SECTION N - EXTERNAL WORKS

SECTION N.1 - ROADS AND HARDSTANDING

1. General

1.1 The construction of roads and hardstanding shall generally be carried out only after
completion of all drainage systems, services and ducts which may affect the Works,
unless otherwise agreed by the S.O.

2. Subgrade

2.1 Material for the top 300mm of subgrade shall have a minimum soaked laboratory
California Bearing Ratio (CBR) of 5% when compacted to 95% of the maximum dry
density determined in the BS 1377 Compaction Test (4.5 kg Heavy Rammed Method).

2.2 Throughout the top 300mm of subgrade, the materials shall be compacted to not less
than 95% of the maximum dry density determined in the BS 1377 Compaction Test (4.5
kg Heavy Rammed Method).

2.3 In cut area, the top 300mm of the subgrade shall be scarified and recompacted to 95% of
the maximum dry density determined in the BS 1377 Compaction Test (4.5 kg Heavy
Rammed Method). If the S.O. is fully satisfied that the subgrade in its natural state
possesses a density exceeding the requirements, then the surface of the subgrade shall
be trimmed and rolled to obtain a smooth finish.

2.4 Where the material in cut area is found to be unsuitable for use in the top 300mm of
subgrade or to a suitable level to be determined by the S.O., it shall be removed and
replaced with suitable material which shall be compacted as indicated above.
Alternatively, stabilizing agent may be used subjected to the S.O. approval.

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

i. Where rock surfaces extend over the whole width of the formation:

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

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

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

The rock outcrop shall be cut down to at least the formation level.

3. Lower Subbase

3.1 Where shown or stated in the Drawings, this work shall consist of furnishing, placing,
compacting and shaping lower subbase material on a prepared and accepted subgrade

N/1

External Works
 in accordance with this Specification and the lines, levels, grades, dimensions and cross-
sections shown in the Drawings and/or as required by the S.O.

3.2 The lower subbase material shall be of inorganic soil, sand, gravel, weathered or
fragmented rock, or a mixture of any of these materials, essentially free from vegetative
and other organic matter.

3.3 Prior to placing any lower subbase material, the underlying subgrade (particularly the top
300mm of the subgrade) shall have been shaped and compacted in accordance with the
provisions of subsection 2. Notwithstanding any earlier approval of finished subgrade,
any damage to or deterioration of the subgrade shall be made good to the satisfaction of
the S.O. before the lower subbase is constructed.

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

Each layer of lower subbase shall be processed as necessary to bring its moisture
content to a uniform level throughout the material suitable for compaction, and shall then
be compacted using suitable compaction equipment approved by the S.O. to not less
than 95% of the maximum dry density determined in the BS 1377 Compaction Test (4.5
kg Heavy Rammer Method). Compaction shall be carried out in a longitudinal direction
along the formation and shall generally begin at the outer edge and progress uniformly
toward the crown on each side in such a manner that each section receives equal
compactive effort, all to the satisfaction of the S.O.

The lower subbase shall be finished in a neat and workmanlike manner, and its average
thickness over any 100-metre length shall not be less than the required thickness. The
top surface of the lower subbase shall have the required shaped, superelevation, levels
and grades and shall be everywhere within the tolerances specified in subsection 8.

4. Subbase

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

4.2 The subbase material shall be of a natural or prepared aggregate comprising crushed
rock, weathered or fragmented rock, gravel or crushed gravel, sand, or a mixture of any
of these materials. The gradation of the material shall conform to one of the envelopes
shown in Table 1.

N/2

External Works
 TABLE 1 - GRADATION LIMITS FOR SUBBASE MATERIAL

BS Sieve % Passing by Weight

Size
A B C D E F

50.0 mm 100 100 - - - -

25.0 mm - 79-95 100 100 100 100
9.5 mm 30-65 40-75 50-85 60-100 - -
4.75 mm 25-55 30-60 35-65 50-85 55-100 70-100
2.0 mm 15-40 20-45 25-50 40-70 40-100 55-100
425 μm 8-20 15-30 15-30 25-45 20-50 30-70
75 μm 2-8 5-20 5-20 5-20 6-20 8-25

4.3 Prior to placing of any subbase material, the underlying subgrade (particularly the top
300mm of the subgrade) or lower subbase shall have been shaped and compacted in
accordance with the provisions of subsection 2 or subsection 3.3 as appropriate.
Notwithstanding any earlier approval or finished subgrade or lower subbase, any damage
to or deterioration of the subgrade or lower subbase shall be made good to the
satisfaction of the S.O. before the subbase is constructed.

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

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

Throughout the placing, adjustment of moisture content and compaction of subbase

material, care shall be taken to maintain a uniform gradation of the material and prevent
its separation into coarse and fine parts, all to the satisfaction of the S.O.

The subbase shall be finished in a neat and workmanlike manner; its width shall be
everywhere at least of that specified or shown in the Drawings on both sides of the
centreline; and its average thickness over any 100-metre length shall not be less than the
required thickness. The top surface of the subbase shall have the required shape,
superelevation, levels and grades, and shall be everywhere within the tolerances
specified in subsection 8.

5. Crushed Aggregate Base Course

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

5.2 The crushed aggregate base course material shall be of crushed rock, or crushed gravel,
or a mixture of crushed and natural aggregate, which is hard, durable, clean and

N/3

External Works
 essentially free from clay and other deleterious materials.
The material shall conform to the following physical and mechanical quality requirement: -

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

ii) The aggregate crushing value when tested in accordance with MS 30 shall be
not more than 30;
iii) The flakiness index when tested in accordance with MS 30 shall be not more
than 30;
iv) The gradation shall comply with the envelope shown in Table 2 for the type
specified.

TABLE 2 GRADATION LIMITS FOR

CRUSHED AGGREGATE ROAD BASE

BS Sieve % Passing by Weight

Size
Type 1 Type 11

50.0mm 100 100

37.5mm 95 - 100 85 - 100
28.0mm - 70 - 100
20.0mm 60 - 80 60 - 90
10.0mm 40 - 60 40 - 65
5.0mm 25 - 40 30 - 55
2.36mm 15 - 30 -
2.00mm - 20 - 40
600μm 8 - 22 -
425μm - 10 - 25
75μm 0-8 2 - 10

5.3 Prior to the placing of any crushed aggregate base course material, the underlying
subgrade or lower subbase or subbase shall have been shaped and compacted in
accordance with the provisions of the appropriate section of this Specification.
Notwithstanding any earlier approval of finished subgrade or lower subbase or subbase,
any damage to or deterioration of the subgrade or lower subbase or subbase shall be
made good to the satisfaction of the S.O. before crushed aggregate base course is
constructed.

The crushed aggregate base course shall be placed to the required width and thickness
as shown in the Drawings or directed by the S.O. in one layer or more, each layer not
exceeding 200mm compacted thickness. Where two or more layers are required, they
shall be of approximately equal thickness and none shall be less than 100mm compacted
thickness. Spreading shall be done by a mechanical spreader approved by the S.O. or, if
approved by the S.O., by a motor grader.

Prior to spreading, crushed aggregate base course shall be processed as necessary to

bring its moisture content to a uniform level throughout the material suitable for
compaction. Spread material shall be maintained at the correct moisture content for
proper compaction by sprinkling with water or drying as may be necessary, and shall be
compacted using suitable compaction equipment approved by the S.O. to not less than
95% of the maximum dry density determined in the BS 1377 Compaction Test (4.5 kg
Heavy Rammer Method).

Compaction shall be carried out in a longitudinal direction along the carriageway, and
shall generally begin at the outer edge and progress uniformly toward the centre of each
side, except on superelevated curves where rolling shall begin at the lower edge and

N/4

External Works
 progress uniformly toward the higher edge. In all cases, compaction shall be carried out
in such a manner that each section receives equal compactive effort, all to the
satisfaction of the S.O.

Throughout the placing, adjustment of moisture content and compaction of crushed

aggregate road base material, care shall be taken to maintain a uniform gradation of the
material and prevent its separation into coarse and fine parts, all to the satisfaction of the
S.O.

The material shall have a CBR value of not less than 80 when compacted to 95% of the
maximum dry density determined in the BS 1377 Compaction Test (4.5 kg Heavy
Rammer Method) and soaked for 4 days under a surcharge of 4.5 kg.

The crushed aggregate base course shall be finished in a neat and workmanlike manner;
its width shall be everywhere at least of that specified or shown in the Drawings on both
sides of the centrelines; and its average thickness over any 100-metre length shall not be
less than the required thickness. The top surface of the crushed aggregate base course
shall have the required shape, superelevation, levels and grades and shall be
everywhere within the tolerances specified in subsection 7.2.

6. Binder and Wearing Course

6.1 Asphaltic Concrete

Unless otherwise shown in the Drawings, this work shall consist of furnishing, placing,
shaping and compacting asphaltic concrete wearing course on a prepared and accepted
bituminous or bitumen primed pavement courses immediately after the application of a
tack coat. The materials shall be supplied in accordance with JKR Specification No.JKR
20401-0029-97 and laid in accordance with the Guidelines for The Laying of Asphaltic
Concrete as described in the same Specification, and to the lines, levels, grades,
dimensions and cross-sections shown in the Drawings and/or as required by the S.O.

6.2 Bituminous Macadam

Unless otherwise shown in the Drawings, this work shall consist of furnishing, placing,
shaping and compacting bituminous Macadam wearing course on a prepared and
accepted bituminous or bitumen primed pavement course immediately after the
application of a tack coat. The materials shall be supplied in accordance with JKR
Specification No.JKR 20401-0030-97 and laid in accordance with the Guidelines for The
Laying of Bituminous Macadam as described in the same Specification, and to the lines,
levels, grades, dimensions and cross-sections shown in the Drawings and/or as required
by the S.O.

7. Horizontal Alignment, Surface Levels and Surface Regularity of Pavement Courses

7.1 Horizontal Alignment

The horizontal alignment shall be determined from the centreline of the pavement surface
shown in the Drawings. The edges of the pavement as constructed and all other parallel
construction lines shall be correct within a tolerance of + 50mm and - 0mm from the
centreline. Kerbs, channel blocks and edge lines shall be laid with a smooth alignment
within a tolerance of + 25mm and - 0mm from the centreline.

7.2 Surface Levels of Pavement Courses

The design levels of pavement courses shall be calculated from the vertical profile, cross
fall and pavement course thickness shown in the Drawings. The level of any point on the

N/5

External Works
 constructed surface of a pavement course shall be the design level subject to the
appropriate tolerances given in Table 3.

TABLE 3 - TOLERANCES IN SURFACE LEVELS OF PAVEMENT COURSES

Pavement Course Tolerance

Wearing Course ± 5mm

Binder ± 5mm

Road base + 0mm

- 20mm

Subbase and Lower Subbase + 10mm

- 20mm

The combination of permitted tolerances in the levels of different pavement courses shall
not result in a pavement thickness less than that shown in the Drawings. Each pavement
course shall have an average thickness not less than that shown in the Drawings.

N/6

External Works