Kishor Kumar

    Methodology for Box Culverts

    Structure / /

    Methodology for Box Culverts 1. Reference Drawings of Box Culverts Reviewed drawings shall be referred to for casting of box culverts. 2. Working Drawings Working drawings, structural drawings, and relevant details shall be submitted to the AE prior to commencement of work for approval. After approval, setting out of the structure shall be carried out at site. 3. Scope of Work The work shall consist of widening of existing box culverts or reconstruction/construction of new box culverts as per reviewed drawings. The work includes: Excavation Foundation Preparation PCC & Raft Construction Wall Construction Deck Slab Construction Return Wall & Curtain Wall Construction Apron & Protection Works 4. Reference Contract Agreement IRC: SP: 84-2014 MoRTH Specifications (5th Revision) Relevant Approved Drawings 5. Plant & Machinery Mixer Machine with Weigh Batcher / Batching Plant Transit Mixer Concrete Vibrator & Hand Rammer Trailer / Open Body Truck Water Tanker Water Pump Shuttering Plates & Staging Materials Backhoe Loader / Excavator 6. Materials Cement, mineral admixtures, chemical admixtures, fine aggregates, coarse aggregates, and water shall conform to Clause 1700 of MoRTH Specifications. Reinforcement steel shall be HYSD Fe-500 grade bars conforming to IS:1786 or as shown in approved drawings. Concrete grade shall be as specified in reviewed drawings. Concrete shall be produced, transported, and placed as per approved mix design. 7. Method of Construction Excavation shall be carried out manually or mechanically depending upon site conditions. Care shall be taken to avoid over-excavation. The PCC bed level shall be maintained accurately. If required, the foundation surface shall be sprinkled with water before laying PCC. Layout marking shall be carried out for raft and walls. PCC of grade M15 or as shown in approved drawings shall be laid over prepared foundation. Concrete grades for raft, walls, deck slab, return wall, and curtain wall shall be as per reviewed drawings. Reinforcement steel shall be fixed and tied as per approved BBS and drawings. Formwork for raft including haunch and kick-starter shall be erected properly. Concreting shall be carried out as per Clause 1700 of MoRTH Specifications. Post-concreting inspection shall be carried out after de-shuttering and any defects shall be rectified immediately. Proper curing arrangements shall be ensured after concreting. The same sequence shall be followed for walls, return walls, and curtain walls. Weep holes shall be provided as per approved drawings. Scaffolding and soffit formwork for top slab shall be erected properly. Deck slab reinforcement shall be tied as per approved BBS and drawings. Concreting of top slab shall be carried out after inspection approval. Boulder pitching and apron protection works shall be executed on upstream (U/S) and downstream (D/S) sides. If total wall height is less than 3 m, slab shall be cast monolithically along with walls after casting starter and haunch. Side shutters of wall and deck slab may be removed after 12 hours of concreting or as approved by the Engineer. Proper curing of deck slab and wall surfaces shall be carried out by ponding and wet hessian cloth covering. Soffit staging shall be removed after achieving required strength and as per span criteria. Floor protection works on U/S and D/S sides shall be carried out as per GFC drawings. Traffic diversion arrangements shall be made before commencement of work to ensure safe and smooth vehicular movement. 8. Quality Control Sampling and testing frequency shall be carried out as per MoRTH Clause 1700 and IS:4926-2003 requirements. Concrete Cube Testing Slump Test Reinforcement Inspection Formwork Inspection Line, Level & Alignment Check Cover Measurement 9. Safety All construction vehicles and equipment such as transit mixers, JCBs, and excavators shall have functional reverse horns and safety systems. Excavated areas shall be properly barricaded using safety tapes, caution boards, and barricading arrangements. Workers shall use PPE such as helmets, safety shoes, reflective jackets, gloves, and safety belts. Proper illumination and warning signs shall be provided during night work. Traffic management and diversion arrangements shall be maintained throughout the construction period.

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    Structure

    Methodology for Pre-stressing of HTS Strands

    Structure / /

    Methodology for Pre-stressing of HTS Strands This item of work deals with the activity of Pre-stressing of H.T.S strands of PSC girders with approved materials as per the specifications of the Contract Agreement. General This item of work shall be carried out in compliance with Clause 1800 of MoRTH Specifications. The materials shall conform to Section 1000 and the grout mix shall conform to Section 1808 of MoRTH Specifications. Procedure 1. Cable Fabrication & Laying The length of cable required shall be computed from the drawing including allowances for profiling and gripping length of jack. The strand shall be cut evenly using an abrasive cutter to the required length. Both ends of the cable shall be numbered to maintain correct configuration in the bearing plate and prevent twisting in the duct. The duct shall be profiled as per approved ordinates and cable shall be threaded manually into the duct. Grout vents shall be provided wherever required. Tube ducts of the anchorage shall be fixed with end blocks as shown in drawings. The ducts shall be connected to tube units. The cable consisting of the specified number of strands shall be tied with binding wire at regular intervals and threaded into sheathing. Both ends of the duct shall be closed after strand installation and protruding strands shall be wrapped properly to avoid dirt entry during concreting. 2. Concreting During concreting, cables shall be moved manually at suitable intervals to avoid concrete blockage inside ducts. The strands beyond the bearing plate shall be cleaned using petrol after concreting to remove dust and rust. 3. Stressing Operation Stressing of cables may be carried out from both ends. Bearing plates shall be cleaned and fixed in proper configuration. Wedges shall be fixed to bearing plates and tightened. Jacks shall be mounted properly and aligned with the cable. Master grips of the jack shall be inserted over strands and fixed into pulling plates. Stressing pumps shall be connected to jacks through hose pipes. Correction factor shall be calculated from pressure and elongation readings. Initial pressure of 50 kg/cm² shall be applied to remove cable slackness. Pressure shall then be increased gradually and elongation readings recorded. Tensioning force shall be verified by pressure gauge readings and elongation comparison. Acceptance Criteria During Stressing If calculated elongation is achieved before specified pressure, stressing shall continue till specified pressure is reached provided elongation does not exceed 1.05 times calculated elongation. If specified pressure is reached before calculated elongation, stressing may continue in intervals of 5 kg/cm² provided pressure does not exceed 1.05 times specified pressure. If elongation remains less than 0.95 times calculated elongation at 1.05 times specified pressure: Check functioning of jack, pump and hose pipes. Detension the cable and check for duct blockage. On achieving full load, wedges shall be locked hydraulically. Jack shall be released and retracted. The same procedure shall be repeated for all cables. 4. Grouting All protruding ends of strands shall be cut after prestressing. Nozzles and valves shall be fitted to grout holes. Ducts shall be flushed with lime water before grouting. Grout shall be prepared using Ordinary Portland Cement and non-shrink grout admixture. Grouting shall commence with low pressure until grout flows out from the other end. The outlet shall be closed once grout consistency becomes uniform. After achieving desired pressure, inlet valve shall be closed. Equipment / Machinery Hydraulic Jack Pressure Gauge Compressor Grouting Equipment Grout Cube Moulds Tolerances Parameter Permissible Tolerance Variation from specified horizontal profile ±5 mm Variation from specified vertical profile ±5 mm Variation from specified position in member ±5 mm “`

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    Structure

    Methodology for Structural Concrete for Bridges and Culverts

    Structure / /

    Methodology for Structural Concrete for Bridges and Culverts 1. Scope The work shall consist of producing and placing concrete of grade M15 and higher by weigh batching in accordance with MoRTH Specifications, IRC:112, approved drawings, and contract specifications. 2. Reference Contract Agreement IRC: SP: 84-2014 MoRTH Specifications (5th Revision) IRC: 112 Relevant Drawings 3. Setting Out After completion of site preparation, alignment of the structure shall be marked on the ground using lime and string. Structural points such as abutment walls and wing walls shall be pegged accurately. Temporary Bench Marks (TBM) shall be established nearby for level reference and protected throughout construction activities. 4. Materials 4.1 Cement Cement conforming to IS:269 shall be used after ensuring the required design strength. Manufacturer Test Certificates (MTC) shall be submitted to the AE for every consignment. Independent testing shall also be conducted at approved laboratories. 4.2 Coarse Aggregate Coarse aggregates shall be obtained from approved quarries and shall consist of clean, hard, durable crushed stone conforming to Table 1700-7 of MoRTH Specifications / IS 383. 4.3 Fine Aggregate Fine aggregates shall be clean, durable, and free from deleterious materials. Gradation shall conform to Table 1000-2 of MoRTH Specifications / IS 383. 4.4 Water Water used for mixing and curing shall conform to IS 456 and Section 1010 of MoRTH Specifications. Water shall be free from harmful substances. Use of seawater shall not be permitted. 4.5 Reinforcement Steel Reinforcement steel shall conform to Section 1009.3 of MoRTH Specifications and IS 1786. TMT Fe-500 grade bars shall be used as per approved drawings. 4.6 Bending of Reinforcement Bar Bending Schedule (BBS) shall be prepared and submitted for approval before commencement of work. It shall include shape, number, cutting length, and weight of bars including auxiliary reinforcement. All materials shall be approved by the AE before use in construction. 5. Placing of Reinforcement Reinforcement shall be placed as per approved drawings and inspected by the AE before concreting. Bars shall be tied using 1 mm binding wire. Cover blocks of the same concrete grade shall be used. Spacer bars and chairs shall be provided to maintain spacing and cover. Horizontal reinforcement shall be adequately supported to avoid sagging. 6. Proportioning of Concrete Concrete shall be produced using approved design mix by weigh batching. Measuring equipment shall be maintained in proper condition and calibrated periodically. Water-cement ratio shall be maintained considering moisture content of aggregates and weather conditions. 7. Trial Mixes Trial mixes for all grades of concrete shall be carried out at the site laboratory before commencement of work using approved materials. Additional trial mixes shall be conducted whenever there is a change in source or proportion of materials. 8. Equipment Batching Plant Transit Mixer Concrete Pump Vibrators & Vibrator Needles Wheel Loader Excavator Shuttering Material Bar Bending & Cutting Machine 9. Transporting, Placing & Compaction of Concrete Concrete shall be transported using transit mixers or concrete pumps. The delivery pipeline shall have minimum bends. Concrete temperature during placing shall be between 5°C and 40°C. Concrete shall be compacted within 30 minutes of discharge. Concrete shall be placed in layers not exceeding 300 mm compacted thickness. Fresh concrete shall not be placed against concrete older than 30 minutes without proper construction joints. Concreting shall not be carried out when ambient temperature exceeds 40°C. 10. Formwork Formwork shall conform to Section 1500 of MoRTH Specifications and IRC:87. Only steel formwork shall be used. Formwork shall be rigid and true to shape. Damaged formwork shall not be used without repair. Steel tubes used as supports shall have minimum 4 mm wall thickness. 11. Construction Joints Construction joints shall be kept to a minimum and provided as per drawings. Laitance shall be removed and the concrete surface roughened before placing fresh concrete. 12. Curing Water curing shall be carried out using approved water conforming to MoRTH Specifications. Concrete surfaces shall be kept continuously wet. Wet hessian cloth, sacks, or canvas may be used. Curing shall continue for at least 14 days after concreting. 13. Finishing Finishing shall be carried out as per Clause 1713 of Section 1700 of MoRTH Specifications to achieve smooth and durable concrete surfaces.

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    Structure

    METHOD STATEMENT FOR ROADWAY EXCAVATION

    Earthwork / /

    Scope of Work – Excavation Scope  This work shall consist of excavation by mechanical means in all types of soil in final line, level, grades, cross section as shown in drawings for roadways drains, shoulders, median and foundation for structures, including hauling suitable excavation materials to site for embankment and sub grade construction also disposal of unsuitable cut materials specified manner. Reference  MoRT&H Specification clause No 301 to 303 and technical specification of contract Equipment  Excavators, Dumpers, dewatering arrangements Tools  Line rope, lime powder, pegs etc. Manpower & Responsibilities  Construction manager, Earth work engineer/supervisor, land surveyor, material engineer, safety supervisor, helpers Construction Manager He shall be overall responsible for the activity including planning, organising the resources required to carry out the work in consultation with the project manager, implement and ensure safety requirements during the work including that of utility services. Ensures relevant test conducted and records are maintained as per the contract requirements. Coordinate with the consultant engineer in obtaining necessary approvals for the completed activity. Earthwork Engineer / Supervisor Deploying necessary resources at site as planned. Execute the work as per drawing and maintain quality requirements as per specification. Implement and maintain safety regulations and good housekeeping. Coordinate with the consultant staff in obtaining necessary approvals for the completed activity. Land Surveyor Establishing necessary reference points to carry out the work as per the level and alignment. Checking and recording the levels as completed. Coordinate with the consultant staff in obtaining approvals for the finished work. Material Engineer Implement quality procedures as per plan. Ensure the materials used are meeting the specification requirement conduct the required tests as per the relevant specification and maintain all records. Safety Supervisor Ensure that activity is being carried out safely as prescribed in the project safety plan. Procedure General  The excavation shall be set out true to lines curves, grades and sections in works involving removal of existing carriage way, earthen shoulder, median, shall be excavated to the full width and to the required levels, after satisfying CBR and density requirements, as shown in drawings. After reaching to the required depth, it shall be compacted at OMC to achieve min. of 95% for embankment and 97% of MDD for sub grade.  Excavated soil shall be tested for its suitability for reuse or disposal.  The cut formation, which serves as sub grade, if found suitable, shall be loosened, graded, watered and compacted in layers in the specified manner. Any unsuitable material encountered at the sub grade level shall be removed and replaced with suitable material.  While executing excavation all adequate precautions shall be taken to prevent soil erosion and appropriate drainage measures shall be adopted to keep the site free of water stagnation.  The suitable material obtained from excavation shall be used for filling of roadway embankment, sub grade filling of existing pits in the ROW, landscaping etc. All other unsuitable materials shall be disposed of. Surplus suitable material if any shall be stacked at approved locations. Site Clearance  Controlled blasting shall be carried out in fixed hours as ordered by the Engineer and kept known to the public and authorities in the vicinity sufficiently in advance.  Red flags shall be displayed in all directions during blasting operations. People except those who actually light the fuse shall be prohibited from the area and all persons including workmen shall be evacuated from the flagged area at least 10 minutes before firing. A warning alarm or siren shall be sounded for this purpose. The man in-charge shall satisfy himself that all charges are exploded before allowing any workman or people to enter. Firing  The firing of charge holes shall be done by electric detonators by using a sufficiently long fuse wire (at least 10 m) and all charge holes shall be blasted at one instance. Explosive  The explosives for blasting shall be as per permitted explosives as per procedure and requirement. The weight of charge depends upon the quantity of rock to be blasted/excavated, hardness of rock and site condition. Stemming  Stemming may be used if required, of free dry-running material, which passes through 2.8 mm sieve and retained on 1.2 mm sieve by 90%. Muffling  This shall be done to control the fly rock. Since the drill holes are loaded with less charge, sand/earth bags weighing at least 50 kg shall be kept on each charge hole to control fly rock. Safety Measures  All safety measures shall be as per approved EHS Plan.

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    Earthwork

    METHOD STATEMENT FOR OPEN FOUNDATION

    Concrete Work / /

    METHOD STATEMENT FOR OPEN FOUNDATION Description The work shall cover furnishing and providing plain or reinforced concrete foundation placed in open excavation, in accordance with the approved drawings and these specifications. Materials Materials shall conform to Section 1000 of these specifications. All materials shall be of approved quality, tested, and conforming to relevant IS and MoRTH requirements before use at site. Preparation of Foundations Excavation for laying the foundation shall be carried out in accordance with MoRTH Clause 300. Open foundations shall be constructed only in dry conditions, and adequate dewatering arrangements shall be provided and maintained throughout the execution of work to ensure a stable and workable foundation bed. Setting Out The plan dimensions of the foundation shall be set out at the bottom of the foundation trench and checked with respect to the original reference line and axis. It shall be ensured that at no point the bearing surface is higher than the founding level shown on the drawing. Safe Bearing Capacity (SBC) of Soil As per the drawing requirements, the Safe Bearing Capacity (SBC) of the foundation soil shall be ensured before commencement of the work by the in-house QC laboratory. All results shall be verified and approved prior to execution. Construction Where the bearing surface is earth, a layer of M15 concrete shall be provided below the foundation concrete. The minimum thickness of the lean concrete layer shall be 150 mm unless otherwise specified. No formwork is required for the lean concrete layer. For foundation concrete work, side formwork shall be used. Formwork for the top of foundation concrete shall also be provided if the top has slopes steeper than 1 (vertical) to 3 (horizontal). When concrete is laid on a slope without top formwork, the slump shall be carefully controlled to ensure proper compaction without slippage of freshly placed concrete. In certain cases, it may be necessary to construct the top formwork progressively as concreting proceeds up the slope. Reinforcement shall be placed strictly as shown in the approved drawings. Before laying the lean concrete layer, the earth surface shall be thoroughly cleaned of all loose material and properly wetted. Care shall be taken to avoid muddy conditions. If any portion of the surface is found spoiled due to over-wetting, the same shall be removed and re-prepared before concreting. Inspection Plan and Testing S.No Activity Inspection Required Tests Required Remarks 1 Approval of Previous Element of Structure Yes Yes Jointly recorded 2 Layout & Survey Yes — Joint survey and record 3 Formwork & Reinforcement Check Yes Yes Jointly recorded 4 Concreting Yes — Method control 5 Strength Check Yes Yes QC check jointly Safety Measures ✔ All safety measures shall be strictly implemented as per the approved EHS (Environment, Health & Safety) Plan.

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    Concrete Work

    Method Statement for Earthwork | Embankment and Subgrade Construction (MoRTH)

    Earthwork / /

    Method Statement for Earthwork (Embankment and Subgrade) Scope This work shall consist of embankment construction with approved material from roadway excavation or borrow pits. Reference IRC:SP:84-2014 MoRTH Specifications, Clause No. 305 IRC:36 Technical Specifications of Contract Equipment Excavator / Backhoe Dozer Motor Grader Dumpers Vibratory Roller Water Tanker Auto Level Measuring Tape Tools Hammer Crow Bar Spade Strings Pegs Lime Powder Manpower & Responsibilities Construction Manager Engineer / Supervisor Land Surveyor Material Engineer Safety Supervisor Helpers Construction Manager He shall be overall responsible for the activity including planning and organizing resources in consultation with the Project Manager. He shall ensure safety requirements, conduct relevant tests, maintain records, and coordinate with the consultant for approvals. Engineer / Supervisor Responsible for deploying resources, executing work as per drawings, maintaining quality as per specifications, and ensuring safety compliance. Also responsible for obtaining necessary approvals. Land Surveyor Responsible for establishing reference points, checking levels and alignment, recording completed work, and coordinating with the consultant for approvals. Material Engineer Responsible for implementing quality procedures, ensuring materials meet specifications, conducting tests, and maintaining records. Safety Supervisor Ensure that all activities are carried out safely as per the project safety plan. Materials Materials shall be free from logs, stumps, roots, rubbish, or any deleterious matter affecting stability. The material shall have: Liquid Limit (LL) less than 55% Plasticity Index (PI) less than 25% Free Swell Index less than 50% Minimum MDD of 15.2 kN/m³ as per IS:2720 Part-8 Samples from borrow areas shall be tested in the laboratory to verify these requirements. Procedures Before commencing earthwork, toe limits of embankment shall be marked. Original ground shall be leveled, scarified, watered, and compacted to achieve 95% of MDD. Material shall be excavated from borrow areas and transported by dumpers. Material shall be spread uniformly using grader/mechanical means. Clods shall be broken to maximum size of 75 mm. If NMC is less than OMC, water shall be added to maintain +1% to -2% of OMC. If NMC is more than OMC, material shall be dried by sun exposure. Compaction shall be done using vibratory roller (80–150 kN) to achieve 95% MDD. Rolling shall start from lower edge to upper edge. Each roller pass shall overlap 1/3rd of the previous pass. Acceptance Criteria Field dry density ≥ 95% of MDD Layer thickness tolerance ±25 mm Moisture content +1% to -2% of OMC during compaction Frequency of Testing Gradation Test (IS 2720 Part-4): 2 tests per 3000 cum Plasticity Test (IS 2720 Part-5): 2 tests per 3000 cum Density Test (IS 2720 Part-8): 2 tests per 3000 cum Deleterious Content (IS 2720 Part-27): As required Moisture Content (IS 2720 Part-2): 1 test per 250 cum CBR Test (IS 2720 Part-16): As required Field Compaction Testing One set of ten density measurements for every 3000 sqm or as required for statistical evaluation. Safety Measures All safety measures shall be followed as per approved EHS Plan. Frequently Asked Questions (FAQ) 1. What is the purpose of embankment construction? Embankment construction is carried out to raise the formation level of the road and provide a stable base for pavement layers. 2. What is the required compaction for embankment? The field dry density should be at least 95% of the Maximum Dry Density (MDD) as per MoRTH specifications. 3. What type of soil is suitable for embankment construction? Soil used should have Liquid Limit less than 55%, Plasticity Index less than 25%, and Free Swell Index less than 50%. 4. What is the optimum moisture condition during compaction? Moisture content should be maintained within +1% to -2% of Optimum Moisture Content (OMC) during compaction. 5. What equipment is commonly used in earthwork? Excavators, dumpers, graders, vibratory rollers, and water tankers are commonly used for embankment and subgrade work. 6. What is the maximum layer thickness allowed? Layer thickness tolerance is generally maintained within ±25 mm as per specifications. 7. Why is CBR testing important? CBR (California Bearing Ratio) test determines the strength of subgrade soil and its suitability for pavement design. 8. How frequently should field density tests be conducted? One set of ten density measurements is carried out for every 3000 sqm of compacted area or as required. 9. What are the key safety measures during earthwork? All activities must follow the approved EHS plan, including use of PPE, proper equipment handling, and safe working practices. 10. What is the role of a surveyor in earthwork? The surveyor establishes reference points, checks alignment and levels, and ensures the work is executed as per design.

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    Earthwork

    METHOD STATEMENT FOR SURVEY WORK

    Survey / /

    SCOPE: Survey Procedure Survey Sequence The survey is carried out from the starting point to the end point by following the sequence given below: Deriving of coordinates through DGPS. Running of traverse line between two known DGPS points. Reducing the relative levels between two known DGPS points. Staking in of topographical details in three-dimensional coordinates. Depicting of structural cross road details. Layout of reference line for roads and structures. Netting of original ground levels. Reference MoRTH Clause No: 109 and technical specifications of the project shall be followed. Equipments For the above task, the following precision survey instruments are used to maintain the required accuracy: DGPS (Dual Global Positioning System). Electronic Total Station with inbuilt programs (1″ least count accuracy). Auto Level with graduated vertical scale of 5 mm interpolation accuracy. Compass (to indicate North direction or true meridian) with 1 mm precision as directed by the Engineer. Tools Measuring Tape Pegs Nails Hammer Paint Tins Safety Cones Safety Boards Procedure Project reference center line of the proposed cross-section shall be fixed by the surveyor and marked on the ground using nails. Chainage shall be clearly marked on the existing road using paint. This marking shall be carried out at an interval of 20 m on straight portions and 10 m on curved portions. Offsets shall also be marked on the existing road wherever applicable. Further, prior to the commencement of earthwork or structural work, as per MoRTH specification Clause 109.3 and 109.5, the centerline shall be referenced by providing chainage pillars at the Right of Way (ROW) edge. Initial Survey Methodology Initial Survey (Satellite and Topographical) The survey is carried out for fixing of the control network. The following methodology is based on the measurement of angles and distances on a horizontal plane along with satellite geometry. GTS (Great Trigonometrical Survey) Great Trigonometrical Survey (GTS) points are already established by the Survey of India with reference to Mean Sea Level (MSL). DGPS Data (Dual Frequency Global Positioning System) Initially, pairs of ground control points are established at every 5 km interval. These points are connected to the DGPS network to obtain accurate X, Y, Z coordinates for the entire project. Traverse Traversing is carried out by measuring a set of horizontal angles in different quadrants between two straight points. Reciprocal horizontal distances between two points are measured by establishing traverse stations at every 200 m interval. An open traverse is carried out from a fixed DGPS station and closed at another fixed DGPS station. The coordinates (X, Y) are calculated and any misclosure in Easting and Northing is adjusted to maintain the required accuracy. Formula Δ Easting = Sin (North Bearing) × Horizontal Distance Δ Northing = Cos (North Bearing) × Horizontal Distance Double Territory Level Line Auto level instruments are used to determine the relative difference in elevation between two points. The survey is carried out between fixed DGPS datum points to identify misclosure in height. Precision automatic levels, conforming to MoRTH Clause 900 and fitted with micrometer attachments, shall be used for all double run and TBM transfer works to ensure accuracy. Temporary Bench Marks (TBM) Precast pillars of size 150 mm × 150 mm × 750 mm, reinforced with 6 mm bars and provided with a central 8 mm rod (marked with a dot on the top surface), are used as TBM pillars. These pillars are embedded such that 300 mm remains above ground level. Yellow, black, and red paints are used for marking their identification name and number. Traverse Station Traverse stations are marked by fixing a nail at the center and highlighting it with a yellow paint mark on one edge of the existing carriageway surface at every 250 m interval. Each station is assigned a unique identification number. Survey Details – OGL, Calibration & Safety Original Ground Level (OGL) The laid out reference line is taken as “0”. On the longitudinal section (L-section), cross-sections are taken at specified and prescribed offset distances on the original ground. Levels are observed at every 10 m interval in the longitudinal direction and up to PROW in the cross-sectional direction. The RLs (Reduced Levels) of OGL are observed and calculated from a known station and closed on another known station to ensure accuracy. Calibration Internal calibration shall be carried out once every month for leveling instruments and total stations in specified formats. Calibration certificates for level instruments and total stations must be submitted with valid certification from the manufacturer. A “Survey File” containing necessary data such as DGPS details, traversing details, horizontal and vertical control points, reference pillars, survey monuments, and horizontal alignment setting-out details shall be submitted to the Client/Engineer. Responsibility The responsibility for implementation of this procedure lies with the surveyors deployed at various sections for different activities, along with the Survey Engineer and Section In-Charge. Safety Precautions Do not aim the telescope at the sun, as it may damage the EDM of the instrument. Never place the instrument directly on the ground, as it may damage the base. Do not carry instruments along with the stand from one station to another. All safety measures shall be followed as per HIRA (Hazard Identification and Risk Assessment). Avoid heavy shocks and vibrations to the instruments. Remove the battery before storing the instrument in its case. Do not store wet instruments inside the case; allow them to dry before storage. Before removing the instrument from the case, note the layout position to place it back correctly. All staff and workmen shall wear reflective jackets and PPE at the work area. A minimum of 6 cones and a “Men at Work” signboard shall be used during survey work on roads. Staff and workmen shall not use mobile phones while moving on the road. Required safety equipment shall be provided at site to ensure safe working conditions.

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    Survey

    Wet Aggregate Impact Value Test | IS Procedure & Calculation

    Aggregate / /

    Wet Aggregate Impact Value Test OBJECT To determine the Aggregate Impact value of coarse Aggregate. APPARATUS AIV machine, IS Sieve 12.5mm, 10.0mm, 2.36mm, Oven, Brush, Balance 0.1 gm accuracy. PROCEDURE The test sample shall consist of aggregate the whole of which passes a 12.5-mm IS Sieve and retained on 10 mm IS Sieve. The aggregate comprising the test sample shall be dried in an oven for a period of four hours; the weight becomes constant at a temperature of 105 to 110°C and cooled. The measure shall be filled about one-third full with the aggregate and tamped with 25 strokes of the rounded end of the tamping rod. A further similar quantity of aggregate shall be added and a further tamping of 25 strokes given. The measure shall finally be filled to overflowing, tamped 25 times and the surplus aggregate struck off, using the tamping rod as a straight-edge. The net weight of aggregate in the measure shall be determined to the nearest gram (weight A) and this weight of aggregate shall be used for the duplicate test on the same material. This oven-dried sample is immersed in water for three days. Wet sample after the immersion period is surface dried by suitable cloth. The cup shall be fixed firmly in position on the base of the machine and the whole of the test sample placed in it and compacted by a single tamping of 25 strokes of the tamping rod. The hammer shall be raised until its lower face is 350 mm above the upper surface of the aggregate in the cup, and allowed to fall freely onto the aggregate. The test sample shall be subjected to a total of 15 such blows each being delivered at an interval of not less than one second. The crushed aggregate shall then be removed from the cup and the whole of it sieved on the 2.36 mm IS Sieve and washed with water till no further significant amount passes in one minute. The fraction retained on the sieve shall be dried in an oven to the constant weight at 105 to 110°C and weighed to an accuracy of 0.1 g (weight B). The fraction retained on the sieve (weight B) shall be subtracted from the weight of the original oven dried sample (weight A). The resultant weight (weight A – weight B) shall represent the fraction passing 2.36 mm IS Sieve (weight C). Two tests shall be made. CALCULATION Aggregate Impact Value = (C / A) × 100 Where: C = Weight of fines formed A = Weight of the oven-dried sample

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    Aggregate

    Procedure for Sampling & Testing of Incoming Materials (QA/QC Highway Works)

    Soil / /

    SAMPLING AND TESTING PROCEDURE FOR CEMENT: Check the seal number as per invoice of the browser. If the seal found tight and match with the invoice, then collect a representative sample of 20kg for in-house testing in the presence of client. Conduct the routine test like fineness, % passing on 90 mic sieve and allow for unload, if found complied to IS 4031. The tests like consistency, soundness, compressive strength, initial and final setting of the cement shall be tested as per IS 4031. Prepare formats for above tests and get it signed by client and file the records. Maintain invoice register for cement receipt at plant. Ensure all the tests shall be performed as per week number of the cement. SAMPLING AND TESTING OF REINFORCEMENT: Once the reinforcement lots arrived to site from approved sources, unload the material in stacking yard. Inspect the reinforcement lot as per invoice and ensure tagging of reinforcement for every lot. Collect 2 samples (3 pieces of 1m length for each sample) from every dia of reinforcement for a lot of 50t and 3 samples for 100MT. Bring the cutting pieces to lab and in the sampling register. Check the weight per running meter for the samples collected. Rolling margin of all samples shall be collected for every lot. If the rolling margin found within the tolerable limits as per IS 1786-2008, accept the lot. Otherwise inform to supplier to take back the lot. Invoice with test certificate shall be verified by quality in charge and sign on test certificate. Enter the details of reinforcement received in the invoice register and get the signature of client. If any lot required for independent lab testing, raise RFI and collect the samples in the presence of client. Sign the sample card by client and IE representatives and keep one copy in lab and other copy to tie for sample pieces. Physical and chemical properties of the reinforcement tested in independent lab shall be reviewed by quality in charge and client and ensure complied to IS 1786-2008. The test reports of independent lab will be submitted to client for review and approval. SAMPLING AND TESTING OF FINE AGGREGATE: Once the fine aggregate (river sand) load received at site from approved source, collect a representative sample of 20kg for lab testing to check physical properties. Enter the details of river sand in the sampling register. The material shall be tested for sieve analysis and check for zone of the sand and Fineness Modulus (FM). Check the silt content of the sand as per IS 2386. If the sand falls in zone-II and the FM lies in between 2 to 3.5 and the silt content less than 3% , the vehicle shall be allowed for unloading . If the sand doesn’t meet the above requirements (FM and silt content) shall be rejected. If the sand contains over size material more than 10% on 10mm sieve shall be screened and use for permanent works. Independent lab testing of sand shall be tested as per approved ITP. SAMPLING AND TESTING OF BITUMEN: Once the bitumen tanker arrived at site, verify the invoice number and seal of the tanker. Collect the sample with sampler of weight not less than 1 kg. Enter the sample details in sampling register and sample number shall be given. Test the sample for absolute viscosity, softening point, and penetration. If the test results found satisfactory, allow the tanker for unload. Review the conducted test results and compare with MTC. Prepare the test reports and get it signed by client and file the records. Maintain the invoice register for incoming bitumen and get the signature in theregister by client. The sample shall be collected for independent lab testing frequency as per theapproved ITP. SAMPLING AND TESTING OF ADMIXTURE: Once the admixture barrels arrived at site, verify the invoice number and batch number of the material. Collect the sample with sampler of weight not less than 2 kg. Enter the sample details in sampling register and sample number shall be given. Test the sample for density at room temperature. If the test results found satisfactory, then allow the admixture to use in permanent work. Review the MTC test results as per IS 9103. Maintain the invoice register for incoming bitumen and get the signature in the register by client. SAMPLING AND TESTING OF EMULSION (SS-1 & RS-1): Once the emulsion tanker arrived at site, verify the invoice number and seal of the tanker. Collect the sample with sampler of weight not less than 1 kg. Enter the sample details in sampling register and sample number shall be given. Test the sample for viscosity by say bolt furl viscometer. If the test results found satisfactory, allow the tanker for unload. Conduct the balance tests like residue test by evaporation. Review the conducted test results and compare with MTC. Prepare the test reports and get it signed by client and file the records. Maintain the invoice register for incoming emulsions and get the signature in the register by client. The sample shall be collected for independent lab testing frequency as per the approved ITP. SAMPLING AND TESTING OF GEO-GRIDS / GEO-TEXTILE: Once the Geogrid material arrived at site, verify the invoice number and grade. Raise the RFI and Collect the sample from bundle I roll of size not less than 2m*2m from each grade. Enter the sample details in sampling register and sample number shall be given. Count the number of ribs in machine direction and transverse direction. The samples shall be tagged with sample card mentioned all the details with signatures of client. The collected samples shall be sent for independent lab testing as per approved ITP. Review the MTC test results as per grade requirement. Maintain the invoice register for Geogrid and get the signature of client. TEST PROCEDURE OF CTSB MIX DESIGN Raise RFI for sampling of aggregates for CTSB Mix Design. Sample the individual aggregates jointly. Do individual gradation for each aggregate as mentioned in MoRTH

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    Soil

    Method Statement for Dismantling Culverts, Bridges, Pavements and Other Structures

    Concrete Work / /

    Method Statement for Dismantling Culverts, Bridges, Pavements and Other Structures [last_updated] 1. Purpose The purpose of this Method Statement is to define the detailed construction methodology for dismantling culverts, bridges, pavements, kerbs, and other structures in accordance with the provisions of MoRTH Clause 202 and relevant amendments in the Technical Specifications. 2. Scope of Work The work shall consist of removing existing culverts, bridges, pavements, kerbs, and other structures that interfere with new construction activities or are unsuitable to remain in place. The work shall also include salvaging, disposal of dismantled materials, and backfilling of resulting trenches and pits. Existing structures located within the highway limits and designated for removal shall be dismantled up to the extent shown in the Good for Construction (GFC) drawings or as directed by the Authority Engineer. Dismantling operations shall be carried out using suitable equipment such as backhoe loaders, excavators, dozers, graders, tractor dozers, jackhammers, or excavators fitted with rock breakers, depending upon the type of structure. Care shall be taken to avoid disturbance or damage to adjacent pavements, structures, underground utilities, and any work intended to remain in place. All dismantling operations that may affect new construction shall be completed before commencement of new works. Traffic diversion, safety arrangements, and traffic management measures shall be implemented as per approved methodology prior to dismantling activities. Dismantling work shall commence only after obtaining approval from the Authority Engineer. 3. Sequence of Operations 3.1 Dismantling of Culverts and Bridges Existing culverts and bridges shall be dismantled carefully to prevent damage to reusable materials, portions of structures to be retained, nearby properties, and adjacent structures. Where existing culverts or bridges are to be extended or incorporated into the new work, only the required portion shall be removed as directed by the Authority Engineer. Connecting edges shall be cut, chipped, and trimmed to the required alignment and levels without weakening the remaining structure. Reinforcement bars intended for future connection as dowels or ties shall be protected from damage during dismantling operations. Pipe culverts shall be dismantled carefully to avoid breakage or damage to the pipes. 3.2 Dismantling of Pavements and Other Structures Existing pavements, kerbs, gutters, and other structures shall be dismantled as specified in the drawings and Technical Specifications. Portions intended to remain in service shall be cut neatly along straight lines or existing joints with faces perpendicular to the pavement surface. Sufficient dismantling shall be carried out to achieve proper grades, alignment, and connection with the proposed works. Concrete pavements, bituminous pavements, shoulders, and base courses designated for dismantling shall be broken into pieces not exceeding 0.02 cubic metres. Dismantled materials shall either be stockpiled at approved locations for reuse or disposed of as directed by the Authority Engineer. Holes, depressions, and excavated areas resulting from dismantling operations shall be backfilled using approved material and compacted to the specified density. Disposal of dismantled materials shall be carried out in accordance with the relevant Technical Specifications and environmental requirements. 4. Equipment Used Backhoe Loader Excavator Bull Dozer Tractor Dozer Motor Grader Jack Hammer Excavator with Rock Breaker

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    Concrete Work
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