Green Collective

Sustainable Village

ANNEXURE -A

PROJECT SPECIFICATIONS

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1 GENERAL SPECIFICATIONS FOR WORK:

1.1 Earth works

This work shall consist of excavation, removal and satisfactory disposal of all materials necessaryfor
the construction of roadway, side drains and waterways in accordance with the lines, grades and cross
sections shown in the drawings or as indicated by the Engineer in charge. Excavation for road works
shall confirm to the specification of section 300 of MoRTH. It shall include the hauling and stacking of
or hauling to sites of embankment and subgrade construction, suitable cutmaterials as required, as also
the disposal of unsuitable cut materials in specified manner, trimmingand finishing of the road to
specified dimensions or as directed by the Engineer in charge.

1.2 Classification of Excavated Material

The excavated materials are basically classified as soil, ordinary rock, hard rock, marshy soil etc.which
is specified in section 301.2.1 of MoRTH 5th Revision.

Authority For classification

1.3 The classification of excavation shall be done by the Engineer in charge

Road Formation in Cutting

Where hard strata are available, and the formation level is below existing ground level, excavation shall
be done with due consideration of the stability of slopes. In case of rocks the provisions of clause
301.3.5 and 301.6 of MoRTH shall apply.

• For widening of existing pavement, the existing shoulders shall be removed to their full width and
up to subgrade level to enable proper compaction in the widened portions.
• The Engineer in charge shall ensure that the Contractor had taken adequate protective measures
to see that the excavation operations do not affect or damage adjoining structures. For safety
precautions, guidance may be taken from IS: 3764.
• In rocky formation, the surface irregularities shall be corrected with granular base material to
achieve the specified profile and levels
• Where blasting is involved for rock cutting, guidelines given in Clause 302 of MoRTH Specifications
shall be followed
• The edges of the roadway as constructed should be correct within a tolerance limit of ±40mm in
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plain and rolling terrains and ±50 mm in hilly terrain.

• No point on the slopes shall vary from the designated slopes by more than 150 mm measured at
right angles to the slope (300 mm in case of rock excavation). The same shallbe ensured by Engineer
in charge.

1.4 Disposal of excavated materials

All the excavated materials are the property of the Kerala PWD. The material obtained from the
excavation of roadway, shoulders, verges, drains, cross drainage works etc., shall be used for filling up
of roadway embankment, the existing pits in the right -of-way and for landscaping of the road as
directed by the Engineer in charge, including levelling and spreading with all lifts and leadupto 1000 m
and no extra payment shall be made for the same. All hard materials, such as hard rocks, rubble, etc.,
not intended for use as above shall be stacked neatly on specified land as directed by the Engineer in
charge with all lifts and lead upto 1000 m. Unsuitable and surplus material not intended for use within
the lead specified above shall also, if necessary, be transportedwith all lifts and lead beyond initial 1000
m, disposed of or used as directed by the Engineer in charge.

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1.5 Embankment / Subgrade Construction

The following points should be noted while embankment construction.

• Engineer in charge shall ensure that only suitable material is used in the construction of filland that
the required density is achieved at the expected moisture content
• Embankment construction in waterlogged and marshy areas shall be in accordance with IRC: 34-
2011
• Spreading of material shall be done by means of motor grader or other approved mechanical
means
• Generally, embankments shall be constructed in 250 mm compacted layers parallel to thefinished
grade of the road.
• The samples of soil brought to site shall be tested to determine the laboratory maximum dry
density (MDD) and optimum moisture content (OMC) in accordance with IS: 2720 (Part8).
• Moisture content at site shall be checked by using rapid moisture meter, deficiency in moisture
content will be made +/-2% either at borrow area or after spreading
• If moisture content is made +/-2% after spreading, mixing of material shall be done by means of
disc harrows fitted with motor grader
• After attaining OMC, vibratory roller shall be used for compacting to attain required degreeof
compaction
• For each completed layer the field density shall be checked (One test for each 1,000 square meters)
by laboratory personnel. If test results show the required density is not achieved further
compaction is necessary (density requirements is mentioned in table 1 and compaction
requirement is mentioned in table 2)

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Table 1: Density requirements of embankment and subgrade material.

Sl. Type of work Maximum laboratory dry

No. density when tested as per
IS: 2720 (Part 8)
1 Embankments up to 3.0 m height, not subjected to Not less than 15.2 kN/m3.
extensive flooding.
2 Embankments exceeding 3.0 m height or embankments Not less than 16.0 kN/m3.
of any height subjected to long periods of inundation.
3 Subgrade, earthen shoulders, verges/backfill. Not less than 17.5 kN/m3.

Table 2: Compaction Requirement for Embankment and Sub-grade

Sl. Type of work/Material Relative compaction as

No. percentage of max.
laboratory dry density as
per IS:2720(Part 8)
1 Subgrade and earthen shoulders. Not less than 97%

2 Embankment Not less than 95%

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

The subgrade must be prepared over the full width of the embankment. This is generally carried out
in lengths of greater than 100 metres. In some cases, to maintain traffic, part width working may be
necessary. When the road is to be placed on existing material (excavated material can bereused in this
section), this shall be fully loosened to a depth of 150 mm below the subgrade level.Any lumps shall be
removed or broken up to be less than 50 mm in size. The subgrade must be compacted uniformly by
use of adequate and appropriate compaction equipment.

In case of sub grade preparation, a greater number of passes is required using vibratory roller to attain
required field density. Final layer shall be checked by means of templates and rectification ifany will be
done by making up the deficiency or by loosening and further compacted

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Construction of rockfill embankment is suitable when the foundation conditions are poor. Special rock
equipment and procedures are to be followed for rock borrowing, hauling, placing and compaction.

All embankments, subgrades, earthen shoulders and miscellaneous backfills shall be constructed in
accordance with the lines, grades, and cross-sections shown on the drawings or as directed bythe
Engineer in charge. It shall follow the specification as per clause 305 of MORTH 5th revision.

2 Ground Improvement/ Soil Stabilization

2.1 Ground Improvement using PVD with Surcharge

Using geosynthetic drains viz., Prefabricated Vertical Drains (PVD) with surcharge, weak embankment
foundations having problematic sub-soil conditions can be improved to carry the design load of the
embankment. The design and construction of PVD with surcharge is carried outas per IS: 15284 (Part
2). The details of materials and installation are given in Clause 314.2 of MoRTH Specifications for Road
and Bridge works.

a. Engineer in charge shall ensure that the geosynthetic band drain is stored in such a waythat it is
protected from UV light. As storage and handling is done as per ASTM D 4873
b. Engineer in charge should ensure that the blanket of granular coarse sand is spread overthe
entire area and covered with geotextile layer on top and bottom
c. Engineer in charge shall be ensured that the geotextile has not been damaged during
installation. Should give directions to replace the damaged ones from site
d. The surcharge shall be placed with approved embankment material with adequate sideslopes.
e. Engineer in charge shall specify the locations where shear strength parameters of sub soilis to be
measured
f. The design and construction of this is carried out in accordance with IS: 15284 (Part 2).
g. The details of materials and installation are given in Clause 314.3 of MoRTHSpecifications
for Road and Bridge works.
h. Before starting the installation, the Engineer in charge shall verify the installationprocedure
submitted by the contractor and modification if need any shall be suggested
i. Engineer in charge shall ensure that the installation procedure for the stone column is asper the
procedure submitted earlier
2.2 Ground Improvement using Geosynthetic

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Geogrid has been used to reinforce road sections. The inclusion of geogrid in subgrades changes the
performance of the roadway in many ways. Tensile reinforcement, confinement, lateral spreading
reduction, separation, construction uniformity and reduction in strain have been identified as primary
reinforcement mechanisms. Empirical design and post-construction evaluation have lumped the
above described benefits into better pavement performance during the design life. Geogrid with
reduced aggregate thickness option is designed for roads.

j. Clearing and grubbing should conform to the requirement of 'Specification for Road and BridgeWorks,
MORTH'.
k. The top foundation soil shall be free from undulations and prepared to the level as indicated inthe
construction working drawings or as directed by the Engineer in charge.

l. If geotextiles or low strength geogrids are used, a cushion layer of sand must be given for minimizing
installation damages. Sand layer shall be compacted to specified design modified proctor density.
m. Slack/wrinkles in the reinforcement layer shall be removed manually. Direct movement of vehicles on
the reinforcement shall be prevented.
n. The reinforcement should not be exposed to sunlight for more than the maximum duration permitted
in the approved drawing/installation methodology.
o. Required overlapping length must be detailed in the drawing by the designer
p. An overlap of 300 mm or as indicated by Engineer in charge shall be provided between the adjacent
rolls. There should be no joints or seams along the principal strength direction of the basal
reinforcement.
q. Where reinforcement is to be anchored by passing it round an anchorage block (thrust block),such as
a gabion basket, and back on itself, then the reinforcement should be pulled tight around the block and
secured by pinning or weighting until fill around the block has been placed
r. Reinforcement layer should be covered with well graded sand having angle of internal frictionas per
approved drawings.
s. All filling shall be done in layers of 200 mm thickness. If ground water table is encountered proper
dewatering arrangement shall be arranged
t. Fill in immediate contact with the reinforcement should be placed and spread in the longitudinal
direction of the reinforcement only.
u. Under no circumstances should tracked vehicles be allowed to traffic over the laid, unprotected
reinforcement.
v. The sequence of fill placement should be considered with care, particularly over very poor softsoil
where bearing capacity is very low

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2.3 Soil Stabilization using Cement/ Lime

Soil is modified with lower cement content to improve the material to get the required subbase
properties. The specifications for materials and construction procedures are given underClause 403 of
MoRTH Specifications for Road and Bridge works (5th revision 2013)

The following points shall be kept in mind while executing the work.
• The subgrade shall be checked for line, grade and its compaction must be ensured.
• The surface shall be scarified and reshaped if required. In such cases, necessary densitychecks
shall be followed and the layer got approved by the Engineer in charge.
• Stabilization shall be carried out preferably by mechanical means.
• Rotavators or agricultural machineries like ploughs or disc harrows shall be used for in-situmixing
the lime with soil.

• It shall be ensured by trial runs that the plant used and method of processing shall becapable
of pulverizing the soil to the required degree and achieving uniform mixing.
• Wherever manual mixing is adopted, it shall be ensured that mixing of the ingredients isuniform
to the full depth of the layer processed.
• The degree of pulverisation shall be as specified (100% passing 26.5 mm sieve and 80%passing 5.6
mm sieve as per Clause 402.3.2 of MoRTH Specifications).
• Mixing shall be uniform so that no streaks of free cement are visible.
• After mixing, the cement content of the mix shall be determined.
• Before compaction, the moisture content of the mixed material shall be brought to the
desired level, normally optimum moisture content.
• The time interval between mixing of cement with soil and compaction shall not exceed 3hours.
• Rolling shall commence from edge and progress towards the centre. In curves, the rollingshall
proceed from the inner edge to the outer edge.
• The surface after rolling shall be free from movement, compaction planes, ridges, cracksor loose
materials.
• After rolling, the compacted layer shall be checked for compaction control, levels andshape.
• The layer shall be subjected to curing for 7 days and the subsequent pavement coursesshall be
laid immediately to prevent further drying out of the layer.
• No traffic shall be allowed over the stabilized layer.

In this method, a pre-determined quality of lime is added to soil, mixed thoroughly and compactedat
the required moisture content to get the desired subbase. The specifications for materials and

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construction procedures are given under Clause 402 of MoRTH Specifications for Road and Bridgeworks
(5th revision 2013)

3. Protection works

3.1 DR Retaining Wall

a) Solid retaining walls shall not be preferred where retaining heights exceeding 3 m
b) It shall be ensured by the Engineer in charge that masonry work is laid to line, level, curveand
shapes as per working drawings
c) For masonry works over rock, a levelling course of 100 mm thickness M15 grade of
concrete shall be laid and then stone masonry work shall be done
d) In case headers are not available, precast headers of M15 concrete shall be used. Castin-situ
headers are not permitted

3.2 RR Retaining Wall

a) Through bond stones shall be provided in masonry upto 600mm thickness, in case of thickness more
than 600m a set of two or more bond stones overlapping each other at leastby 150mm shall be
provided in line from face to back

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4 Pavement Layer construction

4.1 Granular Subbase

Granular subbase is made with well graded aggregates, spread and properly compacted on a
previously prepared subgrade. Construction of GSB layer shall be as per MoRTH Cl: 401. When sub
base is laid in two layers as upper and lower sub base, the thickness of each layer shall not be less than
150mm.

Materials
• The material for granular subbase shall be natural sand, crushed gravel or rock free fromorganic
or other deleterious substances conforming to the grading as per MoRTH Table 400-2
• Water absorption for aggregate shall be checked as per IS:2386 Part 3
• If water absorption of aggregate is greater than 2% then the aggregate shall be tested for wet
aggregate Impact value as per IS:5640
• Grading III and IV GSB shall be used for lower sub base and Grading V and VI shall be used for sub
base cum drainage layer.
Table: 2- Physical Requirements for Material for
Granular Sub Base (MoRTH Table 400-2)
Aggregate Impact Value (AIV) IS:2386-Part 4 Max Value of 40 AIV
Liquid Limit IS:2720-Part 5 Maximum Value of 25
Plasticity Index IS:2720-Part 5 Maximum Value of 6
CBR at 98% Dry Density IS:2720-Part 5 Minimum 30 unless otherwise
specified in the contract

Laying Trials
Once the plant trials have been successfully completed and approved, the contractor shallcarry out
laying trials, to demonstrate that the proposed mix can be successfully laid and compacted in
accordance with clause MoRTH Cl:501. The laying trial shall be carried out on a suitable area which is
not to form part of the works. The area of the laying trials shall be a minimumof 100sq.m of construction
like that of the project road, and it shall be in all respects, particularly compaction, the same as the
project construction, on which the bituminous material is to be laid.

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The contractor shall previously inform the Engineer in charge of the proposed method for laying and
compacting the material. The plant trials then establish if the proposed laying plant, compaction plant,
and methodology can produce satisfactory results.

Once the laying trials have been approved, the same plant and methodology shall be applied to the
laying of the material on the project and no variation of either shall be acceptable, unless approved in
the writing by the Engineer in charge, who may at his discretion require furtherlaying trials.

Construction
The following points shall be given attention during execution of the work.
Engineer in charge shall check and certify that the subgrade is in line, grade and well compacted before
laying GSB layer
1. Engineer in charge shall ensure the Moisture content of the mix in accordance with
IS:2720(Part 2) and suitably adjusted so that at the time of compaction it is from 1% to 2%below
optimum moisture content (OMC).
2. Spreading of GSB shall be done by using a motor grader
3. Immediately after spreading, the rolling shall be done with Engineer in charge shall ensurethat
roller used is as specified below
a. 80 to 100 kN weight smooth wheel for compacted thickness <100mm
b. 80 to 100 kN vibratory roller for a compacted single layer upto 200mm
4. Rolling shall commence from edge and progress towards the centre. In curves, the rollingshall
proceed from the inner edge to the outer edge.
5. Rolling shall continue till the density achieved is at least 98% of the maximum dry density
(MDD) determined as per IS: 2720 (Part 8).
6. It shall be ensured by the Engineer in charge that sufficient thickness of the layer is
obtained after compaction and required density is achieved after final compaction
7. After compaction, Engineer in charge shall inspect the compacted surface and ensure thatit is
in required grade and camber.
8. If any surface irregularities are found during inspection, Engineer in charge shall
immediately give instruction to contractor for rectification of defects immediately

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4.2 Wet Mix Macadam

Wet mix Macadam (WMM) is constructed as a subbase or base and in accordance with IRC: 109. The
detailed specification and construction procedures for the work are given under Clause 406 of MoRTH
Specification for Road and Bridge works (5th revision 2013).

• Thickness of a single compacted Wet Mix Macadam layer shall not be less than 75mm. whenvibrating
or other approved types of compacting equipment are used compacted thickness of sub base course
may be upto 200mm with approval of the Engineer in charge
• The aggregate used shall conform to the physical requirement set for as per MoRTH given in Table 3
below
• Aggregate should satisfy the grading requirement as per MoRTH table 400-13.
Wet mix macadam shall be prepared in an approved mixing plant of suitable capacity having
provision for controlled addition of water and forced mixing arrangement like pugmill. The plant shall
satisfy the features mentioned in MoRTH Cl: 406.3.3. Physical requirement of materialfor WMM shall
satisfy the values given in table below

Table: 3- Physical Requirement of Coarse Aggregate for

Wet Mix Macadam (MoRTH Table 400-12)
Los Angeles Abrasion Value IS:2386 Part 4 40% Maximum
Aggregate Impact Value IS:2386 Part 4 30% Maximum
Combined Flakiness and Elongation Indices IS:2386 Part 1 35% Maximum

Laying Trials
Laying trials shall follow the same procedure as mentioned under GSB layer construction

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Construction
The following points shall be carefully observed while executing the work.

a) Engineer in charge shall check the subgrade/subbase for density requirement, line, grade and cross
section. If required, Engineer in charge shall suggest surface scarification and reshaped followed by
density check
b) Adequacy of the lateral confinement of the WMM mix shall be checked before the commencement
of the work.
c) Spreading of mix shall be done using paver finisher. In exceptional cases where it is not possible to
utilize mechanical means like motor grader
d) WMM shall be prepared in an approved mixing plant of suitable capacity having provision for
controlled addition of water and forced/positive mixing arrangement like pugmill or pan typemixer
of concrete batching plant
e) For small quantity of wet mix preparation, mixing in a concrete mixer may be permitted.
f) The mixing shall be uniform and there should be no segregation of coarse and fineaggregates.
g) The optimum moisture content for WMM mix shall be determined in accordance with IS: 2720(Part
8).
h) While adding water in the plant, due allowance shall be given for loss of moisture due to
evaporation during transporting to site.
i) At the time of compaction, the moisture content shall not vary more than the agreed limit.
j) The wet mix shall be spread by the paver finisher or motor grader.
k) For portions where, mechanical means cannot be used, manual means as approved by theEngineer
in charge shall be used only in restricted areas
l) After spreading, the surface of the aggregate shall be carefully checked with a template. Anyhigh or
low spots noticed shall be removed or filled up, as required.
m) The thickness of the layer shall be checked.
n) Rolling of the spread material shall begin immediately from edge to the centre.
o) In curve portions, rolling shall proceed from inner edge to the outer
• If thickness of single compacted layer does not exceed 100mm, a smooth wheelroller
of 80 to 100 kN weight may be used
• If compacted single layer thickness is upto 200mm, then compaction shall be donewith
help of vibratory roller of minimum weight 80 to 100 kN
• Speed of roller shall not exceed 5Km/h

p) Rolling shall continue till the required density is achieved as per IS:2720 Part-8. By site trialsnumber

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of passes required by each roller to achieve the specified level of compaction shall be determined.
q) After final compaction, the layer can dry for 24 hours.
r) No traffic shall be allowed over the WMM layer

Rectification of surface irregularities

a) If the surface irregularity of the WMM layer exceeds the permissible tolerance, the same shall be
rectified.
b) If the irregularities developed during rolling which exceed 12mm when tested with 3m straightedge.
These surfaces shall be loosened, and premixed material shall be added or removedas required. And
rolling again to achieve uniform surface conforming the desired grade andcamber
c) Such areas shall be scarified to the full depth, excess material removed or fresh material added, as
found necessary and recompacted to the required density.
d) In no case, the depression shall be filled up with unmixed or ungraded materials or fines

4.3 Prime Coat over Granular Base

Prime coat is the application of a single coat low viscosity bituminous material over a granular baseor
subbase. The specifications and procedure for applying prime coat is given under Clause 502 of MoRTH
Specifications (5th revision).

Materials

a) The primer shall be cationic bitumen emulsion SS1 grade conforming to IS: 8887
b) For WMM, SS1 grade bitumen emulsion shall be used at the rate of 0.7 to 1.0 lit/m2.
c) The quantity of primer shall be selected based on site trials to achieve a penetration of 8 mm to
10 mm into the primed layer and there is no run-off of excessive primer.

Construction
• Primer shall be applied by a self-propelled or towed bitumen pressure sprayer equipped
for spraying the material uniformly at specified rates and temperatures. Hand spraying the
material shall not be allowed except in small areas
• Granular surface shall be swept clean by power brooms or mechanical sweepers and free
from dust
• The primer shall be applied at a uniform rate using a bitumen pressure sprayer at the rate
specified above

• No heating or dilution of SS1 bitumen emulsion is permitted at site.

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• A primed surface shall be allowed to cure for at least 24 hours to allow for the
moisture/volatiles to evaporate before the bituminous mix is placed.
• Any excess primer shall be blotted with a light application of sand.
• A primed surface shall not be allowed to traffic.

4.4 Tack Coat

A tack coat is a very light spray application of low viscosity liquid bituminous material to existing
bituminous material, cement concrete or primed granular surface to create a bond betweenthe new
bituminous layer and the existing surface. Work shall be carried out in accordance with MoRTH Cl:503.

Materials
1. The binder for tack coat is either cationic bitumen emulsion (RS1) complying with IS: 8887 or
suitable low viscosity paving bitumen VG 10 grade conforming to IS: 73.
Construction
1. Tack coat shall not be applied if the weather is rainy, windy or if the temperature in the
shade is less than 10°C. If emulsion is used, the surface may be slightly damp. If cutback
bitumen is used for tack coat, the surface shall be dry.
2. The tack coat shall be applied at a uniform rate using a bitumen pressure sprayer at the
rate specified. Hand spraying may be permitted in small areas or narrow strips where the
sprayer cannot be used.
3. The surface on which the tack coat is to be applied shall be clean, free of dust, dirt and any
other extraneous matter.
4. Immediately before the tack coat is applied, the surface shall be swept clean with a
mechanical broom and high-pressure air jet.
5. The granular or stabilized surfaces shall be primed before the application of tack coat.
6. No heating or dilution of RS1 bitumen emulsion is permitted at site.
7. The spraying temperature for bitumen emulsion is 20°C to 70°C
8. The tack coat shall be allowed to cure till all the volatiles are evaporated before any
subsequent layer is placed. No plant or vehicles other than those required for the
subsequent layer work shall be allowed over the tack coat.

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Table 3 Rate of Application of Tack Coat (MoRTH Table 500.5)

Type of Surface Rate of Spray of Binder in Kg/sq.m
Bituminous Surface 0.20-0.30
Granular Surface Treated with Primer 0.25-0.30
Cement Concrete Pavement 0.30-0.35

4.5 Dense Bituminous Macadam (DBM)

The specifications for the design and construction of Dense Bituminous Macadam are giver
under Clause 505 of MoRTH Specifications (5th revision 2013).

Materials
a) The bitumen shall be viscosity graded paving bitumen complying with IS: 73 or as specified inthe
contract.
b) The coarse aggregate shall be crushed rock retaining on 2.36 mm sieve. Gradation of the
aggregate shall be as per Table 4

Table 4 Composition of Dense Graded Bituminous Macadam (MoRTH Table 500-10)

Grading 1 2
Nominal aggregate size* 37.5mm 26.5mm
Layer Thickness 75-100mm 50-75mm
IS Sieve (mm) Cumulative % by weight of total aggregate passing
45 100 -
37.5 95-100 100
26.5 63-93 90-100
19 - 71-95
13.2 55-75 56-80
9.5 - -
4.75 38-54 38-54
2.36 28-42 28-42
1.18 - -
0.6 - -
0.3 7-21 7-21
0.15 - -
0.075 2-8 2-8

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

of total mix

*The nominal maximum particle size is the largest specified sieve size upon which any of the
aggregate is retained

** Corresponds to specific gravity of aggregates being 2.7. in case aggregate have specific gravity
more than 2.7, the minimum bitumen content can be reduced proportionately. Further the region
where highest daily mean air temperature is 300C or lower and lowest daily air temperature is -
100C or lower, the bitumen content may be increased by 0.5%.

c) The physical properties of coarse aggregate shall be as per Table 500-8 of MoRTHSpecifications
d) The filler shall be finely divided mineral matter such as rock dust, hydrated lime or cement. Thegrading
limits of filler shall be as per Table 500-9 of MoRTH Specifications.

Job Mix Formula/Mix Design

The contractor shall submit the Mix design duly conducted and approved by a Govt. Engineering
college/ Govt. Institution, to the Engineer in charge at least 21days before the start of work. The job
mix formula proposed in the works, shall also include the following details:

a) Source and location of all materials;

b) Proportions of all materials expressed as follows:
• Binder type, and percentage by weight of total mix;
• Coarse aggregate/fine aggregate/mineral filler as percentage by weight of total aggregateincluding
mineral filler;
c) A single definite percentage passing each sieve for the mixed aggregate;
d) The individual gradings of the individual aggregate fraction, and the proportion of each in the
combined grading;
e) The results of mix design such as maximum specific gravity of loose mix, compacted specimen
densities, Marshall stability, floe, air voids, VMA, VFB and related graphs and results of AASHTO T
283 moisture susceptibility test
f) Where the mixer is a batch mixer, the individual weights of each type of aggregate, and binder per
batch
g) Test results of physical characteristics of aggregate to be used

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h) Temperature during transportation shall be around 140 to 150 degree Celsius

While establishing the job mix formula, the contractor shall ensure that it is based on correctand truly
representative sample of the materials that will actually be used in the work and that themix and its
different ingredients satisfy the physical and strength requirements of these specifications.

Approval of the job mix formula shall be based on independent testing by the Engineer in charge

Permissible Variation in Job Mix Formula

Once the laboratory job mix formula is approved, the contractor shall carry out plant trials to establish
that the plant can produce a uniform mix conforming to the approved job mix formula.The permissible
variations of the individual percentages of the various ingredients in the actual mixformula to be used
shall be within the limits as specified in table5 and shall remain within the gradation band. These
variations are intended to apply to individual specimens taken for quality control tests in accordance
with section 900 of MoRTH standards

Table 5. Permissible Variation in the Actual Mix from the Job Mix Formula
Description Base/Binder Course
Aggregate passing 19mm sieve or larger +/-8%
Aggregate passing 13.2mm, 9.5mm +/- 7%
Aggregate passing 4.75mm +/- 6%
Aggregate passing 2.36mm, 1.18mm, 0.6mm +/- 5%
Aggregate passing 0.3mm, 0.15mm +/- 4%
Aggregate passing 0.075mm +/-2%
Binder content +/-0.3%
Mixing temperature +/- 100C

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Construction
a) The layer on which the DBM is to be placed shall be prepared in accordance with Clause502 or
902 of MoRTH Specifications.
b) If any geosynthetic material is to be provided as per design, this shall be done in
accordance with the Clause 703 of MoRTH Specifications.
c) If the design requires stress absorbing layer, it shall be provided in accordance with the
requirements of Clause 517 of MoRTH Specifications.
d) Tack coat shall be provided on the cleaned surface as per Clause 503 of MoRTH
Specifications.
e) If the surface on which the DBM is to be placed is not a bitumen bound surface, a primecoat
shall be provided as per Clause 502 of MoRTH Specifications.
f) Transportation of the mix shall be carried out as prescribed in Clause 501.4 of MoRTH
Specifications.
g) The Clause 501.5.1 of MoRTH Specifications shall be followed for weather and seasonal
limitations.

Spreading and compaction

a) Laying trials shall be carried out as per MoRTH specification
b) Compaction of the mix spread shall be carried as per Clause 501.6 and 501.7 of MoRTH
Specifications and based on the site trials.
c) The temperature of the mix at the time of laying and rolling shall be around 120 to 130 0C
d) Joints shall be prepared as per Clause 501.7 of MoRTH Specifications.
e) No traffic shall be allowed over the DBM layer till the mat cools down to the ambient
temperature.

4.6 Bituminous Concrete (BC)

Bituminous concrete surfacing is done in accordance with requirement of IRC: 29- 1968.The
construction of BC wearing, and profile corrective courses is given in Clause 507 of MoRTH

Specifications for Road and Bridge works (5th edition 2013). For grade 1 the thickness shall be 45to
50mm

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Laying Trials
Once the plant trials have been successfully completed and approved, the contractor shallcarry out
laying trials, to demonstrate that the proposed mix can be successfully laid andcompacted all in
accordance with clause MoRTH Cl:501. The laying trial shall be carried out on asuitable area which is
not to form part of the works. The area of the laying trials shall be a minimumof 100sq.m of construction
like that of the project road, and it shall be in all respects, particularly compaction, the same as the
project construction, on which the bituminous material is to be laid.

The contractor shall previously inform the Engineer in charge of the proposed method for laying and
compacting the material. The plant trials then establish if the proposed laying plant, compaction plant,
and methodology can produce satisfactory results. The density of the finished paving layer shall be
determined by taking cores, no sooner than 24 hours after laying, or by otherapproved method.

Once the laying trials have been approved, the same plant and methodology shall be applied to the
laying of the material on the project and no variation of either shall be acceptable, unless approved in
the writing by the Engineer in charge, who may at his discretion require furtherlaying trials

Material
a. Paving bitumen complying with IS: 73 shall be used for designing BC mix.
b. Coarse aggregates shall be crushed rock retained on 2.36 mm sieve. The source of aggregateshall be
approved only after testing for stripping. Aggregate shall satisfy the Requirement as per Table 11.5
c. Fine aggregates shall consist of crushed or naturally occurring mineral material or a combinationof the
two passing IS 2.36 mm sieve and retained on 75 micron. They shall be clean, hard, durable, dry and free
from dust, and soft or friable matter, organic or other deleterious impurities.
d. The fine aggregate shall have a sand equivalent value of not less than 50 when tested as per IS: 2720
(Part 37). The plasticity index of the fraction passing 0.425 mm sieve shall not exceed4, when tested in
accordance with IS: 2720 (Part 5).
e. Filler shall be finely divided mineral matter such as rock dust, hydrated lime or cement as approved by
the Engineer in charge. When the aggregates fail to meet the water sensitivity test,then 2% hydrated lime
by weight of aggregate shall be added without any additional payment.
f. The combined aggregate grading shall be tested and should confirm the limit given in table 6

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Table 6 Physical Properties of Coarse Aggregate (MoRTH Table 500-16)

Grain size analysis Max 5% passing IS:2386 Part I
0.075mm sieve
Combined Flakiness and elongation Maximum 35% IS: 2386 Part I
Los Angeles Abrasion Value Maximum 30% IS: 2386 Part IV
Aggregate Impact Value Maximum 24% IS: 2386 Part IV
Soundness 5 Cycles IS: 2386 Part V
• Sodium Sulphate Maximum 12%
• Magnesium Sulphate Maximum 18%
Polished Stone Value Min 55 BS: 812-114
Water absorption Maximum 2% IS: 2386 Part III
Coating and Stripping of Bitumen Minimum retained IS:6241
Aggregate Mix coating 95%
Retained Tensile Strength Minimum 80% AASHTO 283

Construction
a. Laying shall be suspended during rain, fog and dust storms or if free standing water is present on
the surface.
b. Bituminous work shall not be carried out if the temperature of the surface to be laid is below
100C.
c. The surface on which the mix to be placed shall be cleaned by means of a mechanical broom.
Then a high-pressure air compressor shall be used to remove any dust or loose matters.
d. If a crack prevention layer is specified, it shall be provided in accordance with the requirement of
Clause 522 of MoRTH Specification.
e. Tack coat shall be provided as specified. If the layer to receive the mix is a freshly laid bituminous
layer not contaminated by dust, tack coat is not mandatory when overlay is done within two days.
f. All bituminous premixes shall be prepared in a properly calibrated hot mix plant of adequate
capacity and capable of delivering a uniform mix with thoroughly coated aggregates.
g. The temperature requirement for bituminous mixes shall be as given in table 2300-36 (Table 500-
2 of MoRTH Specifications).
h. The difference in temperature between the binder and the aggregate should at no time exceed
140C.
i. If the plant used is continuous type, the combined grading of the cold feed aggregate mixshall

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Be within the grading limits approved for the mix.

j. The binder content shall be based on the combined grading including filler.
k. The mix from the hot mix plant shall be transported to the site in clean insulated trucks. The trucks
shall be covered with water proof covers during transport and waiting for tipping.

Spreading and compaction

• Spreading of the bituminous mix shall be carried out using a self-propelled sensor paver.
• In restricted areas where mechanical paver cannot find access, manual spreading using
experienced persons can be allowed.
• Paving shall be stopped 300 mm before expansion joints of structures and resume 300 mm after
the joint. The 600 mm left unpaved shall be kept clean free of any paving materials and other
matters.
• Bituminous mix with temperature more than 145°C shall not be placed over a bridge deckunless
approved heat damage measures are taken.
• The bituminous mix shall be kept clean and uncontaminated. If the mix gets contaminateddue to
some reason, the same shall be made good.
• The base or binder course layer shall not be left uncovered for more than 3 days or as specified
in the contract. If not covered in 3 days’ time due to valid reasons, a tack coat shall be provided
before placing the wearing course.
• The compaction of the bituminous mix shall commence immediately after laying
• The temperature of the mix at the time of laying and rolling shall be around 120 to 130 0C

The initial or breakdown rolling is done with 8-10 tonnes dead weight smooth wheeled
rollers. The intermediate rolling shall be done with 8-10 tonnes vibrating rollers or Pneumatic Tyre
Roller (PTR) of 12-15 tonnes weight with nine wheels with a minimum tyre pressure of 5.6kg/cm2

4.7 Road Markings

Road markings are defined as lines, patterns, words or other devices, except signs appliedor attached
to the carriageway for controlling, warning and guiding and informing the users. They can also be
applied in other facilities used by vehicles to mark parking spaces or designate areas for other uses.
Road markings shall be uniform in design, position and application so that they may be recognized and
understood immediately.

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The work shall consist of providing road marking of specified width, layout and design usingpaint
of the required specifications as given in the contract and as per guidelines contained in from IRC:35-
1997.

a) Materials

Road marking shall be of ordinary road marking paint hot applied thermoplastic compound,
reflectorized paint or cold applied reflective paint as specified in the item and the material shall meet
the requirements as specified in these specifications.

b) Ordinary Road Marking Paint

Ordinary paint used for road marking shall conform to Grade I as per IS:164. The road marking shall
preferably be laid with appropriate road marking machinery.

c) Hot Applied Thermoplastic Road Marking

The thermoplastic material shall be homogenously composed of aggregate, pigment, resins and glass
reflectorizing beads. The color of the compound shall be white or yellow as specified in the drawings
or as directed by the Engineer in charge. The specification shall be as per MoRTH: Cl:803.4

d) Reflectorizing Glass Beads

Two types of glass beads are used to produce reflectorized pavement markings.
Type 1 beads are those which are a constituent of the basic thermoplastic compound.
Type 2 beads are those which are to be sprayed on the surface vide clause 803.6.4

The glass beads shall be transparent, colorless and free from milkiness, dark particles andexcessive air
inclusions. These shall conform to the requirements spelt out in MoRTH clause 803.4.2.3.

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