CIVIL ENGINEERING STANDARD

PRACTICES FOR HIGHWAYS

Volume – 01
August - 2020
J P Mishra
Vice President
Ph. No: 7225022228
 MEETING
A meeting is a gathering of two or more people that has been convened for the purpose of
achieving a common goal through verbal interaction, such as sharing information or
reaching agreement.
There are six general types of meetings
1. Status update meeting
2. Information sharing meeting
3. Decision making meeting
4. Problem solving meeting
5. Innovation meeting
6. Team building meeting

2
 MONITORING

✓Project Monitoring refers to the process of keeping track of all project related metrics
including team performance and task duration, identifying potential problems and taking
corrective actions necessary to ensure that the project is within the scope, on budget and
meets the specified deadlines.

SCOPE OF THE PROJECT

Under this Agreement, the scope of the project shall mean and include:-
A. Construction of the Project Highway on the Site set forth in Schedule-A and as specified in
Schedule-B together with provision of Project Facilities as specified in Schedule-C, and in
conformity with the Specifications and Standards set forth in Schedule-D.
B. Maintenance of the Project Highway in accordance with the provisions of this Agreement
and in conformity with the requirements set forth in Schedule-E and
C. Performance and fulfilment of all other obligations of the Contractor in accordance with the
provisions of this Agreement and matters incidental thereto or necessary for the
performance of any or all of the obligations of the Contractor under this Agreement.
3
 PROJECT COMPLETION SCHEDULE
The Project Milestones may be as below:-

S. No. Physical Milestones Financial Milestones

1 Project Milestone-I – 20 % I Payment Milestone – On achievement of 10 %

Physical Progress
2 II Payment Milestone - On achievement of 30 %
Project Milestone-II – 35 % Physical Progress
3 III Payment Milestone - On achievement of 50 %
Physical Progress
4 Project Milestone-III – 75 % IV Payment Milestone - On achievement of 75 %
Physical Progress
5 V Payment Milestone - On achievement of 90 %
Physical Progress
6 Scheduled Completion Date – 100 % VI Payment Milestone - On achievement of 100 %
Physical Progress

4
 Some Important Codes to Refer
✓GUIDELINES FOR THE DESIGN OF FLEXIBLE PAVEMENTS
IRC:37-2018 (Fourth Revision)

✓GUIDELINES FOR THE DESIGN OF PLAIN JOINTED RIGID PAVEMENTS FOR HIGHWAYS
IRC:58-2015 (Fourth Revision)

✓MINISTRY OF ROAD TRANSPORT & HIGHWAYS

MoRTH (Fifth Revision) – 2013
SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

✓GUIDELINES ON TRAFFIC MANAGEMENT IN WORK ZONES

IRC:SP:55-2014 (First Revision)

✓CODE OF PRACTICE FOR ROAD SIGNS

IRC:67-2012 (Third Revision)
5
 CLASSIFICATION OF ROAD SIGNS
Road signs are of three types :

1) Mandatory/Regulatory signs:-
All Mandatory or Regulatory Signs are circular
in shape.

2) Cautionary/Warning Signs:-
Cautionary/Warning signs are triangular
in shape with red border and black symbol
in white background used to caution and
alert the road users to potential danger.

3) Informatory / Guide Signs:-

All Informatory signs and Guiding signs for
facilities are rectangular in shape.

6
7
 SECTION: 112- ARRANGEMENT FOR TRAFFIC DURING CONSTRUCTION

SECTION: 112.3- Passage of Traffic along a Temporary Diversion

Diversion shall be of 7 m carriageway and 2.5 m earthen shoulders on each side (total width
of roadway 12 m) with the following provision for road crust in the 7 m width:

2.500 Earthen Shoulders + 7.000 MCW + 2.500 Earthen Shoulders = 12.000 M (Total Width)

i. Earthwork – As per requirement

ii. 200 mm (compacted) granular sub-base
iii. 225 mm (compacted) granular base course
iv. Priming and Tack Coat and
v. Premix carpet with Seal Coat :- DBM/BC based on MSA

8
 CONCLUSION ON SAFETY

For Road safety following should be implemented:-

✓Reduce unsafe behaviours and increase safe behaviours (By imposing law and fines)
✓Improving driving skills (By better driving licence procedure)
✓Increase awareness about the rules of the road
✓Target unsafe actions by preventing use of (a) Mobile phones and (b) drunk driving.
✓Address specific segment of people by different mean.

9
 SITE ENGINEERING DATA

For All Site Civil Engineers, Surveyors & Supervisors

• Units and Dimensions:

There are four types of systems for measurements:-
1. CGS - Centimetre Gram Second
2. FPS - Foot Pound Second
3. MKS - Meter Kilogram Second
4. SI - International System of Units

10
 UNITS OF LENGTH, BREADTH, WIDTH, DEPTH & HEIGHT
• 1 mm = 1000 micron, 1 micron = 1/1000 mm
• 1000 mm = 100 cm = 1M
• 10 mm = 1 cm
• 100 cm = 1 Meter = 1000 mm
• 1 mm = 1/1000 Meter
• 1 cm = 1/100 Meter
• 1000 meter = 1 Km
• 1 inch = 2.54 cm = 25.4 mm
• 1 foot = 30.48 cm = 304.8 mm
• 1 Meter = 1000/304.8 = 3.28 feet
• 3 feet = 1 yard
• 1760 yard = 1 mile =1760 x 3= 5280 feet
• 1 Mile = 5280/3.28 = 1609 Meter = 1.609 Km
• 1 revenue chain = 66 feet = 22 yard (@20 meter)
• 1 engineering chain= 100 feet (@30 meter) 11
 AREA & VOLUME RELATIONSHIP
• 1 acre = 10 revenue chain (L) x 1 revenue chain (B)
= 10 x 66 feet x 66 feet = 43560 Sqft
• 1 acre = 100 decimal = 43560 Sqft
• 1 decimal = 435.60 Sqft
• 1 Sqm = 3.28 feet x 3.28 feet = 10.758 Sqft
• 10 M x 10 M = 100 Sqm = 1 Aare
• 100 Aare = 1 Hectare = 100 x 100 sqm = 10000 Sqm
• 1 acre = 43560/10.758 = 4049 Sqm = 0.4049 Hectare
• 1 Hectare = 10000 Sqm = 10000/4049 = 2.47 acres
• 1 cubic meter = 1mx1mx1m = 1 m3
= 3.28 ft x 3.28 ft x 3.28 ft = 35.287 cft
• 3 Cum = 3 x 35.287 cft = 105.861 cft
• 100 cft = 100/35.287 = 2.833 cum = 1 Brass
12
 SOME IMPORTANT CONVERSIONS
Area of a Rectangle = LxB in Sqft/Sqm
Volume of Rectangular section = L x B x D = Quantity = Area x Height/Depth in Cft/Cum
Area of a Circle = (π/4) × D2 in Sqft or Sqm
Volume of Circular Section = (π/4) × D2 x L = Quantity in Cft or Cum

Weight
Gram, Pound, Kilogram, Metric Tonne
1000 Milligram = 1 Gram
1000 Gram = 1 Kilogram
1000 Kilogram = 1 Metric Tonne
1 Kilogram = 9.81 Newton, say 10 Newton
1 Newton = 101.936 Gram, say 100 Grams
1 Pound = 453.6 Gram
1 Kilogram = 2.204 Pound
13
 Something Different
Not less than = Minimum
Not more than = Maximum
Bigger to Biggest:-
• 1 Million = 10,00,000 (10 Lakhs) = 1000 times of 1000= 1000 x 103 = 106
• 1 Billion = 1000 Million = 1000 times of 1 Million = 1000 x 106 = 109
• 1 Trillion = 1000 Billion = 1000 times of 1 Billion = 1000 x 109 = 1012

Smaller to Smallest:-
• 1 Micron = 1/1000mm = 1/ 103 mm = 1 x 10-3 mm
• 1 Micro Meter = 1X10-3 X 10-3 = 1X10-6 Meter (One Millionth of a Meter )
• 1 Nano Meter = 1X10-6 X 10-3 = 1X10-9 Meter (One Billionth of a Meter )
• 1 Pico Meter = 1X10-9 X 10-3 = 1X10-12 Meter (One Trillionth of a Meter )

14
 SOME IMPORTANT CONVERSIONS
MEASUREMENTS
Standard weight of 1 Meter steel bars:-
1. 8 mm = 0.395 Kg
2. 10 mm = 0.617 Kg
3. 12 mm = 0.888 Kg
4. 16 mm = 1.578 Kg
5. 20 mm = 2.469 Kg
6. 25 mm = 3.853 Kg
7. 32 mm = 6.320 Kg
How to find the Weight of any diameter of 1 Meter length bar
Density of steel = 7850 Kg per cum, e.g. taking 20 mm dia bar
Weight = Volume x Density
= π/4 x D2 x L x Density
= π/4 x (0.020 m x 0.020 m) x 1 m x 7850 Kg / m3
= 2.469 m3 x Kg / m3 = 2.469 Kg 15
 SOME IMPORTANT CONVERSIONS
MEASUREMENTS

• How to find the weight of steel = D2 /162

• Weight of steel (W) = π/4 x D2 x L x Density
= 3.14/4 x D2 x 1m x 7850 kg/ m3
= 0.785398 x D2 x 1m x 7850 kg/ m3
= D2 x 0.785398 x 1m x 7850 kg/ m3
= D2 x 6165.375 x 1 kg/ m2
We know that x/y = x/y and (x/y)/(x/y) = 1
e.g. 1/1000 = (1/1)/1000/1 = 1/1 x 1/1000 = 1/1000
Hence W = (D2 x 1 kg/1)/(m x m)/6165.375
= (D2 x 1 kg/1)/(1000 mm x 1000 mm)/6165.375
= (D2 x 1 kg/1)/162 = D2 /162 kg

16
 SOME IMPORTANT CONVERSIONS
MEASUREMENTS
Time:-
➢ 60 Second = 1 Minute
➢ 60 Minutes = 1 Hour ➢ AM = Anti Meridiem
(AAROHANAM MARTANDASHYA)
= 3600 Seconds
➢ PM = Post Meridiem
➢ 24 Hour = 1 Day
(PATANAM MARTANDASHYA)
➢ 7 Days = 1 Week
➢ 15 Days = Fort Night
➢ 30 Days = 1 Month
➢ 365 Days = 1 Year
➢ 10 Years = 1 Decade
➢ 100 Years = 1 Century
➢ 1000 Years = 1 Millennium

17
 HIGHWAY TERMINOLOGY
1. DILIP BUILDCON LIMITED 12. Lender Engineer Survey ) benchmark is a
(DBL) permanently fixed reference
13. Mobilization
survey station (or Point),
2. MoRTH (Ministry Of Road
14. Pre Construction Activities having know elevation with
Transport And Highways)
respect to a standard datum
15. Video Recording
3. Project (mean sea level)
16. Estimating and Costing
4. Tender/ Bid/ Notice 25. Temporary Benchmark (TBM)
17. Analysis of rates
5. Earnest Money, Bid 26. TBM Pillars
Submission & Opening 18. Budget Preparation
27. Chainage, BS, IS, FS, HI & RL
(Monthly/Annual)
6. Lowest Bidder/ LOI
28. Traversing
19. Lime Powder
7. Performance Bank Guarantee
29. Coordinates
(PBG) 20. Line Dori, Plumb Bob, Nails
30. Topography
8. Agreement 21. Measuring Tape
31. Existing Carriage Way
9. Appointed date(EPC) 22. Total Station, Tripod, Prism
32. Proposed Carriage Way
10. Financial Closer(HAM) 23. Auto Level Machine, Tripod
Stand, Levelling Staff 33. Proposed Center Line (PCL)
11. Try Party Agreement
24. Permanent Benchmark (GTS) 34. Preparation of inventory of
A G.T.S. (Great Trigonometrical existing carriage way
18
35. Format Preparation 49. Director & CEO 64. Resident Engineer
36. Encumbered land 50. President/ Vice President 65. Other Engineers
37. Unencumbered land 51. GM/PH/PM/CM/SE 66. RO/PD Office/TL
Office/Project camp Office
38. Preparation of Appendix 52. Hierarchy
67. Scope of Project/ Obligations
39. Land Acquisition 53. Junior/ Senior Staff
68. EPC (Engineering
40. Utility Survey/ Shifting 54. Site
Procurement and
41. Tree counting, Girth 55. Salary Construction)
Measurement & cutting
56. Client/ Authority 69. Contractor
42. Electrical utility
57. Project Director (PD) 70. Execution/Construction
43. Water pipe line
58. Regional Officer (RO) 71. Maintenance
44. Telephone lines & OFC Cables
59. Consultants 72. HAM (Hybrid Annuity
45. Dismantling of Permanent/ Model)
60. Authority’s Engineer
Temporary Structures
73. Concessionaire
61. Independent Engineer
46. Correspondence
74. Concession Period
62. Project Management
47. Company/ Organisation
Consultants 75. DLP (Defect Liability Period)
48. Managing Director
63. Team Leader 76. Statement & Methodology
19
77. Flexible Pavement 91. Soil Sampling of NGL 106. Median
78. Rigid Pavement 92. ROW Pillar 107. Depressed Median
79. Work Execution Plan 93. Recording of OGL Before C&G 108. Flush Median
80. Project Safety Plan (PSP) 94. Plan & Profile 109. Right Median Edge (RME)
81. Project Quality Assurance 95. Cutting or Filling 110. Left Median Edge(LME)
Plan (PQP)
96. Borrow Area Searching, 111. Earthwork Unit
82. Project Environmental Plan Sampling & Testing
112. Excavators
83. Applicable Permits 97. FSI, Gradation, Procter Test
113. Dumper Trucks
84. Consent for Establishment 98. MDD, OMC, CBR
114. Dozers
(CFE)
99. Design CBR/ Effective CBR
115. Motor Graders
85. Consent for Operation (CFO)
100. Selected Soil/Suitable Soil
116. Soil Compactors
86. RFI (Request for Inspection)
101. Unsuitable Soil /Rejected
117. Water Tankers
87. Format Approvals Soil/Expansive Soil/BC Soil
118. Backhoe Loaders
88. Design & Drawing, 102. Quarry/ Crusher/ Aggregate
Submission and Approval 119. Loader
103. Crust- Soft & Hard
89. Million Standard Axel (MSA) 120. Clearing & Grubbing (C&G)
104. Standards and Specifications
@ 8MT
105. Proposed Centre Line & Toe
90. Material Source Approval
Line 20
121. OGL Compaction & Testing 137. Field Density Test 151. Sensor Paver
122. Recording of OGL after C&G 138. Relative Compaction 152. Level Pegs
123. Loading of Borrowed Soil 139. Sub-Grade Top 153. String Wire
124. Transportation of soil 154. Pug Mill/CTB Plant
125. Dumping 140. Level Tolerance 155. Concrete Batching Plant
126. Embankment/Sub-Grade 141. Blanketing 156. Weigh Bridge
127. Layer, Bed, Thickness 142. GSB (Granular Sub 157. Sand Source and Stacking
Base)/Drainage Layer
128. Grading with Grader 158. Structures
143. Minimum/Maximum
129. Static Roller 159. Foundation
Thickness
130.Vibro/ Dynamic Roller (80- 160. Sub Structure
144. Single/Double Layer
100kN)
161. Super Structure
145. Individual/Combined
131. Lines, Grades & X-Sections
Gradation 162. Plain Cement Concrete (PCC)
132. Camber/Transverse Slope
146. Formation Width 163. Reinforced Cement Concrete
133. Gradient/Longitudinal Slope (RCC)
147. Paved/Earthen Shoulder
134. Side Slope 164. Reinforced Earth (RE) Wall
148. Lateral Confinement
135. Moisture V/s OMC 165. Levelling Pad & RE Panel
149. WMM (Wet Mix Macadam)
136. Rolling/Compaction 21
150. Offset
166. Reinforced Fill/ Retained Fill 179. Bitumen-VG 30 & VG 40 192. Slump/ Consistency of
concrete means ability of
167. Reinforcing/ Geosynthetic 180. Bitumen Temperature
concrete to flow. Concrete with
Material
181. Aggregate Temperature better consistency increases
168. Coping Beam the workability and
performance. A good
169. Friction Slab
182. Mix Temperature at plant consistent concrete reduces
170. Drainage Spout the placing and compaction
183. Mix Temperature at site
171. HPC (Hume Pipe Culvert) efforts and reduces the time of
184. Laying Temperature concrete.
172. Box Culvert(BC) Up to 6m
185. Rolling Temperature 193. PQC (Pavement Quality
173. Slab Culvert(SC) Up to 6m Concrete)
186. Ambient Temperature
174. Minor Bridge(MNB) Up to 60m 194. Cement Content
187. Dense Bituminous Macadam
total span
(DBM) Grade-I & Grade-II 195. Admixture
175. Major Bridge (MJB) More than
188. Bituminous Concrete (BC) 196. Curing Compound
60m total span
Grade-I & Grade-II
176. Hot Mix Batching Plant 197. Fiber
189. Mastic Asphalt
177. Thermic Oil 198. Water
190. Wearing Course
178. LDO/FO 199. Water Cement Ratio
191. DLC (Dry Lean Concrete)
22
200. Workability of concrete is the 210. Metal Beam Crash Barrier 224. Toe Wall
property of freshly mixed (MBCB)
225. Quadrant Pitching
concrete which determines the
211. Median Guard rail/ pedestrian
ease and homogeneity with 226. Curtain Wall
Guard rail
which it can be mixed, placed,
227. Apron (flexible/ Rigid)
consolidated and finished. 212. Service Road
228. Project Completion
201. PQC Mix Temperature 213. Main Carriage Way (MCW)
229. Anti Crash Barrier
202. Coarse Aggregate 214. Shyness
230. Approach Slab
203. Fine Aggregate 215. Median
231. Raised Footpath
204. Binding Material 216. Median Opening/ Flaring
232. RCC Drain
205. Characteristics Compressive 217. Median Filling
Strength 233. Iron Grating
218. Chute Drain
206. MPa / N/mm2 234. With Wheel Load/ Without
219. Median Plantation
Wheel Load
207. Lane (Single Lane/ 2 Lane/ 3
220. Slope Protection
Lane/ 4 Lane/ 6 Lane) 235. Earthen Drain
221. Bed Protection
208. Kerb 236. Avenue Plantation
222. Retaining Wall
209. Road Furniture/ Road 237. Perennial Trees
Signage/ Thermoplastic 223. With Surcharge/Without
238. Ornamental Trees
Painting Surcharge Retaining Wall
23
239. At Grade Intersections 251. Riding quality tests b) Roadside furniture
240. Minor Junction 252. Pavement composition Test c) Street lightening
241. Major Junction 253. Cross-Section Test d) Pedestrian facilities
242. Trumpet is a 3-leg interchange 254. Structural Test for bridges e) Landscaping and tree
which takes the shape of a) NDT (Non Destructive Test) –
plantation
trumpet. Trumpet interchanges Ultrasonic Pulse Velocity Test,
have been used where one f) Rest areas cum Truck lay-byes
Rebound Hammer Test
highway terminates at another g) Bus-bays and bus shelters
highway. These involve at least b) Destructive Test – Core Cutting
one loop ramp connecting traffic 255. Other tests like:- Environmental h) Traffic aid posts
either entering or leaving the Audit , Safety Audit i) Medical aid posts
expressway with the far lanes of
the continuous highway. 256. Provisional Completion j) Advance Traffic Management
Certificate (Pre-COD) System(ATMS)
243. Project Facilities
257. Punch list & Closure of NCR k) Others
244. Milestone
258. Completion Certificate (CC) i. Vehicle Rescue Posts
245. Change of Scope (COS)
259. Final Billing/ Payment ii. Operation &
246. Extension of Time (EOT) Maintenance Center
260. Submission of as Built Drawing
247. Monthly Billing/ IPC/ Invoice (Admin Building)
261. Demobilization
248. Tests on Completion iii. Rain Water Harvesting
Project Facilities:-
249. Visual & physical test
a) Toll plazas
250. Test drive
24
 MORTH
MINISTRY OF ROAD TRANSPORT AND HIGHWAYS

• First Published : April, 1973

• Second Revision : February, 1988
• Third Revision : April, 1995
• Fourth Revision : August, 2001
• Fifth Revision : April 2013

25
 CONTENTS OF MORTH
SECTION No. DESCRIPTION

100 GENERAL
200 SITE CLEARANCE
300 EARTHWORK, EROSION CONTROL AND DRAINAGE
400 SUB-BASES, BASES (NON BITUMINOUS) AND SHOULDERS
500 BASES AND SURFACE COURSES (BITUMINOUS)
600 CONCRETE PAVEMENT
700 GEOSYNTHETICS
800 TRAFFIC SIGNS, MARKINGS AND OTHER ROAD APPURTENANCES
900 QUALITY CONTROL FOR ROAD WORKS
1000 MATERIALS FOR STRUCTURES
1100 PILE FOUNDATIONS
1200 WELL FOUNDATIONS

26
 CONTENTS OF MORTH

SECTION No. DESCRIPTION

1300 BRICKS MASONRY

1400 STONE AND CONCRETE BLOCK MASONRY
1500 FORMWORK
1600 STEEL REINFORCEMENT
1700 STRUCTURAL CONCRETE
1800 PRESTRESSING
1900 STRUCTURAL STEEL
2000 BEARINGS
2100 OPEN FOUNDATIONS
2200 SUBSTRUCTURE
2300 CONCRETE SUPERSTRUCTURE
2400 SURFACE AND SUB-SURFACE GEOTECHNICAL INVESTIGATION

27
 CONTENTS OF MORTH

SECTION No. DESCRIPTION

2500 RIVER TRANNING WORK AND PROTECTION WORK

2600 EXPANSION JOINTS
2700 WEARING COAT AND APPURTENANCES
2800 REPAIR OF STRUCTURES
2900 PIPE CULVERTS
3000 MAINTENANCE OF ROAD
3100 REINFORCED EARTH
3200 SOIL NAILING

28
 SECTION: 113- GENERAL RULES FOR THE MEASUREMENT OF WORKS FOR PAYMENT

✓All measurements and computations, unless otherwise indicated, shall be carried nearest
to the following limits:
i) length and width 10 mm
ii) height, depth or thickness of
a) earthwork, subgrade, 5 mm
b) sub-bases, bases, surfacing 5 mm
iii) structural members 2.5 mm
iv) areas 0.01 Sqm
v) volume 0.01 Cum

SECTION: 120- FIELD LABORATORY

✓The field laboratory building and equipment shall be the property of the Contractor. The
Employer and the Engineer shall have free access to the laboratory.

29
 SECTION: 201- CLEARING AND GRUBBING

This work shall consist of cutting, removing and disposing of all materials such as trees
bushes, shrubs, stumps, roots, grass, weeds, rubbish, top organic soil, etc. to an average
depth of 150 mm In thickness.

SECTION: 201.5- MEASUREMENTS FOR PAYMENT

1. Clearing and grubbing for road embankment, drains and cross-drainage structures
shall be measured on area basis in terms of hectares.
2. Cutting of trees up to 300 mm in girth and removal of their stumps, including removal
of stumps up to 300 mm in girth left over after trees have been cut by any other
agency, and trimming of branches of trees extending above the roadway and backfilling
to the required compaction shall be considered incidental to the clearing and grubbing
operations.

30
 Section: 300- Earthwork for Embankment & Subgrade
1) This work shall consist of excavation, removal and disposal of materials necessary for the
construction of roadway, side drains and waterways in accordance with requirements of
these Specifications and the lines, grades and cross-sections shown in the drawings or
as indicated by the Engineer.
2) These Specifications shall apply to the construction of embankments including sub-grades,
earthen shoulders and miscellaneous backfills with approved material obtained from
approved source, including material from roadway and drain excavation, borrow pits or
other sources.
3) All embankments, sub-grades, earthen shoulders and miscellaneous backfills shall be
constructed 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.

Grades :- Camber, Cross Slope, Cross Fall, Gradient, Longitudinal Slope, Side Slope.

31
32
33
34
35
Section: 305.2- General Requirements for Suitability of Materials :-

1) The materials used in embankments, subgrades, earthen shoulders and miscellaneous

backfills shall be soil, moorum, gravel, reclaimed material from pavement, flyash, pond
ash, a mixture of these or any other material as approved
2) Expansive clay having excessive swelling and shrinkage properties ("free swelling index"
exceeding 50 percent ) shall not be used as a fill material.
3) An expansive clay having "free swelling index" value less than 50 percent will be used as
a fill material.
4) Subgrade and top 500 mm portion of the embankment just below sub-grade shall be
non-expansive in nature(FSI less than 50%).
5) Clay having liquid limit within 50 and plasticity index within 25 is suitable for this
purpose.
6) The material to be used in subgrade shall be non-expansive and shall satisfy design CBR
at the Specified Dry Density and Moisture Content.

36
Section- 305.2.1.4 : (Size of Soil Particles)

a) The size of the coarse material in the mixture of earth shall ordinarily not exceed 75 mm
when placed in the embankment and 50 mm when placed in the sub-grade.
b) However, the Consultant/Client may at his discretion permit the use of material coarser
than this also.
c) The maximum particle size in such cases, however, shall not be more than two-thirds of
the compacted layer thickness.
d) Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when
being placed in the embankment and a maximum size of 50 mm when being placed in the
subgrade.

37
 Table 300-1 : Minimum Density Requirements of Embankment and Sub-Grade Materials

Sr. Type of Work Maximum laboratory dry Maximum laboratory dry

No. unit weight unit weight
As per 5th Revision As per 4th Revision

Embankments up to 3 m height, Not less than 15.2 Not less than 1.52
1 not subjected to extensive
flooding. kN/cu.m gm/cc

Embankments exceeding 3 m Not less than 16 kN/cu.m Not less than 1.60
2 height or embankments of any
height subject to long periods of gm/cc
inundation.

Subgrade and earthen· Not less than 17.5 Not less than 1.75
3 shoulders/verges / backfill.
kN/cu.m gm/cc

38
 305.2.2.4 : Compaction Requirements

✓It shall be ensured that the subgrade material when compacted to the density
requirements as in Table 300-2 shall yield the specified design CBR value of the Sub-Grade.

Table 300-2 : Compaction Requirements for Embankment and Sub-grade.

Sr. Type of work/material Relative compaction as percentage of max.
No laboratory dry density as per 15:2720 (Part 8)

1 Subgrade and earthen shoulders Not less than 97%

2 Embankment, Not less than 95%

3 Expansive Clays(FSI more than 50%)

a) Subgrade and 500 mm portion just Not allowed
below the subgrade.
b) Remaining portion of embankment 90-95%

39
 Conversion

1.75 gm /cc = 17.5 kN/m3

1.75 gm /cc = (1.75 X 1k/1000 X 1N/100)/(1M/100X1M/100X1M/100)
= (1.75 X 1k X 1N X 100 X 100 X 100 )/(1000X100X1MX1MX1M)
= 17.5 kN/m3 Hence Proved.
17.5 kN/m3 = 1.75 gm /cc
17.5 kN/m3 = (17.5 X 1gmX1000 X 100)/ (100cm X 100 cm X 100 cm)
= 17.5 gm X 1/10 cm3
= 1.75 gm/cm3 Hence Proved.

40
 BLACK COTTON (BC) SOILS

Properties :
1. They are highly expansive in nature.
2. They have high swelling and
shrinkage characteristics.

• Swelling and Shrinkage :The reduction

in volume of a soil mass due to
evaporation of pore water is known as
shrinkage. If water is added to such soils,
increase in volume takes place, which is
known as swelling. The soils which
exhibit these characteristics are called
expansive soils.
• The compression of saturated soils (no
air) is mainly due to the expulsion of
water from the voids.

41
 Most Important Definitions

✓MDD :- Maximum Dry Density is the highest density achieved at optimum moisture
content provided. It is defined as the maximum weight of solids per unit volume.
✓OMC :-Optimum Moisture Content is the percentage of water at which Maximum Dry
Density can be achieved. Moisture content of each layer of soil shall be checked. At the
time of compaction the Optimum Moisture Content should range from 1% above to 2%
below.
✓Compaction is defined as the Maximum Dry Density that can ideally be obtained for a
soil at a given water content by applying compaction. It is only a theoretical concept
which can never be reached in practice.
✓The process of expulsion of air from the voids of partially saturated soil, under the effect
of Dynamic Loadings such as rolling and tamping is known as compaction.
✓Compaction is the decrease in volume, brought intentionally so as to increase the
density at an unaltered water content.
✓It is the process by which the soil particles are artificially rearranged by mechanical
methods and packed into a smaller volume.

42
 PHYSICAL PROPERTIES OF SOILS

A soil mass is, in general, a three phase system composed of solid, liquid and gaseous
matter.

43
 RELATIVE COMPACTION
The dry density achieved in the field is compared with maximum dry density obtained in the
Standard Proctor Test.
The ratio of Dry Density in the Field to the Maximum Dry Density is known as Relative
Compaction or Percent Compaction.

Field Density
Relative Compaction (%) = x 100
Lab Density

e.g. FDD = 1.97 gm/cc and MDD = 2.01 gm/cc

(1.97 gm/cc)
Hence Relative Compaction = x 100
(2.01 gm/cc)

= 98 %
Where there’s a will there’s a way. It is a proverb that means if someone is determined to do
something, he will find a way to accomplish it regardless of obstacles. – By Pauline Kael
44
 SOIL COMPACTION

✓The compaction shall be done with the help of self-propelled single drum vibratory roller
or pad foot vibratory roller of 80 to 100 kN Static Weight.
✓To achieve the desired compaction, clods or hard lumps of earth shall be broken to have
a maximum size of 75 mm when being placed in the embankment and a maximum size of
50 mm when being placed in the subgrade.
✓Loosening, levelling and compacting original ground supporting embankment to
facilitate placement of first layer of embankment, scarified to a depth of 150 mm, mixed
with water at OMC and then compacted by rolling so as to achieve minimum dry density
as desired for embankment construction.
✓Subgrade (500 mm portion) is always compacted to the known density.
✓In case of the existing soil meeting the required CBR criteria, top 250 mm portion shall
be removed.
✓Bottom 250mm portion shall be loosened and recompacted for not less than 97% of
desired compaction for subgrade. Balance top 250 mm thickness of subgrade layer will
be constructed as above.
45
 SOME DEFINITIONS AND RELATIONSHIPS
• Bulk unit weight : It is defined as the total weight per unit total volume. It is also known as
total unit weight or wet unit weight. It is expressed in the units of N/m3 or KN/m3
• Dry unit weight : It is defined as weight of solids per unit total volume.
• Specific Gravity : is defined as the ratio of the weight (or mass) or a given volume of solids to
the weight (or mass) of an equal volume of water.
• Relative density : The soil corresponding to higher void ratio is called loose and that
corresponding to lower void ratio is called dense. The term used to indicate the strength
characteristics in a qualitative manner is termed as Relative density.
• Liquid Limit (L.L.) : A soil containing high water content is in a liquid state. At some
particular water content the soil becomes plastic. That water content at which soil changes
from liquid state to the plastic state is known as liquid limit (L.L.).
• Plastic Limit (P. L.) : The soil in the plastic stage can be moulded into various shapes. This
water content at which soil changes it’s state from plastic to semi-solid, is known as the
plastic limit (P.L). In other words plastic limit is the water content at which the soil just fails
to behave plastically.
• Plasticity Index : The numerical difference between liquid limit and plastic limit is known as
plasticity index. In other words it is the range of water content over which soil remains
plastic.
46
 SECTION: 3100- REINFORCED SOIL Frication Slab/
RCC Crash Barrier

The reinforced soil retaining

structures can be used as,

RE Panels
RE Panels
(i) Reinforced soil retaining wall,
(ii) Reinforced soil abutment,
(iii) Reinforced soil slope.
G L
Leveling Pad Leveling Pad
Table 1 Desirable Gradation for Reinforced Soil Fill
Sieve Size Percentage Finer (in %)
75 mm 100
4.75 mm 85 - 100
425 micron 60 – 90
75 micron < 15
47
Incorrect Method of RE Wall Work

48
Correct Method of Soil Compaction in RE Wall. Area after each Layer Compaction

49
50
Cohesion :- is a measure of the forces, that cement particles of soils.

Cohesive fill :-
• Soft clay
• Stiff clay
Non-Cohesive fill :-
• Dry sand with no cementation
• Dry sand with some cementation

1) Cohesionless means (c = 0). Required cohesion for RE Wall fill soil is Zero.
2) Required angle of Repose (Φ) not less than 30°.

51
Non-Cohesive fill

52
 Reinforced Soil Quality requirements
1. The reinforced soil/fill is essentially borrowed.
2. It is desirable that the reinforced fill be free draining with majority of the shear strength
component derived from internal friction.
3. The desirable gradation of the reinforced fill is shown in Table 1.
4. The gradation proposed would ensure that the fill is well graded, free draining and has
adequate shear strength once it is compacted.
5. The backfill should have Plasticity Index, PI < 6 and Coefficient of uniformity Cu > 2.
6. Soil with more than 15 percent passing 75 micron sieve, but less than 10 percent of
particles smaller than 15 microns are acceptable provided PI is less than 6 and angle of
friction is not less than 30°.
7. Connection between the facia panels and the reinforcing element shall be done by using
either nut or bolt, HDPE inserts with bodkin joint, hollow embedded devices,
polymeric/steel strips/rods/pipes, fibre glass dowels or any other material shown in the
drawings. Several types of connections are being used.
8. The facing system should be able to meet the functional requirements such as rigidity,
flexibility, aesthetics, environmental considerations etc. depending on location, purpose
and use of structure. 53
 Section - 305.2.2.3 : Fly-Ash

1) IRC:SP:58-2001, "Guidelines for Use of Flyash in Road Construction".

2) The term fly-ash shall cover all types of coal ash such as pond ash, bottom ash or mound
ash.
3) A thick soil cover shall bind the edge of the embankment to protect the flyash against
erosion. Minimum thickness of such soil cover shall be 500 mm.
4) As per the guidelines, it is mandatory to use fly ash in the construction of road and flyover
embankments within a radius of 300 km from a thermal power plant. For a radius of 300
km or more, the thermal power plant will bear the entire transportation cost.
5) Soil mixed with Fly Ash and lime increases California Bearing Ratio (CBR), increased
(84.6%) on addition of only Fly Ash to soil.
6) It can be used for Stabilizing and Constructing sub-base or base.
7) It can be used for upper layer of pavements.
8) It can be used for filling purposes and it is also mixed in concrete for pavements to cost
effective use.
54
Section: 305.3.5- Spreading Material in layers and Bringing to Appropriate Moisture
Content
1) The embankment and sub-grade material shall be spread in layers of uniform thickness
in the entire width with a motor grader.
2) The compacted thickness of each layer shall not be more than 250 mm when vibratory
roller/vibratory soil compactor is used.
3) The compacted thickness of each layer shall not be more than 200 mm when 80-100 kN
static roller is used. In RE Wall works it is compulsory to lay only 200 mm thick layers in
any condition.
4) The motor grader blade shall have hydraulic control suitable for initial adjustment and
maintain the same so as to achieve the specific slope and grade.
5) Clods or hard lumps of earth shall be broken to have a maximum size of 75 mm when
being placed in the embankment and a maximum size of 50 mm when being placed in the
subgrade.
6) Successive layers shall not be placed until the layer under construction has been
thoroughly compacted.
7) The specified compaction requirements are as per Table 300-2.
8) Each compacted layer shall be finished parallel to the final cross-section of the
embankment. 55
 Design Understanding

1. Pavement Designs will need to understand for

utilising the Available material along Project Corridor.
2. The pavement will be designed for “ EFFECTIVE CBR”
3. Effective CBR is Combined CBR of Sub grade Portion
and its below 500mm portion which can be
OGL/Embankment Portion
4. The CBR effective will be worked out from the both
CBR of of Sub grade and OGL/Embankment as per the
availability.

For same case if OGL CBR is 5%

required BA CBR will be 8% for
required Design CBR i.e. 7%

56
57
58
59
 SECTION: 400- SUB-BASES, BASES (GSB & WMM) AND SHOULDERS

Granular sub-base (GSB) :

1. This work shall consist of laying and compacting well-graded material on prepared
subgrade.
2. The thickness of each layer shall not be less than 150 mm.
3. Gradings III and IV shall preferably be used in lower sub-base.
4. Gradings V and VI shall be used as a sub-base-cum-drainage layer.

60
 Table 400-2 : Physical Requirements for Materials for Granular Sub-base
1. Aggregate Impact Value (AIV) 40 maximum
2. Liquid Limit Maximum 25
3. Plasticity Index Maximum 6
4. Plastic Limit Non Plastic (NP)
5. CBR at 98% dry density Minimum 30%

Spreading and Compacting :

1) Immediately after spreading the mix by grader, rolling shall be done by an approved vibratory
roller of minimum 80 to 100 kN static weight capable of achieving the required compaction.
2) Rolling shall commence at the lower edge and proceed towards the upper edge
longitudinally for portions having unidirectional crossfall or on super elevation.
3) For carriageway having crossfall on both sides, rolling shall commence at the edges and
progress towards the crown.
4) Each pass of the roller shall uniformly overlap not less than one-third of the track made in
the preceding pass.
5) The speed of the roller shall not exceed 5 Km per hour. Rolling shall be continued till the
density achieved is at least 98 percent of the Maximum Dry Density for the determined material.
61
 Table 400-1 : Grading for Granular Sub-base Materials
IS Sieve Percent by Weight Passing the IS Sieve
Designation
Grad- I Grad II Grad III Grad IV Grad V Grad VI
75.0 mm 100 - - - 100 -

53.0 mm 80-100 100 100 100 80-100 100

26.5 mm 55-90 70-100 55-75 50-80 55-90 75-100

9.50 mm 35-65 50-80 - - 35-65 55-75

4.75 mm 25-55 40-65 10-30 15-35 25-50 30-55

2.36 mm 20-40 30-50 - - 10-20 10-25

0.85 mm - - - - 2-10 -

0.425 mm 10-15 10-15 - - 0-5 0-8

0.075 mm <5 <5 <5 <5 - 0-3

62
 SECTION: 406- WET MIX MACADAM (WMM) SUB-BASE/BASE :

1) The material shall be laid in one or more layers as necessary to lines, grades and
cross-sections shown on the approved drawings.

2) The thickness of a single compacted Wet Mix Macadam layer shall not be less than 75
mm and the compacted depth of a single layer of the sub-base course may be up to 200
mm (Maximum).

Table 400-12 : Physical Requirements of Coarse Aggregates for Wet Mix Macadam

Sr. No Test Requirement

1 Los Angeles Abrasion value 40 percent (Max.)

2 Aggregate Impact value 30 percent (Max.)
3 Combined Flakiness and Elongation indices 35 percent (Max.)*
(Total)

63
 SPECIFICATIONS FOR WMM
1) Material finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
2) While constructing wet mix macadam, arrangement shall be made for the lateral
confinement of wet mix. The mix shall be spread by a paver finisher.
3) Wet Mix Macadam shall be prepared in an approved mixing plant of suitable capacity
having provision for controlled addition of water and forced/ positive mixing arrangement
like pugmill or pan type mixer of concrete batching plant.
4) After the mix has been laid to the required thickness, grade and camber the same shall be
uniformly compacted to the full depth with suitable roller.
5) For a compacted single layer up to 200 mm, the compaction shall be done with the help of
vibratory roller of minimum static weight of 80 to 100kN.
6) The speed of the roller shall not exceed 5 km/h.
7) Roller should progress parallel to the center line of the road, uniformly over-lapping each
preceding track by at least one-third width until the entire surface has been rolled.
8) Rolling shall be continued till the density achieved is at least 98 percent of the
maximum dry density for the determined material.
64
 SECTION: 502- PRIME COAT
• Applied on Granular Surface
• Single Coat – Low Viscosity Liquid
Bituminous Material
• Primer may be of :-
a. Cationic Bitumen Emulsion SS1 Grade or
b. Medium Curing Cutback.
Rate of spray:
Sr. No. Type of Surface Rate of Spray (Kg/Sqm)
1 WMM/WBM 0.7-1.0
2 Stabilized Soil bases/Crusher Run Macadam 0.9-1.2

• No Heating or Dilution of SS1 Bitumen is permitted at site.

• Avoid causing runoff due to excess coat. Desired penetration 8-10 mm.

65
 SECTION: 503- TACK COAT

• Applied on Bituminous Surface or Cement Concrete Surface

• Single Coat – Low Viscosity Liquid Bituminous Material
• Binder – Cationic Bitumen Emulsion RS1 Grade
• Temperature & Heating –
a. 20 °C to 70°C (Bitumen Emulsion)
b. 50 °C to 80°C (Cut Back)

• Rate of spray:

Sr. No. Surface Rate (Kg/Sqm)

1 Bituminous Surface 0.20 to 0.30
2 Granular Surface treated with Primer 0.25 to 0.30
3 Cement Concrete Pavement 0.30 to 0.35
66
 Section: 505- Dense Bituminous Macadam (DBM)

Coarse Aggregates: The coarse aggregates shall consist of crushed rock, crushed gravel or
other hard material retained on the 2.36 mm sieve.
Fine Aggregates: Fine aggregates shall consist of crushed or naturally occurring material,
or a combination of the two, passing 2.36 mm sieve and retained on the 75 micron sieve.
Natural sand shall not be allowed in binder and wearing courses. However, natural
sand up to 50 percent of the fine aggregates may be allowed in base courses.
Fine aggregates shall have a sand equivalent value of not less than 50 when tested.
The plasticity index of the fraction passing 0.425 mm shall not exceed 4 when tested.
Mixing: Pre-mixed bituminous materials shall be prepared in a hot mix plant of adequate
capacity and capable of yielding a mix of proper and uniform quality with thoroughly
coated aggregates.
The difference in temperature between the binder and aggregate shall at no time
exceed 14°C.

67
 Table 500-2 : Mixing, Laying and Rolling Temperatures for Bituminous
Mixes (Degree Celsius)
Sr. Bitumen Bitumen Aggregate Mixed Laying *Rolling
No. Viscosity Temperature Temperature Material Temperature Temperature
Grade Temperature
1 VG-40 160-170 160-175 160-170 150 Min 100 Min

2 VG-30 150-165 150-170 150-165 140 Min 90 Min

3 VG-20 145-165 145-170 145-165 135 Min 85 Min

4 VG-10 140-160 140-165 140-160 130 Min 80 Min

5 Modified 165-185 165-185 150-170 130-160 115-155

Bitumen

*Rolling must be completed before the mat cools to these minimum temperatures.
68
 MODIFIED BITUMEN, IRC : SP : 53-2010
IS : 15462 : 2004 classify the polymer and rubber modified bitumen into the following four
types:
a) PMB(P) Plastomeric Thermoplastic Based.
b) PMB(E) Elastomeric Thermoplastic Based.
c) NRMB Natural Rubber and SBR Latex Based, and
d) CRMB Crumb Rubber / Treated Crumb Rubber Based.

ADVANTAGES OF MODIFIED BITUMEN

• Lower susceptibility to temperature variations
• Higher resistance to deformation at high pavement temperature
• Delay of cracking and reflective cracking
• Better age resistance properties
• Better adhesion between aggregates and binder
• Higher fatigue life of mixes
• Overall improved performance

69
 Table 500-10 : Composition of Dense Graded Bituminous Macadam

Grading Grade 1 Grade 2

Nominal aggregate size* 37.5 mm 26.5 mm

Layer thickness 75-100 mm 50-75 mm

Bitumen content % by mass Min 4.0** Min 4.5**

of total mix

70
 Special Attention For Do Not Laying

Laying:-shall not be done in below mentioned circumstances:-

1. In presence of standing water on the surface;
2. When rain is imminent, and during rains, fog or dust storm;
3. When the base/binder course is damp;
4. When the air temperature on the surface on which it is to be laid is
less than 10°C for mixes with conventional bitumen and is less than
15°C for mixes with modified bitumen;
5. When the wind speed at any temperature exceeds the 40 Km per
hour at 2 m height.

71
 Special Attention on JMF

1. The nominal maximum particle size is the largest specified sieve size upon which any of
the aggregate is retained .
2. In case aggregate have specific gravity more than 2.7, the minimum bitumen content can
be reduced proportionately.
3. Further the region where highest daily mean air temperature is 30 ∘C or lower and lowest
daily air temperature is – 10∘C or lower, the bitumen content may be increased by 0.5
percent.
4. Bitumen content indicated in Table 500-10 is the minimum quantity.
5. Content of Bitumen percentage by mass of total mix shall be minimum 4% for grade 1
and minimum 4.5% for grade 2.
6. The bitumen quantity shall be determined in accordance with Clause 505.3.
7. The Fines to Bitumen (F/B) ratio by weight of total mix shall range from 0.6 to 1.2.

72
 Spreading of DBM Mix
1. Bituminous materials shall be spread, levelled and tamped by an approved self
propelled paving machine equipped with an electronic sensing device.
2. As soon as possible after arrival at site, the materials shall be supplied continuously to
the paver and laid without delay.
3. The rate of delivery of material to the paver shall be regulated to enable the paver to
operate continuously.
4. The travel rate of the paver, and its method of operations, shall be adjusted to ensure an
even and uniform flow of bituminous material across the screed, free from dragging,
tearing and segregation of the material.
Compaction of DBM layers
1. Bituminous materials shall be laid and compacted in layers, which enable the specified
thickness, surface level, regularity requirements and compaction to be achieved.
2. Compaction of bituminous materials shall commence as soon as possible after laying.
Compaction shall be substantially completed before the temperature falls below the
minimum rolling temperatures.
3. Rolling of the longitudinal joints shall be done immediately behind the paving
operation.
73
 Compaction of DBM layers
4. After this, rolling shall commence at the edges and progress towards the center
longitudinally except that on super-elevated and unidirectionally cambered
portions, it shall progress from the lower to the upper edge parallel to the center line
of the pavement.
5. Rolling shall continue until all roller marks have been removed from the surface.
6. All deficiencies in the surface after laying shall be made good by the attendants
behind the paver, before initial rolling is commenced.
7. Bituminous materials shall be rolled in a longitudinal direction, with the driven
rollers nearest the paver.
8. The roller shall first compact material adjacent to joints and then work from the
lower to the upper side of the layer, overlapping on successive passes by at least
one-third of the width of the rear roll.
9. In case of a pneumatic-tyred roller, at least the nominal width of 300 mm overlap
will be required.

74
 Compaction of DBM layers

10. In portions with super-elevated and unidirectional camber, after the edge has been
rolled, the roller shall progress from the lower to the upper edge.
11. Rollers should move at a speed of not more than 5 km per hour.
12. The roller shall not be permitted to stand on pavement which has not been fully
compacted, and necessary precautions shall be taken to prevent dropping of oil,
grease, petrol! diesel or other foreign matter on the pavement either when the
rollers are operating or standing.
13. The wheels of roller machine shall be in good working order, to prevent the mix
from adhering to the Wheels.
14. Only sufficient moisture to prevent adhesion between the wheels of rollers and the
mix should be used.
15. Surplus water shall not be allowed to stand on the partially compacted pavement.

75
DBM Laying Work DLC Laying Work
76
 Section: 501.8.3.4 Profile Corrective Course

Where the maximum thickness of profile corrective course will be not more than 40 mm,
the profile corrective course shall be constructed as an integral part of the overlay course.
In other cases, the profile corrective course shall be constructed as a separate layer.

77
 SECTION: 507 Bituminous Concrete(BC)

1. This work shall consist of construction of Bituminous Concrete, for use in

wearing and profile corrective courses.
2. This work shall consist of construction in a single layer of bituminous
concrete on a previously prepared bituminous bound surface.
3. A single layer shall be 30 mm/40 mm/50 mm in thickness.

78
 Table 500-17 : Composition of Bituminous Concrete Pavement Layers

Grading Grade 1 Grade 2

Nominal aggregate size* 19 mm 13.2 mm

Layer thickness 50 mm 30-40 mm

Bitumen content % by mass of Min 5.2* Min 5.4**

total mix

79
 Special Attention on JMF

1. The nominal maximum particle size is the largest specified sieve size up on
which any of the aggregate is retained .
2. In case aggregate have specific gravity more than 2.7, the minimum bitumen
content can be reduced proportionately.
3. The region where highest daily mean air temperature is 30°C or lower and
lowest daily air temperature is - 10 °C :- The bitumen content may be increased
by 0.5 percent.

80
 SECTION: 600- CONCRETE PAVEMENT

Section: 601- Dry Lean Cement Concrete (DLC) sub-base :

1) The work shall consist of construction of (zero slump) dry lean concrete sub-base for
cement concrete pavement in accordance with the requirements of Specifications.
2) It shall be done in conformity with the lines, grades and cross-sections shown on the
drawings or as directed by the Engineer.
Required Ingredients for DLC work :
1) Cement: Any of the following types of cement may be used with prior approval of the
Engineer:
a. Ordinary Portland Cement 43 Grade
b. Portland Slag Cement
c. Portland Pozzolana Cement

81
2) Flyash Content in DLC :
1) Fly-ash up to 20 percent by weight of cementitious material (cement +flyash) may be
used along with 43/53 grade cement
2) May be used to replace OPC cement grade 43 up to 30 percent by weight of cement.
3) Use of Fly-ash shall be permitted only after ensuring that facilities exist for uniform
blending through a proper mechanical facility with automated process control like batch
mix plant.
3) Aggregates: (Coarse Aggregates and Fine Aggregates)
1) The maximum size of the coarse aggregate shall be 26.5 mm, and aggregate gradation
shall comply with Table 600-1.
2) The Fine Aggregates shall consist of clean natural sand and crushed stone sand or a
combination of the two.
3) The mix shall be proportioned with a maximum aggregate cementitious material ratio of
15:1.

82
4) Water :
1) The water content shall be adjusted to the optimum for facilitating compaction by rolling.

Moisture Content in DLC Mix :

1) 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 Engineer.
2) While laying in the main work, the lean concrete shall have a moisture content between the
optimum and optimum +2 percent, keeping in view the effectiveness of compaction achieved
and to compensate for evaporation losses.

Cement Content in DLC Mix :

Cement Content will be as per the Approved Mix Design of the particular Project. As per the
MoRTH Section 601.3.3 the Cement content will be as below :-
1) The minimum cement content shall be 150 kg/cum of concrete.
2) In case flyash is blended at site as part replacement of cement, the quantity of flyash shall not be
more than 20 percent by weight of cementitious material and
3) The content of OPC shall not be less than 120 kg/cum.
83
 Concrete Strength

1. The average compressive strength of each consecutive group of 5 cubes shall not be less
than 10 MPa at 7 days.
2. In addition, the minimum compressive strength of any individual cube shall not be less
than 7.5 MPa at 7 days.

Drainage layer

1. A drainage layer conforming to Clause 401 shall be laid above the subgrade before
laying the Dry Lean Concrete sub-base, as specified in the drawings and the Contract.
2. The Dry Lean Concrete shall be laid on the prepared granular drainage layer (DL).

84
 Placing of DLC
1. Lean concrete shall be placed by a paver with electronic sensor on the drainage layer or as
specified in the Contract.
2. The equipment shall be capable of laying the material in one layer.
3. The pace and programme of the Dry Lean Concrete sub-base construction shall be matching
suitably with the programme of construction of the Cement Concrete Pavement(PQC) over it.
4. The Dry Lean Concrete sub-base shall be overlaid with PQC only after 7 days of sub-base
construction or after achieving the strength of 7.5 MPa.
5. The Dry Lean Concrete shall be laid in such a way that it is at least 750 mm wider on each side
than the proposed width including paved shoulders of the concrete pavement.

Compaction of DLC
1. The compaction shall be carried out immediately after the material is laid and levelled.
2. In order to ensure thorough compaction, rolling shall be continued on the full width till there is
no further visible movement under the roller and the surface is well closed.
3. The minimum dry density obtained shall not be less than 98 percent of that achieved during
the trial length construction.
4. The densities achieved at the edges i.e. 0.5 m from the edge shall not be less than 96 percent of
that achieved during the trial construction.
85
 Compaction of DLC (Continue)
5. The spreading, compacting and finishing of the lean concrete shall be carried out
rapidly.
6. The time between the mixing of the first batch of concrete and the final finishing of
the same shall not exceed 90 minutes when the temperature of concrete is between
25°C and 30°C.
7. If temperature of mix is less than 25°C then final finishing can be done within 120
minutes
8. Double drum smooth-wheeled vibratory rollers of minimum 80 to 100 kN static
weight are suitable for rolling dry lean concrete.
9. Longitudinal joint in Dry Lean Concrete shall be staggered by 300-400 mm from the
longitudinal joint of concrete pavement.
10. As soon as the lean concrete surface is compacted, curing shall commence.

86
 SECTION: 602- CEMENT CONCRETE PAVEMENT (PQC)
1. The work shall consist of construction of un-reinforced, dowel jointed, plain cement
concrete pavement.
2. It shall be in conformity with the lines, grades and cross sections shown on the
drawings.
Equipment and Accessories with Terminology regarding Plain jointed rigid
pavements (PQC):-
1. Ambient Temperature- is the air temperature of an environment or weather
temperature.
2. Desired PQC Mix Temperature limit at laying site- 6°C to 30 °C.
3. No concreting shall be done when the mix temperature is more than 30°C.
4. Automatic slip form paver equipped with electronic sensor controls with independent
units designed to (i) Spread, (ii) Consolidate, (iii) screed, (iv) float finish, (v) Texture
and (vi) cure the freshly placed concrete.
5. Concrete batching plant

87
 Regarding Plain jointed rigid pavements (PQC)
6. Wheel Loader.
7. Air Compressor.
8. Dumpers.
9. Water Tanker.
10. Auto Level.
11. Concrete - Power saw cutting machine with water jet & accessories.
12. The PQC will be laid over the DLC only after 7 days or achieving 7.5 MPa strength.
13. Cleaning of DLC bed over which PQC laying has to be carried out.
14. Sprinkling of water on DLC bed.
15. Separation membrane shall be impermeable PVC sheet -125 micron thick transparent
color laid flat with minimum creases.
16. The separation membrane shall be omitted when two layers of wax-based curing
compound is used.
17. Providing protection of separation membrane during laying.
88
 Regarding Plain jointed rigid pavements (PQC)

18. Fixing of survey pegs for level, line and alignment. Use of lime powder for marking.
19. Positioning of Slip form Paver as per requirement.
20. Dowel bars in the contraction joints, construction joints and expansion joints.
21. The thickness of the sheath shall not exceed 0.5 mm and shall be tightly fitted on the
bar for at least two-thirds of the length from one end for dowel bars in
contraction/construction joints and half the length plus 50 mm for expansion joints.
22. Tie bars shall be provided in longitudinal joints.
23. Tie Bar Painting (75mm from centre on each side).
24. Water cement ratio maximum 0.4 , minimum suggested 0.36.
25. When Ordinary Portland Cement (OPC) is used the quantity of cement shall not be
less than 360 kg/cum.
26. In case flyash grade-1 is blended, the quantity of flyash shall be up to 20% maximum
by weight of cementitious (OPC Cement +Flyash) .In no case OPC shall be less than
310 kg/cum.

89
 Regarding Plain jointed rigid pavements (PQC)

27. When GGBS is blended, the quantity of GGBS shall be up to 50% maximum by weight
of cementitious (OPC Cement +GGBS) .In no case OPC shall be less than 250 kg/cum.
28. Placing of concrete.
29. Sampling of cement concrete – Minimum 6 cubes and 6 flexural beams per day works.
30. The characteristic flexural strength of concrete shall not be less than 4.5 MPa.
31. The water content shall be the minimum required to provide the agreed workability for
full compaction of the concrete.
32. The workability of the concrete at the point of placing shall be adequate. A slump value
in the range of 25 ± 15 mm is reasonable for paving works.
33. Surface finish and texturing time- shall not exceed 120 minutes. Addition of water for
surface finish shall not be permitted.
34. Surface texturing should be finished within 120 minutes from the addition of the water
to the mix.
35. The texturing shall be done by tinning in the transverse direction (i.e. at right angle to
the longitudinal axis of the road).
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 Regarding Plain jointed rigid pavements (PQC)

36. Tined grooves shall be 3 mm wide and 3 to 4 mm deep from surface.

37. The Random spacing between tines in mm i.e. 10,14,16,11,10,13,15,16,11,10,21,13,10.
38. Marking of chainage at every 100 m interval should be done by embossing.
39. Application of sprayed liquid curing membrane.
40. The surface and sides of the slab shall be cured by the application of approved resin-
based aluminized reflective curing compound
41. 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.
42. Mechanical saw cutting of joints shall be done up to the required depth from edge-to-
edge of the pavement.
43. Transverse and longitudinal joints in the PQC and DLC shall be staggered.
44. Sawing of joints shall be carried out with diamond studded blades soon after the concrete
has hardened to take the load.
45. Sawing operation could start as early as 4-8 hours after laying of concrete pavement but
not later than 8 to 12 hours.
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 Regarding Plain jointed rigid pavements (PQC)
46. Sawing operation will start depending upon the ambient temperature, wind velocity, relative
humidity and required maturity of concrete achieved for this purpose.
47. Transverse joints shall be of contraction, construction and expansion joints constructed at
the spacing described in the drawings.
47. Transverse construction joint shall be placed whenever concreting is completed after a day’s
work or is suspended for more than 30 minutes.
48. The contraction joints shall be placed transversely at pre-specified locations as per
drawings/ design using dowel bars.
49. Contraction joints shall consist of a mechanical sawn joint groove, 3 to 5 mm wide and one
fourth to one-third depth of the slab ± 5 mm. Contraction joint shall be widened
subsequently to accommodate the sealant.
50. The longitudinal joints shall be constructed by forming or by sawing.
51. The longitudinal joints may be cut after the final set of the concrete. Joints should be sawn to
at least one-third the depth of the slab ±5 mm.
52. The cutting of joints should be avoided over the deck slabs of structures rather it should be
executed with specific method out of the slab area.
53. At both ends of the culvert’s slab, a contraction joint shall be provided in the concrete
pavement.
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 Regarding Plain jointed rigid pavements (PQC)
54. 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.
55. Tie bars shall be positioned to remain in the middle from the top or within the upper middle
third of the slab depth.
56. All joints shall be sealed using sealants.
57. All grooves shall be cleaned of any dirt or loose material by air blasting with filtered, oil-free
compressed air.
58. The sides of the grooves shall be sand blasted to increase the bondage between sealant and
concrete.
59. The groove shall be cleaned and dried at the time of priming and sealing.
60. A highly compressible heat resistant paper-backed debonding strip shall be inserted in the
groove.
61. When sealants are applied, an appropriate primer shall also be used.
62. Priming and sealing with applied sealants shall not be carried out when the naturally occurring
temperature is below 7°C.
63. For large road projects, sealant shall be applied with extruder having flexible hose and nozzle.
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 Regarding Plain jointed rigid pavements (PQC)
64. The sealant shall not be heated to a temperature higher than the safe heating temperature.
65. Cold applied sealants with chemical formulation like polysulphide/polyurethane/ silicone as per
IRC:57 shall be used.
66. Sealant shall be applied, slightly to a lower level than the slab with a tolerance of 3 ± 1 mm.
67. Surface Levels and Regularity shall be checked as per MORTH clause 902.3.
68. The maximum number of permitted irregularities of pavement surface shall comply with the
requirements of Clause 902.4.
69. The actual strength of the concrete in the slab shall be ascertained by carrying out tests on cores
cut at the rate of 2 cores for every 150 cum of concrete. The average of the results of crushing
strength tests on these cores shall not be less than 0.8 x 0.85 times the corresponding
characteristic compressive strength of cubes, where the height to diameter ratio of the cores is
two.
70. Acceptance Criteria in Quality Cement Concrete Pavement slabs having cracks of severity rating
more than 2 i.e. cracks of width more than 0.5 mm for single discrete cracks, multiple and
transverse cracks and cracks of width more than 3 mm in case of longitudinal cracks and of
depth more than half of the concrete pavement slabs, shall be removed and replaced.
71. No vehicular traffic shall be allowed to ply on the finished surface of a concrete pavement within
a period of 28 days of its construction and until the joints are permanently sealed and cured.

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 Selection of Materials
A. Cement: Any of the following types of cement may be used with prior approval of the
Engineer, but preference shall be to use 43 grade or higher.
• Ordinary Portland Cement 43 Grade
• Portland Slag Cement
• Portland Pozzolana Cement
B. Flyash:-
• Flyash up to 20 percent by weight of cementitious material may be used in Ordinary
Portland cement 43 and 53 Grade as part replacement of cement provided uniform
blending with cement is ensured.
• The Portland Pozzolana Cement produced in factory shall not have flyash content more
than 20 percent by weight of cementitious material.
• Certificate from the manufacturer to this effect shall be produced before use.

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 Selection of Materials
C. Admixtures are of 2 types being used as below:-
1. Chemical Admixtures: Admixtures are manufactured chemicals which are added to
the concrete before or during mixing. The most often used admixtures are air
entraining agents, water reducers, retarders and accelerators (Reducing setting time).
Admixtures are used to give special properties to fresh concrete. Name are as:-
• Fosroc
• BASF
• Chroyso
2. Mineral Admixtures are as:-
• Fly ash
• Granulated slag
• Silica fume
D. Aggregates:
• Aggregates for pavement concrete shall be natural material with a Los Angeles Abrasion
Test value not exceeding 35 percent.
• The aggregates shall be free from chert, flint, chalcedony or other Silica in a form that can
react with the alkalies in the cement.
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 Selection of Materials
3. The maximum size of coarse aggregate shall not exceed 31.5 mm for pavement
concrete.
4. The aggregate which has water absorption more than 2 percent shall not be used in
the concrete mix.
5. The fine aggregates shall consist of clean natural sand or crushed stone sand or a
combination of the two. Fine aggregate shall be free from soft particles, clay, shale,
loam, cemented particles, mica and organic and other foreign matter.
6. The fine aggregates shall have a sand equivalent value of not less than 50.
7. 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.
E. Steel for Dowels and Tie Bars
F. Joint Filler Board
G. Joint Sealing Compound:
1. The joint sealing compound shall be of hot poured, elastomeric type
2. Shall be cold polysulphide/ polyurethane/silicone type having flexibility, resistance to
age hardening and durability.
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 Selection of Materials

Cold poured sealants shall be one of the following:

I. polysulphide
II. polyurethane
III. silicone

H. Proportioning of Concrete:
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. The mix design shall be based on the flexural strength of concrete.

98
 Selection of Materials

I. Cement Content:
It will be used as per the Mix Design of that particular Project. As per MoRTH :-

1. When Ordinary Portland Cement (OPC) is used the quantity of cement shall not be less
than 360 kg/cum.
2. In case flyash grade-I is blended at site as part replacement of cement, the quantity of
flyash shall be up to 20 percent by weight of cementitious material.
3. The quantity of OPC in such a blend shall not be less than 310 kg/cum.
4. The minimum of OPC content, in case ground granulated blast furnace slag cement
blended, shall also not be less than 310 kg/m3.

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 Workability
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.
2. The workability requirement at the batching and mixing plant and paving site shall be
established by slump tests carried during trial paving.
3. A slump value in the range of 25 ± 15 mm is reasonable for paving works.
4. The water content shall be the minimum required to provide the agreed workability for
full compaction of the concrete.
Sub-base
1. The cement concrete pavement shall be laid over the sub-base constructed in
accordance with the relevant drawings and Specifications.
2. A separation membrane shall be used between the concrete slab and the sub-base.
3. Separation membrane shall be impermeable PVC sheet 125 micron thick transparent or
white in color laid flat with minimum creases.
4. Before placing the separation membrane, the sub-base shall be swept clean of all the
extraneous materials using air compressor.
5. The separation membrane shall be omitted when two layers of wax-based curing
compound is used.
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 Providing Joints in Rigid Pavement
1. It shall be ensured that the required depth of cut is made from edge-to-edge of the
pavement.
2. Transverse and longitudinal joints in the pavement and Dry Lean Concrete sub-base shall
be staggered so that they are not coincident vertically.
3. 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 crew members without damaging
the texture of the pavement.
4. Sawing operation could start as early as 4-8 hours after laying of concrete pavement but
not later than 8 to 12 hours depending upon the ambient temperature, wind velocity,
relative humidity and required maturity of concrete achieved for this purpose.
5. Transverse joints shall be contraction, construction and expansion joints constructed at
the spacing described in the drawings.
6. Transverse joints shall be straight within the tolerances.
7. Contraction joints shall consist of a mechanical sawn joint groove, 3 to 5 mm wide and one-
fourth to one-third depth of the slab ± 5 mm or as stipulated in the drawings.
8. The expansion joint shall consist of a joint filler board and the adjacent slabs shall be
completely separated from each other by the joint filler board.
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 Providing Joints in Rigid Pavement

9. Transverse construction joint shall be placed whenever concreting is completed after a

day’s work or is suspended for more than 30 minutes.

Regarding Tie Bars

1. Tie bars shall be provided at the longitudinal joints as per dimensions and spacing
shown in the drawing.
2. The direction of the tie bars at curves shall be radial in the direction of the radius.
3. Tie bars in longitudinal joints shall be deformed steel bars of strength 500 MPa.
4. The bars shall be free from oil, dirt, loose rust and scale.
5. 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.

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 Dowel Bars
1. Dowel bars shall be mild steel rounds.
2. They shall be straight, free of irregularities and burring restricting slippage in the
concrete.
3. Dowel bars in the contraction joints, construction joints and expansion joints shall
be covered by a thin plastic sheath.
4. The thickness of the sheath shall not exceed 0.5 mm and shall be tightly fitted on the
bar for at least two-thirds of the length from one end for dowel bars in
contraction/construction joints and half the length plus 50 mm for expansion joints.
Weather and Seasonal Limitations
1. No concreting shall be done when the temperature of the concrete reaching the
paving site is above 30°C. Besides.
2. To bring down the temperature, if necessary, chilled water or ice flakes should be
made use of.
3. When the ambient temperature is more than 35°C, no concreting shall be permitted.
4. No concreting shall be done when the concrete temperature is below 5°C and the
temperature is further falling.

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 Placing of Pavement Concrete
1. The total time taken from the addition of the water to the mix, until the completion of the
surface finishing and texturing shall not exceed 120 minutes when concrete temperature
is less than 25°C and 90 minutes when the concrete temperature is between 25°C and
30°C. When the time between mixing and laying exceed these values, the concrete shall be
rejected and removed from the site.
2. Tipping trucks delivering concrete shall normally not run on plastic sheathing nor shall
they run on completed slabs until after 28 days of placing the concrete.
3. The addition of water to the surface of the concrete to facilitate the finishing operations
will not be permitted.
4. While the concrete is still plastic, its surface shall be textured by brush or tines.
5. The surface and edges of the slab shall be cured by the application of a sprayed liquid
curing membrane.
6. 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 by embossing.

104
Wrong Method of PQC Unloading Correct Method of PQC unloading

105
 Regarding Surface Texture

1. After final floating and finishing of the slab and before application of the liquid curing
membrane, the surface of concrete slabs shall be textured in the transverse direction
(i.e., at right angles to the longitudinal axis of the road).
2. The texturing shall be done by tinning the finished concrete surface by using
rectangular steel tines.
3. The tinning unit shall have facility for adjustment of the download pressure on the
tines as necessary to produce the desired finish.
4. Tined grooves shall be 3 mm wide and 3 to 4 mm deep.
5. The Centre to Centre spacing between the tines shall be 18 to 21 mm.
6. Before commencing texturing, the bleeding water, if any, shall be removed.
7. Texturing shall be done at the right time such that the grooves after forming shall not
close and they shall not get roughened.
8. Swerving of groove patterns will not be permitted.
9. The completed textured surface shall be uniform in appearance.

106
PQC Texturing Joint Cutting & Ensure Depth.

107
✓Brush Texturing: 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 center of the gap between tufts in the other row.
The brush shall be replaced when the shortest tuft wears down to 90 mm long.

Curing:
1. Immediately after the surface texturing, the surface and sides of the slab shall be cured
by the application of approved resin-based aluminized reflective curing compound
which hardens into an impervious film or membrane with the help of mechanical
sprayer.
2. 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.

Strength: Compressive and flexural strength shall be tested after 28 days water curing in
the laboratory.

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 Flexural Strength of Pavement Concrete

1. It is the ability of a beam or slab to resist failure in bending.

2. It is measured by load unreinforced 150 x 150 mm concrete beams with a span three
times the depth usually 450 mm.
3. The flexure strength is expressed as modulus of rapture (MR) in MPa. Flexural strength is
about 12 to 20% of compressive strength.
4. The flexural strength test results shall prevail over compressive strength for compliance.

109
 SECTION: 900-QUALITY CONTROL FOR ROAD WORKS

Table 900-1 : Tolerances in Surface Levels

1) Subgrade ±20mm

2) Sub-base
a) Flexible pavement (GSB+WMM) ±10mm
b) Dry Lean Concrete Pavement (DLC) ±6mm

3) Base-course for flexible pavement

a) Bituminous Base/Binder course (DBM) ±6mm

4) Wearing course for flexible pavement (BC) ±6mm

5) Cement Concrete Pavement (PQC) ±5mm

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 QUALITY CONTROL FOR ROAD TOP SURFACE

✓For checking the compliance with the above requirement for bituminous wearing
courses and concrete pavements, measurements of the surface levels shall be taken on
a grid of points spaced at 6.25 m along the length and at 0.5 m from the edges and at
the center of the pavement. Straight edge, Wedge, Spirit level are required to execute
these items of checking.

✓The longitudinal profile shall be checked with a 3 metre long straight edge/moving
straightedge as directed by the Engineer at the middle of each traffic lane along a line
parallel to the center line of the road.

✓The riding quality of bituminous concrete wearing surface, as measured by a standard

towed fifth wheel bump integrator, shall not be more than 2000 mm per Km.

111
 TESTS ON COMPLETION
The Concessionaire/Contractor shall, no later than 30 (thirty) days prior to the likely
completion of the Project, notify the Authority's Engineer/ Independent Engineer and the
Authority of its intent to subject the Project of Tests, and no later than 7/10 days prior to the
actual date of Tests, furnish to the Authority's Engineer/Independent Engineer and the
Authority detailed inventory and particulars of all works and equipment forming part of the
Project.
In pursuance of the provision of Clause of this Agreement, the Authority's Engineer/
Independent Engineer shall conduct, or cause to be conducted, the Tests specified in this
Paragraph. The Tests may be as below:-
• Visual & physical test
• Test drive
• Riding quality test
• Pavement composition Test
• Cross-Section Test
• Structural Test for bridges
• Other tests like:- Environmental Audit , Safety Audit
112
 General Quantity of steel Assumptions By Prof. B. N. Dutta

Sr.
No. Description Percentage

1 Slab 1.0% of total volume of concrete (78.5 Kg/Cum of Concrete)

2 Beam 2.0% of total volume of concrete (157 Kg/Cum of Concrete)

3 Column 5.0% of total volume of concrete (393 Kg/Cum of Concrete)

4 Footing 0.8% of total volume of concrete (63 Kg/Cum of Concrete)

113
 Some More Definitions and Interpretation

Grade separated structures

1) The structure through which the traffic flows at different levels are called grade
separated structures.

2) The grade separated structure which is provided for crossing the vehicles under the
Projects Expressway is called as Vehicular Underpass (VUP).

3) The grade separated structure which is provided for crossing the vehicles over the
Projects Expressway is called as Vehicular Overpass (VOP).

4) A structure provided below the Project Expressway for crossing of the pedestrians is
called Pedestrian Underpass (PUP).

5) A structure provided below the Project Expressway for crossing of the cattle is called
Cattle Underpass (CUP).

114
 Some More Definitions and Interpretation

6) A pedestrian/cattle underpasses through which light vehicles of height up to 3 m can

also pass is called Light Vehicular Underpass (LVUP).

7) Flyover is synonymous to VUP/VOP.

8) A structure provided above the Project Expressway for crossing of pedestrians is

called Foot Over Bridge (FOB).

9) A structure provided over the railway lines to carry the Project Expressway is called
Road Over Bridge (ROB).

10) A structure provided below the railway lines to carry the Project Expressway is called
Road Under Bridge (RUB).

115
 VUP PUP

CUP
LVUP

116
 FOB

VOP

ROB
RUB

117
Thanks to our Director and CEO “Mr. Devendra Jain Sir”
for providing the opportunity to get this prepared.

THANKS TO ALL OF YOU FOR BEING WITH US.

DILIP BUILDCON LIMITED, BHOPAL

Prepared on 10th August-2020