Sub-Bases, Bases (Non-Bituminous) and Shoulders

Section 400

401. GRANULAR SUB-BASE

401.1. Scope
This work shall consist of laying and compacting well-graded material on
prepared sub-grade in accordance with the requirements of these Specifications. The
material shall be laid in one or more layers as sub-base lower sub-base and upper sub-
base (termed as sub-base hereinafter) as necessary according to lines, grades and cross-
sections shown on the drawing or as directed by the Engineer.

401.2. Materials
401.2.1. The Material to be used for the work shall be natural sand, moorum,
gravel, crushed stone, or combination thereof depending upon the grading required.
Materials like crushed slag, crushed concrete, brick metal and kankar may be allowed
only with the specific approval of the Engineer. The material shall be free from organic
or other deleterious constituents and conform to one of the three gradings given in
Table 400-1.
While the gradings in Table 400-1 are in respect of close-graded granular sub-
base materials, one each for maximum particle size of 75 mm, 53 mm and 26.5 mm, the
corresponding gradings for the coarse-graded materials for each of the three maximum
particle sizes are given at Table 400-2. The grading to be adopted for a project shall be
as specified in the Contract.
401.2.2. Physical requirements: The Material shall have a 10 per cent fines
value of 50 kN or more (for sample in soaked condition) when tested in compliance
with BS: 812 (Part 111). The water absorption value of the coarse aggregate shall be
determined as per IS: 2386 (Part 3); if this value is greater than 2 per cent, the
soundness test shall be carried out on the material delivered to site as per IS: 383. For
Grading II and II materials, the CBR shall be determined at the density and moisture
content likely to be developed in equilibrium conditions which shall be taken as being
the density relating to a uniform air voids content of 5 per cent.
TABLE 400-1. GRADING FOR CLOSE-GRADED GRANULAR
SUB-BASE MATERIALS
_______________________________________________________________
IS Sieve Per cent by weight passing the IS sieve
------------------------------------------------------------
Designation Grading I Grading II Grading III
__________________________________________________________________
75.0 mm 100 --- ---
53.0 mm 80-100 100 ---
26.5 mm 55-90 70-100 100
9.50 mm 35-65 50-80 65-95
4.75 mm 25-55 40-65 50-80
2.36 mm 20-40 30-50 40-65
0.425 mm 10-25 15-25 20-35
0.075 mm 3-10 3-10 3-10
_________________________________________________________________________
CBR Value (Minimum) 30 25 20

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

TABLE 400-1. GRADING FOR CLOSE-GRADED GRANULAR

SUB-BASE MATERIALS
________________________________________________________________
IS Sieve Per cent by weight passing the IS sieve
------------------------------------------------------------
Designation Grading I Grading II Grading III
________________________________________________________________
75.0 mm 100 --- ---
53.0 mm 100 ---
26.5 mm 55-75 50-80 100
9.50 mm
4.75 mm 10-30 15-35 25-45
2.36 mm
0.425 mm
0.075 mm <10 <10 <10
________________________________________________________________
CBR Value(Minimum) 30 25 20
________________________________________________________________

Note: The Material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS: 2720
(Part 5) shall have liquid limit and plasticity index not more than 25 and 6 per cent respectively.

401.3. Strength of Sub-Base

It shall be ensured prior to actual execution that the material to be used in the
sub-base satisfies the requirements of CBR and other physical requirements when
compacted and finished.

When directed by the Engineer, this shall be verified by performing CBR tests
in the laboratory as required on specimens remoulded at field dry density and moisture
content and any other tests for the “quality” of materials, as may be necessary.

401.4. Construction Operation

401.4.1. Preparation of Sub-grade: Immediately prior to the laying of sub-

base, the sub-grade already finished to Clause 301 or 305 as applicable shall be
prepared by removing all vegetation and other extraneous matter, lightly sprinkled with
water if necessary and rolled with two passes of 80 – 100 kN smooth wheeled roller.

401.4.2. Spreading and Compacting: The sub-base material of grading

specified in the Contract shall be spread on the prepared sub-grade with the help of a
motor grader of adequate capacity, its blade having hydraulic controls suitable for
initial adjustment and for maintaining the required slope and grade during the operation
or other means as approved by the Engineer.

When the sub-base material consists of combination of materials mentioned in

Clause 401.2.1, mixing shall be done mechanically by the mix-in-place method.

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Section 400

Manual mixing shall be permitted only where the width of laying is not
adequate for mechanical operations, as in small-sized jobs. The equipment used for
mix-in-place construction shall be rotavator or similar approved equipment capable of
mixing the material to the desired degree. If so desired by the Engineer, trial runs with
the equipment shall be carried out to establish its suitability for the work.

Moisture content of the loose material shall be checked in accordance with IS:
2720 (Part 2) and suitably adjusted by sprinkling additional water from a truck mounted
or trailer mounted water tank and suitable for applying water uniformly and at
controlled quantities to variable widths of surface or other me4ans approved by the
Engineer so that, at the time of compaction, it is from 1 per cent below the optimum
moisture content corresponding to IS: 2720 (Part 8). While adding water, due
allowance shall be made for evaporation losses. After water has been added, the
material shall be processed by mechanical or other approved means like disc harrows,
rotavators until the layer is uniformly wet.

Immediately thereafter, rolling shall start. If the thickness of the compacted

layer does not exceed 100 mm, a smooth wheeled roller of 80 to 100 kN weight may be
used. For a compacted single layer up to 225 mm the compaction shall be done with
the help of a vibratory roller of minimum 80 to 100 kN static weight with plain drum or
pad foot-drum or heavy pneumatic tyred roller of minimum 200 to 300 kN weight
having a minimum tyre pressure of 0.7 MN/m 2 or equivalent capacity roller capable of
achieving the required compaction. Rolling shall commence at the lower edge and
proceed towards the upper edge longitudinally for portions having unidirectional cross-
fall and super-elevation and shall commence at the edges and progress towards the
centre for portions having cross-fall on both sides.

Each pass of the roller shall uniformly overlap not less than one-third of the
track made in the proceeding pass. During rolling, the grade and cross-fall shall be
checked and any high spots or depressions, which become apparent, corrected by
removing or adding fresh material. The speed of the roller shall not exceed 5 km per
hour.

Rolling shall be continued till the density achieved is at lease 98 per cent of the
maximum dry density for the material determined as per IS:2720 (Part 8). The surface
of any layer of material on completion of compaction shall be well closed, free from
movement under compaction equipment and from compaction planes, ridges cracks or
loose material. All loose, segregated or otherwise defective areas shall be made good
to the full thickness of layer and re-compacted.

401.5. Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause

902.

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Section 400

Control on quality of materials and works shall be exercised by the Engineer in

accordance with Section 900.

401.6. Arrangements for Traffic

During the period of construction, arrangement of traffic shall be maintained in

accordance with Clause 112.

401.7. Measurements for Payment

Granular sub-base shall be measured as finished work in position in cubic

metres.

The protection of edges of granular sub-base extended over the full formation as
shown in the drawing shall be considered incidental to the work of providing granular
sub-base and as such no extra payment shall be made for the same.

401.8. Rate

The Contract unit rate for granular sub-base shall be payment in full for
carrying out the required operation including full compensation for:
(i) Making arrangements for traffic to Clause 112 except for initial treatment to verges, shoulders and
construction of diversions;

(ii) furnishing all materials to be incorporated in the work including all royalties, fees, rents where necessary and
all leads and lifts;

(iii) all labour, tools, equipment and incidentals to complete the work to the Specifications;

(iv) carrying out the work in part widths of road where directed; and

(v) carrying out the required tests for quality control.

402. LIME TREATED SOIL FOR IMPROVED

SUB-GRADE/SUB-BASE

402.1. Scope

This work shall consist of laying and compacting an improved sub-grade/lower

sub-base of soil treated with lime on prepared sub-grade in accordance with the
requirements of these Specifications and in conformity with the lines, grades and cross-
sections shown on the drawings or as directed by the Engineer. Lime treatment is
generally effective for soils, which contain a relatively high percentage of clay and silty
clay.

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Section 400

402.2. Materials

402.1.1. Soil: Except when otherwise specified, the soil used for stabilisation
shall be the local clayey soil having a plasticity index greater than 8.
402.2.2. Lime: Lime for lime-soil stabilisation work shall be commercial dry
lime slaked at site or pre-slaked lime delivered to the site in suitable packing. Unless
otherwise permitted by the Engineer, the lime shall have purity of not less than 70 per
cent by weight of Quicklime (CaO) when tested in accordance with IS: 1514. Lime
shall be properly stored to avoid prolonged exposure to the atmosphere and consequent
carbonation, which would reduce its binding properties.

402.2.3. Quantity of Lime in stabilised mix: Quality of lime to be added as

percentage by weight of the dry soil shall be as specified in the Contract. The quantity
of lime used shall be related to its calcium oxide content, which shall be specified.
Where the lime of different calcium oxide content is to be used, its quantity shall be
suitably adjusted to the approval of the Engineer so that equivalent calcium oxide is
incorporated in the work. The mix design shall be done to arriv3e at the appropriate
quantity of lime to be added, having due regard to the purity of lime, the type of soil,
the moisture-density relationship, and the design CBR/Unconfident Compressive
Strength (UCS) value specified in the Contract. The laboratory CBR/UCS value shall
be at least 1.5 times the minimum field value of CBR/UCS stipulated in the Contract.

402.2.4. Water: The water to be used for lime stabilisation shall be clean and free
from injurious substances. Potable water shall be preferred.

402.3. Construction Operations

402.3.1. Weather limitations: Lime-soil stabilisation shall not be done when the air
temperature in the shade is less than 10 C.

402.3.2. Degree of pulverisation: For lime stabilisation, the soil before addition of
stabiliser, shall be pulverised using agricultural implements like disc harrows
and ratovators to the extent that it passes the requirements set out in Table
400-3 when tested in accordance with the method described in Appendix 3.

TABLE 400-3. SOIL PULVERISATION REQUIREMENTS FOR

LIME STABILISATION

IS Sieve designation Minimum per cent by weight

Passing the IS Sieve

26.5 mm 100
5.6 mm 80
______________________________________________________________________

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

402.3.3. Equipment for Construction: Stabilised soil sub-bases shall be

constructed by mix-in-place method of construction or as otherwise approved by the
Engineer. Manual mixing shall be permitted only where the width of laying is not
adequate for mechanical operations, as in small-sized jobs.

The equipment used mix-in-place construction shall be rotavator or similar

approved equipment capable of pulverising and mixing the soil with additive and water
to specified degree to the full thickness of the layer being processed, and of achieving
the desired degree of mixing and uniformity of the stabilised material. If so desired by
the Engineer, trail runs with the equipment shall be carried out to establish its
suitability for work.

The thickness of any layer to be stabilised shall be not less than 100 mm when
compacted. The maximum thickness shall be 200 mm, provided the plant used is
accepted by the Engineer.

402.3.4. Mix-in-place method of construction: Before deploying the

equipment, the soil after it is made free of undesirable vegetation or other deleterious
matters shall be spread uniformly on the prepared sub-grade in a quantity sufficient to
achieve the desired compacted thickness of the stabilised layer. Where single-pass
equipment is to be employed, the soil shall be lightly rolled at the discretion of the
Engineer.

The Equipment used shall either be of single-pass or multiple pass type. The
mixers shall be equipped with an appropriate device for controlling the depth of
processing and the mixing blades shall be maintained or reset periodically so that the
correct depth of mixing is obtained at all times.

With single-pass equipment the forward speed of the machine shall be so

selected in relation to the rotor speed that the required degree of mixing, pulverisation
and depth of processing is obtained. In multiple-pass processing, the prepared sub-
grade shall be pulversied to the required depth with successive passes of the equipment
and the moisture content adjusted to be within prescribed limits mentioned hereinafter.
The blending or stabilising material shall then be spread uniformly and mixing
continued with successive passes until the required depth and uniformity of processing
have been obtained.

The mixing equipment shall be so set that it cuts slightly into the edge of the
adjoining lane processed previously so as to ensure that all the material forming a layer
has been properly processed for the full width.

402.3.5. Construction with manual means: Where manual mixing is

permitted, the soil from borrow areas shall first be freed of all vegetation and other
deleterious matter and placed on the prepared sub-grade. The soil shall then be
pulverised by means of crow-bars, pick axes or other means approved by the Engineer.

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Section 400

Water in requisite quantities may be sprinkled on the soil for aiding

pulverisation. On the pulverised soil, the blending materials(s) in requisite quantities
shall be spread uniformly and mixed thoroughly by working with spades or other
similar implements till the whole mass is uniform. After adjusting the moisture content
to be within the limits mentioned later, the mixed material shall be levelled up to the
required thickness so that it is ready to be rolled.
402.3.6. Addition of Lime : Lime may be mixed with the prepared material
either in slurry form or dry state at the option of the Contractor with the approval of the
Engineer.

Dry lime shall be prevented from blowing by adding water to the lime or other
suitable means selected by the Contractor, with the approval of the Engineer.

The tops of windrowed material may be flattened or slightly trenched to receive

the lime. The distance to which lime may spread upon the prepared material ahead of
the mixing operation shall be determined by the Engineer.

No traffic other than the mixing equipment shall be allowed to pass over the
spread lime until after completion of mixing.

Mixing or re-mixing operations, regardless of equipment used, shall continue

until the material is free of any white streaks or pockets of lime and the mixture is
uniform.

Non-uniformity of colour reaction, when the treated material is tested with the
standard phenolphthalein alcohol indicator, will be considered evidence of inadequate
mixing.
402.3.7. Moisture content for compaction: The moisture content at
compaction checked vide IS: 2720 (Part 2) shall neither be less than the optimum
moisture content corresponding to IS: 2720 (Part 8) nor more than 2 per cent above it.

402.3.8. Rolling: Immediately after spreading, grading and levelling of the

mixed material, compaction shall be carried out with approved equipment preceded by
a few passes of lighter rollers if necessary. Rolling shall commence at edges and
progress towards centre, except at superelevated portions where it shall commence at
the inner edge and progress towards outer edge. During rolling the surface shall be
frequently checked for grade and cross-fall (camber) and any irregularities corrected by
loosing the material and removing/adding fresh material. Compaction shall continue
until the density achieved is at least 98 per cent of the maximum dry density for the
material determined in accordance with IS: 2720 (Part 8).

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

Care shall be taken to see that the compaction of lime stabilised material is
completed within three hours of its mixing or such shorter period as may be found
necessary in dry weather.

During rolling it shall be ensured that roller does not bear directly on hardened
or partially hardened treated material previously laid other than what may be necessary
for achieving the specified compaction at the joint. The final surface shall be well
closed, free from movement under compaction planes, ridges, cracks or loose material.
All loose or segregated or otherwise defective areas shall be made good to the full
thickness of the layer and recompacted.

402.3.9. Curing: The sub-base course shall be suitably cured for a minimum
period of 7 days after which subsequent pavement courses shall be laid to prevent the
surface from drying out and becoming friable. No traffic of any kind shall ply over the
completed sub-base unless permitted by the Engineer.

402.4. Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause

902.

Control on the quality of materials and works shall be exercised by the Engineer
in accordance with Section 900.

402.5. Strength
When lime is used for improving the sub-grade, the soil-lime mix shall be tested
for its CBR value. When lime stablised soil is used in a sub-base, it shall be tested for
unconfined compressive strength (UCS) at 7 days. In case of variation from the design
CBR/UCS, in situ value being lower, the pavement design shall be reviewed based on
the actual CBR/UCS value shall be constructed by the Contractor at his own cost.

402.6. Arrangements of Traffic

During the period of construction, arrangement of traffic shall be maintained in
accordance with Clause 112.

402.7. Measurements for Payment

Stabilised soil sub-base shall be measured as finished work in position in cubic
metres.

402.8. Rates

The Contract unit rate for lime stabilised soil sub-base shall be payment in full
for carrying out the required operations including full compensation for all components
listed in Clause 401.8 (i) to (v).

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

403. CEMENT TREATED SOIL SUB-BASE/BASE

403.1. Scope

This work shall consist of laying and compacting a sub-base/base course of soil
treated with cement on prepared sub-grade/sub-base, in accordance with the
requirements of these Specifications and in conformity with the lines, grades and cross-
sections shown on the drawings or as directed by the Engineer.

403.2. Materials

403.2.1. Material to be stabilised : The material used for cement treatment

shall be including sand and gravel, laterite, kankar, brick aggregate, crushed rock or
slag or any combination of these. For use in a sub-base course, the material shall have
a grading shown in Table 400-4; it shall have a uniformity coefficient not less than 5,
capable of producing a well closed surface finish. For use in a base course, the material
shall be sufficiently well graded to ensure a well-closed surface finish and have a
grading within the range given in Table 400-4. If the material passing 425 micron sieve
is plastic, it shall have liquid limit not greater than 45 per cent and plasticity index not
grater than 20 per cent determined in accordance with IS:2720 (Part 5). The physical
requirements for the material to be treated with cement for use in a base course shall be
same as for Grading I Granular Sub-base, clause 401.2.2.

403.2.2. Cement: Cement for cement stabilisation shall comply with the
requirements of IS: 269. 455 OR 1489.

TABLE 400-4 GRADING LIMITS OF MATERIAL FOR

STABILISATION WITH CEMENT

Percentage by mass Passing

IS Sieve Size Sub-base Base

Finer than : Within the range :

53.0 mm 100 100

37.5 mm 95 95-100
19.0 mm 45 45-100
9.5 mm 35 35-100
4.75 mm 25 25-100
600 micron 8 8-65
300 micron 5 5-40
75 micron 0 0-10

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

403.2.3. Lime: If needed for pre-treatment of highly clayey soils, Clause

402.2.2 shall apply.

403.2.4. Quantity of cement in stabilised mix: The quantity of cement to be

added as per cent by weight of the dry soil shall be specified in the Contract. Also if
lime is used as pretreatment for highly clayey soils, the quantity as per cent by weight
of dry soil shall be specified in the Contract. The mix design shall be done on the basis
of 7-day unconfined compressive strength (UCS) and/or durability test under 12 cycles
of wet-dry conditions. The laboratory strength values shall be at least 1.5 times the
minimum field UCS value stipulated in the Contract.

403.2.5. Water: The water to be used for cement stabilisation shall be clean and
free from injurious substances. Potable water shall be preferred.

403.3. Construction Operations

403.3.1. Degree of Pulverisation: For stabilisation shall not be done when the
air temperature in the shade is less 100. C.

403.3.2. Degree of pulverisation: For stabilisation, the soil before addition of

stabilizer, shall be pulverised, where necessary, to the extent that it passes the
requirements as set out in Table 400-5 when tested in accordance with the method
described in Appendix 3.

TABLE 400-5. SOIL PULVERISATION REQUIREMENTS FOR

CEMENT STABILISATION
IS Sieve designation Minimum
by weight passing the IS sieve

26.5 mm 100

5.6 mm 80

403.3.3. Clauses 402.3.3. to 402.3.5 shall apply as regards spreading and

mixing the stabiliser except that cement or lime plus cement as the case may be, shall
be used as the stabilising material.

403.3.4. Moisture content for Compaction: The moisture content at

compaction checked vide IS: 2720 (Part 2) shall not be less than the optimum moisture
content corresponding to IS: 2720 (Part 8) nor more than 2 per cent above it.

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

403.3.5. Rolling: Clauses 402.3.8 shall apply except that care shall be taken to
see that the compaction of cement stabilised material is completed within two hours of
its mixing or such shorter period as may be found necessary in dry weather.

403.3.6. Curing: The sub-base/base course shall be suitably cured for 7 days.
Subsequent pavement course shall be laid soon after to prevent the surface from drying
out and becoming friable. No traffic of any kind shall ply over the completed sub-base
unless permitted by the Engineer.

403.4. Surface Finish and Quality Control of Works :

The surface finish of construction shall conform to the requirements of Clause

902.

403.5. Strength

Control on the quality of materials and works shall be exercises by the Engineer
in accordance with Section 900.

Cement treated soil sub-base/base shall be tested for the unconfined

compressive strength (UCS) value at 7 days, actually obtained in situ. In case of
variation from the design UCS, in situ value being on lower side, prior to proceeding
with laying of base/surface course on it, the pavement design shall be reviewed for
actual UCS value. The extra pavement thickness on account of lower UCS shall be
constructed by the Contractor at his own cost.

403.6. Arrangements for Traffic

During the period of construction, arrangements of traffic shall be maintained in

accordance with Clause 112.

403.7. Measurements for Payment

Stabilised soil-sub-base/base shall be measured as finished work in position in

cubic metres.

403.8. Measurements for Payment

The Contract unit rate for cement treated soil sub-base/base with pretreatment
with lime if required shall be payment in full for carrying out the required operations
including full compensation for all components listed in Clause 401.8 (I) to (V)

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Section 400

404. WATER BOUND MACADAM SUB-BASE/BASE

404.1. Scope

404.1.1. This work shall consist of clean, crushed aggregates mechanically

interlocked by rolling and bonding together with screening binding material where
necessary and water laid on a properly prepared sub-grade/sub-base/base or existing
pavement, as the case may be and finished in accordance with the requirements of these
Specifications and in close conformity with the lines, grades, cross-sections and
thickness as per approved plans or as directed by the Engineer.

404.1.2. It is however, not desirable to lay water bound macadam on an existing

thin black topped surface without providing adequate drainage facility for water that
would get accumulated at the interface of existing bituminous surface and water bound
macadam.

404.2. Material

404.2.1 Coarse aggregates: Coarse aggregates shall be either crushed or

broken stone, crushed slag, overburnt (Jhama) brick aggregates or any other naturally
occurring aggregates such as kankar and laterite of suitable quality. Materials other
than crushed or broken stone and crushed slag shall be used in sub-base courses only.
If crushed gravel/shingle pieces retained on 4.75 mm sieve shall have at least two
fractured faces. The aggregates shall conform to the physical requirements set forth in
Table 400-6. The type and size range of the aggregate shall be specified in the Contract
or shall be as specified by the Engineer. If the water absorption value of the coarse
aggregate is greater than 2 per cent, the soundness test shall be carried out on the
material delivered to site as per IS: 2386 (Part 5).

404.2.2. Crushed or broken stone: The crushed or broken stone shall be hard,
durable and free from excess flat, elongated, soft and disintegrated particles, dirt and
other deleterious material.

TABLE 400-6. PHYSICAL REQUIREMENTS OF COARSE AGGREGATES

FOR
WATER BOUND MACADAM FOR SUB-BASE/BASE COURSES

Test Test Method Requirements

1.  Los Angeles IS : 2386 40 per cent (Max)
Abrasion Value (Part – 4)
Or
 Aggregate IS : 2386 30 per cent (Max)
Impact Value (Part – 4) or
IS:5640 **

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Section 400

2. Combined Flakiness IS : 2386 30 per cent (Max)

and (Part – 1)
Elongation Indices
(Total)

* * *

 Aggregate may satisfy requirements of either of the two tests.

** Aggregates like brick metal, kankar, laterite etc., which get softened in presence of
water shall be tested for Impact value under wet conditions in accordance with IS:
5640.

*** The requirement flakiness index and elongation index shall be enforced only in the
case of crushed broken stone and crushed slag.

404.2.3. Crushed slag: Crushed slag shall be made from air-cooled blast
furnace slag. It shall be of angular shape, reasonably uniform in quality and density
and generally free from thin, elongated and soft pieces, dirt or other deleterious
materials. The weight of crushed slag shall not be less than 11.2 kN per m 3 and the
percentage of glossy material shall not be more than 20. It should also comply with the
following requirements:

(i) Chemical stability : To comply with requirements of appendix of BS: 1047.

(ii) Sulphur Content : Maximum 2 per cent.

(iii) Water abosorption : Maximum 10 per cent.

404.2.4. Over-burnt (Jhama) brick aggregates: Jhama brick aggregates shall

be made from over-burnt bricks or brick bats and the free from dust and other
objectionable and deleterious materials.

404.2.5. Grading requirement of coarse aggregates : The coarse aggregates

shall confirm to one of the Gradings given in Table 400-7 as specified, provided,
however, the use of Grading No.1 shall be restricted to sub-base courses only.

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Section 400

TABLE 400-7. GRADING REQUIR

EMENTS OF COARSE AGGREGATES

Grading Size Range IS Sieve Per Cent by

No. Designation Weight Passing

1. 90 mm to 45 mm 125 mm 100
90 mm 90-100
63 mm 25-60
45 mm 0-15
22.4 mm 0-5

2. 63 mm to 45 mm 90 mm 100
63 mm 90-100
53 mm 25-75
45 mm 0-15
22.4 mm 0-5

3. 53 mm to 22.4 mm 63 mm 100
53 mm 95-100
45 mm 65-90
22.4 mm 0-10
11.2 mm 0-5

Note: The impact thickness for a layer with Grading 1 shall be 100 mm while for layer with other Gradings ie2 &
3, it shall be 75 mm.

404.2.6. Screening: Screenings to fill voids in the coars aggregate shall

generally consist of the same material as the to the coarse aggregate. However, where
permitted, predominately non-plastic material such as moorum or gravel (other than
rounded river borne material) may be used for this purpose provided liquid limit and
plasticity index of such material are below 20 and 6 respectively fraction passing 75
micron does not exceed 10 per cent.

Screening shall conform to the grading set forth in Table 400-8. The
consolidated details of quantity of screening required for various grades of stone
aggregates are given in Table 400-9. The table also gives the quantities of materials
(loose) required for 10 m2 for sub-base/base compacted thickness of 100/75 mm.

The use of screening shall be omitted in the case of soft aggregates such as
brick metal, kankar, laterites, etc. as they are likely to get crushed to a certain extent
under rollers.

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Section 400

TABLE 400-8. GRADING FOR SCREENINGS

Grading Size of IS Sieve Per cent by weight

Classif- Screening Designation Passing the IS Sieve
Cation

A. 13.2 13.2 mm 100

mm 11.2 Mm 95-100
5.6 mm 15-35
180 micron 0-10

B. 11.2 mm 100
11.2 5.6 mm 90-100
mm 180 micron 15-35

TABLE 400-9. APPROXIMATE QUANTITIES OF COARSE

AGGREGATES AND SCREENINGS REQUIRED FOR 100/75 MM
COMPACTED THICKNESS OF WATER BOUND MACADAM (WBM)
SUB-BASE/BASE COURSE FOR 10M2 AREA

Screenings

Stone Screening Crushable Type such

Classi- Size Compact Loose As Moorum or Gravel
Fication Range -ed Qty.
Thick-
Ness Grading For WBM Grading Loose
Classi- Sub-base Classi- Quantity
Fication Base Course Fication
& Size (Loose & Size
Quantity)

Grading 1 90 mm 100 mm 1.21 to Type A 0.27 to Not 0.30 to

to 1.43 m3 13.2 mm 0.30 m3 Uniform 0.32 m3
45 mm
Grading 2 75 mm 0.91 to Type A 0.12to -do- 0.22 to
63 mm 1.07 m3 13.2 mm 0.15 m3 0.24 m3
to
-do- 45 mm -do- -do- -do- 0.20to -do- -do-
0.21m3

15
 Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

-do-
Grading 3 75 mm -do- -do- 0.18 to -do- -do-
0.21 m3
53 mm
to
22.4
mm

404.2.7. Binding Material: Binding material to be used for water bound

macadam as a filler material meant for preventing ravelling, shall comprise of a suitable
material approved by the Engineer having a Plasticity Index (PI) value of less than 6 as
determined in accordance with IS: 2720 (Part-5).

The quantity of binding material where it is to be used, will depend on the type
of screening. Generally, the quantity required for 75 mm compacted thickness of water
bound macadam will be 0.06-0.09 m 3/10m2 and 0.08-0.010 m3/10m2 for 100 mm
compacted thickness.

The above mentioned quantities should be taken as a guide only, for estimation
of quantities for construction etc.

Application of binding materials may not be necessary when the screening used
are of crushable type such as moorum or gravel

404.3. Construction Operations

404.3.1. Preparation of base: The surface of the sub-grade/sub-base/base to

received the water bound macadam course shall be prepared to the specified lines and
cross-fall (camber) and made free of dust and other extraneous material. Any ruts of
soft yielding places shall be corrected in an approved manner and rolled until firm
surface is obtained if necessary by sprinkling water. Any sub-base/base/surface
irregularities, where predominant, shall be made good by providing appropriate type of
profile corrective course (levelling course) of Clause 501 of these Specifications.

As far as possible, laying waterbound macadam course over an existing thick

bituminous layer may be avoided since it will cause problems of internal drainage of
the pavement at the interface of two courses. It is desirable to completely pick out the
existing thin bituminous wearing course where water bound macadam is proposed to be
laid over it. However, where the intensity of rain is low and the interface drainage
facility is efficient, water bound macadam can be laid over the existing thin bituminous
surface by cutting 50 mm x 50 mm furrows at an angle of 45 degree to the centre line
of the pavement at one metre intervals in the existing road. The directions and depth of

16
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

furrows shall be such that they provide adequate bondage and also serve to drain water
to the existing granular base course beneath the existing thin bituminous surface.

404.3.2. Inverted Choke: If water bond macadam is to be laid directly over the
subgrade, without any other intervening payment course, a 25 mm course of screenings
(Grading B) or coarse sand shall be spread on the prepared sub-grade before application
of the aggregate is taken-up. In case of fine sand or silty or clayey sub-grade, it is
advisable to lay 100 mm insulating layer of screening or coarse sand on top of fine
grained soil, the gradation of which will depend upon whether it is intended to act as
drainage layer as well. As a preferred alternative to inverted choke, appropriate
geosynthetics performing functions of separation and drainage may be used over the
prepared sub-grade as directed by the Engineer. Section 700 shall be applicable for use
of geosyntetics.

404.3.3. Spreading coarse aggregates: The coarse aggregates shall be spread

uniformly and evenly upon the prepared sub-grade/sub-base/base to proper profile by
using templates placed across the road about 6 m apart, in such quantities that the
thickness of each compacted layer is not more than 100 mm for grading 1 and 75 mm
for Grading 2 and 3, as specified in Clause 404.2.5. Wherever possible, approved
mechanical devices such as aggregate spreader shall be used to spread the aggregate
uniformly so as to minimise the need for manual rectification afterwards. Aggregates
placed at locations which are inaccessible to the spreading equipment, may be spread in
one or more layers by any approved means so as to achieve the specified results.

The spreading shall be done from stockpiles along the side of the roadway or
directly from vehicles. No segregation of large or fine aggregates shall be allowed and
the coarse aggregate as spread shall be of uniform gradation with no pockets of fine
material.

The surface of the aggregates spread shall be carefully checked with the
templates and all high or low spots remedied by removing or adding aggregates as may
be required. The surface shall be checked frequently with a straight edge while
spreading and rolling so as to ensure a finished surface as per approved drawings.

The coarse aggregates shall not normally be spread more than 3 days in advance
of the subsequent construction operations.

404.3.4. Rolling: Immediately following the spreading of the coarse aggregate,

rolling shall be started with three wheeled power rollers of 80 to 100 kN capacity or
tandem or vibratory rollers of 80 to 100 kN static weight. The type of roller to be used
shall be approved by the Engineer based on trial run.

Except on super-elevated portions where the rolling shall proceed from inner
edge to the outer, rolling shall begin from the edges gradually progressing towards the
centre. First the edge/edges shall be compacted with roller running forward and

17
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

backward. The roller shall then move inward parallel to the centre line of the road, in
successive passes uniformly lapping preceding tracks by at least one half width.

Rolling shall be discontinued when the aggregates are partially compacted with
sufficient void space in them to permit application of screenings. However, where
screenings are not to be applied, as in the case of crushed aggregates like brick metal,
laterite and kankar, compaction shall be continued until the aggregates are thoroughly
keyed. During rolling, slight sprinkling of water may be done, if necessary. Rolling
shall not be done when the sub-grade is soft or yielding or when it causes a wave-like
motion in the sub-grade or sub-base course.

The rolled surface shall be checked transversely and longitudinally, with

templates and any irregularities corrected by loosening surface adding or removing
necessary amount of aggregates and re-rolling until the entire surface conforms to
desired cross-fall (camber) and grade. In no case shall the use of screenings to be
permitted to make up depressions.

Material which gets crushed excessively during compaction or becomes

segregated shall be removed and replaced with suitable aggregates.

It shall be ensured that shoulders are built up simultaneously along with water
bound macadam courses as per Clause 407.4.1.

404.3.5. Application of Screenings: After the coarse aggregate has been rolled
to Clause 404.3.4, screenings to completely fill the interstices shall be applied gradually
over the surface. These shall not be damp or wet at the time of application. Dry rolling
shall be done while the screenings are being spread so that vibrations of the roller cause
them to settle into the voids of the coarse aggregate. The screenings shall not be
dumped in piles but be spread uniformly in successive thin layers either by the
spreading motions of hand shovels or by mechanical spreaders, or directly from tipper
with suitable grit spreading arrangement. Tipper operating for spreading the screenings
shall be so driven as not to disturb the coarse aggregate.

The screenings shall be applied at a show and uniform rate (in three or more
applications) so as to ensure filling of all voids. This shall be accompanied by dry
rolling and brooming with mechanical brooms, handbrooms or both. In no case shall
the screenings be applied so fast and thick as to form cakes or ridges on the surface in
such a manner as would prevent the direct bearing of the rollers on the coarse
aggregate. These operations shall continue until no more screenings can be forced into
the voids of the coarse aggregate.

The spreading, rolling, and brooming of screenings shall be carried out in only
such lengths of the road which could be completed within one day’s operation.

404.3.6. Sprinkling of Water and grouting: After the screenings have been
applied, the surface shall be copiously sprinkled with water, swept and rolled. Hand

18
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

brooms shall be used to sweep the wet screenings into voids and to distribute them
evenly. The sprinkling, sweeping and rolling operation shall be continued, with
additional screenings applied as necessary until the coarse aggregate has been
thoroughly keyed, well bonded and firmly set in its full depth and a grout has been
formed of screenings. Care shall be taken to see that the base or subgrade does not get
damaged due to the addition of excessive quantities of water during construction.

In case of lime treated soil sub-base, construction of water bound macadam on

top of it can cause excessive water to flow down to the lime treated sub-base before it
has picked up enough strength (is still “green”) and thus cause damage to the sub-base
layer. The laying of water bound macadam layer in such cases shall be done after the
sub-base attains adequate strength, as directed by the Engineer.

404.3.7. Application of Binding Material : After the application of screenings

in accordance with Clauses 404.3.5 and 404.3.6. the binding material where it is
required to be used (Clause 404.2.7) shall be applied successively in two or more thin
layers at a slow and uniform rate. After each application, the surface shall be copiously
sprinkled with water, the resulting slurry swept in with hand brooms, or mechanical
brooms to fill the voids properly, and rolled during which water shall be applied to the
wheels of the rollers if necessary to wash down the binding material sticking to them.
These operations shall continue until the resulting slurry after filling of voids, forms a
wave ahead of the wheels of the moving roller.

404.3.8. Setting and Drying: After the final compaction of water bound
macadam course, the pavement shall be allowed to dry overnight. Next morning
hungry spots shall be filled with screeings or bindings material as directed, lightly
sprinkled with water if necessary and rolled. No traffic shall be allowed on the road
until the macadam has set. The Engineer shall have the discretion to stop hauling
traffic from using the completed water bound macadam course, if in his opinion it
would cause excessive damage to the surface.

The compacted water bound macadam course should be allowed to completely

dry and set before the next pavement course is laid over it.

404.4. Surface Finish and Quality Control Work

404.4.1. The surface finish of construction shall conform to the requirements of

Clause 902.

404.4.2. Control on the quality of Material and works shall be exercised by the
Engineer in accordance with Section 900.

404.4.3. The water bond macadam work shall not be carried out when the
atmospheric temperature is less than 00C in the shade.

19
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

404.4.4. Reconstruction of defective macadam: The finished surface of water

bound macadam shall conform to the tolerance of surface regularity as prescribed in
Clause 902. However, where the surface irregularity of the course exceeds the
tolerances or where the course is otherwise defective due to sub-grade soil mixing with
the aggregates, the course to its full thickness shall be scarified over the affected area,
reshaped with added material or removed and replaced with fresh material as applicable
and recompacted. In no case shall depression be filled up with screenings or binding
material.

404.4.5. Arrangement for Traffic: During the period of construction, the

arrangement of Traffic shall be done as per Clause 112.

404.4.6. Measurements for Payment: Water bound macadam shall be

measured as finished work in position in cubic metres.

404.7. Rate:

The contract unit rate for water bound macadam sub-base/base course shall be
payable in full for carrying out the required operations including full components listed
in Clause 401.8 (i) to (v) including arrangement of water used in the work as approved
by the Engineer.

20
 Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

405. CRUSHED CEMENT CONCRETE SUB-BASE/BASE

405.1. Scope

This work shall consist of breaking and crushing the damaged cement concrete
slabs and recompacting the same as sub-base/base course in one or more layers. Where
specified, it shall also include treating the surface of the top layer with a penetration
coat of bitumen. The work shall be performed on such widths and lengths as may be
specified, in accordance with the requirements of these Specifications and in
conformity with the lines, grades and cross-sections shown on the drawings or as
otherwise directed by the Engineer.

405.2. Materials

405.2.1. Coarse aggregate : Coarse aggregate for this work shall be broken
cement concrete slabs crushed to a size not exceeding 75 mm and as far as possible,
conforming to one of the gradings given in Table 400-7.

405.2.2. Key aggregate: Key aggregate for the penetration coat shall consist of
crushed stone, crushed gravel, shingle or other stones. It shall be clean, strong, durable,
of fairly cubical shape and free of disintegrated pieces, organic or other deleterious
matter and adherent coatings. The aggregate shall be hydrophobic and of low porosity.

The aggregate shall be of 11.2 mm size defined as 100 per cent passing through
13.2 mm sieve and retained on 506 mm sieve and shall satisfy the physical
requirements set forth in Table 500-3.

405.2.3. Construction Operations

405.3.1. General: Crushed cement concrete sub-base/base course may be

constructed in or two layers, depending upon the thickness of the concrete slabs
dismantled and crushed. The thickness of each layer shall, however, not exceed 100
mm in case of sub-base and 75 mm in case of base course.

The course shall be constructed as water bound macadam to Clause 404, using
crushed cement concrete as coarse aggregate except that no screenings or binding
material need be applied. Where specified, the top layer shall be treated with a
penetration coat of binder described in Clause 405.3.2.

405.3.2. Application of penetration coat over the top layer: Before the
application of the penetration coat, the surface shall be cleaned of dust, dirt and other
foreign matter, using mechanical broom or any other equipment specified by the
Engineer. Dust removed in the process shall be blown off with the help of compressed
air.

21
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

The binder shall be heated to the temperature appropriate to the grade of

bitumen used and sprayed on the dry surface in a uniform manner at the rate of 25 kg
per 10 m2 area in terms of the residual bitumen with the help of either self-heating
arrangement and spray nozzle capable of spraying bitumen at specified rates and
temperatures so as to provide a uniform, unbroken spread of bitumen. Excessive
deposits of binder caused by stopping or starting of the sprayer or through leakage or
any other reason shall be suitably corrected.

Immediately after the application of binder, the key aggregates, in a clean and
dry state shall be spread uniformly on the surface at the rate of 0.13 m 3 per 10 m2 area,
preferably by means of a mechanical gritter, capable of spreading aggregate uniformly
at specified rates or otherwise manually with the approval of the Engineer, so as to
cover the surface completely. Immediately after the application of the key aggregates,
the entire surface shall be rolled to Clause 506.3.8.

405.4. Surface Finish and Quality Control of Works

The surface finish of construction shall conform to the requirements of Clause

902.

Control on the quality of material and works shall be exercised by the Engineer
in accordance with Section 900.

405.5. Arrangements for Traffic

During the period of construction, arrangements of traffic shall be done as per

Clause 112.

405.6. Measurements for Payment

Breaking the existing cement concrete pavement slabs, crushing and

recompacting the slab material as sub-base/base course shall be measured as a single
item in terms of the volume of sub-base/base laid in position in cubic metres.
Penetration coat shall be measured as finished work in square metres.

405.7. Rates
405.7.1. The Contract unit rate for crushed cement concrete sub-base/base
course shall be payment in full for carrying out the required operations including full
compensation for:
(i) making arrangements for traffic to Clause 112 except for initial treatment to verges/shoulders and
construction of diversions;

(ii) breaking the cement concrete slabs, crushing, sieving and incompacting the slab material as sub-
base/base course;

(iii) all labour, tools, equipment and incidental to complete the work to the Specifications; and

(iv) carrying out the work in part widths of road where directed.

22
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

405.7.2. The Contract unit rate for penetration coat shall be payment in full for
carrying out the required operations including full compensation for all components
listed in Clause 504.8.

406. WET MIX MACADAM SUB-BASE/BASE

406.1. Scope

This work shall consist of laying and compacting clean, crushed, graded
aggregate and granular material, premixed with water, to a dense mass on a prepared
subgrade/sub-base/base or existing pavement as the case may be in accordance with the
requirements in these Specifications. The Material shall be laid in one or more layers
as necessary to lines, grades and cross-sections shown on the approved drawings or as
directed by the Engineer.

The thickness of a single compacted Wet Mix Macadam layer shall not be less
than 75 mm. When vibrating or other approved types of compacting equipment are
used, the compacted depth of a single layer of the sub-base course may be increased to
200 mm upon approval of the Engineer.

406.2. Materials

406.2.1. Aggregates

406.2.1.1. Physical requirements: Coarse aggregates shall be crushed stone. If

crushed gravel/shingle is used, not less than 90 per cent by weight of the gravel/shingle
pieces retained on 4.7mm sieve shall have at least two fractured faces. The aggregates
shall conform to the physical requirements set forth in Table 400-10 below.

TABLE 400-10. PHYSICAL REQUIREMENTS OF AGGREGATES FOR WE

MIX MACADAM FOR SUB-BASE/BASE COURSES

Test Test Method Requirements

1. * Los Angeles IS:2386 (Part-4) 40 per cent (Max.)

Abrasion value
Or
* Aggregate IS:2386 (Part-4) 30 per cent (Max.)
Impact value Or IS:5640
2. Combined Flakiness IS:2386 (Part-1) 30 per cent (Max)**
and Elongation
indices (Total)

23
 Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

* Aggregate may satisfy requirements of either of the two tests.

** To determine this combined proportion, the flaky stone from a representative sample should first be
separated out. Flakiness index is weight of flaky stone metal divided by weight of stone sample. Only
the elongated particles be separated out from the remaining (non-flaky) stone metal. Elongation index
is weight of elongated particles divided by total non-flaky particles. The value of flakiness index and
elongation index so found are added up.

If the water absorption value of the coarse aggregate is greater than 2 per cent,
the soundess test shall be carried out on the material delivered to site as per IS:2386
(Part-5).

406.2.1.2. Grading requirements: The aggregates shall conform to the grading

given in Table 400-11.

TABLE 400-11. GRADING REQUIREMENTS OF AGGREGATES

FOR WET MIX MACADAM

IS Sieve Per cent by weight

Designation passing the IS Sieve

53.00 mm 100
45.00 mm 95-100
26.50 Mm --
22.40 Mm 60-80
11.20 Mm 40-60
4.75 Mm 25-40
2.36 mm 15-30
600.00 micron 8-22
75.00 micron 0-8

Materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.

The final gradation approved within these limits shall be well graded from
coarse to fine and shall not vary from the low limit on one sieve to the high limit on the
adjacent or vice versa.

406.3. Construction Operations

406.3.1. Preparation of base: Clause 404.3.1. shall apply.

406.3.2. Provision of lateral confinement of aggregates: While constructing

wet mix macadam, arrangement shall be made for the lateral confinement of wet mix.
This shall be done by laying materials in adjoining shoulders along with that of wet mix
macadam layer and following the sequence of operations described in Clause 407.4.1.

24
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

406.3.3. Preparation of Mix: Wet Mix Macadam shall be prepared in an

approved mixing plant of suitable capacity having provision for controlled addition of
water and forced/positive mixing arrangement like pugmill or pan type mixer of
concrete batching plant. For small quantity of wet mix work, the Engineer may permit
the mixing to be done in concrete mixers.

Optimum moisture for mixing shall be determined in accordance with IS: 2720
(Part-8) after replacing the aggregate fraction retained on 22.4 mm sieve with material
of 4.75 mm to 22.4 mm size. While adding water, due allowance should be made for
evaporation losses. However, at the time of compaction, water in the wet mix should
not vary from the optimum value by more than agreed limits. The mixed material
should be uniformly wet and no segregation should be permitted.

406.3.4. Spreading of mix: Immediately after mixing, the aggregates shall be

spread uniformly and evenly upon the prepared subgrade-sub-base/base in required
quantities. In no case should these be dumped in heaps directly on the area where these
are to be laid nor shall their hauling over a partly completed stretch be permitted.

The mix may be spread either by a paver finisher or motor grader. For portions
where mechanical means cannot be used, manual means as approved by the Engineer
shall be used. The motor grader shall be capable of spreading the material uniformly
all over the surface. Its blade shall have hydraulic control suitable for initial
adjustments and maintaining the same so as to achieve the specified slope and grade.

The paver finisher shall be self-propelled, having the following features:

(i) Loading hopper and suitable distribution mechanism.

(ii) The screed shall have tamping and vibrating arrangement for initial compaction to the layer as it is spread
without rutting or otherwise marring the surface profile.

(iii) The paver shall be equipped with necessary control mechanism so as to ensure that the finished surface is
free from surface blemishes.

The surface of the aggregate shall be carefully checked with templates and all
high or low spots remedied by removing or adding aggregate as may be required. The
layer may be tested by depth blocks during construction. No segregation of large and
fine particles should be allowed. The aggregates as spread should be of uniform
gradation with no pockets of line materials.

406.3.5. Compaction: After the mix has been laid to the required thickness,
grade and crossfall/camber the same shall be uniformly compacted, to the full depth
with suitable roller. If the thickness of single compacted layer does not exceed 100
mm, a smooth wheel roller of 80 to 100 kN weight may be used. For a compacted
single layer upto 200 mm, the compaction shall be done with the help of vibratory
roller of mi8nimum static weight of 80 to 100 kN or equivalent capacity roller. The
speed of the roller shall not exceed 5 km/h.

25
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

In portions having unidirectional cross fall/super-elevation, rolling shall

commence from the lower edge and progress gradually towards the upper edge.
Thereafter, roller should progress parallel to the centre line of the road, uniformly over-
lapping each preceding track by at least one third width until the entire surface has been
rolled. Alternate trips of the roller shall be terminated in stops at least 1 m away from
any preceding stop.

In portions in camber, rolling should begin at the edge with the roller running
forward and backward until the edges have been firmly compacted. The roller shall
then progress gradually towards the centre parallel to the centre line of the road
uniformly overlapping each of the preceding track by at least one-third width until the
entire surface has been rolled.

Any displacement occurring as a result of reversing of the direction of a roller

or from any other cause shall be corrected at once as specified and/or removed and
made good.

Along forms, kerbs, walls or other places not accessible to the roller, the
mixture shall be thoroughly compacted with mechanical tampers or a plate compacor.
Skin patching of an area without scarifying the surface to permit proper bonding of the
added material shall not be permitted.

Rolling should not be done when the subgrade is soft or yielding or when it
causes a wave-like motion in the sub-base/base course or subgrade. If irregularities
develop during rolling which exceed 12 mm when tested with a 3 metre straight edge,
the surface should be loosened and premixed material added or removed as required
before rolling again so as to achieve a uniform surface conforming to the desired grade
and crossfall. In no case should the use of unmixed material be permitted to make up
the depressions.

Rolling shall be continued till the density achieved is at least 98 per cent of the
maximum dry density for the material as determined by the method outlined in IS: 2720
(Part-8).

After completion, the surface of any finished layer shall be well-closed, free
from movement under compaction equipment or any compaction planes, ridges, cracks
and loose material. All loose, segregated or otherwise defective areas shall be made
good to the full thickness of the layer and re-compacted.

406.3.6. Setting and drying: After final compaction of wet mix macadam
course, the road shall be allowed to dry for 24 hours.

406.4. Opening to Traffic

Preferably no vehicular traffic of any kind should be allowed on the finished

wet mix macadam surface till it has dried and the wearing course laid.

26
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

406.5. Surface Finish and Quality Control of Work

406.5.1. Surface evenness: The Surface finish of construction shall conform to

the requirements of Clause 902.

406.5.2. Quality Control: Control on the quality of materials and works shall
be exercised by the Engineer in accordance with Section 900.

406.6. Rectification of Surface Irregularity

Where the surface irregularity of the wet mix macadam course exceeds the
permissible tolerance or where the course is otherwise defective due to subgrade soil
getting mixed with the aggregates, the full thickness of the layer shall be scarified over
the affected area, reshaped with added premixed material or removed and replaced with
fresh premixed material as applicable and recompacted in accordance with Clause
406.3. The area. The area treated in the aforesaid manner shall not be less than 5 m
long and 2 m wide. In no case shall depressions be filled up with unmixed and
ungraded material or fines.

406.7. Arrangement for Traffic

During the period of construction, arrangement of traffic shall be done as per

the Clause 112.

406.8. Measurements for Payment

Wet mix macadam shall be measured as finished work in position in cubic

metres.

406.9. Rates

The Contract unit rate for wet mix macadam shall be payment in full for carrying
out the required operations including full compensation for all components listed in
Clause 401.8.

407. SHOULDERS, ISLANDS AND MEDIAN

407.1. Scope

The work shall consist of constructing shoulder (hard/paved/earthen with brick or

stone block edging) on either side of the pavement, median in the road dividing the
carriageway into separate lanes and islands for channelising the traffic at junctions in
accordance with the requirements of these Specifications and in conformity with the
lines, grade and cross-sections shown on the drawings or ad directed by the Engineer.

27
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

407.2. Materials

Shoulder on either side of the road may be of selected earth/granular

material/paved conforming to the requirements of Clause 305/401 and the median may
be of selected earth conforming to the requirements of Clause 305.

Median/Traffic islands shall be raised and kerbed at the perimeter and the
enclosed area filled with earth and suitably covered with grass turf/shrubs as per Clause
307 and/or paved as per Clause 409.3.4 or 409.3.5.

Paved shoulders shall consist of sub-base, base and surfacing courses, as shown
in the drawings for the same shall conform to relevant Specifications of the
corresponding items. When paved or hard shoulders are not provided, the pavement
shall be provided with brick/stone block edgings as shown in the drawings. The bricks
shall conform to Clause 1003 of these Specifications. Stone blocks shall conform to
Clause 1004 of these Specifications and shall be of size 225 mm x 110 mm x 75 mm.

407.3. Size of Shoulders/Median/Islands

Shoulder (earthen/hard/paved)/median/traffic islands dimensions shall be as

shown on the drawings or as directed by the Engineer.

407.4. Construction Operations

Shoulder: The sequence of operations shall be such that the construction of

paved shoulder is done in layer each matching the thickness of adjoining pavement
layer. Only after a layer of pavement and corresponding layers in paved and earth
shoulder portion have been laid and compacted, the construction of next layer of
pavement and shoulder shall be taken up.

Where the materials in adjacent layers are different, these shall be laid together
and the pavement layer shall be compacted first. The corresponding layer in paved
shoulder portion shall be compacted thereafter, which shall be followed by compaction
of earth shoulder layer. The adjacent layers having same material shall be laid and
compacted together.

In all cases where paved shoulders have to be provided along side of existing
carriageway, the existing shoulders shall be excavated in full width and to the required
depth as per Clause 301.3.7. Under no circumstances, box cutting shall be done for
construction of shoulders.

Compaction requirement of earthen shoulder shall be as per Table 300-2. In the

case of bituminous courses, work on shoulder (earthen/hard/paved), shall start only
after the pavement course has been laid and compacted.

28
Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

During all stages of shoulder (earthen/hard/paved) construction, the required

crossfall shall be maintained to drain off surface water.
Regardless of the method of laying, all shoulder construction material shall be
placed directly on the shoulder. Any spilled material dragged on to the pavement
surface shall be immediately removed, without damage to the pavement, and the areas
so affected thoroughly cleaned.

407.4.2. Median and Islands: Median and Islands shall be constructed in

ammanner similar to shoulder upto the road level. Thereafter the median and islands,
if raised, shall be raised at least 300 mm by using kerb stones of approved material and
dimensions and suitably finished and pained and directed by the Engineer. If not
raised, the median and islands shall be differentiated from the shoulder/pavement as the
case may be, as directed by the Engineer. The confined area of the median and islands
shall be filled with local earth or granular material or any other approved material and
compacted by plate compactor/power rammer. The confined areas after filling with
earth shall be turfed with grass or planted with shrubs and in case of granular fill it can
be finished with tiles/slabs as directed by the Engineer.

407.4.3. Brick/Stone block edging: The bricks/stone blocks shall be laid on

edge, with the length parallel to the transverse direction of the road. They shall be laid
on a bed of 25 mm sand, set carefully, rolled in to position by a light roller and made
flush with the finished level of the pavement.

407.5. Surface Finish and Quality Control of Works:

The surface finish of construction shall conform to the requirements of Clause
902. Control on the quality of materials and works shall be exercised by the Engineer
in accordance with Section 900.

407.6. Measurements for Payment

Shoulder (earthen/hard/paved), island and median construction shall be measured
as finished work in position as below:
(i) For excavation in cu. M.
(ii) For earth work/granular fill in cu. M.
(iii) For sub-base, base, surfacing courses in units as for respective items.
(iv) For kerb in running metres.
(v) Fur turfing and tile/slab finish in sq.m.
(vi) For brick/stone block edging in sq.m.

407.7. Rate
The Contract unit rate for shoulder (hard/paved/earthen with brick or stone block
edging), island and median construction shall be payment in full for carrying out the
required operations including full compensation for all components listed in Clause

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Section 400

401.8 (i) to (v) as applicable. The rate for brick/stone block edging shall include the
cost of sand cushion.

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

408. CEMENT CONCRETE KERB AND KERB WITH CHANNEL

408.1. Scope

This work shall consist of constructing cement concrete kerbs and kerbs with
channel in the central median and/or along the footpaths or separators in conformity
with the lines, levels and dimensions as specified in the drawings.

408.2. Materials

Kerbs and kerb with channel shall be provided in cement concrete of Grade
M20 in accordance with Section 1700 of these Specifications.

408.3. Type of Construction

These shall be cast-in-situ construction with suitable kerb casting machine in all
situations except at locations where continuous casting with equipment is not
practicable. In those situations, precast concrete blocks shall be used.

408.4. Equipment

A continuous kerb casting equipment of adequate capacity and controls, capable

of laying the kerbs in required cross-sections and producing a well-compacted mass of
concrete free of voids and honeycombs, shall be used.

408.5. Construction Operation

408.5.1. Kerb shall be laid on firm foundation of minimum 150 mm thickness of

cement concrete of M10 grade cast in-situ or on extended width of pavement. The
foundation shall have a projection of 50 mm beyond dthe kerb stone. Before laying the
foundation of lean concrete, the base shall be levelled and slightly watered to make it
damp.

408.5.2. In the median portions in the straight reaches, the kerb shall be cast in
continuous lengths. In the portions where footpath is provided and/or the slope of the
carriageway is towards median (as in case of superelevated portions), there shall be
sufficient gap/recess left in the kerb to facilitate drainage openings.

405.5.3. After laying the kerbs and just prior to hardening of the concrete, saw
cut grooves shall be provided at 5 m intervals or as specified by the Engineer.

408.5.4. Kerbs on the drainage ends such as along the footpath or the median in
superelevated portions, shall be cast with monolithic concrete channels as indicated in
drawings. The slope of the channel towards drainage pipes shall be ensured for
efficient drainage of the road surface.

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

408.5.5. Vertical and horizontal tolerances with respect to true line and
level shall be  6 mm.

408.6. Measurements for Payments

Cement concrete kerb/kerb with channel shall be measured in linear metre for
the complete item of work.

Foundation of kerb, where separately provided shall be measured in linear metre

for complete item of work.

408.7. Rates

The Contract unit rates for cement concrete kerb/kerb with channel and
foundation for kerb shall be payment in full compensation for furnishing all materials,
labour tools, equipment for construction and other incidental cost necessary to complete
the work.

409. FOOTPATHS AND SEPARATORS

409.1. Scope

The work shall consist of constructing footpaths and/or separators at locations

as specified in the drawings or as directed by the Engineer. The lines, levels and
dimensions shall be as per the drawings. The scope of the work shall include provision
of all drainage arrangements as shown in the drawings or as directed.

409.2. Materials

The footpaths and separators shall be constructed with any of the following
types:
(a) Cast-in-situ cement concrete of Grade M20 as per Section 1700 of the Specifications:

(b) Precast cement concrete blocks/tiles of Grade M20 as per Section 1700 of the Specifications. The
minimum thickness of the cement concrete block/tile shall be 25 mm and minimum size shall be 300 mm x
300 mm.

(c) Natural stone slab cut and dressed from stone of good and sound quality, uniform in texture, free
from defects and at least equal to a sample submitted by the Contractor and approved by the Engineer. The
minimum thickness of the natural stone slab shall be 25 mm and minimum size shall be 300 mm x 300 mm.

409.3. Construction Operations

409.3.1. Drainage pipes below the footpath originating from the kerbs shall be
first laid in the in the required slope and connected to the drains/sumps/storm water
drain/drainage chutes as per provisions of the drawings, or as specified.

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Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

409.3.2. Portion on back side of kerbs shall be filled and compacted with
granular sub-base material as per Clause 401 of the Specifications in specified
thickness.
409.3.3. The base shall be prepared and finished to the required lines, levels and
dimensions as indicated in the drawings with the following:-
(a) Minimum 150 mm thick, compacted granular sub-base material as per Clause 401 of the
Specifications.
(b) Minimum 25 mm thick cement concrete of Grade M 15.

Over the prepared base, precast concrete blocks/tiles/natural stone slabs and/or
cast-in-situ slab shall be set/laid as described in Clauses 409.3.4.and 409.3.5.
409.3.4. Precast cement concrete blocks/tiles/natural/stone slab: The
blocks/tiles/slabs shall be set on a layer of average 12 mm thick cement-sand mortar
(1:3) laid on prepared base in such a way that there is not rocking. The gaps between
the blocks/tiles/slabs shall not be more than 12 mm and shall be filled with cement-sand
mortar (1:3).
409.3.5. Cast-in-situ cement concrete: The minimum thickness of the cement
concrete shall be 25 mm and it shall be cast on the prepared base in panels of specified
size in a staggered manner. Construction joints shall be provided as per Section 1700
of he Specifications.

409.4. Measurements for Payment

Footpaths and separators shall be measured in sq.metre between inside of kerbs.

409.5. Rates
Contract unit rates shall be inclusive of full compensation of all labour,
materials, tools, equipment and incidental to construction of footpaths. Cost of
providing pipes and arrangements for their discharge into appropriate drainage channels
shall be incidental to the construction of footpaths.

410. CRUSHER-RUN MACADAM BASE

410.1. Scope
This work shall consist of furnishing, placing and compacting crushed stone
aggregate sub-base and base courses constructed in accordance with the requirements
set forth in this Specification and in conformity with the lines, grades, thicknesses and
cross-sections shown on the plans or as directed by the Engineer.
410.2. Materials
The material to be used for the work shall be crushed rock. If crushed
grave/shingle is used, not less than 90 per cent by weight of the gravel/shingle pieces
retained on 4.75 mm sieve shall have at least two fractured faces. It shall be free from
any organic matter and other deleterious substances and shall be of such nature that it
can be compacted readily under watering and rolling from a firm, stable base. The

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Section 400

aggregate shall conform to the grading and quality requirements shown in Tables 400-
12 and 400-13.

At the option of the Contractor, the grading for either 53 mm maximum size or
37.5 mm maximum size shall be used, except that once a grading is selected, it shall not
be changed without the Engineer’s approval.

TABLE 400.12. AGGREGATE GRADING REQUIREMENTS

Per cent passing by weight

Sieve Size
53 mm max. size 37.5 mm max. size

63 mm 100
45 mm 87-100 100
22.4 mm 50-85 90-100
5.6 mm 25-45 35-55
710 micron 10-25 10-30
90 micron 2-9 2-9

TABLE 400.13. PHYSICAL REQUIREMENTS OF COARSE

AGGREGATES FOR CRUSHER-RUN MACADAM BASE
Test Test Method Requirements

1. * Los Angeles IS : 2386 40 maximum

Abrasion value (Part-4)
Or
* Aggregate IS : 2386 30 maximum
Impact value (Part-4) or
IS : 5640
Combined Flakiness IS : 2386 30 maximum ***
And Elongation (Part-1)
Indices (Total)
2.
** Water absorption IS : 2386 2 per cent Maximum
(Part-3)
Liquid Limit of IS : 2720 Not more than 25
3. Material passing (Part-5)
425 micron
Plasticity Index of IS : 2720 Not more than 6
4. material passing (Part-5)
425 micron

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 Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

* Aggregate may satisfy requirements of either of the two tests.

** If the water absorption is more than 2 per cent, soundness test shall
be carried out as per IS:2386 (Part-5).

*** To determine this combined proportion, the flaky stone from a

representative sample should be first be separated out. Flakiness
index is weight of flaky stone metal divided by weight of stone
sample. Only the elongated particles be separated out from the
remaining (non-flaky) stone metal. Elongation index is weight of
elongated particles divided by total non-flaky particles. The value
of flakiness index and elongation index so found are added up.

Construction Operations

410.3.1. Preparation of subgrade: Any ruts, deformations or soft yielding

places which occur in the sub-base or subgrade shall be corrected and compacted to the
required density before the aggregate base course is placed thereon.

410.3.2. Spreading watering, mixing and compaction: The aggregate shall be

uniformly deposited on the approved subgrade by means of the hauling vehicle with or
without spreading devices. Aggregate will be distributed over the surface to the depth
specified on the plans or as directed by the Engineer.

After the base course material has been deposited, it shall be thoroughly blade-
mixed to full depth of the layer by alternately blading the entire layer to the centre and
back to the edges of the road. It shall then be spread and finished to the required cross-
section by means of a motor grader.

Water shall be applied prior to and during all blading and processing operations
to moisten the material sufficiently to prevent segregation of the fine and coarse
particles. Water shall be applied in sufficient amounts during construction to assist in
compaction.

Alternatively, mixing of the crusher run material and water may be done in a
mixing plant as per Clause 406.3.3.

Compaction shall commence immediately after the spreading operation. If the

thickness of single compacted layer does not exceed 100 mm, a smooth wheel roller of
80 to 100 kN weight may be used. For a compacted single layer upto 200 mm the
compaction shall be done with the help of vibratory roller of minimum static weight of
80 to 100 kN or equivalent capacity roller. The speed of the roller shall not exceed 5
km/h. Each layer f material shall be compacted to not less than 98 per cent of the
maximum density as determined by IS: 2720 (Part-8).

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 Sub-Bases, Bases (Non-Bituminous) and Shoulders
Section 400

410.3. Surface Finish and Quality Control of Work

The surface finish of construction shall conform to the requirements of Clause

902.

Control on the quality of materials and works shall be exercised by the Engineer
in accordance with Section 900.

410.4. Arrangements for Traffic

During the period of construction, arrangement of Traffic shall be maintained

in accordance with Clause 112.

410.5. Measurements for Payment

Crusher-run macadam base shall be measured as finished work in position in

cubic metres.

410.7. Rate

The Contract unit rate for crusher run macadam base shall be payment in full for
carrying out the required operations including operations including full cpensation for
items as in Clause 401.8 (i) to (v).

* * *

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