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Sabarmati River Front Development Corporation Limited Page 1
SECTION IV
TECHNICAL SPECIFICATIONS
Signature of Bidder
TECHNICAL SPECIFICATION FOR CIVIL WORK

(RETAINING WALL, SPECIAL FILL, ROAD WORK)
Signature of Bidder
4.2 Technical Specifications for Earthwork
4.2.1 Scope..............................................................................................................
4.2.2 Applicable Codes .....................................................................................................
4.2.3 Drawings ..................................................................................................................
4.2.4 Classification of Earth ..............................................................................................
4.2.5 General............................................................................................................
4.2.6 Clearing....................................................................................................................
4.2.7 Excavation ..............................................................................................................
4.2.8 Description ...............................................................................................................
4.2.9 Setting out ................................................................................................................
4.2.10 Dewatering and Protection ......................................................................................
4.2.11 Backfilling ................................................................................................................
4.2.12 Disposal of Surplus Excavation Materials ...............................................................
4.2.13 Drainage ..................................................................................................................
4.2.14 Measurement and Rates .........................................................................................
4.2.15 Working with other Contractors..........................................................................

Sub-Section 4.2
Technical Specifications for Earthwork
4.2.1 Scope
This part of the specification deals with requirements for construction of road on east bank
at various location, Construction of retaining wall, Concrete Pavement, earthwork in
excavation in different materials, site grading, filling in areas shown in drawings, back
filling, conveyance and disposal of excess excavated soil or stacking them properly as
directed by the Engineer and all operations covered within the intent and purpose of these
specifications.
The backwater of Vasana barrage exists above riverbed level at Subhash Bridge
and stagnant water pools is met with almost throughout the year.
The entire work of construction will be carried out in dry condition works and
whatsoever arrangement required for dewatering is included in the scope of the
work and no separate payment will be paid on this account.
4.2.2 Applicable Codes
The provisions of MORTH specifications for Road and Bridge Works published by IRC,
New Delhi (August 2001) shall be followed for all purposes of the earthwork shall be
followed.
4.2.3 Drawings
The Engineer will furnish drawings wherever in his opinion such drawings are required to
show the areas to be excavated or filled sequence of priorities etc. The contractor shall
follow such drawings strictly.
4.2.4 Classification of Earth
For purpose of earth work soil shall be classified as under:
Loose / Soft soil: Any soil which generally yields to the application of picks and shovels,
phawras, rakes or any such ordinary excavating implements or organic soil, gravel, silt
sand, turf, clay, peat etc. fall under this category.
Dense / Hard Soil: Any soil, which generally requires the close application of picks, or
jumpers or scarifies to loosen it. Stiff clay, gravel and cobble stone etc. fall under this
category.
(Note: Cobble stone is the rock fragments usually rounded or semi-rounded having
maximum diameter in any one direction between 80 & 300 mm).
Mud: Mud is a mixture of ordinary soft soil and water in fluid or weak solid state.
Soft / disintegrated rock: (Not requiring blasting). This shall include the type of rock and
boulders, which may be quarried or split with crowbars. Laetrile and hard conglomerates
also come under this category.
4.2.5 General
a. The contractors shall furnish all tools, plant, instruments qualified supervisory
staff, labour, materials, any temporary works, consumables and everything
necessary, whether or not such items are specifically stated herein, for completion
of the job in accordance with the requirements of specifications.
b. The contractor shall carry out the survey of the site before excavation and set out
properly all utility and service lines and establish levels for various works such as
earthwork in excavation for grading, foundations, plinth filling, drains, cable
trenches, water pipe lines, culverts, retaining walls etc. These will be checked by
the Engineer and thereafter recorded plan duly signed by the contractor shall be
furnished to the Engineer for his approval before starting actual foundation
excavations.
c. The excavation shall be done to correct lines and levels. This shall include where
required, proper strutting and strong shoring to maintain excavation and impart
safety against collapse of soil and erection and maintenance of sand barricades
around excavations with warning signs displayed during night for safety purposes.
The warning signs shall be with reflector type paints.
The rates quoted shall include for dumping of excavated material in regular heaps, bunds,
rip rap with regular slopes as directed by the Engineer within all leads and levelling the
same so as to provide natural drainage. Soil excavation shall be properly stacked as
directed by the Engineer. As a rule all softer materials shall be laid along the centre of the
heaps, the harder and more resistant materials, forming the casing on the sides and the
top.
4.2.6 Clearing
The area to be excavated / filled shall be cleared of all fences, trees, plant logs, stumps,
bush, vegetation, rubbish, slush, pavement structure etc. and other objectionable matter. If
any roots or stumps of trees are met during excavation, they shall be removed. The
material so removed shall be disposed off as directed by the Engineer. Where earth fill is
intended, the area shall be cleared of all loose or soft patches, top soil containing
objectionable matter / materials before filling commences. No separate payment shall be
made for such clearing works.
4.2.7 Excavation
4.2.7.1 Description
Excavation shall consist of removal of materials for the construction of the foundations of
approach structures retaining walls, head walls, and other similar structures in accordance
with the requirements of this specification on the lines and dimensions shown on the
drawings or as directed by the Engineer. The work shall include all necessary strutting,
shoring, bracing, draining and pumping, the removal of all logs, stumps, shrubs and other
deleterious matter and obstructions necessary for placing the foundations, trimming
bottoms of excavation, backfilling, cleaning up the site and disposal of all surplus
materials.
4.2.7.2 Setting out
The joint site measurements and levels by acceptable sounding method shall be carried
out by the contractor for arriving at the exact quantity of the earthwork. After the site has
been cleared the limits of earthwork for foundations shall be set out true to lines and
sections as shown on the drawing or as directed by the engineer in charge. The contractor
shall provide all labour, survey instruments and materials such as string, pegs, nails,
bamboos, stones, lime mortar, concrete etc., required in connection with the setting out.
He shall be responsible for the maintenance of benchmarks and other marks and stakes
as long as they are required for the work in the opinion of the Engineer.
4.2.7.3 Dewatering and Protection

Where water is met with in excavation due to seepage, springs, rain or other reasons, the
contractor shall take adequate measures such as bailing, pumping, construction of
diversion channels, drainage channels, bunds, and any other necessary works to keep the
foundation trenches/ pits dry when so required and to keep the green concrete/ masonry
protected against damage by or undermine its strength including erosion at the contractors
cost and risks. In this regard and other details thereof, it shall be left to the choice of the
contractor but subject to the approval of the Engineer. Approval of the Engineer shall
however, not relieve the contractor of his responsibility for the adequacy of dewatering and
protection arrangements and the safety of the works. Pumping from inside of any
foundation enclosures shall be done in such a manner as to preclude the possibility for the
movement of water through any freshly placed concrete. No pumping shall be permitted
during the placing of concrete or for any period of at least 24 hours thereafter, unless it is
done from a suitable sump separated from the concrete work by a watertight wall or similar
means.
At the discretion of the contractor and at his cost, cement grouting or other approved
methods may be used to prevent or to reduce seepage and to protect the excavation area.
The contractor shall take all precautions in diverting channels and in discharging the
drained water so as not to cause damage to the works or to adjoining property.
4.2.7.4 Backfilling
The back filling shall follow in sequential manner after placing of each lift of retaining wall
heights/levels as shown in the approved drawings.
Selected granular borrow base fill material of quality as specified in section 305 of
MORT&H specifications (August 2001) shall be used, placed and compacted in the Active
Zone behind the Reinforced Retaining Wall as shown in the drawings, for all purposes of
back filling with following modifications/ additions.
The fill materials in Active Zone shall confirm to the grading requirements given in Table
300-3, class III of MORTH Specifications (August 20001).Mechanically stabilised earth
shall be of good quality, free draining, granular and/or selected fill. The recommended soil
gradation is in the range of).02 mm to 6mm or as indicated in the drawings.
The phy (angle of repose) values shall not be less than 30 degree.
The riverbed material confirming to the prescribed specification only to be used for special
fill behind retaining wall from d/s of Vasana barrage. The dredging of sand from riverbed or
any other methodology for excavating sand from project area of Sabarmati River Front
Development from Railway Bridge to u/s of Vasana barrage will not be allowed. The back
filled materials shall be compacted to the extent relative compaction as percentage of
maximum laboratory dry density worked out as per IS: 2720 (Part 8) shall not be less than
95% modified proctor density.
All required care shall be taken for keeping Retaining wall intact and to ensure that they
are not damaged while dumping, spreading, watering and compacting of the backfilled
materials.
The measurements for this item shall be in Cubic meter and the rate shall be inclusive of
followings:
1. Cost of arrangement of land as a source of material of required quality and

quantity for construction.
2. Compacting ground supporting Backfilling / Sub-grade.
3. Cost of watering or drying of material in borrow area during construction as

required.
4. Spreading in layers bringing to appropriate moisture content and compacting to

specification requirements.
5. Spreading and dressing top and slopes of the filling including rounding of corners.
6. All labour, material, tools, equipments and incidentals necessary to complete the
work to the specifications.
Before starting the work of this item, the contractor shall submit the method
statement for scrutiny of the Engineer. No work shall be commenced for this item
before the method statement given by the contractor is approved.
Successive layers shall not be placed until the layer under construction has been
thoroughly compacted so that relative compaction as percentage of maximum laboratory
dry density tested as per IS: 2720 (Part-B) shall not be less than 95.
All care shall be taken by the contractor for not disturbing / damaging the Retaining wall.
To the extent available, selected surplus soils from the excavation shall be used as backfill
as may be directed by the Engineer and after obtaining his concurrence before actually
taking any action in the re-use of this excavated stuff. Fill material shall be free from clots,
salts, sulphates, and organic or other foreign deleterious materials. All clots of earth shall
be broken or removed. The contractor may use the back filling material available from river
bed if found suitable.
If any selected fill material is required to be borrowed the contractor shall make
arrangement for bringing the material from outside borrow pits. The material sources shall
be subject to the prior approval of the Engineer. The contractor shall make necessary
access roads to such borrow areas at his own cost, if such access roads do not exist.
Backfilling shall be carried out in such a manner as not to cause undue thrust on any part
of the structure. Annular space around foundations shall be back filled with coarse sand
after clearing it of all debris and in layers of 150 mm. loose thickness, watered and
compacted to the satisfaction of the engineer in charge and up to the original surface level.
The remaining back filling shall be done in like manner as aforesaid, using excavated
earth if approved or by borrowed earth from approved source.
Where necessary to facilitate compaction of the ground to 95% relative compaction as

stated above, a further depth of maximum of 0.20 meter thickness shall be loosened,
watered and compacted in accordance with Clause 305.3.5 and 305.3.6 to not less than
95% of maximum dry density, determined in accordance with IS:2720 (Part i)
Borrow materials
No borrow area shall be made available by the Employer for this work. The arrangement
for the source of supply of the material for embankment and sub grade as well as
compliance to the different environmental requirements in respect of excavation and
borrow areas as stipulated, from time to time, by the Ministry of Environmental and Forest,
Government of India and the local bodies, as applicable shall be the sole responsibility of
the Contractor. The contractor shall follow all mining rules and pay royalties and other
taxes as applicable. The riverbed material confirming to the prescribed specification only
to be used for special fill behind retaining wall from d/s of Vasana barrage. The dredging of
sand from riverbed or any other methodology for excavating sand from project area of
Sabarmati River Front Development from Railway Bridge to u/s of Vasana barrage will not
be allowed.
The contractor shall at least 7 working days before commencement of compaction submit
the following to the Engineer for approval:
i) The Values of maximum dry density and optimum moisture content obtained in
accordance with IS: 2720 (Part 8) for each fill material he intends to use.
ii) The graphs showing values of density against moisture content from which each
of the values in (i) above of the maximum dry density and optimum moisture
content were determined.
iii) The dry density-moisture content-CBR relationship for each of the fill materials he
intends to use in the backfilling.
4.2.7.5 Disposal of Surplus Excavation Materials
All the excavated materials shall be the property of the client. Where the excavated
material is directed to be used in the construction of the works for general grading,
planning, filling or in embankments the operations shall be so arranged in such a manner
that the capacity for cutting, haulage and compaction are nearly the same. Prior approval
for the same shall be obtained from the Employer / Engineer. The remaining surplus or
unused excavated stuff shall be disposed off as may be directed by the engineer in
charge. All hard materials such as hard murrum, rubble etc. not intended for filling in
foundations, plinth or embankments shall be stacked neatly for future use as directed by
the Engineer.
4.2.8 Drainage
Drainage shall be very strictly followed as per drawing and specification in detail. Drainage
system comprising of perforated PVC drainpipe of 100mm diameter and of sufficient
strength, wrapped with non-woven geo-textile, as per approved drawing shall be provided
as shown in the drawing and filter media running along the Retaining wall. The retained fill
shall have drainage by well-graded crushed aggregate to allow free draining of the
reinforced fill along with the retained fill.
4.2.9 Measurement and Rates
The measurement and payment for backfilling shall be as per the Clauses 305.8 and
305.9 of MORTH specification (August 2001).
Rate for earthwork shall include the following
a) Excavation and disposing surplus earth as directed by the engineer in charge.
b) Setting out works, profiles etc.

c) Site clearance such as cleaning of vegetation, roots, shrubs, brushwood etc.
d) Bailing/pumping out water in excavation from rains, sub soil water etc.
e) Protection works, temporary supports for safety, by underpinning if need be to

existing services, i.e. drains, water mains, cables and other utility services met
within the course of excavation. Removal of electricity and / or telephone cable,
posts, etc. as necessary, shall be arranged by the engineer in charge.
f) Forming (or leaving) steps inside deep trenches and their removal :
g) Removing slips or falls in excavation.
h) Fencing and/ or other suitable measures for protection against risk of accidents,
as approved by the engineer in charge.
i) Excavation for insertion of planking and strutting where required.
j) Backfilling the trenches with selected material.
k) Transporting and using the excavated stuff as embankment including watering

and compaction.
l) Scrapping, watering and compaction of the original ground to 95% proctor density
at O.M.C.
4.2.10 Working With other agency
Since the other agency shall be executing earth filling behind the special fill area, the level
of earth filling will have to match with earth work in general filling and the work has to be
carried out in sequential manner. The work, as far as possible shall be executed in such
manner that at any given point of time there is hardly any level difference between the
general fill and the special fill and no gray areas of loose fill at junction of the general fill
and special fill are left uncompacted.
SUB SECTION 4.4

GENERAL SPECIFICATIONS FOR OTHER CONCRETING
4.4.1 General ..............................................................................................................
4.4.1.1 Other Codes and Specifications ........................................................................
4.4.1.2 Grade of Concrete .............................................................................................
4.4.1.2.1 Controlled Concrete ..........................................................................................
4.4.1.2.2 Ordinary Concrete. ............................................................................................
4.4.1.2.3 Strength Requirement of Concrete ................................................................... ...
4.4.1.3 Materials ............................................................................................................ ...
4.4.1.3.1 Cement..
4.4.1.3.2 Fine Aggregates ................................................................................................
4.4.1.3.3 Coarse Aggregates ...........................................................................................
4.4.1.3.4 Reinforcing Steel ...............................................................................................
4.4.1.3.5 Water .................................................................................................................
4.4.1.3.6 Admixture ..........................................................................................................
4.4.1.4 Storage of Materials...........................................................................................
4.4.1.4.1 Cement..............................................................................................................
4.4.1.4.2 Aggregates ........................................................................................................
4.4.1.4.3 Reinforcing Steel ...............................................................................................
4.4.1.5 Mixing of Concrete .............................................................................................
4.4.1.5.1 Transport, Placing and Compaction of Concrete .............................................
4.4.1.6 Sampling and Strength of Designed Concrete Mix............................................
4.4.1.6.1 General...........................
4.4.1.6.2 Frequency of Sampling...
4.4.1.6.3 Test Specimen.
4.4.1.6.4 Test Results of Samples.
4.4.1.7 Acceptance Criteria..
4.4.1.7.1 Compressive Strength.
4.4.1.7.2 Flexural Strength..
4.4.1.7.3 Quantity of Concrete Represented by Strength Test Samples .........................
4.4.1.8 Inspection and Testing .......................................................................................
4.4.1.8.1 Testing...............................................................................................................
4.4.1.8.2 Core Test...
4.4.1.8.3 Manufacturers Certification Testing Rules,etc
4.4.1.10 Chloride Contents.
4.4.1.11 Measurements for Payment
4.4.1.12 Unacceptable Work..
4.4.1.13 Steel/plywood form work and staging material.....................................................
4.4.1.14 PVC water stop..................
4.4.1.15 Joint fealer .............................
4.4.1.16 Polysulphide sealant..............
SUBSECTION 4.4
GENERAL SPECIFICATIONS FOR OTHER CONCRETING (Retaining wall,
ramps, concrete pavements, staircases and other R.C.C works)
4.4.1 General
For all items of concrete in any portion of the structure or its associated works, controlled
concrete shall be used unless otherwise specified, when ordinary concrete of the mix
shown on drawings or as directed by the Engineer-in-charge may be used.
The provision of the latest revisions of the following I.S. codes shall form a part of this
specification to the extent they are relevant.
IS 226 Specification for structural steel (Standard Quality)

IS 280 Specification for mild steel wire for general engineering purpose
IS 303 Plywood for general purpose
IS 383 Specification for coarse and fine aggregates from natural sources for
concrete
IS 432 (All parts) - Specifications for mild steel and medium tensile steel bars
hard drawn steel wire for concrete reinforcement.
PART - I Mild Steel and Medium tensile bars
PART II Hard drawn steel wires
IS 456 Code of practice for plain and reinforced concrete (Fourth revision-2000)
IS 460 Specification for test sieves (All Parts).
IS 516 Methods of tests for strength of concrete
IS 650 Standard sand for testing of cement
IS 1139 Hot rolled mild steel and medium tensile steel deformed bars for concrete
reinforcement.
IS 1199 Methods of sampling and analysis of concrete.
IS 1200 Method of measurement of building and civil engineering works.
IS 1343 Code of practice for pre-stressed concrete
IS 1542 Sand for plaster
IS 1566 Specification for hard drawn steel wire fabric for concrete reinforcement
IS 1732 Dimensions for round and square steel bars for structural and general
engineering purposes.
IS 1786 Specification for high strength deformed steel bars & wires for concrete,
reinforcement
IS 1791 Batch type concrete mixture
IS 2062 Specification for structural steel (fusion welding quality)
IS 2386 Methods of test for aggregates for concrete (All Parts)
IS 2502 Code of practice for bending and fixing of bars for concrete reinforcement
IS 2751 Code of practice for welding of MS Plain and deformed bars for reinforced
concrete construction
IS 5525 Recommendation for determining reinforcement in reinforced concrete
works.
IS 5640 Method for determining the aggregate impact value of soft coarse
aggregate
IS 5816 Method of test for splitting tensile strength of concrete cylinder
IS 6006 Uncoated stress relieved strand for pre-stressed concrete
IS 6461 Glossary of terms relating to cement concrete
IS 8041 Specifications for rapid hardening Portland cement
IS 8043 Specifications for hydraulic Portland cement
IS 8112 Specification for 43 grade ordinary Portland cement.
IS 9103 Admixtures for concrete.
IS 9556 Code of practice for design and construction diaphragm walls.
IS: 12269 Specification for 53 grade ordinary Portland cement,
4.4.1.1 Other Codes and Specifications
Other IS Codes pertaining to the items of cement concrete work in structural work and not
listed above shall also be deemed to come under the purview of this clause. Specifications
in this volume and Diaphragm wall specifications IS also apply.
4.4.1.2 Grade of Concrete
4.4.1.2.1 Controlled Concrete
For controlled concrete, design of the mix shall be arrived at after preliminary tests and in
its production all necessary precautions shall be taken to ensure that the required works
cube strength is attained and maintained. The design of the concrete mix will be done as
per relevant IS codes and from representative samples of the aggregates.
The controlled concrete shall be in grades designated as M-20, M-25, M-30 and M-35 as
per the terminology used for such designation in IS codes of practices. Controlled concrete
shall only be done by Batching Plant. Volumetric equivalent mix shall not be allowed.
4.4.1.2.2 Ordinary Concrete
In case of ordinary grade concrete, mix is not required to be designed by preliminary tests,
Proportion of cement, fine aggregates, coarse aggregates are specified by volume. The
ordinary concrete shall be in grades designated as M-10, and M-15 with the suffix
ordinary added to it. In the designation of a concrete mix. letter M refers to the mix and
the number to the specification works (compressive) strength of 150mm cube of the mix
expressed in N/mm2 28 days.
4.4.1.2.3 Strength Requirement of Concrete
Only ordinary Portland cement conforming to IS269 shall be used. The compressive
strength requirements for various grades of concrete, controlled as well as ordinary shall
be as given in Table 1. Where rapid hardening Portland cement is permitted the 28 days
compressive strength requirement specification is Table 1 shall be met at 7 days.
For controlled concrete, the mix shall be so designed as to attain in preliminary tests, a
strength at least 33 percent higher than that required on work tests, for concrete mix up to
and including M-20 and 25 percent higher for higher strengths. Preliminary tests need not
be made in case of Ordinary Concrete.
Table - 1
2
Grade of Concrete Compressive work strength in N/mm on 150mm cubes as per
testing conducted in Accordance with IS 516
Min. At 7 Days Min at 28 Days

M-10 7.0 10.0
M-15 10.0 15.0
M-20 13.5 20.0
M- 25 17.0 25.0
M- 30 20.0 30.0
M- 35 24.0 35.0
Note: In all cases, the 28 days compressive strength specified in Table-1 shall alone be
the criteria for acceptance or rejection of the concrete.
When the strength of a concrete mix, as indicated by tests, lies in between the strength for
any two grades specified in Table-1. Such concrete shall be classified for all purposes as
concrete belonging to the lower of the two grades between which its strength lies.
4.4.1.3 Materials
Prior to deciding on the source for procurement of constituents of concrete viz. Fine and
coarse aggregates, the contractor/s shall specifically assess the soluble chloride and
sulphate contents of fine and coarse aggregates (at source) and their permissible limits
shall be got approved by Engineer. Regular checks as directed shall also be carried out
not only at supply source but also prior to their use in the permanent work to ensure that
the aggregate do not contain impurities exceeding the permissible limits.
4.4.1.3.1 Cement
The cement shall be ordinary Portland cement or rapid hardening Portland cement
conforming to IS: 269, 8112, 12269 & 8041.Fresh quality cement shall be procured only
from approved manufacturer / supplier (Major cement plant manufacturer like Ultratech,
Ambuja,Vikram, Sanghi) and shall be subject to prior approval of the Engineer-in-charge.
Following types of cement shall be used
a) Unless specified otherwise, all cement used for the work shall be ordinary
Portland cement or such other cement as may be permitted by the Engineer.
Portland cement 53 grade shall comply with the requirements of the latest issue of
the IS 269, 8112, 12269. High alumina cement, rapid hardening cement etc. and
Portland slag cement may be used only when permitted by the Engineer, and
such cement shall be in accordance with relevant IS Portland pozolona cement
when permitted by Engineer shall conform to IS 1489 but it shall not be used for
RCC structural member.
b) Cement which has remained in bulk storage at the mill for more than 6 months, or
which has remained in bag in dealers storage for over 3 months, or which has
been stored at project site for more than 3 months shall be re-tested before use.
Cement shall also be rejected if it fails to conform to any of the requirements of
these specifications such cement shall not be allowed to used in the structure.
Table -2
Grade of Concrete Minimum cement content and water cement ratio
Minimum cement content Maximum water cement

Kg/cum ratio
M-15 250 0.50
M- 25 300 0.40
M- 30 350 0.40
4.4.1.3.2 Fine Aggregates
Well-graded sand consisting of 50percent coarse sand shall be used (see IS: 2116 -
1965). Fine aggregates shall consist of natural sand, manufactured sand, or and approved
combination thereof and shall conform to IS 383. The grading zone of sand proposed for
use shall be supplied by the contractor and got approved from the Engineer before use.
The sand shall be of Siliceous material, sharp, hard strong and durable and shall be free
from adherent coatings, clay, dust, alkali, organic material, deleterious matter, lumps etc.
Either natural or manufactured sand shall be prepared for use by such screening or
washing, or both, as necessary, to remove all objectionable foreign matter while
separating the sand grains to be required size fractions. Natural sand shall be washed,
unless specific written authority is given by the Engineer to use and that meets
specifications and standards of cleanliness. The cost of screening and washing must be
borne by the contractor. The fine aggregates shall be taken from a source approved by the
Engineer and this shall not be allowed to be changed without the permission of the
Engineer.
4.4.1.3.3 Coarse Aggregates
All the aggregates shall conform to IS: 383-1970. Well-graded coarse aggregate of 20-mm
size shall be normally used in reinforced concrete Retaining walls.
Coarse Aggregates shall consist of hard, strong, durable particles of crushed stone and
shall be free from thin elongated soft pieces, organic or other deleterious matter. It shall
not have adherent coating. It will be from a source approved by the Engineer-in-Charge
and shall confirm to IS 383. Coarse aggregates from approved quarries only meeting the
test requirements shall be permitted in all concrete.
Coarse aggregate shall be washed if necessary to remove all vegetable and other
perishable substances and objectionable amount of other foreign matter. The cost of
washing and screening being borne by the contractor.
4.4.1.3.4 Reinforcing Steel
Unless specified otherwise HYSD, TMT bars conforming to IS: 1786 (Fe 500 grade) shall
be used. The extra payment on account of any higher grade of steel used in the work will
not be payable and contractor unit rate includes any of the above grade specified in the
contract. Reinforcement from primary manufacturers i.e SAIL, TATA Steel and VIZAG
(RINL) is only permitted.
All reinforcement bars and other structural steel sections used shall be clean and free from
loose mill scales, dust, rust, oils, grease, paint or other coatings which may deduce the
bond with concrete.
The joints between main reinforcement, bars the links and other steel sections shall be
properly welded with respect to design considerations and handling requirements. Welding
shall be done according to relevant Indian Standard while using steel bars in concrete
construction.
Reinforcing Steel shall be clean and free from loose mill scales, dust, loose rust and coats
of paints, oil, grease or other coating which may impair or reduce bond. Following
categories as shown on drawings shall be used.
a) Mild steel and medium tensile steel bars and hard drawn steel wire shall conform
to IS 432 latest addition.
b) TMT bars high yield strength steel deformed bars shall conform to IS1786. (Fe
415 /Fe 500 grade)
c) Hard drawn steel wire fabric shall conform to IS 1566.
d) Structural Steel sections and plates shall conform to IS 2062.
4.4.1.3.5 Water
Clean water free from deleterious impurities, as specified in IS: 456-2000 shall be used in
concrete mixing.
Water used for both mixing and curing shall be free from injurious amounts of deleterious
materials. Potable water are generally considered satisfactory for mixing and curing
concrete, water shall be got tested before use in concrete and curing. The cost for the
same shall be borne by the contractor.
4.4.1.3.6 Admixture
If required, chemical admixtures in concrete may be used as specified in IS 456-2000. No

materials other than the essential ingredients i.e. cement, aggregates and water, shall
ordinarily be used in the manufacture of concrete or mortar. But the Engineer may permit
the use of approved admixture for imparting special characteristics to the concrete, if so
specified, on satisfactory evidence that its use does not in any way adversely affect the
properties of concrete particularly its strength, volume change, durability and has no
deleterious effect on the reinforcement. Admixtures where allowed will generally be
conforming to relevant ASTM Standards and IS 9103.
4.4.1.4 Storage of Materials
4.4.1.4.1 Cement
The contractor shall make arrangements to the satisfaction of the Engineer for the storage
of cement to prevent deterioration due to moisture and / or intrusion of foreign matter. Bulk
cement if procured by the contractor shall be stored in approved waterproof bin or silo.
Bagged cement shall be stored in a suitable weather tight warehouse in such a manner as
to provide easy access for identification and inspection of each consignment. Stored
cement shall meet the test requirements as per IS-269 at any time after storage when a
retest is ordered by the Engineer. Each consignment shall be stacked separately with the
date of receipt flagged on it, not more than 12 bags being stacked in height, the bags
being arranged with headers and stretchers. Normally consignments shall be used in the
order of receipt at site unless otherwise directed. In case of large concrete pours, the
Engineer will decide on the batch of cement to be used taking into consideration the
quantity of cement with particular reference to the concerned concrete pours. Any
additional work in handling and storage of cement contingent upon this requirement shall
be to the contractors account and no extra claim for exposure to moisture in transit, in
storage at the works and until it enters the concrete mixers shall be admissible. The
Contractor shall keep accurate records of the procurement of the cement by him and of its
use in the work as prescribed under this contract.
4.4.1.4.2 Aggregates
Coarse and fine aggregates shall be stacked separately in such manner as to prevent
contamination by foreign material. All aggregates shall be stored on concrete or masonry
platforms. Each size shall be kept separate with wooden, steel, concrete, or masonry bulk-
heads, or shall be stored in separate stacks, taking care to prevent the materials at the
edges of the stock piles from getting intermixed. Stacks of fine and coarse aggregates
shall be kept sufficiently apart. The aggregates shall be stored in easily measurable stacks
of suitable heights as may be directed by the Engineer.
4.4.1.4.3 Reinforcing Steel
Reinforcing steel shall not be stored directly on the ground. These shall be stored under
cover, and shall be protected from rusting, oil, grease and distortions as may be directed
by the Engineer.
Bending of Reinforcement
Reinforcement steel shall conform accurately to the dimensions shown on relevant

drawings and conforming to IS2502. Bars shall be bent cold to the specified shapes and
dimensions as directed by the Engineer using a proper bar bender, operated by hand or
power, to attain proper radii of bends. Bars shall not be bent or straighten in a manner that
will cause injury to the material. Bars bent during transport or handling shall be
straightened before being used on work; they shall not be heated to facilitate bending.
Unless otherwise specified, a U type hook at the end of each mild steel bar shall invariable
be provided. The hook shall be of required as specified in IS code of practices. In case of
deformed or bars which are not round, the diameter shall be taken as the diameter of a
circle having an equivalent effective area. The deformed bar shall have standard L hooks
when under tension. The hook shall be suitably encased with adequate concrete cover to
prevent any splitting of the concrete.
Placing of Reinforcement
All reinforcement bars shall be accurately placed in exact position shown on the drawings,
and shall be securely held in position during placing of concrete by annealed binding wire
not less than 1 mm in size and conforming to IS 280 and by using stays blocks or metal
chairs, spacer, metal hangers, supporting wires or other approved devices at sufficiently
close intervals. Bars will not be allowed to sag between supports nor displaced during
concreting or any other operation over the work. All devices used for positioning shall be of
non corrodible material. Wooden and metal supports will not extend to the surface of
concrete, except where shown on the drawings, Placing bars on layers of freshly laid
concrete as the work progress for adjusting bar spacing will not be allowed. Places of
broken stone or brick and wooden blocks shall also not be used. Layers of bars shall be
separated by spacer bars, pre-cast mortar blocks or other approved devices only.
Reinforcement after being placed in position shall be maintained in a clean condition until
completely embedded in concrete. Special care shall be exercised to prevent any
displacement of reinforcement in concrete already placed.
To protect reinforcement from corrosion, concrete cover shall be provided as indicated on

the drawings. All bars protruding from concrete and to which other bars are to be spliced
and which are likely to be exposed for an indefinite period shall be protected by a thick
coat of neat cement slurry.
In the case of columns and walls, vertical bars shall be kept in normal position with timber
templates having slots accurately cut in for bar position. Such templates shall be removed
after the concreting has progressed up to a level just below them.
Bars crossing each other, where required, shall be secured by binding wire (annealed) of
size not less than 1 mm and conforming to IS280 in such a manner that they do not slip
over each other at the time affixing and concreting. As far as possible, bars of full length
shall be used. In case this is not possible, overlapping of bars shall be done as directed by
the Engineer. When practicable, overlapping bars shall not touch each other, but be kept
apart by 25mm or 1 1/4 times the maximum size of the coarse aggregates whichever is
greater, by concrete between them. Where this is not feasible, overlapping bars shall be
bound with annealed steel wire, not less than 1 mm thickness twisted tight in eight shapes
around the lapped bars. The overlaps shall be staggered for different bars and located at
fixed locations only along the span where neither shear nor bending moment is maximum.
Measurement for Payment for steel
Reinforcement shall be measured in lengths separately for different diameters as actually

used in the work including overlaps. From the length so measured the weight of
reinforcements shall be calculated in tones as per IS 1732, Fe415/Fe500 TMT steel being
procured by the Contractor. Lengths shall include hooks at ends. Wastage, overlaps,
couplings & welded joints, spaced bars and annealed steel wire for binding shall not be
measured and cost of these items shall be deemed to be included in the rates for
reinforcement.
Rate
Rate for reinforcement shall include cost of all steel including procurement, cost of
bending, placing, binding and fixing in position as shown on the drawings and as directed
by the Engineer. It shall also include cost of all devices if acceptable to Engineer for
keeping reinforcement in approved position, cost of jointing as per approved method, and
all wastage, overlaps and spacer bars.
4.4.1.5 Mixing of Concrete
For all work, concrete shall be mixed in a batching plant of appropriate capacity and
transport to the site by transit mixer which along with other accessories shall be kept in
first class working condition and so maintained throughout the construction. Mixing shall
be continued till materials are uniformly distributed and uniform colour of the entire mass is
obtained and each individual particle of the coarse aggregate show complete coating of
mortar containing its proportionate amount of cement. Hand mixing contractor must take
the permission of the Engineer in advance. Mixing plant shall be thoroughly cleaned
before changing from one type of cement to another.
4.4.1.5.1 Transport, Placing and Compaction of Concrete
The method of transporting and placing concrete shall be approved by the Engineer.
Concrete shall be so transported and placed that no contamination, segregation or loss of
its constituent materials takes place.
All formwork and reinforcement contained in form work shall be cleaned and made free
from standing water or dust immediately before placing of concrete.
No concrete shall be placed in any part of the structure until the approval of the Engineer
has been obtained in writing.
If concreting is not started within 24 hours of the approval being given, it shall have to be
obtained again from the Engineer. Concreting then shall proceed continuously over the
area between construction joints. Fresh concrete shall not be placed against concrete,
which has been in position for more than 30 minutes unless it is ensured that the re-
vibration limit of the earlier concrete is not crossed or a proper construction joint is formed.
Concrete when deposited shall have a temperature of not less than 4.5 degree centigrade
and not more than 38 degree centigrade unless otherwise specified. It shall be compacted
in its final position within 30 minutes of its discharge from the mixer unless carried in
properly designed agitators, operating continuously, when this time shall be within 30
minutes of its discharge from the agitator except where otherwise agreed to by the
Engineer concrete shall be deposited in horizontal layers to a compacted depth of not
more than 0.45 meter when internal vibrators are used and not exceeding 0.30 meter in all
other cases. Unless otherwise agreed to by the Engineer, concrete shall not be dropped
into place from a height exceeding 1.25 meters. The provision of surface vibrators shall be
made in Anchored Slab concreting. The construction sequence of Anchor slab furnished
by client shall be strictly adhered.
4.4.1.6 Sampling and Strength of Designed Concrete Mix
4.4.1.6.1 General
Samples from fresh concrete shall be taken as per IS 1199 and codes shall be made,
cured and tested at 28 days in accordance with IS 516.
In order to get a relatively quicker idea of the quality of concrete, optional tests on beams
for modulus of rupture at 72 2 h or at 7 days, or compressive strength tests at 7 days
may be carried out in addition to 28 days compressive strength test. For this purpose the
values should be arrived at based on actual testing. In all cases, the 28 days compressive
strength specified in Table 1 shall alone be the criterion for acceptance or rejection.
4.4.1.6.2 Frequency of Sampling
Sampling Procedure
The minimum frequency of sampling of concrete of each grade shall be in accordance with
the following:
Table - 2
3
Quantity of Concrete in the Work, m Number of Samples (six cubes of 15
cmx15cm per set)
1 5 1
6 15 2
16 30 3
31 50 4
51 and above 4 plus one additional sample for each
3
additional 50 m or part thereof
Note: At least one sample shall be taken from each shift. Where concrete is produced at
continuous production unit, such as ready-mixed concrete plant, frequency of sampling
may be agreed upon mutually by suppliers and purchasers.
4.4.1.6.3 Test Specimen
Three test specimens shall be made for each sample for testing at 28 days. Additional
samples may be required for various purposes such as to determine the strength of
concrete at 7 days or at the time of striking the formwork, or to determine the duration of
curing, or to check the testing error. Additional samples may also be required for testing
samples cured by accelerated methods as described in IS 9103. The specimen shall be
tested as described in IS 516.
4.4.1.6.4 Test Results of Samples

The test results of the sample shall be the average of the strength of three specimens. The
individual variation should not be more than 15 percent of the average. If more, the test
results of the sample are invalid.
4.4.1.7 Acceptance Criteria
4.4.1.7.1 Compressive Strength
The concrete shall be deemed to comply with the strength requirements when both the
following condition are met :
a) The mean strength determined from any group of four consecutive test results
complies with the appropriate limits in col 2 of Table 11 of IS : 456-2000.
b) Any individual test result complies with the appropriate limits in col 3 Table 11 IS :
456-2000.
4.4.1.7.2 Flexural Strength
When both the following conditions are met, the concrete complies with the specified
flexural strength.
a) The mean strength determined from any group of four consecutive test results
2
exceed the specified characteristics strength by at least 0.3 N/mm
b) The strength determined from any result is not less than the specified
2
characteristic strength less 0.3 N/mm
4.4.1.7.3 Quantity of Concrete Represented by Strength Test Samples
The quantity of concrete represented by a group of four consecutive test results shall
include the batches from which the first and last samples were taken together with all
intervening batches.
For the individual test results requirements given in col. 2 of Table 11 or in item (b) of 16.2
of IS: 456 - 2000 only the particular batch from which the sample was taken shall be at
risk.
Where the mean rate of sampling is not specified the maximum quantity of concrete that
3
four consecutive test results represent shall be limited to 60 m .
4.4.1.8 Inspection and Testing
To ensure that the construction complies with the design an inspection procedure should
be set up covering materials, records, workmanship and construction.
Tests should be made on reinforcement and the constituent materials of concrete in

accordance with the relevant standards, where applicable, use should be made of suitable
quality assurance schemes.
Care should be taken to see that:
a) Design and detail are capable of being executed to a suitable standard, with due
allowance for dimensional tolerances;
b) There are clear instructions on inspection standards;
c) There are clear instructions on permissible deviations ;
d) Elements critical to workmanship, structural performance, durability and

appearance are identified; and
e) There is a system to verify that the quality is satisfactory in individual parts of the
structure, especially the critical ones.
Immediately after stripping the formwork, all concrete shall be carefully inspected and any
defective work or small defects either removed or made good before concrete has
thoroughly hardened.
4.4.1.8.1 Testing
In case doubt regarding the grade of concrete used either due to poor workmanship or
based on results of cube strength tests, compressive strength tests of concrete on the
basis of IS may be carried out.
4.4.1.8.2 Core Test

The points from which cores are to be taken and the number of cores required shall be at
the discretion of the engineer-in charge and shall be representative of the whole of
concrete concerned. In no case, however, shall fewer than three cores be tested.
Core shall be from top extending up to full depth or diaphragm wall and core recovery as
well as core quality designation shall be obtained. The cores shall be tested for its
compressive strength.
Cores shall be prepared and tested as described in IS 516.
Concrete in the member represented by a core test shall be considered acceptable if the
average equivalent cube strength of the cores is equal to at lest 85 percent of the cube
strength of the grade of concrete specified for the corresponding age and not individual
core has strength less that 75 percent.
4.4.1.9 Manufacturers Certification Testing Rules etc.
For all materials required for concrete including cement, aggregates, water, reinforcing
and pre-stressing steel the original copies of test certificates, test results etc. either carried
out by the manufacturer or any other agency, the mix design recommendations etc. shall
be submitted to the Engineer for his approval & record. It shall remain the property of the
Engineer.
4.4.1.10 Chloride Contents
Since the chloride contents of the constituent materials of the concrete would be
detrimental to the strength of concrete. It is desirable to keep check on the overall chloride
content of the concrete to keep it minimum. Especially for reinforced concrete, the total
chloride content of the concrete when manufactured according to the requirement of
workability and strength shall not exceed 500 PPM. by weight of cement. The cost of
testing for the chloride content of the ingredients of concrete and of undertaking remedial
measures if the chloride content is more than the permissible limit shall be borne by the
contractor.
4.4.1.11 Measurements for Payment
The concrete shall be measured in cubic metre. Any concrete used in excess of the
theoretical dimension shown on the drawing will not be paid.
The unit rate for concrete shall include the cost of all materials, labours, tools and plant
required for mixing, placing in position, vibrating, compacting, finishing including full curing
for 28 days as per directions of the Engineer, and all other incidental expenses for
producing and laying in position concrete of specified strength to complete the structure or
its components as shown on the drawings and according to these specifications. The rate
shall also include the cost of making, fixing and removing of all centring and forms
required for the work unless otherwise specified in the contract. Rate Excluding the cost of
reinforcement.
All expenses likely to be incurred by the contractor in transporting materials procured at

the site of works, the expenses incurred in improving the quality of materials to acceptable
levels (such as screening, washing etc.) and the expenses incurred for proper storage of
materials as directed by the Engineer etc. are to be included in the unit rate.
4.4.1.12 Unacceptable Work
All defective concreting work, including but not limited to defects arising out of honey-
combing, under sizing, under strength etc. will have to be demolished and rebuilt by the
contractor at his own cost as may be directed by the Engineer. In the event of such works
being accepted by carrying out minor repairs etc. as suggested by the contractor and
accepted by the Engineer. He will be paid for the work actually carried out by him at the
reduced rate as may be asked by the Engineer for portion of the work that may be
accepted with repairs done by the contractor.
4.4.1.13 Specification For Steel/plywood Formwork And Staging Material
1) All the steel material used for formwork and staging should conform to IS2062 (for
sheets/plates) and IS 1161, in case of tubes or equivalent IS specifications. All
steel formwork shall be made from 4 mm thick MS plates and all plywood
formwork shall be made from 12 mm thick laminated water proof ply.
2) Detailed general arrangement drawing / scheme drawing for formwork /staging

material shall be submitted for approval of the consulting engineers along with the
design calculation before commencement of construction. Design of formwork
shall be done taking into consideration the safety aspects, access for inspection
and shortest time period for assembling and dismantling.
3) All the formwork and staging material used shall be factory manufactured only.
The deflection limits should not exceed the following :-
a) For beams and girders having span less than 3.0 m, deflection shall not be
exceed 3 mm
b) For beams and girders having span less than 3.0 m, deflection shall be the least
of: 15 mm or L/1000.
c) For skin plate, the deflection at any position shall not exceed 3 mm.
4) Formwork in contact with concrete shall be treated with a coating of release agent
of approved make, for easy stripping of formwork.
5) Retaining wall should be cast monolithically in a single pour and no joint lines shall
be permitted. Entire stem should be cast in single lift and no construction joint is
permitted.
Measurements for Payment
The formwork is already included in the respective items of concreting in the specification;
4.4.1.14 Providing and fixing 225 mm wide P.V.C. water stop in expansion joints
General
(a) Polyvinyl chloride (PVC) water stops shall normally have a centre bulb of 12.5 mm
inside diameter and 25 mm out side diameter. It shall be 225 mm in width and shall have
minimum of two or three longitudinal ribs on each side of the bulb evenly distributed
between the bulb and the edge of the water stops. Each rib shall be 6.33 mm high and the
rib adjacent to the centre bulb shall have web thickness 12.5 mm and the rib adjacent to
the edge shall have a web thickness of 10 mm. For this purpose, the contractor shall
submit to the Engineer-in-charge, for approval, four sets of drawings showing details of the
water stops, including dimensions, shapes and details of intersections and splices
between water stops of the same size and of different sizes. Fabrication and procurement
of materials shall be made only after the approval of the drawings by the Engineer -in-
charge. Any fabrication or procurement of materials performed prior to approval of the
drawings shall be at the Contractors risk.
The Engineer-in-charge shall have the right to ask the contractor to make any changes in
the drawings, which may be necessary to make the finished installation conforming to the
requirements and intent of these specifications without additional cost to the Corporation.
Approval by the Engineer -in charge to the Contractors drawings shall not re leave the
contractor of his obligation to meet all the requirements at these specifications or of the
responsibility for the correctness of the Contractors drawings.
(b) One set of the above drawings will be returned to the Contractor either approved,
disapproved, or conditionally approved and these shall be resubmitted for approval, if so
directed.
(c) The water stops shall be dense, homogeneous and free from holes and other
imperfections. The water stops shall meet the material and test requirements given
hereinafter. The cross section of the water stops shall be uniform along its length and the
thickness shall be symmetrical transversely. Tolerance for the dimensions given above
shall be plus 5 mm in width, plus 2 mm in thickness and plus 1 mm for other dimensions.
(d) Certified copies of the laboratory test reports on the physical properties of the PVC
water stops and a certificate stating that PVC water stops as furnished meeting with all
other requirements of those specifications, be obtained by the Contractor from the
manufacturer of the PVC water stops shall submit to the Engineer-in-charge with the test
report of the PVC water stop carried out by the Contractor. Three samples of PVC water
stops of 25 to 30 cm length shall be obtained by the Contractor from the supplier and shall
be submitted to the Engineer-in-charge. These samples shall be furnished at least 60 days
prior to embedment of any water stops in the structure.
(e) The Contractor shall arrange to obtain the water stops from the suppliers in rolls
securely packed, containing a single length of not less than 12 linear meters and having
inside diameter of not less than 0.3 meter.
Materials
(a) The PVC water stops shall be fabricated by an extrusion process from the elastomeric
plastic compound, the basic resin of which shall be virgin Polyvinyl chloride. No reclaimed
Polyvinyl Chloride shall be used.
(b) The compound shall contain any additional resin, plasticizers inhibitors or other
materials, needed to ensure that the finished product shall have the following physical
characteristics as per the CWC specification for PVC seal.
2
1. Tensile strength Kg/cm 116 minimum
2. Ultimate elongation % 300 minimum
2
3. Tear Resistance Kg/cm 49 minimum
2
4. Stiffness in flexure Kg/cm 24.6 minimum
5. Accelerated extraction
2
(a) Tensile strength minimum 105 kg/cm
(b) Ultimate elongation minimum 250%
6. When tested in accordance with the effect of alkali test as described in the
following paragraphs, the material shall not show an increase in weight of more than 0.25
percent or a loss in weight of more than 0.1 percent or loss in weight of more than 0.10
after 7 days, or more than 0.40 percent increase in weight or more than 0.30 percent loss
in weight after 28 days. After 28 days immersion the dimensions of the sample shall not
differ from those of the original sample by more than 1.0 percent. After 7 days immersion,
the Durometer hardness reading of sample shall not differ by more than plus or minus 5
from the reading on the original sample.
7. When tested in accordance with the cold bend test described in the
following paragraph, the material shall show no signs of cracking or chipping.
8. PVC water stop confirming to IS 12200 of standard make is only

acceptable.
Inspection and Tests
(a) All water stops shall be subject to laboratory tests before transport. Samples of the
finished water stops and material for tests shall be furnished to the Engineer -in-charge.
All tests shall be made by and at the expense of the contractor.
(b) Samples for laboratory tests to determine physical properties of the compound shall be
taken in accordance with the random process to obtain following number of tests units
from each lot received.
Size of lot received Number of tests
45 Meters 1
45 to 90 Meters 2
90 to 450 Meters 4
450 to 900 Meters 8
Over 900 Meters Additional one test for every 100 m
(c) Laboratory tests to determine physical properties of the water stops required to be
furnished under these specification shall be performed on test specimens cut from test
units taken from the finished products. The contractor shall furnish the specimens at his
cost for test at places as directed.
(d)Test shall be made in accordance with the following methods.
i) Tensile strength ASTM designation D 638
ii) Elongation ASTM Designation D 638
iii) Durometer hardness ASTM Designation D 2240 (Type A)
iv) Accelerated extraction.
v) Effect of alkali
vi) Cold bend test
vii) Impact resistance.
Installation
(a) Location and embedment of the PVC water stops shall be as shown on the drawings,
with approximately one half of the width of the water stops embedded in the concrete on
each side of the joint. In order to eliminate faulty installation that may result in leakage,
care shall be taken that the water stops are correctly positioned and secured during
installation. All water stops shall be installed so as to form a continuous watertight
diaphragm in the joint, unless otherwise shown. Adequate provision shall be made to
completely protect the water stops during the progress of the work.
(b) Additional vibration, over and above that used for adjacent concrete placement, shall
be carried out to ensure complete embedment of the water stop in the concrete. Larger
pieces of aggregate near the water stop shall be removed by hand during embedment to
assure complete contract between the water stop and the surrounding concrete. Splices in
the continuity or at the intersections of junctions of PVC water stops shall be performed by
heat-sealing the adjacent surface in accordance with the Manufacturers
recommendations. A thermostatically controlled electric heat source shall be used to make
all splices. The correct temperature at which splices should be made will differ with the
material compounds but should be sufficient to melt. All splices shall be neat with the ends
of the joined water stops in true alignment. A meter box guide and portable saw shall be
provided and used to cut the ends to be joined to ensure good alignment and contract
between joined surfaces. After splicing, a remoulding iron with rubs and corrugations to
match the pattern of the water stop shall be used to reform the ribs at the splices. The
continuity of the characteristics members of the cross sections of the water stop design
(ribs, tubular centre axis, protrusions, and the like) shall be maintained across the splices.
(c) Where splices are required between water stops of different size, the splices shall be
made as recommended by the manufacturer of the water stops and drawings showing the
details of the splices shall be submitted to the Dept. for approval, as required in paragraph
General above.
(d) Prior to embedment, the edges of the water stops shall be secured to looped wire in
the end bulbs to improve the Concrete bond as shown on the drawings. The bars shall
conform to the provisions of section 5 Reinforcement Steel fabrication and erection. The
manner in which the water stop is secured to the reinforcing bars shall be subject to
approval.
Measurement and Payment
Measurement for payment, for furnishing and placing PVC water stops shall be made on
the basis of linear meter measured along the centre line of the water stop with no
allowance for lap at splices and intersection. The contractor unit rate includes complete
item of PVC water stop. The payment shall be made at the rate quoted for the item with no
allowance floor lap at splices and intersection. The unit price shall include making splices
and intersections and of furnishing all labour, equipment, and materials, required for
installing the water stops and protecting the water stops from damage during the progress
of the work. The unit rate shall also include the cost of preparing and submitting the
drawings, producing samples for approval of the Engineer-in-charge and costs of all
incidental work needed to complete the work as per the specifications.
4.4.1.15 Providing and fixing in Expansion joints, SILFLEX/Capcell HD 100 Supreme or

equivalent (Polyurethane foam filler) of the best quality, including in all shapes and
all levels etc. complete as per drawing or as directed by Engineer-in-Charge.
1.0 Material
1.1 Polyurethane from filler shall be Capcell HD-100 of Supreme or equivalent. It should
comply with BS 5628 Part 3. It should be semi-rigid, UV resistant, high performance
laminated closed cell polyethylene foam joint filler in sheet form.
1.2 The density of polyurethane shall be 100Kgs / cum. The water absorption should be
0.012%. The operating temperature of foam filler should be between -40 c to +100 c.
1.3 It should be bitumen free and chemical resistant. It should possess excellent recovery
after compression.
2.0 Workmanship
2.1 The Capcell HD 100 board shall be cut neatly with all edges even and to the size required
(size of the structure at the expansion joint.).
2.2 The concrete surfaces must be clean, dry and free of dirt, grease, oil or other
contaminants that would interfere with proper adhesion. It shall be placed resting on the
existing structure at the joint before the structure adjoining to the joint is constructed.
2.3 The board shall be snugly filled the gap in between the expansion joint.
2.4 On retaining wall surface the board shall be provided recessed on the exposed side, to
accommodate polysulphide sealant. At the time of concreting, the recessed gap, shall be
filled with the capcell HD board with a both side adhesive tape to keep it in position. The
same shall be removed until the gap is sealed with the polysulphide sealant.
3.0 Mode of Measurement and Payment

2
3.1 The item will be measured and paid in sqmt (m ), for the actual area provided and measured
at site. Wastage will not be paid for.
4.4.1.16 POLYSULPHIDE SEALANT

Providing and filling the expansion joints, with Polysulphide sealant of size 25mm x
12mm with application of primer including scraping / removing the expansion filler
materials from joints, cleaning, repairing of the edges with epoxy mortar of
approved colour and make, fixing of abro tapes on the edges to prevent the
adjoining surface, etc. complete as directed by engineer-in-charge. The contractor
should furnish a guarantee of 10 years as directed.
1.0 Materials
1.1 Material shall confirm to relevant material specification.
2.0 Workmanship
2.1 Preparation - The joint surfaces must be thoroughly dry, clean, and all the dirt, laitance,
oil or grease, rust, scale and protective lacquers from metal surfaces should be cleaned
before positioning a bond breaker or back up tape.
2.2 Supply and Handling - Joint filler must be checked for tight packing so that no gaps or
voids exist at the base of the sealing slot.
2.3 Installation - A thin coat of primer should be applied on the concrete surfaces and allowed
to dry "tack free" before sealing. The mixed polysulphide sealant must be applied after the
evaporation of the solvent but before the primer film has completely reacted. After 3 hours
the surface should be re primed before the application of sealant. The sealant should be
thoroughly mixed with a paddle stirrer for a full five numbers (at 300 - 500spm). The mix
should be applied by a Gun to the joint and should be tooled to a smooth finish. These
joints should be flush and unpainted.
3.0 Measurement for Payment
3.1 The sealant Joint shall be measured in running meters.
3.2 The contract unit rate shall include the cost of materials, labour, equipment and other
incidental charges for fixing the sealant in position.
601. DRY LEAN CEMENT CONCRETE SUB-BASE
601.1. Scope
601.1.1. The work shall consist of construction of dry lean concrete subbase for cement concrete
pavement in accordance with the requirements of these Specifications and in conformity
with the lines, grades and cross-sections shown on the drawings or as directed by the
Engineer. The work shall include furnishing of all plant and equipment, materials and
labour and performing all operations, in connection with the work, as approved by the
Engineer.
601.1.2. The design parameters of dry lean concrete sub-base, viz., width, thickness, grade of
concrete, details of joints, if any, etc. shall be as stipulated in the Contract drawings.
601.2. Materials
601.2.1. Source of materials: The Contractor shall indicate to the Engineer the source of all
materials with relevant test data to be used in the lean concrete work sufficiently in
advance and the approval of the Engineer for the same shall be obtained at least 45 days
before the scheduled commencement of the work. If the Contractor later proposes to
obtain the materials from a different source, he shall notify the Engineer for his approval at
least 45 days before such materials are to be used.
601.2.2. Cement: Any of the following types of cement may be used with prior approval of the
Engineer;
(i) Ordinary Portland Cement IS : 269
(ii) Portland Slag Cement IS : 455
(iii) Portland Pozzolana Cement IS :1489
If the subgrade is found to consist of soluble sulphates in a concentration more than 0.5 per cent,
cement used shall be sulphate resistant and shall conform to IS : 6909.
Cement to be used may preferably be obtained in bulk form. It shall be stored in accordance with
stipulations contained in Clause 1014 and shall be subjected to acceptance test prior to its
immediate use.
601.2.3. Aggregates:
601.2.3.1. Aggregates for lean concrete shall be natural material complying with IS : 383. The
aggregates shall not be alkali reactive. The limits of deleterious materials shall not exceed
the requirements set out in IS : 383. In case the Engineer considers that the aggregates
are not free from dirt, the same may be washed and drained for at least 72 hours before
batching, as directed by the Engineer.
601.2.3.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong, dense, non-
porous and durable pieces of crushed stone or crushed gravel and shall be devoid of
pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The
maximum size of the coarse aggregate shall be 25 mm. The coarse aggregate shall
comply with Clause 602.2.4.2.
601.2.3.3. Fine aggregate: The fine aggregate shall consist of clean, natural sand or crushed
stone sand or a combination of the two and shall conform to IS : 383. Fine aggregate shall
be free from soft particles, clay, shale, loam, cemented particles, mica, organic and other
foreign matter. The fine aggregate shall comply with Clause 602.2.4.3.
601.2.3.4. The coarse and fine aggregates may be obtained in either of the following manner:
(i) In separate nominal sizes of coarse and fine aggregates and mixed together
intimately before use.
(ii) Separately as 25 mm nominal single size, 12.5 mm nominal size graded

aggregates and fine aggregate of crushed stone dust or sand or a combination of these
two.
The material after blending shall conform to the grading as indicated in Table 600-1.
Table 600-1. AGGREGATE GRADATION FOR DRY LEAN CONCRETE
Sieve designation Percentage passing the sieve by weight

26.50 mm 100
19.00 mm 80100
9.50 mm 55-75
4.75 mm 35-60
600.00 micron 10-35
75.00 micron 0-8
601.2.4. Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amounts of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete. It shall meet the requirements stipulated in IS : 456.
601.2.5. Storage of materials: All materials shall be stored in accordance with the provisions of
Clause 1014 of these Specifications and other relevant IS Specifications. All efforts must
be made to store the materials in proper places so as to prevent their deterioration or
contamination by foreign matter and to ensure their satisfactory quality and fitness for use
in the work. The storage place must also permit easy inspection, removal and storage of
materials. All such materials even though stored in approved godowns must be subjected
to acceptance test immediately prior to their use. The requirement of storage yard
specified in Clause 602.2.9. shall also be applicable.
601.3. Proportioning of Materials for the Mix
601.3.1. The mix shall be proportioned with a maximum aggregate cement ratio of 15:1. The water
content shall be adjusted to the optimum as per Clause 601.3.2. for facilitating compaction
by rolling. The strength and density requirements of concrete shall be determined in
accordance with Clause 601.6 by making trial mixes.
601.3.2. Moisture content: The right amount of water for the lean concrete in the main work shall
be decided so as to ensure full compaction under rolling and shall be assessed at the time
of rolling the trial length. Too much water will cause the lean concrete to be heaving up
before the wheels and picked up on the wheels of the roller and too little will lead to
inadequate compaction, a low in-situ strength and an open-textured surface.
The optimum water content shall be determined and demonstrated by rolling during trial
length construction and the optimum moisture content and degree of compaction shall be
got approved from the Engineer. While laying in the main work, the lean concrete shall
have a moisture content between the optimum and optimum +2 per cent, keeping in view
the effectiveness of compaction achieved and to compensate for evaporation losses.
601.3.3. Cement content: The minimum cement content in the lean concrete shall not be less
than 150 kg/cu.m. of concrete. If this minimum cement content is not sufficient to produce
concrete of the specified strength, it shall be increased as necessary without additional
cost compensation to the Contractor.
601.3.4. Concrete strength: The average compressive strength of each consecutive group of 5
cubes made in accordance with Clause 903.5.1.1. shall not be less than 10 MPa at 7
days. In addition, the minimum compressive strength of any individual cube shall not be
less than 7.5 MPa at 7 days. The design mix complying with the above Clauses shall be
got approved from the Engineer and demonstrated in the trial length construction.
601.4. Subgrade
The subgrade shall conform to the grades and cross sections shown on the drawings and
shall be uniformly compacted to the design strength in accordance with these
Specifications and Specification stipulated in the Contract. The lean concrete subbase
shall not be laid on a subgrade softened by rain after its final preparation; surface trenches
and soft spots, if any, must be properly back-filled and compacted to avoid any weak or
soft spot. As far as possible, the construction traffic shall be avoided on the prepared
subgrade. A day before placing of the sub-base, the subgrade surface shall be given a
fine spray of water and rolled with one or two passes of a smooth wheeled roller after a
lapse of 2-3 hours in order to stabilise loose surface. If Engineer feels it necessary,
another fine spray of water may be applied just before placing sub-base.
601.5. Construction
601.5.1. General: The pace and programme of the lean concrete sub base construction shall be
matching suitably with the programme of construction of the cement concrete pavement
over it. The sub-base shall be overlaid with cement concrete pavement only after 7 days
after sub-base construction.
601.5.2. Batching and mixing: The batching plant shall be capable of proportioning the materials
by weight, each type of material being weighed separately in accordance with Clause
602.9.3.2. The cement from the bulk stock shall be weighed separately from the
aggregates. The capacity of batching and mixing plant shall be at least 25 per cent higher
than the proposed capacity for the laying arrangements. The batching and mixing shall be
carried out preferably in a forced action central batching and mixing plant having
necessary automatic controls to ensure accurate proportioning and mixing. Other types of
mixers shall be permitted subject to demonstration of their satisfactory performance during
the trial length. The type and capacity of the plant shall be got approved by the Engineer
before commencement of the trial length. The weighing balances shall be calibrated by
weighing the aggregates, cement, water and admixtures physically either by weighing in
the large weighing machine or in a weigh bridge. The accuracy of weighing scales of the
batching plant shall be within 2 per cent in the case of aggregates and +1 per cent in the
case of cement and water.
The design features of Batching Plant should be such that the shifting operations of the
plant will not take very long time when they are to be shifted from place to place with the
progress of the work.
601.5.3. Transporting: Plant mix lean concrete shall be discharged immediately from the mixer,
transported directly to the point where it is to be laid and protected from the weather by
covering the tippers/dumpers with tarpaulin during transit. The concrete shall be
transported by tipping trucks, sufficient in number to ensure a continuous supply of
material to feed the laying equipment to work at a uniform speed and in an uninterrupted
manner. The lead of the batching plant to paving site shall be such that the travel time
available from mixing to paving as specified in Clause 601.5.5.2 will be adhered to.
601.5.4. Placing: Lean concrete shall be laid/placed by a paver with electronic sensor. The
equipment shall be capable of laying the material in one layer in an even manner without
segregation, so that after compaction the total thickness is as specified. The paving
machine shall have high amplitude tamping bars to give good initial compaction to the sub-
base.
The laying of the two-lane road subbase done either in full width or lane by lane.
Preferably the lean concrete shall be placed and compacted across the full width of the
road, by constructing it in one go or in two lanes running forward simultaneously.
Transverse and longitudinal construction joints shall be staggered by 500-1000 mm and
200-400 mm respectively from the corresponding joints in the overlaying concrete slabs.
601.5.5. Compaction
601.5.5.1. The compaction shall be carried out immediately after the material is laid and levelled.
In order to ensure thorough compaction which is essential, rolling shall be continued on
the full width till there is no further visible movement under the roller and the surface is
closed. The minimum dry density obtained shall be 97 per cent of that achieved during the
trial length construction vide Clause 601.7. The densities achieved at the edges i.e 0.5 m
from the edge shall not be less than 95 percent of that achieved during the trial
construction vide Clause 601.7.
601.5.5.2. The spreading, compacting and finishing of the lean concrete shall be carried out as
rapidly as possibly and the operation shall be so arranged as to ensure that the time
between the mixing of the first batch of concrete in any transverse section of the layer and
the final finishing of the same shall not exceed 90 minutes when the concrete temperature
is above 25 and below 30 degree Celsius and 120 minutes if less than 25 degree Celsius.
This period may be reviewed by the Engineer in the light of the results of the trial run but in
no case shall it exceed 2 hours. Work shall not proceed when the temperature of the
concrete exceeds 30 degree Celsius. If necessary, chilled water or addition of ice may be
resorted to for bringing down the temperature. It is desirable to stop concreting when the
o
ambient temperature is above 35 C. After compaction has been completed, roller shall not
stand on the compacted surface for the duration of the curing period except during
commencement of next days work near the location where work was terminated the
previous day.
601.5.5.3. Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static weight
are considered to be suitable for rolling dry lean concrete. In case any other roller is
proposed, the same shall be got approved from the Engineer, after demonstrating its
performance. The number of passes required to obtain maximum compaction depends on
the thickness of the lean concrete, the compatibility of the mix, and the weight and type of
the roller etc., and the same as well as the total requirement of rollers for the job shall be
determined during trial run by measuring the in-situ density and the scale of the work to be
undertaken.
601.5.5.4. In addition to the number of passes required for compaction there shall be a preliminary
pass without vibration to bed the lean concrete down and again a final pass without
vibration to remove roller marks and to smoothen the surface.
Special care and attention shall be exercised during compaction near joints, kerbs,
channels, side forms and around gullies and manholes. In case adequate compaction is
not achieved by the roller at these points, use of plate vibrator shall be made, if so directed
by the Engineer.
601.5.5.5. The final lean concrete surface on completion of compaction and immediately before
overlaying, shall be well closed, free from movement under roller and free from ridges, low
spots, cracks, loose material, pot holes, ruts or other defects. The final surface shall be
inspected immediately on completion and all loose, segregated or defective areas shall be
corrected by using fresh lean concrete material laid and compacted as per Specification.
For repairing honeycombed surface, concrete with aggregates of size 10 mm and below
shall be spread and compacted. It is necessary to check the level of the rolled surface for
compliance. Any level/thickness deficiency should be corrected after applying concrete
with aggregates of size 10 mm and below after roughening the surface. Similarly the
surface regularity also should be checked with 3 m straight edge. The deficiency should be
made up with concrete with aggregates of size 10 mm and below.
601.5.5.6. Segregation of concrete in the dumpers shall be controlled by premixing each fraction of
the aggregates before loading in the bin of the batching plant, by moving the dumper back
and forth while discharging the mix on it and other means. Even paving operation shall be
such that the mix does not segregate.
601.5.6. Joints: Contraction and longitudinal joints shall be provided as per the drawing.
At longitudinal or transverse construction joints, unless vertical forms are used, the edge of
compacted material shall be cut back to a vertical face where the correct thickness of the
properly compacted material has been obtained.
601.5.7. Curing: As soon as the lean concrete surface is compacted, curing shall commence. One
of the following two methods shall be adopted:
(a) The initial curing shall be done by spraying with liquid curing compound. The
curing compound shall be white pigmented or transparent type with water
retention index of 90 per cent when tested in accordance with BS 7542. Curing
compound shall be sprayed immediately after rolling is complete. As soon as the
curing compound has lost its tackiness, the surface shall be covered with wet
hessian for three days.
(b) Curing shall be done by covering the surface by gunny bags/hessian, which shall
be kept continuously moist for 7 days by sprinkling water.
601.6. Trial Mixes
The Contractor shall make trial mixes of dry lean concrete with moisture contents like 5.0,
5.5, 6.0, 6.5 and 7.0 per cent using cement content specified and the specified aggregate
grading but without violating the requirement of aggregate-cement ratio specified in Clause
601.3.1. Optimum moisture and density shall be established by preparing cubes with
varying moisture contents. Compaction of the mix shall be done in three layers with
vibratory hammer fitted with a square or rectangular foot as described in Clause 903.5.1.1.
After establishing the optimum moisture, a set of six cubes shall be cast at that moisture
rd
for the determination of compressive strength on the 3 and the seventh day. Trial mixes
shall be repeated if the strength is not satisfactory either by increasing cement content or
using higher grade of cement. After the mix design is approved, the Contractor shall
construct a trial section in accordance with Clause 601.7.
If during the construction of the trial length, the optimum moisture content determined as
above is found to be unsatisfactory, the Contractor may make suitable changes in the
moisture content to achieve a satisfactory mix. The cube specimens prepared with the
changed moisture content should satisfy the strength requirement. Before production of
the mix, natural moisture content of the aggregate should be determined on a day-to-day
basis so that the moisture content could be adjusted. The mix finally designed should
neither stick to the rollers nor become too dry resulting in ravelling of surface.
601.7. Trial Length
601.7.1. The trial length shall be constructed at least 14 days in advance of the proposed date of
commencement of work. At least 30 days prior to the construction of the trial length, the
Contractor shall submit for the Engineers approval a Method Statement giving detailed
description of the proposed materials, plant, equipment, mix proportion, and procedure for
batching, mixing, laying, compaction and other construction procedures. The Engineer
shall also approve the location and length of trial construction which shall be a minimum of
60 m length and for full width of the pavement. The trial length shall contain the
construction of at least one transverse construction joint involving hardened concrete and
freshly laid sub-base. The construction of trial length will be repeated till the Contractor
proves his ability to satisfactorily construct the subbase.
601.7.2. In order to determine and demonstrate the optimum moisture content which results in the
maximum dry density of the mix compacted by the rolling equipment and the minimum
cement content that is necessary to achieve the strength stipulated in the drawing, trial
mixes shall be prepared as per Clause 601.6.
601.7.3. After the construction of the trial length, the in-situ density of the freshly laid material shall
be determined by sand replacement method with 20 cm dia density cone. Three density
holes shall be made at locations equally spaced along a diagonal that bisects the trial
length; average of these densities shall be determined. These main density holes shall not
be made in the strip 50 cm from the edges. The average density obtained from the three
samples collected shall be the reference density and is considered as 100 per cent. The
field density of regular work will be compared with this reference density in accordance
with Clauses 601.5.5.1 and 903.5.1.2. A few cores may be cut as per the instructions of
the Engineer to check segregation or any other deficiency.
601.7.4. The hardened concrete shall be cut over 3 m width and reversed to inspect the bottom
surface for any segregation taking place. The trial length shall be constructed after making
necessary changes in the gradation of the mix to eliminate segregation of the mix. The
lower surface shall not have honey-combing and the aggregates shall not be held loosely
at the edges.
601.7.5. The trial length shall be outside the main works. The main work shall not start until the
trial length has been approved by the Engineer. After approval has been given the
materials, mix proportions, moisture content, mixing, laying, compaction plant and
construction procedures shall not be changed without the approval of the Engineer.
601.8. Tolerances for Surface Regularity, Level, Thickness, Density and Strength
The tolerances for surface regularity, level, thickness, density and strength shall conform
to the requirements given in Clause 903.5. Control of quality of materials and works shall
be exercised by the Engineer in accordance with section 900.
601.9. Traffic
No heavy commercial vehicles like trucks and buses shall be permitted on the lean
concrete sub-base after its construction. Light vehicles if unavoidable may, however, be
allowed after 7 days of its construction with prior approval of the Engineer.
601.10. Measurements for Payment
The unit of measurement for dry lean concrete pavement shall be the cubic metre of
concrete placed, based on the net plan areas for the specified thickness shown on the
drawings or as directed by the Engineer.
601.11 Rate
The Contract unit rate payable for dry lean concrete sub-base shall be payment in full for
carrying out the required operations including full compensation for all labour, materials
and equipment, mixing, transport, placing, compacting, finishing, curing, testing and
incidentals to complete the work as per Specifications, all royalties, fees, storage and rents
where necessary and all leads and lifts.
602.1. CEMENT CONCRETE PAVEMENT
602.1.1 The work shall consist of construction of unreinforced, dowel jointed, plain cement
concrete pavement in accordance with the requirements of these Specifications and in
conformity with the lines, grades and cross sections shown on the drawings. The work
shall include furnishing of all plant and equipment, materials and labour and performing all
operations in connection with the work, as approved by the Engineer.
602.1.2. The design parameters, viz., thickness of pavement slab, grade of concrete, joint details
etc. shall be as stipulated in the drawings.
602.2. Materials
602.2.1. Source of materials: The Contractor shall indicate to the Engineer the source of all
materials to be used in the concrete work with relevant test data sufficiently in advance,
and the approval of the Engineer for the same shall be obtained at least 45 days before
the scheduled commencement of the work. If the Contractor later proposes to obtain
materials from a different source, he shall notify the Engineer for his approval, at least 45
days before such materials are to be used with relevant test data.
602.2.2. Cement: Any of the following types of cement capable of achieving the design strength
may be used with prior approval of the Engineer, but the preference should be to use at
least the 53 Grade.
i) Ordinary Portland Cement, 53 Grade IS : 12269.
If the soil around has soluble salts like sulphate in excess of 0.5 per cent, the cement used
shall be sulphate resistant and shall conform to IS : 12330.
Guidance may be taken from IS: SP: 23, Handbook for Concrete Mixes for ascertaining
the minimum 7 days strength of cement required to match with the design concrete
strength. Cement to be used may preferably be obtained in bulk form. If cement in paper
bags are proposed to be used, there shall be bag-splitters with the facility to separate
pieces of paper bags and dispose them of suitably. No paper pieces shall enter the
concrete mix. Bulk cement shall be stored in accordance with Clause 1014. The cement
shall be subjected to acceptance test just prior to its use.
602.2.3. Admixtures: Admixtures conforming to IS : 6925 and IS : 9103 shall be permitted to

improve workability of the concrete or extension of setting time, on satisfactory evidence
that they will not have any adverse effect on the properties of concrete with respect to
strength, volume change, durability and have no deleterious effect on steel bars. The
particulars of the admixture and the quantity to be used, must be furnished to the Engineer
in advance to obtain his approval before use. Satisfactory performance of the admixtures
should be proved both on the laboratory concrete trial mixes and in trial paving works. If air
entraining admixture is used, the total quantity of air in air-entrained concrete as a
percentage of the volume of the mix shall be 51.5 per cent for 25 mm nominal size
aggregate.
602.2.4. Aggregates:
602.2.4.1. Aggregates for pavement concrete shall be natural material complying with IS : 383 but
with a Los Angeles Abrasion Test result not more than 35 per cent. The limits of
deleterious materials shall not exceed the requirements set out in IS: 383.
The aggregates shall be free from chert, flint, chalcedony or other silica in a form that can
react with the alkalies in the cement. In addition, the total chlorides content expressed as
chloride ion content shall not exceed 0.06 per cent by weight and the total sulphate
content expressed as sulphuric anhydride (SO3 ) shall not exceed 0.25 per cent by weight.
602.2.4.2. Coarse aggregate: Coarse aggregate shall consist of clean, hard, strong, dense, non-
porous and durable pieces of crushed stone or crushed gravel and shall be devoid of
pieces of disintegrated stone, soft, flaky, elongated, very angular or splintery pieces. The
maximum size of coarse aggregate shall not exceed 25 mm for pavement concrete.
Continuously graded or gap graded aggregates may be used, depending on the grading of
the fine aggregate. No aggregate which has water absorption more than 2 per cent shall
be used in the concrete mix. The aggregates shall be tested for soundness in accordance
with IS : 2386 (Part-5). After 5 cycles of testing the loss shall not be more than 12 per cent
if sodium sulphate solution is used or 18 percent if magnesium sulphate solution is used.
Dumping and stacking of aggregates shall be done in an approved manner. In case the
Engineer considers that the aggregates are not free from dirt, the same may be washed
and drained for at least 72 hrs before batching as directed by the Engineer.
602.2.4.3. Fine aggregate: The fine aggregate shall consist of clean natural sand or crushed
stone sand or a combination of the two and shall conform to IS: 383. Fine aggregate shall
be free from soft particles, clay, shale, loam, cemented particles, mica and organic and
other foreign matter. The fine aggregate shall not contain deleterious substances more
than the following:
Clay lumps 4.0 percent
Coal and lignite 1.0 percent
Material passing IS Sieve No. 75 micron 4.0 percent
602.2.5. Water: Water used for mixing and curing of concrete shall be clean and free from
injurious amount of oil, salt, acid, vegetable matter or other substances harmful to the
finished concrete. It shall meet the requirements stipulated in IS: 456.
602.2.6. Mild steel bars for dowels and tie bars: These shall conform to the requirements of IS :
432, IS : 1139 and IS : 1786 as relevant. The dowel bars shall conform to Grade S 240
and tie bars to Grade S 415 of I.S.
602.2.7. Sill flex(supreme industries make) joint filler: joint filler material of sill flex (supreme
industries make )is only permitted. It shall be 25 mm less in depth than the thickness of the
slab within a tolerance of 3 mm and provided to the full width between the side forms. It
shall be in suitable lengths which shall not be less than one lane width. Holes to
accommodate dowel bars shall be accurately bored or punched out to give a sliding fit in
the dowel bars.
602.2.8. Joint sealing compound: The joint sealing compound shall be of hot poured,
elastomeric type or cold polysulphide type having flexibility, resistance to age hardening
and durability. If the sealant is of hot poured type it shall conform to AASHTO M282 and
cold applied sealant shall be in accordance with BS 5212 (Part 2).
602.2.9. Storage of materials: All materials shall be stored in accordance with the provisions of
Clause 1014 of the Specifications and other relevant IS Specifications. All effort must be
made to store the materials in proper places so as to prevent their deterioration or
contamination by foreign matter and to ensure their satisfactory quality and fitness for the
work. The platform where aggregates are stock piled shall be levelled with 15 cm of
watered, mixed and compacted granular sub-base material. The area shall have slope and
drain to drain off rain water. The storage space must also permit easy inspection, removal
and storage of the materials. Aggregates of different sizes shall be stored in partitioned
stack-yards. All such materials even though stored in approved godowns must be
subjected to acceptance test as per Clause 903 of these Specifications immediately prior
to their use.
602.3. Proportion of Concrete
602.3.1. After approval by the Engineer of all the materials to be used in the concrete, the
Contractor shall submit the mix design based on weighed proportions of all ingredients for
the approval of the Engineer. The mix design shall be submitted at least 30 days prior to
the paving of trial length and the design shall be based on laboratory trial mixes using the
approved materials and methods as per IS : 10262 (Recommended Guidelines for Mix
Design) or on the basis of any other rational method agreed to by the Engineer. Guidance
in this regard can also be obtained from IS : SP : 23 Handbook on Concrete Mixes. The
target mean strength for the design mix shall be determined as indicated in Clause
903.5.2. The mix design shall be based on the flexural strength of concrete.
602.3.2. Cement content: The cement content shall not be less than 350 kg per cu.m. of
concrete. If this minimum cement content is not sufficient to produce in the field, concrete
of the strength specified in the drawings/design, it shall be increased as necessary without
additional compensation under the Contract. The cement content shall, however, not
exceed 425 kg per cu.m. of concrete.
602.3.3. Concrete strength

602.3.3.1. While designing the mix in the laboratory, correlation between flexural and compressive
strengths of concrete shall be established on the basis of at least thirty tests on samples.
However, quality control in the field shall be exercised on the basis of flexural strength. It
may, however, be ensured that the materials and mix proportions remain substantially
unaltered during the daily concrete production. The water content shall be the minimum
required to provide the agreed workability for full compaction of the concrete to the
required density as determined by the trial mixes or other means approved by the
Engineer and the maximum free water cement ratio shall be 0.50.
602.3.3.2. The ratio between the 7 and 28 day strengths shall be established for mix to be used in
the slab in advance, by testing pairs of beams and cubes at each stage on at least six
batches of trial mix. The average strength of the 7 day cured specimens shall be divided
by the average strength of the 28 day specimens for each batch, and the ratio R shall be
determined. The ratio R shall be expressed to three decimal places.
If during the construction of the trial length or during normal working, the average value of
any four consecutive 7 day test results falls below the required 7 day strength as derived
from the value of R, then the cement content of the concrete shall, without extra payment,
be increased by 5 per cent by weight or by an amount agreed by the Engineer. The
increased cement content shall be maintained at least until the four corresponding 28 day
strengths have been assessed for its conformity with the requirements as per Clause
602.3.1. Whenever the cement content is increased, the concrete mix shall be adjusted to
maintain the required workability.
602.3.4. Workability
602.3.4.1. The workability of the concrete at the point of placing shall be adequate for the
concrete to be fully compacted and finished without undue flow. The optimum workability
for the mix to suit the paving plant being used shall be determined by the Contractor and
approved by the Engineer. The control of workability in the field shall be exercised by the
slump test as per IS : 1199.
602.3.4.2. The workability requirement at the Batching Plant and paving site shall be established
slump tests carried during trial paving. These requirements shall be established from
season to season and also when the lead from Batching plant site to the paving site
changes. The workability shall be established for the type of paving equipment available. A
slump value in the range of 30 15 mm is reasonable for paving works but this may be
modified depending upon the site requirement and got approved by the Engineer. These
tests shall be carried out on every truck/dumper at Plant site and paving site initially when
the work commences but subsequently the frequency can be reduced to alternate trucks
or as per the instructions of the Engineer.
602.3.5. Design mix

602.3.5.1. The Contractor shall carry out laboratory trials of design mixes with the materials from
the approved sources to be used. Trial mixes shall be made in presence of the Engineer
or his representative and the design mix shall be subject to the approval of the Engineer.
They shall be repeated if necessary until the proportions that will produce a concrete
which complies in all respects with this Specification, and conforms to the design/drawings
have been determined.
602.3.5.2. The proportions determined as a result of the laboratory trial mixes may be adjusted if
necessary during the construction of the trial length. Thereafter, neither the materials nor
the mix proportions shall be varied in any way except with the written approval of the
Engineer.
602.3.5.3. Any change in the source of materials or mix proportions proposed by the Contractor
during the course of work shall be assessed by making laboratory trial mixes and the
construction of a further trial length unless approval is given by the Engineer for minor
adjustments like compensation for moisture content in aggregates or minor fluctuations in
the grading of aggregate.
602.4. Sub-base
The cement concrete pavement shall be laid over the sub-base constructed in accordance
with the relevant drawings and Specifications contained in Clause 601. If the sub-base is
found damaged at some places or it has cracks wider than 10mm, it shall be repaired with
fine cement concrete or bituminous concrete laying separation layer. Prior to laying of
concrete it shall be ensured that the separation membrane as per Clause 602.5 is placed
in position and the same is clean of dirt or other extraneous materials and free from any
damage.
602.5. Separation Membrane
A separation membrane shall be used between the concrete slab and the subbase.
Separation membrane shall be impermeable plastic sheeting 125 microns thick laid flat
without creases. Before placing the separation membrane, the sub-base shall be swept
clean of all the extraneous materials using air compressor. Wherever overlap of plastic
sheets is necessary, the same shall be at least 300 mm and any damaged sheeting shall
be replaced at the Contractors expense. The separation membrane may be nailed to the
lower layer with concrete nails.
602.6. Joints
602.6.1. The location and type of joints shall be as shown in the drawing. Joint shall be
constructed depending upon their functional requirement as detailed in the following
paragraphs. The location of the joints should be transferred accurately at the sire and
mechanical saw cutting of joints done as per stipulated dimensions. It should be ensured
that the full required depth of cut is made from edge to edge of the pavement. Transverse
and longitudinal joints in the pavement and sub-base shall be staggered so that they are
not coincident vertically and are at least 1 m and 0.3 m apart respectively. Sawing of joints
shall be carried out with diamond studded blades soon after the concrete has hardened to
take the load of the sawing machine and personnel without damaging the texture of the
pavement. Sawing operation could start as early as 6-8 hours depending upon the season.
602.6.2. Transverse joints
602.6.2.1. Transverse joints shall be contraction and expansion joints constructed at the spacing
described in the Drawings. Transverse joints shall be straight within the following
tolerances along the intended line of joints which is the straight line transverse to the
longitudinal axis of the carriageway at the position proposed by the Contractor and agreed
to by the Engineer, except at road junctions or roundabouts where the position shall be as
described in the drawings:
(i) Deviations of the filler board in the case of expansion joints from the intended line
of the joint shall not be greater than 10 mm.
(ii) The best fit straight line through the joint grooves as constructed shall be not more
than 25 mm from the intended line of the joint.
(iii) Deviations of the joint groove from the best fit straight line of the joint shall not be
greater than 10 mm.
(iv) Transverse joints on each side of the longitudinal joint shall be in line with each
other and of the same type and width. Transverse joints shall have a sealing
groove which shall be sealed in compliance with Clause 602.11.
602.6.2.2. Contraction joints: Contraction joints shall consist of a mechanical sawn joint groove,
3 to 5 mm wide and 1/4 to 1/3 depth of the slab 5 mm or as stipulated in the drawings
and dowel bars complying with Clause 602.6.5 and as detailed in the drawings.
The contraction joints shall be cut as soon as the concrete has undergone initial hardening
and is hard enough to take the load of joint sawing machine without causing damage to
the slab.
602.6.2.3. Expansion joints: The expansion joints shall consist of a joint filler board complying
with Clause 602.2.7 and dowel bars complying with Clause 602.6.5 and as detailed in the
drawings. The filler board shall be positioned vertically with the prefabricated joint
assemblies along the line of the joint within the tolerances given in Clause 602.6.2.1 and
at such depth below the surface as will not impede the passage of the finishing straight
edges or oscillating beams of the paving machines. The adjacent slabs shall be
completely separated from each other by providing joint filler board. Space around the
dowel bars, between the sub-base and the filler board shall be packed with a suitable
compressible material to block the flow of cement slurry.
602.6.3. Transverse construction joint: Transverse construction joints shall be placed

whenever concreting is completed after a days work or is suspended for more than 30
minutes. These joints shall be provided at the regular location of contraction joints using
dowel bars. The joint shall be made butt type. At all construction joints, steel bulk heads
shall be used to retain the concrete while the surface is finished. The surface of the
concrete laid subsequently shall conform to the grade and cross sections of the previously
laid pavement. When positioning of bulk head/stop-end is not possible, concreting to an
additional 1 or 2 m length may be carried out to enable the movement of joint cutting
machine so that joint grooves may be formed and the extra 1 or 2 m length is cut out and
removed subsequently after concrete has hardened.
602.6.4. Longitudinal joint
602.6.4.1. The longitudinal joints shall be saw cut as per details of the joints shown in the drawing.
The groove may be cut after the final set of the concrete. Joints should be sawn to at least
1/3 the depth of the slab 5 mm as indicated in the drawing.
602.6.4.2. Tie bars shall be provided at the longitudinal joints as per dimensions and spacing
shown in the drawing and in accordance with Clause 602.6.6.
602.6.5. Dowel bars
602.6.5.1. Dowel bars shall be mild steel rounds in accordance with Clause 602.2.6 with
details/dimensions as indicated in the drawing and free from oil, dirt, loose rust or scale.
They shall be straight, free of irregularities and burring restricting slippage in the concrete.
The sliding ends shall be sawn or cropped cleanly with no protrusions outside the normal
diameter of the bar. The dowel bar shall be supported on cradles/dowel chairs in pre-
fabricated joint assemblies positioned prior to the construction of the slabs or mechanically
inserted with vibration into the plastic concrete by a method which ensures correct
placement of the bars besides full re-compaction of the concrete around the dowel bars.
602.6.5.2. Unless shown otherwise on the drawings, dowel bars shall be positioned at mid depth of
the slab within a tolerance of 20 mm, and centered equally about intended lines of the
joint within a tolerance of 25 mm. They shall be aligned parallel to the finished surface of
the slab and to the centre line of the carriageway and to each other within tolerances given
hereunder, the compliance of which shall be checked as per Clause 602.10.7.
(i) For bars supported on cradles prior to the laying of the slab:
(a) All bars in a joint shall be within 3 mm per 300 mm length of bar
(b) 2/3rd of the bars shall be within 2mm per 300 mm length of bar
(c) No bar shall differ in alignment from an adjoining bar by more than 3 mm per 300
mm length of bar in either the horizontal or vertical plane
(d) Cradles supporting dowel bar shall not extend across the line of joint i.e. no steel
bar of the cradle assembly shall be continuous across the joint.
(ii) For all bars inserted after laying of the slab:
(a) Twice the tolerance for alignment as indicated in (i) above
602.6.5.3. Dowel bars, supported on cradles in assemblies, when subject to a load of 110 N
applied at either end and in either the vertical or horizontal direction (upwards and
downwards and both directions horizontally) shall conform to be within the following limits:
(i) Two-thirds of the number of bars of any assembly tested shall not deflect
more than 2 mm per 300 mm length of bar
(ii) The remainder of the bars in that assembly shall not deflect more than 3
mm per 300 mm length of bar.
602.6.5.4.The assembly of dowel bars and supporting cradles, including the joint filler board in the
case of expansion joints, shall have the following degree of rigidity when fixed in position:-
(i) For expansion joints, the deflection of the top edge of the filler board shall be not
greater than 13 mm, when a load of 1.3 kN is applied perpendicular to the vertical
face of the joint filler board and distributed over a length of 600 mm by means of a
bar or timber packing, at mid depth and midway between individual fixings, or 300
mm from either end of any length of filler board, if a continuous fixing, is used. The
residual deflection after removal of the load shall be not more than 3 mm.
(ii) The joint assembly fixings to sub-base shall not fail under the 1.3 kN load applied
for testing the rigidity of the assembly but shall fail before the load reaches 2.6 kN.
(iii) The fixings for contraction joint shall not fail under 1.3 kN load and shall fail before
the load reaches 2.6 kN when applied over a length of 600 mm by means of a bar
or timber packing placed as near to the level of the line of fixings as practicable.
(iv) Fixings shall be deemed to fail when there is displacement of the assemblies by
more than 3mm with any form of fixing, under the test load. The displacement
shall be measured at the nearest part of the assembly to the centre of the bar or
timber packing.
602.6.5.5. Dowel bars shall be covered by a thin plastic sheath for at least two-thirds of the length
from one end for dowel bars in contraction joints or half the length plus 50 mm for
expansion joints. The sheath shall be tough, durable and of an average thickness not
greater than 1.25 mm. The sheathed bar shall comply with the following pull-out tests:
i. Four bars shall be taken at random from stock and without any special preparation
shall be covered by sheaths as required in this Clause. The ends of the dowel bars which
have been sheathed shall be cast centrally into concrete specimens 150 x 150 x 600 mm,
made of the same mix proportions to be used in the pavement, but with a maximum
nominal aggregate size of 20 mm and cured in accordance with IS:516. At 7 days a tensile
load shall be applied to achieve a movement of the bar of at least 0.25 mm. The average
bond stress to achieve this movement shall not be greater than 0.14 MPa.
602.6.5.6. For expansion joints, a closely fitting cap 100 mm long consisting of waterproofed card
board or an approved synthetic material like PVC or GI pipe shall be placed over the
sheathed end of each dowel bar. An expansion space at least equal in length to the
thickness of the joint filler board shall be formed between the end of the cap and the end
of the dowel bar by using compressible sponge. To block the entry of cement slurry
between dowel and cap it may be taped.
602.6.6. Tie bars
602.6.6.1. Tie bars in longitudinal joints shall be deformed steel bars of strength 415 MPa
complying with IS:1786 and in accordance with the requirements given below. The bars
shall be free from oil, dirt, loose rust and scale.
602.6.6.2. Tie bars projecting across the longitudinal joint shall be protected from corrosion for 75
mm on each side of the joint by a protective coating of bituminous paint with the approval
of the Engineer. The coating shall be dry when the tie bars are used.
602.6.6.3. Tie bars in longitudinal joints shall be made up into rigid assemblies with adequate
supports and fixings to remain firmly in position during the construction of the slab.
Alternatively, tie bars at longitudinal joint may be mechanically or manually inserted into
the plastic concrete from above by vibration using a method which ensures correct
placement of the bars and recompaction of the concrete around the tie bars.
602.6.6.4 Tie bars shall be positioned to remain within the middle third of the slab depth as
indicated in the drawings and approximately parallel to the surface and approximately
perpendicular to the line of the joint, with the centre of each bar on the intended line of the
joints within a tolerance of 50 mm, and with a minimum cover of 30 mm below the joint
groove.
602.7. Weather and Seasonal Limitations
602.7.1. Concrete during monsoon months: When concrete is being placed during monsoon
months and when it may be expected to rain, sufficient supply of tarpaulin or other water
proof cloth shall be provided along the line of the work. Any time when it rains, all freshly
laid concrete which had not been covered for curing purposes shall be adequately
protected. Any concrete damaged by rain shall be removed and replaced. If the damage
is limited to texture, it shall be retextured in accordance with the directives of the Engineer.
602.7.2. Concreting in hot weather: No concreting shall be done when the concrete temperature
is above 30 degree Centigrade. Besides, in adverse conditions like high temperature, low
relative humidity, excessive wind velocity, imminence of rains etc., if so desired by the
Engineer, tents on mobile trusses may be provided over the freshly laid concrete for a
minimum period of 3 hours as directed by the Engineer. The temperature of the concrete
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mix on reaching the paving site shall not be more than 30 C. To bring down the
temperature, if necessary, chilled water or ice flakes should be made use of.
No concreting shall be done when the concrete temperature is below 5 degree Centigrade
and the temperature is descending.
602.8. Side Forms, Rails and Guide wires
602.8.1 Side forms and rails: All side forms shall be of mild steel of depth equal to the thickness
of pavement or slightly less to accommodate the surface regularity of the sub-base. The
forms can be placed on series of steel packing plates or shims to take care of irregularity
of sub-base. They shall be sufficiently robust and rigid to support the weight and pressure
caused by a paving equipment. Side forms for use with wheeled paving machines shall
incorporate metal rails firmly fixed at a constant height below the top of the forms. The
forms and rail shall be firmly secured in position by not less than 3 stakes/pins for each 3m
length so as to prevent movement in any direction. Forms and rails shall be straight within
a tolerance of 3 mm in 3m and when in place shall not settle excess of 1.5 mm in 3 m
while paving is being done. Forms shall be cleaned and oiled immediately before each
use. The forms shall be bedded on a continuous bed of low moisture content lean cement
mortar or concrete and set to the line and levels shown on the drawings within tolerances
10 mm and 3 mm respectively. The bedding shall not extend under the slab and there
shall be no vertical step between adjacent forms of more than 3 mm. The forms shall be
got inspected from the Engineer for his approval before 12 hours on the day before the
construction of the slab and shall not be removed until at least 12 hours afterwards.
602.8.2. At all times sufficient forms shall be used and set to the required alignment for at least
200 m length of pavement immediately in advance of the paving operations, or anticipated
length of pavement to be laid within the next 24 hrs whichever is more.
602.8.3. Use of guidewires
602.8.3.1. Trimix vacuumed dewatering system , a guidewire shall be provided along both sides of
the slab. Each guidewire shall be at a constant height above and parallel to the required
edges of the slab as described in the contract/drawing within a vertical tolerance of 3
mm. Additionally, one of the wires shall be kept at a constant horizontal distance from the
required edge of the pavement as indicated in the contract/drawing within a lateral
tolerance of 10 mm.
602.8.3.2. The guidewires shall be supported on stakes not more than 8 m apart by connectors
capable of fine horizontal and vertical adjustment. The guidewire shall be tensioned on the
stakes so that a 500 gram weight shall produce a deflection of not more than 20 mm when
suspended at the mid point between any pair of stakes. The ends of the guidewires shall
be anchored to fixing point or winch and not on the stacks.
602.8.3.3. The stack shall be positioned and the connectors maintained at their correct height and
alignment from 12 hours on the day before concreting takes place until 12 hours after
finishing of the concrete. The guidewire shall be erected and tensioned the connectors at
any section for at least 2 hours before concreting that section.
602.8.4. The Contractor shall submit to the Engineer for his approval of line and level, the stakes
and connectors which are ready for use in the length of road to be constructed by 12 hours
on the working day before the day of construction of slab. Any deficiencies noted by the
Engineer shall be rectified by the Contractor who shall then re-apply for approval of the
affected stakes. Work shall not proceed until the Engineer has given his approval. It shall
be ensured that the stakes and guidewires are not affected by the construction equipment
when concreting is in progress.
602.9. Construction
602.9.1 General: A systems approach may be adopted for construction of the pavement, and the
Method Statement for carrying out the work, detailing all the activities including indication
of time-cycle, equipment, personnel etc., shall be got approved from the Engineer before
the commencement of the work. The above shall include the type, capacity and make of
the batching and mixing plant besides the hauling arrangement and paving equipment.
The capacity of paving equipment, batching plant as well as all the ancillary equipment
shall be adequate for a paving rate of atleast 300 m in one day.
602.9.2. Batching and mixing: Batching and mixing of the concrete shall be done at a central
batching and mixing plant with automatic controls, located at a suitable place which takes
into account sufficient space for stockpiling of cement, aggregates and stationary water
tanks. This shall be, however, situated at an approved distance, duly considering the
properties of the mix and the transporting arrangements available with the Contractor.
602.9.3. Equipment for proportioning of materials and paving
602.9.3.1. Proportioning of materials shall be done in the batching plant by weight, each type of
material being weighed separately. The cement from the bulk stock may be weighed
separately from the aggregates and water shall be measured by volume. Wherever
properly graded aggregate of uniform quality cannot be maintained as envisaged in the
mix design, the grading of aggregates shall be controlled by appropriate blending
techniques. The capacity of batching and mixing plant shall be at least 25 per cent higher
than the proposed capacity of the laying/paving equipment.
602.9.3.2. Batching plant and equipment:

(1) General- The batching plant shall include minimum four bins, weighing hoppers,
and scales for the fine aggregate and for each size of coarse aggregate. If cement
is used in bulk, a separate scale for cement shall be included. The weighing
hoppers shall be properly sealed and vented to preclude dust during operation.
Approved safety devices shall be provided and maintained for the protection of all
personnel engaged in plant operation, inspection and testing. The batch plant
shall be equipped with suitable non-resettable batch counter which will correctly
indicate the number of batches proportioned.
(2) Bins and hoppers- Bins with minimum number of four adequate separate
compartments shall be provided in the batching plant.
(3) Automatic weighing devices- Batching plant shall be equipped to proportion

aggregates and bulk cement by means of automatic weighing devices using load
cells.
(4) Mixers- Mixers shall be pan type, reversible type or any other mixer capable of
combining the aggregates, cement, and water into a thoroughly mixed and uniform
mass within the specific mixing period, and of discharging the mixture, without
segregation. Each stationary mixer shall be equipped with an approved timing
device which will automatically lock the discharge lever when the drum has been
charged and release it at the end of the mixing period. The device shall be
equipped with a bell or other suitable warring device adjusted to give a clearly
audible signal each time the lock is released. In case of failure of the timing
device, the mixer may be used for the balance of the day while it is being repaired,
provided that each batch is mixed 90 seconds or as per the manufacturers
recommendation. The mixer shall be equipped with a suitable non-resettable
batch counter which shall correctly indicate the number of batches mixed.
The mixers shall be cleared at suitable intervals. The pickup and throw-over
blades in the drum or drums shall be repaired or replaced when they are worn
down 20 mm or more. The Contractor shall (1) have available at the job site a
copy of the manufacturers design, showing dimensions and arrangements of
blades in reference to original height and depth, or (2) provide permanent marks
on blade to show points of 20 mm wear from new conditions. Drilled holes of 5
mm diameter near each end and at mid point of each blade are recommended.
Batching Plant shall be calibrated in the beginning and thereafter at suitable
interval not exceeding 1 month.
(5) Control cabin- An air-conditioned centralised control cabin shall be provided for
automatic operation of the equipment.
602.9.3.3. Paving equipment: Trimix vacuumed dewatering system is proposed for paving..
Vibrators shall operate at a frequency of 8300 to 9600 impulses per minute under load at a
maximum spacing of 60 cm. The variable vibration setting shall be provided in the
machine.
602.9.3.4. Concrete saw: The Contractor shall provide adequate number of concrete saws with
sufficient number of diamond-edge saw blades. The saw machine shall be either electric
or petrol/diesel driven type. A water tank with flexible hoses and pump shall be made
available in this activity on priority basis. The Contractor shall have at least one standby
saw in good working condition. The concreting work shall not commence if the saws are
not in working condition.
602.9.4. Hauling and placing of concrete
602.9.4.1. Freshly mixed concrete from the central batching and mixing plant shall be transported
to the paving site by means of trucks/tippers of sufficient capacity and approved design in
sufficient numbers to ensure a constant supply of concrete. Covers shall be used for
protection of concrete against the weather. The trucks/tippers shall be capable of
maintaining the mixed concrete in a homogeneous state and discharging the same without
segregation and loss of cement slurry. The feeding to the work is to be regulated in such a
way that the paving is done in an uninterrupted manner with a uniform speed throughout
the days work.
602.9.4.2. Placing of concrete
Concrete mixed in central mixing plant shall be transported to the site without delay and
the concrete which, in the opinion of the Engineer, has been mixed too long before laying
will be rejected and shall be removed from the site. The total time taken from the addition
of the water to the mix, until the completion of the surface finishing and texturing shall not
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exceed 120 minutes when concrete temperature is less than 25 C and 90 minutes when
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the concrete temperature is between 25 C to 30 C. Trucks/tippers delivering concrete
shall not run on plastic sheeting nor shall they run on completed slabs until after 28 days
of placing the concrete.
602.9.4.3. Before any paving is done, the site shall be shown to the Engineer, in order to verify the
arrangement for paving besides placing of dowels, tie-bars etc., as per the relevant
Clauses of this Specification. The mixing and placing of concrete shall progress only at
such a rate as to permit proper finishing, protecting and curing of the pavement.
602.9.4.4. In all cases, the temperature of the concrete shall be measured at the point of
discharge from the delivery vehicle.
602.9.4.5. The addition of water to the surface of the concrete to facilitate the finishing operations
will not be permitted except with the approval of the Engineer when it shall be applied as a
mist by means of approved equipment.
602.9.4.6. If considered necessary by the Engineer, the paving machines shall be provided with
approved covers to protected the surface of the slab under construction from direct
sunlight and rain or hot wind.
602.9.4.7. While the concrete is still plastic, its surface shall be brush textured in compliance with
Clause 602.9.8 and the surface and edges of the slab cured by the application of a
sprayed liquid curing membrane in compliance with Clause 602.9.9. After the surface
texturing, but before the curing compound is applied, the concrete slab shall be marked
with the chainage at every 100 m interval.
602.9.4.8. As soon as the side forms are removed, edges of the slabs shall be corrected wherever
irregularities have occurred by using fine concrete composed of one part of cement to 3
parts of fine chips and fine aggregate under the supervision of the Engineer.
602.9.4.9. If the requirement of Clause 902.4. for surface regularity fails to be achieved on two
consecutive working days, then normal working shall cease until the cause of the
excessive irregularity has been identified and remedied.
602.9.5. Cancelled
602.9.6. Deleted
602.9.8. Surface texture
602.9.8.1. After the final regulation of the slab and before the application of the curing membrane,
the surface of concrete slab shall be brush-textured in a direction at right angles to the
longitudinal axis of the carriageway.
602.9.8.2. The brushed surface texture shall be applied evenly across the slab in one direction by
the use of a wire brush not less than 450 mm wide but longer brushes are preferred. The
brush shall be made of 32 gauge tape wires grouped together in tufts spaced at 10 mm
centres. The tufts shall contain an average of 14 wires and initially be 100 mm long. The
brush shall have two rows of tufts. The rows shall be 20 mm apart and the tufts in one row
shall be opposite the centre of the gap between tufts in the other row. The brush shall be
replaced when the shortest tuft wears down to 90 mm long.
602.9.8.3. The texture depth shall be determined by the Sand Patch Test as described in Clause
602.12. This test shall be performed at least once for each days paving and wherever the
Engineer considers it necessary at times after construction as under:
Five individual measurements of the texture depth shall be taken at least 2 m apart
anywhere along a diagonal line across a lane width between points 50 m apart along the
pavement. No measurement shall be taken within 300 mm of the longitudinal edges of a

concrete slab constructed in one pass.
602.9.8.4. Texture depths shall not be less than the minimum required when measurements are
taken as given in Table 600-2 nor greater than a maximum average 1.25 mm.
TABLE : 600-2 Texture Depth
Time of Test Number of Required Texture Depth (mm)

Measurements
Specified Value Tolerance
1. Between 24 hours and 7 days after An average of 5 1.00 0.25

the constn., of the slab or until the measurements
slab is first used by vehicles.
2. Not later than 6 weeks before the An average of 5 1.00 +0.25

road is opened to public traffic. measurements -0.35
602.9.8.5. After the application of the brushed texture, the surface of the slab shall have a uniform
appearance.
602.9.8.6. Where the texture depth requirements are found to be deficient, the Contractor shall
make good the texture across the full lane width over length directed by the Engineer, by
retexturing the hardened concrete surface in an approved manner.
602.9.9. Curing
602.9.9.1. Immediately after the surface texturing, the surface and sides of the slab shall be cured
by the application of approved resin-based aluminised reflective curing compound which
hardens into an impervious film or membrane with the help of a mechanical sprayer.
Curing compounds shall contain sufficient flake aluminium in finely divided dispersion to
produce a complete coverage of the sprayed surface with a metallic finish. The compound
shall become stable and impervious to evaporation of water from the surface of the
concrete within 60 minutes of application and shall be of approved type. The curing
compounds shall have a water retention efficiency index of 90 per cent in accordance with
BS Specification No. 7542.
602.9.9.2. The curing compound shall not react chemically with the concrete and the film or
membrane shall not crack, peel or disintegrate within three weeks after application.
Immediately prior to use, the curing compound shall be thoroughly agitated in its
containers. The rate of spread shall be in accordance with the manufacturers instructions
checked during the construction of the trial length and subsequently whenever required by
the Engineer. The mechanical sprayer shall incorporate an efficient mechanical device for
continuous agitation and mixing of the compound during spraying.
602.9.9.3. In addition to spraying of curing compound, the fresh concrete surface shall be
protected for at least 3 hours by covering the finished concrete pavement with tents as
described in Clause 602.7.2, during adverse weather conditions as directed by the
Engineer. After three hours, the pavement shall be covered by moist hessian and the
same shall then be kept damp for a minimum period of 14 days after which time the
hessian may be removed. The hessian shall be kept continuously moist. All damaged/torn
hessian shall be removed and replaced by new hessian on a regular basis.
602.9.9.4. The Contractor shall be liable at his expense to replace any concrete damaged as a
result of incomplete curing or cracked on a line other than that of a joint.
602.10. Trial Length
602.10.1. The trial length shall be constructed at least one month in advance of the proposed start
of concrete paving work. At least one month prior to the construction of the trial length, the
Contractor shall submit for the Engineer=s approval a detailed method statement giving
description of the proposed materials, plant, equipment and construction methods. All the
major equipments like paving train, batching plant; tippers etc., proposed in the
construction are to be approved by the Engineer before their procurement. No trials of new
materials, plant, equipment or construction methods, nor any development of them shall
be permitted either during the construction of trial length or in any subsequent paving
work, unless they form part of further, approved trials. These trial lengths shall be
constructed away from the carriageway but with at least a subbase layer below it.
602.10.2. The Contractor shall demonstrate the materials, plant, equipment and methods of
construction that are proposed for concrete paving, by first constructing a trial length of
slab, at least 60 m but not more than 300 m long for mechanised construction and at least
30 m long for hand guided methods. If the first trial is unsatisfactory, the Contractor shall
have to demonstrate his capability to satisfactorily construct the pavement in subsequent
trials.
602.10.3. The trial length shall be constructed in two parts over a period comprising at least part
of two separate working days, with a minimum of 30 m constructed each day for
mechanised construction and a minimum of 15 m on each day for hand guided
construction. The trial length shall be constructed at a similar rate (speed, around 1m/hr)
to that which is proposed for the main work.
602.10.4. Transverse joints and longitudinal joints of each type that are proposed for dowel-jointed
unreinforced concrete slabs in the main work shall be constructed and assessed in the trial
length. If in the trial length the construction of expansion joint and longitudinal joint is not
demonstrated, the first 2 expansion joints and at least the first 150 m of longitudinal
construction joint for mechanised paving in the main work, shall be considered as the trial
length for these joints.
602.10.5. The trial length shall comply shall the Specification in all respects, with the following
additions and exceptions:
602.10.5.1.Surface levels and regularity
(i) In checking for compliance with Clause 903.5 the levels shall be taken at
intervals at the locations specified in this Clause along any line or lines parallel to
the longitudinal centre line of the trial length.
(ii) The maximum number of permitted irregularities of pavement surface

shall comply with the requirements of Clause 902.4. Shorter trial lengths shall be
assessed pro-rata based on values for a 300 m length.
602.10.5.2.Joints
(iii) Alignment of dowel bars shall be inspected as described in Clause

602.10.7 in any two consecutive transverse joints. If the position or alignment of
the dowel bars at one of these joints does not comply with Clause 602.6.5, if that
joint remains the only one that does not comply after the next 3 consecutive joints
of the same type have been inspected, then the method of placing dowels shall be
deemed to be satisfactory. In order to check sufficient joints for dowel bar
alignment without extending the trial length unduly, the Contractor may, by
agreement with the Engineer, construct joints at more frequent joint intervals than
the normal spacing required in the Contract.
(iv) If there are deficiencies in the first expansion joint that is constructed as a
trial, the next expansion joint shall be a trial joint. Should this also be deficient,
further trial expansion joints shall be made as part of the trial length which shall
not form part of the permanent works, unless agreed by the Engineer.
602.10.5.3. Density
(v) Density shall be assessed as described in Clause 602.3.3. from at least 3

cores drilled from each part of the trial length.
602.10.5.4. Position of tie bars
(vi) Compliance with Clause 602.6.6 for the position and alignment of tie bars
shall be checked by drilling additional cores from the slab unless they can be
determined from cores taken for density.
602.10.6. Approval and acceptance
602.10.6.1. Approval of the materials, plant, equipment and construction methods shall be given
when a trial length complies with the Specification. The Contractor shall not proceed with
normal working until the trial length has been approved and any earlier defective trial
lengths have been removed, unless that can be remedied to the satisfaction of the
Engineer. If the Engineer does not notify the Contractor of any deficiencies in any trial
length within 10 days after the completion of that trial length, the Contractor may assume
that the trial length, and the materials, plant, equipment and construction methods adopted
are acceptable.
602.10.6.2. When approval has been given, the materials, plant, equipment and construction
methods shall not thereafter be changed, except for normal adjustments and maintenance
of plant, without the approval of the Engineer. Any changes in material, plant, equipment
and construction methods shall entitle the Engineer to require the Contractor to lay a
further trial length as described in this Clause to demonstrate that the changes will not
adversely affect the permanent works.
602.10.6.3. Trial lengths which do not comply with the Specification, with the exception of areas
which are deficient only in surface texture and which can be remedied in accordance with
Clause 602.9.8.6 shall be removed immediately upon notification of deficiencies by the
Engineer and the Contractor shall construct a further trial length.
602.10.7. Inspection of dowel bars
602.10.7.1. Compliance with Clause 602.6.5. for the position and alignment of dowel bars at
construction and expansion joints shall be checked by measurements relative to the side
forms or guide wires.
602.10.7.2 When the slab has been constructed, the position and alignment of dowel bars and any
filler board shall be measured after carefully exposing them in the plastic concrete across
the whole width of the slab. When the joint is an expansion joint, the top of the filler board
shall first be exposed sufficiently in the plastic concrete to permit measurement of any
lateral or vertical displacement of the board. During the course of normal working, these
measurements shall be carried out in the pavement section at the end of day=s work by
extending slab length by 2 m. After sawing the transverse joint groove, the extended 2 m
slab shall be removed carefully soon after concrete has set to expose dowels over half the
length. These dowels can be tested for tolerances.
602.10.7.3 If the position and alignment of the bars in a single joint in the slab is unsatisfactory
then the next two joints shall be inspected. If only one joint of the three is defective, the
rate of checking shall be increased to one joint per day until the Engineer is satisfied that
compliance is being achieved. In the event of non-compliance in two or more successive
joints, the Contractor shall revert to the construction of fresh trial lengths and make any
necessary alteration to concrete mix, paving plant or methods until the dowel bar position
and alignment are satisfactory.
602.10.7.4. After the dowel bars have been examined, the remainder of the concrete shall be
removed over a width of 500 mm on each side of the line of the joint and reinstated to the
satisfaction of the Engineer. The dowels shall be inserted on both sides of the 1 m wide
slab by drilling holes and grouting with epoxy mortar. Plastic sheath as per Clause
602.6.5.5 shall be provided on dowels on one of the joints. The joint groove shall be
widened and sealed as per Clause 602.11.
602.11. Preparation and Sealing of Joint Grooves
602.11.1. General
All transverse joints in surface slabs shall be sealed using sealants described in Clause
602.2.8. Joints shall not be sealed before 14 days after construction.
602.11.2. Preparation of joint grooves for sealing
602.11.2.1. Joint grooves usually are not constructed to provide the minimum width specified in
the drawings when saw cut joints are adopted. They shall be widened subsequently by
sawing before sealing. Depth/width gauges shall be used to control the dimension of the
groove.
602.11.2.2. If rough arises develop when grooves are made, they shall be ground to provide a
chamfer approximately 5 mm wide. If the groove is at an angle upto 10 degree from the
perpendicular to the surface, the overhanging edge of the sealing groove shall be sawn or
ground perpendicular. If spalling occurs or the angle of the former is greater than 10
degrees, the joint sealing groove shall be sawn wider and perpendicular to the surface to
encompass the defects upto a maximum width, including any chamfer, of 35 mm for
transverse joints and 20 mm for longitudinal joints. If the spalling cannot be so eliminated
then the arises shall be repaired by an approved thin bonded arris repair using
cementitious materials.
602.11.2.3. All grooves shall be cleaned of any dirt or loose material by air blasting with filtered,
oil-free compressed air. If need arises the Engineer may instruct cleaning by pressurised
water jets. Depending upon the requirement of the sealant manufacture, the sides of the
grooves may have to be sand blasted to increase the bondage between sealant and
concrete.
602.11.2.4 The groove shall be cleaned and dried at the time of priming and sealing.
602.11.2.5. Before sealing the temporary seal provided for blocking the ingress of dirt, soil etc.,
shall be removed. A highly compressible heat resistant paper-backed debonding strip as
per drawing shall be inserted in the groove to serve the purpose of breaking the bond
between sealant and the bottom of the groove and to plug the joint groove so that the
sealant may not leak through the cracks. The width of debonding strip shall be more than
the joint groove width so that it is held tightly in the groove. In the case of longitudinal
joints, heat resistant tapes may be inserted to block the leakage through bottom of the
joint.
602.11.3. Sealing with sealants
602.11.3.1. When sealants are applied, an appropriate primer shall also be used if recommended
by the manufacturer and it shall be applied in accordance with their recommendation. The
sealant shall be applied within the minimum and maximum drying times of the primer
recommended by the manufacturer. Priming and sealing with applied sealants shall not
be carried out when the naturally occurring temperature in the joint groove to be sealed is
o
below 7 C.
602.11.3.2. If hot applied sealant is used it shall be heated and applied from a thermostatically
controlled, indirectly heated preferably with oil jacketed melter and pourer having
recirculating pump and extruder. For large road projects, sealant shall be applied with
extruder having flexible hose and nozzle. The sealant shall not be heated to a
temperature higher than the safe heating temperature and not for a period longer than the
safe heating period, as specified by the manufacturer. The dispenser shall be cleaned out
at the end of each day in accordance with the manufacturer=s recommendations and
reheated material shall not be used.
602.11.3.3 Cold applied sealants with chemical formulation like polysulphide may be used. These
shall be mixed and applied within the time limit specified by the manufacturer. If primers
are recommended they shall be applied neatly with an appropriate brush. The Movement
Accommodation Factor (MAF) shall be more than 10 per cent
602.11.3.4. The sealants applied at contraction phase of the slabs would result in bulging of the
sealant over and above the slab. Therefore, the Contractor in consultation with the
Engineer, shall establish the right temperature and time for applying the sealant.
Thermometer shall be hung on a pole in the site for facilitating control during the sealing
operation.
602.11.3.5. Sealant shall be applied, slightly to a lower level than the slab with a tolerance of 5
2
mm.
602.11.3.6. During sealing operation, it shall be seen that no air bubbles are introduced in the
sealant either by vapors or by the sealing process.
602.11.4. Testing of applied sealants: Manufacturers certificate shall be produced by the

Contractor for establishing that the sealant is not more than six months old and stating that
the sealant complies with the relevant standard as in Clause 602.2.8. The samples shall
meet the requirement of AASHTO M 282 for hot applied sealant or BS 5212 : (Part- 2) for
cold applied sealant.
602.12. Measurement of Texture Depth - Sand Patch Method

602.12.1. The following apparatus shall be used:
(i) A cylindrical container of 25 ml internal capacity
(ii) A flat wooden disc 64 mm diameter with a hard rubber disc, 1.5 mm thick, stuck to
one face, the reverse face being provided with a handle.
(iii) Dry natural sand with a rounded particle shape passing a 300 micron IS sieve and
retained on a 150 micron IS sieve.
602.12.2. Method: The surface to be measured shall be dried, any extraneous mortar and loose
material removed and the surface swept clean using a wire brush both at right angles and
parallel to the carriageway. The cylindrical container shall be filled with the sand, tapping
the base 3 times on the surface to ensure compaction, and striking off the sand level with
the top of the cylinder. The sand shall be poured into a heap on the surface to be treated.
The sand shall be spread over the surface, working the disc with its face kept flat in a
circular motion so that the sand is spread into a circular patch with the surface
depressions filled with sand to the level of peaks.
602.12.3. The diameter of the patch shall be measured to the nearest 5 mm. The texture depth of
concrete surface shall be calculated from 31000/(DxD) mm where D is the diameter of the
patch in mm.
602.13. Opening to Traffic
No vehicular traffic shall be allowed to run on the finished surface of a concrete pavement
within a period of 28 days of its construction and until the joints are permanently sealed.
The road may be opened to regular traffic after completion of the curing period of 28 days
and after sealing of joints is completed including the construction of shoulder, with the
written permission of the Engineer.
602.14. Tolerance for Surface Regularity, Level, Thickness and Strength
The tolerances for surface regularity, level, thickness and strength shall conform to the
requirements given in Clause 903.5. Control of quality of materials and works shall be
exercised by the Engineer in accordance with Section 900.
602.15. Measurements for Payment
602.15.1. Cement Concrete pavement shall be measured as a finished work in square metres with
specified thickness. The volume to be paid for will be calculated on the basis of thickness
and plans shown on the project drawings and adjusted for the deficiency in thickness. No
additional payment shall be made for extra thickness of the slab. The full payment will be
made to this item after 28 days strength of the concrete is found to be satisfactory.
The unit for measurement for concrete pavement shall be the cubic metre of concrete
placed, based on the net plan areas for the specified thickness shown on the Drawings or
directed by the Engineer. The rate shall include all provisions of this Specification and
shall include the provision of all materials including polythene film, concrete, stock piling,
mixing, transport, placing, compacting, finishing, curing together with all formwork, and
including testing and submission of test certificates and records. No deduction shall be
made in measurement for openings provided that the area of each is less than 0.5 sq.m.
The unit rate as entered in the Bill of Quantities shall also include the full costs of
contraction, expansion, construction, and longitudinal joints. It shall also include joint filler,
keys, caulking rod, debonding strip, sealant primer, joint sealant, dowel bar and tie rod.
602.15.2. Pavement thickness
All precautions and care shall be taken to construct pavement having uniform thickness as
called for on the plans.
Thickness of the cement concrete pavement shall be calculated on the basis of level data
of the cement concrete pavement and the underlying sub-base taken on a grid of 3 m x
3.75 m the former measurement being in longitudinal direction.
A day=s work is considered as a lot for calculating the average thickness of the slab. In
calculating the average thickness, individual measurements which are in excess of the
specified thickness by more than 10 mm shall be considered as the specified as thickness
plus 10 mm.
Individual areas deficient by more than 25 mm shall be verified by the Engineer by

ordering core cutting and if in his opinion the deficient areas warrant removal, they shall be
removed and replaced with concrete of the thickness shown on the plans.
When the average thickness for the lot is deficient by the extent shown in Table 600-3, the
Contract unit price will be adjust as per this Table.
TABLE 600-3 PAYMENT ADJUSTMENT FOR DEFICIENCY IN THICKNESS
Deficiency in the average thickness of Per cent of Contract unit price payable
days work
Up to 5mm 100
6 10 mm 87
11-15 mm 81
16 20 mm 75
21 25 mm 70
In the stretch where deficiency of average thickness is more than 25 mm, the section
whose thickness is deficient by 26 mm or more is identified with the help of cores. Such
slabs shall be removed and reconstructed at the cost of the Contractor. During such
rectification work, care shall be taken to replace full slab and to the full depth.
602.16. Rate
The Contract unit rate for the construction of the cement concrete shall be payment in full
for carrying out the operations required for the different items of the work as per these
Specifications including full compensation for all labour, tools, plant, equipments, testing
and incidentals to complete the work as per Specifications, providing all materials to be
incorporated in the work including all royalties, fees, storage, rents where necessary and
all leads and lifts.
PRECAST KERB
Providing & fixing M25 grade of concrete precast exposed /fare finish kerb stones of
following sizes on the foundation prepared of M15 grade concrete as of approved
design including curing, formwork etc. complete. The rate shall also include for
erecting and fixing the pieces in position with necessary equipments and materials.
The rate shall also include the flush pointing in CM (1:2) for all joints of the kerb
stones. (Sample must be approved). Monolithic and homogeneous casting is
required using rubber mould only. Two layer casting is not allowed in any case. The
contractor rate shall also include the cost of foundation of M15 grade.
1.0 Materials: Water, Cement, Grit, Sand, Graded stone aggregate 20-mm. nominal size as
per general specification of other concreting.
2.0 General:
2.1 Contractor shall have to manufacture the blocks as per the dimensions given in the drawing.
2.2 Specific machineries shall be used to manufacture the precast blocks. These machineries
should be compatible to produce blocks of required strength and dimensions. Moulds/ Dies
of the machine shall be dimensionally checked & to be got approved before commencing the
production.
2.3 Contractor shall prepare proper Drying Yard for keeping the blocks before curing. The drying
yard shall be levelled and covered so that no shrinkage cracks are formed.
2.4 Contractor shall prepare adequate size curing pond to cure the blocks for not less than 21
Days. No other means of curing shall be allowed.
2.5 The technical specification of concrete shall confirm to IS 456-1978.
2.6 The concrete mix shall be M25. Concrete work shall have exposed concrete surface or as
specified in the item.
2.7 Deleted
2.8 The ingredients required for ordinary concrete containing one bag of cement of 50 Kg. by
weight (0.0342 m3.) for different proportions of mix shall be as per IS 456-1978. The
proportion of the aggregate for the kerb stone shall be modified as per the approval of the
engineer-in-charge.
2.9 The water cement ratios shall not be more than those specified as per IS. The cement of the
mix shall be increased, if the quantity of water in a mix has to be increased to overcome the
difficulties of placement and compaction so that the water cement ratio specified in the table
is not exceeded.
2.10 The maximum size of coarse aggregate shall be as large as possible within the limits
specified but in no case greater than 1/4th of the minimum thickness of the member,
provided that the concrete can be placed without difficulty so as to surround all
reinforcement thoroughly and to fill the corners of the form.
2.11 For reinforced concrete work, coarse aggregates having a nominal size of 20 mm. are
generally considered satisfactory.
2.12 Admixture shall be used in concrete only with approval of the Architect and Engineer-in-
charge based upon the evidence that with the passage of time, neither the compressive
strength of concrete is reduced nor are other requisite qualities of concrete impaired by the
use of such admixtures.
3.0 Workmanship:
3.1 Deleted.
3.2 Mixing:
3.2.1 For all work, concrete shall be mixed in a mechanical mixer which along with other
accessories shall be kept in first class working condition and maintained throughout the
construction. Measured quantity of aggregate, sand and cement required for each batch
shall be poured into the drum of the mechanical mixer while it is continuously running. After
about half a minute of dry-mixing, measured quantity of water required for each batch of
concrete mix shall be added gradually and mixing continued for another one and a half
minute. Mixing shall be continued till materials are uniformly distributed and uniform colour of
the entire mass is obtained and each individual particle of the coarse aggregate shows
complete coating of mortar containing its proportionate amount of cement. In no case shall
the mixing be done for less than 2 minutes after all ingredients have been put into the mixer.
3.2.3 Mixers, which have been out of use for more than 30 minutes, shall be thoroughly cleaned
before putting in a new batch. Unless otherwise agreed to by the Architect and Engineer-in-
charge, the first batch of concrete from the mixture shall contain only 2/3rds of normal
quantity of coarse aggregate. Mixing plant shall be thoroughly cleaned before changing from
one type of cement to another.
3.3 Consistency: The degree of consistency which shall depend upon the nature of the work
and methods of vibration of concrete, shall be determined by regular slump tests in
accordance with IS: 1199-1959. The slump of 10 mm. to 25 mm. shall be adopted when
vibrators are used.
3.4 Inspection:
3.4.1 All Moulds shall be cleaned and made free from standing water, dust, snow or ice
immediately before placing of concrete.
3.4.2 Formwork/Metal Mould for exposed concrete surface (If indicated):
3.4.3 All the moulds shall be checked for exact dimensions of the Precast blocks. All the edges
of the Precast blocks shall confirm the profile of the final drawing & edges/ curvatures of
the moulds shall be checked accordingly. Moulds shall be regularly checked for
correctness of dimensions of Blocks, twists, bends due to handling, etc. before starting
every days work.
3.4.4 Care shall be taken to set all formwork/Mould in perfect line, level (or in required camber
or slope as specified) and plumb. Formwork/Mould propping shall be strong, rigid and
sturdy. The formwork/Mould shall be as per pattern & design shown in drawings.
Formwork/Mould shall be done accurately and precisely so as to achieve neat, clean and
smooth concrete surface, in line, level and plumb. Clinks, twists, offsets, warps, riveting
etc. in plates or forms shall not be allowed. Before placing concrete, forms shall be
thoroughly cleaned off of all rust, dust and loose materials. Colorless oil or grease of
approved quality shall be applied before placing steel. Also the formwork material will be of
wood/plywood/steel or any sort of such material, as approved by the Architect, so that all
exposed concrete surfaces have uniform colour.
3.4.5 For all kind of exposed concrete work only one brand (to be approved by the Architect or
Engineer-in-charge) of cement shall be used.
3.4 Removal of Moulds:
Specific time shall be identified for removal of moulds, such that the concrete of the
Precast blocks shall gain strength to withstand the stresses generated due to self weight
and handling to drying yards without any deformation to shape/ dimensions/ edges.
3.5 Drying Period:
Sufficient time shall be given to the block after it is removed from the mould so that it can
gain strength and dry in shade to prevent any cracks due to shrinkage. This shall be done
in drying yards.
3.6 Curing Period:

Curing of block shall be done only in curing pond and curing shall be done for minimum 14
days.
3.7 Drying period after removing from pond & before delivery to site:
Water should be drained of from the block before it is actually sent to the site. Time should
be provided for proper draining of water, which may be present in the block kept for curing
in the pond.
3.8 Precautions:
3.8.1 Precaution shall be taken while transporting of the blocks to site.
3.8.2 The blocks should be loaded and unloaded with due care so as to avoid generation of
stresses leading to breaking of block.
3.8.3 Care should be taken to prevent the block from breaking during transporting.
3.9 Laying:
3.9.1 The pits of the required size shall first be excavated, true to line and level. The relevant
specifications shall be followed for excavation work.
3.9.2 The pits shall be filled with a layer of 100mm thick PCC bedding. The curbs then shall be
Placed in position as per drawing. The concrete kerb shall be cured minimum for 7 days.
All concrete shall be compacted to produce a dense homogeneous mass with the
assistance of vibrators, unless otherwise, permitted by the Architect and Engineer-in-
charge. Sufficient vibrators in serviceable condition shall be kept at site so that spare
equipment is always available in the event of breakdowns.
3.9.3 Concrete shall be judged to be compacted when the mortar fills the spaces between the
coarse aggregate and begins to cream upto form an even surface. Compaction shall be
completed before the initial setting starts i.e. within 30 minutes of addition of water to dry
mixture.
3.11 Curing:
Only pond curing shall be adopted and curing shall be done for min. 14 days.
3.12 Sampling and testing of concrete:
3.12.1 Samples from fresh concrete shall be taken as per IS : 1199-1959 and cubes shall be
made, cured and tested at 7 days or 28 days as per requirements in accordance with IS :
516-1959. A random sampling procedure shall be adopted to ensure that each concrete
batch shall have a reasonable chance of being tested i.e. the sampling should be spread
over the entire period of concreting and cover all mixing units.
NOTE : At least 1 sample shall be taken from each shift. Ten test specimens shall be made
from each sample, 5 for testing at 7 days and the remaining 5 at 28 days. The samples of
concrete shall be taken on each day of the concreting as per above frequency. The number
of specimens may be suitably increased as deemed necessary by the Architect and
Engineer-in-charge when procedure of tests given above reveals a poor quality of concrete
and in other special cases.
3.12.2 The average strength of the group of cubes cast for each day shall not be less than the
2.
specified cube strength of 250 Kg/cm at 28 days. 20% of the cubes cast for each day
may have value less than the specified strength provided the lowest value is not less than
85% of the specified strength. If the concrete made in accordance with the proportions
given for a particular grade, does not yield the specified strength, such concrete shall be
classified as belonging to the appropriate lower grade. Concrete made in accordance with
the proportions given for a particular grade shall not, however, be placed in a higher grade
on the ground that the test strength are higher than the minimum specified.
3.12.3 If rock pockets/honeycombs in the opinion of Architect and Engineer-in-charge are of such
an extent or character so as to effect the strength of the structure, materially or to
endanger the life of the steel reinforcement, he may declare the concrete defective and
require the removal and replacement of the portion of the structure affected.
Precast Kerb Stones :
1.1 The relevant specifications of concreting as per item above shall be followed except that
work shall be carried out for precast concrete kerbstones as specified in the item.
1.2 All Precast members shall be cast at workshop. Sufficient curing shall be done before
placement of the same.
1.3 The method of transporting and placing the precast members shall be as approved by the
Architect and Engineer-in-charge. Members shall be so transported that no breakage or
undue stresses are induced in them.
1.4 If required, all members shall have a key provided on both the faces i.e. top and bottom
surfaces, of adequate size so as to fill the same with concrete while laying. The function of
this key is to avoid the leakage through the joint between the precast member and the
member on which it is laid.
4.0 Mode of Measurements and Payment:
1.1 The rate shall include cost of formwork but exclude the cost of reinforcement.
1.2 The volume occupied by reinforcement shall not be deducted from R.C.C. work.
1.3 The rate shall be for a unit as specified in BOQ.
PAVER BLOCK
5.09 Providing and laying shot blasted interlocking/ Non- interlocking grey/Colored
paver blocks of high density 60 mm thick M-40 grade for footpath, cycle track and
other areas as mentioned in the drawing. Including providing and laying 50 to 80

mm thick average bedding layer of coarse sand below paver block as per required
grading and specification. Laid paver block shall be mechanically compacted. The
work of the paving blocks shall be executed in line and level by skilled mason of
flooring work only. It should be laid in such a way that the no cutting of the paver
block to be necessary. Cutting of paver block by machine cut only and laying to be
done by skilled flooring mason. The Finished surface of the Paver Block shall have
Coarse Sand Texture Finish. Paver blocks shall be compacted and shall be re-laid if
necessary.
1.0 The scope of work: It includes manufacturing, supplying and laying of Precast paver
blocks at footpath, parking area, service lane and other areas.
The work includes:
1.1 Paver block should be laid over prepared sub grade.
1.2 Clearing the site by removing all obstacles such as stones, debris etc. for laying of paver
blocks.
1.3 Manufacturing of paver blocks by one of the approved suppliers as per requirements in
technical specification enclosed.
1.4 Supplying of paver blocks at site, including handling at both ends. The type of paver block
may be interlocking or non-interlocking.
1.5 Providing and laying 50 to 80 mm coarse sand bedding for laying blocks.
1.6 Laying of paver blocks at site as per requirement in technical specification, within shortest
possible time.
1.7 Testing of paver blocks through reputed Govt. /Non Govt. Test house and submission of
test results as per requirements in Technical Specifications. Client reserves the right to
carryout test at random. Cost for such tests to be borne by contractor.
1.8 The contractor shall guarantee that all material and components designed, fabricated,
supplied and laid by him shall be free from any type of defect due to faulty material and/or
workmanship/erection for a period of five year from the date of completion of work at
individual sites. However, the contractor for five years shall render free maintenance.
2.0 Technical Specifications:
2.1 Paver Block Manufacturing Facilities:
The Paver Block shall be made in factory with following minimum facilities:
Concrete Block making Machines:

The machine should be capable of producing high quality Paver Blocks by obtaining high
level of compaction by application of hydraulic compaction and also by high intensity
vibration to the moulds. The machine should have automatic control panel for uniformity in
strength.
Concrete Batching & Mixing Plant: (Not essential)
The concrete Mix Design should be followed for each batch of materials. The concrete
ingredient should be mixed in concrete Batching & Mixing plant with minimum capacity of
30 cum/hour. The plant should be equipped with automatic control panel for maintaining
water cement ratio from batch to batch to obtain concrete of uniform quality and strength.
The plant should be equipped with adequate mechanism for mechanized loading of raw
materials into mixer and conveyor belt for transportation of concrete from mixer to
concrete block making machine to maintain quality of wet cement.
Curing:
The factory should have well designed curing area to ensure adequate curing of paver
blocks. Steam curing facility of the paver blocks is preferable.
Laboratory (Desirable but not essential) :
The factory should have the following:
Compression testing machine of adequate capacity.
Other tools and equipment for testing raw materials and paver blocks.
(1) Systematic record of test results of various paver blocks manufactured in the factory.
(2) Concrete Mix Design for various grade of concrete used for making of paver blocks.
2.2 Specifications for Coloured Paver Blocks:
Colour concrete paver blocks shall be manufactured as per attached specifications using
approved colour Pigment of iron oxide of approved brand like Bayer, Tata etc. with
minimum colour pigment of 3% by weight of cement. The colour shade shall be as
selected by SRFDCL before commencement of the work. The job also includes providing
50 mm thick sand bedding to match the shade of the paver block.
The colour of the paver block shall be guaranteed against fading of colour for period of 12
months from the date of laying of the same at site.
All other technical specifications & Procedure for testing, laying & sampling of Colour
pavers will be as per attachment.
2.3 Paver Block Characteristics:
The concrete pavers should have perpendicularities after release from the mould and the
same should be retained until the laying.
The surface should be reasonably smooth and of anti skid and anti glare type.
The paver should have uniform chamfers to facilitate easy drainage surface run off.
The pavers should have uniform interlocking space of 2mm to 3mm to ensure compacted
sand filling after vibration on the paver Surface.
The concrete mix design should be followed for each batch of materials separately and
automatic batching plant is to be used to achieve uniformity in strength and quality.
The pavers shall be manufactured in Double layer only.
Skilled labour should be employed for laying blocks to ensure line and level of laying,
desired shape of the surface and adequate compaction of the sand in the joints.
2.4 Paver Block Dimensions:
Thickness 60mm
Layers Double layered, top layer minimum 8 to 10 mm
Shape Irregular (Uniform Shape with no Hollow Or Cracks) / as per drawing
Chamfer 4mm to 6mm along top edges
Colour Natural cement grey Colour without use of any pigment.
For Colour pavers refer specifications for Colour pavers
Dimensional (+/-) 2mm for length & width,
Tolerance (+/-) 3mm for Height (Thickness)
2.5 Testing of Paver Blocks:
SPECIFICATION
SR. NO. * TEST Average Values
(Average of Minimum Five Samples/Site)
1. Compressive Strength Min. 40 N/Sq.mm for 60mm thick
2. Flexural Strength Minimum 4.5 N/Sq.mm
3. Abrasion Resistance Maximum 1.5
4. Water Absorption Maximum 5.80%
5. Minimum Cement Content 380 Kg/Cum (Not Essential)
* Sampling and testing procedure as per enclosed specifications
3.0 Sampling & Testing Procedures for Paver Blocks:
3.1 Sample Size:
INTERNAL Average of minimum 3 samples per 5000 Blocks.
EXTERNAL Minimum 2 Blocks per 10000 bocks. Average of minimum 8 blocks per site.
3.2 Sampling For Testing: Sampling for testing of paver blocks shall be done in accordance
with Appendix-A.
Compressive Strength: Testing for compressive strength shall be undertaken in

accordance with Appendix-B. The average compressive strength of the blocks tested shall
be 40 N/Sq.mm.
Abrasion Resistance: Testing for abrasion shall be in accordance with IS 1237

(Specifications for Cement Concrete Floor Tiles).
Flexural Strength: Testing for flexural shall be in accordance with IS 1237 (Specifications
for Cement Concrete Floor Tiles).
Water Absorption: Testing for water absorption shall be in accordance with IS

2185:1979: Part I (Specifications for Concrete Masonry Units).
APPENDIX A
Method of sampling: Before laying paver blocks, each designated section comprising not
more than 50000 blocks, shall be divided into ten approximately equal groups. Three
blocks shall be drawn from each group.
Marking and identification: All samples shall be clearly marked at the time of sampling in
such a way that the designated sections of part thereof, and the consignment represented
by the sample, are clearly defined.
The sample shall be dispatched to the approved test laboratory taking precaution to avoid
damage to the paving in transit. Protect the paving from damage and contamination until
they have been tested. The testing shall be carried as soon as possible, after the sample
has been taken. As soon as practicable after sampling. The samples shall be stored in
water at 20 degree C 5 degree C for 24 hours prior to testing.
APPENDIX B
Test For Compressive Strength:
Testing Machine: The testing machine shall be of suitable capacity for the test and
capable of applying the load of the rate specified. It shall comply, as regards repeatability
and accuracy, with the requirements of clause 2.1 of BS: 1881-Part 4.
Procedure: The sample specimen shall be tested in a wet condition after being stored for
o o
at least 24 hours in water maintained at a temperature of 20 C + or 5 C. Before the
specimens are submerged in water, the necessary area shall be determined.
The plates for testing machines shall be wiped clean and any loose grit or other material
removed from the contact faces of the specimen. Plywood, nominally 4 mm thick shall be
used as packing between the upper and lower faces of the specimen and the machine
plates and these boards shall be larger than the specimen by the margin of at least 5 mm
at all points. Fresh Packing shall be used for every specimen tested.
The specimen shall be placed in the machine with the wearing surface in the horizontal
plane and in such a way that the axes of the specimen are aligned with those of the
machine plates.
The load shall be applied without shock and increased continuously at the rate of
approximately 15 N/ Sq.mm per minute until no greater load can be sustained. The
maximum load applied to the specimen shall be recorded.
Calculation of corrected strength for individual Blocks: The compressive strength of

each block specimen shall be calculated by dividing the maximum load by full cross
section area of the block and multiplying with an appropriate factor of:-
a) For 100 mm thick blocks 1.24
b) For 80 mm thick blocks 1.18
c) For 60 mm thick blocks 1.06
Compressive Strength Calculation: The average corrected compressive strength for the
designed block section shall be calculated.
4.0 Method of laying:
Blocks shall be placed on the sand bedding etc. which were well rammed so as to act as
firm bed. Blocks shall be laid in such manner that no gap shall be left in between. Blocks
so laid shall be compacted by means of mechanical compactor or equivalent compacting
method so as to obtain required finished surface. All the joints shall be matched and if any
manufacturing defect is detected the lot shall be replaced and relaying shall be done with
out any extra cost up to satisfaction of Engineer in charge.
Measurement and payment shall be on Square meter basis.
50 mm thick coarse sand shall be laid as cushioning layer for arranging the paver blocks.
Joints of the paver blocks shall be filled with the sand.
The paver blocks shall be laid properly on the prepared sub-base as per manufacturer's
specification and as per Architect and Engineer-in-charge's instruction.
Paver block shall be laid by the approved agency only. If manufacturer of the paver block
providing the laying services, then it shall be laid through the supplying agency only. The
laborers for paver block fixing shall be skilled flooring mason only. Only cutting tool shall
be used for cutting the paver block. Full depth cutting toll shall be used for proper finished
surface after cutting. Manual cutting or breaking of the paver block is not permitted.
After laying of the paver block fine sand shall be spread over it and paver block shall be
compacted with mechanical compactor. Any settlement or undulation in the laid area shall
be repaired immediately.
5.0 Mode of Measurement and payment:
Measurement will be done in sqmt of the actual area laid.

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Sabarmati River Front Development Corporation Limited Page 1

TECHNICAL SPECIFICATION FOR CIVIL WORK

4.2 Technical Specifications for Earthwork

4.2.2 Applicable Codes .....................................................................................................

4.2.3 Drawings ..................................................................................................................

4.2.4 Classification of Earth ..............................................................................................

4.2.7 Excavation ..............................................................................................................

4.2.8 Description ...............................................................................................................

4.2.9 Setting out ................................................................................................................

4.2.10 Dewatering and Protection ......................................................................................

4.2.11 Backfilling ................................................................................................................

4.2.12 Disposal of Surplus Excavation Materials ...............................................................

4.2.13 Drainage ..................................................................................................................

4.2.14 Measurement and Rates .........................................................................................

4.2.15 Working with other Contractors..........................................................................

Technical Specifications for Earthwork

4.2.2 Applicable Codes

4.2.4 Classification of Earth

For purpose of earth work soil shall be classified as under:

4.2.7.2 Setting out

4.2.7.3 Dewatering and Protection

1. Cost of arrangement of land as a source of material of required quality and

2. Compacting ground supporting Backfilling / Sub-grade.

3. Cost of watering or drying of material in borrow area during construction as

4. Spreading in layers bringing to appropriate moisture content and compacting to

Where necessary to facilitate compaction of the ground to 95% relative compaction as

4.2.7.5 Disposal of Surplus Excavation Materials

4.2.9 Measurement and Rates

Rate for earthwork shall include the following

a) Excavation and disposing surplus earth as directed by the engineer in charge.

b) Setting out works, profiles etc.

c) Site clearance such as cleaning of vegetation, roots, shrubs, brushwood etc.

e) Protection works, temporary supports for safety, by underpinning if need be to

g) Removing slips or falls in excavation.

i) Excavation for insertion of planking and strutting where required.

j) Backfilling the trenches with selected material.

k) Transporting and using the excavated stuff as embankment including watering

4.2.10 Working With other agency

SUB SECTION 4.4

IS 226 Specification for structural steel (Standard Quality)

4.4.1.1 Other Codes and Specifications

4.4.1.2 Grade of Concrete

4.4.1.2.1 Controlled Concrete

4.4.1.2.2 Ordinary Concrete

4.4.1.2.3 Strength Requirement of Concrete

Min. At 7 Days Min at 28 Days

Following types of cement shall be used

Grade of Concrete Minimum cement content and water cement ratio

Minimum cement content Maximum water cement

4.4.1.3.2 Fine Aggregates

4.4.1.3.3 Coarse Aggregates

4.4.1.3.4 Reinforcing Steel

c) Hard drawn steel wire fabric shall conform to IS 1566.

d) Structural Steel sections and plates shall conform to IS 2062.

If required, chemical admixtures in concrete may be used as specified in IS 456-2000. No

4.4.1.4 Storage of Materials

4.4.1.4.3 Reinforcing Steel

Reinforcement steel shall conform accurately to the dimensions shown on relevant

To protect reinforcement from corrosion, concrete cover shall be provided as indicated on

Measurement for Payment for steel

Reinforcement shall be measured in lengths separately for different diameters as actually

4.4.1.5 Mixing of Concrete

4.4.1.5.1 Transport, Placing and Compaction of Concrete

from standing water or dust immediately before placing of concrete.