SPECIAL SPECIFICATION OF EARTHWORK AND BLANKETING

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Date: 2018.06.25
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Location: New Delhi
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 NORTHEAST FRONTIER RAILWAY
(CONSTRUCTION ORGANISATION)
SPECIAL SPECIFICATION
1. GENERAL
1.1 These specifications shall apply to all such works as are required to be executed
under the contract or otherwise directed by the Engineer. In every case the work
shall be carried out to the satisfaction of the Engineer and shall conform to grades
and cross sections shown on the drawings or as indicated by the Engineer. The
quality of the work and materials shall comply with the requirements set forth in the
succeeding sections. Where the drawings and specifications describe of portion of
the work only general terms and not in complete details, it shall be understood that
only the best general practice is to prevail. Materials and workmanship of the best
quality are to be employed and that the instructions of the Engineer are to be fully
complied with and shall be binding on the contractor. The contractor shall be fully
responsible to ensure that the finished works are free from any defects, weakness,
cracks etc.
1.2 CODES OF PRACTICE AND SPECIFICATIONS :
1.2.1 The abbreviations mentioned else where for standard specifications and code of
practices shall be considered to have the following meaning.
IS : Indian Standard of the Indian Standards Institution.
IRS : Indian Railway Standard Specifications and Code of Practices.
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GCC 2013 : N. F. Railway General & Standard Special Conditions of Contract
: Indian Railway Unified Standard Specification Volume-I & II 2010 edition.
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IRC : Indian Roads Congress.

RDSO : Research, Designs and Standards Organisations (Ministry of
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Railways).
1.2.2 Wherever a reference is made to any of the standard specifications and code of practice it
shall be taken as a reference to the latest versions/revision of the same and shall include all
the ERRATA/corrections made in the same from time to time.
1.3 MEASUREMENTS
1.3.1 All measurements shall be made in the metric system. Different items of works shall
be measured in accordance with the procedures set forth in the relevant sections
read in conjunction with G.C.C. and special conditions of the contract.
1.3.2 All measurements and computations, unless otherwise indicated shall be carried
nearest to the following limits.
i) Length and breadth 10 mm
ii) Height, depth or thickness of earthwork, C.C. work 5 mm
iii) Area 0.01 Sqm.
iv) Cubic contents 0.01 Cum.
1.4 Site clearance wherever involved shall be undertaken and the same shall be considered
incidental to the earthwork items and rates for the same shall be deemed to be inclusive of
all clearing operations.

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 1.5 Specifications not specified in the tender documents for this work, shall be in accordance
with Indian Railway Unified Standard Specification Volume-I & II 2010 edition corrected up-
to-date and the contractor shall be bound by them for the performance of the contract.
2.0 EARTHWORK
2.1 The changes mentioned in the tender documents are field changes are meant guidance only.
For the purpose of payment, actual lengths will be measured on ground.
2.2 It shall be the responsibility of contractor to ensure that no work on the embankment or
cutting is commenced until the existing ground levels at different cross sections have been
recorded and such records of levels have been jointly signed and dated by the contractor and
the Engineer or his authorized representative. Cross-sectional profiles plotted on the basis of
the recorded ground levels shall also be jointly signed by the contractor(s) and the Engineer.
The points at which the cross sectional ground levels are to be recorded and the extent of
leveling work to be done shall be decided by the Engineer. The contractor may bring to the
notice of the Engineer such additional cross-sections that in his opinion should be taken for
proper assessment of quantities. Such representation, however, should be made before the
commencement of any earthwork. The Engineer’s decision thereon shall, however, be final and
binding on the contractor.
2.2.1 Contractor shall sign every page of the level book and cross section sheets where original
ground and final level of completed work are recorded in token of his acceptance of these levels
and cross sections for the purpose of computation of quantities of payments. No dispute
whatsoever shall be entertained on this account.
2.3 Contractor shall clear all shrubs and jungles on the existing ground up to a distance of 3m from
the proposed toe of the embankments. All tree stumps will have to be uprooted from the area
to be covered by the formations embankment will not be paid for separately and the rate of
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earthwork includes such uprooting of tree stumps.
2.3.1 No extra payment will be admissible for filling up the hollows left after uprooting of tree
stumps in the area covered by the embankment. Initial ground levels as represented by the
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cross sections taken before commencement of work will not be deemed to be vitiated, and will
hold good for the assessment of the earthwork quantities, even though there may be some loss
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of earth in marshy/bed area due to shrinkage.

2.4 Benching has to be done on the existing banks where embankment is to be formed. No extra
payment for benching in either case will be admissible.
2.5 The type of soil to be used in the embankment which will be brought from out-side the railway
land will be got approved from the Engineer in advance. Organic clay, silts, peat and shrinkable
soils of low bearing capacity shall not be used for making the embankment.
2.6 Contractor should set out the work according to the plan and as directed by the Engineer or
his representative. Reference pegs are to be made permanent and kept clear of all obstructions.
He should obtain the approval in writing from the Engineer, for the correctness of the setting
out and the reference marks, before commencing the actual execution of the works.
2.6.1 All over 12.5 m along the proposed embankment, profiles shall be erected to enable smooth
execution of the earthwork in layers. No extra payment will be admissible for this.
2.7 While carrying out the filling work the contractor will take all necessary precautions to see
that no infringement is caused, with signaling and other installations and structures for the
smooth movement of traffic along the Railway track in and outside station limits. In course of
doing work if infringements are likely to arise he shall intimate the Engineer in advance of
his/their programme in writing so that necessary arrangements can be provided for carrying
out such items.
2. 8 The side slopes will be as designs and drawings approved by the Engineer.

2. 8.1 If any blasting operations are necessary, they are to be carried out in accordance with the
provisions under Standard Special Conditions for blasting and explosive as contained in

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 General Conditions of Contracts, and Indian Railway Unified Standard Specification Volume-I &
II 2010 edition with up-to date corrections.
2.9 No extra payment towards cost of bailing or pumping out water from borrow pits or cutting or
foundations excavation will be made. In case the embankment is to be made for such work, it
should be clearly understood that the rates quoted are inclusive of all charges for such items
incidental to earth work.
2.9.1 SPECIFICATIONS FOR FORMING EMBANKMENT WITH MECHANICAL COMPACTION.
2.9.2 After site clearance all pockets and depressions left in the soil, if any, shall be made and
compacted.
2.9.3 Earthwork shall be done in layers not exceeding 300 mm in thickness in the loose state, and
compacted preferably at or near the optimum Moisture Content (OMC) with suitable rollers to
obtain the density specified in para 2.11.3(a) & 2.11.3(b). The number of passes of the rollers and
the optimum thickness of such layer will be fixed after carrying out field trails with the roller
proposed to be used, from time to time, and from location to location, the main criteria being
to obtain the maximum density achievable uniformly.
2.11.3 Coarse grained soils shall be compacted to get a maximum density Index (relative density) of
(a) 70% as obtained in accordance with IS: 2720 (Pt.XIV-1983).
2.11.3 All other types of soils when compacted shall attain at least 98% of the max. dry density as
(b) determined using heavy compaction in accordance with IS: 2720 (Pt.VIII) 1983 followed by field
trials as per IS : 10379-1982 which shall form the basis for actual densities with the approval of
the Engineer.
2.11.4 Where the moisture content of the borrow soil in any layer is above OMC, it shall be left for
drying for a suitable period to bring down the moisture content very near to OMC before
rolling is commenced. If the soil is dry, water shall be sprinkled either in the borrow pit or over
spread layer, as per convenience, in order to attain a moisture content near to OMC, before
rolling is commenced. Where the natural moisture content of the borrowed soil is high,
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compaction at higher moisture contents upto plastic limit can be allowed with the permission
of Engineer. However, its effect on the design must be analysed and, if necessary, bank profile
should be revised.
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2.11.5 Each layer shall be compacted to the desired density over the entire width commencing from
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the two sides, before another layer is started.

2.11.6 While compacting, it shall be ensured that there is a maximum overlap of 15 cm before each
run of the roller.
2.11.7 Care shall be taken during the compaction operation to slope the surface of the bank to
facilitate the siding and to minimise the absorption of rainwater, particular attention being
given to prevention of pounding.
2.11. 8 The density of each layer of compacted soil shall be ascertained by testing an adequate number
of soil samples as decided by the Engineer.
2.11.9 The quality of works shall be determined by considering the mean density of the samples in
each layer. The mean density shall be equal to or exceed the minimum specified density. If the
density is found to be less than the minimum specified by more than 2% further rolling shall be
done at the appropriate location.
2.11.10 The contractor shall be allowed to pay a further layer of soil only after compaction of preceding
layer has been satisfactory.
2.11.11 The top of the formation shall be finished to a slope of 1 in 30 away from the centre.
2.11.12 In bank filling above or against structures such as bridges, the materials shall be deposited in
layers not more than 200 mm in thickness sloping away from the structure with each layer
carefully tamped. Only the best available materials approved by the Engineer shall be used for
this purpose.
2.11.13 Beyond the theoretical profile of bank an extra width of 50 cm shall be rolled either side which
after finishing the bank up-to final height shall be dressed by removing the loose earth on
account of rollers not able to compact the soil at the edge of the formation width.
2.11.14 The additional earth, after finishing the bank up-to final height shall be removed and spread at

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 the toe of the bank with proper slope for drainage. No extra payment will be made for
providing and subsequent removal of this extra earth and contractor is to quote his rates
accordingly.
2.12 No hand roller or hand ramming is permitted. However, where it is physically not possible to
use the mechanical roller, the compaction may be done by using hand roller or hand
hammer/tamper with prior written permission of the Engineer, in which case thickness of layer
to be restricted to 150 mm in loose state, so as to achieve the prescribed degree to compaction.
2.13 Necessary arrangement for the will testing at site will have to be organised by the contractor in
accordance with these specifications as directed by the Engineer and no extra payment will be
made to him on this account. The contractor shall also establish a self-sufficient laboratory for
soil testing and quality control testing.
2.14 SETTING UP SOIL TESTING LABORATORY AT SITE
In each contract section field soil testing laboratory should be set up (Contractor should
purchase equipment for soil testing) to carry out soil testing.
2.15 Under mentioned soil tests should be carried out:-
i) MDD & OMC of soil.
ii) Liquid limit and plastic limit test (for classification of soil),
iii) Sieve analysis to classify soil as coarse grained or fine grained soil,
iv) Field density of compact soil in each layer at an interval of 50 m this should be
minimum 98% of MDD as determined using heavy compaction in accordance with is IS:
2720 (Pt.VIII) 1983.
v) In each of coarse grained soil density index (relative density) of compacted soiling
accordance with IS: 2720 (Pt.XIV) – 1983.
2.16 List of equipment required for soil testing
i) Equipment for liquid limit and plastic limit test,
ii) Modified proctor test mould,
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iii) Tube reamer weight 4.90 kg. Drop height 450 mm.
iv) Infra-red lamp and torsion balance meter,
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v) IS sieve Nos. IS 100, 63, 20, 10 and 4.75 for coarse grain sieve analysis and 2mm, 1.0 mm,
600 micron, 800 micron, 425 micron, 212 micron, 150 micron & 76 micron IS sieves for
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fine grain sieve analysis.

vi) Chemical balance with weight box.
vii) Physical balance with weight box.
viii) Knife,
ix) Tray,
x) Crucibles,
xi) Weight,
xii) Measuring cylinder,
2.17 List of Equipment for Field Compaction Test.
i) Core cutter with Dolly-Volume 10 (x) cum,
ii) Reamer,
iii) Moisture meter (Complete set)
iv) Physical balance with weight,
v) Knife,
vi) Tray.
2.18 Soil should be used on embankment only after passing by AEN/XEN after conducting tests.
Soil testing should be done from borrow pits and graph should be plotted. Test results should
be signed by IOW/AEN/SEN.
2.19 Under mentioned registers should be maintained at site and contractor’s signature obtained.
i) MDD & OMC of soil
ii) Sieve analysis of soil
iii) Plastic limit and liquid limit of soil,

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 iv) Record of passing soil by XEN
v) Field compaction result layer-wise at 50 m interval.
vi) Earthwork calculation registers
vii) Site order book.
viii) Log book of daily work done.
ix) Any other register required for work.
All above register should be submitted to Dy.CE/CON alongwith each CC bill.
2.20 PEGGING OUT OF ALIGNMENT
2.21 The alignment should be marked on the ground from apex to apex of adjoining curves, so that
there is no possibility of having lateral shift in alignment produced from two ends. On straight
pegs should be fixed at 50 m interval and on curve it should be fixed at 25 m interval and at all
TPs.
2.22 Top of sub-bank should normally be 30 cm above HFL but depending to the site conditions the
height of sub-bank should be decided by XEN in charge of the work. The top level of sub-bank
should be decided before starting the work so that toe line can be marked correctly.
2.23 Earthwork should not be started in bank and sub-bank till dag belling at toe line is done and it
is checked by XEN. Dag belling of toe line should be done at a distance of 1 metre from actual
toe of bank/sub-bank. Height of sub-bank should be decided before dug belling is done so that
toe line (including sub-bank) can be marked correctly. Dag belling of toe should be done
considering 50 cm. Extra width for main bank (which is to be dressed later on), in case of sub-
bank extra width should be considered for main bank as well as for sub-bank i.e. total extra
weight of 100 cm.

2.24 MEASUREMENT AND PAYMENT.

2.24.1 It should be clearly noted that the payment for earth filling shall be made on the basis of net
quantity after deduction of shrinkage from the Gross quantity.
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2.24.2 The percentage of deductions due to shrinkage shall be made as under unless otherwise stated
in the description of the works :
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for earth filling with mechanical compaction. 5% (Five percent)

for earth filling without mechanical compaction. 10% (Ten percent)
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2.24.3 The gross quantity will be arrived from the cross sectional areas after plotting the final
formation levels of finished formation over the original ground levels. The total height of filling
(including the shrinkage) to be done shall be decided by the Engineer. Extra quantity of earth
filling beyond the required width and height (including the shrinkage) and beyond the toes
will not be paid. The toes of the bank shall be as per final slope for a required profile on the
basis of formation levels shown in the longitudinal section. The contractor should quote his
rate accordingly.
2.24.4 In case earthwork is done under water in isolated locations rates quoted by the tenderer must
take into account all possibilities of base settlement in marshy area etc. after making necessary
investigation and payment shall be made only on final cross sections. No additional payment
or any claim will be accepted.
2.24.5 If bandelling etc. is required for earthwork under water to be contained, the rate for earthwork
would cater for this.
2.25 The “Turfing of bank” will not be commenced before slopes are dressed to the specific section
and without the written permission of the Engineer. It will consist of sods not less than 7.5 cm
in thickness and 23 cm square, well beaten into the slope of the bank, and laid in manner so
that their edges are in close contact and form a level and compact surface. The contractor shall
be responsible to ensure that the turf grows properly. In the event of its not doing so, he will
replace such parts, as have not grown at his won expenses.
2.26 When the earth for making of formation is borrowed from adjacent private lands contractor
must ensure that minimum distance of borrow pit in private land from the toe of new bank is
at least equal to the height of bank plus 3.0 metres.
2.27 Under no circumstances incomplete work will be taken over by the department. The

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 contractor shall notify sufficiently in advance his intention of handling over a particular stretch
of completed/finished work so as to enable recording final levels.
3.0 EXCAVATION FOR STRUCTURES.
3.1 Pits trenches for foundations of bridges, culvert wells, apron and other structures shall be
taken out to the levels and dimensions shown on the approved drawings or to such other levels
and dimensions as the Engineer may direct. The bottom of all excavations shall be carefully
leveled and stopped on benches as directed by the Engineer. Any pocket of soft or loose
materials and fissures in the bottom pits and trenches shall be removed and the cavities so
formed filled or grouted with concrete as directed by Engineer. When any excavation has been
done and trimmed to the required levels and dimensions, the Engineer shall be informed
accordingly so that he may inspect the complete pit or trench and no excavation shall be filled
in and covered with concrete until it has been inspected and the contractor has been
authorised to proceed with work. All surplus excavation not required for refilling shall be
deposited in embankments, or otherwise disposed off as directed. The work shall include all
necessary sheeting, shoring, bracing, drawing and pumping out water, removal of all legs,
stumps, grabs and other deleterious matters, obstructions, necessary for placing the
foundations.
3.2 When required by the Engineer, materials in the last 500 mm of depth of the excavations shall
not be removed until immediately before the concrete is to be placed.
3.3 All excavation for structures shall generally be as small as practicable, consistent with the
proper construction of work. Any excavation taken out to a greater depth than that required
shall be back filled with concrete of the foundation grade at the cost of the contractor.
3.4 Where water is met with during excavation due to stream flow, seepage, sorings, rain or other
reasons, the contractor shall take adequate measures such as bailing, pumping, constructing
diversion channel, drainage channel, bonds and other necessary works to keep the foundation
trenches dry and other necessary and to protect the green concrete against damage by eruption
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or sudden rising of water level. Approval of the Engineer to any method adopted for the
adequacy of dewatering and protection arrangements and for the sound safety of the work
shall be required.
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3.5 Refilling of foundation pits and trenches shall be carried out only after the foundation and
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structure works within the excavation have been inspected and approved by the Engineer.
Unless otherwise directed by the Engineer all fillings shall consist of approved materials. All
space between foundation concrete and the sides of excavation shall be refilled to the original
surface, using approved plant, in single layers not exceeding 250 mm loose thickness which
shall be watered and completed to a dry density not less than that of the adjoining soil strata.
Timber sheeting and other excavation support shall be carefully removed as the filling
proceeds but the removal of such supports will not relieve the contractor of his responsibility
for the stability of the works.
3.6 MEASUREMENTS OF PAYMENT
3.6.1 Excavation for structures shall be measured in cubic metres, limited to the dimensions shown
in the approved drawing or as directed by the Engineer keeping in view practical necessity for
proper execution of the work. Foundation sealing, de-watering including pumping shall be
deemed to be incidental to the work and no extra payment shall be payable for this work.
3.6.2 For any special treatment of foundation such as grouting of cavities and fissures, extra payment
will be made at mutually agreed rates.
3.7 RATES
The contract unit rate for the item of earthwork in excavation for structures shall be paid in full
for carrying out the required work including full compaction to –
i) Setting out including all ancillary works like pegging and supply of pegs etc.
ii) Construction of necessary sheeting, shoring and bracing and then subsequent removal.
iii) Removal of all logs, stumps, grubs and other deleterious matters and obstructions for
placing foundations including trimming of bottom of excavations.
iv) Foundation sealing, de-watering including pumping.

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 v) Back filling upto the top of foundation clearing up the site and disposal of all surplus
materials within leads upto 200 m inclusive of all leads, descents etc.
vi) All labour, materials, tools, constructions plants, safe guards and incidental necessary to
complete the work as per specification.
4.0 MATERIALS FOR STRUCTURES
All materials to be used in the work shall be in conformity with the requirement laid down
hereunder. All other materials not specified herein fully are required to be used in the work
conforming to the appropriate code described under clause 1.2.1. These materials shall only be
used on being approved by the Engineer or his representative and in case being rejected shall
be removed from site and replaced at his own expenses by the Contractor.

4.1 BINDING WIRE

4.1.1 Binding wires used for binding the reinforcement shall be of approved quality soft annealed
iron wire not less than 1 mm (18 SWG) size, conforming to IS : 280.
4.2 REINFORCEMENT STEEL
4.2.1 All structural steel for bridges shall conform to IS : 2062 – 1992. Grade `B' type.
4.2.2 Reinforcement to be used in RCC/ PSC bridge works shall conform to IS: 1786 , 1979
4.2.3 High Tensile prestressing steel (strands) used for PSC girders shall conform to IS: 6006-1983
class-I type.
4.3 TIMBER
4.3.1 The timbers used for structural purpose whether permanent/semi permanent or temporary
work shall conform to IS : 883.
4.4 WATER FOR CONCRETE AND MORTAR
4.4.1 Water shall be clean and free from injurious amount of deleterious materials. Normally
portable water from an approved source may be considered satisfactory for washing aggregates,
mixing and curing concrete, and shall comply with the provision of IS : 456.
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4.5 AGGREGATE FOR CONCRETE
4.5.1 General – The aggregates (coarse and fine) for concrete shall comply in all respects with IS : 383
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and shall be obtained from a source approved by the Engineer.

4.5.2 Aggregate which are not clean are to be washed to the satisfaction of the Engineer or his
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representative in water of quality as described in Clause 4.4. If the Engineer so directs, the
contractors shall provide and operate a washing plant to ensure adequate supply of clean
aggregates within the approved grading limit. All such washed aggregates shall be stored and
drained for at least 24 hours before being used for concreting.
4.5.3 The coarse aggregate, unless otherwise specified or authorised by the Engineer shall not be
delivered to the site. All aggregates shall be protected from dust contamination by methods
approved by and to the satisfaction of the Engineer or his representative.
4.6 SAMPLES AND TESTS
4.6.1 GENERAL : The samples of all the materials proposed to be used by the contractor in the work
shall be got tested by the contractor in an approved laboratory and necessary test certificates
including manufacturers certificates of tests, proof sheets, mill sheets etc. showing that the
materials have been tested in accordance with and conform to the requirements of the
appropriate IS Codes and other relevant Standard Specifications or these specifications, shall
be supplied in original free of charges on request to the Engineer or his representative.
4.6.2 Samples of the following materials shall be submitted to the Engineer or his representatives
free of charge for testing and approval.
i) Coarse and fine aggregate,
ii) Any other materials as directed by Engineer.
4.6.3 Samples provided to the Engineer or his representatives for their retention are to be kept in
leveled boxes suitable for storage. Materials or workmanship not corresponding in character
and quality with approved samples shall be rejected.
4.6.4 Samples required for testing and approval must be supplied giving sufficient time to allow for

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 such testing and approval, due allowance being made to the fact that if samples are rejected
further samples shall be required. Delay to the works arising from the late submission of
samples shall not be acceptable as a reason for delay in the completion of the work.
4.6.5 The testing of the materials may be carried out by the Railway in any laboratory of its choice if
required. If the materials are not found to comply with the various provisions laid down in the
relevant IS Codes. Other relevant Standard Specifications or these specifications, the same
shall be rejected irrespective of the test certificate submitted by the contractor.
4.6.6. In addition the Engineer shall have the right to require the contractor at any time to draw
samples of aggregates or any other materials from stock piles on the site or any other locations
to be drawn in accordance with IS-2386 and tested in laboratory approved by the Engineer in
accordance with the appropriate clause of IS : 2386 at the cost of the contractor.
4.6.7 Tests for the determination of impurities in the sand shall be made once daily until the
Engineer is satisfied that the specified compression strength is being regularly obtained, such
tests shall be made once weekly and at other times as directed by the Engineer.
4.6.7.1 The cement and steel brought by the contractor will also be tested from each lot as directed by
the Engineer or his representative. The contractor will also furnish original purchase bills.
Random samples shall also be taken to assess the weight per metre of steel. The payment shall
be on the actual weight basis taking advantage of tolerance in the IS : Code.
4.6.8 ADDITIONAL TESTS
In addition to the tests required under clause hereof the Engineer or his representative may
order tests to be carried out by an independent person appointed by him at such place or in
such laboratory as he may determine in accordance with the appropriate clause of IS : 2386 or
IS : 2586 and the cost of such tests shall be borne by the contractor.
4.6.9 The results of all such tests as described herein above and later or in succeeding paras shall be
forwarded to the Engineer or his representative for his retention as record.
4.6.10 INSPECTION OF MATERIALS
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4.6.10.1 Wherever the Engineer or his representative gives notice to the contractor that materials are to
be inspected off the site, the contractor shall, having regard to the location of the materials
and the nature of the inspection, test or examination required, give to the Engineer or his
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representative at least one week's notice of such materials being ready for inspection, test or
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examination.
4.6.10.2 Delay to works arising from the late submission of such notice will not be acceptable as reason
for delay in the completion.
4.6.11 REJECTION OF MATERIALS
4.6.11.1 Materials shall be tested before leaving the manufacturer’s premises, where appropriate.
Materials may as well be tested on the site and they may be rejected if found not suitable or not
in accordance with the specifications notwithstanding the results of tests at manufacturer’s
works or elsewhere or test certificates.
4.6.11.2 The Engineer or his representative shall have the right to order at any time, that any aggregate
or other construction materials which do not meet with his approval shall not be used in the
works and such rejected materials shall be removed from the site by the contractor at his own
expenses, notwithstanding any prior approval which might have been given earlier.
4.6.11.3 In case of default on the part of the contractor in removing rejected materials within the time
specified in notice, the Engineer shall be at liberty to have them removed by other means at
the cost of the contractor.

4.6.12 STORAGE OF MATERIALS

4.6.12.1 All materials to be used in permanent works shall be stored on rocks, supports, stock piles in
bins under cover etc. as appropriate, to prevent deterioration or damage from any cause
whatsoever to the satisfaction of the Engineer or his representative.
4.6.12.2 The contractor shall at all times maintain on the site such quantities of each type of aggregates as are
considered by the Engineer or his representative to the sufficient to ensure continuity of works.
4.6.12.3 Each type and grading of aggregate shall be stored in separate tacks on a hard floor having sufficient

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 slope to ensure adequate drainage of surplus water. Wet and washed aggregate shall be kept in storage
for at least 24 hours to ensure adequate drainage before being used for concreting.
4.7 CEMENT
4.7.1 In general, for all mass and reinforced concrete works, ordinary port-land cement conforming
to IS : 269 shall be used. However, Railway reserves the right to ask the contractor at any time
for using other varieties of Standard cement complying with the relevant IS Codes or any other
Standard Specifications and the contractor shall use the same. Two or more types of cement in
one member of the structure shall not be allowed.
5.0 CEMENT CONCRETE WORKS
5.1 GRADE OF CONCRETE
5.1.1 Nominal mix concrete is to be used where it is shown in the drawings or as directed by the
Engineer.
5.2 STRENGTH REQUIREMENT OF CONCRETE
5.2.1 In designation of concrete mix, letter ‘M’ refers to mix and the number of the specified 28 days
work cube compressive strength of that mix on 150 mm cubes expressed in N/mm sq.
5.2.2 The compressive strength requirements for various grades of concrete shall be as given in table
below :-
S/N Grade of concrete Compressive work test strength in N/mm sq.
Of 150mm cubes after mixing conducted in
accordance with IS : 516
Min. at 7 days Min. at 28 days
i) M10 (Nominal mix.1:3:6) 7 10
ii) M15 (Nominal mix 1:2:4) 10 15
iii) M20 (Nominal mix 1:1 ½ :3) 13 20
iv) M25 (Controlled mix 1:1:2) 17 25
v) M30 (Controlled mix) 20 30
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vi) M40 (Controlled mix) 27 40
vii) M45 (Controlled mix) 30 45
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5.2.1 Where the strength of a concrete mix as indicated by tests, lies in between the strength of any
two grades specified in table above, such concrete shall be classified for all purpose as concrete
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belonging to the lower of the two grades between which its strength lies.
5.3 TESTS AND STANDARDS OF ACCEPTANCE
5.3.1 PRELIMINARY TESTS FOR CONTROLLED CONCRETE
5.3.1.2 Trial mixes shall be made using samples of the aggregates cement and water, typical of those
to be used in the works.
5.3.1.3 Should the strength shown by the preliminary tests prove to be below the figures specified in
para 5.2.2 the contractor shall make such changes in proportions as are required to bring the
concrete upto the required strength.
5.3.1.4 Wherever mix has been approved, no variations shall be made in the proportions, the original course of
the cement and aggregates or in the type, size and grading zone including water cement ratio without
the consent of the Engineer who may require further tests to be made.
5.3.1.5 For controlled concrete, the concrete mix shall be so designed as to attain in preliminary tests
strength of at least 35 percent higher than that required on work given in table under Clause
5.2.2.
5.3.1.6 WORKS STRENGTH TESTS FOR CONCRETE
5.3.1.6.1 The contractor shall be held responsible for ensuring that the crushing strength of the
concrete as placed is not less than the designed strength as per approved plans.
5.3.2 SAMPLING AND STRENGTH OF DESIGNED CONCRETE MIX
5.3.2.1 GENERAL
5.3.2.1.1 Samples from fresh concrete shall be taken as per IS 1199 and cubes shall be made
cured and tested at 28 days in accordance with IS 516.

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5.3.2.1.2 In order to get a relatively quicker idea of the quality of concrete, optional tests on beams for
modulus of rupture at 72+ 2h or at 7 days or compressive strength test at 7 days may be carried
out in addition to 28 days compressive strength test, For this purpose the values should be
arrived at based on actual testing. In all cases the 28 days compressive strength specified in
Table 2 shall alone be the criterion for acceptance or rejection of the concrete
5.3.2.2 FREQUENCY OF SAMPLING
5.3.2.2.1 Sampling Procedure
5.3.2.2.2 A random sampling procedure should be adopted to ensure that each concrete batch shall
have reasonable chance of being tested that is, the sampling should be spread over the entire
period of concreting and cover all mixing units.
5.3.2.2.3 Frequency
5.3.2.2.4 The minimum frequency of sampling of concrete of each grade shall be in accordance with the
following:

Quantity of concrete in the work, cum Number of samples

1-5 1
6-15 2
16-30 3
31-50 4
51 and above 4 plus one additional sample for each
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additional 50 cum or art thereof.
5.3.2.2.5 Note
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At least one sample shall be taken from each shift. Where concrete is produced at
continuous production unit such as ready mixed concrete plant, frequency of sampling
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may be agreed upon mutually by suppliers and purchasers.

5.3.2.3 TEST SPECIMEN

5.3.2.3.1 Three test specimens shall be made for each sample for testing at 28 days. Additional
samples may be required for various purposes such as to determine the strength of
concrete at 7 days or at the time of striking the form work, or to determine the
duration of curing, or to check the testing error. Additional samples may also be
required for testing samples cured by accelerated methods as described in IS 9103. The
specimen shall be tested as described in IS 516.
5.3.2.4 TEST RESULTS OF SAMPLE
5.3.2.4.1 The test results of the sample shall be the average of the strength of three specimens.
The individual variation should not be more than +15 percent of the average. If more
the test results of the sample are invalid.
5.3.2.4.2 The contractor shall provide at his own expense all necessary labour, materials including
cement moulds, equipment for sampling and all other ancillaries required in preparing
specimens etc. as given in clause 5.3.2.2 and arrange to carry out test on these specimens in his
own field laboratory. The contractor shall test these specimens in presence of the representative
of the Engineer. Duplicate results shall be maintained under the joint signature of the
contractor and the Engineer’s representative. One set of the result being kept with the

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 contractor and the other with the Engineer’s representative.
5.3.2.4.3 All work shall be carried out under the supervision of a qualified and competent Engineer of the
contractor who shall supervise proportioning, placing and compacting of concrete at all stages.
5.3.2.4.4 The Engineer reserves the right to take samples of concrete test cubes independently at his own
discretion. The contractor shall provide all facilities at his own expense in preparation of such
samples and concrete test tubes such as labour materials including concrete moulds, equipment
for sampling and all other ancillaries required in their preparation. Contractor shall also
arrange to transport these specimen to the laboratory selected by Railway at his own cost.
Contractor shall depute his representative during testing who shall sign the test results as a
token of contractor’s acceptance.
5.4 STANDARD OF ACCEPTANCE
5.4.1 The average strength of the group of cubes cast for each day shall not be less than the specified
work cubes strength. 20 percent of the cubes cast for each day may have values less than the
specified strength, provided the lowest is not less than 85 percent of the specified.
5.5 PROPORTIONING CONCRETE
5.5.1 Ordinary concrete mix shall generally be specified by volume. Volume of ingredients shall be
worked out taking 50 kg. Of cement as 0.035 cum in volume. While measuring aggregates by
volume, shaking, ramming or hammering shall not be done. Allowance for bulking of damp
sand be made as IS: 2386 (Part-III).
5.5.2 Proportion of ingredients required for ordinary concrete containing one 50 kg bag of cement for
different grades of concrete is given below :-

Grade of concrete Mix by volume

M10 1:3:6
M15 1:2:4
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M20 1:1.5:3
M25 1:1:2
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5.6 WORKABILITY OF CONCRETE

Optimum quantity of water shall be mixed just to produce a design concrete of required
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workability. Workability shall be such that the concrete surrounds and properly grips all
reinforcement. The degree of consistency, which shall depend upon nature of work and
method of vibration of concrete, shall be determined by regular slump tests to be carried out by
the contractor at his cost. Usually for mass concrete in R.C.C. works where vibrations are used
the slumps shall be within 10 mm to 25 mm. The frequency of such tests and the natures of
slumps shall be maintained within the limits specified by the Engineer. The Engineer also
reserves the right to carry out slump tests independently at his own discretion.
5.7 CONTROLLED CONCRETE
5.7.1 The proportions of the ingredients shall be taken by weight from the stock piles collected at site
and already approved on the basis of preliminary tests. Care shall be taken that the supply of
properly graded aggregate of uniform quality is maintained till the completion of works except
where it can be shown to the satisfaction of the Engineer that the supply of properly graded
aggregate of uniform quality cannot be maintained till the completion of works. Grading of
aggregate shall be controlled by obtaining them in the right propositions as required. Grading
of coarse and fine aggregate shall be checked as frequently as possible and as determined by the
Engineer.
5.7.2 Cement shall have to be weighed from bulk stocks at site and not by bags, it shall be weighed
separately from the aggregates.
5.7.3 Water shall either be measured by volume in calibrated buckets or weighed. All necessary
equipment shall be maintained in a clean and serviceable condition. Their accuracy shall be
periodically checked.
5.7.4 To maintain the specified water cement ratio constant and at its correct value, moisture

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 contents in both fine and coarse aggregates shall be determined with reference to IS : 2386
(Part-III) and amount of mixing water shall then be adjusted suitably.
5. 8 MIXING CONCRETE
5. 8.1 All concrete shall be mixed at site in a drum type mechanical mixer in first class working
condition. Mixing shall be continued till materials are uniformly distributed and a uniform
colour of the entire mass is obtained and each individual particle of the coarse aggregate shows
complete coating of cement mortar. The mixing shall in no case be less than 2 minutes after all
the ingredients have been put into the mixer.
5. 8.2 Mixer which has been out of use for more than 30 minutes shall be thoroughly cleaned before
putting in a new batch. Mixing plant shall be thoroughly cleaned before and after use. A
standby mixing plant equivalent to that in use, shall be provided and maintained ready for
immediate use during any break down.
5.9 FORM WORK
5.9.1 The term form work includes all temporary or permanent form essential for forming the
concrete, together with all temporary construction props, bracings required for the support. In
general the erection and removal of form work shall be in accordance with the provision given
under clause 9.2 of I.R.S. Concrete Bridge Code (April, 1982 edition).
5.9.2 CONSTRUCTION & PREPARATION OF FORM WORK FOR BRIDGES
5.9.2.1 Forms for concrete shall be made of either metal or timber suitably lined and of substantial and
rigid construction true to shape, alignment and dimensions as shown on the approved
drawings.
5.9.2.2 Forms shall be mortar tight and shall be made sufficiently rigid by the use of ties and bracings
to prevent any displacement, deflection or movement of any kind. They shall be strong enough
to withstand of the construction, all pressure, ramming and vibration, movement of persons,
materials and plant during and after placing the concrete. Special measures shall be taken to
ensure that the form work does not hinder the shrinkage of concrete because without this
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cracking could occur before the form work is removed.
5.9.2.2.1 When the forms are ready for commencing concreting, the contractor shall inform the Engineer
or his representative to inspect and accept the forms as to their strength, alignment and general
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fitness. Being satisfied with the form work Engineer then may allow the contractor for puring
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concrete but such inspection and permission shall not relieve the contractor of his
responsibility for safety of men, machinery, materials and for results obtained.
5.9.3 REMOVAL OF FORM WORK
5.9.3.1 The consent of Engineer or his representative shall be obtained in all cases before removing any
form work but such permission shall not relieve the contractor of his responsibility in respect of
any injury or damage to the concrete work arising from the removal of the forms.
5.9.3.2 Forms shall be so constructed and fitted as to be removable in sections in the desired sequence
without damaging the surface of concrete or disturbing other sections.
5.9.3.3 Due consideration ;shall be given to the local conditions, character of structure, the weather,
climate and temperature and other conditions that influence the setting of concrete before
removal of form work.
5.9.3.4 Where internal metal ties are permitted, they shall be extracted or cut without causing any
damage to concrete and remaining holes filled with mortar. No permanently embedded metal
part shall have less than 25 mm clear cover to the finished concrete surface. The contractor
shall make good, at his own expense, any injury or damage to the concrete work arising from
removal and striking of forms and supports.
5.9.3.5 The form works shall be cleaned and made good to the satisfaction of the Engineer before
reuse. The cost of all form work shall be deemed to have been included in the rate for cement
concrete items of work and shall not be paid separately.
5.10 TRANSPORT, PLACING AND COMPACTION OF CONCRETE
5.10.1 The method of transporting and placing concrete shall be approved by the Engineer or his
representative. All concrete shall be so transported and placed that no contamination
segregation or losses of its constituent materials take place.

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5.10.2 All form work and reinforcement, contained in it shall be cleaned and made free from standing water,
dust, snow or ice immediately before placing of concrete. No concrete shall be placed in any part of the
structure until the approval of the Engineer or his representative has been obtained. Concrete shall be
compacted in its final position within 30 minutes of its discharges from the mixer. Concrete when
deposited shall have a temperature of not less than 4.5 degree C and not more than 38 degree C.
5.10.3 Except when otherwise agreed to by the Engineer or his representative, concrete shall be
deposited in horizontal layers to a compacted thickness of not more than 450 mm when
internal vibrators are used and not exceeding 300 mm in all other cases. In no case concrete
shall be allowed to be dropped from a height of more than 2 meters.
5.10.4 When concrete is conveyed by chutes the plant shall be of such size and design so as to ensure
practically continuous flow. Slope of the chute shall be so adjusted that the concrete flows
without the use of excessive quantity of water and without segregation of its ingredients. The
delivery end of chute shall be as close as possible to the point of deposit. The chute shall be
thoroughly flushed with water before and after each working period and the water used for this
purpose shall be discharged outside the form work.
5.10.5 All concrete shall be compacted to produce a dense homogeneous mass with the help of
vibrators except in case of concrete poured under water, where vibrator cannot be used. To
ensure thorough and properly compacted concrete the contractor shall carry out a necessary
compacting factor tests at his own cost at such frequency and the value of compacting factor to
be maintained as decided by the Engineer. The contractor shall have to carry out other tests
like Penetrometer and Vee Bee Consist meter tests or any other tests as directed by the
Engineer at his own cost. The Engineer, however, reserves the right to carry out such tests,
independently at his own discretion. Sufficient vibrators in serviceable condition shall be kept
at site so that spare equipment is always available in the event of break-downs. Internal
vibrators shall be capable of producing not less than 10,000 cycles per minute, and external or
form vibrator not less than 3,000 cycles per minute. Vibration shall not be applied through
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reinforcement, and where vibrator of the immersion type are used, contact with reinforcement
and all inserts shall be avoided as far as practicable.
5.11 CONCRETING UNDER WATER
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5.11.1 The methods, equipment, materials and proportions of the mix to be used shall be got approved
by the Engineer or his representative before concreting under water. Greatest care shall be
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taken to prevent the cement being washed out and the concrete shall be deposited by means of
a tremis or using the skip boxes system. Pumping shall not be done while concrete is being
placed or until 24 hours thereafter.
5.11.2 The deposition of concrete should be done continuously until it has been brought to the
required height. The top surface shall always be kept as nearly level as possible to prevent
formation of scum.
5.12 FINISHING
5.12.1 Immediately after the removal of forms, all exposed bars or bolts passing through RCC member and used
for shuttering or any other purpose shall be cut inside the RCC member to a depth of atleast 25 mm
below the surface of the concrete and resulting holes be closed by cement mortar.
5.12.2 If in the opinion of the Engineer, the pockets/honey comb in the structure are found to such an
extent or character as to affect the strength of the structure materially or endanger the life of
the reinforcement, he may declare such concrete defective and order for its removal and
replacement at the expense of the contractor.
5.13 CURING

5.13.1 All concrete shall be protected immediately after compaction and during hardening from
harmful effects of rain, funning water, sunshine, frost and driving winds, shocks, vibrations,
traffic and rapid temperature changes. All exposed faces of concrete shall be kept continuously
wet by applying water or covering with wet sacking, hessian etc. for a period of not less than 14
days from the date of deposition.

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 5.14 CONSTRUCTION JOINTS

5.14.1 All construction joints horizontal or vertical shall be at predetermined position

according to approved drawing or as directed by the Engineer. Prior to commencement
of fresh concreting over any construction joint which has set but not hardened, the
removal of laitance and roughening shall be done by wire brushing and washing and
care shall be taken to avoid dislodgement of coarse aggregates.
5.14.2 At construction joints where the concrete has et hard, any skin or laitance shall be
thoroughly hacked, swept cleaned and washed with clean fresh water. The surplus
water shall be removed immediately before depositing fresh, concrete. The neat
cement, grout shall be followed by 13 mm thick layer of cement mortar of same
proportion as in concrete and the concreting resumed immediately thereafter. The first
batch of fresh concrete shall be forced hard on to the mortar layer and the set faces,
angles and corners by means of compacting tools, vibrators etc. and the damping effect
on vibration in such position shall be allowed for.
5.14.3 Construction joints shall be avoided as far as possible in case of structure, especially at
tensile zones. Where unavoidable, concreting shall be carried out continuously upto
such joints which shall preferably be transverse to the line of main compression.
However, in all cases, the position of construction joints shall be predetermined and got
approved by the Engineer.
5.15 REINFORCEMENTS

5.15.1 All reinforcement shall be cleaned thoroughly by removing loose scales, oil, grease or
other deleterious materials. The contractor shall obtain the approval of the Engineer or
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his representative to the reinforcement when fixed in position before any concrete is
deposited in the forms.
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5.15.2 Bars shall be bent cold or straightened in a manner to the satisfaction of the Engineer
or his representative. Bars bent during transport or handling shall be straightened
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before using on work. They shall not be heated to facilitate bending. Welding shall be
done as per IS Code of practice or IRS Concrete Bridge Code as applicable.
5.15.3 PLACING AND MAINTENANCE OF REINFORCEMENT IN POSITION

5.15.3.1 All reinforcement bars shall be cut and Standard hooks for M.S. rounds made at ends
and accurately placed in position as shown on the approved drawings and shall be
securely held in position before and during concreting by annealed binding wire (as
specified in Clause 4.1) and by using dense concrete spacer blocks prepared and cured
as directed by the Engineer or his representative, or metal chairs, metal spacers,
supporting wires or other approved device at sufficiently close intervals. Bars
representative, or metal chairs, metal spacers, supporting to get displaced during
concreting or any other operation over the work. Metal supports shall not extend to
the surface of the concrete, except where shown on the drawings, pieces of broken
stone or brick and wooden blocks shall not be used.
5.15.3.2 As far as possible, bars of full length shall be used. Where bars are required or
permitted to be lapped by the Engineer, or his representative, the over laps shall be
staggered for different bars and located at points, along the span where neither shear
nor is bending moment maximum. The concrete cover measured over the reinforcing
bars shall be in accordance with the approved drawings.

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 5.16 MEASUREMENT FOR PAYMENT

5.16.1 The work of cement concrete shall be measured in cubic meters. The volume occupied
by reinforcement shall not be deducted in R.C.C. works. The measurement shall also be
for the purpose of computing cement consumption. Reinforcement shall be measured
in length (running metre) separately for different diameters as actually used in work
including overlaps, hooks ends and inclusive of chairs, supports as actually placed and
incorporated in the work. Form the length so measured the weight the reinforcements
shall be calculated in quintals on the same basis on which steel is supplied to the
contractor by the Railway.
The weight of binding wire shall not be taken into account in computing the
reinforcement quantity. This measurement shall be only for the purpose of working out
reinforcement consumed in the work.
5.17 SETTING OF FIELD LABORATORY BY CONTRACTOR

5.17.1 The contractor shall set up a field laboratory of his own at work site as a part of
concrete work and shall be kept open for use and inspection by the Railway at any time.
5.17.2 All the pressure gauge and other machines, equipment and measuring instruments
shall be got checked and calibrated regularly as directed by the Engineer, by an
independent agency and the adjustment certificate furnished to the Engineer. The
contractor shall render all reasonable assistance and help in making such checks and
tests etc. The cost of all checks and calibrations shall be borne by the contractor. The
cost of all tests for materials and cubes shall also be borne by the contractor.
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Alternatively, the contractor shall arrange to get the cubes and their materials, as
required tested at his own cost, in approved laboratory to the satisfaction of the
Engineer.
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6.0 ABUTMENTS, PIERS AND R.C.C. BOXES

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6.1 The abutments, piers, pier caps are to be constructed of concrete grades as mentioned
in the approved drawing. The individual members are to be monolithic with the
parent member
6.2 WEEP HOLES

Sufficient Nos. of weep holes including provision of Asbestos pipes (in the weep hole
portion only) in abutments, wing and return walls is to be provided as shown in the
approved drawing or as directed by the Engineer with contractor’s own labour,
materials etc. No extra payments will be admissible for provision of the weep holes in
the bridges and no deduction from quantity of concrete shall be made for weep holes.

7.0 SLOPE PITCHING AND APRON

For pitching the slopes of banks, bridge floors, apron on bridge approaches, hand
packed rough stones weighing between 30 kg and 50 kg with not less than 150 mm size
shall be used in such a manner as to provide maximum interlocking amongst the
individual stones. The size to be adopted should suit the total thickness required as per
drawings. The work should be carried out as to provide uniform slopes and curvature
around abutments. The rates also include provision of steps shown in plan and
pitching work under water wherever required.

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8.0 PACKING BEHIND ABUTMENT

Boulders to be used behind abutment, wing and return walls, shall be collected from
approved quality of stone to angular shape and shall not be less than 150 mm size in any
direction and shall have its maximum dimension not less than 250 mm and shall weigh
not less than 12 kg and not more than 55 kgs. The hand packing should be done in
sections as shown in the drawing or as directed by the Engineer.
9.0 R.C.C. HUME PIPE (Heavy Duty)
9.1 Relevant item of the schedule of items and approximate quantities include supply at the
contractor’s cost of reinforced concrete pipes as per RDSO’s Drawing No.RDSO/B-16-09-RI and
shall be in accordance with specifications mentioned below. Cost should include the cost of
reinforcement steel and cement.
9.1.1 The pipes will be of flush joint, design as shown in above stated plan.

9.2 The rates shall include all charges to be incurred in supplying, loading at the
manufacturer’s premises and transporting upto the site of work, all cost of materials
and labour incidental to loading, unloading, handling etc. together with the cost of
transport, handling at the site of work placement in position aligning and joining the
pipes with cement mortar of (1:2) proportion, curing etc. complete. Cement as per
requirement for joining pipes also will be supplied by the contractor unless otherwise
specified.
9.3 The contractor will have to advise Railway of the source of the supply of the R.C.C.
pipes including the name of the manufacturer and location of the manufacturer’s
premises.
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9.4 METHOD OF MANUFACTURE

The methods of manufacture of R.C.C. pipes will be such so as to conform to the

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dimensions, specifications etc. as stated in the RDSO’s plan. In addition the

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specification as per IS: 458 – 1971 shall be the guiding factor for manufacture of the
pipes. Where there is any discrepancy between the two, the specification mentioned in
drawing will prevail.
9.5 During manufacture, tests on concrete shall be carried out as detailed in IS : 456 – 2000
and the contractor will furnish results of compressive tests of concrete cylinders or
cubes made from the concrete used for the pipes duly certified by the manufacturer,
concrete shall be mixed in a mechanical mixer.
9.6 The following information shall be clearly marked in each pipe by the manufacturer :-
i) Drawing No.
ii) Date of manufacture and
iii) Name of the manufacturer or his registered trade mark, if any or both.
9.7 Sampling, inspection and testing of pipes shall be at the cost of contractor in
accordance with the provision in IS: 458 – 1971 and IS: 3597 – 1985 at the manufacturer’s
premises before these are dispatched to the site. Further inspection of all pipes will be
carried out at the site of work before being placed in position.
9. 8 If the Railway desires, edge bearing test is to be conducted by the manufacturer on
samples selected as per IS: 458 -–1974 and is to be carried out as per IS: 3597 – 1985 and
the test results supplied. Cost of such tests is to be borne by the contractor.

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9.9 The reinforcement provided in the hume pipe as per drawing, can be checked and
approved by the Railway’s representative before concreting is done. The contractor
shall obtain from the manufacturer and submit to the Railway a certificate indicating
the details relating to quantity, quality and dispersion of steel in the pipes.
9.10 Subsequent to the initial inspection of the pipes at the manufacturer’s premises,
damages caused to the pipes in the course of handling and transporting of pipes to the
site of work will make the pipes liable to be rejected. The decision of the Engineer in
this regard shall be final and binding.
10.0 Laying of the pipes will conform to the provision of IS: 783 – 1985 or as shown in the
approved general arrangement drawing.
11.0 Specifications , shall be in accordance with Indian Railway Unified Standard Specification
Volume-I & II 2010 edition corrected up- to-date and the contractor shall be bound by them for
the performance of the contract.
12.0 RDSO's Guidelines and specification for Design of formation for Heavy Axel load GE-0014 of
November 2009 shall be followed and contractor shall be bound by the RDSO's guideling GE-0014
of November 2009 including the correction slips issued time to time.

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 Special Specification for blanketing:-
1 GENERAL
1.1 These specifications shall apply to the works as are required to be executed under the
contract or otherwise directed by the Engineer. In every case the work shall be carried
out to the satisfaction of the Engineer and shall conform to grades and cross sections
shown on the drawings or as indicated by the Engineer. The quality of the work and
materials shall comply with the requirements set forth in the succeeding sections.
Where the drawings and specifications describe of portion of the work only general
terms and not in complete details. It shall be understood that only the best general
practice is to prevail. Materials and workmanship of the best quality are to be employed
and that the instructions of the Engineer are to be fully complied with and shall be
binding on the contractor. The contractor shall be fully responsible to ensure that the
finished works are free from any defects, weakness, cracks etc.

1.2 CODES OF PRACTICE AND SPECIFICATIONS :

The abbreviations mentioned elsewhere for standard specifications and code of practices shall
be considered to have the following meaning.
IS : Indian Standard of the Indian Standards Institution.
IRS : Indian Railway Standard Specifications and Code of Practices.
GCC : N.F. Railway General & Standard Special Conditions of Contract
2013 & Standard specifications – 2013.
IRC : Indian Roads Congress.
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RDSO : Research, Designs and Standards Organisations (Ministry of Railways).
1.2.1 Wherever a reference is made to any of the standard specifications and code of practice it shall
be taken as a reference to the latest versions/revision of the same and shall include all the
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ERRATA/corrections made in the same from time to time.

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1.3 MEASUREMENT
1.3.1 All measurement shall be made in the metric system. Different items of works shall be
measured in accordance with the procedures set forth in the relevant sections read in
conjunction with GCC and special conditions of the contract.
1.3.2 All measurements and computation, unless otherwise indicated shall be carried nearest
to the following limits.
(i) Length and breadth 10mm.
(ii) Height depth or thickness 5mm
(iii) Area 0.01 Sqm.
(iv) Cubic contents 0.01 Cum.
1.4 Site clearance wherever involved shall be undertaken and the same shall be considered
incidental to the Blanketing works and rates for the same shall be deemed to be
inclusive of all clearing operations.
1.5 RDSO’s “GUIDELINES GE-0014 of NOVEMBER-2009, including latest correction slips
to it shall form the basis of principles for conducting all testing, supply and
compaction of Blanketing materials on embankments.
1.6 While selecting a sample for bulk supply the Railway shall consider that the rate offered
by the contractor is for the supply mixing/ blending, laying, watering, compaction as
per specification and finishing of blanket including all taxes, any lead and lifts etc.

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2.0 BLANKETING
2.1 The chainages mentioned in the tender documents are field chainages are meant for
guidance only. For the purpose of payment actual lengths will be measured on ground
2.2 Standard section for blanketing on formation for single line is given in RDSO’s guide
lines. This section is for guidance of contractor to assess the type of work involved but the
actual dimensions, side slopes etc. may vary to some extent depending on local
conditions.
2.3 The Railway will hand over the site of work to the contractor for laying the blanketing
material on the embankment in stages of about 500 mts. long stretch at a time for the
blanketing works. Next 500 mts. stretch will be handed over after satisfactory completion
of the 1st layer of blanket in the 1st stretch. After completion of blanketing about 1 km
length in full height work in the next stretch will be allowed. However, Railway will
handed over the embankment of last 500 mts stretch for blanketing 1(one) month before
the completion period of the contract.
2.4 It shall be the responsibility of contractor to ensure that no work on the embankment
commence until the existing formation levels (with earth) at different cross sections have
been recorded and such records of levels have been jointly signed and dated by the
contractor and the Engineer or his authorized representative. Cross section profiles
plotted on the basis of the recorded formation levels shall also be jointly signed by the
contractors and the Engineer. The points at which the cross sectional levels are to be
recorded and the extent of leveling work to be done shall be decided by the Engineer. The
contractor may bring to the notice of the Engineer such additional cross sections that in
his opinion should be taken for proper assessment of quantities. Such representation,
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however, should be made before the commencement of any blanketing work. The
Engineer’s decision thereon shall however, be final and binding on the contractor.
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2.5 Contractor shall sign every page of the level book and cross section sheet where original
ground and final level of completed work are recorded in token of his acceptance of these
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levels and cross sections for the purpose of computation of quantities of payments. No
dispute whatsoever shall be entertained on this account.
2.6 Contractor shall clear all grass shrubs or jungles on the existing ground /top of
embankment for which payment will not be made separately and the rate of blanketing
work includes such works. The top surface of the formation shall not be damaged by the
contractor in the process of blending/ placing the materials of blanketing on the
foundation. Any damage done to the formation shall be made good (including necessary
compaction) by the contractor at his own cost.
2.7 MEASUREMENT
Measurement of blanket material should be done in accordance with Para 1.10.11 Chapter-I of Indian
Railway Unified Standard Specification Volume-I & II 2010 edition.

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2.80. RECOMMENDED SPECIFICATIONS OF BLANKET MATERIAL (Mandatory)
2.81 Specifications of the material for blanket layer over prepared sub-grade should
be such that it is well-graded sandy gravel layer of adequate hardness. Particles
size gradation curve should be more or less within Enveloping Curves of blanket
material as shown in Fig. 9 below & Grading Percentages within the range given
in Table-5 below and should also have following criteria satisfied :
i) Cu > 7 and Cc between 1 and 3.
ii) Fines (passing 75 microns) : 3% to 10%.
iii) Los Angeles Abrasion value < 35%.
iv) Minimum required Soaked CBR value 25 of the blanket material
compacted at 100% of MDD
In exceptional cases on technical and economic considerations, LAA value may
be relaxed upto 40% by Pr CE on Open Line & CAO/C in construction projects.
v) Filter Criteria should be satisfied with prepared subgrade/subgrade layer just
below blanket layer, as given below :
Criteria–1: D15 (blanket) < 5 x D85 (sub-grade)
Criteria–2: D15(blanket) > 4 to5 D15 (sub-grade)
Criteria–3: D50(blanket) < 25 x D50 (sub-grade)
2.82 Filter Criteria is optional, at present. This can be adopted with the experienced
gained of its compliance for different types of soils with blanket.
AL
N
FI

191
 FI
N

192
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3.0 QUALIFYING AND QUALITY ASSURANCE TESTS (Mandatory)
Qualifying tests as part of pre-selection of good earth for track subgrade,
embankment fill is required to be carried out.
Also, quality of compaction is required to be done to ensure good quality
construction.

i) Selection of soil: For selection of soil to be used as embankment fill CBR

test is required to be conducted on material. CBR test is conducted on ground
soil, embankment fill, prepared sub-grade & blanket material to ensure the
minimum specified CBR value of these materials to be used in construction.
This test is carried out on soil sample in laboratory as per procedure given in
IS:2720 (Part 16)-1987 & in field as per IS:2720 (Part 31)– 1969.

ii) Quality Assurance Test on Compacted Layer : Quality Assurance Tests

are required to be conducted on part completion stages of formation, prior to
clearing for further earthwork, track linking work:
Heavy Proctor test is required to be conducted to determine the Maximum
Dry Density of soil as per IS: 2720 (part 8). In-situ density is measured in the
field by Sand Replacement Method (IS: 2720 – part 28) or Core Cutter Method
(IS: 2720 – part 29) to calculate the degree of compaction. this shall be
determined in laboratory as per BIS procedure with the specified frequency of
earthwork quantity, as envisaged in ‘Guidelines of Earthwork in Railway
Projects, GE:G-1, July 2003.

Second Step Plate Load Test (Optional) is required to be conducted in-situ

for measurement of Deformation Modulus EV2 of compacted layers of
embankment, blanket, prepared subgrade etc. The test procedure has been
detailed in German Code DIN:18134- 2001,’Determining Deformation &
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Strength Characteristics Of Soil By Plate Loading Test”. The minimum value of
EV2 should be ensured at different levels as specified.
Brief procedure of these above tests has been given in Annexure-2.
N

3.1 Frequency of Quality Assurance Tests

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a) CBR test for selection of formation materials and other tests required for
ensuring conformation of the materials (blanket, subgrade) as per
specification e.g. size gradation, Cu, Cc, Los Angles Tests, OMC/MDD etc.
shall be conducted at following frequency :

i) Embankment Fill : one set of tests for every 5000 cum

ii) Prepared subgrade : one set of tests for every 2000 cum
iii) Blanket material : one set of tests for every 500 cum

b) In-situ Degree of Compaction (or In-situ dry density measurement) test shall
be conducted on each compacted layers in random pattern at following
frequency for the different layers :
i) Embankment Fill : one density measurement at every 500 sqm surface
area of each compacted layers
ii) Blanket and Prepared Subgrade : one density measurement at every 200
sqm surface area of each compacted layers.

c) Second step Plate Load Test : This test is in practice in German Railways
and recommended by UIC Code 719 to measure the quality of earthwork and
blanketing after compaction. For Indian Railways, this test is made optional
presently. In the guidelines, this test has been included as a future
development for quality assurance test on compacted surface. This should be
done for EV2 measurement at top of each formation layers eg. at sub-soil,
compacted subgrade, prepared subgrade, blanket etc. at the frequency of one
test per km length of section.

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4.0 SPECIFICATIONS & RECOMMENDATIONS : ( M a n d a t o r y)

4.1 The following Specifications for two different systems for blanket, subgrade,
embankment fill are mandatory provisions to be adopted, as follows:
i) Conventional blanket layer over formation subgrade
ii) Blanket layer over prepared subgrade layer (good/imported soil)

Any of the two system may be considered for adoption in the field based on
good soil availability and material cost economics. These are given in form of
following:
a) Table 6 (Specification and thickness of subgrade layers for Heavier Axle
Loads),
b) Formation cross-sections (Fig. 10 – Formation Profiles and Layers for Heavy
Axle Load), and

c) Bar Diagrams (Fig. 11 – Formation Layer Thickness).

4.2 In order to design & construction of stable formation for heavy axle load, EV2
should be determined in the field as per procedure given in German Code DIN :
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18134 at ground. Undrained shear strength, Cu of ground soil from Unconfined
Compression (UCC) test or Vane Shear Test and Penetration Number (N –
Value) from Standard Penetration Test should also be determined. If EV2 value
N

is less than 20 MPa or Sub-soil strata having (Cu) < 25 KPa (mostly in Marshy
area) or N-value < 5 will also require ground improvement.
FI

4.3 If, naturally available materials do not meet the desired specifications,
blanket material can be produced by mechanical process from crushing
or blending method or combination of these two methods. Details of these two
methods are given in Appendix – C. Naturally available sand, quarry dust or
crusher run, if available at low cost, can be used as prepared subgrade also.

194
Table 6 - Specification and thickness of subgrade layers for Heavier Axle Loads
1. Single Blanket Layer over Embankment Fill- Specification and Layer Thickness

Layers Specification Axle Load 25T Axle Load 30 T Axle Load 32.5T

i) Cu > 7 and Cc between 1 and 3.

Blanket – Well Graded 60 cm for SQ3, 75 cm for SQ3, 80 cm for SQ3,
ii)Fines (passing 75 microns) :3% to 10%
Sand Gravel Layer
iii) Los Angeles Abrasion value < 40% 75 cm for SQ2 80 cm for SQ2 100 cm for SQ2
(iv) Minimum CBR value 25 of the blanket material
100 cm for SQ1 ( SQ1 only
compacted at 100% of MDD
with dispensation of PCE/
CAO) SQ2/SQ3 are preferred SQ2/SQ3 are preferred
(v) Size gradation within specified range or
soil below blanket. soil below blanket.
enveloping curves.
SQ2/SQ3 are preferred soil
below blanket. Blanket Compacted upto Blanket Compacted upto
(vi) Filter Criteria should be satisfied with subgrade
100% MDD 100% MDD
layer, as given below :
Blanket Compacted upto 98
Criteria–1: D15 (blanket) < 5 x D85 (sub-grade) % MDD
Criteria–2: D15(blanket) >4to5 D15 (sub-grade)
Criteria–3: D50(blanket) < 25 x D50 (sub-grade)
For new line construction, For new line construction,

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Minimum EV2 – determined from 2nd step Plate Load
Test on top of compacted blanket layer (Ref : Min. EV2 – 100 MPa Min. EV2 – 120 MPa Min. EV2 – 120 MPa
German Code : DIN 18134 – 2001) As in-situ Assurance Test As in-situ Assurance Test

N
Embankment Fill CBR= 7 - 5 (of compacted soil at 98% of MDD) T = 50 cm T = 75 cm T = 75 cm
Top Layer of
Thickness (T)

Minimum EV2 = 45 MPa

FI
(Organic soils to be avoided) ( SQ1 to be avoided) SQ2/SQ3 soils
CBR > = 6 generally, but
not < 5 in isolated cases
SQ2/SQ3 soils
CBR > = 6 generally, but
not <5 in isolated cases
SQ2/SQ3 soils
CBR > = 7 generally, but
not < 6 in isolated cases
(For SQ1 soil, CBR > = 4
generally, but not < 3 in
Compacted upto 98% of
Compaction : top 1 m. & for Lower Fill
MDD
Layers CBR > = 3) Compacted upto 98% of MDD
Compacted upto 97% of MDD

Ground Soil/Sub-soil Minimum Undrained Cohesion of soil, Cu = 25 KPa or Min. Ev2 = 20 MPa Min. Ev2 = 20 MPa Min. Ev2 = 20 MPa
Strata Minimum Ev2 = 20 MPa
Ground Improvement is required, if Cu < 25 kPa or
Ev2 < 20 MPa

Note : 1. SQ1 (fines > 50%), SQ2 (fines : 12 to 50 %), SQ3 ( fines <12%)
2. For axle load 25 T and higher, blanket & Embankment fill thickness can be reduced with determination of soil strength parameters CBR & Threshold
stress determined based on repeated Triaxial tests.
3. Uniform total thickness of formation layers of 2 m should be provided including blanket, top layer of embankment fill etc.

195
 2. Two Layer System (Blanket & Prepared Subgrade on Embankment Fill)

Layers Specification Axle Load 25T Axle Load 30 T Axle Load 32.5T

Blanket – Well Graded i) Cu > 7 and Cc between 1 and 3. 30 cm for SQ3, 45 cm for SQ3, 45 cm for SQ3,
Sand Gravel Layer ii)Fines (passing 75 microns) :3% to 10% 45 cm for SQ2 60 cm for SQ2 60 cm for SQ2
iii) Los Angeles Abrasion value < 40%
(iv) Minimum CBR value 25 of the blanket material SQ2/SQ3 are soil SQ2/SQ3 are soil SQ2/SQ3 are soil below
compacted at 100% of MDD below blanket. below blanket. blanket.
(v) Size gradation – within specified range or Compacted upto Compacted upto 100% Compacted upto 100% MDD
enveloping curves 100% MDD MDD
(vi) Filter Criteria should be satisfied with subgrade
layer, as given below :
For new line construction, For new line construction,
Criteria–1: D15 (blanket) < 5 x D85 (sub-grade) Min. EV2 – 100 MPa Min. EV2 – 120 MPa Min. EV2 – 120 MPa
Criteria–2: D15(blanket) >4to5 D15 (sub-grade)
As in-situ Assurance test As in-situ Assurance Test
Criteria–3: D50(blanket) < 25 x D50 (sub-grade)
Minimum EV2 - determined from 2nd step Plate Load Test
on top of compacted blanket layer (Ref : German Code
: DIN 18134 – 2001)

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Layer 1 : Prepared CBR >= 6 - 8 (of compacted soil upto 97%) 100 cm 100 cm 100 cm
Subgrade SQ2/SQ3 & Limit fines 12 – 50% ( SQ1 to be avoided) CBR > = 7 generally, CBR > = 7 generally, CBR > = 8 generally, but not
(Good/Imported Soil) Plasticity Index < = 12 but not < 6 in but not < 6 in isolated < 7 in isolated cases

N
isolated cases cases
Compaction : 98% MDD
98% MDD 98% MDD
Minimum EV2 : 60 MPa

Embankment Fill
(Organic soils to be avoided)
FI
CBR > = 4 – 5 (of compacted soil upto 97%)
45 MPa

CBR > = 5 generally,

but not < 4 in
60 MPa
CBR > = 5 generally,
but not < 4 in isolated
CBR > = 5 generally, but not
< 4 in isolated
isolated cases cases cases
(For SQ1 soil, CBR > = 30 MPa 30 MPa
3 generally, but not < 97% MDD 97% MDD
2 in isolated cases)
Minimum EV2 : 30 MPa
Compaction : 97% MDD
Ground Soil/Sub-soil Minimum Undrained Cohesion of soil, Cu = 25 KPa or Min. Ev2 = 20 MPa Min. Ev2 = 20 MPa Min. Ev2 = 20 MPa
Strata Minimum EV2 = 20 MPa
Ground Improvement is required, if Cu < 25 kPa, or
Ev2 < 20 MPa
Total Thickness (Blanket + - 130-145 cm 145-160 cm 145 – 160 cm
Layer 1)

Note : Uniform total thickness of formation layers of 2 m should be provided including blanket, prepared subgrade & top layer of embankment fill etc.

196
Fig 10. Formation Profiles and Layers for Heavy Axle Load

Single Layer System (Blanket on Embankment Fill)

CL of Track
8.50m (Presently 6.85 m on IR)
1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
V 35cm Ballast Cushion
:1 Top of Formation
Layer Values 2H
Blanket Thickness - 60 cm for SQ3,
Blanket Min. CBR 25 1 : 30 1 : 30 75 cm for SQ2, 100 cm for SQ1 soil below
(Specification as per Compaction - 98% of MDD
Min Ev2 100 MPa e = 1.1-1.25 m
RDSO Guidelines) (SQ1/SQ2/SQ3 soil of Min. 50 cm Top Layer of Embankment Fill
CBR 5 - 6, (3-4 for SQ1))
Embankment Fill CBR 6 Generally but not < 5
in isolated cases 2H
(Top Layer) (For SQ1 soil, CBR  4 1 : 30 1 : 30
Min. 1 m :1
generally, but not < 3 in Embankment Fill V H.F.L.
top 1m. & for Lower Fill (SQ1/SQ2/SQ3 Category Soils)
Layers CBR 3)
Compaction - 97% of MDD G. L.
Min. Ev2 45 MPa
Ground/Sub-soil Min. Ev2 = 20 MPa
Ground Treatment Required Natural Ground/Subsoil Soils Fines (<75 micron)
Strata if Ev2 < 20 MPa SQ 1 Fines >50%
Proposed Track Formation For Heavy Axle Load - 25T SQ 2 12% to 50%
SQ 3 <12%

CL of Track
8.50m (Presently 6.85 m on IR)
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1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
V 35cm Ballast Cushion
:1 Top of Formation
Layer Values 2H
Blanket Thickness - 75 cm for SQ3,
N

Blanket Min. CBR 25 1 : 30 1 : 30 80 cm for SQ2 soil below

(Specification as per Compaction - 100% of MDD e = 1.5-1.55 m
RDSO Guidelines) Min Ev2 120 MPa 75 cm Top Layer of Embankment Fill
FI

(SQ2/SQ3 soil)
CBR 6 Generally but not < 5
Embankment Fill
in isolated cases
(Top Layer) 1 : 30 1 : 30 2H
Compaction - 98% of MDD Min. 1 m :1
Min. Ev2 45 MPa Embankment Fill V H.F.L.
Ground/Sub-soil Min. Ev2 = 20 MPa (SQ1/SQ2/SQ3 Category Soils, Min. CBR 2-3)
Strata
Ground Treatment Required G. L.
if Ev2 < 20 MPa

Natural Ground/Subsoil Soils Fines (<75 micron)

SQ 1 Fines >50%
Proposed Track Formation For Heavy Axle Load - 30T SQ 2 12% to 50%
SQ 3 <12%

CL of Track
8.50m (Presently 6.85 m on IR)
1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
V 35cm Ballast Cushion
:1 Top of Formation
Layer Values 2H
Blanket Thickness - 80 cm for SQ3,
Blanket Min. CBR 25 1 : 30 1 : 30 100 cm for SQ2 soil below
(Specification as per Compaction - 100% of MDD
Min Ev2 120 MPa e = 1.55-1.75 m
RDSO Guidelines) 75 cm Top Layer of Embankment Fill
(SQ2/SQ3 soil)
CBR 7 Generally but not < 6
Embankment Fill
in isolated cases
(Top Layer) 1 : 30 1 : 30 2H
Compaction - 98% of MDD Min. 1 m :1
Min. Ev2 45 MPa Embankment Fill V H.F.L.
Ground/Sub-soil Min. Ev2 = 20 MPa (SQ1/SQ2/SQ3 Category Soils, Min. CBR 2-3)
Strata
Ground Treatment Required G. L.
if Ev2 < 20 MPa

Natural Ground/Subsoil Soils Fines (<75 micron)

SQ 1 Fines >50%
Proposed Track Formation For Heavy Axle Load - 32.5T SQ 2 12% to 50%
SQ 3 <12%

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Two Layer System (Blanket + Prepared Subgrade on Embankment Fill)

CL of Track
8.50m (Presently 6.85 m on IR)
1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
Layer Values V 35cm Ballast Cushion
:1 Top of Formation
Blanket Min. CBR 25 2H
Blanket Thickness - 30 cm for SQ3,
(Specification as per Compaction - 100% of MDD
Min Ev2 100 MPa 1 : 30 1 : 30 45 cm for SQ2 soil below
RDSO Guidelines)
e = 1.3-1.45 m
Prepared Subgrade CBR 7 Generally but not < 6 (SQ2/SQ3 soil) 100 cm Prepared Subgrade
(Good/Imported in isolated cases Min. Ev2 = 45 MPa
Compaction - 98% of MDD
soil)
Min. Ev2 45 MPa 1 : 30 1 : 30 2H
Min. 1 m : 1V
Embankment Fill CBR 5 Generally but not < 4 Embankment Fill H.F.L.
in isolated cases (SQ1/SQ2/SQ3 Category Soils)
(For SQ1 soil, CBR > = 3
generally, but not < 2 in G. L.
isolated cases)
Compaction - 97% of MDD
Min. Ev2 30 MPa Natural Ground/Subsoil Soils Fines (<75 micron)

Ground/Sub-soil Min. Ev2 = 20 MPa SQ 1 Fines >50%

Ground Treatment Required
Strata if Ev2 < 20 MPa SQ 2 12% to 50%
SQ 3 <12%
Proposed Track Formation For Heavy Axle Load - 25T

CL of Track
8.50m (Presently 6.85 m on IR)
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1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
Layer Values V 35cm Ballast Cushion
:1 Top of Formation
Blanket Min. CBR 25 2H
Blanket Thickness - 45 cm for SQ3,
(Specification as per Compaction - 100% of MDD
N

Min Ev2 120 MPa 1 : 30 1 : 30 60 cm for SQ2 soil below

RDSO Guidelines)
e = 1.45-1.6 m
Prepared Subgrade CBR 7 Generally but not < 6 (SQ2/SQ3 soil) 100 cm Prepared Subgrade
(Good/Imported in isolated cases Min. Ev2 = 60 MPa
FI

Compaction - 98% of MDD

soil)
Min. Ev2 60 MPa 1 : 30 1 : 30 2H
Min. 1 m : 1V
Embankment Fill CBR 5 Generally but not < 4 Embankment Fill H.F.L.
in isolated cases (SQ1/SQ2/SQ3 Category Soils)
(For SQ1 soil, CBR > = 3
generally, but not < 2 in G. L.
isolated cases)
Compaction - 97% of MDD
Min. Ev2 30 MPa Natural Ground/Subsoil Soils Fines (<75 micron)
Ground/Sub-soil Min. Ev2 = 20 MPa SQ 1 Fines >50%
Ground Treatment Required
Strata if Ev2 < 20 MPa SQ 2 12% to 50%
SQ 3 <12%
Proposed Track Formation For Heavy Axle Load - 30T

CL of Track
8.50m (Presently 6.85 m on IR)
1.20m 0.35m 0.35m 1.20m
1.325m 2.75m 1.325m
Layer Values V 35cm Ballast Cushion
:1 Top of Formation
Blanket Min. CBR 25 2H
Blanket Thickness - 45 cm for SQ3,
(Specification as per Compaction - 100% of MDD
Min Ev2 120 MPa 1 : 30 1 : 30 60 cm for SQ2 soil below
RDSO Guidelines)
e = 1.45-1.6 m
Prepared Subgrade CBR 8 Generally but not < 7 (SQ2/SQ3 soil) 100 cm Prepared Subgrade
(Good/Imported in isolated cases Min. Ev2 = 60 MPa
Compaction - 98% of MDD
soil)
Min. Ev2 60 MPa 1 : 30 1 : 30 2H
Min. 1 m :1
Embankment Fill CBR 5 Generally but not < 4 Embankment Fill V H.F.L.
in isolated cases
(For SQ1 soil, CBR > = 3
(SQ1/SQ2/SQ3 Category Soils)
generally, but not < 2 in G. L.
isolated cases)
Compaction - 97% of MDD
Min. Ev2 30 MPa
Natural Ground/Subsoil Soils Fines (<75 micron)
Ground/Sub-soil Min. Ev2 = 20 MPa
Ground Treatment Required
SQ 1 Fines >50%
Strata if Ev2 < 20 MPa SQ 2 12% to 50%
Proposed Track Formation For Heavy Axle Load - 32.5T SQ 3 <12%

198
Fig 11. – Bar Diagrams Showing Formation Layers Thickness

Single Layer System

Soils Fines (<75 micron)

Blanket (Min. CBR – 25) SQ 1 Fines >50%
SQ 2 12% to 50%
Embankment Fill (Top Layer)
SQ 3 <12%

200

180
AL
140
100
Thickness (cm)

120 80 75 80
FI

100 100
75
80 60

60

40 75 75 75 75
50 50 50
20

0
Soil Type Below Blanket SQ1* SQ2 SQ3 SQ2 SQ3 SQ2 SQ3
Min. CBR of Top Layer CBR  6 generally but CBR  6 generally but CBR  7 generally but
of Embankment Fill not < 5 in isolated cases not < 5 in isolated cases not < 6 in isolated cases

25 T 30 T 32.5 T
* (For SQ1 soil, CBR > = 4 generally, Axle Load
but not < 3 in top 1 m. & for Lower
Fill Layers CBR > = 3)

199
 Two Layer System
(Blanket + Prepared Subgrade on Embankment Fill)

Soils Fines (<75 micron)

Blanket (Min. CBR – 25) SQ 1 Fines >50%
Prepared Subgrade (of SQ2/SQ3 Soil) SQ 2 12% to 50%
SQ 3 <12%

200

180

160

140
60 60
45 45 45
Thickness (cm)

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120 30

100
N

80
FI

60
100 100 100 100
40 100 100

20

0
Soil Type Below Blanket SQ2 SQ3 SQ2 SQ3 SQ2 SQ3
Min. CBR of Prepared CBR  7 generally but CBR  7 generally but CBR  8 generally but
Subgrade not < 6 in isolated cases not < 6 in isolated cases not < 7 in isolated cases

25 T 30 T 32.5 T
Axle Load

200
 Annexure-2

QUALITY ASSURANCE TESTS

1. Standard Test Procedure For California Bearing Ratio (Laboratory Method)

(Ref: BIS Code – IS : 2720 (part 16) – 1979 Laboratory Determination of CBR)

California Bearing Ratio

California Bearing Ratio (CBR) test is a penetration test developed by the California State
Highway Department of USA for the evaluation of subgrade strengths for roads and
pavements.
California Bearing Ratio (CBR) is defined as the Ratio of Force per unit Area required to
penetrate a soil mass with a circular plunger of 50 mm diameter at the rate of 1.25
mm/minute to that required for corresponding penetration of a standard material. The test
is arbitrary and results may not be directly related to fundamental properties governing the
strength of soils such as cohesion, angle of internal friction etc. Schematic of CBR Test
shown below:

AL
N
FI

Apparatus:

i) CBR mould 150 mm diameter and 175 mm high with detachable perforated base
plate. (Net capacity is 2250 ml).
ii) Collar 50 mm high.
iii) Penetration plunger - 50 mm diameter.
iv) One annular and a few slotted surcharge masses 2.5 kg each.
v) Rammer 2.6 kg with 310 mm drop and 4.89 kg with 450 mm drop.
vi) Steel rod 15-20 mm in dia and 400 mm long.
vii) Cutting edge.
viii) Loading machine of approximately 5000 kg capacity, fitted with a calibrated proving
ring giving a constant rate of penetration of about 1.25 mm/minute.
ix) Penetration measuring 2 dial gauges accurate to 0.01 mm.
x) Soaking tank of pan, drying oven, dishes and calibrated measuring jar.

201
xi) Swelling gauge consisting of a perforated plate with an adjustable extension stem.
xii) I.S. Sieves 4.75 mm and 19 mm.
xiii) Straight edge, mixing basin.
xiv) Filter paper
xv) Weights

Preparation of test specimen

The test may be conducted on undisturbed as well as disturbed (remoulded) soil specimen
which may be compacted statically or dynamically.

Undisturbed soil specimen

Undisturbed soil specimen shall be obtained from the field in natural condition. For this, use
127.3 mm high mould and attach the steel cutting edge to its one end. Push the mould
gently into the ground. When the mould is full of soil, it shall be taken out carefully. The top
and bottom surfaces are then trimmed flat so as to achieve the correct length of specimen
for testing. The specimen is then sealed with paraffin wax on both sides of the mould so as
to preserve it with the natural moisture content.

Remoulded specimen (From disturbed sample)

When undisturbed specimen is not available, the specimen can be prepared by remoulding
the disturbed soil sample. It can be prepared on maximum dry density of soil determined by
AL
compaction test. The water content used for compaction should be at optimum moisture
content.

Remoulded specimens are prepared in the laboratory by compaction. The test material
N

should pass 19 mm I.S. sieve and retained on 4.75 mm sieve.

FI

TEST PROCEDURE

1. Soaking of remoulded specimen:

Weight the mould with base plate and the specimen. Keep the filter paper on the specimen
and place the perforated top plate with adjustable stem over the specimen. Keep the mould
in a tank in which water is filled for soaking. Apply weights to produce a surcharge equal to
the weight of base material and pavement to the nearest 2.5 kg on the compacted soil
specimen. The whole mould and weights shall be immersed in a tank of water allowing free
access of water to top and bottom of the specimen. The tripod for the expansion measuring
device shall be mounted on the edge of the mould and the initial dial gauge reading
recorded. This set up shall be kept as such undisturbed for 96 hours noting down the
readings every day against the time of reading. A constant water level shall be maintained
in the tank throughout the period.
At the end of the soaking period, the final reading of the dial gauge shall be noted, the
tripod removed and the mould is taken out of the water tank.
The free water collected in the mould shall be removed and the specimen allowed to
draining downward for 15 minutes. After draining out water, the weights, the perforated
plate and the top filter paper shall be removed and the mould with the soaked soil sample
shall be weighed and the mass recorded.

202
2. Penetration Test:

The mould containing the test specimen is placed on the lower plate of the testing machine
with the base plate in position and the top surface exposed. Surcharge mass is placed on
the specimen. If the specimen has been soaked previously, the surcharge shall be equal to
that use during the soaking period. To prevent upheaval of soil into the hole of the
surcharge weights, 2.5 kg annular weight shall be placed on the soil surface. The plunger
shall be seated under a load of 4 kg so that full contact is established between the surface
of the specimen and the plunger. Load shall be applied to the penetration plunger so that
the penetration is approximately 1.25 mm per minute. Reading of the load shall be taken at
penetrations of 0.0, 0.5, 1.0, 2.0, 2.5, 4.0, 5.0, 7.5, 10.0 and 12.5 mm.
After the completion of the test, the plunger is raised and the mould is detached from the
loading equipment. About 20 to 50 g of soil shall be collected from the top 30 mm layer of
specimen for water content determination.

LOAD PENETRATION CURVE

The load penetration curve is drawn as shown in Fig.2. The curve is generally convex
upwards, although the initial portion of the curve may be concave upwards due to surface
irregularities. A correction shall then be applied by drawing a tangent to the upper curve at
the point of contraflexure. The corrected curve shall then be taken to be this tangent plus
the convex portion of the original curve with the origin of strains shifted to the point where
the tangent cuts the horizontal strain axis as illustrated in Fig. below:
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N
FI

Load Penetration Curve for a CBR Test

DETERMINATION OF CBR

Corrected load value shall then be taken from the load penetration curve corresponding to
the penetration value at which CBR is desired. The CBR is then determined as follows:-

CBR=PT/Psx100
Where,

PT =Corrected load corresponding to the chosen penetration from the load penetration curve,
Ps =Standard load for the same depth of penetration as for Ps

The CBR values are usually calculated for penetration of 2.5mm and 5mm. Generally, the
CBR value at 2.5 mm penetration will be greater than that at 5mm penetration and in such a

203
 case; the former shall be taken as the CBR value for design purpose. If the CBR value
corresponding to a penetration of 5mm exceeds that for 2.5mm, the test shall be repeated. If
identical results follow, the bearing ratio corresponding to 5mm penetration shall be taken for
design.

Standard Loads for CBR test

Penetration Depth Unit Standard Load Total Standard Load

(mm) (kg/cm2) (kg)
2.5 70 1370
5.0 105 2055
7.5 134 2630
10.0 162 3180
12.5 183 3600

Test Observations are recorded in the table as given in the code.

Report

The CBR value shall then be reported correct to the first decimal place. The details shall be
reported in prescribed proforma:-

CBR of specimen at 2.5 mm penetration -

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CBR of specimen at 5 mm penetration -
CBR of specimen at …….Penetration -
Results of repeat test, if conducted :
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2. STANDARD TEST PROCEDURE FOR PLATE LOAD TEST

(Ref: German Code - DIN 18134: 2001- Determining The Deformation And Strength
Characteristics Of Soil By Plate Load Test)

Test in which a load is applied in increments to a soil sample using a circular loading plate
and a loading device, released in decrements, and the entire process is repeated. The
average normal stress below the plate, σ0, is plotted against the settlement, s, for each load
increment so as to obtain a load settlement curve.

Strain Modulus

The strain modulus, EV, is a parameter expressing the deformation characteristics of a soil,
and is calculated taking values from the load-settlement curve obtained from the first and
second loading cycle, from the gradient of the secant between points 0.3 x σ0max and 0.7 x
σ0max .

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 General Test Conditions

a) The plate loading test may be carried out on coarse grained and composite soils as well as
on stiff to firm fine grained soils. Care shall be taken to ensure that the loading plate is not
place on particles larger than approximately one quarter of its diameter.

b) In the case of rapidly drawing equigranular sand or soil which has formed a surface crust,
has been softened or has been otherwise disturbed in its upper zone, the plate loading test
shall be conducted with the disturbed soil being removed. The density of the soil under test
shall, as far as possible, be uniform throughout.

c) For fine grained soils (e.g. silt, clay), the plate loading test can only be carried out and
evaluated satisfactorily if the soil is stiff to firm in consistency. In case of doubt, the
consistency of soil under test shall be determined at various depths up to a depth equal to
the diameter of loading plate, d, below ground level.

APPARATUS:

(a) Reaction Loading System: The reaction loading system shall produce a reaction load
which is atleast 10 kN greater than the maximum test load required and may be loaded in a
truck or trailer or any other object of sufficient mass.
(b) Plate Loading Apparatus: It consists of loading plate, an adjustable spirit level, and a
loading system with hydraulic pump, hydraulic jack assembly and high pressure pose.
(c) Devices for measuring the load applied: The load on the plate is best measured by
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means of a strain gauge with a limit of error of 1% which shall be fitted between the
loading plate and piston.
(d) Settlement measuring device: For measuring the settlement of the loading plate, a
contact arm assembly shall be used. This consists of a frame supported at three points, a
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vertically adjustable, torsion proof, rigid contact arm, and a displacement transducer or dial
gauge.
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(e) Programmable pocket calculator: Suitable for calculating quadratic equations.

(f) Loading plates of 300 mm and 600 mm diameter.

TEST PROCEDURE:

(i) Test Area Preparation

A test area sufficiently large to receive the loading plate shall be levelled using suitable
tools (e.g. steel straight edge or trowel) or by turning or working the loading plate back and
forth. Any loose material shall be removed.

(ii) Setting up the plate loading apparatus

The loading plate shall lie in full contact with the test surface. A spirit level shall be fitted to
the upper face of the plate and when the test area is inclined, adjusted accordingly. The
piston of the hydraulic jack shall be place centrally on and at right angles to the loading
plate beneath the reaction loading system and secured against tipping. The minimum
clearance between loading plate and contact area of the reaction load shall be 0.75 m for a
300 mm plate, 1.10 m for a 600 mm plate and 1.30 m for a 762 mm plate. The reaction
load shall be secured against displacements at right angles to the direction of loading.

(iii)Arrangement for settlement measuring device

The contact arm assembly shall be positioned so that its supports are located 1.5 m form
the centre of the loading plate. The dial gauge or displacement transducer shall be set up
vertically. When placing the loading plate, care shall be taken to ensure that the stylus of

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 the contact arm can be passed into the rectangular opening without hindrance and
positioned centrally on the plate.

(iv)Preloading
Prior to starting the test, the strain gauge and the dial gauge or displacement transducer
shall be set to zero and the plate preloaded for about 30 seconds. The load applied shall
correspond to normal stress of 0.01 MN/m2 when using a 300 mm or a 600 mm plate and to
a normal stress of 0.005 MN/m2 when using a 762 mm plate. The reading of the gauge or
transducer at this load shall be taken as zero reading.

(v) Determining the strain modulus

To determine the strain modulus, EV, the load shall be applied in not less than six stages, in
approximately equal increments, until the required maximum normal stress is reached.
Each increase in load (from stage to stage) shall be completed within one minute. The load
shall be released in stages, to 50% and 25% of the maximum load and then to the load
corresponding to the zero reading. Following that a further 2nd loading cycle shall be carried
out in which the load is to be increased only to the penultimate stages of the first cycle.
When testing soil, the time interval between the applications of each load increment shall be
2 minutes. For testing of granular layer, one minute is sufficient.

To determine the strain modulus, a 300 mm loading plate shall be used and load is
increased until a settlement of 5 mm or a normal average stress below the plate of 0.5
MN/m2 is reached. If the required settlement is reached first, the normal average stress
measured at this stage shall be taken as maximum stress.
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EVALUATION AND REPRESENTATION OF RESULTS

(a) Load settlement curve: For each load increment, the average normal stress, σ0, and the
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associated reading, M, shall be recorded and the stress shall be plotted against the
settlement. A smooth curve shall be drawn through measuring points for each cycle.
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(b) Calculation of strain modulus: Calculation of the strain moduli of the first loading and
loading cycle shall be smooth load-settlement curves. These shall be expressed by
calculating the settlement, s, at the centre of the loading plate using relation :

s= a0+ a1 x σ0 + a2 x σ02 where σ0 = Average normal stress below the plate in MN/m2
a0, a1 & a2 = Factors in mm/MN2/m4

For determination of the factors, a

value of s equal to zero shall be ignored.
The strain modulus, EV , shall be
calculated using the following equation :

EV= 1.5 x r x1/(a1+a2 x σ0max)

Where,
σ0 = Average normal stress below the
plate in MN/m2
a1, a2 = Factors in mm/MN2/m4
r = Radius of loading plate in mm, and
σ0max = Maximum average normal stress
in MN/m2
FIG. : Load–Settlement Curve for
determining the Strain Modulus

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3. STANDARD TEST PROCEDURE FOR LABORATORY COMPACTION TEST

Compaction is the process of densification of soil by reducing air voids. The degree of
compaction of a given soil is measured in terms of its dry density. The dry density is
maximum at the optimum water content. A curve is drawn between the water content and
dry density to obtain the maximum dry density and optimum water content.

Dry density = M / V (1+w)

Where,
M = total mass of soil
V = volume of soil
w = water content

APPARATUS

1. Cylindrical metal compaction mould

Capacity : 1000 cc with dia 100 mm + 0.1, 2250 cc with dia 150 mm + 0.1
Internal diameter : 100 mm + 0.1, 150 mm + 0.1
Internal effective height of mould: 127.3 + 0.1 mm
Collar: 60 mm high
Detachable base plate
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2. Rammer Mass: For Heavy compaction = 4.9 kg, Dia: 50 mm
3. IS sieve: 19 mm & 4.75 mm
Oven: Thermostatically controlled to maintain a temperature of 105 0 to 1100 C
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4.
5. Weighing Balance: sensitivity - 1 g for capacity 10 kg,
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0.01g for capacity 200 g

6. Steel straight edge of about 300 mm in length with one edge levelled.
7. Gradation jar
8. Large mixing pan
9. Spatula

PREPARATION OF SAMPLE

1. Break the clods of soil sample as received from the field and remove the organic matter like
tree roots, pieces of bark etc. from the sample.
2. Dry the sample in the air. In wet weather, use drying oven but the temperature
of the sample should not exceed 600 C.
3. Take a representative portion of air-dried soil material and large enough to provide about 6
kg of material passing a 19-mm IS sieve (for soils not susceptible to crushing during
compaction, or about 15 kg of material passing a 19-mm IS sieve (for soils susceptible to
crushing during compaction)
4. Sieve above material through 19 mm & 4.75 mm IS sieve.
5. Sieve above material through 19-mm IS sieve and if soil retained on this sieve is more than
5%, use mould of 2250 cm3 and reject soil retained on 19-mm sieve after its proportion of
the total sample has been recorded.
6. If percentage retained on 4.75 mm IS sieve is greater than 20, then use mould of 2250
cm3 otherwise use small mould of 1000 cm3.
7. Determine the ratio of fraction retained and that passing 4.75 mm IS sieve to to access the
density of the soil.

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8. Mix the soil sample retained on 4.75 mm sieve and that passing 4.75 mm sieve for further
testing.
9. Mix the sample thoroughly with a suitable amount of water depending on the soil type.:-
(a) Sandy and gravely soil: 3 to 5%
(b) Cohesive soil: 12 to 16% approx.
10. Store the soil sample in a sealed container for a minimum period of 16 hours.

PROCEDURE

1. Clean and dry the mould and base plate and apply a thin layer of grease on the inside the
mould.
2. Weigh the mould to the nearest 1 gram. Attach the collar to the mould and place on a solid
base.
3. Compact the moist soil in to the mould in five layers of approximately equal mass, each
layer being given 25 blows from 4.9 kg rammer dropped from a height of 450 mm above
the soil. The blows should be distributed uniformly over the surface of each layer.
4. Remove the collar and trim off the excess soil projecting above the mould by using straight
edge. Take the weight of mould with compacted soil in it.
5. Remove 100 g of compacted soil specimen for the water content determination.
6. Add water in increment of 1 to 2 % for sandy and gravely soils and 2 to 4 % for cohesive
soils.
7. Above procedure will be repeated for each increment of water added. The total number of
determination shall be at least four and moisture content should be such that the OMC at
which MDD occurs, is within that range.
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PRECAUTIONS

1. Ramming should be done continuously taking care of height of 450 mm free fall accurately.
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2. The amount of soil taken for compaction should be in such a way that after compacting the
last layer, the soil surface is not more than 5 mm above the top rim of the mould.
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3. Weighing should be done accurately.

Moisture Content (%)

Curve for Dry Density v/s Moisture Content

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 Appendix – C

MECHANICAL PROCDUCTION OF BLANKET MATERIAL

If, naturally available materials do not meet the desired specifications, blanket material can
be produced mechanically by crushing or blending method or combination of these two
methods. Detail of these two methods are given below :

1. Crushing Methodology:

In the event of non-availability of natural source of blanket material, depending on the

proximity of project site from the parent rock/boulder sources, it may be decided to crush the
rock/boulder in order to produce crushed blanket material. Salient features of this
methodology are:

 Crushed blanket material may be produced as sole product or in conjunction with ballast or
any other nominal size.

 Trials and permutations of feed speed, crushing cycle, sieve combinations may be required to
arrive at the required particle size gradation.

 It is possible to achieve near total produce of desired gradation through production cycle
management. Alternately, it may be possible to get by-products of other sizes in the desired
proportion and blanket material as main produce or vice-versa.
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 Optimisation of production rates and costs can be achieved by controlling the output at each
sieve stage.
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 It is ideal to mix the required quantity of water for OMC (accounting for loss/gain of moisture
due to weather conditions) at the crusher plant and transport the material in wet condition.
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 Quarry dust or natural by-product of production of higher size coarse aggregates may
themselves be suitable for use as blanket material. In all such cases, where large scale
crushing is taking place for production of ballast, trials may be conducted to arrive at ideal
particle size gradation of the by-product also.

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1.1 Case study :

Site visit was carried out in the month of May 2005 at Chandigarh to inspect crushing
methodology for production of blanket material. Details collected are as follows:
i) Name of crusher owner: Hargobind stone crusher
ii) Address: Burjkotian, Chandimandir, Panchkula, Chandigarh
iii) Make of crusher: Gurudev, Lalkuwan, Delhi
iv) Source of stone: River Ghaggar
v) Plant capacity: 830 cft/hour (Approximately)
vi) Approximate cost: 22 lakh
vii) Number of persons 10 labourers, 1 foreman, 2 helpers
for operating the plant:
viii) Storage capacity : 4000 cubic feet
ix) Power: 5 HP to 7HP
x) Alternative power supply : Can be operated by 320 KVA Genarator
xi) Number of bins: Three
xii) Number of sieve combination: Three of 20 mm, 10 mm & 6 mm sizes
xiii) Tank ( For water): For wet mixing facilities
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The schematic diagram of for production of blanket at this crusher is given below:
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2 Blending Methodology :

2.1 Blanket material could be obtained by proper blending of two or more soils or in combination
with soils and crushed material like stone chips or quarry dust.

2.2 Before approving such sources, trials for blending to judge the final product, needs to be
done. Detail methodology of blending to be adopted to produce large quantity of blanket
material with consistent quality, needs also to be laid down in advance.

 Blending of either natural or crushed materials in a pre decided ratio could be adopted.
 Theoretical and laboratory trials are required in order to establish the desirable ratio of the
blending materials. This exercise may be done in advance before finalizing the contracts for
such a material. The methodology of blending trials is explained below :

o Identify the usable materials/soils.

o Take equal weight of the soils for sieve analysis.
o Write down the weight retained at each sieving stage for all the soils.
o Apportion a percentage component to each soil and work out a theoretical mix.
o Draw particle size distribution curve of the mix to find out desirability of gradation.
o If not successful, make another trial, and so on.
o Trials and plotting work can also be done using simple computer programs.

2.3 Mechanical blenders using simple technology are now available in the market. Two types of
mechanical blenders are quite common:
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i) Drum type blenders: Drum type machines may involve weigh batching or manual
feeding of material. They involve more moving parts. Hence, these machines are both
manpower and maintenance intensive. They may pose a problem of segregation of
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material and as such do not afford any cost advantage either in the short or long run.
These may be suitable for small quantities and not for large-scale production as required
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in construction projects.

ii) Pug mill type blenders: For continuous production of mix in large quantities, the best
way is to feed the aggregates/ soils of pre decided gradation by way of 3 or 4 bins with
conveyor belt. The required output grading can be achieved by adjustment of gate
openings of bins. The use of pug mill type blenders is found very cost effective, as the
manpower involvement is very little and only 4-5 people can run a plant of 100 tph. The
pug mill blender consists of:

1) Four bin aggregate unit

2) Pug mill mixer unit
3) Water tank and metering system
4) Conveyor belts
5) Storage silos (optional)
6) Anti segregation surge hopper
7) Automation and controls

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 A schematic diagram showing the various arrangements is shown below:

The other important features of this technology are:

 Automatic feeding of soils/aggregates under gravity,
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 Arrangement for precise control of mixing of water,
 Either direct loading into trucks, or optional storage at plant,
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 Availability of domestic manufacturers, and low cost of set up,

 Advantage of removal and relocation with ease.
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2.4 Case study:

NHAI project site between Sultanpur-Utratia Bye Pass Road, near Lucknow was visited in
the month of June 2005 in connection with production of blanket by blending. Details
collected are as follows:

(i) Name of work executing Atlanta

agency:
(ii) Address: Amar Saheed Path, Lucknow
(iii) Makes of blender: Gujrat Appolo Equipment
Ahemdabad
(iv) Plant capacity: 160 ton per hour
(v) Approximate cost: 50 lakhs
(vi) Number of persons 7
for operating the plant:
(vii) Alternative Power supply: Can be operated by 125 KVA
Genarator
(viii) Number of bins: Four

(ix) Salient features: bins, pug mills, wet mix

computerized blender

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2.5 The equipment for blending should enable blending of two or more materials uniformly so
that the blended material satisfies the specification. The equipment chosen should be cost
effective and easy to handle with and efficient. A non-exhaustive list of some of the
available mixers/blenders based on market survey & internet search are given below :

S. Trade Make Mixing Address E-mail Web-Site

No. Name Capacity Address Address
1 Drum Mix Speed Speed exports @
Plant Crafts Crafts speedcrafttsi Not available
Limited Limited, ndia.com,
15-120
Layak info@
ton per
Bhawan, speedcrafttsi
hour
Boring ndia.com
Canal Road
Patna,
Bihar
2 30 M Shakti Shakti
Supermobile Industrials Industrials shakti_ind@v Not available
Concrete 65,Ganga, snl.com
Batching Off Marve
12 to 30
Plant Road
m3/h
Malad (W),
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Mumbai
400064

3 Wet Mix Gujrat Gujrat sales@the- www.apollo.co.

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Plant Appolo 160 ton Appolo appolo.com in

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Equipment per hour Equipment

Ahmedabad

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