TECHNICAL SPECIFICATION (TS)

Table of Clauses

200 Materials .............................................................................................................40

210 Wire Ropes......................................................................................................40
2 220 Blasting Materials ...........................................................................................40
2 300 Steel Work ............................................................................................................40
310 Supply and Fabrication of Steel Parts ..............................................................42
320 Supply of Thimbles ..........................................................................................42
330 Supply of Bulldog Grips ..................................................................................43
340 Miscellaneous Supply .....................................................................................43
400 Transportation

500 Construction ..............................................................................................................45

510 Site Clearance .................................................................................................45
520 All Excavation..................................................................................................45
530 Foundation Excavation ...................................................................................45
540 Construction of Gabion ....................................................................................46
550 Concrete Works............................................................................................... 47
560 Masonry and Mortar Work ...............................................................................50
570 Erection and Finishing work .............................................................................51
580 Surrounding Works ........................................................................................ 51
590 Site Installation and Supervision ......................................................................51
600 Miscellaneous Works ................................................................................................52
610 Gabion Works ...............................................................................................52
620 Concrete and Masonry Work .........................................................................52
630 Pretensioning of Wire Ropes.......................................................................... 53
640 Walkway Adjustments.....................................................................................53
650 Finishing Works .............................................................................................53
660 Other Miscellaneous .........................................................................................54
 Technical Specification (TS)
200 MATERIALS
210 Wire Ropes
Wire Ropes will be provided by the Employer form its store. As the wire ropes are procured
centrally, the specification and manufacturer’s quality assurance has already been verified. The
concerned contractor/fabricator, however, shall verify the correct dimension in diameter, length,
properly cut ends, and avoid the kinks while receiving the cable from the said store according to the
approved check list.

220 Blasting Materials

As these materials are sensible, destructive, and requires special care under security and expert
supervision during handling, storing and its use. They are procured under expert guidance and stored
in Military facilities, wherever possible, their specification as per the requirement has been earlier
verified and should not be of great concern to the Contractor. Its handling shall be strictly under the
HMG law and regulations.
300 STEEL WORK
Bid and actual fabrication of the bridge parts shall be based on the "Terms of Steel works" given
below in addition to relevant ISI Codes. In case of discrepancies between the two the "Terms of
Steelworks" shall prevail.
Safety and health provisions shall be made according to IS: 818-1968, and shall entirely be the
Contractor/ Fabricator’s responsibility.
The following “Terms of steel works” has to be strictly followed while performing the steel parts
fabrication work.
a) Straightening
All materials shall be straight and if necessary, before being worked shall be straightened
and/or flattened by pressure, unless required to be of curvilinear form and shall be free from
twists.

b) Cutting
Cutting may be affected by shearing, cropping or sawing. Gas cutting by mechanically
controlled torch is permitted for mild steel only. Gas cutting of high tensile steel is also
permitted provided special care is taken to leave sufficient metal to be removed by machining
so that all metal that has been hardened by flame is removed. No loads shall be transmitted
into metal (except welded joints) through a gas cut surface.

c) Holing and Punching

Holes for bolts or pins shall be drilled (not to be formed by gas cutting). Punching may be
permitted for materials with thickness < 14mm, provided the holes are punched 3 mm less in
diameter than the required size and reamed after punching to the full diameter. When holes
are drilled or punched in one operation through two or more separable parts, these parts shall
be separated after drilling or punching and the burrs removed. To obtain uniformity the use of
templates and jigs is mandatory for holing.

d) Assembly
The component parts shall be assembled in such a manner that they are neither twisted nor
otherwise damaged and shall be so prepared that the specified cambers, if any, are provided.

e) Bolting
Where necessary washers shall be tapered or otherwise suitably shaped to give the heads of
nuts and bolts a satisfactory bearing. The threaded portion of each bolt shall project through
the nut at least two threads. In all cases where the full bearing areas of the bolt is to be
developed, the bolt shall be provided with a washer of sufficient thickness under the nut to
avoid any threaded portion of the bolt being within the thickness of the parts bolted together.
Threading of rods and holes shall be done by machines.
f) Welding
Welding shall be in accordance with any of the following standards as appropriate, and shall
be conducted by appropriately qualified welders:
IS: 816-1989 : Code of practice for use of metal arc welding for general
construction in mild steel.
IS: 823-1964 & : Code of practice for use of welding in bridges and structures
IS: 1024-1979 : subject to dynamic loading.
If there are any new editions of Indian Standard those should be used as references. The use
of templates and jigs is mandatory for welding of assembly. Following special requirement in
conjunction with galvanization has to be made. Sections should have corners cropped to allow
free flow of zinc during galvanization.
Avoid narrow gaps between plates. Overlapping surfaces and back to back angles and
channels should be avoided. Where small areas are unavoidable edges should be sealed by a
continuous pore free weld to prevent penetration of pickle acids.

g) LSTB Standard Designs

The LSTB Standard Design and Drawings are integral parts of these technical specifications.
Details for the steel works can be found in the set of Standard Steel Drawings, which will be
made available to the Contractor after the contract is signed / awarded.

h) Quality Requirements, Quality Control and Quality Assurance (Guarantee)

The quality control of the raw materials acquired, fabrication process, and that of ready made
product is the responsibility of the prime contractor/fabricator, who should guarantee that all
raw materials are of standard quality according to Indian Standards Institution and to the
specifications given in the "Terms of Steel works" and fabrication of the bridge parts are
correct according to LSTB Design and Drawings. The cost for all damages due to use of low
quality materials has to be borne by the contractor/fabricator. At the time of delivery the parts
and materials shall have to be free from any defects in material or workmanship in all respects
and shall remain reasonably perfect till the end of maintenance period when a final check shall
be carried out.
If any mistakes in the LSTB Designs and Drawings are found by the workshop, The
Employer’s Technical Section has to be informed immediately in writing. The changes in steel
profile have to be done only with written permission from the Employer in case of proven
non-availability of certain profiles in the market.
The cost of other materials thus proposed and used will be fixed according to their respective
weight and the lower among the bid price and official cost of the Employer.

i) Inspection, Tests and Final Check

The Contractor/Fabricator shall coordinate to provide access and other facilities for the
inspection and, if required, tests of the works at any/or all stages during fabrication of the steel
parts. Unless otherwise agreed this inspection should be carried out at the place of fabrication.
The inspection shall be facilitated by a properly accredited person (quality control manager)
available at the fabricator’s floor during all working hours together with a complete set of
drawings and any further instructions which may have been issued.
Following steel parts have to be in assembled form during such inspection: The parts shall be
assembled after completion of the galvanization, on a flat, level and hard top place. Once
dismantled, any damage to the galvanization of the steel parts has to be rectified before
delivery.
• All anchorage parts
• Walkway deck with minimum of four cross-beams in assemblage
• Both towers, complete
• Windguy stay strut
• Complete truss
• Clamps and turnbuckles
 Such inspection shall be made prior to delivery and shall be conducted so as not to interfere
unnecessarily with the operation of other work. Such inspections are supplementary and
intended to clear the delivery only, and shall not be considered as a final acceptance.
The final check of all steel parts will be conducted along with the final check of the bridge
and the discrepancies found during such final check have to be rectified by the
Contractor/Fabricator at its own cost. On a default situation, such works shall be conducted by
the Employer and the cost incurred for such works shall be made a liability in the
Contractor/Fabricator’s account (either from its retention money or from other payments
and/or their property according to the prevailing rules and regulations).
All gauges and templates, measuring instruments etc. necessary to satisfy the inspector shall
be supplied by the manufacturer. The inspector may at his discretion check the test results
obtained at the manufacturers works by independent tests and should the material so tested be
found to be unsatisfactory, the costs of such tests shall be borne by the manufacturer, and, if
satisfactory, the costs shall be borne by the Employer. In any case the quality assurance of
Principal Manufacturer has to be made available by the Contractor/Fabricator, whenever
required by the Employer.
j) Storing, handling and protection of steel parts (specially Threads)
All structural and reinforcement steel shall be stored and handled without subjecting them to
excessive stresses and damage. The threaded parts including anchorage rods, clamps,
suspenders etc. have to be protected with grease and jute immediately after completion.
k) Labeling, Packing and delivery
Each member (or set of members) has to be labeled clearly indicating both the drawing
number and the part number corresponding to the steel-part list and the drawing number
provided by the Employer, but only after galvanization.
Straight bars and plates shall be bundled. All bolts, nuts, washers and other small and loose
parts shall be packed in cases or strong bags and labeled in order to prevent damage or
distortion during transportation. The costs of packing and labeling shall be included in the
bids. The Wire mesh netting has to be delivered in bundles. Each transport unit shall not
exceed 45 kg in weight. For each delivery the workshop has to prepare a detailed list of the
bridge parts to be delivered, containing the drawing numbers, part numbers, description of
parts, quantities and weights.

310 Supply and Fabrication of Steel Parts

311 Structural Steel
Structural steel supplied by the workshop shall comply with the requirements of IS: 226-1975,
specification for Structural Steel (Standard Quality). The dimensions for hot rolled materials are
specified in IS: 800-1984 & 808-1989 (General construction in steel). Steel grade shall be standard
quality FE 410, and should have following properties:
Yield stress  250 N/mm2
Tensile strength  410 N/mm2
Elongation  23%
Permissible tolerance of physical dimension =  2.5%
312 Reinforcement Steel
Reinforcement steel supplied by the workshop shall be ribbed torsteel with high yield strength
deformed bar of grade FE 415 confirming to IS: 1786-1985. All reinforcement shall be clean and
free from loose mill-scales, dust, loose rust and coats of paint, oil or other coatings which may
destroy or reduce bond. All reinforcement steel shall be cold bent. Points for anchor rods shall be
formed by grinding. Joining of reinforcement steel bars by welding is prohibited.

320 Supply of Thimbles

Thimbles supplied by the workshop shall conform to the standard specifications of Thimbles (IS:
2315-1978). The workshop is responsible that all thimbles can be fitted to the provided pins, steel
parts etc. Thimbles should be hot dip galvanized with minimum zinc coat of 40m.
330 Supply of Bulldog Grips
Bulldog grips supplied by the workshop shall confirm to the standard specifications of Bulldog grips
(IS: 2361-1970). In addition it also should fulfill the following requirements:
The bridges must be drop-forged and suitably scored to grip a round strand rope of right hand lay
having six strands. Bridge, U-bolts and nuts should be hot dip galvanized with minimum zinc coat of
40m. The thread of U-bolt and nuts on it should withstand specific torque.
The bulldog grips should have minimum grip strength of :
13mm  2.7 tone, 26mm  6.6 tone, 32mm  8.3 tone,
36mm  9.0 tone, 40mm  9.7 tone,
Note: Thimbles, bulldog grips, nuts, bolts and washers have to be galvanized according to IS:
2629-1966, and Recommended practice for Hot-dip Galvanizing of Iron and Steel.
340 Miscellaneous Supply
341 Wire mesh Netting for LSTB Bridge
The wire used for fabrication of wire mesh netting shall be of 10 SWG (3.15 mm), conforming to IS:
280-1978, heavy coat galvanized according to IS: 4826-1979 (hot dip galvanized, minimum zinc
coating of 270 gm/m2 and should pass uniformity of zinc coat and adherence test). In addition, G.I.
wire should have tensile strength of 380-500N/mm2. The meshes shall be of chain link type, mesh
size 60 x 60 mm. The width shall be 1.30 m for suspended bridge and 1.2 m for suspension bridge.

342 Sign Board

Only if necessary.

343 Bolts, Nuts & Washers

Bolts, nuts, & washers shall confirm the standard specification of bolts, screws, nuts & washers (IS:
1363-1984 for hexagon head bolts) / (IS: 1367-1979/1980 conditions for threaded fasteners) / (IS:
6610-1972 for heavy washers) / (IS: 5369-1975 for plane & lock washers) /( IS: 5372-1975 for taper
washers). Bolts, nuts & washers shall be hot dip galvanized unless otherwise stated.

351 Hot Dip Galvanization of Steel Parts

Galvanizing of steel parts shall be executed in accordance with IS: 2629-1966 (Recommended
Practice for Hot-Dip Galvanizing of Iron & Steel) and IS 4759-1984 (specification for hot-dip zinc
coating on structural steel).

a) Galvanization Process
Galvanizing should follow the process as below :
Preparatory Alkaline Cleaning (Rinsing) Acid
work cleaning with water Bath

Cooling with Galvanization Dry Pre-flux Cleaning (Rinsing)

water treatment with water

• Preparatory work
All welding slag should be removed from the steel parts to be galvanized. Acid traps should
be avoided.
• Alkaline cleaning
Rust, oil and other contaminants should be removed from the steel by preliminary treatment
with Alkaline cleaning in Sodium Hydroxide Solution of 10 ~ 15% concentration.
The concentration of the solution should be monitored at regular intervals and adjusted
accordingly to have good cleaning effect.
• Rinsing
After Alkaline cleaning, steel should be flushed with running water.
• Acid Bath
The preliminary treated steel is then cleaned by Acid Bath in Hydrochloric Acid Solution of
50% concentration.
 During the operation, close control of acid content in the solution is necessary. It is done by
testing for acid (PH value = 1 to 3, measured by PH meter) and iron contents at regular
intervals. The strength of the solution should be maintained by periodic addition of fresh
concentrated acid. If the iron content in the solution is more than 100g/liter (density measured
by hydrometer, maximum permissible value = 1.2), it should be changed by the new fresh
solution.
• Rinsing
After Acid Bath steel should be flushed with running water.
• Pre-flux treatment
Acid bathed steel is dipped in a solution of Zinc Ammonium Chloride (ZnCl 23NH4Cl) of 20 ~
40% concentration. This solution is prepared by mixing 45% of Zinc Chloride (Zncl 2) + 55%
of Ammonium Chloride (NH4Cl).
The concentration of solution should be controlled at regular intervals. For this specific
gravity of the solution is maintained (Hydrometer reading in range of 1.1 to 1.15 ) by adding
required quantities of pre-flux chemicals in proportions.
• Dry
After pre-flux treatment, steel is dried for galvanization.
• Galvanization
The treated steel is dipped into the molted Zinc (zinc bath). Temperature of the molted Zinc
should be maintained within the range of 4500 C to 4700 C. Appropriate dipping time also
should be maintained.
• Cooling
After the hot dip, steel is cooled with water.

b) Quality Checking of Galvanization

• Galvanizing Process
Check the galvanizing plant and its set up to be ensured that all the galvanizing process is
available and maintained.
• Quality of Zinc
This can be checked by chemical testing of raw zinc used for the galvanization. Zinc content
should not be less than 98.5%.
• Quality of galvanization
By visual check the following:
- Galvanized steel should be free from rust and black spots, acid traps, welding slags.
- Galvanized coating should be free from ash, pimple and bulky deposition.
- Galvanized coating should be continuous, smooth and evenly distributed as far as
possible.
- Zinc coat should be adherent. This can be checked by hammering or scratching.
- No zinc paint or almonium paint is applied to hide rust spots. This is very unhealthy
practice, which frequently applied by the galvanizers.
- Zinc thickness can be measured by Deltascope (electromagnetic instrument for
measuring coating thickness over ferrous material). In our case zinc coat should not be
less than 80 µm in any steel parts.
- Treatment of Threads: Extra zinc on threads should be removed with a rotating wire
brush immediately after galvanizing or with gas blow and cleaning with rotating brush
if galvanization is already hardened. Re-threading of the galvanized parts is not
permitted.
400 TRANSPORTATION
It is wholly the responsibility of the Contractor to control transportation activities and
quality/quantity of any materials procured or received from the Employer’s stores, loading and off-
loading of the same, and the delivery at designated site.
411 Materials and Equipment
Materials, such as cement and steel parts should be transported with due attention so as not to incur
any damage to them either due to exposure to excessive moisture or mishandling. The cement bags
to be delivered at site should contain its full original weight viz. 50 kg. The Contractor shall entirely
be responsible for the quality and quantity of materials received at the point of origin and their
 delivery at site in the same quantity and quality. No reasons whatsoever will be accepted for
materials not reaching to site in proper condition and in required quantity. Loss during
transportation, if any is entirely on the Contractor’s account.
Other materials and equipment shall be transported properly so as to minimize the loss or damage
during transportation. Work being delayed because of equipment being damaged during
transportation is Contractor’s concern which has to be considered during bidding and shall not be
considered a reason for time extension.
In the case of blasting materials, the transportation, handling, storage and use of explosives shall be
subject to the laws and regulations of the Government as well as to the instructions of the
Employer’s Engineer. The Contractor shall maintain an inventory record of storage and withdrawal
of all explosives and such information shall be duly communicated to the Engineer. The Contractor
shall provide such reasonable and adequate protective facilities as are necessary to prevent loss, theft
or damage of explosives. The Engineer shall be informed promptly of any such loss. Security
provision should be made accordingly at the Contractor’s cost.
412 Wire Ropes and Bulldog Grips
Wire Ropes and Bulldog Grips supplied from Employer’s store shall be under direct responsibility of
the Contractor till it is fitted in the bridge. The Contractor must transport them immediately to site
with proper handling so that i) cable is not damaged, kinked, or the loose ends opened and ii)
Bulldog Grips do not get damaged. It is the Contractors responsibility to check cutting, coiling, and
the quantities of cable as well as the quantities of Bulldog grips received from Employer’s store,
their loading and unloading.

500 CONSTRUCTION
The construction works includes civil, mechanical, finishing works together with erection, running
and maintenance of the camp.

510 Site Clearance

The areas to be occupied by the permanent works and any borrow areas shall be cleared of trees,
stumps, roots, vegetation, structures and other obstructions to the extent required by the design. All
materials thus removed during site clearance shall be the property of the Employer.

520 All Excavation

All excavation has to be carried out according to design, designed cut slope , designed provision of
shuttering, and the safety has to be maintained. All excavation has been classified as follows.
521 Soil
It is when soil can be removed by shovels, picks or which include big stones of a size which require
moving by hand.
522 Soft Rock
It is when bed rock can be removed by means of crowbars and picks without any blasting.
523 Hard Rock (by Quarrying out)
This includes quarrying by wedging.
524 Hard Rock (by Blasting)
The hard rock encountered in foundation excavation has to be removed by blasting it with industrial
gelatin, detonator, and adequate length of fuse wire.
525 Excavation in Shallow Water
It is defined as excavation below the ground water level and includes all necessary measures for
dewatering like water courses, ditches, rock pits but without provision and operation of pumps.

530 Foundation Excavation

Excavation for the permanent construction such as foundation blocks shall be made to the lines,
grades and dimensions shown on the drawings. All necessary precautions (including control of
blasting) shall be taken to preserve the material below and beyond the established lines of all
excavation and also to the safety of workers and others.
 When excavated to the required levels and dimensions, the surface has to be cleaned, prepared, and
approved by the Engineer prior to the placing of concrete, masonry, or any other filling materials.
The classification of excavation are similar to the aforementioned and listed under following
headings:

531 Soil (ref. 521)

532 Soft Rock (ref. 522)
533 Hard Rock by Quarrying out (ref. 523)
534 Hard Rock by Blasting (ref. 524)
535 Hard Rock by Chiseling
Hard rock which can not be removed by wedging and due to other constraints can not be blasted,
such surface has to be chiseled to acquire the required level and dimensions as per the design, i.e.,
for finishing the foundation surfaces.
536 Backfilling
Common material generally shall be used for backfilling behind civil structures and behind a filter
bed of gravel fill as shall be shown in the drawing. Fill material shall be placed in position shown
on the drawings and will be obtained from designated borrow areas, excavation on site or any other
suitable area, as designated by the design and directed by the Engineer. Backfilling shall be of
continuous compacted layers not exceeding 300 mm thickness. In case of retaining wall, proper
filter materials for weep holes are to be provided in order to drain out water behind the wall.
All local material required for the construction of the work shall have to be obtained from borrow
areas beyond a minimum haulage distance of 30 meters. The Contractor is responsible for any kind
of river bank erosion which ultimately may endanger the stability of foundations, as a result of
carelessness in collecting local material from such critical areas.

550 Concrete Works

Concrete shall be composed of cement, sand, coarse aggregate and mixed with water as specified
herein and shall be well mixed to an even consistency as required by this specification and/or as
directed by the Engineer. No concrete shall be placed in any section of the works until the
foundation for that section has been completely dewatered, suitably prepared, and has been approved
by the Engineer.
The below given specifications of concrete components are for all type of concrete classification that
are most commonly used in SBD works. They are:

Pos. No. Description Mark Code

• 551 Plain Lean Concrete 1:4:8 M75 All items
• 552 Plain Mass Concrete 1:3:6 M100 according to
• 553 Reinforced Cement Concrete 1:2:4 M150 ISC-456:
Plumb Concrete with 60% PMC and 40%
• 554
boulders
In plumb concrete, the minimum gap of 100 mm between the adjacent boulders should be fully
maintained and that the boulders are not in contact with each other. And these gaps between the
boulders are filled with concrete of designed mix and rammed adequately avoiding any voids.
Each layer of boulders should be placed on 100 mm thick concrete mats.
Completed concrete structures should be sound without voids (honey combs), wall vertical to plumb
and line and have overall finishing.
a) Cement
Ordinary Portland cement conforming to IS 269-1989, without any warps or any sign of air setting
shall only be used for all works under this contract. Cement shall be transported and stored without
exposing it directly to rain or excessive moisture and should be stacked on wooden platforms at least
5.0 cm above the ground. It shall not be stored for a long time, which might set the cement,
reducing its strength. The Contractor shall build or maintain suitable store on site. A result of
laboratory test may be required by the Employer.
b) Sand (conforming to IS 383:1970)
Collection
This item shall include quarrying, collecting, sieving, washing of sand, if required and haulage to
site.
Quality requirement
Sand selected must be free from mica, loam, clay, mud and organic matter.
Washing
Contaminating impurities like clay, loam, mud, have to be washed. The quality of river sand shall
have to be approved by the Engineer before the haulage.

c) Coarse Aggregate (conforming to IS 383:1970)

Collection
Gravel can be collected from river deposits, quarries or by breaking boulders into required size as
defined by the design. Aggregate of unsuitable rock, such as mica, marl, and sand stone shall not be
used.
Surface
Gravel with rough and triangular surface are preferred for good bondage. Flat and flaky particles are
not to be used.
Purity
Gravel should be free from organic contaminants, deleterious substances like loam, clay, mud or
stone dust and other organic matter.
Grading
Aggregate shall be well graded. The approximate % requirement of gravel size, may they be from
river bed or broken shall be
5 - 10 mm 12.5 %
10 - 20 mm 25.0 %
20 - 40 mm 62.5 %
d) Stone
Quality requirement
All stones shall consist of unweathered, hard, dense, durable, uncoated and sound rock fragments.
The stones shall be thoroughly wetted by soaking in water immediately prior to placing.
Gabions and Rubble masonry shall be made of rock fragments which are reasonably rectangular in
shape.
Dry stone masonry and block stone masonry shall be made of all side dressed blocks with facing side
made smooth, either out of boulders or out of stratified rock.
Size
For masonry, the size of stone shall be as per IS code specification i.e. max. length > 3H, B > ¾
thickness of wall.
The size of stone for gabion work shall be between 100 mm and 200 mm.
Stones for plumb concrete shall be rock fragments between 100 and 225 mm in size.
e) Water
Water for washing aggregates, mixing, and curing concrete shall be fresh and shall be free from
objectionable quantities of silt, organic matter, alkalis, salts and other impurities.
f) Mixing and Placing
The proportions of cement, sand, coarse aggregate and water for the concrete mix of any
classification shall be as given in the Table below. Measurement shall be in volume.
 Concrete Grade
1:3:6
40%
Material Required 1:4:8 1:3:6 1:2:4
Bo
(m3) Plain lean Plain mass Rein-
uld
M - 75 M - 100 forced
er

Gravel - 10 mm (m3) 0.11 0.11 0.07 0.11

Gravel - 20 mm (m3) 0.23 0.23 0.14 0.22
Gravel - 40 mm (m3) 0.55 0.55 0.33 0.52
Sand (m3) 0.47 0.47 0.28 0.445
Boulders-225 m (m3) - - 0.50 -
Water (aprx.) (Lt) 150 150 100 200
Cement (Kg) 170 220 132 320

Permissible Stress N/cm2

Concrete Grade 1:3:6 +
1:3:6 1:2:4
40% Boulder
Stress in bending 300 200 500
Compression direct 250 150 400
Stress in bond 40 20 60
Tension stress in bending 30 20 50
Slump test shall be carried out to confirm workability and water cement ratio. Slump should not
exceed 80 mm.
Concrete shall not be dropped freely from a height of more than 1.5m. Concrete shall be placed in
horizontal layers not exceeding 25mm and shall be consolidated immediately to its full depth and
worked into corners and angles of forms, all around the reinforcement and embedded parts.
Consolidation shall be achieved according to the requirement.
Concreting shall take place during favorable weather conditions. Working joints shall be thoroughly
maintained so as to keep the required design bond and strength. The working joints be roughened,
cleaned and wetted before further work commences.
Concrete shall be mixed on a cleanly prepared platform and transported from the mixing area to
the area of placement as quickly as possible.
g) Curing and Protection
Concrete shall be cured by maintaining the surface wet (using suitable and approved method) for at
least 7 days. Concrete shall be protected from direct rain for 12 hours, from flowing water for 14
days. The contractor shall ensure that no structural and physical damage be inflicted on it.
h) Reinforcement and Steel Parts
The contractor shall assemble and fix the steel parts and the reinforcement (conforming to 312) as
shown on the drawings. Reinforcement and steel parts stored in neat racks above the ground shall be
cleaned of all loose rust, mill scale, dirt, grease, paint and other foreign substances and shall be
maintained in a clean condition until embedded in concrete.

555 Formwork
Formwork shall be made from functional, straight and stout timber uniform enough to leave a smooth
surface later on.
Formwork shall withstand the pressure resulting from the placement and vibration of the concrete,
maintained rigidly in position, and shall be sufficiently tight to prevent the loss of mortar or the
water content of the concrete. The Contractor shall ensure the safety and quality during the work.
Form work shall only be removed after the minimum stripping times which shall be:
- Non load bearing members and side forms : 3 days
- Load bearing members up to 3m span : 10 days
- Load bearing members up to 6m span : 20 days
- Load bearing members above 6m span : 30 days
560 Masonry and Mortar Work
561 Dry Stone Masonry or Pitching
Stones must be laid with the largest possible areas of contact to provide sufficient friction. Special
attention shall be given to bonding stones of which at least five should be inserted per cubic meter of
masonry. Chips and sprawls of stones should be wedged into the work wherever necessary for its
stability, but should be less than 10% by volume of the masonry. The base of walls shall be stones
with large bearing areas to provide efficient load transfer to the ground. The top of the walls shall be
covered with neatly dressed flag stones laid in such a way that they cannot be dislodged by animals
or people climbing over them.

562 Cement Masonry (Incl. Pos. No. 563/64)

Cement mortar must be mixed on a clean surface in a ratio of one part of cement and four parts of
sand (for Block stone and Rubble masonry 1:4) and one part of cement with six parts of sand (for
Rubble masonry 1:6), by volume.
One cubic meter of masonry has to contain:
1:4 1:6
Cement 114 kg 75 kg
Sand 0.42 m3 (loose) 0.47 m3 (loose)
Stones 1.1 m3 1.1 m3 (loose)
Face stones shall not be narrower or shorter than its height. Joints should not exceed 1cm in
thickness. Stones shall be soaked in water prior to putting them in masonry. Stones shall not be
less than 10cm in any direction, and should be carefully laid, hammered down into place with
wooden mallets, and solidly bedded with mortar. Chips and sprawls shall be wedged in to avoid
thick beds of joints and mortar. Exposed faces shall be flush pointed and smooth. A proper bond
shall be maintained with at least five bonding stones in a cubic meter of masonry. The whole
structure shall be cured for 7 days.
Permissible Stress N/cm2
Rubble Rubble Block Stone Masonry
Type of Masonry Masonry Masonry 1:4
Stratified Non-str.
1:6 1:4
blocks blocks
Slenderness
ratio h/d 0.5 2.0 0.5 2.0 0.5 2.0 0.5 2.0
Stress in Bending 130 70 190 110 210 130 370 200
Compression Direct 100 50 140 80 160 100 380 150
Tension stress in
13 7 19 11 21 13 37 20
bending
h=height of wall d = thickness of wall

565 Cement Plaster

Surface mortar shall be applied to concrete and masonry as indicated in the drawings. Before
application of mortar, surfaces shall be without efflorescence, clean, scored and well wetted.
Ordinary Portland cement shall be used. Suitable sand has to be transported from the nearest
possible source, sheaved to get the correct granular composition, and approved by the Engineer.
Surface mortar shall be moist cured and protected from damage for at least 7 days.
In general, cement plaster (rendering) is executed in three steps: Render coat, leveling coat and
finishing coat. For structures with rough and absorbent surfaces, the render coat may not be required
if so directed by the Engineer. The render coat consists of a 3-5 mm thick, rich mortar paste with
600 to 800 kg cement per m3 of finished mortar and with sand 0-8 mm (mortar 1:2.5). The surface
shall remain rough to ensure a good bonding to the next coat. The leveling coat should be 10 to 15
mm thick and shall be applied only after shrinkage cracks have appeared in the render coat. Dosage:
Cement 250-300 kg/m3, sand 0-6 mm (mortar 1:6). The finishing coat shall provide an aesthetic
finish and shall be applied to the leveling coat as soon as possible. Thickness 2 to 5 mm. Dosage:
Cement 500-600kg/m3, sand 0-3 mm (mortar 1:3). The average mortar shall contain in this case
the cement to sand ratio of 1:4.
570 Erection and Finishing work

573/4 Cable Hoisting

This includes hoisting of all cables together with the placing and fixing of thimbles, bulldog grips
and pretensioning.
The Contractor shall hoist the cable across the river, over onto the top of towers, further to
anchorage blocks strictly according to a accepted method. The work shall include the correct fitting
of all cable terminals either with thimbles and bulldog grips or with sockets. The work shall also
include the pretensioning (proper setting of design sag) of main cables, windguy/windtie cables,
spanning cables and sidestay cables along with the adjustment of stabilizing cables, diagonal
stabilizing cables, the correct fitting of handrail and fixation cables as indicated in the drawings.
Safety of the workers, materials, and others should be of prime concern during this work, the
responsibility for which entirely lies with the Contractor.
575 Erection of Walkway
The Contractor shall be fully responsible for all the necessary safety precautions during the
erection of the walkway. The steel deck has to be properly fitted as specified in the drawings
including suspender and cross beams. The wire mesh netting shall be folded around to the
handrail cable fixed to the fixation cables and suspenders with binding wire of 12 SWG @ an
interval of 30 cm.
All clamps, bulldog grips, nuts etc. shall be retightened upon the completion of the bridge.
Permitted deviations from the hoisting sag specified in the drawings shall be:
- For suspended bridges : + 0.02% of the span

576 Protection from soil and debris

All anchorages and foundations shall be cleaned of soil, mud and debris and all possible measures
shall be taken to avoid steel parts, cable, etc. from being covered by soil, mud or debris.

580 Surrounding Works

As soon as practicable, after cutting of a permanent slope, backfilling or the forming of an
embankment slope, the Contractor shall encourage the growth of a vegetation cover by turfing or
grass showing, transplanting the slope with ready made turf properly cut from another area, and
afforestation (planting of trees and plants) as shown in the drawings or as directed by the Engineer.
This work includes the care and protection of the plantations from any damage until the end of the
period of maintenance. Additional slope and river bank protection works, such as, wicker work
fences, brushwood work, and terracing may be required if indicated in the design.