Construction Methodology

(GOVT.
OF INDIA UNDERTAKING)
National Highways & Infrastructure Development Corporation Ltd (NHIDCL)
Construction Methodology
FOR
Construction of Hnahthial Bypass (Package

(Package-2) on Aizawl-Tuipang
Tuipang section of NH-
NH
54 in the State of Mizoram on EPC Mode of Contract, with JICA Loan Assistance”
Mathiyan Construction Pvt. Ltd.

CONSTRUCTION METHODOLOGY
AIZAWL-TUIPANG NH 54 ROAD PROJECT (HNAHTHIAL BYPASS PACKAGE-2)
Index
Chapter Page no.
GENERAL INFORMATION ………………………………………………………......…………….01

INTRODUCTION.…………………………………………………………….............……………... 01
OBJECTIVE………………………………………………………...............………………………... 01
COMMENCEMENT OF WORK…………………………………...............……………………....…01
SCOPE OF WORK……………………………………………….......……………………………..... 01
DEFINITION……………………...………………………………......……………………………… 02
SITE FACILITIES………………………………………………….......……………………………...02
QUARRY SETUP..……………………………………………………….............………………….. 02
CRUSHER SETUP……………………………………………………................………………...…..03
BATCHING PLANT……………………………………………………........…………………….... .03
GSB MIXING FACILITY&WMM PLANT………………………………..................……………... 04
HOT MIX PLANT………………………………………………………………………................…. 04
OTHER FACILITIES……………………………………………………………………..................... 04
CONSTRUCTION WATER SUPPLY……………………………………………………….............. 04
ELECTRIFICATION…………………………………..………………………………...............…… 04
APPROACH & SERVICE ROADS……………………………………..........................................…. 05
QUARRY……………………………………………………………………………….........…..…… 05
CONSTRUCTION METHODOLOGY FOR ROAD WORKS……………………….............…….... 05
CONSTRUCTION OF TRACK PATH………………………………………………....................….. 05
CLEARING AND GRUBBING –SITE CLEARANCE………………………….....................……… 06
METHOD STATEMENT FOR EARTHWORK IN EXCAVATION FOR SOIL AND ORDINARY
ROCK (NOT REQUIRING BLASTING)……………………………........................................…….. 08
EXCAVATION IN HARD ROCK REQUIRING CONTROLLED
BLASTING……………………………..........................................................................………………09
METHOD STATEMENT FOR EMBANKMENT WITH EARTH
(EXCAVATED OR BORROW) ...................................................................................................……..10
METHOD STATEMENT FOR SUB GRADE WITH BORROWED
EARTH……………………………….................................................................................…….......…16
METHOD STATEMENT FOR GRANULAR SUB BASE
[GSB]……………………………………………………............................................................…...…18
METHOD STATEMENT FOR WET MIX MACADAM (WMM)
CONSTRUCTION………………………..................................................................................……….21
METHOD STATEMENT FOR
PRIMER………………………………………………………………………………..........……….....24
METHOD STATEMENT FOR TACK
COAT…………………………………………………………………………………......................….26
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METHOD STATEMENT FOR DBM

CONSTRUCTION……………………………………………………..........................…………….....27
METHOD STATEMENT FOR BC
CONSTRUCTION…………………………………………………………….....................…………..31
METHOD STATEMENT FOR CAST IN-SITU
CULVERT………………………………………………………..........................................………….36
METHODOLOGY FOR MASONRY RETAINING
WALL………………………………………………………………..............................................……50
EQUIPMENT
REQUIRED……………………………………………………………………………………………..50
SETTING OUT…………………………………………………………………...…………………….50
MATERIALS…………………………………………………………………………………..……….51
PROPORTIONING……………………………………………………………………………..………51
CONCLUSION…………………………………………………………………………………...……..51
SAFETY & QUALITY…………………………………………………………………..............…….. 57
RECORD…………………………………………………………………………………………..….....59
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1. GENERAL INFORMATION:
1.1. Introduction
This note describes the methodology to be adopted by the Project Team for the execution
of works of the Construction of Hnahthial Bypass (Package-2) to 2 lane unpaved shoulder
in The State Of Mizoram(the “Project”) through Engineering, Procurement, Construction
tender (the “EPC”) Contract for National Highways and Infrastructure Development
Corporation Ltd(the “Authority”).This methodology note provides brief work
procedures, which shall be adopted for execution of the work, giving outline of
construction and resource planning for Road & Structure works.
1.2. Objective
The objective of this note is to provide an overall construction methodology with resource
planning to cover major items of works covered under this contract. The Quality Control
systems / Procedures & Industrial safety plans applicable for the works shall be describe
with separately in Project Quality Plan and Project Safety Manual. The Construction
Methodology provides the details of the inputs planned for the proper execution of works
meeting quality and technical specifications set by the client in the contract.
Name of Client: National Highways and Infrastructure Development Corporation Ltd

(NHIDCL)
Construction Period: 549 days [18 Months] from the Commencementdate.
Defect Liability Period: 42 months
1.3. Commencement ofwork:
Commencement Dateis
 Signing of the Contract Agreement by both theParties

 Delivery to the Contractor of reasonable evidence of the Employer’s
financialarrangements
 Effective Access to and Possession of theSite
 Receipt by the Contractor of the AdvancePayment
It has been decided that Commencement Date as 1 st October 2020.
2. SCOPE OFWORK
The scope of work will broadly include construction of two-lane roads as per standards
with construction of new pavement, up gradation of existing pavement, construction and
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/or rehabilitation of major and minor bridges, culverts, road intersections, interchanges,
drains etc. and the defect liability thereof for one year.
Salient Activities in this package include the construction of the followings -
 Main Carriageway with earthwork in excavation in ordinary soil, ordinary rock and
hardrock
 Embankment including subgrade.
 RCC Culverts forcross-drainage.
 PCC and masonry wall for earth retaining/sloperetainingstructure
 Drainage and protective work.
 Road signals, traffic signs, paintingetc.
3. DEFINITION
 Any Reference to Authority means Client[NHIDCL]

 Any reference to Supervision Consultant means Authority’s Engineer [Rodic
Consultants Pvt. Ltd. With TPF GETINSA EUROESTUDIO S.L in Joint
Venture in association with Anandjiwala Infra Advisory]
 Any reference to any period of time shall mean a reference to that according to
Indian standardtime;
 Any reference to day shall mean a reference to a calendarday;
 References to a “business day” shall be construed as a reference to a day (other
than a Sunday) on which banks in Delhi are generally open for business
 Any reference to month shall mean a reference to a calendar month as per the
Gregoriancalendar;
 References to any date, period or Project Milestone shall mean and include such
date, period or Project Milestone as may be extended pursuant to this Agreement
 GAD means General ArrangementDrawing
 LOA Date means Letter of AwardDate
4. SITE FACILITIES
The Site facility setup shall be developed on areas taken on rent / lease after detailed site survey.
This set-up will house all major construction activity plants, site office, stores, go-downetc.
4.1. Quarry setup:
The quarry operation shall be done from the hill / pit quarries or river bed quarries,
available in the vicinity of the project. Before setup, exploration shall be done to ascertain
the quality of available rock, extent of overburden, convenience of quarrying etc. Location
of road, nearby residential area, environment aspects will also be considered during
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selection. On selection, the area shall be suitable leased / acquired for use and mining
commenced. Screening plants shall be set-up at one or more locations near the collection
points and the material screened. The suitable material will then be carted to the crusher
location for further processing to produceaggregates.
A very detailed investigation, as aforesaid shall be carried out to determine the right
quality of rock and confirm availability of sufficient quantity of the same asper the project
requirements. After this exercise is concluded, quarry shall be set up in one / multiple
locations based on the availability of such area(s).
Quarry Selection and operation shall be as per detailed guidelines of the Quarry & Mining
department.
4.2. Crusher setup:
Crusher shall be setup at selected area considering the area available, connectivity to the
highway, nearby inhabitants, environmental aspect etc.
Efforts shall be made to setup thecrusher near the finalized quarry location or at any other
suitable area (including work station) that can be obtained on lease and hire.
 Coarse Aggregates – All coarse aggregate for roadwork and structural work for the
project will primarily be produced using the crusher setup located as indicated
above. However, in order to commence the initial activities, procurement form
local sources, duly approved by the Authority’s Engineerfor quality shall be
resorted to, till the crusher becomes fully operational. Sourcing of aggregates from
such local sources shall be done after due consideration of the overall economics of
procurement.
4.3. BatchingPlant:
Concrete for the project shall be manufactured primarily at the batching plants located in
the Work Stations. The concrete manufacturing units will have facilities including
batching plant of 20m3/hr capacity, cement storage, generator and internal power grid,
aggregate storage and cleaning area, internal road for vehiclemovement.
Further for small pours of cross drainage work, mobile self-loading/weighing batching
plants of 4 m3/Batch capacity will be stationed near the structure.
Coarse Aggregates- As above.
Fine Aggregates – This shall be sourced through the screening process at the quarry
location as indicated for aggregate production or any other suitable approved source of
supply.
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4.4. GSB Mixing Facility & WMMPlant:
GSB mixing facility and WMM plant shall be setup at the work station. These will have
sufficient capacity to meet the requirement and facility etc. for the production.
4.5. Hot Mix Plant:
All bituminous product of the project shall be manufactured at central hot mix plant. The
plant will have hot mix plant itself, aggregate storage and cleaning area, internal road for
vehicle movement.
4.6. Other Facilities:
Other facilities also shall be developedasbelow:

 Main SiteOffice
 SiteStore
 Open & Fuel Storage Area / HSDBunk
 Structural & Rebar Fabrication andstorage Area
 ScrapYard
 Mechanical Workshop & Plant Maintenance
 Generator Shed
 Vehicleparking Space
 Labour Rest Area
 Laboratory & Quality ControlRoom
 Weigh Bridge & First AidCentre
5. CONSTRUCTION WATER SUPPLY
The water for the project shall be sourced from the ground water through bore/tube well, which
shall be stored in a surface water tank of suitable capacities. Bore / tube wells shall be installed at
Central installation. The pumps of required capacity shall be installed for pumping of water from
surface tank to overhead storage tanks at batching plant, office and camp area. Underground water
pipelines shall be laid for distribution of water.
In case the water from streams is found to be good, it will be used for construction purpose.
6. ELECTRIFICATION
Construction power shall be drawn from the Grid power/ generating sets. Within central
installation area suitable capacity & number of DG sets shall be installed for batching plant,
fabrication yard, site lighting, office, workshop & camp.
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7. APPROACH & SERVICEROADS

The project access is available from Aizawl side. For accessing the site from other locations
access road, kaccha road will be constructed.
Temporary access, internal service roads within central installation & from the existing road
network / ROW to work locations shall be constructed according to requirements.
8. QUARRY
As mentioned above Quarry Selection and operation shall be as per detailed guidelines of the
Quarry & Mining department.
9. CONSTRUCTION METHODOLOGY FOR ROADWORKS
Project alignment is in hilly terrain along an Hnahthial Bypass Pkg-2 for 6.996 km.
The project highway shall be Construction of Hnahthial Bypass (Package-2) on Aizawl-Tuipang

section of NH-54 in the State of Mizoram on EPC Mode of Contract, with JICA Loan Assistance
for 6.996 Km with slope protections measures such as toe wall, retaining wall with PCC drains.The
entire road length is divided into following:
Types Description
TCS 1 Open Country Plain Rolling Terrain
TCS 2 Hill Side Widening
TCS 3 Valley Side Widening
TCS 4 Box Cutting
9.1. Construction of Track path
Marking of Road Alignment
The operation may be carried out in parts based on proposed planning / requirement of the
work or as instructed by the Authority’s Engineer or his representative. The stretch where
activity is to be carried out shall be taken over from the Authority’s Engineer or his
representative. A document of handing over and taking over shall be maintained. Before
starting of the operation, alignment of the road including the extent of ROW, cutting and
fill- width extent to be marked and got checked by the Authority’s Engineer or his
representative.
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Reconnaissance of overhead and underground obstruction
On taking over the site, the list shall be prepared of surface obstruction for the properties
and other facilities / utilities required to be dismantled / shifted for construction of road
and inform the Authority’sEngineer or his representative for further instruction. Lists of
such utilities / obstructions are to be submitted to the Authority’sEngineer or his
representative for his further instruction, necessary shifting or dismantling as the case
maybe.
Access Road construction
Identify the location of hills having steep/vertical slopes and height more than 20m from
existing road level. Identify the location within the ROW from where access road can be
constructed. Access road shall be prepared with excavator, hydraulic breaker, dozer,
dumpers with gradient not steeper than 8% to facilitate plying of heavy construction
equipment along the slope. Separate team will independently construct the track
path/access road prior to start of actual construction. Minimum 3.5m width of track path
will be constructed and at every 250m local widening will be done to cross the vehicles.
For construction of bridge foundations, existing road widening or road diversion may be
required. The widening of road or diversion of road shall be done as per the site feasibility
near by the proposed bridge structure.
9.2. Clearing and Grubbing –Site Clearance
Before start of excavation or embankment filling work clearing and grubbing of road
stretch shall be performed as per following methodology.
9.2.1. Scope
Scope of this work shall involve cutting, excavating, removing and disposing /
stacking of all materials such as trees, bushes, shrubs, stumps, roots, grass, weeds
and top soil up to 150mm in thickness, rubbish which is unsuitable for incorporation
in the work in the opinion of the Authority’sEngineer or his representative. The work
shall include draining out stagnant water, if any, from the area of proposed road land,
drain, cross drainage structures or other area as specified in the drawing.
9.2.2. Procedure
The procedure described below shall apply for clearing and grubbing for the entire
stretch of work unless and until instructed otherwise by the Authority’sEngineer or
his representative.
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a) Clearing and Grubbing Operation
Clearing and grubbing operation shall be carried out covering the full-width of ROW
including the excavation, embankment slopes of the existing road where applicable
unless and otherwise instructed by the Authority’sEngineer or his representative.
Clearing and grubbing shall be performed in advance of earthwork operations.
Clearance operation for bushes, shrubs and other vegetation, roots, tress up to 300
mm girth width shall be carried out engaging crawler /tire mounted dozers with
ripper or tractors with harrow disc attachments capable to perform the work.
Excavations below the general ground level arising out of removal of trees and
stumps shall be filled with suitable soil and compacted thoroughly so as to make the
surface at these locations conform to the surrounding area.
Ant-hills both above and below the ground shall be removed up to the extent of their
working and shall be filled and compacted thoroughly. Depending upon the area of
work roller or plate compactor may be used for compaction of soil.
b) Removal ofStagnant Water and Diversion ofWaterCourses
In case of small isolated water bodies with stagnant water falling within
embankment, stagnant water shall be removed, provided feasible, by bailing out or
pumping using surface discharge pumps or making channels leading to adjacent low-
lying areas, provided available. Care shall be taken against damage to the works,
crops or other properties while dischargingwater.
Where watercourses have to be diverted from the sites of embankment, a new

channel shall be formed as per the instruction of the Authority’sEngineer or
hisrepresentative. The original channel shall be cleared of all vegetation. The soft
deposit at the sides and bottom of the old channel, if any, shall be removed upto a
depth of 150mm or as per instruction of the Authority’sEngineer or his
representative. The old channel shall be filled with suitable soil and compacted as
per instruction of the Authority’sEngineer or hisrepresentative.
c) Dismantling Culverts, Bridges Pavements and Structure
d) Disposal of Materials
Materials arising out of clearing and grubbing operations and found to be unsuitable
for use shall be disposed at the specified location as provided by the
Authority’sEngineer or his representative.
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Materials found suitable for the work shall be stacked within ROW as per instruction
of the Authority’sEngineer or his representative.
9.3. Method Statement for Earthwork in Excavation for soil and ordinary rock (not requiring
Blasting)
9.3.1. Scope
The scope consists of earthwork in excavation for soil and ordinary rock by
excavator and hydraulic breaker mounted on excavator as per technical
specification 301, 302 and 303 of MORTH specifications.
9.3.2. Produce
 Set out the limits of excavation as per true to lines and levels with pegs or
lime powder.
 The excavation shall be carried out by Excavator and excavated material
shall be transported by Dumper. Refer time cycle for excavator and
dumper. Keep the objective in view that soil from excavation should be put
to best possible use in fill areas unless the material is declared unfit.
 Excavation is started from high point to low point.
 Slopes and Benches will be created during exaction as per the drawing.
 The earthen slopes will be compacted by tamping with the excavatorbucket.
Excavation will be done up to formation level.
 Drain will be excavated as per the drainage plan with slopes.
 Excavated materials usable in pavement construction should be stacked at
convenient locations and proper records are to be kept.
 In case of different strata is encountered after removal top layer, the levels
will be taken jointly to prepare the cross section. The cross section thus
arrived will form the basis of measurement.
 Close watch on the cut slopes and excavated areas are to be maintained
whether these require any protection/drainage measures for
stability/performance.
9.3.3. Disposal of Surplusmaterial
 Disposal area will be identified and informed to Department prior

toexcavation.
 Care will be taken so that disposed material will not contaminate and
pollute the existing waterstreams.
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 After dumping of surplus earth, the earth will be leveled to create plain
surfaceor as instructed by theAuthority’sEngineer/Department.
9.4. Excavation in Hard Rock requiring controlled blasting
The scope consists of earthwork in excavation for hard rock by controlled blasting method
as per technical specification 301, 302 and 303 of MORTH specifications.
The rock excavation in hilly area requires the controlled blast method to carry out
excavation with safety and to form the slope as per design for slope stability. In controlled
blasting Pre-splitting is the most commonly used techniques in surface work. This method
involves drilling of closely spaced holes at the planned excavation perimeter which are
loaded with explosives in order to generate an appropriate boreholepressure.
The operation procedure is as follows:
 Fabrication and installation of Safetysigns,

 Construction of temporary access road to reach the hill top
 Marking of ROW.
 Identification of dumping yard for boulders and muck in consultation with
Authority’s Engineer & retaining wall structure for using theboulders
 Removal of overburden, loose material by excavator andbucket.
 Removal of soft / weathered rock by excavator bucket, hydraulic breaker mounted
onexcavator.
 Shifting of Compressor / ROC 203 / Jackhammers athill
 Drilling holes in hard rock. The holes shall be drilled at predefined angle at both
sides to prevent over breaks and also not to fly or minimum fly of rock (throw)
towards existingroad.
 For side slope ‘Line Drilling’ can be adopted which involves single row of closely
spaced, non-charged holes along the excavationline.
 Controlled presplit blasting during block shall be carried out. Traffic blockage of is
required during blasting operation. Till clearance of any fallen cut spoils on the
existing road, traffic shall not be allowed to travel further.
 The experienced blasters will be deployedforexecution. Removal of muck from
blastingzone.
 Muck removal will be done by excavator and dumpers with access road or muck
will be deposited in structural chutes which will be erected inclined on the slopes.
At the end of chutes, there will be hopper to deposit the muck intodumpers.
 The hard rock will be used either for producing the aggregates in crusher or
constructing the masonry structure, pitchingetc.
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The suitability of equipment for installation of rock supports shall fulfill following criteria
 capability to drill horizontal or inclinedhole

 capability to drill minimum and maximum size ofhole
 capability to drill maximum length ofhole
Traffic Management and Safety
 Construction zones will be identified. Suitable cautionary boards will be displayed.

 Loose material towards the hill side removed with excavator anddisposed to
designatlocation.
 Traffic safety measures such as Traffic barricade, signages will be provided as per
thelocation.
 Safety stewards/marshals with flags will beprovided.
 Before blasting, sufficient warning shall be given to enable the people working in
the blasting area to get off the dangerzone.
 All approaches to the project site, where regular blasting operations are undertaken,
shall be sign-posted for warning the public and indicating the days and timings
when blasting is to be carriedout.
 Loud wailing notes of not less than 1-minute duration shall be sounded on sirens to
warn the public before commencement of firing. The end of firing operations must
be followed by sounding an all-clear signal on the sirens as a continuous long note
of not less than 1-minuteduration.
 The danger zone shall be suitably cordoned off and flag men posted at important
points. All approaches to the site shall be closed by barriers at a distance of not less
than 400 m, 10 minutes before firing is to take place.
 Safety practices as per IS 4081:1986 will befollowed.
 Team, comprising of Excavator, loader, dumpers to be positioned nearby to clear
the blockage in case of rock fall on the access/ existing carriageway.
9.5. Method Statement for Embankment with Earth (Excavated or Borrow)
9.5.1. Scope
The scope consists of construction of embankments in layers as per technical

specification 305 of MORTH specifications.
9.5.2. Material
The material shall be soil, moorum, gravel, fly-ash or a mixture of these three, fly
(pond) ash or any other material approved by the Authority’sEngineer. The
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material shall satisfy the requirements defined in clauses 305.2, 305.2.1, 305.2.1.2,
305.2.1.4, 305.2.2.2 of the Technical Specification.
The material should fulfill following requirements.
 DensityRequirements
 1.52 tonnes /cum. For embankment up to 3mheight.
 1.60 tonnes /cum. For embankment more than 3 M
 For fly ash separate density requirement as per contract shall be
applicable
 CBR : Minimum CBR requirement as perpavementdesign
 Coarsematerial : Size not more than 75MM
 Freeswellindex : Not exceeding 50 % (to be used only below 500mm of
top of embankment)
 LiquidLimit : Not exceeding50
 Plasticity Index : Not exceeding25
9.5.3. Construction Operation
Mark the limits of embankment with lime powder or pegs on the ground, after
clearing and grubbing is completed. The marking shall be done 30 cm beyond the
drawing dimension. Where the fill is to be deposited against an existing
embankment, continuous horizontal benches of 300 mm wide shall be cut into the
oldslope.
The ground shall be compacted with roller to achieve minimum density

requirement of Table 300.2. Where ever necessary the ground shall be loosened to
a depth 250mm, watered and compacted to 95% [% of max. laboratory dry density
as perIS:2720(Part-8)].
The top soil in the borrow area shall be removed by grubbing / stripping so that
earth without vegetation are excavated andloaded.
The material shall be spread in layers of uniform thickness not exceeding 250 mm
compacted thicknesses. Grader or a combination of dozer and grader can be used
for thisactivity.
When the grader is used for grading activity, the grader will initially spread this
heap of earth dumped over a stretch to approximately line & level. At this stage the
material should have moisture content of 1% above to 2% below the OMC
[Optimum Moisture Content]. If not, either mixingordrying process should be
adopted. If required additional water shall be added to increase the moisture
11
content up to the permitted limits. After sprinkling water with the browser, the
material shall be thoroughly mixed to obtain a homogenous mix.
When a combination of grader & dozer are used, the dozer shall carry out the initial
spreading to the approximate line & level. The dozer shall also carry out mixing
after spraying of water. The grader shall carry out the final & precise grading. The
in-situ moisture content shall be checked with the help of rapid moisture meter.
Refer time cycle of Dozer D6H and Grader.
Compaction of fill shall start immediately after achieving the required moisture
content. Compaction shall be done with the help of vibratory compactor. The
compaction pattern including the no of passes required shall be finalized after full
scale trials at site. Refer time cycle of vibratory compactor: 10T. The general
pattern shall be asfollows.
 Initial rolling, 2 static passes withvibratoryroller.

 Subsequent rolling, 4 vibratorypasses.
(One pass shall include both forward and reverse movement of roller)
The compaction shall commence from the lower end and shall move to upper end
width bywidth.
Table- Compaction requirements for Embankment

Sl Type of Relative compaction as %age of maximum
No. Work/Material laboratory dry density as per IS:2720 (Part 8)
1 Embankment Not less than 95%

a) Up to 3m height
Further layer shall commence only after the under-laying layer is tested and
approved for compaction.
The rain cuts shall be repaired before placing further layers of embankment.
The compaction behind the structure shall be accomplished with the use of
vibratory roller or plate compactor to achieve 98% of MDD [Maximum Dry
Density].
The surface of embankment shall have suitable cross fall to enable efficient surface
drainage.
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When earth available from the excavation for roadway formation and drainage
excavation falls short of the requirement of embankment construction in the
remaining reaches, borrow earth shall be obtained from approved area identified
near ROW. The volume of borrow excavation and of compacted embankment shall
be different if there is a variation in the respective dry densities. Hence the quality
control tests shall be conducted on the material at the borrow area prior the
commencement of borrowing operation and at the embankment location after
thecompletion.
The following tests are pertinent to embankment
Sl. Test Code Frequency

No
1 Sand Content IS: 2720 (Part – 4) 2 tests per 3000 cum
2 Plasticity test IS: 2720 (Part – 5) Each type 2 tests per 3000 cum
3 Density test IS: 2720 (Part – 8) 2 tests per 3000 cum subject to
aminimum of 1 test per 1000 sqm.
4 Deleterious content IS: 2720 (Part –27) Authority’s Engineer to decide
5 Moisture Content IS: 2720 (Part – 2) 1 test per 250 cum.
9.5.4. List of Equipment and Time cycle
For excavation in Soil by Excavator

1. EXCAVATOR : PC 210
Bucket capacity 1.2 CUM
Fill factor 0.9
Net Bucket capacity 1.08 CUM
Excavation swing & loading one bucket 0.5 MIN
Efficiency 80%
No of cycles per hour 96
CapacityofExcavator 103.7 CUM/HR
Time to loadone dumper 5.8 MIN
Time required to placeanotherdumper 2 MIN
Total Cycle time for loadingone Dumper 7.8 MIN
No of cyclesperhour 7.7
Capacity 92.5 CUM/HR
Say 92 CUM/HR
For 11 hrs working 1012 cum/day
Say 1000 cum/day
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Earthwork in excavation in Ordinary Rock by Excavator

2. EXCAVATOR : PC 210
Bucket capacity 1.2 CUM
Fill factor 0.8
Net Bucket capacity 0.96 CUM
Excavation swing & loading one bucket 0.6 MIN
Efficiency 75%
No of cycles per hour 75.0
CapacityofExcavator 72.0 CUM/HR
Time to loadone dumper 8.3 MIN
Time required to placeanotherdumper 2 MIN
Total Cycle time for loadingone Dumper 10.3 MIN
No of cyclesperhour 5.8
Say 69 CUM/HR
Say 750 cum/day
Earthwork - Dumper Time cycle

3. Dumper: HYVA, AMW (20Ton)
Assuming Lead 2 KM
Loose volume 12.5 CUM
Less for Voids 80 %
Compacted Volume 10 CUM
Positioning For Loading 2 MIN
Loading, excavator 6 MIN
Excavation/Borrow area @15Km/hr 8 MIN
Dumping of earth 3 MIN
Return @15Km/hr 8 MIN
Contingencies 4 MIN
Total time 31 MIN
Say 19.5 CUM/HR
For 11 hrs working 214.5 cum/day
Say 210 cum/day
Number of Dumpers perexcavation set 4
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Earthwork- Grader Time Cycle

3. Grader: CAT
Blade width 2.3 M
Speed 2.5 KM/HR
Overlap 35 %
No of passes 5
Ideal Output in sqm 747.5 SQM/HR
Efficiency 70 %
Net output in Sqm 523.25 SQM/HR
Max permissible Layer thickness 0.2 M
say 100 CUM/HR
Say 800 cum/day
Earthwork – VibroRoller Compaction Time cycle

5. Vibratory Compactor: 10 T, CASE
Drum width 2.1 m
Speed 2 km/hr
Overlap 33 %
No of passes 5
Efficiency 90 %
Say 100 CUM/HR
Say 800 cum/day
Earthwork – Water sprinkling – Water Tanker Time cycle

6. Water Tanker ,10000 LTR
Lead 6 KM
Loading Time 30 MIN
Forward Speed 10 KM/HR
Return Speed 20 KM/HR
Forward Traveling time 36 MIN
Return Traveling Time 18 MIN
Spraying 45 MIN
15
Contingencies 5 MIN
Total 134 MIN
Capacity 4478 LTR/HR
OMC of the earth 9 %
NMC of the earth 3 %
Required water 6 %
MDD of the earth 1800 KG/CUM
Water reqd per cum 108 LTR/CUM
Quantum of earth watered per hr 41.5 CUM/HR
say 40 CUM/HR
Say 425 cum/day
9.6. Method Statement for Sub grade with Borrowed Earth:
9.6.1. Scope
The scope of work consists of construction of sub grade in layers as per technical
specification 305 of MORT&H specification.
9.6.2. Material
The material shall be soil, moorum, a mixture of these or any other material as
approved by the Authority’sEngineer. The material should fulfill following
requirements
 MDD: Minimum 1.75tonnes/cum

 CBR: Minimum 8% (4 Days soaked), If necessary,mixing to be done for
requiredCBR.
 Size of coarse material not more than 50MM
9.6.3. Source
The source satisfying the material requirement shall be tested and got approved
from the Authority’sEngineer. Borrow areas/Tank bed material satisfying the
requirement characteristics can be used. Mixing of two sources may be resorted to,
in order to obtain minimum qualifyingrequirements.
 Mark the limits of sub grade with lime powder or pegs on the completed
embankment layer. The marking shall be done 30 cm beyond the drawing
16
dimension where the fill is to be deposited against an existing sub grade,

continuous horizontal benches of 300 mm wide shall be cut into the oldslope.
 The topsoil in the borrow area shall be removed by grubbing/stripping so
that earth without vegetation are excavated andloaded.
 The borrow material shall be loaded with the help of excavator on the
dumpers for transporting to the embankment location. Refer time cycle of
excavator Poclain CK90 and Dumper (10T/ 20T).
 Mixing of material shall be resorted to for obtaining requisite quality of
material. Mixing shall be done using disc harrows. Full scale trials shall
bedoneat site to finalize the mix proportion and process. The material shall be
dumped between the limiting lines marked with lime powder.
 The material shall be spread in layers of uniform thickness not exceeding

250 mm-compacted thickness. Grader or a combination of dozer and grader
can be used for thisactivity.
 When a combination of dozer and grader is used, the dozer shall carry out
the initial spreading to the approximate line and level. The dozer shall also
carry out mixing after spraying of water. The grader shall carry out the final
precise grading. The in-situ moisture content shall be checked with the help of
rapid moisture meter. Refer time cycle of Dozer and Grader.
 Compaction of fill shall start immediately after achieving the required
moisture content. The compaction shall be done with the help of vibratory
compactor. The compaction pattern including no of passes required shall be
finalized after full-scale experiment at site. Refer time cycle of Vibratory
Compactor: 10 T, CASE. The general pattern shall be asfollows:
o Initial rolling 2 static passes with Vibratoryroller
o Subsequent rolling 4 vibratorypass
 The compaction shall commence from the lower end and shall move to
upper end width bywidth
 Further layer shall commence only after the underlying layer is tested and
approved forcompaction
 The rain cuts shall be repaired before placing further layers of subgrade
 The compaction behind structure shall be accomplished with the use of
vibratory roller or plate compactors to achieve 97% ofMDD.
 The surface of sub grade shall have the suitable cross fall to enable efficient
surface drainage. The finished sub grade shall be within the tolerance limits
specified in Table 900.1 of MORTH Specifications (i.e., +20mm).
 The Quality control tests shall be conducted on the material at the borrow
area prior the commencement of borrowing operation and at the sub grade
location after the completion of compaction operation. Following tests are
pertinent to subgrade.

17
1 Sand Content IS:2720 (Part-4) 2 tests per 3000 cum

2 Plasticity test IS:2720 (Part-5) Each type 2 tests per 3000 cum
3 Density test IS:2720 (Part-8) 2 tests per 3000 cum subject to
a minimum of 1 test per 1000
sqm
4 Deleterious IS:2720 (Part-27) Authority’sEngineer to decide
Content
5 Moisture Content IS:2720 (Part-2) 1 test per 250 cum.
9.7. Method Statement for Granular Sub Base[GSB]
9.7.1. Scope
The scope of work consists of construction of Granular Sub-Base (GSB) in layers

as per technical specification 401of MORT&H specification
9.7.2. Material
The material shall be natural aggregate free from organic and other deleterious
constituents and shall confirm to Table 400-1 and Table 400-2 with the percentage
passing 0.075mm size restricted to 5%. The material shall have 4 days soaked CBR
of minimum 30%
9.7.3. Source
The natural aggregate of identified Quarry shall be used for GSB
 Mark the limits of GSB with lime powder or pegs on the completed
subgrade.
 Requisite sub-surface drain and drain outlet at the level of sub-grade/sub-
base shall be completed prior to commencement of GSBconstruction
 The material shall be loaded with the help of loader on the dumpers for
transporting to the GSB location. Refer time cycle Dumper (20T)
 The material of GSB layer confirming the Table 400.1. Shall be spread in
layers of uniform thickness of 200 mm compacted. Grader shall be used for
this activity
 The material should have moisture content of +1% to +2% below the
optimum moisture content [OMC]. If not, either mixing or drying process
should be adopted. Water shall be added to increase the moisture content up
to the permitted limits. After sprinkling water with the browser, the material
18
shall be thoroughly mixed to obtain a homo generous mix. The mixing shall
be carried out
 With the help of grader. The grader shall then carry out the final precise
grading. Refer time cycle of Water Tanker and Grader (CAT)
 Compaction of GSB shall start immediately after achieving the required
moisture content. The compaction shall be done with the help of vibratory
compactor. The compaction pattern including no of passes required shall be
finalized after full-scale experiment at site to achieve 98% of MDD. Refer
time cycle of Vibratory Compactor: 10 T, CAT. The general pattern shall
be asfollows
 Initial rolling 2 static passes with Vibratoryroller
 Subsequent rolling 4 vibratorypass
 The compaction shall commence from the lower edge and shall move to
upper edge width by width. Quality control tests shall be carried out prior to
commencement of nextlayer
 The Quality control tests shall be conducted on the material at the source
prior transportation and at the GSB location after the completion of
compaction operation. Following tests are pertinent toGSB
SL.NO TEST CODE FREQUENCY

1 Gradation Table 400.1 1 test per 200 cum.
2 Atterberg limits IS:2720 (Part- 1 test per 200 cum.
5)
3 Moisture content IS:2720 (Part- 1 test per 250 cum.
2)
4 Density IS:2720 (Part- 1 test per 500 sqm.
8)
5 Deleterious IS:2720 (Part- As required
content 27)
6 CBR IS:2720 (Part- As required
16)
9.7.5. List of Equipments and Time Cycle
1. Grader: CAT
Blade width 2.3 M
Speed 2.5 KM/HR
Overlap 35 %
No of passes 6
Efficiency 75 %
19

say 90 CUM/HR
2. Vibratory Compactor: 10 T, CASE

Drum width 2.1 m
Speed 2.5 km/hr
Overlap 33 %
No of passes 6
Efficiency 80 %
Net output in sqm 455 SQM/HR
Capacity 91 CUM/HR
Say 90 CUM/HR
3. Water Tanker ,10000 LTR

Lead 6 KM
Loading Time 30 MIN
Forward Speed 10 KM/HR
Return Speed 20 KM/HR
Forward Traveling time 36 MIN
Return Traveling Time 18 MIN
Spraying 45 MIN
Contingencies 5 MIN
Total 139 MIN
Capacity 4317 LTR/HR
OMC of the earth 7 %
NMC of the earth 2 %
Required water 5 %
MDD of the earth 2100 KG/CUM
Water reqd per cum 105 LTR/CUM
Quantum of earth watered per hr 41.11 CUM/HR
say 40 CUM/HR
3. Dumper: HYVA, AMW (20Ton)

Assuming Lead 16 KM
Loose volume 12.5 CUM
20
Less for Voids 75 %

Compacted Volume 9.38 CUM
Positioning For Loading 5 MIN
Loading, excavator 6 MIN
Quarry area – 1 Km @ 10 km/hr 6 MIN
Excavation/Borrow area @15Km/hr 6 MIN
Dumping of earth 8 MIN
Return @15Km/hr 66 MIN
Contingencies 5 MIN
Total time 156 MIN
Capacity 3.6 CUM/HR
Say 3.5 CUM/HR
For 11 hrs working 38.5 cum/day
Say 38 cum/day
9.8. Method Statement for Wet Mix Macadam (WMM) Construction
9.8.1. Scope
The scope of work consists of construction of Wet Mix Macadam of 2 layers

totaling 200 mm to 250 mm in new carriageway and service road.
9.8.2. Material
Coarse aggregate - The coarse aggregate shall be crushed stone of identified

Quarry having following physical characteristics
Physical Characteristics of Material
SL. TEST CODE REQUIREMENT

No
1 Aggregate Impact IS:2386 (Part4) Maximum30%
Value & Los angeles
value or IS:5640 Maximum40%
2 Combined Flakiness IS:2386 (Part1) Maximum 35%
and Elongation
indices (Total)
9.8.3. Source
The crushed aggregate of identified Quarry shall be used for WMM. The fraction
of material passing through 4.75 mm sieve shall be crusher run screening only.
21
1. Mark the limits of WMM with lime powder or pegs on the completed GSB.
2. The material shall be thoroughly mixed in the Wet Mix plant as per the
approved mix formula. Refer to time cycle of Wet mix plant (160 T
Capacity).
3. The material shall be loaded on to the dumpers directly from the wet mix
plant for transporting to the WMM location. Refer time cycle Dumper
(20T) Lateral confinement shall be provided by laying the material for
shoulder prior to commencement of wet mix laying operation.
4. The material shall be spread with a sensor Paver. The material shall be
spread in layers of uniform thickness of 125mm as per drawing for the
firstlayer.
5. Compaction of WMM shall start immediately after laying is completed.
The compaction shall be done with the help of vibratory compactor. The
compaction pattern including no of passes required shall be finalized after
full-scale experiment at site. Refer time cycle of Vibratory Compactor: 10
T, L&T Case, Greaves Bomag the general pattern shall be asfollows
a. Initial Rolling: 2 Static passes with Vibratory Roller
b. Subsequent Rolling: 4 vibratory passes
The compaction shall commence from the lower edge and shall move to
upper edge width by width. Quality control tests shall be carried out prior to
commencement of nextlayer.
6. The second layer of WMM shall be laid to the limits andcompacted
7. The rain cuts shall be repaired before placing GSB/drainagelayer
8. The compaction behind structure shall be accomplished with the use of
vibratory roller or plate compactors to achieve 98% ifMDD
9. The surface of WMM shall have the suitable cross fall to enable efficient
surface drainage. The finished level WMM shall be within the tolerance
limits specified in Table 900.1. (i.e., +10 mm to –10mm)
10. The Quality control tests shall be conducted on the material at the source
prior transportation and at the WMM location after the completion of
compactionoperation following tests are pertinent toWMM.
11.
SL.NO TEST CODE FREQUENCY

1 Aggregate Impact IS:2386 (Part-4) 1 test per 200 cum.
Value
2 Gradation Table 411 1 test per 100 cum.
3 Flakiness and IS:2386 (Part-1) 1 test per 200 cum.
Elongation Index
22
CONSTRUCTION METHODO
METHODOLOGY
AIZAWL-TUIPANG
TUIPANG NH 54 ROAD P
PROJECT (HNAHTHIAL BYPASS PACKAGE-2)
PACKAGE
4 Atterberg limits for IS:2720 (Part-5) 1 test per 100 cum.

aggregate passing
425micron sieve
5 Density IS:2720 (Part-8) 1 test per 500 sqm
9.8.5. List of Equipment and Time cycle
Dumper (20Ton): For carrying material for Plant area to stretches

Lead 16 KM
Loading time 10 Min
Forward Traveling time 48 Min
Unloading time 15 Min
Total time 116 Min
Capacity 4.5 Cum/Hr
No of Dumpers 12 nos
Paver (Sensor)
Paver width 9.5 Meter
Speed 0.075 Km/Hr
Ideal Output in sqm 712.5 Sqm/Hr
Efficiency 75 %
Net output in Sqm 534.38 Sqm/Hr
Layer thickness 0.125 Meter
Capacity 66.8 Cum/Hr
Vibratory Compactor: 10 T, Case

Drum width 2.1 Meter
Speed 2.5 KM/HR
Overlap 35 %
No of passes 6
Ideal Output in sqm SQM/HR
Efficiency 80 %
Net output in Sqm 455 SQM/HR
Wet Mix Plant

Rated Capacity 160 TON/HR
Efficiency
ency 80 %
Density 2.3 TON/CUM
23
9.9. Method Statement for Primer
9.9.1. Scope
The work shall consist of application of single coat of low viscosity liquid
bituminous material to an absorbent granular surface preparatory to any
superimposed bituminous treatment or construction.
9.9.2. Functions of Prime Coat
 It assists in promoting & maintaining adhesion between a granular base & a

subsequently applied bituminous surface by pre coating the surface of the
base & by penetrating the voids near thesurface.
 It helps to seal the surface pores in the base thus reducing the migration of
moisture and to a great extent prevents the absorption of the first spray of
surfacingbinder.
 It helps to strengthen the base near its surface by binding the finer particular
of aggregate.
 It helps to stabilize cohesive soil by water proofing thebinder.
9.9.3. Requirement of a Primer
A primer must be capable of wetting and penetrating the dust film covering a
granular base and coating the aggregate particles with a strongly adhering film of
bituminous binder. It must also be capable of penetrating the surface of the base
normally to a depth of between 5 mm to 10 mm on dense graded base. These
requirements are met if low viscosity cut back bitumen which are solution of
bitumen in light and heavy oil are used asprimer.
After spraying a primer its temperature falls to that of the road surface and its
viscosity increases rapidly. The primer then cures because of the loss of light oils
by evaporation. The primer must be so constituted that a thin, strong layer of
bitumen is formed on the surface of the base and so that any light oilspresentare
able to evaporate rapidly this enabling the primer to dry within reasonable time.
The Primer used for Prime coat shall be bitumen emulsion complying with IS 8887
& CRS (Cationic slow setting) – 1 grade confirming to ASTM D 2397/AASHTO
M 140 and shall be refinery produced.
1. Weather & Seasonal limitation: The bituminous primer shall not be

applied on a wet surface or during dust storm or when the weather is foggy,
24
rainy or windy. The prime coat for surface treatment should not be applied
when the temperature in the shade is less than10 degree C
2. Equipment: The primer distributor shall be pneumatic tired self-propelled

pressure distributor equipped for spraying the material uniformly at
specified rate andtemperature.
3. Preparation of road surface: The surface to be primed shall be swept

clean, free from dust and shall be dry. It shall be shaped to the specified
grades and section. It shall be free from ruts and, any other irregularities
and segregated materials.
4. Application of bituminous primer:
 The surface of the base should be well swept with a

mechanicalbroom.
 The dust if any on the surface to be blown with an Air Compressor.
Moistening of the surface to be done immediately prior to primer to
assist the primer to wet the surface uniformly and facilitates its
penetration into base. Care should be taken however not to apply on
excess of water since voids that are filled with water cannot be filled
with primer. For the prime coat to be readily absorbed the base
should be just dump to a depth of about 10 mm and beginning to
dryout.
 The bituminous primer shall be sprayed / distributed uniformly at
the rateof6.0 to 9.0 kg/Sqm over the dry surface using self –
propelled sprayer equipped with self-heating arrangement, suitable
pump, adequate capacity compressor and spraying bar with nozzles
having constant volume or pressure system capable of supplying
primer at specified rate and temperature so as to provide a uniformly
unbroken spread of primer.
 Before spraying primer, the calibration of the primer sprayer to be
conducted on trial stretch to determine the speed of the sprayer and
ht of the nozzle bar to as to spray the required rate ofprimer.
 Spraying temperature shall be between 30 degree C to55 degreeC
5. Control Test
Type of Test Frequency

Construction
Primer 1. Quality of Binder. Two samples per lot
25
2. Binder temperature At regular close interval

for application
3. Rate of spread of Two test per day
binder.
6. Curing of Primer
After applying primer, the surface shall be allowed to cure for at

least 24 hours so as to allow penetration into the base course and
aeration of volatile from the primer material.
9.10. Method Statement for Tack Coat
9.10.1. Scope
The work consists of application of a single coat of low viscosity liquid bituminous
material to an existing good surface preparatory to another bituminous construction
over it.
9.10.2. Materials
The binder used for tack coat shall be bitumen emulsion complying with IS 8887
and CRS-1 grade confirming to ASTM D 2397/AASHTO M140 and shall be
refinery produced.
 The surface on which the tack coat is to be applied shall be cleaned of dust
and any extraneous material by using mechanical broomer.
 First dust shall be removed from the surface with the help ofcompressor.
 Binder material inside the sprayer is heated to a temperature of 50o C to
80o C.
 Once the temperature is attained the binder shall be applied uniformly with
the aid of either self-tired propelled bituminous pressure with self-testing
arrangement and spraying bar with nozzles having constant volume &
pressure system, capable of spraying on primed surface & 2.0 to 2.5 kg/10
Sqm on bituminous surface so as to provide uniformly unbroken spread of
bituminous.
 Tack coat shall be allowed to cure without being disturbed until the cutter
has been completely evaporated.
26
Quality Control Test Frequency
 Quality of Binder Two samples per lot

 Binder temperature of close interval at regular close interval
 Rate of spread of Binder close interval Two test per day
9.11. Method Statement for DBM Construction
9.11.1. Scope
The scope of work consists of construction of Dense Bitumen Macadam in one

layer of 50 mm to 100 mm thickness in Main Carriageway.
9.11.2. Materials
Bitumen: The bitumen shall be modified bitumen as per IRC: SP: 73
Coarse aggregate: The coarse aggregate shall be crushed stone of identified

Physical Characteristics of aggregate
SL.NO TEST CODE REQUIREMENT

1 Aggregate Impact Value IS:2386 (Part4) or Maximum 30%
IS:5640
2 Combined Flakiness and IS:2386 (Part1) Maximum 30%
Elongation indices (Total)
3 Coating and Stripping of AASHTO T 182 Minimum retained
Bitumen Aggregate coatings 95%
Mixtures
4 Soundness - Loss of Sodium IS:2386(Part5) 5 Maximum 12%
Sulphate cycles
5 Soundness - Loss of IS:2386(Part5) 5 Maximum 18%
Magnesium Sulphate cycles
6 Water absorption IS:2386 (Part3) Maximum 2%
Fine aggregate: Fine aggregates passing 2.36 mm sieve and retained on 75-micron
sieve shall be crusher-run screenings of identified Quarry. No separated fine
aggregate shall be added if the requisite quantity of fine aggregate is available in
the crushed aggregate.
27
Filler: The mineral filler shall be rock dust/ crusher screenings available in the
crushed aggregate. No separated filler shall be added if the requisite quantity filler
is available in the crushed aggregate
Aggregate Gradation: The grading of the aggregate mix as used in work shall be
a smooth curve within and approximately parallel to the envelope in Table 500-10.
Source: The crushed aggregate of identified Quarry shall be used for DBM
9.11.3. Mix Design
The Job Mix Formula shall produce a mix meeting with the following
requirements.
SL.NO DESCRIPTION REQUIREMENTS
1 Marshall stability with 75 blows Minimum 820 kg
2 Marshall flow 2 to 4 mm
3 Air voids 3% to 5%
4 Voids in mineral aggregates 12% to 14%
(VMA)
5 Voids in mineral aggregates filled 65% to 75%
with bitumen (VFB)
6 Bitumen content Not less than 4%
7 Stability to Flow ratio 205 to 410
8 Water Sensitivity Not less than 75%
9 Filler Bitumen ratio 0.6 to 1.2
 Mark the limits of DBM with lime powder or pegs on the completed
WMM. The surface shall be cleaned with a mechanical broom and dust is
blown off with compressedair.
 Prime coat shall be applied in accordance with clause 502 on the granular
surface Tack coat shall be applied wherever necessary in accordance with
clause 503 on the previous bituminous slayer.
 Tack coat shall be applied wherever necessary in accordance with clause
503 on the previous bituminous slayer
 The material as per JMF shall be mixed in the Hot Mix Plant. (Refer to time
cycle of Hot MixPlant)
 The material shall be loaded on to the dumpers directly from the hot mix
plant for transporting to the DBM location. Refer time cycle Dumper(20T)
28
 Lateral confinement shall be provided by laying the material for shoulder

prior to commencement of layingoperation.
 The material shall be spread with a sensor Paver.The material shall be
spread in layers of uniformthickness
 Compaction of DBM shall start when the temperature is between 120 to
140 degrees. The compaction shall be done with the help of vibratory
compactor and Pneumatic tired roller of 150-250 KN. The compaction
pattern including no of passes required shall be finalized after full-scale
experiment at site toachieve98% of MDD. Refer time cycle of Vibratory
Compactor: 10 T or Pneumatic tired rollers 12-15T. The general pattern
shall be as follows
a) Initial rolling 2 static passes with Vibratory roller
b) Intermediate rolling 2 vibratory passes
c) Final rolling 2 passes with PTR or Tandem Rollers
 The compaction shall commence from the lower edge and shall move to
upper edge width by width Rolling operation shall be completed before the
temperature falls below 100 degrees. The wheels of roller shall be kept
moist to prevent the mix from adhering to them Quality control tests shall
be carried out prior to commencement of next layer of DBM orBC.
 The compaction behind structure shall be accomplished with the use of
vibratory roller or plate compactors to achieve 98% MarshallDensity
 The finished level DBM shall be within the tolerance limitsspecified in
Table900.1. (i.e., +6 mm to – 6mm)
 The Quality control tests shall be conducted on the material at the source
prior transportation and at the DBM location after the completion of
compaction operation. Following tests are pertinent toDBM
SL NO TEST CODE FREQUENCY

1 Quality of binder IS: 73 Penetration between 60 and 70
2 Aggregate Impact Value IS: 2386(part 4) 30% Maximum
3 Flakiness and IS: 2386(part 1) 30% Maximum
Elongation Index
4 Stripping value AASHTO T 182 Minimum Retained coating 95%
5 Water absorption of IS: 2386(part 3) 2% Maximum
6 sand equivalent test IS: 2720(Part- Not less than 50
37)
7 Mix grading Table 500.9 of 1 test for each 400 tonnes of mix
specification subject to a minimum of 2 tests
clause 507 per day
29
METHODOLOGY
AIZAWL-TUIPANG
PACKAGE
8 Stability of Mix ASTM D-1559 1set of 3 Marshal specimens to

be tested for stability, flow,
voids every 400 tonnes of mix,
subject to a minimum of 2 sets
per day.
9 Control of temperature At regular close intervals 1 test
for each 400 tonnes of mix
subject to a minimum of 2 tests
per day
10 Control of binder Regular control and through
content and gradation in checks on the
the mix
11 Rate of spread of mixed weight of mix and layer
material thickness
12 Density of compacted 1 test per 250 Sqm area
layer
9.11.5. List of Equipment and Time Cycle
Hot mix Plant:

Rated Capacity 120 Ton/HR
Efficiency 75 %
Density 2.45 Ton/Cum
Capacity 36.73 Cum/HR
Dumpers: 20 Tons
Lead 16 Kms
Capacity 20 Tons
Loading time 12.5 Min
Speed 20 Km/HR
Return Traveling time 48 Min
Contingencies 5 Min
Total time 144.5 Min
Paver with sensor

Paver width 7.5 Meter
Speed 0.15 Km/HR
30
Ideal Output in sqm 843.75 Sqm/Hr

Efficiency 75 %
Net output in Sqm 632.81 Sqm/HR
Layer thickness 75 mm
Tandem Roller: 10 T
Speed 3 KM/HR
Overlap 3000% %
No of passes 6
Ideal Output in sqm 578 SQM/HR
Efficiency 7500% %
Layer thickness 75 MM
Pneumatic Tire Roller:

Speed 2.5 Km/HR
Overlap 25 %
No of passes 3
Ideal Output in sqm 1313 Sqm/HR
Efficiency 75 %
Net output in Sqm 984.375 Sqm/HR
Layer thickness 75 Meter
9.12. Method Statement for BC Construction
9.12.1. Scope
The scope of work consists of construction of Bituminous Concrete (Asphalt

Concrete) of 30/ 40 mm thick in Main Carriageway & in service road, loops &
ramps.
9.12.2. Materials
Bitumen: The bitumen shall be modified bitumen as per IRC: SP:73
31
Coarse aggregate: The coarse aggregate shall be crushed stone of identified

Physical Characteristics of aggregate
SL.NO TEST CODE REQUIREMEN

T
1 Aggregate Impact Value& IS:2386 (Part4) or Maximum 30%
Los Angeles Abrasion IS:5640
Value
2 Combined Flakiness and IS:2386 (Part1) Maximum 30%
Elongation indices (Total)
3 Coating and Stripping of AASHTO T 182 Minimum retained
Bitumen Aggregate coatings 95%
Mixtures
4 Soundness - Loss of Sodium IS:2386(Part5) 5 Maximum 12%
Sulphate cycles
5 Soundness - Loss of IS:2386(Part5) 5 Maximum 18%
Magnesium Sulphate cycles
6 Water absorption IS:2386 (Part3) Maximum 1%
7 Stone polishing value BS:812 (Part 114) Not less than 55
Fine aggregate: Fine aggregates passing 2.36 mm sieve and retained on 75-micron
sieve, shall be crusher-run screenings of identified Quarry. No separated fine
aggregate shall be added if the requisite quantity of fine aggregate is available in
the crushed aggregate.
Filler: Filler shall consist of finely divided hydrated lime or cement
Aggregate Gradation: The grading of aggregate mix as used in work shall be a

smooth curve within and approximately parallel to the envelope in Table 18 grade
1.
Source: The crushed aggregate of identified Quarry shall be used for BC
9.12.3. Mix Design
The Job Mix Formula shall produce a mix meeting with the following requirements
SL.NO DESCRIPTION REQUIREMENTS

1 Marshall stability with 75 blows Minimum 820 kg
2 Marshall flow 2 to 4 mm
32
3 Air voids 3% to 5%
4 Voids in mineral aggregates (VMA) 14% to 16%
5 Voids in mineral aggregates filled with bitumen 65% to 75%
(VFB)
6 Bitumen content Not less than 4.5%
7 Water sensitivity (ASTM D1075) loss of stability Minimum 75%
on immersion in water at 60degree C retained strength
8 Swell test (Asphalt Institute MS-2, No.2) 1.5% Maximum
9 Wax content of bitumen 4.5% Maximum
1. Mark the limits of BC with lime powder or pegs on the completed DBM. The
surface shall be cleaned and dust is blown off with compressedair.
2. Tack coat shall be applied wherever necessary in accordance with clause 503
on the previous bituminouslayer.
3. The material as per JMF shall be mixed in the Hot Mix Plant.
4. The material shall be loaded on to the dumpers directly from the hot mix plant
for transporting to the BC location. Refer time cycle Dumper (20T).
5. Lateral confinement shall be provided by laying the material for shoulder, kerb
and edge stone prior to commencement of laying operation.
6. The material shall be spread with a sensor Paver. The material shall be spread
in layers of uniformthickness.
7. Compaction of BC shall start when the temperature is between 120 to 140
degrees. The compaction shall be done with the help of vibratory compactor
and Pneumatic tired roller. The compaction pattern including no of passes
required shall be finalized after full-scale experiment at site to achieve 98% of
MDD. Refer time cycle of Vibratory Compactor: 10 T and Pneumatic tired
roller. The general pattern shall be asfollows
a) Initialrolling 2 static passes with Vibratoryroller
b) Intermediaterolling 2 vibratorypasses
8. The compaction shall commence from the lower edge and shall move to upper
edge width by width Rolling operation shall be completed before the
temperature falls below 100 degrees the wheels of be kept moist to prevent the
mix from adhering to them. The second layer of BC shall then be laid to limits
andcompacted.
9. The compaction behind structure shall be accomplished with the use of
vibratory roller or plate compactors to achieve 98% MarshallDensity.
10. The finished level BC shall be within the tolerance limits specified in Table
900.1. (i.e., +6 mm to –6mm).
33
11. The Quality control tests shall be conducted on the material at the source prior
transportation and at the BC location after the completion of compaction
operation. Following tests are pertinent toBC
SL NO TEST CODE FREQUENCY

1 Quality of binder IS: 73 Penetration between 60 and 70
2 Aggregate Impact Value IS: 2386(part 4) 30% Maximum
3 Flakiness and Elongation IS: 2386(part 1) 30% Maximum
Index
4 Stripping value AASHTO T Minimum Retained coating
182 95%
5 Water absorption of IS: 2386(part 3) 2% Maximum
aggregate
6 sand equivalent test IS: 2720(Part- Not less than 50
37)
7 Mix grading Table 500.9 of 1 test for each 400 tonnes of
specification mix subject to a minimum of 2
clause 507 tests per day
8 Stability of Mix ASTM D-1559 1set of 3 Marshal specimens to
be tested for stability, flow,
voids every 400 tonnes of mix,
subject to a minimum of 2 sets
per
9 Control of temperature At regular close intervals
10 Control of binder content and 1 test for each 400 tonnes of

gradation in the mix mix subject to a minimum of 2
tests per day
11 Rate of spread of mixed Regular control and through
material checks on the weight of mix
and layer thickness
12 Density of compacted layer 1 test per 250 Sqm area
subject to condition that 10%
density tests shall be done on
the edges.
Water sensitivity (ASTM Minimum 75% As required
D1075) loss of stabilityon retained
immersion in water at strength
60degree C
14 Swell test (Asphalt Institute 1.5% Maximum As required
MS-2, No.2)
15 Wax content of bitumen 4.5% Maximum As required
34
METHODOLOGY
AIZAWL-TUIPANG
PACKAGE
16 Polished Stone value Initially one set of three

samples for each source and
subsequently by changes in
quality of aggregates
17 Sand Equivalent Test Three test on aggregatesfor
each 400 T of mix subject to
two tests per plant per day.
9.12.5. Test on completed layer of Bituminous Construction shall be as follows:
1. Relative compaction
2. Layer Thickness
9.12.6. List of Equipment and Time Cycle
Hot Mix Plant

Rated Capacity 120 Ton/HR
Efficiency 75 %
Density 2.5 Ton/Cum
Capacity 36 Cum/HR
Dumpers: 20 Tons
Lead 16 Kms
Capacity 20 Tons
Loading time 12.5 Min
Speed 20 Km/Hr
Return Traveling time 48 Min
Contingencies 5 Min
Total time 123.5 Min
Paver with Sensor:

Paver width 7 meter
Speed 0.25 Km/hr
Ideal Output in sqm 1312.5 sqm/hr
Efficiency 75 %
Net output in Sqm 984.38 sqm/hr
Capacity 49.22 cum/hr
35
Tandem Roller: 10 T
Drum width 1.65 meter
Speed 3 km/hr
Overlap 30 %
No of passes 6
Ideal Output in sqm 578 sqm/hr
Efficiency 75 75 %
Net output in sqm 433.1 Sqm/hr
Capacity 21.66 cum/hr
Pneumatic Tire Roller:

Speed 2.5 Km/Hr
Overlap 25 %
Noofpasses 3
Ideal Output in sqm 1313 Sqm/Hr
Efficiency 7500% %
Net output in sqm 984.375 Sqm/Hr
9.13. Method Statement for Cast In - Situ Culvert:
Culverts are mainly the cross-drainage structures and are of following types:
 Box Culvert
 HumePipeCulvert
9.13.1. Box Culvert:
The construction methodology mainly consists of following
a. Base RaftConstruction
b. WallConstruction
c. DeckConstruction
a. Construction of Base Raft with HaunchPortion:
Setting Out
36
Survey points shall be marked on either direction of the alignment by total

station from control points.
A benchmark shall also be established at nearby site location where no

disturbance will occur throughout the execution phase. The benchmark
shall be checked at frequent interval as and when required. The foundation
shall be marked on ground with clearance of formwork space required.
Dewatering
The open foundations are provided mainly for the cross-drainage structures,
hence required advance planning for dewatering before excavation to
commence at per site conditions.
If required water shall be diverted through other channels, or otherwise

dewatering shall be done if required. At this location depending upon the
flow of water a pump of capacity may be sufficient to keep the foundation
dewatered. Pumped out water shall be released at the farthest point to the
maximum possible. The surface water source shall be checked and if
possible, stopped from joining this stream or be diverted to some other
stream.
Excavation
The excavation shall be done with safe side slopes and with sufficient
margin for working on structural concrete. Excavation shall be carried out
either by JCB or excavator and excavated material shall be disposed by
using tractor trolleys or dumpers as directed. The pit level reached up to
PCC bottom shall be properly leveled and compacted before laying Plain
Cement Concrete.
The excavated soil if found not suitable shall be disposed off at places as
directed by the client/supervising consultant otherwise it shall be stockpiled
at suitable location for backfilling or directly sent to road embankment front
as fill. Dewatering shall be carried out either by pumps if required. Water
seeping through sides and coming from bottom shall be collected through
side trench into a pit outside the foundation area for pumping out.
Foundation pit sides if required shall be supported by earth filled empty
cement bags.
Foundation size shall be laid out at foundation level and spot levels shall be
taken in a grid pattern of about 2 m c/c in both directions jointly with the
37
client/supervising consultant. Foundation shall be declared as approved on

reaching the design foundation level and for laying leveling course.
Leveling Course
The excavated pit shall be manually dressed with sufficient working space
around the raft to be constructed. Fix forms like ISMC 100 or wooden
planks at the edge as formwork. P.C.C shall be supplied from the batching
plant throughtransit mixers. It shall be unloaded through chute/s and then it
shall be manually spread & compact leveling course thickness. After initial
set the concrete surface shall be sprinkled with water to save it from
cracking. Curing shall be done by keeping it moist with Hessian cloth or by
continuous spay of water. After allowing it to gain strength over 24 hours it
shall be released for raft activities.
Reinforcement
As per the approved construction drawing/s and bar bending schedule

reinforcement of raft is pre-straightened / cut / bend in the rebar yard.
Reinforcement bars shall be shifted to the location in advance. Marking for
the raft shall be done on leveling course. Rebar shall be tied as per
approved drawing/s & schedule. To hold the top rebar mesh of raft rebar
chairs shall be provided at appropriate places to avoid the sagging of top
mesh.
After completion of top reinforcement, erect the wall Vertical bars with
binders/spacers. Necessary pipe support with inclined member shall be
provided to the vertical bars temporarily from sides to avoid tilting of rods.
Formwork
Concrete cover blocks of same grade that of foundation shall be tied to the
reinforcement before fixing formwork. Steel formwork plates applied with
de-molding oil is fixed in position with the help of props & ties/spacers
against each other to line & level as required. During concreting the
formwork shall not lose its alignment. Foundation dimensions and
reinforcement shall be inspected and if any deviations found shall be
corrected before pouringof concrete.Concrete shall be poured into the
foundation using direct chute or concrete pump as per accessibility. Chutes
shall be made using M.S. sheets / CGI sheets. Chutes shall be placed with
appropriate slope so that concrete free flows. Concrete shall be laid in 300
mm to layers and vibrated with diesel or electrically operated 60 mm
needles. The layer thickness shall be selected such that the next layer is laid
38
before previous layer initially sets. Exposed top surface of concrete shall be
smooth finish using mason’s trowel. The wall portion shall be made rough.
Cut piece Reinforcement rods of diameter higher than 25mm shall be

embedded (depth of embedment not) along the centre line of base raft to
support inclined props to be used for 2nd stage formwork of wall before
final setting of concrete.
After the initial set, protect concrete surface with moist hessian cloth. After
final set mortar bunds shall be made for ponding of water, sand layer be
laid in bunds to retain water for the proper curing. Within 24 hours concrete
will gain sufficient strength and de-shuttering shall be done carefully.
Formwork Removal
The concrete shall be allowed to gain strength over 12 to 24 hours. Then

forms shall be removed without damage to concrete. The forms, side
supports and shoring shall be safely removed, cleaned and stacked properly
for future use. The exposed concrete surfaces shall be inspected for
blemishes. Blemishes if any shall be mended immediately back-filled with
excavated material up to raft top level. This filling will help in curing the
foundation if kept moist. Top of raft shall be provided with cement sand
mortar bund and kept inundated with water for curing till curing period is
over.
b. Wall Construction
Against the dowels left through raft balance reinforcement shall be tied for
predetermined lift to be concreted. Vertical rods shall be provided with
requiredoverlaps as per construction drawings. Efforts shall be made to
minimize overlaps. Horizontals shall be tied in position. Concrete cover
shall be provided by Concrete cover blocks tied with reinforcement as
required.
Forms fixing
Steel formwork shall be procured or fabricated in the central fabrication

yard as per detailed drawing. After completion of fabrication, the steel
formwork shall be assembled at workshop /fabrication yard and given
numbering to facilitate the easy erection at site. The formwork dimensions
and supporting system should be checked thoroughly as per drawing before
dispatch to site for fixing.
39
The steel formwork shall be transported to site by truck/ trailer. The loading
and unloading of formwork shall be under controlled supervision so that the
formwork should not get damaged during handling.
After completion of reinforcement work, Steel forms in panels shall be

erected, aligned and fixed in position as required against the already tied
reinforcement. The forms shall be placed over the seating channel fixed by
tie bolts through left out holes in already concreted straight portion over
haunch. The forms shall be side supported with the help of struts taking
reaction from the channel placed against the embedded reinforcement in
already concreted raft. There shall be retrievable tie rods conduit pipes
holding forms from both faces of walls. The line and level shall be achieved
as per approved drawings and then cleared the wall for concreting. A
schematic wall formwork arrangement has been attached above only to
support the methodology, whereas the actual execution shall be done as per
the final drawing issued by concerneddepartment.
Concreting
The concrete mixed from centralized batching plant/s shall be delivered

through transit mixers. It shall manually or through crane +
bucket/Concrete pumps as per site condition. Concrete shall be vibrated
with needle (electrical/petrol/diesel) vibrators. It shall be ensured that
concreting is continuous and completed in a single pour to minimize
number of cold joints. The exposed area of the walls shall be green cut to
receive next liftconcrete.
Forms removal inspection & curing
After gaining strength over about 1 day the side form panels shall be safely
removed, cleaned and use/lifted up and fixed for the next lift. The
demolded concrete surfaces shall be inspected for blemishes, if noticed
shall be mended immediately as per approved methodology. The exposed
concrete surfaces shall be covered with moist Hessian cloth & shall be
maintained moist over the curing period.
c. Deck with Wall 2nd lift & Corbel Construction
The general construction methodology shall be comprised of followings –
a) Fabrication of shutter &reinforcement

b) Staging
c) Formwork &Reinforcement
40
d) Concrete
e) Wing Wall
a) Fabrication of shutter &reinforcement

Standard shutters shall be used or required size shutters shall be
fabricated at centralized fabrication yard as per drawing for G.A of
Formwork & Staging. The shutters shall be transported to site by
truck / trailer.
Reinforcement shall be fabricated at centralized yard as per BBS
made in accordance to the latest “Good For Construction” Drawing
and approved by Authority’sEngineer and it shall be transported to
site by truck / trailer.
Store the fabricated rebars on wooden / concrete sleepers to avoid

any contamination from soil / ground water.
b) Staging
After completion of wall upto required height, staging for deck will
start.
Erect vertical member in form of props / H-Frame /MS Pipe/ Cup

lock pipe above the base slab of RCC Box in between the walls as
per staging drawing. Brace the vertical members in bothdirections.
Erect the longitudinal girder and cross girders as per staging

drawing.
c) Formwork &Reinforcement
Parallelly with girder erection fix the balance wall inner side shutter
and align by taking support from the staging erected as per staging
and formwork drawing. Apply shuttering oil to the formwork before
fixing.
Fix soffit shuttering over cross girder. Check the soffit shuttering
level and introduce necessary wooden packing below the shuttering
joints for having provision for de shuttering and leveling.
Apply shuttering oil over the soffit shuttering and start

reinforcement work as per the GFC drawings.
41
Fix the prefabricated reinforcement bars for deck as well as for

balance wall portion of wall as per GFC drawings. Reinforcement
cover shall be maintained as per GFC Drawing by means of cover
blocks placed at suitable intervals. The cover Block shall be of same
grade of concrete ofDeck.
Fix the reinforcement bars for the crash barrier reinforcement as per
GFC Drawing.
Fix the side / end shutter of wall and deck after applyingshuttering
releasing agent.
To keep the shutter joints leak proof, forms or masking tape shall be
used injoints.
Support the side / end shutters by inclined support members as

shown in the formwork/stagingdrawing.
d) Concrete
After checking of staging, formwork and reinforcement, cast the

wall and deck. Concrete shall be placed in a single continuous pour
in such a sequence, which will avoid formation of cold joints.
Concrete shall be produced in controlled batching plant as per

approved Mix Design and shall be transported to site by Transit
Mixer. The slump and temperature of at site before pouring and it
should be as per requirement of Inspection and test plan of casting
of RCC Box / specification of contract. Concrete shall be poured in
the formwork by Static concrete Pump/placer boom without any
disruption to avoid cold joints. Separate arrangement for concreting
shall be kept ready for any major mechanical fault of concreting
equipment.
Needle vibrator is to be operated vertically in combination with the

shutter vibrator. No vibrator to be run for more than 2 minutes at
one place to prevent segregation. Do not allow any pocket formation
or honey-comb in the concrete. Feel the flow of concrete by
hammering the shutters by a wooden mallet.
Deck concrete top level shall be finished smoothly.
Remove the end and side shutter after 24 hrs of concreting.
42
Start curing of deck and wall by using wet Hessian cloth or by

continuous water sprinkling arrangement to keep the girder wet upto
14days.
The soffit and staging shall be removed depending on the span

length as per guidelines of relevant IS Code.
e) WingWall
These are gravity type concrete structure shall be cast after

completion of RCC Box culvert as per construction drawing. The
general methodology of construction includes P.C.C leveling course
and construction of P.C.C Wing wall.
Formwork as per construction drawing shall be erected over the

leveling course. The formwork shall be fixed as per enabling
drawing issued by concerneddepartment. After fixing of formwork
P.C.C shall be laid upto full height in a single pour. No horizontal
joint is permitted for Wingwall.
9.13.2. Hume Pipe Culvert:
a) Scope:
This work shall consist of unloading, stacking, handling, furnishing
and installing reinforced cement concrete pipes, of the type,
diameter and length required at the locations shown on the drawings
or in accordance with the requirements of contract specification.
b) Pipe Uploading:
Unloading of the pipe shall be controlled so as not to collide with

the other pipe sections or fittings, and care shall be taken to avoid
chipping or spalling, especially to the ends.
Pipes shall be unloaded at Project Work station location designated

for thesame or at work site location directly to avoid re-handling
ofpipes.
Care shall be taken that no personnel are on the path where the pipe
will be lowered. If the pipe has to be moved after unloading, the
sections shall be rolled or lifted and shall never be dragged. Pipe
sections shall not be rolled over rough or rocky ground.
43
Mobile Hydra Crane of 10-12MT capacity shall be used for

unloading of circular pipe sections. When mechanical equipment
shall be used for unloading, the lifting device, which connects to the
pipe, shall enable proper and safe handling without damage to the
pipe. Lifting devices such as slings, chain, steel wire, cable and rope
shall be placed around the pipe and arranged so that the pipe is lifted
in a horizontal position. If there is any possibility of damage of the
pipe during lifting operation, rubber padding shall be provided
between the pipe and lifting device. Regardless of the method used
to unload pipe, precautions shall be taken to avoid damage to the
pipe and assure the pipe is unloaded in a safe manner.
c) Pipe Stacking:
Any stockpiling of pipe shall be as near as possible to where the

pipe shall be installed. The bottom layer of pipe shall be placed on a
flat base, adequately blocked by wooden wedges to prevent sliding
as more layers are added above. Each layer of socket and spigot
pipe shall be arranged so that all the sockets are at the same end.
The sockets in the next layer should be at the opposite end, and
projecting beyond the spigots of the pipe sections in the lower layer.
Where only one layer is being stockpiled, the socket and spigot ends
shall alternate between the adjacent pipe sections. All pipes shall be
supported by the pipe barrel so that the joint ends are free of load
concentrations.
Pipe sections generally shall not be stockpiled at the job site in a

greater number of layers than required. All flexible gasket materials
not cemented to the pipe, including joint lubrication compounds,
shall be stored in a cool dry place to be distributed as needed.
Rubber gaskets and preformed or bulk mastics should be kept clean,
away from oil, grease, and excessive heat and out of the direct rays
of the sun.
d) Pipe Transportation:
In case, stacking and installation location of pipes are different, the

same shall be loaded by mobile hydra crane from stacking yard on a
flat-bed trailer, transported to the installation location, unloaded and
stacked as per the method described earlier in this methodology.
During transportation of pipes adequate lateral support shall be
provided in form of ropes/slings with rubber padding securely fixed
44
with the body of trailer. Precautions shall be taken to avoid damage

to the pipe and assure the pipe is unloaded in a safemanner.
To make sure that concrete pipe does not roll or slide during
transportation, the following guidelines to be followed:
Load pipe as compactly aspossible.

Immobilize symmetrically stacked pipes by securing themingroups.
Use blocking systems and tie-downs to increase the effect offriction.
e) Survey & Setting Out Works:
Survey points shall be marked on either direction of the alignment

by total station from control points. A benchmark shall also be
established at nearby site location where no disturbance will occur
throughout the execution phase. The benchmark shall be checked at
frequent interval as and when required. The foundation shall be
marked on ground with clearance of formwork space required.
All the Survey Instruments used shall be calibrated periodically as

per Calibration Plan. Survey Check Reports / other relevant data
shall be maintained in relevant Inspection formats.
f) Dewatering:
The Pipe Culverts are provided mainly for the cross-drainage

structures, hence required advance planning for dewatering before
excavation to commence as per siteconditions.
If required water shall be diverted through other channels, or

otherwise dewatering shall be done if required. At this location
depending upon the flow of water a pump of about 5 to 10 HP
capacity may be sufficient to keep the foundation dewatered.
Pumped out water shall be released at the farthest point to the
maximum possible. The surface water source shall be checked and
if possible, stopped from joining this stream or be diverted to some
other stream.
g) Excavation:
The foundation bed for pipe culverts shall be excavated true to the
lines and grades shown on the drawings or as directed by
Authority’sEngineer. The pipes shall be placed in shallow
45
excavation of the natural ground or in open trenches cut in existing

embankment, taken down to the levels as shown on the drawings.
In case of high embankment where the height of fill is more than 3

times the external diameter of the pipe, the embankment shall first
be built to an elevation above the top of the pipe equal to the
external diameter of the pipe and to width on each side of the pipe
of not less than 5 times the diameter of pipe, after which a trench
shall be excavated and the pipe shall be laid.
Where trench is involved, its width on either side of the pipe shall
be minimum 150mm or 1/4th of the diameter of the pipe whichever
is more and shall not be more than 1/3rd diameter of the pipe. The
sides of the trench shall be nearly vertical as possible.
The pipe shall be placed where the ground for the foundation is
reasonably firm and any unsuitable material encountered during
excavation, shall be removed and the extra depth of excavation shall
then be backfilled with approved granular material which shall be
properly shaped and thoroughlycompacted up to the specified level.
h) Bedding:
The bedding surface shall provide a firm foundation of uniform

density throughout the length of culvert, shall conform to the
specified levels and grade, and shall be one of the following two
types as specified on the drawings –
First Class Bedding: First class bedding consists of forming and

shaping the bed with graded sand or any other granular material
passing 5.6mm sieve, compacted/rammed. The compacted thickness
of bedding layer shall be as shown on the drawings and in no case
shall it be less than 75mm.
Concrete Cradle Bedding: When indicated on drawing or directed

by the Authority’sEngineer, the pipe shall be bedded in a cradle
constructed of concrete having mix not leaner than M15 conforming
to Section 1700 of MORTH. The shape and dimensions of the
cradle shall be as per drawing. The pipes shall be laid on the
concrete bedding before setting of concrete.
As per drawing concrete cradle of 500mm width shall be provided

below each pipe joint and 1st class bedding shall be provided in
46
space between the cradle below pipe. The height of cradle / bedding
shall be as per drawing. Length shall be varying considering the
type of pipe (1 / 2 / 3 x 1000 dia.) culvert.
Cradle/ bedding shall be constructed in 2 stages –

Stage -1 – Initial 250mm height
Stage -2 – Balance 300mm height after placing and jointing of
pipes.
i) Laying of Pipes:
The pipes shall be lifted, loaded and unloaded by tire mounted

hydra crane and shall be transported from yard to site by flat-bed
truck/trailer. The lowering of pipe in the bed shall be done with
tripod-pulley arrangement / simply by manual labour / hydra crane
in a manner that the pipe is placed in a proper position without any
damage.
Start laying from the outlet and proceed towards inlet ensuring the
specified lines and grade. Where 2 or more lines of pipes are to be
laid adjacent to each other, they shall be separated by a distance
equal to at least ½ diameter of the pipe subject to a minimum
of450mm.
j) Jointing of Pipes:
The pipes shall be joined by collar joint.
In case of collar joint, the collar shall be of RCC 150 to 200mm

wide and having the same strength as the pipes to be jointed.
Caulking space shall be between 13 and 20mm according to the
diameter of the pipe. Caulking material shall be slightly wet mix of
cement and sand in the ratio of 1:2 rammed with caulking irons.
Before caulking, the collar shall be so placed that its center
coincides with the joint and an even annular space is left between
the collar and the pipe.
For jointing pipe under light hydraulic pressure, the recess at the
end of the pipe shall be filled with jute braiding dipped in hot
bitumen or another approved compound. Pipes shall be so jointed
that the bitumen ring of the one pipe shall set into the recess of the
next pipe.
47
After finishing, the joint shall be kept covered and cured for at least
3 days.
k) Backfilling:
Trenches shall be backfilled immediately after the pipes have been

laid, the jointing material has hardened and the curing period is
over. Backfilling up to 300mm above top of the pipe shall be
carefully done and the soil thoroughly rammed, tamped or vibrated
in layers not exceeding 150mm, particular care being taken to
thoroughly consolidate the materials under the haunches of pipe.
Light mechanical tamping equipment –Walk behind roller / soil
compactor shall be used for compaction purpose.
Filling of the trench shall be carried out simultaneously on both

sides of the pipe in such a manner that unequal pressures do not
occur.
In case of high embankment, after filling the trench up to the top of

the pipe in the above said manner, a loose fill of a depth equal to
external diameter of the pipe shall be placed over the pipe before
further layers are added and compacted.
l) Head wall & Other Ancillary Works:
Headwall, wing wall, apron and other ancillary works shall be

constructed in accordance with the details shown on the drawings or
as directed by Authority’sEngineer. The sequence and methodology
of construction shall follow the relevant section of MORT&H
technical specification. (Masonry for the walls shall conform to
Section 1300, 1400 or 1700 as applicable and aprons shall conform
to section 2500).
m) Opening to Traffic
No traffic shall be permitted to cross the pipe line unless height of

filling above the top of the pipe line is at least 600mm.
48
n) Time Cycle
D
a
Hume PipeCulvertUnit y
s
1 2 3 4 5 6 7 8 9 1 1 1 1 1 1 1 1 1
0 1 2 3 4 5 6 7 8
i) Excavation for 1.0 day

foundation
ii) Levelling & 0.5 day
Dressing at FdnLvl.
Bedding P.C.C 0.5 day
Cradle Layout
Bedding - P.C.C
iii) 3.0 day
cradle and 1st
Class granular
filling
iv) Pipe Laying & 4.0 day
Jointing
v) Curing & waiting 3.0 day
v) Backfilling 4.0 day
vi) Brickwork at ends 14. day
& headwall 0
vii Other Finishing 7.0 day
) works etc
EffectiveDuration 18. day
0 s
o) Equipment Deployment:
The plant and equipment to be allocated to each team for carrying

out are:
Hydra - 1 No.
Tipper Trucks -1 No.
Water Tanker -1 No.
JCB -1 No.
T.M. -2 No.
Vibrator with needle -1 No.
49
p) Manpower Deployment:
Site Engineer – 1 No.

Site Supervisor – 1 No.
Land Surveyor – 1 No.
Survey Helper – 2 No.
Testing Engineer – 1 No.
Skilled & Unskilled – 8 No.
q) Safety:
Provide warning signs and any other necessary signs and

barricades, which shall be used to mark work is in progress
on theroads.
Provide men with flags to warn approachingtraffic.
Provide flashing lamps, which shall be operational during
the hours of darkness and situated in such a manner as to
clearly indicate the existence of thehazard.
9.14. METHODOLOGY FOR MASONRY RETAINING WALL
9.15. Equipment Required
Following equipment are required for construction of masonry retaining wall:
Sr. Plant
Make / Capacity Nos. Required Remarks
No. Description
For transportation of
1 Dumper 20 ton As required. boulder, cement and
sand
2 Water tanker 10 KL As required.
For mixing the mortar,
Tools &
3 As required. stone
tackles
dressing and laying
9.16. Setting Out

Survey points shall be marked over the ground on either direction of the alignment
by total station from control points.
50
A temporary benchmark shall also be established near the work. The benchmark
shall be checked at frequent interval as and when required.
9.17. Materials
Stones used in masonry shall be of approved quality locally available sandstone,

quartzite, black trap, etc. They shall be hard, sound and free from decay,
weathering and fissures. Stones with round surface shall not be used.
Cement Mortar: Cement mortar shall be prepared by mixing cement and sand by
volume. Proportion of cement and sand shall be 1:4 (one part of cement and four
part of sand) or as specified. The sand being used shall be sieved before use.
The mortar shall be used as soon as possible after mixing and before it has begun
to set and in any case within initial setting time of cement, after the water is added
to the dry mixture. Mortar unused for more than initial setting time shall not be
used in masonry work.
9.18. Proportioning
The unit of measurement for cement shall be bag of cement weighing 50 Kg and
this shall be taken as 0.035 cubic meter. Measurement of dry sand is done by
making use of a box of size 40 X 35 X 25 cm which has the same volume as that of
a standard bag of cement. In case of damp sand, it’s quantity shall be increased
suitably to allow for bulkage.
9.19. Conclusion
Excavation
 The excavation shall be done with safe side slopes and with sufficient
margin for working on structural concrete. Excavation shall be carried out
either by JCB or excavator and excavated material shall be disposed by
using tractor trolleys or dumpers as directed.
 The pit level reached up to PCC bottom shall be properly leveled as per the
slope mentioned in the drawings and compacted before laying Plain
Cement Concrete.
 The excavated soil if found not suitable shall be disposed of at places as
directed by the client/supervising consultant otherwise it shall be stockpiled
at suitable location for backfilling or directly sent to road embankment front
51
as fill. Dewatering shall be carried out either by pumps if required. Water

seeping through sides and coming from bottom shall be collected through
side trench into a pit outside the foundation area for pumping out.
Foundation pit sides if required shall be supported by earth filled empty
cement bags.
 Foundation size layout shall be given at foundation level, spot levels shall
be taken in a grid pattern of about 2 m c/c in both directions jointly with the
client/supervising consultant. Foundation shall be declared as approved on
reaching the design foundation level and for laying leveling course.
PCC M15 leveling course
 The excavated pit shall be manually dressed with sufficient working space
around the foundation width constructed.
 Fix forms like ISMC 100 or wooden planks at the edge as formwork.
 P.C.C shall be supplied from the batching plant through transit mixers. It
shall be unloaded through chute/s and then it shall be manually spread &
compacted in uniform layer of leveling course thickness.
 After initial set the concrete surface shall be sprinkled with water to saveit
from cracking. Curing shall be done by keeping it moist with Hessian cloth
or by continuous spay of water. After allowing it to gain strength over 24
hours it shall be released for further activities.
Stone Dressing
Stone shall be hammer dressed on the face, the sides and the beds to enable
it to come in proximity with the neighboring stone. The “bushing”
(projection) on the face shall not be more than 40mm on an exposed face
and 19mm on the face to be plastered. It shall not have depression more
than 10mm from the average wall surface.
Laying
All stones shall be wetted before lying to prevent absorption of water from
mortar. The stones shall be laid so that the pressure is always perpendicular
to the natural bed. The courses (if any) shall be built perpendicular to the
pressure which the masonry will bear.
In case of battered walls, the base of stone and plan of courses (if any) shall
be at right angles to the batter.
The walls shall be carried up truly plumbed or to the specified batter. Every
stone shall be carefully fitted to the adjacent stones, so as to form neat and
closejoints.
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Vertical joints shall be staggered as far as possible.
Stone will be brought to level course at every 1.5m or designated level.
The bond shall be obtained by fitting in closely the adjacent stones.

Transverse bonds shall be provided by the use of bond stones extended
from the front to theback of the wall. At angular junctions the stones at each
alternate course shall be well bonded into the respective courses of the
adjacentwall.
Face stones shall extend and bond well in the back. These shall be arranged
to break joints as much as possible, and to avoid long vertical lines of
joints. The depth of stone from the face of the wall inwards shall not be less
than the height or breadth at the face.
Where there is a break in the masonry work, the masonry shall be raked in
sufficiently long steps for facilitating joining of old and new work. The
stepping of the raking shall not be more than 45 degrees with the
horizontal. The masonry work shall not be raised more than 1.5 meters per
day.
Hearing of chips
The hearting or interior filling of the wall shall consist of rubble stones
which may be of any shape but shall not be less than 150mm on any face.
These shall be carefully laid, hammered down with a wooden mallet into
position and solidly bedded in mortar. The hearting should be laid nearly
level with facing and backing, except that at about one-meter intervals,
vertical bonds stones shall be firmly embedded to form a bond between
successive courses.
Insertion of chips
The chips and spalls of stones shall be used wherever necessary to avoid
thick mortar beds or joints and it shall also be ensured that no hollow
spaces are lefty anywhere in the masonry. The chips shall not be used
below their hearting stone to bring these up to the level of face stones. The
use of chips shall be restricted to the filling of interstices between the
adjacent stones in hearting and this shall in no case exceed 20% of the
quantity of stonemasonry.
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Bond stone
Bond or through stone 600 x 150x150 mm running across the thickness of

wall shall be provided in the walls, two or more bond stones overlapping
each other by at least 300mm shall be provided in a line from face to back.
At least one bond stone or a set of bond stones shall be provided for every
0.5 sqm courses and shall be staggered in subsequent course. An
identification mark for the bond stones shall be given on both faces.
Jointing
Stones shall be so laid that all joints are fully packed with mortar. Face joint
shall be minimum 20mm thick. The joint shall be raked to a minimum
depth of 20mm during the progress of work when the mortar is still green.
For the faces of the wall which are not to be plastered, stone surface shall
be cleared of mortar splashing to give uniform stone appearance.
Pointing
 The joints between the stones shall be raked and cleaned before pointing.
 Cement sand mortar of 1:3 will be used for pointing.
 The mortar shall be filled and pressed into the raked joints manually.
 The surplus mortar shall be removed from the edges and stone surface is
cleaned of all mortar.
Curing
 Green work shall be protected from rain, running water of accumulated

water from any source, by suitablemeans.
 Masonry work, during progress shall be kept thoroughly wet by sprinkling
water at regular intervals, on allfaces.
 Curing shall be done after 24 hours of completion of day’s work and shall
be done for 7 days aftercompletion.
 Proper watering cans with spray nozzles, rubber or PVC pipes shall be used
for this purpose.
Staging/Scaffolding
Single scaffolding having one set of vertical support, shall be used and
other end of the horizontal scaffolding member shall rest in a hole provided
in header course. The support shall be sound and strongly clamped with the
horizontal pieces over which the scaffolding planks shall be fixed.
54
The holes left in the masonry works for supporting the scaffolding shall be
filled and made good with plain cement concrete of grade 1:3:6 during
pointing. Suitable access shall be provided to the working platform area.
The following measure shall be taken during erection of the

scaffolding/staging.
 Sufficient wooden sleeper or log, in addition to base plates shall be

provided, particularly, where scaffolding is erected on softgrounds.
 Adjustable bases to compensate for uneven ground shall beused.
 Proper anchoring of the scaffolding/staging at reasonable intervals
shall be provided in each direction with the main structure
whereveravailable.
 Horizontal and diagonal braces shall be provided to prevent the
scaffolding fromrocking/swaying.
 The scaffolding/staging shall be checked at every stage for
plumbline.
 All clamps and couplings shall be properly tightened with nuts and
bolts to avoidslippage.
For smaller works wooden ballies will be used for scaffolding/staging.
Coping
 50mm thick PCC coping is provided on the top of masonry wall

 Wooden planks tied by binding wire or trough bolts will be used for
shutteringpurpose.
Weep holes
 In the stone masonry structure, weep holes will be provided with

PVC pipe of 100mm during the masonry construction.
 Weep hole shall be spaced 1m c/c and staggered in both directions.
 Weep holes shall be extended full width of masonry with slope of
one vertical to 20 horizontals towards draining face.
 The lowest row of weep hole shall be provided 150mm above
lowest ground level.
Filter media and Backfilling
 Filter media and Backfilling with approved material shall be started

after 7 days ofwork.
55
 The soil shall be thoroughly rammed, tamped or vibrated in layers

not exceeding150mm.
 Filter media will be provided as per the drawing.
TIME CYCLE CALCULATION FOR DIFFERENT STRUCTURES:
Note : Quantities shown are approx. only , only for justification of duration considered
Sl. Duratio
Item Description Qty Unit Unit
No. n
1 RCC Retaining Wall
Raft with Haunch Portion:
i) Excavation for Raft & Shear Key constr. 540 cum 2 day
ii) Leveling& Dressing 198 sqm 1 day
iii) P.C.C for Raft and shear key portion 19.8 cum 1 day
iv) Reinforcement for Raft & Wall portion 60.3 mt 8 day
Shuttering for Raft portion & staging for
v) 12 sqm 3 day
reinforcement
vi) Checking & conc for raft portion 402 cum 1 day
Subtotal Duration 16
Wall Lifts (2.6m ht)
Wall Reinforcement binding for 1st lift upto
vii) 1.55 mt 2 day
2.6 m
viii) Wall shuttering 1st Lift Upto 2.6m 104 sqm 2 day
ix) Checking & Conc of Wall 1st Lift 62.1 cum 1 day
Subtotal Duration 5 day
Nos of lifts – 4
Duration for wall 20 day
Total Duration 36 days
2 RCC Drain
Raft with Haunch Portion : 60m length
i) Excavation for Raft & Shear Key constr. 120 cum 1 day
ii) Leveling& Dressing 120 sqm 1 day
iii) P.C.C for Raft 10.8 cum 1 day
iv) Reinforcement for Raft & Wall portion 1.8 mt 1 day
Shuttering for Raft portion & staging for
v) 28.8 sqm 1 day
Reinforcement
vi) Checking & conc for raft portion 14.4 cum 1 day
Subtotal Duration 6
Wall Lifts (1.2 m ht)
56
vii) Wall Reinforcement binding 0.9 mt 1 day

viii) Wall shuttering 1st Lift 288 sqm 2 day
ix) Checking & Conc of Wall 1 cum 1 day
Subtotal Duration 4 day
Raft and wall will move in series
Hence for 60m drain, duration is 4 days
m/day
i.e 1 set of shuttering, drain casting 15
3 Masonry Wall - 20m x ave width 1.8, ht 6m; qty = 216m3;
i) Bed preparation & PCC 6.4 M3 1 day
ii) Bottom layer, 81 M3 2.7 day
iii) PCC band 4.2 M3 0.5 day
iv) Middle layer 63 M3 2.1 day
v) PCC band 3 M3 0.5 day
vi) Top layer 45 M3 1.5 day
vii) PCC band 1.2 M3 0.5 day
viii) Total 8.8 day
10. SAFETY & QUALITY:
The OH & Safety and Environmental Management Plan for the Project shall be prepared to meet
the various Safety and Environmental Management requirements as mentioned in Contract
documents and also as per the established OH & Safety and Environmental Management Systems
and Procedures of MCPL.
General Safety Arrangements:
 All employees, workmen and labour of MCPL and its subcontractor engaged for work
shall be wearing proper P.P.E before entering the site. Induction training shall be given to
all workmen before engaging to work at site.
 Barricading shall be provided to cover the entire length of the working area. The
barricading shall be as per the approved scheme. Painting of barricading shall be done with
approved colour scheme for prominent visibility.
 All the Vehicles engaged for the work shall be fitted with proper indicator systems.
 Reverse light; rear view mirror and reverse horn shall be fitted with all the vehicles.
 Break, Steering condition, Tire pressure shall be checkedperiodically.
 Proper speed limit shall be maintained within the project site.
 Driver shall not drive vehicle when he is not fit mentally and physically.
57
 Proper caution boards, flag boys shall be placed to caution the vehicle movement at
unloading points.
 Trained Supervisors shall be deployed at working sites.
 Unauthorized persons and visitors shall not be allowed within the critical area/Hard Hat
area.
 Trained Flag boy and warning systems shall be provided.
 Periodic training shall be provided to drivers, helpers, bank men and flag boys.
 Tool box talks shall be carried at frequent intervals by safety personnel/ site in- charge.
 Proper supervision and proper planning of the activity shall be done.
 Proper illumination shall be provided during nightwork.
 Good housekeeping shall always be maintained nearby working area to prevent any kind
of hazards.
 Any lifting equipment shall be engaged in work after proper checking and load any lifting
equipment shall be engaged in work after proper checking and load testing as per relevant
requirement. Periodic maintenance shall be done for of all lifting equipment / devices
deployed at work. Record shall be maintained in prescribed format. Lifting devices shall
also be checked for correctness of load criteria before deploying at work. Any loading
/unloading /lowering of materials shall be supervised by competent MCPL representative
at site.
All necessary and required safety measures/precautions during the Execution of Job shall be
undertaken. It shall be ensured that the construction materials, equipment and facilities will
not cause damage to existing property or interfere with the operation of the Project. All
equipment such as lifting tools & tackles, Cranes, Excavators, Dumpers, Roller and Dozer etc
shall be checked periodically for its fitness. Maintenance for all equipment / plants shall be
done periodically to ensure its safe working. It shall be complied with all applicable provisions
of the safety regulations; cleanup program and other measures that are in force at the site.
It shall comply with the instructions given by the client Safety Engineer or his authorized
nominee regarding safety precautions, protective measures, clean-up requirements etc. for all
Major activities potential risks shall be identified and eliminated / minimized at planning stage
by the Project Safety officer, Project Manager and Works Manager. The risk assessment
analysis considers the risk index (Risk index guide contains Tasks, Hazard Identification, Risk
Assessment & Risk Control measures.) as H – High, M –Medium or Moderate and L – Low
(acceptable / Tolerable risk).
The Project safety officer will refer to risk index guide for determining risk index. Activity &
associated risk when high or medium is recorded and suitable measures shall be taken to
control the risks. The Works Manager and Line Supervisors along with Project Safety officer
shall review, High and Medium Risk activities, in order to reduce the level of the risk.
Corporate Occupational Health & Safety Department shall be informed about actions taken to
contain the risks. H – High and M – Medium risk shall be brought under control by taking
58
suitable measures. Where the activity / risk are not covered in risk index guide, it is further
evaluated and included in risk index guide by the Corporate Occupational Health & Safety
Department for future references. The risk assessment at Project level shall be carried out for
every new activity undertaken, when the project is ongoing and the measures identified for
risk control shall be recorded in risk control document by the project site. New measures may
be required in the form of addition of new work methods / procedures / improved safety
equipment / additional Occupational Health & Safety training / safety signs / posters etc.
Environment:
As per Project Environment Management Plan.
This methodology should be read in conjunction with the Quality and Safety procedures laid
down by IMS department specific to this project.
11. RECORD:
This segmental methodology will be retained up to the project completion.
59

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(GOVT.

National Highways & Infrastructure Development Corporation Ltd (NHIDCL)

Construction of Hnahthial Bypass (Package

Mathiyan Construction Pvt. Ltd.

Chapter Page no.

GENERAL INFORMATION ………………………………………………………......…………….01

METHOD STATEMENT FOR DBM

Name of Client: National Highways and Infrastructure Development Corporation Ltd

Construction Period: 549 days [18 Months] from the Commencementdate.

Defect Liability Period: 42 months

1.3. Commencement ofwork:

 Signing of the Contract Agreement by both theParties

It has been decided that Commencement Date as 1 st October 2020.

Salient Activities in this package include the construction of the followings -

 Any Reference to Authority means Client[NHIDCL]

4.1. Quarry setup:

4.2. Crusher setup:

Coarse Aggregates- As above.

4.4. GSB Mixing Facility & WMMPlant:

4.5. Hot Mix Plant:

4.6. Other Facilities:

Other facilities also shall be developedasbelow:

5. CONSTRUCTION WATER SUPPLY

7. APPROACH & SERVICEROADS

9. CONSTRUCTION METHODOLOGY FOR ROADWORKS

The project highway shall be Construction of Hnahthial Bypass (Package-2) on Aizawl-Tuipang

9.1. Construction of Track path

Marking of Road Alignment

Reconnaissance of overhead and underground obstruction

Access Road construction

9.2. Clearing and Grubbing –Site Clearance

a) Clearing and Grubbing Operation

b) Removal ofStagnant Water and Diversion ofWaterCourses

Where watercourses have to be diverted from the sites of embankment, a new

9.3.3. Disposal of Surplusmaterial

 Disposal area will be identified and informed to Department prior

9.4. Excavation in Hard Rock requiring controlled blasting

The operation procedure is as follows:

 Fabrication and installation of Safetysigns,

 capability to drill horizontal or inclinedhole

Traffic Management and Safety

 Construction zones will be identified. Suitable cautionary boards will be displayed.

9.5. Method Statement for Embankment with Earth (Excavated or Borrow)

The scope consists of construction of embankments in layers as per technical

The material should fulfill following requirements.

9.5.3. Construction Operation

The ground shall be compacted with roller to achieve minimum density

 Initial rolling, 2 static passes withvibratoryroller.

Table- Compaction requirements for Embankment

1 Embankment Not less than 95%

The following tests are pertinent to embankment

Sl. Test Code Frequency

9.5.4. List of Equipment and Time cycle

For excavation in Soil by Excavator

Earthwork in excavation in Ordinary Rock by Excavator

Earthwork - Dumper Time cycle

Number of Dumpers perexcavation set 4

Earthwork- Grader Time Cycle

Earthwork – VibroRoller Compaction Time cycle