Name of work :-

Name of Work: ANJAR PACKAGE 1)Strengthening And Resurfacing of Patri-kundrodi-Chasra Road ch.
Km 0/00 to 9/300, TA:-Mundra,Dist:- Kachchh 2) Strengthening to Sugariya Modsar Road Ch 0/00
To 4/200 Ta:Anjar Dist:Kutch(By Resurfacing &Construction of New Box Culverts At Ch 2/600
&3/800)

Specification

Item No.3 : Dismantling of Flexible Pavements : Dismantling of flexible pavements and disposal of
dismantled materials up to a lead of 1000 metres, stacking serviceable and unserviceable materials
separately. (ii) By Mechanical means (a) Bituminous Courses.

[Link] work shall consist of removing, as here in after set forth, existing culverts, bridges, pavements, kerbes
and other structures like guard- rails, fences utility poles, manholes, catch basins, Inlets, etc. Which are in
place but interfere with the new construction or are not suitable to remain inplace, and. of salvaging and
disposing of the resulting materials and backfilling the resulting trenches and pits.
2 .Existing culverts, bridges, pavements and other structures which are within the highway and which are
designated to be removed shall be removed upto the limits and extent specified in the drawings or as
Indicated by the Engineer-in-charge.
3. Dlsmantaling and removal operations shall be carried out with such equipment and in such a manner as to
leave undisturbed, adjacent pavement, structures and any other work to be left In place.
4. All operations necessary for the removal of any existing structure which might endanger new construction
shall be completed prior to the start of new work.
5. The structures shall be-dlsmantaled carefully and the resulting materials so removed as not to cause any
damage to the serviceable materials to 60 salvaged, the part of the structure to be ratained and any other
properties or structures nearby.
6. Unless otherwise specified, the superstructure portion of culverts/bridges snail be entirely removed and
other parts removed to below the ground level or as necessary depending upon the interference they cause to
the new construction. Removal of overlying or adjacent material if required in connection with the
dismantling of the structured, shall be incidental to this item.
7. Where existing culverts/bridges are to be extended or otherwise incorporated in the new work, only such
part of the existing structure shall be removed as are necessary to provide a proper connection to the new
work. The connecting edges shall be cut, chipped and trimmed to the required lines and grades without
weakening or damaging any part of the structure to be retained. Reinforcing bars which are to be left in plate
so as to project Into new work* as dowels or ties shall, not 6e injured during removal of concrete.
8. Pipe culverts shall be carefully removed In such a manner to avoid damage to the pipes.
9. Steel, structures shall unless otherwise provided be carefully dismantaled In such a manner as to avoid
damage to members thereof. If specified In the drawing or directed by the Engineer-in-charge that structure
Is to be removed In a condition suitable for re-erection, all members shall be match marked by the contractor
with white lead paint before dismantling end pins, nuts, loose plates, etc. shall be similarly marked to
indicate their proper location, all pins, pin holes and machined surfaces shall be painted with a mixture of
white lead and tallow and all loose parts shall be securely wired to adjacent members or packed in boxes.
10. Timber structures shall be removed In such a manner as to avoid damage to such timber or lumber as is
designated to be salvaged by the Engineer-in-charge.
11. In removing pavements, kerbs, gutters and other structures like guard rails, fences, manholes, catch
basines, Inlets, etc. where portions of the existing construction are to be left In the finished work the same
shall be removed to an existing joint or out and chipped to a true line with a face perpendicular to the surface
of the existing strata. Sufficient removal shall be made to provide for proper grades and connections with the
new work as directed by the Engineer-in-charge.

167
12. All concrete pavements, base course In carriage way and shoulders etc. designated for removal shall be
broken to pieces whose volume shall not exceed 0.02 cubic metre and stockpiled at designated locations If
the material is to be used later or otherwise arranged for disposal as directed.
13. Where directed by the Engineer-in-charge holes and depressions caused by dismantling operation's shall
be backfilled with excavated or other approved material and throughly compacted In line with surrounding
area.
14. All materials obtained by dismantling shall be, the property of Government. Unless otherwise specified,
materials having any salvage value shall be placed in neat stacks of like material within the right-of-way as
directed by the Engineer-in-charge, for which Contractor will "remain responsible for Its safe custody and
preservation for 60 days after recording measurements of the salvaged material.
15. Pipe culverts that are removed shall be cleared and neatly piled on the right-of way at points designated
by the. Engineer-in-charge.
16. Structural steel removed from old structure shall, unless otherwise specified or directed, be stored In a
neat and presentable manner. Structures or portions thereof which are-specified in the contract for re-
erections shall be stored In separate piles.
17. Timber or lumber from old structure which Is designated by the Engineer-in-charge as materials to be
shall have all ralls and bolts removed therefrom and shall be stored In neat piles locations suitable for
loading.
18. All the products of dismantling operations which In the opinion of the Engineer-in-charge cannot be used
or auctioned shall be disposed as directed, within 100 metres.
19. The work of dismantling structures shall be paid for In units Indicated below by taking measurements
before and after, as applicable.
(I) Dismantling brick/concrete (Plain and Reinforced), mansonary Cubic Metre
(II) Dismantling flexible and cement concrete pavement. Cubic Metre
(III) Dismantling steel structure. Tonne
(IV) Dismantling timber structure. Cubic Metre
(V) Dismantling pipes, guard rails, kerbs, gutters and fencing. Linear Metre
(VI) Utility poles. Nos.
20. The contract unit rates for the various Items of dismantling shall be payment In full for earring out the
required operations Including full compensation for all labour, materials, tools, equipment, safeguards and
Incidentals necessary to complete the work. These will also include excavation and backfilling where
necessary and for handling, salvaging, piling and disposing of the dismantled materials within all lifts and
upto a lead of 100 metres.
Mode of Payment: The payment shall be made on Cum basis of work done.

168
Item No.5: Construction of 500 mm thick compacted SUBBASE (with unscreened gravel and coarse
Sand) including watering up to OMC, rolling, and consolidation with vibratory roller, levelling with
motor grader etc as directed. (CBR not less than 15%)
401.1 Scope
This work shall consist of laying and compacting well-graded material on prepared subgrade in accordance
with the requirements of these Specifications. The material shall be laid in one or more layers as sub-base or
lower sub-base and upper sub-base (termed as subbase hereinafter) as necessary according to lines, grades
and cross-sections shown on the drawings or as directed by the Engineer.
401.2 Materials
401.2.1 The material to be used for the work shall be natural sand, crushed gravel, crushed stone, crushed
slag, or combination thereof depending upon the grading required. Use of materials like brick metal, Kankar
and crushed concrete shall be permitted in the lower sub-base. The material shall be free from organic or
other deleterious constituents.
401.3 Construction Operations
401.3.1 Preparation of Sub-grade
Immediately prior to the laying of sub-base, the subgrade already finished to Clause 301 or 305 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.
401.3.2 Spreading and Compacting
The sub-base material of the grading specified in the Contract and water shall be mixed mechanically by a
suitable mixer equipped with provision for controlled addition of water and mechanical mixing. So as to
ensure homogenous and uniform mix. The required water content shall be determined in accordance with
IS:2720 (Part 8). The mix shall be spread on the prepared subgrade 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. Moisture content
of the mix shall be checked in accordance with IS:2720 (Part 2) and suitably adjusted so that, at the time of
compaction, it is from 1 to 2 percent below the optimum moisture content.
Immediately after spreading the mix, rolling shall be done by an approved roller. If the thickness of the
compacted layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be used. For
a compacted single layer upto 200 mm the compaction shall be done with the help of a vibratory roller of
minimum 80 to 100 kN static weight capable of achieving the required compaction. Rolling shall commence
at the lower edge and proceed

169
towards the upper edge longitudinally for portions having unidirectional crossfall or on superelevation. For
carriageway having crossfall on both sides, rolling shall commence at the edges and progress towards the
crown.
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 crossfall (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 percent 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.
401.4 Surface Finish and Quality Control of Work
The surface finish of construction shall conform to the requirements of Clause 902. Control on the quality of
materials and works shall be exercised by the Engineer in accordance with Section 900.
401.5 Arrangements for Traffic
During the period of construction, arrangements for the traffic shall be provided and maintained in
accordance with Clause 112.
401.6 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.
401.7 Rate
The Contract unit rate for granular sub-base shall be payment in full for carrying out the required operations
including full compensation for:
i) making arrangements for traffic to Clause 112 except for initial treatment to verges, shoulders and
construction of diversions;
ii) supplying all materials to be incorporated in the work including all royalties, fees, rents where applicable
with 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
v) carrying out the required tests for quality control.
Mode of Payment: The payment shall be made on Cum basis of work done.

170
Item no 6 : Construction of Grannular sub base of 200mm thick in by providing GSB Gr - I coarse
graded material using B.T Metal 26.5mm to 53 mm @ 35 % ,26.5mm to 4.75mm 45% & Below
2.36mm 20 % in uniform layer with motor grader on prepared surface mxing by mix in place method
with vibratory roller to achive the desired density complete as per close 401.

401.1. Scope

This work shall consist of laying and compacting well-graded material on prepared subgrade in
accordance with the requirements of these Speci-fications. The material shall be laid in one or more
layers as sub-base or lower sub-base and upper sub-base (termed as sub-base hereinafter) as
necessary according to lines, grades and cross-sections shown on the drawings or as directed by the
Engineer.

401.2. Materials

401.2.1. The material to be used for the work shall be natural sand, moorum, gravel, crushed stone, or
combination thereof depending upon the grading required. Materials like crushed slag, crushed
concrete, BT metal and kankar may be allowed only with the specific approval of the Engineer. The
material shall be free from organic or other deleterious constituents and conform to one of the three
gradings given in Table 400-1.

While the gradings in Table 400-1 are in respect of close-graded granular sub-base materials, one each
for maximum particle size of 75 mm, 53 mm and 26.5 mm, the corresponding gradings for the coarse-
graded materials for each of the three maximum particle sizes are given at Table 400-2. The grading to
be adopted for a project shall be as specified in the Contract.

Material used in GSB shall be BT MC metal 75mm to 26.5 @ 35%, 26.5 o 4.75 mm @ 45% and coarse
sand 20% for gradation.

401.2.2. Physical requirements: 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 BS:812 (Part 111). The water absorption
value of the coarse aggregate shall be determined as per IS : 2386 (Pan 3); if this value is greater than 2
per cent, the soundness test shall be carried out on the material delivered to site as per IS : 383. For
Grading II and IIImaterials, the CBR shall be determined at the density and moisture content likely to be
developed in equilibrium conditions which shall be taken as being the density relating to a uniform air
voids content of 5 per cent.

table 400-2. grading for coARse graded granular sub-base material

171
 Sieve Designation Per cent passing by 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 <10 <10 <10

CBR Value (Minimum) 30 25 20

Note : The material passing 425 micron (0.425 mm) sieve fur all the three grading when tested
according to IS : 2720 (Part 5) shall have liquid limit and plasticity index not more than 25 and 6 per
cent respectively.

401.3. Strength of sub-base

It shall be ensured prior to actual execution that the material to be used in the sub-base satisfies the
requirements of CBR and other physical requirements when compacted and finished.

When directed by the Engineer, this shall be verified by performing CBR tests in the laboratory as
required on specimens remoulded at field dry density and moisture content and any other tests for the
“quality” of materials, as may be necessary.

401.4. Construction Operations

401.4.1. Preparation of subgrade : Immediately prior to the laying of sub-base, the subgrade
already finished to Clause 301 or 305 as applicable shall be prepared by removing all vegetation and
other extraneous mailer, lightly sprinkled with water if necessary and rolled with two passes of 80 -100
kN smooth wheeled roller. Scarifying of existing surface as required as directed to be done by
contractor.

172
401.4.2. Spreading and compacting : The sub-base material of grading specified in the. Contract
shall be spread on the prepared subgrade 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 men-tioned in Clause 401.2.1, 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, trial 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 tank
and suitable for applying water uniformly and atontrolled 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 (Pan 8). While adding
water, due allowance shall be made for evaporation losses. After water has been added, the material
shall be processed by mechanical & other approved means like disc harrows, rotavators until the layer
is uniformly wet.

Immediately thereafter, rolling shall start. If the thickness of the com-pacted layer does not exceed1
100 mm, a

smooth wheeled roller of 80 100 kN weight may be used. For a compacted single layer upto 215 mm
the compaction shall be done with the help of a vibratory roller 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 a
minimum tyre pressure of 0.7 MN/m2 or equivalent capacity capable of achieving the required
compaction. Rolling shall commence at

the lower edge and proceed towards the edge longitudinally portions having unidirectional
upper for crossfall

and super-elevation and shall the edges and towards the centre for portions
commence at progress having

crossfall 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 crossfall (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.

173
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.

401.5. Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause 902.

Control on the quality of materials and works shall be exercised by the Engineer in accordance with
Section 900.

401.6. Arrangements for Traffic

During the period of construction, arrangement of traffic shall be maintained in accordance with Clause
112.

401.7. 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.

401.8. Rate

The Contract unit rate for granular sub-base shall be payment in full for carrying out the required
operations including full compensation for :

(i) malting arrangements for traffic to Clause 112 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 labor, tools, equipment and incidentals to complete the work to the Speci-fications;

174
 (iv) carrying out the work in part widths of road where directed; and (v) carrying out the
required test for quality control.

Item no 7 Providing and laying compacted WBM 150 mm thickness of B.T. M.C. metal of size 45 to 63
mm size including using 20% grit stone screening & stone dust as filler including spreading watering
& consolidation by vibratory roller etc. complete.

404. WATER BOUND MACADAM SUB-BASE/BASE

404.1. Scope

404.1.1. This work shall consist of clean, crushed aggregates mechanically interlocked by rolling and
bonding together with screening, binding material where necessary and water laid on a properly
prepared sub grade/ sub-base/ base or existing pavement, as the case may be and finished in
accordance with the requirements of these Specifications and in close conformity with the lines,
grades, cross-sections and thickness as per approved plans or as directed by the Engineer.

404.1.2. It is, however, not desirable to lay water bound macadam on an existing thin black topped
surface without providing adequate drainage facility for water that would get accumulated at the
interface of existing bituminous surface and water bound macadam.

404.2. Materials

404.2.1. Coarse aggregates : Coarse aggregates shall be either crushed or broken stone, crushed slag,
over burnt (Jhama) brick aggregates or any other naturally occurring aggregates such as kankar and
late rite of suitable quality. Materials other than crushed or broken stone and crushed slag shall be
used in sub-base courses only. If crushed gravel/ shingle is used, not less than 90 per cent by weight of
the gravel/ shingle pieces retained on 4.75 mm sieve shall have at least two fractured faces. The
aggregates shall conform to the physical requirements set forth in Table 400-6. The type and size range
of the aggregate shall be specified in the Contract or shall be as specified by the Engineer. 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 delivered to site as per IS : 2386 (Part 5).

404.2.2. Crushed or broken 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.

TABLE 400-6. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES FOR WATER BOUND

MACADAM FOR SUB-BASE/BASE COURSES

Test Test Method Requirements

1 * Los Angeles IS:2386 40 per cent (Max)

175
 Abrasion value (Part-4)

Or

* Aggregate IS:2386 30 per cent (Max)

Impact value (Part-4) or

IS:5640**

2 Combined

Flakiness and IS:2386 30 per cent (Max)

Elongation (Part-1)

Indices (Total)

***

* Aggregate may satisfy requirements of either of the two tests.

** Aggregates like brick metal, kankar, laterite etc. which get softened in presence of water shall
be

tested for Impact value under wet conditions in accordance with IS: 5640.

*** The requirement of flakiness index and elongation index shall be enforced only in the case of
crushed

broken stone and crushed slag.

404.2.3. Crushed slag : Crushed slag shall be made from air-cooled blast furnace slag. It shall be of
angular shape, reasonably uniform in quality and density and generally free from thin, elongated and
soft pieces, dirt or other deleterious materials. The weight of crushed slag shall not be less than 11.2
kN per m3 and the percentage of glossy material shall not be more than 20. It should also comply with
the following requirements:

(i) Chemical stability : To comply with requirement of

appendix of BS : 1047

(ii) Sulphur content : Maximum 2 per cent

(iii) Water absorption : Maximum 10 per cent

404.2.4. Overburnt brick aggregates : Jhama brick aggregates shall be made from
(Jhama) overburnt

176
bricks or brick bats and be
free from dust and other objectionable and deleterious materials.

404.2.5. Grading requirement of coarse aggregates : The coarse aggregates shall conform to one of the
Gradings given in Table 400-7 as specified, provided, however, the use of Grading No.1 shall be
restricted to sub-base courses only.

TABLE 400-7. GRADING REQUIRMENTS OF COARSE AGGREGATES

Grading Size Range IS Sieve Designation Per cent by weight

No. passing

1. 90 mm to 45 mm 125 mm 100

90 mm 90-100

63 mm 25-60

45 mm 0-15

22.4 mm 0-5

2. 63 mm to 45 mm 90 mm 100

63 mm 90-100

53 mm 25-75

45 mm 0-15

22.4 mm 0-5

3. 53 mm lo 22.4 mm 63 mm 100

53 mm 95-100

45 mm 65-90

22.4 mm 0-10

11.2 mm 0-5

177
Note : The compacted thickness for a layer with Grading 1 shall be100 mm while for layer with other
Gradings i.e. 2 & 3, it shall be 75 mm.

404.2.6. Screenings: Screenings to fill voids in the coarse aggregate shall generally consist of the same
material as the coarse aggregate. However, where permitted, predominantly non-plastic material such
as moorum or gravel (other than rounded river borne material) may be used for this

purpose provided liquid limit and plasticity index of such material are below 20 and 6 respectively and
fraction passing 75 micron sieve does not exceed 10 per cent.

Screenings shall conform to the grading set forth in Table 400-8. The consolidated details of quantity of
screenings required for various grades of stone aggregates are given in Table 400-9. The table also
gives the quantities of materials (loose) required for 10 m2 for sub-base/base compacted thickness of
100/75 mm.

The use of screenings shall be omitted in the case of soft aggregates such as brick metal, kankar,
laterites, etc. as they arc likely to get crushed to a certain extent under rollers.

TABLE 400-8. GRADING FOR SCREENINGS

Grading Size of IS Sieve Designation Per cent by weight

Classification Screenings passing the IS Sieve

A 13.2 mm 13.2 mm 100

11.2 mm 95-100

5.6 mm 15-35

180 micron 0-10

B 11.2 mm 11.2 mm 100

5.6 mm 90-100

180 micron 15-35

178
TABLE 400-9. APPROXIMATE QUANTITIES OF COARSE

AGGREGATES AND SCREENINGS REQUIRED FOR 100/75 MM COMPACTED THICKNESS OF WATER

BOUND MACADAM (WBM) SLB-BASE/BASK COURSE FOR 10M2 AREA

Classificati Size Compacted Lose Screenings

on Range thickness Qty.

Stone Screening Crushable type such

as Moorum or Gravel

For.
Grading WHM Grading Loose

Sub-
Classificati base/ Classificati Qty.

90
Grading 1 mm to 100 mm 1.21 to Type A 0.27 to Not 0.30 to

45 0.30
mm 1.43m3 13.2mm m3 uniform 0.30 m3

63
Grading 2 mm to 75 mm 0.91 to Type A 0.12 to -do 0.22 to

45m 0.15
m 1.07 m3 13.2mm m3 0.24 m3

-do- -do- -do- -do- Type B 0.20 to -do- -do-

179
 0.22
11.2mm m3

53m
Grading 3 m to 75 mm -do- -do- 0.18 To -do- -do-

22.4m 0.21
m m3

404.2.7. Binding material : Binding material to be used for water bound macadam as a filler material
meant for preventing ravelling, shall comprise of a suitable material approved by the Engineer having a
Plasticity Index(PI) value of less than 6 as determined in accordance with IS: 2720 (Part-5).

The quantity of binding material where it is to be used, will depend on the type of screenings.
Generally, the quantity required for 75 mm compacted thickness of water bound macadam will be
0.06-009 m3/10m2 and 0.08-0.10m3/10m2 for 100 mm compacted thickness.

The above mentioned quantities should be taken as a guide only, for estimation of quantities for
construction etc.

Application of binding materials may not be necessary when the screenings used are of crushable type
such as moorum or gravel.

404.3. Construction Operations

404.3.1. Preparation of base: The surface of the subgrade/ sub-base/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 places shall be corrected in an approved
manner and rolled until firm surface is obtained if necessary by sprinkling water. Any sub-
base/base/surface irregularities, where predominant, shall be made good by providing appropriate
type of profile corrective course (levelling course) to Clause 501 of these Specifications.

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 50 mm x 50 mm 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

180
course beneath the existing thin bituminous surface.

404.3.2. Inverted choke : If water bound macadam is to be laid the subgrade, without any
directly over other

intervening pavement course, a 25 mm course of screenings or coarse sand shall be

(Grading B) spread

on the prepared subgrade before application of the aggregates .is taken up. In case of a fine sand or
silty or clayey subgrade, it is advisable to lay 100 mm 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 geosynthetics functions of

performing separation

and drainage may be used over the prepared subgrade as directed by the Section 700 shall
Engineer. be

applicable for use of geosynthetics.

404.3.3. Spreading coarse aggregates : The coarse aggregates shall be spread uniformly and evenly
upon the prepared subgrade/sub-base/ base to proper profile by using templates placed across the
road about 6 m apart, in such quantities that the thickness of each compacted layer is not more than
100 mm for Grading 1 and 75 mm for Grading 1 and 3, as specified in Clause 404.2.5. Wherever
possible, approved mechanical devices such as aggregate spreader shall be used to spread the
aggregates uniformly so as to minimise 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 not normally be spread more than 3 days in advance of the subsequent
construction operations.

404.3.4. Rolling: Immediately following the spreading of the coarse aggregate, rolling shall be started

181
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 superelevated 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
width.

Rolling shall be discontinued when the aggregates arc partially compacted with sufficient void space in
them to permit application of screenings. However, where screenings are not to be applied, as in the
case of crushed aggregates like brick metal, laterite and kankar, 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 subgrade is soft or yielding or when it causes a wave-like
motion in the subgrade or sub-base course. 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 re-rolling until the entire surface conforms to desired
crossfall (camber) and grade. In no case shall the use of screenings the permitted to make up
depressions.

Material which gets crushed excessively during compaction or becomes segregated shall be removed
and replaced with suitable aggregates.

It shall be ensured that shoulders are built up simultaneously along with water bound macadam
courses as per Clause 407.4.1.

404.3.5. Application of screenings: After the coarse aggregate has been rolled to Clause 404.3.4,
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 die 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 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 (he road
which could be completed within one day’s operation.

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404.3.6. 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 beer
thoroughly keyed, well-bonded and firmly set in its full depth and a grout has been formed of
screenings. Care shall be taken to sec that the base or subgrade 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 sub-base attains adequate strength, as directed by the Engineer.

404.3.7. Application of binding material: application of screenings in accordance with Clauses

After the 404.3.5

and 404.3.6. the binding required to used (Clause 404.2.7) shall be

material where it is be applied

successively in two or more thin rate. After each application, the

layers at a slowand uniform surface shall

be copiously sprinkled water, the resulting slurry swept in with hand brooms, or mechanical
with brooms to

fill the voids properly, during which water shall be applied to the wheels of the rollers if
and rolled necessary

to wash down the binding material sticking to them. These operations shall continue until the resulting
slurry after filling of voids, form a wave ahead of the wheels of the moving roller.

404.3.8. Setting 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.

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404.4. Surface Finish and Quality Control of Work

404.4.1. The surface finish of construction shall conform to the requirements of Clause 902.

404.4.2. Control on the quality of materials and works shall be exercised by the Engineer in
accordance with Section 900.

404.4.3. The water bound macadam work shall not be carried out when the atmospheric
temperature is less than 0°C in the shade.

404.4.4. Reconstruction of defective macadam: The finished surface of water bound. macadam shall
conform to the tolerance of surface regularity as prescribed in Clause 902. However, where the surface
irregularity of the course exceeds the tolerances or where the course is otherwise defective due to
subgrade 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 recompacted. In no case shall depressions be filled up with screenings or binding material.

404.5. Arrangement for Traffic

During the period of construction, the arrangement of traffic shall be done as per Clause 112.

404.6. Measurements for payment

Water bound macadam shall be measured as finished work in position in cubic metres.

404.7. Rate

The Contract unit rate for water bound macadam sub-base/base course shall be payable in full for
carrying out the required operations including full compensation for all components listed in Clause
401.8 (i) to (v) including arrangement of water used in the work as approved by the Engineer.

Item no 8: Providing and laying, spreading and compacting 150m thick graded stone aggregate to
Wet Mix Macadam specification including premixing the material with water at OMC in mechanical
mix plant carraige of mixed material by tipper tp site, laying in uniform layers with mechanical
means in sub-base /base course on well prepared surface and compacting with vibratory roller to
achieve the desired density

406.1. Scope

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This work shall consist of laying and compacting clean, crushed, graded aggregate and granular
material, premixed with water, to a dense mass on a prepared sub grade/sub-base/base or existing
pavement as the case may be in accordance with the requirements of these Specifications. The
material shall be laid in one or more layers as necessary to lines, grades and cross-sections shown on
the approved drawings or as directed by the Engineer.

The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75 mm. When
vibrating or other approved types of compacting equipment arc, used, the compacted depth of a single
layer of the sub-base course may be increased to 200 mm upon approval of the Engineer.

406.2. Materials

406.2.1. Aggregates

[Link]. Physical requirements: Coarse aggregates shall be crushed stone. If crushed gravel/shingle is
used, not less than 90 per cent by weight of the gravel/shingle pieces retained on 4.75 mm sieve shall
have at least two fractured faces. The aggregates shall conform to the physical requirements set forth
in Table 400-10 below.

TABLE 400-10. PHYSICAL REQUIRMENTS OF COARSE AGGREGATES

FOR WET MIX MACADAM FOR SUB-BASE/BASE COURSES

Test Test Method Requirements

1* Los Angeles IS:2386 40 per cent (Max)

Abrasion value (Part-4)

Or

* Aggregate IS:2386 30 per cent (Max)

Impact value (Part-4) or

2Combined

Flakiness and IS:2386 30 per cent (Max)**

Elongation (Part-1)

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 Indices (Total)

* Aggregate may satisfy requirements of either of the two tests.

** To determine this combined proportion, the flaky stone from a representative sample should
first be separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample.
Only the elongated particles beseparated out from the remaining (non-flaky) stone metal. Elongation
index is weight of elongated particles divided by total non-flaky particles. The value of flakiness index
and elongation index so found are added up.

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 delivered to site as per IS:2386(Part-5).

[Link]. Grading requirements : The aggregates shall conform to the grading given in Table 400-11.

GRADING REQUIREMENTS OF AGGREGATES

TABLE 400-11. FOR

WET MIX
MACADAM

IS Sieve Designation Per cent by weight passing the IS sieve

53.00 mm 100

45.00 mm 95-100

26.50 mm —

22.10 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.

406.3. Construction Operations

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406.3.1. Preparation of base : Clause 404.3.1. shall apply.

406.3.2. Provision of lateral confinement of aggregates: While con-structing 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 and following the sequence
of operations described in Clause 407.4.1.

406.3.3. Preparation of mix: Wet Mix Macadam shall be prepared in an approved mixing plant of
suitable

having provision for controlled, addition of water and forced/positive mixing

capacity 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 IS:2720 (Part-8) after replacing
the aggregate fraction retained on 22.4 mm sieve with material of 4.75 mm to 22.4 mm 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.

406.3.4. Spreading of mix : Immediately after mixing, the aggregates shall be spread uniformly and
evenly upon the prepared subgrade/sub- base/bass in required quantities. In no case should these be
dumped in heaps directly on the area where these are to be laid nor shall their hauling over a partly
completed stretch be permitted.

The mix may be spread either by a paver finisher or motor grader. For portions where mechanical
means cannot be used, manual means as approved by the Engineershall 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:

(i) Loading hoppers and suitable distribution mechanism

(ii) 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.

(iii) The paver shall be equipped with necessary control mechanism so as to ensure that the finished
surface is free from surface blemishes.

187
The surface of the aggregate shall be carefully checked with templates and all high or low spots
remedied by removing or adding aggregate may be required. The layer may be tested by depth blocks
during construction. No segregation of larger and fine panicles should be allowed. The aggregates as
spread should be of uniform gradation with no pockets of fine materials.

406.3.5. Compaction: After the mix has seen laid to the required thickness, grade and crossfall/camber
the same shall be uniformly com-pacted, to the full depth with suitable roller. If the thickness of single
compacted layer does not exceed 100 mm, a smooth wheel roller of 80 to 100 kN weight may be used.
For a compacted single layer upto 200 mm, the compaction shall be done with the help of vibratory
roller of minimum static weight of 80 to 100 kN or equivalent capacity roller. The speed of the roller
shall not exceed 5 km/h.

In portions having unidirectional cross fall/superelevation, 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 track 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/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 subgrade is soft or yielding or when it causes a wave-like motion
in the sub-base/base course or subgrade. If irregularities develop during rolling which exceed 12 mm
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
crossfall. In no case should 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 made good to the full thickness of the layer and recompacted.

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406.3.6. Setting and drying: After final compaction of wet mix mac-adam course, the road shall be
allowed to dry for 24 hours.

406.4. 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 laid.

406.5. Surface Finish and Quality Control of Work

406.5.1. Surface evenness : The surface finish of construction shall conform to the requirements of
Clause 902.

406.5.2. Quality control : Control or, the quality of materials and works shall be exercised by the
Engineer in accordance with Section 900.

406.6. 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 subgrade soil getting mixed with the aggregates, the
full thickness of the layer shall be scarified over the affected area, re-shaped with added premixed
material or removed and replaced with fresh premixed material as applicable and recompacted in
accordance with Clause 406.3. The area treated in the aforesaid manner shall not be less than 5 m long
and 2 m wide. In no case shall depressions be filled up with unmixed and ungraded material or fines.

406.7. Arrangement for Traffic

During the period of construction, arrangement of traffic shall be done as per Clause 112.

406.8. Measurements for Payment

Wet mix macadam shall be measured as finished work in position in cubic metres.

406.9. Rates

189
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 listed in Clause 401.8.

Item no 10 : Providing & applying evenly priming coat with bitumen Emulsion (SS1) on prepared
surface of granular base including cleaning of road surface and sparying primer at the rate of
7.50 Kg. / 10 Smt using using mechanical means.

502 PRIME COAT OVER GRANULAR BASE

502.1 Scope

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. The work shall be carried out on a previously prepared granular/ stabilized
surface to Clause 501.8.

Materials

The primer shall be cationic bitumen emulsion SS1 grade conforming to IS:8887 or
medium curing cutback bitumen conforming to IS:217 or as specified in the Contract.

Quantity of SS1grade bitumen emulsion for various types of granular surface shall be as given in
Table 500-3.

Table 500-3 :Quantity of Bitumen Emulsion for Various Types of Granular Surfaces

Type of Surface Rate of Spray (kg/sq.m)

WMM/WBM 0.7-1.0
Stabilized soil bases/Crusher Run Macadam 0.9-1.2

Cutback for primer shall not be prepared at the site. Type and quantity of cutback bitumen
for various types of granular surface shall be as given in Table 500-4.

190
 Table 500-4 :Type and Quantity of Cutback Bitumen for Various Types of Granular Surface

Type of Surface Type of Cutback Rate of Spray

(kg/sq.m)
WMM/WBM MC 30 0.6-0.9
Stabilized soil bases/ Crusher Run Macadam MC 70 0.9-1.2

The correct quantity of primer shall be decided by the Engineer and shall be such that it can be
absorbed by the surface without causing run-off of excessive primer and to achieve desired
penetration of about 8-10 mm.

Weather and Seasonal Limitations

Primer shall not be applied during a dust storm or when the weather is foggy, rainy or windy or
when the temperature in the shade is less than 1DOC. Cutback bitumen as primer shall not be
applied to a wet surface. Surfaces which are to receive emulsion primer should be damp, but no free
or standing water shall be present. Surface can be just wet by very light sprinkling of water.

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 502.4

502.4.1

Construction Equipment

The primer shall be applied by a self-propelled or towed bitumen pressure sprayer equipped for
spraying the material uniformly at specified rates and temperatures. Hand spraying shall not be
allowed except in small areas, inaccessible to the distributor, or in narrow strips where primer shall be
sprayed with a pressure hand sprayer, or as directed by the Engineer.

Preparation of Road Surface

The granular surface to be primed shall be swept clean by power brooms or mechanical sweepers
and made free from dust. All loose material and other foreign material shall be removed
completely. If soil/ moorum binder has been used in the WBM surface, part of this should be
brushed and removed to a depth of about 2 mm so as to achieve good penetration.

Application of Bituminous Primer

After preparation of the road surface as per Clause 502.4.2, the primer shall be sprayed uniformly
at the specified rate. The method for application of the primer 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.

No heating or dilution of SS1 bitumen emulsion and shall be permitted at site. Temperature of cutback
bitumen shall be high enough to permit the primer to be sprayed effectively though the jets of the
spray and to cover the surface uniformly.

Curing of Primer and Opening to Traffic

A primed surface shall be allowed to cure for at least 24 hours or such other higher period as is found to
be necessary to allow all the moisture/volatiles to evaporate before any subsequent surface treatment
or mix is laid. Any unabsorbed primer shall first be blotted with a light application of sand, using

174
 the minimum quantity possible. A primed surface shall not be opened to traffic other than that
necessary to lay the next course.

Quality Control of Work

For control of the quality of materials and the works carried out, the relevant provisions of Section
900 shall apply.

Arrangements for Traffic

During construction operations, arrangements for traffic shall be made in accordance with the
provisions of Clause 112.

Measurement for Payment

Prime coat shall be measured in terms of surface area of application in square metres.

Rate

The contract unit rate for prime coat shall be payment in full for carrying out the required
operations including full compensation for all components listed in Clause 401.7 (i) to (v) and as
applicable to the work specified in these Specifications. Payment shall be made on the basis of the
provision of prime coat at an application rate of quantity at 0.6 kg per square metre or at the rate
specified in the Contract, with adjustment, plus or minus, for the variation between this quantity and
the actual quantity approved by the Engineer after the preliminary trials referred to in Clause
502.4.3.
PAyement Shall be Made on SMT Basis

Item no 11: Providing and laying 50.00 mm thick compacted bitumenous macadam (BM) using crushed
stone aggregate as per MORT & H gradation and Emulsion (RS-1) for tack coat @ 2.5 kg/10smt. & VG-
40 grade bitumen at the rate of 3.40% by weight of total mix (i.e. 34kg/mt by wt. of total mix) for

175
binding including heating and mixing the asphalt and aggregates in Batch mix plant and transporting
the mix and spreading the same by Sensor paver finisher and consolidation with vibratory road roller
including using all necessary equipments, tools, plants, including cost of all materials, firewood, oil,
lubricants, labour charges etc. complete.

503 Tack Coat

This work shall consist of the application of a single coat of low viscosity liquid bituminous material to an
existing bituminous road surface preparatory to the superimposition of a bituminous mix, when specified
in the Contract or instructed by the Engineer.

503.2. Materials

503.2.1. Binder: The binder used for tack coat shall be bitumen emulsion complying with IS 8887 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 for emergency applications as directed by the
Engineer.

503.3. 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 10°C. 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.

176
503.4. Construction

503.4.1. 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.

503.4.2. Preparation of base: The surface on which the tack coat is to De applied shall be clean and free
from dust, dirt, and any extraneous material, and be otherwise prepared in accordance with the
requirements of Clauses 501.8 and 902 as appropriate. Immediately before the application of the tack
coat, the surface shall be swept clean with a mechanical broom, and high pressure air jet, or by other
means as directed by the Engineer.

503.4.3. 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 500-2.

The normal range of spraying

TABLE 500-2.

RATE OF APPLICATION OF TACK COAT

Type of Surface Quantity of liquid bituminous

material in Kg per sq. m. area

i) Normal bituminous surfaces 0.20 to 0.25

177
ii) Dry and hungry bituminous surfaces 0.25 to 0.30

iii) Granular surfaces treated with primer 0.25 to 0.30

iv) Non bituminous surfaces

a) Granular base (not primed) 0.35 to 0.40

b) Cement concrete pavement 0.30 to 0.35

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 geosynthetic is proposed for use, the provisions of Clauses 703.3.2 and
703.4.4 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.

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.

503.4.4. Curing of tack coat: The tack coat shall be left to cure until all the volatiles have evaporated
before any subsequent construction is started. No plant or vehicles shall be allowed on the tack coat
other than those essential for the construction.

[Link] Control of Work

For control of the quality of materials supplied and the works carried out, the relevant provisions of
Section 900 shall apply.

[Link] for Traffic

178
During the period of construction, arrangements for traffic shall be made in accordance with the
provisions of Clause 112.

504 BITUMINOUS MACADAM

Scope

This work shall consist of construction in a single course having 50 mm to 100 mm 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 mix, there is a potential that it may trap water or moisture vapour
within the pavement system. Therefore, adjacent layer (shoulders) should have proper drainage
quality to prevent moisture-induced damage to the BM.

Materials

504.2.1 Bitumen

The bitumen shall be viscosity graded paving bitumen complying with Indian Standard Specification
for paving bitumen, IS:73 or as specified in the Contract. The type and grade of
bitumen to be used would depend upon the climatic conditions and the traffic. Guidelines for
selection of bitumen are given in Table 500-1.

504.2.2 Coarse Aggregates

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material retained
on 2.36 mm sieve. It shall be clean, hard, durable and cubical shape, free from dust and soft
organic and other deleterious substances. The aggregate shall satisfy the physical requirements
specified in Table 500-6. Where crushed gravel is proposed for use as aggregate, not less than
90 percent by weight of the crushed material retained on

179
4.75 mm sieve shall have at least two fractured faces resulting from crushing operation. Before
approval of the source, the aggregates shall be tested for stripping. 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.

504.2.3 Fine Aggregates

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a

combination of two, passing 2.36 mm sieve and retained on 75 micron sieve. It shall be clean, hard,
durable, free from dust and soft organic and other deleterious substances. Natural sand shall not be
used in the binder course.

Table 500-6 : Physical Properties of Coarse Aggregate

Property Test Requirement Test method

Cleanliness Grain size analysis Max. 5% passing IS:2386 Part I
0.075 micron
Particle shape Combined Flakiness and Max. 35% IS:2386 Part I
Elongation Indices
Strength Los Angeles Abrasion Max. 40% IS:2386 Part IV
Value or
Aggregate Impact Value Max. 30% IS:2386 Part IV
Durability Soundness (Sodium or 5 cycles
Magnesium)
Max. 12% IS:2386 Part V
Sodium Sulphate
IS:2386 Part V
Magnesium Sulphate Max. 18%
Water absorption Water absorption Max. 2% IS:2386 Part Ill
Stripping Coating and Stripping of Min. Retained Coating IS:6241
Bitumen Aggregate 95%
AASHT0283
••Water sensitivity Retained Tensile strength* Min. 80%
If the
agent minimum retained tensile strength falls below 80 percent, use of anti stripping
••
• is recommended to meet the minimum requirements.

Aggregate Grading and Binder Content

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The combined grading of the coarse aggregates and fine aggregates, when tested in accordance
with IS:2386 Part 1, wet sieving method, shall conform to limits given in Table 500-8. The type
and quantity of bitumen and appropriate thickness is also given in Table 500-7.

Proportioning of Material

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. The aggregate may be proportioned and blended
to produce a uniform mix complying with the requirements in Table 500-7. The binder content
shall be within a tolerance of ± 0.3 percent by weight of total mix when individual specimens are
taken for quality control tests in accordance with the provisions of Section 900.

504.3 Construction Operation

504.3.1 Weather and Seasonal Limitations

The provisions of Clause 501.5.1 shall apply.

Table 500-7 : Aggregate Grading and Bitumen Content

Grading 1 2
Nominal maximum aggregate size* 40mm 19mm
Layer thickness 80-100 mm 50-75 mm
IS Sieve size (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 90-100
26.5 75-100 100
19 - 90-100
13.2 35-61 56-88
4.75 13-22 16-36
2.36 4-19 4-19
0.3 2-10 2-10

181
 0.075 0-8 0-8
Bitumen content** percent by 3.3** 3.4**
mass of total mix
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 aggregates have specific
gravity more than 2.7, bitumen content can be reduced proportionately. Further, for regions
where highest daily mean air temperature is 30°C or lower and lowest daily mean air
temperature is -10°C or lower, the bitumen content may be increased by
0.5 percent.

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 501.8 and 902.3 as appropriate, and a prime coat,
shall be applied in accordance with Clause 502 where specified, 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 get access, other approved methods
shall be used as directed by the Engineer.

Preparation and Transportation of the Mix

The provisions of Clauses 501.3 and 501.4 shall apply.

Spreading

The provisions of Clause 501.5.3 shall apply.

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 Rolling

Compaction shall be carried out in accordance with the provisions of Clauses 501.6 and 501.7.

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 903.

504.4 Surface Finish and Quality Control of Work

The surface finish of the completed construction shall conform to the requirements of Clause 902.
For control of the quality of materials and the works carried out, the relevant provisions of
Section 900 shall apply.

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, by the
Contractor the course shall be covered by a seal coat to the requirement of Clause 512 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.

. Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with the
provisions of Clause 112.

Measurement for Payment

Bituminous macadam shall be measured as finished work in cubic metres, or by weight in metric
tonnes, where used as regulating course, or square metres at the specified thickness as indicated in
the Contract or shown on the drawings, or as otherwise directed by the Engineer.

183
 Rate

The contract unit rate for bituminous macadam shall be payment in full for carrying out the
required operations as specified. The rate shall include cost for all components listed in Clause
[Link].

Payment Shall be Made on MT BASIS

Item no 12 Providing and laying 50 mm thick compacted D.B.M with B.T. stone aggregates as per
MoRT&H gradation & Emulsion (RS-1) for tack coat @ 2.5 kg/10smt. specification with bitumen grade
VG - 40 for mixing at the rate of 45.00kg/MT by weight of total mix i.e (4.50 % by weight of total ,
heating the asphalt VG-40 and aggregates by Batch mix plant & spreading the same by Sensor paver
finisher including rolling & consolidation with 10-12 tones vibratory and power roller & providing all
materials, equipments, tools & plants, fire wood, oil, kerosene, labour charges etc. and using
contractor's own machineries drum mix plant and paver finisher etc. complete

503 Tack Coat

This work shall consist of the application of a single coat of low viscosity liquid bituminous material to an
existing bituminous road surface preparatory to the superimposition of a bituminous mix, when specified
in the Contract or instructed by the Engineer.

503.2. Materials

503.2.1. Binder: The binder used for tack coat shall be bitumen emulsion complying with IS 8887 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 for emergency applications as directed by the
Engineer.

503.3. Weather and Seasonal Limitations

184
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 10°C. 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.

503.4. Construction

503.4.1. 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.

503.4.2. Preparation of base: The surface on which the tack coat is to De applied shall be clean and free
from dust, dirt, and any extraneous material, and be otherwise prepared in accordance with the
requirements of Clauses 501.8 and 902 as appropriate. Immediately before the application of the tack
coat, the surface shall be swept clean with a mechanical broom, and high pressure air jet, or by other
means as directed by the Engineer.

503.4.3. 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 500-2.

185
The normal range of spraying

TABLE 500-2.

RATE OF APPLICATION OF TACK COAT

Type of Surface Quantity of liquid bituminous

material in Kg per sq. m. area

i) Normal bituminous surfaces 0.20 to 0.25

ii) Dry and hungry bituminous surfaces 0.25 to 0.30

iii) Granular surfaces treated with primer 0.25 to 0.30

iv) Non bituminous surfaces

a) Granular base (not primed) 0.35 to 0.40

b) Cement concrete pavement 0.30 to 0.35

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 geosynthetic is proposed for use, the provisions of Clauses 703.3.2 and
703.4.4 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.

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.

186
503.4.4. Curing of tack coat: The tack coat shall be left to cure until all the volatiles have evaporated
before any subsequent construction is started. No plant or vehicles shall be allowed on the tack coat
other than those essential for the construction.

[Link] Control of Work

For control of the quality of materials supplied and the works carried out, the relevant provisions of
Section 900 shall apply.

[Link] for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112

505 DENSE BITUMINOUS MACADAM

Scop
e

The specification describes the design and construction procedure for Dense Bituminous
Macadam, (DBM), for use mainly, but not exclusively, in base/binder and profile corrective
courses. The work shall consist of construction in a single or multiple layers of DBM on a
previously prepared base or sub-base. The thickness of a single layer shall be 50 mm to
100 mm.

Materials

505.2.1 ·Bitumen

The bitumen shall be viscosity grade paving bitumen complying with the Indian Standard
Specification IS:73, modified bitumen complying with Clause 501.2.1 or as otherwise
specified in the Contract.

187
The type and grade of bitumen to be used shall be specified in the Contract.

188
Coarse Aggregates

The coarse aggregates shall consist of crushed rock, crushed gravel or other hard material
retained on 2.36 mm sieve. They shall be clean, hard, durable, of cubical shape, free from dust
and soft or friable matter, organic or other deleterious substances. Where the Contractor's
selected source of aggregates has poor affinity for bitumen, the Contractor shall produce test
results that with the use of anti-stripping agents, the stripping value is improved to satisfy the
specification requirements. The Engineer may approve such a source and as a condition for
the approval of that source, the bitumen shall be treated with an approved anti-stripping agent,
as per the manufacturer's recommendations, at the cost of the Contractor. The aggregates
shall satisfy the requirements specified in Table 500-8.

Where crushed gravel is proposed for use as aggregate, not less than 90 percent by weight of
the crushed material retained on the 4.75 mm sieve shall have at least two fractured faces.

Fine Aggregates

Fine aggregates shall consist of crushed or naturally occurring mineral material, or a

combination of the two, passing the 2.36 mm sieve and retained on the 75 micron sieve.
These shall be clean, hard, durable, dry and free from dust, and soft or friable matter, organic
or other deleterious matter. Natural sand shall not be allowed in binder courses. However,
natural sand upto 50 percent of the fine aggregate may be allowed in base courses. The fine
aggregate shall have a sand equivalent value of not less than 50 when tested in accordance
with the requirement of IS:2720 (Part 37). The plasticity index of the fraction passing the
0.425 mm sieve shall not exceed 4, when tested in accordance with IS:2720 (Part 5).

Filler

Filter shall consist of finely divided mineral matter such as rock dust, hydrated lime or
cement approved by the Engineer. The filler shall be graded within the limits indicated in
Table 500-9.

The filler shall be free from organic impurities and have a plasticity Index not greater
than 4. The Plasticity Index requirement shall not apply if filler is cement or lime. Where the
aggregates fail to meet the requirements of the water sensitivity test in Table 500-8, then
2 percent by total weight of aggregate, of hydrated lime shall be used and percentage of fine
aggregate reduced accordingly.

Aggregate Grading and Binder Content

189
When tested in accordance with IS:2386 Part 1 (wet sieving method), the combined
grading of the coarse and fine aggregates and filler for the particular mixture shall fall within
the limits given in Table 500-10 for grading 1 or 2 as specified in the Contract. To avoid gap
grading, the combined aggregate gradation shall not vary from the lower limit on one sieve
to higher limit on the adjacent sieve.

190
 Table 500-8 : Physical Requirements for Coarse Aggregate for Dense Bituminous Macadam

Property Test Specification Method of Test

Cleanliness (dust) Grain size analysis Max 5% passing IS:2386 Part I

0.075 mm sieve

Particle shape Combined Flakiness and Max35% IS:2386 Part I

Elongation Indices*

Strength Los Angeles Abrasion Max35% IS:2386 Part IV

Value or
Aggregate Impact Value Max27%

Durability Soundness either :Sodium Max 12% IS:2386 Part V

Sulphate or
Magnesium Sulphate Max 18%

Water Absorption Water Absorption Max2% IS:2386 Part Ill

Stripping Coating and Stripping of Minimum retained IS:6241

Bitumen Aggregate Mix coating 95%

Water Sensitivity Retained Tensile Min. 80% AASHTO 283

Strength**

* To determine this combined proportion, the flaky stone from a representative sample
should first be separated out. Flakiness index is weight of flaky stone metal divided by
weight of stone sample. Only the elongated particles be separated out from the remaining
(non-flaky) stone metal. Elongation index is weight of elongated particles divided by total
non-flaky particles. The values of flakiness index and elongation index so found are added
up.
** If the minimum retained tensile test strength falls below 80 percent, use of anti stripping
agent is recommended to meet the requirement.

Table 500-9 : Grading Requirements for Mineral Filler

191
IS sieve (mm) Cumulative Percent Passing by Weight of Total Aggregate

0.6 100

0.3 95-100

0.075 85- 100

192
 Table 500-10 : Composition of Dense Graded Bituminous Macadam

Grading 1 2
Nominal aggregate size* 37.5mm 26.5 mm
Layer thickness 75-100 mm 50-75 mm
1
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 100
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8
Bitumen content % by mass Min 4.0** Min 4.5**
of total mix

* The nominal maximum particle size is the largest specified sieve size upon which any of
the aggregate is retained.
•• Corresponds to specific gravity of aggregates being 2.7. In case aggregate have specific
gravity more than 2.7, the minimum bitumen content can be reduced proportionately.

Further the region where highest daily mean air temperature is 30°C or lower and lowest
daily air temperature is - 10°C or lower, the bitumen content may be increased by

0.5 percent.

Bitumen content indicated in Table 500-10 is the minimum quantity. The quantity shall be
determined in accordance with Clause 505.3.

193
 Mix Design

The bitumen content required shall be determined following the Marshall mix design
procedure contained in Asphalt Institute Manual MS-2.

The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.

194
 Requirements for the Mix

Apart from conformity with the grading and quality requirements for individual ingredients, the
mixture shall meet the requirements set out in Table 500-11.

Table 500-11 : Requirements for Dense Graded Bituminous Macadam

Properties Viscosity Modified bitumen Test Method

Grade Paving
Hot climate Cold climate
Bitumen
Compaction level 75 blows on each face of the specimen
Minimum stability (kN 9.0 12.0 10.0 AASHTOT245
at 600C)
Marshall flow (mm) 2-4 2.5-4 3.5-5 AASHTOT245
Marshall Quotient 2-5 2.5-5 MS-2 and
(Stability) ASTM 02041
Flow

%air voids 3-5

% Voids Filled with 65-75
Bitumen (VFB)
Coating of aggregate 95% minimum IS:6241
particle
Tensile Strength ratio 80% Minimum AASHTOT283
% Voids in Mineral Minimum percent voids in mineral aggregate (VMA)
Aggregate (VMA) are set out in Table 500-13

Binder Content

The binder content shall be optimized to achieve the requirements of the mix set out in
Table 500-11. The binder content shall be selected to obtain 4 percent air voids in the mix
design. The Marshall method for determining the optimum binder content shall be adopted

195
as described in the Asphalt Institute Manual MS-2.

Where maximum size of the aggregate is more than 26.5 mm, the modified Marshall method
using 150 mm diametre specimen described in MS-2 and ASTM D 5581 shall be used. This
method requires modified equipment and procedures. When the modified Marshall test is
used, the specified minimum stability values in Table 500-12 shall be multiplied by 2.25, and
the minimum flow shall be 3 mm.

196
 Table 500-12 : Minimum Percent Voids In Mineral Aggregate (VMA)

Nominal Maximum Minimum VMA Percent Related to

Particle Size 1 (mm) Design Percentage Air voids

3.0 4.0 5.0

26.5 11.0 12.0 13.0

37.5 10.0 11.0 12.0

Note : Interpolate minimum voids in the mineral aggregate (VMA) for designed percentage air
voids values between those listed.

Job Mix Formula

The Contractor shall submit to the Engineer for approval at least 21 days before the start the
work, the job mix formula proposed for use in the works, together with the following details:

i) Source and location of all materials;

ii) Proportions of all materials expressed as follows:

a) Binder type, and percentage by weight of total mix;

b) Coarse aggregate/Fine aggregate/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 fraction, and the
proportion of each in the combined grading;

v) The results of mix design such as maximum specific gravity of loose

mix (Gmm), compacted specimen densities, Marshall stability,flow, air
voids, VMA, VFB and related graphs and test results of AASHTO T 283
Moisture susceptibility test;

197
 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 mix and its different ingredients satisfy the physical and strength requirements
of these Specifications.

198
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 by the Contractor to the Engineer for approval before the placing
of the material.

Plant Trials- Permissible Variation in Job Mix Formula

Once the laboratory job mix formula is approved, the Contractor shall carry out plant
trials to establish that the plant can 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 500-13 and shall remain within the gradation band. These variations are
intended to apply to individual specimens taken for quality control tests in accordance with
Section 900.

Table 500-13: Permissible Variations in the Actual Mix from the Job Mix Formula

Description Base/binder Course

Aggregate passing 19 mm sieve or larger ±8%
Aggregate passing 13.2 mm, 9.5 mm ±7%
Aggregate passing 4.75 mm ±6%
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm ±5%

Aggregate passing 0.3 mm, 0.15 mm ±4%

Aggregate passing 0.075 mm ±2%

Binder content ±0.3%

199
Mixing temperature ± 10°C

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 501. The laying trial shall be carried out on a

200
suitable area which is not to form part of the works. The area of the laying trials shall be
a minimum of 100 sq.m 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 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. The compacted layers of Dense Graded Bituminous
Macadam (DBM) shall have a minimum field density equal to or more than 92% of the density
based on theoretical maximum specific gravity (Gmm) obtained on the day of compaction in
accordance with ASTM D 2041 .

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.

Construction Operations

Weather and Seasonal Limitations

The provisions of Clause 501.5.1 shall apply.

Preparation of Base

The base on which Dense Graded Bituminous Material is to be laid shall be prepared in
accordance with Clauses 501 and 902 as appropriate, or as directed by the Engineer.

Geosynthetics

201
Where Geosynthetics are specified in the Contract, this shall be in accordance with the
requirements stated in Clause 703.

Stress Absorbing Layer

Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance
with the requirements of Clause 517.

Prime Coat

Where the material on which the dense bituminous macadam is to be laid is other than a

202
bitumen bound layer, a prime coat shall be applied, as specified, in accordance with the
provisions of Clause 502, or as directed by the Engineer.

Tack Coat

Where the material on which the dense bituminous macadam is to be laid is either bitumen
bound layer or primed granular layer, tack coat shall be applied, as specified, in accordance
with the provisions of Clause 503, or as directed by the Engineer.

Mixing and Transportation of the Mix

The provisions as specified in Clauses 501.3 and 501.4 shall apply. Table 500-2 gives the
mixing, laying and rolling temperature for dense mixes using viscosity grade bitumen. In case
of modified bitumen, the temperature of mixing and compaction shall be higher than the mix
with viscosity grade bitumen. 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 have uniform quality, the plant shall be calibrated from time to time.

Spreading

The provisions of Clauses 501.5.3 and 501.5.4 shall apply.

Rolling

The general provisions of Clauses 501.6 and 501.7 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 may be varied only with the express
approval of the Engineer in writing.

Opening to Traffic

It shall be ensured that the traffic is not allowed without the approval of the Engineer in writing,
on the surface until the dense bituminous layer has cooled to the ambient temperature.

203
 Surface Finish and Quality Control of Work

The surface finish of the completed construction shall conform to the requirements of
Clause 902. All materials and workmanship shall comply with the provisions set out in
Section 900 of these Specifications.

Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with
the provisions of Clause 112.

204
 Measurement for Payment

Dense Graded Bituminous Materials shall be measured as finished work either in cubic
metres, tonnes or by the square metre at a specified thickness as indicated in the Contract
drawings, or documents, or as otherwise directed by the Engineer.

Rate

The contract unit rate for Dense Graded Bituminous Macadam shall be payment in full for
carrying out all the required operations as specified and shall include, to all components
listed in Clause [Link]. The rate shall include the provision of bitumen, at 4 percent and
4.5 percent by weight of the total mixture for grading 1 and grading 2 respectively.
Payment Shall be made on MT Basis

The variation in actual percentage of bitumen used shall be assessed and the payment
adjusted plus or minus accordingly.

Item no 13:
Providing and laying 25 mm thick compacted S.D.B.C with B.T. stone chips as per
MORT & H gradation and asphalt VG - 40 for mixing at the rate of 5.00 % by weight of
total mix i.e (50.00 kg/MT by weight of total mix) including heating the asphalt and
aggregates by continuous DRUm mix plant & spreading the same by paver finisher
including rolling & consolidation with 10-12 tones vibratory and power roller &
providing all materials, equipments, tools & plants, fire wood, oil, kerosene, labour
charges etc. and using contractor's own machineries Batch mix plant and paver
finisher etc. complete.

Item no 14:
Providing & laying 40 mm. thick Compacted Bitumine Concrete(BC)with BT aggregate
as per M.O.R.T.&[Link] & asphalt grade VG-40 for mixing at the rate of 55
Kg./M.T. i.e. 5.50% of total weight of total mix including heating the aggregate &
asphalt in batch mix plant & spreading the same by sensor paver finisher &
consolidation with vibratory roller & flushing sand @ 0.30 Cum/ 100 Smt. including
providing all materials equipments, tools & plants, fire wood, oil, kerosene, labour
charges etc complete using constractors own machinery drum mix plant & paver

189
finisher etc complete
507 BITUMINOUS CONCRETE

Scope

This work shall consist of construction of Bituminous Concrete, for use in wearing and profile
corrective courses. This work shall consist of construction in a single layer of bituminous
concrete on a previously prepared bituminous bound surface. A single layer shall be 30
mm/40 mm/50 mm thick.

Materials

Bitumen

The bitumen shall conform to Clause 504.2.1.

Coarse Aggregates

The coarse aggregates shall be generally as specified in Clause 504.2.2, except that the
aggregates shall satisfy the physical requirements ofTable 500-16 and where crushed gravel is
proposed for use as aggregate, not less than 95 percent by weight of the crushed material retained
on the 4.75 mm sieve shall have at least two fractured faces.

Table 500-16 :Physical Requirements for Coarse Aggregate for Bituminous Concrete

190
 Property Test Specification Method of Test
Cleanliness (dust) Grain size analysis Max 5% passing IS:2386 Part I
0.075 mm sieve
Particle shape Combined Flakiness and Max35% IS:2386 Part I
Elongation Indices
Strength Los Angeles Abrasion Value or Max30% IS:2386 Part IV
Aggregate Impact Value Max24%
Durability Soundness either:Sodium Max 12% IS:2386 Part V
Sulphate or
Magnesium Sulphate Max 18%
Polishing Polished Stone Value Min 55 BS:812-114
Water Absorption Water Absorption Max2% IS:2386 Part Ill
Stripping Coating and Stripping of Minimum retained IS:6241
Bitumen Aggregate Mix coating 95%
Water Sensitivity Retained Tensile Strength* Min 80% AASHT0283

* If the minimum retained tensile test strength falls below 80 percent, use of anti stripping agent
is recommended to meet the requirement.

Fine Aggregates

The fine aggregates shall be all as specified in Clause 505.2.3.

Filler

Filler shall be as specified in Clause 505.2.4.

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 filler shall fall within the limits shown in Table 500-17. The
grading shall be as specified in the Contract.

191
 Table 500-17: Composition of Bituminous Concrete Pavement Layers

Grading 1 2
Nominal aggregate size* 19mm 13.2 mm
Layer thickness 50mm 30-40 mm
IS Sieve 1 (mm) Cumulative % by weight of total aggregate passing
45
37.5
26.5 100
19 90-100 100
13.2 59-79 90-100
9.5 52-72 70-88
4.75 35-55 53-71
2.36 28-44 42-58
1.18 20-34 34-48
0.6 15-27 26-38
0.3 10-20 18-28
0.15 5-13 12-20
0.075 2-8 4-10
Bitumen content % by mass Min 5.2* Min 5.4**
of total mix
**
Notes:

192
 minimum bitumen content can be reduced proportionately. Further the region where
highest daily mean air temperature is 30°C or lower and lowest daily air temperature is -
10°C or lower, the bitumen content may be increased by
The
nomin 0.5 percent
al
maxi
mum
particl
e size
is the
larges
t
specifi
ed
sieve
size
up on
which
any of
the
aggre
gate
is
retain
ed.

Corres
ponds
to
specifi
c
gravit
y of
aggre
gate
being
2.7. In
case
aggre
gate
have
specifi
c
gravit
y
more
than
193
2.7,
the
 Mix Design

Requirements for the Mix

Clause 505.3.1 shall apply.

' Binder Content

Clause 505.3.2 shall apply.

Job Mix Formula

Clause 505.3.3 shall apply.

Plant Trials -Permissible Variation in Job Mix Formula

The requirements for plant trials shall be as specified in Clause 505.3.4, and permissible limits for
variation as given in Table 500-18.

Table 500-18 : Permissible Variations in Plant Mix from the Job Mix Formula

Description Permissible Variation

Aggregate passing 19 mm sieve or larger ±7%
Aggregate passing 13.2 mm, 9.5 mm ±6%
Aggregate passing 4.75 mm ±5%
Aggregate passing 2.36 mm, 1.18 mm, 0.6 mm ±4%
Aggregate passing 0.3 mm, 0.15 mm ±3%
Aggregate passing 0.075 mm ± 1.5%
Binder content ±0.3%

194
Mixing temperature ± 10oc

Laying Trials

The requirements for laying trials shall be as specified in Clause 505.3.5. The compacted layers of
bituminous concrete (BC) shall have a minimum field density equal to or more than 92 percent of
the average theoretical maximum specific gravity (Gmm) obtained on the day of compaction in
accordance with ASTM 02041.

Construction Operations

Weather and Seasonal Limitations

The provisions of Clause 501.5.1 shall apply.

195
Bases and Surface Courses (Bituminous) Section 500

Preparation of Base

The surface on which the bituminous concrete is to be laid shall be prepared in accordance with
Clauses 501 and 902 as appropriate, or as directed by the Engineer. The surface shall be thoroughly
swept clean by mechanical broom and dust removed by compressed air. In locations where a
mechanical broom cannot get access, other approved methods shall be used as directed by the
Engineer.

Geosynthetics

Where Geosynthetics are specified in the Contract, this shall be in accordance with the
requirements stated in Clause 703.

Stress Absorbing Layer

Where a stress absorbing layer is specified in the Contract, this shall be applied in accordance with the
requirements of Clause 517.

Tack Coat

The provisions as specified in Clause 504.4.6 shall apply.

Mixing and Transportation of the Mix

The provisions as specified in Clauses 501.3, 501.4 and 504.4.7 shall apply.

Spreading

191
The general provisions of Clauses 501.6 and 501.7 shall apply, as modified by the approved laying
trials.

Rolling

The general provisions of Clauses 501.6 and 501.7 shall apply, as modified by the approved laying
trials.

Opening to Traffic

Provisions in Clause 504.5 shall apply.

Surface Finish and Quality Control

The surface finish of the completed construction shall conform to the requirements of

191
 Traffic Signs, Markings and other Road Appurtenances Section 800

Clause 902. All materials and workmanship shall comply with the provisions set out in Section
900 of these Specifications.

Arrangements for Traffic

During the period of construction, arrangements for traffic shall be made in accordance with the
provisions of Clause 112.

Measurement for Payment

The measurement shall be as specified in Clause 505.8.

Rate

The contract unit rate shall be all as specified in Clause 504.9, except that the rate shall include
the provision of bitumen at 5.2 percent & 5.4 percent for grading 1 and grading 2 by weight of
total mix respectively. The variation in actual percentage of bitumen used will be assessed and
the payment adjusted plus and minus accordingly.

Item no 18: Road marking with hot applied thermoplastic paints with reflectorising glass beads on
bitumin surface providing and laying a hot applied thermoplastic compound 2.5 mm thick including
reflectorising glass beads @ 250gms per sqm area, thickness of 2.5mm is excluding of surface applied
glass beds as per IRC:35-2015. The finished surface to be level, uniform and free from streaks and
holes. zebra patta /bump patta lane /center line/ edge line/cut patta. The white color marking should
provide ,liminance coefficinet on cemend road shalll be min 130 mcd/m2/lux and Asphalt road shall
be min 100 mcd /m2/lux during the service life during the day time. The marking should meet the
performance criteria for night time reflectivity, wet reflectivity and skid resistance as mentioned in
the section-15 of IRC 35-2015. Warranty for the Retro reflectivity should be two years.

339
 Traffic Signs, Markings and other Road Appurtenances Section 800
Scope

The work shall consist of providing road markings of specified width, layout and design using paint of
the required specifications as given in the Contract and as per guidelines contained in from IRC:35-
1997.

Materials

Road markings shall be of ordinary road marking paint hot applied thermoplastic compound,
reflectorised paint or cold applied reflective paint as specified in the item and the material shall
meet the requirements as specified in these Specifications.

803.3 Ordinary Road Marking Paint

803.3.1 Ordinary paint used for road marking shall conform to Grade I as per

IS:164.

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

machinery.

803.4
Hot Applied Thermoplastic Road Marking

Thermoplastic Material
803.4.1
General

[Link]

The thermoplastic material shall be homogeneously composed of aggregate, pigment, resins and glass
reflectorizing beads. The colour of the compound shall be white or yellow (IS colour No. 356) as
specified in the drawings or as directed by the Engineer.

339
Requirements :

i) Composition: The pigment, beads, and aggregate shall be uniformly

dispersed in the resin. The material shall be free from all skins, dirt and
foreign objects and shall comply with requirements indicated in Table
800-9.

Table 800·9 : Proportions of Constituents of Marking Material (Percentage by Weight)

Component White Yellow

Binder 18.0 min. 18.0 min.
Glass Beads 30-30 30-30
Titanium Dioxide 10.0 min. --
Calcium Carbonate and Inert Fillers 42.0 max. See Note below
Yellow Pigments -- See Note below

Note: Amount of yellow pigment, calcium carbonate and inert fillers shall be at the option of
the manufacturer, provided all other requirements of this Specification are met.

ii) Properties: The properties of thermoplastic material, when tested in

accordance with ASTM D36/BS-3262-(Part 1), shall be as below:

a) Luminance :

White: Daylight luminance at 45°-65 percent min. as per AASHTO M 249

Yellow: Daylight luminance at 45°-45 percent min. as per AASHTO M249

b) Drying time : When applied at a temperature specified by the

manufacturer and to the required thickness, the material shall set to
bear traffic in not more than 15 minutes.

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

d) Cracking resistance at low temperature: The material shall show no

cracks on application to concrete blocks.

e) Softening point: 102.5°C ± 9.5°C as per ASTM D 36.

339
 f) Yellowness index (for white thermoplastic paint): not more than
0.12 as per AASHTO M 249

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

339
 iv) Reflectorisation : Shall be achieved by incorporation of beads, the
grading and other properties of the beads shall be as specified in
Clause 803.4.2.

v) Marking : Each container of the thermoplastic material shall be clearly and

indelibly marked with the following information:
'
1) The name, trade mark or other means of identification of
manufacturer

2) Batch number

3) Date of manufacture

4) Colour (white or yellow)

5) Maximum application temperature and maximum safe heating

temperature.

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

Reflectorizing Glass Beads

General

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

Type 1 beads are those which are a constituent of the basic thermoplastic compound vide Table
800-9 and Type 2 beads are those which are to be sprayed on the surface vide Clause 803.6.4.

339
The glass beads shall be transparent, colourless and free form milkiness, dark particles and
excessive air inclusions.

These shall conform to the requirements spelt out in Clause [Link].

Specific Requirements

a) Gradation :The glass beads shall meet the gradation requirements for the
two types as given in Table 800-10.

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 Table 800·10: Gradation Requirements for Glass Beads

Sieve Size Percent Retained

Type 1 Type2
1.18 mm 0 to 3
850 micron 5 to 20 0 to 5
600 micron -- 5 to 20
425 micron 65 to 95 --
300 micron -- 30 to 75
180 micron 0-10 10 to 30
Below 180 micron -- 0 to 15

b) Roundness: The glass beads shall have a minimum of 70 percent true

spheres.

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

d) Free flowing properties: The glass beads shall be free of hard lumps and
clusters and shall dispense readily under any conditions suitable for paint
striping. They shall pass the free flow-test.

Test Methods

The specific requirements shall be tested with the following methods:

i) Free-flow test: Spread 100 grams of beads evenly in a 100 mm diameter glass
dish. Place the dish in a 250 mm inside diameter dessicator which is filled
within 25 mm of the top of a dessicator plate with sulphuric acid water
solution (specific gravity 1.10). Cover the dessicator and let it stand for 4
hours at 20°C to 29°C. Remove sample from dessicator, transfer beads to a
pan and inspect for lumps or clusters. Then pour beads into a clean, dry
glass funnel having a 100 mm stem and 6 mm orifice. If necessary, initiate
flow by lightly tapping the funnel. The glass spheres shall be free of lumps and
clusters and shall flow freely through the funnel.

341
ii) The requirements of gradation, roundness and refractive index of glass beads
and the amount of glass beads in the compound shall be tested as per
BS:6088 and BS:3262 (Part 1).

iii) The Contractor shall furnish to the Engineer a copy of certified test
reports from the manufacturer of glass beads obtained from a reputed
laboratory showing results of all tests specified herein and shall certify

342
 that the material meets all requirements of these Specifications.
However, if so required, these tests may be carried out as directed by
the Engineer.

803.4.3 Application Properties of Thermoplastic Material

The thermoplastic material shall readily get screeded/extruded at temperatures specified by

the manufacturers for respective method of application to produce a line of specified thickness
which shall be continuous and uniform in shape having clear and sharp edges.

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

Preparation

i) The material shall be melted in accordance with the manufacturer's

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

After transfer to the laying equipment, the material shall be maintained

Reflectorised Paint

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Reflectorised paint, if used, shall conform to the Specification by the manufacturers and
approved by the Engineer. Reflectorising glass beads for reflectorising paints where used
shall conform to the requirements of Clause 803.4.2.

Application

803.6.1 Marking shall be done by machine. For locations where painting cannot be
done by machine, approved manual methods shall be used with prior approval of the
Engineer. The Contractor shall maintain control over traffic while painting operations are in
progress so as to cause minimum inconvenience to traffic compatible with protecting the
workmen.

344
 Where the compound is to be applied to cement concrete pavement, a sealing primer as
recommended by the manufacturer, shall be applied to the pavement in advance of placing of the
stripes to ensure proper bonding of the compound. On new concrete surface any laitance and/or
curing compound shall be removed before the markings are applied.

The thermoplastic material shall be applied hot either by screeding or extrusion process. After
transfer to the laying apparatus, the material shall be laid at a temperature within the range
specified by the manufacturer for the particular method of laying being used. The paint shall be
applied using a screed or extrusion machine.

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

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

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

least 2.5 mm unless specified otherwise. Where arrows or letters are to be provided,
thermoplastic compound may be hand-sprayed. In addition to the beads included in the
material, a further quantity of glass beads of Type 2, conforming to the above noted
Specification shall be sprayed uniformly into a mono-layer on to the hot paint line in quick
succession of the paint spraying operation. The glass beads shall be applied at the rate of 250
grams per square metre area.

The minimum thickness specified is exclusive of surface applied glass beads. The method of
thickness measurement shall be in accordance with Appendices B and C of BS:3262 (Part 3).

803.6.6 The markings shall be done to accuracy within the tolerances given below:

i) Width of lines and other markings shall not deviate from the specified
width by more than 5 percent.

ii) The position of lines, letters, figures, arrows and other markings shall not
deviate from the position specified by more than 20 mm

345
iii) T nment of any edge of a longitudinal line shall not deviate from the specified
h alignment by more than 10 mm in 15 m.
e
iv) The length of segment of broken longitudinal lines shall not deviate from
a the specified length by more than 150 mm.
l
i
g

In broken lines, the length of segment and the gap between segments shall be as indicated on the
drawings; if these lengths are altered by the Engineer, the ratio of the lengths of the painted
sections shall remain the same.

346
 Properties of Finished Road Markings

The finished lines shall be free from ruggedness on sides and ends and be parallel to the
general alignment of the carriageway. The upper surface of the lines shall be level, uniform and
free from streaks.

a) The stripe shall not be slippery when wet.

b) The marking shall not lift from the pavement in freezing weather.

c) After application and proper drying, the stripe shall show no appreciable
deformation or discoloration under traffic and under road temperatures
upto 60°C.

d) The marking shall not deteriorate by contact with sodium chloride,

calcium chloride or oil dripping from traffic.

e) The stripe or marking shall maintain its original dimensions and position.
Cold ductility of the material shall be such as to permit normal movement with
the road surface without chopping or cracking.

f) The colour of yellow marking shall conform to IS Colour No. 356 as

given in IS:164

Measurements for Payment

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

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

803.6.9 Rate

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

Item no 26 : Chevron sign :-Providing and fixing sign boards made out of 1.5mm aluminium sheet /
3mm ACP (Aluminum composite Panel); size 60x50 cm as per design of IRC-67-2012. Pre treated with
phospheting process & acid etching; coated with one coat of epoxy primer and two coats of best
quality epoxy paint ;reflectorised with Micro Prismatic Grade retro refiectivesheeting of Type-11 as
per ASTM D-4956 and latest [Link]; 3.3 mtr long stand post of 75 x 75 x 6mm / 65NB
Circular MS Pipe as required and frame fabricated from suitable size iron angle of 50 x 50 x 5mm;
painted with bestquality epoxy coatings in black and white bends. the details of symbol or inscription
/ numerals for each board shall be as per the instruction of engineer in [Link] fixing at site shall
be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing [Link]
under the supervision of engineer in charge. A warranty for 10 years for the Retro reflective sheeting
from originaa manufacturer & a certified copy of 3 year outdoor exposure test report from third
party test lab for the product offered shall be submitted by contractor. (A) Class-C Type-11 Retro
Reflective sheeting

Item no 23: Tree Guard sign :-Providing & fixing sign board made out of 2mm aluminium sheet / 3mm
ACP (Aluminum composite Panel) , size 30cms diameter circle, pretreated with phospheting process
and acid etching, painted with one coat of epoxy primer and two coats of best quality epoxy paint
reflectorised with retro reflective sheeting as per latest M.O.S.T. specifications. A warranty for 10
years for the Retro reflective sheeting from original manufacturer & a certified copy of 3 year
outdoor exposure test report from third party test lab for the product offered shall be submitted by
contractor. (A) Class-C Type-11 Retro Reflective sheeting.

Item no 24: Village Name Sign :-Providing and fixing sign boards made out of 2mm aluminium sheet /
4mm ACP (Aluminum composite Panel); size 90x60 cms. rectangular as per design of IRC-67-2012. Pre
treated with phospheting process & acid etching; coated with one coat of epoxy primer and two
coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro refiectivesheeting of
Type-11 as per ASTM D-4956 and latest [Link]; 3.3mtr long stand post of 75 x 75 x

361
6mm / 65NB Circular MS Pipe as required and frame fabricated from suitable size iron angle of 35 x
35 x 3mm; painted with bestquality epoxy coatings in black and white bends. The details of symbol
or inscription/letters / numerals for each board shall be as per the instruction of engineer in charge.
The fixing at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation,
curing [Link] under the supervision of engineer in charge. A warranty for 10 years for the
Retro reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure
test report from third party test lab for the product offered shall be submitted by contractor. (A)
Class-C Type-11 Retro Reflective sheeting

Item no 27: Direction (Junction) Sign :-Providing and fixing sign boards made out of 2mm aluminium
sheet / 4mm ACP(Aluminum composite Panel); size 244x122 cms. rectangular as per design of IRC-67-
2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy primer
and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 4.0mtr long (2
Nos.) stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from
suitable size iron angle of 50 x 50 x 5mm; painted with bestquality epoxy coatings in black and white
bends. The details of symbol foreach board shall be as per theinstruction of engineer in charge. The
fixing at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation,
curing [Link] under the supervision of engineer in charge. A warranty for 10 years for the
Retro reflective sheeting from original manufacturer & a certified copy

of 3 year outdoor exposure test report from third party test lab for the product offered shall be
submitted by contractor. (A) Class-C Type-11 Retro Reflective sheeting

Item no 28: Cautionary Warning Sign :-Providing and fixing sign boards made out of 2mm aluminium
sheet / 4mm ACP (Aluminum composite Panel); size 90 x 90 x 90 cms. equilateral triangle as per
design of IRC-67-2012. Pre treated with phospheting process & acid etching; coated with one coat of
epoxy primer and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade
retro refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 3.6mtr
long stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from
suitable size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white
bends. The details of symbol foreach board shall be as per theinstruction of engineer in charge. The
fixing at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation,
curing [Link] under the supervision of engineer in charge. A warranty for 10 years for the
Retro reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure

362
test report from third party test lab for the product offered shall be submitted by contractor. (A)
Class-C Type-11 Retro Reflective sheeting

Item no 29: Facility Informatory Sign :-Providing and fixing sign boards made out of 2mm aluminium
sheet / 4mm ACP(Aluminum composite Panel); size 80 x 60 cmsrectangular as per design of IRC-67-
2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy primer
and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 3.6mtr long
stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white bends.
The details of symbol foreach board shall be as per theinstruction of engineer in charge. The fixing at
site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing
[Link] under the supervision of engineer in charge. A warranty for 10 years for the Retro
reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure test
report from third party test lab for the product offered shall be submitted by contractor. (A) Class-C
Type-11 Retro Reflective sheeting

Item No 30 Regulatory / Mandatory Sign :-Providing and fixing sign boards made out of 2mm
aluminium sheet / 4mm ACP (Aluminum composite Panel); size 60 cms Dia Circle as per design of IRC-
67-2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy primer
and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 3.6mtr long
stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white bends.
The details of symbol foreach board shall be as per theinstruction of engineer in charge. The fixing at
site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing
[Link] under the supervision of engineer in charge. A warranty for 10 years for the Retro
reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure test
report from third party test lab for the product offered shall be submitted by contractor. (A) Class-C
Type-11 Retro Reflective sheeting

Item no 31: STOP Sign :-Providing and fixing sign boards made out of 2mm aluminium sheet / 4mm
ACP (Aluminum composite Panel); size 90 cms Octagone as per design of, IRC-67-2012. Pre treated
with phospheting process & acid etching; coated with one coat of epoxy primer and two coats of best
quality epoxy paint ;reflectorised with Micro Prismatic Grade retro refiectivesheeting of Type-11 as
per ASTM D-4956 and latest [Link]; 3.6mtr long stand post of 75 x 75 x 6mm / 65NB

363
Circular MS Pipe as required and framem fabricated from suitable size iron angle of 35 x 35 x 3mm;
painted with bestquality epoxy coatings in black and white bends. The details of symbol foreach
board shall be as per theinstruction of engineer in charge. The fixing at site shall be in 1:2:4 CC
blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing [Link] under the
supervision of engineer in charge. A warranty or 10 years for the Retro reflective sheeting from
original manufacturer & a certified copy of 3 year outdoor exposure test report from third party test
lab for the product offered shall be submitted by contractor. (A) ClaSS C ype-11 Retro Reflective
sheeting

Item no 32: Distance Informatory / Destination Sign :-Providing and fixing sign boards made out of
2mm aluminium sheet / 4mm ACP (Aluminum composite Panel); size 180x120 cms. rectangular as
per design of IRC-67-2012. Pre treated with phospheting process & acid etching; coated with one
coat of epoxy primer and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic
Grade retro refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link];
4.0mtr long (Nos.) stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame
fabricated from suitable size iron angle of 50 x 50 x 5mm; painted with bestquality epoxy coatings in
black and white bends. The details of symbol foreach board shall be as per theinstruction of engineer
in charge. The fixing at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link]
excavation, curing [Link] under the supervision of engineer in charge. A warranty for 10 years
for the Retro reflective sheeting from original manufacturer & a certified copy of 3 year outdoor
exposure test report from third party test lab for the product offered shall be submitted by
contractor. (A) Class-C Type-11 Retro Reflective sheeting

Item no 33: Place Identification Sign :-Providing and fixing sign boards made out of 2mm aluminium
sheet / 4mm ACP (Aluminum composite Panel); size 150x90 cms. rectangular as per design of IRC-67-
2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy primer
and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 4.0mtr long (2
Nos.) stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from
suitable size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white
bends. The details of symbol foreach board shall be as per theinstruction of engineer in charge. The
fixing at site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation,
curing [Link] under the supervision of engineer in charge. A warranty for 10 years for the
Retro reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure
test report from third party test lab for the product offered shall be submitted by contractor. (A)
Class-C Type-11 Retro Reflective sheeting

364
Item no 34: Hazard Marker Sign :-Providing and fixing sign boards made out of 2.0 mm aluminium
sheet / 4 mm ACP (Aluminum composite Panel); size 90x30 cms. rectangular as per design of IRC-67-
2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy primer
and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 1.8mtr long
stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white bends.
The details of symbol foreach board shall be as per theinstruction of engineer in charge. The fixing at
site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing
[Link] under the supervision of engineer in charge. A warranty for 10 years for the Retro
reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure test
report from third party test lab for the product offered shall be submitted by contractor. (A) Class-C
Type-11 Retro Reflective sheeting

Item no 36: Give Way Sign :-Providing and fixing sign boards made out of 2mm aluminium sheet /
4mm ACP (Aluminum composite Panel); size 90 x 90 x 90 cms. equilateral triangle as per design of
IRC-67-2012. Pre treated with phospheting process & acid etching; coated with one coat of epoxy
primer and two coats of best quality epoxy paint ;reflectorised with Micro Prismatic Grade retro
refiectivesheeting of Type-11 as per ASTM D-4956 and latest [Link]; 3.6mtr long
stand post of 75 x 75 x 6mm / 65NB Circular MS Pipe as required and frame fabricated from suitable
size iron angle of 35 x 35 x 3mm; painted with bestquality epoxy coatings in black and white bends.
The details of symbol foreach board ,shall be as per theinstruction of engineer in charge. The fixing at
site shall be in 1:2:4 CC blockof size 45 x 45 x 60 Cms. for each [Link] excavation, curing
[Link] under the supervision of engineer in charge. A warranty for 10 years for the Retro
reflective sheeting from original manufacturer & a certified copy of 3 year outdoor exposure test
report from third party test lab for the product offered shall be submitted by contractor. (A) Class-C
Type-11 Retro Reflective sheeting

801 TRAFFIC SIGNS

365
 Scope

The work shall consist of the fabrication, supply and installation of ground mounted traffic signs
on roads. The details of the signs shall be as shown in the drawings and in conformity with the Code
of Practice for Road Signs, IRC:67-2010.

Materials

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

Concrete

Concrete for foundation shall be of M 15 Grade as per Section 1700 or the grade shown on the
drawings or otherwise as directed by the Engineer.

Reinforcing Steel

Reinforcing steel shall conform to the requirement of IS:1786 unless otherwise shown on the
drawing.

Bolts, Nuts, Washers

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

Plates and Supports

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

366
 Substrate

Sign panels shall be fabricated on aluminium sheet, aluminium composite panel, fibre glass
sheeting, or sheet moulding compound. Aluminum sheets used for sign boards shall be of
smooth, hard and corrosion resistant aluminium alloy conforming to IS:736-Material Designation
24345 or [Link] Composite Material (ACM) sheets shall be sandwiched construction with a
thermoplastic core of Low Density Polyethylene (LOPE) between two thick skins/sheets of
aluminium with overall thickness and 3 mm or 4 mm (as specified in the Contract), and aluminium
skin of thickness 0.5 mm and 0.3 mm respectively on both sides.
The mechanical proportion ofACM and that of aluminium skin shall conform to the requirements given in
Table 800-1, when tested in accordance with the test methods mentioned against each of them.

Table 800-1 : Specifications for Aluminium Composite Material (ACM)

S. No. Description Specification

Standard Test Acceptable Value
A Mechanical Properties of ACM
1) Peeloff strength with retro reflective ASTM 0903 Min. 4 N/mm
sheeting (Drum Peel Test)
2) Tensile strength ASTM E8 Min. 40 N/mm2
3) 0.2% Proof Stress ASTM E8 Min. 34 N/mm2
4) Elongation ASTM E8 Min.6%
5) Flexural strength ASTM 393 Min. 130 N/mm2
6) Flexural modulus ASTM 393 Min. 44.00 N/mm2
7) Shear strength with Punch shear ASTM 732 Min. 30 N/mm2
test
8 Properties of Aluminium Skin
1) Tensile strength (Rm) ASTM E8 Min. 65 N/mm2
2) Modulus of elasticity ASTM E8 Min. 70,000 N/mm2
3) Elongation ASTM E8 A50 Min. 2%

367
 4) 0.2% Proof Stress ASTM E8 Min. 10 N/mm2

Plate Thickness

Shoulder mounted ground sings with a maximum side dimension not exceeding 600 mm shall
not be less than 1.5 mm thick with Aluminium and 3 mm thick with Aluminium Composite Material. All
other signs be at least 2 mm thick with Aluminium and 4 mm thick with Aluminium Composite
Material. The thickness of the sheet shall be related to the size of the sign and its support and shall
be such that it does not bend or deform under prevailing wind and other loads. In respect of sign
sizes not covered by IRC:67, the structural details (thickness, etc.) shall be as per the approved
drawings or as directed by the Engineer.

Traffic Signs having Retro-Reflective Sheeting

General Requirements

The retro-reflective sheeting used on the sign shall consist of the white or coloured sheeting having a
smooth outer surface which has the property of retro-reflection over its entire surface.
It shall be weather-resistant and show colour fastness. It shall be new and unused and shall show
no evidence of cracking, scaling, pitting, blistering, edge lifting or curling and shall have negligible
shrinkage or expansion. A certificate of having tested the sheeting for co-efficient of retro-
reflection, day/night time colour luminous, shrinkage, flexibility, linear removal, adhesion, impact
resistance, specular gloss and fungus resistance and its having- passed these tests shall be
obtained from a Government Laboratory/Institute, by the manufacturer of the sheeting. The
retro-reflective sheeting shall be either of Engineering Grade material with enclosed lens, High
Intensity Grade with encapsulated lens or Micro-prismatic Grade retro-reflective element
material as given in Clauses 801.3.2 to 801.3.7. Guidance on the recommended application of
each class of sheeting may be taken from IRC:67.

High Intensity Grade Sheeting

368
[Link] High Intensity Grade (TypeIll)

This high intensity retro reflective sheeting shall be of encapsulated lens type consisting of
spherical glass lens, elements adhered to a synthetic resin and encapsulated by a flexible,
transparent waterproof plastic having a smooth surface or as an unmetallised micro prismatic
reflective material element. The retro-reflective surface after cleaning with soap and water and
in dry condition shall have the minimum co-efficient of retro-reflection (determined in
accordance with ASTM 0:4956-09) as indicated in Table 800-2.

Table 800-2 : Acceptable Minimum Co-efficient of Retro-Reflection for High

Intensity Grade Sheeting (Type Ill) (Encapsulated Lens Type)

(Candelas Per Lux Per Square Metre)

Observation Entrance Angle White Yellow Orange Green Red Blue Brown
Angle in in Degrees
Degrees
0.108 -40 300 200 120 54 54 24 14
0.108 +30° 180 120 72 32 32 14 10
0.2° -40 250 170 100 45 45 20 12
0.2° +30° 150 100 60 25 25 11 8.5
0.5° -40 95 62 30 15 15 7.5 5.0
0.5° +30° 65 45 25 10 10 5.0 3.5

A minimum of Coefficient of Retro-reflection (RA) cd/fclft' (cd-lx-1m2 ).

B Values for 0.1° observation angles are supplementary requirements that shall apply only when
specified by the purchaser in the Contract or order. When totally wet, the sheeting shall show
not less than 90 percent, of the values of retro reflectance indicated in above Table. At the end
of 7 years, the sheeting shall retain at least 80 percent of its original retro-reflectance.

High Intensity Micro-Prismatic Grade Sheeting (HIP) (Type IV)

This sheeting shall be of high intensity retro-reflective sheeting made of micro-prismatic retro-
reflective element material coated with pressure sensitive adhesive. The retro-reflective surface after

369
cleaning with soap and water and in dry condition shall have the minimum co- efficient of retro-
reflection (determined in accordance with ASTM 0:4956-09)as indicated in Table 800-3.

Table 800-3 :Acceptable Minimum Co-efficient of Retro-Reflection for High

Intensity Micro-Prismatic Grade Sheeting (Type IV)

(Candelas Per Lux Per Square Metre)

Observation Entrance White Yellow Orange Green Red Blue Brown

0.106 -40 500 380 200 70 90 42 25
0.106 +30° 240 175 94 32 42 20 12
0.2° -40 360 270 145 50 65 30 18
0.2° +30° 170 135 68 25 30 14 8.5
0.5° -40 150 110 60 21 27 13 7.5
0.5° +30° 72 54 28 10 13 6 3.5

A Minimum Coefficient of Retro reflection (RA) cd/fc/ft2 (cd-lx-1m2 ).

B Values for 0.1° observation angles are supplementary requirements that shall apply only when
specified by the purchaser in the contract or order. When totally wet, the sheeting shall show
not less than 90 percent of the values of retro reflection indicated in above Table . At the end
of 7 years, the sheeting shall retain at least 80 percent of its original retro-reflectance.

Prismatic Grade Sheeting

Prismatic Grade Sheeting (Type VIII)

The reflective sheeting shall be retro reflective sheeting made of micro prismatic retro reflective

370
material. The retro reflective surface, after cleaning with soap and water and in dry condition shall
have the minimum co-efficient of retro reflection (determined in accordance with ASTM E 810)as
indicated in Table 800-4.

Prismatic Grade Sheeting (Type IX)

The reflective sheeting shall be retro-reflective sheeting made of micro prismatic retro-reflective
material. The retro-reflective surface, after cleaning with soap and water and in dry condition
shall have the minimum co-efficient of retro-reflection (determined in accordance with ASTM E
810)as indicated in Table 800-5.

Table 800-4: Acceptable Minimum Co-efficient of Retro-Reflection for Prismatic Grade

Sheeting (Type VIII) (Candelas Per Lux per Square Metre)

Observation Entrance White Yellow Orange Green Red Blue Brown Fluor- Fluor- Fluor-
Angle Angle escent escent escent
Yellow Yellow Orange
/
0.1° 9 -4' 1000 750 375 100 150 45 30 800 600 300
0.1° 9 +30° 460 345 175 46 69 21 14 370 280 135
0.2° -4' 700 525 265 70 105 32 21 560 420 210
0.2° +30° 325 245 120 33 49 15 10 260 200 95
0.5° -4' 250 190 94 25 38 11 7.5 200 150 75
0.5° +30° 115 86 43 12 17 5 3.5 92 69 35

A Minimum Coefficient of Retro reflection (RA) cd/fc/fF (cd-lx-1m 2 ).

B Values for 0.1' observation angles are supplementary requirements that shall apply only
when specified by the purchaser in the contract or order. When totally wet, the

371
 sheeting shall show not less than 90 percent of the values of retro reflection indicated
in above Table. At the end of 10 years, the sheeting shall retain at least 80 percent of
its original retro-reflectance.

Table 800-5 : Acceptable Minimum Co-efficient of Retro-Reflection for Prismatic Grade

Sheeting (Type IX) (Candelas Per Lux per Square Metre)

Obser- Entrance White Yellow Orange Green Red Blue Fluorescent Fluore- Fluore-
vation Yellow/ scent scent
Green Yellow Orange
0.1° 9 -4' 600 500 250 66 130 130 530 400 200
0.1°9 +30° 370 280 140 37 74 17 300 220 110
0.2° -4' 380 285 145 38 76 17 300 230 115
0.2° +30° 215 162 82 22 43 10 170 130 65
0.5° -4' 240 180 90 24 48 11 190 145 72
0.5° +30° 135 100 50 14 27 6.0 110 81 41
1.0° -4' 80 60 30 8.0 16 3.6 64 48 24
1.0° +30° 45 34 17 4.5 9.0 2.0 36 27 14

A Minimum Coefficient of Retro reflection (RA) cd/fc/ft2 (cd-lx-1m2 ).

B Values for 0.1° observation angles are supplementary requirements that shall apply
only when specified by the purchaser in the contract or order. When totally wet, the
sheeting shall show not less than 90 percent of the values of retro reflection
indicated in above Table. At the end of 10 years, the sheeting shall retain at least 80
percent of its original retro-reflectance.

[Link] Prismatic Grade Sheeting (Type XI)

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A Retro-reflective sheeting typically manufactured as a cube corner. The reflective sheeting
shall be retro-reflective sheeting made of micro prismatic retro-reflective material. The retro-

reflective surface, after cleaning with soap and water and in dry condition shall have the
minimum co-efficient of retro-reflection (determined in accordance with ASTM E 810) as
indicated in Table 800-6.

Table 800-6 :Acceptable Minimum Co-efficient of Retro-Reflection for Prismatic Grade

Sheeting Type A (Type XI) (Candelas Per Lux per Square Metre)

Obser· Entrance White Yellow Orange Green Red Blue Brown Fluore· Fluore· Fluore-
vation Angle scent scent scent
Yellow/ Yellow Orange
Green

0.1°B -4' 830 620 290 83 125 37 25 660 500 250

0.1°B +30° 325 245 115 33 50 15 10 260 200 100
0.2° -4' 580 435 200 58 87 26 17 460 350 175
0.2° +30° 220 165 77 22 33 10 7.0 180 130 66
0.5° -4' 420 315 150 42 63 19 13 340 250 125
0.5° +30° 150 110 53 15 23 7.0 5.0 120 90 45
1.0° -4' 120 90 42 12 18 5.0 4.0 96 72 36
1.0° +30° 45 34 16 5.0 7.0 2.0 1.0 36 27 14

A Minimum Coefficient of Retro-reflection (RA) cd/fc/ft 2 (cd-lx-1m2 ).

B Values for 0.1° observation angles are supplementary requirements that shall apply only when
specified by the purchaser in the contract or order. When totally wet, the sheeting shall show
not less than 90 percent of the values of retro reflection indicated in above Table. At the end
of 10 years, the sheeting shall retain at least 80 percent of its original retro-reflectance.

801.3.5 Adhesives

The sheeting shall have a pressure-sensitive adhesive of the aggressive-tack type requiring no heat,
solvent other preparation for adhesion to a smooth clean surface, in a manner recommended
by the sheeting manufacturer. The adhesive shall be protected by an easily removable liner
(removable by peeling without soaking in water or other solvent) and shall be suitable for the type

373
of material of the base plate used for the sign. The adhesive shall form a durable bond to smooth,
corrosion and weather resistant surface of the base plate such that it shall not be possible to
remove the sheeting from the sign base in one piece by use of sharp instrument. The sheeting
shall be applied in accordance with the manufacturer's specifications.

Fabrication

Surface to be reflectorised shall be effectively prepared to receive the retro-reflective sheeting. The
aluminium sheeting shall be de-greased either by acid or hot alkaline etching and all scale/dust
removed to obtain a smooth plain surface before the application of retro-reflective sheeting. If the
surface is rough, approved surface primer may be used. After cleaning, metal shall not be handled,
except by suitable device or clean canvas gloves, between all cleaning and preparation operation
and application of reflective sheeting/primer. There shall be no opportunity for metal to come in
contact with grease, oil or other contaminants prior to the application of retro-reflective sheeting.
Complete sheets of the material shall be used on the signs except where it is unavoidable. At
splices, sheeting with pressure-sensitive adhesives shall be overlapped not less than 5 mm. Where
screen printing with transparent colours is proposed, only butt joint 'shall be used. The material
shall cover the sign surface evenly and shall be free from twists, cracks and folds. Cut-outs to
produce legends and borders shall be bonded with the sheeting in the manner specified by the
manufacturer.

Messages/Borders

The messages (legends, letters, numerals etc.) and borders shall either be screen-printed or of
cut out from durable transparent overlay or cut out from the same type of reflective sheeting
for the cautionary/mandatory sign boards. Screen printing shall be processed and finished with
materials and in a manner specified by the sheeting manufacturer. For the informatory and
other sign boards, the messages (legends, letters, numerals etc.) and borders shall be cut out from
durable transparent overlay film or cut-out from the same reflective sheeting only. Cut-outs
shall be from durable transparent overlay materials as specified by the sheeting manufacturer and
shall be bonded with the sheeting in the manner specified by the manufacturer. For screen-printed
transparent coloured areas on white sheeting, the co- efficient of retro-reflection shall not be less
than 50 percent of the values of corresponding colour in Tables 800-2 to 800-8 as applicable.
Cut-out messages and borders, wherever used, shall be either made out of retro-reflective
sheeting or made out of durable transparent overlay except those in black which shall be of non-

374
reflective sheeting or opaque in case of durable transparent overlay.

Colour for Signs

Signs shall be provided with retro-reflective sheeting and/or overlay film/ screening ink. The
reverse side of all signs shall be painted grey.

Except in the case of railway level crossing signs the sign posts shall be painted in 250 mm
side bands, alternately black and white. The lowest band next to be ground shall be in black.

The colour of the material shall be located within the area defined by the chromaticity
coordinates in Table 800-7 and comply with the luminance factor when measured as per ASTM D-
4956.

Table 800-7 : Colour Specified Limits (Daytime)

Colour 1 2 3 4 Daytime
Luminance
Factor (Y%)
X y X y X y X y Min. Max.
White 0.303 0.300 0.368 0.366 0.340 0.393 0.274 0.329 15 ..
Yellow 0.498 0.412 0.557 0.442 0.479 0.520 0.438 0.472 24 45
Green 0.026 0.399 0.166 0.364 0.286 0.446 0.207 0.771 2.5 11
Red 0.648 0.351 0.735 0.265 0.629 0.281 0.565 0.346 2.5 11
Blue 0.140 0.035 0.244 0.210 0.190 0.255 0.065 0.216 1 10
Orange 0.558 0.352 0.636 0.364 0.570 0.429 0.506 0.404 12 30
Brown 0.430 0.340 0.610 0.390 0.550 0.450 0.430 0.390 1 6
Fluorescent 0.387 0.610 0.369 0.546 0.428 0.496 0.460 0.540 60 ..
Yellow-Green
Fluorescent 0.479 0.520 0.446 0.483 0.512 0.421 0.557 0.442 45 .-
Yellow

375
Fluorescent 0.583 0.416 0.535 0.400 0.595 0.351 0.645 0.355 25 --
Orange

The colours shall be durable and uniform in acceptable hue when viewed in day light or under normal
headlights at night.

The Regulatory/Prohibitory and warning signs shall be provided with white background and red
border. The legend/ symbol for these signs shall be in black colour. The Mandatory sign shall be
provided with Blue background and white Symbol/letter.

The colours chosen for informatory or guide signs shall be distinct for different classes of roads. For
National Highways and State Highways, these signs shall be of green background and for
Expressways these signs shall be of blue background with white border, legends and word
messages.

801.3.9 Refurbishment

Where existing signs are specified for refurbishment, the sheeting shall have a semi-rigid
aluminium backing or materials as per Clause 801.2.5, pre-coated with aggressive-tack type
pressure sensitive adhesive. The adhesive shall be suitable for the type of material used for the sign
and should thoroughly bond with that material.

Sizes of Letters

Letter size should be chosen with due regard to the speed, classification and location of the road,
so that the sign is of adequate size for legibility but without being too large or obtrusive. The size
of the letter, in terms of x-height, to be chosen as per the design speed is given in Table 800-8.

Table 800-8 : Acceptable Limits for Sizes of Letters

376
 Design Minimum 'x' Height Minimum Sight Distance/ Maximum Distance
Speed of the Letters Clear Visibility Distance (m) from Centre Line (m)
(Km./hr.) (mm)
40 100 45 12
50 125 50 14
65 150 60 16
80 250 80 21
100 300 90 24
120 400 115 32

The thickness of the letters and their relation to the x-height, the width, the heights are
indicated in Table IV (a) of the Annexure-4 of IRC:67 to facilitate the design of the informatory signs
and definition plates.

For advance direction signs on non-urban roads, the letter size ('x' height) should be minimum
of 150 mm for Expressway, National and State Highways and 100 mm for other roads. In case of
overhead signs, the size ('X' height) of letters may be minimum 300 mm. Thickness of the letter
could be varied from 1/6 to 1/5 of the letter 'x' size. The size of the initial uppercase letter shall be
1-1/3 times x-height. In urban areas, letter size shall be 100 mm on all directional signs. For easy
and better comprehension, the word messages shall be written in upper case letters only.

Letter size on definition plates attached with normal sized signs should be 100 mm or 150 mm. In
the case of small signs, it should be 100 mm. Where the message is long, as for instance in "NO
PARKING" and "NO STOPPING" signs, the message may be broken into two lines and size of letters
may be varied in the lines so that the definition plate is not too large. The lettering on definition
plates will be all in upper case letters.

Warranty and Durability

The Contractor shall obtain from the manufacturer a ten year warranty for satisfactory field
performance including stipulated retro-reflectance of the retro-reflective sheeting of micro-
prismatic sheeting and a seven-year warranty for high intensity grade and submit the same to the
Engineer. The warranty shall be inclusive of the screen printed or cut out letters/legends and their
bonding to the retro-reflective sheeting. The Contractor/supplier shall also furnish the LOT
numbers and certification that the signs and materials supplied against the assigned work meets all

377
 the stipulated requirements and carry the stipulated warranty and that the contractor/supplier is
the authorized converter of the particular sheeting.

All signs shall be dated during fabrication with indelible markings to indicate the start of warranty. The
warranty shall also cover the replacement obligation by the sheeting manufacturer as well as
contractor for replacemenUrepair/restoration of the retro-reflective efficiency.

A certificate in original shall be given by the sheeting manufacturer that its offered retro-
reflective sheeting has been tested for various parameters such as co-efficient of retro-
reflection, day/night time colour and luminance, shrinkage, flexibility, linear removal, adhesion, impact
resistance, specular gloss and fungus resistance; the tests shall be carried out by a Government
Laboratory in accordance with various ASTM procedures and the results must show that the
sheeting has passed the requirements for all the above mentioned parameters. A copy of the test
reports shall be attached with the certificate.

Installation

The traffic signs shall be mounted on support posts, which may be of Gl pipes conforming to IS:1239,
Rectangular Hollow Section conforming to IS:4923 or Square Hollow Section conforming to IS:3589.
Sign posts, their foundations and sign mountings shall be so constructed as to hold these in a
proper and permanent position against the normal storm wind loads or displacement by
vandalism. Normally, signs with an area up to 0.9 sq.m shall be mounted on a single post, and for
greater area two or more supports shall be provided. Post-end(s) shall be firmly fixed to the
ground by means of properly designed foundation. The work of foundation shall conform to
relevant Specifications as specified.

All components of signs (including its back side) and supports, other than the reflective portion and
G.I. posts shall be thoroughly de-scaled, cleaned, primed and painted with two coats of epoxy/
fibre glass/ powder coated paint. Any part of support post below ground shall be painted with
protective paint.

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

Measurement for Payment

378
 The measurement of standard cautionary, mandatory and information signs shall be in
numbers of different types of signs supplied and fixed, while for direction and place
identification signs, these shall be measured by area in square metres.

Rate

The Contract unit rate shall be payment in full for the cost of making the road sign, including all
materials, installing it at the site furnishing of necessary test certificates, warranty and
incidentals to complete the work in accordance with these Specifications.

Item no 35: Providing and erecting a "Thrie" W - metal beam crash barrier comprising of 3 mm thick
corrugated sheet metal beam rail, 85 cm above road/ground level, fixed on ISMC series channel
vertical post, 150 x 75 x 5 mm spaced 2 m centre to centre, 0.85 m high above road level. The vertical
post fixing at site with base plate of size 240 mm x 320 mm x 16 mm fixed with nut and bolts on kerb
for each post etc. complete.. All steel parts and fitments to be galvanised by hot dip process, all
fittings to confirm to IS:1367 and IS:1364, metal beam rail to be fixed on the vertical Post with a
spacer of channel section 150 x 75 x 5 mm, 550 mm long complete as per Morth Specification clause
810 including butt welding to all nuts & bolts & including 3 mm ACM type reflector 100 mm wide &
4.5 m long, type -4 class B High intensity Grade Sheeting as per IRC 67:2012 etc. complete as per
instruction of Engineer In Charge. Also radium red/yellow colour strip of size 100 x 300 mm shall be
fixed on vertical front side of post for better night visibility. The spacer,post, thrie beam raill shall be
Cold roll formed & galvanized with 550 gm/ square meter.

811 CRASH BARRIERS

Scope

The work shall consist of construction, provision and installation of crash barriers at locations
as shown in the drawing or as directed by the Engineer. The type of the crash barrier shall be
as specified in the Contract.

379
 Concrete Crash Barrier

Materials

All materials shall conform to Section 1000 Materials for Structures as applicable, and
relevant Clauses in Section 1600 shall govern the steel reinforcement.

The minimum grade of concrete shall be M25.

Construction Operations

The concrete barriers shall be either (i) precast or (ii) constructed by the "cast-in-place
with fixed forms" method or the "extrusion or slip form" method or a combination thereof at the
Contractor's option with the approval of the Engineer. Where "extrusion or slip form" method
is adopted full details of the method and literature shall be furnished.

The concrete barrier may be precast in lengths upto 6 m depending upon the feasibility of
transport and lifting arrangements. Longitudinal roadside concrete barrier shall be placed
on adequate bedding as detailed in the drawing. The top and exposed faces of the
barriers shall conform to the specified tolerances, as defined in Clause [Link], when
tested with 3 m straight edge, laid on the surface.

An expansion joint with pre-moulded asphalt filler board shall be provided at the junctions
of crash barrier on structure and crash barrier on the fill. The crash barrier on the fill shall

380
Traffic Signs, Markings and other Road Appurtenances Section 800

be constructed in pieces of length not exceeding 20 m, with pre-moulded asphalt filler board
joints.

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

Tolerance

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

End Treatment

The road side concrete barrier shall be provided with an end treatment by tapering the height
of terminating end within a length of 8 m to 9 m. Median crash barrier shall be terminated
sufficiently away from the median opening. It shall be provided with an end treatment, which
shall be obtained by tapering the height of terminating end of the median barrier within a
length of 8 m to 9 m.

Measurement for Payment

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

Rate

381
The Contract unit rate shall include full compensation for furnishing all labour, materials
including steel for reinforcement tools, equipment and incidental costs necessary for doing
all the work involved in constructing the concrete barrier complete in place in all respects as
per these Specifications.

Metal Beam Crash Barrier

Materials

Metal beam rail shall be corrugated sheet steel beams of the class, type, section and
thickness indicated on the drawings. Railing posts shall be made of steel of the section,
weight and length as shown on the drawings. All complete steel rail elements,

382
terminal sections, posts, bolts, nuts, hardware and other steel fittings shall be galvanized. All
elements of the railing shall be free from abrasions, rough or sharp edges and shall not be
kinked, twisted or bent.

The "W' beam type safety barrier shall consist of a steel post and a 3 mm thick "W"
beam rail element. The steel post and the blocking out spacer shall both be channel section
of 75 mm x150 mm & size 5 mm thick. The rail shall be 70 em above the ground level
and posts shall be spaced 2 m center-to-center. Double "W' beam barrier shall be as
indicated in IRC:5-1998.

The thrie beam safety barrier shall have posts and spacers similar to the ones mentioned
above for "W" beam type. The rail shall be placed at 85 em above the ground level.

The "W" beam, the thrie beam, the posts, spacers and fasteners for steel barriers shall
be galvanized by hot dip process (zinc coated, 0.55 kg per square metre; minimum single
spot) unless otherwise specified. The galvanizing on all other steel parts shall conform to the
relevant IS Specifications. All fittings (bolts, nuts, washers) shall conform to the IS:1367 and
IS:1364. All galvanizing shall be done after fabrication.

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

Construction Operations

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

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

Splices and end connections shall be of the type and designs specified or shown on the

362
plans and shall be of such strength as to develop full design strength of the rail elements.

Installation of Posts

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

363
Traffic Signs, Markings and other Road Appurtenances Section 800

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

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

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

364
Steel Reinforcement Section 1600

[Link] Posts for metal beam guardrail on bridges shall be bolted to the structure
as detailed on the plans. The anchor bolts shall be set to proper location and elevation with
templates and carefully checked.

Erection

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

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

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

End Treatment for Steel Barrier

End treatments shall from an integral part of safety barriers which should not spear, vault
or roll a vehicle for head-on or angled impacts. The two end treatments recommended
for steel barriers are ''Turned-down-guardrail" and "Anchored in back slope", as shown on
the drawings or as directed by the Engineer.

Tolerance

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

Measurements for Payment

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

527
 Steel Reinforcement Section 1600

Item No 48: Providing and fixing pre-cast concrete kerb stone of gray

cement based concrete block 30cm length,30cm height

and 15cm thick of M200 grade concret as per approved

design and including excavation for fixing in proper line

and level,filling the joint with C:M 1:3 (1cement:3fine

sand) etc complete.

This item shall be consist of precast Concrete kerb stone of grey cement based concrete block 30 cm

length, 30 cm height and 15 cm thick of M-250 grade concrete as per approved design including

excavation for fixing in proper line and level, filling the joint with C.M. 1:3 (1 cement : 3 fine sand) etc.

complete.

Kerb block shall be of size 30 cm x 30 cm x 15 cm thick of M-250 grade and joints shall be filled

with C.M. 1:3 (1 cement : 3 fine sand).

528
 Steel Reinforcement Section 1600

The Rate and Mode of measurement shall be as per completed item including all labour &

materials involved to execute this item as per Rmt. basis. Contract rate shall be for a unit of one Rmt.

basis.

Item No :49 Providing and fixing pre-cast Rubber Dye / steel Dye

inter locking concrete block 60mm thick with grade of

concrete M300 pnumatic compressed / vibrated

mechanically and as per approved design Confirming to

IS 15658 : 2006 including 35 mm Sand layer for levelling

and filling the joint with sand in proper line and level as

per guidlines of IRC : SP 63-2018 etc. Complete.

1.0 Materials

1.1 For materials of the concrete Mix Design followed etc. the item No.5.8.3 / page No.40 of the
general technical specification for building works booklet must be followed with all necessary
material related to mix Design and concrete Mix shall be M30 in place of M25.

2.0 Workmanship

2.1 interlocking paving block including preparing sub base 5cmThick sand bedding & laying
interlocking blocks 100mm thick of C.C. M- 30 super refractive hydraulically pressed of
approved shape and size and fixing with plate vibrator & providing and fixing outer C.C. M- 15
precast supporting blocks of size 0.10m X 0.30m including fixing and filling the joints in C.M.
1:3 as per detail drawing etc. complete..

3.0 Mode of Measurement and Payment

3.1 The interlocking paving block shall be measured in “Square Meter” basis with complete Item
include cost of materials including necessary reinforcement, labour, plant, form work including
fixing the paver block in position etc. complete. as specified.

529
 Steel Reinforcement Section 1600
tem no 43: Providing and fixing in position FE 500D TMT bar reinforement including cutting, bending
and tying complete as per detailed drawings. (A) R.C.C. Kerb. (B)

R.C.C. Footpath.(C) R.C.C. Approch slab.(D) Wearing Coat.

Item No 61:Providing and laying in position FE 500D TMT bar reinforcement including cutting,
bending, hooking and tying complete as per detailed drawings for the following.(A) Piers (B)
Abutments (C) R.C.C. Returns

1601 DESCRIPTION

This work shall consist of furnishing and placing coated or uncoated mild steel or high
strength deformed reinforcement bars of the shape and dimensions shown on the drawings
and conforming to these Specifications or as approved by the Engineer.

1602 GENERAL

Steel for reinforcement shall meet the requirements of Section 1000 of these
Specifications.

Reinforcements may be either mild steel or high strength deformed bars. They may be
uncoated or coated with epoxy.

1603 PROTECTION OF REINFORCEMENT

Uncoated reinforcing steel shall be protected from rusting or chloride contamination.

Reinforcements shall be free from rust, mortar, loose mill scale, grease, oil or paints. This
may be ensured either by using reinforcement fresh from the factory or by thoroughly
cleaning it using any suitable method such as sand blasting, mechanical wire brushing etc.,
as directed by the Engineer. Reinforcements shall be stored above the ground in a clean
and dry condition, on blocks, racks or platforms and shall be suitably marked to facilitate
inspection and identification.

530
Steel Reinforcement Section 1600

Portions of uncoated reinforcing steel and dowels projecting from concrete, shall be protected
within one week after initial placing of concrete, with a brush coat of neat cement mixed
with water to a consistency of thick paint. This coating shall be removed by lightly tapping
with a hammer or other tool not more than one week before placing of the adjacent pour of
concrete. Coated reinforcing steel shall be protected against damage to the coating. If the
coating on the bars is damaged during transportation or handling and cannot be repaired, the
same shall be rejected.

In case of fusion bonded epoxy coated reinforcement or hot dipped galvanized bars used,
reference shall be made Clause 1010.3.2 of Section 1000 of these specifications.

1604 BENDING OF REINFORCEMENT

Bar bending schedule shall be furnished by the Contractor and got approved by the Engineer
before start of work.

Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar
Bending Schedules.

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Section 1600 Steel Reinforcement
Steel Reinforcement Section 1600

Bars shall be bent cold to the specified shape and dimensions or as directed by the Engineer
using a proper bar bender, operated by hand or power to obtain the correct shape and radii
of bends.

Bars shall not be bent or straightened in a manner that will damage the parent material or
the coating.

Bars bent during transport or handling shall be straightened before being used on work. They
shall not be heated to facilitate straightening.

1605 PLACING OF REINFORCEMENT

a) The reinforcement cage should generally be fabricated in the yard at

ground level and then shifted and placed in position. The reinforcement
shall be placed strictly in accordance with the drawings and shall be
assembled in position only when the structure is otherwise ready
for placing of concrete. Prolonged time gap between assembling of
reinforcement and casting of concrete, which may result in rust formation
on the surface of the bars, shall not be permitted.

b) Reinforcement bars shall be placed accurately in position as shown

on the drawings. The bars, crossing one another shall be tied together
at every intersection with binding wire (annealed), conforming to
IS:280 to make the skeleton of the reinforcement rigid such that the
reinforcement does not get displaced during placing of concrete, or
any other operation. The diameter of binding wire shall not be less than
1 mm.

c) Bars shall be kept in position usually by the following methods:

i) In case of beam and slab construction, industrially produced

polymer cover blocks of thickness equal to the specified cover,
shall be placed between the bars and formwork, subject to
satisfactory evidence that the polymer composition is not harmful
•
to concrete and reinforcement. Cover blocks made of concrete
may be permitted by the Engineer, provided they have the same
strength and specification as those of the member.

ii) In case of dowels for columns and walls, the vertical reinforcement
532by means of timber templates with slots cut
shall be kept in position
in them accurately, or with cover blocks tied to the reinforcement.
Timber templates shall be removed after the concreting has
progressed upto a level just below their location.
Steel Reinforcement Section 1600
iii) Layers of reinforcements shall be separated by spacer bars at
approximately one metre intervals. The minimum diameter of

528

533
Steel Reinforcement Section 1600

spacer bars shall be 12 mm or equal to maximum size of main

reinforcement or maximum size of coarse aggregate, whichever
is greater. Horizontal reinforcement shall not be allowed to sag
between supports.

iv) Necessary stays, blocks, metal chairs, spacers, metal hangers,

supporting wires etc. or other subsidiary reinforcement shall be
provided to fix the reinforcement firmly in its correct position.

v) Use of pebbles, broken stone, metal pipe, brick, mortar or wooden

blocks etc., as devices for positioning reinforcement shall not be
permitted.

d) Bars coated with epoxy shall be placed on supports that do not damage
the coating. Supports shall be installed in a manner such that planes of
weakness are not created in hardened concrete. The coated reinforcing
steel shall be held in place by use of plastic or plastic coated binding
wires especially manufactured for the purpose. Refer Section 1000 of
these Specifications for other requirements.

e) Placing and fixing of reinforcement shall be inspected and approved by

the Engineer before concreting is commenced.

1606 BAR SPLICES

Lapping

All reinforcement shall be furnished in full lengths as indicated on the drawing. No splicing
of bars, except where shown on the drawing, shall be permitted without approval of the
Engineer. The lengths of the splice shall be as indicated on drawing or as approved by the
Engineer. Where practicable, overlapping bars shall not touch each other, and shall be kept
apart by 25 mm or 1.25 times the maximum size of coarse aggregate, whichever is greater. If
this is not feasible, overlapping bars shall be bound with annealed steel binding wire not less
than 1 mm diameter and twisted tight in such a manner as to maintain minimum clear cover
to the reinforcement from the concrete surface. Lapped splices shall be staggered or located
at points along the span where stresses are low.

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Steel Reinforcement Section 1600
Welding

Splicing by welding of reinforcement will be permitted only if detailed on the drawing or

approved by the Engineer. Weld shall develop an ultimate strength equal to or greater
than that of the bars connected.

While welding may be permitted for mild steel reinforcing bars conforming to IS:432,
welding of deformed bars conforming to IS:1786 shall in general be prohibited. Welding
may be permitted in case of bars of other than Fe 240 grade including special

530
 Steel Reinforcement Section 1600

welding grade of Fe 415 grade bars conforming to IS:1786, for which necessary chemical
analysis has been secured and the carbon equivalent (CE) calculated from the chemical
composition using the formula :

CE = c + Mn + Cr+Mg+V + Ni+Cu
6 5 15

is 0.4 or less.

1606.2.3 The method of welding shall conform to IS:2751 and IS:9417, any
supplemental specifications and Clause 1904.8 of these Specifications to the satisfaction of
the Engineer.

Welding may be carried out by metal arc welding process. Oxy-acetelene welding shall not
be permissible. Any other process may be used subject to the approval of the Engineer and
necessary additional requirements to ensure satisfactory joint performance. Precautions on
overheating, choice of electrode, selection of correct current in arc welding etc., should be
strictly observed.

All bars shall be butt welded except for smaller diameter bars (diameter of less than
20 mm) which may be lap welded. Single-V or Double-V butt joints may generally be used.
For vertical bars single bevel or double bevel joints may be used.

Welded joints shall be located well away from bends and shall be not less than twice the bar
diameter away from a bend.

Generally, shop welding in controlled conditions is to be preferred, where feasible. Site

welding where necessary shall, however, be permitted when the facilities, equipment,
process, consumables, operators and welding procedure, are adequate to produce and
maintain uniform quality at par with that attainable in shop welding, to the satisfaction of the
Engineer.

Joint welding procedures which are to be employed shall invariably be established by a

procedure specification. All welders and welding operators to be employed shall be qualified
by tests prescribed in IS:2751. Inspection of welds shall conform to IS:822 and destructive or
non-destructive testing may be undertaken when deemed necessary. Joints with weld defects
detected by visual inspection or dimensional check inspection, shall not be accepted.

Suitable means shall be provided for holding the bars securely in position during welding.
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 Steel Reinforcement Section 1600
It must be ensured that no voids are left in welding. When welding is done in two or three
stages, the surface shall be cleaned properly after each stage. Bars shall be cleaned of all
loose scale, rust, grease, paint and other foreign matter before carrying out welding. Only
competent and experienced welders shall be employed on the work with the approval of the
Engineer. No welding shall be done on coated bars.

M.S. electrodes used for welding shall conform to IS:814.

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Steel Reinforcement Section 1600

Welded joints shall preferably be located at points where steel will not be subject to
more than 75 percent of the maximum permissible stresses and welds so staggered that at
any one section, not more than 20 percent of the bars are welded.

Specimens of welded pieces of reinforcement taken from the site, shall be tested. The
number and frequency of tests shall be as directed by the Engineer.

Mechanical Couplers and Anchorages

Mechanical Couplers

Bars may be joined with approved patented mechanical devices as indicated on the drawing
or as approved by the Engineer e.g. by special grade steel sleeves swaged on to bars in end
to end contact or by screwed couplers. In case such devices are permitted by the Engineer,
they shall develop at least 125 percent of the characteristic strength of the reinforcement
bar.

Anchorages

Bars may be anchored with approved patented mechanical anchorages as indicated on the
drawing or as approved by the Engineer. The anchorages shall be connected to the reinforcing
bar by the use of taper thread system. The anchorage shall be capable of developing the
characteristic strength of reinforcement without damage to concrete and shall have sufficient
diameter and width to develop adequate shear cone strength. The connection shall develop
125% of the characteristic strength of reinforcement bar.

1607 TESTING AND ACCEPTANCE

The material shall be tested in accordance with relevant IS specifications and necessary
test certificates shall be furnished. Additional tests, if required, will be got carried out by the
Contractor at his own cost.

The supply, fabrication and placing of reinforcement shall be in accordance with these
Specifications and shall be as checked and accepted by the Engineer.

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Manufacturer's test certificate regarding compliance with Indian Standards for each lot of steel,
shall be obtained and submitted to the Engineer. If required by the Engineer, the Contractor
shall carry out confirmatory tests in the presence of a person authorized by the Engineer.
Cost of these tests shall be borne by the Contractor. The sampling and testing procedure
shall be as laid down in IS:1786. If any test piece selected from a lot fails, no re-testing shall
be done and the lot shall be rejected.

1608 MEASUREMENT FOR PAYMENT

Reinforcement shall be measured in length including hooks, if any, separately for different
diameters as actually used in work, excluding overlaps. From the length so measured, the

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weight of reinforcement shall be calculated in tonnes on the basis of IS:1732. Wastage,
overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed steel
wire or other methods for binding and placing, shall not be measured and cost of these items
shall be deemed to be included in the rates for reinforcement.

1609 RATE

The contract unit rate for coated/uncoated reinforcement shall cover the cost of material,
royalty, fabricating, transporting, storing, bending, placing, binding and fixing in position as
shown on the drawings and as per these Specifications and as directed by the Engineer,
including all labour, equipment, supplies, incidentals, sampling, testing and supervision.

The unit rate for coated reinforcement shall be deemed to also include cost of all material,
labour, tools and plant, royalty, transportation and expertise required to carry out the coating
work as well as sampling, testing and supervision required for the work.

1. Payment Shall be Made on KG BASIS

Deputy Executive Engineer

R&B Sub Division

Anjar-Kutch

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