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MINISTRY OF ROAD TRANSPORT & HIGHWAYS

SPECIFICATIONS FOR ROAD AND BRIDGE WORKS

(Fifth Revision)

Published By the Indian Roads Congress,


on Behalf of the Govt. of India,
Ministry of Road Transport & Highways

Copies can be had from Indian Roads Congress,


Jamnagar House, Shahjahan Road, New Delhi &
Sector 6, R.K. Puram, Kama Koti Marg, New Delhi

Price Rs. 3,000/-


Plus packing & postage charges
First Published April, 1973
Reprinted November, 1975
Reprinted May, 1978
Reprinted September, 1981
Reprinted October, 1983
Reprinted April, 1986
Second Revision February, 1988
Reprinted August, 1988
Reprinted April, 1990
Reprinted June, 1992
Reprinted February, 1993
Reprinted July, 1993
Third Revision April, 1995
Reprinted January, 1997 (Incorporates Corrigendum No.1 & 2 and
Col. 12 & 15 p. 662)
Reprinted January, 1998
Reprinted January, 1999
Reprinted IWay, 1999
Reprinted February, 2000
Reprinted September, 2000 (Section 700 "Geosynthetics" Changed to
"Geosynthetics and Reinforced Earth1')
Fourth Revision August, 2001
Reprinted January, 2002
Reprinted March, 2002
Reprinted September 2002
Reprinted November, 2002
Reprinted March, 2003
Reprinted June, 2003
Reprinted July, 2003
Reprinted December, 2003
Reprinted May, 2004
Reprinted September, 2004
Reprinted April, 2005
Reprinted October, 2005
Reprinted March, 2006
Reprinted September, 2006
Reprinted March, 2007
Reprinted August, 2007
Reprinted February, 2008
Reprinted August, 2008
Reprinted November, 2008
Reprinted March, 2009
Reprinted June, 2009
Reprinted December, 2009
Reprinted March, 2010
Reprinted July, 2010
Fifth Revision April, 2013
(Rights of publication and Translation are reserved)

Printed at: India Offset Press, A-I Mayapuri Ind. Area Phase-I New Delhi-11064

(1000 copies)
PREFACE TO THE FIFTH REVISION

This edition of the Specifications for Road and Bridge Works marks the Fifth Revision. In
the last decade and a half, significant developments have taken place in the highways
sector. The massive National Highways Development Projects (NHDP) undertaken by the
Government of India is in progress involving execution of a large nurr~berof high value road
projects. These require adoption of latest international practices so as to achieve technical
execellence and the best quality. Concrete bridges have also undergone major changes with
deveopment of new structural forms, new methods of computer based analysis and design
and development of high strength materials, IRC:112 for concrete bridges based on the limit
state method has come into force. Over the past few years, many IRC codes have also been
completely revised necessitating extensive changes in the Ministry's specifications for road
and bridge works.

Some of the important additions in this revision of Specifications for Road and Bridge Works
cover stone mastic asphalt, microsurfacing, sand asphalt base course, prefabricated vertical
drains (PVD), natural geo textiles, geo cells for use in base and sub base in pavement
and slope protection, variable message sign boards, soil nailing, cold applied retro-reflective
paints, audible and vibratory pavement markings, solar powered road markers, traffic
control & safety devices in construction zone, traffic impact attenuators and advance traffic
management system. Some of the new areas covered in bridges include high performance
concrete, HDPE sheathings, Pot-PTFE bearings, jack down method of well sinking, dynamic
testing of piles and mechanically woven wire crates for gabions.

The Fifth Revision of the Specifications for Road and Bridge Works is the result of the
concerted efforts of the officers of the Roads Wing and other professionals who contributed
to the drafting of this document. I wish to express my gratitude to all of them and the Indian
Roads Congress for undertaking the assignment of bringing out this publication.

Feedback and suggestion for further improvement would be welcome from users of this
edition.

(C. Kandasamy)
DG(RD) & SS
03-0 1-20 13
Section 1000 Materials For Structures

The Contractor shall set up a field laboratory with necessary equipment for testing of all
materials, finished products used in the construction as per requirements of conditions of
contract and the relevant specifications. The testing of all the materials shall be carried out
by the Engineer for which the shall make all the necessary arrangements and bear the entire
cost.

Test which cannot be carried out in the field laboratory have to be got done at the Contractor's
cost at any recognized laboratoryltesting establishments approved by the Engineer.

1015.2 Sampling of Materials

Samples provided to the Engineer for inspection are to be in labelled boxes suitable for
storage.

Samples required for testing and approval must be supplied well in advance by at least 48
hours or before the miniml-~rnperiod required for carrying out the relevant tests. Delay to
works arising from the late submission of samples, will not be acceptable as a reason for
delay in completion of the works.

If materials are brought from abroad, the cost of samplingltesting whether in India or abroad
shall be borne by the Contractor.

1015.3 Rejection of Materials not Conforming to the Specifications.

Any stack or batch of material(s) of which sample(s) does (do) not conform to the prescribed
tests and quality shall be rejected by the Engineer and such materials shall be removed from
site by the Contractor at his own cost. Such rejected materials shall not be made acceptable
by any rectifications.

1015.4 Testing and Approval of Plant and Equipment

All plants and equipment used for preparing, testing and production of materials for
incorporation into the permanent works, shall be in accordance with manufacturer's
specifications and shall be got approved by the Engineer before use.
Bearings Section 2000

ii) In order to avoid contamination of moving surfaces, bearings should


not normally be dismantled after leaving the manufacturer's workshop.
However, if for any reason, a bearing is required to be dismantled, it
shall be done only under expert supervision for which the manufacturer's
help may be sought.
iii) Transfer of load froni the superstructure to the bearirlgs should not be
allowed until the beddirlg material has developed sufficient strength.
Temporary clamping devices shol-lld be removed at the appropriate
time before the bearings are required to accommodate movement.
The holes exposed on removal of temporary transit clamps should be
filled with selected material. Where re-use of these fixing holes may
be required, the material used for filling the holes should be capable of
being easily removed without damaging the threads.
iv) Suitable temporary supporting arrangements under bearing base
plates should be made to accommodate thermal movement and elastic
deformation of the incomplete superstructure. Such temporary supports,
if provided, should be removed once the bedding material has reached
its required strength. Any voids left as a consequence of their removal
should be made good using the same bedding material. Steel folding
wedges and rubber pads are suitable for use as temporary supports
under bearing plates.

2006.5.2 Bedding

i) The bedding material shall be selected keeping in view a number of


factors such as the type and size of bearing, construction sequence,
load on the bearing, required setting time, friction requirements, access
around bearings, design and condition of surface in the bearing area
and thickness, strength and shrinkage of bedding material.
ii) Commonly used bedding materials are cementitious or chemical resin
mortar and grout. In some cases, it may be necessary to carry out trials
to ascertain the most suitable material.
iii) The bedding material, whether above or below the bearing, should
extend over the whole area of the bearing in order to ensure even
loading. After installation, there shall be no voids or hard spots. The top
surface of any extension of the bedding beyond the bearing shall have
a dowliward slope away from the bearing.
iv) The bedding material shall be capable of transmitting the applied load
to the structure without being damaged. Surfaces to receive bedding
mortar shall be suitably prepared so as to be compatible with the mortar
chosen.
Section 2000 Bearings

2006.5.3 Fixing of Bearings


i) Bearings s h o ~ ~be
l danchored in order to counter vibration and accidental
impact. Anchorage should be accurately set into recesses cast into the
structure using templates. The remaining space in the recesses should
be filled with material capable of withstanding the loads.
ii) Bearings that are to be installed on temporary supports should be
firmly fixed to the substructure by anchorage or other means to prevent
disturbance during subsequent operations. Voids beneath the bearings
should be completely filled with bedding material using the appropriate
method.
iii) Bearings may be fixed directly to metal bedding plates that may be cast
in or bedded on top of the supporting structure to the correct level and
location.
iv) If the structure is of steel, the bearings may be bolted directly onto it.
Care shall be taken to ensure that there is no mismatch between the
bolt holes of the structure and those of the bearing.
v) Threaded fasteners shall be tightened uniformly to avoi'd overstressing
of any part of the bearing.

I 2006.5.4 Bearings Supporting In-situ Concrete Deck


i) Where bearings are installed prior to casting of an in-situ concrete deck,
formwork around bearings should be properly sealed to prevent grout
leakage. It is essential that the bearings and particularly the working
surfaces are protected during concreting operations. Sliding plates
should be fully supported and care taken to preve:nt tilting, displacement
or distortion of the bearings under the weight of green concrete. Any
mortar contaminating the bearings should be completely removed
before it sets.
ii) For bearings supporting precast concrete or steel beams, a thin layer
of synthetic resin mortar should be used between bearings and the
beams. Bearings shall be bolted to anchor plates or sleeves embedded
I in precast concrete elements or to machined sole plates on steel
I elements.
a

2006.5.5 Installation Tolerances

+
Bearings shall be located so that their centre lines are within 3 mm of their correct position.
The level of a bearing or the mean levels of more than 1 bearing at any support, shall be
+
within a tolerance of 0.0001 times the sum of the adjacent spans of a continuous girder, but
+
not exceeding 5 mm. Bearings shall be placed in a horizontal plane within a tolerance of
I 1 in 200 in any direction, even under superstructure in gradient.
....!.
....
...
...
...
....
...
.-.*.
....
....
;.:.:
...
..
Bearings Section 2000
..
...
--
..
2006.6 Maintenance

i) Bearings shall be designed and manufactured to make them


maintenance free so as to withstand undesirable effects caused
by extreme atmosphere or aggressive environmental conditions1
unforeseen events.
ii) Suitable easy access to the bearings shall be provided for inspection
and maintenance. Provision shall also be available for jacking up the
superstructure so as to allow repairlreplacement of bearings.
iii) The area surrounding the bearings shall be kept clean and dry to avoid
damage to the bearings. The bearings shall also be periodically cleaned
to remove deposits of salts, debris, dust or other foreign material.
iv) Periodic inspection and nominal maintenance of bearings shall be
carried out in order to ensure .their better performance and longer life.
The bearings are required to be inspected at intervals of one year for ,the
first five years after installation and at intervals of two years thereafter.
v) The bearings shall also be examined carefully after unusual occurrences
such as passage of heavy trafficloversized loads, earthquakes and
battering by floating debris in high floods.

2007 INSPEC'I'ION AND TESTING

1 Where ally patented items are used, the manufacturer's certificate for the same with test
proofs shall be submitted along with the design and got approved by the Engineer before
their use in work.

2008 'TEST AND STANDARDS OF ACCEPTANCE

The materials shall be tested in accordance with these Specifications and shall meet .the
prescribed criteria.

The work shall conform to these Specifications and shall meet the prescribed standards of
acceptance.

2009 MEASUREMENTS FOR PAYMENT

Bearings shall be measured in numbers, according to their capacities and particular


specifications given on the drawings.

The quantity of elastomeric bearings shall be measured in cubic centimetres of finished


dimensions.
;:,I. .
, ..
.....
....
Section 2000 Bearings
... .
. :.
.......
.-.-
.. ...-.
.,..,
...-.
.......
........
..... .
...-.
.. :
>.
..
.. - . 2010 RATE
....
....
, .

*+-
The contract unit rate of each type of bearing shall include the cost of manufacturi~g,supplying
and fixing the bearings in position complete as specified on the drawings or as directed by
the Engineer.
.:
.. .,
.. -.
.......
....
......
......
-a.
.-.+
The rate shall also include the cost of samples and their testing as required under the
..-..,
.--.....
. +.- ..-
..-
. . ..
..... specifications or as directed by the Engineer.
...
. .~
. .
...
.. . . ~

In case of steel bearings the rate shall include the cost of all nuts, bolts and all tests prescribed
. . .
. . in the specifications and shown on the drawings.
OPEN FOUNDATIONS
I
.;:.I
....I
, :.
..
.....
Open Foundations Section 2100
.;:/
...
2101 DESCRIPTION

The work shall cover furnishing and providing plain or reinforced concrete foundation placed
in open excavation, in accordance with the drawings and these Specifications or as directed
by the Engineer.
2102 MATERIALS
4
1
Materials shall conform to Section 1000 of these Specifications.
2103 GENERAL

A method statement indicating the following shall be submitted by the Contractor for approval
of the Engineer, well in advance of the commencement of construction of open foundation :
i) Sources of materials
ii) Design, erection and removal of formwork
iii) Production, transportation, laying and curing of concrete
iv) Personnel employed for execution and supervision
v) Tests and sampling procedures
vi ) Equipment details
vii) Quality Management System to be adopted including Quality Manual
viii) Any other relevant information
Details of necessary arrangements for execution under water wherever necessary, shall be
I
included in the method statement.
I
Dimensions, lines and levels shall be set out and checked with respect to permanent
reference lines and permanent bench mark so that the foundations are located correctly and
in accordalice with the drawings.
-
....
.-.
:
.,::
....
I Formwork, steel reinforcement and structl-~ralconcrete for open foundations shall conform to
I-/ ._!
,..:. Sections 1500, 1600 and 1700 respectively of these Specifications.
I

.. :I.
1 2104 WORKMANSHIP

I 2104.1 Preparation of Foundations


I
I
Excavation for laying the foundation shall be carried out in accordance with Section 300 of
these Specifications. The last 300 mm of excavation shall be done just before laying of lean
.. concrete below foundation. Excavation shall be made or~lyto the exact depth as shown
.I1 on the drawing. In the event of excavation having been made deeper than that shown on
1 the drawing or as ordered by the Engineer, the extra depth shall be made up with M I 0
I concrete in case of foundation resting on soil and with concrete of the same grade as that
of the foundation, in case of foundation resting on rock. This shall be done at the cost of the
I
Contractor and shall be considered as incidental to the work.
Open foundations shall be constructed in dry conditions and the Contractor shall provide for
.:.
...
...
-1 adequate dewatering arrangements, wherever required, to the satisfaction of the Engineer.
......
;-:.: I
.....,
....
_ _ _ /
"
...
....
- -1
663
Appendices Appendices

Sieve Size Percent Passing

2.36 rrlm 20-35


600 mic 10-22
300 mic 6-16
150 mic 4-12
75 mic 2-8
The Marshall test specimens shall be prepared using 5 percent bitumen of 801100 grade
by weight of aggregates blended with varying percentages of antistripping agents from 0
to 1 percent in steps of 0.25 percent. The test samples shall give a void content of about 6
percent. At least 8 standard Marshall specimens for each of the varying antistripping agent
percentages shall be prepared. Each set of 8 test specimens shall be sorted out in two groups
of 4 each so that the average specific gravity of the specimen in Group I shall be essentially
,the same as in Group II. Group-l shall be tested for Marshall Stability in the usual procedure
I ASTM D1559. Group-Il specimens shall be.immersed in water for 24 hours at 60°C k I0Cand
then shall be tested immediately for Marshall stability as per ASTM D 1559.

Calculation: The numerical index of resistance of bituminous mixtures to the detrimental


effect of water shall be expressed as the index of retained stability:

Average Marshall Stability of Grol-~p-ll


x 100 percent
Average Marshall Stability of Group-l

Requirement for Acceptance: A minimum of 75 percent of retained Marshall strength shall


be required for acceptance.
Appendices Appendices

Appendix - 120011-1
H ~ R Y O F S I N K M a ~ N o

LOWEST BED LEVEL LOWESTWA I E R LEVEL - HIOWST m000 rn


HUGrnoFCURB HEIGm OF CUTllffi EDGE -
STElNING SINKING lmmmGE
DATB
REDUCED RLOFTOP RLOFTOP HEIGHTOF TOTAL WL. 01: INfl'IAL FINAL SINKING RL OF DePTHOF STRATA Worn EcXXNlRI- ECCEHlRl QuANnm REPORT REPORT REMARKS SIGNAlURE
LEVEL (RL) OF S*INING OF SEINING SEINING HEIGHT OF RE- GAUGE GAUGE DURING B O ~ M SUMP MBT cm CITY WDREDGED REGARDING ANY SPECIAL. OF
OPBOTXOM BEFORE AFiER CAST STElNlNG WE& READING READlNG THE.DAY OFCUlTlffi BELOW WflW WNGX- AU)W MAlFRlAL OBSTACLESOR MFRKW)OF SUPERVlSlNG
OF CUlTlNG CASVNG CASTING (COL.4-COL.3) (INCLUDING) (AT WHICH (COL9-COL.Q EDGE CVITlffi AXlS Y-AXIS SAND BELOW SINKING OFRCER
EDGE CURBAND CuTTlNG (COL7-COL.81 EDGE LXJRlNGSlNKMG EMPLOYED
CLTITlNG EDGEIS
EDC& PLACED)
(COW-COL3)
MFmE MEIRE MEIRE MEIRE MEIRE MEIRE MElRE TONNEF MEIRE MElRE CuBICMEntE
1 2 3 J 5 6 7 8 9 10 II 12 13 I4 I5 16 I7 I8 19 20 21

! 2 L i
Appendices

Appendix - 120011-2

PLAN UF WEU. NO.....


Appendices Appendices

Appendix 1200111

(Refer Clause 1208.10)


TILT A N ) SHIFT IN WELL N0:-
-
1 J REDUCED LEVELS (R.L'S) OF G A W MARKS
, TILT ALONG ' TILT AL'JNG IaULTANT
7
SH IF1 .c
ALONG X-AXIS ALONG Y - AX1S X-AXIS
COLUMN
Y-AXIS
COLUMN
n
~ O Llo'+
l.
'
ALON(i
X-AXIS .
ALONG
Y-AXIS
I RESULI'ANT . ACTir)N REMARKS SIGNA-
01:
TAKENFOR
. DATE TOTAL TOTAL. (PLACE). (PLACE) D m B N c E (US) (DIS) . DIFFEWCE 6 9 COL. I I ') WITH . 0 1 4 RECfiFlCVnON SUPERVISING
SlElNING SINKING END END (COL.5 - (COl-8 - DIVIDED BY D l V l D ~ l nY
i DIRfXTION, D I M O N , 0rnfcER
COL.4) Ca7) WELL DIA WELL D I A .
MEIRE MEmJ? MEIRE MEIRES
'
MEW MtTKE
-. - -

1 2 3 4 5 6 7 8 9 10 11 12 13 I4 15

1
I I
1
I i
I
I
I

. r - -
.. Appendices Appendices
.--I

I;-
Appendix - 1500/1
(Refer Clause 1503.2)

INFORMATION TO BE SUPPLIED BY 'THE


MANUFACTURERS OF PROPRIETARY SYSTEMS

1 1 GENERAL

I 1. I The information which the manufacturer is required to supply shall be in such


detail as to obviate unsafe use of the equipment due to the intention of the manufacturer not
: 4 having been made clear or due to wrong assumptions on the part of the user.
1.2
. -I The user shall refer unusual problem or problems of erection/assembly not
I
3
in-keeping with-the intended use of the equipment, to the manufacturer of the equipment.
I
2 INFORMATION REQUIRED
i
2.1 The manufacturers of proprietary systems shall supply the following
information:

a) Description of basic functions of equipment


b) List of items of equipment available, giving range of sizes, spans and
such like, with the manufacturer's identification numbers or other
I~ references.
c) The basis on which the safe working loads have been determined
and whether the factor of safety given applies to collapse or yield.
d) Whether the supplier's data is based on calculations or tests. This
shall be clearly stated as there may be wide variations between results
obtained by either method.
e) Instructions for use and maintenance, including any points which
require special attention during erection, especially where safety is
concerned.
f) Detailed dimensional information, as follows :
(i) Overall dimensions and depth and widths of members;
(ii) Line drawings including perspectives and photographs showing
normal uses;
(iii) Self weight;
(iv) Full di~iiensions of cor~nections and any special positioning
arrangements;
Appendices Appendices

(v) Sizes of members, including tube diameters and thicknesses of


materials;
(vi) Any permanent camber built into the equipment; and
(vii) Sizes of holes and dimensions giving their positions.
g) Data relating to strength of equipment as follows :
(i) Average failure loads as determined by tests;
(ii) Recommended maximum working loads for various conditions of
use;
(iii) Working resistance moments derived from tests;
(iv) Working shear capacities derived from tests;
(v) Recommended factors of safety used in assessing recommended
loads and deflections based on test results;
(vi) Deflections under load together with recommended pre-camber
and limiting deflections;
(vii) If working loads depends on calculations, working stresses
should be stated. If deflections depend on the theoretical
moments of inertia or equivalent moments of inertia rather than
tests, this should be noted;
(viii) Information on the design on ,the loading against wind and other
horizontal loadings; and
(ix) Allowable loading relating to maximum extension of bases and/or
heads.
Appendices Appendices
'3

.! Appendix-I 70011

(Refer Clause 1717.7.5)

SPECIFICATION FOR CONSTRUCTION JOINTS

Location

The location of construction joint shall be as shown on the drawing or as approved by the
Engineer. If additionallnew joints are approved by the Engineer, the following considerations
for their location shall be taken into account:

(i) Joints shall be provided in non-aggressive zones or in non-splash


zones. If not feasible, the joints shall be sealed.
(ii) Joints should be positioned where they are readily accessible for
preparation and concreting , such as location where the cross-section
is relatively small, and where reinforcement is not congested.
(iii) In beams and slabs, joints should not be near 'the supports. Construction
Joints between slabs and ribs in composite beams should be avoided.
(iv) For box girders, it is preferable to cast the soffit and the webs without
any joint.

1 (v) Location of joints shall minimize the effects of the discontinuity on the
i I
durability, struct~~ral
integrity and the appearance of the structure.

Preparation of Surface of the Joint


.' '1 Laitance shall be removed before fresh concrete is cast. The surface shall be roughened.
.. ,
--,
..
....
Care shall be taken that they should not dislodge the coarse aggregates. Concrete may be
.-
....-.--, brushed with a stiff brush soon after casting while the concrete is still fresh.
::j
.: 7
.-
.<.
If the concrete has partially hardened, it shall be treated by wire brushing or with a stiff water
?j
..
..
I
jet followed by drying with air jet immediately.

Fully hardened concrete shall be treated with mechanical hand tools or grit blasting, taking
care not to split or crack aggregate particles.
I;:
.:>. I:
... Before further concrete is cast, the surface should be thoroughly cleaned to remove debris
.-..,
..
- .,
and accumulated rubbish, one effective method being by air jet.

I Where there is likely to be a delay before placing the next concrete lift, protruding reinforcement
shall be protected. Before the next lift is placed, rust, loose mortar or other contamination shall
be removed from the reinforcements. In aggressive environment, the concrete shall be cut
I back to expose the reinforcements for a length of about 50 mm to ens[-lrethat contaminated
I
concrete is removed.
Appendices Appendices

'The joint surface shall not be contaminated with release agents, dust or curing membrane.

Concreting of Joints

The old surface shall be thoroughly cleaned and soaked with water. Standirlg water shall be
removed shortly before the new concrete is placed and the new concrete shall be thoroughly
compacted. Concreting shall be carried out continuously 1.1ptothe construction joints.

Surface retarders may be used to improve the quality of construction joints.

For a vertical constructionjoint, a stopping board shall be fixed previously at the predetermined
position and shall be properly stayed to prevent its displacement or bulging when concrete is
compacted against it. Concreting shall be continued right upto the board.
Appendix-1700-1 : Permeability Test

II PREsuRE- GAUGE r HANDLE

PERMEABILITY CELL WATER RESERYIOR


Appendices Appendices

i?MC TUBE LOmm 4 SU~JECTED


TO A PRESSURE OF 0 0 5 M Pa
S Y PUMP/ WATER HEAD FOR
S MtNUTES \
MS.PLATE
159 x15OxfOmrn PVC f UBE IAIR VENT
f- -
10rnm(D 150 mrn

LATE
x3mm

k--*
( SHEATHING SAMPLE LENGTH f

Fig. 180011-4 : Dimensions are in mm.


Appendices Appendices

Appendix 1800/11

(Refer Clause 1808)

PKESTREssJNGKEPORT :

NUMBER OR NAME OF THE BRIDGE: SPAN No. Stressing Sequence Drg. No. Left end of cable = A
Right end ofC&Ic = B
Ave. Cube Stmngth at the time of stressing : kg/cm2 ELEMENT'IGIRJXR No. Marlis of Plant Used Jxb : Specificxi Gitugc A~ssull:
during Jacking
High Tensile Steel (UIS) kglcm2 LAST D X EOF:(=ONCRETIN Pulllps :

Cube Strength :at 28 days kg/cm2 DATE OF PRES'IRESSING Gaups :


Max-Jack Rcssure not to exc-d under any circu~nstances kg/cm2

COLUMNS 1
Calculated Gauge Mark Readings Gauge Mark
Stressing Elongation of extension in mnl at Readings of extensioa Reading at Instant of
Squence ahc pnssure of 100kg in mm at the prcssun Locking
cm2. . of 200kglcm2.'

Signature of Officers present Jurinj prestressins


... .
Client ,Cnntr;stor Systen~supolier
Appendices Appendices

(Refer Clause 1809)

SPECIFICATIONS FOR GROUTING OF POST-TENSIONED


CABLES IN PRESTRESSED CONCRETE BRIDGES

1 GENERAL

1.I 'The recommendations cover the cement grouting of post- tensioned tendons
of prestressed concrete members of bridges. This also covers some of the essential protective
measures to be adopted for minimising corrosion in PSC bridges.

1.2 'The purpose of grouting is to provide permanent protection to the post-


tensioned steel against corrosion and to develop bond between the prestressing steel and
the surrounding structural concrete. The grout ensures encasement of steel in an alkaline
environment for corrosion protection and by filling the duct space, it prevents water collection
and freezing.

2 MATERIALS

2.1 Water

Only clean potable water free from impurities conforming to Section 1000 shall be permitted.
No sea or creek water is to be used at all.

2.2 Cement

Ordinary Portland cement should be used for preparation of the grout. It should be as fresh
as possible and free of any lumps. Pozzolana cement shall not be used.

2.3 Sand

It is not recommended to use sand for grouting of prestressing tendons. In case the internal
diameter of the ducts exceeds 150 mm, use of sand may be considered. Sand used, shall
conform to IS1383 and shall pass ,through IS Sieve No. 150. The weight of sand in the grout
shall not be more than 10 percent of the weight of cement, unless proper workability can be
ensured by addition of suitable plasticizers.

2.4 Admixtures

Acceptable admixtures conforming to IS:9102 may be used if tests have shown that their use
improves the properties of grout, i.e. increasing fluidity, reducing bleeding, entraining air or
expanding the grout. Admixtures must not contain chlorides, nitrates, sulphides, sulphites or

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