A. Physical Properties of Materials
|
A.1 PERMISSIBLE VALUES OF WATER ABSORPTIONS, IMPACT, ABRASION OF AGGREGATES FOR DIFFERENT TYPES OF WORKS Test Methods as per IS Code:2386:1963 (Pt-III & Pt-IV) and Specification For Coarse & Fine Aggregate as per IS Code: 383:1970 in conjunction with MoRTH & MoRD Specifications)
|
ITEMS of Work
|
WATER ABSORPTION %
|
IMPACT LOSS %
|
ABRASION LOSS %
|
Premix Carpeting
|
1.0%
|
30.0%
|
30.0%
|
Bituminous Concreting
|
2.0%
|
24.0%
|
30.0%
|
Dense Bituminous Maccadam
|
2.0%
|
27.0%
|
35.0%
|
Bituminous Maccadam
|
2.0%
|
30.0%
|
40.0%
|
Wet Mix Maccadam
|
2.0%
|
30.0%
|
40.0%
|
Water Bound Maccadam (Sub Base, Base, Surface)
|
2.0%
|
Sub Base 50.0% Base 40.0% Surfacing 30.0%
|
40.0%
|
Granular Sub Base (Stone Aggregate)
|
2.0%
|
Based on CBR Value
|
Stone aggregate Used For Concreting
|
2.0%
|
45.0%
|
50.0%
|
Bricks : Upto Class Designation 12.5
|
20.0%
|
---
|
---
|
Bricks : Above Class Designation 12.5
|
15.0%
|
---
|
---
|
A.2 Aggregate Crushing Value
|
The aggregate crushing value, when determined in accordance with IS 2386 (Part 4) shall not exceed the following values:
|
Purpose of work
|
Max (IS 383:1970)
|
Ref. IS Code (Test Method)
|
a) For aggregates to be used in concrete for wearing surfaces, (such as runways, roads, pavements, spillways and stilling basins)
|
30 percent
|
IS 2386 (Part 4)
|
b) For aggregates to be used in concrete other than for wearing surfaces
|
45 percent
|
A.3 Soundness of Aggregate
|
Purpose:- The test determines resistance. Note: If the water absorption value of coarse aggregate is more than 2 percent, the Soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part-5)
|
For concrete liable to be exposed to the action of frost, the coarse and fine aggregates shall pass a sodium or magnesium sulphate accelerated soundness test specified in IS 2386 (Part 5), the limits being set by agreement between the purchaser and the supplier.
|
The test determines the resistance to disintegration of aggregate by saturated solution of Sodium Sulphate. It indicates soundness against weathering.
|
Purpose of work
|
Maximum Permissible Value
|
Ref. IS Code (Test Method)
|
a) For fine aggregate (All works)
|
10 percent when tested with sodium sulphate ( Na2SO4 ), and 15 percent when testing with magnesium sulphate (MgSO4 )
|
IS 2386 (Part 5)
|
b) For coarse aggregate (All Works)
|
12 percent when tested with sodium sulphate (Na2SO4), and18 percent when tested with magnesium sulphate (MgSO4)
|
A.4 Flakiness Index of Aggregates
|
Purpose: Use of flaky aggregate results in loss of strength of granular base and surface course
|
Type of work
|
Permissible Limit
|
Ref. IS Code (Test Method)
|
Subbase
|
Max 30 %
|
IS: 2386 (Part 1)-1963
|
Base
|
Max 25 %
|
Surface Course
|
Max 20 % .
|
Note: The requirement of Flakiness Index shall be enforced only in the case of crushed or broken stone and crushed slag.
|
B. Free Swell Index Test of Soil
|
Purpose: On saturation, certain soils expand in volume due to the presence of particular minerals. Soil with free swell index more than 50% is considered inadequate for use as fill material.
|
Type of work
|
Permissible Limit
|
Ref. IS Code (Test Method)
|
Construction of embankment by filled earth
|
Max 50 %
|
IS: 2720 (Part 40)-1977
|
C. Field Density of Soil by Core Cutter method
|
Purpose: Determination of soil density (Degree of Compaction) in field
|
Layer
|
Permissible Limit
|
Ref. IS Code & Specifications
|
Below Subgrade
|
Not less than 97 %
|
Test Method as per IS: 2720 (Part 25)-1974, Permissible Limit is in conjunction with MoRTH & MoRD.
|
Subgrade
|
Not less than 100 %
|
D. ROAD WORKS
|
D.1. Properties of Binding Materials for Road Work
|
Test for Bitumen Emulsion: Viscosity by Saybolt-Furol Viscometer
|
Purpose: Viscosity indicates the resistance to flow due to its internal friction.
|
Type of Emulsion
|
Acceptance Limits at 50 o C
|
Ref. IS Code & Specifications
|
Rapid Setting (RS-1)
|
20-100
|
IS 3117-1965 (Appendix A) and IS: 8887-2004 (MoRTH & MoRD Specifications)
|
Rapid Setting (RS-2)
|
100-300
|
Medium Setting (MS)
|
50-400
|
Slow Setting (SS-1)
|
20-100
|
Slow Setting (SS-2)
|
30-150
|
Test for Residue of Bitumen Emulsion on 600 Micron Sieve
|
Purpose: The test is required to assess the suitability of Bituminous material for road construction work.
|
Requirement Criterion ( Decisive Factor)
|
Type of Emulsion
|
Residue Percentage
|
Ref. IS Code & Specifications
|
Rapid Setting (RS-1)
|
0.05
|
IS: 8887-2004
|
Rapid Setting (RS-2)
|
0.05
|
Medium Setting (MS)
|
0.05
|
Slow Setting (SS-1)
|
0.05
|
Slow Setting (SS-2)
|
0.05
|
Flash point Test of Bitumen Cut Back
|
Purpose: The Flash point of bitumen that contains a volatile distillate is the temperature at which it begins to give off ignitable vapour. The principal purpose of flash-point testing is to determine maximum safe mixing and applying temperatures.
|
Requirement Criterion ( Decisive Factor)
|
Type of Cut Back Bitumen Medium Curing
|
Flus point Pensky Martens Closed Type (Minimum) 0 C
|
Ref. IS Code & Specifications
|
MC 30
|
38
|
IS 217-2004
|
MC 70
|
38
|
MC 250
|
65
|
Viscosity of Bitumen Cutback ( Kinematic Viscosity)
|
Purpose: Kinematic Viscosity of Cutback is determined to ascertain its suitability as construction materials.
|
Requirement Criterion ( Decisive Factor)
|
Type of Cut Back Bitumen Medium Curing
|
Kinematic Viscosity at 60 o C,
|
Min
|
Max
|
Ref. IS Code & Specifications
|
MC 30
|
|
30
|
60
|
IS 1206 (Part-3)-1978
|
MC 70
|
|
70
|
140
|
MC 250
|
|
250
|
500
|
Temperature of Binder
|
Purpose: Temperature of binder shall be measured by using metallic contact thermometer with digital display to ensure that it has been heated to required extent.
|
The range of thermometer for different type of bituminous materials and accuracy shall be as under:
|
1) Melted Bitumen: Ambient to 200 0 C accuracy plus minus 1.0 0 C
|
2) Cutback Bitumen: Ambient to 100 0 C accuracy plus minus 0.5 0 C
|
3) Bitumen Emulsion: Ambient to 80 0 C accuracy plus minus 0.5 0 C
|
Prime Coat of Granular Base (Slow setting Bitumen Emulsion)
|
Porosity
|
Type of Surface
|
Viscosity at 60 0 C, Saybolt Furol ( Seconds)
|
Low
|
WMM / WBM
|
14-28
|
Track Coat
|
Tack Coat Rapid setting Bitumen Emulsion, Grade-1 conforming IS: 1887 or Cut back bitumen of Medium Curing grade as per IS: 217
|
Rate (Kg per Sqm) of Application of Binder
|
Type of Surface
|
|
Qty of emulsion Kg per Sqm
|
Normal Bituminious Surface
|
|
0.20 to 0.25
|
Dry & Hungry Bituminious surface
|
|
0.25 to 0.30
|
Granular (Primed)
|
|
0.25 to 0.30
|
CC Pavement
|
|
0.30 to 0.35
|
Mixing, Laying & Rolling Temperature for Bituminous Macadam
|
Bitumen Penetration
|
Bitumen Mixing ( 0 C)
|
Aggregate Mixing ( 0 C)
|
Aggregate Mixing (0 C)
|
Laying ( 0 C)
|
35
|
160-170
|
160-175
|
Max. 170
|
Min 140
|
65
|
150-165
|
150-170
|
Max. 165
|
Min 130
|
90
|
140-160
|
140-165
|
Max. 155
|
Min 130
|
Indian Standard PAVING BITUMEN — SPECIFICATION ( Fourth Revision ) IS: 73:2013 (Table 1 )
|
Requirements for Paving Bitumen, IS 73 : 2013 (Clause 6.2)
|
In the third revision in 2006 grading of bitumen was changed from penetration grade to viscosity grade. The variability in performance at high temperatures can be addressed by adopting a viscosity-graded bitumen specification (based on viscosity at 60°C) in lieu of the penetration-graded specification (based on penetration at 25°C). Four grades of bitumen based on the viscosity values were presented.
|
Characteristics
|
Paving Grades
|
VG10
|
VG20
|
VG30
|
VG40
|
Penetration at 25°C, 100 g, 5 s, 0.1 mm
|
80
|
60
|
45
|
35
|
Absolute viscosity at 60°C, Poises
|
800-1200
|
1600-2400
|
2400-3600
|
3200-4800
|
Kinematic viscosity at 135°C, cSt, Min
|
250
|
300
|
350
|
400
|
Flash point (Cleveland open cup), °C, Min
|
220
|
220
|
220
|
220
|
Solubility in trichloroethylene, percent, Min
|
99
|
99
|
99
|
99
|
Softening point (R&B), °C, Min
|
40
|
45
|
47
|
50
|
Tests on residue from rolling thin film oven test:
|
a) Viscosity ratio at 60°C, Max
|
4
|
4
|
4
|
4
|
b) Ductility at 25°C, cm, Min
|
75
|
50
|
40
|
25
|
Requirements for Paving Bitumen, IS 73 : 2006 (Clause 6.2)(Third Revision)
|
Characteristics
|
Paving Grades
|
VG10
|
VG20
|
VG30
|
VG40
|
Absolute viscocity at 60 0 C, Poises, Min
|
800
|
1600
|
2400
|
3200
|
Kinematic viscosity at 135°C, cSt, Min
|
250
|
300
|
350
|
400
|
Flash point (Cleveland open cup), °C, Min
|
220
|
220
|
220
|
220
|
Solubility in trichloroethylene, percent, Min
|
99
|
99
|
99
|
99
|
Penetration at 25 0 C, 100 g, 5 s, 0.1 mm
|
80-100
|
60-80
|
50-70
|
40-60
|
Softening point (R&B), °C, Min
|
40
|
45
|
47
|
50
|
Tests on residue from rolling thin film oven test:
|
a) Viscosity ratio at 60°C, Max
|
4
|
4
|
4
|
4
|
b) Ductility at 25°C, cm, Min
|
75
|
50
|
40
|
25
|
D.2 Water bound Macadam Sub-Base/Base/Surfacing (MoRTH & MoRD Specifications)
|
Course aggregate can be crushed or broken stone, crushed slag, over burnt brick aggregate, Kankar, Laterine meeting the prescribed requirements. The thickness of compacted layer should be 100 mm for grading-1 and 75 mm for grading 2 & 3.
|
Screening materials:(IS : 2720 ( Part-5): The use of screenings shall be omitted in the case of soft aggregate like brick metal, Kankar, Laterite etc. In case the screenings are not of crushable type such as moorum or gravel, it is necessary to add bin) Physical requirement: Screening should normally consist of same material as the course aggregate. However, where economic consideration so warrant, non plastic material such as moorum or gravel with LL less than 20 & Plasticity index 6 may be used. Fraction passing 75 micron should not exceed 10%. The binding material: Binding materials may not be necessary if the screenings used are of crushable type. Used as a filler material shall comprise of a suitable material approved by the Engineer-In-Charge having plasticity index of value ;less than 6 for sub base/base course and 4-10 for surfacing. - Therefore, binding materials should be applied in two or more layer for surfacing and uniform manner . Generally, the quantity required for 10.00 Sqm of 75 mm thickness of WBM is 0.06 Cum to 0.09 Cum and for 100 mm thickness, the binding materials would be 0.08 Cum to 0.10 Cum.
|
Grading requirement of Course aggregate for WBM Works ( IS: 2386, Part-5) (MoRTH & MoRD Specifications)
|
Grading No
|
Size Range
|
IS Sieve Designation
|
Percent by Wt passing the IS Sieve
|
I
|
90 mm to 45 mm
|
125 mm
|
100
|
90 mm
|
90-100
|
63 mm
|
25-60
|
45 mm
|
0-15
|
22.4 mm
|
0-5
|
II
|
63 mm to 45 mm
|
90 mm
|
100
|
63 mm
|
90-100
|
53 mm
|
25-75
|
45 mm
|
0-15
|
22.4 mm
|
0-5
|
III
|
53 mm to 22.4 mm
|
63 mm
|
100
|
53 mm
|
90-100
|
45 mm
|
65-90
|
22.4 mm
|
0-10
|
11.2 mm
|
0-5
|
The compacted thickness for a layer with grading-I shall be 100 mm while for layer with other grading i.e 2 & 3, it shall be 75 mm
|
Grading requirement of screening for WBM Works ( IS: 2386, Part-5) (MoRTH & MoRD Specifications)
|
Grading Classification
|
Size of Screenings
|
IS Sieve Designation
|
Percent by Wt passing the IS Sieve
|
A
|
13.2 mm
|
13.2 mm
|
100
|
11.2 mm
|
95-100
|
5.6 mm
|
15-35
|
180 micron
|
0-10
|
B
|
11.2 mm
|
11.2 mm
|
100
|
5.6 mm
|
90-100
|
180 micron
|
15-35
|
Approximate quantity of course aggregate and screening required for 100/75 mm compacted thickness of water bound maccadam (WBM) subbase/base/surfacing course for 10 Sqm area. (MoRTH & MoRD Specifications)
|
|
Compacted thickness (mm) / Loose Qty(Cum)
|
Stone Screenings
|
Crushable Screenings such as moorum or gravel
|
Classification / Size Range(Sqm)
|
Grading classification & Size
|
For WMB Sub base / Base Course (Loose Qty) Cum
|
Properties.
|
Grading-1 (90 to 45)
|
100 mm/1.21 to 1.43 Cum
|
Type-A 13.2 mm
|
0.27 to 0.30
|
LL < 20% PI < 6 % Passing 0.075 mm < 10 %
|
Grading-2 (63 to 45)
|
75 mm/0.91 to 1.07 Cum
|
Type-A 13.2 mm
|
0.12 to 0.15
|
------Do----
|
Grading-2 (63 to 45)
|
75 mm/0.91 to 1.07 Cum
|
Type-B 11.2 mm
|
0.20 to 0.22
|
------Do----
|
Grading-3 (53 to 22.4)
|
75 mm/0.91 to 1.07 Cum
|
Type-B 11.2 mm
|
0.18 to 0.21
|
------Do----
|
Volumetric Analysis of WBM work
|
Purpose: The test is conducted to make sure that adequate quantity and composition of material have been used in the construction.
|
Procedure
|
Dig a pit 0.50 m x 0.50 m in the area where random checking is to be carried out. Take out all the WBM materials from the Pit. One of the following test to be conducted.
|
Test-1:Refill the pit with the dug material without compacting. If the pit can be filled by using not more than 65 % of the dug material, it is indicative of adequate compaction and use of specified quantity of all material combine together.
|
Test-2: i) Separate the portions of the WBM materials passing and retained on 11.2 mm size sieve when type B screening have been used. When A type screenings have been used, the proportion of WBM materials passing and retained on 13.2 mm size should be determined.
|
ii) Measure the loose volumes of the two portions using cylinders of known volume and compare the combinded volume with the combinded specified quantities of coarse aggregate screenings+ Binding material.
|
iii) The volume of materials retain on 11.2 mm size sieve ( or 13.2 mm size sieve, as the case may be) shall be compared with the specified quantity of coarse aggregate viz. 0.912 to 1.07 Cum per 10 sqm for WBM grading 2 & 3. Due allowances shall be made for crushing during rolling.
|
iv) The material passing on 11.2 mm size sieve ( or 13.2 mm size sieve, as the case may be) shall be compared with the specified quantity of stone screenings and binding materials or crushable screenings as the case may be.
|
v) For the coarse aggregate, the qty may be check by conducting an aggregate impact test and determining the presence of any over sized aggregate.
|
vi) For the Finer fraction passing 425 micron size sieve , the plasticity Index shall be determined to check that it is less 6.
|
D.3 Granular Sub base (GSB) (MoRTH & MoRD Specifications)
|
Material: Natural sand, moorum, gravel, crushed stone, crushed slag, brick metal, Kankar or a combination thereof and it shall conform grading requirement. The sub base material should be spread in layers not exceeding 100 mm compacted thickness. It vibratory roller is used, the compacted thickness of layer can be upto a max of 225 mm When sub base materials consist of a combination of materials, mixing shall be done mechanically by mix-in-place method. Moisture content of the loose material shall be checked in accordance with IS: 2720 (Part-2) Compaction should be carried out at OMC, with tolerance limit of plus minus 2 %. Each layer should be compacted to 100 % maximum dry density as per prescribed standard Proctor Test IS 2720 ( Part-7)
|
Grading for Granular Sub base materials
|
IS Sieve Designation
|
Percentage by weight passing the sieve
|
Remarks
|
Grading-I
|
Grading-II
|
Grading-III
|
75 mm
|
100
|
------
|
.-----
|
Note: 1: The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS: 2720 (Part-5) shall have Liquid limit and plasticity index not more than 25 & 6 percent respectively. 2) On clayey subgrade, the percent passing IS Sieve 0.075 mm shall not exceed 5 3) The wet aggregate impact value (IS: 5640) shall not exceed 50 4) The material to be used in the subgrade shall have minimum soaked CBR value 20 CBR value not less than 15 can be permitted with the approval of the competent authority.
|
53 mm
|
-----
|
100
|
.------
|
26.5 mm
|
55-75
|
50-80
|
100
|
9.5 mm
|
------
|
------
|
-----
|
4.75 mm
|
10-30
|
15-35
|
25-45
|
2.36 mm
|
-----
|
-----
|
------
|
0.425 mm
|
-----
|
------
|
-------
|
0.075 mm
|
< 10
|
< 10
|
< 10
|
D.4 Composition of Bituminous Macadam (MoRTH & MoRD Specifications)
|
IS Sieve
|
Percent Passing by weight of Total Aggregate
|
Remarks
|
26.5
|
100
|
Note: For Condition in cooler area of india or where the percent passing 0.075 mm sieve is on higher side of the range, appropriate bitumen contents may be upto 0.5 percent higher, subject to approval of the Engineer
|
19
|
90-100
|
13.2
|
56-88
|
4.75
|
16-36
|
2.36
|
4-19
|
0.03
|
2-10
|
0.075
|
0-5
|
Bitumen content % by weight of Total Mixture
|
3.3 to 3.5
|
Bitumen Penetration Grade
|
35 to 90
|
D.5 20 mm thick premix carpet Open Graded Premix Surfacing (MoRTH & MoRD Specifications)
|
Binder: The binder shall be a penetration grade of bitumen of a suitable grade S-65/90 as specified in contract. IS 73
|
Field inspection criteria
|
Quantities of materials required for 10 Sqm area
|
Aggregate
|
Quantity
|
a) Nominal size 13.2 mm (Passing 22.4 mm Sieve and retained on 11.2 mm sieve)
|
0.18 m 3
|
b) Nominal size 11.2 mm (Passing 13.2 mm Sieve and retained on 5.6 mm sieve)
|
0.09 m 3
|
Total
|
0.27 m 3
|
Binder
|
Quantity
|
a) For 0.18 m 3 of 13.2 mm nominal size stone 52 Kg bitumen per m 3
|
9.5 Kg
|
a) For 0.09 m 3 of 11.2 mm nominal size stone 56 Kg bitumen per m 3
|
5.10 Kg
|
Total
|
14.60 Kg
|
Grading requirement for Chips for surface dressing
|
IS Sieve Designation
|
Cumulative percent by weight of total aggregate passing for the following nominal sizes (mm)
|
13.2
|
9.5
|
6.3
|
19.00
|
100
|
----
|
-----
|
13.20
|
85-100
|
100
|
-----
|
9.50
|
0-40
|
85-100
|
100
|
6.30
|
0-7
|
0-35
|
85-100
|
4.75
|
----
|
0-10
|
-----
|
3.35
|
----
|
----
|
0-35
|
2.36
|
0-2
|
0-2
|
0-10
|
0.60
|
----
|
-----
|
0-2
|
0.08
|
0-1.50
|
0-1.5
|
0-1.5
|
Minimum 65 % by weight of aggregate
|
Passing 13.2 mm, Retained 9.5 mm
|
Passing 9.5 mm Retained 6.3 mm
|
Passing 6.3 mm Retained 3.35 mm
|
NOTE:-
|
Mixing temperature of Bitumen should be in range of 150 0 C to 163 0 C Mixing temperature of Aggregate should be in range of 155 0 C to 163 0 C Provided that the difference between the temperature of aggregate and the binder should not exceed 140C Binder should be a penetration grade bitumen of a suitable grade of S-65/90 depending on the climatic condition of the area.
|
Premix carpet using Bitumen Emulsion
|
The quantities of material required for 20 mm thick premix carpet should be as indicated below
|
i) Aggregate same as 20 mm carpeting
|
ii) Binder: Cationic Bitumen Emulsion
|
a) For 0.18 cum of 13.2 mm nominal size stone at 78 Kg Cationic Bitumen Emulsion per cum
|
14.00 Kg per 10 Sqm area
|
a) For 0.09 cum of 11.2 mm nominal size stone at 84 Kg Cationic Bitumen Emulsion per cum
|
7.50 Kg per 10 Sqm area
|
Total
|
21.50 Kg per 10 Sqm area
|
Binder for premix carpet wearing course shall be bitumen emulsion of Medium Setting (MS) grade complying with IS: 8887 and having a bitumen content of 65 % minimum by weight.
|
Emulsion for liquid seal coat shall be of RS grade of MS grade where specified. Emulsion for premeix seal coat shall be of SS (Slow Setting) grade.
|
Seal Coat
|
Type-A: Liquid seal coat comprising of an application of layer of bituminious binder followed by a cover of stone Chips.
|
Type-B:Premixed seal coat comprising of a thin applicationn of fine aggregate premixed with bituminious binder
|
Type-C:Premixed seal coat comprising of an application of 6.7 mm size stone chips premixed with bituminious binder.
|
Type A Seal coat with bitumen: Apply bitumen with a temperature between 150 0 C and 163 0 C uniformly with a sparayer. Thereafter, spread stone chips over the bitumen layer
|
Quality control requirements of Seal Coat
|
a) Quantity of Coarse aggregates & Binders along with Gradation requirement of aggregate for seal coat
|
Type of Seal Coat
|
Qty of Aggregate required per 10 Sqm area
|
Gradation Requirement of coarse Aggregate
|
Binder Content per 10 Sqm
|
100 % Passing sieve designation
|
100 % retained sieve designation
|
Bitumen in Kg
|
Type- A
|
0.09 Cum
|
11.2 mm
|
2.36 mm.
|
9.8
|
Type- B
|
0.06 Cum
|
2.36 mm
|
180 microns
|
6.8
|
Type- C
|
0.09 Cum
|
9.5 mm
|
2.36 mm.
|
4.5 % by weight of total mix
|
D.6 Stone Aggregate for DBM (Clause 507, Table 500-10 MoRTH)
|
IS Sieve (mm)
|
Grading Requirements (% Passing) Ref. Range
|
Grading -I (40 mm nominal size) Layer Thickness 80-100 mm
|
Grading -II (25 mm nominal size) Layer Thickness 50-75 mm
|
45
|
100
|
-----
|
37.5
|
95-100
|
100.00
|
26.5
|
63-93
|
90-100
|
19
|
-----
|
71-95
|
13.2
|
55-75
|
56-80
|
4.75
|
38-54
|
38-54
|
2.36
|
-----
|
28-54
|
0.30
|
7-21
|
7-21
|
0.075
|
2-8
|
2-8
|
Minm Bitumen Content % By Weight of Total mix
|
4.00%
|
4.50%
|
Bitumen Grade (Pen)
|
65 or 90
|
65 or 90
|
D.7 Wet Mix Macadam (WMM) (Section 400, Clause 406 , Table 400-11 of MoRTH)
|
IS Sieve (mm)
|
Grading Requirements (% Passing) Ref. Range
|
Remarks
|
53
|
100
|
As per Table 400-11, The gradation Should be within the above limits and not varied from the low limit of one sieve to the high limit of adjacent sieve or vice-versa . he materials finer than 425 micron shall have Plasticity Index (PI) not exceeding 6.
|
45
|
95-100
|
22.4
|
60-80
|
11.2
|
40-60
|
4.75
|
25-40
|
2.36
|
15-30
|
0.60
|
8-22
|
0.075
|
0-8
|
D.8 Bituminous Concrete Pavement (Section 500, Table 500-18 of MoRTH)
|
IS Sieve (mm)
|
Grading Requirements (% Passing) Ref. Range
|
Grading-I, Nominal Size 13 mm, Layer Thickness 35 - 40 mm
|
Grading-II, Nominal Size 10 mm, Layer Thickness 25 - 30 mm
|
26.5
|
100.00
|
-----
|
19
|
79-100
|
100.00
|
13.20
|
59-79
|
79-100
|
9.50
|
52-72
|
70-88
|
4.75
|
35-55
|
53-71
|
2.36
|
28-44
|
42-58
|
1.18
|
20-34
|
34-48
|
0.60
|
15-27
|
26-38
|
0.30
|
10-20
|
18-28
|
0.15
|
5-13
|
12-20
|
0.075
|
2-8
|
4-10
|
Minm Bitumen Content % By Weight of Total mix
|
5.0 - 6.0
|
5.0 -7.0
|
Bitumen Grade (Pen)
|
65.00
|
65*
|
D.9 Grouting Work
|
Clause 1904.2.2 of MoRD Specification : All materials used for the pot- hole and patch repairing of bituminous Surface and underlying layers shall be in accordance with these Specifications and shall be of the same type as specified for the original construction or higher.
|
D.10 Horizontal Alignment
|
Purpose: It is necessary to check the the horizontal alignment to ensure that the work is set out in accordance with the approved drawings and dimensions.
|
Locations on Road
|
Permitted Tolerance
|
In Plain and Rolling Terrain
|
In Hilly terrain
|
Edges of carriage way.
|
Plus minus 20 mm
|
Plus minus 30 mm
|
Edges of road way and lower layer of pavement
|
Plus minus 30 mm
|
Plus minus 50 mm
|
E. BRICKS
|
Classification and quality of Bricks ( Ref IS: 1077 : 1992)
|
Class Designation
|
Compressive Strength not Less than ( N/mm2) (approx )
|
Remarks
|
35
|
35.00
|
As per specification of work, compressive strength of 1st class and 2nd class brick are 105 Kg/ Cm 2 ,75 Kg/ Cm 2 Water Absorption The bricks, when tested in accordance with the procedure laid down in IS 3495 ( Part 2) : 1992 after immersion in cold water for 24 hours, water absorption shall not be more than 20 percent by weight up to class 12'5 and 15 percent by weight for higher classes
|
30
|
30.00
|
25
|
25.00
|
20.0
|
20.00
|
17.5
|
17.50
|
15.0
|
15.00
|
12.5
|
12.50
|
10.0
|
10.00
|
7.5
|
7.50
|
5.0
|
5.00
|
3.5
|
3.50
|
As per specification of building work, SoR 2017,Building work, the requirement of bricks shall be as follows
|
Type of Bricks
|
Dimension (in mm) (Length x Breadth x Depth)
|
Minimum Compressive Strength
|
Water Absorption (max)
|
Actual Nominal Tolerance
|
1 st Class
|
250x120x70 255x123x72 plus minus 3
|
105 Kg/ cm 2
|
20 % by weight
|
2 nd Class
|
250x120x70 255x123x72 plus minus 5
|
75 Kg/ cm 2
|
25 % by weight
|
Efflorescence of Bricks
|
The bricks when tested in accordance with the the rating of efflorescence shall not be more than 'moderate' up to class 12·5 and 'slight' for higher classes.
|
Nil - When there is no perceptible deposit of efflorescence. Slight - When not more than 10 percent of the exposed area of the brick is covered with a thin deposit of salts. Moderate - When there is a heavier deposit than under ‘slight’ and covering up to 50 percent of the exposed area of the brick surface but unaccompanied by powdering or flaking of the surface. Heavy - When there is a heavy deposit of salts covering 50 percent or more of the exposed area of the brick surface but unaccompanied by powdering or flaking of the surface. Serious - When there is a heavy deposit of salts accompanied by powdering and/or flaking of the exposed surfaces.
|
F. CONCRETING WORKS
|
F.1 Criteria of Graded Course aggregate for Concrete works ( Clause 4.1 and 4.2 of IS 383:1970)
|
Gradation analysis
|
IS Sieve Designation
|
Percentage passing for graded aggregate of nominal size
|
40 mm
|
20 mm
|
16 mm
|
12.5 mm
|
80 mm
|
100
|
-----
|
-----
|
-----
|
63 mm
|
-----
|
-----
|
-----
|
-----
|
40 mm
|
95-100
|
100
|
|
|
20 mm
|
30-70
|
95-100
|
100
|
100
|
16mm
|
------
|
------
|
90-100
|
------
|
12.5 mm
|
------
|
------
|
------
|
90-100
|
10 mm
|
10-35
|
25-55
|
30-70
|
40-85
|
4.75 mm
|
0-5
|
0-10
|
0-10
|
0-10
|
2.36 mm
|
-----
|
-----
|
-----
|
-----
|
F.2 Criteria of Fine aggregate for Building works (Clause 4.3 of IS 383:1970) Sieve Analysis
|
IS Sieve Designation
|
Percentage passing for
|
Grading Zone-I
|
Grading Zone-II
|
Grading Zone-III
|
Grading Zone-IV
|
10 mm
|
100
|
100
|
100
|
100
|
4.75 mm
|
90-100
|
90-100
|
90-100
|
95-100
|
2.36 mm
|
60-95
|
75-100
|
85-100
|
95-100
|
1.18 mm
|
30-70
|
55-90
|
75-100
|
90-100
|
600 micron
|
15-34
|
35-59
|
60-79
|
80-100
|
300 micron
|
5-20
|
8-30
|
12-40
|
15-50
|
150 micron
|
0-10
|
0-10
|
0-10
|
0-15
|
F.3 Permissible Limit of Cement test Result (Ref. IS:8112 & IS:269)
|
Items of Test
|
Permissible Limit (Ref. IS:8112 & IS:269)
|
1. Initial Setting time
|
Minm 30 minutes
|
2. Final Setting time
|
Maxm 600 minutes
|
3. Soundness (Le Chatelier Method)
|
Maximum 10mm
|
4. Fineness (Sieving Method)
|
Maximum 10 %
|
F.4 Concrete Cube
|
METHODS OF TESTS FOR STRENGTH OF CONCRETES: IS 516 : 1959 : Procedure for making and curing compression test specimens of concrete. Tests for the determination of compressive strength.
|
Frequency of Sampling (As per IS 456 2000) Sampling Procedure A random sampling procedure shall be adopted to ensure that each concrete batch shall have a reasonable chance of being tested that is, the sampling should be spread over the entire period of concreting and cover all mixing units. Frequency The minimum frequency of sampling of concrete of each grade shall be in accordance with the following:
Quantity of Concrete Work, m3 Number of Samples
1- 5 1
6- 15 2
16- 30 3
31-50 4
51 and above 4 plus one additional sample for each additional 50 m3 or part thereof
NOTE- At least one sample shall be taken from each Shift. Where concrete is produced at continuous production unit, such as ready-mixed concrete plant, frequency of ’sampling may be agreed upon mutually by suppliers and purchasers.
|
Test Specimen Three test specimens shall be made for each sample for testing at 28 days. Additional samples may be required for various purposes such as to determine the strength of concrete at 7 days or at the time of striking the formwork, or to determine the duration of curing, or to check the testing error. Additional samples may also be required for testing samples cured by accelerated methods as described in IS 9103. The specimen shall be tested as described in IS 516.
|
ACCEPTANCE CRITERIA (As Per IS 456: 2000) Compressive Strength, the concrete shall be deemed to comply with the strength requirements when both the following condition are met: a) The mean strength determined from any group of four consecutive test results compiles with the appropriate limits in col 2 of Table 11. b) Any individual test result complies with the appropriate limits in col 3 of Table 11.
|
Testing In case of doubt regarding the grade of concrete or results of cube strength tests (As per IS 456: 2000) In case of doubt regarding the grade of concrete used, either due to poor workmanship or based on results of cube strength tests, compressive strength tests of concrete on the basis of Core Test and/or Load test may be carried out. Core Test : The points from which cores are to be taken and the number of cores required shall be at the discretion of the engineer-in-charge and shall be representative of the whole of concrete concerned. In no case, however, shall fewer than three cores be tested. Cores shall be prepared and tested as described in IS 516. Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of the cores is equal to at least 85 percent of the cube strength of the grade of concrete specified for the corresponding age and no individual core has a strength less than 75 percent.
|
Load Test : In case the core test results do not satisfy the requirements or where such tests have not been done, Load Test may be resorted. Load Tests for Flexural Members, Members Other Than Flexural Members. Load Tests for Flexural Members The structure should be subjected to a load equal to full dead load of the structure plus 1.25 times the imposed load for a period of 24 h and then the imposed load shall be removed. The deflection due to imposed load only shall be recorded. If within 24 h of removal of the imposed load the structure does not recover at least 75 percent of the deflection under superimposed load, the test may be repeated after a lapse of 72 h. If the recovery is less than 80 percent, the structure shall be deemed to be unacceptable. If the maximum deflection in mm, shown during 24 h under load is less than 40L2/D, where L is the effective span in m; and D, the overall depth of the section in mm, it is not necessary for the recovery to be measured.
|
Non-destructive Tests Non-destructive tests are used to obtain estimation of the properties of concrete in the structure. The methods adopted include ultrasonic pulse velocity [see IS 133 11 (Part l)] and rebound hammer [IS 13311 (Part 2)], probe penetration, pullout and maturity. Nondestructive tests provide alternatives to core tests for estimating the strength of concrete in a structure, or can supplement the data obtained from a limited number of cores. These methods are based on measuring a concrete property that bears some relationship to strength. The accuracy of these methods, in part, is determined by the degree of correlation between strength and the physical quality measured by the non-destructive tests. Any of these methods may be adopted, in which case the acceptance criteria shall be agreed upon prior to testing.
|
G. General Construction in Steel
|
IS:800-1984 : This code applies to general construction in steel. Specific provisions for bridges, chimneys, cranes, tanks, transmission line towers, storage structures, tubular structures and structures using cold formed light gauge sections, etc, are covered in separate codes. The provisions of this code generally .apply to riveted, bolted and welded constructions, using hot rolled steel sections. This code gives only general guidance as regards the various loads to be considered in design, For actual loads to be used reference may be made to IS : 875-1964.
|
H. REINFORCEMENT
|
IS:1786 - 1985 : This standard covers the requirements of deformed steel bars and wires for use as reinforcement in concrete, in the following three strength grades: a) Fe 415, b) Fe 500, and c) Fe 550. Note:- The figures following the symbol Fe indicates the specified minimum 0.20 Percent proof stress or yield stress in N/mm2.
|
I. Mix Design of Concrete (As per IS :10262-2009)
|
This standard provides the guidelines for proportioning concrete mixes as per the requirements using the concrete making materials including other supplementary materials identified for this purpose. The proportioning is carried out to achieve specified characteristics at specified age, workability of fresh concrete and durability requirements. This standard is applicable for ordinary and standard concrete grades only. All requirements of IS:456-2000 in so far as they apply, shall be deemed to form part of this standard.
|
The following data are required for mix proportioning of a particular grade of concrete: a) Grade designation b) Type of cement c) Maximum nominal size of aggregate d) Minimum cement content e) Maximum water-cement ratio f) Workability g) Exposure conditions as per Table 4 and Table 5 of IS : 456-2000 h) Maximum temperature of concrete at the time of placing j) Method of transporting and placing; k) Early age strength requirements, if required: l) Type of aggregate m) Maximum cement content; and n) Whether an admixture shall or shall not used and the type of admixture and the condition of use.
|
Note: 1) Aggregates should be used in saturated surface dry condition, 2) Two more trials having variation of ±10 percent of water-cement ratio shall be carried out, 3)The slump shall be measured and the water content and dosage of admixture shall be adjusted for achieving the required slump based on trial. 4) Minimum cement Content from Table 5 of IS:456-2000, Maximum cement content 450 kg/m3 (As per clause 8.2.4.2 of IS: 456-2000) or limited to 500 kg/m3 (Clause no 5.8.4.1 of CPWD Specification(Vol-I) 2009
|
A. Physical Properties of Materials
|
A.1 PERMISSIBLE VALUES OF WATER ABSORPTIONS, IMPACT, ABRASION OF AGGREGATES FOR DIFFERENT TYPES OF WORKS
Test Methods as per IS Code:2386:1963 (Pt-III & Pt-IV) and Specification For Coarse & Fine Aggregate as per IS Code: 383:1970 in conjunction with MoRTH & MoRD Specifications)
|
ITEMS of Work
|
WATER ABSORPTION %
|
IMPACT LOSS %
|
ABRASION LOSS %
|
Premix Carpeting
|
1.0%
|
30.0%
|
30.0%
|
Bituminous Concreting
|
2.0%
|
24.0%
|
30.0%
|
Dense Bituminous Maccadam
|
2.0%
|
27.0%
|
35.0%
|
Bituminous Maccadam
|
2.0%
|
30.0%
|
40.0%
|
Wet Mix Maccadam
|
2.0%
|
30.0%
|
40.0%
|
Water Bound Maccadam (Sub Base, Base, Surface)
|
2.0%
|
Sub Base 50.0%
Base 40.0%
Surfacing 30.0%
|
40.0%
|
Granular Sub Base (Stone Aggregate)
|
2.0%
|
Based on CBR Value
|
Stone aggregate Used For Concreting
|
2.0%
|
45.0%
|
50.0%
|
Bricks : Upto Class Designation 12.5
|
20.0%
|
---
|
---
|
Bricks : Above Class Designation 12.5
|
15.0%
|
---
|
---
|
A.2 Aggregate Crushing Value
|
The aggregate crushing value, when determined in accordance with IS 2386 (Part 4) shall not exceed the following values:
|
Purpose of work
|
Max (IS 383:1970)
|
Ref. IS Code (Test Method)
|
a) For aggregates to be used in concrete for wearing surfaces, (such as runways, roads, pavements, spillways and stilling basins)
|
30 percent
|
IS 2386 (Part 4)
|
b) For aggregates to be used in concrete other than for wearing surfaces
|
45 percent
|
A.3 Soundness of Aggregate
|
Purpose:- The test determines resistance.
Note: If the water absorption value of coarse aggregate is more than 2 percent, the Soundness test shall be carried out on the material delivered to site as per IS: 2386 (Part-5)
|
For concrete liable to be exposed to the action of frost, the coarse and fine aggregates shall pass a sodium or magnesium sulphate accelerated soundness test specified in IS 2386 (Part 5), the limits being set by agreement between the purchaser and the supplier.
|
The test determines the resistance to disintegration of aggregate by saturated solution of Sodium Sulphate. It indicates soundness against weathering.
|
Purpose of work
|
Maximum Permissible Value
|
Ref. IS Code (Test Method)
|
a) For fine aggregate (All works)
|
10 percent when tested with sodium sulphate ( Na2SO4 ), and 15 percent when testing with magnesium sulphate (MgSO4 )
|
IS 2386 (Part 5)
|
b) For coarse aggregate (All Works)
|
12 percent when tested with sodium sulphate (Na2SO4), and18 percent when tested with magnesium sulphate (MgSO4)
|
A.4 Flakiness Index of Aggregates
|
Purpose: Use of flaky aggregate results in loss of strength of granular base and surface course
|
Type of work
|
Permissible Limit
|
Ref. IS Code
(Test Method)
|
Subbase
|
Max 30 %
|
IS: 2386 (Part 1)-1963
|
Base
|
Max 25 %
|
Surface Course
|
Max 20 % .
|
Note: The requirement of Flakiness Index shall be enforced only in the case of crushed or broken stone and crushed slag.
|
B. Free Swell Index Test of Soil
|
Purpose: On saturation, certain soils expand in volume due to the presence of particular minerals. Soil with free swell index more than 50% is considered inadequate for use as fill material.
|
Type of work
|
Permissible Limit
|
Ref. IS Code
(Test Method)
|
Construction of embankment by filled earth
|
Max 50 %
|
IS: 2720 (Part 40)-1977
|
C. Field Density of Soil by Core Cutter method
|
Purpose: Determination of soil density (Degree of Compaction) in field
|
Layer
|
Permissible Limit
|
Ref. IS Code & Specifications
|
Below Subgrade
|
Not less than 97 %
|
Test Method as per IS: 2720 (Part 25)-1974, Permissible Limit is in conjunction with MoRTH & MoRD.
|
Subgrade
|
Not less than 100 %
|
D. ROAD WORKS
|
D.1. Properties of Binding Materials for Road Work
|
Test for Bitumen Emulsion: Viscosity by Saybolt-Furol Viscometer
|
Purpose: Viscocity indicates the resistance to flow due to its internal friction.
|
Type of Emulsion
|
Acceptance Limits at 50 o C
|
Ref. IS Code & Specifications
|
Rapid Setting (RS-1)
|
20-100
|
IS 3117-1965 (Appendix A) and IS: 8887-2004
(MoRTH & MoRD Specifications)
|
Rapid Setting (RS-2)
|
100-300
|
Medium Setting (MS)
|
50-400
|
Slow Setting (SS-1)
|
20-100
|
Slow Setting (SS-2)
|
30-150
|
Test for Residue of Bitumen Emulsion on 600 Micron Sieve
|
Purpose: The test is required to assess the suitability of Bituminious material for road construction work.
|
Requirement Criterion ( Decisive Factor)
|
Type of Emulsion
|
Residue Percentage
|
Ref. IS Code & Specifications
|
Rapid Setting (RS-1)
|
0.05
|
IS: 8887-2004
|
Rapid Setting (RS-2)
|
0.05
|
Medium Setting (MS)
|
0.05
|
Slow Setting (SS-1)
|
0.05
|
Slow Setting (SS-2)
|
0.05
|
Flash point Test of Bitumen Cut Back
|
Purpose: The Flash point of bitumen that contains a volatile distillate is the temperature at which it begins to give off ignitable vapour. The principal purpose of flash-point testing is to determinemaximum safe mixing and applying temperatures.
|
Requirement Criterion ( Decisive Factor)
|
Type of Cut Back Bitumen Medium Curing
|
Flus point Pensky Martens Closed Type (Minimum) 0 C
|
Ref. IS Code & Specifications
|
MC 30
|
38
|
IS 217-2004
|
MC 70
|
38
|
MC 250
|
65
|
Viscosity of Bitumen Cutback ( Kinematic Viscosity)
|
Purpose: Kinematic Viscosity of Cutback is determinded to assertain its suitability as a construction materials.
|
Requirement Criterion ( Decisive Factor)
|
Type of Cut Back Bitumen Medium Curing
|
Kinemic Viscosity at 60 o C,
|
Min
|
Max
|
Ref. IS Code & Specifications
|
MC 30
|
30
|
60
|
IS 1206 (Part-3)-1978
|
MC 70
|
70
|
140
|
MC 250
|
250
|
500
|
Temperature of Binder
|
Purpose: Temperature of binder shall be measured by usung metallic contact thermometer with digital display to ensure that it has been heated to required extent.
|
The range of thermometer for different type of bituminious materials and accuracy shall be as under:
|
1) Melted Bitumen: Ambient to 200 0 C accuracy plus minus 1.0 0 C
|
2) Cutback Bitumen: Ambient to 100 0 C accuracy plus minus 0.5 0 C
|
3) Bitumen Emulsion: Ambient to 80 0 C accuracy plus minus 0.5 0 C
|
Prime Coat of Granular Base (Slow setting Bitumen Emulsion)
|
Porosity
|
Type of Surface
|
Viscosity at 60 0 C, Saybolt Furol ( Seconds)
|
Low
|
WMM / WBM
|
14-28
|
Track Coat
|
Tack Coat Rapid setting Bitumen Emulsion, Grade-1 conforming IS: 1887 or Cut back bitumen of Medium Curing grade as per IS: 217
|
|
Rate (Kg per Sqm) of Application of Binder
|
Type of Surface
|
|
Qty of emulsion Kg per Sqm
|
Normal Bituminious Surface
|
|
0.20 to 0.25
|
Dry & Hungry Bituminious surface
|
|
0.25 to 0.30
|
Granular (Primed)
|
|
0.25 to 0.30
|
CC Pavement
|
|
0.30 to 0.35
|
Mixing, Laying & Rolling Temperature for Bituminious Macadam
|
Bitumen Penetration
|
Bitumen Mixing ( 0 C)
|
Aggregate Mixing ( 0 C)
|
Aggregate Mixing (0 C)
|
Laying ( 0 C)
|
Rolling ( 0 C)
|
35
|
160-170
|
160-175
|
Max. 170
|
Min 140
|
Min 110
|
65
|
150-165
|
150-170
|
Max. 165
|
Min 130
|
Min 100
|
90
|
140-160
|
140-165
|
Max. 155
|
Min 130
|
Min 100
|
Indian Standard PAVING BITUMEN — SPECIFICATION ( Fourth Revision ) IS: 73:2013 (Table 1 )
|
Requirements for Paving Bitumen, IS 73 : 2013 (Clause 6.2)
|
Characteristics
|
Paving Grades
|
Method of Test, Ref
|
VG10
|
VG20
|
VG30
|
VG40
|
|
80
|
60
|
45
|
35
|
IS 1203
|
|
800-1200
|
1600-2400
|
2400-3600
|
3200-4800
|
IS1206 (Part 2)
|
|
250
|
300
|
350
|
400
|
IS 1206 (Part 3)
|
|
220
|
220
|
220
|
220
|
IS 1448 [P : 69]
|
Solubility in trichloroethylene, percent, Min
|
99
|
99
|
99
|
99
|
IS 1216
|
|
40
|
45
|
47
|
50
|
IS 1205
|
Tests on residue from rolling thin film oven test:
|
|
4
|
4
|
4
|
4
|
IS 1206 (Part 2)
|
|
75
|
50
|
40
|
25
|
IS 1208
|
Requirements for Paving Bitumen, IS 73 : 2006 (Clause 6.2)(Third Revision)
|
Characteristics
|
Paving Grades
|
Method of Test, Ref
|
VG10
|
VG20
|
VG30
|
VG40
|
Absolute viscocity at 60 0 C, Poises, Min
|
800
|
1600
|
2400
|
3200
|
IS1206 (Part 2)
|
|
250
|
300
|
350
|
400
|
IS 1206 (Part 3)
|
|
220
|
220
|
220
|
220
|
IS 1209
|
Solubility in trichloroethylene, percent, Min
|
99
|
99
|
99
|
99
|
IS 1216
|
Penetration at 25 0 C, 100 g, 5 s, 0.1 mm
|
80-100
|
60-80
|
50-70
|
40-60
|
IS 1203
|
|
40
|
45
|
47
|
50
|
IS 1205
|
Tests on residue from rolling thin film oven test:
|
|
4
|
4
|
4
|
4
|
IS 1206 (Part 2)
|
|
75
|
50
|
40
|
25
|
IS 1208
|
D.2 Water bound Macadam Sub-Base/Base/Surfacing (MoRTH & MoRD Specifications)
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Course aggregate can be crushed or broken stone, crushed slag, over dburnt brick aggregate, Kankar, Laterine meeting the prescribed requirements.
The thickness of compacted layer should be 100 mm for grading-1 and 75 mm for grading 2 & 3.
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Screening materials:(IS : 2720 ( Part-5): The use of screenings shall be omitted in the case of soft aggregate like brick metal, Kankar, Laterite etc.
In case the screenings are not of crusable type such as moorum or gravel, it is necessary to add bin) Physical requirement: Screening should normally consist of same material as the course aggregate. However,where economic consideration so warrant, non plastic material such as moorum or gravel with LL less than 20 & Plasticity index 6 may be used. Fraction passing 75 micron should not exceed 10%.
The binding material: Binding materials may not be necessary if the screenings used are of crushable type. Used as a filler material shall comprise of a suitable material approved by the Engineer-In-Charge having plasticity index of value ;less than 6 for subbase/base course and 4-10 for surfacing. - Therefore, binding materials should be applied in two or more layer for surfacing and unifrom manner . Generally, the quantity required for 10.00 Sqm of 75 mm thickness of WBM is 0.06 Cum to 0.09 Cum and for 100 mm thickness, the binding materials would be 0.08 Cum to 0.10 Cum.
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Grading requirement of Course aggregate for WBM Works ( IS: 2386, Part-5) (MoRTH & MoRD Specifications)
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Grading No
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Size Range
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IS Sieve Designation
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Percent by Wt passing the IS Sieve
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I
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90 mm to 45 mm
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125 mm
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100
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90 mm
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90-100
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63 mm
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25-60
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45 mm
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0-15
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22.4 mm
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0-5
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II
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63 mm to 45 mm
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90 mm
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100
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63 mm
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90-100
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53 mm
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25-75
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45 mm
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0-15
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22.4 mm
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0-5
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III
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53 mm to 22.4 mm
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63 mm
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100
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53 mm
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90-100
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45 mm
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65-90
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22.4 mm
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0-10
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11.2 mm
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0-5
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The compacted thickness for a layer with grading-I shall be 100 mm while for layer with other gradings i.e 2 & 3, it shall be 75 mm
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Grading requirement of screening for WBM Works ( IS: 2386, Part-5) (MoRTH & MoRD Specifications)
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Grading Classification
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Size of Screenings
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IS Sieve Designation
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Percent by Wt passing the IS Sieve
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A
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13.2 mm
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13.2 mm
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100
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11.2 mm
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95-100
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5.6 mm
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15-35
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180 micron
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0-10
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B
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11.2 mm
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11.2 mm
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100
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5.6 mm
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90-100
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180 micron
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15-35
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Approximate quantity of course aggregate and screening required for 100/75 mm compacted thickness of water bound maccadam (WBM) subbase/base/surfacing course for 10 Sqm area. (MoRTH & MoRD Specifications)
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Compacted
thickness (mm) /
Loose Qty(Cum)
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Stone Screenings
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Crushable Screenings such as moorum or gravel
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Classification / Size Range(Sqm)
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Grading classification
& Size
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For WMB Subbase/
Base Course
(Loose Qty) Cum
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Properties.
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Loose Qty in Cum
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Grading-1 (90 to 45)
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100 mm/1.21 to 1.43 Cum
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Type-A
13.2 mm
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0.27 to 0.30
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LL < 20%
PI < 6 %
Passing 0.075 mm < 10 %
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0.30 to 0.32
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Grading-2 (63 to 45)
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75 mm/0.91 to 1.07 Cum
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Type-A
13.2 mm
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0.12 to 0.15
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------Do----
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00.22 to 0.24
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Grading-2 (63 to 45)
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75 mm/0.91 to 1.07 Cum
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Type-B
11.2 mm
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0.20 to 0.22
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------Do----
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------Do----
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Grading-3 (53 to 22.4)
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75 mm/0.91 to 1.07 Cum
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Type-B
11.2 mm
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0.18 to 0.21
|
------Do----
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------Do----
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Volumetric Analysys of WBM work
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Purpose: The test is conducted to make sure that adequate quantity and composition of material have been used in the construction.
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Procedure
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Dig a pit 0.50 m x 0.50 m in the area where random checking is to be carried out. Take out all the WBM materials from the Pit. One of the following test to be conducted.
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Test-1:Refill the pit with the dug material without compacting. If the pit can be filled by using not more than 65 % of the dug material, it is indicative of adequate compaction and use of specified quantity of all material combine together.
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Test-2:
i) Separate the portions of the WBM materials passing and retained on 11.2 mm size sieve when type B screening have been used. When A type screenings have been used, the proportion of WBM materials passing and retained on 13.2 mm size should be determined.
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ii) Measure the loose volumes of the two portions using cylinders of known volume and compare the combinded volume with the combinded specified quantities of coarse aggregate screenings+ Binding material.
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iii) The volume of materials retain on 11.2 mm size sieve ( or 13.2 mm size sieve, as the case may be) shall be compared with the specified quantity of coarse aggregate viz. 0.912 to 1.07 Cum per 10 sqm for WBM grading 2 & 3. Due allowances shall be made for crushing during rolling.
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iv) The material passing on 11.2 mm size sieve ( or 13.2 mm size sieve, as the case may be) shall be compared with the specified quantity of stone screenings and binding materials or crushable screenings as the case may be.
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v) For the coarse aggregate, the qty may be check by conducting an aggregate impact test and determining the presence of any over sized aggregate.
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vi) For the Finer fraction passing 425 micron size sieve , the plasticity Index shall be determined to check that it is less 6.
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D.3 Granular Sub bse (GSB) (MoRTH & MoRD Specifications)
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Material: Natural sand, moorum, gravel, crushed stone, crushed slag, brick metal, Kankar or a combination thereof and it shall conform grading requirement.
The subbase material should be spread in layers not execeding 100 mm compacted thickness. It vibratory roller is used, the compacted thickness of layer can be upto a max of 225 mm
When subbase materials consist of a combunation of materials, mixing shall be done mechanically by mix-in-place method.Moisture content of the loose material shall be checked in accordance with IS: 2720 (Part-2)
Compaction should be carried out at OMC, with tolerance limit of plus minus 2 %. Each layer should be compacted to 100 % maximum dry density as per prescribed standard Proctor Test IS 2720 ( Part-7)
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Grading for Granular Subbase materials
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IS Sieve Designation
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Percentage by weight passing the sieve
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Remarks
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Grading-I
|
Grading-II
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Grading-III
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75 mm
|
100
|
------
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.-----
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Note:
1: The material passing 425 micron (0.425 mm) sieve for all the three gradings when tested according to IS: 2720 (Part-5) shall have Liquid limit and plasticity index not more than 25 & 6 percent respectively.
2) On clayey subgrade, the percent passing IS Sieve 0.075 mm shall not exceed 5
3) The wet aggregate impact value (IS: 5640) shall not exceed 50
4) The material to be used in the subgrade shall have minimum soaked CBR value 20 CBR value not less than 15 can be permitted with the approval of the competent authority.
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53 mm
|
-----
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100
|
.------
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26.5 mm
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55-75
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50-80
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100
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9.5 mm
|
------
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------
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-----
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4.75 mm
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10-30
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15-35
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25-45
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2.36 mm
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-----
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-----
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------
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0.425 mm
|
-----
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------
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-------
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0.075 mm
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< 10
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< 10
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< 10
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D.4 Composition of Bituminious Macadam (MoRTH & MoRD Specifications)
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IS Sieve
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Percent Passing by weight of Total Aggregate
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Remarks
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26.5
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100
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Note:
For Condition in cooler area of india or where the percent passing 0.075 mm sieve is on higher side of the range, appropriate bitumen contents may be upto 0.5 percent higher, subject to approval of the Engineer
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19
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90-100
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13.2
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56-88
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4.75
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16-36
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2.36
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4-19
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0.03
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2-10
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0.075
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0-5
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Bitumen content % by weight of Total Mixture
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3.3 to 3.5
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Bitumen Penetration Grade
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35 to 90
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D.5 20 mm thick premix carpet Open Graded Premix Surfacing (MoRTH & MoRD Specifications)
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Binder: The binder shall be a penetration grade of bitumen of a suitable grade S-65/90 as specified in contract. IS 73
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Field inspection criteria
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Quantities of materials required for 10 Sqm area
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Aggregate
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Quantity
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a) Nominal size 13.2 mm (Passing 22.4 mm Sieve and retained on 11.2 mm sieve)
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0.18 m 3
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b) Nominal size 11.2 mm (Passing 13.2 mm Sieve and retained on 5.6 mm sieve)
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0.09 m 3
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Total
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0.27 m 3
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Binder
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Quantity
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a) For 0.18 m 3 of 13.2 mm nominal size stone 52 Kg bitumen per m 3
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9.5 Kg
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a) For 0.09 m 3 of 11.2 mm nominal size stone 56 Kg bitumen per m 3
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5.10 Kg
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Total
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14.60 Kg
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Grading requirement for Chips for surface dressing
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IS Sieve Designation
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Cumulative percent by weight of total aggregate passing for the following nominal sizes (mm)
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13.2
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9.5
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6.3
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19.00
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100
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----
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-----
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13.20
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85-100
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100
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-----
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9.50
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0-40
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85-100
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100
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6.30
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0-7
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0-35
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85-100
|
4.75
|
----
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0-10
|
-----
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3.35
|
----
|
----
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0-35
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2.36
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0-2
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0-2
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0-10
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0.60
|
----
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-----
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0-2
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0.07
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0-1.50
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0-1.5
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0-1.5
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Minimum 65 % by weight of aggregate
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Passing 13.2 mm,
Retained 9.5 mm
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Passing 9.5 mm
Retained 6.3 mm
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Passing 6.3 mm
Retained 3.35 mm
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NOTE:-
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Mixing temperature of Bitumen should be in range of 150 0 C to 163 0 C
Mixing temperature of Aggregate should be in range of 155 0 C to 163 0 C
Provided that the difference between the temperature of aggregate and the binder should not exceed 140C
Binder should be a penetration grade bitumen of a suitable grade of S-65/90 depending on the climatic condition of the area.
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Premix carpet using Bitumen Emulsion
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The quantities of material required for 20 mm thick premix carpet should be as indicated below
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i) Aggregate same as 20 mm carpeting
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ii) Binder: Cationic Bitumen Emulsion
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a) For 0.18 cum of 13.2 mm nominal size stone at 78 Kg Cationic Bitumen Emulsion per cum
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14.00 Kg per 10 Sqm area
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a) For 0.09 cum of 11.2 mm nominal size stone at 84 Kg Cationic Bitumen Emulsion per cum
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7.50 Kg per 10 Sqm area
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Total
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21.50 Kg per 10 Sqm area
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Binder for premix carpet wearing course shall be bitumen emulsion of Medium Setting (MS) grade complying with IS: 8887 and having a bitumen content of 65 % minimum by weight.
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Emulsion for liquid seal coat shall be of RS grade of MS grade where specified. Emulsion for premeix seal coat shall be of SS (Slow Setting) grade.
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Seal Coat
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Type-A: Liquid seal coat comprising of an application of layer of bituminious binder followed by a cover of stone Chips.
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Type-B:Premixed seal coat comprising of a thin applicationn of fine aggregate premixed with bituminious binder
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Type-C:Premixed seal coat comprising of an application of 6.7 mm size stone chips premixed with bituminious binder.
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Type A Seal coat with bitumen: Apply bitumen with a temperature between 150 0 C and 163 0 C uniformly with a sparayer. Thereafter, spread stone chips over the bitumen layer
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Quality control requirements of Seal Coat
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a) Quantity of Coarse aggregates & Binders along with Gradation requirement of aggregate for seal coat
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Type of Seal Coat
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Qty of Aggregate required per 10 Sqm area
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Gradation Requirement of coarse Aggregate
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Binder Content per 10 Sqm
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100 % Passing sieve designation
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100 % retained sieve designation
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Bitumen in Kg
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Bitumen Emulsion in Kg
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Type- A
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0.09 Cum
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11.2 mm
|
2.36 mm.
|
9.8
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12 to 14
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Type- B
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0.06 Cum
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2.36 mm
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180 microns
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6.8
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10 to 12
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Type- C
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0.09 Cum
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9.5 mm
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2.36 mm.
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4.5 % by weight of total mix
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9 to 11
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D.6 Stone Aggregate for DBM (Clause 507, Table 500-10 MoRTH)
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IS Sieve (mm)
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Grading Requirements (% Passing) Ref. Range
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Remarks
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Grading -I
(40 mm nominal size) Layer Thickness 80-100 mm
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Grading -II
(25 mm nominal size) Layer Thickness 50-75 mm
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45
|
100
|
-----
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As per Table 500-10 , The final gradation is within the above limits and not varied from the low limit of one sieve to the high limit of adjacent sieve or vice-versa.
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37.5
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95-100
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100.00
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26.5
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63-93
|
90-100
|
19
|
-----
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71-95
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13.2
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55-75
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56-80
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4.75
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38-54
|
38-54
|
2.36
|
-----
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28-54
|
0.30
|
7-21
|
7-21
|
0.075
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2-8
|
2-8
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Minm Bitumen Content % By Weight of Total mix
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4.00%
|
4.50%
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Bitumen Grade (Pen)
|
65 or 90
|
65 or 90
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D.7 Wet Mix Maccadam (WMM) (Section 400, Clause 406 , Table 400-11 of MoRTH)
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IS Sieve (mm)
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Grading Requirements (% Passing) Ref. Range
|
Remarks
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53
|
100
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As per Table 400-11 ,The gradation Should be within the above limits and not varied from the low limit of one sieve to the high limit of adjacent sieve or vice-versa .
he materials finer than 425 micron shall have Plasticity Index (PI) not execeding 6.
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45
|
95-100
|
22.4
|
60-80
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11.2
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40-60
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4.75
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25-40
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2.36
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15-30
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0.60
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8-22
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0.075
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0-8
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D.8 Bituminous Concrete Pavement (Section 500, Table 500-18 of MoRTH)
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IS Sieve (mm)
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Grading Requirements (% Passing) Ref. Range
|
Remarks
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Grading-I, Nominal Size 13 mm,
Layer Thickness 35 - 40 mm
|
Grading-II, Nominal Size 10 mm,
Layer Thickness 25 - 30 mm
|
26.5
|
100.00
|
-----
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The Combined Aggregate grading shall not vary from the low limit of one sieve to the high limit of adjacent sieve.
|
19
|
79-100
|
100.00
|
13.20
|
59-79
|
79-100
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9.50
|
52-72
|
70-88
|
4.75
|
35-55
|
53-71
|
2.36
|
28-44
|
42-58
|
1.18
|
20-34
|
34-48
|
0.60
|
15-27
|
26-38
|
0.30
|
10-20
|
18-28
|
0.15
|
5-13
|
12-20
|
0.075
|
2-8
|
4-10
|
Minm Bitumen Content % By Weight of Total mix
|
5.0 - 6.0
|
5.0 -7.0
|
|
Bitumen Grade (Pen)
|
65.00
|
65*
|
|
D.9 Grouting Work
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Clause 1904.2.2 of MoRD Specification : All materials used for the pot- hole and patch repairing of bituminious Surface and underlying layers shall be in accordance with these Specifications and shall be of the same type as specified for the original construction or higher.
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D.10 Horizontal Alignment
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Purpose: It is necessary to check the the horizontal alignment to ensure that the work is set out in accordance with the approved drawings and dimensions.
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Locations on Road
|
Permitted Tollerence
|
In Plain and Rolling Terrain
|
In Hilly terrain
|
Edges of carriage way.
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Plus minus 20 mm
|
Plus minus 30 mm
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Edges of road way and lower layer of pavement
|
Plus minus 30 mm
|
Plus minus 50 mm
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E. BRICKS
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Classification and quality of Bricks ( Ref IS: 1077 : 1992)
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Class Designation
|
Compressive Strength not Less than ( N/mm2)
(approx )
|
Remarks
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35
|
35.00
|
As per specification of work, compressive strength of 1st class and 2nd class brick are 105 Kg/ Cm 2 ,75 Kg/ Cm 2
Water Absorption
The bricks, when tested in accordance with the procedure laid down in IS 3495 ( Part 2) : 1992 after immersion in cold water for 24 hours, water absorption shall not be more than 20 percent by weight up to class 12'5 and 15 percent by weight for higher classes
|
30
|
30.00
|
25
|
25.00
|
20.0
|
20.00
|
17.5
|
17.50
|
15.0
|
15.00
|
12.5
|
12.50
|
10.0
|
10.00
|
7.5
|
7.50
|
5.0
|
5.00
|
3.5
|
3.50
|
As per specification of building work, SoR 2017,Building work, the requiremrnt of bricks shall be as follows
|
Type of Bricks
|
Dimension (in mm)
(Length x Breadth x Depth)
|
Minimum Compressive Strength
|
Water Absorption (max)
|
Actual Nominal Tolerance
|
1 st Class
|
250x120x70 255x123x72 plus minus 3
|
105 Kg/ cm 2
|
20 % by weight
|
2 nd Class
|
250x120x70 255x123x72 plus minus 5
|
75 Kg/ cm 2
|
25 % by weight
|
Efflorescence of Bricks
|
Nil - When there is no perceptible deposit of efflorescence.
Slight - When not more than 10 percent of the exposed area of the brick is covered with a thin deposit of salts.
Moderate - When there is a heavier deposit than under ‘slight’ and covering up to 50 percent of the exposed area of the brick surface but unaccompanied by powdering or flaking of the surface.
Heavy - When there is a heavy deposit of salts covering 50 percent or more of the exposed area of the brick surface but unaccompanied by powdering or flaking of the surface.
Serious - When there is a heavy deposit of salts accompanied by powdering and/or flaking of the exposed surfaces.
|
F. CONCRETING WORKS
|
F.1 Criteria of Graded Course aggregate for Concrete works ( Clause 4.1 and 4.2 of IS 383:1970)
|
Gradation analysis
|
IS Sieve Designation
|
Percentage passing for graded aggregate of nominal size
|
40 mm
|
20 mm
|
16 mm
|
12.5 mm
|
80 mm
|
100
|
-----
|
-----
|
-----
|
63 mm
|
-----
|
-----
|
-----
|
-----
|
40 mm
|
95-100
|
100
|
|
|
20 mm
|
30-70
|
95-100
|
100
|
100
|
16mm
|
------
|
------
|
90-100
|
------
|
12.5 mm
|
------
|
------
|
------
|
90-100
|
10 mm
|
10-35
|
25-55
|
30-70
|
40-85
|
4.75 mm
|
0-5
|
0-10
|
0-10
|
0-10
|
2.36 mm
|
-----
|
-----
|
-----
|
-----
|
F.2 Criteria of Fine aggregate for Building works (Clause 4.3 of IS 383:1970) Sieve Analysis
|
IS Sieve Designation
|
Percentage passing for
|
Remarks
|
Grading Zone-IV
|
Grading Zone-I
|
Grading Zone-II
|
Grading Zone-III
|
10 mm
|
100
|
100
|
100
|
100
|
(Clause 4.3 of IS 383:1970)
|
4.75 mm
|
90-100
|
90-100
|
90-100
|
95-100
|
2.36 mm
|
60-95
|
75-100
|
85-100
|
95-100
|
1.18 mm
|
30-70
|
55-90
|
75-100
|
90-100
|
600 micron
|
15-34
|
35-59
|
60-79
|
80-100
|
300 micron
|
5-20
|
8-30
|
12-40
|
15-50
|
150 micron
|
0-10
|
0-10
|
0-10
|
0-15
|
F.3 Permissible Limit of Cement test Result (Ref. IS:8112 & IS:269)
|
Items of Test
|
Permissible Limit (Ref. IS:8112 & IS:269)
|
Remarks
|
1. Initial Setting time
|
Minm 30 minutes
|
(Ref. IS:8112 & IS:269)
|
2. Final Setting time
|
Maxm 600 minutes
|
3. Soundness (Le Chatelier Method)
|
Maximum 10mm
|
4. Fineness (Sieving Method)
|
Maximum 10 %
|
F.4 Concrete Cube
|
METHODS OF TESTS FOR STRENGTH OF CONCRETES : IS 516 : 1959 : Procedure for making and curing compression test specimens of concrete. Tests for the determination of compressive strength.
|
Frequency of Sampling (As per IS 456 2000)
Sampling Procedure A random sampling procedure shall be adopted to ensure that each concrete batch shall have a reasonable chance of being tested that is, the sampling should be spread over the entire period of concreting and cover all mixing units.
Frequency The minimum frequency of sampling of concrete of each grade shall be in accordance with the following:
Quantity of Concrete Work, m3 Number of Samples
1- 5 1
6- 15 2
16- 30 3
31-50 4
51 and above 4 plus one additional sample for each additional 50 m3 or part thereof
NOTE- At least one sample shall be taken from each Shift.Where concrete is produced at continuous production unit, such as ready-mixed concrete plant, frequency of ’sampling may be agreed upon mutually by suppliers and purchasers.
|
Test Specimen
Three test specimens shall be made for each samplefor testing at 28 days. Additional samples may be required for various purposes such as to determine the strength of concrete at 7 days or at the time of striking the formwork, or to determine the duration of curing, or to check the testing error. Additional samples may also be required for testing samples cured by accelerated methods as described in IS 9103. The specimen shall be tested as described in IS 516.
|
ACCEPTANCE CRITERIA (As Per IS 456: 2000)
Compressive Strength, the concrete shall be deemed to comply with the strength requirements when both the following condition are met:
a) The mean strength determined from any group of four consecutive test results compiles with the appropriate limits in col 2 of Table 11.
b) Any individual test result complies with the appropriate limits in col 3 of Table 11.
|
Testing In case of doubt regarding the grade of concrete or results of cube strength tests (As per IS 456: 2000)
In case of doubt regarding the grade of concrete used,either due to poor workmanship or based on results of cube strength tests, compressive strength tests of concrete on the basis of Core Test and/or Load test may be carried out.
Core Test : The points from which cores are to be taken and the number of cores required shall be at the discretion of the engineer-in-charge and shall be representative of the whole of concrete concerned.In no case, however, shall fewer than three cores be tested. Cores shall be prepared and tested as described in IS 516.
Concrete in the member represented by a core test shall be considered acceptable if the average equivalent cube strength of thecores is equal to at least 85 percent of the cube strength of the grade of concrete specified for the corresponding age and no individual core has a strength less than 75 percent.
|
Load Test : In case the core test results do not satisfy the requirements or where such tests have not been done, Load Test may be resorted. Load Tests for Flexural Members, Members Other Than Flexural Members.
Load Tests for Flexural Members
The structure should be subjected to a load equal to full dead load of the structure plus 1.25 times the imposed load for a period of 24 h and then the imposed load shall be removed.
The deflection due to imposed load only shall be recorded. If within 24 h of removal of the imposed load the structure does not recover at least 75 percent of the deflection under superimposed load, the test may be repeated after a lapse of 72 h. If the recovery is less than 80 percent, the structure shall be deemed to be unacceptable.
If the maximum deflection in mm, shown during 24 h under load is less than 40L2/D, where L is the effective span in m; and D, the overall depth of the section in mm, it is not necessary for the recovery to be measured.
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Non-destructive Tests
Non-destructive tests are used to obtain estimation of the properties of concrete in the structure. The methods adopted include ultrasonic pulse velocity [see IS 133 11 (Part l)] and rebound hammer [IS 13311 (Part 2)], probe penetration, pullout and maturity. Nondestructive tests provide alternatives to core tests for estimating the strength of concrete in a structure, or can supplement the data obtained from a limited number of cores. These methods are based on measuring a concrete property that bears some relationship to strength. The accuracy of these methods, in part, is determined by the degree of correlation between strength and the physical quality measured by the non-destructive tests.
Any of these methods may be adopted, in which case the acceptance criteria shall be agreed upon prior to testing.
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G. General Construction in Steel
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IS:800-1984 : This code applies to general construction in steel. Specific provisions for bridges, chimneys, cranes, tanks, transmission line towers, storage structures, tubular structures and structures using cold formed light gauge sections, etc, are covered in separate codes.
The provisions of this code generally .apply to riveted, bolted and welded constructions, using hot rolled steel sections.
This code gives only general guidance as regards the various loads to be considered in design , For actual loads to be used reference may be made to IS : 875-1964.
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H. REINFORCEMENT
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IS:1786 - 1985 : This standard covers the requirements of deformed steel bars and wires for use as reinforcement in concrete, in the following three strength grades: a) Fe 415, b) Fe 500, and c) Fe 550.
Note:- The figures following the symbol Fe indicates the specified minimum 0.20 Percent proof stress or yield stress in N/mm2.
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I. Mix Design of Concrete (As per IS :10262-2009)
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This standard provides the guidelines for proportioning concrete mixes as per the requirements using the concrete making materials including other supplementary materials identified for this purpose. The proportioning is carried out to achieve specified characteristics at specified age, workability of fresh concrete and durability requirements .
This standard is applicable for ordinary and standard concrete grades only. All requirements of IS:456-2000 in so far as they apply, shall be deemed to form part of this standard.
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The following data are required for mix proportioning of a particular grade of concrete:
a) Grade designation
b) Type of cement
c) Maximum nominal size of aggregate
d) Minimum cement content
e) Maximum water-cement ratio
f) Workability
g) Exposure conditions as per Table 4 and Table 5 of IS : 456-2000
h) Maximum temperature of concrete at the time of placing
j) Method of transporting and placing;
k) Early age strength requirements, if required:
l) Type of aggregate
m) Maximum cement content; and
n) Whether an admixture shall or shall not used and the type of admixture and the condition of use.
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