National Highways Authority of India Bid Document/Volume II/Section 5

NATIONAL HIGHWAYS AUTHORITY OF INDIA

TECHNICAL SPECIFICATIONS
SECTION 5

1. PREAMBLE
1.1 The Technical Specifications contained herein shall be read in conjunction with the other
Bidding Documents as specified in Volume-1.
1.2 SITE INFORMATION
1.2.1 The information given hereunder and provided elsewhere in these documents is given in
good faith by the Employer but the Contractor shall satisfy himself regarding all aspects
of site conditions and no claim will be entertained on the plea that the information
supplied by the Employer is erroneous or insufficient.
1.2.2 The area in which the works are located is mostly plain terrain, the approximate
longitude and latitude of the region being 75.47o E, 31.24o N
1.2.3 General Climatic Conditions
1.2.3.1 The variation in daily temperature in this region is as under:
i) During summer months, from about 35o C to 45o C maximum
ii) During winter months, from about 1o C minimum to 14o C
1.2.3.2 The average annual rainfall in the area is of the order of 400mm to 800mm, a good
portion of which is concentrated during the months of July to September each year.
1.2.3.3 The relative humidity is around 30% (average).
1.2.4 Seismic Zone
The works are located in Seismic Zone IV as defined in IRC:6-2002.
2. GENERAL REQUIREMENTS
The Technical Specifications in accordance with which the entire work described
hereinafter shall be constructed and completed by the Contractor shall comprise of the
following :
2.1 PART –I: General Technical Specifications
The General Technical Specifications shall be the “SPECIFICATIONS FOR ROAD
AND BRIDGE WORKS (FOURTH REVISION, Reprint of March 2002”), as corrected
in the original issued by the Ministry of Road Transport and Highways, Government of
India and published by the Indian Roads Congress.
2.2 PART II: Supplementary Technical Specifications
The Supplementary Technical Specifications shall comprise of various
Amendments/Modifications/Additions to the “SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS” referred to in PART –I above and additional Specifications for
particular item of works not already covered in PART-I.
2.2.1 A particular clause or a part thereof in “SPECIFICATIONS FOR ROAD AND BRIDGE
WORKS (FOURTH RIVISION, Reprint of March 2002”) as corrected in the original
referred in PART-I above, where Amended/Modified/Added upon, and incorporated in

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PART-II, referred to above, such Amendment/Modification/Addition supersedes the

relevant Clause or part of the Clause.
2.2.2 The Additional Specifications shall comprise of specifications for particular item of
works not already covered in PART-I.
2.2.3 When an Amended/Modified/Added clause supersedes a Clause or part thereof in the said
Specifications, then any reference to the superseded Clause shall be deemed to refer to the
Amended/Modified/Added Clause or part thereof.
2.2.4 In so far as Amended/Modified/Added clause may come in conflict or be inconsistent
with any of the provisions of the said Specifications under reference, the
Amended/Modified/Added Clause shall always prevail.
2.2.5 The following Clauses in “SPECIFICATIONS FOR ROAD AND BRIDGE WORKS
(FOURTH REVISION, Reprint of March 2002”) have been amended/modified/added
upon,.
102, 107, 108, 109, 110, 112, 121, 124, 201, 202, 301, 304, 305, 306, 401, 406, 501, 507,
509, 801, 803, 901, 903, 1006, 1007, 1010, 1014, 1502, 1503, 1509, 1513, 1703, 1704,
1705, 1706, 1707, 1709, 1713, 1802, 1804, 1806, 2005, 2009, 2504, 2706, 3004, 3104,
3106 and 3107
2.2.6 Additional Specifications
The following clauses have been added to the “SPECIFICATIONS FOR ROAD AND
BRIDGE WORKS (FOURTH REVISION, Reprint of March 2002”)
1. Appendix –I (Specification for Modified Binder)
2. Appendix –II (Specification for Expansion Joints)
3. Appendix – III (Void Former)
2.2.7 In the absence of any definite provisions on any particular issue in the aforesaid
Specifications, reference may be made to the latest codes and specifications of IRC and
BIS in that order. Where even these are silent, the construction and completion of the
works shall conform to sound engineering practice as approved by the Engineer and in
case of any dispute arising out of the interpretation of the above, the decision of the
Engineer shall be final and binding on the Contractor.

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AMENDMENTS/MODIFIFCATIONS/ADDITIONS TO EXISTING CLAUSES OF

GENERAL TECHNICAL SPECIFICATIONS

Clause 102 DEFINITIONS

The following abbreviations shall be added in the Clause
“MORT&H: Ministry of Road Transport & Highways
Clause 107 CONTRACT DRAWINGS
Sub-Clause Add the following after end of the para :
107.1
After careful study of the drawings issued by the employer the contractor shall
prepare all supplementary and working drawings incorporating latest field
information for construction purpose and shall submit the same to the
Engineer for approval prior to taking up actual construction.
Clause 108.4 Delete first two sentences
Clause 109.9 Delete 2nd and 3rd sentence and add the following “ setting out of the road
alignment and measurement of angles shall be done by using total station”
Clause 110 ENCUMBRANCES IN CONSTRUCTION AREA, INCLUDING TREES
AND UTILITIES
Replace whole of this clause with the following:
Clause 110.1 The contractor shall be responsible to coordinate with service
provider/concerned authorities for cutting of trees, shifting of utilities and
removal of encroachments, etc. and making the site unencumbered from the
project construction area required for completion of work. This will include
initial and frequent follow-up meetings/actions/discussions with each involved
service provider/concerned authorities. The contractor will not be entitled for
any additional compensation for delay in cutting of trees, shifting of utilities
and removal of encroachments by the service provider/concerned authorities.
Payment for cutting of trees and shifting of utilities as required by the
concerned department shall be made by the Employer.
Clause 110.2 Drawings scheduling the affected encumbrances such as trees and services like
water pipes, sewers, oil pipelines, cables, gas ducts, electricity lines,
accessories, telephone poles and OFC cables, etc. included in the contract
document shall be verified by the contractor for accuracy of scope.
Clause 110.3 The Employer will make payments to the respective service
provider/authorities for cutting of trees and shifting of utilities, wherever
required. The contractor will obtain necessary approval from such Authorities
after payments by the Employer and also in cases where payments are not
required to be made for such shifting. The Employer will also write to all
concerned departments/service provider organization for expediting and
facilitating cutting of trees, shifting of utilities and removal of encroachments,
etc.
Clause 110.4 Any services affected by the Works must be temporarily supported by the
Contractor who must also take all measures reasonably required by the various
bodies to protect their services and property during the progress of the works.
It shall be deemed to be part of the Contract and no extra payment shall be
made for the same.

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Clause 110.5 The Contractor may be required to carry out certain works for and on behalf of
the various bodies and he shall also provide, with the prior approval of the
Engineer, such assistance to the various bodies as may be authorized by the
Engineer.
Clause 110.6 Payment
For coordinating the work of cutting of trees, shifting of utilities and removal
of encroachments, etc. these will be incidental to the work and no separate
payment will be made for the same.
Clause 112.1 General
Delete the last sentence and add the following:
“Two weeks before undertaking work which would, involve any obstruction
whatsoever to traffic the Contractor shall submit, for the Engineer’s approval, a
Traffic Control Plan.
The plan shall include:
i) Typical drawings for temporary diversions in accordance with Sub-clause
112.3
ii) Typical details of arrangements for construction under traffic including
details of traffic arrangements proposed to be in place after the cessation
of work each day.
Special consideration shall be given in the preparation of the Traffic Control
Plan to the safety of pedestrians and workers and delineation of the roadway at
night.
Temporary diversions will be constructed only with the approval of the
Engineer and will generally only be constructed at bridge sites where new
bridges are to be located on the existing road alignment. Road works shall
generally be constructed under traffic.
Clause 112.2 This clause shall read as under:
“For widening and strengthening of the existing carriageway when the
widening is concentric and where part width of the existing carriageway is
proposed to be used for passage of traffic, widening of shoulders with
bituminous top layer shall be provided on one side of the existing road with the
following minimum requirement to be provided by the contractor :
At least one 5.5 m lane to remain open to traffic at all times
i) The surface used by the through traffic shall at all times be a firm
Bituminous compacted surface, free of pot holes and other defects
ii) The Contractor shall plan his construction activity in such lengths so that
there is least inconvenience to the movement of traffic. However, in case
the Contractor wants to take up work in longer continuous stretches, the
diversion shall have a minimum width of 7.0 m with bituminous surface
iii) The treatment in the widening portion for traffic movement shall consist
of 200 mm thick granular sub-base course overlaid with 200 mm thick
WMM layer and treated with Premix Carpet
iv) Construction activity shall be restricted to only one side of the existing
road, at a time

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In case of eccentric widening of existing two lane to four lane, the additional
two lanes shall be constructed first up to the stage of Dense Bituminous
Macadam for a minimum length of 2 km and traffic diverted to it, and only
thereafter the required treatment to the existing carriageway including
construction of median shall be taken up.
Clause 112.4 Traffic and Safety Control
Add the following paras in the end of Clause 112.4 :
The Contractor shall be fully responsible for the adequate safety of all site
operations and methods of construction.
The Contractor shall submit to the Engineer detailed proposal covering safety
measures proposed to be adopted at site.
Persistent breaches of the safety provisions by the Contractor and his
employees shall constitute a sufficient cause for action.
The following additional safety provisions shall also be observed by the
Contractor:
§ All workmen shall use safety helmets at work site, which should be
provided by the Contractor
§ All workmen shall wear reflective jackets, while working in the traffic
movement zone
§ Adequate precautions shall be taken to prevent danger from electric cables,
while digging operation is underway
§ Workers employed on bituminous works, stone crushers, concrete batching
plants, etc, shall be provided with protective goggles
§ Those engaged in welding work shall be provided with welder protective
shields
§ All scaffolds, ladders and other safety devices shall be maintained in a safe
and sound condition
§ All display boards shall be of retroreflective material and of sizes
mentioned in the drawing
§ All vehicles will have reverse horns
§ In addition, if any directions are given by the ‘Engineer’ to augment the
safety measures, the Contractor has to abide by his directions
§ A safety officer shall be nominated to prepare safety programme, and
oversee the safety arrangements at site
Clause 112.6 Measurement for payment and rate
This clause shall read as under:
Treatment in the widening portion by providing Granular sub base, WMM and
Premix Carpet shall be measured under Clauses 401, 406 and 522 and paid for.
These rates shall include full compensation for construction including supply
of materials, labour, tools etc. and maintenance of surface.
Providing and maintaining traffic arrangements during construction along with
safety measures for the workers and supervision staff, including traffic control,

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barricading, night lighting, and road signages etc. shall be measured in kms
length and shall be paid proportionately on completion of various stages of
construction. The total length shall not exceed the length of road under
improvement.
Clause 121 FIELD LABORATORY
Clause 121.3 Laboratory Equipment
This Clause shall read as under:
“The following items of laboratory equipment shall be provided by the
Contractor in the field laboratory”

A: GENERAL
i) Balance
a) 7 kg. To 10 kg capacity semi-self indication Type- 2 Nos.
Accuracy 1 gm Electronic
b) 500 gm capacity semi-self-indicating Electronic Type- 2 Nos.
Accuracy 0.01 gm.
c) Pan balance 5 kg capacity Accuracy 0.5 gm 3 Nos.
d) Platform Scale – 300 kg. Capacity 1 No.
ii) Ovens-Electrically operated, thermostatistically controlled 1 No.
(a) From 100o C to 220o C Sensitivity 1o C
iii) Sieves: as per I.S. 460-1962 2 Sets
- I.S. Sieves 450 mm internal dia of sieve sets as per ISI of
required sieve sizes complete with lid and pan
- I.S. Sieve 200 mm internal dia (brass frame and steel or 2 Sets
brass wire cloth mesh) consisting of sieve sets of required
sieve sizes complete with lid and pan
iv) Sieve shaker capable of taking 200 mm and 450 mm dia sieves 1 No.
electrically operated with time switch assembly (As per IS)
v) 200 tonnes compression testing machine 1 No.
vi) Stop Watches 1/5 sec. Accuracy 2 Nos.
vii) Glassware comprising of Beakers, Pipettes, dishes, measuring 1 Doz
cylinder (100 to 1000 cc capacity) glass rods and funnels, each
glass thermometers range 0oC to 100o C and metallic
thermometers range up to 300o C
viii) Hot plates 200 mm dia (1500 watt) 2 Nos.
ix) Enamel trays
a) 600 mm x 450 mm x 50 mm 6 nos.
b) 450 mm x 300 mm x 40 mm 6 nos.
c) 300 mm x 250 mm x 40 mm 6 nos.
d) Circula r plates of 250 mm dia 6 nos.
B: FOR SOILS
i) Water Still 1 No.

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ii) Liquid limit device with and A.S.T.M. grooving tools as per 2 Nos.
ISI-2720
iii) Sampling pipettes fitted with pressure and suction inlets, 10 1 set
capacity
iv) Compaction apparatus (Proctor) as per ISI 2720 (Part 8) 2 Nos.
complete with collar, base plate and hammer
v) Modified AASHTO compaction apparatus as per I.S. 2720 2 Nos.
(Part 7) 1974 or Heavy Compaction Apparatus as per IS
complete with collar, base plate hammer
vi) Sand pouring cylinder with conical funnel and tap and 6 Nos.
complete as per I.S. 2720 (Part 28) 1974 including modified
equipment
vii) Sampling tins with lids 100 mm dia x 75 mm ht ½ kg capacity 24
and miscellaneous items like moisture, tins with lid (50 grams) Nos.
etc.
viii) Lab C.B.R. testing equipment for conducting CBR testing, 1 set
load frame with 5 Tonne capacity, electrically operated with
speed control as per I.S. 2720 (Part 16)
ix) Standard penetration test equipment 2 Nos.
x) Speedy moisture meter complete with chemicals `2
Nos.
C. FOR BITUMEN AND BITUMINOUS MIXES
i) Constant temperature bath for accommodating bitumen test 1 No.
specimen, electrically operated and thermo statistically
controlled
ii) Penetrometer automatic type, adjustable weight arrangement
and needles as per I.S. 1203-1958
iii) Soxhlet extraction or centrifuge type apparatus complete with 1 No.
extraction thimbles with solvent and filter paper
iv) Laboratory mixer including required accessories 1 No.
v) Marshall compaction apparatus automatically operated as per 1 Set
ASTM 1559-62 T complete with accessories
vi) Distant reading thermometer 1 No.
D. FOR CEMENT, CEMENT CONCRETE AND MATERIALS
i) Water still 1 No.
ii) Vicat needle apparatus for setting time with plungers, as per 1 No.
I.S. 269-1967
iii) Moulds
a) 150 mm x 300 mm ht cylinder with capping component As
b) Cubicles 150 mm,. 100 mm (each size) reqd.
As
reqd.
iv) Concrete permeability apparatus 1 No.
v) High frequency mortar cube vibrator for cement testing 1 No.

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vi) Concrete mixer power driven, 1 cu ft capacity 1 No.

vii) Variable frequency and amplitude vibrating table size 1 metre 1 No.
x 1 metre, as per the relevant British Standard
viii) Flakiness index test apparatus 1 No.
ix) Aggregate impact test apparatus as per IS 2386 (Part 4) 1963 1 No.
x) Los Angeles abrasion apparatus as per IS 2386 (Part 4) 1963 1 No.
xi) Flow table as per IS 712-1973 1 No.
xii) Equipment for slump test 4 nos.
xiii) Equipment for determination of specific gravity for fine and 4 nos.
coarse aggregate as per IS:2386 (Part 3) 1963
xiv) Compression and flexural strength testing machine of 200 T 1 No.
capacity with additional dial for flexural testing
xv) Core cutting machine with 10 cm dia diamond cutting edge 2 Nos.
xvi) Needle Vibrator 4 Nos.
xvii) Air entrainment meter 1 No.
xviii) 0.5 Cft, 1 cft cylinder for checking bulk density of aggregate As
with tamping road reqd.
xix) Soundness testing apparatus for cement 1 Set
E. For Control of Profile and Surface Evenness
i) Total Station 1 No.
ii) Precision automatic level with micrometer attachment 22 sets
iii) Distomat or equivalent 1 set
iv) Theodolite – Electronically operated with computerized output 1 set
attachment
v) Precision staff 3 sets
vi) 3 metre straight edge and measuring wedge 3 sets
vii) Camber templates 2 lane
a) Crown type cross section 1 set
b) Straight run cross- section 2 sets
viii) Steel tape
a) 5 m long 2 sets
b) 10 m long 2 sets
c) 20 m long 2 sets
d) 30 m long 2 sets

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Clause 121.7 This clause shall be read as under:

“The cost of provision of field laboratory including supply of laboratory
equipment and also provision of adequate number of qualified personnel,
erection, maintenance and running of laboratory including all consumable like
chemicals and reagents shall be deemed to have been included in the contract
price”.
Clause 124 PROVIDING AND MAINTAINING VEHICLES FOR THE ENGINEER
The heading of this clause shall read as under:
“PROVIDING AND MAINTAINING VEHICLES FOR THE
ENGINEER AND EMPLOYER”
Clause 124.1 Scope
This clause shall read as under:
“The work covers providing and maintaining hard top passenger cars and/or
hard top jeeps for use by the Engineer and the Employer as descried under Bill
of Quantities.
Clause 124.2 Description
Para 1 of this Clause shall read as under:
“The passenger cars shall be petrol/diesel run, Ambassador Cars or equivalent
having cylinder capacity of minimum 1400 cc for senior personnel of the
Engineer and Project Director of the Employer. The hard top jeeps shall be 4W
drive Maruti Gypsy model MG 410 or equivalent for other personnel of the
Engineer and other staff of the Engineer. The number of vehicles to be
provided by the contractor shall be decided by the Engineer/Employer at
various times, out of the total provision in the bill of quantities and indicated in
writing”
Clause 124.4 Withdrawal of Vehicles
The first sentence for this Clause shall read as under:
The Contractor shall withdraw particular vehicle/vehicles for the non-use by
the Engineer/Employer if so directed by the Engineer
Clause 124.5 In line 2, replace “Vehicle day” by “Vehicle month”
Average mileage per month shall not exceed 3000 kms per vehicle.
Clause 124.6 Rate
Add the words ‘and Employer’ after the word ‘Engineer’ in second line.
Clause 201 CLEARING AND GRUBBING
Clause 201.1 Scope
Delete the last sentence and replace with as under :
“Clearing and grubbing shall be performed less than one month in advance of
earthwork operations and in accordance with the requirements of these
specifications. Areas requiring clearing and grubbing shall be determined by
the Engineer”.

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Clause 201.4 Disposal of Materials

Replace “1000 m” with “5000 m” in the second paragraph last sentence
Clause 201.5 Measurements for Payment
Delete the last two sentences in first paragraph and the whole of second and
third paragraph and replace as under:
Cutting of trees up to 300 mm in girth measured at one meter above ground
including removal of stumps and roots and trimming of branches of trees
extending above the roadway shall be considered incidental to the clearing and
grubbing and no separate payment shall be made for the same.
Removal of stumps and roots of trees of girth above 300 mm and back filling
to required compaction shall be measured in terms of number of stumps of
trees and will be payable.
Clause 201.6 Rates
Clause 201.6.1 Delete “as well as stumps left over after cutting of trees carried out by another
agency” from the second sentence
Replace “1000 m” with 5000m” in the last sentence
Add the following paragraph:
“The removal from site and disposal of all materials obtained from clearing
and grubbing operations, which, in the opinion of the Engineer cannot be used
or auctioned, shall be included in the Contract unit rate”
Clause 201.6.2 Replace “1000 m” with “5000m” in last sentence
Clause 202.5 Disposal of Materials
Substitute ‘lead of 1000 m’ by ‘5000 m,’ wherever appearing this clause.
Clause 202.7 Rates
Delete the last sentence of the first paragraph and replace with:
“These will also include excavation and back filling where necessary to the
required compaction and for handling, piling and disposal of the dismantled
materials with all lifts and le ads as specified in Sub-clause 202.5. the cost of
cartage of materials with no salvage value to disposal sites up to a lead of 5000
m is deemed to be included in the rates for dismantling”
Clause 301 EXCAVATION FOR ROADWAY AND DRAINS
Clause 301.1 Scope
Insert the following between the words ‘roadway’ and ‘side’ in the second line
“road shoulders, verge, medians”
Clause 301.3.7 This Clause shall read as under:
“In works involving widening of existing pavements or providing paved
shoulders, the existing shoulders/verge/median shall be removed to its full
width. The subgrade material within 0.5 m from the lowest part of the
pavement shall be checked for density which should not be less than 97% as
per table 300-2. In case the density is found to be less than 97%, then the
subgrade shall be loosened, excavated and recompacted as per Clause 305 to a

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density not less than 97% of maximum dry density determined according to
IS:2720 (Part 8). Any unsuitable material encountered in this portion of
subgrade shall be removed and replaced with suitable material and compacted
in accordance with Clause 305”.
Clause Disposal of excavated materials
301.3.11
Delete this sub-clause and replace with:
“All the excavated materials shall be the property of the Employer. Suitable
material obtained from the excavation of the roadway, shoulders, verges,
drains, cross drainage works, etc. shall be used for:
i) filling for roadway embankments
ii) filling existing pits in the right of way as directed by the Engineer,
including levelling and spreading, with all lifts and lead up to 5000 m
iii) for landscaping of the road as directed by the Engineer, including
levelling and spreading, with all lifts and lead up to 5000 m
Unsuitable and surplus material, which, in the opinion of the Engineer cannot
be used in the works, shall be removed from site by the Contractor and
disposed off at the approved location in accordance with all statutory
requirements as approved by the Engineer”
Clause 301.8 Read item (i) of last para as ‘loosening, excavating and recompacting’
Read unit of item(v) of last para as km cu.m. in place of cum for disposal of
samples materials beyond initial lead of 5000 m.
Clause 301.9 Rates
Clause 301.9.1 In item (ii) replace “1000m” with “5000m”
Add the followin g after item (vi)
“(vii) The removal from site and disposal of all surplus or unsuitable materials
obtained from excavation operations, which, in the opinion of the Engineer
cannot be used in the Works, shall be included in the Contract rate”
Clause 301.9.2 This clause shall read as under :
“The contract unit rate for loosening and recompacting at subgrade level shall
include full compensation for loosening to the specified depth, removing the
loosened soil outside the roadway excavation, rolling the surface below,
breaking the clods, spreading the excavated soil in layers, watering where
necessary and compacting to the requirements”.
Clause 301.9.5 Replace “1000m” with “5000m” in the first sentence.
Clause 301.9.6 Replace “1000m” with “5000m” in the first sentence.
Clause 304 EXCAVATION FOR STRUCTURES
Clause 304.3.4 Preparation of Foundation
In para 2 and 3 of clause 304.3.4 substitute ‘concreteM-10’ in place of ‘1:3:6
nominal mix’
Clause 304.5.1 Replace 1000m with 5000m in item (v).

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Clause 304.5.3 Replace 1000m with 5000m in last line.

Clause 305 EMBANKMENT CONSTRUCTION
Clause 305.2.1 Physical requirements
Replace the existing table 300-1 by the following :
Table 300-1
DENSITY REQUIREMENTS OF EMBANKMENT AND SUBGRADE MATERIALS
Sl. Type of work Engineering properties of samples remolded as per IS
No. 2720 (part 8)
Max dry Maximum Minimum Angle of
density Cohesion internal friction
(gm/cc) (Kg/Esq.) (Degree)
1. Embankment up to 3 m height, not Not less than - -
subjected to extensive flooding 1.52
2. Embankment exceeding 3 m height Not less than - -
and up to 6 m height 1.60
3. Subgrade and earthen Not less than - -
shoulders/verge/backfill 1.75
4. High embankment (embankments Not less than 0.10 27o
exceeding 6 m height) 1.75
- Approaches to ROB and flyover

Clause Add new sub clause

305.2.1.6
“Materials used as subgrade in embankment shall have a 4 day soaked CBR
value of minimum 7%.
Clause Borrow Materials
305.2.2.2
Para 1 of this Clause shall read as under:
No borrow area shall be made available by the Employer for this work. The
arrangement for the source of supply of the material for embankment and
subgrade as well as compliance to the different environmental requirements
in respect of excavation and borrow areas as stipulated, from time to time, by
the Ministry of Environment and Forests, Government of India and the local
bodies, as applicable shall be the sole responsibility of the Contractor”
The Table 300-2 shall read as under:
Table 300-2
Compaction requirements for embankment and subgrade

Sl. Type of work/Material Relative compaction as %age of

No. maximum laboratory dry density
as per IS:2720 (Part 8)
1. Subgrade and earthen shoulders Not less than 97
2. Embankment
a) Up to 6 m height Not less than 95
b) Exceeding 6 m height Not less than 97

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Sl. Type of work/Material Relative compaction as %age of

No. maximum laboratory dry density
as per IS:2720 (Part 8)
3. Expansive clays
a) Subgrade and 500 mm Not allowed
portion just below the
subgrade
b) Remaining portion of
Not less than 90
embankment

Para 8 of this Clause given below Table 300-2 shall read as under :
“The contractor shall at least 7 working days before commencement of
compaction submit the following to the Engineer for approval:
i) The Values of maximum dry density and optimum moisture content
obtained in accordance with IS:2720( Part 8) for each fill material he
intends to use.
ii) The graphs showing values of density against moisture content from which
each of the values in (i) above of the maximum dry density and optimum
moisture content were determined
iii) The dry density –moisture content-CBR relationship for each of the fill
materials he intends to use in the subgrade
Clause 305.3 Construction Operations
Clause Compacting ground supporting embankment/subgrade
305.3.4
Para 1 of this clause shall read as under:-
Where necessary, the original ground shall be leveled, mixed with water and
then compacted by rolling to facilitate placement of 1st layer embankment and
its compaction in accordance with the requirement as given in table 300.2
Add the following sentence at the end of para 2.
“Where necessary to facilitate compaction of the subgrade to 97% relative
compaction as stated above, a further depth of maximum 0.20 meter thickness
shall be loosened, watered and compacted in accordance with Clause 305.3.5
and 305.3.6 to not less than 95% of maximum dry density, determined in
accordance with IS:2720 (Part I)”
Clause Compaction
305.3.6
Insert in 3rd line of second para of this clause:
“15-30 tonne weight having tyre pressure of at least 7 kg/sq. cm” in place of
“adequate capacity capable of achieving required compactions”
Clause Insert “including removal of top soil after word ‘materials’ appearing in first
305.9.1 line of item (v)”
Clause Read “5000 m” in place of “1000 m” in the last sentence
305.9.6

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CLAUSE 306 SOIL EROSION AND SEDIMENTATION CONTROL

Clause 306.4 Measurement for payment
Substitute Clause 306.4 as follows:
“All temporary sedimentation and pollution control works shall be deemed as
incidental to the earthwork and other items of work and as such no separate
payment shall be made for the same”

CLAUSE 309 SURFACE/SUB -SURFACE DRAINS

Clause 309.4 Measurement for payment
Substitute Clause 309.4 as below:
The measurement for surface drains shall be in cubic content for earthwork in
excavation, cement concrete and reinforced cement concrete works and in
weight for steel reinforcement.
CLAUSE 401 GRANULAR SUB -BASE
Clause 401.2 Materials
Clause Delete last sentence of Para 1 and add the following:
401.2.1
The material shall be free from organic or other deleterious constituents and
conform to the Grading I given in Table 400-2”
Delete para 2 of Clause 401.2.1
Clause 401.3 The clause shall read as follows:
It shall be ensured prior to actual execution that the material to be used in the
sub-base has a minimum CBR value of 30% when compacted and finished.
When directed by Engineer, this shall be verified by performing tests in the
laboratory. The CBR tests shall be conducted on specimen soaked for 4 days
and compacted to 98% of the maximum dry density as per IS :2720 (Part 8)

Clause 406. WET MIX MACADAM SUB -BASE/BASE COURSE

Clause Add at the end of 1st para
406.2.1.1
The fraction of material passing through 4.75 m m sieve shall be crusher run
screening only.

Clause Preparation of mix

406.3.3
Delete last sentence of para 1 of Clause 406.3.3

Clause Spreading of mix

406.3.4

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Substitute first sentence of para 2 of this clause by

“The mix shall be spread by a paver finisher.”

Clause 501 General Requirements for Bituminous Pavement Layer

Clause 501.3 Mixing
The first sentence of para 1 replace the words “hot mix plant of adequate
capacity” as under:
“Hot mix plant of batch type of minimum capacity of more than 120 tonne per
hour”
Clause In the last sentence replace “1000m” with 5000m”
501.8.3.2
Clause Laying the Profile Corrective Course
501.8.3.4
Clause This clause shall read as under:
501.8.3.4.1
“The surface on which profile corrective course is to be laid shall be
thoroughly swept clean of dust and any other extraneous material using
mechanical broom and dust collected removed or blown off using compressed
air except in places where mechanical means cannot reach”
“After preparing the granular surface as in Clauses 501.8.3.1, 501.8.3.2 and
501.8.3.3, the profile corrective course with materials as per Clause
501.8.2.3/501.2.4 shall be laid and compacted to the requirement of particular
specification Clause. Where a bituminous profile corrective course is to be
laid over primed granular surface, a tack coat conforming to Clause 503 shall
be applied prior to laying profile corrective course.”
Clause This Clause shall read as under:
501.8.3.4.2
“An existing bituminous surface shall be prepared as per Clauses 501.8.3.3 and
501.8.3.4.1. The bituminous profile corrective course shall be laid after
applying tack coat conforming to Clause 503, and compacted to the
requirement of specification Clause”
Clause Profile Corrective Course
501.8.7.3
Replace the last sentence of the para as under:
x-sectional area of the profile corrective course shall be measured at interval
given below or as determined by the Engineer and volume calculated using the
method End areas.
Add the following at the end of para:
For overlay sections, the contractor must obtain a detailed profile (maximum
10 meter spacing for straight length, 5 m spacing for curves) and cross sections
of the existing road surface and that proposed for the Engineer’s approval a
vertical alignment and finished section that:-
Will achieve the required cross falls or super elevations and a properly

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designed vertical profile

§ Permit execution of the designed DBM and the B.C. course throughout
and
§ Can be accomplished using quantities of DBM for pre-levelling that will
not exceed those allowed for in the BOQ, to the extent possible
§ Detailed report using latest software shall be prepared for each km and
submitted to Engineer 15 days before the start of work. The report shall
contain (i) existing cross section (ii) proposed cross section (iii) profile
giving grade and levels and quantities of materials required for profile
correction.
Following discussions with the Engineer, the contractor may be required to
adjust the vertical alignment to achieve an appropriate balance, as judged by
the Engineer, between vertical profile and required quantity of pre-levelling
course.
The pre-levelling course or courses shall be laid using electronic paving
control and a guide wire (or guide wires) fixed at points not exceeding every
5.0 metres, so that subsequent courses can be laid at constant thickness to
achieve the vertical profile and cross falls approved by the Engineer.
At the discretion of the Engineer the Contractor may be required to lay all
DBM layers, but not the BC layers, using electronic controls and guide wires.
Clause In the last sentence replace “1000 m with “5000m”
501.8.8.1
Clause 502 PRIME COAT OVER GRANULAR BASE
Clause 502.2 Materials
Clause Delete the following sentence from the para:
502.2.3
“Slow setting cationic emulsion as per IS: 8887 may also be used, but the
particular grade to be used for the work shall be got approved by the Engineer”
Clause 504 BITUMINOUS MACADAM
Sub-clause Delete the words “indicated in table 500-4” and insert “grade of S-65” in the
504.2.1 last line
Sub-Clause Add the word “except for item of tack coat” after words “required operation”
504.8 in 2nd line
Clause 507 DENSE GRADED BITUMINOUS MACADAM
Clause 507.2 Materials
Clause This clause shall read as under:
507.2.1
The Bitumen shall be paving bitumen of Penetration Grade 60/70 as per Indian
Standard Specifications for Paving Bitumen – IS:73
Clause Coarse aggregates
507.2.2
(i) From Table 500.8 delete from the bottom of the table marked with single
asterisk “Aggregate may satisfy, etc.” and modify as under:

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Aggregate should satisfy both the tests of Los Angeles Abrasion Value and
Aggregate Impact Value.
Clause Delete the words “or naturally occurring mineral” and “or a combination of
507.2.3 two” appearing in the 1st sentence of Clause.
Clause Insert the following paragraph between existing paragrah 3 and 4
507.3.3
Mix design shall be carried out in accordance with the modified Marshall
method described in Asphalt Institute Manual MS-2
Clause Add as follows:
507.4.8
The temperature of mix at the time of laying shall be in the range 120-145
degree Celsius
Clause 507.9 Rate
Add the words ‘except for the item of tack coat’ after the words ‘required
operations’ in second line.
Clause 509 BITUMINOUS CONCRETE
Clause The first part of first line shall be read as under:
509.2.1
“Bitumen shall be paving bitumen of penetration grade 60/70 as per IS
Specification for paving bitumen IS-73
Clause This Clause shall read as follows:
509.2.4
“Filler shall consist of finally divided hydrated lime or cement as approved by
the Engineer”
Clause 801. TRAFFIC SIGNS
Clause This clause shall read as under:
801.1.2
“All road signs shall be of retro-reflectorised type and made of high intensity
grade with encapsulated lens type sheeting vide clause 801.3, fixed over
aluminum sheeting as per these specifications”
Clause 803 ROAD MARKINGS
Clause 803.3 Deleted
Clause 901 GENERAL
Clause 901.1 This clause shall read as under:
“All materials to be used, all methods adopted and all works performed shall
be strictly in accordance with the requirements of these Specifications. The
Contractor shall set up a field laboratory at locations approved by the Engineer
and equip the same with adequate equipment and personnel in order to carry
out all required tests and Quality Control work as per Specifications and/or as
per clause 121 and/or as directed by the Engineer. The list of laboratory
equipment and the facilities to be provided shall be as per Clause 121 and shall
be got approved from the Engineer in advance.

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Clause 901.5 This Clause shall read as under:

“The Contractor shall provide necessary cooperation and assistance in
obtaining the samples for tests and carrying out the field tests as required by
the ‘Engineer’ from time to time. This may include provision of laboratory
equipment, transport, consumables, personnel, including labour, attendants,
assistance
Clause 903 QUALITY CONTROL TEST DURING CONSTRUCTION
Clause 903.4 Tests on Bituminous Constructions
In Table 900-4, serial No. 6 for Dense Bituminous Macadam/Semi Dense
Bituminous Concrete and for Bituminous Concrete add the following at the
end in the frequency column (xvii) and (xviii)
“10% of the density tests shall be done on edges”
Clause 1006 CEMENT
The first para of this Clause shall read as under:
“Cement to be used in the works, shall be any of the following with prior
approval of the ‘Engineer’
a) Ordinary Portland Cement 33 grade conforming to IS:269
b) Ordinary Portland Cement 43 grade, conforming to IS:8112
c) Ordinary Portland Cement 53 grade, conforming to IS:12269
d) Portland Blast Furnace Slag Cement conforming to IS :455
Delete para 4 and 5 from Clause 1006”
Clause 1007 COARSE AGGREGATES
Delete from the first sentence “crushed gravel… Inert material” appearing in
4th and 5th line.
Add the following at the end of the Clause
“Primary and secondary stone crusher should be employed for getting proper
size and grading of coarse aggregates”
Clause 1009.2 Steel for Prestressing
Add (e) to the list of codes to which acceptable prestressing steel shall
conform :
(e) Stress relieved low relaxation seven ply strand for prestressed
concrete –IS:14268
Clause 1010 WATER
In para (C) the permissible limit for Chlorides (Cl) shall be read as “250
mg/lit for structures having length more than or equal to 30 m”
Clause 1014 STORAGE OF MATERIALS
Clause 1014.3 Aggregates
The following shall be added to this Clause:
“Aggregates shall be stored or stockpiled in such a manner that segregation of

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fine and coarse sizes will be avoided and also that the various sizes will not
become intermixed before proportioning. They shall be stored, stockpiled and
handled in such a manner that will prevent contamination by foreign
materials”
Clause 1502 MATERIALS
This Clause shall read as under:
“All materials shall comply with the requirements of IRC-87
Material and components used for formwork shall be examined for damage or
excessive deterioration before use/reuse and shall be used if found suitable
after necessary repair.
Only steel form work shall be used. The steel used for forms shall be of such
thickness that the forms remain true to shape. All bolts should be
countersunk. The use of approved internal steel ties or plastic spacers shall be
permitted. Structural steel tubes used as support for forms shall have a
minimum wall thickness of 4 mm”
Clause 1503 DESIGN OF FORMWORK
Clause 1503.2 The following shall be added to this Clause
“For distribution of load and load transfer to the ground through staging, an
appropriately designed base plate must be provided which shall rest on firm
sub-stratum”.
Clause 1509 REUSE OF FORMWORK
This Clause shall read as under:
“After forms are stripped, all materials to be reused shall be thoroughly
cleaned. Holes bored through sheathing for form ties shall be plugged by
driving in common corks or foamed plastics. Patching plaster may also be
used to fill small holes. After cleaning and before refixing, each formwork
shall be got approved from the Engineer.
Formwork and staging shall be so used so as to maintain qualit y of the
exposed surface. However, if in the opinion of the Engineer, any particular
panel/member has become unsatisfactory for use at any stage, the same will
be rejected.
All bent steel props shall be straightened before reuse. The maximum
deviation from straightness is 1/600 of length. The maximum permissible
axial loads in used props shall be suitably reduced depending upon their
condition.
Clause 1513 RATE
Add the following at the end of the first para:
“The unit rate shall also include all costs for preparation of erection scheme,
designs of falsework and formwork and their approval”
Clause 1703 GRADES OF CONCRETE
Add the following at the end of this Clause :
The concrete mixes leaner than M15 shall be called as nominal mix concrete.

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“Nominal mix concrete is that concrete for which concrete is not to be

designed by tests and in which the proportions of materials are in accordance
with the drawing and the specification clause mentioned below:
i) All the materials for this concrete shall conform to section 1000 of
MORT&H Specifications
ii) Minimum cement content and maximum water cement ratio for above
said nominal mix concrete shall conform to Clause 1703.2 Table 1700-
3(A) of MORT&H Specifications
iii) Mixing of above said nominal mix concrete shall conform to Clause
1708 of MORT& H specifications
iv) Transporting, Placing and compaction of above said nominal mix
concrete shall conform to clause 1709 of MORT & H specifications.
Clause 1704 PROPORTIONING OF CONCRETE
Add the following at the end of this Cla use :
“In proportioning concrete, the quantity of both cement and aggregate shall be
determined by weight. Where the weight of cement is determined by
accepting the manufacturer’s weight per bag, a reasonable number of bags
shall be weighed separately to check the net weight. Where cement is
weighted from bulk stock at site and not by bag, it shall be weighed separately
from the aggregates. Water shall either be measured by volume in calibrated
tanks or weighed. All measuring equipment shall be maintained in a clean,
and serviceable condition. Their accuracy shall be periodically checked”
“It is most important to keep the specified water – cement ratio constant and
at its correct value. To this end, moisture content in both fine and coarse
aggregates shall be determined as frequently as possible, frequency for a
given job being determined by the Engineer according to the weather
conditions. The amount of mixing water shall then be adjusted to compensate
for variations in the moisture content. For the determination of moisture
content in the aggregates, IS :2386 (Part III) shall be referred to. Suitable
adjustments shall also be made in the weight of aggregates to allow the
variation in weight of aggregates due to variation in their moisture content”
Clause 1704.4 Additional requirement
In para (a) substitute “0.06%” for “0.1%”, “0.06% for “0.2% and : 0.1% for
“0.3% for the three items respectively.
Clause 1705 ADMIXTURES
This Clause shall read as under:
“Duly tested admixtures/additives conforming to IS 6925 and IS9103 (without
replacement of cement) may be used subject to satisfactory proven use, with
the approval of the Engineer. Admixtures generating Hydrogen or Nitrogen
and containing chlorides, nitrates, sulphides, sulphates and any other material
liable to affect the steel or concrete shall not be permitted”
“The general requirements, physical and chemical requirements shall be as
per Clause 1012”
Clause 1706 Size of Coarse aggregate

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Table 1700-7 in this clause shall read as under:

Maximum Nominal
Sl.
Components size of coarse
No.
aggregate (mm)
i) RCC well curb 20
ii) RCC/PCC well steining 40
Well cap or pile cap solid type piers and
iii) 40
abutments
RCC work in girders, slabs, kerb, approach
iv) slab, piers and abutments, pie r/abutment caps, 20
piles
v) PSC work 20
PCC in bottom plug and top plug/intermediate
vi) 40
plug
vii) RCC work in wearing coat and handrails 12.5
As specified or as
viii) Any other work directed by the
Engineer

Clause 1707 EQUIPMENT

Para 1 of this Clause shall read as under:
“Unless specified otherwise, equipment for production, transportation and
compaction of concrete shall be as under”
a) For production of concrete
i) “Batching and mixing of the concrete shall be done in a concrete
batching and mixing plant fully automatic with a minimum capacity of
15 cum. Per hour. The plant shall be approved by the Engineer”
ii) In special cases, for culverts, the Engineer may allow mixing of
concrete by a diesel or electrically operated mechanical mixer with
integrated weigh batching facility having a capacity of 500 litres and
automatic water measuring system”
Para 3 of this clause shall read as under:
Measurement of cement + 3 per cent of quantity of cement in each batch
batch

Measurement of water + 3 per cent of quantity of water in eatch batch

Measurement of aggregate + 3 per cent of quantity of aggregate in each batch

Measurement of admixture + 3 per cent of quantity of admixture in each
batch.

Clause 1709 Transporting, Placing and Compaction of Concrete

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Add the following paragraph at the end of 2nd para of Clause 1709
For placing Concrete with pumps: Pipe lines from the pump to the placing
area should be laid out with a minimum of bends. For large concrete
placements standby pumps shall be available. Suitable valves (air release
valves, shutoff valves etc.) shall be provided as per site needs. The pumping
of concrete shall be preceded by a priming mix to lubricate the pump and
pipelines. A rich mix of cremy consistency shall be required for lubricating
the pipelines. Continuous pumping shall be done to the extent possible. After
concrete has been placed the lines and all related equipment shall be cleaned
immediately. A plug sponge ball shall be inserted in the end near the pump
and shall be forced through the line by either water or air pressure. Pipes for
pumping should not be made from materials, which can harm concrete;
aluminum alloy pipelines shall not be used.

Clause 1713 PROTECTION AND CURING

Clause 1713.1 Water Curing

Add the following at the end of para I.

“Wherever possible, use of water sprinklers or perforated pipes should be

encouraged for curing of concrete. Such arrangement must be maintained for
a minimum period of 14 days after concreting”.
“Approved concrete curing compounds should be preferred where water
curing cannot be done reliably”

Clause 1802 MATERIALS

Clause 1802.2 Sheathing

Add the following at end of the Clause :
“Where dummy core or cable is not provided during concreting, the diameter
of sheathing shall be at least 10 mm more than required otherwise”

Clause 1804 WORKMANSHIP

Clause Post – tensioning
1804.3.1
The following para shall be inserted between the 5th and the 6th para.

“The steel sheaths or duct formers shall be suitably tied to secondary

reinforcement or to properly located withdrawable through-shutter bolts,
precast concrete blocks or similar effective means, in such a manner that they
do not give rise to excessive friction when the steel is being tensioned.”

Clause 1806 TENSIONING EQUIPMENT

Add the following at the end

“Before initial use and subsequently at suitable intervals, the prestressing
equipment shall be checked to determine any variation from the normal values
during use.
So far as these variations depend upon external influence (e.g. temperature in

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the case of oil jacks) they shall be taken into account”

Clause 2005 ELASTOMERIC BEARINGS

Clause 2005.3 Acceptance Specifications

In para 5, substitute the words “Engineer or his authorized representative” for

the word “Inspector”

Clause Inspection Certificate

2005.3.5
In para 4, substitute the words “Engineer or his authorized representative” for
the word Inspector authorized by Engineer”

Clause 2009 MEASUREMENTS FOR PAYMENT

Add the following after para 2.

“Paper bearings shall be measured in square metres”

Clause 2504 Pitching/Revetment on Slopes

The heading of this clause shall read as under:

Pitching/Revetment on slopes and filter media

Clause Filter Media

2504.2.2

Para 1 of this clause shall read as under:

The material for the filter shall consist of sand, gravel, stone or coarse sand to
prevent escape of the embankment material through the voids of stone
pitching/weep holes in abutments as well as to allow free movement of water
without creating any uplift head on pitching one or more layers of graded
materials, commonly known as filter medium, shall be provided underneath
the pitching. The material for filter media behind abutment shall conform to
general guidelines given in Appendix 6 of IRC:78 (Standard Specifications
and Code of Practice for road bridges Section II).

Clause 2702 WEARING COAT

Clause 2702.1.1 This Clause shall read as under:

Principles of Bituminous wearing coat shall comprise the following :

i) A coat of mastic asphalt, 15 mm thick, with a prime coat over the top of
the deck before the wearing coat is laid. The prime coat of mastic asphalt
shall be 30% straight run 30/40 penetration grade bitumen and 50% light
solvent (Benzol) to be laid over the deck slab. The insulation layer of 15
mm thick mastic asphalt with 75% lime stone dust filler and 25% of 30/40
penetration grade bitumen shall be laid at 375°F with broom over the
prime coat.
ii) 50mm thick asphaltic concrete wearing coat in two layers of 25mm each
as per Clause 509 of MORT&H specification for Road and Bridge works
(Fourth Revision).

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Clause 2706 WEEP HOLE

This clause shall read as under:
“Weep holes shall be provided in solid plain concrete/reinforced concrete and
brick abutments, wing walls, return walls as shown in the drawing or as
directed by the Engineer to drive moisture from the back filling. Weep holes
shall be provided with 100 mm dia A.C. pipe and shall extend through the full
width of concrete with slope of about 1 vertical: 20 horizontal towards the
draining face.
The spacing of weep holes shall generally be 1 m in either direction or as
shown in the drawing with the lowest at about 150 mm above the low water
level or ground level whichever is higher or as directed by the Engineer”

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National Highways Authority of India Bid Document/Volume II/Section 5

APPENDIX –I
(Page 1 of 1)
ADDITIONAL TECHNICAL SPECIFICATION FOR MODIFIED BINDER

1) The scope, material, proportion requirements, mixing, quality control of materials etc. shall be
as per Clause 521 of MORT&H Specifications. For details IRC:SP:53-2002 may be referred
instead of IRC:SP:53:1999 as mentioned in the specifications.
2) Modify clause 521.6 to read “The payment shall be made as consolidated rate of Bituminous
Concrete as per Clause 509

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APPENDIX II

GOVERNMENT OF INDIA

MINISTRY OF ROAD TRANSPORT AND HIGHWAYS

REVISED
INTERIM SPECIFICATIONS
FOR
EXPANSION JOINTS

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National Highways Authority of India Bid Document/Volume II/Section 5

Government of India
Ministry of Road Transport & Highways

Gram Parivahan Bhawan

“ROADIND” 1, Parliament Street
New Delhi 110 001

No. RW/NH-34059/1/96-S&R Dated 25th January 2001

To
1. The Chief Engineers of States/UT PWDs
(Dealing with National Highways and other Centrally Financed Schemes)

2. The Director General (Boarder Roads)

Kashmir House, New Delhi

3. The Chairman,
National Highways Authority of India,
1, Eastern Avenue, Maharani Bagh, New Delhi

4. The Engineer-in-Chief,
Municipal Corporation of Delhi, Town Hall, Delhi

Sub: Revised interim specifications for Expansion Joints – Corrigendum

Sir,
Please refer to this Ministry’s circular letter of even number dated 30th November 2000 enclosing
therewith the Revised Interim Specifications for Expansion Joints for adoption on all National
Highways and other centrally sponsored bridge projects. In order to remove certain anomalies
and keeping in view the proprietary nature of the expansion joints products being manufactured
by the various firms, the following corrections in some clauses of the Revised Interim
Specifications (circulated earlier on 30.11.2000) may be noted for guidance and compliance:-
i) Page 8 – IV: Strip/box Seal Expansion Joint :
Para: 2(a) Edge Beam :
The first sentence of this para shall be read as under:
“This shall be either extruded or hot rolled steel section or cold rolled cellular steel section,
including continuously shop welded section with suitable profile to mechanically lock the
sealing element in place throughout the normal movement cycle”
ii) Para 2(a):
This para shall be read as under:
“The steel for edge beams shall conform to any of the steel grade corresponding to RST 37-2
or 37-3 or 52-3 (DIN), ASTM A36 or A588, CAN/CSA Standard G40.21 Grade
300 W or equivalent”

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iii) Page 13- V: Modular Strip/box Seal Joint

Para 3.1:
The last but one sentence of this para shall be read as under:
“The material shall conform to any of the steel grade corresponding to RST 37-2 or 37-3
or 52-3 (DIN), ASTM A36 or A588, CAN/CSA Standard G-40.21 Grade 300 W or
equivalent”.
2. Please acknowledge receipt of this letter.

Yours faithfully,

(B. Chakrabarti)
Executive Engineer (B)S&R
For Director General (RD) & AS

Encl: As above

Copy to:

1. PPS to Secy (RT & H)

2. TS to DG(RD)
3. Secretary, IRC
4. Director, NITHE
5. All Technical Officers of the Roads Wing
6. All ROs/ELOs

Sd/- 25.01.01
(B. Chakrabarti)
Executive Engineer (B)S&R
For Director General (RD) & AS

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National Highways Authority of India Bid Document/Volume II/Section 5

Government of India
Ministry of Road Transport & Highways

Gram Parivahan Bhawan

“ROADIND” 1, Parliament Street
New Delhi 110 001

No. RW/NH-34059/1/96-S&R Dated 30th November 2000

To

1. The Chief Engineers of States/UT PWDs

(Dealing with National Highways and other Centrally Financed Schemes)

2. The Director General (Boarder Roads)

Kashmir House, New Delhi

3. The Chairman,
National Highways Authority of India,
1, Eastern Avenue, Maharani Bagh, New Delhi

4. The Engineer-in-Chief,
Municipal Corporation of Delhi, Town Hall, Delhi
Sub: REVISED INTERIM SPECIFICATIONS FOR EXPANSION JOINTS .
Sir,
In supersession of this Ministry’s Circular letter of even number dated March 31, and July 21,
1997 on the above subject, please find enclosed herewith revised interim specifications for
expansion joints for adoption on all National Highways and other centrally sponsored bridge
projects. Salient points of revised interim specifications are mentioned below:
1.1 Criteria for adoption
1.1.1 Suitability Criteria for adoption of different types of expansion joints is given in
Annex –I.
It may be noted that some provisions pertaining to single strip seal and modular joints
have since been revised in the modified interim specification placed below for further
adoption.
1.1.2 Special type of modular expansion joint should be provided for bridges having wide deck
and large span length involving complex movements/rotations in different
directions/planes, with prior approval of the Ministry
1.1.3 Dynamic/fatigue testing under simulated conditions shall be done for modular joints to be
installed on bridges located in seismic zones IV & V.
1.1.4 Specification for strip seal joints contained in Clause 2607 of this Ministry’s
“Specifications for Roads & Bridge Works” stands substituted by those given herein.

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2. While arranging supply of expansion joints, a warranty of trouble - free performance for at
least ten years and free rectification of defects/replacement, if any, during this period may
be insisted upon from the contractor/suppliers for all types of joints except for Buried
joints, Filler joints and Asphaltic plug joint.
3. The performance of the expansion joints shall be observed regularly by the client
particularly during the warranty period. The joints showing any defect during this period
shall be got repaired/replaced by the respective firms at their own cost failing which the
particular supplier may be debarred from supplying their expansion joint system for
National Highway works and other Centrally sponsored schemes.
4. It is requested that the contents of this circular be brought to the notice of all officers in
your department concerned with National Highways and other Centrally sponsored
schemes.
5. It may be noted that a Committee of IRC is already working on a draft code for expansion
joints. These interim specifications will be in force till the code is finalized by the
Committee and made applicable by the Ministry.
6. You are also requested to send your comments/suggestions, if any, for further
improvement of the interim specifications.
7. Please acknowledge receipt of this letter.

Yours faithfully,
Sd/-
(I.K. Pandey)
Superintending Engineer (B) S&R
For Director General (RD) & AS

Encl: As above
Copy to :-
1. PPS to Secy (RT & H)
2. TS to DG(RD)
3. Secretary, IRC
4. Director, NITHE
5. All Technical Officers of the Roads Wing
6. All ROs/ELOs
Sd/-
(I.K. Pandey)
Superintending Engineer (B) S&R
For Director General (RD) & AS

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I. BURIED JOINT

Clause 2604 of MOST Specification for Road & Bridge Works (Third Revision) may be
deemed modified as under:
1. This joint shall consist of continuously laid bituminous /asphaltic surfacing over the
joint gap bridged by a steel plate resting freely over the top surface of the deck
concrete
2. The width of the joint gap shall be kept as 20 mm.
3. The steel plate shall conform to weldable structural steel as per IS:2062. The plate
shall be 12 mm thick and 200 mm wide. The plate shall be made of minimum number
of pieces (not exceeding two pieces per traffic lane width) welded together to form the
required length.
4. 8 mm dia, 100 mm long nails, spaced at 300 mm centers along the center line of the
plate shall be welded to the bottom surface of the steel plate to protrude vertically into
the joint gap in order to prevent dislodging of the plate
5. The plate and the nails shall be protected against corrosion by galvanizing or any other
approved anticorrosive coating with a minimum thickness of 100 micron. These shall
be completely free of oil, rust, loose paint or other similar material before application
of anticorrosive coating.
6. The concrete surface shall be free from any loose material and cleared of any grease,
oil, paint, etc. and the surface shall be sand blasted, clean of all laitance and level true,
prior to placement of the steel plate.
7. The plate shall be placed symmetrical to the center line of the joint and it shall be
ensured that the plate does not get displaced from its position while laying the wearing
course.

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II. ASPHALTIC JOINT

1. Asphaltic plug joint shall consist of a polymer modified bitumen binder, carefully
selected single size aggregate, closure/bridging metallic plate and heat resistant foam
caulking/backer rod.
2. General requirements:
2.1 The joint shall extend to the full depth of the wearing course down to structural concrete.
Where needed, a recess may be cut into the deck slab concrete to accommodate the
minimum required depth of the joints.
2.2 The joint shall be provided in the entire width of the structure including kerb and/or
footpath. A recess in the kerb and/or footpath shall be made to allow the joint to pass
beneath them. The expansion gap in the adjoining kerbs and/or footpaths shall be sealed
with a suitable sealant such as polysulphide sealant.
2.3 Expansion joint shall cater for a horizontal movement of 25 mm & vertical movement of
2 mm. This shall be certified by the manufacturer/supplier of the joint.
2.4 The minimum width (in traffic direction) of the joint shall be 500 mm and maximum
width shall be 750 mm.
2.5 Minimum depth of joint shall be 75 mm and maximum depth shall not exceed 100 mm.
2.6 The joint shall be capable of performing satisfactorily, within the temperature (ambient)
range of –5 to +50 degree C.
3. Material:
3.1 Binder :The polymer modified bitumen binder shall have the capacity to fill the gaps and
voids between single size aggregate and to impart flexibility to accommodate various
design movements. It shall be a patented blend of bitumen, synthetic polymer, fillers and
surface active agent and shall be so formulated as to combine necessary fluidity for the
installation process, low temperature flexibility and flow resistance at high ambient
temperatures. The binder shall satisfy following requirement:
Softening point :100 deg. C minimum
Core penetration at 25 deg. C. 0.1 mm (BS 2499) : 100 mm max.
Flow resistance at 70 deg. C, 5 hours (BS 2499) : 3 mm max
Extension Test : 5 cycle of extension to 50
per cent at a rate of 3.2
(blocks prepared to ASTMD1190 and tested to mm/hour at 25 deg. C
limits BS 2499)
Safe heating temperature :210 deg. C.

3.2 Aggregates: The aggregate shall be single size aggregate chosen from basalt granite,
grit stone or gabro group. The nominal size of aggregate shall be 12.5 mm for depths of
joints up to 75 mm and 20 mm for joints of more depths of joint. The aggregate shall not
be flaky and the Flakiness Index shall not be more than 25 per cent. The aggregate shall
satisfy following grading requirements:

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IS sieve Designation Nominal size of aggregate

20 mm 12.5 mm
Percentage by weight passing the sieve
26.5 mm 100 --
19.9 mm 85-100 100
13.2 mm 0-35 85-100
09.5 mm 0-7 0-35
06.3 mm -- 0-7
02.3 mm 0-2 -----2
600 micron --- ----
75 micron 0-1 0-1

The aggregate should have good (i) Polished Stone Value (PSV), (ii) Aggregate Abrasion
Value (AAV), (iii) Aggregate Impact Value(AIV) and (iv) Aggregate Crush Value
(ACV). In addition surface characteristics should promote proper adhesion. The
following are the required values:
PSV>60
AAV<05
AIV<18
ACV=10-25
3.3 Closure Plate: The closure plate shall be weldable structural steel conforming to IS
2062. The minimum thickness of steel plate shall be 6 mm and the width shall not be less
than 200 mm. Closure plate shall be provided with as large length as possible and welded
together to form the required length. The number of pieces shall not be more than two
per traffic lane width. It shall be provided with equidistant holes at a maximum spacing
of 300 mm centers for anchorage to the caulking/backer rod along the longitudinal center
line of the plate. The plate shall be protected against corrosion by galvanizing or any
other approved anti-corrosive coating paint with a minimum thickness of 100 micron.
3.4 Foam caulking/Backer Rod A closed cell polyolefine or open cell polyurethane foam
cylindrical caulking or backer rod having diameter equal to 150 per cent of the joint
opening shall be provided. It shall be heat resistant and possess good flexibility and
recovery characteristics with density of 25 to 30 kg/cu.m.
4. Installation
4.1 The Expansion joint shall be installed by the manufacturer/Supplier
4.2 The block out for the joint shall be marked and constructed to the dimensions as indicated
in the drawing or recommended by manufacturer/supplier
4.3 The recess for the block out shall be thoroughly cleaned of any loose or foreign material
by wire brushing and air blowing and dried with hot compressed air.

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4.4 The recess is in the deck slab, if required shall be repaired with epoxy mortar and cleaned
and dried again
4.5 The foam caulking/backing rod shall be placed about 25 mm down into the joint opening
4.6 The aggregate shall be washed, cleaned and heated to a temperature between 120-180
deg. C. prior to placement
4.7 The binder shall be preheated to temperature of 170-190 deg. C before application
4.8 While scaling the joint opening with preheated binder, care shall be taken that the binder
does not spill on to the joint surface of the deck
4.9 The joint shall not be installed when the ambient temperature goes below +5 deg. C or
above +35 deg. C or while it is raining/snowing (Planning for installation must take into
account the weather condition).
4.10 When element weather resumes, the joint installation may be continued after the upper
layer and/or exposed surface of the partially completed joint has been re-prepared by
heating and/or coating with binder as necessary.
5. Handling and storage
All the aggregates and binder shall be pre-bagged and clearly marked. All the material
shall be stored on concrete platform at 150 mm above the ground in covered enclosures
to avoid contamination.
6. Tests and Standard of Acceptance:
The material shall be tested in accordance with these specifications and shall meet
prescribed criteria. The manufacturer/supplier shall furnish the requisite certificate from
the recognized testing laboratory of India or abroad.
The work shall conform to these specifications and shall meet the prescribed standards of
acceptance.
III. COMPRESSION SEAL JOINT
1. Compression seal joint shall consist of steel armoured nosing at two edges of the joint gap
suitably anchored to the deck concrete and a preformed chloroprene elastomer or closed
cell foam joint sealer compressed and fixed into the joint gap with special adhesive
binder.
2. Material
2.1 Steel nosing: The steel nosing shall be of angle section ISA 100x100 conforming to
weldable structural steel as per IS:2062. The thickness of legs shall not be less than 12
mm. The top face of the angle shall be provided with Bleeder holes of 12 mm diameter
spaced at maximum 100 mm centers so as to ensure that there are no voids in the concrete
beneath the angle.
2.2 Anchorage: The anchorage steel shall conform to IS:2062 or equivalent.
The steel nosing shall be anchored to the deck by reinforcing bars or anchor plates cast in
concrete or a combination of anchor plates and reinforcing bars. Anchor bars shall
engage the main structural reinforcement of the deck and in case of anchor pla tes and
anchor loops, this shall be achieved by passing transverse bars through the loops or plates.
The minimum thickness of anchor plates shall be 12 mm. Total cross sectional area of
bars on each side of the joint shall not be less than 1600 sq. mm per m length of the joint

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and the center to center spacing shall not exceed 250 mm. The ultimate resistance of each
anchorage shall not be less than 600 KN/m in any direction.
2.3 Corrosion protection: All steel section shall be protected against corrosion by hot dip
galvanizing or any other approved anticorrosive coating with a minimum thickness of 100
micron.
2.4 Joint Seal:
2.4.1 The sealing element shall be preformed continuous chloroprene or closed cell foam seal
with high tear strength, insensitive to soil, gasoline and ozone. It shall have high
resistance to ageing and ensure water tightness. The seal should be vulcanized in a single
operation for the full length of the joint required for carriageway, kerbs and footpaths, if
any. The seal shall cater for a horizontal movement up to 40 mm and vertical movement
of 3 mm.
2.4.2 The physical properties of chloroprene/closed cell foam sealing element shall conform to
the following:
a) Chloroprene seal:
Shall be preformed extruded multi-web cellular section of chloroprene of such a
shape as to promote self removal of foreign material during normal service
operations. Chloroprene of joint seal shall conform to clause 915.1 of IRC:83(Part-II)
and satisfy the properties stipulated inTable 2 – strip seal element specifications of
these specifications except in respect of the working movement range of the sealing
element which shall be as specified in Cl. 2.4.1 above.
b) Closed Cell Foam Seal
Shall be of preformed non-extruded non cellular section made from low density
closed cell, cross linked ethylene vinyl acetate, polyethylene copolymer that is
physically blown using nitrogen. The material shall possess properties as indicated in
the Table:
TABLE –1
Property Special value
i) Density 41.7-51.3 kg/cu.m.
ii) Compression Set on 25 mm 50 per cent compression samples (ASTM D
3575) for 22 hours at 23 degree Celsius, 2 hour
recovery; 13 per cent set
iii) Working temperature -70 to +70 deg. C
iv) Water absorption (total 0.09766 kg/sq.m.
immersion for 3
months )(ASTM 3575)
v) Tensile strength 0.8 Mpa
vi) Elongation at break (ASTM D 195+/- 20 per cent
3575)

2.5 Lubricant cum Adhesive : The type and application of material used in bonding the
preformed joint seal to the steel nosing and concrete shall be as recommended by the
manufacturer/supplier of the seal system.

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3.0 Handling and Storage

i) The expansion joint materials shall be handled with care and stored under cover
ii) All joint material and assemblies shall be protected from damage and assemblies shall
be supported to maintain true shape and alignment during transportation and storage.
4. Installation:
4.1 The expansion joint shall be installed by the manufacturer/supplier or their authorized
representative, who will ensure compliance of installation procedure and instructions.
4.2 The dimension of the joint recess and the width of the gap shall conform to the approved
drawing
4.3 Anchoring steel shall be welded to the main reinforcement in the deck maintaining the
level and alignment of the joint
4.4 Concreting of pocket/recess shall be done with great care using proper mix conforming to
same grade as that of the deck concrete but no less than M30 grade in any case. The
water-cement ratio shall not be more than 0.40. If needed, suitable admixtures may be
used to achieve the workability. The width of pocket shall not be less than 300 mm on
either side of the joint. Care shall also be taken to ensure efficient bonding between
already cast/existing deck concrete and the concrete in the joint recess.
4.5 At the time of installation, joint shall be clean and dry and free from spalls and
irregularities which might impair a proper joint seal
4.6 Concrete or metal surfaces shall be clean, free of rust, laitance, oils, dirt, dust or other
deleterious materials.
4.7 The lubricant cum adhesive shall be applied to both faces of the joint and joint seal prior
to installation in accordance with the manufacturer’s instructions.
4.8 The joint seal shall be compressed to the specified thickness for the rated joint opening
and ambient temperature at the time of installation, which shall be between +05 to +35
degree C.
4.9 The joint seal shall be installed without damage to the seal. Loose fitting or open joints
shall not be permitted.
5. Acceptance Criteria:
5.1 All steel elements shall be furnished with corrosion protection system.
5.2 For the joint seal the acceptance test shall conform to the requirements stipulated in para
2.4 above. The manufacturer/supplier of this type of joint shall produce a test certificate
to this effect conducted in a recognized laboratory in India or abroad.
5.3 Prior to acceptance 25 per cent of the completed and installed joints, subject to a
minimum of one joint, shall be subjected to water tightness test. Water shall be
continuously ponded along the entire length for a min imum period of 4 hours for a depth
of 25 mm above the highest point of deck. The width of ponding shall be at least 50 mm
beyond the anchorage block of the joint on either side. The depth of water shall not fall
below 25 mm any time during the test. A close inspection of the underside of the joint
shall not reveal any leakage.

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6. Tests and Standards of Acceptance:

The materials shall be tested in accordance with these specifications and shall meet the
prescribed criteria. The manufacturer/supplier shall furnish the requisite certificates from
the recognized testing laboratory of India or abroad.
The work shall conform to these specifications and shall meet the prescribed standards of
acceptance.
IV. STRIP /BOX SEAL EXPANSION JOINT
1. Components
Strip Seal expansion joint shall comprise the following items:
(a) Edge Beam
This shall be either extruded or hot rolled steel section or cold rolled cellular steel
section with suitable profile to mechanically lock the sealing element in place
throughout the normal movement cycle. Further, the configuration shall be such that
the section has a minimum thickness of 10 mm all along its cross section (flange and
web). Thickness of lips holding the seal shall not be less than 6 mm. The minimum
height of the edge beam section shall be 80 mm. The minimum cross sectional area
of the edge beam shall be 1500 mm2
(b) Anchorage
Edge beams shall be anchored to the deck by reinforcing bars, or anchor plates cast in
concrete or a combination of anchor plate and reinforcing bars, Anchor bars, shall
engage the main structural reinforcement of the deck and in case of anchor plates or
loops, this shall be achieved by passing transverse bars through the loops or plates.
The minimum thickness of anchor plate shall be 12 mm. Total cross sectional area of
bar on each side of the joint shall not be less than 1600 mm. Sq. per metre length of
the joint and the center to center spacing shall not exceed 250 mm,. The ultimate
resistance of each anchorage shall not be less than 600 KN/m in any direction.
2. Material
a) The steel for edge beams shall conform to any of the steel grade corresponding to
RST 37-2 OR 37-3 (DIN), ASTM A36 or A588, CAN/CSA Standard G40.21 Grade
300 W or equivalent.
b) Anchorage steel shall conform to IS:2062 or equivalent.
c) All steel sections shall be protected against corrosion by hot dip galvanizing or any
other approved anticorrosive coating with a minimum thickness of 100 micron.
d) Chloroprene of strip seal element shall conform to Cla use 915.1 of IRC:83(Part II).
The properties of chloroprene shall be as specified in Table -2: strip seal element
specifications.
3. Fabrication (Pre -installation)
a) The strip seal joint system and all its component parts including anchorages shall be
supplied by the manufacturer/system supplier.
b) The width of the gap to cater for movement due to thermal effect, pre-stress,
shrinkage and creep, superstructure deformations (if any) and sub-structure
deformations (if any) shall be determined and intimated to the manufacturer.

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Depending upon the temperature at which the joint is to be installed, the gap
dimension shall be preset.

TABLE –2 STRIP SEAL ELEMENT SPECIFICATION

PROPERTY SPECIFIED VALUE

Hardness* 63+- 5 shore A
DIN 53505 55+ - 5 Shore A
ASTN D 2240(Modified)
Tensile Strength* Min 11 Mpa
DIN 53504 Min 13.8 Mpa
ASTM D412
Elongation at fracture* Min 350 per cent
DIN 53504 Min 250 per cent
ASTM D 412
Tear Propagation Strength Min 10N/mm
Longitudinal Min 10N/mm
Transverse Min 25 per cent
Shock Elasticity Min 220 Cu.mm
Abrasion
Residual Compressive Strain Max 28 per cent
(22 h/70 deg. C/30 per cent strain)
Ageing in hot air
(14 days/70 deg. C
Change in hardness Max +7 Shore A
Change in tensile strength Max –20 per cent
Change in elongation at fracture Max – 20 per cent
Ageing in ozone No cracks
(24 h/50 pphm/25 deg.
C/20 per cent elongation)
Swelling behaviour in Oil (168h/25 deg Max + 5 per cent
C) Max – 10 Shore A
ASTM oil NO. 1
Volume Change
Change in hardness
ASTM Oil No. 3
Volume change Max + 25 per cent
Change in hardness Max – 20 Shore A
Cold hardening Point Max – 35 deg. C

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*Only one set of specifications viz. ASTM or DIN shall be followed depending on
the source of supply
c) Each strip seal expansion joint system shall be fabricated as a single entity unless
stage construction or excessive length prohibits monolithic fabrication. It shall fit the
full width of the structure as indicated on the approved drawing. The system shall be
preset by the manufacturer prior to transportation. Presetting shall be done in
accordance with the joint opening indicated on the drawing.
d) The finally assembled joint shall then be clamped and transported to the work site.
4. Handling and Storage:
a) For transportation and storage, auxiliary brackets shall be provided to hold the joint
assembly together.
b) The manufacturer/supplier shall supply either directly to the Engineer or to the Bridge
Contractor all the materials of strip seal joints including sealants and all other
accessories for the effective installation of the joints.
c) Expansion joint material shall be handled with care. It shall be stored under cover on
suitable lumber padding.
5. Installation :
5.1 The joint shall be installed by the manufacturer/supplier or their authorized representative
who will ensure compliance to the manufacturer’s instructions for installation.
5.2 Taking the width of gap for movement of the joint into account, the dimensions of the
recess in the decking shall be established in accordance with the drawings or design data of
the manufacturer. The surfaces of the recess shall be thoroughly cleaned and all dirt and
debris removed. The exposed reinforcement shall be suitably adjusted to permit
unobstructed lowering of the joint into the recess.
5.3 The recess shall be shuttered in such a way that dimensions in the joint drawing are
maintained. The formwork shall be rigid and firm.
5.4 Immediately prior to placing the joint, the presetting shall be inspected. Should the actual
temperature of the structure be different from the temperature provided for presetting
correction of the presetting shall be done. After adjustment, the brackets shall be tightened
again.
5.5 The joint shall be lowered in a pre-determined position. Following placement of the joint
in the prepared recess, the joint shall be leveled and finally aligned and the anchorage steel
on one side of the joint welded to the exposed reinforcement bars of the structure. Upon
completion, the same procedure shall be followed for the other side of the joint. With the
expansion joint finally held at both sides, the auxiliary brackets shall be released, allowing
the joint to take up the movement of the structure.
5.6 High quality concrete shall then be filled into the recess. The packing concrete must
feature low shrinkage and have the same strength as that of the superstructure, but in any
case not less than M 35 grade. Good compaction and careful curing of concrete is
particularly important. After the concrete has cured, the movable installation brackets and
shuttering still in place shall be removed.
5.7 The neoprene seal shall be field installed in continuous lengthy spanning the entire
roadway width. To ensure proper fit of the seal and enhance the ease of installation, dirt,
spatter or standing water shall be removed from the steel cavity using a brush, scrapper or
compressed air. The seal shall be installed without any damage to the seal by suitable hand
method or machine tools.

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5.8 As soon as the concrete in the recess has become initially set, a sturdy ramp shall be placed
over the joint to protect the exposed steel beams and neoprene seals from the site traffic.
Expansion joint shall not be exposed to traffic before the carriageway surfacing is placed.
5.9 The carriageway surfacing shall be finished flush with the top of the steel sections. The
actual junction of the surfacing/wearing coat with the steel edge section shall be formed by
a wedge shaped joint with a sealing compound. The horizontal leg of the edge beam shall
be cleaned beforehand. It is particularly important to ensure thorough and careful
compaction of the surfacing in order to prevent any premature depression forming in it.
6. Acceptance Criteria:
i) All steel elements shall be finished with corrosio n protection system.
ii) For neoprene seal, the acceptance test shall conform to the requirements in Table -I.
The manufacturer/supplier shall produce a test certificate accordingly, conducted in
a recognized independent laboratory, in India or abroad.
iii) The manufacturer shall produce test certificates indicating that anchorage system
had been tested in a recognized laboratory to determine optimum configuration of
anchorage assembly under dynamic loading.
iv) Prior to acceptance 25 per cent of the completed and installed joints, subject to a
minimum of one joint, shall be subjected to water tightness test. Water shall be
continuously ponded along the entire length for a minimum period of 4 hours for a
depth of 25 mm above the highest point of deck. The width of ponding shall be at
least 50 mm beyond the anchorage block of the joint on either side. The depth of
water shall not fall below 25 mm anytime during the test. A close inspection of the
underside of the joint shall not reveal any leakage.
v) Investigation of fatigue strength of the edge beam section with anchorages to
withstand
2 x 106 load change cycles of 85 KN vertical load and 10 KN of horizontal load
without showing sign of distress shall be required. The supplier shall produce a test
certificate in this regard conducted in a recognized laboratory, in India or abroad.
vi) As strip seal type of joint is specialized in nature, generally of the proprietary type,
the manufacturer shall be required to produce evidence of satisfactory performance
of this type of joint.
7. Tests Standards of Acceptance:
The materials shall be tested in accordance with these specifications and shall meet the
prescribed criteria. The manufacturer/supplier shall furnish the requisite certificates from
the recognized testing laboratory of India or abroad.

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V. MODULAR STRIP/BOX SEAL JOINT

1. A modular expansion joint shall consist of two or more modules/cells to cater to a

horizontal movement in excess of 70 mm. It shall allow movements in all 3 directions
and rotation about all axes as per the design requirements. It shall ensure that during all
movements cycles of the joint, opening and closing (gaps) of all modules are equal.
2. Component :
2.1 The structural system consisting of two edge beams, one or more central/separation
beams or lamellas and cross support bars supporting individuals or multiple central beams
to transfer the loads to the bridge deck through the anchorage system.
2.2 Resilient or shock absorption support system for central beams as well as support bars to
dampen dynamic loading thus reducing the forces transmitted to the substructure and
anchorages as also to accommodate vertical and transverse movements apart from
longitudinal movement.
2.3 Sliding or control system which allows closing and opening of the joint and also ensures
that all modules open are close equally.
2.4 Mechanically locked sealing system of chloroprene which provides water tight, noiseless
and easy replacement system.
3. Materials:
3.1 Edge and central beams : These shall be either extruded or hot rolled steel sections or
cold rolled cellular steel sections including continuously shop welded sections for central
beams with suitable profile to mechanically lock the sealing element in place throughout
the normal movement cycle. Further, the configuration shall be such that the section has
a minimum thickness of 10 mm all along the cross section (Flange and Web). The
thickness of lips holding the seal shall not be less than 6 mm. The cold rolled cellular
sections shall be relieved of any locked in stressed through annealing process. These
shall be closed at both ends and be air tight after installation of seal to prevent ingress of
moisture in the hollow portion. The minimum height of edge beams and central beam
sections shall be 80 mm. Minimum cross sectional area of edge beam shall be 1500 sq.
mm. The material shall conform to any of the steel grade corresponding to RST 37-2 or
37-3 (DIN), ASTM A 558, CAN/CSA standard G-40.,21 Grade 300 W or equivalent.
The material for support bars may be same as that of edge/central beams or as per
manufacturer’s recommendations.
3.2 Chloroprene Seal: This shall be preformed extruded single strip or cellular section of
chloroprene of such a shape as to promote self removal of foreign material during normal
joint operation. The seal shall possess high tear strength and be insensitive to oil,
gasoline and ozone. It shall have high resistance to ageing and ensure water tightness.
Chloroprene seal shall conform to clause 915.1 of IRC :83(part – II). The properties of
chloroprene shall conform to table –2- strip seal element specification of these
specifications.
3.3 Anchorage: The anchorage steel shall conform to IS:2062 or equivalent.
3.3.1 Edge beams shall be anchored to the deck by anchor plates cast in concrete or a
combination of anchor plate and reinforcing bars. Anchor plates or loops shall be
anchored by passing transverse bars through the loops or plates.
3.3.2 The minimum thickness of anchor plate shall be 12 mm. Anchor bars on each side of the
joint shall not be less than 1600 mm sq. per metre length of the joint and the center anchor

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bars to center spacing shall not exceed 250 mm. The ultimate resistance of each
anchorage shall not be less than 600 KN/m in any direction. The anchor loop at the edge
profiles should be at a right angle to the joint. Planned deviations of this direction are
allowable only for the range of 90o +/- 20o (The anchoring reinforcement of the
construction must lie parallel to the anchor loops).
3.4 Support and Control System : The overall system and components of the resilient/shock
absorption system and sliding/control system shall conform to the specifications
recommended by the manufacturer. The center to center spacing of traverse support bar
shall not exceed 1.75 m.
3.5 Corrosion Protection : All steel sections shall be protected against corrosion by hot dip
galvanizing or any other approved anticorrosive coating with a minimum thickness of
100 micron.
4. Fabrication (pre -installation):
4.1 The modular expansion joint system and all its component parts including anchorages
shall be supplied by the Manufacturer.
4.2 The width of the gap to cater for movement due to thermal effect, prestress, shrinkage and
creep,. Superstructure deformations (if any) and sub-structure deformations (if any) shall
be determined and intimated to the manufacturer. Depending upon the range of
temperature at which the joint is likely to be installed, the gap dimension shall be present.
4.3 Each modular expansion joint system shall be fabricated as a single entity free from any
joint in the longitudinal direction unless stage construction or excessive length prohibits
monolithic system shall be preset by the manufacturer prior to transportation. Pre-setting
shall be done in accordance with the joint opening indicated on the drawing.
4.4 The finally assembled joint shall then be clamped and transported to the work site.
5. Handing and Storage:
5.1 For transportation and storage, auxiliary brackets shall be provided to hold the joint
assembly together
5.2 The manufacturer/supplier shall supply either directly to the Engineer or to the Bridge
Contractor entire assembly of Modular Strip/Box Seal joints including sealants and all
other accessories for the effective installation of the joints.
5.3 Expansion joint material shall be handled with care. It shall be stored under cover on
suitable lumber padding.
6. Installation:
6.1 The joint shall be installed by the manufacturer/supplier only.
6.2 Taking the width of gap for movement of the joint into account, the dimensions of the
recess in the decking shall be established in accordance with the drawings or design data
of the manufacturer. The surface of the recess shall be thoroughly cleaned and all dirt and
debris removed. The exposed reinforcement shall be suitably adjusted to permit
unobstructed lowering of the joint into the recess.
6.3 The recess shall be shuttered in such a way that dimensions in the drawing are
maintained. The formwork shall be rigid and firm.
6.4 Immediately prior to pla cing the joint, the presetting shall be inspected. Should the actual
temperature of the structure be different from the temperature provided for presetting,
correction of the presetting shall be done. After adjustment, the brackets shall be
tightened again.

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6.5 The joint shall be lowered in a pre-determined position. Following placement of the joint
in the prepared recess, the joint shall be leveled and finally aligned and the anchorage
steel on one side of the joint welded to the exposed reinforcement bars of the structure.
Upon completion, the same procedure shall be followed for the other side of the joint.
With the expansion joint finally held at both sides, the auxiliary brackets shall be
released, allowing the joint to wake up the movement of the structure.
6.6 Controlled concrete having strength not less than that in superstructure subject to the
minimum of M35 shall be filled into the recess. The packing concrete must feature low
shrinkage. Good compaction and careful curing of concrete is particularly important.
After the concrete has cured, the movable installation brackets and shuttering still in place
shall be removed.
6.7 The chloroprene seal shall be field installed in continuous lengths spanning the entire
roadway – width. To ensure proper fit of the seal and increase the ease of installation,
dirt, spatter or standing water shall be removed from the steel cavity using a brush,
scrapper or compressed air. The seal shall be installed without damage to the seal by
suitable hand method or machine tools.
6.8 As soon as the concrete in the recess has become initially set, a sturdy ramp shall be
placed over the joint to protect the exposed steel beams and neoprene seals from site
traffic. Expansion joint shall not be exposed to traffic loadin g before the carriage way
surfacing is placed.
6.9 The carriage way surfacing shall be finished flush with the top of the steel sections. The
actual junction of the surfacing /wearing coat with the steel edge section shall be cleaned
beforehand. It is particularly important to ensure thorough and careful compaction of the
surfacing in order to prevent any premature depression forming in it.
7. Acceptance criteria:
7.1 All steel elements shall be finished with corrosion protection system.
7.2 For chloroprene seal, the acceptance test shall conform to the requirements stipulated in
para 2(d) under strip/box seal expansion joints
7.3 The manufacturer/supplier shall produce a test certificate accordingly, conducted in a
recognized laboratory, in India or abroad.
7.4 Fatigue strength of internal beams and support connections shall be investigated to
withstand 2 million cycles of vertical load of 85 KN and a horizontal load of 10KN
without showing signs of distress. The supplier shall have to produce a test certificate in
this regard conducted by a recognized laboratory from India or abroad.
7.5 The manufacturer/supplier shall produce test certificates indicating that anchorage system
had been tested in a recognized laboratory to determine optimum configuration of
anchorage assembly under dynamic loading.
7.6 Prior to acceptance 25 per cent of the completed and installed joints, subject to a
minimum of one joint, shall be subjected to water tightness test. Water shall be
continuously ponded along the entire length for a minimum period of 4 hours for a depth
of 25 mm above the highest point of deck. The width of ponding shall be at least 50 mm
beyond the anchorage block of the joint on either side. The depth of water shall not fall
below 25 mm any time during the test. A close inspection of the underside of the joint
shall not reveal any leakage.
7.7 As modular strip/box seal type of joint is specialized in nature, generally of the
proprietary type, the manufacturer shall be required to produce evidence of satisfactory
performance of his product.

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8. Tests and Standards of Acceptance:

The materials shall be tested in accordance with these specifications and shall meet the
prescribed criteria. The manufacturer/supplier shall furnish the requisite certificates from
the recognized testing laboratory in India or abroad. The work shall conform to these
specifications and shall meet the prescribed of acceptance.
VI. CRITERIA FOR PERMITTING FOR LOCAL MANUFACTURING OF
EXPANSION JOINTS BY INDIAN FIRMS/JOINT VENTURES

1. Manufacturing of expansion joint system by Indian firms/joint venture shall be allowed

under appropriate license of and with technical collaboration of the foreign principal
manufacturer of repute under the following conditions:-
i) The materials and the finished products for unitary/modular strip seal expansion
joints shall be of the similar specification and quality as of those used for the
expansion joints being manufactured by the principal company abroad.
ii) The foreign principal shall have direct participation in the quality assurance system
both in regard to manufacture and testing of the joints in India through their engineers
who shall make periodic visits to India for imparting training and expertise in the
manufacture and testing as well as to supervise the quality control and testing
procedure of the joints to be manufactured by the Indian firm to ensure full
technology transfer to the Indian firms. The manufacturing process, facilities
available for manufacture and testing of the joints with the Indian firm and the testing
procedure are required to be certified by the foreign principal before the joints are
manufactured on regular basis in India.
iii) The foreign principal manufacturer along with the Indian firm shall furnish a joint
guarantee against the defective materials used in manufacture, workmanship as well
as a guarantee for quality assurance at various stages of manufacture of the strip
seal/modular seal expansion joints in India. This guarantee shall remain valid for a
period of 10 years from the date of supply of the joints to the client except for the
defects arising out of the force majeure situations.
iv) The firm shall arrange for all testing of the joints to be carried out in India at their
establishment or at an independent laboratory. Tests such as dynamic testing which
cannot be performed for want of facilities in India at present shall be got done
through the foreign principal who shall furnish the necessary certificate for
acceptance.
v) There should be clear stipulation in the technical collaboration agreement that the
foreign manufacture will have “buy back” arrangement of the Indian product
manufactured in India under their license for marketing in other countries. This will
ensure that the foreign collaborator accepts the Indian product as equivalent to their
original product in use abroad.
vi) An original sample of the foreign manufacturer’s joints shall be kept at the Indian
manufacturer’s works factory for comparing the quality, dimensions, finish etc. of the
Indian products while inspecting these products by the Client against specific orders
for supply.
2. The firm seeking permission to manufacture the joints in India shall submit the relevant
supporting documents to ensure compliance to the stipulations contained in paras (i) to
(vi) above and to prove that the joints shall be manufactured by them as per the Revised
Interim Specifications.

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Annex-I
SUITABILITY CRITERIA FOR ADOPTION OF DIFFERENT
TYPES OF EXPANSION JOINTS

Sl. Type of Suitability for adoption of Expected Special consideration

No. Expansion joint Service life
joints
1. Buried joint Simply supported spans up to 10 years Only for decks with
10 m bituminous/asphaltic
wearing coat. Steel
plate may need
replacement if found
corroded or distorted at
the time of
relaying/renewal of
wearing coat.
2. Filler joint Fixed end of simply supported 10 years The sealant and joint
spans with insignificant filter would need
movement of simply supported replacement if found
spans not exceeding 10 m. damaged.
3. Asphaltic Plug Simply supported spans for 10 years Only for decks with
Joint right or skew (up to 20 degree) bituminous/asphaltic
moderately curved or wide wearing coat. Not
deck with maximum horizontal suitable for bridge with
movement not exceeding 25 longitudinal gradient
mm. Ambient temperature more than 2% and cross
should be in the range of 5 camber/super-elevation
degree to 50 degree Celsius exceeding 3%. Not
suitable for curved spans
and spans resting on
yielding supports.
4. Compression Simply supported continuous 10 years Chloroprene/Closed
Seal Joint* spans right or skew (up to 30 Foam seal may need
(Chloroprene degree ), moderately curved replacement during
/Seal and with maximum horizontal service.
Closed Cell movement not exceeding 40
Foam Seal) mm)
5. Elastomeric Simply supported or 10 years Liable to excessive wear
Slab Seal continuous spans. Right or and tear under high
Joint* skew (less than 20 degree), traffic intensity. Not
moderately curved with suitable for bridges
maximum horizontal located in heavy rainfall
movement up to 50 mm area and spans resting
on yielding support.
6. Single Strip Moderate to large simply 25 years Elastomeric seal may
Seal Joint* supported cantilever need replacement during
/continuous construction service.
having right skew or curved
deck with maximum horizontal
movement up to 70 mm.

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Sl. Type of Suitability for adoption of Expected Special consideration

No. Expansion joint Service life
joints
7. Modular Large to very large continuous 25 years Elastomeric seals may
Strip/box seal /cantilever construction with need replacement during
Joint* right deck having maximum service.
horizontal movement in excess
of 70 mm.
8. Special For bridges having wide deck 25 years Elastomeric seal may
joints*for and large span length involving need replacement during
special complex movements/rotations service. Provision of
conditions in different directions/planes, these joints may be
provision of special type of made with prior
modular expansion joints such approval of the Ministry.
as Swivel Joists joints may be
made.

*These are proprietary items for which 10 years warranty shall be insisted upon.

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APPENDIX III

VOID FORMER
Void former tubes shall consist of galvanised corrugated light sheet metal tube subject to approval
of Engineer having minimum thickness of 0.5 mm with end cones and tie down clips. The
diameter and the sheet metal thickness of the void formers shall satisfy the following:

Internal Dia. (d) External Dia (d) Sheet Metal Material Weight
(mm) (mm) Thickness-(t) (mm) (m³/m) (kg/m)

500 504 0.5 0.198 8.5

600 605 0.5 0.285 10.2

Corrugations
The void formers shall be spirally lock seamed and corrugated on patented special machines with
three 6-8 mm tube corrugations between the seams. The spacing between seams shall not exceed
120 mm. The radial rigidity of the tube shall be as below:

(t) I
(mm) (cm4 /m)
0,5 0,20

End Cones
Void formers are to be supplied with end cones mounted in place on the tubes to seal the void
formers. The dimensions and installation lengths of the end cones shall be as under:

Internal dia. of void Internal dia. of end cone Length of end cone
former (mm) (mm) (mm)

500 250 500

600 300 600

Tie Down Clips

In order to minimise horizontal and vertical movement of the void formers during concreting
operations the void formers shall be fitted with tie down clips with necessary accessories.
Storage and Installation of Void Formers
The storage and installation of void formers shall be carried out as per manufacturer’s literature
on the subject and subject to approval of Engineer-in-charge.
Standard of Acceptance

The roundness of the void tubes before pouring of concrete shall meet tolerances permitted as per
concreting specifications. The stiffness of the tubes must be sufficient enough to resist a change of
roundness not more than 2cm. on account of the pressure from concrete.

The tie down clips shall be fixed in such a way that movement does not exceed ± 1 cm vertically
and ± 2 cm. horizontally. In case of joints, these shall be strong enough to stop the pipes from
moving in relation to each other.

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Rate

The unit rate of Plain Concrete or Reinforced Concrete or Prestressed Concrete as defined in
respective section shall be deemed to cover the cost of void former.

Where the contract unit rate for void former is specially provided as separate item it shall include
the cost of supply of void formers, end cones, tie down clips and other accessories, their storage
and installation at site including all operations as per instructions of manufacturer. Measurement
of the void former shall be made in running meters from one end of the end cone of the void
former to the other end of the end cone of the void former.

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