SPECIFICATION

Unit 5 Specification
Definition :
 A specification is a specific description of a particular subject.
 An engineering specification contains detailed description of all workmanship and
materials which are required to complete an engineering project in accordance with its
drawings and details.
 The technical drawings of a structure will show the proportions and relative positions
of the various component of the structure.
 It is not possible to furnish the information on the drawings, regarding the quality of
materials to be used and the quality of workmanship to be achieved during
construction, due to shortage of space.
 This data regarding the materials and workmanship is conveyed in a separate contract
document which is known as the’ specification’ for the work.

Purpose of specification :
(i) The specification clearly illustrate the quality of the materials, the workmanship
desired and the method of doing work. This enables the contractor to quote the correct
rates for the works.
(ii) As the specification give detailed information regarding the materials and the
workmanship, it serves as a guide to the contractor as well as to the supervising staff,
during the construction and execution of the work.
(iii) The specification protect the interest of the owner against low quality materials or bad
workmanship, at the same time it provides freedom to the contractors for turning out
or constructing the satisfactory structures.
(iv) As the specifications give details regarding the quality of the materials, the contractor
can arrange the same in time and complete the work within scheduled time.
(v) As the cost of work directly depends on its specifications, the specifications give
correct idea about the estimated cost, and funds can be arranged accordingly.

Necessity of specification :
(i) The cost of an unit quantity is governed by its specification.
(ii) Specifications of a work are required to describe the quality and quantity of different
materials required for a construction work .Thus a contractor can make a programme
to procure the materials required for a project and the owner can check the quality of
materials conforming to the specification avoiding dispute with contractor.
(iii) This also specifies the workmanship and the method of doing work. Thus
specification of a work serves as a guide to the supervising staff of the contractor as
well as to the owner to execute the work .

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(iv) A work is carried out according to its specification and the contractor is paid for the
same. Any change in specification changes the tendered rate.
(v) As the rate of work is based on specification, a contractor can calculate the rates of
various items of works in a tender with his procurement rates of materials and labour.
Thus tender paper without specification of works is baseless, incomplete and invalid.
(vi) Specification is necessary to specify the equipments, tools and plants to be engaged
for work and thus enables to procure them beforehand.
(vii) The necessity of specification is to verify and check the strength of materials for a
work involved in a project.
(viii) Specification is an essential contract document and is required for Arbitration or court
cases.

Technique of specification :
While writing specification the following principles shall be adopted:
(a) Description of materials : The quality and size of materials required to do an item of
work shall be fully described for checking up at site according to the bindings
provided in the specification. The proportion of mixing or treatment of materials if
required before use shall be clearly described.
(b) Workmanship : Complete description of workmanship, the method of mixing to the
proportion, the method of laying, preparation of base or surface, compaction, finishing
and curing, etc. specially applicable to the item of work shall be clearly stated in
different clauses.
(c) Tools and plants ( T.&P.) : The tools and plants to be engaged to carry out a work
shall be described. The method of operation and by whom to be supplied shall be
stated.
(d) Protection of new work : The method of protection of new works against damage or
the method of curing if required, the test of completed work if necessary shall be
described in separate clauses.
(e) Expression : While writing specification, the requirements of the specification shall
be expressed clearly and in concise form avoiding repetition and unusual words. The
style of tense shall remain same throughout. The sentences shall be short, simple and
concise. As the specifications are the legal documents, terms such as suitable, proper
used and words having more than one meaning shall be avoided.
(f) Clauses of specification : As far as possible, the clauses shall be arranged in the order
in which work shall be carried out. While framing clauses for quality of materials,
workmanship, tools and plants, etc. practical possibilities shall be realised. Correct
and complete but not repeated information shall be given so that the owner and the
contractor can carry out the work following the specification.

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Types of specification :
The specifications are broadly divided into two types :-
(a) General specification (b) Detailed specification
(a) General specification :-
 In general specification , nature and class of works, names of materials and
proportion that should be used in the various items of works are described.
 Only a brief description of each and every item is given.
 It is useful for estimating the project.
 They do not form part of contract document.

(b) Detailed specification : - The detailed specification describes the item of work in
details accurately and complete in all respects in relation to the drawings of the
works.
Usually following details are given in the detailed specification :
1. Qualities and Quantities of the materials.
2. Method of measuring quantities of materials.
3. Precautions to be observed in transporting and handling of the materials.
4. Proportion of the mortar and concrete.
5. Shuttering and centering details.
6. Method of mixing mortars and concrete.
7. Methods of laying concrete or mortars.
8. Various tests to be conducted at various stages of the work.
9. Curing methods.
10. Methods of doing the work and workmanship.
11. Methods of execution.
12. Methods of measurement.
13. General precautions.
14. Details of works which are included in the rate, etc.

Standard specification :-
Detailed specifications for different works are drawn up by an engineering department
and printed to serve as a standard guide to the department and also to refer it in the
specification part of a tender paper to avoid writing the lengthy specifications. Thus,
standard specifications save valuable time, labour, stationery expenditure and above
all eliminates the scope of deviations and mistakes during preparation of huge number
of tender papers through a Divisional office.

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For example , specifications for earthwork, concrete works, brick work,etc. are
commonly required for different works. The specifications for these common works
become the same. So, it is not necessary to write such common specifications
repeatedly in the specification part of a tender paper, Instead of writing such
specifications they are referred to the departmental standard specification.
The departmental specifications may be revised periodically according to the
development of technology.

Special specification : -
Some items that are not covered or works not well covered by the departmental
standard specification, special specifications for such items are drawn up by the
Engineer-in-Charge, approved and included in the tender paper under a heading ‘
special specification’.

Open specifications or manufacturers specifications :-

 Open specifications are specifications of products of manufacturers which state both
physical and chemical properties and such other informations of the product, but not
description of workmanship to be achieved during construction.
 The physical properties specify mainly the strength, weight, thickness or size and such
other physical properties of the product.
 The chemical properties specify mainly the composition of chemical contents of the
product and precautionary measures if any required for storing the product.

Restricted specifications :-
o In restricted specification, the material for an item of work is described and the
procurement among some approved manufacturers or brands of the material is
restricted.
o Thus the standard of materials such as for plumbing, painting, fittings, etc. are
assured to be of a certain degree of quality up to the satisfaction of the owner.
o The materials of the approved manufacturers should be equivalent in quality
and more or less as per cost.
o To provide restricted specification for materials an up-to-date knowledge of
the market for the qualities and cost of different manufacturers is essential.
o Such time to time market study encourages competition among the
manufacturers to improve the quality of their products with competitive rates
in order to be included in the approved list of the restricted specification.

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General specification of First class building :-

(a) Foundation and plinth : Brickwork in foundation and plinth shall be of first class brick
in cement or lime mortar over cement or lime concrete.
(b) Filling : Foundation trenches and plinth shall be filled up with local sand.
(c) Damp-proof course : D.P.C. shall be 2.5 cm thick cement concrete or 2 cm thick
cement mortar with 5% pudlo by weight of cement or other standard water-proofing
materials.
(d) Superstructure : Superstructure shall be of first class brickwork in cement mortar.
(e) Roofing : The roof shall be 10cm thick R.C.C. slab with 10cm average thick lime
terracing over it.
(f) Flooring : Mosaic flooring shall be provided in all the floors including staircase.
(g) Finishing : Inside and outside shall be 12mm thick cement plastered. The inside of
drawing, dining and bedrooms shall be distempered and remaining portions white-
washed three coats. The outside shall be two coats decorative waterproof cement
coating.
Wall surface of lavatory shall be covered with glazed tiles up to the top level of door.
(h) Doors and windows : Doors and windows frames shall be of seasoned teak wood and
shutters of 3cm thick teak wood panelling. Brass fittings shall be provided. Doors and
windows shall be varnished with French polish.
(i) Miscellaneous : Rain water pipes shall be of Asbestos cement or cast-iron, finished
with paint. All sanitary, water supply and electrical fittings shall be of first class
materials.

General specification of a second class building :-

(a) Foundation and plinth : The brickwork in foundation and plinth shall be of first
class
brick with lime mortar over lime concrete.
(b) Filling : Foundation trenches and plinth shall be filled up with earth.
(c) Damp-proof course : D.P.C. shall be 2cm thick cement mortar with 5% pudlo by
weight of cement or other standard water-proofing materials.
(d) Superstructure : Superstructure shall be of second class brick work in mud mortar.
(e) Roofing : The roof shall be flat terraced roof or R.B. roof.
(f) Flooring : The flooring shall be 2.5cm cement concrete over 7.5 cm lime concrete.
(g) Finishing : The inside walls shall be plastered with lime or cement mortar, outside
walls shall be pointed or plastered with lime or cement mortar. Inside shall be
white washed three coats, and other outside colour-washed two coats over one
coat of white-wash.

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(h) Doors and windows : Doors and windows frame shall be of seasoned teak wood
and shutters of 4.5cm shisham or deodar wood, panelled. They shall be fitted with
iron fittings. Doors and windows shall be painted with two coats.
(i) Miscellaneous : Rain water pipes shall be cast-iron. Electrification, sanitary and
water supply fittings shall be of class B-type.

Detailed specification :
(A) Building works :

(i) Earthwork in excavation of foundation trenches :-

1) Before the earthwork is started, the whole area where the work is to be done shall be
cleared of grass, roots of trees and other organic matter.
2) The excavation shall be carried out exactly in accordance with the dimension shown on
the drawings or such other dimensions as the Engineer-in-charge may decide.
3) Sides of the trenches shall be vertical and its bottom shall be perfectly levelled, both
longitudinally and transversely. Where the soil is soft, loose or slushly the trench shall be widened
for allowing steps on either side or the sides sloped or shored up.

4) During excavation if rocks or rocky soils are found those shall be levelled as far as possible and
small spaces which are difficult to level shall be filled in with concrete.

5) If the excavation is in earth, the bottom of the trenches shall be sprinkle with a little water and
rammed. Any excess digging or any patches of bad soil or hollows shall be removed by placing
concrete or shall be subject to any other special treatment as the Engineer-in-charge decides.

6) No material excavated from foundation trenches, shall be placed nearer than one metre to the
outer edges of the excavation.

7) Water in trenches must be bailed or pumped out and where it is apprehended that the sides may
fall down arrangement shall be made for adequate timber shoring.

8) When it is specified that the work is to be carried out without removing pipes, cables, sewers, etc.
all of them shall be temporarily shored and saved from any damage.

9) The materials or valuables found during excavation shall be the property of the Government.

10) The cost of all materials and labour required for fencing in and protection against risk of
accidents due to open excavation shall be provided.

ii) Earthwork in filling :-

(a) Earth : Earth used for filling shall be loose, free from brick-bat, stone, boulder not larger than
75mm in any direction, salts, organic or other foreign matter. Normally excavated earth from
the same area shall be used for filling. However, if such earth contains deleterious materials,
salt-petre earth, etc. the same shall not be used.

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(b) Filling : The spaces around the foundation, pipes and drains in trenches shall be cleared of all
debris, brick-bats, etc. The filling shall be done in layers, not exceeding 20 cm each layer.
Each layer shall be watered, rammed and consolidated before the succeeding one is laid. Earth
shall be rammed with iron rammers where feasible and with the bull-ends of crow bars where
rammer cannot be used. Special care shall be taken that no damage is caused to the pipes,
drains and masonry in the trenches below. In case of filling under floors the finished level of
filling shall be kept sloping, as intended to be given to the floor.

Plain Cement Concrete :-

(a) Materials : (i) Coarse aggregate : It shall be crushed or broken from hard stone obtained from
approved quarry.
o It shall be hard, strong, dense and durable, clean and free from soft friable, thin, flat,
elongated or laminated, flaky pieces and shall be roughly cubical in shape.
o Coarse aggregate may be gravel, may either be river bed shingle or pit gravel. It shall
be sound, hard, clean suitably graded in size.
o Unless specially mentioned the size of the coarse aggregate shall be 20 mm graded
down and shall be retained in a 5mm square mesh so that the voids do not exceed
42%.
o In the case of road or mass concrete work bigger size 40 to 60 mm may be specified.
(ii) Fine aggregate : Aggregate most of which passes 4.75 mm IS sieve is known as fine
aggregate. Sand as fine aggregate shall be coarse, consisting of sharp, angular grains and be
of standard specification. It shall be clean and free from dust, dirt and organic matters. Sea
sand shall not be used. Crushed dust stone may also be used as fine aggregate.
(iii) Cement : Cement shall be fresh Portland cement.
(iv) Water : Water used shall be clean and reasonably free from injurious quantities of
deleterious materials such as oils, acids, alkalies, salts and vegetable growth. Generally
potable water shall be used.

(b) Proportioning : Proportion of cement, sand and coarse aggregate shall be 1:2:4 or as
specified.
o Coarse aggregate and sand shall be measured by measuring box of 30 cm x 30 cm x
38 cm or of suitable size equivalent to the content of one bag of cement of 1/30 cum
or 0.035 cum. Cement shall be measured by bag weighing 50 kg. Sand shall be
measured on the basis of dry volume. In case of damp sand, the bulkage shall be
determined at site and the extra quantity of sand so determined shall be added.
o No extra quantity shall be permitted unless bulkage is determined. As the bulking of
sand vary from day to day and at different parts of the day on account of varying
moisture content, frequent tests for bulking shall be carried out with the sand to be
used.
o While measuring the aggregate, shaking, ramming or hammering shall not be done.

( C) Mixing : (1) Hand mixing : Hand mixing by batches shall be permitted on small works.
Normally all structural concrete shall be mixed in mixer machine.

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 Mixing by hand shall be employed only in special cases with the specific prior
permission of the Engineer in charge.
 The mixing shall be done on a clean water tight masonry or concrete slab or steel
plate platform.
 Measured quantity of sand shall be spread evenly. The cement shall be dumped on the
sand and distributed evenly.
 The sand and cement shall be mixed thoroughly with spade, turning the mixture over
and over again, until it is of even colour through out and free from streaks.
 The measured quantity of coarse aggregate shall be spread out and the sand cement
mixture shall be spread on its top.
 This shall be mixed at least three times by shoveling and turning over by twist from
centre to side, then back to the centre and again to the sides.
 A hollow shall be made in the middle of the mixed pile. Three quarters of the total
quantity of water required shall be added while the material is turned in towards the
centre with spades. The remaining water shall be added by a water can fitted with
rose head, slowly turning the whole mixture over and over again until a uniform
colour and consistency is obtained through out the pile.
 The mixing platform shall be washed at the end of the day.

(2) Machine mixing : The mixer drum shall be flushed clean with water. Measured quantity of
dry coarse aggregate shall be placed first in the hopper.
o This shall be followed with measured quantity of fine aggregate and then cement. In
case, damp sand is used, add half of the quantity of coarse aggregate followed by
cement and sand. Finally add balance quantity of the coarse aggregate.
o The dry materials shall be mixed in the mixing drum for at least four turns of the
drum, after which the correct quantity of water shall be added gradually while the
drum is in motion, to ensure even distribution with the dry materials.
o The total quantity of water for mixing shall be introduced before 25 per. of the
mixing time has elapsed and shall be regulated to achieve the specific water cement
ratio.
o The mixing shall be thorough to have a plastic mix of uniform colour. The complete
contents of the mixed concrete shall be emptied before recharging.
o When the mixer is closed down for the day or for any time exceeding 20 min., the
drum shall be flushed clean.

Mixing time : The materials shall be mixed in a drum for a period of not less than 2 min. and
until a uniform colour and consistency are obtained. The time shall be counted from the
moment all the materials have been put into the drum.

(D) Consistency : The quantity of water to be used for each mix of 50 Kg cement to give the
required consistency shall be taken as per IS 456 :2000 . The quantity of water shall be
regulated by carrying out regular slump test.

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Table 7.3: Proportions for nominal mix concrete

Total quantity of aggregates by mass Quantity of

per 50 kg of cement, to be taken as the water per 50 kg Proportion of fine
Grade of
S.N. sum of the individual masses of fine of cement aggregate to coarse
concrete
and coarse aggregates (Maximum) in (maximum) in aggregate (By mass)
kg litres

1 M5 800 60

2 M 7.5 625 45
Generally 1 : 2 but
subject to an upper limit
3 M 10 480 34
of 1 : 1.5 and a lower
limit of 1 : 2.5
4 M 15 350 32

5 M 20 250 30

(E) Laying : The entire concrete used in the work shall be laid gently ( not thrown) in layers not
exceeding 15 cm and shall be thoroughly vibrated by means of mechanical vibrators till a
dense concrete is obtained.
o Compaction can be hand compaction or vibrator depending upon the thickness of the
member and feasibility of vibrator done under the supervision of Engineer – in –
charge.
o Hand compaction shall be done with the help of punning rods and tamping with
wooden tampers so that concrete is thoroughly compacted and completely worked
into the corners of the formwork.
o The layers of concrete shall be so placed that the bottom layer does not finally set
before the top layer is placed.
o Compaction shall be completed before the initial setting starts i.e. within 30 min. of
addition of water to the dry mixture.
o During cold weather casting of concrete shall not be done when the temperature falls
below 4.5ºC .
o During hot weather precautions shall be taken to see that the temperature of wet
concrete does not exceed 38ºC.
o Concrete shall not be deposited under water. Where found necessary to deposit any
concrete under water, the method and equipment shall first be approved by engineer-
in-charge.
o Concrete shall be deposited continuously until it is brought to required height; while
depositing, the top surface shall be kept as nearly level as possible and the formation
of seams shall be avoided.

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o The concrete shall be deposited under water by one of the approved methods such as
Tremie method, Drop and bottom bucket, bags, etc.
o When the placing of concrete is suspended, or resumed on the following day,
necessary roughening of the surface for joining future work shall be done before the
concrete sets.
o When the work is resumed the previous work must be thoroughly cleaned,
roughened, watered and a grout of neat cement slurry of the proportion, 1 Kg of
cement per 2 litres of water applied uniformly.

(F) Protection and curing : Freshly laid concrete shall be protected from rain by suitable
covering. The work should be protected from damage and rain during construction.
o After the concrete has begun to harden i.e. about 1 to 2 hours after its laying, it shall
be protected with moist gunny bags, sand or any other material approved by the
Engineer-in-charge against quick drying.
o After 24 hours of laying of concrete the surface shall be cured by flooding with water
of about 25 mm depth or by covering with wet absorbent materials.
o The curing shall be done for a minimum period of 14 days.
o Over the foundation concrete, the masonry work may be started after 48 hours of its
laying, but the curing of cement concrete shall be continued along –with the masonry
work for a minimum period of 14 days.
o In case of cement concrete used as sub-grade for flooring, the flooring may be
commenced before the curing period of sub-grade is over but the curing of sub-grade
shall be continued along with the top layer of flooring for a minimum period of 14
days.
o The water used for curing shall not produce any objectionable stains or unsighty
deposit on concrete surface.
(G) Form work : If centering and shuttering are required to be done for this work these shall be
done in accordance with the specification for form work under Reinforced Cement Concrete.

iv) Steel reinforcement : -

(a) Steel reinforcement : Reinforcement shall be conforming to the I.S. code , shall be clean and free
from loose mill scales, dust, loose rust, coats of paints, oil or other coatings which may destroy or
reduce bond. It shall be stored in such a way as to avoid distortion and to prevent deterioration and
corrosion.

(b) Bending and overlapping : Bars shall be bent cold, correctly and accurately to the size and shape
as shown on the detailed drawings or as directed by the Engineer-in-charge.

o Preferably bars of full length shall be used. Overlapping of bars, where necessary , shall be
done by the Engineer-in-charge.
o The overlapping bars shall not touch each other and these shall be kept apart by 25 mm or
114 times the maximum size of the coarse aggregate whichever is greater, with concrete
between them.

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o But where this cannot be done, the overlapping bars shall be bound together at intervals
not exceeding twice the diameter of such bars with two strands of annealed steel wire of
0.9 mm to 1.6 mm thickness twisted tight.
o The overlaps shall be staggered for different bars and located at points, along span, where
neither shear nor bending moment is maximum.
o In case of mild steel the ends of rods shall be bent into semi-circular hooks, having clear
diameter equal to four times the diameter of the bar, with a length beyond the bend equal
to four times the diameter of the bar. In case of deformed bars, the hooks are not required.
o Wherever facility is available, welding of bars shall be resorted. The location and type of
welding shall be approved by the Engineer-in-charge.
(H) Placing in position : Reinforcement bars shall be placed in position as shown in the drawings.
o The bars crossing one another shall be tied together at every intersection with two
strands of annealed steel wire 0.9 to 1.6 mm diameter twisted tight to make the
skeleton of the steel work rigid so that the reinforcement does not get displaced doing
the deposition of concrete.
o Tack welding shall also be permitted in lieu of binding with steel wire if approved by
Engineer-in-charge.

The reinforcement bars shall be kept in position by the following methods :-

(i) In case of columns and walls, the vertical bars shall be kept in position by means of timber
templates with slots accurately cut in them, or with block cement mortar ( 1:2) suitably tied to
the reinforcement.

(ii) In case of R.C.C. beams and slab construction, precast cover blocks in cement mortar 1:2,
about 4x4 cm section and of thickness equal to the specified cover shall be placed between the
bars and shutterings so as to secure and maintain the requisite cover of concrete over
reinforcement.

(iii) In case of cantilevered and double reinforced beams or slabs the vertical distance between the
horizontal bars shall be maintained by introducing chain spacers or support bars of steel at 1.0
m or at shorter spacing to avoid sagging.

(iv) In case of other R.C.C. structure such as arches, domes, etc. cover blocks, spacers and
templates shall be used as directed.

v) Form work : - Form work shall include all forms or moulds required for forming the concrete
which is cast-in-situ, together with all temporary construction required for their support.

(a) Materials for form work : Form work shall be of ply wood or steel approved by the Engineer-
in-charge.

o Timber used for form work shall be easily workable with nails without splitting and of
light weight.
o It shall be stiff and strong enough to avoid undue deflection when loaded and not liable
to warp when exposed to sun and rain or wetted during casting of concrete.

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o Form work shall be rigid construction true to shape and dimensions shown on
drawings.
o It shall be strong enough to withstand the dead and live loads and forces caused by
ramming and vibrations of concrete and other incidental loads imposed upon it during
and after casting of concrete. It shall be made sufficiently rigid by using adequate
number of braces and ties.
o To make up any settlement in the form work either before or during the placing of
concrete, hard wood wedges shall be provided where required.
o All form work shall be so constructed as to be removed in sections in the desired
sequence, without damaging the surface of concrete or disturbing other sections.
o Forms should be easy to strip after connecting and no piece should be keyed into the
concrete. The completed form work shall be approved after inspection by the Engineer-
in-charge before the reinforcement bars are placed in position.

(vi) First class Brick work : -

(a) Materials : Bricks shall be first class of standard specification, regular in shape and size with
sharp edges and corners. They shall emit a clear ringing sound on being struck.
o They shall be of uniform deep red or copper colour, free from cracks, chips,
efflorescence, flaws and lumps of any kind.
o Dry bricks shall not absorb more than 20 % of their weight when immersed in water
for 24 hours. Bricks shall have an average compressive strength of not less than 100
kg per sq cm and not more than 125 kg per sq cm.
o For cement mortar, cement shall be fresh Portland cement of standard quality.
o Sand shall be medium coarse sand, clean, sharp and free from clay, mica or organic
matter. For lime mortar, lime shall be slaked and fresh stone-lime screened at work
site conforming to standard specification.
o Surki shall be made from first class brick having uniform colour and free from
admixture of foreign matter.
o Water used shall be clean and reasonably free from oils, acids, alkalies, salts and
vegetable growth. Generally potable water shall be used.
(b) Mortar : The brick work shall be done with the specified mortar ( cement or lime ) mixing the
ingredients in the specified proportion.
o In the case of cement mortar, the unit of measurement for cement shall be a bag of
cement and shall be taken as 0.035 cu m.
o Sand in specified proportion shall be measured in boxes of suitable size 35x25x40
cm. Sand shall be measured on the basis of its dry volume.
o In case of damp sand, its quantity shall be increased suitably to allow for bulkage.
o Materials for mortar shall be first mixed dry till of uniform colour on a solid clean
water tight platform and then mixed wet at least three times by adding water
gradually and evenly to have a workable consistency of a stiff paste.
o Only the quantity of cement mortar which can be used with in 30 min. shall be
prepared at a time. In case of lime mortar, it shall be used on the day it is made.

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(c) Soaking of Bricks : All bricks shall be thoroughly soaked in water by submerging them in
clean water for at least four hours just before use. The wetted bricks shall be stacked on a
clean platform to avoid any contact with mud.
(d) Laying : The brick laying shall be of English bond unless specially mentioned.
o A Layer of mortar shall be spread on full width over a suitable length of the lower
course. Each brick shall be properly bedded with frog upward and set home (in
position ) by gently tapping with handle of trowel or wooden mallet.
o Its inside faces shall be buttered with mortar before the next brick is laid and pressed
against it.
o On completion of a course, all vertical joints shall be fully filled from the top with
mortar. Half, or cut bricks shall not be used except where necessary to complete the
bond.
o No damaged or broken bricks shall be used.
o Closers in such cases, shall be cut to the required size and used near the ends of the
walls. In exposed brick work, selected bricks of the specified class shall be used for
the face work.
o The brick work shall be true to line, plumb and all vertical joints shall be truely
vertical.
o Vertical joints in alternate courses shall come directly one over the other.
o Thickness of brick course shall be kept uniform. All connected brick work shall be
carried up simultaneously and no proportion of work shall be left more than one
metre below the rest of the work.
o Where this is not possible, in the opinion of the Engineer-in-charge, the work shall be
raked back according to bond ( and not toothed) at an angle not steeper than 45°.
o The work done per day should be more than one metre height.
o All iron fixtures, pipes, outlets of water, hold fasts of doors and windows, which are
required to be built into the walls shall be embedded in mortar or cement concrete as
specified in their correct position as per direction, as the work proceeds.
(e) Joints : Brick shall be so laid that all joints are full of mortar. The thickness of joints shall not
exceed 1.0 cm. All face joint shall be raked to a minimum depth of 15 mm by raking tool
during the progress of work when the mortar is still green ( fresh ) so as to provide proper key
for plastering or pointing to be done. The face of the brick work shall be cleaned on the same
day on which brick work is laid and all mortar droppings removed promptly.
(f) Brick Coping : The top courses of all plinth, parapet, steps and top wall below R.C.C. shall
be laid with brick on edges unless specified otherwise.
(g) Curing : Brick work shall be protected from rain by suitable covering when the mortar is
green. Masonry work in cement mortar or lime mortar shall be kept constantly moist on all
faces for a minimum period of seven days.
Brick work carried out during the day shall be suitably marked indicating the date on which
the work is done so as to keep a watch on the curing period.
(h) Scaffolding : For all exposed brick work, double scaffolding having two sets of vertical
supports shall be provided.

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o The supports shall be sound and strong, tied together with horizontal pieces over
which scaffolding planks shall be fixed. For all other brick work in buildings, single
scaffolding shall be permitted.
o In such cases, the inner end of the horizontal scaffolding pole shall rest in a hole
provided only in the header course for the purpose.
o Only one header for each pole shall be left out. Such holes for scaffolding shall,
however, not be allowed in pillars or columns less than one metre in width.
o The holes left in masonry works for scaffolding purposes shall be filled and made
good before plastering.

(vi) Half brick thick partition wall in cement mortar :-

(a) Brick work : Bricks shall be first class and the proportion of cement mortar shall be 1:3(
cement : sand ) The brick work shall be done in the same manner as brick work in cement
mortar except that all courses shall be laid with stretchers and between the main and partition
walls there shall be ‘T’ junctions at each end.
For ‘T’ junctions alternate layers of bricks of partition wall shall be entered by half brick
depth in the adjoining walls.
(b) Reinforcement : Expanded metal mesh or black iron wire net as specified shall be provided at
every alternate or third layer as required.
Flat bars of section about 25 mmx2 mm may be used as hoop iron reinforcement for walls
where specially mentioned. In such case they shall be hooked at corners and junctions.
Before laying the iron band half the mortar for the joint shall first be laid and other half laid
after the iron band is placed in position and stretched up to the full length of the wall.
Care must be taken that the iron band is fully embedded in mortar. The height of the brick
work shall not be carried out to more than 1.2 m height at a time.
(c) Curing : The curing shall be done in the same manner as brick work for the main walls.

(vii) Random Rubble Stone Masonry : -

(a) Stone : Stone shall be of the type specified. It shall be hard, sound, free from decay,
weathering and defects like cavities, cracks, flaws, sand holes, veins patches of soft or
loose materials, etc.
It shall be obtained from an approved quarry. Where required by Engineer-in-charge the
stone shall be got tested for water absorption test as per IS:1124-1974. Stone with round
surfaces shall not be used.
(b) Size of stone : Normally stones used should be small enough to be lifted and placed by
hand. The length of the stone shall not exceed three times the height, and the breadth on
base shall not be greater than three-fourth the thickness of wall nor less than 15 cm.
The height of the stone may be up to 30 cm.
(c) Dressing : The stone shall be hammer dressed on the face , the sides and the beds, to enable
it to come into close proximity with the neighbouring stone.
The ‘ bushing’ in the face shall not project more than 4cm on an exposed face, and one cm
on a face, which is to be plastered.

14 | P a g e
 SPECIFICATION

(d) Mortar : The ingredients of mortar, cement and sand or lime and surki shall be first mixed
dry in the specified proportion till of uniform colour on a solid clean platform and then
mixed wet at least three times by adding water gradually and evenly.
(e) Laying : All the stones shall be washed and wetted before use, to remove dust,etc.
o The walls shall be carried up truly to plumb or to the specified batter.
o Every stone shall be carefully fitted to the adjacent stones, so as to form neat and
close joints. Stone may be brought to level courses at plinth , window sill, and roof
level. Levelling up at plinth level, window sills and roof level shall be done with
concrete comprising of one part of the mortar as used for the masonry and two
parts of graded stone aggregate of 50 mm nominal size and shall be included in the
items.
o The bond shall be obtained by fitting in closely, the adjacent stones and by using
bond-stones.
o Face stones shall extend and bond well into the backing. These shall be arranged to
break joints as much as possible, and to avoid long vertical joint lives.
o The hearting shall be done with rubble stones which may be of any shape but shall
not pass through a circular ring of 15 cm inner diameter.
o The thickness of these stones in any direction shall not be less than 10 cm. The
stones shall be carefully laid, hammered down with a wooden mallet into position
and properly bedded in mortar.
o Wherever necessary stone chips and spawls may be used to avoid thick mortar
beds or joints and at the same time ensuring that no hollow spaces are left
anywhere in the masonry.
o The hearting shall be laid nearly level with faulting and backing, except that at
about one metre intervals, vertical ‘ Plumb’ projecting about 15 cm to 20 cm shall
be firmly embedded to form a bond between successive courses.
o No chips shall be used below the hearting stone to bring these upto the level of face
stones. The use of chips shall be restricted to the filling of interstices between the
adjacent stones in hearting, and these shall not exceed 20% of the quantity of stone
masonry.
o The masonry work in the structure shall be carried regularly. Where the masonry of
one part has to be delayed, the work shall be raked back at an angle not exceeding
45°.
(f) Bond stones : Bond or through stones running right through the thickness of walls, shall be
provided in walls upto 60 cm thick and in case of walls more than 60 cm thickness , a set of
two or more bond stones overlapping each other by at least 15 cm shall be provided in a
line form face to back.
o In case of highly absorbent stones the bond shall extend about two-third into the
wall. Through stones in such cases may give rise to damp penetration, therefore for
all thickness of such walls, a set of two or more bond stones overlapping each other
by at least 15 cm shall be provided.

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 SPECIFICATION

o In case the bond stones of suitable lengths are not available cement concrete blocks
of 1:3:6 mix ( cement : coarse sand : graded stone aggregate of 30 mm nominal
size) conforming to the specified sizes shall be used.
o For every 0.5 sq m of the wall surface at least one bond stone shall be provided. All
the bond stones in the stone masonry shall be marked suitably as directed by the
Engineer-in-charge.
(g) Quions : The quions shall be of selected stones which shall be neatly dressed with the
hammer or chisel to form the required angle, and laid header and stretcher alternately.
(h) Joints : Stone masonry shall be so laid that all joints are fully packed with mortar and chips.
All the face joints shall not be more than 20 mm thick.
If plastering or pointing is not required the joints shall be struck flush and finished at the
time of laying.
Otherwise the joints shall be raked to a minimum depth of 20 mm by raking tool during the
progress of work, when the mortar is still green.
(i) Scaffolding : Single scaffolding having one set of vertical supports shall be allowed. The
supports shall be sound and strong tied together by horizontal pieces, over which the
scaffolding planks shall be kept and fixed.
The inner end of the horizontal scaffolding member may rest in a hole provided in the
masonry. Such holes, however shall not be allowed in pillars under one metre in width or
near the skew-back of arches.
The holes left in the masonry work for supporting scaffolding shall be filled and made good
with cement concrete 1:3:6.
(j) Curing : Random rubble masonry work in cement or composite mortar shall be kept
constantly moist on all faces for a minimum period of 7 days. In case of masonry with lime
mortar, curing shall be commenced 2 days after laying of masonry, and shall be continued
for 7 days thereafter.
(k) Protection : Green work shall be protected from rain by suitable covering. The masonry
work shall also be protected from damage, mortar droppings and rain during construction.

(viii) Coarse Rubble Stone Masonry :-

(a) Stone : Shall be as stated in the above article of random rubble masonry.
(b) Size of stone : Shall be as stated in the above article of random rubble masonry.
(c) Dressing : The face stone shall be hammer dressed on all beds, and joints,so as to give them
approximately rectangular block shape.
o These shall be squared on all joints and beds. The bed joint shall be rough chisel
dressed for at least 8 cm back from the face,and side joints for at least 4 cm such
that no portion of the dressed surface is more than 6 mm from a straight edge
placed on it.
o The bushing on the face shall not project more than 4 cm as on exposed face and
one cm on a face to be plastered.
o The hammer dressed stone shall also have a rough tooling for a minimum width of
2.5 cm along the four edge of the face of the stone, when stone work is exposed.

16 | P a g e
 SPECIFICATION

(d) Mortar : The mortar for joints shall be as specified.

(e) Laying : All stones shall be cleaned and wetted before use. The wall shall be carried up
truly to plumb or to the specified batter.
o All courses shall be laid truly horizontal and all vertical joints shall be truly
vertical.
o The height of each course shall not be less than 15 cm nor more than 30 cm.
o The face stones shall be laid alternate headers and stretchers.
o No pinning shall be allowed on the face. No face stone shall be less in breadth than
its height.
o At least one third of the stones shall tail into the work for length not less than twice
their height.
o The hearting shall be done with stones carefully laid on their proper beds in mortar.
o Chips and spawls shall be used where necessary to avoid thick beds of mortar and
at the same time ensuring that no hollow spaces are left anywhere in the masonry.
o The chips shall not be used below the hearting stone to bring these up to the level
of face stones.
o The use of chips shall be restricted to the filling of interstices between the adjacent
stones in hearting and these shall not exceed 10% of the quantity of the masonry.
o The masonry of the structure shall be carried up regularly but where breaks are
unavoidable, the joints shall be raked back at an angle not exceeding 45°.
o No toothing shall be done at such places.
(f) Bond stone : Shall be as stated in the above article of random rubble masonry.
(g) Quoins : The quoins shall be of the same height as the course in which these occur.
These shall be at least 45 cm long and shall be laid stretchers and headers alternatively.
These shall be laid square on the beds, which shall be rough chisel dressed to a depth of at
least 10 cm.
These stones shall have a minimum of 2.5 cm wide chisel drafted margins at all four edges.
All the four edges shall be in the same plane.
(h) Joints : All the bed joints shall be horizontal and all side joints vertical. All the joints shall
be fully packed with mortar.
The face joints shall not be more than one cm thick.
When the plasterings or pointing is not required to be done, the joints shall be struck flush
and finished at the time of laying.
If the plastering and pointing are to be done the points shall be raked to a minimum depth
of 20 mm by raking tool during the progress of work, when the mortar is still green.
(i) Curing, Scaffolding : Shall be as stated in the above article of random rubble masonry.

(ix) Wood work for door and window frames :-

(a) Materials : Timber shall be of teak, sal, deodar, etc. as mentioned, well seasoned, dry, free
from sap, knots, crack or any other defects or diseases.
o It shall be sawn in the direction of the grains. Sawing shall be truly straight and
square.

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 SPECIFICATION

o The scantling, shall be planned smooth and accurate to the full dimensions, rebate,
roundings and mouldings as shown in the drawings made, before assembling.
o Patching or plugging of any kind shall not be permitted except as provided.
(b) Joints : These shall be mortise and tenon type, simple, neat and strong.
Mortise and tenon joints shall fit in fully and accurately with out wedging or filling.
The joints shall be glued framed, put together and pinned with hard wood or bamboo pins not
less than 10 mm dia. after frames are put together pressed in position by means of a press.
(c) Surface Treatment : Wood work shall not be painted, oiled or otherwise treated before it has
been approved by the Engineer-in-charge.
All portions of timber abuting against masonry or concrete or embedded in ground shall be
painted with approved wood primer or boiling coaltar.
(d) Gluing of joints : The contract surface of tenon and mortise joints shall be treated before
putting together with bulk type synthetic resin adhesive of a make approved by the Engineer-
in-charge.
(e) Fixing in position : The frame shall be placed in position truly vertical before the masonry
reaches half the highest of the opening with iron clamps or as directed by the Engineer-in-
charge.
o In case of door frames without sills, the vertical members shall be embedded in the
flooring to a depth of 40 mm or as directed by the Engineer-in-charge.
o The door frames with out sills while being placed in position, shall be suitably
strutted and wedged in order to prevent warping during construction.
o The frames shall also be protected from damage, during construction.

(x) Wood work for door and window shutters :-

(a) Materials : Specified timber shall be used, and it shall be well seasoned , dry, free from sap,
knots, crack or any other defects or disease. Patching or plugging of any kind shall not be
permitted except as provided.
(b) Joinery work : All pieces shall be accurately cut and planned smooth to the full dimension.
All members of the shutters shall be straight with out any warp or blow and shall have
smooth, well planned faces at right angles to each other.
o In case of panelled shutters the corners and edges of panels shall be finished as
shown in drawings, and these shall be feather tongued into styles and rails.
o The panels shall be framed into groovers to the full depth of the groove leaving an
air space of 1.5 mm and the faces shall be closely fitted to the sides of the groove.
o In case of glazed shutter, sash bars shall have mitred joints with styles. Styles and
rails shall be properly and accurately mortised and tenoned .
o Rails which are more than 180 mm in width shall have two tenons.
o Styles and end rails of shutters shall be made out of one piece only.
o The tenons shall pass through styles for at least 3/4th of the width of the style.
o When assembling a leaf, styles shall be left projecting as a horn.
o The styles and rails shall have 12 mm groove in panelled portion for the panel to fit
in.

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 SPECIFICATION

o The depth of rebate in frames for housing the shutters shall in all cases be 1.25 cm
and the rebate in shutters for closing in double shutter doors or windows shall be not
less than 2cm. The rebate shall be splayed.
o The joints shall be pressed and secured by bamboo pins of about 6 mm diameter. The
horns of styles shall be sawn off.
(c) For battened shutters : Plank for battens shall be 20 mm thick unless otherwise specified and
of uniform width of 125 to 175 mm.
o These shall be planned and made smooth, and provided with minimum 12 mm
rebated joints. The joint lines shall be chamfered.
o Unless otherwise specified the battens for ledges and braces shall be 30 mm thick
and fixed with the battens on the inside face of shutter with minimum two number 50
mm long wood screws per batten.
o The ledges shall be 225 mm wide and braces 175 mm wide, unless otherwise
specified. The braces shall incline downwards the side on which the door is being
hung.
(d) Gluing of joints for panelled or Glazed Shutters : The contact surfaces of tenon and mortise
joints shall be treated before putting together with bulk type synthetic resin adhesive of a
make approved by the Engineer-in-charge.
o Shutters shall not be painted, oiled or otherwise treated before these are fixed in
position and passed by the Engineer-in-charge.
o For glazed shutters, mounting and glazing bars shall be tub-tenoned to the maximum
depth which the size of the member would permit or to a depth of 25 mm, whichever
is less.
(e) Fittings : Details of fittings to be provided shall be as per the schedule of fittings supplied by
the Engineer-in-charge in each case.
o The cost of providing and fixing shutters shall include the cost of hinges and
necessary screws for fixing the same.
o All other fittings shall be enumerated and paid for separately. The fittings shall
conform to their respective IS specifications.
o Where fittings are stipulated to be supplied by the department free of cost, screws
for fixing the fittings shall be provided by the contractor and nothing extra will be
paid for the same.

(xi) Cement sand plaster work : -

(a) Materials : Cement shall be fresh Portland cement and sand shall be medium quality,
cleaned, free from organic matter or salts. All the materials including water shall be of
standard specification.
(b) Preparation of mortar : The materials shall be at first mixed dry thoroughly till uniform in
colour in the required proportion and then shall be mixed wet adding water slowly and
gradually for at least 4 times to give a uniform paste.
So much material shall be prepared at a time as can be used within the initial setting time
( 30 min.) of cement.

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 SPECIFICATION

(c) Preparation of surface : The surface of the wall shall be brushed, cleaned, washed
,watered and wetted with water before plastering.
o In case of cement plaster on cement concrete the face shall be lightly roughened,
cleaned, washed and wetted.
o To ensure uniform thickness of plaster as specified, narrow strips of about 10 cm
wide plaster shall be applied first a distance of about 1m centres and the gaps
between such strips shall immediately be filled up with mortar.
(d) Laying : The plastering shall be started from the top and worked towards the ground.
The whole surface shall be made flush with wooden straight edges and rubbed thoroughly
with wooden floats to ensure an even surface.
Rounding of corners if desired by the Engineer-in-charge shall be carried out in one
operation.
(e) Curing : Plastering surface shall be kept wet by sprinkling water after 12 hours for at least
7 days and shall be protected from rain or sun.

(xii) Corrugated Galvanized Iron sheet roofing :-

(a) Corrugated Galvanised Iron sheets : C.G.I. sheets shall be of the specified gauge. If the
gauge is not specified, they shall be 0.63 mm thick (24 B.G.)
o The sheets shall be free from twist or buckle and shall have uniform
corrugations, true in depth and pitch, and parallel to the sides of the sheet.
o The galvanizing shall be clean and undamaged in the carriage by the rubbing of
zinc covering and free from ungalvanised spot or other defects.
(b) Laying : Sheets shall be laid on wooden or steel purlins as indicated on the working
drawing.
o The tops of all purlins shall be in one plane so that the sheets may be fixed with
purlins without exerting any pressure hammering.
o According to I.S. specification 277-1962 an end lap of 15 cm in the lengthwise
direction and side laps of two corrugations shall be provided.
o In ridges and hips where plain sheets are used a lap of 23 cm shall be maintained.
The lines of corrugations shall be parallel to the sides of the roof unless
specified.
o The roof slope shall not be laid flatter than 1 in 4 if not otherwise specially
mentioned.
o Holes for hook bolts etc. shall be drilled but not punched in the ridges of the
corrugations from the underside while the sheets are on the ground.
o A sheet shall be fixed on every purlin under it at least at three places at regular
intervals. Care shall be taken so that all holes, on the corrugation shall occur in
the ridge of the sheet as laid.
o Sheets shall be fixed to the purlins by means of 8 mm diameter galvanised hook
bolts and nuts with a washer of bitumen, and a limpet washer in each fixation .

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 SPECIFICATION

o The diameter of the holes in the washer shall be same as the G.I. bolts or hook
bolt. All nuts shall be tightened from top of a sheet uniformly to give a leak-
proof covering.
(c) Wind Ties : If specified wind ties of 40x12 mm flat iron shall be fixed at the end laps and
eaves of the sheets. The fixing shall be done with the same hook bolts which secure the
sheets to the purlins.

(B) Road Works :

(I) Embankment Construction : ( Without Optimum Moisture Condition )
(a) Materials : Materials used in embankment shall be earth, moorum, gravel, a
mixture of these or any material approved by the engineer-in-charge.
 Such materials shall be free from logs, stumps, roots, rubbish or any
other ingredients likely to deteriorate or affect the stability of the
embankment.
 The work shall be so planned and executed that the best available
materials are saved for the top portion of the embankment.
 Highly expansive clays exhibiting marked swell and shrinkage
properties may be deposited only at the bottom of the embankment and
no such material shall be placed nor permitted to remain in the top 50
cm portion of the embankment below the sub-grade.
(B) Foundation Preparation : The foundation of the embankment shall be ploughed to a
depth of 15 to 25 cm. All the clods shall be broken into fine earth and the area roughly
levelled. The surface shall then be well watered before starting the earth work.
(C) Source of Supply : The material used in the embankment shall be obtained either from
cutting high ground or from borrow pits as per direction.
o The borrow pits may be excavated along the road sides, so as to form road
side drains with proper slopes and sections.
o The clear berm width between the toe of bank and the inner edge of the
borrow pits shall be specified, but it shall not be less than 5 m after making
due allowance for further development.
o Borrow pits shall be rectangular in shape with one side parallel to the road
centre line and these shall be dug as near the boundary as possible.
o Borrow pits shall not be dug continuously ,but ridges not less than 8m width
shall be left at intervals not exceeding 300 m.
o Small drains shall be cut through the ridges to facilitate drainage. Borrrow pits
shall be well drained.
o The bed level of the borrow pits, shall, as far as possible, slope down
progressively towards nearest cross drain, if any, and shall not be lower than
the bed of the cross drain.

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 SPECIFICATION

o Borrow pits shall not be dug within 800 m of town or villages. If unavoidable
their depth shall not exceed 30cm and shall be drained.
o In case it is necessary to borrow filling materials from temporarily acquired
cultivable land, the borrow pits depths shall not exceed 45 cm.
o The top soil to a depth of 15cm shall be stripped and stacked aside.
o Thereafter the soil shall be dug out to a further depth not exceeding 30 cm and
used in the embankment. The top soil shall then be spread back in the land.
o In case of flood and marginal banks, the earth shall be obtained from borrow
pits on the river side of the banks.
o No borrow pits shall be excavated on the land side of the bank.
o The minimum berm width between the toe of the bank and the edge of the
borrow pits on the river side shall be 15m and that between the toe of the bank
and the edge of the borrow pits on the land side 25 m.
o The guide banks shall be constructed from materials obtained from excavation
for laying stone aprons and further borrow pits excavated if necessary
according to the directions.
(D ) Earth filling and Compactions : Before starting the filling the toe lines of the
embankment shall be marked be pegs driven into the ground at about 15 m
centre to centre by continuous nicking (dry bailings) to indicate the limits of
the side slopes. Bamboo and string profiles shall be erected at every 60 m
intervals in straight reaches and at 15 m intervals in curve profiles.
o The embankment material shall be spreaded in layers not exceeding 20 cm
depth in the full width of the embankment including slopes, and the section of
the formation shall be kept slightly sloping away from the centre to avoid
formation of water pools due to rain.
o As far as possible the height of filling in different sections shall be kept
uniform. All clods shall be broken while placing earth.
o Organic matter of any kind shall be removed and disposed of as per directions.
Each earth layer shall be adequately watered to aid compaction.
o Joining of old and new embankments shall be done by steeping in an overall
slope of about 1 to 5.
o In case the embankment material is too wet, it shall be dried by aeration and
exposure to the sun, till the moisture content is acceptable for compaction.
o It shall then be rolled with roller of minimum 0.5 tonne weight, not less than 5
times, till it gets evenly and densely consolidated with wooden or steel
rammers of 7 to 10 kg weight having a base of 20 cm square diameter.
o The labour for ramming shall be at least one rammer of six diggers.
o Every third layer of earth and the top most layer shall be well consolidated
with a paver roller of minimum 8 tonnes weight, rolled not less than 5 times,

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 SPECIFICATION

till the soil starts behaving as an elastic material and get compressed only
elasticity under the roller load.
Before laying the next layer, the surface of the under layer shall be moistened and
sacrified with pick axes or spades, for providing satisfactory bond between the layers.

( e) Dressing : The embankment shall be dressed neatly as per designed section and grade,
after it has been thoroughly compacted and consolidated. The top and slopes shall be
protected from any damage and maintained, till the work is completed and handed
over to the engineer-in-charge.

( f) Cutting : Where the formation level of the road is lower than the ground level, cutting
shall be done upto the formation level. Side slopes except in rock cutting shall be
evenly and truly dressed.
( g) Disposal of surplus Earth : Earth from cutting shall be utilised for embankment filling
as per directions. Earth not required for embankment shall be disposed of as per
directions. The area where the surplus earth is disposed of shall be levelled and neatly
dressed. When the surplus earth is disposed of at a distance more than 50 m, the extra
lead shall be paid for.

(II) Sub-Grade :-
In the sub-grade composed of clay, fine sand or other soils that may be forced up into
the coarse aggregate during rolling operations an insulation layer of granular material
or oversize brick aggregate not less than 10 cm thick of suitable thickness shall be
provided for banketting the sub-grade.
In the water-logged areas, special arrangements shall be made to improve the sub-
grade and the total pavement thickness shall be designed after testing the properties of
the sub-grade soil.
(a) Sub-grade Preparation : The surface of the formation for a width of sub-base, shall
first be cut equal to the combined depth of sub-base and surface courses below the
proposed finished level.
o It shall than be cleaned of all foreign substances.
o Any ruts or soft yielding patches that appear due to improper drainage
conditions, traffic handling or from any other cause, shall be corrected and the
sub-grade dressed off parallel to the finished profile.
(b) Consolidation : The sub-grade shall be consolidated with a power road roller of 8 to
12 tonnes.
o The rolling shall be continued till the sub-grade soil is evenly and densely
consolidated and start behaving as an elastic mass (the roller shall pass a
minimum of 5 runs on the sub-grade).

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 SPECIFICATION

o All undulations in the surface that develop due to rolling shall be made good
with material or quarry spoils as the case may be and the sub-grade shall be
rerolled.
(c) Surface Regularity : The finished surface shall be uniform and conform to the lines,
grades and typical cross-section as given in the drawing. When tested with the
template and straight edge, the variation shall be within the specified tolerances.
In case the surface irregularity of the sub-grade is not within the tolerance limits, the
contractor shall be liable to rectify these with fresh materials or quarry spoils as the
case may be and the sub-grade shall be rerolled.
(III) Sub-Bases :-
The sub-bases may be one of the following :
(a) Lime fly ash stabilised soil
(b) Water Bound Macadam with Stone Aggregate
(c) Water Bound Macadam with Brick Aggregate
(d) Water Bound Macadam with Over burnt (Thana) Brick Aggregate
(a) Lime fly ash stabilised soil sub-base : This sub-base may be used where lime and fly ash
conforming to IS specification are available and where arrangements can be made for
pulverizing the soil and mixing it with lime and fly ash.
This can be used instead of soling or oversize metal in the sub-base courses.
This sub-base is not recommended in clay sub-grades with high moisture contents where the
soil is in the form of wet lumps which cannot be pulverised.
Mix Proportioning : The actual mix proportion shall be determined through laboratory tests for
meeting the requirements.
The quantity of water shall be as per the O.M.C. requirements determined on soil-lime-fly ash
mixture by the proctor density method.
A typical mix proportion of soil, lime, flyash is given below : - Soil : Lime : Flyash = 85:3:12
by weight.
Construction Operation :- The mixing shall preferably be done by mechanical plant either of
the single pass or multiple pass type.
o If such plant is not available, manual method may be adopted with rigorous quality
control.
o In the manual method the soil shall be pulverised be means of crow bars, pick axes,
bullock drawn ploughs , etc. and deposited on the road bed in the stacks of suitable
size, 30 cm in height.
o Water in required quantity shall be sprinkled while pulverising the soil.
o On the pulverised soil stacks, lime and fly ash in a thoroughly mixed form and in the
required quantity shall be spread uniformly and mixed by cutting with spades till the
whole mass becomes uniform.
o The mixed soil shall then be spread over the prepared sub-grade in the required
thickness and shall be rolled within +1% and -2% of the O.M.C.

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 SPECIFICATION

Rolling : The rolling shall be done with 8-10 tonne roller and shall be continued till the required
density ( 95% of Lab Proctor Density) and a smooth surface is obtained with out leaving any
roller marks on the surface.
Curing : Before placing the next layer, the compacted surface shall be cured for at least 7 days.
Curing is done be sprinkling water over the surface 5 to 6 times daily. The surface shall not be
allowed to dry during curing period.
(b) W.B.M. with Stone Aggregate Sub-base : -
o Stone aggregate of size 30 mm to 40 mm is used. This is standard sub-base and is used
where stone aggregate is available at reasonable rates.
o This consists of clean crushed coarse aggregate mechanically interlocked by rolling and
voids there of filled with screening and binding material with the assistance of water.
o It is laid on the prepared sub-grade , sub-base, base or existing pavement as the case
may be. W.B.M. may be used as a sub-base, base course or surface course.
Quantities of coarse aggregate screening and binding material required to be stacked for 100
mm approx.. compacted thickness of W.B.M. sub-base course for 10 sq m shall be as follows :

Materials Loose Qnty.

Grading I 90 mm to 40 mm Coarse Aggregate 1.35 cu m

Type A 12.5 mm size Stone Screenings 0.42 cu m

Building materials 0.10 cu m

Foundation Preparation : In the case of an existing un surfaced road, where new material is to be
laid, the surface shall be scarified and reshaped to the required grade, camber and shape as
necessary .
Weak places shall be strengthened, corrugations removed and depressions and pot holes made
good with suitable materials, before spreading the aggregate for W.B.M.
Spreading Aggregate : The coarse aggregate shall be spread uniformly and evenly upon the prepared
base in the required quantities with a twisting motion to avoid segregation.
o In no case shall these be dumped in heaps directly on the area where these are to be laid nor
shall their hauling over a partly completely base be permitted.
o The aggregates shall be spread uniformly to proper profile by using templates placed across
the road six metre apart where specified approved mechanical devices may be used to spread
the aggregate uniformly.
o The levels along the longitudinal direction upto which the metal shall be laid shall be first
obtained at the site as per directions.
o The surface of the aggregate spread shall be carefully trued up and all high or low spots
remedied by removing or adding aggregates as may be required.
o The W.B.M. sub-base shall be normally constructed in layers of 100 mm compacted
thickness. No segregation of large or fine particles shall be allowed and the coarse aggregate
as spread shall be of uniform gradation with no packets of fine material.

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 SPECIFICATION

o Normally the coarse aggregate shall not be spread in lengths exceeding three days average
work ahead of the rolling and blending of the preceding section.
Rolling : Immediately after spreading the coarse aggregate, it shall be compacted to the full width by
rolling with either a three-wheel power roller of 8 to 10 tonnes or an equivalent vibratory
roller. Initially, light rolling is done, which shall be discontinued when the aggregate is
partially compacted with sufficient void space in them to permit application of screenings.
o The rolling shall be started from the edges with roller moving forward and backward and
adding the screening simultaneously until the edges have been firmly compacted.
o The roller shall then progress gradually from the edges to the centre, parallel to the centre line
of the road and overlapping uniformly each preceding rear wheel track by one half width and
shall continue until the entire area of the course has been rolled by the rear wheel.
o Rolling shall continue until the road metal is thoroughly keyed with no creeping of metal
ahead of the roller.
o Slight spinkling of water shall be done while rolling, if required.
o On the super-elevated curves, the rolling shall proceed from the lower edge and progress
gradually continuing towards the upper edge of the pavement.
o Rolling shall not be done when the sub-grade is soft or yielding or when the rolling causes a
wave-like motion in the sub-base or sub-grade.
o When rolling develops irregularities that exceed 12 mm when tested with a three metre
straight edge, the irregular surface shall be lossened and then aggregate added to or removed
from it as required and the area rolled until it gives a uniform surface conforming to the
approved cross-section and grade.
o The surface shall also be checked transversely by template for camber and any irregularities
shall be corrected in the manner described above.
Application of Screenings : After lightly rolling the coarse aggregate, the screenings shall be applied
gradually over the surface to completely fill the interstices.
o While spreading the screenings, dry rolling shall be continued, so that the jarring effect of the
roller causes them to settle into the voids of the coarse aggregates.
o The screenings shall not be dumped in piles on the coarse aggregate, but shall be spread
uniformly in successive thin layers either by the spreading motion of the hand ,shovels or a
mechanical spreader.
o The screening shall be applied in three or more applications at a slow rate, as to ensure filling
of all voids.
o Rolling and brooming shall continue with the screening spreading. Mechanical brooms or
hand brooms or both may be used for this purpose.
o In no case shall the screenings be applied, so fast and thick as to form cakes, ridges on the
surface making the filling of voids difficult, or to prevent the direct bearing of the roller on
the coarse aggregates.
o The spreading, rolling and brooming of screenings shall be performed on sections which can
be completed within one day’s operation and shall continue until no more screenings can be
forced into the voids of the coarse aggregate.
o Damp and wet screenings shall not be used under any circumstances.

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 SPECIFICATION

Sprinkling and Grouting :

o After spreading the screening and rolling, the surface shall be copiously sprinkled with water,
swept and rolled.
o Hand brooms shall be used to sweep the wet screenings into the voids and to distribute them
evenly.
o The sprinkling, sweeping and rolling operations shall be continued and additional screenings
applied where necessary until the coarse aggregates are well bonded and firmly set for the
entire depth and until a grout has been formed of screenings and water that will fill all voids
and form a wave of grout ahead of the wheels of the roller.
o The quantity of water to be used during the construction shall not be excessive so as to cause
damage to the sub-base or sub-grade.
Application of Binding Materials : After the application of screenings and rolling, a suitable binding
material shall be applied at a uniform and slow rate in two or more successive thin layers.
o After each application of binding material, the surface shall be copiously sprinkled with water
and the resulting slurry swept in with hand brooms or mechanical brooms or both so as to fill
the voids properly.
o The surface shall then be rolled by a 8 – 10 tonne roller, water being applied to the wheels in
order to wash-down the binding material that may get stuck to the wheels.
o The spreading of binding material, sprinkling of water, sweeping with brooms and rolling
shall continue until the slurry that is formed well, after filling the voids form a wave ahead of
wheels of the moving roller.
Setting and Drying : After final compaction of the course, the road shall be allowed to cure overnight.
Next morning defective spots shall be filled with screenings or binding materials, lightly
sprinkled with water, if necessary and rolled. No traffic shall be allowed till the macadam sets.
Surface Evenness : The surface evenness of completed W.B.M. sub-base in the longitudinal and
transverse direction shall be as specified. The maximum permissible undulation when measured
with a 3m straight edge should not be more than 15 mm for longitudinal profile. The maximum
permissible undulation when measured with a camber template should not be more than 12 mm
for cross profile.
Rectification of Defective Construction : Where the surface irregularity of the W.B.M. sub-base
course exceeds the tolerances given above, or where the courses is otherwise defective due to
sub-grade soil mixing with the aggregates, the layer to its full thickness shall be sacrified over
the affected area, reshaped with added material or removed and replaced with fresh material as
applicable and recompacted. The area so treated shall not be less than 10 sq.m. In no case shall
depressions be filled up with screenings and binding material.
(C)(D) Water Bound Macadam with Brick Aggregate / Over burnt ( Jhama) Brick Aggregate Sub-
base :
Brick aggregate of size 120 mm and 40 mm is used. This aggregate is used when stone
aggregate is costly. This is also used over soft clayey sub-grades with high moisture contents
and low C.B.R. values. Over burnt (Jhama) brick aggregate of size 90 mm and 40 mm is used.
This is used when stone aggregate is costly and over burnt brick aggregate is easily available.

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 SPECIFICATION

Quantities of Materials : Approximate quantity of brick aggregate required to be stacked for 100 mm
average compacted thickness of W.B.M. sub-base shall be 1.60 cu.m.(approx..) The quantity of
binding material, if required, shall be as specified by the engineer-in-charge.
Brick aggregate shall be broken from well burnt or over burnt brick bats and shall be
homogeneous in texture, roughly cubical in shape and free from dirt and other foreign matter.
Foundation Preparation, Spreading Aggregate, Rolling, Application of Screening, Sprinkling and
Grouting, Application of Binding Materials, Setting and Drying, Surface Evenness,
Rectification of Defective Construction – Specifications shall be same as for W.B.M. with stone
Aggregate sub-base described above.
(IV) Bases :
The base course may consists of any one of the following :-
(a) W.B.M. with stone aggregate
(b) Bituminous Macadam
(a) W.B.M. with stone aggregate :- Stone aggregate of size 63 mm to 40 mm is used for the
construction of base.
o This is standard type of base course used in road work. For important roads such as
National Highways and Main City Roads, this forms the lower part of the base course
overlaid by a bitumen bound base.
o W.B.M. base course consists of clean, crushed stone aggregate mechanically
interlocked by rolling, and voids in the aggregate filled with screening and binding
materials with the assistance of water, laid on the prepared sub-base or existing
pavement, in one or more layers as the case may be.
Quantities of Materials : Quantities of course aggregates and screenings required to be stacked
for 75mm (approx..) compacted thickness of W.B.M. base course for 10 sq.m. shall be as given
in Table below :
Classification Coarse Loose Grading / Stone For W.B.M.
Aggregate quantity in classification Screenings surface
size range in cu.m. and size for W.B.M. course in
mm loose course cu.m.
in cu.m.
Grading 2 63 - 40 1.0 Type A 0.20 0.16
12.5mm
Grading 2 63 - 40 1.0 Type B 10 mm 0.30 0.25

Grading 3 50 - 20 1.0 Type 10 mm 0.30 0.24

The quantity of binding material required for 75 mm(approx..) compacted thickness will be
0.90 m3/10m2 in the case of W.B.M. base course and 0.13 m3/10 m2 when the W.B.M. is to
function as a surface course.
Foundation Preparation : If new material is to be laid in the existing unsurfaced road, the
surface shall be sacrified and reshaped to the required grade, camber and shape as
necessary. All the weak spots shall be strengthened, corrugations removed and

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 SPECIFICATION

depression and pot holes made good with suitable materials before spreading the
aggregate to the W.B.M.
o In case the existing road surface is black topped and the crust thickness is to be
improved by a larger of W.B.M. 50mm x 50mm furrows shall be cut in the existing
surface at one metre intervals at 45° to the centre line of the carriage way before
proceeding with the laying of course aggregate.
o Aggregate spreading shall be done in the manner described in W.B.M. with stone
aggregate of article ‘Sub-Bases’ described above, except that the W.B.M. base course
shall be normally constructed in layers of not more than 75mm compacted thickness.
Rolling, Application of Screening, Sprinkling and Grouting – Shall be as specified in article
‘Sub-bases’ above.
Setting and Drying : After final compaction of the course, the road shall be allowed to cure
overnight. The next morning, defective spots shall be filled with screenings or binding material,
lightly sprinkled with water, if necessary and rolled.No traffic shall be allowed till the macadam
sets.
Surface Evenness : The maximum permissible undulation when measured with a 3m straight
edge shall be 12mm for longitudinal profile.
The minimum permissible undulation when measured with a camber template shall be 8mm for
cross profile.
The longitudinal profile shall be checked with a 3m long straight edge at the middle of each
traffic lane along a line parallel to the centre line of the road.
The transverse profile shall be checked with a series of 3 camber boards at 10m intervals.
Rectification of Defective Construction - Specification shall be as described in the article ‘Sub-
bases’ in W.B.M. with stone aggregate, above.
(b) Bitumen Macadam ( Hot mixed Dense Bitumen Macadam) :
This work consists of construction in a single course of 50mm/75mm thickness of compacted
crushed aggregates premixed with a bituminous binder, laid immediately after mixing on a sub-
base prepared previously. The Bitumen Macadam is used in all the important roads.
Proportioning of Materials : The binder content for premixing shall be 3.5% and 4.0% by
weight of the total mix for aggregate grading A and B respectively, or as directed by the
Engineer-in-charge.
o The quantities of aggregate to be used shall be sufficient to yield the specified thickness
after compaction.
o The contractor shall be responsible for ensuring proper proportioning of material and
producing a uniform mix.
o A variation in binder content of +- 0.3% by weight of total mix be permissible.
Weather and Seasonal limitations :Bituminous macadams shall not be laid during rainy weather
or when the base course is damp or wet or when the atmospheric temperature is 16°C or below.
Surface Preparation : Shall be done as follows :

( i) Repairs : All the pot holes or patches and rust in the surface on which bituminous macadam
is to be laid, shall be repaired removal of all loose and defective materials by cutting in
rectangular patches and replacing with suitable material.

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 SPECIFICATION

o For the purpose of repairs the area of pot hole shall be taken up to 0.75 sq.m. and
depth upto 5 cm.
o All pot holes, patches and ruts 2.5 cm deep shall be repaired and brought to level
with the same mix used in bituminous macadam and properly consolidated while
those of depth greater than 2.5 cm shall be repaired with similar specifications as
adopted originally.

(ii) Cleaning : Before applying the binder, all dust, dirt, caked mud, animal dung, loose and
foreign material etc. shall be removed 30cm on either side, beyond the full width, which is to be
treated by means of mechanical sweepers and blowers, if available.

o In case mechanical sweepers are not available, the cleaning shall be done with wire
brushes, small picks, brooms, etc. The material so removed shall be disposed of as
directed.
o In case of W.B.M. surface, the interstices between road metal shall be exposed upto a
depth of about 10 mm by means of wire brushes.
o The surface shall then be brushed with soft broom to remove all loose aggregate.
o Finally, the traces of fine dust which get accumulated while brushing shall be
thoroughly removed from the surface by blowing with gunny bags.

(iii) Tack Coat : The binder shall be heated in a boiler to a temperature as specified for the
grade used and maintained at that temperature.

o Thermometer shall be used for measuring the temperature.

o The binder shall be evenly applied to the clean dry surface preferably by means of a
pressure sprayer at the rate of 0.75 kg/sq m of the road surface, or as specified.
o An even and uniform distribution of the binder shall be ensured.
o The binder shall be applied longitudinally along the length of the road and never across
it.
o The edges of the binder surface shall be defined by wire or a cord stretched in position.
Excessive deposits of binder caused by stopping or starting of the sprayer or through
leakage or any other reason shall be suitably corrected.

(iv) Preparation of Mix : A hot mix plant of adequate capacity and capable of producing a
proper and uniform quality mix shall be used for the preparation of the mix.

o Batch types or continuous type plant having a co-ordinated set of essential units such as
a dryer for heating the aggregate may be used.
o The temperature of the binder at the time of mixing shall be in the range of 150°-
177°C and of aggregate in the range shall exceed 14°C.
o Thorough mixing shall be done to ensure the homogeneous mixture, and that all the
particles of the aggregate are coated uniformly.

(v) Transporting Mixed Materials : The transporting of the mixed material shall be done in
clean vehicles.

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 SPECIFICATION

Every precaution shall be taken to prevent segregation of the mixed material and to ensure that
they do not become contaminated with dust or foreign matter.

Adequate precautions shall also be taken in transit to cover the materials to prevent loss of heat,
specially in cold weather.

(vi) Spreading : The mix transported from the hot mix plant to the site shall be spread by means
of a self-propelled mechanical paver with suitable screeds capable of spreading, tamping and
finishing the mix, true to specified grade, lines and cross-sections.

o However, in restricted locations and in narrow widths, where the available plants
cannot operate, in the opinion of engineer-in-charge, he may permit manual laying of
the mix.
o Longitudinal joints and edges shall be constructed true to the delineating lines parallel
to the road centreline.
o All joints shall be cut vertical to the full thickness of the previously laid mix and the
surface painted with hot bitumen before placing fresh material.

(vii) Rolling : After the spreading of mix, rolling shall be done by 8-10 tonne power or other
approved plant.

o Rolling shall commence at the edges and progress towards the centre longitudinally.
o Except on superelevation portions, where rolling shall start from the lower to the upper
edge, parallel to the centre line of the road.
o When the roller has passed over the whole area once, any high spots or depressions
which become apparent, shall be corrected by removing or adding fresh material.
o The rolling shall then be continued till the entire surface has been compacted, there is
no crushing of aggregates and all roller marks have been eliminated.
o Every pass of the roller shall uniformly overlap not less than one-third of the track
made in the preceding pass.
o The roller wheels shall be kept damp, if necessary, to prevent the bituminous material
form sticking to the wheels and being picked up .
o No full lubricating oil shall be used for this purpose.
o Care shall be taken that roller does not stand on newly laid material, as there is a risk
that surface may get deformed.
o The longitudinal and transverse edges of the bituminous macadam laid and compacted
earlier shall be cut to their full depth so as to expose the fresh surface, which shall be
painted with a thin coat of appropriate binder before the new mix is placed against.
(viii) Quality Control Tests : Shall be as specified or as per standard practice of the department.
(ix) Surface Evenness : The maximum permissible undulation when measured with a 3m
straight edge shall not exceed 10 mm for longitudinal profile.

The maximum permissible variation from specified cross profile when measured with a camber
template shall not exceed 6 mm.

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 SPECIFICATION

The transverse profile shall be checked with a set of three camber board at intervals of 10m.
The finished surface shall be uniform and conform to the lines, grades and typical cross-
sections shown in the drawings.

(x) Rectification: In case the surface irregularities fall outside the specified tolerances, the
contractor shall be liable to rectify them by adding fresh material and recompacting to
specifications, where the surface is low.

Similarly where the surface is high, the full depth of the layer shall be removed and replaced
with fresh material and compacted to specifications.

In all the cases, where the removal and replacement of a bituminous layer is involved, the area
treated shall not be less than 5m long and not less than a lane width.

(V) Surface Dressing Using Hot Bitumen (Two Coats) :-

o This consists of the application of two coats of surface dressing, each coat consisting of a
layer of bituminous binder sprayed on a base previously prepared, followed by a cover of
stone dripping properly rolled to form a wearing course.
o The existing W.B.M. kanker or gravel surface shall be cleaned thoroughly before application
of bituminous binder. This work shall be carried out only at 16° C or above atmospheric
temperature .
o No bituminous materials shall normally be applied when the road surface or material is damp,
or when weather is foggy or rainy or during dust storms.

Quantity of Materials : Unless otherwise specified or directed, the quantities of materials shall
be as specified in Table below. Proper record shall be kept to ensure that the daily out-turn of
work is co-related with the quantity of bitumen used as per given in bitumen register.
Coat Stone Chipping
Nominal size in Specification Quantity in m3 per Bitumen quantity
mm 100 m2 in kg/m2
First Coat 12.5 100% passing through 20mm 1.5 1.8
sieve, and retained on 10mm
sieve
Second coat 10 100% passing through 12.5 1.10 1.1
mm sieve and retained on 6.3
mm sieve

First Coat : Shall be applied as under –

(i) Preparation of Surface : Shall be done as under:-

Repairs :- Pot holes or patches and ruts in the W.B.M. base or surface course which is to be surface
treated, shall be repaired by removal of all loose and defective material by cutting in rectangular
patches and replacement with suitable material.

For the purpose of repairs the area of pot holes shall be taken upto 0.75 sq.m. and depth upto 5 cm.
All pot holes, patches and ruts upto 2.5 cm deep shall be repaired and brought to level with premix
and properly consolidated, while those of depth greater than 2.5 cm shall be repaired with similar
specifications as adopted originally.

32 | P a g e
 SPECIFICATION

Cleaning : Before the application of the binder, all dust, dirt, caked mud, animal dung, losse and
foreign material etc. shall be removed 30 cm on either side, beyond the full width to be treated, by
means of mechanical sweepers, and blowers, if available or other wise with wire brushes, small picks,
broom etc.

o The material so removed shall be disposed of as directed by the engineer-in-charge.

o For a W.B.M. surface, the interstices between the road metal shall be exposed upto a depth of
about 10mm by means of wire brushes.
o The surface shall then be brushed with the brooms to remove all loose aggregate.
o Finally, the traces of fine dust which get accumulated while brushing shall be thoroughly
removed from the surface by blowing with gunny bags.

(ii) Application of Binder (Hot Bitumen) :- The binder shall be heated in a boiler to a temperature as
specified for the grade used and maintained at that temperature.

o The thermometer shall be used for measuring the temperature.

o The binder shall be applied evenly to the clean dry surface by means of pressure sprayer at the
specified rate.
o The binder shall be applied longitudinally along the length of the road and never across it.
o The edges of the binder surfaces shall be defined by wire or a cord stretched in position.
o Heating in cut drums and pouring from perforated tins, cans and such other methods shall not
be permitted, except in the case of petty works and repairs with specific approval of the
engineer-in-charge.
o Excessive deposits of binder caused by stopping or starting of the sprayer or through leakage
or any other reason shall be suitably corrected before the stone chippings are spread.

(iii) Blinding or Spreading Stone Chippings : Stone Chippings free from dust and in a dry and clean
state shall be spread evenly.

o Immediately after the binder is applied and is still hot, at the specified rate.
o Preferably the spreading shall be done by means of a mechanical gritter, otherwise manually
with a twisting motion to avoid segregation which otherwise shall have to be removed by
brushing the excess stone chippings over the surface into hungry spots to obtain a uniform
surface, free from waviness, depressions and other irregularities.
o The surface shall be checked by means of a chamber board laid across the road centre line of
the road and a 3m straight edge laid parallel to the road centre line of the road and undulations
if any shall be corrected by addition or removal of blindage till a surface free from undulation
is obtained.
o If a uniform surface is assumed at this stage, the completed surface should be normally free
from undulations and unevenness..

(iv) Consolidation of Blindage :- The road surface shall be compacted by a power roller of 6 to 8
tonnes, immediately after the spreading of the stone chippings.

o The roller shall be started at edges and working towards the centre ( or to the outside edge in
case of super elevated curve).

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 SPECIFICATION

o Each pass of the roller shall uniformly overlap not less than one-third of the track made in the
preceding pass.
o Care shall be taken that roller shall be worked or started and stopped with out jerks and shall
not be stopped or reversed each time at the same location to cause the displacement of stone
and other irregularities when the stone chippings are firmly embedded, the consolidation is
considered to be completed.
o Usually 5-6 trips shall be made for through compaction of the surface or as specified. Along
kerbs, manholes and all places not accessible to the roller, compaction shall be secured by
means of steel rammers or hand rollers.

Second Coat : - Shall be done as follows –

(i) Road Surface Cleaning :- The road surface shall be examined and any loose material and foreign
matter be removed by brooming or blowing off by fanning with gunny bags, care being taken not
to loosen the blindage which is already set.

(ii) Application of Binder : The binder (bitumen) shall be applied in hot condition immediately after
the blinding has been set and the surface has been cleaned. The binder shall be applied at the
specified rate in the same manner as in the first coat.

(iii) Blinding or Stone Chipping Spreading : The stone chippings shall be spread immediately after the
second application of binder at the specified rate and in the same manner as in first coat.

(iv) Consolidation of Blindage : After spreading the stone chippings and light brooming the surface
shall be compacted in the same manner as in case of first coat. The prepared surface shall be
protected from traffic for 24 hours or such specified period.

(v) Surface Finishing : The finished surface shall be uniform and conform to the lines, grades and
typical cross-sections shown in the drawings.

(V) Premix Carpet with Hot Bitumen :-

This type of treatment is normally applied on roads where the motor traffic is of medium intensity,
but bullock cart traffic is fairly heavy.

Premix carpet with hot bitumen treatment is suitable for district roads and for internal and service
roads in colonies. The consolidated thickness shall be 2 cm to 2.5 cm as specified.

This treatment consists of applying a tack coat on the prepared base followed immediately by
spreading aggregates pre-coated with specified binder to camber and consolidated.

Care should be taken not to lay premix carpet during rainy weather or when the base course is
damp or wet or when the atmospheric temperature in the shade is 16°C or below.

Quantity of Materials :- Shall be as shown in Table below –

Consolidated Binder hot bitumen Stone chippings in m3/10m2
thickness of premix
Tack coat in kg/m2 Carpet 12.5 m size 10 m size
carpet

2.0 cm 1.0 52 kg/cu m of 12.5 1.8 0.9

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 SPECIFICATION

mm size and 56 kg
per cu m of 10 mm
stone chippings

2.5 cm 1.0 - do - 2.25 1.12

Preparation of Premix : Dry aggregate suitably heated to the temperature as directed shall be placed
in the mixer to facilitate mixing with the binder.
o Approved type mixer shall be employed for mixing the aggregates with bituminous binder.
o The binder shall be heated to the temperature appropriate to the grade of bitumen, in
boilers of suitable design avoiding local overheating and ensuring a continuous supply.
o After about 15 sec. of dry mixing the heated binder shall be distributed over the aggregate
at the specified rate.
o The mixing of binder with chippings shall be continued until the chippings are thoroughly
coated with the binder.
o The mix shall be immediately transported from the mixer to the point of use in suitable
vehicles or wheel barrows.
o The vehicle employed for transport shall be clean and be covered to prevent loss of heat.
Spreading and Rolling :- The premixed material shall be spread on the road surface with rakes to the
required thickness and camber or shall be evenly distributed with the help of a drag spreader
without loss of time.
o The camber shall be checked by means of camber boards and all inequalities shall be
removed.
o As soon as sufficient length of bituminous material has been laid, rolling of the surface shall
be started with 6-9 tonne power rollers, preferably of smooth wheel tandem type.
o Rolling shall be started at the edges and progress towards the centre longitudinally.
o Except on the super elevated portions rolling shall progress from the lower to upper edge,
parallel to the centreline of the pavement.
o The consolidated thickness shall in no place be less than the specified thickness by more than
25%
o When the roller has passed over the whole area once, any high spots or depressions which
become apparent shall be corrected by adding or removing the premixed materials.
o Rolling shall be continued till the entire surface has been compacted and rollers marks are
eliminated.
o The roller wheels shall be kept damp to prevent the premix from adhering to the wheels and
being picked up, care shall be taken to see that roller does not stand on newly laid material as
it may get deformed.
o The edges along and transverse of the carpet, laid down compacted earlier, shall be painted
with a thin surface, coat of appropriate binder before placing new mix against it.
o The prepared finished surface shall be protected from traffic for 24 hours or other specified
period.

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 SPECIFICATION

Surface Evenness, Rectification - Specifications shall be same as that of ‘Bitumen Macadam’

described earlier.
(Vi) Cement Concrete Pavement : -
The pavement shall consist of concrete 1:2:4 (cement: coarse sand: graded stone aggregate 40 mm
nominal size) or richer mix as specified. The cement concrete shall be laid on the prepared base
including compaction curing of the concrete.
Preparation of Surface :- The surface shall be examined for soft patches and treated suitably for
obtaining uniform bearing capacity.
o The prepared surface shall conform to the line, grade and cross-section as shown in the
drawings, for which the sub-base may be sacrified or by adding extra material and
consolidating the same.
o In case the existing sub-base is to be widened, and the cement concrete is laid on the entire
road including the widened portion, every precaution shall be taken to avoid unsightly cracks
along the junction of old and newly laid strips.
o If desired, a longitudinal construction joint shall have to be provided.
Form Work :- Necessary form work shall be provided for all expansion, contraction, construction and
longitudinal joints as well as for the outer edges.
o The form shall be of steel. If approved, wooden forms may be used. The timber forms shall be
free from warps and twists.
o The thickness of wooden forms shall not be less than 7.5cm.
o The tempering edge of the forms shall be true to level and grade and shall be carpped along
the inner edge with angle iron if it has to serve as longitudinal forms and templates.
o Wooden stakes or steel pins 20 cm diameter, shall be used for keeping the forms in position
and preventing lateral displacement.
o Usually steel channel sections of required section and length shall be used for steel forms.
o They shall be straight, have a broad base and of sufficient stiffness to withstand, without
distortion, the impact due to placing and compaction of the concrete.
o All the joints suitable locking device shall be provided to ensure continuity of line and level.
Steel pins shall be used to hold them in position.
Setting Forms :- The forms shall be set to exact grade and alignment and shall be extended by 30 cm
beyond the point of depositing concrete and shall be checked by means of levelling
instrument. Usually the width of any bay shall not be kept more than 4m.
o The forms shall be thoroughly cleaned before setting, and shall be firmly fixed by stacks or
pins to prevent displacement due to placing and compacting the concrete.
o After setting, the working faces shall be thoroughly oiled before placing concrete.
o Form shall be removed after 48 hours, after placing the concrete. For important goods hand
mixing of concrete shall in no case be allowed.
Transportation, Placing and Compaction :- Approved methods shall be used for transporting and
placing the concrete in position.
o Care shall be taken that while transporting and placing, no contamination, segregation or loss
of concrete materials takes place.
o No concreting shall be done in part until approval has been obtained for it.

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o Concreting shall be done continuously over the area between the construction joints. Fresh
concrete shall not be placed against concrete which has been in position for more than 30 min.
unless a proper construction joints is formed.
o When the temperature falls below 4.5°C, the concreting shall not be done.
o After placing the concrete, it shall be protected against frost by suitable coverings.
o Concrete damaged by frost shall be removed and work shall be done. Similarly in hot weather
the temperature of wet concrete shall not exceed 38°C.
o The concrete shall be placed and distributed in the required quantity, so as to obtain required
uniform compacted thickness at all places.
o The concrete shall be deposited on the base in such a manner as to require as little rehandling
as possible. It shall be thoroughly spaced or vibrated against and along the faces of the form.
o Workers shall not be allowed to walk on the freshly laid concrete.
Compaction :- After laying, the concrete shall be compacted by tampering with 75 cm wide tamper
made of selected shod with steel, to ensure a dense homogeneous mass free from voids, honey
combing and surface undulation.
o The tamper shall be shaped to the cross-section of the road slab and also shall not weight
more than 10 kg/m.
o It shall be about 60 cm longer than the proposed width of the road slab, and shall rest the
sides of the forms.
o The tamper shall be drawn forward with sawing motion in combination with series of lifts and
drops alternately with lateral shifts of about 2.5 cm.
o The compaction shall be done till the mortar in mix just works up to the surface.
o If specified, the compaction shall be done by vibrators, having screed frequency not less than
2500 impulses per min.
o If the thickness of the slab is more than 20 cm, internal vibrators may also be used.
o After concrete compaction, the surface level shall be checked by straight edge longitudinally
and by tamper itself transversely.
o All the low spots shall be made with cement concrete by compaction till a uniform surface is
obtained. A string may also be used for checking the surface.
Surface Finish :- The surface may be floated, belt or brush finished as per direction or specification in
the item. The surface regularity both in longitudinal and transverse direction shall be within the
tolerance limit given below :
Longitudinal Profile Cross Profile

Machine laid concrete 8 mm 4 mm

Manually laid concrete 8 mm 6 mm

Floated Finish :- Shall be produced by a smoothening board following the tamper or by wooden
floats.

Belt Finish : It is similar to floated finish. The belt usually consists of a piece of convas 15 cm wide
and 100 cm longer than the width of the slab, having wooden handles at each end. At the preliminary

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stage the belt shall be drawn slowly across by a series of long strokes and finally by short strokes with
rapid advance, intermediate stages being used as approved.

Brush Finish :- Shall be carried out by a stiff fibre brush having a long handle attached to it, drawing
it transversely across the slab standing neither as a platform bridging the slab or across half the width
from either side of slab. This finish shall be carried out after the surface is slightly set.

Curing : Specification shall be same as described in the article ‘Cement Concrete’ of this chapter.

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