Jordan-General Specifications - Part1

Part ( 1 ) :
General
Provisions
Technichal Specifications General Provisions
FORMAT AND REFERENCING SECTION 1.1
SECTION 1.1 : FORMAT AND REFERENCING

1.1.1 FORMAT OF SPECIFICATIONS
1. Part
This Manual of Standard Specifications is divided into Parts. Each Part is designated by a single digit
number followed by a title.
2. Section
Each Part is divided into Sections. Each Section is designated by the Part number, a decimal point and a
2-digit sequential number, followed by a title.
3. Subsection
Each Section is divided into Subsections. Each Subsection is designated by the Part number, a decimal
point and a 2-digit Section number, a decimal point and a one-digit number followed by a title.
4. Clause
Each Subsection is divided into Clauses. Each Clause is designated by a one-digit sequential number and
a decimal point.
5. Item
Each Clause may be divided into items. Each item is designated by the Clause number, a decimal point
and a one-digit or 2-digit sequential number, followed (if required) by a title in lower case lettering. The
text then normally follows on the same line.
6. Pay Item
All Pay Items listed in the Specifications have a number in parenthesis entered alongside each Pay Item
wherever occurring in the Specification. In case more than one item under any one section occurs, a serial
one-digit or 2-digit sequential number is used, these numbers are cross referenced in the Bill of
Quantities.
1.1.2 REFERENCING
1. The Specifications for Items in the Bills of Quantities are prescribed in the respective Section/s
corresponding to the type of Works involved.
2. All provisions of such Section/s, including any Supplemental and Special Specifications, shall be
construed as Specifications for such Item of Work, except in respect of those provisions clearly
inapplicable in the context in which they appear or unless they are waived or modified in the Contract
Documents or by Variation Order.
3. Specifications and Drawings may contain cross references to other Sections, Clauses, Items, etc.,
which shall likewise be construed as Specifications for the Item of Work involved.
4. Any references in the Specifications to Work or materials not required by the Contract, will be
deemed not to apply.
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ABBREVIATIONS AND SEFIINITIONS SECTION 1.2
SECTION 1.2 : ABBREVIATIONS AND DEFINITIONS

1.2.1 ABBREVIATIONS
1. Interpretation
Wherever the following abbreviations of titles, terms and units of measurement are used in the
Specifications or on the Drawings, the intent and meaning shall be interpreted as described hereunder.
2. Tiles and Terms
AASHTO - American Association of State Highway and Transportation

Officials
ABS - Acrylonitrile-Butadiene-Styrene
ACI - American Concrete Institute
AISC - American Institute for Steel Construction
AISI - American Iron and Steel Institute
ANSI - American National Standards Institute
API - American Petroleum Institute
ASTM - American Society for Testing and Materials
A.V. - average
AWG - American Wire Gauge
AWS - American Welding Society
bit. - bitumen/Bituminous
BFSC - bituminous Fog Seal Coat
BS - British Standard
BSSC - bituminous Slurry Seal Coat
BST - bituminous Surface Treatment
CB - circuit Breaker
CBR - California Bearing Ratio
Conc. - concrete
CIE - Commission Internationale de I’Eclairage
DBSC - double Bituminous Seal Coat
DIN - Deutsches Institute Fur Normalizieung
equiv. - equivalent
FSS - Federal Standard Specification (USA)
Hwy - highway
Ht - height
H:V - horizontal: vertical
IEC - International Electrical Commission
IEE - Institution of Electrical Engineers (UK)
ISO - International Organization for Standardization
L.L. - liquid limit
L.S. - lump sum
max - maximum
MCCB - molded case circuit breaker
mcd - Minute Candle
min - minimum (or minute)
MUTCD - Manual on Uniform Traffic Control Devices
NEC - National Electrical Code (UK)
NEMA - National Electrical Manufacturers’ Association (USA)
NJB - New Jersey barrier
pav’t - pavement
P.C. - prime cost
PCC - Portland cement concrete
PE - polyethylene
P.I. - plasticity index
P.L. - plastic limit
PTFE - Polyterafluoroethylene
PVC - polyvinyl chloride
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qty - quantity
RC - reinforced concrete
RCP - reinforced concrete pipe
rdwy - roadway
ROW - right-of-way
SBSC - single bituminous seal coat
S.G. - specific gravity
SI - Systeme International D’Unites
Sta. - Station (location along a survey line)
SWG - standard wire gauge (UK)
TBSC - triple bituminous seal coat
u.P.V.C. - un-plasticized polyvinyl chloride
VDE - Verband Deutscher Electrotechniker
Wgt - weight
3. Units of Measurement
No. - number
mm - millimeter/s
cm - centimeter/s
m - meter/s
lin. m - linear meter/s
km - kilometer/s
mm2 - square millimeter/s
cm2 - square centimeter/s
m2 - square meter/s
ha - hectare/s
m3 - cubic meter/s
gm - gram/s
kg - kilogram/s
ton - metric ton(1,000 kg)
ml - milliliter/s
ltr - liter/s
Pa - Pascal/s
N - Newton/s
kN - kilo Newton
MN - mega Newton
A - amperes
mA - milli amperes
V - volt/s
W - Watt
kW - kilowatt
C - Celsius (Centigrade)
Hz - Hertz (Frequency)
rpm - revolutions per minute
km/h - kilometers per hour
sec - seconds
min - minute/s (or minimum)
h - hour/s
mS - milli Siemens
dB - decibel/s
dBA - decibels absolute
ppm - parts per million
in. - inch/inches (1 in. = 25.4 mm)
ft - foot/feet (1ft = 0.3048 m)
in2 - square inch/inches
ft2 - square foot/feet
ft3 - cubic foot/feet
lb. - pound/s (weight)
psi - pounds per square inch
gal - gallon/s (U.S.)
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gal (Imp) - gallon/s (Imperial)

mph - miles per hour
HP - horsepower
USG - American gage
4. Spelling Usage
For consistency, American spelling has been adopted throughout these Specifications, apart from several
words for which English spelling is, by custom, more commonly utilized.
1.2.2 DEFINITIONS
In addition to the definitions contained in the Conditions of Contract, the following words and
expressions shall have the meanings assigned to them. Other technical terms shall, in general, have the
meanings conforming to those given in AASHTO Standards.
ACCEPTED – Accepted in writing by the Engineer (or by the Employer where appropriate) as meeting
the requirements of the Contract Documents and of any authorized variations thereto. “Acceptance”
means accepted in writing as aforesaid. “Acceptable” means acceptable to the Engineer as aforesaid.
ADDENDUM – Amendment of or revision to any of the Contract Documents issued to Tenderers, and
which is deemed to form part of the Contract Documents.
APPROVED – Approved in writing by the Engineer, including subsequent written approval or

confirmation of previous verbal approval by the Engineer. “Approval” means approval in writing as
aforesaid.
CERTIFICATE OF GUARANTEE – A signed statement by a person having legal authority to bind a

company or supplier to its product, and which confirms that the materials and test results conform to the
standards of these Specifications.
DIRECTED – Directed in writing by the Engineer, including subsequent written direction or

confirmation of previous verbal direction by the Engineer.
DIVIDED HIGHWAY – A highway with separate roadways for traffic traveling in opposite directions.
HIGHWAY – A public way for purposes of vehicular travel and which includes the entire area within the
right-of-way.
PRESPLITTING – Establishment of a free surface, or shear plane, in rock cuts, by controlled use of
explosives in specially aligned and closely spaced drill holes along the slope line.
SHEATHING – Backfilling to the inside faces of structures such as retaining walls and abutments, using
proprietary filler cloth and porous blocks, or using selected, free-draining material such as gravel or non-
cementitious sand, etc, prior to placing and compacting normal backfill.
SOIL STABILIZATION – Procedure whereby cement, bitumen or lime is added to soils (subgrade
layer) or to granular materials (sub-base course) in order to improve their load bearing capacity and their
resistance to weathering and displacement.
SUBGRADE – The top surface of embankment or excavated area on which the pavement structure and
shoulders are constructed. Also referred to as Subgrade Surface or Subgrade Level.
SUBGRADE LAYER – The top layer of material, of at least 200 mm compacted thickness, immediately
below the subgrade surface.
SUBSIDIARY WORKS – Works which are subsidiary to or necessary or essential to, or in support of, or
usual to, the execution and completion of other Works.
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SUBSTRUCTURE – All of that part of the structure below the bearings of simple and continuous spans,
skewbacks of arches and tops of footings of rigid frames, together with the backwalls, wingwalls, and
wing protection railings.
SPECIAL SPECIFICATIONS – Provisions and requirements which have particular or unique reference
to the project, including additions and revisions to the Supplemental and Standard Specifications.
SUPPLEMENTAL SPECIFICATIONS – Revisions to the Standard Specifications.
TOPPING – Selected material, comprising gravel or gravely soil of specified grading which is used to
construct the subgrade layer for a compacted depth of at least 200 mm below final subgrade level.
VOLUNTEER CRACKS – Cracks or portions of cracks in Portland cement concrete pavements that are
not coincident with constructed joints.
WORKING DRAWINGS – Shop drawings, steel bending schedules, stress sheets, fabrication and
erection drawings, falsework drawings, and any other supplementary drawings or data which the
Contractor is required to submit to the Engineer for approval, generally before such Works commence.
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SCOPE AND CONTROL OF WORKS SECTION 1.3
SECTION 1.3 : SCOPE AND CONTROL OF WORKS

1.3.1 INTENT OF CONTRACT
1. The intent of the Contract is to provide for the construction and completion in every detail and
subsequent maintenance of the Works described. The Contractor shall furnish all labor, materials, tools,
equipment, transportation, supplies and facilities and shall carry out all Permanent and Temporary Works
and all other items necessary for proper completion of the Works in accordance with all requirements of
the Contract Documents.
2. Where the Specifications or Drawings describe any portions of the Works in outline only, and
not in complete detail, the best general engineering practice shall prevail and only first quality materials
and workmanship shall be used.
1.3.2 SILENCE OF SPECIFICATIONS
1. The apparent silence of the Specifications, Drawings or other Contract Documents as to any
detail or the apparent omission from them of a detailed description concerning any Works or
requirements, shall be regarded as meaning that good engineering practice shall apply and shall be to the
approval of the Engineer.
1.3.3 CONTRACTOR’S WORK AREAS
1. The Contractor shall make all necessary arrangements, including payment if need be, regarding
any land outside the Site that may be needed as work areas. The Employer will not acknowledge any
liability in respect of such land. The Contractor shall also be responsible for insuring that all roads and
temporary facilities needed are sufficient to divert traffic adequately.
2. The Contractor shall locate and select sites outside the right-of-way or the site (as defined in
Clause 1 of the General Conditions) for the use of his plant, equipment, site offices, residences,
Temporary Works or any other uses which are essential during the execution of the Contract. The
Contractor shall take the necessary measures for using these sites and shall be responsible for all expenses
that may become due in return for such use. Prior to using any land owned by the Jamahiriya or by any
private owner outside the Site, the Contractor shall obtain the approval of the concerned Authorities and
the Engineer.
3. The Contractor, if so required by the Engineer, whether before or after completion of the Works,
shall remove his constructional plant and duly clean the site and shall, wherever applicable, remedy all
damage and pay all monies due to land owners in return for using their land.
4. It is the contractor responsibility to verify the stability of side slopes in cut areas by specialized
staff. The contractor shall run at his own expense the required site investigation process in prior of cutting
in the relevant areas. The proposal of site investigation program as well the final recommendation should
be approved by the engineer. No direct payment shall be done for this work, all expenses should be
included in the contractors prices.
1.3.4 WATER SUPPLY
The Contractor will be deemed to have carried out adequate investigations as to the availability of water
for the purpose of the Works and to have consulted and arranged with the appropriate Authorities and
taken into consideration all legal aspects. The Contractor shall be responsible for the supply of sufficient
water of the specified quality at all times during progress of the Works.
1.3.5 ELECTRICITY SUPPLY
1. The Contractor shall make his own arrangements for the supply of all electric power required for
execution of the Works.
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2. The Contractor shall provide and maintain adequate, efficient lighting for all parts of the Works
required by the Engineer and, without prejudice to his liability under the General Conditions of Contract
shall, in connection with any installations for the supply of electricity for power or for lighting, take all
necessary precautions for ensuring the safety of his workmen and others.
1.3.6 EXISTING UTILITIES AND OTHER OBSTRUCTIONS
1. Categories of Obstructions
1.1 Obstructions shall be classified as follows:
1.1.1 Existing private and public owned utilities, above and below ground, which are required
to be either protected, adjusted, relocated or removed.
1.1.2 Obstructions, above and below ground (other than utilities), which are required to be
taken down, dismantled, demolished or excavated, and removed, as appropriate.
2. Existing Utilities
2.1 Utilities shall include, but not be limited to, existing water lines, gas lines, sewer lines, wire
lines, service connections, water and gas meters and valve boxes, light poles and masts, pylons,
cableways, signals, and all utility appurtenances within the limits of the proposed construction.
2.2 The necessary utility diversions may be specified or directed to be carried out by the Contractor.
Alternatively, the Employer may make arrangements for such works to be executed by other parties,
normally the Utility Owners. In the event the utility diversions are specified or directed to be executed by
the Contractor, the Contractor shall take into account that the diversion works will be carried out to the
requirements and approval of the Utility Owners and/or under their supervision.
2.3 The Contractor shall review, verify and adjust or correct as necessary or applicable the utility
Drawings provided by the Employer or the Engineer, to reflect the actual locations and requirements and
shall submit revised drawings to the Engineer for his approval. The Contractor shall for this purpose
excavate trial pits on site or take any other measures needed as may be necessary for identification and
verification of existing utilities.
2.4 The Employer will, in co-operation with the Engineer and Contractor, coordinate with all Utility
Owners to ensure prompt adjustment, relocation or removal of all affected utilities, including any
additional utilities that may be encountered during the Works. The Employer and Engineer will facilitate,
to the maximum extent practicable, the Contractor’s Work Program, in this respect.
2.5 The Contractor shall take into account, in his Program of Work, the time effort involved in the
follow-up and execution of Works pertaining to all utility adjustments, relocations and removals. He shall
schedule his construction activities so as to avoid or minimize any potential delays, inconvenience or
damage to the Works that may result from utility interference or the operations of adjustment, relocation
and removal.
2.6 The Contractor shall follow up the execution of the utility diversions whether they are carried
out by himself directly or by other parties. The Contractor shall, in good time, inform the Employer and
the Engineer.
2.7 The Contractor shall be responsible for safeguarding and protecting from damage all utilities and
appurtenances encountered during the Works. He shall be responsible for the costs of making good any
damage thereto, arising out of his own negligence.
3. Obstacles
3.1 Obstacles shall include, but not be limited to existing buildings, walls, fences, gates, wells, septic
tanks, manholes, pits, pipes, culverts, roadways, sidewalks, signs and rubbish dumps, whether or not
shown on the Drawings.
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3.2 At the commencement of the Contract, the Contractor shall examine the Site and identify / verify
all obstacles within the right-of-way above or below ground, and shall record all such information on
suitable Site Drawings which shall be submitted to the Engineer within one month of commencement of
the Works.
1.3.7 SIGN BOARDS
1. The Contractor shall furnish and erect 2 metal sign boards inscribed in Arabic (or Arabic and
English if required) as directed by the Engineer, using approved letter sizes. The Contractor shall provide
posts of 50 mm painted steel pipe or of 50 mm angle iron on which signs shall be erected. Posts shall be
fixed in concrete foundations of the type specified. Sign boards and posts shall be painted in conformity
with the relevant requirements of Part 8 “Incidental Construction”, using paint selected by the Engineer.
2. Each sign board shall be erected in a prominent, approved position, one at each end of the length
of highway being constructed. Sign boards shall be maintained in good order at all times and sign boards
and supports shall be dismantled and removed from the site at the completion of the Works.
1.3.8 TEMPLATES AND STRAIGHT EDGES
1. The Contractor shall provide and use a sufficient number of metal or wooden templates or other
needed devices to control and check correct shaping of finished surfaces of the Works. A sample template
shall be submitted to the Engineer for approval. Templates shall be maintained in good condition at all
times.
2. The Contractor shall also provide a sufficient number of metal straight edges of the required
length and approved by the Engineer, to control the longitudinal dimensions of the Works.
3. Templates and straight edges shall be checked from time to time and repaired or replaced as and
when directed by the Engineer.
1.3.9 SURVEYING EQUIPMENT
1. The Contractor shall provide on Site sufficient and suitable surveying instruments and other
equipment for his own use in setting out and leveling of the Works.
2. The accuracy of survey instruments may be verified at any time by the Engineer and any
unsatisfactory instruments shall be promptly calibrated or removed and replaced by the Contractor at his
own expense.
3. On completion of the Contract, all survey instruments shall become the property of the
Contractor, unless a Pay Item for such instruments is included in the Bills of Quantities in which case the
instruments shall become the property of the Employer.
1.3.10 SETTING OUT OF WORKS
1. The Contractor shall, prior to any setting out, submit to the Engineer for his approval, a planned
method of operations for setting out the Works. The plan shall include the accuracy, positions of the
various types of stakes, method of marking stakes, and methods to be used for protecting stakes, etc. No
survey work shall proceed prior to the Engineer’s approval of the Contractor’s plan.
2. At least 24 hours before he intends to survey any portion of the Works, the Contractor shall give
written notice to the Engineer. Such notice shall include the time, location and type of Works to be set
out.
3. The Contractor shall set out the Works and obtain approval of his setting out before proceeding
with construction. If, in the opinion of the Engineer, modification of the lines or grade is advisable, before
or after survey, the Engineer will issue detailed instructions to the Contractor who shall revise the setting
out accordingly.
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4. The Contractor shall be responsible for preservation of all existing stakes, marks and monuments
and if any construction stakes or marks are destroyed or disturbed, the Contractor shall replace them at his
own expense.
1.3.11 HAUL ROUTES FOR HEAVY VEHICLES
1. The Contractor shall prepare proposals for routes to be used by heavy vehicles particularly for
hauling fill materials. Routes shall where possible, avoid existing roads and built-up areas. Signs shall be
provided and maintained to direct construction traffic to and from haul routes. Details of haul routes and
signing shall be submitted to the Engineer for approval within a period not exceeding one month prior to
the commencement of the Works in the relevant area and the signs shall be erected prior to actual
commencement of the Works.
2. Haul routes shall operate using one-way or two-way traffic systems as required by the Engineer.
If at any time he considers that any section of the route needs repair work, he may withdraw his approval
of its use until the Contractor has carried out the work to the Engineer’s satisfaction.
3. If any where it is necessary, as required in the Special Specifications, for Contractor’s plant or
vehicles to cross public highways, and where required by the Engineer, all such crossings shall be
equipped with manually controlled traffic lights. During extended periods when the Contractor’s plant is
not using the crossing, the traffic signals shall be switched off and the Advance Warning signs obscured.
4. Stationary vehicles, equipment, huts, stockpiles of materials, etc., shall be kept well clear of
crossing points so that persons using the highway and the haul road shall have adequate sight distance at
all times.
1.3.12 SCAFFOLDING AND FALSEWORK
1. The Contractor shall provide scaffolding and falsework to facilitate carrying out construction of
the Works in the required sequence. Scaffolding and falsework shall be properly designed and constructed
specifically for the loads intended. Full details of the proposed arrangements shall be submitted to the
Engineer for his approval. Such approval, however, shall not relieve the Contractor of his responsibility
with regard to the adequacy of all scaffolding and falsework used in the Works.
1.3.13 USE OF EXPLOSIVES
1. Control Measures
1.1 In addition to his obligations under the Conditions of Contract, the Contractor shall abide by all
rules and regulations of the concerned authorities regarding purchasing, transportation, storing, handling
and using the explosive materials.
1.2 Explosives and detonators shall be stored in special buildings as approved by the concerned
authorities. These secured buildings should be located and clearly marked in Arabic and English
“DANGER – EXPLOSIVES” as approved by the concerned authorities. Explosives and detonators shall
be stored in separate buildings.
1.3 All possible precautions shall be taken against accidental fire or explosion, and to ensure that the
explosives and detonators are kept in proper and safe condition.
1.4 Explosives and detonators shall always be transported in separate vehicles and kept apart until
the last possible moment. Metallic tools shall not be used to open boxes of explosives.
2. Blasting Procedures
2.1 Blasting shall only be carried out by experienced shot firers. Priming, charging, stemming and
shot firing shall be carried out with greatest regard for safety and in strict accordance with the Rules and
Regulations of the concerned authorities. Adequate warning of blasting shall always be given and all
persons cleared from the area, before blasting takes place.
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2.1 Police and other local authorities shall be kept fully informed of the blasting program so that
they may be present when blasting takes place if they so require.
3. Explosives Inventory
3.1 The Contractor shall maintain an up-to-date inventory of all explosives and explosive devices
and shall submit a monthly report to the Engineer, detailing the use of all explosives by date and location.
1.3.14 FIRE FIGHTING EQUIPMENT
1. Adequate, fully operational fire fighting equipment shall be furnished and maintained by the
Contractor whose workmen shall be trained in the operation of such equipment.
2. Fire fighting arrangements shall made as required by the local Civil Defense Authorities.
3. Adequate water for fire fighting shall be available and outlets located so as to be readily
accessible.
4. All equipment shall be regularly tested and properly maintained.
1.3.15 PHOTOGRAPHIC RECORDS OF CONSTRUCTION
1. Where it is permitted the Contractor shall submit each month good quality photographs of at
least 5 different subjects as agreed by the Engineer. For each subject, the Contractor shall supply 3 color
prints (gloss finish) size 20 cm x 25 cm plus negatives and a color transparency. Negatives and
transparency should be separately exposed but as far as possible should show identical scenes.
2. Each print and transparency supplied shall be titled and referenced to a suitable key plan. Prints
and negatives shall also be suitably cross referenced.
1.3.16 SITE CLEANING AND FINAL CLEAN UP
1. Site Cleaning During Progress of Works
1.1 All parts of the Site, and adjacent roads affected by the Works, shall be maintained in a clean
and tidy condition during progress of the Works. All waste and surplus materials and other rubbish
resulting from the Works or otherwise, shall be cleared away at intervals as directed by the Engineer.
1.2 If the Contractor fails to remove any surplus or waste materials from the Site within 3 days after
being instructed to do so by the Engineer, these materials may be removed by others at the Contractor’s
expense.
2. Final Clean Up on Completion
2.1 The entire Site shall be delivered up on completion of the Works, in a clean, neat and presentable
condition, all as specified hereunder and as described in the Conditions of Contract.
2.2 Slopes of embankments, excavations, highway approaches and connections, ditches, channels,
and material sites within or adjacent to the highway ROW, shall be trimmed and finished to the lines and
grades shown on the Drawings. Ditches and channels within or adjacent to the highway ROW shall be
cleared of debris and obstructions. All materials resulting from these operations shall be burned or
disposed of in approved locations outside the highway ROW. All burning shall be carried out in
conformity with local regulations.
2.3 All culverts shall be cleaned out. Excess earth, debris and waste materials adjacent to ends of
culverts and bridges, or to poles, posts, trees, etc. shall be removed and the areas shaped, trimmed and left
in a neat and presentable condition. All stones, roots and other waste materials exposed on slopes and
which are liable to become loosened shall be removed and disposed of. All materials and debris resulting
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from clearing and grubbing operations not previously removed, shall be burned or otherwise disposed of.
Shaping and grading of wadi courses shall extend 20 meters for culverts and 50 meters for bridges.
2.4 Stockpiling of material on the finished pavements and drifting of material across the pavements
will not permitted. Finished pavements and shoulders shall be cleaned of all dirt and rubbish. Foreign
material shall be removed up to a distance of 50 m each side beyond the toe of embankments.
2.5 Spoil tips, borrow pits and deposited materials shall be trimmed and regularized to profiles and
levels as directed. Flow of water courses affected concerning these sites, existing between the Employer
and the persons or authorities concerned, shall be observed.
1.3.17 MEASUREMENT
1. Realignment of utilities as prescribed in Clause 2 of Sub-Section 1.03.6 shall be entered as a

provisional sum in the Bill of Quantities.
2. Reference Clause 3 of Sub-Section 1.03.6, the Contractor, unless otherwise specified in the
Special Specifications and included in the Bills of Quantities shall bear all costs of taking down,
demolishing, excavating, removing and stockpiling, storing or disposing of all obstacles as directed. He
shall be responsible for the cost of making good any damage to obstacles which are to be preserved,
arising out of his own negligence.
3. All other works prescribed in this section shall not be measured for direct payment, but shall be
considered as subsidiary work, the costs of which will be deemed to be included in the Contract prices for
pay items.
PAY ITEM UNIT OF MEASUREMENT

(1) Realignment of Utilities (Provisional Sum)
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TEMPORARY WORKS SECTION 1.4
SECTION 1.4 : TEMPORARY WORKS

1.4.1 SCOPE
1. The Contractor shall construct all temporary detour roads, temporary bridges and culverts, and
other facilities for his Works or for maintenance of traffic in locations affected by his works that warrant
such Temporary Works.
2. The Contractor shall construct, and maintain all detour routes in accordance with Section 8.10 of
this specification ensuring at all times that the detour routes are signed, striped, maintained and furnished
with all traffic control devices as shown, directed and/or needed.
1.4.2 DESIGN REQUIREMENTS
1. Designs and detailed working drawings for proposed Temporary Works shall be submitted for
approval, prior to commencing such Works. The Contractor will be held responsible for any damage that
may result from the Temporary Works.
2. Design live load for temporary bridges related roads exposed to heavy vehicles shall not be less
than the design live load for permanent bridges, or as directed by the Engineer.
3. Where measures are taken for continuously regulating and supervising traffic, the minimum
width of temporary roads and bridges for one-way traffic shall be 3.5 m. In all other cases, the minimum
width shall be 7 m.
1.4.3 AGREEMENT OF PROPERTY OWNERS
1. The Contractor shall obtain the agreement of the affected land owners and of the Engineer prior
to commencing Temporary Works required for his Works. Such approval shall not in any way relieve the
Contractor of his responsibilities under Conditions of Contract.
1.4.4 PHASED PROGRAM
1. The execution of Temporary and Permanent Works shall be phased so as to minimize disruption
to traffic. The Contractor shall submit a phased program of his proposals one month before he intends to
commence work on any part of the highway.
1.4.5 MEASUREMENT
1. Measurement and payment for detour construction and traffic maintenance shall be as given
under Section 8.10 of this specification.
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CONTROL OF MATERIAL & STANDARDS FOR SAMPLING & TESTING SECTION 1.5
SECTION 1.5 : CONTROL OF MATERIALS & STANDARDS

FOR SAMPLING & TESTING
1.5.1 STORAGE OF MATERIALS
1. Materials shall be so stored as to assure the preservation of their quality and fitness for the
Works. Stored materials, approved before storage, may again be inspected prior to their use in the Works.
Stored materials shall be located so as to facilitate their prompt inspection.
2. Materials shall not be stored in the ROW except where permitted by the Engineer. Stockpiling of
aggregate material within the ROW shall also be confined to such authorized areas.
3. Where materials are stockpiled on Government or private property, such sites shall be
abandoned immediately upon utilization of all stockpiled materials and the natural surface shall be
restored as far as practicable to the original condition by the Contractor and to the satisfaction of the
Engineer.
1.5.2 HANDLING MATERIALS
1. All materials shall be handled in such manner as to preserve their quality and fitness for the
Works. Aggregates shall be transported to the Works in tight vehicles, constructed so as to prevent loss or
undue segregation of materials after loading.
1.5.3 MATERIALS SUPPLIED BY EMPLOYER
1. The Contractor shall be responsible for all materials furnished by the Employer and shall make
good any shortages or deficiencies, from any cause whatsoever, or any damage which may occur, after
delivery of such materials.
1.5.4 LOCAL MATERIAL SOURCES
1. When material deposits are not designated on the Drawings, the Contractor shall be responsible
for locating and providing suitable materials from his own sources.
2. Any information provided in the tender documents about sources of local materials is considered
as a guideline only and does not relieve the Contractor of his responsibility in respect of investigation and
supply of suitable materials as specified.
3. Materials, regardless of their source, shall not be incorporated in the Works until approved by
the Engineer.
1.5.5 SOURCES OF SUPPLY AND QUALITY REQUIREMENTS
1. All materials, including manufactured articles, and machinery incorporated in the Works, shall
meet all specified quality requirements and be approved by the Engineer.
2. The Contractor shall, before placing any purchase order for any materials intended for
incorporation in the Works, submit for approval a complete description of all such materials, names of the
firms from whom he proposes to purchase them and copies of all test reports verifying conformity with
the provisions of the Specifications. Materials shall not be ordered without the approval of the Engineer.
When directed by the Engineer or otherwise specified the Contractor shall submit suitable samples for
approval.
3. The Engineer shall have the right to retest all materials which have been tested and accepted at
the source of supply after delivery to the Site and prior to incorporation into the Works and to reject any
such materials which are clearly defective or, when retested, do not conform with the Specifications.
1-13
1.5.6 CERTIFICATES OF GUARANTEE AND PRODUCTION PLANT

INSPECTIONS
1. Certificates of Guarantee & Test Certificates
1.1 All shipments of materials shall be accompanied by a Manufacturer’s Certificate of Guarantee or

Test Certificate from an approved independent qualified laboratory approved by the Engineer. All
certified materials delivered to the Site shall undergo additional laboratory testing if required by the
Engineer.
1.2 Any Certificate of Guarantee issued when the required tests have not been recently performed on
representative samples of the materials, will not be accepted.
1.3 Issuance of an invalid or erroneous Certificate of Guarantee shall be just cause for rejection of
the materials without further testing.
1.5.7 SAMPLING AND TESTING PROCEDURES
1. Sampling
1.1 Samples of all materials shall be submitted to the Engineer for inspection, testing and acceptance
before incorporation in the Works. All materials being used will be subject to inspection, testing, or
rejection at any time prior to such incorporation.
1.2 Where untested and unaccepted materials have been used without approval of the Engineer, such
use shall be at the Contractor’s risk.
2. Source Tests
2.1 All source samples shall be taken by the Contractor in the presence of the Engineer, using
approved sampling procedures. All source approval tests shall be performed under the supervision of the
Engineer or, when so specified, by an independent laboratory approved by the Engineer and engaged by
the Contractor.
2.2 After approval of any source of materials, the Contractor shall produce from such source only to
the extent that materials produced are of substantially the same quality as the approved samples.
2.3 The Engineer will periodically order retesting of previously approved sources to verify that they
continue to conform to the Specifications and may order retesting at the same or at a different laboratory
from the one performing the original source approval tests. If retesting indicates that a previously
approved source no longer conforms with the Specifications, the Contractor shall forthwith cease
production from such source.
3. Job Control Tests
3.1 Job control tests shall be performed by the Contractor prior to submitting any materials to the
Engineer for approval. The Contractor shall submit details to the Engineer of his job control testing
program.
3.2 The Engineer may declare the Contractor’s job control testing program unacceptable if frequent
rejections of submitted materials occur when subjected to the Project Control Tests.
1-14
4. Project Control Tests
4.1 All Project Control samples shall be taken jointly by the Engineer and the Contractor. Tests shall
be performed in the Site Laboratory, or in situ as appropriate, under the supervision of the Engineer. The
minimum requirements for testing shall be as given in Part 9.
4.2 The Engineer may order retesting of any material if there has been a significant delay in the
construction operations or if he determines that the material has deteriorated since its original acceptance.
Material which does not conform with the Specifications will be rejected and shall be removed from the
Works and replaced or corrected by the Contractor. The Engineer may order additional testing to
ascertain the extent of unacceptable material.
5. Check Tests
5.1 The Engineer may periodically order check tests to verify the accuracy of Project Control testing
and equipment. The Engineer may direct that check tests be performed by qualified persons other than
those normally responsible for Project Control testing, or he may direct that the samples be sent to the
Employer’s Central laboratory or to an approved independent laboratory for testing.
5.2 The Contractor shall provide the Engineer with all necessary Test Report forms and expendable
materials required to perform all required tests. Copies of all test results will be issued to the Contractor.
1.5.8 SAMPLING AND TESTING STANDARDS
1. Standards to be supplied
1.1 If required by the Special Specifications, the Contractor shall at the commencement of the
Contract furnish for use on site by the Engineer and the Contractor one complete set of the following
standards. The set shall become the property of the Contractor upon completion of the Works.
1.1.1 AASHTO Standard Specifications for Transportation Materials and Methods of

Sampling and Testing (Part I: Specifications, and Part II: Tests).
1.1.2 ASTM Standards for Testing and Materials: Section 00 plus all Volumes in Sections 1
to 6 inclusive, plus Specifications, as required, from Sections 7 to 15 inclusive.
1.1.3 Relevant Standards (those referred to in the Specification)
1.1.4 British Standard.
2. Precedence of Materials and Testing Specifications
2.1 All references to methods of testing or specifications of AASHTO, ASTM and others will be
deemed to refer to the latest methods of testing as specified in the Contract Documents. Unless otherwise
specified AASHTO methods of sampling and testing shall be adopted where available. In the case of
absence of an appropriate AASHTO specification, the ASTM specification shall govern.
1.5.9 UNACCEPTABLE MATERIALS
1. All materials not conforming to the requirements of the Specifications at the time they are used
will be rejected and shall be removed immediately from the Site unless otherwise instructed by the
Engineer.
2. No rejected material, the defects of which have been corrected, shall be used until approval has
been given.
1-15
1.5.10 MEASUREMENT
1. Unless shown as Pay Items in the Bill of Quantities all sampling, testing, and retesting, material
sources, quality requirements, certificates’ inspections, storage and handling requirements, standard
specifications to be furnished, and all other Works prescribed in this Section shall not be measured for
direct payment, but shall be considered as subsidiary Works the costs of which will be deemed to be
included in the Contract prices for Pay Items.
1-16
SUPERVISION STAFF, HOUSING AND FACILITITES SECTION 1.6
SECTION 1.6 : SUPERVISION STAFF OFFICES, HOUSING AND

FACILITIES
1.6.1 SCOPE
1. If required in the Special Specification, he Works shall consist of the following:
1.1 Construction of a Supervision Staff Residence and Office Building, complete with
utility services, carports, site grading and drainage, construction of access roads and parking
areas and incidental improvements.
1.2 Provision and delivery to the Site, of self contained Mobile Homes, complete with all
furniture, fittings and equipment necessary for their proper use and functioning.
1.6.2 SITE FOR SUPERVISION STAFF BUILDING
1. The Contractor shall coordinate with the Engineer for the selection of the site for the buildings of
supervision staff, offices and residence. After approval by the Engineer, the Contractor will be
responsible for the providing of the site.
2. The site selected shall not be subject to flooding or other foreseeable natural hazards.
3. Upon completion of the Works, all the above mentioned facilities are deemed to become the
property of the Contractor unless otherwise specified in the Special Specification.
1.6.3 SUPERVISION STAFF BUILDING
1. General
1.1 The supervision staff building shall be constructed, complete with all utility services as
specified, built in accordance with locally recognized good quality construction practice and conforming
with the requirements of all relevant local bylaws, building regulations and other requirements of local
authorities.
1.2 Detailed requirements concerning the supervision staff residence and office building including
the working drawings, outline structural and utility requirements, handover, upon completing the facility
and ownership upon completion of the Works, types of furniture and fittings, equipment and office
supplies, measurement and payment, and any other pertinent details shall be as given in the Special
Specifications and included in pertinent manuals that may from time to time be issued by the
Government.
1.6.4 PURCHASE AND DELIVERY OF MOBILE HOMES
The purchase and delivery by the Contractor of mobile homes and all pertinent details and requirements
including measurement and mode of payment shall be as given in the Special Specifications and included
in pertinent manuals that may from time to time be issued by the Government.
1-17
FIELD CONTROL LABORATORY SECTION 1.7
SECTION 1.7 : FIELD CONTROL LABORATORY

1.7.1 SCOPE
1. The Contractor shall provide, deliver and maintain for the use of both the Contractor and the
Engineer and for the duration of the Contract at an agreed location on the work site an approved mobile
trailer or building with services, furniture, equipment, apparatus, fittings, materials and supplies as a field
control laboratory. The Engineer and his staff will have the right to use the laboratory at any time, and as
required, during the life of the project.
2. The laboratory equipment shall be installed in a building or trailer constructed specially for this
purpose which shall have minimum dimensions of 2.4m width 8m length and 2.2m clear height, and be
well air-conditioned, isolated and dust- and weather-tight to provide comfortable working conditions. It
shall be supplied with an adequately pressurized water system, a reliable electrical system at 220V 50
Hertz, refrigerator, heater, sinks, drains, cabinets, desks, tables, drawers, and chairs, etc., to provide
comfortable working conditions for the laboratory personnel, together with diesel generator unit of
minimum capacity of 5KW at 220V 50 Hertz complete with controls and oil storage tank.
3. The quality of equipment shall not be inferior to that of other well known brands.
4. In addition to this building or trailer, an adjacent room of an area not less than 4x5 meters shall
be provided, which shall be weather tight and provided with electricity and pressurized running water at
all times, sinks, drains and sanitary drainage facilities.
5. The building or trailer and the equipment, on completion of the Works, shall be the property of
the Contractor.
1.7.2 MATERIALS
1. The equipment, apparatus, supply of materials and size of laboratory shall permit the execution
of the standardized procedures specifically required of the following tests:
AASHTO DESIGNATION
T – 11 Amount of Material Finer than 75mm Sieve in Aggregate.
T – 19 Unit Weight and Voids in Aggregate.
T – 22 Compressive Strength of Cylindrical Concrete Specimens.
T – 23 Making and Curing Concrete Test Specimens in the Field.
T – 24 Obtaining and Testing Drilled Cores and Sawed Beams of Concrete.
T – 26 Quality of Water to be Used in Concrete.
T – 27 Sieve Analysis of Fine and Coarse Aggregate.
T – 84 Specific Gravity and Absorption of Fine Aggregate.
T – 85 Specific Gravity and Absorption of Coarse Aggregate.
T – 87 Dry Preparation of Disturbed Soil and Soil Aggregate. Samples for Test.
T – 88 Particle Size Analysis of Soils.
T – 89 Determining the Liquid Limit of Soils.
T – 90 Determining the Plastic Limit and Plasticity Index of Soils.
T – 92 Determining the Shrinkage Factors of Soils.
T – 96 Resistance to Abrasion of Coarse Aggregate by Use of the Los Angeles Machine.
T – 99 The Moisture-Density Relations of Soils Using a 5.5lb (2.5Kg) Rammer and a 12 in.
(305mm) Drop.
T – 100 Specific Gravity of Soils.
T – 104 Soundness of Aggregate by Use of Sodium Sulphate or Magnesium Sulphate.
T – 119 Slump of Portland Cement Concrete.
T – 126 Making and Curing Concrete Test Specimens in the Laboratory.
T – 176 Plastic fines in Graded Aggregates and Soil by the Use of Sand Equivalent test.
T – 180 Moisture-Density Relations of Soils Using a 10lb (4.54Kg) Rammer and an 18 in.
(457mm) Drop.
T – 191 Density of Soil In-Place by the Sand Cone Method.
T – 193 81 (1986) The California Bearing Ratio.
1-18
T – 204 Density of Soil In-Place by the Drive Cylinder Method.

T – 205 Density of Soil In-Place by the Rubber Balloon Method.
T – 245 82 (1986) Resistance to Plastic Flow of Bituminous Mixtures Using Marshall
Apparatus.
ASTM DESIGNATION
D2041 Standard Method for theoretical maximum specific gravity of Bituminous paving
mixture
D-1557 moisture density relation of soils and soil aggregate moisture using 10-Ib (4.54kg)
Rammer and 18 in. (457mm) Drop
D-1883 Standard test method for bearing ratio of laboratory compacted soil, and D-2049
standard test method for relative density of cohesion-less soil.
BS SIGNATION
BS – 812 Determination of Flakiness Index.
BS – 812 Determination of Elongation Index.
2. In addition to the equipment, apparatus, materials and supplies needed to perform the above
mentioned tests the following shall be furnished if needed:
2.1 U.S. Standard 12 inch (0.30m) diameter brass sieves.

Sieve Size Sieve Openings
ASTM – AASHTO Designation mm Inches Quantity
3 inches 76.2 3.00 1
2 ½ inches 63.5 2.50 1
2 inches 50.8 2.00 1
1 ½ inches 38.1 1.50 1
1 inch 25.4 1.00 1
No. 12 1.68 0.0661 1
Brass Pan 1
Brass Cover 2
Motorized concrete diamond Core Drill powered and equipped to take 4(0.10m) and 6 inch
(0.15m) concrete samples.
2.2 U.S. Standard 8 inch (0.20m) diameter brass sieves.

Sieve Size Sieve Openings
ASTM – AASHTO Designation mm Inches Quantity
1 inch 25.4 1.000 2
¾ inch 19.1 0.750 2
½ inch 12.7 0.500 2
3/8 inch 9.52 0.375 2
No. 4 4.76 0.187 2
No. 8 2.38 0.0832 2
No. 10 2.00 0.0787 4
No. 16 1.19 0.0469 2
No. 30 0.59 0.0232 2
No. 40 0.42 0.0165 2
No. 50 0.297 0.0117 2
No. 80 0.177 0.0070 2
No. 100 0.177 0.0070 2
No. 200 0.074 0.0029 6
Brass Pan 2
Brass cover, less ring 2
2.3 Miscellaneous Quantity

- Soil mortar 1
- Soil pestle 1
- Wire sieve 1
- Fine sieve brush 2
- Sample splitters (riffles) – 2.5”, 1”, ¼” 1
- Brass irrigation tube 1
- Rubber tubing with pinch clamp 1
1-19
2.3 Miscellaneous (continued) Quantity

- Weighted foot for sand level 1
- Rubber stopper for cylinder 4
- Wide mouth funnel 1
- Measuring can 1
- Supply of standard stock solution As Required
- Plastic measuring cylinders 4
- Plywood carrying case 1
- Stainless steel round sample bowl,
(9in (0.23m) diameter 4in (0.10m) deep 1
- Square drying pan,
10 ½ in x 10 ½ in x 1 in
(0.27m x 0.27m x 0.025m) 1
- Technical grade
anhydrous calcium chloride As Required
- Glycerin U.S.P. As Required
- Formaldehyde 40% by volume As Required
- Standard liquid limit device with
grooving tool 1
- Mixing dish, diameter 115mm capacity
250ml. 1
- Flexible spatula (4in x 11/16in size)
(101.6mm x 17.5mm) 3
- Flexible spatula (6in x 11/16in size)
(152.4mm x 17.5mm) 2
- Graduated cylinder, 100cc. capacity 2
- Graduated cylinder, 1000cc, capacity 2
- Plastic limit plate 1
- Porcelain evaporating dish, 3in dia.
(76mm) 1
- Graduated cylinder, 25ml capacity 4
- Modified compaction hammer
(2in dia. 10lb 18in drop)
(50.8mm, 4.5kg, 0.46m drop) 2
- Modified compaction mold 0.333 ft3
(0.009 m3.) volume. 6in (0.15m) int.
dia 4.584in (0.12m) high 3
- Straight edge 3
- Mixing trowel 2
- Mixing pans, rectangular
(15in x 16in x 3in deep) 6
- Triple beam balance (capacity 210
gm sensitivity 0.01 gm) 1
- Solution balance (capacity 20Kg
sensitivity 1 gm) 1
- Moisture cans, (3 ounce (85gm) capacity) 24
- Field scale 1
- Wash bottle, (100ml. capacity) 2
- Mixing pan (18in x 18in x 3in)
(0.46m x 0.46m x 0.076m) 1
- Sample ejector with 2in (51mm), 3in (76mm),
4in (102mm) and 6in (152mm) disc
and reaction plate 1
- Triple beam scale (capacity 1610 gm
sensitivity 0.01 gm) 1
- Density spoon 4
- Field can (1 gallon (4 liter) capacity)
W/cover 12
- One inch steel chisel 2
- Rubber mallet 2
- Sand-cone (with fine extra jugs) 2
- Steel rulers 2
1-20

- Drying oven 24in (0.61m) x 20in (0.51m) x 24in
(.61 m), 2000 watt
external size thermostatically
controlled capable of maintaining
a temperature of 110 5C 1
- Loading machine, with proving rings,
with 30 and 60KN capacity and
penetration piston for CBR test 1
- Mold (6in (015m) int. dia., 7in (0.18m)
height) with perforated base for CBR test 4
- Spacer disk for CBR test 2
- Upper perforated plate for CBR test 4
- Surcharge weights (5lbs. (2.27kg) each) 8
- Tripod support for dial gauge 4
- Dial gauge (0.001in) (0.0254mm0 4
- Bitumen extractor (min. capacity
1500 gm) 1
- Extraction filter ring (Package
of 100) 10
- Carbon Tetrachloride gal (38 liter) 10
- Special machine for taking core
samples of asphalt concrete and
sand asphalt 1
- Mold assembly for Marshall Test 3
- Compaction hammer 2
- Mold holder 2
- Breaking head 2
- Thermostatic water bath 1
- Flow meter 2
- Vacuum pump for GMM 1
- Electronic balance self calibrated,
(0.01 gm) capacity 3.6kg with hook 1
- Range 240mm manometer filled with
mercury mounted on stable anodized
aluminum support with stopcock 1
- Woulf bottle 1
- Glass stopcock 1
- Rubber tube (heavy wall) 6.5mm 4 meter
- Rubber tube (heavy wall) 5mm 4 meter
- Thermometer from 0C to 110C,
1 divisions 2
- Thermometer from 0C to 200C,
1 divisions 2
- Soil and concrete testing
thermometer from –7C to 93C,
1C divisions 2
- Metal thermometer from 0C to 150C,
2C divisions 2
- Armored thermometer from 10C
to 399C 2
- 150mm cube molds for concrete test 18
- Slump cone test apparatus complete 2
- Compression test machine
122 ton capacity 1
- Guard for testing machine 1
- Volumetric flask 500ml.at 20C 4
- Conical metal mold for specific
gravity test 1
- Metal tamping rod for specific
gravity test 1
- Wire basket for specific gravity test 1
1-21

- Complete set of plate bearing
test apparatus including dial
gauges, plates (min.(0.5m) dial),
hydraulic jacks, truck tipper
and any other small tools and
equipment required 1
- Graduated cylinder 100 c.c. 4
- Breaker 100 c.c. 4
- Breaker 250 c.c. 4
- Beaker 500 c.c. 4
- Beaker 1000 c.c. 4
- Hot Plate 1000 Watts 2
- Stopwatch 30 min. 1/5 sec. 1
- Asbestos gloves 2
- Glass marking pencil 12
- Laboratory tongs 2
- Magnet holder for dial indicator 4
- Stainless steel laboratory oven
24in x 18.9in x 15.75in
(0.6m x 0.48m x 0.4m), 2000 watt 1
- A small gas oven with 2 gas bottles 1
- Automatic dynamic motorized sieve
shaker for 8 inch (0.20m) U.S. standard
sieves, fitted to the electrical system
of the laboratory with electrical timer. 1
- Sensitive balance 0-500 gm. capacity.
0.001 gm. Sensitivity with weights. 1
- Electrical scale 0-500 gm. capacity,
and 0.001 gm. accuracy with direct
scale reading 0-100 gms. fitted to
electrical system of laboratory. 1
- Pan type scale heavy duty solution
balance 0-20 kg., accuracy 1 gm.,
with scale. 1
- Set 0-1000 grams. weights. 1
- Even arm solution balance (direct
reading) 0-5000 gm capacity and
sensitivity 0.5 gm. 1
- Proctor penetrometer and case. 1
- 6in (0.15m) concrete cylinders
capping set. 1
- Motorized concrete diamond core drill
powered and equipped to take 4 (0.10m)
and 6 (0.15m) inch concrete samples 1
- All accessories and enough tools,
equipment and others as described
in the apparatus of the above
mentioned tests. 1
2.4 The Contractor shall provide calibration certificates every six months in addition to validity
certificates for the equipment.
2.5 In case some test can not be performed in the field laboratory, the Contractor may at the
approval of the Engineer arrange for carrying out the required tests in an approved laboratory at his own
expense.
1-22
2.6 Chemical, solvents, chemicals for speedy moisture capping compound, distilled water, pH
indicator, paper books and others shall be furnished in ample quantities proportional to the size of the
work.
2.7 Enough sample bags, thermometers with different ranges, glass beakers graduated, mixing pans,
moisture can, evaporating dishes, laboratory tongs, metric system caliper, sieve brushes, scoops, cutting
edges, dial gauges, flexible blade spatulas, spades for sampling, pick chisels, wash bottles, asbestos
gloves, tin sample boxes, graduated and un-graduated cylinders, straight edges, 6 cylindrical molds, etc.
2.8 Balloon density apparatus.
2.9 One dozen spare balloons.
2.10 200 pounds (90kg) of 40 Ottawa sand or equivalent:
2.11 The following Books:
(i) AASHTO Standard Specifications for Highway Materials and Methods of Sampling
and Testing part I and II, latest edition.
(ii) ASTM Standard for testing soils.
1.7.3 DELIVERY AND COMPLETION
1. The Contractor shall deliver the laboratory ready and complete for use of the Engineer and to his
satisfaction within sixty days of signing the Contract and before any work requiring material control and
laboratory testing is started.
2. The Engineer may at any time require tests run at any other approved Laboratory by the Client
such as CBR, pipe testing, steel, etc., or other tests not required to be supplied by this section. The
Contractor in such case shall, at his own expense provide the material and pay the nominal fees for tests
by the Client approved Laboratory. The Field Control Laboratory shall be, on delivery, under the direct
supervision of the Engineer’s Representative. The Contractor may use the laboratory after the approval of
the Engineer’s Representative.
1.7.4 MEASUREMENT
1. The Works prescribed in this section shall not be measured for direct payment, but shall be
considered as subsidiary Works, the costs of which will be deemed to be included in the Contract prices
for Pay Items.
1-23
MAINTENANCE OF BUILDINGS & UTILITY SERVICES SECTION 1.8
SECTION 1.8 : MAINTENANCE OF BUILDINGS & UTILITY

SERVICES
1.8.1 SCOPE
1. These Works shall consist of maintaining and providing all necessary and normal utility services
throughout the Contract Period, in respect of the following buildings:
1.1 Supervision Staff Residence and Office Building
1.2 Mobile Homes
2. All details and requirements for works under this section including maintenance duties, utility
services, adequacy of maintenance and utility services, and any other details shall be as given in the
Special Specifications.
1.8.2 MEASUREMENT
1. These Works shall be measured as the number of months for which maintenance Work has been
carried out, and utility services provided and maintained, as specified, and including the provision of any
necessary materials and fittings.

(1) Provide maintenance
and utility services
for the buildings specified Monthly Sum
1-24
PROVISION OF WORKMAN TO ASSIST ENGINEERS REPRESENTATIVE SECTION 1.9
SECTION 1.9 : PROVISION OF WORKMEN TO ASSIST

ENGINEER’S REPRESENTATIVE
1.9.1 SCOPE
1. These Works shall consist of the provision by the Contractor of skilled and semi-skilled
workmen in the numbers specified, to assist and work under the direction of the Engineer’s
Representative, on a monthly basis throughout the Contract Period.
2. Details and requirements under this section shall be as given in the Special Specifications.
1.9.2 MEASUREMENT
1. These Works shall be measured as the numbers of man-months of attendance on site, and
satisfactory performance in their duties, of skilled and semi-skilled workmen.

(1) Provide skilled workmen Man-month
(2) Provide semi-skilled

workmen Man-month
1-25
PROVISION OF VEHICLES FOR USE BY SUPERVISION STAFF SECTION 1.10
SECTION 1.10 : PROVISION OF VEHICLES FOR USE BY

SUPERVISION STAFF
1.10.1 SCOPE
1. These Works shall consist of the purchase and delivery to the Site of new Motor Vehicles of the
types and in the numbers specified, payment of all customs and clearance charges and fees, registration in
the Employer’s name, fully insured for the duration of the Contract, and handed over in undamaged
condition and fully operational in all respects, for use by the Engineer and his supervision staff.
2. Operating and maintenance costs, including provision of experienced drivers and including fuel
and consumables, will be the responsibility of the Contractor.
3. All vehicles shall be supplied new, and shall be covered, at all times during the contract period,
by an approved comprehensive insurance policy allowing it to be driven on the public highway by any
qualified driver.
4. The vehicles shall be maintained and served by the Contractor who shall bear all running costs
(fuel, oil, etc.) repair costs, insurance costs etc. and shall be kept in a first class condition by the
Contractor.
5. The Engineer and his Supervision Staff shall make careful use of vehicles and shall ensure that
any defects, or servicing requirements are promptly brought to the Contractor’s attention to assist in
keeping the vehicles in first class condition.
6. In the event of breakdown or repair casting longer than one day, a suitable replacement vehicle
(or vehicles) shall be provided by the Contractor to ensure that the Engineer has, at all times, the full
compliment for his use.
7. If the Contractor fails to provide an immediate replacement the Engineer reserves the right to
rent a suitable replacement car, all at the expense of the Contractor.
1.10.2 PURCHASE AND DELIVERY OF VEHICLES
1. Within two weeks of signing the Contract, the Contractor shall submit to the Employer,
catalogues, brochures, specifications and prices, etc. relating to the various types of motor vehicles
required. Details shall be supplied from at least three manufacturers unless a particular make of vehicle is
specified to be purchased.
2. The Contractor shall proceed immediately with the purchase of the vehicles selected by the
Employer and shall arrange for their delivery to the Site and hand over to the Employer fully operational
and ready for use by the Engineer.
3. All vehicles shall be delivered clear, registered and insured in the Employer’s name within 30
days, or as otherwise specified, after selection by the Employer of the types and makes of vehicles
required.
4. All supervision staff vehicles shall become the property of the Employer upon completion of the
contract.
5. In the event of any delay in handing over any vehicles, the Contractor shall immediately provide
on a temporary basis at his own expense, acceptable equivalent vehicles in new or near new condition for
sole use by the Supervision Staff. The operating and maintenance costs of all such temporary vehicles
shall be paid for by the Contractor.
1-26
PROVISION OF VEHICLES FOR USE BY SUPERVISION STAFF SECTION 1.10
1.10.3 MEASUREMENT
Motor Vehicles for Engineer and Supervision Staff shall be a Prime Cost Item and shall be measured by
the numbers of each type of new vehicle selected by the Employer, purchased, delivered, handed over to
the Employer and accepted. Payment of a certain percentage shall be added to the prime cost to cover
expenses, overhead, and profit.

(1) Vehicle (each type) No.
(2) Expenses, overhead and profit Percentage of prime cost
(3) Operation and Maintenance

of vehicle (each type) Vehicle-month
(4) Driver Man-month
1-27
FIRST AID CENTERS, ACCIDENT PROCEDURE AND PREVENTION SECTION 1.11
SECTION 1.11 : FIRST AID CENTERS, ACCIDENT

PROCEDURES AND PREVENTION
1.11.1 FIRST AID CENTERS
1. If specified in the contract documents, the Contractor shall furnish and erect or construct First
Aid Centers, complete with necessary utilities including telephone, and located on Site as agreed by the
Engineer. Each Center shall be fully equipped with first aid facilities and incidentals appropriate to its
intended use. The type of building proposed and the equipment to be provided shall be approved by the
Engineer and by the local medical Authorities, before installation.
2. Each Center shall be staffed by at least one trained attendant at all times during progress of the
Works. The attendant shall be responsible for administration of first aid to accident victims, contacting
emergency and ambulance services whenever necessary, and care of the Center and of all first aid
equipment.
3. First aid boxes, stretchers and blankets shall be stored adjacent to each working area. Blankets
and stretchers shall be protected from dirt and damp. First aid boxes and stretchers shall be inspected by
the attendant at regular intervals and any deficiencies made good promptly.
4. The Contractor shall keep detailed records of all accidents occurring during progress of the
Works and prominent notices shall be displaced in all working areas in Arabic and English detailing
accident procedures to be followed.
1.11.2 ACCIDENT EMERGENCY PROCEDURES
1. At the commencement of the Contract, the Contractor shall establish and agree with the
Engineer, procedures to be followed in the event of accident emergencies. When such procedures have
been agreed, they shall be drawn up in writing by the contractor in a concise form, in Arabic and English,
and displayed prominently at all sites and working areas. In drawing up these emergency procedures, the
Contractor shall consult and liaise with the local emergency and related services, including hospital, fire,
police, etc.
2. A clearly defined chain of authority shall be established and all responsible persons in the chain
shall be adequately briefed on their responsibilities. A list of responsible people defining their various
roles shall be drawn up in Arabic and English and displayed at the sites and working areas. Copies shall
also be issued to local emergency services.
3. Ambulance teams and other similar outside organizations may be called to the Site in
emergencies during the period of the Works and arrangements therefore be made for those concerned to
visit the Site and familiarize themselves in advance with access routes and any special procedures.
1.11.3 ACCIDENT PREVENTION
1. Safety Measures on Site
1.1 The Contractor shall, throughout the Contract period, have full regard for the safety of all
persons on the Site and shall maintain the Site (so far as it is under his control) in an orderly state
appropriate to the avoidance of accidents to all such persons.
2. Protective Clothing for Workers
2.1 All workers exposed to substantial risk shall be issued with protective clothing and personal
protective equipment suitable for the various tasks on which they may be engaged. The following list
provides a guide as to what are considered to be minimum requirements:
2.1.1 Head Protection: All persons shall wear protective helmets at all times whilst on Site.
1-28
FIRST AID CENTERS, ACCIDENT PROCEDURE AND PREVENTION SECTION 1.11
2.1.2 Foot Protection: Strong boots shall be worn at all times. Heavy rubber knee boots may
be appropriate.
2.1.3 Hand Protection: Suitable gloves shall be worn, particularly where the person is
exposed to possible cuts, burns, electric shock, or to corrosive and irritant substances.
2.1.4 Eye Protection: Safety goggles, face shields and fixed shields shall be provided as
appropriate for protection against flying particles, hazardous substances or injurious light rays.
Eye protectors shall always be worn by operators when sand-blasting, shot-blasting, air and
water cleaning, guniting, shotcreting, grinding or chipping metal, burning and welding. Unless
the risk is not significant, eye protectors shall also be worn by operators breaking, cutting or
drilling concrete or stone or similar material, and by operators injecting liquids under pressure.
2.1.5 Body Protection: Protective clothing shall be waterproof where appropriate. Special
clothing may be necessary for persons handling injurious substances and for persons using
welding or burning equipment.
2.1.6 Lung Protection: Masks or respirators shall be used where there is unavoidable short
term exposure to harmful fumes or dust. Ventilation or other methods of eliminating the hazard
shall be the primary safeguard.
1.11.4 MEASUREMENT
1. First Aid Centers shall be measured by the number furnished and erected, or constructed, at
approved locations, complete with all essential utility services including electricity, water, sewerage, and
material telephone connections, all necessary furniture and fittings and fully equipped with first aid and
emergency medical equipment.
2. Provision of First Aid Attendants shall be measured by the number of man months of attendance
on Site and satisfactory performance in their duties, of trained attendants.
3. Safety measures by Contractor and Protective Clothing for Workers shall not be measured for
direct payment, but shall be considered as subsidiary Works the cost of which will be deemed to be
included in the Contract prices for Pay Items.

(1) First Aid Center No.
(2) First Aid Attendants Man Month
1-29
CONTRACTOR’S PLANT AND EQUIPMENT SECTION 1.12
SECTION 1.12 : CONTRACTOR’S PLANT AND EQUIPMENT

1.12.1 GENERAL
1. Plant and equipment used on the Works shall be of sufficient size and in such mechanical
condition as to meet the requirements of the Specifications and shall be available for use when required
by the Engineer. The Engineer may order removal and replacement of unsatisfactory plant or equipment.
2. Wherever plant or equipment of a particular size or type is specified, the Contractor may request
permission to use an alternative type in place of that specified. In such cases, the Contractor shall furnish
evidence to the Engineer, before approval is given, that the production of the plant or equipment proposed
is at least equal to that of the specified type.
1.12.2 CONTRACTOR’S SCHEDULE OF PLANT AND EQUIPMENT
1. The Contractor shall submit together with his Tender, a detailed schedule of the numbers and
types of plant and equipment which he proposes to utilize on Site to carry out the Works. The schedule
shall contain full details for each item, including type, manufacturer, model, identification number, year
of manufacture, number of years in use, and, for all new and previously used items, the manufacturer’s
brochures, catalogs and specifications.
1.12.3 PROVISION AND USE OF PLANT AND EQUIPMENT
1. The Contractor shall furnish all plant and equipment listed in his Schedule and necessary for
construction of each phase of the Works. Such plant and equipment shall be delivered to the Site,
inspected, and approved by the Engineer prior to commencement of the particular phase of the Works for
which it is intended. Any plant or equipment, or part thereof, which becomes excessively worn or
defective shall be promptly repaired or replaced, as required by the Engineer.
2. The Contractor shall not remove from the Site any approved plant or equipment without the
permission of the Engineer.
1.12.4 MEASUREMENT
1. The Works prescribed in this Section shall not be measured for direct payment, but shall be
considered as subsidiary Works the costs of which will be deemed to be included in the Contract prices
for Pay Items.
1-30
MEASUREMENT PROCEDURES SECTION 1.13
SECTION 1.13 : MEASUREMENT PROCEDURES

1.13.1 GENERAL
1. All Works shall be measured net and in accordance with the General Conditions of Contract. All
units of measurement shall be in the Metric System, unless specified otherwise.
2. The method of measurement and computations to be used in determining quantities of materials

furnished and of Works performed shall be as defined in respective sections in the Specification.
3. All field measurements of quantities for monthly certificates and for final payment shall be made
by the Contractor in the presence of the Engineer. Original copies of the field measurement notes, signed
by the Contractor, will be retained by the Engineer.
4. If the Contractor fails to measure any Pay Items, the Engineer may, at his discretion, estimate
quantities of such items for the monthly Payment Certificate or recommend that no payment be made for
the Items not measured and quantities not computed until it is measured.
1.13.2 MANUFACTURED ITEMS
1. Whenever standard manufactured items are specified, such as fence wire, plates, rolled shapes,
pipe conduit, etc. and these items are identified by gauge, unit weight, section dimensions, etc., such
identifications shall be deemed to be nominal weights or dimensions. Unless controlled by tolerances in
cited specifications, manufacturing tolerances in cited specifications, manufacturing tolerances
established by the industries involved may be accepted by the Engineer at the recommendation of the
Libyan concerned authorities.
1.13.3 GAGE DESIGNATIONS
1. The term “gage” when referring to the size steel plate shall mean U.S. Standard Gage, except
when referring to galvanized sheets used in the manufacture of corrugated metal pipe, metal plate pipe
culverts and arches and metal cribbing, when “gage” shall be as specified in AASHTO M 36 or AASHTO
M 167, and when referring to wire when “gage” shall be as specified in AASHTO M32.
1.13.4 FITTINGS AND ACCESSORIES
1. When any Items are shown on the Drawings or specified as requiring miscellaneous fittings and
accessories for which no separate measurement is provided, the Pay Item will be deemed to include for all
such fittings and accessories.
1.13.5 WEIGHT MEASUREMENTS
1. All materials which are to be measured or proportioned by weight shall be weighed on accurate
and approved scales by competent and qualified personnel, at locations designated or approved by the
Engineer.
2. Trucks used to haul material being paid for by weight shall be weighed empty each day at such
times as the Engineer directs and each truck shall bear a plainly visible and legible identification mark.
3. Bituminous materials delivered by truck transport shall be measured by net certified weights or
volumes, subject to correction for loss or foaming.
4. Bituminous materials transported directly from the refinery to the Site may be measured at the
refinery with temperature compensating meters in lieu of weighing.
1-31
1.13.6 LINEAR AND AREA MEASUREMENTS
1. All items which are to be measured by linear meter, such as pipe culverts, guardrail, under-
drains, etc., shall be measured parallel to the base or foundation upon which such structures are placed,
unless otherwise shown on the Drawings.
2. Unless otherwise specified, longitudinal measurements for area computations shall be made
horizontally and no deductions shall be made for fixtures with an area less than one square .meter.
Transverse measurements for area computations shall be the neat dimensions shown on the Drawings or
as ordered by the Engineer.
3. No measurements shall be made of rolled down or sloping edges of bituminous courses.
1.13.7 VOLUME MEASUREMENTS IN VEHICLES
1. Materials to be measured by volume in the hauling vehicle shall be hauled in approved type
vehicles and measured therein at the point of delivery. Vehicles for this purpose may be of any size or
type approved by the Engineer, provided that the body is of such shape that the actual contents may be
readily and accurately determined. All vehicles shall be loaded to their level capacity and the Engineer
may require loads to be re-leveled when the vehicles arrive at the point of delivery.
2. When requested by the Contractor and if approved by the Engineer, material specified to be
measured by the m3. may be weighed and such. weights will be converted to m3. for payment purposes.
Factors for conversion from weight measurement to volume measurement will be determined by mutual
agreement between the Engineer and the Contractor, if no agreement is obtained, the factors will be
determined by the Engineer and shall be accepted by the Contractor.
1.13.8 EARTHWORK VOLUME MEASUREMENTS
1. The average end area method shall be used in computing quantities of earthworks, unless
otherwise specified in the Special Specification, except where the error exceeds plus or minus 5% when
compared with the results obtained using the prismoidal formula, in which case the Engineer will direct
the use of the prismoidal formula. The Contractor shall request such direction before he submits his
quantities for approval.
2. The quantities of excavation paid for under the Contract unit prices shall be limited to the lines
shown on the Drawings and on approved cross sections. Excavation beyond lines shown on approved
cross sections shall not be paid for unless approved by the Employer. Excavation in excess of approved
cross sections will be measured for payment only in the case of unsuitable materials ordered by the
Engineer to be removed.
3. The Engineer will adjust the angle of slopes for cuts and fills as the Works proceed and make
determinations of the appropriate slope angles following his evaluation of soil conditions in case there is a
change in the type of the soil. The actual slopes of the cuts as constructed shall be measured and recorded
by the Contractor. The Engineer will check these records and, if satisfactory, will approve the
measurements as a basis for payment.
4. Within 60 days of the date of field survey, the Contractor shall submit to the Engineer for his
approval, plots of the original and final earthwork cross sections together with the area and volumetric
earthwork computations. The Contractor’s cross sections shall be on transparent cross section sheets for
print reproductions. All sheets shall have a title block and be of the size designated by the Engineer. On
final approval of the Contractor’s cross sections, the Contractor shall submit the original transparencies
and 3 prints of each such transparency.
5. In case of any variations from the approved Drawings, the Contractor shall submit the original
and 2 copies of the plotted cross sections and profiles and the notes and computations of his survey. The
Contractor shall take cross sections at 20 m intervals along the centerline and at other locations if directed
by the Engineer, upon mutual agreement between the Engineer and the Contractor, the Contractor may
submit cross sections intermediate to these locations. The Engineer will indicate, on one copy, his
1-32
approval of the proposed lines of the Works or his revisions thereto and return such copy to the
Contractor. The Contractor shall resubmit for approval any cross sections the Engineer may have revised.
6. The Contractor may, as an alternate method of earthwork computation, request approval to use
an electronic computer. Such request shall include details of the computer hardware, the earthwork
software programs, the input and output, and a complete summary of the methods and procedures to be
used. The Contractor may use an electronic computer for computations, only if approved, and
continuance of such approval is contingent upon satisfactory results being achieved. If results are not as
represented or are otherwise deemed unsatisfactory, the Contractor shall recomputed the earthwork
quantities by the cross section method.
1-33
SCOPE AND BASIS OF PAYMENT SECTION 1.14
SECTION 1.14 : SCOPE AND BASIS OF PAYMENT

1.14.1 SCOPE OF PAYMENT
1. The Contractor shall receive and accept compensation provided for in the Contract as full
payment for all labor, materials, tools, equipment, organizational costs, insurance, shipping, duties and
other charges, overheads, profit, royalties, transport, handling, setting up, payments to others for land or
use of land or damage to property of others, all Temporary Works, incidental Works necessary for proper
completion of the Works and which are not paid for separately but are subsidiary to the Works of Pay
Items, including drainage to protect the Works during construction, haulage, tools, equipment, placement
of materials where specified or directed, sheeting, shoring, centering and supports, laboratory equipment
and personnel for testing, housing and facilities and all other items necessary for or usual to proper
execution, completion and maintenance of the Works.
1.14.2 BASIS OF PAYMENT
1. Quantities determined as specified under the “Measurement” Subsections shall be paid for at the
respective Contract prices per unit of measurement, for each of the particular Pay Items shown in the Bills
of Quantities, which prices shall be full compensation for furnishing all items necessary for proper
execution, completion and maintenance of the Works as prescribed in Subsection 1.14.1 “Scope of
Payment”.
2. Wherever any “Measurement” Subsection specifies that no measurement shall be made for direct
payment of Works prescribed in the Section, performance of such Works shall not be paid for directly but
shall be considered as subsidiary Works the costs of which will be deemed to be included in the Contract
prices for Pay Items.
3. Wherever a “Measurement” Subsection is omitted from any Section of these Specifications, the
Works prescribed in such Section shall not be measured for direct payment unless shown as Pay Items in
the Bills of Quantities, but shall be considered as subsidiary Works the costs of which will be deemed to
be included in the Contract prices for Pay Items.
4. If any accepted quantities vary from those shown in the Bills of Quantities, the unit prices paid
shall be determined as prescribed in the Conditions of Contract.
1-34
Part ( 2 ) :
Earthworks
Technichal Specifications Earthworks
CLEARING AND GRUBING SECTION 2.1
SECTION 2.1 : CLEARING AND GRUBBING

2.1.1 SCOPE
1. These Works shall consist of the removal and satisfactory disposal of all vegetation, surface
debris and scattered stones and rocks within the limits of the right-of-way (ROW), easement areas and
borrow pits (except items designated to remain or which are to be removed at a later stage of the Works).
2. Removal of structures and similar obstructions and removal of utilities shall be as specified in
Section 2.02 – “Removal of Obstructions and Utilities”.
2.1.2 CONSTRUCTION
1. The Contractor shall set out the approved construction limits and the Engineer will designate all
trees, shrubs, plants, vegetation, etc. and other items to remain within the ROW. The Contractor shall
carefully preserve all such items from damage or defacement.
2. All surface objects, trees, stumps, roots, stones and rocks (up to 0.2 m3 or 500kg individual size
or weight), and other protruding obstructions, not designated to be retained, shall be cleared or grubbed to
ground level. In case of trees of one meter or less girth should be removed entirely or at least one meter
below ground level or as instructed by the Engineer.
3. In areas to be rounded at the top of cut slopes, stumps shall be cut off below the surface of the
final slope line.
4. Grubbing along the lines of proposed channels and ditches shall be taken below final excavated
elevations.
5. Stump holes and other holes from which obstructions are removed within the ROW of
construction, shall be backfilled with suitable material and compacted in accordance with Section 2.06 –
“Embankment Construction”, and those holes which are outside the ROW shall be filled to the adjacent
level.
6. Perishable material shall be burned under the constant care of competent watchmen at such times
and in such a manner that any vegetation or other items designated to remain in the ROW, or other
adjacent property, will not be jeopardized. Burning shall be carried out in accordance with applicable
laws and ordinances.
7. Materials, stones, rocks, and debris which cannot be burned and perishable materials, shall be
removed from the ROW and disposed of at approved dumping areas off the Site, provided permission of
the respective property owners has been obtained in writing to dump such materials on their land. Where
designated on the drawings, the Contractor shall make all necessary arrangements with property owners
for obtaining written permission to dispose of materials, at his own expense.
2.1.3 MEASUREMENT
for Pay Items.
2-1
REMOVAL OF OBSTRUCTIONS & UTILITIES SECTION 2.2
SECTION 2.2 : REMOVAL OF OBSTRUCTIONS AND

UTILITIES
2.2.1 SCOPE
1. The Works shall consist of the removal, wholly or in part, and satisfactory disposal of all
buildings, fences, structures, abandoned pipelines, and any other obstructions, as shown on the Drawings,
which are not designated or permitted to remain, except for any obstructions as shown on the Drawings
which are to be removed and disposed of at a later stage of the Works. It shall also include the salvaging
of designated materials and backfilling the resulting trenches, holes and pits.
2. The Contractor shall examine the Site and record all obstructions and utilities at the
commencement of the Works, as specified in Subsection 1.03.6 – “Existing Utilities and Other
Obstructions”.
2.2.2 CONSTRUCTION
1. General
1.1 The Contractor shall raze, remove and dispose of all buildings, foundations, structures, fences
and other obstructions, any portions of which are on the ROW, except utilities and items for which other
arrangements for removal have been made. All designated salvageable material shall be removed, without
causing unnecessary damage, and in sections or pieces, which may be readily transported, and shall be
stored by the Contractor at approved locations, for later use or possession of others.
1.2 Unusable perishable material shall be destroyed. Non-perishable material may be disposed off
the Site, provided permission of the respective property owners has been obtained in writing to dump
such materials on their land.
1.3 Basements or cavities left by structure removal shall be filled to the level of the surrounding
ground and, if within the prism of construction, shall be compacted to the type of compaction within the
range for the adjacent roadway embankment as specified in Section 2.06 – “Embankment Construction”.
1.4 Salvaged, pipe culverts and other drainage structures shall be stored at accessible approved
locations on Site and shall become the property of the Employer.
2. Removal of Bridges, Culverts and Ditches
2.1 Bridges, culverts and other drainage structures in locations traversed by traffic shall not be
removed until approved arrangements have been made by the Contractor to maintain the flow of traffic.
2.2 Substructures shall be removed down to the elevations of the natural streambed. Those parts
outside the stream shall be removed 300 mm below natural ground surface. Where such portions of
existing structures lie wholly or in part within the limits for a new structure, they shall be removed to the
extent necessary to accommodate construction of the proposed structure.
2.3 Steel bridges and timber bridges, designated to be salvaged, shall be dismantled without causing
unnecessary damage. Steel members shall be match marked, unless this requirement is waived by the
engineer. All salvaged material shall be stored as previously specified for reuse or possession of others.
2.4 Blasting or other operations necessary for removal of existing structures or other obstructions,
and which may damage new construction in the vicinity, shall be completed prior to commencing the new
construction.
2-2
3. Removal of Pipes
3.1 All pipes unless otherwise directed shall be removed and precautions taken to avoid breaking or
damaging the pipes. The Contractor shall exercise utmost care during the removal of pipes so as to avoid
unnecessary damage.
4. Removal of Rocks and Boulders
4.1 Large rocks and boulders of individual size greater than 0.2 m3 or greater than 500 kg in
individual size or weight which lie within the limits of the Works, shall be removed and disposed of as
directed.
5. Removal of Fences and Gates
5.1 When fences and gates enclosing pasture land or farm land are to be removed, the Contractor
shall notify the Engineer sufficiently in advance to permit the property owner reasonable time to construct
alternative fencing or make other suitable arrangements.
6. Removal of Wells
6.1 Existing wells, abandoned or active, which lie within the limits of the Works, as shown on the
Drawings, shall be dismantled, backfilled, and compacted. All salvageable materials shall be removed and
stored at approved locations on Site. All salvageable material shall become the property of the Employer.
Wells shall be filled to the level of the surrounding ground and, if within the prism of construction, shall
be compacted after obtaining the Engineer’s permission to the type of compaction within the range
designated.
7. Removal of Utilities
7.1 The Contractor through the Engineer shall notify all Utility Owners and co-operate with them in
respect of removals and relocations.
7.2 Unless shown otherwise on the Drawings, realignment or relocation of active Utilities will be the
responsibility of the respective Owners and such Works will be coordinated by the Employer.
7.3 The removal of all disconnected or abandoned Utilities within the ROW shall be carried out by
the Contractor, unless the Utility Owner indicates his intention to carry out such removal and the
salvaging of materials, fittings, parts, etc.
7.4 The Contractor through the Engineer shall advise each affected Utility Owner in writing of his
proposed construction schedule and liaise with the Employer who will arrange for inspection by the
Utility Owners and interruption or disconnection of the Utilities as appropriate.
7.5 The Contractor shall be responsible for supporting and protecting realigned Utilities, and
existing Utilities that are to remain in place, for the duration of the Contract and shall provide all
necessary Temporary Works in this respect. Any damage caused to Utilities and attributable to the
Contractor shall be repaired at his expense.
7.6 All excavation and backfill shall conform with the requirements of Section 2.06 – “Embankment
Construction” and Section 2.09 – “Excavation and Backfill for Structures”, as appropriate.
2.2.3 MEASUREMENT
1. Removal and disposal of large rocks and boulders which exceed the requirements of sub-section
2.01.2 Clause 2 (page 2-1) shall be measured by m3 of “Unclassified Highway Excavation” as prescribed
in Section 2.03 – “Highway Excavation”.
2. Unless shown as Pay Items in the Bills of Quantities, the Works (other than removal and
disposal of large rocks and boulders) prescribed in this Section shall not be measured for direct payment,
2-3
but shall be considered as subsidiary Works the costs of which will be deemed to be included in the
Contract prices for Pay Items.
3. Where the Bills of Quantities contain a PROVISIONAL SUM for “Realignment or Replacement
of Utilities by Owners”, this sum will be used by the Employer to reimburse Utility Owners for approved
realignment or replacement Works carried out by such Owners or the Contractor and agreed with the
Employer.
(1) Realignment and Replacement PROVISIONAL SUM
of Utilities
(2) Removal of Buildings,

Fences, Pipes and Structures LUMP SUM
2-4
HIGHWAY EXCAVATION SECTION 2.3
SECTION 2.3 : HIGHWAY EXCAVATION

2.3.1 SCOPE
1. These Works shall consist of excavating material in the cut sections of the highway, including
watercourses, ditches and wadi relocations (but excluding borrow pits and structural excavation) all as
and where shown on the Drawings, and hauling the excavated material either to locations for highway
embankments or to stockpiles or to waste.
2. These Works shall also include any necessary excavations outside the ROW ordered by the
Engineer to safeguard and protect the Works. These may include diversion of existing wadi channels;
excavation of materials obstructing or impairing the flow along stream channels; and excavation of
unstable materials including dune sand which may slide or encroach into ditches or onto the ROW.
Disposal of all such excavated materials shall be as instructed by the Engineer.
3. As part of the “Inspection of Site” obligations under the Conditions of Contract, the Contractor
will be deemed to have satisfied himself, at the time of tendering, as to the type and nature of soils and
rock that will be encountered, and their location, suitability and sufficiency to meet the specified
embankment and other requirements.
2.3.2 CONSTRUCTION
1. Utilization of Excavated Materials
1.1 All suitable soils, rock, boulders and other materials complying with Tables 2.1 and 2.2 shall be
excavated in such a manner that they can be utilized, if intended to be used, as embankment fill or in
subgrade, shoulder or elsewhere as appropriate.
Table 2.1: Soil Suitable for Embankment
1 - Maximum dry density not less than 1.7 (T-180D)

2 - Organic matter not more than 5% (T-267)
3 - No use of A-6, A-7 soil (AASHTO M-145)
4 - Maximum size not more than 2/3 of the layer thickness
5 - No use of high to medium expansive soil
6 - C.B.R. should not be less than 8% (AASHTO T-193)
Table 2.2: Rock Fill Suitable for Embankment
1 - Size 25% larger than 30 cm

2 - Size 50% larger than 7.5 cm
3 - Bulk specific gravity not less than 2.25
4 - Water absorption not more than 6%
5 - Testing by
a) plate bearing test
b) surveying method
6 - Filling material should not be A-6, A-7 soil (AASHTO M-145)
2-5
1.2 If the Contractor chooses to excavate suitable material to waste or put it to other uses, and
replace it by borrow excavation for embankment areas, this shall be undertaken at no extra cost to the
Employer.
1.3 Materials such as existing concrete, bituminous or other surfaces or other materials shall, if
shown on the Drawings, be stockpiled for a specific purpose or for future use. Such materials shall be
excavated and handled in a manner that will exclude foreign or undesirable material. Stockpiles shall be
neatly formed and maintained in an approved manner.
1.4 Suitable topsoil material if specified shall be stockpiled during excavation operations and shall
subsequently be spread and compacted on embankment slopes and elsewhere as directed, to facilitate re-
growth of vegetation.
2. Drainage of Excavation Areas
2.1 During construction, surfaces in excavation areas shall be adequately drained at all times. Side
ditches or gutters emptying from cut to embankment shall be so constructed as to avoid damage to
embankments by erosion.
2.2 The Contractor shall, at an early stage of the Works, provide adequate drainage by scheduling
ditch and other construction so as to prevent saturation or erosion of embankments and cut slopes. All
such drainage ditches and construction grades shall be cleaned and trimmed at regular intervals and when
directed so that there will be an unobstructed runoff of stormwater during construction.
2.3 Damage to the Works attributable to saturation or erosion through failure to provide adequate
drainage shall be repaired by the Contractor at his own expense.
2.4 Whenever groundwater is encountered which may adversely affect construction, the Contractor
shall advise the Engineer who will evaluate the situation and order necessary remedial measures.
3. Obliteration of Disused Roadways
3.1 obliteration of roadways which are no longer in use shall include filling of all ditches and rough
grading of the old roadway to produce within the ROW a neat and well drained ground surface.
4. Rock Blasting
4.1 When blasting of rock slopes is carried out, a reasonably uniform face shall be left, regardless of
whether or not the excavation is carried beyond the specified side slopes. All breakage and slides shall be
removed by the Contractor and disposed of as directed.
4.2 Unless otherwise approved, all excavation of rock cuts higher than 4.5m and requiring blasting
for their excavation, shall be carried out in accordance with the requirements of Section 2.05 – “Pre-
splitting Rock Cuts”.
4.3 All drilling and blasting shall be done in such a manner as will most nearly complete the
excavation to the required grade lines, and produce the least practicable disturbance of the material to be
left in place. Blasting by means of drill holes, tunnels, or any other methods shall be entirely at the
Contractor’s risk. All requirements and obligations of Subsection 1.03.13 – “Use of Explosives” shall be
strictly observed.
4.4 Where necessary or directed, the Contractor shall provide heavy mesh blasting mats for
protection of persons, properties, and the Works. If, in the opinion of the Authorities and the Engineer,
blasting would be dangerous to persons or adjacent structures, or is being carried out in an unsafe or
unacceptable manner, the Engineer may prohibit blasting and order the rock to be excavated by other
means.
4.5 If the flow of traffic is to be interrupted during blasting operations, the Contractor shall secure
approval of his schedule for such interruptions and his proposed methods for safeguarding the public and
property.
2-6
4.6 Excessive blasting will not be permitted. Over-breakage and the backfilling thereof shall be at
the Contractors expense. Any material outside the approved cross section limits which may be shattered
or loosened because of blasting shall be removed by the Contractor at his own expense. All rock slopes
with loose material shall be scaled by workmen and all loose material removed.
4.7 Backfilling of over-breakage shall be carried out as directed, using approved soil or crushed
materials or other special aggregate, as shown on the Drawings. Un-drained pockets shall not be left in
the surface of the rock.
5. Excavation of Unsuitable Material
5.1 Where excavation to finished grades and cross sections exposes unsuitable material in the
subgrade, slopes or ditch inverts, etc the Engineer may require the Contractor to remove the unsuitable
material and backfill the excavated areas using approved material. The Contractor shall conduct his
operations in such a way that necessary cross section measurements are taken before such backfill is
placed.
5.2 The Engineer may designate as unsuitable, soils that cannot be properly compacted in
embankments. Unsuitable material shall be disposed of as directed. Wasted unsuitable material shall not
be deposited on any cropland.
5.3 When the Contractor is directed to excavate unsuitable material below the surface of the original
ground in fill areas, other than that required for clearing and grubbing, the depth to which unsuitable
material shall be removed will be determined by the Engineer. The Contractor shall schedule the
excavation so that cross sections are taken before and after material has been removed.
6. Slopes, Subgrade and Ditches
6.1 All excavated slopes, subgrade and ditches shall be finished true to lines, grades and cross
sections as shown on the Drawings.
6.2 Slopes, except in solid rock or other material which require special treatment, shall be trimmed
to slopes not steeper than the specified slope angles and rounded at top and bottom to a smooth profile to
blend in with the adjacent terrain. Material shall not be loosened beyond the specified slope lines.
6.3 In cuts where earth overlays a rock formation, slopes shall be benched in an approved manner.
6.4 Ditches of all types shall be excavated and trimmed neatly in conformity with the specified
grades and cross sections. All projecting rock, stumps, roots or similar shall be removed. Ditches include
side ditches, furrow ditches, irrigation ditches, wadi relocations, etc.
6.5 Where the subgrade is composed of rock as defined in Section 2.07 – “Subgrade Construction
and Topping”, it shall be undercut to a depth of 200 mm below top of subgrade to allow for subsequent
placing and compaction of the subgrade layer (topping).
6.6 The subgrade in cut, where the soil is unsuitable for retention as the subgrade layer, shall be sub-
excavated to a depth of 200 mm below top of subgrade to allow for subsequent placing and compaction of
the subgrade layer (topping). If the material of the subgrade is suitable for retention as subgrade layer
then scarify to the required depth, water and compact.
6.7 The Engineer will periodically check all or any part of the Works, to determine conformance to
the correct lines, grades and elevations. Tolerances on finished subgrade elevations of the surface at the
underside of the subgrade layer, shall be as specified in Section 2.07 – “Subgrade Construction and
Topping”.
7. Unstable materials Outside Right-of-Way
7.1 Materials, including sand dunes, outside the ROW or ditch slopes which, in the opinion of the
Engineer, are potentially unstable and liable to slide or encroach into the ROW or into the ditches, shall
be excavated and disposed of as specified for unsuitable material, unless it is approved for use as
embankment fill.
2-7
8. Disposal of Unsuitable and Surplus Materials
8.1 Unsuitable and surplus materials disposed of elsewhere than within the ROW shall be spread,
leveled and shaped as directed so as to present a neat and tidy appearance. No materials shall be disposed
of in such a way as to adversely affect natural drainage courses or to cause damage to the highway or
adjacent public or private.
8.2 If approved by the Employer, Government land can be used for disposal to the maximum extent
practicable. If private land is use for disposal, the Contractor shall secure the consent of the landowner or
tenant and, if necessary, and at his own expense, pay for the use of such land. The use of cropland for
disposal purposes will not be permitted.
2.3.3 Measurement
1. All excavated material of whatever type (except for unauthorized rock undercut below top of
subgrade) shall be measured as “unclassified” which shall be deemed to include all materials encountered
of any nature, including silts, clays, sand, gravel and granular materials and fractured, jointed and solid
rock, and unsuitable material.
2. Highway Excavation shall be measured by m3 of material excavated, hauled away and either
wasted, stockpiled, or deposited on or in vicinity of highway embankment areas, completed and accepted.
Measurements shall be of volumes computed from the cross sections shown on the Drawings and the
original ground elevations taken jointly by the Consultant and the contractor before clearing and grubbing
operations.
3. Ditch Excavation shall be measured by linear meter of each type excavated and trimmed to
required line, grade and cross section, including depositing excavated material along the side of ditch if
directed or hauling away and wasting, stockpiling or depositing on or in the vicinity of highway
embankment areas, completed and accepted.
4. Excavation on Unstable Material (from areas outside the ROW) shall be measured by m3 of
unstable or sand dune material excavated, hauled away and disposed of as directed, completed and
accepted. Measurements shall be of volumes computed from surveyed cross sections of original and final
ground elevations. When cross sectioning is impractical in the opinion of the Engineer, approval may be
given to measure volumes in the vehicles removing such excavated material.
5. Rock blasting, backfilling of over-breakage, the trimming and grading of cut slopes, ditches and
of other below-subgrade surfaces, drainage of excavation areas, obliteration of disused roadways, and
other ancillary excavation Works shall not be measured for direct payment, but shall be considered as
subsidiary Works the costs of which will be deemed to be included in the Contract prices for Pay Items.

(1) Unclassified Highway Excavation Cubic meter (m3)
(2) Unclassified Ditch Excavation

(each type) except side ditches Linear meter
(3) Excavation of Unstable material

outside Right-of-Way Cubic meter (m3)
2-8
BORROW EXCAVATION SECTION 2.4
SECTION 2.4 : BORROW EXCAVATION

2.4.1 SCOPE
1. These Works shall consist of excavating suitable material from borrow pits, channels and
designated borrow areas and hauling to locations for highway embankments or to stockpiles, all as and
where shown on the Drawings, or as approved by the Engineer.
2. The Contractor shall be responsible for the location of suitable borrow pits if and when required,
and for the suitability and sufficiency of borrow materials to meet the specified embankment and other
backfilling requirements.
3. Borrow pits shall be utilized if there is insufficient suitable excavated material to satisfy the
embankment and other backfilling requirements or if the Contractor chooses to excavate suitable material
to waste or put it to other uses, and replace it by suitable material excavated from borrow pits.
2.4.2 LOCATION OF BORROW PITS
1. Borrow pits in the vicinity of the Row shall have their location approved by the Engineer.
Generally the borrow pits shall not be located within 50m from the toe of embankment slope or top of cut
or formed slope, unless otherwise approved by the Engineer. In water courses Borrow pits shall be only
located Down stream.
2. In each case where a borrow pit is proposed within privately-owned property, the Contractor
shall secure the consent of the landowner in writing and, if necessary and at his own expense, pay for the
use of the material and land. The Contractor shall be responsible for any claims for compensation or
complaints arising out of borrow pit operations and shall indemnify and keep indemnified the Employer
against all such claims.
3. The side slopes of borrow pits or channels shall be constructed as shown on the Drawings or as
directed. In no case shall the side slopes of borrow pits be steeper than 3:2 (H:V).
4. Details of the Contractor’s proposed haul routes and traffic arrangements in relation to borrow
pit operations shall be submitted for approval before any borrow excavation commences.
5. Overburden and any unsuitable top layers within each borrow pit shall be completely removed
and stockpiled in the vicinity, ready for re-use prior to abandonment of the pit.
6. Prior to abandonment of any borrow pit or borrow area, the Contractor shall spread and level the
original overburden over the exposed surfaces and clean up, grade and contour the pit or area and the
adjoining properties occupied during execution of borrow operations, whether Government-, or privately-
owned, all to the satisfaction of the Engineer.
2.4.3 BORROW MATERIAL
1. Borrow shall be material approved as meeting the requirements for the particular embankment,
backfill or other use for which the material is intended.
2. The Contractor shall submit representative samples of materials from each of the proposed
borrow pits or borrow areas. Testing shall conform with the relevant requirements of Section 1.05-
“Control of Materials and Standards for Sampling and Testing” and that listed on Table 2.3 No. borrow
material shall be used in the Works before its approval.
3. The Engineer will periodically require follow-up testing of borrow materials in accordance with
Table 2.3 to verify that no change in quality has occurred since the original approval.
2-9
BORROW EXCAVATION SECTION 2.4
Table 2.3: Required Tests and Minimum Repetition for Earthworks at the Source of Materials
Description all Tests Required Tests Repetitions Required

1. Classification of materials
as per AASHTO * One test for each borrow pit
Embankment (at -0.8m from P.G.L 2. Any other test as required or suitable cut area for fill
and downward) in Special Specifications and
Drawings * When material changed
3. C.B.R
1. Gradation of material * One test for each borrow pit
2. Plasticity index or suitable cut area for fill
Subgrade and shoulders (upper three
3. Any other test as required
layers, between -0.2 to -0.8m from
in Special Specifications and * or for each 400m3
P.G.L and downward)
Drawings
4. C.B.R * When material changed
1. Gradation of material
2. Plasticity index
* Test for each source
Selected topping -0.2m from P.G.L
in Special Specifications and
* When material changed
Drawings
4. C.B.R
2.4.4 MEASUREMENT
1. No measurements shall be made of any borrow pits or of any excavation from borrow pits.
2-10
PRE-SPLITTING ROCK CUTS SECTION 2.5
SECTION 2.5 : PRESPLITTING ROCK CUTS

2.5.1 SCOPE
1. These Works shall consist of pre-splitting rock cuts to produce a uniform plane of rupture to that
the resulting back-slope will be reasonably even with no overhang or protrusions, in close conformity to
the lines and slopes shown on the Drawings and shall not be altered by subsequent blasting and
excavation operations.
2. Pre-splitting involves the establishment of a free surface or shear plane by the controlled use of
explosives and blasting accessories in appropriately aligned and spaced holes.
2.5.2 CONSTRUCTION
1. Faces of all cut slopes 1:2 (H:V) or steeper, exceeding 5m in height and which require blasting
to excavate, shall be formed by “pre-splitting” unless otherwise directed. Pre-splitting techniques for
forming the faces of other formations, which could be excavated by means not requiring blasting, may be
ordered by the Engineer.
2. Pre-splitting shall be by line drilling bore holes of 50 mm to 100 mm diameter at uniform

intervals along the staked slope line. Except for required offsets, hole alignment shall be such that at no
point does the hole deviate more than 300 mm from the staked slope line. Localized irregularities of
surface variations that do not constitute a safety hazard or an impairment to drainage courses or facilities
will be accepted.
3. Where the depth of cut to be pre-split exceeds 10m, the cut shall be drilled, blasted, and
excavated in 2 or more lifts, unless otherwise approved by the Engineer. When 2 or more lifts of drilling
are required, the staked slope line for the top lifts shall be set back from the slope line of the underlying
lift a distance of 0.5m to permit operation of drilling equipment for each succeeding line of drilled holes.
Where benching is required, primary blasting holes shall not be drilled to an elevation lower than the pre-
split line holes.
4. The distance between the closest line of primary blasting holes and the line of pre-split holes
shall be determined during the blasting test. The distance and primary blasting charge shall allow for
proper fragmentation but over-breakage behind the pre-split line will not be permitted, and in no case
shall the distance be less than one meter.
5. Prior to starting drilling operations for pre-splitting, the Contractor shall submit a layout plan
outlining the position of all drill holes, depth of drilling, type of explosives to be used, loading pattern,
and sequence of firing. The drilling and blasting plan is for record purposes only and shall not absolve the
Contractor of his responsibilities in respect of proper drilling and blasting procedures.
6. The Contractor shall drill, blast and excavate short test sections, not exceeding 30m in length in
each geological formation, to determine the controlled blast method, hole spacing, and charge best suited
to the material encountered. The Contractor shall utilize a 0.75m pre-split hole spacing for the initial test
section. In order to obtain the desired rock fracture, necessary adjustments shall be made and approval
obtained before proceeding with full scale drilling and blasting operations.
7. Only standard cartridge explosives prepared and packaged by explosive manufacturing firms or
other authorities shall be used in slope holes. These may consist of fractional portions of standard
cartridges to be fixed to the detonating cord in the field or solid column explosives jointed and fixed to
the detonating cord in the field or solid column explosives jointed and fixed to the detonating cord in the
field. Ammonium nitrate, fuel oil type explosives shall not be used in the holes drilled for controlled
blasting along the slope line.
8. A 15m minimum horizontal length of finished pre-split rock slope depth shall be produced prior
to any primary blasting.
2-11
PRE-SPLITTING ROCK CUTS SECTION 2.5
9. Prior to detonation of any charge, the Engineer shall be notified and kept informed of all
activities and movements of traffic within and adjacent to the area where the Works are being performed.
10. The Engineer may order discontinuance of the pre-splitting operations when the rock formation
is of such character that, in his opinion, no advantage is apparent.
11. Methods other than pre-splitting, which will assure cleanly sheared rock faces and control of
over-break, may be used only if approved. Such approval may be withdrawn by the Engineer at any time
if subsequent results are found to be unsatisfactory.
2.5.3 MEASUREMENT
for the Pay Items.
2-12
EMBANKMENT CONSTRUCTION SECTION 2.6
SECTION 2.6 : EMBANKMENT CONSTRUCTION

2.6.1 SCOPE
1. These Works shall consist of constructing highway embankments, including preparation of the
areas upon which they are to be placed; placing and compacting approved material within areas where
unsuitable material has been removed; and placing and compacting approved embankment material in
holes, pits and other depressions within the right-of-way area, all in accordance with the lines, grades and
cross sections shown on the Drawings.
2.6.2 MATERIALS
1. Material specified in Table 2.1 or in the A-1, A-2-4, A-2-5 or A3 “when confined” groups as in
AAHSTO M145 shall be used when available except for rock fill embankments, if material of this
character is not available then materials from A-2-6, A-2-7, A-4, A-5, groups (AASHTO M145) or that
specified under ‘Special Specifications’ may be used provided it complies with Table 2.1; however,
special attention should be given to the design and construction. Materials classified as A6 or A7 shall not
be used.
2. The 200m depth of embankment immediately below the topping layer shall consist of material
having a 4-day soaked CBR of at least 15% when tested in accordance with AASHTO T 193 and with a
gradation and P.I. as specified under Section 2.07 – “Subgrade Construction and Topping”.
3. The 600mm depth of embankment immediately below the topping layer shall consist of material
having a 4-day soaked CBR of at least 15% when tested in accordance with AASHTO T 193 with PI not
more than 15, If not rock fill. If rock fill material is used for the Bottom 400mm then those requirement
shall apply to the top 200mm.
4. In areas subject to flooding and prolonged inundation of the embankment, such as at bridge and
culvert sites, the material used in embankment, unless rock, shall conform to AASHTO M 145, Class A-
1-a, A-1-b, A-2-4.
5. Where embankments are to be constructed using fine wadi materials or sand dune materials
subject to side slope erosion or requiring confinement for stabilization purposes, the embankment plating
or confining layer shall be constructed using AASHTO M 145 Class A-1-a, A-1-b, or A-2-4 materials or
as otherwise approved.
6. The material used in rock-fill embankments shall consist predominantly of rock fragments of
such size that the material can be placed in layers of the thickness prescribed conforming to requirements
stated on Table 2.2.
7. Rock-fill material shall be obtained from roadway or tunnel excavation and shall be sound,
dense, hard and durable rock capable of being spread and compacted as specified. Individual pieces are to
be clean and angular. It shall be the contractor’s responsibility to excavate material from rock cuts,
whether by blasting or other manner, so that all excavated materials are of suitable size.
8. When suitable materials of widely divergent characteristics are drawn from different sources,
such materials may, if approved, be mixed to meet the embankment requirements. Rock and other
materials shall be incorporated in such manner as to avoid segregation and an accumulation of boulders,
etc at the toe of embankment slopes.
9. Logs, trees, stumps, weeds, heavy grass, frozen soil, vegetable matter or other undesirable and
non-compactable materials shall not be placed in embankments.
10. Rocks, broken concrete or other solid materials larger than 100mm in any dimension shall not be
used as backfill in areas where piling Works are to be carried out
2-13
2.6.3 CONSTRUCTION
1. General
1.1 Prior to placing embankment material on any area, it shall have been cleared and grubbed as
specified in Section 2.01 – “Clearing and Grubbing”, and the foundation prepared as specified herein.
1.2 Equipment used for foundation preparation and for placing, spreading and compacting
embankment materials shall be of approved types and furnished in sufficient numbers for the purposes
intended. Provision and use of such equipment shall conform with the relevant requirements of Section
1.12- “Contractor’s Plant and Equipment” and with the Contractor’s approved Work Program.
1.3 Draglines shall not be used to construct embankment unless approval is given and only when
special procedures are adopted to keep the layers uniform and the embankment properly graded and well-
drained at all times
1.4 Surfaces of embankment layers shall be kept properly shaped and drained at all times. The
Contractor shall utilize a sufficient number of motor graders or tractors to level and maintain the surface
of each layer of embankment during all placing and compacting operations.
1.5 Rock-fill shall not be used in the top 20cm of the embankment (below the topping). Water must
be added as required, and with the approval of the Engineer, to achieve maximum compaction.
1.6 Whenever feasible, trucks, scrapers, tractors and other heavy hauling equipment shall be routed
over the embankment in such a manner as will contribute effectively to compaction of the fill material.
1.7 Where an embankment is to be constructed over an area previously occupied by a building

basement, cellar, irrigation canal, well, any previous excavation, or adjacent to structures, and where the
proper use of normal compaction equipment is not practicable, the embankment shall be constructed and
compacted in accordance with the backfilling requirements of Section 2.09 – “Excavation and Backfill for
Structures” until the use of normal compaction equipment is practicable. Layers shall not exceed 200mm
thickness (after compaction) and shall be compacted to the degree of compaction specified for the
embankment.
1.8 Each embankment layer shall be tested and approved prior to placing the following layer. At
least one field density test shall be carried out for every 1500 square meters of each compacted layer.
1.9 The Engineer may at any time order suspension of delivery of materials to the embankment Sites
until previously delivered materials have been properly placed and preceding layers are leveled and
uniformly compacted to the specified density.
1.10 Unacceptable material placed in any embankment shall be removed and disposed off by the
Contractor at his own expense.
1.11 The Contractor shall be responsible for the stability of all embankments and shall replace all
embankment sections which, in the opinion of the Engineer, have been damaged or displaced due to
carelessness or neglect on the part of the Contractor, or due to normally occurring natural causes, such as
storms, and not attributable to the unavoidable movement of the natural ground upon which the
embankment is constructed.
1.12 All embankment side slopes shall be neatly finished true to the lines and not steeper than the
slope angles as shown on the Drawings. The bottom (toe) of side slopes shall be graded to a well rounded,
smooth profile to blend in with the adjacent terrain.
1.13 The side slopes of rock-fill embankments shall be thoroughly blanketed with A-1, A-2-4
material, and compacted to the satisfaction of the engineer.
1.14 The Engineer may permit the Contractor to utilize suitable surplus material at his own expense to
widen embankments or flatten slopes, etc within the right-of-way. Surplus material used in such manner
shall be compacted to 90 per cent of maximum density, but this shall not be measured for payment. When
2-14
widening embankments, the Contractor shall bear the cost of modifying the culverts and any protection
work necessary.
2. Trial Embankment Sections
2.1 Prior to commencement of embankment construction, the Contractor shall construct trial
sections of embankment, for each significant soil category (excluding rock) to be encountered along the
line of the highway. Each trial section shall be 2 lanes wide by 100m long at approved locations on or
adjacent to the Site.
2.2 Compaction and other equipment used shall be as specified and listed in the Contractor’s
Equipment Schedule and approved Program of Work. These field moisture content of the different soils
and the relationship between the number of compaction equipment passes and density attained.
2.3 The initial sections of highway rock embankment shall serve as the trial sections for rock fill, in
order to establish the optimum degrees of consolidation for the different layer thickness. This shall be
obtained by compaction trials correlating number of passes of the roller with settlement of the layer, or by
different approved methods. The maximum permitted layer thickness shall be related to the unit weight of
the vibratory roller and for compaction, as given in Table 2.4, and shall not exceed 100cm loose
thickness.
Table 2.4: Maximum permitted layer thickness

Maximum Thickness of Layer
Minimum Roller Mass* (Kg/m Width)
( Loose Thickness )
40cm 2300 - 2900
60cm 2900 - 3600
80cm 3600 - 4300
over 100cm 4300 - 5000
* For multiple rollers, this shall be assumed as the high axle load
3. Foundation Preparation
3.1 If the original surface upon which embankment is to be placed is an existing roadbed, the surface
shall be plowed, scarified or otherwise broken up regardless of the height of the embankment to be placed
thereon.
3.2 Clearing and grubbing, and removal of tree stumps, shall be undertaken. The degree of
compaction for the area to be cleared shall then be determined. The top 150mm of the surface on which
the embankment, of less than 1.5m height is to be placed shall be scarified, brought to a uniform moisture
content within the specified range, and compacted to the density specified for the embankment.
3.3 Where embankment is to be placed and compacted on hillsides or where new embankment is to
be compacted against embankments or where embankment is built part width at a time, the slopes steeper
than 3:1 (H:V) when measured at right angles to the highway centerline shall be continuously benched as
the embankment is brought up in layers. Benching shall be of sufficient width to permit operation of
spreading and compaction equipment, and in any case not less than 2m wide except where insufficient
width is available between existing and new embankments. Each horizontal cut shall begin at the
intersection of the original ground and the vertical sides of the previous cuts. The vertical face of each
bench shall not be less than 1m in height and not exceed 2m. Authorized benching shall be measured as
highway excavation.
3.4 Where embankment is to be placed and compacted on wadi slopes, the entire slope area shall be
graded and trimmed to remove any vertical faces and overhangs. The final graded slope shall not be
steeper than 1.5:1 (H:V). The slope shall then be continuously benched as the embankment is brought up
in layers, all as described above for embankment on hillsides.
3.5 All surfaces to receive rock-fill are to be cleared and all vegetation removed off site before
filling is placed. All unsuitable soil shall be removed to a depth as required by the Engineer. Soil surfaces
2-15
are to be scarified and re-compacted to at least 95% of the maximum dry density as modified AASHTO
(T-180). Compaction is to be to a depth of at least 200mm below ground surface. Hard or smooth surfaces
are to be roughened before filling is placed. Existing road surfaces and the like are to be broken up and
removed.
3.6 Rock-fill shall not be placed on any slopes steeper than 1:1. All slopes steeper than 1:1 shall
therefore be regarded to a slope of 1:1 or shallower and all vertical faces and overhangs removed.
4. Embankment Construction
4.1 Roadway embankment consisting of soil or granular material shall be placed in horizontal layers
not exceeding 250 mm thickness (before compaction), shall be compacted as specified and shall be
approved prior to placing the next layer. The thickness of the first layer over areas of Class A3 dune sand
may exceed 250 mm in order to bridge these areas. Approximately uniform thickness of each layer shall
be achieved prior to compaction. As the compaction of each of each layer shall be carried out to ensure
uniform density. The correct moisture content shall be maintained at all times.
4.2 Where embankments are to be constructed to a height in excess of 1.5m above top of original
ground level the Engineer may approve layer thickness up to 300 mm (after compaction) if the
Contractor’s equipment and the nature of the material result in the required density throughout the layer
thickness.
4.3 When the moisture content of the embankment material does not fall within the required
moisture range, (optimum moisture 2% water shall be added and thoroughly mixed into the soil by
approved methods or the material shall be aerated, whichever is necessary to adjust the material to the
required moisture content.
4.4 When water is added to embankment material, the amount added shall be sufficient to provide a
moisture content within the required range plus a unavoidable losses. Water added in excess of this
amount shall be removed by aeration or other approved means at the Contractor’s expense. Satisfactory
methods and sufficient equipment shall be used for the furnishing and handling of the water in a manner
that will minimize loss due to evaporation or waste.
4.5 Embankments that consist of rock-soil material with sufficient soil to make rolling feasible, shall
be placed and compacted in an approved manner and to the required degree of consolidation. Water shall
be added as and when directed to assist in the compaction of such materials.
4.6 In the case of embankments which are to be formed of approved rock - soil material containing
an appreciable quantity (normally not exceeding 30% greater than 80mm) of rock fragments and which
cannot be placed in layers of the thickness prescribed without crushing, pulverizing, or otherwise
breaking down the fragments, the embankment may be constructed in layers not exceeding in thickness
twice the average size of the largest rock fragments and in any case not exceeding 600 mm (before
compaction).
4.7 Rock-fill materials shall be placed in such a manner that the larger rocks are well distributed and
the voids are filled to the maximum practical extent by smaller particles, each layer shall be bladed into a
neat and homogeneous mass prior to compaction. Any rocks found protruding from the leveled surface
shall be removed and replaced by smaller particles. Initial breakdown compaction shall be performed with
heavy bulldozers. After compaction each layer must be tested, using either the Survey Test or the Plate
Bearing test, and approved by the Engineer before the next layer is placed. Survey test shall be carried out
for each layer while plate bearing test shall be carried out for every second layer. The top two layers shall
be tested by both methods. if plate bearing test result shows successive satisfaction result then the
engineer could reduce the number of repetitions of such tests. Oversize rock pieces may be used in high
rock-fill embankments to a level 3 meters below sub-base. When rock fragments of size exceeding
600mm are used , they should be covered.
2-16
2.6.4 TESTING
1. General
1.1 The Engineer shall test the compaction of soils and the consolidation of rock and rock-soil
materials in accordance with these Specifications to ensure that adequate compaction or consolidation has
been achieved. All such tests shall be fully documented by the Contractor, in an approved manner.
1.2 In the case of cohesion-less, free draining rock-soil materials, where maximum density tests fail
to produce a well defined moisture – density relationship, the relative density test shall be used,
alternatively an electronic compaction meter or any other approved test equipment shall be provided by
the Contractor and used to determine the degree of consolidation achieved.
1.3 To determine the degree of consolidation for embankment consisting of rock fill, average
differential settlement values shall also be determined from surveys of an adequate number of grid point
elevations as and when directed, at the commencement of, during and after embankment construction. For
full details of the method (The Survey Test) refer to clause 3, page 2-24. Degree of consolidation for rock
materials.
1.4 If it is required to determine the modulus of soil reaction by the Plate Bearing test, this shall be
undertaken using the method given in AASHTO T222-81 (1986).
2. Standards of Compaction for Soil and Granular materials
2.1 The following compaction standards shall apply to embankment materials other than
predominantly rock materials. The “maximum density” of soil type materials shall be the modified
maximum density determined in accordance with AASHTO T 180 (Method D). The “relative density”
shall be the relative density determined in accordance with ASTM D2049, which identifies the state of
compactness of the material with respect to its loosest and densest state. The relative density shall be the
standard to which the field density is referred for comparison in the case of cohesion-less, free draining
granular materials.
2.2 Soil type materials shall be compacted to at least 95% modified maximum density for the full
depth of embankment. The 600 mm of embankment material immediately below the topping layer shall
be compacted to at least 100% modified maximum density. Moisture content shall be within plus or
minus 2% of optimum at the time of compaction.
2.3 Cohesion-less, free draining granular materials (of 75 mm maximum size and with not more than
15% passing 0.075 mm (No. 200 sieve) shall be compacted to at least 75% of relative density for the full
depth of embankment. The 600 mm depth of such material immediately below the topping layer shall be
compacted to at least 80% of relative density.
2.4 Minimum in-situ soil tests required during the construction of embankment are listed on
Table 2.5.
2.5 All suitable surplus material utilized to widen embankments or flatten slopes, etc within the
right-of-way shall be compacted to at least 90% modified maximum density.
3. Degree of Consolidation for Rock Materials
3.1 To ensure proper compaction of rock-fill embankments, the contractor shall be required to
conduct compaction tests using equipment and materials available in order to determine the best
compaction control criteria.
3.2 A rock-fill test section shall be placed on a firm surface approved by the Engineer, and the
material and layer thickness shall conform to the requirements of these specifications.
3.3 The test section shall be of sufficient dimensions to permit the establishment of at least twenty
leveling points on a 5 meter square grid, and on fewer than 3 points on any one line and no point less than
2-17
three meters from the edge of the layer. The arrangement of the leveling points shall be approved by the
Engineer.
3.4 Compaction shall then commence with a minimum of three passes of a vibratory roller. Leveling
points are then established. Short lengths of painted steel bars hammered flush with the surface of the
rock-fill have been found suitable for this purpose. A level reading is taken at each leveling point on top
of a moveable 30 cm square flat steel plate. A hole drilled in the center of the plate will enable a visual
check to be made that the plate is located centrally over the bar each time.
3.5 Further readings are taken at the leveling points after two additional passes with the roller. If the
average settlement is less than half of one per cent (0.5%) of the average compacted layer thickness, or as
determined by the Engineer, the rock-fill compaction test is complete.
3.6 If the average settlement is more than half of one percent (0.5%), two additional passes of the
roller are required and the leveling procedure repeated. If the average settlement is now less than half of
one percent (0.5%), the test is complete. If not, this step is then repeated.
3.7 The total number of passes of the rolling equipment necessary to obtain the required result will
establish the minimum number of passes to be used on the rock embankments. The contractor shall then
use this simplified procedure, that is, the equipment, rolling pattern, and number of passes, during the
construction of rock embankments. However, in no case shall the number of passes be less than five. (5).
3.8 This verification procedure shall be conducted for each change of material and at least once each
week during the initial stages of construction until a reliable rolling pattern is established. The frequency
can then be reduced as approved by the Engineer.
Table 2.5: Required Tests and Minimum Repetitions for Earthworks during Embankment
Construction
Control on Site (The Road)

Required Tests Repetitions Required
* One test for every 1000 linear meter for each
1. Maximum dry density (Proctor)
layer
2. Soil Classification as per
AASHTO
3. Any other test as required per * When material changed
special specification and Drawings
4. Field density * For every 1500m2 for each layer
3.9 Documentation of the rock-fill compaction tests shall be maintained in the project records.
4. Monitoring Settlement of Rock-fill
4.1 On completion of the embankment. This shall consist of leveling transverse sections (a minimum
of five points) at a maximum spacing of 30 m along the embankment. These shall be referenced to a
stable approved datum. Leveling shall be carried out at suitable time intervals until the average rate of
settlement over a period of one month does not exceed 0.05 mm per day. No permanent pavement
construction will be permitted until the specified criterion is achieved.
2.6.5 MEASUREMENT
1. All embankment; of whatever type, shall be measured as “unclassified” which shall be deemed
to include all materials of any nature, including silts, clays, sand, gravel and granular materials and
fractured, jointed and solid rock.
2. Embankment Construction shall be measured by m3 of approved unclassified material placed,

spread, watered as necessary, compacted and finished, and accepted. Measurements shall be of volumes
computed from cross sections shown on the Drawings and the original ground elevations, less the volume
2-18
of subgrade layer (topping) which shall be measured separately as prescribed in Section 2.07 – “Subgrade
Construction and Topping”.
3. The volume of embankment displaced by pipe culverts, box culverts and associated end walls,
bridge piers and abutments, shall be deducted from the measured volume of embankment. No deduction
shall be made for pipes less than 500 mm in diameter and associated end walls.
4. Surplus materials utilized at the Contractor's option within the ROW but, beyond the cross
sections shown on the Drawings, shall not be measured for payment.
5. Replacement of Unsuitable Material (the excavation and disposal of which are measured under
"Highway Excavation") shall be measured by cubic meter of approved unclassified material furnished
from approved sources, placed, spread, watered as necessary, compacted, finished as directed, and
accepted. Measurements shall be of volumes computed from the cross sections shown on the Drawings
and the depths of excavation of unsuitable material ordered by the Engineer, and paid for under item for
Embankment.
6. No adjustment or allowances of any kind shall be made in respect of expansion or shrinkage of

earthwork volumes which may occur during excavation and compaction Works.
7. Scarifying old roadbeds, construction of the trial embankment section if it is outside the road and
foundation preparation, testing including furnishing and using an approved type electronic compaction
meter and grid pattern consolidation surveys, and other ancillary embankment Works shall not be
measured for direct payment, but shall be considered as subsidiary Works the costs of which will be
deemed to be included in the Contract Prices for Pay Items.

(1) Embankment Construction Cubic Meter (m3)
2-19
SUBGRADE CONSTRUCTION AND TOPPING SECTION 2.7
SECTION 2.7 : SUBGRADE CONSTRUCTION AND TOPPING

2.7.1 SCOPE
1. These Works shall consist of furnishing materials, constructing the subgrade layer and preparing
the subgrade surface (top of subgrade, P.G.L.) ready to receive the pavement structure and shoulders, all
as and when shown on the Drawings.
2. The subgrade layer is the 200 mm minimum depth of selected material (topping) immediately
below the subgrade surface (top of subgrade, P.G.L.).
3. Construction using cement, bitumen or lime stabilized material for the subgrade layer, shall be as
specified in Section 2.08 - "Stabilized Subgrade Construction".
2.7.2 MATERIALS
1. Topping shall consist of selected borrow material having a 4-day soaked CBR of not less than
25% when tested in accordance with ASSHTO T 193 when compacted at 100% of modified proctor
ASSHTO (T-180-D) and having a maximum P.I. of 12%. Topping gradation shall be reasonably smooth
without gap grading. All topping material shall pass 75 mm sieve and not ore than 18% shall pass 0.075
mm (No. 200) sieve.
2. In situ material shall be deemed to be rock if it is natural solid mineral matter occurring in large
masses; if it is non-ripable by D8 or equivalent; and if 100 mm diameter core specimens, when tested in
accordance with ASTM D2938, have a crushing strength of at least 7 MN/m2 (70 kg/cm2) when dry and
at least 4 MN/m2 (40 kg/cm2) when tested after soaking in water for 24 hours.
3. Minimum tests required on subgrade are listed on Table 2.6.
Table 2.6: Required Tests & Minimum Repetitions for Earthworks for Sub-grade & Topping
Description all Tests Required Tests Repetitions Required

1. Proctor * One test for every 1000
linear meter for each layer
2. Gradation of material * When material changed
3. Plasticity index
4. Classification of materials
as per AASHTO
Top 60cm of Embankment below
5. C.B.R
Sub-grade layer
Drawings
7. Field Density * Test for every 1500m2 or
100 linear meter for each
layer
1. Proctor * One test for every 500 linear
meter for each layer
2. Gradation of material * When material changed
3. Plasticity index
4. C.B.R
Sub-grade layer (selected topping )
each
Drawings
6. Field Density * Test for every 1500m2 or
100 linear meter for each
layer
7. Thickness of layer
2-20
2.7.3 CONSTRUCTION
1. Subgrade in Cut
1.1 Where the subgrade is located in rock, the subgrade, unless shown otherwise on the Drawings,
shall be undercut to a depth of 200 mm by drilling or blasting as directed. No rock shall project more than
50 mm above the undercut surface elevation. The subgrade layer shall then be constructed using approved
topping material, as specified for subgrade in embankment.
1.2 Where the subgrade is on in situ soil which is of a quality and CBR value at least equal to those
specified for topping, the 200 mm depth of such material immediately below top of subgrade shall be
scarified and all roots, sod, vegetable and other undesirable matter and stones larger than 75 mm in any
dimension shall be removed. The material shall then be brought to a uniform moisture content within the
specified range and compacted to 100% AASTHTO T 180 (Method D) Maximum density.
1.3 Where the subgrade is on in situ soil which is unsuitable for retention as the subgrade layer, the
200 mm depth of such material immediately below the top of subgrade layer shall be sub-excavated,
hauled away and disposed off. The subgrade layer shall then be constructed using approved topping
material, as specified for subgrade in embankment. If shall be excavated for further 20 cm and replaced
by suitable material to satisfy the requirements of section 2.06.2-3.
2. Subgrade in Embankment
2.1 the 200 mm minimum depth of embankment immediately below top of subgrade shall consist of
selected, approved topping material. The topping shall be spread in one layer over the full width of the
top of embankment, brought to a uniform moisture content within the specified range and compacted to
100% AASHTO T 180 (Method D) maximum density.
3. Surface Tolerances
3.1 All finished elevation, lines and grades shall be in accordance with the details shown on the
Drawings. Each cross section shall be checked at maximum intervals of 25 m, at each change in cross
slope and elsewhere as directed.
3.2 The tolerances on elevations of finished subgrade, top of embankment under the subgrade layer
and sub-excavated (undercut) surface shall be as follows:
Surface Tolerances
Finished Subgrade:
Soil +10 or –30 mm
Rock (if approved) +50 or –50 mm
Top of Embankment or
Sub-excavated Surface:
Soil +10 or –30 mm
3.3 When the finished subgrade surface is tested with a 4 m long straightedge placed parallel to, or
at right angles to the centerline, the maximum depression of the surface from the testing by straight edge
shall be 30mm.
4. Maintenance of Finished Subgrade
4.1 The finished and approved subgrade shall be continuously maintained in a smooth, well-
compacted and properly drained condition until the sub-base (or base) course is constructed. Re-approval
of the subgrade completion or if the subgrade layer is damaged by traffic or any other causes prior to the
placement of the sub-base layer.
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2.7.4 MEASUREMENT
1. Subgrade layer or layers in undercut rock, in sub-excavated soil and in embankment, shall be
measured by m3 of approved topping material furnished, spread, compacted, completed, and accepted.
Measurements shall be of volumes computed from the cross sections shown on the Drawings.
2. Subgrade layer or layers in approved in situ material shall be measured by m2 of subgrade layer
scarified to a minimum depth of 200 mm including removal of undesirable matter, compacted, completed,
and accepted. Measurements shall be of areas computed from cross sections shown on the Drawings.
3. Sub-excavation of soil material and undercutting of rock below top of subgrade shall be
measured as unclassified excavation, as prescribed in Section 2.03 – “Highway Excavation”.
4. No adjustments or allowances of any kind shall be made in respect of expansion or shrinkage of

earthwork volumes, which may occur during excavation and compaction Works.
5. Maintenance and drainage of finished subgrade, retesting for re-approval, disposal of surplus
materials and other ancillary subgrade Works shall not be measured for direct payment, but shall be
considered as subsidiary Works the costs of which will be deemed to be included in the Contract Prices
for Pay Items.

(1) Subgrade Layers
(Topping) Cubic meter (m3)
(2) Subgrade Layers

(In situ material) Square meter (m2)
2-22
STABILIZED SUBGRADE CONSTRUCTION SECTION 2.8
SECTION 2.8 : STABILIZED SUBGRADE CONSTRUCTION

2.8.1 SCOPE
1. These Works shall consist of furnishing mixing, spreading, compacting and finishing the
subgrade layer, composed of sand, sandy gravel, sandy clay soil or similar materials, stabilized with
cement or bitumen or lime as appropriate, as and where shown on the Drawings.
2.8.2 MATERIALS
1. Cement, bitumen and lime for use as stabilizing agents shall conform with the relevant
requirements of Section 3.01 – “Materials”. Unless shown on the Drawings the Engineer will determine
the type of cement to be used or the type and grade of bitumen to be used, or whether hydrated lime or
quicklime shall be use.
2. The material to be stabilized shall conform with the gradation and other requirements specified
for the particular stabilizing agent to be used.
3. Curing seal shall consist of an approved proprietary curing compound, or MC-70 cutback
bitumen to Prime Coat standard as specified in Section 4.01 – “Materials” and Section 4.02 –
“Bituminous Prime and Tack Coats”.
4. Water shall be potable and shall conform with the relevant requirements of Section 5.01 –
“Concrete and Concrete Mixes and Testing”.
2.8.3 CONSTRUCTION OF TRIAL SECTIONS
1. At least 10 days before commencement of Site stabilization Works and after completion of
laboratory mix design, the Contractor shall lay trial sections for each type of subgrade stabilization
intended to be constructed. Each trial section shall be laid using the same materials, mix proportions,
mixing, spreading and compaction equipment, and construction procedures, proposed for use in the
Works.
2. Each trial section shall serve as a field verification of the laboratory mix design. The results of
the dry density and moisture content measurements made in the trial section will be used in association
with the laboratory tests to establish the required moisture content and minimum compaction effort to be
attained in the Site stabilization Works.
3. Each trial section shall also demonstrate the adequacy of mixing spreading and compaction
equipment and the suitability of the methods and organization proposed.
2.8.4 CONSTRUCTION GENERALLY
1. Construction of stabilized subgrade layers in cut and in embankment, and the maintenance of
finished subgrade, shall conform generally with the relevant requirements of Section 2.07 – “Subgrade
Construction and Topping” and with the requirements specified herein for each type of stabilization to be
executed as part of the Works.
2.8.5 CEMENT STABILIZATION PROCEDURES
1. Mix Design
1.1 The material to be stabilized shall, unless otherwise approved, be a naturally occurring silty or
clayey soil with a P.I. not exceeding 20% and L.L. not exceeding 45%. If the PH value of soil is less than
12.0, up to 2% calcium chloride (based on laboratory testing) may be added to increase the alkalinity. The
soil shall contain not more than 4% sulphate and not more than 8% chlorides.
2-23
1.2 The cement content and optimum moisture content for the soil-cement mix shall be determined
as specified in Section 3.04 – “Stabilized Courses”. The minimum compressive strength at 7 days after
molding shall be adjusted until this strength is achieved.
1.3 The maximum volume change (swelling) shall be 2% and the maximum loss in weight shall be
7%, when cylinders are molded and tested in accordance with AASHTO T 135, Method B.
1.4 Cement content and water content of the mix on the Site shall each be within –0% to +2% of the
approved mix design.
2. Mixing, Placing, Compacting and Finishing
2.1 Mixed in place procedures will normally apply in the case of subgrade stabilization when the soil
to be stabilized is a naturally occurring, in situ material.
2.2 Equipment used for scarifying and pulverizing the in situ soil, applying the bitumen and mixing
the soil and cement bitumen, and compacting and finishing the soil-bitumen subgrade layer, shall be of
approved types and shall be operated all as specified in Section 3.04 - "Stabilized Course".
2.3 Plant for batch mixing or continuous mixing of soil and cement shall be of approved types and
shall be all operated as specified in Section 3.04 - Stabilized Courses".
2.4 Where bath mixing or continuous mixing is approved, the equipment used for transporting,
placing spreading, compacting and finishing the soil-cement mix shall be of approved types and shall be
all operated as specified in Section 3.04 - "Stabilized Courses".
2.5 Procedures for making good any areas lower than the allowable tolerances and the application of
a curing seal to the completed surface shall be as specified in Section 3.04 - "Stabilized Courses".
2.8.6 TESTING OF BITUMEN STABILIZED SUBGRADE
1. Sampling and testing shall be as specified in Section 3.04 - "Stabilized Courses", except as
follows
1.1 Cement content in accordance with AASHTO T 144

1.2 Gradation of mix in accordance with AASHTO T 88
2.8.7 BITUMEN STABILIZATION PROCEDURES
1. Mix Design
1.1 The material to be stabilized shall, unless otherwise approved, be a naturally occurring sand, or
silty or clayey gravel, with a P.I. not exceeding 15% and L.L. not exceeding 35% and with not more than
35% passing 0.075 mm (No. 200) sieve.
1.2 The optimum bitumen content for the soil-bitumen mix shall be determined as specified in
Section 3.04 - "Stabilized Courses".
1.3 The minimum compressive strength of cylinders at 7 days after molding and at 25 degrees C,
shall be 2 MN/m2 (20 kg/cm2) and the Marshall stability shall be 2,000 N (204 kg).
1.4 The Index of Retained of Retained strength when tested in accordance with AASHTO T 165
shall not be less than 70%.
to be stabilized is a naturally occurring in situ material.
2-24
2.2 Equipment used for scarifying and pulverizing the in situ soil, applying the bitumen and mixing
the soil and bitumen, and compacting and finishing the soil-bitumen subgrade layer, shall be of approved
types and shall be operated all as specified in Section 3.04 - "Stabilized Courses".
2.3 Plant for batch mixing or continuous mixing of soil and bitumen shall be of approved types and
shall be operated all as specified in Section 3.04 - "Stabilized Courses".
2.4 When batch mixing or continuous mixing is approved, the equipment used for transporting,
placing, spreading, compacting and finishing the soil-bitumen mix shall be of approved types and shall be
all operated as specified in Section 3.04 - "Stabilized Courses".
2.5 Procedures for making good any areas lower than the allowable tolerance and the application of
2.8.8 TESTING OF BITUMEN STABIIZED SUBGRADE
1. Sampling and testing shall be as specified in Section 3.04 - "Stabilized Courses.
2.8.9 LIME STABILIZATION PROCEDURES
1. Mix Design
1.1 The material to be stabilized shall, unless otherwise approved, be a naturally occurring clayey
gravel, clayey sand or lean clay soil with not more than 50% passing 0.425 mm (No. 40) sieve. The soil
shall be of a standard acceptable for use in embankments.
1.2 The lime content and optimum moisture content for the soil-lime mix shall be determined as
specified in Section 3.04 - "Stabilized Courses".
1.3 The minimum cylinder compressive strength at 7 days after molding shall be 1 MN/m2 (10
kg/cm2).
1.4 Lime content and water content of the mix on Site shall each be within -0% to +2% of approved
mix design percentage.
2. Safety Precautions
2.1 safety precautions when handling quicklime or hydrated lime shall be observed, as specified in
Section 3.04 - "Stabilized Courses".
to be stabilized is a naturally occurring, in situ material.
3.2 Equipment used for scarifying and pulverizing the in situ soil, mixing the soil and lime (either
dry or as a slurry), and compacting and finishing the soil-lime subgrade layer, shall be of approved types
and shall be all operated as specified in Section 3.04 - "Stabilized Courses".
3.3 Plant for batch mixing or continuous mixing of soil and lime shall be of approved types and shall
be operated all as specified in Section 3.04 - "Stabilized Courses".
3.4 Where batch mixing or continuous mixing is approved, the equipment used for transporting,
placing , spreading, compacting and finishing the soil-lime subgrade layer shall be of approved types and
shall be operated all as specified in Section 3.04 - "stabilize Courses".
3.5 Procedures for making good any areas lower than the allowable tolerances and the application of
2-25
2.8.10 TESTING OF LIME STABILIZED SUBGRADE
1. Sampling and testing shall be as specified in Section 3.04 - "Stabilized Courses".
2.8.11 SURFACE TOLERANCES
1. All slopes lines and grades shall be in accordance with the details shown on the Drawings. Each
cross section shall be checked at maximum intervals of 25m at each change in cross slope and elsewhere
as directed.
2. The smoothness of finished subgrade surfaces and the tolerances on elevations of sub-excavated
(undercut) surfaces and on finished subgrade surfaces shall conform with the requirements specified in
Section 2.07 - "Subgrade Construction and Topping".
2.8.12 MEASUREMENT
1. Stabilized Subgrade Layer in undercut rock, is sub-excavated soil and in embankment, shall be
measured by m3 of each type of stabilized material furnished, spread, compacted, completed, and
accepted. Measurements shall be of volumes computed from the cross section shown on the Drawings.
2. Stabilized Subgrade Layer incorporating naturally occurring in situ soil shall be measured by the
m3 of subgrade layer scarified, pulverized, mixed with stabilizing agent of each type, compacted,
completed, and accepted. Measurements shall be of volumes computed from cross section shown on the
Drawings.
3. Measurements shall also be made of the Trial Section or section in accordance with the length,
width and thickness of each complete Section ordered by the Engineer, if it is outside the road.
4. Sub-excavation of soil material and undercutting of rock below top of subgrade shall be
measured as unclassified excavation, as prescribed under Section 2.03 - "Highway Excavation".
5. No adjustments or allowances of any kind shall be made in respect of expansion or shrinkage of

earthwork volumes which may occur during excavation and compaction Works.
6. Maintenance and drainage of finished subgrade, retesting for re-approval if necessary, disposal
of surplus materials and other ancillary subgrade Works shall not be measured for direct payment, but
shall be considered as subsidiary Works the costs of which will be deemed to be included in the Contract
prices for Pay Items.

(1) Cement Stabilized Subgrade Layer:
Imported Soil Cubic meter (m3)
In Situ Soil Cubic meter (m3)
(2) Bitumen Stabilized Subgrade Layer

(3) Lime Stabilized Subgrade Layer:
2-26
EXCAVATION AND BACKFILL FOR STRUCTURES SECTION 2.9
SECTION 2.9 : EXCAVATION AND BACKFIL FOR

STRUCTURES
2.9.1 SCOPE
1. These Works shall consist of all excavation in any material for bridges, underpasses and
overpasses; for buildings and pump houses; for culverts, storm drains, utility ducts and under-drains; for
drainage and utility structures; for retaining walls of all types; and for other major and minor structures;
and including all necessary clearing and grubbing; bailing; drainage; pumping; sheeting; temporary
shoring and cribbing; construction of temporary cofferdams or cribs; and disposal of all excavated
material and backfilling with suitable approved material; all as and where shown on the Drawings.
2. These Works shall also include the removal of those portions of existing structures below ground
which would in any way obstruct or interfere with construction of new structures.
3. As part of the “Inspection of Site” obligations under the Conditions of Contract, the Contractor
will be deemed to have satisfied himself, at the time of tendering, as to the type and nature of soils and
rock that will be encountered in structural excavations.
2.9.2 EXCAVATION
1. General
1.1 The Contractor shall notify the Engineer a sufficient time in advance of the beginning of nay
excavation for structures so that the Engineer may, where necessary, survey and record the cross sectional
elevations and measurements of the existing ground and existing structures affected by the proposed
structure. Any materials removed or excavated before these measurements have been taken and approved
by the Engineer will not be paid for.
1.2 The Contractor shall be solely responsible for the safety at all times of all foundation and trench
excavations whether supported or otherwise. Approval of the Contractor’s support system or omission of
a support system for any excavations shall not absolve the Contractor from his sole responsibility in this
regard.
1.3 The sides of all foundation pits and trenches shall be vertical unless otherwise shown on the
Drawings and the walls shall be adequately supported at all times. Walls more than 1.5 m in depth shall
be sloped at a safe slope or supported in an approved manner unless the material through which the pit or
trench is cut deemed to be sufficiently self supporting and not requiring external support.
1.4 The Contractor shall take necessary precautions, including shoring or otherwise, to protect
employees in the excavation and on the ground above. The Engineer will not enter excavated areas to
approve the foundation and further Works until he deems the areas to be safe.
1.5 In areas where the excavation is adjacent to public roads and walkways, the Contractor shall
erect all necessary barricades, barriers, enclosed walkways, and warning signs necessary to restrict the
exposure of the public to the excavation. All such safety measures shall conform with the requirements of
Section 8.10 – “Maintenance of Traffic and Detours” and shall be subject to approval.
1.6 Pits and trenches shall be kept free from water until footing concrete has been placed or pipes
have been installed. The Contractor shall minimize, to the maximum extent practicable, the length of time
that excavated area are open. He will be held responsible for damage due to weather, equipment and other
causes during periods when the excavations are left open.
1.7 The Contractor shall schedule the Works so that no excavation is left in an exposed condition for
a period greater than 30 days unless otherwise approved. If the Contractor fails to meet this requirement,
the Engineer may order the Contractor to suspend further excavation until the construction progress
enables the Contractor to meet such requirement.
2-27
1.8 In areas where the excavation is adjacent to public highways and walkways, no excavation shall
be scheduled to be left in an exposed condition for more than 7 days unless otherwise approved.
1.9 The Contractor shall schedule highway excavation and embankment and drainage Works so that
they complement each other. If the Contractor’s earthwork progress exceeds the progress of the drainage,
the Engineer may point where the highway becomes a dam to cross drainage, the Engineer may order the
Contractor to open adequate waterways through the highway at the locations where drainage structures
are to be installed. Any damage to the highway caused by water passing through these openings shall be
repaired at the Contractor’s expense.
1.10 The Contractor must notify the Engineer of any cracks or sign of failure, immediately when such
signs are noticed.
2. Temporary Shorting and Cribbing
2.1 When shoring and/or cribbing is required to protect adjacent property or to protect the public
during construction, the Contractor’s design for such shoring and cribbing shall be submitted for approval
prior to commencing its construction.
2.2 All shoring and cribbing shall be designed with adequate factors of safety to serve with minimal
maintenance, for the duration of its intended use, and shall include adequate safety provisions to protect
the public from construction activities.
2.3 Notwithstanding any approval of temporary shoring and cribbing the Contractor shall be solely
responsible for the adequacy of their construction and for maintenance and all necessary safety
precautions associated therewith.
3. Excavation for Bridges Underpasses and Overpasses and other Major Structures
3.1 The foundations for bridges, underpasses and overpasses, buildings, pump houses and other
major structures, shall be excavated in accordance with the dimensions as shown on the Drawings and
shall be of sufficient size to permit the placing of the full width and lengths of the footings with full
horizontal beds.
3.2 The excavation shall be carried to the elevations shown on the Drawings or as established by the
Engineer. Borings and soil tests, made during design, and actual investigation of the completed
foundation excavation shall be utilized by the Engineer to determine final depth. No concrete shall be
placed prior to approval of the excavation pit.
3.3 The Contractor shall be responsible for ensuring by testing or otherwise that the soil at
foundation level has not less than the bearing capacity as shown on the Drawings.
3.4 Unless shown otherwise on the Drawings, the bottom of all excavations shall be covered with a
75 mm minimum depth of lean (blinding) concrete Class 15 to serve as a working platform.
3.5 Foundation pits or trenches shall be of sufficient size and provide minimum sufficient working
space to permit construction of structures or structure footings of the full width and length shown on the
Drawings.
3.6 Where footings are to be constructed using formwork, the excavations shall generally not extend
more than 500 mm beyond the maximum dimension on each side of the proposed footing unless
additional working space is clearly required and approves, by the Engineer. Any un-authorized over-
width of excavation beyond the lateral limits shown on the drawings or approved by the Engineer shall be
backfilled with selected fill and compacted.
3.7 Where footings are to be located, in or adjacent to firm, original ground and where formwork is
not required or ordered, any unauthorized over-depth excavation below the approved elevation of base of
footing shall be backfilled with blinding concrete. Any unauthorized over-width of excavation beyond the
lateral limits shown on the drawings shall be backfilled with selected fill, or blinding concrete as directed
by the Engineer.
2-28
3.8 Where excavation to rock foundation is required, the excavation shall proceed in such manner as
to allow the solid rock to be exposed and prepared in horizontal beds or properly serrated for receiving
the concrete. All loose and disintegrated rock and thin strata shall be removed.
3.9 All blasting necessary for any pier or groups of piers or abutment shall be performed prior to
placing and concrete. Blasting will not be permitted in the vicinity of concrete which has not cured for at
least 14 days.
3.10 When unstable material or other unsuitable material is encountered below foundation elevation,
the Contractor shall excavate such material and replace it with suitable backfill material or concrete as
directed.
3.11 Where foundation piles are used, the excavation of each pit shall be completes before the piles
are driven. All foundation piling shall be driven in any one pier or abutment before concrete is placed in
any column of that pier or abutment. After the driving is completed, all loose and displaced material shall
be removed leaving a smooth solid bed to receive the concrete.
3.12 Suitable and substantially watertight cofferdams shall be used whenever water bearing strata are
encountered above the elevation of the bottom of the excavation. Cofferdams shall be placed such as to
give easy access of all parts of the foundation.
3.13 Cofferdams shall be sunk to a depth below the bottom of the excavation and to the elevation
necessary to adequately seal the cofferdams, shall be substantially braced in all directions, and of such
construction as will permit them to be pumped free of water kept free until the concrete has been placed.
3.14 When the bottom within the cofferdam is of sandy or porous material which will not, in the
opinion of the Engineer, permit the footing to be placed in the dry, it shall be sealed in accordance with
the relevant requirements of Section 5.06 "Plain and Reinforced Concrete Structures" so that it may be
pumped dry. Other suitable means of sealing out the water may be approved.
3.15 If, in the opinion of the Engineer, the necessity for a seal course over the bottom is due to
inadequate or improper cofferdam construction, the Engineer may order the removal and reconstruction
of the cofferdam or placing of a seal course, all at the Contractor's expense.
3.16 Unless shown otherwise on the Drawings or agreed with the Engineer, cofferdam and shall
sheeting and bracing shall be removed after completion of concreting.
4. Excavation for Culverts, Storm Drains, Ducts & Miscellaneous Structures
4.1 Excavation shall be carried out to the limits required for construction and to the depth required
for bedding material or removal of unsuitable material. All trench excavation shall proceed upgrade,
commencing at the downstream end.
4.2 Foundation material supporting the bedding or structure shall be AASHTO M 145 Class A-1-a,
A-1-b or A-2-4 compacted to 95% AASHTO T 180 maximum density. If the natural material does not
meet the classification requirements, it shall be sub-excavated to a depth of 200 mm and replaced with
material meeting the specified requirements. Any rock or hard material within 200 mm of the bottom of
the pipes shall be similarly sub-excavated and replaced with material meeting the specified requirements.
4.3 If no special bedding material is required, the foundation for pre-cast and prefabricated culverts
shall be formed to the shape of the culvert, including all protrusions. The shaping shall extend to 25% of
the height of culvert.
4.4 Where rock is encountered in the toe wall excavation for concrete box culverts or concrete
headwalls or end-walls for pipe culverts and the rock is of such quality as will prevent erosion, part of the
toe wall may be eliminated in the rock strata as directed and the toe wall shall be keyed into the rock
strata in a satisfactory manner.
4.5 Pre-cast concrete pipes and metal pipes if chosen shall be installed in trenches cut into
previously constructed and compacted embankment or from top of subgrade. Unless otherwise shown on
the Drawings, trench width shall not be greater than the external diameter of the pipe plus 600 mm on
each side.
2-29
4.6 In the case of metal pipes, the bottom of the trench shall be shaped to a template so that at least
10% of the overall height of pipe or arch will be in contact with the bottom of the trench as excavated.
Recesses shall be excavated to receive any parts of the pipe which extend below the outside perimeter.
Where rock, hardpan or other unyielding material is encountered it shall be removed below design grade
or as ordered by the Engineer for a depth of at least 200 mm and backfilled as specified.
4.7 Trenches for cast in situ pipes shall be cut into previously constructed and compacted
embankment from top of subgrade or embankment height or twice the nominal span of the pipe
whichever is less. Trench width shall not be greater than the external diameter or span of pipe plus 300
mm on each side when external forms are used, or the external span of pipe plus 100 mm on each side
when external forms are not used.
4.8 When excavation is required for installation of ducts, the Contractor shall notify the Engineer
upon completion of the excavation. No ducts shall be laid until the depth and cross section of the
excavation has been approved.
2.9.3 BACKFILLING
1. General
1.1 The Contractor shall obtain approval for his proposed method and rate of placing of backfill,
before backfilling commences.
1.2 Backfill materials shall be uniformly graded granular material, capable of being compacted to
required compaction, and having adequate permeability to permit free drainage through it. Backfill
material shall also conform to the following:
1.2.1. Minimum D10 value 1mm

Maximum Plasticity Index 10 per cent
1.2.2 Requirement for bridges, culverts etc. specified in subsequent sections.
1.3 Backfill material shall not be placed against any structure until approval is given. Unless
otherwise shown on the Drawings structures shall be backfilled to the same requirements as specified for
the adjacent embankment.
1.4 Backfill shall be placed in level layers for the full width of the excavated area until the elevation
of the original ground or surrounding embankment is reached. Backfill next to walls, between columns or
in other confined areas, shall be compacted by approved hand or portable equipment.
1.5 Each successive layer of backfill shall contain only sufficient materials to ensure proper
compaction and in no case shall layer be greater than 200 mm thickness (before compaction). The
moisture content of the backfill material shall be uniform and within the moisture range designated.
1.6 Jetting of fills or other hydraulic methods involving or likely to involve liquid or semi-liquid
pressure, will not be permitted.
1.7 Water shall be drained from the areas to be backfilled wherever practicable. In cases where, in
the opinion of the Engineer, it is not practicable to drain the areas to be backfilled, the initial backfill
material shall consist of crushed, open graded material deposited and compacted to an elevation above the
water level where normal backfill operations can progress.
1.8 Additional water to be added during placement of backfill material to achieve required
compaction shall be fresh water or brackish water approved by the Engineer.
1.9 Minimum tests required during backfilling operations to verify material quality are listed on
Table 2.7.
2-30
Table 2.7: Required Tests and Minimum Repetitions for Earthworks and Structures Backfill
Control on Site (The Road)

Required Tests Repetitions Required
1. Proctor * Test for each Structure
2. Gradation of Materials * When material changed
3. Plasticity Index
4. Any other Tests as required in
Special Specification and Drawings
* 50% of layers and for each footing and for each
5. Field Density
abutment and as per instruction of the Engineer.
2. Backfilling for Bridges, Underpasses and overpasses
2.1 Structure shall not be subject to the pressures of backfilling or to live loads until the 28-day
strength of the concrete has been reached, unless a shorter period is approved in special circumstances
where the load is sufficiently small as not to constitute a risk of any damage to the structure in the opinion
of the Engineer. If approved this period may be extended if subnormal curing conditions exist.
2.2 Backfill placed around culverts, abutments and piers, shall be deposited on both sides to
approximately the same elevation at the same time. Special care shall be taken to prevent any wedging
action against the structure and slopes bounding the excavation shall be stepped, where necessary, to
prevent such wedge action occurring.
2.3 All backfill intended to support falsework loads, including temporary fills and pier backfill, shall
be designed for the minimum support required. As a minimum, such material shall be AASHTO M 145,
Class A-1-a, A-1-b or A-2-4, compacted to 90% AASHTO T 180 maximum density.
2.4 backfill for bridge abutments and approach embankments within 20 m of any part of the
substructure shall be AASHTO M 145, Class A-1-a, A-1-b or A-2-4 compacted to 95% AASHTO T 180
maximum density up to the underside of the subgrade layer. The 200 mm minimum thickness of subgrade
layer shall consist of approved topping material placed and compacted to 100% maximum density as
specified under Section 2.07 - "Subgrade Construction and Topping". The backfill shall be completed to
the level of the original ground or to the top elevation of any adjacent embankment.
2.5 Backfill around retaining walls shall be completed to the level of the original ground line and to
such heights above original ground line or to the levels as shown on the Drawings. Care shall be exercised
to prevent forward movement of the wall.
2.6 Unless shown otherwise on the Drawings, when special permeable backfill (sheathing) is to be
placed against the back faces of abutments, retaining walls or wing walls, it shall consist of a continuous
covering of approved type proprietary filter cloth protected by a continuous wall of 200 mm minimum
thickness pre-cast, porous (no-fines) concrete blocks laid in stretcher bond with dry joints. Prior to
construction of the block wall, a Type I or Type 3 under-drains of at least 150 mm diameter shall be laid
along the base of the wall under the sheathing in accordance with the relevant requirements of the Section
8.04 - "Pipe Under-drains", where the materials for Type 1 and 3 Under-drains are given.
3. Backfilling for Culverts, Storm Drains & Miscellaneous Structures
3.1 Backfill for culverts, storm drains and miscellaneous structures within 300 mm of any part of the
structure shall be Class A-1-a, A-1-b or A-2-4. Backfilling and contraction of the Subgrade (topping)
layer shall be as specified for bridges, underpasses and overpass.
3.2 Backfill around and over pipe culverts shall not commence until headwalls and wingwalls have
been constructed and attained the specified 28-days strength.
2-31
3.3 Water used for compaction of backfill around metal pipes shall be from an approved source and
shall not contain more than 0.5% combined chlorides and sulphate nor contain other potentially harmful
minerals.
3.4 When pipes or other structures temporarily extend above the grade of the partially constructed
embankment, the Contractor shall construct the fill over the structure of sufficient depth to protect the
structure from any damage resulting from construction or other traffic.
3.5 In no case shall surplus material be dumped in stream channel.
3.6 Concrete bedding, concrete cradles, concrete hunching and concrete encasement for concrete
pipes shall be as specified in Section 5.13 - "Pipe Culverts, Storm Drains and \utility Ducts".
3.7 Over width or over depth excavation for pre-cast concrete pipes shall be made good at the
Contractor's expense by provision of an in situ concrete cradle or increased thickness of concrete bedding
as directed, or by the use of other approved suitable materials.
3.8 Over width excavation for in situ concrete pipes shall be made good at the Contractor's expense
by concrete bedding brought up to the external haunch of the pipe, or by the use of other approved
suitable materials.
3.9 Over depth excavation for metal pipes shall be made good by furnishing and backfilling an
approved, fine granular material containing not more than 0.5% of combined chlorides and sulfates.
3.10 The Contractor shall complete the backfill around box culverts to the level of the original ground
line and to the full width of excavation area. If the top of culvert extends above the original ground line
the Contractor shall continue the backfill to the top of culvert and for a width of 3 m on each side of the
culvert for the full width of highway embankment. If the embankment is in place at the time of
backfilling, the Contractor shall backfill around the culvert to the top of embankment.
3.11 Backfill around pipe culverts and storm drains shall be completed to the level of original ground
line and to the full width of excavation area. If the top of the culvert extends above the original ground
line the Contractor shall continue the backfill to the op of the culvert for a width of 1.5 times the
maximum external width of the culvert on each side of the culvert centerline to the full width of the
highway embankment. If the embankment is in place at the time of backfilling, the Contractor shall
backfill around the culvert to the top of culvert or as shown on the Drawings.
3.12 Any existing highway pavement cut through, damaged or removed during excavation for pipe
culvert installation shall be reinstated, after pipe installation and trench backfilling, using approved base
and surfacing course materials at least equivalent to those in the original pavement. Materials and
construction shall conform with the relevant requirements of Section 4.01 - "Pavement repairs and trench
Reinstatement Works".
3.13 Miscellaneous structures other than pipe culverts and storm drains shall be backfill in accordance
with the methods specified. Compaction of backfill when structures are outside the highway right-of-way
or in approach roads, minor roads or similar areas, shall be to 90% AASHTO T 180 maximum density.
2.9.4 MEASUREMENT
1. Structural backfilling shall not be measured for direct payment, but shall be considered as
subsidiary Works the costs of which will be deemed to be include in the Contract Prices for structural
Excavation or Sub-excavation of Unsuitable Material, as appropriate.
2. All structural excavation, of wherever type, shall be measured as “unclassified” which shall be
deemed to include all materials encountered of any nature, including silts, clays, sand, gravel and granular
materials and fractured, jointed and solid rock.
3. Structural excavation for box culverts less than one m2 in external cross section and structural
excavation for pipe culverts, storm drains, ducts, under-drains (subsoil drains), pits, catch-basins,
manholes, inlets, energy dissipaters, slope protection Works, fence posts, guardrail posts, lighting
columns, sign pots, signal supports and all other minor structures, shall not be measured for direct
2-32
payment, but shall be considered as subsidiary Works the costs of which will be deemed to be included in
the Contract Prices for Pay Items.
4. Structural Excavation shall be measured by cubic meter of material excavated for the major
structures specified in Clause 3 above, hauled away and disposed of as directed, or stockpiled on or in the
vicinity of the Works, and the excavated areas backfilled, completed and accepted.
5. Measurement of structural excavation shall be of original ground elevations, or ground

elevations after removal of all unclassified highway excavation. Limits shall not be greater than vertical
planes 500 mm from the maximum dimension, on each side of the footing or other controlling portion of
the structure. Where structures are to be constructed against natural ground or rock, excavation limits
shall be the dimensions of the structure as shown on the Drawings. Bottom limits shall be ordered
foundation elevations. Only material excavated from its original position shall be measured for payment.
No measurements shall be made of structural excavation in embankments previously constructed by the
Contractor.
6. Sub-excavation of Unsuitable Material shall be measured by m3 of unsuitable material sub-

excavated as ordered, hauled away and disposed of as directed, and the excavated areas backfilled,
completed and accepted. Measurements shall be of volumes computed from the cross sections and depths
of excavation ordered by the Engineer.
7. Unauthorized over-depth and over-width excavation and the concrete backfill required in such
cases, shall not be measured for direct payment, but shall be considered as Subsidiary Works the costs of
which will be deemed to be included in the Concrete Prices for Pay Items.
8. Temporary cofferdams, temporary shoring and cribbing, bailing, drainage, pumping, sheeting,
and all other Temporary Works shall not be measured for direct payment, but shall be considered as
subsidiary Works the costs of which will be deemed to be included in the Contract Prices for Pay Items.

(1) Unclassified Structural
Excavation Cubic meter (m3)
(2) Sub-excavation of Unsuitable

Material Cubic meter (m3)
2-33
RECONSTRUCTION OF EXISTING FARM DIKES SECTION 2.10
SECTION 2.10 : RECONSTRUCTION OF EXISTING FARM

DIKES
2.10.1 SCOPE
1. These Works shall consist of furnishing materials and reconstructing sections of existing farm
dikes that have been partially or totally excavated in order to permit new highway construction, and
furnishing materials and constructing new diversion and spur dikes.
2. Construction of diversion dikes shall consist of placing material to the lines and grades required
to intercept and divert the flow of surface water to an appropriate discharge or dispersion point.
3. Construction of spur dikes shall consist of placing material to the lines and grades required to
channel surface water away from bridge abutments.
2.10.2 MATERIALS
1. Only approved materials from the roadway excavation, drainage excavation, structural
excavation, or borrow may be used to reconstruct existing farm dikes, or construct new diversion or spur
dikes.
2. Riprap and Construction Fabric shall be of the types shown on the Drawings and shall conform
with the relevant requirements of Section 8.05 – “Slope Protection and Stabilization”.
2.10.3 CONSTRUCTION
1. Reconstruction of existing farm dikes shall include rebuilding of existing improvements, at or

near the same location, to either new lines, grades and cross sections, or to their original lines, grades and
cross sections, as indicated on the Drawings.
2. Farm dikes shall be compacted in an approved manner and to a density at least equivalent to the
density of material in the original dike or as otherwise directed.
3. Reconstruction of existing farm dikes, and construction of diversion and spur dikes, shall be as
shown on the Drawings and in accordance with the relevant requirements of Section 2.03 – “Highway
Excavation” and Section 2.06 – “Embankment Construction”. All material shall be compacted to 95%
AASHTO T 180 maximum density, unless otherwise specified.
4. Construction fabric and riprap shall be installed on spur dikes and diversion dikes wherever
shown on the Drawings. The installation of riprap and construction fabric shall conform with all relevant
requirements of Section 8.05 – “Slope Protection and Stabilization”. Fabric damaged or unduly displaced
by dumping or otherwise of riprap, shall be replaced at the Contractor’s expense.
2.10.4 MEASUREMENT
1. Reconstruction of Existing Farm Dikes shall be measured by cubic meter (m3) constructed
including the furnishing of all materials, compacted, completed, and accepted.
2. Spur Dikes and Diversion Dikes shall be measured by cubic meter (m3) in place of material
furnished, placed, compacted, completed, and accepted. Quantities measured as Farm Dikes, Spur Dikes,
or Diversion Dikes shall not also be included under embankment quantities.
3. Riprap shall be measured by cubic meter (m3) of each type furnished, placed, completed, and
accepted in accordance with drawings.
4. Construction Fabric shall be measured by m2 furnished, placed, secured, completed and

accepted.
2-34
RECONSTRUCTION OF EXISTING FARM DIKES SECTION 2.10

(1) Reconstruction of
Existing Farm Dikes Cubic meter (m3)
(2) Construction of Spur

Dikes and Diversion Dikes Cubic meter (m3)
(3) Loose Stone Riprap Cubic meter (m3)
(4) Mortared Stone Riprap Cubic meter (m3)
(5) Construction Fabric Square meter (m2)
2-35
TEMPORARY SOIL EROSION CONTROL SECTION 2.11
SECTION 2.11 : TEMPORARY SOIL EROSION CONTROL

2.11.1 SCOPE
1. These Works shall consist of temporary control measures as shown on the Drawings or required
by the Engineer during progress of the Works, to control soil erosion and water pollution, by use of
berms, dikes, silt fences, brush barriers, dams, sediment basins, fiber mats, netting, gravel, mulches,
grasses, slope drains, and other erosion control devices or methods.
2. The temporary erosion control provisions shall be coordinated with permanent erosion control
features to assure economical, effective and continuous erosion control throughout the period of the
Works.
2.11.2 MATERIALS
1. Geo-textile or jute matt lining or may other approved material as appropriate can be used for soil
erosion control.
2. All other materials shall meet commercial grade standards and be approved before being
incorporated in the Works.
2.11.3 CONSTRUCTION
1. Control Measures Generally
1.1 A schedule of proposed temporary (and permanent) soil erosion control Works shall be
developed by the Contractor at the commencement of the Contract, in consultation with the Engineer and
to his satisfaction.
1.2 The Contractor shall carry out (and maintain) temporary erosion control to prevent soil erosion
that will adversely affect construction operations, damage adjacent properties, or cause contamination of
adjacent streams or other watercourses, lakes, ponds or other areas of water impoundment. Such Works
may involve construction of temporary berms, dikes, dams, sediment basins, slope drains or use of
temporary mulches, mats, seeding or other control devices or methods as necessary to control erosion.
Cut and fill slopes shall be seeded and mulched as the excavation proceeds, to the extent considered
desirable and practicable by the Engineer.
1.3 Temporary erosion control may include construction outside the right-of-way where such work
is necessary, as a result of roadway construction, such as borrow pit operations, haul roads and equipment
storage sites.
1.4 The contractor shall incorporate erosion control features as shown on the drawings into the
works at the earliest practicable time as outlined in his schedule, to minimize the need for temporary
erosion control measures.
1.5 Where erosion is a problem, clearing and grubbing operations shall be so scheduled and
performed that grading operations and permanent erosion control features can follow immediately
thereafter if conditions permit; otherwise, temporary erosion control measures may be required between
successive construction stages.
1.6 The Engineer will limit the area of clearing and grubbing, excavation, borrow and embankment
operations in progress commensurate with the Contractor’s capability and progress in keeping the
finished grading, mulching, seeding and other permanent erosion control measures current in accordance
with the schedule. Should seasonal limitations make such coordination unrealistic, temporary erosion
control measures shall be taken immediately to the extent feasible and justified.
1.7 The Engineer may increase or decrease the amount of surface area of erodible earth material to
be exposed at one time by clearing and grubbing, excavation, borrow and fill operations as determined by
his analysis of project conditions.
2-36
TEMPORARY SOIL EROSION CONTROL SECTION 2.11
1.8 In the event that temporary erosion control measures are required due to the Contractor’s
negligence, carelessness or failure to install permanent controls as part of the Works, scheduled or
ordered by the Engineer, such Works shall be carried out by the Contractor at his own expense.
2.11.4 MEASUREMENT
for Pay Items.
2-37
SAND DUNES STABILIZATION SECTION 2.12
SECTION 2.12 : SAND DUNE STABILIZATION

2.12.1 OBJECTIVES
1. The destruction or stabilization of wind blown sand accumulation in order to prevent further
migration and encroachment.
2. The diversion of wind blown sand around works requiring protection.
3. Stopping sand movement in front of the works to be protected.
4. Aiding sand movement in order to avoid deposition over a specific location, especially by
surface smoothing and obstacle removal.
2.12.2 SCOPE
1. The above objectives are achieved by the use of one or more methods of surface modifications
summarized below. The following methods are listed with potentially more attractive ones first.
2.12.3 METHODS
1. Alignment: Align route upwind of sand source to avoid major dune fields.
2. Oiling: Oiling involves the covering of wind blown materials with a suitable oil product such as
high gravity surface and may destroy dune forms. This is often a quick, cheap and effective method.
3. Fencing: The use of relatively porous barriers to stop or divert sand movement or destroy or
stabilize dunes, cheap portable and expendable structures are suitable such as palm fronds, chicken wire
or snow fencing.
4. Planting: Planting of appropriate vegetation designed to stop or reduce sand movement, bind
surface sand and provide surface protection.
5. Paving: Paving shall be designed to increase the siltation coefficient of wind transported
material by smoothing or hard surface of relatively level areas. Paving can be with concrete asphalt or
wind-stable aggregates such as crushed rock or gravel.
2.12.4 MEASUREMENT
1. Unless shown in the Bill of Quantities or otherwise specified in the Special Specifications, the
works prescribed in this section shall not be measured for direct payment, but shall be considered as
subsidiary works the cost of which will be deemed to be included in the contract prices for Pay Items.
2-38
Part ( 3 ) :
Sub-base &
Base Courses
Technichal Specifications Subbase & Base Courses
MATERIALS SECTION 3.1
SECTION 3.1 : MATERIALS

3.1.1 SCOPE
1. Materials Specified for use in the construction of the sub-base and base courses for flexible and
rigid pavements, may include any or all of the following:
1.1 Granular screened material, or partially crushed of approved classes, consisting of well
graded gravel including sand and silt, or crushed stone or crushed gravel for sub-base course
construction.
1.2 Crushed stone, of approved classes, for base course construction.
1.3 Stabilizing materials including Portland cement, bitumen and lime, used where
specified in sub-base and base courses (and in sub-grades).
2. All material sources and the quality of materials proposed for use in the Works shall be approved
prior to procuring or processing material from such sources. Inspection, sampling, testing and retesting as
necessary, shall be at the Contractor’s expense as prescribed in Section 1.06 – “Control of Materials and
Standards for Sampling and Testing” and as specified hereunder for specific materials.
3. Depending upon the location of the works, the estimated traffic and the results of the material
survey, the designer may find it difficult to obtain the required materials, as required in the General
Specification, within an economic distance from the works. The designer may, with the approval of the
Client, relax the requirements of the General Specification to allow locally available materials to be used
for base and sub-base courses. Such relaxation of the General Specification requirements will be part of
the Special Specification for the particular work, and will not in any way reduce the standard of the work
on the requirements of the Client.
4. Storage and handling of all materials shall conform with the relevant requirements of Section
1.05 – “Control of Materials and Standards for Sampling and Testing”. Materials shall be stored on hard,
clean surfaces or as directed by the Engineer.
3.1.2 GENERAL
1. Sources and Production
1.1 Locating sources and manufactures of materials in accordance with the requirements of the
Specifications are the responsibility of the Contractor, who shall produce the required granular materials
and aggregates at the rates and in the quantities necessary to complete the Works on time.
1.2 The Contractor shall have satisfied himself as to the location, suitability and quantity of
materials available; extent of work necessary to obtain the material available; the work required to open
the quarry and to crush, screen and wash the materials; and the length of haul to the Site.
1.3 Prior to starting quarry or borrow pit operations, the Contractor shall obtain written permission
from the Authorities or Owners concerned.
1.4 Screening plants or crushing and screening plants shall not be put into operation prior to their
approval. If, after any plant is put into operation, it fails to perform as intended, the Contractor shall either
rectify the defects in the existing plant to the satisfaction of the Engineer, or shall provide alternative
approved plant.
1.5 Approval of the crushing and screening plants and other equipment shall in no way relieve the
Contractor of his responsibilities in respect of producing granular materials and aggregates which
conform to the Specifications and in the quantities required for the completion of the Works on time.
3-1
2. Stockpiling
2.1 Stockpile areas shall be surveyed prior to stockpiling to establish control points and to obtain a
record of existing cross sections for future use in determining stockpile quantities. The areas shall be
adequately drained at all times.
2.2 Stockpiling procedures shall not result in noticeable degradation or segregation of the stockpiled
material, or introduction of foreign materials into the stockpile, or coning. Heights of granular material
and aggregate stockpiles shall not exceed 3 m. berms.
3. Sampling and Testing
3.1 Sampling and testing procedures shall conform with the relevant requirements of Section 1.05 –
“Control of Materials and Standards for Sampling and Testing" and with the following requirements.
3.2 The Contractor shall submit to the Engineer, 10 days prior to the scheduled beginning of
crushing and screening operations, a statement of origin and composition of all stone and/or gravel
aggregates and granular materials proposed for use in the Works.
3.3 In order to ascertain the properties of granular and aggregate materials, the Contractor shall
submit for testing and approval, representative samples of all materials intended for incorporation in the
Works, prior to starting quarry or borrow pit operations. The representative samples shall be taken by the
Contractor in the presence of the Engineer.
3.4 Tests performed by the Contractor shall be utilized in assessing the locations, extent of deposits
and quantities of materials which will conform to the Specifications when properly processed, and shall in
no way obviate the need for further testing by the Engineer. Approval of specific sources of materials
shall not be construed as final approval and acceptance of materials from such sources.
3.5 The Contractor may conduct necessary tests in the Field Laboratory in the presence of the
Engineer and the Contractor's Materials Engineer.
3.6 Processed materials shall be tested and approved before being stockpiled on Site or incorporated
in the Works and may be inspected and tested at any time during their preparation, storage and use.
Questionable materials, awaiting testing and approval, shall not be unloaded and mixed with materials
previously approved. If the grading and quality of any materials delivered to the Site do not conform to
the grading and quality of the established control samples, the Engineer will reject such materials.
3.7 Samples shall satisfy all specified test requirements. The contractor shall permit the Engineer to
inspect any and all materials used or to be used, at any time during or after their preparation, or while
being used during progress of the Works. Unsatisfactory materials, whether in place or not, shall be
removed promptly from the Site. The Contractor shall furnish all necessary labor, transport, tools and
equipment required by the Engineer for such inspections.
3.1.3 GRANULAR MATERIAL FOR SUB-BASE
1. Granular material for use in sub-base courses, shall be a naturally occurring gravel, blended as
necessary with fine or coarse material and screened to produce the specified gradation. Crushing of
natural granular material shall not normally be required, unless for the purpose of meeting the gradation
requirements, or when shown on the Drawings (to produce a higher quality sub-base with improved
mechanical stability).
2. Gravel shall consist of hard, durable and sound stones, free from deleterious substances not
mentioned below. Other requirements are:
Crystalline gypsum (expressed as SO3) 5% max.
Clay lumps and friable particles 10% max.
Flakey and elongated particles as follows:

Crushed rock 40% max. each
3-2
Crushed gravel 45% max. each

Natural gravel 50% max. each
(Determined in accordance with BS812 Section

105.1:1985 and B812 Part 1: 1975)
Maximum dry density (gm/cm3) 2.05 min.
Chert content (determined by percentage by weight insoluble in hydrochloric acid) to be specify

in special technical specification.
3. Granular materials delivered to the road site shall meet the requirement of class A or B as shown
in table 3.1, when tested in accordance with AASHTO T-27 after dry mixing and just before spreading
and compacting. The Class of granular material to be used shall be as shown on the Drawings or
otherwise as selected by the Engineer. The actual gradation shall, in all cases, be continuous and smooth
within the specified limits for each Class. If gradation is tested after compaction, a tolerance of 3% is
allowed in the upper limit for the percentage of material passing sieve no. 200.
Table 3.1: Gradation of Granular Material by Class

Percent by weight passing
Sieve Designation
Class A Class B
( square openings)
63 mm (2 ½ in.) 100 -
50 mm (2 in.) 80 – 100 100
37.5 mm (1 ½ in.) 70 – 95 80 – 100
25 mm (1 in.) 55 – 90 60 - 95
12.5 mm (½ in.) 45 – 75 47 - 80
4.75 mm (No. 4) 30 – 60 30 - 60
2.00 mm (No. 10) 22 – 48 22 – 45
0.425mm (No. 40) 10 – 30 10 – 30
0.075mm (No. 200) 5 – 12 5 - 12
4. The material shall contain a minimum of 25% (Dry condition) when tested in accordance with
AASHTO T 176.
5. The loss in weight of granular material shall not exceed 45% after 500 revolutions, when tested
in accordance with AASHTO T 96 (Los Angeles Abrasion Test).
Abrasion after 100 Rev.

The ratio of wear loss = ------------------------------------, should not be more than
twenty percent of the maximum allowed abrasion after 500 revolution.
6. The granular material shall have a 4-day soaked CBR of not less than 40 when compacted at
100% of modified protector AASHTO (T 180-D) and tested in accordance with AASHTO T 193.
7. When tested for soundness in accordance with AASHTO T 104, the materials shall not show
signs of disintegration and the percentage loss in weight after 5 cycles shall not exceed 12% in the case of
the sodium sulphate test and 18% in the case of the magnesium sulphate test.
8. The portion of granular material, including any blended material, passing the 0.425 mm (No. 40)
mesh sieve shall have a liquid limit (L.L.) of not more than 30 and a plasticity index (P.I.) shall neither be
less than 2 nor grater than 8 when tested in accordance with AASHTO T 89 and T 90. Non Plastic
condition might be accepted if crushed lime stone is use provided that angularity test (R) value shall not
be less than 8.
9. If additional fine material is required to correct the gradation of the granular material, or for
adjusting the L.L. or P.I. of the fraction passing 0.425 mm (No 40) sieve, it shall be uniformly blended
and mixed with the granular material. Additional fine material for these purposes shall be obtained from
the crushing of stone, gravel, or slag, if naturally occurring fine material is not available.
3-3
3.1.4 AGGREGATE FOR BASE COURSES
1. Aggregate for use in base course construction shall be crushed stone. Aggregate may be washed,
if directed, to remove excessive quantities of clay, silty clay or salts.
2. Crushed stone and crushed gravel shall consist of hard, durable and sound particles or fragments
of stone, free from other deleterious substances not mention below, other requirements are gypsum, or
flakey particles. Other requirements:
Gypsum content (expressed as SO3) 2%max.
Clay Lumps and friable particles 8% max.
Elongated and flakey particles for Crushed rock

(Determined in accordance with BS812 part
1:1975)
Granit & Basalt 40% max. each

Lime Stone 35% max. each
Maximum Dry density (g/cm3) 2.1 min.
Chert content (determined as percentage by weight insoluble in hydrochloric acid to be specified in

special technical specification.
3. Methods used in production of crushed rock shall ensure that the finished product will be as
uniform as practicable. Crushing shall result in a product such that, for particles retained on 4.75 mm (No.
4) sieve at least 80% by weight shall have at least two fractured faces.
4. Any material passing 4.75 mm (No. 4) sieve and produced in the crushing process shall be
incorporated in the base material up to the gradation limits for the particular Class of aggregate involved.
5. Crushed aggregate for base course delivered to road site shall meet the requirements of Class A
or Class B gradations as shown in Table 3.2, when tested in accordance with AASHTO T 27 after dry
mixing and just before spreading and prior to compacting. The Class of aggregate to be used shall be as
shown on the Drawings or otherwise as selected by the Engineer. The actual gradation shall, in all cases,
be continuous and smooth within the specified limits for each Class. Gap graded aggregate will not be
accepted. If gradation is tested after compaction a tolerance of 3% is allowed in upper limit for percentage
of material passing sieve 200.
Table 3.2: Gradation of Base Course Aggregate by Class

Percent by weight passing
Sieve Designation
Class A Class B
( square openings)
50 mm (2 in.) 100
37.5 mm (1 ½ in.) 100 70 – 100
25 mm (1 in.) 75 – 100 55 - 85
19 mm (¾ in.) 60 - 90 50 - 80
12.5 mm (½ in.) 45 - 80 -
9.5 mm (⅜ in) 40 - 70 40 - 70
4.75 mm (No. 4) 30 - 65 30 - 60
2.00 mm (No. 10) 20 - 40 20 - 50
0.425mm (No. 40) 8 - 20 10 – 30
0.075mm (No. 200) 5 – 10 5 - 15
The material shall contain a minimum of 35% (Dry condition) when tested in accordance with AASHTO
T 176.
6. The loss in weight shall not exceed 45% after 500 revolutions, when tested in accordance with
AASHTO T 96 (Los Angeles Abrasion Test).
3-4

The ratio of wear loss = ----------------------------------- , should not be more than
twenty percent of the maximum allowed abrasion after 500 revolution.
7. The crushed aggregate base course material shall have a 4-day soaked CBR of not less than 80
when compacted at 100% of modified proctor AASHTO (T180-D) and tested in accordance with ASHTO
T 193.
8. When tested for soundness in accordance with AASHTO T 104, the material shall not show
signs of disintegration and the loss by weight shall not exceed 12% in the case of the sodium sulphate test
and 18% in the case of the magnesium sulphate test.
9. The portion of aggregate, including any blended material, passing the 0.425 mm (No. 40) mesh
sieve shall have a liquid limit (L.L.) of not more than 25 and plasticity index (P.I.) of not more than 6
when tested in accordance with AASHTO T 89 and T 90. In case of using cohesion-less base course
material the exposed surface shall exhibit intact and coherent surface to resist water erosion and fretting,
the contractor at his own expense shall ensure such property any solution should not applied unless
approved in writing by Engineer, such solution may include single bituminous surface treatment, bonding
material and other necessary treatment all as directed and approved by the engineer. Provided that
angularity test should be more than 8.
10. If additional fine material is required to correct the aggregate gradation, or for adjusting the L.L.
or P.I. of the fraction passing the 0.425 mm (No. 40) sieve, it shall be uniformly blended and mixed with
the aggregate material Reworking of the material in situ to obtain the specified gradation will be
permitted. Additional fine material for these purpose shall be obtained from the crushing of stone, gravel,
or natural material.
3.1.5 STABILIZING AGENTS
1. Cement as Stabilizing Agent
1.1 Cement shall be Portland cement conforming to AASHTO M 85 Type II, or sulphate resistant
Portland cement conforming to AASHTO M 85, Type V, as specified in the Special Specification.
2. Bitumen as Stabilizing Agent
2.1 Bitumen may include straight run (penetration grade) bitumen; RC cutback bitumen, MC
cutback bitumen, or cationic emulsified bitumen, Type SS. Penetration grade, cutback bitumen and
emulsified bitumen shall conform with all relevant requirements herein.
2.2 The selection of a suitable bitumen will depend on the properties of the material to be stabilized
and shall be subject to laboratory and field trials by the Contractor, under the supervision of the Engineer.
2.3 When the material moisture content is high and material must be dried, the use of penetration
grade bitumen or viscous cutback bitumen and plant mixing of materials are appropriate.
2.4 When the natural moisture content of the material is low, cutback bitumen or emulsified bitumen
are appropriate.
3. Lime as Stabilizing Agent
3.1 Hydrated lime (calcium hydroxide) and quicklime (calcium oxide) shall conform to AASHTO M
216. Mixing of different brands of lime or use of lime from different mills will not be permitted.
3.2 Lime slurry shall be a homogeneous pumpable mixture of lime and water. Slurry shall be a
premixed material in which the lime solids content shall be not less than 30% by weight.
3-5
3.1.6 MEASUREMENT
1. Granular, aggregate and stabilized materials for sub-base and Base Courses shall be measured as
prescribed in the appropriate Sections of these Specifications.
3-6
GRANULAR SUB-BASE COURSES SECTION 3.2
SECTION 3.2 : GRANULAR SUB-BASE COURSES

3.2.1 SCOPE
1. These Works shall consist of furnishing granular sub-base material of the required Class, mixing,
spreading on prepared subgrade, compacting and finishing, all as and where shown on the Drawings.
3.2.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 3.01 - "Materials", in
respect of granular material Class A or Class B for sub-base construction.
3.2.3 SUBGARDE SURFACE PREPARATION
1. The subgrade shall have previously been constructed in accordance with the requirements of
Section 2.07 - "Subgrade Construction and Topping" and properly maintained and kept well drained
thereafter.
2. At all special grade control points, such as at bridge structures, existing pavements, etc the
subgrade shall be lowered to a depth sufficient to permit construction of the sub-base course to the
specified elevations and thickness. Transitions shall be of sufficient length to avoid abrupt changes of
grade and shall be within plus or minus 3% of the final design grade unless otherwise directed. Surplus
material shall be removed and disposed off.
3. The subgrade shall be inspected and approved immediately prior to commencement of sub-base
construction. And soft, yielding material shall be removed and replaced by approved topping material.
Holes, depressions and other irregularities shall be made good as directed and the subgrade re-compacted
as necessary and finished ready to receive the sub-base course.
3.2.4 EQUIPMENT
1. Equipment used to handle, place, spread, water, compact and finish sub-base shall conform with
the requirements of Section 1.12 - "Contractor's Plant and Equipment" and with the Contractor's approved
Work Program.
1. Before commencement of Site sub-base construction, the Contractor may be required to lay and
compact trial sections of varying thickness of sub-base. Each trial section shall be 2 lanes wide by 50 m
long, at approved locations on or close to the Site. Each trial section shall be laid using the same
materials, mix proportions, mixing, spreading and compaction equipment, and construction procedures,
proposed for use in the Works.
2. The objectives of these trials shall be to determine the adequacy of the Contractor's equipment.
The loose depth measurements that will result in the specified compacted layer depths, the field moisture
content, and the relationship between the number of compaction passes and the resulting density of the
sub-base material.
3. The Contractor shall not proceed with sub-base construction until the methods and procedures
established in the trails have been approved.
3.2.6 CONSTRUCTION
1. Stockpiling of Granular Material
1.1 Stockpiling procedures shall conform with the relevant requirements of Section 3.01 -
"Materials".
3-7
1.2 Methods used for stockpiling granular material and removing it from stockpiles shall not result
in significant degradation or segregation nor the introduction of significant amounts of foreign materials
or extraneous matter.
1.3 Granular material adversely affected, in the opinion of the Engineer, by stockpiling of handling
procedures, shall not be incorporated in the Works regardless of previous approval of such material, until
the deficiencies have been rectified in an acceptable manner.
2. Mixing and Spreading
2.1 All components of sub-base course material shall be mixed thoroughly and uniformly with water
in situ. The amount of water added, as approved by the Engineer, shall be such that the material will be
uniform and within the specified moisture content range at the time of compaction. Wetting of granular
material in stockpiles or in trucks before or during delivery to the Site will not be permitted. However,
water shall be added to the material, if necessary, during placing and compaction of sub-base material.
2.2 The sub-base material shall be placed on the subgrade in a uniform layer or layers not exceeding
200 mm thickness (after compaction). Where the required un-compacted thickness is greater than 250 mm
but less than 500 mm, the material shall be placed in layers of equal thickness.
2.3 if approved, heavy duty vibratory compaction equipment is used, the maximum layer thickness
may be increased up to 300 mm (after compaction) provided compaction tests with appropriate testing
equipment indicate that the specified compaction standard will be attained and uniform throughout the
thickness.
2.4 The sub-base material shall be placed to the required width using a self-propelled spreader or a
motor grader equipped with blade extensions. Water shall be applied by approved spraying equipment
and thoroughly mixed with the sub-base material.
2.5 The material shall not be handled in such a way as to cause segregation. If the spreading
equipment causes segregation in the material, or leaves ridges or other objectionable marks on the surface
which cannot be readily eliminated or prevented by adjustment of the equipment, the use of such
equipment shall forthwith be discontinued and it shall be replaced by a spread or grader capable of
spreading the material in a proper manner.
2.6 All segregated material shall be removed and replaced with well-graded material. "Skin"
patching will not be permitted. Only minor surface manipulation and watering to achieve the required
surface tolerances will be permitted during the compaction process.
2.7 Neither hauling nor placement of material will be permitted when, in the judgment of the
Engineer, the weather or surface conditions are such that hauling operations will cause cutting or rutting
of the subgrade or cause contamination of the sub-base material.
3. Compaction
3.1 The Contractor shall plan the sequence of operations so that the least amount of water will be
lost by evaporation from uncompleted surfaces. If the Contractor delays placing of succeeding layers of
material to the extent that additional water is required to prevent raveling or excessive drying, the
application of such water shall be carried out as directed and at the Contractor's expense.
3.2 The sub-base material shall be compacted by means of approved compaction equipment,
progressing gradually from the outside towards the center, with each succeeding pass uniformly
overlapping the previous pass.
3.3 Rolling shall continue until the entire thickness of each sub-base layers is thoroughly and
uniformly compacted to 100% AASHTO T 180 (Method D) maximum density. Final rolling of the
completed course shall be by means of an approved self-propelled roller. Rolling shall be accompanied by
sufficient blading, to insure a smooth surface, free from ruts or ridges and having the proper shape. When
additional water is required, it shall be applied in an approved manner.
3-8
3.4 Any areas inaccessible to normal compaction equipment shall be compacted by use of portable
mechanical tampers until the required standard of compaction is achieved.
3.5 Each layer shall be completely compacted and approved prior to delivery of materials for the
subsequent layer.
3.6 Prior to placing a subsequent layer, the existing surface shall be made sufficiently moist as
directed, to ensure proper bond between the layers.
3.7 The edges and edge slopes of the sub-base course shall be bladed or otherwise dressed to
conform to the lines and dimensions shown on the Drawings and to present straight, neat lines and slopes
as free of loose material as practicable.
3.8 Material which has dried out prior to final compaction, or which has dried and de-compacted
subsequent to final compaction, shall be watered and re-compacted using approved equipment and
procedures. If the Contactor is unable to return the material to its original or specified condition with
respect to compaction, thickness and surface tolerances, the Contractor shall remove the material and
reconstruct the sub-base course on a re-approved Subgrade.
4. Tolerances
4.1 The fully compacted and completed sub-base course shall conform to the lines, grades and cross
4.2 The elevations of the finished sub-base course shall be checked by the Contractor in the presence
of the Engineer at maximum intervals of 10 m and at intermediate points as directed.
4.3 The tolerances on elevations of finished surface shall be plus 10 mm to minus 20 mm, minus
tolerance shall be compensate by the proceeding layer.
4.4 When the finished surface is tested with a 4 m long straightedge, placed parallel to, or right
angles to the centerline, the maximum deviation of the surface from the testing edge between any 2
contact points shall not exceed 10 mm.
4.5 All areas which exceed the specified tolerances shall be corrected by removing the defective
sections of sub-base and reconstructing them or, if approved, by adding new material mixing and re-
compacting and finishing to the specified standard.
5. Maintenance of Completed Sub-base
5.1 Following completion and acceptance of the sub-base course, it shall be maintained by the
Contractor at his own expense. The sub-base shall be bladed, broomed and otherwise maintained, keeping
it free from raveling and other defects until such time as the base course is placed. Water shall be applied
at such times and in such quantities as directed by the Engineer.
3.2.7 TESTING
1. Every 500 linear meter of sub-base material or whenever there is a change in the material source
shall be subject to a full set of tests after mixing in situ and, if found satisfactory, shall be approved for
compaction. This approval shall not be deemed to constitute acceptance of the sub-base course.
2. Sampling and testing shall conform with the relevant requirements of Section 1.05 – “Control of
Materials and Standards for Sampling and Testing”.
3. Compaction shall be tested in accordance with AASHTO T 191 or AASHTO T 205. If there is a
delay between the construction of any layer and the following layer, if necessary and required by the
Engineer the compaction of the lower layer may be re-verified to ensure that it has not loosened due to
traffic, passage of construction equipment, adverse weather conditions or otherwise.
3-9
3.2.8 MEASUREMENT
1. Granular Sub-base Course shall be measured by m3 of granular material furnished, screened,

crushed if so specified, mixed with water, placed, spread, compacted and finished, completed, and
accepted. Measurements shall be of volumes computed from the cross sections shown on the Drawings
and of the field measurements of area and compacted depth of each Trial Section.
2. No measurement shall be made for direct payment of over-depth construction, regardless of the
Engineer’s permission for it to remain in place.

(1) Granular Sub-base Course Cubic meter (m3)
3-10
AGGREGATE BASE COURSE SECTION 3.3
SECTION 3.3 : AGGREGATE BASE COURSE

3.3.1 SCOPE
1. These Works shall consist of furnishing crushed aggregate base course material of the required
Class, mixing, spreading on prepared sub-base course, compacting and finishing, all as and where shown
on the Drawings.
3.3.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 3.01 – “Materials”, in
respect of crushed aggregate Class A or Class B for base course construction.
3.3.3 SURFACE PREPARATION
1. Where a sub-base course is present, it shall have previously been constructed in accordance with
the requirements of Section 3.02 – “Granular Sub-base Courses” and properly maintained and kept well
drained thereafter.
2. The sub-base surface shall be inspected and approved prior to commencement of base
construction. Holes, depressions and other irregularities shall be made good as directed and the sub-base
re-compacted as necessary and finished ready to receive the base course.
3. Where sub-base course is omitted in the contract drawing and the aggregate base course is
placed directly on completed Subgrade, preparation of the sub-grade surface shall be as specified in
Section 3.02 – “Granular Sub-base Courses”.
3.3.4 EQUIPMENT
1. Equipment used to handle, place, spread, water, compact and finish base course shall conform
with the requirements of Section 1.12 – “Contractor’s Plant and Equipment” and with the Contractor’s
approved Work program.
3.3.5 CONSTRUCTION OF TRIAL SECTION
1. If the Engineer deems it necessary the contractor shall lay and compact trail sections of varying
thickness of base. Each trail section shall be 2 lanes wide by 50 m long, at approved locations on or close
to the Site. Each trial section shall be laid using the same materials, mix proportions, mixing spreading
and compaction equipment, and construction procedures, proposed for use in the Works.
2. The objectives of these trials shall be to determine the adequacy of the Contractor’s equipment,
the loose depth measurements that will result in the specified compacted layer depths, the field moisture
content for compaction, and the relationship between the number of compaction passes and the resulting
density of the base course material.
3. The Contractor shall not proceed with base course construction until the methods and procedures
established in the trials have been approved.
3.3.6 CONSTRUCTION
1. Stockpiling of Aggregate Materials
1.1 Stockpiling procedures shall conform with the relevant requirements of Section 3.01 –
“Materials”.
1.2 Methods used for stockpiling aggregate materials and removing them from stockpiled shall not
result in significant degradation nor the introduction of significant amounts of foreign materials or
extraneous matter.
3-11
1.3 Aggregate materials adversely affected, in the opinion of the Engineer, by stockpiling or
handling procedures, shall not be incorporated in the Works regardless of previous approval of such
material, until the deficiencies have been rectified in an acceptable manner.
2. Mixing and Spreading
2.1 All components of base course material may be premixed with water, in a pugmill mixing plant
or on site. The amount of water added, as determined shall be such that the material will be uniform and
within the specified moisture content range at the time of compaction. The Engineer may allow other
methods of mixing provided such method(s) do not reduce the standard of work required by the Client. If
such alternative mixing methods are allowed the Contractor will be required to demonstrate, in the
presence of the Engineer, his ability to attain the requirement given in the General Specification and / or
Special Specification as applicable.
2.2 The premixed material shall be placed on the sub-base in a uniform layer or layers not exceeding
250 mm in thickness (before compaction). Where the required un-compacted thickness is grater than 250
mm but less than 500 mm, the material shall be placed in layers of equal thickness.
2.3 If approved, heavy duty vibratory compaction equipment is used, the maximum layer thickness
may be increased up to 350 mm (after compaction)
provided compaction tests indicate that the specified compaction standard will be attained.
2.4 The base course material shall be placed to the required width using a self-propelled spreader or
motor grader, and shall be delivered such that it is ready for compaction without further shaping.
2.5 The material shall not be handled in such a way as to cause segregation. If the spreader cause
segregation in the material, or leaves ridges or other objectionable marks on the surface which cannot be
readily eliminated or prevented by adjustment of the spreader operation, the use of such spreader shall
forthwith be discontinued and it shall be replaced by a spreader capable of spreading the material in a
proper manner.
2.6 All segregated material shall be removed and replaced with well-graded material. “Skin”
patching will not be permitted. Only minor surface manipulation and watering to achieve the required
surface tolerances will be permitted during the compaction process.
2.7 Hauling or placement of material will not be permitted when, in the judgment of the Engineer,
the weather or surface conditions are such that hauling operations will cause cutting or rutting of the sub-
base or subgrade or cause contamination of the base course material.
3. Compaction
3.1 The Contractor shall plan the sequence of operations so that the least amount of water will be
lost by evaporation from uncompleted surfaces. If the Contractor delays placing of succeeding layers of
material to the extent that additional water is required to prevent raveling or excessive drying, the
application of such water shall be carried out in an approved manner and at the contractor’s expense.
3.2 The base course material shall be compacted by means of approved compaction equipment,
progressing gradually from the outside towards the center, with each succeeding pass uniformly
overlapping the previous pass.
3.3 Rolling shall continue until the entire thickness of each base layer is thoroughly and uniformly
compacted to 100% AASHTO T 180 (Method D) maximum density. Final rolling of the completed
course shall be means of an approved self-propelled roller. Rolling shall be accompanied by sufficient
blading, to ensure a smooth surface, free from ruts or ridges and having the proper shape. When
additional water is required, it shall be applied in by an approved manner.
3.4 Any areas inaccessible to normal compaction equipment shall be compacted by use of portable
mechanical tampers until the required standard of compaction is achieved, or to the satisfaction of the
Engineer.
3-12
3.5 Each layer shall be completely compacted and approved prior to delivery of materials for the
following layer.
3.6 Prior to placing a following layer, the surface shall be made sufficiently moist as directed, to
ensure proper bond between the layers.
3.7 The edges and edge slopes of the base course shall be bladed or otherwise dressed to conform to
the lines and dimensions shown on the Drawings and to present straight, neat lines and slopes as free of
loose material as practicable.
3.8 Material which has dried out prior to final compaction, or which has dried and de-compacted
subsequent to final compaction, shall be watered and re-compacted using approved equipment and
procedures. If the Contractor is unable to return the material to its original or specified condition with
respect to compaction, thickness and surface tolerances, for the final layer only the Contractor shall
scarify the material and reconstruct the base course on a re-approved sub-base surface or to the
satisfaction of the Engineer.
4. Tolerances
4.1 The fully compacted and completed base course shall conform to the lines, grades and cross
4.2 The elevations of the finished base course shall be checked by the Contractor in the presence of
the Engineer at intervals of 20m on straight lines and of 10 m on curves, and at intermediate points as
directed.
4.3 The tolerances (for final layer only) on elevations of finished surface shall not exceed + 10mm
or –15mm.
4.4 When the finished surface is tested with a 4 m long straightedge, placed parallel to, or at right
4.5 All areas which exceed the specified tolerances shall be corrected by removing the defective
sections of base course and reconstructing them or if approved, by scarifying and adding new material
and re-compacting and finishing to the specified standard.
5. Maintenance of Completed Base
5.1 Following completion and acceptance of the base course, it shall be maintained by the
Contractor at his own expense. The surface shall be broomed, rolled and otherwise maintained, keeping it
free from raveling and other defects until such time as the following course is placed. Water shall be
applied at such times and in such quantities as directed.
3-13
Table 3.3: Required Test & Minimum Repetition for Base course Material
Source of Material Control on Site (The Road)
Required Test Repetitions Required Required Test Repetitions Required
(A) For all Tests in (A) (B) For all Tests in (B)
1. Gradation of Material Test for each source 1. Proctor Test for every 500
linear meter for each
layer
2. Plasticity Index For every 2000m3 2. Gradation of Material When material change
3. Abrasion When material change 3. Plasticity Index
4. C.B.R 4. C.B.R
5. Sand Equivalent 5. Abrasion
6. Percentage of 6. Sand Equivalent
fractured Grains / Base
course 7. Clay Lumps &
Friable particles
7. Any other tests as 8. Any other tests as Test for every 750m2
required in Special required in Special and for every layer.
specification and specification and
Drawings Drawings
9. Field Density
10. Thickness
3.3.7 TESTING
1. Sub-Base and Base course material shall be tested in accordance with Table 3.3 at stock pile and
at the mixing plant for source of material tests and in-situ after dry mixing prior to spreading and
compaction for control on site tests and if satisfactory shall be approved for use. This approval shall not
be deemed to constitute acceptance of the base for full payment purposes.
2. Sampling and testing shall conform with relevant requirements of Section 1.05 – “Control of
Materials and Standards for Sampling and Testing”.
3. Compaction shall be tested in accordance with AASHTO T 191, AASHTO T 205 or any
acceptable method. If there is a significant delay between the construction of any layer and the following
layer, the Engineer may require the compaction of the lower layer to be re-verified to ensure that it has
not loosened due to traffic, passage of construction equipment, adverse weather conditions or otherwise.
3.3.8 MEASUREMENT
1. Aggregate Base Course shall be measured by m3 of aggregate materials furnished, crushed and
screened, mixed with water, placed, spread, compacted and finished, completed, and accepted.
Measurements shall be of volumes computed from the cross sections shown on the Drawings and of the
field measurements of area and compacted depth of each Trial Section.
2. No measurement shall be made for direct payment of over-depth construction, regardless of the
Engineer’s permission for it to remain in place.

(1) Aggregate Base Course Cubic meter (m3)
3-14
STABILIZED COURSES SECTION 3.4
SECTION 3.4 : STABILIZED COURSES

3.4.1 SCOPE
1. These Works shall consist of furnishing, mixing, spreading, compacting and finishing courses
composed of sand, sandy gravel, sandy clay soil or similar (and including granular material which does
not meet the standards specified for base) stabilized with cement or bitumen or lime as appropriate, as and
where shown on the Drawings. Other stabilizing approved techniques and testing may be followed if
applicable
3.4.2 MATERIALS
1. Cement, bitumen and lime for use as stabilizing agents shall conform with the relevant
requirements of Section 3.01 – “Materials”. Unless shown on the Drawings the Engineer will determine
the type of cement to be used or the type and grade of bitumen to be used, or whether hydrated lime or
quicklime shall be used.
2. The material to be stabilized shall conform with the gradation and other requirements specified
for the particular stabilizing agent to be used.
3. Curing seal shall consist of an approved proprietary curing compound, or MC-70 cutback
bitumen to Prime Coat standards as specified in Section 4.01 – “Materials” and Section 4.02 –
“Bituminous Prime and Tack Coasts”.
4. Water shall be potable and shall conform with the relevant requirements of Section 5.01 –
“Concrete and Concrete Mixes and Testing”.
1. Prior to placing of stabilized sub-base on subgrade, the subgrade shall have been properly
completed and approved as specified in Section 2.07 – “Subgrade Construction and Topping” or Section
2.08 – “Stabilized Subgrade Construction”.
1. If the Engineer requires it, before commencement of Site stabilization Works and after
completion of laboratory mix design, the contractor shall lay a trial section of stabilized material 2 lanes
wide by 50 m long, at an approved location on or near to the Site. This trial section shall be laid using the
same materials, mix proportions, mixing, spreading and compaction equipment, and construction
procedures that are proposed for use in the Works.
2. The trial section shall serve as a field verification of the laboratory mix design. The result of the
dry density and moisture content measurements made in the trial section will be used in association with
the laboratory tests to establish the moisture content and minimum per cent compaction to be attained in
the Site stabilization Works.
3. The trial section also demonstrate the adequacy of mixing, spreading and compaction equipment
and the suitability of the methods and organization proposed.
3.4.5 CEMENT STABILIZATION PROCEDURES
1. Mix Design
1.1 The material to be stabilized shall be a sandy or gravelly soil of low plasticity or aggregate,
which conforms to the following gradations:
3-15
Table 3.4: Sandy and Gravelly Soils

Sieve No. % by weight passing
Aggregate Soil
50 mm ( 2 in.) 100
20 mm ( ¾ in) 60 – 95 100
4.75 mm ( No. 4) 15 – 75 50 – 100
0.425 mm ( No. 40) 10 – 35 15 – 60
0.15 mm ( No. 100) 5 – 15 5 – 30
0.075 mm ( No. 200) 0–5 0 – 10
1.2 The cement content and optimum moisture content for the proposed mix shall be determined in
the field laboratory and in the presence of the Engineer. Cylinders molded in accordance with AASHTO
T 134 shall be cured and tested in compression at 7 days and 28 days. Curing shall be in accordance with
AASHTO T 126. Load rate of application shall be in accordance with AASHTO T 22. The minimum
compressive strength at 7 days after molding shall be 4 MN/m2 (40 kg/cm2) and the cement content of
trial mixes shall be adjusted until this strength is achieved.
1.3 The maximum volume change (swelling) shall be 2% and the maximum loss in weight shall be
not more than 8%, when cylinders are molded and tested in accordance with AASHTO T 135, Method B.
1.4 Cement content and water content of the mix on the Site shall each be within –0.2% to + 2% of
the approved mix design.
2. Plant Mixing Generally
2.1 When cement and granular material are to be mixed in a stationary plant, the plant shall be an
approved type pugmill mixing plant of either the batch mix type with revolving blade or rotary drum, or
the continuous mixing type. Proportioning of materials and of water may be by either weight or volume.
2.2 Cement shall be added in such a manner that it is uniformly distributed during the mixing
operation. Safe, convenient facilities shall be provided for sampling cement in the supply line to the
weigh hopper or pugmill.
2.3 Means shall be provided whereby the Engineer may verify the amount of water per batch or the
rate of flow for continuous mixing. The time of the addition of water and the points at which it is
introduced into the mixer shall be as approved.
2.4 The charge in a batch mixer, or the rate of feed to a continuous mixer, shall not exceed that
which will permit complete mixing of all of the material. Dead areas in the mixer, in which the material
does not move or is not sufficiently agitated, shall be corrected.
2.5 The moisture content of the completed mixture shall be not more than one per cent below
optimum moisture content at the point of delivery to the Works.
3. Batch Mixing
3.1 Batch mixing plants shall be equipped with a sufficient number of paddles of a type and
arrangement to produce a uniformly mixed batch.
3.2 The mixer platform shall be of ample size to provide safe and convenient access to the mixer and
other equipment.
3.3 The mixer shall be equipped with a timing device which will indicate by a definite audible or
visual signal the expiration of the mixing period. The device shall be accurate to within 2 seconds.
3.4 The time of mixing a batch shall begin after all ingredients are in the mixer and shall end when
the mixer is half emptied. Mixing shall continue until a homogeneous mixture of uniformly distributed
and properly coated materials of uniform appearance is produced. The time of mixing shall not be less
than 30 seconds. When blending of different sizes is required, the materials shall be blended as they enter
the mixer.
3-16
3.5 Cement for each batch shall be weighed on scales separate from the aggregate batching scales.
Each cement scale graduation shall be approximately 0.001 times the total capacity of the scales. The
total capacity shall not be greater than that of commercially available scales when weighing twice the
amount of cement required when the plant is operated at full capacity. No scale shall be used with a
capacity less than 500 kg.
4. Continuous Mixing
4.1 Continuous mixing plants shall be designed such that granular materials are drawn from the
storage facility by feeders which continuously supply the correct amount of granular material in
proportion to the cement and so arranged that the proportion of each size can be separately adjusted if
more than one size is used. Storage facilities containing fine material shall be equipped with vibrating
units which shall vibrate the side walls of the feeder to prevent any hang-up of materials while the plant is
operating.
4.2 A control system shall be provided that will automatically close down the plant when the
material in any storage facility approaches the strike-off capacity of the feed gate. The plant will not be
permitted to operate unless the control system is in proper working order.
4.3 The feeder for the granular material shall be mechanically or electrically driven. Mechanically
driven feeders shall be directly connected with the drive on the cement feeder. The drive shaft on the
feeder shall be equipped with a revolution counter reading to 0.1 of a revolution. Electrically driven
feeders shall be actuated from the same circuit that services the motor driving the cement feeder.
4.4 The cement feeder and the granular material feeders shall be equipped with devices by which the
rate of feed can be determined while the plant is in full operation.
5. Mixed in Place Procedures
5.1 Mixed in place procedures will normally be permitted when the granular material to be stabilized
is in situ Site material.
5.2 Plant and equipment for pulverizing (if required) and for mixing all materials will be approved
on the basis of preliminary trials to establish that such plant and equipment are capable of producing the
specified degree of mixing and uniformity of stabilized material for the full thickness of each layer.
Single pass or multi-pass equipment may be used.
5.3 The mixing equipment shall be equipped with a device for controlling the depth of processing
and the mixing blades shall be maintained or reset periodically so that the correct depth of mixing is
obtained at all times. Cement shall be spread ahead of the mixer by means of a cement spreader, fitted
with a device to ensure a uniform and controllable rate of spread of cement transversely and
longitudinally.
5.4 If multi-pass equipment is utilized, the fine cohesive fraction (if any) of the material shall first be
pulverized to the required depth with successive passes and the moisture content adjusted if it is more
than 3% below the value required for compaction. Cement shall then be spread and mixing continued
with successive passes until the required depth and uniformity have been achieved.
5.5 If it is necessary to adjust the moisture content of the material to the optimum for compaction,
water shall be added during the mixing operation using a water sprayer of such design that the water is
added in a uniform and controllable manner both transversely and longitudinally.
5.6 The mixing equipment shall be set so that it cuts slightly into the edge of any adjoining
completed lane so as to ensure that all material forming the layer has been properly processed. The
Engineer may approve the use of scarifiers or preparizers ahead of the mixing equipment. The output of
the mixing equipment shall be such that a minimum rate of 20 linear m./hr measured longitudinally of
completed stabilized layer can be maintained in order to permit satisfactory compaction of the mix.
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6. Placing of Stationary Plant Mixes
6.1 Immediately prior to depositing the mix, the surface area to be covered shall be moistened and
kept moist.
6.2 The cement stabilized mix shall be protected against moisture loss during transporting, by use of
suitable covers. The mix shall be deposited on the roadbed at a quantity per linear meter which provide
the compacted thickness
for the width being spread without resort to spotting, picking up, or otherwise shifting the mixture.
Segregation shall be prevented and the mix shall be free from pockets of coarse or fine materials.
6.3 The mix shall be spread in widths of not less than 2 lanes, insofar as the width of surface
permits. Longitudinal construction joints shall fall within 300 mm of lane lines. The mix shall be spread
by one or more spreaders operating in a staggered position across the subgrade. If traffic conditions
require that less than 2 lanes be spread, not more than 2 hours shall elapse between the times of placing
the material in adjacent lanes.
6.4 The compacted thickness of any one layer shall not exceed 200 mm and shall be not less than 80
mm. When more than one layer is placed, the surface of the lower layer of compacted mix shall, until
covered with the next layer, be kept moist with water or a curing seal as specified.
6.5 In the case of areas inaccessible to mechanical spreading equipment, the mix may be spread in
one layer by approved methods only. After spreading, the material shall be thoroughly compacted to the
required lines, grades, and cross section by means of pneumatic tampers, or other approved compacting
equipment.
6.6 Use of motor graders will not be permitted during spreading or compacting operations. Motor
graders may be used only to trim the edges and surfaces after compaction in order to finish within the
specified tolerances.
6.7 A motor grader may be classified as a self-propelled mechanical spreader if it has been equipped
with end wings on the blade, has the blade locked in a position perpendicular to the direction of travel,
and is equipped with cross slope and automatic grade controls that meet the requirements for the specified
type of spreading.
6.8 Each layer of the mix shall be spread in one operation with an approved type self-propelled
mechanical spreader such that the layer is made ready for compaction without further shaping. The
spreader shall be provided with a fully automatic and adjustable screed that strikes off and distributes the
material to the full width being spread and to the surface tolerances specified.
6.9 The spreader shall be equipped with grade sensing controls to automatically control the
longitudinal grade and transverse slopes of the screed. Screed action includes any cutting, crowding, or
otherwise that produces a finished surface texture of uniform appearance.
6.10 Cement stabilized mixes shall not be mixed or placed while the atmospheric temperature is
below 2 degrees C and shall not be placed on frozen ground. A curing seal as specified shall be applied to
the surface of the compacted mix before the atmospheric temperature approaches 2 degrees C.
7. Compaction and Finishing
7.1 Immediately upon completion of spreading or spreading and mixing in place operations, and
completion of shaping, the mix shall be initially compacted by one complete coverage using approved
type rollers.
7.2 If the finished surface after initial compaction is outside the specified tolerance, all high spots
shall be trimmed off to within the specified tolerance. Filling of low areas by drifting or hauling of
trimmed material will not be permitted.
7.3 Following trimming, the finished surface shall be finally compacted to not less than 100% of the
laboratory density of the approved job mix specimens as determined by AASHTO T 134. Final
3-18
compaction shall be accomplished in such a manner that no loose material remains on the surface and all
tear marks are eliminated.
7.4 The surface tolerances shall conform with the tolerance requirements for granular sub-base. In
the case of any areas which are lower than the allowable tolerance, the stabilized layer shall be removed
and fresh stabilized mix placed and properly compacted and finished, unless filling of the low areas with
bituminous concrete or cement concrete is approved.
7.5 When the superimposed course will be cement concrete, the low areas may, if approved, be
filled with concrete at the time and during the same operation that the concrete pavement is placed. Such
additional concrete shall be at the Contractor's expense.
7.6 When the superimposed curse will be bituminous concrete, the low areas may, if approved, be
filled with bituminous concrete to the same standard. This filling shall be carried out as a separate
operation prior to placing the bituminous concrete course (unless the thickness to be placed is too small to
make this practicable) and shall be at the Contractor's expense.
7.7 Not more than 2 hours shall elapse between the time water is added to the mixed materials and
the time of completion of initial compaction. Final compaction shall be completed within 30 minutes of
initial compaction.
7.8 At the end of each day's work and when operations are delayed or stopped for more than 2 hours,
a vertical construction joint shall be made in the fully compacted layer, perpendicular to the centerline.
Additional mix shall not be placed until the construction joint has been approved.
7.9 One hour after the stabilized mix has been finally compacted, vertical longitudinal joints shall be
constructed by cutting into the existing edge to a depth of approximately 100 mm. The mix cut away shall
be discarded. The face of the cut joints shall be moistened in advance of placing the adjacent lane.
8. Curing
8.1 Curing seal as specified shall be applied uniformly to the completed surface at a rate of between
0.75 and 1.25 liter/ m2, as determined by the Engineer. The curing seal shall be applied on the same day
that final compaction is performed and as practicable thereafter. The surface shall be kept moist until seal
is applied.
8.2 Damage to the curing seal or stabilized surface shall be promptly repaired by the Contractor at
his own expense, in an approved manner.
3.4.6 TESTING OF CEMENT STABILIZED COURSES
1. For every 5,000 m2 of each stabilized layer or for each day's completed area (whichever is
smaller) the following sampling and testing shall be carried out.
1.1 In situ density of a minimum of 3 samples (taken immediately after final compaction)
determined in accordance with AASHTO T 191 or T 205 and which shall be not less than 100%
of the density of the approved laboratory mix.
1.2 Cement content in accordance with AASHTO T 211.
1.3 Gradation of mix in accordance with AASHTO T 27.
1.4 Moisture - density relationship for mix sample fresh the Site, in accordance with
AASHTO T 134 if the source of the material is changed.
1.5 Compressive strength of a set of 3 test specimens molded and cured in accordance with
AASHTO T 134 and T 126, and tested in accordance with AASHTO T 22.
3-19
3.4.7 BITUMEN STABILIZATION PROCEDURES
1. Mix Design
1.1 The material to be stabilized if specified in the Special Specification shall be a sand, sandy
gravel or silty or clayey gravel and sand material with a P.I. not exceeding 12% and L.L. not exceeding
25% and with not more than 30% passing a 0.075 mm (No. 200) sieve.
1.2 Bitumen-soil mix proportions shall be established by field laboratory trial mixes, carried out in
the presence of the Engineer. The compressive strength shall be determined in accordance with AASHTO
T 167 and in such a way as to ensure that the optimum composition of the mix is established.
1.3 The laboratory trial mixes, after being air cured for a period of 7 days and tested in accordance
with AASHTO T 167, shall have a minimum compressive strength at 25 degrees C, of 2 MN/m2 (20
kg/cm2) and a Marshall stability at 60degrees C, of 2,000 N (204 kg). The index of Retained Strength
when tested using a Marshall mould shall be not less than 70%
2. Stationary Plant Mixing
2.1 When approval is given to utilize stationary plant for mixing, whether batch mixing plant or
continuous type mixing plant, the plant and equipment and handling and mixing procedures shall conform
with the relevant requirements of Section 4.03 - "Bituminous Courses" and with the appropriate
requirements specified herein for plant mixing of cement stabilized materials.
3.1 Approved type multi-pass or approved type purpose-built, single-pass equipment shall be
utilized for on Site mixing and placing. Operators shall be trained and fully experienced in the operation
of such equipment.
3.2 Multi-pass equipment may consist of suitable bitumen distributor and motor graders or as
otherwise approved.
3.3 The process of pulverizing the fine grained cohesive fraction (if any) of the granular material
shall be as specified for cement stabilized courses. Bitumen, of the type and grade selected by the
Engineer, shall then be applied to the surface using approved type heating and pressure distribution
equipment. Emulsified bitumen shall not normally require heating.
3.4 Spreading and mixing of the bitumen and granular or other material shall be carried out as
specified for cement stabilized course.
4. Placing and Spreading Stationary Plant Mixes
4.1 The placing and spreading of stationary plant mixes shall be as specified for cement stabilized
courses.
5.1 Compaction of bitumen stabilized courses to 100% of laboratory density of approved job mix
specimens, finishing, and provision of longitudinal joints, shall be as specified for cement stabilized
courses.
6. Tolerances and Replacement of Unsatisfactory Areas
6.1 Finished surface tolerances and the rectification procedures for any areas which fail to meet such
tolerance, shall be as specified for cement stabilized courses.
3-20
6.2 In the case of high spots requiring trimming after initial compaction, raking or similar
procedures may be required. If the areas is unduly damaged or pitted, the stabilized mix shall be removed
and replaced with fresh stabilized mix spread and properly compacted and finished.
3.4.8 TESTING OF BITUMEN STABILIZED COURSES
1. For every 5,000 m2 of each stabilized layer or for each day's completed area (whichever is the
1.1 In situ density of a minimum of 3 samples (taken immediately after completion of final
compaction) determined in accordance with AASHTO T 191 or T 205 and which shall be not
less than 100% of the density of the approved laboratory mix:
1.2 Composition of the mix by extraction in accordance with AASHTO T 164.
1.3 Compressive strength in accordance with AASHTO T 167, of samples before

compaction.
1.4 Marshall stability in accordance with AASHTO T 245, of samples before compaction.
3.4.9 LIME STABILIZATION PROCEDURES
1. Mix design
1.1 The material to be stabilized shall be a clayey gravel, clayey sand or lean clay soil with not more
than 50% passing 0.425 mm (No. 40) sieve and Plasticity Index greater than 10%.
1.2 The lime content and optimum moisture content shall be determined in the field laboratory and
in the presence of the Engineer. Cylinders molded in accordance with AASHTO T 220 shall be cured and
tested at 7 days and 28 days. Load rate of application shall be in accordance with AASHTO T 22. The
minimum compressive strength at 7 days after molding shall be one MN/m2 (10 kg/cm2).
1.3 Lime content and water content of the mix on Site shall each be within -0.2% to + 2.5% of the
approved mix design percentages.
2. Safety Precautions
2.1 Special precautions shall be taken when handling quicklime as it will rapidly corrode equipment
and can inflict server skin burns to personnel coming in contact with it.
2.2 Suitable methods for handling quicklime shall be adopted, including fully mechanized or bottom
dump handling equipment and protective clothing worn by the operators. Working operations should take
into account the wind direction to minimize the dust problem and consequent eye or skin irritation to any
personnel in the vicinity.
2.3 When hydrated lime is used, precautions shall also be taken against the effects of prolonged
exposure to the skin.
3. Stationary Plant Mixing
3.1 When approval is given to utilize stationary plant for mixing, whether batch mixing plant or
continuous type mixing plant, the plant and equipment and handling and mixing procedures shall be as
specified for cement stabilization and as specified herein for plant mixing of lime stabilized materials.
4.1 Mixed in place procedures will normally be permitted when the soil to be stabilized is in situ site
material.
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4.2 Spreading and mixing of the lime and soil material shall be carried out as specified for cement
stabilized courses.
5. Placing and Spreading Stationary Plant Mixes
5.1 The placing and spreading of stationary plant mixes shall be as specified for cement stabilized
courses.
6.1 Compaction of lime stabilized courses to 100% of laboratory density of approved job mix
specimens, finishing and provision of longitudinal joints, shall be as specified for cement stabilized
courses with the following modifications:
6.1.1 When quick lime is used, the layer shall not be compacted immediately after spreading
the lime, as hydration of the lime will cause damage to the compacted layer. The time within
which the compaction shall be completed will be estimated in the laboratory.
6.1.2 Compaction shall not take place after lime hydration. Any lime stabilized material that
has been mixed or deposited after lime hydration, shall be removed and replaced with fresh
material, mixed and treated as specified.
7. Tolerances and Replacement of Unsatisfactory Areas
7.1 Finished surface tolerances and the rectification procedures for any areas which fail to meet such
tolerances shall be as specified for cement stabilized course.
3.4.10 TESTING OF LIME STABILIZED COURSES
1. For every 5,000 m2 of each stabilized layer or for each day's completed area (whichever is the
1.1 In situ density of a minimum of 3 samples (taken immediately after completion of final
compaction) determined in accordance with AASHTO T 191 or T 205 and which shall be not
less than 100% of the density of the approved laboratory mix.
1.2 Lime content in accordance with AASHTO T 232.
1.3 Gradation of mix in accordance with AASHTO T 27.
1.4 If the source of materials change, the moisture - density relationship in accordance with
AASHTO T 134 and gradation of the new mix in accordance with AASTO T27.
1.5 Compressive strength of a set of 3 test specimens molded and cured in accordance with
AASHTO T 134 and T 126, and tested in accordance with AASTO T 22.
3.4.11 MEASUREMENT
1. Cement Stabilized Course, Bitumen Stabilized Course and Lime Stabilized Course, shall be
measured by m3 of compacted mix furnished, premixed and placed, or mixed in place, compacted,
trimmed, jointed, cured, completed and accepted. Measurements shall be of the area and thickness
dimensions shown on the Drawings.
2. Measurement shall also be made of the Trial Section in accordance with the length, width and
thickness ordered by the Engineer.
3-22

(1) Cement Stabilized Course Cubic meter (m3)
(2) Bitumen Stabilized Course Cubic meter (m3)
(3) Lime Stabilized Course Cubic meter (m3)
3-23
Part ( 4 ) :
Bituminous
Construction
Technichal Specifications Bituminous Cobstruction
SECTION 4.1 : MATERIALS

4.1.1 SCOPE
1. Materials specified for use in the construction of the various bituminous pavement courses may
include any or all of the following:
1.1 Coarse and fine mineral aggregates and filler.
1.2 Bitumen products including penetration graded bitumen, cutback bitumen, emulsified
bitumen, modified bitumen, and rejuvenating agents for use in bituminous courses and surface
treatments.
1.3 Reinforcing grids for reinforcement of bituminous wearing courses.
2. All material sources and the quality of materials proposed for use in the Works shall be approved
prior to procuring or processing material from such sources. Inspection, sampling, testing and retesting as
necessary, shall be at the Contractor's expense as prescribed in Section 1.05 - "Control of Materials and
Standards for Sampling and Testing" and as specified hereunder for specific materials.
3. Storage and handling of all materials shall conform with the relevant requirements of Section
1.05 - "Control of Materials and Standards for Sampling and Testing". Materials shall be stored on hard,
clean surfaces.
4.1.2 AGGREGATE MATERIALS GENERALLY
1. Sources and Production
1.1 Locating sources and manufacture of materials in accordance with the requirements of the
Specifications are the responsibility of the Contractor, who shall produce the required aggregates at the
rates in the quantities necessary to complete the Works on time.
1.2 The Contractor shall have satisfied himself as to the location, suitability and quantity of
materials available; extent of work necessary to obtain the material available; the work required to open
the quarry and to crush, screen and wash (if necessary) the materials; and the length of haul to the Site.
1.3 Prior to starting quarry operations, the Contractor shall obtain written permission from the
Authorities or owners concerned.
1.4 Crushing and screening plants shall not be put into operation prior to their approval. If, after any
plant is put into operation, it fails to perform as intended, the Contractor shall either rectify the defects in
the existing plant to the satisfaction of the Engineer, or shall provide alternative approved plant.
1.5 Approval of the crushing and screening plants and other equipment shall in no way relive the
Contractor of his responsibilities in respect of producing aggregates which conform to the Specifications
and in the quantities required for the completion of the Works on time.
2. Stockpiling
2.1 Stockpile areas shall be surveyed prior to stockpiling to establish control points and to obtain a
record of existing cross sections for future use in determining stockpile quantities. The areas shall be
adequately drained at all times.
2.2 Stockpiling procedures shall not result in degradation or segregation of the stockpiled material,
or introduction of foreign materials into the stockpile. Heights of aggregate stockpiles shall not exceed
5m.
4-1
3.1 Sampling and testing procedures shall conform with the relevant requirements of Section 1.05 -
"Control of Materials and Standards for Sampling and Testing" and with the following requirements.
3.2 The Contractor shall submit to the Engineer, 30 days prior to the scheduled beginning of
crushing and screening operations, a statement of origin and composition of all aggregates proposed for
use in the Works.
3.3 In order to ascertain the properties of aggregate materials, the Contractor shall submit for testing
and approval, representative samples of all materials intended for incorporation in the Works, prior to
starting quarry operations. The representative samples shall be taken by the Contractor in the presence of
the Engineer.
3.4 Test performed by the Contractor shall be utilized in assessing the locations, extent of deposits
and quantities of materials which will conform to the Specifications when properly processed. Any
special tests that may be required by the Engineer or in the special specification shall be carried out by the
Contractor, in his own laboratory, or an outside laboratory, approved by the Engineer. All testing as
carried out by the Contractor shall in no way obviate the need for further testing by the Engineer.
Approval of specific sources of materials shall not be constructed as final approval and acceptance of
material from such sources.
3.5 The Contractor may conduct necessary tests in the Field Laboratory in the presence of the
Engineer.
3.6 Processed materials shall be tested and approved before being stockpiled on Site or incorporated
in the Works and may be inspected and tested at any time by the Engineer during their preparation,
storage and use. Questionable materials, awaiting testing and approval, shall not be unloaded and mixed
with materials previously approved. If the grading and quality of any materials delivered to the Site do
not conform to the grading and quality of the established control samples, the Engineer will reject such
materials.
3.7 Samples shall satisfy all specified test requirements. The Contractor shall permit the Engineer to
inspect any and all materials used or to be used, at any time during or after their preparation, or while
being used during progress of the Works. Unsatisfactory materials, whether in place or not, shall be
removed promptly from the Site. The Contractor shall furnish all necessary materials, labor, tools and
equipment and transport required by the Engineer for such inspections.
4.1.3 AGGREGATES FOR BITUMINOUS PAVING MIXES
1. Aggregates for use in bituminous base course, binder and wearing courses, leveling course, and
macadam and cold mix courses, shall consist of crushed stone.
2. Coarse aggregate shall be the fraction of crushed aggregate material retained on 4.75 mm (No. 4)
sieve. Fine aggregate shall be the fraction of crushed aggregate material passing 4.75 mm (No. 4) sieve.
Mineral filler shall be added when the combined grading of coarse and fine aggregates is deficient in
material passing 0.075 mm (No. 200) sieve.
3. The material from hot bins passing the number 40 sieve (0.425mm) when tested in accordance
with AASHTO T90 shall be non plastic. In addition the material from cold bins should not have PI larger
than 4.
4. Aggregates shall not contain gypsum more than 1% when tested in accordance to AASHTO T
105, and the coarse fraction of the aggregate shall not contain more than :
5% chert and flint for aggregate to be used in the Wearing course.

5% chert and flint for aggregate to be used in the Binder course.
5. Aggregates shall be of uniform quality, free from decomposed stone, organic matter, shale and
any other deleterious substances.
4-2
6. The percentage by weight of friable particles, clay lumps, and other deleterious matter shall not
exceed 1% as determined by AASHTO T 112.
7. Aggregate particles shall be clean, hard, durable and sound. Crushing shall result in a product
such that, for particles retained on 4.75 mm (No. 4) sieve, at least 90% by weight shall have 2 or more
fractured faces.
8. The flakiness index and the elongation index test should be conducted in accordance with BS
812, the following are the maximum limits:
Wearing Course Binder & Asphalt Base

Course
Flakiness Index F.I 25 30
Elongation Index E.I 25 30
9. Aggregates shall be washed if directed, to remove any clay lumps, organic matter, adherent dust
or clay films or other extraneous or deleterious matter that may prevent or detract from proper adhesion of
bitumen to the aggregate particles.
10. Mineral filler shall consist of finely divided mineral matter such as limestone dust if added
separately; hydrated lime; other non-plastic mineral filler, free from clay and organic impurities; or
Portland cement, conforming to AASHTO M 17.
11. Combined coarse and fine aggregates for bituminous mixes, including mineral filler, when tested
in accordance with AASHTO T 27 and T11, shall conform to the gradations shown in Table 4.1.
Table 4.1: Gradation of Aggregates for Bituminous Mixes
% by weight passing
Heavy Traffic Medium & Light Traffic
Binder Wearing Binder Wearing
Sieve No.
Course Course Course Course
37.5 mm ( 1 ½ in.) - - - -
25 mm ( 1 in.) 100 100 100 100
19 mm ( ¾ in.) 70 – 100 90 – 100 70 – 100 90 – 100
12.5 mm ( ½ in.) 53 – 90 71 – 90 53 – 90 71 – 90
9.5 mm ( ⅜ in.) 40 – 80 56 – 80 40 – 80 56 – 80
4.75 mm ( No. 4) 30 – 56 35 – 65 30 – 56 35 – 65
2.36 mm ( No. 8) 23 – 38 23 – 38 23 – 49 23 – 49
1.18 mm ( No. 20) 13 – 27 13 – 27 14 – 43 14 – 43
0.30 mm ( No. 50) 5 – 17 5 – 17 5 – 19 5 – 19
0.15 mm ( No. 100) 4 – 14 4 – 14 4 – 15 4 – 15
0.075 mm ( No. 200) 2–8 2–8 2–8 2–8
12. The loss in weight of aggregate after 500 revolutions, when tested in accordance with AASHTO
T 96, shall not exceed 35%
Abrasion after 100 revolution

Ratio of wear loss = ------------------------------------ less than or equal 25%.
Abrasion after 500 revolution
13. When tested for soundness in accordance with AASHTO T104 the coarse aggregate (retained on
No.4 sieve) shall not show signs of disintegration and the loss by weight after 5 cycles shall not exceed
9% in the case of the sodium sulphate test and 12% in the case of the magnesium sulphate test.
14. When tested for resistance to stripping in accordance with the AASHTO T-182 at least 95%
coated particles should be achieved. Scandinavian test shall be carried out and at least 60% of the coarse
aggregate surface area shall remain coated with a bitumen film especially for exposed surfaces other wise
anti stripping agent must be added to achieve the required coating.
15. The material shall contain a minimum 50% sand equivalent. Test sample shall be taken from hot
bins.
4-3
4.1.4 AGGREGATES FOR SEAL COATS
1. Cover aggregates for bituminous seal coats shall consist of screenings of crushed stone.
Aggregate for slurry seals shall consist of crushed stone fines or natural sand blended with not less than
50% crushed stone fines. For heavy duty applications slurry aggregate shall consist of 100% crushed
fines. Wadi gravel shall not be used for seal costs, suitability of suggested crushed stone fines for use in
slurry seal shall be demonstrated prior to use.
2. Aggregates shall not contain crystalline or amorphous gypsum (expressed as SO3) more than 1%
when tested in accordance to AASHTO T 105.
3. Aggregate particles shall be clean, hard, durable and sound. For particles retained on 4.75 mm
(No. 4) sieve, at least 90% by weight shall have 2 or more fractured faces and 100% by weight shall have
one or more fractured faces.
4. Flakiness Index and Elongation Index tested in accordance with BS-812 shall not exceed 25%
for each of flakiness and elongation indices. The percentage by weight of clay lumps & friable particles
as determined by AASHTO T 112 shall not exceed 3%. Light weight aggregate of specific gravity of 2 or
less shall not exceed 3% as determined by AASHTO T 113.
5. If necessary, aggregates shall be washed, or processed by any alternative approval method, to

remove any clay lumps, organic matter, adherent dust or clay films or other extraneous or deleterious
matter that may prevent or detract from proper adhesion of bitumen to the aggregate particles.
6. Cover aggregates and aggregates for slurry seals, when tested in accordance with AASHTO T 27
and T11, shall conform to the gradations given in Table 4.2.
Table 4.2: Gradation of Aggregates for Seal Coats

% by weight passing
1st Application 2nd Application Slurry
Sieve No. Grading B Grading C Aggregate
25 mm ( 1 in.) 100
19 mm ( ¾ in.) 90 – 100
12.5 mm ( ½ in.) 20 – 55 100 100
9.5 mm ( ⅜ in.) 0 – 15 58 – 100 90 – 100
4.75 mm ( No. 4) 0–5 10 – 30 65 – 90
1.18 mm ( No. 20) - 0 – 10 45 – 70
0.60 mm ( No. 16) - 0–5 30 – 50
0.30 mm ( No. 50) - - 18 – 30
0.15 mm ( No. 100) - - 10 – 20
0.075 mm ( No. 200) 0 – 0.5 0 – 0.5 5 – 15
7. The loss in weight of aggregate after 500 revolutions, when tested in accordance with AASHTO
T 96 (Los Angeles Test), shall not exceed 35%.
8. When tested for soundness in accordance with AASHTO T 104, the aggregates shall not show
signs of disintegration and the loss by weight shall not exceed 10% in the case of the sodium sulphate test
or 12% in the case of the magnesium sulphate test.
9. When tested for resistance to stripping in accordance with AASHTO T 182, at least 95% of the
aggregate surface area shall remain coated with a bitumen film.
10. The material shall contain a minimum 50% of sand equivalent as determined by AASHTO T
176.
4-4
4.1.5 STABILIZING AGENTS
1. Cement as Stabilizing Agent
1.1 Cement shall be Portland cement Type II, or sulfate resistant cement Type V, in accordance with
the relevant AASHTO standards.
2. Bitumen as Stabilizing Agent
2.1 Bitumen may include straight run (penetration grade) bitumen; RC cutback bitumen, MC
cutback bitumen, or cationic emulsified bitumen, Type SS. Penetration grade, cutback bitumen and
emulsified bitumen shall conform with all relevant requirements herein.
2.2 The selection of a suitable bitumen will depend on the properties of the material to be stabilized
and shall be subject to laboratory and field trials by the Contractor, under the supervision of the Engineer.
2.3 When the material moisture content is higher than the normal in-situ value, material must be
dried, the use of penetration grade bitumen, viscous cutback bitumen or asphalt emulsion plant mixing of
materials shall be appropriate.
2.4 When the natural moisture content of the material is lower than the normal in-situ value, cutback
bitumen or emulsified bitumen are appropriate.
3. Limes as Stabilizing Agent
3.1 Hydrated lime (calcium hydroxide) and quicklime (calcium oxide) shall conform to AASHTO M
216. Mixing of different brands of lime or use of lime from different mills will not be permitted.
3.2 Lime slurry shall be a homogeneous pumpable mixture of lime and water. Slurry shall be a
premixed material in which the lime solids content shall be not less than 30% by weight.
4.1.6 BITUMEN GENERALLY
1. Type and Grade
1.1 Each bitumen product furnished for use in the Works shall be obtained from an approved source
by the Client and shall exhibit uniform characteristics.
1.2 The grade of bitumen may be changed by the Engineer by one grade either side of the specified
grade at no extra cost to the Employer. When more than one type or grade is specified under any item, the
Engineer will select the type and grade to be used in the Works. Any such change must be approved by
the Client.
2. Transporting Bitumen
2.1 All transporting of bitumen shall be by conveyances that are free from contamination. Tank cars
or tank trucks used for transporting bitumen shall be carefully inspected, drained, and cleaned if
necessary, before loading, to prevent contamination of the bitumen from residues of previous loads.
Bitumen may also be delivered and transported in metal drums.
2.2 Tank trucks or trailers used to transport bitumen shall be equipped with and approved sampling
device which shall be built into the tank or re-circulating or discharge line in such a manner that a sample
can be drawn during circulation or discharge.
3. Storage of Bitumen
3.1 The Contractor shall provide an adequate storage facility for bitumen, at the site of the mixing
plant. This facility should be clean and stable and provided with cover and shelter from excessive
temperatures.
4-5
3.2 No open fires or smoking shall be allowed in or around the storage facility.
3.3 The storage capacity should be sufficient to maintain a uniform operation while allowing for
delayed shipments and time for testing. Different batches of bitumen should be separated, so as to allow
for easy identification.
3.4 If the bitumen is delivered to the site in metal drums, on arrival the drums shall be inspected for:
perforations
rusting
melting
other defects that would directly cause pollution or chemical change to the bitumen. Any
drum(s) showing any of these defects shall be rejected at the discretion of the Engineer.
3.5 The stored bitumen products should be protected from temperatures which may exceed the range
of -50C to +600C or required according to flash point test as determined by AASHTO T 48.
4. Heating of Bitumen
4.1 Heating equipment shall be of an approved type. Any method of agitation or heating that
introduces free steam or moisture into the bitumen will not be approved. During the process of its
manufacture, conveyance, storage, or construction use, bitumen of whatever type shall not be heated to
temperatures more than 10 degrees C above the maximum application temperature specified for the
respective type of bitumen nor above 170 degrees C, whichever is the lower. Materials heated in excess of
these temperatures will be rejected and shall not be used in the Works.
4.2 Tanks for heating and storage of bitumen shall be capable of heating the material, under
effective and positive control at all times, to the specified temperature. The system shall provide uniform
heating for the entire contents of the tank. The circulation system shall be of adequate size to insure
proper and continuous circulation of the bitumen during the entire operating period. Suitable means shall
be provided, either by steam or oil jacketing, or other insulation, for maintaining the required temperature
of bitumen, weigh buckets, spray bars, and other containers.
4.3 Thermometers of approved type and adequate range (calibrated in 2 degrees C increments) for
accurately measuring the temperature of the bitumen while heating, shall be located so as to be readily
visible and shall be kept clean and in proper working order at all times.
4.4 Where storage tanks are required, their capacity shall be sufficient for at least one day's
production.
4.5 Bitumen materials, wasted through careless handling or rendered unsuitable for use by
overheating shall not be used in the Works.
5.1 Procedures for sampling of bituminous materials shall conform to AASHTO T 40.
5.2 General requirements and procedures for sampling and testing of the various types of bitumen
shall conform with the requirements of Section 1.05 - "Control of Materials and Standards for Sampling
and Testing".
5.3 Testing for conformity of bitumen products to AASHTO and other specified standards shall,
unless otherwise directed, be performed at the refinery laboratories or at any other approved laboratory by
the Client.
4-6
4.1.7 BITUMEN PRODUCTS
1. Penetration Graded Bitumen
1.1 The various grades of penetration graded bitumen Asphalt cement shall conform generally with
the requirements of AASHTO M 20, or with the Specification shown in Table 4.3 below or any other
approved specification by the Client.
Table 4.3: Properties of penetration Grade of Bitumen

Penetration Grade
80 -
40 - 50 60 - 70
100
Min Max Min Max Min Max
Ductility at 25ºC (cm) 100 - 100 - 100 -
Penetration at 25ºC (0.1mm) 40 50 60 70 80 100
Softening point (ºC) 50 58 48 56 48.5 48
Specific Gravity at 25ºC 1.01 1.06 1.01 1.06 1.0 -
Loss on Heating to 163ºC (%wt) - 1.0 - 1.0 - 1.0
Penetration of residue % of Original 75 - 75 - 75 -
Solubility in Trichloroethylene %wt 99 - 99 - 99.5 -
Ash content %wt - 1.0 - 1.0 - 1.0
Flashpoint (Cleveland Open Cup) ºC 250 - 250 - 225 -
1.2 If its required in special specification to use viscosity graded asphalt cement it shall meet the
requirement of AASHTO M 226-80 table 1,2.
1.3 Sampling and testing shall be in accordance with the AASHTO standard method listed in
AASHTO M 20.
1.4 Penetration bitumen application temperature range shall be so that appropriate viscosity range
for each application is achieved. If however the viscosity curve are not available the values given in table
4.4 shall be generally consider as guidance.
Table 4.4: Bitumen Grade

40/50 60/70 80/100
Application Temperature ºC 150 – 170 145 – 165 140 – 160
2. Bitumen Modifier
2.1 An approved modifier shall be incorporate in all penetration grader bitumen whenever specified
immediately prior to the time of use, unless otherwise shown on the Drawings. The modifier (catalyst)
shall serve to polymerize the bitumen by converting the benzylic carbon groups into ketones.
2.2 The modified bitumen shall demonstrate significantly reduced temperature susceptibility and/or
improved adhesive qualities. The workability of the modified bitumen shall be unchanged from that of
unmodified bitumen.
2.3 The mixing and preparation of Modified Bitumen shall be carried out in accordance with the
manufactures instructions, and with the approval of the Engineer.
3. Rapid-Curing (RC) Cutback Bitumen
3.1 RC cutback shall conform with the requirements of AASHTO M 81, which covers Grades RC-
70, RC-250, RC-800, and RC-3000 and are listed in Table 4.5.
4-7
Table 4.5: Properties of R.C. Cutback Bitumen

RC 70 RC 250 RC 800 RC 3000
Min Max Min Max Min Max Min Max
Kinematic Viscosity at 60ºC
70 140 250 500 800 1600 3000 6000
centistokes
Flash Point (Tag, Open cup) ºC - - 27 - 27 - 27 -
Water percent - 0.2 - 0.2 - 0.2 - 0.2
Distillation test:
Distillate, % by volume of
distillate to 360ºC
To 190ºC 10 - - - - - - -
To 225ºC 50 - 35 - 15 - - -
To 260ºC 70 - 60 - 45 - 25 -
To 315ºC 85 - 80 - 75 - 70 -
Residue from distillation to 360ºC
Volume % of sample by difference 55 - 65 - 75 - 80 -
Tests on residue from distillation
Absolute viscosity at 60ºC poises 600 2400 600 2400 600 2400 600 2400
Ductility, 5 cm/min, at 25ºC cm 100 - 100 - 100 - 100 -
Solubility in Trichloroethylene % 99 - 99 - 99 - 99 -
Spot test with:
Standard naptha Negative for all grades
Naptha-xylene solvent
- percent xylene Negative for all grades
Heptane-xylene solvent
3.2 Sampling and testing shall be in accordance with the AASHTO standard methods listed in
AASHTO M 81.
3.3 RC cutback bitumen spraying temperature ranges shall be so that appropriate viscosity for each
application is achieved, if however the viscosity curve are not available the values given below should be
generally consider as guidance :
RC Cutback Spraying
Grade Temp ºC
RC – 70 40 - 75
RC – 250 65 - 105
RC – 800 90 - 115
RC – 3000 105 - 135
4. Medium-Curing (MC) Cutback Bitumen
4.1 MC cutback shall conform with the requirements of AASHTO M 82, which covers Grades MC-
30, MC-70, MC-250, MC-800 and MC-3000 and are listed in Table 4.6.
4-8
Table 4.6: Properties of M.C. Cutback Bitumen

MC 30 MC 70 MC 250 MC 800 MC 3000
Min Max Min Max Min Max Min Max Min Max
Kinematic Viscosity
30 60 70 140 250 500 800 1600 3000 6000
at 60ºC centistokes
Flash Point (Tag,
38 - 38 - 66 - 66 - 66 -
Open cup) ºC
Water percent - 0.2 - 0.2 - 0.2 - 0.2 - 0.2
Distillation test:
Distillate, % by
volume of
distillate to 360ºC
To 225ºC - 25 0 20 0 10 - - - -
To 260ºC 40 70 20 60 15 55 0 35 0 15
To 315ºC 75 93 65 90 60 87 45 80 15 75
Residue from
distillation to 360ºC
Volume % of sample
50 - 55 - 67 - 75 - 80 -
by difference
Tests on residue from
distillation
Absolute viscosity at
300 1200 300 1200 300 1200 300 1200 300 1200
60ºC poises
Ductility, 5 cm/min,
100 - 100 - 100 - 100 - 100 -
at 25ºC cm
Solubility in
99 - 99 - 99 - 99 -
Trichloroethylene %
Spot test with:
Standard naptha Negative for all grades
Naptha-xylene
solvent
Heptane-xylene
solvent
4.3 Sampling and testing shall be in accordance with the AASHTO standard methods listed in
AASHTO M 82.
4.3 MC cutback bitumen spraying temperature ranges shall be so that appropriate viscosity for each
generally consider as guidance:
MC Cutback Spraying
Grade Temp ºC
MC – 30 21 - 63
MC – 70 45 - 80
MC – 250 70 - 110
MC – 800 95 - 125
MC – 3000 110 - 145
5. Slow-Curing (SC) Cutback Bitumen
5.1 SC cutback shall conform with the requirements of ASTM D 2026 which covers Grades SC-70,
SC-250, SC-800, and SC-3000, and are shown in Table 4.7.
4-9
Table 4.7: Properties of S.C. Cutback Bitumen

SC 70 SC 250 SC 800 SC 3000
Min Max Min Max Min Max Min Max
Kinematic Viscosity at 60ºC
70 140 250 500 800 1600 3000 6000
centistokes
Flash Point (Tag, Open cup) ºC 66 - 79 - 93 - 107 -
Distillation test:
Total distillate to 360ºC, % volume 10 30 4 20 2 12 - 5
Solubility in Trichloroethylene % 99 - 99 - 99 - 99 -
Kinematic Viscosity on distillation
residue at 60ºC centistokes 4 70 8 100 20 160 40 350
Asphalt residue :
Residue of 100 penetration, % 50 - 60 - 70 - 80 -
Ductility of 100 penetration 100 - 100 - 100 - 100 -
residue at 25ºC, cm Water, % - 0.5 - 0.5 - 0.5 - 0.5
5.2 Sampling and testing shall be in accordance with the appropriate ASTM standard methods.
5.3 SC cutback bitumen spraying temperature ranges shall be so that appropriate viscosity for each
generally consider as guidance.
SC Cutback Spraying
Grade Temp ºC
SC – 70 45 - 80
SC – 250 70 - 110
SC – 800 95 - 125
SC – 3000 110 - 145
6. Emulsified Bitumen Generally
6.1 Selection and use of emulsified bitumen shall generally be in accordance with the
recommendations in AASHTO R 5, subject to the following requirements.
6.2 Emulsified bitumen which have been subjected to freezing temperature while in storage shall be
retested and acceptance or rejection of the material shall be based on the results of the retest.
6.3 The manufacturer shall furnish samples of the base bitumen used in the emulsion.
6.4 When samples of undiluted emulsion are not readily available for test purposes, tests may be
made on the diluted emulsion and the respective specifications modified to reflect the changes in
properties resulting from dilution of the bitumen.
6.5 All emulsified bitumen shall adhere firmly to the surface of the mineral aggregate or the
highway surface as appropriate. Failure of the emulsified bitumen to perform satisfactorily on the job
shall be deemed cause for its rejection regardless of satisfactory laboratory test results.
7. Anionic Emulsified Bitumen
7.1 Anionic emulsified bitumen shall, prior to dilution, conform with the requirements of AASHTO
M 140, for types SS-1 and SS-1h and as listed in Table 4.8.
4-10
Table 4.8: Properties of Anionic Emulsified Bitumen

Slow Setting
SS-1 SS-h
Test on emulsion Min Max Min Max
Viscosity, Saybolt Furol at 25ºC,s 20 100 20 100
Viscosity, Saybolt Furol at 50ºC,s - - - -
Storage stability test, 24-h, % - 1 - 1
Cement mixing test, % - 2 - 2
Sieve test, % - 0.1 - 0.1
Residue by distillation, % 57 - 57 -
Tests on residue from distillation test:
Penetration 25ºC, 100g, 5s 100 200 40 90
Ductility, 25ºC, 5cm/min, cm 40 - 40 -
Solubility in Trichloroethylene % 97.5 - 97.5 -
7.2 Sampling and testing shall be in accordance with AASHTO T 59.
7.3 Emulsified bitumen spraying temperature range shall be so that appropriate viscosity for each
application is achieved, if however the viscosity curve are not available these values should be generally
as guidance 25 - 65 degrees C. The temperature range for pugmill mixing shall be 15-65 degrees C.
8. Cationic Emulsified Bitumen
8.1 Cationic emulsified bitumen shall, prior to dilution, conform with the requirements of AASHTO
M 208, for Type CSS-1 and as listed in Table 4.9.
Table 4.9: Properties of Cationic Emulsified Bitumen

Slow Setting
CCS -1
Test on emulsion Min Max
Viscosity, Saybolt Furol at 25ºC,s 200 100
Storage stability test, 24-h, % - 1
Particle charge test positive
Cement mixing test, % - 2
Sieve test, % - 0.1
Residue by distillation, % 57 -
Tests on residue from distillation test:
Penetration 25ºC, 100g, 5s 100 250
Ductility, 25ºC, 5cm/min, cm 40 -
Solubility in Trichloroethylene % 97.5 -
8.2 Sampling and testing shall be in accordance with AASHTO T 59.
8.3 Emulsified bitumen spraying temperature range shall be so that appropriate viscosity for each
application is achieved, if however the viscosity curve are not available these values should be generally
as guidance 25-65 degrees C. The temperature range for pugmill mixing shall be 15-65 degrees C.
9. Reinforcing Grids
9.1 Grid reinforcement for bituminous wearing courses, when shown on the Drawings, shall consist
of approved type, high strength polymer (polypropylene) grid matting, with rectangular-shaped openings,
and furnished in rolls of at least 50 m single lengths.
9.2 The reinforcing grid shall be non-corrodible, temperature stable up to at least 160 degrees C and
exhibit a minimum tensile strength, longitudinally and transversely, of 0.010 MN/m at 8% strain.
4-11
4.1.8 MEASUREMENT
1. Granular Material, Base Course Aggregate, Aggregates for Bituminous Seal Coats and for
Bituminous mixes, Modified (Penetration Graded) Bitumen, Straight Run (penetration Graded) Bitumen,
Cutback Bitumen, Emulsified Bitumen, Portland Cement, Lime and Reinforcing Grid, shall be measured
as prescribed in the appropriate Sections of these Specifications.
4-12
BITUMINOUS PRIME AND TACK COATS SECTION 4.2
SECTION 4.2 : BITUMINOUS PRIME AND TACK COATS

4.2.1 SCOPE
1. These Works shall consist of furnishing and applying MC cutback bitumen prime coat to a
previously constructed subgrade, sub-base or aggregate base course, highway shoulders, or concrete
pavement; and furnishing and applying RC cutback bitumen or emulsified bitumen as a tack coat to a
previously constructed bituminous base or wearing surface to provide bond for a superimposed
bituminous course; all as and where shown on the Drawings.
4.2.2 MATERIALS
1. Medium-Curing Cutback Bitumen
1.1 MC cutback bitumen (for prime coats) shall be as recommended by ASTM D2399-83 for open
and tight surfaces however if not specified in the special technical specification MC-70 as specified in
section 4.01 (material) shall be used.
2. Rapid-Curing Cutback Bitumen
2.1 RC cutback bitumen (for tack coats) shall be Grades RC-70 or RC-250 as appropriate and as
specified in Section 4.01 -"Materials" or as required in the Special Specification.
3. Slow-Setting Emulsified Bitumen
3.1 Slow-setting emulsified bitumen (for tack coats) shall be slow-setting Grades SS-1, SS-1h, CSS-
1, or CSS-1h, as appropriate and as specified in Section 4.01 - "Material", or as required by the Engineer.
4.2.3 EQUIPMENT
1. Equipment used for diluting emulsified bitumen, heating cutback bitumen, spraying cutback and
emulsified bitumen, and for application of blotting material to prime coats, shall conform with the
requirements of Section 1.12 - "Contractor's Plant and Equipment" and with the Contractor's approved
Work Program.
1. The Engineer may, if he deems necessary require trial sections to be constructed prior to the
commencement of on Site prime or tack coat applications. The Contractor shall construct trial sections
using varying application rates of bitumen, as selected by the Engineer. Each trial section shall be 2 lanes
wide by 50 m long, at approved locations on or close to the Site.
2. Each trial section shall be constructed using the same materials, mixing and spraying equipment,
and construction procedures, proposed for use in the Works.
3. The objectives of these trials shall be to determine the adequacy of the Contractor's equipment
and the most suitable application rates for cutback bitumen prime and tack coats.
4. The Contractor shall not proceed with any site coat applications until the methods and
procedures established in the trials have been approved.
4.2.5 APPLICATION PROCEDURES
1. General
1.1 All equipment used for surface cleaning, heating bitumen (if required) and application of prime
and tack coats, shall be adequate for the purposes intended and shall be approved before use.
4-13
1.2 All surface to receive prime or tack coats shall conform with the specified tolerances and
compaction requirements and shall be properly cleaned using power brooms or power blowers. The
surfaces shall be approved before applying any bitumen material.
1.3 Application of prime coats and tack coats shall be performed only when the surface to be treated
is sufficiently dry, for tack coat and sufficiently moist for prime coat, and when the atmospheric
temperature is above 100C for the application of tack coat, 150C for the application of prime coat. There
should be no fog, rain, strong winds, dusty conditions, or dust storms.
1.4 The surface of all structures, curbs, gutters and other highway appurtenances shall be protected
in an approved manner to prevent them from being splattered or stained with bitumen or damaged during
equipment operation. The Contractor shall be responsible for making good any such staining or damage
to the satisfaction of the Engineer.
1.5 Traffic shall not be permitted on surfaces after they have been cleaned and prepared for prime or
tack coat application.
1.6 If there are undue delays in scheduling priming or subsequent paving after priming, the surface
tolerances and compaction of the granular course shall be re-verified and deficient areas corrected or
replaced in an approved manner at the Contractor's expense.
1.7 The Contractor shall maintain prime coats and tack coats intact until they are covered by the
subsequent pavement course. Any area where the coats have been damaged shall be cleaned of all loose
material, any surface defects repaired and the coat re-applied at the Contractor's expense. Traffic control
measures shall conform with the relevant requirements of Section 8.10 - "Maintenance of Traffic and
Detours".
2. Prime Coat Application
2.1 If required by the Engineer, when the surface is an untreated subgrade or a granular surface, the
cleaned surface shall be given a light application of water and allowed to dry to the condition deemed
appropriate by the Engineer before the bituminous material is applied.
2.2 Heating of MC cutback bitumen and its temperature at the time of application shall conform with
the relevant requirements of Section 4.01 - "Materials".
2.3 Areas to be primed shall be as shown on the Drawings and including 200 mm widths outside the
edges of the pavement line; top of embankment slopes to pavement lines; and between curbs or gutter
edges for bridge checks.
2.4 Application rates for prime coat will be determined by the Engineer from the trial sections, and
shall be generally within the following ranges:
Range of Application Rates for Prime Coat

Type of Surface liter / m2
Untreated subgrade surfaces,

shoulders sub-base and base
courses 0.75 - 2.0
Other surfaces (determined from field tests or trials)
2.5 The Engineer may order additional trail sections and/or alter the previously established rates of
application during progress of the Works.
2.6 Prime coat (MC-70) cutback, or other grade if ordered by the Engineer, shall be applied at the
rate selected by the Engineer, using approved type pressure distributors operated by skilled workmen. The
spray nozzles and spray bar shall be adjusted and frequently checked so that uniform distribution is
ensured. Spraying shall cease immediately upon any clogging or interference of any nozzle, and
corrective measures taken before spraying is resumed.
4-14
2.7 Hand spraying will be approved only for priming small patches or inaccessible areas that cannot
be primed by normal operation of the pressure distributor.
2.8 Application of prime at the junction of spreads shall not be excessive. Any excess shall be
removed from the surface and any skipped areas or recognized deficiencies shall be corrected by use of
hand sprays.
2.9 When required by the Engineer, a light covering of blotting material shall be applied to the prime
coat 48 hours after spraying and when it has not dried sufficiently to withstand damage by traffic. The
blotting material shall be a smooth fine sand, or other approved material.
2.10 Prime coat shall be cured for 3 days before traffic is allowed on it or before the succeeding
pavement layer is placed, or as directed by the Engineer.
3. Tack coat Application
3.1 Tack coat application shall be (as shown on the Drawings) on clean dry surface and the rate shall
be as ordered by the Engineer. Emulsified bitumen shall be diluted and thoroughly mixed with an equal
amount of water before application.
3.2 Heating of RC cutback bitumen and its temperature at the time of application shall conform with
the relevant requirements of Section 4.03 "Bituminous Prime and Tack Coats". Where slow-setting
emulsified bitumen (SS or CSS Type) is used for tack coat, it shall not normally require heating except in
temperatures below 20 degrees C.
3.3 The rate of application shall be approved by the Engineer and after trial tests are carried out it
shall be between 0.1 and 0.6 kg./m2. depending on weather RC cutback or emulsified bitumen is used and
the surface condition of the bituminous course on which the tack coat is to be sprayed. The Engineer may
alter the previously established rates of application during progress of the Works, if he deems it
necessary.
3.4 The tack coat shall be allowed to dry only until it is in a suitable tacky condition to receive the
superimposed bituminous course. Tack coat application shall not proceed so far in advance of the
following course that it dries out completely.
3.5 Spraying procedures shall be as specified for prime coat application.
3.6 Blotting material shall not be applied to tack coats.
4.2.6 MEASUREMENT
1. Bituminous Prime Coat shall be measured by the liter (or ton) of bituminous material of each
type furnished, applied, completed and accepted. Measurement shall be of the material before heating and
shall be as per rate chosen from the Trail Section.
2. Bituminous Tack Coat shall be measured by the liter (or ton) of bituminous material of each type
furnished, applied, completed and accepted.
3. Surface preparation, protective measures to avoid staining or damage to appurtenances, blotting

of prime coats when required, and cleaning stains and repairing damage caused by equipment, etc shall
not be measured for direct payment, but shall be considered as subsidiary Works the costs of which will
be deemed to be included in the Contract prices for the Pay Items.

(1) Bituminous Prime Coat ton
(2) Bituminous Tack Coat ton
4-15
BITUMINOUS COURSES SECTION 4.3
SECTION 4.3 : BITUMINOUS COURSES

4.3.1 SCOPE
1. These Works shall consist of the general requirements for furnishing materials, mixing at a
central mixing plant, and spreading and compacting various bituminous concrete and other bituminous
mixes, including installation of reinforcing fabric when specified, all as and where shown on the
Drawings.
2. Requirements with particular application to bituminous base course, binder and wearing courses,
leveling course, macadam course, cold mix courses, or recycled bituminous base course, are specified in
the respective Sections relating to such courses.
3. In the case of any conflict or ambiguity between the particular bituminous course Sections of
these Specifications and this Section, the requirements of the particular Sections shall prevail.
4.3.2 MATERIALS
1. Bituminous plant mixes shall generally be composed of coarse mineral aggregate, fine mineral
aggregate, mineral filler or cement if required, and penetration graded bitumen with mix additives if
specified, cutback bitumen or emulsified bitumen appropriate to the type of bituminous course to be
constructed.
2. All materials shall conform with the relevant requirements of Section 4.01 - "Material".
4.3.3 JOB MIXES AND PROJECT MIXES
1. At least 30 days prior to the date the Contractor intends to begin production at the mixing plant
and after receiving approval of the aggregates, and after the delivery to the Site of the bitumen specified,
the Contractor shall submit for approval his proposed Job Mix Formula. Therefore sample from materials
use in preparing mix design (aggregate and bitumen) shall be sent to the client’s laboratories to be tested
for final approval of the mix design.
2. The Job Mix Formula shall stipulate a single combined grading of all aggregate and filler
materials showing the specific % by weight passing each sieve size and the specific % by weight of each
material to be used in the total mix.
3. The Job Mix Formula shall be established by the Contractor, under the supervision of the
Engineer, in the field laboratory. Mix design procedures shall conform with the Marshall method of mix
design and relevant procedures contained in asphalt Institute Manual MS-2. All trial mixes shall be
prepared and tested by the Contractor in the presence of the Engineer.
4. The Job Mix Formula shall specify a combination of mineral aggregates including filler and
bitumen (plus bitumen modifier if any) in such proportions as to produce a Job Mix which is within the
limits of the specified gradation and bitumen content ranges and which meets the Marshall test
requirements, as prescribed for each particular type of bitumen course.
5. The Marshall test procedure shall be used to determine the percentage of bitumen to be
incorporated in the mix. The job Mix Formula shall take into consideration the absorption of bitumen into
the aggregates. Air voids shall be calculated in accordance with the procedure given in the Asphalt
Institute Manual, MS-2.
6. When compacting specimens in accordance with the Marshall test procedure, the number of
blows applied with the compaction hammer shall be 75 on each side, unless otherwise specified.
7. In order to meet the requirements, an approved additive such as Portland cement, hydrated lime
or liquid anti-strip agent, may be required in the job Mix. Portland cement shall meet the requirements of
AASHTO M 85. Hydrated lime shall meet the requirements of ASTM C 207, Type N. Cement or
hydrated lime will normally be required in the approximate range of 2-3% by weight of the aggregates
4-16
and shall be added at the cold feed in dry or slurry form as directed. Liquid anti-striping agent, if needed
will normally be required in the approximate range of 0.6-1.0% by weight of the bitumen, or according to
the manufacturers specifications.
8. Upon receipt of approval of the Job Mix Formula, the Contractor shall adjust his mixing plant to
proportion the individual aggregates, mineral filler and bitumen to produce a final project mix within the
limits given in Table 4.10 with respect to the Job Mix gradations:
Table 4.10: Maximum Variations of Project Mix From Approved Job Mix
Sieve Designation Specified
(square openings) Tolerance
9.500 mm (⅜ in.) and above + or – 5.0%
4.750 mm (No. 4) + or – 4.0%
2.360 mm ( No. 8) + or – 4.0%
1.180 mm ( No. 16) + or – 4.0%
0.600 mm ( No. 30) + or – 4.0%
0.300 mm ( No. 50) + or – 4.0%
0.150 mm ( No. 100) + or – 4.0%
0.075 mm ( No. 200) + or – 1.5%
Bitumen content + or – 0.3%
Temperature of mix on discharge + or - 5ºC of specified mixing temperature
9. Any deviation from these limits shall be made only with the approval of the Engineer, unless it is
allowed for in the Special Specifications.
10. Conformance to gradation requirements will be determined on the extracted aggregate in

accordance with AASHTO T 30. The bitumen content shall be determined in accordance with AASHTO
T 164.
11. The Engineer will test the project mix at least twice daily during plant operation and, if
necessary, direct the Contractor to readjust the plant to conform to the Job Mix Formula. If, due to
differing cold feed or hot bin gradations, the Contractor cannot consistently produce a project mix
meeting the Job Mix requirements, production shall cease, the Job Mix shall be redesigned and re-
approved and the plant readjusted to produce a new Job Mix.
12. The participation of the Engineer in the preparation of the Job Mix Formula shall in no way
relieve the Contractor of responsibility for producing project mixes meeting the specified requirements.
4.3.4 EQUIPMENT
1. General
1.1 Plant and equipment for mixing, transporting, spreading and compacting bituminous mixes, shall
conform with the requirements of Section 1.12 - “Contractor’s Plant and Equipment” and with the
Contractor’s approved Work Program.
4-17
2. Mixing Plant
2.1 Bituminous mixes shall be produced in an approved type batch mixing plant of adequate size
with a minimum capacity of not less than 80 ton/hr and a mixer capacity of not less than 750 kg batch.
The plant shall conform with the relevant requirements of AASHTO M 156.
2.2 A mechanical batch counter shall be installed as part of the timing device and shall be designed
to register only completely mixed batches.
2.3 The mixing plant shall be fully equipped to control the gradation of hot dry aggregates and of
cold damp aggregates. A suitable dust collection system shall be installed, capable of returning all dust to
the mixture whenever required. Suitable filters shall be incorporated whenever the mixing plant is in the
vicinity of town, or whenever they are required by law. The plant should be equipped with separate bin
for mineral filler material.
2.4 The cold feed system shall be of continuous belt feed type or other approved system. It should be
easily modified to allow hydrated lime slurry to be added to the mix prior to heating, and dry powered
lime added after heating.
2.5 An approved type automatic weighing, cycling and monitoring system shall be installed as part
of the batching equipment. Facilities for easy sampling of the aggregates from the hot bins whilst the
plant is in operation and shall also be provided.
2.6 The use of a continuous mixing plant will only be considered in special circumstances. In such
cases, if the Contractor proposes to use a continuous mixing plant for all or part of the bituminous mixing,
full details of the plant including its in-service record if not new and the manufacturer’s specifications,
shall be submitted for approval before proceeding with the purchase or delivery to Site of such plant.
2.7 The Contractor shall systematically inspect and verify, in the presence of the Engineer, on a
weekly basis and also whenever suspect, the following key operational aspects of the mixing plant:
2.7.1 State of repair of the screens, and their frame mountings.
2.7.2. Proper working of cold and hot bin gates.
2.7.3 Accuracy of batching scales for filler, aggregates and bitumen.
2.7.4 Proper working of the nozzles of the mixer bitumen sprayer
2.7.5 State of repair of the paddle tips and liners of the mixer
2.7.6 Thermometers in working conditions.
2.8 The Contractor shall furnish, for reference and retention by the Engineer, one complete set of the
manufacturer’s instruction and operating manuals for the mixing plant intended for use.
2.9 At the commencement of the Contractor at least one copy of the ASTM and AASHTO
(applicable copies) latest edition and 3 copies each of the latest editions of Asphalt Institute Specification
SS-1 and Manuals MS-2, MS-3, MS-8 and MS-22 shall be furnished by the Contractor for use by the
Engineer’s supervisory staff and, in addition, one copy of each as appropriate shall be issued to each of
the Contractor’s senior staff involved in bituminous course Works. At the end of the Contract all the
copies shall become the property of the Ministry.
3. Spreading and finishing Equipment
3.1 Bituminous courses shall be spread and finished using approved type, self-contained, power-
propelled pavers of sufficient capacity to be capable of laying up to 80 ton/hr. Pavers shall be provided
with electrically controlled vibratory screed of strike-off assembly with devices for heating the screed,
and shall be capable of spreading and finishing the various courses of bituminous plant mix to the proper
thickness and in lane and shoulder widths applicable to the typical cross sections shown on the Drawings,
and in incremental widths down to 2.4 m minimum and up to 8 m maximum.
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3.2 The pavers shall employ mechanical devices such as equalizing runners, straightedge runners,
evener arms or other compensating devices, to maintain trueness of grade and confine the edges of the
mix to true lines without the use of stationary side forms. Joint leveling devices shall be provided for
smoothing and adjusting longitudinal joints between lanes.
3.3 The pavers shall be equipped with a receiving hopper having sufficient capacity for a uniform
spreading operation. The hopper shall be equipped with a distribution system to place the mix uniformly
in front of the full length of the screed.
3.4 The screed or strike-off assembly and extensions shall effectively produce a finished surface of
the required evenness and texture without tearing, shoving, or gouging the mix.
3.5 The pavers shall be capable of being operated at forward speeds consistent with satisfactory
laying of the mix. Speed shall be fully adjustable between 3 m/min and 6 m/min.
3.6 The automatic controls shall consist of an automatic linkage arrangement such that, through the
process of automatically adjusting the screed thickness control, the mix can be placed and finished to a
predetermined grade and a uniform crown or cross section. Articulated averaging beams shall be at least 9
m in length.
3.7 If during construction, it is found that the spreading and finishing equipment in operation leaves
in the pavement surface tracks or indented areas or other objectionable irregularities that are not
satisfactorily corrected by scheduled operations, the use of such equipment shall be discontinued and
other satisfactory spreading and finishing equipment shall be provided by the Contractor.
3.8 The Contractor shall make available, for reference by the Engineer, the manufacturer’s
instruction and operating manuals for each paver intended for use.
4.3.5 CONSTRUCTION OF TRIAL SCTION
1. Immediately prior to finalization of the Job Mix Formula, the Contractor shall lay trial sections
of the various bituminous mixes intended for use in the Works. Each trial section shall be 2 lanes wide by
50 m long at approved locations close to the Site. Each trial section shall be laid using the same materials,
proposed Job Mix, mixing, spreading and compaction procedures, proposed for use in the Works.
2. Each trial section shall serve as a field verification of the Job Mix design. The mix density
achievable and the air voids at that density shall be determined and, if less than required, the Job Mix
Formula shall be adjusted accordingly.
3. Each trial section shall also demonstrate the adequacy of hauling, spreading and compaction
equipment and the suitability of the construction methods and organization proposed.
4. If the trial section meets the required specification, the Job Mix Formula will be approved.
5. The trial section shall be carried out at the Contractor’s expense and is to be removed from Site,
if required by the Engineer.
4.3.6 MIXING PROCEDURES
1. Each aggregate ingredient shall be heated and dried such that the temperature recorded in the hot
fines bin after screening shall not exceed 170 degrees C. if any aggregates contain excess moisture so as
to cause foaming in the mixture or their temperature is in excess of 170 degrees C, they shall be removed
from the bins and disposed of as directed.
2. Immediately after heating, the aggregates shall be screened into at least 3 sizes and conveyed
into separate bins ready for batching and mixing with the bitumen. When the aggregates furnished are of
such size and grading that separating into 3 bins is impractical, the number of required separations may, if
approved, be reduced to 2 only. Screening operations shall produce, at plant operating capacity,
gradations in each of the sizes of heated and dried aggregates that are reasonably uniform and will result
in the production of a mix conforming to the Job Mix requirements.
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3. The dried and heated aggregate and (cold) mineral filler shall be combined in the plant in the
proportionate amounts as determined by the Job Mix. Just prior to bitumen entering the mixer, bitumen
modifier (catalyst) or anti-stripping additive, if required, shall be thoroughly mixed with the bitumen
which shall then be introduced into the pugmill mixer in the proportionate amount determined by the Job
Mix.
4. The temperature of the bitumen upon entering the pugmill shall be within 150C of the aggregate
temperature. Unless otherwise directed, the bitumen temperature shall be as given in Table 4.11
Table 4.11: Bitumen Temperature
Type and Grade Viscosity Max. Temperature ºC immediately
of asphalt Centistokes after discharge from Pugmill
85 – 100 pen 170 ± 20 160
60 – 70 pen 170 ± 20 163
40 – 50 pen 170 ± 20 170
5. Any mix subjected to higher temperature than those shown in Table 4.11 shall be rejected.
6. The mixing time required in order to obtain a homogeneous mix and adequate coating of the
aggregates with bitumen shall be determined by the
Contractor in the presence of the Engineer. This time shall be determined whenever the source of
aggregate for the mix changes.
7. In batch plants, mixing tine shall begin upon entry of bitumen into the pugmill.
8. Mixing time for continuous mixing plants will be determined by the following formula or other
approved methods:
Mixing time (sec) = Pugmill dead capacity (kg) divided by pugmill output (kg/sec)
1. When the bituminous mix is to be placed on a prepared subgrade, sub-base, or base, the surface
shall be prepared to meet the appropriate specified compaction and surface tolerance requirements. The
surface shall then be primed as specified in Section 4.02 – “Bituminous Prime and Tack Coats”. No
bituminous mix shall be laid on a prime coat until it has been inspected and approved.
2. When the bituminous mix is to be placed on an existing bituminous surface, the surface shall be
cleaned of all foreign material and broomed free of dust. Any loose, broken or shattered bituminous
material along the edges of the existing surface shall be removed and the exposed subgrade, and a
sufficient width of the shoulder adjacent to the edge of the existing surface, shall be shaped, bladed,
compacted and broomed to provide a uniform firm subgrade for the new surface course.
3. Broken, soft, or unstable areas of existing bituminous surface, base or subgrade shall be removed
and replaced. The areas shall be excavated to a depth as directed and refilled with the specified
bituminous mix.
4. Prior to placing of the bituminous mix on an existing bituminous surface when required, a tack
coat as specified in Section 4.02 – “Bituminous Prime and Tack Coats” shall be applied to the existing
surface at the rate determined by the Engineer. No mixture shall be laid on a tack coat until it has been
inspected and approved.
4.3.8 DELIVERY, SPREADING AND FINISHING
1. Delivery of Mix to Site
1.1 A sufficient number of haul vehicles shall be provided so that adequate supplies of mix are
delivered to ensure that continuous paving will be achieved.
1.2 Hauling equipment for aggregates and bituminous mixes shall consist of vehicles having dump
bodies suitable for dumping materials in a windrow or in spreader boxes. The bodies shall be so
constructed that their volume measurement can be accurately determined. They shall be constructed and
maintained such that loss of materials during hauling operations will not occur. Dump controls shall be
capable of operation from the driver’s seat.
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1.3 Hauling equipment for hot bituminous mixes shall have tight, clean, smooth metal beds which
are periodically thinly coated with a lime solution or other approved material to prevent adherence of the
mix. All hauling units shall be equipped with a canvas or other approved type cover which shall be used
to cover the hot material upon loading at the mixing plant and shall not be removed until the mix is
discharged into the paver.
1.4 The dispatching of the hauling vehicles to the Site shall be so scheduled that all material
delivered is placed at least 90 minutes before sunset to allow sufficient time for compaction, unless the
use of artificial light is approved. Delivery of material shall be at a uniform rate and in an amount well
within the capacity of the paving and compacting equipment.
1.5 The mix at delivery to the paver shall be not more than 100C below discharge temperature at the
mixing plant. The minimum temperature for the commencement of breakdown rolling is 1200C. Mix
loads of temperature less than 1200C shall not be accepted, and the load shall be disposed of and another
load used. If there is consistent failure to meet the temperature requirement the Engineer shall order
paving operations to stop until suitable measures are taken by the Contractor to ensure that temperature
requirements are met.
1.6 Each haul vehicle shall be weighed after each loading at the mixing plant and accurate records
shall be kept of the gross weight and net weight of each load, for each vehicle and dates and time of
loading.
2. Setting Out and Reference Lines
2.1 The Contractor shall survey the centerline profile and crown of the existing surface or base and
determine a reference grade line, which will be submitted for approval. A reference line of wire or
suitable cord shall be installed at a uniform grade parallel to the approved reference grade line such that
conformance with the required geometrics, surface tolerance and minimum thickness requirements shall
be ensured. The reference line shall be supported at 8 m maximum spacing unless there is noticeable sag
in the line or the pavement surface, in which case the maximum spacing shall be 4 m.
2.2 The reference line shall be maintained taut and free from sags at all times during spreading and
initial compacting operations.
2.3 Except where the paver is matching a previously placed layer, a wire or cord reference line shall
be installed on both sides of the paver for the initial bituminous course being laid. Thereafter only one
reference line will normally be required, if the paver is equipped with adequate automatic super-elevation
control.
3. Spreading and Finishing
3.1 Bituminous mixed shall be laid only when the air temperature is at least 5 degrees C or above
when the existing surface is free from moisture, and when the weather is not foggy, rainy, dusty or
excessively windy (particularly at low temperatures).
3.2 After completion of surface preparation, the bituminous mix shall be spread and finished true to
crown and grade by approved automatically controlled bituminous pavers. The mix may be spread and
finished by approved hand methods only where the Engineer determines that machine methods are
impracticable. Hand methods include heated hand tampers of at least 10 kg weight and approved type
mechanical (vibratory) tampers.
3.3 The paver shall spread the bituminous mix without tearing the surface and shall strike a finish
that is smooth, true to cross section, uniform in density and texture and free from hollows, transverse
corrugations and other irregularities.
3.4 The paver shall be operated at a speed which gives the best results for the type of paver being
used and which coordinates satisfactorily with the rate of delivery of the mix to the paver. A uniform rate
of placement shall be achieved without repeated intermittent operation of the paver.
3.5 The mix shall be delivered to the paver in time to permit completion of spreading, finishing and
compaction of the mix during daylight hours.
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3.6 If during laying, the paver is repeatedly delayed because of lack of mix or if the paver stands at
one location for an extended period, resulting in the (unrolled) mat under and adjacent to the rear of the
spreader falling below the minimum temperature for breakdown rolling, the affected portion of mat shall
be cut out and discarded and a transverse joint shall be constructed. Paving shall not recommence until
the Engineer is satisfied that paving will proceed without interruptions.
3.7 Contact surface of curbing, gutters, manholes, and similar structures shall be painted with a thin,
uniform coating of tack coat material. The bituminous mixture shall be placed uniformly high near the
contact surfaces so that after compaction it will be 10 mm above the edge of such structure.
3.8 If during the paving operations, it is found that the spreading and finishing equipment in
operation leaves in the pavement surface tracks or indented areas or other objectionable irregularities that
are not satisfactorily corrected by the scheduled operations, the use of the equipment shall be
discontinued, until faults are corrected to the approval of the Engineer. If this is not possible, other
satisfactory spreading and finishing equipment shall be provided by the Contractor.
3.9 Unless otherwise directed by the Engineer, where successive bituminous layers are to be placed,
the surface of each existing layer shall be swept clean with a power broom, or by other approved means
and a tack coat applied at the rate designated by the Engineer and in accordance with the relevant
requirements of Section 4.02 – “Bituminous Prime and Tack Coats”.
3.10 Transverse joints in succeeding layers shall be offset by at least 2 m. longitudinal joints shall be
offset at least 150 mm.
3.11 Bituminous mix shall be spread in one or more layers so that, after rolling, the nominal thickness
of each layer of the compacted bituminous material does not exceed 2 to 3 times maximum size of
aggregate. This maximum thickness may be increased slightly when such increase is more appropriate to
total pavement thickness and provided the Engineer determines that such increased thickness will not be
detrimental to the quality of the finished bituminous course, and the Contractor can show that the required
density is attained throughout the layer thickness.
3.12 Transitions and structure approaches shall meet the design criteria for geometrics, the surface
tolerance specifications, and shall not be visually discontinuous or abrupt in appearance.
3.13 Side roads, entrances and lay-bys shall be paved in accordance with the details shown on the
Drawings.
4. Joints and Edges
4.1 All joints between old and new pavements or between successive days’ work shall be such as to
ensure thorough and continuous bond between the old and new material.
4.2 Before placing fresh mix against previously laid or against old pavement, the contact surface
shall be cut back to a near vertical face, and shall be sprayed or painted with a thin uniform coat of tack
coat material unless otherwise directed. Longitudinal joints shall be made by overlapping the paver screed
on the previously laid material (cut back as necessary) and depositing a sufficient amount of fresh mix so
that the joint formed will be smooth and tight.
4.3 The Contractor shall schedule paving operations so as to minimize the exposure of the leading
lane of longitudinal joints prior to the completion and compaction of the joint. As a minimum, the leading
lane shall not be laid in advance of the adjacent trailing lane by more than one half day of paving, and in
no case shall the leading lane be more than 0.5 km ahead of the trailing lane without approval. In the
event of failure to conform with these requirements, the Engineer may temporarily suspend paving on the
leading lane.
4.4 Unsupported edges of bituminous layers shall be rolled immediately following the rolling of the
longitudinal joint. The material along the unsupported edge may, if approved, be raised slightly by hand
methods, to ensure that the full weight of the roller will bear fully on the edge material.
4-22
4.5 On completion, the longitudinal edges of bituminous pavement shall be true to the width and
alignment as shown on the Drawings. The edges shall be cut back if necessary prior to rolling, additional
mix placed manually in a longitudinal strip adjoining each pavement edge, and the edge rolled down to a
neat 3:1 (H:V) slope or as shown on drawings.
4.6 Transverse joints shall be carefully constructed and thoroughly compacted to provide a smooth
riding surface. Joints shall be straight-edged and string-lined to assure smoothness and true alignment. If
the joint is formed with a bulkhead, such as a board, to provide a straight line and vertical face, it shall be
checked with a straight edge before fresh material is placed against it to complete the joint. If a bulkhead
is not used to form the joint and the roller is permitted to roll over the end of the new material, the line
shall be located back of the rounded edge a sufficient distance to provide a true surface and cross-section.
If the joint has been distorted by traffic or by other means, it shall be trimmed to line. In either case, the
joint face shall be painted with a think coating of asphalt before the fresh material is placed against it.
5. Compaction
5.1 Rollers shall be operated by competent and experienced operators in accordance with the
manufacturer's instructions, copies of which shall be submitted to the Engineer. Rollers shall be kept in
operation continuously if necessary, so that all parts of the pavement receive substantially equal
compaction at the time desired.
5.2 After spreading and strike-off, and as soon as the mix conditions permit the rolling to be
performed without excessive shoving or tearing, the mixture shall be thoroughly and uniformly
compacted, using approved types, sizes and numbers of rollers. Rolling shall not be prolonged to the point
where cracks appear or shoving or displacement occur.
5.3 All rollers shall be self-propelled vibratory steel wheel, 2-axle tandem steel-tired and pneumatic-
tired types, in proper operating condition, capable of reversing without backlash or tearing of the surface
and shall be operated at speeds slow enough to avoid displacement of the bituminous mix. The minimum
numbers of rollers required is 3, of which one must be a pneumatic type. The Contractor shall select a
suitable method and pattern of rolling that will achieved the required compaction, to the Engineers
approval.
5.4 Prior to use on Site of pneumatic-tired rollers, the Contractor shall furnish, for reference and
retention by the Engineer, manufacturer's charts or tabulations showing the contact areas and contact
pressures for the full range of tire inflation pressures and for the full range of tire loadings for each type
and size of compactor tire to be used. The Contractor shall ensure that tire pressures are maintained at all
times in conformity with such charts or tabulations. The maximum allowable tolerances shall be plus or
minus 35 kN/m2 (5 psi).
5.5 Rollers should move at a slow but uniform speed, generally with the drive roll or wheels nearest
the paver. Recommended speeds are shown in Table 4.12 (Km/hr).
Table 4.12: Recommended Speeds of Rollers
Breakdown Intermediate Finish
Steel Tired Static Weight Rollers 3 5 5
Pneumatic Tired Rollers 5 5 9
Vibratory Rollers 4.5 4.5 -
5.6 If vibratory rollers are used, when it is required to change direction the vibration should be
turned off before the roller is stopped, and turned on after motion in the new direction begins.
5.7 Rolling shall begin as soon as the mixture will bear the roller weight without undue
displacement. The minimum temperature of the mat at which rolling shall be allowed to start is 1200C.
5.8 Breakdown rolling shall consist of 3 complete coverage unless otherwise directed. Rolling shall
be longitudinal, beginning at the low side of the spread of material and proceeding towards the high side,
overlapping on successive trips by at least one half the width of the rear wheels. Alternate trips of the
rollers shall be of slightly differing lengths.
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5.9 The speed of the rollers, rolling pattern and, in the case of vibratory rollers, the frequency and
amplitude of vibration, shall be approved by the Engineer. To prevent adhesion of the mix to the rollers,
the wheels shall be kept properly and lightly moistened with water. An excessive use of water will not be
permitted.
5.10 The rolling pattern, type and number of rollers shall be established by a site trial so as to achieve
the required compaction. The approved rolling pattern shall be followed.
5.11 The initial or breakdown rolling shall be followed by intermediate rolling involving 3 coverage
with pneumatic-tired rollers unless otherwise specified. Tire contact pressure shall be as approved.
5.12 Finishing rolling shall then be carried out by means of tandem power steel rollers unless
otherwise designated. If, the specified density is not achieved, changes shall be made in size and number
of rollers being used to ensure the compaction requirements are met.
5.13 The compacted density shall be equal to or greater than 97% and 98% for binder course and
wearing course, respectively, of the average Marshall bulk specific gravity for each day's production
unless otherwise directed by the Engineer, or allowed for in the Special Specification.
5.14 Any mix that becomes loose, broken, mixed with foreign material, or which is in any way
defective in finish or density, or which does not conform in all other respects with the specified
requirements shall be removed, replaced with suitable material and properly finished.
4.3.9 SAMPLING AND TESTING
1. Sampling and testing shall conform with the relevant requirements of Section 1.05 - "Control of
Materials and Standards for Sampling and Testing", and Tables 4.13.
Table 4.13: Test For Bituminous Pavements, Minimum Tests Required
Work Item (A) Tests at Source of Frequency for all (B) Tests at Road Frequency for
Material tests in (A) site all tests in (B)
4-1 1-Specific gravity and -Test for each
Materials water absorption source
used in 2-Abrasion test -When material
Asphalt mix changes
( at Batching 3-chert content -As required
Plant) 4-Clay lumps and
friable materials
5-Flaky and elongated
particles
6-Soundness
4-2 1 1-Gradation -Test for each
Materials source
used in 2- Specific gravity and -When material
Asphalt mix water absorption changes
3-Plasticity Index -As required
4-Sand equivalent
5-Striping with asphalt
4-3 Asphalt 1-Complete mix design -For each project
mix design in accordance with -when material
each layer American Asphalt quality changes
(at batching Institute (MS2) -when results are
plant) 2-loss of stability not consistent with
mix design
-As required
4-4 Asphalt At Batching Plant -Test each 3 Behind Spreader -Test each
for each working days working day
layer 1-Stability -Test for each 1-Stability -Test for each
2-Flow batching plant 2-Flow batch
3-Extraction (binder -As required 3-Extraction(binder -As required
content and gradation) content & gradation)
4-24
4-Air voids 4-Air voids

5-Voids in mineral 5-Voids in mineral
aggregates aggregates
6-Daily Marshall 6-Daily Marshall
density density
7-Loss of Stability -Once a week 7-Road density and -Test each
-As required Thickness (after final 200LM per
compaction) lane and for
each layer
8-Loss of stability -Once a week
-As required
2. The Marshall bulk specific gravity shall be determined in accordance with AASHTO T 166 or
AASHTO T 275. The Marshall specimens shall be prepared from the same material used in construction,
taken from samples of fresh bituminous mix at the mixing plant or from tucks delivering mix to the Site.
Oven heating for up to 30 minutes to maintain the heat of the sample is permissible.
3. The bulk specific gravity of the mix as placed and compacted in situ shall be determined from
100 mm nominal diameter core samples, or slab samples cut from each compacted layer on the road at
locations designated by the Engineer who may require additional tests to determine limits of areas
deficient in density, or for recheck.
4. Samples for in situ bulk specific gravity determinations shall be taken in sets of 2 from each
pavement location. Minimum frequency of sampling for each bituminous layer shall be one set/lane/500
m, minimum of one set per day of placing bituminous layers.
5. The Contractor shall cut the samples with an approved core drill in the presence of the Engineer.
The equipment shall be capable of cutting the mixture without shattering the edges or otherwise
disturbing the density of the specimen.
6. The Contractor shall, when necessary, furnish and apply cold water, ice, or other cooling
substance to the surface of the pavement to prevent the sampling from shattering or disintegration. The
Contractor shall fill and compact all test holes at his own expense.
4.3.10 SURFACE TOLERANCE
1. The fully compacted and completed bituminous course shall conform to the lines, grades and
cross sections as shown on the Drawings.
2. The elevations of the finished course shall be checked by the Contractor in the presence of the
Engineer at maximum intervals of 12.5m (half station) and at intermediate points as directed.
3. When the finished surface is tested with a 3 m long straightedge, placed parallel to, or at right
contact points shall not exceed the tolerances specified for each type of bituminous course laid.
4. All areas which exceed the specified tolerances shall be corrected by removing the detective
sections of bituminous course and reconstructing them or, if approved, by adding new material and re-
compacting and finishing to the specified standard or increasing the thickness of the succeeding course.
5. The tolerances specified for evenness of finished surfaces for all types of bituminous courses,
shall not invalidate the tolerances specified for construction thickness and elevations of such courses.
4.3.11 DETERMINATION OF THICKNESS OF COURSES
1. The Contractor shall compensate for minor deficiencies in the thickness of any bituminous
course in the pavement structure by increasing the thickness of the subsequent bituminous course. After
completion of the final (wearing) course any deficiencies in the thickness of any course which have not
been compensated for by increasing the thickness of a subsequent course, will be considered deficiencies
in the final (wearing) course.
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2. Cylinder core samples shall be taken as specified for in situ bulk specified gravity core samples.
3. Thickness of bituminous courses shall be determined by average caliper measurement of cores,

rounded upwards to the nearest mm.
4. Paved sections to be measured separately shall consist of each 300 linear meter section in each
traffic lane. The last section in each traffic lane shall be 300 m plus the fractional part of 300 m
remaining. Other areas such as intersections, entrances, crossovers, ramps, etc. shall be measured as one
section and the thickness of each shall be determined separately. Small irregular unit areas may be
included as part of another section.
5. One core shall be taken from each section by the Contractor at approved locations and in the
presence of the Engineer. When the measurement of the core from any paved section is not deficient by
more than 5 mm. From the specified thickness, the core will be deemed to be of the specified thickness as
6. When the measurement of the core from any paved section is deficient by more than 5 mm but
not more than 20 mm, 2 additional cores spaced at not less than 100 m shall be taken and used together
with the first core to determine the average thickness of such section.
7. When the measurement of the core from any paved section is less than the specified thickness by
more than 20 mm, the average thickness of such section shall be determined by taking additional cores at
not less than 5 m intervals parallel to the centerline in each direction from the affected location until, in
each direction, a core is taken which is not deficient by more than 20 mm. Exploratory cores for deficient
thickness will not be used in average thickness determinations.
8. Any deficiencies in the total thickness of bituminous courses shall be subject to a proportional
reduction in the area of final (wearing) course measured for payment. Alternatively, the Contractor shall
construct all at his own expense, a wearing course overlay, if practicable in the judgment of the Engineer.
Any such overlay shall be a minimum of 40 mm compacted thickness and to the specified standard of the
course it is overlaying.
9. If the deficiency in total asphalt layers thickness is from 0 – 3mm, full payment will be made, on
condition that deficiencies are not found in more than 10% of the total project. Deficiencies exceeding
3mm shall be left to the substantial handing-over procedure.
4.3.12 MEASUREMENT
1. Bituminous Courses shall be measured as prescribed in each of the respective Sections for each
type of bituminous course constructed and accepted. Measurement shall not include the rolled down edge
strips of bituminous courses placed outside the edge of paving as shown on the Drawings.
2. Bituminous Prime Coat and Bituminous Tack Coat shall be measured as prescribed in Section
4.02 – “Bituminous Prime and Tack Coats”.
3. Bituminous overlays constructed by order of the Engineer to correct deficiencies in total

thickness of bituminous courses or to compensate for major deficiencies in the thickness of any
underlying bituminous course, shall not be measured for direct payment, but shall be considered as
subsidiary Works the costs of which will be deemed to be included in the Contractor Prices for Pay Items.
4. Establishment of the Job Mix Formula, surface preparation, construction of joints, hand painting
of contact surfaces, remedial treatment of surface irregularities, cutting of cores and slabs for testing or
measurement purposes, reinstatement of core and slab areas of pavement, rolled down longitudinal
bituminous edge strips, additional thickness of bituminous course in excess of the specified thickness, and
other ancillary items shall not be measured for direct payment, but shall be considered as subsidiary
Works the costs of which will be deemed to be included in the Contractor Prices for Pay Items.
4-26
BITUMINOUS BASE COURSES SECTION 4.4
SECTION 4.4 : BITUMINOUS BASE COURSE

4.4.1 SCOPE
1. These Works shall consist of furnishing materials, mixing at a central mixing plant, and
spreading and compacting bituminous base course on an approved sub-base course or subgrade, as and
where shown on the Drawings.
4.4.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 4.01– “Materials”.
2. Unless otherwise shown on the Drawings, bitumen for base course construction shall be 60/70
penetration graded bitumen.
3. When an approved modifier (catalyst) is to be added and mixed with the bitumen, the bitumen
used shall not be of lower penetration than 80/100 grade.
4.4.3 JOB MIX AND PROJECT MIX
1. The Job Mix Formula shall be established by the Contractor in accordance with the procedures
and requirements of Section 4.03 – “Bituminous Courses”.
2. The Job Mix for bituminous base course shall conform to the following composition limits as
shown in Table 4.14. The particular job mix to be used in a project shall be given in the Special
Specifications.
Table 4.14: Job Mix Requirements For Bituminous Base Course
Property Heavy Traffic Medium-Light Traffic
Marshall Stability at 60ºC (Kg) 750 700
Flow (mm) 2 – 3.5 2–4
Voids in Mineral Aggregates (VMA) 12 (min) 12 (min)
Air Voids (%) 4–8 4–7
Filler Bit Ratio 1.2 – 1.5 1.0 – 1.4
Stiffness (Kg/mm) 300 (min) 250 (min)
*Loss of Stability (%) 25 (max) 25 (max)
* This test to be performed if directed by the Engineer or if required in the Special Specification.
(this test is based upon AASHTO T165-86).
3. After the job mix formula has been established and approved, all mixes furnished shall conform
to it within the stated tolerances.
4. The job Mix Formula shall be re-establish if the source of aggregate, filler or bitumen changes.
4.4.4 EQUIPMENT
1. Plant and equipment for mixing, hauling, placing and compacting bituminous base course
material, shall conform with the relevant requirements of Section 4.03 – “Bituminous Courses”.
1. Trial sections shall be constructed as and where directed and in accordance with the relevant
requirements of Section 4.03 – “Bituminous Courses”.
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1. Handling and mixing of bitumen (including modifier and anti-stripping agent, if any) and
aggregates (including mineral filler if required) shall be in accordance with the relevant requirements of
Section 4.03 – “Bituminous Courses”.
1. Preparation of the surface upon which the bituminous base course mix is to be laid, shall be
appropriate to the type and condition of such surface and shall conform with the relevant requirements of
1. General
1.1 The delivery, spreading and finishing of bituminous mix for base course shall conform with the
relevant requirements of Section 4.03 – “Bituminous Courses” and with the following particular
requirements.
2. Rollers
2.1 Initial breakdown rolling shall be carried out by use of 2 dual-drum vibrating steel-wheeled
vibrating rollers each of minimum weight 7,000 kg and with vibrating frequency of 2,000-3,000
cycles/min. These rollers shall be purpose made for compaction of hot bituminous courses.
2.2 Intermediate rolling shall be carried out by use of at least 2 self-propelled, tandem pneumatic
smooth-tired rollers each capable of exerting contact pressures of up to 690 kN/m2 (100 psi) and ballast –
adjustable to ensure uniform wheel loadings.
2.3 Final rolling shall be carried out by use of 2, 2-axle tandem steel-tired rollers each of minimum
weight 10,000 kg, capable of exerting contact pressures of up to 65 kg/cm (350 lb/in.).
2.4 The number of rollers used for any stage of rolling nay be reduced by the Engineer to one,
provided that the base course width being compacted is less than 5.5 m in width, and provided an
equivalent standby roller is available on Site as replacement, in the event of breakdown of the operating
roller.
3. Standard of Compaction
3.1 The compacted density of the bituminous base course shall be equal to or greater than 97% of
the average Marshall bulk density for each day’s production. The Special Specifications may require the
degree of compaction of the bituminous base course to be expressed as a percentage of the maximum
theoretical Specific Gravity of the mix.
1. Sampling and testing shall conform with the relevant requirements of Section 4.03 –“Bituminous
Courses”, and Table 4.12.
1. Surface tolerances shall conform with the relevant requirements of Section 4.05 – “Bituminous
Courses” and with the following particular requirements.
2. The tolerances on elevations of finished bituminous base course surface shall be not greater than
plus 10 mm to minus 10 mm.
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3. When the finished surface is tested with a 3 m long straightedge, placed parallel to, or at right
4.4.11 DETERMINATION OF THICKNESS
1. Procedures for determining the average compacted thickness of bituminous base course shall
conform with the relevant requirements of Section 4.03 – “Bituminous Courses” and with the following
particular requirements.
2. Cores for thickness measurements shall be used to determine if changes are necessary in the
constructed thickness of succeeding bituminous layers to rectify any thickness deficiencies in the
bituminous base course.
3. In any case where the bituminous base course will not be covered by superimposed binder or
wearing courses, the base course shall be deemed to be the final (wearing) course for the purposes of
determining the proportion of Wearing course area measured for payment or for the purposes of any
overlay ordered to correct deficiencies.
4.4.12 MEASUREMENT
1. Bituminous Base Course shall be measured by m2 of mix furnished, spread, compacted,

completed and accepted. Measurements shall be of the areas and thickness as shown on the Drawings.
2. Where Bituminous Base Course is intended to serve as a wearing course, any deficiencies in
thickness shall, unless an overlay is constructed at the Contractor’s expense, result in a proportion only of
the base course area being measured for payment. Proportions shall be determined in accordance with the
thickness deficiencies and area proportions tabulated in Section 4.03 – “Bituminous Courses”.
3. Bituminous prime coat shall be measured as prescribed in Section 4.02 – “Bituminous Prime and
Tack Coats”.
4. All other incidental items shall not be measured for direct payment, as prescribed in Section 4.03
– “Bituminous Courses”.
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BITUMINOUS BINDER AND WEARING COURSES SECTION 4.5
SECTION 4.5 : BITUMINOUS BINDER AND WEARING

COURSES
4.5.1 SCOPE
1. These Works shall consist of furnishing materials, mixing at a central mixing plant, spreading
and compacting bituminous binder course and bituminous wearing course on an approved base as and
where shown on the Drawings.
4.5.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 4.01 – “Materials”.
2. Unless otherwise shown on the Drawings, bitumen for binder and wearing courses construction
shall be 60/70 penetration graded bitumen, and or any other suitable grade for the climatic condition of
the project.
3. When an approved modifier (catalyst) is to be added and mixed with the bitumen, the bitumen
used shall not be of lower penetration than 80/100 grade.
1. The Jon Mix Formula shall be established by the Contractor in accordance with the procedures
2. The Job Mix for bituminous binder and wearing courses shall conform to the following
composition limits, as shown in Table 4.15. The particular job mix to be used and shall be given in the
Special Specification.
Table 4.15: Job Mix Requirement to Bituminous Binder and Wearing

Heavy Traffic Medium-Light Traffic
Property Binder Wearing Binder Wearing
Marshall Stability at 60ºC (Kg) 900 1000 800 900
Flow (mm) 2 – 3.5 2 – 3.5 2–4 2–4
Voids in Mineral Aggregates (VMA) 13 (-1) 14 (-1) 13 (-1) 14 (-1)
Air Voids (%) 4–7 4–6 3–5 3–5
Stiffness (Kg/mm) 500 (min) 500 (min) 400 (min) 400 (min)
*Loss of Stability (%) 25 (max) 25 (max) 25 (max) 25 (max)
* This test to be carried out in accordance with AASHTO T165-82.
3. After the Job Mix Formula has been established and approved, all subsequent mixes shall
conform to it within the allowable tolerances.
4. The Job Mix Formula shall be re-established if the source of aggregate, filler or bitumen is
changed.
4.5.4 EQUIPMENT
1. Plant and equipment for mixing, hauling, placing and compacting bituminous binder course and
wearing course materials, shall conform with the relevant requirements of Section 4.03 – “Bituminous
Courses”.
1. Trial section shall be constructed as and where directed and in accordance with the relevant
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aggregates (including mineral filler if required) shall be in accordance with the relevant requirements of
1. Preparation of the surface upon which the bituminous binder course and the bituminous wearing
course mixes are to be laid, and the use of prime and tack coats, shall be appropriate to the type and
condition of such surfaces and shall conform with the relevant requirements of Section 4.03 –
“Bituminous Courses”.
1. General
1.1 The delivery, spreading and finishing of bituminous mixes for binder and wearing courses shall
conform with the relevant requirements of Section 4.03 – “Bituminous Courses” and with the following
particular requirements.
2. Rollers
2.1 Initial breakdown rolling shall be carried out by use of 2 dial-drum vibrating steel-wheeled
vibrating rollers each of minimum weight 7,000 kg and with vibrating frequency of 2,000-3,000
cycles/min. These rollers shall be purpose made for compaction of hot bituminous courses.
2.2 Intermediate rolling shall be carried out by use of at least 2 self-propelled, tandem pneumatic
smooth-tired rollers each capable of exerting contact pressures of up to 690 kN/m2 (100 psi) and ballast –
adjustable to ensure uniform wheel loadings.
2.3 Final rolling shall be carried out by use of 2, 2-axle tandem steel-tired rollers each of minimum
weight 10,000 kg, capable of exerting contact pressures of up to 65 kg/cm2 (350 lb/in2.).
2.4 The number of rollers used for any stage of rolling may be reduced by the Engineer to one,
provided that the course being compacted is less than 5.5m in width, and provided an equivalent standby
roller is available on Site as replacement, in the event of breakdown of the operating roller.
3. Standard of Compaction
3.1 The compacted density of the bituminous wearing course shall be not less than 98% of the
average Marshall bulk density for each day’s production.
3.2 The Special Specified may require the degree of compaction to be expressed as a percentage of
the maximum theoretical specific gravity of the mix.
1. Sampling and testing shall conform with the relevant requirements of Section 4.03 –
“Bituminous Courses”, and table 4.12.
1. Surface tolerance shall conform with the relevant requirements of Section 4.03 – “Bituminous
Courses” and with the following particular requirements.
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2. The tolerances on elevations of the final bituminous wearing course surface shall not be greater
than 10mms.
3. When the finished wearing course surface is tested with a 3m long straightedge, placed parallel
to, or at right angles to the centerline, the maximum deviation of the surface from the testing edge
between any 2 contact points shall not exceed 5.0 mm.
4. The combination of the permitted tolerances in the levels of the different pavement layers,
excluding aggregate base and sub-base courses, shall not result in a reduction of thickness by more than
10mms from the specified thickness, as shown on the drawings, nor a reduction in the final wearing
course thickness by more than 5mm from that specified or shown on the drawings.
4.5.11 DETEMINATION OF THICKNESS
1. Procedures for determining the average compacted thickness of bituminous binder and wearing
courses shall conform with the relevant requirements of Section 4.03 - "Bituminous Courses" and with
the following particular requirements.
2. Cores for thickness measurements of the binder course shall be used to determine if changes are
necessary in the constructed thickness of the wearing course to rectify any thickness deficiencies in the
binder course.
4.5.12 MEASUREMENT
1. Bituminous Binder Course and Bituminous Wearing Course shall be measured by m2 of mix
furnished, spread, compacted, completed and accepted. Measurements shall be of the areas and thickness
as shown on the Drawings.
2. Deficiencies in thickness of the wearing course shall, unless an overlay is constructed at the
Contractor's expense, result in a proportion only of the wearing course area being measured for payment.
Proportions shall be determined in accordance with the thickness deficiencies and area proportions
tabulated in section 4.03 - "Bituminous Courses".
3. Bituminous Prime coat and Bituminous Tack Coat shall be measured as prescribed in Section
4.02 - "Bituminous Prime and Tack Coats".
- "Bituminous Courses".
4-32
BITUMINOUS SEAL COATS SECTION 4.6
SECTION 4.6 : BITUMINOUS SEAL COATS

4.6.1 SCOPE
1. These works shall consist of the furnishing of materials and one or more applications of cutback
bitumen and cover material, or a single application of emulsified bitumen, or spreading emulsified
bitumen slurry, to previously prepared base course or wearing course surfaces, as and where shown on the
Drawings.
2. Bituminous Slurry Seal Coat (BSSC) shall consist of spreading and screeding a mixture of
emulsified bitumen, sand aggregate and water.
3. Single Bituminous Seal Coat (SBSC) shall consist of a single application of cutback or straight
run bitumen, and sand aggregate or as specified.
4. Double Bituminous Seal Coat (DSBC) shall consist of an application of cutback or straight run
bitumen and (coarse graded) cover aggregate followed not less than 5 days later by a second application
of cutback or straight run bitumen and (medium graded) aggregate, or as specified.
4.6.2 MATERIALS
1. Bitumen
1.1 Bitumen for SBSC and DBSC (seal coat) applications shall be Rapid-Curing RC-800 Grade and
or any suitable grade conforming with the relevant requirements of Section 4.01 - "Materials", and
AASHTO M-81.
1.2 Bitumen for BSSC (slurry) applications shall be a cationic, slow setting emulsified bitumen
Grade CSS-1, conforming with the relevant requirements of Section 4.01 - "Materials", unless otherwise
specified in the Special Specification.
2. Aggregates
2.1 Cover aggregates shall consist of screenings of crushed stone or crushed gravel. Aggregate for
slurry seals shall consist of crushed stone or gravel fines or natural sand blended with not less than 50%
crushed fines. for heavy duty applications slurry aggregate shall consist of 100% crushed fines.
2.2 The properties of cover and slurry seal aggregates and their gradations shall be in accordance
with the relevant requirements of Section 4.01 - "Materials".
4.6.3 EQUIPMENT
1. All plant and equipment used for pugmill mixing of slurry mixes, heating and spraying of
cutback and emulsified bitumen, spreading, rolling and brooming of cover aggregate, and applying and
spreading slurry seals, shall conform with the requirements of Section 1.14 - "Contractor's Plant and
Equipment", and with the contractor's approved Work Program.
4.6.4 CONSTRUCTION OF TRIAL SCTIONS
1. Before commencement of Site seal coat applications, the Contractor shall construct trial sections
using varying application rates for bitumen and for aggregates, as selected by the Engineer. Each trail
section shall be 2 lanes wide by 50 m long, at approved locations on or close to the Site.
2. Each trail section shall be constructed using the same materials, mixing, spraying, spreading,
rolling and brooming equipment, and construction procedures, proposed for use in the Works. Trail
sections for slurry seals shall be along existing bituminous pavements in the vicinity of the Site.
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3. The objectives of these trails shall be to determine the adequacy of the Contractor's equipment,
the most suitable application rates for cutback bitumen, emulsified bitumen and the various gradations of
aggregate, and the most suitable consistency of slurry seal to fill cracks and leave a residual coating of 3
mm over the entire bituminous wearing surface.
4. The Contractor shall not proceed with any seal coat applications until the methods and
procedures established in the trails have been approved.
4.6.5 RATES OF APPLICATION
1. Application rates for cutback and emulsified bitumen and for the various cover aggregate
gradations, will be determined by the Engineer from the trial sections and shall be generally within the
ranges given in Table 4.16.
Table 4.16: Application Rates

Approx rate of Application
Aggregate Binder
Types of seal coat
Kg/m2 Kg/m2
Coarse Aggregate seal coat 12.5 – 20.0 1.00 – 1.80
Medium Aggregate seal coat 10.0 – 15.0 0.90 – 1.80
Slurry seal Generally 5 – 6 Kg/m2 for the mix
2. The Engineer may order additional trail sections and alter the previously established rates of
application during progress of the Works.
4.6.6 CONSTRUCTION
1. General
1.1 Applications of bitumen and aggregate and subsequent rolling shall be completed between
sunrise and sunset and under favorable weather conditions as determines by the Engineer. The
atmospheric temperature shall be above 15 degrees C and the weather shall not be foggy, rainy, dusty or
unduly windy.
1.2 Generally, where the seal coat is to carry traffic prior to final sweeping, speed signs shall be
erected to control the speed of traffic. Provision for traffic control shall be in accordance with the relevant
requirements of Section 8.01 - "Maintenance of Traffic and Detours".
1.3 When bituminous coatings are applied to sections of highway which are to be promptly opened
to traffic, and the ambient temperature is contributing to slow curing and excessive pickup, the Contractor
shall suspend operations until the Engineer approves continuation of sealing Works.
1.4 The surface to be treated shall be dry or slightly damp and the moisture content of aggregates at
the time of application to the coated surface shall not exceed 3% by weight.
1.5 Unless otherwise directed, the minimum time interval between successive seal coats, in DBSC
and TBSC applications, shall be 5 days.
2. Surface Preparation
2.1 Granular surfaces shall be primed in accordance with the requirements of Section 4.02 -
"Bituminous Prime and Tack Coats" prior to construction of the surface treatment. If there are delays in
scheduling the seal coating, which results in deterioration of the surface, the Engineer may order
appropriate repairs or corrective treatment prior to seal coating.
2.2 When coatings are applied to existing pavement surfaces, all pavement repairs shown on the
Drawings shall first be completed. Where applicable, the positions of traffic markings shall be surveyed
and recorded to enable their accurate replacement after the seal coating have been applied.
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2.3 Immediately before applying any bituminous material, all dirt, dust and other objectionable
material shall be removed from the surface and cracks shall be repaired or sealed as directed. If required,
the surface shall be slightly dampened with a light application of water immediately prior to application
of bitumen.
2.4 Surfaces to be slurry sealed shall be lightly sprayed, immediately prior to spreading the slurry,
with a slow-curing 3:1 water: emulsion mixture applied at the rate of 0.4-0.8 liter/m2.
3. Heating of Bitumen
3.1 The temperature of cutback bitumen and of emulsified bitumen at the time of application shall be
as specified in Section 4.01 - "Materials".
4. Spreading Slurry Seal
4.1 Spreading of slurry seal shall be by means of an approved type spreader box which shall be
capable of spreading at least one traffic lane width. It shall have flexible rubber or similar strips fastened
on each side to prevent loss of slurry and shall have baffles incorporated in the box to ensure uniform
application. A rear, flexible strike-off blade of adjustable type shall also be provided.
4.2 Areas inaccessible to the slurry spreader box shall be slurry sealed using hand or other approved
methods.
4.3 The slurry seal coat shall be uniform and homogeneous after spreading and shall not show signs
of separation of the emulsion and/or aggregate after setting.
5. Spraying of Bitumen
5.1 The bitumen cutback or emulsified bitumen for fog and seal coats shall be applied by means of a
pressure distributor uniformly and continuously over the section to be treated. The rate of application
shall be as designated by the Engineer.
5.2 A strip of building paper or heavy polyethylene sheeting, at least one m in width, and with a
length equal to that of the spray bar of the distributor plus 300 mm shall be used at the beginning of each
application. If the cut-off is not positive, the paper shall be used at the end of each spread. The paper shall
be removed and disposed of, after use. The distributor shall be moving forward at proper application
speed at the time the spray bar is opened. Any skipped areas or deficiencies shall be corrected
immediately as directed.
5.3 The length of spray run shall not exceed that which can be covered by the aggregate spreading
equipment.
5.4 The application width of bitumen shall be not more than 150 mm wider than the width covered
by the aggregate spreader. Under no circumstances shall operations proceed in such a manner that the
bitumen will be allowed to chill, set up, dry, or otherwise impair retention of the cover aggregate.
5.5 The Contractor shall keep a complete record of bitumen used, based on distributor tank
measurements and on areas to which the bitumen has been applied. These records shall be submitted to
the Engineer as verification of the accuracy of the tachometer as well as verification of application rates
designated by the Engineer.
5.6 Distribution of bitumen shall be so regulated and sufficient material left in the distributor at the
end of each application, that there will be a uniform distribution across the spray bar. In no case shall be
distributor be allowed to expel air with the bitumen, thereby causing uneven coverage.
5.7 The angle of the nozzles and the height of the spray bar shall be adjusted and regularly checked
to ensure uniform distribution. The height of the spray bar above the pavement surface should remain
constant throughout the spraying process. Distribution shall cease immediately upon clogging or partial
blocking of any nozzle and corrective measures shall be taken before application is resumed.
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6. Application of Aggregate
6.1 If directed, aggregate shall be washed prior to use in order to eliminate or reduce any dust
coating or salts before delivery to the spreader.
6.2 operation of the aggregate spreader at speeds which cause the particles to roll over after striking
the bitumen covered surface will not be permitted.
6.3 Immediately upon application of bitumen, aggregate of the required gradation shall be spread at
the rate designated by the Engineer. Spreading shall be accomplished in such a manner that the tires of the
hauling units or aggregate spreader do not come in contact with the uncovered bitumen surface.
6.4 Where adjacent spreads are to be made, the first aggregate spread shall not extend closer than
150 mm to the edge of bitumen application. The adjacent spread of bitumen shall overlap this 150 mm
and complete aggregate coverage shall be achieved on the second spread promptly upon completion of
the first spread to ensure a smooth riding surface.
6.5 Immediately after aggregate has been spread, deficient areas shall be covered by additional
aggregate. Piles, ridges or uneven distributions of aggregate shall be removed and corrected to insure
against permanent ridges, bumps, or depressions in the completed surface. Additional aggregate shall be
spread in whatever quantities necessary to prevent pick-up by rollers or traffic, after which the surface
shall be rolled as directed.
6.6 Care shall be taken to prevent aggregate from entering ditches or inlets of any type. The
Contractor shall be responsible for removal of any such aggregate materials or other accumulated debris
arising out of his operations.
7. Rolling and Brooming
7.1 Aggregate shall not be spread more than 150 m ahead of initial rolling operations.
7.2 Rollers shall not stop, start or turn on the surface being rolled. Any damage to the surface arising
out of non-compliance with these requirements shall be made good as directed, at the Contractor's
expense.
7.3 Initial "breakdown" rolling shall proceed behind the spreader (after any adjustments by hand
methods to correct for uneven distribution, etc). One complete coverage shall be achieved using 2-axle
self-propelled steel-wheeled rollers of 6-8 tons weight and operating at a maximum speed of 5 km/h.
initial rolling shall be completed within 30 minutes of spreading aggregate.
7.4 The Engineer may order the alternative use of pneumatic-tired rollers for initial rolling if the
achievement of adequate embedment of the aggregate is liable to result in excessive crushing when steel-
wheeled rollers are used.
7.5 Immediately following completion of the initial rolling, the surface shall be rolled using self-
propelled pneumatic-tired rollers operated at a maximum speed of 8 km/h, until at least 3 complete
coverage’s have been achieved.
7.6 If necessary during rolling operations, additional screenings shall be lightly spread by hand
methods and re-rolled, to make good any small areas visibly deficient in cover material.
7.7 Light drag brooming of the surface shall be carried out 24 hours after completion of rolling and
in such a manner that embedded aggregate particles will not be dislodged. This brooming shall result in
uniform distribution of loose screenings over the surface which shall than be re-rolled using pneumatic-
tired rollers until at least 2 complete coverage have been achieved.
7.8 Light drag brooming and re-rolling shall be repeated 24 hours after the initial brooming, if so
directed.
7.9 Excess (surplus) screenings shall be salvaged and stockpiled or disposed of as directed.
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8. Maintenance and Protection of Sealed Surfaces
8.1 BFSC and BSSC shall be protected from traffic until such time as the coatings have cured
sufficiently and will not be damaged by, adhere to or be picked up by, the tires of vehicles.
8.2 Each coat of SBSC and DBSC shall be maintained and protected from traffic for at least 3 days
after completion of rolling.
8.3 At the end of the 3-day maintenance period for each seal coat, or earlier if directed, the surface
shall be finally swept, using a rotary broom, to remove loose screenings. Surplus screenings shall be
stockpiled or disposed of as directed.
8.4 Adequate traffic control (including speed control measures) shall be taken during the
maintenance periods, in accordance with the relevant requirements of Section 8.01 - "Maintenance of
Traffic and Detours".
4.6.7 TOLERANCES AND RECORDS
1. The Contractor shall be responsible for ensuring the accurate calibration of pressure distributions
and for the correct rates of application of bitumen as designated by the Engineer.
2. Readings shall be taken of bitumen tanker contents and temperature immediately prior to, and
immediately upon completion of each spraying run and the actual application rate in kg/m2 shall be
calculated. Complete records shall be maintained of all such measurements and the specific locations,
with and lengths of the respective runs.
3. The tolerances on temperature adjusted application rates of cutback bitumen shall be plus or
minus 5% of the designated rate.
4. Applications of cutback bitumen varying by more than 5% but less than 10%, after temperature
adjustment, below the specified rate of application shall, if accepted, be subject to a 10% reduction in
quantity or area measurements as appropriate.
5. Applications of cutback bitumen varying by more than 5% but less than 10%, after temperature
adjustment, above the specified rate of application shall, if accepted, be measured on the basis of the
designated application rate.
6. Applications of cutback bitumen varying by more than 10%, after temperature adjustment, above
or below the specified rate of application shall be rejected and the unsatisfactory material replaced or
made good as directed, at the Contractor’s expense.
7. The Contractor shall maintain, on a daily basis, complete records of the volumes and tonnage of
each type of aggregate delivered to the Site and used in each section of the Works for seal coat
applications.
8. All records and calculations of bitumen application, and aggregate delivery and use, shall be
submitted to the Engineer at the end of each day when seal coat applications have been carried out. No
measurements will be made of bitumen applications which are not supported by adequate, verifiable
records.
4.6.8 MEASUREMENT
1. The quantity of seal coat to be paid for shall be the number of square meters for each application
as entered in the Bill of Quantities. No separate payment shall be made for bituminous material, or cover
aggregates.
4-37
BITUMINOUS LEVELING COURSE SECTION 4.7
SECTION 4.7 : BITUMINOUS LEVELING COURSE

4.7.1 SCOPE
1. These Works shall consist of furnishing materials, mixing at a central mixing plant, and
spreading and compacting bituminous wearing course on an existing pavement surface, as and where
shown on the Drawings or directed.
4.7.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 4.01 – “Materials”.
2. Unless otherwise shown on the drawings materials shall conform with the requirements of
Section 4.05 – “Bituminous Binder and Wearing Courses”.
2. The Job Mix for bituminous leveling shall conform with the requirements of Section 4.05 –
“Bituminous Binder and Wearing Courses”.
4.7.4 EQUIPMENT
1. plant and equipment for mixing, hauling, placing and compacting bituminous leveling course
materials shall conform with the relevant requirements of Section 4.03 – “Bituminous Courses”.
1. Trial Sections shall be constructed as and where directed and in accordance with the relevant
1. Damaged pavement surfaces shall, where directed, be repaired by patching prior to receiving the
bituminous leveling course. The extent of patching shall be as shown on the Drawings or as directed.
2. Areas of existing pavement to be patched shall be cut out to neat lines to a depth ordered by the
Engineer, thoroughly cleaned, and the exposed edges of pavement painted or sprayed with a thin coat of
rapid curing cutback bitumen Grade RC-70 or RC-250 in accordance with the relevant requirements of
Section 4.02 – “Bituminous Prime and Tack Coats”. The cut out pavement shall be patched with
bituminous material as shown on the Drawings or as directed and conforming with the relevant
requirements of Section 4.01 – “Materials”.
3. Patching shall be carried out in accordance with the relevant requirements of Section 4.03 –
“Bituminous Courses”.
4. Patching shall be carried out in layers not exceeding 80 mm in thickness. Each layer shall be
thoroughly compacted by means of approved pneumatic tampers prior to placing the succeeding layer.
Each layer shall be protected from damage and all dirt or foreign material shall be removed before placing
subsequent layers. The final layer shall be rolled with a heavy roller. Each layer shall be approved prior to
placement of subsequent layers.
5. All cut-out pavement material and surplus patching material shall be removed from the site and
disposed of by the Contractor prior to placing the leveling courses.
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BITUMINOUS LEVELING COURSE SECTION 4.7
6. In areas where leveling courses are required, as shown on the Drawings or directed, the
contractor shall take cross sections of the existing pavement after completing any patching. The cross
sections will be taken at intervals of 12.5 meters or as directed. When the survey is approved, the
Engineer will determine and inform the Contractor of the locations, grades and thickness of leveling
courses to obtain the desired surface.
7. Prior to placing the leveling courses the existing pavement surface shall be prepared in
accordance with the relevant requirements of Section 4.03 – “Bituminous Courses”, including the use of
prime and tack coats as appropriate.
1. The delivery, spreading and finishing of leveling courses, including compaction, shall conform
with the relevant requirements of Section 4.05 – “Bituminous Binder and Wearing Courses”.
2. In areas where a specific grade and super-elevation are to be achieved by the leveling courses,
setting out and level control shall be based on a reference line installed in accordance with the relevant
requirements of Section 4.03 – “Bituminous Courses”. In areas of minor leveling such as filling of pits or
small isolated areas, a mobile reference line or alternative control system may be approved.
1. Sampling and testing of leveling courses shall conform with the relevant requirements of Section
4.03 – “Bituminous Courses”, and Table 4.13.
2. Where sampling and testing are not feasible due to thickness or other constrains, the Engineer
will determine specification compliance based on an approved rolling pattern or other basis.
1. Surface Tolerances for leveling courses shall conform with the relevant requirements for Binder
Courses in Section 4.04 – “Bituminous Base Course”.
1. The Engineer may use thickness measurements, spread rates, cross section or other methods to
verify quantities placed. Thickness measurements shall be in accordance with the relevant requirements
of Section 4.03 – “Bituminous Courses”.
4.7.11 MEASUREMENT
1. Bituminous leveling courses shall be measured by the m3 of mix furnished, spread, compacted,
completed and accepted. Measurements shall be based on the areas and thickness shown on the Drawings
or as directed.
2. Patching shall be measured by the m3 of mix furnished, spread, compacted, completed and
accepted. Measurements shall be based on the areas and thickness shown on the Drawings as directed.
3. Bituminous Tack Coat shall be measured as prescribed in Section 4.02 – “Bituminous Prime and
Tack Coats”.
4-39
BITUMINOUS COLD MIX COURSES SECTION 4.8
SECTION 4.8 : BITUMINOUS COLD MIX COURSES

4.8.1 SCOPE
1. These Works shall consist of furnishing materials, mixing manually or at central mixing plant, or
in a travel-mix plant and spreading and compacting bituminous cold mix courses comprising unheated
mineral aggregate or cut-back asphalt on a prepared surface, as and where shown on the Drawings or
directed.
4.8.2 MATERIALS
1. All materials shall conform with the relevant requirements of Section 4.01- “Materials”.
2. The type and grade of bitumen for the paving mixture shall be as shown on the Drawings or as
directed. The bitumen shall conform with the relevant requirements of AASHTO M81, M82, M140 or
M208.
2. The Job Mix shall conform with the relevant requirements of Section 4.04 – “Bituminous Base
Course” or Section 4.05 – “Bituminous Binder and Wearing Courses”.
4.8.4 EQUIPMENT
1. Plant and equipment for mixing, hauling, placing and compacting bituminous cold mix courses
shall conform with the relevant requirements of Section 4.03 – “Bituminous Courses”. In the continuous
mixing plant, the devices feeding asphalt, aggregate and water shall be interlocked to maintain
automatically the correct proportions. In a travel mix plant, the equipment used may be either a hopper
type, or a rotary type mixer. Both types of equipment should be capable of thoroughly mixing the asphalt
and aggregate, uniformly dispersing the asphalt, and adequately coating the aggregate particles producing
a uniform mix.
1. Handling and mixing of bitumen and aggregate shall be in accordance with the relevant
requirements of Section 4.03 – “Bituminous Courses” with the following exceptions:
1.1 Aggregates shall not be heated but shall be fed cold to the plant. The temperature of the
bitumen upon entering the pugmill shall be adequate to ensure uniform application to the cold
aggregate. The bitumen temperature shall be designated by the Engineer and shall be in general
accordance with the relevant requirements of Section 4.01 – “Materials”.
1.2 Mixing time shall be the shortest time necessary to remove excess volatiles or water and
to produce a satisfactory mixture.
4-40
BITUMINOUS COLD MIX COURSES SECTION 4.8
1. Preparation of the surface upon which bituminous cold mix courses are to be laid, and the use of
prime and tack coats, shall be appropriate to the type and condition of such surfaces and shall conform
with the relevant requirements of Section 4.03 – “Bituminous Courses”.
1. The delivery, spreading and finishing of bituminous cold mix courses shall conform with the
relevant requirements of Section 4.03 – “Bituminous Courses”.
2. Requirements for rolling and compaction shall comply with the relevant requirements of Section
4.06 – “Bituminous Base Courses” or Section 4.05 – “Bituminous Binder and Wearing Courses”.
1. Sampling and testing shall conform with the relevant requirements of Section 4.03 –
“Bituminous Courses”, and Table 4.13.
Base Courses”.
2. Finished elevations and straight edge tolerances shall conform with the relevant requirements of
Section 4.04 – “Bituminous Base Courses” or Section 4.05 – “Bituminous Binder and Wearing Courses”.
1. Procedures for determining the average compacted thickness of bituminous cold mix courses
shall conform with the relevant requirements of Section 4.03 – “Bituminous Courses”.
2. Cores for thickness measurements of bituminous cold mix courses shall be used to determine if
changes are necessary in the thickness of succeeding layers in accordance with the relevant requirements
of Section 4.04 – “Bituminous Base Course” or Section 4.05 – “Bituminous Binder and Wearing
Courses”.
4.8.12 MEASUREMENT
1. Bituminous cold mix courses shall be measured by the m2 of mix furnished, spread, compacted,
completed and accepted. Measurements shall be of the areas and thickness as shown on the Drawings.
2. Deficiencies in thickness of bituminous cold mix wearing course shall, unless an overlay is
constructed at the Contractor’s expense, result in a proportion only of the wearing course area being
measured for payment. Proportions shall be determined in accordance with the thickness deficiencies and
area proportions tabulated in Section 4.03 – “Bituminous Courses”.
3. Bituminous prime coat and bituminous tack coat shall be measured as prescribed in Section 4.02
– “Bituminous Prime and Tack Coats”.
4-41
RECYCLED BITUMINOUS BASE COURSE SECTION 4.9
SECTION 4.9 : RECYCLED BITUMINOUS BASE COURSE

4.9.1 SCOPE
1. These Works shall consist of removal, crushing and stockpiling existing bituminous pavement,
mixing with new aggregate, bitumen (and, if specified, an approved modifying agent) at a central, in
place (hot) mixing plant, and spreading and compacting recycled bituminous base course on a prepared
surface, as and where shown on the Drawings or directed.
4.9.2 MATERIALS
1. Recycled material shall consist of existing bituminous pavement, processed such that 100% will
pass the 37.5 mm (1.5 in) sieve.
2. If the Engineer determines that recycled bituminous material is causing degradation of the
aggregate, he shall revise the job-mix as required.
3. New materials shall conform with the relevant requirements of Section 4.01 – “Materials”.
4. Unless shown otherwise on the Drawings, bitumen for recycled bituminous base course shall be
graded to suit the project climatic condition and type of work, if not specified grade 60-70 penetration
conforming with the requirements of AASHTO M20 shall be used or as shown on the drawing.
5. Modifying agent used to soften the old bitumen shall in accordance with the design and
approved by the Engineer.
6. Existing pavement shall be removed in such a manner as to prevent unnecessary intermixing

with the underlying base, sub-base or subgrade material.
7. The stockpile height shall not be grater than 3 meters. Construction equipment will not be
permitted on the stockpiles.
2. The properties of the new modified mix shall meet all the requirement as specified.
4.9.4 EQUIPMENT
1. The Job Mix for recycled bituminous base course shall conform with the relevant requirements
of Section 4.04 – “Bituminous Base Course”, subject to any modifications by the Engineer.
2. Plant and equipment for milling mixing, hauling, placing and compacting recycled bituminous
base course materials shall conform with the relevant requirements of Section 4.03 – “Bituminous
Courses”. Mixers shall have a filter unit to stop pollution of the environment.
4.9.5 COSNTRUCTION OF TRIAL SECTIONS
requirements of section 4.03 – “Bituminous Courses”.
4-42
aggregate (including recycled material, new aggregate and mineral filler if required) shall be in
accordance with the relevant requirements of Section 4.03 – “Bituminous Courses”.
2. Crushing of existing pavement materials for recycling may be accomplished by portable or

stationary crushers or may be the direct result of the pavement removal method such as cold milling.
3. Crushed pavement material shall be separated into a minimum of two sizes prior to heating and
mixing. Te fine size shall have a minimum of 80% passing the 4.75mm (No. 4) sieve. The coarse size
shall have a minimum of 60% retained on the 4.75mm (No. 4) sieve.
4. Heated and dried new aggregate shall be combined in the appropriate proportions and gradations
with the recycled bituminous material and mixed at such temperature and for such time necessary to
achieve a thorough coating of the new aggregate. New bitumen and/or modifier shall then be incorporated
into the mixture and mixed to produce a homogenous mixture with satisfactory coating of all aggregate.
5. If both bitumen and modifier are used they shall be introduced into the mixing area through
separate metering devices.
6. Preheating of the crushed recycled bituminous material immediately before introduction to the
mixer may be permitted subject to the approval of the Engineer. Preheating methods shall not result in
loss of bitumen from the recycled material.
1. Preparation of the surface upon which the recycled bituminous base course is to be laid shall be
appropriate to the type and condition of such surface and shall conform with the relevant requirements of
1. The delivery, spreading and finishing of recycled bituminous base course shall conform with the
relevant requirements of Section 4.04 – “Bituminous Base Course”.
1. Sampling and testing of recycled bituminous base course shall conform with the relevant
requirements of Section 4.03 – “Bituminous Courses”, and Table 4.13.
Base Course”.
1. Procedures for determining the average compacted thickness of recycled bituminous base course
shall be in accordance with the requirements of Section 4.04 – “Bituminous Base Course”.
4.9.12 MEASUREMENT
1. Recycled bituminous base course shall be measured by the m2 of mix furnished, spread,
compacted, completed and accepted. Measurements shall be of the areas shown on the Drawings.
2. Removal and crushing of existing pavement materials for incorporation in recycled bituminous
base course shall not be measured for direct payment.
4-43
3. Bituminous prime coat shall be measured as prescribed in Section 4.02 “Bituminous Prime and
Tack Coats”.
4-44
PAVEMENT REPAIRES & TRENCH REINSTATMENT WORKS SECTION 4.10
SECTION 4.10 : PAVEMENT REPAIRS AND TRENCH

PREINSTATMENT WORKS
4.10.1 SCOPE
1. These Works shall consist of removing defective bituminous pavement, preparing surfaces to
receive repairs, furnishing materials, placing and finishing new pavement, as and where shown on the
Drawings or directed.
4.10.2 MATERIALS
1. All pavement materials shall conform with the relevant requirements of Section 4.01 –
“Materials” and Section 3.01 – “Materials”.
2. Sub-grade materials shall conform with the relevant requirements of Section 2.07 – “Subgrade
Construction and Topping”.
4.10.3 EQUIPMENT
1. All Plant and equipment shall conform with the relevant requirements of Section 1.12 –
“Contractors Plant and Equipment”.
4.10.4 PREPARATION OF PAVEMENT
1. Cracks in bituminous pavement which, in the opinion of the Engineer, do not required
reconstruction shall be prepared by wire brushing and blowing out with compressed air.
2. Detective bituminous pavement which, in the opinion of the Engineer, requires reconstruction
shall be cut back to good material using pneumatic cutting tools. The cut edges shall be square or
rectangular and in line with the direction of traffic. The depth of cut shall be determined by the Engineer
and may include asphalt layers, base and sub-base layers and subgrade layers (in the case of failed
pavement, excavation shall include a minimum of 300 mm of subgrade material). All excavated materials
shall be removed and disposed of off-site. When the bottom of the excavation consists of earth or granular
material it shall be thoroughly compacted using mechanical compactors to the satisfaction of the
Engineer. Excavated bituminous surfaces shall be thoroughly cleaned and wire brushed prior to receiving
repair materials.
3. Utility trench reinstatements in bituminous pavement shall be prepared in the same way as
defective bituminous pavement. Excavation shall include a minimum of 300 mm of subgrade material.
4.10.5 PLACING AND FINISHING REPAIR MATERIALS
1. Cracks of 3 mm width or wider shall be filled with clean, coarse sand then saturated with 1:1
diluted emulsified bitumen, or as directed. Cracks of less than 3 mm shall be filled with emulsified
bitumen, or as directed. Cracks shall be filled to the road surface. Any excess bitumen shall be removed
with a squeegee and the bitumen surface shall be sprinkled liberally with coarse sand.
2. Excavations below subgrade level shall be filled to a level specified by the Engineer with
subgrade material in layers not exceeding 150 mm and compacted using mechanical compactors to
conform with the requirements of Section 2.07 – “Subgrade Construction and Topping” and to the
satisfaction of the Engineer.
3. Sub-base and/or base course, if required, shall be placed in layers not exceeding 150 mm and
compacted using mechanical compactors. They shall conform with the relevant requirements of Section
3.02 – “Granular Sub-Base Courses” or Section 3.03 – “Aggregate Base Courses” and shall be to the
grading shown on the Drawings or specified by the Engineer.
4-45
PAVEMENT REPAIRES & TRENCH REINSTATMENT WORKS SECTION 4.10
4. Prior to receiving bituminous material the excavations shall be thoroughly cleaned. Subgrade,
sub-base or base course material shall be primed with a light coating of MC cutback bitumen and existing
bituminous surfaces shall be lightly painted with emulsified bitumen, all in accordance with the
requirements of Section 4.02, “Bituminous Prime and Tack Coats”.
5. The excavation shall be filled with bituminous pavement materials placed in layers not
exceeding 70 mm and compacted using vibratory compactors. Unless ordered to the contrary by the
Engineer, the top layer shall be compacted by steel wheeled roller, first compacting the 150 mm strips
adjacent to the traffic edges, then rolling in the direction of traffic. Bituminous materials shall conform
with the relevant requirements of Section 4.04 – “Bituminous Base Course” and Section 4.05 –
“Bituminous Binder and Wearing Courses” and shall be to the grading shown on the Drawings or
specified by the Engineer.
6. New utility trenches shall be backfilled to the details shown on the Drawings, or ordered,
including any surrounds, hunching or protective materials. Construction of subgrade and pavement shall
be as for pavement repairs.
7. No excavated areas shall remain open overnight.
1. Testing of repair materials shall conform with the relevant requirements of Section 4.03 –
“Bituminous Courses”, and Table 4.12. Sampling shall be as ordered by the Engineer.
1. Levels shall be checked by straight edge in relation to the adjacent existing pavement.
2. Surface tolerances for bituminous layers shall conform with the relevant requirements of Section
4.04 – “Bituminous Base Course” and Section 4.05 – “Bituminous Binder and Wearing Courses”.
3. Any deficiency in the wearing course surface will be corrected by cutting out and replacing.
4.10.8 MEASUREMENT
1. Sealing of cracks shall not be measured for direct payment.
2. Pavement repairs shall be measured by the m2 of repair, prepared, filled, compacted, completed
and accepted. Measurement shall be of the areas shown on the Drawings or ordered.
3. Trench reinstatements shall be measured by the m2 of reinstatement prepared, filled, compacted,

completed and accepted. Measurement shall be of the areas shown on the Drawings or ordered. New
utility trench construction will not be measured under this item.
4. No separate measurement will be made for excavation, prime or tack coats or pavement
materials.
4-46
Part ( 5 ) :
Concrete,
Steel &
Structure
Technichal Specifications Concrete, Steel & Structures
CONCRETE & CONCRETE MIXES AND TESTING SECTION 5.1
SECTION 5.1 : CONCRETE AND CONCRETE MIXES AND

TESTING
5.1.1 SCOPE
1. These Works shall consist of the specifications for concrete materials including sampling, testing
and storage of such materials, concrete strength requirements, concrete testing procedures and
requirements, and job mixes.
5.1.2 MATERIALS
1. Cement
1.1 Cement shall be ordinary cement, originating from manufacturers approved by the Engineer and
shall, except in special, approved circumstances, conform to AASHTO Relevant Standards. This includes
ordinary cement, sulfate resisting cement, pozzolanic and all other types of cement if so required.
1.2 Only one type or brand of cement shall be used in any one structural member. Mixing of types or
brands will not be permitted.
1.3 All cement shall be subject to approval and shipments of cement shall be accompanied by a
manufacturer’s Certificated of Guarantee and/or laboratory test certificate. Approval of any cement
sample shall not relieve the Contractor of the responsibility to fabricate concrete of the specified strength.
1.4 When tests at the factory or field tests subsequent to the original approval tests show that the
cement does not comply with the specifications, the entire consignment from which the sample was taken
shall be rejected and the Contractor shall immediately remove the rejected material from the Site and
replace it with cement which meets the required specifications.
1.5 Whenever low alkali cement is specified the total alkali content estimated as sodium oxide
equivalent, shall not exceed 0.60% by weight. Approval of any cement sample shall not relieve the
Contractor of the responsibility to fabricate concrete of the specified quality and strength.
1.6 If no local test certificate is available the Contractor shall obtain from each proposed
manufacturer a typical sample of cement, which shall be fully and independently tested in accordance
with the appropriate standard and the results submitted for approval. Primary and secondary sources of
the required cements shall be given.
1.7 Details shall also be submitted of the manufacturer’s name and address of producing works,
manufacturer’s description of cement type and brand name and standards to which compliance is
guaranteed.
1.8 Average values and corresponding maximum and minimum values in respect of the following
composition and properties shall be submitted, covering a continuous production period of at least 6
months ending not earlier than 3 months before submission of the data. The contractor shall state if any
material or production process changes have been made since the end of the above period; if any are
reposed, brief details shall be given.
5-1
Composition Properties
Insoluble residue Lime saturation factor (LSF)

Silica (SiO2) Alumina-iron ratio (A/F)
Alumina (A12O3) Tri-calcium aluminates (Ca3Al)
Total Iron (Fe2O3) Free lime in clinker (as CaO)
Calcium (CaO) Total acid solution alkalis
Magnesium (MgO) Heat of hydration
- at 7 days
- at 28 days
Potassium (K2)
Sodium (Na2) Fineness (m2/kg)
Sulfate (SO3) Setting times
- Initial (min)
- Final (min)
Sulfur (S)
Chloride (Cl) Soundness (mm)
Loss on ignition Compressive strength
- 3 days
- 7 days
- 28 days
- 3 months
1.9 The requirement of item 1.8 may be dispensed with at the discretion of the Engineer, who shall
give such dispensation in writing.
1.10 The manufacturer’s bulk average test certificate for each consignment of cement shall be
submitted, showing the results for chemical composition and physical properties determined in
accordance with the relevant standard. Samples shall be taken for each consignment of cement and tested
as directed by the Engineer in an approved independent laboratory.
1.11 Where bulk cement deliveries are proposed, the Contractor shall provide all information required
by the Engineer concerning off-Site storage and loading arrangements and shall provide reasonable
facilities for the Engineer to inspect these arrangements for approval purposes. Consignments shall be
used in the order in which they are delivered.
1.12 Storage capacity shall be sufficient to meet the schedule of work so that continuous work is
achieved. Cement shall be stored in moisture-proof storage sheds. Neither stale, caked, nor reclaimed or
re-sacked cement shall be used. The contractor shall not store cement in areas subject to flooding.
1.13 Cement remaining in bulk storage at the mill, prior to shipment, for more than 6months or
cement stored in bags in local storage by the Contractor or a vendor for more than 3 months after
shipment from the mill, may be retested before use and will be rejected if it fails to meet any of the
requirements of these specifications.
2. Aggregates Generally
2.1 Aggregates for concrete shall conform to the requirements of AASHTO.
2.2 Potential aggregate sources shall be examined and particular attention shall be paid to the
following aspects of the deposits and the actual or proposed extraction and production arrangements:
2.2.1 Name, location, local and national grid reference, type of deposit, potential variability,
method of extraction
2.2.2 Methods and degree of control exercised over extraction
2.2.3 Processing methods, types of plant, number of processing stages, standards of

maintenance and process control, producer’s laboratory facilities and technical staffing
5-2
2.2.4 Stockpiling arrangements, loading and supply arrangements

2.2.5 Potential variations in end products due to variations inherent in the deposit and in the
existing methods of extraction, processing and stockpiling.
2.2.6 Possible modifications to existing extraction, processing, storage and handling

arrangements, and supervision arrangements to reduce end product variations.
2.2.7 Possible requirements for supplementary processing on Site.
3. Sampling Aggregates
3.1 Aggregates deposits shall be sampled and tested in an appropriate and systematic manner to
assess their potential variability and to assist in determining appropriate methods of extraction and
processing.
3.2 The deposit investigation and sampling program shall be relevant to each type of deposit and
shall be devised and supervised by an experienced approved engineering geologist after a field
reconnaissance of the potential deposit areas, or of the existing Works.
3.3 Each size of aggregate shall be sampled at the discharge points on the production plant
(conveyors or hoppers, not stockpiles) at 3 well spaced intervals during the course of each of 3
consecutive production days. These samples shall be designated “production samples”.
3.4 In addition, selected samples shall be taken from the producer’s stockpiles to represent any
readily visible variations in physical characteristics or appearance of materials ready for loading. These
samples shall be designated “stockpile samples”.
3.5 All samples shall be taken by arrangement with and in the presence of the Engineer and shall be
tested as required below. Reference should be made to ASTM D75 and C702 for the sampling of
aggregates.
3.6 Representative portions of the above samples shall be taken for reference purposes and shall be
split and retained on Site by the Contractor and by the Engineer.
4. Testing Aggregates
4.1 Each production sample shall be tested for the following:
4.1.1 Proportion of natural (uncrushed) material (% by weight) grading, passing 75mm sieve
(U.S. Sieve N.200 to AASHTO M92 or ASTM M81) when tested in accordance to AASHTO
T11.
4.1.2 Total acid soluble chloride content and total acid soluble sulfate content (% by weight).
4.1.3 Flakiness and elongation indices.
4.2 Representative portions of equal weight shall be taken from each of the production samples of
each size of aggregate and then combined to provide composite production samples for each size of
aggregate. The composite samples shall be tested as for the individual unless otherwise directed by the
Engineer.
4.2.1 Potential Reactivity tests for alkali-silicate and alkali-carbonate reactions: petrographic
examination in accordance with ASTM C295, rapid chemical method in accordance with ASTM
C289 and rock expansion test in accordance with ASTM C586.
4.2.2 If one or more of the tests in sub-item 4.2.1 above are positive then the mortar prism
test in accordance with ASTM C227 shall be carried out.
4.2.3 Partial chemical analysis, including insoluble residue (ASTM D3042-84), chloride
content, sulfate content and calculated approximate composition.
5-3
4.2.4 ASTM Soundness Test C88, using sodium sulfate solution or ASTM Soundness Test
C88, using magnesium sulfate solution.
4.2.5 Aggregate Impact Value by the Los Angeles test in accordance with AASHTO T96-83
ASTM C131-81 , ASTM C535-81).
4.2.6 10% Fine Value according to BS 812
4.2.7 Aggregate Abrasion Value according to BS812
4.2.8 Specific Gravities and Water Absorption BS 812 or approved ASTM equivalent.
4.3 Stockpile samples shall be examined and tested in as many of the above mentioned respects as
are considered relevant by the Engineer.
4.4 Aggregate for use in concrete or mortar that will be subject to wetting, extended exposure to
humid atmosphere, or contact with moist ground, shall not contain material that is deleteriously reactive
with the alkalis in the cement, or any which may be additionally present in the aggregates and mixing
water or water in contact with the concrete or mortar, in amounts sufficient to cause excessive localized
or general expansion of concrete or mortar.
5. Fine Aggregates
5.1 Fine aggregates shall conform to the requirements of AASHTO. Fine aggregates shall consist of
natural sand or crushed rock having hard and durable particles or, if approved by the Engineer, other inert
materials having similar characteristics, 100% passing 9.5 mm sieve and 2% to 10% passing 0.15 mm
sieve. It shall not contain harmful materials such as iron pyrites, coal, mica, shale or any materials, which
may attack the reinforcement in such a form or in sufficient quantity as to adversely affect the strength,
durability and texture of the concrete.
5.2 The Contractor shall, when directed by the Engineer, wash the fine aggregates to remove
deleterious substances or for consistency of concrete color. Such washing shall not be carried out using
Sea Water.
5.3 The total acid soluble sulfate content (BS812: Part 118:1988) of fine aggregate, determined in
accordance with BS812 expressed as sulphur trioxide (SO3), shall not exceed 0.40% by dry weight of
fine aggregate. The total acid soluble chloride content (BS812: Part 117:1988) expressed as sodium
chloride (NaCl), shall not exceed 0.10% by dry weight of fine aggregate. The following additional
requirements shall apply to the concrete mix:
5.3.1 Total sulfate content (as SO3) of any mix , excluding that present in the cement but
including any present in the other materials, shall not exceed 2.5% by weight of cement in the
mix.
5.3.2 Total chloride content (as NaCl) of any mix, including any chloride present in the other
materials and in the mix water, shall not exceed 0.35% by weight of cement in the mix.
5.4 If required or specified fine aggregate shall meet the following additional requirements:
5.4.1 Fineness modulus, AASHTO M6: ± 0.20% of approved value which shall be not
greater than 3.1 or less than 2.3. Sieve analysis to AASHTO T27.
5.4.2 Sodium or Magnesium sulfate soundness max 12%, 18%, loss respectively. Testing to
be in accordance with AASHTO T104.
5.4.3 Content of clay lumps and friable particles, AASHTO T112-82 3% max.
5.4.4 and equivalent AASHTO T176: min 57%.
5.4.5 Coal and lignite AASHTO T113-82 : 0.5% Max.
5-4
5.4.6 Organic impurities AASHTO T21-81 : not darker than standard color.
5.5 The amount of hollow shells likely to form voids and present in material retained on a 2.36 mm
sieve determined by direct visual separation, shall not exceed 13% by weight of the entire sample.
5.6 The grading of fine aggregate shall comply with AASHTO M6 unless otherwise specified.
5.7 If the fineness modulus varies by more than 0.2 from the value assumed in the concrete mix
design, the use of such fine aggregate shall be discontinued until suitable adjustments can be made in the
mix proportions to compensate for the difference in gradation.
6. Coarse Aggregate
6.1 Coarse concrete aggregates shall conform to AASHTO and shall consist of gavel, crushed
gravel, or crushed stone free from coating of clay or other deleterious substances. It shall not contain
harmful or any other materials which may attack the reinforcement in such a form or in sufficient quantity
as to adversely affect the strength and durability of the concrete. If necessary, coarse aggregate shall be
washed to removed deleterious substances or for consistency of concrete color in the Project
Specifications.
6.2 The total acid soluble sulfate content (BS812 : Part 118 , 1988) or course aggregate expressed as
sulphur trioxide (SO3), shall not exceed 0.40% by weight. The total acid soluble chloride contents of
coarse aggregates (BS812 : Part 117:1988) expressed as sodium chloride (NaC1), shall not exceed 0.05%
by weight. These limits are subject to the following overriding requirements:
6.2.1 The total sulfate content (as SO3) of any mix, excluding that present in the cement but
including any present in the other materials, shall not exceed 2.5% by weight of cement in the
mix.
6.2.2 The total chloride content (as NaCl) of any mix, including any chloride present in the
other materials and the mix water, shall not exceed 0.35% by weight of cement in the mix.
6.3 If required or specified coarse aggregate shall meet the following additional requirements:
6.3.1 Sodium sulfate or magnesium sulfate soundness AASHTO T104: 5 cycles: Max 12% or
18% loss respectively.
6.3.2 Abrasion, in accordance with AASHTO requirements.
6.3.3 Content of clay lumps friable particles AASHTO T112-81: Max3% by weight.
6.3.4 Soft fragments and shale : Max 5% by weight.
6.3.5 Flakiness index , BS812 : 30% Max. Elongation index , BS812 : 30% Max.
6.3.6 Coal and Lignite , AASHTO T113-82 : 0.5% Max.
6.4 The grading of coarse aggregate shall comply with AASHTO M43 unless otherwise specified.
7. All-in Aggregates
7.1 The grading of all-in aggregates shall comply with AASHTO. All-in aggregates are composed of
a mixture of coarse aggregates and fine aggregates. They shall be used only with the prior approval of the
Engineer.
8. On Site Storage of Aggregates
8.1 Adequate stocks of tested and approved aggregates shall be maintained on Site and the capacity
of the storage bins for each type and grading of aggregate shall be sufficient to hold the respective
quantities required for the maximum amount of concrete which the Contractor is obliged or intends to put
5-5
in any continuous operation in one day. Stockpiles shall be built in layers of 1.5 m maximum height and
segregation of the aggregates prevented. Different grades of aggregates shall be totally separated.
8.2 Dense concrete or bituminous slabs shall be laid with sufficient falls to cover all aggregate
stockpile areas or bins and shall extend to cover all surrounding areas where aggregates are likely to be
discharged or handled. These areas shall be swept and kept clean at all times to ensure that the aggregates
ate not contaminated by the adjacent ground through trafficking or otherwise, and shall be constructed
with adequate drainage for surplus water.
8.3 Windbreaks shall be provided where aggregates might suffer excessive contamination by
windblown materials. During periods of heavy rain the bins or compounds shall be covered by tarpaulins
or other approved means.
9. Rejection of Aggregates
9.1 The general or localized build up of fines in aggregate stockpiles shall not be allowed and any
material, which, in the opinion of the Engineer, is so affected will be rejected after testing.
9.2 Aggregates which have suffered segregation or contamination during processing, handling at
source, transportation to the Site, stockpiling and handling on Site, or which otherwise do not conform
with requirements of the Specifications, either locally or generally, will be rejected and shall be removed
promptly from the Site.
9.3 Aggregates which are found to be contaminated during transportation or during stockpiling or
during handling shall be promptly removed from the Site by the Contractor notwithstanding any prior
approval of the source which may have been given by the Engineer.
10. Washing and Processing Aggregate
10.1 The Contractor may be required to carry out on site supplementary processing or effective
washing of coarse and fine aggregates where the aggregate producer’s methods, in the opinion of the
Engineer, may not result in end products which consistently conform with all requirements of the
Specifications, or where aggregates suffer unacceptable changes during loading at source or during
subsequent transportation to the site, or otherwise.
11. Water
11.1 General. Water for concrete mix or for curing shall be free of harmful substances such as oil,
grease, salts, acids, alkalis, organic matters, fine (dissolved or suspended) and any other substances that
reduce the strength or durability of concrete.
11.2 Potable Water. Potable water satisfying AASHTO T26 and BS3148 is suitable for mixing and
curing.
11.3 Non-potable Water. Non-potable water may be used when potable water is not available
provided the impurities do not exceed the values given in Table 5.1.
Table 5.1: Maximum Permitted Impurities in Non-Potable Water
Max Concentration
Impurity Method
(gm/Kg)
-
Chloride as (Cl )
a) Pre-stressed concrete or concrete in bridge decks 500 ASTM D512
b) Other reinforced concrete in moist environment or

containing aluminum embedment or dissimilar
metals or with stay in place galvanized metals
form 1000
Sulfate as SO4 300 ASTM D516
Alkalis as (Na2O + K2O) 600 AASHTO T-26
Total Solid 5000
5-6
11.4 Cube Specimens: Non-potable water, regardless of its purity, shall not
be used for mixing until mortar cubes made with it are shown to be at least 90% of the strength of mortar
cubes made with potable water. The cubes shall be made and tested in accordance with AASHTO T106
(ASTM C109) for 7 day and 28 day strengths.
11.5 Mix Design: The water used in the mix design shall be the same as the water approved for site
use.
11.6 Special Cases: Water used for pre-stressed concrete structures or for concrete containing or in
contact with aluminum fittings or fixtures shall not contain chloride ions.
12. Admixtures
12.1 General: The quantity and method of using admixtures shall be in accordance with the
manufacturer’s recommendations and in all cases shall be subject to the approval of the Engineer.
12.2 In all cases the Contractor shall provide the following information for the Engineer’s approval:
12.2.1 The quantity to be used, in kilograms per kilogram of cement and in kilograms per
cubic meter of concrete.
12.2.2 The detrimental effects caused by adding a greater or lesser quantity in kilograms per
cubic meter of concrete.
12.2.3 The chemical name(s) of the main active ingredient(s).
12.2.4 Whether or not the admixture leads to the entrainment of air.
12.3 If required by the Engineer, the Contractor shall demonstrate the action of an admixture by
means of trial mixes.
12.4 Calcium chloride: The use of calcium chloride in any form is prohibited.
12.5 Guidance: Reference may be made to ACI Committee 212 report “Guide for Use of Admixtures
in Concrete”.
5.1.3 DEFINTIONS
1. Crushing Strength
1.1 The crushing strength of a test cube obtained in accordance with B.S 1881: Part 108, cured in
accordance with B.S 1881: Part 111 and tested in accordance with B.S 1881: Part 116 on a machine
complying with the requirements of B.S 1881: Part 115. Alternative standard cylinders may be tested in
accordance to ASTM or AASHTO specifications with relevant correction factors.
2. Average Strength
2.1 The mean of the crushing strengths of specimens taken from a sample of concrete.
3. Characteristic Strength
3.1 The value of the crushing strength below which 5% of the population of all possible strength
measurements of the specified concrete are expected to fall.
4. Fresh Concrete
4.1 Concrete during the initial period of two hours from the addition of water to the cement.
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5. Batch
5.1 The quantity of concrete mixed in one cycle of operations of a batch miser or the quantity of
concrete conveyed ready-mixed in a vehicle, or the quantity discharged during one minute from a
continuous mixer.
6. Sample
6.1 A quantity of concrete taken from a batch whose properties are to be determined.
7. Regular Sampling
7.1 The sampling of concrete nominally of the same mix received regularly from the same source.
8. Specimen
8.1 Cubes taken from a sample for testing.
5.1.4 CONCRETE STRENGTH REQUIREMENTS
1. Design Mixes
1.1 Mixes for the classes of concrete shown in Table 5.2 shall be designed by the Contractor, when
specified for use in any part of the Works. The quantity of water used shall not exceed that required to
produce a concrete with sufficient workability to be placed and vibrated in the particular locations
required. Unless otherwise approved by the Engineer, the mix designs shall be on the basis of
continuously graded aggregates and all mix designs shall be subject to approval.
1.2 The properties of aggregates used in all the proposed concrete mixes shall be such that the Initial
Drying Shrinkage and Drying Shrinkage of concrete prepared and tests in an approved laboratory in
accordance with B.S 1881:Part 5 shall not exceed 0.06% and 0.045% respectively.
1.3 The 7-day compressive strengths shall not be less than 70% of the specified 28 day strengths.
1.4 The characteristic strength of concrete shall be determined on test specimens obtained and
prepared in accordance with B.S 1881: Part 108. The test specimen shall be cured in accordance with B.S
1881: Part 111and tested in accordance with B.S. 1881: Part 116 using testing machines that comply with
requirements of B.S. 1881: Part 115. Alternative ASTM or AASHTO specification may be used with
appropriate correction factors applied. Relative correction factor for concrete compressive strength
determined by standard cylinders compared that of cubes shall be as follows:
Concrete Grade Ratio of strength

N/mm2 cylinder / cube
7 – 20 0.77
20 – 25 0.85
over 25 0.87
1.5 International procedure for concrete mix design should be followed:
5-8
Table 5.2: Concrete Class and Design Mixes

Characteristic Strength
Concrete Class Use
N/mm (= MPa)
7 7 Mass Concrete
10 10 Mass Concrete
15 15 Mass Concrete
20 20 Mass & Reinforced Concrete
25 25 Reinforced Concrete
30 30 Reinforced Concrete
35 35 Reinforced & Pre-stressed Concrete
40 40 Pre-stressed Concrete
50 50 Pre-stressed, Pre-cast Concrete
60 60 Pre-stressed, Pre-cast Concrete
2. Normal Concrete Mixes
2.1 Concrete for use as backfilling in structural excavation shall be no-fines concrete of a nominal
mix with aggregate graded as given in Table 5.3. The cement: aggregate ratio shall be not less than 1:15
by weight and sulfate resisting cement shall be used, if necessary.
Table 5.3: Nominal Concrete Mixes For Backfill

Grading of Aggregate
Sieve Size % Dry Weight Passing
90 mm 100
40 mm 85 – 100
20 mm 0 – 20
10 mm 0–5
3. Compliance with strength Requirements
3.1 General: Compliance with the specified characteristic strength shall be based on tests made on
cubes at an age of 28 days unless there is evidence, satisfactory to the Engineer, that a particular testing
regime is capable of predicting the strength at 28 days of concrete tested seven days.
3.2 Unless otherwise directed by the Engineer, the rate of sampling shall be as given in Table 5.4 but
not less than one sample shall be taken on each day that concrete of that grade is used.
Table 5.4: Rates of Sampling And Testing

Sample from one batch selected randomly to represent an average
Use of Concrete
volume of not more than the lesser of
Pre-stressed concrete 10 m3 or 10 batches
Reinforced concrete 20 m3 or 20 batches
Mass concrete 50 m3 or 50 batches
3.3 Testing: One set of cubes, cylinders (minimum of 4) shall be made from a sample taken from a
randomly selected batch of concrete. Samples shall be taken at the point of discharge from the delivery
vehicle. For compliance purposes:
3.3.1 The average strength determined from any group of four consecutive test cubes shall
exceed the specified characteristic strength by not less than 0.5 times the “current margin”;
3.3.2 Each individual test result shall be greater than 85% of the specified characteristic
strength.
3.4 The “current margin” shall be taken as two thirds of the specified characteristic strength for
concrete up to Class 15 or 15 N/mm2 for concrete of Class 20 or above, unless in accordance with clause
1 of sub-section 5.01.5 or Clause 5 of sub-section 5.01.5, a smaller margin is agreed by the Engineer.
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3.5 If only one cube result fails to meet the second requirement 3.3.2, then that result shall be
considered to represent only the particular batch of concrete from which that cube was taken.
3.6 If the average strength of any group of four consecutive test cubes fails to meet the first
requirement 3.3.1, then all the concrete in all the batches represented by all such cubes shall be deemed
not to comply with the strength requirements. For the purposes of this clause the batches of concrete
represented by a group of four consecutive test cubes shall include the batches from which samples were
taken to make the first and the last cubes in the group of four, together with all the intervening batches.
3.7 Special Testing: Special testing shall be used if required in the Contract.
3.8 One test cube shall be made from each of two independent representative samples taken from
every batch of concrete selected for testing.
3.9 The average strength of the two test cubes taken from the same batch of concrete shall exceed
the specified characteristic strength by not less than 2.0 N/mm2 or one-tenth of the specified strength,
whichever is the smaller.
3.10 If the average strength of the test specimens taken to represent a given batch of concrete fails to
meet the appropriate requirement, the whole of that batch of concrete represented by those specimens
shall be deemed not to comply with the strength requirements of the Specification. Compliance with this
requirement in respect of a given batch of concrete shall not be adduced as evidence of compliance in
respect of any other batch. Core sampling length measurement testing of specimens taken from the failed
part of structure shall be taken and tested according to:
ASTM C42-84
AASHTO T24-80
AASHTO T148
3.11 Compressive strength results evaluation shall be in (according to ACI code), average
compressive strength results of tested core specimens for each sample shall not be less than 85% of the
required specified strength and the lowest compressive strength of any tested core specimen shall not be
less than 0.75 of the required specified strength.
5.1.5 REQUIREMENTS FOR DESIGN MIXES
1. Current Margin
1.1 The current margin for a concrete mix shall be determined by the Contractor and shall be taken
as the lesser of:
1.1.1 1.64 times the standard deviation of cube tests on at least 100 separate batches of
concrete of nominally similar proportion of similar materials and produced over a period not
exceeding 12 months, by the same plant under similar supervision, but not less than one sixth of
the characteristic strength for concrete up to Class 15 or 7.5N/mm2 for concrete of Class 20 or
above;
1.1.2 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 a period
exceeding 5 days but not exceeding 6 months, by the same plant under similar supervision, but
not less than one third of the characteristic strength for concrete up to Class 15 or 7.5 N/mm2 for
concrete of Class 20 or above.
1.2 Where there is insufficient data to satisfy sub-item 1.1.1 or 1.1.2 above, the margin for the initial
mix design shall be taken as two thirds of the characteristic strength for concrete up to Class 15 or 15.0
N/mm2 for concrete of Class 20 or above. This margin shall be used as the “current margin” only until
sufficient data is available to satisfy sub-items 1.1.1 or 1.1.2 above. However, subject to the Engineer’s
approval, when the specified characteristic strength approaches the maximum possible strength of
concrete made with a particular aggregate, a smaller margin not less than one third of the characteristic
strength up to Class 15 or 7.5 N/mm2 for concrete of Class 20 or above may be used for the initial mix
design.
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2. Suitability of Proposed Mix Proportions
2.1 The Contractor shall submit for the Engineer’s approval, prior to the supply of any designed mix,
the following information.
2.1.1 The nature and source of each material along with physical ,mechanical and chemical
properties for the constituents of the concrete mix.
2.1.2 Either appropriate existing data as evidence of satisfactory previous performance for
target mean strength, current margin, workability and water/cement ratio, or full details of tests
on trial mixes carried out in accordance with item 3 below.
2.1.3 The quantities of each material per cubic meter of fully compacted concrete.
2.2 Any change in the source of material or in mix proportions (except changes in cement content of
not more than 20 kg/m3) shall be subject to the Engineer’s prior approval.
3. Trial Mixes
3.1 The Contractor shall give notice to enable the engineer to be present at the making of trial mixes
and preliminary testing of the cubes. The contractor shall prepare trial mixes, using samples of approved
material typical of those he proposes to use in the works, for all grades, to the Engineer’s satisfaction
before commencement of concreting.
3.2 The contractor shall ascertain the workability of the trial mixes to the Engineers satisfaction.
3.3 The concreting plant and means of transport employed to make the trial mixes and to transport
them representative distances shall be similar to the corresponding plant and transport to be used in the
Works. A clean dry mixer shall be used and the first batch discarded. Test cubes shall be taken from trial
mixes as follows. For each mix a set of six cubes shall be made from each of three consecutive batches.
Three from each set of six shall be tested at an age of 28 days and three at an age of seven days. The tests
shall be carried out in a laboratory approved by the Engineer.
3.4 The average strength of the nine cubes tested at 28 days shall exceed the specified characteristic
strength by the current margin minus 3.5 N/mm2.
4. Additional Trial Mixes
4.1 During production the Contractor shall carry out trial mixes and tests, if required by the
Engineer, before substantial changes are made in the materials or in the proportions of the materials to be
used, except when adjustments to the mix proportions are carried out in accordance with sub-paragraph
5.1 below.
5. Control of Strength of Designed Mixes
5.1 Adjustment to mix proportions: Adjustments to mix proportions shall be made subject to the
Engineer’s approval, in order to minimize the variability of strength and to maintain the target mean
strength. Such adjustments shall not be taken to imply any change in the current margin.
5.2 Change of current margin: When required by the Engineer, the Contractor shall recalculate the
current margin in accordance with Clause 1above. The recalculated value shall be adopted as directed by
the Engineer, and it shall become the current margin for concrete produced subsequently.
6. Change to Mix Design
6.1 Change in mix proportion requested by the Contractor to previously approved mix designs shall
only be made after new approval by the Engineer.
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6.2 When, in the opinion of the engineer, cement is being lost due to windy conditions, the
Contractor shall add additional amounts of cement as directed by the Engineer. No additional payment
will be made for the added cement.
6.3 As the work progresses, the Engineer reserves the right to require the Contractor to change the
proportions from time to time if conditions warrant such changes to produce satisfactory results. Any
such change may be made within the limits of the specifications at no additional compensation to the
Contractor.
7. Design Limits For Concrete Mixes
7.1 For concrete made with Portland cement, the minimum cement content given in Tables 5.5A,
and 5.5C shall be used to provide acceptable durability.
7.2 Except where authorized by the Engineer in writing, the cement content shall be not greater than
550kg/m3
Table 5.5: Minimum Cement Content Required In Portland Cement Concrete To Ensure
Durability-Pre-stressed Concrete
Pre-stressed Concrete Nominal size
of Aggregate (mm)
Exposure
40 20 14 10
Kg/m3 Kg/m3 Kg/m3 Kg/m3
Surfaces sheltered from severe rain and against
freezing whilst saturated with water, e.g.
(1) surface protected by a water proof membrane
Moderate (2) internal surfaces, whether subject to 300 300 320 340
condensation or not
(3) buried concrete and concrete continuously
under water
(1) soffits
(2) surfaces exposed to driving rain, alternate
Severe 300 300 320 340
wetting and drying (e.g. in contact with
backfill) and to freezing whilst wet
(1) surfaces subject to the effects of de-icing
salts or salt spray, e.g. roadside structures and
Very marine structures
320 360 390 410
Severe (2) surfaces exposed to the action of sea water
with abrasion or moorland water having a pH of
4.5 or less
When the maximum free water / cement ratio can be strictly controlled, these may be reduced to:
Pre-stressed Concrete Nominal size of Aggregate (mm) Maximum free

Exposure
40 20 14 10 water/cement Ratio
Moderate 300 300 300 310 0.55
Severe 300 300 300 310 0.55
Very Severe 300 330 350 370 0.45
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Table 5.5B: Minimum Cement Content Required in Portland Cement Ensure Durability
Reinforced Concrete

of Aggregate (mm)
Exposure
40 20 14 10
condensation or not
under water
(1) soffits
Severe 260 290 320 340
320 360 390 410
4.5 or less

Exposure
Moderate 240 260 290 310 0.55
Severe 240 260 290 310 0.55
Very Severe 290 330 350 370 0.45
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Table 5.5C: Minimum Cement Content Required in Portland Cement Ensure Durability Plain
Concrete

of Aggregate (mm)
Exposure
40 20 14 10
condensation or not
under water
(1) soffits
Severe 240 280 310 330
270 310 330 350
4.5 or less

Exposure
Moderate 200 230 250 270 0.65
Severe 220 250 280 300 0.55
Very Severe 240 280 300 320 0.50
7.3 Minimum cement content in the case of exposure to sulfate attack is given in Table 5.6.
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Table 5.6: Requirements for the Durability of Concrete Exposed to Sulfate Attack
Concentration of sulfate Requirement for dense, fully compacted concrete made with
Expressed SO3 aggregate complying with AASHTO
(a) Minimum cement
water/cement Ratio
In soil
(b) Maximum free

In content
ground Nominal maximum size
Total SO3 in
Class
water of aggregate (mm)

SO3 2:1 Type of Cement
(parts
water
per 20 40 10
extract
100000) Kg/m3 Kg/m3 Kg/m3
% g/l
1 < 0.2 - < 30 Ordinary Portland or 240 280 330 0.55
Portland Blast-furnace
2 0.2<5.0 - 30<120 Ordinary Portland or 290 330 380 0.50

Portland Blast-furnace
Sulfate-resisting 240 280 330 0.55

Portland
Super-sulfated 270 310 360 0.50
3 0.5<1.0 1.9<3.1 120<250 Super-sulfated 290 330 380 0.45
4 1.0<2.0 3.1<5.6 250<500 Sulfate-resisting 330 370 420 0.45

Portland or super-
sulfated
5 > 2.0 > 5.6 > 500 Sulfate-resisting 330 370 420 0.45
Portland or Super-
sulfated plus adequate
protective coatings
Note 1. Requirements (a) and (b) both apply.
Note 2. This table applies only to concrete made with aggregates complying with the requirements of
AASHTO placed in near-neutral ground waters of pH 6 to 9, containing naturally occurring
sulfates but not contaminants such as ammonium salts. Concrete prepared from ordinary or
sulfate-resisting Portland cement should not be recommended in acidic conditions (pH 6 or less).
Note 3. For SO3 contents near the upper limit of Class 2, cement contents above these minima are
advised.
Note 4. Where the total SO3 in column 2 exceeds 0.5%, a 2:1 water extract may result in a lower site
classification if much of the sulfate is present as low-solubility calcium sulfate. Reference should
be made to BRS Digest 174: 1975.
Note 5. For severe conditions (e.g. thin sections, sections under hydrostatic pressure on one side only
and sections partly immersed) consideration should be given to a further reduction of the
water/cement ratio and , if necessary, an increase in cement content to ensure the degree of
workability for full compaction and thus minimum permeability.
Note 6. The following codes apply to cement types. Ordinary Portland: BS 12.Sulfate resisting Portland:
BS 4027.Super Sulfated: BS 4248.
7.4 Workability: The required range of workability is given in Table 5.7.
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Table 5.7: Limits of Workability

Slump Vebe Compaction
Type of Work Workability
(mm) (sec) factor
Heavily vibrated Very low 0 – 10 12 0.75
Lightly reinforced with vibrators Low 10 – 30 6 – 12 0.83
Lightly reinforced without vibration and

intermediately reinforced with vibration Medium 30 – 60 3–6 0.9
Heavily reinforced with vibration High 60 – 180 0–3 0.95
Note: The applicable codes for the test list above are:
Slump Test: BS 1881: Part 102
Vebe Test: BS 1881: Part 104
Compaction Factor Test: BS 1881: Part 103.
7.5 Maximum Chloride Content: The total chloride content of a concrete mix determined in
accordance with BS812 arising from the aggregate and any other source shall not exceed the appropriate
limit given in table 5.8.
Table 5.8: Maximum Total Chloride

Maximum total chloride
content expressed as % of
Type or use of concrete Method of testing
chloride ion by weight of
cement
Pre-stressed concrete 0.06 AASHTO T260
conventially reinforced concrete in a
moist environment & exposed to
chlorides 0.1 AASHTO T260
Ditto but not exposed to chlorides 0.15 AASHTO T260
Other reinforced concrete construction 0.3 AASHTO T260

Note: % chloride ion × 1.648 = % equivalent sodium chloride
% chloride ion × 1.565 = % anhydrous calcium chloride.
7.6 Maximum Sulfate Content: The total water-soluble sulfate content of the mix, determined in
accordance with BS812 expressed as SO3, shall not exceed 4%. The sulfate shall be calculated as the total
from the various constituents of the mix.
7.7 Where air-entraining agents are required or specified to improve resistance to frost damage or
de-icing salt, the average air content of the fresh concrete shall be as follows:
for natural aggregates of 10 mm nominal maximum size: 7%

7.8 The method of determining air content of fresh concrete shall be BS 1881: Part 106, AASHTO
T196-80, AASHTO 199-82 or AASHTO 199-82 or AASHTO T 196-80 and T199-82.
7.9 Maximum aggregate size of any mix shall be related to the members size, reinforcement spacing
and cover by limiting to the smallest of the following:
1/5 of the smallest internal dimension.

3/4 of the minimum clear distance between reinforcements.
3/4 of the minimum cover
1/3 of the thickness of reinforced concrete slab.
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5.1.6 REQUIREMENTS FOR COMBINING MATERIALS
1. Measurement for Proportioning Materials
1.1 Cement: The cement shall be measured in bulk or as packed by the manufacturer, a sack of
cement shall weigh 50 kilograms. Measurement shall be accurate to within (0 - +4%) throughout the
range of use.
1.2 Water: The mixing water shall be measured by weight or by volume. In either case the
measurement shall be accurate to within ( + or - 1.0% ) throughout the range of use.
1.3 Aggregates: The aggregates shall be measured by weight. The measurement shall be accurate to
within (+ or - 2.0% fine, course aggregates) throughout the range of use.
1.4 Additives: Additives shall be measured by volume of in liquid form and by weights if solid. The
measurement shall be accurate to within 3.0 per cent throughout the range of use.
2. Assembly and Handling of Material
2.1 Assembly: aggregates shall be assembled in such quantities that sufficient material approved by
the Engineer is available to complete any continuous pour necessary for structures. The batching site shall
be of adequate size to permit the stockpiling of sufficient un-segregated materials having proper and
uniform moisture content to ensure continuous and uniform operation. Aggregates shall enter the mixer in
a manner approved by the Engineer and so as to ensure that no matter foreign to the concrete or any
matter capable of changing the desired proportions is included. In the event that 2 or more sizes or types
of coarse or fine aggregates are used on the same project, only 1 size or type of each aggregate may be
used on one continuous pour.
2.2 Stockpiling of Aggregates: All aggregates shall be stockpiled before use in order to prevent
segregation of material, to ensure a uniform moisture content, to provide uniform conditions for
proportioning plant control and to aid in obtaining concrete that is uniform as to materials and moisture
content. The use of equipment or methods of handling aggregates which results in the degradation of the
aggregates is strictly prohibited. Bulldozers with metal tracks shall not be used on coarse aggregate
stockpiles. All equipment used for handling aggregates shall be approved by the Engineer. Stockpiling of
aggregates shall be in the manner approved by the Engineer, and in addition, every precaution shall be
taken to prevent segregation. Segregation shall be prevented by making no layer higher than 1.5 meters
and if 2 or more layers are required, each successive layer shall not be allowed to “cone” down over the
next lower layer. Aggregates shall not be stockpiled against the supports of proportioning hoppers and
weighing devices.
2.3 Segregation: Aggregated aggregates shall not be used until they have been thoroughly remixed
and the resultant pile is of uniform and acceptable gradation at any point from which a representative
sample is taken. The Contractor shall remix aggregate piles when ordered by the Engineer.
2.4 Transporting of aggregates: If aggregates are to be transported from a central proportioning plant
to the mixer in batch-boxes or dump trucks, such equipment shall be of sufficient capacity to carry the full
volume of materials for each batch of concrete. Partitions separating batches shall be approved by the
Engineer and shall be adequate and effective to prevent spilling from one compartment to another while
in transit or being dumped.
2.5 Storage of Cement: Cement may be stored in bulk (unpacked) or in bags in securely locked dry
places.
2.5.1 All cement bags shall be marked with the date of manufacture. Additionally all bags
shall be marked with the date of storage so that they can be taken out for use in the same order as
they were brought in to storage.
2.5.2 Cement bags shall be placed on wooden shelves at least 100 mm above ground and
150mm clear of walls.
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2.5.3 Unpacked cement shall not be used six months after manufacture
and bagged cement three months after manufacture.
2.5.4 No cement shall be used which has been affected by humidity, regardless of the date of
manufacture.
3. Mixing
3.1 Concrete shall be mixed in quantities required for immediate use. Concrete shall not be used
which has developed initial set. Re-tempering concrete by adding water or by other means will not be
permitted. Concrete that is not within the specified slump limits at the time of placement shall not be used
and shall be disposed of as directed by the Engineer.
3.2 The concrete may be mixed at the site of the works, in a central-mix plant, or in a truck mixer.
The mixer shall be of an approved type and capacity. Ready-mixed concrete shall be mixed and delivered
in accordance with the requirements of Sub-Section 5.01.7 “Ready-Mixed Concrete and Central-Mixed
Concrete”.
3.3 The coarse aggregate shall first be loaded into the mixer followed be the fine aggregate. Some
mixer water shall be added to the mix before the cement is loaded into the mixer. Water shall be
continually added throughout the mixing. Additives, if required and approved by the Engineer. Shall be
added according to the manufacturers’ instructions or as in mix design report requirement. Retarders shall
be added within one minute or 25% of the total mixing time whichever is the smaller.
3.4 The mixing time shall b measured from the introduction of all of the constituent materials,
except water and additives, into the mixer. The required mixing time shall be calculated as follows but
shall be not less than two minutes:
3.4.1 Mixing time in seconds = 45+20S where S is the capacity of the mixer in cubic meters.
The mix time, after the additions of all the water, shall be not less than 75% of the total mix
time.
3.5 The manufacturers’ instructions shall be followed in respect of overloading the mixer and the
selection of the rate of revolutions of the mixer.
3.6 To avoid segregation in the fresh concrete, the free drop height on emptying the mixer shall be
not greater than 1.5 meters.
3.7 After mixing, the concrete shall be homogeneous and comply with the provisions of these
specifications. The Engineer may, if the mix fails to produce concrete of the required strength vary the
mix time.
4. Central Mixing
4.1 Plants for concrete shall comply with the following requirements, in addition to those set forth
above:-
4.1.1 Cement: Means provided for storing cement shall be as approved by the Engineer. The
Contractor shall clean all conveyors, bins and hoppers of unapproved cement before starting to
manufacture concrete for the Works.
4.1.2 Aggregate: Coarse and fine aggregate to be used in concrete shall be kept in stockpiles
and bins apart from aggregate used in other work. Aggregate shall come from a source approved
by the Engineer. The Contractor shall clean all conveyors, bins and hoppers of unapproved
aggregate before stating to manufacture concrete for the Works.
4.1.3 Consistency: The Contractor shall be responsible for producing concrete that is
homogeneous and complies with the provisions of these specifications.
4.1.4 Hauling: Mixed concrete from the central-mixing plant shall be transported in truck
mixers, truck agitators, non-agitating trucks having special bodies or other approved containers.
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4.1.5 Time of Haul: The time elapsing from the time water is added to the mix until the
concrete is deposited in place shall be not greater than:
4.1.5.1 For concrete produced on site and transported by means other than transit
mixers or agitate trucks,
4.1.5.2 Thirty minutes when air temperature is 25C or higher.
4.1.5.3 Forty minutes when air temperature is 18C or below.
4.1.5.4 Interpolated time between 18C and 25C.
4.1.6 For concrete transported by transit mixer or agitators, the time taken for 300 revolutions of the
transit mixer or agitator or 20 minutes, whichever is the lesser.
4.1.7 The maximum haul time may be reduced at the Engineer’s discretion if the slump changes or
there are signs of the concrete beginning to dry.
4.1.8 Delivery: The Contractor when supplying concrete from a central plant shall have sufficient
plant capacity and transporting equipment to ensure continuous delivery at the rate required. The rate of
delivery of concrete during concreting operations shall be such as to provide for the proper handling,
placing and finishing of the concrete. The method of delivery and handling the concrete shall be such as
will facilitate placing with a minimum of re-handling and without damage to the structure or the concrete.
Methods of delivery and handling for each site shall be approved. The Engineer may delay or suspend the
mixing and placing of concrete at any site, for which he considers the Contractor’s delivery equipment
inadequate, until such time as the Contractor provides additional delivery equipment.
5.1.7 READY-MIXED CONCRETE AND CENTRAL IXEDCONCRETE
1. General
1.1 “Ready-Mixed Concrete” and “Central-Mixed Concrete” shall consist of a mixture of cement,
water and aggregate, without air entraining or water- reducing admixture. When air-entraining or water-
reducing or any other type of admixture is required it shall be at the Engineer’s discretion. The terms
ready- mixed or central-mixed concrete shall include transit-mixed concrete and will be referred to
hereinafter as ready-mixed concrete (RMC).
1.2 Ready-mixed concrete may be used in the construction of all Works, when approved by the
Engineer.
1.3 Permission to use ready-mixed concrete from any previously approved plant may be rescinded at
any time upon failure to comply with the requirements of the Specification.
2. Materials
2.1 All materials used in the manufacture of ready–mixed concrete shall conform to the
requirements of Sub-Section 5.01.2 “Materials”
3. Equipment
3.1 Equipment shall be efficient, well maintained, and shall be of the type and number as outlined in
the Contractor’s program of Work. Transit mixers and agitator trucks shall comply with the standards
specified in ASTM C94.Non-agitating equipment used for transporting concrete shall be water tight and
be equipped with gates that will permit controlled discharge of concrete and, when required by the
Engineer, be fitted with covers for protection against the weather.
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4. Supply
4.1 Where transit mixers are used, the constituent materials shall be mixed dry in the mixer and
water added directly before pour and mixed at the speed and number of turns in accordance with the
manufacturers’ recommendations.
4.2 Where concrete is mixed at a central plant on or off site, the concrete may be supplied to the
pouring area by agitator trucks or transit mixers which rotate at the speed specified by the manufacturers.
Non-agitating trucks may be used if the central plant is on site.
4.3 Uniformity tests in accordance with Clause 5 below or as directed by the Engineer shall be
carried out.
4.4 Time of haul shall not exceed the maxima stated in sub-item 4.1.5 of subsection 5.01.6 of the
Specification.
5. Uniformity Tests
5.1 Four samples of fresh concrete shall be taken, two after 15% of discharge from the truck mixer
or agitator truck and two after 85% discharge and within 20 minutes. Slump and compaction factor tests,
in accordance with item 7.4 of subsection 5.01.5 of the specification shall be carried out including any
other tests specified or required by the Engineer.
6. Samples
6.1 Samples for strength test shall be taken as specified in Clause 3 of subsection 5.01.4 of the
Specification.
6.2 At least six specimens shall be prepared per sample. Three of these shall be tested at 7 days and
three at 28 days.
7. Control of Delivery
7.1 Driver of delivery trucks shall be provided with trip tickets, which shall be signed by a
responsible member of the central plant staff, for submission to the Engineer. The ticket shall contain the
following information.
7.1.1 Name and address of the Central Plant.
7.1.2 Serial number of the ticket and date.
7.1.3 Truck number.
7.1.4 Class and/or strength of concrete.
7.1.5 Cement content of the mix.
7.1.6 Loading time.
7.1.7 Slump.
7.1.8 Any other type of relevant information.
7.2 The Engineer may send his representative to the central plant who may:
7.2.1 Check the batching and mixing
7.2.2 Verify loading time.
7.2.3 Take a copy of the trip ticket.
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7.3 The Contractor and/or concrete supplier shall afford the Engineer and/or his representative,
without charge, all facilities necessary to take samples, conduct tests and inspect the central plant to
determine whether the concrete being furnished in accordance with the Specification.
7.4 Concrete delivered in outdoor temperatures lower than 5 degrees C, or if the temperature is
expected to drop below 5 degrees C during the curing period, shall arrive at the Works having a
temperature of not less than 10 degrees C nor greater than 32 degrees C.
7.5 In supplying read-mixed concrete, the plant shall have sufficient batching and transporting
capacity to ensure continuous delivery at the rate required. The rate of delivery of concrete during
concreting operations shall provide for the proper handling, placing and finishing of concrete. If the rate
of delivery does not provide a continuous concrete operation, the Engineer may suspend all or parts of
further concrete work until such time as the Contractor provides sufficient additional delivery equipment
which, in the opinion of the Engineer will provide for a continuous concrete operation.
5.1.8 MEASUREMENT
1. Scope
1.1 Concrete works to be measured for payment under Section 5.01 include mass, reinforced and
pre-stressed concrete of both in-situ and pre-cast construction of a general nature but do not include
specific components of highway structures, such as concrete piles, concrete parapets and safety barriers,
pre-cast concrete curbs and tiles etc., which are separately described in other sections of the specification.
2. What to measure
2.1 Concrete shall be measured by the cubic meter (m) in place and accepted, by the Engineer, based
on dimensions shown on the Drawings or as otherwise directed by the Engineer in writing.
2.2 Different classes of concrete shall be measured separately.
2.3 Concrete formed by different types of form and/or falsework shall be measured separately.
2.4 Concrete of the same class requiring the same falsework but different class of surface finish shall
be measured separately.
2.5 Voids, openings or gaps whose size is 0.05 cubic meters or more shall be measured and deducted
from the volume of concrete in which they occur.
2.6 All service ducts, irrespective of diameter, shall be measured and deducted from the volume of
concrete in which they are located.
3. Items not measured
3.1 Reinforcing bars shall not be measured for deduction.
3.2 Pre-stressing ducts, anchors, cones, couplers and grouting tubes shall not be measured for
deduction.
3.3 Embedded metals, bolts, nuts, anchorages, hooks etc. shall not be measured for deduction.
3.4 Holes introduced, with the consent of the Engineer, by the contractor for the convenience of
transportation, erection or construction shall not be measured for deduction irrespective of the size of the
holes and whether or no not the holes are made good.
3.5 Additional concrete placed, with the consent of the Engineer, by the Contractor solely for the
purpose of facilitating his work shall not be measured for payment.
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4. Inclusion in the Rates
4.1 The rates for items entered in the Bill of Quantities shall include for:
4.1.1 Cement, aggregates, water and additives, including their testing, storage, handling and
transportation.
4.1.2 Washing of aggregates, if required.
4..1.3 Ice, if required, added in the mix water.
4.1.4 Plant, machinery and equipment required for the production of concrete.
4.1.5 Design of mixes, taking samples and testing specimen.
4.1.6 Transportation and delivery of concrete to work areas.
4.1.7 Placing, vibrating and finishing of concrete.
4.1.8 All formwork irrespective of the material used and the quality of surface finish
specified.
4.1.9 All falsework supporting and stabilizing formwork.
4.1.10 Curing of concrete.
4.1.11 Tooling, if required, to achieve the specified surface finish.
4.1.12 Corrective measures and the means of carrying them out required in the event of the
concrete being out in accordance with the drawing and/or specification.
4.1.13 Handling, transportation and erection of pre-cast concrete members.
4.1.14 Grout and/or epoxy used in pre-cast construction including material and equipment for
temporary pre-stress, if required.
4.1.15 Material, plant and equipment associated with particular methods of construction such
as deck construction by pushing or by the balanced cantilever technique.
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CONCRETE HANDLING, PLACING AND CURING SECTION 5.2
SECTION 5.2 : CONCRETE HANDLING, PLACING AND

CURING
5.2.1 SCOPE
1. These operations shall consist of the placing, compacting and curing of concrete of mass
concrete, reinforced concrete and pre-stressed concrete structures.
5.2.2 MATERIALS
1. All concreting materials shall comply with section 5.01 “Concrete and Concrete Mixes and
Testing” of the Specification.
5.2.3 PLACING
1. General
1.1 Pouring of concrete shall not commence without the written approval of the Engineer. Such
approval shall be sought in writing by the Contractor at least 24 hours in advance.
1.2 The method and sequence of pour, the equipment t be used, the method of compaction and
curing procedure shall be approved by the Engineer, prior to concrete pour.
1.3 The free-drop height of concrete shall be not greater than 1.5m and the method of placing shall
be such as to suit the conditions and prevent segregation.
1.4 Placing of concrete shall be continuous between predetermined points such as construction
joints, contraction joints and expansion joints.
1.5 The slopes of chutes, where used, shall be not greater than 1 vertical to 2 horizontal or smaller
than 1 vertical to 3 horizontal. The slope of the chute shall be constant along its length. The capacity of
the chute shall be adequate to deliver the required volume of concrete at the required rate.
1.6 Aluminum pipes shall not be used for delivering concrete. The internal diameter of delivery
pipes, if used, shall be not less than 8 times the maximum aggregate size. At the point of delivery, pipes
shall be vertical.
1.7 Where bucket and hopper is used for delivery of concrete, the discharge opening shall be not less
than 5 times the maximum aggregate size. The sides of hoppers shall be sloped at not less than 60 degrees
to the horizontal.
1.8 When buggies are used to transport fresh concrete, they shall be run on level tracks which are
securely fixed. The buggies shall be run smoothly without sudden jerks and the distance shall be not
greater than 60 meters.
1.9 All chutes, buckets and hoppers, buggies and pipes shall be kept clean and free from coatings of
hardened concrete by thorough flushing with water after each run. The water used for flushing shall be
discharged clear of the concrete already in place.
1.10 The external surface of all concrete shall be thoroughly worked during the placing by means of
tools of an approved type. The working shall be such as to force all coarse aggregate from the surface and
to bring mortar against the forms to produce a smooth finish, substantially free from water and air
pockets, or honeycomb.
1.11 Concrete shall be deposited in water only with the permission of the Engineer and under his
supervision. The minimum cement content of the class of concrete being deposited in water shall be
increased 10 per cent without further compensation and the slump shall be approximately 15 centimeters.
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1.12 When depositing in water is allowed, the concrete shall be carefully placed in the space in which
it is to remain in a compact mass, by means of a tremie, bottom-dumping bucket or other approved means
that does not permit the concrete to fall through the water without adequate protection. The concrete shall
not be disturbed after being deposited. No concrete shall be placed in running water, and forms which are
not reasonably watertight shall not be used for holding concrete deposited under water.
1.13 When casing is used in drilled shafts, the casing shall be smooth and properly oiled in
accordance with the manufacturers’ manual and shall extend sufficiently above the grade of the finished
shaft to provide excess concrete to be placed for the anticipated slump due to the casing removal. When
the casing is to be pulled, the concrete placed in the casing shall have such a slump and be of such
workability that vibration of the concrete will not be required.
1.14 No concrete work shall be stopped or temporarily discontinued within 45 centimeters of the top
of walls and columns unless such work is finished with a coping having a thickness of not less than 45
centimeters in which case the joint shall be made at the under edge of the coping.
1.15 Concrete in simple slab spans shall be placed in one continuous operation for each span, unless
otherwise directed on the Drawings or directed by the Engineer.
1.16 Concrete in in-situ beam and slab construction shall be laced in one continuous operation, or
when so shown on the Drawings or approved by the Engineer, may be placed in two separate operations,
each of which shall be continuous; first, to the top of the girder stems, and second, to completion. Where
a construction joint is permitted between the girder stem and the roadway slab, complete details of key or
other methods of bonding will be as shown on the Drawings or directed by the engineer and such joints
must be constructed strictly in accordance therewith. When such a joint is permitted, deck concrete shall
not be placed until the concrete in the girder stem has hardened sufficiently so as not be damaged by the
concreting operations of the deck pour.
1.17 Concrete in arch rings shall be placed in such a manner as to load the centering uniformly. Arch
rings shall be divided into section such that each section can be cast for the full cross-section is one
continuous operation. The arrangement of the section and the sequence of placing shall be as approved by
the Engineer, and shall be such as to avoid the creation of initial stress in the reinforcement. The section
shall be bonded together by suitable keys or dowels. When permitted by the Engineer, arch rings may be
cast in a single continuous operation.
2. Pumping
2.1 Before concrete can be placed by pumping, the Contractor shall obtain the Engineer’s approval
in writing for the pumping machine to be used, the trucking arrangements and method of pumping.
2.2 The mix design shall be checked for its suitability for pumping and the concrete shall be tested
regularly during pumping for its uniformity and that its properties have not been altered by pumping. If
changes to slump, water-cement ratio, consistency or any other characteristics occur, corrective measures
shall immediately be taken to ensure that concrete delivered by the pump complies with the requirements
of the Specification. Samples shall be taken at discharge from the mixer/agitator truck, from the pump
and at discharge from the pump.
2.3 The internal diameter of delivery pipe of the pump shall be not less than 3 times the maximum
aggregate size. The pipes shall not rest on any part of the formwork; they shall be supported
independently and securely and be readily accessible so that sections can easily be detached to remove
any blockage.
5.2.4 COMPACTING
1. Poker Vibrators
1.1 The type and size of poker vibrators shall suit the pour size, density of reinforcement and
member dimensions. Unless otherwise authorized by the Engineer, the vibrator shall be selected from
Table 5.9 below:.
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Table 5.9: Selection Of Poker Diameter For Size Of Pour

Size of Pour (m/h) Poker Diameter (mm) Speed (Vibrations/min)
2–4 20 – 45 9000
5 – 10 50 – 65 9000
10 – 20 60 – 75 7000
20 – 30 80 – 115 7000
30 – 40 140 – 170 6000
1.2 Poker vibrators shall be inserted into the concrete vertically at regular intervals which shall be no
greater 0.45m. They shall be inserted quickly and withdrawn slowly. The withdrawal rate shall be not
more than 75mm/sec. A cycle of insertion and withdrawal shall be between 10 and 30 seconds.
1.3 Poker vibrators shall be kept clear of formwork and concrete previously cast.
1.4 Vibrators shall be so manipulated as to work the concrete thoroughly around the reinforcement
and embedded fixtures and into corners and angles of the forms. Vibrators shall not be used as a means to
cause concrete to flow or run into position in lieu of placing. The vibration at any point shall be of
sufficient duration to accomplish compaction, but shall not be prolonged to the point where segregation
occurs.
1.5 Compaction shall be sufficient to achieve maximum density without segregation in the fresh
concrete.
1.6 Standby pokers of the same type shall be provided at all times. The standby shall be not less than
half the number of pokers used for compacting the pour.
Vibrations shall only be carried out by professional technicians having experience of the type of work.
2. Other Vibrators
2.1 Form vibrators, vibrating tables and surface vibrators where required shall first be approved by
the Engineer and they shall conform to the requirements of ACI-309.
2.2 Where form vibrators are used, the form shall be adequately designed so that the vibration will
not cause joints to leak and dimensions and geometry to alter.
2.3 Unless otherwise permitted by the Engineer, the use of form vibrators shall be limited to
members whose thickness does not exceed 150mm.
5.2.5 CURING
1. Materials
1.1 Hessian or Burlap: They shall be clean and free from harmful materials. Their unit weight shall
be not less than 230 g/m2.
1.2 Impermeable membranes: The following impermeable membranes may, with the Engineer’s
approval, be used.
1.2.1 Clear polyethylene film with no holes, tears, scratches and contamination of any type.
1.2.2 Hessian coated with white polyethylene of density not less than 300g/m2 The coating
may be on one side only but shall be not less than 0.1mm thick and shall not peel during and
after use.
1.3 Curing Compounds: These shall conform to AASHTO M148 (ASTM-C309).
1.4 Sand: It shall be natural sand free of silt and clay and contaminants, which can be harmful to the
concrete.
1.5 Water: It shall satisfy the requirements of Section 5.01 of the Specification.
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2. Method of Curing
2.1 General: The method of curing to be used shall be approved by the Engineer. It shall not cause
any undesirable blemishes such as surface discolorations and surface roughness. Curing compounds shall
not be used on construction joints and surfaces that are to receive waterproofing, paint or membranes.
2.2 Ponding: Curing by ponding may be used for horizontal surfaces such as bases, pile caps and
slabs. Large areas of horizontal surfaces shall be separated into ponds not exceeding 5 m2. The ponds
shall first be filled between 12 to 24 hours after pour, unless otherwise authorized by the Engineer, and
shall be replenished from time to time so as to maintain the ponding for the specified curing period. The
concrete temperature and the temperature of the curing water shall be not greater than 10C.
2.3 Sprinkling: Unless otherwise approved by Engineer, curing by spraying shall commence
between 12 and 24 hours after the concrete pour. The concrete shall be maintained damp at all times
during the curing period by periodic light sprays.
2.4 Wet Hessian/Burlap: Members to be cured by wet hessian or wet burlap shall be completely
wrapped with the material which shall be kept moist at all time during the curing period by regular
spraying. Unless otherwise approved by the Engineer, the overlap under normal conditions shall be not
less than one-quarter the width of the hessian or burlap and not less than one- half the width in windy
and/or rainy conditions. Before members are wrapped for curing they shall first be evenly moistened.
Unless approved by the Engineer, burlaps shall be supplied only in rolls and burlap bags shall not be
used. Secondhand hessian and burlap, if approved for use, shall be clean without holes and contamination
of any kind that can affect the concrete.
2.5 Waterproof Sheets: Waterproof sheets used for curing shall, unless directed by the Engineer, be
spread immediately after the pour. The sheet shall, unless approved by the Engineer, be clear of the
concrete surface but be arranged in such a manner as to prevent the movement air over the concrete
surface. Waterproof sheets shall not be used when the air temperature is 25C or higher.
2.6 Curing Compounds: Curing compounds shall be applied in two applications at a coverage rate of
not less than 1 liter/7.4 m2 per application or as recommended by manufacturer.
2.6.1 The first coat shall be applied immediately after the removal of the forms and the
acceptance of the concrete finish and after the disappearance of free water on unformed surfaces.
If the concrete is dry or becomes dry, it shall be thoroughly wetted with water and curing
compound applied just as the surface film of water disappears. The second application shall be
applied after the first application has set. During curing operations, any unsprayed surfaces shall
be kept wet with water. The curing membrane will not be allowed on areas against which further
concrete is to be placed.
2.6.2 Hand operated spray equipment shall be capable of supplying a constant and uniform
pressure to provide uniform and adequate distribution of the curing membrane at the rates
required. The curing compound shall be thoroughly mixed at all times during usage.
2.6.3 The curing membrane shall be protected against damage for the entire specified curing
period. Any coating damaged or otherwise disturbed shall be given an additional coating. Should
the curing membrane be continuously subjected to injury, the Engineer may require wet burlap,
polyethylene sheeting, or other approved material to be applied at once.
2.6.4 No traffic of any kind will be permitted on the curing membrane until the curing period
is completed, unless the Engineer permits the placement of concrete in adjacent sections, in
which case the damaged areas shall be immediately repaired as directed.
2.7 Steam Curing
2.7.1 Low Pressure Steam Curing: This shall be in accordance with the recommendations of
ACI 517.
2.7.2 High Pressure Steam Curing: This shall be in accordance with the recommendations of
ACI 516.
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3. Curing Time
3.1 The minimum curing time shall be the number of days given in Table 5.10 unless the average
surface temperature of the concrete during the required number of days falls below 100C, in which case
the period of curing shall be extended until the maturity of the concrete reaches the value given in the
Table.
Table 5.10: Normal Curing Periods
Minimum periods of protection for different types of cement
Conditions under Number of days (where the average Equivalent maturity (degree
which concrete is surface temperature of concrete hours) calculated as the age of
maturing exceeds 10ºC during the whole period) concrete in hours multiplied by
the number of ºC by which the
average surface temperature of
the concrete exceeds 10ºC
OPC OPC
Other* SRPC or Other* SRPC or
RHPC RHPC
1. Hot weather or
drying winds 7 4 3 3500 2000 1500
2. Conditions not
4 3 2 2000 1500 1000
covered in 1
NOTE: Other* includes all permitted cements except OPC, RHBC, and SRPC.
KEY: OPC= Ordinary Portland cement.
RHPC = Rapid-hardening Portland cement.
SRPC = Sulfate resisting Portland cement.
3.2 The minimum curing time given in Table 5.10 above shall be compared with the time required
for cubes, cured under identical conditions to those which the concrete is subjected to, attain 70% of the
characteristic strength. The greater shall be taken as the minimum curing time.
5.2.6 HOT WEATHER CONCRETING
1. Definitions
1.1 For the purpose of this sub-section of the Specification, Hot Weather is as defined in ACI 305R-
77 (Revised 1982) Chapter 1.
2. General
2.1 The production and delivery of concrete, the placing and curing and the testing and inspection of
concrete shall, in addition to the requirements of the Specification, accord with the recommendations of
ACI 305R-77 (Revised 1982).
2.2 No concreting shall commence when the air temperature is 32C and rising. The Contractor shall
schedule his operations to place and finish concreting during the hours that the air temperature will be
below 320C.
3. Control of Temperature
3.1 Stockpile of aggregates shall be protected from sunlight by suitable covering. If directed by the
Engineer, they shall be regularly sprayed with clean water.
3.2 Water shall be stored in tanks away from sunlight and insulated by suitable means so as not to be
affected by high air temperature. Water tanks liable to be exposed to sunlight shall be covered with
suitable reflective paint such as white gloss paint.
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3.3 If directed by the Engineer or as a condition for concreting in adverse weather conditions,
sufficient ice shall be added to the mix water to ensure that the temperature of the fresh concrete shall not
exceed 320C.
3.4 Additives as recommended in ACI 305R-77 shall be used to improve workability and/or delay
initial setting.
4. Mixing and Placing
4.1 Aggregates and cement shall be thoroughly pre-mixed before adding water.
4.2 Transit mixers, if used, shall be coated with a reflective paint and while waiting to be discharged,
shall be kept out of direct sunlight.
5. Concrete Protection
5.1 Before the concrete can be de-shuttered, the formwork and shutters shall be cooled by spraying
with water.
5.2 The concrete and the falsework shall be protected against sunlight, if directed by the Engineer.
5.3 If curing is by hessian, it shall be coated with a white polyethylene backing.
5.4 Members exposed to strong winds shall be provided with windbreakers. The windbreakers shall,
if directed by the Engineer, be kept moist by regular spraying.
5.2.7 COLD WEATHER CONCRETING
1. Definitions
1.1 For the purpose of this sub-section of the Specification, Cold Weather is as defined in ACI
306.1-87, Section 1, Part 1.2.
2. General
2.1 ACI 306.1-87 “Standard Specification for Cold Weather Concreting” applies.
2.2 The production and delivery of concrete, the placing and curing and the protection requirement
shall be in accordance with the recommendations of ACI 306R-78 “Cold Weather Concreting”
2.3 No concreting shall commence when the air temperature is 60C and falling, unless authorized by
the Engineer.
3. Mixing and Placing
3.1 Aggregates and water, forms, reinforcement etc, shall be free of snow, frost or ice.
3.2 Aggregates and water may be pre-heated in which case the aggregates and water shall, if
directed by the Engineer, be mixed prior to introducing cement in the mix. The aggregates shall not be
pre-heated to a temperature in excess of 1000C and the water in excess of 600C with the additional
requirement that the temperature of the water an aggregate mix, before the introduction of cement, shall
not exceed 380C.
3.3 Water may be pre-heated by boiling and added to aggregates not pre-heated provided the
temperature of the water and aggregate mix, before the introduction of cement, does not exceed 380C.
3.4 The temperature of concrete at the time of discharge and for three days after the pour shall be not
less than 50C.
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4. Protection
4.1 When directed by the Engineer, members shall be protected against cold winds by suitable
windbreaks.
4.2 Adequate insulation by way of insulation boards, planks, sheets etc. shall be provided to
maintain the required minimum concrete temperature during the curing period.
4.3 Protection measures shall be maintained for a period at which the concrete attains a strength of at
least 65% of the characteristic strength.
5.2.8 NIGHT CONCRETING
1. Night concreting shall not be carried out unless prior approval of the Engineer, in writing, is
obtained.
2. Details of the artificial lighting system shall be submitted in advance of the proposed concreting
for the Engineer’s approval. In all cases, at least one stand-by generator shall be available at all times of
the concreting operation.
5.2.9 MEASUREMENT
1. The provisions of this section of the specification are not measured directly for payment but shall
be considered subsidiary to the different classes of concrete described and measured for payment under
the provisions of Section 5.01 “Concrete and Concrete Mixes and Testing” of the Specification.
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STEEL REINFORCEMENT & FIXING SECTION 5.3
SECTION 5.3 : STEEL REINFORCEMENT AND FIXING

5.3.1 SCOPE
1. These works shall consist of the supply and fixing of the unstressed steel bars, wires, mesh and
mats for the reinforcement of concrete in accordance with the Drawings and Specification.
5.3.2 MATERIALS
1. Reinforcing Bars and Wires
1.1 Hot rolled steel bars shall conform to AASHTO M31M (ASTM A615M) or to BS 4449.
1.2 Cold worked steel bars shall conform to BS 4461.
2. Welded Fabric Reinforcement
2.1 Welded wire fabric shall conform to AASHTO M55 (ASTM A185).
2.2 Welded bar fabric reinforcement shall conform to BS 4482.
3. Fabricated Mat Reinforcement
3.1 Fabricated mat reinforcement shall conform to AASHTO M54M (ASTM A184M).
4. Certification and Identification
4.1 Thee copies of a mill test report shall be supplied to the Engineer for each lot of billet steel
reinforcement supplied for use on the project. The mill test report shall be sworn to by a person having
legal authority to bind the manufacturer and shall show the following information:
4.1.1 The process or processes used in the manufacture of the steel from which the bars were
rolled.
4.1.2 Identification of each heat of open-hearth, basic oxygen, or electric furnace and/or each
lot of acid bessemer steel from which the bars were rolled.
4.2 The bars in each lot shall be legibly tagged by the manufacturer and/or fabricator before being
offered for inspection. The tag shall show the manufacturer’s test number and lot number or other
designation that will identify the material with the certificate issued for that lot of steel.
4.3 The fabricator shall furnish 3 copies of a certificate which shows the heat number or numbers
from which each size of bar in the shipment was fabricated.
5. Inspection and Sampling
5.1 The sampling and testing of reinforcement bars may be made at the source of supply when the
quantity to be shipped or other conditions warrant such procedure. Bars not inspected and sampled before
shipment will be inspected and sampled after arrival at the site.
5.3.3 CONSTRUCTION
1. General
1.1 All reinforcement shall be free from detrimental dirt, loose mill scale, scaly rust, paint, grease,
oil or other foreign substance. There shall be no evidence of pitting or visual flaw in the test specimen or
on the sheared ends of the bars.
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1.2 Rust shall be removed by wire brushing or, if directed by the Engineer, by sand blasting, light
rust without visible sign of peeling need not be removed.
2. Storage
2.1 Reinforcement shall be stored clear of the ground on platforms, skids or other supports and be
protected against contamination by dirt, grease, oil etc. at all times. If directed by the Engineer, the
contractor shall provide cover to the reinforcement.
2.2 Reinforcement of different grades and different diameters shall be stored separately and marked
to facilitate inspection and checking.
3. Cutting and Bending
3.1 Cutting and bending of reinforcement shall be based on an approved bar bending schedule.
3.2 Reinforcement shall be cut in specialist cutting machines or cold cut by hand only. Cutting with
oxyacetylene torch is strictly forbidden.
3.3 Unless otherwise provided in the special specification such as bending to BS 4466, bars shall be
bent to the following minimum bend diameters:
Bar Diameter, d. Mild Steel High Yield Steel

Up to 25 mm 4d 6d
25 to 35 mm 6d 8d
35 to 60 mm 10d 10d
3.4 Bars shall be bent cold. Bending by heating, if approved by the Engineer, shall be carried out in
such a manner as not to impair the physical and mechanical characteristics of the bar.
3.5 The straight bar length for a hook of 180 shall be not less than 4 times the bar diameter or 60mm
whichever is the larger.
3.6 The straight bar length of a hook of 90 shall be not less than 12 times the bar diameter.
3.7 The straight bar length after hook in stirrups shall be 6 times the bar diameter or 60mm
whichever is the larger.
3.8 Cold worked bars and hot rolled high yield bas shall not be re-bent or straightened once having
been bent. Where it is necessary to bend mild steel bars projecting from the concrete, the bend diameter
shall comply with the requirements of item 3.3 above.
3.9 If bending of the bar in accordance with this specification causes the bar to crack, the bar shall
be rejected, irrespective of any prior approval that may have been given, and removed from the Site.
3.10 Bars shall be cut and bent to the following tolerances:
Bar length (mm) Tolerance (mm)

Up to 1000 5
1000 – 2000 +5, - 10
above 2000 +5, - 25
3.11 No adjustment to bar length after bending will be permitted.
4. Fixing
4.1 Reinforcement shall be placed and maintained in the position shown on the Drawings. Unless
agreed otherwise by the Engineer, all bar intersections shall be securely tied together with the ends of the
wire turned into the main body of the concrete. 1.2mm diameter annealed iron wire shall be used for in
situ members having exposed soffits. 1.6mm diameter soft annealed iron wire shall be used elsewhere.
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4.2 The correct cover to reinforcement on all exposed faces of concrete shall be maintained by using
approved proprietary spacers. Where instructed by the Engineer the adequacy of such spaces shall be
demonstrated by site trials.
4.3 Concrete cover blocks where permitted by the Engineer shall be of approved dimensions and
designed so that they will not overturn when the concrete is placed. They shall be made with 10mm
maximum size aggregate and the mix proportion shall be such as to produce the same strength as the
adjacent concrete. Tying wire shall be cast in the blocks in order to secure the blocks to the
reinforcement.
4.4 Wherever it is necessary for the Contractor to splice reinforcement at positions other than those
shown on the Drawings the approval of the Engineer shall be sought and obtained before the
reinforcement is placed. Splices shall be staggered where possible and shall be designed to develop the
strength of the bar without exceeding the allowable unit bond stress.
4.5 Proprietary mechanical splicing devices shall be used only with prior approval of the Engineer.
They shall be able to withstand without any slippage a force of not less than 1.25 times the characteristic
yield stress of the smaller bar spliced multiplied by the cross-sectional area or the smaller bar.
4.6 Mesh reinforcement shall comply with the sizes of sheets and diameter and spacing of bars as
shown on the Drawings. The sheets of mesh shall be lapped as shown on the Drawings. The method of
placing the mesh and securing it in position shall be approved by the Engineer.
4.7 Welding of reinforcement bars, if allowed by the Engineer, shall be carried out in accordance
with the latest publications of the American Welding Society publication “Structural Welding Code for
Reinforcing Steel”, and shall be able to withstand a force of not less than 1.25 times the characteristic
yield stress of the smaller of the welded bars multiplied by the cross-sectional area of the smaller bar.
4.8 Cold worked steel bars shall not be welded.
4.9 Where galvanizing or epoxy coating is required to be applied to the reinforcement, specific
instructions will be given by the Engineer taking into account the particular design conditions which
apply.
5.3.4 MEASUREMENT
1. Measurement of different grades of steel reinforcement will be based on the theoretical quantity
of metric tones complete in place as shown on the Drawings or placed as ordered by the Engineer. No
allowance will be made for clips, wire or other fastening devices for holding the reinforcement in place.
Measurement will not be made of reinforcement chairs to separate slab steel or similar reinforcement to
retain wall steel or similar usage elsewhere. Measurement of splices in reinforcement not shown on the
Drawings will not be made, unless such splices were agreed or authorized by the Engineer.
2. Calculated weights shall be based upon Table 5.11.
Table 5.11: Weights of Reinforcing Bars

Diameter Weight Diameter Weight Diameter Weight
(mm) Kg/m (mm) Kg/m (mm) Kg/m
5 0.145 18 2.000 34 7.130
6 0.222 20 2.470 36 7.990
7 0.302 22 2.990 38 8.900
8 0.395 24 3.550 40 9.870
10 0.617 26 4.170 45 12.500
12 0.888 28 4.830 50 15.400
14 1.210 30 5.550
16 1.580 32 6.310
3. Separate measurement for bars of different diameter but of the same grade shall not be made.
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4. Fabric mesh reinforcement shall be measured separately and will be based on the theoretical
quantity of metric tones complete in place as shown on the Drawings or placed as ordered by the
Engineer. No separate measurement shall be made for different mesh sizes or different wire or bar
diameters.
PAY ITEMS UNIT OF MEASUREMENT

(1) Mild steel bar reinforcement Metric tons
(2) High tensile steel bar reinforcement Metric tons
(3) Fabric wire mesh reinforcement Metric tons
(4) Fabric bar mesh reinforcement Metric tons
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FORMS, FORMWORK AND FALSEWORK SECTION 5.4
SECTION 5.4 : FORMS, FORMWORK AND FALSEWORK

5.4.1 SCOPE
1. These works shall consist of the design, supply and use of forms, formwork and falsework for
the construction of concrete highway structures.
5.4.2 DEFINITIONS
1. Forms and formwork
1.1 The section of the temporary works used to give the required shape and support to poured
concrete. It consists primarily of sheeting material, such as wood, plywood, metal sheet or plastic sheet, in
direct contact with the concrete and joists or stringers that directly support the sheeting.
2. Falsework
2.1 Any temporary structure used to support a permanent structure while it is not self-supporting.
3. Scaffold
3.1 A temporarily provided structure that provides access, or on or from which persons work, or that
is used to support material, pant or equipment.
4. Tower
4.1 A composite structure, usually tall, used principally to carry vertical loading.
5. Camber
5.1 The intentional curvature of the formwork, formed initially to compensate for subsequent
deflection under load.
5.4.3 MATERIALS
1. Wood
1.1 Notional Wood: soft wood free of faults such as splitting, warping, bending, knots etc.
1.2 Imported Wood: When imported softwood or hardwood is used for falsework, the minimum
timber grade, determined in accordance with B.S4978 shall be SC3.
1.3 Hardwood used as load-bearing wedges and packing shall be limited to those listed in Table
5.12.
Table 5.12: Permitted Hardwoods for Load-Bearing Wedges and Packing

Standard name Botanical species
ash Fraxinus excelsior
beech Fagus sylvatica
greenheart Ocotea rodiaei
jarrah Eucalyptus marginata
karri eucalyptus diversicolor
oak Quercus spp
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2. Plywood
2.1 Plywood shall conform to the requirements of Part 11”Carpentry Works” of the General
Technical specification for Buildings Vol.1 of the Ministry of Works.
2.2 When plastic coated plywood is used, the Phenol resin on melamine shall be not less than 20%
of the total coating weight.
3. Steel
3.1 Steel shall conform to the requirements of Section 5.16 “Structural Steelwork and Metal
components”.
4. Aluminum
4.1 Aluminum shall conform to the requirements of ASTM B221.
5. Other Materials
5.1 Other materials, with the approval of the Engineer, may be used for falsework. These include,
but not limited to, fiber-glass reinforced plastic, polystyrene, polyethylene, PVC, rubber, concrete, brick
etc.
5.4.4 DESIGN
1. General
1.1 Forms and formwork and falsework shall be designed by the Contractor and submitted to the
Engineer with full design calculations, detailed drawings, material specification and test certificates for
his approval, which approval shall not relieve the Contractor from his responsibilities under the Contract.
1.2 Falsework design shall be in accordance with B.S 5972 “Code of Practice for Falsework”.
1.3 If the Contractor intends to use ready made proprietary type of falsework, he shall submit all
relevant data, including independent test certificates, which will enable the Engineer to determine whether
or not the Contractor’s proposed falsework are acceptable.
2. Forms and formwork
2.1 Formwork shall be sufficiently rigid so as to prevent any grout loss during concreting and shall
not distort due to environmental effects and concreting operations so that member dimensions, shape,
required finish and texture are within the tolerances specified.
2.2 Forms and formwork shall be designed to be readily assembled, stripped and transported without
distortion to panels and members of the formwork.
2.3 The method of stripping forms without damaging the concrete or special textured surface finish,
if incorporated, shall be fully considered in the design.
2.4 If form liners are to be used to achieve the specified surface finish, samples of a size as directed
by the Engineer shall be submitted for approval.
2.5 Form lining shall not bulge, warp or blister, nor shall it stain the concrete. Form lining shall be
used in the largest practicable panels to minimize joints. Small panels of the lining material shall not be
permitted. The joints in the lining shall be tight and smoothly cut. Adjacent panels of form lining shall be
so placed that the grain of the wood will be in the same direction (all horizontal or all vertical). Thin
metal form lining will not be permitted. Undressed lumber of uniform thickness, which is properly
supported to meet the above requirements, may be used in lieu of the lined forms specified herein.
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2.6 Metal forms, if used, shall be of such thickness that the forms will remain true to shape. All bolt
and rivet heads shall be countersunk. Clamps, pins or other connecting devices shall be designed to hold
the forms rigidly together and to allow removal without injury to the concrete. Metal forms which do not
present a smooth surface or do not line up properly shall not be used. Care shall be exercised to keep
metal forms free from rust, grease or other foreign matter. Under such circumstances the continued use of
the metal forms will depend upon satisfactory performance and their discontinuance may be required at
any time by the Engineer. Steel panels or panels with metal frames and wood or combination shall be so
designed as to leave no lipping or ridges in the finished concrete.
2.7 The width and thickness of the lumber, the size and spacing of studs and wales shall be
determined with due regard to the nature of the Work and shall be sufficient to ensure rigidity of the
forms and to prevent distortion due to the pressure of the concrete.
2.8 Form bolts, rods or ties and removable ties through plastic (PVC) pipes shall be made of steel.
They shall be the type which permit the major part of the tie to remain permanently in the structure or
removed entirely. They shall be held in place by devices attached to the wales capable of developing the
strength of the ties. The Engineer may permit the use of wire ties on irregular sections and incidental
construction if the concrete pressures are nominal and the form alignment is maintained by other means.
Form ties will not be permitted through forms for handrail. Pipe spreaders shall not be used unless they
can be removed as the concrete is placed, as determined by the Engineer. Wood or metal spreaders shall
be removed as the concrete is placed, as determined by the Engineer. The use of cofferdam braces or
struts will not be permitted except in unusual situations and then only with approval of the Engineer.
2.9 Where the bottom of the forms is inaccessible, the lower form boards shall be left loose or other
provisions made so that extraneous material may be removed from the forms immediately before placing
the concrete.
2.10 If directed by the Engineer the exterior side of forms shall be painted with an approved, good
quality high gloss white oil base enamel paint prior to placing concrete. Paint shall be applied to metal
forms only and this shall be emphasized in the Special Specifications. When complete coverage is not
obtained with one coat, the Engineer will order additional coats as he deems necessary to obtain complete
coverage. Forms shall be repainted when ordered by the Engineer.
2.11 Unless provided otherwise on the Drawings or directed by the Engineer, all exposed edges shall
be beveled by using dressed, mill cut, triangular molding, having 20 millimeter sides.
3. Falsework
3.1 Falsework ad centering shall be designed to provide the necessary rigidity to support all loads
placed upon it without settlement or deformation in excess of the permissible tolerance for the structure
given in the Specifications. Falsework columns shall be supported on hardwood, concrete pads or metal
bases to support all falsework that cannot be founded on rock, shale or thick deposits of other compact
material in their natural beds. Falsework shall not be supported on any part of the structure, except the
footings, without the written permission of the Engineer. The number and spacing of falsework columns,
the adequacy of sills, caps and stringers and the amount of bracing in the falsework framing shall be
subject to approval of the Engineer.
3.2 All timber shall be of sound wood, in good condition and free from defects that might impair its
strength. If the vertical members are of insufficient length to cap at the desired elevation for the horizontal
members, they shall preferably be capped and frames constructed to the proper elevation. Ends of the
vertical members shall be cut square for full bearing to preclude the use of wedges. If vertical splices are
necessary, the abutting members shall be of the same approximate size, the ends shall be cut square for
full bearing and the splice made in a manner approved by the Engineer.
3.3 The Contractor shall compute falsework settlement and deflection for bridges so that when the
final settlement is complete, the structure will conform to the required camber, section and grade as
3.4 The contractor shall provide mean for accurately measuring settlement in falsework during
placement of concrete, and shall provide a competent observer to observe and correct the settlement.
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3.5 Screw jacks, if used, shall be designed for use with a slenderness ratio not exceeding 60. The
slenderness ratio shall be taken as the ratio of the clear distance between effective bracing in both
horizontal directions to the diameter of the screw jack measured at the root of the thread. The
manufacturers’ certificate showing the ultimate load capacity of the screw jack shall be submitted with
the design calculations for the falsework. If directed by the Engineer, the Contractor shall furnish a test
certificate carried out at an approved independent laboratory.
3.6 Props and towers supporting forms or partially completed structures shall be interconnected in
plan orthogonally at levels to be determined in the design. They shall also be interconnected by diagonal
bracings in orthogonal vertical planes.
5.4.5 FINISHES
1. Formed Finishes
1.1 Class F1. This class of surface finish denotes a special finish required form aesthetic
considerations. In additions to the requirements of Class F2 finish, the following additional requirements
shall apply.
1.1.1 It is of major importance that the special finishes required on F1 surfaces are uniformly
and consistently maintained with no variation in the color or consistency of the concrete within
the same structure. In order to achieve this, the Contractor shall make trial panels of the formed
finishes specified. These panels shall be not less than 1.5m high and 1m wide and 250 mm thick
and shall be cast in the manner and with materials as proposed for the actual work. These panels
are for the approval of the liners and are preliminary to the test samples carried out on site.
1.1.2 The Contractor shall provide at his own expense as many panels as required by the
Engineer until a satisfactory trial panel has been accepted by the Engineer. In addition, the
Engineer will require samples of pier, part of a deck, section of retaining wall and /or underpass
wall and typical pre-cast edge unit to be cast on site in the same manner as proposed for the
prototypes. The Contractor shall submit to the Engineer and obtain his approval for all details
before commencement of trials. These samples when approved, will form the standard against
which the corresponding finishes on the actual work will be judged.
1.1.3 Where forms and form-liners to be used for the special finishes specified are
manufactured outside the country the forms and form-liners shall not be permitted on Site until
the Engineer has inspected the forms and form-liners and is satisfied that they are suitable for the
Works. Samples and trial panels carried out at the place of manufacture to demonstrate to the
Engineer that the forms and form-liners and the methods of assembling and de-shuttering them
are acceptable shall not be paid for and will not relieve the Contractor of the requirement for
carrying out trial panels on site as described above.
1.1.4 If the required finish in the opinion of the Engineer, has not been obtained in the Works,
the Contractor shall promptly carry out at his own expense all measures required by the Engineer
to obtain the specified finish. Theses may include grit blasting followed by the application of
polyester or epoxy paint. Where such remedial action is ordered by the Engineer, the entire
exposed surface shall be so treated irrespective of whether or not the defective areas are
localized or extensive.
1.2 Class F2. Formwork shall be lined with a material approved by the Engineer to provide a
smooth finish of uniform appearance. This material shall leave no stain on the concrete and shall be so
joined and fixed to its backing so that it imparts no blemishes. It shall be of the same type and obtained
from only one source for any one structure. The Contractor shall make good any imperfections in the
finish as directed by the Engineer. Internal ties and embedded metal parts will not be permitted unless
otherwise approved by the Engineer.
1.3 Class F3. Irregularities in the finish shall be no greater than those resulting from the use
of wrought thick square edged boards arranged in a uniform pattern. The finish is intended to be left as
struck. Imperfections such as fins and surface discoloration shall, however, be made food as and when
required by the Engineer.
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1.4 Class F4. No special requirements.
2. Unformed Finishes
2.1 Class U1. The concrete shall be uniformly leveled and screeded to produce a plain or
ridged surface as described in the Contract. No further work shall be applied to the surface unless is used
as the first stage for Class U2 or Class U3 finish.
2.2 Class U2. After the concrete has hardened sufficiently, the concrete Class U1 surface
shall be floated by hand or machine sufficiently only to produce a uniform surface free from screed
marks.
2.3 Class U3. When a moisture film has disappeared and the concrete has hardened
sufficiently to prevent laitance from being worked to the surface, a Class U1 surface shall be steel-
trowelled under form pressure to produce a dense, smooth uniform surface free from trowel marks.
5.4.6 TOLERANCES
1. The tolerances in the forms and formwork shall be such that members formed shall be within the
tolerances for the size and type of the member specified elsewhere in the Specification.
2. Falsework shall be fixed such that the completed structure shall be within the required tolerances
in plan, elevation and slope for the size and type of structure specified elsewhere in the Specification.
5.4.7 CONSTRUCTION REQUIREMENTS
1. The forms and falsework shall be inspected by the Engineer after assembly on the work area and
immediately before concreting. No pour shall commence until the forms and falsework have been
2. The inside surfaces of all forms shall, except for pavement formwork, or unless otherwise agreed
by the Engineer, be coated with a release agent approved by the Engineer. Release agents shall be applied
strictly in accordance with the manufacturer’s instructions and shall not come into contact with the
reinforcement or pre-stressing tendons and anchorages. Different release agents shall not be used in
formwork which will be visible in the finished work.
3. Immediately before concrete is placed, all forms shall be thoroughly cleaned out.
4. Forms that are to be re-used shall be thoroughly cleaned and re-oiled and, if necessary, shall be
reconditioned by revision or reconstruction. Unsatisfactory lumber will be condemned by the Engineer,
and shall be removed from the Site.
5. Runways used to move plant, equipment or materials shall be clear of the reinforcement and
shall be robust enough not to deflect excessively or cause movement to the forms sue to dynamic effects.
6. During concreting, the forms and their supports shall be constantly monitored for signs of
imminent failure. There shall be skilled operatives in constant attendance during concreting who are
qualified to make immediate adjustments to the forms and falsework so that concreting can satisfactorily
be completed.
7. The Engineer may suspend concreting operations if, in his opinion, the forms and falsework are
in danger of failure and that the actions taken by the Contractor are insufficient or inadequate to guarantee
the safe and satisfactory completion of concreting. In such an event, the Engineer may instruct the
Contractor to remove, at his expense, the concrete already poured.
8. Immediately after the removal of the forms, all fins caused by form joints and other projections
shall be removed and all pockets cleaned and filled with a cement mortar composed of 1 part by volume
of Portland cement and 2 part sand. Sufficient white Portland cement shall be mixed with the cement in
the mortar, so that when dry the color will match the surrounding concrete. Patches shall be moistened
prior to mortaring to obtain a good bond with the concrete. When directed by the Engineer, the Contractor
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shall at his own expense, substitute an approved epoxy grout for the Portland cement mortar or provide an
epoxy bonding agent to be used in conjunction with the Portland cement mortar. If, in the judgment of the
Engineer, pockets are of such extent or character as to materially affect the strength of the structure or to
endanger the life of the steel reinforcement, he may declare the concrete defective and require the
removal and replacement of that portion of the structure affected. The resulting surfaces shall be true and
uniform. Portions of the structure which cannot be finished or properly repaired to the satisfaction of the
Engineer shall be removed.
5.4.8 REMOVAL OF FORMWORK AND FALSEWORK
1. To facilitate finishing, forms on handrails, ornamental work, and other vertical surfaces that
require a rubbed finish, shall be removed as soon the concrete has hardened sufficiently that it will not be
injured, as determined by the Engineer. In determining the time for the removal of forms consideration
shall be given to the location and character of the structure, weather and other conditions influencing the
setting of the concrete.
2. Formwork shall be removed in a manner not to damage the concrete, and at times to suit the
requirements for its curing and to prevent restraint that may arise from elastic shortening, shrinkage or
creep.
3. Where the concrete compressive strength is confirmed by tests on concrete cubes stored under
conditions approved by the Engineer that simulate the field conditions, formwork supporting concrete in
bending may be struck when the strength is 10N/mm2 or three times the stress to which it will be
subjected, whichever is the greater.
4. For ordinary structural concrete made with ordinary Portland cement only, in the absence of
control cubes the period before striking shall be in accordance with the minimum periods given in Table
5.13, unless otherwise directed by the Engineer.
Table 5.13: Minimum Period Before Striking for Ordinary Structural Concrete Made With
Ordinary Cement.
Minimum period before striking
Type of Formwork Surface Temperature of Concrete
16ºC 7ºC t ºC
Vertical formwork to columns, walls and large 300 hours
12 hours 18 hours
beams t + 10
100 days
Soffits to formwork to slabs 4 days 6 days
t + 10
250 days
Props to slabs 10 days 15 days
t + 10
230 days
Soffits to formwork to beams 9 days 14 days
t + 10
360 days
Props to beams 14 days 21 days
t + 10
5.4.9 MEASUREMENTS
1. The provisions of this section of the Specification are not measured directly for payment but
shall be considered subsidiary to the different classes of concrete described and measured for payment
under the provisions of Section 5.01 “Concrete and Concrete Mixes and Testing” of the Specification.
2. Test panels carried out by the Contractor to demonstrate to the Engineer’s satisfaction that the
specified F1 finish can be achieved shall be measured for payment for the appropriate class of concrete
measured for payment under the provisions of Sections 5.01 “Concrete and Concrete Mixes and Testing”
of the Specification. Test panels not accepted by the Engineer shall not be measured for payment.
3. Test samples, such as a section of retaining wall or a complete pier, carried out by the Contractor
and approved by the Engineer for use as reference bench marks for the quality to be attained in the Works
shall be measured for payment for the appropriate class of concrete measured for payment under the
provisions of Section 5.01 “Concrete and Concrete Mixes and testing” of the Specification. Test samples
not accepted by the Engineer shall not be measured for payment.
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CONCRETE PAVEMENT SECTION 5.5
SECTION 5.5 : CONCRETE PAVEMENT

5.5.1 SCOPE
1. These Works shall consist of furnishing materials and constructing cement concrete pavement,
with or without reinforcement, on a prepared base all as and where shown on the Drawings.
5.5.2 MATERIALS
1. Concrete for pavement construction shall be Class 20 or higher having a minimum flexural
strength of 4N/mm2 and maximum aggregate size of 40mm. Unless otherwise shown on the Drawings.
2. Cement shall conform with the relevant requirements of Section 5.01 “Concrete an Concrete
Mixes and Testing”. The type of cement shall be as required by the special specifications.
3. Chemical admixtures shall be in accordance with sub-section 5.01.2 Paragraph 12 “admixtures”.
4. Steel reinforcing bars and steel wire fabric shall conform with the relevant requirements of
Section 5.03 “Steel Reinforcement and Fixing”.
5. Dowel bars shall be plain steel bars conforming to AASHTO M31M (ASTM A615M) Grade 40
or 60. Sleeves for dowel bars shall be approved types. Tie bars shall be deformed steel bars of approved
type and shall conform to AASHTO M42. (ASTM A616).
6. Water for use in concrete and mortar mixes and for curing purposes shall conform with the
relevant requirements of section 5.01 “Concrete and Concrete Mixes and Testing”.
7. Curing membrane materials shall conform with the relevant requirements of Section 5.02
“Concrete Handling, Placing and Curing”. Unless otherwise shown on the Drawings, a liquid curing
compound shall be used conforming to AASHTO M148.(ASSTM C309).
8. Moisture barrier (for spreading on the granular base prior to placing concrete) shall be either
PVC plastic film conforming to ASTM D1593, Type II, or PE plastic film conforming to ASTM D2103,
Type 2000. The film shall be 0.15 mm to 0.20 mm in thickness.
9. Materials for use in expansion joints, construction joints ad weakened plane joints shall be
approved proprietary sealants, fillers and plastic strips, as shown on the Drawings and conforming with
the requirements of section 5.21 “Joint Sealing and Joint Filler”.
10. Poured filler shall conform to AASHTO M173 (ASTM D1190). Preformed fillers shall conform
to AASHTO M33, (ASTM D994) AASHTO M153, (ASTM D1752) AASHTO M213 (ASTM D1751) or
AASHTO M220, (ASTM D2628) as appropriate and shall be punched to admit dowels where required.
Preformed filler for each joint shall be furnished in a single piece unless otherwise approved.
5.5.3 EQUIPMENT
1. Plant and equipment for base course and concrete pavement construction shall conform with the
requirements of Section 1.14 “Contractor’s Plant and Equipment” and with the Contractor’s approved
Work Program.
2. At the option of the Contractor, unless otherwise shown on the Drawings, stationary side forms
or slip-form paving equipment may be utilized for concrete pavement construction.
5.5.4 BASE COURSE SURFACE PREPARATION
1. The base course provided immediately beneath the concrete pavement shall have been
constructed in accordance with Section 3.03 and 3.04, as applicable.
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2. Immediately prior to placing concrete, the base course surface shall be inspected to ensure that it
conforms to the compaction and elevation tolerances specified.
3. Moisture barrier material shall be placed over the base course surface prior to placing concrete.
All seams shall be lapped a minimum of 150 mm and the barrier material anchored in place by approved
methods.
4. Storing or stockpiling of other equipment and materials on the base course will not be permitted.
5.5.5 PREPARATORY WORKS
1. Before placing concrete, the Contractor shall provide a sufficient supply of water and ensure that
it will remain available throughout the pavement construction period. An inadequate water supply will be
considered sufficient cause for delaying or stopping mixing operations. In case of a deficiency of water,
the requirements for curing concrete already placed shall take precedence.
2. Slip-form paving and finishing machines shall be in proper adjustment and satisfactory working
order. Prior to placing concrete, the Contractor shall demonstrate proper adjustment of all screeds and
floats on slip-form pavers by measurements from grade stakes driven to known elevation. Satisfactory
operation and adjustment of all propulsion and control equipment, including pre-erected grade and
alignment lines, shall be demonstrated by moving slip-form pavers and finishing machines over a 100 m
length or prepared base course with all propulsion and control equipment fully operational.
3. The Contractor shall make adequate advance arrangements for preventing delay in delivery
placing of the concrete. An interval of more than 45 minutes between placing of any 2 consecutive
batches or loads shall constitute cause for stopping paving operations.
5.5.6 TRIAL LENGTH
1. General
1.1 At least one month prior to the construction of the trial length of surface slabs the Contractor
shall submit for the Engineer’s approval a detailed description of the proposed materials, plant, equipment
and construction methods. No trials of new materials, plant, equipment or construction methods; nor any
development of them shall be permitted either during the construction of the trial length or in any
subsequent paving work, unless they form part of further approved trials.
1.2 The Contractor shall demonstrate the materials, plant, equipment and methods of construction
that are proposed for concrete paving, by first constructing a trial length of slab, at least 150m but not
more than 300m long for mechanized construction, and at least 30m long for hand guided methods.
1.3 The trial length shall be constructed in tow parts over a period comprising at least part of two
separate working days, with a minimum of 75m constructed each day when mechanized paving plant is
used and a minimum of 15m on each day for hand guided methods. The trial length shall be constructed
at a similar rate to that which is proposed for the main Works.
1.4 At least tow transverse joints and one longitudinal joint of each type that are proposed for un-
reinforced concrete slabs and jointed reinforced concrete slabs in the main Works shall be constructed and
assessed in the trial length. If in the trial length expansion joints are not demonstrated, the first 2
expansion joints and at least the first 150m of longitudinal construction joint for mechanized paving, or
30m for hand guided method of construction laid in the main/works, shall be considered the trial length
for these joints. One construction joint shall be demonstrated in each trial length.
2. Assessment
2.1 The trial length shall comply with the Specification in all respects.
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5.5.7 CONSTRUCTION CENERALLY
1. Concrete shall be handled, placed, compacted and cured in accordance with the relevant
requirements of Section 5.02 “Concrete Handling, Placing and Curing”.
2. Steel reinforcing bars, steel wire fabric, dowel bars and tie bars, shall be handled and fixed in
proper positions in accordance with the relevant requirements of Section 5.03 “Steel Reinforcement and
Fixing”.
3. All concrete shall be placed while fresh. The use of water for re-tempering any concrete will not
be permitted. Any concrete showing improper proportions of materials, including water, shall not be used
in the pavement, and any such unsatisfactory concrete shall be removed and disposed of by the Contractor
at his own expense.
4. Unless otherwise shown on the Drawings, concrete pavement shall be constructed in traffic lane
widths separated by contact joints, or monolithically in multiples of traffic lane widths with a longitudinal
weakened plane joint at each traffic lane line.
5. Concrete shall be spread, shaped, and consolidated so that the completed pavement will conform
to the thickness and cross sections shown on the Drawings. Sides of pavement may be constructed on a
batter not exceeding 1:6 (H:V), provided the top of the pavement is maintained at the specified width.
6. When the pavement being constructed is continuous to an existing parallel concrete pavement,
the elevation of the new pavement surface shall conform as closely as possible to the elevation of the
existing pavement surface and in a manner which will prevent ponding.
7. Pavement shall be constructed using paving equipment which is capable of producing a finished
surface meeting straightedge tolerances. Failure of equipment in this respect will constitute cause for
stopping placement of concrete until equipment deficiency or malfunction is corrected.
5.5.8 STATIONARY SIDE FORM CONSTRUCTION
1. Side form sections shall be straight, free from warps, bends, indentations, or other defects.
Defective forms shall be removed from the Works. Metal side forms shall be used except at end closures
and traverse contact joints where straight forms of other suitable materials may be used.
2. Side forms may be built up by rigidly attaching a section to either top or bottom of forms. If such
build-up is attached to the top of metal forms, it shall be made of metal.
3. Side forms shall be of sufficient rigidity, both in the form and in the interlocking connection with
adjoining forms, that springing will not occur under the weight of equipment for from the pressure of
concrete. The Contractor shall provide sufficient forms so that there will be no delay in placing concrete.
4. Before placing side forms, the base course surface shall be at the proper elevation and grade.
Side forms shall have full bearing upon the base course throughout their length and width of base and
shall be placed to the required grade and alignment of the edge of the finished pavement. They shall be
firmly supported during the entire operation of placing, compaction, and finishing the pavement.
5. Immediately in advance of placing concrete, side forms shall be trued and maintained to the
required line and grade for a sufficient distance ahead to prevent delay in placing concrete.
6. Side forms shall remain in place for 24 hours after placing the concrete, and in all cases until the
edge of the pavement no longer requires the protection of the forms.
7. Side forms shall be thoroughly cleaned and oiled each time they are used and before concrete is
placed against them.
8. Concrete shall be spread, screeded, shaped, and consolidated by one or more machines. These
machines shall uniformly distribute and consolidate concrete without segregation and so that the
completed pavement will conform to the required cross sections with a minimum of handwork. The
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number and capacity of machines furnished shall be adequate to perform the Works required at a rate
equal to that of concrete delivery.
9. Concrete shall be effectively consolidated over the full paving width by means of surface
vibrators, internal vibrators or by other method of consolidation the produces equivalent results without
segregation.
10. When vibrators are used to consolidate concrete, the rate of vibration shall be not less than 3,500
cycles/min for surface vibrators and not less than 5,000 cycles/min for internal vibrators. Amplitude of
vibration shall be sufficient to perceptible on the surface of concrete up to 0.5 m away from the vibrating
element. The Contractor shall furnish a tachometer or other suitable device for measuring and indicating
frequency of vibrations.
11. Vibrators shall not rest on new pavement or side forms. Power to vibrators shall be connected so
that vibration ceases when forward or backward motion of the machine is stopped.
12. When concrete is being placed adjacent to an existing pavement, that part of the equipment
supported on existing pavement shall be fitted with protective pads on crawler tracks or rubber-tired
wheels with the bearing surface offset to run a sufficient distance from the pavement edge to avoid
breaking or cracking such edge.
13. Concrete placed in special situations such as at existing ramp termini, truck weigh stations,
ramps, at connectors with steep grades and high rates of super-elevation, at short section of city streets, on
sharp curves, and in short lengths or in widths other than multiples of traffic lanes, shall be spread and
shaped by any suitable powered finishing machines, supplement by handwork as necessary.
Consolidation of such concrete shall be by means of high frequency internal vibrators and completed
within 15 minutes after it has been placed.
14. Vibrating of concrete placed in special situations shall be done with care and in such manner as
to ensure adequate consolidation adjacent to forms and uniform consolidation across the full paving
width. Use of vibrators for shifting masses or piles of concrete will not be permitted. Methods of
spreading, shaping and compacting that result in segregation, voids or rock pockets shall be discontinued,
and the Contractor shall adopt methods which will produce a dense and homogeneous pavement.
5.5.9 SLIP-FORM CONSTRUCTION
1. Slip-form pavers shall be equipped with traveling side forms of sufficient dimensions, shape and
strength to support the concrete laterally for a sufficient length of time to produce pavement of the
required cross section. Slip-form paving equipment shall spread, consolidate and screed freshly placed
concrete in such a manner that a minimum of handwork will be required to produce a dense homogeneous
pavement.
2. No abrupt changes in longitudinal alignment of the pavement will be permitted. The horizontal
deviation shall not exceed 30mm from the alignment shown on the Drawings
3. Concrete shall be effectively consolidated over the full paving width by means of high frequency
internal vibrators. Vibrators may be mounted with their axes parallel or normal to pavement alignment.
When vibrators are mounted with their axes parallel with the pavement alignment, they shall be spaced at
intervals not exceeding 750 mm measured center to center. When vibrators are mounted with their axes
normal to pavement alignment, they shall be spaced so that lateral clearance between individual vibrating
units does not exceed 150 mm.
4. The vibration rate of each vibrating unit shall be not less than 5,000 cycles/min. Amplitude of
vibration shall be sufficient to be perceptible on the surface of concrete along the entire length of
vibrating units and for a distance up to 0.5m there from. The Contractor shall furnish a tachometer or
other suitable device for measuring and indicating frequency of vibration.
5. When concrete is being placed adjacent to an existing pavement, that part of the equipment
supported on existing pavement shall be fitted with protective pads on crawler tracks or rubber-tired
wheels with the bearing surface offset to run a sufficient distance from the pavement edge to avoid
breaking or cracking such edge.
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5.5.10 CONSTRUCTION OF JOINTS
1. Joints Generally
1.1 Joints in pavement will be designated as longitudinal contact joints, transverse contact joints,
longitudinal weakened plane joints and transverse weakened plane joints. Joints shall be constructed as
and where shown on the Drawings and in accordance with the following requirements.
1.2 All transverse joints shall be constructed at the specified angle to centerline of pavement and the
faces of all joints, both transverse and longitudinal, shall be normal to the face of the pavement.
1.3 Joints shall be maintained clean and free of all soil, sand, gravel, concrete, or asphalt mix and
other foreign material until joint filler material or sealant has been placed.
1.4 Tie bars in previously placed pavement for longitudinal joints shall not be straightened.
2. Contact Joints
2.1 Contact joints are those made by placing fresh concrete against hardened concrete.
2.2 Curing compound shall be applied to the face of each contact joint and allowed to dry prior to
placing fresh concrete against that joint face. This provision is also applicable to existing concrete
pavement not constructed as part of the Works.
3. Weakened Plane Joints
3.1 Longitudinal weakened plane joints shall be constructed at traffic lane lines in multilane
monolithic concrete pavements, by cutting grooves with a power driven saw.
3.2 Transverse weakened plane joints shall be spaced as shown on the Drawings and Special
Specifications but for un-reinforced concrete slabs the spacing of transverse joints shall not exceed 4m
and the length/width ratio shall be not greater than 2:1. This spacing may be increased, with the approval
of the Engineer, by 20% if limestone coarse aggregate is used throughout the depth of the slab. They shall
be constructed by either cutting grooves with a power driven saw of the multiple-bladed span type or by
inserting a plastic strip in the fresh concrete.
3.3 Sawed grooves shall be cut to a minimum depth of 50 mm and a maximum width of 6 mm.
Every fourth transverse weakened plane joint in the initial lane of concrete and also the first joint
immediately after the transverse contact joint shall be sawed within 24 hours after the concrete has been
placed and every second transverse weakened plane joint shall be sawed within 48 hours after placing the
concrete. Sawing should be undertaken as soon as possible after the concrete has hardened sufficiently to
enable a sharp edged groove to be produced without disrupting the concrete and before random cracks
develop in the slab. The minimum and maximum time will depend on site conditions. The exact times for
such sawing shall be designated by the Engineer.
3.4 Unless otherwise shown on the Drawings, the longitudinal and transverse weakened plane joints
in the initial lane of concrete may be sawed at such time, after 24 hours, as the Contractor may elect,
except that they shall be completed before placing concrete in succeeding adjacent lanes and before the
Contractor’s vehicles or public traffic uses the pavement.
3.5 In succeeding lanes of concrete pavement, the transverse joints opposite those which have
opened in the initial lane shall be sawed within 24 hours after the concrete has been placed, the exact time
to be determined by the Engineer, but in all cases not more than 3 consecutive transverse weakened plane
joints shall be omitted.
3.6 The remaining longitudinal and transverse weakened plane joints In succeeding lanes may be
sawed at such time, after 24 hours, as the Contractor may elect, except that they shall be completed before
placing concrete in the succeeding adjacent lanes and before the Contractor’s vehicles or public traffic
uses the pavement.
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3.7 No sawing shall be done where volunteer transverse cracks exist. If a volunteer transverse crack
falls within 2 m of the location of a proposed sawed joint, the sawed joint shall be relocated outside the 2
m zone.
3.8 Unless otherwise shown on the Drawings, insert-type transverse weakened plane joints shall be
formed by placing a continuous strip of plastic or other material which shall not react adversely with the
chemical constituents of the concrete or bond with the concrete. The strip shall have a minimum thickness
of 0.3 mm and a width of 50-55 mm.
3.9 After placement, the vertical axis of the insert-type strip shall be within 13.5 degrees of a plane
normal to the surface of the pavement. The top of the strip shall not be above nor more than 10 mm below
the finished pavement surface. Final alignment of the strip shall be as shown on the Drawings and shall
not vary by more than 30 mm from a 4 m long straightedge.
3.10 Insert-type transverse strips shall be placed by means of a mechanical installation device which
shall vibrate the plastic concrete sufficiently to cause an even flow of concrete about the joint material.
After installation of the strip, the concrete shall be free of segregation, rock pockets or voids and the
finished concrete surface on each side of the joint shall be in the same plane. Splices in the joint strip will
not be permitted.
3.11 The Contractor shall maintain a standby multiple-bladed power driven span type joint saw, in
proper operating condition, on Site at all times while concrete paving operations are underway, regardless
of the type of weakened plane joint being constructed.
3.12 Unless otherwise shown on the Drawings, Insert-type longitudinal weakened plane joints at
traffic lane lines in multilane monolithic concrete pavement shall he formed by placing a continuous strip
of plastic or other material which shall not react adversely with the chemical constituents of the concrete.
The joint insert material shall be of such width and type that when placed vertically in the concrete it will
not bond with the concrete and will form an effective weakened plane joint to 50 mm depth below the
finished surface of the concrete. The joint material shall not be deformed from a vertical position, either
in the installation or in subsequent finishing operations performed on the concrete.
3.13 Alignment of the finished longitudinal joint shall be uniformly parallel with the centerline of the
pavement and shall be free of any local irregularity which exceeds 12 mm measured by a 4 m long
straightedge, except for normal curvature of centerline. The mechanical installation devices shall vibrate
the concrete during placing of the strip sufficient to cause the concrete to flow evenly about the joint
material, producing homogeneous concrete free of segregation and pockets or voids.
5.5.11 CONCRETE SURFACE FINISHING
1. Preliminary Finishing Generally
1.1 Prior to completion of float finishing and texturing, water shall not be applied to the pavement
surface in excess of the amount lost by evaporation.
1.2 Placement of concrete shall cease in sufficient time to enable finishing operations to be
completed during daylight hours, unless lighting facilities provided by the Contractor are approved as
adequate for allowing later placement and finishing.
1.3 Preliminary finishing procedures to be adopted will depend on whether side forms or slip-forms
are being used.
2. Stationary Side Form Preliminary Finishing
2.1 After spreading and compacting, concrete shall be given a preliminary finish by either machine
float or hand methods, as directed. Hand methods shall normally only be permitted in the event of minor
breakdown of the machine float or other emergency. A standby machine float shall be made available by
the Contractor, if the Engineer deems such provision necessary to avoid undue delays.
2.2 In the case of the machine float method, self-propelled machine floats shall be used to finish the
surface smooth and true to grade. The number and capacity of machine floats furnished shall be adequate
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to perform all finishing required at a rate equal to that at which concrete is delivered. Any delay
exceeding 30 minutes in performing preliminary finishing shall constitute cause for stopping delivery of
concrete until machines performing such Work are again in proper position to continue without delay.
2.3 Machine floats shall be capable of running either on side forms or on adjacent lanes of
pavement. When machine floats run on adjacent pavement, the concrete surface shall be protected as
specified under “Stationary Side Form Construction”.
2.4 Floats shall be constructed of hardwood, steel, or steel-shod wood and shall be equipped with
devices to permit adjustment of the underside to a true flat surface.
2.5 In the case of hand methods, the surface shall be finished smooth and true to grade with suitable
manually operated floats or powered finishing machines. Finishing shall take place as far back from
concrete spreading operations as concrete remains workable. The number of finishing passes shall be
sufficient to remove all perceptible inequalities.
3. Slip-Form Preliminary Finishing
3.1 The surface shall be given a preliminary float finish by means of devices incorporated in the
slip-form paver. These may be supplemented, at the Contractor’s option, with suitable machine floats.
3.2 Any edge slump of pavement, exclusive of edge rounding, in excess of 5 mm, shall be corrected
before concrete has hardened.
4. Final Finishing
4.1 After preliminary finishing has been completed, edges of initial paving widths shall be rounded
to 12 mm radius. Transverse contact joints, expansion joints, and the edge of longitudinal contact joints
adjacent to hardened concrete pavement, shall be rounded to 6 mm radius.
4.2 In advance of curing operations, pavement shall be given an initial and a final texturing. Initial
texturing shall be performed with a burlap drag or broom device which will produce striations normally
parallel with the pavement centerline. Final texturing shall be performed with a spring steel tine device
which shall produce grooves parallel with the centerline unless otherwise directed. The steel tine shall not
operate closer than 75 mm to the pavement edge.
4.3 Except when texturing areas of pavement finished using hand methods, burlap drags, brooms,
and tine devices shall be installed on self-propelled equipment having external alignment control. The
installation shall be such that when texturing, the area of burlap in contact with the pavement surface shall
be maintained constant at all times.
4.4 Broom and tine devices shall be provided with positive elevation control. Down pressure on
pavement surface shall be maintained at all times during texturing so as to achieve uniform texturing
without measurable variations in pavement profile. Self-propelled texturing machines shall be operated so
that travel speed when texturing is maintained constant.
4.5 Failure of equipment to conform to the above requirements will constitute cause for stopping
placement of concrete until the equipment deficiency or malfunction is corrected.
4.6 Spring steel tines of the final texturing device shall be rectangular in cross section, 3-4 mm wide,
20 mm center-to-center and of sufficient length, thickness and resilience to form grooves approximately 5
mm deep in the fresh concrete surface. Final texture shall be uniform in appearance with all grooves
having a depth of 2-5 mm. This texture pattern shall be adopted unless otherwise shown on the Drawings.
4.7 Finished pavement shall be checked by the Engineer not more than 10 days following placement
of the concrete, to verify that it conforms to correct lines, grades and cross sections.
4.8 When the finished surface is tested with a 4 m long straightedge, placed parallel to, or at right
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4.9 All high points which exceed the specified tolerances shall be corrected by grinding as directed.
4.10 The Contractor shall obtain drilled 100 mm diameter cores from the completed pavement, at
locations selected by the Engineer, to verify compliance with the thickness requirements. The Contractor
shall fill all core holes with fresh concrete and finish the surface neatly to match the surrounding concrete.
5.5.12 CURING PROCEDURES
1. Curing Procedures Generally
1.1 Immediately the finishing process is complete, the entire exposed area of the pavement,
Including edges, shall be cured by the curing compound method unless approval is given for water curing.
1.2 When the side forms are removed before the expiration of 72 hours following the start of curing,
the exposed pavement edges shall also be cured. If the pavement is cured by means of the curing
compound method, the saw cut and all portions of the curing compound which have been disturbed by
sawing operations shall be restored by spraying with additional curing compound.
1.3 When the ambient temperature is above 25 degrees C and whenever deemed necessary by the
Engineer, cooling of the concrete with a fine spray of water shall be continued after curing seal is applied,
until the Engineer determines that a cooling effect is no longer required.
2. Curing Compound Method
2.1 Surfaces of the concrete which are exposed to the air shall be sprayed uniformly with an
approved curing compound as specified in Section 5.02 “Concrete Handling, Placing and Curing”.
2.2 Unless otherwise shown on the Drawings, the application rate shall be 0.25 ltr/m2 At any point
the application rate shall be within 20% of the specified application rate and the average application rate
shall be within 10% of the specified application rate. Runs, sags, thin areas, skips, or gaps in the applied
curing compound shall be evidence that the application is unsatisfactory.
2.3 Curing compound shall be applied using approved mechanical sprayers of the fully atomizing
type, equipped with a tank agitator which shall provide for continual agitation of the curing compound
during application. The power operated spraying equipment shall be equipped with an operational
pressure gage and a means of controlling the pressure.
2.4 The spray shall be adequately protected against wind and the nozzles shall be so oriented or
moved mechanically transversely as to result in not less than the minimum specified rate of coverage
uniformly on all exposed faces.
2.5 Hand spraying of small and irregular areas and areas inaccessible to mechanical spraying
equipment will be permitted.
2.6 The curing compound shall be applied before any drying shrinkage or craze cracks begin to
appear. In the event of any drying or cracking of the surface, application of water with an atomizing
nozzle shall be started immediately and shall be continued until application of the compound is resumed
or started. The compound shall not, however, be applied over any resulting free standing water.
2.7 Should the film of compound be damaged from any cause before the expiration of 7 days after
the concrete is place, the damaged portion shall be repaired immediately with additional compound.
3. Water Curing Method
3.1 When water curing is permitted, the concrete shall be kept continuously wet by the application
of water for a minimum period of 7 days after the concrete has been placed. Cotton mats, rugs, carpets, or
earth or sand blankets may be used as a curing medium to retain to moisture during the curing period.
3.2 When cotton mats, rugs, carpets, or earth or sand blankets are to be used as a curing medium to
retain moisture, the entire surface of the concrete shall be kept damp by applying water with a nozzle that
so atomizes the flow that a mist and not a spray is formed, until the surface of the concrete is covered
with the curing medium
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3.3 The moisture from the nozzle shall not be applied under pressure directly upon the concrete and
shall not be allowed to accumulate on the concrete in a quantity sufficient to cause a flow or wash the
surface. At the expiration of the curing period, the concrete surfaces shall be entirely cleared of curing
medium.
3.4 When the concrete is to be water cured without the use of a moisture retaining medium, the
entire surface of the pavement shall be kept damp by the application of water with the atomizing nozzle,
until the concrete has set, after which the entire surface of the concrete shall be sprinkled continuously
with water for a period of not less than 7 days.
5.5.13 DETERMINATION OF CONCRETE THICKINESS
1. Thickness of Concrete pavement shall be determined by average caliper measurement of cores,

rounded upwards taken to the nearest mm.
2. pavement sections to be measured separately shall consist of each 300 linear m section in each
traffic lane. The last section in each traffic lane shall be 300 m plus the fractional part of 300 m
remaining. Other areas such as intersections, entrances, crossovers, ramps, etc shall be measured as one
section each and the thickness of each shall be determined separately. Small irregular unit areas may be
included as part of another section,
3. One core shall be taken from each section by the Contractor at approved locations and in the
presence of the Engineer. When the measurement of the core from any pavement section is not deficient
by more than 5 mm form the specified thickness, the core will be deemed to be of the specified thickness
as shown on the Drawings.
4. When the measurement of the core from any pavement section is deficient by more than 5mm
but not more than 20 mm, 2 additional cores spaced at not less than 100 mm shall be taken and used
together with the first core to determine the average thickness of such section.
5. When the measurement of the core from any pavement section is less than the specified
thickness by more than 20 mm, the average thickness of such section shall be determined by taking
additional cores at not less than 5m intervals parallel to the centerline in each direction from the affected
location Until, in each direction, a core is taken which is not deficient by more than 20 mm. Exploratory
cores for deficient thickness will not be used in average thickness determinations.
6. Where the average thickness of concrete pavement is deficient by more than 5 mm but not more
than 20 mm adjustments shall be made in the area measurements as shown in Table 5.14.
Table 5.14: Concrete Thickness Deficiency

Deficiency in Thickness as Determined by Cores
Proportion of Area Measured for Payment
(mm)
0.0 to 5.0 100%
5.1 to 10.0 90%
10.1 to 15.0 75%
15.1 to 20.0 50%
7. When the pavement is more than 20 mm deficient in thickness, the Contractor shall remove such
deficient areas and replace them with concrete pavement of the specified quality and thickness, all at his
own expense.
8. When the limits of a deficient area to be removed and replaced are within 3 m of an expansion,
contraction or construction joint, the entire concrete pavement up to the joint shall be removed and
replaced at the Contractor's expense.
9. If approved, and provided the pavement section is not deficient by more than 25mm, the
Contractor may leave the deficient concrete pavement in place, in which case no measurement for
payment shall be made of such section.
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5.5.14 MEASUREMENT
1. Un-reinforced concrete (URC), jointed reinforced concrete (JRC) and Continuously reinforced
concrete (CRC) of different thickness pavements shall be measured by m2 of concrete pavement
constructed, including furnishing of all materials, placing, jointing, finishing and curing concrete,
completed, and accepted. Measurements shall be of the surface area dimensions as shown on the
Drawings, adjusted for thickness deficiencies as specified.
2. Successful trial lengths of URC, JRC or CRC Pavements shall be measured by the square meter
and be paid for under the appropriate type of concrete pavement. Unsuccessful trial lengths shall not be
measured for payment.
3. Base course surface preparation, furnishing and installing moisture barrier, excavation for
thickened portions of pavement, cutting of cores from the finished pavement for testing or measurement
purposes, and additional thickness of concrete in excess of the specified thickness, shall not be measured
for direct payment, but shall be considered as subsidiary Works the costs of which will be deemed to be
included in the Contract Prices for Pay Items.
PAY ITEMS UNIT OF MEASUREMENT

(1) Un-reinforced Concrete
Pavement (URCP) Square meter (m2)
(State thickness)
(2) Jointed reinforced Concrete

Pavement (JRCP) Square meter (m2)
(State thickness)
(3) Continuously reinforced Concrete

Pavement (CRCP) Square meter (m2)
(State thickness)
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PLAIN & REINFORCED CONCRETE STRUCTURES SECTION 5.6
SECTION 5.6 : PLAIN AND REINFORCED CONCRETE

STRUCTURES
5.6.1 SCOPE
1. This Section of the Specification describes the construction of plain and reinforced concrete
structures.
5.6.2 MATERIALS
1. Concrete
1.1 Concrete shall be produced and supplied in accordance with Section 5.01 “Concrete and
Concrete Mixes and Testing”.
2. Reinforcement
Reinforcement shall conform to Section 5.03 “Steel Reinforcement and Fixing”.
3. Formwork and Falsework
3.1 Formwork and Falsework shall be designed and supplied in accordance with Section 5.04
“Forms, Formwork and Falsework”.
4. Plant and Equipment
4.1 Plant and Equipment shall conform to Section 1.12 “Contractor’s Plant and Equipment” and
shall be according to the type and number outlined in the Contractor’s detailed Program of Work as
5.6.3 CONSTRUCTION
1. General
1.1 The Contractor shall notify the Engineer his intention to concrete at least 24 hours in advance.
1.2 The Engineer shall check and certify that:
1.2.1 The form and formwork meet the Specification requirements
1.2.2 The falsework and support props are in accordance with the approved Drawings
1.2.3 The reinforcement conforms to the Drawings and that the correct covers have been
provided
1.2.4 The forms are free of dirt and other deleterious matter.
2. Concreting
2.1 Handling, placing and curing shall be in accordance with Section 5.02 “Concrete Handling,
Placing and Curing”.
3. Slump
3.1 Slump shall be within the limits given in Section 5.02 of the Specification except that the
maximum slump of bridge deck shall be 75 mm unless otherwise agreed by the Engineer.
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4. Construction and Expansion Joints
4.1 Whenever the work of placing concrete is delayed until the concrete shall have taken its initial
set, the point of stopping shall be deemed a construction joint. So far as possible the location of
construction joints shall be as shown on the Drawings, but if not shown on the Drawings, they shall be
planned in advance and the placing of concrete carried out continuously from joint to joint. The joints
shall be perpendicular to the principal lines of stress and in general be located at points of minimum
shear.
4.2 Where dowels, reinforcing bars or other adequate ties are not required by the Drawings, keys
shall be made by embedding water soaked beveled timbers in soft concrete. The key shall be sized as
shown on the details, or as directed by the Engineer, which shall be removed when the concrete has set. In
resuming work the surface of the concrete previously placed shall be thoroughly cleaned of dirt, scum,
laitance or other soft material with stiff wire brushes, and if deemed necessary by the Engineer, shall be
roughened with a steel tool. The surface shall then be thoroughly washed with clean water and pointed
with a thick coat of neat cement mortar, after which the concreting may proceed.
4.3 Expansion joints shall be constructed at the locations, of the materials and to the dimensions
5. Cold joints
5.1 When the continuous placement of concrete in any structural member is interrupted or delayed,
for any reason, for a period long enough for the previously partially placed concrete to take its initial set,
the Engineer may declare such a joint a cold joint in which case the Contractor shall immediately remove
the previously partially placed concrete from the forms. No extra payment will be made for the initial
placement or the removal of concrete which is wasted because of a cold joint. The Engineer may suspend
all or any part of the subsequent concrete work until he deems the Contractor has corrected the cause for
the cold joint occurrence.
5.2 The Engineer may, with due consideration to the location of the cold joint and/or the importance
of the member, allow the Contractor to retain the partially placed concrete and complete the concreting by
a subsequent pour, for which permission the Engineer shall instruct the Contractor to carry out at his own
expense some or all of the following measures before completing the pour:
5.2.1 Surface laitance shall be removed from the surface of the partially placed concrete by
wire brushing or light tooling or by sand blasting as directed by the Engineer without damage to
reinforcement and formwork.
5.2.2 Shear keys shall be cut in the partially placed concrete. The shape, size and orientation
of the shear keys shall be as directed by the Engineer. The reinforcement and formwork shall not
be damaged.
5.2.3 The cleaned surface of the partially placed concrete shall be coated with an approved
bonding agent before placing the subsequent pour.
5.2.4 Additives to facilitate bonding shall be added to the concrete used for the subsequent
pour.
5.2.5 Dowel bars of a type and length to be approved by the Engineer shall be installed in the
partially placed concrete using non-shrink cement grout or resin grout as directed by the
Engineer. The size and spacing of the dowel bars shall be approved by the Engineer. Their
installation shall not damage the reinforcement or formwork.
5.2.6 The partially placed concrete and the subsequent concrete shall be stressed by pre-
stressing bars of a size and type approved by the Engineer to achieve a level of compressive
stress at the interface approved by the Engineer. The method of installing the pre-stressing bars
and type of anchors used shall be approved by the Engineer. Unless otherwise agreed by the
Engineer, the drill hole shall be grouted with a cement grout containing expanding additive to
the manufacturer's recommendations.
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6. Finishing
6.1 Unless otherwise noted in the Drawings or provided for in the Special Specification, the
following classes of finishes shall be used for formed surfaces:
6.1.1. Pre-cast parapets, cladding panels, New Jersey barriers, wall copings etc, which form
architectural features ……………………...…………….… Class F1.
6.1.2 Exposed faces of retaining walls, abutments, piers, columns, bridge deck, box culvert
etc., which are not in contact with earth and which can be seen
……………………………………………………………… Class F2.
6.1.3 Backs of retaining walls and solid abutments, outer faces of box culverts, faces of
abutment columns and bottom of band seats for spill-through abutments, plinths for columns,
piers, lighting masts and sign gantries etc., which are generally in permanent contact with earth
………………...……………………………………………. Class F3.
6.1.4 Inner faces of box girders, cellular deck slabs, cellular bases and pile caps etc., which
are not in contact with earth and which are not visible………Class F3.
6.1.5 Sides of bases, footings, pile caps etc., which are to be permanently below final ground
level………………………………...…………………..……..Class F4.
6.2 Unless otherwise noted in the Drawings or provided for in the Special Specification, the
following classes of finishes shall be used for unformed surfaces:
6.2.1 Top of bases, footings, pile caps, box culvert roof etc, which are to be
backfilled……………………………………………………Class U1.
6.2.2 Top of walls, slabs etc, which are to receive coping or tiling
………………………………………………………………Class U2.
6.2.3 Top of box culvert bottom slab, apron slab of box culvert and top of walls and slabs
which are to be exposed ………………………..………….Class U3.
6.3 Finish to bridge decks that are to receive an approved waterproof system shall first be finished to
Class U1. Then, when the concrete has sufficiently handed to prevent laitance being worked to the surface
it shall be floated to produce a uniform surface free from screed marks and exposed aggregate. Finally the
surface shall be textured by brushing or otherwise to the waterproofing manufacturer’s requirements as
agreed by the Engineer. The accuracy of the finished surface shall be such that it does not deviate from
the required profile by more than 10 mm over a 3 m gage length or have any abrupt irregularities more
than 3 mm.
6.4 Surfaces, other than bridge deck, which are to receive approved waterproofing systems shall be
finished to Class U2, unless noted otherwise in the Drawings.
7. Concrete Cover to Reinforcement
7.1 The cover shall be not less than the size of the bar or the maximum aggregate size plus 5 mm. in
the case of bundled bars, it shall be equal to or greater than the size of a single bar of equivalent area plus
5 mm.
7.2 Where surface treatment such as grooved finish or bush hammering cuts in to the face of the
concrete, the expected depth of the treatment shall be added to the cover.
7.3 The cover to reinforcement should also be determined by considerations of durability under the
envisaged conditions of exposure. The cover of dense natural aggregate concrete to all reinforcement,
including links, shall be not less than the value given in Table 5.15 for particular classes of concrete and
conditions of exposure. In addition, it may be necessary to specify concrete mix details to provide the
required durability.
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Table 5.15: Cover to reinforcement under particular conditions of exposure

Cover** (mm)
Concrete class
Environment Example
50 and
25 30 40
Over
Extreme + + 65* 55
Concrete surfaces exposed to:
abrasive action by sea water Marine structures
water with a pH 4.5 Parts of structure in contact with

or
brackish water
Very Severe + ++ 50* 40

Concrete surfaces directly
de-icing salts Walls and structure supports
affected by:
adjacent to the carriageway Parapet
edge beams
or sea water spray Concrete adjacent to the sea
Severe + 45* 35 30
Concrete surfaces exposed to:
driving rain Wall and structure supports remote
from the carriageway
or alternate wetting and drying Bridge deck soffits Buried parts of

structures
Moderate 45 30 30 25
Concrete surfaces above ground
level and fully sheltered all of
the following:
rain, Surface protected by bridge
de-icing salts, deck waterproofing or by
sea water spray permanent formwork
Interior surface of
pedestrian subways, voided
superstructures or cellular
abutments
Concrete surfaces permanently Concrete permanently under
saturated by water with a pH water
exceeding 4.5
** Actual cover may be up to 5 mm less

+ Concrete grade not permitted
* Air entrained concrete should be specified where the surface is liable to freezing whilst wet
++ For parapet beams only grade 30 concrete is permitted provided it is air entrained and the cover
is 60mm.
8. Tolerances
8.1 In-Situ Construction
8.1.1 Length: The horizontal and vertical dimensions of in-situ concrete members, but not
cross-sections, shall be within the following tolerances:
Length (mm) Tolerance (mm)

Up to 3000 8
3001-4500 10
4501-6000 15
Additional for every
subsequent 5000 mm 5 mm
5-53
8.1.2 Cross-Section: Slab and wall thicknesses and the cross-sectional dimensions of
beams, columns, piers etc., shall be within the following tolerances:
Member dimensions (mm) Tolerance(mm)

Up to 500 6
501-750 10
8.2 Pre-cast construction
8.2.1 Length: The horizontal and vertical dimensions of members, but cross-sections, shall
be within the following tolerances:
Length (mm) Tolerance (mm)

Up to 3000 6
3001-4500 9
4501-6000 12
8.2.2 Cross Section: Slab and wall thicknesses and the cross sectional dimensions of
beams, columns, piers etc., shall be within the following tolerances.
Member dimensions (mm) Tolerance (mm)

Up to 500 6
501-750 9
8.3 Squareness
8.3.1 For in-situ and pre-cast construction the tolerance between the short side and the long
side shall be within the following limits:
Member Size (mm) Tolerance (mm)

Up to 1200 6
1201-1800 9
Above 1800 10
8.4 Straightness
8.4.1 For in-situ and pre-cast construction the straightness or bow, defined as deviation form
the intended line, shall be within the following tolerances.
Member Length (mm) Tolerance (mm)

Up to 3000 6
3001-6000 9
6001-1200 12
subsequent 6000 mm + or - 6 mm.
8.5 Alignment
8.5.1 The alignment of members shall be within the following tolerances:
Column and piers. 1:400 of column or pier length.
Others. 1:600 of length.
5-54

Jordan-General Specifications - Part1

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Part ( 1 ) :

SECTION 1.1 : FORMAT AND REFERENCING

SECTION 1.2 : ABBREVIATIONS AND DEFINITIONS

2. Tiles and Terms

AASHTO - American Association of State Highway and Transportation

gal (Imp) - gallon/s (Imperial)

APPROVED – Approved in writing by the Engineer, including subsequent written approval or

CERTIFICATE OF GUARANTEE – A signed statement by a person having legal authority to bind a

DIRECTED – Directed in writing by the Engineer, including subsequent written direction or

SUPPLEMENTAL SPECIFICATIONS – Revisions to the Standard Specifications.

SECTION 1.3 : SCOPE AND CONTROL OF WORKS

1.3.2 SILENCE OF SPECIFICATIONS

1.3.3 CONTRACTOR’S WORK AREAS

1.3.4 WATER SUPPLY

1.3.5 ELECTRICITY SUPPLY

1.3.6 EXISTING UTILITIES AND OTHER OBSTRUCTIONS

1.1 Obstructions shall be classified as follows:

1.3.7 SIGN BOARDS

1.3.8 TEMPLATES AND STRAIGHT EDGES

1.3.9 SURVEYING EQUIPMENT

1.3.10 SETTING OUT OF WORKS

1.3.11 HAUL ROUTES FOR HEAVY VEHICLES

1.3.12 SCAFFOLDING AND FALSEWORK

1.3.13 USE OF EXPLOSIVES

1.3.14 FIRE FIGHTING EQUIPMENT

4. All equipment shall be regularly tested and properly maintained.

1.3.15 PHOTOGRAPHIC RECORDS OF CONSTRUCTION

1.3.16 SITE CLEANING AND FINAL CLEAN UP

1. Site Cleaning During Progress of Works

2. Final Clean Up on Completion

1. Realignment of utilities as prescribed in Clause 2 of Sub-Section 1.03.6 shall be entered as a

PAY ITEM UNIT OF MEASUREMENT

SECTION 1.4 : TEMPORARY WORKS

1.4.2 DESIGN REQUIREMENTS

1.4.3 AGREEMENT OF PROPERTY OWNERS

1.4.4 PHASED PROGRAM

SECTION 1.5 : CONTROL OF MATERIALS & STANDARDS

1.5.2 HANDLING MATERIALS

1.5.3 MATERIALS SUPPLIED BY EMPLOYER

1.5.4 LOCAL MATERIAL SOURCES

1.5.5 SOURCES OF SUPPLY AND QUALITY REQUIREMENTS

1.5.6 CERTIFICATES OF GUARANTEE AND PRODUCTION PLANT

1. Certificates of Guarantee & Test Certificates

1.1 All shipments of materials shall be accompanied by a Manufacturer’s Certificate of Guarantee or

1.5.7 SAMPLING AND TESTING PROCEDURES

3. Job Control Tests

4. Project Control Tests

1.5.8 SAMPLING AND TESTING STANDARDS

1.1.1 AASHTO Standard Specifications for Transportation Materials and Methods of

1.1.3 Relevant Standards (those referred to in the Specification)

1.1.4 British Standard.

2. Precedence of Materials and Testing Specifications

1.5.9 UNACCEPTABLE MATERIALS

SECTION 1.6 : SUPERVISION STAFF OFFICES, HOUSING AND

1. If required in the Special Specification, he Works shall consist of the following:

1.6.2 SITE FOR SUPERVISION STAFF BUILDING

1.6.3 SUPERVISION STAFF BUILDING

1.6.4 PURCHASE AND DELIVERY OF MOBILE HOMES

SECTION 1.7 : FIELD CONTROL LABORATORY

T – 204 Density of Soil In-Place by the Drive Cylinder Method.

2.1 U.S. Standard 12 inch (0.30m) diameter brass sieves.

2.2 U.S. Standard 8 inch (0.20m) diameter brass sieves.