01.

SURVEY WORKS

1. Scope

This item of work shall be dealt in compliance with section 109 of MORT&H

2. Procedure

Alignment Fixing:

1. The control points of GPS (Global Positioning System) pillar is fixed at every 5 km
interval by NHAI (National Highway Authority of India) and handed over for
execution of survey works. The same GPS pillars are also having the value of
coordinate and levels.

2. Keeping the same GPS pillar as a reference, traversing of coordinate has been fixed
between GPS pillar to GPS pillar (ie. every 5 km interval). Closing error of traverse
has been adjusted by bow-ditch method in between two GPS pillars. The traverse
closure was less than 1: 20000

3. Horizontal angle was observed by taking minimum of two sets of rounds from
different locations. All the observations were logged and the spread between
observed rounds of horizontal angles did not exceed 5 seconds (Two sets of angles
agreed within 5 seconds).

4. In between GPS pillars at every 250meter interval, along the road alignment, the sub
control pillar [Bench Mark Pillar (BMP)] is fixed at the end of ROW (Right Of Way).
The location of benchmark pillar is marked at site by paint identifying location.
Benchmark pillars are concrete pillars. Size of concrete pillar is 150X150X450 mm.
12 mm rod is embedded inside and projected 15mm above the concrete pillar.
During the time of traversing the bearing was recorded on the punch point of rod
46
 projected over the benchmark pillar. The coordinate value of each benchmark pillar
was arrived after traverse adjustment by bow-ditch method.

5. The project alignment coordinate given by client - NHAI for a length of km ie. km
to km is fixed over the existing road by 1 - second accuracy of total station. The
alignment point is marked at every 20mtr interval on the straight portion and 10mtr
interval on the curve portion by round head nail. The same point is marked with
yellow point and location (chainage) written on the road for quick reference. For
fixing this alignment for 40 km length, the traversed coordinate of benchmark pillar,
fixed at every 250mtr interval along the project alignment, are used and client has
checked the alignment. Detailed copy of coordinate value of benchmark pillar (BMP)
along-with chainage and location is given to clients and site engineers for their
reference.

Bench Mark Fixing:

For every 250 mtr interval the concrete bench mark pillar is fixed along the
project alignment (from km to km ) at the end of ROW. Location and chainage is marked
at site with paint. The pillar is used for fixing the benchmark.
GPS pillar to GPS pillar (every 5km interval) the level traversing has been done
retaining the RL (Reduced Level) of GPS pillar (GPS level given by NHAI). During the time
of traversing the level, the levels are transferred over every 250mtr interval benchmark
control pillars also. During benchmark level transferring maximum observing distance
were 100mtr, keeping the fore sight and back sight distance equal. The spread between
observed ranges of vertical angles did not exceed 10 seconds. The closing error on a
level circuit did not exceed 12 root of K in mm (where K is distance in Km.). The closing
error has been distributed to all the bench mark in network in between GPS to GPS. The
benchmark pillar (BMP) levels are checked by client.

47
 Detailed benchmark list mentioning level, location and chainage is issued to
client and site engineers for their reference.

Toe Line Fixing:

The toe line is fixed for the every layer by means of calculating the thickness of
pavement layer multiplied by percentage of given formation slope. The toe distance will
be measured from given alignment nail. The cross section drawings also can be followed
for toe line marking.

3. Equipment/ Machinery Requirement:

1. Auto level
2. Total Station
3. Theodolite

4. Records and Documents Maintained:

1. OGL Books

5. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

6. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

7. Traffic

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory
condition till such time they are required. Throughout the construction period site
management shall maintain public vehicular access along the existing right of way.

48
 02. CLEARING AND GRUBBING

A. Scope:

1. Obtain & Check latest construction drawing.

2. The Centerline of the proposed median shall be marked accurately using total
station and get checks by the Engineer’s representative.
3. The benchmarks shall be established after connecting with the GTS benchmarks
in the region.
4. The levels on the Cross section are taken at intervals 10m c/c and thus the batter
line/toe line is marked on ground.
5. Trees and other utilities falling in the work zone are marked & details are
informed and the same shall be cleared as required after necessary approval and
should be back filled by approved material as per good engineering practice.

B. Main Activity:

1. RFI is initiated.
2. The vegetation is completely cleared and tree stumps are extricated along with
roots for girth less than 300mm.
3. The useful materials shall be stockpiled and all other objectionable materials are
disposed as per directions of Engineer.
4. Top soil shall be stripped and removed if found unsuitable and useful material is
stockpiled. The details for the topsoil removal should be provided as per design
requirement of crust.
5. Levels shall be taken after stripping / clearing and prior to filling and
documented.
6. The measurements are recorded as per the provision of agreement and
submitted for verification documentation.
7. The RFI is closed.

C. Shifting of Utilities:

1. Clear and shift utilities like electrical poles, cables, telephone and water supply
lines, trees, drainage structures etc.

D. Preservation of Property/Amenities:

1. Roadside trees, shrubs, any other plants, pole lines, fences, signs, monuments,
buildings, pipelines, sewers and all highway facilities within or adjacent to the
highway which are not to be disturbed shall be protected from injury or damage.
49
 ITNL shall provide and install suitable safeguards approved by the Independent
Engineer for this purpose.
2. During clearing and grubbing, ITNL shall take all adequate precautions against
soil erosion, water pollution, etc., and where required, undertake additional
works to that effect vide Clause 306. Before start of operations, ITNL shall submit
to the Independent Engineer for approval, his work plan including the procedure
to be followed for disposal of waste materials, etc., and the schedules for
carrying out temporary and permanent erosion control works.

E. Disposal of Materials:

All materials arising from clearing and grubbing operations shall be taken over
and shall be disposed of by ITNL with all leads and lifts. The rates deemed to include
credit towards value of usable materials and salvage value of unusable materials. The
transportation of cut trees and stumps will be carried out as per permission/guidelines/
estimates of State Forest Department.

F. Health, safety and environment:

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

G. Quality assurance and quality control:

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

H. Traffic:

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory condition
till such time they are required. Throughout the construction period site management
shall maintain public vehicular access along the existing right of way.

50
 03. EMBANKMENT CONSTRUCTION

1. Scope

This item of work deals with construction of road embankment with approved
materials as per the terms of contract agreement and shall be dealt with in complete
compliance to the technical specifications; placement and compaction shall be carried
out in accordance with clause 305 of specifications.

Drawings used for construction in respect of the alignment, level, cross sections
in respective stretches and other survey detail and relevant technical specifications
viz.clause 305 of technical specification in terms of mandatory guidelines for ensuring
the quality of work.

Prior to the commencement of this work, the materials proposed to be used for
such embankment shall be sourced suitably. Different sources shall be earmarked for
different stretches giving due regard to the load of haulage and most importantly the
suitability and quantum of material availability.

The material used in embankment shall generally be soil, morrum, gravel, a

mixture of these or any other approved material. In respect of quality of material, such
material shall be ensured to be free of logs, stumps, roots, rubbish for any ingredients
likely deteriorate or affect the stability of the embankment. The material resulting from
the roadway excavation if found suitable will also be used.

2. Procedure
1. The toe line and centre line are marked and pegs will be driven.
2. The material shall be dumped in site at respective location.
3. The material shall be spread in layers of uniform thickness not exceeding 250 mm
compacted thicknesses over the entire width of the embankment by mechanical
means and will be graded with grader to the required camber.
4. Moisture content of the material shall be checked and extra required will be
added.
5. The moisture content of each layer shall be checked and it should be with in the
range of OMC +1% to OMC -2 percent. If moisture content is found out of these
limits the same will be brought within limits by addition of water or by aeration
as the case may be.
6. The compaction shall be done with the help of vibratory roller of 8 to 10 ton
static weight. Each layer shall be thoroughly compacted to the densities specified
in the specifications which are mentioned at the end of this document for
reference. The rolling pattern will be finalized in trial stretch.

51
 7. On compaction of the particular stretch necessary field testing shall be carried
out Field density shall be done in the manner and frequency as specified below.

8. If the required field density is not achieved, compaction shall be continued till
required density is achieved.

9. Loose pockets if any will be removed and replaced with approved material.

10. The above stages shall be repeated till the top level of the embankment is
reached to the specified levels and grades. The top levels shall be checked and
shall be within +20mm and -25mm of designed level.

11. All relevant QA and QC documents will be maintained for all stages of
Embankment Construction.

12. Where the ground supporting embankment is found to be unsuitable (material

mentioned in MoRTH clause 305.2.1.1) or the original ground material is having
free swell index greater than 50% the same will be removed upto 500mm and
will be replaced with approved material as per MoRTH clause 305.3.4.

3. Equipment/Machinery:

Grader 1 No as a minimum.
Tippers 10 Nos as a minimum
Water Sprinkler 1 No as a minimum
Roller 80 to 100KN 1 No as a minimum
4. Material Specifications

Maximum Particle Shall not be more than 75mm or should not be more
size than 2/3rds of compacted layer thickness which ever is
minimum.

Free swell index Max 50 %

Liquid limit Max 50 %

Plasticity index Max 25 %

DENSITY REQUIREMENTS OF EMBANKMENT

52
 Type of Work Maximum Laboratory dry unit weight when tested as per
IS 2720 (Part 8)
Embankments Not less than 15.2 KN/cu.m.
upto 3m height
not subjected to
extensive flooding
Embankments Not less than 16.0 KN/cu.m.
exceeding 3m
height

COMPACTION REQUIREMENT FOR EMBANKMENT

Type of work/Material Relative compaction as % of maximum laboratory dry

density as per IS:2720 (part8)
Embankments
a)Upto 3m height Not less than 95
b)High Embankment Not less than 97
(exceeding 3m height)
Expansive clays Such material is not allowed in construction

5. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines / rules &
regulations as mentioned in HSE Plan.

6. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality Assurance
Manual and corresponding Quality Assurance Plan. All quality records as appended to
this procedure shall be maintained in appropriate formats.

7. Traffic
As per the standard construction practices necessary traffic management measures shall
be provided viz. signs, marking flags, lights and flagmen. Fixed signs, barriers and other
traffic control devices shall be maintained in a satisfactory condition till such time they
are required. Throughout the construction period site management shall maintain
public vehicular access along the existing right of way.

53
 4. SUBGRADE CONSTRUCTION

1. Scope

This item of work deals with construction of Subgrade with approved materials
as per the terms of contract agreement and shall dealt with in complete compliance to
the technical specifications; placement and compaction shall be carried out in
accordance with clause 305 of specifications.

The construction shall confirm to the specific alignment, lines and grades given in
the drawing.

Prior to the commencement of this work, the materials proposed to be used for
such subgrade shall be sourced suitably. Different sources shall be earmarked for
different stretches giving due regard to the load of haulage and most importantly the
suitability and quantum of material availability.

The material used in subgrade shall generally be soil, morrum, gravel, a mixture
of these or any other approved material. In respect of quality of material, such material
shall be ensured to be free of logs, stumps, roots, rubbish for any ingredients likely
deteriorate or affect the stability of the subgrade. The material resulting from the
roadway excavation if found suitable will also be used. Material which is having CBR 10%
minimum shall be used in subgrade.

2. Procedure

1. The toe line and centre line are marked and pegs will be driven.

2. The material shall be dumped in site at respective location.

3. The material shall be spread in layers of uniform thickness not exceeding 250 mm
compacted thicknesses over the entire width of the subgrade by mechanical
means and will be graded with grader to the required camber.

4. Moisture content of the material shall be checked and extra required will be
added.

5. The moisture content of each layer shall be checked and it should be with in the
range of OMC +1% to OMC -2 percent. If moisture content is found out of these
limits the same will be brought within limits by addition of water or by aeration as
the case may be.

54
 6. The compaction shall be done with the help of vibratory roller of 8 to 10 ton static
weight. Each layer shall be thoroughly compacted to the densities specified in the
specifications which are mentioned at the end of this document for reference. The
rolling pattern will be finalized in trial stretch.

7. On compaction of the particular stretch necessary field testing shall be carried out
Field density shall be done in the manner and frequency as specified below.

8. If the required field density is not achieved, compaction shall be continued till
required density is achieved.

9. Loose pockets if any will be removed and replaced with approved material.

10. The above stages shall be repeated till the top level of the subgrade is reached to
the specified levels and grades. The top levels shall be checked and shall be within
+20mm to -25mm of designed level.

11. All relevant QA and QC documents will be maintained for all stages of subgrade
Construction.

12. In case the original ground is in subgrade level or is in cutting and if the density
after compaction is not 97% minimum the ground will be loosened upto a depth of
250mm and will be compacted in accordance with 305.3.5 and 305.3.6 of technical
specifications.

3. Equipment/Machinery:

Grader 1 No as a minimum.
Tippers 10 Nos as a minimum
Water Sprinkler 1 No as a minimum
Roller 80 to 100KN 1 No as a minimum

4. Material specifications

Maximum Particle size Shall not be more than 50mm or should not be more
than 2/3rds of compacted layer thickness which ever
is minimum.
Free swell index Max 50 %
Liquid limit Max 50 %
Plasticity index Max 25 %
CBR(4 days soaked) Min As per Highway Design @ 97% MDD

55
5. Density Requirements of Subgrade

Type of Work Maximum Laboratory dry unit weight when tested as per IS
2720(Part 8)
Subgrade Not less than 17.5 KN/cu.m.

6. Compaction Requirement for Subgrade

Type of work/Material Relative compaction as % of maximum laboratory dry

density as per IS:2720(part8)
Subgrade Not less than 97
7. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines / rules &
regulations as mentioned in HSE PLAN.

8. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality Assurance
Manual and corresponding Quality Assurance Plan. All quality records as appended to
this procedure shall be maintained in appropriate formats.

9. Traffic

As per the standard construction practices necessary traffic management measures shall
be provided viz. signs, marking flags, lights and flagmen. Fixed signs, barriers and other
traffic control devices shall be maintained in a satisfactory condition till such time they
are required. Throughout the construction period site management shall maintain
public vehicular access along the existing right of way.

56
 5. GRANULAR SUB BASE CONSTRUCTION

1. Scope

This item of work deals with construction of Granular sub base with approved
materials as per the terms of contract agreement and shall be dealt in compliance to the
clause 401 of specifications.
The construction shall confirm to the specific alignment, lines and grades given in
the drawing.
The material used in Granular sub base shall be crusher, Natural or Combined.

2. Procedure
1. The toe line and centre line are marked and pegs will be driven.

2. The material shall be dumped in site at respective location.

3. The material shall be spread in layers of uniform thickness not exceeding 200 mm
compacted thicknesses over the entire width of the subgrade by mechanical
means and will be graded with grader to the required camber.

4. Moisture content of the material shall be checked and extra required will be
added.

5. The moisture content of each layer shall be checked and it should be with in the
range of OMC +1% to OMC -2 percent. If moisture content is found out of these
limits the same will be brought within limits by addition of water or by aeration as
the case may be.

6. The compaction shall be done with the help of vibratory roller of 8 to 10 ton static
weight. Layer shall be thoroughly compacted to the densities specified in the
specifications which are mentioned at the end of this document for reference. The
rolling pattern will be finalized in trial stretch.

7. On compaction of the particular stretch necessary field testing shall be carried out
Field density shall be done in the manner and frequency as specified below.

8. If the required field density is not achieved, compaction shall be continued till
required density is achieved.

9. Loose pockets if any will be removed and replaced with approved material. The top
levels shall be checked and shall be within +10mm to -20mm of designed level.

57
 10. All relevant QA and QC documents will be maintained for all stages of subgrade
Construction.
3. Equipment/Machinery

GSB Plant 1 No
Grader 1 No as a minimum.
Tippers 10 Nos as a minimum
Water Sprinkler 1 No as a minimum
Roller 80 to 100KN 1 No as a minimum

4. Material Specifications

Liquid limit Max 25 %

Plasticity index Max 6
CBR(4 days soaked) Min 30% @98% MDD
AIV Max. 40% (Testing as per 2386 Part 04)
Gradation Confirming to grading 1 of Table 400-2

COMPACTION REQUIREMENT FOR GSB

Relative compaction as % of maximum laboratory dry density as per

Type of work/Material IS:2720 (part8)
GSB Not less than 98% of MDD

5. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

6. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats

7. Traffic
As per the standard construction practices necessary traffic management
measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory condition
till such time they are required. Throughout the construction period site management
shall maintain public vehicular access along the existing right of way.

₋
58
 6. WET MIX MACADAM CONSTRUCTION

1. Scope

This item of work deals with construction of Wet mix macadam with approved
materials as per the specifications of contract agreement and shall be dealt in
compliance to the clause 406 of specifications.

The construction shall confirm to the specific alignment, lines and grades given in
the drawing.

2. Procedure
Preparation of Mix:

The individual materials gradation shall be checked combined, proportions shall

be fixed and combined gradation confirming to table 400-11 shall be arrived. The
individual bins of wet mix plant shall be calibrated for the particular size of material.
Material shall be fed to the mixing plant bins provided for individual sizes of aggregates
to meet the required gradation. Mixing plant shall be of suitable capacity having
provision for controlled addition of water. While adding water, loss due to evaporation
shall be taken in account. Water in the wet mix shall not vary from the optimum by more
than in the limits of +l/-1 of OMC.

Preparation of Base:

The sub base shall be checked for proper lines and levels. It shall be made free
from dust. Before the laying starts it should be made slightly wet and shall be given one
plain pass. The lateral confinement for wet mix shall be provided by placing material in
the adjoining shoulder portion.

Lying of Wet Mix Macadam:

The wet mix shall be transported from the mixing plant to the site with trippers.
The mix shall be laid with Grader or paver finisher. The paver shall have suitable loading
hoppers and distribution mechanism. The mix shall be laid manually in places where the
paver movement is not possible. High or low spots shall be rectified by adding or
removal of materials as the case may be. The material shall be uniform and shall be free
of pockets of fine material.

The compaction of wet mix shall be done as per clause 406.3.5. The rolling shall
be done with 80-100KN vibratory roller. The rolling pattern shall be established in the
trial stretch. Care shall be given at every stage so that there will not be any segregation.

59
 The finished layer shall be checked for compaction in accordance to the
specifications given below. The top shall be checked for level control and shall be within
+10mm and -10mm of designed level.

3. Equipment/Machinery

WMM Plant 1 No
Grader 1 No as a minimum.
Tippers 10 Nos as a minimum
Water Sprinkler 1 No as a minimum
Roller 80 to 100KN 1 No as a minimum
Paver Finisher 1 No

4. Material Specifications

Los Angeles Abrasion Value Max 40%

Aggregate Impact Value Max 30%
Combined Flakiness and Elongation Index Max 30%
Plasticity index Max 6
Gradation Confirming to Table 400-13
Compaction 1 test for 500Sq.m

COMPACTION REQUIREMENT FOR WMM

Type of work/Material Relative compaction as % of maximum laboratory dry

density as per IS: 2720(part8)
WMM Not less than 98% of MDD

5. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

6. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

60
7. Traffic

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory condition
till such time they are required. Throughout the construction period site management
shall maintain public vehicular access along the existing right of way.

61
 7. APPPLICATON OF PRIME COAT AND TACK COAT
Prime Coat:
OBJECTIVE
 To penetrate the existing base course surface so as to plug capillary voids in it.
 To coat and bond loose mineral particles on the surface of the base course.
 To seal surface pores and make the surface of the base course water –resistant.
 To provide adhesion between the base and the superimposed bituminous
surface course in conjunction with tack coat.
SCOPE
 Scope covers providing a single coat of Low Viscosity Liquefied bituminous
material to a porous Granular surface with Bitumen Emulsion preparatory to any
superimposed bituminous treatment.
REFERENCES
 Contract agreement
 MOSRT&H
 IS-8887-2004
 IRC-16-2008
RESPONSIBILITY
 Highway Engineer & Quality Material Engineer

PROCEDURE
Prime Coat:
 The material shall be such that it can penetrate deep into base course about 10
mm and conforming to IS-8887-2004(SS-1).
 The surface to be primed shall be swept clean, free from dust and shall be dry.
 Before laying the primer the surface shall be made to the required profile using
compactor and template.

62
  The prime coat shall be provided on the granular surface with Bitumen Emulsion
complete as per MOSRT&H specification at the rate of 7.0 kg to 9.0 kg per 10
sqm.
 The primer shall be spread uniformly to cover the dry surface using primer
distributor equipped with self propelled or towed pressure sprayer with self
heating arrangement and spraying bar with nozzles having constant volume or
pressure system.
 The rate of spray of prime and tack coat is checked at site by keeping iron plate of
200 mm x 200 mm size and 20 mm depth and weight, on the surface where
primer is to be applied.
 After application the weight of the plate is taken and the rate of spray is
determined.
 Primed surface shall be allowed to cure for at least 24 hours. No traffic shall be
permitted other than that necessary to lay the next course.
Tack Coat:
Objective
 To provide adequate bond between two layers .
Scope
It covers a very light application of low viscosity liquid bituminous material to an
existing bituminous, cement concrete or primed granular surface to ensure a bond
between the surface being paved and the overlaying course.

REFERENCES
 Contract agreement
 MOSRT&H
 IS-8887-2004
 IRC-16-2008

RESPONSIBILITY
 Highway Engineer & Quality Material Engineer
63
PROCEDURE
 The material shall be bitumen emulsion complying with IS-8887-2004(RS-1).
 The surface to be tack coated shall be swept in, free of dust and shall be dried
using Mechanical Broom.
 The temperature of emulsion should be in range of 20-70 o C at time of spraying.
 The rate of emulsion shall be 2 to 2.5 kg per 10 sqm. on bituminous surface and
shall be 2.5 to 3 kg/10 m 2 for granular surface treated with primary/secondary
bituminous surface.
 After the application of Tack Coat at the specified rate of the spray, the
subsequent bituminous layer (DBM/BC) shall be laid. Quality control test to be
done as per MOSRT&H Clause 903.4

DOCUMENTATION
 Manufacturers Certificate
 Laboratory and field test results

HEALTH, SAFETY AND ENVIRONMENT

 All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

QUALITY ASSURANCE AND QUALITY CONTROL

 Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan.
 All quality records as appended to this procedure shall be maintained in
appropriate formats.

64
TRAFFIC

 As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen.
 Fixed signs, barriers and other traffic control devices shall be maintained in a
satisfactory condition till such time they are required.
 Throughout the construction period site management shall maintain public
vehicular access along the existing right of way.

65
 8. DENSE BITUMINOUS MACADAM CONSTRUCTION

1. Scope

This item of work deals with construction of Dense Bituminous Macadam with
approved materials as per the specifications of contract agreement and shall be dealt in
compliance to the clause 507 of specifications.
The construction shall confirm to the specific alignment, lines and grades given in
the drawing.

2. Procedure
Mix Design

The mix design shall be carried out according to MS-2 of Asphalt Institute. The
optimum bitumen content and job mix formula are arrived. The physical requirements of
the aggregate shall confirm to table 500-8 and job mix shall confirm to grading 2 of table
500-10 of technical specifications. The mix properties shall confirm to table 500-11 of
technical specifications. The permissible variations from the job mix formula shall be
according to table 500-13.

Preparation and Transportation of Mix:

The individual bins of hot mix plant shall be calibrated for the particular size of
material. Material shall be fed to the mixing plant bins provided for individual sizes of
aggregates to meet the required gradation. The temperature of binder and aggregate at
the time of mixing shall be as per IRC 111-2009 .The difference between and the
aggregate temperature shall not exceed 14'C any time.
The mix shall be transported to the site with trippers properly covered with
tarpaulins.

Preparation of Base:

The sub base shall be checked for proper lines and levels. The surface shall be
swept free from dust with air compressor. The tack coat shall be done if the WMM
surface was primed and left for quite some time.

Laying of Dense Bituminous Macadam:

The mix shall be laid with paver finisher. The paver shall have suitable loading
hoppers and distribution mechanism. The paver shall have electronic sensor paver and
string wire shall be run on steel pegs driven on both sides at 10m interval in straight
portions and 5m interval in curved portions. The mix shall be laid manually in places
where the paver movement is not possible.
66
 The compaction of DBM shall be done as per clause 501.6 and 501.7. The rolling
shall be as mention in flow chart. The rolling pattern shall be established in the trial
stretch. The DBM shall be laid as per MoRTH Cl 507 (as per the cross section) compacted
thickness.

The finished layer shall be checked for compaction. The compaction shall be
checked by taking cores for every 700sq.m area and the % compaction shall not be less
than 92% of lab GMM of loose mix. The top shall be checked for level control and the
levels shall be within ±6mm of designed level.

All relevant QA and QC documents will be maintained for all stages of DBM
construction.

3. Equipment/Machinery

Hot Mix Plant 1 No

Tippers 10 Nos as a minimum
Rollers 8 to 10 T Smooth wheeled tandom rollers 2 No as a minimum
12-15 Tonnes PTR 1 No minimum
Paver Finisher 1 No
Steel pegs 50 Nos minimum.

4. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

5. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

6. Traffic

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory condition
till such time they are required. Throughout the construction period site management
shall maintain public vehicular access along the existing right of way.

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 9. BITUMINOUS CONCRETE CONSTRUCTION

1. Scope

This item of work deals with construction of Bituminous Concrete with approved
materials as per the specifications of contract agreement and shall be dealt in
compliance to the clause 509 of specifications.

The construction shall confirm to the specific alignment, lines and grades given in
the drawing.

2. Procedure
Mix Design

The mix design shall be carried out according to MS-2 of Asphalt Institute. The
optimum bitumen content and job mix formula are arrived. The physical requirements of
the aggregate shall confirm to table 500-16 and job mix shall confirm to grading 1 of
table 500-17 of technical specifications. The mix properties shall confirm to table 500-11
of technical specifications. The permissible variations from the job mix formula shall be
according to table 500-18.

Preparation and Transportation of Mix:

The individual bins of hot mix plant shall be calibrated for the particular size of
material. Material shall be fed to the mixing plant bins provided for individual sizes of
aggregates to meet the required gradation. The temperature of binder and aggregate at
the time of mixing shall be as per IRC 111-2009.The difference between and the
aggregate temperature shall not exceed 14'C any time. The mix shall be transported to
the site with trippers properly covered with tarpaulins.

Preparation of Base:

The base shall be checked for proper lines and levels. The surface shall be swept
free from dust with air compressor. The tack coat shall be done if the DBM surface was
old for quite some time.

Laying of Bituminous Concrete:

The mix shall be laid with paver finisher. The paver shall have suitable loading
hoppers and distribution mechanism. The paver shall have electronic sensor paver and
string wire shall be run on steel pegs driven on both sides at 10m interval in straight
portions and 5m interval in curved portions. The mix shall be laid manually in places
where the paver movement is not possible.
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 The compaction of BC shall be done as per clause 501.6 and 501.7. The rolling
shall be done with 80-100KN smooth wheeled tandom roller, 12-15 tonnes pneumatic
tyred roller. The rolling pattern shall be established in the trial stretch.

The finished layer shall be checked for compaction. The compaction shall be
checked by taking cores for every 700sq.m area and the % compaction shall not be less
than 92% of lab GMM of loose mix. The top shall be checked for level control and the
levels shall be within ±6mm of designed level.

All relevant QA and QC documents will be maintained for all stages of BC

Construction.

3. Equipment/Machinery

Hot Mix Plant 1 No

Tippers 10 Nos as a minimum
Rollers 80 to 100KN Smooth wheeled tandom rollers 2 No as a minimum
12-15 Tonnes PTR 2 No minimum
Paver Finisher 1 No
Steel pegs 50 Nos minimum.

4. Health, safety and environment

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

5. Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

6. Traffic

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed signs,
barriers and other traffic control devices shall be maintained in a satisfactory condition
till such time they are required. Throughout the construction period site management
shall maintain public vehicular access along the existing right of way.

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 10. METHODOLOGY OF KERB CONSTRUCTION
OBJECTIVE

 The objective is to provide Kerb in Shoulder & Median portions.

SCOPE
 To provide Kerb Foundation in Median Portion of the Highway
 To provide Kerb & Kerb Channel in the median and shoulder portion.
REFERENCE
 agreement specification.
 MOSRT&H
 Drawing and Mix Design for Kerb Concrete
RESPONSIBILITY
 Highway Engineer and Quality Material Engineer
PROCEDURE
 As per the drawing and Mix Design for Kerb Concrete, laying of Kerb is carried
out.
 Kerb Foundation is laid by suitably placing the side shuttering.
 Kerb is laid by Kerb Casting machine.
 The line and level shall be maintained and shall be within allowable tolerances.
DOCUMENTATION:
 Test results
 Check List
 Level Book
HEALTH, SAFETY AND ENVIRONMENT

All employees working within the limit of this project shall follow the guidelines /
rules & regulations as mentioned in HSE PLAN.

QUALITY ASSURANCE AND QUALITY CONTROL

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records as
appended to this procedure shall be maintained in appropriate formats.

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 11 METHODOLOGY FOR DRY LEAN CEMENT CONCRETE
(D.L.C)

Object and Scope : The work shall generally consist of laying and compacting
Dry Lean Cement Concrete as a sub base material on prepared GSB in
accordance to the requirements, cross sections, and grades as shown in
drawings and specifications given (Clause 601).

Reference:-

 Contract agreement
 MOSRT&H
Responsibility
 Highway Engineer and Quality Material Engineer

Materials:

Aggregates: Crushed stone aggregates which confirms to the physical

requirement set forth in IS 383 and grading as specified in table 600 –1 shall be
used in the work in accordance with clause 601, after obtaining prior approval.

TABLE – 600-I
I.S.Sieve (mm) % Passing

26.5 100
19.0 75-95
9.5 50-70
4.75 30-55
2.36 17-42
0.600 8-22
0.300 7-17
0.150 2-12
0.075 0-10

Construction operation:

Preparation of Sub base:

Prior to laying of D.L.C material, the sub base will be prepared by making
free from duct and other extraneous matter and rolled with a roller, if necessary
by lightly sprinkling with water .

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Machinery and Equipment:
The equipment to be used for laying and spreading of base (D.L.C) shall
be using self propelled mechanical pavers, or motor grader with hydraulic control
blades, vibratory tandem roller and water tank as and when necessary.

Preparation of Mix: The D.L.C mix will be prepared in a mixing plant of

capacity 60 – 80 TPH which have a provision for controlled addition of water.

Optimum moisture content at determined earlier in the lab will be

maintained at the plant after giving due allowance for evaporation losses as per
clause 601.3.2

Method for laying:

Sequence of work:

Spreading: Immediately upon receiving the mixed material, the mix shall be
spread uniformly in layers on the prepared sub base according to the thickness
specified by using mechanical paver, for portions where paver finished can’t be
used, laying shall be processed by motor grader.

Level control: The levels of D.L.C coarse shall be taken in 10 mts intervals
longitudinally and as per requirement in transversely to control the grade and
camber simultaneously.

Compaction: - After mix has been laid to the required thickness, grade and
camber compaction will be carried out with the help of a tandem vibratory roller of
capacity 80-100 N.

Rolling shall commence at the lower edge and proceed towards the upper edge
longitudinally with a overlap of not less than one third of in the preceding pass
and will be continued till 98% of the maximum dry density determined earlier is
achieved with clause 601.6.5.1 of MORT& H.

Segregation: - In the event of any segregation or surface irregularity noticed after

the compacting scarifying to full thickness and adding fresh fine material and re
compaction to the required density. It shall be rectified by surface finish and
quality control.

(a) The horizontal alignment will confirm to clause 902.2 as the surface levels will
be maintained as specified in table 900-1 in accordance to clause 902.3 of
MORT & H.

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(b) Surface regularity will be checked with a 3-mt long straight edge and will
confirm to the specifications mentioned in table 900-2 as per clause 902.4 of
MORT & H.

(c) Control on the quality of materials and worked executed will be checked as
per the frequency mentioned in table 900-3 in accordance with clause 900.3 of
MORT & H.

Curing: As soon as the D.L.C surface is compacted either covering surface by

gunny bags or applying the curing compound in approved manner.

Health, safety and environment

All employees working within the limit of this project shall follow the
guidelines / rules & regulations as mentioned in HSE PLAN.

Quality assurance and quality control

Quality Assurance & Quality Control of this work shall be as per Quality
Assurance Manual and corresponding Quality Assurance Plan. All quality records
as appended to this procedure shall be maintained in appropriate formats.

Traffic

As per the standard construction practices necessary traffic management

measures shall be provided viz. signs, marking flags, lights and flagmen. Fixed
signs, barriers and other traffic control devices shall be maintained in a
satisfactory condition till such time they are required. Throughout the
construction period site management shall maintain public vehicular access
along the existing right of way.

73
12. METHOD STATEMENT OF PAVEMENT QUALITY CONCRETE (PQC)

1. PURPOSE
PQC is used as a Top layer of Cement concrete road. Advantages
of PQC are as under.
• Good friction and drainage characteristics.
• High strengths and stability to withstand the shear stresses induced by
heavy wheel loads and high tyre pressures.
• A durable, hard-wearing, weather-proof surface free from loose material.
• Facilitate economic maintenance.
 More life of Pavement.

2. SCOPE
The work shall consist of Construction of un-reinforced, dowel
jointed, plain cement concrete pavement in accordance to the
requirements of MoSRT&H specifications and in conformity with lines,
grades and cross sections as shown in approved drawing.

3. Reference:-

 Contract agreement
 MOSRT&H
 IS-10262
 IRC-44

4 Responsibility
 Highway Engineer and Quality Material Engineer

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5 MATERIALS AND MIX PROPORTION
5.1 Aggregate Proportions
5.2 PQC Mix Design for 1 Cu. m.

6 BATCHING & MIXING

For the batching and mixing of PQC, RMC plant, available under
good supervision. Batching & Mixing shall be done as per approved
design mix proportions in RMC Plant.

7 PROCEDURE OF LAYING PQC

a. If the DLC is found damaged at any places or it has cracks wider than
10 mm, it shall be repaired wit fine cement concrete or
bituminous concrete before laying of separation membrane.
b. The laying/ Constructed of PQC by hand guided / Mechanized
method.
c. A Separation Membrane shall be used between the PQC and DLC.
Separation Membrane shall be 125 micron thick laid flat without
creases. Prior to laying of Separation, it shall be ensured that the
position is correct, the same is clean of dirt or other extraneous
materials and free from any damage.
d. FRL of PQC shall be maintained by providing shuttering as per
approved drawings.
e. Transporting of concrete shall be done by dumper / transit mixtures
after completion of batching and mixing.
f. As shown in approved drawings of Contraction Joint, Mild steel round
bars confirming IS: 432 & IS: 1139 shall be used as Dowel bars as per
Drawings. Dowel bars shall be supported on cradles/dowel chairs to
hold the position in mid with the tolerance of + 20 mm. Dowel bars
shall be covered by a thin plastic sheath for at least 2/3 of the length
or half plus 50 mm.
g. As shown in approved drawings of Longitudinal Joint, Fe 415 / 500
deformed steel bars confirming IS: 1786 shall be used.

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 h. Workability of Concrete shall be 30 + 15 mm at the time of placing or it
shall be modified depending upon the site requirements.
i. Surface vibrator shall be used to level the top and after completion of
finishing works, texturing works shall be start with texture brush
without delay.
j. Immediately after the surface texturing, surface and sides of slab shall
be cured by spraying curing compound to prevent against evaporation
losses.
k. Stopper shall be provided at the end of construction of day.
8. JOINTS
The location and type of joints shall be shown in the drawing and it
shall be constructed as per functional requirements as described as under.

9.1 Transverse joints:

Transverse joints shall be Expansion and Contraction Joints.
9.1.1 Expansion joint shall be used where cement concrete pavement is
designed with
Structures like Box Culverts, Bridges, etc.
9.2.2 The Contraction Joint shall be provided at interval of 4.5 m of slab.
The Contraction joint shall be cut as soon as possible as the concrete
has undergone initial hardening by mechanical sawn joint groove, 3 to
5 mm wide 1/4 or 1/3 depth of slab. Before opening the traffic
Contraction joint shall be widened 10 to 11 mm and 20 mm depth to
apply Poly sulphide sealant as shown in approved drawings.

9.2 Longitudinal joints:

The Longitudinal joints shall be provided throughout the lane axis of
paving width where continuous groove or key / tie bars are
provided. The groove may be cut after final set of the concrete at
least 1/3 depth of slab. Before opening the traffic Longitudinal joint
shall be widened 6 to 8 mm and 15 mm depth to apply Poly
sulphide sealant as shown in approved drawings.
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10 SURFACE TEXTURE
As described in point 7.i, surface texture shall be measured by
sand patch method as per MOSRT&H specifications before opening the
traffic.

11 CURING
In addition of 7.j, the next day the surface shall be covered by moist
hessian clothes or pond curing or other any other suitable method. The
surface of PQC shall be kept damp minimum 14 days.

12 PRECAUTIONS
9.1 Care shall be taken for workability of concrete.
9.2 Surface texturing shall be done before hardening of the concrete.
9.3 Curing of PQC is most essential to prevent cracks.
9.4 Joint construction shall be under good supervision to prevent spall
of concrete.

13 QUALITY CONTROL & ASSURANCE

Quality Assurance Manual and corresponding Quality Assurance
Plan should be followed to ensure the quality of PQC, 6 cubes and 6
beams shall be cast to assure the design compressive and flexural
strength. Tolerance in surface level for PQC shall be +5 mm to -6 mm.
Texture depth shall meet criteria as per MOSRT&H Table 600-2.

14 Health, safety and environment

All employees working within the limit of this project shall follow the
guidelines / rules & regulations as mentioned in HSE PLAN.

15 Traffic

77
 As per the standard construction practices necessary traffic
management measures shall be provided viz. signs, marking flags, lights
and flagmen. Fixed signs, barriers and other traffic control devices shall be
maintained in a satisfactory condition till such time they are required.
Throughout the construction period site management shall maintain public
vehicular access along the existing right of way.

78