standard specification jkr road

Standard Specification For Road Works

Cawangan Jalan, Ibu Pejabat JKR, K.L

KERAJAAN MALAYSIA JABATAN KERJA RAYA MALAYSIA

CAWANGAN JALAN KETUA PENGARAH KERJARAYAIBU PEJABAT JABATAN KERJARAYA MALAYSIA JABATAN KERJARAYA MALAYSIAJALAN SULTAN SALAHUDDIN, JALAN SULTAN SALAHUDDIN50582 KUALA LUMPUR. 50582 KUALA LUMPUR

FOR INTERNAL USE ONLY

STANDARD SPECIFICATION FOR

ROAD WORKS




ADDENDUM NO. 1

This Addendum shall be made part of the ‘JKR Standard Specification For Roads Works’

1. Table 4.8 - Gradation Limit For Asphaltic Concrete Clause 4.2.4.2, page S4 – 21 should read as follows :

Mix Type

Wearing Course

Binder Course

Mix

Designation

ACW 20

ACB 28

B.S Sieve

% Passing by weight

37.5 mm

28.0 mm

20.0 mm

14.0 mm

10.0 mm

5.0 mm

3.35 mm

1.18 mm

425 um

150 um

75 um

100

76 -- 100

64 -- 89

56 -- 81

46 -- 71

32 -- 58

20 -- 42

12 -- 28

6 -- 16

4 -- 8

100

80 -- 100

72 -- 93

58 -- 82

50 -- 75

36 -- 58

30 -- 52

18 -- 38

11 -- 25

5 -- 14

3 -- 8

2. Table 4.9- Design Bitumen Contents Clause 4.2.4.3, page S4 - 23 should read as follows :

ACW 20 - Wearing Course

4.5 -- 6.5 %

ACW 28 - Binder Course

4.0 -- 6.0




ADDENDUM NO. 2This Addendum shall be made part of the ‘JKR Standard Specification For Roads Works’

6.2.5.5 Sign Faces

Sign faces for permanent traffic sign shall be asshown on the Drawing and shall comply withthe Malaysian Standard Specification forReflective Sign Faces Materials (MS 1216). Allretro-reflective sheeting shall be fixed in accor-dance with the manufacturer’s instruction.

Unless otherwise agreed by the S.O., signfaces shall be formed from a single piece ofretro-reflective sheeting.

Where, with the aggrement of the S.O., morethan one retro-reflective sheeting is used, thenumber of sheets shall be kept to a minimum.All faces up to 1 m in size shall be producedwith a single sheet and no joint will be accepted.

Only vertical and horizontal joint shall be per-mitted and all join in retro-reflective shettingshall be overlapped by not less than 6 mm. Theoverlap in the horizontal joint shall be from thetop and the vertical joint shall be from the left;but joints will be only be accepted for prismaticretro-reflective sheeting.

Retro-reflective sheeting shall be applied evenly over the whole surface of the sign plateand shall adhere fully. it shall be free fromtwists, cracks, folds or cuts, air bubbles andother blemishes.

All retro-reflective sheeting used on the samesign shall be carefully matched for colour toproduce a uniform appearance both by day andby night. Non-uniform shades of colour on anyone sign will not be accepted.

The edges of all the retro-reflective sheetingshall be properly fitted to ensure no delimination of the sheeting from the base substrate.

where shetting is applied to the extruded section by pressure roller, it shall extend overthe top and bottom edges of this sections by notless than 3 mm.

Any cut-outlet letters, numerals, symbols andborders shall be of material compatible with thesheeting to which they are applied. They shallbe applied in accordance with the sheetingmanufacturer’s instruction.

The finish of all sign faces shall be capable ofpassing the tests described in MS 1216, andand standard of fabrication and workmanshipshall be such that under normal conditions ofservice and proper maintenance, the sign facesshall last not less than 5 years without any seriousblemishes or defects for EngineeringGrade retro-reflective sheeting and 8 years forHigh Intensity and prismatic retro-reflectivesheeting.

The Contractor shall furnish to the S.O. a letterof warranty for the specified period for all signfaces from the manufacturer of the sheeting orthe sign fabricator.

The retro-reflective sheeting manufacturer shallfurnish the S.O. written warranty that the fluo-rescent colours shall be durable for a minimum3 years for temporary signs.



6.2.6.1.2 Requirements

i) Photometric - Coefficient of Retroreflection RA

when the sheeting applied on aluminiumtest panels is measured in accordance wth ASTM E 810, it shall have minimum coefficient of retro-reflective value as shown in Table I. The rotation angle shall be *90° , the observation angles shall be 0.2° and 0.5°, the entrance angles and +50°, and the entrance angle (component ß1) shall be - 4°, +30°, and +50°, and the entrance angle component ß2 = 0°.


ADDENDUM NO. 3This Addendum shall be made part of the ‘JKR Standard Specification For Roads Works’

6.2.6.1 FLUORESCENT ORANGE WIDE ANGLE PRISMATIC RETRO-REFLECTIVE SHEETING FOR THE WORK ZONE

6.2.6.1.1 Description

The flurescent orange wide angle prismaticretro-reflective sheeting is specifically designedfor use on rigid substrade work zone signs toprovide high visual impact under nighttime anddaytimedriving condition, including low visibility periods such as dawn, dusk, and overcast days. The sheeting shall consist ofprismatic lenses formed in a transparent flurescent orange synthetic resin, sealed, andbaked with and aggressive presure sensitiveadhesive protected by a removable liner. Thesheeting shall have a smooth surface with a distinctive interlocking diamond seal patternand orrientation marks visible from the face.

TABLE I

Minimum Coefficient of Retroreflection RA(Candelas per footcandle per square foot)

(90° Rotation Angle*)

Observation Angle ( ° ) Entrance Angle ( ° ) Orange

0.20.20.2

1.50.50.5

- 4+30+50

-4+30+50

20012050

805020

* The datum mark (arrow) imprinted on the face of the sheeting shall be the datum mark for testpurposes. For the specified 90° rotation angle, the sheeting shall be positioned on the goniometerso that the direction of this datum mark is perpendicular to the observation plane (this geometry isequivalent to a 90° orientation angle with a presentation angle of 0° in the measurement geometrydescribed in Fed. Test Method Standard 370).



i) Daytime Color

Color shall conform to the reqiurement of Table II. Daytime color and maximum spectral radiance factor (peak reflectance) of sheeting mounted on aluminium test panels shall be determined instrumentally in accordancewith ASTM E 991.

The value shall be determined on a HunterLabLabscan 6000 0/45 spectrocolorimeter withoption CMR 559 [or approved equal 0/45(45/0) instrument withcircumferential viewing(illumination)]. Computation shall be done inaccordance with ASTM E 308 for the 2°observer.


TABLE IIColor Specification Limit ** (Daytime)

Color 1 2 3 4 ReflectanceLimit Y (%)

X Y X Y X Y X Y Min. Max.

Orange(New)

Orange(Weathered)

.583

.583

.416

.416

.523

.523

.397

.397

.560

.560

.360

.360

.631

.631

.369

.369

30

20

-

45

Maximum spectral radiance factor, new : 110%, min.weathered : 60%, min.

iii) Nighttime Color.

Nighttime color of the sheeting applied to alumium test panel shall be determinedinstrumentally in accordance with ASTM E 881 and calculated in the u’, v’ coordinate system in accordance with ASTM E 308. Sheeting shall be measured at 0.33° observation and - 4° entrance at 90° rotation. Color shall conform to the requirements of Table III.

** The four pairs of chromaticity coordinates determine the acceptable color in terms of the CIE 1931 standard colorimetric system measured with standard illuminatant D65.

TABLE IIColor Specification Limit ** (Nighttime)

Color 1 2 3 4

u’ v’ u’ v’ u’ v’ u’ v’

Orange(New and

Weathered).400 .540 .475 .529 .448 .522 .372 .534



iv) Resistance to Accelerated Weathering.

The retro-reflective surface of the sheeting shall be weather resistant and show no appreciable cracking, blistering, crazing, ordimensional change after 1 year’s unprotected outdoor exposure in south Florida, south-facing and inclined 45° from the vertical, or after 1500 hours’exposure in a xenon arc weatherometer in accordance with ASTM G 26, Type B, Method A. Following exposure, panels shall be washed in a 5% HCL solution for 45 seconds, rinsed throughly with clean water, blotted with a soft clean cloth and brought to equilibrium at standard conditions. After cleaning, the coefficient of retroreflection shall be not less than 100 when measured as in D.2, below, and the color is expected conform to the requirements of Table II and III for weathered sheeting. The sample shall :

a) Show no appreciable evidence of cracking, scaling, pitting, blistering, edge lifting or curling or more than 1/32inch (0.08 cm) shrinkage or expansion.

b) Be measured only at angles of 0.2° observation, - 4° entrance and 90° rotation. Where more than one panel of a color is measure, the coefficient or retroreflection shall be the averange of all determinations.

v) Impact Resistance.

The retroreflective sheeting applied according to the sheeting manufacturer’s recommendations to a test panel of alloy 6061-T6, 0.040” (0.10 cn) by 3” (7.6 cm) by 5” (12.7 cm) and conditioned for 24 hours, shall show no cracking outside the impact of 100 inch-pounds (11.3Nm) usinga weight with a 5/8 in. (15.8 mm) diameterrounded tip dropped from a height necessary to generate an impact of 100 inch-pounds, at test temperatures of both 32° F (0° C) and 72° F (22° C).

vi) Resistance to Heat.

The retroreflective sheeting, applied to a test panel as in E., above and conditioned for 24 hours, shall be measured in accordance with paragraph. A. at 0.2° observation and - 4° entrance angles at 90° rotation and exposed to 170 + 5°F (77 + 3°C) for 24 hours in an air circulating oven. After heat exposure the sheeting shall retain a minimum of 70% of the original coefficient of retroreflection.

vii) Field Performance

Retroreflective sheeting processed and applied to sign blank materials in accodance with the sheeting manufacturer’s recommendations, is expected to perform effectively for a minimum of 3 years. the retroreflective sheeting will be considered unsatisfactory if it has deteriorated due to natural causes to the extent that : (1) the sign is ineffectivefor its intended purposed when viewed from a moving vehicle under normal day and night driving conditions; or (2) the coefficient of retroreflection is less than 100 when measured at 0.2° observation and - 4° entrance at 90° rotation. All measurements shall be made after sign cleaning according to the sheeting manufacturer’s recommendations.





STANDARD SPECIFICATION FOR ROADS WORKS

CONTENT PAGE

SECTION 1 General S1-11 to S1-31

SECTION 2 Earthworks S2-1 to S2-20

SECTION 3 Drainage Works S3-1 to S3-31

SECTION 4 Flexible Pavement S4-1 to S4-55

SECTION 5 Portland Cement Concrete Pavement S5-1 to S5-21

SECTION 6 Road Funiture S6-1 to S6-22

SECTION 7 Street Lighting S7-1 to S7-19

SECTION 8 Traffic Signals S8-1 to S8-33

SECTION 9 Concrete S9-1 to S9-39

SECTION 10 Piling Works S10-1 to S10-35




SECTION 1

GENERAL




SECTION 1 - GENERALPage

1.1 GENERAL DESCRIPTION OF THE PROJECT S1-111.2 SCOPE OF WORKS S1-111.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT S1-11

1.3.1 Notes S1-111.3.2 Abbreviations S1-111.3.3 Units of Measurement S1-11

1.4 PROGRAMME OF WORKS S1-121.5 LIMITATION OF SITE S1-121.6 SUPPLY OF MATERIALS S1-121.7 MATERIALS OF MALAYSIAN ORIGIN S1-121.8 SETTING OUT S1-131.9 DIMENSIONS AND LEVELS S1-131.10 PROTECTION OF WORKS S1-131.11 DESIGN OF TEMPORARY WORKS BY THE CONTRACTOR S1-131.12 CONTRACTOR'S SUPERINTENDENCE S1-141.13 INSPECTION AND TESTS S1-141.14 COVERING UP OF WORK S1-141.15 OFFICE ACCOMMODATION FOR S.O. AND HIS STAFF S1-141.16 VEHICLES FOR THE S.O.'S STAFF S1-161.17 CONTRACTOR'S OFFICE AND ACCOMODATION S1-161.18 MATERIAL TESTING LABORATORY AND STAFF S1-161.19 PROVISION FOR SURVEY INSTRUMENTS AND CHAINMEN S1-171.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION

OF TRAFFIC S1-171.20.1 Maintenance of Existing Roads, Bridges, Culverts, etc. S1-171.20.2 Temporary Diversions S1-171.20.3 Half-width Construction and Traffic Control S1-181.20.4 Temporary Traffic Signs S1-191.20.5 Temporary Works S1-19

1.21 LOCATION, TEMPORARY PROTECTION AND TEMPORARYDIVERSION OF PUBLIC UTILITY INSTALLATIONS AND OTHER SERVICES S1-19

1.22 WATER AND ELECTRICITY SUPPLY S1-201.23 PROJECT SIGNBOARD S1-201.24 PHOTOGRAPHIC RECORD OF WORKS S1-201.25 AS-BUILT DRAWINGS AND MICROFILMING S1-211.26 CLEARING UP OF SITE S1-211.27 OPPORTUNITIES FOR OTHER CONTRACTORS S1-21




Page

APPENDIX 1A GENERAL DESCRIPTION OF PROJECT S1-22

APPENDIX 1B SCOPE OF WORKS S1-23

APPENDIX 1C VEHICLES FOR S.O. AND HIS STAFF S1-24

APPENDIX 1D LIST OF LABORATORY EQUIPMENT

(a) Soil Testing Equipment S1-25(b) Concrete Testing Equipment S1-27(c) Flexible Pavement Testing Equipment S1-27

APPENDIX 1E SURVEY EQUIPMENT S1-30

FIGURE 1-1 APERTURE CARD FOR MICROFILM S1-31



SECTION 1 - GENERAL

1.1 GENERAL DESCRIPTION OF THE PROJECT

The general description of the project is asgiven in Appendix 1A.

1.2 SCOPE OF WORKS

The Works covered in this Contract comprisethe provision by the Contractor at his own riskand cost of all materials, tools, plants, labour,transport and everything else necessary for theconstruction and completion of the Works asgiven in Appendix 1B all to the approval of theS.O.

1.3 NOTES, ABBREVIATIONS AND UNITS OF MEASUREMENT

1.3.1 Notes

i) Any clause in this Specification which relates to work or materials not includedin the Works shall be deemed not applicable.

ii) Unless stated to the contrary, any dimension of material described meansthe finished or fully compacted dimension.

iii) All Standards and Codes of Practice referred to in this Specification shall be deemed to be the editions current at the time of Tender. If the Malaysian Standard exists, which the S.O. deems tobe equivalent to the British or other Standard specified, then the Malaysian Standard shall be followed.

In the event of any discrepancy between the provision of this Specification and the provision within the relevant Standards or Codes of Practice as mentioned in this Specification, then the provision of this Specification shall take precedence.

iv) The terms "Engineer" and "Superintending Officer" shall be synonymous.

1.3.2 Abbreviations

a) M.S. means Malaysian Standards published by the Scientific and Industrial Research Institute of Malaysia (SIRIM).

b) B.S. means British Standards published by the British Standard Institution.

c) A.A.S.H.T.O. means The American Association of State Highway and Transportation Officials.

d) A.S.T.M. means The American Society for Testing and Materials.

e) M.D.D. means Maximum Dry Density.

f) O.M.C. means Optimum Moisture Content.

g) C.B.R. means California Bearing Ratio.

h) S.O. means Superintending Officer.

i) B.Q. means Bill of Quantities.

1.3.3 Units of Measurement

All units of measurement used in this Specification and in the Bill of Quantities shall be in accordance with the metric system unless otherwise stated.

Where British Imperial units are shown or stated the following conversions shallapply :-




1 inch = 25.40 millimetres1 foot = 0.3048 metres1 lb = 0.4536 kilograms1 gallon = 4.5461 litres1 lb/sq.in = 6.895 x 10-3 N/sq.mm

1.4 PROGRAMME OF WORKS

Within thirty (30) days after the receipt of the Letter of Acceptance of Tender, the Contractor shall submit to the S.O. for his approval a programme showing the order of work activities and time schedule in which the Contractor proposes to carry out the Works and shall, whenever required by the S.O. or the S.O.'s representative, furnish in writing, particulars of the Contractor's arrangement for carrying out such worksand of the construction plants andtemporary works, if any, which the Contractor intends to supply, use or construct as the case may be. The submission to and approval by the S.O. or the S.O.'s representative of such a programme or the furnishing of such particulars shall not relieve the Contractor of any of his duties or responsibilities under the Contract.

If at any time it should appear to the S.O. that the actual progress of the Works does not conform to the approvedprogramme referred to herein before, theContractor shall submit for approval, a revised programme showing the modifications to the previously approved programme necessary to ensure the completion of the whole Works within the time set for completion.

1.5 LIMITATION OF SITE

The Contractor shall ensure that all his plants, materials, temporary workshops, stores and offices are kept within the Site at locations approved by the S.O.

Should the Contractor require additional land outside the Site for his workyards, stores, offices, temporary haul roads or any other temporary structures, he shall, on his own, purchase or rent any additional area he may need.

Areas or area to be rendered as part of the Site shall be subject to the S.O.'s approval.

1.6 SUPPLY OF MATERIALS

The Contractor shall place orders for specified materials at such times as will enable him to execute the Works in accordance with his approved programme.

If the Contractor's failure to supply any material causes any interruption or delayin the progress of the Works, the Government may supply any portion or all of the materials and the cost borne by the Contractor shall be either that as calculated at the current market rates or the actual cost to the Government at the date of supply, including overheads or any other charges, whichever is the greater.

Any costs incurred under this Section shall be deducted from the Contract Sum. No claim for loss of profit under the conditions of this Contract shall be deemed to have arisen. No action taken under this Section shall in any way affect or modify the right of the Government to claim for damages in theevent of the Contractor's failure to complete the Works by the agreed date.

1.7 MATERIALS OF MALAYSIAN ORIGIN

Materials of Malaysian origin where available must be used by the Contractorto the exclusion of imported materials and this requirement shall be allowed for in his tender.




Under no circumstances shall the Contractor be permitted to use imported materials unless he can prove to the satisfaction of the S.O. that the materials are not available locally, or ifavailable are not of an acceptable standard.

1.8 SETTING OUT

Before commencing the Works at any location, the Contractor shall provide and install precast concrete reference beacons on both sides of the road centre-line at a spacing of 300 metres. The beacons shall be firmly sited at rightangles to the centre-line at a distance from the centre-line of 15 metres or suchother distance as directed by the S.O. The beacons shall be not less than 75 mm square in plan and shall project at least 600 mm above the surrounding ground. Each beacon shall be clearly marked with its chainage and elevation above datum.

The Contractor shall take all practicable steps to safeguard the beacons including fencing and concreting-in where necessary in the opinion of the S.O. and shall immediately replace any damaged beacons. The Contractor shall give the S.O. not less than 24 hours notice of his intention to set out or give levels for any part of the Works in order that arrangements may be made for checking.

1.9 DIMENSIONS AND LEVELS

All temporary benchmarks, reference markers and levels as shown on the Drawings shall be checked on the Site by the Contractor at his own expense and be confirmed by the S.O.

Before the Works or any part thereof arecommenced, the Contractor shall verify the levels of the existing ground surface within areas where earthworks are to be performed and the locations and bed levels of water-courses. These may differ from the locations and levels shown on the Drawings owing to changes which could have taken place during the interval between the original survey and construction.

The levels and dimensions taken by the Contractor jointly with the S.O. shall form the basis of measurement of the relevant work quantities.

1.10 PROTECTION OF WORKS

From the commencement of the Works to the date the Works are taken over by the Government, the Contractor shall take full responsibility for the care thereof together with all temporary works and in case any damage, loss or injury shall happen to the Works or to any part thereof or to any temporary works from any cause whatsoever, he shall at his own cost repair and make good the same so that at completion, the Works shall be in good order and condition andin conformity in every respect with the requirements of the Contract and the S.O.'s instructions. The Contractor shallalso be liable for any damage to the Works occasioned by him in the course of any operations carried out during the Defects Liability Period.

1.11 DESIGN OF TEMPORARYWORKS BY THE CONTRACTOR

Unless otherwise provided in the Drawings, the Contractor shall submit tothe S.O. for his approval, 2 copies of all working or shop drawings produced by him including all drawings made by his approved sub-contractors for all temporary works.




Such submission shall be made at least two weeks before the temporary work isscheduled to commence. Notwithstanding the approval by the S.O., the Contractor is solely responsiblefor the adequacy and safety of his work and for any necessary modification or addition whenever found necessary by the S.O.

1.12 CONTRACTOR'S SUPERINTENDENCE

The Contractor shall provide all necessary superintendence during the execution of the Works and as long thereafter as the S.O. may consider necessary for the proper fulfillment of the Contractor's obligations under the Contract.

A competent Site Agent, whose appointment shall be approved by the S.O., shall be employed by the Contractor for management on Site. The Site Agent shall have the authority to receive instructions from the S.O. andto act on behalf of the Contractor. The Site Agent shall be stationed on Site for the whole duration of the Contract and shall not be replaced without the approval of the S.O.

If the Site Agent needs to be absent fromSite for more than three (3) consecutive days, he shall give prior notice to the S.O. who may require the Contractor to temporarily appoint another Site Agent.

1.13 INSPECTION AND TESTS

The S.O. or his representative may at any stage of the Works carry out inspection, measurement and tests on any part of the Works to ensure compliance with the requirements of thisSpecification and of the Drawings.

The Contractor shall provide thenecessary attendance whenever required by the S.O. or his representative.

Notwithstanding any tests which may have been carried out off the Site, the S.O. shall be empowered to order further tests of any materials or goods tobe made on the Site and to reject such materials or goods should they fail to pass such tests on Site.

When required by the S.O., the Contractor shall submit a copy of the result of any quality control test carried out by the Contractor on his own during the progress of the Works.

1.14 COVERING UP OF WORK

Before any part of the Works is permanently covered up, the Contractor shall give due notice to the S.O. for the inspection and measurement of dimensions. The S.O. shall attend without unreasonable delay for the purpose of examination andmeasurement unless he considers it unnecessary and advises the Contractor accordingly.

1.15 OFFICE ACCOMMODATION FORS.O. AND HIS STAFF

The Contractor shall provide and maintain a site office for the use of the S.O. and his supervisory staff, all in accordance with the relevant Drawings inclusive of all furniture and fittings as shown on the Drawings.

The Contractor is permitted to provide a relocatable site office as an alternative tothe JKR designed type shown on the Drawings.




The quality of such a relocatable site office shall be of equivalent standard butnot inferior to the JKR designed type and shall be equipped with similar furniture and fittings as indicated in the JKR designed site office.

Where a relocatable site office is to be provided, the Contractor shall submit details of the relocatable site office together with his tender. Such details should include the name of the manufacturer, floor area and layout, list of furniture and fittings and brochures if available. The Contractor shall alsoindicate whether the proposed site officeis new or otherwise.

Unless otherwise shown on the Drawings, the site office is to be sited, constructed and positioned as approved by the S.O.

The Contractor shall make proper arrangements for and pay all charges in connection with conservancy. The site office shall comply with local building by-laws. It shall be erected or provided by the Contractor within four (4) weeks from the date of possession of Site.

On completion of the Works, the Contractor shall further maintain the siteoffice till the end of the Defects LiabilityPeriod unless otherwise directed by the S.O. and thereafter remove from the Sitethe site office with all furniture and fittings which become the property of the Contractor.

Where electricity and piped water are available from public utility authorities, the Contractor shall arrange for the site office to be connected to the electricity and water supplies.Otherwise, the Contractor shall supply the site office with electric power from generators and shall provide an adequate supply of water for washing and potable filtered water for drinking purposes.

Sanitary facilities with disposal to septic tanks located not nearer than 5 m from the building shall be provided.

The office shall be illuminated by fluorescent fittings giving a general levelof illumination of at least 2 lumens/ sq.m. Additional lighting in the form of wall or deck lamps shall be provided where required by the S.O. Lighting to toilets and corridors may be by tungsten filament bulbs.

Thermostatically controlled air-conditioners capable of maintaining a temperature below 23°C in the office shall be provided.

The Contractor shall arrange for the installation of a telephone with a separate connection to the telephone exchange for the exclusive use of the S.O. at all times. The telephone shall also be be fitted with 4 extensions unlessnot required by the S.O. The Contractorshall be responsible for the connection to such exchange and the payment of rental for the telephone services but the Government shall reimburse the Contractor for the cost of making calls.

Where a telephone exchange is not within practical distance, an automatic mobile telephone such as the ATUR (Automatic Telephone Using Radio) service shall be provided.

The Contractor shall keep the offices accessible at all times and in every way habitable for working purposes throughout the duration of the Contract.The Contractor shall also provide such labour and cleaning materials as are required to maintain the site office in a thoroughly clean and sanitary condition.




1.16 VEHICLES FOR THE S.O.'S STAFF

The Contractor shall provide new vehicles as listed in the B.Q. and Appendix 1C for the sole use of the S.O.and his staff at all times. All necessary fuel, oil and lubricants, general maintenance, comprehensive insurances and roadtax shall be provided by the Contractor together with a licensed and competent driver for every vehicle. Replacement vehicles shall be provided when normal vehicles are not available such as during periods of servicing, maintenance or repair. The vehicles willrevert to the Contractor at the completion of the Contract unless otherwise stated in the B.Q.

1.17 CONTRACTOR'S OFFICE AND ACCOMODATION

The Contractor shall provide and maintain a suitable office for himself and his staff in a position or positions to be approved by the S.O.

In addition, the Contractor shall provideand maintain temporary accomodation and living facilities, stores, workshops, etc., including all necessary services for water supply, drainage and lighting for his staff. Before any work can commence the Contractor shall submit to the S.O. details of the proposed buildings and services and shall obtain the S.O.'s approval together with any necessary approval in writing from the relevant statutory authority.

The Contractor shall be responsible for all fees and other charges or expenses incurred in connection with such office and housing and shall keep the whole area in a clean, tidy and well drained condition.

When instructed by the S.O., the Contractor shall remove all such buildings and appurtenant works from the Site, clean up the area and restore it to its original condition.

The Contractor shall provide adequate first aid facilities appropriate to the size and composition of his staff and labour force. The Contractor shall afford the S.O.'s site staff full use of the services and facilities as and when required.

1.18 MATERIAL TESTING LABORATORY AND STAFF

The Contractor shall provide and maintain a laboratory at the Site throughout the duration of the Contract.Earthworks and pavement construction will not be permitted to commence until the laboratory and necessary equipment have been provided.

The said laboratory shall be in accordance with the Drawings and shall be equipped as indicated in Appendix 1D. It shall be maintained in a clean and tidy condition to the satisfaction of the S.O. The laboratory shall be adequately supplied with water and electricity.

The laboratory shall be used exclusively by the S.O. and his staff. However the Contractor shall provide helpers to assistthe S.O. as and when requested.

All laboratory equipment shall become the property of the Contractor on completion of the Works.

On completion of the Works, the building shall be removed from the Site and the Site left in a neat and tidy condition.




1.19 PROVISION FOR SURVEYINSTRUMENTS AND CHAINMEN

The Contractor shall provide for the soleuse of the S.O. and his staff all such instruments, equipment and chainmen asthe S.O. may require to enable him to check the accuracy of the Contractor's setting out and any measurements taken.The chainmen shall have knowledge of Bahasa Malaysia or English and as far as possible the same men shall be provided throughout the Contract period.

The instruments and equipment to be provided are as listed in Appendix 1E.

The Contractor shall be responsible throughout the Contract period for all such instruments, equipment and chainmen and shall ensure that the instruments and equipment are at all times in good working condition and adjustment. All instruments and equipment shall remain the property of the Contractor on completion of the Works.

1.20 MAINTENANCE OF EXISTING ROADS AND PROTECTION OF TRAFFIC

1.20.1 Maintenance of Existing Roads, Bridges, Culverts, etc.

The Contractor shall maintain all sections of existing roads and all bridges, drains and culverts included therein within the Site to the conditions at the time of possession of Site for the full duration of the Contract. Such maintenance shall include routine activities such as grass cutting, clearing of drains, patching of potholes, etc.

He shall also be responsible for maintaining the free flow of traffic on these sections of existing road.

The Contractor shall arrange for the conveyance of materials and plants so asto cause minimum damage to existing roads and installations and minimum inconvenience to the public. He shall not deposit any earth, rubbish or materials upon any road, street, pavement or footway to cause hindranceor obstruction of vehicles or pedestrians.

The Contractor shall be responsible for any damage caused by any work carried out by him or by construction traffic to any existing roads or installations from whatsoever cause arising thereof and shall repair, maintain and reinstate the same to their original condition to the satisfaction of the S.O. The Contractor shall also keep such roads clear ofslurry, boulders and loose earth which may be dropped in the course of transportation.

Upon failure on the part of the Contractor to fulfill his obligations under this Section, the S.O. may take whatever action and any means necessary to satisfy the requirements and all costs incurred by the S.O. shall be deducted from any monies due or to become due to the Contractor under this Contract.

1.20.2 Temporary Diversions

Temporary diversions shall be constructed wherever the Site isintersected by existing roads, footpaths, cycle tracks, access to properties, etc.

Such diversion ways shall be of a standard of construction at least equivalent to that of the original road, path, track or access.




They shall be constructed in advanceof the closure of the existing ways and regularly maintained, for as longas required, in a satisfactory condition. On completion of thework, the original ways shall be reinstated to their original condition to the approval of the S.O. At least fourteen (14) days notice in writing of any proposed temporary diversions of traffic shall be given to the S.O. for his approval.

Where access roads are to be permanently closed by theconstruction of the Works, as shown on the Drawings, diversion ways shall not be required. Such closures shall not be effected until any specified alternative access has been provided and only with the written approval of the S.O.

The Contractor shall maintain reasonable access to all properties adjoining the Works where suchaccess exists during construction, and shall ensure that all the necessary fences, planking and gangways are adequately lit to the satisfaction of the S.O.

Where the Contractor proposes to use existing local streets astemporary diversion ways, he shall give at least fourteen (14) days notice in writing of his proposal to the S.O. for his approval. The Contractor shall maintain and/or reinstate these temporary diversion ways to their original condition throughout the entire duration of the temporary diversion, all to the satisfaction of the S.O.

If the Contractor fails to maintain and/or reinstate these temporary diversion ways to the satisfaction of the S.O., the S.O. shall have the rightto carry out these works himself and all costs incurred shall be deducted from the Contract Sum.

Where, in the opinion of the S.O., a detour is not feasible, constructionon existing public roads shall be undertaken only over half of the full width of the roadway at any time. The lengths of such half-width construction shall be kept as short as is practicable.

For all temporary diversions, the Contractor shall provide, install and maintain adequate temporary construction signs in accordance with Sub-Section 1.20.4.

1.20.3 Half-width Construction and Traffic Control

Where half-width construction is necessary, work on culverts shall be completed and the embankment adjacent to them must be reinstated so that at least half the full width shall be available for use by the public at all times.

In the event of the operation of single-way traffic becomingnecessary and when approved by the S.O. on any particular length of the Works or on the Works or on the approaches to the Works, the Contractor shall maintain through traffic routes by providing a width ofat least 3 metres for single-way traffic. He shall also provide approved electrically operated signals for traffic control on each of the affected lengths and any additional traffic signs as may be directed.




The electrical signal lights shall be automatic in operation, but the S.O. may, at any time, require them to be hand operated by a competent operator.

The Contractor shall make suitable arrangements for emergency servicing of the electrically operated traffic signals to be available at all times. Manually operated "Stop/Go"signs shall only be used with the prior approval of the S.O.; and shall, if so approved, be of the size, colour and type as shown on the Drawings and complying with the requirementsof the ARAHAN TEKNIK(JALAN) 2C/85 (Manual on Traffic Control Devices for Temporary Signs and Work Zones Control), published by Cawangan Jalan, Ibu Pejabat JKR, Kuala Lumpur.

At least fourteen (14) days notice in writing of any proposed single-way traffic system shall be given to the S.O. for his approval before such a system can be implemented.

1.20.4 Temporary Traffic Signs

The Contractor shall at all times takefull and sufficient precautions to ensure the safety of all traffic through and around the Work Site and of traffic that is diverted owing to the Works.

To this end the Contractor shall erect and maintain on the Site and at prescribed points on the approaches to the Site, all traffic signs, signals and warning lights necessary for the direction and control of traffic. The sizes of all such signs and the lettering and wording thereon shall be as shown on the Drawings and approved by the S.O. before erection.

Construction and excavation shall besign posted and, during periods of darkness, shall be lit to the approval of the S.O.

Temporary traffic signals shall comply with the requirements of theARAHAN TEKNIK (JALAN) 2C/85 published by Cawangan Jalan, Ibu Pejabat JKR, Kuala Lumpur and shall be reflectorised and kept clean and legible at all times.

The Contractor shall position, cover or remove these signs as may be directed by the S.O.

1.20.5 Temporary Works

The Contractor shall provide, maintain and remove on completion of the Works all temporary works including diversion ways, tracks, staging, bridging, etc., and shall make them safe and suitable in everyrespect for carrying all plants and materials and for all purposes relatedto the Works.

1.21 LOCATION, TEMPORARYPROTECTION AND TEMPORARY DIVERSION OF PUBLIC UTILITYINSTALLATIONS AND OTHER SERVICES

The Contractor shall be responsible for locating the positions of all public utilityinstallations, including water mains, overhead and underground cables, pipes,sewers and drains and all service connections to buildings, and where necessary, shall adopt such methods of excavation as may be required by the appropriate authorities or owners to ensure that no damage is caused to them.




The Contractor shall make good, at his own expense, any damage caused by him to the existing services to the approval of and in accordance with the instruction of the appropriate authority or owner concerned, and shall keep the Government indemnified at all times from all claims, costs and expenses which may arise on account of any damage (whether permanent, temporary or recurring) to the said services.

All such installations which are encountered in the course of the Works shall be adequately supported, slung-up, strutted or otherwise protected from injury to the satisfaction of the respective authority.

The temporary diversion or relocation of any service within or outside the Works to permit the construction of the Works shall be the responsibility of the Contractor. Where a service is required to be interrupted or relocated the Contractor shall inform and obtain the approval of the S.O. who shall notify the appropriate authority or owner of the required removal and/or relocation.

Temporary diversion shall mean works involved in the diversion of services that will be reinstated to their original position and condition on completion of the works in the affected areas. In planning his work for the diversion or relocation of services, the Contractor shall make reasonable allowance for the time necessary to obtain the S.O.'s approval for the work and for theappropriate authorities or owners to authorise the work, obtain the necessary materials and carry out the work.

The Contractor shall not be entitled to any extension of time due to his failure to allow for a reasonble period of time necessary for obtaining approval and completing the work.

1.22 WATER AND ELECTRICITYSUPPLY

The Contractor shall provide at his own risk and cost all water, lighting and electric power where required for use in the Works and shall pay all costs, fees and charges and comply with all safety regulations and statutes in connection therewith.

The Contractor shall also provide and maintain temporary water storage together with any distribution piping which may be necessary.

1.23 PROJECT SIGNBOARD

The Contractor shall provide, erect and maintain signboards at locations to be decided by the S.O. and pay all charges in connection with this, including obtaining permission, licences and fees, etc. Each sign board shall comply with the design and specification as shown onthe Drawings. On completion of the project, the Contractor shall dismantle and clear away the signboards as directed by the S.O.

1.24 PHOTOGRAPHIC RECORD OF WORKS

The Contractor shall provide a camera of reasonable quality for the purpose of taking record photographs and slides of the Works as and when directed by the S.O. The Contractor shall bear the costsof providing the film, development of film, printing two (2) copies of each exposure in 3R size and documenting the photographs in suitable albums.

The negatives of the photographs shall be the property of the Government and no prints from these negatives may be supplied to any person or persons exceptwith the approval of the S.O.




A suitably typed caption shall be affixed to the reverse side of each photograph describing the subject and the time at which it was taken. One copy of each photograph shall be signed by the Contractor and the S.O.

1.25 AS-BUILT DRAWINGS AND MICROFILMING

Drawings for recording as-built construction details of the Works shall be prepared by the Contractor and shall be certified by the S.O. or his representative. The originals, in good quality transparencies, and two (2) printed copies of all as-built drawings shall be supplied by the Contractor to the S.O. progressively as sections of the Works become completed. All drawingsshall be completed within one month after the completion of the respective section.

As-built drawings shall be A1 size (838 mm x 584 mm) unless otherwise approved by the S.O.

The Contractor shall also microfilm the as-built drawings using 35.0 mm film with the aperture card format as shown in Figure 1-1 and submit the same to theS.O.

1.26 CLEARING UP OF SITE

The Contractor shall make every effort to keep the Site in a reasonably clean and tidy condition for the duration of theWorks. He shall, in addition, from time to time on the completion of any area of the Works or where directed by the S.O.,remove rubbish, surplus materials, or any other construction debris from such areas as may be attributable to his work under this Contract and generally leave them in a satisfatory condition, to the approval of the S.O.

On completion of the Works, the Contractor shall remove all rubbish, debris and surplus materials from the Site and leave the whole Site in a neat and tidy condition to the satisfaction of the S.O.

1.27 OPPORTUNITIES FOR OTHER CONTRACTORS

The Contractor shall, when required by the S.O., afford all reasonable opportunity to any other Contractors employed by the Government and their workmen and to the workmen of the Government and of any other duly constituted authorities who may be employed in the execution on or near the Site of any work not included in the Contract.





APPENDIX 1A

GENERAL DESCRIPTION OF PROJECT




APPENDIX 1B

SCOPE OF WORKS




APPENDIX 1C

VEHICLES FOR S.O. AND HIS STAFF

All vehicles shall be NEW and of the types listed below :-

Type A - 2000 c.c. four-door, air-conditioned saloon car;

Type B - 1600 c.c. five-door, air-conditioned estate car;

Type C - 1500 c.c. four-door, air-conditioned Proton Saga;

Type D - 2000 c.c. four-wheel-drive, air-conditioned Trooper or equivalent with hard top;

Type E - 2250 c.c. four-wheel-drive, air-conditioned long-wheel- base Land Rover or equivalent with hard top.




APPENDIX 1D

LIST OF LABORATORY EQUIPMENT

The Contractor shall provide and maintain the following testing laboratory equipment which shallbecome the property of the Contractor at the end of the Contract :-

No.

(a) Soil Testing Equipment

(1) Moisture content tins - 76 mm x 25 mm with lids. 25

(2) Electric balance of 1 kg capacity, accurate to 0.1 g with a tare correction of not less than 100 g. 1

(3) Electric forced draught oven, capacity of 0.08 cu.m. 1

(4) Atterberg limit machine calibrated with a grooving device as specified in B.S. 1377. 1

(5) Glass plates - 457 mm x 609 mm x 6 mm. 2

(6) Linear shrinkage moulds - 254 mm. 5

(7) Spatulas - 152 mm. 2

(8) 203 mm diameter B.S. sieves - 75 mm, 63 mm, 50 mm, 37.5 mm, 28 mm, 25 mm, 20 mm, 14 mm, 12.5 mm, 10 mm, 9.5 mm, 6.3 mm, 5 mm, 4.75 mm, 3.35 mm, 2.36 mm, 2 mm, 1.18 mm, 600 um, 425 um, 300 um, 212 um, 150 um, 75 um. Lid and pan together with vibrating machine. 1 of each

(9) 203 mm diameter B.S. sieves - 75 um, 425 um. 2 of each

(10) Wash sieves - 75 um. 2

(11) Sample splitter - 50 mm. 2

(12) Sample splitter - 12 mm. 2

(13) Balance of 10 kg capacity, accurate to 1 g. 1

(14) Standard compaction hammer, electric motor operated, as specified in B.S. 1377. 1




No.

(15) Standard compaction mould as specified in B.S. 1377. 1

(16) Compaction mould extruder as specified in B.S. 1377. 1

(17) Steel scoop. 1

(18) Rubber mallet. 1

(19) Measuring flasks - 1000 c.c. 2

(20) Vernier calipers - 152 mm. 1

(21) Steel rule - 305 mm. 1

(22) Compression machine suitable for laboratory and field C.B.R.'s with all fittings necessary for field and laboratory operation as specified in B.S. 1377. 1

(23) C.B.R. moulds fitted with collars and base plates for compaction and soaking and tripods for small measurement fitted with dial gauges having 0.01 mm divisions and 25 mm travel as specified in B.S. 1377. 10

(24) 2.26 kg surcharge weights - ring type. 6

(25) 2.26 kg surcharge weights - horseshoe type. 9

(26) Complete field density kit, sand replacement type suitable for volume measurement of 0.005 cu.m to an accuracy of not less than 0.0001 cu.m as specified in B.S. 1377. 2

(27) Hand auger suitable for boring to depths of 3 m and supplied with 100 mm diameter heads suitable for boring in cohesive and cohesionless soils. 1

(28) Crowbar, pick and spade. 1 of each

(29) Drying pans - 406 mm x 406 mm x 76 mm. 6

(30) British Standard 1377 - "Methods of Test for Soils for Civil Engineering Purposes", latest edition. 1




(b) Concrete Testing Equipment

No.

(1) 152 mm x 152 mm x 152 mm standard concrete test cube steel moulds as specified in B.S. 1881. 6

(2) Slump cones with tamping rods as specified in B.S. 1881. 2

(3) Compacting factor apparatus as specified in B.S. 1881. 1

(4) Tank for curing of concrete specimens to accomodate 50 Nos. x 152 mm cubes in layers not more than 50 mm deep. 1

(c) Flexible Pavement Testing Equipment

(1) Metal tray, 0.6 m square or similar suitable for measuring spray rates of bituminous materials and spread rates of cover aggregate for surface dressing. 4

(2) Metal thickness gauge (or set of slotted sleeves) as specified in M.S. 30 fordetermination of aggregate flakiness index. 1

Additional items required for asphaltic concrete and/or bituminous Macadam :-

(3) Balance of 2 kg capacity, accurate to 0.1 g suitable for weighing samples suspended in liquid. 1

(4) Steel moulds for Marshall test specimens (100 mm diameter) with base, extension collar, extraction collar and extraction plate as specified in B.S. 598. 6

(5) Extractor for removing Marshall test specimens from moulds without distortion or shock as specified in B.S. 598. 1

(6) Compaction hammer and automatic compactor for Marshall test specimens as specified in B.S. 598. 1 of each

(7) Compaction pedestal and mould holder for Marshall test as specified in B.S. 598. 1 of each

(8) Thermostatically controlled hot plate. 1

(9) Thermometers for use in laboratory and in asphaltic mixes for Marshall test as specified in B.S. 598. 2 of each




No.

(10) Rubber and heat resistant gloves. 2 pairs of each

(11) Filter papers - 100 mm diameter. As needed

(12) Containers for heating aggregates and bituminous materials. As needed

(13) Pavement coring machine of the thin-walled diamond bit type for obtaining 100 mm diameter samples of bituminous surfacings. 1

(14) 100 mm diameter thin-walled diamond bits for use with pavement coring machine. As needed

(15) Tools for cutting and trimming pavement cores. As needed

(15) Metal bottles of suitable capacity for bitumen extraction by direct determination as specified in B.S. 598. As needed

(16) Machine to rotate the bottles about their longitudinal axes at a speed of between 10 rev/min to 30 rev/min as specified in B.S. 598. 1

(18) Volumetric flasks of suitable capacity. As needed

(19) Centrifuge capable of developing an acceleration of 25,000 m/sq.second as specified in B.S. 598. 1

(20) Filtration apparatus for extraction of bitumen by direct determination as specified in B.S. 598. 1

(21) Recovery apparatus for extraction of bitumen by direct determination as specified in B.S. 598.

(22) Pressure filter of appropriate size, air pump and funnel for extraction of bitumen by direct determination as specified in B.S. 598. 1 of each




No.Further items required for asphaltic concrete :-

(23) Wire basket of 6.5 mm or smaller mesh with wire hanger as specified in M.S. 30, for determination of specific gravity and water absorption of aggregates. 1

(24) Airtight container of similar capacity as wire basket above. 1

(25) Gas jar - 1.5 litre. 1

(26) Pyconometer - 1 litre. 1

(27) Warm air blower. 1

(28) Mechanical mixer of 2 kg capacity, for preparation of asphaltic concrete mixtures. 1

(29) Thermostatically controlled water bath for Marshall test specimens as specified in B.S. 598. 1

(30) Steel Marshall testing head as specified in B.S. 598. 1

(30) Compression testing machine with proving ring, capable of applying loads of up to at least 22 kN at a constant rate of strain of 50 mm + 3 mm per minute and recording the maximum load achieved as specified in B.S. 598. 1

(31) Dial gauge and mounting assembly for measuring Marshall test flows of up to 10 mm with accuracy of + 0.1 mm as specified in B.S. 598. 1

Testing which is specifically required in the Contract and any test defined in quoted BritishStandard Specifications which are required to ensure compliance with the Contract but cannot bedone in the Site testing laboratory shall be carried out at approved laboratories off the Site. Thesetests shall be carried out as directed by the S.O. The cost incurred by the Contractor shall bedeemed to have been included in the tendered rates.




APPENDIX 1E

SURVEY EQUIPMENT

The Contractor shall provide and maintain the following instruments and equipment for the purpose of measurements and setting out. These shall become the property of the Contractor at theend of the Contract :-

1 No. Theodolite of direct read out accurate to 1 second.

2 No. Automatic levels - Wild NA2 or Koni 007 or equivalent.

2 No. Levelling staves - 5 m aluminium.

1 No. 50 m x 5 mm steel measuring band divided throughout and numbered at 5 m intervals.Divided over first 30 m at 1 m intervals. Divided over first 5 m at 50 mm intervals.

1 No. Repair set for the same.

2 No. 30 m steel box tapes, white face.

2 No. 30 m fibreglass box tapes.

10 No. 2.5 m ranging rods.

2 No. 1 m spirit level, steel or aluminium.

2 No. Survey umbrellas.

Templates, straightedges, canvas bags, pegs, hammers, parangs, etc.




Figure 1.1

APPERTURE CARD FOR MICROFILM




SECTION 2

EARTHWORKS




SECTION 2 - EARTHWORKS

Page

2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL S2-35

2.1.1 Description S2-352.1.1.1 Clearing S2-352.1.1.2 Grubbing S2-352.1.1.3 Stripping Topsoil S2-35

2.1.2 Construction Methods S2-352.1.2.1 Areas To Be Cleared S2-352.1.2.2 Areas To Be Cleared, Grubbed and Stripped Of Topsoil S2-362.1.2.3 Topsoil S2-362.1.2.4 Timber S2-362.1.2.5 Structures S2-372.1.2.6 Disposal Of Material S2-37

2.2 EARTHWORKS S2-38

2.2.1 Definitions S2-38

2.2.2 General Requirements S2-39

2.2.3 Roadway Excavation S2-392.2.3.1 Dimensional Tolerances S2-392.2.3.2 Separation and Stockpiling of Suitable Material S2-402.2.3.3 Removal of Excavated Material From Site S2-402.2.3.4 Removal of Unsuitable Material S2-402.2.3.5 Replacement of Unsuitable Material Under Standing Water S2-402.2.3.6 Widening Cuts S2-402.2.3.7 Excavation of Rock S2-412.2.3.8 Storage and Handling of Explosives S2-422.2.3.9 Blasting S2-422.2.3.10 Safety Measures S2-422.2.3.11 Insecure Material S2-43

2.2.4 Earth Embankment S2-432.2.4.1 Material S2-432.2.4.2 Borrow Pits S2-432.2.4.3 Placement of Fill Material S2-432.2.4.4 Compaction S2-44

2.2.5 Rock fill Embankment S2-45




Page

2.2.6 Embankment Over Soft Ground S2-462.2.6.1 Foundation Treatment S2-462.2.6.2 Surcharge and Staged Construction S2-462.2.6.3 Settlement Markers S2-462.2.6.4 Settlement Records S2-47

2.2.7 Subgrade S2-47

2.2.8 Protective Vegetation for Erosion Control S2-482.2.8.1 Topsoil S2-482.2.8.2 Turfing S2-482.2.8.3 Seeding S2-48



SECTION 2 - EARTHWORKS

2.1 CLEARING, GRUBBING AND STRIPPING TOPSOIL

2.1.1 Description

This work shall consist of clearing, grubbing and stripping topsoil in the areas designated hereunder and/or shown on the Drawings and/or directed by the S.O., and of clearing only in other areas designated hereunder and/or shown on the Drawingsand/or directed by the S.O., all as specified herein and as required by the S.O. The work shall also includethe demolition and disposal of structures in said areas, except whereotherwise provided for in the Contract, as specified herein and as required by the S.O.

2.1.1.1 Clearing

Clearing shall consist of the cutting and/or taking down, removal and disposal of everything above ground level, including objects overhanging the areas to be cleared such as tree branches, except such trees, vegetation, structures or parts of structures, and other things which are designated in the Contract to remain, or be removed by others, or which the S.O. directs are to be left undisturbed. The materialto be cleared shall include but not necessarily be limited to trees, stumps (parts above ground), logs, brush, undergrowth, long grasses, crops, loose vegetable matter and structures (except those structures whose removal or clearance is otherwise provided for in the Contract).

Clearing shall also include thelevelling of obsolete dikes, terraces, ditches, etc., unless otherwise directed by the S.O.

2.1.1.2 Grubbing

Grubbing shall consist of the removal and disposal of surface vegetation, the bases of stumps, roots, the underground parts of structures, and other obstructions to a depth of at least 0.50 metre below ground level, all to the satisfaction of the S.O.

2.1.1.3 Stripping Topsoil

Stripping topsoil shall consist of the removal of topsoil to an average depth of at least 100 mm below ground level, and its stockpiling for use in the Works, and/or its disposal, as directed by the S.O.

2.1.2 Construction Methods

2.1.2.1 Areas To Be Cleared

The entire road reserve area shall be cleared as described above, unless otherwise shown on the Drawings and/or directed by the S.O.

Clearing shall be carried out to the extents deemed necessary andapproved or directed by the S.O. in areas outside the road reserve where channel excavation or other work is required.

In areas which are to be cleared only, and in which grubbing and stripping topsoil are not required, the methods of work shall be such as will not unduly damage the surface vegetation and topsoil, and care shall be taken




not to disturb the topsoil and the root systems of grasses and other surface vegetation. No topsoil shall be removed from such areas, except as directed by the S.O., and any topsoil, grasses andother surface vegetation otherwise removed or disturbed shall be replaced and made good at theContractor's own expense, all to the satisfaction of the S.O.

2.1.2.2 Areas To Be Cleared,Grubbed and Stripped Of Topsoil

Except as otherwise shown on the Drawings and/or directed by the S.O., clearing, grubbing and stripping topsoil shall be carried out in all areas of roadway excavation and in all areas where embankment is to be constructed,except that grubbing and stripping topsoil shall not be carried out in those areas where :-

i) embankment is to be constructed on earth designated as swamp or soft ground;

ii) embankment is to be constructed to a height at the centre-line of 1.50 metres or more on ground with a cross-slope of not more than 1(vertical) to 30 (horizontal).

Clearing, grubbing and stripping topsoil shallbe carried out to the extents deemed necessaryand approved or directed by the S.O. in areasboth inside and outside the road reserve wherechannel excavation or other work is required.

Except where further excavation is required,holes and cavities in the ground surface afterclearing, grubbing and stripping topsoil shall befilled with materials similar to the adjacentground, and such fill shall be compacted to adry density similar to that of the surroundingmaterial, all to the satisfaction of the S.O.

This work shall be considered incidental to the work of clearing,grubbing and stripping topsoil, and shall not be measured for payment.

2.1.2.3 Topsoil

Topsoil to be stockpiled for the Works shall be sufficiently fertile to promote and support the growth of vegetation, and shall betaken from such areas where clearing, grubbing and stripping topsoil is required as approved or directed by the S.O. Before stockpiling, topsoil shall be separated from objectionable materials, all to the satisfaction ofthe S.O. The Contractor shall arrange for stockpile sites either within or outside the road reserve, at his own expense, and all to the satisfaction of the S.O.

Otherwise, topsoil removed during grubbing and stripping operations shall be separated from objectionable materials and spread within the road reserve or borrow areas, or otherwise disposed of, as approved or directed by the S.O.

2.1.2.4 Timber

The ownership of timber is vested in the Government. Saleable timber shall be trimmed and stacked in accordance with the requirements of the appropriate Government agency, in accessible places within the road reserve as approved or directed by the S.O.

The Contractor shall have the right to use unsaleable timber (or saleable timber when permission is granted in writing by the




appropriate Government agency or authority) for his own purposes in connection with the Contract, always provided that heshall comply with the requirements of the S.O. agency or authority) for his own purposes in connection with the Contract, always provided that heshall comply with the requirements of the S.O.

2.1.2.5 Structures

Major structures are those which cannot practicably be cleared by bulldozer and/or hydraulic excavator, whose demolition requires pneumatic tools, explosives and/or other specialised equipment. A brief description of each major structure (if any) and depth to which extent it shall be demolished is given in the Bill of Quantities.

All fences, buildings, structures, and encumbrances of anycharacter within the limits of the road reserve, except those to be removed by others or designated to remain, shall be demolished and removed by the Contractor.

Materials designated in the Contract or directed by the S.O. to be salvaged, shall be carefully removed and stored, and shall be the property of the Government.

2.1.2.6 Disposal Of Material

Unwanted material from clearing,grubbing and stripping topsoil (including the demolition of structures) shall be disposed of asapproved or directed by the S.O.

Combustible material including all timber (except timber to be salvaged or used), all brush, stumps, roots, vegetation and other combustible refuse may be piled up within the road reserve and burned, where burning is allowed.

All burning shall be subject to the prior approval of the relevant Government authorities, and shall be carried out in conformance with all pertinent regulations. Burning shall also be carried out at such places and at such times andin such a manner as to prevent fire from damaging vegetation and property within the road reserve designated to be preserved, and from spreading to areas adjoining the road reserve and damaging vegetation and property therein.

Should the clearing, grubbing and stripping of topsoil be carried out at a time when burning is not permitted, the Contractor may pile up combustible materials within the road reserve outside the limits of the road works, and burn it at a time when burning is permitted.

Where burning is not permitted at any time, or theContractor elects not to burnunwanted material, combustible material shall be disposed of together withincombustible material.




Incombustible material, includingwhere appropriate the remains of burning, shall be disposed of in a safe and tidy manner at solid waste dumps outside the Site, unless otherwise approved or directed by the S.O. The Contractor shall be solely responsible for making the necessary agreements, and payingexpenses and claims arising from the use of such solid waste dumps whether on Government or private land.

2.2 EARTHWORKS

2.2.1 Definitions

(a) Formation Level

Formation level means the top surface of the subgrade.

(b) Subgrade

Subgrade means that part of the embankment or existing ground in cutting which is immediately below the subbase or lower subbase of the road pavement and shoulders.

(c) Common Excavation

Common excavation shall mean excavation in any materials which are not rock or artificial hard materials as defined in Sub-Sections 2.2.1 (f) and (g).

(d) Unsuitable Materials

Unsuitable materials shall include :-

i) running silt, peat, logs, stumps, perishable or toxic material, slurry or mud, or

ii) any material

- consisting of highly organic clay and silt;

- which is clay having a liquid limit exceeding 80% and/or a plasticity index exceeding 55%;

- which is susceptible to spontaneous combustion;

- which has a loss of weightgreater than 2.5% on ignition;

- containing large amounts of roots, grass and other vegetable matter.

Materials that are soft or unstable merely because they are too wet or too dry for effectivecompaction are not to be classified as unsuitable, unless otherwise classified by the S.O.

(e) Suitable Materials

Suitable materials shall mean those materials other than the unsuitable materials defined in Sub-Section 2.2.1 (d) above.

(f) Rock

Rock shall mean material found in ledges or masses in its original position which would normally have to be loosened either by blasting or by pneumatic tools or,if excavated by hand, by wedges and sledge hammers. It shall not include material which can be loosened with a track-type tractorwith mounted and drawn ripper of the following descriptions :-




i) Tractor Unit : Equipment with a minimum weight of 20 tonnes and nett horse power rating of 200 brake horse power or more. The tractor unit is to be in good condition and operated by experienced personnel skilled in the use of ripping equipment;

ii) Ripping Unit : The ripper to be attached to the tractor shall be themost efficient parallelogram type recommended by the tractor or ripper manufacturer. The ripper shall have a single shank in good working condition with sharpened cutting point.

Boulders or detached pieces shall only be regarded as rock if they individually exceed 0.5 cubic metre.

(g) Artificial Hard Material

This shall mean any hard artificial material which would require the useof blasting or approved pneumatic tools for its removal but shall exclude individual masses less than 0.5 cubic metre.

2.2.2 General Requirements

The work shall include the excavation of all types of material, backfilling, compaction, forming embankments and slopes, etc., as is necessary for the completion of the Works up to the formation levels, inaccordance with the lines, grades, dimensions, shapes and typical cross- sections shown on the Drawings and to the approval of the S.O.

The Contractor shall provide where necessary temporary water courses, ditches, drains, pumping or other means of maintaining the earthworks free from water. Such provision shall include carrying out the work of forming thecuttings and embankments in such a manner that their surfaces have at all times a sufficient gradient to enable them to shedwater and prevent ponding.

In pumping out excavations and in the lowering of water tables the Contractor shall pay due regard to the stability of all structures.

Adequate means for trapping silt shall be provided on all temporary drainage systems. Similar arrangements shall be made for all earthworks including excavations whether for pile trenches, foundations or cuttings.

Should the surface of completed areas be damaged by erosion or by any other cause the Contractor shall at his own cost make good such areas to the satisfaction of the S.O.

The Contractor shall exercise care in preventing wastage of suitable material needed for embankment or fill construction.

2.2.3 Roadway Excavation

2.2.3.1 Dimensional Tolerances

Slopes in cutting shall be trimmed mechanically to neat and even surfaces which shall have gradients not steeper than that shown on the Drawings. Widths of excavations shall not exceed the dimensions shown on the Drawings by more than 300 mm, unless otherwise approved by the S.O.




2.2.3.2 Separation and Stockpiling of Suitable Material

Where excavation reveals a combination of suitable and unsuitable materials, the Contractor shall, wherever the S.O. considers it practicable, carry out the excavation in such amanner that the suitable materialsare excavated separately for use in the Works without contamination by the unsuitable materials. The Contractor shall stockpile separately material for subgrade as specified in Sub- Section 2.2.7.

2.2.3.3 Removal of Excavated Material From Site

No excavated material shall be removed from the Site except on the direction or with the approval of the S.O. Should the Contractor be permitted to remove suitable materials from the Site to suit his operational procedure, then he shall make good any consequent deficit of fill material arising there from, at his own expense. Unless designated dump sites have been shown on the Drawings, the Contractor shall dispose of surplus suitable material at his own dump areas outside the Site as approved by the S.O. In doingso, the Contractor shall comply with statutory requirements such as payment of royalties, environmental protection, etc.

2.2.3.4 Removal of Unsuitable Material

Unsuitable material shall beexcavated to such depth and over such area as directed by the S.O. and be transported and disposed of in an approved manner. Unlessapproval of the S.O. to dump andspread the unsuitable materials within the Site is obtained, the Contractor shall be responsible for providing his own dump site for such unsuitable materials. The Contractor shall comply withstatutory requirements such as payment of royalties, environmental protection, etc. Voids created due to removal of unsuitable material shall be backfilled with suitable material compacted to a dry density not less than that of the surrounding material or that specified for the respective part of the earthworks or as directed by the S.O.

2.2.3.5 Replacement of Unsuitable Material Under Standing Water

Where it is decided by the S.O. that replacement of unsuitable material shall be done under standing water, voids created due to removal of unsuitable material shall be backfilled with hard clean crushed rock, natural gravelor sand having grading within therespective limits specified in Table 2.1.

2.2.3.6 Widening Cuts

The S.O. may instruct the Contractor or the Contractor himself may elect to obtain material for the Works by widening cuts. In the latter case, the Contractor shall first request permission in writing from the S.O.




TABLE 2.1 - GRADING LIMITS OF MATERIALS FOR REPLACEMENT OF UNSUITABLE MATERIAL

Where the rock is of satisfactory quality, the Contractor may elect to crush and screen it to produce aggregates required for concrete, roadbase, subbase, or other purposes.Excavated rock needed for earthwork construction which the Contractor elects so to use for producing select materials shall be replaced at the Contractor's own expense by borrow of satisfactory quality approved by the S.O.

Otherwise, excavated rock shall be used in the construction of embankment and fill, to the fullest practical extent, in either of the two following ways :-

i) excavated rock shall be broken down to a maximum particle size of 400 mm and used as rock fill as described in Sub-Section 2.2.5;

ii) excavated rock shall be broken down to a maximum particle size of 150 mm, blended with suitableearth fill material in a proportion not exceeding 1 rock to 1 earth, and used as common fill.

The Contractor may only waste excavated rock with the approval of the S.O. Excavated rock needed for earthwork construction which the Contractor elects to waste shall be replaced at the Contractor's own expenseby borrow of satisfactory quality approved by the S.O.


B.S. Sieve Size

% Passing By

Weight

Crushed Rock or

Gravel

63.0 mm 37.5 mm 20.0 mm 10.0 mm

100 85 - 100 0 - 20 0 - 5

Sand

10.0 mm 5.0 mm

1.18 mm 300 um 150 um

100 90 - 100 45 - 80 10 - 30 2 - 10

2.2.3.7 Excavation of Rock

Rock excavation shall be carried out by methods appropriate to Site requirements as approved by the S.O. Where explosives shall be used, the relevant security regulations dealing with purchase, transport, handling, storage and usage of explosives shall be complied with.

All material from rock excavations shall be used as far as is practicable in the Works.



2.2.3.8 Storage and Handling of Explosives

Proper buildings or magazines, with separate compartments for detonators, in suitable positions for the storage of explosives in manner and quantities to be approved shall be provided. The prevention of any unauthorised issue or improper use of any explosivebrought on the Works shall bethe responsibility of the Contractor and only experienced and responsible men shall be employed to handle explosives for the purpose of the Works.

2.2.3.9 Blasting

Explosives shall be used in the quantities and manner recommended by the manufacturers. Blasting shall be restricted to such periods as the S.O. may prescribe. If, in the opinion of the S.O., blasting would be dangerous to persons or property or to any finished work, or is being carried on in a reckless manner, he may prohibit it, and order the rock to be excavated by other means. The use of explosives in large blasts, i.e. exceeding 9 kg of explosive, as in seams, drifts, shafts, pits, or large holes, is prohibited unless authorised in writing by the S.O. Such authorisation shall not in any way relieve the Contractor of his liabilities under the Conditions of Contract.

All necessary precautions shall betaken to preserve in the soundest possible condition the materials below and beyond the lines of all excavations. Delayed blasting to reduce shock waves shall be usedto avoid damage to concrete and other works already completed. As the excavation approaches its final lines, blasting shall be carried out by means of parallel drill holes perpendicular to the toe of the excavation and parallel to the finally required face.

2.2.3.10 Safety Measures

When blasting is carried out closeto properties or roads, appropriatesafety rules shall be strictly adhered to. Where necessary or as directed by the S.O., the use ofheavy mesh blasting mats shall be used to ensure that no damage is caused to persons or property on or off Site. Special care shall be taken in wet ground to ensure that individual explosions are reduced to such size as to preclude damage to any buildingsor structures. Plaster shooting will not be permitted within 400 metres of any building or structure. If traffic on any road or railway has to be interrupted for blasting operations, the Contractor shall obtain approval of his schedule for such interruption from the appropriate authorities and shall prove to the S.O. that he has obtained it, prior to the interruption.




2.2.3.11 Insecure Material

The slopes of cuttings shall becleared of all rock fragments which move when prised witha crow-bar. Where, in the slopes of cuttings, layers of rock and soft material alternate and the S.O. considers that the slope, immediately after dressing, will not permanently withstand the effect of weather, the Contractor shall excavate any insecure material to an approved depth and build up the resulting spaces with grade 15P/20 concrete or masonry using rock similar to the adjoining natural rock so as to ensure a solid face.

2.2.4 Earth Embankment

2.2.4.1 Material

Fill materials for use in forming embankments shall be the suitable material obtained from excavation in cuttings. Where the quantity of such materials is inadequate, the Contractor shall obtain suitable materials from the designated borrow pits or from his own borrow pits which have been approved by the S.O.

2.2.4.2 Borrow Pits

The Contractor shall be responsible for locatingborrow pits. Designated borrow pits shown on the Drawings only indicate to the Contractor potential areas for borrow. Whether the Contractor obtains materials from the designated or his own borrow pit, it shall be his responsibility to ascertain the suitability of the pit with respect to the quantity and quality of the materials, whichshall be subject to the approval of the S.O. The Contractor shall pay all necessary fees, taxes or royalties to the appropriate authorities and observe all relevant regulations. The Contractor shall keep the borrow pits free from pondingwater and the excavation neat and tidy and shall carry out necessary erosion protection measures as instructed by the S.O.

2.2.4.3 Placement of Fill Material

All fill materials shall be deposited in layers. The loosedepth for each layer of fill shall be determined from the trial compaction. Each layer shall extend over the full width of the fill area and shall be compacted in accordance with the requirements of Sub-Section 2.2.4.4. Each compacted layer shall be maintained at all times with a sufficiently even surface in order to drain away the sur face water.




Where embankment is to be constructed on ground with a cross-slope flatter than 1(vertical) to 10 (horizontal) but steeper than 1 (vertical) to 30 (horizontal), the foundation material, except where this is rock, shall be scarified to a depth of 100 mm, blended with embankment fill material and compacted as described in Sub-Section 2.2.4.4.

Where embankment is to be constructed against existing embankment or on ground with across-slope of 1 or more (vertical)to 10 (horizontal), the foundation shall be excavated in all materials(including hard rock) to form benches with horizontal and vertical faces from which construction of the embankment shallproceed. The benches shall be contiguous beneath the full width of the embankment, and shall be of a suitable width to accomodateconstruction equipment such as motor-graders, trucks, rollers, etc.Scarifying of the horizontal and vertical faces of the benches shallnot normally be required, and thematerial excavated in forming thebenches may normally be used asfill in the embankment as approved by the S.O.

2.2.4.4 Compaction

(a) General

All materials used in embankments and as fill elsewhere shall be compacted as soon as practicable after being placed and spread.

Compaction shall be undertaken to the requirements of this Section by plant approved by the S.O.All compaction requirements shall be controlled by means of field density measurement.

For compaction of embankment slope, the Contractor may either extend each compacted layer beyond the design slope surface by at least 600 mm and then trim back to the required slope angle, or he may employ a tow type roller to compact thesloping surface.

(b) Compaction Trials

The B.S. 1377 Compaction Test (4.5 kg rammer method) shall be used in determining the moisture versus density relation of soil.

The Contractor shall submit tothe S.O. for his approval the proposed method of compaction for each main type of material to be used in the embankment. This shall include the type of compaction plant for each type of material and the number of passes in relation to the loose depth of material to achieve desired compaction. The maximum compacted thickness for fill shall be limited to 300 mm unless otherwise approved by the S.O. The Contractor shall carry out field compaction trials, supplemented by any necessary laboratory investigations, as required by the S.O.




This shall be done by using the procedures proposed by the Contractor for earthworks and shall satisfy the S.O. that all the specified requirements regarding compaction can be achieved. Compaction trials with the main types of material likely to be encountered shall be completed before the works with the corresponding materials will be allowed to commence. Each trialarea shall be not smaller than 8 m x 15 m.

(c) Degree of Compaction

The whole of the embankment below the top 300 mm of the subgrade shall be compacted to not less than 90% (for cohesive material) or 95% (for cohesionless material) of the maximum dry density determinedin the B.S. 1377 Compaction Test(4.5 kg rammer method).

(d) Field Density Testing

Field density tests on each layer of compacted earth fill shall be carried out using the sand replacement method in accordance with B.S. 1377 or by using other means of testing of comparable accuracy approved by the S.O.

(e) Moisture Control

Each layer of earth fill shall be processed as necessary to bring its moisture content to a uniform level throughout the material, suitable for compaction. The optimum moisture content as determined by the B.S. 1377 Compaction Test (4.5 kg rammer method) shall be used as a guide in determining the proper

moisture content at which each soil type shall be compacted. Water shall be added, or the material aerated and dried to adjust the soil to the proper moisture content to obtain the required density. A satisfactory method and sufficient equipment as approved by the S.O. shall be used for the furnishing and handling of water.

If the natural water content of suitable materials is too high for the proper compaction to be carried out, the Contractor can either bring down the moisture content by aeration or drying or alternatively replace it withsuitable materials of compactable moisture range at his own cost.

2.2.5 Rock fill Embankment

Rock used in rock fill embankments shall be of maximumparticle size of 400 mm so that it canbe deposited in horizontal layers, each not exceeding 500 mm in compacted depth and extending over the full width of the embankment except for any specified external cover to slopes or new formation level. The materials shall be spread and levelled by a crawler tractor weighing not less than 15 tonnes. Each layer shall consist of reasonably well graded rock and all large voids shall be filled with broken fragments before the next layer is placed. The top surface and side slopes of embankments so formed shall be thoroughly blinded with approved fine graded material to seal the surface.




There shall be a transition layer between rock fill and earth fill or thetop 300 mm of subgrade of at least 300 mm compacted thickness. This shall consist of uniformly graded crushed rock between 6 mm and 150mm as approved by the S.O.

Each layer of rock used as rock fill in embankments shall be systematically compacted by at least 12 passes of a vibrating roller with a static load per 25 mm width of roll of at least 45 kg or a grid roller with load per 25 mm width of roll of at least 200 kg or other approved plant.

2.2.6 Embankment Over Soft Ground

2.2.6.1 Foundation Treatment

Prior to forming embankment over soft ground, the soil overwhich fill material shall be placed shall be given strength improvement treatment as specified and to the details as shown on the Drawings or as directed or approved by the S.O. Treatment by means of replacement of unsuitable material shall be as specified in Sub-Sections 2.2.3.4 and 2.2.3.5.

The first layer or layers of fill materials shall be deposited over the full width of the embankment and berms in thicknesses and compacted as approved by the S.O. The Contractor shall provide compaction plant suitable for working over soft ground.

2.2.6.2 Surcharge and Staged Construction

Where indicated in the Contract or directed by the S.O., the embankment shall be built todifferent heights in stages with or without surcharge with allowancefor consolidation time periods in between stages, all in accordance with the Contract. Where surcharge is specified, the Contractor shall be responsible for the provision of surcharge material and the removal and disposal of excess material on completion of consolidation or when directed by the S.O.

2.2.6.3 Settlement Markers

Markers shall be provided and installed by the Contractor in the positions indicated on the Drawings for the purpose of measuring settlements taking place under the embankments during and after the construction period. The design of markers shall be as shown on the Drawings and the Contractor shall be responsible for supplyingand installing such markers and for extending the markers as the work proceeds. Adjustments to the height of markers shall be made when required by the S.O. Each marker shall be identified by painting on it the chainage of its position.

The Contractor shall take all necessary measures to protect markers from damage by plant and vehicles at all times and shallrepair any such damage to the satisfaction of the S.O. Readily visible barriers shall be installed around each marker.




2.2.6.4 Settlement Records

Joint measurement of settlement shall be taken weekly while fill is being placed in the vicinity of the markers. Thereafter, readings shall be taken fortnightly for aperiod as directed by the S.O.The readings shall be submitted on an approved printed form to be supplied bythe Contractor.

For the measurement of the volume that has settled below the original level of the foundation of the embankment, the measured settlement of each marker shall be used for volume computation following the method shown on the Drawings.

2.2.7 Subgrade

Material for the top 300 mm of subgrade shall have a minimum California Bearing Ratio (CBR) as shown on the Drawings when compacted to 95% of the maximum dry density determinedin the B.S. 1377 Compaction Test (4.5 kg rammer method) under 4 days soaked condition.

Throughout the top 300 mm of subgrade, the material shall be compacted to not less than 95% (for cohesive material) or 100% (for cohesionless material) of the maximum dry density determinedin the B.S. 1377 Compaction Test(4.5 kg rammer method).

In cut area, the top 300 mm of the subgrade shall be scarified and recompacted to 95% (for cohesive material) or 100%

(for cohesionless material) of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method). If the S.O. is fully satisfied that the subgrade in its natural state possesses a density exceeding the requirements, then the surface of the subgrade shall be trimmed and rolled to obtain a smooth finish.

Where the material in cut area is found to be unsuitable for use in the top 300 mm of subgrade it shall be removed and replaced with suitable material which shall be compacted asindicated above.

The subgrade shall be finished in a neat and workmanlike manner, and the widths of embankments and cuts shall be everywhere at least those specified or shown on the Drawings on both sides of the centreline. The top surface of the subgrade shallhave the required shape, superelevation, levels and grades andshall be finished everywhere to within + 10 mm and minus 30 mm of therequired level.

i) Where rock surface extends over the whole width of the formation :-

The rock surface shall be trimmed to a free draining profile, at or below formation levels. No high spot shall protrude above the formation levels.

Any voids or cavities more than 0.5 metre below the formation level shall be filled up with approved lean concrete having 7-day cube strength greater than 7 N/sq.mm. The rock surface shall then be brought up to the formation levels with approved




crushed rock or gravel, regulated and blinded.

ii) Where rock outcrop occurs over part of the formation only:-

The rock outcrop shall be cut down to a level not less than 300 mm below the formation level. The surface shall then be brought up to level with suitable subgradematerial.

2.2.8 Protective Vegetation for Erosion Control

2.2.8.1 Topsoil

Topsoil stockpiled for the Works in accordance with Sub- Sections 2.1.1.3 and 2.1.2.3 shall be spreadand lightly compacted to an even thickness of 50 mm as directed by the S.O. in areas to be turfed and/or seeded, or used as the S.O.shall otherwise direct for tree planting and other purposes.

2.2.8.2 Turfing

Turfing shall be carried out as soon as practicable on all earth slopes and other areas as shown on the Drawings and/or where directed by the S.O. The type of turf shall be as indicated on the Drawings or other alternative type as approved by the S.O. andshall be free of lallang and essentially free of weeds.

Turf shall be obtained in unbroken sods with a substantial amount of topsoil and shall be approximately 250 mm x 250 mm in size and 100 mm thick, from an approved source, and shall be placed in position as soon as practicable after cutting.

Turf sods shall be stacked and watered when they cannot be laid immediately after cutting.

The surfaces to be turfed shall be trimmed and thoroughly wetted. The turf shall then be carefully laid to form a complete and uniform cover as shown on the Drawings. Turf laid on slopes steeper than 1 (vertical) and 3 (horizontal) shall be pegged down with bamboo stakes approximately 250 mm in length.Approved fertiliser shall be applied after placing of turf at suitable times and at rates of application approved by the S.O.

All turf shall be regularly watered and fertilised to the satisfaction of the S.O. until the vegetation is satisfactorily established. Any dead turf shall be replaced with new turf at the Contractor's own expense.

2.2.8.3 Seeding

Seeding or hydroseeding shall be carried out as soon as practicable on slopes and other areas as shown on the Drawings and/or directed by the S.O.

The Contractor shall submit to the S.O. for his consideration andapproval, at least four (4) weeks in advance of the proposed work, full details of his proposed method of seeding or hydroseeding. The information submitted shall include, but not necessarily be limited to, a full description of the following aspects of the work :-




i) the preparation of the areas to be seeded or hydroseeded, including if appropriate the amount of topsoil to be used and its method of application;

ii) the details and results of investigations to determine whichtypes of grass and legume are compatible with the soil in the areas to be seeded;

iii) the types of grass and legume (if any) and strains of seed to be used, and the function, root and growth characteristics of each type;

iv) the rates of application of the grass and legume seeds;

v) the composition of fertiliser to be used at the time of seeding and itsrate of application;

vi) the composition of fertiliser to be used after seeding, the times of application after seeding, and the rates of application;

vii) the type of mulch to be used and its method and rate of application;

viii) the amounts of lime or other chemicals (if any) to be applied to improve the soil before, during and/or after seeding;

ix) the type and amounts of binding agent to be applied with the seeds, mulch, fertiliser, etc., as appropriate.

x) the proportions and methods of preparation of the seeding mix;

xi) the equipment and methods to be used in preparing and placing the seeding mix and other materials;

xii) the cultivation and after-care of the seeded areas, including rates and frequencies of watering, fertilising, grass cutting and general maintenance for at least 1year after seeding;

xiii) the time after seeding required forestablishing permanent, dense growth of grasses, which will require minimal maintenance;

xiv) guarantees of the success of the seeding work.

All grass shall be regularly watered untilthe vegetation is satisfactorily established to the satisfaction of the S.O.Any dead grass shall be replaced at the Contractor's own expense.





SECTION 3

DRAINAGE WORKS




SECTION 3 - DRAINAGE WORKS

Page

3.1 GENERAL S3-54

3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS S3-54

3.2.1 Description S3-54

3.2.2 Materials S3-543.2.2.1 Excavation S3-543.2.2.2 Granular Bedding Material S3-543.2.2.3 Concrete Bedding S3-543.2.2.4 Ordinary Backfill Material S3-543.2.2.5 Granular Backfill Material S3-543.2.2.6 Concrete Backfill S3-55

3.2.3 Excavation S3-55

3.2.4 Backfilling with Ordinary or Granular Backfill Material S3-56

3.3 CHANNEL EXCAVATION S3-57


3.3.2 Materials S3-57

3.3.3 Construction Methods S3-58

3.4 SURFACE DRAINAGE S3-58

3.4.1 Surface Drainage Types S3-58

3.4.2 Surface Drain Construction S3-583.4.2.1 Unlined Drains S3-583.4.2.2 Cast In Situ Concrete Drains S3-593.4.2.3 Precast Concrete Drain Sections S3-59

3.5 STONE PITCHING S3-60


3.5.2 Materials S3-603.5.2.1 Stone S3-603.5.2.2 Cement Mortar S3-60




Page

3.5.3 Construction Methods S3-603.5.3.1 Grouted Stone Pitching S3-603.5.3.2 Ungrouted Stone Pitching S3-61

3.6 GABIONS S3-61


3.6.2 Materials S3-613.6.2.1 Wire Mesh Gabions S3-613.6.2.2 Polyvinyl Chloride Coating S3-623.6.2.3 Stone S3-62


3.7 BRICKWORK S3-63


3.7.2 Materials S3-633.7.2.1 Common Bricks S3-633.7.2.2 Cement Mortar S3-63

3.7.3 Construction Methods S3-633.7.3.1 Brick Laying S3-633.7.3.2 Plastering Brickwork S3-64

3.8 SUBSOIL DRAINS S3-64

3.8.1 Description S3-643.8.2 Materials S3-64

3.8.2.1 Pipes S3-643.8.2.2 Filter Material S3-643.8.2.3 Filter Cloth S3-653.8.2.4 Cement Mortar S3-65


3.9 R.C. PIPE CULVERTS S3-66


3.9.2 Materials S3-663.9.2.1 Pipes S3-663.9.2.2 Cement Mortar S3-663.9.2.3 Bedding Material S3-66




Page

3.9.3 Excavation and Backfilling for R.C. Pipe Culverts S3-673.9.3.1 Excavation S3-673.9.3.2 Backfilling S3-68

3.9.4 Installation of R.C. Pipe Culverts S3-683.9.4.1 General S3-683.9.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars S3-683.9.4.3 Rebated Pipe Culverts S3-693.9.4.4 Spigot and Socket Pipe Culverts S3-70

3.10 CORRUGATED METAL PIPE CULVERTS S3-70


3.10.2 Materials S3-703.10.2.1 Pipes S3-703.10.2.2 Bitumen Coating S3-713.10.2.3 Bolts and Nuts S3-713.10.2.4 Cement Mortar S3-713.10.2.5 Bedding Material S3-71

3.10.3 Excavation and Backfilling for Corrugated Metal Pipe Culverts S3-72

3.10.4 Installation of Corrugated Metal Pipe Culverts S3-723.10.4.1 General S3-723.10.4.2 Mortar Lining S3-72

3.11 PRECAST BOX CULVERTS S3-72


3.11.2 Materials S3-723.11.2.1 Precast Box Culverts S3-723.11.2.2 Cement Mortar S3-723.11.2.3 Bedding Material S3-72

3.11.3 Excavation and Backfilling S3-733.11.3.1 Excavation for Precast Box Culverts S3-733.11.3.2 Backfilling S3-733.11.4 Installation of Precast Box Culverts S3-73

3.12 EXTENSION OF CULVERTS S3-74

3.12.1 Extension of Pipe Culverts S3-743.12.2 Extension of Box Culverts S3-74



SECTION 3 - DRAINAGE WORKS

3.1 GENERAL

This work shall consist of the construction of surface drains, subsoil drains, pipe culverts, box culverts, sumps and other drainage structures in accordance with this Specification or as directed by the S.O. Drainage works shall be constructed to the lines, levels, grades and cross-sections shown on the Drawings or as directed by the S.O.

3.2 EXCAVATION AND BACKFILLING FOR DRAINAGE WORKS

3.2.1 Description

This work shall consist of excavationfor the construction of surface drains,subsoil drains, cast in site box culverts, and other drainage structures, except pipe culverts, not otherwise provided for in this Specification, and shall include furnishing, placing, compacting and shaping foundation bedding materials, backfilling excavations against completed structures with suitable material or granular backfill where specified, and the removal anddisposal of all excess excavated material, in accordance with this Specification and as shown on the Drawings and as required by the S.O.

Excavation and backfill for pipe culverts and precast box culverts shall be in accordance with the provisions of Sub-Section 3.9.

3.2.2 Materials

3.2.2.1 Excavation

Material excavated shall be classified as common excavation or rock as defined in Section 2 of this Specification.

3.2.2.2 Granular Bedding Material

Granular bedding material for thefoundations of structures shall be suitably graded broken rubble, crushed stone, crushed gravel, sand or other material as specified on the Drawings or as required by the S.O.

3.2.2.3 Concrete Bedding

Concrete bedding or blinding for the foundations of structures shallconform to the requirements of Section 9 of this Specification for the class of concrete specified on the Drawings or required by the S.O.

3.2.2.4 Ordinary Backfill Material

Ordinary backfill material shall be suitable material as defined in Section 2 of this Specification. The maximum particle size of thebackfill material shall be 50 mm.

3.2.2.5 Granular Backfill Material

Granular backfill material shall be sand, crushed stone, crushed gravel or a mixture of crushed and natural aggregates, shall be essentially free from vegetative and other organic matter and clay,and shall not contain lateritic or concretionary materials.




The material shall conform to the following physical and mechanical quality requirements:-

i) the fines shall be non-plastic;

ii) sand shall have a gradation conforming to the envelope shown in Table 3.1;

TABLE 3.1 - GRADING LIMITS FOR SANDBACKFILL

3.2.2.6 Concrete Backfill

Concrete backfill where specified shall be of the grade as shown on the Drawings and shall conform to Section 9 of this Specification.

3.2.3 Excavation

The Contractor shall notify the S.O. sufficiently in advance of the beginning of any excavation so that cross-section elevations and measurements may be taken of the undisturbed ground. The natural ground adjacent to the structure shallnot be disturbed without permission of the S.O.

Trenches and foundation pits for structures and structure footings and underdrains shall be excavated to thelines, grades and elevations shown on the Drawings or as directed by the S.O. Excavations must be kept free from water and temporary drains, sumps and pumps shall be provided when necessary. The rate ofexcavation and backfill shall be approved by the S.O. The elevationsof the bottoms of footings shown on the Drawings are approximate only and the S.O. may order in writing such changes in the dimensions or elevations of footings as may be deemed necessary to secure a satisfactory foundation.

Boulders, logs and other objectionable materials encountered in excavation shall be removed.

After each excavation is completed the Contractor shall notify the S.O. to that effect and no footing, bedding material or structure shall beplaced until the S.O.


B.S. Sieve Size % Passing By Weight

10.0 mm 5.0 mm

1.18 mm 300 um 150 um

100

90 - 100 45 - 80 10 - 30 2 - 10

iii) material other than sand shall have a gradation conforming to one of the envelopes shownin Table 3.2.

TABLE 3.2 - GRADING LIMITS FOR GRANULAR BACKFILL OTHER THAN

SAND

% Passing By Weight B.S. Sieve Size

A B C

37.5mm 28.0mm 20.0mm 10.0mm 5.0mm 2.0mm 425um 75um

100

70 –100 60 – 90 45 – 75 30 – 60 20 – 50 10 – 30

0 – 2

-

100 70 - 100 45 - 75 35 - 65 25 - 50 10 - 30 0 – 2

- -

100 -

45 – 75 30 – 60 15 – 35

0 – 2



to that effect and no footing, bedding material or structure shall beplaced until the S.O. has approved the depth of excavation and the character of the foundation material.

Rock and other hard foundation material shall be cleared of all loose material and cut to a firm surface, either level or stepped or serrated, as specified or shown on the Drawings or directed by the S.O. All seams and crevices shall be cleared out and grouted with Portland cement grout at the time the footing is placed.

All loose and disintegrated rock and thin strata shall be removed. When the footing is to rest on material other than rock, special care shall be taken not to disturb the bottom of theexcavation, and excavation to final grade shall be deferred until just before the footing is to be placed. When, in the opinion of the S.O., thefoundation material is soft or mucky or otherwise unsuitable, the Contractor shall remove the unsuitable material and insert foundation fill material or concrete as specified or shown on the Drawings or directed by the S.O. If foundation fill material is required it shall be placed and compacted in layers not more than 150 mm thick or as directed by the S.O. The degree of compaction shall be equivalent to that of the surrounding foundations.

All excavation surfaces and surfaces of backfill material against which concrete is to be placed shall be even and firm and true to line and level.

All excavated material, so far as suitable, shall be utilized as backfill or embankment. The surplus material, whether or not temporarily allowed to be placed within a stream area, shall be finally disposed of in such a manner as not to obstruct the stream nor otherwise impair the efficiency or appearance of the works, nor is it to endanger the partly finished structure.

Excavated material suitable for use as backfill may be deposited by the Contractor in storage piles at points convenient for rehandling of the material during the backfilling operation.

Excavated material shall be deposited in such places and in such a manner as not to cause damage to highway, services or property either within or outside the road reserve, and so as to cause no impediment to the drainage of the Site or surrounding area.

3.2.4 Backfilling with Ordinary or Granular Backfill Material

All spaces excavated under this Specification and not occupied by a permanent structure shall be backfilled. Backfill material shall befree from large lumps, wood and other extraneous material.

Backfill not within the embankment areas shall be placed in layers not more than 250 mm in depth (compacted measurement) and shall be compacted to a density comparable with the adjacent undisturbed material.




Backfill within the embankment areas shall be made with approved material placed in uniform layers notto exceed 150 mm in depth (compacted measurement) and each layer shall be constructed in accordance with Section 2 of this Specification except that mechanical tampers may be used for compaction. Each layer of backfill shall be wetted uniformly as necessary and compacted to the same requirements as the adjacent earthwork as specified in Section 2 of this Specification. Unless otherwise approved by the S.O., hand tamping will not be accepted.

In placing backfill and embankment, the material shall be placed insofar as possible to approximately the same height on both sides of the structure. If conditions require backfilling appreciably higher on oneside, the additional material on the higher side shall not be placed until permission is given by the S.O. or until the S.O. is satisfied that the structure has enough strength to withstand any pressure created.

Backfill for embankment shall not beplaced behind the walls of box culverts until the top slab is placed for the required time and not less than three days. Backfill and embankment behind abutments held at the top by superstructure shall be carried up simultaneously behind opposite abutments and side walls.

No backfilling shall be placed against any structure until permissionshall have been given by the S.O. Jetting of fill or other hydraulic methods involving, or likely to involve, liquid or semi-liquid pressure shall be prohibited.

Special care shall be taken to preventany unduly high pressures against the structures.

The placing of embankment and the benching of slopes shall continue in such a manner that at all times there will be a horizontal berm of thoroughly compacted material for a distance at least equal to the height of the abutment or wall to be backfilled.

3.3 CHANNEL EXCAVATION

3.3.1 Description

This work shall consist of excavationfor waterway channels both inside and outside the road reserve as shown on the Drawings or directed by the S.O., and shall include all required excavation for widening, training or permanently diverting rivers, streams and irrigation and drainage channels other than drains and ditches appurtenant to the roadway, except excavation of topsoil for use in the Works and excavation required for clearing and grubbing. This work shall also include the backfilling of old channels, haulage to their points of utilization in the Works or the removal and disposal of allexcavated materials, the constructionof appurtenant bunds, dikes and berms, and the shaping and finishing of all earthworks involved in the construction of channels in accordance with the required lines, levels, grades and cross-sections.

3.3.2 Materials

Channel excavation shall be classified as common excavation or rock as specified in Section 2 of this Specification.





All suitable materials removed from channel excavations shall be used forbackfilling waterways to be abandoned and constructing bunds, dikes and other earth appurtenances as required. Surplus suitable materials shall be used as far as is practicable in constructing the roadway. The Contractor shall provide borrow of satisfactory qquality and approved by the S.O. should this be necessary to completethe work. Borrow which is requiredto replace suitable excavated materials needed for construction which the Contractor elects to waste shall not be paid for.

Excavated unsuitable material, suitable material surplus to that needed for construction and suitable material that the Contractor elects to waste, shall be disposed of at designated areas in such a manner as to present a neat appearance and not obstruct flow in any channels, ditches or drains, nor cause damage to highway works or property, all to the satisfaction of the S.O.

During construction, channel excavations shall be kept drained as far as is practicable and the work shall be carried out in a neat and workmanlike manner.

All channels and appurtenances shallbe excavated and constructed to the lines, levels, grades and cross-sections shown on the Drawings or as directed by the S.O. Excavation beyond the limits required shall not be paid for and shall be backfilled at the Contractor's expense as directed by the S.O. should he deem it necessary.

Sections of channel abandoned owing to diversions shall be backfilled as directed by the S.O.

3.4 SURFACE DRAINAGE

3.4.1 Surface Drainage Types

Surface drains of the types shown onthe Drawings shall be constructed to the lines, levels, grades and cross-sections as specified or as directed by the S.O. Surface drains shall include interceptor drains, roadside drains, embankment toe drains, shoulder drains, bench drains, berm drains, median drains, outfall drains, cascade drains, etc.

Any of the above drains may be constructed either unlined or lined using cast in situ concrete, precast or porous concrete drain sections, or stone pitching.

3.4.2 Surface Drain Construction

3.4.2.1 Unlined Drains

Excavation for unlined drains shall be trimmed to form a smooth, firm surface to the required lines, levels, grades and cross-sections as shown on the Drawings or as required by the S.O.

Any areas of over excavation shall be made good to the satisfaction of the S.O., all at the Contractor's expense.




3.4.2.2 Cast In Situ Concrete Drains

Excavation shall be carried out to the lines and levels as specified and as shown on the Drawings. Templates which may be of timber or steel shall then be provided to ensure the thickness and shape of the concrete drains. The concrete shall be poured in sections not exceeding 2 m in length and shall be carried out between end forms in alternate bays. Construction joints shall not be formed in the inverts.

All concrete shall be grade 20/20 concrete unless otherwise specified and shall conform to therequirements of Section 9 of this Specification. Weep holes shall be cast in situ as shown on the Drawings or as directed by the S.O.

3.4.2.3 Precast Concrete Drain Sections

Precast concrete block inverts shall be of the shapes and dimensions as shown on the Drawings and shall be of grade 20/20 concrete conforming to the requirements of Section 9 of this Specification or of porous concrete unless otherwise specified. The precast concrete drain sections shall be manufactured using good quality moulds and the finished product shall be round and have smooth inside surfaces all to the approval of the S.O. Ready made precast concrete drain sections may be used subject to the approval of the S.O.

Ready made precast concrete drain sections may be usedsubject to the approval of the S.O. Samples of ready made drain sections shall be submitted to the S.O. for his approval before placing of orders. Notwithstanding any approval given by the S.O., any defective or broken drain section shall be replaced by the Contractor at his own expense before or after laying in position.

Precast concrete drain sections shall be laid on concrete bedding in trenches excavated to the lines and levels as specified and jointed to produce a neat even alignment and gradient. The jointshall be grouted with 1:3 cement mortar complying with Sub-Section 3.5.2.2 and weep holes shall be provided as shown on theDrawings or as directed by the S.O.

Porous concrete shall comply with the requirements of porous concrete for pipes as described in M.S. 525. Cement and aggregates used in the manufacture of the porous concrete drain sections shall conform to the requirements of Section 9 of this Specification.

Mass concrete for bases shall be of grade 10/25 concrete or as specified and to the dimensions and thicknesses as shown on the Drawings.




3.5 STONE PITCHING

3.5.1 Description

This work shall consist of the construction of all structures or parts of structures to be composed of stonepitching either grouted or ungrouted as shown on the Drawings or as directed by the S.O. including erosion protection pavements and aprons, drain linings, culvert inlets and outlets, etc. The work shall be carried out all in accordance with this Specification and to the lines, levels, grades, dimensions and cross-sections shown on the Drawings and as required by the S.O.

3.5.2 Materials

3.5.2.1 Stone

Stone shall be clean rough quarrystone, or pit or river cobbles, or a mixture of any of these materials,and shall be essentially free from dust, clay, vegetative matter and other deleterious materials. Individual pieces of stone shall beapproximately cubical or spherical and shall have least dimensions in the range 100 to 150 mm and a maximum dimension of 250 mm, maximum, unless otherwise specified. The stone shall be hard, tough, durable and dense, resistant to the action of air and water, and suitable in all respects for the purpose intended.

3.5.2.2 Cement Mortar

Cement mortar, unless otherwise specified, shall contain 1 part ordinary Portland cement to 3 parts fine aggregate by volume. Water shall be added to the mix to produce a suitable consistency for the intended use, all to the satisfaction of the S.O. The constituent materials of the mortar shall comply with the appropriate requirements of Section 9 of this Specification.

The ingredients for mortar shall be measured in proper gauge boxes and mixed on a clean boarded platform or in an approved mechanical batch mixer.

All mortar shall be used within 30 minutes of mixing and no reworking of mortar shall be permitted thereafter.


3.5.3.1 Grouted Stone Pitching

Prior to constructing grouted stone pitching, the surfaces against which it is to be placed shall have been finished in accordance with the appropriate provisions of this Specification.Notwithstanding any earlier approval of these finished surfaces, any damage to or deterioration of them shall be made good to the satisfaction of the S.O. before grouted stone pitching is placed.




Construction of grouted stone pitching shall commence at the lowest part of each structure or section of a structure and continue progressively upward. Long structures such as drainlinings and slope protection pavements shall be constructed insections of practicable length, to the satisfaction of the S.O. The surface against which the work is to be placed shall be moistened with clean water a little in advance of construction, and covered with a layer of cement mortar about 50 mm thick. Stones shall then be firmly set byhand into the mortar, densely packed against adjacent stones and built up to form a stone structure of more or less uniform thickness which shall nowhere beless than 150 mm (measured perpendicularly to the surface covered). All the while that stones are being placed, all voids in the structure shall be packed solidly with mortar and stone spalls; however the surfaces of stones in the exposed faces and edges shall not be covered with mortar. The exposed surfaces and edges of the structure shall beconstructed such that they have as large a proportion as practicable composed of stone faces. Weep holes shall be provided as shown on the Drawings or as directed by the S.O.

Mortar which has been mixed formore than 30 minutes shall not beused in the works. Nor shall mortar be laid against the supporting surface more than 2 minutes before pitching stone and

building up the structure to full thickness is commenced on any section of the work, as the construction advances.

The work shall be carried out andfinished all to the satisfaction of the S.O.

3.5.3.2 Ungrouted Stone Pitching

Where shown on the Drawings, ungrouted stone pitching shall be hand set to provide maximum interlocking effect. The stones, the largest of which shall be used at the bottom, shall be well bedded on a 75 mm layer of gravel or aggregate rammed to aneven surface. The whole work shall be finished to the satisfaction of the S.O

3.6 GABIONS

3.6.1 Description

This work shall consist of the construction of miscellaneous erosion protection and retaining structures to be composed of stone filled wire mesh gabions. The work shall be carried out all in accordance with this Specification and as shown on the Drawings and/or as approved by the S.O.

3.6.2 Materials

3.6.2.1 Wire Mesh Gabions

Gabions shall be rectangular baskets of the required dimensions as shown on the Drawings or ordered by the S.O.Unless otherwise specified, they shall be of the following standarddimensions :-




i) width - 1.00 metre;

ii) length - 1.00, 2.00 or 3.00 metres;

iii) height - 0.50 or 1.00 metre.

Gabions longer than 1.00 m shall be divided into compartments of equal length not exceeding 1.00 m by wire mesh diaphragms securely tied along all edges. Each gabion or compartment of agabion shall be provided with at least 4 cross-connecting wires if its height is 0.50 m or less, andwith at least 8 cross-connecting wires if its height is in the range 0.50 to 1.00 metre.

Gabions shall be fabricated from steel wire manufactured in accordance with B.S. 1052 and galvanised in accordance with M.S. 407, or such similar standards as the S.O. shall approve. The galvanised wire sizes used shall be in accordance with Table 3.3.

TABLE 3.3 - GALVANISED WIRE SIZESFOR GABIONS

Gabion mesh shall be tripletwisted and shall have a uniform hexagonal pattern with openings of 100 x 120 mm or less. The mesh shall be securely tied to selvage wires to form rectangular panels which shall be securely wired together to form thecompleted gabion baskets. The ties and connections for each gabion basket shall comprise not less than 8% of its total weight, and the fabrication shall be all to the satisfaction of the S.O.

3.6.2.2 Polyvinyl Chloride Coating

When specified on the Drawings,all wire used in the fabrication of gabions and in the wiring operation during construction shall, after galvanising, have extruded on to it a coating of polyvinyl chloride (PVC). The PVC coating, not inclusive of galvanising, shall nowhere be lessthan 0.55 mm in thickness.

3.6.2.3 Stone

Stone fill for gabions shall be clean rough quarry stone, or pit or river cobbles, or a mixture of any of these materials, and shall be essentially free from dust, clay, vegetative matter and other deleterious materials. Individual pieces of stone shall have least dimensions not less than 20 mm larger than the gabion mesh openings and greatest dimensionsnot more than 250 mm. The stoneshall be hard, tough, durable and dense, resistant to the action of air and water, and suitable in all aspects for the purpose intended. The material shall be approved by the S.O.


Type of Wire

Minimum Diameter

Selvage (perimeter) wire

Mesh wire

Tying and connecting wire

3.50 mm

2.70 mm

2.20 mm




Prior to placing gabions, the surface on and against which they are to be constructed shall have been prepared and finished in accordance with the relevant provisions of the appropriateSections of this Specification. Notwithstanding any earlier approvalof these finished surfaces, any damage to or deterioration of them shall be made good to the satisfaction of the S.O. before gabions are placed.

Each gabion basket shall be put in place in its turn, completely fabricated except for the fastening down of the lid, stretched to the correct shape and dimensions, and fastened securely to all contiguous baskets along each edge with tying wire. The basket shall then be tightlypacked with approved stone by hand in such a manner that voids are kept to a practicable minimum and are uniformly distributed in the stone mass. Finally, the lid of the basket shall be securely fastened down with tying wire along all hitherto unfastened edges, all to the satisfaction of the S.O. In no case shall the weight of the finished gabion be less than 1300 kg per cubic metre.

As a gabion structure is built up, backfilling against finished gabions shall be carried out as necessary for proper progressive construction, all in accordance with the relevant provisions of the appropriate Sections of this Specification. Unlessotherwise specified, vertical joints between gabions shall be staggered in gabion structures in a pattern similar to the joints in running bond brickwork.

3.7 BRICKWORK

3.7.1 Description

This work shall include the laying of brickwork to the lines, levels and grades shown on the Drawings and/or as directed by the S.O.

3.7.2 Materials

3.7.2.1 Common Bricks

Common bricks shall be sound, hard, well burnt, of proper size and clean and shall give a clear ring when struck. They shall be Class 3 standard format complying with the requirements of M.S. 76. Bricks shall be obtained from manufacturers approved by the S.O.


Cement mortar for brickwork shall comply with the requirements of Sub-Section 3.5.2.2.


3.7.3.1 Brick Laying

Brickwork shall be executed withcement mortar and shall be of thethickness and bonds as shown on the Drawings. Bricks shall be kept damp until used and shall belaid on a full bed of mortar. The brickwork shall be true to line and plumb, and courses shall be kept truly level. The thickness of mortar joints shall not exceed 10 mm and shall be such that 4 courses of brickwork forms a height of 300 mm.




Newly laid brickwork shall be protected from the harmful effects of sunshine, rain, running and surface water and shocks. Any brickwork that is damaged shall be taken down and rebuilt and the joints raked out and pointed as directed by the S.O. Any such remedial work shall be at the Contractor's own expense.

3.7.3.2 Plastering Brickwork

All exposed brickwork surfaces shall be plastered. The plaster shall be applied in 2 coats generally to a total thickness of 20 mm and shall be finished witha steel trowel for internal surfacesand with a wooden float for external surfaces.

Plain plaster shall consist of 1 part masonry cement complying with M.S. 794 to 3 parts of sand by volume. where ordinary portland cement is used, plasticiser of a type approved by the S.O. may be added to the mixin accordance with the manufacturer's instructions.

Ordinary Portland cement and water shall comply with the appropriate requirements of Section 9 of this Specification.

Weep holes shall be provided as shown on the Drawings or as directed by the S.O.

3.8 SUBSOIL DRAINS

3.8.1 Description

This work shall include the supply and installation of subsoil drains constructed in accordance with this Specification at the locations and in accordance with the lines, levels and grades as shown on the Drawings and/or as directed by the S.O.

3.8.2 Materials

3.8.2.1 Pipes

Porous concrete pipes for subsoil drains shall comply with M.S. 525.

Clay pipes for subsoil drains shallcomply with B.S. 1196.

Polyvinyl Chloride (PVC) pipes for subsoil drains shall comply with Australian Standard Specification 2439 or B.S. 3656.

3.8.2.2 Filter Material

Filter material used in the construction of subsoil drains shall consist of hard, clean sandconforming to the grading limits given in Table 3.4. The material passing the 425 um sieve shall benon-plastic when tested in accordance with B.S. 1377.

TABLE 3.4 - GRADING LIMITS FOR FILTER MATERIAL


B.S. Sieve

Size

% Passing By

Weight

10.0mm 5.0mm 2.36mm 1.18mm 600um 300um 150um

100

90 - 100 75 - 100 55 - 90 35 - 59 8 - 30 0 - 10



3.8.2.3 Filter Cloth

The synthetic filter cloth shall be a non-woven type of approved manufacture having the followingproperties :-

(a) Chemical Composition Requirements

Fibres used in the manufacture ofthe engineering fabric shall consist of a long chain synthetic polymer, composed of at least 85% by weight of polypropylene, -ethylene, -esteramide or -vinylidene chloride and shall contain stabilisers and/or inhibitors addedto the base plastic (as necessary) to make the fabric resistant to deterioration from ultraviolet and heat exposure.

(b) Physical Property Requirements

The physical properties of the filter cloth shall comply with Table 3.5.

TABLE 3.5 - PHYSICAL PROPERTYREQUIREMENTS FOR FILTER CLOTH

(c) Filtration Requirement

Equivalent opening size of the filter cloth determined by sieving as described in ASTM D422 shallbe less than the eighty-five percentage size of the adjacent soil.

(d) Permeability Requirement

The equivalent Darcy Permeability of the filter cloth shall be greater than 10 times the Darcy Permeability of the soil to be drained.


1:3 cement mortar for use in pipe joints shall comply with Sub-Section 3.5.2.2.


Excavation for subsoil drains shall be carried out all in accordance with the appropriate provisions of Sub-Section 3.2.

Filter material as described in Sub-Section 3.8.2.2 above shall be placedand uniformly compacted by asuitable method approved by the S.O. to form a firm, even bedding forthe pipe drain as shown on the Drawings.

The pipe sections shall be set firmly against the filter material bedding with the flow lines in the design position. For pipes with mating joints, the receiving ends shall be upgrade, and the pipe joints shall be fully mated. For butt jointed pipes with collars, the pipe sections shall be fully contiguous, and the collars properly centred over the joints.


Grab Strength (ASTM D1682)

Puncture Strength (ASTM D3787 - 80a)

Burst Strength (ASTM D3786 - 80a)

0.9 kN

0.4 kN

2100 kN/sq.m



Joints shall be spot mortared as necessary to hold the pipe sections correctly centred and aligned, but notso as to unduly restrict the infiltrationof water through the joints.

Slotted or perforated pipes shall be tightly wrapped in filter cloth such that the entire length of the mortared pipe is covered by at least 2 layers ofcloth. All joints in both layers shall have an overlap of at least 100 mm and joints in the outer layer shall be offset by at least 300 mm from jointsin the inner layer, all to the satisfaction of the S.O.

After pipe laying and, if appropriate, wrapping has been approved by the S.O., the remainder of the filter material shall be placed and uniformly compacted by a suitable method approved by the S.O. to form a dense, even surround to the pipe as shown on the Drawings. Careshall be taken that the pipe is neither damaged nor displaced.

Backfill shall then be placed and compacted in accordance with the appropriate provisions of Sub-Section 3.2.4.

3.9 R.C. PIPE CULVERTS

3.9.1 Description

This work shall comprise the supply and installation of reinforced concrete pipe culverts, inclusive of excavation, backfilling, jointing, bedding, construction of headwalls, wingwalls, aprons and sumps and channel protection works, all in accordance with this Specification and the details shown on the Drawings.

3.9.2 Materials

3.9.2.1 Pipes

Reinforced concrete pipes shall conform to the requirements of M.S. 881 and shall be supplied by manufacturers approved by the S.O.

Rebated pipes of diameter 600 mm and above shall be internally rebated.

Collars shall be precast with grade 25 concrete and shall be suitably reinforced allin accordance with Section 9 of this Specification. The width of the collar shall be not less than 150 mm and the minimum thickness shall be 50 mm.

Rubber rings for spigot and socket pipes shall comply with the requirements of Type 2 as specified in B.S. 2494.


1:3 cement mortar for jointing of reinforced concrete pipes shall conform to the requirements of Sub-Section 3.5.2.2.

3.9.2.3 Bedding Material

Type A bedding shall consist of grade 20/20 concrete complying with Section 9 of this Specification.

Type B bedding shall consist of clean, natural sand or gravelly sand of suitable gradation and quality, approved by the S.O. The material shall have a maximum particle size of not more than 12 mm.




3.9.3 Excavation and Backfilling for R.C. Pipe Culverts

3.9.3.1 Excavation

(a) General

Unless otherwise directed by the S.O., prior to construction of a pipe culvert, the earthworks at the required location shall have been constructed to a level at least 600 mm above the top of culvert design levels or to the top of subgrade levels, whichever is lower.

Pipe culverts specified to be constructed in trench conditions shall be excavated in accordance with Sub-Section 3.9.3.1 (b) below.

Where drainage conditions or other circumstances so require, the S.O. may direct the Contractor to construct thepipe culvert without first constructing the earthworks tothe level specified above, in which case excavation and foundation preparation shall be in accordance with Sub-Section 3.9.3.1 (c) below.

(b) Trench Method

The trench to receive a culvertpipe shall be of sufficient width and depth to enable the placing of bedding material and construction of pipe jointsin accordance with this Specification, and the bottom of the trench shall be trimmedto a suitably smooth plane surface which shall be kept free from water, all to the satisfaction of the S.O.

Where rock or other hard unyielding foundation material is encountered in the trench, it shall be excavated toa depth below the bottom of pipe design levels of at least 300 mm or 12.5 mm per 300 mm of fill to be placed over the top of the pipe, whichever is greater, up to a maximum of 75% of the internal diameter of the pipe. The hard material so excavated shall be replaced with suitablematerial uniformly compactedin layers of not more than 150mm compacted thickness to provide satisfactory support for the pipe, all to the satisfaction of the S.O.

(c) Open Ground Method

Where existing ground levels are above top of bedding material design levels and firm foundation materials are encountered, excavation and foundation preparation shall be similar to that described in the trench method above. Otherwise a firm foundation plane shall be prepared, whichshall be essentially free draining along the line of the culvert, by trimming the existing ground, or such fill asit is necessary to place and compact, over a width sufficient to permit satisfactory construction of the pipe bedding, all to the satisfaction of the S.O. Hard materials shall be excavated from the pipe foundation overa width equal to the outside diameter of the pipe to the same depth as specified in the trench method, and shall be replaced with suitable




material uniformly compactedin layers of not more than 150mm compacted thickness to provide satisfactory support for the pipe, all to the satisfaction of the S.O.

Where soft or unstable soil is encountered in the foundation,it shall be excavated over a width of at least 1.5 times the outside diameter of the pipe on each side of the culvert centre-line to the depth directed by the S.O., and replaced with suitable material uniformly compacted in layers of not more than 150 mm compacted thickness to provide satisfactory support for the pipe, all to the satisfaction of the S.O.

3.9.3.2 Backfilling

Backfilling against reinforced concrete pipe culverts and their appurtenant structures shall be carried out in accordance with theconstruction methods described in Sub-Section 3.2.4, using material conforming to the requirements of Sub-Section 3.2.2.5. Special care shall be taken to properly compact backfill against the undersides of culvert pipes without disturbing or damaging the pipes and joints.Backfill shall be built up evenly on both sides of each pipe culvertalong its entire length.

Heavy plant and equipment shall not operate within 1.5 m of any pipe culvert until backfilling and, where appropriate, pavement construction has advanced to a stage which provides at least 600 mm of cover to the culvert. Subject to the approval of the S.O., light compaction equipmentmay be operated above pipe culverts after a minimum of 300 mm of cover has been placed andcompacted.

3.9.4 Installation of R.C. Pipe Culverts

3.9.4.1 General

The type, size and class of pipe tobe installed at each location shall be as shown on the Drawings or as directed by the S.O. Culverts shall not be installed at any location until the type of pipe, theexact location, the lines, levels and grades, the length of pipe anddetails of inlet and outlet structures have been confirmed by the S.O. In addition, special requirements recommended by the manufacturer with respect to assembly and installation shall becomplied with.

Especially where elliptically reinforced pipe sections are used, care shall be taken to ensure that the loading axes are positioned exactly vertically.

3.9.4.2 Butt Ended Pipe Culverts with Precast Concrete Collars

The pipes shall be laid on Type Abedding in conformity with the dimensions shown on the Drawings. Before placing any concrete bedding, the pipes shall be assembled complete with precast concrete collars to the




correct levels and grades on precast concrete spacing blocks of the same class of concrete as the bedding material and of sufficient size to eliminate any risk of settlement of the pipes before or during concreting.

All joints shall be fully mortared with 1:3 cement mortar before concreting of the cradle, all to the satisfaction of the S.O. The concretecradle shall be cast as one monolithicunit. Alternatively, part of the concrete cradle below the underside of the pipe may be constructed monolithically at least 24 hours before the assembly and mortaring up of the pipe sections and collars, on condition that shear connectors are provided across horizontal construction joints to the satisfaction of the S.O.

During installation, the ends of the pipes shall be butted and the collar centred about the joint using wedges or other approved means. The annular shall be completely filled with 1:3 cement mortar with only sufficient water added to ensure adequate workability and the wedgesremoved before finally fairing the joint. Special care shall be taken to ensure that excess cement mortar is neatly cleaned off. For pipes over 900 mm in diameter the jointing space shall be filled from inside the pipe after completion of embankment construction using 1:3 cement mortar. When installed, the clearance between the outer diameter of pipe and the inner diameter of collar shall be at least 20 mm.

Following pipe assembly and mortaring up as above, the remainder of the cradle shall be cast monolithically, all to the satisfaction of the S.O.

Where vertical construction jointsin the concrete cradle are unavoidable due to circumstanceson Site, transfer bars shall be provided to the satisfaction of theS.O.

Special care shall be taken when placing the concrete cradle to avoid the entrapment of air underneath the pipe. To eliminate this possibility, concrete shall be placed to one side of the pipe only until such time as the level of the concrete surface rises above the underside of the pipe on the side remote from that on which concrete is being placed. The concrete shall then be brought up at the same level on both sides of the pipe.

3.9.4.3 Rebated Pipe Culverts

The pipes shall be laid on Type Abedding in conformity with the dimensions shown on the Drawings.

The method of construction shall follow that described in Sub-Section 3.9.4.2 for butt ended pipe culverts except for the exclusion of precast concrete collars.

The rebated joint shall be internally flush and fully mortared with 1:3 cement mortar,all to the satisfaction of the S.O.




3.9.4.4 Spigot and Socket Pipe Culverts

The pipes shall be laid on Type B bedding in conformity with thedimensions shown on the Drawings. The bedding material shall be accurately shaped by a template to fit the lower part of the pipe exterior for a height of atleast 10% of the outside diameter of the pipe. Gaps shall be left in the bedding material and recessesdug in the earth foundation of sufficient width and depth to accomodate the socket without it resting on the bottom of the recess. The widths of the recesses in the foundation and thebedding shall both exceed the width of the socket by more than 50 mm.

Jointing of the pipes shall be carried out strictly in accordance with the manufacturer's recommendations, all to the satisfaction of the S.O.

Concrete pipes as specified aboveshall be laid true to line and level,each pipe being separately boned between sight rails. Pipes shall be laid in an upstream direction with the sockets towards the inlet and shall rest on even foundations for the full length of the barrel. Rubber ring joints shall be installed strictly in accordance with the manufacturer's instructions. Priorto jointing, rubber rings and jointing surfaces shall be cleaned of all contaminants except for specified lubricants. The spigot of each pipe shall be inserted concentrically in the socket of theone previously laid, and the pipe then adjusted and fixed in its correct position with the spigot correctly entered in the socket.

Care shall be taken to see that therubber ring is adequately compressed to seal the joint. All pipes shall be laid to the satisfaction of the S.O.

3.10 CORRUGATED METAL PIPE CULVERTS

3.10.1 Description

This work shall comprise the supply and installation of bolted, corrugated metal pipe culverts inclusive of excavation, backfilling, jointing, bedding, construction of headwalls, wingwalls, aprons and sumps and channel protection works, all in accordance with this Specification and the details shown on the Drawings.

3.10.2 Materials

3.10.2.1 Pipes

The pipe sections shall befabricated from zinc-coated(galvanised) steel sheetsconforming to AASHTO M218 or from structural plates conforming to AASHTO M167 depending on the pipe size requirements.

The dimensions of the pipes shallconform to AASHTO M36. All pipes shall be clearly identified by marking on each section the following information :-

i) name of manufacturer;ii) diameter of pipe;iii) gauge number;iv) date of manufacture.

The above markings shall have been marked by the manufacturer.




The Contractor shall submit to the S.O. the material test certificates from the manufacturershowing the chemical composition and mechanical properties of the base metal and the amount of zinc coating for every lot of pipes supplied. The S.O. may order further tests in thesections supplied to Site at the rate of not more than 1 in 100.

All costs on such tests shall be borne by the Contractor.

3.10.2.2 Bitumen Coating

Where specified, the pipe sections or plates shall be coated with an approved bitumen coating at the factory by the hot-dip process for Type A as specified in AASHTO M190. Before coating, any damage to the galvanising shall be made good in a manner approved by the S.O.

3.10.2.3 Bolts and Nuts

All bolts and nuts shall be of highstrength carbonated steel meeting the provisions of ASTM A449 and ASTM A563 Grade `C' respectively. The galvanising on bolts and nuts must meet the requirements of ASTM A153.

Diameters of bolt holes in the longitudinal seams, except those at the plate corners, shall not exceed the bolt diameter by morethan 3 mm. The bolt holes in the circumferential seams, including those at the plate corners, shall not exceed the bolt diameter by more than 6 mm. The minimum distance from the centre of a holeto the edge of a plate shall be 1.75 times the diameter of the bolt.

For pipe material conforming to AASHTO M218 (corrugation 68 mm pitch x 13 mm depth) with diameters of 1500 mm or smaller,12 mm diameter bolts shall be used. Bolt holes along circumferential seams shall have spacings of not more than 314mm.

For pipe material conforming to AASHTO M167 (corrugation 150 mm pitch x 50 mm depth) with diameters of 1500 mm or larger, 19 mm diameter bolts shall be used. Four bolt holes per300 mm of longitudinal seam shall be provided and these shall be staggered in rows 51 mm aapart with holes in one row in thetrough and holes in the other row in the crest of the corrugation. Bolt holes in the circumferential seams shall have spacings of not more than 254 mm.

Notwithstanding the above, the Contractor shall satisfy the S.O. as to the adequacy of all bolted connections.


1:3 cement mortar shall comply with the requirements of Sub-Section 3.5.2.2.


Corrugated metal pipe culverts shall be bedded on Type B bedding as specified in Sub-Section 3.9.2.3.




3.10.3 Excavation and Backfilling for Corrugated Metal Pipe Culverts

Unless otherwise directed and/or approved by the S.O., the pipe culvert shall be laid in a trench excavated in accordance with Sub-Section 3.9.3.1 (b).

Where the open ground method is approved, the work shall comply with Sub-Section 3.9.3.1 (c).

3.10.4 Installation of Corrugated Metal Pipe Culverts

3.10.4.1 General

The culvert sections shall be assembled, strutted, and protected during construction in accordance with the manufacturer's instructions. Special attention shall be given to the sequence oftightening bolts and the specified torque to be applied during assembly. After assembly the bitumen coating shall, where damaged, be repaired and made good with further application of the bitumen coating.

3.10.4.2 Mortar Lining

For corrugated metal pipe culverts of 1800 mm diameteror more, or where directed by the S.O. for pipes of smaller diameters, a 1:3 cement mortar lining shall cover the inverts of the pipes to a thickness of 25 mm above thecrest of the corrugations over a minimum of one third of thecircumference centrally

placed along the entire length of the culvert. The lining shall be constructed after completion of earthworks and wingwalls.

3.11 PRECAST BOX CULVERTS

3.11.1 Description

This work shall comprise the supply and installation of precast box culverts inclusive of excavation, backfilling, jointing, bedding, construction of headwalls, wingwalls, aprons and sumps and channel protection works, all in accordance with this Specification and the details shown on the Drawings.

3.11.2 Materials

3.11.2.1 Precast Box Culverts

Precast box culverts shall be of approved manufacture complyingwith Australian Standard Specification 1597 Part 1, or anyequivalent alternative standard acceptable and approved by the S.O.


1:3 cement mortar for jointing of precast box culvert sections shall conform to the requirements of Sub-Section 3.5.2.2.


Precast box culverts shall be bedded on Type B bedding as specified in Sub-Section 3.9.2.3.




3.11.3 Excavation and Backfilling

3.11.3.1 Excavation for Precast Box Culverts

Unless otherwise directed by the S.O., prior to construction of a precast box culvert, theearthworks at the required location shall have been first constructed to a level at least 600 mm above the top of the culvert design levels orto the top of subgrade levels, whichever is lower, and the precast box culvert shall then be constructed in a trench excavated in accordance with Sub-Section 3.9.3.1 (b).

Where drainage conditions or other circumstances so require, the S.O. may direct the Contractor to construct the precast box culvert without first constructing the earthworks to the level specified above, in which case excavation and foundation preparation shall be in accordance with Sub-Section 3.9.3.1 (c).

3.11.3.2 Backfilling

Backfilling against precast box culverts and their appurtenant structures shall be carried out in accordance with the construction methods described in Sub-Section 3.2.4, using materialconforming to the requirements of Sub-Section 3.2.2.5. Special care shall be taken to properly compact backfill without disturbing or damaging the precast box culvert sections.

Backfill shall be built up evenly on both sides of each box culvert along its entire length.

Unless otherwise approved bythe S.O., heavy plant and equipment shall not operate within 2.0 m of any precast box culvert until backfilling and, where appropriate, pavement construction has advanced to a stage which provides at least 300 mm of cover to the culvert.

3.11.4 Installation of Precast Box Culverts

The type and size of precast box culvert to be installed at each location shall be as shown on the Drawings or as directed by the S.O. Precast box culverts shall not be installed at any location until the exact location, the lines, levels and grades, the length of culvert and details of inlet and outlet structures have been confirmed by the S.O. In addition, special requirements recommended by the manufacturer shall be complied with.

Precast box culverts shall be laid on Type B bedding as specified in Sub-Section 3.9.4 inconformity with the dimensions shown on the Drawings. Where specified on the Drawings or directed by the S.O., Type B bedding shall be laid on a layer ofcrushed aggregate of maximum particle size not exceeding 50mm.




All joints shall be fully mortared with 1:3 cement mortar, all to the satisfaction of the S.O. In addition, a 3 mm layer of 1:3 cement mortar shall be spread on top of the legs of the invert in order to ensure uniform bearing between the invert and lid.

Lifting holes shall be filled with 1:3 cement mortar.

3.12 EXTENSION OF CULVERTS

3.12.1 Extension of Pipe Culverts

The existing wingwalls, aprons and concrete bedding shall be demolished wherever indicated on the Drawings to expose the existing pipe culvert on the side(s) to be extended. The end of the existing pipe culvert to be extended shall thenbe wire-brushed or some other means employed to give a clean pipeend.

Extension joints shall be formed as shown on the Drawings by injecting Thioflex 600 - Gun Grade (manufactured by Expandite) or its equivalent to a thickness of not less than 25 mm in the 15 mm wide gapbetween the existing pipe and the new pipe. The remaining space in the gap shall then be filled with Flexcell Expansion Filler.

Bakau piles shall be installed as shown on the Drawings, unlessotherwise directed by the S.O.

3.12.2 Extension of Box Culverts

The existing wingwalls, aprons and concrete bedding shall be demolished wherever indicated on the Drawings to expose the existing box culvert on the side(s)to be extended. The end of the existing box culvert to be extended shall then be wire-brushed or some other means employed to give a clean surface.Extension joints shall be formed as shown on the Drawings by injecting Thioflex 600 - Gun Grade (manufactured by Expandite) or its equivalent to a thickness of not less than 25 mm in the 15 mm wide gap between the existing box culvert and the new box culvert section. The remaining space in the gap shall then be filled with Flexcell Expansion Filler.

Bakau piles shall be installed as shown on the Drawings, unless otherwise directed by the S.O.





SECTION 4

FLEXIBLE PAVEMENT




SECTION 4 - FLEXIBLE PAVEMENT

Page

4.1 UNBOUND PAVEMENT COURSES S4-78

4.1.1 Lower Subbase S4-784.1.1.1 Description S4-784.1.1.2 Materials S4-784.1.1.3 Construction Methods S4-78

4.1.2 Subbase S4-794.1.2.1 Description S4-794.1.2.2 Materials S4-794.1.2.3 Construction Methods S4-80

4.1.3 Gravel Surfacing S4-814.1.3.2 Materials S4-814.1.3.3 Construction Methods S4-82

4.1.4 Crushed Aggregate Roadbase S4-834.1.4.1 Description S4-834.1.4.2 Materials S4-834.1.4.3 Construction Methods S4-84

4.2 BITUMINOUS PAVEMENT COURSES S4-85

4.2.1 Bitumen Prime Coat S4-854.2.1.1 Description S4-854.2.1.2 Materials S4-854.2.1.3 Equipment S4-854.2.1.4 Construction Methods S4-87

4.2.2 Bituminous Tack Coat S4-884.2.2.1 Description S4-884.2.2.2 Materials S4-884.2.2.3 Equipment S4-884.2.2.4 Construction Methods S4-89

4.2.3 Bituminous Surface Dressing S4-904.2.3.1 Description S4-904.2.3.2 Materials S4-904.2.3.3 Equipment S4-914.2.3.4 Construction Methods S4-93




Page

4.2.4 Asphaltic Concrete S4-994.2.4.1 Description S4-994.2.4.2 Materials S4-994.2.4.3 Asphaltic Concrete Mix Design S4-1024.2.4.4 Equipment S4-1054.2.4.5 Construction Methods S4-110

4.2.5 Bituminous Macadam S4-1164.2.5.1 Description S4-1164.2.5.2 Materials S4-1164.2.5.3 Equipment S4-1164.2.5.4 Construction Methods S4-116

4.3 SHOULDERS S4-119


4.3.2 Materials S4-1194.3.2.1 Earth Shoulders S4-1194.3.2.2 Gravel Shoulders S4-119


4.4 HORIZONTAL ALIGNMENT, SURFACE LEVELS AND SURFACE REGULARITY OF PAVEMENT COURSES S4-120

4.4.1 Horizontal Alignment S4-120

4.4.2 Surface Levels of Pavement Courses S4-120

4.4.3 Surface Regularity S4-121



SECTION 4 - FLEXIBLE PAVEMENT

4.1 UNBOUND PAVEMENT COURSES

4.1.1 Lower Subbase

4.1.1.1 Description

This work shall consist of furnishing, placing, compacting and shaping lower subbase material on a prepared and accepted subgrade in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.1.1.2 Materials

Lower subbase material shall be inorganic soil, sand, gravel, weathered or fragmented rock, or a mixture of any of these materials, essentially free from vegetative and other organic matter and expansive clay minerals. It shall have a maximum particle size of 75 mm or less, and shall have a CBR value not less than that shown on the Drawings when compacted to95% of the maximum dry densitydetermined in the B.S. 1377 Compaction Test (4.5 kg rammer method) and soaked for 4 days under a surcharge of 4.5 kg.

4.1.1.3 Construction Methods

Prior to placing any lowersubbase material, the underlying subgrade (particularly the top 300mm of the subgrade) shall havebeen shaped and compacted in

accordance with the provisions ofSub-Section 2.2.7.Notwithstanding any earlier approval of finished subgrade, any damage to or deterioration of the subgrade shall be made good to the satisfaction of the S.O. before lower subbase is constructed.

Lower subbase shall be placed over the full width of the formation to the required thickness as shown on the Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200 mm compacted thickness. Where two or more layers are required they shall be of approximately equal thickness and none shall be less than 100 mm compacted thickness.

Each layer of lower subbase shallbe processed as necessary to bring its moisture content to a uniform level throughout the material suitable for compaction, and shall then be compacted using suitable compaction equipment approved by the S.O. to not less than 95% of the maximum dry density determinedin the B.S. 1377 Compaction Test(4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction along the roadbed, and shall generally begin at the outer edge and progress uniformly towards the crown on each side in such a manner that each section receivesequal compactive effort, all to thesatisfaction of the S.O.




The lower subbase shall be finished in a neat and workmanlike manner, and shall have an average thickness over any 100 metre length not less than the required thickness. The top surface of the lower subbase shallhave the required shape, superelevation, levels and grades,and shall be everywhere within the tolerances specified in Sub-Section 4.4.

4.1.2 Subbase

4.1.2.1 Description

This work shall consist of furnishing, placing, compacting and shaping subbase material on a prepared and accepted subgradeor lower subbase in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.1.2.2 Materials

Subbase material shall be a natural or prepared aggregate comprising crushed rock, weathered or fragmented rock, gravel or crushed gravel, sand, or a mixture of any of these materials. It shall have a small proportion of plastic or non-plastic fines and shall be essentially free from vegetative and other organic matter, expansive clay minerals and lumps of clay. The material shall conform to the following physical and mechanical qualityrequirements :-

i) the liquid limit shall be not more than 25%;

ii) the plasticity index shall be not more than 6;

iii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 35;

iv) unless otherwise specified on the Drawings or directed by the S.O., the material shall have a CBR value of 30 or more when compacted to 95% of the maximum dry density determined in the B.S.1377 Compaction Test (4.5 kgrammer method) and soaked for 4 days under a surcharge of 4.5 kg;

v) the gradation shall conform to one of the envelopes shown in Table 4.1 with the fraction passing the B.S. 75 um sieve not greater than 2/3of the fraction passing the B.S. 425 um sieve.





% Passing By Weight B.S. Sieve Size

A

B

C

D

E

F

50.0 mm 25.0 mm 9.5 mm

4.75 mm 2.00 mm 425 um 75 um

100

- 30-65 25-55 15-40 8-20 2-8

100

79-95 40-75

30-60 20-45 15-30 5-20

-

100 50-85 35-65 25-50 15-30 5-20

-

100 60-100 50-85 40-70 25-45 5-20

-

100 -

55-100 40-100 20-50 6-20

-

100 -

70-100 55-100 30-70 8-25

TABLE 4.1 - GRADATION LIMITS FOR SUBBASE MATERIAL


Prior to placing any subbase material, the underlying subgrade (particularly the top 300 mm of the subgrade) or lower subbase shall have been shaped and compacted inaccordance with the provisions of Sub-Section 2.2.7 or Sub-Section 4.1.1.3 as appropriate. Notwithstanding any earlier approval of finished subgrade or lower subbase, any damage to or deterioration of the subgrade or lower subbase shall be made good to the satisfaction of the S.O. beforesubbase is constructed.

Subbase shall be placed with equipment approved by the S.O. over the full width of the formation to the required thickness as shown on the Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200 mm compacted thickness. Where two or more layers are required they shall be of approximately equal thickness and none shall be less than 100 mm compacted thickness.

Each layer of subbase shall be processed as necessary to bring its moisture content to a uniform level throughout the material

suitable for compaction, and shallthen be compacted using suitable compaction equipment approved by the S.O. to not less than 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction along the carriageway, and shall generally begin at the outer edge and progress uniformly towards the centre on each side, except on superelevated curves where rolling shall begin at the lower edge and progress uniformly towards the higher edge. In all cases compaction shall be carried out in such a manner that each section receives equal compactiveeffort, all to the satisfaction of theS.O.

Throughout the placing, adjustment of moisture content and compaction of subbase material, care shall be taken to maintain a uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction of the S.O.



The subbase shall be finished in aneat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of thecentre-line; and its average thickness over any 100 metre length shall be not less than the required thickness. The top surface of the subbase shall have the required shape, superelevation, levels and grades,and shall be everywhere within the tolerances specified in Sub-Section 4.4.

4.1.3 Gravel Surfacing

4.1.3.1 Description

This work shall consist of furnishing, placing, compacting and shaping gravel surfacing material on a prepared and accepted subgrade or lower subbase in accordance with this Specification and the lines, levels,grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.1.3.2 Materials

Gravel surfacing material shall bea natural or prepared soil-aggregate mixture comprising gravel and sand size particles together with a small proportion of plastic fines, and shall be essentially free from vegetative and other organic matter, expansive clay minerals and lumps of clay. The material shall conform to the following physicaland mechanical quality requirements :-

i) the liquid limit shall be not more than 35%;

ii) the plasticity index shall be in the range 4 to 10;

iii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 35;

iv) the gradation shall conformto one of the envelopes shown in Table 4.2 with the fraction passing the B.S. 75 um sieve not greater than 2/3 of the fraction passing the B.S. 425 um sieve.


TABLE 4.2 - GRADATION LIMITS FOR GRAVEL SURFACING

% Passing By Weight B.S. Sieve

Size

A

B

C

D

37.5 mm 12.5 mm 4.75 mm 2.00 mm 425 um 75 um

100

45 - 75 30 - 60 20 - 45 15 - 30 8 - 20

100

55 - 85 35 - 65 25 - 50 15 - 30 8 - 20

100

60 - 100 50 - 85 40 - 70 25 - 45 8 - 20

100

- 55 - 90 40 - 70 20 - 50 8 - 25



Material with a maximum particle size of 37.5 mm, while otherwise not conforming to the gradation specification but satisfying the other requirements, shall be acceptable provided that it shall have a CBR value of 30 or more when compacted to 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method) and soaked for 4 days under a surcharge of 4.5 kg.


Prior to placing any gravel surfacing material, the underlyingsubgrade (particularly the top 300mm of the subgrade) or lower subbase shall have been shaped and compacted in accordance with the provisions of Sub-Section 2.2.7 or Sub-Section 4.1.1.3 as appropriate. Notwithstanding any earlier approval of finished subgrade or lower subbase, any damage to or deterioration of the subgrade or lower subbase shall be made good to the satisfaction of the S.O. before gravel surfacing is constructed.

Gravel surfacing shall be placed to the required width and thickness as shown on the Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200 mm compacted thickness. Where twoor more layers are required they shall be of approximately equal thickness and none shall be less than 100 mm compacted thickness.

Each layer of gravel surfacing shall be processed as necessary tobring its moisture content to a

uniform level throughout the material suitable for compaction, and shall then be compacted using suitable compaction equipment approved by the S.O. to not less than 95% of the maximum dry density determinedin the B.S. 1377 Compaction Test(4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction along the carriageway, and shall generally begin at the outer edge and progress uniformly towards the centre on each side, except onsuperelevated curves where rolling shall begin at the lower edge and progress uniformly towards the higher edge. In all cases compaction shall be carried out in such a manner that each section receives equal compactiveeffort, all to the satisfaction of theS.O.

Throughout the placing, adjustment of moisture content and compaction of gravel surfacing material, care shall be taken to maintain a uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction of the S.O.

The gravel surfacing shall be finished in a neat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre length shall be not less than the required thickness and its minimum thickness at any point shall be not less than the requiredthickness minus 20 mm.




The top surface of the gravel surfacing shall have the required shape, superelevation, levels and grades, and shall be everywhere within 10 mm of the required plane or such higher, approximately parallel plane, as the S.O. shall approve.

4.1.4 Crushed Aggregate Roadbase

4.1.4.1 Description

This work shall consist of furnishing, placing, compacting and shaping crushed aggregate roadbase material on a prepared and accepted subgrade or lower subbase or subbase in accordancewith this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.1.4.2 Materials

Crushed aggregate roadbase material shall be crushed rock, or crushed gravel, or a mixture of crushed and natural aggregates, which is hard, durable, clean and essentially free from clay and other deleterious materials.

The material shall conform to the following physical and mechanical quality requirements:-

i) the plasticity index shall be not more than 6;

ii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 30;

iii) the flakiness index when tested inaccordance with M.S. 30 shall benot more than 30;

iv) not less than 80% of particles retained on the B.S. 4.75 mm sieve shall have at least one fractured face;

v) the weighted average loss of weight in the sodium sulphatesoundness test (5 cycles) when tested in accordance with AASHTO Test Method T 104 shall be not more than 12%;

vi) the material shall have a CBRvalue of not less than 80 whencompacted to 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method) and soaked for 4 days under a surcharge of 4.5 kg;

vii)the gradation shall comply with the envelope shown in Table 4.3 for the type specified.

TABLE 4.3 - GRADATION LIMITS FORCRUSHED AGGREGATE ROADBASE


% Passing By Weight

B.S. Sieve

Size

Type I

Type II

50.0 mm 37.5 mm 28.0 mm 20.0 mm 10.0 mm 5.0 mm 2.36 mm 2.00 mm 600 um 425 um 75 um

100

95 - 100 -

60 - 80 40 - 60 25 - 40 15 - 30

- 8 – 22

- 0 – 8

100

85 - 100 70 - 100 60 - 90 40 - 65 30 - 55

- 20 - 40

- 10 - 25 2 - 10




Prior to placing any crushed aggregate roadbase material, the underlying subgrade or lower subbase or subbase shall have been shaped and compacted in accordance with the provisions ofthe appropriate Section of this Specification. Notwithstanding any earlier approval of finished subgrade or lower subbase or subbase, any damage to or deterioration of the subgrade or lower subbase or subbase shall bemade good to the satisfaction of the S.O. before crushed aggregateroadbase is constructed.

Crushed aggregate roadbase shallbe placed to the required width and thickness as shown on the Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200 mm compacted thickness. Where twoor more layers are required they shall be of approximately equal thickness and none shall be lessthan 100 mm compacted thickness. Spreading shall be done by a mechanical spreader approved by the S.O. or, if approved by the S.O., by motor grader.

Prior to spreading, crushed aggregate roadbase shall be processed as necessary to bring its moisture content to a uniform level throughout the material suitable for compaction. Spread material shall be maintained at the correct moisture content for proper compaction by sprinkling with water or drying as may be necessary, and shall be compacted using suitable compaction equipment approvedby the S.O. to not less than 95%

of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method).

Compaction shall be carried out in a longitudinal direction along the carriageway, and shall generally begin at the outer edge and progress uniformly towards the centre on each side, except onsuperelevated curves where rolling shall begin at the lower edge and progress uniformly towards the higher edge. In all cases compaction shall be carried out in such a manner that each section receives equal compactiveeffort, all to the satisfaction of theS.O.

Throughout the placing, adjustment of moisture content and compaction of crushed aggregate roadbase material, care shall be taken to maintain a uniform gradation of the material and prevent its separation into coarse and fine parts, all to the satisfaction of the S.O.

The crushed aggregate roadbase shall be finished in a neat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre length shall be not less than the required thickness. The top surface of the crushed aggregate roadbase shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances specified in Sub-Section 4.4.2.




4.2 BITUMINOUS PAVEMENT COURSES

4.2.1 Bitumen Prime Coat

4.2.1.1 Description

This work shall consist of the careful and thorough cleaning of the surface of a prepared and accepted crushed aggregate roadbase, and the furnishing and application to the cleaned roadbase surface of a bituminous priming material, all in accordance with this Specification and the lines, dimensions and cross-sections shown on the Drawings and/or asrequired by the S.O.

4.2.1.2 Materials

The bituminous priming material shall be either cut-back bitumen or bitumen emulsion as stated in the Bill of Quantities.

Cut-back bitumen shall be grade RC-70 or MC-70 conforming to the requirements of M.S. 159.

Bitumen emulsion shall be slow setting, grade SS-1 or SS-1K, conforming to the requirements of M.S. 161, as appropriate to thetype of roadbase material to be primed and approved by the S.O.

4.2.1.3 Equipment

The equipment used by the Contractor shall include a power broom, a compressed air blower, a self-propelled pressure distributor for bituminous material, and as necessary, equipment for storing and heatingbituminous material.

(a) Power Broom

The power broom shall be a rotary type specifically designed for sweeping road surfaces, and shall be approved by the S.O.

(b) Compressed Air Blower

The compressed air blower shall comprise a portable air compressor of 3 cu.m/min. incapacity at 0.7 N/sq.mm delivery pressure with a suitable hose and nozzle for blowing clean a road surface after power brooming, and shall be approved by the S.O.

(c) Pressure Distributor for Bituminous Material

The distributor shall be a purpose built model of recognised manufacture and shall be approved by the S.O.It shall conform to the requirements described hereunder.

The distributor shall have a suitable capacity and shall be equipped with a gas or oil fired heating system capable of heating a full charge of bituminous material to l80°C. The heating system shall be such that overheating of the bituminous material will not occur and shall be of a type in which flames from the burner do not come into direct contact with the casing of the tank containing the bituminous material. The tank shall be insulated in sucha manner that when filled with bituminous material at l80°C and not heated,




the drop in temperature shall be less than 3°C per hour. Athermometer shall be provided to measure continuously the temperature of the bituminous material in the tank and shall be so arranged that the highest temperature in the tank is measured. The tank shall be fitted with an accurately calibrated dipstick or contents gauge, and the pipe for filling the tank shall be fitted with an easily replaceable filter.

The distributor shall run on pneumatic tyred wheels of such width and number that the load produced on the road surface when the vehicle is fully charged shall not exceed l2 kg/mm of tyrewidth. The vehicle shall be equipped with a `fifth wheel' tacheometer system to accurately measure its forward speed during spraying operations.

The distributor shall be equipped with a full circulation type spray bar with nozzles from which the bituminous material is sprayed onto the road surface uniformly over the full spraying width. Thespraying width shall be variable in increments of not more than 100 mm up to a maximum of 5.0 metres. The spraying pump shall be driven by a separate power unit and shall be equipped with an accurate pressure gauge and an accurate flow rate gauge or meter. On the suction side the pump shall be fitted with an easily replaceable filter. The spray bar and pump shall be so designed that bituminous materialat even temperature and uniform pressure may be sprayed uniformly over the spraying width atcontrolled rates in the range

0.25 to 8.0 litres/sq.m at normal distributor operating speeds, suchthat deviation from the prescribedrate of application shall not exceed 10%.

The distributor shall be equipped with a hand spraying system.

The meters for the `fifth wheel' tachometer system and the bituminous material pumping flow rate, pumping pressure and temperature shall be located in such a manner that the vehicle driver can easily read them while operating the distributor. The spray bar shall be controlled by a second operator riding at the rear of the vehicle in such a position that all the discharge sprays are inhis good view.

All measuring equipment on the distributor shall have been recently calibrated, and accurate and satisfactory records of the calibrations shall be submitted to the S.O. If in the course of the work the rates of application of bituminous material are found to be inaccurate, the distributor shallbe withdrawn from the Works and recalibrated to the satisfaction of the S.O. before being returned to service.

The S.O. may require such performance tests as he considers necessary to check that the distributor is operating satisfactorily. As directed by the S.O., the Contractor shall make the distributor and its equipment available for such tests and shall supply all necessary assistance, materials, tools, testing apparatus,etc., all at the Contractor's own expense.




(d) Storage and Heating Facilitiesfor Bituminous Material

Tanks for storage of bituminous material shall have a capacity suited to the proposed rate of utilisation of the material and the method and frequency of its delivery to the Works, all to the satisfaction of the S.O. The tanksand, where necessary, barrel decanters shall be equipped with heating systems which provide for effective and positive control of the temperature of the bituminousmaterial at all times up to the temperature required for utilisation. The method of heating shall be such that neither flames nor the products of combustion shall come into direct contact with the bituminous material or thecasing of its immediatecontainer, and such that no portion of the bituminous material shall be subject to overheating.


(a) General Conditions

Bitumen prime coat work shall only be carried out in dry, warm weather when the surface to be treated is essentially dry.

(b) Surface Preparation and Cleaning

Prior to applying the prime coat, the crushed aggregate roadbase shall have been shaped and compacted in accordance with the provisions of Sub-Section 4.1.4.3.

Notwithstanding any earlier approval of finished crushed aggregate roadbase, any damage to or deterioration of the roadbase shall be made good to the satisfaction of the S.O. before prime coat is applied.

Immediately prior to applyingthe bituminous material, the full width of the surface to be treated shall be swept using a power broom followed by a compressed air blower and, ifnecessary, scraped using hand tools to remove all dirt, dust and other objectionable material, all to the satisfactionof the S.O.

(c) Application of Bituminous Material

The bituminous priming material shall be sprayed on to the cleaned roadbasesurface by means of a pressure distributor. Any areas inaccessible to the distributor spray bar shall be treated using the distributor's hand spraying system. The rate or rates of application shall be as directed by the S.O. based on the results of test applications, but shall usually be in the range 0.5 to 1.0 litre/sq.m. The temperature of cut-back bitumen shall be maintained in the range 50°C to 70°C during spraying operations. For bitumen emulsions, the spraying temperature shall be in the range 25°C to 45°C.




If necessary, in order to prevent the bituminous material from flowing on the sprayed surface, the prescribed prime coat shall be applied in two separate spraying operations. Where the condition of the treated surface indicates that it is necessary, bituminous material additional to that prescribed shall be applied as the S.O. shall direct.

Prime coat shall be distributeduniformly over the surface to be treated without streaking; the quantities applied shall notdeviate by more than 10% from those prescribed. Areas with insufficient bituminous material shall be resprayed as necessary to make up the deficiency, all to the satisfaction of the S.O.

The surfaces of structures, road furniture and trees adjacent to the areas being sprayed shall be protected in such a manner as to prevent their being spattered or marred by bituminous material. Bituminous materialshall not be discharged into road drains, gutters, etc.

(d) Curing and Opening to Traffic

Prime coat shall normally be left undisturbed for at least 24 hours after application and shall not be opened to traffic until, in the opinion of the S.O., it has penetrated the roadbase and cured sufficiently so that it will not be picked up by the wheels ofvehicles.

The Contractor shall maintain the prime coat, all to the satisfaction of the S.O., until the overlying pavement course is constructed, which shall not be within 24 hours after the application of the bituminous priming material nor within such longer period as is required, in the opinion of the S.O., for the prime coat to achieve maximum penetration of the roadbase and become fully cured.

4.2.2 Bituminous Tack Coat

4.2.2.1 Description

This work shall consist of the careful and thorough cleaning of the surface of a prepared and accepted bituminous or bitumen primed pavement course, and the furnishing and application to the cleaned surface of a bituminous tack coat prior to the constructionof an overlying bituminous pavement course, all in accordance with this Specification and the lines, dimensions and cross-sections shown on the Drawings and/or asrequired by the S.O.

4.2.2.2 Materials

Bituminous tack coat material shall be rapid setting bitumen emulsion of grade RS-1 or RS-1K conforming to the requirements of M.S. 161.

4.2.2.3 Equipment

The equipment shall be as specified in Sub-Section 4.2.1.3.






Bituminous tack coat shall only be applied to a clean, dry, bituminous or bitumen primed surface.

Bituminous tack coat shall only be applied as far in advance of the construction ofthe overlying bituminous pavement course as is necessary to achieve a satisfactory degree of tackiness before the overlying material is placed, all to the satisfaction of the S.O.


Prior to applying bituminous tack coat, the surface to be treated shall have been prepared in accordance with the appropriate Sections of this Specification. Notwithstanding any earlier approval of this surface, any damage to it or deterioration of it shall be made good before tack coat is applied.

Immediately prior to applyingbituminous tack coat, the full width of the surface to be treated shall be swept using a power broom followed by a compressed air blower, and if necessary, scraped using hand tools, to remove all dirt, dust and other objectionable material, all to the satisfactionof the S.O.


The bituminous tack coat shall be sprayed on to the cleaned bituminous or bitumen primed surface by means of a pressure distributor. Any areas inaccessible to the distributor spray bar shall be treated using the distributor's hand spraying system. The rate or rates of application shall be asdirected by the S.O. based onthe results of test applications,but shall usually be in therange 0.25 to 0.55 litres/sq.m.The temperature of the bituminous material shall be maintained in the range 25°C to 45°C during spraying operations.

Tack coat shall be distributed uniformly over the surface to be treated without streaking; the quantities applied shall notdeviate by more than 10% from those prescribed. Areas with bituminous material in excess of these limits shall have the excess removed at the Contractor's expense, and areas with insufficient bituminous material shall be resprayed as necessary to make up the deficiency, all to the satisfaction of the S.O.

The surfaces of structures, road furniture and trees adjacent to the areas being sprayed shall be protected in such a manner as to prevent their being spattered or marred by bituminous material. Bituminous materialshall not be discharged into road drains, gutters, etc.




Traffic shall be kept off the tack coat at all times, and the Contractor shall maintain the tack coat, all to the satisfaction of the S.O., until the overlying pavement course is constructed.

4.2.3 Bituminous Surface Dressing

4.2.3.1 Description

This work shall consist of the careful and thorough cleaning of the surface of a prepared and accepted bituminous or bitumen primed pavement course, and the furnishing and placing on the cleaned surface of one or two applications of bituminous material and cover aggregate, all in accordance with this Specification and the lines, dimensions and cross-sections shown on the Drawings and/or asrequired by the S.O. When one application of bituminous material and cover aggregate is placed the term `single bituminous surface dressing' (SBSD) shall apply, and when two applications of bituminous material and cover aggregate are placed, the term `double bituminous surface dressing' (DBSD) shall apply.

4.2.3.2 Materials

(a) Bituminous Material

Bituminous binder for bituminous surface dressing shall be penetration graded bitumen, or cut-back bitumen,or bitumen emulsion as shown on the Drawings or otherwise specified.

Penetration graded bitumen shall be 80-100 grade conforming to M.S. 124.

Cut-back bitumen shall be grade RC-70 or MC-70 conforming to M.S. 159.

Bitumen emulsion shall be rapid setting of grade RS-1, RS-1K, RS-2, RS-2K or RS-3K conforming to M.S. 161. The grade of emulsion selected shall be anionic or cationic as appropriate to the type of rock from which the cover aggregate is derived, and shall be approved by the S.O.

(b) Additives for Bituminous Material

An adhesion and anti-stripping agent shall be added to the bituminous material if the S.O. shall so direct or approve. The additive shall beof a type approved by the S.O. and the required quantityof additive shall be thoroughly mixed with the bituminous material in accordance with the manufacturer's instructions or as directed by the S.O. for such time as is necessary to produce a homogenous mixture.

(c) Aggregates for Bituminous Surface Dressing

For single bituminous surface dressing the cover aggregate shall be nominal 20 mm, 14 mm, 10 mm or 6 mm size chippings as shown on the Drawings and/or directed by the S.O.




For double bituminous surface dressing the cover aggregate for the first application of bituminous material and cover aggregate shall be nominal 20 mm size chippings, and the cover aggregate for the second application of bituminous material and cover aggregate shall be nominal 10 mm size chippings.

Cover aggregates shall be screened, crushed stone and shall comprise clean, dry, hard, tough, sound, angular and cubical chippings free from vegetative and other organic matter, clay and other deleterious substances, and containing few, if any, flaky or elongated particles. Dusty chippings shall be washed clean, all to the satisfaction of the S.O. Cover agregates shall conform to the followingphysical and mechanical requirements :-

i) using the type of bituminous material to be used in the Works, treated with additive if so required, the coated area inthe coating and stripping test for bitumen aggregatemixtures, AASHTO Test Method T 182, shall not be less than 95%;

ii) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 30;

iii) the weighted average loss of weight in the sodium sulphate soundness test (5 cycles) when tested in accordance with AASHTOTest Method T 104 shall be not more than 12%;

iv) the flakiness index when tested in accordance with M.S. 30 shall be not more than 25;

v) the polished stone value when tested in accordance with M.S. 30 shall be not less than 40;

vi) the gradation shall conform to the appropriate envelope shown in Table 4.4.

4.2.3.3 Equipment

The Contractor shall provide all the plant and equipment necessary for executing the work in accordance with this Specification, and shall furnish the S.O. with such details of particular items of equipment, e.g. manufacturer, model type, capacity, weight, etc., as the S.O. shall require.

The equipment shall include a power broom, a compressed air blower, a self-propelled pressure distributor for bituminous material, all necessary equipmentfor storing and heating bituminous material, aggregate spreading equipment, a suitable number of tip-trucks and a self-propelled pneumatic tyred roller.




(e) Aggregate Spreading Equipment

Aggregates shall be placedusing mechanical spreaders of a type approved by the S.O. The spreaders shall be capable of applying aggregate uniformly over the full width of the area being treated and shall have controls to regulate the rate of spread as required by this Specification, all tothe satisfaction of the S.O.

(f) Tip-Trucks

The Contractor shall provide a suitable number of tip-trucks of a type approved by the S.O., capable of spreading aggregate in accordance with this Specification.


TABLE 4.4 - GRADATION LIMITS FOR BITUMINOUS SURFACE DRESSING

% Passing By Weight B.S.

Sieve Size

Nominal 20 mm

Chippings

Nominal 14 mm

Chippings

Nominal 10 mm

Chippings

Nominal

6 mm Chippings

25.0 mm 20.0 mm 14.0 mm 10.0 mm 6.3 mm

4.75 mm 2.36 mm

100 85 - 100 0 - 20

- -

0 - 5 0 - 2

- 100

85 - 100 0 - 20

- 0 - 5 0 - 2

- -

100 85 - 100 0 - 20 0 - 10 0 - 2

- - -

100 85 - 100 0 - 25 0 - 10

(a) Power Broom

The power broom shall be as specified in Sub-Section4.2.1.3(a).

(b) Compressed Air BlowerThe compressed air blower shall be as specified in Sub-Section 4.2.1.3 (b).

(c) Pressure Distributor for Bituminous Material

The distributor shall be as specified in Sub-Section 4.2.1.3(c).

(d) Storage and Heating Facilities for Bituminous Material

Storage and heating facilities for bituminous material shall be as specified in Sub-Section 4.2.1.3 (d).



(g) Pneumatic Tyred Roller

The pneumatic tyred rollershall be of recognised manufcature and shall be approved by the S.O. It shall conform to the requirements described hereunder.

The pneumatic tyred rollershall be self-propelled and capable of being reversed without backlash; it shall be equipped with power steering and dual controls allowing operation from either the left or right side.

The roller shall have nine wheels equipped with smooth treaded tyres all ofthe same size and construction, and capable of operating at inflation pressures of up to 0.9 N/sq.mm. Five wheels shall be on the driven axle and four on the steering axle, all equally spaced onboth axles and arranged sothat the tyres on the steering axle track midwaybetween those on the driven axle with a small overlap. The roller shall beequipped with water tanks,sprinkler systems and padsof coconut matting to keepall tyres evenly wetted during operation.

The roller shall be equipped with means of adjusting its total weight by ballasting so that the load per wheel can be varied in the range 1.0 to 2.0 tonnes.

In operation, the ballasted weight and the tyre inflation pressure shall be adjusted to meet the requirements of each particular operation. Each tyre shall be kept inflated at the specified pressure such that the pressure difference between any two tyres shall not exceed 0.04 N/sq.mm. Means shall be provided for checking and adjusting tyre pressures at all times at the place of the works.

The Contractor shall provide the S.O. with a calibration chart for the roller showing the relationship between the quantity or depth of ballastand total weight, and also a chart showing the relationship between wheel load, tyre inflation pressure and contact pressure.



Bituminous surface dressing shall only be carried out in dry, warm weather when the surface to be treated is dry. Work shall be discontinued when rain appears imminent and during periods of strong wind.

The S.O. may order the discontinuation of work on account of adverse weather, unsatisfactory condition of materials, equipment or




surface to be treated, or such other conditions as he shall consider detrimental to the work.


Prior to constructing a bituminous surface dressing, the surface to be treated shall have been prepared in accordance with the appropriate Sections of this Specification.Notwithstandingany earlier approval of this surface, any damage to or deterioration of it shall be made good before surface dressing is commenced.

Immediately prior to commencing surface dressing,the full width of the surface tobe treated, together with an additional 300 mm width on each side, shall be swept using a power broom followed by a compressed air blower and, if necessary, scraped using hand tools to remove all loose particles, dirt, dust and other objectionable material, all to the satisfaction of the S.O.

In double bituminous surface dressing construction, the surface of the first application of bituminous material and cover aggregate shall be similarly made good and cleaned, immediately prior to commencing the second application.


The bituminous material for a single bituminous surface dressing or for each application of bituminous material and cover aggregate of a double bituminous surface dressing, shall be sprayed on to the cleanedsurface to be treated by meansof a pressure distributor. Any areas inaccessible to the distributor spray bar shall be treated using the distributor's hand spraying system.

The rate or rates of application shall be as directed by the S.O. based on the results of laboratory tests and/or test applications but forpenetration graded bitumen shall usually be in the appropriate range given in Table 4.5.

TABLE 4.5 - RATES OF APPLICATIONOF PENETRATION GRADED BITUMEN


Nominal Size of Aggregate

Rate of Application of Penetration Graded

Bitumen

20 mm

14 mm

10 mm

6 mm

2.0 - 3.0 litre/sq.m






The rates of application for cut-back bitumens and bitumen emulsions shall be commensurately higher depending on their residual bitumen contents.

The temperature of the bituminous material shall be maintained during spraying operations within the appropriate range given in Table 4.6.

The bituminous material shall be distributed uniformly over the surface to be treated without streaking; the quantities applied shall not deviate by more than 10% from those prescribed. The rate of application shall be checked for each spraying run by measuring the volume of bituminous material in the distributor before and after spraying and the area treated. Adjustments shall be made as necessary to ensure that the prescribed rate of application is maintained in subsequent runs. Spraying shall be discontinued immediately if any defect develops in the distributor, and it shall not be resumed until the fault has been rectified to the satisfaction of the S.O.

The spraying of bituminous material over any portion of the surface to be treated shall not be carried out more than two minutes in advance of placing the cover aggregate on that portion at the specifiedrate; an the progress of spraying the bituminous material shall be restricted asnecessary to comply with this requirement.

TABLE 4.6 - SPRAYING TEMPERATUREFOR BITUMINOUS

Bituminous materials Bituminous materials shall not be heated to spraying temperatures too soon in advance of requirements. Any bituminous material which has been heated to spraying temperature for more than ten hours or which has been overheated shall be rejected.


Bituminous Material

Spraying Temperature

80-100 penetration grade bitumen Cut-back bitumen grade RC-70 or MC-70 Bitumen emulsions

150 oC to 165 oC 50 oC to 65 oC 25oC to 45 oC



In cases where the bituminous material is applied in lanes there shall be a small overlap of bituminous material at the joints between lanes equal in width to the edge strip of the sprayed area which does not receive the full rate of application of bituminous material. For double bituminous surface dressing, joints in the second application of bituminous material shall be offset from those in the first application by 150 - 300 mm for longitudinal joints and by at least 1.0 metre, where possible, for transverse joints.

Each spraying run shall commence and terminate on lengths of building paper placed across the full spraying width immediately before and after the section to be sprayed. Sufficient building paper shall be placed so that the distributor may be started and stopped with the spray bar over paper, and so that the correct distributor road speed and rateof spraying can be maintainedover the entire length of the section to be sprayed, all to the satisfaction of the S.O. Immediately after use and before application of cover aggregate, the building paper shall be removed and disposed of in a manner approved by the S.O.

Provision shall be made for a volume of bituminous material of at least 10% of the capacity of the distributor, or such other quantity as the S.O. shall direct, to remain in the distributor tank at the completion of each spraying run, in order to avoid air entrapment within the bitumen spraying system.

The surfaces of structures, road furniture and trees adjacent to the areas being sprayed shall be protected in such a manner as to preventtheir being spattered or marred by bituminous material. Bituminous materialshall not be discharged into road drains, gutters, etc.

(d) Application of Cover Aggregate

Before each spraying run of bituminous material commences, sufficient aggregate to provide full cover at the prescribed rate of application over the entire area to be sprayed shall have been loaded in trucks at the Site of the Works in readiness for spreading.

Immediately following the application of the bituminous material, the clean, dry cover aggregate shall be uniformly spread overthe bituminous material using mechanical spreaders approved by the S.O.




The aggregate shall be placed as quickly as practicable after the application of bituminous material on all parts of the area to be covered, and for no portion of the surface to be treated shall there be a delay of more than two minutes between the application of the bituminous material and the spreading of the aggregate.

The trucks feeding the aggregate to the mechanical spreaders shall operate backward during aggregate spreading in order that the wheels of the spreaders and trucks shall not run on uncovered bituminous material.

The rate of application of cover aggregate shall be as directed by the S.O. based on the results of laboratory tests and/or tests applications, but shall usually be in the appropriate range given in Table 4.7

TABLE 4.7 - RATES OF APPLICATION OF COVER AGGREGATE

The rate of application shall be checked for each spraying run from measurements of thequantities of aggregate in the trucks and the area treated, or by sampling and measuring the aggregate spread on the road. Any bare or insufficiently covered areas shall be made good by hand spreading as quickly as possible. Aggregate in excessof the rate prescribed shall be evenly distributed over the surface or removed as quicklyas possible, all to the satisfaction of the S.O.

In cases where the surface dressing is constructed in lanes, the edge of the aggregate spread adjacent to an untreated lane shall coincide with the edge of the sprayed area which receives the full rate of application of the bituminous material. Thiswill leave a narrow strip of bituminous material of partial thickness which shall be overlapped by the bituminous material spray and aggregate spread of the adjacent lane.

Immediately following the spreading of the aggregate to the satisfaction of the S.O., the aggregate shall be rolled with a pneumatic tyred roller approved by the S.O. to embed the aggregate in the bituminous material. Rolling shall commence as quickly as practicable after the application of the bituminous material and aggregate on all parts of the area to be covered, and for no portion of the surface to be treated shall there be a delay of more


Nominal Size

Rate of Application of Aggregate

20 mm

14 mm

10 mm

6 mm

17 – 27 kg/sq.m

12 – 18 kg/sq.m

8 – 12 kg/sq.m

5 – 8 kg/sq.m



than 3 minutes between the application of the bituminous material and the commencement of rolling.

The pneumatic tyred roller shall be ballasted to anoperating weight of 9 - 10 tonnes and its tyre inflation pressure shall be 0.53 N/sq.mm for surface dressing work. Rolling shall be continued for as long as is necessary to thoroughly embed the aggregate in the bituminous material, all to the satisfaction of the S.O.

Rolling shall generally begin at the outer edge of surface dressing and progressuniformly towards the centre on each side, except on superelevated curves where rolling shall begin at the lower edge and progress uniformly towards the higher edge. Consecutive roller passes shall generally overlap by about one half of the roller's width.

When, in the opinion of the S.O., the bituminous material has hardened sufficiently to prevent the dislodgement of embedded aggregate by the action of the power broom, allloose aggregate shall be sweptfrom the treated surface using the power broom and compressed air blower and disposed of to the satisfaction of the S.O. Where the dressing so prepared is the first application of a double bituminous surface dressing, construction of the second application of bituminous material and cover aggregate

shall then proceed as soon as is practicable.

(e) Opening to Traffic

Bituminous surface dressing shall normally not be openedto traffic until such time as, in the opinion of the S.O., thesurfacing shall have developed sufficient strengthto withstand normal traffic forces without dislodgement of the aggregate. This will usually be not less than 24 hours after the completion of rolling. Where it is necessaryto allow earlier use of thefinished surface to facilitate the movement of traffic, vehicles may be allowed to run on the work after rolling has been completed, providedthat speeds are restricted to 30km per hour or less and sharpturning movements are prohibited. The finished surface shall subsequently have to be closed temporarily to enable the loose aggregate to be swept off and disposed of as described in Sub-Section 4.2.3.4 (d).

Ideally, the first application of bituminous material and coveraggregate of a double bituminous surface dressing should not be opened totraffic before construction of the second application. However, where it is necessary to facilitate the movement of traffic, the first application may be opened to traffic prior to construction of the second application. Nevertheless, traffic movement on the completed




first application shall be kept to a practicable minimum and the second application shall be constructed as soon as is practicable after the completion of the first.

4.2.4 Asphaltic Concrete

4.2.4.1 Description

This work shall consist of furnishing, placing, shaping and compacting asphaltic concrete binder course and/or wearing course on a prepared and accepted bituminous or bitumen primed pavement course, and shall include the careful and thorough cleaning of surfaces which are to be covered without receiving a bituminous tack coat.The work shall be carried out all in accordance with this Specification and the lines,levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.2.4.2 Materials

(a) Aggregates

Aggregate for asphaltic concrete shall be a mixture of coarse and fine aggregates and, if necessary, mineral filler. The individual aggregates shall be of sizes suitable for blending to produce the required gradation of the combined aggregate, all to the satisfaction of the S.O.

Coarse aggregates shall be screened crushed hard rock, angular in shape and free from dust, clay, vegetative and other

organic matter, and other deleterious substances. They shall conform to the following physical and mechanical quality requirements :-

i) the aggregate crushing value when tested in accordance with M.S. 30 shall be not more than 30;

ii) the weighted average loss of weight in the sodium sulphatesoundness test (5 cycles) when tested in accordance with AASHTO Test Method T104 shall be not more than 12%;

iii) the flakiness index when tested in accordance with M.S. 30 shall be not more than 30;

iv) the water absorption when tested in accordance with M.S. 30 shall be not more than 2%;

v) the polished stone value whentested in accordance with M.S. 30 shall be not less than 40 (only applicable to aggregates for wearing course).

Fine aggregates shall be clean natural sands, screened quarry fines, or mining sand. Mining sand shall be thoroughly washed before use. Other types of fine aggregate may be used subject to the approval of the S.O.

Fine aggregates shall be non-plastic and free from clay, loam, aggregations of material, vegetative and other organic matter, and other deleterioussubstances.




They shall conform to the following physical and mechanical quality requirements:-

i) the weighted average loss of weight in the sodium sulphatesoundness test (5 cycles) when tested in accordance with AASHTO Test Method T104 shall be not more than 12%;

ii) the water absorption when tested in accordance with M.S. 30 shall be not more than 2%.

Notwithstanding compliance withthe requirements of this Specification, limestone aggregates shall not be permitted for use in wearing course.

The gradation of the combined coarse and fine aggregates, together with ordinary Portland cement added as an adhesion and anti-stripping agent and, if necessary, any other mineral filler, shall conform to the appropriate envelope shown in Table 4.8


TABLE 4.8 - GRADATION LIMITS FOR ASPHALTIC CONCRETE

Mix Type Wearing Course Binder Course

Mix Designation

ACW 20 ACB 28

B.S. Sieve % Passing by weight

37.5 mm

28.0 mm

20.0 mm

14.0 mm

10.0 mm

5.0 mm

3.35 mm

1.18 mm

425 um

150 um

75 um

100

76 - 100

64 - 89

56 - 81

46 - 71

32 - 58

20 - 42

12 - 28

6 - 16

4 - 8

100

80 - 100

72 - 93

58 - 82

50 - 75

36 - 58

30 - 52

18 - 38

11 - 25

5 - 14

3 - 8



The gradation envelopes in the above Table are purposely wider than the tolerances for good works control of asphaltic concrete mixes. For each type of mix required in the Works, the Contractor shall establish a job mix formula gradation which shall consist of a single definite percentage passing for each sieve size in the above Table and shall produce a smooth curve within and essentially parallel to the appropriate gradation envelope. This job mix formula gradation, with the allowable tolerances for a single test as specified in Sub-Section 4.2.4.3 (c), then becomes the job control envelope and this job control envelope must be totally within the limits of the appropriate gradation envelope in the above Table.

(b) Mineral Filler

Mineral filler shall be finely divided mineral matter such as rock dust, limestone dust, hydrated lime, hydraulic cement, or such othersuitable material as the S.O. shall approve. At the time of mixing with bitumen it shall be sufficiently dry toflow freely and shall be essentially free from agglomerations. Not less than 70% by weight shall pass the B.S. 75 um sieve.

(c) Bituminous Material

Bituminous binder for asphaltic concrete shall be penetration graded bitumen of 80-100 grade conformingto M.S. 124.

(d) Anti-Stripping Agent

Ordinary Portland cement shall be added to the combined aggregate for asphaltic concrete to serve as an

adhesion and anti-stripping agent. The amount of cement added for this purpose shall be 2% by weight of the combined aggregate. (Additional cement may also be added, if necessary, to serve as filler.)

Ordinary Portland cement for this purpose shall conform to the requirements of M.S. 522 and shall be dry, free flowing and free from agglomerations at the time of use.

Notwithstanding the use of ordinary Portland cement as an anti-stripping agent as specified above, the Contractor shall be responsible for ensuring that thebitumen binder adheres satisfactorily to the aggregate and does not strip from it during the service life of the asphaltic concrete.

Accordingly, the Contractor shall carry out bitumen stripping tests with the proposed aggregates to demonstrate to the complete satisfaction of the S.O. that the aggregates will perform satisfactorily in service with the specified bitumen binder. Such tests shall be carried out in accordance with AASHTO Test Method T 182, or such other test methods as the S.O. shall direct or approve. When AASHTO TestMethod T 182 is used, the coated area atthe end of the mixture's period of immersion in water shall be not less than 95%.

Where, in the opinion of the S.O., ordinary Portland cement does not perform satisfactorily as an anti-stripping agent, the Contractor may propose to use another adhesion and anti-stripping agent in addition to, or wholly or partially instead of, the ordinary Portland cement specified above. Such agent shall be of a type approved by the S.O. and shall be thoroughly mixed with the bituminous binder,




all in accordance with the manufacturer's instructions. In such a case, the agent shall be added to the bitumen binder used in the bitumen stripping tests in the appropriate amount and manner.

Aggregate which does not perform satisfactorily in the bitumen stripping tests, using the approved adhesion and anti-stripping agent when appropriate, shall not be used in asphaltic concrete.

4.2.4.3 Asphaltic Concrete Mix Design

(a) Job Mix Formulae

After obtaining supplies or production (as applicable) of all aggregates consistent as to gradation and other qualities, the Contractor shall propose a job mix formula for each class of mix required in the Works. In order to attain optimum quality of the mixtures, the job mix formula for each class shall be prepared on the basis of testing several trial gradations within the limits set in Table 4.8 at an appropriate range of bitumen contents. As a guide to the testing range of bitumen contents, the designbitumen content will usually be in the appropriate range given in Table 4.9.

TABLE 4.9 - DESIGN BITUMEN CONTENTS

A sample of each trial mix (i.e. each combination of trial gradation and bitumen content) shall be subject to acomprehensive Marshall method test and analysis as follows :-

i) preparation of specimens for the standard stability and flow test in accordance with AASHTO Test Method T 245 using the 75 blows/face compaction standard;

ii) determination of the bulk specific gravity of the specimensin accordance with AASHTO Test Method T 166;

iii) determination of the stability andflow values in accordance with AASHTO Test Method T 245;

iv) analysis of the density and voids parameters to determine the percentage of voids in the compacted aggregate, the percentage of voids in the compacted aggregate filled with bitumen, and hence the percentage of air voids in the compacted mix.

For each trial mix conforming to a proposed job mix formula, the parameters of the above tests and analyses shall conform to the requirements of the appropriate type of mix as given in Table 4.10.


ACW14 - Wearing Course 5.0 – 7.0 %

ACW14 - Binder Course 4.5 - 6.5 %

ACB 28 - Binder Course 4.0 - 6.0%



Air voids shall be defined as the small pockets of air between the coated aggregate particles in a compacted asphaltic concrete mix. The portion of the bitumen absorbed into the aggregate particles must therefore be allowed for when calculating the air voids. For combined aggregate with a water absorption of not more than 2.0%, the absorbed bitumen may be estimated on the basis that the absorption of bitumen will be approximately 20% of the water absorption.

Voids in the aggregate of a mix shall be calculated on the basis of the weighted average bulk specific gravity on an oven dried basis of the coarse and fine aggregate fractions (separated by the ASTM # 10 sieve or B.S. 2.0 mm sieve) as determined in accordance with AASHTO Test Method T 84 and T 85 as applicable.

The Marshall density of an asphaltic concrete mix is defined as the average density of a set of three (3) test specimens moulded for thestandard stability and flow test in accordance with AASHTO Test Method T 245 using the 75 blows per face compaction standard.

The Contractor shall submit to the S.O. full details of his proposed job mix formula for each class of mix required in the Works including :-

i) the gradation analysis of each aggregate to be used in the mix;

ii) the proportions for cold batching the aggregates;

iii) the mixing plant screen sizes, the smallest of which shall generally be not more than 3.2 mm;

iv) the gradation analysis of the aggregate in each of the mixing plants' hot bins and of the mineralfiller (including any ordinary Portland cement added as anti-stripping agent);


TABLE 4.10 - TEST AND ANALYSIS PARAMETERSFOR ASPHALTIC CONCRETE

Parameter

Wearing Course

Binder Course

Stability S

Flow F

Stiffness S/F

Air voids in mix

Voids in aggregate filled with bitumen

> 500 kg

> 2.0 mm

> 250 kg/mm

3.0% - 5.0%

75% - 85%

> 450kg

> 2.0mm

> 225 kg/mm

3.0% - 7.0%

65% - 80%



v) the job mix formula gradation of the combined aggregate and filler;

vi) the proportions for combining thehot bin aggregates and filler;

vii)the bitumen content (by weight oftotal mix);

viii)the dry and wet mixing times if abatch plant is to be used, or the mixing time if a continuous mix plant is to be used;

ix) the full results of the comprehensive Marshall methodtests and analyses as described above for each trial mix used in determining the job mix formula.

The S.O. may require changes of anyof the factors in each proposed job mix formula and further tests and analyses in order to attain optimum quality of the asphaltic concrete mixes.

(b) Plant Trials

After having received the S.O.'s preliminary approval of his proposed job mix formulae, the Contractor shall arrange to mix, lay and compact asphaltic concrete conforming to the proposed formula for each class of mix required in the Works. A minimum of 10 tonnes of each mix shall be placed in trial areas to demonstrate to the satisfaction of the S.O. that the mixing,laying and compacting equipment conforms to the requirements of this Specification, and that the proposed mixes are satisfactory. The trial areas shall not be part of the Contract Works but shall be provided by the Contractor at his own expense. They shall be approved by the S.O.

As directed by the S.O., comprehensivesampling and testing of each class of mix shall be carried out to check for satisfactory compliance with its job mix formula, and for a satisfactory degree of compaction.

As a result of the plant trials, the S.O. may require amendments to the job mixformulae, further tests and analyses, and possibly additional plant trials before finally approving the mixes for full scale production and use in the Works.

(c) Compliance with the Job Mix Formulae

The S.O.'s final approval of the job mixformulae shall bind the Contractor to furnish asphaltic concrete mixes meeting the precise gradations and bitumen contents specified in these formulae within the tolerances set forth in Table 4.11.

Modifications to a job mix formula may only be made with the approval of the S.O. Should the S.O. at any time have reason to believe that the materials and methods of mixing and laying are different from those approved, he shall so advise the Contractor, and may order that asphaltic concrete works be discontinued pending further trials and testing.




4.2.4.4 Equipment

The Contractor shall provide all the plant and equipment necessary for executing the work in accordance with this Specification and shall furnish the S.O. with such details of particular items of equipment, e.g.manufacturer, model type, capacity, weight, operating features, etc., as the S.O. shall require.

(a) Road Cleaning Equipment

Road cleaning equipment will be required where asphaltic concrete is to be laid on a surface which is not to receive a tack coat. The equipment shall be the same as that required for preparing a surface for a tack coat, and shall include a power broom and compressed air

blower as specified in Sub-Sections 4.2.1.3 (a) and 4.2.1.3 (b) respectively.

(b) Asphalt Mixing Plant

The asphalt plant shall be either a batch plant or a drum mix plant or a continuous mix plant of recognized manufacture and shall be approved by the S.O. It shall conform to the requirements described hereunder.

The mixing plant shall have a capacity suited to the Works and sufficient to enable the paver to operate more or less continuously when paving at normal speeds at the required thicknesses. The plant shall be so designed as to enable consistent production of asphaltic


TABLE 4.11 - TOLERANCES FOR ASPHALTIC CONCRETE MIXES

ParameterPermissible Variation

% By Weight of Total Mix

Bitumen. Fractions of combined aggregate passing 5.0 mm and larger sieves. Fractions of combined aggregate passing 3.35 mm and 1.18 mm sieves. Fractions of combined aggregate passing 425 um and 150 um sieves. Fraction of combined aggregate passing 75 um sieve.

+ 0.2%

+ 5.0%

+ 4.0%

+ 3.0%

+ 2.0%



concrete mixes within the tolerances prescribed in this Specification, all to the satisfaction of the S.O.

Scales for all weigh boxes or hoppers shall be of the springless dial type,accurate to within 0.5% of the maximum load that may be required. Scale dials and pointers shall be easily read from their operator's normal position without significant parallax errors. Scales shall be substantially constructed so that they shall maintain their accuracy after initial adjustment. The Contractor shall furnish not less than ten 25 kg test weights at the plant for checking, adjusting and calibrating scales.

Tanks for storage of bitumen shall have a capacity suited to the proposed rate of utilization of the material and the method and frequency of its delivery to the Works, all to the satisfaction of the S.O. The tanks shall be provided with means of measuring the volume of their contents at all times and of drawing off samples of the contents. The bitumen feeding system shall provide for continuous circulation of hot binder through the system and back into the feed tank. The end of the return line discharging into the feed tank shall always be kept submerged in the bitumen in the tank in order to prevent oxidation of the returning hot binder. The storage tanks, and where necessary barrel decanters, and all elements of the bitumen feeding system shall be equipped with heating systems or insulating jackets as necessary to provide for effective and positive controlof the temperature of the bitumen at all times up to the temperature required for utilisation. . The method of heating shall be such that neither flames nor the products of combustion shall come into direct contact contact with the bitumen or the casing of its immediate container, and such that no portion of the bitumen shall be subject to overheating.

The plant shall be provided with accurate mechanical means for uniformly feeding the aggregates into the dryer so that uniform production andtemperature of the heated aggregates will be obtained. A separate feed bin with an adjustable gate opening shall be provided for each aggregate to be included in the combined aggregate for the mix; normally four bins will be required. The feed bins and gates shall be so constructed and equipped that theyshall be readily accessible for calibratingat all times, and shall provide for a continuous and uniform flow of each aggregate required in the mix.

The plant shall have a rotary drum dryerof satisfactory design for drying and heating the combined aggregate so that its temperature will be at the required level at the time it is mixed with the bitumen. The burner shall be so designed that complete combustion of the fuel will be obtained, and the aggregate will remain clean and not become coated with soot or oil.

The plant shall be equipped with four (or more) screens, the smallest of whichshall generally be not more than 3.2 mm. The screens shall have a normal capacity slightly in excess of the maximum output of the mixing plant. The screens shall be readily accessible for inspection.

The plant shall include four (or more) storage bins for screened aggregates, each with a capacity of not less than twice the pugmill dead load capacity. The bins shall be arranged so as to provide separate dry storage for each screened fraction of the aggregate. Each bin shall be provided with an overflow pipe of such size and location as to prevent any backing up of material into other bins. Each bin shall be so constructed that representative aggregatesamples can be readily obtained, and




shall have means for observing the aggregate level. Separate dry storage shall be provided for mineral filler, and the plant shall be satisfactorily equipped to feed filler into the mixer.

Satisfactory means by either weighing or metering shall be provided to obtain the prescribed amount of bitumen in the mix within the specified tolerance. Means shall be provided for checking the quantity or flow rate of binder entering the mixer. Suitable means shallbe provided for maintaining the prescribed temperature of the bitumen inthe pipelines, weigh bucket or flow meter, and spray bars.

An armoured thermometer with a range of 30 oC to 200 oC shall be fitted in the bitumen feed line at a suitable location near the discharge valve at the mixer unit. Suitable dial-scale mercury actuated thermometers, electric pyrometers or other thermometric instruments shall be fitted at the discharge chute of the dryer and in each hot aggregate storage bin to indicate the temperatures of the heated aggregates.

The plant shall be equipped with a dust collector so constructed as to waste the material collected or feed it uniformly tothe heated aggregate.

The plant shall be equipped with adequate and safe stairways to the mixing platform and sampling locations,and guarded ladders and cat-walks shall provide access to all other positions as necessary for proper operation, inspection and maintenance of the plant,all to the satisfaction of the S.O. All gears, pulleys, chains, sprockets and other dangerous moving parts shall be properly guarded and protected. Ample and unobstructed space shall be provided on the mixing platform, and clear and unobstructed passage shall be maintained at all times in and around

the truck loading area, which shall be kept free from drippings from the mixer.

Special Requirements for Batch Plants

Each storage bin for screened aggregate shall be provided with a bottom outlet gate so constructed as to prevent leakagewhen closed. These gates shall have a quick and complete closing action.

The plant shall be equipped with a weigh box or hopper for accurately weighing out aggregate from each of thescreened aggregate storage bins. The weigh box or hopper shall be suspended from its scale's lever mechanism and shall be sufficiently large to hold a full batch equal to the pugmill capacity without hand raking or spilling of the aggregate. The discharge gate shall be so constructed as to allow rapid and complete emptying of the weigh box or hopper into the mixer, and prevent leakage when closed.

The plant shall be equipped with a binder weigh bucket which shall be charged through a fast acting non-drip valve in the binder feed pipe located directly over the bucket. The bucket shall be suspended from its scale's lever mechanism and shall have a capacity sufficient to weigh out binder up to 20%of the weight of the pugmill dead load capacity. The bucket shall have a discharge mechanism which shall provide for rapid and complete emptying of the bucket in a thin uniformsheet or multiple sprays over the full length and width of the mixer. The dicharge mechanism shall not leak or drip when closed.

The batch mixer shall be a suitable twinshaft pugmill, with a capacity of at least 500 kg of asphaltic concrete, capable of producing a thoroughly homogeneous mixture. The clearance of the paddle blades from all fixed and




moving parts of the mixer shall be not more than 20 mm. If the pugmill is not enclosed it shall be equipped with a dusthood to prevent loss of fines from the mixture. The discharge gate shall be so constructed as to allow rapid and complete emptying of the mixer, and prevent leakage of any mix constituent when closed.

The mixer shall be equipped with an accurate time lock system for controlling the operations of a complete mixing cycle. It shall lock the aggregateweigh box or hopper gate after charging the mixer with aggregate, until the closing of the mixer gate at the completion of the mixing cycle; it shall lock the binder weigh bucket discharge mechanism during the dry mixing and wet mixing periods. (The dry mixing period is defined as the interval of time between the opening of the aggregate weigh box or hopper gate and the start of discharging the binder weigh bucket. The wet mixing period is defined as the interval of time between the start of discharging the binder weigh bucket andthe opening of the mixer gate.) The dry and wet mixing periods shall both be adjustable in increments of not more than 5 seconds from zero to not less than120 seconds total for dry and wet mixing.

Special Requirements for Drum Mix Plants

The cold material feeder unit shall consist of not less than 5 compartments with suitable heaped capacity appropriate for the plant. Each bin shall be provided with a control gate and measuring feeder suitable for accurate blending of the aggregates on to the coldfeed collecting conveyor. The cold feed system shall incorporate a device for moisture compensation capable of

producing an accurate and continuous blend of the individual aggregate sizes from the cold feed compartment.

The drum mixer shall be of an inclined, oil-fired and parallel flow type in which the aggregates and exhaust gases flow inthe same direction. The drum mixer length to diameter ratio shall be such as to ensure efficient drying and intimate mixing of aggregate, filler and binder over the full range of rated operating efficiencies. A bypass chute shall be incorporated for sampling of cold aggregate.

Freshly mixed material shall bedelivered and stored in a surge silo through a proper conveyor system.

Special Requirements for Continuous Mix Plants

Each storage bin for screened aggregate shall be provided with an accurately controlled variable orifice gate discharging on to an aggregate feed mechanism. The discharge orifice shall be rectangular with one dimension variable by means of an adjustable and lockable gate, which shall have an indicator showing the distance it is open.These gates shall be used for accurately proportioning the screened aggregates for the mix.

The plant shall have means of calibrating the aggregate bin discharge gate openings by weighing test samples obtained by diverting the aggregate fed out of each bin into a suitable test box. Test boxes shall have a capacity of not less than 100 kg each.

The plant shall have satisfactory means of effecting positive interlocking control between the flow of screened aggregatesfrom the storage bins and the flow of binder from the meter or other proportioning device. This control shall




be accomplished by interlocking mechanical means or another positive method satisfactory to the S.O.

The continuous mixer shall be a suitabletwin-shaft pugmill with an adjustable dam and paddles with reversible blade pitch for adjusting the volume of mixture held in the pugmill. Theclearance of the paddle blades from all fixed parts of the mixer shall be not more than 20 mm. The binder shall be fed into the mixer through a spray bar directed on to the aggregate across the full width of the pugmill at the feed end.The discharging mixture shall pass over the dam into a hopper with a discharge gate so constructed as to allow rapid andcomplete emptying of the hopper, and prevent leakage of the mix when closed.The mixer shall be equipped with a permanent gauge for measuring the depth of mixture in the pugmill and a manufacturer's calibration plate showingthe volume of mixture in the pugmill at each increment of depth.

The mixing time shall be determined using the formula :-

Mixing time (seconds) = Dead weight of mix in pugmill (kg)Pugmill output (kg per second)

and for a given output it may be varied slightly by adjusting the depth (and hence weight) of the mixture held in the pugmill by varying the dam height, the configuration of the paddle blades, or both. However for substantial adjustments of the mixing time, in order to maintain the depth at a level compatible with efficient mixing, i.e. so that the paddle tips just break out of the mixture at the height of their action, the rate of feed of materials to the mixer (and hence output) should be changed.

(c) Tip-Trucks

The Contractor shall provide a suitable number of tip-trucks of a type approved by the S.O. for transporting asphaltic concrete from the mixing plant to the paving works. The trucks shall have trays with smooth, flat beds and sides, and shall have load capacities of not lessthan 5 tonnes. Prior to loading, the inside of each truck tray shall be lightly and evenly coated with a soap or detergent solution, or such other liquid as the S.O. shall approve, to prevent adhesion of the asphaltic concrete. The trucks shall be equipped with covers of canvas or other suitable material to protect the asphaltic concrete.

(d) Asphalt Paver

The asphalt paver shall be of recognizedmanufacture and shall be approved by the S.O. It shall conform to the requirements described hereunder.

The paver shall be self-propelled and capable of reverse as well as forward travel. It shall be equipped with a hopper at the front designed to receive the paving mixture from tip-trucks, and shall have a mechanical distribution system for spreading the mixture evenly and without segregation over the surfaceto be paved in front of a screeding and compacting unit which shall be equipped with a suitable heating device.The screeding and compacting mechanism shall be capable of confining the edges of the material being laid without the use of stationary side forms, shall be adjustable to strike off the mixture to the thickness and cross-section shape required, and shall be controlled by an automatic levelling device to produce an even carpet of bituminous mixture with a uniform surface texture free from indentations, ridges, tear marks or other irregularities.




The paver shall be capable of laying the bituminous mixture in paving widths in the range 2.5 to 3.75 m and of finishing the pavement layer true to the required lines, grades, levels, dimensions and cross-sections, subject to compaction by rolling, all to the satisfaction of the S.O.

(e) Rollers

A pneumatic tyred roller and two steel wheeled tandem rollers shall be provided. However, a three wheeled steel roller may be substituted for one ofthe tandem rollers if the S.O. shall so approve. All rollers shall be of recognized manufacture and shall be approved by the S.O.

The pneumatic tyred roller shall be as specified in Sub-Section 4.2.3.3 (g). Steel wheeled rollers shall conform to the requirements described hereunder.

Steel wheeled rollers shall be self-propelled and capable of being reversed without backlash; they shall be equippedwith power steering and dual controls allowing operation from either the left orright side. They shall be equipped with water tanks, sprinkler systems and scraper blades to keep all wheels evenly wetted and clean during operation.

Each steel wheeled roller shall be ballasted so that its total operating weight is in the range 8 to 10 tonnes andits driven roll (or rolls) shall exert a rolling force of not less than 3.5 tonnes/metre of roll width. The Contractor shall provide the S.O. with a calibration chart for each roller showing the relationships between the quantity ordepth of ballast and total weight and rolling force.



Asphaltic concrete paving work shall only be carried out in dry weather when the surface to be covered is dry, or if so specified, has received a bituminous tack coat which shall have achieved a satisfactory degree of tackiness, all to the satisfaction of the S.O. All laying, rolling and finishing work shall be carried out during daylight hours, unless the Contractor shall have provided suitable flood-lighting for the job site, to the satisfaction of the S.O.

The S.O. may order the discontinuation of work on account of adverse weather, unsatisfactory condition of materials, equipment or surface to be paved, or such other conditions as he shall consider detrimental to the work.


Prior to constructing an asphaltic concrete pavement layer, the surface to be covered shall have been prepared in accordance with the appropriate Sections of this Specification. Notwithstanding any earlier approval of this surface, any damage to or deterioration of it shall be made good before asphaltic concrete paving work is commenced.

If the surface to be covered is not to be provided with a bituminous tack coat, then immediately prior to commencing asphaltic concrete paving, it shall be swept using a power broom followed by a compressed air blower and, if necessary, scraped using hand tools to remove all loose particles, dirt, dust and other objectionable




material, all to the satisfaction of the S.O.

If the surface to be covered is to be provided with a bituminous tack coat, then this shall be applied all in accordance with the provisions of Sub-Section 4.2.2.

(c) Aggregate Handling and Heating

Each aggregate to be used in the asphaltic concrete mixes shall be stored in a separate stockpile near the mixing plant. Stockpiles of sand and other fine aggregates shall be kept dry using waterproof covers and other means as necessary. In placing the aggregates in the stockpiles and loading them into the mixing plant's cold aggregate feed bins, care shall be taken to prevent segregation or uncontrolled combinationof materials of different gradation. Segregated or contaminated materials shall be rescreened or rejected for use in the Works and removed from the mixingplant site.

The aggregates shall be fed into the dryer at a uniform rate proportioned in accordance with the appropriate job mixformula. The rate of feed for each aggregate shall be maintained within 10% of the rate prescribed, and the total rate of feed shall be such that the plant's screens shall never be overloaded.

The aggregates shall be dried and heatedso that when delivered to the mixer they shall be at a temperature in the range 150ºC to 170ºC.

Immediately after heating, the aggregates shall be screened into four (or more) fractions which shall be separately stored in the hot aggregate storage bins in readiness for mixing.

Ordinary Portland cement and/or other mineral filler to be used in the mix shall be stored separately and kept completely dry. Its rate of feed into the plant shall be accurately controlled by weight or volumetric measurement, all to the satisfaction of the S.O.

(d) Heating of Bitumen

The binder shall be heated so that when delivered to the mixer it shall be at a temperature in the range 140ºC to 160ºC.

(e) Mixing Asphaltic Concrete

The mixing plant shall be socoordinated and operated as to consistently produce asphaltic concrete mixes within the tolerances prescribed in this Specification, all to the satisfaction of the S.O.

Mixing in Batch Plants

For each batch the screened hot aggregates shall be weighed out into the aggregate weigh hopper in accordance with the proportions prescribed in the appropriate job mixformula; the sequence of weighing out shall commence with the largest sized aggregate and progress down to the fines, unless the S.O. shall otherwise approve. Mineral filler shall be weighed out into the filler weigh hopper, where this is provided, or added last to the aggregate weigh hopper, in accordance with the job mix formulaproportions.

The hot binder shall be weighed out into the binder weigh bucket in ccordance with the proportions prescribed in the job mix formula.




The hot aggregates and filler shall bedischarged into the pugmill and mixed dry for the dry mixing time prescribed in the job mix formula, which shall usually be in the range 5 to 10 seconds. The hot binder shall then be added and wet mixing performed for the wet mixing time prescribed in the job mix formula; this shall be sufficient so that all particles of aggregate are uniformly coated with bitumen, and shall usually be 45 seconds or more for dense graded mixtures.

The volume of each batch shall be such that the tips of the pugmill paddle blades just break out of the mixture at the height of their action.

After the completion of wet mixing, each batch of asphaltic concrete shallbe discharged from the pugmill either into a storage hopper or directly into a truck for hauling to the paving site. Care shall be taken that no segregation of the mix occurs.

Mixing in Continuous Mix Plants

The screened hot aggregates and filler shall be fed continuously from their storage bins in accordance with the proportions prescribed in the appropriate job mix formula, combined in the plant, and fed continuously into the mixer. The hotbinder shall be sprayed on to the combined aggregate as it enters the pugmill at the rate required to achieve the bitumen content prescribed in the job mix formula. The materials shall then be carried through the pugmill and in the process be thoroughly mixed by the action of the paddles and discharged over the dam into the storage hopper. The mixing time (as defined in Sub-Section 4.2.4.4 (b)

shall be as prescribed in the job mix formula; this shall be sufficient so that all particles of aggregate are uniformly coated with bitumen, and shall usually be 45 seconds or more for dense graded mixtures.

The plant shall be so adjusted as to maintain the level of mixture in the pugmill such that the tips of the paddle blades just break out of the mixture at the height of their action.

(f) Transportation of Asphaltic Concrete

Asphaltic concrete shall be transported from the mixing plant to the site of the paving works in loads of not less than 5 tonnes using tip-trucks as specified in

Sub-Section 4.2.4.4 (c). Except where asphaltic concrete is to be hand laid, it shall be discharged directly into the paver hopper, as required, from the tip-trucks. Care shall be taken in the truck loading, hauling and unloading operations to prevent segregation of the mix. During transportation, the asphaltic concrete shall be protected from contamination by water, dust, dirt and other deleterious materials.

The temperature of asphaltic concrete immediately before unloading from the truck either into the paver hopper or on to the road for hand spreading shall be not less than 125ºC. Any load which has cooled below the specified temperature in the truck shall be rejected for use in the Works and removed from the Site of the Works.

(g) Laying Asphaltic Concrete

The sequence of laying operations shall be planned in advance by the Contractor and approved by the S.O.




Generally each paving layer shall have a compacted thickness of not less than twice the nominal maximum aggregate size of the mixture, and not more than 100 mm. Where applicable, e.g. on superelevated sections and on carriageways with cross-slope in onedirection only, laying shall commence along the lower side of the carriageway and progress to the higher side. Laying shall not be carried out in a downhill direction along any section of road.

As far as is practicable, laying shall be carried out using a paver approved by the S.O. Hand-casting of bituminous mix on to the machinefinished surface shall be kept to the practicable minimum necessary for correcting blemishes and irregularities. In any areas inaccessible to the paver, laying shallbe carried out by hand methods using rakes, lutes and other hand tools, all to the satisfaction of the S.O. All laying of bituminous mix shall be such that after compaction by rolling the specified course or layer thickness and surface profile shall be achieved. Care shall be taken to achieve a uniform surface texture free from indentations, ridges, tear marks or otherirregularities, and to prevent segregation of the mix.

At the commencement of initial rolling the temperature of asphaltic concrete shall be not less than 110ºC. Material which has cooled below the specified temperature before laying shall not be used and shall be removed from the Site of theWorks. The Contractor shall provideaccurate thermometers at the paving site at all times, and shall check the temperature of asphaltic concrete in the paver hopper at regular intervals

and before laying restarts after each interruption of the paving operation.

As far as is practicable, the paver shall be operated continuously and the supply of bituminous mix shall be regulated so as to enable continuous paving. Transverse joints in a paving lane shall be kept to a practicable minimum, and intermittent stopping and restarting of the paver shall be avoided as far as is practicable.

Care shall be taken that no bituminous mix is placed on expansion joints at bridges, inspection covers for utilities ducts, drainage and sewerage manholes andthe like, and that catchpits, drainage openings through kerbs, etc., remain properly open and serviceable. During laying operations, such areas and openings shall be protected by suitably shaped and secured boards or other materials approved by the S.O., and compaction of mix in the immediately surrounding or adjacent areas shall be completed by hand methods, all to the satisfaction of the S.O. Alternatively, bituminous mix shall be laid and compacted by hand methods as necessary around surfacing discontinuities of these types, all to the satisfaction of the S.O.

(h) Construction Joints

Existing bituminous surfacing which new bituminous mix is to adjoin shall be cut back to present a straight, vertical edge not less than 25 mm deep and a smooth transition section not less than 0.5 metre long against which to lay the new material. The specified thickness of the new surfacing shall be built up gradually from the vertical joint to avoid any bumps or ridges across thecarriageway.




Where longitudinal or transverse joints are required in a layer of bituminous mix under construction, the material first laid and compacted shall be cut back to a vertical face forthe full thickness of the layer on a line satisfactory to the S.O. before the adjacent area is paved.

At all construction joints, a thin uniform coating of bitumen emulsionof grade RS-1 or RS-1K shall be brushed on to the vertically cut joint faces some 10 to 15 minutes before laying the next section of bituminousmix commences to ensure good bonding. Also, all contact surfaces of kerbs, gutters, manholes, catchpits, etc., shall be similarly treated with a coating of bitumen emulsion before bituminous mix is placed against them.

Construction joints in a layer of bituminous mix shall be offset from those in any immediately underlying bituminous layer by at least 100 mm for longitudinal joints and at least 0.5metre, where possible, for transverse joints.

(i) Compaction of Asphaltic Concrete

For each layer of asphaltic concrete, compaction by rolling shall commence as soon after laying as thematerial will support the rollers without undue displacement; nevertheless the temperature of asphaltic concrete at the commencement of rolling shall be not less than 110ºC.

In any areas inaccessible to the rollers, proper compaction shall be carried out using vibrating plate compactors, hand tampers or other suitable means, all to the satisfaction of the S.O.

Initial (or breakdown) rolling shall be carried out with an approved steelwheeled tandem roller or three wheeled steel roller. The principal heavy rolling shall be carried out with an approved pneumatic tyred roller immediately following the initial rolling; the pneumatic tyred roller shall be ballasted to an operating weight of not less than 15 tonnes and its tyre inflation pressure shall be not less than 0.7 N/sq.mm. The final rolling shall be carried out with an approved steel wheeled tandem roller and shall serve toeliminate minor surface irregularitiesleft by the pneumatic tyred roller.

All rollers shall operate in a longitudinal direction along the carriageway with their driven wheelstowards the paver. Rolling shall generally commence at the lower edge of the paved width and progressuniformly to the higher edge, except that where there is a longitudinal construction joint at the higher edge, this shall be rolled first ahead of the normal pattern of rolling. Generally, successive roller passes shall overlapby half the width of the roller, and the points at which the roller is reversed shall be staggered. However, when operating on gradients in excess of 4%, the breakdown roller shall not pass over any previously unrolled mix when operating in the downhill direction.

In all cases, compaction shall be carried out in such a manner that each section receives equal compactive effort, all to the satisfaction of the S.O.

The steel wheeled rollers shalloperate at speeds of not more than 5km/hr and the pneumatic tyred rollers shall operate at speeds of not more than 8 km/hr. No roller or




heavy vehicle shall be allowed to stand on newly laid bituminous mix before compaction has been completed and the material has thoroughly cooled and set. Rolling shall continue as long as is necessaryto achieve the appropriate requirement as follows :-

Care shall be taken to prevent over-compaction of asphaltic concrete.

Within 24 hours of laying and compacting the bituminous mix, the Contractor shall cut core samples of not less than 100 mm nominal diameter at locations selected by the S.O. The rate of sampling shall be 1 sample per 500 sq.m of mix laid, but not less than 2 samples for the work completed in each paving session. These core samples shall be used by the S.O. to determine the thickness of the compacted layer of mix and the compacted density of the material in accordance with either ASTM Test Method D 1188 or ASTM Test Method D 2726, whichever is applicable.

(j) Finished Asphaltic Concrete

Asphaltic concrete binder and wearing courses shall be finished in aneat and workmanlike manner; their widths shall be everywhere at least those specified or shown on the Drawings on both sides of the centre-line; ;

the average thickness over any 100 metre length shall be not less than the required thickness, and the minimum thickness at any point shall be not less than the required thickness minus 5 mm.

The top surface of a wearing or binder course shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances specified in Sub-Section 4.4.

(k) Opening to Traffic

Asphaltic concrete shall not be opened to traffic until compaction has been completed and the material has thoroughly cooled and set in the opinion of the S.O. This will usuallybe not less than 4 hours after the commencement of rolling. Where it is necessary to allow earlier use of the finished surface to facilitate themovement of traffic, vehicles may be allowed to run on the work after rolling has been completed, provided that speeds are restricted to 30 km/hr or less and sharp turningmovements are prohibited.


Type of PavementLayer

Required CompactedDensity

Wearing course 98 - 100% Marshalldensity

Binder course 95 - 100% Marshall density



4.2.5 Bituminous Macadam

4.2.5.1 Description

This work shall consist of furnishing,placing, shaping and compacting bituminous macadam roadbase and/or levelling course and/or binder course and/or wearing course on a prepared and accepted bituminous orbitumen primed pavement course, and shall include the careful and thorough cleaning of surfaces which are to be covered without receiving abituminous tack coat. The work shallbe carried out all in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and/or as required by the S.O.

4.2.5.2 Materials

The materials for bituminous macadam (aggregates, mineral filler, bituminous binder and anti-stripping agent) shall comply with all the requirements of Sub-Section 4.2.4.2, except for the combined gradation requirements.

For each bituminous macadam mix, the gradation of the combined coarseand fine aggregates, together with ordinary Portland cement added as an adhesion and anti-stripping agent and, if necessary, any other mineral filler, shall conform to the appropriate envelope given in Table 4.12. The binder content shall also bein accordance with Table 4.12.

Where the characteristics of the aggregates require a binder content other than that given in the above Table, the revised target binder content shall be agreed between the Contractor and the S.O. and the sametolerances shall apply.

4.2.5.3 Equipment

The equipment shall be all as specified in Sub-Section 4.2.4.4.


All the provisions of Sub-Section 4.2.4.5 for the construction of asphaltic concrete pavement courses shall apply as appropriate to the construction of bituminous macadampavement courses with thefollowing variations and additions.

(a) Aggregate Heating

The aggregates shall be dried and heated so that when delivered to the mixer they shall be at a temperature in the range 140 oC to 160 oC.

(b) Rolling Temperature

The temperature of bituminous macadam at the commencement of rolling shall be not less than 100 oC.

(c) Compacted Density

The compacted density of bituminous macadam shall be as follows :-


Type of PavementLayer

Required CompactedDensity

Bound roadbase 90 - 100% Marshalldensity

Levelling course 90 - 100% Marshalldensity

Binder course 95 - 100% Marshalldensity

Wearing course 98 - 100% Marshalldensity



The Marshall density of a bituminous macadam mix is defined as the average density of a set of three test specimens moulded in the same way as asphaltic concrete specimens are prepared for the standard stability and flow test in accordance with AASHTO Test Method T 245 using the 75 blows per face compaction standard. The bulk specific gravity of the specimens shall be determined in accordance with AASHTO Test Method T 166.

The Marshall density of each mix shall be determined using a sample (or samples) taken from the mixing plant soon after the commencement of preparing each mix for the Works.(Note : Stability and flow tests are not normally required for bituminousmacadam mixes.)

(d) Finished Bituminous Macadam

Bituminous macadam roadbase shall be finished in a neat and workmanlike manner; its width shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line; and its average thickness over any 100 metre length shall be not less than the required thickness. The top surface of bituminous macadam roadbase shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances specified in Sub-Section 4.4.2.

Bituminous macadam levelling course shall be finished in a neat and workmanlike manner; its dimensionsshall be as specified or shown on the Drawings or as directed by the S.O., all to the satisfaction of the S.O. The top surface of bituminous macadam levelling course shall have the

required shape,, superelevation, levels and grades, and shall be everywhere within the tolerances for binder course specified in Sub-Section 4.4.

Bituminous macadam binder and wearing courses shall be finished in aneat and workmanlike manner; their widths shall be everywhere at least those specified or shown on the Drawings on both sides of thecentre-line; the average thickness over any 100 metre length shall be not less than the required thickness, and the minimum thickness at any point shall be not less than the required thickness minus 5 mm. Thetop surface of a wearing or binder course shall have the required shape, superelevation, levels and grades, and shall be everywhere within the tolerances specified in Sub-Section 4.4.





TABLE 4.12 - GRADATION LIMITS AND BINDER CONTENTSFOR BITUMINOUS MACADAM

Mix Type Bound Roadbas

e

Bound Roadbase

Levelling Course

Binder Course

Binder Course

Wearing Course

Wearing Coursex

Mix Designatio

n

BMR40 BMR28 BML10 BMB28 BMB20 BMW14 BMW20

B.S. Test Sieve

% Passing

by Weight

50.0 mm 37.5 mm 28.0 mm 20.0 mm 14.0 mm 10.0 mm 6.3 mm 3.35 mm 1.18 mm 300 mm 75 mm

100 95 - 100 70 - 94

- 56 - 76

- 44 - 60 32 - 46

- 7 - 21 2 - 9

- 100

90 - 100 71 - 95 56 - 80

- 44 - 60 31 - 45

- 7 - 21 2 - 8

- - - -

100 85 - 100 30 - 60 15 - 25

- -

2 - 6

- 100

90 - 100 71 - 95 58 - 82

- 44 - 60 32 - 46

- 7 - 21 2 - 8

- -

100 95 - 100 65 - 85 52 - 72 39 - 55 32 - 46

- 7 - 21 2 - 8

- - -

100 95 - 100 70 - 90 45 - 65 30 - 45 15 - 30

- 3 - 7

- -

100 95 - 100 65 - 85 52 - 72 39 - 55 32 - 46

- 7 - 21 2 - 8

Binder Content

3.5 "

±

0.5%

4.0 "

±

0.5%

5.1 "

±

0.5%

4.7 "

±

0.6%

4.7 "

±

0.6%

5.0 "

±

0.5%

4.9 "

±

0.5%



4.3 SHOULDERS

4.3.1 Description

This work shall consist of furnishing,compacting and shaping earth or gravel shoulder material on a prepared and accepted subbase or lower subbase or subgrade, all in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shownon the Drawings and/or as required by the S.O.

For paved shoulders, the bituminous surfacing and underlying pavement courses shall be constructed as described in the appropriate Sections of this Specification.

4.3.2 Materials

4.3.2.1 Earth Shoulders

Earth shoulder material shall be suitable material as described in Sub-Section 2.2.1.

4.3.2.2 Gravel Shoulders

Gravel shoulder material shall conform to the requirements for gravel surfacing material set forthin Sub-Section 4.1.3.2.


Shoulders shall be constructed in stages or in one operation as directedor approved by the S.O., but in no instance shall a shoulder be built up to a level higher than that part of the abutting carriageway structure whichhas been completed and accepted.

Prior to placing any shoulder material, the underlying subbase or lower subbase or subgrade shall havebeen shaped and compacted in accordance with the provisions of

Sub-Section 4.1.2.3, and the abuttingcarriageway structure course or courses shall likewise have been shaped and compacted in accordancewith the provisions of the appropriate Sub-Section or Sub-Sections of this Specification. Notwithstanding any earlier approvalof the underlying and abutting pavement courses, any damage to ordeterioration of these underlying and abutting pavement courses shall be made good to the satisfaction of the S.O. before shoulder constructionproceeds.

Shoulders shall be placed to the required width and thickness as shown on the Drawings or directed by the S.O. in one layer or more, each layer not exceeding 200 mm compacted thickness at the point of maximum thickness. Where two or more layers are required they shall be of approximately equal shape and thickness, and none shall be less than100 mm compacted thickness at the point of maximum thickness.

Each layer of shoulder material shall be processed as necessary to bring itsmoisture content to a uniform level throughout the material suitable for compaction, and shall then be compacted using suitable compaction equipment approved by the S.O. to not less than 95% of the maximum dry density determined in the B.S. 1377 Compaction Test (4.5 kg rammer method). Compaction shall be carried out in a longitudinal direction along the shoulder and shall generally begin at the outer edge and progress uniformly towardsthe carriageway, except onsuperelevated curves where rolling shall begin at lower edge and progress uniformly towards the higher edge.




In all cases, compaction shall be carried out in such a manner that each section receives compactive effort appropriate to its thickness, all to the satisfaction of the S.O.

Throughout the placing, adjustment of moisture content and compaction of shoulder material, care shall be taken to maintain a uniform gradation of the material and preventits seperation into coarse and seperate parts, all to the satisfaction of the S.O.

Where shown on the Drawings or directed by the S.O., earth shoulders shall be turfed in accordance with Sub-Section 2.2.8.2.

Shoulders shall be finished in a neat and workmanlike manner. The total width of carriageway and shoulder shall be everywhere at least that specified or shown on the Drawings on both sides of the centre-line. The top surface of each shoulder shall have the required shape, superelevation, levels and grades, shall be everywhere within 10 mm of the required plane, and shall provide a flush joint with thecarriageway surface and shall be uniformly free draining away from the carriageway, all to the satisfaction of the S.O.

4.4 HORIZONTAL ALIGNMENT, SURFACE LEVELS ANDSURFACE REGULARITY OF PAVEMENT COURSES

4.4.1 Horizontal Alignment

The horizontal alignment shall be determined from the centre-line of the pavement surface shown on the Drawings. The edges of the pavement as constructed and all other parallel construction lines shall

be correct within a tolerance of + 50 mm and minus 0 mm from the centre-line, except for kerbs, channelblocks and edge lines which shall be laid with a smooth alignment within a tolerance of + 25 mm and minus 0 mm from the centre-line.

4.4.2 Surface Levels of Pavement Courses

The design levels of pavement courses shall be calculated from the vertical profile, crossfall and pavement course thicknesses shown on the Drawings. The level of any point on the constructed surface of a pavement course shall be the design level subject to the appropriate tolerances given in Table 4.13.

TABLE 4.13 - TOLERANCES IN SURFACELEVELS OF PAVEMENT COURSES

The combination of permittedtolerances in the levels of different pavement courses shall not result in apavement thickness less than that shown on the Drawings. Each pavement course shall have an average thickness not less than that shown on the Drawings.


Pavement Course

Tolerance

Wearing Course

Binder Course

Roadbase

Subbase and Lower Subbase

+ 5 mm

+ 5 mm

+ 0 mm - 20 mm

+ 10 mm - 20 mm



4.4.3 Surface Regularity

The regularity of surfaces shall be within the relevant limits given in Table 4.14.

A longitudinal irregularity is a variation in profile of the road surface as measured by the rolling straight-edge or wedge and straight-edge device. The permissible number of such longitudinal irregularities is indicatedin Table 4.14.

The traverse length of 300 m and its associated maximum permissible number of irregularities shall apply wherever the continuous length of the completed carriageway is 300 mor more, whether or not it isconstructed in shorter lengths.

Where the total length of pavement is less than 300 m the measurements shall be taken on 75 m lengths.

The transverse regularity of a newly laid surface shall be measured with a3 m straight-edge and shall have no greater depression under the straight-edge than that shown in Table 4.14


TABLE 4.14 - TOLERANCES FOR SURFACE IRREGULARITIES

Longitudinal Direction Transverse Direction

Maximum Permissible Number

of Surface Irregularities

Class of Surface

Regularity Depth Exceeding 4

mm Depth Exceeding 7 mm

over traverse length

of 300 m


of 75 m


of 30 m


of 75 m

Maximum

Permissible Depth of

Transverse Irregularities

Class SR1

Class SR2

Class SR3

20 40

60

9 18

27

2 4 4

1 2 3

4 mm

8 mm

12 mm

No longitudinal irregularity exceeding 10 mm shall be permitted for Class SR1 Surface Regularity and no longitudinal irregularity exceeding 15 mm shall be permitted for Class SR2 and Class SR3 Surface Regularities. The class of Surface Regularity for each portion of the Works shall be as stated on the Drawings or in the Bills of Quantities.




SECTION 5

PORTLAND CEMENT CONCRETE PAVEMENT




SECTION 5 - PORTLAND CEMENT CONCRETE PAVEMENT

Page

5.1 DESCRIPTION S5-125

5.2 MATERIALS S5-125

5.2.1 Cement S5-125

5.2 2 Aggregate S5-125

5.2.3 Joint Filler S5-125

5.2.4 Joint Sealants and Seals S5-125

5.2.5 Waterproof Membrane S5-126

5.2.6 Curing Materials S5-126

5.3 PRODUCTION OF CONCRETE S5-128

5.3.1 Concrete S5-128

5.3.2 Equipment S5-128

5.4 CONSTRUCTION S5-128

5.4.1 Preparation of Subgrade or Subbase S5-128

5.4.2 Construction by Machine S5-1285.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction S5-1285.4.2.2 Construction by Fixed Form Paving Machine S5-1295.4.2.3 Construction by Slip Form Paving Machine S5-131

5.4.3 Construction by Hand-Guided Method S5-132

5.4.4 Manual Construction S5-1325.4.4.1 Side Forms for Manual Construction S5-133




Page

5.5 JOINTS S5-133

5.5.1 Transverse Expansion Joints S5-133

5.5.2 Transverse Contraction Joints S5-1345.5.2.1 Planes of Weakness S5-1345.5.2.2 Load Transfer Assemblies S5-135

5.5.3 Longitudinal Joints S5-135

5.5.4 Transverse Construction Joints S5-135

5.5.5 Sealing Joints S5-135

5.5.6 Concrete Saw S5-136

5.6 SURFACE TEXTURE S5-136

5.6.1 Texture of Running Surfaces S5-136

5.6.2 Measurement of Texture Depth : Sand Patch Method S5-1375.6.2.1 Apparatus S5-1375.6.2.2 Method S5-137

5.7 ROUNDING OF EDGES S5-137

5.8 CURING S5-137

5.9 REMOVING FORMS S5-138

5.10 OPENING TO TRAFFIC S5-139

5.11 TREATMENT OF MANHOLES AND GULLIES S5-139

5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY S5-139



SECTION 5 - PORTLAND CEMENTCONCRETE PAVEMENT

5.1 DESCRIPTION

This work shall consist of constructing aPortland cement concrete pavement withor without reinforcement in accordance with this Specification, including all relevant requirements of Section 9, and in conformity with the lines, levels, grades, dimensions and crosssections shown on the Drawings. Portland cement concrete shall consist of a mixture of Portland cement, fine aggregate, coarse aggregate and water, with or without admixture.

5.2 MATERIALS

All materials shall conform to the relevant requirements in Section 9 of this Specification. In addition the following requirements shall also be complied with.

5.2.1 Cement

Cement shall be ordinary Portland cement unless otherwise shown on the Drawings or directed by the S.O.

5.2 2 Aggregate

Coarse aggregate to be used for at least the top 50 mm of the slab shall have a polished stone value of not less than 40.

5.2.3 Joint Filler

The expansion joint filler shall conform to the requirements of AASHTO M153 or M213.

5.2.4 Joint Sealants and Seals

Joint sealants shall consist of hot or cold-poured compounds or preformed seals as indicated on the Drawings and shall comply with the following requirements :-

(a) Hot-Poured Sealants

Hot-poured sealants shall comply with the requirements of B.S. 2499 for Type A2 sealants.

(b) Cold-Poured Sealants

Cold-poured sealants shall comply with the performance requirements for the Normal type of sealant given in B.S. 5212.

The sealant shall be composed of a curing agent and a base resin, which shall be in such proportions as recommended by the manufacturer to provide a fast cure if the material is mixed and applied by special machines, or a retarded cure if mixedby hand. It shall cure within 1 hour and remain active for not less than 4 hours. The sealant shall be applied after the curing period of the primer and within the period that the primer remains active.

Materials to be mixed and applied byhand shall be supplied in separate containers and shall be mixed in the correct proportions using a powered stirrer or mixer or any other method approved by the S.O.




(c) Gunning Grade Sealants

Gunning grade sealants consisting oftwo-part poly-sulphide-based sealingcompounds shall comply with B.S. 4254. Alternatively, poly-urethane-based sealing compounds may be used provided their performance is not inferior to B.S. 4254 material.

(d) Preformed Compression Seals

Preformed compression seals shall be made from natural rubber and shall conform to the requirements contained in Table 5.1.

5.2.5 Waterproof Membrane

Plastic sheeting shall have a minimum thickness of 125 um and shall be of a quality as approved by the S.O.

5.2.6 Curing Materials

The exposed surface of concrete pavements shall be cured immediately after the surfacetreatment by the application of one of the following curing materials :-

(a) White Pigmented LiquidMembrane-Forming Compound

White pigmented liquid membrane-forming compound shall conform to the requirements of AASHTO M148, Type 2.

(b) Aluminised Curing Compound

Aluminised curing compound shall be stable and impervious to evaporation of water from the concrete surface within 60 minutes after application.

It shall have test certificates from an approved testing laboratory to show that the compound has a curing efficiency of 90%.

The curing compound shall contain sufficient flaked aluminium in finely divided dispersion to produce complete coverage of the sprayed surface with a metallic finish. The curing compound shall not react chemically with the concrete to be cured and shall not crack, peel or disintegrate within 2 weeks after application.





TABLE 5.1 - SPECIFICATION FOR PREFORMED NATURAL RUBBER COMPRESSIONSEALS

Property.

Units

Requirement

Hardness.

IRHD

55 + 5

Tensile Strength, minimum.

MPa

15

Elongation at break, minimum.

%

400

Compression Set, 24 hours at 100 oC, maximum.

%

40

Ageing Resistance, maximum change from unaged values after 72 hrs + 0 hrs at 100 oC :- - 2 hrs - hardness - tensile strength - elongation at break.

IRHD % %

0 to + 10 - 20 - 25

Ozone Resistance, 20% elongation, 96 hours at 140 oC, 50 pphm.

-

No cracking

Change in Volume after immersion in water for 7 days at laboratory temperature, maximum.

%

0 to + 5

Recovery of Finished Seals, under 50% deflection, after 72 hrs + 0 hrs at 100 oC. - 2 hrs

%

85

Note : All tests are in accordance with ISO Standards.



5.3 PRODUCTION OF CONCRETE

5.3.1 Concrete

Concrete shall be of the grade shownon the Drawings and shall comply with the relevant requirements of Section 9 of this Specification.

5.3.2 Equipment

All equipment used such as batching plant and mixers shall comply with the relevant requirements of Section 9 of this Specification.

5.4 CONSTRUCTION

5.4.1 Preparation of Subgrade or Subbase

Prior to placing concrete pavement, the underlying subgrade or subbase shall have been shaped and compacted in accordance with the provisions of Sub-Sections 2.2.7 or 4.1.2 as appropriate and the waterproof membrane laid as required in the Drawings. Notwithstanding any earlier approvalof finished subgrade or subbase, anydamage to or deterioration of the subgrade or subbase shall be made good to the satisfaction of the S.O. before the waterproof membrane is laid and the concrete pavement constructed.

5.4.2 Construction by Machine

The concrete slab shall be constructed either by fixed form or by slip form paving plant in a continuous process in either one or two layers, as approved by the S.O.

Prior to the placing of concrete, all of the required joint assemblies such as dowel bars, tie bars, etc., shall be installed in accordance with the requirements of Sub-Section 5.5. Inone-layer construction, the slab reinforcement shall also be installed and fixed in accordance with therelevant requirements of Section 9.

In two-layer construction, the thickness of the top layer shall be notless than 50 mm or twice the maximum size of the coarse aggregate, whichever is the greater, and shall be at least 15 mm thicker than the depth of the groove former, if used. Placement of reinforcement and concreting of the top layer shall be done immediately, and in any case not more than 30 minutes, afterthe completion of the bottom layer.

5.4.2.1 Fixed Forms, Rails and Guide Wires For Machine Construction

(a) Fixed Forms and Rails

All forms and rails shall be made of steel and be sufficiently robust and rigid to support the weight and pressure caused by the paving equipment. Side forms for use with wheeled paving machines shall incorporate metal rails firmly fixed at a constant height below the top of the forms.

The forms shall be secured by using not less than three pins for each 3 m length, having one pin fixed at each side of every joint. Forms shall be tightly joined together by a locked joint, free from play or movement in any direction.




Forms shall be cleaned and oiled immediately before each use. The rails or running surfaces shallbe kept clean in front of the wheels of any paving machines. The forms shall be straight withina tolerance of 3 mm in 3 m.

The forms shall be bedded on low moisture content cement mortar and set to the pavement surface level as described in the Contract within a tolerance of ±3mm. The bedding shall not extend under the slab. There shall be no vertical step between the ends of adjacent forms greaterthan 3 mm. The horizontal alignment for forms shall be to the required alignment of the pavement edge as described in the Contract within a tolerance of±10 mm. The mortar or concrete bedding shall be broken out after use.

Prior to concreting, the forms shall be approved by the S.O.

Forms shall not be removed earlier than 6 hours after the completion of the construction of the slab. Care shall be taken to prevent damage to the concrete and any projecting tie bars duringthe removal of the forms. If the removal of forms results in any damage to the concrete the periodof 6 hours shall be increased to that which is necessary to avoid further damage and the Contractor shall make good the damaged areas.

b) Guide Wires

Unless otherwise agreed by the S.O., a guide wire shall be provided along each side of the slab to be constructed by slip

form paving plant. (Each guide wire shall be at a constant height above and parallel to the requirededges of the slab within a verticaltolerance of ±3 mm. In addition, one of the wires shall be at a constant horizontal distance from the required edge of the pavement within a lateral tolerance of ±10 mm.

The guide wires shall be supported from stakes not more than 8 m apart by connectors capable of fine horizontal and vertical adjustment. The guide wire shall be tensioned on the stakes so that a 500 gramme weight shall produce a deflection of not more than 20 mm when suspended at the mid-point between any pair of stakes. The ends of the guide wires shall be anchored to fixing points which shall be not closer to the edge of the slab than the row of stakes and in no circumstances shall a guide wire be anchored to a stake.

The stakes and guide wires shall be checked and approved by the S.O. prior to concreting.

5.4.2.2 Construction by Fixed Form Paving Machine

A fixed form paving train shall consist of separate powered machines which spread, compact and finish the concrete in a continuous operation.

Concrete shall be discharged without segregation into a hopperspreader which is equipped with the means to control its rate of deposition on to the subbase or on to the lower layer. . The concrete shall be spread in each layer




without segregation and to a uniform uncompacted density over the whole area of the slab. The deposited concrete shall be struck off to the necessary level by the underside of the hopper as it is traversed across the spreading machine. The machineshall be capable of being rapidly adjusted for changes in average and differential surcharge necessitated by changes in slab thickness or crossfall.

Prior to being compacted, the surface level of each loose spreadlayer shall be adjusted to the correct surcharge by means of rotating strike off blades or a screw device.

The concrete shall be compacted by vibration or by a combination of vibration and mechanical tamping so as to comply with Sub-Section 5.3.1 throughout the full depth of the slab. Poker vibrators shall be used adjacent tothe side forms and the edge of previously constructed slabs.

The initial regulation and finish to the surface of the slab shall be effected by means of a beam oscillating transversely or obliquely to the longitudinal axis of the pavement. This beam shallbe readily adjustable for both height and tilt.

Joint grooves shall be constructedin compliance with Sub-Section 5.5. The concrete shall be recompacted around the former by a hand held vibrating plate compactor drawn along or on each side of the joint, prior to regulation of the surface by the diagonal finishing beam.

The regulation and finishing of the surface of the slab shall be carried out by a machine which incorporates twin oblique oscillating finishing beams whichshall be readily adjustable for both height and tilt. The beams shall weigh not less than 170 kgper linear metre, be of rectangularsection and span the full width of the slab. The leading beam shall be vibrated. The beams shall be supported on a carriage, the levelof which shall be controlled by the average level of not less than four points evenly spaced over at least 3.5 m of the supporting rail, beam, or slab, on each side of theslab that is being constructed. The final regulation and surface finishing of the slab shall be carried out after any wet forming of joint grooves. After the final regulation and before texture is applied, any excess concrete on top of the groove former shall be removed.

When a concrete slab is constructed in more than one width, flanged wheels on the paving machines shall not be run directly on the surface of any completed part of the slab. The second or subsequent slabs shall be constructed either by supporting machines with flangedwheels on flat- bottom section rails weighing not less than 15 kg/m laid on the surface of the completed slab, or by replacing the flanged wheels on that side ofthe machine by smooth flangelesswheels. Before flangeless wheelsor rails are used, the surface regularity of the slab over which they are to pass shall comply with Sub-Section 5.4.1 and its surface shall be thoroughly cleaned and brushed to remove




all extraneous matter. Flangeless wheels or rails shall be positionedsufficiently far from the edge of the slab to avoid damage to that edge.

5.4.2.3 Construction by Slip Form Paving Machine

A slip form paving train shall consist of powered machines which spread, compact and finishthe concrete in a continuous operation.

A slip form paving machine shall compact the concrete by internal vibration and shape it between sliding side forms or over fixed side forms by means of either a conforming plate or by vibrating and oscillating finishing beams.

The concrete shall be deposited without segregation in front of the slip form paver across its whole width and to a height which at all times is in excess of the required surcharge. The deposited concrete shall be struckoff to the necessary average and differential surcharge by means of a strike-off plate or a screw auger device extending across the whole width of the slab. The equipment for striking off the concrete shall be capable of beingrapidly adjusted for changes in the average and differential surcharge necessitated by changes inslab thickness or crossfall.

The level of the conforming plateand finishing beams shall be controlled automatically from the guide wires by sensors attached at the four corners of the slip form paving machine. The alignment of the paver shall be controlled automatically from the

guide wires by at least one sensorattached to the paver. The alignment and level of ancillary machines for finishing, texturing and curing of the concrete shall be automatically controlledrelative to the guide wires or to the surface and edge of the slab.

Slip form paving machines shall have vibration of variable output, with a maximum energy output of not less than 2.5 kW per metre of slab per 300 mm depth of slab for a laying speed of up to 1.5 mper minute or pro rata for higher speeds. The machines shall be ofsufficient mass to provide adequate reaction on the traction units to maintain forward movements during the placing of concrete in all situations.

Joint grooves shall be constructedin compliance with Sub-Section 5.5. The concrete shall be compacted around the former by a separate vibrating plate compactor with twin plates. The groove former shall be compacted to the correct level by another vibrating float which maybe included with the transverse joint finishing beam. In addition a hand held vibrating float, at least 1 m wide, shall be drawn over the surface along the joint. Any excess concrete on top of thegroove former shall be removed before the surface is textured. Where a concrete surface slab is constructed in more than one width or where the edge needs to be matched for level to another section of surface slab, and the surface levels at the edges are notachieved, paving shall be carried out over separate fixed side formssupporting the edge to the required levels.




5.4.3 Construction by Hand-Guided Method

Areas to be constructed by hand-guided method shall be agreed with the S.O. The slabs shall be constructed in one layer. Dowel bars, tie bars and reinforcement, if specified, shall be fitted in position as shown on the Drawings.

The concrete shall be spread uniformly without segregation or varying degrees of precompaction, by conveyor, chute or by other means approved by the S.O. The concrete shall be struck off by a screed so that the average and differential surcharge is sufficient to ensure that after compaction the surface is to the required level.

The concrete shall be compacted by vibrating finishing beams. In addition, internal poker vibrationshall be used for slabs thicker than 200 mm and may be used for lesser thicknesses. When used, the pokers shall be at points not more than 500 mm apart over the whole area of theslab, and adjacent to the side forms or the edge of a previously constructed slab.

The surface shall be regulated and finished to the level of the top of the forms or adjacent slab or pavement layer by using twin vibrating finishing beams. The beams shall bemetal with a contact face at least 50 mm wide and a vibrating unit havinga minimum centrifugal force of 4 kNwith a frequency recommended by the manufacturer or an equivalent compactive effort. The vibrating beams shall be moved forward at a steady speed of 0.5 m to 1 m per minute whilst vibrating over the compacted surface to produce a smooth finish.

Details of joints shall be as shown onthe Drawings. Joint grooves shall beconstructed in compliance with Sub-Section 5.5. Any irregularities at wetformed joint grooves shall be rectified by means of a vibrating float at least 1.0 m wide drawn along the line of the joint. The whole area of the slab shall be regulated by two passes of a scraping straight edge not less than 1.8 m wide or by a further application of a twin vibrating finishing beam. Any excess concreteon top of the groove former shall be removed before the surface is textured.

The surface shall be brush-textured as described in Sub-Section 5.6.

The concrete shall be cured in compliance with Sub-Section 5.8.

5.4.4 Manual Construction

Areas to be constructed by manual method shall be agreed with the S.O.The slabs shall be constructed in one layer. Dowel bars, tie bars and reinforcement, if specified, shall be fixed in position as shown on the Drawings.

The concrete shall be spread uniformly without segregation or varying degrees of pre-compaction, by conveyor, chute or by other means approved by the S.O. The concrete shall be struck off by a screed so that the average and differential surcharge is sufficient to ensure that after compaction the surface is to the required level.

The concrete shall be compacted by internal poker vibrator or other means approved by the S.O. The vibrations shall be at points not morethan 500 mm apart over the whole




area of the slab, and adjacent to the side forms or the edge of a previously constructed slab.

The surface shall be regulated and finished to the level of the top of the forms or adjacent slab or pavement layer by using an approved portable hand screed. The screed shall be at least 600 mm longer than the width of the slab to be struck off and compacted. It shall be of approved shape, sufficiently rigid to retain its shape and constructed either of metalor of other material shod with metal.

Compaction shall be attained by raising and dropping the screed in successive positions until the required compaction and reduction of surface voids is secured.

The screed shall then be placed on the forms and slid along them, without lifting, in a combined longitudinal and transverse shearing motion moving always in the direction in which the work is progressing. If necessary, this shall be repeated until the surface is of uniform texture, true to grade and contour, and free from porous areas.

After the concrete has been struck off and compacted, it shall be furthersmoothed, screeded and compacted by means of a longitudinal hand floator other equipment as approved by the S.O.

Details of joints shall be as shown onthe Drawings. Joint grooves shall beconstructed in compliance with Sub-Section 5.5. Any irregularities at wetformed joint grooves shall be rectified by suitable means approved by the S.O.

The concrete shall be cured in compliance with Sub-Section 5.8.

As soon as surplus water has risen tothe surface, the pavement shall be given a broomed finish.

5.4.4.1 Side Forms for Manual Construction

All side forms shall be made of steel and be sufficiently robust and rigid to withstand construction forces. Timber forms shall only be used for workwhich is less than 200 m in length.

The forms shall comply with other requirements of Sub-Section 5.4.2.1 as appropriate.

5.5 JOINTS

Joints shall be constructed as specified herein and/or as directed or approved bythe S.O. Before any joint materials are set in place, the underlying pavement course at those locations shall have beenapproved by the S.O.

Preformed expansion joint filler shall be placed around each structure which extends into or through the pavement over the full interface with the concrete pavement slab before concrete is placed.

5.5.1 Transverse Expansion Joints

The components for each transverse expansion joint shall be assembled inadvance and placed in position as a unit.

Each assembly shall consist of an installing template, preformed joint filler of the required dimensions in a single piece, dowel bars and sleeves of the required sizes and lengths at the required locations, and spacing and supporting elements for the dowel bars, as shown on the Drawings.




The installing template shall be metal plate of adequate rigidity approved by the S.O., cut to the required depth and crown of the slab and having a length 10 mm less thanthe required length of the joint. It shall be slotted from the bottom as necessary to permit removal. Suitable means shall be provided on the template for facilitating its removal.

One half length of each dowel bar shall be thoroughly coated with a 200 pen bitumen blended with creosote oil or other material as approved by the S.O. A dowel sleeve shall be fitted on to the coatedend of each dowel.

The dowel supports shall be constructed so as to hold dowels in correct alignment, both vertically andhorizontally, subject to a tolerance of not more than 1 in 100.

When assembled, the top of the installing template shall be about 5 mm above the top of the preformed filler. The filler shall be vertical and shall be in a plane at right angles to the centre line of the road, subject to a tolerance of not more than 1 in 500.

The joint assembly shall be placed sothat the installing template is on the side of the filler remote from pouringoperations. The top of the filler shall be 10 mm below the required concrete surface, and the bottom shall rest on or extend slightly into the underlying pavement course. The assembly and its installation shall have been approved by the S.O. before any concrete is placed against it.

Stakes for supporting the installing template shall be of a cross-section and length satisfactory to the S.O.

5.5.2 Transverse Contraction Joints

Transverse contraction joints shall consist of planes of weakness createdby forming or cutting grooves in the surface of the pavement and, when shown on the Drawings, shall include load transfer dowel bar assemblies.

5.5.2.1 Planes of Weakness

(a) Sawn Grooves

When sawn grooves are specifiedthey shall be sawn in the concrete after its initial set.

Grooves shall be at right angles to the centre line of the pavement, shall be true to line and shall have the width and depth shown on the Drawings.

All joints shall be sawn before uncontrolled shrinkage cracking takes place but not until the concrete has hardened to the extent that tearing and ravelling isnot excessive, usually 4 to 24 hours after placing. If extreme conditions exist which make it impracticable to prevent erratic cracking by early sawing, formedgrooves shall be used.

Any procedure for sawing joints that results in premature and uncontrolled cracking shall be revised immediately by adjusting the sequence of cutting the joints or the time interval involved between the placing of the concrete or the removal of the curingmedium and cutting of the joints.




(b) Formed Grooves

When formed grooves are specified, they shall be made by depressing an approved tool or device into the soft, freshly laid concrete. The tool or device shall remain in place until the concrete has attained its initial set and then be removed without disturbing the adjacent concrete. The line, width and depth shall be as shown on the Drawings.

5.5.2.2 Load Transfer Assemblies

Load transfer assemblies for transverse contraction joints shall be as shown on the Drawings. They shall be of similar construction to the assemblies for transverse expansion joints except thatno joint filler shall be required and, consequently, noinstalling template shall be used.

5.5.3 Longitudinal Joints

Longitudinal joints shall be constructed as shown on the Drawings.

Planes of weakness shall be created by forming or cutting grooves as previously specified.

Tie bars across a longitudinal joint shall be placed perpendicular to the joint and shall be rigidly supported as shown on the Drawings. The barsshall not be painted or coated with bitumen or other material.

When adjacent lanes of pavement are constructed separately, steel side forms shall be used which will form a key along the longitudinal joint as shown on the Drawings.

5.5.4 Transverse Construction Joints

Concreting operations shall be planned such that transverse construction joints shall be constructed at designed transverse expansion or contraction joints.

Transverse construction joints shall be keyed or butt joints formed by placing suitable bulkheads approved by the S.O.

When there is an interruption of more than 30 minutes in the concreting operations, a transverse construction joint shall be constructed. As far as is practicable, this construction joint shall be formed at a designed transverse expansion or contraction joint.

When this is not possible, transverse construction joints shall be constructed at least 3 metres from alltransverse expansion or contraction joints. In such cases, tie bars 12 mm in diameter and 1 metre long at 600 mm centres shall be placed at the transverse construction joints. Wire fabric or bar mat reinforcement shall extend across all such transverse construction joints.

5.5.5 Sealing Joints

Joints shall be sealed as soon after completion of the curing period as feasible and before the pavement is opened to traffic, including construction traffic. Immediately prior to sealing, each joint shall be thoroughly cleaned of all foreign material, including membrane curing




compound, and the joint faces shall be clean and surface dry when the seal is applied.

The sealing material shall be applied in accordance with the dimensions shown on the Drawings or as directed by the S.O.

Sealing material to be applied hot shall be stirred during heating so thatlocalized overheating does not occur.The pouring shall be done in such a manner that the material will not be spilled on to the exposed surfaces of the concrete. Any excess material onthe surface of the concrete pavement shall be removed immediately and the pavement surface cleaned. The use of sand or similar material as a cover for the seal will not be permitted.

Preformed compression seals for sealing joints shall be of the cross-sectional dimensions shown on the Drawings. Seals shall be installed using suitable tools, without elongation, and secured in place withan approved adhesive which shall cover both sides of the concrete joints. The seals shall be installed in a compressed condition and shall at time of placement be below the levelof the pavement surface by approximately 5 mm. The seals shall be in one piece for the full width of each transverse joint.

Notwithstanding the above, all sealants shall be applied or installed in accordance with the manufacturer's instructions or recommendations.

5.5.6 Concrete Saw

When sawing of joints is specified, the Contractor shall provide sawing equipment adequate in number of

units and power to complete thesawing with a water-cooled diamondedge saw blade, or an abrasive wheel, to the required dimensions and at the required rate. The Contractor shall provide at least one stand-by saw in good working order. An ample supply of saw blades shallbe maintained at the site of the work at all times during sawing operations.The Contractor shall provide adequate artificial lighting facilities for night sawing. All of this equipment shall be on the job before and continuously during concrete placement.

5.6 SURFACE TEXTURE

5.6.1 Texture of Running Surfaces

After the final regulation and before the application of the curing membrane, the surfaces of concrete slabs to be used as running surfaces shall be brush-textured in a direction at right angles to the centre line of the carriageway.

The type of brush and method of application for surface texturing shallbe approved by the S.O. based on trial brushing to be conducted by the Contractor.

The texture depth shall be determined by the sand patch test as described herein.

The average texture depth for eachset of 10 tests shall not be less than 0.75 mm and not more than one test of each set shall show a texture depthof less than 0.65 mm. In no case shall the maximum texture depth exceed 2 mm.




5.6.2 Measurement of Texture Depth : Sand Patch Method

5.6.2.1 Apparatus

i) A cylindrical container - 25 ml capacity.

ii) A flat wooden disc 64 mm in diameter with a hard rubber disc, 1.5 mm thick, stuck to one face, the reverse face being provided with a handle.

iii) Dry natural sand passing a 300 um B.S. sieve and retained on a 150 um B.S. sieve.

5.6.2.2 Method

The surface to be measured shall be dried, any extraneous mortar and/or loose material removed, and the surface swept clean usinga wire brush both at right angles and parallel to the centre line of the carriageway. The cylinder shall be filled with the sand, tapping the base three times on a hard surface to ensure compaction, and striking off the sand, level with the top of the cylinder. The sand shall be poured into a heap on the surface to be tested. The sand shall be spread over the surface, working the disc with its face kept flat, in a circular motion so that the sand is spread into a circular patch with the surface depressions filled with sand to the level of thepeaks.

The diameter of the patch shall be measured to the nearest 5 mm.The texture depth in mm of concrete surfaces shall be calculated as:-

31000 where D is the diameter of the of the D x D patch in mm.

5.7 ROUNDING OF EDGES

Where shown on the Drawings or directed by the S.O., edges of concrete slabs shall be rounded as follows.

After brush texturing but before the concrete has attained its initial set, top edges of concrete slabs shall be worked with an approved tool and rounded to a radius of 5 mm. A well defined and continuous rounded edge shall be produced and a smooth, dense mortar finish obtained.

At all transverse joints, any tool marks appearing on the slab adjacent to the joints shall be eliminated by brooming the surface. In doing this, the rounding of the edge of the slab shall not be disturbed. All concrete on top of joints shall be removed completely.

5.8 CURING

The exposed surfaces of concrete pavement shall be cured immediately after surface texturing and rounding of edges by treating with a curing compound fulfilling the requirements of Sub-Section 5.2.6. It shall be mechanically sprayed on to the surface at a rate of 0.22 to 0.27 litre per square metre using a fine spray. The mechanical sprayer shall incorporate an efficient mechanical device for continuous agitation and mixing of the compound in its container during spraying. For the sides of slip formed slabs or when the side forms are removed within the curing period, and for small areas where a mechanical distributor cannot be used, the compound shall be sprayed by hand lance at a rate of 0.27 to 0.36 litre per square metre.




The compound shall form a uniform, continuous, coherent film that shall not crack or peel and shall be free from pin holes or other imperfections. If discontinuities, pin holes or abrasions exist, an additional coat shall be applied within 30 minutes to the affected areas. Necessary precautions shall be taken to ensure proper curing at the joints and that none of the curing compound entersjoints which are to be sealed with joint sealing compounds. Rope of moistened paper, fibre or other suitable material shall be used to seal the top of the joint opening, and the concrete in the region of the joint shall be sprayed with curing compound immediately after the rope seal has been installed.

Approved stand-by facilities or approved alternative methods for curing concrete pavement shall be provided at areadily accessible location at the site of the work for use in the event of mechanical failure of the spraying equipment or any other conditions which may prevent correct application of the membrane curing compound at the proper time. In the event of a failureof the regular spraying equipment, the paving operation shall be stopped, and the stand-by or alternative curing method shall be used on the remaining portion of the paving already placed.

Concrete surfaces to which membrane curing compounds have been applied shall be adequately protected for the duration of the entire curing period frompedestrian and vehicular traffic, except as required for joint sawing operations and surface tests, and from any other cause which will disrupt the continuity of the membrane. The curing membrane so formed shall be maintained intact for a period of not less than fourteen (14) days.

In addition, the entire surface shall be protected from the effects of solar radiation by the use of frames covered with material with heat and rain deflecting properties for not less than 4 hours after application of the curing compound.

Notwithstanding the foregoing, concrete surfaces which are subjected to heavy rainfall within 3 hours after the curing compound has been applied shall be resprayed, all as specified above at no additional cost.

Concrete liable to be affected by runningwater shall be adequately protected fromdamage during the setting period.

5.9 REMOVING FORMS

Forms shall not be removed until the freshly placed concrete has set for at least 6 hours. The forms shall be removed carefully so as to avoid damage to the pavement.

As soon as forms are removed, the ends of all expansion joints shall be cleaned of concrete and the full width of the filler exposed for the full depth of the slab. Any areas showing a minor degreeof honeycombing shall be repaired with 1:3 cement mortar. Where the S.O. considers that a major degree of honeycombing is present, the work shallbe considered defective and shall be removed and replaced at the expense of the Contractor. In such cases, the section of concrete removed shall be to the full width and depth of the slab and at least 3 metres long.




5.10 OPENING TO TRAFFIC

No pavement shall be opened to any traffic earlier than twenty-eight (28) days from the completion of concreting.

The Contractor shall erect and maintain suitable barricades and shall employ watchmen to exclude public traffic and that of his employees and agents from the newly constructed pavement.

These barriers shall be arranged so as not to interfere with public traffic on anylane intended to be kept open and necessary signs and lights shall be maintained by the Contractor clearly indicating any lanes open to traffic.

Where, as shown on the Drawings, it is necessary to provide for traffic across the pavement, the Contractor shall, at hisown expense, construct suitable and substantial crossings to bridge the newlyconstructed concrete pavement for as long as the S.O. shall direct.

Any part of the pavement damaged by traffic or other cause prior to its final acceptance shall be repaired or replaced all at the expense of the Contractor in a manner suitably satisfactory to the S.O.

5.11 TREATMENT OF MANHOLES AND GULLIES

Manhole covers, gullies and their framesshall be isolated from the main pavement slab as shown on the Drawings and their surrounds cast in separate operations.

Manholes and gully recesses shall be formed by casting the main slab against formwork boxes with vertical sides, placed and fixed accurately. The formwork boxes shall be removed before the concrete around the manhole or gully cover is to be placed and preformed joint filler, 20 mm thick,

fixed to the slab edges so exposed. This shall be to the full depth of the slab allowing for the depth of the groove required for sealing. Alternatively, the recesses may be sawn out after the concrete has hardened.

Reinforcement shall be placed as shown on the Drawings and concrete placed by hand in the space between the main slab and the manhole or gully frame. This concrete shall be of the same grade as that of the main slab, and the mix shall be modified as necessary to permit full compaction by the methods adopted.

5.12 HORIZONTAL ALIGNMENTS, SURFACE LEVELS AND SURFACE REGULARITY

The alignment, levels and regularity of the finished surface shall be in compliance with Sub-Section 4.4 of this Specification.





SECTION 6

ROADSIDE FURNITURE




SECTION 6 - ROAD FURNITURE

Page

6.1 CORRUGATED SHEET STEEL BEAM HIGHWAY GUARDRAIL S6-143


6.1.2 Materials S6-1436.1.2.1 Beam Element S6-1436.1.2.2 Posts S6-143

6.1.3 Installation of Guardrails S6-1446.1.3.1 Setting Posts (Timber or Steel) S6-1446.1.3.2 Placing Beams S6-1446.1.3.3 Anchorages S6-144

6.1.4 Marking and Storage S6-1446.1.4.1 Marking S6-1446.1.4.2 Storage S6-144

6.1.5 Basis of Acceptance S6-1446.1.5.1 Beam Elements S6-1446.1.5.2 Posts and Block-Outs S6-145

6.2 TRAFFIC SIGNS S6-145


6.2.2 Sign Definitions S6-145

6.2.3 Sign Classification S6-145

6.2.4 Standards S6-146

6.2.5 Permanent Traffic Signs S6-1466.2.5.1 General Requirements S6-1466.2.5.2 Foundations S6-1466.2.5.3 Posts S6-1476.2.5.4 Sign Plate S6-1476.2.5.5 Sign Faces S6-1486.2.5.6 Backing Frames S6-1496.2.5.7 Construction and Assembly S6-1496.2.5.8 Location and Erection S6-1516.2.5.9 Covering of Permanent Traffic Signs S6-151




Page

6.2.6 Temporary Traffic Signs S6-152

6.2.7 Traffic Signs On Gantries S6-152

6.2.8 Preparation and Finish of Metal and Other Surfaces S6-152

6.3 ROAD MARKINGS S6-153


6.3.2 Road Marking Materials S6-153

6.3.3 Preparation of Site S6-153

6.3.4 Preparation of Material on Site S6-154

6.3.5 Laying S6-154

6.3.6 Protection of Markings S6-154

6.3.7 Reflectorisation S6-154

6.3.8 Thickness S6-154

6.3.9 Tolerance on Width S6-156

6.3.10 Defective Materials or Workmanship S6-156

6.3.11 Clearing Up S6-156

6.4 CONCRETE KERB S6-157



6.4.3 Installation of Kerbs S6-1576.4.3.1 Excavation S6-1576.4.3.2 Cast In Situ Kerb S6-1576.4.3.3 Precast Concrete Kerb S6-1576.4.3.4 Slipforming for Concrete Kerb S6-1586.4.3.5 Backfilling S6-158



SECTION 6 - ROAD FURNITURE

6.1 CORRUGATED SHEET STEELBEAM HIGHWAY GUARDRAIL

6.1.1 Description

This work shall comprise the supply and installation of corrugated sheet steel beam highway guardrails inclusive of bolts, nuts, posts and other ancillary works, all in accordance with this Specification, and the Drawings, and as directed bythe S.O.

6.1.2 Materials

6.1.2.1 Beam Element

Unless otherwise specified on theDrawings, corrugated sheet steel beam highway guardrails shall conform to the requirements of AASHTO Specification M180 for Class `A' Type II (galvanised)guardrail with effective length of beam 3810 mm (12 feet 6 inches). Guardrails shall be fabricated and furnished completewith terminal or buffer sections, connecting and splicing bolts, nuts and washers, etc., all conforming to the requirements of AASHTO Specification M180 and as necessary for erecting the guardrails as shown on the Drawings or as required by the S.O.

6.1.2.2 Posts

(a) Steel Posts

Steel posts shall be channelsections of dimensions as shown on the Drawings and the material shall conform to B.S. 449 Part 1Grade 43. The block-out pieces,

if used, shall be channel sections of dimensions as shown on the Drawings and shall be of the same material as that used for theposts. Both the posts and block-out pieces shall be hot-dip galvanised in accordance with Sub-Section 6.1.2.1.

(b) Timber Posts

Timber posts and block-out pieces shall be of medium hardwood (except the species Merpauh and Rengas) as classified by the Malaysian Timber Industry Board in its publication `Malaysian Hardwood', and shall be treated according to M.S. 733. The preservative retention in the outermost 25 mm shall not be less than 16 kg per cubic metre. Heavy hardwood can also be used as an alternative with the approval of the S.O.

Guardrail timber posts and block-out pieces shall be of the dimensions as shown on the Drawings. The fibres of the blockshould run in the same directionas those of the post. The post shall be sound and free from loose knots or decay with no cracks at the top. All cut faces shall be smooth and square as shown on the Drawings.

All timber components shall be cut and drilled before treatment with preservative.




6.1.3 Installation of Guardrails

6.1.3.1 Setting Posts (Timber or Steel)

Before posts are erected, the alignment and finished levels of the guardrails shall be set accurately on site for approval bythe S.O.

Post holes at the correct positionsshall be dug either manually or mechanically to the required level. The posts shall then be set plumb in the holes with the front face forming a smooth line to the approval of the S.O. After the posts are in place, the holes shall be backfilled with grade 20/20 concrete compacted in such a manner as not to displace the posts from correct alignment as shown on the Drawings. Posts may be installed by means of driving with suitable equipment ifthe S.O. is satisfied that the Contractor is capable of installingthe post to the designed depth, line and level, accurately.

Posts shall be spaced as indicatedon the Drawings.

6.1.3.2 Placing Beams

The guardrail beams shall be fixed and firmly bolted together with the block-out pieces on to the post to the lines and grades asshown on the Drawings, and as directed by the S.O.

6.1.3.3 Anchorages

Anchorages shall be constructed as shown on the Drawings and asdirected by the S.O.

6.1.4 Marking and Storage

6.1.4.1 Marking

In addition to the marking specified in AASHTO Specification M180, the JKR logo shall also be marked on eachbeam element.

6.1.4.2 Storage

All galvanised beam elements, terminal sections, bolts, nuts and washers and posts shall be stored under a cover that will protect them from rain until they are erected or used. While in storage, the material shall not be in direct contact with the soil and there shall be a minimum space of 300 mm between the lowest most elements and the ground surface.

6.1.5 Basis of Acceptance

6.1.5.1 Beam Elements

All material shall be subjected to inspection and sampling in accordance with AASHTO Specification M180 at a samplingrate of 1 in every 200 or as directed by the S.O.

The Contractor shall provide and arrange the testing facilities and the test pieces as and when requested by the S.O. The cost ofall sampling and testing shall be borne by the Contractor. If, in the subsequent installation, thereis detection of non-compliance with the requirements of this Specification through random sampling carried out by the S.O.,then the material of the lot will berejected and the Contractor shall remove the same from the Site athis own cost.




6.1.5.2 Posts and Block-Outs

(a) Steel

For each lot of 200 pieces or less of either steel posts or steel block-outs supplied to the Site, the Contractor shall submit certificates from an approved testing laboratory certifying compliance with the properties required and the mill certificate. However, the S.O. reserves the right to conduct further tests on the materials supplied.

The Contractor shall provide andarrange the testing facilities and test samples at his own expense as and when instructed by the S.O. The steel which has been rejected by the S.O. shall be removed from the Site.

(b) Timber

For each lot of 200 pieces or less of either timber posts or timber block-outs supplied to theSite, the Contractor shall submita test report from an approved testing laboratory certifying compliance with specified timber species and other qualities. However, the S.O. reserves the right to conduct further tests on the materials supplied.

6.2 TRAFFIC SIGNS

6.2.1 Description

This work shall consist of the supply,assembly, erection and installation of sign faces, sign plates, posts and backing frames, all in accordance with the details shown on the Drawings and as specified herein.

It shall include all excavation and backfilling, all necessary foundations, anchorages, fixtures and fastenings, brackets, lighting units and electrical installations where required, application of paintsand finishes, etc., to complete the work all to the satisfaction of the S.O.

6.2.2 Sign Definitions

For the purpose of this Specification,traffic signs are defined as follows :-

i) Non-illuminated signs are those signs which are not lit either internally or externally and shall be retro-reflective;

ii) Externally illuminated signs are those which comprise either retro-reflective or non-retro-reflective facing with external lighting luminaire.

6.2.3 Sign Classification

For the purpose of this Specification,the following clasifications shall apply :-

(a) Permanent Traffic Signs

Any of the traffic signs defined in Sub-Section 6.2.2 above or any part thereof as designated on the Drawings or as directed by the S.O. to remain in position upon completion of the Works.

(b) Temporary Traffic Signs

Any of the traffic signs defined in Sub-Section 6.2.2 above or any part thereof designed by the Contractor with the approval of the S.O. which will not remain in position at the completion of the Works.




6.2.4 Standards

All traffic signs shall, except where specified otherwise, comply with the requirements of ARAHAN TEKNIK(JALAN) Series 2, published by Cawangan Jalan, Ibu Pejabat JKR, Kuala Lumpur.

6.2.5 Permanent Traffic Signs

6.2.5.1 General Requirements

Permanent traffic signs shall be constructed, assembled, located and erected as shown on the Drawings or as directed by the S.O.

Each complete traffic sign or partthereof shall be capable of passing the tests specified in B.S. 873.

All externally illuminated traffic signs shall comply with Category1 luminance of B.S. 873 unless otherwise shown on the Drawings.

Before the commencement of fabrication of any traffic sign, unless otherwise shown on the Drawings, the Contractor shall submit for the S.O.'s approval the details of fabrication drawingsfor all signs.

All traffic sign housings shall be provided with vandal and weather resistant locks. Keys, in the quantities determined by the S.O., shall be provided to the S.O. Types of lock shall be kept to a minimum.

Traffic signs shall be carefully handled to prevent damage (methods shall include the use of proper slings), and shall be

transported and stored in accordance with the manufacturer's instructions.

6.2.5.2 Foundations

The type and size of foundations for permanent traffic signs shall be as shown on the Drawings and, unless otherwise stated therein, shall comply with this Specification.

All excavations, erection of formworks, placing of reinforcement, etc., for foundations shall be carried out incompliance with this Specification and shall be approved by the S.O. before placing of concrete and backfilling.

Unless otherwise shown on the Drawings, signs supported by a single post placed in the ground shall have the post installed centrally in 300 mm diameter holes filled with grade 20/20 concrete complying with Section9 of this Specification to within 450 mm of the ground surface. The hole shall be excavated either mechanically or manually.

Posts shall be supported for a minimum of three (3) days after placing the concrete. Backfilling shall not take place until at least 48 hours after placing the concrete, or other period agreed by the S.O.

Where signs are illuminated, provision shall be made for cable entry through the foundation by means of ducting as shown on the Drawings.




Where pockets are formed in concrete foundations their plan dimensions shall be 100 mm larger than those of the post.

All backfilling of foundation pits and reinstatement of existing surfaces above the foundations shall comply with the relevant requirements of this Specification.

6.2.5.3 Posts

Posts for permanent traffic signs shall be as shown on the Drawings and shall comply with B.S. 873.

Posts shall be of tubular hollow section steel of not less than 50 mm outside diameter complying with B.S. 1387.

Unless otherwise shown on the Drawings, posts shall not protrude above the top of the signunless supporting an external luminaire where the protrusion shall be kept to a minimum.

Signs erected on a single post shall be positioned so that the post is in the centre of the sign, unless otherwise shown on the Drawings.

Compartments for electrical equipment shall be as shown on the Drawings. In the case of signssupported by more than one post, such compartments shall be on the post furthest from the carriageway unless otherwise directed by the S.O.

Flange plates shall have holes or slots as shown on the Drawings to accommodate any holding down bolts.

6.2.5.4 Sign Plates

All permanent sign plates shall beas shown on the Drawings and shall comply with B.S. 873. Sign plates shall be made of 10 S.W.G. sheets of aluminium alloyHS 30-WP conforming to B.S. 1470 with a minimum thickness of 3 mm.

A sign plate not exceeding 1.2 min height and 2.4 m in width shall be made from a single sheet.

Where more than one sheet is used to make up a sign plate, the sheets shall be rectangular, of approximately the same size and shape, and the position of the joints shall be to the approval of the S.O.

Sign plates shall be drilled at all locations where rivets or bolts arerequired for attaching the plate to the backing frame or fixings before application of the sign face. However, riveting shall be carried out only after the application of the sign face.

Subject to the S.O.'s approval, double sided "Very High Bond" (V.H.B.) tapes may be used as an alternative to rivets. Nevertheless,the tape shall comply with the following requirements :-

i) Peel Adhesion - 440 N per 100 mm;

ii) Tensile Adhesion - 910 kPa;

iii) Dynamic Shear -550 kPa.




Where top and bottom light spill screens are required as shown on the Drawings, these shall extend for the whole width of the sign, be fabricated out of the same material as the sign plate and shall have corners cut to the sameradius as the other corners of the sign plate.

Top and bottom light spill screensshall be considered part of the sign plate and any stiffeners and mounting fittings shall be designed to accommodate the combined size.

6.2.5.5 Sign Faces

Sign faces for permanent traffic signs shall be as shown on the Drawings and shall comply with the `Draft Malaysian Standard Specification for Reflective Sign Face Materials' (SIRIM Reference D111 [ISCF]), and on replacement of this draft, the respective Malaysian Standard Specification.

All retro-reflective plastic sheeting shall be fixed in accordance with the manufacturer's instructions.

Unless otherwise agreed by the S.O., sign faces shall be formed from a single piece of plastic sheeting.

Where, with the agreement of theS.O., more than one plastic sheetis used, the number of sheets shall be kept to a minimum. All faces up to 1 m in size shall be produced with a single sheet and no joint will be accepted.

Only vertical and horizontal joints shall be permitted and all joints in plastic sheeting shall be overlapped by not less than 6 mm. The overlap in the horizontal joints shall be from thetop and the vertical joints shall befrom the left; butt joints in plasticsheeting will not be accepted. Plastic sheeting shall be applied evenly over the whole surface of the sign plate and shall adhere fully. It shall be free from twists, cracks, folds or cuts, air bubblesand other blemishes.

All plastic sheetings used on the same sign shall be carefully matched for colour to produce a uniform appearance both by day and by night. Non-uniform shades of colour on any one sign will not be accepted.

The edges of all plastic sheeting shall be sealed. Edge sealing shallbe continuous and uniform and shall also be applied to all bolt and rivet holes.

A coat of clear lacquer shall be applied to the whole of the face and edges of each finished sign plate at the time of fabrication. The lacquer shall be continuous and uniform and shall be of the type specified or supplied by the manufacturer of the sheeting material.

Where sheeting is applied to extruded sections by pressure roller, it shall extend over the top and bottom edges of these sections by not less than 3 mm.




Any cut-out letters, numerals, symbols and borders shall be of material compatible with the sheeting to which they are applied. They shall be applied in accordance with the sheeting manufacturer's instructions.

Screen processed letters, numerals, symbols and borders shall be screen printed with materials in accordance with the sheeting manufacturer's instructions. Any inks, pastes and finishing coats used shall be compatible with the sheeting material.

The finish of all sign faces shall be capable of passing the tests described in B.S. 873, and the standards of fabrication and workmanship shall be such that under normal conditions ofservice and proper maintenance, the sign faces shall last not less than 5 years without any serious blemishes or defects for Engineering Grade retro-reflective sheeting and 8 years for High Intensity retro-reflective sheeting. The Contractor shall furnish to the S.O. a letter of warranty for the specified period for all sign faces from the supplier of the sheeting or the sign fabricator.

6.2.5.6 Backing Frames

Backing frames for permanent traffic signs shall be as shown on the Drawings and shall comply with this Specification.

Signs exceeding 600 mm in height or width shall be stiffened by means of angles while signs exceeding 1 m in height or widthshall have a backing frame

fabricated from 40 mm x 40 mm x 3 mm angles. The angles used for the backing frames shall be made from aluminium alloy HE9-TE conforming to B.S. 1474.

The angles shall be welded, bolted or riveted together to form the backing frames as shown on the Drawings.

Backing frames shall not project beyond the face of the sign.

Where large signs are built in sections, the backing frames of these sections shall be bolted together with 8 m diameter bolts at not more than 200 mm centres.

The details of joints between angles of the backing frame and of joints between sections of large signs shall be to the approval of the S.O.

The sign plate shall be riveted or bonded with double sided V.H.B.tape to the backing frame after the application of the sign face.

6.2.5.7 Construction and Assembly

Traffic signs shall be constructed and assembled as shown on the Drawings and shall comply with B.S. 873.

All sign plates, backing frames, purlins, posts and other components shall be de-burred prior to assembly.

Where framing and stiffening are not an integral part of the sign plate, their joints shall be welded or joined with suitable brackets utilising nuts, bolts and washers.




Where purlins are adopted, they shall be attached to each vertical member of the backing frame andthe sign stiffening and framing shall be continuous in the verticaldirection. Unless otherwise permitted by the S.O., purlins shall be spaced equally apart. Connections shall be made at every point where a purlin crosses a post.

Where purlins are not adopted, the sign stiffening and framing shall be continuous in the horizontal direction.

All rivets and other devices used in the fixing of sign plates to theirstiffeners or backing frames, or those used in the construction of housings, shall be of a material compatible with the materials being joined.

Spacing of rivets or other devicesused in the fixing of sign plates totheir stiffeners or backing frames shall be uniform and shall not exceed 150 mm around the outside edge of any sheet or section of a sheet, and shall not exceed 300 mm on cross braces. Hollow rivets shall be filled with a plastic plug flush with the head of the rivet.

An additional washer of neoprene, nylon or other material approved by the S.O. shall be used against the sign face to protect it from the effects of any metal nuts, bolts, washers and/or screws.

Where traffic signs, including external lighting luminaires or their supports, are required to have holding down bolt fixings, the bolts shall be lightly greased

before final installation and they and their anchorages shall be installed so as to achieve the loadings, torque settings and requirements shown on the Drawings.

Sign plates shall be connected to posts by a method approved by the S.O.

Banding systems shall be of stainless steel.

Where ferrous components are permitted, any drilling of such components shall be completed before the application of any finish.

Any hole drilled to accommodaterivets or bolts in plates with plastic sheeting shall, immediately prior to the insertion of the rivet or bolt, have a clear lacquer, as recommended by the manufacturer of the plastic sheeting, applied to its edge to prevent the ingress of moisture. The surfaces of rivets or bolts exposed on the sign face shall be coloured by a material approved by the S.O. to match that part of the face.

Traffic signs to be erected on road lighting columns shall have fixings compatible with the column cross-section and finish. Unless otherwise permitted by the S.O., columns shall not be drilled and wiring shall be contained in approved external conduits.

In addition to the requirements ofthis Specification, variable message traffic signs shall be of atype approved by the relevant authorities.




6.2.5.8 Location and Erection

The approximate location of eachpermanent traffic sign shall be as shown on the Drawings. All traffic signs shall have their exactlocation determined by the S.O. and recorded on the as-built Drawings.

All posts shall be erected plumb and where two or more posts are provided for any one sign, the face of the posts shall be lined up.

Signs erected on two posts shall have each post positioned so that the distance from the centre of the post to the edge of the sign plate is 300 mm unless otherwise directed by the S.O.

Any pockets formed in concrete foundations to receive the posts shall immediately prior to erection be cleaned out. The postsshall be placed centrally in the pockets and be bedded on and filled up to finished foundation level with grade 20/20 concrete.

Traffic signs mounted on posts, except those on gantries, shall be erected to have their faces plumb and orientated in relation to the carriageway in accordance with ARAHAN TEKNIK (JALAN) 2B/85.

Traffic signs mounted on gantriesshall be erected as shown on the Drawings.

No traffic sign shall be dismantled, resited or removed without prior approval from the S.O.

6.2.5.9 Covering of Permanent Traffic Signs

Where it is required in the Contract that permanent traffic signs are to be blanked-out or are to have an alternative message, the covering to be adopted shall comply with the following requirements.

The covering shall be 1.5 mm (16 S.W.G.) thick made from a material compatible with that of the sign plate, or a material approved by the S.O.

Cover plates shall be fixed by means of 5 mm diameter stainless steel bolts, washers and nuts or non-ferrous rivets not more than 600 mm apart, the bolts passing through 12 mm diameter, 5 mm thick plastic distance pieces between the sign face and cover plate. Any holes remaining in the finished sign face shall be filled with blocked rivets coloured on the face by methods approved by the S.O.

Where self-adhesive plastic film is used, it shall be compatible with the sign face materials and be applied and removed in compliance with the manufacturer's instructions.

Any loose covering used must be sufficiently opaque to prevent reflection from the covered sign and be securely fastened to the back of the sign. Under no circumstances shall tape or other adhesive material be applied to the face of the sign. A minimum space of 50 mm shall be left between the covering and the face to permit airflow over the sign.




Traffic signs which are to be covered shall not be erected on trafficked highways without the covering in place.

Removal of any covering shall becarried out with minimum disturbance to traffic and only after the S.O. has given his approval.

Irrespective of any requirement inthe Contract to cover signs, any traffic sign erected at such a time that its legend does not relate either wholly or in part to the traffic movement and route in operation, shall have its sign face securely covered with one of the materials described above until such time as the S.O. authorises its removal.

6.2.6 Temporary Traffic Signs

Temporary traffic signs shall beconstructed either as non-illuminatedor externally illuminated signs as directed by the S.O.Location and erection of temporary traffic signs shall be in accordance with ARAHAN TEKNIK (JALAN) 2C/85. Erection of temporary traffic signs mounted on posts shall complywith Sub-Section 6.2.5.8.

Any temporary covering of temporary traffic signs shall comply with Sub-Section 6.2.5.9.

Removal of temporary traffic signs shall be carried out as soon as they become superfluous or a hazard to traffic. Methods of removal and making good shall be submitted to the S.O. for approval beforehand. Making good shall be carried out immediately after removal of the traffic sign to the satisfaction of the S.O.

6.2.7 Traffic Signs On Gantries

Where traffic signs are erected on gantries, the signs shall comply with the relevant requirements of this Specification.

Fabrication and construction of gantries shall be as shown on the Drawings and as directed by the S.O.

6.2.8 Preparation and Finishof Metal and Other Surfaces

Traffic signs shall be prepared, protected against corrosion and finished in compliance with B.S. 873.

Faces of sign plates shall be preparedto receive sign face materials in compliance with B.S. 873 and in accordance with the manufacturer's recommendations.

Steel backing frames, fittings and purlins shall be prepared and protected in compliance with B.S. 873.

Steel posts and post housings shall be prepared and protected in compliance with B.S. 873.

Backs of aluminium or aluminium alloy sheets forming plate signs and external parts of luminaire housings and other permanently exposed components shall, to prevent retro-reflection, be dulled with paint usinga method approved by the S.O.

Ferrous steel shall be finished both inside and out by galvanising, electro-plating or application of zinc or aluminium spray or other equivalent finish approved by the S.O.Aluminium and other metals shall beleft untreated unless otherwise shown on the Drawings.




Unless otherwise shown on the Drawings, stainless steel shall be left untreated except where the component is visible against the sign face when it shall be coloured on the face by methods approved by the S.O.

External surfaces shall be prepared and protected as described in the Contract. Cabinets and feeder pillars shall have final coats of paint applied on Site after final installation, including the fitting of any internal apparatus required as partof the permanent Works. Internalsurfaces shall, unless otherwise shown on the Drawings, receive the same treatment as for externalsurfaces except that final paint coats shall be applied before internal components are installed.

6.3 ROAD MARKINGS

6.3.1 Description

This work shall consist of the supply of road marking material and its application to form continuous or intermittent lines, letters, arrows, symbols or figures. The markings shall be white or yellow laid to the dimensions and at the locations shown on the Drawings and as specified herein or as directed by the S.O. The work includes the supply of all labour, tools, equipment, materials, and warning and traffic guidance signs as necessary for the safe and efficient completion of the entire work.

6.3.2 Road Marking Materials

The marking material shall be one ofthe types detailed below as indicated on the Drawings or as directed by the S.O.

(a) Thermoplastic Material

Thermoplastic material shall comply with the requirements ofB.S. 3262 Part 1. Yellow thermoplastic material shall be of standard colour B.S. 381C No. 356 (Golden Yellow).

(b) Road Marking Paint

Road marking paint shall comply with the requirements of M.S. 164. Yellow paint shall be of standard colour B.S. 381C No. 356 (Golden Yellow).

6.3.3 Preparation of Site

Thermoplastic material and road marking paint shall be applied only on a surface which is clean and dry. It shall not be laid over loose detritus, mud or extraneous matter orover old material or paint marking incompatible with the paint being applied.

A tack coat compatible with the marking material shall be applied in accordance with manufacturer's instructions prior to the application of thermoplastic material.

If a primer or undercoat is necessary to ensure proper adhesion of the marking paint to the road surface without bleeding or other discoloration, the primer or undercoat shall be fully compatible with the marking paint and the road surface. The rate of application of tack coat, primer or undercoat shall be in accordance with the manufacturer's instructions and to thesatisfaction of the S.O.


HStandard Specification For Road Works


6.3.4 Preparation of Material on Site


Thermoplastic material shall be supplied in block or powder form. If the material is supplied in block form it shall be broken into pieces, each weighing not more than 4 kg, which shall be melted in a heater fitted with a mechanical stirrer to prevent local overheating.

A thermometer of sufficient accuracyshall be used during laying to ensure that overheating of the material does not occur. Once molten hydrocarbonresins shall be used within 6 hours and wood and gum resins shall be used within 4 hours. The material shall not be heated beyond the manufacturer's specified temperature during application. Excess material shall be discarded on completion of application.


All paint shall be thoroughly stirred before application to keep the pigments in uniform suspension. Theuse of thinners or other additives shall not be permitted unless otherwise approved by the S.O.

6.3.5 Laying

Centre lines, lane lines and edge lines shall be marked by approved mechanical means or as directed by the S.O. Other markings shall be applied by brush, spray, screed, hand-propelled or self-propelled machine according to the marking configuration and the type of marking material approved for use. The rate of application of the marking material for each coat shall be that recommended by the manufacturer unless otherwise

specified. When more than one coat is used, the succeeding coat shall not be applied until the previous coat hasfully set.

Road markings of a repetitive nature other than centre lines, lane lines, etc., shall, unless otherwise decided by the S.O., be set out with stencils which comply with the size and spacing requirements as shown on the Drawings.

6.3.6 Protection of Markings

All markings shall be protected from traffic until they have dried sufficiently so that no pick-up by vehicle tyre will occur.

6.3.7 Reflectorisation

Solid glass beads to be incorporated in marking materials prior to application to road surfaces shall be Class `A' glass beads complying with the requirements of Table 1 ofB.S. 6088 (see Table 6.1).

Solid glass beads for additional surface reflectorisation shall be Class `B' glass beads complying withthe requirements of Table 2 of B.S.6088 (see Table 6.2).

6.3.8 Thickness

The determination of thickness shall be in accordance with B.S. 3262 Part 3, Appendices B and C.





TABLE 6.1 - CLASS `A' GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESSAND DEFECTS

B.S. Sieve

Percentage Retained

Min. % Spherical Beads by mass

as tested in accordance with

Appendix C

Max. % Defective Beads as tested in accordance with

Appendix D

1.18 mm

850 um

425 um

0 to 3

0 to 10

90 to 100

70

30

TABLE 6.2 - CLASS `B' GLASS BEADS : PARTICLE SIZE DISTRIBUTION, ROUNDNESS AND DEFECTS

B.S. Sieve (um)

Percentage Retained

Min. % Spherical Beads by mass as tested in

accordance with Appendix C

Max. % Defective Beads as tested in accordance

with Appendix D

850

800

300

180

Below 180

0 to 5

5 to 20

30 to 75

10 to 30

0 to 15

80

20




Thermoplastic material shall be laid to the followingthicknessess :-

i) for synthetic hydrocarbon resin binder -

-screed lines : not less than 2 mm nor more than 5 mm;

-sprayed lines other than yellow lines : not less than 1.5 mm;

-sprayed yellow edge lines (for`no parking', `no waiting', etc.) : not less than 0.8 mm.

ii) for gum or wood resin binders -

-screed lines : not less than 3 mm not more than 5mm;

-sprayed lines other than yellow lines: not less than 2 mm;

-sprayed yellow edge lines (for `no parking', `no waiting', etc.) : not less than 2 mm nor more than 3 mm.


Road marking paint shall be laid to give a wet film thickness of not less than 315 microns and not more than400 microns.

6.3.9 Tolerance on Width

The tolerance on the specified width of the marking shall be within the range of + 10% and minus 0%.

6.3.10 Defective Materials or Workmanship

Materials which are defective or which have been applied in an unsatisfactory manner or toincorrect dimensions or in a wrong location, shall be removed by approved chemical or mechanical means. To the extent necessary, the road pavement shall be made good and the markings reapplied all at the Contractor's own expense and to the approval of the S.O.

Where directed by the S.O., existing markings shall be removed in the same manner as above.

6.3.11 Clearing Up

The Contractor shall clean up all spatters, splashes and smirches ofmarking material completely to the satisfaction of the S.O.




6.4 CONCRETE KERB

6.4.1 Description

This work shall consist of the supply and installation of cast in situ or precast concrete kerbs constructed at the locations and in accordance with the lines, levels, grades, dimensions and types as shown on the Drawings,all in accordance with this Specification.

6.4.2 Materials

Concrete for kerb sections shall be grade 25/20 concrete unless otherwise indicated on the Drawings and shall conform to the requirements of Section 9 of this Specification.

Unless otherwise shown on the Drawings, bedding shall be grade 10/25 concrete.

6.4.3 Installation of Kerbs

6.4.3.1 Excavation

Excavation shall be made to the required depth and the base shall be trimmed and compacted to a firm and even surface. All soft and unsuitable material shall be removed and replaced with suitable material as defined in Section 2 of this Specification. The bedding material shall then be placed and compacted to form a bed of required thickness as shown on the Drawings.

6.4.3.2 Cast In Situ Kerb

When a cast in situ kerb is placednext to a concrete pavement, expansion joints in the kerb shall be located in line with expansion joints in the pavement. Expansionjoints shall be formed at theintervals shown on the Drawings using preformed filler 10 mm in thickness in accordance with the specification for the pavement joint filler.

Concreting shall generally be inaccordance with the requirements of Section 9 of this Specification. Forms shall not be removed within 24 hours of the concrete being placed. Minor defects shall be repaired with mortar containing 1 part Portlandcement to 2 parts sand.

After placing and compaction, the concrete shall be covered with suitable material and kept moist for a period of 7 days.

6.4.3.3 Precast Concrete Kerb

Precast concrete kerbs shall be cast using steel moulds and shall be of the types as shown on the Drawings.

Each kerb shall be set so that its front top arris conforms to the line and grade required. All spaces under the kerb shall be filled with bedding material which shall be thoroughly tamped.




Kerbs shall be laid with joints as narrow as possible and filled withmortar containing 1 part Portlandcement to 2 parts sand. Where a Portland cement concrete pavement is to be constructed contiguous to a kerb, expansion joints shall be constructed in the kerb directly in line with pavement expansion joints. The expansion joint in the kerb shall be 20 mm in width and shall be filled with an expansion joint filler of the same nominal thickness as the pavement joint. Any voids between filler and the concrete kerb shall be filled with mortar.

6.4.3.4 Slipforming for Concrete Kerb

In situ concrete kerbs shall be laid by an approved automatic kerbing machine or, if practicable in the case of concretepavements, by the concrete paver itself. The kerbs shall be dense with regular sides, edges, arrises and chamfers, finished to a fine surface free from blow holes and dragging, and shall be impervious.

6.4.3.5 Backfilling

The spaces in the front and backof each kerb shall be refilled to the required elevation with suitable material approved by the S.O. which shall be tamped in layers of not more than 150 mm until properly compacted.

The finished work shall be true toline, grade and level to within ±10 mm and shall present a smooth appearance free from kinks and distortion visible to the eye.





SECTION 7

STREET LIGHTING




SECTION 7 - STREET LIGHTINGPage

7.1 GENERAL

7.1.1 Scope of Work S7 - 162

7.1.2 On Site Commissioning Tests S7 - 162

7.1.3 As-Built Drawings S7 - 162

7.1.4 Maintenance S7 - 163

7.1.5 Traffic Safety and Control S7 - 163

7.2 LOW VOLTAGE UNDERGROUND CABLES

7.2.1 General S7 -164

7.2.2 Types of Cables S7 - 1647.2.2.1 Power Cables S7 - 47.2.2.2 Earthing Conductors S7 - 4

7.2.3 Lengths of Cables S7 - 164

7.2.4 Cable Routes S7 - 164

7.2.5 Cable Trenches S7 - 165

7.2.6 Cable Ducts S7 - 165

7.2.7 Cable Termination S7 - 1667.2.7.1 Termination of PVC Insulated Armoured Cable S7 - 1667.2.7.2 Termination of Paper Insulated Cables S7 - 166

7.2.8 Cable Jointing S7 - 167

7.2.9 Cable Markers S7 - 167

7.2.10 Cable Laying and Installation S7 - 168

7.3 STREET LIGHTING LUMINAIRES

7.3.1 Light Distribution Requirements S7 - 170

7.3.2 Constructional Requirements S7 - 1707.3.2.1 Luminaires S7 - 1707.3.2.2 Lamps S7 - 1717.3.2.3 Ballast S7 - 1727.3.2.4 Capacitors S7 - 1727.3.2.5 Ignitors S7 - 172




page

7.4 FEEDER-PILLARS S7 - 14

7.4.1 General S7 - 172

7.4.2 Fabrication of Feeder-Pillars S7 - 172

7.4.3 Factory Inspection S7 - 173

7.4.4 Foundation S7 - 173

7.4.5 Earthing S7 - 173

7.4.6 Time Switches S7 - 173

7.4.7 Contactors S7 - 173

7.4.8 By-Pass Switches and Selector Switches S7 - 173

7.5 COLUMNS AND BRACKETS S7 - 16

7.5.1 General S7 - 174

7.5.2 Design Loading S7 - 174

7.5.3 Fabrication of Column Sections S7 - 1747.5.3.1 Doors and Door Openings S7 - 1747.5.3.2 Service Slots S7 - 174

7.5.4 Bracket Arms S7 - 174

7.5.5 Base-Plates S7 - 175

7.5.6 Baseboards S7 - 175

7.5.7 Street Lighting Cut-Outs S7 - 175

7.5.8 Earthing Terminals S7 - 175

7.5.9 Cable Entry S7 - 175

7.5.10 Erection of Columns S7 - 175

7.5.11 Protection Against Corrosion S7 - 176



SECTION 7 - STREET LIGHTING

7.1 GENERAL

7.1.1 Scope of Work

This work shall comprise the design of cabling works and the supply and installation of all luminaires, lamps, ballasts, capacitors, ignitors, feeder pillars, columns, ducting and cabling,and all necessary ancillary equipment, together with the transportation, storage, erection, connection, testing and commissioning of the same for a complete street lighting system, all inaccordance with the Drawings and this Specification. The work shall also include cabling from the nearest specified power source of the local supply authority to the street lighting system, if required.

7.1.2 On Site Commissioning Tests

On completion of the installation work on site, the Electrical Contractor shall, at his own expense, arrange for all necessary tests to be carried out on the installation by competent personnel as part of the tests required of him for the whole ofthe installation under this Contract.

The tests to be carried out shall be asprescribed in the latest edition of the IEE Wiring Regulations and the Electricity (Board Supplies) Rules 1949, and shall include other tests deemed necessary by the S.O. In theevent that the installation fails to passany of these tests, the Electrical Contractor shall take such measures as are necessary to remedy the defects and the installation shall not be considered to have been completed until all such tests have been passed.

Tests on cables shall include continuity, phasing out and insulationresistance between conductors and between conductors and sheaths by employing a 500 V insulation tester.The date of commissioning shall be agreed to by the S.O. and theElectrical Contractor shall ensure that the installation is safe before the cable is energised.

The S.O. reserves the right to be present at all tests and the Electrical Contractor shall give at least one (1) week's notice in writing to the S.O. for this purpose. In any case, no test shall be carried out without prior approval from the S.O. Copies of alltest certificates shall be submitted to the S.O. within one (1) week of the completion of the testing.

7.1.3 As-Built Drawings

Within three (3) calender months from the practical completion of the installation, one set of true-to-scale negatives (110/115 g/sq.m A0 or A1 sizes) and four sets of prints of each of the following as-built drawings shall be submitted to the S.O. by the Electrical Contractor :-

i) Site plans;

ii) Schematic wiring diagrams;

iii) Layout plans showing cable routes with reference to easily recognisable buildings and structures, sizes and types of cables, locations and types of joints, cable ducts, street lighting poles and luminaires, feeder pillars and earthing points.




These as-built drawings shall be properly stencilled and shall have, at the lower right hand corner, the Electrical Contractor's name and address, the date of commissioning, the scale, drawing number (this shall be obtained from the S.O.) and title, and the following particulars:-

JABATAN KERJA RAYACAWANGAN ELEKTRIKCONTRACT NO.TENDER NO.

In addition, one (1) set of the as-built drawings shall be properly framed and kept in the switchroom.

If the as-built drawings submittedare not acceptable by the S.O., the Electrical Contractor shall amend and resubmit the drawingswithin two (2) weeks from the date of return of the drawings.

7.1.4 Maintenance

During the Defects Liability Period, the Electrical Contractor shall perform maintenance work for the complete cabling and associated works. All labour, materials, tools and parts necessary to rectify the defects due to manufacturing or installation faults shall be supplied and/or executed at no extra cost to the Government. Maintenance work shall be carried out as soon as the Electrical Contractor has been informed by the S.O. to do so.

The work to be performed shall include but shall not be limited to thefollowing :-

i) replacing or making good any defective cables, cable joints and cable terminations;

ii) replacing any broken or defectivecable markers;

iii) making good any damage to buildings, concrete areas, slopes, drains, culverts, existing cables, pipes, etc., which have not been properly made good as a result ofthe Electrical Contractor's work; and

iv) carrying out any other work deemed necessary by the S.O.

7.1.5 Traffic Safety and Control

When work is being carried out beside any public road or other existing road, warning signs shall be erected. The general arrangement and location of temporary warning signs shall be strictly in accordance with ARAHAN TEKNIK (JALAN) 2C/85, published by Cawangan Jalan, Ibu Pejabat JKR, Kuala Lumpur, and shall be submitted by the Electrical Contractor and approved by the S.O. before work commences.

Where it is necessary for any pit or trench to be left open overnight, flashing warning lamps shall be placed at each end of the pit or trench and at intervals not greater than 10 m apart. In built-up areas, barricades shall be erected along the length of the pit or trench in addition to the warning lamps.

Where necessary, flag-men shall be stationed to control traffic.





7.2.1 General

The Electrical Contractor shall submit, for the approval of the S.O., a program of work for the excavationof cable trenches, laying of cables, reinstatement of trenches, etc., one (1) week before the work is to be executed.

7.2.2 Types of Cables

7.2.2.1 Power Cables

Power cables shall be manufactured and tested in accordance with :-

i) M.S. 274 or B.S. 6346 and shall have high conductivity plain copper stranded conductors, insulated with PVC suitable for a voltage of between 600 and 1000 V, laid together and bedded with PVC, armoured with galvanised steel wires and sheathed with PVC; or

ii) B.S. 6480 Part 1 and shall have high conductivity plain copper stranded conductors, insulated with strong long-fibred paper, uniform in texture, free from metallic particles, mass impregnated with non-draining insulating oil compound suitable for a voltage of between 600 and 1000 V, lead alloy sheathed and served; or

iii) B.S. 6480 Part 1 and shall have high conductivity plain copper stranded conductors, insulated with strong long-fibred paper, uniform in texture, free from metallic particles, mass impregnated with non-draining insulating oil compound suitable for a voltage of between 600 and 1000 V, lead alloy sheathed, double steel tape armoured and served.

7.2.2.2 Earthing Conductors

Cables from street-lighting cut-outs and earthing cables to luminaires shall be 2.5 sq.mm PVC/PVC cables bundled together with cable ties and terminated with lugs where necessary.

7.2.3 Lengths of Cables

The lengths of each type of cable indicated on the Drawings and/or in the B.Q. are for tendering purposes only. The Electrical Contractor shall as certain the length of each cable required before placing orders for cables. The actual length of each cable installed shall be measured on site and the Electrical Contractor shall be paid according to the rate specified in the Contract. The rates quoted shall include any wastage dueto cutting to lengths, terminations, etc.

7.2.4 Cable Routes

Cable routes shown on the Drawingsare for tendering purposes only. The Electrical Contractor shall, after consulting the S.O., peg out cable routes for the S.O.'s approval prior toexcavation of the cable trenches.




7.2.5 Cable Trenches

Unless otherwise specified, cable trenches shall be 750 mm deep. Theyshall be of sufficient width as to enable provision of adequate spacingbetween cables but in any case shall not be less than 450 mm wide.

Trenches shall be as straight as possible and shall have vertical sides which shall be timbered where necessary so as to avoid subsidence damage. The bottoms of trenches shall be firm and of smooth contour and any objects likely to damage the cable sheathing shall be removed. Material excavated from trenches shall be placed or removed so as to prevent nuisance or damage to adjacent areas or buildings.

Trench excavation and backfilling shall be so executed that all roads, walls, sewers, drains, pipes, cables, structures, etc., shall be reasonably secured against risk of subsidence damage. Provision shall be made during excavation and until interim restoration has been completed for reasonable access of persons and vehicles to the areas of buildings adjacent to the trenches.

Where a trench passes from a footway to a roadway or at other positions where a change in level is necessary, the bottom of the trench shall rise and/or fall gradually.

7.2.6 Cable Ducts

At road crossings, sewerage pipe crossings, water pipe crossings, paved areas, concrete areas and where specified by the S.O., cables shall be protected by galvanised steelpipes buried to a depth of 900 mm below finished ground level. The pipes shall be heavy duty pipes

complying with B.S. 1387, complete with screwed and socketed joints. Unless otherwise specified, the pipes shall be 150 mm in diameter.

The Electrical Contractor shall provide pumps and other appliances for the necessary pumping required for the disposalof water so as to prevent any risk of the cables and other materials to be laid in the trench from being detrimentally affected. Where necessary, bailing shall be provided.

Where it is necessary to cross drains, culverts or similar obstructions which are too deep for the cables to be buried below, galvanised steel pipes as specifiedabove shall be provided. The pipes shall be supported at each end in a concrete block and shall project through the blocks into the ground to a depth of at least 750 mm.

All ducts shall be extended at least 600 mm beyond paved areas, concrete areas, drains, roadcrossings, pipe crossings, etc.

Cables entering buildings shall beprotected by pitch fibre ducts of 150 mm diameter, complying with B.S. 4108, complete with bend pieces, buried to a depth of 900 mm and encased in 75 mm of concrete all round. The ducts shall be installed with a gradient so as to drain away any water in the ducts. All ducts passing through walls shall be effectively sealed and made water-tight.




Unless otherwise approved by theS.O., the number of cables installed in each duct shall be such that the space factor shall benot less than 60%. A drawn wire shall be provided for each duct.

Unless specified to be provided by others, the above galvanised steel pipes and /or pitch fibre ducts shall be provided by the Electrical Contractor whether or not they are shown on the Drawings.

7.2.7 Cable Termination

Unless otherwise permitted, all cabletermination and jointing works shall be carried out in the presence of the S.O. A plastic laminated plate engraved with details such as size of cable, number of cores, date of commissioning, date of jointing, length of cable, distance of cable joint, etc., shall be securely fixed near the termination.

7.2.7.1 Termination of PVC Insulated Armoured Cables

PVC/SWA/PVC cables shall be provided with compression cable gland termination. The cable gland shall be of gunmetal or brass and shall grip both the innerand outer PVC sheath of the cable. It shall be so designed that any strain on the cable is taken bythe steel wire armouring which shall be effectively sealed between the gland itself and the outer cable sheath.

7.2.7.2 Termination of Paper Insulated Cables

PILCDS and PILCDSTAS paper insulated cables, unless otherwisespecified, shall be terminated by the heat shrinkable method.

The cables shall be tested for moisture before termination is commenced. Samples of paper both from the layers nearest to and furthest from the conductor shall be immersed in transformer oil or paraffin wax heated to a temperature of approximately 115ºC. If any residual moisture is present, this will be detected immediately through the presenceof bubbles. Samples of paper shall be tested singly and shall not be touched by hand, but shall be gripped with a pair of tweezers.

Phasing and insulation resistance tests shall be taken on each lengthof cable laid before termination iscommenced.

The heat shrinkable termination materials used shall be supplied in a complete kit to suit various sizes of cable and to provide stress controlled, non-tracking, environmentally sealed termination. They shall consist of high permittivity, high resistivity, heat shrinkable, stress controlled, UV stable, non-tracking polymeric materials and heat-activated sealants to prevent ingress of moisture and contamination.

Terminations shall meet the performance tests of IEC 112, IEC 446 and IEC 507, Section 3. They shall also have the following performance characteristics :-




i) A.C. Voltage withstandfor 15 minutes, 50 Hz :4.0 kV phase to earth;

ii) A.C. Voltage withstandfor 4 hours, 50 Hz :3.0 kV phase to earth;

iii) Impulse Voltage withstand 10 positive and 10 negative,1.2/50 microseconds :8.0 kV peak phase to earth;

iv) Continuous A.C. Voltage :1.5 kV phase to earth;

v) Insulation Resistancebetween phase conductorand ground : > 1000 Megaohms.

7.2.8 Cable Jointing

Jointing of cables shall be undertaken only by competent and fully experienced jointers.

Cable boxes, compounds and jointing materials used shall be of an approved type. Every cable joint shall be started and finished on the same day.

Wherever cables are to be jointed in the open during wet weather conditions, the Electrical Contractor shall take all necessary precautions to prevent moisture from getting intothe cables. Where cable sheaths are to be used as earth continuity conductors, the glands shall have the necessary contact surface to provide a low resistance path under fault conditions.

Phasing and insulation resistance tests shall be taken before jointing is commenced.

Core numbers printed on papers shall be observed when jointing and, whenever possible, such numbers shall be maintained throughout the system. Core numbers `0', `1', `2' and `3' shall denote neutral, red, yellow and blue phases respectively. In the case of 2-core cables, core number `1' shall denote the phase conductor and `0' the neutral. Crossing of cores in the cable boxes shall be avoided wherever possible and connections shall be consistent with the foregoingrequirements.

7.2.9 Cable Markers

Cable markers with lettering and signs as shown on the Drawings shall be provided by the Electrical Contractor at every change of direction of underground cable routes and every 15 m on straight runs. Cable markers shall be of heavy duty reinforced concrete construction and shall be approved by the S.O.

The cable marker shall form a trapezoidal block with a 100 mm square top face and 150 mm square bottom face, and shall be 400 mm in height as shown on the Drawings. The top face shall be indented in bold lettering with the initials "L.V." and a directional sign or signs indicating the direction/directions of the cable route. The cable marker shall be buried to a depth of 300 mmor any other depth as directed by the S.O. Cable joint markers of similar construction but with the symbol "X"shall be provided and installed at every cable joint in a similar manner.




7.2.10 Cable Laying and Installation

All cables shall be handled, laid and installed according to this Specification, the latest edition ofthe IEE Wiring Regulations, the cable manufacturer's recommendations and ERAReports, using proper installation equipment, all to the satisfaction of the S.O.

All cables shall be supplied in complete lengths to suit the circuits they serve and no straightthrough joints shall be used. Straight through joints in the cable shall only be permitted in very exceptional circumstances such as those arising from unavoidable limitations in manufactured length. Where straight through joints or other approved joints are permitted by the S.O., the cost of such joints shall be borne by the Electrical Contractor. No joints in the cable will be allowed unless approved in writing by the S.O.

The minimum bending radius of the cables shall be in accordance with Table 52 C of the latest edition of the IEE Wiring Regulations. Wherever cables arecut, the ends shall be immediatelysealed in an approved manner unless it is intended to proceed with cable jointing or terminationimmediately.

Unless otherwise permitted by the S.O., no cable shall be laid and/or covered up in the absence of the S.O.

(a) Cable Laid Direct In Ground

Before any cable is laid, the trench shall be thoroughly inspected and any debris and other sharp objects shall be removed. The bottom of the trench shall be covered with a layer of clean sand 75 mm thick. The cables shall then be laid on this bedding in an orderly mannerwithout overlapping and crossing each other. 75 mm of clean sand shall cover the laid cables and shall be spread over the trench before placing the cable protective covers.

Cable protective covers shall be of clay bricks. The bricks shall benew, well burnt and in complete pieces. They shall be laid lengthwise from end to end alongthe entire route of the underground cable if the cable size is not more than 120 sq.mm. For cable sizes in excess of 120 sq.mm, more than one row of bricks shall be laid. Each cable shall be seperately protected by these bricks and the cover shall have at least 25 mm overhang on each side of the cable.

The trench shall then be backfilled with earth and shall be compacted in layers of 150 mm using a mechanical rammer. An orange coloured multi-strand nylon rope of minimum 6 mm diameter shall be laid at a depth of 300 mm along the trench to identify the cable route. At every 10 m interval, an extra 2 m of nylon rope shall be coiled and laid. The finished surface shall beleft proud by 50 mm to allow for subsidence and the Electrical




Contractor shall be responsible for the removal of any surplus material to a position indicated bythe S.O.

The surface of the refilled trench shall be temporarily reinstated and maintained in a thoroughly safe condition until complete consolidation of the soil has been achieved. As soon as the soil has consolidated, the trench shall be made good to its original condition, all to the satisfaction ofthe S.O.

(b) Cable Installed In Precast Concrete Trenches

Methods of installation of cables in precast concrete trenches shall be in accordance with Type L, Type M, or Type N of Table 9Aof the latest edition of the IEE Wiring Regulations. However, if the method is not specified, the cables shall be installed as directed by the S.O.

Cables laid in the bottoms of trenches shall be in accordance with Method Type L of Table 9Aof the latest edition of the IEE Wiring Regulations.

Cables installed on trench walls shall be in accordance with Method Type M or Type N of thelatest edition of the IEE Wiring Regulations and shall be secured on a cable tray by means of saddles at suitable intervals. In the case of single core cables, whether secured individually or in a group to the cable tray, non-ferrous saddles shall be used. Cable trays shall be fabricated from perforated hot-dipped galvanised sheets finished in an orange enamel.

The minimum thickness of the sheet steel used shall be 1.5 mm for cable trays with widths of up to 300 mm, and 2.0 mm for widths exceeding 300 mm. Cabletrays shall be supported at least 25 mm from the trench wall by mild steel brackets at 600 mm intervals. Brackets shall be anti-rust treated and painted with one coat of primer. Samples of cable trays and brackets shall be submitted to the S.O. for approval prior to installation.

To provide electrical continuity, all cable joints shall be bridged by means of tinned copper tape of dimensions not less than 25 mm x 3 mm. All saddles for cables on cable trays shall be installed by bolts, washers and nuts. All tees, intersection units, adaptor units, etc., shall be factory manufactured unless otherwise approved by the S.O. Trenches inside buildings shall befilled with clean sand up to a level above the cable ducts.

(c) Cable Run On Walls and Under Floor Slabs

Cable run on walls and under floor slabs shall be mounted on perforated hot-dipped galvanised sheet steel cable trays. The construction and finish of the cable trays and the method of installation of cables on cable trays shall be as described in Sub-Section 7.2.10 (b) above.

Cable trays shall be suspended from floor slabs by hangers or mounted on walls by brackets at 600 mm intervals. The materials and finishes used for the hangers, brackets and other suspending and supporting structures shall be




the same as those described for brackets in Sub-Section 7.2.10 (b) above.

Where cable trays pass through floors or fire resistant walls, the surrounding holes shall be sealed to the full thickness of the floor or wall with non- hygroscopic fire-resisting material of minimum 2-hour fire rating as approved by the Jabatan Bomba Malaysia.

7.3 STREET LIGHTING LUMINAIRES

7.3.1 Light Distribution Requirements

Unless otherwise specified, the performance and light distribution of street lighting luminaires shall be of the Low Threshold Increment (LTI) type.

The direction of maximum intensity of flux shall lie between 0º and 65ºof the downward vertical and the maximum permissible value of the intensity emitted at 90º and 80º shall not exceed 10 cd/1000 lumens and 30 cd/1000 lumens respectively.

Each luminaire shall normally direct two beams along the length of the road. The polar light distribution curves for the luminaire shall generally be smooth and free from any abrupt variations so that the luminous intensity diminishes smoothly and progressively from its maximum.

7.3.2 Constructional Requirements

7.3.2.1 Luminaires

All luminaires shall be new, totally enclosed, dust proof,insectproof and watertight and shall be tested in accordance with B.S. 4533. All exposed parts shall be of non-corrosive materials. The luminaires shall provide the requisite light distribution with the size and type of lamp specified. Each luminaire shall consist of a lamp compartment made up of an upper canopy or housing and a lower bowl assembly, a lampholder, cable clamps, mains connectors and earth terminations, as well as all necessary control gear. The control gear shall be pre-wired and integral with the luminaire.The luminaire wiring shall be of a size and insulated with a material that will more than effectively withstand the current, voltage and temperatures expected within the luminaire during both the starting and operating modes in the ambient temperature of the Site.

The lamp compartment of the luminaire shall be accessible via ahinged bowl made of ultraviolet stabilised plastic material such as acrylic which shall, in the closed position, bed firmly upon a soft resilient neoprene or non-ageing felt gasket. The gasket shall be positively secured in theluminaire housing and shall be weather-resistant. The bowl shall be secured firmly to the luminairebody by means of stainless steel clips and hinged pins.In the lowered position of the bowl, it shall be restrained from becoming detached or being




blown towards the other portion of the luminaire or the column arm. If independent reflectors are incorporated in the luminaire, such reflectors shall be of high purity aluminium mirrors,chemically anodised to yield optimum reflection of light distribution. Full details of the luminaire and accessories shall befurnished as required in the Appendices to this Specification.

7.3.2.2 Lamps

(a) High Pressure Sodium Vapour(HPSV) Lamps

High presssure sodium vapour (HPSV) lamps shall conform to IEC Publication 662 and shall have a colour temperature of approximately 21,000 K. The majority of the light output shall fall within the 560-610 nanometre waveband, i.e. in the yellow/orange, range.

The lamps shall have an initial luminous efficiency of approximately 115 lumens per watt for a 400 watt lamp and 100 lumens per watt for a 250 watt lamp. The lumens output after 100 operating hours shall be 45,000 lumens for a 400 watt lamp and 25,000 lumens for a 250 watt lamp.

The lamps shall be of tubular or of any other approved shape and shall have plated brass caps securely fitted to the glass envelopes. The cap shall be of GESE40 material to fit the luminaire supplied.

The lamps supplied shall have a mortality rate not greater than 10% at 5,000 switched operating hours and shall not take longer than 4 minutes after the initial "switch on" to attain 80% of theirguaranteed output at the rated voltage of 200/250 V and frequency 50 Hz. The reignition period after an interruption of the supply shall not be longer than 1 minute to attain 80% of the lumens output.

(b) Low Pressure Sodium Vapour(LPSV) Lamps

Low pressure sodium vapour (LPSV) lamps shall conform to the requirements as laid down in B.S. 3767. The majority of the lumens output shall be within the 580-590 nanometre waveband range. The lamps shall have aninitial luminous efficacy of approximately 160 lumens perwatt for a 135 watt lamp. The lumens output after 100 operating hours shall be not less than 50 lumens per watt.

The lamps shall be of tubular shape with a bayonet cap (B.C.), shall take no longer than 11 minutes after initial "switch on" to attain 90% of of their quoted lumens output.

All LPSV lamps shall be guaranteed for a minimum operating life of 4,000 operating hours. All lamps shall be suitable for use, in conjunction with their control gears, on 220/240 V supply and shall be capable of being started and operated at 10% reduction in rated voltage.




7.3.2.3 Ballast

The ballast shall be manufacturedto B.S. 4782. It shall be correctly rated for its duty and shall be designed to operate on a dual mains voltage of 220/240 V by means of suitable tappings. The tappings shall be brought out to marked terminals. The ballast shall have laminated cores and high conductivity windings with power loss and noise kept to a minimum.

7.3.2.4 Capacitors

Capacitors shall be manufactured to B.S. 4017 and housed in extruded aluminium canisters with shrouded screw terminals. They shall not be fused but shall have an an external safety discharge resistor. The capacitor shall be capable of raising the power factor of each circuit to at least 0.85 lagging.

7.3.2.5 Ignitors

Ignitors for the discharge lamps shall be of the electronic / superimposed pulse type rated forthe appropriate wattage. The unit shall be capable of operating on avoltage ranging from 200 to 250 volts. The unit shall be totally enclosed with an externalterminal block for the supply connection and a length of high tension cable shall be included for the lamp connection. It shall be compatible with the normal control gear.

The case of the unit shall carry a label showing the connections and listing the appropriate voltage.

7.4 FEEDER-PILLARS

7.4.1 General

Feeder-pillars shall be supplied completely assembled with control gear and all internal electrical and mechanical inter-connections and structural parts for voltages up to andincluding 1,000 volts A.C. They shall comply with and be tested to the requirements of B.S. 5486.

7.4.2 Fabrication of Feeder-Pillars

The Electrical Contractor shall submit a design drawing of the shape, size, electrical and mechanicalconnections, materials, etc., of the feeder-pillar for the approval of the S.O. prior to manufacture. The plinth, foundation work, etc., shall beincluded in the design drawing.

The feeder-pillar housing shall consist of a drip canopy, rigidly welded channeled steel framework manufactured from 2.64 mm (12 s.w.g.) sheet steel. It shall be hot-dip galvanised and the process of galvanising, treatment before galvanising and treatment after galvanising shall be as described in Sub-Section 7.5.10 of this Specification. On the front and rear sides of the feeder-pillar, the following sign shall be stencilled in red paint using a lettering height of 90 mm :-

BAHAYA415 V

LAMPU JALAN

The door of the feeder-pillar shall be rigidly reinforced and hinged internally to prevent unauthorised access. The feeder-pillar shall be lockable with eitherwedge-type locks protected by screw




plugs or some other secret locks approved by the S.O. The feeder-pillar shall be self-ventilated and weather proof and such ventilation openings shall be protected by wire mesh to prevent the entry of vermin, rodents and birds.

A baseboard made of tufnol or other approved treated hardwood of at least 16 mm thickness shall be included to mount equipment such as time switches, contactors, etc.

7.4.3 Factory Inspection

The Electrical Contractor shall make arrangements to witness the electrical tests and for joint inspection to be carried out at the factory prior to transportation to the Site.

7.4.4 Foundation

The Site of the foundation of the feeder-pillar shall be filled where required, compacted and levelled before the reinforced concrete base of minimum 250 mm height above the finished earth level is constructed. Cable entry ducts shall also be provided.

7.4.5 Earthing

The earthing system for the feeder-pillar shall comply with the Rules and Regulations of the Supply Authority, The British Code of Practice C.P. 1013, the relevant sections of the latest edition of the IEE Wiring Regulations and the Contract Drawings.

Each feeder-pillar shall be effectivelyearthed using 4.8 mm x 16 mm diameter steel core copper-jacketted earth electrodes, 25 mm x 3 mm

copper tape, precast concrete earth chambers with covers, etc.

7.4.6 Time Switches

Time switches supplied for the control of luminaires, etc., shall be ofthe synchronous/step-by-step motor-wound handset dial plug-in type. They shall incorporate a 24-hour spring reserve or a battery back-up system. Time switches shall be rated as specified in the Drawings and shall be operational on a 220/240 V, 50 Hz supply.

7.4.7 Contactors

Contactors shall comply with B.S. 5424 with uninterrupted ratings, mechanical duty Class 2 and a utilisation category of at least AC3. The contactor coils shall be fully tropicalised and wound for continuous operation for a 220/240 V, 50 Hz supply. The contacts of the contactor shall be rated for the breaking capacity of the connected load.

7.4.8 By-Pass Switches and Selector Switches

Single or three-phase by-pass switches as applicable shall be connected in parallel with the contactors for use in the event of the failure of the contactors. These shall be manufactured to B.S. 5419 and shall be capable of breaking the load connected to the contactors without undue ageing or damage.

A four-position selector switch shall be provided to select the mode of operation and shall be appropriately labelled.




7.5 COLUMNS AND BRACKETS

7.5.1 General

All columns and brackets shall be of tapered, octagonal, hot-dip galvanised interchangeable sections complying in all respects with the Drawings. They shall be manufactured to comply with B.S. 1840 and B.S. 5649 with Grade 43C or 50C steel conforming to B.S. 4360. The base-plates and bracket arms shall be manufactured as seperate units suitable for mounting or fixing on to the columns.

7.5.2 Design Loading

The columns shall be designed to withstand loadings comprising :-

i) loads due to wind speeds of up to27 m/sec.;

ii) loads due to the weight of the columns, lighting luminaires and bracket arms;

iii) other applied loads if applicable.

7.5.3 Fabrication of Column Sections

Each column section shall be mechanically formed and longitudinally welded by the continuous automatic gas shielded electric arc process (M.I.G. process) to B.S. 5135. The sections shall be constructed so as to overlap each other by a minimum of 1.5 times the diameter of the immediate lower section (external across-faced dimension) and to be easily assembled on site by using simple tools without employing welding techniques. The manufacturer shall provide a mark on the finished column section indicating the

minimum overlapping position of 1.5times the external across-faced dimension.

7.5.3.1 Doors and Door Openings

Weather proof doors shall be provided with an anti-vandal locking device over the door opening of each column as shown on the Drawings. The complete locking device shall be made from stainless steel. Door openings shall have internal reinforcement to compensate for the loss of stiffness in the columns caused by forming the door openings.

7.5.3.2 Service Slots

For flange mounted types of columns, cable entries shall be through the flange plates via a hole of suitable diameter as shown on the Drawings. Asuitable duct for cable entry shall also be provided at the concrete base.

For planted root types of columns, service slots shall be on the same side and vertically below the service doors.

7.5.4 Bracket Arms

Bracket arms shall be of suitable outreach as indicated on the Drawings and in the B.Q. The bracket arms shall be octagonal in shape for up to 2.0 m in length. For bracket arms longer than 2.0 m in length, the extra length shall be formed from Grade 43C tubular steelconforming to B.S. 4360. The bracket arms shall be arranged so as to give a 50 uplift as shown on the Drawings. A tubular steel spigot of appropriate dimensions for the




luminaire shall be welded at the end of each bracket arm. After welding, etc., bracket arms shall be treated as described in Sub-Section 7.5.10 before being hot-dip galvanised.

7.5.5 Base-Plates

For flange mounted types of columns, flange-plates of substantial thicknesses as shown on the Drawings shall be welded on to the columns.

For planted root types of columns, detachable anti-sink plates shall be supplied.

Base-plates, nuts and bolts, etc., shallbe hot-dip galvanised after manufacture.

7.5.6 Baseboards

A piece of baseboard shall be included in each base compartment for cable termination or control gearsassembly. Baseboards shall be made from fibre board of 10 mm thickness. Alternative baseboards made from galvanised perforated metal may also be used with the approval of the S.O. Baseboards shall be made to the dimensions as indicated on the Drawings and shall be fixed securely in position inside the columns.

7.5.7 Street Lighting Cut-Outs

Street lighting cut-outs shall be of a type manufactured for use in street lighting installations. They shall have facilities for double fusing loop-in loop-out terminals. The cut-out bases shall have a supply cable contact block rating of at least 50 Aand shall be capable of accepting circular cable cores of up to 25 sq.mm copper 2-core or 4-core

cables as appropriate. Cut-outs shall be provided with adequate shroudingto prevent cross-phasing or accidental contact with live metal.

The fuse carriers shall be self-aligning and shall accept any of the standard rated fuses for the purpose. Each unit shall possess high mechanical and di-electric strength and shall be suitable for use in the tropics. Samples of complete cut-out units shall be submitted for the approval of the S.O.

7.5.8 Earthing Terminals

Columns shall be provided with a corrosion resistant terminal having substantial contact surfaces for the attachment of an earthing lead. This terminal shall be provided close to the door opening inside each column. Where bolts are used, they shall be not less than 6 mm in diameter and shall be provided with two suitable washers and nuts.

7.5.9 Cable Entry

Armoured cables brought into the columns shall be provided with compression cable gland terminations.

An appropriate type of earthing clamp shall be provided to bond the armouring of the cables which shall be effectively earthed.

7.5.10 Erection of Columns

Columns shall be installed in accordance with the manufacturer's recommendations and as shown on the Drawings. The Electrical Contractor shall peg out the positionsof the columns for the approval of the S.O. before planting the columns.




Columns shall be erected such that the service doors shall face away from on-coming traffic except at parapets of bridges and retaining walls. At such locations, the orientation of the service doors shall be determined by the S.O. After erecting each column, backfill shall be compacted by means of suitable ramming equipment.

7.5.11 Protection Against Corrosion

Individual sections of the columns, base-plates, doors and bracket arms shall be protected against corrosion by hot-dip galvanising the sections both internally and externally, all in accordance with B.S. 729. All welding works shall be completed before galvanising.

Treatment prior to galvanising shall include degreasing, rinsing, pickling, further rinsing and fluxing.

The minimum average weight of the zinc coating shall be 460 g/sq.m for any individual test area.

The galvanised columns and bracket arms shall be of prime finish and of good uniformity, i.e. they shall be free from injurious defects such as blisters, flux and uncoated spots.

The planted sections of columns and the base-plates shall be factory-coated with bitumen using the hot-dipping process conforming to AASHTO M 190.





SECTION 8

TRAFFIC SIGNALS




SECTION 8 - TRAFFIC SIGNALS

Page

8.1 GENERAL

8.1.1 Scope of Work S8-182

8.1.2 Design and Construction8.1.2.1 Contractor's Responsibility S8-1828.1.2.2 Cleanlines S8-1828.1.2.3 Metric Range of preferred Dimensions S8-1828.1.2.4 Self-Tapping Screw S8-1828.1.2.5 Corrosion S8-182

8.1.3 Compliance With Manufacturer's Instruction S8-183

8.1.4 Component and materials8.1.4.1 Conditions of Operation S8-1838.1.4.2 Maintenance To Be Kept To A Minimum S8-1838.1.4.3 Components S8-1838.1.4.4 Metering S8-183

8.1.5 Identification of Equipment S8-184

8.1.6 Protective Requirements8.1.6.1 General S8-1848.1.6.2 Insulating Bushes S8-1848.1.6.3 Isolation From Main Supply S8-1848.1.6.4 Earthing of Transformer Secondary Circuits S8-1848.1.6.5 Current Loading of Wires S8-1848.1.6.6 Danger Notices S8-1858.1.6.7 Cable Connecting Units S8-1858.1.6.8 Insulation S8-1858.1.6.9 Whiskering of Tin S8-185

8.1.7 Electricity Supply S8-185

8.1.8 On-Site Commisioning Test Procedures S8-185

8.1.9 Documentation8.1.9.1 General S8-1868.1.9.2 Hardware, Software and maintenance Manual S8-186

8.1.10 Guarantee of Supply S8-187

8.1.11 Warranty Period S8-187




Page


8.2.1 Type of Cables S8-1878.2.1.1 Power Cables S8-1878.2.1.2 Feeder Cables for Vehicle Detectors S8-1888.2.1.3 Loop Cables for Vehicle Detectors S8-1888.2.1.4 Earthing Conductors S8-188

8.2.2 Cable Termination S8-188

8.2.3 Cable Jointing S8-188

8.2.4 Cable Markers S8-188

8.3 SIGNAL LANTERNS

8.3.1 Standard Requirements S8-189

8.3.2 Optical Requirements S8-1898.3.2.1 Optical Arrangement for Drivers S8-1898.3.2.2 Optical Arrangement for Pedestrians S8-1898.3.2.3 Height of Signal S8-189

8.3.3. Constructional Requirements S8-1908.3.3.1 Lamps S8-1908.3.3.2 Target Boards S8-190

8.4 SIGNAL POSTS AND MAST ARMS


8.4.2 Cable Entry S8-191

8.4.3 Connecting Facilities for Cables S8-191

8.4.4 Location and Erection S8-191

8.4.5 Finish S8-191

8.5 PEDESTRIAN PUSH-BUTTONS


8.5.2 Location S8-192

8.5.3 Pedestrian Demand Indicator S8-192

8.5.4 Audible Signal S8-192




Page

8.6 TRAFFIC CONTROLLER

8.6.1 General Requirements S8-1192

8.6.2 Housing S8-193

8.6.3 Controller Mains Switch Board S8-193

8.6.4 Facility Switch S8-194

8.6.5 Pedestrian Facilities S8-194

8.6.6 Logic Module S8-1948.6.6.1 Microcomputer System S8-1948.6.6.2 Input/Output Interfaces S8-1958.6.6.3 Real 'Time-Of-Day' Clock S8-1958.6.6.4 Operator Interface and Controller Display S8-1958.6.6.5 Supply Monitor S8-1958.6.6.6 Watchdog Timer S8-196

8.6.7 Mains Supply Interruptions S8-196

8.6.8 Circuit Breakers S8-196

8.6.9 Inputs S8-196

8.6.10 Interchangeability S8-196

8.6.11 Vibration and Noise S8-196

8.6.12 Radio Interference S8-196

8.6.13 Safety S8-196

8.6.14 Timing S8-197

8.7 VEHICLE DETECTORS


8.7.2 Number of Traffic Lanes S8-197

8.7.3 Supply Voltage S8-197

8.7.4 Equipment Construction S8-197

8.7.5 Performance Requirements S8-197




Page

8.8 ROADWORKS

8.8.1 General S8-197

8.8.2 Permission to Excavate Road S8-198

8.8.3 Excavation, Backfilling, Reinstatement and maintenance of Excavations S8-198

8.8.3.1 General S8-1988.8.3.2 Excavation S8-1988.8.3.3 Bedding of Excavation S8-1998.8.3.4 Cable Ducts S8-1998.8.3.5 Cable Laying and Installation S8-1998.8.3.6 Cable Laid Direct On The Ground S8-2008.8.3.7 Cables Installed in Precast Concrete Trenches S8-2008.8.3.8 Backfilling of Excavations And Reinstatements S8-2018.8.3.9 Sensing Loop Slots S8-2018.8.3.10 Maintenance of drains and Services During Excavations S8-2018.8.3.11 Reinstatement of Drains and Precast Units S8-2028.8.3.12 Completion of Works S8-2028.8.3.13 Maintenance of Excavation S8-202

8.8.4 Traffic Arrangements S8-203

8.8.4.1 General S8-2038.8.4.2 Arrangement and Location of Signs Barriers and Barricades S8-2038.8.4.3 Temporary Warning lamps S8-2048.8.4.4 Use of Traffic Guidance Cones S8-2048.8.4.5 Temporary Traffic Diversions S8-2048.8.4.6 Temporary Traffic Control S8-2048.8.4.7 Plant and Equipment S8-2058.8.4.8 Vehicles S8-2058.8.4.9 Maintenance of Signs, Lights, Barriers,Temporary Traffic

Diversions, etc. S8-205



SECTION 8 - TRAFFIC SIGNALS

8.1 GENERAL

8.1.1 Scope of Work

This work shall comprise the design of cabling works and the supply and installation of all signal lanterns, traffic controllers, detectors, posts, ducting and cabling, and switchgearswith all necessary ancillaryequipment, together with thetransportation, storage, erection, connection, testing and commissioning of the same for a complete traffic signal installation, all in accordance with the Drawings and this Specification. The work shall also include cabling from the nearest specified power source of thelocal supply authority to the traffic control system, if required.

The type of signal operation, numberof plans, number and sequence of phases, cycle times, timings of each phase, offset times, locations of controllers and power source tappingpoints, and other specific requirements shall be as shown on the Drawings.

8.1.2 Design and Construction

8.1.2.1 Contractor's Responsibility

The Contractor shall design the interconnecting signal cabling forthe proposed signal system as shown on the Drawings. The cabling design drawings are to beapproved by the S.O. before construction commences. Equipment offered shall be in all respects suitable for the requirements and for the environmental conditions specified. The Contractor shall

be responsibile for the design, material quality and workmanship of the system and every part of the system offered, whether manufactured by him or supplied to him by other manufacturers. Approval by the S.O. does not relieve the Contractor of these responsibilities.

Materials shall as far as possible be of Malaysian origin except where such materials can be shown to be unavailable in Malaysia.

8.1.2.2 Cleanliness

Particular attention shall be givenin the design of the equipment forthe exclusion of dust, dirt, etc., especially in the case where forced ventilation is employed.

8.1.2.3 Metric Range of Preferred Dimensions

Except as may be agreed for practical reasons, design shall make use of the metric range of preferred dimensions and tolerances.

8.1.2.4 Self-Tapping Screws

Self-tapping screws shall be used only for retaining duties. They shall not be used for fixing removable covers, nor for the support of direct loads.

8.1.2.5 Corrosion

All equipment shall be designed to resist corrosion in the Malaysian environment for a period of 20 years from the date of installation.




8.1.3 Compliance With Manufacturer's Instructions

The Contractor shall ensure that the equipment and parts used shall be entirely suitable for the work to be performed and that they shall be manufactured to proper tolerances and fit. He shall further ensure that the loading of equipment shall under all normal circumstances not exceed the maximum laid down or agreed toin writing by the manufacturer.

The Contractor shall be responsible for the inspection of all equipment and parts before their incorporation in the Works to ensure that they comply with the requirements of thisSpecification and that they are not defective in any way as regards materials or workmanship. Should any such non-compliance or defects be found during the inspection, the Contractor shall correct or cause to be corrected such non-compliance and defects, all at the Contractor's expense and to the satisfaction of theS.O.

8.1.4 Components and Materials

8.1.4.1 Conditions of Operation

The system shall be designed to operate continuously. Account shall be taken of equipment beingsited in all exposed locations.

8.1.4.2 Maintenance To Be Kept To AMinimum

The materials and components, excluding expendable items such as lamps, shall be such as to provide a life expectancy of up to20 years unless specifically statedotherwise in this Specification. Components which have ashorter life span but are easily

replaceable may be accepted withthe aproval of the S.O.

8.1.4.3 Components

All active and passive components, their mounting and the plugs, sockets and connections, shall be designed for a life expectancy of 20 years as specified in Sub-Section 8.1.4.2. All shall operate well within their ratings with due consideration for the environmental conditions and temperature rises within cabinets or enclosures.

Thermionic valves other than cathode-ray tubes shall not be used.

Metal oxide or grade II carbon resistors shall be used. Grade I carbon film resistors shall not be used.

Where high dissipation power resistors are used, metal oxide resistors shall be used whenever they are available, in preference to wire wound types.

Metal can transistors shall be used wherever possible. Germanium transistors shall not be used unless approved by the S.O.

8.1.4.4 Metering

The equipment shall be provided with waveforms and voltage test points as necessary for indicating circuit conditions.




8.1.5 Identification of Equipment

The Contractor shall mark or label clearly all modules, units and main parts of the system with a functional code or title, type number, trade name and serial number. The marking or labelling of main items shall be clearly visible on the outside. The labels and markings of encased units or modules shall be visible when the case or cover is removed. Components shall not be marked with circuit references. The marking shall be adjacent to the component. Markings required for controls, maintenance or warning shall be adjacent to the part concerned. Markings shall maintain legibility throughout the life of the equipment in the specified environmental conditions.

Techniques used shall be approved by the S.O.

8.1.6 Protective Requirements

8.1.6.1 General

All metal work not normally required to carry current shall be connected to an earth point except where otherwise dictated by transmission or other requirements (such metal work shall include cases, screens, cores, cable glands, cable conduits and cable sheaths, etc.).

8.1.6.2 Insulating Bushes

Insulating bushes shall be provided wherever conductors carrying dangerous voltages pass through holes in metal parts and where the conductors would be likely to touch the edge of the holes.

8.1.6.3 Isolation From Main Supply

Unless otherwise agreed by the S.O., systems shall be completely isolated from the mains supply by means of a suitable double-wound transformer which shall include an earthed screen. The primary and secondary outputterminations shall be separated in an approved manner.

The main transformers at thecontroller shall be provided with primary tappings so that the equipment operates with mains supply in the range of 200 to 260 volts.

8.1.6.4 Earthing of Transformer Secondary Circuits

When a dangerous voltage is connected to the primary windingof a transformer, the secondary circuit shall be connected where practicable to an earthed point.

8.1.6.5 Current Loading of Wires

All wirings shall be suitably ratedto carry in excess of the current permitted by their fuses, circuit breakers or other current linking devices. Similar precautions shallbe taken to reduce the possibility of overheating components.

Provisions shall be made in the equipment :-

i) to prevent damage to circuits due to failure of any pulses, power supplies or mains supply;

ii) to prevent damage to power supplies by inadvertent removal of the load.




8.1.6.6 Danger Notices

All equipment or units working at a voltage at or above 150 volts D.C. or 100 volts A.C. (RMS) shall be protected by an approved cover, which shall be removable. The cover shall have a sign with a danger symbol indication of the voltage. The highest voltage to which access can be had by removal of the cover shall be shown, where dangerous voltages exist.

8.1.6.7 Cable Connecting Units

Terminal strips and terminals shall be clearly and indelibly coded. Terminals carrying mains electrical power shall besegregated from other terminals. Unless approved by the S.O., notmore than three cable cores shall be retained by any terminal. All wiring and cabling shall be neat, adequately supported to prevent vibration, and so arranged as to prevent strain on individual wires, particularly on hinged panels.

8.1.6.8 Insulation

If no value is specified, the insulation resistance between any two parts not intended to be in electrical contact shall not be less than 100 megaohms when measured at a voltage appropriateto the equipment. Where `n' suchpaths are effectively connected inparallel, the resistance of the combination shall be not less than100/n megaohms.

8.1.6.9 Whiskering of Tin

Where non-insulated electronic circuits are positioned within 4 mm of a non-insulated tinned surface, a loose barrier of insulated materials shall be provided between the surface andthe connection to prevent the possibility of unwanted contact. Approved soldered-in-lead through connectors are exempted from this requirement.

8.1.7 Electricity Supply

The Contractor shall comply with allLLN or the power source authority requirements in getting an electricity supply to the installation, and any costs associated with obtaining this supply shall be included in the Tendered rates. The Contractor shall ensure that the equipment supplied will function correctly at the supply voltage, and shall allow for normal variation and surges.

8.1.8 On-Site Commissioning Test Procedures

Testing and commissioning of all equipment shall be successfully completed within one (1) month from the date of completion of the installations.

The Contractor shall notify the S.O. when the on-site commissioning tests are to be undertaken. The Contractor and the Supervisor shall forward to the S.O. duly certified copies of the test results when the tests have been successfully completed. When the S.O. has received these test results and issatisfied that the system has passed the test, the S.O. shall notify the Contractor in writing that the system has passed the on-site




commissioning tests. The S.O. shall notify the Contractor in writing of allfaults detected during these tests. If the S.O. decides the system is not in accordance with the Contract, he may reject the system, and he shall inform the Contractor of the reasons in writing within a reasonable time.

8.1.9 Documentation

8.1.9.1 General

System manuals for each equipment associated with the Contract shall be delivered to the S.O. Reissues shall be provided if site commissioning and testing make this necessary.

All documentation shall be indexed and shall carry an issue number and date.

Two copies each of the documentation shall be supplied to the S.O.

All documentation shall be produced in uniform style in A4 size. All diagrams relating to the final documentation shall be reduced to page height, bound and correctly referenced to the text. They shall fold clear of the text for ease of use.

Great care shall be taken to ensure that in the writing of all documentation, expert familiarity with apparently simple features isnot advertently assumed. Difficulties should be anticipated.

All documentation shall be in English or Bahasa Malaysia.

8.1.9.2 Hardware, Software and Maintenance Manual

The manual shall contain descriptions of the complete hardware system followed by maintenance procedures. Adescription of the complete software system shall also be included.

The hardware description shall start with the overall configuration of the system, with layouts showing the location of every unit, with block diagrams and an explanation of the operation of the system.

Detailed descriptions of component units shall explain their operation. Block diagrams showing the flow and interaction of data, logic diagrams, circuit diagrams with component valves, and layout diagrams shall be provided. Parts lists and wiring schedules shall be provided, but care shall be taken to avoid these obscuring the operational description. Maintenance procedures shall cover the diagnosis of faults,testing and setting up adjustments, replacement of unitsand routine mechanical servicing.

The software description should aim at enabling new programs foran intersection to be written, and to provide the basic standard techniques used in writing the system programs. Where programming technique is dependent on particular features of the system, it is important that program material is specially written. This shall be in the form of guidance, referring to operational features in thesoftware manual.




An as-built plan showing the final wiring diagrams, pole locations, controller locations, detector placement, conduit runs and timing plan shall be included in each controller cabinet.

8.1.10 Guarantee of Supply

The Contractor shall be required to ensure that for a period of not less than 10 years from the date of commissioning the system, a supply of replacement components and materials or their agreed equivalent is available, as the S.O. may require. A Contractor who is not a manufacturer is required to submit a letter from the manufacturer certifying that the manufacturer will support the equipments and components.

8.1.11 Warranty Period

After acceptance of the installation, the Contractor shall still be subject toobligation of free servicing, change in phasing, maintenance and free replacement of all defective parts andfused bulbs for a period of twelve (12) months from the date of issue ofthe Certificate of Completion. Aqualified Service Engineer provided by the Contractor must be available on 24 hours service a day to attend toany breakdown at anytime including public holidays.

All repairs and replacements required during the Warranty Period shall be carried out with despatch and an adequate supply of spares shall be available for this purpose. The Contractor shall be liable for damages if he does not undertake remedial works within 24 hours.

The Contractor shall carry out any repair within 24 hours of being informed of the damages. Upon failure to do so, the S.O. has the option to appoint another party for repair and the cost thus incurred will be borne by the Contractor.

All maintenance conducted shall be entered into the Local Controller Logbook, dated and signed by the maintenance staff of the Contractor.

Repainting of the signal aspects, posts, and local controllers shall be performed just before the end of the Warranty Period.


8.2.1 Types of Cables

8.2.1.1 Power Cables

Power cables shall be manufactured and tested in accordance with M.S. 274 and shall have high conductivity plaincopper stranded conductors, insulated with PVC suitable for a voltage of between 600 and 1000 V, laid together and bedded with PVC, armoured with galvanised steel wires and sheathed with PVC. The copper conductors for Mains Power cables running from the power source to the controller shall have a nominal cross-sectional area not less than 16 sq.mm. Other interconnectingsignal cables shall be multicore cables having copper conductors of nominal cross-sectional area not less than 1.5 sq.mm with a minimum of 5 cores.




The current rating of cables shall comply with the appropriate Tables of the latest IEE Wiring Regulations for the class of conductor used.

8.2.1.2 Feeder Cables for Vehicle Detectors

The material for feeder cables to vehicle detectors shall be screened, twisted balanced-twin cables which shall be manufactured and tested in accordance with M.S. 274. The core conductors shall be of annealed copper having a nominal cross-sectional area of 1.5 sq.mm unless otherwise specified. The cable shall have a nominal characteristic impedance(Zc) of 90 ohms at 50 kHz.

The conductors shall be insulated.The insulation shall be waterproof and, when installed, shall withstand a temperature of 70ºC without suffering damage ordeformation.

8.2.1.3 Loop Cables for Vehicle Detectors

The material for inductive type vehicle-detector loop cables shall be in accordance with Australian Standard 2276.3 unless otherwise specified herein. Any deviation from A.S. 2276.3 shallbe at the request of or subject to the approval of the S.O. The detector sensing shall be of a typewhich can be easily assembled from bulk cable on Site, and shall be approved by the S.O.

8.2.1.4 Earthing Conductors

Earthing conductors shall have a nominal cross-sectional area of 2.5 sq.mm and earthing rods shallhave a minimum cross-sectional area of 10 sq.mm.

8.2.2 Cable Termination

Unless otherwise permitted, all cabletermination and jointing works shall be carried out in the presence of the S.O. A plastic laminated plate engraved with details such as size of cable, number of cores, date of commissioning, date of jointing, length of cable, distance of cable joint, etc., shall be securely fixed near the termination.

PVC/SWA/PVC cables shall be provided with compression cable gland termination. The cable gland shall be of gunmetal or brass and shall grip both the inner and outer PVC sheath of the cable. It shall be so designed that any strain on the cable is taken by the steel wire armouring which shall be effectively sealed between the gland itself and the outer cable sheath.

8.2.3 Cable Jointing

No cable jointing shall be allowed for interconnecting signal cables. Jointing of mains power cables shall be allowed only when approved by the S.O.

8.2.4 Cable Markers

Cable markers with lettering and signs as shown on the Drawings shall be provided by the Contractor at every change of direction of underground mains power cable routes and at every 15 metres on straight runs. Cable markers shall be




of heavy duty reinforced concrete construction and shall be approved by the S.O.

The cable marker shall form a trapezoidal block with a 100 mm square top face and 150 mm square bottom face, and shall be 400 mm in height as shown on the Drawings. The top face shall be indented in bold lettering with the initials `L.V.' and a directional sign or signsindicating the direction/directions of the cable route. The cable marker shall be buried to a depth of 300 mmor any other depth as directed by the S.O. Cable joint markers of similar construction but with the symbol `X' shall be provided and installed at every cable joint in a similar manner.

8.3 SIGNAL LANTERNS

8.3.1 Standard Requirements

All components, their installation and performance, shall be in accordance with A.S. 2144 unless otherwise specified herein. Any deviation from A.S. 2144 shall be at the request of or subject to the approval of the S.O.

8.3.2 Optical Requirements

8.3.2.1 Optical Arrangement for Drivers

Each signal face shall, unless otherwise shown on the Drawings, contain three optical systems arranged vertically, eachhaving a diameter of not less than 295 mm nor more than 305mm. For post-mounted signals, the coloured lens of the upper optical system shall be red, the middle one amber, and the lowerone green.

For horizontal overhead signals, the coloured lens of the left-most optical system shall be green, the middle one amber, and the right-most one red, as seen by thedriver.

Primary signals shall be fitted with a type A visor and secondarysignals shall be fitted with a type B visor as described in A.S. 2144.

8.3.2.2 Optical Arrangement for Pedestrians

Each signal face shall contain two optical systems arranged vertically, each having a diameterof not less than 295 mm nor more than 305 mm, which shall incorporate pedestrian symbols asshown on the Drawings. The upper optical system shall illuminate a red `DON'T WALK' symbol and the lower one a green`WALK' symbol. The optical system spacings shall be as shown on the Drawings.

8.3.2.3 Height of Signal

(a) Post-Mounted Signals Intended For Drivers

The height of signals shall be such that when erected the centre of the amber optical system shall be not less than 2.4 metres nor more than 4 metres above the carriageway level. Where no amber signal is installed these dimensions apply to the centre of the green signal.




(b) Light Signals Intended For Pedestrians

The height of signal shall be such that when erected the height of the lower edge of the housing enclosing the green signal shall be not less than 2.1 metres nor more than 2.6 metresabove the carriageway level.

(c) Overhead Mounted Traffic Control Light Signals

The height of overhead mounted signals shall be such that when erected, the lowest point of the signal head assembly shall be not less than 5.5 metres nor more than 8.5 metres above the carriageway level.

8.3.3 Constructional Requirements

8.3.3.1 Lamps

The lamp used in the optical system, to meet the requirementsof A.S. 2144 Section 3, shall be a 12 V, 50 W, long life tungsten halogen lamp.

The bulb shall be clear, uncoloured and the filament shall only be used in the horizontal position. The lamp shall meet the following requirements as tested in A.S. 2144 :-

i) nominal lumens : 820 lm at 12 V;

ii) nominal life : 2000 hours continuousburning at 12 V input;

iii) nominal colour temperature :2850 K at 12 V input;

iv) overall length : 44 mm maximum;

v) overal diameter : 12 mm maximum;

vi) nominal operating voltage :11.7 V.

Each tungsten halogen lamp shallbe provided with an appropriate transformer complying with the requirements of B.S. 9720, mounted within the signal head and connected to a terminal blockwhich may be mounted remotely.Wiring between the lamp holder and the transformer and the terminal block shall be in compliance with the requirementsof M.S. 136 and B.S. 6007.

8.3.3.2 Target Boards

Unless otherwise specified, a target board shall be provided with each signal face intended forvehicle drivers, extending not lessthan 275 mm above the centre of the upper optical system nor less than 275 mm below the centre of the lower optical system. It shall extend not less than 280 mm horizontally eitherside of the vertical centre line of the optical system. Other types of target boards shall be as shownon the Drawings. The target boards shall be manufactured from a durable resilient material and shall be stiffened where necessary to resist distortion due to wind and extreme ambient temperature. All target boards shall have an orange border not less than 45 mm nor more than 55 mm wide.




8.4 SIGNAL POSTS AND MAST ARMS


All signal posts, signal mast arms and mountings of signal lanterns shall be as shown on the Drawings. The posts and mast arms shall be so designed and constructed as to provide adequate support and stability for the signal head assembly.

All signal posts shall be of tubular hollow section of steel with a nominal diameter of 100 mm and fitted with a weather-proof cap to prevent ingress of water.

Mast arms shall be tubular hollow sections of steel of a generally tapered form mounted on a baseplateas shown on the Drawings.

Every post shall be provided with one nickel-plated brass earthing screw located within the post, 25 mm below the top.

The posts and mast arms shall be capable of having holes drilled in thevertical section, 1 metre above the ground, for the mounting of one pedestrian push-button assembly in accordance with Sub-Section 8.5.

8.4.2 Cable Entry

Buried posts shall incorporate a cable-entry aperture as shown on the Drawings. Baseplate-mounted posts shall provide for entry of the cable into the interior of the post through a hole in the baseplate having a diameter not less than the inside diameter of the post.

8.4.3 Connecting Facilities for Cables

Provision shall be made for the connection of terminating and interconnecting cables coming from within the post or mast arm and of cables from the traffic signal lanterns.

8.4.4 Location and Erection

The posts and mast arms shall be erected at the approximate locations as shown on the Drawings. On roadways whose edges are defined by a raised kerb, the posts shall be erected so that no part of the signal head other than overhead signals projects over the roadway.

Where possible, the signal should have a clearance of 300 mm to 450mm behind the kerb line. The post shall be at a distance not less than 1 metre before the edge line.

In areas where there is no kerb, the steel posts should be erected so that the signal head is clear of the shoulder (or usable area) and should not be less than 2 m nor more than 3 m from the edge of thenearest traffic lane.

All posts and mast-arms shall have their exact location determined by the S.O. and recorded on the as-built Drawings.

8.4.5 Finish

Unless otherwise specified, the interior and exterior of steel posts shall be protected by a finish complying with the requirements of M.S. 740.




The exterior surface of steel posts shall bepainted with alternate black and orange bandsof 300 mm width in weather resisting plasticsmaterial as specified in Clause 6 of B.S. 873,Part 1, and as shown on the Drawings.

Any surface cut after galvanizing, painting, orthe application of the plastics finish, shall bewire brushed and given two coats of good qual-ity zinc-rich paint in accordance with B.S.4652.

8.5 PEDESTRIAN PUSH-BUTTONS


All pedestrian push-buttons, their mechanism and operation, shall bein accordance with A.S. 2353 unless otherwise specified herein. Any deviation from A.S. 2353 shallbe at the request of or subject tothe approval of the S.O.

8.5.2 Location

Pedestrian push-button detectors shall be provided facing the footpath at each end of each crosswalk where pedestrian actuated signals are required as shown on the Drawings.

8.5.3 Pedestrian Demand Indicator

When the button is pressed, an internally illuminated panel shall light up bearing the legend `NANTI',which shall be white on a black or blue background. It shall continue tobe displayed until the cross signal (green man) commences. The pedestrian demand indicator shall be provided with all pedestrian push-buttons unless otherwise shown on the Drawings.

8.5.4 Audible Signal

An audible signal shall, unless otherwise specified, be provided with all pedestrian push-buttons in accordance with A.S. 2353.

8.6 TRAFFIC CONTROLLER

8.6.1 General Requirements

A controller is the complete timing mechanism which controls the signal phases at an intersection. The controller shall be microprocessor-based consisting of :-

i) a microprocessing unit;

ii) interfacing for inputs and outputs;

iii) ancillary equipment.

The control equipment and components shall be housed in a weatherproof cabinet as specified in Sub-Section 8.6.2.

The controller shall be able to provide four phases and shall be capable of expansion to at least eightphases by the addition of modules onsite, which shall be in addition to anyspecial phase required in connection with start up sequences, all reds, etc. It shall also provide a variety of timing functions and differing operational modes. The controller unit shall be capable of operating a minimum of eight plans in a 24 hourperiod. All active and passive components, their mountings and plugs, sockets and connections shall be suitable for their application.




8.6.2 Housing

The housing shall have a weatherproof enclosure for the protection of :-

i) the logic module;

ii) interfacing and/or lamp switchingmodules;

iii) power supplies;

iv) a `call-recorded' tranformer;

v) mains switch board;

vi) facility switch;

vii)shelf space for mounting of vehicle detectors.

The housing cabinet shall be in accordance with A.S. 2578, Part 1, unless otherwise specified herein. Any deviation from A.S. 2578, Part1, shall be at the request of or subject to the approval of the S.O.

Housing shall be manufactured from such material approved by the S.O.

Appropriate means of entry and support for cables shall be provided.

Sufficient ventilation shall be provided to prevent condensation inside the cabinet under all weather conditions. Charcoal or some other dehydration agent shall be placed in the housing as directed by the S.O.

All non-current carrying metal parts shall be bonded together and effectively earthed in accordance with CP 1013.

All means of access shall be protected by locks of different patterns and the corresponding locks and keys shall be identical for controller housings of the same make, type and series. Not less than two keys of each type shall be supplied with each controller and they shall be handed over to the S.O.after the completion of testing and commissioning.

A log book shall be provided in each housing for the purpose of maintenance and inspection records.The log book shall be attached to thehousing by a cord or similar method to prevent removal from the housing cabinet. A pocket or shelf shall be provided within the housing for its storage.

8.6.3 Controller Mains Switch Board

The controller mains switch board shall consist of :-

i) one mains switch and one mains fuse (rated 30 A);

ii) one isolation switch together witha fuse to control mains supply, active to all lamps;

iii) one flashing yellow feature switch and fuse;

iv) one equipment switch and fuse (rated 15 A) to supply four sub-circuits labelled as :-. controller. detectors. auxiliary. general purpose outlet;

v) neutral link;

vi) earth link.




The controller shall be suitable for operation at 240 V + 6%, 50 Hz + 1%, single phase A.C. supply.

8.6.4 Facility Switch

A facility switch shall be provided toswitch the signal lanterns to ON, OFF or FLASH or other facilities such as manual operation. The switch shall only control the signal lamps and flashing yellow circuits while leaving the control equipment fully operative.

Access to this facility shall be via a separate locked door or some other means which does not give access to the controller. The facility shall be located not less than 1 metre from the ground level.

8.6.5 Pedestrian Facilities

Pedestrian indications shall be allocated as exclusive phases or be connected in parallel to a green phase(s).

When the pedestrian indications areconnected in parallel to a green vehicle phase, the steady pedestrian green shall commence at a preset period adjustable to 0, 1, 2, 3, 4 or 5 seconds before or after the start of the green vehicle phase. The steady pedestrian green shall persist until the end of a preset period.

It shall be followed by the flashing pedestrian green. The flashing pedestrian green shall flash at 76 to84 flashes per minute, and the lampshall be on for between 50% to 70% of the time. The amber signal terminating the vehicle green phase shall not commence until a preset period adjustable to 0, 1, 2, 3, 4 or5 seconds has elapsed after the termination of the flashing pedestriangreen.

When the pedestrian indications are allowed an exclusive phase, the pedestrian steady green shall be controlled by the appropriate control command and followed by the flashing green pedestrian signal. The intergreen periods shall be inserted before the pedestrian steady green and between the end of the flashing green and the start of the next vehicle phase green. It shall be possible to operate the pedestrian phase with or without pedestrian detection. This shall be selected by aswitch or other methods within the controller, subject to the approval of the S.O.

8.6.6 Logic Module

Arrangement of the microprocessor based logic module shall be subject to the approval of the S.O.

8.6.6.1 Microcomputer System

The microcomputer system shall contain a stored program in read-only-memory (ROM). Part or all of the ROM shall be reprogrammable. The stored program shall permit the traffic controller to be operated in different traffic modes as follows :-

i) isolated traffic-actuated operation;

ii) cableless/Synchronous operation;

iii) fixed time operation.

All information relating to a particular signal installation, such as number of plans, signal groups, detector logic, time setting and description of logical




and conditional features, shall be contained in the reprogrammable ROM.

Time settings may be stored by means of :-

i) reprogrammable ROM; and

ii) battery back-up RAM.

The RAM settings shall be such that they may be changed by means of a detachable keyboard while the controller is functioning. The reprogrammableROM shall be separate from the CPU and its associated circuitry to facilitate field servicing.

8.6.6.2 Input/Output Interfaces

The Contractor shall provide for the approval of the S.O., detailedtechnical information on the input and output interfaces. Inputs include those from vehicle detectors, pedestrian push buttons and signal links. The output shall be to the vehicle signal lamps, pedestrian lamps, wait indicators and signal linking.

8.6.6.3 Real `Time-of-Day' Clock

For cableless/synchronous linking operations, a hardware clock shall be provided. The circuit generating the hardware clock shall be backed up by a standby battery for up to 48 hours or more (when fully charged).

The clock shall derive its timing from two sources, either from the50 Hz mains supply or a crystal oscillator. When the mains supply is normal, the 50 Hz mains frequency shall provide thetime. The crystal reference signalshall be phase locked to the mains frequency by a digital phase locked loop. The real time clock shall provide time in seconds, minutes, hours and days to the microprocessor via a data bus.

8.6.6.4 Operator Interface and Controller Display

A keyboard display unit shall be provided as an operator interface with the controller logic module. Visual indicators shall be provided to indicate the status of various traffic parameters such asthe phase currently running, basephase step for each phase, demand for each phase, pedestrian demands recorded, etc.

When operated in link mode, the display shall be able to provide all traffic parameters associated with the appropriate link mode.

8.6.6.5 Supply Monitor

All D.C. power supplies tovarious cards in the logic module shall be constantly monitored to ensure correct operation of the controller.

The monitor shall be arranged so that if one or more of the supply output voltages falls below certain preset levels, the power failure detection circuit will activate to cause the controller to black out the intersection.




The mains supply voltage shall also be monitored. Any voltage drop below certain levels shall cause a black out situation.

8.6.6.6 Watchdog Timer

A watchdog timer shall be used to detect failure of the microprocessor system to executeits traffic control program. Any failure to execute traffic instruction shall black out the intersection.

8.6.7 Mains Supply Interruptions

In the event of a mains supply interruption equal to or less than50 milliseconds, the controller shall continue to function correctly. Whena controller commences to fail (aftera mains supply interruption in excess of 50 milliseconds) it shall shut down for the duration of the mains interruption plus a nominal period of about 5 - 10 seconds. At the expiration of this nominal period the controller shall commence operation at an all red state. This state shall persist for at least 5 seconds and shall be followed by the pre-selected phase.

8.6.8 Circuit Breakers

Appropriate fuses or circuit breakers shall be provided by the Contractor for the connection of the controller tothe mains supply. A mains isolation switch shall also be provided.

8.6.9 Inputs

All inputs shall be suitably protected against high voltage peaks and short circuits.

8.6.10 Interchangeability

All parts shall be interchangeable with like parts for equipment of the same make, type and series.

8.6.11 Vibration and Noise

The apparatus shall be reasonably quiet and the mechanism shall not cause undue vibration. The apparatus shall be constructed so as to reduce to a minimum any damage to lamps and equipment due to vibration caused by traffic.

8.6.12 Radio Interference

The design of equipment shall be such as to prevent interference to telegraphic, telephonic or radiotransmissions. The apparatus will be considered to meet this requirement, as far as radio interference is concerned, if the interference produced by it does not exceed the limits laid down in M.S. 71 and B.S. 800.

8.6.13 Safety

Where right of way signals are shown for any controlled traffic in one phase, it shall not be possible through failure of any operating component of the controller to give a right of way signal to a conflicting traffic signal.

The Contractor shall satisfy the S.O. as to how the conflicting green state can be detected and what action is to be taken on its detection. The use of two independent safeguard systems is favoured. A method of testing the operation of the safeguards shall be provided.



FOR INTERNAL USE ONLY Standard Specification For Road Works

The Contractor shall satisfy the S.O. as to how the conflicting green state can be detected and what action is to be taken on its detection. The use of two independent safeguard systems is favoured. A method of testing the operation of the safeguards shall be provided.

8.6.14 Timing

The duration of all periods timed by the controller shall be within + 10% of the nominal time whenthe applied main voltage is withinthe range between + 10% of the nominal value and + 4% of its nominal frequency. This shall apply to those timing arrangements which measure selected fixed periods. The flashing rate of any flashing signals shall be between 76 and84 flashes per minute within the same voltage and frequency limits.

8.7 VEHICLE DETECTORS


All equipment, its construction and performance, shall be in accordance with A.S. 2703 unless otherwise specified herein. Any deviation fromA.S. 2703 shall be at the request of or subject to the approval of the S.O.

8.7.2 Number of Traffic Lanes

The loop detector shall sense traffic flow on one to four traffic lanes depending on where it is installed. It shall sense traffic moving in one direction only and detection on a twoway road shall be achieved by using two sets of detectors so that the information obtained for each direction is separate.

8.7.3 Supply Voltage

The detectors shall operate on 240 V + 6%, 50 Hz + 1% single phase A.C. power supply. Power shall be supplied from the traffic controller.

8.7.4 Equipment Construction

The Contractor shall be responsible for the manufacture, installation and commissioning of the detector system.

8.7.5 Performance Requirements

The detector shall respond to any vehicle, except bicycles and trishaws, normally encountered on public roads travelling at any speed. The Contractor shall satisfy the S.O. with respect to the accuracy of the detector unit in terms of false or nil presence actuation at normal operating sensitivity for all types of vehicles including high-bodied vehicles and multi-axle vehicles.

8.8 ROADWORKS

8.8.1 General

The Contractor shall carry out all necessary roadworks in connection with the installation of the system. These shall include any roadworks associated with :-

i) installation of Local Controller and Detector Recording housings;

ii) installation of signal poles and heads;

iii) installation of cable ducting;



If an existing conduit has been installed across the road carriageway,all cross-carriageway cabling shall be carried by this conduit.

8.8.2 Permission to Excavate Road

The Contractor shall apply to the S.O. for approval to excavate the roadway. This approval shall not be unreasonably withheld.

The application shall be made not less than seven (7) days before the commencement of the work.

The Contractor shall comply with thefollowing conditions and other additional instructions from the S.O. :-

i) trenching in sidetables, footpathsand carriageways shall be excavated, backfilled, reinstated and maintained as specified in this Sub-Section;

ii) cables to be laid in carriageway shall be at least 750 mm below the carriageway level;

iii) cables running longitudinally in footpaths and side-tables shall be at least 600 mm clear of the edge of the kerb line or carriageway and at least 750 mmbelow the adjacent carriageway channel level;

iv) no work shall be done during traffic peak hours unless approved by the S.O.

8.8.3 Excavation, Backfilling Reinstatement and Maintenance of Excavations

8.8.3.1 General

The Contractor shall cause as little obstruction as possible to the general public during the execution of all works under this Contract, and shall pay due regard to the interests and convenience of the public and of all private persons who have property in or are resident in the neighbourhood of the works.

The Contractor shall ensure that no delay occurs between opening excavations, laying cables, backfilling and reinstatement and that these actions form a continuous process.

8.8.3.2 Excavation

Each trench shall be excavated to the required level and materials taken out shall not be re-used unless otherwise specified or directed by the S.O.

For excavation in side-tables, turfs shall be carefully removed,stacked and periodically watered for later re-use. The remaining excavated materials may be stockpiled on the Site for later backfilling but excavated topsoil shall be kept separate.

For excavation in carriageways and footpaths, selected granularmaterials, excavated premix and subbase may be stockpiled on Site for later backfilling. All other unsuitable excavated material must be removed to spoil on the day it is excavated.




All excavated materials shall be kept clear of the carriageways at all times.

All sides of excavations shall be vertical. In soft or unstable ground the sides shall be adequately supported.

All excavations shall be kept free of standing water.

If, for unavoidable reasons, a trench running laterally across a road cannot be backfilled and must be left open overnight or fora longer period, then steel plates,securely bolted and adequate to take traffic loading, shall be placed across the trench and the section of road opened to traffic.

8.8.3.3 Bedding of Excavation

Before ducts are laid, the trench beds shall be levelled and sand placed on the bed and hand tamped to a thickness of not less than 75 mm. All ducts shall be covered by a layer of sand hand tamped to a thickness of at least 75 mm above the crown of the duct.

8.8.3.4 Cable Ducts

At road crossings, sewerage pipecrossings, water pipe crossings, paved areas, concrete areas and areas specified by the S.O., cables shall be protected by galvanised steel pipes buried to a depth of 900 mm below finished ground level. The pipes shall be heavy duty pipes, complying with B.S. 1387, complete with screwed and socketed joints. Unless otherwisespecified, the pipes shall be 150 mm in diameter. Where it is

necessary to cross drains, culvertsor similar obstructions which are too deep for the cables to be buried below, galvanised steel pipes shall be provided. The pipes shall be supported at each end in a concrete block and shall project through the blocks into the ground to a depth of a least 750 mm. All ducts shall beextended at least 600 mm beyondpaved areas, concrete areas, drains, road crossings, pipe crossings, etc.

Unless otherwise approved by theS.O., the number of cables installed in each duct shall be such that the space factor shall not be less than 60 %. A drawn wire shall be provided in each duct.

Unless specified to be provided by others, the above galvanised steel pipes shall be provided by the Contractor whether they are shown on the Drawings or not.

8.8.3.5 Cable Laying and Installation

All cables shall be handled, laid and installed according to this Specification, the IEE Wiring Regulations, cable manufacturer'srecommendations and ERAReports by using proper installation equipment.

All cables shall be supplied in complete length to suit the circuits they serve and no straightthrough joints shall be used. Straight through joints in the cable will only be permitted in very exceptional circumstances such as those arising from unavoidable limitations in manufacturing length. If straight through joints or other approved




joints are permitted by the S.O., the cost of such joints shall be borne by the Contractor. No joints in the cable will be allowedunless approved in writing by the S.O.

The minimum bending radius of the cable shall be in accordance with Table 52C of the IEE Wiring Regulations (15thEdition). Wherever cables are cut, the ends shall be immediately sealed in an approved manner unless it is intended to proceed with cable jointing or termination straight away.

Unless otherwise permitted by the S.O., no cable shall be laid and covered up in the absence of the S.O.

8.8.3.6 Cable Laid Direct On The Ground

Where trench beds have been covered with sand, the cables shall then be laid on this bedding in an orderly manner without overlapping and crossing each other. After laying the cables, a layer of 75 mm clean sand shall cover the cables and shall be carefully spread over the trench before placing the cable protective covers.

The cable protective covers shall be clay bricks. The bricks shall be new, well burnt and in complete pieces. They shall be laid lengthwise from end to end along the entire route of the underground cable if the cable size is not more than 120 sq.mm.For cable sizes exceeding 120 sq.mm, more than one row of

the underground cable if the cable size is not more than 120 sq.mm. For cable sizes exceeding 120 sq.mm, more than one row of bricks shall be laid. Each cable shall be separately protected by these bricks and the cover shall have at least 25 mm overhang on each side of the cable.

An orange coloured, multi-strandnylon rope of minimum 6 mm diameter shall be laid at a depth of 300 mm along the trench to identify the cable route. At every10 metres interval, an extra 2 metres length of nylon rope shallbe coiled and laid.

8.8.3.7 Cables Installed in Precast Concrete Trenches

Methods of installation of cables in precast concrete trenches shall be in accordance with Table 9Aof the IEE Wiring Regulations (15th Edition) for Type L, Type M or Type N cables. However, if the method is not specified, the cables shall be installed as directed by the S.O.

Cables laid at the bottom of trenches shall be Type L cables in accordance with Table 9A of the IEE Wiring Regulations (15thEdition). Cables installed on the trench walls shall be Type M orType N cables in accordance with Table 9A of the IEE Wiring Regulations (15th Edition) and the cables shall be secured on a cable tray by means of saddles at suitable intervals. In the case of single core cables, whether secured individually or in groups to the cable tray, non ferrous saddles shall be used.




The cable tray shall be fabricated from perforated hot-dipped galvanised sheets finished in an orange enamel. The minimum thickness of the sheet steel used shall be 1.5 mm for cable trays with widths of up to 300 mm and shall be 2.0 mm for widths exceeding 300 mm. The cable tray shall be supported at least 25 mm from the trench wall by mild steel brackets at 600 mm intervals. The brackets shall be treated with anti-rust and painted with one coat of primer. Samplesof the cable tray and brackets shall be submitted to the S.O. for approval prior to installation.

To provide electrical continuity, all cable joints shall be bridged by means of tinned copper tape of dimensions not less than 25 mm x 3 mm. All saddles for cables on cable trays shall be installed using bolts, washers and nuts. All tees, intersection units, adaptor units, etc., shall be factory manufactured unless otherwise approved by the S.O.

8.8.3.8 Backfilling of Excavations and Reinstatements

For excavations in sidetables, berms and slopes, the excavated material shall be replaced in 150 mm layers in the reverse order towhich the material was excavated. Each layer shall be compacted with a power driven rammer. The top 150 mm of the excavation and adjacent disturbed ground shall be filled with good loamy topsoil and hand tamped. Approved qualitygrass turfs shall be closely and continuously fitted over the topsoiled area where necessary and directly pegged down to prevent displacement.

For excavations in carriageways and footpaths the backfilling shallbe done in 150 mm layers to within 300 mm of the surface level using clean sand andsuitable excavated granular material or other approved granular material. Each layer shall be compacted using a powerdriven rammer. The next 230 mm of backfill shall consist of crushed aggregate roadbase conforming to Sub-Section 4.1.4 of this Specification, laid and compacted by a power driven rammer. A tack coat of cationic bituminous emulsion shall be applied on the crushed aggregate surface and a 75 mm thick layerof compacted asphaltic premix shall be placed as the final layer,all in accordance with the relevant requirements of Section 4 of this Specification.

8.8.3.9 Sensing Loop Slots

The Contractor shall be responsible for providing the slot in the roadway for the loop sensor; the installation and jointing of the loop feeder cable; the backfilling of the slot in the roadway; and the slot or trenchesfor the feeder cables, all as shown on the Drawings.

8.8.3.10 Maintenance of Drains and Service During Excavations

The Contractor shall ensure that he has full knowledge of the location of all drains and services in the area of any excavation prior to the excavation commencing. The Contractor shall ensure that all precautions are taken not to disturb such drains and services and shall be




responsible for their maintenance during the reinstatement of such excavations.

The Contractor should note if the Site of the Works is subject to frequent and heavy rainfall and all precautions shall be taken to maintain existing drainageways to prevent flooding.

8.8.3.11 Reinstatement of Drains and Precast Units

The Contractor shall carry out thereinstatement of all existing precast channel drains, gulleys, pavement slabs, dividers, kerbs,etc., which have been affected by any trench opening. Only excavated units in a sound and undamaged condition may be replaced, otherwise the Contractor shall supply and lay similar new units. The units shall be replaced to the original lines and levels and shall be bedded, backed and jointed to the satisfaction of the S.O.

8.8.3.12 Completion of Works

On completion of reinstatement works at any one site, the Contractor shall clear away all debris, surplus materials and plant and leave the site in a clean and tidy condition. The Contractor shall carry out any further remedial works as directed by the S.O. and shall obtain the S.O's written approval for the reinstatement works.

8.8.3.13 Maintenance of Excavation

The Contractor shall be entirely responsible for the proper maintenance and good condition of each excavation and each reinstatement up to a period of three (3) calendar months after the date of the S.O.'s written approval of such reinstatement works.

All excavation sites prior to, during, and after reinstatement shall be maintained in a sound and firm condition, free from depressions, humps, loose stones and any other similar defects such as not to constitute danger or unreasonable nuisance to traffic or members of the public. Loose materials or stones shall not be allowed to accumulate over or around any excavation, but shall be promptly swept clear.

Any part of reinstatement in a footpath or carriageway that settles more than 15 mm below the adjacent undisturbed surface level shall promptly be re-surfaced to a level not more than15 mm above the adjacent undisturbed surface level. The resurfacing shall be carried out byapplying a prime/tack coat and asphaltic premix as specified in Section 4 of this Specification.

The Contractor shall be required to maintain a small mobile gang of workmen for the above purpose, and a regular system of daily inspection shall be institutedfor all trenches awaiting temporary and permanent reinstatement. Should the Contractor default in the maintenance of excavations and reinstatement where, in the S.O.'s judgement,




such default would constitute in any way a traffic hazard, then the S.O. shall have the power toattend forthwith to such defects and the entire cost of the work plus 25% shall be borne by the Contractor.

Before the expiration of the maintenance period of each item of work, the Contractor shall write to the S.O. for final inspection of the work to determine any outstanding defects which have to be rectified. The Contractor will only be absolved of all the responsibilities of the maintenance after such defects are rectified to the satisfaction of the S.O.

In the event that the Contractor fails to notify the S.O. of the date of expiration of the maintenance period and has not arranged for the inspection of the work, the maintenance period of each item of work shall be deemed to have been extended by the Contractor due to his fault to such time until the final inspection is carried out.

8.8.4 Traffic Arrangements

8.8.4.1 General

Obstructions and excavations shall be adequately fenced and guarded at all times for the protection of all persons who use the roadway. Particular attention shall be paid to the positioning of the barriers. The whole obstruction or excavation shall becompletely fenced off, but unnecessary blocking of traffic lanes shall not be permitted. Roads shall not be used for the unnecessary storage of materials.

On multilane roads, not more than one traffic lane in either direction shall be closed except asmay be otherwise directed by the S.O. On roads of not more than one traffic lane in each direction, the Contractor shall ensure that both lanes are kept open during peak periods as previously defined. This may be accomplished by the use of steel plates as specified in Sub-Section8.8.3.2.

When the work is such that the simultaneous closing of several lanes cannot be avoided and would cause undue interference with traffic, the work should either be carried out at night or during weekends. However, the S.O. may give permission for the simultaneous closing of lanes for emergency works or other works as deemed necessary.

8.8.4.2 Arrangement and Location of Signs, Barriers and Barricades

The general arrangement and location of temporary signs at works in progress shall be strictlyin accordance with ARAHAN TEKNIK (JALAN) 2C/85, published by Cawangan Jalan, Ibu Pejabat JKR, Kuala Lumpur,and shall be submitted by the Contractor and approved by the S.O. before work commences.

Work on a road involving less than one-third of a traffic lane and work on a footpath in the immediate vicinity of the carriageway of a high speed road shall be deemed to be minor obstructions. In these cases, as it will not be necessary to close up one full lane, shorter barriers shall be used.




All traffic signs used in temporary signing must be reflectorised. When practicable, signs shall be sited where they will receive maximum benefits from street lighting.

8.8.4.3 Temporary Warning Lamps

Temporary warning lamps shall be used during the hours of darkness in conjunction with all temporary signs, barriers and other traffic control devices which are to remain in position atnight. Lamps shall be kept alight at all times during the hours of darkness.

Warning lamps shall consist of standard battery operated flashinglights and shall be placed at salient points of the site every night.

8.8.4.4 Use of Traffic Guidance Cones

When a portion of a roadway is closed to traffic by the use of barriers, barricades or signs, traffic guidance cones shall be placed on the road so as to guide traffic smoothly from the wide section to the narrow section in which a portion of the roadway has been closed to traffic.

Cones shall be used only when the work is in progress or where there is a watchman who can reposition any of the cones whichmay have been dislodged by the traffic. Otherwise they shall be removed from the roadway when work ceases at night. At night, continuously operating flashing lights shall be used to guide the traffic.

Cones shall be of rubber or equivalent flexible material and shall be bright orange in colour.

8.8.4.5 Temporary Traffic Diversions

For the duration of the work, a satisfactory roadway shall be provided for the traffic. Where a sufficient width of carriageway isnot available, a temporary traffic diversion shall be constructed if possible. The extra carriageway shall be properly maintained in a smooth and hard condition at all times for the duration of the work.

The maintenance of pedestrian movement shall be provided by construction of temporary walks, barricades and handrails. Certain areas along the construction site may be restricted to pedestrian use where such restrictions are in the interest of pedestrian safety.

8.8.4.6 Temporary Traffic Control

It is essential that traffic control atthe site be exercised diligently and by competent personnel, if the need arises.

The methods of temporary traffic control are :-

i) Police supervision : this applies where the works are of a very short duration with some special feature, such as a busy road junction;

ii) Manually operated 'Stop' and 'Go' signs : this applies at works of short duration, provided that traffic is not dense. Red and green flags should, under no




circumstances, be used for traffic control, but could be used to supplement the disc signs.

8.8.4.7 Plant and Equipment

In all cases where traffic is permitted to use the whole or a portion of the existing road, all plant items and similar obstructions shall be removed from the road at night, if at all practicable. During the day, a red flag shall project beyond the extremity of all plant items (otherthan vehicles) adjacent to thetraffic lane.

Plant and equipment shall be lit atnight if within 5 metres of the edge of the carriageway by two red lights suspended vertically from the point of obstruction nearest to the carriageway. The lights may be omitted in cases where there are permanent obstructions, such as trees less than 5 metres from the edge of carriageway and the plant or equipment are not closer to the road than the permanent obstructions.

8.8.4.8 Vehicles

Vehicles which carry out operations on the road and which are required to travel slowly or to stop at frequent intervals should be made as conspicuous as possible. This shall be achieved by painting such vehicles a distinctive colour, and/or painting their rear portions with diagonal stripes of a contrasting colour, and/or providing

flashing lights on the top of the vehicles. They should also have aplate on the rear side with the words `SLOW MOVING' or `KENDERAAN PERLAHAN'.

8.8.4.9 Maintenance of Signs, Lights, Barriers,Temporary Traffic Diversions, etc.

Signs, lights, barriers and other traffic control devices shall be maintained in good order and in the correct position day and night. Signs shall be neat, clear and legible at all times. Temporary traffic diversions shallbe maintained in good order at alltimes.





SECTION 9

CONCRETE




SECTION 9 - CONCRETE

Page


9.2 MATERIALS S9-211

9.2.1 Cement S9-2119.2.1.1 Transportation and Storage S9-211

9.2.2 Aggregates S9-2119.2.2.1 Coarse Aggregates S9-2119.2.2.2 Fine Aggregates S9-2119.2.2.3 Grading S9-2119.2.2.4 Sampling and Testing of Aggregates S9-2129.2.2.5 Storage of Aggregates S9-213

9.2.3 Water S9-213

9.2.4 Admixtures S9-214

9.3 CLASSIFICATION OF CONCRETE MIXES S9-214

9.3.1 Requirements for Prescribed Mixes S9-214

9.3.2 Requirements for Designed Mixes S9-2159.3.2.1 Target Mean Strength S9-2159.3.2.2 Suitability of Proposed Mix Proportions S9-2169.3.2.3 Mixes S9-2179.3.2.4 Control of Strength of Designed Mixes S9-217

9.3.3 Requirements for Concrete9.3.3.1 Workability S9-2189.3.3.2 Concrete Grade S9-2189.3.3.3 Minimum Cement Content S9-2189.3.3.4 Maximum Cement Content S9-2189.3.3.5 Total Chloride Content S9-2199.3.3.6 Maximum Sulphate Content S9-220

9.4 COMPLIANCE WITH SPECIFIED REQUIREMENTS

9.4.1 Prescribed Mix S9-220

9.4.2 Designed mix S9-2219.4.2.1 Characteristic Strength S9-2219.4.2.2 Sampling and Testing S9-2219.4.2.3 Testing plan S9-222

9.4.3 Additional Cubes S9-223




Page


9.5.1 Supervision S9-223

9.5.2 Batching and Mixing S9-223

9.5.3 Transporting S9-224

9.5.4 Placing S9-224

9.5.5 Temperature Requirements S9-226

9.5.6 Compaction S9-226

9.5.7 Curing and protection S9-2279.5.7.1 Normal Curing S9-2279.5.7.2 Accelerated Curing S9-228

9.5.8 Ready-Mixed Concrete S9-228

9.6 CONSTRUCTION WITH CONCRETE

9.6.1 Construction Joints S9-228

9.6.2 Fixing Blocks, Brackets, built-In-Bolts, Holes, Chases, etc. S9-229

9.6.3 Precast Concrete Construction9.6.3.1 Manufacturer Off the Site S9-2309.6.3.2 Storage S9-2309.6.3.3 Handling and Transport S9-2309.6.3.4 Assembly and Erection S9-2309.6.3.5 Forming Structural Connections S9-2309.6.3.6 Protection S9-231

9.7 STEEL REINFORCEMENT



9.7.3 Construction Method S9-2329.7.3.1 Cutting and Bending of Reinforcement S9-2329.7.3.2 Fixing of Reinforcement S9-2329.7.3.3 Splicing S9-2339.7.3.4 Supporting and Spacer Blocks S9-2339.7.3.5 Welding of Reinforcement S9-233




Page

9.8 FORMWORK AND SURFACE FINISH FOR STRUCTURE

9.8.1 Design and Construction9.8.1.1 Description S9-2349.8.1.2 Voids In Concrete S9-2349.8.1.3 Form Lining S9-2359.8.1.4 Projecting Reinforcement, Fixing Devices S9-235

9.8.2 Finishes9.8.2.1 Formed Surfaces S9-2359.8.2.2 Unformed Surfaces S9-2369.8.2.3 Remedial Treatment of Surfaces S9-236

9.8.3 Preparation of Formwork Before Concreting S9-237

9.8.4 Removal of Formwork S9-237



SECTION 9 - CONCRETE

9.1 DESCRIPTION

This work shall consist of the construction of all structures or parts of structures to be composed of Portland cement concrete with or without steel reinforcement, except for reinforced concrete pipe culverts, which shall be constructed in accordance with the provisions of Section 3.9, and Portlandcement concrete pavement, which shall be constructed in accordance with the provisions of Section 5. The work shall be carried out all in accordance with this Specification and the lines, levels, grades, dimensions and cross-sections shown on the Drawings and as required by the S.O.

9.2 MATERIALS

9.2.1 Cement

The cement to be used throughout the work shall be Portland cement obtained from an approved manufacturer. The cement shall be described under one of the following headings :-

i) Ordinary Portland Cement- the cement shall comply with

M.S. 522;

ii) Rapid Hardening Portland Cement- the cement shall comply with

M.S. 522;

iii) Moderate Sulphate Resisting Portland Cement- the cement shall comply with

B.S. 12;

iv) Sulphate Resisting Portland Cement- the cement shall comply with

B.S. 4027.

Manufacturer's certificates of test will, ingeneral, be accepted as proof ofsoundness. Additional tests shall be carried out on any cement which appears to have deteriorated through age, damage to containers, improper storage or any other reason. In any event, the batch of cement which has been sampled and tested and found not to have complied with the requirements shall be rejected and removed from the Site.

9.2.1.1 Transportation and Storage

The cement shall be transported to the Site in covered vehicles adequately protected against water. It shall be stored in a weather-proof cement store to theapproval of the S.O. and shall betaken for use in the Works in the order of its delivery into the store.Cement delivered in bulk shall bestored in silos of an approved design.

9.2.2 Aggregates

Aggregates shall be naturally occurring sand, gravel or stone, crushed or uncrushed except as otherwise specified, and shall comply with M.S. 29. They shall be obtained from a source approved by the S.O. and shall be hard, strong, durable and clean. They shall be free from adhering coatings and shall not contain any harmful material in sufficient quantity so as to affect adversely the strength, durability andimpermeability of the concrete.

Marine aggregates shall not be used unless otherwise specified.




9.2.2.1 Coarse Aggregate

Coarse aggregate shall comply with M.S. 29.

9.2.2.2 Fine Aggregate

Fine aggregate shall comply withM.S. 29. If it is found necessary, the fine aggregate shall be washed and screened to the satisfaction of the S.O.

9.2.2.3 Grading

(a) Coarse Aggregate

The grading of coarse aggregate shall be analysed as described in M.S. 30 and shall be within the limits given in Table 9.1.


TABLE 9.1 - COARSE AGGREGATE

% Passing By Weight

Nominal Size of

graded aggregate

Nominal Size of

single-sized aggregate

B.S. 410 Test

Sieve

(mm)

37.5mm to

5.0 mm

20.0mm to

5.0 mm

14.0 mm to

5.0 mm

63.0 mm

37.5 mm

20.0 mm

14.0 mm

10.0 mm

75.0

63.0

37.5

20.0

14.0

10.0

5.0

2.36

100 -

95 - 100

30 - 70 -

10- 35

0 - 5 -

- -

100

95 - 100 -

25 - 55

0 - 10 0 -

- - -

100

90 - 100

40 - 85

0 – 10

-

100

85 - 100

0 - 30

0 - 5 - - - -

-

100

85 - 100

0 - 20 -

0 - 5 - -

- -

100

85 - 100 -

0 - 20

0 - 5 -

- - -

100

85 - 100

0 - 45

0 - 10 -

- - - - -

85 - 100

0 - 20 -



9.2.2.4 Sampling and Testing of Aggregates

Samples of the fine and coarse aggregates approved by the S.O. shall be kept on Site, and shall give a fair indication of the general quality of the aggregates for comparison with the aggregates delivered during the course of the work.

Tests shall be carried out on samples of the latter taken at intervals as required by the S.O. The method of sampling and testing shall be in accordance with M.S. 30 and other standardsas specified in Table 9.3. Any batch of aggregate rejected by theS.O. shall be removed from the Site.


(b) Fine Aggregate

The grading of fine aggregate shall be analysed as described in M.S. 30 and shall be within the limits of one of the grading zones given in Table 9.2.

TABLE 9.2 - FINE AGGREGATE

% Passing By Weight B.S. 410 Test Sieve

Grading Zone 1

Grading Zone 2

Grading Zone 3

Grading Zone 4

10.0 mm

5.0 mm

2.36 mm

1.18 mm

600 um

300 um

150 um

100

90 - 100

60 – 95

30 - 70

15 - 34

5 - 20

0 - 10

100

90 - 100

75 – 100

55 – 90

35 – 59

8 – 30

0 – 10

100

90 – 100

85 – 100

75 – 100

60 – 70

12 – 40

0 - 10

100

95 – 100

95 – 100

90 – 100

80 – 100

15 – 50

0 - 15



9.2.2.5 Storage of Aggregates

Separate storage facilities with adequate provision for drainage shall be provided for each different size of aggregate used.

Aggregate shall be handled and stored so as to minimise segregation and contamination.

9.2.3 Water

Water shall comply with the requirements of M.S. 28. It shall be clean and free from harmful matter and shall be from a source approved by the S.O. The Contractor shall make adequate arrangements tosupply and store sufficient water at the work site for use in mixing and curing concrete. All costs for installing and maintaining the supplyshall be borne by the Contractor.


TABLE 9.3 - TESTING OF AGGREGATE

Properties

Test Methods

Limits

Grading

Elongation Index

Flakiness Index

Water Absorption

Clay, Silt and Dust

Organic Impurities

Aggregate Crushing

Value

Soundness Test (Sodium Sulphate)

Chloride Content

Sulphate Content

M.S. 30

M.S. 30

M.S. 30

M.S. 30

M.S. 30

M.S. 30

M.S. 30

AASHTO Test Method T104

B.S 812 Part 4

B.S 1377 Test 9

Table 9.1 & Table 9.2

not exceeding 30%

not exceeding 25%

not exceeding 1.5%

not exceeding 2%

not exceeding 0.4%

not exceeding 20%

loss not exceeding 12%

not exceeding 0.06% by weight

of chloride ions

not exceeding 0.4% be

weight of SO3



9.2.4 Admixtures

Suitable admixtures may be used in concrete mixes with the prior approval of or as directed by the S.O.

All requirements for sampling, acceptance tests, uniformity tests, independant tests, chloride content, information to be provided by manufacturer, compliance and storage certificates and marking shallbe in accordance with M.S. 922.

All admixtures shall be used strictly in accordance with manufacturer's instructions.

Before allowing the admixture to be used in the work, relevant tests basedon trial mixes shall be carried out. The trial mix shall be made using job-site materials and under job-site conditions. A control mix shall be made using a conventional trial mix, that is without using the admixture, to determine the water/cement ratio and mix proportions required to give the specified strength with the required slump. Using the same mixproportions as in the control mix, a test shall be prepared using the recommended dosage of the admixture. The results of relevant tests obtained from the control mix and test mix shall be compared. TheS.O. may allow the use of the admixture only when the results are found to be satisfactory and comparable to the effects as claimed by the manufacturer. Table 9.4 of admixture acceptance test requirements shall be complied with.

Admixtures which contain calcium chloride or calcium formate as the active constituents shall not be used for structural concrete containing reinforcement, prestressing tendons or other embedded metal.

9.3 CLASSIFICATION OFCONCRETE MIXES

The concrete mixes shall be classified as :-

(a) Prescribed Mix

The Contractor shall provideconcrete that contains constituents in the specified proportions.

(b) Designed Mix

The Contractor shall select the mix proportions and unless otherwise specified, the workability, in order to satisfy the strength and other requirements of the Contract.

9.3.1 Requirements for Prescribed Mixes

Unless otherwise specified, the concrete mix shall be as detailed in Table 9.5 which shows the weights of cement and total dry aggregates, in kilograms, to produce approximately one cubic metre of fully compacted concrete, together with the percentages by weight of fine aggregates in total dry aggregates.




9.3.2 Requirements for Designed Mixes

9.3.2.1 Target Mean Strength

The concrete mix shall be designed to have at least the required minimum cement content and to have a target meanstrength greater than the required characteristic strength by at least the current margin.

The current margin for each particular type of concrete shall be determined by the Contractor and shall be taken as the lesser of :-

i) 1.64 times the standard deviation of cube tests on at least 100 separate batches of concrete of nominally similar proportion of similar materialsand produced over a period not exceeding 12 months by the same plant under similar supervision, but not less than 2.5 N/sq.mm for concrete of grade 15 or 3.75 N/sq.mm for concrete of grade 20 or above;

ii) 1.64 times the standard deviation of cube tests on at least 40 separate batches of concrete of nominally similar proportions of similar materials and produced over aperiod exceeding 5 days but not exceeding 6 months by the same plant under similar supervision, but not less than 5 N/sq.mm for concrete of grade 15 or 7.5 N/sq.mm for concrete of grade 20 or above.

Where there are insufficient data to satisfy (i) or (ii) above, the margin for the initial mix design shall be taken as 7.5 N/sq.mm for concrete of grade 15 and 12 N/sq.mm for concrete of grade 20 or above. This margin shall be used as the current margin only until sufficient data are available to satisfy (i) or (ii) above. However, subject to the approval of the S.O., when the specified characteristic strength approaches the maximum possible strength of concrete made with a particular aggregate,a smaller margin not less than 5 N/sq.mm for concrete of grade 15or 7.5 N/sq.mm for concrete of grade 20 or above may be used for the initial mix design.




Fine aggregate is expressed as a percentage by weight to the total dry aggregates. The lower value shall be used for finer grading.

9.3.2.2 Suitability of Proposed Mix Proportions

The Contractor shall submit for the approval of the S.O., prior to the supply of any designed mix, the following :-

i) the nature and source of each material;

ii) appropriate existing data as evidence of satisfactory previous performance for target mean strength, current margin, workability andwater/cement ratio; ORfull details of tests on trial mixes carried out in accordance with Sub-Section 9.3.2.3;


TABLE 9.5 - PRESCRIBED MIXES FOR GENERAL USEPER CUBIC METRE OF CONCRETE

Nominal Max. Sizes of

Aggregate (mm)

40

20

Workability

Medium High Medium High

Grade of Concrete

28-day

Characteristic Strenght of Concrete

(N/sq.mm)

Slump Limits

(mm)

50 -100

100 - 150

25 - 75

75 - 125

15P

15

Cement (kg)

Total aggregate

(kg)

Fine aggregate (%)

250

1850

30 - 45

270

1800

30 - 45

280

1800

35 - 50

310

1750

35 – 50

20P

20

Cement (kg)

Total aggregate

(kg)

Fine aggregate (%)

300

1850

25 - 35

320

1750

25 – 40

320

1800

25 – 40

350

1750

20 - 45

25P

25

Cement (kg)

Total aggregate

(kg)

Fine aggregate (%)

340

1800

25 - 35

360

1750

25 - 40

360

1750

25 - 40

390

1700

30 - 45



iii) the proposed quantities of each material per cubic metre of fully compacted concrete.

9.3.2.3 Trial Mixes

The Contractor shall give notice to enable the S.O. to be present atthe making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using samples of approvedmaterial typical of those he proposes to use in the Works, for all grades to the satisfaction of the S.O. prior to commencement of concreting.

Sampling and testing procedures shall be in accordance with M.S. 26. Three separate batches of concrete shall be made. The workability of each of the three trial batches determined by means of the slump test, compacting factor test or vebe consistometer test in accordance with M.S. 26, shall be appropriate to the proposed uses and methods of placing and compaction of the mix and shall be approved by the S.O. Six cubes shall be made from each batch. Three from each set of sixshall be tested at an age of 7 daysand three at an age of 28 days. The average strength of the nine cubes tested at 28 days shall exceed the specified characteristicstrength by the current margin minus 3.5 N/sq.mm. The approved trial mix shall then be designated as the "designed mix" and its corresponding workabilityas the "designed workability".

During production, the S.O. may require additional trial mixes to be made before a substantial change is made in the materials or in the proportion of the materials to be used. Trial mixes need not be carried out when adjustments are made to the mix proportions in accordance with Sub-Section 9.3.2.4.

9.3.2.4 Control of Strength of Designed Mixes

(a) Adjustment to Mix Proportions

Adjustment to mix proportions shall be made subject to the approval of the S.O. in order to minimise the variability of strength and to maintain the target mean strength. The specified limits of minimum cement content and maximum water/cement ratio shall be maintained. Changes in cement have to be declared. Such adjustment shall not be taken to imply any change in the current margin.

(b) Change of Current Margin

A change in the current margin used for judging compliance withspecified characteristic strengths becomes appropriate when the results of a sufficiently large number of tests show that the previously established margin is significantly too large or too small.




Recalculation of the margin shall be carried out in accordance with Sub-Section 9.3.2.1. Although a recalculated margin is almostcertain to differ numerically fromthe previous value, the adoption of the recalculated value will not generally be justified if the two values differ by less than 18% when based on tests on 2 separatebatches or less than 11% when based on tests on 100 separate batches, or less than 5% when based on tests on 500 separate batches.

On the adoption of a recalculated margin it shall become the current margin for the judgement of compliance with the specified characteristic strength of concreteproduced subsequent to the change.

9.3.3 Requirements for Concrete

9.3.3.1 Workability

The workability of the fresh concrete shall be such that the concrete is suitable for the conditions of handling and placing so that after compaction, it surrounds all reinforcement, tendons and ducts and completelyfills the formwork.

Workability of the concrete shall be within one of the following limits :-

i) Slump- ±25 mm or ± one-third of

the "designed workability", whichever isthe greater.

ii) Compacting Factor- ±0.03 where the

"designed workability" is 0.9 or more.

- ±0.04 where the "designed workability" is between 0.8 and 0.9.

- ±0.05 where the "designed workability" is 0.8 or less.

iii) Vebe

- ±3 seconds or ±one-fifth of the "designed workability", whichever isless.

9.3.3.2 Concrete Grade

The grade of concrete to be used in the Works shall be as stated on the Drawings and in the Bill of Quantities.

(Concrete grade shall be designated as GRADE X/Ywhere `X' is the numerical value of the characteristic strength in N/sq.mm as determined from test cubes at 28 days, and `Y' is the nominal size of aggregate in mm. For a prescribed mix, a suffix `P' shall be added after `X').

9.3.3.3 Minimum Cement Content

The minimum cement content shall be in accordance with Table 9.6 unless otherwise shown on the Drawings.

9.3.3.4 Maximum Cement Content

The maximum cement content shall not exceed 550 kg/cu.m unless otherwise described in the Contract or agreed by the S.O.




9.3.3.5 Total Chloride Content

The total chloride content of the concrete mix arising from the aggregate or any other source shall not in any circumstances exceed the limits in Table 9.7 expressed as a percentage relationship between chloride ions and weight of cement in the mix.

Tests shall be carried out in accordance with B.S. 1881 for each grade of concrete, to demonstrate that these limits are not exceeded.


Prestressed Concrete

Reinforced Concrete

Plain Concrete

Exposure

Nominal max. size of

aggregate (in mm)

40 20

Nominal max. size of

aggregate (in mm) 40 20

Nominal max. Size of aggregate

(in mm) 40 20

Max. Free

Water/ Cement

Ratio

Surfaces sheltered from severe rain :- 1) surface protected

by a water-proof membrane;

2) internal surfaces, whether or not subject

to condensation; 3) surfaces continuously buried and/or submerged under water.

(kg/cu.m) 300 320

(kg/cu.m) 270 300

(kg/cu.m) 250 280

0.55

1) soffits; 2) surfaces exposed to

driving rain, alternate wetting and drying e.g.in contact with backfill.

320 350

320 350

270 300

0.50

1) surfaces exposed to the action of sea

water with abrasion having a pH of 4.5 or less.

350 380

350 380

320 350

0.45

TABLE 9.6 - MINIMUM CEMENT CONTENT AND MAXIMUM FREEWATER/CEMENT RATIO FOR DESIGNED MIX



Notes on Table 9.7 :-

(1) % Chloride ionsx 1.648= % equivalent sodium

chloride.

(2) % Chloride ionsx 1.56= % equivalent anhydrous

calcium chloride.

9.3.3.6 Maximum Sulphate Content

The total estimated sulphate content of any mix, including thatpresent in the cement shall not exceed 4.0% by weight of cement in the mix. Tests shall be carried out in accordance with B.S. 1881 for each grade of concrete to demonstrate that theselimits are not exceeded.

9.4 COMPLIANCE WITH SPECIFIED REQUIREMENTS

9.4.1 Prescribed Mix

A prescribed mix shall be judged on the basis of the specified mix proportions. The workability shall bechosen to suit the construction requirements.

Notwithstanding this, strength tests shall be carried out during the progress of work. The rate of sampling shall be as per Rate 2 for ordinary structural concrete as in Table 9.8. For each sampling, three test cubes shall be made. One test cube from each sample-batch shall be tested for the 7-day compressive strength.


TABLE 9.7 - MAXIMUM TOTAL CHLORIDE

Type of Concrete

Maximum Total Chloride ( % )

Reinforced Concrete made with cement complying with M.S. 522. Plain Concrete containing embedded metal and made with cement complying with M.S. 522.

0.35 for 95% of test results with no result

greater than 0.50.

Concrete made with cement complying with B.S. 4027.

0.2

Prestressed Concrete and Structural Concrete that is steam cured.

0.1



If the cube strength falls below 75% of the 28-day compressive strength, then the S.O. may directthe Contractor to take necessary steps to review the process of the production of concrete for future use.

The remaining two test cubes from the sample-batch shall be tested for the 28-day compressivestrength. The appropriate strength requirement shall be considered to be satisfied if at least one of the following is complied with :-

i) none of the two test cubes is below the specified compressive strength;

ii) the average strength of the two test cubes is not less than the specified compressive strength and the difference between the two strengths is not more than 20% of the average strength.

In the event that the results of the test do not meet the specified requirements, the S.O. shall determine the action to be taken in respect of the concrete memberrepresented by the sample-batch test cubes. Such action may include demolition of the member. The Contractor shall, if required by the S.O., take cored samples from the hardened concrete member and carry out the compressive strength test.

9.4.2 Designed Mix

9.4.2.1 Characteristic Strength

The characteristic strength of concrete is that 28-day cube strength, below which not more than 5% of the test results may be expected to fall. Compliance with the specified characteristic strength shall be judged by tests made on cubes at an age of 28 days.

9.4.2.2 Sampling and Testing

All sampling and testing of constituent materials shall be carried out in accordance with theprovisions of the appropriate available Malaysian Standards. In particular, sampling and testingof fresh and of hardened concreteshall be carried out in accordancewith the provisions of M.S. 26.

The rate of sampling shall be as given in Table 9.8, but not less than one sample shall be taken from each source of production on each day that concrete of any particular grade is used.




* The sample shall be taken from one single batch randomly selected from the group of batches.

9.4.2.3 Testing Plan

Three test cubes shall be made from a single sample taken from a randomly selected batch of concrete. The samples shall be taken at the point of discharge from the mixer or, in the case of ready-mixed concrete, at the point of discharge from the delivery vehicle.

One test cube from each sample shall be tested for the 7-day compressive strength. If the cubestrength falls below the 7-day strength as determined from the trial mixes, then the Contractor shall take the necessary steps to review the process of the production of concrete and make certain adjustments where applicable.

The remaining two test cubes from the same sample shall be tested for the 28-day compressive strength. The average strength of the two cubesshall constitute the 28-day compressive strength of the sample.

For compliance purposes :-

i) the average 28-day strength determined from any group offour consecutive samples shallexceed the specified characteristic strength by at least 0.5 times the curent margin.

The current margin shall be takenas 7.5 N/sq.mm for concrete of grade 15 or 12 N/sq.mm for concrete of grade 20 or above unless, in accordance with Sub-Section 9.3.2.1 or 9.3.2.4 (b), a smaller margin has been established to the satisfaction of the S.O.


TABLE 9.8 - MINIMUM RATE OF SAMPLING

Rate

Volume of concrete from which a sample shall be taken

Rate 1 (Prestressed Concrete)

Every 10 cu.m or every group of 10 batches *

Rate 2 (Ordinary Structural

Concrete)

Every 20.0 cu.m or every group of 20 batches *

Rate 3

(Mass Concrete)

Every 50 cu.m or every group of 50 batches *



In this respect, consecutive samples are samples taken at intervals not exceeding 14 days. In all cases, at least four samples shall be taken of concrete on the first day of concreting for each grade of concrete to be used in the Works, irrespective of the volume of concrete produced or the sampling rate.

ii) Each individual sample test resultshall be at least 85% of the specified characteristic strength.

If any one sample test result fails to meet the second requirement (ii), then that result may be considered to represent only the particular batch of concrete from which the sample test cubes were taken.

If the average strength of any group of four consecutive sample test results fails to meet the first requirement (i), or more than one sample test result in a group fails to meet the second requirement (ii), then all the concrete in all the batches represented by all such sample test results shall be deemed not to comply with the strength requirements.

For the purpose of this Sub-Section, batches of concrete represented by groups of four consecutive sample test results shall include the batches from which samples were taken to obtain the first and the last sample results in the group of four, together with all the intervening batches.

9.4.3 Additional Cubes

Additional cubes may be reuqired forvarious purposes. These shall be made and tested in accordance with M.S. 26 but the methods of samplingand the conditions under which the cubes are stored shall be varied according to the purpose for which they are required.

For determining the cube strength of prestressed concrete before transer orof concrete in a member beforestriking formwork, sampling shall beat the point of placing and the cubes shall be stored as far as possible under the same conditions as the concrete in the members.

The extra cubes shall be indentified at the time of making and shall not be used for the normal quality control or compliance procedures.


9.5.1 Supervision

The Contractor shall ensure the required standard of control over materials and workmanship. The S.O. shall be afforded all reasonable opportunity and facility to inspect thematerials and the production of concrete, to take any samples and to make any test.

9.5.2 Batching and Mixing

The quantities of cement, fine aggregate and various sizes of coarseaggregate shall be measured by weight unless otherwise approved by the S.O. A separate weighing machine shall be provided for weighing the cement. Alternatively the cement may be measured by using a whole number of bags in each batch. The quantity of water




shall be measured by volume or by weight. Any solid admixtures to be added shall be measured by weight but liquid or paste admixtures may be measured by volume or weight.

The batch weight of aggregate shall be adjusted to allow for the moisture content of the aggregate being used. The accuracy of the measuring equipment shall be within :-

± 3% of the quantity of cement per batch;

±3% of the quantity of water per batch;

±3% of the quantity of total aggregate per batch;

± 5% of the quantity of admixture per batch.

The mixer shall comply with the requirements of B.S. 1305 or B.S. 4251 where applicable. The mixing time shall be not less thantwo minutes or more than five minutes after all the ingredients have been placed in the mixer. For cements other than ordinary Portland cement, the mixing time shall not be less than that recommended by the manufacturer and subject to the S.O.'s approval of the trial mix.

Mixers that have been out of use for more than 30 minutes shall bethoroughly cleaned before any fresh concrete is mixed. Unless otherwise agreed by the S.O., thefirst batch of concrete through themixer shall then contain only two-thirds of the normal quantity of coarse aggregate.

Mixing plant shall be thoroughly cleaned before changing from one type of cement to another.

The water content of each batch of concrete may be adjusted so as to produce a concrete of the workability required.

9.5.3 Transporting

Concrete shall be transported from the mixer to the formwork as rapidly as practicable by methods which willprevent segregation or loss of the ingredients and maintain the requiredworkability. It shall be deposited as near as practicable in its final position to avoid rehandling. The concrete shall be conveyed by chutesor concrete pumps only with permission from the S.O.

9.5.4 Placing

For all concrete whether mixed on oroff the site of the Works, each batch shall be placed and compacted within 2 hours of adding the cement to the dry aggregates and within 45 minutes (or any other period of timeas approved by the S.O. if admixture is used) of adding water to the cement and aggregates. Concrete shall not be placed in any part of the structure until the S.O.'s approval has been obtained. If concreting is not started within 24 hours of approval given, approval shall againbe obtained from the S.O.

All formwork and reinforcement contained in it shall be clean and freefrom standing water immediately before the placing of the concrete. Concreting shall be carried out continuously between and up to predetermined construction joints in onesequence of operation. In the event of unavoidable stoppage in positions




not predetermined, the concretingshall be terminated on a horizontal plane and against vertical surfaces by the use of stopping-off boards.

Fresh concrete shall not be placedagainst in situ concrete which hasbeen in position for more than 45 minutes (or any other period of time as approved by the S.O. ifadmixture is used) unless a construction joint is formed in accordance with Sub-Section 9.6.1. When in situ concrete has been in place for 4 hours, no further concrete shall be placed against it for a further 20 hours.

Except where otherwise agreed by the S.O., concrete shall be deposited in horizontal layers to acompacted depth not exceeding 450 mm where internal vibrators are used; or 300 mm in all other cases. The surface of the concrete shall be maintained reasonably level during placing.

Concrete shall not be dropped into place from a height exceeding 1500 mm. When trunking or chutes are used, they shall be kept clean and used in such a manner as to avoid segregation.

The Contractor shall maintain an experienced steel fixer at the site of reinforced concrete works during the placing of concrete to reposition any reinforcement which may be displaced during the work.

No concrete shall be placed in flowing water. Underwaterconcrete if deemed unavoidable by the S.O. shall be placed in position by tremies or pipelines from the mixer. Concrete to be placed under water shall be an approved mix with the amount ofcement increased by 20%. During and after concreting underwater, pumping or dewatering operations in the immediate vicinity shall be suspended until the S.O. permits them to continue. Where the concrete is placed by a tremie, the following requirements shall be applicable :-

i) unless otherwise agreed by the S.O, when concreting of bored piles is being carried out under water, temporary casing shall be installed to the full depth of the borehole so that fragments of ground cannot drop from the sides of the hole into the concrete as it is placed;

ii) the hopper and tremie pipe shall be a closed system. The bottom of the tremie shall be kept as far as practicable beneath the surface of the placed concrete;

iii) the tremie pipe shall be large enough with due regard to thesize of aggregate. For 20 mmaggregate the tremie pipe shall be of diameter not less than 150 mm and for larger aggregate, larger diameter tremie pipe shall be required;




iv) unless otherwise agreed by the S.O., the first charge of concrete shall be placed with a sliding plug pushed down the tube ahead of it to prevent mixing of concrete and water;

v) the tremie pipe shall always penetrate well into the concrete with an adequate margin of safety against accidental withdrawal if the pipe is surged to discharge theconcrete;

vi) the concrete shall be deposited wholly by tremie and the method of deposition shall not be changed part way up to prevent the laitance from being entrapped within the structure;

vii)all tremie pipes shall be scrupulously cleaned after use.

9.5.5 Temperature Requirements

During hot weather, additional precautions shall be taken to prevent premature setting and loss of water during placing of concrete in the formwork. These precautions shall include :-

i) no concrete having an internal temperature exceeding 33ºC shall be deposited;

ii) concrete shall not be placed in formwork or around reinforcement whose temperatureexceeds 36ºC;

iii) newly placed concrete shall be protected from direct sunlight andfrom loss of moisture by covering, shading or other means;

iv) no concrete shall be placed when the air temperature at the point of deposition exceeds 36ºC.

9.5.6 Compaction

Unless otherwise agreed by the S.O.,concrete shall be thoroughly compacted by vibration and thoroughly worked around the reinforcement, tendons, or duct formers, around embeddedfixtures and into corners of the formwork to form a dense homogenous mass free from voids and which will have the required surface finish when the formwork is removed. Vibration shall be applied continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner which does not promote segregation of the ingredients.

The concrete maintained between thetwo walls of formwork shall be compacted by vibrating of the internal type and concrete in slabs with no formwork on its upper surface shall be compacted either by vibrators of the pan type or by a vibrating screed.

The internal vibrators shall be inserted and withdrawn slowly and ata uniform pace of approximately 100 mm per second. Compaction shall be deemed to be completed when cement mortar appears in an annulus around the vibrator. Over vibration leading to segregation of the mix must be avoided. The internal vibrators shall be inserted at points judged by the area of mortar showing after compaction, with a certain allowance made for overlapping, and they shall not be allowed to come into contact with




the formwork or the reinforcement and shall be inserted at a distance of not less than 75 mm from the former.

The pan vibrator shall be placed on the surface of the concrete which shall have previously been tamped and levelled leaving an allowance in height for compaction until the cement mortar appears under the pan. The vibrator shall then be lifted and placed on the adjoining surface and this operation shall berepeated until the whole surface has been compacted. Alternatively a vibrating screed spanning the full width of thesurface may also be used.

Whenever vibration has to be applied externally, the design of formwork and disposition of vibration shall receive special consideration to ensure efficient compaction and to avoid surface blemishes. The mix shall be suchthat there will be no excess water on the top surface on completion of compaction.

External vibrators shall be firmly secured to the formwork which must be sufficiently rigid totransmit the vibration and strong enough not to be damaged by it.

Internal vibrators shall be capableof operating at not less than 10,000 cycles per minute and external vibrators at not less than3,000 cycles per minute. Sufficient vibrators in serviceablecondition shall be on Site so that spare equipment is always available in the event of breakdown.

Concrete shall not be subjected toany disturbance within 24 hours after compaction. No standing orflowing water shall be allowed to come into contact with exposed concrete surfaces during the first two hours after placing and compaction of the concrete.

9.5.7 Curing and Protection

All work shall be protected from damage by shock or overloading or falling earth or flowing water, etc.

9.5.7.1 Normal Curing

Exposed surfaces, immediately after compaction, shall be protected from the sun and rain ina manner approved by the S.O. All concrete, after it has set, shall be kept continuously damp until thoroughly cured. Provision shallbe made for adequate water distribution to all parts of the Works, so that if required, this treatment can be continued efficiently throughout the whole period of construction. In order to keep the concrete continuouslydamped, all exposed surfaces shall be covered with continuously damped gunny bagsor shall have water impounded on them for the full period of curing which shall be not less than 7 days.

Other methods of curing may be used subject to the approval of the S.O.




9.5.7.2 Accelerated Curing

Elevated temperature curing maybe used only with ordinary Portland cement. After the completion of the placing of the concrete, 4 hours shall elapse before its temperature is raised. The rise in temperature within any period of 30 minutes shall not exceed 10ºC and the maximum temperature attained shall not exceed 70 ºC. The rate of subsequent cooling shall not exceed the rate of heating. The use of accelerated curing methodsfor concrete containing other types of cement or any admixtureshall be subject to the approval ofthe S.O.

9.5.8 Ready-Mixed Concrete

Ready-mixed concrete shall comply with the requirements of M.S. 523. The concrete shall be carried in purpose-made agitators operating continuously or truck mixers. The concrete shall be compacted and in its final position within 2 hours of the introduction of cement to aggregate and within 45 minutes (or any other period of time as approved by the S.O. if admixture is used) after the addition of water to the cement-aggregate mix unless otherwise agreed by the S.O. The time of such introduction shall be recorded on the Delivery Note together with the weight of the constituents of each mix.

Ready-mixed concrete delivered to the job site shall be accompanied by manufacturer's certificates stating the details of mix proportions by weight, grade of concrete, type and size of aggregate, date and time of production, type and dosage of chemical admixtures and other

relevant production details in suitable format. In addition the manufacturer shall supply to the S.O.test certificates for testing of materials, indicating the sources of supplies and other relevant details.

9.6 CONSTRUCTION WITHCONCRETE

9.6.1 Construction Joints

The position and detail of any construction joints not described in the Contract shall be subject to the approval of the S.O. and shall be so arranged as to minimise the possibility of the occurance of shrinkage cracks.

If for any reason the Contractor has to interrupt a planned pour for more than 45 minutes (or any other periodof time as approved by the S.O. if admixture is used), additional construction joints shall be positioned and constructed as directed by the S.O.

The number of construction joints shall be kept as few as possible consistant with reasonable precautions against shrinkage. Concreting shall be carried out continuously up to construction joints. The joints shall be at right angles to the general direction of the member and shall take due account of shear and other stresses.

Concrete shall not be allowed to run to a feather edge and vertical joints shall be formed against a stop board.The top surface of a layer of concreteshall be level and flat unless design considerations make this undesirable.Joint lines shall be so arranged that they coincide with features of the finished work, wherever possible.




At horizontal construction joints, gauge strips about 25 sq.mm in section shall be placed inside the forms along all exposed surfaces to ensure a straight joint on those surfaces.

If a kicker (i.e. starter stub) is used it shall be at least 70 mm high and carefully constructed. It is preferablefor the kicker to be incorporated withthe previous concrete. Where possible, the formwork shall be designed to facilitate the preparation of the joint surface, as the optimum time for treatment is usually two to four hours after placing.

Where vertical construction joints are necessary in mass concrete structures, reinforcing bars shall be placed across the joints so as to makethe structure monolithic, all to the satisfaction of the S.O.

Prior to recommencement of concreting on a joint, the surface of the concrete against which new concrete will be cast shall be free from laitance and shall be roughenedto the extent that the largest aggregate is exposed but not disturbed. Care shall be taken to avoid damaging the lines of the joint.Care shall also be taken that the jointsurface is clean and damp but not wet. Immediately before the fresh concrete is placed against the joint, fresh cement mortar shall be applied to the exposed surface.

Where the S.O. considers that special preparation is necessary, e.g. for an in situ structural connection, preparation shall be carried out, preferably when the concrete has set but not hardened, by spraying with a fine spray of air and water or brushing with a stiff brush sufficiently to remove the outer

mortar skin and expose the larger aggregates without disturbing them. Where this treatment isimpracticable, sand blasting or a needle gun shall be used to remove the surface skin and laitance. Hardened surfaces shall not be hacked.

9.6.2 Fixing Blocks, Brackets, Built-In-Bolts, Holes, Chases, etc.

All fixing blocks, brackets, built-in-bolts, holes, chases, etc., shall be accurately set out and formed and carefully sealed prior to the concrete being placed. No cutting away of concrete for any of these items shall be done without the permission of the S.O.

Bolts and other inserts to be cast intothe concrete shall be securely fixed to the formwork in such a way that they are not displaced during the concreting operations, and that there is no loss of materials from the wet concrete through holes in the formwork.

Unless shown otherwise on the Drawings or instructed by the S.O., reinforcement shall be locally movedso that the minimum specified cover is maintained at the locations of inserts, holes, chases, etc.

Temporary plugs shall be removed and the threads of built-in-bolts shall be proved to be free and shall be greased before handing over any partof the Works.




9.6.3 Precast Concrete Construction

9.6.3.1 Manufacture Off the Site

After the method of manufacture has been approved, no changes shall be made without the consentof the S.O.

The Contractor shall inform the S.O. in advance of the date of commencement of manufacture and casting of each type of item.

When the S.O. requires tests to be carried out, no items to which the tests relate shall be dispatchedto the Site until the tests have been satisfactorily completed and the results approved by the S.O.

All items shall be indelibly marked to show the item mark as described in the Contract, the production line on which they were manufactured, the date on which the concrete was cast and, if they are of symmetrical section, the face that will be uppermost when the member is in its correct position in the Works.

9.6.3.2 Storage

When items are stored, they shallbe firmly supported only at the points described in the Contract. The accumulation of trapped water and deleterious matter in the units shall be prevented. Careshall be taken to avoid rust staining and efflorescence.

Items shall be stacked in such a manner that their removal in correct order of age is facilitated.

9.6.3.3 Handling and Transport

Items shall be lifted only at pointsdescribed in the Contract or otherwise agreed by the S.O. and shall be handled and placed without impact. The method of lifting, the type of equipment and transport to be used, and the minimum age of the items to be handled shall be subject to the approval of the S.O.

9.6.3.4 Assembly and Erection

The method of assembly and erection described in the Contractshall be strictly adhered to on Site.

Immediately a unit is in position,and before the lifting equipment is removed, temporary supports or connections between items, asnecessary, shall be provided. The final structural connections shall be completed as soon as is practicable.

9.6.3.5 Forming Structural Connections

No structural connections shall bemade until approval has been given by the S.O.

Unless otherwise agreed by the S.O., the composition and water/cement ratio of the in situ concrete or mortar used in any connection and the packing of joints shall be in accordance with the assembly instructions.

Levelling devices shall only be released or removed with the approval of the S.O.




9.6.3.6 Protection

At all stages of construction, precast concrete units and other concrete associated therewith shall be properly protected to prevent damage to permanently exposed surfaces, especially arrises and decorative features.

9.7 STEEL REINFORCEMENT

9.7.1 Description

The work shall consist of furnishing and placing reinforcing steel in accordance with this Specification and in conformity with the Drawingsor as directed by the S.O.

9.7.2 Materials

Hot rolled mild steel and high yield bars shall comply with the requirements of M.S. 146, as denoted on the Drawings. Cold worked steel bars shall comply with the requirements of B.S. 4461. Hard drawn mild steel wire shall comply with the requirements of M.S. 144.

Steel fabric reinforcement shall comply with the requirements of M.S. 145 and shall be delivered to the Site in flat sheets.

Bar-mats shall conform to the requirements of M.S. 146 and shall consist of bars of the sizes and spacings as shown on the Drawings.

Dowel bars shall be plain round bars conforming to the requirements of M.S. 146. They shall be free from burring or other deformations restricting slippage in the concrete. Dowel bar sleeves

used for debonding shall be of approved synthetic material. The closed end of the sleeve shall be filled with 25 mm thick compressible foam filler and the sleeve shall fit tightly over the lengthof bar to be debonded.

The Contractor shall furnish manufacturer's certificates for reinforcement supplied by him, and these shall be submitted for acceptance by the S.O. before any material is brought onto the Site. The characteristic strengths of steel reinforcement are given in Table 9.9.

TABLE 9.9 - CHARACTERISTICSTRENGTH OFSTEEL REINFORCEMENT

Binding wire shall be 1.6 mm diameter soft annealed steel wire complying with the requirements of B.S. 1052.

The Contractor shall, on request, furnish the S.O. with samples of reinforcement brought onto the Site,not withstanding any previous acceptance on the manufacturer's testcertificates. The reinforcement represented by by the sample may


Designation

Nominal

Sizes ( mm )

Characteristic

Strength, fy ( N/sq.mm )

Hot rolled grade 250 ( M.S. 146 )

Hot rolled grade 460 ( M.S. 146 )

Cold worked ( B.S. 4461 )

Hard drawn steel wire( M.S. 144 )

All sizes

All sizes

All sizes

Up to and

including 12

250

460

460

485



be rejected by the S.O. and shall, if itfails to meet the Specification, require its removal from the Works Site.

Steel reinforcement shall be stored inclean and dry conditions. When placed in the Works it shall be clean and free from loose rust, mill scale, oil, grease, paint, dirt or anything which may reduce its bond with concrete.

If directed by the S.O., the steel shall be brushed or otherwise cleaned before use, at the Contractor's expense.


9.7.3.1 Cutting and Bending of Reinforcement

Bars shall be of their correct lengths and bent to the exact shapes required before being fixed in the work.

Bars shall be cut and bent cold bythe application of slow, steady pressure or in an approved bar-bending machine. Bending at temperatures in excess of 100 oC may only be carried out with the S.O.'s approval and under his supervision. Except where otherwise indicated on the Drawings, bars shall be bent and measured in accordance with B.S. 4466.

Cold worked and hot rolled bars shall not be straightened or bent again once having been bent. Where it is necessary to bend mild steel reinforcement already cast in the concrete, the internal radius of bend shall be not less than twice the diameter of the bar.

Special care shall be taken that the overall length of bars with multiple bends is accurate and that after bending and fixing in position the bars remain in place without wrap or twist.

9.7.3.2 Fixing of Reinforcement

The number, size, length, form and position of all reinforcing bars, links, stirrups, spacer bars and other parts of the steel reinforcement, shall be in accordance with the Drawings.

Reinforcement shall be secured against displacement. Unless specified otherwise, the actual concrete cover shall be not less than the required nominal cover minus 5 mm. In a member where the nominal cover is dimensioned to the links, spacersbetween the links and formwork shall be of the same dimension asthe nominal cover.

Unless otherwise permitted by the S.O., all intersecting bars shall be tied together with binding wire and the ends of the wire shall be turned into the mainbody of the concrete.

The Contractor shall take particular care that the reinforcement is laid out correctlyin every respect and temporarily suspended by annealed wire or supported on concrete blocks or other approved spacers in the forms to prevent displacement before or during the placing and compacting of concrete.




Stirrups and distance pieces shall be kept tight to the bars they embrace or support and all reinforcement shall be kept away from the face of the concrete at the distances shown on the Drawings.

No concrete shall be placed until the reinforcement has been inspected and approved by the S.O.

Reinforcement temporarily left projecting from the concrete at construction or other joints shall not be bent out of position duringthe periods in which concreting issuspended except with the approval of the S.O.

9.7.3.3 Splicing

Laps and joints including lapping bars, sleeving, threading and other mechanical connections shall be made strictly in accordance with the method specified and at the positions shown on the Drawings or as otherwise approved by the S.O.

9.7.3.4 Supporting and Spacer Blocks

Supporting and spacer blocks required for ensuring that the reinforcement is correctly ositioned shall be as small as possible consistent with their purpose, of a shape acceptable to the S.O., and designed so that they will not overturn when the concrete is placed. They shall be made of concrete with 10 mm maximum aggregate size and they shall be of at least the same strength and material source as the adjacent concrete. Wire cast in the block for the purpose of tying it to the reinforcement shall

be as described in Sub-Section 9.7.2. Other types of spacers may be used only with the approval of the S.O.

9.7.3.5 Welding of Reinforcement

Reinforcement in structures shall not be welded except where detailed on the Drawings or required by the Specification. If the reinforcement needs to be welded, the reinforcement shall comply with the requirements of B.S. 4360.

Welding shall be carried out in accordance with B.S. 5135 and B.S. 638. Butt welds shall be of the double V type and two butt weld bond tests shall be carried out on a specimen prepared to represent each form of butt welded joint used in welding the reinforcement and for each position of welding. The method of making butt weld tests shall bethat laid down in B.S. 709. The specimen shall pass the test to thesatisfaction of the S.O. before approval is accorded to use the joint which the specimen represents.

Welded joints shall not be made at bends in reinforcement. Unless otherwise approved by theS.O., joints in parallel bars of theprincipal tensile reinforcement shall be staggered in the longitudinal direction at a distance not less than the end anchorage length for the bar.

All welding shall be performed by a competent welder approved by the S.O.




The S.O. shall be informed in advance of when welding is to becarried out so that he may supervise and inspect the work. Welding shall not be performed in the field during rain or other adverse conditions.

9.8 FORMWORK AND SURFACE FINISH FOR STRUCTURE

9.8.1 Design and Construction

9.8.1.1 Description

Formwork shall include all temporary or permanent forms required for forming the concrete,together with all temporary construction required for their support.

The design and construction of formwork shall be carried out by competent persons. Where required by the S.O., strength and deflection calculations and drawings of the proposed formwork shall be submitted by the Contractor for prior approval. Not withstanding any approval by the S.O. with respect to the design submitted by the Contractor, the responsibility or the adequacy and safety of the design shall remain with the Contractor.

The formwork shall be sufficiently rigid and tight to prevent loss of grout or mortar from the concrete at all stages of construction and shall be appropriate for the methods of placing and compacting.

Formwork (including supports) shall be sufficiently rigid to maintain the forms in their correct position, shape, profile and dimensions. The supports shall be designed to withstand theworst combination of forces due to self weight, formwork weight,formwork forces, reinforcement weight, wet concrete weight, construction and wind loads, together with all incidental dynamic effects caused by placing, vibrating and compacting the concrete.

Where internal metal ties are permitted they or their removableparts shall be extracted without damage to the concrete and the remaining holes filled with mortar of the same strength as thecast concrete. No permanently embedded metal parts shall have less than the specified cover to the finished concrete surface. Except for ties used for anchoringvoid formers all ties shall be at least 1.2 metres apart and through bolts will not be permitted on exposed faces. All holes left by ties shall be made good within one day of the removal of the formwork using a mortar of the same strength as thecast concrete.

The formwork shall be so arranged as to be readily dismantled and removed from thecast concrete without shock, disturbance or damage. Where necessary, the formwork shall be so arranged that the soffit form, properly supported, can be retained in position for such period as may be required by the condition of the maturing concrete or the Specification. If acomponent is to be prestressed




whilst still resting on the soffit form, provision shall be made to allow for elastic deformation and any vibration in weight distribution. As far as practicable,formwork joints shall coincide with construction joints.

9.8.1.2 Voids In Concrete

Voids, where shown on the Drawings, shall be formed with non-recoverable void formers of expanded polystyrene, or by other methods approved by the S.O. They shall not deviate by more than 12 mm from the positions shown on the Drawings,nor shall the cross-section deviatefrom the specified shape by morethan 12 mm.

Void formers shall be secured andadequately anchored to prevent movement or flotation outside thelimits specified above, during the concreting operation.

Anchor ties secured to the soffit form will be permitted providing they comply with the requirements of Sub-Section 9.8.1.1.

Void formers of expanded polystyrene need not be vented. Hollow void formers shall be vented by the provision of 50 mm diameter holes between eachvoid and the soffit at positions approved by the S.O.

As soon as possible and at least three (3) months prior to the casting of the first deck slab with voids, the Contractor shall construct a model of a size and form to be agreed with the S.O. using the proposed formers, method of fixing, and simulating

reinforcement and prestressing cable ducts, to demonstrate that the proposed methods of fixing the formers and placing concrete around them and the reinforcement will produce voids within the tolerances, surrounded with properly compacted concrete of the required strength.

The attention of the Contractor is drawn to the inflammation natureof expanded polystyrene and he shall take all necessary precautions to minimise the risk of fire.

Concreting of voided slabs in structures shall not commence until the model test has been completed and approved by the S.O.

9.8.1.3 Form Lining

The type and treatment of any lining (plywood, metal, plastic, etc.) of the forms shall be ppropriate to the concrete finish required.

9.8.1.4 Projecting Reinforcement, FixingDevices

Where holes are needed in form to accomodate projecting reinforcement or fixing devices, care shall be taken to prevent lossof grout when concreting or damage when removing forms.

9.8.2 Finishes

9.8.2.1 Formed Surfaces

Formed concrete surfaces shall have one of the following classes of finish. Unless otherwise specified, all exposed concrete surfaces shall be of Class F2, all




unexposed surfaces shall be of Class F1 and Class F3 finish shall be used only where shown on the Drawings.

(a) Class F1

This finish shall be obtained by the use of properly designed formwork of closely jointed sawntimber or other approved material. Small blemishes causedby entrapped air or water may be expected but the surface shall be free from voids and honeycombing.

(b) Class F2

This finish shall be obtained by the use of properly designed formwork of closely jointed wrought boards, approved plywood or other approved material. Only very minor surfaceblemishes shall occur, with no staining or discolouration.

(c) Class F3

This finish shall be obtained by the use of properly designed steelforms or plastic coated plywood or wrought boards or other approved material. The surface shall be improved by carefully removing all fins and other projections, thoroughly washing down and then filling the most noticeable surface blemishes witha cement and fine aggregate pasteto match the colour of the original concrete. Form release agent shall be carefully chosen to ensure that the surface shall not be stained or discoloured.

After the concrete has been properly cured, the surface shall be rubbed down where necessary,to produce a smooth and even surface.

9.8.2.2 Unformed Surfaces

(a) Class U1

The concrete shall be uniformly levelled and screeded to produce a plain, ridged or broom roughened surface. No further work shall be applied to the surface unless it is used as the first stage for a Class U2 or Class U3 finish.

(b) Class U2

After the concrete has hardened sufficiently, the concrete Class U1 surface shall be floated by hand or machine to produce a uniform surface free from screed marks.

(c) Class U3

When the moisture film has disappeared and the concrete has hardened sufficiently to prevent laitance from being worked to thesurface, a Class U1 surface shall be steeltrowelled under firm pressure to produce a dense, smooth uniform surface free fromtrowel marks.

9.8.2.3 Remedial Treatment of Surfaces

Any remedial treatment of surfaces shall be agreed with the S.O. following inspection immediately after removing the formwork and shall be carried outwithout delay.




Any concrete, the surface of which has been treated before being inspected by the S.O., shall be liable to rejection.

9.8.3 Preparation of Formwork Before Concreting

Before concreting, all forms shall bethoroughly cleaned out, free from sawdust shavings, dust, mud or other debris.

The inside surfaces of forms shall, except for permanent formwork, or unless otherwise agreed by the S.O.,be coated with an approved non-staining form oil or other approved material to prevent adhesion of the concrete. Such release agents shall be applied strictly in accordance withthe manufacturer's instructions and shall not come into contact with the reinforcement or prestressing tendons and anchorages. For any exposed surface only one release agent shall be used throughout the entire area.

All formwork shall be inspected by the S.O. after preparation and immediately prior to depositing concrete and no concrete shall be deposited until approval of the formwork has been obtained from the S.O.

9.8.4 Removal of Formwork

The Contractor shall inform the S.O. and obtain his approval before striking any formwork, but such approval shall not relieve the Contractor of his responsibilities for the safety of the work.

The removal shall be done in such a manner as not to damage the concrete, and shall take place at times to suit the requirements for its curing.

Where the concrete compressive strength is confirmed by tests on concrete cubes stored under conditions that simulate the field conditions, formwork supporting concrete in bending may be struck when the cube strength is 10 N/sq.mm or twice the stress to which it will be subjected, whicheveris the greater. In the absence of such tests, the minimum periods between concreting and the removal of forms are given in Table 9.10.

TABLE 9.10 - MINIMUM PERIODSBETWEEN CONCRETING AND REMOVAL

OF FORMS


Vertical faces of beams, wall columns, piles, foundation plinths and precast items.

3 days

Underside of slabs.

14 days

Underside of beams.

28 days



The periods stated above are based on the use of ordinary Portland cement. They may be changed if other types of cement are used, subject to the S.O.'s agreement.

For prestressed in situ decks, temporary supports shall not be removed until the deck is stressed to the satisfaction of the S.O.

Where it is intended that formwork is to be reused it shall be cleaned andmade good to the satisfaction of the S.O.

Following the removal of formwork,no further loads shall be imposed upon concrete until at least after the completion of the curing period or until such later time as in the opinionof the S.O. the concrete shall have attained sufficient strength to safely withstand such loads. Full design loads shall not be applied to any structure until all load bearing concrete is at least 28 days old.





SECTION 10PILING WORKS




SECTION 10 - PILING WORKS

Page


10.2 GENERAL REQUIREMENTS FOR TOLERANCE

10.2.1 Setting Out S10-245

10.2.2 Position S10-245

10.2.3 Verticality S10-245

10.2.4 Rake S10-245

10.2.5 Forcible Corrections S10-245

10.2.6 Piles Out of Alignment or Position S10-245

10.2.7 Records S10-245

10.3 PRECAST REINFORCED CONCRETE PILES


10.3.2 Materials S10-24610.3.2.1 Concrete S10-24610.3.2.2 Reinforcement S10-24610.3.2.3 Pile Shoes S10-246

10.3.3 Manufacture and Storage of Precast Reinforced Concrete Piles S10-24610.3.3.1 Casting S10-24610.3.3.2 Handling and Storage S10-247

10.3.4 Installation of Precast Reinforced Concrete Piles S10-24710.3.4.1 Pitching of Piles S10-24710.3.4.2 Driving of Piles S10-24710.3.4.3 Repair of Damaged Pile Heads S10-24810.3.4.4 Lengthening of Piles S10-24810.3.4.5 Cutting and preparation of Pile Heads S10-249




Page

10.4 PRESTRESSED SPUN CONCRETE PILES


10.4.2 Materials10.4.2.1 Concrete S10-25010.4.2.2 Reinforcement S10-25010.4.2.3 End Plates S10-25010.4.2.4 Pile Shoes S10-250

10.4.3 Manufacture and Storage of Prestressed Spun Concrete Piles S10-25010.4.3.1 Casting S10-25010.4.3.2 Handling and Storage S10-251

10.4.4 Installation of Prestressed Spun Concrete Piles S10-25110.4.4.1 Pitching and Driving of Piles S10-25110.4.4.2 Lengthening of piles S10-25110.4.4.3 Cutting and preparation of Pile Heads S10-251

10.5 BORED CAST-IN PLACE PILES

10.5.1 Description S10-25210.5.2 Materials10.5.2.1 Concrete and Reinforcement S10-25210.5.2.2 Permanent Casings S10-25210.5.2.3 Drilling Fluid S10-252

10.5.3 Boring Operations10.5.3.1 Diameter of Piles S10-25210.5.3.2 Boring S10-25210.5.3.3 Temporary Casings S10-253 10.5.3.4 Stability of Piling Excavations Using Drilling Fluid S10-25310.5.3.5 Spillage and Disposal S10-25310.5.3.6 Pumping of Boreholes S10-25310.5.3.7 Continuity of Construction S10-25310.5.3.8 Enlarged pile Bases S10-25410.5.3.9 Cleanliness of Pile Bases S10-25410.5.3.10 Inspection S10-254

10.5.4 Placing of Reinforcement S10-25410.5.4.1 Joints in Longitudinal Bars S10-25410.5.4.2 Positions of Reinforcement S10-254




page

10.5.5 Concreting Operations S10-25410.5.5.1 Placing Concrete S10-25410.5.5.2 Workability of Concrete S10-25410.5.5.3 Compaction S10-25510.5.5.4 Placing Concrete In Dry borings S10-25510.5.5.5 Placing Concrete Under Water or Drilling Fluid S10-255

10.5.6 Extraction of Casing10.5.6.1 Workability of Concrete S10-25610.5.6.2 Concrete Level S10-25610.5.6.3 Vibrating Extractors S10-256

10.5.7 Construction of Pile Heads S10-25710.5.7.1 Water levels S10-25710.5.7.2 Cutting and preparation of Pile heads S10-25710.5.7.3 Temporary Backfilling Above Pile Casting Level S10-257

10.6 STEEL H-SECTION PILES



10.6.3 Manufacture and Storage of Steel H-Section Piles S10-25710.6.3.1 Manufacture S10-25710.6.3.2 Handling and Storage S10-258

10.6.4 Installation of Steel H-Section Piles S10-25810.6.4.1 Pitching and Driving of Piles S10-25810.6.4.2 Lengthening of Piles S10-25810.6.4.3 Cutting and preparation of Pile Heads S10-258

10.7 STEEL PIPE PILES



10.7.3 Manufacture and Storage of Steel Pipe Piles S10-25810.7.3.1 Welding S10-25810.7.3.2 Fabrication of Piles S10-25910.7.3.3 Matching of Pile Lengths S10-25910.7.3.4 Straightness of Piles S10-25910.7.3.5 Fabrication of Piles On Site S10-25910.7.3.6 Handling and Storage S10-25910.7.3.7 Marking of Piles S10-259




Page

10.9.4 Installation of Pressure-Treated Timber Piles10.9.4.1 Pitching and Driving of Piles S10-26410.9.4.2 Lengthening of Piles S10-26510.9.4.3 Cutting and preparation of Pile heads S10-265

10.10 BAKAU PILES



10.10.3 Delivery and Inspection of Bakau Piles S10-266

10.10.4 Installation of Bakau Piles S10-26610.10.4.1 Pitching of Piles S10-26610.10.4.2 Driving of Piles S10-26610.10.4.3 Lengthening of Piles S10-26710.10.4.4 Cutting and Preparation of Pile Heads S10-267

10.11 PILE TESTING

10.11.1 Test Piles S10-267

10.11.2 Preliminary Pile Load Tests S10-267

10.11.3 Production Pile Load Tests S10-267

10.11.4 Testing Procedure S10-26710.11.4.1 Preparation of Test Pile S10-26710.11.4.2 Method of Loading S10-26710.11.4.3 Measurement of Settlement S10-268

10.11.5 Method of Testing S10-26810.11.5.1 General S10-26810.11.5.2 Maintained Load Test S10-26910.11.5.3 Constant Rate of Penetration (CRP) Test S10-269

10.11.6 Submission of Results S10-269

10.11.7 Interpretation of Test Results S10-269

10.11.8 Load Testing of Bakau Piles S10-270



SECTION 10 - PILING WORKS

10.1 DESCRIPTION

This work shall consist of the supply, installation and testing of piles in accordance with this Specification and the lines, levels, grades and cross-sections shown on the Drawings and as directed by the S.O.

10.2 GENERAL REQUIREMENTS FOR TOLERANCES

10.2.1 Setting Out

Setting out shall be carried out using the data and reference points as shown on the Drawings. Immediately before installation of the pile, the pile position shall be marked with suitable identifiable pins, pegs or markers.

10.2.2 Position

For a pile cut off at or above ground level the maximum permitted deviation of the pile centre from the centre points shown on the Drawingsshall not exceed 75 mm in anydirection. For a pile cut off below ground level an increase in this tolerance is permitted in accordance with Sub-Sections 10.2.3 and 10.2.4 hereinbelow.

10.2.3 Verticality

The maximum permitted deviation of the finished pile from the vertical is 1 in 75.

10.2.4 Rake

The piling rig shall be set and maintained to attain the required rake. The maximum permitted

deviation of the finished pile from the specified rake or the rake shown on the Drawings is 1 in 25.

10.2.5 Forcible Corrections

Forcible corrections to concrete pilesshall not be permitted. Forcible corrections may be permitted to other types of piles if approved by the S.O. However, no forcible corrections shall be made to piles which have deviated beyond the permissible limits specified in Sub-Sections 10.2.2, 10.2.3 and 10.2.4 above.

10.2.6 Piles Out of Alignment or Position

The Contractor shall, if ordered by the S.O., extract and reinstall any pile which has deviated out of position or alignment by more than the specified limit, or alternatively the substructure shall be modified to the approval of the S.O. The cost of such extraction and reinstallation or any extra cost in the design and construction of a modified foundation shall be borne by the Contractor if, in the opinion of theS.O., such extra works have been made necessary due to the error and/or negligence of the Contractor.

10.2.7 Records

The Contractor shall keep records of the installation of each pile as required by the S.O. and shall submit two signed copies of these records to the S.O.not later than at noon of the next working day after the pile has been installed. The signed records shall form part of the records for the Works.

Any unexpected driving or boring conditions shall be noted in the records.




10.3 PRECAST REINFORCED CONCRETE PILES

10.3.1 Description

This work shall comprise the supply and installation of precast reinforced concrete piles, inclusive of pitching and driving, lengthening and cutting and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

10.3.2 Materials

10.3.2.1 Concrete

Unless otherwise specified, ordinary Portland cement shall beused for the casting of piles.

The materials and workmanship shall be as specified under Section 9 of this Specification. The grade of concrete and the details of reinforcement to be used shall be as shown on the Drawings.

10.3.2.2 Reinforcement

The main reinforcing bars in pilesnot exceeding 12 m in length shall be in one continuous length unless otherwise approved by the S.O.

In piles exceeding 12 m long, joints shall be permitted in main longitudinal bars at 12 m nominalintervals. Joints in adjacent bars shall be staggered at least 1 m apart along the length of the pile.Joints shall be butt welded as specified in Sub-Section 9.7.5 of this Specification.

Other means of jointing reinforcement, such as by means of mechanical couplings shall be to the approval of the S.O.

10.3.2.3 Pile Shoes

The type of pile shoes to be used shall be as shown on the Drawings and shall comply with the following as relevant :-

i) "Chilled-hardened" cast iron shoes as used for making greyiron castings to B.S. 1452, Grade 10; or

ii) Mild steel to B.S. 4360, Grade 50B; or

iii) Cast steel to B.S. 3100, GradeA.

Mild steel straps cast into the shoes shall be as shown on the Drawings. Rock shoes where required shall consist of wrought iron shoes and mild steel straps cast into "Chilled-hardened" castiron blocks, as shown on the Drawings.

10.3.3 Manufacture and Storage of Precast Reinforced Concrete Piles

10.3.3.1 Casting

The length of piles to be cast shall be as shown on the Drawings, subject to revision bythe S.O. Based on the results ofpile driving resistance and/or loadtests carried out on piles driven on the site, the S.O. may from time to time order the lengths of piles to be modified.




Piles shall be cast on a horizontal platform in approved moulds to the dimensions as shown on the Drawings. The concreting of each pile shall be completed in one continuous operation and no interruptions will be permitted. Lifting holes shall be formed during casting in the positions and in accordance with the detailsshown on the Drawings.

The cross-sectional dimensions ofthe pile shall not be less than those shown on the Drawings andshall not exceed them by more than 6 mm. Any face of a pile shall not deviate by more than 6 mm from a straight edge 3 m long laid on the face, and the centroid of any cross-sections of the pile shall not deviate by more than 12 mm from the straight lineconnecting the centroids of the end faces of the pile.

After a pile has been cast, the date of casting, reference number,and the length shall be clearly marked with indeletable marker on the top surface and on the head of the pile. In addition, each pile shall be marked at intervals of 0.5 m along its lengthbefore being driven.

10.3.3.2 Handling and Storage

The method and sequence of lifting, handling, transporting andstoring piles shall be such that piles are not damaged. Only the designed lifting and support points shall be used. During transport and storage, piles shall be placed on adequate supports located under the lifting points of the piles. All piles within a stack shall be in groups of the same length. Packings of uniform

thicknesses shall be provided between piles at the lifting points.

10.3.4 Installation of Precast Reinforced Concrete Piles

10.3.4.1 Pitching of Piles

Piles shall be pitched accurately in the positions as shown on the Drawings. At all stages during driving and until the pile has set or been driven to the required length, all exposed piles shall be adequately supported and restrained by means of leaders, trestles, temporary supports or other guide arrangements to maintain position and alignment and to prevent buckling and damage to the piles.

10.3.4.2 Driving of Piles

Each pile shall be driven continuously until the specified set and/or depth has been reached, unless otherwise approved by the S.O. The driving equipment used shall be of such type and capacity to the approval of the S.O. A follower (long dolly) shall not be used unless otherwise approved by the S.O.

A detailed record of the driving resistance over the full length of each pile shall be kept. The log shall record the number of blows for every 0.5 m of pile penetration. The Contractor shallinform the S.O. without delay if an unexpected change in driving characteristics is encountered.

Where required by the S.O. set shall be taken at approved intervals during the driving to establish the behaviour of thepiles.




A set shall be taken only in the presence of the S.O. unless otherwise approved. The Contractor shall provide all facilities to enable the S.O. to check driving resistances. The final set of a pile other than as friction pile, shall be recorded as the penetration in millimeters per10 blows. The temporary compression of the pile shall be recorded if required.

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground. When required, careful levelling from a datum unaffectedby the piling shall be made on the pile heads already driven, before and after driving subsequent piles. Piles which have been displaced as a result of driving adjacent piles shall be redriven to the required resistance.

10.3.4.3 Repair of Damaged Pile Heads

If a pile is to be subjected to further driving, concrete in the damaged pile head shall be cut off square at sound concrete, and all loose particles shall be removed by wire brushing, followed by washing with water. Care shall be exercised to ensure that the reinforcement in the pile head is not in any way damaged. Any damaged reinforcement shall be made good to the satisfaction of the S.O. The headshall be replaced with concrete ofan approved grade. The new head shall be cast truly in line with the remainder of the pile andbe properly cured and allowed to harden sufficiently to develop the strength necessary for further

driving. If a pile has been driven to the required set or depth but sound concrete of the pile is below cut-off level, the pile shall be made good to the cut-off level as described above.

10.3.4.4 Lengthening of Piles

Where piles have to be lengthened, other than by means of welding of steel plates as detailed on the Drawings, the reinforcement shall be stripped ofall surrounding concrete for a distance equal to thirty times the diameter of the main reinforcement measured from the pile head for spliced joints and 300 mm for butt welded joints and all lateral reinforcement shallbe removed. The lengthening bars shall butt on the exposed bars in true alignment and shall be butt welded as specified or shall be spliced with bars of the same diameter as the main pile bars, 60 diameters in length and lapping the main bars for a distance of 30 diameters above and below the joint, and shall be securely bound with 1.63 mm soft annealed iron wire. New binders of similar size shall be provided and spaced at half the centres of the binders in the main body of the pile and shall be securely bound with 1.63 mm soft annealed iron wire and the pile extended by concreting in properly constructed mounds to the length required.




Care shall be taken to form the joint between the old and new concrete as specified hereinbefore. The extension shallbe truly in line with the remainder of the pile, , and be properly cured and allowed toharden sufficiently to develop thestrength necessary for further driving.

10.3.4.5 Cutting and Preparation of Pile Heads

When a pile has been driven to the required set or depth, the headof the pile shall be cut off to the level specified or shown on the Drawings. The length of reinforcing bars projecting abovethis level shall be as shown or specified on the Drawings. If the length of reinforcing bars left projecting is insufficient, then they shall be extended by either of the following methods :-

(a) Butt Welding

The extension bars shall butt on the projecting bars in true alignment and shall be butt welded in accordance with Sub-Section 9.7.3.5 of this Specification.

(b) Splicing

The projecting bars shall be stripped of all surroundingconcrete as necessary to allow splices of length 60 diameters with extension bars. Theextension bars shall be securely bound to the projecting bars with 1.63 mm soft annealed iron wire.The concrete of the pile shall be made good either before or together with the casting of the pile cap, all to the satisfaction of the S.O.

Care shall be taken to avoid cracking or otherwise damaging the rest of the pile. Any cracked or defective concrete shall be cut away and made good with new concrete properly bonded to the old.




10.4 PRESTRESSED SPUN CONCRETE PILES

10.4.1 Description

This work shall comprise the supply and installation of prestressed spun concrete piles,inclusive of pitching and driving, lengthening and cutting and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

10.4.2 Materials

10.4.2.1 Concrete

Unless otherwise specified, ordinary Portland cement shall beused for the casting of piles. The materials and workmanship shall be as specified under Section 9 of this Specification. The grade of concrete to be used shall be as shown on the Drawings.

10.4.2.2 Reinforcement

The prestressing tendons and the non-prestressing reinforcement ofthe piles including workmanship shall be as specified under Sections 11 and 9 respectively of this Specification and to the details as shown on the Drawings.

10.4.2.3 End Plates

Details of end plates of each length of pile shall be as shown on the Drawings.

Each end plate shall be machine-finished and provided with a chamfer to accommodate the welding when two lengths of pileare jointed.

10.4.2.4 Pile Shoes

If specified, the type of pile shoesto be used shall be as shown on the Drawings and shall be in accordance with Sub-Section 10.3.2.3.

10.4.3 Manufacture and Storage ofPrestressed Spun Concrete Piles

10.4.3.1 Casting

The length of piles to be cast shall be as shown on the Drawings, subject to revision by the S.O. Based on the results of pile driving resistance and/or loadtests carried out on piles driven on the site, the S.O. may from time to time order the lengths of piles to be modified.

Piles shall be hollow cylinders manufactured by the centrifugal casting process. Moulds shall be of metal, well braced and stiffened against deformations caused by the hydrostatic pressure of the wet concrete while spinning. The metal forms shall have smooth joints and inside surfaces. The forms shall be accessible for adequatecleaning.

The spiral reinforcement shall be securely held to the longitudinal reinforcement during casting and spinning. Any welding used shall not affect the strength of the prestressing tendons.

The pile shall not be removed from the moulds until after the specified transfer strength is achieved.

The external diameter and the thickness of the pile shall not be




less than that shown on the Drawings and shall be constant over the entire length of the pile and coaxial with the end plate at each end.

After a pile has been cast, the date of casting, reference number and length shall be clearly marked with indeletable marking on the top surface and on the head of the pile. In addition, each pile shall be marked at intervals of 0.5 m along its length before being driven.


The method and sequence of lifting, handling, transporting andstoring piles shall be such that piles are not damaged. Only the designed lifting and support points shall be used.

All piles within a stack shall be ingroups of the same length. Packings of uniform thicknessess shall be provided between piles atthe lifting points.

10.4.4 Installation of Prestressed SpunConcrete Piles

10.4.4.1 Pitching and Driving of Piles

Pitching and driving of piles shallbe in accordance with Sub-Sections 10.3.4.1 and 10.3.4.2. Piles shall not be driven until the concrete has achieved the specified characteristic strength.


Where lengthening of piles is required, the details of the joint shall be as shown on the Drawings. When two lengths of pile are jointed, the end plates shall bear over their complete areas. Shims for packing shall notbe accepted.


When a pile has been driven to the required set or depth, the head of the pile shall be cut off tothe level specified or shown on the Drawings. The Contractor shall submit to the S.O. for approval, his proposed method for cutting of piles. Pile heads shall be constructed to details as shown on the Drawings.




10.5 BORED CAST-IN-PLACE PILES

10.5.1 Description

This work shall comprise the boring or grabbing, with or without casing,and subsequently filling the hole with plain or reinforced concrete to form bored cast-in-situ piles, all in accordance with this Specification and to the details shown on the Drawings.

10.5.2 Materials

10.5.2.1 Concrete and Reinforcement

The concrete and reinforcementto be used and workmanship for bored cast-in-situ piles shall be as specified under Section 9 of this Specification. The grade of concrete and the details of reinforcement to be used shall be as shown on the Drawings.

10.5.2.2 Permanent Casings

Permanent casings which form part of the designed pile shall be as specified in the Drawings.

10.5.2.3 Drilling Fluid

Drilling fluid material, bentonite, shall comply with Specification No. DF CP4 of the Oil Companies Materials Associationor its equivalent. A certificate shall be obtained by the Contractor from the manufacturerof the bentonite powder, showingthe properties of each consignment delivered to the site.This certificate shall be made available to the S.O. on request.

Bentonite shall be mixed thoroughly with clean fresh waterto make a suspension which will maintain the stability of the pile excavation for the period necessary to place concrete and complete construction. Preparation of the suspension shall comply with the manufacturer's instructions.

Where saline or chemically contaminated ground water occurs, special precautions shall be taken to modify the bentonite suspension or prehydrate the bentonite in fresh water to render it suitable in all respects for the construction of piles.

10.5.3 Boring Operations

10.5.3.1 Diameter of Piles

The diameter of piles shall not beless than the specified designed diameter at any level throughout its length.

10.5.3.2 Boring

Boring shall be carried down to the depth as required and directed by the S.O.

When deemed necessary by the S.O., the Contractor shall take undisturbed soil samples while the pile is being bored. The samples shall be taken to an approved Laboratory for testing.

Sampling and all subsequent handling and testing shall be carried out in accordance with B.S.5930.




Piles shall not be bored close to other piles which have recently been cast and which contain workable or unset concrete, such that a flow of concrete could be induced from or damage caused to any of the piles.

10.5.3.3 Temporary Casings

Temporary casings of approved quality or an approved alternativemethod shall be used to maintain the stability of pile excavations which might otherwise collapse.

Temporary casings shall be free from significant distortion. They shall be of uniform cross-section throughout each continuous length. During concreting they shall be free from internal projections and encrustedconcrete which might prevent theproper formation of the piles being cast.

10.5.3.4 Stability of Piling Excavations Using Drilling Fluid

Where the use of drilling fluid or a column of water is approved formaintaining the stability of boring, the level of fluid or column of water in theexcavation shall be maintained such that the fluid pressure always exceeds the pressure exerted by the soil and external ground water and an adequate temporary casing shall be used in conjunction with the method to ensure the stability of the strata near ground level until concrete has been placed. The fluid water level shall be maintained at a level not less than 1 metre above the level of the external ground water.

In the event of a rapid loss of bentonite suspension or water from the piling excavation, the excavation shall be backfilled without delay and the instructionsof the S.O. shall be obtained priorto resuming boring at thatlocation.

10.5.3.5 Spillage and Disposal

All reasonable steps shall be taken to prevent the spillage of bentonite suspension or water on the site in areas outside the immediate vicinity of the boring operations. Discarded bentonite water shall be removed from the site without delay. The disposal of bentonite water shall comply with the regulations of the Local Controlling Authorities.

10.5.3.6 Pumping of Boreholes

Pumping from the borehole shall not be permitted unless a casing has been placed into the stable stratum to prevent the further ingress of water in significant quantities from other strata into the boring, or, unless it can be shown that pumping will not have a detrimental effect on the surrounding soil or its properties.

10.5.3.7 Continuity of Construction

A pile constructed in stable soil, without the use of temporarycasings or other support, shall be bored and concreted without delay to ensure that the soil characteristics are not significantly altered.




10.5.3.8 Enlarged Pile Bases

The enlarged pile base shall not be smaller than the dimensions specified and shall be concentric with the pile shaft diameter. Asloping surface of the frustum forming the enlargement shall make an angle to the horizontal of not less than 55º.

10.5.3.9 Cleanliness of Pile Bases

On completion of boring, loose, disturbed or remoulded soil or fragments of rock shall be removed from the base of the pile.

10.5.3.10 Inspection

For dry boreholes, each hole shallbe inspected prior to the placing of concrete in it. The inspection shall be carried out from the ground surface in the case where the borehole diameter is less than 750 mm. Where the borehole diameter exceeds 750 mm, adequate equipment conforming to B.S. 5930 shall be provided toenable the Contractor and the S.O. to descend into the borehole for the purpose of inspection.

For wet boreholes, i.e. holes filled with drilling fluid or water, a suitable probe shall be providedto ascertain the evenness and cleanliness of the pile base.

10.5.4 Placing of Reinforcement

10.5.4.1 Joints in Longitudinal Bars

Reinforcement shall be such that the full strength of the bar is effective across the joint and the joint shall be made so that there is no relative displacement

of the reinforcement during the construction of the pile and the spacing of the reinforcing bars shall be maintained in such a waythat proper concreting shall not be impeded.

10.5.4.2 Positions of Reinforcement

Adequate spacer blocks, guide tubes, and lifting wires shall be provided so as to maintain the reinforcing steel in the positions as specified.

Where temporary casings are employed, the longitudinal reinforcement shall extend at least 1.0 metre below the bottomof the casing so that movement ofthe reinforcement during extraction of the casing is minimised.

10.5.5 Concreting Operations

10.5.5.1 Placing Concrete

The method of placing and the workability of concrete shall be such that a continuous monolithicconcrete shaft of the full cross-section is formed.

10.5.5.2 Workability of Concrete

The workability of the concrete shall be determined by the slump test as described in M.S. 26.

The suggested slump details for typical concreting situations shall be as specified in Table 10.1 below. The slump shall be measured at the time of discharge into the borehole.




10.5.5.3 Compaction

Internal vibrators shall not be used to compact concrete unless it can be satisfied that they will not cause segregation or arching of the concrete.

10.5.5.4 Placing Concrete In Dry Borings

Approved measures shall be taken to avoid segregation and bleeding and to ensure that the concrete at the bottom of the pile is not deficient in grout.

Where piles are vertical, concrete may be poured through a funnel with a length of tube so that the flow is directed and does not hit reinforcement bars or the side of the hole. Chutes extending to near the base shall be employed for raking piles of large diameter. For raking piles of small

diameter, an enriched mix shall be used in the first few batches ofconcrete to minimise segregation.

10.5.5.5 Placing Concrete Under Water or Drilling Fluid

Concrete to be placed under water or drilling fluid shall be placed by tremie unless otherwiseapproved and shall not be discharged freely into the water or drilling fluid.

Before placing concrete, measures shall be taken to ensure that there is no accumulation of silt or other material at the base of the boring.


Typical Conditions of Use

Slump Range (mm)

Placed into water-free unlined bore. Widely spaced reinforcement leaving room for free movement between bars

75 to 125

Where reinforcement is not spaced widely enough to give free movement between bars. Where casting level of concrete is within the casing. Where pile diameter is less than 600 mm.

100 to 175

Where concrete is to be placed by tremie under water or drilling fluid.

150 to collapse

TABLE 10.1 - SLUMP RANGE FOR TYPICAL CONCRETING SITUATIONS



The hopper and pipe of the tremie shall be clean and watertight throughout. The pipe shall extend to the base of the boring and a sliding plug or barrier shall be placed in the pipe to prevent direct contact between the first charge of concrete in the pipe of the tremie and the water or drilling fluid. The tremie pipe shall at all times penetrate the concrete which has previously been placed and shall not be withdrawn from the concrete until the completion of concreting. At all times, a sufficient quantity of concrete shall be maintained within the tremie pipe to ensure that the pressure from it exceeds that from the water or drilling fluid.

The internal diameter of the tremie pipe shall not be less than 150 mm for concrete made with 20 mm aggregate and not less than 200 mm for concrete made with 40 mm aggregate. The tremie pipe shall be so designed that external projections are minimised, allowing the tremie pipe to pass through the reinforcing cage without causing damage or uplifting. The internal face of the tremie pipe shall be from projections.

10.5.6 Extraction of Casing

10.5.6.1 Workability of Concrete

Temporary casings shall be extracted while the concrete within them remains sufficiently workable to ensure that the concrete is not lifted.

10.5.6.2 Concrete Level

When the casing is being extracted, a sufficient quantity of concrete shall be maintained within it to ensure that the pressure from external water, drilling fluid or soil is exceeded and that the pile is neither reduced in section nor contaminated.

No concrete shall be placed in theboring once the bottom of the casing has been lifted above the top of the concrete; it shall be placed continuously as the casing is extracted until the desired head of concrete is obtained.

Adequate precautions shall be taken in all cases where excess heads of water or drilling fluid could be caused as the casing is withdrawn because of the displacement of water or fluid by the concrete as it flows into its final position against the wall of the pile shaft. Where double casings are used in the boring, theproposed method of working shall be with the approval of the S.O.

10.5.6.3 Vibrating Extractors

The use of vibrating extractors shall be permitted subject to the condition that work shall be carried out in such a manner and at such times as to minimise nuisance and disturbance.




10.5.7 Construction of Pile Heads

10.5.7.1 Water Levels

In the event of the ground water level being higher than the required pile head casting level shown on the Drawings, the Contractor shall submit his proposals for approval prior to placing concrete. The pile head shall not be left below the groundwater level unless approved precautions are taken.


The top of the pile shall be brought above the cut-off level ofthe pile to permit all laitance and weak concrete to be removed andto ensure that it can be properly keyed into the pile cap. Pile heads shall be constructed to the details shown on the Drawings.

10.5.7.3 Temporary Backfilling Above Pile Casting Level

After each pile has been cast, anyempty bore remaining shall be protected and shall be carefully backfilled as soon as possible with approved materials.

10.6 STEEL H-SECTION PILES

10.6.1 Description

This work shall comprise the supply and installation of steel H-section piles, inclusive of pitching and driving, lengthening and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

10.6.2 Materials

All steel H-section piles shall comply with B.S. 4 with regard to sectional dimensions and the steel shall comply with the requirements of B.S. 4360. The sections and grades to be used shall be as specified or as shown on the Drawings.

10.6.3 Manufacture and Storage ofSteel H-Section Piles

10.6.3.1 Manufacture

Unless otherwise approved by theS.O. the strengthening of the toe in lieu of a shoe or the strengthening of the head of a pile shall be made from material of the same grade as the pile and to the details as shown on the Drawings.

For standard rolled sections the deviation from straightness in millimetres shall not exceed 1.04 (L-4.5) where L is the length of the pile in metres.

For proprietary sections made up from rolled sections the deviationfrom straightness shall not exceed1/1000 of the length of the pile.

Each pile shall be clearly marked with white indeletable marking atthe flanged head showing its reference number and overall length. In addition, each pile shall be marked at intervals of 0.5 m along its length before being driven.




The length of piles to be suppliedshall be as shown on the Drawings subject to revision by the S.O. Based on the results of pile driving resistance and/or loadtests carried out on piles driven on the Site, the S.O. may from time to time order the lengths of piles to be modified.


All operations such as handling and transporting of piles shall be carried out in such a manner that damage to piles and their coatings is minimised. Piles that are damaged during handlingand transporting shall be replaced by the Contractor at his own expense. All damaged and rejected piles shall be removed from the Site forthwith.

Piles within a stack shall be in groups of the same length and on approved supports.

10.6.4 Installation of Steel H-Section Piles


Pitching and driving of piles shallbe in accordance with Sub-Sections 10.3.4.1 and 10.3.4.2.


Where lengthening of piles is required, the piles shall be jointedby butt welding. Butt welded joints shall be stiffened with plates fillet welded on all four sides as detailed on the Drawings.All weldings shall be continuous and complying with B.S. 638, B.S. 5135 and B.S. 5950 for arc welding and B.S. 4577 for resistance welding as appropriate.The type and size of weld shall be as detailed on the Drawings.


When a pile has been driven to the required set or depth and before encasing in concrete, the piles shall be cut to within 20 mm of the levels shown on the Drawings. Pile heads shall be constructed to the details as shown on the Drawings.

The remaining section which canbe reused for lengthening of pilesshall be stored and protected as directed by the S.O.

10.7 STEEL PIPE PILES

10.7.1 Description

This work shall comprise the supply and installation of steel pipe piles, inclusive of pitching and driving, lengthening and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

10.7.2 Materials

All steel pipes shall comply with B.S. 6323 with regard to sectional dimensions and the steel shall comply with the requirements of B.S. 4360.

10.7.3 Manufacture and Storage ofSteel Pipe Piles

10.7.3.1 Welding

Unless otherwise specified, all welds shall be full penetration butt welds complying with the requirements of B.S. 5153.




10.7.3.2 Fabrication of Piles

The root edge or root face lengthsof piles that are to be butt welded shall not differ by more than 25%from the thickness of piles not exceeding 12 mm in thickness; orby more than 3 mm for piles exceeding 12 mm in thickness. When piles of unequal thickness are to be butt welded together, thethickness of the thinner material shall be the criterion.

Pile lengths shall be set up so thatthe differences in dimensions are matched as evenly as possible.


10.7.3.3 Matching of Pile Lengths

Longitudinal seam welds and spiral seam welds of lengths of pipe piles forming a completed pile shall, whenever possible, be evenly staggered. However, if in order to obtain a satisfactory match of the ends of piles or the specified straightness, thelongitudinal seams or spiral seams are brought closely to one alignment at the joint, then they shall be staggered by at least 100 mm.

10.7.3.4 Straightness of Piles

Unless otherwise approved, the deviation from straightness shall not exceed 1/600 of a length not exceeding 10 m. When two or more such lengths are joined, the deviation from straightness shall not exceed 1/960 of the completed length.

10.7.3.5 Fabrication of Piles on Site

When pile lengths are to be madeup on Site, all test procedures anddimensional tolerances shall conform to the Specification for the supply of pipe materials. Adequate facilities shall be provided for supporting and aligning the lengths of pile.


All piles within a stack shall be ingroups of the same length and on approved supports. All operations such as handling, transporting and pitching of piles shall be carried out in a manner such that damage to piles and their coatings is minimised. Piles that are damaged during handlingand transporting shall be replacedby the Contractor at his own expense. All damaged and rejected piles shall be removed from the Site forthwith.

10.7.3.7 Marking of Piles

Each pile shall be clearly marked with white indeletable marking showing its reference number andoverall length. In addition, each pile shall be marked at intervals of 0.5 metre along its length before being driven.




10.7.4 Workmanship

10.7.4.1 Welding Procedures

The Contractor shall submit for approval, full details of the welding procedures and electrodes with drawings and schedules as may be necessary. Tests shall be undertaken as may be required by the S.O. and shall be in accordance with the requirements of B.S. 4870.

10.7.4.2 Welders' Qualifications

Only welders who are qualified in the approved welding procedure shall be employed. Copies of certificates relating to welders' tests shall be made available to the S.O. on request.

10.7.4.3 Radiographs

During production of welded tube piles, at least one radiographapproximately 300 mm long shallbe required on each completed length as a spot check on weld quality. This shall be taken on a circumferential or longitudinal weld and its position shall be as directed by the S.O.

For spirally welded piles, one of the following tests shall be carried out :-

i) for tubes of wall thickness 12mm or less, three spot check radiographs, one at each end of each length of the tube as manufactured and one at a position to be chosen at the time of testing by the S.O.; and spot check radiographs asrequired by the S.O. on the weld joints between strip lengths;

ii) for tubes of any wall thickness, continuous ultra-sonic examination over the whole weld, supplementedwhere necessary by radiographs to investigate defects revealed by the ultrasonic examination.

10.7.4.4 Acceptance Standards

If the results of any weld test do not conform to the specified requirements, two additional specimens from the same length of pile shall be tested. In the caseof failure of one or both of these additional tests, the length of pile covered by the test shall be rejected.

10.7.5 Protective Coatings

If protective coatings are specified, the preparation of surfaces and the application of the coatings shall be carried out by skilled labour having experience in the preparation of the coatings specified.

10.7.5.1 Surface Preparation

Unless otherwise specified, all surfaces to be coated shall be blast cleaned with an approved abrasive in accordance with B.S. 4232 or SIS 05 59 00 to remove rust, mill scale and other adheringmaterials, to provide a finish to second quality (near white) of B.S. 4232 or SIS 05 59 00 grade Sa 2 1/2.

10.7.5.2 Application and Type of Primer

Immediately after surface preparation, the surface shall be coated with an approved primer or the specified coating to avoid recontamination. No coat shall be




applied to a metal surface which is not thoroughly dry.

The primer shall be compatible with the specified coating.

10.7.5.3 Part to be Welded

The coating within 200 mm of a weld shall be applied after welding.

10.7.5.4 Thickness, Number and Colour of Coats

The minimum dry film thickness of the finished coating, including the minimum dry film thickness of each coat and the minimum number of coats that are to be applied, shall be as specified and shown on the Drawings. Coatings shall be applied in accordance with the manufacturer's instructions.

10.7.5.5 Inspection of Coatings and Acceptibility

The finished coating shall be generally smooth, of a dense and uniform texture and free from sharp protuberances or pin holes.

Any coat damaged by subsequentprocesses or which has deteriorated to an extent such thatproper adhesion of the coating may not be obtained or maintained, shall be recleaned to the original standard and recoatedwith the specified sequence of coats.

The completed coating shall be checked for thickness and continuity by an approved magnetic gauge or detector. Areaswhere the thickness is less than that specified shall receive approved additional treatment.

10.7.6 Installation of Steel Pipe Piles


Pitching and driving of piles shallbe in accordance with Sub-Sections 10.3.4.1 and 10.3.4.2.


Unless otherwise approved, where lengthening of piles is required, the piles shall be jointedby butt welding along the entire periphery as detailed on the Drawings.


When a pile has been driven to the required set or depth and before encasing in concrete, the pile shall be cut to within 20 mm of the levels shown on the Drawings and protective coatingsshall be removed from the surfaces of the pile head 100 mm above the soffit of the concrete. Pile heads shall be constructed to details as shown on the Drawings.

10.7.6.4 Concreting of Pile Shaft

If concreting is specified or shown on the Drawings after the pile has been cut off to the specified level, the shaft shall be filled with concrete in a continuous operation. The method of placing shall be approved by the S.O.

The reinforcement cage in the pile shall be made sufficiently rigid and kept in its correct position during concreting.




The length of the reinforcing barsprojecting above the pile cut off level shall be as shown on the Drawings.

10.8 MICROPILES

10.8.1 Description

This work shall comprise the drillingof a hole, placing of reinforcement unit and subsequently filling the holewith grout to form micropiles, all in accordance with this Specification and to the details shown on the Drawings.

10.8.2 Materials

10.8.2.1 Reinforcement Unit

The type of reinforcement unit to be used, the diameter and/or thickness, grade, yield strength and working stress shall be as specified or as shown on the Drawings.

10.8.2.2 Grout

Unless otherwise specified, the grout shall be non-shrink cement grout. The grout mix design such as the water-cement ratio, the minimum cement and grout strength at 7 and 28 days shall be as specified and shown on the Drawings.

If admixtures are used, details of admixtures shall be submitted to the S.O. for approval beforecommencement of works. The use of the admixture shall fully comply with the manufacturer's instructions.

10.8.3 Drilling Operations

10.8.3.1 Diameter of Piles

The diameter of piles shall not beless than the specified/designed diameter at any level throughout its length.

10.8.3.2 Drilling

The Contractor shall submit to the S.O. details of drilling equipment and drilling procedure for approval before commencement of works. Drilling operations shall be carried out in accordance with therelevant requirements of Sub-Section 10.5.3.

10.8.4 Grouting Operations

10.8.4.1 Mixing and Placing Grout

The Contractor shall provide details of the method and equipment used in grout mixing. Further information such as grouting pressure, grouting procedure, grouting equipment and techniques employed in grouting underwater shall also be furnished for approval.

Grout shall be mixed on Site and shall be free from segregation, slumping and bleeding. Grout shall be pumped into its final position in one continuous operation as soon as possible and in no case more than half an hourafter mixing.

10.8.4.2 Testing Grout

Grout shall be tested in accordance with B.S. 1881 and B.S. 4550.




10.8.5 Construction of Pile Heads


Where lengthening is required, the pile reinforcement unit shall be connected on Site to the details shown on the Drawings.

Other means of jointing reinforcement shall be to the approval of the S.O.


Pile heads shall be constructed to the details as shown on the Drawings.

10.9 PRESSURE-TREATED TIMBER PILES

10.9.1 Description

This work shall comprise the supply and installation of pressure-treated timber piles, inclusive of pitching and driving, lengthening and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings. The timber terms used in this Specification shall have the meanings assigned to them in M.S. 229.

10.9.2 Materials

Unless otherwise approved by the S.O., Kempas (Koompassia Malaccensis) shall be used and this shall not be of a lesser quality than the grading specified in Appendix Aof M.S. 822.

Pressure-treated timber piles shall conform to M.S. 822 and shall be approved by SIRIM.

10.9.3 Manufacture and Storage ofPressure-Treated Timber Piles

10.9.3.1 Manufacture

Before commencement of work the Contractor shall notify the S.O. of the name of the supplier and manufacturer for approval.

The method of preservative treatment for timber piles shall bethe full-cell process as described in M.S. 360. The preservative used shall comply with M.S. 733.The depth of penetration of preservative shall be a minimum of 25 mm and the net dry salt retention in the treated part of the timber shall be a minimum of 16 kg/cu.m.

Piles shall be within -2 mm and +6 mm of their specified cross-sectional dimensions. The centroid of any cross-section of a pile shall not deviate by more than 25 mm from the straight lineconnecting the centroids of the end faces of the pile.

Before the treated timber pile is accepted for the work the Contractor shall obtain from the manufacturer of the treated piles a warranty on an approved form which provides, that for a ten year period, the treated piles shallbe free from fungus and insect attack.




Each treated pile shall be permanently marked with identifications which indicate thatthey comply with this Specification, manufacturer's trade mark, type of treatment, charge number and date of treatment and the length of the pile. The end plates of each pile shall have SIRIM Control Labels.

The S.O. may require inspection and testing at the treatment plant to observe and ensure that the manufacturing process and control testings of the piles are carried out in accordance with this Specification. Records of theactual treatment schedule shall bekept during the treatment process,and the Contractor shall furnish such records for the piles supplied when requested by the S.O.

10.9.3.2 Delivery and Storage

The Contractor shall notify the S.O. of the delivery of timber piles to the Site, and provide the necessary facilities to enable the S.O. to inspect each pile and take random sampling for determination of depth of penetration and the net dry salt retention.

Accepted piles shall be marked and stacked in lengths on drained hard ground. Each pile shall be stacked clear of the ground and have an air space around it. The piles shall be separated by sticks or blocks placed vertically one above the other and closely spaced horizontally to avoid sagging of the piles. All rejected piles shall be removed from the Site forthwith.


10.9.4 Installation of Pressure-Treated Timber Piles


Pitching and driving shall be in accordance with Sub-Sections 10.3.4.1 and 10.3.4.2.

Piles shall be provided in one single length of 6.0 m each unlessotherwise approved. Any pile driven to the required set at a depth of 6.0 m or less shall be in one continuous length.

The pile head shall be adequately protected during driving, so that brooming and splitting do not occur. The pile head shall be fitted with toothed metal plates asapproved by the S.O. during normal driving.

In the case of hard driving, unlessotherwise approved by the S.O., ametal helmet shall be fitted to thetop of the pile. The top of the pile shall first be trimmed to fit closely into the recess of the underside of the helmet. A hard wood dolly and, if necessary, a packing piece shall be used abovethe helmet.

If during driving the head of the pile becomes excessively broomed or otherwise damaged, the damaged part shall be cut off and the helmet refitted.




When fissures appear in a pile during driving, which in the opinion of the S.O. will affect its strength, the pile shall be rejectedand replaced at the Contractor's expense.


If jointing is required, pile joints shall be made by using Mild Steel Welded Boxes 450 mm long fabricated from 5 mm thick plates unless otherwise shown on the Drawings. Joint boxes shall be painted with red lead paint or otherwise protected against corrosion to the satisfaction of theS.O. The internal dimensions of the box shall be 3 mm undersize of the pile cross-sectional dimensions. The joint and the ends of the piles to be jointed shall be constructed so that the necessary strength and stiffness are developed at the joint.


When a pile has been driven to the required set or depth, the headof the piles shall be cut off squareto sound wood and treated with an approved preservative and a waterproof coating all in accordance with M.S. 822. The pile head shall be embedded for adepth of not less than 150 mm in the concrete cap which shall be atleast 150 mm thick round the piles.

When piles are cut-off at the pile cap level, all cut-offs and bored holes shall be treated as follows :-

i) the cut-offs or bored holes shall be given two flood coats of 10% m/v solution of the preservative, or as specified inaccordance with M.S. 360, allowing each application to soak thoroughly into the cut or bored surface;

ii) immediately after the preservative solution has dried, the pile heads shall be heavily coated with a bituminous compound which conforms to B.S. 3416 for the whole depth that the pile is to be enclosed in the pile cap.

10.10 BAKAU PILES

10.10.1 Description

This work shall comprise the supply and installation of bakau piles, inclusive of pitching and driving, lengthening and preparation of pile heads, all in accordance with this Specification and to the details shown on the Drawings.

10.10.2 Materials

Unless otherwise approved by theS.O. only Bakau Minyak (Rhizophora Apiculapa) or BakauKurap (Rhizophora Mucronata) shall be used. Bakau piles shall be provided in one single length of not less than 5.0 m each. The diameter of piles at the small end shall not be less than 75 mm unless otherwise specified.




All bakau piles shall be free fromrot, fungal or pest attack and any other defects. The piles shall be reasonably straight and circular incross-section with all branch joints trimmed off to the general outline of the piles but leaving the bark intact on the piles.

10.10.3 Delivery and Inspection of BakauPiles

The Contractor shall notify the S.O. of the delivery of piles to theSite and provide labour and facilities to enable the S.O. to inspect and measure each pile at the time of unloading. Accepted piles shall be stacked on an approved surface in an approved area and kept constantly in a damp condition. Rejected piles shall be removed from the Site forthwith.

10.10.4 Installation of Bakau Piles

10.10.4.1Pitching of Piles

Piles shall be pitched accurately in the positions and at spacings asshown on the Drawings or as approved by the S.O.

10.10.4.2Driving of Piles

The length of piles to be driven shall be as shown on the Drawings. Based on the results of pile driving resistance and/or load tests carried out on piles driven on the site, the S.O. may, from time to time order the lengths or spacing of piles to be modified.

Unless otherwise approved, bakau piles shall be driven by means of a drop hammer of at least 250 kg in mass, suspended from a shear-leg or approved pile-frame.

Piles shall be driven in an approved sequence to minimise the detrimental effects of heave and lateral displacement of the ground. When required, levels and measurements shall be taken to determine the movement of theground or any pile resulting from the driving process. If any pile rise occurs as a result of adjacent piles being driven, the Contractorshall submit to the S.O. for approval, his proposals for correcting this and to avoid the same in subsequent work.

The pile head shall be flat and at right angles to the axis of the pile,its edges chamfered to minimise splitting during driving. The Contractor shall take precautions to avoid damage to the pile head during hard driving by providing a suitable metal helmet. A hardwood dolly and, if necessary, a packing piece shall be used abovethe helmet. If during driving the head of the pile becomes excessively broomed or otherwise damaged, the damaged part shall be cut off, the head retrimmed and the helmet refitted.





Where a pile has to be jointed,it shall be to the details as shown on the Drawings. Onlyone joint shall be allowed. The two pile ends to bejointed shall be of the same diameter and each shall be cutat right angles to its axis to make contact over the whole cross-section when the two timbers are co-axial. A mild steel tube connector of No. 9 gauge to B.S. 6323 shall be used to join the two pile ends. The steel tube connector shall be painted with red lead paint or otherwise protected against corrosion all to the satisfaction of the S.O. The pile ends shall be trimmed or packed in the connector to provide a tight fit.


When the piles have been driven to the required depth, the top of the piles shall be cut off to a uniform level. The cut-off level shall be below the lowest dry season ground water level as shown on the Drawings or as approved by the S.O.

10.11 PILE TESTING

10.11.1 Test Piles

In order to determine the required length of pile at each location, the Contractor shall drive test piles as shown on the Drawings and/or as instructed by the S.O. Test piles shall be driven with the same hammer that is used for driving foundation piles.

10.11.2 Preliminary Pile Load Tests

Preliminary pile load tests shall be carried out before the S.O. issues to the Contractor, in writing, instructions on the pile length and pile length combinations for the manufacture and supply of the piles.The Contractor shall not proceed to manufacture or supply the piles until he has received instructions in writing to do so from the S.O.

The lengths of the piles for thepreliminary load tests shall be determined by the S.O.

10.11.3 Production Pile Load Tests

Load tests shall also be carried out during the installation of piles for thepermanent Works. Such pile load tests shall be referred to as production pile load tests.

10.11.4 Testing Procedure

10.11.4.1Preparation of Test Pile

The pile head shall be cut off or built up to the necessary elevationand shall be capped appropriatelyto produce a bearing surface perpendicular to the axis of the pile. The arrangement shall be such that none of the test load is carried by the ground under the cap.

10.11.4.2Method of Loading

The test load shall be applied in one of the following ways :-

i) by means of a jack which obtains its reaction from kentledge heavier than the required load;




ii) by means of a jack which obtains its reaction from tension piles or other suitable anchors.

The load shall be measured using a calibrated load gauge and also a calibrated pressure gauge in the hydraulic system. The jack and load gauge shall be carefully aligned so that the load applied is co-axial with the pile.

When method (i) is used, care shall be taken to ensure that the centre of gravity of the kentledge is on the axis of the pile. The nearest edge of the crib supporting the kentledge stack shall not be closer than 1.3 m to the surface of the test pile. Kentledge shall not be used for testing raked piles.

When method (ii) is used, all anchor piles shall be at a distance of at least three (3) pile shaft diameters from the test pile, centre to centre, and in no case shall they be less than 2 m from the test pile.

If the anchor piles are to be permanent working piles, their levels shall be observed during application of the test load to ensure no residual uplift occurs.

10.11.4.3Measurement of Settlement

Settlements shall be measured by use of a reference beam or wire supported independantly of the load test pile, reaction pile or piles supporting reaction loads. Settlements shall be measured to the nearest 0.1 mm for reference beams or 0.5 mm for reference

wires. The reference beam supports shall be located at least 3 m from the load test pile, reaction pile or piles supporting reaction loads. The reference beams or wires shall be protected from the effects of temperature changes.

10.11.5 Method of Testing

10.11.5.1General

Maintained Load Tests shall be conducted on test piles as selected by the S.O. The loading tests shall be carried out in accordance with Sub-Section 10.11.5.2.

When instructed or approved by the S.O., Constant Rate of Penetration Tests shall also be conducted on other piles. The tests shall be carried out in accordance with Sub-Section 10.11.5.3.

Prior to the performance of any load test, the Contractor shall submit to the S.O. for his approval, working drawings showing the method and equipment he proposes to use in the performance of the load testand the measurement of settlements. Such submission shall include design calculations of lateral supports or other methods to be used in ensuring against buckling. Horizontal supports to ensure buckling stability shall be provided to the pile to be loaded whenever the ratio of the unsupported height to the least cross-sectional dimension is 20 or more. Horizontal supports shall provide full support without restraining the vertical movement of the pile in any way.




10.11.5.2Maintained Load Test

The Maintained Load Test shall be carried out as follows :-

i) the full test load on a pile shall be twice the design load noted on the Drawings and it shall be applied in twelve equal increments. At least twohours shall elapse between theaddition of each load increment, i.e. until the rate ofsettlement is reduced to less than 0.25 mm/hour and slowing down;

ii) the full test load shall be maintained on the pile for at least 48 hours and settlementsshall be recorded at intervals of not more than 12hours. The test pile shall then be unloaded in four equal increments at one hourintervals until the full load is removed. Settlement readings shall be made immediately after and before every load increment is applied or removed.

10.11.5.3Constant Rate of Penetration (CRP) Test

For each pile load test, three cycles of pile loading test at a constant rate of penetration shall be carried out to a full test load equal to twice the design load.

The rate of loading shall be such that a constant rate of penetration is maintained throughout the test insofar as is practicable. The rateof movement of each pile to be tested shall be agreed upon with the S.O. prior to the start of the test. At least twelve readings of settlements and their

corresponding loads shall be made in the loading process.

After attaining a test load equal totwice the design load, the load shall gradually be released and at least four readings of settlement and their corresponding loads shall be made during the unloading process. The settlement obtained when the load has been completely released shall also be recorded. An interval of at least 15 minutes shall elapse before the next CRPtest is commenced.

10.11.6 Submission of Results

Full test data and results shall be jointly signed by the S.O.'s representative and the Contractor's authorised agent immediately upon completion of the test, and shall consist of the following :-

i) for the Maintained Load Test, for each stage of loading, the period for which the load was held, the load and the maximum settlement. These are to be plotted as time-settlement graphs.

ii) for the CRP test, the maximum load reached and a graph of load against penetration;

10.11.7 Interpretation of Test Results

The S.O.'s interpretation and conclusions on the test results shall be final. Unless otherwise specified, the pile so tested shall be deemed to have failed if :-

i) the residual settlement after removal of the test load exceeds 6.50 mm; or




ii) the total settlement under the Working Load exceeds 12.50 mm; or

iii) the total settlement under twice the Working Load exceeds 38.0 mm, or 10% of pile diameter/width whicheveris the lower value.

10.11.8 Load Testing of Bakau Piles

In general, all relevant Sub-Sections stated hereinbefore shall apply to the load testing of bakau piles, except that what is understood as single test piles in these Sub-Sections shall mean a group of test piles for bakau piles.

The load testing of bakau piles shall be carried out on a group of nine bakau piles, made up of three rows of piles, three in a row.

An approved reinforced concrete pilecap with a loading pedestal shall be cast centrally over the group of piles to be tested. The loading pedestal shall be short to ensure stability, and it shall have an approved mild steel bearing plate cast on top. The load shall be applied centrally on to the steel plate.

Bakau piles shall be tested to failure by the Maintained Load Test as described hereinbefore. The load on the pile group shall be applied in 2 to 4 equal increments as directed by the S.O. until the failure load is reached. The failure load (i.e. ultimate load) is that load at which the piles continue to settle at a constant rate without further increase of applied load.

For each increment of load, the settlement readings shall be recorded at 15 minute intervals until the rate of settlement is less than 0.25 mm per hour. The loadat each increment shall be maintained at a constant value throughout the test.

Graphs of time-settlement, load-time and load-settlement, to a suitable scale, shall be plotted and submitted to the S.O. with allrecords of the readings.


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