Specifications for Road and Bridge Works, 2013 (Fifth Revision)

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MORTH 250: Materials for Road and Bridge Works - Key Points

Though MORTH 250 does not provide explicit clause-wise formulas or tables, it specifies updated materials and technologies for road and bridge construction:

Key Material Specifications:

• Stone Mastic Asphalt (SMA): High durability surface course with gap-graded aggregates and polymer-modified bitumen.
• Microsurfacing: Thin, quick-setting surface treatment using polymer-modified emulsions.
• Sand Asphalt Base Course: Fine aggregate mix for base layers.
• Prefabricated Vertical Drains (PVD): For soil consolidation in embankments.
• Natural Geotextiles & Geocells: Used in base, sub-base, and slope protection for reinforcement and drainage.
• High Performance Concrete (HPC): For bridges, with superior strength and durability.
• HDPE Sheathings: For corrosion protection of prestressing tendons.
• Pot-PTFE Bearings: For bridge expansion joints.
• Mechanically Woven Wire Crates: For gabion walls.

Important Testing & Quality Control:

• Dynamic pile testing for foundation integrity.
• Use of cold-applied retro-reflective paints and solar-powered road markers for safety.

Typical Material Property Table (Example for HPC):

Conceptual Diagram of Pavement Layers with New Materials:

graph TD
  A[Surface Course] -->|Stone Mastic Asphalt| B[Binder Course]
  B -->|Sand Asphalt Base| C[Base Course]
  C -->|Geocells + Geotextiles| D[Sub-base]
  D -->|Prefabricated Vertical Drains| E[Subgrade]

For detailed mix designs, testing methods, and specifications, refer to the latest MORTH manuals and IRC codes linked with these materials.

Subsurface Investigations & Foundations - MORTH 250 Key Points

1. Subsurface Investigations (Clause 2401.1)

• Purpose: Assess soil/rock suitability for foundations.
• Methods: In-situ tests, borehole sampling.
• Data to record:
  • Soil profiles along structure length.
  • Mechanical & physical properties: grain size, sensitivity, porosity.
  • Groundwater level, artesian conditions.
  • Presence of deleterious materials.
  • Expected construction difficulties (e.g., sinking, driving effort).

2. Foundations Excavation & Filling (Clause 1.5)

• Excavation in rock: fill annular space with M15 concrete up to top of rock.
• For depths >1.5 m (ordinary rock) or >0.6 m (hard rock), fill with boulders grouted with cement.
• Protective works must be completed before floods to prevent undermining.

3. Tolerances (Clause 2106)

4. Measurement for Payment (Clause 2107)

• Excavation, lean concrete, concrete, and reinforcement steel measured per respective sections.
• Rates include all incidental works (dewatering, blasting, etc.).

Quick Reference Table: Pipe Foundations & Well Foundations (Sections)

Summary Diagram: Subsurface Investigation Process

flowchart TD
    A[Start Investigation] --> B[Borehole Drilling]
    B --> C[Sample Collection]
    C --> D[Lab Testing]
    D --> E[In-situ Testing]
    E --> F[Soil Profile & Parameters]
    F --> G[Foundation Design Inputs]

This concise overview aligns with MORTH 250 specifications for subsurface investigations and foundation works

Key Specifications for Embankment & Subgrade Construction (MORTH 250)

1. Density Requirements (Table 300-1)

2. Compaction Requirements (Table 300-2)

3. Construction Notes

• Use approved materials from borrow pits or excavation.
• Submit max dry density & optimum moisture content (IS:2720 Part 8) for approval before compaction.
• Ensure compaction meets density & moisture criteria to achieve design CBR value.
• Foundation preparation includes cutting, trimming, cleaning, and sealing seams with cement grout.

Formula for Relative Compaction

[ \text{Relative Compaction (%)} = \frac{\text{Field Dry Density}}{\text{Maximum Laboratory Dry Density}} \times 100 ]

Summary Flowchart of Embankment Construction Process

flowchart TD
    A[Material Selection] --> B[Testing for Max Dry Density & Optimum Moisture]
    B --> C[Approval by Engineer]
    C --> D[Setting Out Embankment/Subgrade]
    D --> E[Layer-wise Filling & Moisture Conditioning]
    E --> F[Compaction to Specified Relative Density]
    F --> G[Quality Control & Testing]
    G --> H[Completion & Surface Finishing]

Ensure compliance with MORTH Clause 305 for all embankment and subgrade works.

MORTH 250: Key Specifications for Pavement Construction & Surface Treatments

Relevant Clauses & Pages

• Bituminous Pavement Layers: Clause 501 (p.149)
• Prime Coat: Clause 502 (p.166)
• Tack Coat: Clause 503 (p.168)
• Bituminous Macadam: Clause 504 (p.170)
• Dense Bituminous Macadam: Clause 505 (p.174)
• Sand Asphalt Base Course: Clause 506 (p.183)
• Bituminous Concrete: Clause 507 (p.188)
• Close-Graded Premix Surfacing: Clause 508 (p.192)
• Surface Dressing: Clause 509 (p.194)
• Open-Graded Premix Surfacing: Clause 510 (p.198)
• Seal Coat: Clause 511 (p.205)
• Slurry Seal: Clause 512 (p.207)
• Fog Spray: Clause 513 (p.213)
• Micro-Surfacing: Clause 514 (p.215)
• Stone Matrix Asphalt (SMA): Clause 515 (p.219)
• Mastic Asphalt: Clause 516 (p.225)

Key Formulas & Specifications

1. Prime Coat Application Rate

[ \text{Application Rate} = \frac{\text{Quantity of Bitumen (liters)}}{\text{Area (m}^2\text{)}} ]

• Typical rate: 0.7 to 1.5 l/m² depending on base type.

2. Tack Coat Application Rate

• Typical rate: 0.15 to 0.3 l/m².

3. Bituminous Macadam (BM) Mix Design

• Gradation as per IS 73:1983.
• Bitumen content: 3.5% to 5% by weight of total mix.

4. Dense Bituminous Macadam (DBM)

• Higher bitumen content than BM.
• Designed for durability and load distribution.

5. Surface Dressing

• Aggregate size: 10-14 mm for first coat, 6-10 mm for second coat.
• Bitumen application rate varies with aggregate size and surface texture.

Typical Pavement Layer Structure

MORTH 250: Drainage and Surface Drains - Key Points

Surface Drains (Clause 309.2)

• Excavation: To specified lines, grades, levels, and dimensions per Clause 301.
• Material: Excavated soil removed; suitable material reused for embankment/sub-grade; unsuitable disposed as directed.
• Bed & Sides: Dressed to conform to dimensions, levels, slopes.
• Lining/Turfing: As per drawings where required to prevent erosion.
• Execution: Planned in sequence to ensure adequate drainage and minimize erosion/sedimentation.

Sub-Surface Drains (Clause 309.3 & Table 704.2.2)

• Prefabricated Vertical Drains (PVDs):
  • Core Material: Polypropylene/Polyethylene.
  • Core Structure: Corrugated, filament, dimpled, studded.
  • Filter Material: Polyester/Polypropylene nonwoven fabric.
  • Filter Properties:

• Flow Capacity: >1.5 × 10⁻⁵ m³/s

Summary Flowchart of Drain Construction Process

flowchart TD
    A[Excavation to Specified Dimensions] --> B[Remove/Reuse Excavated Material]
    B --> C[Dress Bed and Sides]
    C --> D{Lining/Turfing Required?}
    D -- Yes --> E[Apply Lining/Turfing]
    D -- No --> F[Proceed]
    E --> F
    F --> G[Ensure Proper Sequence with Other Works]
    G --> H[Complete Drain Construction]

**Use this as a checklist for surface and sub-surface drain construction per MORTH 250

Bridge Bearings and Expansion Joints (MoRTH 250 Highlights)

Bridge Bearings

• Types: Fixed, rocker, roller (full cylindrical only), elastomeric, sliding.
• Material: No MS-on-MS sliding; use stainless steel sliding on stainless steel with mild steel matrix or PTFE on stainless steel.
• Installation:
  • Bearings must be set level, exact position, with uniform bearing.
  • Thin mortar pads ≤12 mm allowed for leveling.
  • Bottom of girders must be plane at bearing locations.
  • Bearings must be accessible for inspection and jacking.
• Seismic Zones IV & V: Bearings must have guides to prevent displacement.
• Skew Bridges:
  • Skew < 20°: Bearings placed perpendicular to bridge axis.
  • Skew > 20°: Follow drawings for bearing location.

Expansion Joints

Key Installation Procedure for Reinforced Elastomeric Joint (Clause 2610.6)

• Steel Inserts:
  • Cast deck with pockets for inserts.
  • Inserts flush with wearing course, maintaining camber.
  • Use spacer bars for positioning and leveling.
  • Anchor rods welded/tied to deck reinforcement.
  • Second stage concreting within 24 hours preferred.
• Spacer Bars:
  • Removed after concreting.
  • If snug, gas cut to avoid concrete damage.
• Special Cases:
  • Simply supported bridges on elastomeric bearings: alternate joints restrained.
  • Other bearings: spacer bars removed before concreting carefully.

Additional Notes

• Contractor responsible for correct bearing placement and installation.
• Bearings must be stored under

Key Specifications & Formulas for Reinforced and Prestressed Concrete (MORTH 250)

1. Measurement for Payment (Clause 1718)

• Concrete measured in cubic meters (m³).
• Volume of reinforcement/prestressing cables not deducted from concrete volume.
• Slabs measured continuously, beams measured below slabs.
• Contract rate includes materials, labor, equipment, formwork (Section 1500), sampling, testing, and supervision.
• Rate reduction formula for sub-standard concrete strength:

[ \text{Percentage reduction} = \frac{\text{Design Strength} - \text{Observed Strength}}{\text{Design Strength}} \times 100 ]

2. Prestressing (Section 1800)

• Prestressing involves stressing wires/strands/tendons using jacks and anchoring internally or externally.
• Materials for prestressed concrete must comply with Sections 1700 (concrete) and 1600 (steel).
• Tendon sheathing:
  • Use HDPE or metallic steel sheaths (plain or coated).
  • Sheaths must have smooth internal surfaces for tendon movement.

3. Durability Testing (Clause 1717.7.7)

• For durability, perform Rapid Chloride Ion Permeability Test per Clause 1714.3.1.

Summary Table: Prestressing Materials

flowchart TD
    A[Concrete & Steel Materials] --> B[Prestressing Process]
    B --> C[Stress Wires/Strands with Jacks]
    C --> D[Anchor Tendons Internally/Externally]
    D --> E[Ensure Sheathing (HDPE/Steel) Smoothness]
    E --> F[Durability Testing (Chloride Ion Permeability)]

For detailed design, refer to IS 1343 for prestressed concrete and IS 456 for reinforced concrete.

Key Quality Control & Testing Procedures as per MORTH 250

1. Pavement Concrete (Clause 903.5.2.1 & Table 900-6)

• Sampling & Testing:

  • For every 150 m³ concrete, cast 3 beams + 3 cubes for 7-day and 28-day strength tests.
  • Minimum 3 pairs of beams and cubes daily per mix type.
  • Flexural strength test results govern compliance.
  • Specimens must be transported carefully to avoid damage.

• Frequency of Tests (Table 900-6):

  Test Parameter	Frequency
  Level tolerance	As per Clause 902.3
  Pavement width & edge position	Clause 902.2
  Pavement thickness	Clause 902.3 & 903.5.2.4
  Joint alignment & dowel groove	1 joint per 400 m or daily work
  Surface regularity	Once daily
  Dowel bars alignment	Trial length & once every 2 km
  Texture depth	Clause 602.12

2. Sub-base and Base Control Tests (Table 900-3)

• Granular Materials:

  • Gradation, Atterberg limits, moisture content: 1 test/400 m³
  • Density: 1 test/1000 m²

• Lime/Cement Stabilized Soil:

  • Lime/Cement quality: 1 test per consignment (min 1/5 tonnes)
  • Moisture & density: 2 tests/500 m²

3. Bituminous Works (Table 900-4)

• Prime/Tack Coat:

  • Binder quality: per IS:73, IS:217, IS:8887
  • Binder temperature: regular intervals
  • Rate of spread: 3 tests/day

• Seal Coat / Surface Dressing:

  • Aggregate impact value: 1 test/200 m³
  • Grading: 2 tests/day
  • Water absorption, stripping value, soundness: 1 test per source/change

4. General Notes

• Engineer has authority

Protective Surface Coatings & Repairs (MORTH 250)

Key Specifications for Acrylic Elastomeric Coating (Clause 2808.2 & Table 2800-2)

Protective Coatings for Steel (Table 1900-3)

Traffic Management During Construction (MORTH 250)

Key Specifications from Clauses 112.1 & 112.4:

• Traffic Management Plan (TMP): Must be prepared and approved before work starts, including:

  • Safety officer & team
  • Traffic safety devices & signs as per IRC:SP:55
  • Worker safety (PPE)
  • First aid & emergency response
  • Detailed drawings of traffic arrangements

• Traffic Safety Measures:

  • Barricades with black & white stripes, red warning lights at night (sunset to sunrise)
  • Flashing yellow beacons on all construction equipment in traffic lanes
  • Protection of drop-offs with a 1:4 vertical to horizontal wedge of compacted stable material
  • Clear channel marking with pavement markings, painted drums, lanterns (solar lights allowed)
  • One-way traffic via temporary signals or flagmen with red/green flags and lanterns

• Signage:

  • Minimum 2 reflective signs on each approach: one at transition start, one 120 m before
  • Signs per Engineer’s approval and IRC guidelines

Drop-off Protection Formula:

Traffic Control Devices Reference:

• IRC:SP:55 (for device types, sizes, and placement)
• Section 100 of MORTH 250 (for signage, signaling, barricading, lighting)

flowchart TD
    A[Start Construction] --> B[Prepare Traffic Management Plan]
    B --> C[Engineer Approval]
    C --> D[Implement Traffic Safety Measures]
    D --> E[Set Barricades & Signs]
    E --> F[Protect Drop-offs (1:4 slope wedge)]
    F --> G[Manage Traffic Flow (One-way, Flagmen, Signals)]
    G --> H[Continuous Monitoring & Safety]
    H --> I[Completion & Removal of Devices (With Engineer Approval)]

Summary: The contractor must ensure minimal traffic disruption by providing safe, well-marked, and illuminated traffic passages, using approved signage, barricades, and safety personnel, following IRC and MORTH specifications strictly.

MORTH 250 - Measurement and Payment: Key Points

Though specific clauses are not provided, typical MORTH (Ministry of Road Transport and Highways) specifications for Measurement and Payment include:

Key Formulas:

• Quantity Measurement:
  [ \text{Quantity} = \text{Length} \times \text{Width} \times \text{Thickness} ] (For earthwork, concrete, bituminous layers, etc.)

• Payment Calculation:
  [ \text{Payment} = \text{Quantity} \times \text{Rate per unit} ]

Common Specifications:

• Measurements are taken net after deductions for openings or voids.
• Payment is made only for work done and verified by site measurements.
• Units vary by work type:
  • Earthwork: cubic meters (m³)
  • Bituminous work: square meters (m²) or tonnes
  • Concrete: cubic meters (m³)

Typical Tables (Example for Bituminous Work):

flowchart LR
    A[Measurement] --> B[Verification by Engineer]
    B --> C[Quantity Calculation]
    C --> D[Apply Unit Rates]
    D --> E[Payment]

For exact details, refer to the latest MORTH specifications or detailed contract documents.

Communication Systems for Toll and Emergency (MORTH 250)

1. Lane Communication System (Clause 815.11)

• Hands-free two-way voice communication between toll collectors and control room.
• Toll collector alerts supervisor by pressing a single button.
• Supervisor can monitor any lane communication silently.
• Operates independently of lane computer system.
• Supports broadcast (one-way) communication from control room to all lanes.
• Implemented in toll booths, plaza rooms, and access points.

2. Mobile Radio Communication System (Clause 816.10.1 & 816.10.2)

• Covers entire route, modular, rugged, and maintenance-friendly.
• Components:
  • Base Station Unit: transmitter, receiver, antenna, power supply.
  • Repeater Unit: extends coverage, installed at sub-centres.
  • Mobile Units: mounted on ambulances, cranes, patrol vehicles; unique address codes.
• Features on control panels:
  • Power ON/OFF, emergency call button, volume control, digital display, functional buttons.
• Operates on rechargeable batteries with 24-hour backup.

3. Emergency Call Management System (Clause 816.17.2)

• PC-based console with graphical highway map.
• Audible/visual alerts for:
  • Incoming calls,
  • Call box status (healthy, faulty, in call, on hold).
• Call queueing, logging, recording conversations.
• Periodic health checks with alarms for faults or vandalism.
• Unique call numbers, operator annotations.
• Multiple operator terminals expandable.
• Supports call hold, terminate, and seamless configuration of call boxes.
• Audio-visual alerts for handicapped operation.

Summary Table: Key Features

flowchart LR
    TollCollector -- Press Button --> Supervisor
    Supervisor -- Monitor Silently --> TollCollector
    ControlRoom --

Key Specifications & Guidelines for Storage and Handling of Materials (MoRTH 250)

• Storage Location: Near site, firm levelled ground, access roads free from water logging.
• Handling Equipment: Mobile cranes, gantries, derricks, chain pulley blocks, winches with adequate capacity.
• Stacking: Use racks, stands, sleepers, and access tracks; ensure proper lighting.
• Material Protection:
  • Fabricated steel marked and kept off ground/water.
  • Store all materials above ground on platforms/skids.
  • Keep materials free from dirt, corrosion, distortion.
• Special Storage:
  • Electrodes: Dry, warm racks.
  • Bolts, nuts, washers: In gunny bags on racks, coated with protective oil.
  • Paint: Airtight containers.
  • Tools: Covered containers.
• Quality Control: Reject rusted, bent, or damaged steel.
• Standards to Follow: IS 7293, IS 7969 for safe handling.
• Responsibility: Contractor liable for material loss/damage.

Recommended Storage Setup Diagram

graph TD
    A[Storage Area] --> B[Firm Levelled Ground]
    A --> C[Handling Equipment]
    C --> D[Mobile Crane]
    C --> E[Gantries/Derricks]
    C --> F[Chain Pulley Blocks]
    A --> G[Stacking Racks & Sleepers]
    G --> H[Fabricated Steel (Marked)]
    G --> I[Raw Steel]
    G --> J[Electrodes (Dry/Warm)]
    G --> K[Fasteners (Oiled)]
    G --> L[Paint (Airtight)]
    G --> M[Tools (Covered)]

Note: Plan storage to suit erection sequence and avoid damage. Always get Engineer’s approval for storage & handling methods.

Safety and Environmental Considerations (MORTH 250 - Clauses 816.7, 816.8, 2804, 1208)

1. System Safety Requirements (Clause 816.7)

• ATMS classified as safety-related; software integrity level SIL 2 (EN50128).
• Equipment installation per IEC 65, IEC 364.
• Metal enclosures must have earthing terminals; earthing per overall policy.

2. Environmental/Climatic Requirements (Clause 816.8)

• IS:9000 Tests for traffic signs and road equipment:
  • Temperature cycling: 0°C ±3°C to 60°C ±2°C, rate 1°C/min, 3 cycles, 3 hours each.
  • Damp heat cyclic: 25°C to 40°C, 95% RH, 6 cycles of 12 hours.
  • Vibration: 10–55 Hz, 0.35 mm amplitude, 20 sweep cycles, 3 axes, 30 min at resonance.

3. Personnel and Environmental Safety (Clause 2804.1.8)

• Avoid skin contact with epoxy (especially hardeners).
• Use rubber gloves with cloth liner, protective clothing, eye protection, and respirators during spraying.
• Wash skin immediately if contact occurs; flush eyes for 15 minutes if contaminated.
• Dispose of used materials and containers properly.

4. Repair Materials (Polymer Mortar) (Clause 2804.2)

• Latex acrylic polymer with:
  • Pot life: 60 minutes at 30°C
  • Compressive strength: ≥18.2 N/mm² at 28 days
  • Flexural strength: 3.0 to 5.0 N/mm² at 28 days
  • Slant shear bond: 3.0 to 5.0 N/mm²

5. **Well Foundation Safety (Clause 1208.8.9