Method Statement

Construction of 4-Lane ROB on NH-18 (Chittoor & RVS Nagar) Quality Assurance Services
METHOD STATEMENT INDEX

Item No. Description Page No.
1.0 CLEARING AND GRUBBING B2
2.0 EXCAVATION OF ROADWAY B3
3.0 EMBANKMENT AND SUB-GRADE CONSTRUCTION B 4-5
4.0 GRANULAR SUB – BASE B6
5.0 WET MIX MACADAM B7
6.0 PRIME COAT B8
7.0 TACK COAT B 9-10
8.0 DENSE GRADED BITUMINOUS MACADAM B-11
9.0 BITUMINOUS CONCRETE B-12
10.0 CONCRETE FOR STRUCTURES B 13-20
11.0 WIDENING OF PIPE CULVERT B 21-22
12.0 BOX/SLAB CULVETRS AND UNDERPASS B 23-25
13.0 BRIDGES B 26-33
14.0 WIDENING OF BITUMINOUS ROAD FROM 2LANE TO 4LANE B 34
METHODOLOGY FOR SLOPE PROTECTION WORKS (SLOPE PITCHING) IN

15.0 HIGH EMBANKMENTS B 35-36
B-1
Quality Assurance (QA) Manual
1.0 CLEARING AND GRUBBING
SCOPE:
The work shall consist of cutting, removing and disposing of all material such as trees, bushes, shrubs, stumps,
roots, grasses, weeds, top organic soil not exceeding 150mm in thickness, Rubbish etc. It shall include necessary
excavation; back filling of pits resulting from uprooting of trees and stumps to required compaction and disposal
of cleared materials to a distance up to 1000m.
The width and length over which site clearance is to be carried out shall be as shown in the drawing or as
instructed by the Authority Engineer.
If the Contractor clears the site in advance of the main works such that grass and other vegetation re-grows
prior to the main works commencing at any particular location
B-2
2.0 EXCAVATION OF ROADWAY
SCOPE:
The work shall consist of excavation, removal and satisfactory disposal of the materials necessary for the
construction of roadway and side drains, as per specification and the lines, grades and cross-sections shown in
the drawing. It shall be stacked or hauled to sites of embankment and sub-grade construction if the cut
materials are suitable.
WORK METHODOLOGY:
After the site is cleared, the topsoil has to be removed and stored. The work shall be so done that the suitable
material available from excavation can be used in the embankment. All debris and unsuitable materials shall be
disposed off as directed by the Authority Engineer.
The cut formation, which serves as sub-grade shall have a density of 98% relative compaction within the
500mm depth from the proposed sub-grade top level. Any unsuitable material encountered shall be replaced
with suitable material and compacted in layers to the required relative compaction.
B-3
3.0 EMBANKMENT AND SUB-GRADE CONSTRUCTION
GENERAL:
Materials, obtained from the cutting or borrow areas shall be used to construct embankments.
Materials for use in Embankment shall not contain particles larger than 75mm. However the 500mm in the sub-
grade shall not contain particles larger than 50mm. In addition, the materials shall have a CBR value as per
pavement design for Sub grade or as mentioned in the EPC agreement measured after 4 days soaking and shall
conform to the requirements of MORT&H specifications.
SP-73-2015
In-situ materials in the 500mm below sub-grade top level in cutting that does not meet these requirements,
shall be if suitable, placed in the embankment and replaced with material from cutting or borrow pits that do
meet the requirements for use in the 500mm below sub-grade top level.
The Contractor shall ensure that earthwork (Embankment / Sub-grade) proceed towards completion in orderly
and continuous manner. The Contractor shall submit a written request for approval of any layer at least 24
working hours in advance before he intends to cover a completed layer. Fill material for subsequent layer shall
be placed immediately after approval of the previous layer to ensure retention of moisture.
Should any layer be left unprotected for more than 24 hours and found damaged due to rains or movement of
vehicles, subsequent to approval, the Contractor shall request for re-approval of such a layer.
COMPACTION OF EARTHWORKS
B-4
The moisture content of fill material shall be adjusted immediately prior to the compaction by either uniformly
mixing water or drying out the material so that the moisture content during compaction shall be in accordance
with the Optimum Moisture content determined in the laboratory.
Each layer shall be compacted at the Optimum Moisture Content to a dry density equal to the percentage of
Maximum Dry Density (MDD) Specified below:
Top level in cutting and shoulder
Compaction of Embankment layers, and the layers, 500mm below the Sub grade top level, shall be completed
to the procedures proposed by the Contractor in accordance with the clauses of specification. The materials
500mm below sub grade top level in both fill areas and in cuttings shall be completed in three compacted
layers.
The Specification shall apply to the construction of embankment including Sub-grade and earthen shoulders
with approved materials obtained from roadway and drain Excavation or Borrow pits. All embankments shall be
constructed as per Specification and as per drawings.
MATERIALS:
The materials used in the embankment, sub-grade and earthen shoulders, shall be soil, murum, gravel or a
mixture of these as per specification. These shall be free of logs, stumps, roots, rubbish etc.
WORK METHODOLOGY:
 Topsoil unto a maximum thickness of 150mm shall be removed and stored as directed by the Authority
Engineer The original ground level shall be scarified, watered and rolled before the first layer is spread.
 In case where the difference between the sub- grade level (Top of the sub-grade on which the pavement
rest) and ground level is less than 500mm, the methodology of work shall be in accordance with MORT&H,
IRC-SP-73-2015-Manual- of- Specification
GENERAL QUALITY CONTROL PROCEDURES:
Quality of compaction material shall be controlled through extensive checks on the Borrow materials, the
compaction process and the end project, singly or in combination. However, in every case the end product must
conform to the construction specifications.
B-5
4.0 GRANULAR SUB – BASE
SCOPE:
The work shall consist of laying and compacting well-graded materials on prepared sub-grade in accordance
with the requirement of the specification. The material shall be laid in one or two layers as necessary as per
Design in accordance with the lines, grades and cross sections on the drawings.
MATERIAL:
The material used for the work shall be crushed stone and shall confirm to Grading –I & Grading –V of Table
400-1 of MORT&H Specification. The Material shall be free from organic or other deleterious constituents.
WORK METHODOLOGY:
The sub-base material of grading specified in the contract shall be spread on the prepared sub-grade with the
help of motor-grader of adequate capacity. Moisture content of the loose material shall be checked and suitably
adjusted by sprinkling additional water from the water tanker suitable for applying water uniformly and at
controlled Quantities to variable widths. At the time of compaction, the moisture content shall 1 to 2%
below the optimum moisture content. Immediately thereafter, rolling shall start. Vibratory roller of minimum
80to 100KN Static weight capacity shall be used for compaction. Rolling shall start at the lower edge and
proceed towards the upper edge. Each pass of the roller shall uniformly overlap not less than 1/3 of the track
made in the preceding pass. The speed of the roller shall not exceed 5km per hour. The required compaction
shall be 98% of maximum dry density achieved with Modified Proctor Test.
B-6
5.0 WET MIX MACADAM
SCOPE:
The work shall consist of Laying and compacting clean, crushed, graded aggregates and granular materials pre
mixed with water to a dense mass on a prepared sub-base in accordance with the requirements of the
specification. If crushed gravel/single is used, not less than 90 percent by weight of the gravel/single pieces
retained on 4.75 mm sieve shall have at least two fractured faces. If crushed risings or millings from dismantled
bituminous pavement is used, the contractor shall blend the material with crushed stone, in a mixing plant or
crusher, to achieve the required physical and grading requirements. The thickness of a single compacted wet
mix macadam layer shall not be less than 75 mm. When vibrating or other approved types of compacting
equipment are used, the compacted depth of a single layer of the sub-base course may be increased to 200mm
upon approval.
WORK METHODOLOGY:
Wet mix macadam shall be prepared in an approved mixing plant having provision for controlled addition of
water or a WMM plant. The mix shall be spread by a paver finisher. The surface of the layer shall be carefully
checked with the templates and all high and low spots remedied by removing or adding aggregates as may be
required. After the mix has been laid to the required thickness, the same shall be uniformly compacted to the
full depth with suitable roller. Compaction shall be done by vibratory roller with a maximum speed of not more
than 5km per hour. Rolling shall be continued till the density achieved is at least 98% of the Maximum Dry
Density. When tested with a straight edge, 3 m long, the irregularities must not exceed more than 12 mm on
the surface. After final compaction of wet mix macadam course, the surface shall be allowed to dry for
minimum 24 hours. Traffic shall not be allowed on the road till the surface is primed and overlaid with the next
layer.
B-7
6.0 PRIME COAT
SCOPE:
The work shall consist of an application of a single coat of slow setting bituminous emulsion to a porous
granular surface.
MATERIAL:
The primer shall be cationic bitumen emulsion SS-1 conforming to IS-8887 and spread at the rate of 7 Kg to 10
kg per 10 Sqm as per Table 500-4 of Mort&H 5th .
WORK METHODOLOGY:
The surface to be primed shall be carefully swept clean of dust and loose particles with mechanical brooms. The
surface shall be sprayed lightly with water and shall be allowed to dry. Primer shall not be sprayed when the
weather is foggy, rainy or windy or when the temperature in shade is less than 10 0C.
The surface to be primed shall be checked for line, camber and level, and the surface corrected, made good as
necessary and approved by the Authority Engineer before any bituminous spray is applied. The surface shall be
got approved prior to the Contractor’s intention to start spraying.
As soon as possible after the surface to be sprayed has been prepared as specified and approved by the
engineer, the prime or tack coat shall be sprayed onto it at the specified rate. Spraying shall be carried out
within 12 hours after the surface has been prepared and approved.
The rate of application of primer shall be 7 kg to 10kg per 10 sqm. and it shall be sprayed uniformly all over the
surface to be primed to seal the surface pores and make the surface of the base course water resistant and also
to harden and toughen the base course layer. The surface shall be allowed to cure for at least 24 hours or more
after priming and no traffic shall be allowed on it. Any unabsorbed primer shall be blotted with an application of
minimum quantity of sand.
Bitumen distributor shall be used for spraying prime coat and tack coat. It shall be truck mounted and shall have
sufficient power to maintain uniform speed for the proper application of the binder. The truck shall be equipped
with an accurate tachnometer showing to the driver the speed in meters per minute.
The truck shall be with a gauge bar and chain or any other acceptable device clearly visible to the driver to
enable him to follow the required edge. The distributor tank shall have the capacity of at least 4,000 liters and
shall be fitted with a device for indicating the quantity in the tank at any time. It shall be equipped with heaters
capable of maintain temperatures and be fitted with an accurate thermometer.
Spray bar shall be available for spraying in widths varying from 0.5 m to 4 m and shall be adjustable transversely
so that the operation can follow the required edge independently. The spray nozzles shall be arranged to give a
uniform spray and the shut-off shall be quick acting with an anti-drip device. The pressure in the spray bar shall
be sufficient to give a good distribution and spraying of the binder.
Distributors shall be checked and calibrated before starting any work. This includes the calibration of all the
metering devices and checking the uniformity of the transverse distribution of spray.
All distributors shall be furnished with a “rate of spray / machine speed” chart.
B-8
No hand spraying shall be permitted except in small areas, inaccessible to the distributor or in narrow strips or
to make good a defective area caused by a blocked nozzle. Primer shall not be applied on a wet surface.
7.0 TACK COAT
SCOPE:
The work shall consist of application of a single coat of slow setting bituminous emulsion to an existing
bituminous road surface or granular surface treated with primer, preparatory to the superimposition of
bituminous mix. The rate of application shall be 0.2 kg to 0.3 kg per square meter for bituminous surface and
0.25 kg to 0.3 kg. Per square meter for granular surfaces treated with primer & Tack coat may not be essential
between each and every bituminous Layers and shall be applied as per Specifications. .
MATERIAL:
The material used for tack coat shall bituminous emulsion complying with IS 8887. It shall not be applied when
weather is foggy or windy or rainy and when the temperature is less than 10 0C.
WORK METHODOLOGY:
The surface to be primed shall be carefully swept clean of dust and loose particles with mechanical brooms. The
surface shall be sprayed lightly with water and shall be allowed to dry. Primer shall not be sprayed when the
weather is foggy, rainy or windy or when the temperature in shade is less than 10 0C.
The surface to be primed shall be checked for line, camber and level, and the surface corrected, made good as
necessary and approved by the Authority Engineer before any bituminous spray is applied. The surface shall be
got approved prior to the Contractor’s intention to start spraying.
As soon as possible after the surface to be sprayed has been prepared as specified and approved by the
engineer, the prime or tack coat shall be sprayed onto it at the specified rate. Spraying shall be carried out
within 12 hours after the surface has been prepared and approved by the Authority Engineer.
The rate of application of tack coat shall be 0.2kg to 0.30 kg per square meter for bituminous surface & 0.25 kg
to 0.30kg per square meter for granular surface treated with primer and it shall be sprayed uniformly all over
the surface to be primed to seal the surface pores and make the surface of the base course water resistant and
also to harden and toughen the base course layer. The surface shall be allowed to cure until all the volatiles here
evaporated before any subsequent construction is stored, No plant of vehicles shall be allowed on the tack
coat other than those essential for the crusher.
B-9
Bitumen distributor shall be used for spraying prime coat and tack coat. It shall be truck mounted and shall have
sufficient power to maintain uniform speed for the proper application of the binder. The truck shall be equipped
with an accurate tachnometer showing to the driver the speed in meters per minute.
The truck shall be with a gauge bar and chain or any other acceptable device clearly visible to the driver to
enable him to follow the required edge. The distributor tank shall have the capacity of at least 4,000 liters and
shall be fitted with a device for indicating the quantity in the tank at any time. It shall be equipped with heaters
capable of maintain temperatures and be fitted with an accurate thermometer.
Spray bar shall be available for spraying in widths varying from 0.5 m to 4 m and shall be adjustable transversely
so that the operation can follow the required edge independently. The spray nozzles shall be arranged to give a
uniform spray and the shut-off shall be quick acting with an anti-drip device. The pressure in the spray bar shall
be sufficient to give a good distribution and spraying of the binder.
Distributors shall be checked and calibrated before starting any work or when required by the Authority
Engineer. This includes the calibration of all the metering devices and checking the uniformity of the transverse
distribution of spray.
All distributors shall be furnished with a “rate of spray / machine speed” chart.
No hand spraying shall be permitted except in small areas, inaccessible to the distributor or in narrow strips or
to make good a defective area caused by a blocked nozzle. Primer shall not be applied on a wet surface.
B-10
8. DENSE GRADED BITUMINOUS MACADAM
SCOPE:
Dense Graded Bituminous Macadam (DBM) shall be a hot-laid plain mixture of well-graded aggregate and VG-
40 grade bitumen.
The Dense Graded Bituminous Macadam shall mainly but not exclusively, be used in base/ binder and profile
corrective courses. DBM shall also be used as road base material. The thickness of a single layer shall be 50mm
to 100mm.
MATERIALS:
 Bitumen - Shall be paving Bitumen of VG-40 grade

Complying with IS-73- 2006.
 Coarse Aggregate - Shall be as per contract Specification
 Fine Aggregate - Shall be as per contract Specification
 Filler - Shall consist of finely grounded particles such as rock dust,
hydrated lime, ordinary Portland cement as per mix design.
AGGREGATE GRADING AND BINDER CONTENT
The combined grading of the coarse and fine aggregates and added filler for particular mixture shall fall within
the limits shown in MORT& H Specification.
WORK METHODOLOGY:
The base on which Dense Graded Bituminous Macadam is to be laid shall be prepared in accordance with the
specification. The surface shall be thoroughly swept clean by a mechanical broom and the dust be removed by
compressed air. After the application of tack coat, DBM mix produced as per the Job Mix Formula shall be laid
by paver and rolled in accordance with the specification requirements till the specified density is achieved.
The job mix formula shall be scrutinized by Authority Engineer and submitted for the approval of the Authority
Engineer at least 20 days before the starting of the work. Plant and laying trials shall be carried out satisfactorily
before the actual start of the work.
B-11
9.0 BITUMINOUS CONCRETE
SCOPE:
The work shall consist of construction of Bituminous Concrete for use in wearing course in a single layer on a
previously prepared bituminous bound surface. The single layer thickness shall be 50mm or as required by the
contract drawing and specifications.
MATERIAL:
 Bitumen - Shall be paving Bitumen of PMB / CRMB / VG Grade

Complying with IRC SP: 53
 Coarse Aggregate - Shall be confirming to technical specifications
 Fine Aggregate - Shall be confirming to technical specifications
 Filler - Shall be confirming to technical specifications
The mix shall be designed and approval as per the contract specifications.
WORK METHODOLOGY:
The surface where the wearing course is to be laid shall be thoroughly swept clean by mechanical broom and
dust be removed by compressed air. Tack coat shall be applied as per specifications. Asphalt mix shall be
transported in tipper trucks. No Laying of wearing course shall be done in bad weather or while raining. The
wearing course shall not be laid when the temperature is less than 10 0 C and the wind speed exceeds 40 km per
hour. The rate of delivery of material to the paving site shall be regulated to enable the paver to operate
continuously. Mix shall be laid and compacted before the temperature falls below the specified temperature.
The compaction shall be continued till the specified density is achieved. Rollers shall not have a speed of more
than 5km per hour.
Job mix formula shall be scrutinized by Authority Engineer and submitted for the approval of the Authority
Engineer at Least 20 days before the start of work at site. The plant and laying trails shall be carried out
satisfactory before the actual work.
Adequate quality control at every stage of the work shall be maintained and fully equipped laboratory shall be
set up to ensure the quality of the work.
B-12
Periodic sieve analysis of each type of aggregate from the cold bins shall be done to ensure the gradation of the
mix as per job Mix Formula. Three Marshal Specifications shall be prepared and tested for stability, flow value,
voids content and density and the obtained values shall be as per the design values.
The longitudinal profile of the finished surface shall be tested with the straight edge 3 meter long parallel to the
center line and the transverse profile with camber plate. Any irregularities greater than 6mm shall be corrected.
The longitudinal profile of the finished surface shall also be tested with a rough meter\ project meter and the
value shall be according to the specification.
10.0 CONCRETE FOR STRUCTURES
SCOPE:
The work shall consist of furnishing and placing structural concrete and incidental constructions according to
the Specification and drawing in the contract.
MATERIAL
All materials shall conform to the Specifications for cement, aggregate, water and admixtures etc.
GRADING OF CONCRETE
Specified characteristic compressive strength of

GRADE DESIGNATION
150mm cubes at 28 days, in MPa
M-15 15
M-20 20
M-25 25
M-30 30
M-35 35
M-40 40
M-45 45
M-50 50
M-55 55
WORK METHODOLOGY:
B-13
Before any plant for batching, mixing transporting, placing, compacting and finishing concrete is ordered or
delivered to site, the Contractor shall submit to the Authority Engineer full details including drawing of all such
plants which is proposed to use and arrangements proposed to make.
Concrete for the works shall be batched and mixed in one or more central plants unless the Authority Engineer
agrees to some other arrangement. If the Contractor proposes to use ready mix concrete, contractor shall
submit to the Authority Engineer for approval with full details and test results.
 Authority Engineer may suggest changes in the design if not satisfied with the control of
materials being used and control during the mixing. Batching and mixing plants shall be
modern and efficient equipment complying with the requirements of MORT&H specifications
SP-73& 10262-Manual-of-Specifications
Mixing shall be continued till materials are uniformly distributed and a uniform color if entire mass is obtained.
In no case shall mixing be done for less than 2 minutes.
Concrete shall be transported to the works and placed as near as practical to its final positions, by means which
shall prevent adulteration, segregation or loss of ingredients and which shall ensure that the concrete is of the
required workability at the point and time of placing. Concrete shall not be freely poured into place from a
height exceeding 1.5 m.
The time elapsing between mixing and placing a batch of concrete shall be as short as practicable.
All formworks and reinforcement contained in it shall be cleaned and made free from standing water, dust,
snow or ice immediately before placing the concrete.
Concreting shall proceed continuously on the area between the construction joints. Fresh concrete shall not to
be placed against concrete, which has been in position for more than 30 minutes unless a proper construction
joint is formed.
Concrete shall be deposited in horizontal layers to a compacted depth of not more than 450mm. Concrete shall
be compacted with the assistance of mechanical immersion vibrator. The Contractor shall ensure that vibrators
are operated with pressures and voltages not less than those recommended by the manufactures.
A sufficient number of vibrators shall be operated to enable the entire quantity of concrete being placed to be
vibrated for the necessary period and in addition, stand-by vibrators shall be available for instant use at each
place where concrete is being placed.
Concrete when deposited shall have temperature of not less than 5°C and preferably not more than 30°C and in
no case more than 40°C. In case of site mixing, fresh concrete shall be placed and compacted in its final position
within 30 minutes of its discharge from the mixer. When the concrete is carried in properly designed agitator
B-14
operating continuously, the concrete shall be placed and compacted within 1 hour of the addition of cement to
the mix and within 30 minutes of its discharge from the agitator .
Vibration shall be done continuously during the placing of each batch of concrete until the expulsion of air has
practically ceased and in a manner that does not promote segregation.
Construction joints shall be provided as shown in the drawing. The joints shall be provided in a direction
perpendicular to the member axis.
When it is necessary to deposit concrete under water concrete it shall contain 10% more cement than that
required for the same mix placed in the dry. Concrete shall not be placed in water having temperature below
50C. All under water concreting shall be carried out by tremie method only. The temperature of concrete, when
deposited shall not be less than 160 C or not more than 300C.
Concrete shall be protected during the first stage of hardening from loss of moisture and from the development
of temperature differential within the concrete sufficient to cause cracking.
The methods used for curing shall not cause damage of any kind to the concrete. Curing shall be continued for
as long as may be necessary to achieve the above objectives but in any case for at least 14 days or until the
concrete is covered by later construction whichever is the shorter period.
The curing process shall commence as soon the concrete is hard enough to resist damage from the process, and
in the case of large area or continuous pours, shall commence on the completed section of the pour before the
rest of the pour is finished.
Water used for curing shall be of the same quality as that used for mixing. Curing compound shall become
stable and impervious to the evaporation of water from the concrete surface within 60 minutes of application.
The material shall not react chemically with the concrete and shall not crack, peel or disintegrate within 3
weeks after the application.
Immediately after removing the forms, exposed bars shall be cut to a depth of at least 50 mm below the surface
of concrete and the resulting holes shall be filled with cement mortar. All fins caused by form joints, all cavities,
honeycomb spots, broken edges etc. shall be thoroughly cleaned and rectified by mortar of cement and fine
aggregates. All construction and expansion joints in the concrete work shall be tooled and free from any mortar
or concrete.
CONCRETE: QUALITY OF WORK
Check Method Frequency Accepted range
B-15
I)Prior to concreting For every change To conform to the

of source respective specifications
1. Mix design
2. Weigh batching
3. Line & level
4. Formwork
5. Placing of reinforcement
6. Plant & Equipment
7. Adequate man power To Be Satisfactory
8. Curing Arrangement
9. Walk-way for inspection For every
10. Safety arrangement
11. Lighting, if night work concreting
operation
1. II) Batching and pouring of concrete
1. Mixing of Concrete
2. Transportation, placing and
compacting of Concrete
3. Construction joint
4. Collection of Test cubes
2. III)Post- Concreting
1. Curing
2. Stripping side shutters
3. Stripping soffit shutters -Do-
4. Removal of Props
-Do-
IV)Quality of workmanship
-Do-
-Do-
-Do-
B-16
Sl.No. Check Method Frequency Acceptance Range
1 Min Strength of For every As per approved design and drawing

concrete concrete
Operation
2 Minimum cement
contest and Max.
“ -do-
w/c ratio
3 Maximum Cement
Content
“ 540 kg/ cum
Type of Structure Slump in mm
4 Consistency by IS-516 “ RCC with widely 40-50

slump test spaced
reinforcement
50-75
RCC with fairly
spaced
reinforcement
75-125
RCC & PSC with
Highly congested
Reinforcement
100-200
Underwater
concreting through
tremie e.g. button
plug, cast in situ
piling
Trial Mixes of Avg. strength of 9 cubes at 28 days shall
B-17
5 concrete cube exceed specified characteristic strength by

strength current margin minus 3.5 Mpa
1) Mean strength determined from any
group of 4 consecutive samples should
Compressive exceed the specified characteristic
strength of working strength
6 For each Lot 2) Strength of any samples is not less
cubes (28 days)
than specified characteristic strength
minus 3.5 Mpa
FREQUENCY
Quantity of Concrete in m3 No. of Samples
1-5 1
6-15 2
16-30 3
31-50 4
51 & above 4 plus one addl. For each addl. 50 m3 or part thereof
MORTAR
Mortar shall be composed of fine aggregate and ordinary Portland cement. The mix proportion shall be as
stated on the drawings or elsewhere in the specification.
The mixing shall be done in a mechanical mixer. Hand mixing can be restored to as long as uniform density of
mix and its strength are assured subject to prior approval of the Authority Engineer. Mortar shall be mixed only
in such quantity as required for immediate use.
SETTING OUT OF WORKS
Check List
1) Working benchmarks shall be established with reference to permanent BM obtained from Government of
India.
2) Survey instruments
i. Leveling Instruction; Precision automatic levels having standard deviation of 2mm /km and fitted with
Micrometers
ii. Measurement of Angle: Theodolite having an accuracy of one Second
B-18
iii. Measurement of distance: Distomate (Electronic distance meter)

3) A proper record of all benchmarks, survey control points and setting out points with suitable supporting
sketches should be maintained.
SUB STRUCTURE
Specified
S. No Test Specification Frequency
Value
1 Material MORT&H spec- Sec: 1000 As specified
2 Form Work Sec: 1500 of MORT& H For each member
For each
3 Concreting As per specification
concreting
Tolerance in Concrete
4 Clause 2208 of MORT& H Each Member
elements
Variation in c/s dimensions +10mm, - 5mm
Misplacement from specified position in plan 10 mm
Variation of level at top ±10mm
Variation of R.L. of bearing Area ±

5mm
Variation from plumb over full height ±

10mm
Surface irregularities measured with 3 M straight.

Edge
5 mm
 All surface except bearing areas
 Bearing Area 3mm
SUPERSTRUCTURE
Sl.
Test Specification Frequency Specified Value
No.
To conform to section 1000 of MORT& H

As
1 Materials specification test as indicated in the As indicated
indicated
manual
Dimensions line and Each As per approved

2 As per approved Drawing
level Member drawing
B-19
Each
3 Form Work Section 1500 of MORT& H specification
Member
4 Steel reinforcement Section 1600 of MORT& H specification -Do-
5 Structural Conc. Section 1600 of MORT& H specification -Do-
6 Pre-stressing Section 1800 of MORT& H specification -Do-
Quality and
7 Section 2300 of MORT& H specification -Do-
workmanship
Tolerance for cast-in-

8 Cl. 2306.2 of MORT& H specification -Do-
situ super-structure
TOLERANCE IN VARIATIONS
Thickness of top and bottom slab for box girder and bottom
1 -5 mm to + 10 mm
flange for T girder or slab
2 Web Thickness -5 mm to + 10 mm
3 Overall width or depth +

- 5mm
Not more than +

- 10mm or +-0.1% of
4 Length overall and length between bearing
span whichever is lesser
5 Surface irregularities on 3m straight edge 5 mm
B-20
11.0 PIPE CULVERT
SCOPE:
The scope of this document covers the following activities:
i) Cutting, removing and disposing of all materials such as trees, bushes, shrubs, stumps, roots, grass,
weeds, top organic soil etc., which are unsuitable for incorporation in the works, from the area within toe
line containing road embankment drains, cross drainage structures and such other areas as may be
specified in the drawings.
 Excavation necessary for construction of CD Works complete as per MORT&H, IRC-SP-73-2007-Manual- of-
Specification
ii) Selection of various Construction Materials, Testing of Materials, and approvals.
iii) Construction of Cross Drainage Work Pipe Culvert with approved materials/methods etc. complete as per
MORT& H / Contract specifications Section 2900 and also as per other relevant sections of MORT& H/
Contract specifications applicable for Concrete Works as specified in Construction Methodology.
Work Sequence:
Site Clearance Works:
Site Clearance, grubbing, Dismantling of existing structures and disposal of unserviceable materials at
designated areas and stacking of serviceable materials for use in embankment construction works etc. shall be
carried out as per MORT& H.
Survey and Setting out Works:
After the Site has been cleared the excavations shall be set out true to lines, curves, slopes, grades and sections
as shown in the drawings and as per established bench marks / Co-ordinates.
All the Survey Instruments used shall be calibrated periodically as per Calibration Plan. Survey Check Reports /
other relevant data shall be maintained in relevant Inspection formats.
Construction of Pipe Culvert:
The foundation bed for Pipe Culverts shall be excavated true to the lines and grades as per the drawings. In case
of high embankment where the height of filling is more than three times the external diameter of the pipes, the
embankment shall first be built to an elevation above the top of the pipe equal to the external diameter of the
pipe, and to width on each side of the pipe not less than five times the diameter of the pipe, after which the
trench shall be excavated. For the construction of head of head walls, the excavation shall be carried out as per
MORT& H Clause 304. Bed concrete PCC (M15 Grade Nominal Mix) for head wall shall be done over compacted
sand bedding. Head wall shall be constructed by using P.C.C M20. All the materials used in the work shall
conform to the requirements laid down in section 1000 of MORT& H / contract specifications. Bedding for pipe
B-21
shall be prepared by granular filling. Over the compacted granular fill, 150mm thick M15 grade PCC shall be laid.
Slope of the bedding shall be as per drawing.
The Hume pipes shall be laid, as per drawing, where two or more pipes shall be laid adjacent to each other;
they shall be separated by distance as mentioned in the drawing. The laying of pipe shall be carried out as per
MORT& H.
The pipes shall be joined by collar joint. The collars shall be of RCC 150 to 200 mm wide and having the same
strength as the pipes to be jointed. Caulking space shall be between 13 to 20 mm according to the diameter of
the pipe. Caulking material shall be slightly wet mix of cement and sand in the ratio of 1:2 rammed with
caulking irons. Before caulking, the collar shall be so placed that its center coincides with the joint and an even
annular space is left between the collar and the pipe.
B-22
12.0 BOX / SLAB CULVERTS & UNDERPASS
Scope:
This work method statement covers all cross drainage structures in contract package as indicated in the
drawings. The cross drainage works involved are of following types as specified in the drawings.
Underpasses
Box / Slab culverts
Minor and Major Bridges
Work Sequence:
Box Culverts & Underpass:
1. Marking of layout for excavation: The location of the structure shall be done by the survey department
jointly. The coordinates and centerline shall be established and marked on the ground. Original Ground
Levels shall also be recorded jointly.
2. Working Drawing: The working drawing shall be prepared based on existing ground levels & shall be
submitted to the Authority Engineer for review.
3. Excavation: The excavation for construction shall be started after Authority Engineer reviews working
drawings. The excavation shall be carried mechanically or manually up to desire depth as shown in
drawings maintaining proper grade & levels.
4. PCC: Bottom of founding level shall be checked jointly and recorded before laying of PCC for foundation
and clearance obtained for laying of PCC.
5. PCC M 15 (approved mix) in foundation shall be place manually or by any other means in single layer.
Side forms shall be provided and the top level checked. The placed concrete shall be compacted by
means of manual compactor with proper tamping & the surface leveled.
6. Curtain Wall: Excavation for curtain wall shall be done as per drawings.
7. Formwork for Curtain Wall: For the base, raft of curtain walls shall be fixed with proper line & levels and
proper supporting arrangements.
8. The formwork shall be got checked and approved by the Authority Engineer and Authority Engineer for
sample works. The concrete will be placed manually, compacted by electrical / diesel operated vibrators
& shear keys will be provided at intervals as per drawings. The curtain wall will be constructed in lifts as
required.
9. Box Wall: Simultaneously placing & tying of reinforcement for box wall shall be started as per approved
bar bending schedule.
10. Shuttering work will be started for walls from bottom of slab level with proper line & level & proper
supporting arrangements.
11. The concrete will be placed by concrete pump or any other means, compacted by electrical / diesel
operated vibrators.
12. Side forms shall be removed after 24 hours & curing shall be done minimum for 14 days.
B-23
13. Box Slab: After completion of walls, scaffolding and form work will be started for soffit of top slab of box
maintaining required line and level.
14. Placing & tying of reinforcement for slab shall started as per approved bar bending schedule.
15. The concrete will be placed by concrete pump or any other means, compacted by electrical / diesel
operated vibrators.
16. Side forms shall be removed after 24 hours & curing shall be done for 21 days.
Slab Culverts:
1. Marking of layout for excavation: The location of the structure shall be fixed by the surveyor as per the
drawing. The coordinates and centerline shall be established and marked on the ground. Original Ground
Levels shall also be recorded.
2. Working drawings: The working drawing shall be prepared based on existing ground levels & shall be
submitted to the Authority Engineer for review.
3. Excavation: The excavation for construction shall be started after Authority Engineer reviews the working
drawings. The excavation shall be carried mechanically or manually up to the desired depth as shown in
drawings, maintaining proper grade & levels.
4. PCC: Bottom of founding level shall be checked jointly and recorded before laying of PCC for foundation
and clearance obtained for laying of PCC.
5. PCC M 15 (approved mix) in foundation shall be placed manually or by any other means in single layer.
Side forms shall be provided and the top level checked. The placed concrete shall be compacted by
means of manual compactor with proper tamping & the surface leveled.
6. Layout shall be marked on the surface of the PCC for placing of reinforcement for piers and abutments.
Reinforcement shall be put in place as per approved BBS.
7. Formwork for base raft excluding retaining wall shall be fixed with proper line & level and proper
8. The formwork shall be got checked and approved by Authority Engineer for sample works. The concrete
will be placed with concrete pump / manually, compacted by electrical / diesel operated vibrators &
shear keys will be provided in the wall portion at intervals as required for various lifts of pier and
abutments.
9. Side forms shall be removed after 24 hours & curing shall be done for 14 days.
10. The staging for the slab is executed as per the approved design. The supports should be firm enough to
take up the dead + live load of the slab. The reinforcement of slab is placed as per the approved Bar
Bending Schedule. Concrete work should be executed after checking of reinforcement, shuttering and
concreting arrangements etc by the Authority Engineer.
11. RE Wall: Simultaneously excavation for Reinforced Earth walls up to the required founding level bottom
shall be started after getting.
12. The formwork shall be got checked and approved by the Authority Engineer. The concrete will be
placed by manually, compacted by electrical / diesel operated vibrators.
Q.C. Procedures:-
B-24
All the basic materials used for CD works shall conform to section 1000 of MORT& H specifications.
The QC laboratory will conduct tests to confirm the acceptability of the materials proposed to be used in the
works.
Routine testing on stacked materials will be carried out from time to time as directed by the Authority Engineer.
The frequency of tests will conform to requirements of technical specifications.
The approved source will not be changed without prior approval of the Authority Engineer.
Stockpiles of aggregates will be inspected at regular intervals by Authority Engineer.
Construction water and curing water will be tested & approved by the Authority Engineer. With the approved
materials and mix design, concrete will be produced at batching plant and transported to site through transit
mixers as per site requirement.
For field tests like slump test for workability of mix, sampling of concrete for compressive strength etc, required
tools and equipments will be kept ready at site.
Shear keys will be provided in concrete wherever required.
Side forms will be tripped after 24 hours of pour and will be followed by curing. The bottom forms for desk slabs
will be removed after 14 days with prior permission of the Authority Engineer.
Checklists for all activities i.e. formwork, reinforcement, placing of concrete etc. will be checked prior to start of
concreting.
The Contractor’s qualified Engineer will inspect the pouring location and will ensure that all check lists are duly
signed by the Authority Engineer, all equipments are available at site to conduct the necessary field tests prior
to actual pouring at site.
13.0 BRIDGE WORK
SCOPE:
The Scope of this document covers the following activities:
 Survey and Setting out works marking pile caps/pier shafts/ abutment.
B-25
 Selection, testing and acceptance of Materials and Mixes for Cast-in-situ pile caps, pier shafts, abutment/
pedestal.
 Deployment of Plant / Equipment / Machinery etc.
 Construction Methodology for pier shafts, abutment/ pedestal.
Sub Structure:
Work Sequence:
Open Foundation for Piers / Abutments/ Retaining Walls
1. Marking of layout for excavation: The location of the structure shall be marked by the survey
department jointly. The coordinates and centerline shall be established and marked on the ground and
recorded jointly. Original Ground Level shall also be recorded jointly.
2. Excavation: The excavation for construction shall be started after getting approval of working drawings
from Engineer. The excavation shall be carried mechanically or manually up to desire depth as shown in
drawings maintains proper levels.
3. PCC: Founding level for foundation shall be checked and recorded jointly before laying of PCC and
clearance obtained for laying of PCC.
PCC M 15 (approved mix) in foundation shall be placed manually / other means in single layer, side forms
shall be provided and the top level checked. The placed concrete shall be compacted by means of
manual compactor with proper tamping & the surface leveled.
4. Reinforcement: The Bar Bending Schedule for open foundation & pier shaft shall be prepared and
submitted to Engineer for prior approval.
Reinforcement shall be cut and bent as per approved BBS and kept ready.
Layout shall be marked on the surface of the PCC for placing of reinforcement.
Reinforcement shall be placed in position as per approved BBS.
5. Formwork: The design of formwork and supports shall be submitted to Authority Engineer for prior
approval.
Formwork as per approved design shall be fixed with proper line & levels and proper supporting
arrangements.
The formwork and supporting arrangement shall be got checked and approved by the Authority
Engineer Shuttering oil shall be applied used to the shutters.

6. Concreting: The concrete will be placed by concrete pump/ manually and compacted by electrical /
diesel-operated vibrators.
Side forms shall be removed after 24 hours & curing shall be done for 14 days.
Shutter Vibrator shall used for concreting done in single pour.
Pier/ Abutment / Ret. Walls
1. Reinforcement: The Bar Bending Schedule shall be prepared and Reinforcement shall be cut and bent
as per approved BBS and kept ready.
B-26
Reinforcement shall be placed in position as per approved drawing and approval shall be obtained
from the Authority Engineer and Authority Engineer.
2. Formwork: The design of formwork and supports shall be submitted to IE for prior approval. Layout
shall be marked on the top surface for the foundation.
Formwork as per approved design for pier starter shall be fixed with proper line & levels and with
proper supporting arrangements.
The formwork and supporting arrangement shall be got checked and approved by Authority Engineer
and Authority Engineer. The concrete shall be placed by crane bucket concrete pump, compacted by
electrical / diesel-operated vibrators.
Starter forms shall be removed after 12 hours.
Pier forms shall be fixed after removing of starter forms and proper alignment of formwork shall be
carried out. The supporting arrangements shall be carried out as per approved drawing.
3. Concrete: The concrete will be placed using concrete pump/ crane & bucket arrangement.
The length of concrete hose shall be kept such that free fall of concrete does not exceed 1.5 meters.
Concrete shall be compacted by electrical / diesel operated needle vibrators / shutter vibrators as per
requirements.
Pier from shall be removed after 24 hrs. of concreting and curing shall be carried out for 14 days .
Pier cap / Abutment cap
1. Formwork: The design of formwork and supports shall be submitted to Authority Engineer for prior
approval. Formwork for pier cap/abutment cap shall be fixed with proper line & levels and with proper
2. Reinforcement & Concreting: The BBS shall be prepared and Reinforcement shall be cut and bent as
per approved BBS and kept ready.
Reinforcement shall be placed in position as per approved BBS.
The concrete shall be placed using concrete pump/ crane & bucket arrangement and compacted by
electrical / diesel – operated vibrators. Side forms shall be removed after 12 hours.
Soffit forms shall be removed after 14 days of concreting or attaining required strength, whichever is
earlier.
Curing shall be carried out for at least 14 days.
Pedestal
1. Formwork: The design of formwork and supports shall be submitted Authority Engineer for prior
approval.
Location of pedestal shall be marked over pier cap.
Formwork for pedestal cap shall be fixed with proper line & levels and with proper supporting
arrangements.
Curing shall be carried out for at least 14 days.
B-27
2. Reinforcement & Concreting: The Bar Bending Schedule shall be prepared and Reinforcement shall be
cut and bent as per approved BBS and kept ready.
Reinforcement shall be placed in position as per approved BBS before fixing the side forms.
The reinforcement shall be got checked by Authority Engineer before concreting.
The concrete shall be placed using crane & bucket arrangement and compacted by electrical / diesel-
operated vibrators. Side forms shall be removed between 12 to 24 hours.
Soffit forms shall be removed after 14 days of concreting for attaining required strength, whichever is
earlier.
Curing shall be carried out for 14 days.
Testing Process:
All the basic material shall be used for bridge works shall conform to the section 1000 of MORT&H /
SP-73-2007-Manual-of-Specifications
The QC-laboratory will test to confirm the acceptability of the materials proposed shall used in the works.
All the materials from various sources will be tested & got approved prior to use.
Routine testing on stacked materials will be carried out from time to time as per MORT&H / SP-73-2007-
Manual-of-Specifications
The Frequency of tests will conform to requirements of MORT&H / SP-73-2007-Manual-of-

Specifications.
The approved sources will not be changed without prior approval of the Authority Engineer.
Stockpiles of aggregates will be inspected at regular intervals with the support of Authority Engineer.
Construction water and curing water will be tested & got approved by the Authority Engineer. With the
approved materials and mix design, concrete will be produced at batching plant and transported to site through
transit mixer as per site requirement.
For field tests like slump test for workability of mix, sampling of concrete for compressive strength etc, required
tools and equipments will be kept ready at site.
Shear keys will be provided in concrete wherever required.
Side forms will be stripped after 24 hours of pour and will be followed by curing. The bottom forms for desk
slabs will Removed after 14 days.
Checklist for all activities i.e. formwork, reinforcement, placing of concrete and post concrete inspection etc will
be prepared and got checked by the Authority Engineer.
The Contractor will inspect the pouring location and will ensure that all check lists are duly signed. All
equipment is available at site to conduct the necessary field tests prior to actual pouring at site.
B-28
Super Structure:
SCOPE:
The Scope of this document covers the following activities:
 Survey and Setting out works marking superstructure deck.

 Selection, testing and acceptance of Materials and Mixes for Cast-in-situ superstructure deck.
 Deployment of plant / Equipment / Machinery etc.
 Construction Methodology for superstructure deck.
Work Sequence:
General
The superstructure would be cast in situ and would be cast in two stages. During first stage concreting of
longitudinal girders and diaphragms shall be carried out up to bottom of deck and then second stage concreting
shall be carried out for deck portion.
To cast the superstructure steel formwork is used, supported on the ground staging comprising of heavy-duty
tower & H- frame. The adjustments to the formwork i.e. lowering and raising are made by providing the
adjustable stirrup heads fixed to the staging towers & H-frame.
The ground supporting staging is leveled and compacted.
The reinforcement is cut, bent kept ready. Before fixation of reinforcement the form panels are applied with a
coat of coat of form release agent and all the joints are sealed of using 6 mm foam and filler paste is used.
The placement of the concrete would be through concrete pump and concreting of longitudinal girders, end
diaphragm is done in layers. The placed concrete is vibrated using needle vibrators.
The final top surface is given a broom finish by using brooms. Adequate lighting arrangements would be
provided for concreting during nights.
For curing of the deck, bunds shall be made by sand cement mortar.
The formwork and staging H-frames are removed and moved to next span leaving the heavy – duty towers
underneath the bridge beams for 21 days.
Placement of bearing shall be done as per drawings and complying to manufacture’s specifications.
Detailed Methodology:
B-29
Preliminary works: During the previous stages of construction i.e. up to the substructures level the supporting
earth is in undulated condition. The entire area of soil supporting the staging, the loose topsoil is removed. The
ground is leveled and compacted. Prior to the whole operation the bearing capacity of the soil checked whether
it satisfies the design criteria adopted in the design of formwork. If the bearing capacity is lesser than required,
same shall be improved by preparing sand bed. Sand bed shall be fully saturated to achieve the maximum
density. On the leveled and compacted earth the position of the heavy duty towers/ H-frames are marked and
is excavated in a trench to fit the height of available heavy duty towers / H-frames.
The details design of staging, formwork shall be submitted to Authority Engineer for prior approval. The
approved staging / formwork shall be fabricated at yard.
Survey works: The survey work would be carried out along the alignment to fix the bridge beam and center line
of the bridge axis.
All the levels and coordinates of the points to be checked. The contractor inspection at predetermined and pre-
marked points shall offer checking of levels and coordinates.
Erection of staging and formwork;
(A) Erection of H-frame / from panels (End spans)

(B) Erection of Heavy duty towers/ H-frames / from panels (central spans)
(A) Erection of H-frames /from panels underneath longitudinal girders (end spans)
The H-frames are used under the longitudinal girders. To accommodate a modular size of H- frame the soil may
be even cut to more depth locally as per the site conditions. The H-frames are placed in position over base plate
resting on wooden sleepers.
After the complete of the H-frame towers, the bracing are to make up the entire tower rigid under the bridge
beam. On the top of the tower the adjustable stirrup heads are put in position where the cross bearer beam
rests. The soffit shutter of girder shall be placed over cross bearers. To attain the soffit levels of the bridge girder
fine adjustments in level is obtained by adjusting the adjustable stirrup head.
The H-frames for support of diaphragm / deck panels shall be erected over cross bearers. Longitudinal bearers
shall be placed the over H- frames and soffit from panels of bridge deck and diaphragm are placed over it and
tightened by bolts.
The form panels shall be cleaned and applied with a coat from release agent. The form panels are jointed with
the 6mmfoam sheet and sealing compound and any adjustments are made in the stirrup heads to meet the
required soffit levels or by placing of packing materials. The side forms of the bridge beam are fixed to the soffit
and verticality is checked with a plumb.
B-30
(B) Erection of Heavy Duty towers / H-frames / from panels (central span):
To provide safety during construction, staging of longitudinal girders of central spans shall be carried out using
Heavy-duty towers.
Heavy-duty towers shall be supported on grillage footings. Longitudinal trusses shall be placed over heavy-duty
towers.
Cross bearers shall be placed over trusses, which shall support the soffit form panels.
H-frames would be supported on cross bearers of longitudinal girders.
The H-frame are fixed to the base plates, positioned on the bearers and on the top, adjustable stirrup heads are
provided to take the longitudinal bearers and cross bearers, which support the superstructure form panels. The
H-frame is cross braced to make the system rigid. When the bracing of the H-frames is completed, the bearer
beams are fixed in the stirrup heads and packed with timber / steel section.
The form panels are held in position by bolting arrangement and joints of top panel shall be sealed of using 6
mm thick foam sheet and sealing compound. To meet the requisite levels of the form panel with one end other
minor adjustment i.e. small rise in the stirrup head is carried out.
When the entire staging and formwork is ready, the same is checked and approved by Authority Engineer. The
deck profile is checked and approved by Authority Engineer before concreting. Any minor adjustments to the
deck profiles are made by Rising or lowering stirrup heads or by placing packing material.
To provide access for the access for the execution of the works the access towers are placed at the abutment /
pier location. Railing by all round the walkway is provided by using pipe/ timber frames.
PLACEMENT OF REINFORCEMENT:
The BBS shall be prepared and got approved from Authority Engineer. The reinforcement are cut and bent at
the site. The reinforcement work would be carried in two phases.
 Longitudinal girder and diaphragms reinforcement

 Deck Reinforcement
Before placement of reinforcement the entire formwork is cleaned using compressed air. The reinforcement is
fixed in position and tied using binder steel. Suitable cover blocks are provided to provide cover to the
B-31
reinforcement. When the entire reinforcement of bridge beam and diaphragms is completed the same is got
approved by Authority Engineer.
The second phase of reinforcement fixing starts after concreting of longitudinal girders and diaphragm is
completed up to deck bottom level. The top reinforcement is fixed in position as described earlier. The
reinforcement projecting into crash barrier is also provided. When the entire reinforcement work is completed
the same is again got checked by Authority Engineer. Pockets for the fixing expansion joints would be left by
using thermo coal (insulation material).
The reinforcement in the location of the drainage spouts is moved locally to accommodate the recess of the
drainage hole. The drainage spouts are fixed at their respective locations. The drainage spouts are packed with
sand wooden pocket so that the concrete doesn’t get filled in.
CONCRETING:
Before the concreting operations are planned the entire checking with the supervision consultants would be
completed. All the loose materials are removed/ blown using air compressor. The concreting operation would
be done in single pour from end diaphram to end diaphram. Pier to concrete, the arrangement for concreting
are checked so that no interruption occurs during concreting. Approved mix design would be followed during
concreting.
The placement of the concrete would be through concrete pump/ crane and bucket arrangements. The placed
concrete is vibrated using needle vibrators of appropriate diameters.
Phase I – Up to bottom of deck slab
At the diaphragms and longitudinal girders location, the concrete would be carried in the layers. The concrete
shall be vibrated using 60 mm/40 mm/ 25 mm vibrators. The 60 mm needle vibrator is used in the non-
congested area, in the bottom of girders, where reinforcement congestion is present the vibration would be
carried out by 25/ 40 mm needle vibrators and shutter vibrators.
Phase II – Deck slab
The concrete will be executed in horizontal strips of 3.0 m widths. The concrete placing would be carried
forward by finishing activities. The final top surface is given a texture finish using brooms. When the concrete of
the first strip is partially complete, masons would finish the concrete top surface using floats & trowels. The
B-32
green concrete would be made rough; exposing the aggregate partially, where further concrete is to be carried
out i. e. in the location of crash barrier.
CURING:
Immediately after concrete is hardened, curing shall be started. For the curing purpose, flexible pipe, which is
connected to the main line from which continuous curing is carried out, may be engaged. Bunds of size shall be
made using sand cement mortar. Curing shall be carried out for period of 28 days.
DE-SHUTTERING:
The de-shuttering of the form panels would be completed in stages.
In the stage 1, side form panels of longitudinal girder, diaphragms and desk is removed after 24 hrs. of
concreting.
In the stage 2, H-frames and soffit panels of deck are removed after 14 days of concreting.
In stage3, stagings along with soffit panels underneath longitudinal girders and diaphragms are removed after
21 days of concreting.
B-33
14. WIDENING & REHABILITATION OF EXISTING 2 LANE BITUMINOUS ROAD TO 4 LANE INCLUDING
SERVICE ROADS
1. Suitable traffic diversion scheme shall be developed for each location. This may change based on
location to location. The traffic diversion shall incorporate suitable road furniture, sign boards, safety
equipment etc. The traffic diversion shall be approved by the Authority Engineer.
2. The portion to be widened shall be made flush with the existing pavement. The existing pavement
must be cut to full depth level, and after reaching subgrade level, existing soil shall be checked for
compliance to CBR requirements.
3. The excavated earth shall be stored in heaps adjoining the road within the ROW.
If subgrade CBR is found not suitable matching to the MORT&H, IRC-SP-73-2007-Manual- of-
Specification suitable earth shall be used from borrow areas.
4. If it is found suitable, loosening and recompacting is done to the required compaction level.
5. Each pavement crust layer shall be built as per the approved pavement design and each matching with
the adjacent existing pavement.
6. The side slopes shall be maintained as per design (usually 2:1).
7. The top layer is laid for the entire width covering both existing portion and new portion.
9. Quality control in each stage shall be as per the MORT&H, IRC-SP-73-2007-Manual-of- Specification
10. In case of service roads, the above methodology shall hold good for both eccentric and concentric
widening.
B-34
15.METHODOLOGY FOR SLOPE PROTECTION WORKS (SLOPE PITCHING) IN

HIGH EMBANKMENTS
(ACCEPTANCE CRITERIA: REFER SEC 2500 OF MORT&H)
Scope:
This work will consist of covering the slopes of guide bunds, training works and road embankments
with stone, boulders, cement concrete blocks or stones in wire crates over a layer of granular material
called filter.
Equipments, Tools & Plants Required:

1. Hand Tools
2. Water tanker
3. Dumper
4. Formwork
Procedure:
Slope Preparation:
The compacted layers shall be trimmed to the required slope and profile as per the approved drawing
using line and pegs. Any depression shall be filled up and compacted thoroughly using wooden
rammers.
Placing of filter layer:
GSB material (approved as filter material) shall be placed manually over prepared base and shall be
compacted in uniform layer of 150mm maintaining slope and profile as per the approved drawing.
Dry rubble pitching:
Over the prepared filter layer dry pitching shall be carried out either with stones of specified quality
or concrete blocks (of M15 grade) having weigh less than 40 kg maintaining slope and profile as per
the approved drawing. Pitching shall be commenced from bottom of the slope and continued to the
top. In case of rubble pitching care shall be taken to minimize void between the stones, which
however shall be filled up with spalls size of Minimum 25mm.
Construction of chute drain:
Chute drain shall be constructed at 25M C/C along the road alignment parallel to the slope of pitching
as per the dimension, slope and profile as mentioned in approved drawing. Firstly 75mm thick
B-35
leveling course (M15 grade) shall be placed along the embankment slope over filter layer and shall be
extended to the Kerb face. The drain wall shall be constructed with PCC M15 concrete. At junction of
chute drain with kerb, the kerb shall be cut to the required dimension.
Construction of Toe drain:

Construction of Toe drain shall be done in RCC. Soil at toe portion shall be trimmed, leveled and
trenched to the required shape and size. Shuttering and prepared to pour concrete reinforcement
fixing to specified size and concrete quality, maintaining the dimensions, slope and profile as
mentioned in approved drawing. Surface shall be covered with RCC precast cover blocks after
completing drain casting for reasonable length.
Curing:
Curing of concrete shall be continued for 7 days by sprinkling of water.
B-36

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Construction of 4-Lane ROB on NH-18 (Chittoor & RVS Nagar) Quality Assurance Services

METHOD STATEMENT INDEX

1.0 CLEARING AND GRUBBING B2

2.0 EXCAVATION OF ROADWAY B3

3.0 EMBANKMENT AND SUB-GRADE CONSTRUCTION B 4-5

4.0 GRANULAR SUB – BASE B6

5.0 WET MIX MACADAM B7

6.0 PRIME COAT B8

7.0 TACK COAT B 9-10

8.0 DENSE GRADED BITUMINOUS MACADAM B-11

9.0 BITUMINOUS CONCRETE B-12

10.0 CONCRETE FOR STRUCTURES B 13-20

11.0 WIDENING OF PIPE CULVERT B 21-22

12.0 BOX/SLAB CULVETRS AND UNDERPASS B 23-25

13.0 BRIDGES B 26-33

14.0 WIDENING OF BITUMINOUS ROAD FROM 2LANE TO 4LANE B 34

METHODOLOGY FOR SLOPE PROTECTION WORKS (SLOPE PITCHING) IN

1.0 CLEARING AND GRUBBING

2.0 EXCAVATION OF ROADWAY

3.0 EMBANKMENT AND SUB-GRADE CONSTRUCTION

Top level in cutting and shoulder

GENERAL QUALITY CONTROL PROCEDURES:

4.0 GRANULAR SUB – BASE

5.0 WET MIX MACADAM

6.0 PRIME COAT

7.0 TACK COAT

8. DENSE GRADED BITUMINOUS MACADAM

 Bitumen - Shall be paving Bitumen of VG-40 grade

AGGREGATE GRADING AND BINDER CONTENT

9.0 BITUMINOUS CONCRETE

 Bitumen - Shall be paving Bitumen of PMB / CRMB / VG Grade

10.0 CONCRETE FOR STRUCTURES

Specified characteristic compressive strength of

CONCRETE: QUALITY OF WORK

Check Method Frequency Accepted range

I)Prior to concreting For every change To conform to the

Sl.No. Check Method Frequency Acceptance Range

1 Min Strength of For every As per approved design and drawing

Type of Structure Slump in mm

4 Consistency by IS-516 “ RCC with widely 40-50

Trial Mixes of Avg. strength of 9 cubes at 28 days shall

5 concrete cube exceed specified characteristic strength by

Quantity of Concrete in m3 No. of Samples

SETTING OUT OF WORKS

iii. Measurement of distance: Distomate (Electronic distance meter)

1 Material MORT&H spec- Sec: 1000 As specified

2 Form Work Sec: 1500 of MORT& H For each member

Variation in c/s dimensions +10mm, - 5mm

Misplacement from specified position in plan 10 mm

Variation of level at top ±10mm

Variation of R.L. of bearing Area ±

Variation from plumb over full height ±

Surface irregularities measured with 3 M straight.

To conform to section 1000 of MORT& H

Dimensions line and Each As per approved

4 Steel reinforcement Section 1600 of MORT& H specification -Do-

5 Structural Conc. Section 1600 of MORT& H specification -Do-

6 Pre-stressing Section 1800 of MORT& H specification -Do-

Tolerance for cast-in-

3 Overall width or depth +

Not more than +

5 Surface irregularities on 3m straight edge 5 mm

11.0 PIPE CULVERT