to prevent the surface from drying out and
becoming friable. No traffic of any kind shall ply over the completed sub-base
unless permitted by the Engineer.
132.4 Quality Control
In the Laboratory: A sample of the soil, to be stabilized, (minimum 30 Kg.)
together with a sample of lime, to be used for stabilization shall be submitted to
the Municipal Soil Testing Laboratory, at least one week prior to taking up the
stabilization work.
The Laboratory shall furnish:
The percentage of lime required to be added to the soil for achieving the
designed value of CBR.
The maximum dry density and optimum moisture content for the soil-lime mix.
On the Field:
i) During the rolling operations, field density test shall be taken to
ascertain that at least 95% of the laboratory density has been attained.
ii) Field CBR tests shall be performed after a period of 7 days
132.5 Measurements for Payment: Stabilised soil sub-base/base shall be measured
as finished work in position in cubic meters.

132.6 Rates: The contract unit rate for cement treated soil sub-base / base with pre-
treatment with lime if required shall be payment in full for carrying out the
required operations including full compensation for all components listed below:
i. Making arrangements for traffic to Clause 30 except for initial treatment
to verges, shoulders and construction of diversions,
ii. furnishing all materials to be incorporated in the work including all
royalties, fees, rents where necessary and all leads and lifts,
iii. All labour, tools, equipment and incidentals to complete the work to the
Specifications,
iv. Carrying out the work in part widths of road where directed and carrying
out the required tests for quality control.
133.0 Sand Drains (100 to 200mm Diameter) :
133.1 Materials: Material shall consist of sound, hard, durable particles of free draining
sand-gravel crushed stone with grading as per Class-I of Table 100.1. The
material shall be free from organic materials, clay balls or other deleterious
matter.
133.2 Construction: Pre-boring of holes of specified diameter and specified spacing &
depth shall be done either by manual auguring or by mechanical push through
method in which detachable shoe at the bottom of the casing is mechanically
pushed through the weak strata. The premixed aggregate shall be poured into
the hole through the tremie pipe and tamped mechanically. The height of
compacted pour shall not exceed 0.5m. The filling shall be done up to specified
level.
133.3 Measurements: The work of providing sand drains shall be measured finished in
running meter depth of specified diameter.
133.4 Rate: The contract per running meter rate for provision of sand drains shall be
payment in full for supply of materials, boring of holes and filling of materials
including tamping.
134.0 Stone Columns (300 to 500mm Diameter):
134.1 Materials: Material shall consist of sound, hard, durable particles of free draining
sand-gravel / crushed stone with grading as per Class-III of Table 100.1. The
material shall be free from organic materials, clay balls or other deleterious
matter.
134.2 Construction: The stone column may be installed by making the bore into the
ground by removal of material or by driving a metal casing with a shoe at the tip
and displacing the material laterally. The premixed aggregate shall be poured
into the hole through the tremie pipe and tamped mechanically. The height of
compacted pour shall not exceed 0.5m. The filling shall be done up to specified
level.
134.3 Measurements: The work of providing sand drains shall be measured finished in
running meter depth of specified diameter.
134.4 Rate: The contract per running meter rate for provision of sand drains shall be
payment in full for supply of materials, boring of holes and filling of materials
including tamping.
135.0 Prefabricated Vertical Drains:
135.1 Material: Prefabricated drains of composite construction made of inner core
acting as drainage channel with outer sleeve fabricated out of non-woven Geo-
textiles with ISO-9000 certification from reputed manufacturers are to be installed
by mechanical or hydraulic equipment.

The band drain material shall have the following minimum properties, which have
a direct bearing on the performance of the band drain.
Table 100.4 Physical requirement for band drains
Item Test Method Unit Value
1. Discharge Capacity at hydraulic
ASTM 0-4716 CU.M. /
grade I = 0.50, 350 KPa vertical 45 * 10-6
NTU Sec.
pressure
2. Width Nominal mm 100 ± 5
3. Weight of PVD Conventional gm/m Min. 75
4. Tensile Strength ASTM 0-5035 kN 1.50
5. Elongation at 1 kN ASTM 0-5035 % < 10
135.2 Construction Operation: The drains shall be installed as per manufacturer's/
designer's guidelines to depths and at spacing as shown in the drawings. The
general depth to which the drains are to be installed would be as designed. The
contractor shall submit to the engineer the complete design considering 90%
consolidation should be achieved by 6 months and scheme for installation of
vertical band drains - the particular brand of drain to be used with its properties,
the equipment and methodology to be used for the installation of the drains and
all details shall be submitted to the engineer prior to the commencement of
ground improvement work.
After installation of vertical band drains, a blanket of clean granular coarse sand
to be used as drainage layer as approved by the Engineer-In-Charge. The
thickness of sand blanket shall be 500mm.
The finished sand blanket shall be covered with geo-textile layer and the
embankment shall be constructed as per specification.
Additional Surcharge: Additional surcharge by approved embankment shall be
placed over formation level upto a height of about 2.5m with a pressure intensity
of about 3.5 t I Sq. M. at formation level. The surcharge shall be placed with
adequate side slope to avoid any slope failure. The surcharge needs to be kept
in place for about 6-9 months time to achieve desire degree of consolidation.
After the desired degree of consolidation is achieved, the additional surcharge
shall be removed without the road embankment and the surcharge material shall
be .removed by the contractor at his own cost. The rate shall include its material
cost, its transport, placements and efforts of all types of removal. The item details
shall be as indicated in BOQ. After removal of surcharge, the damaged
embankment top shall be made good as instructed by the Engineer-In-Charge.
The additional quantity of earthwork for embankment construction due to the
settlement of sub-surface soil because of surcharge loading shall not be paid
separately. The quantity of earthwork for embankment construction shall be
measured from the initial and final levels of formation only.
135.3 Instrumentation of Monitoring: To ensure the performance of band drains and
geo-textile in the ground improvement process it is necessary that
instrumentation for recording settlement and pore water pressure be provided.
135.4 Measurements & Rates: Measurements & Rates for these items shall be as
indicated in the respective items in the BOO.
136.0 Treatment to Water Mains and Sewer Line Trenches
136.1 The trenches shall be re-excavated to remove top two meter soil.· without
disturbing the water/ sewer Mains.
The backfill material shall consist of free draining sand - gravel material or
crushed stone and shall be free of organic material, clay balls or other

deleterious matter of grading specified in the contract. The trench to be covered

with Geo-membrane that shall be as per Clause 260.
136.2 Measurements for Payment:
Measurements for re-excavation of trenches and backfilling shall be per running
meter length of trench including disposal of excavated material. The
measurements for Geo- membrane shall be per square meter of the membrane
as laid as per the drawing.
136.3 Rates:
The contract unit rates shall be payment in full for all items such as excavation,
dressing the -sides, backfilling the trench with granular material as per
specification including full compensation for all materials, labour tools equipment
and other incidentals to complete the work as shown on the drawing with all
leads and lifts. The rate for geo-membrane shall be per square meter as per
clause 260.
140.0 Excavation for Structures
141.0 Scope : Excavation for structures shall consist of the removal of material for the
construction of foundations for bridges, culverts, retaining walls, headwalls, cut-
off walls, pipe culverts and other similar structures, in accordance with the
requirements of these Specifications and the lines and dimensions shown on the
drawings or as indicated by the Engineer. The work shall include construction of
the necessary cofferdams and cribs and their subsequent removal; all necessary
sheeting, shoring, bracing, draining and pumping; the removal of all logs,
stumps, grubs and other deleterious matter and obstructions, necessary for
placing the foundations; trimming bottoms of excavations, backfilling and clearing
up the site and the disposal of all surplus material.
141.1 Classification of Excavation : All materials involved in excavation shall be
classified in accordance with Clauses 102 and 103.
141.2.1 Setting Out: After the site has been cleared, the limits of excavation shall be set
out true to lines, curves and slopes.
141.2.2 Excavation: Excavation shall be taken to the width of the lowest step of the
footing and the sides shall be left plumb where the nature of soil allows it. Where
the nature of soil or the depth of the trench and season of the year do not permit
vertical sides, the Contractor at his own expense shall put up necessary shoring,
strutting and planking or cut slopes to a safer angle or both with due regard to
the safety of personnel and works and to the satisfaction of the Engineer.
The depth to which the excavation is to be carried out shall be as shown on the
drawings, unless the type of material encountered is such as to require changes,
in which case the depth shall be as ordered by the Engineer. Propping shall be
undertaken when any foundation or stressed zone from an adjoining structure is
within a line of 1 vertical to 2 horizontal from the bottom of the excavation.
Where blasting is to be resorted to, the same shall be carried out in accordance
with Clause 103.3.2 and all precautions indicated therein observed. Where
blasting is likely to endanger adjoining foundations or other structures, necessary
precautions such as controlled blasting, providing rubber mat cover to prevent
flying of debris etc. shall be taken to prevent any damage.
141.2.3 Dewatering and Protection: Normally, open foundations shall be laid dry.
Where water is met with in excavation due to stream flow, seepage, springs, rain
or other reasons, the Contractor shall take adequate measures such as bailing,
pumping, constructing diversion channels, drainage channels, bunds, depression
of water level by well-point system, cofferdams, and other necessary works to

keep the foundation trenches dry when so required and to protect the green
concrete / masonry against damage by erosion or sudden rising of water level.
The methods to be adopted in this regard and other details thereof shall be left to
the choice of the Contractor but subject to approval of the Engineer. Approval of
the Engineer shall, however, not relieve the Contractor of the responsibility for
the adequacy of dewatering and protection arrangements and for the quality and
safety of the works.
Where cofferdams are required, these shall be carried to adequate depths and
heights, be safely designed and constructed and be made as watertight as is
necessary for facilitating construction to be carried out inside them. The interior
dimensions of the cofferdams shall be such as to give sufficient clearance for the
construction and inspection and to permit installation of pumping equipments,
etc., inside the enclosed area.
If it is determined beforehand that the foundations cannot be laid dry or the
situation is found that the percolation is too heavy for keeping the foundation dry,
the foundation concrete shall be laid under water by tremie pipe only. In case of
flowing water or artesian springs, the flow shall be stopped or reduced as far as
possible at the time of placing the concrete.
Pumping from the interior of any foundation enclosure shall be done in such a
manner as to preclude the possibility of the movement of water through any fresh
concrete. No pumping shall be permitted during the placing of concrete or for any
period of at least 24 hours thereafter, unless it is done from a suitable sump
separated from the concrete work by a watertight wall or other similar means.
At the discretion of the Contractor, cement grouting or other approved methods
may be used to prevent or reduce seepage and to protect the excavation area.
The Contractor shall take all precautions in diverting channels and in discharging
the drained water as not to cause damage to the works, crops or any other
property.
141.2.4 Preparation of Foundation: The bottom of the foundation shall be levelled both
longitudinally and transversely or stepped as directed by the Engineer. Before
footing is laid, the surface shall be slightly watered and rammed. In the event of
excavation having been made deeper than that shown on the drawings or as
otherwise ordered by the Engineer, the extra depth shall be made up with
concrete or masonry of the foundation at the cost the Contractor.. Ordinary filling
shall not be used for the purpose to bring the foundation to level.
When rock or other hard strata is encountered, it shall be freed of all soft and
loose material, cleaned and cut to a firm surface either level and stepped as
directed by the Engineer. All seams shall be cleaned our and filled with cement
mortar or grout to the satisfaction of the Engineer. In the case of excavation in
rock, annular space around footing shall be filled with lean concrete (1:3:6
nominal mix) up to the top level of rock.
If the depth of fill required is more than 1.5m above the top of the footing, filling
up to 1.5m above top of footing shall be done with lean concrete (1:3:6 nominal
mix) followed by boulders grouted with cement.
When foundation piles are used, the excavation of each pit shall be substantially
completed before beginning pile-driving operations therein. After pile driving
operations in a given pit are completed, all loose and displaced material therein
shall be removed to the elevation of the bottom of the footings.
141.2.5 Slips and Slip-outs: If there are any slips or slip-outs in the excavation, these
shall be removed by the Contractor at his own cost.

141.2.6 Public Safety: Near towns, villages and all frequented places, trenches and
foundation pits shall be securely fenced, provided with proper caution signs and
marked with red lights at night to avoid accidents. The Contractor shall take
adequate protective measures to see that the excavation operations do not affect
or damage adjoining structures. For safety precautions, guidance may be taken
from 18:3764.
141.2.7 Backfilling : Backfilling shall be done with approved material after concrete or
masonry is fully set and carried out in such a way as not to cause undue thrust
on any part of the structure. All space between foundation masonry or concrete
and the sides of excavation shall be refilled to the original surface in layers not
exceeding 150 mm compacted thicknesses. The compaction shall be done with
the help of suitable equipment such as mechanical tamper, rammer, plate
vibrator etc., after necessary watering, so as to achieve a density not less than
the field density before excavation.
141.2.8 Disposal of Surplus Excavated Materials: Clause 105 shall apply.
141.3 Measurements for Payment: Excavation for structures shall be measured in
cum. for each class of material encountered, limited to the dimensions shown on
the drawings or as directed by the Engineer. Excavation over increase width,
cutting of slopes, shoring, shuttering and planking shall be deemed as
convenience for the Contractor in executing the work and shall not be measured
and paid for separately.
Preparation of rock foundation shall be measured in square metres. Foundation
sealing, dewatering, including pumping shall be deemed to be incidental to the
work unless separate provision is made for in the Contract. In the latter case,
payment shall be on lump sum basis as provided in the Bill of Quantities.
141.4 Rates:
141.4.1 The Contract unit rate for the items of excavation for structures shall be payment
in full for carrying out the required operations including full compensation for:
o setting out;
o construction of necessary cofferdams, cribs, sheeting, shoring, bracing and
their subsequent removal;
o removal of all logs, stumps, grubs and other deleterious matter and
obstructions, for placing the foundations including trimming of bottoms of
excavations;
o foundation sealing, dewatering including pumping when no separate
provision for it is made in the Contract;
o backfilling, clearing up the site and disposal of all surplus material within all
lifts and leads up to 1000 m or as otherwise specified; and
o all labour, materials, tools, equipment, safety measures, diversion of traffic
and incidentals necessary to complete the work to Specification.
141.4.2 The Contract unit rate for preparation of rock foundation shall be full
compensation for cutting, trimming and cleaning the foundation surface and filling
I sealing of all seams with cement grout or mortar including all materials, labour
and incidentals required for completing the work.
141.4.3 The Contract unit rate for transporting ·material from the excavation for structures
shall be full compensation for all labour, equipment, tools and incidentals
necessary on account of the additional haul or transportation involved beyond
the initial lead of 1000m.

150.0 Embankment & Sub-Grade Construction

151.0 Embankment Construction:
151.1 General
151.1.1 Description: These Specifications shall apply to the construction of embankments
including sub-grades, earthen shoulders and miscellaneous backfills with
approved material obtained from roadway and drain excavation, borrow pits or
other sources. All embankments, sub-grades, earthen shoulders and
miscellaneous backfills shall be constructed in accordance with the requirements
of these Specifications and in conformity with the lines, grades and crosssections
shown on the drawings or as directed by the Engineer.
151.2 Materials and General Requirements:
151.2.1 Physical Requirements:
151.2.2 The materials used in embankments, sub-grades, earthen shoulders and
miscellaneous backfills shall be soil, moorum, gravel, a mixture of these or any
other material approved by the Engineer. Such materials shall be free of logs,
stumps, roots, rubbish or any other ingredient likely to deteriorate or affect the
stability of the embankment / subgrade.
151.2.2.1 The following types of material shall be considered unsuitable for embankment:
a) Materials from swamps, marshes and bogs;
b) Peat, log, stump and perishable material; any soil that classifies as OL, OI, OH
or Pt in accordance with IS:1498;
c) Materials susceptible to spontaneous combustion;
d) Materials in a frozen condition;
e) Clay having liquid limit exceeding 50 and plasticity index exceeding 35;
f) Materials with salts resulting in leaching in the embankment.
151.2.2.2 Expansive clay exhibiting marked swell and shrinkage properties ("free swelling
index" exceeding 50 per cent when tested as per IS: 2720 - Part-40) shall not be
used as a fill material. Where expansive clay with acceptable "free swelling
index" value is used as a fill material, subgrade and top 500mm portion of the
embankment just below sub-grade shall be non-expansive in nature.
151.2.2.3 Any fill material with a soluble sulphate content exceeding 1.9 grams of
sulphate (expressed as S03) per litre when tested in accordance with BS:1377
Test 10, but using a 2:1 water-soil ratio shall not be deposited within 500 mm or
other distance described in the Contract, of concrete, cement bound materials or
other cementitious materials forming part of the Permanent Works.
Materials with a total sulphate content (expressed as S03) exceeding 0.5 per cent
by mass, when tested in accordance with 8S:1377 Test 9 shall not be deposited
within 500mm, or other distances described in the Contract, of metallic items
forming part of the Permanent Works.
151.2.2.4 The size of the coarse material in the mixture of earth shall ordinarily not
exceed 75mm when being placed in the embankment and 50mm when placed in
the sub-grade. However, the Engineer may at his discretion permit the use of
material coarser than this also if he is satisfied that the same will not present any
difficulty as regards the placement of fill material and its compaction to the
requirements of these Specifications. The maximum particle size shall not be
more than two-thirds of the compacted layer thickness.
151.2.2.5 Ordinarily, only the materials satisfying the density requirements given in Table
100.5 shall be employed for the construction of the embankment and the sub-
grade.

Table 100.5 Density Requirements for acceptance of soils to be used as of

Embankment and Sub-grade Materials
Maximum Laboratory Dry
Sr.
Type of Work Unit Weight when tested as
No.
per IS:2720 (Part-8)
Embankments upto 3 metres height, not
1 Not less than 15.2 kN / Cu. M.
subjected to extensive flooding
Embankments exceeding 3 metres
2. height or embankments of any height Not less than 16.0 kN / Cu. M.
subject to long periods of inundation
Sub-grade and earthen shoulders/ Not less than 17.5 kN / Cu. M.
3.
verges/ backfill Ø Value not less than 27°
Notes:
1. This table is not applicable for light weight fill material, e.g. 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.
3. The material to be used in sub-grade should have minimum 2 times design
CBR at the maximum laboratory dry unit weight applicable, determined by
using 5 kg surcharge and by soaking in water by four days.
151.2.3 General Requirements:
151.2.3.1 The materials for embankment shall be obtained from approved sources with
preference given to materials becoming available from nearby roadway
excavation or any other excavation under the same Contract.
The work shall be so planned and executed that the best available materials are
saved for the sub-grade and the embankment portion just below the sub-grade.
151.2.3:2 Borrow Materials: Where the materials are to be obtained from designated
borrow areas, the location, size and shape of these areas shall be as indicated
by the Engineer and the same shall not be opened without his written
permission. Where specific borrow areas are not designated by the Employer /
the Engineer, arrangement for locating the source of supply of material for
embankment and subgrade as well as compliance to environmental
requirements in respect of excavation and borrow areas as stipulated, from time
to time by the Ministry of Environment and Forests, Government of India and the
local bodies, as applicable, shall be the sole responsibility of the Contractor.
Borrow pits along the road shall be discouraged. If permitted by the Engineer,
these shall not be dug continuously. Ridges of not less than 8m width should be
left at intervals not exceeding 300m. Small drains shall be cut through the ridges
to facilitate drainage. The depth of the pits shall be so regulated that their bottom
does not cut an imaginary line having a slope of 1 vertical to 4 horizontal
projected from the edge of the final section of the bank, the maximum depth in
any case being limited to 1.5m. Also, no pit shall be dug within the offset width
from the toe of the embankment required as per the consideration of stability with
a minimum width of 10m.
Haulage of material to embankments or other areas of fill shall proceed only
when sufficient spreading and compaction plant is operating at the place of
deposition.
No excavated acceptable material other than surplus to requirements of the
Contract shall be removed from the site. Should the Contractor be permitted to
remove acceptable material from the site to suit his operation procedure, then he
shall make good any consequent deficit of material arising therein.

Where the excavation reveals a combination of acceptable and unacceptable

materials, the Contractor shall, unless otherwise agreed by the Engineer, carry
out the excavation in such a manner that the acceptable materials are excavated
separately for use in the permanent works without contamination by the
unacceptable materials. The acceptable materials shall be stockpiled separately.
The Contractor shall ensure that he does not adversely affect the stability of
excavation or fills by the methods of stockpiling materials, use of plants or sitting
of temporary buildings or structures. The Contractor shall obtain representative
samples from each of the identified borrow areas and have these tested at the
site laboratory following a testing programme approved by the Engineer. It shall
be ensured that the sub-grade material when compacted to the density
requirements as in Table 100.6 shall yield the design CBR value of the sub-
grade.
Table 100.6Compaction Requirements for Embankment and Sub-grade
Relative Compaction as percentage of
Type of Work / Material max. laboratory dry density as per
IS:2720 (Part-8) - MPD
Sub-grade and Earthen Shoulders Not less than 97
Embankment Not less than 95
Embankment with Clay Soils
a) Sub-grade and 500mm portion
Not Allowed
just below the sub-grade
b) Remaining portion of
Not less than 90
embankment
The Contractor shall at least 7 working days before commencement of
compaction submit the following to the Engineer for approval:
i. The values of maximum dry density and optimum moisture content obtained in
accordance with IS: 2720 (Part-8), appropriate for each of the fill materials he
intends to use.
ii. A graph of density plotted against moisture content from which each of the
values in (i) above of maximum dry density and optimum moisture content were
determined.
iii. The Dry density-moisture content - CBR relationships for light, intermediate
and heavy compactive efforts (light corresponding to IS: 2720 (Part-7) or
proctor compaction, heavy corresponding to IS: 2720 (Part-8) or modified
proctor density and intermediate inbetween the two) for each of the fill
materials he intends to use in the sub-grade.
Once the above information has been approved by the Engineer, it shall form the
basis for compaction.
151.2.3.3 Construction Equipment:
151.2.3.3.1 Vibratory Roller 15-20 T static weight with 1 or 2 smooth surface steel drums
151.2.3.3.2 Layer thickness - 20 cm to 30 cm (compacted)
151.2.3.3.3 Compaction degree - 97% of MDD
151.2.3.3.4 Roller type and layer thickness:
Type of Roller Static Weight Layer Thickness
Static 8 to 10 T 100 mm
Vibratory 9 to 11 T 200mm
Heavy Vibratory 5 to 20 T 250 to 300 mm

151.2.4 Construction Operations: These specifications shall "apply to the construction

of embankments, shoulders and miscellaneous backfills with approved material
obtained either from excavation for road construction or brought from outside by
the contractor. All embankments shall be constructed in accordance with the
requirements of these specifications and in conformity with the lines, grades and
cross sections shown on the drawings or as directed by the Engineer.
151.2.5 After the site has been cleared, the work shall be set out to Clause 54. The limits
of the embankment shall be marked by fixing better pegs on both sides at regular
intervals as guides before commencing the earthwork. To ensure their safety, it
is desirable to fix the pegs about 0.5 metres back from the actual limits of the fill
and to paint them in distinctive colour.
In all cases, the original ground shall be compacted by rolling as directed by the
Engineer. When the height of the embankment is less than 0.5m and the original
ground does not already have a relative compaction of at least 95% then same
shall be loosened to a depth of 0.5m watered and compacted in layers not
exceeding 250mm in loose thickness to the maximum dry density of the material,
determined in accordance with IS: 2720 (Part-VII). However, before relaying and
compacting the loosened material, the surface below this level shall be suitably
compacted as directed by the Engineer. When so directed by the Engineer, any
suitable materials occurring in the embankment foundation shall be removed and
replaced by approved material suitably compacted. Embankment work shall not
proceed until the foundations for embankment have been inspected by the
Engineer, found satisfactory and approved.
151.2.6 Spreading Materials in layers and bringing to appropriate Moisture Content: The
embankment material shall be spread uniformly over the entire width of the
embankment in layers not exceeding 250mm in loose thickness. Successive
layers of embankment shall not be placed until the layer under construction has
been thoroughly compacted to the requirements set down herein under:
Moisture content of the material shall be checked at the source of supply and if
found less than specified for compaction, the same shall be made good either at
the source or after spreading the soil in loose thickness for compaction. In latter
case, water shall be sprinkled directly from hose line or from a water tank
mounted on a truck, flooding shall not be permitted under any circumstances.
If the material delivered to the road bed is too wet, it shall be dried, by
compaction. Should circumstances arise where owing to wet weather, the
moisture content cannot be reduced to the required amount by the above
procedure, work on compaction shall be suspended.
Moisture content of each layer of soil shall be adjusted (making due allowance
for evaporation loss), so that at the time of compaction, it is in the range of 1 %
above 2% below the optimum moisture content.
After adding the required amount of water, soil shall be processed by means of
hammer rotary mixer or as otherwise until the layer is uniformly wet.
Clods or hard lumps of earth shall be broken to have maximum size of 150mm,
when being placed in the lower layers of the embankment and maximum size of
60mm, when being placed in the top 0.5 meter portion of the embankment below
the sub-grade.
151.2.7 Compaction: Each layer of the material shall be thoroughly compacted by using
a power roller of not less than 8-10 Tonne or any other approved plant. Rolling
shall be done as specified in Clause 151.2.7. The field dry density of material

after compaction shall be not less than specified % in Table 100.6 of the
maximum laboratory dry density as per IS:2720 (Part-VIII).
Subsequent layers shall be placed only after the finished layer has been tested
according to Clause 622 and accepted by the Engineer.
When density measurements reveal any soft areas in the embankment, further
compaction shall be carried out as directed by the Engineer. If in spite of that the
specified compaction is not achieved, the material in the soft areas shall be
removed and replaced by approved material, compacted to the density
requirements and satisfaction of the Engineer.
The surface of the embankment at all time during construction be maintained at
such cross fall as well shed water and to prevent flooding.
151.2.8 Rolling : A power roller shall, as a rule, be not less than 10 tonnes but if at any
time still heavier rollers are required on the works, the contractors shall have to
bring them as may be directed by the Engineer. In case of trenches not more
than 2.5 m in width, an earth master or any other similar equipment manually or
machine operated, shall be invariably employed.
Rolling shall progress from edges to the centre of the road in strips parallel to the
centre line of the road. Rolling shall be done by lapping uniformly each
proceeding rear wheel track by at least one half width of the track. On super
elevations, rolling shall be started at inner edge and shall progress towards outer
edge. During and after rolling, the surface shall be checked for grade and
camber. Rolling shall be started worked or stopped without jerks. Rolling shall
not be normally done in length less than 100m (300'). On completion of day's
work, the roller shall be made to stand on the side width of the road and shall be
guarded by a watchman.
A red lantern shall be hung on the roller at night so as to be visible from . both
sides of the road.
151.2.9 Finishing Operations: These shall include the work of shaping and dressing the
shoulders, road bed and side slopes to conform to the alignment, levels, cross
sections and dimensions shown on the drawings or as directed by the Engineer,
subject to the surface tolerances described in Clause 613. Both the upper and
lower ends of the side slopes shall be rounded off to improve appearance and
merge the embankment with the adjacent terrain.
When earthwork operations have been subsequently, compacted the roadway
area shall be cleared or all debris and ugly scars in the construction areas,
responsible for objectionable appearance be eliminated.
152.0 Construction of Embankment and Sub-grade under Special Conditions:
152.1 Embankment and Sub-grade around Structures: To avoid interference with
the construction of abutments, wing walls or of culvert / bridge structures, the
Contractor shall, at points to be determined by the Engineer suspend work on
embankment forming approaches to such structures, until such time as the
construction of the latter is sufficiently advanced to permit the completion of
approaches without the risk of damage to the structure.
Unless directed otherwise, the filling around culverts, bridges and other
structures upto a distance of twice the height of the road from the back of the
abutment shall be carried out independent of the work on the main embankment.
The fill material shall not be placed against any abutment or wing wall, unless
permission has been given by the Engineer but in any case not until the concrete
or masonry has been in position for 14 days. The embankment and subgrade
shall be brought up simultaneously in equal layers on each side of the structure

to avoid displacement and unequal pressure. The sequence of work in this

regard shall be got approved from the Engineer.
The material used for backfill shall not be an organic soil or highly plastic clay
having plasticity index and liquid limit more than 20 and 40 respectively when
tested according to IS:2720 (Part-5). Filling behind abutments and wing walls for
all structures shall conform to the general guidelines given in Appendix 6 of
IRC:78 (Standard Specifications and Code of Practice for Road Bridges - Section
VII) in respect of the type of material, the extent of backfill, its laying and
compaction etc. The fill material shall be deposited in horizontal layers in loose
thickness and compacted thoroughly to the requirements of Table 100.6.
Where the provision of any filter medium is specified behind the abutment, the
same shall be laid in layers simultaneously with the laying of fill material. The
material used for filter shall conform to the requirements for filter medium spelt
out in Clause 120.2.2 unless otherwise specified in the Contract.
Where it may be impracticable to use conventional rollers, the compaction shall
be carried out by appropriate mechanical means such as small vibratory roller,
plate compactor or power rammer. Care shall be taken to see that the
compaction equipment does not hit or come too close to any structural member
so as to cause any damage to them or excessive pressure against the structure.
152.2 Construction of embankment over ground incapable of supporting
construction equipment: Where embankment is to be constructed across
ground which will not support the weight of repeated heavy loads of construction
equipment, the first layer of the fill may be constructed by placing successive
loads of material in a uniformly distributed layer of a minimum thickness required
to support the construction equipment so that no pore pressure is built up or no
bearing pressure failure of sub-soil takes place to cause movement of sub-soil as
permitted by the Engineer. The Contractor, if so desired by him, may also use
suitable geosynthetic material to increase the bearing capacity of the foundation.
This exception to normal procedure will not be permitted where, in the opinion of
the Engineer, the embankments could be constructed in the approved manner
over such ground by the use of lighter or modified equipment after proper
ditching and drainage have been provided. Where this exception is permitted, the
selection of the material and the construction procedure to obtain an acceptable
layer shall be the responsibility of the Contractor. The cost of providing suitable
traffic conditions for construction equipment over any area of the Contract will be
the responsibility of the Contractor and no extra payment will be made to him.
The remainder of the embankment shall be constructed as specified in Clause
151.2.4.
152.3 Embankment Construction under water: Where filling or backfilling is to be
placed under water, only acceptable granular material or rock shall be used
unless otherwise approved by the Engineer. Acceptable granular material shall
consist of graded, hard durable particles with maximum particle size not
exceeding 75mm. The material should be non-plastic having uniformly coefficient
of not less than 10. The material placed I open water shall be deposited by end
tipping without compaction.
152.4 Earthwork for High Embankment: In the case of high embankments, the
Contractor shall normally use the material from the specified borrow area. In
case, he desires to use different material for his own convenience, he shall have
to carry out necessary soil investigations and redesign the high embankment at
his own cost. The Contractor shall then furnish the soil test data and design of
high embankment for approval of the Engineer, who reserves the right to accept
or reject it.

If necessary, stage construction of fills and any controlled rates of filling shall be
carried out in accordance with the Contract including installation of instruments
and its monitoring.
Where required, the Contractor shall surcharge embankments or other areas of
fill with approved material for the periods specified in the Contract. If settlement
of surcharged fill results in any surcharging material, which is unacceptable for
use in the fill being surcharged, lying below formation level, the Contractor shall
remove the unacceptable material and dispose it as per direction of the
Engineer. He shall then bring the resultant level up to formation level with
acceptable material.
152.4.1 Earthwork for widening existing road embankment : When an existing
embankment and/or subgrade is to be widened and its slopes are steeper than 1
vertical on 4 horizontal, continuous horizontal benches, each at least 300mm
wide, shall be cut into the old slope for ensuring adequate bond with the fresh
embankment / subgrade material to be added. The material obtained from cutting
benches could be utilized in the widening of the embankment subgrade.
However, when the existing slope against which the fresh material is to be
placed is flatter than 1 vertical on 4 horizontal, the slope surface may only be
ploughed or scarified instead of resorting to benching.
Where the width of the widened portions is insufficient to permit the use of
conventional rollers, compaction shall be carried out with the help of small
vibratory rollers / plate compactors / power rammers or any other appropriate
equipment approved by the Engineer. End dumping of material from trucks for
widening operations shall be avoided except in difficult circumstances when the
extra width is too narrow to permit the movement of any other types of hauling
equipment.
152.4.2 Earthwork for embankment and subgrade to be placed against sloping
ground Where an embankment / subgrade is to be placed against sloping
ground, the latter shall be appropriately benched or ploughed / scarified as
required in Clause 152.1 before placing the embankment / subgrade material.
Extra earthwork involved in benching or due to ploughing / scarifying etc. shall be
considered incidental to the work.
For wet conditions, benches with slightly inward fall and subsoil drains at the
lowest point shall be provided as per the drawings, before the fill is placed
against sloping ground. Where the Contract requires construction of transverse
subsurface drain at the cut-fill interface, work on the same shall be carried out to
Clause 309 in proper sequence with the embankment and subgrade work as
approved by the Engineer.
152.4.3 Earthwork over existing road surface: Where the embankment is to be placed
over an existing road surface, the work shall be carried out as indicated below:
a) If the existing road surface is of granular or bituminous type and lies within 1 m
of the new sub-grade level, the same shall be scarified to a depth of 150mm or
more is specified, so as to provide ample bond between the old and new
material ensuring that at least 500mm portion below the top of new sub-grade
level is compacted to the desired density.
b) If the existing road surface is of cement concrete type and lies within 1 m of
the new sub-grade level the same shall be removed completely.
c) If the level difference between the existing surface and the new formation level
is more than 1 m, the existing surface shall be permitted to stay in place
without any modification.

152.4.4 Settlement Period: Where settlement period is specified in the Contract, the
embankment shall remain in place for the required settlement period before
excavating for abutment, wing wall, retaining wall, footings, etc. or driving
foundation piles. The duration of the required settlement period at each location
shall be as provided for in the Contract or as directed by the Engineer.
152.1 Measurements & Payments: Measurements of embankment shall be made by
made by taking cross-section at intervals in the original position before the work
starts and after its completion and computing the volume in cu. m. by the-
method of average end areas.
The measurements of fill material from borrow areas shall be the difference
between the net quantities. of compacted fill and the net quantities of suitable
material brought from roadway and drainage excavation. For this purpose it shall
be assumed that one Cu.M. of suitable material brought to site from road and
drainage excavation forms one Cu.M. of compacted fill and all bulking or
shrinkage shall be ignored.
152.2 The rate: for embankment or filling in with contractor's earth or moorum shall
include the cost of materials, fencing lighting watching, haulage, spreading,
levelling, watering, rolling etc. complete.
153.0 Rock Fill Embankment:
The size of rock pieces in rock fill embankment shall be such that they can be
deposited in layers so as to suit the conditions evaluated in the field compaction
trials or as directed by the engineer. The rock fill shall consist of hard, durable
and inert material, preferably maximum size not exceeding 300 mm and percent
finer than 125 mm not exceeding 10 percent.
153.1 Spreading & Compaction:
The material shall be tipped, spread and levelled in layers extending to the full
width of embankment by a suitable dozer. Fragments of rock shall then be
spread on top of layer to the required extent and layer compacted by minimum of
5 passes of vibratory roller having static weight 8-10 tonnes. The compacted
thickness of each layer shall not exceed 500mm. After compaction of each layer,
the surface voids shall be filled with broken fragments. The top layer of rockfill,
on which normal earth fill will rest shall be thoroughly blinded with suitable
material to seal its surface.
153.2 Measurements for Payment:
Measurement shall be made by taking cross-sections at intervals in the original
position before the work starts and after its completion and computing the
volume in Cu. M. by the method of average and areas.
153.3 Rate:
The Contract unit rate shall be paid in full for carrying out all the above
operations including cost of rock fill, broken fragments and blinding material and
shall provide full compensation for all items as per Clause 213.1.
154.0 Stabilised Soil Sub-Grade Construction:
154.1 Lime Treated Soil: Soil used shall be local clay soil having plasticity" index
greater than 8 and lime for stabilization work shall be as per specifications in
clause 132.1.1. Quantity of lime to be added as percentage by weight of the dry
soil shall be related to its calcium oxide content. The mix design shall be done to
arrive at the appropriate quantity of lime to be added, having due regard to the
purity of lime, the type of soil, the moisture density relationship, and the design
CBR value specified in the contract. The laboratory CBR value shall be at least
1.5 times the minimum field value of CBR stipulated in the contract. The design

CBR is to be limited to 15 for 2.5cm penetration. Water to be used for lime

stabilization shall be cleaned and free from injurious, substances.
154.1.1 Materials:
154.1.1.1 Soil: Except when otherwise specified, the soil used for stabilization shall be the
local clayey soil having a plasticity index greater than 8.
154.1.1.2 The material to be used for the work shall be sand, moorum, crushed stone or
combination thereof. The material shall be free from all deleterious constituents.
The materials passing 425 micron sieve when tested according to IS: 2720 shall
have liquid limit and plasticity index not more than 25% and 6 % respectively.
154.1.1.3 All other details as per Clause No.132.0.
154.2 Cement Treated Soil
154.2.1 The material to be used for cement treatment shall be soil sand, gravel including
crushed rock. The material shall have grading shown in Table 100.7. If material
passing 425 micron sieve is plastic, it shall not have liquid greater than 45
percent and plasticity index not greater than 20 per cent determined in according
with IS 2720 part 5.
Table 100.7 Grading Limits of Material For Stabilisation With Cement
IS Sieve Size Percentage by Mass Passing
Sub-Base Base
Finer Than Within the range
53.00 mm 100 100
37.50 mm 95 95-100
19.0 mm 45 45-100
9.50 mm 35 35-100'
4.75 mm 25 25-100
600 Micron 8 8-65
300 Micron 5 5-40
75 Micron 0 0-10
154.2.2 Materials :
154.2.2.1 Cement : Cement shall comply with the requirements of IS: 269, 455, or 1489.
154.2.2.2 Lime : If needed for pre-treatment of highly clayey soils as per Clause 132.1.1.
154.2.2.3 Water : The water to be used for cement stabilization shall be clean and free
from injurious substances. Potable water shall be preferred.
154.2.3 Quantity of Cement in Stabilised Mix: The quantity of cement to be added as
per cent by weight of the dry soil shall be specified in the Contract. Also if lime is
used as pre-treatment for highly clayey soils, the quantity as per cent by weight
of dry soil shall be specified in the Contract. The mix design shall be done on the
basis of 7 -day unconfined compressive strength (UCS) and/or durability test
under 12 cycles of wet-dry conditions. The laboratory strength values shall be at
least 1.5 times the minimum field UCS value stipulated in the Contract.
154.2.4 Construction Operations:
154.2.4.1 Weather Limitations: Stabilisation shall not be done when the air temperature in
the shade is less than 10°C.
154.2.4.2 Degree of Pulverisation: For stabilization, the soil before addition of stabilizer
shall be pulverized, where necessary, to the extent that it passes the
requirements as set out in Table 100.8 when tested in accordance with the
method described in Appendix 3.

Table 100.8 Soil Pulverisation Requirements for Cement Stabilisation

Minimum per cent by weight
IS Sieve Designation
passing the IS sieve
26.5mm 100
5.6mm 80
154.2.4.3 The equipment used for mix-in-place construction shall be a rotavator or similar
approved equipment capable of pulverizing and mixing the soil with additive and
water to specified degree to the full thickness of the layer being processed, and
of achieving the desired degree of mixing and uniformity of the stabilized
material. If so desired by the Engineer, trial units with the equipment shall be
carried out to establish its suitability for work.
154.2.4.4 Moisture Content for Compaction: The moisture content at compaction
checked vide IS:2720 (Part-2) shall not be less than the optimum moisture
content corresponding to IS:2720 (Part-8) nor more than 2 per cent above it.
154.2.4.5 Rolling : Clause 132.3.2 shall apply except that care shall be taken to see that
the compaction of cement stabilized material is completed within two hours of its
mixing or such shorter period as may be found necessary in dry weather.
154.2.4.6 Curing: The sub-base/base course shall be suitably cured for 7 days.
Subsequent pavement course shall be laid soon after to prevent the surface from
drying out and becoming friable. No traffic of any kind shall ply over the
completed sub-base unless permitted by the Engineer:
154.2.4.7 Surface Finish and Quality Control of Works: The surface finish of
construction shall conform to the requirements of Clause 132.4.
154.2.4.8 Strength: Control on the quality of materials and works shall be exercised by the
Engineer in accordance with Section 623.
Cement treated soil sub-base / base shall be tested for the unconfined
compressive strength (UCS) value at 7 days, actually obtained in situ. In case of
variation from the design UCS, in situ value being on lower side, prior to
proceeding with laying of base/surface course on it, the pavement design shall
be reviewed for actual UCS value. The extra pavement thickness needed on
account of lower UCS shall be constructed by the Contractor at his own cost.
154.2.4.9 Arrangement to Traffic: During the period of construction, arrangement of traffic
shall be maintained in accordance with Clause 30.
154.2.4.10 Measurements for Payment: Stabilised soil sub-base/base shall be measured
as finished work in position in cubic metres.
154.2.4.11 Rates: The contract unit rate for cement treated soil sub-base / base with pre-
treatment with lime if required shall be payment in full for carrying out the
required operations including full compensation for all components listed in
Clause 213.1.
155.0 Embankment with Fly Ash:
a. Materials :
Soil: As per Specifications given in the Clause 151.2.3.2.
Fly Ash: Fly Ash or Pond Ash available from coal heated plants.
b. Equipment: Vibratory roller with frequency range of 1800-2200 rpm.
c. Construction of Embankment:
a) Pond ash and cover material shall be spread in layers of uniform
thickness not exceeding 200mm compacted thickness over the entire
width of the embankment by mechanical means as specified in Clause

No.151.2.6. Moisture control of both pond ash and cover shall be done
as per Clause No.151.2.6.
b). For better compaction of pond ash, it is preferred to have a vibratory
roller with frequency' range (1800-2200 rpm). For compaction of pond
ash static as well as vibratory rollers may be employed. In case of
vibratory roller, the lift thickness shall be restricted to 25cm compacted
over the entire width of the embankment. The pond ash should be
compacted to 95% of its MDD and in no case its maximum density
should be less than 1.2 gm/cc. Moisture content of pond ash at
compaction will vary from OMC to OMC +2%.
c) After achieving the designed thickness of first pond ash layer, a cover
soil layer of 40cm compacted thickness shall be provided as Clause
NO.151.
d) The same procedure shall be adopted for subsequent pond ash and soil
layers, till the required height is achieved.
e) Pond ash shall be used upto 500mm below GSB layer.
f) Width of side cover soil shall be 2000mm measured horizontally. The
cover soil shall comprise soil as per Clause 151.
d. Payment shall be made in accordance with Clause 151.

200.0 Granular Sub-Base I Base

210.0 Granular Sub-Base:
211.0 Materials: The material to be used for the work shall be natural sand, gravel,
crushed stone, or combination thereof depending upon the grading required.
Materials like crushed slag, crushed concrete may be allowed only with the
specific approval of the Engineer. The material ~hall be free from organic or
other deleterious constituents and conform to one of the grading given in Table
200.2 as specified in the contract.
211.1 Physical Requirement : The material shall have a 10 per cent fines value of 50
KN or more (for sample in soaked condition) when tested in compliance with
IS:812 (Part-III). The water absorption value of the coarse aggregate shall be
determined as per IS:2386 (Part-III); if this value is greater than 2%, the
soundness test shall be carried out on the material as per IS:383.
211.2 Grading Requirement : The. grading· in Table 200.2 is in respect of coarse
graded granular sub-base materials, one each for maximum particle size of
75mm, 53mm and 26.5mm. The coarser grading is intended to make the layer to
act as drainage layer. Hence, if directed by the Engineer a separation layer by
way of geo-textile as per Clause 260 between sub-grade and sub-base and layer
of geo-grid in between sub-base and base be provided. The grading to be
adopted for a project shall be as specified in the contract.
Table 200.2 Grading for Coarse Graded Granular Sub-Base Materials
(Permeable Layer)
Per Cent by weight passing the IS Sieve
Grading I Grading II Grading III
75.0 mm 100 - -
53.0 mm 100 -
26.5 mm 55-75 50-80 100
9.50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm <5 <5 <5
CBR Value (minimum) with 5 Kg.
Surcharge at Maximum Dry
30 25 20
Density as per IS:2720 (Part-8)
and after soaking for four days ,
Note:
1.The material passing 425 micron (0.425mm) sieve for all the three gradings
when tested according to IS:2720 (Part-5) shall have liquid limit and plasticity
index not more than 25 and 6 per cent respectively.
2.The layer of coarse graded sub-base shall be separated from subgrade by
providing suitable geo-textile of strength mentioned in the contract and at top
a layer of geo-grid or geo-net specified in contract· be provided.
3.The material passing 19 mm sieve and duly adjusted for fraction retained on
19 mm sieve shall be used for finding maximum dry density.
211.3 Strength of Sub-Base : It shall be ensured prior to actual execution that the
material to be used in the sub-base satisfies requirement of 1.1 times the design

CBR mentioned in Table 200.2 and other physical requirements when

compacted and finished.
When directed by the Engineer, this shall be verified by performing CBR test in
the laboratory as required on specimens re-moulded at maximum dry density
and at OMC using material passing 19 mm sieve.
The value of laboratory CBR shall be 1.5 times the design CBR mentioned in
Table 200.2.
211.4 Equipment : Roller 80 to 100 KN weight if thickness of layer is less than 100
mm. 80 to 100 KN static weight vibratory or pneumatic tyred roller of 200 to 300
KN weight having minimum tyre pressure of 0.7 KN /sq. m.
212.0 Preparation of Sub-grade: Immediately prior to ·the laying of subbase, the sub
grade already finished to Clause 100 or 150 as applicable shall be prepared by
removing all vegetation and other extraneous matter, lightly sprinkled with water
if necessary and rolled with two passes of 80-100 kN smooth wheeled roller.
212.1 Spreading and Compacting: The sub-base material of grading specified in the
Contract shall be spread on the prepared sub-grade with the help of a motor
grader of adequate capacity, its blade having hydraulic controls suitable for initial
adjustment and for maintaining the required slope and grade during the operation
or other means as approved by the Engineer. When the sub-base material
consists of combination of materials mentioned in Clause 211, mixing shall be
done mechanically by the mix-in-place method.
Manual mixing shall be permitted only where the width of laying is not adequate
for mechanical operations, as in small-sized jobs. The equipment used for mix-in-
place construction shall be a rotavator or similar approved equipment capable of
mixing the material to the desired degree. If so desired by the Engineer, trail runs
with the equipment shall be carried out to establish its suitability for the work.
Moisture content of the loose material shall be checked in accordance with
IS:2720 (Part-2) and suitably adjusted by sprinkling additional water from a truck
mounted or trailer mounted water and suitable for applying water uniformly and
at controlled quantities to variable widths of surface or other means approved by
the Engineer so that, at the time of compaction, it is from 1 per cent above to 2
per cent below the optimum moisture content corresponding to IS:2720 (Part-8).
While adding water, due allowance shall be made for evaporation losses. After
water has been added, the material shall be processed by mechanical or other
approved means like disc harrows, rotavators until the layer is uniformly wet.
Immediately thereafter, rolling shall start. If the thickness of the compacted layer
does not exceed 100mm, a smooth wheeled roller of 80 to 100 kN weight may be
used. For a compacted single layer upto 225mm, the compaction shall be done
with the help of a vibratory roller of minimum 80 to 100 kN static weight with plain
drum or pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300 kN
weight having a minimum tyre pressure of 0.7 MN/m2 or equivalent capacity roller
capable of achieving the required compaction. Rolling shall commence at the
lower edge and proceed towards the upper edge longitudinally for portions
having unidirectional cross fall and super-elevation and shall commence at the
edges and progress towards the centre for portions having cross fall on both
sides.
Each pass of the roller shall uniformly overlap not less than one-third of the track
made in the preceding pass. During rolling, the grade and cross fall (camber)
shall be checked and any high spots or depressions, which become apparent,
corrected by removing or adding fresh material. The speed of the roller shall not
exceed 5 km per hour.

Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material determined as per IS:2720 (Part-8). The
surface of any layer of material on completion of compaction shall be well closed,
free from movement under compaction equipment and from compaction planes,
ridges, cracks or loose material. All loose, segregated or otherwise defective
areas shall be made good to the full thickness of layer and re-compacted.
212.2 Surface Finish and Quality Control of Works: The surface finish of
construction shall conform to the requirements of Clause 613. Control on the
quality of materials and works shall be exercised by the Engineer in accordance
with Section 620.
212.3 Arrangement for Traffic: During the period of construction, arrangement of
traffic shall be maintained in accordance with Clause 30.
213.0 Measurements for Payment: Granular sub-base shall be measured as finished
work in position in cubic metres.
The protection of edges of granular sub-base extended over the full formation as
shown in the drawing shall be considered incidental to the work of providing
granular sub-base and as such no extra payment shall be made for the same.
213.1 Rates: The contract unit rate for granular sub-base shall be payment in full for
carrying out the required operations including full compensation for:
a) Making arrangements for traffic to Clause 30 except for initial treatment to
verges, shoulders and construction of diversions,
b) Furnishing all materials to be incorporated in the work including all royalties,
fees, rents where necessary and all leads and lifts,
c) All labour, tools, equipment and incidentals to complete the work to the
Specifications,
d) Carrying out the work in part widths of road where directed and
e) Carrying out the required tests for quality control.
220.0 Water Bound Macadam:
221.0 Description : Coarse aggregates shall be crushed or broken stone, crushed
slab. The aggregate shall confirm to the physical requirements given in Table
200.3(Table:1 of IRC:19-2005.) The type and size of the aggregate shall be
specified in the contract. If the water absorption value of the coarse aggregate is
greater than 2%, the soundness test shall be carried out on the material as per
IS : 2386 (Part 5). The crushed or broken stone shall be hard, durable and free
from excess flat, elongated, soft and disintegrated particles, dirt and other
deleterious materials. Screening to field wise in the coarse aggregate shall
generally consist of the same material as the coarse aggregate.
WBM should not be laid directly over a silty or clayey subgrage. It is advisable to
lay a suitable intervening granular layer. (As per clause 2.1.3 of IRC:19-2005)
222.0 Materials:
222.1 Coarse Aggregates – General Requirements ( clause 3.1 of IRC:19-2005)
222.1.1 Coarse aggregates shall consists of clean crushed or broken stone, crushed
slag, overburnt brick ( Jhama ) metal or naturally occurring aggregates such as
kankar and laterite of requisite quantity as stated hereinafter. Use of crushable
type aaggregates should generally be restricted to lower layers of the pavement.
The aggregate shall conform to the physical requirements set forth in
Table:200.3 (clause 3.1.1 of IRC: 19-2005)
222.1.2 Physical Requirements of crushed stone : The crushed or broken stone shall be
hard, durable and free from excess flat, elongated, soft and disintegrated

particles, dirt and other deleterious material and shall meet requirement given in
table 200.3.
222.1.3 Crushed slag: Crushed Slag shall be manufactured from air –cooled blast
furnace slage. It shall be angular in shape, reasonably uniform in quality and
density, and generally free from soft, alongated and flat pieces, dirt or other
deleterious material. Crushed slag shall not weigh less than 11.2 kM per m 3 and
the glassy material in it shall not be in excess of 20 percent . It should also
compty with the following requirements.
(i) Chemical stability: To comply with requirement of Appendix of BS : 1047
(ii) Sulphur Content: Maximum 2 percent
(IS 14685 – 1999)
(iii) Water absorption: Maximum 10 percent
(IS 2386, Part 3)
(clause 3.1.3 of IRC: 19-2005)
222.1.4 Overburnt (Jhama) Brick metal: Brick metal shall be made out of overburnt bricks
or brick bats and be free from dust and other deleterious materials. (clause 3.1.4
of IRC: 19-2005)
222.1.5 Kankar: Kankar shall be tough having a blue opalescent fracture. It shall not
contain any clay in the cavities between nodules. (clause 3.1.5 of IRC: 19-2005)
222.1.6 Laterite: Laterite shall be hard, compact, heavy and of dark colour. Light coloured
sandy laterities, as also those containing ochreous clay shall not be used.
(clause 3.1.6 of IRC: 19-2005)
Table 200.3Physical Requirements of Coarse Aggregates for Water Bound
Macadam
Sl Type of
Test Test Method equipments
No. Consutruction
Los Angeles
Abrasion Value* IS 2386 (Part 4) Max. 50 %
1 Sub-Base or
Aggregate Impact IS 2386 (Part 4)
Max. 40 %
Value* or IS 5640**
Los Angeles
Base course or
2 with bituminous
Aggregate Impact IS 2386 (Part 4)
surfacing Max. 30 %
Value+ or IS 5640**
Flakiness Index*** IS 2386 (Part 1) Max. 20 %
Los Angeles
Surfacing or
3
course Aggregate Impact IS 2386 (Part 4)
Max. 30 %
Value+ or IS 5640**
Flakiness Index*** IS 2386 (Part 1) Max. 15 %
* Aggregates may satisfy the requirements of either the Los Angeles test or
Aggregate Impact Value Test.
** Aggregates like brick metal, Kankar. Laterite, etc., which get softened in
presence of water should invariably be tested for impact value under wet
condition in accordance with IS 5640

*** The requirement of Flakiness Index shall be enforced only in case of

crushed/broken stone and crushed slag
+
Sample for test shall be representative of materials to be used and collected in
accordance with the procedure set forth in IS 2430
222.2 Grading Requirement: As per Table 200.4.
222.2.1 The coarse aggregates shall confirm to one of the grading in Table: 200.4 given
below. Grading 1 shall be used only for sub-base courses, with a compacted
layer thickness of 100mm. The size of aggregates to be used would depend on
the type of aggregates available and compacted thickness of the layer. The
crushable type aggregates like brick metal, kankar and laterite shall also
generally satisfy the grading requirements of Table:200.4. Relaxation in grading
may be permitted for such materials with the permission of the Engineer. (Refer
clause: 3.2 of IRC:19-2005).
Table 200.4 Size and Grading Requirements of Coarse Aggregates for WBM
Size range and Sieve Per cent Weight
Grading
compacted thickness for Designation (IS Passing the
No.
layer 460) sieve
1 90 mm to 45 mm (100 mm) 125mm 100
90mm 90-100
63mm 25-60
45mm 0-15
22.4mm 0-5
2 63 mm to 45 mm (75 mm) 90mm 100
63mm 90-100
53mm 25-27
45mm 0-15
22.4mm 0-5
53 mm to 22.4 mm (75
3 63mm 100
mm)
53mm 90-100
45mm 65-90
22.4mm 0-10
11.2mm 0-5
222.3 Screenings :
222.3.1 Screenings to fill voids in the coarse aggregates shall generally be of the same
material as the coarse aggregates. However, from economic considerations,
predominantly non-plastic material such as kankar, moorum or gravel (other than
river-borne rounded aggregate) may also be used for this purpose provided that
the Liquid limit and plasticity index of such material are below 20 and 6
respectively and the fraction passing 75 micron sieve does not exceed 10 per
cent.
222.3.2 As far as possible, screenings shall conform to the grading shown in Table
200.5. Screenings of type A shall be used in conjunction with coarse aggregates
of grading 1, and of type B with coarse aggregates of grading 3. With coarse
aggregates of grading 2, either type A or type B screenings may be used. For
crushable screenings like moorum and gravel, the grading given in Table 200.5
shall not be binding.:

222.3.3 The use of screenings may be dispensed with when crushable type soft
aggregates such as brick metal, kankar, laterite, etc., are used as coarse
aggregates, as these are likely to get crushed to a certain extent during rolling.:
Table 200.5 Grading Requirements of Screenings for WBM
Size of
Grading Screenings Sieve Designation Percent by
Classification Passing the Sieve Weight
(IS 460)
13.2mm 100
11.2mm 95-100
A 13.2mm
5.6mm 15-35
180 micron 0-10
11.2 mm 100
B 11.2mm 5.6 mm 95-100
180 micron 15-35
222.4 Binding Material : Binding Material to be used for water bound macadam as a
filler material meant for preventing ravelling, shall comprise of a fine grained
material passing 100 percent through 425 micron sieve and possessing PI value
of 4-8 when WBM is used as surfacing course and less than 6 when the WBM is
adopted as a sub-base/base course with bituminous surfacing. If limestones
formations are available nearby, limestones dust or kankar nodules may be used
as binding material. (Refer clause 3.4 of IRC:19-2005) Application of binding
material may not be necessary, where the screenings consist of crushable type
material like moorum or gravel. However, for WBM used as a surfacing course,
where the PI of crushable type screenings is less than 4, application of a small
quantity of binding material having PI of 4-6 would be required at the top. The
quantity of screenings could be reduced correspondingly. (clause 3.4 of IRC:19-
2005)
The quantity of binding material where it is to be used, will depend on the type of
screenings. Approximate quantities of coarse aggregates and screenings
required for 100 mm compacted thickness of WBM sub-surface course are given
in Table:200.5.1 given below. The quantities of materials for WBM sub-
surface/base or surfacing course for a compacted thickness are given in
Table:200.5.2
Table 200.5.1 Approximate Quantities or Coarse Aggregates and Screenings
Required for 100 mm compacted thickness of WBM Sub·base Course per 10 m2
Coarse Aggregates Screenings
Stone Screenings Crushable Type Such as
Size Loose Moorum or Gravel
Range Quantity Grading Loose
Classification Properties and Loose
2 classification quality
(mm) (m ) 3 size quality
and size (m ) 3 3
(m ) (m )
1 2 3 4 5 6 7
LL<20,
Type A, 0.30
90 to 21 to PI<6,
Grading 1 0.27 to 0.30 to
45 1.43 13.2 mm Percent passing 0.32
75 micron <10

Table 200.5.2 Approximate Quantities or Coarse Aggregates and Screenings

Required for 75 mm compacted thickness of WBM Sub·base/Base Course /
surfacing Course per 10 m2
Coarse Aggregates Screenings
Stone Screenings Crushable Type
Such as Moorum or
Loose quality or Gravel
Size Loose WBM
Range Quantity Grading sub-
Classification WBM
2 classification base / Properties Loose
(mm) (m ) surfacing
and size base and size quality
course *
course 3
3
(m )
3
(m )
* (m )
3
(m )
1 2 3 4 5 6 7 8
LL<20,
PI<6,
Type A, 0.22
63 to 0.91 to 0.12 to 0.10 to Percent
Grading 2 to
45 1.07 13.2 mm 0.15 0.12 passing 0.24
75 micron
<10
63 to Type B, 0.20 to 0.16 to
Grading 2 -do- -do- -do-
45 11.2 mm 0.22 0.18
53 to 0.18 to 0.14 to
Grading 3 -do- -do- -do- -do-
22.4 0.21 0.17
* Qualities in Col. 6 are 80 percent of those in Col.5 as larger quality of binding
material will need to be used where the WBM is to act as a surfacing course
The quantity of binding material where it is to be used will depend on the type of
screening and function of WBM. Generally, the quantity required for 75mm
compacted thickness of water bound macadam will be 0.06-0.09 m3 I 10m2 in
case of WBM sub-base/base course and 0.10-0.15 m2 / 10m2. The quantity
required will be 0.08-0.10 m3 /10m2 for 100mm compacted thickness. The above
mentioned quantities should be taken as a guide only, for estimation of
quantities for construction etc. Application of binding materials shall not be used
when WBM layer is provided as sub-base I base to serve also as drainage layer.
222.5 Preparation of Base : The surface of the sub-grade I sub-base I base to receive
the water bound macadam course shall be prepared to the specified lines and
crossfall (camber) and made free of dust and other extraneous material. Any ruts
or soft yielding placed shall be corrected in an approved manner and rolled until
firm surface is obtained if necessary by sprinkling water. Any sub-base I base I
surface irregularities, where predominant, shall be made good by providing
appropriate type of profile corrective course (levelling course).
As far as possible, laying water bound macadam course over an existing thick
bituminous layer may be avoided since it will cause problems of internal drainage
of the pavement at the interface of two courses. It is desirable to completely pick
out the existing thin bituminous wearing course where water bound macadam is
proposed to be laid over it. However, where the intensity of rain is low and the
interface drainage facility is efficient, water bound macadam can be laid over the
existing thin bituminous surface by cutting 50mm x 50mm furrows at an angle of
45 degrees to the centre line of the pavement at one metre intervals in the
existing road. The directions and depth of furrows shall be such that they provide

adequate bondage and also serve to drain water to the existing granular base
course beneath the existing thin bituminous surface.
Inverted Choke: If water bound macadam is to be laid directly over the sub-
grade, without any other intervening pavement course, a 25mm course of
screenings (Grading B) or coarse sand shall be spread on the prepared sub-
grade before application of the aggregates is taken up. In case of a fine sand or
silty or clayey sub-grade, it is advisable to lay 100mm insulating layer of
screening or coarse sand on top of fine grained soil, the gradation of which will
depend upon whether it is intended to act as a drainage layer as well. As a
preferred alternative to inverted choke, appropriate geosynthetic performing
functions of separation and drainage may be used over the prepared sub-grade
as directed by the Engineer. Section 260 shall be applicable for use of geo-
synthetics.
222.6 Spreading Coarse Aggregates : The coarse aggregates shall be spread
uniformly and evenly upon the prepared sub-grade I sub-base I base to proper
profile by using templates placed across the road about 6m apart, in such
quantities that the thickness of each compacted layer is not more than 75mm as
specified in Clause 222.2 Wherever possible, approved mechanical devices such
as aggregate spreader shall be used to spread the aggregates uniformly so as to
minimize the need for manual rectification afterwards. Aggregates placed at
locations which are inaccessible to the spreading equipment, may be spread in
one or more layers by any approved means so as to achieve the specified
results.
The spreading shall be done from stockpiles along the side of the roadway or
directly from vehicles. No segregation of large or fine aggregates shall be
allowed and the coarse aggregate as spread shall be of uniform gradation with
no pockets of fine material.
The surface of the aggregates spread shall be carefully checked with templates
and all high or low spots remedied by removing or adding aggregates as may be
required. The surface shall be checked frequently with a straight edge while
spreading and rolling so as to ensure a finished surface as per approved
drawings.
The coarse aggregates shall normally be spread more than 3 days in advance of
the subsequent construction operations.
222.7 Roller: If the thickness of single layer does not exceed 100mm a smooth
wheeled Roller of 80-100 KN weight be used. For a compacted single layer upto
200mm, the compaction shall be done with the help of vibratory Roller of
minimum static weight of 80-100 KN.
222.8 Rolling: Immediately following the spreading of the coarse aggregate, rolling
shall be started with three wheeled power rollers of 80 to 100 KN capacity or
tandem or vibratory rollers of 80 to 100 KN static weight. The type of roller to be
used shall be approved by the Engineer based on trial run.
Except on super-elevated portions where the rolling shall proceed from inner
edge to the outer, rolling shall begin from the edges gradually progressing
towards the centre. First the edge / edges shall be compacted with roller running
forward and backward. The roller shall then move inward parallel to the centre
line of the road, in successive passes uniformly lapping preceding tracks by at
least one half widths. Rolling shall be discontinued when the aggregates are
partially compacted with sufficient void space in them to permit application of
screenings. Compaction shall be continued until the aggregates are thoroughly
keyed. During rolling, slight sprinkling of water may be done, if necessary. Rolling
shall not be done when the sub-grade is soft or yielding or when it causes a

wave-line motion in the sub-grade or sub-base course. If irregularities develop

during rolling, which exceed 12 mm when tested with a 3 m straight edge, the
surface shall be loosened and aggregates added or removed as required before
rolling again so as to achieve all uniform surface conforming to the desired cross
section and grade. (Refere clause 4.4.4 of IRC:19- 2005)-
The rolled surface shall be checked transversely and longitudinally, with
templates and any irregularities corrected by loosening the surface, adding or
removing necessary amount of aggregates and rerolling until the entire surface
conforms to desired cross fall (camber) and grade. In no case shall the use of
screenings be permitted to make up depressions.
Material which gets crushed excessively during compaction or becomes
segregated shall be removed and replaced with suitable aggregates.
222.9 Application of Screenings : After the coarse aggregate has been rolled to
Clause 222.9 screenings to completely fill the interstices shall be applied
gradually over the surface. These shall not be damp or wet at the time of
application. Dry rolling shall be done while the screenings are being spread so
that vibrations of the roller cause them to settle into the voids of the coarse
aggregate. The screenings shall not be dumped in piles but be spread uniformly
in successive thin layers either by the spreading motions of hand shovels or by
mechanical spreaders, or directly from tipper with suitable grit spreading
arrangement. Tipper operating for spreading the screenings shall be so driven as
not to disturb the coarse aggregate.
The screenings shall be applied at a slow and uniform rate (in three or more
applications) so as to ensure filling of all voids. This shall be accompanied by dry
rolling and brooming with mechanical brooms, hand-brooms or both. In no case
shall be the screenings be applied so fast and thick as to form cakes or ridges on
the surface in such a manner as would prevent filling of voids or prevent the
direct bearing of the roller on the coarse aggregate. These operations shall
continue until no more screenings can be forced into the voids of the coarse
aggregate.
The spreading, rolling and brooming of screenings shall be carried out in only
such lengths of the road which could be completed within one day's operation.
222.10 Sprinkling of Water and Grouting : After the screenings have been applied, the
surface shall be copiously sprinkled with water, swept and rolled. Hand brooms
shall be used to sweep the wet screenings into voids and to distribute them
evenly. The sprinkling, sweeping and rolling operation shall be continued, with
additional screenings applied as necessary until the coarse aggregate has been
thoroughly keyed, well-bonded and firmly set in its full depth and a grout has
been formed of screenings. Care shall be taken to see that the base or sub-
grade does not get damaged due to the addition of excessive quantities of water
during construction. .
In case of lime treated soil sub-base, construction of water bound macadam on
top of it can cause excessive water to flow down to the lime treated sub-base
before it has picked up enough strength (is still "green") and thus cause damage
to the sub-base layer. The laying of water bound macadam layer in such cases
shall be done after the subbase attains adequate strength, as directed by the
Engineer.
222.11 Application of Binding Material: After the application of screenings in
accordance with Clauses 222.10 the binding material where it is required to be
used (Clause 222.4) shall be applied successively in two or more thin layers at a
slow and uniform rate. After each application, the surface shall be copiously
sprinkled with water, the resulting slurry swept in with hand brooms, or

mechanical brooms to fill the voids properly, and rolled during which water shall
be applied to the wheels of the rollers if necessary to wash down the binding
material sticking to them. These operations shall continue until the resulting
slurry after filling of voids, forms a wave ahead of the wheels of the moving roller.
222.12 Wetting and Drying: After the final compaction of water bound macadam
course, the pavement shall be allowed to dry overnight. Next morning hungry
spots shall be filled with screenings or binding material as directed, lightly
sprinkled with water if necessary and rolled. No traffic shall be allowed on the
road until the macadam has set. The Engineer shall have the discretion to stop
hauling traffic from using the completed water bound macadam course, if in his
opinion it would cause excessive damage to the surface. The compacted water
bound macadam course should be allowed to completely dry and set before the
next pavement course is laid over it.
222.13 Surface Finish and Quality Control of Work : The surface finish of construction
shall conform to the requirements of Clause 613.Control on the quality of
materials and works shall be exercised by the Engineer in accordance with
Section 600.
Reconstruction of Defective Macadam: The finished surface of water bound
macadam shall conform to the tolerance of surface regularity as prescribed in
Clause 600. However, where the surface irregularity of the course exceeds the
tolerances or where the course is otherwise defective due to sub-grade soil
mixing with the aggregates, the course to its full thickness shall be scarified over
the affected area, reshaped with added material or removed and replaced with
fresh material as applicable and re-compacted. In no case shall depressions be
filled up with screenings or binding material.
222.14 Arrangement for Traffic: During the construction, the arrangement of traffic
shall be done as per Clause 30.
222.15 Measurements for Payment: Water bound macadam shall be measured as
finished work in position in cubic metres.
222.15.1 Rate : The Contract unit rate for water bound macadam sub-base I base course
shall be payable in full for carrying out the required operations including full
compensation for all components listed in Clause 213.1 including arrangement of
water used in the work as approved by the Engineer.
230.0 Open Graded Granular Sub-base with Geo-Cell Confinement:
230.1 Materials : Open graded granular material confined in Geo cell made of Geo- net
or Geo- grid. Thickness in multiples of 300 mm.
230.1.1 Physical Requirements of crushed stone: The crushed or broken stone shall
be hard, durable and free from excess flat, elongated, soft and disintegrated
particles, dirt and other deleterious material. Open graded granular material shall
conform to the requirements given in Table 200.6. the grading of the granular
material shall be as per Table 200.6.
Table 200.6 Physical Requirements of Coarse Aggregates for Open Graded
Granular Material & Water Bound Macadam for Sub-Base Course
Test Test Method Requirements
IS:2386 (Part-4)
Los Angeles Abrasion Value 40 per cent (Max)
or
IS:2386 (Part-4) or
Aggregate Impact Value 30 per cent (Max)
IS:5640
Combined Flakiness and
18:2386 (Part-1) 30 per cent (Max)
Elongation Indices (Total)

230.1.2 Grading Requirements: As in Table 200.4

230.1.3 Geo-Cell : Geo-net or Geo-Grid of design strength shall provide open graded
aggregate of sub-base with confinement, the thickness of layer shall be as per
the design. The geo-net or geo-grid shall be laid in vertical plain, in zigzag
,pattern and tied at the nodes forming compartment or cells of designed
diameter. The spacing of the geo-net or geo-grid shall be not more than 1.2
times the depth of the geo-cell. Geo-net, Geo-grid is as per Clause No. 260.
230.1.4 Geo-Textile : Geo-Textile shall be as per the specifications given in Clause No.
260
230.1.5 Laying : Layer of Geo-Textile shall be provided at bottom on the prepared sub-
grade. The Geo-cell shall be laid on the geo-membrane. The nodes shall be tied
as per manufacturer's directions. The cells so formed are then filled to the full
depth as one layer.
230.1.6 Rolling as single layer with 80-100 KN smooth wheeled Roller and 60-80 KN
static weight vibratory Roller.
230.1.7 Measurements for Payment : The geo-textile and geo-cell shall be measured per
Square Metre of the sub-base as laid. Measurement for the aggregate shall be
as per WBM given in Clause No.220.
230.1.8 Rates : Rates shall be per 8quare Metre of the sub-base area for geo-cell and
geo-membrane and as per Clause No.220 for aggregate.
235.0 Crushed Cement Concrete
235.1 Scope : This work shall consist of breaking and crushing the damaged cement
concrete slabs and re-compacting the same as sub-base/base course in one or
more layers. Where specified, it shall also include treating the surface of the top
layer with a penetration cot of bitumen. The work shall be performed on such
widths and lengths as may be specified, in accordance with the requirements of
these Specifications and in conformity with the lines, grades and cross-sections
shown on :the drawings or as otherwise directed by the Engineer.
235.2 Materials:
235.2.1 Coarse Aggregate : Coarse Aggregate for this work shall be broken cement
concrete slabs crushed to a size not exceeding 75mm and as far as possible,
conforming to one of the gradings given in Table 200.4.
235.2.2 Key Aggregate: Key Aggregate for the penetration coat shall consist of crushed
stone, crushed gravel, shingle or other stones. It shall be clean, strong, durable,
of fairly cubical shape and free of disintegrated pieces, organic or other
deleterious matter and adherent coatings. The aggregate shall be hydrophobic
and of low porosity.
The aggregate shall be of 11.2mm size defined as 100 per cent passing through
13.2mm sieve and retained on 5.6mm sieve and shall satisfy the physical
requirements set forth in Table 200-5.
235.2.3 Binder: Binder for the penetration coat for the top layer shall be bitumen of a
suitable grade, as directed by the Engineer and satisfying the requirements of
18:73, 217 or 454, as applicable or any approved cutback or emulsion satisfying
the requirements of 18:8887.
235.2.4 Construction Operations
235.2.5 General: Crushed cement concrete sub-base/base course may be constructed in
one or two layers, depending upon the thickness of the concrete slabs
dismantled and crushed. The thickness of each layer shall, however, not exceed
100 mm in case of sub-base and 75mm in case of base course.

The course shall be constructed as water bound macadam to Clause 220, using
crushed cement concrete as coarse aggregate except that no screenings or
binding material need be applied. Where specified, the top layer shall be treated
with a penetration coat of binder described in Clause 235.2.6.
235.2.6 Application of penetration coat over the top layer: Before the application of the
penetration coat, the surface shall be cleaned of dust, dirt and other foreign
matter, using mechanical broom or any other equipment specified by the
Engineer. Dust removed in the process shall be blown off with the help of
compressed air.
The binder shall be heated to the temperature appropriate to the grade of
bitumen used and sprayed on the dry surface in a uniform manner at the rate of
25 Kg per 10 sq. m area in terms of the residual bitumen with the help of either
self-propelled or towed bitumen pressure sprayer with self-heating arrangement
and spray nozzle capable of spraying bitumen at specified rates and
temperatures so as to provide a uniform, unbroken spread of bitumen. Excessive
deposits of binder caused by stopping or staring of the sprayer or through
leakage or any other reason shall be suitably corrected.
Immediately after the applicable of binder, the key aggregates, in a clean and dry
state shall be spread uniformly on the surface at the rate of 0.13 Cu. M. per 10
sq.m area, preferably by means of a mechanical grader, capable of spreading
aggregate uniformly at specified rates or otherwise manually with the approval of
the Engineer, so as to cover the surface completely. Immediately after the
application of the key aggregates, the entire surface shall rolled to Clause
352.4.4.
235.2.7 Surface Finish and Quality Control of Works : The surface finish of construction
shall conform to the requirements of Clause 600.Control on the quality of
material and works shall be exercised by the Engineer in accordance with
Section 600.
235.2.8 Arrangements for Traffic: During the period of construction, arrangement of traffic
shall be done as per Clause 30.
235.2.9 Measurements for Payment: Breaking the existing cement concrete pavement
slabs, crushing and re-compacting the slab material as sub-base/ base course
shall be measured as a single item in terms of the volume of sub-base/base laid
in position in cubic metres. Penetration coat shall be measured as finished work
in square metres.
235.2.10 Rates:
235.2.10.1 The Contract unit rate for crushed cement concrete sub-base/base course
shall be payment in full for carrying out the required operations including full
compensation for:
a) making arrangements for traffic to Clause 30 except for initial treatment to
verges I shoulders and construction of diversions;
b) breaking the cement concrete slabs, crushing, sieving and re-compacting
the slab material as sub-base/base course;
c) all labour, tools, equipment and incidentals to complete the work to the
Specifications; and
d) carrying out the work in part widths of road where directed. 235.2.10.2 The
Contract unit rate for penetration coat shall be payment in full for carrying
out the required operations including full compensation for all components
listed in Clause 504.8.

240.0 Wet Mix Macadam:

240.1 Material
240.1.1 Aggregates:
240.1.1. Physical Requirements: Coarse aggregates shall be crushed stone. If crushed
gravel / shingle are used, not less than 90 per cent by weight of the gravel/
shingle pieces retained on 4.75mm sieve shall have at least two fractured faces.
The aggregates shall conform to the physical requirements set forth in Table
200.7 below.
Table 200.7 Physical Requirements for Granular Materials for Wet Mix
Macadam
Test Test Method Requirements
IS:2386 (Part-4)
Los Angeles Abrasion Value 40 per cent (Max)
or
IS:2386 (Part-4) or
Aggregate Impact Value 30 per cent (Max)
IS:5640
Combined Flakiness and
18:2386 (Part-1) 30 per cent (Max)
Elongation Indices (Total)
If the water absorption value of the coarse aggregate is greater than 2 per cent,
the soundness test shall be carried out on the material as per IS:2386 (Part-5).
240.1.1.2 Grading Requirement: The aggregate shall confirm to the grading given in
Table 200.8.
Table 200.8 Grading Requirement for Granular Materials for Wet Mix
Macadam
Per cent by weight passing the IS
sieve
53.00 mm 100
45.00 mm 95-100
26.50mm -
22.40 mm 60-80
11.20 mm 40-60
4.75 mm 25-40
2.36 mm 15-30
600.00 Micron 8-22
75.00 Micron 0-8
Materials finer than 425 Micron shall have Plasticity Index (PI) not exceeding 6.
The final gradation approved within these limits shall be well-graded from coarse
to fine and shall not vary from the low limit on one sieve to the high limit on the
adjacent sieve or vice versa.
240.2 Preparation of Base: Clause 222.5 shall apply.
240.2.1 Provision of Lateral Confinement of Aggregates: While constructing wet mix
macadam, arrangement shall be made for the lateral confinement of wet mix. .
This shall be done by laying materials in adjoining shoulders along with that of
wet mix macadam layer.
240.2.2 Preparation of Mix: Wet Mix Macadam shall be prepared in an approved mixing
plant of suitable capacity having provision for controlled addition of water and

forced / positive mixing arrangement like pugmill or pan type mixer of concrete
batching plant. For small quantity of wet mix work, the Engineer may permit the
mixing to be done in concrete mixers.
Optimum moisture for mixing shall be determined in accordance with 15:2720
(Part-8) after replacing the aggregate fraction retained on 22.4mm sieve with
material of 4.75mm to 22.4mm size. While adding water, due allowance should
be made for evaporation losses. However, at the time of compaction, water in the
wet mix should not vary from the optimum value by more than agreed limits. The
mixed material should be uniformly wet and no segregation should be permitted
240.2.3 Spreading of Mix: Immediately after mixing, the aggregates shall be spread
uniformly and evenly upon the prepared sub-grade/ sub-base I base in required
quantities. In no case should these be dumped in heaps directly on the area
where these are to be .Iaid nor shall their hauling over a partly completed stretch
be permitted.
The mix may be spread either by a pave finisher or motor grader. For portions
where mechanical means cannot be used, manual means as approved, by the
Engineer shall be used. The motor grader shall be capable of spreading the
material uniformly all over the surface. Its blade shall have hydraulic control
suitable for initial adjustments and maintaining the same so as to achieve the
specified slope and grade.
The paver finisher shall be self-propelled, having the following features:
a) Loading hoppers and suitable distribution mechanism
b) The screed shall have tamping and vibrating arrangement for initial
compaction to the layer as it is spread without rutting or otherwise marring
the surface profile.
c) The paver shall be equipped with necessary control mechanism so as to
ensure that the finished surface is free from surface blemishes.
The surface of the aggregate shall be carefully checked with templates and all
high or low spots remedied by removing or adding aggregate as may be
required. The layer may be tested by depth blocks during construction. No
segregation of larger and fine particles should be allowed. The aggregates as
spread should be of uniform gradation with no pockets of fine materials.
240.2.4 Compaction: After the mix has been laid to the required thickness, grade and
cross fall I camber the same shall be uniformly compacted, to the full depth with
suitable roller. If the thickness of single compacted layer does not exceed
100mm, a smooth wheel roller of 80 to 100 kN weight may be used. For a
compacted single layer upto 200mm, the compaction shall be done with the help
of vibratory roller of minimum static weight of 100 to 200 kN or equivalent
capacity roller. The speed of the roller shall not exceed 5 Km/H.
In portions having unidirectional cross fall / super elevation, rolling shall
commence from the lower edge and progress gradually towards the upper edge.
Thereafter, roller should progress parallel to the centre line of the road, uniformly
over-lapping each preceding track by at least one third width until the entire
surface has been rolled. Alternate trips of the roller shall be terminated in stops
at least 1 m away from any preceding stop.
In portions in camber, rolling should begin at the edge with the roller running
forward and backward until the edges have been firmly compacted. The roller
shall then progress gradually towards the centre parallel to the centre line of the
road uniformly overlapping each of the preceding tracks by at least one-third
width until the entire surface has been rolled.

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

from any other cause shall be corrected at once as specified and I or removed
and made good.
Along forms, kerbs, walls or other places not accessible to the roller, the mixture
shall be thoroughly compacted with mechanical tampers or a plate compactor.
Skin patching of an area without scarifying the surface to permit proper bonding
of the added material shall not be permitted.
Rolling should not be done when the sub-grade is soft or yielding or when it
causes a wave-line motion in the sub-base I base course or sub-grade. If
irregularities develop during rolling which exceed 12mm when tested with a 3
metre straight edge, the surface should be loosened and premixed material
added or removed as required before rolling again so as to achieve a uniform
surface conforming to the desired grade and cross fall. In no case should be the
use of unmixed material be permitted to make up the depressions.
Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in
IS:2720 (Part-8).
After completion, the surface of any finished layer shall be well-closed, free from
movement under compaction equipment or any compaction planes, ridges,
cracks and loose material. All loose, segregated or otherwise defective areas
shall be good to the full thickness of the layer and re-compacted.
240.2.5 Setting and Drying : After final compaction of wet mix macadam course, the
road shall be allowed to dry for 24 hours.
240.2.6 Opening to Traffic: Preferably no vehicular traffic of any kind should be allowed
on the finished wet mix macadam surface till it has dried and the wearing course
has been laid.
240.2.7 Surface Finish and Quality Control of Work:
240.2.7.1 Surface Evenness: The surface finish of construction shall conform to the
requirements of Clause 600.
240.2.7.2 Quality Control: Control on the quality of materials and works shall be exercised
by the Engineer in accordance with Section 600.
240.2.7.3 Rectification of Surface Irregularity: Where the surface irregularity of the wet
mix macadam course exceeds the permissible tolerances or where the course is
otherwise defective due to sub-grade soil getting mixed with the aggregates, the
full thickness of the layer shall be scarified over the affected area, reshaped with
added premixed material or removed and replaced with fresh premixed material
as applicable and re-compacted in accordance with Clause 240.2.4. The area
treated in the aforesaid manner shall not be less than 5m long and 2m wide. In
no case shall depressions be filled up with unmixed and ungraded material or
fines.
240.2.8 Arrangement for Traffic : During the period of construction, arrangement for
traffic shall be done as per Clause 30.
240.2.9 Measurements for Payment : Wet mix macadam shall be measured as finished
work in position in cubic metres.
240.2.9.1 Rates: The Contract unit rate for wet mix macadam shall be payment in full for
carrying out the required operations including full compensation for all
components.

260.0 Geo-Synthetic Fabric

261.0 Geo-Synthetic: Geo-Synthetic is .a general classification for all synthetic
materials used in geo-technical engineering application. It includes geo-textiles,
geo-grids, geo-nets, geo-membranes and geo-composites.
262.0 Geo-Textiles : Any permeable textile natural or synthetic, used with foundation,
soil, rock, earth, or any other geo-technical engineering related material. In the
present specifications, it is related to synthetic material only.
Geo-textile shall be made of polyethylene or polypropylene or polyester or similar
fibres, either woven or non-woven in variety, through machine made process of
heat bonding or needle punching or weaving' techniques. These fabrics are
required to pass water through but retain the soil particles, which require specific
cross-plant permeability or permittivity and apparent opening size or equivalent
opening size of 0.095mm. The above two requirements along with the
requirement of strength and durability denote general characteristics of geo-
textiles to be used. The type of geo-textile to be used in a particular application
shall be decided on the basis of design.
The physical properties include specific gravity, mass per unit area, thickness.
The mechanical properties include tensile strength (machine direction, cross M
direction) strain at failure, modulus, fatigue strength, puncture strength; friction
and creep. Environmental properties include resistance to chemicals,
temperature, light & weather, bacteria and design life.
263.0 Geo-Grid : A deformed or non-deformed grid of polymeric material used primarily
for reinforcement purposes with foundation, soil, rock, earth, or any other geo-
technical engineering related material.
Geo-Grid shall be made from integrally jointed, mono or bi-directionally
orientated or stretched meshes made from polyethylene or polypropylene or
polyester or similar polymer, with high secant modulus, in square, rectangular,
hexagonal or oval mesh form. Their junction strength shall be high with high
creep resistance, and dimensional stability. Their open structure shall permit
effective interlocking with soil, aggregates, rock, etc., they shall be used as a
tensile member or reinforcement. Characteristic strength at a maximum
elongation of 15 per cent in the direction of the length of the roll. The physical
properties include mass per unit area, thickness at rib & junction and polymer
type. The mechanical properties shall include peak tensile strength, yield point
elongation, tensile strength at 2% strain & 5% strain.
264.0 Geo-Net : These are net made of polymeric material used for drainage of
foundation, soil, rock, earth or any other geo-technical engineering related
material.
Geo-Net shall be made from a single extruded un-oriented process from
polyethylene or polypropylene 'or similar polymer. It shall have square or
rectangular net shape aperture when used for protective works like gabions and
mattresses. While in polygonal aperture, it shall be used as a separator. It shall
not be used as soil reinforcement due to its high creep characteristics, neither as
a slope reinforcement or soil retaining wall or asphaltic reinforcement. Geo-nets
used in protective works for highway structures shall be at least 650 Gm. / sq. m
in unit weight. It shall be black in colour, available in roll form in suitable width.
265.0 Geo-Membrane : An essentially impermeable membrane of polymeric material
used with foundation, soil, rock, earth or any other geotechnical engineering be
made from PVC or polyethylene sheets of at least 0.8mm thickness, duly
protected from ultra-violet exposure with 2.5 per cent carbon black, in black

colour, supplied in roll form with 3m or above width. The joints of these sheets
shall be heat bonded or seamed for effective permeation cut off, at site using
standard equipment as part of the laying process. While fixing on to a slope, they
shall not be punctured or stapled to impair their use. The physical properties
include thickness, specific gravity and mass per unit area. The mechanical
properties shall include tensile strength at yield, elongation at yield, modulus of
elasticity, tear resistance, impact resistance ,puncture resistance, soil to liner
friction
266.0 Geo-Composite : A manufactured material using geo-textiles, geogrids, geo-
nets and / or geo-membrane in laminated or composite form. Geo-Composites
shall be made from combination of geo-nets, geogrids, or geo-membranes of
above description using heat bonded, seamed, stitched or wrap techniques.
Their principal use shall be to regulate drainage in cross,.plane or in-plane
directions. Minimum unit weight of such material shall conform to the special
provisions or as per Contract drawing. .
267.0 The placement of Geo-synthetic shall conform to manufacturer's specifications.
The contractor shall submit to the engineer the complete design & scheme of
installation - the particular brand and its properties equipment and methodology
to be used for installation.
268.0 The payment shall be as per area covered. No separate payment shall be made
for laps.
269.0 The rate shall be per square meter of geo-synthetic installed.

300.0 Bituminous Mixes
301.0 Properties of Bitumen

301.1 Density: Density is the unit weight of a given bituminous mix. This gives an
indication· of the bitumen content in the designed mix and helps to establish the
basis for controlling/determination of compaction during construction. Densities
of specimens obtained from pavements determine the effectiveness of rolling.
301.2 Ductility: Ductility is an indication of the extension or stretch ability of bitumen
under standard conditions. A small briquette of bitumen of a given dimension at a
standard test condition is pulled in an apparatus at a standard rate of speed until
the thread of bitumen breaks. The length of the pull measured in centimeters is
designated as ductility of the bitumen sample under test.
301.3 Flash point : Flash point is the minimum temperature at which bitumen gives an
instantaneous flash in the presence of an external open flame.
301.4 Penetration: Penetration determines the relative hardness or consistency of
bitumen by measuring the distance that a standard needle will penetrate
vertically into a sample of bitumen at 25°C under a load of 100 grams applied for
5 seconds.
301.5 Softening point: Softening point is the temperature at which a standard quantity
of bitumen will become fluid. It is usually tested by a ball/ring test method.
301.6 Solubility: The portion of bitumen which fully dissolves in carbon tetrachloride
represents the actual binder material in the bitumen sample.
301.7 Thin film oven test: This test indicates the amount of hardness that may be
expected to occur in bitumen during plant mixing. The tendency to harden is
measured as a percentage of penetration after and before the thin film oven test.
50 grams of the sample is held in a standard size cup, rotated on a shelf inside a
well ventilated oven maintained at 165°C for 5 hours. Penetration is taken before
and after the test.
301.8 Viscosity: Viscosity of bitumen determines the flow characteristics of bitumen at
a given temperature. It is measured by Saybolt Furol or using Brookfield DV-II
apparatus and is stated in the seconds or in Poise.
302.0 Properties of Bituminous Mixes:
302.1 Voids: Determination of voids in a compact specimen of paving mixture is done
by checking the specific gravity of aggregate and the specific gravity of bitumen
used.
302.2 Bleeding: The exudation of bituminous material on a roadway surface after
construction.
302.3 Blinding: A covering of stone ships, sand or other suitable material applied to a
road surface after an application of asphalt.
302.4 Corrugations- Ripples, waves or uniform undulations which are liable to appear
in all types of road surfaces.
302.5 Foam - The condition of hot asphalt cement caused by rain or water getting into
the hot bitumen and causing excessive building up of small steam bubbles.
302.6 Greedy- Applied to an aggregate or surface which will absorb a large quantity of
bituminous binding material.
302.7 Hot laid mixtures - Plant mixes of bitumen and aggregates which must be
spread and compacted while in a heated condition. They are prepared with
bituminous cements and lose their workability when cooled to atmosphere
temperature. The following thumb rules have been evolved on normal paving
bitumen on hot laid mixtures:

Blue smoke from the mix : Overheating

Steam from the mix : Too much moisture
Distribution of bitumen on aggregate not uniform: Mixing temp too low
Mix looks stiff and dull rather than black and shiny: Deficiency bitumen
Mix lies slumped on the floor : Excessive bitumen
302.8 Lean: Containing a deficiency of bituminous material or conversely containing
excess of aggregate.
302.9 Adhesion of bitumen: Bitumen has excellent adhesive qualities provided the
conditions are favorable. However in presence of water the adhesion does create
some problems. Most of the aggregates used in road construction possess a
weak negative charge on the surface. The bitumen aggregate bond is because of
a weak dispersion force. Water is highly polar and hence it gets strongly attached
to the aggregate displacing the bituminous coating.
TABLE 301.1 PROPERTIES OF VARIOUS GRADES OF BITUMEN (PAVING
BITUMEN)
Sr Grades and Requirements
Characteristics
No. 80/100 60/70 30/40
1 Specific gravjty at 27° C, min 0.99 0.99 0.99
2 Water percent by mass, max 0.2 0.2 0.2
Flash point, Cleveland open cup,
3 o 175 175 175
C min.
4 Softening Point oC 35 to 50 40 to 55 50 to 65
o
Penetration at 25 C, 100g, 5 sec.,
5 80 to 100 60 to 70 30 to 40
1/10 mm
6 Penetration ratio, min. 35 35 35
7 Ductility at 27°C, in cm, min. 75 75 50
Paraffin wax content, percent by
8 4.5 4.5 4.5
mass, max
9 Frass break point, °c min -8 -6 -4
Loss on heating, thin film oven
10 1 1 1
max, test, percent by mass
Retained penetration after thin
11 film oven test, 25°C 100 g, 5sec., 47 52 55
1/10 mm, percent of original, min
Matter soluble in
12 Trichloroethylene, percent by 99 99 99
mass, min
13 Viscosity at
(a)600, Poises 500±100 1000±200 2500±500
o
(b )135 C, cSt, min 110 150 220
303.0 Types of Bitumen: Bitumen or bituminous binders available in India are
specified in IS: 73-1992 and industrial bitumen are specified in IS: 702 - 1988. It
is a viscous liquid or a solid consisting essentially of hydrocarbons and their
derivatives soluble in Trichloroethylene. These are substantially non voltaic and
soften gradually when heated. These are obtained by refinery process from
crude petroleum.
There are two types of bitumen:-

i. Paving bitumen from non waxy crude referred as Type S

ii. Paving Bitumen from waxy crude referred as Type A
These are generally referred to based on the penetration characteristic as:
(i) S 35, S 45, S 65, S 90, S 200
(ii) A 35, A 55, A 65, A 90
Paving bitumen is further classified as
(a) Conventional paving binder bitumen
(b) Bitumen emulsions
(c). Cutback bitumen
(d) Modified bitumen
304.0 GRADES OF BITUMEN GENERALLY IN USE ON ROADS
The different grades of paving bitumen are described further:
304.1 Bitumen 80/100 (90): The characteristics of this grade conform to that of S-90
grade of IS: 73-1992.
304.2 Bitumen 60/70 (65): The characteristics of this grade conform to that of S-65
grade of IS: 73-1992. 60170 grade is harder in comparison to 80/100 grade and
is used mainly in construction of National Highways & State Highways and in hot
climate areas.
304.3 Bitumen 30/40: The characteristics of this grade conform to that of S- 35 grade
of IS:73 -1992. Bitumen 30/40 is used in specialized applications like airport
runway construction as this grade is harder than 60/70 grade.
305.0 Bitumen Emulsion: Bitumen emulsion is a free flowing liquid at ambient
temperatures. Bitumen emulsion is a stable dispersion of fine globules of
bitumen in continuous water phase. Dispersion is obtained by processing
bitumen and water under controlled conditions through a colloidal mill together
with selected additives. The use of proper quality and quantity of emulsifiers is
essential to ensure that the emulsion has stability over time and also that it
breaks and sets when applied on aggregates/road surface.
305.1 Emulsions: Different Types of Emulsion and their application are given in
following Table
Table 301.2 Types of Bitumen Emulsions and their Application
Type Application
These emulsions are suitable for single
Rapid Setting coat or two coat surface dressing Tack
coat etc
Applicable to premix carpet, patch work
Medium Setting
and pot hole filling
Suitable for recycling prime coat, slurry
Slow Setting sealing, dense and semi-dense cold
mixes, mix seal surfacing,
Suitable for chip-sealing and micro
Polymer Modified Bitumen Emulsion
surfacing
The recommended uses of emulsified bitumen of cationic type suggested are as
follows:
RS-1 Tack coat applications
RS-2 Surfacing dressing work
MS Premix carpet, patch work

SS-1 Fog seal, Crack sealing, Prime coat applications

Physical and chemical requirements of bitumen emulsion (cationic type) is given in
table
Table 301.3 Physical and Chemical requirements of Bitumen Emulsion
SI Type of Emulsion
N Characteristics
o RS-1 RS-2 MS SS-1 SS-2
Residue on 600 micron
1 IS Sieve (Percent by 0.05 0.05 0.05 0.05 0.05
mass, Max)
Viscosity by Saybolt Furol

Viscometer, second
2
30-
At 25 oC - - - 20-100
150
At 50°C 20-100 100-300 50-300 - -
Coagulation of emulsion
3 Nil Nil Nil Nil Nil
at low temperature*
Storage stability after 24
4 ,2 1 1 2 2
h
Weak
Positiv Posit
5 Particle charge Positive Positive Positiv
e ive
e
Coating ability and water
Resistance
Coating, dry aggregate - - Good - -
6
Coating, after spraying - - Fair - -
Coating, wet aggregate - - Fair - -
Coating after spraying - - Fair - -
Stability to mixing with
Cement
7
(Percentage ,.
- - - 2 2
coagulation )Max
No
No No No No
coag
8 Miscibility with water coagula coagula coagul coagul
ulati
tion tion ation ation
on
Tests of residue:
a)Residue by
60 67 65 50 60
evaporation, Percent, Min
b) Penetration 250C/100 60-
9 80-150 80-150 60-150 60-350
g/5 sec 120
c) Ductility 270C/cm, Min 50 50 50 50 50
d)Solubility:ln
98 98 98 98 98
trichloroethylene, Min

* This requirement shall be applicable only under situations where the ambient
temperature is below 15°C.
305.2 Bitumen emulsions are of two types, cationic and anionic. Anionic bitumen
emulsions do not give good performance with siliceous aggregate; hence it is not
used in road construction. Cationic bitumen emulsions give good performance
with aggregates. Therefore, cationic bitumen emulsions are far more popular
than anionic bitumen emulsions. Cationic bitumen emulsions available in India
are governed by IS: 8887:1995.
305.3 Bitumen emulsions have been further classified into the following types:
Rapid Setting-1 Type RS-1
Rapid Setting -2 Type RS-2
Medium Setting Type MS
Slow Setting -1 Type SS-1
Slow Setting -2 Type SS-2
306.0 Cutback Bitumen
This is a free flowing liquid at normal temperatures. The viscosity of bitumen is
reduced substantially by adding some solvent. Cutback is used in tack coat
applications. IS: 217-1988 specifies the different grades of cutback.
310.0 Common Materials & Items
311.0 Anti-Stripping Agent:
Anti-stripping agents are used for bituminous materials and mixes to ensure
adhesion between aggregates (hydrophilic in nature) and bitumen, even under
submergence in water. Prior approval of the Engineer shall be taken in respect of
both qualitative and quantitative use of a particular product. The anti-stripping
agents shall be fatty acid amines having a long hydrocarbon chain.
311.1 Physical and Chemical Requirements: The anti-stripping agents shall conform
to the physical and chemical requirements as detailed in Table 300.4.
Table 300.4 Specification for Anti-Stripping Compound
Sr.
Test Method Limit
No.
1. Appearance Visual Liquid / Solid
2. Odour Smelling Agreeable
3. Specific Gravity 27°C IS:1202-1978 0.860 -1.03
4. Pour Point °C Maximum IS:1448 42
5. Flash Point ° (COC) IS:1448 150
Water Content per cent Vol.
6. IS:1448 1.0
Maximum
Solubility in diesel oil (HDO or
As given at the end of
7. LDO) in the ratio of 2:98 at Complete
Appendix
50°C
Total base value mg KOH/g
8. ASTM D 664 200
minimum
Nitrogen content per cent Wt.
9. Elemental Analyser 7.0
minimum
Stripping value with bitumen
IS:6241 As given at
10. containing 1 per cent Wt. anti No stripping
the end of Appendix
stripping compound at 40°C

Sr.
Test Method Limit
No.
24 hours
IS:6241 As given at Complete
11. Under water coating test
the end of Appendix Coating
Should not
Thermal Stability at 163°C - 5 IS:6241 As given at
12. lose its
hours the end of Appendix
efficacy
Boiling water test per cent
13. ASTM D 3625 95
minimum coating
Retained Marshall Stability As given at the end of
14. 75
per cent minimum Appendix
311.2 Storage and Handling: Anti-stripping agents shall be properly stored in closed
containers made of steel or aluminium. Containers made of zinc, copper,
polythene PVC and most types of rubber are not suitable for use. As most of the
anti-stripping agents cause irritation when in contact with human skin and are
also irritating to the eyes, protective gloves for hands and goggles for the eyes
shall be used while handling them, especially in case ·of liquid anti-stripping
agents.
311.3 Use in Sprayed Work:
311.3.1 Additive Dosage: The dosage shall be determined depending on the nature
(stripping value) of the aggregate and the size of aggregate. While the
recommended minimum dose of anti-stripping agent for sprayed work is given in
Table 300.5, the actual dosage shall be determined in the laboratory as directed
by the Engineer.
Table 300.5 Tentative Recommended Minimum Dose of Anti-Stripping Agent
for Sprayed Work
Dose of Anti-stripping Agent in per cent by weight of bitumen
Aggregate Surface Penetration Surface
Stripping Liquid
dressing with Macadam / Dressing with
Value Seal
pre-coated Built up spray uncoated
Coat
aggregate grout aggregate
0-25 0.5 0.6 0.7 0.8
25-50 0.6 0.7 0.8 1.0
50-100 0.75 . 1.0 1.0 1.0
311.3.1.1 Mixing Procedure during Construction: The anti-stripping agent supplied in
liquid, solid or concentrates form shall be thoroughly mixed with liquid bituminous
material or with straight run bitumen. When used with straight run bitumen, the
correct doseof anti-stripping agent shall be mixed in a hot bitumen tank boiler.
The two constituents shall be agitated till the anti-stripping agent is thoroughly
mixed. The dose of anti-stripping agent shall suitably be increase~ if the binder is
to remain in bitumen boiler for a longer period.
311.3.2 Use in Premix Work:
311.3.3 Additive Dosage: The dosage shall be determined depending on the nature
(stripping value) of the aggregate and the per cent voids in the mix. While the
recommended minimum doses of different types of bituminous premix materials
in terms of voids content are given in Table 300.6, the actual dosage shall be
determined in the laboratory as directed by the Engineer.

Table 300.6 Tentative Recommended Minimum. Dose of Anti-Stripping

Compound in Bitumen Premix Works
Dose of Anti-Stripping Agent in per cent by weight of
Stripping Value bitumen
of Aggregates Voids content 3- Voids content 5- Voids content
5 per cent 10 per cent 10-15 per cent
0-25 0.3 0.4 0.5
25-50 0.4 0.5 0.6
50-100 0.6 0.8 1.0
311.3.4 Mixing Procedure During Construction: The required dose of the anti-striping
agent shall be poured into the hot bitumen tank and allowed 15 to 30 minutes of
circulation or stirred to ensure a homogeneous mix. It is necessary to use a
stable antistripping agent or increase the dose according to expected
degradation. Alternatively, the correct dose shall be injected into the bitumen line
by means of a pump. The agent is fed into the bitumen first before it is sprayed
on the aggregate in the mix, thus no separate mixing time for mixing the agent
with bitumen is required. In rolled asphalt and bitumen mastic surfacing works,
precoated chippings are pressed into the hard surface while the mix is still hot to
make the newly laid surface skid resistant. These chippings shall be precoated
with bitumen treated with anti-stripping compound.
312.0 Polymer and Rubber Modified Bitumen Binder: The modified bitumen used for
the work shall be conformed to the guidelines and tests published by Indian
Road Congress - IRCSP 53-2002 and further modified as per IS 15462: 2004.
Each type of modified bitumen is further classified as per grading/penetration
value as given in Table 300.7. The modified bitumen shall be purchased from
refineries only.
TABLE 300.7 Types of Modified Bitumen and Their Grading
Particular type of
Type of Grade available for pavement
Polymer/ Rubber
PMB works
Modified Bitumen
Plastomeric
A PMB 120 PMB 70 PMB 40
Thermoplastic
Elastomeric
B PMB 120 PMB 70 PMB40
Thermoplastic
NRMB
C Natural Rubber (NRMB) NRMB 120 NRMB 70
40
CRMB
D Crumb Rubber (CRMB) CRMB 50 CRMB 55
60
a) Base Binder: The base binder into which the modifier is incorporated shall
conform to IS:73. The choice of grade shall be such that it is compatible with
the modifier and, when mixed shall have the properties described in Modifier
Proportions Clause No. c).
b) Modifier: The modifier shall be a natural rubber, crumb rubber or any other
polymer which is compatible with the base binder and which allows the
properties given in Modifier Proportions Clause No. c) to be achieved. For
further details, IRC:SP:53-1999 may be referred to. The modifier, in the
required quantity shall be blended at the refinery or at the site plant capable of
producing modified binder.
c) Modifier Proportions: The quantity of modifier to be added shall be
determined by tests on the base binder and the modified binder and the

properties desired. A reference may be made to the Manual for Construction

and Supervision of Bituminous Works for indicative dosage of different types
of modifiers. The properties of the modified binder shall be as given in Table
300.7, 300.8,300.9,300.10 & 300.11 (IS-15462:2004) according to the
requirements of the Contract.
Table 300.8 Requirements of Polymer Modified Binder (PMB)
(Plastomeric Thermoplastic Based) Type-A
Grade and Requirements
Sl No Characteristics
PMB 120 PMB 70 PMB40
Penetration at 25 °C, 0.1 mm,
1 90 to 150 50 to 90 30 to 50
100g, 5 Sec
Softening Point, (R&B), °C
2 50 55 60
Minimum
Frass Breaking Point,* °C
3 -20 -16 -12
Maximum
4 Flash Point, COC, °C Minimum 220 220 220
Elastic Recovery of Half Thread in
5 Ductilometer at 15 °C, % Minimum 50 40 30
or complex modify requirement
Separation, Difference in softening
6 3 3 3
point, R&B, °C Maximum
7 Viscosity at 150 °C, Poise 1-3 2-6 3-9
8 Thin Film Oven Tests and TFOT on Residue
a) Loss in Weight, % Maximum 1.0 1.0 1.0
Increase in Softening Point,°C
b) 7 6 5
Maximum
Reduction in Penetration of
c) 35 35 35
Residue, at 25 °C, % Maximum
d) 35 35 35
Ductilometer at 25 °C, % Minimum
* Relevant to snow bound cold climate areas
Table 300.9 Requirements of Polymer Modified Binder (PMB)
(Elastomeric Thermoplastics Based) Type-B
1 90 to 150 50 to 90 30 to 50
100g, 5 Sec
2 50 55 60
Minimum
3 -20 -16 -12
Maximum
5 70 70 70
6 3 3 3


b) 7 6 5
Maximum
c) 35 35 35
d) 50 50 50
* Relevant to snow bound cold climate area
Table 300.10 Requirements of Natural Rubber Binder (NRMB)
(Natural Rubber Based) Type-C
NRMB 120 NRMB 70 NRMB 40
1 90 to 150 50 to 90 30 to 50
100g, 5 Sec
2 45 50 55
Minimum
3 -20 -16 -12
Maximum
5 50 40 30
6 4 4 4
b) 7 6 5
Maximum
c) 40 40 40
d) 35 25 20
* Relevant to Snow Bound Cold Climate Areas
Table 300.11 Requirements of Crumb Rubber Modified Binder

(Crumb and Modified Crumb Rubber Based) Type-D
CRMB 50 CRMB 55 CRMB 60
1 <70 <60 <50
100g, 5 Sec
2 Softening Point, (R&B), °C 50 55 60


Minimum
4 50 50 50
5 4 4 4
a) Loss in mass, % Maximum 1.0 1.0 1.0
b) 7 6 5
Maximum
c) 40 40 40
d) 35 35 35
d) Mixing: The modifier shall be blended with the base binder so that it disperses
thoroughly prior to use. The type of mixing equipment used shall be suited to the
modified type. Further guidance is given in the Manual for Construction and
Supervision of Bituminous Works.
312.1 Quality Control of Materials:
(1) Binder Properties: For control of the quality of the base binder, the relevant
provisions of Section 600 shall apply. Additionally, the modified binder shall be
tested for all the properties listed in Table 300.7, 300.8, 300.9, 300.10 & 300.11
as appropriate and certificates produced prior to use.
During use, the requirements for softening point, penetration and elastic
recovery shall be tested regularly. If the modified binder is produced on site
then tests shall be carried out daily. If pre-blended modified binder is used test
shall be carried out weekly.
(2) Storage Stability: Pre-blended modified binders which are to be stored
without circulation or agitation facility shall be tested for storage stability prior to
use, in accordance with Appendix-I of IRC:SP:53-1999. The mean of the
differences in softening point, top to bottom, of not less than three pairs of
samples shall not exceed 5° C.
Other pre-blended modified binders shall be stored with appropriate circulation or
agitation facility, according to the manufacturer's instructions.
312.2 Measurement for Payment: Modified binder supplied for the Contract shall be
paid for in Tonnes.
312.3 Rate: The contract rate for modified binder shall be as per contract agreement.
313.0 Prime Coat
313.1 Prime coat: This work shall consist of the application of a single coat of low
viscosity liquid bituminous material to a porous granular surface preparatory to
the superimposition of bituminous treatment or mix.
Priming is spraying of low viscosity liquid bituminous materials on the surface of
non-bituminous granular base course preparatory to the superimposition of
bituminous treatment. The objectives of priming a granular surface are as under:

(i) to penetrate the existing base course surface so as to plug capillary voids in
it.
(ii) to coat and bond loose mineral particles on the surface of the base course.
(iii) to seal surface peres and make the surface of the base course water-
resistant.
(iv) to provide adhesion between the base and the superimposed bituminous
surface course in conjunction with a tack coat.
Prime Coat is not to be regarded as a substitute for tack coat, the objective of
which is to ensure a proper bond between the surface being paved and the new
bituminous course being placed over it.
Materials
The bituminous material to be used as primer should be such that it can
penetrate deep into base course (about 10 mm depth) to perform its intended
function in an environment friendly manner. Bitumen emulsion or medium curing
cutback bitumen can be used as primer.
313.1.1 Primer: The choice of a bituminous primer shall: depend upon the porosity
characteristics of the surface to be primed as classified in IRC: 16. These are:
i) Surfaces of low porosity; such as wet mix macadam and water bound
macadam,
ii) Surfaces of medium porosity; such as cement stabilized soil base,
iii) Surfaces of high porosity; such as a gravel base.
a) Primer Viscosity: The type and viscosity of the primer shall comply with the
requirements of IS: 8887:2004 as sampled and tested for bituminous primer in
accordance with these standards. The guidance on viscosity and the rate of
spray is given in Table 300.10A.
Table 300.10A Viscosity Requirement and Quantity of Liquid Bituminous
Primer
Quantity of Liquid
Kinematic Viscosity of
Type of Surface Bituminous Material per
Primer at 60 °C
10 Sq. M. (Kg)
Low Porosity 30-60 7 to 12
Medium Porosity 70-140 9 to 12
High Porosity 250-500 12 to 15
b) Choice of Primer: The primer shall be bitumen emulsion, complying with IS:
8887:2004 and as per Table 300.10.1 of a type and grade as specified in the
Contract or as directed by the Engineer. The cationic bitumen emulsion SS-1
grade confirming to IS:8887/ASTM D2397 shall be used as primer. The quantity
of SS-1 grade bitumen emulsion for various types of granular surfaces shall be
as per Table:300.10.1. (as per Clause 3.2.2 of IRC:16-2008 Table 1)
The use of medium curing cutback as per IS: 217 shall be restricted only for site
at sub-zero temperatures or for emergency applications as directed by the
Engineer. Cutback should not be prepared in the field. The type and quantity of
Cutback Bitumen Primer to be used as per Clause 3.2.3 of IRC:16-2008 Table
300.10.2 is given below.

Table 300.10.1 Quantity of Bitumen Emulsion as Primer for Various Surface

Types
Type of Surface Rate of Spray (kg/m3)
WMM / WBM 0.7 - 1.0
Mechanically stabilized soil base, lime
/cement -stabilized soil and lime cement 0.9 - 1.2
base
Gravel Base, Crusher Run Macadam
1.2 - 1.5
and Crushed Rock base
Table 300.10.2 Type and Quality of Cutback Primer
Rate of Spray
Type of Surface Type of Cutback
(kg/m3)
WMM / WBM MC 30 0.6 – 0.9
Mechanically stabilized soil
base, lime stabilized cement MC 70 0.9 - 1.2
soil and lime cement base
Gravel Base, Crusher Run
Macadam and Crushed MC 250 1.2 - 1.5
Rock base
The correct quantity of primer will be the maximum amount that can be absorbed
by the surface without caus.ing run-off of excessive primer (sometimes referred
as "finger" to form at the lower edges of the primed area) and is to be decided by
the supervising engineer at the site to achieve desired penetration of 10 mm.
313.2 Weather and Seasonal Limitations··: Bituminous primer shall not be applied to a
wet surface or during a dust storm or when the weather is foggy, rainy or windy
or when the temperature in the shade is less than 10° C surfaces which are to
receive emulsion primer should be damp, but no free or standing water shall be
present.
313.2.1: Equipment:
All equipments required for execution of priming work shall be in good working
condition at site. The primer distributor shall be a self propelled or towed bitumen
pressure sprayer equipped for spraying the material uniformly at specified rates
and temperature. Hand spraying of small areas using pressure hand sprayer
may be permitted at specific strategic locations, where distributor is not
accessible or if narrow strips of (< 3 m) granular surface are to be primed.
Pouring of primer using perforated can should not be permitted. SS-1 grade
bitumen emulsion stored at site in the tank shall have arrangement like
circulation pump to ensure its proper mixing before withdrawal from tank and
transfer to browser.
313.2.2: Preparation of surface:
The base course surface to .be primed shall be swept clean and made free from
dust. All loose material and other foreign material on the surface shall be
removed completely. Power brooms or mechanical sweepers may be used for
cleaning of surface. The surface to be primed (whether with SS-1 emulsion or
medium curing cutback bitumen) should be kept dry in case cutback is used as
primer. If Soil/Moorum binder has been used in the WBM surface, part of this
should be brushed and removed up to a depth of 2 mm so as to provide good
bond.
313.2.3: Application of Primer:

After the base to be primed has been prepared as in section 313.2.2, the primer
shall be uniformly applied using the appropriate equipment at application rate
specified in Table 300.10.1 or 300.10.2 as applicable. The spraying should be
carried out using pressure sprayer or distributor. The method of application of
primer will also depend on the type of equipment to be used, size of nozzles,
pressure at spray bar and speed of the forward movement of vehicle. A trial
section shall be laid to check the efficacy of equipment as well as penetration
depth (10 mm) of the priming material.
313.4: Temperature of Application of Primer:
No heating of SS-1 bitumen emulsion is permitted at site. In case of cutback
bitumen, temperature of application of primer should be high enough to permit
the primer to be sprayed effectively through the jets of the spray bar and to cover
the base course surface effectively. The temperature of product at the time of
application should be more than 10°C.
313.5: Air Curing and Opening of Traffic:
The primed surface shall be allowed to cure for at least 24 hours or any other
higher period, as is found to be necessary to allow all the moisture or volatiles to
evaporate before any subsequent bituminous surface treatment or mix is laid.
Excessive and unabsorbed primer if any shall be blotted with a light application
of sand using the minimum quantity possible. A primed surface shall not be
opened for traffic other than that necessary construction vehicles to lay the next
bituminous course.
Arrangement for traffic
During the period of construction, appropriate arrangement for traffic diversion
shall be made as specified in IRC:SP:55 to prevent any possible damage of
primed surface.
313.6: Quality Control:
The Quality Control shall be undertaken as under:
Test Frequency or Tests
Quality of Binder One set of test for a tanker or lot of 10
tonne as per IS:217 for cutback
bitumen and IS:8887 for bitumen
emulsion (Appendix-1 )
Binder Temperature for application Regular Intervals
Rate of spread of binder 1 test per 1000 m2 and not less than two
tests per day
(Appendix 2)
313.3 Measurements for Payment: prime coat shall be measured in terms of surface
area of application in square metres.
313.4 Rate: The contract unit rate for prime coat shall be payment in full for carrying
out the required operations including for all components listed in Clause318.11 (i)
to (v) and as applicable to the work specified in these Specifications. The rate
shall cover the provision of tack coat at 0.2 Kg per Square Metre, with the
provision that the variance in actual quantity of bitumen used will be assessed
and the payment adjusted accordingly.
314.0 Tack Coat
This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to an existing bituminous, cement concrete or primed
granular road surface to ensure a bond between the surface being paved and the
overlaying course. The track coat material is not expected to penetrate into

pavement and for this reason, the application should be very light to provide
adequate bond between two layers. The preparatory to the superimposition of a
bituminous mix, when specified in the Contract or instructed by the Engineer.
314.1 Binder: The binder used for tack coat shall be bitumen emulsion complying with
IS: 8887:2004 of a type and grade as specified in the Contract or as directed by
the Engineer. The use of cutback bitumen as per IS: 217 shall be restricted only
for sites at sub-zero temperatures or for emergency applications as directed by
the Engineer.
The binder used for tack coat shall be either Cationic Bitumen Emulsion (RS- l)
confonning to IS: 8887/ASTM D 2397 or suitable low viscosity Paving bitumen of
VG 10 grade conforming to IS:73. The use of cutback bitumen RC-70 (in cold
climate) as per IS:217 shall be restricted only for sites where atmospheric
temperature at the time of application reaches below 0oC or for emergency
applications.
314.2 Weather and Seasonal Limitations: Bituminous material shall not be applied to a
wet surface or during a dust storm or when the weather is foggy, rainy or windy
or when the temperature in the shade is less than 10oC, where the tack coat
'consists of emulsion, the surface shall be slightly damp, but not wet. Where the
tack coat is of cutback bitumen, the surface shall be dry.
314.3 Construction :
314.3.1 Equipment: The tack coat distributor shall be a self-propelled or towed bitumen
pressure sprayer, equipped for spraying the material uniformly at a specified
rate. Hand spraying of small areas, inaccessible to the distributor, or in narrow
strips, shall be sprayed with a pressure hand sprayer, or as directed by the
Engineer.
314.3.2 Preparation of Base: The surface on which the tack coat is to be applied shall
be clean and free from dust, dirt and any extraneous material, and be otherwise
prepared in accordance with the requirements of Clauses 318.8 and 600 as
appropriate. Immediately before the application of tack coat, the surface shall be
swept clean with a mechanical broom, and high pressure air jet, or any other
means as directed by the Engineer.
The method of application of tack coat will also depend on the type of equipment
to be used, size of nozzles, pressure at spray bar and speed of the forward
movement of vehicle. A spraying trial shall demonstrate that the equipment and
method to be used is capable of providing a uniform spray, within specified
tolerance limit. The quantity of tack coat shall be checked periodically using tray
coating test as described in Appendix 2. The dilution of RS-I bitumen emulsion is
not permitted
314.3.3 Application of Tack Coat: 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 300.11A. The normal range of spraying temperature for a bituminous
emulsion shall be 20°C to 70°C and for a cutback, 50°C to 80°C if RC-70/MC-70
is used. Where a geo-synthetic is proposed for use, the provisions of Clause 260
shall apply. The method of application of the tack coat will depend on the type of
equipment to be used, size of nozzles, pressure at the spray bar, and speed of
forward movement. The Contractor shall demonstrate at a spraying trial, that the
equipment and method to be used is capable of producing a uniform spray,
within the tolerances specified.

Table 300.11A Rate of Application of Tack Coat

Rate of Sparay
Rate of Sparay
(Bitumen VG -
Sl. No Type of Surface (Emulsion)
10)
(Kg / m2)
(Kg / m2)
(i) Bituminous Surfaces 0.20 to 0.30 0.30 to 0.40
Granular surfaces treated
(ii) 0.25 to 0.30 0.35 to 0.45
with primer
(iii) Cement concrete pavement 0.30 to 0 15 0.40 to 0.50
Where the material to receive an overlay is a freshly laid bituminous layer that
has not been subjected to traffic or contaminated by dust, a tack coat is not
mandatory where the overlay is completed within two days.
314.3.4 Curing of Tack Coat: The tack coat shall be left to cure until all the volatiles
have evaporated before any subsequent construction is started, which is
indicated by change in colour from brown to black. No plant or vehicles shall be
allowed on the tack coat other than those essential for the construction.
314.3.5 Temperature of Application of Track Coat:
No heating of RS-1 Bitumen Emulsion is permitted at site. Paving Bitumen if
used shall be heated to its appropriate application temperature in bitumen boiler
to achieve desired viscosity of less than 2 poise. The normal range of spraying
temperature for a bituminous emulsion shall be 20°C to 70°C and for a cutback.
500C to 800C if RC- 70/MC·70 is used. In case of cutback bitumen, temperature
of application of primer should be high enough to permit the tack coat to be
sprz.yed effectively through the jets of the spray bar and to cover the base
course surface uniformly. In case of the use of paving grade bitumen, viscosity at
the time of application shall be less than 2 poise so that spraying is uniformly.
314.3.6 Quality Control:
Tests to be conducted on bitumen, cutback bitumen and bitumen emulsion are
given in Appendix- 1. Manufacture shall provide test certificate for each batch
indicating date of manufacture, batch number and signature of quality control in
charge. The details of tray test for measurement (If quantities are given in
Appendix -2.The Quality Control sball be undertaken as under: -
Test Frequency of Tests
Quality of Binder test per batch of One set of test for a tanker or lot of 10
product by the manufacturer tonne as per IS:73 for bitumen and
IS:8887 for bitumen emulsion (Appendix-
1)
Binder Temperature for application Regular Intervals
Rate of spread of binder 1 test per 1000 m2 and not less than two
tests per day (Appendix- 2)
314.4 Quality Control of Work: For control of the quality of materials supplied and the
works carried out, the relevant provisions of Section 600 shall apply.
314.5 Arrangements for Traffic: During the period of construction, arrangements for
traffic shall be made in accordance with the provisions of Clause 30.
314.6 Measurements for Payment: Tack coat shall be measured in terms of surface
area of application in square metres.
314.7 Rate: The contract unit rate for tack coat shall be payment in full for carrying out
the required operations including for all components listed in Clause 318.11 (i) to
(v) and as applicable to the work specified in these Specifications. The rate shall

cover the provision of tack coat at 0.2 Kg per Square Metre, with the provision
that the variance in actual quantity of bitumen used will be assessed and the
payment adjusted accordingly.
315.0 Paving Fabrics:
315.1 This work shall consist of furnishing and placing as asphalt / bitumen overlay
textile (paving fabric) beneath a pavement overlay or between pavement layers
to provide a water resistant membrane and crack retarding layer.
The paving fabric will be a non-woven heat set material consisting of at least 85
per cent by weight polyolefins, polyesters or polyamides. The paving fabric shall
be resistant to chemical attack, rot and mildew and shall have no tears or defects
which will adversely alter its physical properties. The fabric shall be specifically
designed for pavement applications and be heat bonded only on one side to
reduce bleed through of tack coat during installation. The fabric shall meet the
physical requirements of Table 300.12. Heavy duty paving fabrics should be
used in areas experiencing unusually high impact forces or heavy loads such as
airport runways and taxiways:
Table 300.12 Physical Requirements of Paving Fabrics
Standard
Property Units Test Method
Requirements
Tensile Strength Kg. 36.3 ASTM D 4632
Elongation % 50 ASTM D 4632
Asphalt Retention Kg./10 Sq. M. 10 Texas DOT 3099
Melting Point °C 150 ASTM D 276
Heat bonded on
Surface Texture - Visual Inspection
one side only
315.2 Tack Coat: The tack coat used to impregnate the fabric and bond the fabric to
the pavement shall be a paving grade Bitumen of 80-100 penetration. A cationic
emulsion may be used as approved by the Engineer. The use of cutbacks or
emulsions which contain solvents shall not be used.
315.3 Construction & Installation
315.3.1 Storage & Shipment: The fabric shall be kept dry and wrapped so that it is not
exposed to ultraviolet rays. It shall be stored as per manufacturer's directives.
315.3.2 Weather Limitation: The temperature at the time of laying shall not be less than
15 degrees C
315.3.3 Surface Preparation: The pavement surface shall be cleaned of all dirt, water
and oil to the satisfaction of the Engineer. Cracks 3mm wide or more shall be
cleaned and filled with suitable bituminous materials. Potholes and other
pavement distress shall. be repaired as directed by the Engineer.
315.3.4 Tack Coat application: The tack coat shall be spread by means of calibrated
distributor spray bar. Brush application will be permitted for overlaps. The coat
shall be applied uniformly vat the rate of1 kg/sq,m. or as recommended by the
fabric manufacturer. The rate of application shall be reduced by 20% at the
locations of speed changes of vehicles are frequent. The temperature of tack
coat shall be not less than 140 and not more than 160degree C so as to permit a
uniform spray pattern and to avoid damage to the fabric. For Emulsions, the
distributor tank temperatures shall be between 55 and 70 degree C.
315.3.5 Fabric Placement: It shall be placed prior to cooling of tack coat using
mechanical or manual laydown equipment capable of providing smooth and
wrinkle free installation. When Emulsions are used, emulsions shall be allowed to
cure properly prior to placement of the fabric. Wrinkles in excess of 25 mm shall

be slit and laid flat. Brooming and / or pneumatic rolling will be required to
maximise paving fabric contact with pavement. Care in movement of paver and
other vehicles shall be taken to avoid damage to the fabric. Overlap shall be
shingle lapped in the direction of paving.
315.3.6 Overlay placement: Minimum thickness of overlay over the fabric shall be
40mm. The overlay shall closely follow fabric placement. Excess tack coat be
removed by broadcasting hot mix or and on the fabric.
315.4 Measurement for Payment: Each application of paving fabric shall be measured
as finished work, for the area specified, in square metres.
316.5 Rate : The contract unit rate for the paving fabric shall be payment in full for
components listed in Clause 318.11, (i) to (xi).
316.0 Stress Absorbing Membrane & Stress Absorbing Membrane inter layer:
316.1 Crack Prevention Courses: This clause covers the provision of Stress
Absorbing Membrane (SAM) and Stress Absorbing Membrane Interlayer (SAMI)
as measures to inhibit the propagation of cracks. A SAM is an elastomeric
bitumen rubber membrane, which is laid over a cracked road surface, together
with a covering of aggregate chips, in order to extend the life of the pavement
before major treatment is carried out. SAM can be laid as a single coat or a
double coat. A SAMI is a layer which is applied to a cracked pavement surface
but which is followed (within 12 months) by the application of an overlay course.
A SAMI may be a material similar to that used for a SAM .. It may alternatively
consist of a bitumen impregnated geo-textile.
316.2 Materials:
316.2.1 Binder: Binder shall be a modified binder complying with the requirements of
Clause 311.4, according to the requirements of the Contract, except that paving
grade bitumen of 90 penetration complying with the requirements of IS: 73 shall
be used in the case of bitumen impregnated geo-textile.
316.2.2 Aggregate: The requirements of Clause 318.1.1 apply except that the Polished
Stone Value requirements do not apply in the case of a SAMI. Where required by
the contract, aggregate shall be pre-coated using either of the techniques
permitted by Clause 510.2.5 of MoRTH.
316.2.3 Rates of spread of binder and aggregate: The rates of spread of binder and
aggregate shall be according to one of the size alternatives in Table 300.12, as
required by the Contract.
Geo-textile: The use of geo-textile as prescribed for SI. No.7 in Table 300.12
shall conform to the requirements of Clause 135.0.
316.2.4.1 Preparation of base: The base on which the SAM, SAMI or bitumen
impregnated geo-textile is to be laid shall be prepared, in accordance with
Clause 300 and as directed by the Engineer. The surface shall be thoroughly
cleaned wither by using a mechanical brush or any other equipment I method
approved by the Engineer. Dust removed in the process shall be blown off with
compressed air.
316.2.4.2 Application of Binder: The equipment and general procedures shall all be in
accordance with the Manual for Construction and Supervision of Bituminous
Works. The application temperature for modified binder shall be 160-170°C.
Binder for bitumen impregnated geo-textile shall be applied according to Clause
313. The surface on which the binder is to be applied shall be dry.

Table 300.13 Quantity of Materials required for 10 Sq. M. of Road Surfacefor

Stress Absorbing Membrane
Specification of Quantity of
Type and Width of Quantity of
SAM to be Binder Kg
Crack 2 Chipping
applied /10m
Hair cracks and Single coat SAM
0.10 m3 of
map cracks upto or 2nd coat of two 8-10
5.6mm chips
3mm width coat SAM
Map cracks or
0.11 m3 of
alligator cracks Single coat SAM 10-12
5.6mm chips
3mm to 6mm width
0.12 m3 of
Two coat SAM
5.6mm and
Map cracks or
11.2mm chips in
alligator cracks 1st coat 12-14
1:1 ratio
6mm to 9mm width
0.10 m3 of
2nd coat 8-10
5.6mm chips
Two coat SAM
Cracks above 9mm 0.12 m3 of
1st coat 14-16
width and cracked 11.2mm chips
area above 50% 0.10 m3 of
2nd coat 8-10
S.6mm chips
All types of cracks Single coat SAM 8-10 0.10 m3 of
with crack width
As interlayer 5.6mm chips
below 6mm
All types of cracks Single coat SAM 0.10 m3 of
with crack width 10-12
As interlayer 11.2mm chips
above 6mm
Note:
1.Binder quantities for bitumen impregnated geo-textile shall be in the range 0.9 to
1.2 litres/m2. Binder quantities outside this range are permitted according to the
geo-textile manufacturer's instructions and subject to the agreement of the
Engineer.
316.2.4.3 Application of Aggregates: The equipment and general procedures shall all be
in accordance with the Manual for Construction and Supervision of Bituminous
Works. Immediately after application of the modified binder, clean, dry aggregate
shall be spread uniformly on the surface.
316.2.4.4 Sweeping: The surface of SAMs and SAMls shall be swept to ensure uniform
spread of aggregate and that there are no loose chips on the surface.
316.2.4.5 Two Coats SAM or SAMI: Where a two coat SAM or SAMI is required by the
Contract, the second coat shall be applied within 90 days of the first. '
316.2.4.6 Geo-textile Placement: For bitumen impregnated geo-textile, the requirements
of Clause 260.
316.2.5 Opening to Traffic: Traffic may be permitted over a SAM or SAMI 2 hours after
rolling, but the speed shall be limited to 20 Km/H, until the following day. Speed
control measures are to be approved by the Engineer prior to laying.
316.2.6 Surface Finish and Quality Control of Work: The surface finish shall conform
to the requirements of Clause 613. For control on the quality of materials

supplied and the works carried out, the relevant provisions of Section 600 shall
apply.
316.2.7 Arrangement for Traffic: During the period of construction, arrangements for
traffic shall be made.
316.2.8 Measurement for Payment: Each application of SAM, SAMI or bitumen
impregnated geo-textile shall be measured as finished work, for the area
specified, in square metres.
316.2.9 Rate: The contract unit rate for SAM, SAMI or bitumen impregnated geo-textile
shall be payment in full for carrying out the required operations including full
compensation for all components listed in Clause 318.11, (i) to (xi).
317.0 Bituminous Cold Mixes
317.1 Binder: The binder shall be a bituminous emulsion as specified in IS- 8887:2004
and in clause 305 or 306. Alternatively, a cutback bitumen as specified in
ASHTO M 82 (ASTM 02027) OR ASTM 0 2026, namely MC 70, 250, 800 & 3000
and SC 250. 800 and 3000 may be used, or, if approved by the Engineer, an
equivalent material which conforms with IS:8887 and IS:217.
A general guide for the use of these binders is given in Table 300.14 and in the
Manual for Construction and Supervision of Bituminous Works. However, the
final selection shall be made only after laboratory evaluation with the aggregates
to be used. The binder with the highest residual viscosity at ambient
temperatures that can reasonably be handled by the mixing and laying
equipment proposed shall be used.
Table 300.14 Uses of Bitumen in Cold Mix
Type of Emulsified Bitumen Cutback Bitumen
Construct Slow
ion Medium Curing
Anionic Cationic Curing
(MC)
(SC)
MS-2h, HFMS-2h
Cold-Laid
MS-2,HFMS-2
Plant Mix
Pavemen
CSS – 1h
HFMS-2s
CMS -2h
CSS – 1
t Base
CMS -2
SS -1h
SS -1
and
3000
3000
250
800
250
800
Surface
70
Open-
Graded
X X X X
Aggregat
e
Well-
Graded
X X X X X X X X X X X
Aggregat
e
Patching,
Immediat X X X X X X X
e Use
Patching,
X X X X
Stockpile
317.2 Aggregates: The aggregates shall comply with the requirements of Clause
318.1.1 and 318.1.2. If the aggregates are not properly coated with anionic

emulsion or cutback bitumen, a small amount of hydrated lime, an approved anti-

stripping agent (See 311) or a change to cationic emulsion shall be proposed by
the Contractor for the approval of the Engineer.
317.2.1 Coarse Aggregates: The coarse aggregates shall consist of crushed rock,
crushed gravel or other hard material retained on the 2.36 mm sieve. They shall
be clean, hard, durable, of cubical shape, free from dust and soft or friable
matter, organic or other deleterious matter. Where the Contractor's selected
source of aggregates have poor affinity for bitumen, as a condition for the
approval of that source, the bitumen shall be treated with approved anti-stripping
agents, as per the manufacturer's recommendations, without additional payment.
Before approval of the source, the aggregates shall be tested for stripping. The
aggregates shall satisfy the physical requirements set forth in Table 300.15
Table 300.15. Physical Requirements for Coarse Aggregates for Cold
Bituminous Mix
Property Test Specification
Max 5% passing
Cleanliness Grain size analysis
0.075mm sieve
Flakiness and
Particle shape Elongation Index Max 30%
(Combined)
Los Angeles Abrasion
Strength Max 40%
Value
Durability Soundness
Sodium Sulphate Max 12%
Magnesium Sulphate Max 18%
Water Absorption Water Absorption Max 2%
Coating and Stripping of
Minimum retained
Stripping Bitumen Aggregate
coating 95%
Mixtures
Retained Tensile
Water Sensitivity Min 80%
Strength
Notes: Where crushed gravel is proposed for use as aggregate, not less than
90% by weight of the crushed material retained on the 4.75mm sieve shall have
at least two fractured faces.
317.2.2 Fine Aggregates: Fine aggregates shall consist of crushed or naturally occurring
material, or a combination of the two, passing 2.36mm sieve and retained on 75
micron sieve. They shall be clean, hard, durable, dry and free from dust and soft
of friable matter, organic or other deleterious matter.
317.3 Mix Design
317.3.1 The Design Mix: Bituminous Cold Mix consists of a mixture of unheated mineral
aggregate and emulsified or cutback bitumen. This Specification deals only with
plant mix (as opposed to mixed-in-place). Two types of mix are considered,
namely Designed Cold Mix and Recipe Cold Mix. The Design Mix procedure
shall be used unless the Recipe Mix procedure is specifically approved by the
Engineer.
317.3.2 Designed Cold Mix: This Specification is based on The Asphalt Institute Manual
MS-14, which contains additional information for guidance. These mixes are
considered suitable for use as base course. appropriate to their stability. in new
work or major repair work.

317.3.3 Aggregate Grading and Binder Content: The combined aggregate grading for
the particular mixture. when tested in accordance with IS 2386 (Part-1). (wet
sieving method). shall fall within the limits shown in Table 300.16.
Table 300.16 Aggregate Grading and Bitumen Content

Nominal Maximum Size
9.5 13.2 19.0 26.5
(mm)
Allowable Thickness
25-35 36-50 51-75 76-100
(mm)
IS Sieve (mm) Cumulative % by weight of total aggregate passing
37.5 - - - 100
26.5 - - 100 90-100
19.0 - 100 90-100 -
13.2 100 90-100 - 56-80
9.5 90-100 - 60-80 -
4.75 60-80 45-75 38-65 29-59
2.36 35-65 25-55 20-50 19-45
0.30 6-25 5-20 3-20 5-17
0.075 2-10 2-9 2-8 1-7
Guide to Binder Content, % be weight of total mixture
Cutback Min. 4 to Max. 6
Emulsion Min. 7 to Max. 10
317.3.4 Binder Content: The binder content shall be optimized to achieve the
requirements of the mixture set out in Table 300.17. The method adopted shall
be that described in Appendix F and H of Asphalt Institute's Manual. MS-14.
317.3.5 Requirements for the mixture: Apart from conformity with the grading quality
requirements for individual ingredients. the mixture shall meet the requirements
set out in Table 300.17.
Table 300.17 Mixture Requirements for Designed Cold Mix
Parameter Emulsion1 Cutback2
Minimum Stability (kN at 2.2 for paving 2.2 for
22.2°C) Emulsion maintenance
(kN at 25°C) Cutback 3.3 for paving
Percent maximum
503 254
stability loss on soaking
Minimum flow (mm) 2 2
Compaction Level
50 75
(number of blows)
Per cent air voids 3-55 3-5
Per cent voids in mineral
See Table 300.18
aggregated (VMA)
Per cent minimum
50 -
coating
Notes:

1
Using Marshall Method for emulsified asphalt-aggregate cold mixture design,
Appendix F, MS-14
2
Using Marshall method for cutback asphalt-aggregate cold mixture design,
Appendix H, MS-14
3
With vacuum saturation and impression
4
Four days soak at 25°C
5
Refers to total voids in the mix occupied by air and water
6
Coating Test, Appendix F, MS-14.
Table 300.18 Minimum Per Cent Voids in Mineral Aggregate (VMA)
Nominal Maximum Particle Size IS
Minimum VMA (per cent)
Sieve (mm)
9.5 16.0
12.5 15.0
19.0 14.0
25.0 13.0
37.5 12.0
317.3.6 Job Mix Formula: The Contractor shall inform the Engineer in writing, at least
one month before the start of the work, the job mix formula proposed for use in
the works, and shall give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable :
A. Binder, as percentage by weight of total mixture;
B. Coarse aggregate I Fine aggregate as percentage by weight of total
aggregate;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The results of tests enumerated in Table 300.19 as obtained by the
Contractor;
(v) Test results of physical characteristics of aggregates to be used;
(vi) Spraying temperature of binder if appropriate
While working out the job mix formula, the Contractor shall ensure that it is based
on a correct and truly representative sample of the materials that will actually be
used in the work and that the mixture and its different ingredients satisfy the
physical and strength requirements of these Specifications;
Approval of the job mix formula shall be based on independent testing by the
Engineer for which samples selected jointly with the Engineer of all ingredients of
the mix shall be furnished by the Contractor as required by the former.
The approved job mix formula shall remain effective unless and until modified by
the Engineer. Should a change in the source of materials be proposed, a new job
mix formula shall be established and approved by the Engineer before actually
using the materials.
Permissible Variation from the Job Mix Formula: It shall be the responsibility
of the Contractor to produce a uniform mix conforming to the approved job mix
formula, subject to the permissible variations of the individual percentages of the
various ingredients in the actual mix from the job mix formula to be used, within
the limits as specified in Table 300.19. These variations are intended to apply to
individual specimens taken for quality control tests in accordance with Section
600.

317.3.7 Weather and Seasonal Limitations: Construction with cold mix must not be
undertaken when ambient temperatures below 10°C are expected, during rain, in
standing water, or generally when poor weather is predicted. Bitumen emulsions
and cutbacks depend on the evaporation of water and I or· solvent for the
development of their curing and adhesion characteristics. Cold weather, rain and
high humidity slow down the rate of curing. Extra manipulation may be required
to remove volatiles in cool and humid conditions. Wind increases the rate of
evaporation.
Table 300.19/20 Permissible Variations from the Job Mix Formula
Description Permissible Variation
Base / Binder Course Wearing Course
Aggregate passing 19mm sieve
±8% ±7%
or larger
Aggregate passing 13.2mm,
±7% ±6%
9.5mm
Aggregate passing 4.75mm ±6%
±5%
Aggregate passing 2.36mm,
±5% ±4%
1.18mm,0.6mm
Aggregate . passing 0.3mm,
±4% ±3%
0.15mm
Aggregate passing O.075mm ±2% ± 1.5%
Binder Content ±0.3% ±0.3%
317.3.8 Preparation of the base: The base on which cold mix is to be laid shall be
prepared, shaped and levelled to the required profile in accordance with Clauses
318.10 and 600as appropriate, and a prime coat, where specified, shall be
applied in accordance with Clause 313 or as directed by the Engineer.
317.3.9 Tack Coat: A tack coat in accordance with Clause 314 shall be applied over the
base on which the cold mix is to be laid where specified in the Contract.
317.3.10 Preparation and transportation of the mixture : Mixing can be carried out
using one of the following types of mixer, which is provided with equipment for
spraying the binder at a controlled rate and, if necessary, for heating the binder
to a temperature at which it can be applied uniformly to the aggregate:
a) rotary drum type concrete mixer,
b) single or twin shaft concrete or macadam mixer,
c) batch or continuous type mixer without dryer on screens other than a
scalping screen.
A sufficient number of haul trucks with smooth, clean beds should be available to
ensure continuous operation of the mixing plant. The type of truck used for
transporting the mixture from the mixer to the road site must be suited to the
Contractor's nominated laying procedure methodology.
317.3.11 Spreading: Designed cold mix shall be placed only when the specified density
can be obtained. The mixture shall not be placed on any wet surface or when
weather conditions will otherwise prevent its proper handling or finishing.
If spreading by motor grader, the grader must have a blade that is straight and
sharp and long enough to ensure finishing to close, straight, transverse
tolerances and all joints and linkages must be in good condition. The grader must
be heavy enough to hold the blade firmly and uniformly on the surface while
spreading the mixture.

If climatic conditions and aggregate grading permit evaporation of moisture of

volatiles without aeration by manipulation, a conventional self-propelled asphalt
paver shall be used to place designed cold mix.
Other methods of spreading may be used as approved by the Engineer.
317.3.12 Compaction: Initial compaction of the laid material shall be carried out using a
pneumatic-tyred roller of a weight appropriate to the layer thickness to be
compacted with single layer thickness being 25-100mm and all compaction being
in accordance with Clause 318.8. Smooth tyres shall be used. Final rolling and
smoothing of the surface should be completed using steel wheel rollers. The
Contractor shall demonstrate at laying trials that his: proposed laying and
compaction methods can achieve a satisfactory result.
317.3.13 Opening to Traffic: Traffic shall not be allowed to run on new work until all the
water or volatiles in the mixture have evaporated, as determined by the
Engineer. The rate of evaporation will be influenced by the temperature, humidity
and wind conditions.
317.3.14 Surface Finish and Quality Control of Work: The surface finish of construction
shall conform to the requirements of Clause 900. For control of the quality of
supplied materials and the works carried out, the relevant provisions of Section
600shall apply.
317.3.15 Arrangements for Traffic: During the period of construction, arrangements for
317.3.16 Measurement for Payment: Designed Cold Mix shall be measured as finished
work, for the area covered, in cubic metres, by weight in metric tones, or by
square metres at a specified thickness as specified in the Contract.
317.3.17 Rate: The contract unit rate for Designed Cold Mix shall be payment in full for
components listed in Clause 318.11 (i) to (xi). The rate shall cover the provision
of the specified grade of cutback in the mix at 5 percent of the weight of the total
mix or emulsion at 8 per cent of the weight of the total mix, with the provision that
the variation of quantity of binder will be assessed on the basis of the amount
agreed by the Engineer and the payment adjusted as per the rate for cutback or
emulsion .quoted in the Bill of Quantities.
318.0 Bituminous Hot Mixes
318.1 Aggregates:
318.1.1 Coarse Aggregates: Coarse Aggregates shall consists of crushed rock retained
on 2.36mm sieve. They shall be cleaned, hard, durable, of cubical shape, free
from dust, and soft or friable matter, organic or other deleterious matter. Where
the selected sources of aggregate have poor affinity for bitumen, the bitumen
shall be treated with approved anti-stripping agents as per the manufacturer's
recommendations. The aggregate shall satisfy the physical requirements set
forth in the individual relevant clause for the material in question.
material or a combination of the two passing 4.75mm sieve and retained on 75
Micron sieve. They shall be cleaned, hard, durable, dry, and free from dust, and
soft or friable matter, organic or other deleterious matter. The amount of
rounded, natural sand in the total fine aggregate shall be 10 percent if the BM is
used within 100 mm from the road surface and to 50 percent if the BM is used
more than 100 mm below the road surface. (clause 3.3 of IRC: 27-2009)
318.1.3 Source of Materials·: The source of all materials to be used on the: project must
be tested to the satisfaction of and be expressly approved by the Engineer. The
Engineer may from time to time withdraw approval of a specific source, or attach

conditions to the existing approval. Any change in aggregate source for

bituminous mixes, will require a new mix design and laying trials, where the mix
is based on a job mix design. Stockpiles from different sources, approved or
otherwise, shall be kept separate, such that there is no contamination between
one material and another. Each source submitted for approval shall contain
sufficient material for at least 5 days work.
318.1.4 Binder: As per clauses 301,302 & 303. Binder shall be an appropriate type of
bituminous material complying with relevant Indian Standards. The choice of
binder shall be stipulated in the Contract or by the Engineer. Where penetration
grades of bitumen are specified, they are referred to by a single figure
designation in accordance with IS:73.
318.2.1 Mixing: Pre-mixed bituminous materials, including bituminous macadam, dense
bituminous macadam, semi-dense bituminous concrete and bituminous concrete,
shall be prepared in a hot mix plant of adequate capacity and capable of yielding
a mix of proper and uniform quality with thoroughly coated aggregates.
Appropriate mixing temperatures can be found in Table 300.21(Table: 10 Refer
IRC:111-2009) of these Specifications; the difference in temperature between the
binder and aggregate should at no time exceed 14°C. In order to ensure uniform
quality of the mix and better coating of aggregates, the hot mix plant shall be
calibrated from time to time. The essential features of the hot mix plant are given
in Annex 1 (of IRC:27) “Specifications for Bitumen Macadam”. Table: 300.21
gives the mixing, laying, and rolling temperature for dense graded mixtures. In
case of modified bitumen, the temperature of mixing and compaction shall be
higher than mix with conventional bitumen as binder. The exact temperature
depends upon the type and amount of modifier used and shall be adopted as per
the recommendations of the manufacturer. In order to ensure uniform quality of
mix the plant shall be calibrated from time to time.
If a continuous mixing· plant is to be used for mixing the bituminous bound
macadam, the Contractor must demonstrate by laboratory analysis that the cold
feed combined grading is within the grading limits specified for that bituminous
bound material. In the case of a designed job mix, the bitumen and filler content
shall be derived using this combined grading. Further details are available in the
Manual for Construction and Supervision of Bituminous works.
Table 300.21 Mixing, Laying and rolling Temperatures for Dense Mixtures
(Degree Celcius)
Bitumen Bitumen Aggregate Mixed Laying *Rolling
Viscosit Temperatur Temperatur Material Temperatur Temperatur
y Grade e e Temperatur e e
e
YG-40 160-170 160-175 160-170 150 Min. 100 Min.
YG-30 150-165 150-170 150-165 140 Min 90 Min.
VG-20 145-165 145-165 145-165 135 Min. 85 Min.
VG-1O 140,160 140-165 140-160 130 Min 80 Min.
*Rolltng must be completed before the mat cools to these minimum
temperatures.
318.3.1 Transporting: Bituminous materials shall be transported in clean insulated
vehicles, and unless otherwise agreed by the Engineer, shall be covered while in
transit or awaiting tipping. Subject to the approval of the Engineer, a thin coating
of diesel or lubricating oil may be applied to the interior of the :vehicle to prevent
sticking and to facilitate discharge of the material.
318.4 Laying:

318.4.1 Weather and Seasonal Limitations: Laying shall be suspended while free-
standing water is present on the surface to be covered, or during rain, fog and
dust storms. After rain, the bituminous surface, prime or tack coat, shall be blown
off with a high pressure air jet to remove excess moisture, or the surface left to
dry before laying shall start. Laying of bituminous mixtures shall not be carried
out when the air temperature at the surface on which it is to be laid is below 10°C
for mix with conventional bitumen as binder and is less than 15°C for mix with
modified bitumen as binder or when the wind speed at any temperature exceeds
40 Km/H at 2m height unless specifically approved by the Engineer.
318.5 Cleaning of Surface : The surface on which the bituminous work is to be laid
shall be cleaned of all loose and extraneous matter by means of a mechanical
broom or any other approved equipment I method as specified in the contract.
The use of a high pressure air jet from a compressor to remove dust or loose
matter shall be available full time on the site, unless otherwise specified in the
Contract.
318.6 Spreading: Except in areas where a mechanical paver cannot access,
bituminous materials shall be spread, levelled and tamped by an approved self-
propelled hydrostatic paver finisher preferably with sensor. As soon as possible
after arrival at site, the materials shall be supplied continuously to the paver and
laid without delay.
The rate of delivery of material to the paver shall be regulated to enable the
paver to operate continuously. The travel rate of the paver, and its method of
operations, shall be adjusted to ensure an even and uniform flow of bituminous
material across the screed, free from dragging, tearing and segregation of the
material. In areas with restricted space ( such as confined space, footways,
irregular shape and varying thickness, approaches to expansion joints, etc)
where a mechanical paver cannot be used, the material shall be spread, raked
and levelled with suitable hand tools by experienced staff, and compacted to the
satisfaction of the Engineer.
The minimum thickness of material laid in each paver pass shall be in
accordance with the minimum values given in the relevant part of these
Specifications. When laying binder course or wearing course approaching an
expansion joint of ,a structure, machine laying shall stop 300mm short of the
joint. The remainder of the pavement up to the joint, and the corresponding area
beyond it, shall be laid by hand, and the joint or joint cavity shall be kept clear of
surfacing material.
Bituminous material, with a temperature greater than 145°C, shall not be laid or
deposited on bridge deck waterproofing systems, unless precautions against
heat damage have been approved by the Engineer.
Hand placing of pre-mixed bituminous materials shall only be permitted in the
following circumstances:
i) For laying regulating courses of irregular shape and varying thickness,
ii) In confined spaces where it is impracticable for a paver to operate
iii) For footways
iv) At the approaches to expansion joints at bridges, viaducts or other
structures
Manual spreading of pre-mixed wearing course material or the addition of such
material by hand-spreading to the paved area, for adjustment of level, shall only
be permitted in the following circumstances:
i. At the edges of the layers of material and at gullies and manholes
ii. At the approaches to expansion joints at bridges, viaducts or other structures

iii. As directed by the Engineer

318.7 Cleanliness and Overlaying: Bituminous material shall be kept clean and
uncontaminated. The only traffic permitted to run on bituminous material to be
overlaid shall be that engaged in laying and compacting the next course or,
where a binder course is to be sealed or surface dressed, that engaged on such
surface treatment.
Binder course material shall not remain uncovered by either the wearing course
or· surface treatment, whichever is specified in the Contract, for more than three
consecutive days after being laid. The Engineer may extend this period, by the
minimum amount of time necessary, because of weather conditions or for any
other reason. If the surface of the base is subjected to traffic, or not covered
within three days, a tack coat shall be applied, as directed by the Engineer.
318.8 Compaction: Bituminous materials shall be laid and compacted in layers which
enable the specified thickness, surface level, regularity requirements and
compaction to be achieved.
Compaction of bituminous materials shall commence as soon as possible after
laying. Compaction-shall be substantially completed before the temperature falls
below the minimum rolling temperatures stated in the relevant part of these
Specifications. Rolling of the longitudinal joints shall be done immediately behind
the paving operation. After this, rolling shall commence at the edges and
progress towards the centre longitudinally except that on super elevated and
unidirectional cambered portions, it shall progress from the lower to the upper
edge parallel to the centre line of the pavement. Rolling shall continue until all
roller marks- have been removed from the surface and minimum specified field
density is achieved . All deficiencies in the surface after laying shall be made
good by the attendants behind the paver, before initial rolling is commenced. The
initial or breakdown rolling shall be done with 8-10 tonnes dead weight smooth-
wheeled rollers. The intermediate rolling shall be done with 8- 10 tonnes dead
weight or vibratory roller or with a pneumatic tyred roller of 12 to 15 tonnes
weight having nine wheels, with a tyre pressure of at least 5.6 Kg / Sq. Cm. The
finish rolling shall be done with 6 to 8 tonnes smooth wheeled tandem
rollers.Where compaction is to be determined by density of cores the
requirements to prove the performance of rollers shall apply in order to
demonstrate that the specified density can be achieved. In such cases the
Contractor shall nominate the plant, and the method by which he intends to
achieve the specified level of compaction and finish at temperatures above the
minimum specified rolling temperature. Laying trials shall then demonstrate the
acceptability of the plant and method used.
Bituminous materials shall be rolled in a longitudinal direction, with the roller as
close as possible to the paver. The roller shall first compact material adjacent to
joints and then work from the lower to the upper side of the layer, overlapping on
successive passes by at least one-third of the width of the rear roll or, in the case
of a pneumatic-tyred roller, at least the nominal width of 300mm.
In portions with super-elevated and unidirectional camber, after the edge has
been rolled, the roller shall progress from the lower to the upper edge.
Rollers should move at a speed of not more than 5 km per hour. The roller shall
not be permitted to stand on pavement which has not been fully compacted, and
necessary precautions shall be taken to prevent dropping oil, grease, petrol, or
other foreign matter on the pavement either when the rollers are operating or
standing. The wheels of rollers shall be kept moist with water, and the spray
system provided with the machine shall be in good working order, to prevent the
mixture from adhering to the wheels. Only sufficient moisture to prevent adhesion

between the wheels of rollers and the mixture should be used. Surplus water
shall not be allowed to stand on the partially compacted pavement.
The density of the finished paving layer shall be determined by taking 150mm
diameter cores. The density of finished paving layer shall not be less than 92% of
the average (sample size N = 2 ) theoretical maximum specific gravity of the
loose mix (Gmm) obtained on that day in accordance with ASTM D2041. See
Annex 3 for the outline of ASTM D2041
318.9 Joints : Where longitudinal joints are made in pre-mixed bituminous materials,
the materials shall be fully compacted and the joint made flush in one of the
following ways; only method (iii) shall be used for . transverse joints:
a) All joints shall be cut vertical to the full thickness of the previously laid mix.
All loosened material shall be discarded and the vertical face be coated with
any viscosity grade bitumen, or cold applied emulsified bitumen. While
spreading the material along the joint the material spread shall overlap 25 mm
10 50 mill on the previously laid mix beyond the vertical face of the joint. The
thickness of the loose overlap material should be approximately a qum1er
more than the final compacted thickness. The overlapped mix should be
dragged back 10 the hot lane so that the roller can press the small excess into
the hot side of the joint to obtain a high joint density.
b) By using two or more pavers in echelon, where this is practicable and in
sufficient proximity for adjacent width to be fully compacted by continuous
rolling.
In multilayer construction the longitudinal joint in one layer shall offset the joint in
the underneath layer by about 150 mm.
For transverse joints method a) above can apply Transverse joints in the
successive and adjoining layers should have a minimum offset of 2 m.
i. By heating the joints with an approved joint heater when the adjacent width
is being laid, but without cutting back or coating with binder. The heater
shall raise the temperature of the full depth of material, to within the
specified> range of minimum rolling temperature and maximum
temperature at any stage for the material, for a width not less than 75mm.
The Contractor shall have equipment available, for use in the event of a
heater breakdown, to form joints by method (iii);
ii. By using two or more pavers operating in echelon, where this is
practicable, and in sufficient proximity for adjacent widths to be fully
compacted by continuous rolling;
iii. By cutting back the exposed joint, for a distance equal to the specified
layer thickness, to a vertical face, discarding all loosened material and
coating the vertical face completely with 80/100 penetration grade hot
bitumen, or cold-applied bitumen, or polymer modified adhesive bitumen
tape with a minimum thickness of 2mm, before the adjacent width is laid.
All joints shall be offset at least 300mm from parallel joints in the layer beneath or
as directed, and in a layout approved by the Engineer. Joints in the wearing
course shall coincide with either the lane edge or the lane marking, whichever is
appropriate. Longitudinal joints shall not be situated in wheel track zones.
Transverse joints in the successive and adjoining layers should have a minimum
offset of 2m. (IRC:111-2009 clause 5.7.3)
All joints shall be cut vertical to the full thickness of the previously laid mix. All
loosened material shall be discarded and the vertical face be coated with any
viscosity grade bitumen, or cold applied emulsified bitumen. While spreading the
material along the joint the material spread shall overlap 25 mm to 50 mm on the

previously laid mix beyond the vertical face of the joint. The thickness of the
loose overlap material should be approximately a quarter more than the final
compacted thickness. The overlapped mix should be dragged back to the hot
lane so that the roller can press the small excess into the hot side of the joint to
obtain a high joint density. (IRC:111-2009 clause 5.7.3)
318.10 Preparation of Surface:
This work shall consist of preparing an existing granular or blacktopped surface
bituminous course. The work shall be performed on such widths and lengths as
shown on the drawings or as instructed by the" Engineer. The existing surface
shall be firm and clean, and treated with Prime and Tack Coat as shown on the
drawings as otherwise stated in the Contract.
318.10.1 Preparing existing granular surface: Where the existing surface is granular, all
loose materials shall be removed, and the surface lightly watered where the
profile corrective course to be provided as a separate layer is also granular.
Where the profile corrective course of bituminous material is to be laid over the
existing granular surface, the latter shall, after removal of all loose material, be
primed in accordance with Clause 313.
The surface finish of all granular layers on which bituminous works are to be
placed, shall, unless otherwise specifically instructed by the Engineer, be free
from dust. All such layers must be capable of being swept, after the removal of
any non-integral loose material, by means of a mechanical broom, without
shedding significant quantities of material and dust removed by air jet, washing,
or other means approved by the Engineer.
After cleaning the surface shall be correct to line and level, within the tolerances
specified for base course.
318.10.1.1 Scarifying existing bituminous surface: Where specified or shown on the
drawings, the existing bituminous layer in the specified width shall be removed
with care and without causing undue disturbance to the underlying layer, by a
suitable method approved by the Engineer. After removal, all loose and
disintegrated material, the underlying layers which might have been disturbed
should be suitably reworked and compacted to line and level. After
supplementing the base material as necessary with suitable fresh stone, the
compacted finished surface shall be primed in accordance with Clause 313.
Reusable materials shall be stacked as directed by the Engineer within 1000m of
their origin.
318.11 Rates for Premixed Bituminous Material : The contract unit rate for premixed
bituminous material shall be payment in full or carrying out the required
operations including full compensation for, but not necessarily limited to:
i. Making arrangements for traffic to Clause 30 except for initial treatment to
verge, shoulders and construction of diversions,
ii. Preparation of the surface to receive the material,
iii. Providing all materials to be incorporated in the work including
arrangement for stock yards, all royalties, fees, rents where necessary and
all leads and lifts,
iv. Mixing, transporting, laying and compacting the mix, as specified,
v. All labour, tools, equipment, plant including installation of hot mix plant,
power supply units and all machinery, incidental to complete the work to
these Specifications,
vi. Carrying out the work in part widths of the road where directed,
vii. Carrying out all tests for control of quality and,

viii. The rate shall cover the provision of bitumen at the rate specified in the
contract, with the provision that the variation in actual percentage of
bitumen used will be assessed and the payment adjusted accordingly.
ix. The rates for premixed material are to include for all wastage in cutting of
joints etc.,
x. The rates are to include for all necessary testing, mix design, transporting
and testing of samples, and cores. If there is not a project specific
laboratory, the Contractor must arrange to carry out all necessary testing at
an outside Laboratory, approved by the Engineer, and all costs incurred are
deemed to be included in the rate quoted for the material.
xi. The cost of all plant and laying trials as specified to prove the mixing and
laying methods is deemed to be included in the Contractor's rates for the
material.

350.0 Bituminous Base

351.0 Bituminous Macadam:
Bituminous Macadam (BM) shall consist of mineral aggregate and appropriate
binder, mixed in a hot mix plant and laid with a mechanical paver. It is an open
graded mixture suitable for base course. It is laid in a single course or in multiple
layers on a previously prepared base. ( caluse 2.2 of IRC:27-2009) This work
shall consist of construction in a single course having 50mm to 100mm thickness
or in multiple courses of compacted crushed aggregates premixed with a
bituminous binder on a previously prepared base to the requirements of these
Specifications.
Since the bituminous macadam is an open graded mixture, there is a potential
that it may trap water or moisture vapour within the pavement system. Therefore,
adjacent layer should have proper drainage quantity to prevent moisture-induced
damage to the B.M. (caluse 2.3 of IRC:27-2009)
351.1 Coarse Aggregates: As per 318.1.1. The aggregates shall satisfy the physical
requirements set forth in Table 300.22.(caluse 3.3 Table:3 of IRC:27-2009)
The coarse aggregate shall consist of crushed rock, crushed gravel or other hard
material retained on 2.36 mm sieve. It shall be clean, hard, durable and cubical
shape. free from dust and soft organic and other deleterious substances. The
aggregate shall satisfy the physical requirements specified in Table 300.22
Where crushed gravel is proposed for use as aggregate, not less than 90% by
weight of the crushed material retained on 4.75 mill sieve shall have at least two
fractured faces resulting from crushing operation.
Table 300.22 Physical Requirements for Coarse Aggregates
Property Test Requirement Test method
Max 5% passing
Cleanliness Grain size analysis IS:2386 -part I
0.075mm
Flakiness and
Particle shape Elongation Index Max 40% IS:2386 -part I
(Combined)
Strength* Max 40% IS2386 -part IV
Value
Aggregate Impact
Max .30 % IS:2386 -part IV
value
Soundness (Sodium 5 cycles
Durability or Magnesium),
IS:2386 -part V
Magnesium Sulphate Max 18% IS:2386 -part V
Water
Water Absorption Max 2% IS:2386 -part III
Absorption
Minimum
Coating and Stripping
Stripping Retained Coating IS:6241
of Bitumen Aggregate
95 %
Water Retained Tensile
Min 80% AASHTO 283
Sensitivity strength**
Notes
• Elongation test to be done on non-flaky particles.

** If the minimum retained coating in the stripping test is less than 95%
Change Bitumen Content for Grade 1 and Grade 2 to 3.3 % and 3.4 %
respectively in Table 300. 23
Table 300.23 Composition of Bituminous Macadam
Mix Designation Grading 1 Grading 2 Grading 3
Nominal Aggregate Size 40mm 19mm 40mm
Layer Thickness 80-100mm 50-75mm 80-100 mm
lS Sieve (mm) Cumulative % by weight of total aggregate
passing
45 100 100
37.5 90-100 50-75
26.5 75-100 100 --
19 - 90-100 --
13.2 35-61 56-88 30-50
4.75 13-22 16-36 10-17
2.36 4-19 4-19 3-15
0.3 2-10 2-10 2-5
0.075 0-8 0-8 0-3
Bitumen Content, % by 3.2 (Min) 3.3 (Min) 2.9 (Min)
weight of Total Mixture
Bitumen Grade 35 to 90 35 to 90 35-65
* Nominal maximum aggregate size is the largest specified sieve size upon
which any of the aggregate material is retained.
** Corresponds to specific gravity of the Aggregate being 2.7. In case aggregate
have specific gravity more than 2.7, bitumen content can be reduced
proportionately. Further, for regions where highest daily mean air temperature
is 300C or lower and lowest-daily mean air temperature is – 100C: or lower the
bitumen content may be increased by as much as 0.5 percent. Tolerance of
0.3%; by weight of mix is allowed to individual specimen taken up for quality
control
351.2 Fine Aggregates: As per Clause 318.1.2.
351.3 Bitumen: The bitumen shall be paving bitumen of Penetration Grade complying
with Indian Standard Specifications for "Paving Bitumen" IS:73 and of the
penetration indicated in Table 300.23.
351.4 Preparation of the base: The base on which bituminous macadam is to be laid
shall be prepared, shaped and compacted to the required profile in accordance
with Clauses 318.10 and 600 as appropriate, and a prime coat, shall be applied
in accordance with Clause 313 where specified, or as directed by the Engineer.
351.5 Tack Coat: A tack coat in accordance with Clause 314 shall be applied as
required by the Contract documents, or as directed by the Engineer.
351.6 Preparation and transportation of the mixture : The provisions of clause
318.2.1 and 318.3.1 shall apply.
351.7 Spreading: The provisions of clauses 318.6 shall apply.
351.8 Rolling: Compaction shall be carried out in accordance with the provisions of
Clauses 318.8 and 318.9.Rolling shall be continued until the specified density is
achieved, or where no density is specified, until there is no further movement
under the roller. The required frequency of testing is defined in Clause 600.

351.9 Surface Finish and Quality Control of Work : The surface finish of the
completed construction shall conform to the requirements of Clause 600. For
control of the quality of materials supplied and the works carried out, the relevant
provisions of Section 600 shall apply.
351.10 Protection of the Layer: The bituminous macadam shall be covered with either
the next pavement course or wearing course, as the case may be, within a
maximum of forty-eight hours. If there is to be any delay, the course shall be
covered by a seal coat to the requirement of Clause 370 before opening to any
traffic. The seal coat in such cases shall be considered incidental to the work and
shall not be paid for separately.
351.11 Arrangement for Traffic : During the period of construction, arrangements for
351.12 Measurement for Payment: Bituminous Macadam shall be measured as
finished work in cubic metres, or by weight in metric tones, where used as
regulating course, or square metre at the specified thickness as indicated in the
Contract or shown on the drawings, or as otherwise directed by the Engineer.
352.0 Bituminous Penetration Macadam: (alternate to B.M) The work shall consist of
construction of one or more layers of compacted crushed coarse aggregates with
alternate applications of bituminous binder and key aggregates in accordance
with the requirements of these Specifications to be used as a base course on
roads, subject to the requirements of the overall pavement design, in conformity
with the lines, grades and cross-sections shown on the drawings or as directed
by the Engineer. Thickness of an individual course shall be 50mm or 75mm, or
other as specified.
352.1 Aggregates : The aggregates shall satisfy the physical requirements set out in
clause 318.1. The coarse and key aggregates shall conform to the grading given
in Table 300.25 below.
352.2 Quantities of Materials: The quantities of materials used for this work shall be
as specified in Table 300.26.
Table 300.26 Composition of Penetration Macadam
Cumulative per cent by weight of total aggregate passing
IS Sieve For 50mm Compacted For 75mm Compacted
Designation Thickness Thickness
(mm) Coarse Key Coarse Key
Aggregate Aggregate Aggregate Aggregate
63 - - 100 -
45 100 - 58-82 -
26.50 37-72 - - 100
22.40 - 100 5-27 50-75
13.20 2-20 50-75 - -
11.20 - - - 5-25
5.60 - 5-25 - -
2.80 0-5 0-5 0-5 0-5
Approx. Loose
Aggregate
0.06 0.015 0.09 0.018
Quantities (m3 /
m2)
Binder Quantity
5 6.8
(Penetration

Grade) (Kg
/m2)
Note: If cutback bitumen is used, adjust binder quantity such that the residual
bitumen is equal to, the values in this table. 352.3
Bitumen : The binder shall be paving bitumen of suitable penetration grade within
the range of S-35 to S-90 or A-35 to A-90 (35 to 90) as per Indian Standard
Specifications for "Paving Bitumen" IS:73 or approved cutback satisfying the
requirements of IS:217 or IS:454. The actual grade of bitumen or cutback to be
used shall be as specified or as directed by the Engineer.
352.4.1 Weather and Seasonal Limitations The provisions of Clause 318.4.1 shall
apply.
352.4.2 Equipment: A mechanical broom, compressor, self propelled or trailed bitumen
heater I distributor, mechanical aggregate spreader and 8 to 10 tonne smooth
steel wheel roller or vibrating roller are required for the preparation of Penetration
Macadam.
352.4.3 Preparation of the base : The base on which the Penetration Macadam Course
is to be laid shall be prepared, shaped and compacted to the specified lines,
grades and sections to Clauses 610 as appropriate, or as directed by the
Engineer. A prime coat, where specified, shall be applied over the base in
accordance with Clause .313 or as directed by the Engineer. A tack coat as per
Clause 314 shall be applied.
352.4.4 Spreading coarse aggregates : The coarse aggregate shall be dry and clean
and free from dust, and shall be spread uniformly and evenly at the rate specified
in Table 300.26. It shall be spread by a selfpropelled or tipper tail mounted
aggregate spreader capable of spreading aggregate uniformly at the specified
rates over the required widths. The surface of the layer shall be carefully
checked with camber templates to ensure correct line and level and cross fall.
The spreading shall be carried out such that the rolling and penetrating
operations can be completed on the same day. Segregated aggregates or
aggregates contaminated with foreign material shall be removed and replaced.
352.4.5 Compaction: After the spreading of coarse aggregates, dry rolling shall be
carried out with an 8-10 tonne smooth steel wheel roller.
The requirements given in Clause 318.8 shall apply.
After initial dry rolling, the surface shall be checked with a crown template and a
3 metre straight-edge. The surface shall not vary more than 10mm from the
template or straight-edge. All surface irregularities exceeding the above limit
shall be corrected by removing or adding aggregates as required.
The rolling shall continue until the compacted coarse aggregate has a firm
surface true to the cross section shown on the plans and has a texture that will
allow free and uniform penetration of the bituminous material.
352.4.6 Application of Bituminous Material : After the coarse aggregate has been
roller and checked, the bituminous binder shall be applied, at the rate given in
Table 300.26, in accordance with Clause318, and a temperature directed by the
Engineer. At the time of applying the binder, the aggregates shall be surface dry
for the full depth of the layer.
In certain circumstances, depending on the type and size of aggregate used, the,
Engineer may direct the' placing of a bed of clean sand or quarry fines, not
exceeding 10mm in thickness, on the prepared foundation before placing the
coarse aggregate. The sand or fine material shall be slightly wetted, just
sufficient for it to slurry up during the compaction process. Where cut back is

used, if flooding of the binder occurs it should be applied in two operations, or as

directed by the Engineer.
352.4.7 Application of Key Aggregates : Immediately after the first application of
bitumen, the key aggregates, which shall be clean, dry, and free from dust shall
be spread uniformly over the surface by means of an approved mechanical
spreader' or by approved manual methods at the rate specified in Table 300.26.
Where directed by the Engineer, the surface shall be swept and the quantity of
key aggregate adjusted to ensure uniform application, with all the surface voids
in the coarse aggregate being filled without excess. The entire surface shall then
be rolled with an 8-10 tonnes smooth steel wheel Toller (or vibrating roller
operating in non-vibratory mode) in accordance with the procedure specified in
Clause 352.4.5.
352.4.8 Surface Finish and Quality Control : The surface finish of the completed
construction shall conform to the requirements of Clauses 610 & 620. For control
of the quality of materials supplied and the works carried out the relevant
352.4.9 Surfacing: The Penetration Macadam shall be provided with a surfacing (binder
/ wearing course) within a maximum of forty-eight hours. If there is to be any
delay, the penetration macadam shall be covered by a seal coat to the
requirements of Clause 370: before opening to traffic. The seal coat in such
cases shall be considered incidental to the work and shall not be paid for
separately.
352.4.10 Arrangements for Traffic : During the period of construction, arrangements for
traffic shall be made in accordance with the provision of Clause 30.
352.4.11 Measurement for Payment: Penetration Macadam base course shall be
measured as finished work in square metres.
352.4.12 Rate: The contract unit rate for Penetration Macadam course shall be payment in
full for carrying out the required operations including, but not necessarily limited
to, all components listed in Clause 318.11.
353.0
354.0 Dense Graded Bituminous Macadam (DBM) : Dense Graded Bituminous
Macadam with polymer or rubber modified binder laid over crack prevention
course as per clause 316.
(Clause 2.2: IRC:111- 2009)
Dense graded bituminous mixes shall consist of mineral aggregate and
appropriate bituminous binder. mixed in a hot mix plant and laid with a
mechanized paver. Dense graded bituminous mixes. such as binder and wearing
courses are usually laid on a previously prepared bituminous layer. Binder
course is the intermediate layer between bituminous base course and bituminous
wearing course, Three different specifications for dense graded bituminous
mixes are available for use for highways, Purpose, layer thickness and number
of layers allowed for these specifications are given in Table 300.26.1,
Table 300.26.1 Types of Dense Graded Bituminous Mixes, their Use, Number
of Layers and Layer Thickness
Number of Thickness of
Specification Purpose
Layers each Layer
Base/ Binder course/
Dense Bituminous Single or 50mm –
Overlay for
Macadam (DBM) Multiple 100mm
strengthening
Semi Dense Wearing Course Single 25mm – 40mm

Number of Thickness of
Specification Purpose
Layers each Layer
Bituminous
Concrete (SDBC)
Bituminous 25 mm/ 40 mm/
Wearing Course Single
Concrete (BC) 50 mm
354.1 Materials .
354.2 Bitumen : The bitumen shall be paving bitumen of Penetration Grade complying
with Indian Standard Specifications for viscosity graded "Paving Bitumen" IS:73
and of the penetration indicated in Table 300.29 ,for dense bituminous
macadam, or this bitumen as polymer or rubber modified complying with the
IS:15462 or as otherwise specified in the Contract. Guidance on the selection of
an appropriate grade of viscosity-graded paving bitumen is given in the Manual
for Construction and Supervision of Bituminous Works and also shown in Table:
300.26.2 to 300.26.4.
Table 300.26.2 Viscosity Graded (VG) Bitumens and their General Applications
Viscosity Grade (VG) General Applications
VG-40 Use in highly stressed areas such as those in
intersections, near toll booths, and truck parking lots in
(40 - 60 penetration) lieu of old 30/40 penetration grade
VG-30 Use for paving in most of India in lieu of old 60/70
(50 - 70 penetration) penetration grade
VG-20 Use for paving in cold climatic. hIgh altitude regions of
(60 - 80 penetration) North India
VG-10 Use in spraying applications and for paving in very cold
(80 - 100 penetration) climate in lieu of old 80/100 penetration grade
Table 300.26.3 Selection Criteria for Viscosity-Graded (VG) Paving Bitumen
Based on Climatic Conditions
Lowest Daily Mean Air Less than 20 20oC to More than
o o o
Temperature, C C 30 C 30oC
More than -10oC VG-10 VG-20 VG-30
o
-10 C or lower VG-10 VG-10 VG-20
Table 300.26.4 Selection Criteria for Grade of Modified Bitumen
Highest Daily Mean Air Temperature, 0C
Lowest Daily Less than
o 20oC to 30oC More than 30oC
:mean Air 20 C
Temperature, 0C Grade of Modified Bitumen
PMB/NRMB 120 PMB/NRMB 70 PMB/NRMB 40
More than -10oC
PMB/NRMB 120 PMB/NRMB 120 PMB/NRMB 70
-10oC or lower
PMB =Polymer Modified Bitumen
NRMB =Natural Rubber Modified Bitumen
CRMB = Crumb Rubber Modified Bitumen
Note : When commercial vehicles exceeds 2000 per day per lane and the highest
daily mean temperature exceeds 400C. VG-40 or modified bitumen of
equivalent stiffness are recommended for bituminous concrete and top layer of
dense bituminous macadam.

354.3 Coarse Aggregates: The coarse aggregates shall consist of crushed rock,
crushed gravel or other hard material retained on the 2.36mm sieve. They shall
be clean, hard. Durable, of cubical shape, free from dust and soft or friable
matter, organic or other deleterious matter. Where the Contractor's selected
source of aggregates have poor affinity for bitumen, as a condition for the
approval of that source, the . bitumen shall be treated with approved anti-
stripping agent, as per the manufacturer's recommendations, without additional
payment. Before approval of the source, the aggregates shall be tested for
stripping. The aggregates shall satisfy the physical requirements specified in
Table 300.27
Where crushed gravel is proposed as aggregate, not less than 95% and 90% by
weight of the crushed material retained on 4.75 mm sieve shall have at least two
fractured faces for bituminous concrete and DBM /SDBC respectively,
Table 300.27
Physical
Requirements
Test Requirement Test method
for Coarse
Aggregates
Property
Max 5% passing
Cleanliness Grain size analysis IS:2386 -part I
0.075mm
Flakiness and
Particle shape Elongation Index Max 35% IS:2386 -part I
(Combined)
Los Angeles Abrasion BC Max 30%
IS2386 -part IV
Value Other Max 35%
Strength*
Aggregate Impact BC Max 30%
IS:2386 -part IV
value Other Max 27%
Polishing ** Polishing Stone Value Min 55 IS:2386 -part IV
Soundness (Either 5 cycles
Sodium or
Durability Magnesium), IS:2386 -part V
Magnesium Sulphate Max 18% IS:2386 -part V
Water
Water Absorption Max 2% IS:2386 -part III
Absorption
Minimum
Coating and Stripping
Stripping Retained Coating IS:6241
of Bitumen Aggregate
95 %
Water Retained Tensile
Min 80% AASHTO 283
Sensitivity strength***
* The: aggregate may satisfy either of the two tests
** Only for wearing courses
*** If the minimum retained tensile strength falls below 80%. use of anti-stripping
agent is recommended to meet the minimum requirements
mineral material, or a combination of the two, passing 2.36mm sieve and
retained on 75 micron sieve. They shall be clean, hard, durable, dry and free
from dust and soft of friable matter, organic or other deleterious matter. The fine

aggregates shall have a sand equivalent value of not less than 50 when tested in
accordance with the requirement of 1S:2720 (Part-37). The plasticity index of the
fraction passing the 0.425mm sieve shall not exceed 4 when tested in
accordance with 1S:2720 (Part-5).
354.4.2 Filler: Filler shall consist of finely divided mineral matter such as rock dust,
hydrated lime or cement approved by the Engineer. The use of hydrated lime is
encouraged because of its very good anti-stripping and antioxidant properties.
The Filler shall be graded within the limits indicated in Table 300.28. Total filler
content should be carefully regulated.
Table 300.28 Grading Requirements for Mineral Filler
IS Sieve (mm) Cumulative per cent passing by weight of total aggregate
0.600 100
0.3 95-100
0.075 85-100
The filler shall be inert material 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 hydrated 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 Moisture Susceptibility Test ( AASHTO T283 with
freeze and thaw option) in Table 300.29, then 2 per cent by total weight of
aggregate, of hydrated lime shall be added without additional cost. See Annex 2
for the outline of AASHTO T283.
354.4.3 Aggregate: Grading and Binder Content: When tested in accordance with
IS:2386 Part-1 (wet sieving method), the combined grading of the coarse and
fine aggregates and added filler for the particular mixture shall fall within the
limits shown in Table 300.29 for dense bituminous macadam grading 1 or 2 as
specified in the Contract. The type and quantity of bitumen and appropriate
thickness are also indicated for each mixture type. The combined aggregate
grading shall not vary from the lower limit on one sieve to the higher limit on the
adjacent sieve to avoid gap grading.
Bitumen content indicated in Table 300.29 is the minimum only. The exact
bitumen content required shall be determined following the Marshall Mix Design
procedure containecl in the Asphalt Institute Manual MS-2 (Sixth Edition).
The fines to bitumen (F/B) ratio by weight of total mix shall range from 0.6(01.2
for all mixes in Table 300.29.
Table 300.29 Aggregate Grading and- Bitumen Content
Specification DBM SDBC BC
Grading I 2 I 2 1 2
Nominal
maximum
37.5mm 26.5mm 13.2mm 9.5mm 13.2mm
aggregate 19mm
size*
Layer 50-
75·100mm 40mm 25mm 25/40mm
thickness 75mm 50mm
IS Sieve
Cumulative Percent by weight of total aggregate passing
Size(mm)
45 100

Specification DBM SDBC BC

37.5 95- 100 100
26.5 63-93 90-100 100
90-
19 - 71 – 95 100 100
100
13.2 55-75 56-80 90-100 100 59-79 90- 100
90-
9.5 - - 70-90 52-72 70-88
100
4.75 38-54 38-54 35-51 35 51 35-55 53-71
2.36 28-42 28-42 24-39 24-39 28-44 42-58
1.18 - - 15-30 15-30 20-34 34-48
0.6 15-27 26-38
0.3 7-21 7- 21 9- 19 9-19 10-20 18-28
0.15 5-13 12- 20
0.075 2-8 2-8 3-8 3-8 2-8 4-10
Bitumen
content 4% 4.5% 4.5% 5% 5.2% 5.4%
(Min)**
Note:
* Nominal maximum aggregate size is the largest specified sieve size upon
which any of the aggregate material is retained. The combined aggregate
grading shall not vary from the low limit on one sieve to the high limit on
the adjacent sieve.
** Corresponds to specific gravity of the, Aggregate being 2.7. In case
aggregate have specific gravity more than 2.7 bitumen content can be
reduced proportionately. Further for regions where highest daily mean air
temperature is 30oC or lower and Iowest daily mean air temperature is -
10oC or lower, the bitumen content may be increased by as much as 0.5
percent
Table 300.30 Requirement of the Dense Graded Bituminous .Mix Using
Viscosity-Graded (VG) Paving / Modified Bitumen
Viscosity of Modified Bitumen
Test
Properties Grade Paving Cold
Hot Climate Method
Bitumen Climate
Compaction level
(Number of 75 blows on each face of the specimen
blows)
Minimum stability AASHTO
9.0 12 10
(kN at 60oC) T245
Marshall flow AASHTO
2-4 2.5-4 3.5-5
(mm) T245
Marshall Quotient
2-5 2.5-5
(stabilitylflow)
MS·2 and
% Air Voids 35 ASTM
D2041
% Voids filled 65-75 MS-2

Viscosity of Modified Bitumen

Test
Properties Grade Paving Cold
Hot Climate Method
Bitumen Climate
with bitumen
(VFB)
Tensile Strength AASHTO
80% (Minimum)
Ratio T283
Coating of
Aggregate
95% (Minimum) IS : 6241
Particles with
bitumen
% Voids in Mineral aggregate VMA
Nominal
Maximum Particle Min. % VMA related to designed % air voids***
size (mm)
3 4 5
9.5 14 15 16
13.2 13 14 15
19.0 12 13 14
26.5 . 11 12 13
37.5 10 11 12
***For intermediate value of designed percentage air voids Interpolate the VMA.
Note:
1. The nominal maximum particle size is one size larger than the first sieve to
retain more than 10 per cent.
2. Interpolate minimum voids in the mineral aggregate (VMA) for design air voids
values between those listed.
354.4.5 Binder Content: The binder content shall be optimised to achieve the
requirements of the mixture set out in Table 300.30 and the traffic volume as
specified in the Contract. The Marshall method for determining the optimum
binder content shall be adopted as described in the sixth edition of the Asphalt
Institute Manual MS-2, replacing the aggregates retained on the 26.5mm sieve
by the aggregates passing the 26.5mm sieve and retained on the 22.4mm sieve,
where approved by the Engineer. Where maximum l size of aggregate is greater
than 26.5 mm in the gradation of dense bituminous macadam mixture specified,
the modified Marshall method using 150 mm ( 6 inches) diameter specimen
described in the Asphalt Institute Manual MS-2 (sixth edition) and ASTM D5581
shall be used. This test method requires modified equipment and procedure. This
is applicable for thickness greater than 75mm.;When the modified Marshall test
is used, the specified minimum stability values and the specified flow values
given in Table: 300.30 shall be multiplied by 2.25 and 1.5 respectively .
354.5 Job Mix Formula :
The laboratory mix design gives the proportion of the mineral aggregate
combination in terms, of individual sieve sizes, for actual operational purpose in
the field, blending of the two or more size of aggregates (each size having within
its range of individual sieve size) would be necessary. This blending ratio is
obtained on a weight basis giving percent weight of the coarse aggregate, fine
aggregate and filler needed to give the ultimate gradation. This mineral
aggregate combination together with the corresponding optimum bitumen

content as determined in the laboratory, constitute the job mix Cannula for
implementation during construction. The job mix formula proposed for the use in
the work shall give the following details
The Contractor shall inform the Engineer in writing, at least 20 days before the
start of the work. of the job mix formula proposed for use in the works, and shall
give the following details:
(i) Source and location of all materials;
(ii) Proportions of all materials expressed as follows where each is applicable :
(a) Binder type, and percentage by weight of total mixture;
(b) Coarse aggregate I Fine aggregate I Mineral filler as percentage by
weight of total aggregate including mineral filler;
(iii) A single definite percentage passing each sieve for the mixed aggregate;
(iv) The individual gradings of the individual aggregate fractions, and the
proportion of each in the combined grading.
(v) The results of tests enumerated in Table 500.30 as obtained by the
Contractor;
(vi) Where the mixer is a batch mixer, the individual weights of each type of
aggregate, and binder per batch;
(vii) Test results of physical characteristics of aggregates to be used;
(viii) Mixing temperature and compacting temperature. While establishing the
job mix formula, the Contractor shall ensure that it is based on a correct
and truly representative sample of the materials that will actually be used
in the work and that the mixture and its different ingredients satisfy the
physical and strength requirements of these Specifications.
Approval of the job mix formula shall be based on independent testing by the
Engineer for which samples of all ingredients of the mix shall be furnished by the
Contractor as required by the Engineer.
The approved job mix formula shall remain effective unless and until a revised
Job Mix Formula is approved. Should a change in the source of materials be
proposed, a new job mix formula shall be forwarded to the Engineer for approval
before the placing of the material.
354.5.2 Plant Trials - permissible variation in Job Mix Formula : Once the laboratory job
mix formula is approved, the Contractor shall carry out plant trials at the mixer to
establish that the plant can be set up to produce a uniform mix conforming to the
approved job mix formula. The permissible variations of the individual
percentages of the various ingredients in' the actual mix from the job mix formula
to be used shall be within the limits as specified in Table 300.32. These
variations are intended to apply to individual specimens taken for quality control
tests in accordance with Section 600 of MoRTH Specifications.
Table 300.32 Permissible Variations from the Job Mix Formula
Permissible Variation
Description
DBM SDBC/BC
Aggregate passing
19mm sieve or larger ±8% ±7%
13.2mm,9.5mm ±7% ±6%
4.75mm ±6% ±5%
2.36mm, 1.18mm, 0.6mm ±5% ±4%
0.3mm, 0.15mm ±4% .±3%

Permissible Variation
Description
DBM SDBC/BC
0.075mm ±2% ± 1.5%
Binder Content ±0.3% ±0.3%
Mixing Temperature ± 10° C ± 10° C
Once the plant trials have demonstrated the capability of the plant, and the trials
are approved, the laying operation may commerce. Over the period of the first
month of production for laying on the works, the Engineer shall require additional
testing of the product to establish the reliability and consistency of the plant.
354.6 Scope: This clause specifies the construction of Dense Graded Bituminous
Macadam (DBM), for use mainly, but not exclusively, in base/binder and profile
corrective courses, DBM is also intended for use as road base material. This
work shall consist of construction in a single or multiple layers of DBM on a
previously prepared base or subbase. The thickness of a single layer shall be
50mm to 100mm.
354.7 Laying Trials : Once the plant trials have been successfully completed and
approved, the Contractor shall carry out laying trials, to demonstrate that the
proposed mix can. be successfully laid, and compacted all in accordance with
Clause 318. The laying trial shall be carried out on a suitable area which is not to
form part of the works, unless specifically approved in writing, by the Engineer.
The area. of the laying trials shall be a minimum of 100 sqm of construction
similar to that of the project road, and it shall be in all respects, particularly
compaction, the same as the project construction, on which the bituminous
material is to be laid.
The trials establish that the proposed laying plan, compaction plan, and
methodology are capable of producing satisfactory results. The density of
finished paving layer should not be less than the 92% of the average density
(Sample size N=2) based on theoretical maximum specific gravity of the loose
mix (Gmm) obtained on the day of trial following ASTM D2041. See Annex 3 for
the outline of ASTM D2041.
The Contractor shall previously inform the Engineer of the proposed method for
laying and compacting the material. The plant trials shall then establish if the
proposed laying plant, compaction plant, and methodology is capable of
producing satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying, or by other
approved method.
Once the laying trials have been approved, the same plant and methodology
shall be applied to the laying of the material on the project, and no variation of
either shall be acceptable, unless approved in writing by the Engineer, who may
at his discretion require further laying trials.
354.8 Construction Operations :
354.8.1 Weather and Seasonal Limitations: The provisions of Clause 318.4.1 shall
apply.
354.8.2 Preparation of Base : The base on which Dense Graded Bituminous Material is
to be laid shall: be prepared in accordance with Clauses 318.5and 600as
appropriate, or as directed by the Engineer. The surface shall be thoroughly
swept clean by a mechanical broom, and the dust removed by compressed air.
In locations where mechanical broom cannot access, other approved methods
shall be used as directed by the Engineer.

354.8.3 Geo-Synthetics : Where Geo-synthetics are specified in the Contract, this shall
be in accordance with the requirements stated in Clause 260.
354.8.4 Stress Absorbing Layer: Where a stress absorbing layer is specified in the
Contract, this shall be applied in accordance with the requirements of Clause
316.
354.8.4.1 Profile correcting coarse:
Profile correcting Course: Depending upon requirement, profile-correcting course
for correcting the existing pavement profile shall be laid either as a separate
layer or as a composite layer with varying thickness. Where the maximum
thickness of the profile corrective course is less than 40 mm, the profile
corrective course shall be laid as an integral part of the overlaying layer. In other
cases the profile corrective course shall be constructed as a separate layer.
When it is laid as a separate layer, type of material for the use as the profile
corrective course may differ.
354.8.5 Prime Coat : Where the material on which the dense bituminous macadam is to
be laid is other than a bitumen bound layer, a prime coat shall be applied, as
specified, in accordance with the provisions of Clause 313, or as directed by the
Engineer.
354.8.6 Tack Coat : Where the material on which the dense bituminous macadam is to
be placed is bitumen bound surface, a tack coat shall be applied as specified, in
accordance with the provisions of Clause 314, or as directed by the Engineer.
354.8.7 Mixing and Transportation of the mixture : The provisions as specified in
Clauses 318.2.1 and 318.3.1 shall apply.
354.8.8 Spreading: The provisions of Clauses 318.6 shall apply.
354.8.9 Rolling: The general provisions of Clauses 318.8 shall apply, as modified by the
approved by laying trials. The compaction process shall be carried out by the
same plant, and .using the same method, as approved in the laying trials, which
may be varied only with the express approval of the Engineer in writing.
354.8.10 Opening to Traffic : The newly laid surface shall not be open to traffic for at
least 24 hrs. after laying and completion of compaction, without the express
approval of the Engineer in writing.
354.8.11 Surface Finish and Quality Control of Work : The surface finish of the
completed construction shall conform to the requirements of Clause 600. All
materials and workmanship shall comply with the provisions set out in Section
600.
354.8.13 Measurements for Payment : Dense Graded Bituminous Materials shall be
measured as finished work wither in cubic metres, tons or by the square metre at
a specified thickness as detailed on the Contract drawings, or documents, or as
354.8.14 Rate: The contract unit rate for Dense Graded Bituminous Macadam shall be
payment in full for carrying out the all required operations as specified, and shall
include, but not necessarily limited to all components listed in Clause 318.11.
The rate shall include the provision of bitumen, at 4.25 per cent by weight of the
total mixture.The variation in actual percentage of bitumen used will be assessed
and the payment adjusted, up or down, accordingly.

360.0 Wearing Coat
361.0 Open Graded Premix Surfacing using Paving Grade Bitumen

361.1.1 Scope: This work shall consist of the preparation, laying and compaction of an
open-graded premix surfacing material of 20mm thickness composed of small-
sized aggregate premixed with a bituminous binder on a previously prepared
base, in accordance with the requirements of these Specifications, to serve as a
wearing course.
361.1.2 Materials:
361.1.2.1 Binder : The binder shall be a paving grade bitumen of a suitable grade as
specified in the Clause No. 318.1.4, or as directed by the Engineer, and
satisfying the requirements of IS:73. The binder for track coat shall be rapid
setting cationic bitumen emulsion conforming to IS:8887. ( As per Clause 3.1.1 of
IRC:14-2004). The quantity of binder for track coat and premix binder is given in
Table:300.33.1 and Table:300.33.2 below respectively. ( As per Table: 4 and
Table:5 of IRC:14-2004).
Table 300.33.1 Quantity of Binders For tack Coat
Item Quantity per 10m3 area of road surface
On a granular Surface (Primed) 2.5 to 3.5 kg
On an existing black surface* 2.0 to 3.0 kg
* In case of the existing black top surface is extremely rich in binder, or fatty, the
tack coat may be eliminated in hot climate regions at the discretion of the
Engineer in Charge , if a good bond between the existing surface and the
superimposed layer can be ensured.
Table 300.33.2 Quantity of Binders For PREMIX CARPET
Item Quantity per 10m3 area of road surface
For 13.5 mm size coarse aggregates 9.5 kg @ 52 kg per m3
For 11.2 mm size coarse aggregates 5.1 kg @ 56 kg per m3
Total 14.6 kg
361.1.2.2 Aggregate: The aggregate shall conform to Clause No.318.1 except that the
water absorption shall be limited to a maximum of 1 per cent. The Polished
Stone Value, as measured by the test in IS 812 (Part- 114), shall not be less than
55.
361.1.2.2.1 Proportioning of Materials : The materials shall be proportioned in
accordance with Table 300.34.
Table 300.34 Quantities of Materials required for 10m2 of Road Surface for
20mm thick Open Graded Premix Surfacing using Paving Grade Bitumen or
Emulsion
Aggregates Quantity
i. Nominal Stone Size 13.2mm (passing 22.4mm sieve and retained 0.18m3
on 11.2mm sieve)
ii. Nominal Stone Size 11.2mm (passing 13.2mm sieve and 0.09m3
retained on 5.6mm sieve)
Total 0.27m3
Binder (quantities in terms of straight run bitumen)
a) For 0.18 m3 of 13.2mm nominal size stone at 52 Kg. bitumen per 9.5 Kg.
m3
b) For 0.09 m3 of 11.2mm nominal size stone at 56 Kg. Bitumen per 5.1 Kg.

Aggregates Quantity
m3
Total 14.6 Kg.
361.1.3 Construction :
As per clause 362.1.4
361.1.4 Payment & Rate : It shall be measured as finished work, for the area specified to
be covered in square meter at specified thickness. The area will be the net area
covered. As per clause 318.
361.1.5 Rate
The contract unit rate shall be as per clause 318 and include bitumen quantities
as per Table 300.34 for premix, 3.0 kg per 10 sq.m. for tack coat, 13 kg per 10
sq. m. for liquid seal coat and 11 kg per 10 sq.m. for premix seal coat. The rate
will be adjusted as per actual material used.
361.2 Open Graded Premix Surfacing using Cationic Bitumen Emulsion
361.2.1 Scope : This work shall consist of the preparation, laying and compaction of an
open-graded premix surfacing of 20mm thickness composed of small-sized
aggregate premixed with a cationic bitumen emulsion on a previously prepared
surface, in accordance with the requirements of these Specifications, to serve as
a wearing course.
361.2.2 Materials:
361.2.2.1 Binder : The binder for Premix wearing course shall be cationic bitumen
emulsion of Medium Setting (MS) grade complying with IS:8887 and having a
bitumen content 65 per cent minimum by weight. For liquid seal coat RS grade of
Cationic Bitumen Emulsion shall be used. Where expressly specified in the
Contract MS grade emulsion shall be used or otherwise directed by the
Engineer. Slow Setting (SS) grade Cationic Bitumen Emulsion shall be used for
premix seal coat.
361.2.2.1.1 Aggregate: The requirements of Clause NO.318.1 shall apply.
361.2.2.1.2 Proportioning of Materials : The materials shall be proportioned in
accordance with Table 300.35 and Table 300.36.
Table 300.35 Quantities of Aggregate for 10m2 area
(A) Premix Carpet
(b) Coarse aggregate nominal 13.2mm size; passing IS 22.4mm sieve
0.18 m3
and retained on IS 11.2mm sieve
(c) Coarse aggregate nominal 11.2mm size; passing IS 13.2mm sieve
0.09 m3
and retained on IS 5.6mm sieve
(B) For Seal Coat (Refer Clause 370) Type A
Table 300.36 Quantities of Emulsion Binder
Particulars For 10m2 area
For Premix Carpet 20 to 23 Kg.
For Seal Coat (Refer Clause 370)
(a) for liquid seal coat 12 to 14 Kg.
(b) for premix seal coat 10 to 12 Kg.
361.2.3.1 Weather and Seasonal Limitations : The provisions of Clause 318.4.1 shall
apply.

361.2.3.2 Preparation of Base: The underlying surface on which the bituminous surfacing is
to be laid shall be prepared, shaped and conditioned to the specified lines, grade
and cross-section in accordance with Clause
318.10. A prime coat where needed shall be applied in accordance with Clause 313 as
361.2.3.3 Tack Coat: A tack coat shall be applied over the base preparatory to laying of
the surfacing in accordance with the requirements of Clause 314.
361.2.3.4 Preparation of Premix : Hot mix plant of appropriate capacity and type shall be
used for the preparation of the mix material. The hot mix plant shall have
separate dryer arrangement for heating aggregate.
The temperature of the binder at the time of mixing shall be in the range of 150°C
to 163°C and that of the aggregate in the range of 155°C to 163°C provided that
the difference in temperature between the binder and aggregate at no time
exceeds 14°C. Mixing shall be thorough to ensure that a homogeneous mixture
is obtained in which all particles of the aggregates are coated uniformly and the
discharge temperature of mix shall be between 130°C and 160°C.
The mix shall be immediately transported from the mixer to the point of use in
suitable vehicles or hand barrows. The vehicles employed for transport shall be
clean and the mix being transported covered in transit if so directed by the
Engineer.
361.2.3.5 Spreading and Rolling : The pre mixed material shall be spread by suitable
means to the desired thickness, grades and cross-full (camber) making due
allowance for any extra quantity required to fill up depressions, if any. The cross-
fall should be checked by means of camber boards and irregularities levelled out.
Excessive use of blades or rakes should be avoided. As soon as sufficient length
of bituminous material has been laid, rolling shall commence with 8-10 tonne
rollers, smooth wheel tandem type, or other approved equipment. Rolling shall
begin at the edge and progress toward the centre longitudinally, except that on
super elevated and unidirectional cambered portions, it shall progress from the
lower to upper edge parallel to the centre line of the pavement.
When the roller has passed over the whole area once, any high spots or
depressions, . which become apparent, shall be corrected by removing or adding
premixed materials. Rolling shall then be continued until the entire surface has
been rolled and all the roller marks eliminated. In each pass of the roller, the
preceding track shall be overlapped uniformly by at least 1/3 width. The roller
wheels shall be kept damp to prevent the premix from adhering to the wheels. In
no case shall fuel/lubricating oil be used for this purpose. Excess use of water for
this purpose shall also be avoided.
Rollers shall not stand on newly laid material. Rolling operations shall be
completed in every respect before the temperature of the mix falls below 100°C.
joints along and transverse to the surfacing laid and compacted earlier shall be
cut vertically to their full depth so as to expose fresh surface which shall be
painted with a thin coat of appropriate binder before the new mix is placed
against it.
361.2.3.6 Seal Coat: A seal coat conforming to Clause 370 of the type specified in the
Contract shall be applied to the surface immediately after laying the surfacing.
361.2.3.7 Opening to Traffic: No traffic shall be allowed on the road until the seal coat has
been laid. After the seal coat is laid, the road may be opened to traffic according
to Clause 30.
361.2.3.8 Surface Finish and Quality Control of Work: The surface finish of the
construction shall conform to the requirements of Clause 600. For control on the

quality of materials supplied and the works carried out, the relevant provisions of
Section 600shall apply.
361.2.3.9 Arrangements for Traffic : During the period of construction, arrangements for
361.2.3.10 Measurements for Payment : Open Graded Premix Surfacing shall be
measured as finished work, for the area instructed to be covered, in square
metres. The area will be the net area covered and all allowances for wastage
and cutting of joints shall be deemed to be included in the rate.
361.2.3.11 Rate: The contract unit rate for Open Graded Premix Surfacing shall be payment
in full for carrying out the required operations including full compensation for all
components listed in Clause 318.11 ..
362.0 Close Graded Premix Surfacing or MSS
362.1 This work shall consist of the preparation, laying and compaction of a close-
graded premix surfacing material of 20mm thickness composed 'of graded
aggregates premixed with a bituminous binder on a previously prepared surface,
in accordance with the requirements of these Specifications, to serve as a
wearing course.
Close graded premix shall be of Type A or Type B as specified in the contract
documents.
362.1.1 Binder: The provisions of Clause NO.361.2.2.1 shall apply.
362.1.2 Coarse Aggregates : The aggregate shall conform to Clause No.318.1.1 except
that the water absorption shall be limited to maximum of 1 per cent. The polished
stone value, as measured by the test in IS:812 (Part-114) shall not be less than
55.
362.1.3 Fine Aggregates : The fine aggregates shall consist of crushed rock quarry
sands, natural gravel/sand or a mixture of both. These shall be clean, hard,
durable, un-coated, mineral particles, dry and free from injurious, soft or flaky
particles and organic or deleterious substances as per Clause 318.1.2.
362.1.3.1 Aggregate Gradation: The coarse and fine aggregates shall be so graded or
combined as to conform to one or the other gradings shown in Table 300-37, as
specified in the contract.
Table 300.37
IS Sieve Designation (mm) Cumulative Per Cent by weight of total
aggregate passing
Type A Type B
13.2mm - 100
11.2mm 100 88-100
5.6mm 52-88 31-52
2.8mm 14-38 5-25
0.090mm 0-5 0-5
362.1.3.2 Proportioning of Materials: The total quantity of aggregates used for Type A or B
close-graded premix surfacing shall be 0.27 cube metre per 10 square metre
area. The quantity of binder used for premixing in terms of straight-run bitumen
shall be 22.0 Kg and 19.0 Kg per 10 Square Metre area for Type A and Type B
surfacing respectively.
362.1.4.1 Weather and Seasonal Limitations: The provisions of Clause 318.4.1 shall
apply.

362.1.4.2 Preparation of Base: The surface on which the Bituminous Concrete is to be

laid shall be prepared in accordance with Clauses 318 and 600 as appropriate,
or as directed by the Engineer. The surface shall be thoroughly swept clean by a
mechanical broom, and the dust removed by compressed air. In locations where
a mechanical broom cannot access, other approved methods shall be used as
directed by the Engineer.'
362.1.4.3 Geo-Synthetics : Where Geo-synthetics are specified in the Contract, this shall
362.1.4.4 Stress Absorbing Layer: Where a stress absorbing layer is specified in the
Contract, this shall be applied in accordance With the requirements of Clause
316.
362.1.4.5 Tack Coat: Where specified in the Contract, or otherwise required by the
Engineer, a tack coat shall be applied in accordance with the requirements of
Clause 314.
362.1.4.6 Mixing and Transportation of the mixture : The provisions as specified in
362.1.4.7 Spreading: The general provisions of Clauses 318.6 shall apply.
362.1.4.8 Rolling: The general provisions of Clauses 318.8 shall apply, as modified by the
approved laying trials.
362.1.4.9 Opening to Traffic: The traffic may be allowed after completion of the final
rolling when the mix has cooled down to the surrounding temperature. Excessive
traffic speeds should not be permitted.
362.1.4.10 Surface Finish and Quality Control of Work : The surface finish of the
construction shall conform to the requirements of Clause 600. For control on the
quality of materials supplied and the works carried out, the relevant provisions of
Section 600.
362.1.4.11 Arrangements for Traffic : During the period of construction, arrangements for
362.1.4.12 Measurements for Payment: Close-Graded Premix Surfacing, Type A or Type
B shall be measured as finished work, for the area specified to be covered, in
square metres at a specified thickness. The area will be the net area covered
and all allowances for wastage and cutting of joints shall be deemed to be
included in the rate.
362.1.4.13 Rate: The contract unit rate for Close-Graded Premix Surfacing, Type A or Type
B shall be payment in full for carrying out the required operations Including full
compensation for all components listed in Clause 318.11.
363.0 Semi Dense Bituminous Concrete:
363.1 Scope : This clause specifies the construction of Semi-Dense Bituminous
Concrete, for use in wearing I binder and profile corrective courses. This work
shall consist of construction in a single or multiple layers of semi-dense
bituminous concrete on a previously prepared bituminous bound surface. A
single layer shall be 25mm to 100mm in thickness.
363.2 Bitumen : The bitumen shall be paving bitumen of Penetration Grade complying
with Indian Standard Specifications for "Paving Bitumen" IS:73 and of the
penetration indicated in Table300AO, for semi-dense bituminous concrete, or this
bitumen as modified by one of the methods specified in Clause 311, or as
otherwise specified in the Contract. Guidance on the selection of an appropriate
grade of bitumen is given in the Manual for Construction and Supervision of
Bituminous Works.

363.2.1 Coarse Aggregates : The coarse aggregates shall be generally as specified in

Clause 354.1, except that the aggregates shall satisfy the physical requirements
of Table 300.38 .
363.2.2 Fine Aggregates: Fine aggregates shall be all as specified in Clause 354.2.
363.2.3 Filler : Filler shall be generally as specified in Clause 354.3. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table
300.38 then 2 per cent by total weight of aggregate, of hydrated lime shall be
added without additional cost.
Table 300.38 Physical Requirements for Coarse Aggregates for Semi-Dense
Bituminous Concrete Pavement Layers
Grain size analysis Max 5% passing
Cleanliness (Dust)
IS:2386 Part-1 0.075mm sieve
Flakiness and
Elongation Index
Particle shape Max 30% (Combined)
(Combined) IS:2386
Part-1
Strength * IS:2386 Part- Max 35%
Value
4*
Aggregate Impact Value Max 27%
Polished Stone Value
Polishing Min 55
BS:812 Part-114
Soundness IS:2386
Durability Part-5
Water Absorption
Water Absorption Max 2%
IS:2386 Part-3
Bitumen Aggregate Minimum retained
Stripping
Mixtures AASHTO coating 95%
T283**
Retained Tensile
Strength IS:6241
* Aggregate may satisfy requirements of either of these two tests.
** The water sensitivity test is only required if the minimum retained coating in
the stripping test is less than 95%.
363.2.4 Aggregate Grading and Binder Content: When tested in accordance with
IS:2386 Part-1 (wet sieving method), the combined grading of the coarse and
fine aggregates and added filler shall fall within the limits shown in Table 300.39
for gradings 1 or 2 as specified in the Contract.
363.3 Mixture Design:
363.3.1 Requirements for the mixture : Apart from conformity with the grading and
quality requirements for individual ingredients the mixture shall meet the
requirements set out in Table 300.31.

Table 300.39 Physical Requirements for Coarse Aggregates for Semi·-Dense

Bituminous Concrete Pavement Layers
Max 5% passing
Cleanliness (Dust) Grain size analysis
0.075mm sieve
Flakiness and
Particle shape Elongation Index Max 30%
(Combined)
Max 35%
Strength Value
Polishing Polished Stone Value Min 55
Minimum retained
coating 95%
Mixtures
Retained Tensile
Strength
The requirements for minimum per cent voids in mineral aggregate (VMA) are set
out in Table 300.31 .
binder content shall be adopted as described in the Asphalt Institute Manual MS-
2, replacing the aggregates retained on the 26.5mm sieve and retained on the
22.4mm sieve, where approved by the Engineer.
Table 300.40 Composition of Semi-Dense Bituminous Concrete Pavement
Layers
Grading 1 2
Nominal Aggregate Size 13mm 10mm
Layer Thickness 35-40mm 25-30mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45
37.5
26.5
19 100
13.2 90-100 100
9.5 70-90 90-100
4.75 35-51 35-51
2.36 24-39 24-39
1.18 15-30 15-30
0.6 - -
0.3 9-19 9-19
0.15 - -
0.075 3-8 3-8
Bitumen Content % by Min. 4.5 Min. 5.0

Grading 1 2
Mass of Total Mix
Bitumen Grade (pen) 65 65
Notes : 1. The combined aggregate grading 'shall not vary from the low limit on one
sieve to the high limit on the adjacent sieve.
2. Determined by the Marshall Method
Table 300.41 Requirements for Semi-Dense Bituminous Pavement Layers
Minimum Stability (kN) 8.2
Minimum Flow (mm) 2
Maximum Flow (mm) 4
75 Blows on each of the two faces of
Compaction Level (Number of Blows)
the specimen
Per cent air voids 3-5
Per cent voids in mineral aggregate
See Table 300.31
(VMA)
Per cent voids filled with bitumen (VFB) 65-78
i. Job Mix Formula : The procedure for formulating the job mix formula shall be
generally as specified in Clause 354.5 and the results of tests enumerated in
Table 300.32 as obtained by the Contractors.
ii. Plant Trials - permissible variation in Job Mix Formula : The requirements for
plant trails shall be all as specified in Clause 354.5.1 and permissible limits
for variation as shown in Table 300.32.
363.4.1 Weather and Seasonal Limitations The provisions of Clause 318.4.1 shall
apply.
363.4.2 Preparation of Base : The surface on which the Semi Dense Bituminous
Material is to be laid shall be prepared in accordance with Clauses 318.10 and
600 as appropriate, or as directed by the Engineer. The surface shall be
thoroughly swept clean by a mechanical broom, and the dust removed by
compressed air. In locations where a mechanical broom cannot access, other
approved methods shall be used as directed by the Engineer.
363.4.3 Geo-Synthetics : Where Geo-synthetics are specified in the Contract, this shall
363.4.4 Stress Absorbing Layer: Where a stress absorbing layer is specified in the
316.
363.4.5 Tack Coat: Where specified in the Contract, or otherwise required by the
Clause 314.
363.4.6 Mixing and Transportation of the mixture: The provisions as specified in
Clauses 318.2,.1 and 318.3.1 shall apply.
363.4.7 Spreading: The general provisions of Clauses 318.6 shall apply.
363.4.8 Rolling : The general provisions of Clauses 318.8 shall apply, as modified by the
approved laying trials. The compaction process shall be carried out by the same
plant, and using the same method, as approved in the laying trials, which maybe
varied only with the express approval of the Engineer in writing.

363.4.9 Opening to Traffic: The newly laid surface shall not be open to traffic for at least
24 hrs. after laying and the completion of compaction, without the express
materials and workmanship shall comply with the provisions set out in Section
600.
363.4.12 Measurements for Payment : Dense Graded Bituminous Materials shall be
measured as finished work wither in cubic metres, tons or by the square metre at
a specified thickness as detailed on the Contract drawings, or documents, or as
363.4.13 Rate : The contract unit rate shall be payment as specified in Clause 354.10.14,
except that the rate shall include the provision of bitumen at 4.75 per cent, by
weight of total mixture. The variance in actual percentage of bitumen used will be
assessed and the payment adjusted up or down, accordingly.
364.0 Bituminous Concrete:
364.1 Scope: This clause specifies the construction of Bituminous Concrete, for use in
wearing and profile corrective courses. This work shall consist of construction in
a single or multiple layers of bituminous concrete on a previously prepared
bituminous bound surface.
364.2 Bitumen : The bitumen shall be paving bitumen of Penetration grade complying
with Indian Standard Specification for Paving Bitumen, IS:73 and of the
penetration indicated in Table 300.43, for bituminous concrete, or this bitumen as
modified by one of the methods specified in Clause 311, or as otherwise
specified in the Contract. Guidance on the selection of an appropriate grade of
bitumen is given in the manual for Construction and Supervision of Bituminous
Works.
364.2.1 Coarse Aggregates : The coarse aggregates shall be generally as specified in
Clause 354.1, except that the aggregates shall satisfy the physical requirements
of Table 300.44.
364.2.2 Fine Aggregates : The fine aggregates shall be all as specified in Clause 354.2.
364.2.3 Filler : Filler shall be generally as specified in Clause 354.3. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table
300.44 then 2 per cent by total weight of aggregate, of hydrated lime shall be
added without additional cost.
364.2.4 Aggregate Grading and Binder Content: When tested in accordance with
IS:2386 (Part-1) (Wet Grading Method), the combined grading of the coarse and
fine aggregates and added filler shall fall within the limits shown in Table 300.43
for gradings 1 or 2 as specified in the Contract.
Table 300.42 Requirements for Dense Bituminous Pavement Layers
Minimum Stability (kN) 9.0
Minimum Flow (mm) 2
Maximum Flow (mm) 4
75 Blows on each of the two faces of
Compaction Level (Number of Blows)
the specimen
Per cent air voids 3-6
Per cent voids in mineral aggregate See Table 300.31

(VMA)
Per cent voids filled with bitumen (VFB) 65-75
Loss of Stability on immersion in water
Min. 75 per cent retained strength
at 60°C (ASTM D 1075)
Table 300.43 Composition of Bituminous Concrete Pavement Layers
Grading 1 2
Nominal Aggregate Size 19mm 13mm
Layer Thickness 50mm 40mm
IS· Sieve (mm) Cumulative % by weight of total aggregate passing
45
37.50
26.50 100
19 79-100 100
13.20 59-79 79-100
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 :
2-8 (Lime powder or 4-10 (Lime powder or
0.075 OPC/PPC cement, filler OPC/PPC cement, filler
shall be 2%) shall be 2%)
Bitumen Content, % by
5.0 - 6.0 Min 6
weight of total mixture
Bitumen Grade (pen) 65 65
Notes: 1. The combined aggregate grading shall not vary from the low limit on one
sieve to the high limit on the adjacent sieve.
2. Determined by the Marshall Method
364.3 Mixture Design:
364.3.1 Requirements for the mixture : Apart from conformity with the grading and
quality requirements for individual ingredients, the mixture shall meet the
requirements set out in Table 300.42. The requirements for minimum per cent
voids in mineral aggregate (VMA) are set out in Table 300.31
binder content shall be adopted as described in the Asphalt Institute Manual MS-
2, replacing the aggregates retained on the 26.5mm sieve and retained on the
22.4mm sieve, where approved by the Engineer.
364.3.3 Job Mix Formula: The procedure for formulating the job mix formula shall be
generally as specified in Clause 354.5 and the results of tests enumerated in
Table 300.44 as obtained by the Contractors.

Table 300.44 Physical Requirements for Coarse Aggregates forBituminous

Concrete Pavement Layers
Max 5% passing
Cleanliness (Dust)1 Grain size analysis
0.075mm sieve
Flakiness and
Particle shape Elongation2 Index Max 30% (Combined)
(Combined)
Strength * IS:2386 Part- Max 40%
Value 3
4*
Polishing Polished Stone Value Min 55
Soundness
Durability
Minimum retained
coating 95%
Mixtures
Retained Tensile
Strength
Notes: IS:2386 Part-11
IS:2386 Part-12
(The elongation test to be done only on non-flaky aggregates in the sample.)
IS:2386 Part-4*3
IS:2386 Part-4*
BS:812 Part-114
IS:2386 Part-5
18:2386 Part-3
AASHTO T283**
IS:6241
* Aggregate may satisfy requirements of either of these two tests.
** The water sensitivity test is only required if the minimum retained coating in the
stripping test is less than 95%.
364.3.3.1 Plant Trials - Permissible Variation in Job Mix Formula : The requirements for
plant trials shall be all as specified in Clause 354.5.1, and permissible limits for
variation as shown in Table 300.32.
364.4.1 Weather and Seasonal Limitations : The provisions of Clause 318.4.1 shall
apply.
364.4.2 Preparation of Base: The surface on which the Bituminous Concrete is to be
laid shall be prepared in accordance with Clauses 318.10 and 600 as
appropriate, or as directed by the Engineer. The surface shall be thoroughly
swept clean by a mechanical broom, and the dust removed by compressed air.
In locations where a mechanical broom cannot access, other approved methods
shall be used as directed by the Engineer.

364.4.3 Geo-Synthetics: Where Geo-synthetics are specified in the Contract, this shall
364.4.4 Stress Absorbing layer: Where a stress absorbing layer is specified in the
316.
364.4.5 Tack Coat: Where specified in the Contract, or otherwise required by the
Clause 314.
364.4.6 Mixing and Transportation of the mixture : The provisions as specified in
364.4.7 Spreading: The general provisions of Clauses 318.6 shall apply.
364.4.8 Rolling : The general provisions of Clauses 318.8 shall apply, as modified by the
approved laying trials.
364.4.9 Opening to Traffic: The newly laid surface shall not be open to traffic for at least
24 hrs. after laying and the completion of compaction, without the express
'materials and workmanship shall comply with the provisions set out in Section
600.
364.4.11 Arrangements for Traffic: During the period of construction, arrangements for
364.4.12 Measurements for Payment: The measurement shall be as specified in Clause
354.8.13
364.4.13 Rate: The contract unit rate shall be payment as specified in Clause 354.8.14,
except that the rate shall include the provision of bitumen per cent indicated in
Table 300.43 or as indicated in the contract, by weight of total mixture. The
variance in actual percentage of bitumen used will be assessed and the payment
adjusted up or down, accordingly.
365.0 Mastic Asphalt (IS 5317:2002)
365.1 This work shall consist of constructing a single layer of mastic asphalt wearing
course for road pavements and bridge works. Mastic asphalt is an intimate
homogeneous mixture of selected well-graded aggregates, filler and bitumen in
such proportions as to yield a plastic and void less mass, which when applied hot
can be trowelled and floated to form a very dense impermeable surfacing.
365.2 Materials
365.2.1 Binder: The binder shall be a paving bitumen of Grade 35 conforming to IS:73
industrial bitumen of grade 85/25 conforming to 13:702 etc. meeting the
requirements given in Table 300.45.
365.2.2 Coarse Aggregate : The coarse aggregate shall consist of crushed stone,
crushed gravel/shingle or other stones. They shall be clean, hard, durable, of
fairly cubical shape, uncoated and free from soft, organic or other deleterious
substances. They shall satisfy the physical requirements given in Table
300.44.The percentage and grading of the coarse aggregate to be incorporated
in the mastic asphalt depending upon the thickness of the finished course shall
be as specified in Table 300.45.
Table 300.45 Requirements for Physical Properties of Binder
Property Test Method Requirement
Penetration at 25°C (1/100 IS 1203 10 to 40

cm)
Softening Point,.°C (ring &
IS 1205 50 to 90°C
ball method)
Loss on heating for 5h at
Max. S 1212 1
163°C, % by mass
Solubility in trichloroethylene,
Min. IS 1216 99
% by mass
Ductility at 27°C cm Min. IS 1208 3
Table 300.46 Grading and Thickness of Mastic Asphalt Paving and Grading
of Coarse Aggregate
Coarse
Nominal Size of
Thickness Aggregate
Application Coarse
Range (mm) Content, % by
Aggregate (mm)
mass of total mix
Roads and
25-50 13 40 ± 10
Carriageways
Heavily Stressed
Areas, i.e.,Junctions 40-50 13 45 ± 10
and Toll Plazas
Nominal Size of Coarse Aggregate 13mm
IS Sieve (mm) Cumulative % passing by weight
19 100
13.2 88-96
2.36 0-5
Fine Aggregate : The fine aggregate shall be the fraction passing the 2.36mm
and retained on the 0.075mm sieve consisting of crusher run screening, natural
sand or a mixture of both. These shall be clean, hard, durable, uncoated, dry and
free from soft or flaky pieces and organic or other deleterious substances. The
grading of fine aggregate inclusive of filler shall be as given in Table 300.47.
365.2.3 Filler: The filler shall be limestone powder passing the 0.075mm sieve and shall
have a calcium carbonate content of not less than 80 percent by weight when
determined in accordance with IS:1514.
Table 300.47 Grading of Fine Aggregate (Inclusive of Filler)
Percentage by weight of Total
IS Sieve
Aggregate
Passing 2.36mm but . retained on
0-25
0.600mm
Passing 0.600mm but retained on
5-35
0.212mm
Passing 0.212mm but retained on
10-20
0.075mm
Passing 0.075mm 0-5
365.2.4 Mix Design
365.2.4.1 Hardness Number: The mastic asphalt shall have a hardness number at the
time of manufacture of 60 to 80 at 25°C prior to the addition of coarse aggregate
and 10 to 20 at 25°C at the time of laying after the addition of coarse aggregate
The hardness number shall be determined in accordance with the method
specified inIS:1195-1978.

365.2.5 Binder Content : The binder content shall be so fixed as to achieve the
requirements of the mixture specified in Clause 365.2.5.1 and shall be in the
range of 14 to 17 per cent by weight of total mixture as indicated in Table 300.47.
365.2.6 Job Mix Formula: The Contractor shall inform the Engineer in writing at least 1
month before the start of the work of the job mix formula proposed to be used by
him for the work, indicating the source and location of all materials, proportions of
all materials such as binder and aggregates, single definite percentage passing
each sieve for the mixed aggregate and results of the tests recommended in the
various Tables and Clauses of this Specification.
365.3 Construction Operations
365.3.1 Weather and Seasonal Limitations: The provisions of Clause 318 shall apply,
except that laying shall not be carried out when the air temperature at the surface
on which the Mastic Asphalt is to be laid is below 10°C.
365.3.2 Preparation of the base : The base on which mastic asphalt is to be laid shall
be prepared, shaped and conditioned to the profile required, in accordance with
Clause 318 or 600 as 'appropriate or as directed by the Engineer. In the case of
a cement concrete base, the surface shall be thoroughly power brushed clean
and free of dust and other deleterious matter. Under no circumstances shall
mastic asphalt be spread on a base containing a binder which might soften under
high application temperatures. If such material exists, the same shall be cut out
and repaired before the mastic asphalt is laid.
365.3.3 Tack Coat: A tack coat in accordance with Clause 314 shall be applied on the
base or as directed by the Engineer.
365.3.4 Preparation of Mastic Asphalt : Penetration of mastic asphalt consists of two
stages. The first stage shall be mixing of filler and fine aggregates and then
heating the mixture· to a temperature of 170°C to 210°C. Required quantity of
bitumen shall be heated to 170°C to 180°C and added to the heated aggregated.
They shall be mixed and cooked in an approved type of mechanically agitated
mastic cooker for some tim'e till the materials are thoroughly mixed. Initially the
filler along is to be heated in the cooker for an hour and then half the quantity of
binder is added. After heating and mixing for some time, the fine aggregates and
the balance of binder are to be added and further cooked for about one hour.
The second stage is incorporation of coarse aggregates and cooling the mixture
for a total period of 3 hours. During cooking and mixing, care shall be taken to
ensure that the contents in the cooker are at no time heated to a temperature
exceeding 210°C.
Where the material is not required for immediate use it shall be cast . into blocks
consisting of filler, fine aggregates and binder, but without the addition of coarse
aggregate, weighing about 25 Kgs each. Before . use, these blocks shall be
reheated to a temperature of not less than 175°C and not more than 210°C,
thoroughly incorporated with the requisite quantity of coarse aggregates and
mixed continuously. Mixing shall be continued until laying operations are
,completed so as to maintain the coarse aggregates in suspension. At no stage
during the process of mixing shall be the temperature exceeds 210°C.
The mastic asphalt blocks (without coarse aggregate) shall show on analysis a
composition within the limits as given in Table 300.47.
The mixture shall be transported to the laying site in a towed mixer transporter
having arrangement for stirring and keeping the mixture hot during
transportation.
365.3.5 Spreading: The mastic asphalt shall be laid, normally in one coat, at a
temperature between 175°C and 210°C and spread uniformly by hand using

wooden floats or by machine on the prepared and regulated surface. The

thickness of the mastic asphalt and the percentage of added coarse aggregate
shall be in accordance with Table 300. 46 or as specified by the Engineer. Where
necessary, battens of the requisite dimensions should be employed. Any blow
holes that appear in the surface shall be punctured while the material is hot, and
the surface made good by further floating.
365.3.6 Joints: All construction joints shall be properly and truly made. These joints shall
be made by warming existing mastic asphalt by the application of an excess
quantity of the hot mastic asphalt mixture which afterwards shall be trimmed to
leave it flush with the surfaces on either side.
365.3.7 Surface Finish: The mastic asphalt surface can have poor skid resistance to
skidding, the mastic asphalt after spreading, while still hot and in a plastic
condition shall be covered with a layer of stone aggregate. This aggregate shall
be 13.2mm size (passing the 19.0mm sieve and retained on the 9.5mm sieve) or
9.5mm size (passing the 13.2mm sieve and retained on the 6.7mm sieve)
subject to the approval of the Engineer. Hard stone chips, complying with the
quality requirements of Table 300.44 ,shall be pre-coated with bitumen at the
rate of 2 ± 0.4% of S-65 penetration grade. The addition of 2% of filler complying
with Table 300.47 may be required to enable this quantity of binder to be held
without draining. The chips shall then be applied at the rate of 0.005 Cu. M. per
10 Sq. M. and rolled or otherwise pressed into the surface of the mastic layer
when the temperature of the mastic asphalt Is not less than 100°C.
365.3.8 Opening to Traffic: Traffic may be allowed after completion of the work when
the mastic asphalt temperature at the mid-depth of the completed layer has
cooled to the daytime maximum ambient temperature.
365.3.9 Surface Finish and Quality Control of Work: The surface finish of the
completed construction shall conform to the requirements of Clause 620.
365.3.10 For control of the quality of materials supplied and the works carried out, the
relevant provisions of Section 600shall apply.
The surface of the mastic asphalt,' tested with a straight edge 3.0m long, placed
parallel to the centre line of the carriageway, shall have no depression greater
than 7mm. the same limit shall also apply to the transverse profile when tested
with a camber template.
365.3.12 Measurement for Payment: Mastic asphalt shall be measured as finished· work
in square metres at a specified thickness, or by weight in tones as stated in the
Contract.
365.3.13 Rate : The contract unit rate for mastic asphalt shall be payment in full for
components listed under Clause 318.11 (i) to (ix).

370.0 Seal Coat

370.1 Scope : This work shall consist of the application of a seal coat for sealing the
voids in a bituminous surface laid to the specified levels, grade and cross fall
(camber).
Seal coat shall be of either of the two types specified below:
Liquid seal coat comprising of an application of a layer of bituminous binder
followed by a cover of stone chips.
370.2 Binder: The requirements of Clauses 361.2.2.1 shall apply.
The quantity of bitumen per 10 square metres, shall be 9.8 Kg. for Type A seal
coat. Where bituminous' emulsion is used as a binder the quantities for Type A
seal coats shall be 15 Kg per 10 square meters rapid setting (clause 4.2.2 of
IRC:14-2004). .
370.2.1 Stone Chips for Type A Seal Coat: The stone chips shall consist of angular
fragments of clean, hard, tough and durable rock of uniform quality throughout.
They should be free of soft or disintegrated stone, organic or other deleterious
matter. Stone chips shall be of 6.7mm size defined as 100 per cent passing
through 11.2mm sieve and retained on 2.36mm sieve the quantity used for
spreading shall be 0.09 cubic metre per 10 square metre area. The chips shall
satisfy the quality requirements in Table300.22 except that the upper limit for
water absorption value shall be 1 per cent.
370.3.1 Weather and Seasonal Limitations : The requirements of Clause 318.6.1 shall
apply.
370.3.2 Preparation of Surface : The seal coat shall be applied immediately after laying
the bituminous course which is required to be sealed. Before application of seal
coat materials, the surface shall be cleaned free of any dust or other extraneous
matter.
370.3.3 Construction of Type A Seal Coat : Bitumen shall be heated to 150°C-163°C
and sprayed at the rate specified on the dry surface in a uniform manner with a
self-propelled mechanical sprayer as described in the Manual for Construction
and Supervision of Bituminous Works.
Immediately after the application of binder, stone chips, which shall be clean and
dry, shall be spread uniformly at the rate specified on the surface preferably by
means of a self-propelled or towed mechanical grit spreader so as to cover the
surface completely. If necessary, the surface shall be brushed to ensure uniform
spread of chips.
Immediately after the application of the cover material, the entire surface shall be
rolled with a 8-10 tonne smooth wheeled steel roller, 8-10 tonne static weight
vibratory roller, or other equipment approved by the Engineer after laying trials if
required. Rolling shall commence at the edge~ and progress towards the centre
except in super elevated and unidirectional cambered portions where it shall
proceed from the lower edge to the higher edge. Each pass of the roller shall
uniformly overlap not less than one-third of the track made in the preceding pass.
While rolling is in progress, additional chips shall be spread by hand in necessary
quantities required to make up irregularities. Rolling shall continue until all
aggregate particles are firmly embedded in the binder and present a uniform
closed surface.
370.3.4 Opening to Traffic : In the case of Type A Seal Coat, traffic shall not be
permitted to run on any newly sealed area until the following day. In special

circumstances, however, the Engineer may open the road to traffic immediately
after rolling, but in such cases, traffic speed shall be rigorously limited to 16 Km.
per hour until the following day.
370.3.5 Surface Finish and Quality Control of Work : The surface finish of construction
shall conform to the requirements of Clause 610
For -control on the quality of materials supplied and the works carried out, the
relevant provisions of Section 600 shall apply.
370.3.6 Arrangement for Traffic: During the period of construction, arrangements for
370.3.7 Measurement for Payment: Seal Coat shall be measured as finished work, over
the area specified to be covered, in square metre at the thickness specified in the
Contract.
370.3.8 Rate: The contract unit rate for seal coat shall be payment in full for carrying out
the' required operations including full compensation for all components listed in
Clause 318.11.
375.0 Slurry Seal
375.1 Scope : Slurry seals are mixtures of fine aggregate, Portland cement filler,
bitumen emulsion and additional water. When freshly mixed, they have a thick
consistency and can be spread to a thickness of 1.5 - 5 mm. They may be used
to seal cracks, arrest fretting and fill voids and minor depressions, to provide a
more even riding surface or a base for further treatment; they may also be used
on top of a single coat surface dressing.
375.2 Materials : The materials for slurry seal immediately prior to mixing shall conform
to the following requirements :
375.2.1 Emulsified Bitumen : The emulsified bitumen shall be a cationic rapid setting
type as approved by the Engineer, conforming to the requirements of IS:8887 ..
Where special mobile mixing machines are available, Class .A4* rapid setting .or
Class K3* road emulsions to BS~ 434: Part I should be used, to obtain very early
resistance to traffic and rain. Generally, emulsion for slurry seal should be
capable of producing a slurry that will develop early resistance to traffic and rain
and is sufficiently stable to permit mixing with the specified aggregate, without
breaking during the mixing and laying processes. If approved by the Engineer, a
slow setting emulsion may be used. Guidance on selection of an appropriate
grade of emulsion is given in the Manual for Construction and Supervision of
Bituminous Works.
375.2.2 Water : Water shall be of such quality that the bitumen will not separate from the
emulsion before the slurry seal is in place.
The pH of the water must lie in the range 4 to 7, and if the total dissolved solids
in the water amount to more than 500ppm, the Engineer may reject it, or order
the Contractor to conduct a trial emulsion mix to demonstrate that it does not
cause early separation.
375.2.3 Aggregate : The aggregate shall be crushed rock, or slag and may be blended,
if required, with clean, sharp, naturally occurring sand free from soft pieces and
organic and other deleterious substances to produce a grading as given in Table
300.47 A. The aggregates shall meet the requirements of the film stripping test
(IS:6241). and a suitable amount and type of anti-stripping agent added, as may
be needed (details given in Appendix 5).
375.2.4 Additives: It is usual to use ordinary Portland cement, hydrated lime or other
additives to control consistency, mix segregation and setting rate. The proportion
of the additive should not normally exceed 2 per cent by weight of dry
aggregates.

375.3 Mixture Design : A range of residual binder contents for each aggregate grading
is given in Table 300.47 A. The optimum mixture design for the aggregate
additive, water and bitumen emulsion mixture should be determined in
accordance with ASTM D 3910.
375.4.1 Weather and Seasonal Limitations: Clause 318.4.1 shall apply.
Table 300.47 Aggregate Grading, Binder Content and Approximate Coverage
Rate
Percentage by Mass Passing
Sieve Size (mm) Finished Thickness of Sealing
5mm 3mm 1.5mm
9.5 100 - -
4.75 90-100 100 -
3.35 - 80-100 100
2.36 65-90 75-100 95-100
1.18 45-70 55-90 70-95
0.600 30-50 35-70 55-75
0.300 18-30 20-45 30-50
0.150 10-21 10-25 10-30
0.075 5-15 5-15 5-15
Quantity of residual binder, percentage by
7.5-13.5 10-16 12-20
mass of aggregate
Approximate coverage rate (Kg./m2) 8-15 4-6 2-4
375.4.2 Surface Preparation : Any necessary remedial work to the road surface and
structure shall be completed either prior to or as part of the Contract and agreed
as acceptable by the Engineer, according to the provisions of Clause 318.
Before slurry seal is applied, street furniture and, where directed by the Engineer,
road markings, shall be masked using self-adhesive masking material or other
material firmly secured against the passage of the spreader box or the tools used
for hand laying. Any packed mud or other deposits on the surface shall be
removed, all organic growth shall be removed by suitable means, and the
surface shall be swept free of all loose material.
375.4.3 Tack Coat : If required by the Engineer, a tack coat may be applied prior to the
slurry seal, with or without grit or chips, in order to seal the existing substrata and
enhance the bond to the existing road surface. Unless otherwise agreed by the
Engineer, the rate of spread of tack coat shall be 0.15 to 0.30 Iitres I m2 for
bituminous surfa.ces and .04 to 0.6 litres I m2 for concrete surfaces.
375.4.4 Mixing and Transportation of Mixture : Mixing (and laying) techniques vary
according to the type of emulsion used. For class A4 rapid setting and K3
emulsions, only special mobile mixing machines should be used. These carry
supplies of aggregate, emulsion, water and filler (e.g. ordinary Portland cement
or hydrated lime) and are fitted with metering devices to feed the ingredients in
their correct proportions to a mixer fitted to the rear of the machine. From the
mixer the slurry is fed into the screed box towed by the machine.
For all other emulsions, mixing may be by hand, concrete mixer or other mixer
which effectively coats the aggregate uniformly and produces a slurry seal of
suitable consistency for satisfactory laying. For large areas, a bulk transit
concrete mixer may be used into which the ingredients (including water) are

measured and mixed as the mixer travels to the area to be treated. A screed box
fitted with an adjustable rubber screed should be towed by the mixer which feeds
it during laying.
The special mobile mixing machine, when used, shall be capable of uniform
application to provide a continuous surface without ridges or segregation. Before
laying begins, the Contractor shall provide the Engineer with a test certificate
showing test results for rate of application carried out under the supervision of a
competent authority, demonstrating that the machine has been tested, using the
system to be· used in the Contract, not more than six weeks before the
commencement of the work.
Where the material is to be hand laid, the slurry may be supplied to site pre-
mixed in suitable containers and steps shall be taken to ensure that the material
in each container is of an even consistency throughout the container immediately
prior to use.
375.4.5 Application : Transverse joints for machine laid areas shall be formed with
spreading, starting and finishing on a protective strip not less than 100 mm wide
at each end of the length being treated. Transverse joints shall be formed such
that there shall be no ridges or bare strips.
Unless otherwise approved by the Engineer, longitudinal joints shall coincide with
lane markings. Longitudinal joints shall be formed such that there shall be no
ridges or bare strips. Hand work around street furniture and other obstructions
should meet the same performance requirements and form a homogeneous
surface with the rest of the treated carriageway.
Footways and other confined areas may be spread by hand using squeegees
and brooms. Transverse joints shall be formed with spreading, starting and
finishing on a protective strip not less than 100mm wide at each of the lane
length being treated. Transverse joints shall be formed such that there shall be
no ridges or bare strips. Kerb edges and other areas not being treated shall be
suitably masked with self adhesive masking material. Footways shall be finished
by dragging a dampened broom transversely over the footway under its own
weight.
All voids, cracks and surface irregularities shall be completely filled. In warm dry
weather the surface, immediately ahead of the spreading, shall be slightly
damped by mist water spray applied mechanically, or for hand laying by a hand
operated pressure sprayer, unless otherwise approved by the Engineer.
375.4.6 Rolling : The need for rolling shall be as instructed by the Engineer. Where
rolling is required. a pneumatic-tyred roller having an individual wheel load
between 0.75 and 1.5 tonnes shall be used, or as may be directed by the
Engineer. Rolling shall commence as soon as the slurry has set sufficiently to
ensure that rutting or excessive movement will not occur.
375.5 Opening to Traffic : Masking shall be removed after the slurry seal has been
applied, without damage to the edge of the surfacing, and before opening the
road or footway to traffic.
The Contractor shall remove surplus aggregate from the treated areas using a
method agreed by the Engineer. The Contractor shall monitor the slurry seal
closely for a minimum period of 2 hours and if necessary the lane shall be swept
again. The monitoring shall continue until the slurry seal has reached sufficient
stability to carry unrestricted traffic. If there are' signs of distress, the Engineer
shall require the Contractor to reinstate traffic safety and management
procedures or other such remedial action where necessary in order to prevent
further damage.

Further operations to remove subsequently loosened aggregate shall be carried

out over the next 48 hours. The areas treated and adjacent side roads, footways
and paved areas shall be kept substantially free of loose aggregate for a period
of 30 days after completion of the work. 375.6 Surface Finish and Quality Control
of Work : Generally, the surface finish of the completed construction shall
conform to the requirements supplied and the works carried out, the relevant
In addition, the finished slurry shall have a uniform surface texture throughout the
work, without variations of texture within the lane width, or from lane to lane, due
to segregation of aggregates, or due to variations in the emulsion / water content
of the mixture.
The finished surface shall be free from blow holes and surface irregularities in
excess of 3mm beneath a 1 metre straight edge due to scraping, scabbing,
dragging, droppings, excess overlapping or badly aligned longitudinal or
transverse joints, damage by rain or frost, or other defects which remain 24
hours after laying. 375.7 Arrangements for Traffic : During the period of
construction, arrangements for traffic shall be made in accordance with the
provisions of Clause 30.
375.8 Measurements for Payment : Slurry seal shall be measured as finished work as
specified, in square metres.
375.9 Rates: The contract unit rate for slurry seal shall be payment in full for carrying
out the required operations including full compensation for all components listed
in Clause 318.11 (i) to (xi).
380.0 Recycling of Bituminous Pavement
380.2 Scope : This Clause of the Specifications covers the recycling of existing
bituminous pavement materials to upgrade an existing bituminous pavement
which has served its first-intended purpose. The work shall be performed on
such widths and lengths as may be directed by the Engineer and may consist of
pavement removal, stockpiling of materials from the old pavement, addition of
new bitumen and untreated aggregate in the requisite proportions, mixing,
spreading and compaction of the blended materials.
Recycling processes can be categorised into in-situ recycling (where processing
takes placed on site), and central plant recycling (where reclaimed material is
processed off site). The processes can be further sub-divided into hot and cold
processes. This Specification covers the hot process only. However, reclaimed
aggregated from cold in-situ recycling can be used in the Bituminous Cold Mix
process specified in Clause 317, subject to the resultant mixes achieving the
specified standards.
380.3 Reclaimed Bituminous Materials for Central Plant Recycling:
380.3.4 Proportion of reclaimed materials less than 10 per cent : If not more than 10% of
reclaimed bituminous material is to be used in the production of bituminous
macadam or dense graded bituminous base or binder course material, then
Clauses 380.2.2 to 380,2.9 do not apply. However:
i) all reclaimed bituminous material shall be pre-treated before use such that
the material is homogeneously mixed and the maximum particle size of
reclaimed materials does not exceed 40mm.
ii) the mixed material shall comply with the requirements of Clauses 351 or 354
as appropriate.
380.2.2 Proportions of reclaimed materials greater than 10 per cent : Reclaimed
bituminous material of an amount greater than 10 per cent, may be used in the
production of bituminous macadam and dense graded bituminous base and

binder course material, subject to the requirements of Clauses 380.2.3 to 380.2.9

and subject to the satisfactory completion of full trial investigations in respect of
all related materials, layer thickness, machine operations and finished works on a
case-by-case basis entirely at the contractors cost and subject to the approval of
the Engineer. For estimating purposes, a maximum amount not greater than 30
per cent reclaimed bituminous material should be assumed.
380.2.3 Materials for Recycled Pavement: The recycled materials shall be a blend of
reclaimed and new materials proportioned to achieve a paving mixture with the
specified engineering properties. The reclaimed materials shall be tested and
evaluated to find the optimum blend meeting the mixture requirements. Such
testing and evaluation shall be carried out on representative samples, either
cores sampled from the carriageway or samples taken from stockpiles in
accordance with current practice. The sampling frequency should be sufficient to
determine how consistent the reclaimed material is and to provide representative
samples for composition analysis and measurement of properties of recovered
binder. As an absolute minimum, one sample to represent 500n:t0f lane
carriageway shall be taken.
380.2.4 Bitumen Extraction: The procedure described in ASTM 0-2172 shall be used to
quantitatively separate aggregate and bitumen from any representative sample
of reclaimed bituminous pavement.
380.2.5 Aggregate Evaluation: Mechanical sieve analysis (lS: 2386, Part-I, wet . sieving
method) shall be performed on the aggregate portion of the reclaimed bituminous
pavement sample to determine the grading. It is essential that the reclaimed
materials to be recycled are consistent, as variable materials will cause problems
with the control of quality and impede the efficiency of the recycling operation.
Suitable sources of consistent material of sufficient quantity for the scheme being
considered need to be identified either in existing pavements, from stockpiled
planings of known origin or from another suitable source, before a decision can
be made on the optimum percentage of reclaimed material.
After selecting the proportion of reclaimed materials to be recycled, the grading
of the mixture may need adjustment, to meet Specification requirements, by the
addition of selected aggregate sizes. Evaluation of bitumen : When the amount
of reclaimed bituminous material to be used in the mixture exceeds 10%, the
penetration value of the recovered binder from the reclaimed bituminous
material, before mixing, shall exceed 15 pen, after recovery of binder in
accordance with the requirements of IS 2000 : Part-397, when tested in
accordance with IS:1203. Provided the above requirement is met, hardening of
the old binder, during the original mixing process or through ageing, can be
compensated for by adding a softer bitumen, to obtain the appropriate final grade
of binder.
The determination of the type and amount of binder required to be added in the
final mix is essentially a trial and error procedure.
After mixing with recycled materials, the binder recovered from the mixture shall
have a recovered penetration value not less than the value specified in Table
300.48.
Table 300.48 Minimum Recovered Binder Penetration of Recycled Mixture
Specified Grade of Binder Minimum Recovered Penetration
(Penetration) Value of Binder after Mixing
45 27
65 39
90 54

380.2.7 Rejuvenators : The use of rejuvenators, and a test to measure their

effectiveness, is described in Clause 380.6.3.
380.2.8 Untreated Aggregate: If necessary, fresh untreated aggregate shall be added to
the reclaimed bituminous pavement to produce a mix with the desired grading.
The aggregate shall be checked for quality requirements in accordance with
Table 300.22 as appropriate. Reclaimed aggregate, if any, or any aggregate
normally used for the desired bituminous mixture, or both, may be used for this
purpose.
380.2.9 Combined Aggregate Grading : The blend of reclaimed and new aggregate
shall meet the grading criteria specified in the relevant parts of Clause 351 or
354, as appropriate and as approved by the Engineer. The blend of aggregates
shall be checked for resistance to stripping as specified in Tables 300.22 as
appropriate.
380.3 Mixture Design : The combined aggregate grading and binder content shall
comply with the relevant tables in Clauses 351 or 354. For dense graded
bituminous mixtures, the mixture design shall also comply with the requirements
of Table 300.30.
380.4 Reclaiming Old Pavement Materials : The removal of pavement materials to
the required depth shall be accomplished either at ambient temperature (cold
process) or at an elevated temperature (hot process). as approved by the
Engineer.
380.4.1 Cold Removal Process: In the cold process, the ripping and crushing
operations shall be carried out using scarifiers, grid rollers, or rippers or by any
other means as directed by the Engineer. The removed materials shall be loaded
and hauled for crushing to the' required size as directed by the Engineer.
Alternatively, cold miling or planing machines can be used to reclaim bituminous
pavement to controlled depths. After the bituminous layers are removed, any
remaining aggregate materials that are to be incorporated in the recycled hot
mixture shall be scarified and removed. When the pavement material removal is
completed, any drainage deficiencies shall be corrected. After that, the base I
sub-base as the case may be shall be cut, graded and compacted to the required
profile and density.
380.4.2 Hot Removal Process : In this process, the road surface shall be heated, by any
suitable means approved by the Engineer, before scarification. A self-propelled
plant shall be used, and a milling drum that follows the planer removes the
heated soft bituminous layer. The depth, width and speed of travel shall be
adjusted to suit specified requirements as directed by the Engineer. During the
heating process, the surface temperature of the road shall not exceed 200°C for
more than 5 minutes.
380.4.3 Stockpiling : In the cold process, the reclaimed bituminous pavement material
shall be stockpiled with the height of stockpiles not exceeding 3m. The reclaimed
untreated aggregate base I sub-base material shall be stockpiled in the same
manner as new aggregate. The number and location of stockpiles shall be
carefully planned for efficient operation of the hot-mix plant.
380.5 Mixing and Laying: Generally, the requirements of Clauses 351 or 354, as
appropriate, shall apply.
380.6 In Situ Recycling - The Remix and Repave Processes : These processes are
suitable for the production of· bituminous concrete wearing course in accordance
with the provisions of Clause 364.
380.6.1 Scope : In the process of repaving, the existing surface is preheated and
scarified but the scarified material is not removed. A layer of fresh bituminous

mix material prepared in the integrated mixing unit of the plant is then spread
evenly on the scarified surface to give a uniform profile. The spread material
should be compacted as soon as possible after laying. In the process, the total
thickness of the pavement is increased by up to 50mm.
In the remix process, the scarified material should be taken from the mixing unit
of the plant where it is recycled with fresh binder, aggregate and recycling agent.
Then the recycled mixture is spread on the preheated surface and tamped and
compacted to the required profile.
380.6.2 Heating and Scarifying: Surfaces to be treated shall be heated by plant with
surfaced insulated and fully enclosed. The heated width of surfacing shall exceed
the scarified width by at least 75mm on each side, except against the edge of the
carriageway or kerb face. When new surfacing material is spilled onto the road
surface it shall be removed before the existing surface is heated and scarified.
Areas of unscarified material shall not .exceed 50mm x 50mm.
The depth of scarification shall be such that the bottom of the scarified layer is
parallel to and below the finished road surface level by. the thickness of wearing
course material specified. A tolerance of ±6mm is permissible.
Where street furniture and other obstructions occur, these shall be suitably
protected or removed and the void covered. Surface dressing and large areas of
road marking shall be removed by milling, planning, scarifying or by similar
approved processes.
The heated surface shall be evenly scarified to comply with the requirements of
this Clause. When street furniture is left in place or raise, the adjacent areas shall
be scarified by other means, with the material either left in place or removed,
prior to passage of the machine. If furniture needs to be repositioned on
completion of work, the new wearing course material shall be used to make good
the road surface for a maximum width of 200mm around the obstruction.
During the reheating process the surface temperature of the road shall not
exceed 200°C for more than 5 minutes.
380.6.3 Rejuvenator : For Remix, when required, rejuvenator shall be uniformly sprayed
across the full-width of the processed material. The machine shall incorporate a
meter for continuous verification of quantities which shall be within ±5% of the
specified rate. The volume of rejuvenator shall vary in relation to the operating
speed the machine, which shall be related to the volume of material mixed or
scarified.
The rejuvenator shall be a non-emulsified aromatic extract. Its properties shall be
verified using the Rolling Thin Film Oven Test.
Rejuvenation of the existing pavement may also be performed by adding new
hot-mix bituminous material containing a soft binder of suitable penetration for
restoring the binder in the existing pavement to the required penetration.
380.6.4 Mixing : When required, new hot-mix material shall be mixed with the heated
and scarified road pavement material in a pugmill within the Remix machine,
observing the mixing temperatures specified in the Table 300.24.
After mixing, the recycled bituminous materials shall be automatically fed to a
finishing unit, which spreads and levels the mixture to the specified thickness and
cross-section. The new bituminous concrete wearing course shall be material
complying with Clause 364.
380.6.5 Additional Material (General) : The proportion of new hot-mix' bituminous
material, and the proportion of existing bituminous pavement material shall be as
directed by the Engineer, together with the amount the road surface level is to be
raised (if any).

The type and quantity of the new hot-mix material shall be determined by using
the Marshall Mix Design procedure specified in The Asphalt Institute Manual MS-
2, before work commences. Remix designs shall incorporate the stated
proportion of material sampled from the existing road surface.
When additional coarse or fine aggregate or filler are required to be added, they
shall comply with the requirements of Clause 364. The amount of additional
coarse or fine aggregate or filler to be added to the existing bituminous pavement
material shall be notified to the Engineer.
380.6.6 Additional Aggregate (Remix Process) : The coarse aggregate, fine aggregate
and filler added to the Remixed material shall comply with the requirements of
Clause 364.
380.6.7 New Surfacing (Repave and Remix / Repave Processes) : New surfacing
material shall be bituminous concrete wearing course complying with Clause
364, or other wearing course material approved by the Engineer.
The new surfacing material shall be laid on, and compacted with, the re-profiled
surfacing, which shall be at a temperature within the range of 100°C to 150°C.
380.6.8 Binder: The binder shall be recovered from sampled taken from each layer of
material laid. The method of recovery shall be in accordance with IS 2000 :. Part-
397 or an equivalent test. The penetration of the binder shall be in the range 35-
70 pen.
380.6.9 Mixture Design : The surfacing material shall be sampled from the paver hopper
or augers. Care shall be taken that only the material forming the new surface
layer is sampled. The sample shall be reduced on site by rifling or quartering to
approximately 5 kg and placed loose in an air-tight container.
The sample shall only be reheated once whilst within the container. As soon as
the sample reaches the required temperature, the reheated material shall be
remixed and three Marshall test specimens prepared in accordance with the
procedures specified in MS-2.
The bulk density of each specimen shall be measured before Marshall Stability
testing. The mean stability and flow of the three specimens, measured in
accordance with the procedures specified in MS-2, shall comply with the
requirements of Table 300.30.
Finally the 3 Marshall specimens shall be combined and the maximum
theoretical specific gravity (Gmm) of the mixture is determined in accordance with
ASTM 0-2041. This maximum theoretical specific gravity (Gmm) corresponds to
0% air voids in the mixture. The actual bulk specific gravity of a Marshall
specimen determined in the Laboratory (Gmb) will naturally be less than Gmm .
The percent air voids (P a) in the specimen of the compacted mixture given by :
should meet the requirements of air voids laid down in Table 300.30.
380.7 Opening to Traffic : For recycled material forming the base or binder course
layer, Clause 351 or 354 shall apply as appropriate. For recycled material
forming the wearing course layer, Clause 364 shall apply.
380.8 Surface Finish and Quality Control : The surface finish of the completed
construction shall conform to the requirements of Clause 600.
For control of the quality of materials supplied and the works carried out the
relevant provisions of Section 600 shall apply.
380.9 Arrangements for Traffic : During the period of construction, arrangements for

380.10 Measurement for Payment : The recycled pavement work shall be payment in
full for carrying out the required operations including full compensation for all
items as Clause 318.11 (i) to (xi).

400.0 Cement Concrete
410.0 Structural Concrete :

Structural Concrete shall be as per IS:456-2000 : Clause-6.
410.1 Concrete Making Materials
410.1.1 Cement: Ordinary Portland Cement conforming to IS:269, IS:8112, IS:12269;
Portland Slag Cement conforming to IS:455, Portland Pozzolana Cement as per
IS:1489 (Part-1)
410.1.2 Mineral Admixtures: Fly Ash conforming to Grade-I of IS:3812
410.1.3 Aggregates: Aggregates shall comply with requirements of IS:383
The size of Aggregate : The nominal maximum size of coarse aggregate should
be 20mm.
410.1.4 Water: Water as per Clause 5.4 of IS:456 2000.
410.1.5 Admixtures: Admixtures shall comply with IS:9103
410.1.6 Reinforcement: Reinforcement shall be mild steel and medium tensile steel bars
conforming to IS:432 (Part-1), high strength deformed steel bars conforming to
15:1786
410.2 Storage of Materials : Storage of Materials shall be as per IS:4082
410.3 Production of Concrete as per Clause 10 of IS:456.
425.0 Ready Mix Concrete
The contractor shall procure RMC from the RMC plant approved by MCGM only.
The RMC prepared and transported will be as per relevant IS:4926. The
following information on the performance of Ready Mix Concrete supplied by the
plant shall be obtained.
425.1 Following past data regarding raw materials and equipment deployed shall be
obtained from RMC manufacturer .
Proforma Table 400.1
Cement Grade Source Type IS
2
Strength (N/mm ) 3 days 7 days 28 days 6 months 1 Year
Average
Standard
Deviation
Initial Setting
Time
Final Setting
Time
425.2 Coarse Aggregate

Size Source Grading Zone

Standard
Characteristic Property Average Value Remarks
Deviation
Fineness Modules
Specific Gravity
Bulk Density

Crushing Value
Impact Value
Abrasion Value
Soundness (average
loss after 5 cycles)
Water absorption
Deleterious Materials
Surface Water
425.3 Fine Aggregate

Source Grading Zone
Standard
Characteristic Property Average Value Remarks
Deviation
Fineness Modules
Specific Gravity
Bulk Density
Crushing Value
Impact Value·
Abrasion Value
Soundness (average loss
after 5 cycles)
Water absorption
Deleterious Materials
Surface Water
425.4 Water
Source
Property Average Standard Deviation
p. H Value
% of strength of cubes
prepared with boiled
water
solids in water -
Organic
Inorganic
Sulphates (S03)
Suspended Matters
425.5 Mineral Admixtures
Source
Property Average Standard Deviation
Fineness Modulus

Lime Reactivity
Minimums Compressive Strength
N/mm2
Drying Shrinkage % Maximum
Soundness Expansion
Chemical Analysis
425.6 Chemical Admixtures
Source
 Water content, % of control sample
 Slump
 Time of Setting, allowable deviation from Control sample-hours
Initial
Maximum
Minimum
Final
Maximum
Minimum
425.6.1 Compressive Strength
% of Control Standard
Average Remarks
Sample Deviation
1 day
3 days
7 days
28 days
6 months
1 year
425.6.2 Flexural Strength
% of Control Standard
Average Remarks
Sample Deviation
3 days
7 days
28 days
425.7 RMC Plant Data:Batching Tolerance
Material Tolerance
Cement ±%
Aggregates ±%
Mineral Admixture ±%
Chemical Admixture ±%
425.8 Mixing Efficiency as per IS

425.9 Conveyance: Ready Mix Concrete shall be brought to the site by transit mixers
(agitators).
RMC Procurement & Delivery : The contractor shall procure RMC from the RMC
plant approved by MCGM only. Ready Mix Concrete prepared and transported
will be as per relevant IS 4296. Ready Mix Concrete will be brought to the site
from RMC plant only by transit mixers (agitators). Every transit mixer will carry
delivery challan, mentioning the minimum following details:
Description Values
i) Name of Manufacturer and Depot
ii) Serial No. of Challan
iii) Date
iv) Truck No.
v) Name of Contractor to whom the
RMC is being supplied
vi) Location of contract work
vii) Grade of concrete
viii) Specified workability
ix) Cement content and Grade of
Cement
x) Time of loading
xi) Quantity of concrete
A computerized print out showing details of ingredients of ready mix concrete
including admixture viz. the actual weight of each ingredients, required weight of
each ingredient as per mix design etc. shall invariably be obtained with each
transit mixer carrying RMC on site. The computerized sheet shall be signed by
the site in charge and contractor's representative and shall be preserved as a
record on the site. When the truck arrives on site, the drum should always be
speeded to about 10 to 15 rev/min. for at least 5-10 minutes, to make sure that
the concrete is thoroughly mixed and uniform, before discharge. All taxes / duties
etc. will be borne by the contractors and not by the MCGM. No extra payment will
be made for the use of admixtures
The defect liability period of 5 years will be the responsibility of the main
contractor.
425.10 Data on Various Mixes-
Control mix 28 days strength without admixture and slump of 50 mm
W:C ratio
A:C ratio
0.50 0.45 0.40 0.35
3
3.50
3.75
4
4.25
425.11 Concrete Slump & Retention Data

W:C ratio
Admixture %
0.50 0.45 0.40 0.35
0.5
0.75
1
1.25
1.5
1.75
2
425.12 Concrete Compressive Strength for Required Grade of Concrete
Average Strength in
Age of Concrete (Days) Standard Deviation
N/mm2
1
3
7
28
150
365
425.13 Concrete flexural Strength
Average Strength in
Age of Concrete (Days) Standard Deviation
N/mm2
7
28
150
425.14 Client's Requirement
Type of Structure
Location of concreting
Properties of Concrete Required Values
Grade of Concrete
Exposure Conditions
Type of Cement
Minimum Cement Content
Maximum Cement Content
Minimum / Maximum W:C Ratio
Density of Concrete
Workability / retention
Maximum Size of Aggregate
Admixtures
Mode of Placement
Rate of Placement

Type of Formwork
425.14 Mix Design Report
Client
Grade of Concrete
Characteristic Strength @ 28 days Mpa
Degree of Control
Standard Deviation
Target Mean Strength Mpa
Max. Size of Aggregates
Cement
Fine Aggregates
Cement
Fine Aggregates
Coarse Aggregates (CA-I)
Coarse Aggregates (CA-II)
Free Water Cement Ratio by Weight
Aggregate Cement Ratio by Weight
(C:FA AC-I: CA-II)
Quantities Kg. I Cu. M.
Cement
FA
CA-I
CA-II
Water Ltd./Cu.M.
Admixtures Dosage (SIKAMENT-600)
Stump Details :
Initial Slump
Lab Cube Strength MPa
3 days strength
7 days strength
28 days strength
430.0 Paving Tiles :
430.1 Materials : Precast concrete paving tiles with or without perforation shall be
manufactured and tested in accordance with IS:13801, except as described here
below, to the approval of the Engineer. Pre-cast concrete paving tiles shall be
manufactured to the dimensions, patterns, and colours indicated in the drawings.
The tiles are to be either 250mm or 300mm x 100mm rectangular or any other
size and / or shape as shown in the drawings or instructed by the Engineer and
shall be hydraulically pressed using a coloured concrete topping not less than
8mm thickness. The pre-cast concrete paving tiles shall have a minimum
thickness of 38mm and shall be laid to the pattern indicated in the drawings.
The tiles shall be manufactured using a minimum of 350 Kg. Cement per Cubic
Metre of Mix.

All tiles shall be free from segregation, (honey-combing, broken or damaged

corners and imperfect plane surface). Correction of any defects by a method of
polishing or grouting will not be allowed.
431.0 Paver Block for Pedestrian Ways & Footpaths : The interlocking paver block
of 60 mm thickness to be used for pedestrian ways and footpaths. The average
tensile splitting strength shall not be less than 2.8 MPa with a provision that no
individual block shall have a strength less than 2.6 MPa.
The laying procedure and the sampling and testing procedure for the paver
blocks shall be as given in Clause No.440.
431.1 Measurements for Payment: The unit of measurement for the paver block
surfacing shall be Sq. M. of area covered by the paver block including sand
bedding for the specified thickness shown on the drawing.
431.2 Rate: The contract unit rate payable for paver block pavement shall be payment
in full for carrying out the required operations including full compensation for all
labour, materials (paver blocks, sand and concrete for confinement) and
equipment, transport, placing, compacting, finishing, curing, testing and
incidentals to complete the work as per specifications, all royalties, fees, storage
and drains where necessary and all leads and lifts.
440.0 Paver Blocks / Interlocking Concrete Block Pavement:
440.1 The concrete pavers should have perpendiculars after release from the mould
and the same should be retained until the laying. The surface should be of anti-
skid and anti-glare type. The pave should have uniform chamfers to facilitate
easy drainage of surface run off. The pavers should have uniform interlocking
space of 2mm to 3mm to ensure compacted sand filling after vibration on the
paver surface.
440.2 The concrete mix design should be followed for each batch of materials
separately and automatic batching plant is to be used to achieve uniformity in
strength and quality.
440.3 The pavers shall be manufactured in single layer only.
440.3.1 Skilled labour should be employed for laying blocks to ensure line and level for
laying, desired shape of the surface and adequate compaction of the sand in the
joints.
440.3.2 The pavers are to be skirted all round with kerbing using solid concrete blocks of
size 100mm x 200mm x 400mm or as directed by the Engineer. The kerbing
should. be embedded for 100mm depth. The concrete used for kerbing shall be
cured properly for 7 days minimum.
440.3.3 Bedding Sand Course : The bedding sand shall consist of a clean well graded
sand passing through 4.75mm sieve and suitable for concrete. The bedding .
should be from either a single source or blended to achieve the following
grading.
Table 400.1 Bedding Sand Requirement
In Sieve Size % Passed
9.52mm 100
4.75mm 95-100
2.36mm 80-100
1.18mm 60-100
600 Microns 25-60
300 Microns 10-30
150 Microns 5-15

75 Microns 0-10
Contractor shall be responsible to ensure that single-sized, gap-graded sands or
sands containing an excessive amount of fines or plastic fines are not used. The
sand particles should preferably be sharp not rounded as sharp sand possess
higher strength and resist the migration of sand from under the block to less
frequently areas even though sharp sands are relatively more difficult to compact
than rounded sands, the use of sharp sands is preferred for the more heavily
trafficked driveways. The sand use for bedding shall be free of any deleterious
soluble salts or other contaminants likely to cause . efflorescence.
The sand shall be of uniform moisture content and within 4% - 8% when spread
and shall be protected against rain when stock piled prior to spreading. Saturated
sand shall not be used. The bedding sand shall be spread loose in a uniform
layer as per drawing. The compacted uniform thickness shall be of 45mm and
within +/- 5mm thickness variation shall not be used to correct irregularities in the
base course surface. ..
The spread sand shall be carefully maintained in a loose dry condition and
protected against pre-compaction both prior to and following screeding. Any pre-
compacted sand or screeded sand left overnight shall be loosened before further
laying of paving blocks take place.
Sand shall be slightly screeded in a loose condition to the predetermined depth
only slightly ahead of the laying of paving unit.
Any depressions in the screeded sand exceeding 5mm shall be loosened, raked
and rescreeded before laying of paving blocks. Sampling and Testing
Procedures for Paver Blocks:
440.4 Sample Size: Following are the sample sizes:
a) Internal: Average of minimum 3 samples per 5000 blocks - for paver block
manufacturers
b) External: Minimum 9 Blocks per 5000 Blocks. Average of minimum 9 Blocks
per site: for captioned contractors.
440.4.1 Sampling for Testing: Sampling for testing of paver blocks shall be done in
accordance with clause No. 440.5, 440.6 and 440.7
440.4.2 Compressive Strength : Testing for compressive strength shall be undertaken
in accordance with clause 440.7. The average compressive strength of the
80mm thick paver blocks tested shall be 45 N/Sq. mm. and average compressive
strength of the 60mm to 50 mm:thick paver blocks shall be 35 N/Sq. mm.
440.4.3 Water Absorption: Testing for water absorption shall be in accordance with
IS:2185 : 1979 : Part I (Specifications for Concrete Masonry Blocks) Appendix C.
440.4.4 In case of failure of test sample : In case of failure of test sample for above
test, the contractor should replace the entire lot of paver blocks representing
samples are taken. The samples of replaced lots shall be tested. However, 25%
of the payment of the measurement of the lot will be recovered as penalty.
440.4.5 Tensile Splitting Test: (for blocks subject to vehicular traffic) -The mean tensile
strength of 8 blocks shall be not less than 3.9 MPa and no individual block shall
have tensile strength less than 3.6 MP when tested as per Annex E of BS
6717:2001
440.4.6 Abrasion Resistance ( blocks subject to vehicular traffic) : Set of 3 blocs tested
as per Annex F of BS 6717 :2001 shall be more than 23mm.
440.5 Method for the determination of Water Absorption :
440.5.1 The test specimens shall be completely immersed in water at room temperature
for 24 hours.

440.5.2 The specimens shall then be weighed, while suspended by a metal wire and
completely submerged in water.
440.5.3 They shall be removed from the water and allowed to drain for one minute '
440.5.4 Visible surfaces water being removed with a damp cloth, and immediately
weighed.
440.5.5 Subsequent to saturation, all specimens shall be dried in a ventilated oven at 100
to 115°C for not less than 24 hours and until two successive weightings at
intervals of 2 hours show an increment of loss not greater, than 0.2 percent of
the last previously determined mass of the specimen.
440.5.6 Calculate the absorption as follows:
Absorption, Kg/m3 Absorption, Kg/m3 = A-B
Absorption, Percent
Where
A = wet mass of unit in Kg.
B = dry mass of unit in Kg. and
C = suspended immersed mass of unit in Kg.
440.6 Sampling of Paver Blocks:
440.6.1 Method of Sampling : Before laying paver blocks, each designated section
comprising not more than 50000 blocks, shall be divided into ten approximately
equal groups. Nine blocks shall be drawn from each group.
440.6.2 Marking and Identification : All samples shall be clearly marked at the time of
sampling in such a way that the designated section part thereof and the
consignment represented by the sample, are clearly defined. The sampled shall
be dispatched to the approve test laboratory taking precaution to avoid damage
to the paving in transit. Protect the paving from damage and contamination until
they have been tested. The samples shall be stored in water at 20°C + 5°C for 24
hours prior to testing.
440.7 Procedure for Testing of Compressive Strength for Paver Blocks:
440.7.1 Testing Machine: The testing machines shall be of suitable capacity for the test
and capable of applying the load at the rate specified. It shall comply, as regards
repeatability and accuracy with the requirements of relevant IS specification. ,
440.7.2 Procedure : The sample specimens shall be tested in wet condition after being
stored for at least 24· hours, in water maintained at a temperature of 20°C + 5°C,
before the specimens are submerged in water, the necessary area shall be
determined.
The plates of the testing machine shall be wiped clean and any loose grit or other
material removed from the contact faces of the specimen. Plywood nominally
4mm thick, shall be used as packing between the upper and lower faces of the
specimen and the machine plates, and these boards shall be larger than the
specimen by a margin of at least 5mm at all points. Fresh packing shall be used
for each specimen tested. The specimen shall be placed in the machine with the
wearing surface in a horizontal plane and in such a way that the axes of the
specimen are aligned with those of the machine plates. The load shall be applied
without shock and increased continuously at the rate of Approximately 15 N/Sq.
mm per minute until no greater load can be sustained. The maximum load
applied to the specimen shall be recorded.

440.7.3 Calculation of Corrected Strength: The compressive strength of each block

specimen shall be calculated by dividing the maximum load by full cross section
area and multiplying by an appropriate factors.
Table 400.2 Thickness and Chamfer Correction Factors for Compressive
Strength
Work Size Thickness in Correction Factors
mm Plain Block Chamfered Block
60 1.00 . 1.06
80 1.12 1.18
100 1.18 1.24
440.7.4 Compressive Strength Calculation : The average corrected compressive
strength for the designed block section shall be calculated.
440.8 Laying of Interlocking Paver Blocks : Paver blocks shall be laid in herringbone
laying pattern throughout the pavement. Once the laying pattern has been
established, it shall continue without interruption over the entire pavement
surface. Cutting of blocks, the use of infill concrete or discontinuities in laying
pattern is not be permitted in other than approved locations.
Paver blocks shall be laced on the uncompacted screeded sand bed to the
nominated laying pattern, care being taken to maintain the specified bond
throughout the job. The first row shall be located next to an edge restraint.
Specially manufactured edge paving blocks are permitted or edge blocks may be
cut using a power saw, a mechanical or hydraulic guillotine, bloster or other
approved cutting machine.
Paver blocks shall be placed to achieve gaps nominally 2 to 3 mm wide between
adjacent paving joints. No joint shall be less 1.5mm not more than 4mm.
Frequent use of string lines shall be used to check alignment. In this regard, the
"laying face" shall be checked at least every two metres as the face proceeds.
Should the face become out of alignment, it must be corrected prior to initial
compaction and before further laying job is proceeded with.
In each row, all full blocked shall be laid first. Closure blocks shall be cut and
fitted subsequently. Such closer blocks shall consist of not less than 25% of a full
block.
To infill spaced between 25mm and 50mm wide concrete having screened sand,
coarse aggregate mix and strength of 45 N/Sq. Mm shall be used. Within such
mix the nominal aggregate size shall not exceed one-third the smallest
dimension of the infill space. For smaller spaces dry packed mortar shall be
used.
Except where it is necessary to correct any minor variations occurring in the
laying bond, the paver blocks shall not be hammered into position. Where
adjustment of paver blocks necessary care shall be taken to avoid premature
compaction of the sand bedding.
440.9 Initial Compaction : After laying the paver blocks, they shall be compacted to
achieve consolidation of the sand bedding and brought to design levels and
profiles by not less than Two (3) passes of a suitable plate compactor.
The compactor shall be a high-frequency, low amplitude mechanical flat plate
vibrator having plate area sufficient to cover a minimum of twelve paving blocks.
Prior to compaction all debris shall be removed from the surface.
Compaction shall proceed as closely as possible following laying and prior to any
traffic. Compaction shall not, however, be attempted within one metre of the
laying face. Compaction shall continue until lipping has been eliminated between

adjoining blocks. Joints shall then be filled and recompacted as described in

Clause 3.5.
All work further than one metre from the laying face shall be left fully compacted
at the completion of each day's laying.
Any blocks that are structurally damaged prior to or during compaction shall be
immediately removed and replaced.
Sufficient plate compactors shall be maintained at the paving site for both
bedding compaction and joint filling.
440.10 Joint Filling and Final Compaction : As soon as possible after compaction and
in any case prior to the termination of work on that day and prior to the
acceptance of vehicular traffic, sand for joint filling shall be spread over the
pavement.
Joint sand shall pass a 2.36mm (No.8) sieve and shall be free of soluble salts or
contaminants likely to cause efflorescence. The same shall comply with the
following grading limits.
Table 400.3 Jointing Sand Requirement
IS Sieve Size % Passing
2.36 mm 100
1.18mm 90-100
600 Microns 60-90
300 Microns 30-60
150 Microns 15-30
75 Microns 10-20
The Contractor shall supply a sample of the jointing sand to be used in the
contract prior to delivering any such materials to site for incorporation into the
works. Certificates of test results issued by a recognized testing laboratory
confirming that the samples conform to the requirements of these specifications
shall accompany the sample.
The jointing sand shall be broomed top fill the joints. Excess sand shall then be
removed from the pavement surface and the jointing sand shall be compacted
with not less than one (1) Pass by the plate vibrator and joints refilled with sand
to full depth. This procedure shall be repeated until all joints are completely filled
with sand. No traffic shall be permitted to use the pavement until all joints have
been completely filled with sand and compacted.
Both the sand and paver blocks shall be dry when sand is spread and broomed
into the joints to prevent premature setting of the sand.
The difference in level (lipping) between adjacent blocks shall not exceed 3mm
with not more than 1 % in any 3m x 3mm area exceeding 2mm. pavement which
is deformed beyond above limits after final compaction shall be taken out and
reconstructed to the satisfaction of the Engineer.
440.11 Edge Restraint : Edge restrains need to be sufficiently robust to withstand
override by the anticipated traffic, to withstand thermal expansion and to prevent
loss of the laying course material from beneath the surface course. The edge
restraint should present a vertical face down to the level of the underside of the
laying course.
The surface course should not be vibrated until the edge restraint, together with
any bedding or concrete haunching, has gained sufficient strength. It is essential
that edge restrains are adequately secured.

440.12 Measurements for Payment : The unit of measurement for the paver block
surfacing shall be Sq. M. of area covered by the paver block including' sand
bedding for the specified thickness shown on the drawing.
440.13 Rate: The contract unit rate payable for paver block pavement shall be payment
in full for. carrying out the required operations including full compensation for all
labour, materials (paver blocks, sand and concrete for confinement) and
equipment, transport, placing, compacting, finishing, curing, testing and
incidentals to complete the work as per specifications, all royalties, fees, storage
and drains where necessary and all leads and lifts.
450.0 Dry Lean Cement Concrete with or without Fly Ash:
450.1 Materials As per Clause 410.1. Aggregate gradation shall be as in Table 400.3.
Table 400.3 Aggregate Gradation for Dry Lean Concrete
Percentage passing the sieve by
Sieve Designation
weight
26.50mm 100
19.00rnm 80-100
9.50mm 55-75
4.75mm 35-60
600.00 Micron 10-35
75.00 Micron 0-8
450.1 Proportioning of Materials for the Mix : The mix shall be proportioned with a
maximum aggregate cement ratio of 12: 1 (without fly ash) and 15:1
(cementitious material with fly ash). The water content shall be adjusted to the
optimum for facilitating compaction by rolling. The right amount of water for the
lean concrete in the main work shall be decided so as to ensure full compaction
under rolling and shall be assessed at the time of rolling the trial length. Too
much water will cause the lean concrete to be heaving up before the wheels and
picked up on the wheels of the roller and too little will lead to inadequate
compaction, a low in-situ strength and an open-textured surface.
The optimum water content shall be determined and demonstrated by rolling
during trial length construction and the optimum moisture content and degree of
compaction shall be got approved from the Engineer. While laying in the main
work, the lean concrete shall have a moisture content between the optimum and
optimum +2 per cent, keeping in view the effectiveness of compaction achieved
and to compensate for evaporation losses.
450.2 Cement Content : The minimum cement content in the lean concrete shall not
be less than 150 Kg. I Cu. M. of concrete. If this minimum cement content is not
sufficient to produce concrete of the specified strength, it shall be increased as
necessary without additional cost compensation to the Contractor.
450.3 Concrete Strength : The average compressive strength of each consecutive
group of 5 cubes made in accordance with Clause No. 903.5.1.1 of MoRT&H
shall not be less than 10 MPa at 7 days. In addition, the minimum compressive
strength of any individual cube shall not be less than 10 MPa at 7 days. The
design mix complying with the above Clauses shall be got approved from the
Engineer and demonstrated in the trial length construction.
450.4 Trial Mixes : The Contractor shall make trial mixes of dry lean concrete with
moisture contents like 5.0, 5.5, 6.0,· 6.5 and 7.0 per cent using cement content
specified and the specified aggregate grading but without violating the
requirement of aggregate-cement ratio specified. in Clause· 450.1. Optimum
moisture and density shall be established by preparing cubes with varying

moisture contents. Compaction of the mix shall be done in three layer with
vibratory hammer fitted with a square or rectangular foot as described in Clause
903.5.1.1 of M.O.R.T. & H. After establishing the optimum moisture, a set of six
cubes shall be cast at that moisture for the determination of compressive
strength on the 3rd and the 7th day. Trial mixes shall be repeated if the strength
is not satisfactory either by increasing cement content or using higher grade of
cement. After the mix design is approved, the Contractor shall construct a trial
section in accordance with Clause 601.7 of MoRT&H.
450.5 If during the construction of the trial length, the optimum moisture content
determined· as above is found to be unsatisfactory, the Contractor may make
suitable changes in the moisture content to achieve a satisfactory mix. The cube
specimens prepared with the changed moisture content should satisfy the
strength requirement. Before· production of the mix, natural moisture content of
the aggregate should be determined on a day-to-day basis so that the moisture
content could be adjusted. The mix finally designed should neither stick to the
rollers nor become too dry resulting in ravelling of surface.
450.6 Construction
450.6.1 General : The pace and programme of the lean concrete sub-base construction
shall be matching suitably with the programme of construction of the cement
concrete pavement over it. The sub-base shall be overlaid with cement concrete
pavement only after 7 days after sub-base construction.
450.6.2 Batching and Mixing : The batching plant shall be capable of proportioning the
materials by weight, each type of material being weighed separately in
accordance with Clause 602.9.3.2 of M.O.R.T.&H Specifications. The cement
from the bulk stock shall be weighed separately from the aggregates. The
capacity of batching and mixing plant shall be at least 25 per cent higher than the
proposed capacity for the laying arrangements. The batching and mixing shall be
carried out preferably in a forced action central batching and mixing plant having
necessary automatic controls to ensure accurate proportioning and mixing. Other
types of mixers shall be permitted subject to demonstration of their satisfactory
performance during the trial length. The type and capacity of the plant shall be
got approved by the Engineer before commencement of the trial length. The
weighing balances shall be calibrated by weighing the aggregates, cement, water
and admixtures physically either by weighing with large weighing machine or in a
weigh bridge. The accuracy of weighing scales of the batching plant shall be
within ±2 per cent in the case of aggregates and ±1 per cent in the case of
cement and water.
The design features of Batching Plant should be such that the shifting operations
of the plant will not take very long tie when they are to be shifted from place to
place with the progress of the work.
450.6.3 Transporting : Plant mix lean concrete shall be discharge immediately from the
mixer, transported directly to the point where it is to be laid and protected from
the weather by covering the tippers I dumpers with tarpaulin during transit. The
concrete shall be transported by tipping trucks, sufficient in number to ensure a
continuous supply of material to feed the laying equipment to work at a uniform
speed and in an uninterrupted manner. The lead of the batching plant to paving
site shall be such that the travel time available from mixing to paving as specified
in Clause 450.5.5 will be adhered to.
450.6.4 Placing: Lean concrete shall be laid I placed by a paver with electronic sensor.
The equipment shall be capable of laying the material in one layer in an even
manner without segregation, so that after compaction the total thickness is as

specified. The paving machine shall have high amplitude tamping bars to give
good initial compaction to the sub-base.
The laying of the two-lane road sub-base may be done either in full width or lane
by lane. Preferably the lean concrete shall be placed and compacted across the
full width of the road, by constructing it in one go or in two lanes running forward
simultaneously. Transverse and longitudinal construction joints shall be
staggered by 500-1000mm:and 200-400mm respectively from the corresponding
joints in the overlaying concrete slabs.
450.6.5 Compaction :
450.6.5.1 The compaction shall be carried out immediately after the material is laid and
levelled. In order to ensure thorough compaction which is essential, rolling shall
be continued on the full width till there is no further visible movement under the
roller and the surface is closed. The minimum dry density obtained shall be 97
per cent of that achieved during the trial length construction vide Clause 601.7 of
MoRT&H Specifications. The densities achieved at the edges i.e. 0.5m from the
edge shall not less than 95 per cent of that achieved during the trial construction
vide Clause 601.7 of MoRT&H Specifications.
450.6.5.2 The spreading, compacting and finishing of the lean concrete shall be carried out
as rapidly as possible and the operation shall be so arranged as to ensure that
the time between the mixing of the first batch of concrete in any transverse
section of the layer and the final finishing of the same shall not exceed 90
minutes when the concrete temperature is above 25 and below 30 degree
Celsius and 120 minutes if less than 25 degree Celsius. This period may be
reviewed by the Engineer in the light of the results of the trial run but in no case
shall it exceed 2 hours. Work shall not proceed when the temperature of the
concrete exceeds 30 degree Celsius. If necessary, chilled water or addition of ice
may resorted to for bringing down the temperature. It is desirable to stop
concreting when the ambient temperature is above 35°C. After compaction has
been completed, roller shall not stand on the compacted surface for the duration
of the curing period except during commencement of next day's work near the
location where work was terminated the previous day.
450.6.5.3 Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static
weight are considered to be suitable for rolling dry lean concrete. In case any
other roller is proposed, the same shall be got approved from the Engineer, after
demonstrating its performance. The number of passes required to obtain
maximum compaction depends on the thickness of the lean concrete, the
compatibility of the mix, and the weight and type of the roller etc., and the same
as well as the total requirement of rollers for the job shall be determined during
trial run by measuring the in-situ density and the scale of the work to be
undertaken.
450.6.5.4 In addition to the number of passes required for compaction there shall be a
preliminary pass without vibration to bed the lean concrete down and again a
final pass without vibration to remove roller marks and to smoothen the surface.
Special care and attention shall be exercised during compaction near joints,
kerbs, channels, side forms and around gullies and manholes. In case adequate
compaction is not achieved by the roller at these points, use of plat vibrator shall
be made, if so directed by the Engineer.
450.6.5.5 The final lean concrete surface on completion of compaction and immediately
before overlaying, shall be well closed, free from movement under roller and free
from ridges, low spots, cracks, loose material, pot holes, ruts or other defects.
The final surface shall be inspected immediately on completion and all loose,
segregated or defective areas shall be corrected by using fresh lean concrete

material laid and compacted as per Specification. For repairing honeycombed

surface, concrete with aggregates of size 10mm and below shall be spread and
compacted. It is necessary to check the level of the roller surface for compliance.
Any level/thickness deficiency should be corrected after applying concrete with
aggregates of size 10mm and below after roughening the surface. Similarly, the
surface regularity also should be checked with 3m straight edge. The deficiency
should be made up with concrete with aggregates of size 10mm and below.
450.6.5.6 Segregation of concrete in the dumpers shall be controlled by
premixing each fraction of the aggregates before loading in the bin of the
batching plant, by moving the dumper back and forth while discharging the mix
on it and other means. Even paving operation shall be such that the mix does not
segregate.
450.6.6 Joints: Contraction and longitudinal joints shall be provided as per the drawing. .
At longitudinal or transverse construction joints, unless vertical forms are used,
the edge of compacted material shall be cut back to a vertical face where the
correct thickness of the properly compacted material has been obtained.
450.6.7 Curing : As soon as the lean concrete surface is compacted, curing shall
commence. One of the following two methods shall be adopted:
i) The initial curing shall be done by spraying with liquid curing compound. The
curing compound shall be white pigmented or transparent type with water
retention index of 90 per cent when tested in accordance with 8S:7542.
Curing compound shall be sprayed immediately after rolling is complete. As
soon as the curing compound has lost its tackiness, the surface shall be
covered with wet Hessian for three days.
ii) Curing shall be done by covering the surface buy gunny bags/Hessian,
which shall be kept continuously moist for 7 days by sprinkling water.
Tolerances for Surface Regularity, Level, Thickness, Density and Strength : The
tolerances for surface· regularity, level, thickness, density "and strength shall
conform to the requirements given in Clause 903.5 of MoRT&H Specifications.
Control of quality of materials and works shall be exercised by the Engineer in
accordance with Section 900 of MoRT&H. Specifications.
450.6.8 Traffic : No heavy commercial vehicles like trucks and buses shall be permitted
on the lean concrete sub-base after its construction. Light vehicles if unavoidable
may, however, be allowed after 7 days of its construction with prior approval of
the Engineer.
450.6.9 Measurements for Payment : The unit of measurement for dry lean concrete
pavement shall be the cubic metre of concrete placed, based on the net plan
areas for the specified thickness shown on the drawings or as directed by the
Engineer.
450.6.10 Rate : The Contract unit rate payable for dry lean concrete, sub-base shall be
payment in full for carrying out the required operations including full
compensation for all labour, materials and equipment, mixing, transport, placing,
compacting, finishing, curing, testing and incidentals to complete the work as per
Specifications, all royalties, fees, storage and rents where necessary and all
leads and lifts.

500.0 Road Surface Drainage Components

510.0 Cement Concrete Kerb and Kerb with Channel
510.1 Scope : This work shall consist of constructing cement concrete kerbs and kerbs
with channel in the central median and I or along the footpaths or separators in
conformity with the lines, levels, and dimensions as specified in the drawings.
510.2 Materials: Kerbs and kerb with channel shall be provided in cement concrete of
Grade M-35 in accordance with Section 120 of these Specifications.
510.3 Type of Construction : These shall be cast-in-situ construction with suitable
kerb casting machine in all situations except at locations where continuous
casting with equipment is not practicable. In those situations, precast concrete
blocks shall be used.
510.4 Equipment: A continuous kerb casting equipment of adequate capacity and
controls, capable of laying the kerbs in required cross-sections and producing a
well-compacted mass of concrete free of voids and honeycombs, shall be used.
Kerb shall be laid on firm foundation of minimum 150mm thickness of cement
concrete of M-10 grade cast-in-situ or on extended width of pavement. The
foundation shall have a projection of 50mm beyond the kerbstone. Before laying
the foundation of lean concrete, the base shall be levelled and slightly watered to
make it damp.
In the median portions in the straight reaches, the kerb shall be :cast in
continuous lengths. In the portions where footpath is provided and / or the slope
of the carriageway is towards median (as in case of super elevated portions),
there shall be sufficient gap/recess left in the kerb to facilitate drainage openings.
After laying the kerbs and just prior to hardening of the concrete, saw cut
grooves shall be provided at 5m intervals or as specified by the Engineer.
Kerbs on the drainage ends such as along the footpath or the median in super
elevated portions, shall be cast with monolithic concrete channels as indicated in
drawings. The slope of the channel towards drainage pipes shall be ensured for
efficient drainage of the road surface.
Vertical and horizontal tolerance with respect to true line and level shall be ±
6mm.
510.6 Measurements for Payment : Cement concrete kerb I kerb with channel shall
be measured in linear metre for the complete item of work.
Foundation of kerb, where separately provided shall be measured in linear metre
for complete item of work.
510.7 Rates: The Contract unit rates for cement concrete kerb I kerb with channel and
foundation for kerb shall be payment in full compensation for furnishing all
materials, labour, tools, equipment for construction and other incidental cost
necessary to complete the work.
550.0 Manholes:
The following sizes of manholes should be adopted for various inverts of the S.W.
Drains.
Table 500.1
Minimum Maximum
Sr.N
Size of Manholes Depth upto Depth upto Remarks
o.
Invert Invert
1. 1.22m Dia at bottom 1.52m 2.29m

Minimum Maximum
Sr.N
Size of Manholes Depth upto Depth upto Remarks
o.
Invert Invert
and 0.53m Dia at top
1.52m x 0.91 m at Longer
2. bottom and 0.91 m x 1.22m 2.29m dimensions
0.61 m at top longer the line
1.52m x 1.22m at
1.22m x
3. bottom and 0.91 m x
2.29m
0.61 m at top
5.03m from
1.52m Dia at bottom 2.29m and
4. 2.29m
and 0.53m Dia at top above: to
5.03m brick
1.83m Dia at bottom
5. 2.89m 5.03m Work of 36cm
and 0.53 Dia at top
From 5.03m
1.83m at bottom and
6. 2.89m 5.03m to 9.14m brick
0.53 Dia at top
work of 46m
In case, necessary depth is not available for the construction of manholes given
in the table chambers of suitable size shall be constructed and covered with C.1.
frame and cover of suitable, size or R.C.C. dhapas as directed by the Engineer.
The manholes shall be constructed in the form of the dimensions shown on the
drawings.
The manholes shall be constructed at places shown on the drawing or wherever
directed by the Engineer. Type designs for these manholes are shown on the
drawings but actual dimension shall in each case be determined by the Engineer
as the circumstances may require.
The rate or percentage rate to be quoted in the Bill of Quantities and Rates for
the manholes shall include complete masonry structure plastered with cement
both inside and outside bottom concrete and channel or channels everything
complete C.1. frame and cover C.1. steps etc. which will be supplied by the
Corporation and without excavation.
The walls of the manholes shall be built of brick work in cement mortar and
plastered inside and outside with cement plaster. In the case of conical
manholes, the walls shall be brought upto within seven inches of the road
surface and shall be covered over with a cast iron frame and cover or a cast iron
plate with a cast iron frame and cover as may in each case be required by the
Engineer. Where rectangular manholes are to be constructed the brick walls
shall be brought upto within 0.91 m or 1.22m, as required of the road surface and
shall at this depth be covered over with reinforced cement concrete slab with an
opening of the size and in the position as directed by the Engineer. The opening
shall be formed by means of joints of sizes as shown drawing resting on the side
wall and embedded in the slab. On these as support, walls of brick in cement
shall be erected and brought upto within 18cm of the road surface where they
shall be covered with C.1. frame and cover etc. as described above. The work
shall be properly bedded and courses brought up in a regular and uniform
manner.
The floors shall consist of cement concrete. Salt glazed or concrete or hume half
channel pipes or the required size and curves shall be laid and bedded in cement
on the concrete base to the same line and fall as sewers unless otherwise

directed. Both sides of the channel pipes shall be benched up in concrete and
rendered in cement 20mm thick and formed to a slope of not less than 1 in 12 to
the channel.
Whenever a pipe enters or leaves manholes bricks on edge must be cut to a
proper form and laid around the upper half of the pipe so as to form an arch. All
around the pipe, there shall be a joint of cement mortar 12mm thick between it
and the bricks. The ends of all pipes shall be properly built in and neatly finished
with cement mortar.
Where the depth of the invert exceeds 1 m below the surface of the galvanized
wrought iron or cast iron steps of approved pattern shall be built in the brick work
ground every four courses with such additional hand irons as may be necessary
for safety.
560.0 Water Entrances:
The chamber for water entrances shall be constructed of bricks work in 1:5
cement mortar plastered with cement plastering 12mm thick. The bed of the
chamber shall consist of 23cm layer of 1 :4:8 cement concrete. The invert shall
be formed of cement concrete as shown in the drawing and shall be plastered
with cement plastering 12mm thick. The parda of diaphragm shall be of cast iron
25mm thick and shall be so fixed as to carry the dhapas and to dip into the water
seal to a depth of 20cm. The part of the chamber which is shown on drawing as
below the surface of the road, shall be covered with blue stone dhapas as shown
on the drawing. The other part of the chamber shall be covered with two
mosquito proof close C.1. gratings; fair weather plates in the case of full sized
water gullies and one for single water gullies the grating or gratings being
supported on C.1. frame as shown on the drawing.
Whenever any hole or other communication has to be cut into the wall or made
with a drain or sewer or a manhole or into or with other masonry, the hole or
communication shall be cut or made neatly to the requisite value size and pipe
tail piece, elbow or other article or work for which it is required shall be neatly
and soundly stopped around with, or built in cement and sand (1 to 1). The rate
for cutting the hole or that for the work or which the communication is required
shall include the cost of such stopping. that of any making good that may be
required and also that of any arrangements which the contractors may have to
make in order to stop the access of sewage or water during the execution of their
work. No payment will be allowed to the contractors for cutting out any portion of
the new work for the purpose of other work under contract or in such for stopping
and making good as above described. If the sewer or the drain into which hole or
communication is to be cut is in a working condition and if there is a likelihood of
the workmen being exposed to the danger arising from the sewage gases, such
work and also that of removing such or plug shall be done by the municipal staff
trained for such work and under the supervision of responsible officers as may
be directed .by the Engineer and the cost of such work shall be borne by the
Contractor.
Payment for the items of making connection shall be made only if the connection
is made by making a hole in the masonry of the existing manhole or sump etc.,
and making it good from inside and outside. No payment shall be made if the
connection is made to existing pipe.
All cement work pointing, plastering and concrete work shall be shaded from the
sun and the surface kept moist until, in the opinion of the Engineer, it is
thoroughly set.
Whenever a new work meets the old, certain portions of the old work as may be
ordered by the Engineer, shall be cut away in order that the new work may be

properly bonded into the old. No payment will be allowed to the Contractors
cutting away any portion of the work done under this contract or the purpose of
other similar work or in such case for bonding and making good the same as
above described.
570.0 Footpaths, Medians, Shoulders, Islands & Road Arboriculture
571.0 Footpaths, Medians & Road Arboriculture
571.1 Description : The work shall consist of constructing finishing to footpaths,
medians and/or separators and landscaped areas at locations specified in the
drawings in conformity with the lines and levels and dimensions ·as specified In
the drawings or as directed by the Engineer. The scope of the work shall include
provision of all drainage arrangements within the footpaths as shown on the
drawings or as directed.
571.2 Construction Operation: General: All utility diversions within the footpath and /
or median and / or other paved areas shall be completed to the satisfaction of the
Engineer prior to commending footpath and other pavement finishing.
All drainage works crossing the footpath and / or median shall be laid to the
required slope and connected to the drains / sumps / storm water drain /
drainage chutes gullies etc., as indicated in Drawings and Specification prior to
commencing footpath and other pavement finishing.
Installation of all street lighting installations, traffic sign and traffic signal posts,
and other utility appurtenances and road side barriers shall be completed prior to
commencing the footpath and other pavement finishing.
All permanent obstacles within the footpath area, such as manhole covers, shall
be adjusted to the correct finished levels prior to commencing footpath and other
pavement finishing.
If footpath and / or median finishing is undertaken prior to completion of the
adjacent carriageway construction, the contractor shall protect the footpath and /
or median finishing from damage from road works operations, and shall take
whatever measures are deemed necessary by the Engineer to protect the
finished works.
The contractor shall provide and maintain a temporary surface of completed
granular sub-base material for pedestrians until such time as. the permanent
finishes are constructed.
572.0 Shoulders & Islands:
572.1 Scope: The work shall consist of constructing shoulder (hard / paved / earthen
with brick or stone block edging) on either side of the pavement, median in the
road dividing the carriageway into separate lanes and islands for channelising
the traffic at junctions in accordance with the requirements of these
Specifications and in conformity with the lines, grades and cross-section shown
on the drawings or as directed by the Engineer.
572.2 Materials : Shoulder on either side of the road may be of selected earth I
granular material I paved conforming to the requirements of Clause 150 or 200
and the median may be of selected earth.
Median I Traffic islands shall be raised and kerbed at the perimeter and the
enclosed area filled with earth and suitably covered with grass turf I shrubs and I
or paved as per Clause 571.
Paved shoulders shall consist of sub-base, base and surfacing courses, . as
shown in the drawings and materials for the same shall conform to relevant
Specifications of the corresponding items. Where paved or hard shoulders are

not provided, the pavement shall be provided with brick I stone block edging as
shown in the drawings.
Size of Shoulders I Median I Islands : Shoulder (earthen I hard I paved) I
median I traffic island dimensions shall be as shown on the drawings or as
572.3 Construction Operations :
572.3.1 Shoulder : The sequence of operations shall be such that the construction of
paved shoulder is done in layers each matching the thickness of adjoining
pavement layer. Only after a layer of pavement and corresponding layers in
paved and earth shoulder portion have been laid and compacted, the
construction of next layer of pavement and shoulder shall be taken up.
Where the materials in adjacent layers are different, these shall be laid together
and the pavement layer shall be compacted first. The corresponding layer in
paved shoulder portion shall be compacted thereafter, which shall be followed by
compaction of earth shoulder layer. The adjacent layers having same material
shall be laid and compacted together.
In all case where paved shoulders have to be provided along side of existing
carriageway, the existing shoulders shall be excavated in full width and to the
required depth as per Clause 103.5.
Compaction requirement of earthen shoulder shall be as per Table 100.5. In the
case of bituminous courses, work on shoulder (earthen I hard I paved), shall start
only after .the pavement course has been laid compacted.
During all stages of shoulder (earthen I hard I paved) construction, the required
cross-fall shall be maintained to drain off surface water. Regardless of the
method of laying, all shoulder construction material shall be placed directly on
the shoulder. Any spilled material dragged on to the pavement surface shall be
immediately removed, without damage to the pavement, and the area so affected
thoroughly cleaned.
572.3.2 Median and Islands : Median and Islands shall be constructed in a manner
similar to shoulder up to the road level. Thereafter the median and islands, if
raised, shall be raised at least 300mm by using kerb stones of approved material
and dimensions and suitably finished and painted as directed by the Engineer. If
not raised, the median and islands shall be differentiated from the shoulder I
pavement as the case may be, as directed by the Engineer. The confined area of
the median and islands shall be filled with local earth or granular material or any
other approved material and compacted by plate compactor I power rammer.
The confined area after filling with earth shall be turfed with grass or planted with
shrubs and In case of granular fill it can be finished with tiles I slabs as directed
by the Engineer.
572.3.2.1 Brick I Stone Block Edging : The bricks I stone blocks shall be laid on the
edge, with the length parallel to the transverse direction of the road. They shall
be laid on a bed of 25mm sand, set carefully, rolled into position by a light roller
and made flush with the finished level of the pavement. .
572.3.2.2 Surface Finish and Quality Control of Works : The surface finish of
construction shall conform to the requirements of Clause600.cntrol on the quality
of materials and works shall be exercised by the Engineer in accordance with
Section 600.
572.3.2.3 Measurement for Payment: Shoulder (earthen I hard I paved), island and
median construction shall be measured as finished work in position as below:
a) For excavation in Cu. M.
b) For earthwork I granular fill in C~. M.

c) For sub-base, base, surfacing courses in units as for respective items

d) For kerb in running metres
e) For turfing and tile I slab in Sq. M.
f) For brick I stone block edging in Sq. M.
572.3.2.4 Rate : The Contract unit rate for shoulder (hard I paved I earthen with brick or
stone block edging), island and median construction shall be payment in full for
components listed in Clause 401.8 "(i) to (v) as applicable. The rate for brick I
stone block edging shall include the cost of sand cushion.
573.0 Footpaths and Separators:
573.1 Scope : The work shall consist of constructing footpaths and I or separators at
locations as specified in the drawings or as directed by the Engineer. The lines,
levels and dimensions shall be as per the drawings. The scope of the work shall
include provision of all drainage arrangements as shown in the drawings or as
directed.
573;2 Materials: The footpaths and separators shall be constructed with any of the
following types:
a) Cast-in-situ cement concrete for Grade M-35 as per Section 400 of the
Specifications,
b) Precast cement concrete blocks I tiles of M-35 Grade as per Section 400 of
the Specifications.
c) Natural stone slab cut and dressed from stone of good and sound quality,
uniform in texture, free from defects, and at least equal to a sample submitted
by the Contractor and approved by the Engineer. The minimum thickness of
the natural stone slab shall be 25mm and minimum size shall be 300mm x
300mm.
d) Precast un-reinforced concrete paving blocks of 40 to 50mm thickness: As
per Clause 440.
573.3 Construction Operations: Drainage pipes below the footpath originating from
the kerbs shall be first laid in the required slope and connected to the drains I
sumps I storm water drain I drainage chutes as per provisions of the drawings, or
as specified.
Portion on back side of kerbs shall be filled and compacted with granular sub-
base material as per Clause 401 of the Specifications in the specified thickness.
The base shall be prepared and finished to the required lines, levels, and
dimensions as indicated in the drawings with the following:
a) Minimum 150mm thick, compacted granular sub-base material as per
Clause 401 of the Specifications,
b) Minimum 25mm thick cement concrete of Grade M-15.
Over the prepared base, precast concrete blocks I tiles I natural stone slabs and
I or cast-in-situ slab shall be set I laid
573.3.1 Precast cement concrete blocks I tiles / natural stone slab: The blocks I tiles
/ slabs shall be set on a layer of average 12mm thick cement sand mortar (1 :3)
laid on prepared base in such a way that there is no rocking. The gaps between
the blocks I tiles I slabs shall not be more than 12mm and shall be filled with
cement-sand mortar (1:3).
573.3.2 Cast-In-Situ Cement Concrete : The minimum thickness of the cement concrete
shall be 25mm and it shall be cast on the prepared base in panels of specified

size in a staggered manner. Construction joints shall be provided as per Section

400 of the Specifications.
573.3.3 Measurements for Payment : Footpaths and separators shall be measured in
Sq. M. between inside of kerbs.
573.3.4 Rates : Contract unit rates shall be inclusive of full compensation of all labour,
materials, tools, equipment and incidentals to construction of footpaths. Cost of
providing pipes and arrangement for their discharge into appropriate drainage
channels shall be incidental to the construction of footpaths.
580.0 Road Markings & Street Furniture:
580.1 Specifications of Traffic Signs and Road Markings:
580.1.1 Traffic Signs : Temporary traffic and construction signs are to be provided
during construction and maintenance operations for traffic diversion and
pedestrian safety.
580.1.2 Road Marking:
580.1.2.1 Road markings shall be of hot applied thermoplastic materials with glass
reflectorising beads as per relevant clauses of Section 803 of MoRTH
Specifications.
580.1.2.2 Road markings shall be as per IRC : 35-1997. These markings shall be applied
to road centre lines, edge lines, continuity line, stop lines, give-way lines,
diagonal/chevron markings, zebra crossing and at parking areas by means of an
approved self-propelled machine which has a satisfactory cut-off valves capable
of applying broken lines automatically.
580.1.2.3 Synthetic enamel paints shall be used to display details of structure number,
span arrangement etc. on all culverts and bridges with required description as
per M.O.S.T. guidelines.
580.2 Specifications of Thermo-Plastic Road Marking:
580.2.1 All markings should be strictly in accordance with code of practice for road
marking, paintslRC-35 and as specified by the Engineer-InCharge.
580.2.2 The Thermoplastic material shall be homogeneous / composed of aggregate,
pigment, resins and glass reflector zing beads and shall conform to 8.S.3262
Part-I / ASTMD36.
580.2.3 Requirements:
580.2.3.1 Composition: The material shall be free from all skins, dirt and foreign objects.
Sr.
Component White Yellow
No.
1. Binder · 18.0 Min. 18.0 Min.
2. Glass Beads 20.0 Min. 20.0 Min.
3. Titanium Dioxide 10.0 Min. -
580.2.4 Properties : The properties of thermoplastic material, when tested in accordance
with A.S.T.M.D. 361 BS-3262 (Part-I) shall be as below:
i) Luminance:
White Day Light - Luminance at 45° - 65% min, as per AASHTO M 249 -
Yellow Day Light - Luminance at 45° - 45% as per AASHTO M249
ii) Drying Time : When applied at a temperature specified by the manufacturer
and to the required thickness, the material shall set to beat traffic in not more
than 15 min.
iii) Skid Resistance - not less than 45 as per BS-6044.

iv) Cracking Resistance at Low Temperature: The material $hall show no

cracks on application to concrete blocks.
v) Softening Point: 102.5 as per 9.5c as per ASTMD 36.
vi) Flow Resistance: Not more than 25% per ASSHTO M249.
vii) Yellowness Index (for white thermoplastic paint) not more than 0.12 as per
AASHTO M249.
580.2.4.1 Reflectorisation shall be achieved by incorporation of beads. The grading and
other properties of the beads shall be as under:
580.2.4.2 The glass beads shall be transparent, colourless and free from milkiness, dark
particles and excessive air inclusions. The thermoplastic material shall readily
get screeded 1 extruded at temperature 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.
580.2.4.3 The subject material upto heating to application temperature, shall not exude
fumes which are toxic, obnoxious or injurious to persons or property.
580.2.4.4 Properties of finished road marking shall be as under:
i) The strip shall not be slippery when wet.
ii) After application and proper drying the strip shall not show appreciable
deformation or discolouration under traffic.
iii) The marking shall· not deteriorate by contact with sodium chloride or oil
drippings from traffic.
iv) The strip of marking shall maintain its original dimensions in position. Cold
ductility of the material shall be such as to permit normal movement with the
road surface without chopping or cracking.
v) The colour of yellow marking shall conform to LS. Code No. 356 as given in
IS 164.
vi) Durability: The road markings shall be highly durable in all weather and
traffic conditions. It shall last for a period of five years. The markings when
tested shall show no sign of cracking, flaking, peeling off or disintegration.
580.2.4.5 The marking shall be done by machine.
580.2.4.6 The thermoplastic material shall be applied hot either by screeding of extrusion
machine at a temperature within the range specified by the manufacturer.
580.2.4.7 The surface shall be thoroughly cleaned of all dust, dirt, grease, oil and all other
foreign matter before application of the paint.
580.2.4.8 The paint shall be applied in intermittent or continuous lines as directed and
specified and of uniform thickness of at least 2.5mm, unless specified otherwise.
580.2.4.9 Where arrows or letters are to be provided, the paint may be hand applied.
580.2.4.10 The tenderer shall furnish a copy of certified test reports from the manufacturer
of glass beads obtained from a reputed laboratory showing results of all the tests
specified and shall certify that the material meets all the requirements of
specifications.
580.2.4.11 The thermoplastic material used should be complying to specifications of
B.S.3262 (Part-I) / ASTMD-36.
590.0 Reinforced Earthwork
590.1 Scope : The work covers the construction of reinforced earth structures, together
with the construction of earthwork in layers, assembly and erection of reinforcing
elements and placement of facing panels and all associated components.

590.2 Reinforcing Element:

590.2.1 The reinforcing element shall be Geotextile, aluminium alloy strip, copper strip,
copper strip, carbon steel strip, mats of metal or synthetic grids, or any other
proprietary material which may be approved by the Engineer and indicated on
the drawings.
590.2.2 Geotextile : The material shall conform to Clause 260.
590.2.3 Aluminium alloy strip shall comply with BS:1470 quality 5454 in the H 24
condition.
590.2.4 Copper strip shall comply with BS:2870 quality C 101 or C 102 in the 1/2 H
condition and shall have 0.2 per cent proof stress of not less than 180 N/mm2
590.2.5 Carbon steel strip which shall be galvanized shall comply with BS:1449 (Part 1),
either quality KHR 34/20 P or quality 50/35 P, each having a silicon content of
not less than 0.25 per cent and not more than 0.40 per cent. The fabricated
element shall be galvanized in accordance with BS:729, and the average zinc
coating weight for any individual test area shall not be less than 1000 Gm 1 Sq.
M.
590.2.6 Stainless steel strip shall comply with BS:1449 (Part 2) quality 316 S 31· or 3/6 S
33 except that the material shall be cold: rolled to provide a 0.2 per cent proof
stress of not less than 400 N 1 Sq. Mm. and the tensile strength shall not be less
than 540 N 1 Sq. M.
590.2.7 All metallic components buried in soil shall be of electrolytically compatible
materials.
590.2.8 Geogrids : The supply of geo-grids shall carry a certification of BIS or ISO 9002
for all works. While the reinforcing element for wall or slope portion shall be with
mono oriented Geo-grid, the reinforcement for the foundation of a reinforced
earth wall or slope shall be with bidirectionally oriented Geo-grid. For mono
oriented Geo-grid, the characteristic design tensile strength at a strain not
exceeding 10 per cent in 100 years shall be at least 40 KN 1 m when measured
as per GRI:GG3. The strength for bi-directionally oriented Geo-grid in the
longitudinal direction shall be at least 40 KN 1 m at a maximum elongation of 15
per cent. The Geo-grid shall be inert to all naturally occurring chemicals, minerals
and salts found in soil.
590.3 Earth Fill : The fill material fat reinforced earth structures shall have an angle of
interface friction between the compacted fill and the reinforcing element of not
less than 25°C, measured in accordance with 18:1326 (Part 1). The soil should
be predominantly coarse grained; not more than 10 per cent of the particles shall
pass 75 micron sieve. The soil should have properties such that the salts in the
soil should not react chemically. or electrically with the reinforcing elements in an
adverse manner.
590.4 Facia Material:
590.4.1 The facing shall comprise of one of following:
i) Reinforced concrete (Cast in situ or precast) slabs
ii) Plain cement concrete form fill hollow block (Precast)
iii) Masonry construction, Rubble Facia
iv) Other proprietary and patented proven system
The facing shall be sufficiently flexible to withstand any deformation of the fill.
590.4.2 Facia unit joint filler should be durable resistant to the effect of air pollution and
water / saline water.
590.4.3 Bedding material shall consist of either cement mortar or a durable gasket
seating such as resin bonded cork strip.

590.4.4 Connection between the facia and the reinforcing element shall be by using
polyethylene strips I rods, fibre glass dowels or any other material shown in the
drawing. Any other material used shall be tested to provide 100 per cent joint
strength as of parent element !n continuity.
Overlapping in principal reinforcement or in the joint shall ensure load transfer
through joints, perpendicular to the direction of laying.
590.5 Construction Details:
590.5.1 The plan area of the reinforced earth structure shall be excavated to provide a
nominally level base which may be stepped at the back as required to receive
the horizontal reinforcing element grid.
The depth of the foundation below the finished ground level at the foot of the
slope or wall shall not be less than 1000mm.
Additional strip footing, trough guide made of concrete or anchor key pad shall
be provided at founding level to receive the facia or the bottom most
reinforcement connection. This shall have adequate soil cover against erosion
and scour in particular cases.
590.5.2 Orientation : The reinforcing elements shall be placed at right angles to the face
of the wall, with greater cross-sectional dimension in the horizontal plane. The
placement of the elements including their vertical I horizontal spacing and length
shall be as in the drawing.
590.5.3 Facing Batter: It may be necessary to set facing unit at an additional batter than
as provided in the drawing as there is a tendency for initially positioned units of
facia to lean outward as the fill material is placed and compacted. Care and
caution shall be taken to rectify this phenomenon.
590.5.4 Drainage : Drainage shall be provided as per drawing given in detail. The
retained fill shall have a suitably designed drainage bay to allow free draining of
the reinforced fill.
590.5.5 Laying and Compacting : The reinforcing elements shall be laid free from all
kinks, damage and displacement during deposition, spreading, levelling and
compaction of the fill. The programme of filling shall be such that no construction
plant runs directly on the reinforcement. All construction plant having a mass
exceeding 1000 Kg shall be kept at least 1.5m away from the fact of slope or
wall. In this area (up to 1.5m from the face of slope or wall), following compaction
plant shall be used:
i) Vibratory roller having a weight per metre width of roll not exceeding 1300 Kg
with total weight not exceeding 10,000 Kg.
ii) Vibratory plate compactor of maximum weight 1,000 Kg.
iii) Vibro tamper having a weight not exceeding 75 Kg.
Compaction by any other method like using dozer or back blade ,- compaction by
dozer or excavator bucket shall be permitted with due approval from the
Engineer after ascertaining the level of compaction so achieved.
During construction of reinforced fill, the retained material beyond the
reinforcement at the rear or the structure shall be maintained at the same level
as reinforced fill.
The compacted layer shall not be more than 200mm, to achieve compaction of
95 per cent of maximum laboratory density where measured as per IS:2720 (Part
8). Temporary formwork shall be used to support the construction as per
specified details give in the drawing. The forms, scaffolding and props shall be
sufficient in numbers to allow taking up of a sectoral construction schedule
specified in the design. 590.6 Measurements for Payment: Measurement for

reinforcing elements shall be in linear metre for anchor strips or in Sq. M. for geo-
grid I geotextile etc.
The measurement for facia shall be in Square Metres. The measurement for
foundation for facia and capping beam shall be in linear metres. Measurement
for compacted earthfill shall be in Cubic Metres for compacted soil.
590.7 Rates : Rate shall include cost of labour, plant hire, material storage and
handling expenses, for completing the works.
Rate for providing reinforcing elements shall include material cost, all
transportation costs and storage of the same as per special provisions. The rate
shall also include cost of laying of the reinforcing elements including all overlaps,
jointing or stitching, heat bonding or extension.
Rate for facia fixing shall include cost of joints, all necessary temporary
formwork, scaffolding and all lifts and leads, if any, as shown in the drawing,
unless otherwise specified to the treated separately along with foundation or
slope / wall kerb at the top of slope or wall. Rate for bed block and capping beam
shall include all items of excavation, concrete, reinforcing steel, formwork, labour
and equipment.
Rate for soil fill shall include compaction as desired in requisite layers through
mechanical means, cost of hire or labour for plant operations, dressing and
levelling slopes, including special measures for edge reinforcement as shown in
the drawing.

600.0 Quality Control

610.0 General: All works performed shall conform to the lines, grades, cross-sections
and dimensions shown on the drawing or as directed by the Engineer subject to
the permitted tolerances described here-in-after.
611.0 Horizontal alignments : These shall be reckoned with respect to the centreline
of the carriageway as shown on the drawings. The edges of the carriageway .as
constructed and all other parallel alignments shall be correct within a tolerance of
+ 20 mm there from.
612.0 Longitudinal Profile: The levels of the sub-grade and different pavement
courses as constructed shall not vary from those calculated with reference to the
longitudinal and cross profile of the road shown on the drawings or as directed by
the Engineer, beyond the tolerances mentioned below:
Sub-grade ±25mm.
Sub-base ±20 mm.
Base course ± 10 mm.
Wearing Course ± 10 mm.
Provided, however, that the negative tolerances for wearing course shall not be
permitted in conjunction with the positive tolerance for base course if the
thickness of the former is thereby reduced by more than 6 mm. 613.0 Sub-Grade
and Pavement Courses Thickness Tolerance : The thickness tolerance for
constructed sub-base, base courses & wearing coats shall be as follows :
Sub-grade ± 10 mm
Sub-base ±5mm.
Base course ±3mm.
Wearing Course ±2mm.
614.0 Rectification: Where the surface irregularity of sub-grade and the various
pavement courses falls outside the specified tolerances, the contractor shall be
liable to rectify these in the manner described below and to the satisfaction of the
Engineer .
614.1 Sub-grade: Where the surface is high it shall -be trimmed and suitably
compacted. Where the same is low, the deficiency shall be corrected by adding
fresh material. The degree of compaction and the type of material to be used
shall conform to the requirements of Clause 614.2.
614.2 Stabilised Sub-base: Where the surface is high, the same shall be suitably
trimmed while taking care that the material below is not disturbed due to this
operation. However, where the surface is low, the same shall be corrected as
described herein below.
When the time elapsed between detection of irregularity and the time of mixing is
less than 2 hours, the surface shall. be scarified to a depth of 50mm,
supplemented with freshly mixed material as necessary and recompacted to the
relevant specification. When this time is more than 2 hours, the full depth of the
layer shall be removed from the pavement and replaced with fresh material to
specification. In either case the area treated shall not be less than 5 metres long
by 2 metres wide.
614.3 Water Bound Layer: Where the surface is high or low, the top 75mm shall be
scarified, reshaped with added material as necessary and recompacted to clause
6. The area treated at a place shall be not less than 5 metres long and 2.0
metres wide.

614.4 Bituminous Construction : For bituminous construction other than wearing

course where the surface is low the deficiency shall be corrected by adding fresh
material and re-compacting to specifications. Where the surface is high, full
depth of the layer shall be removed and replaced with fresh material and
compacted to specifications.
614.5 For wearing course, where the surface is high or low, the full depth of the layer
shall be removed and replaced with fresh material and compacted to
specifications. In all cases where the removal and replacement of bituminous
layer is involved, the area treated shall not be less than 5 metres long and not
less than one lane wide.
Table 600.1 Permitted tolerances of Surface Regularity for Pavement
Courses
Cross Profile
Longitudinal Profile
Maximum
(Maximum
Permissible
permissible
Sr. Variation from
Type of construction undulation when
No. specified profile
measured with a 3
when measured
metres straight edge)
with a camber
mm.
template mm.
1. Sub-Base 18 12
Metal Sub-Base (90-
2. 18 12
40mm size aggregate)
3. Metal Base (55mm size) 12 10
4. Bitumen Macadam 10 8
5. Surface Dressing 10 8
6. Bitumen Concrete 8 6
620.0 Quality Control Test during Construction:
621.0 General : The material supplied and the works carried out by the contractor shall
conform to the specification prescribed in the preceding clause.
For ensuring the requisite quality of construction the material and works shall be
subjected to quality control tests, as described hereinafter, by the Engineer. The
testing frequencies set forth are the desirable minimum and the Engineer shall
have the full authority to carry out tests as frequently as he may deem necessary
to satisfy himself that the materials and works comply with the appropriate
specifications.
Where specific procedure is not indicated for quality control tests in those
specifications the same shall be carried out as per the prevalent accepted
Engineering practice to the directions of the Engineer. 622.0 Tests on Earthwork
for embankment Construction Borrow material: 623.0 Plasticity Tests: As and
when required by the Engineer.
a) Density Test: Each soil type to be tested, 1-2, tests per 8000 Cu M.
b) Deleterious Content Test: As and when required by the Engineer
c)Moisture Content Test: One test for every 250 cu. m. of soil.
d)CBR Test on materials to be incorporated in the sub-grade in soaked I
unsoaked sample. As and when required by the Engineer.
623.1 Compaction Control : Control shall be exercised by taking at least one
measurement of density for each 1000 square metres of compacted area or
closed as required to: yield the minimum number of test results for evaluating a

day's work on statistical basis. The determination of density shall be in

accordance with 18:2720 (Part-XVIII). Test locations shall be chosen only
through random sampling techniques. Control, shall not be based on the result of
anyone test but on the mean value of a set of 5- 10 density determinations. The
number of tests in one set of measurements shall be 5 as long as it is felt that
sufficient control over borrow material and the method of compactions is being
exercised. If considerable variations are observed between individual density
results the minimum number of tests in one set of measurement shall be
increased to 10. The acceptance of work shall be subject to the condition that the
mean dry density equals or exceeds the specified density and the standard'
deviation for any set of results is below 0.08 gm.lcc.
However, for earthwork in shoulders and in top 500mm portion of the
embankment below the sub-grade at least one density' measurement shall be
taken for every 500 square metres of the compacted area provided further that
the number of tests in each set of measurements shall be at least 10. In other
respects the control shall be similar as described earlier.
624.0 Tests on Sub-bases and bases: The tests and their frequencies for the different
types of bases and sub bases shall be as given 'below in Table No.600.2.
Evaluation of density results for compaction shall be on lines similar to those set
out in clause 19.6.
Table 600.2
Type of
Construc Test Frequency
tion
I. Gradation One Test per 200 Cu. M.
II. Atterberg limits --------------do-------------
Initially one, & with
III. Deleterious
change of
Constituents
source
IV. CBRTest One test for each source
V. Moisture Content
prior to One test per 200 Cu.M.
Compaction
VI Density of
compacted One test per 500 CU.M.
layer
One Test for each
consignments
subject to a
I. Purity of Lime
minimum of
/ Lime Soil one test / 5
Stabilise tonnes of lime
d Sub-
II. Lime / Cement
Base One Test / 250 Sq. M.
Content
III. Degree of
Pulverisatio One Test / 500 Sq. M.
n
I. Grading One Test / 200Cu. M.
/ bases, WMM. II. Flakiness &
------------ do------------
Elongation

Index
III. Density of
compacted One Test / 200 Cu.M.
layer,
IV. Impact Value, One test / 200 CU.M.
V. Los Angeles
abrasion ------------- do --------------
resistance,
VI. Atterberg's limit on
aggregate
passing 425
One test / 200 Cu.M.
micron sieve
/ binding
material
625.0 Test on Bituminous Construction: The tests and their frequencies for the different
types of Bitumen mix construction shall be as given below in Table No.600.3.
Table No. 600.3
Type of
Constructi Test Frequency
on
I. Quality of Binder One / lot
II. Binder Temperature for

One / 200Sq.M.
Application
Coat / Prime coat
Two Tests / Day or 500
III. Rate of Spread of
Sq.M. whichever
Binder
is Min.
I. Quality of Binder Two tests per lot
II. Aggregate Impact Value

I Los Angeles
One I 200 Cu.M.
abrasion
resistance,
III. Flakiness Index!

Elongation ---------do--------
Index
IV. Aggregate Grading ----------- do ------
V. Temp. of Application One Test per 50 Cu.m.
VI. Water sensitivity of mix One Test per 500 Sq.m.
Initially one set of 3

specimens for
VII. Rate of Spread of each source and
Materials subsequently
with change of
source

Initially one determination

by each method
for each source ,
then as
VIII. Soundness
warranted by
change: of
quality of
aggregate
ix. Polished stone value One for each rock type
x. Percentage of fractured One test per day if gravel

faces is used

xi. Stripping value of specimens for
aggregates ( each source and
immersion tray subsequently
test) with change of
source
xii. Water absorption of

--------- do------
aggregate
i. I to xii As for seal coat
xiii. Binder content and One test per 500 Cu.M. or

aggregate min. two tests
grading per day
xiv. Density of compacted

One test per 250 Sq. M.
layer
I. i to iv and vi to xiv As for B.M.

xv. sand equivalent As directed by Engineer
xvi. Plasticity index As directed by Engineer
For each 400 tonnes of mix

produced, a set
of 3 Marshal
specimens
tested for
stability, flow
xvii. Stability of Mix
value, density
and void content
subject to a
minimum of two
sets being tested
per plant per day
For B.C., as directed by

xviii. Swell test on mix
Engineer
i. i to xii As for seal coat

One test for 400 tonnes,

xiii. Hardness Number min two tests per
day
Same as mentioned under

(i) Quality of Binder
Serial No.1

representative
specimens for
each source of
(ii) Film Stripping Test supply, then as
warranted by
changes in the
quality of
aggregates
(i) Binder Content and Minimum of one test per 25

Aggregate m3 of recycled
Grading material
Minimum of one test per 50

(ii) Recovered Binder
m3 of recycled
Penetration
material
For each 400 tonnes of mix

recycled, a set of
3 Marshall
specimens to be
prepared and
(iii) Mix Stability (Remix I tested for
Repave) stability, flow,
density and void
cement, subject
to a minimum of
two sets of tests
per day
iv. Cold Mix As for Seal Coat
Initially on submission
thereafter daily if
(i) Softening Point site blended,
weekly if pre-
blended
(ii) Penetration at 25°C

- do-
and 4°C
(iii) Elastic Recovery - do-
(iv) Ductility - do-

(v) Flash Point - do-
(vi) Fraass Breaking Initially on submission

(vii)Viscosity at 150°C - do-
Thin film oven test,

penetration,
softening point,
- do -
elastic recovery
of residue, loss
on heating
(i) The requirements of

Clause 704.3.1
of the Ministry's
Specification for
vi. Geo- textiles
Road and
Bridge Works
(Third Revision)
shall apply
626.0 Quality Control Tests for Dry lean concrete

626.1.1 Sampling and Testing of Cubes : Samples of dry lean concrete for making
cubes shall be taken from the un-compacted material from different locations
immediately before compaction at the rate of 3 samples for each 1,000 sq. m. or
part thereof laid each day. The sampling of mix shall be done from the paving
site.
Test cubes of 150mm size shall be made immediately from each mix sample.
Cubes shall be made in accordance with the methods described in IS:516 except
that the cubes shall be compacted by means of a vibratory hammer with the
moulds placed on a level and rigid base. The vibrating hammer shall be electric
or pneumatic type fitted with a square or rectangular foot having an area of
between 7,500 to 14,000 sq. mm. The compaction shall be uniformly applied for
60 ± 5 seconds with a downward force of between 300N and 400N on to each of
the three layers of the lean concrete material placed into the mould. The surface
of each compacted layer shall be scarified before the next layer is added to give
key for the next layer. The final layer shall be finished flush with the top of the
cube mould.
The dry lean concrete cubes shall be cured in accordance with IS:516.
626.1.2 In-situ Density : The dry density of the laid material shall be determined from
three density holes at locations equally spaced along a diagonal that bisects
each 2000 square metre or part thereof laid each day and shall comply with the
requirements as per Clause 450.6.5.1.This rate of testing may be increased at
the discretion of the Engineer in case of doubt or to determine the extent of
defective area in the event of non-compliance. Density holes at random may be
made to check the density at edges.
626.1.3 Thickness: The average thickness of the sub-base layer as computed by the
level data of sub:..base and sub-grade or lower sub-base shall be as per the
thickness specified in the contract drawings. The thickness at any single location
shall not be 10mm less than the specified thickness. Such areas shall be
corrected as stated in Clause 450.6.5.5.Areas which cannot be repaired should
be replaced over full width. The extent of deficient area should be decided based
on cores.
626.1.4 Frequency of Quality Control Tests: The frequency of quality control tests for
levels, alignment and materials shall be as in Table 900-6 of MoRT&H
specifications

Table 600.4 Control Tests for Dense Graded Bituminous Mixes and their
Minimum Frequency
S.N Test Frequency
Number of samples per lot and tests as per
1 Quality of binder
IS, 73 or IRC:SP, 53
Aggregate impacl One test per 350 ml of aggregate for each
2 value/Los Angeles source and whenever there is change in the
Abrasion value quality of aggregate
One lest per 350 m3 of aggregate for each
3 Flakiness index source and whenever there is change in the
quality of aggregate
Soundness lest (Sodium
1 test for each source and whenever there is
4 and Magnesium
change in the quality of aggregate
Sulphate test)
Water absorption of 1 test for each source and whenever there is
5
aggregate change in the quality of aggregate
6 Sand equivalent test
change in the.: quality of aggregate
7 Plasticity Index
change in the: quality of aggregate
8 Polished stone value
Percent of fractured One test per 350 m3 of aggregate when
9
faces crushed gravel is used.
One set for individual constituent and mixed
aggregate from dryer for each 400 tonnes of
10 Mix grading
mix subject to minimum of two tests per day
per plant
Stability and voids
3 tests for stability flow value. density and
analysis of mix including
void contents for each 400 tonnes of mix
11 theoretical maximum
subject to minimum of two tests per day per
specific gravity of loose
plant
mix
1 test for t:ach mix type whenever there is
Moisture Susceptibility of
12 change in the quality or source of coarse or
mix (AASHTO T283)
fine aggregate
Temperature of binder in
boiler,aggregate in dryer
13 At regular intervals
and mix at the time of
laying and compaction
One set for each 400 tonnes of mix subject
14 Binder content
10 minimum of two tests per day per plant
Rate of spread of mix
15 After every 5th truck load
material
Density of compacted
16 One test per 700 m2area
layer
Table 600.5 Control Tests for Bituminous Macadam Work and Their Minimum
Frequency
S.N Test Frequency

As per number of samples and tests per

1 Quality of bituminous binder
lot specified in IS: 73
One test per 350 m3 of aggregate for
Aggregate impact value /
2 each source and whenever there is
Los Angles Abrasion value
change in the qual ity of aggregate
One test per 350 m3 of aggregate for
Flakiness & Elongation
3 each source and whenever there is
Index
1 test for each source and whenever
Soundness tesl (Sodium or
4 there is change in the quality of
Magnesium Sulphate test)
aggregate
1 test for each source and whenever
Water absorpt ion of
5 there is change in the quality of
aggregate
aggregate
When crushed gravel is used as
6 Percent of fractured faces aggregate one test per 350 m3 of
aggregate
One set for individual constituent and
mixed aggregate from dryer / or each 400
7 Mix grading
tonnes of mix subject to minimum of two
tests per day per plant
1 test for each mix design and whenever
8 Stripping (1S:6241) there is change in the source or quality of
coarse aggregate
1 test for each mix design and whenever
9 Water sensitivity there is change in the source or quality of
coarse aggregate
Temperature of binder in
boiler, aggregate in dryer
10 At regular interval
and mix at the lime of laying
and compaction
One set for each 400 tonnes. of mix
11 Binder cement subject to minimum of two tests per day
per plant
Rate of spread of mix
12 At regular interval
material
13 Density of compacted layer One test per 700 m3 area
Type of layer Unevenness, mm NH/SH MDR and Lower Catagory

Bituminous
4-6 20 40
Macadam
627.0 CONTROLS (IRC 111 2009)

627.1 Surface Finish
627.1.1 The levels of the dense graded bituminous mixes shall not vary from
those calculated with reference to longitudinal and cross profile of the roads as per
the Contract beyond ± 6 mm provided that the negative tolerance shall not be

permitted in conjunction with the positive tolerance for the base course if the
thickness of the former is thereby reduced by more than 6 mm.
627.1.2 For checking the compliance with the above requirement
measurements of the surface level shall be taken on a grid of points spaced 6.25
m along the length and 0.5 m from the edges and at the centre of the pavement.
The compliance shall be deemed to be met for the final road surface only if the
tolerance given above is satisfied for any point on the surface.
627.1.3 In case where surface levels fall outside the specified tolerance, the
Contractor shall be liable to rectify these by replacing the full depth of layer. In all
cases of replacement the area treated shall not be less than 5 m in length and not
less than 3.5 m in width.
627.2 Surface Evenness
627.2.1 The measurement and checking of surface unevenness shall be done
by a 3 m straight edge in accordance with the procedures in IRC:SP: 16.
627.2.2 The maximum permissible surface unevenness in longitudinal profile
shall be 6 mm for SDBC and 5 mm for BC. The maximum permissible unevenness
in transverse profile shall be 4 mm for both SDBC and BC
627.2.3 The maximum permissible frequency of surface unevenness in 300 m
length in longitudinal profile shall be as per Table 600.3.3
627.2.4 Where the surface unevenness falls outside the tolerance, in either
case i.e. the surface is low or high, the full depth of the layer shall be removed and
replaced with fresh material and compacted to the specification.
627.2.5 In all cases of removal and replacement the area treated shall not be
less than 5 m in length and 3.5 m in width.
627.3 Surface Roughness
627.3.1 Surface roughness shall be checked in accordance with procedures in
lRC:SP: 16.
627.3.2 The maximum permissible values of surface roughness measured with
a bump integrator are given in Table 600.3.4. Newly constructed surface are
expected 10 give roughness values corresponding to Good category. While the
Average and Poor categories indicate level of service and the intervention criteria
deviation.
627.4 Acceptance Criteria
627.4.1 The acceptance criteria for test on density (N = 3 minimum) and
Marshall stability (N = 2 minimum) shall be subjected to the condition that the
mean value of N samples is not less than the specified value plus [1.65 - 1.65/(No.
of samples)O.5] x standard
Table 600.6 Maximum Permissible Frequency of Unevenness Maximum
Number of Surface Unevenness
MDR and
uneveness,
Type of Surface NH/SH Lower
mm
Category
Semi-Dense Bituminous
4-6 20 40
Concrete
Bituminous Concrete 3-5 15 30
Table 600.7 Maximum Permissible Values of Roughness (mm/km) for Surface
with Dense Graded Bituminous Mixes
Condition of Road Surface (mm I km)
S.N. Type of Surface
Good Average Poor

1 SDBC < 2500 2500-3500 > 3500

2 BC < 2000 2000-3000 >3000

APPENDIX-1
Quality Tests for Tack Coat and Prime Coat
In case of bitumen emulsion residue on 600 micron sieve, viscosity test and
storage stability tests shall be conducted at site. In case of cutback bitumen,
viscosity test, flash point test and residue test shall be conducted at site. In case of
paving grade bitumen, viscosity at 60°C and 160°C shall be determined.
APPENDIX - 2
Method of Test for Measurement of Spread of Binder for Prime Coat and
Tack Coat
Aluminum or other light metal tray of 200 mm x 200 mm size and 20 mm depth are
to be used. A set of three plates is essential for one test. All the plates are to be
weighed and numbered. These are placed at intervals of 10 m along the road in
path between wheels of bitumen distributor. After the distributor crosses a length of
50 m, trays are to be removed and wrapped in weighed polyethylene bags so that
these can be handled, stocked safely for further weighing in laboratory. The trays
shall be weighed to first place of decimal. Similarly, transverse distribution of liquid
bituminous material can be checked by placing three numbers of plates at interval
of 50 cm in the path of binder spraying equipment.

ANNEXURE 1
Features of Hot Mix Plants & Pavers for Bituminous Construction:
Hot mix plant shall be of suitable capacity preferably of batch mix type. Total system
for crushing of stone aggregates arid feeding of aggregate fractions in required
proportions to achieve the desired mix, must be capable of meeting the overall
specification requirements under stringent quality control.
The plant shall have the following essential features:
A General
a) The plant shall have a coordinated set of essential units capable of producing
uniform mix as per the job mix formula.
b) Cold aggregate feed system with minimum 4 bins having bell conveyor
arrangement for initial proportioning of aggregates from each bin in the required
quantities. In order to have free flow of fines from the bin, bin should be titled with
vibrator to intermittently shake it.
c) Belt conveyers below each bin should have variable speed drive motors. There
should be electronic load sensor on the main conveyer for measuring the flow of
aggregates.
d) Dryer unit with burner capable of heating the aggregate to the required
temperature without any visible unburnt fuel or carbon residue on the aggregate and
reducing the moisture con lent of the aggregate to the specified minimum.
e) The plant shall be fitted with suitable type of thermometric instruments at
appropriate places so as to indicate or record/register the temperature of healed
aggregate, bitumen and mix.
f) Bitumen supply unit capable of heating, measuring/metering and spraying of
bitumen at specific temperature with automatic synchronization of bitumen and
aggregate feed in the required proportion.
g) A filler system suitable to receive bagged or bulk supply of filler material and its
incorporation to the mix in the correct quantity wherever required.
h) A suitable built-in dust control system for the dryer to contain/recycle permissible
fines into the mix. It should be capable of preventing the exhaust of fine dust into
atmosphere for environmental control wherever so specified by the Engineer.
i) The plant- should have centralized control panel cabin capable of presetting,
controlling / synchronizing all operations stating from feeding of cold aggregates to
the discharge of the hot mix to ensure proper quality of mix. It should have
indicators for any malfunClionit1g in the operation.
j) Every hot mix plant should be equipped with siren or horn so that the operator
may use the same before starting the plant every time in the interest of safety of
staff.
B For Batch Type Plant

i) Gradation control unit having minimum four decks vibratory screens for accurate
sizing of hot aggregate and storing them in separate bins. This unit should be fully
covered to reduce the maintenance cost and for better environmental condition.
ii) Proper arrangement for accurate weighing of each size of hot aggregate from the
control panel before mixing.
iii) Paddle mixer unit shall be capable of producing a homogeneous mix with uniform
coating of all particles or the mineral aggregate-with binder
C For Continuous Type Plant

i) Gradation control unit having vibratory screens for accurate sizing of hot
aggregate and storing them in separate bins. This unit should be fully covered to
reduce the maintenance cost and for better environmental condition.
ii) There should be appropriate arrangement for regulating and volumetric condition
of the flow of hot aggregate from each bin to achieve the required proportioning.
iii) Paddle mixer unit shall be capable of producing a homogeneous mix with uniform
coating of all particles of the mineral aggregate with binder.
D For Drum Mix Plant

i) It is a prerequisite that only properly screened and graded materials are fed to the
bins. If required, a vibratory screening unit shall be installed at the plant site to
ensure the same. A primary 4-deck vibratory screening unit shall be installed before
the multiple bin cold feed system for screening the aggregates and grading the
same.
ii) Belt conveyers below each bin should have variable speed drive motors. There
should be electronic' load sensor on the main conveyer for measuring the flow of
aggregate.
iii) There should be arrangement to measure moisture content of the aggregate(s)
so that moisture correction may be applied for working out requirements of binder
and filler.
E . Paver Finisher
The paver finisher shall have the following essential features:
a) Loading hoppers and suitable distributing mechanism.
b) All drives having hydrostatic drive/control.
c) The machine shall have a hydraulically extendable screed for appropriate with
requirement.
d) The screed shall have tamping and vibrating arrangement for initial compaction to
the layer as it is spread without rutting or otherwise marring the surface. It shall have
adjustable amplitude and variable frequency.
e) The paver shall be equipped with necessary control mechanism so as to ensure
that the finished surface is free from surface blemishes.
f) The paver shall be fitted with an electronic sensing device for automatic levelling
and profile control within the specified tolerances.
g) The screed shall have an internal heating arrangement.
h) The paver shall be capable of laying either 2.5 to 4.0 m width or 4.0 to 7.0 m
width as stipulated in the Contract.
i) The paver shall be so designed as to eliminate skidding/slippage of the tyres
during operations.

ANNEXURE 2
Outline of AASHTO T283, "Resistance of Compacted Asphalt Mixtures to
Moisture-Induced Damage"
A. Scope and Summary of Test Method
This method covers preparation of compacted bituminous mixtures and the
measurement of the change of diametral tensile strength resulting from the effects
of water saturation and laboratory accelerated stripping phenomenon with a
freeze-thaw cycle. The result may be used to predict long-term stripping
susceptibility of bituminous mixtures and evaluate liquid anti-stripping additives that
are added to bitumen or pulverized mineral materials such as hydrated lime, which
are added to the mineral aggregate.
Each Set of 6 compacted specimens is divided into two equal subsets. One subset
is tested in dry condition for indirect tensile strength. The other subset is subjected
to vacuum saturation and a freeze-thaw cycle (thawing in a hot water bath) before
testing for indirect tensile strength. Numerical indices of retained indirect tensile
strength properties are calculated from the test data obtained by testing the two
subsets :dry and conditioned.
B. Testing Equipment
I. Vacuum container, vacuum pump, manometer, and other accessories as
specified in ASTM D2041, "Theoretical Maximum Specific Gravity and Density of
Bituminous Paving Mixtures".
2. Balance or scale accurate to 0.1 percent of the test load
3. Two water baths capable of maintaining temperatures of 60°C ± 1°C and 25°C ±
0.5°C
4. Freezer maintained at - 18°C ± 3°C
5. 10-ml graduate cylinder
6. Loading jack ,and ring dynamometer (Marshall stability testing machine can be
used) to provide a vertical rate of deformation of 50 mm (2 inches) per minute and
capable of reading the maximum failure load
7. Steel loading Strips with a concave surface having a radius equal to the normal
radius of the test specimen. The loading strips shall be 12.7 mm (0.5 inch) wide for
specimens 100 mm (4 inches) in diameter. The loading strips for 150 mm (6
inches) diameter specimens shall be 19.05 mm (0.75 inch) wide. The length of the
loading strips shall exceed the thickness of the specimens. Steel strip are provided
at the top and bottom of specimens during indirect tensile testing.
C. Test Procedure
1. Make at least 6 compacted specimens for each mixture. 3 to be tested dry and 3
to be tested after partial saturation and moisture conditioning with a freeze-thaw
cycle. Some extra specimens will need to be made 10 establish compaction
procedures in order to obtain specified air void contents in the test specimens by
trial and error.
2. Compact the 6 specimens with a Marshall compactor so that the compacted
specimens have air voids of 7.0 ± 0.5 percent. This level of high air voids can be
obtained by adjusting the number of Marshall blows applied on each side of the
specimen by trial and error (start at about 10 blows as a starting point). Air void
content must be calculated from the bulk specific gravity of the compacted
specimen (determined by saturated surface dry method as per procedure given in

the Asphalt Institute MS-2) and the maximum theoretical specific gravity of the
loose bituminous mixture obtained by ASTM D2041.
3. Separate the 6 specimens into 2 subsets so that the average air voids of the two
subsets are approximately equal.
4. One set will be tested dry. Keep it at room temperature and then place in a 250C
± 0.50C water bath for 2 hours prior to determining their indirect tensile strength.
5. The other subset will be conditioned as follows:
a) Place and submerge the 3 specimens in the vacuum container filled with water
at room temperature. Apply a vacuum of 13-67 kPa absolute pressure (10-26
inches Hg partial pressure) for 30 minutes. Remove the vacuum and leave the
specimens submerged in water for 5 to 10 minutes. [Note: The water saturation
procedure noted above deviates from AASHTO T283, which obtains a specified
degree of saturation. The above procedure keeps the time of saturation constant:
b) Wrap a plastic film around each saturated specimen and place the wrapped
specimen in a plastic bag containing 10 ml of water and seal the plastic bag. Place
the plastic bag in a freezer at temperature of - 180C± 30C for a minimum of 16
hours. Remove the specimens from the freezer.
c) Place the specimens in a water bath maintained at 600C ± 10C for 24 hours.
Remove the plastic bag and the plastic film from each specimen after placing the
specimens under water.
d) . Remove the specimens from hot water bath and place in a water bath
maintained at 250C ± 0.50C for 2 hours
e) Remove the conditioned specimens and test for indirect tensile strength.
6. Determine the indirect tensile strength of the 3 dry and 3 conditioned specimens
at 250C ± 0.50C after removing from water bath. First, measure their mean
thicknesses (t). Then place the two steel loading strips on the bottom and top of
the specimens across diameter and place in the Marshall testing machine or a
compression testing machine. Apply load to the specimens diametrally at a vertical
rate of 50 mm (2 inches) per minute.
7. Record the maximum compressive strength noted on the testing machine and
continue loading until a vertical crack appears in the specimen. Remove the
cracked specimen from the machine and visually estimate the approximate degree
of moisture damage (extent of stripped or bare aggregate) on the fractured faces of
the specimen on a scale of 0 to 5 (5 being the most stripping).
8. Calculate the tensile strength of each specimen as follows in SI units:
St = 2000 P/¶td
Where,
st= tensile strength. kPa
P = maximum loads, N
t = specimen-thickness, mm
d = specimen diameter. mm
9. Express the numerical index of resistance of bituminous mixture to the
detrimental effects of water as the ratio of the original strength that is retained after
accelerated moisture and freeze-thaw conditioning.
Calculate the tensile strength ratio (TSR) as follows:
Tensile strength ratio (TSR) =S2/S1
Where.
S1 = average tensile strength of the dry subset. kPa

S2 = average tensile strength of the conditioned subset, kPa

ANNEXURE 3
Outline of ASTM D2041, "Theoretical Maximum Specific Gravity and Density

of Bituminous Paving Mixtures"
A. Scope and Summary of the Test Method
This test method covers the determination of the theoretical maximum specific
gravity and density of uncompacted bituminous paving mixtures at 25°C. The
theoretical maximum specific gravity (Gmm) is used: (a) 10 calculate air voids in
compacted bituminous mixtures. (b) to calculate the amount of bitumen absorbed
by the aggregate, and (e) to provide target value for the compaction of paving
mixtures in the field.
A sample of loose paving mixture is placed in a tared vacuum vessel. Water at
25°C is added to complete ly submerge the sample. A specified amount of vacuum
is gradually applied to remove the air bubbles entrapped between asphalt mix
particles. After the vacuum is released, the volume of the sample of the void less
paving mixture is obtained by either immersing the vacuum container with the
sample in a water bath and weighing or by filling the calibrated vacuum container
level full of water and weighing in air.
B. Testing Equipment
1. Container (either a or b below)
a) Vacuum bowls - Either a metal or plastic bowl with a diameter ranging from 180
10260 mm and a bowl height of at least 160 mm. The bowl shall be equipped
with a stiff, transparent cover fitted with a rubber gasket and a connection for
the vacuum line. The hose connection shall be covered with a small piece of
fine wire mesh to minimize loss of any fine material from the mix.
b) Vacuum flask for weighing in air only - A thick-walled volumetric glass flask
with a capacity of approx. 4000 ml, fitted with a rubber stopper with a connect
ion for the vacuum line. The hose connection shall be covered with a small
piece of fine wire mesh to minimize loss of any fine material from the mix .
2.Balance capable of being read to the nearest 0.1 gram. If weighing is to be done
under water. a suitable suspension arrangement shall be provided for weighing
the sample while suspended from the center of the balance.
3. Vacuum pump, capable of excavating air from the vacuum container to a
residual pressure of 4.0 kPa (30 mm of Hg) or less. Provide a suitable trap
between the pump and container to minimize water vapour entering the
vacuum pump
4. Residual pressure manometer or calibrated absolute pressure gauge with a
bleed valve to adjust the vacuum level.
5. Water bath capable of maintaining a constant temperature of 25 ± 1°C and
suitable for immersion of the suspended container.
C. Calibration of Containers
1. Bowls - Determine the mass (B) of the container immersed in water at 25 ± 1 0C.
If the bowl is used for weighing in air place the volumetric lid on the bowl while
under water. Remove the water-filled bowl with the lid in place and dry prior to
determining the combined mass of the bowl, lid and water. Repeat 3 times and
average the 3 masses. Designate the average mass as D.
2. Flasks - Calibrate the volumetric flask by accurately determining the mass of the
flask filled with water at 25 ± 1°Co Use a glass cover plate to ensure the flask is
completely full.
D. Test Procedure

I. Separate the particles of the loose paving mixture (while it is warm) by hand so
that the particles are not larger than about 6 mm. Don't fracture the aggregate.
Place the mix sample directly into the tared bowl or flask. Weigh the container
with the sample and designate the net mass of the sample only as A.[Note: The
minimum sample size shall be 1500g for mixes with nominal maximum
aggregate sizes of 12.5 mm or smaller; and shall be 2500g for mixes with
nominal maximum aggregate sizes from 19 to 25 mm]
2. Add sufficient water at 25°C to cover the sample completely. Place the cover
(bowls) or stopper (flasks) on the containers.
3. Place the container with the sample and water on a mechanical agitation device
or agitate manually at frequent intervals (2 to 3 minutes). Begin removing
entrapped air by gradually applying vacuum and increasing the vacuum
pressure until the residual manometer reads 3.7 ± 0.3 kPa (27.5 ± 2.5 mm of
Hg). After achieving this level within 2 minutes, continue the vacuum and
agitation for 15 ± 2 minutes. Gradually release the vacuum with the bleed valve.
4. Weighing in water - Suspend the bowl (without lid) and contents in water for 10 ±
1 minutes and then determine mass. Designate the mass under water of the
bowl and sample as °C
5. Weighing in air
a) Bowl- Submerge the bowl and sample slowly in the 25 ± 1°C water bath. Keep it
there for 10 ± 1 minutes. Immerse the lid in water and slide it onto the bowl
without removing water from the bowl so that no ai r is trapped inside the bowl.
Remove the bowl with the lid in place from the water bath. Dry the bowl and lid
with a dry cloth. Determine the mass of the bowl, sample, and lid and designate
it as E.
b) Flask - Fill the flask slowly with water ensuring not to introduce any air into the
sample. Place the flask in water bath for 10 ± 1 minutes to stabilize the
temperature aI 25°C without submerging the top of the flask. Completely fill the
flask with water using a cover plate without entrapping air beneath the cover
plate. Wipe the exterior of the fl ask and cover plate. Determine the mass of the
flask, plate and its contents completely filled with water. Designate this mass as
E.
6. Calculations
Calculate the maximum specific gravity of the sample of loose paving mixure as
follows:
a) Bowls Used Under Water Determination:
Gmm.=A / [A-(C-B)]
Where,
Gmm = maximum specific gravity of the mixture
A = mass of the dry sample in air. g
B = mass of bowl under water, g
C = mass of bowl and sample under water, g
b) Bowls in Air Determination:

Gmm.=A / (A+D-E)
Where,
D = mass of lid and bowl with water at 25°C, g

E = mass of lid, bowl, sample and water at 25°C, ,g

c) Flask Determination
Gmm.=A / (A+D-E)
Where,
D = mass of cover plate and flask filled with water at 25°C. g
E = mass of flask, cover plate, sample. and water at 25°C, ,g

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MUNICIPAL CORPORATION OF

TECHNICAL SPECIFICATIONS FOR

Municipal Corporation of Greater Mumbai

Municipal Corporation of Greater Mumbai

A.M.C. (Project) Municipal Commissioner

Municipal Corporation of Greater Mumbai

MCGM STANDARD SPECIFICATION FOR ROADS

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230 Base - Open Graded Granular Sub Base with Geo-Cell

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580 Road Markings & Street Furniture 148

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Specifications indicated in BOQ

Technical Specifications outlined in MCGM Standard Specifications

Indian Road Congress Specifications - Latest Edition till 30 days before

Bureau of Indian Standard Specifications - Latest Edition till 30 days

The Asphalt Institute, U.S.A. Publication of Specifications - Latest Edition

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20.0 New Technologies I Materials

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compacting the wearing course or that engaged on such surface treatment

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100.0 Road and Drainage Excavation

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constituted authority having jurisdictions relative to handling, storing and use of

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37.5mm 100 85-100

Sieve Designation Percent by Wt. Passing the Sieve

20mm 60-30 80-100 100

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deleterious matter of grading specified in the contract. The trench to be covered

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150.0 Embankment & Sub-Grade Construction

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Table 100.5 Density Requirements for acceptance of soils to be used as of

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Where the excavation reveals a combination of acceptable and unacceptable

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151.2.4 Construction Operations: These specifications shall "apply to the construction

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to avoid displacement and unequal pressure. The sequence of work in this

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