WD2 - Subsection E Bridge & Culverts 22-12-2014

Package WD82: Construction of New BG Track on Kashiani-Gopalganj SectionConstruction of 65 Nos.
Minor
Bridges Section 8 – Particular Specification
( 51 38 Nos. Box Culverts and 14 6 nos. Plate Girder Bridges)
SUBSECTION BE: MINOR BRIDGES

(BOX CULVERTS & PLATE GIRDER BRIDGES)
TABLE OF CONTENTS
B.1 SCOPE OF THE WORK............................................................................................................. 1

B.1.1 Construction of Minor Bridges and Culverts.........................................................................1
B.1.2 List of Minor Bridges............................................................................................................ 1
B.2 GENERAL REQUIREMENTS..................................................................................................... 5
B.2.1 CONSTRUCTION METHODOLOGY............................................................5
B.2.2 TEMPORARY STAGING AND SUPPORT SYSTEMS.........................................5
B.2.3 SUB-SURFACE AND FOUNDATION INFORMATION........................................5
B.2.4 ESTABLISHMENT OF LINES AND GRADES..................................................5
B.2.5 PROTECTION OF STREAMS AND WATERCOURSES.......................................5
B.2.6 Interference with Traffic....................................................................................................... 6
B.2.7 Structural Appearance and Conformity................................................................................6
B.2.8 Opening of Bridge Decks to Traffic......................................................................................6
B.2.9 Clean Up of Bridge and Structure Sites...............................................................................6
B.2.10 Construction Access......................................................................................................... 6
B.2.11 Railway Equipment........................................................................................................... 6
B.2.12 General Codes and Standards.........................................................................................6
B.3 BORED CAST-IN-PLACE PILES................................................................................................7
B.3.1 Description........................................................................................................................... 7
B.3.2 Materials.............................................................................................................................. 8
B.3.2.1 Steel Casing................................................................................................................. 8
B.3.2.2 Concrete....................................................................................................................... 8
B.3.2.3 Reinforcement.............................................................................................................. 8
B.3.2.4 Drilling Fluid.................................................................................................................. 9
B.3.3 Construction Methods.......................................................................................................... 9
B.3.3.1 General......................................................................................................................... 9
B.3.3.2 Setting Out Piles......................................................................................................... 10
B.3.3.3 Diameter of Piles........................................................................................................ 10
B.3.3.4 Tolerances.................................................................................................................. 10
B.3.3.5 Boring......................................................................................................................... 10
B.3.3.6 Placing Reinforcement................................................................................................ 12
B.3.3.7 Placing Concrete........................................................................................................ 12
B.3.3.8 Extraction of Temporary Casing.................................................................................14
B.3.3.9 Temporary Support.................................................................................................... 14
B.3.3.10 Records...................................................................................................................... 14
B.3.3.11 Measures in Case of Rejected Piles...........................................................................15
B.3.3.12 Pilot Piles.................................................................................................................... 15
B.3.4 Measurement and Payment............................................................................................... 15
B.4..................................................................................................................... PILE LOAD TESTS
16
B.4.1 Description......................................................................................................................... 16
B.4.1.1 General....................................................................................................................... 16
Subsection BE: Minor Bridges & Culverts i of vi

Package WD82: Construction of New BG Track on Kashiani-Gopalganj SectionConstruction of 65 Nos. Minor
B.4.1.2 Definitions................................................................................................................... 16
B.4.2 Supervision........................................................................................................................ 17
B.4.3 Safety Precautions............................................................................................................. 17
B.4.3.1 General....................................................................................................................... 17
B.4.3.2 Kentledge................................................................................................................... 17
B.4.3.3 Tension Piles and Ground Anchors............................................................................17
B.4.3.4 Testing Equipment..................................................................................................... 18
B.4.4 Construction of a Pilot Pile to be Test Loaded...................................................................18
B.4.4.1 Notice of Construction................................................................................................18
B.4.4.2 Method of Construction..............................................................................................18
B.4.4.3 Boring or Driving Record............................................................................................ 18
B.4.4.4 Cut-Off Level.............................................................................................................. 18
B.4.4.5 Pile Head for Compression Tests...............................................................................18
B.4.4.6 Completion of the Testing of Pilot Piles......................................................................18
B.4.5 Preparation of a Working Pile to be tested........................................................................18
B.4.6 Reaction Systems.............................................................................................................. 19
B.4.6.1 Compression Tests.................................................................................................... 19
B.4.6.2 Working Piles............................................................................................................. 19
B.4.6.3 Spacing...................................................................................................................... 19
B.4.6.4 Adequate Reaction..................................................................................................... 19
B.4.6.5 Care of Piles............................................................................................................... 19
B.4.6.6 Loading Arrangement.................................................................................................19
B.4.7 Equipment for Applying Load.............................................................................................19
B.4.8 Measurement of Load........................................................................................................ 19
B.4.9 Adjustability of Loading Equipment....................................................................................20
B.4.10 Measuring Movement of Pile Head.........................................................................20
B.4.10.1 General....................................................................................................................... 20
B.4.10.2 Levelling Method........................................................................................................ 20
B.4.10.3 Independent Reference Frame...................................................................................20
B.4.10.4 Other Methods............................................................................................................ 21
B.4.11 Protection of Testing Equipment.............................................................................21
B.4.11.1 Protection from Weather.............................................................................................21
B.4.11.2 Prevention of Disturbance..........................................................................................21
B.4.12 Supervision............................................................................................................. 21
B.4.12.1 Notice of Test............................................................................................................. 21
B.4.12.2 Records...................................................................................................................... 21
B.4.13 Test Procedure....................................................................................................... 21
B.4.13.1 Proof Test by Maintained Load Test...........................................................................21
B.4.14 Presentation of Results...........................................................................................22
B.4.14.1 Results to be Submitted.............................................................................................22
B.4.14.2 Schedule of Recorded Data.......................................................................................23
B.4.15 Completion of a Test...............................................................................................23
B.4.15.1 Measuring Equipment.................................................................................................23
B.4.15.2 Kentledge................................................................................................................... 24
B.4.15.3 Temporary Piles......................................................................................................... 24
B.4.16 Integrity Testing of Piles.......................................................................................... 24
Subsection BE: Minor Bridges & Culverts ii of vi

B.4.16.1 Purpose...................................................................................................................... 24
B.4.16.2 Method of Testing....................................................................................................... 24
B.4.16.3 Age of Piles at Time of Testing...................................................................................24
B.4.16.4 Preparation of Pile Heads........................................................................................... 24
B.4.16.5 Specialist Sub-Contractor...........................................................................................24
B.4.16.6 Interpretation of Tests.................................................................................................24
B.4.16.7 Report......................................................................................................................... 25
B.4.16.8 Anomalous Results.................................................................................................... 25
B.4.17 Measurement and Payment....................................................................................25
B.4.18 No. of Tests............................................................................................................ 25
B.5............................................................................................................................ TEST BORING
26
B.5.1 Description......................................................................................................................... 26
B.5.1.1 General....................................................................................................................... 26
B.5.1.2 Scope of Geotechnical Investigations.........................................................................26
B.5.2 Role of the Engineer for Geotechnical Investigation..........................................................26
B.5.3 Contractor’s Responsibility for the Geotechnical Investigation..........................................27
B.5.4 Number and Depth of Boreholes.......................................................................................27
B.5.5 Borehole Equipment and Method......................................................................................27
B.5.5.1 Core Drilling................................................................................................................ 27
B.5.5.2 In-Situ Testing and Sampling.....................................................................................27
B.5.5.3 Laboratory Tests........................................................................................................ 27
B.5.5.4 Record of Laboratory Testing and Final Reports........................................................28
B.6.................................................................EXCAVATION AND BACKFILL FOR STRUCTURES
29
B.6.1 Description......................................................................................................................... 29
B.6.2 Materials............................................................................................................................ 29
B.6.2.1 Foundation Fill Material.............................................................................................. 29
B.6.2.2 Backfill Material.......................................................................................................... 30
B.6.3 Construction Methods........................................................................................................ 30
B.6.3.1 Clearing...................................................................................................................... 30
B.6.3.2 Excavation.................................................................................................................. 30
B.6.3.3 Disposal of Excavated Material..................................................................................31
B.6.3.4 Cofferdams................................................................................................................. 31
B.6.3.5 Pumping and Bailing................................................................................................... 32
B.6.3.6 Backfilling................................................................................................................... 32
B.7.............................................................................................. CONCRETE FOR STRUCTURES
34
B.7.1 Description......................................................................................................................... 34
B.7.2 Materials............................................................................................................................ 34
B.7.2.1 Specifications for Materials.........................................................................................34
B.7.2.2 Testing of Materials.................................................................................................... 36
B.7.2.3 Composition of Concrete............................................................................................37
B.7.2.4 Control of Concrete Quality........................................................................................ 40
Subsection BE: Minor Bridges & Culverts iii of vi

B.7.3.1 General....................................................................................................................... 42
B.7.3.2 Scaffolding and Formwork..........................................................................................42
B.7.3.3 Care and Storage of Concrete Materials....................................................................46
B.7.3.4 Preparations before Casting.......................................................................................47
B.7.3.5 Measuring Materials................................................................................................... 47
B.7.3.6 Mixing Concrete......................................................................................................... 47
B.7.3.7 Preparation for Handling and Placing Concrete.........................................................49
B.7.3.8 Perforations and Embedment of Special Devices......................................................53
B.7.3.9 Finishing Concrete Surfaces......................................................................................53
B.7.3.10 Construction, Contraction and Expansion Joints........................................................55
B.7.3.11 Curing Concrete......................................................................................................... 56
B.7.3.12 Removal of Scaffolding and Formwork.......................................................................58
B.7.3.13 Repair of Concrete..................................................................................................... 59
B.7.3.14 Depositing Concrete under Water..............................................................................60
B.7.3.15 Factory and Site Made Precast Concrete Elements...................................................61
B.7.3.16 Control of Heat in Structures......................................................................................62
B.7.3.17 Backfill to Structures................................................................................................... 62
B.7.3.18 Cleaning Up................................................................................................................ 62
B.7.3.19 Concrete Pours Early Age Crack Control and Trials..................................................62
B.7.3.20 Temporary Works....................................................................................................... 62
B.8..................................................................................................................... REINFORCEMENT
63
B.8.1 Description......................................................................................................................... 63
B.8.2 Materials............................................................................................................................ 64
B.8.2.1 Bar Reinforcement..................................................................................................... 64
B.8.2.2 Wire Mesh.................................................................................................................. 64
B.8.2.3 Binding Wire............................................................................................................... 64
B.8.2.4 Bar Sizes.................................................................................................................... 64
B.8.2.5 Ordering Material........................................................................................................ 64
B.8.2.6 Additional Tests.......................................................................................................... 64
B.8.3.1 Protection and Storage...............................................................................................65
B.8.3.2 Cutting and Bending................................................................................................... 65
B.8.3.3 Placing, Supporting and Fastening.............................................................................65
B.8.3.4 Splicing....................................................................................................................... 65
B.8.3.5 Substitutions............................................................................................................... 65
B.9 BRICK AND WATER PROOFING POLYTHENE SHEET WORK.......................................66
B.9.1 Description......................................................................................................................... 66
B.9.2 Materials............................................................................................................................ 66
B.9.2.1 Specifications for Materials for Brick work..................................................................66
B.9.2.2 Specifications for Mortar............................................................................................. 67
B.9.3.1 General....................................................................................................................... 68
B.9.3.2 Workmanship.............................................................................................................. 68
B.9.3.3 Brick Drainage Layers................................................................................................ 68
Subsection BE: Minor Bridges & Culverts iv of vi

B.10.................................................................................................... DRAINAGE OF STRUCTURES
69
B.10.1 Description..................................................................................................................... 69
B.10.2 Materials......................................................................................................................... 69
B.10.2.1 PVC Pipes.................................................................................................................. 69
B.10.3 Construction Methods.................................................................................................... 70
B.10.3.1 Storage and Handling of Materials..............................................................................70
B.10.3.2 PVC Pipes.................................................................................................................. 70
B.10.3.3 Weep Holes................................................................................................................ 70
B.10.4 Measurement and Payment........................................................................................... 70
B.11..............................................................................INSERTS AND FITTINGS IN STRUCTURES
70
B.11.1 Description..................................................................................................................... 70
B.11.2 Materials......................................................................................................................... 70
B.11.3 Construction Methods.................................................................................................... 71
B.12.................................................................................................................... BRIDGE BEARINGS
71
B.12.1 General.......................................................................................................................... 71
B.12.1.1 Working Drawing........................................................................................................ 71
B.12.1.2 Packaging, Handling and Storage..............................................................................71
B.12.1.3 Manufacture or Fabrication............................................................................................. 71
B.12.1.4 Construction and Installation.......................................................................................... 72
B.12.2 Elastomeric Bearings..................................................................................................... 72
B.12.2.1 Description.................................................................................................................. 72
B.12.2.2 Materials..................................................................................................................... 72
B.12.2.3 Method........................................................................................................................ 77
B.12.2.4 Maintenance............................................................................................................... 77
B.12.3 Pot and Dise Bearings.................................................................................................... 78
B.12.3.1 General....................................................................................................................... 78
B.12.3.2 Working Drawings....................................................................................................... 78
B.12.3.3 Materials..................................................................................................................... 78
B.12.3.4 Fabrication Details.......................................................................................................... 79
B.12.3.5 Sampling and Testing................................................................................................. 80
B.12.3.6 Installation...................................................................................................................... 81
B.13.............................................. FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES
82
B.13.1 Description..................................................................................................................... 82
B.13.2 General.......................................................................................................................... 82
B.13.3 Structural Steel Materials............................................................................................... 82
B.13.3.1 82
B.13.3.2 Other Steel....................................................................................................................... 83
B.13.3.3 Castings and Forgings..................................................................................................... 83
B.13.3.4 Fasteners.................................................................................................................... 83
B.13.3.5 Welding Consumables................................................................................................ 84
Subsection BE: Minor Bridges & Culverts v of vi

B.13.3.6 Welding....................................................................................................................... 85
B.13.3.7 Wire Ropes and Cables................................................................................................. 85
B.13.3.8 Loadings and Design Specifications :............................................................................85
B.13.4 Fabrication...................................................................................................................... 87
B.13.4.1 General.......................................................................................................................... 87
B.13.4.2 Preparation of Edges and Ends........................................................................................ 87
B.13.4.3 Preparation of Holes....................................................................................................... 88
B.13.4.4 Bolts, Nuts and Washers................................................................................................ 90
B.13.4.5 Pins and Pin Holes......................................................................................................... 91
B.13.4.6 Shop Drawings, Shop Erection and Match Marking.........................................................91
B.13.4.7 Welding....................................................................................................................... 92
B.13.5 Erection.......................................................................................................................... 95
B.13.5.1 General.......................................................................................................................... 95
B.13.5.2 Organisation and Equipment.......................................................................................... 95
B.13.5.3 Handling and Storing of Materials..................................................................................96
B.13.5.4 Formwork....................................................................................................................... 96
B.13.5.5 Straightening Bent Material............................................................................................ 96
B.13.5.6 Assembling Steel............................................................................................................ 97
B.13.5.7 Field Inspection.............................................................................................................. 97
B.13.5.8 Testing............................................................................................................................. 100
B.13.6 Painting........................................................................................................................ 100
B.13.6.1 Introduction................................................................................................................... 100
B.13.6.2 Scope........................................................................................................................... 101
B.13.6.3 Surface Preparation.................................................................................................. 101
B.13.6.4 Coating Materials...................................................................................................... 101
B.13.6.5 Application of Coating............................................................................................... 102
B.13.6.7 Repair or Remedial Work.......................................................................................... 102
B.13.6.8 Field Painting................................................................................................................ 103
B.13.6.9 On-site Repair Procedures.......................................................................................103
B.13.7 Measurement and Payment......................................................................................... 104
B.14..............................................................................DEMOLITION OF EXISTING STRUCTURES
105
B. 15.........................................................................FILTER WORKS FOR BOX CULVERTS WALL
105
B.15.1 Brick Chips Filter Material............................................................................................ 105
B.15.2 Scope of Work.............................................................................................................. 105
B.15.3 Materials....................................................................................................................... 105
B.15.4 Workmanship............................................................................................................... 105
B.15.4.1 Foundation Preparation............................................................................................ 106
B. 16.......................................................................................... ABUTMENT PROTECTION WORKS
106
B. 16.1 Description................................................................................................................... 106
B. 16.2 Material........................................................................................................................ 106
B. 16.3 Method......................................................................................................................... 106
B. 16.4 Measurement and Payment......................................................................................... 107
Subsection BE: Minor Bridges & Culverts vi of vi

E1 SCOPE OF THE WORK...............................................................................................1

E 1.1 CONSTRUCTION OF MINOR BRIDGES AND CULVERTS...............................................1
E 1.2 LIST OF MINOR BRIDGES-44 NOS. (6 NOS. PLATE GIRDER BRIDGES & 38 NOS. BOX
CULVERTS) 1
E2 GENERAL REQUIREMENTS........................................................................................4
E 2.1 CONSTRUCTION METHODOLOGY..............................................................................4
E 2.2 TEMPORARY STAGING AND SUPPORT SYSTEMS........................................................4
E 2.3 SUB-SURFACE AND FOUNDATION INFORMATION......................................................4
E 2.4 ESTABLISHMENT OF LINES AND GRADES..................................................................4
E 2.5 PROTECTION OF STREAMS AND WATERCOURSES.....................................................4
E 2.6 INTERFERENCE WITH TRAFFIC..................................................................................5
E 2.7 STRUCTURAL APPEARANCE AND CONFORMITY.........................................................5
E 2.8 OPENING OF BRIDGE DECKS TO TRAFFIC..................................................................5
E 2.9 CLEAN UP OF BRIDGE AND STRUCTURE SITES..........................................................5
E 2.10 CONSTRUCTION ACCESS.................................................................................5
E 2.11 RAILWAY EQUIPMENT......................................................................................5
E 2.12 GENERAL CODES AND STANDARDS.................................................................5
E 2.13 ABBREVIATIONS AND DEFINITIONS.................................................................6
E3 BORED CAST-IN-PLACE PILES....................................................................................6
E 3.1 DESCRIPTION............................................................................................................ 6
E 3.2 MATERIALS............................................................................................................... 7
E 3.2.1 STEEL CASING........................................................................................... 7
E 3.2.2 CONCRETE................................................................................................ 7
E 3.2.3 REINFORCEMENT.......................................................................................7
E 3.2.4 DRILLING FLUID......................................................................................... 7
E 3.3 CONSTRUCTION METHODS.......................................................................................8
E 3.3.1 GENERAL................................................................................................... 8
E 3.3.2 SETTING OUT PILES...................................................................................9
E 3.3.3 DIAMETER OF PILES...................................................................................9
E 3.3.4 TOLERANCES............................................................................................. 9
E 3.3.5 BORING..................................................................................................... 9
E 3.3.6 PLACING REINFORCEMENT......................................................................11
E 3.3.7 PLACING CONCRETE................................................................................11
E 3.3.8 EXTRACTION OF TEMPORARY CASING.....................................................13
E 3.3.9 TEMPORARY SUPPORT.............................................................................13
Subsection BE: Minor Bridges & Culverts vii of vi

E 3.3.10 RECORDS................................................................................................ 13
E 3.3.11 MEASURES IN CASE OF REJECTED PILES.................................................14
E 3.3.12 PILOT PILES............................................................................................. 14
E 3.4 MEASUREMENT AND PAYMENT...............................................................................14
E4 PILE LOAD TESTS.................................................................................................... 15
E 4.1 DESCRIPTION.......................................................................................................... 15
E 4.1.1 GENERAL................................................................................................. 15
E 4.1.2 DEFINITIONS........................................................................................... 15
E 4.2 SUPERVISION.......................................................................................................... 16
E 4.3 SAFETY PRECAUTIONS............................................................................................ 16
E 4.3.1 GENERAL................................................................................................. 16
E 4.3.2 KENTLEDGE............................................................................................. 16
E 4.3.3 TENSION PILES AND GROUND ANCHORS................................................16
E 4.3.4 TESTING EQUIPMENT...............................................................................16
E 4.4 CONSTRUCTION OF A PILOT PILE TO BE TEST LOADED...........................................17
E 4.4.1 NOTICE OF CONSTRUCTION....................................................................17
E 4.4.2 METHOD OF CONSTRUCTION..................................................................17
E 4.4.3 BORING OR DRIVING RECORD.................................................................17
E 4.4.4 CUT-OFF LEVEL.......................................................................................17
E 4.4.5 PILE HEAD FOR COMPRESSION TESTS.....................................................17
E 4.4.6 COMPLETION OF THE TESTING OF PILOT PILES.......................................17
E 4.5 PREPARATION OF A WORKING PILE TO BE TESTED.................................................17
E 4.6 REACTION SYSTEMS................................................................................................ 18
E 4.6.1 COMPRESSION TESTS..............................................................................18
E 4.6.2 WORKING PILES.......................................................................................18
E 4.6.3 SPACING.................................................................................................. 18
E 4.6.4 ADEQUATE REACTION.............................................................................18
E 4.6.5 CARE OF PILES........................................................................................18
E 4.6.6 LOADING ARRANGEMENT........................................................................18
E 4.7 EQUIPMENT FOR APPLYING LOAD...........................................................................18
E 4.8 MEASUREMENT OF LOAD........................................................................................18
E 4.9 ADJUSTABILITY OF LOADING EQUIPMENT................................................................19
E 4.10 MEASURING MOVEMENT OF PILE HEAD.........................................................19
E 4.10.1 GENERAL................................................................................................. 19
E 4.10.2 LEVELLING METHOD................................................................................19
E 4.10.3 INDEPENDENT REFERENCE FRAME..........................................................19
Subsection BE: Minor Bridges & Culverts viii of vi

E 4.10.4 OTHER METHODS....................................................................................19

E 4.11 PROTECTION OF TESTING EQUIPMENT..........................................................20
E 4.11.1 PROTECTION FROM WEATHER.................................................................20
E 4.11.2 PREVENTION OF DISTURBANCE...............................................................20
E 4.12 SUPERVISION................................................................................................. 20
E 4.12.1 NOTICE OF TEST......................................................................................20
E 4.12.2 RECORDS................................................................................................ 20
E 4.13 TEST PROCEDURE......................................................................................... 20
E 4.13.1 PROOF TEST BY MAINTAINED LOAD TEST................................................20
E 4.14 PRESENTATION OF RESULTS.........................................................................21
E 4.14.1 RESULTS TO BE SUBMITTED....................................................................21
E 4.14.2 SCHEDULE OF RECORDED DATA.............................................................21
E 4.15 COMPLETION OF A TEST................................................................................22
E 4.15.1 MEASURING EQUIPMENT.........................................................................22
E 4.15.2 KENTLEDGE............................................................................................. 22
E 4.15.3 TEMPORARY PILES...................................................................................23
E 4.16 INTEGRITY TESTING OF PILES........................................................................23
E 4.16.1 PURPOSE................................................................................................. 23
E 4.16.2 METHOD OF TESTING..............................................................................23
E 4.16.3 AGE OF PILES AT TIME OF TESTING.........................................................23
E 4.16.4 PREPARATION OF PILE HEADS.................................................................23
E 4.16.5 SPECIALIST SUB-CONTRACTOR...............................................................23
E 4.16.6 INTERPRETATION OF TESTS....................................................................23
E 4.16.7 REPORT................................................................................................... 23
E 4.16.8 ANOMALOUS RESULTS............................................................................24
E 4.17 MEASUREMENT AND PAYMENT......................................................................24
E 4.18 NO. OF TESTS................................................................................................ 24
E5 TEST BORING.......................................................................................................... 25
E 5.1 DESCRIPTION.......................................................................................................... 25
E 5.1.1 GENERAL................................................................................................. 25
E 5.1.2 SCOPE OF GEOTECHNICAL INVESTIGATIONS...........................................25
E 5.2 ROLE OF THE ENGINEER FOR GEOTECHNICAL INVESTIGATION...............................25
E 5.3 CONTRACTOR’S RESPONSIBILITY FOR THE GEOTECHNICAL INVESTIGATION ..........25
E 5.4 NUMBER AND DEPTH OF BOREHOLES.....................................................................26
E 5.5 BOREHOLE EQUIPMENT AND METHOD....................................................................26
E 5.5.1 CORE DRILLING.......................................................................................26
Subsection BE: Minor Bridges & Culverts ix of vi

E 5.5.2 IN-SITU TESTING AND SAMPLING.............................................................26

E 5.5.3 LABORATORY TESTS...............................................................................26
E 5.5.4 RECORD OF LABORATORY TESTING AND FINAL REPORTS.......................26
E6 EXCAVATION AND BACKFILL FOR STRUCTURES......................................................27
E 6.1 DESCRIPTION.......................................................................................................... 27
E 6.2 MATERIALS............................................................................................................. 28
E 6.2.1 FOUNDATION FILL MATERIAL...................................................................28
E 6.2.2 BACKFILL MATERIAL................................................................................28
E 6.3 CONSTRUCTION METHODS.....................................................................................29
E 6.3.1 CLEARING................................................................................................ 29
E 6.3.2 EXCAVATION........................................................................................... 29
E 6.3.3 DISPOSAL OF EXCAVATED MATERIAL......................................................29
E 6.3.4 COFFERDAMS.......................................................................................... 30
E 6.3.5 PUMPING AND BAILING............................................................................31
E 6.3.6 BACKFILLING........................................................................................... 31
E7 CONCRETE FOR STRUCTURES.................................................................................32
E 7.1 DESCRIPTION.......................................................................................................... 32
E 7.2 MATERIALS............................................................................................................. 33
E 7.2.1 SPECIFICATIONS FOR MATERIALS............................................................33
E 7.2.2 TESTING OF MATERIALS..........................................................................35
E 7.2.3 COMPOSITION OF CONCRETE..................................................................36
E 7.2.4 CONTROL OF CONCRETE QUALITY..........................................................39
E 7.3.1 GENERAL................................................................................................. 41
E 7.3.2 SCAFFOLDING AND FORMWORK..............................................................41
E 7.3.3 CARE AND STORAGE OF CONCRETE MATERIALS.....................................45
E 7.3.4 PREPARATIONS BEFORE CASTING...........................................................45
E 7.3.5 MEASURING MATERIALS..........................................................................46
E 7.3.6 MIXING CONCRETE..................................................................................46
E 7.3.7 PREPARATION FOR HANDLING AND PLACING CONCRETE........................48
E 7.3.8 PERFORATIONS AND EMBEDMENT OF SPECIAL DEVICES.........................51
B.7.3.9 FINISHING CONCRETE SURFACES............................................................52
E 7.3.10 CONSTRUCTION, CONTRACTION AND EXPANSION JOINTS.......................54
E 7.3.11 CURING CONCRETE.................................................................................54
Subsection BE: Minor Bridges & Culverts x of vi

E 7.3.12 REMOVAL OF SCAFFOLDING AND FORMWORK........................................57

E 7.3.13 REPAIR OF CONCRETE.............................................................................57
E 7.3.14 DEPOSITING CONCRETE UNDER WATER..................................................59
E 7.3.15 FACTORY AND SITE MADE PRECAST CONCRETE ELEMENTS....................59
E 7.3.16 CONTROL OF HEAT IN STRUCTURES.......................................................60
E 7.3.17 BACKFILL TO STRUCTURES......................................................................60
E 7.3.18 CLEANING UP.......................................................................................... 60
E 7.3.19 CONCRETE POURS EARLY AGE CRACK CONTROL AND TRIALS ................60
E 7.3.20 TEMPORARY WORKS...............................................................................61
E8 REINFORCEMENT.................................................................................................... 62
E 8.1 DESCRIPTION.......................................................................................................... 62
E 8.2 MATERIALS............................................................................................................. 62
E 8.2.1 BAR REINFORCEMENT.............................................................................62
E 8.2.2 WIRE MESH............................................................................................. 62
E 8.2.3 BINDING WIRE......................................................................................... 63
E 8.2.4 BAR SIZES............................................................................................... 63
E 8.2.5 ORDERING MATERIAL..............................................................................63
E 8.2.6 ADDITIONAL TESTS.................................................................................63
E 8.3.1 PROTECTION AND STORAGE...................................................................63
E 8.3.2 CUTTING AND BENDING..........................................................................63
E 8.3.3 PLACING, SUPPORTING AND FASTENING.................................................63
E 8.3.4 SPLICING................................................................................................. 64
E 8.3.5 SUBSTITUTIONS......................................................................................64
E9 BRICK AND WATER PROOFING POLYTHENE SHEET WORK.......................................65
E 9.1 DESCRIPTION.......................................................................................................... 65
E 9.2 MATERIALS............................................................................................................. 65
E 9.2.1 SPECIFICATIONS FOR MATERIALS FOR BRICK WORK...............................65
E 9.2.2 SPECIFICATIONS FOR MORTAR................................................................66
E 9.3.1 GENERAL................................................................................................. 66
E 9.3.2 WORKMANSHIP.......................................................................................66
E 9.3.3 BRICK DRAINAGE LAYERS........................................................................67
Subsection BE: Minor Bridges & Culverts xi of vi

E 10 DRAINAGE OF STRUCTURES 68
E 10.1 DESCRIPTION................................................................................................. 68
E 10.2 MATERIALS.................................................................................................... 68
E 10.2.1 PVC PIPES................................................................................................ 68
E 10.3 CONSTRUCTION METHODS............................................................................68
E 10.3.1 STORAGE AND HANDLING OF MATERIALS...............................................68
E 10.3.2 PVC PIPES................................................................................................ 68
E 10.3.3 WEEP HOLES........................................................................................... 68
E 11 INSERTS AND FITTINGS IN STRUCTURES69
E 11.1 DESCRIPTION................................................................................................. 69
E 11.2 MATERIALS.................................................................................................... 69
E 11.3 CONSTRUCTION METHODS............................................................................69
E 12 BRIDGE BEARINGS 69
E 12.1 GENERAL....................................................................................................... 69
E 12.1.1 WORKING DRAWING................................................................................69
E 12.1.2 PACKAGING, HANDLING AND STORAGE..................................................69
E 12.1.3 MANUFACTURE OR FABRICATION............................................................70
E 12.1.4 CONSTRUCTION AND INSTALLATION.......................................................70
E 12.2 ELASTOMERIC BEARINGS..............................................................................70
E 12.2.1 DESCRIPTION.......................................................................................... 70
E 12.2.2 MATERIALS.............................................................................................. 70
E 12.2.3 METHOD.................................................................................................. 75
E 12.2.4 MAINTENANCE......................................................................................... 76
E 12.3 POT AND DISC BEARINGS..............................................................................76
E 12.3.1 GENERAL................................................................................................. 76
E 12.3.2 WORKING DRAWINGS..............................................................................76
E 12.3.3 MATERIALS.............................................................................................. 77
E 12.3.4 FABRICATION DETAILS............................................................................78
E 12.3.5 SAMPLING AND TESTING.........................................................................79
E 12.3.6 INSTALLATION......................................................................................... 80
E 13 FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES 80
E 13.1 DESCRIPTION................................................................................................. 80
E 13.2 GENERAL....................................................................................................... 80
Subsection BE: Minor Bridges & Culverts xii of vi

E 13.3 STRUCTURAL STEEL MATERIALS....................................................................81

E 13.3.1 81
E 13.3.2 OTHER STEEL................................................................................................... 81
E 13.3.3 CASTINGS AND FORGINGS...............................................................................81
E 13.3.4 FASTENERS............................................................................................. 82
E 13.3.5 WELDING CONSUMABLES........................................................................83
E 13.3.6 WELDING................................................................................................. 83
E 13.3.7 WIRE ROPES AND CABLES.......................................................................84
E 13.3.8 LOADINGS AND DESIGN SPECIFICATIONS :.............................................84
E 13.4 FABRICATION................................................................................................. 85
E 13.4.1 GENERAL................................................................................................. 85
E 13.4.2 PREPARATION OF EDGES AND ENDS.......................................................85
E 13.4.3 PREPARATION OF HOLES.........................................................................87
E13.4.4 BOLTS, NUTS AND WASHERS..................................................................88
E 13.4.5 PINS AND PIN HOLES...............................................................................89
E 13.4.6 SHOP DRAWINGS, SHOP ERECTION AND MATCH MARKING ..............................89
E 13.4.7 WELDING................................................................................................. 90
E 13.5 ERECTION...................................................................................................... 93
E 13.5.1 GENERAL................................................................................................. 93
E 13.5.2 ORGANISATION AND EQUIPMENT............................................................93
E 13.5.3 HANDLING AND STORING OF MATERIALS................................................94
E 13.5.4 FORMWORK............................................................................................. 94
E 13.5.5 STRAIGHTENING BENT MATERIAL............................................................94
E 13.5.6 ASSEMBLING STEEL.................................................................................95
E 13.5.7 FIELD INSPECTION...................................................................................95
E 13.5.8 TESTING.................................................................................................. 98
E 13.6 PAINTING....................................................................................................... 98
B.13.6.1 INTRODUCTION.......................................................................................98
E 13.6.2 SCOPE..................................................................................................... 99
E 13.6.3 SURFACE PREPARATION..........................................................................99
B.13.6.4 COATING MATERIALS..............................................................................99
E 13.6.5 APPLICATION OF COATING....................................................................100
E 15.6.6 HANDLING, TRANSPORT AND STORAGE................................................100
E 13.6.7 REPAIR OR REMEDIAL WORK.................................................................101
E 13.6.8 FIELD PAINTING.....................................................................................101
E 13.6.9 ON-SITE REPAIR PROCEDURES..............................................................101
Subsection BE: Minor Bridges & Culverts xiii of vi

E 13.6.10 QUALITY ASSURANCE AND INSPECTION REQUIREMENTS......................102

E 13.7 MEASUREMENT AND PAYMENT....................................................................103
E 14 DEMOLITION OF EXISTING STRUCTURES103
E 15 FILTER WORKS FOR BOX CULVERTS WALL 103
E 15.1 BRICK CHIPS FILTER MATERIAL....................................................................103
E 15.2 SCOPE OF WORK......................................................................................... 103
E 15.3 MATERIALS.................................................................................................. 103
E 15.4 WORKMANSHIP............................................................................................ 104
E 15.4.1 FOUNDATION PREPARATION........................................................................104
E 15.5 MEASUREMENT AND PAYMENT....................................................................104
E 16 ABUTMENT PROTECTION WORKS 104
E 16.1 DESCRIPTION............................................................................................... 104
E 16.2 MATERIAL.................................................................................................... 104
E 16.3 METHOD...................................................................................................... 105
B. 16.4 MEASUREMENT AND PAYMENT....................................................................105
E1 SCOPE OF THE WORK...............................................................................

E 1.1 CONSTRUCTION OF MINOR BRIDGES AND CULVERTS.................................
E 1.2 LIST OF MINOR BRIDGES-44 NOS. (6 NOS. PLATE GIRDER BRIDGES & 38
NOS. BOX CULVERTS)....................................................................................
E2 GENERAL REQUIREMENTS........................................................................
E 2.1 CONSTRUCTION METHODOLOGY...............................................................
E 2.2 TEMPORARY STAGING AND SUPPORT SYSTEMS.........................................
E 2.3 SUB-SURFACE AND FOUNDATION INFORMATION.......................................
E 2.4 ESTABLISHMENT OF LINES AND GRADES...................................................
E 2.5 PROTECTION OF STREAMS AND WATERCOURSES.......................................
E 2.6 INTERFERENCE WITH TRAFFIC..................................................................
E 2.7 STRUCTURAL APPEARANCE AND CONFORMITY..........................................
E 2.8 OPENING OF BRIDGE DECKS TO TRAFFIC...................................................
Subsection BE: Minor Bridges & Culverts xiv of vi

E 2.9 CLEAN UP OF BRIDGE AND STRUCTURE SITES............................................

E 2.10 CONSTRUCTION ACCESS...................................................................
E 2.11 RAILWAY EQUIPMENT......................................................................
E 2.12 GENERAL CODES AND STANDARDS...................................................
E 2.13 ABBREVIATIONS AND DEFINITIONS...................................................
E3 BORED CAST-IN-PLACE PILES....................................................................
E 3.1 DESCRIPTION..........................................................................................
E 3.2 MATERIALS.............................................................................................
E 3.2.1 STEEL CASING............................................................................
E 3.2.2 CONCRETE.................................................................................
E 3.2.3 REINFORCEMENT........................................................................
E 3.2.4 DRILLING FLUID..........................................................................
E 3.3 CONSTRUCTION METHODS.......................................................................
E 3.3.1 GENERAL...................................................................................
E 3.3.2 SETTING OUT PILES....................................................................
E 3.3.3 DIAMETER OF PILES....................................................................
E 3.3.4 TOLERANCES..............................................................................
E 3.3.5 BORING......................................................................................
E 3.3.6 PLACING REINFORCEMENT..........................................................
E 3.3.7 PLACING CONCRETE....................................................................
E 3.3.8 EXTRACTION OF TEMPORARY CASING..........................................
E 3.3.9 TEMPORARY SUPPORT................................................................
E 3.3.10 RECORDS...................................................................................
E 3.3.11 MEASURES IN CASE OF REJECTED PILES.......................................
E 3.3.12 PILOT PILES...............................................................................
E 3.4 MEASUREMENT AND PAYMENT.................................................................
E4 PILE LOAD TESTS.....................................................................................
E 4.1 DESCRIPTION..........................................................................................
E 4.1.1 GENERAL...................................................................................
E 4.1.2 DEFINITIONS..............................................................................
E 4.2 SUPERVISION..........................................................................................
E 4.3 SAFETY PRECAUTIONS.............................................................................
E 4.3.1 GENERAL...................................................................................
E 4.3.2 KENTLEDGE................................................................................
E 4.3.3 TENSION PILES AND GROUND ANCHORS......................................
E 4.3.4 TESTING EQUIPMENT..................................................................
Subsection BE: Minor Bridges & Culverts xv of vi

E 4.4 CONSTRUCTION OF A PILOT PILE TO BE TEST LOADED...............................

E 4.4.1 NOTICE OF CONSTRUCTION.........................................................
E 4.4.2 METHOD OF CONSTRUCTION.......................................................
E 4.4.3 BORING OR DRIVING RECORD......................................................
E 4.4.4 CUT-OFF LEVEL..........................................................................
E 4.4.5 PILE HEAD FOR COMPRESSION TESTS..........................................
E 4.4.6 COMPLETION OF THE TESTING OF PILOT PILES.............................
E 4.5 PREPARATION OF A WORKING PILE TO BE TESTED.....................................
E 4.6 REACTION SYSTEMS.................................................................................
E 4.6.1 COMPRESSION TESTS.................................................................
E 4.6.2 WORKING PILES.........................................................................
E 4.6.3 SPACING....................................................................................
E 4.6.4 ADEQUATE REACTION.................................................................
E 4.6.5 CARE OF PILES...........................................................................
E 4.6.6 LOADING ARRANGEMENT............................................................
E 4.7 EQUIPMENT FOR APPLYING LOAD.............................................................
E 4.8 MEASUREMENT OF LOAD..........................................................................
E 4.9 ADJUSTABILITY OF LOADING EQUIPMENT..................................................
E 4.10 MEASURING MOVEMENT OF PILE HEAD.............................................
E 4.10.1 GENERAL...................................................................................
E 4.10.2 LEVELLING METHOD...................................................................
E 4.10.3 INDEPENDENT REFERENCE FRAME...............................................
E 4.10.4 OTHER METHODS.......................................................................
E 4.11 PROTECTION OF TESTING EQUIPMENT...............................................
E 4.11.1 PROTECTION FROM WEATHER.....................................................
E 4.11.2 PREVENTION OF DISTURBANCE...................................................
E 4.12 SUPERVISION..................................................................................
E 4.12.1 NOTICE OF TEST.........................................................................
E 4.12.2 RECORDS...................................................................................
E 4.13 TEST PROCEDURE............................................................................
E 4.13.1 PROOF TEST BY MAINTAINED LOAD TEST.....................................
E 4.14 PRESENTATION OF RESULTS.............................................................
E 4.14.1 RESULTS TO BE SUBMITTED........................................................
E 4.14.2 SCHEDULE OF RECORDED DATA..................................................
E 4.15 COMPLETION OF A TEST...................................................................
E 4.15.1 MEASURING EQUIPMENT.............................................................
Subsection BE: Minor Bridges & Culverts xvi of vi

E 4.15.2 KENTLEDGE................................................................................
E 4.15.3 TEMPORARY PILES......................................................................
E 4.16 INTEGRITY TESTING OF PILES...........................................................
E 4.16.1 PURPOSE...................................................................................
E 4.16.2 METHOD OF TESTING..................................................................
E 4.16.3 AGE OF PILES AT TIME OF TESTING..............................................
E 4.16.4 PREPARATION OF PILE HEADS.....................................................
E 4.16.5 SPECIALIST SUB-CONTRACTOR....................................................
E 4.16.6 INTERPRETATION OF TESTS........................................................
E 4.16.7 REPORT.....................................................................................
E 4.16.8 ANOMALOUS RESULTS................................................................
E 4.17 MEASUREMENT AND PAYMENT.........................................................
E 4.18 NO. OF TESTS..................................................................................
E5 TEST BORING..........................................................................................
E 5.1 DESCRIPTION..........................................................................................
E 5.1.1 GENERAL...................................................................................
E 5.1.2 SCOPE OF GEOTECHNICAL INVESTIGATIONS.................................
E 5.2 ROLE OF THE ENGINEER FOR GEOTECHNICAL INVESTIGATION....................
E 5.3 CONTRACTOR’S RESPONSIBILITY FOR THE GEOTECHNICAL INVESTIGATION.
E 5.4 NUMBER AND DEPTH OF BOREHOLES........................................................
E 5.5 BOREHOLE EQUIPMENT AND METHOD.......................................................
E 5.5.1 CORE DRILLING..........................................................................
E 5.5.2 IN-SITU TESTING AND SAMPLING.................................................
E 5.5.3 LABORATORY TESTS...................................................................
E 5.5.4 RECORD OF LABORATORY TESTING AND FINAL REPORTS..............
E6 EXCAVATION AND BACKFILL FOR STRUCTURES.........................................
E 6.1 DESCRIPTION..........................................................................................
E 6.2 MATERIALS.............................................................................................
E 6.2.1 FOUNDATION FILL MATERIAL......................................................
E 6.2.2 BACKFILL MATERIAL...................................................................
E 6.3.1 CLEARING..................................................................................
E 6.3.2 EXCAVATION..............................................................................
E 6.3.3 DISPOSAL OF EXCAVATED MATERIAL...........................................
E 6.3.4 COFFERDAMS.............................................................................
Subsection BE: Minor Bridges & Culverts xvii of vi

E 6.3.5 PUMPING AND BAILING...............................................................

E 6.3.6 BACKFILLING..............................................................................
E7 CONCRETE FOR STRUCTURES...................................................................
E 7.1 DESCRIPTION..........................................................................................
E 7.2 MATERIALS.............................................................................................
E 7.2.1 SPECIFICATIONS FOR MATERIALS................................................
E 7.2.2 TESTING OF MATERIALS..............................................................
E 7.2.3 COMPOSITION OF CONCRETE......................................................
E 7.2.4 CONTROL OF CONCRETE QUALITY................................................
E 7.3.1 GENERAL...................................................................................
E 7.3.2 SCAFFOLDING AND FORMWORK..................................................
E 7.3.3 CARE AND STORAGE OF CONCRETE MATERIALS............................
E 7.3.4 PREPARATIONS BEFORE CASTING................................................
E 7.3.5 MEASURING MATERIALS.............................................................
E 7.3.6 MIXING CONCRETE......................................................................
E 7.3.7 PREPARATION FOR HANDLING AND PLACING CONCRETE...............
E 7.3.8 PERFORATIONS AND EMBEDMENT OF SPECIAL DEVICES...............
B.7.3.9 FINISHING CONCRETE SURFACES.................................................
E 7.3.10 CONSTRUCTION, CONTRACTION AND EXPANSION JOINTS..............
E 7.3.11 CURING CONCRETE.....................................................................
E 7.3.12 REMOVAL OF SCAFFOLDING AND FORMWORK..............................
E 7.3.13 REPAIR OF CONCRETE.................................................................
E 7.3.14 DEPOSITING CONCRETE UNDER WATER........................................
E 7.3.15 FACTORY AND SITE MADE PRECAST CONCRETE ELEMENTS............
E 7.3.16 CONTROL OF HEAT IN STRUCTURES.............................................
E 7.3.17 BACKFILL TO STRUCTURES..........................................................
E 7.3.18 CLEANING UP.............................................................................
E 7.3.19 CONCRETE POURS EARLY AGE CRACK CONTROL AND TRIALS........
E 7.3.20 TEMPORARY WORKS...................................................................
E8 REINFORCEMENT.....................................................................................
E 8.1 DESCRIPTION..........................................................................................
E 8.2 MATERIALS.............................................................................................
E 8.2.1 BAR REINFORCEMENT.................................................................
Subsection BE: Minor Bridges & Culverts xviii of vi

E 8.2.2 WIRE MESH................................................................................

E 8.2.3 BINDING WIRE............................................................................
E 8.2.4 BAR SIZES..................................................................................
E 8.2.5 ORDERING MATERIAL..................................................................
E 8.2.6 ADDITIONAL TESTS.....................................................................
E 8.3.1 PROTECTION AND STORAGE........................................................
E 8.3.2 CUTTING AND BENDING..............................................................
E 8.3.3 PLACING, SUPPORTING AND FASTENING......................................
E 8.3.4 SPLICING...................................................................................
E 8.3.5 SUBSTITUTIONS.........................................................................
E9 BRICK AND WATER PROOFING POLYTHENE SHEET WORK...........................
E 9.1 DESCRIPTION..........................................................................................
E 9.2 MATERIALS.............................................................................................
E 9.2.1 SPECIFICATIONS FOR MATERIALS FOR BRICK WORK.....................
E 9.2.2 SPECIFICATIONS FOR MORTAR....................................................
E 9.3.1 GENERAL...................................................................................
E 9.3.2 WORKMANSHIP..........................................................................
E 9.3.3 BRICK DRAINAGE LAYERS............................................................
E 10 DRAINAGE OF STRUCTURES
E 10.1 DESCRIPTION..................................................................................
E 10.2 MATERIALS......................................................................................
E 10.2.1 PVC PIPES..................................................................................
E 10.3 CONSTRUCTION METHODS...............................................................
E 10.3.1 STORAGE AND HANDLING OF MATERIALS.....................................
E 10.3.2 PVC PIPES..................................................................................
E 10.3.3 WEEP HOLES..............................................................................
E 11 INSERTS AND FITTINGS IN STRUCTURES
E 11.1 DESCRIPTION..................................................................................
E 11.2 MATERIALS......................................................................................
E 11.3 CONSTRUCTION METHODS...............................................................
Subsection BE: Minor Bridges & Culverts xix of vi

E 12 BRIDGE BEARINGS
E 12.1 GENERAL.........................................................................................
E 12.1.1 WORKING DRAWING...................................................................
E 12.1.2 PACKAGING, HANDLING AND STORAGE........................................
E 12.1.3 MANUFACTURE OR FABRICATION................................................
E 12.1.4 CONSTRUCTION AND INSTALLATION............................................
E 12.2 ELASTOMERIC BEARINGS..................................................................
E 12.2.1 DESCRIPTION.............................................................................
E 12.2.2 MATERIALS................................................................................
E 12.2.3 METHOD....................................................................................
E 12.2.4 MAINTENANCE............................................................................
E 12.3 POT AND DISC BEARINGS.................................................................
E 12.3.1 GENERAL...................................................................................
E 12.3.2 WORKING DRAWINGS.................................................................
E 12.3.3 MATERIALS................................................................................
E 12.3.4 FABRICATION DETAILS................................................................
E 12.3.5 SAMPLING AND TESTING.............................................................
E 12.3.6 INSTALLATION............................................................................
E 13 FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES
E 13.1 DESCRIPTION..................................................................................
E 13.2 GENERAL.........................................................................................
E 13.3 STRUCTURAL STEEL MATERIALS.......................................................
E 13.3.1
E 13.3.2 OTHER STEEL...................................................................................
E 13.3.3 CASTINGS AND FORGINGS.................................................................
E 13.3.4 FASTENERS................................................................................
E 13.3.5 WELDING CONSUMABLES............................................................
E 13.3.6 WELDING...................................................................................
E 13.3.7 WIRE ROPES AND CABLES...........................................................
E 13.3.8 LOADINGS AND DESIGN SPECIFICATIONS :...................................
E 13.4 FABRICATION..................................................................................
E 13.4.1 GENERAL...................................................................................
E 13.4.2 PREPARATION OF EDGES AND ENDS............................................
E 13.4.3 PREPARATION OF HOLES............................................................
E13.4.4 BOLTS, NUTS AND WASHERS.......................................................
Subsection BE: Minor Bridges & Culverts xx of vi

E 13.4.5 PINS AND PIN HOLES..................................................................

E 13.4.6 SHOP DRAWINGS, SHOP ERECTION AND MATCH MARKING..................
E 13.4.7 WELDING...................................................................................
E 13.5 ERECTION........................................................................................
E 13.5.1 GENERAL...................................................................................
E 13.5.2 ORGANISATION AND EQUIPMENT.................................................
E 13.5.3 HANDLING AND STORING OF MATERIALS.....................................
E 13.5.4 FORMWORK...............................................................................
E 13.5.5 STRAIGHTENING BENT MATERIAL................................................
E 13.5.6 ASSEMBLING STEEL....................................................................
E 13.5.7 FIELD INSPECTION......................................................................
E 13.5.8 TESTING....................................................................................
E 13.6 PAINTING........................................................................................
B.13.6.1 INTRODUCTION..........................................................................
E 13.6.2 SCOPE.......................................................................................
E 13.6.3 SURFACE PREPARATION..............................................................
B.13.6.4 COATING MATERIALS..................................................................
E 13.6.5 APPLICATION OF COATING..........................................................
E 15.6.6 HANDLING, TRANSPORT AND STORAGE.......................................
E 13.6.7 REPAIR OR REMEDIAL WORK.......................................................
E 13.6.8 FIELD PAINTING.........................................................................
E 13.6.9 ON-SITE REPAIR PROCEDURES.....................................................
E 13.6.10 QUALITY ASSURANCE AND INSPECTION REQUIREMENTS...............
E 14 DEMOLITION OF EXISTING STRUCTURES
E 15 FILTER WORKS FOR BOX CULVERTS WALL
E 15.1 BRICK CHIPS FILTER MATERIAL.........................................................
E 15.2 SCOPE OF WORK..............................................................................
E 15.3 MATERIALS......................................................................................
E 15.4 WORKMANSHIP...............................................................................
E 15.4.1 FOUNDATION PREPARATION.............................................................
E 16 ABUTMENT PROTECTION WORKS
E 16.1 DESCRIPTION..................................................................................
E 16.2 MATERIAL.......................................................................................
E 16.3 METHOD..........................................................................................
Subsection BE: Minor Bridges & Culverts xxi of vi

B. 16.4 MEASUREMENT AND PAYMENT.........................................................
E1 SCOPE OF THE WORK.............................................................................................................................1

E 1.1 Construction of Minor Bridges and Culverts.....................................................................1
E 1.2 List of Minor Bridges-44 nos. (6 Nos. Plate Girder Bridges & 38 Nos. Box Culverts) .....1
E2 GENERAL REQUIREMENTS.......................................................................4
E 2.1 Construction Methodology................................................................................................4
E 2.2 Construction Drawings..................................................................................................... 4
E 2.3 As-Built Drawings............................................................................................................. 4
E 2.4 Temporary Staging and Support Systems........................................................................4
E 2.5 Sub-surface and Foundation Information.........................................................................5
E 2.6 Establishment of Lines and Grades..................................................................................5
E 2.7 Protection of Streams and Watercourses.........................................................................5
E 2.8 Interference with Traffic.................................................................................................... 5
E 2.9 Structural Appearance and Conformity............................................................................5
E 2.10 Opening of Bridge Decks to Traffic...................................................................................5
E 2.11 Clean Up of Bridge and Structure Sites............................................................................6
E 2.12 Construction Access......................................................................................................... 6
E 2.13 Railway Equipment........................................................................................................... 6
E 2.14 General Codes and Standards.........................................................................................6
E 2.15 Abbreviations and Definitions........................................................................................... 6
E3 BORED CAST-IN-PLACE PILES..................................................................7
E 3.1 Description....................................................................................................................... 7
E 3.2 Materials........................................................................................................................... 8
E 3.2.1 Steel Casing............................................................................................................. 8
E 3.2.2 Concrete................................................................................................................... 8
E 3.2.3 Reinforcement.......................................................................................................... 8
E 3.2.4 Drilling Fluid.............................................................................................................. 9
E 3.3 Construction Methods...................................................................................................... 9
E 3.3.1 General..................................................................................................................... 9
E 3.3.2 Setting Out Piles..................................................................................................... 10
E 3.3.3 Diameter of Piles.................................................................................................... 10
E 3.3.4 Tolerances.............................................................................................................. 11
E 3.3.5 Boring..................................................................................................................... 11
E 3.3.6 Placing Reinforcement............................................................................................ 13
E 3.3.7 Placing Concrete.................................................................................................... 13
E 3.3.8 Extraction of Temporary Casing.............................................................................15
E 3.3.9 Temporary Support.................................................................................................15
E 3.3.10 Records.................................................................................................................. 15
E 3.3.11 Measures in Case of Rejected Piles.......................................................................16
E 3.3.12 Pilot Piles................................................................................................................ 16
E 3.4 Measurement and Payment........................................................................................... 16
E4 PILE LOAD TESTS.................................................................................17
E 4.1 Description..................................................................................................................... 17
E 4.1.1 General................................................................................................................... 17
E 4.1.2 Definitions............................................................................................................... 17
Subsection BE: Minor Bridges & Culverts xxii of vi

E 4.2 Supervision..................................................................................................................... 18
E 4.3 Safety Precautions......................................................................................................... 18
E 4.3.1 General................................................................................................................... 18
E 4.3.2 Kentledge................................................................................................................ 19
E 4.3.3 Tension Piles and Ground Anchors........................................................................19
E 4.3.4 Testing Equipment.................................................................................................. 19
E 4.4 Construction of a Pilot Pile to be Test Loaded................................................................19
E 4.4.1 Notice of Construction.............................................................................................19
E 4.4.2 Method of Construction...........................................................................................19
E 4.4.3 Boring or Driving Record......................................................................................... 20
E 4.4.4 Cut-Off Level........................................................................................................... 20
E 4.4.5 Pile Head for Compression Tests...........................................................................20
E 4.4.6 Completion of the Testing of Pilot Piles..................................................................20
E 4.5 Preparation of a Working Pile to be tested.....................................................................20
E 4.6 Reaction Systems.......................................................................................................... 20
E 4.6.1 Compression Tests.................................................................................................20
E 4.6.2 Working Piles.......................................................................................................... 20
E 4.6.3 Spacing................................................................................................................... 20
E 4.6.4 Adequate Reaction.................................................................................................21
E 4.6.5 Care of Piles........................................................................................................... 21
E 4.6.6 Loading Arrangement.............................................................................................21
E 4.7 Equipment for Applying Load......................................................................................... 21
E 4.8 Measurement of Load.................................................................................................... 21
E 4.9 Adjustability of Loading Equipment................................................................................21
E 4.10 Measuring Movement of Pile Head................................................................................22
E 4.10.1 General................................................................................................................... 22
E 4.10.2 Levelling Method..................................................................................................... 22
E 4.10.3 Independent Reference Frame...............................................................................22
E 4.10.4 Other Methods........................................................................................................ 22
E 4.11 Protection of Testing Equipment....................................................................................22
E 4.11.1 Protection from Weather.........................................................................................22
E 4.11.2 Prevention of Disturbance.......................................................................................23
E 4.12 Supervision..................................................................................................................... 23
E 4.12.1 Notice of Test.......................................................................................................... 23
E 4.12.2 Records.................................................................................................................. 23
E 4.13 Test Procedure............................................................................................................... 23
E 4.13.1 Proof Test by Maintained Load Test.......................................................................23
E 4.14 Presentation of Results.................................................................................................. 25
E 4.14.1 Results to be Submitted..........................................................................................25
E 4.14.2 Schedule of Recorded Data....................................................................................25
E 4.15 Completion of a Test...................................................................................................... 26
E 4.15.1 Measuring Equipment.............................................................................................26
E 4.15.2 Kentledge................................................................................................................ 26
E 4.15.3 Temporary Piles...................................................................................................... 26
E 4.16 Integrity Testing of Piles................................................................................................. 26
E 4.16.1 Purpose.................................................................................................................. 26
E 4.16.2 Method of Testing................................................................................................... 26
E 4.16.3 Age of Piles at Time of Testing...............................................................................26
E 4.16.4 Preparation of Pile Heads.......................................................................................26
Subsection BE: Minor Bridges & Culverts xxiii of vi
E 4.16.5 Specialist Sub-Contractor.......................................................................................27

E 4.16.6 Interpretation of Tests.............................................................................................27
E 4.16.7 Report..................................................................................................................... 27
E 4.16.8 Anomalous Results.................................................................................................27
E 4.18 No. of Tests.................................................................................................................... 28
E5 TEST BORING.......................................................................................28
E 5.1 Description..................................................................................................................... 28
E 5.1.1 General................................................................................................................... 28
E 5.1.2 Scope of Geotechnical Investigations.....................................................................28
E 5.2 Role of the Project Manager for Geotechnical Investigation...........................................29
E 5.3 Contractor’s Responsibility for the Geotechnical Investigation.......................................29
E 5.4 Number and Depth of Boreholes....................................................................................29
E 5.5 Borehole Equipment and Method...................................................................................30
E 5.5.1 Core Drilling............................................................................................................ 30
E 5.5.2 In-Situ Testing and Sampling..................................................................................30
E 5.5.3 Laboratory Tests..................................................................................................... 30
E 5.5.4 Record of Laboratory Testing and Final Reports....................................................30
E6 EXCAVATION AND BACKFILL FOR STRUCTURES......................................31
E 6.1 Description..................................................................................................................... 31
E 6.2 Materials......................................................................................................................... 32
E 6.2.1 Foundation Fill Material........................................................................................... 32
E 6.2.2 Backfill Material....................................................................................................... 32
E 6.3 Construction Methods.................................................................................................... 33
E 6.3.1 Clearing.................................................................................................................. 33
E 6.3.2 Excavation.............................................................................................................. 33
E 6.3.3 Disposal of Excavated Material...............................................................................33
E 6.3.4 Cofferdams............................................................................................................. 34
E 6.3.5 Pumping and Bailing............................................................................................... 35
E 6.3.6 Backfilling................................................................................................................ 35
E7 CONCRETE FOR STRUCTURES................................................................37
E 7.1 Description..................................................................................................................... 37
E 7.2 Materials......................................................................................................................... 37
E 7.2.1 Specifications for Materials.....................................................................................37
E 7.2.2 Testing of Materials.................................................................................................40
E 7.2.3 Composition of Concrete........................................................................................41
E 7.2.4 Control of Concrete Quality.....................................................................................44
E 7.3.1 General................................................................................................................... 47
E 7.3.2 Scaffolding and Formwork......................................................................................47
E 7.3.3 Care and Storage of Concrete Materials.................................................................51
E 7.3.4 Preparations before Casting...................................................................................52
E 7.3.5 Measuring Materials................................................................................................52
E 7.3.6 Mixing Concrete...................................................................................................... 52
E 7.3.7 Preparation for Handling and Placing Concrete......................................................55
Subsection BE: Minor Bridges & Culverts xxiv of vi

E 7.3.8 Perforations and Embedment of Special Devices...................................................59

B.7.3.9 Finishing Concrete Surfaces...................................................................................59
E 7.3.10 Construction, Contraction and Expansion Joints....................................................61
E 7.3.11 Curing Concrete...................................................................................................... 62
E 7.3.12 Removal of Scaffolding and Formwork...................................................................65
E 7.3.13 Repair of Concrete.................................................................................................. 65
E 7.3.14 Depositing Concrete under Water...........................................................................67
E 7.3.15 Factory and Site Made Precast Concrete Elements...............................................68
E 7.3.16 Control of Heat in Structures...................................................................................69
E 7.3.17 Backfill to Structures............................................................................................... 69
E 7.3.18 Cleaning Up............................................................................................................ 69
E 7.3.19 Concrete Pours Early Age Crack Control and Trials...............................................69
E 7.3.20 Temporary Works................................................................................................... 69
E8 REINFORCEMENT.................................................................................71
E 8.1 Description..................................................................................................................... 71
E 8.2 Materials......................................................................................................................... 71
E 8.2.1 Bar Reinforcement.................................................................................................. 71
E 8.2.2 Wire Mesh............................................................................................................... 71
E 8.2.3 Binding Wire........................................................................................................... 71
E 8.2.4 Bar Sizes................................................................................................................ 71
E 8.2.5 Ordering Material.................................................................................................... 72
E 8.2.6 Additional Tests...................................................................................................... 72
E 8.3.1 Protection and Storage...........................................................................................72
E 8.3.2 Cutting and Bending............................................................................................... 72
E 8.3.3 Placing, Supporting and Fastening.........................................................................72
E 8.3.4 Splicing................................................................................................................... 73
E 8.3.5 Substitutions........................................................................................................... 73
E9 BRICK AND WATER PROOFING POLYTHENE SHEET WORK.......................74
E 9.1 Description..................................................................................................................... 74
E 9.2 Materials......................................................................................................................... 74
E 9.2.1 Specifications for Materials for Brick work..............................................................74
E 9.2.2 Specifications for Mortar......................................................................................... 75
E 9.3.1 General................................................................................................................... 75
E 9.3.2 Workmanship.......................................................................................................... 76
E 9.3.3 Brick Drainage Layers.............................................................................................76
E 10 DRAINAGE OF STRUCTURES...............................................................77
E 10.1 Description..................................................................................................................... 77
E 10.2 Materials......................................................................................................................... 77
E 10.2.1 PVC Pipes.............................................................................................................. 77
E 10.3.1 Storage and Handling of Materials..........................................................................78
E 10.3.2 PVC Pipes.............................................................................................................. 78
Subsection BE: Minor Bridges & Culverts xxv of vi

E 10.3.3 Weep Holes............................................................................................................ 78

E 11 INSERTS AND FITTINGS IN STRUCTURES.............................................78
E 11.1 Description..................................................................................................................... 78
E 11.2 Materials......................................................................................................................... 79
E 12 BRIDGE BEARINGS.............................................................................79
E 12.1 General.......................................................................................................................... 79
E 12.1.1 Working Drawing.................................................................................................... 79
E 12.1.2 Packaging, Handling and Storage..........................................................................79
E 12.1.3 Manufacture or Fabrication.....................................................................................80
E 12.1.4 Construction and Installation...................................................................................80
E 12.2 Elastomeric Bearings..................................................................................................... 80
E 12.2.1 Description.............................................................................................................. 80
E 12.2.2 Materials................................................................................................................. 80
E 12.2.3 Method.................................................................................................................... 86
E 12.2.4 Maintenance........................................................................................................... 86
E 12.3 Pot and Disc Bearings.................................................................................................... 87
E 12.3.1 General................................................................................................................... 87
E 12.3.2 Working Drawings................................................................................................... 87
E 12.3.3 Materials................................................................................................................. 87
E 12.3.4 Fabrication Details.................................................................................................. 89
E 12.3.5 Sampling and Testing............................................................................................. 90
E 12.3.6 Installation............................................................................................................... 91
E 13 FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES.................................91
E 13.1 Description..................................................................................................................... 91
E 13.2 General.......................................................................................................................... 91
E 13.3 Structural Steel Materials............................................................................................... 92
E 13.3.2 Other Steel................................................................................................................... 93
E 13.3.3 Castings and Forgings.................................................................................................93
E 13.3.4 Fasteners................................................................................................................ 93
E 13.3.5 Welding Consumables............................................................................................94
E 13.3.6 Welding................................................................................................................... 94
E 13.3.7 Wire Ropes and Cables.......................................................................................... 95
E 13.3.8 Loadings and Design Specifications :.....................................................................95
E 13.4 Fabrication...................................................................................................................... 97
E 13.4.1 General................................................................................................................... 97
E 13.4.2 Preparation of Edges and Ends..............................................................................97
E 13.4.3 Preparation of Holes...............................................................................................99
E13.4.4 Bolts, Nuts and Washers......................................................................................100
E 13.4.5 Pins and Pin Holes................................................................................................102
E 13.4.6 Shop Drawings, Shop Erection and Match Marking...................................................102
E 13.4.7 Welding................................................................................................................. 103
E 13.5 Erection........................................................................................................................ 106
E 13.5.1 General................................................................................................................. 106
Subsection BE: Minor Bridges & Culverts xxvi of vi

E 13.5.2 Organisation and Equipment................................................................................106

E 13.5.3 Handling and Storing of Materials.........................................................................107
E 13.5.4 Formwork.............................................................................................................. 108
E 13.5.5 Straightening Bent Material...................................................................................108
E 13.5.6 Assembling Steel.................................................................................................. 108
E 13.5.7 Field Inspection..................................................................................................... 109
E 13.5.8 Testing.................................................................................................................. 112
E 13.6 Painting........................................................................................................................ 112
B.13.6.1 Introduction........................................................................................................... 112
E 13.6.2 Scope.................................................................................................................... 113
E 13.6.3 Surface Preparation.............................................................................................. 113
B.13.6.4 Coating Materials.................................................................................................. 113
E 13.6.5 Application of Coating...........................................................................................114
E 15.6.6 Handling, Transport and Storage..........................................................................115
E 13.6.7 Repair or Remedial Work......................................................................................115
E 13.6.8 Field Painting........................................................................................................ 115
E 13.6.9 On-site Repair Procedures...................................................................................115
E 13.6.10 Quality Assurance and Inspection Requirements.................................................117
E 13.7 Measurement and Payment......................................................................................... 117
E 14 DEMOLITION OF EXISTING STRUCTURES...........................................................118
E 15 FILTER WORKS FOR BOX CULVERTS WALL.......................................................118
E 15.1 Brick Chips Filter Material............................................................................................ 118
E 15.2 Scope of Work.............................................................................................................. 118
E 15.3 Materials....................................................................................................................... 118
E 15.4 Workmanship............................................................................................................... 118
E 15.4.1 Foundation Preparation................................................................................................ 118
E 15.5 Measurement and Payment......................................................................................... 118
E 16 ABUTMENT PROTECTION WORKS.......................................................................119
E 16.1 Description................................................................................................................... 119
E 16.2 Material........................................................................................................................ 119
E 16.3 Method......................................................................................................................... 119
B. 16.4 Measurement and Payment......................................................................................... 120
Subsection BE: Minor Bridges & Culverts xxvii of vi

WD2: Construction of New BG Track on Kashiani-Gopalganj Section Section 8 –Particular Specification
(38 Nos. Box Culverts and 6 nos. Plate Girder Bridges)
Package WD8: Construction of 65 Nos. Minor Bridges Section 8 – Particular Specification
( 51 Nos Box Culverts and 14 nos Plate Girder Bridge )
B.E 1 SCOPE OF THE WORK
The Contractor shall provide all of the required labour, material and equipment, and do everything
necessary to construct the various type of bridge and culvert required for the works, in accordance
with the terms and conditions of the Contract.
Bridges and culverts sites of new Railway Line from Kashiani to Tungipara via Gopalgonj are located
in the south-West region of Bangladesh and within the administrative districts of Gopalgonj. The
alignment of the new Railway line generally passes by the left bank of the Gorai-Modhumati river
system. The terrain is mainly agricultural land interspersed with many low lying and beel area. The
alignment also crosses two major rivers mainly Kumar at Haridaspur and Doria river. Near near
Tungipara upazila the route passes through the BWDB Polder 01, Polder 02, Polder 04 and ends
Polder 03. Gopalganj.
Construction activities of bridges and culverts will take place on the proposed new railway line from
Kashiani to Tungipara via Gopalgonj. Work shall consist of the construction of 51 38 (Fifty onethirty
eight) nos. of Box culverts single vent to multi vents with pile and without pile foundation depending
upon the subsoil condition and also 14 6 (Fourteensix) nos. of Plate Girder minor bridges with RCC
return type abutment having with RCC bored pile of required dia and depth.
The works under this Contract shall include, but not necessarily be limited to the following:
Contractor will propose the methodology and works plan for construction of new bridges & culverts
and submit to the EngineerProject Managers for approval before commencement of the work. If there
is any structure across the proposed track the contractor will demolish the structure like brick/stone
---masonry/concrete plain & reinforced,— timber structures, flexible and/or cement concrete pavement
---etc. and removed all debris from the site immediately and dump to the Contractor’s designated
dumping ground with all leads & lifts..
There will be no separate payment for this works.
B.E 1.1 Construction of Minor Bridges and Culverts
Construction of 14 6 (Fourteensix) nos. Minor bridges ranging from 10.0m to 15.0m single and
multiple spans Plate Girder bridges supported on cast-in-situ RCC substructures and foundation of
RCC bored cast-in-situ piles of required dia and depth designed for 25t Loading – 2008 Broad Gauge
loading of Indian Railways Standards. The Work of this Contract shall also include 38 (thirty eight) 51
(fifty one) nos. of RCC box culverts of open foundation with sand replacement about 1.0m to 3.0m
depth and RCC bored cast-in-situ pile foundation of required dia and depth suitable for 25t Loading –
2008 Broad Gauge loading of Indian Railways Standards. Construction of the bridges and culverts
has to be done in accordance with the Drawings and Specifications.
Subsection EB: Minor Bridges & Culverts Page 1 of

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BE. 1.2 List of Minor Bridges-65 44 nos. (14 6 Nos. Plate Girder
Bridges & 51 38 Nos. Box CCulverts)
Existing Proposed
Bridge Type of
Chainage Size of Structure Ground Formation Remarks
No. Structure
Level Level
Box
BR-01 02+100 2 X 3.0m X 2.5 m 2.530 5.550
Culvert
BR-02 02+475 1 X 6.0m X 5.0 m " 0.740 6.300

BR-03 03+175 2 X 3.0m X 4.5 m " 2.007 6.820
BR-04 03+660 1 X 3.0m X 5.0 m " 1.376 6.820
BR-05 04+315 3 X 6.0m X 6.0 m " 0.306 6.820
BR-06 05+110 1 X 3.0m X 5.0 m " 1.351 6.820
BR-07 05+860 2 X 3.0m X 4.0 m " 2.226 6.820
BR-08 06+425 1 X 3.0m X 3.5 m " 2.907 6.820
BR-
07+525 1 X 3.0m X 3.5 m " 3.117 6.820
08A
BR-09 08+025 2 X 3.0m X 3.5 m " 2.845 6.820
BR-10 08+740 1 X 3.0m X 4.5 m " 1.665 6.700
BR-11 09+320 1 X 3.0m X 4.0 m " 2.553 6.700
BR-
10+250 1 X 3.0m X 3.0 m " 3.366 6.700
11A
BR-12 10+860 2 X 3.0m X 3.5 m " 2.648 6.700
BR-13 12+150 1 X 3.0m X 4.0 m " 2.134 6.700
BR-14 12+955 2 X 3.0m X 5.0 m " 1.299 6.700
Road underpass
1 X10.0 m + Steel with the vertical
BR-15 13+521 -0.354 8.050
1 X 15.0 m Girder clearance
minimum 3.5 m

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Existing Proposed
Bridge Type of
No. Box
Structure
BR-16 14+275 3 X 5.0m X 5.0 m 0.916
Level 6.520
Level
Culvert
BR-17 14+675 2 X 4.0m X 5.5 m " 0.597 6.520
With 1.5m Earth

BR-18 15+219 2 X 6.0m X 5.0 m " -0.434 6.520 Filling at Box top
slab
Steel
BR-19 16+045 1 X 15.0 m -1.180 7.800 Folsir Khal
Girder
BR- Box
16+850 1 X 6.0m X 6.0 m 0.182 6.430
19A Culvert
Katcha road &
BR-20 17+313 2 X 6.0 m X 6.0 m " 0.161 6.430
Canal
Box Pucca road &
BR-21 17+848 3 X 6.0 mX 6.0 m 0.125 6.430
Culvert Folsir Khal
BR-22 18+256 1 X 5.0 m X 5.5 m " 0.645 6.430
BR-23 18+556 1 X 5.0 m X 5.5 m " 0.382 6.430
BR-24 19+130 1 X 6.0 m X 6.0 m " 0.121 6.430
BR-
19+675 1 X 6.0 m X 6.0 m " 0.186 6.430
24A
BR-25 20+220 1 X 6.0 m X 5.5 m " 0.378 6.430
Road underpass
Steel with the vertical
BR-26 21+214 2 X 10.0 m -0.128 7.000
Girder clearance
minimum 3.5 m
Box
BR-27 22+230 1 X 6.0 m X 6.0 m 0.254 6.130
Culvert
BR-28 23+655 1 X 6.0 m X 5.0 m " 0.621 6.130
BR-29 24+150 1 X 4.0 mX 4.5 m " 1.226 6.130
BR-30 24+590 1 X 4.0 m X 5.5 m " 0.375 6.130
Road underpass
BR-31 25+310 2 X 10.0 m 0.033 6.770
Girder clearance
minimum 3.5 m
Box
BR-32 25+910 1 X 3.0 m X5.0 m 0.286 5.882
Culvert
BR-33 26+807 1 X 6.0 m X5.0 m " 0.252 5.882

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Existing Proposed
Bridge Type of
No. Structure
Level Level Road underpass
BR-34 27+453 2 X 10.0 m 0.772 7.650
Girder clearance
minimum 3.5 m
Road underpass
BR-35 28+377 3 X 10.0 m 0.223 6.650
Girder clearance
minimum 3.5 m
With 2.0m Earth
Box
BR-36 28+800 1 X 3.0 m X 5.0 m 0.750 7.923 Filling at Box top
Culvert
slab
BR-
29+331 1 X 6.0 m X 6.0 m " 4.614 10.860 Kumar River
36A
With 2.0m Earth
Box
BR-38 30+206 1 X 4.0 m X 6.0 m 0.379 8.485 Filling at Box top
Culvert
slab
With 1.5m Earth
2 X 6.0 m X
BR-39 30+979 " -0.968 6.900 Filling at Box top
68.0m
slab
With 1.0m Earth
BR-
31+900 1 X 4.0 m X 5.5 m " 0.228 6.900 Filling at Box top
39A
slab
Box
3231+37561 CulvertSt
BR-40 1 X 156.0 mX9.5 0.326 6.900
3 eel
Girder
Box
BR-41 32+825 1 X 4.0 m X 6.0 m 0.929 7.090
Culvert
With 1.5m Earth
Box
BR-43 34+029 3 X 5.0 m X 5.0m 0.211 7.090 Filling at Box top
Culvert
slab
Steel
BR-44 34+762 1 X 15.0 m 0.401 6.770
Girder
BR-45 35+627 1 X 15.0 m " 0.593 6.720
Box
BR-46 36+232 2 X 4.0 m X4.5 m 0.625 5.320
Culvert
Steel
BR-47 37+120 1 X 15.0 m 0.625 6.630
Girder
Box
BR-48 37+836 2 X 4.0 m X5.5 m 0.749 6.630
Culvert
Steel
BR-49 38+380 1 X 15.0 m 0.655 6.570
Girder
Box
BR-50 39+366 2 X 4.0 m X5.0 m 0.662 6.242
Culvert
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Existing Proposed
Bridge Type of
No. Structure
BR-51 40+537 2 X 4.0 m X5.0 m " 0.804
Level 6.242
Level
BR-52 40+936 1 X 4.0 m X4.5 m " 0.433 5.210
Steel
BR-53 41+437 1 X 15.0 m 0.617 6.400
Girder
Box
BR-54 41+947 1 X 4.0 m X4.5 m 0.264 5.050
Culvert
BR-55 42+710 2 X 4.0 m X4.5 m " 0.027 5.050
Steel
BR-56 43+507 1 X 15.0 m 0.627 6.280
Girder
Box
BR-57 44+236 2 X 4.0 m X4.0 m 0.630 5.100
Culvert
BR-
44+850 1 X 4.0 m X4.5 m " 0.338 5.100
57A
Steel
BR-59 46+206 1 X 15.0 m -0.085 6.400
Girder
Box
BR-60 46+682 2 X 4.0 m X4.0 m 0.040 4.600
Culvert
20.0m widthand
remaining
BR-61 47+107 2 X 4.0 m X4.5 m " -0.038 4.600 portion with
open 'U' type
drain
B.E 2 GENERAL REQUIREMENTS
B.E 2.1 Construction Methodology
The Contractor shall submit to the EngineerProject Manager for his approval, details of the
methodology for the construction of the bridges and culverts, in the form of method statements or
procedures in respect of every significant phase of the Works. The Contractor’s proposed construction
programe methodology, including details of the equipment to be used in the erection of the various
bridge components, prioritization of bridge structures, number of sites to be constructed
simultaneously, etc., shall be submitted to the EngineerProject Manager at least 30 (thirty) days prior
to the commencement of such activity, and the EngineerProject Manager’s approval thereof, shall not
in any way relieve the Contractor of his responsibility for the sufficiency of the method used. Where
the Contractor proposes to use more than one construction methodology for the erection of bridge

116129
components, he shall submit details of each specific method to the EngineerProject Manager for
approval.
E 2.2 Construction Drawings
The Contractor shall submit Construction drawings for all works on the basis of drawings of tender
documents and site conditions as verified at sites for approval of the Project Director before 30 (thirty)
days of commencement of work. Three (3) paper copies and one editable soft copy of the working
drawings are required for approval of the Project Director prior to final acceptance of the works
There is no specific measurement and payment item for the provision of working drawings, the
cost of which is deemed to be included in relevant associated BOQ items and the Contractor’s
overhead
E 2.3 As-Built Drawings
The Contractor shall provide As-Built drawings for all of the works undertaken. The basis of these
drawings shall be those provided by the Project Manager for the construction works as well as the
Contractors own shop drawings and other drawings and documents. Three (3) paper copies and one
editable soft copy of the as-built drawings are required for approval of the Project Director prior to final
acceptance of the works.
There is no specific measurement and payment item for the provision of as-built drawings, the
cost of which is deemed to be included in relevant associated BOQ items and the Contractor’s
overhead.
B.E 2.24 Temporary Staging and Support Systems
Temporary staging and support systems shall be provided by the Contractor as required. The staging
or support system shall be properly designed and constructed for the loads which it will be required to
carry, and complete details, including detailed calculations of the proposed arrangement shall be
submitted at least 30 (thirty) days prior to the installation of the temporary works, to the
EngineerProject Manager for his approval, which when given by the EngineerProject Manager, shall
not in any way relieve the Contractor of his overall responsibility with respect to the execution of the
Work.
Similarly, the Contractor shall design and install shoring & other temporary works required for stability
of existing works, investigate to eliminate damage to existing structural or geotechnical works in
adjacent structures or embankments and obtain the EngineerProject Manager’s written clearance
before proceeding with the permanent works.
There shall be no separate measurement or payment for the design, supply, erection and removal of
any temporary staging and/or support system or making allowance for stability of existing works in
constructing the permanent works, the cost of which is deemed to be included in the concrete work,
girder erections, fabrication, piling and other works.
B.E 2.35 Sub-surface and Foundation Information
Sub-surface and foundation information including the location of all boreholes together with a record
of the ground conditions encountered at specific bridges and culverts sites have been obtained from a
field investigation programme carried out prior to the tendering of the Contract. The said investigation
116129
programme consisted of test boring, and visual inspections and it is believed to represent the best
information in the possession of the EmployerProject Director or the EngineerProject Manager at that
time. This sub-surface and foundation information has been made available to the Contractor without
any implication or representation with respect to physical characteristics or accuracy, and without any
guarantee or obligation of any kind on the part of the EmployerProject Director or the EngineerProject
Manager, neither of whom shall be held liable for any error or inaccuracy in this information.
B.E 2.46 Establishment of Lines and Grades
The Contractor will be responsible for the construction of bridges and culverts to correct lines and
elevations, and for the establishment of the lines and elevations required for setting of bridge spans.
All construction shall conform to the Standards mentioned in the relevant clauses of this Specification.
B.E 2.57 Protection of Streams and Watercourses
The Contractor shall not discharge into any stream, river or watercourse, any oil, solid, noxious or
floating materials, and all water discharged into river streams or watercourses as a result of the
Contractor’s operations shall be free from impurities. The Contractor shall remove from such rivers,
streams or watercourses, any such debris deposited therein as a result of his execution of the Work.
There shall be no separate measurement or payment for the environmental protection of streams,
rivers, or watercourses (including any required clean up), the cost of which is deemed to be included
in the overall prices entered in the Bill of Quantities.
B.E 2.68 Interference with Traffic
The Contractor will be responsible for coordinating with the appropriate authorities of the Government
of the People’s Republic of Bangladesh and respecting their requirements regarding the interference
with vehicular traffic on roads and highways, rail traffic on the existing railway track and water-borne
traffic on navigable waterways which may be above or below structures being constructed for this
project.
B.E 2.79 Structural Appearance and Conformity
Unless otherwise specified in the Contract or directed by the EngineerProject Manager, the concrete
components of a bridge or structure shall be of uniform texture and colour. Without limiting the
generality of the foregoing, the same type of form work and finish, including form oils, shall be used
and the Contractor shall obtain all cement for the structure from the same manufacturing plant unless
otherwise authorized in writing by the EngineerProject Manager.
B.E 2.810 Opening of Bridge Decks to Traffic
Steel bridges shall not be open to rail traffic until load tests prescribed here as acceptance tests have
been carried out and results approved by the EngineerProject Manager.

116129
B.E 2.911 Clean Up of Bridge and Structure Sites
Upon the completion of any bridge or structure, the Contractor shall clean up the general area by
removing all temporary buildings, false work, cofferdams, piling, timber, equipment and debris. He
shall level off and rake all excavated materials not used for backfill, level and rake around all piers,
bents, abutments and side slopes. The whole of the Site and structure shall be left in a clean and
workmanlike condition. No specific measurement or payment will be made for the clean up of the
bridge and structures sites as aforesaid, the cost of which shall be deemed to be included in the
appropriate prices entered in the Bill of Quantities.
B.E 2.1012 Construction Access
The Contractor shall be responsible to provide the necessary access to each bridge and culvert site
as required for all personnel, material, equipment, and plant for the execution of the Work, the cost of
which including the removal of temporary access or repair of existing roadways, shall be deemed to
be included in the prices included in the Bill of Quantities.
B.E 2.1113 Railway Equipment
Where the Contractor arranges to lease railway equipment from the EmployerProject Director, such
as covered wagons, flat wagons, etc., the Contractor shall repair all damage to such equipment
furnished for his use and return it in as good condition as when he received it, less normal wear and
tear.
B.E 2.1214 General Codes and Standards
The work of this section shall be carried out in accordance with Codes and standards mentioned. If
the use of alternative Codes and Standards becomes necessary, a coherent set of standards from the
following sources may be used:
a) The British Standards (B.S.);

b) The American Concrete Institute (ACI);
c) The American Standards for Testing and Materials (ASTM);
d) American Association of State Highway and Transportation Officials (AASHTO);
e) Research Design & Standards Organisation (RDSO);
f) American Railway EngineerProject Managering Association (A.R.E.A.)
g) Bangladesh National Building Code (BNBC)
Where there is a conflict between the requirements of any of the above-listed codes and standards,
the requirements of the Indian Railway Standard (IRS) shall govern for the super structure and
AASHTO will govern for sub structure and foundation.

116129
BE. 2.1315 Abbreviations and Definitions
The abbreviations used in this document shall mean the following:

ADB Asian Development Bank
AASHTO American Association of State Highway and Transportation Officials
ACI American Concrete Institute
ASTM American Society for Testing and Materials
A.R.E.A American Railway EngineerProject Managering Association
BR Bangladesh Railways
BS British Standard
BS EN British Standard, European Norm
BGML Broad Gauge Main Line
CBR California Bearing Ratio
CE Carbon Equivalent
HWL High Water Level
IS Indian Standard
IRS Indian Railway Standard
ISO International Organization for Standardization
LS Lump Sum
LWL Low Water Level
MGML Meter Gauge Main Line
MSL Mean Sea Level
PS Provisional Sum
PVC Polyvinyl Chloride
ROW Right of Way
RDSO Research Designs and Standard Organization
STP Standard Test Procedure of the RHD, (Roads and Highways Department,
Bangladesh)
SPT Standard Penetration Test
cm centimeter
cm2 or sq. cmsquare centimeter
kg kilogram
kg/m3 kilogram per cubic meter
km kilometer
l or L litre
m. or lin.m linear meter
m2 or sq.m square meter
m3 or cu.m cubic meter
ml or mL millilitre
mm millimeter
mm2 or sq.mm square millimeter
MPa mega Pascal
N Newton
No. or nr or no. number
Pa Pascal (Newton per square millimeter)
0
C degrees Centigrade

116129
BE. 3 BORED CAST-IN-PLACE PILES
B.E 3.1 Description
This work comprises the construction of bored cast-in-situ piles for Bridges & Culverts, including the
provision of all materials and structures in accordance with these Specifications and in conformity with
the requirements of the Drawings or other parts of the Contract Documents.
Piles shall be provided with permanent Steel casing in situations where piles are bored in water or
through soft soil. However the Contractor shall take all necessary steps by installing temporary Steel
casing at other substructures if stability of the boreholes during concreting cannot be ensured
otherwise.
Steel casing permanent or temporary is deemed to have been included in the unit rate for bored piles.
Under any circumstances the Contractor may not be permitted to bore all or part of the pile without
steel casing under water and use drilling fluid to stabilize the borehole as referred to in Item B.3.2.4
The results of ground investigations carried out previously in the project area have been made
available to the Contractor but no guarantee of the accuracy or completeness of these investigations
is given or implied by the EmployerProject Director. Final detailed investigation of the Site shall be
the responsibility of the Contractor as required by Item B.5 of the Specification.
The final layout, preliminary pile design and preliminary pile toe levels are shown on the Drawings.
The final design of the foundations is to be determined by the Contractor taking into account the
results of the further ground investigation carried out under Item B.5 of the Specification and the
results of the pile test loading carried out by the Contractor under Item B.4 of the Specification. The
final design shall be approved by the EngineerProject Manager upon submission of detailed
calculations by the Contractor no change to the pile configuration shall be made without the approval
of the Engineerapproval of the Project Director.
B.E 3.2 Materials
BE. 3.2.1 Steel Casing
This part of the Specifications only deals with the permanent steel casing. For steel casing used
during boring of the pile see Item B.3.3 Construction Methods.
When permanent steel casing has been installed the steel shall conform to the Standard Specification
ASTM A36 or equivalent.
The minimum length shall be from 150 mm above the bottom of the pile cap to 5 meter under the river
bed or into firm strata. If the permanent casing is used in the boring operation or if the handling and
transport require a greater thickness to avoid deformation or buckling, the increase in thickness shall
be provided by the Contractor at his own expense.
The steel casing shall be furnished in appropriate lengths and the joints shall be approved by the
EngineerProject Manager.

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The casing shall be handled and stored in a manner that shall prevent buckling and other deformation
as well as accumulation of dirt, oil and paint. When placed in the work it shall be free from dirt, oil,
grease, paint, mill scale and loose or thick rust.
The outside surface of the permanent casing of piles to river piers, for the depth indicated on the
Drawings or determined by the EngineerProject Manager, from the underside of the pile cap shall
receive two coats of anti-corrosion tar type paint. The paint shall be approved by the EngineerProject
Manager and its application shall follow the manufacturer's instructions.
B.E 3.2.2 Concrete
The concrete shall conform to Item B.E 7 of these Specifications, Concrete Class 30.
Concrete placed under water or drilling mud by tremie shall have a cement content of not less than
400kg/m3
The density and consistency of the concrete shall conform to the tremie casting method and the
maintenance of sufficient workability (slump) of all the concrete during the casting and casing handling
period, including reasonably calculated delays, shall be secured by a design mix, (including the
necessary retarders and plasticisers), tested by trial mixes prior to the pile construction.
All relevant concrete properties such as slump, time of setting, temperature and strength shall be
measured on the trial mixes.
B.E 3.2.3 Reinforcement
The reinforcement shall conform to Item B.8 of these Specifications.
B.E 3.2.4 Drilling Fluid
The following clauses shall be complied with if betonies mud is used to stabilize the boreholes:
A) Supply
The Contractor shall obtain a certificate from the manufacturer of the bentonite powder, showing the
properties of the consignment delivered to the Site. This certificate shall be made available to the
EngineerProject Manager on request. The properties to be given by the manufacturer are the
apparent viscosity range (in centipoises) and the gel strength range for solids in water.
Before concreting a pile, the Contractor shall take measures to remove any heavily contaminated
bentonite suspension which could impair the free flow of concrete from the tremie pipe. A sample of
the bentonite suspension shall be taken from the base of the boring using an approved sampling
device and should the specific gravity of the suspension exceed 1.25, placing of concrete shall not
proceed and the Contractor shall modify or replace the bentonite as approved by the EngineerProject
Manager.

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Discarded bentonite shall be removed from the Site without delay and any disposal thereof shall
comply with the regulations of all appropriate regulatory authorities
Control tests for density shall be carried out daily on the support fluid using suitable apparatus. The
measuring device shall be calibrated to read within 0.01 g/ml.
Any other material proposed by the Contractor for the drilling fluid shall have to be approved by the
B) Mixing
Bentonite and any other material shall be mixed thoroughly with clean water to make a suspension
which shall maintain the stability of the pile excavation for the period necessary to place concrete and
complete construction.
Where saline or chemically contaminated groundwater occurs, special precautions shall be taken to
modify the bentonite in fresh water so as to render it suitable in all respects for the construction of
piles.
C) Tests
The frequency of testing drilling fluid and the method and procedure of sampling shall be proposed by
the Contractor and approved by the EngineerProject Manager prior to the commencement of the
work. The frequency may subsequently be varied as required depending on the consistency of the
results obtained. The control tests shall cover the determination of density, viscosity, gel, strength and
pH values.
The Contractor shall supply all equipment and experienced operators required to carry out tests on
the drilling mud. No additional payment shall be made for these tests which shall be considered as an
essential part of the drilling operations.
B.E 3.3 Construction Methods
B.E 3.3.1 General
The Contractor shall demonstrate to the satisfaction of the EngineerProject Manager that his
proposed construction methods for the piles do not result in the pile shafts being weakened by
contamination of the concrete, by sectional reduction, by washing out of cement, by breaking during
pulling of temporary casings or in any other way, including the construction of neighboring piles.
A) Assumed Procedure
The following construction procedure has been assumed in the tender design. The final construction
procedure shall be submitted by the Contractor for EngineerProject Manager’s approval prior to
commencement of piling operations.
1. In the event that permanent steel casing is used, place permanent steel casing in position and
embed casing toe into river bed or firm strata. If no permanent steel casing is required, a
sufficient length of temporary steel casing shall be used if in the opinion of the EngineerProject
Manager that is required to stabilize the upper part of the borehole.

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2. Bore and excavate inside the steel casing down to casing toe level, or to a level approved, and
continue excavation to final pile tip level using either temporary steel casing bored to the pile
toe, or using drilling mud as decided by the EngineerProject Manager. The fluid level inside
casings shall at all times be at least 2 meters higher than outside the casings.
3. Carefully clean up all mud or sedimentation from the bottom of borehole.
4. Place reinforcement cage, inspection pipes, etc.
5. Concrete continuously under water, or drilling fluid, by use of the tremie method.
6. Withdraw the temporary steel casing concurrently with concreting to the instructed level.
7. After hardening, break out the top section of the concrete pile to reach sound concrete and
the designed cut-off level of the top of the pile.
B) Approval of Construction Method
In the Bid, the Contractor shall describe the construction method he proposes, including name of
proposed Sub-Contractors (if any), information on boring equipment, materials, methods of work and
control of quality. For the boring, rotary/auger methods to be used and the Contractor shall submit
references from similar jobs carried out by him and/or his proposed Sub-Contractors.
During contract negotiations, the Contractor shall submit all requested supplementary detailed
information in writing.
After the Contract has been awarded, the Contractor shall prepare a detailed programme and
establish a procedure for the pile construction. The detailed programme shall contain all required
information on materials, equipment, methods of work etc., and be approved in writing by the
EngineerProject Manager. Such approval shall not, however, relieve the Contractor of his
responsibilities for pile design to the extent specified and construction.
The import of any boring equipment or materials by the Contractor, before he has received the
EngineerProject Manager’s approval of proposed construction methods, shall be at the Contractor’s
risk.
B.E 3.3.2 Setting Out Piles
The Contractor shall check the casing position for each pile during and immediately after placing the
casing, and obtain approval of the Engineerapproval of the Project Director.
B.E 3.3.3 Diameter of Piles
The diameter of a pile shall be not less than the specified diameter.
B.E 3.3.4 Tolerances
The centre of the completed pile at the cut off level shall not deviate more than 75 mm from the
position shown on the Drawings. The inclination of the pile shall not deviate more than 1:100 from
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vertical. The Contractor shall provide suitable equipment, such as an inverted pendulum, to check the
verticality of the boreholes at intervals during drilling and prior to concreting.
All piles shall be formed to at least 1000 mm above the cut-off level with a tolerance of 75 mm.
B.E 3.3.5 Boring
A) Methods
Method of boring for piles shall be proposed by the Contractor with reference to the item BE.3.3.1 B)
and approved by the EngineerProject Manager. Water or air jetting and percussion method for boring
of the piles shall not be allowed.
B) Boring Near Recently Cast Piles
Piles shall not be bored so close to other piles which have recently been cast and which contain
workable or unset concrete so that a flow of concrete could be induced from or damage caused to any
of the piles. Boring and excavation for a pile shall not be commenced until 24 hours after completion
of any pile within a radius of 6 meters, centre to centre.
C) Temporary Casings
Temporary casing of approved thickness and quality or an approved alternative method shall be used
to maintain the stability of pile excavations, which might otherwise collapse.
Temporary casings shall be free from significant distortion. They shall be of uniform cross-section
throughout each continuous length. During concreting they shall be free from internal projections and
encrusted concrete which might prevent the proper formation of piles.
D) Stability of Pile Excavation Using Drilling Fluid
If permitted by the EngineerProject Manager, where a borehole is formed without casing under water
or using drilling fluid for maintaining the stability of a boring, the level of the water or fluid in the
excavation shall be maintained so that the water or fluid pressure always exceeds the pressure
exerted by the soils and external ground water. The water or fluid level shall be maintained at a level
not less than 2 meters above the level of the river water level or any artesian pressure level.
In the event of a rapid loss of water or bentonite suspension from the pile excavation, the excavation
shall be backfilled without delay and the instructions of the EngineerProject Manager shall be
obtained before excavation at that location or at an alternate location is resumed.
E) Disposal of Excavated Material
No excavated material shall be dumped into the river or any connecting waterway without the written
approval of the Engineerapproval of the Project Director. Excavated material shall be removed from
Site and dumped either beyond areas affected by dredging, or taken to the Contractors approved
dumping areas on land. The Contractor shall be fully responsible for costs involved in removing the
excavated material to spoil. Discarded bentonite shall be removed from the Site without delay and any
disposal there of shall comply with the regulations of all appropriate controlling authorities

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F) Pumping from Boreholes
Pumping from a borehole shall not be permitted unless a casing has been placed into a stable stratum
which prevents the flow of water from other strata in significant quantities into the boring, or unless it
can be shown that pumping will not have a detrimental effect on the surrounding soil or property.
G) Obstructions
Where boulders or other obstructions render it impossible to bore the pile, excavation operations
inside pile casing as directed by the EngineerProject Manager shall be carried out to remove
obstructions and the Contractor shall be reimbursed for such operations only when the largest
dimension of the obstruction exceeds 200 mm and the obstruction is found more than 2 meters below
river bed.
H) Unexpected Ground Conditions
The Contractor shall report immediately to the EngineerProject Manager any circumstances which
indicate that in the Contractor’s opinion the ground conditions differ from those expected by him from
his interpretation of the Sub-soil Investigation Reports.
I) Boring Records
During the boring of the pile, the Contractor shall compile a 'boring log' indicating depths and types of
the various soil layers encountered. Disturbed samples shall be submitted to the EngineerProject
Manager as requested.
The Contractor shall allow for carrying out sampling and tests to check soil strengths as required by
the EngineerProject Manager.
J) Final Pile Toe Level
The final pile toe level shall be as indicated on the Drawing or as instructed by the EngineerProject
Manager after due consideration of the Contractor’s proposals, boring logs and test results. The final
toe level of other piles may subsequently be altered according to the results of the test loadings
detailed in Item B.E 4.
K) Inspection and Cleaning Bottom of Excavation
The time between final excavation and bottom cleaning and the start of concreting shall be kept as
short as possible and shall not exceed 3 hours. To achieve this, the final 2 meters of excavation shall
not start until all preparations for cleaning, reinforcing and concreting are finished. In case of
unexpected delay the Contractor shall as a temporary measure dump sand or gravel in the bore to 2
meters above toe level.
On completion of the drilling an interval is required, to allow the fine materials to settle 15 (fifteen)
minutes unless otherwise approved by the EngineerProject Manager). Thereafter the bottom of the
excavation shall be carefully cleaned of mud, sedimentation and other soft material and any
temporarily dumped sand or gravel by an approved method.
The Contractor shall show, to the satisfaction of the EngineerProject Manager, that the bottom of the
excavation is clean. Sedimentation tests shall be carried out by the Contractor in the presence of the

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For boring without casing, the diameter of the boring hole for a representative number of piles shall be
measured by caliper prior to the placing of concrete. The verticality of boreholes will be checked as
directed by the EngineerProject Manager. These measurements shall be done by the Contractor
using approved equipment and no reimbursement shall be made.
B.E 3.3.6 Placing Reinforcement
The reinforcement shall be placed as indicated on the Drawings. Reinforcement in the form of a cage
shall be assembled with additional support, such as spreader forks and lacings, necessary to form a
rigid cage. Hoops, links or helical reinforcement shall fit closely around the main longitudinal bars and
be bound to them by approved wire, the ends of which shall be turned into the interior of the pile or
pour. Reinforcement shall be placed and maintained in position.
The cover to all reinforcement shall be not less than 75 mm.
Lap joints in longitudinal steel bars shall be permitted unless otherwise specified. Joints in
reinforcement shall be such that the full strength of the bar is effective across the joint and shall be
made so that there is no relative displacement of the reinforcement during the construction of the pile.
If the final pile toe level instructed by the EngineerProject Manager is deeper than that indicated on
the Drawings, the section of the pile deeper than the toe level indicated on the Drawings is not
required to be reinforced, unless otherwise instructed by the EngineerProject Manager.
B.E 3.3.7 Placing Concrete
A) Approval
No concreting shall take place before the bottom of the excavation has been cleaned, the borehole
inspected and approval obtained in writing from the EngineerProject Manager.
The method for placing concrete requires to be approved and conform with the following:
 The method of placing and the workability of the concrete shall be such that a continuous
monolithic concrete shaft of the full cross section is formed.
 The concrete shall be placed continuously, and without such interruption as would allow the
previously placed batch to have hardened. In this respect the Contractor shall submit details
of his contingency plans, standby plant, etc. to be utilized in the event of an equipment failure.
 The use of pumped concrete and the methods in its use shall be approved by the
 The Contractor shall take all precautions in the design of the mix and placing of the concrete
to avoid arching of the concrete in a casing. No spoil, liquid or other foreign matter shall be
allowed to contaminate the concrete.
B) Workability of Concrete

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Slump measured at the time of discharge into the pile boring shall be in accordance with Table BE .3-
1.
Table B.E 3-1
Piling Mix Slump

Workability Minimum Range Typical Conditions of Use
(mm) (mm)
A 75 75-150 Placed into water-free unlined or
permanently lined bore of 600 mm diameter
or over or where casting level lies below
temporary casing: reinforcement widely
spaced, leaving ample room for free
movement of concrete between bars.
B 100 100-200 Where reinforcement is not spaced widely;
where cut-off level of concrete is within
temporary casing; where pile bore is water-
free and the diameter is less than 600 mm.
C 175 175 or more Where concrete is to be placed by tremie
under water or drilling mud or by pumping.
C) Placing Concrete Under Water or Drilling Fluid
Concrete to be placed under water or drilling fluid shall be placed by tremie and shall not be
discharged freely into the water or drilling fluid.
Before placing concrete, the Contractor shall ensure that there is no accumulation of silt, other
material, or heavily contaminated bentonite suspension at the base of the boring, which could impair
the free flow of concrete from the pipe of the tremie. A sample of the bentonite suspension shall be
taken from the base of the boring using an approved sampling device. If the specific gravity of the
suspension exceeds 1.25, the placing of concrete shall not proceed. In this event the Contractor shall
modify the mud quality.
The concrete shall be a rich coherent mix of high workability in accordance with Item B.E 3.2.2 and
shall be placed in such a manner that segregation does not occur.
During and after concreting, care shall be taken to avoid damage to the concrete from pumping and
dewatering operations.
The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to
the base of the boring and a sliding plug or barrier shall be placed in the pipe to prevent direct contact
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between the first charge of concrete in the pipe of the tremie and the water or drilling fluid. The pipe
shall at all times penetrate the concrete, which has previously been placed and shall not be withdrawn
from the concrete until completion of concreting. The bottom of the tremie pipe shall be kept at least
1.5 meters under the surface of concrete once that amount of concrete has been placed. At all times a
sufficient quantity of concrete shall be maintained within the pipe to ensure that the pressure from it
exceeds that from the water or drilling fluid. The internal diameter of the pipe of the tremie to be
proposed by Contractor considering the required rate of pouring of concrete and approved by the
EngineerProject Manager. However, the internal diameter of the pipe shall not be less than 200mm,
made with 20 mm aggregate and not less than 250 mm for concrete made with 40 mm aggregate. It
shall be so designed that external projections are minimized, allowing the tremie to pass through
reinforcing cages without causing damage. The internal face of the pipe of the tremie shall be free
from projections.
The Contractor shall maintain a continuous record of the volume of concrete used and the level of the
concrete in the pile. Any deviations from the theoretical, or expected, volume/level relationship shall
be immediately reported to the EngineerProject Manager.
B.E 3.3.8 Extraction of Temporary Casing
A) Workability of Concrete
Temporary casings shall be extracted while the concrete within them remains sufficiently workable to
ensure that the concrete is not lifted.
B) Concrete Level
When the casing is being extracted a sufficient quantity of concrete shall be maintained within it to
ensure that pressure from external water, drilling fluid or soil is exceeded and that the pile is neither
reduced in section nor contaminated. The toe of the temporary casing shall be kept a minimum of 2
meters under the outlet of the tremie.
No concrete shall be placed in the boring once the bottom of the casing has been lifted above the top
of the concrete; it shall be placed continuously as the casing is extracted until the desired head of
concrete is obtained.
Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could be
caused as the casing is withdrawn because of the displacement of water or fluid by the concrete as it
flows into its final position against the walls of the shaft.
The pile shall be concreted with a certain over-height to allow for chiseling off the top concrete down
to sound hard concrete. The Contractor shall ensure that concrete is sound and conforms to the
requirements of the Specification at the designated level of the pile top shown on the Drawings after
cutting back over-height concrete.
The pile top shall after clean cutting be embedded 100 mm above the bottom level of the pile cap or
as shown on the Drawings.
C) Vibrating Extractors
The use of vibrating casing extractors shall be permitted.

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D) Reinforcement Cage
During concreting and pulling the casing, the reinforcement cage shall be secured against uplift and
the top shall be kept under close inspection.
E) Supervision
The execution of the pile concreting shall be supervised by a qualified person of the Contractor’s staff,
who will keep records on the relation between quantity of concrete used, level of concrete and
withdrawal of casing.
B.E 3.3.9 Temporary Support
The Contractor shall ensure that free standing piles are temporarily braced or stayed immediately
after driving of the casing to prevent loosening of the piles in the ground and to ensure that no
damage resulting from oscillation, vibration or movement of any free-standing pile length can occur.
B.E 3.3.10Records
The Contractor shall keep records as indicated below for the installation of each pile and shall submit
two signed copies of these records to the EngineerProject Manager not later than noon of the next
working day after the pile was installed. The signed records shall form a record of the work. The
following data are required:
a) Pile location
b) Pile reference number
c) Pile type
d) Nominal cross-sectional dimension or diameter
e) Date and time of boring
f) Date and time of concreting
g) River bed/ground level at commencement of installation of pile
h) Working level
i) Pile toe level
j) River water levels
k) Pile head level
l) Length of temporary casing
m) Length of permanent casing
n) Soils samples taken and in-situ tests carried out
o) Standing water level
p) Length and details of reinforcement
q) Concrete mix
r) Volume of concrete supplied to pile and corresponding levels of concrete and casings
s) All information regarding obstructions, delays and other interruptions to the sequence of
work.

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B.E 3.3.11Measures in Case of Rejected Piles
If any pile is found unsatisfactory in the opinion of the EngineerProject Manager for utilization in the
structure, it shall be cut off below the pile cap if so ordered by the EngineerProject Manager.
The pile shall be replaced as directed by the EngineerProject Manager. All extra expenses shall be
borne by the Contractor and payment shall be made on the basis that no replacement pile had to be
provided for the unsatisfactory pile.
When the safe bearing value of any pile is found by test to be less than the design load, longer piles
or additional piles shall be installed as ordered in writing by the EngineerProject Manager at the
Contractor’s expense.
B.E 3.3.12Pilot Piles
A pile installed before the commencement of the main piling works or a specific part of the works for
the purpose of establishing the suitability of the chosen type of pile and for confirming its design,
dimensions and bearing capacity.
B.E 3.4 Measurement and Payment
The unit of measurement for bored cast-in-place piling shall be the linear meter of pile constructed
and accepted in the structure. The payable lengths of the satisfactory bored piles shall be measured
from the toe level to cut-off level. Reinforcement steel shall be measured in accordance with
Specification Item B.8.4.
Bored piles shall be paid for at the Contract unit price per linear meter in the priced Bill of Quantities.
The rate shall constitute full compensation for all materials including concrete, but excluding
reinforcement steel and testing of piles. The rate shall also include boring equipment, standard
penetration testing, split spoon sampling, boring, excavation, concreting, inspection and control,
cutting off, welding, coupling and all related tools, rigs, cranes, jets, frames, burge, leads, labour, and
other incidental equipment and work necessary to complete the work.
Payment for bored cast-in-place pilot piles, completed and accepted, shall be made at the Contract
unit price per linear meter in the priced Bill of Quantities for providing piles of the size specified. When
pilot piles are incorporated in the foundation as working piles, no additional payment shall be made for
the piles. The cost of steel casing, permanent or temporary, is deemed to have been included in the
pile unit price.
Payment for reinforcement steel shall be at the Contractor’s rates per tonne in the Priced Bill of
Quantities for high yield deformed steel bars under the Pay Item BE- 8.2. No payment shall be made
for unauthorized, defective, unsound or unsatisfactory piles or for any costs incurred by the Contractor
for such piles.
Payment for testing of piles shall be made separately, as detailed in Item BE .4.
Pay items shall be:

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Item Description Unit of

No. Measurement
BE- Bored Cast-in-Place Working Piles (Diameter as indicated on Linear Meter
3.1 the Drawings and stated in the Bill of Quantities)
BE- Bored Cast-in-Place Pilot Piles (Diameter as indicated on the Linear Meter
3.2 Drawings and stated in the Bill of Quantities)
B.E 4 PILE LOAD TESTS
B.E 4.1 Description
B.E 4.1.1 General
This Section deals with the testing of a pile by the application of an axial load or force. It covers
vertical piles tested in compression.
The Contractor shall construct Pilot Piles and conduct vertical Load Test on those Pilot Piles in
consultation with the EngineerProject Manager at a location or locations to be agreed with the
EngineerProject Manager in accordance with this Specification. Working Piles shall not be permitted
to be used as Pilot Piles.
The Contractor shall vertical load test the Working Piles directed by the EngineerProject Manager in
accordance with this Specification.
BE. 4.1.2 Definitions
A) Allowable Load
The load which may be safely applied to a pile after taking into account its ultimate bearing capacity,
negative friction, pile spacing, overall bearing capacity of the ground below and allowable settlement.
B) Compression Pile
A pile which is designed to resist an axial force such as would cause it to penetrate further into the
ground.
C) Kentledge
The dead weight used in a loading test.
D) Maintained Load Test

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A loading test in which each increment of load is held constant either for a defined period of time or
until the rate of movement (settlement or uplift) falls to a specified value.
E) Pilot Pile
A pile installed before the commencement of the main piling works or a specific part of the works for
the purpose of establishing the suitability of the chosen type of pile and for confirming its design,
dimensions and bearing capacity.
F) Proof Load
A load applied to a selected pile to confirm that it is suitable for the load at the settlement specified. A
proof load should not normally exceed 150% of the working load for a Working pile and 300% of
working load or to failure for a Pilot pile, whichever is reached earlier.
G) Reaction System
The arrangement of kentledge, piles, anchors or rafts that provides a resistance against which the pile
is tested.
H) Tension Pile
A pile which is designed to resist an axial force such as would cause it to be extracted from the
ground.
I) Test Pile
Any pile to which a test loading is, or is to be, applied
J) Ultimate Bearing Capacity
The load at which the resistance of the soil becomes fully mobilized
K) Working Load
The load shown in the Drawings which the pile is designed to carry
L) Working Pile
One of the piles forming the foundation of a structure
B.E 4.2 Supervision
All tests shall be carried out only under the direction of an experienced and competent supervisor
conversant with the test equipment and test procedure. All personnel operating the test equipment
shall have been trained in its use.

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B.E 4.3 Safety Precautions
B.E 4.3.1 General
When preparing for, conducting and dismantling a pile test the Contractor shall carry out the
requirement of the various regulations and other statutory instruments that are applicable to the work
for the provision and maintenance of safe working conditions and shall in addition make such other
provision as may be necessary to safeguard against any hazards that are involved in the testing or
preparations for testing.
B.E 4.3.2 Kentledge
Where kentledge is used the Contractor shall construct the foundations for the kentledge and any
cribwork, beams or other supporting structure in such a manner that there will not be differential
settlement, bending or deflection of an amount that constitutes a hazard to safety or impairs the
efficiency of the operation. The kentledge shall be adequately bonded, tied or otherwise held together
to prevent it falling apart or becoming unstable because of deflection of the supports.
The weight of kentledge shall be greater than the maximum test load and if the weight is estimated
from the density and volume of the constituent materials an adequate factor of safety against error
shall be allowed.
B.E 4.3.3 Tension Piles and Ground Anchors
Where tension piles or ground anchors are used the Contractor shall ensure that the load is correctly
transmitted to all the tie rods or bolts. The extension of rods by welding shall not be permitted unless it
is known that the steel will not be reduced in strength by welding. The bond stresses of the rods in
tension shall not exceed normal permissible bond stresses for the type of steel and grade of concrete
used.
B.E 4.3.4 Testing Equipment
In all cases the Contractor shall ensure that when the hydraulic jack and load measuring device are
mounted on the pile head the whole system shall be stable up to the maximum load to be applied.
Means shall be provided to enable dial gauges to be read from a position clear of the kentledge stack
or test frame so that failure in any part of the system due to overloading, buckling, loss of hydraulic
pressure will not constitute a hazard to personnel.
The hydraulic jack, pump, hoses, pipes, couplings and other apparatus to be operated under hydraulic
pressure shall be capable of withstanding a test pressure of 1.5 times the maximum working pressure
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without leaking. The whole system is to be tested to the test pressure of 1.5 times before use in the
real load test.
The maximum test load or test pressure expressed as a reading on the gauge in use shall be
displayed and all operators shall be made aware of this limit.
B.E 4.4 Construction of a Pilot Pile to be Test Loaded
B.E 4.4.1 Notice of Construction
The Contractor shall give the EngineerProject Manager at least 48 hours notice of the
commencement of construction of any pilot pile, which is to be test loaded. Pilot pile locations shall be
proposed by the Contractor and approved by the EngineerProject Manager. Pilot piles shall not be
tested until the concrete in the pile has attained its characteristic strength
B.E 4.4.2 Method of Construction
Each pilot test pile shall be constructed in a manner similar to that to be used for the construction of
the working piles and by the use of similar equipment and materials. Any variation shall only be
permitted with prior approval.
Extra reinforcement and concrete of increased strength shall be permitted in the shafts of pilot piles at
the discretion of the EngineerProject Manager.
B.E 4.4.3 Boring or Driving Record
For each pilot pile which is to be tested, a detailed record of the soils encountered during boring, or of
the progress during driving shall be made and submitted to the EngineerProject Manager daily not
later than noon on the next working day.
B.E 4.4.4 Cut-Off Level
The pile shaft shall terminate at the normal cut-off level, or at a level required by the EngineerProject
Manager.
The pile shaft shall be extended where necessary above the cut-off level of working piles so that
gauges and other apparatus to be used in the testing process are not damaged by water or falling
debris.
B.E 4.4.5 Pile Head for Compression Tests

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For a pile that is tested in compression, the pile head or cap shall be formed to give a plane surface
which is normal to the axis of the pile, sufficiently large to accommodate the loading and settlement-
measuring equipment and adequately reinforced or protected to prevent damage from the
concentrated application of load from the loading equipment.
B.E 4.4.6 Completion of the Testing of Pilot Piles
On completion of the testing of all Pilot Piles, pile caps and piles and other temporary works shall be
cut off at least 1 m below finished ground level and removed from the Site and the area reinstated, all
to the satisfaction of the EngineerProject Manager.
B.E 4.5 Preparation of a Working Pile to be tested
For tests on working piles, the EngineerProject Manager shall nominate the piles for testing.
The Contractor shall prepare the pile for testing in accordance with Item B.E 4.4. Working piles shall
not be tested until the concrete in the pile and all other working piles being used for the test have
attained their characteristic strength.
B.E 4.6 Reaction Systems
B.E 4.6.1 Compression Tests
Compression tests shall be carried out using kentledge, tension piles or specially constructed
anchorages.
Where kentledge is to be used, it shall be supported on cribwork disposed around the pile head so
that its centre of gravity is on the axis of the pile. The bearing pressure under supporting cribs shall be
such as to ensure stability of the kentledge stack. Kentledge shall not be carried directly on the pile
head, except when directed by the EngineerProject Manager.
B.E 4.6.2 Working Piles
Where working pile shall not be used as reaction pile
B.E 4.6.3 Spacing

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Where kentledge is used for loading vertical piles in compression, the distance from the edge of the
test pile to the nearest part of the crib supporting the kentledge stack in contact with the ground shall
be not less than 2.0 meters.
The centre to centre spacing of vertical reaction piles, from a test pile shall be not less than four times
the diameter of the test pile or the reaction piles or 3.0 meters, whichever is the greatest.
B.E 4.6.4 Adequate Reaction
The size, length and number of the piles or anchors, or the area of the rafts, shall be adequate to
transmit the maximum test load to the ground in a safe manner without excessive movement or
influence on the test pile.
B.E 4.6.5 Care of Piles
The method employed in the installation of any reaction piles, anchors or rafts shall be such as to
prevent damage to any test pile or working pile.
B.E 4.6.6 Loading Arrangement
The loading arrangement used shall be designed to transfer safely to the test pile the maximum load
required in testing. Full details shall be submitted to the EngineerProject Manager prior to any work
related to the testing process being carried out on the Site.
B.E 4.7 Equipment for Applying Load
The equipment used for applying load shall consist of one or more hydraulic rams or jacks
with the total capacity of the jacks being at least 1.5 times to the required maximum load. The
jack or jacks shall be arranged in conjunction with the reaction system to deliver an axial load to the
test pile. The complete system shall be capable of transferring the maximum load required for the test.
The length of stroke of a ram for maintaining proof load test shall be sufficient to cater for deflection of
the reaction system under load plus a deflection of the pile head of up to 15% of the pile shaft
diameter. The length of the stroke of a ram for a lateral load test shall be sufficient to cater for
displacement of the reactions system under load plus at least 200% of the anticipated deflection of the
pile head under Service load.
B.E 4.8 Measurement of Load
Suitable approved measuring devices for determining the load on the pile shall be supplied by the
Contractor. Certificates of calibration shall be supplied to the EngineerProject Manager. Load
measuring devices shall be calibrated before and after each series of tests, whenever adjustments or
replacements are made to the devices and at the intervals recommended by the manufacturer of the
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equipment. Pressure gauges and hydraulic jacks shall be calibrated together. Certificates of
calibration shall be supplied to the EngineerProject Manager.
In addition, large diameter (i.e. exceeding 1.2 meter) test piles shall be instrumented at 5 different
depths to measure the load distribution along the piles. The instrumentation shall consist of both a
mechanical system and strain gauges for measuring the pile deformation. The mechanical system
shall consist of 6 mm steel rods or high tensile steel wires gauge No. 23, placed in steel tubes down
to the various depths, and connected to dial gauges at the top. The strain gauges shall be of a stable
type, wholly protected by a steel capsule. They shall be welded to the steel reinforcement, 2 gauges
at each depth.
The EngineerProject Manager shall approve the type of gauges to be used and other details on the
instrumentation.
B.E 4.9 Adjustability of Loading Equipment
The loading equipment shall be capable of adjustment throughout the test to obtain a smooth increase
of load or to maintain each load constant at the required stages of a maintained loading test.
B.E 4.10 Measuring Movement of Pile Head
B.E 4.10.1General
In a maintained load test movement of the pile head shall be measured by two of the methods as
described below. One method for settlement measurements and the other method for control.
B.E 4.10.2Levelling Method
An optical or any other levelling method by reference to an external datum may be used.
Where a level and staff are used, the level and scale of the staff shall be chosen to enable readings to
be made to within an accuracy of 0.5 mm. A scale attached to the pile or pile cap may be used
instead of a levelling staff. At least two datum points shall be established on permanent objects or
other well-founded structures, or deep datum points shall be installed. Each datum point shall be
situated so that only one setting up of the level is needed.
Distance of the datum point should be such that it shall not be affected by the test loading or other
operations on the Site.
Where another method of levelling is proposed this shall have to be approved by the EngineerProject
Manager in writing.

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B.E 4.10.3Independent Reference Frame
An independent reference frame may be set up to permit measurement of the movement of the pile.
The supports for the frame shall be founded in such a manner and at such a distance from the test
pile, kentledge support cribs, reaction piles, anchorages and rafts that movements of the ground in the
vicinity of the equipment do not cause movement of the reference frame during the testing. Check
observations of any movements of the reference frame shall be made and a check shall be made of
the movement of the pile head relative to an external datum during the progress of the test. In no case
shall the supports be less than four test pile diameters or 2 meters, whichever is the greater, from the
centre of the test pile.
The measurement of pile movement shall be made by two dial gauges rigidly mounted on the
reference frame that bear on surfaces normal to the pile axis fixed to the pile cap or head.
Alternatively the gauges may be fixed to the pile and bear on surfaces on the reference frame. The
dial gauges shall be placed in diametrically opposed positions and be equidistant from the pile axis.
The dial gauges shall enable readings to be made to within an accuracy of 0.1 mm.
The reference frames shall be protected from sun and wind.
B.E 4.10.4Other Methods
The Contractor may submit for approval of the Engineerapproval of the Project Director any other
method for measuring the movement of pile heads.
B.E 4.11 Protection of Testing Equipment
B.E 4.11.1Protection from Weather
Throughout the test period all equipment for measuring load and movement shall be protected from
the weather including the adverse effects of sun, wind and precipitation. Temperature readings shall
be taken at the start, end and at the maximum load of each loading cycle.
B.E 4.11.2Prevention of Disturbance
Construction equipment and persons who are not involved in the testing process shall be kept at a
sufficient distance from the test to avoid disturbance to the measurement apparatus.
B.E 4.12 Supervision
B.E 4.12.1Notice of Test

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The Contractor shall give the EngineerProject Manager at least 24 hours notice of the
commencement of the test.
B.E 4.12.2Records
During the progress of a test, the testing equipment and all records of the test as required in Item
B.E4.14.2 shall be available for inspection by the EngineerProject Manager.
B.E 4.13 Test Procedure
B.E 4.13.1Proof Test by Maintained Load Test
The maximum load, which shall be applied in a proof test, is shown on the Drawings. The loading and
unloading shall be carried out in stages as shown in Table B.E 4-1 or as required by the
Following each application of an increment of load the load shall be held for not less than the period
shown in Table B.4-1 or until the rate of settlement is less than 0.25 mm/hour and is slowing down.
The rate of settlement shall be calculated from the slope of the curve obtained by plotting values of
settlement versus time and drawing a smooth curve through the points.
Each stage of unloading shall proceed after the expiry of the period shown in Table B.E 4-1 providing
the rate of recovery is reducing and does not exceed 0.25 mm per hour. The amount of recovery
shall be recorded before the next decrease in load.
For any period when the load is constant, time and settlement shall be recorded immediately on
reaching the load and at approximately 15 minute intervals for 1 hour, at 30 minute intervals between
1 hour and 4 hours, and at 1 hour intervals between 4 hours and 48 hours after the application of the
increment of load.
The EngineerProject Manager may require that the full loading, or any portion of the loading, be
maintained on the pile for periods longer than shown in Table B.E 4-1.

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Table B.E 4-.1
Loading Sequence
Load as Minimum Time Load as Minimum Time
Percentage of of Holding Load Percentage of of Holding Load
Working Load Working Load
Bored Piles
Pilot Pile Working Pile
50 1 hour 25 1 hour
100 1 hour 50 1 hour
125 1 hour 75 1 hour
150 1 hour 100 1 hour
125 10 minutes 75 10 minutes
0 1 hour 0 1 hour
150 6 hours 100 6 hours
200 1 hour 125 1 hour
Proof Load for Working
250 6 hours 150 48 hours
Pile for Bored Pile
275 1 hour
300 48 hours Proof Load for Pilot Pile
275 10 minutes

0 1 hour 0 1 hour
The movement of the pile under the full test load shall be within the limits shown in Table B.E 4-2 or
as otherwise specified by the EngineerProject Manager
Table B.E 4-2
Movement under Working Movement under 150% of Movement under 200% Movement
load Working Load of Working Load * under 300% of
Working Load *
10 mm 15 mm 25 mm 50 mm
* Pilot Piles only

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B.E 4.14 Presentation of Results
B.E 4.14.1Results to be Submitted
Results shall be submitted as:
a) A summary in writing to the EngineerProject Manager, unless otherwise directed, within 24

hours of the completion of the test, which shall give for a proof test by maintained load for each stage
of loading, the period for which the load was held, the load and the maximum settlement or uplift
recorded.
b) The completed schedule of recorded data as in Item B.E 4.14.2 within seven days of the
completion of the test.
B.E 4.14.2Schedule of Recorded Data
The Contractor shall provide information about the tested pile in accordance with the following
schedule where applicable.
A) General
1) Site location
2) Contract identification
3) Proposed structure
4) Date of test
B) Pile Details
1) Identification (number and location of the test pile)

2) Ground level at pile position
3) Head level as which test load is applied
4) Type of pile
5) Length in ground
6) Level in ground
7) Level of toe
8) Details of permanent casing
C) Installation Details
1) Dates and times of boring, driving and concreting of test pile and adjacent piles
2) Date and time of casting concrete
3) Hammer type, size or weight
4) Dolly and packing, type and condition before and after driving
5) Driving log (depth, blows per 250 mm, interruptions or breaks in driving)
6) At final set and at redrive set, for drop or single acting hammers, the length of the drop or
stroke, for diesel hammers the length of the stroke and the blows per minutes, for double-
acting hammers the number of blows per minute
7) Condition of pile head or temporary casing after driving
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D) Test Procedure
1) Weight of kentledge
2) Tension pile, ground anchor or compression pile details
3) Plan of test arrangement showing position and distances of kentledge supports, rafts,
tension or compression piles and reference frame to test pile
4) Jack capacity
5) Method of load measurement
6) Method(s) of penetration measurement
7) Relevant dates and times
E) Test Results
1) In tabular form
2) In graphical form: loads plotted against movements and time
B.E 4.15 Completion of a Test
BE. 4.15.1Measuring Equipment
On completion of a test all equipment and measuring devices shall be dismantled, checked and either
stored so that they are available for use in further tests or removed from the Site.
B.E 4.15.2Kentledge
Kentledge and its supporting structure shall be removed from the test pile and stored so that they are
available for use in further tests or removed from the Site.
B.E 4.15.3Temporary Piles
On completion of a preliminary test, temporary tension piles and Pilot Piles shall be cut off 1 meter
below ground level, removed from the Site and the ground made good with approved material as
specified or directed by the EngineerProject Manager.

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B.E 4.16 Integrity Testing of Piles
B.E 4.16.1Purpose
The purpose of integrity testing is to give information about the physical dimensions, continuity and
consistency of materials used in the piles.
B.E 4.16.2Method of Testing
The method to be adopted shall be one of the following:
Low Strain Integrity Test as per ASTM D5882-00 – Standard Test Method for Low Strain Integrity
Testing of Piles (e.g. echo testing or frequency response testing);
Cross-hole Sonic Logging Method.
Other methods may be considered by the EngineerProject Manager subject to satisfactory evidence
of performance.
Any ducting left in the piles for the purpose of carrying out the tests shall be fully grouted by approved
means after the test results have been accepted in writing by the EngineerProject Manager.
B.E 4.16.3Age of Piles at Time of Testing
In the case of bored cast-in-place concrete piles, integrity tests shall not be carried out until 7 days or
more have elapsed since pile casting.
B.E 4.16.4Preparation of Pile Heads
Where the method of testing requires the positioning of sensing equipment on the pile head, the head
shall be broken down to expose sound concrete and shall be clean, free from water, laitance, loose
concrete, overspilled concrete and blinding concrete and shall be readily accessible for the
attachment of the motion sensing device and the hammer impact area.
B.E 4.16.5Specialist Sub-Contractor
Notwithstanding the Contractor’s obligation to obtain approval of a Sub-Contractor in accordance with

the Conditions of Contract, the testing shall be carried out by a specialist firm, subject to
demonstration of satisfactory performance on other similar contracts before the commencement of
testing. The Contractor shall submit to the EngineerProject Manager the name of the specialist
integrity testing firm, a description of the test equipment, a test method statement and a programme
for executing the specified tests prior to commencement of the Works. The Contractor shall obtain
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the EngineerProject Manager’s approval of the Sub-Contractor and the type of integrity testing prior to
commencing piling works.
B.E 4.16.6Interpretation of Tests
The interpretation of tests shall be carried out by competent and experienced persons.
The Contractor shall give all available details of the ground conditions, pile dimensions and
construction method to the specialist firm before the commencement of integrity testing in order to
facilitate interpretation of the tests.
B.E 4.16.7Report
Preliminary results of the tests shall be made available within 24 hours of carrying out the tests.
The test results and findings shall be recorded and made available within 10 days of the completion of
each phase of testing.
The report shall contain a summary of the method of interpretation including all assumptions,
calibrations, corrections, algorithms and derivations used in the analyses. If the results are presented
in graphical form, the same scales shall be used consistently throughout the report. The units on all
scales shall be clearly marked.
B.E 4.16.8Anomalous Results
In the event that any anomaly is found in the results indicating a possible defect in the pile the
Contractor shall demonstrate that the pile is fit for its intended purpose or shall carry out remedial
works to make it so, to the EngineerProject Manager’s approval. Sonic logging tubes shall be grouted
up after the Contractor has demonstrated that the pile is satisfactory and the EngineerProject
Manager has given written agreement for the tubes to be grouted.
Load tests on large diameter cast-in-place bored piles shall normally be carried out on Working Piles.
The test pile will be paid for at the normal rates for working piles as provided in Item B.3. Separate
payments will be made for carrying out each load test, individual rates shall be provided for different
proof loads, which are specified in the Bill of Quantities. Payment for load tests on large diameter
cast-in-place bored piles shall include provision of special instrumentation to test piles, provision of all
testing equipment, carrying out of the tests, dismantling of equipment and removal from Site, breaking
out pile heads etc. in accordance with the requirements for working piles, preparation of all reports
etc.
Load tests on pilot cast-in-place piles, shall normally be carried out using kentledge. The pilot pile will
be paid for at the rates provided for pilot piles in Item B.3. Separate payments will be made for
carrying out each load test and individual rates shall be provided for different proof loads, which are
specified in the Bill of Quantities. Payment for load tests on pilot piles shall include provision of special
instrumentation to pilot test piles kentledge, provision of all test equipment, carrying out of the tests,
dismantling of equipment and removal from Site, cutting off below level of temporary anchor piles,
preparation of all reports etc.
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Pile integrity testing shall be paid at the rate there for in the priced Bill of Quantities on the number of
piles tested with acceptable results. The rate shall include for provision of all test equipment,
calibration, carrying out of tests, reporting, grouting of holes and any other work incidental thereto.
Additional payment will not be made for any retesting necessitated by anomalous results or otherwise
or for any difference in the constructed length of the piles compared with the length shown on the
Drawings.
B.E 4.18 No. of Tests
The number and location of the tests shall be determined by the EngineerProject Manager.
The minimum number of tests to be carried out is as follows:
At least 1 (one) working pile load test shall be carried out for abutment and pier of each plate girder
bridge location and 1 (one) working pile load test shall be carried out at each Box-culvert location
which may be covered as service pile. The EngineerProject Manager may opt for additional tests or
reduce the number depending on the test results.
At least 1 (one) pilot pile load tests shall be carried out at each plate girder bridge locations
determined by the EngineerProject Manager.
At least 30 % of piles at each substructure shall be integrity tested. The EngineerProject Manager
may increase or decrease the number of tests to render this number more representative of the pile
group.
Pay items shall be:
Unit of
Item No. Description
Measurement
E 4.1 Load Test on Cast-in-Place Working Pile (Category nr
specified in Bill of Quantities)
E .4.2 Load Test on Cast-in-Place Pilot Pile(Category specified in nr
Bill of Quantities)
E 4.3 Pile integrity testing on Cast-in-place pile(Category nr
B.4.1 Load Test on Cast-in-Place Working Pile Number

(Category specified in Bill of Quantities)
B.4.2 Load Test on Cast-in-Place Pilot Pile Number

B.4.3 Pile integrity testing on Cast-in-place pile Number

B.E 5 TEST BORING

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B.E 5.1 Description
B.E 5.1.1 General
The following particular requirements in respect of the geotechnical investigation works to be

undertaken at the Site of the Works shall be read in conjunction with, and in addition to, Item B.E 3 of
the Specification and other document forming the Contract.
B.E 5.1.2 Scope of Geotechnical Investigations
The Bidding Document includes the following extracts of the geotechnical investigation reports that
have been utilised as the basis for the Drawings for the bridges and culverts foundations:
Relevant bore logs for different bridges and culverts are attached along with the document for
information. Based on this investigation, foundation design was prepared.
The issue of these reports is strictly for information purposes only, to provide a basis for the
Contractor’s appraisal of the ground conditions throughout the area of the Site. Any information
provided to the Contractor shall in no way relieve the Contractor of his obligations under this Section
of the Specification, or elsewhere within the Contract documents. Such obligations include the
procurement, interpretation and application of the findings, by the Contractor, of sufficient
geotechnical investigation work, specific to the location of each of the principal foundation units, as to
enable the Contractor to validate or modify the tender foundation designs based on his own
investigations and his interpretation thereof.
For the purposes of definition of the minimum scope of the investigation works, a principal foundation
unit shall be regarded as being the one or more individual foundation elements that collectively
comprise the foundation for a pier or abutment.
The Contractor shall have sole responsibility for determination of the overall scope of the geotechnical
investigation works to be carried out to suit his purposes, and for ensuring that the appropriate
standards of performance are maintained throughout. In this regard, the performance standards for
field work, laboratory testing and reporting shall be the relevant procedures laid down by the American
Society for Testing of Materials (ASTM) or in the absence of an appropriate ASTM procedure, the
corresponding AASHTO or British Standard, or other published standard or specification of
recognised international standing that is approved by the EngineerProject Manager. The Contractor’s
scope of investigation shall include, but not necessarily be limited to, the particular minimum
requirements specified in this Section and contained elsewhere in the Specification.
B.E 5.2 Role of the EngineerProject Manager for Geotechnical

Investigation
In connection with the Contractor’s geotechnical investigation, the EngineerProject Manager shall act
within the framework of the Contract to ensure compliance with the specified requirements. For the
avoidance of doubt, this means:
(i) Ensuring that the minimum specified requirements for the scope of the investigation works are
carried out and
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(ii) Ensuring that the relevant technical standards for the performance of all field work, laboratory
testing and factual reporting are complied with, regardless of whether the work comprises part
of the minimum specified requirements or supplementary work scheduled by the Contractor for
his particular design verification requirements.
B.E 5.3 Contractor’s Responsibility for the Geotechnical Investigation
The Contractor’s responsibility for the Geotechnical Investigation includes, but is not limited to,
responsibility for the management and technical performance of the geotechnical investigation works
so as to obtain a satisfactory subsoil profile to design the piles. The Contractor is required to provide
sufficient qualified specialist personnel to maintain complete supervision of all aspects of the
investigations at all times.
Additional sub-surface and foundation investigations may be carried out during the early stages of
construction in order to review and finalize the design of certain structures. The Contractor shall
provide such equipment, manpower and assistance as the EngineerProject Manager shall deem
necessary and the results of this subsequent investigation will be provided to the Contractor under the
same conditions as specified hereinbefore.
B.E 5.4 Number and Depth of Boreholes
At least 1 (one) drilled borehole shall be carried out for each abutment and pier of the bridge location
and 1 (one) drilled borehole shall be carried out at each culvert location.
B.E 5.5 Borehole Equipment and Method
B.E 5.5.1 Core Drilling
The drilling equipment provided to be rotary drilling machine for sinking of the rotary cored proving
and confirmatory boreholes so as to maximise the achievable quality and recovery of core samples
within the prevailing strata. The minimum permissible drilling size shall be HX, producing core of at
least 76 mm diameter. As a minimum standard, core barrels shall be double tube swivel type
incorporating face discharge bits to minimise core damage by the flushing medium. The Contractor
will be permitted to use bentonite mud suspension for the temporary support of the superficial
deposits in land based boreholes.
Upon completion of each borehole that has been sunk within the footprint of a pier foundation unit, the
bore shall be backfilled to full depth.
B.E 5.5.2 In-Situ Testing and Sampling
Standard penetration tests (ASTM D 1586) shall be performed at 1.5 m intervals throughout the full
depth of soil boring at every borehole. The depth of the borehole shall be 1.5 times the maximum pile
length shown in the Drawings or to a depth where five consecutive SPT values of 50 or more are
achieved, whichever is the greater. Bulk and undisturbed tube samples shall be recovered, as
appropriate to the ground conditions encountered, between successive SPTs. The EngineerProject
Manager shall require additional SPTs to be carried out in rotary cored boreholes if, having taken all

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practicable steps to improve core recovery, the rate of recovery achieved is deemed to remain less
than is acceptable.
B.E 5.5.3 Laboratory Tests
The scheduling of laboratory testing shall be the responsibility of the Contractor in accordance with his
requirements for the validation of foundation designs.
The following laboratory tests shall be performed on soil samples collected from boreholes:
 Visual Inspection of the soil samples
 Natural moisture content
 Liquid limit and plastic limit
 Specific gravity
 Grain size distribution
 Unit weight
 Unconfined compression test where necessary
 Consolidation test for cohesive soils
 Tri axial shear test for cohesive soils
 Direct shear test

B.E 5.5.4 Record of Laboratory Testing and Final Reports
The Contractor shall provide a Factual Report containing the following information, in respect of all of
the investigation work that is carried out, laid out in a format to be agreed with the EngineerProject
Manager:
 A statement compiled by the Contractor describing the purpose and rationale of the
investigation, with specific reference to the Contractor’s obligations in respect of the validation
of the foundation design;
 A description of the work carried out, including references to the Specification and standards
adopted, and departure from these requirements;
 Exploratory hole logs; with existing ground level at the borehole location.
 In situ test records;
 Laboratory test results; and
 Site plan and exploratory borehole location plan.
The Contractor shall provide an Interpretive Report containing the following information, in respect of
all of the investigation work that is carried out, laid out in a format to be agreed with the
EngineerProject Manager:
 A statement compiled by the Contractor describing the approach adopted in undertaking the
interpretation and EngineerProject Managering analysis necessary to derive the parameters
and recommendations required by the Contractor in order to discharge his obligations in
respect of the validation of the foundation design;
 Desk study review and commentary on the factual information provided, other reference
sources adopted, and their interrelationship with the findings of the Contractor’s specific
investigation works;
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 A written appraisal of the prevailing ground conditions throughout the Site area, together with
geological sections, EngineerProject Managering description of the strata profiles and
development of the ground models adopted for foundation design verification purposes; and
 Interpretive comment and analyses fully supporting the Contractor’s recommendations for
final design and construction of the foundations.
There is no separate payment for In-Situ Testing and Sampling for SPTs, Laboratory Tests for Natural
Moisture Content, Liquid Limit and Plastic Limit, Specific Gravity, Grain Size Distribution including
sedimentation analysis, Unit Weight, except for Unconfined Compression Test, Tri axial Shear Test,
Consolidation Test and Direct Shear Test.
Factual and Interpretative reporting shall be paid at the rate thereof in the priced Bill of Quantities.
Such rate shall include both reports as required per borehole and shall be paid upon final submission
and approval. There shall be no adjustment of the rate payable for reporting in respect of the
Contractor’s required investigation works undertaken over and above the specified minimum scope of
work or for any change of the depth of the borehole.
The Pay Items shall be:
Item
Unit of
No.Sl. DescriptionWorks Items
MeasurementUnit
No
B. E 5.1 a) Unconfined Compression Test nr.
(a)
E 5.1 (b) b) Tri axial Shear Test nr.
E 5.1 (c) c) Consolidation Test nr.
E 5.1 (d) d) Direct Shear Test nr.
B.5.2 Factual and interpretive report (combined per borehole) nr.
B.E 6 EXCAVATION AND BACKFILL FOR STRUCTURES
B.E 6.1 Description

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This work shall consist of excavation in any material for the foundation of structures, other than for
pipe culverts, not otherwise provided for in the Specifications; constructing and removing cofferdams,
sheeting; pumping, dewatering and bailing; backfilling of completed structures with suitable material
and disposal of excavated material. Pipes and manholes shall be excavated and backfilled in
accordance with Items B.E 13 and B.E 14
Filling of areas above the natural ground level or above the limits of embankment excavation or
channel excavation is described in Clause A 4 of Subsection A: Earthworks of this Specification.
B.E 6.2 Materials
B.E 6.2.1 Foundation Fill Material
Material for foundation fill shall consist of suitably graded sand to one of the grading envelopes A to C,
gravel or stone as shown on the Drawings or as required by the EngineerProject Manager, or
concrete. Concrete for foundation fill shall conform to the general requirements of Item B.E 7.
Concrete to be placed under water shall conform to the requirements of Item B.E 7.3.14. Concrete
used as foundation fill in dry excavation shall be Class 15.
Material shall be a natural or artificial mixture of sand or other mineral aggregate, free from vegetable
matter, soft particles and excess clay.
a) Grading: The grading shall conform to one of the grading envelopes A to C in Table B.E 6-1.
Table B.E 6-1
A B C D E
Nominal
Not less
fineness 1.5 -2.8 1.0 - 1.5 0.8 - 1.0 0.5 - 0.8
than 2.8
modulus
Sieve
size % passing by weight
(mm)
10 100 100 100 100 100
5.0 90 – 95 95 -100 100 100 100
2.4 70 – 90 90 -100 100 100 100
1.2 45 – 70 70 - 95 95 - 100 100 100
0.6 25 – 45 40 - 80 85 - 100 95 – 100 100
0.3 10 – 20 10 - 50 50 - 80 70 – 90 80 - 95
0.15 0–2 0 – 20 5 - 25 15 – 40 30 - 60
Grading outside the above limits may in certain circumstances be approved by the EngineerProject
Manager. Such permission shall be in writing.
b) Plasticity: The portion passing the 0.425 mm sieve shall, if it is plastic, have a liquid limit not
greater than 30% and a plasticity index not greater than 9% (STP 3.2).
c) CBR: The material shall have a soaked CBR value not less than 8% when compacted to 95%
of maximum dry density as determined by STP 4.5 (Vibrating Hammer compaction).
d) The material shall be free draining.

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B.E 6.2.2 Backfill Material
The Contractor shall carry out the necessary backfilling of the various structures using a competent,
free drainage, granular material with a maximum of 5% by weight passing the Sieve No. 200. The
free-draining backfill material shall be placed against the structures to the minimum width shown on
the Drawings or required by the EngineerProject Manager, with the remainder of the excavation to be
backfilled using other suitable material consistent with the adjacent in situ material or embankment fill.
B.E 6.3.1 Clearing
Prior to starting excavation operations in any area, all necessary clearing and grubbing shall have
been performed.
B.E 6.3.2 Excavation
A) General
The Contractor shall notify the EngineerProject Manager sufficiently in advance of the beginning of
any excavation so that cross section elevations and measurements may be taken of the undisturbed
ground. The natural ground adjacent to the structure shall not be disturbed without permission of the
EngineerProject Manager. Trenches and foundation pits for structures and structure footings shall be
excavated to the lines, grades and elevations shown on the Drawings or as directed by the
EngineerProject Manager. The elevations of the bottoms of footings shown on the Drawings are
approximate only and the EngineerProject Manager may order in writing such changes in the
dimensions or elevations of footings as may be deemed necessary to secure a satisfactory
foundation.
Boulders, logs and other objectionable material encountered in excavation shall be removed. After
each excavation is complete the Contractor shall notify the EngineerProject Manager to that effect
and no footings, bedding material or structure shall be placed until the EngineerProject Manager has
approved the depth of excavation and the character of the foundation material.
The foundation material shall be cleared of all loose material and cut to a firm surface, either level or
stepped or serrated, as specified or shown on the Drawings or directed by the EngineerProject
Manager.
B) Foundation Directly on the Ground
When the footing is to rest on the ground and not on piles, special care shall be taken not to disturb
the bottom of the excavation, and excavation to final grade shall be deferred until just before the
footing is to be placed. When, in the opinion of the EngineerProject Manager, the foundation material
is soft or otherwise unsuitable, the Contractor shall remove the unsuitable material and insert
foundation fill material or concrete as specified or shown on the Drawings or directed by the
EngineerProject Manager. If foundation fill material is required, it shall be placed and compacted in
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layers not more than 150 mm thick to the degree of compaction as specified in Clause A.5 of
Subsection A: Earthworks of this Specification.
C) Foundation on Piles
When the ground between piles is too soft to support green foundation concrete, the Contractor shall
submit his proposals for a bottom form to the EngineerProject Manager for his approval. Extra
excavation and foundation fill or concrete fill in such cases will not be paid for separately. If the bottom
form is achieved by such strengthening of the ground, the Contractor shall, if requested, submit
calculations showing that the pile cap will not be harmed during hardening due to differential
settlements between the piles and the strengthened ground.
B.E 6.3.3 Disposal of Excavated Material
Excavated material classified as suitable by the EngineerProject Manager shall generally be utilized
as backfill or embankment fill. Surplus suitable material shall be stockpiled on Site as described in
section A.4.3, subsection A: Earthwork. Excavated suitable material for use as backfill shall be
deposited by the Contractor in spoil heaps at points convenient for re-handling of the material during
the backfilling operation and approved by the EngineerProject Manager.
Excavated material classified as unsuitable as backfill by the EngineerProject Manager shall be

carried to waste as described in Clause A.4.1 of Subsection A: Earthworks of this Specification.
Excavated material shall be deposited in such places and in such a manner as not to cause damage
to roads, services or property either within or outside the right-of-way and so as to cause no
impediment to the drainage of the Site or surrounding area. The location of spoil heaps shall be
subject to the approval of the Engineerapproval of the Project Director who may require that the
reference lines and the traverse lines of any part of the structure be kept free of obstruction.
BE. 6.3.4 Cofferdams
A) The term “cofferdam” denotes any temporary or removable structure, constructed to hold the
surrounding earth, water or both, out of the excavation, whether such structure is constructed of earth,
timber, steel, concrete or any combination of these. The term includes earth dikes, timber cribs, sheet
piling, removable steel shells and all bracing; and it shall be understood to include excavation
enclosed by pumping wells and well points. The cost of cofferdams, (sheet piling, dikes, related
works, etc.,) is deemed to be included in the prices included in permanent work.
B) The Contractor shall submit upon request, drawings showing his proposed method of cofferdam
construction. Approval of the drawings by the EngineerProject Manager will not in any way relieve the
Contractor of the responsibility for the adequacy of the design for strength and stability or for the
safety of the people working therein.
C) The interior dimensions of cofferdams shall be such as to give sufficient clearance for the
construction and removal of any required forms and the inspection of the interior and to permit
pumping.
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D) If possible, cofferdams shall be so designed that no cross bracing shall be left in place. If this is
not possible, bracings left in place shall be of structural steel. The end of such structural members that
would be exposed when the structure is completed shall be boxed back at least 50 mm behind the
concrete face. The resulting holes shall be completely filled with concrete.
E) In general, sheet piling cofferdams shall extend well below the bottom of the footing and shall
be well braced and as watertight as possible.
F) When foundation piles are to be driven inside a cofferdam and it is judged impossible to de-
water the cofferdam before placing a concrete seal, the excavation may be extended below the
designed level to a depth sufficient to allow for swell of the material during pile driving operations. Any
material that rises to a level above the design level shall be removed.
G) Where it is possible to de-water the cofferdam, the foundation material shall be removed to
exact grade after the foundation piles are driven.
H) Backfilling in a foundation to compensate for excavation, which has been extended below the
required grade, shall be at the expense of the Contractor. Backfilling shall be with concrete or
foundation fill material as indicated on the Drawings, or as directed by the EngineerProject Manager.
If no material is indicated, backfilling shall be concrete of the same kind as required for the structure to
be constructed in the excavation. Unless otherwise permitted no excavation shall be made outside of
cribs or cofferdams or sheet piling and the natural streambed adjacent to the structure shall not be
disturbed without permission from the EngineerProject Manager.
If any excavation or dredging is made at the Site of the structure before caissons, cribs, or cofferdams
are in place, the Contractor shall after the foundation is in place, backfill all such excavation to the
original ground surface or stream bed with material satisfactory to the EngineerProject Manager.
Material deposited within the stream area from foundations or other excavations or from the filling of
cofferdams shall be removed and the stream area freed from obstruction.
I) Cofferdams which have tilted or moved laterally during construction, shall be corrected as
necessary at the expense of the Contractor.
J) Unless otherwise provided cofferdams shall be removed after the completion of the sub-
structure. The removal shall be effected in such a manner as not to disturb or mar the finished work.
The EngineerProject Manager may order the Contractor to leave any part or the whole of the
cofferdam in place.
K) When conditions which, in the opinion of the EngineerProject Manager, render it impossible to
de-water the foundation before placing the footing are encountered, the EngineerProject Manager
may require the construction of a concrete foundation or seal of such dimensions as he may consider
necessary, and of such thickness as to resist any possible uplift. The concrete for such seal shall be
placed as shown on the Drawings or required by the EngineerProject Manager. The foundation shall
then be de-watered and the footing placed. When weighted cribs are used and the weight is used to
overcome partially the hydrostatic pressure acting against the bottom of the foundation seal, special
anchorages such as dowels or keys shall be provided to transfer the entire weight of the crib to the
foundation seal. When a foundation seal is placed under water the cofferdam shall be vented at low
water as directed.
Cofferdams shall be constructed so as to protect newly cast concrete from sudden rising of the water
and to prevent damage to the foundation by erosion.
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B.E 6.3.5 Pumping and Bailing
Pumping and bailing from the interior of any foundation enclosure shall be done in such a manner as
to preclude the possibility of the movement of water through or alongside any concrete being placed.
No pumping or bailing will be permitted during the placing of concrete and for a period of least 24
hours thereafter unless it is done from a suitable pump separated from the concrete work by a
watertight wall or from well points. No separate payment shall be made against pumping and Bailing.
Cost of this work shall be included in foundation items.
Excavations shall be as dry as possible prior to and during placing concrete. Placing concrete under
water will only be permitted if indicated on the Drawings or approved by the EngineerProject Manager.
B.E 6.3.6 Backfilling
Not less than (30) days prior to the commencement of any backfilling operation, the Contractor shall
submit to the EngineerProject Manager for his approval, representative samples of the intended
backfill material, together with copies of any testing of the materials carried out by the Contractor. The
submission of samples and test results as aforesaid shall be carried out for each specific borrow area
or location from which the Contractor intends to obtain the granular free-draining backfill material.
The backfilling of any structure shall be carried out in horizontal lifts not exceeding 250mm before
compaction and the material shall be uniformly compacted to 95% of its Modified Proctor Density
when tested in accordance with ASTM D1557 – 78. The moisture content of the material shall be
uniform throughout the lift being compacted. The placement of backfill material against a concrete
surface shall not commence until the said concrete has attained its 28-day strength as determined by
laboratory compression tests and approved by the EngineerProject Manager. Where backfilling is
required on more than one side of a structure, the backfilling shall be carried out such that the
maximum differential between the heights of the backfill on any two sides of the structures is not more
than 300mm at any time.
All excavations shall be completely backfilled. The backfilling shall either be carried out back to
original ground or to the final design level of the adjacent ground. The granular free-draining backfill
around the structure shall extend horizontally a minimum of 500 mm from the edge of the structure.
Where the excavation extends beyond the limit of the granular free-draining backfill as aforesaid, the
Contractor may either extend the granular free-draining backfill, or he may backfill this remaining
portion of the excavation with competent material obtained from the excavation or from other sources.
This portion of the backfill material shall be placed and compacted in the same manner specified for
the granular material around the structure, save for the fact that the minimum degree of compaction
shall be 93% of its Modified Proctor Density. There shall be no separate measurement of payment for
backfill material placed outside of the minimum backfill configuration, the cost of which shall be
incidental to carrying out the overall backfilling operation.
Where an area to be backfilled contains a configuration of piling, the Contractor shall first place and
compact a zone of granular free-draining backfill up to underside of the pile cap or abutment footing.
This backfilling to the underside of the pile cap or abutment footing shall not commence until such
time as the Contractor has completed all of the piling activity within the area, including the cutting of
the piles and the removal of the material and equipment as aforesaid, and the floor of the excavation
has been prepared as specified hereinbefore. The zone of granular backfill to the underside of the pile

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cap or abutment footing shall extend horizontally, a minimum of 500mm beyond the edge of the pile
cap or abutment footing around its entire perimeter.
When backfill is to be placed between a structure and the inclined surface of the excavation, the
inclined surface shall be horizontally stepped in order to achieve the proper compaction of the placed
material and inclined surface. The horizontal stepping of the inclined surface shall be approximately
equal to the pre-compaction thickness of the lift of material being placed.
The placing and compacting of backfill material shall be carried out in the dry no backfill material shall
be placed by means of jetting or any other type of hydraulic placement. All bracing and shoring of
excavations shall be removed during the backfilling of the excavations such that the stability of the
excavation is maintained and all such temporary materials are completely removed from the
excavation by the time the backfilling has been completed.
The volume of excavation and backfill shall be measured in cubic meters of excavated undisturbed
material. The quantity of excavation for structures to be measured for payment shall include
excavation for all structures except pipe culverts, which will be in accordance with Item B.13. The
measured volume shall be the excavation plan outline, bounded on the bottom by the plane of the
underside of the brick flat soling or the blinding concrete under the reinforced concrete footing and on
the top by the surface of the existing ground and on the sides by vertical planes of the footings.
Backfilling with previously excavated material shall not be measured or paid for separately but shall
be deemed included in the rate for excavation.
Backfill with concrete or sand where directed by the EngineerProject Manager including concrete
seals shall be measured separately as the volume within the plan outline and top and bottom
surfaces. Concrete or sand placed to backfill excavation beyond the excavation required will not be
measured for payment. The plan outline referred to be the excavation plan outline as defined above. If
sand fill is ordered over top level of pile cap, the fill shall be the specified filling volume measured on
the Drawings up to profiles agreed upon in writing by the EngineerProject Manager.
This work measured as provided in this Section shall be paid for at the Contract unit prices per cubic
meter for each particular item. The payment shall be full compensation for all excavation, stockpiling,
backfilling and disposal including compaction; constructing and removing all cofferdams; all
dewatering, pumping and bailing; and for furnishing all materials, labor, equipment, tools, sheeting,
bracing, cofferdams, pumps, and incidentals necessary to complete the work.
All payment for the backfilling and compaction of those areas which were removed as structural
excavation shall be included in the appropriate unit rates below. Filling or backfilling of areas above
the natural ground level or above the limits of road excavation or channel excavation section shall be
paid for under Subsection A: Earthwork.
Pay items shall be:
Item No. Description Unit of Measurement

E 6.1 Excavation and Backfill for Structures m3
E 6.12 Backfill for Structures m3
E 6.13 Sand Backfill for Structures m3

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B.6.1 EXCAVATION AND BACKFILL FOR STRUCTURES CUBIC

METER
B.6.2 BACKFILL FOR STRUCTURES CUBIC METER
B.6.3 SAND BACKFILL FOR STRUCTURES CUBIC METER
B.E 7 CONCRETE FOR STRUCTURES
B.E 7.1 Description
This work shall consist of the construction of all or portions of structures of Portland cement concrete,
of the required grades and types, with or without reinforcement and with or without admixture, in
accordance with these Specifications and to the lines, levels, grades and dimensions shown on the
Drawings and required by the EngineerProject Manager. This work includes cast-in-place concrete
construction and manufacture and erection and placing at permanent location of precast concrete
members or units
Portland cement concrete shall consist of a mixture of Portland cement, water and coarse and fine
aggregate with or without admixture.
B.E 7.2 Materials
B.E 7.2.1 Specifications for Materials
A) Cement
Cement shall conform to the requirements of AASHTO Standard Specification M 85 Type 1, normal
Portland cement, unless other types are indicated on the Drawings or specified by the
Cement shall be sampled and tested in accordance with STP Sections 2.6 and 8.

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Bagged or bulk cement which has partially set or which contains lumps of caked cement shall be
rejected. The use of cement reclaimed from discarded or used bags shall not be permitted. All such
rejected and nonconforming cement shall be removed from the Site completely by and at the
Contractor’s expense.
One brand of cement, as approved by the EngineerProject Manager, shall be used for all concrete
works throughout the Works unless otherwise authorized by the EngineerProject Manager in writing.
B) Water
The water used in mixing and curing concrete shall be tested by methods described in AASHTO Test
Method T 26. All water shall be clean and free from salt, oil, acid, vegetable or other substance
injurious to the finished product. The use of river water will be subject to the approval of the
Engineerapproval of the Project Director. Such approvals may be withdrawn from time to time
depending on the condition of the river.
C) Admixtures
Admixtures or any other additions shall not be used except with the written approval of the
Engineerapproval of the Project Director. .
Admixtures, if specified or permitted, shall fully conform to the requirements of AASHTO Standard
Specification M 194 and plasticizing and retarding admixtures shall conform to the requirements of
ASTM C 1017.
Air-entraining admixture shall be used in each concrete mix unless the Contractor can verify that the
specified percentage of air has been achieved consistently at the point of delivery when no air-
entraining admixture is used. Air entraining admixture shall conform to AASHTO Standard
Specification M 154.
Calcium chloride or admixtures containing calcium chloride shall not be permitted
D) Coarse Aggregate
Coarse aggregate for all types of concrete shall consist of hard durable crushed or broken rock and
generally conform to the requirements of AASHTO Standard Specification M 80. Only one source of
Coarse aggregate shall be used except by written permission from the EngineerProject Manager.
Approval of sources of supply of aggregate shall be obtained from the EngineerProject Manager prior
to delivery of material. Samples and test results shall be submitted for approval of the
Engineerapproval of the Project Director at least 14 days advance of its use. Coarse aggregate shall
be clean, free from dust and other deleterious material.
The amounts of deleterious substances shall not exceed the following limits:
1) Soft fragments; 2% by mass

2) Clay lumps; 0.25% by mass
3) Material passing the 0.075 mm sieve; 0.50% by mass if clay,
The sum of the percentages of all deleterious substances in coarse aggregate as delivered to the
mixer shall not exceed 2 percent.
When the coarse aggregate is subjected to five cycles of the sodium sulphate soundness test, the
weight loss shall not be greater than 10 percent.
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Coarse aggregate shall be free from organic matter or other foreign materials and the permissible
maximum salt contents, expressed as a percentage of the mass of the coarse aggregate, shall be
0.05% for sodium chloride and 0.025% for soluble sulphates.
In addition, coarse aggregates shall comply with the following:
1) Thin or elongated pieces; Flakiness Index (STP 7.3.1) less than 30

2) The aggregate crushing value (STP 7.7.1) shall be less than 30% and the ten percent fines
value (STP 7.7.2) shall be greater than 150 kN.
The coarse aggregates shall have a minimum specific gravity of 2.56 and shall be reasonably graded
and shall meet the grading requirements in Table No. BE .7-1 below .The grading of coarse
aggregate of maximum size 20 mm shall conform to Table B.E 7-1 below. The grading of 40 mm
maximum size coarse aggregate shall be in accordance with AASHTO Standard Specification M 43.
Table B.E 7-1
Grading Requirements for 20 mm

Maximum Size Coarse Aggregate
Sieve Size (mm) % Passing by Weight
25 100
20.0 90 – 100
12.5 20 - 55
10.0 5 - 20
5.0 0-5
2.4 -
1.2 -
In heavily reinforced structures with difficult casting conditions smaller size aggregates may be used if
approved by the EngineerProject Manager.
Aggregate which, when tested in accordance with ASTM C289, Figure 2, is considered deleterious,
will be rejected.
E) Fine Aggregate
Fine aggregate shall consist of natural sand and fine aggregates from different sources of supply shall
not be mixed or stored in the same pile. Fine aggregates, if from different sources, shall be blended to
ensure consistent grading and colour is achieved in accordance with the Specification.
Fine aggregate shall conform to all of the requirements of AASHTO Standard Specification M 6
except as modified by this Specification, and shall be tested accordingly.
The amounts of deleterious substance when tested in accordance with STP 3.4 shall not exceed the
following limits:

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1) Friable Particles; 0.5% by mass
2) Coal and Lignite; 0.25% by mass
3) Material passing the 0.075 mm sieve; 3.0% by mass
4) Any other deleterious materials shall not cause a strength reduction of the concrete of more
than 5% in relation to the strength of concrete free of the concerned deleterious material. The
sum of the percentages of all deleterious substances in fine aggregate, as delivered to the
mixer, shall not exceed 3 percent for fine aggregate. When the fine aggregate is subjected to
five cycles of the sodium sulphate soundness test, the weight loss shall not be greater than 10
percent.
Fine aggregate shall be free from organic matter or other foreign materials and the permissible
maximum salt contents, expressed as a percentage of the mass of the fine aggregate, shall be
0.10% for sodium chloride and 0.25% for soluble sulphates. F.M. shall be greater than 2.5 and
The grading of fine aggregate shall conform to Table B.E 7-2 below
Table B.E 7-2
Grading Requirements for Fine Aggregate

Sieve Size (mm) % Passing by Weight
10.0 100
B.E 7.2.2
5.0 95 – 100
1.2 45 – 80
Testing
0.30 10 – 30
of
0.15 2 – 10
Materials
A) Cement
Cement shall be in accordance with AASHTO M 85. The Contractor must provide the EngineerProject
Manager with manufacturer’s certificates indicating compliance.
Cement shall be sampled and tested for fineness, setting time and strength in accordance with STP
8.1, STP 8.2 and STP 8.3, respectively, at the Contractor’s expense. The Contractor shall notify the
EngineerProject Manager of delivery dates so that there will be sufficient time for sampling the
cement, either at the mill or upon delivery. If this is not done, the Contractor may be required to re-
handle the cement in the store for the purpose of obtaining the required samples.
Sampling shall normally be instructed by the EngineerProject Manager for every batch of cement prior
to this cement being incorporated in the Works.
Any cement that has been stored at Site for a period in excess of three months shall be tested to
verify conformance before use. The cost of providing all samples and all testing shall be borne by the
Contractor

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B) Water
The water proposed by the Contractor to be used in mixing or curing concrete shall be tested by
methods described in AASHTO Test Method T 26.
In sampling water for testing, care shall be taken that the containers are clean and that samples are
representative.
When comparative tests are made with a water of known satisfactory quality, any indication of
unsoundness, marked change in time of setting, or a reduction of more than 10 percent in mortar
strength, shall be sufficient cause for rejection of the water under test.
The water shall be tested at a recognized laboratory approved by the EngineerProject Manager. The
test result shall be signed by the laboratory. The water shall be tested before commencement of work
or if the source is changed or at any time required by the EngineerProject Manager. All testing shall
be carried out at the Contractor’s expense.
C) Admixtures
The Contractor shall submit specifications and samples of any admixtures or additives that he
proposes to use to the EngineerProject Manager at least 28 days before the commencement of
construction or manufacture of the particular structure on which he intends to use such admixtures.
Trial tests of cylinder strength and any other tests shall be carried out for all concrete with admixtures.
When the EngineerProject Manager approves changing the brand or type of cement, the Contractor
will be required to carry out further tests and establish a relative mix design
Any tests the EngineerProject Manager may require on concrete mixes on account of the Contractor’s
proposal to use additives shall be carried out at the expense of the Contractor.
D) Aggregates
1) Selection and Approval
Not less than fifty-six (56) days before the intended start of concrete works, the Contractor shall
advise the EngineerProject Manager of the sources of aggregates to be used to permit samples to be
taken in the presence of a representative of the EngineerProject Manager.
From the aggregate materials proposed by the Contractor, samples shall be selected according to
STP Section 2.4 and in the presence of the EngineerProject Manager. The samples shall be tested at
the Site laboratory or at an approved testing laboratory for conformance with Item B.7.2.1 of these
Specifications.
2) Quality Control
The quality control of the aggregate shall be in accordance with the minimum sampling and testing
frequency given in the Table B.7-3A or as otherwise directed by EngineerProject Manager. Grading
shall be checked daily when aggregates are being produced or delivered to stockpiles on Site.
Moisture contents of fine aggregate shall be determined daily and at any time when a change in
moisture content is expected.

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If the Contractor proposes to change the source of aggregate, the EngineerProject Manager shall be
informed in advance and in no case less than 42 days before the new aggregate is intended to be
used.
Table B.E 7-3A
Standards for Testing Aggregates for Concrete
Minimum sampling/testing
Test
frequency (m3)
Sampling 500
Particle shape, Flakiness Index 2,500
Light particles 500
Friable particles 500
Organic impurities 500
Soundness 2,500
Grading 500
Aggregate Abrasion Value 500
Crushing Value 500
Unit mass 2,500
Specific gravity 500
Absorption 500
Alkali reactivity 2,500
B.E 7.2.3 Composition of Concrete
A) Classes of Concrete
Concrete with cement Type I or Type II for incorporation in the Works shall be of the classes indicated
on the Drawings and shall comply with Table B.E 7-3.
Table B.E 7-3
Concrete Characteristic Maximum Size Minimum

Concrete Strength (N/mm2 @ 28 days) of Coarse Cement
Class Cylinder (150 Cube Aggregate Content (kg/m3)
x 300 mm) (150mm) (mm)
7 7 9 40 180
20 210
10 10 13 40 210
20 240
15 15 19 40 250
20 280
20 20 25 40 300
20 320
25 25 31 40 340

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Concrete Characteristic Maximum Size Minimum
Concrete Strength (N/mm2 @ 28 days) of Coarse Cement
Class Cylinder (150 Cube Aggregate Content (kg/m3)
x 300 mm) (150mm) (mm)
20 360
30 30 37 40 370
20 400
Concrete Maximum Size Minimum

Characteristic of Coarse Cement
Concrete
Strength Aggregate Content Concrete Class
Class
(N/mm2 @ 28 (mm) (kg/m3)
days)
35 35 44 40 400
20 430
40 40 50 20 450
45 45 55 20 475
Note: These are minimum cement contents only for durability and additional payment shall not be
made in the event that the Contractor’s mix designs require greater quantities of cement to achieve
the other requirements of the Specification.
The Contractor shall be responsible for the design of concrete mixes and for ensuring that all concrete
placed in the Works meets the requirements of the Specification
B) Proportioning
When designing the concrete mix, the Contractor shall consider the following conditions:
1) Strength and Shrinkage
The class of the concrete is shown on the Drawings. The class is the specified characteristic cylinder
strength at 28 days. Concrete mixes shall be designed to comply with Specifications Item B.7.2.4. The
drying shrinkage of concrete Class 25 N/mm2 shall be tested in accordance with ASTM C 596 and be
no more than 0.06 percent plus or minus 0.005 percent at fifty six (56) days.
2) Water/Cement Ratio
The ratio of free water to cement when using saturated surface dry aggregate shall be as low as
possible and not exceed 0.50 by weight for all concrete, except for blinding concrete where it shall not
exceed 0.6, unless approved by the EngineerProject Manager.
For concrete in barriers, edge beams and bridge decks directly exposed to traffic or concrete in pile
caps or abutments in contact with the ground, the water cement ratio shall not exceed 0.45, unless
3) Minimum Cement Content
As indicated for the respective class in Table B.E 7-3

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4) Minimum Filler Content
Filler content (fine aggregate less than 0.25 mm and cement) in the concrete shall be according to the
following table (except for mass concrete).
Minimum filler content

Coarse aggregate size (mm)
(kg/m3 of concrete)
12 – 20 435
20 – 40 350
5) Coarse Aggregate
The maximum size of coarse aggregate will generally be stated on the Drawings; either 40 mm or 20
mm. For maximum size of 20mm aggregate the grading to be in accordance with Table B.7-1. Quality
is to comply with the requirements of Item B.E 7.2.1 (D).
6) Fine Aggregate
The grading and quality is to comply with the requirements of Item B.E 7.2.1 (E).
7) Workability
The concrete shall be of suitable workability to obtain full compaction. Slumps measured in
accordance with STP 9.1 shall not exceed 75 mm unless otherwise indicated on the Drawings or
C) Trial Mixes
After the Contractor has received approval for the cement and aggregate to be used, he shall prepare
trial mixes with concrete of designed proportions to prove and establish workability, strength,
shrinkage, water cement/ratio, surface criteria, etc. Methods of transporting fresh concrete and the
compaction equipment shall be considered. The trial mixes shall be made and compacted in the
presence of the EngineerProject Manager, using the same type of plant and equipment as will be
used for the Works.
From each trial mix, cylinders or cubes and mortar bars shall be made and tested in accordance with
Item B.E 7.2.4.
From the same mix as that from which the test specimens are made, the workability of the concrete
shall be determined by the slump test in accordance with STP 9.1 air content tested in accordance
with AASHTO T152 and density tested in accordance with AASHTO T121. The remainder of the mix
shall be cast in a wooden mould and compacted. After 24 hours the sides of the mould shall be struck
and the surface examined in order to satisfy the EngineerProject Manager that an acceptable surface
can be obtained with the mix.
The trial mix proportions should be approved if the required strength, shrinkage limits, air content,
density and design slump are obtained from tests carried out in accordance with Item B.7.2.4 and the
consistency and surface is to the satisfaction of the EngineerProject Manager. When a mix has been
approved, no variations shall be made in the mix proportions, or in the type, size, grading zone or

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source, of any of the constituents without the consent of the EngineerProject Manager, who will
require further trial mixes to be made before any such variations are approved.
Until the results of trial mixes for a particular class have been approved by the EngineerProject
Manager, no concrete of the relevant class shall be placed in the Works.
When the Contractor intends to purchase factory-made precast concrete units, trial mixes may be
dispensed with provided that evidence is given to satisfy the EngineerProject Manager that the factory
regularly produces concrete which complies with the Specifications. The evidence shall include details
of coarse and fine aggregates mix proportions, water/cement ratios, slump tests and strengths
obtained at 28 days and all other quality control tests required the Specification.
B.E 7.2.4 Control of Concrete Quality
A) General
The Contractor shall be fully responsible for providing all concrete conforming to the Specification and
this responsibility shall not be relieved by the testing carried out and approved by the EngineerProject
Manager.
The Contractor shall thus at his own discretion establish additional testing procedures as necessary.
B) Control of Concrete Production
1) Materials
Materials used shall be tested in accordance with Item B.E 7.2.2.
2) Plant and Equipment
Batching plants will be tested by the Contractor in a manner approved by the EngineerProject
Manager before any major concrete casting and at any other time if requested by the EngineerProject
Manager.
3) Fresh Concrete
The frequency of slump tests shall be as directed by the EngineerProject Manager, with at least one
test per 25 m³ of concrete or one test per truckload where delivered by truck.
Slump testing may be carried out at the batch plant, delivery trucks, at the point of placing and
elsewhere where concrete is being handled or placed but the tests at the point of placing shall be the
basis of determining conformance with the Specification.
C) Control of Strength
1) Sampling and Testing
The design and characteristic strengths of concrete have been specified in accordance with AASHTO
Standard Specifications and cylinder strengths shall apply. The term “cube” or “cubes” used in this
Specification is a general reference to “cylinder” specimens taken for the purpose of testing the
characteristic strength.

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The sampling for determination of concrete properties will be carried out by the Contractor, in the
presence of the EngineerProject Manager, as required from the batch plant, delivery trucks, at the
point of placing and elsewhere where concrete is being handled or placed. Concrete sampled at the
point of placing shall be used to determine compliance with the Specification.
Samples will be obtained at uniform intervals throughout the production or delivery of concrete for a
given placement. A placement shall be considered as an operation involving the continuous placing
of concrete between adjacent construction joints. In general, the frequency of sampling of a
class/type of concrete in any one placement shall be in accordance with Table B.E 7-4 and the
Contractor shall provide facilities at the point of sampling to procure the samples of concrete for
testing and the required quantity of concrete for sampling and testing.
Table B.E 7-4 Frequency of Sampling Concrete
Mass Concrete 1 sample per 50 m3 or part thereof

Reinforced Concrete 1 sample per 25 m3 or part thereof
Prestressed Concrete 1 sample per 15 m3 or part thereof
One sample shall consist of a minimum of 6 cylinders, 3 for testing at 7 days and 3 for testing at 28
days.
From the same sample the Contractor shall take specimens for a slump test, an air content test, three
standard drying shrinkage tests and two unit mass tests.
The procedures for sampling and making cubes/cylinders and testing them shall be as described in
STP 9.2.
2) Strength Requirement
The results of the testing shall conform to the strength requirements according to British Standard
BS5400: Part 7, as given below, or to any mathematically correct statistical test for each casting
section.
D) General
The characteristic strength of concrete is the 28 days strength below which not more than 5% of the
test results may be expected to fall.
E) Target Mean Strength
The concrete mix should be designed to have a mean strength greater than the required characteristic
strength by at least the current margin.
The current margin for each particular type of concrete mix shall be determined; it may be taken as
having the smaller of the values given by (1) or (2) below.

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1) 1.64 times the standard deviation of tests on at least 100 separate batches of concrete of
nominally similar proportions of similar materials and produced over a period not exceeding 12
months by the same plant under similar supervision but not less than 3 N/mm2 based on cylinder
strength or 3.75 N/mm2 based on cube strength.
2) 1.64 times the standard deviation of tests on at least 40 separate batches of concrete of
nominally similar proportions of similar materials and produced over a period exceeding 5 days but
not exceeding 6 months by the same plant under similar supervision but not less than 6 N/mm2 based
on cylinder strength or 7.5 N/mm2 based on cube strength.
Where there are insufficient data to satisfy (1) or (2) above, the margin for the initial mix design should
be taken as 12 N/mm2 based on cylinder strength or 15 N/mm2 based on cube strength of the
characteristic strength for concrete. This margin should be used as the current margin only until
sufficient data are available to satisfy (1) or (2) above. However, when the required characteristic
strength approaches the maximum possible strength of concrete made with a particular aggregate, a
smaller margin may be permitted by the EngineerProject Manager for the initial mix design.
F) Testing Plan
Each cylinder/cube shall be made from a single sample taken from randomly selected batches of
concrete.
Compliance with the specified characteristic strength may be assumed if:
1) The average strength determined from any group of four consecutive test cylinders/cubes
exceeds the specified characteristic strength by not less than 0.5 times the current margin, and
2) Each individual test result is greater than 85% of the specified characteristic strength.
The current margin should be taken to be 12 N/mm2 based on cylinder strength of the specified
characteristic strength for concrete, unless as mentioned above a smaller margin has been
established to the satisfaction of the EngineerProject Manager.
If only one cylinder/cube result fails to meet the second requirement then that result may be
considered to represent only the particular batch of concrete from which that cube was taken provided
the average strength of the group satisfies the first requirement.
If more than one cylinder/cube in a group fails to meet the second requirement or if the average
strength of any group of four consecutive test cubes fails to meet the first requirement then all the
concrete in all the batches represented by all such cylinders/cubes shall be deemed not to comply
with the strength requirements. For the purposes of this sub-Section, the batches of concrete
represented by a group of four consecutive test cylinders/cubes shall include the batches from which
samples were taken to make the first and the last cylinders/cubes in the group of four, together with all
the intervening batches.
G) Action to be taken in the Event of Non-Compliance with the Testing Plan
When the average strength of four consecutive test cylinders/cubes fails to meet the first requirement
in (F), above, the mix proportions of subsequent batches of concrete should be modified to increase
the strength.
The action to be taken in respect of the concrete which is represented by the test- cylinders/cubes
which fail to meet either of the requirements (or not by correct statistical proof can be verified to have

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the required strength) shall be determined by the EngineerProject Manager. This may range from
qualified acceptance in less severe cases, to rejection and removal in the most severe cases.
The EngineerProject Manager may also require the Contractor at his own expenses to prove
statistically the strength, by boring out cores and testing them according to a programme approved by
the EngineerProject Manager. The age of the concrete and degree of hardening at the time of the new
testing shall be considered. The equivalent cylinder/cube strength shall comply with the minimum
characteristic strength or as decided by the EngineerProject Manager.
H) Control of Hardening
If the Contractor wants to remove forms and scaffolding earlier than specified herein, extra test
specimens shall be cast by the Contractor in accordance with the instruction of the EngineerProject
Manager. These specimens shall be tested the day before removal of the form. On the basis of the
test results the EngineerProject Manager shall take the final decision on the time for the removal of
forms.
For prestressed concrete, extra test specimens shall be cast by the Contractor in accordance with the
instructions of the EngineerProject Manager, to determine the time for tensioning the tendons. On the
basis of the test results, the EngineerProject Manager shall decide upon the time for prestressing the
concrete.
B.E 7.3.1 General
The Contractor shall in due time and as soon as possible present and discuss his construction
methods and work programme with the EngineerProject Manager and shall obtain his approval before
commencement of any work.
The Contractor shall maintain an adequate number of trained and experienced supervisors and
foremen at the Site to supervise and control the work.
All construction, other than concrete, shall conform to the requirements prescribed in other Sections of
the Specifications, for the particular items of work comprising the complete structure.
B.E 7.3.2 Scaffolding and Formwork
A) Scaffolding (Falsework)
Details, plans and structural calculations for scaffolding shall be submitted by the Contractor to the
EngineerProject Manager for approval, but in no case shall the EngineerProject Manager’s approval
relieve the Contractor of his Contract responsibilities. All scaffolding shall be designed and
constructed by the Contractor to provide the necessary rigidity and to support dead and live loads
without deflection or deformation. The EngineerProject Manager may require the Contractor to employ
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screw jacks or hardwood wedges to take up any settlement in scaffolding and formwork, either before
or during the placing of concrete. Tests may be required by the EngineerProject Manager of materials
proposed by the Contractor for scaffolding. Test loadings of the completed scaffolding may also be
required for the determination of flexibility and strength. All expenses associated with testing shall be
borne by the Contractor.
Scaffolding which cannot be founded on a satisfactory footing shall be supported on piles, which shall
be spaced, driven and removed in a manner approved by the EngineerProject Manager. When the
Contractor wishes to support scaffolding on existing structures, he shall submit his proposals in due
time to the EngineerProject Manager, in writing, including loads from the scaffolding. The
EngineerProject Manager will consider the proposals and respond in writing.
Scaffolding shall be set to give the finished structure a camber, if indicated on the Drawings or
specified by the EngineerProject Manager.
Scaffolding shall remain in place for periods which shall be determined by the EngineerProject
Manager.
B) Formwork
Formwork shall include all temporary or permanent moulds for forming the concrete. Formwork shall
be of wood, metal or other approved materials and shall be built mortar tight and rigid enough to
maintain the concrete in position during placing, compacting, setting and hardening. The Contractor
shall construct the following types of formwork to achieve the specified surface finishes as shown on
the Drawings or directed by the EngineerProject Manager
1) Wrought Formwork
Wrought formwork shall be such as to produce a Class F3 and F4 Concrete Finishes: a true, sound,
smooth finished face on the concrete, free from board marks and other disfigurements and shall be
used for surfaces exposed in the finished work. Panel joints in wrought formwork shall be arranged to
an approved regular pattern. Wrought formwork shall be aligned to a tolerance of ±3 mm but plus and
minus tolerances will not be permitted in close proximity to each other.
2) Steel Formwork
Where internal vibrators are likely to come into contact with the forms, steel formwork shall be used.
All joints and holes shall be caulked or covered with tape which shall be firmly fixed by means of spirit
glue or other oil and grease resistant adhesive. All rivets and bolts on the inside of the formwork shall
be countersunk. Steel formwork shall be painted white on the outside.
3) Rough Formwork
Rough formwork shall be grout proof and may be used for Class F1 and F2 Concrete Finishes which
are not exposed in the finished work.
On surfaces which are to receive waterproofing membrane, imperfections such as fins shall be made
good to the satisfaction of the EngineerProject Manager. Immediately before the waterproofing
operation the surface shall be water jetted or grit blasted to provide a lightly textured finish. The
finished surface shall not deviate from the required profile by more than 5 mm over a 3m gauge length
nor have any abrupt irregularities more than 2 mm.
4) Beams and Slabs
All forms for beams, slabs and similar members shall be designed and constructed so that the sides
may be removed without disturbing the bottom boards or supports thereto.
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5) Narrow Members
Whenever the concreting of narrow members has to be carried out within formwork of considerable
depth, the Contractor shall consider the need for temporary openings in the sides of the forms to
facilitate the placing and consolidation of the concrete. Small temporary openings shall be provided
as necessary at the bottom of forms to permit the expulsion of water, wire, rubbish, and other
deleterious materials prior to placing concrete.
6) Trial Panels
To demonstrate satisfactory workability and to set the standard for surface finishes F3, F4 and F5, the
Contractor shall manufacture representative trial panels/sections for those elements of the structure
above pile cap level using the trial concrete mixes. The panels/sections to be prepared shall be
agreed with the EngineerProject Manager.
The Contractor shall supply for each grade of concrete and for each external surface finish, a section
of formwork complete with reinforcement, prestressing ducts and anchorages, all generally
representative of the sections to be employed in the Works. The capacity of each trial section of
formwork shall be a minimum of 6 m3 of concrete and it shall also form a vertical face of superficial
area not less than 5 m x 2.5 m, and shall contain both horizontal and vertical joints between facing
forms.
The trial panels shall be constructed for approval before commencement of the parts of the Works
incorporating those finishes. A trial panel shall be constructed using the mix for each of the classes of
concrete for which the class of formwork is intended.
The trial panels shall be concreted in the presence of the EngineerProject Manager by the same
personnel and the same equipment as proposed for the Works. This procedure shall, if necessary, be
repeated with modified mixes if either the concrete used does not attain the required minimum
strength or the surface of the concrete after striking the form is not accepted by the EngineerProject
Manager.
When, for each grade of concrete, a trial panel is accepted by the EngineerProject Manager, it shall
be retained on Site for the duration of the Works; all other panels that may have been made for that
grade and location being destroyed.
The trial sections shall be cast before approval can be given by the EngineerProject Manager of the
trial mix and before any concrete is placed in the Works. The Contractor will be responsible for the
demolition and satisfactory disposal of the trial panels.
Where, in the opinion of the EngineerProject Manager, the finished concrete of a trial panel fails to
meet the requirements of the Specification, the panel shall be rebuilt and the trial repeated as
necessary until the EngineerProject Manager’s approval is given. Approved panels shall be retained
as the standard for the class of finish exhibited by the panel.
The Contractor shall dispose of the trial panels off Site when they are no longer required, as agreed
with the EngineerProject Manager.
Formwork for exposed surfaces (“wrought form”) shall be made of dressed lumber of uniform
thickness with or without a form liner of an approved type or shall be of metal sufficiently rigid in itself
with no surface blemishes that will impair the quality of the concrete surface finish. No rusty or bent
metal forms shall be used. Exposed concrete arises shall be provided with formed chamfers, as
indicated on the Drawings or instructed by the EngineerProject Manager.

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Rough lumber may be used for surfaces that will not be exposed in the finished structure (“rough
form”).
All lumber shall be sound, free from warps and twists, sap, shakes, large or loose knots, wavy edge or
other defects affecting the strength or appearance of the finished structure.
All forms shall be set and maintained true to the line designated until the concrete is sufficiently
hardened. Forms shall remain in place for periods, which shall be determined by the EngineerProject
Manager. When forms appear to be unsatisfactory in any way, either before or during the placing of
concrete, the EngineerProject Manager may order the work stopped until the defects are corrected.
If requested, the Contractor shall submit to the EngineerProject Manager working drawings of the
forms and also, if requested, calculations to verify the rigidity and strength of the forms.
The shape, strength, rigidity, watertightness and surface smoothness of reused formwork shall be
maintained at all times. Any warped or bulged lumber must be resized before being reused. Formwork
that is unsatisfactory in any respect shall not be reused.
Metal ties or anchorages within the form shall be so constructed as to permit their removal to a depth
of at least 50 mm from the face without injury to the concrete. All fittings for metal ties shall be of such
design that, upon their removal, the cavities which are left will be of the smallest possible size. The
cavities shall be filled with cement mortar and the surface left sound, smooth, even and uniform in
colour.
Formwork shall be so constructed that easy cleaning out of any extraneous material inside the
formwork can be achieved without disturbing formwork already checked and approved by the
Formwork shall be treated with approved non-staining oil or saturated with water, to facilitate
formwork removal. The EngineerProject Manager may require trials to be carried out before approval
is given for the use of a particular type of oil, to ascertain that the oil proposed by the Contractor does
not discolour or injure the finished concrete face in any way.
Before placing any concrete, all shavings, loose binding wires, soil, rubbish and all foreign matter shall
be removed from the formwork and the formwork shall be carefully and thoroughly washed with water.
If not indicated otherwise, the following tolerances of the finished concrete structures shall apply.
Allowable deviations from plumb or level and from the alignment, profile, grades and dimensions
shown on the Drawings are defined as "tolerances". Tolerances shall be inclusive of surface
irregularities. Deviations from the established lines, grades and dimensions will be permitted to the
extent set forth in BS 5606 and this Section.
The tolerances listed in the following Table B.E 7-5 are the allowable deviations from the dimensions
shown on the Drawings. These tolerances will be a basis for acceptance of the work.
Table B.E 7-5
Description Tolerance (mm unless

shown otherwise)
Variation in Cross Section Dimensions of Columns, Piers,
Crossheads, Slabs, Walls, Beams, and Similar Parts
 ≤ 0.5 m –0 to +5
 ≤3m –5 to +10
 >3m –10 to +15
Deck Joints
 Width of slot –3 to +3
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Description Tolerance (mm unless
shown otherwise)
Variation from Vertical or Specified Batter of Columns,
Piers, Walls, Handrail Posts and Arrises
 Unexposed concrete 10 mm in 3.5 m (1/350)
 Exposed concrete 3 mm in 3.0 m (1/1000)
5 mm in 6 m (1 in 1200)
10 mm in 12 m or more
(1 in 750 max.)
Departure from Plan Position at any Level

 Columns, Piers, Walls, Crossheads, Beams,
Slabs, Kerbs, Railing and other similar parts 20
Departure from Elevation
 Top level of blinding concrete
–30 to +0
 Top level of permanently concealed concrete
–0 to +25
 Level of exposed underside of pier crossheads
–0 to +15
 Top level of other exposed concrete including
bridge deck –0 to +10
Departure from Alignment
 Rows of columns, faces of piers or walls 10
 Handrails, Faces of hand rail posts, Kerbs 5
Maximum Allowance for Irregularities in Exposed

Concrete Surfaces
 Sections less than 1m in dimension when
measured with a straightedge across the 2.5
dimension of the section
 Sections greater than 1m in dimension when
measured with a straightedge across the 3 mm in 3.0 m
dimension of the section, except that when
sections are greater than 3.0 m in dimension,
a 3.0 m straightedge shall be used.
Slab Surface Finish 5 mm in 3.0 m providing
no ponding of water
occurs.
Edge beams and parapets shall be made to such accuracy that no deviations from the correct
alignment are visible.
The cross sectional areas of the superstructure of bridges shall in no place deviate more than 3%
from the theoretically correct cross sectional areas.
Anchors for bearings, expansion joints, railings, etc. shall be placed within the tolerances indicated on
the Drawings or specified by the EngineerProject Manager or in accordance with the component
suppliers’ approved specifications.
C) Blinding Concrete on Single Layer Brick Flat Soling

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A levelling layer of blinding concrete shall be provided as the permanent bottom form for all concrete
structures that will directly bear on prepared soil, whether this blinding concrete is shown on the
Drawings or not. The levelling layer of blinding concrete shall be of thickness not less than 75 mm and
shall be constructed on single layer brick flat soling.
D) Approval of Scaffolding and Formwork
If plans and calculations of scaffolding and formwork are requested by the EngineerProject Manager,
no construction of such scaffolding and formwork shall take place before approval by the
EngineerProject Manager, in writing. Such approval shall not relieve the Contractor of his
responsibilities under the Contract for the adequacy of scaffolding and formwork.
The EngineerProject Manager shall have reasonable time for his examination of the Contractor’s
plans and calculations, especially if scaffolding is introducing temporary loading on new structures.
The Contractor shall not be allowed extensions of Contract time due to awaiting such approval.
The EngineerProject Manager shall inspect all formwork and scaffolding and no concrete shall be
placed until the EngineerProject Manager’s approval has been given. Such approval shall not relieve
the Contractor of any of his responsibilities under the Contract for the successful completion of the
structure.
B.E 7.3.3 Care and Storage of Concrete Materials
A) Storage of Cement
All cement shall be stored in suitable weather proof buildings or silos which will protect the cement
from dampness. These buildings or silos shall be placed in locations approved by the EngineerProject
Manager. Provisions for storage shall be ample, and the shipments of cement as received shall be
separately stored in such manner as to provide easy access for the identification and inspection of
each shipment. Storage buildings shall have a capacity for the storage of a sufficient quantity of
cement to allow sampling at least 14 days before the cement is to be used. Cement shall meet the
test requirements at any time and any cement stored for an elongated time shall be checked and
tested before use regardless of whether it has previously been tested.
B) Storage of Aggregates
Aggregates shall be so stored as to prevent the inclusion of foreign material. Aggregates shall not be
placed upon the finished roadbed. Aggregates of different sizes and kinds shall be placed in different
stockpiles. Stockpiles of blended coarse aggregates shall be built up in successive horizontal layers
not more than 1 meter thick. Each layer shall be completed before the next is started. Should
segregation occur, the aggregates shall be recombined to conform to the grading requirements.
Washed aggregates and aggregates produced or manipulated by methods which involve the use of
water shall be allowed to drain at least 12 hours before use.
B.E 7.3.4 Preparations before Casting

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Before any major casting, the Contractor shall prepare a complete “casting programme” describing
staff and labour, consumption of materials, plant, tools and equipment, reserves of materials, standby
plant and equipment, proposed means of handling and placing the concrete, quality controls, etc.
No concrete shall be mixed and placed until the Contractor’s casting programme has been approved
in writing by the EngineerProject Manager.
Equipment and tools necessary for handling the materials and performing the work to the satisfaction
of the EngineerProject Manager as to the design, capacity, and mechanical condition, shall be at the
Site of the work before casting is started.
If any equipment is not maintained in full working order, or if the equipment as used by the Contractor
proves inadequate to obtain the result prescribed and expected by the EngineerProject Manager,
such equipment shall be repaired or other suitable equipment substituted or added at the discretion of
B.E 7.3.5 Measuring Materials
All material in the concrete mix shall be proportioned by mass although water may be measured by
volume provided two calibrated flow meters are installed in parallel in accordance with Sub-Item
B.E 7.3.6 (C).
B.E 7.3.6 Mixing Concrete
A) General
All concrete shall be mixed in batch mixers, either at the Site of construction, at a central plant, or in
transit. Each mixer shall have attached to it in a prominent place, a manufacturer’s plate showing the
capacity of the drum in terms of mixed concrete and the speed of rotation of the mixing drum.
B) Mixers at Local Site of Construction
Mixers at local Sites shall be approved drum-type capable of combining the aggregate, cement, and
water into a thoroughly mixed and uniform mass within the specified mixing period and of discharging
the mixture without segregation. The mixer shall be equipped with a suitable charging hopper, water
storage and a water measuring device, accurate within 1%. Controls shall be so arranged that the
water can be applied only while the mixer is being charged. Suitable equipment for discharging the
concrete shall be provided. The mixer shall be cleaned at suitable intervals. The pickup and throw-
over blades in the drum shall be replaced when they have lost 10% of their depth.
The mixer shall be operated at a drum speed of between 15 and 20 revolutions per minute. The
batched materials shall be so charged into the drum that a portion of the water shall enter in advance
of the cement and aggregates and the water shall continue to flow into the drum for a minimum time
of 5 seconds after all the cement and aggregates are in the drum. Mixing time shall be measured from
the time all materials except water are in the drum and shall, in the case of mixers having a capacity
of 1 cubic meter or less, not be less than 50 seconds nor more than 70 seconds. In the case of dual
drum mixers, the mixing time shall not include transfer time. The contents of an individual mixer drum
shall be removed before a succeeding batch is emptied therein. Any concrete mixed less than the
specified minimum time shall be discarded and disposed of by the Contractor at his own expense.

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The volume of concrete mixed per batch shall not exceed the mixer’s nominal capacity in cubic feet or
cubic meters as shown on the manufacturer’s guaranteed capacity standard rating plate on the mixer;
except that an overload up to 20% of the mixers nominal capacity may be permitted provided concrete
test data for strength, segregation and uniform consistency are satisfactory, and provided no spillage
of concrete takes place.
Retempering concrete by adding water or by other means shall not be permitted. Concrete which is
not of the required consistency at the time of placement shall not be used and shall be discarded and
disposed off by the Contractor at his own expense.
C) Central Plant Mixers
These mixers shall be of approved drum type capable of combining the aggregate, cement and water
into a thoroughly mixed and uniform mass within the specified mixing period and of discharging the
mixture without segregation. Central plant mixers shall be equipped with an acceptable timing device
that will not permit the batch to be discharged until the specified mixing time has elapsed. The water
system for a central mixer shall be either a calibrated measuring tank or a meter and shall not
necessarily be an integral part of the mixer.
The mixers shall be cleaned at suitable intervals. They shall be examined daily for changes in interior
condition. The pick up and throw-over blades in the drum shall be replaced when they have lost 10%
of their depth.
In addition to the requirements for mixers at local sites detailed above, central plant mixers which
have a capacity of between 2 and 5 cubic meters, or greater than 5 cubic meters, should have a
minimum mixing time of 90 and 120 seconds respectively, provided tests indicate that the concrete
produced is equivalent in strength and uniformity to that attained as stated in the preceding
paragraphs.
Mixed concrete shall be transported from the central mixing plant to the Site of work in agitator trucks
or, upon written permission of the EngineerProject Manager, in non-agitator trucks. Delivery of
concrete shall be so regulated that placing is at a continuous rate unless delayed by the placing
operations. The intervals between deliveries of batches shall not be so great as to allow the concrete
in place to harden partially, and in no case shall such an interval exceed 30 minutes.
D) Agitator Trucks
Unless otherwise permitted in writing by the EngineerProject Manager, agitator trucks shall have
watertight revolving drums suitably mounted and shall be capable of transporting and discharging the
concrete without segregation. The agitating speed of the drum shall not be less than two or more than
six revolutions per minute. The volume of mixed concrete permitted in the drum shall not exceed the
manufacturer’s rating nor exceed 80% the gross volume of the drum.
Upon approval by the EngineerProject Manager, open-top, revolving-blade truck mixers may be used
in-lieu of agitating trucks for transportation of central plant mixed concrete.
Gross volume of agitator bodies expressed in cubic feet or cubic meters shall be supplied by the
mixer manufacturer. The interval between introduction of water into the mixer drum and final
discharge of the concrete from the agitator shall not exceed 45 minutes. During this interval the mix
shall be agitated continuously.
E) Non-Agitator Trucks

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Bodies of non-agitating equipment shall be smooth, water-tight metal containers equipped with gates
that will permit control of the discharge of the concrete. Covers shall be provided when needed for
protection against the weather.
The non-agitating equipment shall permit delivery of the concrete to the Site of the work in a
thoroughly mixed and uniform mass with a satisfactory degree of discharge.
Uniformity shall be satisfactory if samples from the one-quarter and three quarter points of the load do
not differ by more than 30 mm in slump. Discharge of concrete shall be completed within 30 minutes
after the introduction of the mixing water to the cement and aggregate.
F) Truck or Transit Mixers
These shall be equipped with electrically actuated counters by which the number of revolutions of the
drum or blades may readily be verified and the counters shall be actuated at the commencement of
mixing operations at designated mixing speeds. The mixer when loaded shall not be filled to more
than 60% of the drum gross volume. The mixer shall be capable of combining the ingredients of the
concrete into a thoroughly mixed and uniform mass and of discharging the concrete with a satisfactory
degree of uniformity.
Except when intended for use exclusively as agitators, truck mixers shall be provided with a water
measuring device to measure accurately the quantity of water for each batch. The delivered amount
of water shall be within plus or minus 1% of the indicated amount.
Truck mixers may be used for complete mixing at the batch plant and as truck agitators for delivery of
concrete to job sites, or they may be used for complete mixing of the concrete at the job site. They
shall either be a closed watertight revolving drum or an open top revolving blade or paddle type.
The amount of mixing shall be designated in number of revolutions of the mixer drum. When a truck
mixer is used for complete mixing, each batch of concrete shall be mixed for between 70 and 100
revolutions of the drum or blades at the rate of rotation designated by the manufacturer of the
equipment as the “mixing speed”. Such designation shall appear on a metal plate attached to the
mixer. If the batch is at least 0.5 cubic meters less than guaranteed capacity, the number of
revolutions at mixing speed may be reduced to not less than 50. Mixing in excess of 100 revolutions
shall be at the agitating speed. All materials, including the mixing water, shall be in the mixer drum
before actuating the revolution counter which will indicate the number of revolutions of the drum or
blades.
When wash water (flush water) is used as a portion of the mixing water for the succeeding batch, it
shall be accurately measured and taken into account in determining the amount of additional mixing
water required. When wash water is carried on the truck mixer, it shall be carried in a compartment
separate from the one used for carrying or measuring the mixing water. The EngineerProject Manager
will specify the amount of wash or flush water, when permitted; any may specify a “dry” drum if wash
water is used without measurement or without supervision.
When a truck is used for complete mixing at the batch plant, mixing operations shall begin within 30
minutes after the cement has been added to the aggregate. After mixing, the truck mixer shall be used
as an agitator, when transporting concrete, at the speed designated by the manufacturer of the
equipment as agitating speed. Concrete discharge shall be completed within 45 minutes after the
addition of the cement to the aggregates. Each batch of concrete delivered at the job site shall be
accompanied by a time slip issued at the batching plant, bearing the time of departure therefrom.

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When the truck mixer is used for the complete mixing of the concrete at the job site, the mixing
operation shall begin within 30 minutes after the cement has been added to the aggregates.
The rate of discharge of the plastic concrete from the mixer drum shall be controlled by the speed of
rotation of the drum in the discharge direction with the discharge gate fully open.
B.E 7.3.7 Preparation for Handling and Placing Concrete
A) Preparation for Placing Concrete
1) General
Concrete shall not be placed in water unless the method of depositing the concrete has been
approved. In no circumstances shall concrete be placed in running water or be subject to the action
of running water until after the concrete has hardened.
All surfaces of forms and embedded materials that have become encrusted with dried mortar or grout
from concrete previously placed, shall be cleaned of all such mortar or grout before the surrounding or
adjacent concrete is placed.
2) Cleaning Foundations
Immediately before placing concrete, all surfaces of foundations upon or against which the concrete is
to be placed, shall be free from standing water, mud, debris, oil, objectionable coatings and loose,
semi-detached or unsound fragments. Where necessary or required by the EngineerProject
Manager, surfaces of foundations shall be cleaned with high pressure air-water jets. Cleaning shall
be to the satisfaction of the EngineerProject Manager.
The surfaces of absorptive foundations against which concrete are to be placed shall be moistened
thoroughly so that moisture will not be drawn from the freshly placed concrete. Where directed an
approved water barrier such as 0.25 mm thick polyethylene sheet shall be used to cover absorbent
foundations.
3) Cleaning Previously Placed Concrete Surfaces
The surfaces of construction joints shall be clean and damp when to be covered with fresh concrete or
mortar. Cleaning shall consist of the removal of all laitance, loose or defective concrete, coatings,
sand, curing compound if used, and other foreign material and exposure of the tops of the aggregate
(without damaging the aggregate or undercutting or weakening its bond) to the satisfaction of the
The surfaces of blockouts against which concrete is to be placed shall be roughened by scabbling.
The surfaces of construction joints, not prepared at the completion of the previous placement, shall be
roughened by scabbling or other approved means to achieve the above requirement.
The surfaces of all construction joints, including surfaces of blockouts, shall be washed thoroughly
with high pressure air-water jets immediately before placing adjoining concrete. All pools of water
shall be removed from the surfaces of construction joints before the new concrete is placed.
The surfaces of all contraction joints shall be cleaned thoroughly of accretions of concrete or other
foreign material.

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B) Handling and Placing Concrete
The temperature of concrete at the time of placing shall not exceed 30 0C
1) Precautions during Inclement Weather
During windy weather, special care shall be taken to protect new concrete from the harmful effects of
drying winds.
During wet weather the concrete shall be adequately protected as soon as it is in position. Concreting
shall not be carried out during periods of continuous heavy rain unless it is completely covered during
mixing, transporting and placing.
2) Concreting during Hot Weather
During hot weather, steps shall be taken to reduce the concrete temperature and rate of water
evaporation by proper attention to the cooling of the mixing water before use, production methods and
the handling and curing and adopting measures recommended in the American Concrete Institute
Manual of Concrete Practice “Hot Weather Concreting”, reference ACI 305R. Proposals for hot
weather concreting shall be included with the submissions for trial mixes under Item B.7.2.3 (C) of this
Specification.
Concreting in conditions where the shade air temperature exceeds 30 oC will only be permitted when
the Contractor’s proposals for ensuring that the concrete quality will not be impaired have been
accepted by the EngineerProject Manager.
Aggregates shall be shaded in accordance with the recommendations contained in the above ACI
standard. If ice is added to the mixing water, it shall be crushed by a flaking machine and shall be
completely melted before the mixing is complete.
During hot weather, the Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between its discharge from the
mixer and compaction in its final position.
Not withstandingNotwithstanding the above recommendations concreting shall not be carried out
when:
(i) The shade air temperature exceeds 35C; or

(ii) The formwork temperature exceeds 35C, or
(iii) The concrete mix would exceed 30C within 5 minutes of placing; or
(iv) The rate of evaporation from the surface exceeds 1 kg/m2/hour; or
(v) During heavy rain conditions.
In preparation for the placing of concrete all sawdust, chips and other construction debris and
extraneous matter shall be removed from the interior of forms. Struts, stays and braces, serving
temporarily to hold the forms in correct shape and alignment, pending the placing of concrete at their
locations, shall be removed when the concrete placing has reached an elevation rendering their
service unnecessary. These temporary members shall be entirely removed from the forms and not
buried in the concrete.
Concrete must reach its final position in the forms within 20 minutes of the completion of mixing, or as
directed by the EngineerProject Manager.
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Concrete shall be placed so as to avoid segregation of the materials and the displacement of the
reinforcement. The use of long troughs, chutes and pipes for conveying concrete from the mixer to the
forms shall be permitted only on written authorization of the EngineerProject Manager. In case an
inferior quality of concrete is produced by the use of such conveyors, the EngineerProject Manager
may order discontinuance of their use and the institution of a satisfactory method of placing.
Open troughs and chutes shall be of metal or metal lined. Where long steep slopes are required, the
chutes shall be equipped with baffles or be in short lengths that reverse the direction of movement.
All chutes, troughs and pipes shall be kept clean and free from coatings of hardened concrete by
thoroughly flushing with water after each run. Water used for flushing shall be discharged clear of the
structure.
When placing operations would involve dropping the concrete more than 1.5 m, it shall be deposited
through sheet metal or other approved pipes. As far as practicable, the pipes shall be kept full of
concrete during placing and their lower ends shall be kept buried in the newly placed concrete. After
initial set of the concrete, the forms shall not be jarred and no strain shall be placed on the ends of
reinforcement bars which project.
Concrete, during and immediately after depositing, shall be thoroughly compacted. The compaction
shall be done by mechanical vibration subject of the following provisions:
1) The vibration shall be internal unless special authorization of other methods is given by the
EngineerProject Manager or as provided herein.
2) Vibrators shall be of a type and design approved by the EngineerProject Manager. They shall
be capable of transmitting vibration to the concrete at frequencies of not less than 4,500
impulses per minute.
3) The intensity of vibration shall be such as to visibly affect a mass of concrete of 20 mm slump
over a radius of at least 450 mm.
4) The Contractor shall provide a sufficient number of vibrators to properly compact each batch
immediately after it is placed in the forms.
5) Vibrators shall be manipulated to thoroughly work the concrete around the reinforcement and
embedded fixtures, and into the corners and angles of the forms. Vibration shall be applied at
the point of deposit and in the area of freshly deposited concrete. The vibrators shall be inserted
and withdrawn from the concrete slowly. The vibration shall be of sufficient duration and
intensity to thoroughly compact the concrete, but shall not be continued so as to cause
segregation. Vibration shall not be continued at any one point to the extent that localized areas
of grout are formed. Application of vibrators shall be at points uniformly spaced and not further
apart than twice the radius over which the vibration is visibly effective.
6) Vibration shall not be applied directly or through the reinforcement to sections or layers of
concrete which have hardened to the degree that the concrete ceases to be plastic under
vibration. It shall not be used to make concrete flow in the forms over distances so great as to
cause segregation, and vibrators shall not be used to transport concrete in the forms.
7) Vibration shall be supplemented by such spading as is necessary to ensure smooth surfaces

and dense concrete along form surfaces and in corners and locations impossible to reach
with the vibrators.

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The provisions of this Section shall also apply to precast piling, concrete cribbing and other precast
members except that, if approved by the EngineerProject Manager, the manufacturer’s methods of
vibration may be used.
Concrete shall be placed in horizontal layers not more than 600 mm thick except as hereinafter
provided. When less than a complete layer is placed in one operation, it shall be terminated in a
vertical bulkhead. Each layer shall be placed and compacted before the preceding batch has taken
initial set to prevent injury to the green concrete and avoid surfaces of separation between the
batches. Each layer shall be compacted so as to avoid the formation of a construction joint with a
preceding layer which has not taken initial set.
When the placing of concrete is temporarily discontinued, the concrete, after becoming firm enough to
retain its form, shall be cleaned of laitance and other objectionable material to a sufficient depth to
expose sound concrete. To avoid visible joints as far as possible upon exposed faces, the top surface
of the concrete adjacent to the forms shall be smoothed with a trowel. Where a “feather edge” might
be produced at a construction joint, as in the sloped top surface of a wing wall, an inset form shall be
used to produce a blocked out portion in the preceding layer which shall produce an edge thickness of
not less than 150 mm in the succeeding layer. Work shall not be discontinued within 450 mm of the
top of any face, unless provision has been made for a coping less then 450 mm thick, in which case, if
permitted by the EngineerProject Manager, a construction joint may be made at the under side of the
coping.
Immediately following the discontinuance of placing concrete all accumulations of mortar splashed
upon the reinforcement steel and the surfaces of forms shall be removed. Dried mortar chips and dust
shall not be puddled into the unset concrete. If the accumulations are not removed prior to the
concrete becoming set, care shall be exercised not to injure or break the concrete-steel bond at and
near the surface of the concrete, while cleaning the reinforcement steel.
For simple spans, concrete shall preferably be deposited by beginning at the centre of the span and
working from the centre toward the ends. Concrete in girders shall be deposited uniformly for the full
length of the girder and brought up evenly in horizontal layers. For continuous spans, the concrete
placing sequence shall be as shown on the plans or agreed on by the EngineerProject Manager.
Concrete in slab and girder haunches less than 1.0 meter in height shall be placed at the same time
as that in the girder stem.
Concrete in slab spans shall be placed in one continuous operation for each span unless otherwise
provided.
Concrete in T-beam or deck girder spans may be placed in one continuous operation if permitted by
Concrete in columns and pier shafts shall be placed in one continuous operation, unless otherwise
directed.
Unless otherwise permitted by the EngineerProject Manager, no concrete shall be placed in the
superstructure until the column forms have been stripped sufficiently to determine the character of the
concrete in the columns. The load of the superstructure shall not be applied to the supporting
structures until they have been in place at least 21 days and achieved the characteristics strength,
unless otherwise permitted by the EngineerProject Manager.
Pneumatic placing of concrete shall be permitted only if authorized by the EngineerProject Manager.
The equipment shall be so arranged that vibration does not damage freshly placed concrete.

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Where concrete is conveyed and placed by pneumatic means the equipment shall be suitable in kind
and adequate in capacity for the work. The machine shall be located as close as practicable to the
place of deposit. The position of the discharge end of the line shall not be more than 3 meters from
the point of deposit. The discharge lines shall be horizontal or inclined upwards from the machine. At
the conclusion of placement the entire equipment shall be thoroughly cleaned.
Placement of concrete by pumping shall be permitted only if authorized by the EngineerProject

Manager. The equipment shall be so arranged that vibrations do not damage freshly placed concrete.
Where concrete is conveyed and placed by mechanically applied pressure, the equipment shall be
suitable in kind and adequate in capacity for the work. The operation of the pump shall be such that a
continuous stream of concrete without air pockets is produced. When pumping is completed, the
concrete remaining in the pipeline, if it is to be used, shall be ejected in such a manner that there is no
contamination of the concrete or separation of the ingredients. After this operation, the entire
equipment shall be thoroughly cleaned.
B.E 7.3.8 Perforations and Embedment of Special Devices
The Contractor is responsible for determining in advance of making any concrete pours, all
requirements for perforation of concrete sections or embedment therein of special devices of other
trades, such as conduits, pipes, weep holes, drainage pipes, fastenings, etc. Any concrete poured
without prior provision having been made, shall be subject to correction at the Contractor’s expense.
Special devices to be embedded:
 Expansion joints
 Drain outlets including fixing bolts for down pipes
 Bolts and inserts for sign posts
 Bolts and inserts for various purposes regarding inspection and maintenance as directed by the
EngineerProject Manager
Other devices not mentioned above will be shown on the Drawings, or directed by the
EngineerProject Manager. The inserts and fittings shall conform to Items B.E 11 and B.E 12 of this
Specification or as specified elsewhere in the Specification or on the Drawings.
B.7.3.9 Finishing Concrete Surfaces
A)
A) Formed Concrete Surface Finishes
Formed concrete finishes shall be as described in the Table B.E 7-6 below
Table B.E 7-6 – Formed Concrete Surface Finishes

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Class Formed Finish Treatment (if any) after Stripping
Formwork
F1 As struck For areas to be waterproofed:
Immediately after removal of the
formwork all fins and irregular projections
shall be removed by use of a bush
hammer tool form.
F2 The irregularities in the finish shall The finish is intended to be left as struck
be no greater than those obtained but imperfections such as fins and
from the use of wrought square surface discolouration shall be made
edged boards arranged in a uniform good. All cavities produced by ties,
pattern. broken corners and other defects shall be
cleaned thoroughly, and after wetting
shall be pointed and trued with a mortar
similar in constituent parts so that when
dry, matches the surrounding concrete.
All bulges and offsets to be removed by
using a powered disc grinder.
No embedded parts will be permitted.
F3 The finish shall be smooth and of None.

uniform texture and appearance.
The formwork lining shall leave no However, if there are non-compliances
stain on the concrete and shall be so when compared with the agreed trial
joined and fixed to its backing that it panels, then subject to the agreement of
imparts no blemishes. It shall be of the EngineerProject Manager the
the same type and obtained from Contractor may be allowed to make good
only one source throughout any one any imperfections in the finish.
structure. Internal ties and Techniques for making good must be
embedded metal shall not be used. agreed with the EngineerProject
Manager.
F4 As for F3, except that internal ties None.
and embedded metal parts shall be
permitted. The ties and formwork However, if there are non-compliances
joints shall be set out to form a when compared with the agreed trial
regular pattern of vertical and panels, then subject to the agreement of
horizontal lines continuously, and the EngineerProject Manager the
should be set out from expansion Contractor may be allowed to make good
and movement joints where they any imperfections in the finish.
occur. Techniques for making good must be
agreed with the EngineerProject
Manager.
F5 Formed finish to be produced using None.

a controlled permeability liner fixed
to backing firmly, with no residual However, if there are non-compliances
joints. A well compacted surface with when compared with the agreed trial
no blemishes, an even texture and panels, then subject to the agreement of
no discolouration nor micro pores. the EngineerProject Manager the
Internal ties and embedded Contractor may be allowed to make good
materials shall only be permitted on any imperfections in the finish.
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Class Formed Finish Treatment (if any) after Stripping
Formwork
pier faces. Techniques for making good must be
agreed with the EngineerProject
Manager.
One of the following types of finishing shall be applied to unformed concrete surfaces.
Unformed concrete finishes shall be as described in the Table B.7-7 below:
Table B.E 7-7 – Unformed Concrete Surface Finishes
Class Unformed Treatment
U1 Manual Float Finish A wood float shall be used where

specified to give an even texture within
specified deviations.
U2 Manual Steel Float Finish As steel float shall be used where
specified to give a smooth, even surface
free from float marks within specified
deviations.
U3 Mechanical Power Float Finish The concrete shall be allowed to stiffen
sufficiently to be properly worked. A
mechanical power float shall then be
used where specified to produce a
smooth, even surface free from pitting,
grooving and indentation within specified
deviations.
Power floated surfaces shall be provided
with a surface dressing of 2 coats of
Nitofloor Lithurin or similar approved,
applied in accordance with the
manufacturer’s instruction.
U4 Tamped Finish The concrete surface, where specified,
shall be tamped with the edge of a board
or beam to give an even texture of
parallel ribs. Wetting of concrete surface
to assist surface working shall not be
permitted.
U5 Finish for Surfaces to receive Class U5 finish is for surfaces that are to
Waterproofing Membrane receive waterproofing systems.The
concrete shall be levelled and screeded
to produce a uniform surface. When the
concrete has sufficiently hardened and
any bleed water evaporated the surface
shall be trowelled to produce a hard
dense surface free from screed marks
and exposed aggregate. Finally the
surface shall be lightly textured with a
wooden float or equivalent. Alternatively
the concrete shall be levelled, screeded

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Class Unformed Treatment
and floated to produce a uniform surface

and immediately before the waterproofing
operation this surface shall be water
jetted or grit blasted to provide a lightly
textured finish.
The finished surface shall not deviate
from the required profile by more than
6 mm over a 3m gauge length or have
any abrupt irregularities more than 3 mm.
The Class of formed and unformed finish shall be as noted on the Drawings or directed by the
The permissible deviations for a floated finish are as follows:
(i) Abrupt irregularities - nil.
(ii) Gradual irregularities under a 3000 mm straight edge – 3 mm.
B.E 7.3.10Construction, Contraction and Expansion Joints
A) General
Construction joints shall be made only where located on the Drawings or shown in the pouring
schedule, unless otherwise approved by the EngineerProject Manager.
If not detailed on the Drawings, or in the case of emergency, construction joints shall be placed as
directed by the EngineerProject Manager. Shear keys or inclined reinforcement shall be used where
necessary to transmit shear or bond the two sections together.
B) Bonding
Before depositing new concrete on or against concrete which has hardened, the forms shall be re-
tightened. The surface of the hardened concrete shall be roughened as required by the
EngineerProject Manager, in a manner that does not leave loosened particles of aggregate or
damaged concrete at the surface. It shall be thoroughly cleaned of foreign matter and laitance, and
saturated with water. To ensure an excess of mortar at the juncture of the hardened and the newly
deposited concrete, the cleaned and saturated surfaces, including vertical and inclined surfaces, shall
first be thoroughly covered with a thin coating of mortar or neat cement grout against which the new
concrete shall be placed before the grout has attained its initial set.
The placing of concrete shall be carried continuously from joint to joint. The face edges of all joints
which are exposed to view shall be carefully finished true to line and elevation.
C) Expansion and Contraction Joints
Expansion and contraction joints shall be formed in the positions and to the details shown on the
Drawings or as otherwise directed or accepted by the EngineerProject Manager. Care shall be taken
in setting movement joints to take due account of the prevailing temperature, for future creep and
shrinkage of the concrete, and for movement of abutments due to earth pressure and settlements.

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B.E 7.3.11Curing Concrete
All concrete surfaces shall be kept thoroughly wet for at least 14 days after placing. Bridge deck and
sidewalk slabs shall be covered with wet hessian immediately after final finishing of the surface. This
material shall remain in place for the full curing period or may be removed and replaced with pool of
water when the concrete has hardened sufficiently to prevent marking. In both cases the materials
shall be kept thoroughly wet for the entire curing period. All other surfaces if not protected by forms,
shall be kept thoroughly wet, either by sprinkling or by the use of wet burlap until the end of the curing
period. The wood forms are allowed to remain in place during the curing period, but they shall be kept
moist at all times to prevent openings at joints.
After a period of 14 days, the concrete shall be watered daily at certain intervals approved by the
EngineerProject Manager to avoid drying out of the surface. This shall take place during the following
2 weeks. The water used shall be the same as used in concrete mixes unless otherwise approved by
During hot weather or the prevalence of drying winds, windbreaks and sunshades may be required,
and in any case shall be used when the rate of evaporation equals or exceeds 1 kg/m2/hour as
determined in accordance with the American Concrete Institute Standard "Hot Weather Concreting",
ACI 305R, Figure 2.1.5.
When deemed necessary by the EngineerProject Manager during periods of hot weather, water shall
be applied to concrete surfaces being cured by the liquid membrane method or by the forms-in-place
method, until the EngineerProject Manager determines that a cooling effect is no longer required.
A) Other Curing Materials:
1) Liquid Membranes
Liquid membrane forming compounds for curing concrete shall conform to the requirements of
AASHTO M 148 (ASTM C309).
2) Waterproof Sheet Materials
Waterproof paper, polyethylene film, and white burlap polyethylene sheet shall conform to the
requirements of AASHTO M 171 (ASTM C171).
B) Further Details of Requirements Curing Methods
Details of all materials and methods proposed by the Contractor at each location shall be submitted to
the EngineerProject Manager for his approval. The Contractor shall demonstrate their use on trial
panels.
1) Forms-In-Place Method
Formed surfaces of concrete may be cured by retaining the forms in place without loosening for the
required time provided the forms do not stain the concrete surfaces.

116129
2) Water Method
Concrete surfaces shall be kept continuously wet by ponding, spraying or covering with materials that
are kept continuously and thoroughly wet. Such materials may consist of cotton mats, multiple layers
of burlap or other approved materials which do not discolour or otherwise damage the concrete. This
method will normally only be permitted when used in conjunction with the waterproof cover method.
3) Liquid Membrane Curing Compound Method
The liquid membrane method shall not be used on surfaces where a rubbed finish is required or on
surfaces of construction joints unless it is removed by sand blasting prior to placement of concrete
against the joint. Type 2 white pigmented, liquid membranes may be used only on the surfaces of
bridge decks, on surfaces that will not be exposed to view in the completed work or on surfaces where
their use has been approved by the EngineerProject Manager. Liquid membranes shall be a
minimum 95% efficient to BS 7542.
When membrane curing is used, the exposed concrete shall be thoroughly sealed immediately after
the free water has left the surface. Formed surfaces shall be sealed immediately after the forms are
removed and necessary finishing has been done. Only a small portion of the forms shall be removed
at any one time, remedial treatment carried out and curing applied before moving on to the next area.
The solution shall be applied by power-operating atomizing spray equipment in one or two separate
applications. Hand-operated sprayers may be used for coating small areas. Membrane solutions
containing pigments shall be thoroughly mixed prior to use and agitated during application. If the
solution is applied in two increments, the second application shall follow the first application within 30
minutes. Satisfactory equipment shall be provided together with means to properly control and assure
the direct application of the curing solution on the concrete surface so as to result in a uniform
coverage at the rate of 1 litre for each 3 square meters of area.
If rain falls on the newly coated concrete before the film has dried sufficiently to resist damage, or if
the film is damaged in any other manner during the curing period, a new coat of the solution shall be
applied to the affected portions equal in curing value to that above specified.
Where the Contractor proposes to use a curing membrane on surfaces on which a waterproofing
membrane is to be laid, such as but not only the bridge deck, it shall be completely removable or
compatible with the system. Where the Contractor proposes the use of a curing membrane on
surfaces to be coated, it shall be of a film type that fully degrades by exposure to ultraviolet light within
an approved period of time, without leaving a residue that is detrimental to the coating of the concrete.
4) Waterproof Cover Method
This method shall consist of covering the surface with a waterproof sheet material so as to prevent
moisture loss from the concrete. This method may be used only when the covering can be secured
adequately to prevent moisture loss.
The concrete shall be wet at the time the cover is installed. The sheets shall be of the widest
practicable width and adjacent sheets shall overlap a minimum of 150 mm and shall be tightly sealed
with pressure sensitive tape, mastic, glue, or other approved methods to form a complete waterproof
cover of the entire concrete surface. The sheets shall be secured so that wind will not displace them.
Should any portion of the sheets be broken or damaged before expiration of the curing period, the
broken or damaged portions shall be immediately repaired. Sections that have lost their waterproof
qualities shall not be used.
5) Steam or Radiant Heat Curing Method
This method may be used only for precast concrete members manufactured in established plants.
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Steam curing or radiant heat curing shall be done under a suitable enclosure to contain the live steam
or the heat. Steam shall be low pressure and saturated. Temperature recording devices shall be
employed as necessary to verify that temperatures are uniform throughout the enclosure and within
the limits specified.
The initial application of the steam or of the heat shall be from 2 to 4 hours after the final placement of
concrete to allow the initial set of the concrete to take place. If retarders are used, the waiting period
before application of the steam or of the radiant heat shall be increased to between 4 and 6 hours
after placement. The time of initial set may be determined by the Standard Method of Test for "Time
of Setting of Concrete Mixtures by Penetration Resistance" AASHTO T 197 (ASTM C 403), and the
time limits described above may then be waived.
During the waiting period, the temperature within the curing chamber shall not be less than 10 0C and
live steam or radiant heat may be used to maintain the curing chamber at the proper minimum
temperature. During this period the concrete shall be kept wet.
Application of live steam shall not be directed on the concrete or on the forms so as to cause localized
high temperatures. During the initial application of live steam or of radiant heat, the ambient
temperature within the curing enclosure shall increase at an average rate not exceeding 20 0C per
hour until the curing temperature is reached. The maximum curing temperature within the enclosure
shall not exceed 700C. The maximum temperature shall be held until the concrete has reached the
desired strength. In discontinuing the steam application, the ambient air temperature shall not
decrease at a rate to exceed 20 0C per hour until a temperature 100C above the temperature of the air
to which the concrete will be exposed has been reached.
Radiant heat may be applied by means of pipes circulating steam, hot oil or hot water, or by electric
heating elements. Radiant heat curing shall be done under a suitable enclosure to contain the heat,
and moisture loss shall be minimized by covering all exposed concrete surfaces with plastic sheeting
or by applying an approved liquid membrane-curing compound to all exposed concrete surfaces. Top
surfaces of concrete members to be used in composite construction shall be clear of residue of the
membrane curing compound so as not to reduce bond below design limits. Surfaces of concrete
members to which other materials will be bonded in the finished structure shall be clear of residue of
the membrane curing compound so as not to reduce bond below design limits.
Unless the ambient temperature is maintained above 15 0C for prestressed members, the transfer of
the stressing force to the concrete shall be accomplished immediately after the steam curing or the
heat curing has been discontinued.
6) Bridge Decks
The top surfaces of bridge deck top and bottom slabs and approach slabs shall be cured by a
combination of the liquid membrane curing compound method and the water method. The liquid
membrane shall be Type 2 white pigmented and shall be applied progressively and immediately after
finishing operations are complete on each portion of the deck. The water cure shall be applied not
later than 4 hours after completion of deck finishing or, for portions of the decks on which finishing is
completed after normal working hours, the water cure shall be applied not later than the following
morning.
Any proposal from the Contractor for the use of liquid membrane curing compound shall be subject to
the approval of the Engineerapproval of the Project Director.

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B.E 7.3.12Removal of Scaffolding and Formwork
Forms and scaffolding shall not be removed without the approval of the Engineerapproval of the
Project Director. The EngineerProject Manager’s approval shall not relieve the Contractor of his
Contract responsibilities. Any kentledge blocks and bracing shall be removed at the same time as the
forms and in no case shall any portion of the wood forms be left in the concrete.
Forms used on exposed vertical faces shall remain in place for periods which shall be determined by
the EngineerProject Manager and normally not less than 3 days.
Supporting scaffolding and forms under slabs, beams and girders shall normally remain in place until
the full required strength of the concrete has been obtained. If a shorter period is requested, this may
be permitted by the EngineerProject Manager. In such case, special test specimens (see Item B.E
7.2.4) shall be cast to monitor the hardening.
All structures shall be fully stripped before adjacent structures are cast.
B.E 7.3.13Repair of Concrete
As soon as the form has been stripped, the Contractor shall advise the EngineerProject Manager who
shall inspect the concrete before any improvement of the surface takes place.
All wire or metal devices used for securing the formwork which project from or appear on the surface
of the finished concrete shall be removed or cut back to at least a depth equal to the required
reinforcement cover. All holes and pockets so formed shall be filled with cement mortar mixed in the
same proportions as the fine aggregate to cement of the concrete mix used for that particular section
of the structure, after the surface to be patched has been thoroughly cleaned and wetted to receive
the patch.
Excessive honeycombing shall be sufficient to cause rejection of portions of the structure containing
this honeycombing. The Contractor, on receipt of written orders from the EngineerProject Manager,
shall remove and rebuild such portions of the structure at his own expense to the satisfaction of the
Smaller honeycombing and other defects can be repaired if permitted by the EngineerProject
Manager. Structural maintenance and aesthetical points of view shall be taken into consideration
before such approval, if any, may be given. The method of repair shall be approved by the
EngineerProject Manager and an extension of period for a certain part of the performance bond may
be required.
Repair of concrete shall be performed by skilled workmen. Unless inspection is waived by the
EngineerProject Manager in each specific case, repair of concrete shall be performed only in the
presence of the EngineerProject Manager. The requirements of this section of the Specification shall
not negate the EngineerProject Manager’s entitlement to reject concrete for any of the reasons given
in this Specification.

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The Contractor shall correct all imperfections on the concrete surfaces as necessary to produce
surfaces that conform to those specified. For formed concrete, where the forms are removed within
3 days of concrete placement and repair of imperfections completed within 24 hours after removal of
forms, or for unformed concrete where repairs are completed within 24 hours after the placing of the
concrete, repairs shall be dry-pack, mortar or concrete repairs. Otherwise repairs shall be epoxy resin
repairs.
Fins and encrustations shall be neatly removed from formed surfaces and encrustations shall be
removed from unformed surfaces.
Concrete that is damaged from any cause and concrete that is honeycombed, fractured or otherwise
defective, and concrete which is rejected because of excessive surface depressions, shall be rectified
by removing to the extent instructed by the EngineerProject Manager and built up with dry-pack,
mortar, or concrete, as hereinafter specified, to bring the surface to the prescribed lines and surface
finish. Where bulges and abrupt irregularities protrude outside the limits specified on formed
surfaces, the protrusions shall be reduced by bush-hammering and grinding so that the surfaces are
within the specified limits. After the dressing, the irregularities shall not exceed the limits specified.
A) Dry-pack
Dry-pack shall be used for filling holes having a depth greater than the least surface dimension; for
narrow slots cut for repair of cracks; and for tie-rod fastener recesses as specified. Dry-pack shall not
be used for filling behind reinforcement or for filling holes that extend completely through a concrete
section.
Dry-pack shall be composed of a mix of 1 part of cement, by volume, to 2.5 parts, by volume, of fine
aggregate passing a 1.18 mm sieve, together with enough water to produce a mortar which will just
stick together when moulded into a ball by a light pressure of the hands and will not exude water, but
will leave the hands damp.
Dry-pack shall be placed and packed into under-cut holes in layers each having a thickness of
approximately 10 mm. Packing shall be carried out with a hardwood stick struck with a hammer to
compress the dry-pack thoroughly into contact with the surfaces of the hole.
B) Mortar
Mortar-filling, placed under impact by use of a mortar gun, shall be used for repairing defects which
are too wide for dry-pack fillings and too shallow for concrete filling and no deeper than the far side of
the reinforcement that is nearest the surface. All areas to be repaired with mortar shall be trimmed
square for a minimum depth of 10 mm.
C) Concrete
Concrete-filling shall be used for holes extending entirely through concrete sections; for holes which
are greater in area than 0.10 m2 and deeper than 80 mm; and for holes in reinforced concrete which
are greater in area than 0.05 m2 and which extend beyond the reinforcement that is nearest the
surface. All areas to be repaired with concrete shall be trimmed square for a minimum depth of
30 mm.
D) Epoxy Resin
Epoxy resin repairs shall be used where approved. Epoxy resin repairs shall not be made until
28 days after the concrete has been placed, unless earlier repairs are approved, and shall be
completed within 56 days after the concrete has been placed. All materials used for epoxy resin
repairs shall be subject to approval.

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Epoxy resin repairs shall be carried out in accordance with the manufacturer’s recommendations and
as follows:
(i) All imperfections to be repaired with epoxy resin shall be chipped back to sound concrete and
the edges of the holes trimmed square for a minimum depth of 3 mm;
(ii) Immediately before performing a repair, the surface of the concrete to be repaired shall be freed
of all contaminants by grit blasting, scabbling, and shall present a clean, sound, dry, roughened
and dust free surface with the surface temperature not less than 13 oC; and
(iii) Where directed a bonding coat of an unfilled, solvent free epoxy resin shall be placed on the
prepared surface. The repair material, consisting of an approved filled resin or an unfilled resin
with sand or other approved fillers added on Site, prepared, batched and mixed in accordance
with the manufacturer's instructions, shall be placed and given a smooth finish. The repair shall
be cured by maintaining it at a temperature not less than 21 oC for a period of 24 hours.
E) Staining of Concrete
For exposed concrete surfaces, care shall be taken that accumulation of foreign materials or staining
due to any cause does not occur on the finished surface. Any accumulation or staining shall be
cleaned off by the Contractor at his expense.
F) Plugging Form-tie Holes
In formed concrete, surface holes remaining after dismantling form-ties shall be cleaned out and
neatly plugged with dry-pack. The dry-pack shall be colour matched with surrounding concrete.
B.E 7.3.14Depositing Concrete under Water
Concrete shall not be deposited in water except with the approval of the Engineerapproval of the
Project Director and under his immediate supervision; and in this case the method of placing shall be
as defined in this Section.
Concrete placed under water shall be carefully placed in a compact mass, in its final position, by
means of a tremie tube and shall not be disturbed after being deposited. Special care must be
exercised to maintain still water at the point of deposit. Concrete shall not be placed in running water.
The method of depositing concrete shall be so regulated as to produce approximately horizontal
surfaces.
Concrete seals shall be placed in one continuous operation. When a tremie tube or pipe is used, it
shall consist of a tube or pipe not less than 200 mm in diameter. All joints in the tube shall be
watertight. The means of supporting the tremie tube shall be such as to permit free movement of the
discharge end over the entire top of the concrete and to permit its being lowered rapidly when
necessary to choke off or retard the flow. The tremie tube shall be filled by a method that prevents
washing of the concrete. The discharge end shall be completely submerged in concrete at all times
and the tremie tube shall be kept full. Concrete slump shall not be less than 150 mm.
Dewatering shall proceed only when the concrete seal is considered strong enough to withstand any
pressure to be exerted upon it. This time shall be decided by the EngineerProject Manager.
All laitance or other unsatisfactory material shall be removed from the exposed surface by scraping,
jetting, chipping or other means, which do not injure the seal unduly.
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B.E 7.3.15Factory and Site Made Precast Concrete Elements
Any supplier of precast concrete elements shall be approved in writing by the EngineerProject
Manager. Such approval can be withdrawn at any time.
Concrete work in precast concrete elements shall fully conform with all relevant Sections of these
Specifications.
The supplier shall maintain laboratory facilities of the same standard as the Site laboratory.
Unless otherwise approved by the EngineerProject Manager, precast concrete members shall not be
moved from the casting position until the concrete has attained a compressive strength of 80% of the
specified 28 day strength, nor transported until it has developed a strength of 90% of the specified 28
day strength.
Extreme care shall be exercised in handling and moving precast concrete members. Precast girders
and slabs shall be transported in an upright position. Shock shall be avoided and the points of support
and directions of the reactions with respect to the member shall be approximately the same during
transportation and storage as when the member is in its final position. If the Contractor deems it
expedient to transport or store precast units in other than this position, this shall be at the Contractor’s
risk, after notifying the EngineerProject Manager of his intention to do so. Any rejected unit shall be
replaced at the Contractor’s expense by an acceptable unit.
Proposed details on the handling and transportation of precast concrete members shall be submitted
in writing by the Contractor, to the EngineerProject Manager, for his approval. Each precast member
is to be uniquely and permanently marked so as to show its type, date of casting and any other
information required by the EngineerProject Manager.
The tolerances specified shall be applied to the completed work. The length of the first cast units on a
job shall be measured. The Contractor or supplier shall make adjustments to ensure all subsequent
units are within tolerances.
()i) Length:
The overall length of any unit and the length from centre to centre of the bearings of each end shall
not vary by more than 0.06% from the specified length with a maximum variation of 20 mm.
()ii) Cross sectional dimensions:
 sections less than 80 mm ±1.5 mm

 sections over 80 mm and up to 1000 mm ±3.0 mm
 sections over 1000 mm ±6.0 mm.
()iii) Deviation from Specified Camber
Deviation from the specified camber shown on the Drawing shall be not greater than ±1.5 mm per 3 m
of span.
()iv) Bow

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At any section, the longitudinal centre line shall not deviate in the transverse direction from a straight
line joining the centre points of the ends of the unit by more than 10 mm bow for units up to 15 m long,
12 mm bow for units over 15 m up to 20 m long, and a maximum 17 mm bow for units over 20 m long.
B.E 7.3.16Control of Heat in Structures
In structures of major dimensions i.e., pile caps, etc. the heat deriving from the hardening of the
concrete shall be controlled by the Contractor. Temperature gradients introducing risk of cracking
shall not occur and the temperature shall not exceed 70 0C.
The Contractor shall submit timely proposals for avoiding excessive heat generation, such as the
cooling of aggregates before mixing, to the EngineerProject Manager for approval Refer to Sub-Item
B.7.3.7 B).
B.E 7.3.17Backfill to Structures
All spaces which have been excavated and the volumes of which are not occupied by the concrete
structure shall be backfilled and compacted with acceptable material in accordance with the
provisions of Item B.6 as directed by the EngineerProject Manager.
All precautions necessary shall be taken during backfilling and compaction at or near completed
structures or existing structures not forming part of this Contract so that no damage will be caused to
them during backfilling and ensuing compaction.
B.E 7.3.18Cleaning Up
Upon completion of a structure and before final acceptance, the Contractor shall remove all forms and
scaffolding etc. from the Site. Excavated or useless materials, rubbish etc. shall be removed from the
Site and the Site shall be left in a neat and tidy condition satisfactory to the EngineerProject Manager.
B.E 7.3.19Concrete Pours Early Age Crack Control and Trials
The Contractor’s attention is drawn to the very large pours of concrete that will be required in a hot
climate. The Contractor shall make detailed proposals supported by calculations for the control of
early age thermal cracking in all large concrete pours. This shall take account of the mix design, pour
sequence and timing, environmental conditions, construction methods and proposals for cooling
systems and the reinforcement included in the permanent works. Any proposal to modify the
reinforcement shall be submitted to the EngineerProject Manager for review and approval.
The Construction Proposals shall incorporate detailed proposals for trials and tests including
representative full scale trials of concrete pour of critical components. These components shall
include web pours with multiple tendons in the deck cross-section and critical components with cast in
items.
The trials shall be designed to verify the Contractor’s proposals for mix design, placement and

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compaction of concrete.
B.E 7.3.20Temporary Works
The Contractor shall furnish to the EngineerProject Manager complete drawings of all Temporary
Works and stagings he may require for the purpose of carrying out the Works. He shall at the same
time, if so required by the EngineerProject Manager submit his calculations relating to the strength
and anticipated deflections in respect of any of the aforesaid Temporary Works. The Contractor shall
also furnish detailed drawings showing methods he proposes to adopt for the erection of the various
parts of the Temporary Works. All Temporary Works shall be properly designed and substantially
constructed for the loads which they will be called upon to bear. The Contractor shall also present
calculations to show that his proposals do not cause any damage to the permanent structure.
Without prejudice to the other provisions of the Contract, the Contractor shall in connection with the
Temporary Works he has designed submit to the EngineerProject Manager a certificate or certificates
of the following form.
"I certify, but without undertaking any responsibility other than towards (insert name of Contractor)
that in my opinion the Contractor’s Temporary Works designs specified in the schedule attached
hereto are satisfactory for the proper discharge of his responsibilities under the Contract, for the
safety of the said part of the Works and for their safe execution in accordance with the Drawings and
Specification and without detriment to the related Permanent Works."
Each certificate shall be signed by an EngineerProject Manager with appropriate qualifications and
experience who has not been concerned with the original design.
Notwithstanding the furnishing of such drawings and calculations for the Temporary Works, etc., the
Contractor shall remain wholly and entirely responsible until the removal of such works for their
efficiency, security and maintenance and for all obligations and risks in regard to such work specified
or implied in this Contract.
Concrete shall be measured by the number of cubic meters of class and maximum coarse aggregate
size indicated on the Drawings or listed in the Bill of Quantities complete in place and accepted by the
EngineerProject Manager. In computing quantities, the dimensions used shall be those shown on the
Drawings or instructed by the EngineerProject Manager. No deduction from the measured quantity
shall be made for drainage, pipes less than 300 mm in diameter, conduits, chamfers, reinforcement
bars, prestressing tendons, expansion joints, water stops or pile heads embedded in concrete.
Reinforcing steel shall be measured for payment as described in Specifications Item BE .8.
Formwork, scaffolding (falsework), construction joints and surface finishes shall not be measured
separately but shall be deemed to be an integral part of the concrete items. Single layer brick flat
soling under blinding concrete for concrete structures bearing directly on prepared soil shall be
easured in m². The measured area will be the same as that of the base area of the concrete structure.
Concrete of the classes and maximum coarse aggregate sizes shown on the Drawings and measured
as provided in this Section shall be paid for at the Contract unit prices per cubic meter in the priced
Bill of Quantities. The Contractor’s rates shall include all trial mixes (as specified in Item B.7.2.3),
mixing, transporting, placing and compacting the concrete. The rates shall also include all concrete
finishing, curing, the supply, placing and building in of weep pipes or pipe sleeves, forming
construction joints, forming holes or pockets not exceeding 0.15 m³ each.

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The Contractor’s rates shall be fully inclusive of the cost of all labour and materials in providing and
erecting all formwork, falsework and centering and for their subsequent removal.
Payment will not be made for concrete required to be placed outside specified or approved excavation
pay lines due to overbreakage, excess excavation or wasted concrete, or for any other reason.
Separate payment will not be made for carrying out tests and preparing test samples. The entire cost
of securing and testing core specimens of hardened concrete and of removing and replacing rejected
concrete shall be borne by the Contractor.
Separate payment will not be made for any cooling of concrete mix ingredients or concrete to meet
the requirements of the Specification.
Pay items shall be:
Unit of
Measurement
E 7.1 Concrete Class as Detailed on the Drawings and as m3
stated in the Bill of Quantities.
B.7.1 CONCRETE CLASS AS DETAILED ON THE DRAWINGS

CUBIC METER
AND AS STATED IN THE BILL OF QUANTITIES.
B.E 8 REINFORCEMENT
B.E 8.1 Description
This work shall consist of furnishing, testing, cutting, bending and placing bars of the grade, type and
size shown in accordance with these Specifications and in conformity with the requirements shown on
the Drawings.
The Drawings with this Specification show the requirements for the reinforcement. Based on the
Drawings and the Specification, the Contractor shall prepare working shop drawings and complete
reinforcing bar lists, including bar bending details, for each reinforcement detail drawing in an
approved form. All reinforcing bars shown on the reinforcement detail drawings shall be identified on
the bar lists in accordance with the standard reinforcing bar shapes as shown on the Drawings or the
American Concrete Institute Building Code Requirements ACI 318-05. All bar lists shall be identified
with the relevant reinforcement detail drawing and all bars scheduled on the bar lists shall be defined
and dimensioned in an approved manner.
At least twenty-eight (28) days before placing reinforcement at any location, the Contractor shall
furnish to the EngineerProject Manager the working shop drawings and complete reinforcing bar lists
for that structure or the relevant part thereof in accordance with the requirements for Contractor’s
Documents.

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The Contractor shall be responsible for the accuracy of the reinforcing bar bending lists, and cutting,
bending and placing of the reinforcement irrespective of any approval of the working shop drawings
and lists by the EngineerProject Manager
B.E 8.2 Materials
B.E 8.2.1 Bar Reinforcement
All mild steel bars shall have a yield stress not less than 415 N/mm² and shall conform to ASTM A 615
or the latest such equivalent standard or specification in force that is considered by the
EngineerProject Manager to apply.
All high yield steel bars shall be deformed bars with a yield stress not less than 415 N/mm² and shall
conform to ASTM A 615 or the latest such equivalent standard or specification in force that is
considered by the EngineerProject Manager to apply.
The use of cold twisted bars is not permitted. Steel for all bars shall be produced by open hearth,
basic oxygen or electric arc furnace methods, unless otherwise called for on the Drawings or in
special provisions.
B.E 8.2.2 Wire Mesh
Wire mesh shall conform to the requirements of AASHTO Standard Specification M 55 - Welded Steel
Wire Fabric for Concrete Reinforcement.
B.E 8.2.3 Binding Wire
Reinforcement binding wire shall be best black annealed mild steel wire, approximately 1.6 mm in
diameter.
B.E 8.2.4 Bar Sizes
Metric sizes of steel are shown on the Drawings and shall be used.
B.E 8.2.5 Ordering Material
The name of the proposed supplier (or names of proposed suppliers) of the reinforcement shall be
submitted as soon as possible to the EngineerProject Manager for his approval. The Contractor shall
also submit all relevant data on the steel required by the EngineerProject Manager, such as breaking
strength, yield strength, characteristics on elongation, chemical composition etc.

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Copies of orders placed shall be submitted to the EngineerProject Manager.
Bar reinforcement shall be transported in standard bundles, tagged and marked in accordance with
the Manual of Standard Practice of the American Concrete Reinforcing Steel Institute.
No steel shall be delivered without a manufacturer’s mill certificate guaranteeing the yield stress,
metallurgical properties and other mechanical properties pertaining to the lot (or batch) delivered to
the Site, which shall be submitted to the EngineerProject Manager for prior approval.
The steel shall be stored on Site and marked in a way that later enables identification of the steel
corresponding to each lot covered by a mill test certificate.
B.E 8.2.6 Additional Tests
The Contractor shall cut out steel samples as directed by the EngineerProject Manager and these
shall be tested according to the EngineerProject Manager’s instructions by an approved Testing
Institution. Expenses incurred in connection with cutting out, transporting and testing of the samples
shall be paid for by the Contractor. Two samples shall be tested from each batch delivered to Site or a
minimum of one sample shall be tested from each 50 tons of reinforcement delivered to the site.
B.E 8.3.1 Protection and Storage
Reinforcement for structures shall be handled and stored in a manner that will prevent bending out of
the desired shape and any accumulation of dirt, oil and paint. When placed in the works it shall be
free from dirt, oil, grease, paint, mill scale and loose or thick rust.
B.E 8.3.2 Cutting and Bending
Bars shall be cut and bent cold to the dimensions indicated and with equipment and methods
Stirrups and tie bars shall be bent around a pin having a diameter not less than four times the
minimum thickness of the bar. Bends for other bars, where full tension in the bar may occur, shall be
made around a pin having a diameter not less than twenty times the bar diameter. Hooks shall
conform to American Concrete Institute Standard Building Code Requirements for Structural Concrete
ACI 318-05, or as shown on the Drawings. Bending of reinforcement bars shall be as per article 8.23
of division 1 of Standard Specification for Highway Bridge-2002 published by AASHTO.
B.E 8.3.3 Placing, Supporting and Fastening

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All bar reinforcement shall be placed, supported and secured prior to any concreting operations. The
reinforcement shall be checked and approved by the EngineerProject Manager before pouring of
concrete.
Cover blocks required for ensuring that the reinforcement is correctly positioned shall be as small as
possible, consistent with their purpose, of a shape and material acceptable to the EngineerProject
Manager, and designed so that they will not overturn when the concrete is placed. If made of
concrete, the maximum size of aggregate shall be 6 mm and the mix proportion shall be one part of
Portland cement to 2 parts of sand by weight. Wire shall be cast in the block for the purpose of tying it
to the reinforcement. The wire must not be closer than 30 mm from the concrete surface. The use of
small stones or wood blocks shall not be permitted.
The reinforcement shall be held securely in place at the exact position and at the exact spacing as
indicated on the Drawings by the use of wire ties at bar intersections, supports and cover blocks. Wire
ties shall be securely tied and folded so that they do not project beyond the planes formed by the
reinforcing bars. The adequacy of the supports and ties to secure the reinforcement properly shall be
subject to the approval of the Engineerapproval of the Project Director.
B.E 8.3.4 Splicing
Reinforcement shall be furnished in accordance with the working drawings and reinforcing bar lists as
approved in accordance with this Section of the Specification. If such drawings and reinforcing bar
lists include additional splices to those required by the Drawings or the Specification, the extra mass
occasioned by such splices shall not be included in the measurement of reinforcement for payment
All splices for high yield deformed steel bars and mild steel plain steel bars shall have lap lengths as
shown on the Drawings. Lap splices shall generally be located at points of minimum tension in bars.
Except where otherwise shown on the Drawings lap splices shall be made with the bars placed in
contact and securely wired together.
Welding of reinforcing steel shall be done only if detailed on the Drawings or approved in writing by
the EngineerProject Manager. Before the EngineerProject Manager may approve of such welding, the
Contractor shall submit and test any samples as the EngineerProject Manager may require and make
due allowance for the time elapsing before results are available.
B.E 8.3.5 Substitutions
Substitutions of bars shall be permitted only with specific authorization by the EngineerProject
Manager and at the expense of the Contractor. If bars are substituted they shall have a cross
sectional area equivalent to the design area, or larger at his own expense. If substitutions of bars are
permitted, the Contractor shall produce working drawings and reinforcing detailing at his own expense
and to the approval of the Engineerapproval of the Project Director.
The quantity of reinforcement to be measured under this Section shall be the computed weight in
tonnes of material used and accepted as shown on the Drawings provided that the quantity shall not
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include the reinforcement in any item of work for which the basis of payment includes the
reinforcement. In computing the weight to be measured, the theoretical weights of bars of the cross
section shown on the Drawings or authorized, shall be used. The weight shall be calculated based on
a constant mass of 0.00785 kg/mm² per meter run.
Cross Sectional Area and Mass
Nominal size Mass (kg/m) Cross sectional area (mm2)

6 mm 0.222 28.30
8 mm 0.395 50.30
10 mm 0.616 78.50
12 mm 0.888 113.00
16 mm 1.579 201.00
20 mm 2.466 314.00
22 mm 2.980 380.00
25 mm 3.854 491.00
28 mm 4.830 616.00
32 mm 6.313 804.00
The computed weight shall not include the extra material incurred when bars larger than those
specified are used, or the extra material necessary for splices when bars shorter than those specified
are used with the permission of the EngineerProject Manager, or the weight of any devices used to
support or fasten the reinforcement in the correct position including any necessary chairs. However,
payment shall be allowed for lap splices not shown when the bars are longer than 12 meters. Only
one lap splice per every started12 meters will be paid for.
This work, measured as provided above, shall be paid for at the Contract unit price per metric tonne of
reinforcement. The payment shall be full compensation for furnishing and placing reinforcement of any
size as shown in the Drawings and for all labour, binding wire, ties and metal, concrete or other
supports, of scheduling, furnishing, cutting, storing, bending, cleaning, securing and maintaining in
position all reinforcing bars, equipment, tools and incidentals necessary to complete the work
prescribed in this Section.
Pay items shall be:

Unit of
Measurement
E 8.1 High Yield Deformed Steel Reinforcing Bars furnished, tonne
tested, cut, bent and fixed in forms
B-8.1 High Yield Deformed Steel Reinforcing Bars furnished, tested, Tonne
cut, bent and fixed in forms
B.E 9 BRICK AND WATER PROOFING POLYTHENE SHEET WORK
BRICK WORK
B.E 9.1 Description

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This work shall consist of the construction, reconstruction, rehabilitation, facework repairs and
repointing of brickwork structures, in accordance with these Specifications and the lines, levels,
grades, dimensions and locations shown on the Drawings or as required by the EngineerProject
Manager.
B.E 9.2 Materials
B.E 9.2.1 Specifications for Materials for Brick work
i) Bricks
First class bricks shall be made from good brick earth, free from saline deposits, and shall be sand-
moulded. They shall be thoroughly burnt by coal without being vitrified, of uniform and good colour.
They shall be regular and uniform in size, shape and texture with sharp square edges and parallel
faces. They shall be homogeneous in texture and emit a clear metallic ringing sound when struck one
against the other. They shall be free from flaws, cracks, chips, stones, modules of lime or kankar and
other blemishes.
A first class brick shall not absorb more than 1/6th of its weight of water after being soaked for one
hour, and shall show no sign of efflorescence on drying. Bricks not meeting these requirements shall
not be used under any circumstances.
Jhama bricks are those which are so overburnt as to become vitrified or distorted, so as to be
unsuitable for exact brickwork. Jhama bricks may be broken and used for aggregate in earthworks
provided the vitrified mass has not become porous or spongy as a result of overburning and the
aggregate satisfies the requirements of these Specifications.
Perforated bricks shall be of uniform size and colour with sharp edges, square and parallel faces and
have a standard number of perforations. They must be standard commercial products of approved
manufacturers and shall be approved by the EngineerProject Manager. (Hold Point)
Machine-made pressed bricks shall be of the size shown on the Drawings and shall be standard
commercial products of approved manufacturers. The use of machine-made pressed bricks shall be
subject to approval by the EngineerProject Manager (Hold Point) prior to use in the Works.
First class bricks shall have the following dimensions after burning: 242 mm x 113 mm x 70 mm.
Picked Jhama bricks may have dimensions slightly below those for other brick but not less than 235
mm x 110 mm x 70 mm. The unit weight determined in accordance with STP 7.8.3 of first class bricks
shall not be less than 1,100 kg/m 3 and the unit weight of Jhama bricks shall not be less than 1,200
kg/m3.
The crushing strength of bricks shall be tested in accordance with STP 7.8.4. The average crushing
strength of first class bricks shall not be less than 17 MPa. The average crushing strength of Jhama
Bricks shall not be less than 20 MPa.
ii) Cement

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Cement shall be as specified in Item BE-7.
iii) Fine Aggregate
Fine aggregate shall be as specified in Item BE-7. The fineness modulus of sand shall not be less
than 1.50.
iv) Water
Water shall be as specified in Item BE-7.
v) Steel Reinforcement
Steel reinforcement shall be as specified in Item BE-8.
B.E 9.2.2 Specifications for Mortar
Cement mortar shall consist of a mixture of one part by weight of cement to two parts by weight of
sand. The cement and sand shall be mixed dry and in the specified proportion until the colour of the
mixture is uniform. Approved water shall then be added sparingly, only the minimum necessary being
used to produce a workable mixture of normal consistency. The water/cement ratio in no case shall
exceed 50% by weight, or as directed by the EngineerProject Manager. (Witness Point) The mixing
shall be done on a clean board or platform with tied joints, to avoid leakage. At the close of each day’s
work the mixing trough and pans shall be thoroughly cleaned. Cement mortar shall be mixed in such
quantities as can be used in the work within 30 minutes. Mortar, which has taken initial set, shall not
be used nor shall it be remixed with fresh mortar and such mortar shall be discarded and removed
from the working site.
B.E 9.3.1 General
The details of Works shall cover the requirements specified on the Drawings or as directed by the
EngineerProject Manager (Witness Point) at each location. The scope of new Works shall be as
indicated on the Drawings and as confirmed by the EngineerProject Manager. The precise extent of
all brickwork extensions, repairs to defective brickwork, rehabilitation of brickwork and repointing of
mortar joints shall be surveyed by the Contractor and the EngineerProject Manager (Witness Point) at
the commencement of the Works and the locations of all repairs shall be recorded and carefully
marked in paint on each structure to permanently identify the Works to be implemented.
The Contractor shall in due time and as soon as possible present and discuss his construction
proposals and work programme for building new brickwork structures, brickwork extensions to existing
structures, brickwork repairs to defective bricks and rehabilitation of existing structures, and the
repointing of defective joints in existing brickwork. Method statement shall be prepared and obtain
approval from the EngineerProject Manager. (Hold Point)

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B.E 9.3.2 Workmanship
Brickwork shall be built plumbed, curved or battered as shown on the Drawings or as may be
required, by properly supervised skilled masons and workmen. Bricks shall be cleaned and if
necessary, they shall be scrubbed. Bricks shall be soaked in water for at least three hours before use.
Where new work joins previous work, the latter shall be well cleaned and thoroughly watered. All
facework bricks shall be specially selected regarding size, shape and edges. Unless otherwise
specified, bricks shall be laid in English Bond with frogs upward. All horizontal joints shall be parallel
and level. Vertical joints in alternate courses shall come directly over one another. Joint thickness
shall be 6 mm and shall in no case exceed 8 mm. The height of four courses including 4 bed joints
shall rise 300 mm. Walls shall always be carried up regularly along their entire length throughout the
structure unless otherwise directed by the EngineerProject Manager. (Witness Point) The brickwork
shall be cured for at least seven days. Fixtures such as clamps, pipe brackets etc. shall be provided in
the brickwork during execution.
B.E 9.3.3 Brick Drainage Layers
Brick drainage layers to abutments, wing walls and other structures shall be constructed of “dry-laid”
bricks as indicated on the Drawings and with vertical joints not exceeding a width of 10 mm.
Inspection shall be carried in the presence of the EngineerProject Manager (Witness Point)
WATER PROOFING POLYTHENE SHEET WORK
Description
The work covered under this item shall consist of supplying and laying in place polythene sheets over
brick flat soling in floor of buildings and where needed in accordance with the applicable Drawings or
as directed by the EngineerProject Manager.
Construction Method
The sheets shall be laid within the building covering the entire inside floor area. Before laying the
sheets the brick surface shall be cleaned with a duster to give the surface free of extraneous particles.
The sheets shall be free of damage, tear or other imperfection and shall be laid such that there is a
minimum of 225 mm overlap between adjacent strips. The second layer shall be laid over the first in
the same direction but with a stagger of half the strip width.
BE .9.4 Measurement and Payment
Brickwork shall be measured by the number of cubic meters that is ordered, placed and accepted. In
computing quantities, the dimensions of brickwork shown on the Drawings for new work and
extensions shall be used as the basis for measurement. Remedial repairs of defective brick and
replacement of defective brickwork shall also be measured by the number of cubic meters ordered as
indicated on the Drawings or marked up and accepted. No measurements will be taken on the

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defective brickwork that it is necessary to remove. The repointing of existing brickwork joints shall be
measured by the number of square meters of repointing that is ordered, marked up and accepted. No
measurements will be taken on the amount of defective mortar it is necessary to remove.
Dry pack brickwork drainage layers behind the walls of the culvert shall be measured according to the
dimensions on the Drawings in cubic meters
No measurements will be taken of any temporary works.
The work measured as provided above shall be paid for at the Contract unit prices per cubic meter of
brickwork or square meter of repointing.
The Contractor’s rates shall include all temporary measures to retain structural adequacy of an
existing structure, all preparatory work in breaking out defective brickwork and removal of the same,
for mixing mortar, for placing brickwork on/against prepared surfaces to the lines, levels as indicated
on the Drawings or as instructed by the EngineerProject Manager, for finished joints in a neat and
professional manner. The Contractor’s rates shall be fully inclusive of all cost of labour and materials
in providing brickwork with sound mortar joints that will satisfy the structural criteria of the elements of
the whole.
Payment for dry pack brickwork shall include all costs of supplying and placing bricks as shown on the
Drawings.
Payment for single layer brick flat soling shall include the supply of all required materials and all
labour, equipment, tools and incidentals necessary to complete the work.
Payment for water proofing polythene sheet shall be made in square metres of the actually completed
work. No allowance will be made for overlaps. The Work shall be paid for at the Contract unit price.
The payment shall be full compensation for all material, labor, equipment, tools and incidentals
necessary to complete the Work specified in this Section.
Pay items shall be:
Unit of
Measurement
E 9.1 Single Layer Brick Flat Soling as Detailed on the Drawings m2
and as stated in the Bill of Quantities.
E 9.2 Water Proofing Polythene Sheet as Detailed on the m2
Drawings and as stated in the Bill of Quantities.

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B-9.1 SINGLE LAYER BRICK FLAT SOLING AS DETAILED ON THE DRAWINGS

SQUARE METER
B-9.2 WATER PROOFING POLYTHENE SHEET AS DETAILED ON THE

DRAWINGS SQUARE METER
B.E 10 DRAINAGE OF STRUCTURES
B.E 10.1 Description
This work consists of furnishing and erection of drain outlets on bridge decks and drainage of other
structures including PVC piping in accordance with the lines, levels, grades, sizes, dimensions and
types shown on the Drawings.
B.E 10.2 Materials
B.E 10.2.1PVC Pipes
All PVC pipes shall comply with ISO R 161 “Pipes of Plastic Materials for the Transport of Fluids” or
with BS 3505 “Unplasticised PVC Pipes for Cold Water Services”.
B.E 10.3.1Storage and Handling of Materials
PVC parts shall be carefully handled and stored under cover on blocking, racks or platforms so as not
to be in contact with the ground. Materials shall be kept free from dirt, oil, grease and other foreign
matter.

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B.E 10.3.2PVC Pipes
The jointing shall be of a type recommended by the manufacturer of the pipes. Bends shall be of long
sweep, free from kinks. Embedded pipes shall be cast into the structure in the locations as indicated
on the Drawings. During casting of concrete the piping shall be kept in the correct position by means
Exposed pipes shall be parallel to or at right angles to walls, slabs and girders. All exposed pipes shall
be attached to concrete, steel, masonry or timber by galvanized malleable iron or galvanised steel
straps, clamps or hangers of an approved type, held at not less than two points by galvanised steel
bolts or lag screws. The runs shall be supported at not greater than 1 meter centres on horizontal or
near horizontal runs, unless otherwise specified and not less than 50 mm clear of the supporting
members.
All ends of pipes installed during construction shall be closed against the intrusion of foreign material.
B.E 10.3.3Weep Holes
While constructing abutment, wing wall and return wall, weep holes shall be provided therein unless
otherwise shown in the relevant Drawings. The filter media behind the abutments shall be well packed
to a thickness of not less than 450mm with smaller size towards the soil and the bigger size towards
the wall and provided over the entire surface behind the abutment walls to the full height and shall be
laid in layers simultaneously with the laying of fill materials as mentioned in the Drawings. The filter
media shall correspond to Class III grading of Table 300-3 of IRC Specifications or over burnt (Jhama)
brick aggregates size 90mm- 45mm as per Cl.404.2.4 of IRC Specifications. The weep holes shall be
as per Drawings and shall extend through the full width of the abutment wall with a maximum slope of
1 vertical to 20 horizontal towards the abutment face. The spacing of weep holes shall be generally
1.2 m in either direction and shall be staggered. The lowest weep holes shall be located at about 450
mm above the low water level or ground level whichever is higher, or as directed by the
EngineerProject Manager. In general, one weep hole per 1.5 square meter of vertical surface shall be
provided.
No separate payment shall be made for drainage of structures, and the items shall be deemed to be
included in the prices included in the related items of the Bill of Quantities.
B.E 11 INSERTS AND FITTINGS IN STRUCTURES

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This work consists of furnishing and embedding of inserts, fittings and other incidental parts into
bridges and culverts works necessary to provide for further supports for utility pipes and cables and
the like. The type, size and location will be indicated on the Drawings, or instructed by the
B.E 11.2 Materials
Unless otherwise indicated on the Drawings, the inserts shall be made of steel conforming to
AASHTO Standard Specification M 183 (ASTM A 36). Material to be as indicated on the Drawings or
as approved by the EngineerProject Manager.
The inserts and fittings shall be embedded at the locations indicated on the Drawings or as instructed
by the EngineerProject Manager. During casting of concrete in structures, the inserts and fittings shall
be kept in the correct position by means approved by the EngineerProject Manager.
The inserts and fittings shall be plugged or pressed against the formwork in a way that no mortar from
the concrete may enter the thread of the inserts or fittings. After removal of the formwork, the
Contractor shall clean the surface of the insert and fittings to the approval of the Engineerapproval of
the Project Director.
There is no separate payment for the application of inserts and fittings to structures. These works are
deemed to be included under the various items in the Bill of Quantities.
B.E 12 BRIDGE BEARINGS
B.E 12.1 General
This work shall consist of furnishing, testing and installing bridge bearings. Bearing types include, but
are not limited to, elastomeric pad, rocker, roller, pot, spherical, disk and sliding plate bearings.
Included as components of bearings are masonry, sole and shim plates, bronze or copper alloyed
bearing and expansion plates, anchor bolts, PTFE sheets or surfacing, lubricants and adhesives. Also
included in this work is the furnishing and installation of bedding materials used under masonry plates.
Bearings shall be constructed in accordance with the details shown on the plans and specified. When
complete details are not provided, bearings shall be furnished that conform to the limited details
shown on the plans and shall provide the design capacities for loads and movements shown or
specified and the performance characteristics specified.

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B.E 12.1.1Working Drawing
Whenever complete details for bearings and their anchorages are not shown on the plans, the
Contractor shall prepare and submit working drawings for the bearings. Such drawings shall show all
details of the bearings and of the materials proposed for use and must be approved by the
EngineerProject Manager before fabrications of the bearing is begun. Such approval shall not relieve
the Contractor of any responsibility under the contract for the successful completion of the work.
B.E 12.1.2Packaging, Handling and Storage
Prior to shipment from the point of manufacture, bearings shall be packaged in such a manner to
ensure that during shipment and storage the bearings will be protected against damage from
handling, weather, or any normal hazard. Each completed bearing shall have its components clearly
identified, be securely bolted, strapped or otherwise fastened to prevent any relative movement, and
marked on its top as to location and orientation in each structure in the project in conformity with the
plans. Dismantling at the site shall not be done unless absolutely necessary for inspection or
installation.
All bearing devices and components shall be stored at the work site in an area that provides
protection from environmental and physical damage. When installed, bearings shall be clean and free
of all foreign substances.
B.E 12.1.3 Manufacture or Fabrication
Bearing devices or assemblies shall consist of components meeting the material specification of this
Item B.E 12.
Bearing assemblies shall be pre-assembled in the shop by the supplier and checked for proper
completeness and geometry before shipping to the site.
Unless otherwise specified, steel, other than stainless steel, bearing components, including anchor
bolts, shall be hot dip galvanized conforming to IS:4759-1990 and IS:2629-1985.
B.E 12.1.4 Construction and Installation
Bearings shall be installed by qualified personnel to the positions shown on the plans. Bearings shall
be set at time of installation to the dimensions prescribed by the manufacturer, the EngineerProject
Manager, or as shown on the plans and adjusted as necessary to take into account the temperature
and future movements of the bridge.
Bridge bearings shall be set level, in exact position, and must have full and even bearing on all
bearing planes.

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Bearing surfaces located at improper elevations or set not level and true to plane shall require either
grinding of the surface, grout pack bearing seats or modification of the bearing suck that intended
bearing placement is as originally designed with the least amount of bearing modification.
Metallic bearing assemblies not embedded in the concrete shall be bedded on the concrete with a
filler or fabric material conforming to Article 12.10. PTFE Surfaces for Bearings in the AASHTO
Standard Specification for Highway Bridges,
Elastomeric bearing pads shall be set directly on properly prepared concrete surfaces without bedding
material.
Bearings sealed directly on steel work require the supporting surface to be machined so as to provide
a level and planar surface upon which the bearing is placed.
B.E 12.2 Elastomeric Bearings
B.E 12.2.1Description
The work shall consist of furnishing and fixing in position of bearings (up to and including 32.4m span)
in accordance with the details shown on the drawings to the requirements of these specifications.
The term “Elastomeric bearing” in this specification shall refer to bearing consisting of one or more
elastomer slabs bonded to metal plates during manufacture so as to form a sandwich arrangement
and caters for translation and/or rotation of superstructure by elastic deformation of elastomer.
B.E 12.2.2Materials
B.E 12.2.2.a Properties of the Elastomer
The raw elastomer shall be either Virgin Neoprene (polychloroprene) or virgin natural rubber
(polyisoprene). The elastomer compound shall be classified as bring of low temperature grade 0, 2, 3,
4 or 5. The grades are defined by the testing requirements in Tables B.E 12.2a and B.12.2b. A higher
grade of elastomer may be substituted for a lower one.
The elastomer compound shall meet the minimum requirements of Tables B.E 12.2a and B.E 12.2b
except as otherwise specified by the EngineerProject Manager. Test requirements may be
interpolated for intermediate hardness. If the material is specified by its shear modulus, its measured
shear modulus shall lie within 15 percent of the specified value. A consistent value of hardness shall
also be supplied for the purpose of defining limits for the tests in Tables B.E12.2a and B.E12.2b If the
hardness is specified, the measured shear modulus must fall within the range of Table B.E12.2.C
When test specimens are cut from the finished product, the physical properties shall be permitted to
vary from those specified in Tables B.E12.2a and B.E12.2b by 10 percent. All material tests shall be
carried out at 23oC + 2oC unless other wise noted. Shear modulus tests shall be carried out using the
apparatus and procedure described in Annex A of ASTM D4014.

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B.E 12.2.2.b Steel Laminates
Steel laminates used for reinforcement shall be made from rolled mild steel conforming to ASTM A36,
A570, or equivalent, unless otherwise specified by the EngineerProject Manager. The laminates shall
have a minimum nominal thickness of 16 gage. Holes in plates for manufacturing purposes will not be
permitted unless they have been accounted for in the design, as shown on the plans.
B.12.2.2.c Bond
The vulcanised bond between fabric and reinforcement shall have a minimum peel strength of 5.2
KN/m Steel laminated bearings shall develop a minimum peel strength of 6.9 KN/m. Peel strength
tests shall be performed by ASTM D429 Method B.
Table –B.E 12.2.a
Neoprene Quality Control Tests. Note in the Table that ASTM D1043 Refers to
"Modulus of Rigidity," while ASTM D4014 Refers to "Shear Modulus Stiffness,"
The Word "Stiffness" is used here to Cover Both Terms.
PHYSICAL PROPERTIES
D 2240 Hardness (Shore A Durometer) 50 ± 5 60 ± 5 70 ± 5
D 412 Tensile Strength, Minimum (N/mm2)/MPa 15.52 15.52 15.52
Ultimate Elongation, minimum % 400 350 300
HEAT PERSISTENCE
D 573 Change in Durometer Hardness 15 15 15
70 Hours at Maximum points
o Change in Tensile Strength, Maximum % -15 -15 -15
100 C
Change in Ultimate Elongation, Maximum % -40 -40 -40
COMPRESSION SET
D 395 22 Hours @ 100oC Maximum % 35 35 35
Method B
ZONE
D 1149 100 pphm ozone in air by volume, 20%
strain 38oC ± 1oC
100 hours mounting procedure D518, No No No Cracks
Procedure A Cracks Cracks
LOW TEMPERATURE BRITTLENESS
D 746 Grade 0 and 2 - No Test Required
Procedure B Grade 3 Brittleness at - 40oC No Failure No Failure No Failure
Grade 4 Brittleness at - 48oC No Failure No Failure No Failure
Grade 5 Brittleness at - 57oC No Failure No Failure No Failure
INSTANTANEOUS THERMAL STIFFENING
D 1043 Grades 0 and 2 - Tested @ - 31oC Stiffness at test temperature shall
not exceed 4 times the stiffness
Grades 3 - Tested @ - 40oC
measured at 23 Degrees C
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PHYSICAL PROPERTIES
LOW TEMPERATURE CRYSTALLISATION
Quad Shear Grade 0-No Test Required Stiffness at test time and
Test Grade 2-7 days @ 18oC temperature shall not exceed 4
as Described times the stiffness measured at 23
Grade 3-14 days @ 26oC
Degrees C with no time delay. The
Grade 4-21 days @ 37oC stiffness shall be measured with a
Grade 5-28 days @ 37oC quad shear test rig in an enclosed
freezer unit. The test specimens
shall be taken from a randomly
selected bearing. A ± 25% strain
cycle shall be used, and a
complete cycle of strain shall be
applied with a period of 100
seconds. The first 3/4 cycle of
strain shall be discarded and the
stiffness shall be determined by
the slope of the force deflection
curve for the next 1/2 cycle of
loading.
Table B.E 12.2.b
Natural Rubber Quality Control Tests. Note in the Table that ASTM D1043 Refers to
"Modulus of Rigidity," while ASTM D4014 Refers to "Shear Modulus Stiffness,"
The Word "Stiffness" is used here to Cover Both Terms.
PHYSICAL PROPERTIES
D 2240 Hardness (Shore A Durometer) 50 ± 5 60 ± 5 70 ± 5
D 412 Tensile Strength, Minimum (N/mm2)/MPa 15.52 15.52 15.52
Ultimate Elongation, minimum % 450 400 300
HEAT PERSISTENCE
D 573 Change in Durometer Hardness 10 10 10
70 Hours at Maximum points
Change in Tensile Strength, Maximum % -25 -25 -25
70oC
Change in Ultimate Elongation, Maximum % -25 -25 -25
COMPRESSION SET
D 395 22 Hours @ 70oC Maximum % 25 25 25
Method B
ZONE
D 1149 25 pphm ozone in air by volume, 20%
strain 38oC ± 1oC
48 hours mounting procedure D518, No No No
Procedure A Cracks Cracks Cracks
LOW TEMPERATURE BRITTLENESS
D 746 Grade 0, 2 - No Test Required
Procedure B Grade 3 Brittleness at - 40oC No No No Failure
Failure Failure
Grade 4 Brittleness at - 48oC No No No Failure
Failure Failure
Grade 5 Brittleness at - 57oC No No No Failure
Failure Failure
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PHYSICAL PROPERTIES
INSTANTANEOUS THERMAL STIFFENING
D 1043 Grades 0 and 2 - Tested @ - 31oC Stiffness at test temperature shall
not exceed 4 times the stiffness
measured at 23 Degrees C
LOW TEMPERATURE CRYSTALLISATION

Quad Shear Grade 0-No Test Required Stiffness at test time and
Test as Grade 2-7 days @ 18oC temperature shall not exceed 4
Described in times the stiffness measured at 23
Grade 3-14 days @ 26oC
Annex A of Degrees C with no time delay. The
ASTM D4014 Grade 4-21 days @ 37oC stiffness shall be measured with a
Grade 5-28 days @ 37oC quad shear test rig in an enclosed
freezer unit. The test specimens
shall be taken from a randomly
selected bearing. A ± 25% strain
cycle shall be used, and a
complete cycle of strain shall be
applied with a period of 100
seconds. The first 3/4 cycle of
strain shall be discarded and the
stiffness shall be determined by
the slope of the force deflection
curve for the next 1/2 cycle of
loading.
Table B.E 12.2.C
Elastomer Properties at Different Hardnesses
Hardness (Shore 'A') 50 60 70

Shear Modulus at 23 degrees C (MPa) 0.68-0.93 0.93-1.43 1.43-2.14
Creep Deflection at 25 years 25% 35% 45%
Instantaneous Deflection
Constant Dependent on Elastomer Hardness (k) 0.75 0.6 0.55
B.E 12.2.2.d Specification for Fabrication
a) Bearing with steel laminates shall be cast as a single unit in a mould and vulcanised under heat
and pressure. Casting elements in separate units and subsequent bending will not be permitted nor
shall cutting from large size cast be permitted.
b) Bearing of similar size to be used in particular bridge project shall be produced by identical
process and in a lot as far as practicable. Phased production may only be resorted to when the total
number of bearings is large enough.

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c) The moulds used shall have standard surface finish adequate to produce bearings free from
any surface blemishes.
d) Steel plates for laminates shall be sand blasted clean of all mill scale and shall be free from all
contaminants prior to bending by vulcanisation. Rusted plates with pitting shall not be used. All edges
of plates shall be rounded.
e) Spacers used in mould to ensure uniform vulcanising condition and homogeneity of elastomer
through the surface and body of the bearing.
Flash tolerance, finish, and appearance shall meet the requirements of the latest edition of the
Rubber Handbook, published by the Rubber Manufacturers Association, Inc., RMA F3 AND T.063 for
moulded bearings and RMA F2 for extruded bearings.
Table- B.E 12.2.d

Fabrication Tolerances
Plain pads and laminated bearings shall be built to the specified dimension within the following
tolerances:
1. Overall Height
Design Thickness 32 mm or less -0,+3 mm
Design Thickness over 32 mm -0,+6 mm

2. Overall Horizontal Dimensions
0.914m or less -0,+6 mm
Over 0.914m -0+12 mm

3. Thickness of Individual Layers of Elastomer
(Laminated Bearings Only) ± 20% of design value but no
At any point within the bearings more than ± 3 mm
4. Parallelism with Opposite Face

Top and bottom 1 in 200
Sides 1 in 50
5. Position of Exposed Connection Members

Holes, slots or inserts ± 3 mm
6. Edge Cover
Embedded laminates or connection members -0,+3 mm
7. Thickness
Top and bottom cover layer (if required) -0, the smaller of 1.5 mm and
+20% of the nominal cover
layer thickness
8. Size
Holes, slots, or inserts ± 3 mm
B.E 12.2.2.e Designs and Drawings

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The Contractor shall design the bearings in accordance with the horizontal and vertical loads and the
rotations shown on the Drawings, and prepare and submit drawings and calculations of the bearings
to the EngineerProject Manager for approval.
The Contractor shall supply, fix in position and maintain the bearings strictly in accordance with the
Drawings and designs of this Contract.
B.E 12.2.2.f Acceptance Specifications
a) The manufacturer shall install at his plant all test facilities required for process and acceptance
control tests to the complete satisfaction of the EngineerProject Manager. The test facilities and their
operation shall be open to inspection by the EngineerProject Manager on demand. The certificates on
testing of Bridge bearings obtained from Bangladesh Standard Testing Institute (BSTI), Bangladesh
Council of Scientific and Industrial Research (BCSIR) or Bangladesh University of EngineerProject
Managering and Technology (BUET) by the manufacturer will be acceptable, if the manufacturer have
no testing facilities provided at his Plant.
b) All acceptance and process control tests shall be conducted at the manufacturer's plant. Cost of
all material, equipment and labour shall be borne by the manufacturer unless other wise specified
here in or specially agreed to between the manufacture and EngineerProject Manager.
c) Acceptance testing shall be commenced with the prior submittal of testing programme by the
manufacture to the EngineerProject Manager and after obtaining his approval.
d) Any acceptance testing delayed beyond 60 days of production shall require special approval of
the Engineerapproval of the Project Director and modified acceptance testing, if deemed necessary
by him.
e) All acceptance testing shall be conducted by the inspector with aid of the personnel having
adequate expertise and experience in rubber testing provided by the manufacture, working under the
supervision of inspector and to his complete satisfaction.
B.E 12.2.2.g Quality Control Certificate
A lot under acceptance shall comprise all bearings, including a pair of extra test bearings of equal or
near equal size produced under identical conditions of manufacture to be supplied for a particular
project.
The size and composition of acceptance lot shall be got approved by the EngineerProject Manager.
The manufacturer shall certify for each lot of bearing under acceptance:
- that an adequate system of continuous quality control was operated in his plant.
- that process remained in control during the production of the lot of bearings under acceptance
as verified from the quality control records/charts which shall be open to inspection of the
EngineerProject Manager on demand.

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- a certified copy of results of process control testing done on samples of elastomer used in the
production of the lot shall be appended and shall include at least the following information :
Composition of the compound - raw elastomer and ash content the grade of raw elastomer used
(including name, source, age on shelf). Test results of hardness, tensile strength, elongation at break,
compression test accelerated ageing etc.
B.E 12.2.2.h Certificate and Markings
Bearings shall be transported to bridge site after final acceptance by EngineerProject Manager and
shall be accompanied by and authenticated copy of the certificate to that effect.
An information card giving the following details for the bearings, duly certified by the manufacturer
shall also be appended.
Name of manufacturer
Date of manufacture
Elastomer grade used
Bearing dimensions
Production Batch No.
Acceptance Lot No
Date of testing
Specific bridge location, if any
Explanation of markings used on the bearing.
All bearings shall have suitable index markings identifying the information as given above. The
markings shall be made in indelible ink or flexible paint and if practicable should be visible after
installation. The top of the bearing and direction of installation shall be indicated.
B.E 12.2.3Method
Care shall be taken in packing, transportation, storage and handling to avoid any mechanical damage,
contamination with oil, grease and dirt, undue exposure to sunlight and weather.
Installation of multiple bearings one behind the other on a single line of support shall not be permitted.
All the bearings installed along a single line of support shall be of identical dimensions.
Bearings shall be placed between true horizontal surfaces (maximum tolerance 0.2% perpendicular to
load) and at true plan position of their centre lines (marked on receiving surfaces (maximum tolerance
±3 mm). Concrete surfaces shall be free from local irregularities (maximum tolerance ± 1 mm in
height).
For cast in place concrete construction of superstructure where bearings are installed prior to its
concreting, the forms around the bearings shall be soft enough for easy removal. Forms shall also fit
the bearings snugly prevent any leakage of mortar grout. Any mortar contaminating the bearings
during concreting shall be completely removed before setting.

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For pre-cast concrete or steel superstructure elements fixing of bearing to them may be done by
application of epoxy resin adhesive to interface after specified surface preparation. The specifications
for adhesive materials, workmanship and control shall be approved by the EngineerProject Manager.
Care shall be taken to guard against faulty application and consequent behaviour of the adhesive
layer as a lubricant. The bedding by the adhesive shall be deemed effective only as a device for
installation and shall not be deemed to secure bearing against displacement for purpose of design.
B.E 12.2.4Maintenance
The bearings shall be subject to planned maintenance care.
The exposed bearing surface shall be maintained clean and free from contamination with grease or oil
etc.
After installation routine maintenance inspection of all bearings shall be made till the expiration of the
maintenance period to check for any surface cracking or sings of damage, deterioration or distress.
Damaged bearings shall be replaced immediately. To avoid difference in stiffness, all adjacent
bearings on the same line of support shall also be replaced.
B.E 12.3 Pot and Disc Bearings
B.E 12.3.1General
Pot and disc bearings shall be furnished conforming the following requirements; shall be adequate for
the design loads and movements shown on the Drawings, and shall be tested at the appropriate level.
B.E 12.3.2Working Drawings
In addition to the requirements of paragraph C E 12.1.1 the following shall be shown on the working
drawings to be prepared by the Contractor:
The total quantity of each kind of bearing required fixed, guided expansion, or nonguided expansion),
grouped first according to type (load range), and then by actual design capacity.
The plan view and section elevation view showing all relative dimensions of each type of bearing.
The maximum design coefficient of friction as noted on the Drawings.
The type of materials to be used for all bearing elements.
If applicable, any welding process used in the bearing manufacture that does not conform to the
approved processes of the American Welding Society (AWS) shall be clearly described and detailed.

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Vertical and horizontal load, rotation, and movement capacity.
Painting or coating requirements.
Alignment plans.
Installation scheme
Complete design calculations verifying conformance with these specifications.
Anchorage details.
Bearing preset details, if applicable.
The location of the fabrication plant.
The manufacturer's name and the name of his or her representative who will be responsible for
coordinating production, inspection, sampling and testing.
B.E 12.3.3Materials
All materials shall be new and unused, with no reclaimed material incorporated in the finished bearing.
B.E 12.3.3.1 Elastomeric Rotational Element
The elastomeric rotational element used in the construction of pot bearings shall contain only virgin,
crystallization – resistant polychloroprene (neoprene) or virgin natural polyisoprene (natural rubber)
as the raw polymer.
The physical properties of neoprene and natural rubber used in these bearings shall conform to the
following ASTM or AASHTO requirements, with modifications as noted:
ASTM AASHTO
Compound
Requirement Requirement
Neoprene D2000, Line Call Out AASHTO M251
M2BC520A14B14
Natural D2000, Line Call Out AASHTO M251
Rubber M4AA520A13B33
Modifications:
The Shore A Durometer hardness shall be 50 ± 10 points.
(2) Samples for compression set tests shall be prepared using a type 2 die.
B.E 12.3.3.2 Sealant
If used, the type of sealant between the steel pot and the top steel bearing plate shall be as
recommended by the Manufacturer.

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B.E 12.3.3.3 Scaling Ring
The sealing rings between the steel piston and the elastomeric rotational element of pot bearings shall
be brass formed to the size recommended by the Manufacturer. Where more than one flat sealing ring
is used, ring gaps shall be staggered equally around the ring's circumference.
B.E 12.3.3.4 Steel
All steel except stainless steel components of the bearing shall conform to the requirements of Article
12.3 for Carbon Steel or High-Strength Low-Alloy Structural Steel for Welding.
B.E 12.3.3.5 Stainless Steel
Stainless steel shall conform to the requirements of ASTM A167, Type 304 or ASTM A240, Type 304.
Stainless steel in contact with PTFE sheet shall be polished to a bright mirror finish, less than 20
micro-inches root mean square. The minimum thickness of the stainless steel shall be 0.050 inches.
B.E 12.3.3.6 Polytetrafluorethylene Sheet and Strip
Polytetrafluorethylene (PTFE) sheet and strip shall be manufactured either from pure virgin (not
reprocessed) unfilled PTFE resin, from PTFE resin uniformly blended with either 15 percent glass
fiber or 25 percent carbon (maximum filler. percent by weight), or from fabric containing PTFE fibers.
PTFE sheet and strip shall meet the applicable material requirements of Article 18.8 PTFE Surfaces
for Bearings in the AASHTO Standard Specification for Highway Bridges.
Horizontally installed PTFE sheet shall be bonded to and recessed into its steel substrate. Vertically
installed PTFE sheet shall be bonded to and recessed into, or bonded to and mechanically fastened
to its steel substrate. PTFE sheet shall have a minimum thickness of 1/8 inch and shall be recessed
for at least one-half of its thickness into its steel substrate.
Finished PTFE sheet and strip shall be resistant to all acids, alkalis, and petroleum products. stable at
temperatures from -360ºF to + 500ºF, non-flammable, and nonabsorbing of water. The epoxy used to
bond the PTFE to its steel substrate shall be a heat cured, high temperature epoxy capable of
withstanding temperatures of -320ºF to + 500°F.
B.E 12.3.3.7 Polyether Urethane Structural Element
The polyether urethane structural element used in the construction of disc bearings shall be molded
form a polyether urethane compound and shall be monolithic. The physical properties of the polyether
urethane shall conform to one of the requirements listed in Table B.12.3.3.

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B.E 12.3.4 Fabrication Details
The Contractor shall provide the EngineerProject Manager with written notification thirty (30) days
prior to the start of bearing fabrication.
The finish of the mould used to produce the elastomeric rotational element for pot bearings or the
polyether urethane structural element for disc bearings shall conform to good machine shop practice.
The PTFE sheet shall be bonded to its grit blasted steel substrate using an epoxy resin adhesive
under controlled factory conditions in accordance with the instructions of the adhesive manufacturer.
The PTFE sheet shall be recessed into its steel substrate for at least one half of its thickness. If on a
vertical surface, the PTFE sheet may be mechanically fastened to the substrate. The attachment of
the PTFE sheet to its substrate shall be done in accordance with the manufacturing requirements of
Article 18.8. PTFE Surfaces for Bearings in the AASHTO Standard Specification for Highway Bridges.
After fabrication, steel surfaces exposed to the atmosphere, except stainless steel surfaces, shall be
shop painted or coated to protect against corrosion in accordance with the contract plans or
specification. Prior to coating, the exposed steel surfaces shall be cleaned in accordance with the
recommendation of the coating’s manufacturer. Metal surfaces to be field welded shall be given a coat
of clear lacquer or other protective coating approved by the EngineerProject Manager, if the time of
exposure before welding takes place is to exceed three months. The lacquer coating shall be
removed at the time of welding.
Table B.E 12.3.3 Polyether Urethane
Requirements
Physical Property ASTM Compound A Compound B
Test Method Min. Max. Min. Max.
Hardness, Type D Durometer D2240 46 50 60 64
Tensile Stress, psi D412
At 100% elongation 1500 2000
At 200% elongation 2800 3700
Tensile Strength, psi D412 4000 5000
Ultimate Elongation, % D412 350 220
Compression Set-22 hrs. at 158 F % D395 40 40
The final painting or coating of these surfaces shall be done after the completion of welding.
Stainless steel sheet shall be attached to its steel substrate with an approved epoxy to ensure
complete contact, and then sealed with a continuous seal weld.
For pot bearings, the steel piston and the steel pot shall each be machined from a solid piece of steel.
The steel base pot of all bearings shall be either integrally machined, recessed into, or continuously
welded to its bottom steel masonry plate. The outside diameter of the piston shall be no more than
0.030 inches less than the inside diameter of the pot at the interface level of the piston and
elastomeric rotational element. The sides of the piston shall be beveled to facilitate rotation.
For disc bearings, the polyether urethane structural element shall be confined by a limiting ring which
shall be provided by welding a ring to or machining a recess into the upper and lower bearing plates.
The inside diameter of the ring shall be 4 to 6 percent larger than the diameter of the disc element.

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The shear restriction mechanism shall be connected to the bearing plate by welding or other
acceptable means.
All welding shall conform to, and all welders shall be qualified in accordance with the requirements of
the ANSI/AASHTO/ANS D1.5 Bridge Welding Code.
Except as noted, all bearing surfaces of steel plates per foot. Out-of-flatness greater than 0.010
inches per foot on any plate shall be cause for rejection. The bottom surface of lower bearing plates
(masonry plates) designed to rest on bearing pads shall not exceed an out-of-flatness value of 0.0625
inches per foot. Oxygen cut surface shall not exceed a surface roughness value of 1000 micro-inches,
as defined by ANSI B46.1.
Gross bearing dimensions shall have a tolerance of -0, + 1/8".
Every bearing shall show the Project Identification Number, Lot Number, and individual bearing
number indelibly marked with ink on a side that will be visible after erection.
B.E 12.3.5Sampling and Testing
B.E 12.3.5.1 Sampling and Testing Requirements
The manufacturer shall select, at random, sample bearings from completed lots of bearings for testing
by the manufacturer. The manufacturer shall complete the required testing and determine compliance
with this specification before submitting the lots(s) for his quality assurance inspection, testing, and
acceptance consideration. The results of the manufacturer's tests shall be furnished to the
B.E 12.3.5.2 Performance Characteristics
B.E 12.3.5.2.1 Proof Load Test
A test bearing shall he loaded to 150 percent of the bearing’s rated design capacity and
simultaneously subjected to a rotational range of 0.02 radians (1.146º) or design rotation, whichever
is greater, for a period of one (1) hour.
The bearing will be visually examined both during the test and upon disassembly after the test. Any
resultant visual defects, such as extruded or deformed elastomer, polyether urethane or PTFE,
damaged seals or limited rings, or cracked steel, shall be cause for rejection of the lot.
During the test, for pot bearings the steel bearing plate and steel piston shall maintain continuous and
uniform contact for the duration of the test. For disc bearings, continuous and uniform contact shall be
maintained between the polyether urethane element and the bearing plates and between the sliding
steel top plate and the upper bearing plate for the duration of the test. Any observed lift-off will be
cause for rejection of the lot.
B.E 12.3.5.2.2 Sliding Coefficient of Friction

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For all guided and nonguided expansion type, bearings, the sliding coefficient of friction shall be
measured at the bearing's design capacity in accordance with Article 12.8. PTFE Surfaces for
Bearings in the AASHTO Standard Specification for Highway Bridges, and on the fifth and fiftieth
cycles, at a sliding speed of 25mm per minute.
The sliding coefficient of friction shall be calculated as the horizontal load required to maintain
continuous sliding of one bearing, divided by the bearing's vertical design capacity.
The test results will be evaluated as follows:
(a) The measured sliding coefficients of friction shall not exceed 3 percent.
(b) The bearing will, be visually examined both during and after the test. Any resultant visual defects,
such as bond failure, physical destruction, cold flow of PTFE to the point of debonding, or damaged
components, shall be cause for rejection of the lot.
Bearings not damaged during the testing of performance characteristics may be used in the Work.
B.E 12.3.6 Installation
Pot and disc bearings shall be installed in accordance with the alignment plan and installation scheme
as shown in the Drawings. Upon final installation of the bearings, the EngineerProject Manager, in the
presence of the manufacturer’s representative, shall inspect the bearing components to assure that
they are level and parallel to within ± 2.6 mm per meter. Any deviations in excess of the allowed
tolerances shall be corrected.
The quantities of elastomeric bearings and the quantities for pot bearings shall be measured in
number of sets, where one set comprises the bearings required for one girder/prestressed slab at
both ends.
The unit rate for bearings shall include all costs of materials, labour, tools and plants, fabrication,
testing, installation and maintenance as per drawing, all complete.
The pay items shall be:

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Pay Item No. Description Unit
Measurement
E 12.1 Elastomeric bearings:
BE- 12.1(a) Elastomeric bearings:
For 11.60m Deck type plate Girder Bridge e (one set for
Set
each slab) as Detailed on the Drawings and as stated
in the Bill of Quantities.
Set
For 16.75m Deck type plate Girder Bridge (one set for
each slab) as Detailed on the Drawings and as stated
in the Bill of Quantities.
E 12.1(b) For 16.75m Deck type plate Girder Bridge (one set for each Set
slab) as Detailed on the Drawings and as stated in the Bill
of Quantities.
B.E 13 FABRICATION AND ERECTION OF STEEL GIRDER BRIDGES
This work shall include supplying, fabricating, welding, transporting, erecting and painting structural
steel, bolts, nuts, washers, cast steel, steel forgings, cast iron and other incidental metal construction
of the kind, size and quantity in conformity of the Drawings and these Specifications or as directed by
B.E 13.2 General
Finished rolled materials and components shall be free from cracks, flaws, injurious seams, laps,
blisters, ragged and imperfect edges and other defects. It shall have a smooth and uniform finish and
shall be straightened in the mill before shipment. They shall also be free from loose mill scale,
rust, pits or other defects affecting its strength and durability.
Adequate arrangement shall be made by the Contractor during manufacturing process of girder and
built up sections, for inspection of two (2) engineerCivil Engineers of Project Directors from the Project
or Civil Engineering Department of Bangladesh Railway along with one specialist from the
Consultant’s team for a period of up to 10 7 days each in manufacturing work shop. The Contractor
shall bear all costs, including transportation, accommodation, and subsistence allowances, as
required. This cost is deemed to be included in the Contractor’s unit rates and prices.
The acceptance of any material on inspection at the mill i.e., rolling mills, foundry or fabricating plant
where material for the work is manufactured, shall not be a bar to its subsequent rejection, if found
defective.
Unless otherwise specified all structural steel shall be of mild steel conforming to IS: 2062 of Grade
designation as E250 (Fe410W) of Quality B with the chemical composition as mentioned in Table -1
of IS: 2062:2006 and the method of deoxidation as “killed” type, or ASTM A36 or approved equivalent.
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Unless otherwise specified, high tensile structural steel bolts in property classes 8.8 and 10.9 and size
range M16 to M36 conforming to IS: 3757 shall be used for the members of steel conforming to
IS:2062 .
Unless otherwise specified, bolted connection of structural joints using high tensile friction grip bolt of
property Classes 8.8 and 10.9 and size range M16 to M36 shall comply with requirements of IS: 4000-
2003
The fabrication procedure shall conform to IRS Steel Bridge Code & IRS Fabrication Code.
B.E 13.3 Structural Steel Materials
B.E 13.3.1
Unless otherwise permitted herein, all structural steel materials shall confirm to the requirements of
the following Indian Standards, Standard Specifications of Indian Road Congress, RDSO’s Bridge
Rules or equivalent and their latest revisions as appropriate:
IS: 808-1989 Dimensions for hot rolled steel beam, column, channel and angle sections
IS: 1161-1979 Steel tubes for structural purposes
IS: 1239 (Pt 1)-1990 Mild steel tubes, tubulars and other wrought steel fittings Part 1 Mild steel tubes
IS: 1239 (Pt 2)-1999 Mild steel tubes, tubulars and other wrought steel fittings: Part 2 Mild steel
tubular and other wrought steel fittings
IS: 1730-1989 Dimensions for steel plates, sheets~ strips and flats for general engineerProject
Managering purposes
IS: 1732-1989 Dimension for round and square steel bars for structural and general
engineerProject Managering purposes
IS: 1852-1973 Rolling and cutting tolerances for hot rolled steel products
IS: 2062-2006 Hot Rolled Low, medium and High Tensile structural Steel
IS: 3502 Steel chequered plates.
IS: 4923-1985 Hollow steel sections for structural use
IS: 7215 Tolerances for fabrication of steel structures
IS: 8910-1978 General technical requirements for steel and steel product
The use of the structural steel not covered by the above standards may be permitted with the specific
written approval of the Engineerapproval of the Project Director.

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B.E 13.3.2 Other Steel
Except where permitted with the specific written approval of the Engineerapproval of the Project
Director, steels for machined parts and for the uses in the other structural members or elements shall
comply with the following or equivalent Indian standards.
IS: 1875-1992 Carbon steel billets, blooms, slabs & bars for forgings
IS: 6911-1992 Stainless steel plate, sheet and strip
B.E 13.3.3 Castings and Forgings
Steel castings and forgings shall comply with the requirements of the following Indian Standards, or of
equivalent Standard approved by the EngineerProject Manager:
IS: 1030 Carbon Steel castings for General EngineerProject Managering purposes
IS: 1875 Carbon Steel Billets, blooms, slabs, bars for forgings
IS: 2004 Carbon Steel Forgings for General EngineerProject Managering purposes
IS: 2644 High Tensile Steel Casings
IS: 4367 Alloy & tool steel forgings for general industrial use.
B.E 13.3.4Fasteners
Mild steel for bolts and nuts shall conform to IS: 2062 but have a minimum tensile strength of 44
kg/sq. mm and minimum percentage elongation of 14. High tensile steel for bolts and nuts shall
conform to IS: 3757 but with a minimum tensile strength of 58 kg/sq. mm. High strength friction grip
bolts shall be permitted for use only on satisfactory evidence of performance to the requirements
specified by the EngineerProject Manager or included in the special provisions.
For cast steel, the yield stress shall be determined and shall not be less than 50 per cent of the
minimum tensile strength.
Plain washers shall be of steel. Tapered or other specially shaped washers shall be of steel, or
malleable cast iron.
Parallel barrel drifts shall have a tensile strength not less than 55 kg/sq. mm with elongation of not
less than 20 per cent measured on a gauge length of 4ÖSo (So = cross sectional area).
Bolts, nuts, washers and rivets shall comply with the following Indian Standards, or equivalent
Standard approved by the EngineerProject Manager:

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IS: 1363-2002 Hexagon head bolts, screws and nuts of (Pt 1 to Pt 3) product grade C (size range
M5 to M64)
IS: 1364-1992 Hexagon head bolts, screw and nuts (Pt 1 to Pt 3) products grade A & B (size
range M 1.6 to M64).
IS: 1367-1979-94 Technical supply conditions for threaded steel fasteners (Pt 1 to Pt 18) steel
fasteners
IS: 1929-1982 Hot forged steel rivets for hot closing (12 to 36 mm diameter)
IS: 2016-1967 Plain washers.
IS: 3063 Fasteners-single coil rectangular section spring washers.
IS: 3640-1982 Hexagon fit bolts
IS: 3757 -1985 High strength structural bolts
IS: 4000-1992 High strength bolts in steel structures-code of practice
IS: 5369-1975 General requirements for plain washers and lock washers
IS: 5370-1969 Plain washers with outside dia = 3 x inside dia.
IS: 5372-1975 Taper washers for channels (lSMC).
IS: 5374-1975 Taper washer for I beams (lSMB)
IS: 5624-1970 Foundation bolts
IS: 6610-1972 Heavy washers for steel structures
1S:6623-1985 High strength structural nuts
1S:6649-1985 Hardened and tempered washers for high strength structural bolts and nuts
18:7002-1991 Prevailing torque type steel hexagon nuts
B.E 13.3.5Welding Consumables
Welding consumables shall comply with the following Indian Standards as appropriate:
IS: 814 Covered Electrodes for Metal Arc welding of structural steel for (Part 1) welding other
than sheet.
IS: 814 For welding sheets. (Part 2)
IS: 1278 Filler rods and wires for gas welding
IS: 1395 Low and medium alloy steel covered electrodes for manual Metal Arc welding.
IS: 3613 Acceptance tests for wire flux combinations for submerged are welding of structural
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steel.
IS: 7280 Bare wire electrodes for gas shielded are welding of structural steel.
IS: 6419 Welding rods and bare electrodes for gas shielded are welding of structural steel.
IS: 6560 Molybdenum and chromium-molybdenum low alloy steel welding rods and bare
electrodes for gas shielded are welding.
B.E 13.3.6Welding
All welding work shall comply with the following Indian Railways Standard / Indian Standards or
equivalent standard as appropriate:
Indian Railways Standard Welded Bridge Code
IS: 812-1957 Glossary of terms relating to welding and cutting of metal
IS: 816-1969 Code of practice for use of metal arc welding for general construction in mild steel
IS: 822-1970 Code of procedure for inspection of welds
IS: 1024-1979 Code of practice for use of welding in bridges and structures subject to dynamic
loading
IS: 1182-1983 Recommended practice for radiographic examination of fusion welded butt joints in
steel plates
IS: 4353 -1995 Recommendations for submerged arc welding of mild steel and low alloy steels.
IS: 4853-1982 Recommended practice for radiographic inspection of fusion welded butt joints in
steel pipes
IS: 5334-1981 Code of practice for magnetic particle flaw detection of welds
IS: 7307(Pt. I) Approval tests for welding procedures: Part-l fusion welding of steel -1974
IS: 7310(Pt. I) Approval tests for welders working to approved welding -1974 procedures:Part-1
fusion welding of steel
IS: 7318(Pt.1) Approval tests for welders when welding procedure is not required: -1974 Part-l
fusion welding of steel
IS: 9595-1980 Recommendations for metal arc welding of carbon and carbon manganese steels
B.E 13.3.7 Wire Ropes and Cables
These shall conform to the following or relevant Indian Standards except where use of other types is
specifically permitted by the authority.
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IS: 1785 (Pt. 1) Specification for plain hard-drawn steel wire for prestressed concrete: -1983 Part-l
Cold drawn stress relieved wire
IS: 1785 (Pt. 2) Specification for plain hard-drawn steel wire for prestressed concrete: -1983 Part-2.
As- drawn wire
IS: 2266-1989 Steel wire ropes for general engineerProject Managering purposes
IS: 2315-1978 Thimbles for wire ropes
IS: 9282-1979 Wire ropes and strands for suspension bridges
B.E 13.3.8 Loadings and Design Specifications :
This Specification makes reference to the following Indian Standard codes, Indian Road Congress
codes, Indian Railway standard and Rules specifying the Loads for Design of super-structures and
sub-structure of Bridges (Bridge Rules) issued by RDSO:
B.E 13.3.8.1 Loading Codes
IS: 875 (Part-3) Code of practice for Wind Load and Bangladesh National Building Code (BNBC) .
IS: 1893 Code of practice for Seismic Load and Bangladesh National Building Code (BNBC) .
IRS Bridge Rules- Rules specifying the Loads for Design of super-structures and sub-structure of
Bridges (Bridge Rules) issued by RDSO.
B.E 13.3.8.2 Structural Steel and Steel Road Bridges
IRS Steel Bridge Code: Code of practice for design of steel or wrought iron bridges carrying rail, road
or pedestrian traffic.
IRC: 24-2001 Standard Specifications and code of practice for Steel Road Bridges (Section-V)
IRC: 83(Pt-I)-1999 Standard Specifications and code of practice for Steel Roads and Bridges
(Section-IX) Metallic Bearings.
IRC: 83(Pt-II)-1999 Standard Specifications and code of practice for Steel Roads and Bridges
(Section-IX) Elastomeric Bearings.
IS: 800- 1984 Code of practice for General Construction in Steel.

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B.E 13.3.8.3 IRS Specifications
R-19 Wheels and axles for carriages and wagons.
M-3 Class I, II, III & IV steel forgings, blooms for forgings and Billets for re-rolling.
M-28 Classification, testing and approval of metal-arc welding electrodes for use on Indian
Railways.
M-39 Classification, testing and approval of submerged- arc welding wire flux combination.
M-41 Corrosion resistance steel.
M-42 High strength low alloy structural steel with enhanced corrosion resistance
M-43 High strength low alloy structural steel rivet bars with enhanced corrosion resistance.
T-12 Flat bottom railway rails.
P-31 Zinc chromate read-oxide primer.
B.E 13.3.8.4 RDSO’s Specifications
M&C/PCN/102/96 Epoxy zinc phosphate primer.
M&C/PCN/103/86 Epoxy micaceous iron oxide.
M&C/PCN/109/88 Polyurethane red oxide.
M&C/PCN/110/88 Polyurethane aluminium.
M&C/PCN/111/88 High build Epoxy paint
B.13.3.8.5 Wherever reference to the standards mentioned in Item B.E 15.1 appears in the
Specification, it shall be taken as a reference to the latest version of the standards.
B.13.3.8.6 Any revision or addition or deletion of the provisions of this Specification shall be issued
only through the correction slip. No cognizance shall be given to any policy directives issued through
other means

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B.E 13.4 Fabrication
B.E 13.4.1 General
All Works shall be in accordance with the Drawings and as per these Specifications with care being
taken that all parts of an assembly fit accurately together. All members shall carry mark number and
item number and, if required, serial number.
Unless specifically required under the contract, corresponding parts need not be interchangeable, but
the parts shall be match marked as required under Item B.E 15.4.6.
Templates, jigs and other appliances used for ensuring the accuracy of the work shall be of mild steel;
where specially required, these shall be bushed with hard steel. All measurements shall be made by
means of steel tape or other device properly calibrated. Where bridge materials have been used as
templates for drilling, these shall be inspected and passed by the EngineerProject Manager before
they are used in the finished structure.
All structural steel members and parts shall have straight edges and blunt surfaces. If necessary, they
shall be straightened or flattened by pressure unless they are required to be of curvilinear forms. They
shall also be free from twist. Pressure applied for straightening or flattening shall be such as would not
injure the materials. Hammering shall not be permitted. Adjacent surfaces or edges shall be in close
contact or at uniform distance throughout.
The Contractor shall submit his Programme of Work to the EngineerProject Manager for his approval
at least 15 days before the commencement of fabrication. This Programme shall include the proposed
system of identification and erection marks together with complete details of fabrication and welding
procedures.
The Contractor shall prepare Working Drawings for fabricating any member and shall obtain approval
of the Engineerapproval of the Project Director before the start of work. Complete information
regarding the location, type, size and extent of all welds shall be clearly shown on the Working
Drawings. These Drawings shall have clear distinguishing symbols between shop and field welds.
B.E 13.4.2 Preparation of Edges and Ends
All structural steel parts, where required, shall be sheared, cropped, sawn or flame cut and ground
accurately to the required dimension and shape.
End or edge planning and cutting shall be done by any one of the following specified methods or left
as rolled:
Shearing, cropping, sawing, machining, machine flame cutting.
Hand flame cutting with subsequent grinding to a smooth edge.

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Sheared edges of plate not more than 16 mm thick with subsequent grinding to smooth profile, which
are for secondary use such as stiffeners and gussets.
If ends of stiffeners are required to be fitted, they shall be ground, so that the maximum gap over 60
per cent of the contact area does not exceed 0.25 mm.
Where flame cutting or shearing is used, at least one of the following requirements shall be satisfied:
The cut edge is not subjected to applied stress.
The edge is incorporated in weld.

The hardness of cut edge does not exceed 350 HV30.
The material is removed from edge to the extent of 2 mm or minimum necessary, so that the hardness
is less than 350 HV 30.
Edge is suitably heat treated by approved method to the satisfaction of the EngineerProject Manager
and shown that cracks had not developed by dye penetrant or magnetic particle test.
Thickness of plate is less than 40 mm for machine flame cutting for materials conforming to IS: 2062.
The requirement of hardness below 350 HV 30 of flame cut edges and to be approved by the
Whenever specified the EngineerProject Manager, the flame cut edges shall be ground or machined
over and above the requirement (a) to (f).
Where machining for edge preparation in butt joint is specified, the ends shall be smoothed by
grinding or filing.
In the case of high tensile steel at least 6 mm of the material from the flame cut edge shall be
removed by the machining.
Longitudinal edges of all plates and cover plates in plate girders and built-up members shall be
machined except in the following cases:
Rolled edges of single universal plates of flats may not be machined.
Covers to single flange plates may be left unmachined.
Machine flame cutting instead of machining is acceptable for edges of single plates in compression
and for edges of single plates, 25 mm or less thick, in tension.
Edges of single shaped plates over 25 mm thick not capable of being machined by ordinary method
may be machine flame cut and the end surface ground.
Edges of universal plates or flats of the same nominal width used in tiers may be left unmachined, if
so authorised by the EngineerProject Manager.
All edges of splice and gusset plates 12 mm thick and over shall be machined and those less than 12
mm thick may be sheared and ground.
The ends of plates and sections forming the main components of plate girders or of built-up members
shall be machined, machine flame cut, sawn or hand flame cut and ground.
Where ends of stiffeners are required to be fitted, they shall be machined, machine flame cut, sawn,
sheared and ground, or hand flame cut and ground. The ends of lacing bar shall be rounded unless
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otherwise required.
Other edges and ends of mild steel parts may be sheared and any burrs at edges shall be removed.
B.E 13.4.3 Preparation of Holes
B.E 13.4.3.1 Drilling and Punching
Holes for black bolts, high strength bolts and countersunk bolts (excluding close tolerance and turn
fitted bolts) shall be either punched or drilled. The diameter of holes shall be 1.5 mm larger for bolts
for less than 25 mm dia bolts and 2.0 mm for bolts of greater than 25 mm dia of bolts confirming to IS:
3757. The diameter of holes shall be 2.0 mm larger for bolts confirming to IS 4000:1992.
All holes shall be drilled except for secondary members such as floor plate, hand rails etc. Member
which does not carry the main load can be punched subject to the thickness of member not exceeding
12 mm for material conforming to IS: 2062.
Holes through more than one thickness of material or when any of the main material thickness
exceeds 20 mm for steel conforming to IS: 2062 or 16 mm for steel conforming to IS:961, IS:8500,
shall either be sub-drilled or sub-punched to a diameter of 3 mm less than the required size and then
reamed to the required size. The reaming of material more than one thickness shall be done after
assembly.
Where several plates or sections form a compound member, they shall, where practicable, be firmly
connected together by clamps or tacking bolts, and the holes be drilled through the group in one
operation. Alternatively, and in the case of repetition work, the plates and sections may be drilled
separately from jigs and templates. Jigs and templates shall be checked at least once after every 25
operations. All burrs shall be removed.
In the case of repetition of spans, he erection of every span shall not be insisted upon, except where
close tolerance or turned bolts are used, provided that methods are adopted to ensure strict
interchangeability. In such cases, one span in ten or any number less than ten of each type shall be
erected from pieces selected at random by the EngineerProject Manager and should there be any
failure of the pieces to fit, all similar spans shall be erected complete. In the event of spans being
proved completely interchangeable, all corresponding parts shall carry the same mark so that sorting
of the materials at Site is facilitated.
B.E 13.4.3.2 Block Drilling
Where the number of plates to be bolted exceeds three or the total thickness is 90 mm or more, the
bolt holes, unless they have been drilled through steel bushed jigs, shall be drilled out in place 3 mm
all round after assembling. In such cases, the work shall be thoroughly bolted together.

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B.E 13.4.3.3 Size of Holes
The sizes of holes in millimeters are given in Table – B.E 15-1 below:
TABLE- BE.15-1: DIAMETER OF HOLES FOR BOLTS
Nominal dia of bolts (mm) Dia of Holes (mm)

12 13.5
14 15.5
16 17.5
18 19.5
20 21.5
22 23.5
24 25.5
27 29.0
30 32.0
33 35.0
B.E 13.4.3.4 Close Tolerance Bolts and Barrel Bolts
Holes for close tolerance and turn fitted bolts. The diameter of the holes shall be equal to the nominal
diameter of the bolt shank minus 0.15 mm to 0.0 mm.
The members to be connected with close tolerance or turn fitted bolts shall be firmly held together by
service bolts or clamped and drilled through all thickness in one operation and subsequently reamed
to required size within specified limit of accuracy as specified in IS: 919 tolerance grade H8.
The holes not drilled through all thickness at one operation shall be drilled to smaller size and reamed
after assembly.
B.E 13.4.3.5 Holes for High Strength Friction Grip Bolts
All holes for high strength friction grip bolts shall be drilled after removal of burrs. Where the number
of plies in the grip does not exceed three, the diameters of holes shall be 1.5 mm larger for bearing
type joints and 2.0 mm larger for friction type joints and for more than three plies in grip, the diameters
of hole in outer plies shall be as above and dia of holes in inner plies shall not be less than 1.6 mm
and not more than 3.2 mm larger than those in bolts, unless otherwise specified by the
B.E 13.4.3.6 Removal of Burrs

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The Work shall be taken apart after drilling and all burrs left by drilling and the sharp edges of all rivet
holes completely removed.
B.E13.4.4 Bolts, Nuts and Washers
B.E13.4.4.1 Black Bolts
Black bolts are forged bolts in which the shanks, heads and nuts do not receive any further treatment
except cutting of screw threads. They shall be as per shape and size and shall have the standard
dimensions as shown on the Drawings as mentioned in the respective codes.
B.E 13.4.4 2 Close Tolerance Bolts
Close tolerance bolts shall be faced under the head and turned on the shank.
B.E 13.4.4.3 Turned Barrel Bolts
The diameter of the screwed portion of turned barrel bolts shall be 1.5 mm smaller than the diameter
of the barrel unless otherwise specified by the engineerProject Manager. The diameter of the bolts as
given on the drawing shall be the nominal diameter of the barrel. The length of the barrel shall be
such that it bears fully on all the parts connected. The threaded portion of each bolt shall project
through the nut by at least one thread. Faces of heads and nuts bearing on steel work shall be
machined.
B.E 13.4.4.4 High Strength Friction Bolts and Bolted Connections
The general requirement shall be as per relevant IS Specifications mentioned in clause 505.3 of
(Fasteners) of IRC: 24. Unless otherwise specified by the EngineerProject Manager, bolted
connections of structural joints using high tensile friction grip bolts shall comply with requirements
mentioned in IS: 4000-2003.
B.E 13.4.4.5 Washers
In all cases where the full bearing area of the bolt is to be developed, the bolt shall be provided with a
steel washer under the nut of sufficient thickness to avoid any threaded portion of the bolt being within

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the thickness of the parts bolted together and to prevent the nut when screwed up, from bearing on
the bolt.
For close tolerance or turned barrel bolts, steel washers whose faces give a true bearing shall be
provided under the nut. The washer shall have a hole diameter not less than 1.5 mm larger than the
barrel and a thickness of not less than 6 mm so that the nut when screwed up, will not bear on the
shoulder of the bolt.
Taper washers with correct angle of taper shall be provided under all heads and nuts bearing on
beveled surfaces.
Spring washers may be used under nuts to prevent slackening of the nuts when excessive vibrations
occur.
Where the heads or nuts bear on timber, square washers having a length of each side not less than
three times the diameter of bolts or round washers having a diameter of 3 ½ times of diameter of bolts
and with a thickness not less than one quarter of diameter shall be provided.
B.E 13.4.4.6 Service Bolts
Service bolts shall have the same clearance as black bolts and where it is required that there should
be no movement prior to final riveting, sufficient drifts or close tolerance bolts shall be used to locate
the work.
B.E 13.4.4.7 Tightening Bolts
Bolted connection joints with black bolts and high strength bolts shall be inspected for compliance of
requirements of IS: 4000 and IS: 3757.
The EngineerProject Manager shall observe the installation and tightening of bolts to ensure that
correct tightening procedure is used and shall determine that all bolts are tightened. Regardless of
tightening method used, tightening of bolts in a joint should commence at the most rigidly fixed or
stiffest point and progress towards the edges, both in initial snuggling and in final tightening.
The tightness of bolts in connection shall be checked by inspection wrench, which can be torque
wrench, power wrench or calibrated wrench.
Tightness of 10 percent bolts, but not less than two bolts, selected at random in each connection shall
be checked by applying inspection torque. If no nut or bolt head is turned by this application,
connection can be accepted as properly tightened, but if any nut or head has turned all bolts shall be
checked and, if necessary, re-tightened.
B.E 13.4.4.8 Drifts
The barrel shall be drawn or machined to the required diameter for a length of not less than one
diameter over the combined thickness of the metal through which the drifts have to pass. The
diameter of the parallel barrel shall be equal to the nominal diameter of the hole subject to a tolerance

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of +0 mm and –0.125 mm. Both ends of the drifts for a length equal to 1 ½ times the diameter of the
parallel portion of the bar shall be turned down with a taper to a diameter at the end equal to one-half
that of parallel portion.
B.E 13.4.5 Pins and Pin Holes
B.E 13.4.5.1 Pins
The pins shall be parallel throughout and shall have a smooth surface free from flaws. They shall be
of sufficient length to ensure that all parts connected thereby shall have a full bearing on them. Where
the ends are threaded, they shall be turned to a smaller diameter at the ends for the thread and shall
be provided with a pilot nut, where necessary, to protect the thread when being drawn to place.
Pins more than 175 mm in length or diameter shall be forged and annealed.
B.E 13.4.5.2 Pin Holes
Pin holes shall be bored true to gauge, smooth, straight at right angles to the axis of the member and
parallel with each other, unless otherwise required. The tolerance in the length of tension members
from outside to outside of pin holes and of compression members from inside to inside of pin holes
shall be one millimeter. In built-up members, the boring shall be done after the members have been
riveted or welded.
The specified diameter of the pin hole shall be its minimum diameter. The resulting clearance
between the pin and the hole shall not be less than 0.5 mm and not more than 1.0 mm.
B.E 13.4.6 Shop Drawings, Shop Erection and Match Marking
The Contractor shall prepare shop (fabrication) drawings and obtain EngineerProject Manager’s
approval prior to proceeding with fabrication of any structural steel work. The shop drawings shall
show clearly the cut lengths allowing for tolerances, drill hole sizes and positions, welding details,
dimensioned copes, notches or other section reductions or additions to rolled size in the final
fabricated member which should be clearly identified with a mark number. Cambering diagram to be
prepared conforming to IRS Steel Bridge Code as a part of fabrication drawing.
Before being dispatched, the steel work shall be temporarily erected in the fabrication shop for
inspection by the EngineerProject Manager either wholly or in such portion as the EngineerProject
Manager may require so that, both in respect of the alignment and fittings of all connections can be
checked and approved by the EngineerProject Manager. For this purpose, sufficient number of
parallel drifts and service bolts tightly screwed up shall be employed. All parts shall fit accurately and
be in accordance with Working Drawings and Specifications.
The steel work shall be temporarily assembled at place of fabrication. Assembly shall be of full truss
or girder, unless progressive truss or girder assembly, progressive chord assembly or special
complete structure assembly is approved by the EngineerProject Manager.
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The field connections of main members of trusses, arches, continuous beams, spans, bends, plate
girders and rigid frame assembled, aligned, accuracy of holes and camber shall be checked and
approved by the EngineerProject Manager and then only reaming of sub-size holes to specified size
shall be taken up.
After the Work has been approved by the EngineerProject Manager and before it is dismantled, each
part shall be carefully marked for re-erection with distinguishing marks and stamped with durable
markings. Drawings showing these markings correctly shall be supplied to the EngineerProject
Manager.
Unloading, handling and storage of steel work as per these Specifications shall be the responsibility of
the Contractor. The cost of repairs or of rejected material, its removal and the cost of transporting
replacement material to the Site shall be borne by the Contractor.
Where close tolerance or turned barrel bolts are used for cases where interchange ability is not
insisted upon, each span shall be erected and members of each span marked distinctly.
B.E 13.4.7Welding
B.E 13.4.7.1 General
All welding shall be done with the prior approval of the Engineerapproval of the Project Director and
the workmanship shall conform to the Specifications of IRS Welded Bridge Code or other relevant
Indian Standards as appropriate.
Surfaces and edges to be welded shall be smooth, uniform and free from fins, tears, cracks and other
discontinuities. Surface shall also be free from loose or thick scale, slag rust, moisture, oil and other
foreign materials. Surfaces within 50 mm of any weld location shall be free from any paint or other
material that may prevent proper welding or cause objectionable fumes during welding.
The general welding procedures including particulars of the preparation of fusion faces for metal are
welding shall be carried out in accordance with IS: 9595.
The welding procedures for shop and Site welds including edge preparation of fusion faces shall be
submitted in writing in accordance with Clause 22 of IS:9595 for the approval of the Engineerapproval
of the Project Director before commencing fabrication and shall also be as per details shown on the
Drawings. Any deviation from above has to be approved by EngineerProject Manager. Preparation of
edges shall, wherever practicable, be done by machine methods.
Machine flame cut edges shall be substantially as sooth and regular as those produced by edge
planning and shall be left free of slag. Manual flame cutting shall be permitted by the EngineerProject
Manager only where machine cutting is not practicable.
Electrodes to be used for submerged metal arc welding shall conform to IRS M-28. The filler wire and
flux combinations for submerged arc welding shall conform to IRS Specification M-39.
Assembly of parts for welding shall be in accordance with provision of IS: 9595.
The welded temporary attachment should be avoided as far as possible, otherwise the method of
making any temporary attachment shall be approved by the EngineerProject Manager. Any scars from
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temporary attachment shall be removed by cutting, chipping and surface shall be finished smooth by
grinding to the satisfaction of the EngineerProject Manager.
Welding shall not be done when the air temperature is less than 10 degrees Celsius. Welding shall
not be done when the surfaces are moist, during periods of strong winds or in snowy weather unless
the work and the welding operators are adequately protected.
B.E 13.4.7.2 For welding of any particular type of joint, welders shall qualify to the satisfaction of the
EngineerProject Manager in accordance with appropriate welders qualification test as prescribed in
any of the Indian Standards IS: 817, IS:1966, IS:1393, IS:7307 (Part I), IS:7310 (Part I) and IS:7318
(Part I) as relevant.
B.E 13.4.7.3 In assembling and jointing parts of a structure or of built up members, the procedure and
sequence of welding shall be such as to avoid distortion and minimize shrinkage stress.
All requirements regarding pre-heating of parent material and inter-pass temperature shall be in
accordance with provision of IS: 9595.
B.13.4.7.4 Peening of weld shall be carried out wherever specified by

the EngineerProject Manager:
If specified, peening may be employed to be effective on each weld layer except first.
The peening should be carried out after weld has cooled by light blows from a power hammer using a
round nose tool. Care shall be taken to prevent scaling or flaking of weld and base metal from over
peening.
B.E 13.4.7.5 Where the EngineerProject Manager has specified the butt welds are to be ground flush,
the loss of parent metal shall not be greater than that allowed for minor surface defects. The ends of
butt joints shall be welded so as to provide full throat thickness. This may be done by use of extension
pieces, cross runs or other means approved by the EngineerProject Manager. Extension pieces shall
be removed after the joint has cooled and the ends of the weld shall be finished smooth and flush with
the faces of the abutting parts.
The joints and welds listed below are prohibited type, which do not perform well under cyclic loading.
Butt joints not fully welded throughout their cross-section
Groove welds made from one side only without any backing grip
Intermittent groove welds
Intermittent fillet welds
Bevel-grooves and J-grooves in butt joints for other than horizontal position.
Plug and slot welds.
B.E 13.4.7.6 The run-on and run-off plate extension shall be used providing full throat thickness at the
end of butt welded joints. These plates shall comply with the following requirements.
One pair of “run-on” and one pair of “run-off” plates prepared from same thickness and profile as the
parent metal shall be attached to start and finish of all butt welds preferably by clamps.
When “run-on” and “run-off” plates shall be removed by flame cutting, it should be cut at more than 3
mm from parent metal and remaining metal shall be removed by grinding or by any other method
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B.E 13.4.7.7 Tolerances
Tolerances in dimensions of components of fabricated structural steel work shall be specified on the
Drawings and shall be subject to the approval of the Engineerapproval of the Project Director before
fabrication. Unless specified, all parts of an assembly shall fit together accurately within tolerances
specified in Table-C15-2.
A machined bearing surface, where specified by the EngineerProject Manager, shall be machined
within a deviation of 0.25 mm for surfaces that can be inscribed within a square of side 0.5 m.

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TABLE- BE .15-2 FABRICATION TOLERANCES
A. INDIVIDUAL COMPONENTS
Length
Member with both ends finished for contact ± 1 mm
bearing
Individual components of members with end plate + 0 mm,- 2 mm
connection
Other members
i) Upto and including 12 M ± 2 mm
ii) Over 12 M ± 3.5 mm
Width
Width of built-up girders ± 3 mm
Deviation in the width of members required to be + 0 mm,- 3 mm
inserted in other members
Depth
Deviation in the depths of solid web and open web + 3 mm,- 2 mm
girders.
Straightness
Deviation from straightness of columns L/3000 subject to a maximum of 15 mm where L is
length of member
i) In elevation + 5 mm,- 0 mm
ii) In plan L/1000 subject to a maximum of 10 mm
Deviation of centre line of web from centre line of

flanges in built-up members at contact surfaces 3 mm
Deviation from flatness of plate of webs of built-up 0.005 d to a maximum of 2 mm where d is depth of
members in a length equal to the depth of the the member.
member.
Tilt of flange of plate girders

At splices and stiffeners, at supports, at the top 0.005 b to a minimum of 2 mm where b is width of
flanges of plate girders and at bearings the member.
At other places 0.015 b to a maximum of 4 mm where b is width of

the member.
Deviation from squareness of flange to web of L/1000, where L is nominal length of the diagonal
columns and box girders

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Deviation from squareness of fixed base plate (not D/500, where D is the distance from the column axis
machined) to axis of column. This dimension shall to the point under consideration on the base plate.
be measured parallel to the longitudinal axis of the
column at points where the outer surfaces of the
column sections make contact with the base plate.
Deviation from squareness of machined ends to D/1000,where D is as defined in 9 above

axes of columns
Deviation from squareness of machined ends to D/1000, where D is as defined in 9 above

axes of beams or girder.
Ends of members abutting at joints through cleats I/600 of depth of member subject to a maximum of
or end plates, permissible deviation from 1.5 mm
squareness of ends.
B.E 13.5 Erection
B.E 13.5.1 General
The provisions of this item shall apply to erection of steel bridge superstructures or main members of
bridge superstructures, which span between supports.
The Contractor shall erect the structural steel, remove the temporary construction, and do all the work
required to complete the construction included in the contract in accordance with the Drawings and
the Specifications and to the entire satisfaction of the EngineerProject Manager.
B.E 13.5.2 Organisation and Equipment
The Contractor shall submit a Method statement describing the methodology and procedure of
erection, compatible with the details of fabrication with the supporting design calculations for the same
for EngineerProject Manager’s approval.
A detailed scheme must be prepared showing stage wise activities, with complete Working Drawings
and working phase wise instructions by the EngineerProject Manager. This shall be based on detailed
stage wise calculation and take into account Specifications and capacity of erection equipment
machinery, temporary supporting structures, stools, tackles to be used and temporary working loads
as per codal provisions.
The scheme shall be based on site conditions e.g. hydrology, rainfall, flood timings and intensity, soil
and sub-soil conditions in the river bed and banks, maximum water depth, temperature and climatic
conditions and available working space and other conditions as directed by the EngineerProject
Manager.
The scheme shall indicate precisely the type of temporary fasteners to be used as also the minimum
percentage of permanent fasteners to be fitted during the stage erection. The Working Drawings shall
show clearly the temporary jigs, fixtures, clamps, spacer supports, etc.

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The Contractor shall supply and erect all necessary false work, staging, any other necessary
arrangements to erect or transport the bridge components at the locations as per Working Drawings
and shall supply all labour, tools, erection plant and other materials necessary to carry out the Work
complete in all respects.
The Contractor shall supply all bolts, nuts, washers, etc. required to complete erection at site with an
allowance for wastage, etc., of 12 ½ per cent of the net number of field bolts, washers required, or a
minimum of five number of each item.
Service bolts and nuts, ordinary platters, washers, drifts and all other temporary works necessary for
erection of the bridge components shall be supplied by the Contractor for which no extra payment will
be made.
Prior to actual commencement of erection all equipment, machinery, tools, tackles, ropes, etB. shall
be tested to ensure their efficient working capacity. Frequent visual inspection shall be made by the
Contractor in vulnerable areas to detect displacements, distress, drainages, etc.
Deflection and vibratory tests shall be conducted in respect of supporting structures, launching truss
as also the structure under erection and unusual observations reviewed; looseness of fittings are to
be noted.
For welded structures, welders’ qualifications, certificates shall be submitted and approved by the
EngineerProject Manager. Non-destructive tests of joints as per EngineerProject Manager’s directives
are to be carried out.
Precision non-destructive testing instruments available in the market shall be used for noting various
important parameters of the structures frequently and systematic record is to be kept.
Safety requirements shall conform to IS:7205, IS:7273 and IS:7269 as applicable and shall be a
consideration of safety, economy and rapidity
Erection work shall start with complete resources mobilized as per approved Working Drawings and
after a thorough survey of foundations and other related structural Works.
The structure shall be divided into erectable modules as per the scheme and shall be approved by the
EngineerProject Manager. This shall be pre-assembled in a suitable yard or platform and its matching
with members of the adjacent module checked by trial assembly before erection.
The structure shall be set out to the required lines and levels. The stocks and masses are to be
carefully preserved. The steelwork shall be erected, adjusted and completed in the required position
to the specified line and levels with sufficient drifts and bolts. Packing materials are to be available to
maintain this condition. Organized “Quality Surveillance” checks shall be exercised frequently.
Before starting work, the Contractor shall obtain necessary approval of the Engineerapproval of the
Project Director as to the method adopted for erection, the number and character of tools and plants.
The approval of the Engineerapproval of the Project Director shall not relieve the Contractor of his
responsibility for the safety of his method or equipment or from carrying out the work fully in
accordance with the approved Working Drawings and Specifications.
During the progress of work, the Contractor shall employ a competent EngineerProject Manager or
foreman in charge of the work, who shall be adequately experienced in steel erection and acceptable
to the EngineerProject Manager.

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B.E 13.5.3 Handling and Storing of Materials
Suitable area for storage of structures and components shall be located near the site of work. The
access road should be free from water logging during the working period and the storage area should
be on leveled and firm ground.
The store should be provided with adequate handling equipments e.g., road mobile crane, gantries,
derricks, chain pulley blocks, winch of capacity as required. Stacking area should be planned and
have racks, stands, sleeper, access tracks, etc., and properly lighted.
Storage should be planned to suit erection work sequence and avoid damage or distortion.
Excessively rusted, bent or damaged steel shall be rejected. Methods of storage and handling steel,
whether fabricated or not shall be subject to the approval of the Engineerapproval of the Project
Director.
Fabricated materials are to be stored with erection marks visible in fully covered sheds, such as not to
come into contact with earth surface and storm water and should be accessible to handling
equipment.
Small fitting hand tools are to be kept in containers in covered stores.
All materials, consumables, including raw steel or fabricated material shall be stored specification
wise and size wise above the ground upon platforms, skids or other supports in fully covered sheds. It
shall be kept free from dirt and other foreign matter and shall be protected as far as possible from
corrosion and distortion. The electrodes shall be stored specification wise and shall be kept in dry
warm condition in properly designed racks. The bolts, nuts, washers and other fasteners shall be
stored on racks above the ground with protective oil coating in gunny bags. The paint shall be stored
under cover in air-tight containers.
IS:7293 and IS:7969 dealing with handling of materials and equipments for safe working should be
followed. Safety nuts and bolts as directed are to be used while working. The Contractor shall be held
responsible for loss or damage to any material paid for by the EmployerProject Director while in his
care or for any damage to such material resulting from his work.
B.E 13.5.4 Formwork
The formwork shall be properly designed, substantially built and maintained for all anticipated loads.
The Contractor, if required, shall submit plans and calculations for approval to the EngineerProject
Manager. Approval of the plans, however, shall not relieve the Contractor of his responsibility under
the Contract.
B.E 13.5.5 Straightening Bent Material

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The straightening of plates, angles and other shapes shall be done by methods not likely to produce
fracture or any injury. The metal shall not be heated unless permitted by the EngineerProject Manager
for special cases, when the heating shall not be to a temperature higher than that producing a dark
“cherry red” colour, followed by as slow cooling as possible. Following the straightening of a bend or
buckle the surface shall be carefully investigated for evidence of fracture. Sharp kinks and bends may
be the cause for rejection of material.
B.E 13.5.6 Assembling Steel
The parts shall be accurately assembled as shown on the Drawings and match marks shall be
followed. The material shall be carefully handled so that no parts will be bent, broken or otherwise
damaged.
Hammering which will injure or distort the members shall not be done. Bearing surface or surfaces to
be in permanent contact shall be cleaned, before the members are assembled. The truss spans shall
be erected on blocking, so placed as to give the proper camber. The blocking shall be left in place
until the tendon chord splices are fully riveted and all other truss connections pinned and bolted.
Rivets in splices of butt joints of compression members and rivets in railings shall not be driven until
the span has been swung.
All joint surface for bolted connections including bolts, nuts, washers shall be free from scale, dirt,
burrs, other foreign materials and defects that would prevent solid seating of parts. The slope of
surface of bolted parts in contact with bolt head an nut shall not exceed 1 in 20, plane normal to bolt
axis, otherwise suitable tapered washer shall be used.
All fasteners shall have a washer under nut or bolt head whichever is turned in tightening.
Any connection to be bolted shall be secured in close contact with service bolts or with a sufficient
number of permanent bolts before the connections are finally bolted. Joints shall normally be made
by filling not less than 50 per cent of holes with service bolts and barrel drifts in the ratio 4:1. The
assembled connections to be made by close tolerance or barrel bolts shall be completed as soon as
practicable after assembly.
Any connection to be welded shall be securely held in position by approve methods to ensure
accurate alignment, camber and elevation before welding is commenced.
The field welding, bolted and pin connection shall conform to the requirements of clause 1904 as
appropriate.
The correction of minor misfits involving harmless amounts of reaming, cutting and chipping will be
considered a legitimate part of erection. However, any error in the shop fabrication or deformation
resulting from handling and transportation which prevents proper assembling and fitting up of parts by
moderate use of drifts or by a moderate amount of reaming and slight chipping or cutting shall be
reported immediately to the EngineerProject Manager and his approval of the method of correction
obtained. The correction shall be made in the presence of the EngineerProject Manager.

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B.E 13.5.7 Field Inspection
B.E 13.5.7.1 General
All materials, equipment and work of erection shall be subject to the inspection of the EngineerProject
Manager who shall be provided with all facilities including labour, tools and equipment required at all
reasonable times. Any Work found defective or not complying with the Working Drawings and
Specifications shall be rejected.
No protective treatment over the components shall be applied until the appropriate inspection and
testing has been carried out. The stage inspection shall be carried out for all operations so as to
ensure the correctness of fabrication and specified quality. Girder dimensions and camber shall not be
finally checked until all welding and heating operations are completed and the member has cooled to
a uniform temperature.
B.E 13.5.7.2 Testing of Material
Structural steel shall be tested for mechanical and chemical properties as per IS codes as may be
applicable and shall conform to requirements of Specifications IS:2062 and all other relevant
standards.
Bolts, nuts, washers, welding consumables, steel forging, casting and stainless steel shall be tested
for mechanical and chemical properties in the appropriate IS Code.
Rolling and cutting tolerance shall be as per IS: 1852. The thickness tolerance check measurements
for the plate and rolled sections shall be taken at not less than 15 mm from edge.
Laminations in plates shall be carried out by ultra-sonic testing or equivalent methods after approval
of EngineerProject Manager.
Steel Work shall be inspected for surface defects and exposed edge laminations during fabrication
and blast cleaning. Significant edge limitation found shall be reported to the EngineerProject Manager
for his decision.
Chipping, grinding, machining or Ultrasonic testing shall be used to determine depth of imperfection.
B.E 13.5.7.3 Bolted Connections
Bolts and bolted connection joints with high strength friction grip bolts shall be inspected and tested
according to IS: 4000.

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B.E 13.5.7.4 Welding and Welding Consumables
Welding procedure, welded connection and testing shall be in compliance with codal requirements.
All facilities necessary for stage inspection during welding and on completion shall be provided to the
EngineerProject Manager
Adequate means of identification either by identification mark or other record shall be provided to
enable each weld to be traced to the welder(s) by whom it was carried out.
All metal arc welding shall be in compliance with IS:9595 provisions.
All submerged arc welding shall be in compliance with IRS welded Bridge Code.
The method of inspection shall be in accordance with IS:822 and extent of inspection and testing shall
be in accordance with the relevant standards or in the absence of such a standard, as agreed with the
B.E 13.5.7.5 Procedure Test
The Destructive and Non-destructive test of weld shall be carried out according to IS: 7307 (Part I).
Non-Destructive Testing of welds
One or more of the following methods may be applied for inspection or testing of weld:
i) Visual Inspection: All welds shall be visually inspected, which should cover all defects of weld
such as size, porosity, crack in the weld or in the HAZ (Heat Affected Zone) etc. Suitable magnifying
glass may be used for visual inspection. A weld shall be acceptable by visual inspection if it shows
that:
The weld has no cracks.
Through fusion exists between weld and base metal and between adjacent layers of weld metal.
Weld profiles are in accordance with requisite clauses of IS:9595 or as agreed with the
The weld shall be of full cross section, except for the ends of intermittent fillet welds outside their
effective length.
When weld is transverse to the primary stress, undercut shall not be more than 0.25 mm deep in the
part that is undercut and shall not be more than 0.8 mm deep when the weld is parallel to the primary
stress in the part that is undercut.
The fillet weld in any single continuous weld shall be permitted to under run the nominal fillet weld size
specified by 1.6 mm without correction provided that undersize portion of the weld does not exceed 10
per cent of the length of the weld. On the web-to-flange welds on girders, no under-run is permitted at
the ends for a length equal to twice the width of the flange.

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The piping porosity in fillet welds shall not exceed one in each 100 mm of weld length and the
maximum diameter shall not exceed 2.4 mm, except for fillet welds connecting stiffeners to web where
the sum of diameters of piping porosity shall not exceed 9.5 mm in any 25 mm length of weld and
shall not exceed 19 mm in any 300 mm length of weld.
The full penetration groove weld in butt joints transverse to the direction of computed tensile stress
shall have no piping porosity. For all other groove welds, the piping porosity shall not exceed one in
100 mm length and the maximum diameter shall not exceed 2.4 mm.
ii) Magnetic particle and Radiographic Inspection: Welds that are subject to radiographic or
magnetic particle testing in addition to visual inspection shall have no crack.
Magnetic particle test shall be carried out for detection of crack and other discontinuity in the weld
according to IS:5334.
Radiographic test shall be carried out for detection of internal flaws in the weld such as crack, piping
porosity inclusion, lack of fusion, incomplete penetration, etc. This test may be carried out as per
IS:1182 and IS:483.
Acceptance Criteria: The weld shall be unacceptable if radiographic or magnetic particle testing
shows any of the type of discontinuities indicated in the code.
iii. Ultrasonic Inspection: The Ultrasonic testing in addition to visual inspection shall be carried out
for detection f internal flaws in the weld such as cracks, piping porosity inclusion, lack of fusion,
incomplete penetration, etc. Acceptance criteria shall be as per IS: 4260 or any other relevant IS
specification and as agreed to by the engineerProject Manager.
iv. Liquid Penetration Inspection: The liquid penetration test shall be carried out for detection of
surface defect in the weld, as per IS: 3658, in addition to visual inspection.
The non-destructive testing of following welds be carried out using one of the method or methods
described at (ii), (iii) and (iv) above, as may be agreed to by the engineerProject Manager.
All transverse butt welds in tension flange

10 per cent of the length of longitudinal and transverse butt welds in tension flanges
5 per cent of the length of longitudinal and transverse butt welds in compression flanges.
All transverse butt welds in webs adjacent to tension flanges as specified by the engineerProject
Manager.
The particular length of welds in webs to be tested shall be agreed with the EngineerProject Manager,
in case of (b) or (c).
Where specified by the EngineerProject Manager, bearing stiffeners or bearings diaphragms adjacent
to welds flange plates adjacent to web/flange welds, plates at cruciform welds, plates in box girder
construction adjacent to corner welds or other details shall be ultrasonically tested after fabrication.
Any lamination, lamellar tearing or other defect found shall be recorded and reported to
EngineerProject Manager for his decision.
Testing of welding for cast steel: The testing of weld for cast steel shall be carried out as may be
agreed to by the EngineerProject Manager.

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B.E 13.5.7.6 Inspection Requirement
The fabricated member or component made out of rolled and built-up section shall be checked for
compliance of the tolerances given in Table-C15-2. Inspection of member or components for
compliance with tolerances, and the check for deviations shall be made over the full length as per
codal requirements.
During checking, the inspection requirement shall be placed in such a manner that local surface
irregularities do not influence the results.
For plate out-of-plane deviation shall be checked at right angle to the surface over the full area of
plate.
The relative cross-girder or cross frame deviation shall be checked over the middle third of length of
the cross girder or frame between each pair of webs and for cantilever at the end of member.
The web of rolled beam or channel section shall be checked for out-of-plane deviation in longitudinal
direction equal to the depth of the section.
During inspection, the component or member shall not have any load or external restraint.
B.E 13.5.7.7 Inspection Stages
The inspection to be carried out for compliance of tolerances shall include but not be limited to the
following stages:
For completed parts, component/members on completion of fabrication and before any subsequent
operation such as surface preparation, painting, transportation, erection.
For webs of plate and box girder, longitudinal compression flange stiffeners in box girders and
orthotropic decks and all web stiffeners at site joints, on completion of site joint.
For cross girders and frames, cantilevers in orthotropic decks and other parts in which deviations
have apparently increased on completion of site assembly.
Where, on checking member/component for the deviations in respect of out-of-plane or out-of-

straightness at right angles to the plate surface, and any other instances, exceed tolerance, the
maximum deviation shall be measured and recorded. The recorded measurements shall be submitted
to the EngineerProject Manager who will determine whether the component/member may be
accepted without rectification, with rectification or rejected.
B.E 13.5.8 Testing
All structural steel shall have been specifically tested in accordance with the appropriate material
quality standard shown and shall conform with the Standards specified. The acceptance criteria for

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tests shall be as specified in the relevant standard. If not clearly specified the acceptance criteria shall
be determined by the EngineerProject Manager.
The Contractor shall have access to the manufacturer’s test certificates (Mill certificates) pertaining to
all tests referred to in the Standards. All structural steel and welding consumables delivered to Site
shall be covered by such certificate or certificates pertaining to the lot of which the consignment
delivered to Site forms part.
In addition the Contractor shall test a sample consisting of three specimens randomly selected by the
EngineerProject Manager for testing in a designated Laboratory at the Contractor’s expense.
The Contractor shall make provision to enable the EngineerProject Manager to visit the fabrication
works, to enable him to select random samples and test them at a designated laboratory. Moreover,
he shall make provision for testing to be carried out by the Inspecting Agency as per Contract
Fabricated steel girders shall be checked for camber and deflection under proof load upon erection on
bridge bearings to loads specified in IRS.
B.E 13.6 Painting
B.13.6.1 Introduction
B.E 13.6.1.1 The relevant paint manufacturer's product data sheets shall form part of this
Specification.
B.E 13.6.1.2 It is the Contractor's responsibility to ensure that he is conversant with all aspects of this
Specification and to clarify any doubts prior to commencement.The EngineerProject Manager shall be
consulted regarding points not covered herein.
B.E 13.6.2 Scope
B.13.6.2.1 This specification applies to the surface preparation and shop coating external (exposed)
surfaces of the steel bridge spans.
B.E 13.6.2.2 All external surfaces shall be coated except as noted below:
B.E 13.6.2.2.1 Any weld margins to be site welded shall be left uncoated approximately 75mm
width at the edges. Contact surfaces of high strength bolted connections shall be masked and
maintained as rolled. These surfaces and any other surfaces not to be coated shall be protected by
appropriate masking.
B.E 13.6.2.3 The Contractor shall furnish all personnel, equipment, services and material, including
coatings and tools, necessary to perform the work required under this Specification.

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B.E 13.6.3Surface Preparation
B.E 13.6.3.1 All sharp edges shall be rounded as specified herein. All edges must be reduced to a
minimum of 2 mm. (This allows the coating to be applied at the correct DFT.)
All weld defects such as spatter, undercut, rough beads, etc. shall be removed by grinding or weld
repair. Any defects which show up after blast cleaning shall be repaired and re-blasted.
B.E 13.6.3.2 Any oil and grease shall be removed by a method designated in AS 1627 Part 1.
B.E 13.6.3.3 The surface shall be blast cleaned with steel grit or garnet to AS 1627 Part 4 Class 2.5
with a profile between 40 microns and 80 microns, as measured by Testex replica tape (Method A in
AS/NZS 3894 Part 5). Testex replica tape records shall be affixed to the report form. All abrasives
shall be clean, dry and free from oil, dust or other foreign matter. The compressed air supply shall be
free from oil and moisture.
B.E 13.6.3.4 Spent abrasive and dust shall be removed from the surface by blowing with clean, dry air
and/or vacuum cleaning.
B.E 13.6.3.5 The prepared surface shall be coated before flash rusting or contamination of the
surface occurs. Should the surface become contaminated or flash rusting occurs, the blast cleaning
operation in accordance with this specification must be repeated.
B.E 13.6.3.6 The EngineerProject Manager or his representative shall approve surface preparation
prior to application of the coating.
B.13.6.4 Coating Materials
B.E 13.6.4.1 The coating system (EHB6 in AS/NZS 2312-2002) shall consist of a single coat of epoxy
zinc primer applied to a minimum dry film thickness of 75 microns followed by two coats of micaceous
iron oxide (MIO) epoxy each applied to a minimum dry film thickness of 125 microns.
B.E 13.6.4.2 The first coat of MIO shall be metallic grey and the top coat MIO colour shall be
aluminum.
B.E 13.6.4.3 Storage, handling, mixing, thinning and application of the material shall be in accordance
with the manufacturer's recommendations. All coatings shall be used prior to expiration of shelf life,
and catalyzed coatings shall be used prior to expiration of pot fife.
B.E 13.6.4.4 Approved products are shown in Table 1 (below):

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Table - Approved Produce
Primer DFT DFT total

Supplier Top Coats DFT (um)
Product (um) (um)
Ameron Amercoat 2 x Amerlock 2K MIO
75 125 each 325
68K
Dulux Zincanode 2 x Ferreko No. 3
75 125 each 325
402
International Interzinc 52 75 2 x Intergard 475 MIO 125 each 325
International Interzinc 215 2 x InterCURE 420
75 125 each 325
MIO
Jotun Barrier 75 2 x Jotaspeed MIO 125 each 325
Wattyl Galvit EP 100 2 X Sigmacover CM
75 125 each 325
Miocoat
Rapid recoat, low temperature cure epoxies may be used if approved in writing by the Superintendent.
B.E 13.6.4.5 All pints and thinners used in a system shall be from one paint manufacturer.
B.E 13.6.4.6 The MIO top coat colour shall be natural steel grey (charcoal). The Contractor shall
submit to the EngineerProject Manager for review and approval information regarding the coatings to
be used, and a sample of the finished product an at least a 0.5 meter by 0.5 meter steel plate. The
test panel shall be available for reference at the Contractor’s premise
B.E 13.6.5Application of Coating
B.E 13.6.5.1 A stripe coat of primer shall be applied by brush to all welds, corners, edges and
any other areas not fully reachable by spray to obtain specified coverage and thickness.
B.E 13.6.5.2 Ensure the primer is fully cured before over coating.
B.E 13.6.5.3 Each coat shall be free from runs, sags, drips, embedded debris and other visible
defects. Any runs, sags or dry spray in the primer coat shall be removed before application of the top
coat. Any surfaces which become contaminated shall be thoroughly cleaned before application of the
subsequent coat.
B.E 13.6.5.4 Dry film thickness of the primer and complete system shall be measured using an
electronic gauge according to AS 5894 Part 3. At least 10 reading per item shall be taken, and
readings shall meet the requirements of AS 3894.3 Clause 1.8.3.
B.E 13.6.5.5 Adhesion testing to AS 3894.9-2003 on a test sample on at least a 0.5 meter by
0.5 meter steel plate shall be prepared by the Contractor. This shall be submitted to the
EngineerProject Manager for review and approval. The test panel shall be available for reference at
the Contractor’s premises.
B.E 13.6.5.6 Defects shall be repaired according to paragraph B.E15.7.7.
B.E 13.6.5.7 The EngineerProject Manager or his representative shall approve coating
application before shipping.

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B.E 15.6.6Handling, Transport and Storage
B.E 13.6.6.1 The Contractor shall ensure that the items are stored, handled and shipped in a manner
as to minimize damage. Any slings used for lifting shall be cushioned to prevent coating damage. Soft
packing must be placed between slings and painted surfaces. Painted members must not be stacked
on top of one another. Any damage shall be repaired according to paragraphs B.E 15.7.7 and B.E
15.7.9.
B.E 13.6.7Repair or Remedial Work
B.E 13.6.7.1 Any defects occurring after the maximum recoat period shall be corrected by abrading
the affected area and applying a coat according to the manufacturer's recommendations. Edges of
coatings are to be feathered or tapered. Abrasives or other foreign particles are not permitted within
the coating. Wire brushes shall not be used. Repaired areas and repair procedures shall be recorded
in the Contractor's reports.
B.E 13.6.7.2 A test sample for a typical repair on at least a 0.5 meter by 0.5 meter steel plate shall be
prepared by the Contractor. This shall be submitted to the EngineerProject Manager for review and
approval. The test panel shall be available for reference at the Contractor's premises.
B.E 13.6.8 Field Painting
B.E 13.6.8.1 Field splice joints comprising primed splice plates, bolts and primed surfaces shall be top
coated on completion of the joints. Surface preparation, coatings, quality assurance and inspection
requirements shall comply with these specifications and the Painting Map in Table 2 below.
B.E 13.6.8.2 Field welds, the heads of bolts and all areas where the shop paint has been
damaged but will be coated with this coating system, shall be treated according to paragraphs
B.15.7.7 and
B.E 13.6.9On-site Repair Procedures
B.E 15.6.9.1 The following procedure outlines the steps necessary for remedial work to be
done to protective coatings on steelwork damaged as a result of installation of steelwork, welding and
bolting for the Steel Bridges.
B.E 13.6.9.2 For items of high visibility where aesthetics is important, it is essential that the repaired
sections ate kept to a minimum in surface area i.e. chain mark repairs should be feathered to a
maximum of 10mm around the actual damaged. A small 10-20mm brush may be necessary for
application of the topcoat.
B.E 13.6.9.3 Where the defects are numerous and scattered, it may be necessary to apply the topcoat
in full up to the first break i.e., weld or edge. A nook and cranny roller may be necessary.
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B.E 13.6.9.4 Touch up of Metallic or MIO finishes will be noticeable and tinting of the product used for
touch up may be required for a less noticeable repair. This should be done in accordance with the
manufacturers instructions. Guidancs is given below for damage as a result from welding, chain
marks and bolting to the System 1 - EZS plus 2/MIO:
B.E 13.6.9.4.1 Damage to topcoat only (lntegrity of primer and intermediate coats intact).
B.E 13.6.9.4.1.1 Surface Preparation:
Surfaces should be free of oil, grease and salt contamination. Remove all loose and poorly adherent
coatings by power tool or hand sanding. Abrade the edge of the sound finish coat (feather over a
10mm width, less if possible) to ensure good adhesion prior to painting. Ensure the surface is clean
and dry before painting.
B.E 13.6.9.4.1.2 Topcoat
Apply MIO to a dry film thickness of 125microns (180 microns WFT) in accordance with the
manufacturers product data sheet Where the damage to the topcoat is numerous and in a highly
visible area, the MIO should be applied in full by either spray or roller to the first break i.e. weld or
edge.
B.E 13.6.9.4.2 Damage to top and intermediate coats (Integrity of primer coat is intact).
B.E 13.6.9.4.2.1 Surface Preparation
coatings by power tool or hand sanding. Abrade the edge of the sound finish coat (feather over a
10mm width, less if possible) to ensure good adhesion prior to painting. Ensure the surface is clean
and dry before painting.
B.E 13.6.9.4.2.2 Intermediate Coat
Spot apply by brush, roller or spray MIO to a dry film thickness of 125microns (180 microns WFT) in
accordance with the manufacturers product data sheets.
B.E 13.6.9.4.2.3 Topcoat
Apply MIO to a dry film thickness of 125 microns (180 microns WFT) in accordance with the
manufacturer’s product data sheet table 1, Where the damage to the topcoat is numerous and in a
highly visible area, the MIO should be applied in full by either spray or roller to the first break i.e., weld
or edge.
B.E 13.6.9.4.3 Damage to topcoat, intermediate & primer coats (Primer coat damaged &/or bare
steel exposed & corrosion evident.)
B.E 13.6.9.4.3.1 Surface Preparation
coatings and corrosion product by power tool cleaning to an St 3 standard. Abrade the edge of the
sound finish coat (feather over a 10mm width, less if possible) to ensure good adhesion prior to
painting. Ensure the surface is clean and dry before painting.
B.E 13.6.9.4.3.2 Primer Coat

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Spot apply MIO by brush or roller to a dry film thickness of 75microns (127microns WFT) in
accordance with the manufactures product data sheets.
B.E 13.6.9.4.3.3 Intermediate Coat:
Spot apply by brush, roller or spry MIO to a dry film thickness of 125 microns (180 microns WFT) in
accordance with the manufacturers product data sheets.
BE .13.6.9.4.3.4 Topcoat
Apply MIO to a dry film thickness of 125 microns (180 microns WFT) in accordance with the
manufacturer’s product data sheet. Where the damage to the topcoat is numerous and in a highly
visible area, the MIO should be applied in full by either spray or roller to the first break i.e. weld or
edge.
B.E 13.6.10 Quality Assurance and Inspection Requirements
B.E 13.6.10.1 The Contractor shall nominate a Project Officer as the quality assurance officer
overseeing this work. The Project Officer shall have an Australasian Corrosion Association Coating
Inspection Certificate or equivalent certificate approved by the EngineerProject Manager.
B.E 13.6.10.2 No surface preparation or coating application shall take place if the relative
humidity is greater than 85%, the surface temperature less than three degrees above the dew point or
under other unfavourable weather conditions, unless the work is well protected from such conditions.
In addition, the coating shall not be applied if the ambient temperature is below 10°C (5°C for low
temperature cure epoxy) or surface temperature above 45°C.
B.E 13.6.10.3 All stages of the work shall be made available to observation by the
Superintendent or his/her representative to assure compliance with the Specification. The Contractor
is responsible for advising the EngineerProject Manager with sufficient time to enable him/her to be
present at hold points without unnecessary delay or hindrance to the progress of the work. The
Contractor shall provide accessibility and lighting for inspection. Such inspection does not in any way
relieve the Contractor of his own obligation to assure compliance with this Specification
B.E 13.6.10.4 The Contractor shall keep records such as AS 3894 Part 10, 11, 12 including
ambient conditions, surface preparation, application particulars, batch numbers and film thickness.
Such records shall be made available to the EngineerProject Manager or his/her representative upon
request.
B.E 13.6.10.5 Defective work shall be marked with; school grade chalk, masking tape or an
inspection label. Wax crayons or spirit markers shall not be used.
The quantity of structural steel for steel bridges to be measured shall be the computed weight in
metric tonnes of the rolled steel sections, complete in place and accepted, as shown on the Drawings.
In computing the weight to be measured either the theoretical weight of members of the dimensions
shown on the drawings, or authorised, shall be used when available, or a unit weight of 7.84 x 10 -3
kg/cu. cm shall be used. No deduction shall be considered for bolt holes. No additional weight shall be
considered for painting, welds, connection plates, brackets, gussets, railing, chequer plate etc. Bolts,
nuts and washers shall not be measured.

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The Contractor shall supply detailed calculation sheets for the weight of the rolled steel sections in the
fabricated structure.
The structural steel for steel bridges placed as shown on the drawings or as directed by the
EngineerProject Manager will be paid for at the contract unit price per metric tonne of steel for the
BOQ item below which price shall include the cost of all materials, transportation, labour, tools, plant,
staging and equipment required for fabrication, connections, oiling, painting, temporary arrangements
for erection, inspection, tests, incidentals and complete final erection at place as per the approved
Working Drawings and accepted by the EngineerProject Manager
Full compensation for painting, welds, connection plates, brackets, gussets, railing, chequer plate
bolts, nuts and washers shall be considered to be included in the contract unit price paid for structural
steel and no separate payment will be made for these items.
Pay Item shall be:
Unit of
Measurement
E 13.1 Fabrication and Erection of Steel Girder Bridges (as metric tonne
Detailed on the Drawings and as stated in the Bill of
Quantities.)
B-13.1 Fabrication and Erection of Steel Girder Bridges Metric Tonne

(as Detailed on the Drawings and as stated in the
Bill of Quantities.)
B.e 14 DEMOLITION OF EXISTING STRUCTURES
Contractor will propose the demolition procedures along with the protection of existing structures
during the demolition and construction of new structures for EngineerProject Managers approval
before commencement of the demolition work. The demolished portion will be removed from the Site
immediately and dumped to the Contractor’s designated dumping ground. There will be no separate
pay item for demolition of existing structures if any and also for the works mentioned above.
B.E 15 FILTER WORKS FOR BOX CULVERTS WALL
B.E 15.1 Brick Chips Filter Material
Supplying and laying dry 1st class or picked jhama chips as filter in two layers (top and bottom) as per
specific size, range and gradation, including breaking chips, grading, preparation of surface, compacting
each layer etc. complete with supply of all materials and as per direction of EngineerProject Manager in
charge. Well graded between 20mm to 5mm size (WDB Item Code 40-610-30).

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B.E 15.2 Scope of Work
The work to be performed under the provisions of this Section includes furnishing and placing a layer of
first class brick or jhama khoa chips filter material on a prepared sub-grade/ Geotextile under concrete
slabs as shown on the drawings or directed by the EngineerProject Manager.
B.E 15.3 Materials
The brick chips (20mm downgraded 5mm) to be obtained from breaking of first class or jhama bricks
conforming to the Specification and direction of EngineerProject Manager-in-charge.
B.E 15.4 Workmanship
B.E 15.4.1 Foundation Preparation
The foundation for the filter material shall be thoroughly compacted and graded to the elevations to
receive the Geotextile on top as shown on the drawings prior to the placement. The filter material shall
be spread in a uniform layer of the thickness shown over the Geotextile on the drawing or directed by
Measurement of brick chip filter materials shall be the volume computed from the dimensions shown on
the drawings or such other dimensions as directed by the EngineerProject Manager.
Brick chips furnished and placed as filter materials shall be paid for at the unit rate per 1 cum specified
in the schedule of works. The unit rate shall include all materials, labour, tools and equipment for
producing and placing materials as shown on the drawings or as directed by the EngineerProject
Manager. No payment will be made for excess materials provided or placed outside the specified limits.
Pay items shall be:
Unit of
Measurement
E 15.1 Brick Chips Filter Material (as Detailed on the Drawings m3
and as Stated in the Bill of Quantities).
E 15.2 Supply and installation of Separator Geotextile (as m2

Detailed on the Drawings and as Stated in the Bill of
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Quantities).
B-15.1 Brick Chips Filter Material (as Detailed on the Drawings Cubic Meter
and as Stated in the Bill of Quantities).
B-15.2 Supply and installation of Separator Geotextile Square Meter

(as Detailed on the Drawings and as Stated in
the Bill of Quantities).
B.E 16 ABUTMENT PROTECTION WORKS
E 16.1 Description
B. 16.1 Description
Abutment protection works shall be executed as indicated on the Drawings or as directed by the
EngineerProject Manager. The Abutment protection works shall comprise a geotextile fabric to be
overlain with a pavement of thick cement concrete block (450 mm x 450 mm x 150 mm) with stone
chips. Sand shall have a Fineness Modulus (FM) greater than or equal to 2.5 and shingles/stone
chips of 20 mm downgraded. Concrete Class 20 as defined as per specification shall be used with
toe-wall or as designated by the EngineerProject Manager. The Brick Toe-Wall as shown on the
Drawings or as otherwise directed by the EngineerProject Manager shall be constructed complying
with the following requirements:
B.E 16.2 Material
a) Concrete blocks
Materials to be used concrete blocks for abutment protection works are pre-cast concrete blocks as
indicated in the Drawings. The pre-cast blocks to be used in the work shall be approved by the
EngineerProject Manager. The concrete mix to be used for the production of blocks shall be of
Concrete Class 20. Materials to be used for production of concrete mix shall satisfy all requirements
as are prescribed in the relevant chapters.
b) Bricks
First class bricks should have the following dimensions after burning: 242 mm x 115 mm x 70 mm..
The unit weight determined in accordance with STP 7.8.3 of 1st Class bricks shall not be less than
1,100 kg/m3 .
c) Sand used shall have a Fineness Modulus (FM) greater than or equal to 1.2
d) Concrete Class 15 as defined in the specification.

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B.E 16.3 Method
The bed upon which the slope protection is to be placed shall be trimmed to the required grades and
lines as shown on the drawings or as directed and approved by the EngineerProject Manager. In
order to ensure regular straight work and an uniform slope throughout, lines and pegs at an interval of
3 meters are to be put up. Any depression shall be filled with approved material and thoroughly
compacted. On top of compacted earth layer, non-woven geo-textile of 200 g/m2 with an effective
opening size (O90) of min 0.09-mm and max 0.12 mm shall be placed. The geo-textile shall be UV
stabilized poly-propylene or polyester geo-textile. The tensile strength shall be at least 14 kN/m and
the vertical permeability at 2 kPa shall be at least 2 x 10 -3 m/s. The manufacturer shall be a company
of international repute and the product quality must conform to ISO standards. The Contractor shall
submit to the EngineerProject Manager the manufacturer’s original technical brochure to obtain
approval for utilization from the EngineerProject Manager. The properties listed in the manufacturer’s
brochure will be accepted for initial approval.
The geo-textile shall be carefully laid on the compacted earth and shall be secured in place with
appropriate devices approved by the EngineerProject Manager. The overlap shall be at least 60 cm
and the laying shall be executed according to the manufacturer’s recommendations and instructions.
All excess material shall be neatly cut off to the required grade and lines. The edges shall be secured
and firmly fixed under the kerbs of the block-work. A footing trench shall be excavated along the toe of
the slope, the sizes and shape of which will conform to those as shown on the drawing or as directed
and approved by the EngineerProject Manager. Base should be firm and compacted and the blocks
shall be placed so as to provide a minimum number of voids. The trench at the toe of slope shall be
constructed with cement concrete works and the block pitching shall be constructed from the lowest
course and built up in course upwards.
After the site has been cleared the limits of excavation shall be set out true to lines, slopes, grade and
sections as shown on the drawings or as directed by the EngineerProject Manager. The Contractor
shall provide all labour, survey instruments and materials such as strings, pegs, nails, bamboo, etc.,
required in connection with the setting out of works. When so directed the excavated soils shall be
stockpiled at designated locations for re-use to cover embankment slope, cut slopes, and other
disturbed areas where re-vegetation is desired.
The Brick Toe-Wall as shown on the Drawings or as otherwise directed by the EngineerProject
Manager shall be constructed complying with the following requirements:
B. 16.4 Measurement and Payment
The geo-textile shall be measured per m2 (except over lapping) to the grades and lines as indicated
on the drawings or as instructed by the EngineerProject Manager and shall be equal to the surface of
the block-work. The abutment protection work shall be measured in number of square meters of
completed and accepted work placed to the designated thickness. Square meter measurement of
block work shall be based upon the centre line length multiplied by slant length up to the top of wall at
toe. No measurement shall be made for unauthorised areas or for extra thickness. Measurement for
the edge blocks shall be taken in square meter as that of block work.

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The work as measured above shall be paid for at the contract unit rate for the item listed below and
shown in the Bill of Quantities. The payment shall be in full for carrying out the operation for full
compensation of all labour, materials, equipment, tools, supplies and all other items necessary for the
proper completion of the work.
Pay items shall be:
Unit of
Measurement
E 16.1 Supply and Installation of CC Blocks, Stone Chips and m2
Compacted Sand (As specified in Bill of Quantities)
E 16.2 Supply and Installation of Brick Toe Wall (As specified in linear metre
Bill of Quantities)
E 16.3 Supply and Installation of Separator Geotextile (As m2
B-16.1 Supply and Installation of CC Blocks, Stone Chips Square Metre

and Compacted Sand (As specified in Bill of Quantities)
B-16.2 Supply and Installation of Brick Toe Wall Linear

Metre
(As specified in Bill of Quantities)
B-16.3 Supply and Installation of Separator Geotextile Square Metre

(As specified in Bill of Quantities)
FOR GUIDANCE OF QUALITY OF STEEL IS 2062: 2006 IS PROVIDED IN THE DOCUMENT

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Indian Standard
HOT ROLLED LOW, MEDIUM AND HIGH
TENSILE STRUCTURAL STEEL
(Sixth Revision)
1 SCOPE IS No. Title
1.1 This standard covers the requirements of 1732 :1989 Dimensions for round and square
steel including micro-alloyed steel plates, steel bars for structural and general
strips, shapes and sections (angles, tees, EngineerProject Managering purposes
beams, channels, etc), flats, bars, etc, for use (first revision)
in structural work. 1757: 1988
Method for Charpy impact test (V-notch)
1.1.1 The steels are suitable for welded, for metallic material (second revision)
bolted and riveted structures and for general 1852: 1985
EngineerProject Managering purposes. Rolling and cutting tolerances for hot
rolled steel products (fourth revision
1.1.2 Where welding is employed for 1863 : 1979
fabrication and guaranteed-weldability is Hot rolled steel bulb flats (first revision)
required, welding procedure should be as 1956(in various
specified in IS 9595. parts) Glossary of terms relating to iron and
steel (in various parts)
2 REFERENCES 2314 : 1986
Steel sheet piling sections (first
The standards listed below contain provisions, revision)
which through reference in this text constitute 3803 (Part 1):
provisions of this standard. At the time of 1989 Steel -Conversion of elongation values:
publication, the editions indicated were valid. Part 1 Carbon and low alloy steels
All standards are subject to revision and (second revision)
parties to agreements based on this standard 3954: 1991
are encouraged to investigate the possibility Hot rolled steel channel sections for
of applying the most recent editions of the general EngineerProject Managering
standards indicated below; purposes (first revision)
8910 : 1978
IS No. Title General technical delivery requirements
228 (in Method for chemical analysis of for steel and steel products
various steel 9595: 1996
parts) Metal arc welding of carbon and carbon
808: 1989 Dimensions for hot rolled steel manganese steels-
beam, column, channel and Recommendations (first revision)
angle sections (third revision) 10182
1173 :1978 Hot rolled slit steel tee bars Dimensions and tolerances for hot
(second revision) rolled track shoe sections:
1252: 1991 Hot rolled steel bulb angles - Part I) : 1982
Dimensions (first revision) Sections TS 1.1
1599: 1985 Method for bend test (second (Part 2) : 1985
revision) Sections TS H.1
1608: 2005 Metallic materials -Tensile 10842: 1984
testing at ambient temperature Testing and evaluation procedure for Y
(third revision) groove crackability test
1730: 1989 Steel plates sheets, strips and 12778: 1989
flats for structural and general Dimensions for hot rolled steel parallel
EngineerProject Managering flange beam and column sections
purposes (second revision)
1731: 1971 Dimensions for steel flats for
structural and general 3 TERMINOLOGY
EngineerProject Managering
purposes (first revision For the purpose of this standard, the following definitions
in addition to those given in the relevant parts of IS 1956
shall apply

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3.1 Micro-Alloying Elements -Elements, 7 FREEDOM FROM DEFECTS

such as niobium, boron, vanadium and
titanium added singly or in combination to 7.1 All finished steel shall be well and cleanly rolled to the
obtain higher strength to weight ratio dimensions, sections and masses specified. The finished
combined with better toughness, formability material shall be reasonably free from surface flaws;
and weldability as compared to unalloyed laminations; rough/jagged and imperfect edges and all
steel of similar strength level. other harmful defects.
3.2 Weldability -A metallic substance is 7.2 Minor surface defects may be removed by the
considered to be weldable by a given process manufacturer/supplier by grinding provided the thickness
and for the given purpose, when metallic is not reduced locally by more than 4 percent below the
continuity to a stated degree can be obtained minimum specified thickness. Reduction in thickness by
by welding using a suitable procedure, so that grinding greater than 4 percent but not exceeding 7
the joints comply with the requirements percent may be made subject to mutual agreement
specified in regard to both their local between the purchaser and the manufacturer/ supplier.
properties and their influence on the
construction of which they form a part. 7.2.1 Subject to agreement with the purchaser, surface
defects which cannot be dealt with as in 7.2 may be
3.3 Controlled Rolling-A hot rolling process repaired by chipping or grinding followed by welding and
in which the temperature of the steel and its inspection by a mutually agreed procedure such that:
reduction ratio are controlled, particularly
during the final rolling passes, in order to a) After complete removal of the defects and before
achieve fine grain micro structure and welding, the thickness of the item is in no place reduced
optimum mechanical properties. by more than 20 percent;
3.4 Normalizing Rolling -A hot rolling b) Welding is carried out by approved procedure by
process in which the final rolling passes are competent operators with approved electrodes and that
carried out at a suitable higher temperature, the welding is ground smooth to the correct nominal
followed by cooling in natural air to a thickness; and
temperature below the transformation
temperature, in order to produce a structure, c) Subsequent to the finish grinding, the item may be
analogous to that obtained by a separate required to be normalized or otherwise heat-treated at the
normalizing treatment of hot rolled product purchaser's discretion.
4 SUPPLY OF MATERIAL 7.3 Welding as mentioned-in 7.2.1 is not permissible for

grade designation E 250 C material.
General requirements relating a supply of
structural steel shall conform to IS 8910. 8 CHEMICAL COMPOSION
5 GRADES 8.1 Ladle Analysis

There shall be nine grades of steel as given in
Tables 1 and 2. While placing the order the The ladle analysis of the steel, when carried out by the
steel should be designated by 'Designation' method specified in the relevant parts of IS 228or any
(see Tables 1 and 2). other established instrumental/chemical method, shall be
as given in Table 1. In case of dispute, the procedure
6 MANUFACTURE given in IS 228 and its relevant parts shall be the referee
method and where test methods are not specified shall be
The processes used in the steel making and as agreed to between the purchaser and the
further hot rolling into steel plates, strips, manufacturer/supplier.
sections, flats, bars, etc, are left to the
discretion of the manufacturer/ supplier. If 8.2 Product Analysis
required, secondary refining may follow steel
making, as also normalizing rolling/controlled The product analysis shall be carried out on the finished
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rolling during manufacturing of sections or as product from the standard position. Permissible limits of
the agreement between the purchaser and the variation in case of product analysis from the limits
manufacturer/supplier. specified in Table 1 shall be as given in Table 3.
9 SELECTION AND PREPARATION OF 9.7 Before test samples are detached, full particulars
TEST SAMPLES regarding cast number, size and, mass of plates, strips,
sections, flats and bars in each cast shall be furnished by
9.1 The position from which test samples are the manufacturer to the purchaser. In case of plates the
taken shall be so located in the product as to number of plates in each cast shall also be given.
yield the clearest possible information
regarding properties in the cross sectional and 9.8 Test samples shall be cut in such a manner that the
longitudinal planes. The recommended deformation is avoided as far as possible. If shearing of
locations for taking test samples (or plates, flame-cutting is employed, an adequate allowance shall be
sections and bars are indicated in Fig. 1. left for removal by machining.
Alternatively, in case of sections, the samples
may be taken from the web. For testing of flat 9.9 Test samples shall not be subjected to heat treatment
products like plates tensile and bend test unless the material from which they are cut is similarly
pieces may be ·cut in the transverse direction. treated with the material before testing. Any slight
Selection of location of test pieces may also straightening of test samples which may be required shall
be mutually agreed between the purchaser be done cold.
and the manufacturer/supplier.
10 TENSILE TEST
9.2 Wherever practicable, the rolled surface
of the steel shall be retained on the two 10.1 Number of Tensile Tests
opposite sides of the test samples
Number of test samples shall be 2 per cast/heat and a
9.3 In case of flat test samples for tensile test, class of steel product irrespective of cast/heat size.
both surfaces are normally to be left on the
test samples for strips and plates up to 32 mm 10.2 Tensile Test Pieces
thick. At least one rolled surface shall be left
on rectangular test samples taken from plates The tensile strength, yield strength and percentage
exceeding 32mm in thickness. Round test elongation of steel shall be determined from standard test
samples are permitted, but should only be pieces cut crosswise from plates and strips and
adopted for thickness exceeding 20 mm. lengthwise from sections, flats and bars. The test shall be
carried out as on the standard test pieces prepared in
9.4 In case of flats up to 16 mm thick-the test accordance with IS 1608.
sample shall undergo, if possible, no
machining whatever, prior to use as a test 10.2.1 As a rule, test pieces with a proportional gauge
piece. If this is not possible, the test sample length complying with the requirements L0= 5.65 √S0
shall undergo the minimum amount of should be used for the tensile test, where L o is the gauge
machining. length and So is the cross sectional area of the test piece.
9.5 Bars below 28 mm shall be tested without 10.2.1.1 Test pieces with a non-proportional gauge length,
machining. In case of bars having diameters other than 5.65 √S0 may be used in which cash the
or thickness between 28 mm and 71 mm, the elongation values shall be converted to 5.65 √S 0 in
bars may be symmetrically reduced by accordance with IS 3803 (part 1).
machining. For bars having diameters or
thicknesses exceeding 71mm, the test sample 10.3 Tensile Test
may be taken from the position shown in Fig.
1 Tensile strength, yield strength and percentage elongation
when determined in accordance with IS 1608 shall be as
9.6 In case of plates, strips, sections and flats, given in Table 2.
bend tests shall be carried out on rectangular
test samples which a far as possible should 10.3.1 In case of sections the thickness of which is not
116129
be of the full thickness of the product. In case uniform throughout the profile, the limits of sizes given in
of plates, sections and flats exceeding 28 mm Table 2 shall be applied according to the actual maximum
In thickness, it is permissible to remove metal thickness of the piece adopted for testing.
from one side of the test sample before using
it as a test piece. The rolled surface of the test 10.3.2 Should a tensile test piece break outside the middle
piece shall be on the outer side of the bend half of the gauge length (see IS 1608) and the percentage
during the test. elongation obtained is less than that specified, the test
may be discarded at the manufacturer/supplier's option
and another test made from the sample plate, strip,
section, flat or bar.

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Table 1 Chemical Composition

(Clauses 5, 8.1 and 8.2)
Grade Quality Carbon Method of

Designation Ladle Analysis, Percent, Max Equivalent1) Deoxidation1)
(CE), Max
C Mn S P Si
(1) (2) (3) (4) (5) (6) (7) (8) (9)
Semi killed or
E 165 (Fe 290) - 0.25 1.25 0.045 0.045 - -
killed
Semi-killed or
E250 (Fe410 W) A 0.23 1.50 0.045 0.045 0.40 0.42
killed
E250 (Fe410 W) B 0.22 1.50 0.045 0.045 0.40 0.41 Killed
E250 (Fe410 W) C 0.20 1.50 0.040 0.040 0.40 0.39 Killed
Semi killed or
E300 (Fe 440) - 0.20 1.30 0.045 0.045 0.45 0.40
killed
Semi killed or
E350 (Fe 490) - 0.20 1.50 0.045 0.045 0.45 0.42
killed
Semi killed or
E410 (Fe 540) - 0.20 1.60 0.045 0.045 0.45 0.44 killed
Semi killed or
E450 (Fe 570) D 0.22 1.60 0.045 0.045 0.45 0.46
killed
Semi killed or
E450 (Fe 590) E 0.22 1.80 0.045 0.045 0.45 0.48
killed
Notes:
1 Carbon equivalent (CE) based on ladle analysis = C+ Mn/6+ (Cr+Mo+V)/5 + (Ni +Cu)/15
2 When the steel is killed by aluminum alone, the total aluminium content shall not be less than
0.02 percent. When the steel is killed by silicon alone the silicon content shall not be less than 0.10
percent. When the steel is silicon-aluminium killed, the silicon content shall not be less than 0.03
percent and total aluminium content shall not be less than 0.01 percent.
3 Micro alloying elements like Nb, V, Ti and B shall be added singly or in combination. Total micro
alloying elements shall not be more than 0.25.
4 New grades designation system based on yield stress has been adopted, simultaneously old
designations have also been given in parentheses.
5 Steels of qualities A, B and C are generally suitable for welding processes. The weldablity
increases from quality A to C.
6 Copper may be prcscn1 between 0.20 to 0.35 percent as mutually agreed to between the
purchaser and the manufacturer. The copper bearing quality shall be designated with a suffix Cu, for
example E250 Cu. In Case of product analysis the copper-content shall be between 0.17and 0.38
percent.

116129
__________________________
1)
To be supplied subject to the agreement between the purchaser and the manufacturer.
7 Nitrogen content of steel shall not exceed 0.012 percent which shall be ensured by the
manufacturer by occasional check analysis. For micro alloyed steel this is to be reduced to 0.009
percent.
8 The steel if required may be treated with rare earth element for better formability.
9 Lower limits for carbon equivalent and closer limits for other elements may be mutually agreed
to between the purchaser and the manufacturer
10 Incidental element-Elements not quoted in Table 1 shall not be intentionally added to steel
without the agreement of the purchaser, other than for the purpose of finishing the heat. All
reasonable precautions shall be taken to prevent the addition from scrap or other materials used in
manufacture of such elements which affect the hardenability, mechanical properties and applicability.
Table 2 Mechanical Properties

(Clauses 5, 10.3 and 10.3.1)
Grade Quality Tensile Yield Stress Percentage Internal Charpy V-Notch

Designa- Strength ReffMinMpa Elongation, Bend Impact Energy
tion Rm Min Aat Gauge Diameter MinJ
Mpa <20 20- 40> Length, Lo Min1) Room -20ºC
2)
40 5.65 √SoMin Temp
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
E 165 - 290 23 2t - - -
(Fe 290) 165
E250 A 410 250 240 230 23 3t 2t - -
(Fe410W)
E250 (Fe B 410 250 240 230 23 2t 3t
27 2) (see Note 3)
410 W)
E250 (Fe C 410 250 240 230 23 2t 3t
27 2) (see Note 3)
410 W)
E300 - 440 300 290 280 22 2t 3t 50 30
(Fe 440)
E 350 - 490 350 330 320 22 2t 3t 50 25
(Fe 490)
E410 - 540 410 390 380 20 2t 3t 50 25
(Fe 540)
E450 D 570 450 430 420 20 2t 3t 45 20
(Fe 570)
E450 E 590 450 430 420 20 2t 3t 45 20
(Fe 590)
Notes:

116129
1 MPa = 1 N/mm2 = 1 MN/m2 = 0.102 kgf/mm2 =144.4 psi
Temperature of Charpy impact values will be subject to mutual agreement.

The more stringent requirements than those given above may be as agreed to between the purchaser
and the manufacturer.
______________________
1)
t is the thickness of the test piece.
2)
Room temperature = 25± 2º C for Impact test.

116129
Table 3 Permissible Variation for Product
Analysis
(Clause 8.2)
Constituent Permissible
Variation Over the
specified Limit,
Percent, Max
Carbon 0.02
Manganese 0.05
Silicon 0.03
Copper 0.03
Sulphur 0.005
Phosphorus 0.005

116129
FIG. 1 STRUCTURAL STEEL SECTIONS, POSITION AND ORIENTATION OF SAMPLE
11 BEND TEST 12.2 This test is carried out using a V-notch test
piece (see IS 1757) the value for consideration
Number of Bend Test being the arithmetic mean of the results obtained
on three test pieces taken side by side from the
Number of bend test shall be 2 per cast/heat same product (see Table 2). Temperature of
Class of steel Direction of Bend Charpy impact test will be subject to mutual
Product Tests agreement
Plates strips Crosswise
Sections Lengthwise for each 12.3 The test sample shall be taken from the
Flats and bars Type thickest product. If the test sample taken from the
(round hexagonal, Lengthwise thickest product rolled from a cast meets the
etc) requirements, the whole cast shall be deemed to
meet the requirements of the test, if not, the test
Bend Test Piece shall be performed on a section of next lower
thickness rolled from same cast, if it meets the
The test pieces shall be cut crosswise from plates requirements specified, this particular thickness
and strips and lengthwise from sections, flats and as also other sections of lower thickness shall be
bars. When section permits, these shall be not deemed to satisfy the specification. If this
less than 40 mm wide. If the thickness also does not meet the requirements,
manufacturer/supplier so desires, round, square, the test shall be carried out on the next lower
hexagonal and flat bars and structural sections thickness and so on, because the toughness of
shall be bent in the full section as rolled. the product will be dependent on the rolling
direction as well as on the section size.
11.2.1 In all bend test pieces, the rough edge
arises resulting from shearing may be removed by 12.3.1 One test sample shall be taken from
filing or grinding or machining but the test pieces thickest product per cast/heat.
shall receive no other preparation.
12.4 The material .represented shall be deemed
11.3 Bend Test to comply with the standard, if the average value
Bend test shall be conducted in accordance with of 3 test specimens, meets the requirements
IS 1599. given in Table 2 provided no individual value
shall be less than 70 percent of the specified
11.3.1 For bend-test, the test piece at room value. If the average value of the three Charpy
temperature shall withstand bending through 180 0 impact tests fails to comply by an amount not
to an internal diameter not greater than that given exceeding 15 percent of the specified minimum
in Table 2 without cracking. average value, three additional test pieces from
the same sample shall be tested and the results
12 IMPACT TEST added to those previously obtained and a new
average calculated. Provided this new average
complies with the specified requirement, the
12.1 Impact test shall normally be carried out on material represented shall be deemed to comply
products having thickness/diameter greater than with this standard.
or equal to 12 mm or subject to mutual agreement
between the purchaser and the 13 Y GROOVE CRACKABILITY TEST
manufacturer/supplier. The test specimen is
parallel to the direction of rolling and the base Y groove crackability tests may be carried out in
closer to the rolled surface is more than 1 mm accordance with IS 10842 for products of only
from it The notch axis shall be perpendicular to Grade E 250 C material having thickness 12 mm
the rolled surface. and above, if specifically agreed to between the
purchaser and the manufacturer/supplier.
12.1.1 If stated in the order, impact tests may be
116129
carried out on products having a thickness less NOTE- The groove crackability test will not be
than 12 mm, the dimensions of the test pieces applicable for rounds and it is mainly for plates
shall be in conformity with IS 1757. The minimum and sections.
impact energy values of reduced sizes shall be as
shown in Fig. 2.
14 OTHER TESTS Table 4 Indian Standards Which Give

Nominal
14.1 The material may be subjected to non-
Dimensions of Rolled Steel Products
destructing testing to determine soundness of
Relevant
material subject to mutual agreement between Products
Indian
the purchaser and the manufacturer/supplier. Standard
Beam, column, channel
14.2 Metallurgical tests for grain size, and IS808
directionality, inclusion content to be carried out angle section
subject to mutual agreement between the Tee bars IS 1173
purchaser and the manufacturer/supplier. Bulb angles IS 1252
Plates, strips and flats IS 1730
15 DIMENSIONS Flats IS 1731
Round and square bars IS 1732
116129
Unless otherwise agreed to between the Bulb flats IS 1863
purchaser and the manufacturer/supplier, the Sheet piling sections IS 2314
nominal dimensions of rolled products conforming Channel sections IS 3954
to this standard shall be in accordance with the IS 10182 (part
Track shoe sections
relevant Indian Standard. Currently available 1)
Indian Standard are listed in Table 4. IS 10182 (part
2)
Parallel beam and
16 TOLERANCES IS 12778
column sections
Unless otherwise agreed to between the

20.4 BIS Certification Marking
purchaser and the manufacturer, the rolling and
cutting tolerances for steel products conforming
The material may also be marked with the
to this standard shall be those specified in IS
Standard Mark
1852. Stricter tolerances may be followed, if
agreed to between the purchaser and the
manufacturer/supplier.
20.4.1 The use of the Standard Mark is governed
17 RETESTS
by the provisions of the Bureau of Indian
Standards Act, 1986 and the Rules and
Should any one of test pieces first selected fail to
Regulations made there under. The details of
pass any of the tests specified in this standard,
conditions under which the license for the use of
two further samples shall be selected for testing
Standard Mark may be granted to manufacturers
in respect of each failure. Should the test pieces
or producers may be obtained from the Bureau of
from both these additional samples pass, the
Indian Standards.
material represented by the test samples shall be
deemed to comply with the requirements of that
particular test. Should the test pieces from either
of these additional samples fail, the material
represented by the test samples shall be
considered as not having complied with this
standard.
18 CALCULATION OF MASS
The mass of steel shall be calculated on the

basis that steel weighs 7.85 g/cm3,
19 DELIVERY
Subject to prior agreement between the

purchaser and the manufacturer/supplier, suitable
protective treatment may be given to the material
after rolling.
20 MARKING
20.1 Each product, with the exception of round,

square and hexagonal bars and flats, shall carry
a tag or be marked with the manufacturer's name
or trade-mark. Bars and flats shall carry a tag
bearing the manufacturer's name or trade-mark.
Designation of steel should also be similarly
marked on the product or tag.
20.2 Every heavy, medium structural mill and

116129
plate mill product shall be marked with the cast
number. Plates produced from strip in coil form
shall be marked with cast/heat number on top
plate of each pile/ packet
20.3 The ends of the rolled products shall be

painted with a colour code, as agreed to between
the purchaser and the manufacturer/supplier.

116129

WD2 - Subsection E Bridge & Culverts 22-12-2014

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WD2 - Subsection E Bridge & Culverts 22-12-2014

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Package WD82: Construction of New BG Track on Kashiani-Gopalganj SectionConstruction of 65 Nos.

SUBSECTION BE: MINOR BRIDGES

B.1 SCOPE OF THE WORK............................................................................................................. 1

Subsection BE: Minor Bridges & Culverts i of vi

Subsection BE: Minor Bridges & Culverts ii of vi

Subsection BE: Minor Bridges & Culverts iii of vi

B.9.4 Measurement and Payment............................................................................................... 68

Subsection BE: Minor Bridges & Culverts v of vi

Subsection BE: Minor Bridges & Culverts vi of vi

E1 SCOPE OF THE WORK...............................................................................................1

Subsection BE: Minor Bridges & Culverts vii of vi

Subsection BE: Minor Bridges & Culverts viii of vi

E 4.10.4 OTHER METHODS....................................................................................19

Subsection BE: Minor Bridges & Culverts ix of vi

E 5.5.2 IN-SITU TESTING AND SAMPLING.............................................................26

Subsection BE: Minor Bridges & Culverts x of vi

E 7.3.12 REMOVAL OF SCAFFOLDING AND FORMWORK........................................57

Subsection BE: Minor Bridges & Culverts xi of vi

Subsection BE: Minor Bridges & Culverts xii of vi

E 13.3 STRUCTURAL STEEL MATERIALS....................................................................81

Subsection BE: Minor Bridges & Culverts xiii of vi

E 13.6.10 QUALITY ASSURANCE AND INSPECTION REQUIREMENTS......................102

E1 SCOPE OF THE WORK...............................................................................

Subsection BE: Minor Bridges & Culverts xiv of vi

E 2.9 CLEAN UP OF BRIDGE AND STRUCTURE SITES............................................

Subsection BE: Minor Bridges & Culverts xv of vi

E 4.4 CONSTRUCTION OF A PILOT PILE TO BE TEST LOADED...............................

Subsection BE: Minor Bridges & Culverts xvi of vi

Subsection BE: Minor Bridges & Culverts xvii of vi

E 6.3.5 PUMPING AND BAILING...............................................................

Subsection BE: Minor Bridges & Culverts xviii of vi

E 8.2.2 WIRE MESH................................................................................

Subsection BE: Minor Bridges & Culverts xix of vi

Subsection BE: Minor Bridges & Culverts xx of vi

E 13.4.5 PINS AND PIN HOLES..................................................................

Subsection BE: Minor Bridges & Culverts xxi of vi

B. 16.4 MEASUREMENT AND PAYMENT.........................................................

E1 SCOPE OF THE WORK.............................................................................................................................1

Subsection BE: Minor Bridges & Culverts xxii of vi

E 4.16.5 Specialist Sub-Contractor.......................................................................................27

Subsection BE: Minor Bridges & Culverts xxiv of vi

E 7.3.8 Perforations and Embedment of Special Devices...................................................59

Subsection BE: Minor Bridges & Culverts xxv of vi

E 10.3.3 Weep Holes............................................................................................................ 78

Subsection BE: Minor Bridges & Culverts xxvi of vi

E 13.5.2 Organisation and Equipment................................................................................106

Subsection BE: Minor Bridges & Culverts xxvii of vi

B.E 1 SCOPE OF THE WORK

There will be no separate payment for this works.

B.E 1.1 Construction of Minor Bridges and Culverts

Subsection EB: Minor Bridges & Culverts Page 1 of

BR-02 02+475 1 X 6.0m X 5.0 m " 0.740 6.300

BR-03 03+175 2 X 3.0m X 4.5 m " 2.007 6.820

BR-04 03+660 1 X 3.0m X 5.0 m " 1.376 6.820

BR-05 04+315 3 X 6.0m X 6.0 m " 0.306 6.820

BR-06 05+110 1 X 3.0m X 5.0 m " 1.351 6.820

BR-07 05+860 2 X 3.0m X 4.0 m " 2.226 6.820

BR-08 06+425 1 X 3.0m X 3.5 m " 2.907 6.820

BR-09 08+025 2 X 3.0m X 3.5 m " 2.845 6.820

BR-10 08+740 1 X 3.0m X 4.5 m " 1.665 6.700

BR-11 09+320 1 X 3.0m X 4.0 m " 2.553 6.700

BR-12 10+860 2 X 3.0m X 3.5 m " 2.648 6.700