1) LEVELING & GRADING AND ROAD WORKS

Scope of Work

The scope of work includes general leveling and grading of parking areas, depot / stabling yard, Station
and track corridor and design of roads and parking areas. The road works include construction of access
roads from existing roads to the stations, internal roads of depot/ stabling area facility, alternate road
networks due to closure of existing vehicular roads due to development of KCR corridor at designated
points/ stations and the development of motor vehicle parking at particular stations. This shall include all
pavement works and road furniture (road side curb, barriers, traffic signs and pavement markings)

Design Standards

The following design standards or equivalent highly verifiable Chinese Standard shall be adopted for the
design work:

 AASHTO - A Policy on Geometric Design of Highway and Streets

 AASHTO Design Guide for Pavement Structures 1993
 Asphalt Institute Pavement Design Manuals
 FHWA Urban Drainage Design Manual

DESIGN PARAMETERS:

General

The KCR shall be developed on the previously defined corridor with third rail as locomotive power
system. The corridor comprises of exclusive loop corridor of approximately 29.7 km and 13.5 km shared
with Pakistan Railways.

Being powered with third rail electrification system, at grade crossing with vehicular roads need to be
barred. Comprehensive traffic diversion plans are to be established which might require construction of
new roads and intersections.

Leveling and Grading Works

The leveling and grading works shall be include depot area/ stabling yard, track corridor fence to fence as
shown in drawings attached in Volume III of this document and all pavement works area i.e. access roads
and parking areas for vehicular traffic to the station. Existing drainage pattern shall be preferably
maintained. The areas shall be sloped to collect storm water drainage in existing nearby water bodies.

Road Works

The corridor passes through highly populated which require access roads to stations and parking.
Parking areas are to be developed based on the demand basis for each station has at least twenty five
(25) slots for cars, a hundred (100) bike parking slots, Ten (10) slots for taxi/ auto parking and two (02)
bus bays.

Design Parameters

The main features of the roads shall meet the following criteria:

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Geometric Design

Design Vehicle

Single Unit Truck (SU-9 / SU-12)

Length = Varies
Width = 2.44 m
Height = 3.35 - 4.11 m

Design Speed

Access Roads = 50 km/h (maximum)

Parking Areas = 30km/h (maximum)

Roads:
Width of lane = 3.5m (minimum)
Gradient = 6% maximum
Cross Slope = 0.5% (minimum if no longitudinal gradients available)

Roads shall be designed for quick access to and from stations avoiding any unnecessary congestion or
delays of traffic on existing roads due vehicular trips generated for KCR. This shall also take into
consideration the access points of nearby residential and commercial areas.

The road and parking area construction may require land acquisition which shall be a sole responsibility
of the Client and shall be provided to the Contractor free of cost for development works. The area shall
be acquired based on the land demarcated by the Contractor for such use.

Parking areas shall be provided as near to the stations as possible. The design elements of the roads and
pavements shall conform to the relevant design standards enlisted in previous section.

Pavement Design

Design life of road = 20 years

CBR = as per geotechnical investigation results

The Contractor shall study the traffic demand and shall provide adequate pavement structure. All roads
shall be of flexible type with asphalt concrete whereas the parking lots shall be paved with concrete
pavers with minimum pavement thickness as shown in Volume III of this document.

OUTLINE SPECIFICATIONS:

Granular Sub-base Course

All sub-base material shall be free from dirt, organic matter, shale or other deleterious matter and shall be
of such quality that it will bind readily to form a firm, stable sub-base. Material for sub-base shall consist of
well-graded gravel with sand and silt, conforming to the following requirements:

AASHTO Sieve Percent Passing

3 in. (75 mm) 100
# 10 (2 mm) 20 - 100
# 40 (0.45 mm) 5 - 60
# 200 0-8

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All sub-base aggregate shall conform to the following physical requirements.

Liquid Limit (AASHTO T-89) 25 maximum

Plasticity Index (AASHTO T-90) 6 maximum

Sand Equivalent (AASHTO T-176) 25 minimum

Loss by Abrasion (AASHTO T-96) 40 maximum

California Bearing Ratio (CBR)

(at 100% compaction as per ASTM D-1557 or > 30
AASHTO T-180 method ‘D’)

Aggregate Base Course

All aggregates for base course shall consist of clean, tough, durable, sharp angle fragments free of any
excess of thin or elongated pieces and reasonably free of soft, disintegrated or decomposed stone, dirt or
other deleterious matter. Crushed gravel or stone fragments for base courses shall consist of the product
obtained by crushing gravel shall conform to the following grading requirements:

AASHTO Sieve Percent Passing

2 in. (50.8 mm) 100
1 1/2 in.(38.1 mm) 35 - 70
1 in. (25.4 mm) 0 - 15
1/2 in. (12.7 mm) 0- 5

Fine materials for base course shall be quarry screenings or natural material and of suitable binding
quality as approved by the Engineer. The material shall be free from foreign or organic matter, dirt, shale,
clay and clay lumps, or other deleterious matter and shall conform to the following requirements:

AASHTO Sieve Percent Passing

3/8 in. (9.5 mm) 100
#4 85 - 100
# 100 10 - 30

Plasticity Index (AASHTO T-90) 6 maximum

Sand Equivalent (AASHTO T-176) 30 minimum

The combined material shall consist of a mixture of all aggregate uniformly graded from coarse to fine to
conform to the following gradation requirements:

AASHTO Sieve Percent Passing

2 in. (50.8 mm) 100
1 1/2 in.(38.1 mm) 60 - 90
1 in. (25.4 mm) 42 - 77
3/4 in. (19.0 mm) 35 - 70
1/2 in. (12.7 mm) 25 - 60
#4 15 - 40
# 10 10 - 26
# 40 5 - 15
# 200 2-9

All base course aggregates shall conform to the following physical requirements:

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 Loss of Sodium Sulfate Soundness
Test (AASHTO 104) 10% maximum

Loss of Magnesium Sulfate Soundness

Test (AASHTO 104) 12% maximum

Loss by Abrasion Test (AASHTO T-96) 40% maximum

Thin and Elongated Pieces, by Weight

(larger than 25 mm, thickness less 5%
than 1/5 length)

Friable Particles (AASHTO T-112) 0.25% maximum

Bituminous Binder Course

Aggregates

Aggregates for "Bituminous Binder Course" shall consist of coarse aggregates, fine aggregates, and filler
material, if required, all complying with the following requirements:

Gradation
When tested according to AASHTO T-11 and AASHTO T-27, the combined mineral aggregate shall
conform to the following grading:

AASHTO Sieve Class A Class B

Size Percent Passing Percent Passing

1½ in. 100 100

1 in. 100 80 - 100
3/4 in. 80 –100 70 - 90
3/8 in. 60 - 80 55 - 75
No. 4 45 – 65 44 - 62
No. 10 30 – 50 33 - 48
No. 40 15 - 32 16 - 27
No. 200 3 - 10 3 - 10

Gradation of mineral filler shall be:

Sieve Percent Passing

(By Weight)

No. 30 (0.600 mm) 100

No. 50 (0.300 mm) 95 - 100
No. 200 (0.075 mm) 70 - 100

Physical Requirement

The combined mineral aggregate shall meet the quality requirements specified in section "Aggregate
Base Course" and in addition shall conform to the following physical requirements.

Sand Equivalent
(AASHTO T-176) determined after
all processing minimum except
for addition of asphalt binder: 45 minimum

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 Plasticity Index (AASHTO T-90) 6 maximum

Loss of Marshall Stability by

Submerging specimens in water
at 60oC for twenty four (24) hours
as compared to stability measured
after submersion in water at 60oC
for twenty (20) minutes: 25% maximum

Job-Mix

The job mix formula combining the aggregates and bitumen (grade 60-70 penetration) shall be provided
by the Contractor.

Bituminous Wearing Course

Aggregates

Aggregates for "Bituminous Wearing Course" shall consist of coarse aggregates, fine aggregates, and
filler material if required, all complying with the following requirements.

Gradation requirements of mineral filler:

Sieve Percentage Passing

(By Weight)

No. 30 (0.600 mm) 100

No. 50 (0.300 mm) 95 - 100

No. 200 (0.075 mm) 70 - 100

Sand Equivalent (AASHTO T-176)

determined after all processing except
for addition of asphalt binder : 45 minimum

Plasticity index (AASHTO T-90) 3 maximum

Loss of Marshall Stability by

submerging specimens in water
at 60o C for twenty-four (24) hours
as compared to stability measured
after submersion in water at 60o C
for twenty (20) minutes. 25% maximum

When tested according to AASHTO T-11 and AASHTO T-27 the combined aggregate shall conform to
the following gradings:

AASHTO Sieve Size Percent Passing

¾ in. 100
½ in. 80 - 95
3/8 in. -

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 No. 4 48 - 62
No. 10 32 - 45
No. 40 16 - 26
No. 80 8 - 18
No. 200 4-8

Job-Mix

The job mix formula combining the aggregates and bitumen (grade 60-70 penetration) shall be provided
by the Contractor.

Traffic Marking and Pavement Studs

a) Standards and Codes:

Sponsor Number Subject

AASHTO M - 237 Epoxy Resin Adhesive for Bonding Traffic

Markers to Hardened Concrete
AASHTO M - 247 Glass Beads Used in Traffic Paint
ASTM D - 1214 Sieve Analysis of Glass Spheres
FS TT-B-1325 Bead, (Glass Spheres) Retro- reflective
FS TT-P-110 Paint, Traffic Black (Non- reflectorized)

Traffic signs, road markings and pavement studs shall also be in accordance with the
requirements of international standards.

b) Aggregate :

The aggregate shall consist of light coloured silica sand, calcite, quartz, calcined flint, or other
material approved by the Engineer.

c) Pigment and Extender

White Material

The pigment shall be titanium dioxide complying with the requirements of Type A (anatase) or
Type R (rutile) of BS-1851.

Yellow Materials

Sufficient suitable yellow pigment shall be substituted for all or part of the titanium dioxide to
comply with the other requirements of this specification.

All Materials

The extender shall normally be whiting (i.e. calcium carbonate prepared from natural chalk)
complying with the requirements of BS-1795. The manufacturer may substitute lithopone
complying with the requirement of BS-296 for any or all of the whiting.

Binder

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 The binder shall consist of synthetic hydrocarbon resin, or, with the approval of the Engineer, gun
or wood resin, plasticized with mineral oil.

Testing

The samples shall be prepared and tested in accordance with B.S. Specification 3262 (1976)
appendix A to H at stages:

a) At the manufacturer's plant.

b) After it has been re-melted by the road application contractor.

The following properties shall be checked:

o Softening Point
o Colour and Luminance
o Heat Stability
o Flow Resistance
o Skid Resistance

Traffic Signs

The Traffic Signs shall be designed for size, message and installation as per Manual on Uniform
Traffic Control Devices (MUTCD) standards

Sign Materials

Sign materials shall be

a) Aluminium Alloy Sheets: Aluminium alloy sheets shall conform to ASTM B 209, 6061-T6 aluminium,
degreased and alodine-treated, 3 mm thick, unless otherwise noted on the plans.

b) Steel Sheets: Steel sheets shall conform to the requirements of the "Specifications for Cold-Rolled
Carbon Steel Sheets, Commercial Quality," ASTM A-366, 16 gauge thick unless otherwise noted on
the plans.

c) Stainless Steel Bolts, Washers and Self-Locking Nuts: These items shall conform to ASTM A- 276,
chromium-nickel grade. Minimum yield 2,110 kilograms per square centimeter.

d) Vulcanized Fibre Washers: Fibre washers shall conform to ASTM D-710, grey, commercial grade,
when shown on the plans.

e) Hard Rubber Washers

f) Nylon and Neoprene Fittings: Nylon and/or neoprene washers, spacers, sleeves etc.

g) Reflective Sheeting

Precast Cement Concrete Fair Faced Curb Stone and Gutter Blocks

Cement concrete fair faced finished curb stones/gutter block/edge block shall be fair face and precast
using cement-concrete Class ‘C’, conforming to the requirements as stipulated in the section "Plain and

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Reinforced Cement Concrete". The formwork shall conform to the requirements as stipulated in the
section "Formwork".

Excavation shall be made to the required depth and the base upon which the kerb or combination of kerb
and gutter is to be set shall be compacted to a minimum density of ninety (90) percent of the maximum
dry density as determined by AASHTO T-191 Method.

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