Road Construction Method Guide
Road Construction Method Guide
Government of Assam
Implementation of Projects Road under Assam Mala Program
CONTRACTOR
MAY-2023
CONTENTS
Description Page No.
1. Pre-construction Activities 1-2
2. Construction Sequence 2-3
3 Site Establishment 3
4. Field Survey 4
5. Material Selection and Mix Design 4-6
6. Quarry and Crusher Operation 6-7
7. Site Clearance 7-8
8. Cross Drainage Works 8 - 10
9. Earthwork Excavation, Embankment & Subgrade 10 – 13
10. Granular Sub-base 13 – 14
11. Wet Mix Macadam Base 14 - 16
12. Bituminous Course 16 - 18
13. Drainage & Protection Works 18
14. Road Furniture 18 - 19
15. Miscellaneous Works 19
Detailed Item Wise Method Statement Highway
16.
& Structure Works
Method Statement for Design & DRAWING Works
17. PRIOR TO THE PERMANENT WORK FOR
APPROVAL
Improvement and upgradation of Rowta to Missamari road [Ghagra Kachari Village to Phulogori
(From KM 18+800 To 36+937)
01 PRE-CONSTRUCTION ACTIVITIES
01.01 Upon issuance of 90 % of encumbrance free land for execution, the following shall be
obtained from the Authority i.e. National Highways Infrastructure Development
Corporation Limited and / or the Authority’s Engineer :
01.02 Design Stretch as per Approved Plan & Profile will be marked on the field taking
representative of Authority’s Engineer for field approval against prior submitted RFI.
01.03 A joint survey of the stretch so handed over shall be carried out to mark out any
obstructions / encumbrances that may still remain unmoved. A joint meeting with
concerned utility departments / relevant administration authorities shall be convened if
necessary to chalk out a Utilities Relocation Programme for the removal of any such
remaining utilities / encumbrances. Progress of freeing the handed over stretch shall be
monitored against such jointly agreed Utilities Relocation Programme. Necessary follow-
up and coordination with the Employer (Authority), Authority’s Engineer and the
concerned departments / administration authorities shall be made. Though it is not
anticipated, the implications of (a) the very occurrence of, and (b) the late removal of such
obstructions, in the overall progress of works shall be reflected in the Construction
Programme updates.
01.04 The Final Construction Drawings (Good for Construction Drawings) approved shall be
studied for application in field.
01.05 The traffic flow shall be studied and the plans shall be made for traffic arrangements
during construction in various stretches under each Section handed over. Such
arrangements shall cover: (a) the areas where diversions roads are to be made (as payable
item), (b) the sequence of traffic diversion from Existing Carriage Way to New Carriage
Way and back, (c) the possibility of widening in Existing Carriage Way while the traffic is
still in Existing Carriage Way and (d) traffic safety arrangements especially for diversions.
01.06 The precautions necessary for safeguarding the environment shall be studied and
necessary clearances shall be sought from Central Pollution Control Board, Revenue
Department (for making available the land) etc. for siting the Crusher and Batching Plants.
Cooperation and recommendation is expected from the Employer for this purpose.
01.07 The detailed methodology for each work item to be constructed shall be prepared and
submitted for the Authority’s Engineer’s approval in advance.
02 CONSTRUCTION SEQUENCE
02.01 The overall construction sequence shall be as below :
General Activities
Site Establishment
Field and Quantity Survey
Material Selection and Mix Design
Quarry and Crusher Operation
Carriage Way
Site Clearance
Earthwork in Excavation, Embankment and Subgrade
Longitudinal Side Drains, Catch Pits and Cross Drainage Works
Granular Sub Base and Base as a drainage layer with filter at the shoulder end.
Granular shoulder over granular sub base at the shoulder end.
Prime Coat, Tack Coat, Dense Bituminous Macadam and Bituminous Concrete
Miscellaneous Works
Finishing Works
03 SITE ESTABLISHMENT
03.01 Resources (staff, workmen, machinery, office equipment etc.) shall be mobilised as per
the enclosed schedules to facilitate timely commencement of the works.
03.02 At the locations identified under the logistics plan, site establishments shall be made. The
area for locating the site office, workshop area, material store and stockyard, batching
plant etc. shall be leased and construction work shall be carried out (including plant
foundation works).
03.03 Similarly for the quarrying and crushing locations, the area for locating the crusher office,
crushing plant etc. shall be leased and construction work shall be carried out (including
plant foundation works).
03.04 Approach roads to site facilities and quarry and crushing facilities shall be made or
upgraded or strengthened as required.
03.05 Temporary field camp sites shall be established by renting space at various work locations
for the Site Engineers to coordinate the local work stretch requirements.
03.06 Facilities for the Authority’s Engineer including construction of office and residential
building shall be carried out after the issue of necessary drawings and allotment of land
for this purpose. Vehicles for the Engineer’s representatives shall also be mobilised on the
basis of requirements assessed and agreed to.
04 FIELD SURVEY
04.01 The following activities shall be carried out using Total Station / Auto Levels as necessary
and applicable :
04.02 The GTS Bench Mark shall be back sighted and Temporary Bench Marks (Survey Pillars)
shall be established at safe locations along the work stretch. The Centerline for Existing
Carriage Way as already established and pinned by the Engineer’s representatives shall be
validated and the points transferred to safe locations nearby along the work stretch.
Working Bench Marks at about four per km shall be established from the Temporary
Bench Marks to facilitate survey of original ground levels and subsequent layer level
surveys.
04.03 Original Ground Levels (OGL) at 10 m (approx.) longitudinal intervals shall be jointly
surveyed at grid point locations mutually agreed with the Engineer. Such survey work
would cover the width beyond the toe line of either carriage ways. Further field survey
work would continue for layer progress and measurement requirements.
04.04 The Original Ground Levels shall be plotted with reference to the Horizontal Alignment to
obtain the longitudinal and cross profile of the road and surrounding ground. The Finished
Road Levels indicated in the Final Construction Drawings (Good For Construction
Drawings) shall be utilised for setting the embankment top surface considering layer
thickness and camber details specified in the Drawings. Such design embankment top
levels shall be superimposed on the OGLs to produce the cross sections for earthworks.
05.01 The Field Laboratory shall be established in stages, to meet the testing requirement
schedule. Initially, soil testing facilities shall be established. This will be followed by
establishment of aggregate testing and concrete testing, first for CD works, followed by
tests for kerb, Bituminous Works.
05.02 Borrow areas shall be prospected for sampling materials for use in embankment. Based
on the test results of such samples the approval of the Engineer’s representatives for the
material for use in embankment fill shall be obtained.
05.03 Where feasible and found economical, the option of using sand fill confined by borrow
area fill for embankment & subgrade shall also be submitted with test results for such
combination satisfying the requirements.
05.04 The material proposed for use in Granular Sub Base is naturally available material (at layer
bed, to be mixed at location, watered and compacted). Such naturally available material
(River Boulder etc.) comprises of gravelly sand mixtures falling within the Grading-I of
Table 400-2, which is in the contract drawings and specifications.
05.05 The crushed aggregates to be procured from the local market initially shall be tested for
suitability for use in the works and the test results shall be submitted for the approval of
the Engineer.
05.06 The crushed aggregates produced from the Crushing Plants installed by us shall be tested
for suitability and the test results submitted. The crushing parameters shall be so adjusted
to enable the production of crushed aggregates of required quality characteristics and in
required ratios of different grading.
05.07 The mix design for various grades of concrete shall be carried out once the materials
namely cement, sand and crushed aggregates are selected. The mix designs found
complying with the requirements shall be submitted for approval. Upon erection of the
Concrete Batching Plant and the mobilisation of the concreting team, trials shall be
commenced for production of concrete mix complying with the approved mix design
requirements.
05.08 The mix design and casting trials of cast-in-situ kerb shall be carried out to ensure
achievement of required strength and surface finish.
06.01 The quarry site shall be selected as per guidelines detailed above. Necessary clearances /
leases shall be obtained for quarrying boulders from such area.
06.02 The River boulders out of the quarry area shall be loaded to tippers for transporting to
and feeding the crushing plants.
06.03 The required number of crushing plants shall be put up from our own pool of crushing
plants and / or by leasing / hiring crushing plants / agreeing for captive production and
supply by established crushers. The overriding factor in any such combination would be
the potential for consistent supply of crushed aggregates of required specifications and in
required quantity within the required timeframe.
06.04 The crushing plants would have double toggle jaw crushing arrangements in the primary
stage of crushing, impactor in the secondary stage of crushing and vibratory screens. The
enabling and supporting P&M shall include DG sets, Weigh Bridge, wheel loaders, tippers
etc.
06.05 Trial productions shall be commenced once the crushers are installed. The jaw opening
sizes and screen sizes shall all be varied where necessary to obtain the right quality of
aggregates. Such efforts shall also determine the fraction of individual size range gradings.
06.06 The crushing operations shall proceed for 10 hours a day on an average and will be under
the supervision of qualified and experienced technical personnel round the clock to take
care of operation and maintenance.
06.07 Samples shall be obtained from conveyor belts and / or from stockpiles at specified
intervals for carrying out (a) Aggregate Grading, (b) Los Angeles Abrasion Test Value, (c)
Chlorides and Sulphate content (d) Flakiness Index, (e) Water Absorption (f) Alkali
aggregate reactivity and any other tests as may be required under the Contract. The test
results shall act as feedback for further crushing operations.
07 SITE CLEARANCE
07.01 The toe-line shall be established, with reference to the alignment based on the levels
taken earlier. The area for clearing and grubbing shall be identified, covering areas of road
embankment, drains, cross drainage structures and such other areas as specified.
07.02 Trees upto 150mm in girth and stumps and roots shall be removed by a Dozer or
excavator or by manual labor means.
07.03 The Dozer or excavator shall then be deployed to remove all shrubs, bushes, vegetation,
grass, weeds, rubbish and top organic soil not exceeding 150mm in thickness – which is
unsuitable for incorporation in the works.
07.04 The unsuitable and waste matter arising from such clearing and grubbing shall be
disposed of in such a manner as to ensure that there is no mix-up of such matter with
material meant for embankment / subgrade.
07.05 Where the existing pavement and / or the bituminous crust is to be dismantled, the area
of such work shall be jointly assessed. The dismantling work may be carried out
mechanically with a Dozer or an Excavator-cum-loader or by manual means as found
appropriate. The dismantled WBM material shall be used in embankment/ subgrade, after
mixing with earth, provided it satisfies the specifications. The dismantled WBM material
shall also be tested alone to see if satisfies the criteria for GSB, and shall accordingly be
used.
07.06
08.01 The alignment and level of the structure shall be determined and referenced nearby on a
survey pillar.
08.02 For culverts, the detailed drawings for each structure shall be prepared on the basis of
information provided in the Final Construction Drawings and ground level details and
submitted for the Authority’s Engineer’s approval.
08.03 Where the existing structure is to be partially or fully dismantled, the measurements shall
be taken and approval obtained for the dismantling process. The dismantling work shall
then be carried out to meet the requirements.
08.04 After clearing and grubbing, the area for excavation for foundation shall be identified.
Excavation shall be carried out to required lines and levels by manual or mechanical
means depending on the area and volume of excavation.
08.05 For Hume Pipe Culvert works, the granular bed shall be laid and the pipes shall be placed
in required lines and levels and the collars jointed. This shall be followed by backfilling,
construction of head walls and other ancillary and protection works as specified. The work
shall be mostly manual, aided only by a crane where necessary to handle Hume pipes of
larger dia.
08.06 For Slab/ Box type culverts and Bridges, the resources to be utilised shall include concrete
batching plant / site mixers, transit mixers, concrete pump (if necessary for mass
concreting works), 18T crane (in place of concrete pump and manual concreting means)/
concrete placer as is convenient.
08.07 Formwork requirement shall be scheduled on the basis of the sequential construction
programme of the culverts, and bridges. Staging and shuttering components shall mostly
be mobilised from Formwork available at various work sites. Where repetitive design
occurs and the time sequence permits, we may also fabricate typical formwork for mass
repetitions and / or we may resort to standard pre-fabricated components for erection
and jointing at site.
08.08 After excavation, the foundation bed concrete shall be laid. The tied-in reinforcement for
foundation concrete shall be placed in position and the formwork shall be fixed. After
obtaining the clearance, under the inspection of the Engineer’s representative(s) the
concreting work shall be carried out. Water curing of the concrete shall then be
undertaken.
08.09 Necessary piling rigs shall be mobilised where such type of foundations are to be taken
up.
08.10 For superstructure of bridges, whether RCC or PSC, the same shall be cast in-situ using
heavy Duty staging.
08.11 At a time gap adequate enough for the concrete to attain the minimum required strength
for supporting concrete in subsequent lift, this entire sequence of reinforcement placing,
formwork fixing, inspection, concreting and curing for the substructure shall be carried
out in lifts.
08.12 Such repetitive work in different dimensions shall be carried out for abutments, well
staining, piers, wing walls / return walls and dirt walls.
08.13 The staging for the superstructure shall be erected and bearings if applicable shall be
mobilised. Upon completion of the substructure work, where applicable, the bearings
shall be fixed in position. Where required (depending on the sequence of construction
operation), expansion joints shall be placed.
08.14 The staging and shuttering work upon completion shall be followed by reinforcement
caging and tying in. Once the deck reinforcement is ready and bound by formwork in all
sides, the same shall be offered for inspection and upon clearance by the Authority’s
Engineer’s representatives, concreting of the deck slab shall be carried out. Water curing
shall be carried out subsequently.
08.15 Filter media, backfill works and bed protection works shall be carried out to specification
requirements under the supervision of the Authority’s Engineer’s representatives.
08.16 Protection and drainage works on the superstructure shall be taken up covering crash
barriers and handrails, footpath, kerb, drainage spouts etc. Expansion joints, where
required and applicable under the sequence of operations, shall then be placed in
position.
08.17 Mastic asphalt shall be laid on the cured and dry deck of bridges as per requirements
through subcontract under our control and the supervision of the Authority’s Engineer’s
representatives.
08.18 Bituminous wearing course (BC) shall be laid over the mastic asphalt.
09.01 The resource requirement shall be determined on the basis of the observed scope of
work. Such necessary resources shall be mobilised accordingly as per the planned time
schedule.
09.02 Reference aides shall be mobilised which shall include (a) wooden pegs with markings set
with reference to the Working Bench Marks for the required layer spread / finish levels,
(b) marking aides including measurement tapes, lime powder, strings and (c) auto level
instrument with survey staff. Safety aides shall also be mobilised in required numbers to
take care of the safety of the works progress and of the adjoining traffic movement.
09.03 Suitability of the material to be excavated for use in embankment fill shall be determined
through tests.
09.04 Where the material to be excavated is determined to be suitable for use in embankment
fill, the resource deployment and the activity sequence shall be planned in such a way as
to : (a) doze the material from excavation zone to fill zone if the distance in-between is
minimal, or (b) excavate, load, transport and dump the material from excavation zone to
fill zone, at a time.
09.05 The ground supporting embankment to be compacted shall be scarified, leveled, watered
and compacted so as to achieve the minimum dry density specified.
09.06 Upon approval of the embankment / subgrade foundation, work shall be started for the
construction of subsequent layers of embankment and subgrade. The methodology and
materials for use in such layers shall be as determined under Material Selection and Mix
Design.
09.07 The approved borrow area material shall be excavated, transported to site and dumped
on the foundation ready to receive the fill material. The location of dumping in the site
bed shall be handled in such a way as to ensure that the quantity of material once
compacted produces a layer of 200mm thickness. For subgrade, the thickness shall be so
adjusted (175mm, 175mm and 150mm) as to achieve 500mm in three layers. Trials shall
be made to establish the compaction factor with respect to the volume of material
dumped and the compacted volume.
09.08 The dumped materials shall be spread by a tractor fitted with dozing blade. Moisture
content of the material in the site bed shall be determined and necessary drying or
addition of water by sprinkling by water tanker shall be carried out to bring the moisture
content within the Optimum Moisture Content (OMC) range.
09.09 A tractor fitted with rotavator/ disc harrow shall be used (a) for mixing materials from
more than one source (say borrow area soil and river sand), (b) for breaking clods / lumps
in material dumped, and (c) for bringing the entire material within the same moisture
range.
09.10 The finishing of the layer surface shall be done with a motor grader to required camber
and levels.
09.11 Once the grading operation is over, before the moisture content of the graded material
falls out of the OMC range, compaction operation shall be carried out, using vibratory
rollers and / or other suitable compaction equipment as approved by the Authority’s
Engineer.
09.12 Compaction trials shall be carried out to determine the number of passes and the
sequencing of plain and vibratory passes.
09.13 Once compaction work is completed, the stretch shall be tested for achievement of the
minimum dry density. If the density is not achieved, compaction shall be carried out again
and tested. Where soft spots are noticed to produce lower density even after repeated
compaction, such soft areas shall be reworked.
09.14 Once the test results are accepted to indicate achievement of the required density, work
on constructing the subsequent layer shall be started.
09.15 After completion of Embankment Top layer and Subgrade Top layer, grid point levels shall
be taken jointly to ensure any level differences to be within acceptable limits.
10.01 The resources and enabling aides required shall be mobilised as per the planned time
schedule.
10.02 Upon approval of the subgrade top layer, work shall be started for the construction of
granular sub base. The methodology and materials for use in such layers shall be as
determined under Material Selection and Mix Design.
10.03 The approved GSB material shall be excavated, transported to site and dumped on the SG
top layer surface ready to receive the material. The location of dumping in the site bed
shall be handled in such a way as to ensure that the quantity of material once compacted
produces a layer of required thickness. Trials shall be made to establish the compaction
factor with respect to the volume of material dumped and the compacted volume.
10.04 The dumped materials shall be spread by a tractor fitted with dozing blade. Moisture
content of the material in the site bed shall be determined and necessary drying or
addition of water by sprinkling by water tanker shall be carried out to bring the moisture
content within the Optimum Moisture Content (OMC) range.
10.05 A tractor fitted with rotavator / disc harrow shall be used (a) for mixing materials from
more than one source (say natural material and river sand), (b) for breaking clods / lumps
in material dumped, and (c) for bringing the entire material within the same moisture
range.
10.06 The finishing of the layer surface shall be done with a motor grader to required camber
and levels.
10.07 Once the grading operation is over, before the moisture content of the graded material
falls out of the OMC range, compaction operation shall be carried out, using vibratory
rollers and / or other suitable compaction equipment as approved by the Engineer.
10.08 Compaction trials shall be carried out to determine the number of passes and the
sequencing of plain and vibratory passes.
10.09 Once compaction work is completed, the stretch shall be tested for achievement of the
minimum dry density. If the density is not achieved, compaction shall be carried out again
and tested. Where loose material or segregation is noticed, such areas shall be made
good.
10.10 Once the test results are accepted to indicate achievement of the required density, work
on constructing the subsequent layer shall be started.
10.11 After completion of Granular Sub Base, grid point levels shall be taken to ensure any level
differences to be within acceptable limits.
11.01 The resources and enabling aides required shall be mobilised as per the planned time
schedule.
11.02 Upon approval of the GSB top layer, work shall be started for the construction of shoulder
followed by the construction of Wet Mix Macadam (WMM). The methodology and
materials for use in such layers shall be as determined under Material Selection and Mix
Design.
11.03 Shoulder shall be constructed with subgrade material in procedure set out therein. Once
the shoulder layer is completed, the inner edge shall be trimmed to ready the main bed
for receiving the wet mix.
11.04 The mix design for WMM shall be completed as detailed under Material Selection and Mix
Design and the same shall be got approved.
11.05 The WMM shall be laid to a compacted layer using a paver. The paver shall spread the wet
mix through its conveying and screed arrangements and finish with tamping to produce a
smooth surface of required camber and levels.
11.06 Trials shall be made to establish the compaction factor with respect to the volume of
material paved and the compacted volume.
11.07 Where the width of the layer does not permit the use of paver for laying the wet mix, or in
any other case, with the approval of the Engineer, the wet mix may also be dumped at
site, spread and graded with a grader.
11.08 Before the moisture content of the graded material falls out of the OMC range,
compaction operation shall be carried out, using vibratory rollers and / or other suitable
compaction equipment as approved by the Engineer.
11.09 Compaction trials shall be carried out to determine the number of passes and the
sequencing of plain and vibratory passes.
11.10 Once compaction work is completed, the stretch shall be tested for achievement of the
minimum dry density. If the density is not achieved, compaction shall be carried out again
after water sprinkling and tested. Where loose material or segregation is noticed, such
area shall be made good.
11.11 Once the test results are accepted to indicate achievement of the required density, work
on constructing the subsequent layer shall be started.
11.12 After completion of Wet Mix Macadam layer, grid point levels shall be taken to ensure any
level differences to be within acceptable limits.
12 BITUMINOUS COURSES
12.01 The resources and enabling aides required shall be mobilised as per the planned time
schedule. The alignment shall be jointly marked for proper area coverage for prime coat,
tack coat and DBM / BC.
12.02 The WMM surface shall be cleaned for applying bituminous prime coat at the rate of 6 to
9kg/10sqm area. The bitumen sprayer shall be mobilised at site with required bituminous
cutback (medium curing, 80/100 bitumen mixed in required proportion with kerosene)
material. Related aides and accessories (including sampling tray etc.) shall also be
mobilised. The alignment shall be jointly marked for proper area coverage for priming.
12.03 Based on trail runs, the sprayer shall spray the priming material on the WMM surface
travelling at a predetermined speed covering the required area by the pre-determined
pressure of spraying. Sampling and testing shall be done to ensure compliance.
12.04 Upon approval of the bituminous prime coat, work shall be started for the construction of
Dense Bituminous Macadam followed by Bituminous Concrete. The materials for use in
such layers shall be as determined under Material Selection and Mix Design.
12.05 The preparatory works for sensor paver movement including erection of sensor guide
rope supported by struts at regular intervals etc. shall be carried out.
12.06 The mix design for DBM/ BC approval shall be completed beforehand as detailed under
Material Selection and Mix Design.
12.07 The paver shall spread the hot mix through its conveying and screed arrangements and
finish with tamping to produce a smooth surface of required camber and levels.
12.08 Trials shall be made to establish the compaction factor with respect to the volume of
material paved and the compacted volume.
12.09 Where the width of the layer does not permit the use of paver for laying the hot mix, or in
any other qualified case, with the approval of the Engineer, the hot mix may also be
dumped at site, spread and graded by manual means.
12.10 Before the temperature of the hot mix laid falls out of the specified range (120 – 145
degrees Centigrade), compaction operation shall be carried out, using tandem vibratory
rollers, pneumatic tyred rollers and / or other suitable compaction equipment as
approved by the Engineer.
12.11 Compaction trials shall be carried out to determine the number of passes and the
sequencing of plain and vibratory passes.
12.12 Once compaction work is completed, the stretch shall be tested for achievement of the
minimum dry density. Sampling shall also be done and the mix and layer core tested for
compliance with requirements.
12.13 Once the test results are accepted to indicate achievement of the required density, work
on constructing the next layer shall be started.
12.14 After completion of Dense Bituminous Macadam layer and after completion of the
Bituminous Concrete layer, grid point levels shall be taken to ensure any level differences
to be within acceptable limits.
13.01 Drawings and levels of drainage works shall be verified for ensuring uninterrupted flow of
drain water. The drainage works shall be carried out on the basis of detailed method
statement to be submitted well before commencement of the work. Resource
mobilisation and deployment shall be planned accordingly, to ensure completion of the
works before final handing over. Care shall be taken during monsoon periods to minimise
the damage to works constructed.
13.02 Protection works shall be executed on the basis of detailed method statement to be
submitted well before commencement of such works. The progress of such works will be
scheduled to match the overall progress and enable completion before final handing over.
14 ROAD FURNITURE
14.01 The work shall be executed as per the detailed drawings prepared covering continuous
lines, dotted lines, zebra crossings, letters and arrows. The materials proposed for
incorporation in the works shall be accompanied by test certificates. The work shall be
supervised to ensure execution as specified and the resultant work complies with the
requirements.
14.02 Sign boards of various types shall be made-to-order with inscriptions as per the detailed
drawings prepared. The sign boards of required grade and specification shall be ordered
for supply with posts. Supply of sign boards shall be accompanied by test certificates. The
location for erection shall be marked and the foundation works carried out to fix the sign
boards in position.
14.03 The boundary posts, guard posts, kilometre stones etc. shall all be cast as per specification
details in required numbers and erected in positions determined by carrying out
necessary foundation platform works.
15 MISCELLANEOUS WORKS
15.01 Other miscellaneous works and finishing works shall be carried out based on mutually
agreed programs and methods to ensure timely completion of the overall works.
*******
All areas of the site marked in the relevant drawings or specified for clearance or from which material is
to be excavated or upon which filling is to be deposited shall be cleared. All obstructions and bushes,
hedges, trees, stumps, roots and other vegetation except for trees, road kerbs, fencing and other ancillary
road furniture shall also be removed where specified in the contract. Materials cleared shall be disposed
of offsite or as directed by the Supervision Consultant.
Setting out
Prior to commencement of any physical work, a competent surveyor shall be appointed to carry out
demarcation works and establish benchmarks on site. Upon obtaining all the necessary survey data, a
joint survey to check existing ground levels shall be carried out with the consulting engineers.
Site Clearing
(i) All trees, scrub, stumps, bushes etc., within the site boundary shall be removed completely,
including the grubbing out of all roots.
(ii) Trees shall be uprooted or cut down as near to ground level as possible. Branches and foliage shall
be removed and disposed of offsite as directed by Consulting Engineers.
(iii) Stumps and roots whether existing or remaining after trees felling shall where directed by the
Consulting Engineers be grubbed up and uprooted and disposed of offsite.
(iv) The resulting holes shall be filled with approved materials deposited in 225 mm layers and
compacted to the same dry density on the adjoining soil.
(v) The felled vegetation shall be arranged and stockpile in heaps at various locations as agreed with the
Consulting Engineer. This location shall be away from vicinity of permanent work area.
(vi) Burning of felled vegetation can only be done with the approval of relevant Authorities.
(vii) When burning is prohibited, the felled vegetation should be temporarily stock piled at an agreed
location by the Consulting Engineers, until access is available for carting away for disposal.
(i) Top soil shall be removed in accordance with the relevant drawing. It shall be removed to such depth
to such depth and over such area as directed by the Consulting Engineer prior to any further
excavation works which may be required.
(ii) The levels shall be recorded before any work can start. A competent surveyor in the presence of the
Consulting Engineer shall carry out recording levels.
(iii) Topsoil intended for re-use as agreed with the Consulting Engineer, shall be stock piled and or
spread at approved locations.
(iv) Unsuitable topsoil shall be disposed of offsite at locations agreed by the Consulting Engineers.
(i) The flexible pavement shall be removed by cold milling of the pavement surface.
(ii) The thickness to be milled of shall be as closed to the road base as possible. If necessary, it will be
carried out in layers to suit the machinery used.
(iii) The reclaimed asphalt pavement shall be salvaged for re-use and stockpiled at an appropriate
location.
(i) Marking stones such as guard stones, Km stone, 5th Km Stone and hectometer stone shall be
removed manually. The area surrounding the marking stones shall be excavated manually until the
base is exposed.
(ii) The marking stones is then to be lifted manually and transported to a dedicated storage area
(iii) Road kerbs, gutters and pipes shall be removed after excavating the surrounding area.
(iv) Fencing and guard rails shall be removed manually by dismantling all jointed connections and
transported to dedicated storage area.
MACHINERY REQUIRED
1) Dozer
2) JCB
3) Excavator
4) Manpower – Engineer – 1 No., Supervisor – 2 No., Flagmen for safety and labour
Note – The requirement of Flagmen and labour depends upon the number of stretches where work is being
executed
Prior to commencement of any physical work, a competent surveyor shall be inducted to carry out demarcation works
and establish benchmarks on site upon obtaining all the necessary survey data. A joint survey to check existing ground
levels shall be carried out with the consulting engineers.
Machinery required-
1. Excavator
2. Dozer
3. Grader
4. Vibratory roller
5. Water Tanker
6. Dumpers
Manpower–
Note – The requirement of Flagmen and labour depends upon the number of stretches where work is being
executed.
Preparation of Site
(i) A temporary system for rapid dispersal of water on to the earthwork or completed
formation during construction, or which enters the earthworks from any source shall be
devised to prevent water pounding. Where practicable, the water shall be discharged into an
adjacent existing drainage system. Adequate means of tapping silt shall be provided on
temporary system discharging into permanent drainage systems. The arrangements shall be
made in respect of all earthworks including excavation whether for pipe trenches,
foundations or cuttings.
(ii) When any materials are disposed outside the site, the disposed materials shall be graded to a
neat appearance and shall not obstruct natural drainage or cause damage to highways or
property. All precautions shall be taken to prevent any erosion of the soil on the affected
areas.
(iii) All organic soils, when encountered and where possible, will be stockpiled and conserve for
agricultural and horticultural purposes.
The materials used in embankments , sub grades, earthen shoulders and miscellaneous back fills shall be soil,
murum, gravel, a mixture of these or any other material approved by the Engineers / Consultants. Such materials
shall be free of logs, stumps, roots, rubbish or any other ingredient likely to deteriorate or affect the stability of the
Highly Expansive soil such as CH, MH, or OH exhibiting marked swell and shrinkage properties (“Free Swell
Index” exceeding 50 percent when tested as per IS: 2720 – part 40) shall not be used in the construction of sub
grade and Embankment.
Where the materials are to be obtained from borrow areas shall be tested and get
approved by the Engineers / Consultants before using the actual execution of work.
Construction Operations:
Compacting ground supporting embankment/subgrade: Where necessary, the
original ground shall be leveled to facilitate placement of first layer of embankment,
scarified, mixed with water and then compacted by rolling so as to achieve minimum dry
density as given in Table 300-2 of MORT&H.
Where so directed by the Engineer, any unsuitable material occurring in the embankment
foundation shall be removed and replaced by approved materials laid in layers to the
required degree of compaction.
Embankment or subgrade work shall not proceed until the foundations for
embankment/subgrade have been inspected by the Engineer for satisfactory condition
and approved.
Spreading material in layers and bringing to appropriate moisture content: The
embankment and subgrade material shall be spread in layers of uniform thickness not
exceeding 200 mm compacted thickness over the entire width of embankment by
mechanical means, finished by a motor grader and compacted as per Clause 305.3.6.
The motor grader blade shall have hydraulic control suitable for initial adjustment and
maintain the same so as to achieve the specific slope and grade. Successive layers shall
not be placed until the layer under construction has been thoroughly compacted to the
specified requirements as in Table 300-2 and got approved by the Engineer. Each
compacted layer shall be finished parallel to the final cross-section of the embankment.
Moisture content of the material shall be checked at the site of placement prior to
commencement of compaction; if found to be out of agreed limits, the same shall be
made good. Where water is required to be added in such constructions, water shall be
sprinkled from a water tanker fitted with sprinkler capable of applying water uniformly with
a controllable rate of flow to variable widths of surface but without any flooding. The water
shall be added uniformly and thoroughly mixed in soil by blading, dicing or harrowing until
a uniform moisture content is obtained throughout the depth of the layer.
If the material delivered to the roadbed is too wet, it shall be dried, by aeration and
exposure to the sun, till the moisture content is acceptable for compaction.
Moisture content of each layer of soil shall be checked in accordance with IS: 2720 (Part
2). Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when
being placed in the embankment and a maximum size of 50 mm when being placed in the
subgrade.
Compaction: The compaction shall be done with the help of vibratory roller of 80 to 100
kN static weight with plain or pad foot drum or heavy pneumatic tyred roller of adequate
capacity capable of achieving required compaction.
Each layer of the material shall be thoroughly compacted to the densities specified in
Table 300-2. Subsequent layers shall be placed only after the finished layer has been
tested according to Clause 903.2.2 and accepted by the Engineer. A record of the same
shall be maintained by the Contractor.
Excavation of Cuttings
(i) The excavation of cutting shall be carried out in accordance with the relevant approved
drawings and to the levels, width and heights shown thereon.
(ii) Hauling of material from cutting or the importation of fill material to the embankments or
other areas of fill shall proceed only when sufficient compaction plant is operation at the
place of deposition to ensure compliance with specification requirement.
(iii) Any excess depth excavated below the formation level exceeding tolerance of 300 mm shall
be made good by backfilling with suitable material of similar characteristics to that
removed and compacted in accordance.
(iv) The slopes of cuttings shall be cleared of all rock boulders as directed by Supervision
engineers. Any resultant voids shall be made good.
(i) Finish level shall be recorded in accordance to survey practice and jointly checked in the
presence of Engineer.
(ii) The side slopes of cuttings and sub grade shall be as per the approved drawings.
Means:
Man Power:
Highway Engineer
Material Engineer
Survey Engineer
Field Engineers (Execution)
Field Engineers (Quality Control)
Field Supervisors
Skilled & Unskilled Labour
Note – The requirement of Flagmen and labour depends upon the number of stretches where work is being executed
Equipment:
Excavators
Loaders
Dozers
Tippers / Dumpers
Motor graders
Water Tankers with sprinklers
Vibratory Rollers
Survey Equipment: Total Station and Auto Levels
Field Density In-situ Test Equipment.(Sand Replacement Method)
Construction Methods
The construction of earth shoulders will it be accordance with the requirements of Sections 201 and 305 of MORTH.
When the final elevation of the traveled way is different from the elevation of intersecting roads and driveways, the
Contractor shall adjust the grade line of intersecting roads and driveways to meet the elevation of the new shoulder
surfaces. The existing grade line will be adjusted 2 m horizontally for each 35 mm of vertical change in the surfacing
elevation.
During shoulder construction, the embankments shall be adequately drained to prevent damage to the pavement
structure.
The construction of shoulders should be done as per the typical cross sections.
The shoulder shall be tight bladed using a motor grader to remove any vegetation. The underlying sub grade shall be
scarified to a depth of 150 mm and then compacted with at least two complete coverage over the area with an
approved roller.
Shoulder construction shall match the existing width and fill slope or plan section widths, whichever is widest.
Shoulder work will not be considered to have started until soils are placed, graded, and compacted for at least 500 m.
The embankment material shall be placed in successive horizontal layers not exceeding 150 mm in depth before
rolling. Each layer will extend the full width of the embankment and shall be leveled before compaction.
Each layer of embankment material shall be compacted with at least 2 complete coverage over the area with an
approved multiple wheel, pneumatic-tired roller meeting the requirements c. Water may be added to the embankment
material to facilitate compaction.
When the moisture content of the soil used in constructing shoulders is too high to allow rolling or to obtain
satisfactory compaction, each layer shall be diced, harrowed, or otherwise manipulated to facilitate drying.
Any damage to the pavement resulting from shoulder construction activities shall be corrected.
During the course of the operation all required traffic controls should be used and if any semblance of dirt is still on
the surface after the day's work, the appropriate signing should be left up over night.
1. Summary: This work shall consist of laying and compacting coarse graded material on
prepared Subgrade conforming to grading V of table 400-2 of MORT&H and Technical
Specification section 400. The compacted layer thickness shall be 200mm conforming to the lines,
grades and cross-sections shown on the drawing or as directed by the Engineer.
2. Objective: The purpose of this method statement is to describe the sequence of activities and
method for filling of Granular Sub Base and the quality control tests required to be conducted to
make it easier for construction and to form the sub base for the pavement layers.
The following general documents/records shall be kept maintained as per relevant applicable
Quality Management Procedures:
1) Construction Schedules
2) MORT&H and other Technical Specifications including relevant IS/IRC/BS Codes
3) Site order book/complaints including action taken status
4) Product Non-conformance Reports etc.
5) Longitudinal Sections and Cross-section drawings.
All the above documents/records shall be maintained at site and as well as in the laboratory with
proper and defined filing system which can be identified & traceable
4. Means:
a) Man Power:
Highway Engineer
Materials Engineer
QC Engineer
Survey Engineer
Field Engineers (Execution)
Field Engineers (Quality Control)
Sr. Field Supervisors
Jr. Field Supervisors
Skilled & Unskilled Labour
Note – The requirement of Flagmen and labour depends upon the number of stretches where work
is being executed
b) Equipment:
Screening Plant
Excavators
Loaders
Dozers
Tippers / Dumpers
Motor graders
Water Tankers with sprinklers
Vibratory Rollers
Survey Equipment: Total Station and Auto Levels
Field Density In-situ Test Equipment.(Sand Replacement Method)
5. Materials:
The materials used for GSB construction will be Crushed material and confirm to MORT&H
Table 400-1, and as per Technical Specification clause 401.2. 1
The material shall be jointly checked for conformation to gradation requirement. M.D.D & OMC
shall be determined for the material as per IS 2720 part (8).
Materials shall confirm to the following physical requirement.
Sl. Specification
Type of Work Reference Remarks
No Requirement
1 GSB Table 900-1 of -20mm
MORT&H +10mm
PROPOSED MATERIALS
The proposed materials for Granular Sub Base shall be according to Table 400-2 of Grading-V
Morth Specification obtained locally.
6. Construction Method:
1. Suitable materials for Granular Sub Base will be generated from quarry or
river bed by crushing with the crushing plant & using screening plant.
Crushed or screened aggregate for use in Granular Sub Base will be free
from organic and other deleterious matter.
2. The requisite mix ratio will be blended and prepared manually at Crusher
plant having provision for controlled addition of water and forced mixing
arrangement like back hoe loader having 1cum bucket capacity and for
water mixing arrangement with water tanker of 6 kl capacity.
4. The Granular Sub Base material will be transported from the crusher plant
to the place of work. Each dumper load will be tipped under the directions
of the side supervisor.
5. Before unloading the Granular Sub Base arrangement will be made for later
confinement by laying materials in adjoining shoulders.
7. Rolling of the Granular Sub Base layer will be carried out longitudinally and
uniformly overlapping each preceding track at least by one third with until
the entire surface has been rolled. Compaction will commence at the lower
edge of the pavement and progress towards the upper edge. If any
irregularities or undulations develop during rolling (I.e. high spots or
depressions) will be corrected by removing or adding fresh material.
8. Upon the final trim and roll the surface will be well closed and free from
movement under compaction equipment. All loose, segregated or otherwise
defective areas will be made good to the full thickness of the layer and re
compacted. The compaction of the WMM layers will be carried out using
smooth wheeled vibratory roller of 80-100 KN Weight.
9. After completion of Granular Sub Base prior to the application of the Wet
Mix Macadam will be inspected for defects or damage. Remedial action if
required will be carried out in accordance with the specifications of the
contract.
10. Required cross slope and Gradient shall be maintained as per drawings.
11. Moisture content of the loose materials shall be checked before rolling in
accordance with IS 2720 part (2). In case of moisture content is less, the balance
percentage of water will be added to the spreaded material by means of water tanker
fitted with spray bar sprinkling arrangement to ensure that the mix is at its required
moisture content of +1% to -2% of OMC immediate prior to compaction.
Note: The rolling pattern will be established by carrying out on trial stretch of GSB on approved
subgrade in main carriage way portion.
The surface finish and grade of finished granular sub base layer shall confirm to the requirements
of clause 902.
Controls:
Frequency of testing and types of tests to be conducted on compacted granular sub base layer shall
be as follows.
If any non confirmatory observed during inspection and also during testing of materials the same
will be rectified to meet the specifications requirements preventive action will be initiated to
prevent such things in future
The Granular Sub Base construction will be executed as per the above method statement under the
guidance of Highway Engineer and Materials Engineer with the help of supporting staff.
Man Power:
Highway Engineer
Material Engineer
Survey Engineer
Field Engineers (Execution)
Field Engineers (Quality Control)
Field Supervisors
Skilled & Unskilled Labour
Note – The requirement of Flagmen and labour depends upon the number of stretches where work is being
executed
The wet mix macadam (WMM) mix design is carried out by conducting specified tests in
accordance to the technical specification Clause No.406 of contract. As per this clause the material
to be used for WMM will be crushed stone depending upon the grading requirement.
PROPOSED MATERIALS
The proposed materials for Wet Mix Macadam mix design are
1) 40mm size Aggregate
2) 20mm size Aggregate
3) 10mm size Aggregate
4) Stone Dust
REQUIREMENTS AS PER
NATURE OF
S.NO TEST METHOD TECHNICAL
TEST
SPECIFICATION
SELECTED GRADATION
The selected gradation for Wet Mix Macadam is as given below
SPECIFICATION
SIEVE SIZE IN MM
LIMITS
53.00 100
45.00 95-100
22.40 60-80
11.20 40-60
4.75 25-40
2.36 15-30
0.600 8-22
0.075 0-8
CONSTRUCTION
Suitable materials for wet Mix macadam will be generated from quarry by crushing with
the crushing plant. Crushed aggregate for use in Wet mix macadam will be free from
organic and other deleterious matter.
The requisite mix ratio will be blended and prepared in the Wet Mix Macadam Plant
(WMM-Plant) having provision for controlled addition of water and forced mixing
arrangement like pug mill. Previously prepared GSB layer, If required will be re -inspected
and any remedial action carried out prior to the delivery of Mix.
The Wet mix macadam material will be transported from the mixing plant to the place of
work. Each wagonload will be tipped under the directions of the banks man or the side
supervisor.
Before unloading the wet mix macadam arrangement will be made for later confinement by
laying materials in adjoining shoulders along with that of wet mix macadam layer. The mix
will be spread by a paver or grader finisher with out getting segregation along the proposed
alignment.
Rolling of the wet mix macadam layer will be carried out longitudinally and uniformly
overlapping each preceding track at least by one third with until the entire surface has been
rolled. Compaction will commence at the lower edge of the pavement and progress towards
the upper edge. If any irregularities or undulations develop during rolling (I.e. high spots or
depressions) will be corrected by removing or adding fresh material.
Upon the final trim and roll the surface will be well closed and free from movement under
compaction equipment. All loose, segregated or otherwise defective areas will be made
good to the full thickness of the layer and re-compacted. The compaction of the WMM
layers will be carried out using smooth wheeled vibratory roller of 80-100 KN Weight.
After completion of final layer of WMM prior to the application of the Bituminous
Macadam (BM) the WMM will be inspected for defects or damage. Remedial action if
required will be carried out in accordance with the specifications of the contract.
If any non confirmatory observed during inspection and also during testing of materials the same
will be rectified to meet the specifications requirements preventive action will be initiated to
prevent such things in future
The Wet Mix Macadam construction will be executed as per the above method statement under the
guidance of Highway Engineer and Materials Engineer with the help of supporting staff
While dumping the material to form the WMM layers, dust may spread all over near by area, to
prevent this water will be sprinkled over the formation of GSB layer as well as along the route to
the working bed so as to minimize the dust pollution.
Material inspection and testing will be carried out in accordance with the specifications of the
contract.
This method describes the application of Prime Coat over prepared Wet Mix Macadam.
This work consists of application of single coat of low viscosity liquid bituminous material
(Prime Coat) to an absorbent WMM surface preparatory to any superimposed bituminous
treatment or construction.
Temporary Works
Road diversion drainage diversion etc. shall be done as per site requirement.
Surveys
The surface levels of prepared Wet Mix Macadam shall be checked before the application of Prime
Coat.
Utilities
All identified utilities like electrical poles, telephone cables etc.; will be relocated before starting
of the works.
Work Methodology
The WMM surface shall be free from loose foreign material and dust and shall be dry.
The bituminous primer shall be sprayed / distributed uniformly over dry surface of WMM
with self propelled sprayer equipped with self heating arrangement, suitable pump,
adequate capacity compressor and spraying bar with nozzles having pressure system
capable of supplying primer at specified rates and
temperature so as to provide a uniformly unbroken spread of primer.
The temperature shall be kept high enough to permit the primer to be effectively sprayed
through the jets of spray bar and to cover the granular base surface uniformly in the desired
quantity.
Excess priming shall be avoided, any pools of excess primer left on any part of surface
shall be swept out over the adjacent surface before spreading sand to bolt the excess
primer.
Bituminous primer shall not be applied when the temperature in the shade is less than 100c.
The temp. of Emulsion at the time of application shall be 20 – 1000c and the rate of spray is
7.5 kg/10sq.m.
The primer used for prime coat shall be bitumen emulsion complying with IS 8887 and
CSS-1 grade confirming to ASTMD 2397/AASHTO M 208-01 and shall be refinery
produced. The contractor shall demonstrate at a spraying trial that the equipment and
method to be used is capable of producing a uniform spray, with in the tolerance specified
as per terms of contract.
Air compressor and Primer distributor equipped with nozzles to give proper and regular spray.
Temporary Works
Temporary diversion will be constructed for vehicular traffic wherever necessary.
Surveys
Survey will be conducted before and after application of Tack Coat by site Engineer and
requisition will be given to the Engineer for checking.
Utilities
All identified utilities like electrical poles, telephone cables etc.; will be relocated before starting
of the works.
Access
Land access will be provided with the temporary diversions where necessary.
Procurement of RS1
Material Testing
Removal of unwanted material from surface treated with primer or Bituminous courses (if any)
Transiting the Tack Coat with distributor
Pre – spraying check
Spraying of Tack Coat
Work Methodology
Tack coat shall not be applied when the temperature in the shade in less than 100c
Tack Coat will be applied on the top of WMM surface treated with primer or any
bituminous courses as per clause 503 of Tech. Specifications.
The materials used for Tack Coat and the tolerance limits in accordance with the Tech.
specification.
Before application of Tack Coat the surface will be swept clean, free from dust and will be
dry.
Control checks will be carried out as per the Table 900 – 4 of MOST.
o Rate of spread of binder – Not less than Two Tests per day.
The binder will be applied uniformly with the aid of either self-propelled or towed bitumen
pressure sprayer with and spraying bar with nozzles having constant volume or pressure
system, capable of spraying bitumen at specified rates, so as to provide a uniformly
unbroken spread of tack coat.
Air compressor and Tack Coat distributor equipped with nozzles to give and regular spray.
This work shall consists of application of single coat of bituminous prime coat on WMM,
application of tack coat on bituminous layer before laying next layer, mixing, laying and
compacting of Dense Bituminous Macadam
Equipment / Machinery Requirement:
Man Power:
Highway Engineer
Material Engineer
Survey Engineer
Field Engineers (Execution)
Field Engineers (Quality Control)
Field Supervisors
Skilled & Unskilled Labour
Binder:
The material shall be emulsion as per IS 8887 for prime coat and tack coat and viscosity
grade bitumen.
Aggregate:
The coarse aggregate shall consist of crushed stone. The fine aggregate shall consist of
crushed or naturally occurring materials passing through 2.36mm sieve and retained on 75micron
sieve. These shall be clean, hard, durable, dry and free from soft or friable, organic or deleterious
matter. These shall satisfy the physical requirement set forth for the individual relevant materials/
mixes. Before approval of the source it shall be tested for stripping.
This work shall consists of application of a single coat low viscosity, low porous
bituminous material to a wet mix macadam granular surface at the rate of 6-9 kg per
10sqm, to the widths and lines as shown in drawing. The primer shall comply with a
kinematics viscosity of 30-60 centistokes at 600C. The bituminous primer shall not be
applied on wet surface or weather is foggy, rainy or during a dust storm/ wind.
TACK COAT:
This work shall consist of the application of a single coat of low viscosity liquid
bituminous material to a primed/ black top surface at the rate of 2.0 - 3.0 Kg per 10sqm.
The bituminous tack coat shall not be applied on wet surface or weather is foggy, rainy
or during a dust storm/ wind.
The tack coat distributor shall be self-propelled, self-heating bitumen pressure sprayer.
Immediately prior to applying tack coat the surface shall swept clean of dust and loose
particles. Any small and inaccessible areas or narrow strips shall be hand sprayed.
Scope:
This work shall consists of construction in a single course or in multiple course of crushed
aggregates premixed with VG-30 grade bitumen.
Materials:
The aggregate blended with coarse and fines shall consist of crushed rock and it shall
satisfy the physical requirements of grading –1& 2 of DBM of MORT&H Table 500-10.
Procedure:
2. At the time of mixing the temperature of aggregate shall be 150-1700C, bitumen shall be
150-1650C and the mix temperature shall not be more than 1650C. At no time the
temperature difference between aggregate and binder shall not exceed 140C.
3. The material shall be transported in clean vehicles, a thin coating of diesel or lubricating oil
may be applied to the interior of the vehicle to prevent sticking.
4. The surface on which the bituminous layer to be laid shall be swept clean of all loose and
extraneous materials by mechanical or by any other suitable method.
5. The material which to be laid shall be mix designed in accordance with Marshall method.
6. The material shall be spreaded by means of self-propelled paver finisher of with electronic
sensor device, except in inaccessible areas, to the required thickness, lines and camber as
shown in the drawings.
7. The thickness of compacted layer for DBM shall not exceed 60mm. In the inaccessible
areas the mix shall be laid with suitable hand tools.
9. As soon as the material was spreaded, compaction shall commence and completed within
the rolling temperatures. A minimum temperature of 900C shall be maintained at the time
of rolling.
10. Rolling of longitudinal joints shall commence behind the paving operations, after this the
rolling shall start from the lower edge towards upper edge parallel to the centre line of road,
and each pass shall overlap 1/3rd preceding pass. All deficiencies in the surface shall be
made good behind the paver before the initial rolling commenced.
11. The initial rolling shall be done with a smooth wheeled roller of 80-100kN static weight,
followed by intermediate rolling with a vibratory roller of 80-100kN static weight. The
finishing rolling shall be done a smooth wheeled tandem roller of 60-80kN weight.
12. In unidirectional camber and super-elevated portions after the edges has been rolled, the
rolling shall progress from lower to the upper edge.
13. Rolling shall be continued till 98% of the lab density has achieved.
14. All the joints shall offset at least 300mm from parallel joints in the layer beneath,
longitudinal joints shall coincide with either the lane edge or the lane markings and shall
not situated in wheel track zones.
15. The surface levels of completed construction shall vary within +6mm to –6mm.
17. During the period of construction arrangement of traffic shall be in accordance with
MORT&H 112.
1. SCOPE:
This work shall consist of construction of 50 mm thick bituminous Surface course in one
layer of 50 mm thick.
2. MATERIALS:
A) BITUMEN:
B) COARSE/FINE AGGREGATE:
The Coarse aggregate consists of crushed stone. It shall be clean, strong, durable of
fairly cubical shape and free from disintegrated pieces. The following nomenclature & size of
materials proposed to be used in the BC mix.
i) 20 – 10mm.
ii) 10 - 6mm.
iii) 6mm & Down.
C) FILLER:
3. AGGREGATE GRADATION:
The Combined coarse aggregates, fine aggregates and mineral filler and Cement shall
produce a mixture to conform to the grading set in table 500—18 and Contract technical
specification.
4. MIX DESIGN:
The job mix formula for the BC mix is to be prepared at approved bitumen field laboratory
as per relevant clauses and contract technical specifications of BC.
The Job Mix Formula is to be prepared with all details required as per Clause 509.3.3.
6. CONSTRUCTION OPERATION:
A) PREPARATION OF BASE:
The Surface course on which Bituminous Concrete is to be laid shall be prepared, shaped
and conditioned to the specified lines, grades and cross-sections in accordance with clause 501 &
509.4 and as per the Construction drawings.
B) TACK COAT:
Bituminous Course mix will be prepared in a central hot mix plant (Batch mix type) and
capable of yielding a mix of proper and uniform quality with thoroughly coated aggregates.
The plant is having separate cold bin and hot bin to control the gradation of aggregates.
At the time of mixing the temperature of aggregate shall be 150-1700C, bitumen shall be
150-1650C and the mix temperature shall not be more than 1650C. At no time the
temperature difference between aggregate and binder shall not exceed 140C.
The mixture will be transported from the mixing plant to the point of use in suitable tipper
vehicles.
D) SPREADING:
The mix transported from the central hot mix plant to the site will be spread by means of a
paver finisher shall have the essential features of self propelled paver with suitable screeds
capable of spreading, tamping and finishing the mix to specified grade, lines and cross-
sections.
In restricted locations and in narrow width where the available equipment cannot be
operated in the small places, manually laying of mix as per required level & camber will
be done.
As soon as the material was spreaded, compaction shall commence and completed within
the rolling temperatures. A minimum temperature of 900C shall be maintained at the time
of rolling.
7. ROLLING:
After spreading the mix by paver, it shall be thoroughly compacted by rolling with a tandem roller
moving at a speed for not more than 5km/hr immediately following close to the paver. The initial
(or) breakdown rolling, intermediate rolling and finish rolling will be done as per Clause 509.4.8.
8. OPENING TO TRAFFIC:
Traffic may be allowed after completion of the final rolling when the mix has cooled down to the
surrounding temperature.
The surface finish of construction shall conform to the requirements of Clause 903.4.4
Control on the quality of materials and works shall be exercised in accordance with
Section 900.
The work shall consist of reinforcement cement concrete work and furnishing the structure for
box culvert, slab culvert and minor bridges at the location shown in the drawing or as
instructed by the engineer and in accordance with the requirements of the Technical
Specification.
After completion of site preparation, alignment of above said culverts and or minor bridges is
marked on the ground with lime and /or string. With reference to its alignment other points of
structures like wing wall, abutment wall are pegged. For construction purpose temporary bench
mark (TBM) is also established near by the location of structure. The place of TBM shall be
chosen in such a way that it will not be disturbed by the construction activities and it shall
remain in position until all the structure are completed in that location.
Cement
Cement confirming to IS: 12269 shall be used only after ensuring the minimum required
design strength. Manufacturer’s test certificate shall be submitted to the Engineer for every
consignment of cement. The certificate shall cover all the tests for chemical requirements,
physical requirements and chloride content.
Independent tests of samples drawn from the consignment shall be carried out at the site
laboratory or in an independent laboratory approved by the Engineer, immediately after
delivery.
Coarse aggregate
Coarse aggregate shall be produced from approved quarry in required sizes. It shall consist of
clean, hard, strong, dense, non-porous and durable pieces of crushed stone or a suitable
combination thereof as specified.
Maximum nominal size of aggregate for various structural components shall conform to the
Table 1700-7 of MORTH Specifications.
Fine aggregate
Fine aggregate for structural concrete shall be clean, hard, strong and durable pieces of crushed
stone or suitable combination of natural sand. They shall not contain dust, lumps, soft or flaky,
materials, mica or other deleterious materials in
such a quantity to reduce the durability and strength of concrete. Gradation of fine aggregate
shall conform to Table 1000-2 of MORT&H Specifications.
Water
Water shall conform to section 1010 of MORT&H Specifications. Water shall be free from
injurious materials like oils, acids, alkalis, salts, sugar, organic materials or other substances
that may be deleterious to the concrete or steel. Potable water is generally considered
satisfactory for construction purpose. Mixing and curing with seawater shall not be permitted.
Formwork
All materials for formwork shall comply with the requirements of IRC: 87. Only steel
formwork shall be used. All bolts shall be countersunk. The use of approved internal ties or
plastic spacer shall be used. Structural steel tubes used as support for forms shall have a
minimum wall thickness of 4mm.
Reinforcement
Reinforcement shall be Thermo-Mechanically Treated (TMT) deformed bars of grade Fe 500
confirming to IS: 1786 code. Only uncoated steel shall be used as per shape and size shown on
the drawing. It confirms to the specification or as approved by the Engineer.
Concrete
All materials for this concrete shall confirm to the section1000 of MORT&H specifications.
Equipments
i) Batching Plant
ii) Transit Mixer Trucks
iii) Vibrator
iv) Wheel Loader
v) Excavator
vi) Shuttering Material
vii) Bar Bending & Cutting machine
viii) Concrete Pump
DESIGN OF FORMWORK
Complete design and drawings of formwork for slab super structure will be submitted for
approval before start of work.
WORKMANSHIP
Workmanship shall comply with the clause 1504.2, 1504.4 & 1504.10 of MORTH
specifications. Form shall be made so as to produce a finish concrete true to shape, line and
levels and dimensions as shown on the drawings, subject to the tolerances specified in
respective sections of these specifications, or as directed by the engineer.
CONSTRUCTION JOINTS
Construction joints shall be provided as minimum as possible and shall be as per drawings.
Laitance shall be removed before fresh concrete is cast. The surface shall be roughened enough
not to dislodge the coarse aggregate. Concrete may be brushed with stiff brush in its green
stage at the location of construction joint. Fully hardened concrete shall be treated with
mechanical tools to remove the laitance.
10.5. REINFORCEMENT
BENDING OF REINFORCEMENT
Bar bending schedule shall be prepared and shall be submitted to get Engineer approval before
start of work. Bar schedule shall include number, shape and cutting length of bar and weight in
respect of each type. A separate bar bending schedule shall be prepared for auxiliary bars like
spacer, chairs etc.
PLACING OF REINFORCEMENT
Reinforcement shall be placed in accordance with the drawing and get inspected and approved
by Engineer.
After approval from Engineer, immediately pouring of concrete follows.
- Reinforcement shall be tied with binding wire in such a way that it won’t be displaced while
pouring the concrete on it.
- Cover block are made of cement mortar with the same durability of surrounding concrete.
- Layers of bar shall be separated by space bars kept at approximately 1m interval and min.
size is 12mm, or maximum size of main reinforcement, whichever is greater is used.
Horizontal reinforcement shall not be allowed to sag between supports.
- Necessary auxiliary bars like spacer, chairs, and blocks shall be provided to fix in its position.
10.6. CONCRETE
GRADES OF CONCRETE
Concrete used in any structure shall be specified by designation along with prescribed method
of Design Mix or Nominal Mix. For all items of work Design Mix shall be used. Nominal mix
concrete is not designed by test and proportions of materials are in accordance with the
drawing, or as per Table 1700-6 of MORTH. Nominal mix can only be permitted if it is shown
in contract drawing or approved by Engineer. Design mix shall be done as given in IS-10262-
2019 code.
PROPORTIONING OF CONCRETE
In proportioning concrete, the quantity of both cement and aggregate shall be determined by
weight. Cement is weighed from bulk stock at site and aggregates shall weigh separately.
Water shall either be measured by volume in calibrated tanks or weighed. All measuring
equipment shall be in a clean and serviceable condition. Their accuracy shall be periodically
checked. Water cement ratio is maintained constant to its connecting value taking in to account
of moisture
Content of aggregates. The amount of water to be added shall be adjusted to compensate for
the variation in moisture content due to weather condition.
10.7. ADMIXTURES
Duly tested admixtures/ additives confirming to IS 6925 and IS 9103 (without replacement of
Cement) may be used subject to satisfactory proven use, with the approval of Engineer.
Admixture generating Hydrogen or Nitrogen and containing chloride, Sulphide, Sulphates,
Nitrates and any other materials liable to affect steel or concrete shall not be used.
Size of coarse aggregate shall refer to the in MORT&H technical specification table no. 1700-
7.
with plasticizer and lateral pressure due to fast rate of placement by concrete pumps.
1. SCOPE OF WORK:
The work shall consist of construction of Retaining walls. Retaining wall is a structure used to
retain backfill and maintain difference in the elevation of the two ground surfaces. Retaining
wall may be effectively utilized to tackle the problem of landslide in hill area by stabilizing the
fill slopes and cut slopes.
2. BEARING CAPACITY:
The allowable bearing capacity shall be calculated in accordance with IS 6403 on the basis of
soil test data. In case of non-erodible rocks, the bearing capacity shall not exceed one-half the
unconfined compression strength of the rock if the joints are tight. Where the joints are open,
the bearing capacity shall not exceed one-tenth the unconfined compression strength of the
rock. In case of erodible and weak foundations (clay, loose soil, etc) gabion walls shall be
preferred as they can withstand high differential settlements.
In the absence of soil test data, for preliminary design the values given in Table-1 may be
adopted. Bearing capacity of rocks may be determined in accordance with IS: 12070.
The design of a retaining structure shall consist of two principal parts, the evaluation of loads
and pressures that may act on the structure and the design of the structure to withstand these
loads and pressures.
Depth of walls:
The depth of retaining wall below ground level or terrace level shall be at least 500 mm below
side drain within soil or highly jointed rock and foundation shall be on natural firm ground. All
multiple breast walls shall be taken to the firm rock surface.
The rain water flows at a high speed from high retaining walls (~3 m). This shall lead to toe
erosion of soft rocks (shale/sand rock/conglomerate, etc) at the foundation. So, dry stone
pitching shall be done. Stones of 150 mm size may be laid on slope for a distance of 1 m below
the toe of retaining walls.