Professional Documents
Culture Documents
No
Particular
Volume 1
Concession Agreement ,Schedules and SPV
Details for DS Toll Road Limited
Volume 2
RFP, Response to Queries and Addendum for
DS Toll Road Limited
Volume 3
DPR for DS Toll Road Limited
BCEQM
F i w w ~ ~ c o H 6 u T ~
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aarvee assoc~ates
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be slightly more than the existing slab. The bottom of the new slab is to be kept flat as shown
in the figure. The new wearing coat is to be laid with a uni-directional camber of 1 in 60 with
the higher side towards the median side. Reference can be made to the detailed drawings for
better appraisal of the methodology.
REPLACEMENT OF HANDRAIL WITH CRASH BARRIER IN THE MEDIAN
SIDE:
A new crash barrier solid type will be provided on the central verge side. The base
width of the crash barrier will be 450 mm instead of the standard 500 mm (change the
spacing of bars with the internal dimensions).
Step 1: Remove the railings along with post upto kerb level. The kerb is roughly 275 x
450 mm.
Step 2: The existing kerb of size, say 300 x 450mm, which is about 275 to 300mm above
the old concrete structural slab, is to be dismantled without breaking or removing the
vertical rebars which go inside the steel slab.
Step 3: The new kerb will be of (275 + 200) x 450 size and should have reinforcement of
16 dia bars 4 numbers on either side. These bars are vertical. In addition, the
reinforcement of the crash barrier should be provided inside the available depth of 475
mm. If required the end of the reinforcements of the crash barrier can be suitably bent
inside this depth of 475mm.
Step 4: Before concreting the new kerb, a suitable bonding coat should be provided
between the top of old structural slab and the new concreting of the kerb.
On the outer side, a safety kerb of 750 H x 250 V (clear) is to be provided.
P
4
12 thk MA
4
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50 thk BC\
1 in 60
11000 (Carriageway)
450
C,
MEDIAN SIDE
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Pie2 Spalling of Concrete with exposure of reinforcement near drainage spouts due to
inadequate length of drainpipe
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.IThe following table gives the details of existing bridges and the proposed rehabilitation
As indicated above, certain bridges are getting eliminated and no action is taken owing to
different reasons, which are mentioned in the remarks column. Bridge no: 40511 is a
single span slab bridge with a carriageway of 1 lm. This bridge need not be widened and
only camber correction is to be done. It shall be a uni-directional camber as indicated in
the drawings. The repair works to the defects found shall be canied out as mentioned in
the specifications. The schedule of the work for each bridge is given in the following
table.
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Item
I
BRlDGENo:
38711
SPAN ARRANGEMENT 4 x 6.6
DESCRIPTION OF WORK
Dlsmantllng the ra~l~nglparapet
and kerb of the exlstlng br~dges
for prov~dlngnew crash barrler wthout causlng any structural
damage to other parts of the br~dgelncludlng all labour tool and
~ t sd~sposalas per drawlng and MORTH spec~ftcat~ons
2802 and
add~t~onal
spec~f~cat~on
2814
la
lb
W~den~ng
s~de
3a
Prov~d~ng
pla~ncement concrete M I 5 grade as levelling course
(100mm thlck) below the new floor slab for wdened portlon of
fpundatlon slablfloor slab cncludlng center~ng shuttering as per
,MQRTH cpec~f~cat~on
1700
Pla~nCement Concrete M I 5 grade In Open Foundat~onas per
drawlng and MORTH spectflcattons 1500,1700,2100
'6,
Schedule of work
38Nl 1 3 8 W
2 x 5.7
3 x 5.1
39SH
2 x 7.2
40311
2 x 3.4
MI
1 x 10.6
*
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t.
*
*
40511
1 x 6.0
40512
2 x 5.8
40611
4 x 8.7
40711
1 x 10.0
40N1
2 x 8.4
40812
2 x 8.4
*
*
*
*
41012
2 x 6.0
*
*
390H
2 x 6.5
*
*
N%J
zm No1
II
21
-
22
23
24
25
26
BRIDGE NO:^
SPAN ARRANGE MEN^
DESCRIPTION
- -- -. ... ..-. . OF
-. WORK
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38711
4x6.6
1
1
II
II
*
*
*
38811
2 x 5.7
1
I
.,
38911
3 x 5.1
II
I
1
1
*
*
*
I
390H
2x65
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1
II
II
27
specifications 2816
28
29
30
..
32
Schedule of work
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Schedule of work
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Schedule of work
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Schedule of work
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Clause
2809.1
Commencement of dismantling
Add as sub para (i) as below
(i)
Renumber the sub para (i), (ii), (iii) as (ii), (iii) & (iv)
2809.2
2809.3
-T e c h n ~ ~Spec~ficat~ons
al
Contract Package NS 82
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Clause
and other incidental expenses including removal of existing expansion joints for
the satisfactory completion of the work as per these specifications.
2814.1
2814.2
Technical Specifications
Contract Package NS 82
Clause
2814.3
2814.4
Technical Specifications
Contnct Package NS 82
'4
Clause
Slab bridges are being widened with slab extensions. The top of extended slab
will have a cross slope of 1/60 and no profile corrective course will be required
for the widenedlextended portion of the slab bridge.
A tack coat confuming to standard specification clause 503 shall be applied over
the exposed surface of deck slab before the application of SDBC. In addition,
tack coat has to be provided on new concrete surface of widened portion.
The SDBC shall follow standard specification clause 508.
Bituminous concrete confirming to standard specification clause 509 shall be laid
as component of wearing coat over the SDBC in the existing bridge portion and
directly over concrete on the new widened concrete slab. Tack coat has to be
provided on new concrete surface.
The Mastic Asphalt (MORTH specification clause no. 515) shall be overlaid as
the other component of wearing coat on the bituminous concrete.
Rate
The contract unit rate for profile corrective course shall include the cost of tack
coat and shall also cover cost of all materials, labour, tools, plant and equipment
required for mixing, transporting and placing in position, vibrating and
compacting and finishing as per this section or as directed by the Engineer,
including all incidental expenses, sampling and testing, quality assurance and
supervision.
2816
Rate
The contract unit rate shall include the cost of all labour, materials, tools and
plant, scaffolding and all incidental expenses,
supervision as described in these specifications.
Technical Specifications
Contract Package NS 82
.._._.I
Clause
2817
Technical Spscifications
Contract Package NS 82
Clause
c) Extension of existing drainage spouts
For bridges that are not being widened, the existing drainage spouts are to be
retained with minor repairs. The work shall be carried out as shown in the
drawing. The concrete surrounding the spout in the soffit of the slab shall be
chipped out. An extension collar of specified size shall be attached to the existing
pipe as shown in the drawing. The chipped out area shall then be filled with 1:4
cement sand mortar over which a lOmm thick layer of PMC repair mortar shall
be applied.
Rate
The contract unit rate for each drainage spout shall include the cost of all labour,
material, tools and plant required for completing the work as per these
Specifications. It shall also include the cost of providing flow drainpipes in girder
bridges with all fixtures up to the point of ground drains wherever shown on the
drawings.
2818
Rate
The contract unit rate for application of PMC mortar for specified thickness
including cement mortar 1:4 wherever required, shall include cost of all materials,
labour, tools and plant, placing in position, testing and other incidental expenses
including surface preparation for the satisfactory completion of the work as per
these specifications and as shown in the drawings.
2819
. ..
Technical Specifications
Contract Package NS 82
.,
Clause
Measurement for Payment
Fine Crack: Measurement for sealing of fine crack by application of PMC
mortar for specified thickness along with application of PMC slurry for proper
bondage of old concrete and PMC mortar shall be linear metre of crack.
Wide crack: Measurement for sealing of cracks and injection shall be made by
weight of cement consumed in kg for cement grouting.
For provision of nipples required for grouting, the payment shall be for number of
nipples inserted.
Rate
Fine crack:The contract unit rate for application of PMC mortar for specified
thickness shall include cost of all materials, labour, tools and plant, placing in
position, testing and other incidental expenses including surface preparation for
the satisfactory completion of the work as per these specifications and as shown
in the drawings.
Wide crack: The contract unit rate for sealing of cracks and injection of cement
grout shall include cost of all materials, labour, tools and plant, placing in
position, testing, curing and other incidental expenses for the satisfactory
completion of the work as per these specifications.
Injection nipples are being paid separately.
Rate
The contract unit rate for application of PMC mortar for specified thickness shall
include cost of all materials, labour, tools and plant, placing in position, testing
and other incidental expenses including surface preparation for the satisfactory
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completion of the work& per these sp&ifications-andn,
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Technical Specifications
Contract Package NS 82
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Clause
2821
Rate
The contract unit rate for sealing of gap, cracks and injection of cement grout
shall include cost of all material including the gap filling material, labour, tools
and plant, placing in position, testing, curing and other incidental expenses for the
satisfactory completion of the work as per these specifications.
The work is to repair spalls or loss of cover in abutment, pier substructure and
gaps. This shall be executed in accordance with standard Specification Section
2807 and special Specification A-3 (1.6 (a) & @)) and 1.7
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T ~ h n i c a Specifications
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Contract Package NS 82
Clause
Rate
The rate will include cost of cement nipples, admixture fixing compound, all
material and labour in drilling fixing and cutting after the job and removal and
sealing the holes including the cost of drilling equipment, cost of drill, bits and
spares wastage etc.
Rate
The contract unit rate for approach slab shall include the cost of all labour,
material, tools and plant and other cost necessary for completion of the work as
per these Specifications. The rate for base shall include cost of all labour,
material, tools and plant required, including preparation of surface and
consolidation complete in all respects
Technical Specifications
Contract Package NS 82
Clause
SPECIAL SPECIFICATIONS
A-3
REPAIR
PROCEDURE,
SPECIFICATION.
UPGRADATION
AND
MATERIAL
FINE CRACKS
There can be fme visible cracks in bridges. If the cracks are 0.5mm wide or less, these
cracks are to be repaired with PMC mortar. The location of the cracks can be seen
during repair and widening works. , In order to avoid increase in corrosion,
rectification of the cracks by cutting grooves in the concrete and sealing the grooves
with PMC repair mortar after cleaning and applying PMC slurry on the freshly cut
surfaces at all locations is recommended.
Procedure
The size of the groove, which should be cut along the whole length of visible cracks,
shall be 20 x 1Omm. Depth of the groove is lOmm while the width of the groove is
2 0 m n which however, should be symmetrically placed along the crack. In case
reinforcement is met within a depth of 6mm, the depth should be limited to the depth
of the reinforcement from the surface. It is preferable to cut the groove
perpendicularly to the surface but a deviation of 15 degrees in either direction may be
permitted.
After cutting the groove it shall be cleaned properly to ensure a dust free clean
surface and a coating of PMC sluny be applied over the freshly cut surfaces.
The PMC repair mortar shall be used to fill the 20 x lOmm groove while the sluny
coating is still wet, after a lapse of 30 minutes from the time of application of the
slurry, the PMC repair mortar shall be applied and compacted to ensure complete
filling of the groove.' The filling up of the groove shall be finished flush with the
existing concrete surface. After the finishing operation, the filled up groove should
be properly covered with impermeable sheet whose edges are to be sealed by taping.
Curing of the finished surface will be the same as that stated for curing of PMC
mortar (See C1.1.7). Care should be taken to cut the groove with sharp
instrument to avoid damage to the structure.
1 .
Techn~calSpec~ficat~ons
Contract Package NS 82
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10
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Clause
Material Specification
Specification of PMC material is provided at 1.1.7.
1.2
WIDE CRACKS
Wide cracks having width more than 0.5 m m have been found in some of the bridge
components. Moreover, these wide cracks are also found in MasonryPCC
substructure, such as wing walls, abutments and piers. While locating them and to
repair specially the wing walls, it is to be decided whether the old wing wall will be
functional after widening, if so they need to be repaired.
The basic repair methodology consists of injection of cement grout in the wide cracks
after most of the visible gaps have been sealed by applying sealing mortars. The
repair should be in conformation with clause 2806 of MORTH specification.
However, the general procedure is briefly described.
Procedure
The wide gaps should be chased so that grooves are formed which may be 10 x 5 mm
in size. AAer cleaning the surface with wire brush and compressed air, 15mm dia
nipples are to be fixed in 150 - 200mm deep holes with suitable sealing material.
The nipples should have maximum spacing 500 - 600mm. The chased groove also
should be filled up with suitable sealing material. Neat cement along with soluble
glass (Sodium Nitrate) forms excellent quick setting sealing compounds.
Grouting of cement slurry should be done by mechanical pumps. The details of
procedure should be in conformity with clause 2806 of MORTH specification except
for sub clause 2806.6.
Material Specification
- Material specification should be in accordance with clause 2806.1 of MORTH
specification.
1.3
Technical Specifications
Contmct Package NS 82
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Clause
reinforcement bars are exposed, the breaking shall continue so as to expose half the
diameter prior to further treatment.
Reinforcement Preparation
Where exposed reinforcement is sound and does not show any signs of heavy
corrosion or pitting other than typical rusting, it shall be mechanically
cleaned to remove rust and loose mill scale.
b)
Reinforcement Priming
Within one hour of preparing and cleaning, the reinforcement shall be coated with a
primer. The primer shall be PMC slurry using Tapecrete PI51 as polymer latex or
approved equivalent polymer latex.
The primer shall be brush applied on to the cleaned reinforcement ensuring that the
full surface area is in accordance with the manufacturer's recommendation.
Concrete Su$ace Primingfor Bond
Before commencing to apply PMC repair mortar or the inner cement sand mortar, the
prepared concrete substrata shall be thoroughly soaked with clean water. Free surface
water shall be removed before priming. The primer shall be PMC slurry using M/s
CICO Technologies Ltd.'s Tapecrete P151 polymer latex or approved equivalent.
The priming agent shall be well worked into the irregularities according to the
manufacturer's recommendations.
The repair material should be applied before the priming agent sets. The area coated
as one time must be restricted to allow for this provision and any area, which
becomes set shall be recoated as per manufacturer's instruction.
Cementitious Repair Mortar
The repair mortar shall be high build polymer modified cementitious repair mortar.
The PMC repair mortar shall be of appropriate general specification for use in vertical
and overhead application.
The total thickness of mortar shall be applied in one layer not exceeding lSmm
without sagging or slumping. The material shall be applied in accordance with the
manufacturer's recommendations.
The mixing shall be carried out using forces action mixes or with slow speed drive
mixer (400 - 500 rpm) fitted with a spiral paddle. In no circumstances shall water be
used in the PMC repair mortar mix. Re-mixing and re-tampering shall not be
permitted.
The material shall be applied by gloved hand or trowel to the prepared and
surface of the substructure and be well worked inside paying pakicular
.
Technical Specilications
Conttact Package NS 82
12
-.
Clause
packing behind and between the reinforcement. In order to make up the total height
of the girder up to the original soffit level, the balance portion of the girder depth
shall be made up with 1:4 cement sand plaster. Refer to Para 1.7.1 for specifications
of PMC mortar i.e., special specification 1.7
1.4
1.5
Techn~calSpeclficatlons
Contract Package NS 82
~ehab~hdl&
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13
g of Exlstlng Bndges
Clause
PIER AND ABUTMENT SUBSTRUCTURE AFFECTED BY WEATHERING
1.6
AND LOSS OF POINTING/PLASTER
Generally, there are no cases where these defects have been identified. However,
during the construction period, if the defects are noticed, the following methodology
shall be used for repairing the same.
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Techn~calSpecrficat~ons
Contract Package NS 82
--
~ehab111tatl;n&Wtdetungof Ex~stlngBndgs
14
Clause
1.7
SPECIFICATION FOR MATERIALS AND MIX FORMULATIONS FOR
PMC MATERIAL SYSTEM
The acrylic polymer latex to be used for system shall be TAPECRETE P 151
manufactured by MIS CICO Technologies Ltd. Equivalent products of MIS FOSROC
and MIS SIKA are also acceptable.
1.7.1
The grading of the above groups should follow the limits provided below: IS Sieve No.
10 mm
4.75mm
2.361nm
1.18mm
600 micron
300 micron
150 micron
75 micron
Techn~calSpecificat~ons
Contract Package NS 82
Percentage
Coarse
100
95 - 100
90 - 100
40 - 60
0 - 10
0-4
0-3
3 max
Passing
Fine
100
100
100
100
90 - 100
40 - 60
0-10
0-3
15
by weight
Combined
100
98 - 100
80 - 100
70 - 80
45 - 55
0-5
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31
Clause
In the event of using local sand, the sand to be used must satisfy the limits of
deleterious materials and the requirements of soundness as given in Clause. 3.2.1 and
3.6 of IS: 383 respectively. Confirmatoly tests shall be conducted by the contractor
and sample kept for comparison by the Public Works Department.
Cement - Sand Mortar
For repair of spallings, where the depth of spalling exceeds 15mm cement-sand
mortar 1:4 layer have been recommended after the application of PMC repair mortar,
15mm thick.
The composition of the cement sand mortar shall be as follows:
COMPOSITION
Cement
Sand
CICO No. 1 or equivalent
Water
PARTS BY WEIGHT
100
400
3
Variable
The amount of water will depend on the environment condition and is therefore
variable.
In case where two layers of cement-sand mortar are to be used, the second layer shall
be provided after a lapse of 24 hours from the time of application of the first layer.
Conventional practice or surface preparation for good bonding shall be adopted for all
layers.
Conventional curing of the cement sand mortar layer by application of water spray
should be followed for at least 2 days.
Component
Cement
Tapecrete P 151 or equivalent
Cement
Tapecrete P 151
Fine Silica Sand
Cement
Tapecrete P 15 1
Coarse Silica Sand
Fine Silica Sand
Cement
Tapecrete P15 1
Concrete Sand
Mix Formations
PMC SLURRY
Parts by Weight
100
50
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Technical Specifications
Contract Package NS 82
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12,
Clause
Following moist curing, the coating shall be allowed to air dry for at least 3 days
to the application of finishing coat.
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Technical Specifications
Contract Package NS 82
17
33
Clause
1.8
The gunite is a mixture of cement, sand and water. It comprises 100 parts by weight
of cement, 300 parts by weight quartz sand, 35-50 parts by weight water and 2 parts
by weight approved quick setting compound. In general, dry mix shotcrete shall be
used.
Ordinary Portland cement conforming to IS: 269 shall be used for guniting.
Sand for guniting shall comply with the requirements stipulated in IS: 383. In general,
sand should neither be too coarse to increase the rebound nor too fine to increase the
slump. Sand should preferably have a moisture content between 3 and 6%.
The grading of sand shall lie within the limits given below:
IS Sieve Designation
4.75 mm
2.36mm
1.18mm
600 microns
300 microns
150 microns
For thick sections it may be advantageous to incorporate coarse aggregate in the mix
provided adequate guniting equipment is available. Coarse aggregate, when used
shall conform to grading given in Table 1 of IS 9012. The percentage of coarse
aggregate may normally be kept as 20 to 40% of the total aggregate and the mix shall
be suitably designed. Waterlcement ratio for guniting shall fall within the range 0.35
to 0.50 by mass, wet enough to reduce the rebound. Drying shrinkage may be
between 0.06% and 0.1%. The quick setting compound shall be added at the nozzle
with water just before guniting.
The cement and sand shall be batched and mixed and conveyed through a hosepipe
with the help of compressed air. A separate line shall bring the water under pressure.
The cement, sand water mix shall be passed through and intimately mixed in a special
manifold and then projected at high velocity to the surface being repaired. The
density of gunite shall not be less than 2000 kglcum. The strength of gunite shall not
be less than 25 Mpa. For effective guniting the nozzle shall be kept 60 to 150 cm
away from the surface, preferably normal to that surface. While enclosing
reinforcement bars during repairs the nozzle shall be held closer at a slight angle and
the mix shall be wetter than the normal.
Test panels simulating actual field conditions shall be fabricated for conducting preconstruction testing. The procedure for testing the cubes or cylinders taken from the
panels stipulated in clause 6 of IS: 9012 shall be followed. It should be ensured from
tests that a strength of about 30 MPa at 28 days is available for the mortar/concrete
mix.
The defective concrete shall be cut out to the full depth till sound concrete
reached. Under no circumstances should the thickness of concrete to be
less than clear cover to the main reinforcement. No square shoulders
the perimeter of the cut-off portion and all edges shall be tapered. Thereafter,
loose and foreign matenals should be removed and the surface be
.
Technical Specifications
Contract Package NS 82
Rehabilitation &
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27
Clause
make it rough to receive shotcrete after applying a coat of bonding epoxy as per
recommendation of the manufacturer @ 1.0 kg per 1.5 sqm of surface area.
The exposed reinforcement shall be thoroughly cleaned free of rust etc. by wire
brushing. Wherever the reinforcements have been corroded the same shall be
removed ad replaced by additional reinforcement. Before application of gunite a
coat of neat cement slurry should be applied on the surface of the reinforcement.
Sufficient clearance shall be provided around the reinforcement to permit encasement
with sound gunite. Care shall be taken to avoid sand pockets behind the
reinforcements.
Contract Package NS 82
19