Part-1-Road Works - Rev

PROJECT:
CONSULTANCY SERVICES FOR ENTRY JUNCTION

MODIFICATION AND UTILITIES TIE-IN FOR MARSA AL
ARAB DEVELOPMENT
TENDER DOCUMENTS
VOLUME 2 – PART 1
STANDARD SPECIFICATIONS
ROAD WORKS
Employer:
NORTH25
P.O. Box 112288
Dubai – U.A.E.
October 2021
VOLUME 2
Standard Specifications
CONSULTANCY SERVICES FOR ENTRY JUNCTION

MODIFICATION AND UTILITIES TIE-IN FOR MARSA AL
ARAB DEVELOPMENT
Part 1: Road Works
Part 2: Services Works
Roads and Transport Authority

Dubai Emirate
July 2018
PREFACE
Standard Specifications for the Construction of Roads and Bridges in Dubai Emirate
This new version of the Standard Specifications is prepared to be used solely for the
Construction of Roads and Bridges in Dubai Emirate. All the projects pertain to Roads and
Transport Authority and others pertain to Private sectors roads networks shall be governed by
these specifications as per the decree of his highness Sheikh Mohammed bin Rashid Al
Maktoum No. 5 for the year 2005. The updated specifications are cited as "DEPSS-10"
indicating “Dubai Emirate Projects Standard Specifications issued in the year 2010.
These specifications shall be considered as an original part of the contract and tender documents
upon all parties to the contract. All construction contracts of the Dubai Roads are also governed
by this updated version of specifications.
Primarily, the Units of International System (SI) are mainly used in the updated version of the
specifications DEPSS-10 and a conversion table is provided to be used as a reference of units
conversions when different units are used.
Terms used throughout this specification shall have the same meaning as those defined in
accordance with:
BS 6100 2.4.1 2008 “Glossary of building and civil engineering terms. Civil Engineering,
Highway, railway and airport engineering. Highway Engineering”
BS 6100 2.2.1 2008 “Glossary of building and civil engineering terms. Civil engineering.
Substructures. Earthworks. Foundations. Tunnels. Substructures and foundations”
METRIC TO ENGLISH CONVERSION FACTORS
Symbol When You Know Multiply By To Find Symbol
LENGTH
µm micrometers 3.9 x 10-5 inches in
mm millimeters 0.039 inches in
m meters 3.28 feet ft
m meters 1.09 yards yd
km kilometers 0.621 miles mi
AREA
2
mm square millimeters 0.0016 square inches in2
m2 square meters 10.764 square feet ft2
m2 square meters 1.195 square yards yd2
ha hectares 2.47 acres ac
km2 square kilometers 0.386 square miles mi2
VOLUME
mL milliliters 0.034 fluid ounces fl oz
L liters 0.264 gallons gal
m3 cubic meters 35.31 cubic feet ft3
m3 cubic meters 1.308 cubic yards yd3
MASS
g grams 0.035 ounces oz
kg kilograms 2.202 pounds lb
Mg megagrams 1.1023 short tons T
(or "t") (or "metric ton") (2000 lb)
TEMPERATURE (exact)
ºC Celsius 1.8C +32 Fahrenheit ºF
temperature temperature
ILLUMINATION
lx lux 0.0929 foot-candles fc
cd/m2 caldela/m2 0.2919 foot-Lamberts fl
MISCELLANEOUS
J joule 0.7376 footꞏpoundforce ftꞏlbf
N newtons 0.225 poundforce lbf
kPa kilopascals 0.145 poundforce lbf/in2
per square inch
SI is the symbol for the International System of Units.

Appropriate rounding should be made to comply with Section 4 of ASTM E 380.
VOLUME 2
Part 1: Road Works
TABLE OF CONTENTS
Section Description
1 GENERAL
2 SITE CLEARNCE AND EARTHWORKS
3 PAVEMENT CONSTRUCTION
4 CONCRETE WORKS
5 ANCILLARY WORKS
6 WORKS IN CONNECTION WITH SERVICES
7 ROADWAY LIGHTING AND TRAFFIC SIGNALS
8 PILE FOUNDATION
1 SECTION 1 GENERAL
TABLE OF CONTENT
1/1 SITE ESTABLISHMENT ...................................................................................... 2

1/2 SITE OFFICE FOR THE ENGINEER .................................................................. 2
1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR ..................................... 3
1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR .............. 3
1/5 CONTRACTOR’S SITE ORGANISATION........................................................... 3
1/6 SURVEYING EQUIPMENT ................................................................................. 4
1/7 LABORATORY TESTING ................................................................................... 4
1/8 PROGRAMME OF WORKS ................................................................................ 5
1/9 WORK SITE, SETTING OUT AND CROSSSECTIONS...................................... 6
1/10 PROJECT SIGN BOARDS .................................................................................. 7
1/11 PROJECT PHOTOGRAPHS ............................................................................... 8
1/12 QUALITY OF MATERIALS AND SUPPLY .......................................................... 8
1/13 APPROVAL BY THE ENGINEER...................................................................... 11
1/14 EXISTING SERVICES AND SERVICE DIVERSIONS ...................................... 11
1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND
PROPERTIES ................................................................................................... 14
1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL...................................... 15
1/17 TEMPORARY DIVERSION OF TRAFFIC ......................................................... 16
1/18 FIRE PRECAUTIONS ....................................................................................... 16
1/19 SAFETY OFFICERS ......................................................................................... 17
1/20 CONTRACT DRAWINGS AND DOCUMENTS ................................................. 17
1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND
MAINTENANCE INSTRUCTIONS .................................................................... 18
1/22 RECORD DRAWINGS ...................................................................................... 19
1/23 ACCOMMODATION WORKS ........................................................................... 19
1/24 PUBLICITY ........................................................................................................ 19
1/25 TIDYING AND CLEARING THE SITE ............................................................... 20
1/26 SOIL INVESTIGATION ...................................................................................... 20
1/27 WORKS FREE FROM WATER ......................................................................... 20
1/28 OTHER CONTRACTORS ON SITE .................................................................. 20
1/29 MAJOR EQUIPMENT AND PLANT .................................................................. 20
1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI. 32
Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 1

2 SECTION 1 GENERAL
1/1 SITE ESTABLISHMENT

1/1.1 The Contractor shall provide sites for the plant and workshops necessary
for the construction of the Works and shall pay any rents, easements and
license fees levied in connection therewith. Roads & Transport Authority’s
(RTA) formal approval to the site for the Contractor’s plant and workshop
must be received prior to occupying the proposed site.
1/1.2 Site offices for the Engineer and the Contractor shall be erected on a site
proposed by the contractor and approved by Roads & Transport Authority
and as shown in the Drawings. No Contractor’s plant and workshops will
be permitted within this compound.
It is the Contractor’s responsibility to obtain all necessary No Objection

Certificate for the occupation of the sites.
1/1.3 The Contractor shall construct suitable entry and exit roads to and within
the compound and provide a covered parking area as specified in
Appendix-C. The Contractor shall take all necessary precautions to avoid
storm water flooding within the compound and accesses.
1/1.4 The Engineer’s office shall be erected and fully equipped to the
satisfaction of the Engineer.
1/1.5 Within one month after the Completion of the Whole of the Works and in
accordance with the provisions of Clause 1/2.1 the whole area of the
compound shall be reinstated to its original condition and all rubbish and
refuse removed.
1/1.6 The Contractor’s proposed access routes to and within the site shall be
provided and maintained as agreed with the Engineer. The Engineer may
at any time withdraw his approval for the use of any route and may order
such widening, strengthening or repair work as he considers necessary.
1/1.7 The Contractor shall employ at his own cost watchmen for the security of
the site establishment.
1/2 SITE OFFICE FOR THE ENGINEER

1/2.1 The site offices for the Engineer shall comply with the requirements
included in Appendix-C. The offices shall be available in full working order
to the satisfaction of the Engineer within the period stipulated to
commence the works in the Tender (Clause 4) and remain so until one
month after the Completion of the Whole of the Works.
1/2.2 The Contractor shall retain on site for the exclusive use of the Engineer all
codes and standards referred to in the Specification which shall remain in
the custody of the Engineer for his exclusive use until completion of the
whole of the works but shall remain the property of the Contractor.
1/2.3 All Keys for the Engineer’s site offices shall be held by the Engineer until
such offices are removed.
1/2.4 The Contractor shall, at his own cost, provide the Engineer and his staff

3 SECTION 1 GENERAL
with daily cleaning attendance and two full time for serving refreshments,
car cleaning etc.
1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR

1/3.1 The Contractor shall make provision for installation, maintenance and
removal at the completion of the works, of his offices, sheds, and shelters.
He shall provide and maintain at his own cost sanitary facilities on site, first
aid and fire fighting equipment, drinking water facilities, electricity and
telephone for the duration of the Contract.
1/3.2 The Contractor shall be responsible for the security of the site and the
safety of public and adjoining property and shall be liable for any claims
arising from loss or damage suffered. He shall employ watchmen for this
purpose.
1/3.3 All temporary accommodation shall be maintained in an efficient condition

during the period of the Contract and shall be available for inspection by
the Government Medical Officer of Health. The Contractor must comply
immediately with any instruction given by the Medical Officer for cleaning,
disinfestations and maintenance of any building to a hygienic and sanitary
condition.
1/3.4 The Contractor shall confine his apparatus, the storage of materials and
the operations of his workmen to the limits indicated by law, ordinances,
permits or direction of the Engineer. The Contractor shall erect temporary
fences as required by the Engineer. The site boundary lines shall be to the
approval of the Engineer.
1/3.5 The Contractor shall provide and maintain water, electricity and power
required for the works including that required by the Sub-Contractors. Pay
all charges and bear all costs for the necessary temporary installation
including pipework, pumps, water tankers, storage tanks, generating
equipment, etc. and remove on completion and make good all work
disturbed.
1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR

1/4.1 The Contractor shall make provision for the installation, maintenance up to
the completion of the works and removal of fully equipped workshops and
stores. The Contractor shall also provide all necessary construction plant,
equipment and tools necessary for the proper execution of the works. Plant
shall include, but not be limited to, concrete and asphalt manufacturing
plant, mobile plant and sundry equipment required for any particular trade
necessary for the execution and completion of the works. All plant and
equipment required for the Contract is subject to the approval of the
Engineer.
1/5 CONTRACTOR’S SITE ORGANISATION

1/5.1 The Contractor shall perform the setting out of the works as described in
the Drawings and Specification.
1/5.2 The Contractor shall provide the Engineer with all necessary assistance in
checking the setting out of the works and interpreting any information used

4 SECTION 1 GENERAL
by the Contractor for this purpose including the supply of a minimum 2

chainmen as and when required by the Engineer.
1/5.3 The Contractor shall also provide the Engineer with similar assistance in
carrying out additional surveying works should these be found necessary
for the proper execution of the works.
1/5.4 The Contractor shall also provide all assistance as required by the
Engineer for the measurement of the works for monthly valuation, Monthly
Laboratory Report and for the final payment certificate and also for
recording the progress of the works.
1/5.5 The Contractor shall be responsible for all follow up and co-ordination with
all service authorities (Electricity, Water, Drainage, Street Lighting,
Telephone, Horticulture, etc.).
1/5.6 The Contractor shall provide subject to the approval of the Engineer,
qualified and sufficient number of the Engineers, Quantity Surveyors,
Supervisors, Employees and skilled and non-skilled workmen for his
supervision of the works and site administration.
1/5.7 The Contractor shall provide all unskilled labour and all necessary tools as
directed by the Engineer.
1/5.8 If at any time before the commencement or during the progress of the
work, the Engineer decides that for the proper execution of a specified part
of the works, shop drawings are necessary, these drawings shall be
prepared by the Contractor and submitted to the Engineer for approval
according to sub-section 1/21. Such drawings must be provided at least
14 days prior to the commencement of the relevant work on site.
The Contractor shall not proceed with the above mentioned work until
these shop drawings are approved by the Engineer. The Contractor shall
not be entitled to any extra payment or extension of time for the
preparation of the shop drawings.
1/6 SURVEYING EQUIPMENT

1/6.1 The Contractor shall supply and maintain in full working order during the
progress of the works the surveying equipment specified in Appendix-C
herein, and the supply of expendable surveying material as required from
time to time in connection with the works. All equipment specified shall be
new and shall remain in the custody of the Engineer for his exclusive use
until Completion of the Whole of the Works but shall remain the property of
the Contractor.
1/7 LABORATORY TESTING

1/7.1 Testing of all materials and completed works shall be carried out in
accordance with DM Administrative Decision No. 160 for 2000 by:
1 Dubai Municipality – Dubai Central Laboratory (D.C.L) in accordance

with Appendix “A1”.
2 Independent Laboratory in accordance with Appendix “A2”.

5 SECTION 1 GENERAL
1/7.2 The Contractor shall provide the Engineer with all referenced ASTM, BS
Standards or any other standard indicated or referred to within the testing
requirements of the Contract Specifications.
1/7.3 At least 24 hours notice shall be given to DCL before any tests are to be
carried out.
1/7.4 The contractor must make due allowance for the time required for any
testing within his planning and program.
1/8 PROGRAMME OF WORKS

1/8.1 The Contractor shall submit to the Engineer for approval a Critical Path
Programme and other supporting documentation of the works within the
time stipulated in the Conditions of Contract together with details of
equipment, procedures and method of work which the Contractor intends
to utilize and to follow. Due allowance must be made within the
Programme for:
 Traffic detour scheme preparation, planning, phasing, submittal and

approval.
 Maintenance of accesses to all the residential, recreational,
business and institutional premises affected by the works.
 Any restraints and restrictions imposed by Service Authorities or
the Police.
 Activities of other Contractors (v) The pavement wearing course
and road marking to be laid at such a time to avoid damage by
other construction activities.
 Protection and relocation of existing services as may required
based on the information gathered from Trial Trenches and as
directed by the concerned services authority.
 Obtain NOC’s from all Services Authorities.
 Coordination & cooperation with other Contractors working in the
same area.
 Obtaining approvals from the Engineer & RTA.
 Working during month of Ramadan & works during rainy days.
1/8.2 The Contractor shall in accordance with the Conditions of Contract, submit
a comprehensive plant schedule which shall include the proposed dates of
arrival or establishment on site for each major item. Plant shall not be
brought to or removed from site without prior approval of the Engineer.
1/8.3 In addition to the Critical Path Programme, the Contractor shall if required
by the Engineer provide a detailed bar chart schedule to be used by the
Engineer for monitoring the progress of works.
1/8.4 Furthermore, the contractor shall submit to the Engineer a daily work
Programme showing the activities to be undertaken for the day including
laboratory tests and survey checks at least 1 day in advance.
1/8.5 A monthly progress and material testing reports shall be submitted to RTA

6 SECTION 1 GENERAL
roads department. Material report shall contain monthly summaries on

testing, test results, testing frequency and statistical analysis for the results
of the tested material. Also, the material report shall contain a detailed
analysis for the results of tested materials and action taken related to non-
compliance of the test results.
1/8.6 The Contractor has to submit to the Engineer an updated weekly or bi-
weekly progress report based on the approved Clause 14 Programme
using the actual dates and estimated % age completed for each activity.
1/8.7 The contractor is not allowed to give priority in the program for the areas
that have physical obstructions and he has to start the construction for the
open areas.
1/8.8 If the Contractor failed, due to lack or poor details, to get the approval of
the Engineer and RTA on the submitted programme within a period of 90
days from the commencement date of the project, the Contractor's Monthly
Payments may be reduced or completely stopped.
1/9 WORK SITE, SETTING OUT AND CROSSSECTIONS

1/9.1 The Employer, through the Engineer, shall handover to the Contractor the
work site in parts/sections according to priority mentioned in the
programme of work and as detailed on the drawings. The work site means
all land and other locations which the Employer passes to the Contractor to
construct the Works mentioned in the Contract.
1/9.2 The Contractor is responsible for all the setting out of line and levels of the
Works and shall employ adequate qualified staff to carry this out.
1/9.3 Before the commencement of the Works, the Contractor will be supplied
with the information necessary to establish the lines and levels of the
Works. The engineer has to show on the drawings all the survey markers
established but can give no warranty for their existence at the start of the
Contract nor will accept responsibility for replacing any survey markers
found to be missing. Where survey markers have been established by the
Engineer, the Contractor shall check the accuracy of their position and
level and shall immediately notify the Engineer of any discrepancies.
However, it is the Contractor’s sole responsibility to coordinate with Dubai
Municipality Planning & Survey Department and follow their regulations to
get the values (E, N & levels) for sufficient numbers of survey stations
within or near the work site.
1/9.4 All setting out throughout the Works must be related to the Dubai
Municipality Datum Levels. Any Temporary Bench Mark (T.B.M.) to be
fixed on the site shall be tied into the Dubai Municipality Datum.
1/9.5 The Contractor shall, as soon as practicable, supply the Engineer with
records in approved form relating to all reference pegs and bench marks
and shall keep such records up to date by formal notice to the Engineer.
1/9.6 All survey reference pegs shall be carefully preserved except where
construction requires their removal, and before such removal, the approval

7 SECTION 1 GENERAL
of the Engineer & DM Planning & Survey Department shall be obtained.
1/9.7 Before commencing work on any section of the Works, the Contractor shall
survey and level the original ground surface and shall prepare plans and
cross-sections accordingly. These shall, when finally agreed, be signed by
the Engineer and Contractor as truly representing the configuration of the
areas in question before the commencement of the Work. The preparation
of the cross-section drawings shall comply with Clause 1/21.
1/9.8 All setting out shall be approved in writing by the Engineer before work
may commence. The centerlines are to be checked by the Dubai
Municipality Survey Section and approved by the Engineer.
1/9.9 When necessary the Contractor shall provide at his expense sufficient and
approved templates for the purpose of controlling the finished shape of
certain work. The templates will be in accordance with the specifications
and drawings where such are provided. All templates must be approved
and shall be maintained in good order to provide the section required for
the entire works. Templates may be checked from time and any
deficiencies noted shall be rectified immediately. The Contractor shall also
supply straight edges and lines when required to control the work.
1/9.10 The Engineer will, if he deems it necessary, revise the line or grade and
will require the Contractor to adjust the stake-out accordingly.
1/9.11 Where directed by the Engineer, the Contractor shall take such levels and
dimensions as may be required for the purpose of measurement prior to
disturbance of the ground. These shall be agreed between the Contractor
and the Engineer before any surface is disturbed or covered up.
1/9.12 Any change of the ground elevation resulting from compaction or other
works provided for in the Contract Documents shall be deemed included in
such works and paid for within the tender prices listed in the Bill of
Quantities. The Contractor shall consequently in no way be entitled to any
additional payment or claim whatsoever.
1/10 PROJECT SIGN BOARDS

1/10.1 The Contractor shall provide, supply, erect and maintain the requirements
of the project sign boards at location approved by the Engineer, RTA and
Services Authorities. Minimum two sign boards of project sign boards shall
be provided or as described in the Contract.
1/10.2 Project Sign Boards shall be signwritten by a skilled signwriter or any other
methods approved by the Engineer and RTA to show the details described
in the Contract plus any other relevant details to the approval of the Roads
& Transport Authority and the Engineer.
1/10.3 Within one month of completion of the (Whole of the) Works, and after the
works are handed over to the client and respective services authorities.
The Project Sign Boards shall be dismantled and removed by the
Contractor.

8 SECTION 1 GENERAL
1/11 PROJECT PHOTOGRAPHS

1/11.1 The Contractor shall arrange to have monthly record photographs of the
Works taken. These photographs shall cover such extent of the Works as
the Engineer shall direct. The days upon which the photographs are taken
shall be decided by the Engineer.
1/11.2 The Contractor shall provide the Engineer with one set of the monthly
progress photographs of digital format with dates marked / imprinted on it.
1/11.3 One set of photos of digital format to be prepared / processed by an

approved professional. A label giving a brief description shall be affixed in
the bottom right-hand corner of each photo. These photos should be
submitted on a CD for easy future reference.
1/11.4 The Copyright of all photographs shall be vested in the Employer and the
negatives and prints shall be delivered to the Engineer within 4 days of
exposure. The photographs shall not be used for any other purpose
whatsoever without the Employer’s approval.
1/12 QUALITY OF MATERIALS AND SUPPLY

1.12.1 Unless otherwise stated or approved by the Engineer all materials used in
the Works shall be new and of the best quality as specified in the Contract.
1/12.2 All materials and equipment specified in the contract documents which are
to be incorporated in the works must be obtained from or through a Dubai
Emirate supplier and or manufacturer who must be registered and licensed
by the Dubai Municipality. If such specified materials or equipment is not
available from the Dubai Emirate market then any other source is
acceptable subjected to the conditions set in the subsections below.
1/12.3 Materials delivered to the Site for the purpose of the Works, shall be
accompanied by a ‘Certificate of Guarantee” signed by the authorised
representative of the manufacturer. Such Certificate shall state that the
materials specifications and test results are in compliance with the
specified requirement of the pertinent designations of the most recent
edition of ASTM or any other approved equivalent National Standard
unless otherwise directed. Falsification of such Certificates, Materials,
Specifications or Test Results shall be just cause for the rejection of the
materials.
1/12.4 The borrow pit location if not designated in the Contract Documents shall
be approved by the Roads & Transport Authority. The Contractor shall
exercise a continuous quality control upon the extracted material to confirm
its suitability for use.
No material shall be supplied to the site before the Engineer’s approval of

the type of equipment which the Contractor intends to use in the borrow
pit, and for the method of work.
1/12.5 The Contractor shall select rock quarries and shall submit laboratory tested
and accepted samples, within two months before their use, in order for the
Engineer to determine their conformity with the related specifications. The
Contractor shall exercise a continuous quality control upon the extracted

9 SECTION 1 GENERAL
material to confirm its continued suitability for use.
No material shall be supplied on the site before the Engineer’s approval of

the type of equipment which the Contractor intends to use in the quarry,
and for the method of work.
1/12.6 The Engineer’s acceptance of the materials does not relieve the Contractor
of his total responsibility to carry on with additional investigations in order
to obtain and supply during the progress of the works uniform material
conforming to the Specifications.
1/12.7 The Contractor shall be responsible for payment of royalties, if any, arising
due to obtaining of materials for use in the Works. No separate payment
will be made by the Employer as a royalty for materials for use in the
Works.
1/12.8 Wherever in the Specifications tests on materials, tests on completed work

and construction control tests are called for or implied, they shall be carried
out according to, and the materials shall comply with, the requirements of
the Specifications (latest edition) with the priority of latest edition of
standard shall be as follows:
a. UAE & DM Standards

b. International Standard such as ISO
c. National Standard such as BSI & DIN
d. Others as stated in this Specification such as ASTM, etc.
The Contractor shall provide for the exclusive use of the Engineer copies
of each and any codes of practice, international standards, test methods
etc. relevant to the works. In addition the Contractor shall retain on site for
the use of the Engineer all manufacturers literature relating to all the
products to be used in the works, current BSI Handbook No. 3 and the
Manufacturers installations instructions for all relevant products, materials
components and installations.
1/12.9 Where specific material or equipment is referred to in the Contract, it is

intended only to indicate the acceptable standard. The Contractor may
offer alternative materials or equipment of an equal standard. The
Contractor must submit a statement listing proposed alternatives together
with such information and samples as the Engineer may require to satisfy
himself that the alternatives offered are of equal quality to the items
specified. The cost of submitting such samples will be borne by the
Contractor. Acceptance or rejection of any submitted alternative materials
in no way could entitle the Contractor for any additional cost and/or time
extension or whatsoever.
1/12.10 The Contractor will be required to produce documentary evidence that all
materials which are not available in the local market and which have to be
imported have been ordered sufficiently in advance to ensure that no delay
to the works occur. As soon as orders have been placed, copies of such
orders shall be submitted to the Engineer. The Contractor shall be
responsible for delays as a consequence of late ordering.

10 SECTION 1 GENERAL
1/12.11 Should the Engineer discover in the Works any materials other than those
approved, he may order their removal from the site and replacement with
approved materials at no cost to the Employer and in compliance with
Standard Specifications.
1/12.12 All specified materials incorporated in the Works shall be fixed or applied
strictly in accordance with the manufacturer’s printed instructions.
1/12.13 The Bills of Quantities shall NOT be used as a basis for ordering materials
and the Contractor is entirely responsible for assessing the quantities of
materials to be ordered.
1/12.14 All materials or manufactured items shall be carefully loaded, transported,

unloaded and stored in an approved manner, protected from damage and
exposure to weather or dampness during transit and after delivery to the
Site. Damaged material or manufactured items damaged during and after
fixing in position shall be removed, repaired or replaced by and at the
Contractor’s expense.
1/12.15 The Contractor shall erect and maintain ample temporary and weather
proof sheds for proper storage and protection of his own and sub-
contractor’s materials. Cement and other perishable material shall have
floors raised 150mm off the ground. The Contractor shall clear away on
completion and make good all areas disturbed.
1/12.16 Prior to ordering or delivering any material or manufactured items to the

site, the name and address of the supplier(s) and, where required by the
Engineer, adequate samples, sample schedules and manufacturer’s
certificates of all the materials and goods to be used in the Works shall be
submitted to the Engineer for approval and in the case of rejection further
samples shall be submitted until such are approved. The cost of submitting
all such samples shall be borne by the Contractor. All products/materials
shall have approved National Certificate of conformance similar to B.S.I.
Quality Kite Mark or National Agreement Certificate such as BBA for non-
standard products and systems to be approved by the Engineer and shall
be verified by DCL.
All products/materials shall be certified by Dubai Central Laboratory of

Dubai Municipality (DM) or by an accredited certification body approved by
DMDCL.
1/12.17 If judged necessary by the Engineer, the samples shall be tested for
compliance at DCL in accordance with Appendix A1 or in a laboratory
accredited in accordance with Appendix A2 of this Specification and Dubai
Municipality Administrative Decision No. 160:2000.
1/12.18 All materials and equipment specified in the Contract Documents which
are to be incorporated into the Works must be obtained from or through a
Dubai Emirate Supplier and or Manufacturer who must be registered and
licensed by the Dubai Municipality. If such specified materials or
equipment is not available from the Dubai Emirate then any source is
acceptable subject to approval from the Engineer and RTA.

1/12.19 Approval of a source does not mean that all the materials in the source is
approved. No source of supply shall be changed without Engineer's prior
approval. Approved samples shall be retained on site for comparison with
products and materials used in the works and shall be removed when no
longer required by the Engineer.
1/12.20 Any material requiring certification as per RTA regulations shall not be
used unless certified by DM-Dubai Central Laboratory or by an accredited
certification body approved by DMDCL.
1/13 APPROVAL BY THE ENGINEER

1/13.1 The Contractor shall give adequate notice in writing to the Engineer
requesting inspection and approval of various stages of construction of the
Works. Unless stated otherwise in the Contract a notice period of not less
than four hours of normal working time shall be given before the work is
ready for final inspection. The Contractor shall supply printed forms for this
purpose. Further stages of work shall not proceed until the Contractor has
received the written approval of the Engineer.
1/13.2 The Contractor shall give the Engineer details of the source of materials to
be incorporated into the Works. Reasonable notice must be given by the
Contractor to allow the Engineer to carry out such tests and enquiries as
may be appropriate before giving approval.
1/13.3 When items to be incorporated into the Works are to be manufactured or

fabricated off-site the Contractor shall give the Engineer not less than
seven days notice in writing of the commencement of such work.
1/13.4 Where the approval of the Engineer is required under this specification,
such approval shall not in anyway relieve the Contractor of his duties or
responsibilities under the Contract.
1/14 EXISTING SERVICES AND SERVICE DIVERSIONS

1/14.1 The positions of all public and privately owned services shown on the
drawings have been based on the records of various utilities and Public
Authorities and must be regarded as approximate. The Contractor must
verify this information and satisfy himself as to the exact nature and
position of all such apparatus. The Engineer does not guarantee the
accuracy of the information given on the drawings and no warranty is given
or implied.
1/14.2 The Contractor shall take into account the current laws and Latest
recommended measures regarding the safety of service lines, together
with any amendment or additions thereto. The Contractor shall include in
his tender for anything in these laws considered to have a monetary value.
1/14.3 The cost of locating or verifying the location of existing services, liaison
with the various Service Authorities and complying with the above shall be
borne by the Contractor unless provided for elsewhere in the Contract.
1/14.4 Before opening the ground for any purpose, the Contractor must notify all

concerned parties by issue of formal “Notice of Intent” and must obtain

information by Formal Notice regarding the location of all services. The
Complete responsibility for obtaining this information rests with the
Contractor.
1/14.5 Notice of Intent” shall be circulated to all concerned parties including the
following: Roads & Transport Authority Roads Department Dubai Electricity
and Water Authority Emirates Telecommunication Corporation. Roads &
Transport Authority Street Lighting Section Dubai Municipality Drainage
and Irrigation Department Roads & Transport Authority Horticulture
Section Consultants for Water, Electricity and Drainage Departments.
1/14.6 Drawings and notices shall be sent in duplicate one of which shall be
retained by the addressee and the other returned to the sender duly
marked to show underground services. “Notice of Intent” will be given 14
(fourteen) days in advance of the proposed Works. In the event that the
work is not started within 8 (eight) weeks of the date of the “Notice of
Intent”, it will be deemed to have lapsed. A further Notice of Intent will then
be submitted.
1/14.7 The Contractor shall furnish copies of the above Notices of Intent to the
Engineer. The Contractor shall acquaint himself with the position of all
existing services and must obtain clearance from the relevant authority
before commencing any work in a particular area. Written evidence of such
clearance shall be provided to the Engineer by the Contractor. If any
underground service is encountered unexpectedly, excavation shall cease,
and the Engineer’s Representative shall be notified immediately.
Emergency work, as necessary, shall be put in hand without delay and
without prejudice to the indemnity of the Employer.
1/14.8 The Contractor shall prepare records and CAD drawings showing position,
levels and types of each existing service including manholes, joint boxes
and inspection chambers etc. All record drawings shall be prepared using
a Computer Aided Drafting program approved by the Engineer.
CD’s containing the drawings data to be supplied to the Engineer in the

approved digital format for incorporation in the final record drawings.
1/14.9 The Contractor shall take any and all measures reasonably required by
any public or concerned Authority for the support and full protection of all
mains, pipes, cables and other apparatus during the progress of the
Works, and shall construct and provide to the satisfaction of the Authority
concerned, all works necessary for the prevention of damage or
interruption of services.
If in the execution of the Works, by reason of any subsidence caused by,

or any act of neglect or default of the Contractor, any damage to any
apparatus or any interruption of, or delay to the provision of any service is
caused, the Contractor shall report it to the Engineer immediately and bear
and pay the cost reasonably incurred by the Authority concerned in making
good such damage and shall make full compensation to the Authority for
any loss, sustained by reason of such interruption or delay.

1/14.10 The Contractor shall familiarize himself and all his employees with the
dangers of working in or near live sewers and at sewage treatment works;
in particular the risks of physical injury from the exposure to poisonous
gases, of bacterial infection from contact with sewage and of exposure to
poisonous gases, which may be given off by the sewage. Hydrogen
sulphide and methane are prevalent in the sewers in Dubai, and can exist
in excavations where septic sewage from collection tanks is allowed to
seep into groundwater. In the context of this clause the term sewer
includes irrigation mains and drains carrying ground water and/or storm
water.
1/14.11 The Contractor shall, at all times during the progress of the Works, afford
facilities to properly accredited agents of any Public or Utility Authority for
access to all or any of their apparatus situated in or under the site, as may
be necessary for inspecting, reporting, maintaining, removing, renewing or
altering such apparatus in connection with the construction of the Works or
any other purpose whatsoever.
1/14.12 The Contractor will be fully responsible for ensuring observance of the
above regulations of his sub-contractors.
1/14.13 Where any utility or service works are to be constructed under a separate
contract by the Employer within the Site and concurrent with the execution
of the Works, the Contractor shall cooperate with the other Contractor and
shall coordinate his construction operations to avoid interference with the
other Contractor’s operations.
1/14.14The Contractor shall prepare and furnish all necessary shop drawings of
the works required to complete the adjustment of apparatus to finished
grade or specified level. The drawings must be approved by the concerned
Utility Authorities and the Engineer prior to commencement of any work at
the site. Measurement shall be for each utility facility adjusted to finish
grade or level approved by the Engineer.
The Contractor must allow in his rates for services installations for the
production of combined service drawings covering the whole of the
Contract area. The drawings must show both existing services located by
trial pits and coordinated by survey and all proposed new services. The
drawings are to identify interface problems prior to production of working
drawings.
Drawings must be prepared using a Computer Aided Drafting program

approved by the Engineer, Diskettes containing the drawing data of the
original service locations and those containing the drawing data of the
relocated original services and of the new service locations together with
their protection area to be supplied to the Engineer for incorporation in the
final record drawings in the approved digital format.
1/14.15 The Contractor shall prepare CADD shop drawings for utility protection
work and obtain the approval of the appropriate Authority and Engineer
before commencing with construction.

1/14.16 The Contractor shall relocate certain utilities to service reservation areas
as specified in the Contract. This work may only include the construction of
necessary protective housing (e.g. box culverts, slabs, concrete encased
sleeves etc.) in the service reservation areas for utility lines to be
relocated, or this work may include necessary protective housing as
described above and, in addition the relocation of specific utility lines to the
service reservation areas. In both cases the Contractor shall complete the
necessary survey to establish the lines and levels, prepare shop drawings
and submit them to the Engineer for his review and approval. The
Contractor shall obtain approval from the concerned Authority before
commencing this work.
1/14.17 Any public or private service for water, electricity, drainage, etc. affected
by the Works shall not be interrupted without the written permission of the
Engineer. Such permission will be withheld until suitable approved
permanent or temporary alternative service has been provided by the
Contractor or by the owner of the utility or his agents.
1/14.18 For temporary traffic diversions as may be required for the construction of
road crossings, full liaison with the Roads & Transport Authority and Dubai
Police shall be required and the requirements of Clause 1/16 and 1/17
complied with.
1/14.19 Due allowance (s) must be given by the Contractor when preparing the
Programme of Works to comply with this Clause 1/14.
1/14.20 The contractor shall comply with the latest specifications set by various
services authorities for the provision of new services and/or locating,
relocating, protecting, diverting of the existing services.
1/14.21 The contractor shall survey of all the existing services corridors in the
vicinity of the project limits and submit it to the Engineer for approval, in
particular, the gas pipelines reservation which may run along the boundary
of the project if any. No temporary road works are to be undertaken over
the gas pipelines or below DEWA overhead power lines without obtaining
an NOC from the proper service authority. The use of heavy equipment
shall be limited to where no impact can be caused to the gas pipeline or
other services.
Any damage to the services within these areas shall be reported

immediately to the concerned authority and then repaired as per the
approved method of construction at the cost of the contractor and to the
satisfaction of the relevant services authority as described in section 1 of
these specifications.
1/15 PROTECTION AND UPKEEP OF SITE AND ADJACENT AREAS AND

PROPERTIES
1/15.1 The Contractor shall take all necessary precautions to protect buildings,
fences, roads, passages, culverts and other apparatus if found and he
shall not demolish or remove any of these works except according to
specific instructions by the Engineer. In the case of existence of buildings,
ditches, excavations or any other work adjacent to the Site, the Contractor
shall make necessary arrangements and take precautions for their support
and protection at his own expense.

1/15.2 The responsibility lies with the Contractor for the repair and return to the
previous condition of items to which the Contractor’s works have caused
damage. Also, also, it is the responsibility of the contractor to tie-in the new
footpath if any, to the existing footpath, smoothly and neatly and to the
satisfaction of the Engineer.
1/15.3 The Contractor shall not be permitted to use earth works of already
executed roads. Also, the contractor shall extend all ducts out of the
asphalt works wherever required and to the satisfaction of the Engineer.
1/15.4 It is the Contractor’s responsibility to ensure that continuous access is

maintained to all properties adjacent to the works throughout the Contract
period to the Engineer’s satisfaction.
1/15.5 In pursuance of his obligations under the Conditions of Contract, the

Contractor shall whenever required or directed by the Engineer cover up
and protect the works from weather and from damage by his own or other
workmen performing subsequent operations. He shall provide all
necessary dust sheets, hoardings, barriers and guard rails, waterways, etc.
and clear away same at completion. The Contractor shall take all
reasonable and proper steps for the protection of all places on or about the
works which may be dangerous to his workmen or any other persons or to
traffic. The Contractor shall provide and maintain warning signs, warning
lamps and barricades as necessary in all such places.
1/15.6 The Contractor shall furnish and place fresh or brackish water at his own
expense for dust control when and where construction operations require it
and at locations where specifically directed by the Engineer due to
conditions created by the Contractor or his construction operations.
1/15.7 Existing roads, accesses to houses, buildings, etc., and any new roads,
whether part of the Works or not, which are being used by the Contractor’s
constructional traffic shall be kept clean and clear of all dirt, mud and
material dropped from vehicles or from tyres and any damage caused shall
be repaired at the Contractor’s expense. The Contractor shall provide,
maintain and use as directed by the Engineer, suitable equipment
including mechanical road sweepers solely for this purpose throughout the
course of the works.
1/15.8 The contractor shall prepare road furniture inventory before

commencement of works and shall hand over to the client all materials
removed from the site as per this inventory (scrap reusable).
1/16 TRAFFIC MANAGEMENT, SAFETY AND CONTROL

1/16.1 The Contractor shall provide, erect and maintain such traffic signs, lamps,
barriers, traffic control signals, lighting units, road markings and other such
measures as may be necessary for the construction of the works.
1/16.2 The Contractor shall, after consultation with Engineer and all concerned
departments in RTA, prepare a scheme of traffic management for carrying
out the works. Such proposals shall be submitted to the Engineer for his

written approval not less than 30 days before the planned implementation
of each proposal. Prior to commencing any individual diversion or traffic
control the Contractor shall provide to the Engineer details of his overall
scheme of traffic control or diversions for the entire project giving his
programme of diversions etc. All diversions must be approved by the
Traffic Police and Roads & Transport Authority Roads Department prior to
implementation.
1/16.3 The Contractor shall not commence any work which affects the public
highway until all approved traffic safety measures conforming to RTA
Standards are fully operational to the satisfaction of the Engineer.
1/16.4 Temporary traffic signs conforming to RTA Standards and approved by

Roads & Transport Authority Roads Department shall be of good design
and sound construction using reflective sign face material. They shall have
a minimum face dimension of 900mm.
1/16.5 The Contractor shall maintain all signs, lamps, barriers, traffic control
signals and road markings in a clean and legible condition and shall
position, re-position, cover or remove them as required by the progress of
the works.
1/16.6 The Contractor shall be entirely responsible for complying with the
requirements of and coordinating with the Dubai Police Traffic Department
and Roads & Transport Authority Roads Department in relation to the
above.
1/16.7 Traffic diversion is a lump sum item and will be paid as per the Contract
BOQ without any possibility for any claims whosoever due to change of the
scope. The Contractor has to consider this work and any expected
requirements as part of the Contractor's risks.
1/17 TEMPORARY DIVERSION OF TRAFFIC

1/17.1 The Contractor shall construct temporary diversion ways wherever the
construction of the works will interrupt existing public or private roads or
rights of way.
1/17.2 Diversions must be constructed in advance of any interference with the

existing right of way and the subsequent traffic management, safety and
control must be in accordance with Clause 1/16 and as directed by the
Engineer.
1/17.3 The contractor is fully responsible for diversions maintenance and he shall
undertake whatever is necessary to maintain all diversions fully operational
i.e. 24 hours a day and over the entire period of the project.
1/18 FIRE PRECAUTIONS

1/18.1 Adequate precautions shall be taken against fire throughout all the
Contract’s and Subcontractor’s operations. Quantities of flammable
materials on site shall be kept to an absolute minimum, and shall be
properly handled and stored. Gasoline and other flammable liquids as well

as pressurized gas tanks shall be stored in and dispensed from safety

containers; however, storage of such containers shall not be within the
offices building. Except as otherwise provided herein, the Contractor shall
not permit fires to be built or open type heating devices to be used in any
part of the work.
1/18.2 Construction practices, including cutting and welding, and protection of

adjacent materials during construction shall be in accordance with good
standard practices for such work. The Contractor shall provide a sufficient
number of approved portable fire extinguishers distributed around the
buildings and construction site.
1/18.3 The Contractor shall make arrangements for periodic inspection by the
local fire authority and shall co-operate with said authority to promptly carry
out their recommendations at his own expense.
1/19 SAFETY OFFICERS

1/19.1 The Contractor shall inform the Engineer in writing within two weeks of the
start of works the names of responsible people resident on the site who will
be undertaking the duties of Safety Officers and Safety Supervisors on
Site. The Contractor shall also provide detailed written responsibilities and
duties of the safety officers and safety supervisors to the engineer and
shall be subjected to the Engineer approval. Safety Officers shall be in
continuous attendance on site 24 hours a day, one in the day shift and one
in the night shift, throughout the Contract period.
1/20 CONTRACT DRAWINGS AND DOCUMENTS

1/20.1 The Works shall be executed in accordance with the Drawings, other
contract drawings and other such information that may be issued or
approved by the Engineer. The Contractor will be furnished with one set of
transparencies of the original drawings, in addition to an extra digital copy
of the drawings free of charge.
The works shall be executed in accordance with the drawings, other

contract drawings and other such information that may be issued or
approved by the Engineer.
The Contract documents are complementary and represent one unit and
any requirements mentioned in any part of the documents are considered
as mentioned in all other parts. If there is any discrepancy between the
different parts of the Contractor documents, the Engineer is the sole party
who has the authority to interpret and clarify the action to be taken and this
will not, at any case, entitle the Contractor for any additional cost or time
extension or whatsoever.
The Contractor will be furnished with A3 size of the Contract drawings in

addition to an extra digital copy on a CD free of charge.

1/21 SHOP DRAWINGS, WORKING DRAWINGS, OPERATIONS AND

MAINTENANCE INSTRUCTIONS
1/21.1 For any work or part thereof as requested, the Contractor shall supply four
(4) copies of shop/working drawings for approval by the Engineer. All
working drawings shall be A1 size folded to A4 size. An extra digital copy
of the working drawings should be submitted on a CD for easy future
reference or for further extra copy production.
1/21.2 For all above mentioned drawings, the Engineer shall return to the
Contractor one (1) copy with any necessary corrections for resubmittal or
marked with approval.
1/21.3 At the end of the project, the Contractor shall submit to the engineer 2 sets
of printed copies and one digital copy on a CD for all the approved shop
drawings.
Monthly progress report as well as final materials reports both containing

the prescribed summary of testing frequency shall be submitted to the
Engineer and RTA for review.
1/21.4 In additions, the Contractor shall provide the Engineer with all information,
scale drawings and every assistance so that the Engineer can prepare
drawings of work as executed to form a complete record of the finished
work.
All drawings must be prepared using a Computer Aided Drafting system

Drawings shall be plotted by the Contractor as required by the

Specification.
Diskettes containing the drawings data are to be supplied to the Engineer

in the approved digital format.
1/21.5 The Contractor shall record the exact location of all services apparatus
excavated during the works and shall submit drawings to the Engineer
showing such information for incorporation by the Engineer into the Record
Drawings.
1/21.6 The cost related to the production of the drawings, either during
construction or at the time of delivery of the final account (for which 1
negative + 3 copies of all attachments are necessary), shall be borne
directly by the Contractor, and no separate payment shall be in anyway
considered.
1/21.7 Within sixty (60) days of the date of field staking, the Contractor shall
submit to the Engineer for his approval the plotting of the original and final
earthwork cross-sections, together with the area and volumetric earthwork
computations.
1/21.8 The Contractor’s cross-section shall be on transparent cross-section
sheets for print reproduction. CD’s containing the drawings data are to be
supplied to the Engineer in the approved digital format.

1/21.9 On final approval of the Contractor’s cross-sections, the Contractor shall

give the Engineer the original transparent tracings and three (3) prints of
the same along with approved volumetric earthwork computations (in A4
size and bound). The contractor shall also supply to the engineer all data
and drawings on CD’s in the approved digital format If the Contractor fails
or refuses to submit cross-sections within the specified time, the Engineer
may withhold payment for all or any part of the earthwork quantities
involved. All cross-sections shall be plotted on A1 size Drawing folded to
A4 size.
1/22 RECORD DRAWINGS

1/22.1The Contractor is fully responsible for preparing the as built drawings for
the whole works undertaken within the project scope of work.. The
contractor, in close coordination with the Engineer, shall prepare accurate
record drawings showing works as executed complete with existing and
finished levels (top invert and formation levels plans cross and longitudinal
sections locations of all junctions manholes inlets, extent of concrete bed
and structures and all other measures necessary to form a complete
pictorial record of the finished work).
The exact locations with dimensions of existing and new service ducts,
cables, pipes, etc shall be clearly shown on the drawings. All negatives of
record drawings prepared by the Engineer shall be dated and signed by
the Contractor and the Engineer as being a true record of the Works ‘as-
built”. The contractor shall also provide to the engineer all data and
drawings on CD’s in the approved digital format.
The final payment certificate will not be issued to the contractor until all the
above have been received by the Engineer.
1/23 ACCOMMODATION WORKS

1/23.1 The Contractor will be responsible for making all necessary arrangements
with owners and occupiers for carrying out accommodation works,
including, where necessary, access onto or across private land.
1/23.2 Where, in the opinion of the Engineer, the convenience or amenity of an

owner or occupier or of the public generally is affected by the Works, the
Engineer may order the Contractor to complete any accommodation work,
or part of an accommodation work, with the utmost expediency and
irrespective of the Contractor’s overall programme for the Works.
1/24 PUBLICITY
1/24.1 The Contractor or any agents or servants in his employ shall not give any
information concerning Works for publication in the press or on radio,
television or cinema screen or elsewhere without the written approval of
the Engineer.
1/24.2 No advertisements shall be erected within the Site by the Contractor or any
subcontractor without written approval of the Employer. Should any
advertisement be erected within the site without such prior approval the
Engineer may instruct the Contractor to remove it forthwith. Should such

an instruction fail to be carried out within 24 hours, the Engineer may

remove the advertisement and charge the cost to the Contractor.
1/24.3 All advertisement within the site shall be removed within one month of the
date of Certificate of Substantial Completion of the Works, unless the
Employer agrees in writing for any advertisement to remain for a further period.
1/25 TIDYING AND CLEARING THE SITE

1/25.1 The Contractor shall maintain the Site in a clean and orderly condition free
from accumulation of waste materials and rubbish during the entire
construction period to the satisfaction of the Engineer.
1/25.2 On completion the entire site within the Right of Way are to be cleared of
all construction materials and temporary buildings, etc. to the satisfaction
of the Engineer.
1/26 SOIL INVESTIGATION

1/26.1 Any information given about soils investigations carried out is for the
Contractor’s assistance only. It is the Contractor’s responsibility to check
and confirm the existing ground conditions and in particular the likelihood
of encountering water during the course of sub-surface construction.
1/27 WORKS FREE FROM WATER

1/27.1 Except where in the opinion of the Engineer, the route of the work
necessitates underwater construction, the Contractor shall execute all
works in the dry, and shall construct any temporary drains, water courses,
pumping and other works that may be necessary for the purpose. The
Contractor shall have included for the cost of all operations necessary to
comply with this Clause within his tender.
1/28 OTHER CONTRACTORS ON SITE

1/28.1 The Contractor must extent full cooperation by way of liaison and
coordination with other Contractors who may be operating within the site of
the works engaged in essential work for the Government of Dubai.
1/29 MAJOR EQUIPMENT AND PLANT
1/29.1 GENERAL
Equipment shall mean, where mentioned in these Specifications, all

machines, tools, equipment and all necessary parts for its operation and
maintenance. Also, the laboratory tools and instruments and/or equipment
necessary for the proper construction of the road and the proper
completion of all the works.
The Contractor, shall submit, as stipulated in the “Instructions to Tenderer”

a detailed list of plant equipment which he shall undertake to bring to the
site to carry out the work. The list shall include for each piece of
equipment, the type, size, quantity, manufacturer, model, identification
number and year of manufacture. The Contractor shall supply all plant and

equipment necessary for the construction of each phase of the work and it
must be on the site, inspected and approved by the Engineer prior to the
commencement of the particular phase of work. Any plant or equipment of
portion thereof, which becomes worn or defective shall be immediately
repaired or replaced to the satisfaction of the Engineer.
1/29.2 COMPACTING EQUIPMENT
The compaction equipment for earthwork may be towed or self-propelled

and shall include a suitable combination of tamping rollers, grid rollers,
segmented pad rollers, vibrating rollers, pneumatic rollers and other
compaction equipment that can satisfactorily and uniformly obtain the
required compaction.
i Tamping or Sheepfoot Rollers:

Tamping or sheepfoot rollers shall consist of metal rollers, drums,
or shells surrounded by metal studs with tamping feet projecting not
less than sixteen and one-half (16.5) centimeters from the surface
of the roller, drum or shell. Tamping feet shall be spaced not less
than fifteen (15) centimeters or more than thirty (30) centimeters
measured diagonally centre to centre and the cross section area of
each tamper foot, measured perpendicularly to the axis of the stud,
shall be not less than twenty-five and eight-tenths (25.8) square
centimeters. The weight of tamping rollers shall be such that when
fully loaded, the load on each tamper foot will be determined by
dividing the total weight of the roller (loaded) by the number of
tamper feet in one (1) row parallel to the axis of the roller.
ii Pull-Type Steel Rollers:
Pull-type steel rollers shall have not less than one and two-tenths
(1.2) meter effective width of roller and shall be designed and
constructed so that the weight per linear centimeter of roller can be
varied from thirty five and seven-tenths (35.7) kilograms to at least
fifty-three and six-tenths (53.6) kilograms.
iii) Self-Propelled Steel Rollers:

The power mechanism shall be capable of propelling the roller
smoothly and without jerking when starting, stopping, or reversing
directions free from backlash, loose link motion, faulty steering
mechanism and worn king bolts. The steering mechanism shall
have no lost motion, shall operate readily and permit the roller to be
directed on the alignment desired. The faces of all rollers shall be
smooth and free from defects which mark the finished road surface.
Rollers shall be equipped with water tanks and sprinkling devices
which shall be used for wetting the roller to prevent adherence of
the placed material.
Two-axle tandem steel rollers shall weigh not less than eight (8)
tones or more than twelve (12) tones and shall have a weight per
centimeter width of roll between 35 Kg and 70 Kg.

Three axle tandem steel rollers shall weigh not less than eleven
(11) tons. Three axle tandem roller shall be so constructed that the
roller, when locked in position for all treads to be in one plane, are
held with a rigidity which will satisfy the following test under full
load; with the weight of the roller supported on the central roller, the
tread of the central roller shall not be more than three (3)
millimeters above the plane tangent to the tread of the end roller.
With the weight of the roller supported on the end rollers, the tread
of the central roller shall not be more than six (6) millimeters below
the plane tangent to the treads of the end roller.
iv) Trench Rollers:

The trench roller shall be of an approved type and shall weigh not
less than fifty-three and six tenth (53.6) kilograms per centimeter of
width and shall be equipped with water and sprinkling device that
shall be used for wetting the roller to prevent adherence of the
placed material.
iv) Pneumatic-Tyred Rollers:

The tyres on the front and rear axles shall have wide smooth treads
and shall be staggered to provide complete coverage of the entire
area which the roller travels. The tyres shall be inflated to a
pressure that has been approved by the Engineer and the pressure
shall be reasonably uniform in all tyres. The Contractor shall
provide a suitable gauge for determining air pressure in the tire.
Light self-propelled pneumatic-tyred rollers shall be so constructed
so that they may be loaded to provide a gross weight of at least
forty (40) kilograms per centimeter of width of tire tread.
Heavy self-propelled pneumatic-tyred rollers shall be constructed
so that they can be loaded to provide a gross weight of not less
than twenty five (25) tones and they shall have tyre pressures of 6-
6.3 Kg/Cm2.
vi) Vibration Compactors: Equipment using principle of vibration as a

tamping force shall be in good mechanical condition and shall be
capable of transmitting forceful vibrations or impacts to the various
materials placed in construction. The equipment may be the roller
or pad type or a combination of roller and pad type. Vibrating
compactors shall be of the type and force approved by the
Engineer.
1/29.3 HAULING AND WEIGHING EQUIPMENT
i) Hauling Equipment:
Hauling equipment for aggregate 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 so constructed and maintained to
prevent loss of materials during hauling operations.
The equipment shall be provided with dump controls that can be operated
from the driver’s seat. The bodies of hauling equipment using public roads
shall be fitted with tarpaulins to prevent the nuisance of spillage.

ii) Weighing Equipment:

Weighing equipment for truck-hauled material shall consist of accurate and
reliable platform scales and they shall be accurate to one percent throughout
the range of use. The scale shall have a platform of adequate length to
weigh the longest truck or truck-trailer combination which is in use on the
Project, in one operation. Scales shall be inspected and sealed or certified
by an approved scale company, as often as the Engineer deems necessary
to ensure their accuracy. The seal or certification shall show the date of the
inspection. Where no approved scale company exists or at the option of the
Engineer, the Contractor shall check and adjust the scale in the presence of
the Engineer in the method recommended by the manufacturer and/or
approved by the Engineer. It is the Contractor’s responsibility to have
sufficient standard test weights for each scale on the Site.
The Engineer, as often as he deems it is necessary, shall direct the

Contractor to check and adjust any scale on site to ensure its accuracy. The
Contractor, shall when directed by the Engineer, make weight comparisons
with other permanently located scale that met with the approval of the
Engineer. These weight comparisons shall be for the purpose of providing
information on the performance of the Contractor’s scale and will not be
used as a basis for adjusting the scale.
The approaches to the scale platform shall be maintained by the Contractor

to the satisfaction of the Engineer.
The Contractor shall furnish a suitable weather tight building to enclose the
indicating mechanism and shall have adequate lighting for the scale
operator’s use.
The Contractor shall on hand not less than ten (10) twenty-five (25) kilogram
weights for testing the scale.
iii) Controlled Water Distribution Equipment:

Equipment for distribution of water shall consist of distributors or tanks
equipped with spray bars and, when required, pumps to operate under
pressure. The pumps shall be of sufficient capacity to provide uniform and
adequate distribution. They shall be mounted on pneumatic-tyre trailers
pulled by pneumatic-tyred equipment. The minimum capacity of any tank
shall be four (4) cubic metres where applicable.
The distributor equipment shall be constructed to permit accurate and

uniform distribution of the desired quantities of water per unit of surface
area. The control valves shall be constructed to permit full closing and to
prevent leakage. The water control valves shall be constructed to operate
from the driver’s seat or provisions made for an additional operator to
operate the control valve while the equipment is traveling at the proper
speed for distribution.
1/29.4 MAIN PLANT FOR BITUMINOUS PAVING WORKS
i) Equipment for Heating Bituminous Materials:

Equipment for heating bituminous materials shall be of adequate capacity to
heat the material properly by circulating the bituminous material around the
system of heated coils or pipes, or by circulating the bituminous material
through a system of coils or pipes enclosed in a heated jacket or other

approved means.
The heating device shall be constructed so that it will prevent the direct
flame from a burner from striking the surface of the coils, pipes or jackets
through which the bituminous material is circulated. The heating device shall
not be operated in a manner that will injure the bituminous material.
Tankers or trucks received on the work which have defective coils, or from
which the coils have been removed, will be rejected by the Engineer unless
some satisfactory auxiliary means can be provided by the Contractor for the
heating of the bituminous material without the introduction or moisture. The
use of any equipment for the agitation of bituminous material to aid in
heating will be prohibited if it injures or in any way changes the
characteristics of the bituminous material or introduces free steam or
moisture into the tank containing the bituminous material.
Tanker or truck connections for transferring bituminous material from tankers

to distributors, supply tanks, or storage tanks shall be constructed so that
they cannot be used for any other purpose. The use of a tanker or truck
connection or any other equipment by means of which free steam can be
introduced directly into the bituminous materials as a means of agitation or
auxiliary heating will be prohibited.
ii) Bitumen Distributor Equipment:
Equipment for the distribution of bituminous materials shall be equipped with

the following appliances or devices:
Tachometers-Pressure Gauge -Adjustable Length Spray Bars -Separate

Power Unit & Pump on distributing System -Heating Coils and Burner -
Thermometer well and Accurate Thermometer -Measuring Sticks -Quick
Opening Gate in dome
All distributors and supply tanks shall be mounted on dependable motor

trucks or trailers equipped with pneumatic tyres. The units shall be so
designed to ensure that no rutting or other injury to the road surface will
result. The distributor shall have pneumatic tyres of such width and number
that the load produced on the road surface shall not exceed one hundred
and ten (110) kilograms per linear centimeter of the width. They will be
sufficiently powered to maintain the desired speed of the equipment during
operation.
The manometer designating the speed of the truck shall be a separate

operating unit attached to the truck equipped with a larger gauge
approximately fourteen (14) centimeters in diameter and graduated in units
so that the speed of the trucks can be determined within limits of
approximately three (3) metres per minute or equivalent thereto. The gauge
shall be so located that it can be easily read at all times by the driver of the
distributor.
The distributor shall be equipped with either a tachometer, calibrated to
indicate revolutions per minute, attached to the pump shaft or a pressure
gauge, calibrated to indicate kilograms per square centimeter placed in the
distributing system, by which the flow of bitumen may be regulated.

The spray bars shall be constructed to permit adjustment for length in

increments of thirty (30) centimeters for any length up to seven (7) metres, to
permit vertical adjustment of all nozzles to the desired height above the road
surface conforming to the roadway crown, and to permit lateral shifting of the
entire spray bar during operation. The spray bars and nozzles shall be
constructed to prevent clogging of the nozzle during the intermittent
operation and to provide positive and immediate cut-off when distribution of
oil ceases, thus preventing dripping of oil from the bar.
The power unit and pump distribution systems shall have a capacity of not
less than nine hundred fifty (950) litres per minute, shall be equipped with a
by-pass into the supply tank and shall be capable of distributing a uniform
and constant flow of bituminous material through all nozzles at a pressure
between one and one quarter (1.25) and three and one-half (3.5) kilograms
per square centimeter.
The entire distributor assembly shall be so constructed and operated to

ensure accurate distribution of bituminous material at rates of from two-
tenths (0.2) to seven and five tenths (7.5) litres per square metre with
uniform pressure, and with an allowable variation from any specified rate not
to exceed one tenth (0.1) litres per square metre. Minimum capacity of the
distributor shall be four thousand (4,000) litres.
iii) Calibration and Check of Distributors:
All distributors shall be calibrated and checked before being used on the
work. The calibration of the tank will be done by the Contractor in the
presence of the Engineer by the method prescribed by the manufacturer
and/or directed by the Engineer.
The operation of the distributor will be checked by the Engineer the first time
it is used and as often as he deems it necessary thereafter, and when the
operation is found to be satisfactory, a new certificate will be issued.
iv) Stationary Mixing Plants:
Stationary mixing plants shall consist of measuring and proportioning

equipment and mixing equipment. They shall also include dryers when
aggregates are furnished that contain moisture in excess of the amounts
permitted for mixing. The measuring and proportioning equipment shall
consist of a system of hoppers and scales designed for proportioning and
measuring by batch weights or of continuous flow equipment so designed
and operated that the flow of materials can be accurately and continuously
regulated and so arranged to permit easy and accurate checking of the rate
of flow on a weight basis. For continuous flow mixing the proportioning
equipment may be at the stockpile site so that the individual aggregate may
be blended prior to entering the drier. The drier shall be capable of drying
and heating the mineral aggregates to specification requirements.
The proportioning devices for the bituminous materials and aggregates shall
be so synchronized that proper proportioning will be obtained at all times.
The design of the mixing chambers shall provide adjustment to permit a

mixing period of sufficient duration to produce a thorough and uniform mix.

The approval of and continued use of a stationary plant shall be contingent
upon its ability to proportion and mix satisfactorily the several materials in
adequate quantity for the proper progress of the work.
v) Hot Mix Plant:
All equipment shall meet the approval of the Engineer, shall be kept in good
working condition, shall meet the requirements herein specified and shall be
of sufficient capacity to produce and process not less than eighty (80) tons of
mixed material per hour. All plants used by the Contractor for the preparation
of bituminous mixes and (Plant Mix) prepared mixes shall conform to all the
requirements of these Specifications except that scale requirements shall
apply only where weight proportioning is used, and in addition batch mixing
plants and continuous plants shall conform to the special requirements of
these specifications.
vi) Requirements of all Plant
Uniformity:
The plants shall be so designed, co-ordinated and operated to produce a

uniform mixture.
Scale:
Scales for any weight box or hopper may be of either the beam or springless
dial type and shall be of a standard make and design, accurate to one (1)
percent of the maximum load that may be required.
When scales are of the beam type, there shall be a separate beam for each
size of aggregate. There shall be provided a “Tell-tale Dial” that will start to
function when the load being applied is within fifty (50) kilograms of that
desired. Sufficient vertical movement shall be provided for the beams to
permit the telltale dial to function properly. Each beam shall have a
locking device so designed and located that the beam can easily be
suspended or thrown into action.
Dial scales shall be springless, of a standard make, and of such size that the
numeral on the dial can be read at a distance of at least (8) metres. The dial
shall be of a compounding type having full complement of index. Pointers so
placed as to give excessive parallax errors shall not be used. The scales
shall be substantially constructed, and those that easily get out of
adjustment shall be replaced with other makes when so ordered. All dials
shall be so located as to be plainly visible to the operator at all times.
Scales shall be inspected and sealed or certified as often as the Engineer

may deem necessary to ensure their continued accuracy. The initial
inspection shall be done by an approved scale company, or by the
Contractor in the presence of the Engineer by the method prescribed by the
manufacturer and/or as directed by the Engineer. The Contractor shall have

on hand not less than ten (10), twenty-five (25) kilograms weights for testing
the scales.
Equipment for Preparation of Bituminous Material: Tanks for the storage of

bituminous material shall be equipped to heat and hold the material at the
required temperature. The heating shall be accomplished by steam coils,
electricity, hot coils, or other approved means so that the flame shall be in
contact with the tank.
The circulating system for the bituminous material shall be designed to

ensure proper and continuous circulation during the operating period.
Provision shall be made for measuring and sampling storage tanks. Storage
tanks shall have sufficient capacity to provide for continuous operation. The
storage tanks shall be calibrated and equipped with a device whereby the
Engineer may determine the amount of asphalt on hand at any time.
Feeder for Drier: The plant shall be provided with accurate mechanical
means for uniformly feeding the aggregate into the drier so that uniform
production and uniform temperature will be obtained. A separate mechanical
feeder equipped with an adjustable gate opening shall be provided for each
individual aggregate being combined to produce the total aggregate. The
feeders and gate shall be so constructed and equipped that a continuous
and uniform flow of each material will be ensured. They shall also be
installed in such a manner as to be readily accessible for calibrating at all
times.
Drier: The plant shall include a drier or driers which continuously agitate the
aggregate during the heating and drying process. The drier shall be capable
of drying and heating the mineral aggregate to specification requirements.
The burners shall be of such capacity, and they shall be so constructed and
operated that complete combustion of the fuel is obtained.
Screens: Plant screens, capable of screening all aggregates to the specified
sizes and proportions and having normal capacities in excess of the full
capacity of the mixer, shall be provided.
Bins: The plant shall include storage bins (cold & hot) of sufficient capacity to
supply the mixer when it is operating at full capacity. Bins shall be arranged
to ensure separate and adequate storage of appropriate fractions of the
mineral aggregates. Separate dry storage shall be provided for Portland
Cement, hydrated lime, or other similar material when used and the plant
shall be equipped to feed such material into the mixer.
Each bin shall be provided with overflow pipes, of such size and at such
location as to prevent backing up of material into other compartments or
bins. Each compartment shall be provided with its individual outlet gate,
constructed so that when closed there shall be no leakage. The gate shall
cut off quickly and completely. Bins shall be so constructed that samples can
be readily obtained. Bins shall be equipped with adequate tell-tale devices to
indicate the position of the aggregates in the bins at the lower quarter point.
The minimum number of bins shall include at least one bin for each different
stockpile of material being used. Intermixing of material from different
stockpiles in one bin or on the ground shall not be permitted.

Bituminous Control Unit: Satisfactory means, either by weighing or metering

shall be provided to obtain the proper amount of bituminous material in the
mix within the tolerance specified. Means shall be provided for checking the
quantity or rate of flow of bituminous material into the mixer. Suitable means
shall be provided for maintaining the specified temperature of the bituminous
material in the pipelines, metres, weight buckets, and spray bars.
Thermometric Equipment: An armored thermometer of adequate range in

temperature reading shall be fixed in the bituminous feed line at a suitable
location near the charging valve at the mixer unit.
The plant shall also be equipped with either an approved dial-scale mercury-
actuated thermometer, an electric pyrometer, or other approved
thermometric instrument so placed at the discharge chute of the drier as to
register automatically or indicate the temperature of the heated aggregates.
All plants whether continuous or batch type shall be equipped with two
recording thermometers. These instruments shall be provided with dust-
proof cases, long leads, and automatic recording mechanism capable of
recording the desired temperature for a period of twenty-four (24) hours on a
chart not less than twenty (20) centimeters in diameter, or on a continuous
sheet. The chart for either type shall be graduated in hours, minutes, and
degrees of temperature. The maximum time graduation shall be fifteen (15)
minutes and the maximum temperature graduation shall be five (5) degrees
centigrade. Hours on the chart shall be designated as a.m or p.m.
The temperature recording thermometers should be installed on points or a

framework, separate from plant, to eliminate plant vibration.
They shall be located in a manner to provide easy access to the case and
chart. The bulb of one instrument shall be installed in the hot asphalt line as
close as is practicable to the spray bar discharge, the bulb of the second
recording thermometer shall be installed in the hot aggregate bin which
contains the fine aggregate. The bulb shall be located where the hot
materials will flow over it during the proportioning operation and shall not be
located near the corners of the bin or at locations where the material will
collect or pack around it.
The Engineer reserves the right to pass judgment upon the efficiency of
thermometric instruments.
Control of Mixing Time: The plant shall be equipped with positive means to
govern the time of mixing and to maintain a constant time unless changed by
order of the Engineer.
Dust Collectors: The plant shall be equipped with a dust collector

constructed to waste or return uniformly to the hot elevator all or any part of
the material collected as desired.
Safety Requirements: Adequate and safe stairways to the mixer platform

and sampling points shall be provided and guarded ladders to other points
shall be placed at all points where accessibility to plant operations is
required. Accessibility to the top of truck bodies shall be provided by a
platform or other suitable device to enable the Engineer to obtain sampling

and mixture temperature data. A hoist or pulley system shall be provided to

raise scale calibration equipment, sampling equipment and other similar
equipment from the ground to the mixer platform.
All gears, pulleys, chains, sprockets, and other dangerous moving parts shall
be thoroughly guarded and protected. Ample and unobstructed space shall
be provided on the mixing platform. A clear and unobstructed passage shall
be maintained at all times in and around the truck loading area. The area
shall be kept free from dropping from the mixing platform.
vii) Specification Requirements for Batching Plants Weigh Box or Hopper
The equipment shall include a means for accurately weighing each size of
aggregate in a weigh box or hopper suspended on scales and of ample size
to hold a full batch without hand raking or running over. The gate shall close
tightly so that no material is allowed to leak into the mixer while batch is
being weighed. Asphalt plants shall meet requirements in accordance with
ASTMD995 & ASTMD290.
Bituminous Control: The equipment used to measure the bituminous

material shall be accurate to plus minus five-tenths (0.5) percent. The
bituminous material bucket shall be a non tilting type with a loose sheet
metal cover. The length of the discharge opening or spray bar shall be not
less than three-fourths (3/4) the length of the mixer and it shall discharge
directly into the mixer.
The bituminous material bucket, its discharge valve or valves and spray bar
shall be adequately heated. Steam jackets, if used, shall be efficiently
drained and all connections shall be so constructed that they will not
interfere with the efficient operation of the bituminous scales.
The capacity of the bituminous material bucket shall be at least fifteen (15)
percent in excess of the weight of bituminous material required in any batch.
The plant shall have an adequately heated quick-acting, nondrip, charging
valve located directly over the bituminous material bucket.
The indicator dial shall have a capacity of at least fifteen (15) percent in
excess of the quantity of bituminous material used in a batch.
The dial shall be in full view of the mixer operator. The flow of bituminous
material shall be automatically controlled so that it will begin when the dry
mixing period is over and all of the bituminous material required for one
batch will be discharged in not more than fifteen (15) seconds after the flow
has started.
The section of the bituminous line between the charging valve and the spray
bar shall be provided with a valve and outlet for checking the metering
device.
Mixer: The batch mixer shall be an approved type capable of producing

uniform mixture. If not enclosed, the mixer box shall be equipped with a dust
hood to prevent loss of dust.

The clearance of blades from all fixed and moving parts shall not exceed two
and one-half (2.5) centimeters unless the maximum diameter of the
aggregate in the mix exceeds three (3) centimeters, in which case the
clearance shall not exceed three and eight-tenths (3.8) centimeters.
Control of Mixing Time: The mixer shall be equipped with an accurate time
lock to control the operations of a complete mixing cycle. It shall lock the
weigh box gate after the charging of the mixer until the closing of the mixer
at the completion of the cycle. It shall lock the bituminous material bucket
throughout the dry mixing period and shall lock the mixer gate throughout
the dry and wet mixing periods.
The dry mixing period is defined as the interval of the time between the
opening of the weigh box gate and the start of introduction of bituminous
material. The wet mixing period is the interval of time between the start of
introduction of bituminous material and the opening of the mixer gate.
The control of the timing shall be flexible and capable of being set at
intervals as necessary for mixing time throughout the total mixing cycle. A
mechanical batch counter shall be installed as a part of the timing device
and shall be so designed as to register only completely mixed batches.
Automation and Recording of Bituminous Concrete Plants. The plants shall

be equipped with an automatic mass measuring cycling and monitoring
systems approved by the Engineer. Recording equipment shall monitor the
batching sequence of each component of the mixture and produce a printed
record of these operations. For each day's production the Engineer shall be
provided a clear, legible copy of the recording. There should be provisions
so that scales may not be manually manipulated during the printing process.
viii) Special Requirements for Continuous Mixing Plants Aggregate

Proportioning: Continuous Mixing Plants are not recommended for Roads &
Transport Authority projects.
Weight Calibration of Aggregate Feed: The plant shall include means for
calibration of gate opening by weighing test samples. Provisions shall be
made so that materials fed out of individual orifices may be bypassed to
individual test boxes.
The plant shall be equipped to conveniently handle individual test samples

weighing not less than one hundred (100) kilograms. Accurate scales shall
be provided by the Contractor to weigh test samples.
Weight Calibration of Bituminous Material: The bituminous discharge line

shall be equipped with suitable valves and a bypass so that the asphalt
pump of meter may be readily calibrated. For each change of stockpiles, the
plant shall be recalibrated.
Synchronization of Aggregate Feed and Bituminous Material Feed:

Satisfactory means shall be provided to afford positive interlocking control
between the flow of aggregate from the bins and the flow of bituminous
material from the meter or other proportioning device. This control shall be
accomplished by interlocking mechanical means or by any other positive

method satisfactory to the Engineer.
Mixer: The plant shall include a continuous mixer of an approved type,

adequately heated and capable of producing a uniform mixture. It shall be
equipped with a discharge hopper with dump gates which will permit rapid
and complete discharge of the mixture.
The paddles shall be adjustable for angular position on the shaft and
reversible to retard the flow of the mix. The mixer shall have a
manufacturer’s plate giving the net volumetric contents of the mixer at the
several heights inscribed on a permanent gauge. Charts shall be provided
showing the rate of feed of the aggregate per minute for the aggregate being
used.
Bituminous-mix Paver: Bituminous-mix pavers shall be self-contained,

power propelled units, provided with automatically controlled activated
screed or strike-off assembly, heated for the full width of the screed if
necessary, and capable of spreading and finishing courses of bituminous
plant mix material at least 300 millimeter more than the width of one lane
applicable to the specified typical section and thickness shown on the plans.
Pavers used for shoulders and similar construction shall be capable of

spreading and finishing courses of bituminous plant mix material in widths on
the plans. Pavers shall be capable of laying one hundred (100) tons per
hour.
The machines shall employ mechanical devices such as equalising runners,

straight-edge runners, evener arms, or other compensating devices to adjust
the grade and confine the edges of the mixer to true lines without the use of
stationary side forms.
The paver shall be equipped with a distribution system to place the mixer
uniformly in front of the screed.
The screed or strike-off assembly shall effectively produce a finished surface

of a required evenness and texture without tearing, shoving or gouging the
mixture.
The paver shall be capable of being operated, when laying mixture, at

forward speed consistent with satisfactory laying of the mixture.
The automatic controls for the paver shall be automatic linkage arrangement
so that through the process of automatically adjusting the screed, the
thickness of asphaltic mixtures can be placed and finished to predetermined
grade and a uniform crown or cross-section.
The paver shall be equipped with automatic screed controls with sensors
capable of sensing grade from an outside reference line, sensing the
transverse slope of the screed, and providing the automatic signals that
operate the screed to maintain grade and transverse slope.
Manually controlled bituminous-mix pavers may be used only with the written
consent of the Engineer.

A manually controlled bituminous-mix paver shall be of the self-propelled

type with spread and strike-off facilities designed to spread the mixture in
such a manner that no supplemental shaping will be required.
It shall be self vibrator capable of spreading the mixture evenly, producing a

finished surface of the required thickness, density, smoothness and texture
without segregating, tearing, shoving, or gouging the mix.
Screeds must be constructed so as not to follow minor irregularities in the

base and must be readily adjustable to control accurately the depth spread.
No manually operated bituminous-mix paver shall be delivered to the site

prior to its approval by the Engineer.
Self-Propelled Aggregate Spreader: Self-propelled aggregate spreader shall

be approved design supported by at least four (4) wheels equipped with
pneumatic tyres on two (2) axles. The aggregate spreader shall be equipped
with a means of applying the larger cover coat material to the surface ahead
of the smaller cover coat material and with positive control so that the
required amount of material will be deposited uniformly over the full width of
the bituminous material. Other types of aggregate spreaders may be used
provided they accomplish equivalent results and are approved by the
Engineer.
1/30 METEOROLOGICAL AND AMBIENT CONDITIONS PREVAILING IN DUBAI

The average prevailing local conditions at Dubai City shall be assumed as follows
(Table 1-1):
Table 1- 1: local conditions at Dubai City

Serial Parameter Limit or Value
1. Max. Ambient Temperature 55 deg.C
2. Min. Ambient Temperature 1 deg.C
3. Design Ambient Temperature 50 deg.C
4. Max, Metal Temperature under sun 85 deg.C
5. Min. Barometric Pressure 998 mb
6. Max. Ambient Humidity 100%
7. Ambient Humidity 20%
8. Design Ambient Humidity 80% Max
9. Design Wind Velocity 160 Km/hr.
10. Average Yearly Rainfall 80 mm -150 mm
The climate of Dubai is relatively mild from November to April, and hot from May

to October with high relative humidity.
Under certain combinations of the above climatic conditions considerable

condensation may take place.
Particular attention should be paid to the prevailing corrosion conditions. A

considerable amount of salt is contained in the atmosphere which together with
the extremely high ambient humidity, can produce severe corrosion problems.
Distribution of rainfall is irregular, and the precipitation amounts are normally of no

significance, but attention should be paid to the fact that sudden heavy rainfalls in
a very short period of time can occur.
The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 Km/hr. and sand storms and
dust storms occur in the summer months.

1 SECTION 2 SITE CLEARANCE AND EARTHWORKS
TABLE OF CONTENT
2/1 SITE CLEARANCE DESCRIPTION .................................................................... 2

2/2 SURVEY BEFORE COMMENCEMENT .............................................................. 2
2/3 DEMOLITION REQUIREMENTS ........................................................................ 2
2/4 GENERAL SITE CLEARANCE ............................................................................ 3
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED BY THE WORKS 4
2/6 ROAD SIGNS ...................................................................................................... 4
2/7 DISPOSAL OF HISTORICAL ARTIFACTS ......................................................... 4
2/8 DISPOSAL OF SURPLUS MATERIAL ................................................................ 5
2/9 EXCAVATION FOR ROAD CONSTRUCTION ...................................................5
2/10 CLASSIFICATION OF EXCAVATION ................................................................. 5
2/11 EXCAVATION REQUIREMENTS ........................................................................ 6
2/12 BORROW PIT SITE............................................................................................. 8
2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF EARTHWORKS
MATERIALS ....................................................................................................... 9
2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION .................................... 13
2/15 EMBANKMENT CONSTRUCTION ...................................................................13
2/16 EMBANKMENT FOUNDATION ......................................................................... 14
2/17 PLACING AND COMPACTION REQUIREMENTS ........................................... 15
2/18 MOISTURE CONTROL REQUIREMENTS ....................................................... 17
2/19 TESTING METHODS ........................................................................................ 18
2/20 MINIMUM TEST REQUIREMENTS................................................................... 18
2/21 CRUSHED STABILISING MATERIAL ............................................................... 20
2/22 GEOTEXTILE FABRIC ...................................................................................... 21
2/23 EXCAVATION FOR STRUCTURES ................................................................. 23
Volume 2, Part 1, General Specifications-Road Works July 2018 Page 1

2/1 SITE CLEARANCE DESCRIPTION
2/1.1 This work shall consist of the removal, wholly or in part, and satisfactory
disposal of all buildings, fences, structures, abandoned pipelines, and any
other obstruction which are not designated or permitted to remain within
the clearing project limits designated on the plans. It shall also include the
salvaging of designated materials and backfilling the resulting trenches,
holes and pits.
2/2 SURVEY BEFORE COMMENCEMENT
2/2.1 Prior to starting the site clearance, the Contractor shall carry out a
thorough survey of buildings, structures, fences, trees, etc. that are to be
removed. The Engineer shall be fully informed of the results of this survey
and the amount and extent of the demolition and site clearance shall then
be agreed with the Engineer.
2/3 DEMOLITION REQUIREMENTS
2/3.1 The Contractor shall in a careful manner, raze, remove and dispose of all
buildings and foundation structures, fences and other obstructions or any
portions of which are within the Right-of-Way, except utilities and those
for which other provisions have been made for removal. All
designated salvageable material shall be removed, without unnecessary
damage, in sections or pieces which may be readily transported, and shall
be stored by the Contractor at specified places within the project limits or
at designated storage areas as directed by the Engineer. All such
salvageable material shall be deemed the property of the Employer.
2/3.2 Foundations of building structures shall generally be removed to a depth of

1 m below ground level or more if considered necessary by the Engineer.
2/3.3 Where shown on the drawings or where directed by the Engineer,

underground structures, culverts, chambers and foundations other than
building foundations shall be removed to such a level as may be indicated
on the drawings or directed by the Engineer.
2/3.4 Where directed by the Engineer, the Contractor shall excavate in trench
and break out redundant pipe ducts and surrounds. Every precaution
should be taken to avoid breaking or damaging the pipes that are to be
removed and either salvaged or reused. The pipes shall be stored when
necessary so that there will be no loss or damage before relaying.
The Contractor will be required to replace sections lost from storage or

damage by negligence or by the use of improper methods in their removal.
2/3.5 Trenches and pits resulting from demolition and site clearance below
ground level shall be properly cleaned out (including pumping) and filled
with suitable material and compacted in accordance with the relevant

Specifications up to subgrade level or as otherwise directed by the

Engineer.
2/3.6 Where required, the Contractor shall be responsible, prior to demolition,

for the disconnection of all services and clearance from the Dubai
Municipality and all Service Authorities.
2/3.7 Where shown on the drawings or otherwise directed by the Engineer, all
fences, walls or boundary structures to be erected or reinstated shall be
done in the same kind and form as the one it is intended to replace. The
wall, fence or boundary structure shall be made to match the remaining
existing portions. All materials and workmanship shall be in accordance
with the relevant standards and specifications contained herein.
2/4 GENERAL SITE CLEARANCE
2/4.1 Before commencing any excavation or fill, the area located within the
clearing project limits designated on the plans and drawings, shall be
cleared of all trees, stumps, roots, bushes, vegetation, debris, materials or
other obstructions.
2/4.2 Before removal of any trees or shrubs the Contractor shall obtain written
consent from Dubai Municipality Horticultural Section at least two weeks in
advance of the planned removal.
2/4.3 The Engineer's approval of any removal of trees and undergrowth must be
obtained before commencement of work. Where directed all bushes,
undergrowth, etc. shall be grubbed up and burnt or otherwise disposed of
in tips off site (Sub section 2/8). Holes left by stumps or roots shall, within
one week, be filled with suitable material, and compacted to the Engineer's
satisfaction in accordance with Specification Clause 2/17.
2/4.4 GHAF TREES
2/4.4.1 Ghaf Trees are a protected species in the United Arab Emirates they are
to be pruned or moved under the complete supervision and written
approval of Dubai Municipality Horticulture Section.
2/4.4.2 Trees may only be moved if they represent an absolute obstruction to the
works and no diversion of services or the road alignment is possible.
2/4.4.3 The Contractor is responsible for ensuring attendance by the Horticulture

Section and provision of at least the following plants:
i) Mobile crane of sufficient capacity with slings etc. to enable the lifting of
the particular trees in question.
ii) Excavator to carry out excavation prior to tree removal.
iii) Low Bed trailer and tractor or similar to transport the removed
tree/trees to either Mushrif Park or the Dubai terminal of the
Dubai to Al Ain Road, whichever is the nearer to the site.

2/4.4.4 The above plant will be required at both the original and new tree sites.
The Horticulture Department may also require the provision of a supply of
potable water for irrigation of the tree prior to its removal.
2/5 PRESERVATION OF PROPERTY NOT TO BE AFFECTED

BY THE WORKS
2/5.1 Attention is directed to the Contractor's obligations under law and under
this Contract with regard to damage, particularly with regard to protection
of property, plants and landscape and to responsibility for damage claims.
2/5.2 Existing highways, improvements, facilities, adjacent property, services,

and trees and plants designated for preservation shall be protected from
injury or damage which could result from the Contractor's operations.
2/5.3 The form of protection for vegetation within the site shall be of a type and
standard approved by the Dubai Municipality Horticultural Section.
2/6 ROAD SIGNS
2/6.1 All existing road signs, street name plates, gantry cantilever and like
effected by the works are to be recorded (size, dimension, condition.etc)
and carefully taken down and stored on site for reuse as directed by the
Engineer. Signs to be re-erected shall be cleaned, provided with new
fixings where necessary and the posts re-painted in accordance with the
Specifications. Redundant signs shall be transported to the stores or
depots of relevant Authorities. Any sign, street name plate or the like
damaged by the Contractor during his operation shall be repaired or
replaced at the Contractor's cost.
2/7 DISPOSAL OF HISTORICAL ARTIFACTS
2/7.1 Where specified, certain materials arising from the site clearance and
excavation are to remain the property of the Employer. All fossils,
antiquities and other objects of interest or value which may be found or
uncovered on the site shall remain or become the property of the
Employer and upon discovery of such an object the Contractor shall
forthwith:
a. Use his best endeavors not to disturb or damage the object.

b. Cease work which would endanger the object or prevent or impede its
removal.
c. Inform the Engineer of the discovery and precise location of the object.
2/7.2 The Engineer will issue instructions on the procedure to be adopted which
may include conditions to permit the examination, excavation or removal
of the object by a third party.

2/8 DISPOSAL OF SURPLUS MATERIAL
2/8.1 Subject to the provision of Clause 27.1 of the Conditions of Contract Part I
and of the Specification, all materials arising from site clearance which are
surplus to or unsuitable (Section 2/13.3) for use in the Works shall become
the property of the Contractor and shall be disposed of by him either off the
Site to an approved tip or if directed or otherwise agreed by the Engineer
on the Site in an approved manner.
2/8.2 Following consultation with Dubai Municipality Public Health Department,

the Engineer and RTA, the Contractor shall propose two sites for disposal
of unsuitable or surplus material, one of which shall be specified as having
priority and which must be filled before the second is used, together with a
separate location where hard debris, such as concrete, building rubble,
kerbing, road pavement, etc. shall be disposed of. The Contractor shall
seek approval for all the proposed sites from the Dubai Municipality before
work commences and disposal at such sites shall be at no extra cost to the
Employer.
2/8.3 The Contractor has to prepare and submit to the Engineer Earth Work
Cross Section and calculate the total quantity of cut material and total
quantity of filled material.
If the filled material found more than cut material then the Engineer in
coordination with RTA will arrange to provide fill material to the project from
any of RTA running project if available. If not available, then the Contractor
can use the item of imported material.
If the cut material found more than the fill material, then the surplus material
if suitable has to be disposed to one of RTA running project as directed by
RTA. If not available the Contractor can dispose the surplus material at an
approved dumping area.
2/9 EXCAVATION FOR ROAD CONSTRUCTION
2/9.1 This work shall consist of excavating the roadway and borrow pits,
removing and satisfactorily disposing of all materials taken from within the
limits of the Work. It shall include all dewatering, excavation, shaping and
sloping as necessary for the construction, preparation and completion of all
embankments, cuttings, subgrade, shoulders, slopes, gutters, intersections,
approaches and private entrances, as directed, and in conformity to the
alignment, grades, and cross-sections shown on the plans or established
by the Engineer.
2/10 CLASSIFICATION OF EXCAVATION
2/10.1 Excavated material shall be classified as:
- Roadway Excavation.
- Borrow Excavation.

2/10.2 Roadway excavation includes all material of whatsoever nature, suitable

or unsuitable, excavated within the limits of the Right of Way for the
preparation of the road bed. All such material after deduction for material
declared unsuitable by the Engineer shall be considered to be available for
use at locations requiring fill. Roadway excavation shall be sub classified
as Common Excavation and Rock Excavation.
2/10.3 Authority to identify and define the physical characteristics which determine
the classification as "Common Excavation" and "Rock Excavation" in
accordance with the intent of the following provisions shall be vested in the
Engineer.
2/10.4 Common Excavation-' shall consist of the excavation and satisfactory

disposal (subject to Clause 2/15.3) of all soils, certain strata and individual
rock boulders less than 1 cubic meter in volume. Strata which are altered
and weathered and are in place, but which are not firm enough, or in the
opinion of the Engineer are not rigid enough to have all the characteristics
of rock excavation shall be classified as common excavation.
2/10.5 Rock Excavation - shall consist of the excavation and satisfactory disposal
(subject to Clause 2/15.3) of all unaltered and unweathered firm and rigid
igneous, metamorphic and sedimentary solid rock and boulders exceeding one
cubic metre in volume that in the opinion of the Engineer are impracticable to
remove by heavy mechanical excavating equipment (e.g. Cat.D8) or by heavy
duty hydraulic ripper, or by approved pneumatic tools.
These type of rocks would normally be removed by blasting with explosives, or

by heavy duty hydraulic breakers or by drilling and broaching with wedges and
sledge hammers if removed by hand.
2/10.6 Borrow Excavation - If the demand for fill material exceeds the quantity of
suitable material obtained from the necessary roadway excavation then
suitable material shall be imported to the worksite from an approved borrow pit.
The excavation, haulage and discharge of material in its final place from a
borrow pit shall be classified as Borrow Excavation.
2/11 EXCAVATION REQUIREMENTS
2/11.1 All materials removed from an excavation shall be used in the formation of
the embankment, shoulders and at such other places as directed, unless it
is declared unsuitable and ordered to be sent to the disposal site by the
Engineer. No excavated material shall be wasted without written
permission from the Engineer, and when such material is to be wasted, it
shall be hauled to the approved disposal site (Clause 2/8) or as otherwise
Material suitable for top soil, base material, mineral aggregate or other
specified purpose, encountered in excavation, shall be reserved in
stockpile, if so directed, until it can be placed in its proper position in the
roadway during construction. When specified or designated, top soil shall
be used as cover on embankment slopes to aid the regrowth of vegetation

or other purposes.
2/11.2 Excavated materials wasted by the Contractor without written permission of

the Engineer shall be replaced by the Contractor at his own expense.
2/11.3 During the construction of the roadway, the prepared formation shall be
maintained in such condition that it will be well drained at all times.
2/11.4 Rock, shale and other unsuitable material encountered in cuts shall be
excavated to the lateral limits and depth indicated on the plans or as
otherwise directed. Any excess breakage below the depth shown on the
plans or as otherwise directed will not be paid for. Backfill of the excess
breakage shall be approved suitable material and shall have the same
density requirements as specified by the Contract and shall be at the
expense of the Contractor. If the backfill of the excess breakage area
designated by the Engineer is to be a crushed aggregate concrete or other
special aggregate the entire cost of the backfill of the excess breakage
shall be at the expense of the Contractor. Undrained pockets shall not be
left in the surface of the rock, but they shall be treated as directed by the
Engineer.
2/11.5 All slopes, except in solid rock or other material which, in the judgment of
the Engineer, require a modified slope, shall be trimmed accurately to the
slopes shown on the cross-sections drawings, and care must be exercised
that no material shall be loosened beyond the required slopes. Side
ditches if required shall be excavated in conformity to line, grade, and
cross-section as shown on the Drawings or as directed by the Engineer.
2/11.6 In cut areas, excavation shall be for the full construction width down to
'earthworks formation level'. For a further depth of 15 cm the existing
material shall be scarified, watered as necessary, mixed and compacted to
not less than 95% of maximum dry density as determined by BS 1377 Part
4 : 1990 (Method 3.5 or 3.6, AMD 13925:2002). Field density shall be
determined by BSI BS 1377-9, AMD 17229 (2007)
2/11.7 In fill and embankments, an 'improved subgrade layer', using specified

material, shall be placed to bring the embankment level up to 'top of
improved subgrade level' The improved subgrade layer shall be compacted
to not less than 95% maximum dry density BS 1377 Part 4 : 1990 (Method
3.5 or 3.6, AMD 13925:2002). Field density shall be determined by BSI BS
1377-9 AMD 17229 (2007)
2/11.8 The technical requirements of the specifications for ‘Excavation for

Structures” (Sub-Section 2/23) shall be complied with works include cutting
of 1.5m or more in depth.
2/11.9 Where excavation to 'earthworks formation level' (i.e. the earthwork

formation level is the level of the last layer of the earthworks which can be
either “subgrade” or Improved Subgrade), results in a formation or slopes of
unsuitable soil, the Engineer may require the Contractor to remove the
unsuitable material to a depth directed and backfill to the finished graded

section with approved material compacted in accordance with specified

requirements for embankment construction.
The suitability of the existing subgrade shall be investigated up to 0.5m

below the formation level or more than 0.50m below the formation level if
the existing subgrade contains unsuitable material as defined in the clause
2/13.3 below. In this case, subgrade preparation shall be as follows:
 If the CBR of the subgrade at the formation level is satisfying the

minimum requirements, a further depth of 15cm of the existing
subgrade shall be scarified, watered, mixed as necessary and
compacted as described in clauses 2/16 and 2/17 below.
 If the CBR of the subgrade at the formation level does not satisfy
the minimum requirements, a minimum thickness as specified in the
drawings or as directed by the Engineer shall be removed and
replaced with an equal thickness of improved subgrade material and
compacted as described in clauses 2/16 and 2/17 below.
The Contractor shall conduct his operations in such a way that the
necessary cross-sectional measurements can be taken and agreed with the
Engineer before the backfill is placed.
2/11.10 When the Contractor is required or is directed to excavate unsuitable

material in fill areas, following general clearance of the area (see
Specification Subsection 2/16 "Embankment Foundation"), the depth to
which these unsuitable materials are to be removed will be determined by
the Engineer. The Contractor shall so schedule the work so that authorized
cross-sections can be taken before and after the material has been
removed.
2/11.11 All slopes, lines and grades shall be true, correct, and accurate and
according to those on the drawings or otherwise directed and approved by
the Engineer. The 'earthworks formation level' in cuts shall be accurate to
the authorized profile grade to plus or minus two (2) centimeters and, for
'top of improved subgrade' level, plus or minus one (1) centimeter. Where
discrepancies are found in the Work the Contractor shall make necessary
corrections.
2/11.12 The Engineer will check all or any part of the Work, as he deems
necessary, to determine conformance to the lines, grades, elevations and
cross-sections.
2/12 BORROW PIT SITE
2/12.1 The Contractor shall obtain approval from the Employer for the location of
the borrow pit site. The Contractor shall be responsible to determine the
quantities and quality of the available material in the approved borrow site
to meet the requirements of the Contract. When required the borrow area
shall be cleared and grubbed in accordance with the requirements of
Section 2/1.

2/12.2 The Employer may at any time revoke approval of a borrow site where the
Contractor is obtaining borrow material for the Works. Upon receiving such
notice from the Employer, the Contractor shall immediately cease removing
material from said borrow site. In the event the Employer revokes approval
of the borrow site, the Contractor shall locate a new borrow pit site as
specified above.
2/12.3 The Contractor shall not claim any additional payment for any costs by
reason of the necessity of changing borrow site locations due either to the
shortage of the supply of borrow material available from the borrow pit site
approved by the Employer, or due to the Employer's decision to revoke
approval of the borrow site where the Contractor is obtaining borrow
material for the Works.
2/12.4 The Contractor shall leave borrow pits in a condition acceptable to the
Employer and to the Engineer.
2/12.5 The Contractor will be solely responsible for ascertaining the location of
such approved borrow areas during the tender preparation stage.
Locations, distances to the work site and haulage from such approved
borrow areas shall be taken into consideration when preparing the unit
tender price for Borrow Excavation.
2/13 DEFINITION, CLASSIFICATION AND GENERAL USE OF

EARTHWORKS MATERIALS
The following definitions of earthwork materials shall apply: -
2/13.1 Top Soil shall be fertile, friable soil containing organic matter free from
subsoil, refuse, tree roots, noxious weeds, clay lumps and stones
recovered from well drained arable land. The soil shall be free draining, non
toxic and capable of sustaining healthy plant growth. The properties of
Topsoil shall be as described in Table 2-1 below.
Table 2- 1: The properties of Topsoil material

MATERAL Specified Limits Test Method
TYPE Characteristics
Organic content Less than 2% BS 1377: Part 3:
1990: Method 3,
AMD 9028:1996
Topsoil
PH Value Min 7 - Max 9 BS 1377: Part 3:
1990: Method 9,
AMD 9028:1996
2/13.2 SUITABLE MATERIAL
Suitable Material for earthworks shall comprise all material obtained from
excavations within the works or from borrow pits approved by the Engineer
and acceptable in accordance with the Contract for use in the Works.

Suitable material for earthworks shall be an approved soil that meets the
following specifications listed in Table 2-2:
Table 2- 2: Specifications of suitable material for earthworks

Passing 63mm Max 100% BS1377: Part 2: 1990
Test 9.2,AMD
9027:1996
Passing 0.075mm Max 20% BS1377: Part 2: 1990
Test 9.2, AMD 9028:
1996
Liquid Limit Max 40% BS 1377: Part 2: 1990:
Test 4.5, AMD 9028:
1996
Plasticity Index Max 6%* BS1377 Part 2 1990
Clause 5.4, AMD 9027-
1996
Weighted PI Max 400 Calculation (PI x
(PIx0.425)* %passing 0.425mm)
Linear shrinkage Max 3% BS1377 Part 2 1990
Clause 6.5, AMD 9027-
1996.
Soaked CBR (95% Min 10%** BS1377 Part 4: 1990
Suitable fill compaction) Min 15% (Method 7), AMD
material 13925:2002
Free swell Max 1.5% BS 1377 Part 5 1990
AMD 8260: 1994
Organic content Less than 2% BS 1377: Part 3: 1990:
Method 3, AMD
9028:1996
Acid soluble Chloride BS1377:P3:1990:M7.3
Max2%. AMD 9028: 1996
Acid soluble Sulphate BS1377:P3:1990:M5.5,
Max2% AMD 9028: 1996
Organic matter content BS 1377:P3:1990 M3,
Max2% AMD 9028: 1996
Water soluble Chloride BS1377:P3:1990:M7.2,
AMD 9028: 1996
Total Max 5%
Water soluble Sulphate BS1377:P3:1990:M5.5
AMD 9028-1996
PH of the Soil BS 1377: P3:1990: M9,
Min 7 - Max 9 AMD 9028: 1996
* PI less than 6 has been retained as requested by DCL. However where PI

exceeds 6 the concept of Weighted Plasticity Index (WPI) has been introduced
to control the influence of PI on material performance. ** WPI = PI x % passing
0.425mm sieve.
** A minimum soaked CBR = 10% shall only apply to material 0.5m below finished
formation level.
2/13.3 UNSUITABLE MATERIAL
Unsuitable material shall comprise but not be restricted to: -

- Rock particles exceeding 63 mm in size.

- Material containing greater than 2% organic material such as stumps

and other perishable material as determined according to BS1377
Part 3: 1990 method 3, AMD 9028:1996.
- Material susceptible to spontaneous combustion.
- Soils of liquid limit exceeding 40% (BS 1377 Part 2 1990 Clause 4.5,
AMD 9027:1996), and plasticity index exceeding 6 (BS 1377 Part 2
1990 Clause 5.4, AMD 9027:1996)
- Materials containing more than 20% by weight passing Sieve Size
0.075mm determined by BS 1377: Part 2: 1990 Clause 9.2, AMD
9027:1996
- Materials containing more than 5% of water soluble salts by weight of
dry soil. BS 1377 Part 3:1990, (Method 7.2 and 5.5, AMD 9028-1996)
for water soluble chloride and sulphate respectively.
- Any other material which the Engineer may deem to be unsuitable for
earthworks.
The complete range of chemical tests, test methods and specifications shall
be as mentioned in Table 2-3 below:
Table 2- 3: Existing Material – Soil (Unsuitable for Filing)

Test Method Specifications
Acid soluble Chloride BS 1377:P3:1990:M7.3,
More than 2%.
AMD 9028:1996
Acid soluble Sulphate BS 1377:P3:1990:M5.5,
More than 2%
AMD 9028:1996
Organic matter content BS 1377:P3:1990 M3,
More than 2%
AMD 9028:1996
Water soluble Chloride BS 1377:P3:1990: M7.2,
AMD 9028:1996
Total >5%
Water soluble Sulphate BS 1377:P3:1990:M5.5
AMD 9028-1996
PH of the Soil BS 1377: P3:1990: M9,
<7 or >9
AMD 9028:1996
2/13.4 IMPROVED SUBGRADE
Material for an improved subgrade layer shall meet the requirements listed
in Table 2-4 below:

Table 2- 4: Improved subgrade material requirements

MATERA Specified Limits Test Method
L TYPE Characteristics
Improved Passing 63mm Max BS 1377: Part 2: 1990 Clause
Subgrade 100% 9.2, AMD 9027:1996
Passing 0.075mm Max 20% BS 1377: Part 2: 1990 Clause
9.2, AMD 9027:1996
BS 1377: Part 2: 1990: Test
Liquid Limit Max 40% 4.5, AMD 9027:1996
BS 1377 Part 2 1990 Clause
Plasticity Index Max 6% 5.4,AMD 9027-1996
Soaked CBR (95% BS 1377 Part 4: 1990 (Method
compaction) Min 30% 7), AMD 13925-2002
A chemical analysis of the proposed material shall be carried out to satisfy

the following requirements:
 The material shall be shown to have an acid soluble sulphate content of

2% or less and chloride content in the form of acid soluble chloride of
2% or less by dry weight. The applicable test methods should be in
accordance with BS 1377 Part3 (Method 5.5, AMD 9028:1996) and BS
1377 Part3 (Method 7.3, AMD 9028:1996).
 When approved by the Engineer, a sulphate content greater than that
specified may be acceptable when the carbonate content is in the
region of 30-40% (BS 1377, Part3, (Method 6.3, AMD 9028:1996).
 Higher chloride contents may be tolerated provided that the ratio of
(carbonate+sulphate) to chloride contents is maintained at
approximately 15:1.
 When approved by the Engineer a sulphate content greater than that
specified may be acceptable when the carbonate content is in the
region of 30 - 40% (BS 1377 Part 3: 1990 Method 6.3 AMD 9028-1996).
 The moisture content of the material before compaction shall not vary
by more than +/- 3% of the optimum moisture content when tested in
accordance with BS 1377: Part 2 : 1990 Test 3.2, AMD 9027:1996.
 The material for improved subgrade shall be approved soil with a
plasticity index not exceedingly 6 (BS 1377 Part 2 1990 Clause 5.4,
AMD 9027:1996) and liquid limit shall not exceed 40% when tested
according to (BS 1377: Part 2: 1990 Clause 4.5, AMD 9027:1996).
2/13.5 No excavated suitable material shall be removed from the Site without the
Engineer's written permission. Should the Contractor be permitted to
remove suitable material from the site to suit his operational requirements,
and then he shall make good any consequent deficit or filling arising there
from at his own expense.
2/13.6 Dune sand if used shall not contain more than 2% organic matter (BS
1377:P3:1990 M3, AMD 9028:1996) and may contain up to 20% of stone
fragments or cobbles exceeding 20mm but not more than 63mm in size.
2/13.7 Layers of dune sand between layers of granular materials shall not be
allowed.

2/14 MAIN PLANT FOR EARTHWORKS CONSTRUCTION
2/14.1 The Contractor shall employ only that plant which is suited to the soils to be
handled. He shall not at any time use plant which damages or reduces the
natural strength of the soil either in its in-situ state or during handling and
placing or in its final compacted state. Unsuitable or faulty plant shall be
removed from the work site and borrow pits at the order of the Engineer.
2/14.2 The plant and equipment used for earthworks construction shall be
maintained in good working condition for the duration of the works. The
Contractor shall apply adequate quantities of plant and equipment
necessary for the proper execution of the works in an expeditious manner.
2/14.3 Main plant and equipment shall meet the requirements outlined in Clause
1/29 of these Specifications.
2/15 EMBANKMENT CONSTRUCTION
2/15.1 This work shall consist of constructing roadway embankment with suitable
material, including the preparation of the areas upon which they are to be
placed and the placing and compacting of approved material within
roadway areas where unsuitable material has been removed. All
operations will be performed in accordance with the Specifications and in
conformity with the lines, grades, thickness and typical cross-sections
shown on the drawings or as established by the Engineer.
2/15.2 Compaction equipment shall conform to the number and type outlined in
the Contractor's detailed programme of work as approved by the Engineer
and satisfactory performance shall be the basis for such approval.
2/15.3 All materials derived from excavation shall be used in the embankment
unless otherwise declared unsuitable by the Engineer.
2/15.4 Prior to the commencement of embankment, the Contractor shall construct

trial compaction of at least 50m in length. The soils used in the trials shall
be those encountered along the line of the road as approved by the
Engineer and/or those originating from the approved borrow pit. The object
of the trials is to determine the ability of the contractor’s equipment and
processes to meet the requirements of this specification. Steel and
Pneumatic rollers shall be used for the embankment construction. The
Engineer may order additional compaction trials when he deems them
necessary.
2/15.5 During the construction of embankments, the Contractor shall control and
direct construction traffic uniformly over the full width of the embankment
Damage to compacted layers by construction traffic shall be made good by
the Contractor at his own expense.
2/15.6 The Contractor shall be responsible for the stability of all embankments and
shall replace all 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 natural causes, such as storms, and not attributable to

the unavoidable movement of the natural ground upon which the
embankment is made. During construction, the roadway shall be kept
shaped and drained at all times. When unsuitable material has been
placed in the embankment, its removal shall be at the expense of the
Contractor. Throughout the duration of the Contract all damage to
completed earthworks attributable to rain and rainfall run-off or to any other
cause shall be made good by the Contractor without delay and whenever
possible within 24 hours of such damage occurring.
2/16 EMBANKMENT FOUNDATION
2/16.1 All debris, unsuitable material and vegetable matter shall be removed from
the surface upon which the embankment is to be placed and the cleared
surface shall be completely broken up by ploughing, scarifying or stepping
to a minimum depth of twenty (20) centimeters.
2/16.2 The foundation material shall be adjusted to a moisture content within the
moisture range of + 3% of the optimum moisture content and compacted to
not less than ninety-five (95) percent of the Maximum Dry Density as
determined by BS 1377 Part 4: 1990 (method 3.5 or 3.6, AMD 13925:
2002) where the embankment is less than one and a half (1.5 m) meters
below subgrade; and compacted to not less than ninety three (93) percent
of the maximum dry density as determined by BS 1377 Part 4: 1990
(Method 3.5 or 3.6, AMD 13925: 2002) ) where the embankment is more
than one and a half (1.5 m) meters below the subgrade.
In dry cohesionless soils (e.g. dune sand) where conventional sand

replacement measurement of field density cannot be undertaken, the
suitability of compacted layers shall be determined using the Clegg Impact
Soil Tester in accordance with ASTM D5874-02(2007) . A minimum Impact
Value (CIV) =8 (which corresponds to a CBR value of 8%) shall be
achieved.
2/16.3 If the original surface upon which the embankment is to be placed is an old
roadbed, the surface shall be ploughed scarified or broken up. All
aggregate particles shall be reduced to a maximum size of 63 mm. A well-
mixed and uniform layer surface shall be produced. The embankment
layers shall be compacted according to Subsection 2/16 requirements,
regardless of the height of the embankment to be placed, and compacted
to a density not less than ninety five (95) percent of the maximum dry
density as determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6, AMD
13925: 2002).
2/16.4 Where an embankment is to be placed on appreciably sloping ground, this

surface shall be benched in steps or trenched in accordance with the
Engineer's instructions, including if necessary any under draining of the
affected part of the site.
2/16.5 In circumstances where backfill has to be deposited below standing water.

In such cases the Contractor shall use only an approved granular material
of maximum size not greater than 37.5 mm and which on analysis by
sieving (BS 812: Part 103: Section 103.1:1985, cl.7.2 or 7.3, AMD 6003:
1989, or BS 1377: Part 2: 1990: 9.2 or 9.3, AMD 9027: 1996 or latest
edition) complies with the requirements of Table 2-5 below. Such material
shall have a "ten percent fines" value of not less than 5 tones when tested
in accordance with BS 812: 1990 P111 and BS EN 1097-2-1998, AMD
16684: 2006 and may be deposited below water without the associated use
of compaction plant.
2/16.6 Free Draining Backfill

In circumstances where backfill has to be deposited below standing water
in embankment construction, approved granular material shall conform to
the following (Table 2-5):
Table 2- 5: Approved granular material requirements

9.2 or 9.3, AMD 9027: 1996
or BS 812: Part 103: Section
103.1:1985, cl.7.2 or 7.3,
AMD 6003: 1989.
Passing 10 mm Max 100% BS 1377: Part 2: 1990 Clause
9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
Passing 5 mm Max 85% BS 1377: Part 2: 1990 Clause
9.2 or 9.3 or BS 812: Part 103:
Free
Section 103.1:85 cl.7.2 or 7.3,
draining
backfill
AMD 6003: 1989.
Passing 0.600 Max 45% BS 1377: Part 2: 1990 Clause
mm 9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
9.2 or 9.3 or BS 812: Part 103:
Section 103.1:85 cl.7.2 or 7.3,
AMD 6003: 1989.
10% Fines Value Min 5 BS 812: 1990 P111 and /or BS
tones EN 1097-2-1998, AMD 16684:
2006
2/17 PLACING AND COMPACTION REQUIREMENTS
2/17.1 Only approved materials shall be used in the construction of embankments.
2/17.2 In the formation of the embankment it is strictly forbidden to push the

excavated materials from the side of the road to the embankment by means
of bull dozers.
2/17.3 The fill material shall be delivered and spread in layers not exceeding 250
mm thickness after compaction. The layers of fill shall be graded, leveled,
pulverized and mixed, with water added as necessary, to ensure
homogeneous conditions through the full depth of the uncompacted layer.

For field density testing refer to specification sub-section 2/19.
2/17.4 The compacted density of the fill shall be equal to or greater than as
required under Clause 2/16.2 as determined by BS 1377 Part 4: 1990
(Method 3.5 or 3.6, AMD 13925: 2002).
Dune Sand, if found suitable and approved by the Engineer, may be used
as fill material up to a level of 1.5m from bottom of sub-grade. Dry
compaction (at natural moisture content) of 25cm lifts (tested every 15cm)
can be adopted.
In dry cohesionless soils (e.g. dune sand) where conventional sand

replacement measurement of field density cannot be undertake, the
suitability of the compacted fill layer shall be determined using the Clegg
Impact Soil Tester in accordance with ASTM D5874 - 02(2007). A minimum
Impact Value (CIV)=8 (which corresponds to a CBR value of 8%) shall be
achieved.
2/17.5 The material to be imported for the "improved subgrade layer" to be

constructed above "earthworks formation level" up to "top of improved
subgrade" level as shown on the drawings shall conform to the
Specification Sub-Section 2/13 Para 4.
2/17.6 All slopes, lines and grades shall be true, correct, and accurate and
according to those shown on the Drawings or otherwise directed and
approved by the Engineer. The "earthworks formation level" in
embankments shall be accurate to the authorized profile grade to plus or
minus two (2) centimeters and, the 'top of improved subgrade' level, plus or
minus one (1) centimeter for 3 locations maximum each 100 m interval.
Selected material shall be placed wherever required. Where discrepancies
are found in the work the Contractor shall make necessary corrections in a
manner approved by the Engineer.
2/17.7 Grade, level, shape and compact the embankment surface to a uniform cross-
section. At the end of each day's operations, all ruts and depressions that
could hold water should be eliminated.
2/17.8 Hauling, grading and leveling equipment passage should be distributed

over the width and length of each layer of material to avoid channelization.
This action should be practiced during all stages of the road construction.
2/17.9 Use a tamping foot roller to compact embankment side slopes by walking
with a dozer, or by over-building the fill and then removing excess material
to the final slope line. For steeper slopes, compact the slopes as
embankment construction progresses.
2/17.10 In cases where placing embankment is on one side of abutments (bridge

construction), wing walls, piers, or culvert headwalls, use the recommended
compaction methods that prevent excessive pressure.
2/17.11 In cases where placing embankment material is on both sides of a concrete

wall or box structure, conduct operations so compacted embankment

material is at the same elevation on both sides of the structure under

construction.
2/17.12 Place embankment material in horizontal layers not exceeding 250mm in

compacted thickness. In cases where material composed predominately of
boulders and rock fragments of size more than 25centimeter, incorporate
oversize boulders or rock fragments into the embankment layers by
reducing the size of these boulders or placing them individually.
2/17.13 in cases where material composed predominately of boulders or rock

fragments too large for 25 centimeter layers, these materials may be placed
in layers up to 60cetimeters thick. Incorporate oversize boulders or rock
fragments into the 600mm layer by reducing them in size or placing them
individually. Place sufficient earth and smaller rocks to fill the voids.
2/17.14 Ditches, Slope, grade, and shape ditches. Remove all projecting roots,
stumps, rock, or similar matter. Maintain all ditches in an open condition
and free from leaves, sticks, and other debris. Complete slopes, ditches,
culverts, and other underground minor structures before placing aggregate
courses. Slope, shape, and finish as follows:
(a) Slopes. Leave all earth slopes with uniform roughened

surfaces, with no noticeable break as viewed from the road.
Except in solid rock, the bottoms and tops of all slopes including
the slopes of drainage ditches shall be “rounded to remove
sharp angular faces. If a slide or slip out occurs on a cut or
embankment slope, remove or replace the material, and repair
or restore all damage to the work. Bench or key the slope to
stabilize the slide. Reshape the cut or embankment slope to an
acceptable condition..
(b) Shaping: shape the subgrade to a smooth surface to the cross
section and to the cross section required. Shape slope to
gradually transition into slope adjustment without noticeable
breaks. At the ends of cuts and embankments, adjust slope in
the horizontal and vertical planes to blend into each other or into
natural ground.
(c) Finishing. Remove all material larger than 50mm from the top
15 centimetres of the roadbed. Remove unsuitable material
from the roadbed, and replace it with suitable material.
2/18 MOISTURE CONTROL REQUIREMENTS
2/18.1 When the moisture content of the embankment soil does not fall within +
3% of the optimum moisture content, water shall be added and thoroughly
mixed into the soil, by approved methods or the material shall be aerated,
whichever is needed to adjust the soil to the proper moisture content.
2/18.2 The amount of water to be added shall be only that amount that will, as
determined by the Engineer by field tests, provide moisture content in the
soil within the required range plus a reasonable amount to compensate for

evaporation and other unavoidable losses. Water added in excess of this

amount shall be considered as excess water and must be removed by
aeration or other suitable means as directed by the Engineer. Satisfactory
methods and sufficient equipment shall be used for the furnishing and
handling of the water so that there will be no undue loss due to evaporation
or waste. If water is added to cut areas or borrow pits, the surface of the
areas or pits shall be maintained in such a manner that will prevent undue
loss of moisture and segregation.
2/18.3 Use of saline water for earthworks will only be permitted if the percentage
of water soluble salts in the compacted fill does not exceed 5% by weight of
dry soil when tested in accordance with BS 1377 Part 3 : 1990 tests 5 & 7,
AMD 9028:1996 for SO3+Cl).
2/18.4 For subgrade material moisture range refers to sub clause 2/13.4.
2/19 TESTING METHODS
2/19.1 A dry density moisture content relationship test in accordance with BS 1377
Part 4 : 1990 (method 3.5 or 3.6, AMD13925-2002 ) will be made for each
type of soil to be used in the construction of the work to determine the
Maximum Dry Density, the Optimum Moisture Content and the Moisture
Range required of the soil for satisfactory compaction. The Field Density
and actual Moisture Content of the compacted embankment shall be
determined by field tests according to BS 1377 Part 9: 1990 (method 2.1 or
2.2), AMD17229-2007.
2/19.2 Insitu density of dune sand shall be determined in accordance with B.S.
1377 Part 9 Test 2.1 or 2.2:1990, AMD 17229: 2007. However, where
conventional sand replacement measurement of field density cannot be
undertaken the suitability of the fill material shall be determined using the
Clegg Impact Soil Tester in accordance with ASTM D5874 - 02(2007). A
minimum Impact Value (CIV) = 8 (which corresponds to a CBR value of
8%) shall be achieved.
2/20 MINIMUM TEST REQUIREMENTS
2/20.1 For the Contractor's general guidance, the following tests will be required
prior to use, and during the construction of the embankment and of the
subgrade.
EMBANKMENT
2/20.2 Soil samples for Soil classification according to BS 1377: Part 1 and Part 2:
1990 latest edition, laboratory moisture/density relationship tests and
California Bearing Ratio shall be taken prior to use, from any proposed
source of material. Each sample shall represent not more than 5,000 Cu.m
of stockpiled material or part of as directed by the Engineer. Sampling shall
be in accordance with ASTM D75: 2009, BS 1377 Pt 1: 1990 and BS
5930:1999.
2/20.3 For every completed layer of fill, at least FOUR (4) field density tests shall
be performed for every unit of carriageway (One unit being 2250 Sq.m.) or
as directed by the Engineer. Every compacted layer shall be compacted to
not be less than 95% of MDD.
IMPROVED SUBGRADE
2/20.5 Samples for Soil classification, laboratory moisture density relationship

tests and CBR tests shall be taken prior to use, from any proposed source
of material. Each sample shall represent not more than 3,000 Cu.m of
stockpiled material or as part of as directed by the Engineer.
2/20.6 For every completed layer of subgrade, three field density tests shall be
performed on each unit of carriageway. (One unit being 1500 Sq.m) or as
2/20.7 The frequency of field compaction tests on the shoulders shall be three
every unit constructed or as directed by the Engineer (One unit being 1500
Sq.m).
ROCKFILL
2/20.8 Where embankments to be compacted are formed of material consisting
predominantly of rock fragments of such size that the material cannot be
placed in layers of the thickness prescribed without crushing, pulverizing or
further breaking down the pieces resulting from normal excavation
methods, the material may be placed in the embankment in layers not
exceeding a thickness twice the average size of the larger rocks, except
that no layer shall exceed 600 mm of loose measurement.
Materials shall be carefully placed so that all large stones will be well
distributed and the voids completely filled with smaller earth, sand or gravel
to form a solid embankment. Each layer shall be bladed or leveled with
motor grader, bull dozer or similar equipment capable of shifting and
forming the layer into a neat and orderly condition. No. rocks larger than
eighty (80) mm in any dimension shall be placed in the top one hundred
and fifty (150) mm of the embankment unless otherwise noted on the
drawings. Conformance to these provisions and compaction in a manner
and to a point of consolidation approved by the Engineer will be considered
as fulfillment of the requirements for the type of compaction shown on the
drawings.
Normally, compaction tests will not be performed in these areas but the
Engineer reserves the right to test compaction in some other manner if he
deems a test necessary to ensure consolidation. Each layer must be
approved by the Engineer before the next layer is placed.
Embankments, which are formed of materials that contain rock but also
sufficient compatible material other than rock or other hard material to
make rolling feasible, shall be placed and compacted in the manner and to
the point of consolidation approved by the Engineer. Moisture shall be

added as directed by the Engineer. Compaction tests will be made

wherever the Engineer determines they are feasible and necessary. Each
layer must be approved by the Engineer before the next layer is placed.
2/21 CRUSHED STABILISING MATERIAL
2/21.1 In the event the foundation on which the embankment or the subgrade
materials will be laid is saturated by water and unstable, the Engineer may
decide to lay crushed granular material to stabilize the foundation.
Stabilising crushed material shall not be laid directly on ground soil but it
shall always be laid on Geotextile fabric covering the area to be stabilised
as shown on the drawings or directed by the Engineer.
2/21.2 Such stabilising crushed material when tested in accordance with BS EN 933-
1:1997 or BS 1377 Part 2: 1990 method 9.2 or 9.3 latest edition, shall have
the following gradation listed in Table 2-6:-
Table 2- 6: Stabilising crushed material gradation

SIEVES (mm) % PASSING
50 100
25 80 - 100
12.5 60 - 85
5 40 - 70
2 20 - 50
0.85 5 - 25
0.425 0 - 10
0.180 0 - 2
2/21.3 The stabilising crushed material shall have the following characteristics
shown in Table 2-7 below:-
Table 2- 7: Stabilising crushed material characteristics
Material characteristic Limit

Los Angeles Abrasion (ASTM C-131:2006 or Not more than 30% loss
ASTM C-535:2009)
Bulk Specific Gravity (ASTM C-127:2007 Not less than 2.65
and C-128:2007a)
Absorption (ASTM C-127:2007 and Not more than 2.0%
C-128:2007a)
2/21.4 The stabilising crushed material will be laid in layers of 15 cm and

compacted until the foundation is fully stabilised such that the total
thickness of the stabilising layer shall not be less than 30 cm. Only after
inspection and approval by the Engineer the Contractor may be allowed to
continue the construction of the embankment with other layers of
embankment material and/or subgrade material. The Engineer may

decide, after having taken the levels of the existing water table in the area,
and keeping in consideration the finished road levels, to excavate portions
of the foundation saturated by water, disposing of the excavated material,
and replacing it with stabilising crushed material.
2/21.5 Before starting any stabilising of the foundation the Engineer will instruct
the Contractor specifying the areas to be stabilised and the final levels to
be reached with the stabilising crushed material.
2/21.6 Alternative methods of soft area treatment which may be directed by the
Engineer are:
1) Non-friable boulders of sizes between 150-300mm shall be end

dumped over the soft area and rolled until the area is stabilized to
the satisfaction of the Engineer. Further stones of 10-70 mm size
shall be rolled into the area until all the areas are leveled and well
blinded.
2) Crushed rock material free from dirt, organic matter, shale and
any other deleterious material. The acceptance criteria shall be
as follows (Table 2-8):
Table 2- 8: Acceptance criteria Crushed Rock Material

Grading (BS EN 933-1 and BS 1377 Part 2 method 9.2 or 9.3:
1990, AMD 9027: 1996)
Sieve (mm) % Passing
150 mm 100
100 mm 80 - 100
37.5 mm -
25 mm 20 - 50
19 mm -
9.5 mm 0 -15
Physical Requirements
All aggregate materials shall comply with the requirements of sections
2/20.8 and 2/21 of the General Specifications in addition to the following:
Soundness(Magnesium Sulfate, 5 cycles), tested according to (ASTM C

88-2005) = 12% Max
2/22 GEOTEXTILE FABRIC
2/22.1 In areas where the Engineer deems the use of Geotextile fabric necessary,
the Contractor shall furnish and place Geotextile fabric as specified and as

2/22.2 The Geotextile fabric furnished by the Contractor shall be of an approved

grade suitable for placement over fine sand. The Geotextile fabric shall be
a woven or non-woven fabric consisting only of long chain polymeric
filaments or yarns formed into a stable network such that the filaments or
yarns retain their relative position to each other. The fabric shall be
stabilised against ultra violet light, inert to commonly uncounted chemicals
and chemical properties of the insitu soil and water, and it shall conform to
the following minimum requirements Table 2-9:
Table 2- 9: Geotextile fabric specifications

Weight (DIN 53854) 140 g/m2
Thickness under load (2KN/sq.m) 0.7 mm
(DIN 53855)
Tensile Strength (200mm width) 1.6 KN
ASTM D1682
Puncture Resilience (DIN 54307) 1.5 KN
Permeability (DIN 60500) 50 L/sq.m/s
Ultraviolet Stability ASTM 4355 50% after 750 hours
exposure
Burst Strength ASTMD4632 & ASTM3786 2.1 KN
2/22.3 The surface to receive the Geotextile fabric shall be prepared to a relatively
smooth condition free of obtrusions, depressions, and debris. The
Geotextile fabric shall not be laid in a stretched condition, but shall be laid
loosely with the long dimension parallel to the centerline of the roadway. In
the event that the width of the proposed area for fabric requires more than
one panel width of fabric, the panels shall be overlapped a minimum 15
percent of the panel width. Longitudinal joints in the fabric shall have an
overlap of 50cm. To prevent slippage of the overlapping fabric, the areas
of overlap shall be stabilised as approved by the Engineer with pins, anchor
blocks, or aggregate piles. In the event construction machinery is used to
place the fabric, the working platform for the machinery shall be the soil and
not the previously laid fabric.
2/22.4 Prior to placement of the stabilising crushed material the Contractor shall
spread a layer of sand over the Geotextile fabric as directed by the
Engineer. A 5cm thick layer of Crushed Sand which grading limits are
shown below shall cover the Geotextile fabric.
Table 2- 10: Crushed Sand grading

Sieve opening mm % Passing
4.75 100
2.00 66 - 92
0.425 30 - 50
0.150 12 - 28
0.075 5 - 15
Alternatively, Dune sand can be used for blinding and protecting the Geotextile
from puncture or tearing provided the required properties are met.

The aggregate material shall not be dumped directly on the fabric, nor
shall haul trucks be run on the fabric. The aggregate shall be spread by
a wheeled front-end loader.
The blade or bucket shall be kept sufficiently high so that the aggregate is
not being pulled over the fabric, but being dropped at a minimum height to
the satisfaction of the Engineer.
2/22.5 Fabric damaged or displaced before or during installation or during

placement of overlaying aggregate material shall be replaced or repaired to
the satisfaction of the Engineer at the Contractor's expense.
2/23 EXCAVATION FOR STRUCTURES
2/23.1 This work shall consist of all excavation for structures, culverts, headwalls,
catch basins, manholes, inlets, and retaining walls and shall include all
necessary clearing and grubbing, all necessary bailing, drainage, pumping,
sheeting, strutting and the construction of coffer dams or cribs, if found
necessary, and their subsequent removal; also the disposal of all material
obtained from such excavation and backfilling to the level of the original
ground; it shall include the removal of that portion of existing structures
below the ground which is necessitated by the construction of the new
structure.
2/23.2 Prior to commencing any structural excavation work 1.5 meters or more in
depth, the Contractor shall design and submit to the Engineer for review
and approval, within a minimum period of 1 week before the intended
commencement date, detailed working drawings of the structural
excavation support member materials, sizes, spacing and engineering
calculations to validate their design, including the maximum theoretical
deflections of the support members. The system shall be designed in such
a manner that no raker struts or any other support members extend through
surfaces exposed in the finished construction, and no shoring or bracing is
placed under permanent structures.
2/23.3 The engineering calculations shall show lateral earth pressure for the full
excavation depths, forces at various stages of support during installation
and removal and concrete placement, the anticipated equipment loads,
surcharge loads of any description, the maximum design loads to be
carried by various members of the support system and strut preload forces.
2/23.4 If the structure support system proposed includes tieback anchors, the
Contractor's submittal drawings shall show the profile of the soil in which
each anchor is to be installed, the design load for the full depth of the
excavation, the maximum design and proof loads, surcharge loads of any
description; equipment loads, forces at various stages, support during
installation and removal, and the criteria proposed for deformations under
proof loads. Where a proposed system of tieback anchors projects beyond
the vertical projection of the Contract limit lines shown on the Drawings on
to the adjoining property, the permission of the owner shall be obtained in
writing and such permission submitted to the Engineer at the time the shop
drawings of the support systems are submitted.

2/23.5 At locations where the excavation extends below the ground water table, a
dewatering system shall be provided which will effectively reduce the
hydrostatic pressure and lower the ground water levels below excavation
levels, as required for the safe and proper execution of the work and which
will result in obtaining a stable, dry subgrade for the execution of
subsequent operations. The Contractor shall design dewatering methods
and settling basins so that no critical amounts of soil, sand or silt are
removed during either the initial operations or the construction operations.
Complete working drawings showing the type of dewatering and ground
water control system proposed shall be submitted to the Engineer for his
review.
2/23.6 The Contractor's submittal drawings shall show the arrangement, location
and depths of the proposed dewatering system if required. A complete
description of the equipment and materials to be used and the procedures
to be followed shall be shown, together with the standby equipment,
standby power supply and the proposed location or locations of points of
discharge of water. Any required dewatering system design shall also
include the measures taken to prevent damage due to settlement of
pavement, utilities, sewers, buildings and other structures outside the
excavation but within the area affected by the procedures.
2/23.7 The designs of the structure excavation support system and the dewatering
systems specified above shall be prepared by and signed by a Professional
Engineer approved by the Engineer specializing in this type of design work.
Approval of the designs and shop drawings shall not relieve the Contractor
of the adequacy and performance of these temporary works.
2/23.8 Preconstruction Inspection prior to the beginning of construction, the

Contractor and the Engineer shall make a detailed inspection of all adjacent
buildings, pavements, wells and other structures in order to determine its
pre-construction condition and the Contractor shall prepare, for the
Engineer's approval, a typed Inspection report of the findings.
2/23.9 The Report shall include photographs, drawings and sketches with levels
and dimensions illustrating the structures condition, noting in particular any
existing damage or structural inadequacy. Deficiencies and damage shall
be suitably marked on the structure such that it is not permanently defaced.
2/23.10 Three copies of the Report shall be submitted for the approval of the
Engineer. Once approved, five additional copies shall be supplied to the
Engineer.
2/23.11 The Contractor shall notify the Engineer sufficiently in advance of the
beginning of any excavation so that cross-sectional elevations and
measurements may be taken of the undisturbed ground. The natural
ground adjacent to the structure shall not be disturbed without the
permission of the Engineer.
2/23.12 Trenches or foundation pits for structures or structure footings shall be

excavated to the lines and grades or elevations shown on the drawings, or
as ordered by the Engineer. They shall be of sufficient size to permit the
placing of structures or structure footings of the full width and length shown.

The elevations of the bottoms of footings, as shown on the Drawing shall

be considered as approximate only and the Engineer may order, in writing,
such changes in dimensions of elevations of footings as may be deemed
necessary, to ensure a satisfactory foundation.
2/23.13 Unless otherwise provided for in the Drawings or Contract Documents or

directed by the Engineer Structural excavation shall be carried out for a
width of at least 500mm beyond the horizontal outside limits of the
foundation, footing, box culvert or structural member to which the
excavation relates. Concrete blinding or sub-foundations are not to be
considered as structure for the purpose of defining such excavation.
2/23.14 If during the progress of the work, loose or improperly compacted soil is
encountered below the structural foundation levels, or adjacent thereof,
which is the result of prior removal of utilities or structures, such material
shall be completely removed within the limits as directed by the Engineer,
backfilled with suitable material and it should be not less than 95% of the
maximum dry density as determined by BS 1377 Part 4 : 1990 (method 3.5
or 3.6, AMD 13925: 2002). Any previous excavations encountered which
would in the opinion of the Engineer be detrimental to load distribution of
new foundations to the underlaying soil, shall be excavated and backfilled
with Class 25 concrete (clause 4/15).
2/23.15 After each excavation is completed, the Contractor shall notify the
Engineer, for approval of the depth of excavation and the character of the
material, prior to further structural works. Any over excavation shall be
backfilled with Class 25 concrete (clause 4/15) at the Contractors expense.
2/23.16 All rock or other hard foundation material shall be cleaned of all loose
material and cut to a firm surface, either level, stepped, or serrated as
directed by the Engineer. All seams or crevices shall be cleaned and
grouted. All loose and disintegrated rock and thin strata shall be removed.
When the footing is to rest on material other than rock, excavation to final
grade shall not be made until just before the footing is to be placed and
special care shall be taken not to disturb the excavation. When the
foundation material is soft or otherwise unsuitable as determined by the
Engineer, the Contractor shall remove the unsuitable material and backfill
with approved granular material. This foundation fill shall be placed and
compacted in 150mm layers up to the foundation elevation and compacted
to not less than 95% of the maximum dry density as determined by BS
1377 Part 4 : 1990 (method 3.5 or 3.6, AMD 13925: 2002).
The placing of concrete shall follow as closely as practicable the structural

excavation.
2/23.17 Control of Ground Water- Prior to the commencement of construction at

any particular location, the Contractor shall install and maintain a system of
standpipes and other devices to monitor ground water level in any area
which in the opinion of the Engineer is likely to be affected by the
dewatering. The number, location and depth of all standpipes shall be to
the satisfaction of the Engineer.

- The Contractor shall check ground water levels at weekly or

where instructed by the Engineer, more frequent intervals and
submit within 24 hours written reports to the Engineer in a form
to be agreed.
- In the case of uncontrolled flow of water into any excavation, the
Engineer reserves the right to order an immediate cessation of
work and to order the Contractor to take immediate action to
control the inflow of water. Such actions and remedial works
shall be to the Engineer's approval.
-
2/23.18 Notification of Damage - The Contractor shall notify the Engineer
immediately of any movement or any damage not noted in the pre-
construction report, to any structure. The Contractor shall immediately
cease his construction operations in the vicinity and shall take immediate
action to prevent further movement or damage. The Contractor shall keep
the Engineer fully informed of all such action.
2/23.19 Remedial and Preventive Works - Should remedial works be necessary

due to damage caused to the structure or should the Engineer direct the
contractor to carry out any works necessary to prevent damage to the
structure due to the Contractor's construction works, the Contractor will
present, without delay, detailed drawings and specifications, as necessary,
showing his proposed remedial or preventive works for the Engineer's
approval.
In either case the Contractor will suspend all construction activities in the
vicinity of the structure until such time as the remedial or preventive works
are carried out to the Engineer's satisfaction at the Contractor's expense.
2/23.20 Post Construction Inspection - On completion of, but prior to final

acceptance of the works, the Contractor and the Engineer shall re-examine
the structure to determine any change from the original conditions. The
Contractor shall supply to the Engineer for approval five copies of a report
describing measures he proposes to take to correct any damage which
resulted from the construction of the works. The approved corrective
measures shall be carried out by the Contractor at his expense, to the
Engineer's satisfaction before final acceptance of the works.
2/23.21 Utilisation of Excavated Materials - All excavated material determined as

suitable by the Engineer, shall be utilised as backfill or roadway fill. The
surplus material shall be disposed of as specified in sub-section 2/8
paragraph 2. Excavated material shall not be deposited, at any time, so as
to endanger the partly finished structure or cause an obstruction of any
kind. All unsuitable material shall be disposed of to disposal sites that have
been approved for use.
2/23.22 Backfill - Excavated areas around structures shall be backfilled with

excavated materials or imported granular material approved by the
Engineer. Backfill materials shall be placed in horizontal layers not
exceeding 20cm in depth after compaction, or as directed by the Engineer,
and compacted to not less than 95% of the maximum dry density as
determined by BS 1377 Part 4: 1990 (Method 3.5 or 3.6, AMD 13925:
2002). The field density shall be determined by BS 1377 1990 Part 9:

(Method 2.1 or 2.2, AMD 17229: 2007). Each layer of material shall be
moistened or dried as required to enable thorough compaction as specified.
Backfill shall be placed to the original ground level or as indicated on the
drawings.
The specifications for chemical tests shall be as mentioned in the Table

given on this page
Table 2- 11: Sub Base, Road Base, Wet Mix specifications
Test Method Specifications

Acid soluble Chloride BS 812:P 117:1988 1.0% max
Acid soluble Sulphate BS EN 1744-1:1998 0.5% max
Organic matter content BS 1377: P3:1990 0.2% max
M3
2/23.23 Backfill or embankment shall not be placed behind the walls of concrete
structures or rigid frame structures until the top slab is placed and cured.
Backfill and embankment behind abutments when held at the top of the
superstructure shall be carried up simultaneously behind opposite
abutments. Backfill shall be carried up equally on either sides of box
culverts.
2/23.24 For frequency of testing of backfill material refer to sub-section 2/20.

SECTION 3 PAVEMENT CONSTRUCTION
1
TABLE OF CONTENTS
3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS .................................... 3

3/2 TESTING OF AGGREGATES .......................................................................... 3
3/3 APPROVAL AND INSPECTION OF AGGREGATES ....................................... 3
3/4 STORAGE OF AGGREGATES ........................................................................ 4
3/5 TIDYING-UP OF QUARRY AREA .................................................................... 5
3/6 GRANULAR SUB-BASE ................................................................................... 5
3/7 AGGREGATE ROADBASE DESCRIPTION ..................................................... 8
3/9 SPREADING (AND MIXING) AGGREGATE ROADBASE ............................. 10
3/10 COMPACTION OF AGGREGATE ROADBASE ............................................. 11
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE ............................. 11
3/12 FINISHING OF AGGREGATE ROADBASE ................................................... 12
3/14 WET MIX MACADAM ROADBASE, DESCRIPTION ...................................... 13
3/15 WET MIX MACADAM ROADBASE MATERIAL ............................................. 13
3/16 TRANSPORT AND SPREADING WET MIX MACADAM ROADBASE........... 15
3/17 COMPACTION TRIALS OF WET MIX MACADAM ROADBASE.................... 15
3/18 COMPACTION OF WET MIX MACADAM ROADBASE ................................. 16
3/19 FINISHING OF WET MIX MACADAM ROADBASE ....................................... 16
3/20 MINIMUM TEST REQUIREMENTS FOR WET MIX MACADAM ROADBASE
.......................................................................................................................... 17
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION ...................................... 17
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE................ 17
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE ......................... 19
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE ............................ 19
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES ........... 20
3/26 BITUMEN BINDER ......................................................................................... 22
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES ........................................ 23
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS ........................... 27
3/29 PREPARATION OF BITUMEN BINDER ........................................................ 28
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX ......... 28
3/31 PREPARATION OF BITUMINOUS MIX ............................................................ 28
3/32 SURFACE PREPARATION ............................................................................ 29
3/33 PLACING OF THE MIX ...................................................................................... 29
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE ......................... 32
3/35 BITUMINOUS LEVELLING COURSE ............................................................ 33
3/36 THICKNESS CORES...................................................................................... 33
3/37 COMPACTION OF BITUMINOUS LAYERS ................................................... 34
3/38 RE-ROLLING OF BITUMINOUS COURSES .................................................. 35
3/39 CONTACT SURFACES .................................................................................. 35
3/40 JOINTS IN BITUMINOUS PAVING ................................................................ 36
3/41 PROTECTION OF COMPACTED LAYER ...................................................... 39
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES ............................... 39
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES ............................. 40
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS .................................. 41
3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES .. 42
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS ............................... 43
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES ............. 43
3/48 BITUMINOUS PRIME COAT .......................................................................... 43
3/49 BITUMINOUS TACK COAT ............................................................................ 45

2
3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT ......... 46

3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION .............. 46
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT........... 47
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT.......... 48
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE
TREATMENT .................................................................................................. 48

3
3/1 SOURCE OF AGGREGATES FOR PAVING LAYERS
3/1.1 All aggregates for use in the construction of the pavement Layers shall be
obtained only from sources approved by the Engineer.
3/1.2 The contractor shall have determined the location, suitability and quantity of
material available before tendering as well as the cost and the amount of
work required to extract, crush, screen and clean the material and the length
of haul to the job site.
3/1.3 The Contractor shall provide the Engineer, within thirty (30) days prior to the
scheduled beginning of the crushing and screening operations, with a
complete report on the origin and composition of all stone and/or gravel
aggregates to be used in the Work (Aggregate Resources Report/
Petrographic Study, ASTM C295). All materials shall comply with the
specified requirements for the various aggregates.
3/1.4 The source and manufacture of the aggregates which will meet the
requirements of the Specification is the sole responsibility of the Contractor.
It is also the contractor's sole responsibility to manufacture such aggregates
at the rates and in the quantities required to complete the work within the
specified Contract Period.
3/1.5 The approval of the Contractor's crushing and screening plant equipment by
the Engineer shall in no way relieve the Contractor of the responsibility of
producing aggregates which meet the Specifications and in the quantities
required for the completion of the work within the specified Contract Period.
3/1.6 No aggregate producing equipment shall be put into operation prior to the
approval of the equipment by the Engineer. If after the equipment is put into
operation it fails to perform as proposed, the Contractor shall provide
additional equipment or replace the original equipment with more suitable
equipment, as may be directed by the Engineer.
3/1.7 The Contractor shall commence crushing and screening of aggregate

immediately after the Contractor receives approval of his aggregate sources.
3/2 TESTING OF AGGREGATES
3/2.1 Testing to ascertain the properties of all aggregate materials shall be carried
out in accordance with Clause 1/7.
3/3 APPROVAL AND INSPECTION OF AGGREGATES
3/3.1 All sources of aggregates shall be quality tested by the Contractor and, if
satisfactory, approved by the Engineer prior to the processing of material
from such sources. An individual source of aggregate is deemed to be a
particular location within a quarry or borrow pit where material of a constant
specific gravity is obtained (with possible variation due to minor changes in
characteristics of rock). Test certificates obtained by the Contractor or test

4
performed by the Contractor at his expense are intended to assist him in his
estimate of the location, extent and quantities which will comply with the
Specifications, when properly processed, and will in no way obviate the
need for future testing by the Engineer.
3/3.2 Only materials from approved sources shall be processed for incorporation
into the work. Approval of specific sources of materials shall not be
considered as final approval and acceptance of materials from such
sources. The presence of weathered materials discovered in the quarry
areas shall be a cause of rejection of the source of materials.
A quarry is defined as an open excavation or pit from which stone is

obtained by digging, cutting, or blasting. It includes all the materials, whose
chemical, physical and mechanical properties are adversely affected by any
inclement weather in addition to the contamination from the surrounding
environment.
3/3.3 After having received approval of specific sources of material the Contractor
cannot change these without prior written approval of the Engineer.
3/3.4 All processed materials shall be tested and approved before being stored on
the site or incorporated in the works and may be inspected and tested at any
time during the progress of their preparation and use. Questionable
materials, pending laboratory testing and subsequent approval shall not be
unloaded and incorporated with materials previously approved and
accepted.
Questionable materials are defined as material contaminated adversely by

the inclement weather. It is the material that is suspected to be considered
as unsuitable for road works and must be tested for suitability requirements
and stockpiled separately on site prior to it’s use.
3/3.5 If the grading and quality of the material delivered to the site does not
conform to the grading and quality as previously inspected and tested, or
does not comply with the Specifications, the Engineer reserves the right to
reject such material at the site of the work.
3/3.6 Samples must meet all test requirements as specified under the
Specifications. The Contractor shall permit the Engineer to inspect any and
all material used or to be used, at any time during or after its preparation, or
while being used during the process of the work or after the work has been
completed. All such materials not complying with the required specifications,
whether in place or not, shall be rejected and shall be removed promptly
from site The Contractor shall supply, or arrange with any producers or
manufacturers to supply, all necessary material, labour, tools and equipment
for such inspection.
3/4 STORAGE OF AGGREGATES
3/4.1 The stockpile site shall be prepared by clearing and smoothing and must be
approved by the Engineer. Prior to any stockpiling of aggregates, cross-

5
sections of the stockpile site shall be taken and control points established for
use in determining the quantity of subsequently stockpiled material.
3/4.2 The equipment and methods used for stockpiling aggregates and for
removing aggregates from the stockpiles must be approved by the Engineer
and shall be such that no segregation of the aggregate will result and no
foreign material will contaminate the aggregate.
3/4.3 Material shall be stored in a manner that will ensure preservation of their
specified quality and fitness for the work. They shall be placed on hard,
clean surfaces and, when required by the Engineer they shall be placed
under cover. Stored materials shall be located in such a manner to facilitate
prompt inspection and control.
Private property shall not be used for storage purposes without written
consent of the owner or lessee and payment to him, if necessary, at the
Contractor's expense.
3/4.4 The centre of the storage area shall be elevated and sloped to the sides in
order to provide proper drainage of excess moisture. The material shall be
stored in such a way to prevent segregation and to allow proper control of
moisture. Aggregate stockpiles shall be built up in layers not exceeding one
(1) meter. The height of each stockpile shall be limited to a maximum of five
(5) meters.
3/4.5 Sufficient material must be stored in stockpiles to allow for testing and
approval of such materials prior to use in the works.
3/5 TIDYING-UP OF QUARRY AREA
3/5.1 The Contractor shall tidy up the quarry areas on completion and ensures
that side slopes are not steeper than 1 to 2 and in a condition acceptable to
the Employer and to the Engineer.
3/6 GRANULAR SUB-BASE
3/6.1 DESCRIPTION
Granular sub-base shall consist of furnishing, spreading, and compacting

sub-base in accordance with the details shown on drawings and these
Specifications.
3/6.2 MATERIALS,TESTS AND STANDARDS
Granular sub-base material for Road sub-base shall consist of hard, durable
natural/screened gravel, recycled or crushed stone, and shall be free from
clay balls or other deleterious substances. Granular sub-base shall be well
graded and lie within the grading envelope stated below when tested in
accordance with BS 1377: Part 2: 1990: Test 9.2, AMD 9027: 1996.

6
The material should have a minimum soaked CBR value of 30% at 95% of
maximum dry density and should comply with Clause 3/6.4. Organic matter
content (BS 1377 Part 3: 1990 Method 3, ADM 9028:1996) shall not exceed
0.2%.
The grading of granular subbase is dependent upon the maximum sized
aggregate and shall comply with Grading A or B listed in Table 3-1 as
determined from BS 1377: Part 2: 1990, AMD 9027:1996: Test 9.2:-
Table 3- 1: Grading requirements for granular subbase

Sieve Size Percent Passing Percent Passing
Gradation A (Note 1) Gradation B (Note 2)
50.0 mm - 100
37.5 mm 100 75- 100
25.4 mm 70-100 55- 85
20 mm 60- 90 50- 80
10 mm 45- 75 40- 70
5 mm 30- 60 30- 60
2.36 mm 20- 50 20-50
0.60 mm 10-30 10-30
0.075 mm 0-10 0- 10
Note 1: Gradation A will provide a more density, better compaction and binding and
mainly fits requirements of heavily trafficked roads
Note 2: Gradation B is preferred for subgrade of low CBR
3/6.3 SUBBASE CONSTRUCTION
Road sub-base material shall be delivered to the roadbed as uniform

mixture and shall be spread in layers or windrows. Segregation shall be
avoided and the sub-base shall be free from pockets of coarse or fine
materials.
Each road sub-base layer shall be spread by finisher and or grader or other
approved mechanical methods, watered, shaped to a compacted thickness
not exceeding 150 mm and compacted to the required grade and cross-
section. If the contractor can demonstrate that compaction and compaction
test requirements can be achieved in layers exceeding 150mm but not more
than 170mm, approval may be sought from the engineer.
Route hauling equipment shall be uniformly distributed over the full width of
the surface to minimize rutting or uneven compaction.
Compaction shall be accomplished over the full width of each layer by

compacting from the sides to the center, parallel to the centerline of the
road.
Along curbs, headers, walls, and all places not accessible to the roller,
compact the material with approved vibratory rollers or compactors.
At the time of compaction, the moisture content of the laid material shall not
vary by more that + 2 % from the optimum moisture content.
The granular sub-base shall be compacted to not less than 95 % of the

maximum dry density determined in accordance with BS 1377 Part 4: 1990,
AMD 13925: 2002, Method 3.6. Particle size analysis of soils for sieve

7
analysis of fine and coarse aggregate shall be carried out in accordance

with BS 1377: Part 2: 1990: Test 9.2.
.
The surface on completion of compaction shall be well closed, free from
movement under compaction plant and free from ridges cracks or loose
material. The finished surfaces of the road sub-base shall not vary at any
point more than 10 mm above or below the grade established by the
Engineer.
The road sub-base shall be maintained in a condition satisfactory to receive

any subsequent base or surfacing material. Sub-base which does not
conform to the above requirements shall be reshaped or reworked, watered
and thoroughly re-compacted to conform to the specified requirements.
3/6.4 RELEVANT TEST AND STANDARDS
The standards listed in these specifications shall be the latest version at

time of use. The latest version may differ from the version listed at time of
writing of these General Specifications. The following tests should be carried
out and the materials shall conform to the following requirements (Table 3-
2):
Table 3- 2: Test properties for subbase
TEST STANDARD LIMIT
Sampling ASTM D75: 2009 --
Los Angeles Abrasion ASTM C131-2006 or 30 % max.

ASTM C535-2009
Soundness (Magnesium ASTM C88-2005 12 % max.
Sulphate Solution -5 cycles)
Liquid Limit BS 1377 Part 2: 1990 35 % max.

Test 4.5 and 9.3 AMD 9027-1996
Plasticity Index BS 1377 Part 2: 1990 6 max.

Test 5.4, AMD 9027-1996
Linear Shrinkage BS 1377:Part 2: 1990, Method 6.5, 3 % max.

AMD 9027-1996
Soaked CBR at 95 % of BS 1377 Part 4: 1990 30 % min.

Maximum dry density (96 Test 7, AMD8259:1995&AMD
hour soaked) 13925-2002.
Sulphate Content BS EN 1744-1:1998 0.5 % max.

(Acid soluble)
Chloride Content BS 812: 1988: Part 117 1 % max.

(Acid soluble)
Sand Equivalent Value ASTM D-2419-2009 25% min
Organic Matter Content BS 1377 Part 3:1990 Method 3, 0.2%

AMD 9028-1996 maximum

8
3/6.5 MINIMUM TEST REQUIREMENTS FOR GRANULAR SUBBASE
One sample every 3000 cu m of stockpiled or part of as directed by the

Engineer shall be tested for Grading, Plasticity Index, Maximum Dry Density,
and Loss Angeles Abrasion (Table 3-3).
Where the contractor can demonstrate product uniformity, less frequent

sampling to every 5000 cu. m of stockpiled may be approved by the
engineer with firm adherence to the same requirements and testing
frequency for the 3000 cu.m.
.
A minimum of four in-situ density tests shall be made in every Lot
(Approximately 1500 sq.m) of granular sub-base laid or as directed by the
Engineer.
Table 3- 3: Table 1 Testing frequencies for subbase

TEST FREQUENCY
Sampling One per 3000 cu.m
Grading One per 3000 cu.m
Liquid Limit One per 3000 cu.m
Plasticity Index One per 3000 cu.m
Linear Shrinkage One per 3000 cu.m
Los Angeles Abrasion One per 3000 cu.m
Maximum Dry Density (Proctor) One per 3000 cu.m
Soundness (Magnesium Sulphate Solution - 5 cycles) One per 3000 cu.m
Soaked C.B.R. at 95 % of Maximum dry density One per 3000 cu.m
Organic Matter Content One per 3000 cu.m
3/7 AGGREGATE ROADBASE DESCRIPTION
3/7.1 This work shall consist of furnishing and placing one or more courses of
aggregate, including binder soil if required, on a prepared subgrade or sub-
base in accordance with sub-section 3/8 to 3/13 of the Specifications, in
conformity with the lines, grades, thickness and typical cross-sections
shown on the drawings or established by the Engineer.
3/8 AGGREGATE ROADBASE - MATERIAL TESTS AND STANDARDS
3/8.1 All aggregate roadbase material shall be free from dirt, shale or other
deleterious matter and shall be of such quality that it will bind readily to form
a stable aggregate roadbase.
3/8.2 The standards listed in these specifications shall be the latest version at
writing of these general specifications. The requirements for aggregate
roadbase are listed in Table 3-4 below:

9
Table 3- 4: Test properties for aggregate road base

TEST STANDARD REQUIREMENT
Sampling ASTM D75: 2009
Liquid Limit BS 1377 Part 2: 1990 25% maximum
Test 4.5 and 9.3 AMD 9027-
1996
Plasticity Index BS 1377 Part 2: 1990 6 maximum
Test 5.4, AMD 9027-1996
Sand Equivalent ASTM D-2419 - 2009 40 minimum
Loss by Abrasion ASTM C-131:2006 or 25% maximum*
C-535:2009
Flakiness Index BS EN 933-P3-1997, AMD 35 maximum
14866: 2004
Elongation Index BS812 : 1990 Part, Section 35 maximum
105.2
Soundness (Magnesium ASTM C88: 2005 Course aggregate
Sulphate) (5 cycles) = 12% max
Fine Aggregate =
10% max
Organic Matter Content BS 1377 Part 3 : 1990 Method 0.2% maximum
3,AMD 9028-1996
Acid Soluble Chlorides BS 812: 1988 Part 117 1% maximum

(Combined Aggregate)
Acid Soluble Sulphates BS EN 1744-1:1998 0.5% maximum
(Combined Aggregate)
Soaked CBR BS 1377 : Part 4 : 1990: Test 80% minimum
7, ,AMD 8259:1995 & AMD
13925-2002
Aggregate Crushing BS 812-P110:1990 25% maximum
Value
Water Absorption STM C128-2007a & C127- 2.0% maximum
2007 (Coarse aggregate)
2.3% maximum
(fine aggregate)
Maximum Dry Density BS 1377 Part 4 : 1990 2.3 minimum
(MDD) (method 3.5 or 3.6,
AMD13925-2002 )
* This limit for Loss of Abrasion (LOA) is adopted as most of the existing materials have
Max Dry Density of 2.3Mg/Cu.m and exhibit LOA values that ranges from 10% to 18%
as per DCL rerecords.
3/8.3 The gradation limits when tested in accordance with BS 1377: Part 2: 1990:
AMD 9027: 2002 Test 9.2 shall be as follows (Table 3-5): -

10
Table 3- 5: Grading requirements for aggregate road base

SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 70 – 100
28 mm 55 - 85
20 mm 50 - 80
10 mm 40 - 70
5 mm 30 - 60
2.36 mm 20 - 50
0.425 mm 10 - 30
0.075 mm 5 - 15
Aggregate roadbase shall consist of uniform mixtures of gravel and/or

crushed/recycled gravel with sand, silt and clay, conforming to the specified
gradation limits.
3/9 SPREADING (AND MIXING) AGGREGATE ROADBASE
3/9.1 Aggregate roadbase shall be spread on subgrade or sub-base which has

been approved by the Engineer. Aggregate roadbase which has been
placed on a subgrade or sub-base not approved by the Engineer shall be
removed at the Contractor's expense.
The material shall be spread using a paving machine or motor grader

operated with a mechanism which levels off the material at an even depth
and without delay. If necessary, the material may be a spread with the
grader as and when approved by the Engineer. The road base aggregate
course shall not be placed when the underlying surface is muddy, or when it
is raining or dusting
3/9.2 Aggregate road base shall be spread by finisher and or grader or other
approved mechanical methods, watered, shaped to a compacted thickness
not exceeding 150 mm and compacted to the required grade and cross-
section. If the contractor can demonstrate that compaction and compaction
test requirements can be achieved in layers exceeding 150mm but not more
than 170mm, approval may be sought from the engineer.
3/9.3 The material shall be handled in a manner which avoids segregation.

Segregated materials shall be remixed until uniform. Suitable precautions
shall be taken to prevent rutting of the subgrade or sub-base during the
spreading of aggregate road base materials.
No hauling or placement of material will be permitted when, in the judgment

of the Engineer, the weather or road conditions are such that the hauling
operations will cause cutting or rutting of the subgrade or cause
contamination of aggregate roadbase material.

11
3/10 COMPACTION OF AGGREGATE ROADBASE
3/10.1 The moisture content of the aggregate roadbase material shall be adjusted
prior to compaction, by watering with approved sprinkler trucks or by drying
out, as directed by the Engineer, to that required to obtain the specified
density for aggregate roadbase.
Aggregate roadbase shall be compacted to not less than Ninety Eight (98)
percent of the maximum dry density, as determined according to BS 1377:
Part 4: Test 3.6 at a moisture content between ± 1.5 % of the O.M.C. The
field density and actual moisture content shall be determined according to
BS 1377: Part 9: 1990: Test 2.2., AMD 8264:1995.
3/10.2 The aggregate roadbase shall be compacted by means of approved

compaction equipment progressing gradually from the outside of the road
towards the centre with each succeeding pass uniformly overlapping the
previous pass. Rolling shall continue until the entire thickness of each layer
is thoroughly and uniformly compacted to the specified density.
Rolling shall be accompanied by sufficient grader speeding in a manner

approved by the Engineer, to ensure a smooth surface free from ruts or
ridges and having the proper section and crown.
3/10.3 The surface of the material shall on completion of compaction be well

closed, free from movement under the compaction plant and free from
compaction planes, ridges, cracks, or loose material.
3/10.4 Any areas inaccessible to normal compaction equipment shall be

compacted by means of mechanical tampers until satisfactory compaction is
obtained.
3/10.5 The Contractor shall program his operations to avoid the drying out of the sub-
base during construction. If any layer of aggregate roadbase material, or
part thereof, is permitted to dry out after compaction, or does not conform to
the required density or finish, the Contractor shall, at his own expense,
rework, water and re-compact the material, as directed by the Engineer, to
the density specified, before the next layer of aggregate roadbase or
subsequent pavement layers is placed.
3/11 COMPACTION TRIALS FOR AGGREGATE ROADBASE
3/11.1 If directed by the Engineer, prior to the commencement of the aggregate

roadbase operations, the Contractor shall construct trial lengths not to
exceed 50 meters. The materials used in the trials shall be those approved
for use as aggregate roadbase, and the equipment used shall be that
according to the Contractor's approved detailed program of work.
3/11.2 Trial lengths may not form part of the permanent works but may be
permitted in the construction of temporary detours of sufficient length.
3/11.3 The objective of these trials is to determine the adequacy of the Contractor's
equipment, the loose depth measurements necessary to result in the

12
specified compact layers depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.
3/11.4 The Contractor may proceed with the aggregate roadbase work only after
the methods and procedures established in the compaction trials have been
3/12 FINISHING OF AGGREGATE ROADBASE
3/12.1 Immediately prior to the placing of the first layer of the next pavement
course on to the aggregate roadbase the final layer of aggregate roadbase
shall be at the specified density and to the required grade and section.
In order to maintain these requirements while placing the next course it may
be necessary mechanically sweep or clean with compressed air to remove
the loose material and if necessary to water and reshape the surface of the
aggregate roadbase. This work shall be at the Contractor's expense.
3/12.2 The surface of the finished aggregate roadbase will be tested with a three
(3) meter straightedge by the Engineer at selected locations. The variations
of the surface from the testing edge of the straight edge between any two (2)
contacts with the surface shall at no point exceed ten (10mm) when placed
on or parallel to the centre line or ten (10mm) when placed perpendicular to
the centre line of the roadway.
The aggregate cross section as shown on the drawings shall not vary by
more than ten (10) millimeters from the required elevation. All humps and
depressions and thickness deficiencies exceeding the specified tolerance
shall be corrected by removing the defective work or by adding new material
as directed by the Engineer.
Shallow patching of an area without scarifying the surface to permit proper

bonding of the added material will not be permitted.
3/13 MNIMUM TEST REQUIREMENTS FOR AGGREGATE ROADBASE

A minimum of four in-situ Density tests shall be made per unit (1000 sq. m)
of aggregate roadbase laid or as directed by the Engineer.
Also, One sample every 3000 cu m of stockpile or part of as directed by the

Engineer shall be tested for Grading, Plasticity Index, Maximum Dry Density,
and Loss Angeles Abrasion.
Where the contractor can demonstrate product uniformity less frequent

sampling to every 5000 cu. m may be approved by the engineer. The details
are shown in Figure 3-6 below:-

13
Table 3- 6: Frequency of testing for aggregate road base

TEST FREQUENCY
Sampling One per 3000 cu.m
Liquid Limit One per 3000 cu.m
Plasticity Index One per 3000 cu.m
Sand Equivalent One per 3000 cu.m

Loss by Abrasion One per 3000 cu.m
Maximum Dry Density (Proctor) One per 3000 cu.m
Flakiness Index One per 3000 cu.m
Elongation Index One per 3000 cu.m
Soundness (Magnesium Sulphate) (5 cycles) One per 3000 cu.m
*Organic Matter Content One per 3000 cu.m
Acid Soluble Chlorides (Combined Aggregate) One per 3000 cu.m
Acid Soluble Sulphate (Combined Aggregate) One per 3000 cu.m
Soaked CBR One per 3000 cu.m
Aggregate Crushing Value One per 3000 cu.m
Water Absorption One per 3000 cu.m
3/14 WET MIX MACADAM ROADBASE, DESCRIPTION

3/14.1 This work shall consist of furnishing and placing one or more courses of high
quality crushed aggregate, bound by means of carefully controlled moisture
content, on the prepared subgrade or sub-base in conformity to the line,
level and thickness shown on the drawings or as directed by the Engineer.
3/15 WET MIX MACADAM ROADBASE MATERIAL

3/15.1 The coarse aggregate shall consist of crushed rock (each particle shall have
a minimum of one crushed face - DCL Test Method DMS-8:2001) and the
fine aggregate shall be crushed rock or naturally occurring material. The
aggregate shall conform to the following gradation (Table 3-7):
Table 3- 7: Grading for wet mix macadam

SIEVE SIZE (BS) PERCENT PASSING
50 mm 100
37.5 mm 95 – 100
20 mm 60 – 80
10 mm 40 – 60
5 mm 25 – 40
2.36 mm 15 – 30
0.6 mm 8 – 22
0.075 mm 2–8
Volume 2, Part 1, General Specifications-Road Works July Page 13

14
The particle size shall be determined in accordance with the requirements of

BS 1377 Part 2: 1990 (Method 9.2 or 9.3), AMD 9027:1996.
3/15.2 The gradation shall be adjusted as required or as directed by the Engineer

within the above limits to ensure the mix has adequate binding properties.
3/15.3 The standards listed in these specifications shall be the latest version at
writing of these General Specifications. Wet Mix road base material shall
have physical properties which comply with the following values (Table 3-8):
Table 3- 8: Test properties for Wet Mix Macadam

TEST LIMIT
Sampling ASTM D75: 2009
Liquid Limit BS 1377: Part 2: 1990 : Test 4.5, AMD 9027:96 25 % max.
Linear Shrinkage (BS 1377 Part 2: 1990 Method 6.5), AMD 9027:96 3 % max.
Plasticity Index BS 1377: Part 2: 1990: Test 5.4, AMD 9027:96 6 max.
Aggregate Crushing Value (BS 812: 1990 P 110) 30 % max.
Water Absorption (ASTM C128: 2007a / C127 : 2007) 2.0 %
max.
Flakiness Index (BS EN 933: Part 3, 1997 AMD 14866: 2004) 30% max.
Elongation Index (BS 812: 1990 Part 105, Section 105.2) 30% max.
Los Angeles Abrasion Loss (ASTM C-131:06 or C-535:09) 30 % max.
*Soundness Loss (ASTM C 88:2005) 5 cycles 12 % max
(Magnesium Sulphate)
*Organic Matter Content (BS 1377 Pt 3: 1990 Method 3, AMD 9028: 0.2 %
1996) max.
Chloride Content (Acid Soluble) BS 812: 1988 Part 117 1% max.
Sulphate Content (Acid Soluble) BS EN 1744-1:1998 0.5% max.
Sand Equivalent (ASTM D-2419:2009). 45 min
CBR on Remolded Samples after 4 days soaking at 100% of the 80%
maximum dry density (BS 1377: Part 4 : 1990: Test 7, AMD 13925: minimum
2005)
Maximum Dry Density (MDD), BS 1377 Part 4: 1990 (method 3.5 or 2.3
3.6, AMD13925-2002 ) minimum
3/15.4 The moisture content of the Wet Mix Macadam at the time of laying shall be
the optimum + 1 %. Water required to achieve this moisture content shall
be added at the mixing plant. Moisture determination shall be in accordance
with BS 1377: Part 2: 1990: Test 3.2,AMD 9027:96.
3/15.5 The mixing water should be clear, visually clean and free of matter harmful
to the pavement i.e. soluble salts. Sweat water can be used. Water of
questionable quality should comply with the chemical limitations listed in

15
Table 3-9. Water shall be sampled in accordance with BS EN 1008:2008

latest edition.
Table 3- 9: Chemical requirements for mixing water

ITEM LIMIT TEST METHOD
Chloride as CL 250 ASTM D512-04

Sulphate as SO4 350 ASTM D516-07
Alkali Carbonates and Bicarbonates 500 ASTM D513:2006
Total Dissolved Solids including 2000 BS 1377 Part 3:Test
items 1,2 &3 above 1990 AMD 9028(1996)
pH 7-9 ASTM D 1293:2005
3/16 TRANSPORT AND SPREADING WET MIX MACADAM ROADBASE

3/16.1 Transport vehicles carrying the plant mixed material shall have a capacity
suited to the output of the mixing plant and the site conditions and be
capable of discharging cleanly. Material when mixed shall be removed at
once from the mixer transported directly to the point where it is to be laid
and protected from the weather both during transit from the mixer to the
laying site and whilst waiting tipping. The mixture shall be transported from
the plant in vehicles that maintain moisture content and prevent segregation
and loss of the fine material
3/16.2 The material shall be placed and spread evenly. The material shall be
spread using a paving machine or spreader box operated with a mechanism
which levels off the material at an even depth and without delay. Except
where otherwise specified, the material shall be laid and compacted in
layers of maximum compacted thickness of 150mm.
3/17 COMPACTION TRIALS OF WET MIX MACADAM ROADBASE
3/17.1 If directed by the Engineer, prior to the commencement of the Wet Mix
Macadam Roadbase operations, the contractor shall construct trial lengths,
not to exceed 50 meters. The materials used in the trials shall be those
approved for use as Wet Mix Macadam Roadbase and the equipment used
shall be that according to the Contractor's approved schedule of work.
3/17.2 Trial lengths may not form part of the permanent works but may be
permitted in the construction of temporary detours of sufficient length.
3/17.3 The objective of these trials is to determine the adequacy of the Contractor's
specified compacted layer depths, the field moisture content, and the
relationship between the number of compaction passes and the resulting
density of the material.
3/17.4 The Contractor may proceed with the Wet Mix Macadam Roadbase work
only after the methods and procedures established in the compaction trials
have been approved by the Engineer.

16
3/18 COMPACTION OF WET MIX MACADAM ROADBASE
3/18.1 The material shall be compacted to a field density equal to 100% of

maximum dry density value obtained when tested in accordance with BS
1377: Part 4 : Test 3.7 : 1990, AMD 13925-2002.
Field Density tests shall be carried out in accordance BS 1377: Part 9: 1990:
Test 2.2-AMD 8264-1995; AMD 17229-2007
3/18.2 Compaction shall be completed as soon as possible after the material has
been spread.
3/18.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
3/18.4 The surface of any layer of material shall on completion of compaction be

well closed free from movement under compaction plant and free from
compaction planes, ridges, cracks or loose material. All loose, segregated
or otherwise defective areas shall be made good to the full thickness of layer
and re-compacted.
3/18.5 Where directed by the Engineer a Sieve analysis shall be carried out on the
material recovered from 5 consecutive field density tests. Where this sieve
analysis shows oversize material content of 10 % or greater the area of
construction will be removed and the source of the material rejected until
further notice. Where considered necessary other areas of work which were
carried on using material from the same source shall be tested in a similar
manner.
3/19 FINISHING OF WET MIX MACADAM ROADBASE

3/19.1 Immediately prior to the placing of the first layer of the next pavement
course on to the Wet Mix Macadam Roadbase, the final layer of Wet Mix
Macadam Roadbase shall be at the specified density and to the required
grade and section. In order to maintain these requirements while placing
the next course, it may be necessary to water and reshape the surface of
the Wet Mix Macadam Roadbase. This work shall be at the Contractor's
expense.
3/19.2 The surface of the finished Wet Mix Macadam Roadbase will be tested with
a three (3) meter straight edge by the Engineer at selected locations. The
variations of the surface from the testing edge between any two (2) contacts
with the surface shall at no point exceed ten (10) millimeters when placed on
or parallel to the centre line, or ten (10) millimeters when placed
perpendicular to the centre line of the roadway. The Wet Mix Macadam
Roadbase shall be compacted to the thickness and cross sections as shown
on the drawings and shall not vary by more than ten (10) millimeters from
the required elevation.
All humps and depressions and thickness deficiencies exceeding the

specified tolerance shall be corrected by removing the defective work or by

17
adding new material as directed by the Engineer. The following additional

requirements are to be complied with:
 The straight edge shall not have any supports enabling it to rest on
the surface.
 The plus tolerance of 10mm from the required elevation is not
applicable if read in conjunction with the thickness requirements of
asphaltic courses, Clause 3/44 unless design finished level is
revised, if agreed by the Engineer, to enable to obtain the required
thickness of the asphaltic courses in a smooth grading in the affected
road length.
3/19.3 Before placing the next construction layer or applying prime coat, the Wet
Mix Macadam roadbase shall be mechanically swept then cleaned with
compressed air to remove loose material. As soon as possible after
cleaning of the surface, the Wet Mix roadbase shall be sealed by the
application of a prime coat as specified. Should the surface of the material
be allowed to dry out before the seal is applied, it shall be lightly watered
and re-compacted immediately prior to spraying with prime coat.
In the event of a section of wet mix roadbase failing to comply, either by

level or degree of compaction, and where the full depth of the layer has
been allowed to dry out, it shall be removed and replaced at the Contractor's
expense, with fresh material. Watering and re-mixing in place will not be
permitted.
3/20 MINIMUM TEST REQUIREMENTS FOR WET MIX MACADAM

ROADBASE
3/20.1 One sample every 1,000 cu. m. or part of as directed by the Engineer shall
be tested for Grading Plasticity Index, Sand Equivalent value, Maximum Dry
Density, C.B.R. and Loss by Abrasion.
3/20.2 Three insitu density tests shall be made per unit (750 sq.m.) of each layer of
carriageway and three insitu density test per unit (450 lin.m.) of shoulder or
as directed by the Engineer.
3/20.3 Special care shall be taken to obtain full compaction in the vicinity of both
longitudinal and transverse joints.
3/21 BITUMINOUS PAVING COURSES, DESCRIPTION

3/21.1 This work shall consist of the construction of the following hot mix
bituminous courses which shall be either Asphaltic Concrete or Dense
Bitumen Macadam as shown on the drawings. Bituminous Paving Courses
shall consist of coarse aggregates, fine aggregates, filler material, and
bitumen binder.
3/22 COARSE AGGREGATES FOR BITUMINOUS PAVING COURSE
3/22.1 Coarse aggregates, which is the material retained on a 4.75 mm sieve, shall
consist of crushed rock or crushed gravel. It shall be clean, hard, tough,

18
durable and sound, and shall be of uniform quality and free from
decomposed stone, shale, clay, lumps and other deleterious substances.
Sampling of coarse aggregate shall be in accordance with ASTM D75: 2009.
3/22.2 Crushed gravel for use as coarse aggregate shall consist of the product
obtained by crushing material that has first been screened in such a manner
that not less than ninety (90) percent of the material to be crushed is
retained on an ASTM 3/8” sieve.
3/22.3 Percentage of partially crushed faces with minimum one crushed face shall
be 100% by weight of each stockpile of aggregate. In addition, at least 85%
by weight of each separate stockpile of aggregate shall have all faces
crushed. This 85% value may be reduced to 50% for certain categories of
road where indicated on the drawings. Crushed face determination shall be
as per DCL Test Method DMS 7: 2001 and DMS 8:2001.
3/22.4 Each stockpile of coarse aggregate shall have properties which comply with
the following values (Table 3-10): -
Table 3- 10: Properties of coarse aggregate for bituminous paving course

TEST LIMIT
Los Angeles Abrasion Loss(ASTM C-131:06 or C-535:09)

 Base Course and Binder Course 30% max.
 Wearing Course 25% max.
Aggregate Crushing Value (BS 812 : 1990 P 110)
 Base Course and Binder Course 25% max.
 Wearing Course 20% max.
Soundness Loss (ASTM C88 : 2005) – ‘5 cycles’, Magnesium 10% max.
Sulphate
Acid soluble Chlorides (BS 812 : 1988 Part 117) 0.1% max.
Acid soluble Sulphates (BS EN 1744-1:1998) 0.5% max.
Flakiness Index (BS EN 933- Part 3,1997: AMD 14866: 2004)
 Base Course and Binder Course 30 max.
 Wearing Course 25 max.
Elongation Index (BS 812 : 1990 P 105, Section 105.2)
 Base Course and Binder Course 30 max.
 Wearing Course 25 max.
Water Absorption (ASTM C127 : 2007) 2.0% max.
3/22.5 Reclaimed Asphalt Pavement material (RAP) shall be obtained from milling
or excavation of existing asphalt pavements. RAP shall be crushed and
screened as necessary to ensure a maximum size no greater than the
maximum size of asphalt being produced and to achieve a reasonably well
graded, free flowing, and consistent product. RAP shall not be subject to
material properties above.
RAP shall be free of foreign materials such as bound or unbound granular

base, broken concrete or other contaminants.
Prior to use, RAP shall be placed in separate stockpiles not exceeding

100 tones. Each stockpile shall represent a Lot, and test results shall be
traceable between the Lot and asphalt mix containing the relevant RAP.

19
RAP that has been stockpiled for some time and has bound together in
some way shall be reprocessed, to ensure that it is in a free flowing state at
the time of use.
The proportion of RAP in the total mix shall not exceed 20% and the final
grading of combining RAP and virgin quarry aggregates shall conform to the
requirements of Table 3-14 “Aggregate Grading for Asphaltic Concrete”
outlined in Clause 3/25.2 to follow.
3/23 FINE AGGREGATE FOR BITUMINOUS PAVING COURSE
3/23.1 Fine aggregate shall consist of the material passing a 4.75 mm sieve.
3/23.2 Fine aggregate including filler shall be obtained from 100% crushed gravel
or crushed rock pre-screened to exclude natural uncrushed fine material or
weathered unsound fines.
The use of dune sand shall not be permitted.
3/23.3 Fine aggregates shall have properties which comply with the following
values (Table 3-11): -
Table 3- 11: Properties of fine aggregate for bituminous paving course

TEST LIMIT
Soundness Loss (ASTM C-88: 2005)-“5 cycles”, 10 % max.

Magnesium Sulphate
Plasticity Index, (BS 1377:Part 2 : 1990:Test 5, AMD Non Plastic
9027: 1996)
Acid Soluble Chlorides, (BS 812 : 1988 Part 117) 0.1% max.
Acid Soluble Sulphates, (BS EN 1744:1998) 0.5% max.
Water absorption, (ASTM C-128: 2007a) 2.3% max.
Sampling of fine aggregate shall be in accordance with ASTM D75: 2009.
3/24 MINERAL FILLER FOR BITUMINOUS PAVING COURSE
3/24.1 When the combined grading of the coarse and fine aggregates is deficient in
material passing the ASTM No.200 sieve, mineral filler shall be added as
approved by the Engineer at the Contractor's expense.
3/24.2 Mineral filler shall consist of finely ground particles of limestone or cement in
accordance with ASTM D242:2009. It shall be thoroughly dry and free from
organic substances and clay and meet the grading requirements following
(Table 3-12): -

20
Table 3- 12: Grading requirement for mineral filler
MINERAL FILLER
B.S. SIEVE ASTM SIEVE SIZE PERCENTAGE BY

MASS PASSING
600 micron No. 30 100
300 micron No. 50 95 - 100
150 micron No. 100 90 - 100
75 micron No. 200 70 - 100
Grading shall be in accordance with ASTM D 546:2005. Relative density test

as per BS EN 1097: Part 3.
3/25 COMBINED AGGREGATE FOR BITUMINOUS PAVING COURSES
3/25.1 The combined mineral aggregate shall meet the following physical
requirements (Table 3-13): -
Table 3- 13: Physical requirements of the combined mineral aggregates

TEST LIMIT
Sand Equivalent ASTM D2419-2009 determined after 65 minimum
all processing except for addition of asphalt binder
Plasticity Index BS 1377:Part 2 : 1990:Test 5, AMD Non Plastic
9027 1996
3/25.2 When tested according to ASTM C136: 2006 or BS EN933-1:1997, AMD

15907: 2006, the combined mineral aggregate shall conform to Table 3-14
for Asphaltic Concrete and Tables 3-15, 3-16 and 3-17 for Dense Bitumen
Macadam:-
Table 3- 14: Aggregate grading for Asphaltic Concrete (AC)
SIEVE SIZE TOTAL PASSING (BY WEIGHT)

SQUARE OPENINGS
ASTM BASE COURSE BINDER WEARING
COURSE COURSE
37.5 mm 100
25 mm 80 - 100 100 100
19 mm 62 - 92 80 - 100 86 – 100
12.5 mm - 63 - 85 69 – 87
9.5 mm 45 - 75 57 - 77 58 – 78
4.75 mm 30 - 55 40 - 60 40 – 60
2.36 mm 20 - 40 25 - 45 25 – 45
0.85 mm 15 - 30 15 - 30 15 – 30
0.425 mm 10 - 22 10 - 22 10 – 22
0.18 mm 6 - 15 6 - 15 6 – 15

21
0.075 mm 2-8 2-8 2–8
Table 3- 15: Aggregate grading for Dense Bitumen Macadam (DBM) Asphalt Base
Course
B.S. TEST SIEVE AGGREGATE, CRUSHED ROCK OR GRAVEL

mm Percentage by Mass Passing
50 100
37.5 95 - 100
28 70 - 94
14 56 - 76
6.3 44 - 60
3.35 32 - 46
0.300 7 - 21
0.075 2-8
Note: The aggregate shall be in a surface dry condition prior to mixing.
Table 3- 16: Aggregate grading Dense Bitumen Macadam (DBM) Asphalt Base Course
based on layer thickness

mm Percentage by Mass Passing for Finished Thickness of
Base Course
65 – 80mm 50 - 60mm 35 - 45mm
50 100 - -
37.5 95 – 100 100 -
28 70 – 94 90 - 100 100
20 - 71 - 95 95 - 100
14 56 – 76 58 - 82 65 - 85
10 - - 52 - 72
6.3 44 – 60 44 - 60 39 - 55
3.35 32 – 46 32 - 46 32 - 46
0.300 7 – 21 7 - 21 7 - 21
0.075 2–8 2-8 2-8
Table 3- 17: Aggregate grading for Dense Bitumen Macadam (DBM) Wearing Course
based on layer thickness

mm Percentage by mass Passing for Finished Thickness of
Wearing Course
35 – 50 mm 25 – 30 mm 20 mm
28 100 - -
20 95 - 100 100 -
14 70 - 90 95 - 100 100
10 55 - 75 70 - 90 95 - 100
6.3 40 - 60 45 - 65 55 - 75

22
3.35 25 - 40 30 - 45 30 - 45
1.18 15 - 30 15 - 30 15 - 30
0.075 2-6 2-6 2-6
3/25.3 The grading given in Tables 3-14, 3-15, 3-16 and 3-17 represent the
extreme limits which shall determine suitability of aggregate for use from all
sources of supply. The aggregate as finally selected for use in the work
shall have a grading within the limits designated in Tables 3-15, 3-16 and 3-
17 as appropriate and for Table 3-14 may with the Engineer's agreement.
3/25.4 The coarse aggregate, shall show no detrimental amount of stripping when
tested in accordance with ASTM D1664: 1985. The minimum value of non
stripped area shall be 95%. If stripping occurs, the aggregate shall be
rejected and an approved method of treatment specified to change the
material from a hydrophilic to a hydrophobic state as directed by the
Engineer, or an approved additive shall be used with the bituminous binder.
3/25.5 When necessary to improve the coating of aggregate by bitumen, additives

of approved type will be added to the bituminous material in such
percentage as required to obtain satisfactory results in the affinity with
bitumen test performed in accordance with ASTM D1664: 1985. The
approved additive will be used in accordance with Technical Specifications
issued by the manufacturer and approved by the Engineer after appropriate
testing.
3/25.6 No extra payment will be made for required anti-stripping additives.
3/26 BITUMEN BINDER
3/26.1 Bitumen Binder for the "Bituminous Paving Courses" shall be Bitumen
Binder penetration grade 60 - 70 unless otherwise specified as 40 - 50.
3/26.2 The bitumen shall be prepared by refining crude petroleum by suitable

methods and shall be homogeneous, free from water and shall not foam
when heated to 175 degrees C (347 F).
3/26.3 Bitumen penetration grade 60 - 70 and 40 - 50 shall conform to the

requirements of Table 3-18. Sampling shall be in accordance with ASTM
D140.
3/26.4 A sample of the bitumen that the Contractor proposes to use in the work,
together with a statement as to its source and properties shall be submitted
to and approved by the Engineer at least 45 days before the asphalt work
begins.
3/26.5 No bitumen other than that represented by the approved sample shall be
used by the Contractor except with the written consent of the Engineer.
Blending of bitumen from different refineries will not be permitted.

23
Table 3- 18: Properties of bitumen binder for asphalt mixes
60 - 70 PEN 40 - 50 PEN
TEST ASTM MIN. MAX. MIN. MAX.
Penetration 0.1 mm D5: 2006 60 70 40 50
at 25 deg.C, 100g, 5 sec.
Specific Gravity D70: 2009 - - - -
Flash Point, Cleveland D92: 2005a 232 - 23 -
Open Cup, deg. C. 2
Ductility at D113: 2007 100 - 10 -
25 deg.C, cm 0
Solubility trichloro D2042: 2009 99 - 99 -
ethylene, %
*Thin film oven D1754: 2009 - 0.80 - 0.80
3.2mm, 163 deg.
C, 5 hr loss on heating %
*Penetration D5: 2006 52 - 55 -
of residue
% of original
Ductility of D113: 2007 50 - - -
residue at
25 deg C
5 cm/min. cm
Kinematic Viscosity D2170: 2007 240 - 28 -
(Centistokes) 0
at 135 deg.C
Softening Point
Ring & Ball, deg C D36: 2006 48 52 51 55
3/26.6 For Asphaltic Concrete the percentage range of bitumen by weight of total
mix to be added to the aggregate shall be as prescribed in Table 3-19: For
Dense Bitumen Macadam the range shall be as prescribed in Table 3-22.
Table 3- 19: Bitumen content for Asphaltic Concrete (AC) Layers
PAVEMENT COURSE BITUMEN PERCENTAGE BY WEIGHT OF

TOTAL MIX INCLUSIVE OF TOLERANCES
Base 3.2 to 4.4

Binder 3.4 to 4.4
Wearing 3.4 to 4.4
3/27 JOB MIX FOR BITUMINOUS PAVING COURSES
3/27.1 The mix approved for use in the works shall be designed using Marshall
tests and field trials with the following recommendations taken into account:-
- For base course, the combined aggregate mix shall be modified by

substituting all aggregate sizes over 25 mm with an equal weight of
aggregate sizes in the next lower grading sizes as specified in Tables
3-14, 3-15, 3-16 and 3-17.

24
- The combined aggregate gradation should be adjusted within the

allowable limits to achieve maximum stability whilst not going below
the minimum requirement for void content.
- The minimum bitumen binder content according to the results of the

Marshall Method of Mix Design should be used provided that it will still
satisfy the durability, the stability and the void content requirements.
- Prior to final approval, the proposed job mix, but with a bituminous
content at the upper percentage limits shall be compacted to refusal,
(400, 500 and 600 blows) and the resulting voids in the mix shall not
be less than 2% for asphaltic concrete or 3% for DBM.
- The final job mix must display the Marshall characteristics specified in
Table 3-21 for Asphaltic Concrete and Table 3-22 for Dense Bitumen
Macadam.
3/27.2 Determination of VIM, VMA & VFB shall be in accordance with DMS 9:
2001.
3/27.3 At least thirty (30) days prior to the date the Contractor intends to begin
production of plant-mix "Bituminous Paving Course" Mixes and after
receiving approval of the aggregates and bitumen from the Engineer, the
Contractor shall make a written request for the approval of the job-mix
formula from the Engineer. The job-mix formula will be prepared by the
Contractor under the supervision of the Engineer in the Laboratory. The job-
mix design and calibration factor for the mix shall be checked at the Dubai
Central Laboratory.
3/27.4 The laboratory job mix formula shall fix a single definite percentage of
aggregate passing each required sieve size, a single definite percentage of
bitumen binder to be added to the aggregate, a specified target temperature
at which the mix is to be emptied from the mixer, and a specified target
temperature at which the mix is to be delivered to the works site. For
tolerance limits applicable refer to Table 3-20.
3/27.5 The laboratory job mix formula shall be used for the basis of approval of the
job standard mixture.
3/27.6 Trials areas having lengths of at least 50 m to the specified layer thickness
shall be laid outside the area of the permanent work by the Contractor for
the Engineer's approval, before the start of the permanent work. At least
two samples of non-compacted material from the trial area shall be taken in
accordance with ASTM D979: 2001 and shall be analyzed in the presence
of the Engineer to determine the aggregate grading and binder content.
Stability, flow, Marshall Density and voids shall be determined for Marshall
Specimens which are made from Plant/Site mixtures. The results shall be
submitted to the Engineer and shall be approved by him before further
mixing or lying is carried out.
3/27.7 Trial areas may form part of a temporary traffic detour subject to the
approval of the Engineer. The compaction trials according to sub-section
3/42 should be performed on the trial mixes. If the trial areas form part of

25
the temporary traffic detour they shall not be paid for under the relevant Bill
item.
3/27.8 Should the laboratory job mix formula after passing the mixing plant and laid
and compacted with approved plant fail to produce a satisfactory trial area,
the mix proportions may be modified by agreement with the Engineer, as
necessary and within the requirements of Table 3-20, 3-21 and 3-22 as
applicable to produce a mix of satisfactory workability and acceptable
surface finish subject to the mix being rechecked in accordance with the
preceding Clauses of 3/27. After approval of the trial area by the Engineer
this mix shall be designated the 'Job Standard Mix' and shall thereafter be
the approved mix.
3/27.9 All mixes produced shall conform to the Job Standard Mix approved by the
Engineer, within the ranges of tolerance specified in Table 3-20 (within the
limits of Table 3-14, 3-19 and 3-21 for Asphaltic Concrete and Tables 3-15,
3-16, 3-17 and 3-22 for Dense Bitumen Macadam). Each day the Engineer
shall take as many samples of the materials and mix as he considers
necessary and minimum of one sample for every 300 tons laid or part
thereof for checking their required characteristics. When unsatisfactory
results or changed conditions make it necessary, the Engineer shall instruct
the Contractor to establish a new job-standard following approval of the new
mix design in accordance with the preceding Clauses of 3/27.
3/27.10 Should a change in a material be encountered or should a change in a

source of material be made, a new Job-standard Mix shall be submitted by
the Contractor in accordance with the preceding Clauses of 3/27 and
approved by the Engineer before the mix containing the new material is
delivered. Job materials will be rejected if they are found not to have the
characteristics required by the approved Job Standard Mix.
Table 3- 20: Job mix tolerance

Characteristics Tolerance
Aggregate retained on 4.75mm sieve or larger +/- 5%
Aggregate passing 4.75mm sieve and retained on +/- 4%
0.85mm sieve
Aggregate passing 0.85mm sieve and retained on +/- 2%
0.075mm sieve
Aggregate passing 0.075mm sieve +/-1.0%
Bitumen Binder +/-0.2%
Temperature of mixing and placing +/- 10oC
3/27.11 In the event, any bituminous mix that is currently being used in another
running RTA/DM project, is proposed by the contractor for approval of using
that mix in this contract, then prior to according the approval or otherwise,
Engineer will ensure that:
1. Copies of all test reports pertaining to the proposed mix submitted by the
contractor comply with the Specification requirements as stated in this
contract and
2. The proposed mix complies with clause 3/27 of this contract.

26
Table 3- 21: Properties of mix for Asphaltic Concrete (AC)

PROPERTIES BITUMINOUS BITUMINOUS BITUMINOUS
BASE BINDER WEARING
COURSE COURSE COURSE
Number of Compaction blow 75 75 75

at each end of specimen
Cycles for Gyratory 80 80 80

compaction
(ASTM D6925:2009)
Stability (Marshall) 9800 9800 11760
Minimum (N)
(ASTM D2726:2008)
Flow (Marshall) mm 8 - 16 8 - 16 8 - 16
in 0.25 mm
(ASTM D2726:2008)
Stiffness, minimum 1225 1225 1225

(N/0.25 mm)
(ASTM D2726-2008)
Percent air voids 4-8 4-8 4-8
(DMS 9:2001)
Percent voids in 13 14 15
mineral aggregate,
minimum % (V.M.A)
(DMS 9:2001)
Percent voids filled 50 - 65 50 - 70 50 - 70
with bitumen (V.F.B).
(DMS 9:2001)
Loss of Marshall Stability in Max.25% Max. 25% Max. 25%
accordance with DMS 10:
2001
Filler/Bitumen Ratio 0.6 - 1.5 0.6 - 1.5 0.6 - 1.4
Table 3- 22 Properties of mix for Dense Bituminous Macadam (DBM)
BASE COURSE WEARING COURSE

TEST MIN. MAX. MIN. MAX.
Marshall specimens No. 75 - 75 -

of Comp. Blow each end
of specimen
Cycles for Gyratory 80 80
compaction
(ASTM D6925:2009)
Voids in Mix (%) 7 11 6 9
(DMS 9:2001)
Voids in Mineral 14 20 14 20
Aggregate (%)
(DMS 9:2001)
Minimum Stability (N) 7350 - 9800 -

27
(ASTM D2726:2008)
Flow, 0.25mm 8 16 8 16
(ASTM D2726:2008)
Stiffness, minimum 919 - 1225 -
(N/0.25 mm)
(ASTM D2726:2008))
Bitumen Content 3.2 4.0 3.5 4.1
(% of total mix).
(ASTM D6307 - 05
(METHOD A))
Voids Filled with 47 60 48 60
Bitumen (%)
(DMS 9:2001)
Loss of Marshall stability - 25% - 25%
(DMS 10: 2001)
Samples of bituminous paving course mixes shall be taken from the mixing
plant and/or behind the paver prior to compaction, as per ASTM D979: 2006
of latest edition check compliance with the approved job mix requirements
including Tables 3-14, 3-19, 3-20 and 3-21 for asphaltic concrete and Tables
3-15, 3-16, 3-17, 3-19, 3-20 and 3-22 for Dense Bitumen Macadam.
3/27.12 The density of the compacted mixes shall be related to the daily Marshall
Density which shall be determined by making four Standard Marshall
Specimens from samples of the mix taken from the mixing plant or paver.
The density of each sample shall be determined and compared with the
mean value. Any individual result which varies from the mean by more than
0.015 gm/cc shall be rejected. Marshall Tests shall be repeated on a daily
basis to establish the daily Marshall Density for that particular day's
production. The daily Marshall Density shall not vary from the Job Mix
Design Density by more than + 1.0%.
3/27.13 The assistance of the Engineer in the preparation of the job standard mix in
no way relieves the Contractor of the responsibility of producing a
bituminous mix meeting the requirements of the Specifications.
3/28 EQUIPMENT FOR BITUMINOUS PAVING OPERATIONS
3/28.1 Method statement and equipment list shall be according to the type and
number outlined in the Contractor's detailed Programme of Work, as
approved by the Engineer. Requirements for major plant are outlined in
Clause 1/29 of these Specifications.
3/28.2 In addition to the above requirements, trucks used for hauling bituminous
mix shall have tight, clean, smooth metal beds which have been thinly
coated with a minimal amount of paraffin oil, lime solution, or other approved
material to prevent the mix from adhering to the beds. When required by the
Engineer, each vehicle shall be equipped with a canvas cover or other
suitable material of such size as to protect the mix from the weather.
3/28.3 Rolling equipment shall be self-propelled. The wheels on the rollers shall be
equipped with adjustable scrapers and the rollers shall have water tanks and

28
sprinkling apparatus, which shall be used to keep the wheel wet and prevent
the surface material from sticking.
3/29 PREPARATION OF BITUMEN BINDER
3/29.1 The heating of the bitumen binder for mixing and compacting shall be in
accordance with ASTM D6926: 2004 or ASTM D6927:2006.
3/30 PREPARATION OF MINERAL AGGREGATE FOR BITUMINOUS MIX
3/30.1 i. Coarse and fine aggregate shall be stored at the asphalt plant in such
a manner that the separate stockpiles will not become intermixed. The
stockpiles shall be of sufficient size to provide a minimum quantity of
one week's continuous production of asphalt mix. Taking into
consideration the frequency of aggregate testing as mentioned in
Clause 3/47.2 aggregates brought to the asphalt plant to supplement
stocks should be tested and approved prior to placing in the existing
approved stockpiles.
ii. The cold bins shall be calibrated with the materials to be used and the
settings shall be such as to produce a combined gradation in
accordance with the job mix formula. The proportioning shall be such
that surpluses and shortages in the hot bins will not cause breaks in
the continuous operation. All the above shall be as approved by the
Engineer.
iii. The materials shall be heated so that their temperature is within ±8

deg.C of the temperature needed to satisfy the viscosity requirements
of the asphalt cement. The moisture content of the heated and dried
materials shall not exceed 0.5 per cent. The quantity of materials fed
through the drier shall in all cases be held to an amount which can be
thoroughly dried and heated within the limits specified.
3/30.2 Immediately after heating, the aggregate or aggregates shall be screened

into at least five (5) sizes and conveyed into separate bins ready for
batching and mixing with bituminous material. When the aggregates
supplied are of such size and grading that separating into five (5) bins is
impractical, the number of required separations may be reduced to four (4)
or to three (3) with the approval of the Engineer. The efficiency of the
screening operations shall be sufficient to produce, at plant operating
capacity, gradations in each of the sizes of heated and dried aggregates
which are reasonably uniform and result in the production of a mix
complying with the limits specified for the aggregate gradation.
3/31 PREPARATION OF BITUMINOUS MIX
3/31.1 Dried aggregate as specified and prepared as prescribed above shall be

combined in the plant conforming to ASTM D 995 - 02 in the approved
proportions. The bitumen binder shall be introduced into the mix in the
proportion specified by the job-mix formula.

29
3/31.2 The initial mixing time will be designated by the Engineer. Mixing time may
be increased by the Engineer if additional time is necessary to obtain a
homogeneous mix and satisfactory coating.
3/31.3 The batch plants, timing shall begin at the start of the introduction of the
bitumen into the Pugmill.
3/31.4 The length of mixing time for continuous plants will be determined by the
following formula or other approved methods:-
Pugmill dead load capacity in Kg

Mixing time in seconds = ------------------------------------------
Pugmill output in Kg/second
3/31.5 The temperature of the aggregate immediately prior to mixing shall be within
 8 deg.C of the temperature of the asphalt cement and the temperature of
the aggregate and asphalt prior to mixing shall be approximately that of the
completed mix as defined in the job mix formula approved by the Engineer.
The mix temperature shall be within the limits set out in the job mix formula
when emptied from the mixer.
3/32 SURFACE PREPARATION
3/32.1 When the Bituminous Mix is placed on a prepared roadbase and whether or
not a prime coat is designated on the Drawings, the Granular Roadbase
shall be even and firm and within the construction tolerances specified for
the roadbase to the satisfaction of the Engineer.
3/32.2 When the paving layer is constructed on an existing bituminous surface, the
surface shall be cleaned of all foreign material and broomed free of dust. In
addition 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
to receive the new bituminous mix shall be shaped, bladed, compacted and
broomed and primed to provide a uniform firm subgrade for the new surface
course.
3/32.3 The existing bituminous surface, base, or subgrade shall be removed if

broken, shattered, or unstable. The areas shall be excavated to a depth as
directed by the Engineer, and refilled with the Bituminous Mix according to
the Specifications.
3/32.4 Prior to the placing of the mix, when designated on the Drawings or directed
by the Engineer, a prime coat or tack coat shall be applied to the roadbase
or surface in accordance with the Specification for Prime Coat or Tack Coat.
3/33 PLACING OF THE MIX
3/33.1 All bituminous mixes shall be introduced to the paver at a temperature not
less than 135 deg.C and not more than 163 deg.C. Mixes outside this
temperature range shall be discarded.

30
3/33.2 The bituminous mix shall be spread and finished to crown and grade by
automatically controlled bituminous paver. Bituminous mix may be spread
and finished by hand methods only where machine methods are impractical
as determined by the Engineer.
3/33.3 The automatically controlled paver shall lay the bituminous mix without
tearing the surface and shall strike a finish that is smooth, true to cross-
section, uniform in density and texture, free from hollows, transverse
corrugations and other irregularities.
3/33.4 The paver shall be operated at a speed which will give the best results for
the type of paver being used and which co-ordinates satisfactorily with the
rate of delivery of the mix to the paver, to provide a uniform rate of
placement without intermittent operations of the paver.
The mixture shall be laid upon an approved surface, spread and struck off
to the required grade elevation. When paving widths of one or two traffic
lanes, the entire width shall be placed by one paver in one pass;
longitudinal joints will not be permitted. When paving widths of more than
two traffic lanes, two pavers shall operate in echelon so that the entire width
of the roadway is covered in one pass. The second paver shall follow as
closely as possible behind the first paver so that the temperature of the
mixture in the advance lane will not fall below 80oC. Each paver shall be
fully manned at all times that paving operations are in progress.
Plant production, the number of trucks, and the speed of the asphalt
paver(s) shall be such as to insure delivery of the mixture to the project in
sufficient quantities and at such intervals as to permit the paving operation.
Failure to maintain such delivery shall be cause for the Engineer to suspend
the work.
When delivery of material is delayed so that a paver remains idle for more
than 30 minutes or when the temperature of the mix falls below the
minimum specified in Section 3/33.1 of the general specification, the paver
shall be moved away from the end of the lane and the material in place fully
compacted. When adequate material is at hand to insure against further
delay, the material at the end of the partially completed lane shall be cut
back and a transverse joint constructed.
If a void should appear on the asphalt mat after it has been screeded, the
contractor shall place asphalt mixture by hand in the void and rake out all
large aggregate. The Contractor must minimize stepping over the fresh mat
of asphalt during laying.
Spillage of mix in front of the paver is not permitted.
The truck bed shall be raised slowly. When the mix is dumped too rapidly,
segregation occurs as course aggregates will roll down the side of the
loads.
The hydraulic system of the truck-bed hoist should be frequently inspected

to guard against hydraulic fluid leakage. Such a leakage on the roadway
surface will prevent good bonding between the roadway and the new mat.

31
Bumping the Paver - When an end dump truck is used to deliver mix to the paver,
the driver must back the truck up to the lay down machine but stop just short of the
push rollers on the front of the paver. Once the truck has come to a halt and the
driver has released the brakes on the vehicle, the paver operator should start the
machine moving forward picking up the stopped truck.
3/33.5 The mix shall be delivered to the paver in time to permit completion of
spreading, finishing and compaction of the mix during daylight hours.
3/33.6 Joints Construction and Compaction

When new asphalt is laid against existing or old asphalt, the following
specifications shall be considered with regard to the longitudinal joints:
 Longitudinal and transverse joints in succeeding courses shall be offset

from the joint in the underlying course be not less than fifteen (15)
centimeters stepping progressively as shown on the Plans or as directed
by the Engineer.
 The longitudinal joint in the surface course shall be coincident with the
last lines.
 Longitudinal joints shall be always located out of the wheel paths.
 Transverse joints shall be carefully constructed and thoroughly
compacted to provide a smooth riding surface. Joints shall be straight
edged to check smoothness. If the line of joint is formed with a
bulkhead, it shall form a straight line and vertical face. If a bulkhead is
not used to form the joint, the joint shall be made by sawing the
compacted mixture a sufficient back of the end of the placement to
assure full thickness of the pavement at the joints; the material ahead of
the sawed joint shall be removed.
 In either case, the joint shall be painted with a thin coat of tack coat
before the fresh material is placed against it. Cross rolling, unless
prohibited by field conditions is required to obtain through compaction of
these joints.
 Where longitudinal joints are constructed, and due to the required
maintenance of traffic or to unforeseeable conditions, the temperature of
the mixture at the longitudinal edge of the strip first laid becomes less
than 80oC, the edge shall, prior to paving the adjacent strip, be painted
with a thin coat of tack coat. If the edge of the joint is not vertical, it shall
be saw cut to a vertical face.
3/33.7 The leading half of half roadway paving shall not get ahead of the trailing
half of the pavement by more than one (1) average full-day of paving and, in
no case, shall the leading half be more than one half (1/2) kilometer ahead
of the trailing half without the written permission of the Engineer. If the
Contractor fails to comply with this requirement, the Engineer may suspend
paving on the leading half until such time, as the Contractor shall pave the
trailing half to a point approximately even with the leading half.
3/33.8 Unless otherwise directed by the Engineer, where successive layers are to
be placed, the surface of the existing layer shall be swept clean with a
power broom, or by other means as approved by the Engineer, and a tack
coat applied. Tack coat may not be required where the delay between

32
courses laying is less than 48 hours and when the surface is fresh and clean
and at the discretion of the Engineer. The rate of application of tack coat
2
shall range between 0.25 to 0.4 L/m .
3/33.9 Asphaltic concrete mixes, shall be laid at an un-compacted thickness such

that, after rolling the thickness of the compacted layer shall be not less than
2.5 times the maximum aggregate size or :-
Base Course : Min. 6 cm Max. 10 cm

Binder Course : Min. 6 cm Max. 8 cm
Wearing Course : Min. 5cm Max. 6 cm
However, DBM thicknesses shall be as specified in Tables 3-16 and 3-17.
3/33.10 The maximum thickness for layers may be increased when such increase is
more adaptable to total pavement thickness and when in the opinion of the
Engineer it is not detrimental to placement and compaction achievement.
3/33.11 Pre-paving conference. At least 14 days before the start of paving

operations, a pre-paving conference shall be arranged by the contractor to
coordinate attendance all concerned parties and other applicable
subcontractors and submit and prepare to discuss the following:
1. Proposed schedule of paving operations.
2. List of all equipment (excavation, compaction, laydown, haul, Pugmill,

etc.), and personnel used in the production and construction of the
work.
3. Proposed traffic control plan for paving operations including provisions

for pavement drop-offs and moving operations.
4. Contractor quality control plan for paving and sampling and testing.
5. Procedures for constructing the control strip including placing, finishing,

compacting, and smoothness procedures.
6. On the first day of production, produce sufficient mix to construct a 30-

meter long control strip, one-lane wide, and at the designated lift
thickness. Construct the control strip on the project at an approved
location.
7. Construct the control strip using mix production, lay-down, and

compaction procedures intended for the entire mix. Cease production
after construction of the control strip until the asphalt concrete mix and
the control strip are evaluated and accepted.
3/34 PRELIMINARY SURVEY AND REFERENCE STRING LINE
3/34.1 The Contractor shall make the necessary survey required for the reference
grade. When the survey is approved by the Engineer, the Contractor shall
erect and maintain an approved reference string line and operate the paver
to conform to the reference string line for the initial layer and/or any other
layers as directed. Elevation control point stakes for the first layer of

33
bituminous paving course shall be set at a maximum spacing of twenty (20)

meters. For subsequent layers, control points shall be set at ten (10) meters
maximum spacing. The Contractor shall furnish and maintain an approved
mobile string line for all layers not laid with the erected string line. The string
line shall be erected parallel to the reference grade, and the bituminous mix
shall be spread at a constant elevation above, below or at the string line
elevations as directed.
3/34.2 The use of the automatically controlled bituminous paver, to provide both
longitudinal and traverse control, shall include the furnishing and maintaining
of a string line, fixed or mobile, by the Contractor. The longitudinal and
traverse controls shall operate independently of each other, to the extent
that the surface of the bituminous mix will conform to the string line and will
be uniform in cross-section and crown.
3/34.3 The Contractor shall establish the centre-line points and shall maintain the
location of the points until the completion of the surfacing or as directed.
When directed by the Engineer, the Contractor shall erect a string line, to be
used as a guide for the finishing machine, in order to maintain a uniform
edge alignment. If any other method is proposed by the Contractor, it shall
first be approved by the Engineer.
3/35 BITUMINOUS LEVELLING COURSE
3/35.1 A leveling course, consisting of a layer of bituminous material of variable

thickness may be used to eliminate irregularities in existing surfaces or
bases and to vary existing cross-section elements of roadways.
3/35.2 In areas where leveling courses are required, as shown in the Drawings or
determined by the Engineer, the Contractor shall make a survey of the
existing surface or base. When the survey is approved, the Engineer will
determine and inform the Contractor of the precise locations and thickness
of leveling course to obtain the smoothest possible riding surface. Upon
receipt of the locations and thickness from the Engineer, the Contractor shall
proceed with the placement of the Leveling Course.
3/36 THICKNESS CORES
3/36.1 The depth of each bituminous paving course shall be measured by cored
samples. The Contractor shall furnish and operate an approved core drill for
cutting samples from the compacted mix on the road. The equipment shall
be capable of cutting the mix without shattering the edges of the specimen
or otherwise disturbing the density of the specimen. The nominal size of the
cored samples shall be ten (100mm) in diameter for binder course and
wearing course and fifteen (150mm) in diameter for base course and road
base. Samples shall be obtained in accordance with ASTM D979:2001 (06)
in sets of two (2) from the same location of the road.
3/36.2 Cores extracted for thickness measurement may be used for density
determination and density samples may be used for thickness
measurements. Determination of thickness and density of core samples
shall be determined in accordance with ASTM D3549: 2003 & ASTM D1188:
2007 or ASTM D2726: 2005a respectively and as required by Engineer.

34
3/37 COMPACTION OF BITUMINOUS LAYERS
3/37.1 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. Rolling will not be prolonged
to an extent that cracks appear.
3/37.2 Rollers shall be of the steel-wheel and pneumatic tire type and shall be in
good condition, capable of reversing without backlash, and shall be
operated at speeds slow enough to avoid displacement of the bituminous
mix. The number and weight of rollers shall be sufficient to compact the mix
to the required density while it is still in a workable condition. The use of
equipment which results in excessive crushing of the aggregate will not be
permitted. A minimum of three (3) rollers, two (2) steel-wheel and one (1)
pneumatic-tyre type, shall be used with each spreading operation for each
lane. However, the number of rollers required for proper compaction is
based on the square meter area placed rather than the production or
delivery tonnage
3/37.3 The Contractor shall provide adequate back-up equipment for use in the
event of mechanical failure, all to the satisfaction of the Engineer.
3/37.4 Initial or breakdown rolling shall be undertaken by means of either a tandem

power steel roller or three-wheel roller followed by a pneumatic-tyre roller or
as agreed by the Engineer. Rolling shall begin as soon as the mix will bear
the roller without undue displacement. Rolling shall be longitudinal,
beginning at the low side of the spread of material and proceeding toward
the high side, overlapping on successive passes by at least one half (1/2)
the width of the near wheels. Alternate passes of the roller shall be of
slightly different lengths.
3/37.5 The motion of the roller shall at all times be slow enough to avoid
displacement of the mix. Roller speed should be limited to around 4.5kph
and to prevent adhesion of the mix to the rollers, the wheels of the rollers
shall be kept properly moistened with water, but an excess of water will not
be permitted. Under no circumstances shall the use of diesel fuel or any
other asphalt stripping agent be used for preventing adhesion of the asphalt
to the roller wheels.
3/37.6 Final compaction and finish rolling shall be undertaken by means of a

tandem power steel roller, unless otherwise directed. When the specified
density is not obtained, changes in the size and/or number of rollers shall be
made as corrective measures, to satisfy the density requirements.
3/37.7 Rollers shall be operated by competent and experienced roller men and
shall be kept in operation continuously if necessary, so that all parts of the
pavement will receive substantially equal compaction at the time desired.
The Engineer will order the mixing plant to cease operation at any time
proper rolling is not being performed.

35
3/37.8 The compacted bituminous layers density requirements shall be equal to or

greater than ninety eight (98) percent of the average Marshall density of
each day's production for wearing course and ninety seven (97) percent of
the average Marshall density of each day's production for asphaltic
roadbase, base course and binder course. However, densities in excess of
101.8% shall not be permitted.
3/37.9 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 comply in other
respects with the requirements of the Specification shall be removed,
replaced with new materials, and finished in accordance with the
Specifications.
3/38 RE-ROLLING OF BITUMINOUS COURSES
3/38.1 Should any bituminous course fail to achieve the specified density, at the
discretion of the Engineer re-rolling may be allowed subject to the following
conditions:-
a. The densification to be achieved shall be 1% or less.
b. Only PTR's to be used weighing no greater than 18 tons.
c. Re-rolling can only be undertaken immediately after density test results

become available and shall be subject to the direction of the engineer.
d. Re-rolling to take place at the time of the day when the asphalt has
attained its maximum natural temperature, to be determined by
periodic temperature checks of the asphalt with a temperature gauge.
e. Re-rolling to be applied for a maximum of two hours.
f. Re-rolling to be carried out in the presence of the Engineer's

Representative.
g. The section of the works in question shall be cored for density

determination immediately after the completion of re-rolling. Re rolling is
to take place immediately upon receipt of initial reports from Laboratory.
h. If after re-testing, the density achieved is 0.5% below the specified

density, the asphaltic material will be accepted in the works subject to a
20% reduction to the billed rates. If, on the other hand, the density is
greater than 0.5% below the specified density, the asphaltic material
shall be removed and new material to the specification laid at the
Contractor's cost.
3/39 CONTACT SURFACES
3/39.1 Contact surfaces between the bituminous paving and of kerbing, gutters,
manholes, and other appurtenances shall be painted with a thin uniform
coating of tack coat as approved by the Engineer.

36
3/40 JOINTS IN BITUMINOUS PAVING
3/40.1 In widening and lane construction, when new asphalt is laid against
existing or old asphalt, the following specifications shall be considered
with regard to the longitudinal joints:
 Longitudinal joints shall be always located out of the wheel paths. I.e.
the joint should be close enough to the lane edge.
 Offsetting technique shall be used (Figure 3-1) to avoid construction
joints in the wheel path. Longitudinal and transverse joints in
succeeding courses shall be offset from the joint in the underlying
course be not less than hundred and fifty (150) millimeters stepping
progressively as shown on the Plans or as directed by the Engineer.
By all means, the joint shall not be located more than 450mm from
the pavement /lane edge.


Figure 3-1: Pavement layers offsetting technique
 The longitudinal joint in the surface course shall be coincident with

the lane lines.
 Transverse joints shall be carefully constructed and thoroughly
compacted to provide a smooth riding surface.
 Joints shall be straight edged to check smoothness. If the line of
joint is formed with a bulkhead, it shall form a straight line and
vertical face. If a bulkhead is not used to form the joint, the joint shall
be made by sawing the compacted mixture a sufficient back of the
end of the placement to assure full thickness of the pavement at the
joints; the material ahead of the sawed joint shall be removed. In
either case, the joint shall be painted with a thin coat of tack coat
before the fresh material is placed against it.
 In all cases, compacting the longitudinal joint from the cold side of
the joint, should be avoided.
 The joint compaction shall be according to the following procedures:
o For a pneumatic tire roller, the centre of the outside tire should
be placed directly over the top of the joint. Lane 1 is the cold
mix while lane 2 is the hot mix (Figure 3-2).

37
Figure 3-2: Proper placement for a Pneumatic tire roller over the longitudinal
joint
o For a steel wheel roller, the majority of the weight of the drum
should be placed on the lane 2 side (hot mix) with only about
150mm (6 inches) extended over the first lane (cold mix) as
shown in Figure 3-3 below.
Figure 3-3: Proper placement for a Steel wheel roller over the longitudinal joint
 Random Cross and diagonal rolling shall be avoided during the

compaction of the joints.
 Where longitudinal joints are constructed, and due to the required

maintenance of traffic or to unforeseeable conditions, the
temperature of the mixture at the longitudinal edge of the strip first
laid becomes less than 80oC, the edge shall, prior to paving the
adjacent strip, be painted with a thin coat of tack coat. If the edge of
the joint is not vertical, it shall be saw cut to a vertical face.
 Joints between old and new pavement or between successive day's

work shall be properly made, to ensure thorough and continuous
bonding between the two pavements. All construction joints in
previously laid material shall be constructed by cutting the material
back vertically for its full depth to expose a fresh surface.

38
3/40.2 Before placing the fresh mix against a cut joint or against old pavement, the
contact surface shall be sprayed or painted with a thin uniform coat of tack
coat.
 Where a finishing machine is used, the longitudinal joint shall be

made be overlapping the screed on the previously laid material for a
width of at least three (30) millimeters and depositing a sufficient
amount of mix so that the joint formed will be smooth and tight.
 Where a reinforcement fabric is specified for use on longitudinal

joints, the reinforcement fabric shall meet the following criteria:
Item Criteria
Raw material Polyester
Coating Bituminous or as per manufacturer’s
recommendation
Weight of Fabric (g/mm2) 240
Mesh size (mm) 30 x 30
Ultimate strength BS6906 P1 50 longitudinal, 50 transverse
(kN)
Elongation at break BS6906 P1 12 longitudinal, 14 transverse
(%)
Strength at 3% elongation BS
12 Longitudinal, 10 transverse
6906 P1
The application requirements of the reinforcement geogrid shall be strictly in

accordance with the manufacturer’s recommendations. It shall include for the
application of a suitable tack coat to the surface prior to installation. In addition, it shall
be tensioned and fixed in place with an approved pinning bolt system specifically
manufactured for the purpose.
Longitudinal and transverse overlap where applicable shall be terminated towards the
direction of laying to avoid snagging on the paver.
Field testing for joint density

 The Contractor shall perform a joint density evaluation for each sub lot at the
random sample locations selected for in place air void testing.
 Density testing shall be according to ASTM D1188:2007 or ASTM
D2726:2005a. Following the procedures used to measure the performance
properties of the bituminous mix outlined in clauses 3/47.3, 3/47.4, and 3/47.5 in
the General Specifications, the density of both the asphalt mat and the
construction joint can be measured. The following procedure is suggested:
Acceptance criteria
 At each location, the Contractor shall perform a joint density testing at 200mm
(8 inches) from a mat edge that will become a longitudinal joint. This reading will
be compared to density value taken on the interior of the mat more than 600mm
(2 feet) from the mat edge. The evaluation fails when:


39
o The density at the 200mm offset from the mat edge is more than
0.045gm/cc (48 kg/cubic meter) below the interior mat density.
o The density at the 200mm offset from the mat edge is 3% less than the
interior mat density,
o The theoretical maximum density at the 200mm offset from the mat edge
is less than 90% of the theoretical maximum density measured at the
interior mat density.
 The Contractor shall investigate the cause of failure and take corrective actions
during production to improve the joint density.
 Production of the hot mix asphalt shall cease when two (2) consecutive
evaluations fail unless otherwise approved by the Engineer.
 The Contractor shall make changes to the hot mix, the compaction procedure or
placement process before production is resumed.
 The Contractor may produce enough mixture to place approximately 750 linear
meters of pavement one (1) paver width wide. Two (2) joint density evaluations
shall be performed within these 750 linear meters of production and if both
evaluations are acceptable, the Contractor may resume normal operations.
However, if one (1) or both of the joint density evaluations fail, the Contractor
shall make additional changes as approved by the Engineer and an additional
750 linear meters of pavement shall be laid and evaluated as before. This
procedure of placing.
 The evaluating of 750 linear meters sections will be continued until both joint
density evaluations pass.
 The Engineer may require the Contractor to implement different joint
construction methods or provide special joint making equipment to improve joint
density.
 Normal production and joint density verification will resume when both joint
density evaluations pass. Although it is the Contractor’s responsibility to perform
joint density evaluations, the Engineer may make as many independent joint
density verifications as deemed necessary at the random sample locations. The
Engineer’s results will be used to determine joint density when available.
3/41 PROTECTION OF COMPACTED LAYER
3/41.1 The Contractor shall protect all sections of newly compacted pavement from
traffic until they have hardened sufficiently to the approval of the Engineer.
On heavily trafficked roads during the summer months a minimum period of
7 days must elapse before the newly compacted pavement is trafficked.
3/42 COMPACTION TRIALS FOR BITUMINOUS COURSES
3/42.1 Prior to the commencement of the bituminous paving operations, the

Contractor shall construct trial lengths, of at least 30 metres. The materials
used in the trials shall be those approved for use in the bituminous paving
courses and the equipment used shall be that according to the Contractor's
approved detailed Method Statement and equipment list and the programme
of work.

40
3/42.2 The object of these trials is to determine the adequacy of the Contractor's
specified compacted layer depths, and the relationship between the number
of compaction passes and the resulting density of the material.
3/42.3 The Contractor may proceed with the bituminous paving operations only
after the method and procedures established by the compaction trials have
been approved by the Engineer.
3/43 SURFACE TOLERANCE FOR BITUMINOUS COURSES
3/43.1 At final compaction the finished surfaces of the individual layers shall fall
within the following maximum tolerances, measured with a 3 m straightedge
laid in any direction.
- Base Course 6 mm
- Binder Course 4 mm
- Wearing Course 4 mm
3/43.2 The Rideability of the finished wearing course when tested with a Laser Road
Surface Testing Machine shall have an IRI (International Roughness Index) not
exceeding the following values:
 New Construction
o Freeway, Expressway, Arterials and Collectors:
Average value over a 400 meter section  0.90 m/km
o Local Roads (Residential, Commercial and Industrial)
Straight Edge Measurement is required
 Pavement Rehabilitation
o Freeway, Expressway, Arterials and Collectors
 One layer of asphalt :

Average value over a 400 meter section  1.10
 Two layers of asphalt

Average value over a 400 meter section  1.00
o Local Roads (Residential, Commercial and Industrial)
Straight Edge Measurement is required
Peak individual value over a 25 meter section shall be  1.5 m/km (Not
more than 2 values per 400 meters). This applies to both new road
construction and rehabilitation works.

41
The amplitude of the longitudinal profile of the road, filtered between (a)
1 meter and 3.3 meters and (b) 3.3 meters and 13 meters shall not
exceed the following values:
1m to 3.3 m  1.8 mm
3.3 m to 13 m  4.0 mm
3/43.3 All humps and depressions exceeding the specified tolerance shall be
corrected by removing the defective work and replacing it with new
material as directed by the Engineer at the Contractors cost.
3/43.4 Directional ramps on bridges or interchanges and tunnels with widely

spaced joints of more than 25m should be tested, unless otherwise
instructed, and shall have an IRI not exceeding the following values:
 Average value over a 400 meter section  0.90 m/km

(Flexible Pavement)
 Average value over a 400 meter section  1.20 m/km
(Rigid Pavement)
3/43.5 Individual roughness readings at joints in rigid pavement shall be

excluded during processing the roughness data.
3/43.6 Ramps, Loops, U Turn lanes, shoulders and other links with a length
less than the 400m or those roads sections constructed of closely
spaced joints shall be excluded. Also, the adjacent partial lanes to the
existing road widening with pavement transition at construction tie-ins
shall be excluded from roughness testing.
3/43.7 Tolerance on finished surface levels shall be:-
Road surface (Wearing course) +/- 4 mm

Base courses +/- 6 mm
3/44 TOLERANCE IN BITUMINOUS PAVING THICKNESS
3/44.1 The thickness of the bituminous paving courses shall be determined in

accordance with ASTM D3549: 2003.
3/44.2 For the purpose of establishing an adjusted unit rate for bituminous paving
courses, units to be considered separately are defined as three hundred
(300) linear meters in each traffic lane. The last unit in each lane shall be
three hundred (300) meters plus the fractional part of three hundred (300)
meters remaining. At least three (3) samples of cores in sets of two (2) shall
be taken at random from each unit being sampled (i.e. six cores per unit).
3/44.3 Other areas such as intersections, entrances, crossovers, ramps, etc. will be
considered as one unit and the thickness of each unit shall be determined
separately. Small irregular unit areas may be included as part of another
unit. At such point as the Engineer may select in each unit, three (3)
samples of cores in sets of two (2) shall be taken for each unit of bituminous

42
paving course. One unit shall represent an area of not more than 1125
sq.m.
3/44.4 If all the core samples (sets of two (2)) so taken are not deficient by more
than three (3) mm from the specified thickness, full payment will be made. If
any core sample/s (set of two (2)) is deficient by more than three (3) mm
from the specified thickness, two (2) sets of additional core samples shall be
taken from the area represented and if the average of the three (3) sets of
two (2) core samples is not deficient by more than three (3) mm from the
specified thickness, full payment will be made.
If the average thickness of three (3) cores in sets of two (2) from each set is
deficient by more than three (3mm), but not more than ten (10mm), or fifteen
(15) percent (whichever is less), from the specified thickness, an adjusted
unit price as provided in the Bill of Quantities will be paid for the area
represented by these cores in sets of two (2).
3/44.5 In calculating the average thickness of each bituminous paving course,

measurements which are in excess of the specified thickness by more than
three (3mm) will be considered as the specified thickness plus three (3mm),
and measurements which are less than specified thickness by more than ten
(10mm) or fifteen (15) percent (whichever is less), will not be included in the
average.
3/44.6 When the measurement of any core sample/s (set of two (2)) is less than
specified thickness by more than ten (10mm), or fifteen percent (whichever
is less), the actual thickness of the bituminous paving course in this area will
be determined by taking additional core sample/s (set of two (2)) at not less
than three (3) meters intervals parallel to the centre-line in each direction
from the affected location until, in each direction, core sample/s (set of two
(2)) is found which is not deficient by more than ten (10mm), or fifteen (15)
percent (whichever is less). Asphalt areas which are deficient by more than
ten (10) mm or 15% (whichever is less) shall be removed and replaced at
the Contractor's expense. Exploratory core sample/s (set of two (2)) for
deficient thickness may be used in average for adjusted unit price. (Refer to
the Bill of Quantities - Preambles for Pavement Construction for price
adjustments).
3/45 COMPACTION SAMPLING AND TESTING OF BITUMINOUS COURSES
3/45.1 The density of the mix as placed and compacted on the road shall be
determined from cores cut from the compacted courses on the road at
locations specified by the Engineer. Samples shall be obtained in
accordance with ASTM D979: 2001 in sets of two (2) from the same location
on the road.
The frequency of testing shall be three (3) sets of samples per traffic lane
per three hundred (300) linear meters per layer or a minimum of one (1) set
per day for shorter runs, or as directed by the Engineer and such additional
tests to determine limits of area deficient in density, or those over
compacted out of the acceptable range for retest. The density of these
samples will be referred to as "Road Density".

43
3/45.2 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
material without shattering the edges of the specimen. The nominal size of
the samples shall be ten (100mm) in diameter for binder course and wearing
course and fifteen (150mm) in diameter for base course and road base.
3/45.3 All test holes shall be filled and made good with approved material by the
Contractor at his expense.
3/46 WEATHER LIMITATIONS FOR PAVING OPERATIONS
3/46.1 Hot bituminous mix shall be placed when the air temperature is eight (8)
degrees C or above and when the weather is not dusty, foggy or rainy and
when the existing surface is free from moisture. Bituminous mix shall not be
placed during sand storms.
3/46.2 No paving operations shall be started if rain is imminent.
3/47 MINIMUM TEST REQUIREMENTS FOR BITUMINOUS COURSES
3/47.1 Bitumen Material: One sample shall be tested for penetration and
softening point (ring and ball method) test every 80 tones or part thereof.
3/47.2 Aggregate: One sample for each stockpile every 2,000 cu.m. or part
thereof shall be taken and all the required tests shall be performed.
3/47.3 Bituminous Mix: One sample of mix shall be obtained from at least every
300 tones or part thereof and tested for bitumen content in accordance with
ASTM D6307: 2005 (Ignition Method), grading (ASTM D5444: 2005).
Density in accordance with ASTM D1188: 2002 or D2726: 2005 and as
required by the Engineer. Stability in accordance with ASTM D6927: 2006
and voidage contents in accordance with DMS 9: 2001 shall be determined
on Marshall Specimens.
3/47.4 Loss of Marshall Stability shall be tested for at least every 7,000 tons shall
be in accordance with DMS 10: 2001.
3/47.5 Thickness cores and compaction cores shall be taken as specified in Clause
3/44 and 3/45 respectively.
3/48 BITUMINOUS PRIME COAT
3/48.1 Bituminous Prime Coat shall consist of supplying and applying liquid asphalt
to a previously prepared and approved subgrade or subbase, aggregate
base course or wet mix road-base in accordance with this Specification.
3/48.2 Material for Prime Coat shall be:-

Liquid Asphalt for prime coat shall be medium curing cut back asphalt MC-
70 conforms to the requirements of ASTM D2027-97(2004) as modified

44
by Table 3-23 or as directed by the Engineer. Sampling shall be in

accordance with ASTM D140:2009. One sample shall be tested every 5
tones or part thereof.
Table 3- 23: Properties of bituminous prime coat
MEDIUM CURING LIQUID

TEST ASTM Ref. MIN. MAX.
Saybolt Furol Viscosity, at 50 deg.C. D88 : 2007 60 120
sec.
Flash Point, Tag open Cup, deg.C. D3143:2008 38 -
Distillation: Distillate (% of total D402 : 2008
distillation to 360 deg.C)
 To 225 deg C D2026-97 (2004) - 20
 To 260 deg C D2026-97 (2004) 20 60
 To 316 deg C D2026-97 (2004) 65 90
Residue from distillation 55
to 360 deg.C, percent by
volume difference
Tests on residue from
distillation :
- Penetration 25 deg.C, D5:2006 120 250
100g 5 seconds, 0.1 mm.
- Ductility 25 deg.C, cm D113:2002 100 -
- Solubility in trichloroethylene % D2042:2009 99 -
- Water percent D95:2005 - 0.2
3/48.3 Prime coat shall be applied at a rate of not less than 0.75 litres per square
metre and not more 1.0 litre per square metre.
3/48.4 The exact rate of application, which may be varied to suit field conditions,
will be determined by the Engineer following trials to be carried out by the
Contractor.
3/48.5 The surface to be prime coated shall be uniformly smooth and firm and true
to the grades and cross-sections shown on the drawings within specified
tolerances, and so maintained throughout prime coating. Prime coat shall
not be placed on a soft, uneven base. Any holes, depressions or
irregularities shall be repaired by the removal of loose and unsuitable
material and its replacement with suitable material compacted to produce a
dense, even surface of uniform texture. When required, the surface to be
primed shall be lightly bladed and compacted and the Engineer may instruct
a light application of water to facilitate penetration. Priming will not be
permitted when the surface is wet.
3/48.6 Prime coat shall not be applied when the ambient temperature is less than
13 deg. C or during rain, fog, dust storms or other unsuitable weather. The
application temperature for MC-70 liquid asphalt shall be between 50 deg. C
and 80 deg. C as approved by the Engineer. It shall be applied to one lane
of the carriageway width at a time. When applied in two or more lanes there
shall be a slight overlap along adjoining edges. Overlapping will not be

45
permitted at transverse joints and thick paper shall be used to protect the
previous application.
3/48.7 Traffic shall be kept off the prime coat until it has penetrated the subgrade or
roadbase and fully cured and should be left undisturbed for a period of
minimum 48 hours or as otherwise directed by the Engineer
3/48.8 The Contractor shall furnish and spread at his cost sufficient clean fine sand,
of an approved quality, to blot up areas which show an excess of prime coat.
3/48.9 The primed surface shall be maintained in a good, clean condition at all
times until the next course is placed. Any surface irregularities or holes in
the primed surface, however caused, shall be repaired and corrected to the
Engineer's satisfaction.
3/49 BITUMINOUS TACK COAT
3/49.1 Bituminous tack coat shall consist of supplying and applying emulsified
asphalt diluted with an equal quantity of water (1:1) to a previously prepared
bituminous base course or binder course or to an existing bituminous
surface, in accordance with this specification.
3/49.2 The materials for bituminous tack coat shall be slow setting emulsified
asphalt, grade SS-1h (anionic) conforming to the requirements ASTM D977:
2005. Sampling shall be in accordance with ASTM D140: 2009 and testing
in accordance with ASTM D244: 2009. The sampling frequency shall be one
sample for every 5 tones or part thereof for testing.
3/49.3 The tack coat (diluted emulsion) shall be applied in quantities of not less
than 0.3 liters per square meter and not more than 0.5 liters per square
meter.
3/49.4 Immediately before applying the tack coat, all loose material, dirt, clay or
other objectionable material, shall be removed from the surface with a power
broom or blower supplemented with hand brooms, as directed by the
Engineer. After the cleaning operation, and prior to the application of the
tack coat, an inspection of the area to be coated will be made by the
Engineer.
3/49.5 The application temperature for the tack coat shall be between 10 deg. C
and 60 deg. C as directed by the Engineer. The material should not be
applied when the ambient temperature is less than 13 deg. C or during rain,
fog, dust storms or other unsuitable weather.
3/49.6 After application, the surface shall be allowed to dry to the proper condition
of tackiness, or as otherwise directed by the Engineer, to receive the
following pavement course. Time must be allowed for emulsion to break or
cure (i.e.to turn from brown (the surface is slick) to black (the surface
becomes sticky) prior to placing hot mix on it. The length of time required for
this to happen will depend on the weather. In good paving weather, it will
take only few minutes. In marginal weather, it may take several minutes.
Tack coat shall be applied only so far in advance to pavement courses, or

46
as otherwise directed by the Engineer, to obtain the proper condition of

tackiness Time and traffic constraints usually do not allow long cure times,
but, whenever found practical, the time allowed for the curing of tack shall
be maximized and the Contractor shall protect the tack coat from damage
during this period.
3/49.7 If the completed tack coat is damaged by rain or dust, it shall be allowed to
dry, cleaned by power broom or blower and, if required by the Engineer, an
additional light application of tack coat shall be applied. No additional
payment shall be made for this work.
3/49.8 Where, in the opinion of the Engineer, a tack coat is not necessary, the
Contractor shall clear, at his expense the existing surface free of dust and
other deleterious material as indicated in clause 3/49.4 above.
3/50 APPLICATION AND HEATING EQUIPMENT FOR LIQUID ASPHALT
3/50.1 A self-powered pressure distributor should be used for applying asphalt

mixture. The distributor shall have pneumatic tires of such width and
number that the load produced on the base surface shall not exceed 110 Kg
per centimeter of tire width, and shall be so designed and equipped as to
distribute the bituminous material uniformly at even heat on variable width of
surface at readily determined and controlled rates from 0.2 to 7.5 liters per
sq.m. with a pressure range of 1.25 Kg to 5.2 Kg per sq.m. and with an
allowable variation from any specified rate not exceeding 5 percent.
Distributors and booster tanks shall be so maintained at all times that no
dripping of bituminous material will occur from any part of the equipment.
3/50.2 Distribution equipment shall include an independently operated bitumen
pump, technometer pressure gauges, volume measuring devices, a
thermometer for reading the temperature of tank contents, and a hose
attachment for applying bituminous material to spots unavoidably missed by
the distributor. The distributor shall be equipped for circulation and agitation
of the bituminous material during the heating process.
3/50.3 The equipment for heating shall consist of steam coils and equipment for
producing steam, so designed that steam will not be introduced into the
material. In the event of storage tanks being used, an armored thermometer
with a range from 10 deg.C to 150 deg.C shall be fixed to the tank so that
the temperature of the bituminous material may be determined at all times.
3/50.4 Other heating facilities may be used subject to the approval of the Engineer.
3/51 DOUBLE BITUMINOUS SURFACE TREATMENT, DESCRIPTION
3/51.1 This work shall consider of a wearing surface composed of a bituminous

prime followed by two (2) applications of bituminous seal coats with each
seal coat receiving an application of cover material in accordance with the
Specifications and in conformity with the lines shown on the drawings or
established by the Engineer.

47
3/52 MATERIALS FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/52.1 PRIME COAT
The prime coat shall be medium curing cut-back asphalt grade MC-70. The
rate of application shall be between 0.75 to 1.20 litres per square metre or
as specified by the Engineer.
3/52.2 SEAL COAT
The seal coat shall be 85/100 as per ASTM D946 penetration grade
bitumen. The bitumen may be cut back with up to 2% by weight of kerosene
to improve adhesion to the stone. The characteristics of the bitumen are
shown in Table 3-24 following:-
Table 3- 24: Characteristics of the bitumen used for surface treatment
85 - 100 AS PER ASTM D946-2009 PENETRATION GRADE BITUMEN

TEST METHOD OF MIN. MAX.
TESTING (ASTM)
Penetration at 25 deg.C,100 g, 5 D5: 2006 85 100
sec, 0.1 mm.
Flash Point, Cleveland Open D92: 2005a 232 -
Cup, deg.C
Ductility at 25 deg.C, cm D113: 2007 100 -
Solubility in trichloro ethylene, % D2042: 2009 99 -
Thin film oven test 3.2mm, 163 D1754:2009 1.0
deg.C 5 hour loss on heating,
percent
Penetration of residue percent of D5-2006 47 -
original
Ductility of residue at 25 deg.C 5 D113:2007 75 -
cm/min cm
3/52.3 COVER MATERIAL
Aggregate for cover material shall be screenings of crushed stone which are
clean, tough, durable and free from dirt and other objectionable matter. The
percentages of wear shall not be more than thirty (30) as determined by
ASTM C-131:2006. When subjected to five (5) cycles of magnesium
sulphate soundness testing, as determined by ASTM C-88:2005, it shall
have a weight loss not greater than ten (10) percent. Aggregate shall have
a flakiness index of not more than 30 (BS EN 933-Part 3) and an elongation
index of not more than 30 (BS812: Part 105: Section 105.2) and Aggregate
Crushing Value (ACV) of not less than 20% (BS 812: 1990 P110). No less
than sixty (60) percent by weight of crushed stone shall consist of crushed
pieces having two or more faces produced by fracture when tested by DM
standard test method DMS 8: 2001. Aggregate shall conform to the
following gradations (Table 3-25) and shall be approved by the Engineer.

48
Table 3- 25: Gradation for double bituminous surface treatment

DOUBLE BITUMINOUS SURFACE TREATMENT
Sieve 19 12.5 9.5 6.3 4.75 2.0 0.60 0.075

Opening
(mm)
Sieve 3/4" 1/2" 3/8" 1/4" No.4 No.10 No.30 No.200
No.
First 100 70-90 0-15 - 0-2 - - -
Course
Second - - 100 90-100 60-85 0-25 0-5 0-2
Course
3/53 EQUIPMENT FOR DOUBLE BITUMINOUS SURFACE TREATMENT
3/53.1 The equipment used by the Contractor shall include a power broom or a
power blower, or both; a self propelled, pneumatic-tyred roller, or steel-
wheeled tandem roller (4 to 8 tons) or both; self-propelled aggregate
spreading equipment that can be adjusted to spread accurately the specified
amount per square meter; a bitumen distributor and equipment for heating
the asphaltic materials.
3/53.2 Other equipment may be used in addition to the specified equipment when
approved or requested by the Engineer.
3/54 PREPARATION OF MATERIAL FOR DOUBLE BITUMINOUS SURFACE

TREATMENT
3/54.1 HEATING OF BITUMINOUS MATERIALS shall be with equipment as

specified. The use of any method or agitation or heating that introduces free
steam or moisture into the bituminous material is prohibited. Materials
heated to temperatures above twenty eight (28) degrees C higher than the
maximum application temperature specified shall be considered as
overheated and shall be rejected until the material can be resampled and
retested. The reacceptance or final rejection will be made by the Engineer
on the same requirements under which the material was originally tested.
5/54.2 If aggregates are deemed by the Engineer to be dusty or dirty they shall be
washed after which their use shall not be permitted until all free water has
evaporated or been drained.
3/55 APPLICATION OF DOUBLE BITUMINOUS SURFACE TREATMENT
3/55.1 After the prime coat has been applied and has thoroughly penetrated the
surface and cured as specified, the Contractor shall apply 85/100
penetration bitumen and shall apply the cover material and roll and
manipulate the surface, all in accordance with the requirements specified
hereinafter. The material shall be uniformly applied at the rate designated to
the surface being sealed.

49
3/55.2 Bituminous material shall be applied by means of a pressure distributor in a

uniform, continuous speed over the section to be treated and within the
temperature range specified. The quantity of bituminous material to be used
per square meter shall be within the limits hereinafter specified and as
3/55.3 A strip of building paper, at least one (1) meter in width and with a length
equal to that of the spray bar of the distributor plus thirty (30) centimeters,
shall be used at the beginning of each spread. The paper shall be removed
and disposed of in an approved manner. 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 in an approved
manner. Junctions of spreads shall be carefully made to ensure a smooth
riding surface.
3/55.4 The length of spread of bituminous materials shall not be in excess of that
which trucks loaded with cover coat material can immediately cover.
3/55.5 The spread of bituminous material shall not be more than fifteen (150mm)
wider than the width covered by the cover coat material from the spreading
device. Under no circumstances shall operations proceed in such manner
that bituminous material will be allowed to chill, set up, dry or otherwise
impair retention of the cover coat.
3/55.6 The distributor, when not spreading, shall be so designed that the spray bar
or mechanism will not drip bituminous material on the surface of the traveled
way.
3/55.7 Distribution of the bituminous material shall be so regulated and sufficient

bituminous material must remain in the distributor at the end of each
application so that there will be a uniform distribution of bituminous material.
In no case shall the distributor be allowed to expel air with the bituminous
material thereby causing uneven coverage.
3/55.8 The angle of the spray nozzles and the height of the spray bar shall be so
adjusted and frequently checked so that uniform distribution is ensured. If
the raise of the spray bar as the load is removed is excessive and
contributes to drilling and streaking of the seal course, the frame of the
distributor shall be blocked or snubbed to the axle of the truck to maintain a
constant height of the spray bar above the road surface. The distribution
shall cease immediately upon any clogging or interference of any nozzle and
corrective measures shall be taken before distribution is resumed.
3/55.9 APPLICATION OF AGGREGATE
Immediately following the application of the bituminous material, cover

material shall be spread with an approved aggregate spreader in quantities
as specified by the Engineer and within the limits specified herein.
Spreading shall be accomplished in such a manner that the tyres of the
trucks or aggregate spreader at no time contact the uncovered and newly
applied bituminous material.
3/55.10 The operations of distributing bituminous material shall not be in excess of

one hundred (100) linear metres ahead of the spreading of the aggregate.

50
3/55.11 Procedures of starting, stopping or turning of any piece of equipment which

results in displacement of the cover material or damage to the seal courses
shall be prohibited.
3/55.12 The spreading equipment shall be of such width and arrangement that as
the aggregate is placed, complete coverage will be obtained. No brooming,
dragging or blading of the cover material shall be permitted prior to initial
rolling. Any rearrangement of the cover material shall be done by hand
methods. Overlapping the applications of cover material shall be avoided
and all spillage shall be removed from the surface. Before rolling, the
bituminous material shall be uniformly covered.
3/55.13 The rates of application for bituminous material and aggregate for "Double
Bituminous Surface Treatment" shall be within the following limits:
Table 3- 26: Rates of application of Asphalt and aggregate for Double Bituminous
Surface Treatment
Asphalt Aggregate
85/100 Pen
KG/SQ.M. KG/SQ.M.
MIN. MAX. MIN. MAX.
First application (Course) 0.70 1.10 12.5 15.0
Second application (Course) 0.70 0.90 6.5 8.5
3/55.14 MANIPULATION
Immediately after the application of bituminous material and aggregate to

the road surface and after the aggregate has been rearranged as may be
necessary to provide uniform and complete coverage, the surface shall be
sufficiently rolled with an approved pneumatic-tyred roller to embed the
aggregate thoroughly into the bituminous material. Sufficient rollers shall be
provided such that the initial rolling consisting of a single pass of a 10 - 12
ton tandem steel wheel roller followed by at least two (2) complete coverage
with the pneumatic-tyred roller shall be completed within thirty (30) minutes
after the cover material is applied. The rollers shall be operated on each
coverage so that each succeeding trip of the roller will overlap at least fifty
(50) percent of the width of the previous trip. No blading or dragging of the
aggregate will be permitted for the first seal coat. Any rearrangement of the
cover material before or during the initial rolling shall be done by approved
hand methods. Rolling shall be continued after the rolling specified above is
completed until a maximum amount of the aggregate is satisfactorily
embedded in the bituminous material. Pneumatic-tyred rollers shall be
operated at a maximum speed of eight (8) kilometers per hour.
3/55.15 SECOND SEAL COAT
Unless otherwise designated on the drawings, or directed by the Engineer,

the second seal coat shall not be applied for 48 hours after the application of
the first seal coat.

51
3/55.16 Immediately prior to the second application of bituminous material for

sealing, the surface shall be cleaned in an approved manner of all dust and
excess cover material which is not embedded in the first application of
bituminous material for sealing. Care shall be exercised not to dislodge any
cover material which is embedded in the bituminous material. The second
seal coat shall be applied as previously specified. Brooms or drag brooms
shall not be used to shift the cover material until the initial rolling with the
pneumatic-tyred roller is completed and until the bituminous material has
cooled and set up sufficiently to hold the cover material, preferably not
earlier than the day following the application of the second seal coat. Any
rearrangement of the cover material during the initial rolling shall be done by
approved hand methods.
3/55.17 The rolling shall be longitudinal and shall commence at the outer edge of the
shoulder and then progress towards the inner edge. Rolling shall continue
until the entire surface has been completely covered at least three (3) times
with a pneumatic tyred roller. Maximum speed of rollers shall be as
previously specified.
3/55.18 ADDITIONAL MANIPULATION OF COMPLETED SURFACES
The Contractor shall manipulate the surface for a period of five (5) days after
the second seal coat has been applied. The manipulation shall consist of
the application of additional aggregate or additional dragging and rolling or
all of these operations to portions of the surface that, as determined by the
Engineer, require such additional treatment.
The manipulation shall also include the dragging and one (1) complete
rolling over the entire surface each day from the time the surface is
completed until and including the fifth (5th) day after. A light blade equipped
with a broom drag shall be operated immediately ahead of the roller
throughout all rolling during the manipulation period. The daily dragging and
rolling under manipulation may be omitted, if in the opinion of the Engineer,
the weather and roadbed conditions are such that the dragging and rolling
would not be beneficial to the surface.
3/55.19 Aggregate and additional manipulation ordered by the Engineer, in this

work, will not be paid for separately but will be considered subsidiary to the
item of 'Double Bituminous Surface Treatment" included in the "Bill of
Quantities".
3/55.20 Except for times when it is necessary for hauling equipment and/or pilot
trucks to travel on the newly applied seal coat, traffic of all types shall be
kept off the seal coat until it has had time to set properly. The minimum
traffic free period shall be 24 hours.
3/55.21 WEATHER LIMITATIONS
Surface treatment operations shall be carried on only when the surface is

dry, when the atmospheric temperature is above fifteen (15) degrees C, and

52
when the weather is not dusty, foggy or rainy. The above requirements may
be waived, but only when so directed and in writing by the Engineer.
3/56 PROTECTION OF ADJACENT STRUCTURES

FROM BITUMEN SPLASHING
3/56.1 When bituminous materials are being applied, the surface of all structures,
wheel guards, guard rail, kerbs and gutters, and other roadway
appurtenances shall be protected in an approved manner to prevent them
from being splattered with bituminous material or marred by equipment
operation. In the event that any appurtenances become splattered or
marred, the Contractor shall at his own expense, remove all traces of
bituminous materials, and repair all damage, and leave the appurtenances
in an approved condition.

1 SECTION 4 CONCRETE WORKS
TABLE OF CONTENTS
4/1 CEMENT ................................................................................................................. 2

4/2 AGGREGATES GENERAL REQUIREMENTS ....................................................... 6
4/3 FINE AGGREGATES ............................................................................................ 10
4/4 COARSE AGGREGATE FOR CONCRETE .......................................................... 11
4/5 COMBINED AGGREGATE ................................................................................... 11
4/6 WATER FOR CONCRETE .................................................................................... 12
4/7 APPLICABLE TESTS AND CODES ...................................................................... 13
4/8 REINFORCEMENT BARS .................................................................................... 16
4/9 BAR SCHEDULES AND SHOP DRAWINGS ........................................................ 17
4/10 BAR CUTTING AND BENDING ............................................................................ 17
4/11 PLACING AND FIXING REINFORCEMENT ......................................................... 17
4/12 WELDED WIRE FABRIC ....................................................................................... 18
4/13 SPACER BLOCKS ................................................................................................ 18
4/14 ADMIXTURES ....................................................................................................... 18
4/15 CONCRETE MIX SPECIFICATION ...................................................................... 19
4/16 CONCRETE MIX DESIGN .................................................................................... 21
4/17 QUALITY CONTROL ............................................................................................. 23
4/18 CONCRETE DESIGN LIMITS ............................................................................... 27
4/19 CONSISTENCY OF CONCRETE.......................................................................... 27
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS..................................... 28
4/21 ASSEMBLY AND HANDLING MATERIALS .......................................................... 28
4/22 MIXING CONCRETE............................................................................................. 29
4/23 READY MIXED CONCRETE ................................................................................. 30
4/24 TRANSPORT AND PLACING ............................................................................... 31
4/25 COMPACTION OF CONCRETE ........................................................................... 33
4/26 CONSTRUCTION JOINTS .................................................................................... 33
4/27 CURING OF CONCRETE ..................................................................................... 34
4/28 EARLY LOADING .................................................................................................. 35
4/29 CONCRETING AT NIGHT ..................................................................................... 35
4/30 CONCRETING IN HOT WEATHER ...................................................................... 36
4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE......................................... 38
4/32 FORMWORK ......................................................................................................... 39
4/33 CLASSES OF FINISH ........................................................................................... 43
4/34 MORTAR ............................................................................................................... 44
4/35 EXTENT OF POURS ............................................................................................. 45
4/36 POST-TENSIONED CONCRETE WORKS ........................................................... 45

Concrete work shall consist of furnishing all materials and constructing structures of the
forms, shapes and dimensions shown on the Drawings or as directed in accordance with
the details shown on the Drawings and these Specifications.
4/1 CEMENT
4/1.1 ORDINARY PORTLAND CEMENT
Ordinary Portland cement shall conform to the requirements of BS EN 197-

1:2000, Class 42.5N or ASTM C150:09 Type I and with the following
amendments: -
 The acid soluble alkali level measured as Na2 0+0.658 K20 shall not
exceed 0.6% by weight determined by the test method described in BS EN
196 Part 2: 2005.
 The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in
accordance with BS 4550: Part 3 Section 3.8:1978.
 The Tricalcium Aluminates content shall lie within the range of 4% to 13%
when tested according to the method BS EN 196-2: 2005
 The specific surface (fineness) shall be not greater than 375 .m²/Kg and
not less than 280.m²/Kg when tested as described in BS EN 196-2 : 2005
 The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2: 2005.
4/1.2 BLENDED CEMENT
Where Ordinary Portland Cement Type 1, which conforms to ASTM C

150:2009 and amendments mentioned in Clause 4/1.1 is used, blended
cement which conforms to one of the following may be substituted.
 .ASTM C 595:09 Type IP or Type IP (MS)
 ASTM C 1157 Type GU or MS
4/1.2.1 The blended cement shall conform to one of the followings:
 ASTM C 595:09 Type IP or Type IP (MS) where 15 to 25 % Class F Fly

ash has been blended with Portland Cement Type 1 (ASTM C150).
Portland Cement Type 1 shall be low alkali cement conforming to the
chemical requirements listed in Table 2, in ASTM C 150:2009 Standard.
 ASTM C 1157:09 Type GU or Type MS which conform to Option R (i.e.

Low Reactivity with Alkali-Reactive Aggregate).
4/1.2.2 Unless otherwise approved by the Engineer, the product of only one factory of
any brand and type of Portland cement shall be used on each project.

The contractor shall provide the proper means for cement storage and
protection against dampness and cement which has become partially set or
which contain lumps of caked cement will not be permitted.
Cement salvaged from discarded or used bags shall not be used.
Blended cement containing fly ash shall not be used in bridge decks.
4/1.2.3 FLY ASH
If Fly Ash is recommended for concrete works, it shall conform to the

requirements of ASTM C618:89, Class C or Class F.
All Chemical requirements for Fly Ash Class C and Class F listed in ASTM C
618: 89 Table1-A shall apply, with the exception of footnote A.
 Class C fly ash will not be permitted where sulfate resistant cement is
required.
 Fly ash shall be from a pre-approved source.
 The fly ash intended for use on the project shall have been tested and
accepted prior to its use.
 Pre-approval shall include submission of a report from the supplier

confirming that the fly ash is form a source that conforms to the
requirements of Toxicity Characteristic Leaching Procedure (TCLP)
adopted in the UAE.
 The supplier’s submission shall include a detailed report with the results of
TCLP testing for heavy metal and other contaminants in the fly ash.
 The testing report shall include a list of the contaminant tested and the
allowable limits for each contaminant.
 A new report shall be submitted for each pre-approved source annually.

Additional TCLP testing may be required when the Department suspects
that the fly ash source may have become contaminated.
 For any source of fly ash that has not been pre-approved, the Contractor
shall notify the engineer of the source 30 days prior to use in the project.
 The fly ash shall be subject to sampling and testing by the Engineer.
 Test results that do not meet the physical and chemical requirements may
result in the suspension of the use of fly ash until the corrections
necessary have been taken to insure that the material meets the
specifications.

4/1.2.4 GROUND GRANULATED BLAST FURNACE SLAG (GGBS)
 If GGBS is recommended for concrete works, it shall conform to the requirements

of ASTM 595:09 or ASTM C 989:09.
The chemical requirements for the GGBS listed in ASTM 595:09 must be met.
4/1.3 SULPHATE RESISTING CEMENT :
Sulphate Resisting Cement shall comply with BS 4027 – 1996, Class 42.5N or
ASTM C150:09 Type V. In addition the cement shall comply with the
following:-
The acid soluble alkali level measured as (Na2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN 196-2 :
2005
The heat of hydration shall not exceed 290 KJ/Kg at 7 days when tested in
accordance with BS 4550:1978: Part 3 Section 3.8.
 The specific surface shall be not greater than 375 m²/Kg and not less than
280 .m²/Kg when tested as described in BS EN 196: Part 6: 1992.
The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2 : 2005
The Tricalcium Aluminate content shall be 3.5% max when tested

according to the method BS EN 196-2 : 2005
4/1.3 MODERATE SULPHATE RESISTING PORTLAND CEMENT:
Moderate Sulphate Resisting Portland Cement shall comply with ASTM

C150:09 Type II. It shall also comply with Clause 4/1.2. In addition, the
cement shall comply with the following:-
 The acid soluble alkali level measured as (Na2 0+0.658 K2 0) shall not
exceed 0.6% by weight determined in accordance with BS EN196 – 2
2005
The specific surface (fineness) shall not be greater than 375 sq.m/Kg and
not less than 280 sq.m/Kg when tested as described in BS EN 196: Part 6:
1992.
The chloride content shall not exceed 0.1% when tested in accordance
with Clause 4 of BS EN 196-2 : 2005
Contain not less than 4% and not more than 8% proportion of tricalcium
aluminate by weight when tested according to the method BS EN 196-2 :
2005
Contain less than 2.7% proportion of Sulphur trioxide by weight according
to the method ASTM C563-07 or ASTM C114-09.

For any type of cement, the following physical & mechanical test shall also be
included:
 Consistency in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005

 Setting time in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005
 Soundness in accordance with BS EN 196-3: 1995 or BS EN 196-3: 2005
 Compressive Strength BS EN 196-1: 2005
The characteristic values of Mechanical and physical requirements are given

in Table 4-1 below:
Table 4- 1: Mechanical & physical properties of cement
Compressive Strength MPa Initial Soundness

Strength Early Strength Standard Strength Setting
(expansion)
Class Time
2 days 7 days 28 days min. mm
32.5 N - ≥ 16.0 ≤ 52.5
≥ 32.5 ≥ 75
32.5 R ≥ 10.0 -
42.5 N ≥ 10.0
≥ 42.5 ≤ 62.5 ≥ 60 ≤ 10
42.5 R ≥ 20.0 -
52.5 N ≥ 20.0 -
≥ 52.5 ≥ 45
52.5 R ≥ 30.0 -
4/1.4 GENERAL
Each cement batch shall bear manufacturer's name and batch number. Type
of cement shall be the same as mentioned in the approved analysis report.
Each separate consignment of cement shall be tested by the manufacturer
before delivery and certified copies of such tests shall be supplied to the
Engineer before any part of the consignment is used in the works. The
Engineer reserves the right to order a re-test of cement at any time. Approval
of cement does not relieve the Contractor of the responsibility to produce
concrete of the specified strength.
4/1.5 Cement shall be delivered to site in bulk, or with the Engineer's approval, may
be supplied in sealed bags which shall bear the manufacturer's name and the
date of manufacture. Each consignment shall be accompanied by a copy of
the manufacturer's batch test certificate and certificate of guarantee.
4/1.6 Each consignment of cement shall be kept separate, identified and used in
order of delivery.
4/1.7 Any consignment not used within 2 months from the date of manufacture will
not be allowed to be used in the works.
4/1.8 One brand only of cement as approved by the Engineer shall be used
throughout the works unless otherwise authorized by the Engineer in writing.

4/1.9 Each cement batch shall bear manufacturer’s name and batch number
 Type of cement shall be the same as mentioned in the approved analysis

report.
 Each separate consignment shall be tested by manufacture before
delivery.
 Certified copies of batch test certificate and certificate of guarantee shall
be supplied to the Engineer before any part of the consignment is used in
the works.
 The Engineer reserves the right to order a re-test of cement at any time
 Approval of cement does not relieve the Contractor of the responsibility to
produce concrete of the specified strength.
 Cement shall be delivered to site in bulk, or with the Engineer’s approval,
may be supplied in sealed bags bearing manufacturer’s name and date of
manufacture.
 Each consignment shall be kept separate, identified and used in order of
delivery.
 Any consignment not used within 2 months from the date of manufacture
will not be allowed to be used in the works.
4/2 AGGREGATES GENERAL REQUIREMENTS
4/2.1 Except as may be modified hereunder the aggregate (fine and coarse) for all
types of concrete shall comply in all respects with BS 882 "Concrete
aggregates from natural sources" and the fine aggregate shall also comply
with Dubai Municipality Administrative Order No. 143/91.
4/2.2 The aggregates used in the permanent works shall be crushed materials
obtained only from approved sources. Where natural gravel sources are
approved, then it shall be crushed such that it contains at least two crushed
faces.
4/2.3 Before any material from a particular source is used, the Contractor shall
obtain representative samples of fine and coarse aggregates and carry out the
necessary tests and analyses to show that the samples comply with the
Specification. During the progress of the works, the grading and chemical
characteristics may be checked at frequent intervals.
4/2.4 The results of these tests, etc. shall be submitted to the Engineer and his
approval shall be obtained before any of the material is used in the works.
Part of each sample will be required for concrete trial mixes and part shall be
retained for comparison with subsequent deliveries.
4/2.5 Sampling for testing and analysis shall be carried out, where applicable, in
accordance with BS 812 Part 102:1989.
4/2.6 The maximum size of the aggregate shall not be larger than 1/5 of the
narrowest dimension between sides of the member for which the concrete is to
Volume 2, Part 1, General Specifications-Road Works MJuly 2018 Page 6

be used and not larger than 3/4 of the maximum clear distance between
reinforcing bars.
4/2.7 Fine aggregate shall be natural or crushed sand and beach sand shall not be
permitted for use in concrete mixes.
4/2.8 Coarse aggregate shall be crushed aggregate obtained from a quarry
4/2.9 Unless otherwise authorized by the Engineer coarse aggregate shall be
delivered to site in separate sizes according to the maximum specified
aggregate size for each grade of concrete.
4/2.10 Aggregates shall meet the requirements of Table 4.2.
4/2.11 The frequency of testing of aggregates shall be in accordance with Table 4.3
or as directed by the Engineer.
Table 4- 2: Limits for physical, chemical & mechanical properties of aggregates for
concrete
SR. KIND OF TEST METHODS PERMISSIBLE LIMITS

No REQUIREMENT
FINES COARSE
1. Grading BS EN 933-1:97 Standard Standard
(Dry): AMD 15907:
2006
2. Material finer Than
0.075 mm for :
 Natural, uncrushed BS EN 933-1: 97 , max.3% max.1%
/crushed AMD 15907: 2006
or ASTM C117:
2004 (Wet)
 Crushed rock BS EN 933-1: 97: max.7% max.1%
AMD 15907: 2006
or ASTM C117:
2004 (Wet)
3. Clay lumps and friable ASTM C142: 09 max.1% max.1%
particles
4. Light weight pieces ASTM C123: 04 max.0.5% max.0.5%
5. Organic impurities for ASTM C40 : 2004 The color of
fine aggregate the
Supernatant
liquid is
lighter than
standard
color
solution
6. Water absorption ASTM C128 : max.2.3% max.2.0%
2007a ASTM C127
: 2007
7. Specific Gravity ASTM C128 : min.2.60 min.2.60
(apparent) 2007a
ASTM C127 : 2007
8. Shell content in BS EN 933-7:1998 max.10%
aggregates coarser
than 4 mm , Note 1


No REQUIREMENT
FINES COARSE
9. Particle shape
 Flakiness index BS EN max.25*
933:3:1997,AMD
14866: 2007
 Elongation index BS 812:90, Part max.25
105 : Section 105.2
*The index shall be max. 25 for combined aggregates but should not exceed more
than 30 for individual sizes.
9a. Partially crushed faces DMS 8 : 2001 100%.
of coarse aggregate
with at least one
crushed face.
10. Acid soluble BS 812:1988, Part
Chlorides, CL, 117
For reinforced
concrete made with:
 SRPC cements max.0.03% max.0.01%
 OPC & MSRPC max.0.03% max.0.02%

cements
For mass concrete
Made with:
SRPC cements max.0.03% max.0.02%

OPC & MSRPC max.0.03% max.0.04%
cements
For pre-stressed max.0.03% max.0.01%
concrete & steam
Cured structural
concrete
11. Acid soluble BS EN 1744- max.0.3% max.0.3%
sulphate, S03 1:1998
12. Soundness, MgS04, ASTM C88 : 2005 max.12% max.12%
(5 cycles)
13. Mechanical Strength

 10% fines value or BS 812:90, Part min100KN
111
 Impact value BS 812:90, Part max.30%
112: AMD 8772:
1995
 Los Angeles ASTM C131 : 2006 max.25%
Abrasion ASTM C535 : 2009
14. Drying Shrinkage BS EN 1367-Part max.0.03%
4:1998
15. Potential reactivity- ASTM C289:2007 Innocuous Innocuous
Of Aggregates, “Standard Test
Note 2 Method for
Potential Alkali-
Silica Reactivity of
Aggregates
(Chemical


No REQUIREMENT
FINES COARSE
Method)”
or
ASTM test ASTM
C1260-07
6 month -
ASTM C227:2003 expansion
“Standard Test 0.10% max.
Method for
Potential Alkali
Reactivity of
Cement-Aggregate
Combinations
(Mortar-Bar
Method)”
or ASTM test
ASTM C1260-07
(Note 3)
Note 1 : There is no requirement of shell content in sands passing 4 mm sieve size.

Note 2 : Aggregates may initially be assessed for its reactivity in accordance with ASTM
C289 and if potential reactivity is indicated, then mortar bar tests in accordance
with ASTM C227 shall be carried out.
Note 3: Limit of ASTM C1260 should be changed from 0.10% expansion at 14 days to
21days.
Table 4- 3: Frequency of routine tests on aggregates
SR. KIND OF REQUIREMENT-TEST TEST FREQUENCY RATE

No METHOD
1. Grading - BS EN 933-1:1997: AMD Per 2,000m3
15907: 2006
2. Material finer than 0.075 mm - BS - do -
EN 933-1: 1997 or ASTM C117:2004
3
3. Clay lumps and Friable Particles - Per 2,000m
ASTM C 142:1997 (04)
4. Organic impurities - ASTM C Per 2,000m3
40:2004
5. Water absorption - ASTM C128 : - do -
2007a/C127 : 2007
6. Specific Gravity - ASTM C128 : - do -
2007/C127 : 2007
7. Shell content - BS EN 933-7:1998 - do -
8. Particle shape BS 812 :1990 Section - do -
105 Part 105.1.& Section 105 Part
105.2
3
9. Acid soluble chlorides, CL Per 2,000m
Qualitative - BS 812 : 1988 Part 117,
Appendices A/B
Quantitative-BS 812 : 1988 Part 117, Each 12 concrete days if result is

SR. KIND OF REQUIREMENT-TEST TEST FREQUENCY RATE

No METHOD
Appendix C more than 75% of the limit and each
month if result is less than 75% of the
limit.
10. Acid soluble sulphates, Per 2000m3 or Each 24 concrete days
S03 - BS EN 1744-1:1998 if result is more than 75% of the limit
& each 2 months if result is less than
75% of the limit whichever is less.
11. Soundness, Mg S04 (5 cycles)- Each 48 concrete Days or 2,000 m3
ASTM C88 : 2005
12. Mechanical Strength

 10% Fines or impact value - Each 72 concrete Days or 6,000m3
BS 812 Parts 111, 112:
1990
 Los Angeles abrasion - - do -
ASTM C 131, 2006/C
535: 2009
13. Moisture variation in sand – by Twice daily
Moisture Meters
14. Drying Shrinkage At the start of the project and

BS 812 Part 120: 1989: AMD 8773: whenever there is a change in the
1995 source of supply.
15. Potential Reactivity: of aggregates
 ASTM C289:2007 of aggregate- At the start of the project and

Chemical Method)” wherever there is a change in the
source of Supply.
 ASTM C227:2003 of Cement At the start of the project and
aggregate combination wherever there is a change in the
source of Supply
 ASTM C 586:05 - of Carbonate At the start of the project and
wherever there is a change in the
source of Supply
16 Light weight pieces test (ASTM C Per 2,000 m3
123: 2004)
Note1 : Drying Shrinkage and potential reactivity of aggregates shall be determined initially
at the start of the project or whenever there is a change in the source of supply.
Note 2: The salt content of water should be taken into account in the relevant limits for the
concrete.
Note 3: Frequency of testing may be amended by the Engineer based on previous test results
or new requirements
4/3 FINE AGGREGATES
4/3.1 The gradation of fine aggregate shall be in accordance with BS EN

12620:2002: AMD 15333: 2004 or latest edition.
4/3.2 Each batch of aggregate delivered to site shall be kept separate from previous
batches and shall be stored for at least 3 (three) working days before use to
allow inspection and tests to be carried out.
4/3.3 Fine Aggregate shall be clean sharp natural and/or crushed sand.

4/3.4 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
4/4 COARSE AGGREGATE FOR CONCRETE
4/4.1 Coarse aggregate shall be prepared as single sized aggregate and blended to
produce normal size grading. The combined grading shall be within the
appropriate grading limits given in BS EN 12620: 2002.
4/4.2 Aggregates that are deleteriously reactive with the alkalis in the cement in an
amount sufficient to cause excessive expansion of concrete shall not be used.
4/4.3 The Contractor shall mechanically wash aggregate to remove salts and other
impurities in order to meet the requirement specified.
4/5 COMBINED AGGREGATE
4/5.1 Approved coarse aggregate and fine aggregate in each batch shall be
combined in proportions as specified in BS EN 12620:2000 and as approved
by the Engineer. However, in no case shall materials passing the 0.075mm,
sieve exceed three (3) percent by weight of the combined aggregate.
4/5.2 The combined aggregate gradation used in the work shall be as specified,
except when otherwise approved or directed by the Engineer. Changes from
gradation to another shall not be made during progress of the work unless
4/5.3 ADHESIVE
The mortar/adhesive shall be applied to the walls with a suitable notched

trowel strictly in accordance with the adhesive manufacturer's
recommendation. Adhesive shall have the following properties:
Test Requirements Test Method

Tensile Adhesion Strength
≥1.5 N/mm² GSO ISO 13007-2: 4.4.4.2
(28 days)
after water immersion ≥1 N/mm² GSO ISO 13007-2: 4.4.4.3
≥1 N/mm² GSO ISO 13007-2: 4.4.4.4
after heat aging
Open time: Tensile Adhesion GSO ISO 13007-2: 4.4.4.
≥ 1 N/mm² after not
Strength
less than 30min
Shear Bond Strength (28
>2.1 N/mm² ANSI 118.4 F-5.1.1
days)
Slip ≤0.5 N/mm² GSO ISO 13007-2
Compressive Strength ≥17 N/mm² ANSI 118.4
Transverse Deformation 2.5 – 5 mm Class
GSO 180 13007-2
S1
Hardness (72 Hrs) 50-60 ASTM D2240

4/5.4 GROUTS
Before grouting, all tiles must be firmly set, all paper and glue removed from
face of mounted tile and all spacers, strings, ropes, and pegs removed. Grout
to be a proprietary mix based on Portland cement, silica sand mixture and
selected additives with the color selected from the manufacturers range. The
grout shall be water repellent and incorporate anti-mould technology. The
grout shall have the following properties
Abrasion resistance ≤1000 mm³ GSO ISO 13007-4
Flexural Strength >2.5 N/mm² GSO ISO 13007-4
Compressive >15 N/mm2 GSO ISO 13007-4

strength
Shrinkage <3mm GSO ISO 13007-4
Reduced Water GSO ISO 13007-4

absorption after 30 ≤2.0 9
minutes
Joints shall be sufficiently wide to enable the grout to be inserted without

undue difficulty, to fill the full depth of the joints achieving solid joints as much
as practicable without voids or cavities where water could collect.
4/5.5 CERAMIC TILES
All the tiles required for the project shall be sourced from a single
manufacturer operating a quality system for production of ceramic tiles, which
is registered to ISO 9000. The tiles shall be manufactured as per the EN
14411/159 or ISO 13006 as directed by the Engineer and verified by firing at
temperatures not less than 1200oC. the contractor/supplier shall provide
detailed drawings for the wall tile patterns.
The fully glazed tiles of 1st choice quality having the following properties shall
be used for the works.

Water Absorption 2.0% maximum EN 99/BS EN ISO 10545-3
Modulus of Rupture >27 N/mm² EN 100/BS EN ISO 10545-4
Scratch Resistance on Moh. scale 5-6 EN 101
Thermal Shock Resistance Required BS EN ISO 10545-9:1996
Stain Resistance At least Class 2 EN 122
Density 2.4 gm/cm²
4/6 WATER FOR CONCRETE
4/6.1 The Contractor shall make his own arrangement and obtain approval for the
supply of water.

4/6.2 The mixing water should be clear, apparently clean and free from matter
harmful to concrete in its fresh or hardened state. Potable water can be used.
Water of questionable quality should comply with the physical tests of Table 4-
3 and chemical limitation listed in Table 4-4. Water shall also meet the
requirement of BS EN 1008:2002
4/6.3 The temperature of water for concrete should not be less than 5 degree
Celsius or more 25 degree Celsius. Water may be cooled to not less than 5
degree Celsius by the gradual addition of chilled water or ice but on mixing, no
ice particles should be present in the mix.
Alternatively, flaked ice may be used. The ice to be used should be crushed
and should be the product of frozen water which complies with acceptance
criteria of Tables 4-4 and 4-5.
4/6.4 Water for curing concrete shall not contain impurities in sufficient amounts to
cause discoloration of the concrete.
Sources of Water shall be maintained at such depth and the water shall be
withdrawn in such a manner as to exclude silt, mud, grass and other foreign
matter.
Table 4- 4: Acceptance criteria & physical tests for mixing water
Test Limits ASTM Test
Compressive strength, min.% 90 C 109 : 2008

control at 7 days
Setting time, deviation from from 1:00 early to 1:30 C 191 :2008
control, h: min. later
Table 4- 5: Chemical Limitations for mixing water
Max. Concentration, Limit, ppm Test Method

1. Chloride as C1 250 ASTM D 512: (2004) or
BS EN 1008:2002
2. Sulphates as SO4 350 ASTM D 516:2002 or
BS EN 1008:2002
3. Alkali carbonates and 500 ASTM D 513:2006 or
bicarbonates BS EN 1008:2002
4. Total dissolved solids,
including
1, 2 & 3 above 2000 BS 1377 : Part 3 : 1990:
Test 8: AMD 9028: 1996
5. PH min.7/ max. 9 ASTM D1293 : 1999
4/7 APPLICABLE TESTS AND CODES

4/7.1 All concrete, aggregate, cement, steel and water shall be tested during the
construction as per frequency in Tables 4-3 and 4-6 or as directed by the
Engineer.
All test samples shall be supplied by the Contractor at his expense. Samples
shall be obtained in accordance with BS 812,102: 1989, BS EN 1008:2002,
BS 1881:1983 AMD 6095: 1989 and BS EN 196: Part 7: 2007.
Testing shall be at the frequencies stated above or relevant standards. All

sampling shall be carried out by the Engineer.
Table 4- 6: Frequency of routine testing
Sampling Test Frequency

ITEM Test Method
Method Rate
a. Cement
As per BS EN 196-7: BS EN 196-7 BS EN-196 Each 250 ton of
2007 concrete poured.
b. Steel
1. Deformed S. Bar BS EN 15630 BS EN 15630 Each size 100 ton
as per BS Part 1:2002 Part 1:2002 as per the BS
4449:2005 BS 4449:1997 or BS standards
Or BS 4449:1997 4449:1997
2. Strand as per BS 5896 and BS 5896 - As per Clause
BS 5896:1980 and ASTM APPENDIX A 23.3 of
ASTM 416:A416M:20 BS 5896
416:A416M:2006 06
if needed
c. Concrete
1. Air content, as per BS EN 12350- BS EN Once at the time
BS EN 12350- 1:2009 12350- of mix design of
7:2000 7:2000 concrete or as
directed by the
Engineer.
2. Flexural strength BS EN 12350- BS EN Once at the time
of Prism as per BS 1:2009 12390:2000 of mix design of
EN 12390-5:2000 concrete or as
directed by the
Engineer.
3. Bleeding as per BS EN 12350- ASTM C One at the time of
ASTM C232:2009 1:2009 232:2009 mix design of
concrete or as
directed by the
Engineer.
4. Splitting Tensile of BS EN 12350- ASTM C- One at the time of
Conc. Cylinder as 1:2009 496:2004 mix design of
per ASTM C- concrete or as
496:1996 & others directed by the
Engineer.
5. Depth of Water BS EN 12350- BS EN Each 2000m3 of a

Sampling Test Frequency

ITEM Test Method
Method Rate
Penetration (BS 1:2009 12390- particular grade
EN 12390 P- 8:2009 of structural
8:2000) concrete or as
directed by the
Engineer.
3
6. ISAT as per BS BS EN 12350- BS 1881 - Each 2000m of a
1881-p-208:1996 1:2009 208:1996 particular grade
of structural
concrete or as
directed by the
Engineer.
7. Water absorption BS EN 12350- BS 1881- Each 2000m3 of a
of Hardened 1:2009 122:1983 particular grade
Conc. As per BS of structural
1881 P122 concrete or as
directed by the
Engineer.
8. Rapid chloride BS EN 12350- ASTM C Each 2000m3 of a
permeability 1 :2009 1202:2009 particular grade
of structural
concrete or as
directed by the
Engineer.
9. Slump test - as BS EN 12350- BS EN From each transit
per BS EN 12350- 1:2009 12350- mixture load
2:2000 2:2009 arrived at site
10. Concrete Mix BS EN 12350- All mixes are to be
Design (Mixing 1:2009 designed once for
and Sampling in verification and
the lab) as per BS approval.
1881 P125 &
(Sampling) as per
BS EN 12350-
1:2009 (on site)
11. Kerbs-as per BS BS 7263 BS 7263 Sample to be
7263 taken from each
batch of upto 1000
kerb in whole
consignment
d. Water
Water Quality BS EN BS EN 1008- For DEWA WD no
1008:2002 :2002 test is required or
other than DEWA
twice a week or as
directed by the
Engineer.
4/7.2 WORKABILITY

Workability shall be assessed by the following tests the requirements for which
shall be as specified elsewhere in the documents.
 Slump test shall be performed according to BS EN 12350-2:2009
 Compaction factor shall be performed according to BS EN 12350-

4:2009
 Vebe time shall be performed according to BS EN 12350-3:2009
 Flow test shall be performed according to BS EN 12350-5:2009
4/7.3 COMPRESSION TEST
The Compression tests shall be performed on cubes 150 x 150 x 150 mm as

described in BS EN 12390-3:2009. Sampling, making test cubes and curing of
cubes shall be in accordance with BS EN (12350-1:2009 and 12390-1:2009)
respectively.
4/8 REINFORCEMENT BARS
4/8.1 All reinforcement bars shall be of a deformed type in accordance with

BS 4449:2005 except that plain bars may be used where specifically indicated
on the Drawings. Plain bars shall be in accordance with
BS 4449:2005.
4/8.2 All steel reinforcement shall conform to the requirements of the Specifications
for Deformed High Yield Steel Bars grade 460 Type 2, unless otherwise
shown on the Drawings or specified by the Engineer.
4/8.3 Certification. Three (3) copies of a mill test report shall be furnished to the
Engineer for each lot of steel reinforcement bars and a sample of each
proposed reinforcement bar for use on the project shall be provided.
4/8.4 Identification. 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 and other applicable data that will
identify the material with the certificate issued for that lot of steel.
4/8.5 The fabricator shall furnish three (3) copies of a certification which shows the
heat number or numbers from which each size of bar in the shipment was
fabricated.
4/8.6 The Engineer reserves the right to sample and inspect all reinforcement steel
upon its arrival at the work site. The Contractor shall provide a certificate
confirming that samples taken from the bars delivered to the works pass all the
required tests. The frequency of sampling and the method of quality control
shall be in accordance with BS 4449 – 2005.
4/8.7 All reinforcement bars shall be free from detrimental dirt, mill scale, loose rust,
paint, grease, oil or other foreign substance, fins, or tears. There shall be no

evidence of visual flaws in the bars, test specimens or on the sheared ends of
the bars.
4/8.8 Uncoated reinforcement shall be grit-blasted before use to remove rust, oil,
grease, salt and other deleterious materials and where pitting has occurred the
causes and products thereof. Repeated blasting may be required when the
reinforcement is in position, or partially cast in. Partially set concrete adhering
to exposed bars during concreting operations shall be removed.
4/8.9 The minimum thickness of concrete cover to reinforcement shall be as shown

on the drawings. Only approved concrete spacers shall be used. The
concrete shall be of similar grade to the main concrete and shall have non
metallic ties.
4/9 BAR SCHEDULES AND SHOP DRAWINGS
4/9.1 Before ordering reinforcing steel, the Contractor shall check the bar schedules
and adjust them if necessary to the approval of the Engineer. Bar schedules
shall show the weight of each bar, the total weight of each bar size and the
total weight of bars, and bending diagrams for bars in accordance with BS
4466.
4/9.2 The Contractor shall provide and submit to the Engineer for approval any
working drawings additional to the Contract Drawings which may be found
necessary for the production of revised bar schedules or for the completion of
the works.
4/9.3 The approval of working drawings, or revised bar schedules by the Engineer
shall in no way relieve the Contractor of responsibility for the correctness of
such drawings or schedules.
4/10 BAR CUTTING AND BENDING
4/10.1 Reinforcement shall be cut and bent in accordance with BS 8666:2005.

Cutting or bending by the application of heat is not permitted. Welding of
reinforcement shall only be permitted when approved in writing by the
Engineer. If such approval is given then the workmanship shall be in
accordance with BS EN 1011. The Contractor shall submit full technical
details of his proposed procedures prior to seeking approval.
4/10.2 Hot rolled high yield bars shall not be straightened or bent again, having once
been bent. If the Engineer gives approval to bend mild steel reinforcement
projecting from the concrete, the internal radius of bend shall not be less than
four times the nominal size of the bar.
4/11 PLACING AND FIXING REINFORCEMENT
4/11.1 Reinforcement shall be placed and maintained in the position shown in the
Contract Drawings. Unless otherwise permitted by the Engineer, all bar
intersections shall be tied together using 1.2mm diameter steel wire or No. 18

gauge stainless steel wire as indicated on the drawings and the ends of the
tying wire shall be turned into the main body of the concrete.
4/11.2 Metal supports, approved by the Engineer, shall be provided and used to
retain the reinforcement at proper distances from the forms. Supports under
horizontal bars at the bottom of base slabs shall be spaced at not more than
eighty (80) diameters of the bar. All reinforcement shall be so rigidly
supported and fastened that displacement will not occur during construction.
Reinforcing steel shall be inspected in place and must be approved by the
Engineer before any concrete is deposited.
4/11.3 No splices shall be made in the reinforcement except where described in the
Contract Drawings or where approved by the Engineer.
4/11.4 Reinforcement temporarily left projecting from the concrete at construction or

other joints shall not be bent out of position during the periods in which
concreting is suspended, except with the approval of the Engineer.
4/12 WELDED WIRE FABRIC
4/12.1 Welded wire fabric to be used for the reinforcement of concrete shall conform
to the following requirements:
- Dimensions. Welded steel wire fabric shall conform to the size and
dimensions shown on the Drawings.
- Properties. Wire fabric furnished under this specification shall conform to
the requirements for "Welded Steel Wire Fabric for Concrete
Reinforcement" BS 4483 or equivalent.
4/13 SPACER BLOCKS
4/13.1 Spacers as approved by the Engineer shall be of such material and design as
will be durable, not lead to corrosion of the reinforcement and not cause
spalling of the concrete cover.
4/13.2 Spacer blocks made from cement, sand and small aggregate shall match the
mix proportions of the surrounding concrete so far as is practicable with a view
to being comparable in strength, durability and appearance.
4/14 ADMIXTURES
4/14.1 Unless agreed by the Engineer neither admixtures nor cements containing
additives shall be used.
4/14.2 Where the use of admixture had been agreed by the Engineer, they shall
conform to the requirements of Type A, Type D, Type F or Type G as specified
in ASTM C494:2008 and shall be used in strict accordance with the
manufacturer's instructions.

Preliminary tests of cube strength and other tests shall be carried out using the
combination of aggregates cements and admixtures proposed for use.
4/14.3 The Contractor shall be entirely responsible for the use of any approved
admixtures.
4/14.4 Approved methods and equipment shall be used for dispensing and
incorporating the admixture into the concrete. The dispensing unit shall be
designed so that the discharge of the admixture is visible.
4/14.5 The use of an admixture containing chlorides, inorganic sulphates or other

corrosive agents will not be permitted.
4/14.6 Plasticizers and super-plasticizers shall not contain substance, which adversely
affect the durability and performance of the concrete.
4/14.7 If two or more admixtures are used simultaneously in the same concrete mix,
data including manufacturer certificate shall be provided to assess their
interaction and ensure their compatibility
4/15 CONCRETE MIX SPECIFICATION
4/15.1 Concrete shall be as shown in the Table 4-7. The number of mixes may
require to be increased.
The criteria given in this Table are designed to produce concrete of the
required strength and durability.
If the maximum aggregate size is 10 mm then the cement content stipulated
for the class of concrete given in Table 4-7 shall be increased by 40 Kg per
m3. All concrete mixes shall be verified by DM – DCL.
Table 4- 7: Table of mixes without admixtures or additives
Concrete Max.Size Min. Max. Free Characteristic

Class Agg Cement Water/Cement Cube Strength
content Ratio (CCS)
mm. kg.per m3 7-day 28-day

N/mm2 N/mm2
50/20 20 450 0.40 37 50
45/20 20 400 0.40 33 45
40/20 20 370 0.40 30 40
37/20 20 350 0.45 26 37
35/20 20 330 0.45 25 35
30/20 20 310 0.55 20 30
25/20 20 275 0.60 16 25
15/20 20 250 0.65 10 15

The CCSs are for concrete which has been cured at a temperature of 20
degrees C + 2 degree C, and are the values below which no more than 5% of
the test results fall. The 7-day strengths shall be used only as a guide.
4/15.2 Concrete shall comply with BSI BS EN 206-1:2000. Sampling for test
purposes shall comply with BS EN 12350-1:2000, AMD 11031:2000 (on site)
& BS 1881 Part 125:1986, AMD 6107: 1989 (in laboratory).
If air entertainment is specified, the average air content at the time of placing
measured in accordance with BS EN 12350-7:2009 shall be:
Concrete containing 20mm Maximum size aggregate 5%
Concrete for water-retaining shall be watertight and shall comply with the
recommendations of BSI BS EN 206-1:2000.
Concrete for paving or precast units shall be tested to BS EN 12390: Part 5:

2000, AMD 15438: 2004 and shall have minimum flexural beam strength of
3.5N/mm2 at 28 days. If the concrete has a specified CCS of 40N/mm2 or
greater, then the minimum flexural strength shall be 4N/mm2.
If concrete specimens are cured at higher temperatures or for longer periods

than BS EN 12390-1:2000, AMD 15437: 2004 requires, the adjusted CCS
shall be calculated as follows:
100f'/f = A + B log {24D (T+12)/1000}
where:
f’ = adjusted CCS
f = specified CCS
T = curing temperature
D = age at testing in days
A&B = are coefficients given in Table 4-8 below.
The above equation applies only to OPC, MSRPC and SRPC.
Table 4- 8: Coefficients for adjustment for curing temperatures
Recorded Cube Strength N/mm2 A B

Less than 15 10.0 67.5
From 15 to 35 20.0 60.0
Greater than 35 30.0 52.5
This calculation may be applied for curing at temperatures up to 27 degrees C.
Before placing concrete the Contractor shall obtain approval of the mixes
proposed for each class of concrete and the average target strengths. The
mixes shall be designed to achieve the minimum workability and maximum
durability for the Contractor to place and compact the concrete with the
equipment proposed for use. The mean strength shall exceed the CCS by a
margin of 1.64 times the standard deviation expected from the concreting

plant, except that no standard deviation less than 3.5 N/mm2 shall be used as
a basis for designing a mix. Unless otherwise approved a standard deviation
of 7 N/mm2 shall be used for initial mixes.
4/15.3 The ultimate compressive strength of the concrete shall be determined on test
specimens obtained and prepared in accordance with BS EN 12390-1:2000,
AMD 15437:2004.
4/15.4 Mixes for structural concrete shall be designed by the Contractor. The class of
concrete (shown on the drawings) is denoted by the 28 day characteristic cube
strength and the maximum size of aggregate.
4/15.5 The chloride and Sulphate levels in the concrete mix shall comply with the
following requirements:-
Table 4- 9: Maximum Limits of acid soluble Chloride and Sulphate content as a

percentage by Weight of Cement in the Mix.
CHLORIDES AS SULPHATES AS
TYPE OF CONCRETE Cl SO3
ACCORDING TO BS-1881 : 1988 PART 124
Amd 01:1998 Amd 06:2002
a. For reinforced concrete
if made with 0.1% 3.70 (Note 2)
OPC/MSRPC
if made with SRPC 0.1% 3.70 (Note 2)
b. Prestressed concrete & 0.10 3.70
Heat-cured reinforced
concrete
c. For mass concrete
if made with 0.60 3.70
OPC/MSRPC
if made with SRPC 0.12 3.70
Note 1: BS EN 196-21: 1992 Clause 8, Method of Testing Cement Part 21 will be used
to determine the percentage of chloride by weight of cement. The OPC and
MSRPC cements can also contain chlorides, the relevant standard BS EN 197-
1 allows up to 0.1% Cl. Therefore any chloride content present in the cement
has to be taken into account while computing total Cl in the mix. In case the
cement contains the maximum limit of 0.1% Cl, then the aggregates, water and
admixtures used for pre-stressed concrete or heat cured reinforced concrete
should be absolutely free of chlorides.
Note 2: Suggest to SO3 content to be 3.5% for cement Type 1&2 tested in
accordance to BS EN -197-2000. For cement types 3 and 4, SO3 content to be
4%.
4/16 CONCRETE MIX DESIGN
TRIAL MIXES
4/16.1 Preliminary laboratory tests shall be carried out to determine the mixes to
satisfy the specification with the approved materials.

Trial mixes shall be tested to determine the following properties of mixes

proposed for initial field tests:
a) Bleeding in accordance with ASTM C232: 2007 (non-vibrating) shall not

exceed 0.5%.
b) Drying shrinkage in accordance with BS 1881 Part 5:1997
c) Air content if applicable BS EN 12350: P7: 2009.
d) Free water/cement ratio.
e) Workability BS EN 12350-2:2009
f) Chloride permeability shall be maximum 2,000 coulombs, when tested in
accordance with ASTM C-1202: 2007.
g) Fresh and hardened concrete densities BS EN (12350-6:2000 and
12390-7:2009) respectively.
h) Compressive strength BS EN 12390-3:2009.
i) Depth of Water Penetration Test BS EN 12390 Part 8: 2009
(maximum 10 mm at 28 days)
(maximum 15 mm at 7 days).
j) The Initial Surface Water Absorption Test as per BS 1881: P-208: 1996.
Maximum permissible limit for ISAT is 0.2 ml/m2/sec
k) Water absorption of Hardened concrete as per BS 1881: P122: 1983:
AMD 6108:1989 and the maximum permissible limit shall be 2.0%.
If the values obtained are unacceptable, the mixes shall be re-designed.
4/16.2 At least 35 days before commencement of concreting trial mixes shall be

prepared under full-scale site conditions and tested in accordance with BS
1881: 1983.
Samples of concrete incorporating the reinforcing details to be used shall be

cast and examined, before hardening using hand tools, and after hardening by
coring to assess the mixes. Cores shall be taken in accordance with BS EN
12504-1:2000.
Trial mixes shall be made on each of three days; the workability shall equate
to the designed target value. Six cubes from each mix shall be taken, three for
test at 28 days.
Further trial mixes shall be made if the range (the maximum minus the
minimum of the three cube results in any batch) exceeds 15% of the average
of that batch, or if the range of the three batch averages exceeds 20% of the
overall average of the batches.
The mixes shall be tested to determine the following properties:

a) Bleeding in accordance with ASTM C232: 2007
b) Air content if applicable BS 12350: P7: 2009.
c) Free water/cement ratio

d) Tensile strength in accordance with BS EN 12390-6:2000. Splitting

tensile strength of concrete cylinder shall be in accordance with ASTM
C496: 1996. Flexural strength of concrete prism in accordance with BS
EN 12390: P5.
e) Compressive strength
The average 28-day CCS of the three trial mixes shall not be less than the
designed mean strength, and the results of the above tests shall be
acceptable before the mix is approved. Otherwise the mix shall be re-
designed.
4/16.3 The Engineer will review the Contractor's trial-mixes and test the test cubes at
seven (7) and twenty-eight (28) days. The Engineer will then determine which
of the trial mixes shall be used. If none of the trial mixes for a class of
concrete meets the Specifications, the Engineer will direct the Contractor to
prepare additional trial-mixes. No class of concrete shall be prepared or
placed until its job-mix proportions have been approved by the Engineer.
4/16.4 The approval of the job-mix proportions by the Engineer or his assistance to
the Contractor in establishing those proportions, in no way relieves the
Contractor of the responsibility of producing concrete which meets the
requirements of these Specifications.
4/16.5 The Engineer may also require practical tests to be made on the Site by filling
trial moulds to confirm the suitability of the mix for the works, the type of plant
used for mixing, the method of compaction used and the formwork face
intended for use in the works.
4/16.6 All costs connected with the preparations of trial-mixes and the design of the job-
mixes shall be borne by the Contractor.
4/16.7 In the event, any Concrete mix that is currently being used in another running
RTA/DM projects, is proposed by the contractor for approval of using that mix
in this contract, then
1. Prior to according the approval or otherwise, the Engineer must ensure

that all copies of test results pertaining to another running RTA/DM project
submitted by that contractor comply with all specifications as stated in this
contract and
2. shall also ensure that the proposed mix complies with clause 4/16 by
verifying that proposed mix at DCL
NOTE: Any mix that is obsolete & currently not in use shall not be
accepted at all for re-approval.
4/17 QUALITY CONTROL
4/17.1 TEST CUBES

Cubes shall be manufactured in an on-site laboratory, specially equipped for

the purpose, in controlled conditions. They shall be made, cured, stored,
transported and tested to BS EN (12390-1:2000, AMD 15437:2004 and
12390-3: 2009). The method of compacting cubes shall be as approved and
shall be means of vibrating table in the laboratory or 25mm vibrating poker on
site.
4/17.2 SAMPLING CUBES
A sample of concrete shall be taken at random on eight separate occasions

during the first five days of using a mix at least one sample being taken each
day. The standard deviation shall be calculated from at least 40 individual
cube results each representing separate batches of similar concrete produced
by the same plant under the same supervision. The current margin for the
plant shall be thus established as 1.64 times the standard deviation.
Thereafter one sample shall be taken at random for each class of concrete in
accordance with Clause 4/31 of the Specification.
In addition to the above requirements, at least one sample shall be taken from
each individual structural unit, or part of a unit, when the latter is the product of
a single pour.
From each sample three cubes shall be made for testing at 28 days and three
for testing at 7 days for control purposes.
Six cylinder samples shall also be taken to determine the split tensile strength
of the concrete 3 at 7 days and 3 at 28 days, as specified in ASTM C496:
2004. These samples shall be taken from every 100 batches, but at least
once a week during concreting operations, and shall coincide with samples
taken for test cubes.
The frequency of sampling may be required to be varied if directed by the

Engineer.
The procedures shall be repeated when materials or design mixes are

changed.
4/17.3 CUBE STRENGTH RESULTS
The results will be acceptable if:
i) The average strength determined at the age of 28 days from a sample of

three or more cube test results exceed the Characteristic Cube Strength
(CCS) which is the 28 days cube strength obtained in the approved trial
mix by 0.5 times the current margin,
ii) No individual result of the sample is less than the specified Characteristic
Cube Strength (CCS) minus 3 N/mm2).
iii) Number of individual results in the sample below the specified
Characteristic Cube Strength (CCS) is not more than one.
If the above criteria is not satisfied, the unit represented by the sample is
questionable and the following actions may be instructed as appropriate :

i) Cutting and testing cores from placed concrete.

ii) Non-destructive testing of placed concrete.
iii) Load-testing relevant structural units.
iv) Cutting out and replacing defective concrete.
If the range of individual cube strengths made from the same sample
exceeds 15% of the mean, then the method of making, curing and
testing cubes shall be checked. In the event of a sample having a range
exceeding 20%, then the result shall be unacceptable and the Engineer
may order any of the following actions:
a) Changing the mix.

b) Improving quality control.
c) Cutting and testing cores from placed concrete.
d) Non-destructive testing of placed concrete.
In the event of cutting and testing of cores are required, the Contractor
shall cut cores from approved locations and test them to BS 1881- Part
120:1983 as modified by BS 6089:1981.
4/17.4 DURABILITY TESTS
Concrete shall be tested for durability properties by undertaking absorption

and permeability tests where appropriate, or directed by the Engineer, as
directed below:
Water absorption tests shall be carried out in the laboratory on 75mm diameter
cores cut at an age of 24 to 28 days to enable the tests to be carried out
between 28 and 32 days in accordance with BS 1881 Part 122 : 1983, AMD
6108:1989. The upper acceptable limit for absorption after 30 minutes shall
be 2%.
Effective permeability tests in accordance with the method described in BS EN

12390 Part 8: 2009 shall be carried out. The maximum acceptable penetration
at seven days shall be 15 mm and the maximum acceptable penetration at 28
days shall be 10mm.
Initial surface absorption test as per BS 1881: P-208: 1996 shall be carried
out.
Maximum permissible limit for ISAT is 0.2 ml/m2/sec.
In addition to the above, the following specifications shall be satisfied:
1. Initial Surface Absorption Test (ISAT) shall be carried out on prototype

samples of different components of the structure before the mix design or
manufacturing method is approved. The prototype samples shall be short
sections of not less than 1.0m x 1.0m x full thickness. The samples shall
be fully reinforced and cast in similar environment as the actual structure.
The ISAT tests shall be carried out in accordance with BS 1881-208:1996

between 28-40 days after casting the samples and the maximum value

shall not exceed the following limits at 10 minutes after starting the test:
In-situ construction: Less than 0.20 ml/m2/s.
2. In addition to ISAT, the chloride permeability of the concrete shall be

determined using cores taken from the prototype samples cast for ISAT, in
accordance with ASTM C1202: 2009 “Electrical Indication of Concrete’s
Ability to Resist Chloride Ion Penetration”. The following limits shall not be
exceeded.
 In-situ construction: 2000 coulombs
 Underwater construction: 1000 coulombs.
3. The concrete will be deemed to comply with the permeability requirements

of this specification if all test results comply with the following:
a) ISAT results for unprotected surfaces:

Limit given in paragraph 1 above.
b) ISAT results for protected surfaces:
One fifth of the limits for the unprotected surfaces.
c) Rapid Chloride Permeability test results for unprotected
surfaces:
Limit given in paragraph 2 above.
d) Rapid Chloride Permeability test results for protected surfaces:
Charge passed should be less than 500 coulombs.
4. If any of the ISAT and the rapid chloride permeability test result of
unprotected or protected surfaces of a sample failed to meet the above
requirements, then all the concrete work represented by such sample shall
be deemed not to comply with the permeability requirements.
5. If, in the opinion of the Engineer, the concrete which has failed to meet the
permeability requirements of this specification is likely to cause durability
problems, three cores shall be cut from the area represented by failed
samples for additional ISAT and rapid chloride permeability testing. The
actual location shall be decided by the Engineer.
6. The cost of cutting and testing cores and any resultant delay shall be
borne by the Contractor regardless of whether the permeability of the
deposited concrete proves to be satisfactory or not.
7. Where the permeability test results found by testing the three cores taken
from the structure is confirmed as not complying with the permeability
requirements, then the Engineer may instruct that further cores to be cut
and tested in order to determine the full extent of the defective concrete
and further investigations to be carried out.
8. Defective concrete shall be cut out and replaced or alternative remedial

action shall be taken, as the Engineer directs, and the cost of such work
and any resultant delay shall be borne by the Contractor.

4/17.5 OTHER TESTS
When instructed by the Engineer, concrete shall be tested for drying shrinkage
and wetting expansion, for which 75x75mm prisms shall be prepared and
tested in accordance with Test 5 of BS 1881 (1970) Part 5. The maximum
acceptable limits shall be:
Drying Shrinkage : 0.05%

Wetting Expansion : 0.03%
Cubes may be required and trials carried out to determine stripping times for
formwork, the duration of curing and to check testing and sampling errors.
The air content of air-entrained concrete shall be determined (ASTM C231:

2009a) for each batch produced until consistency has been achieved, when
batches may be tested. The maximum value shall not exceed 2%.
Compaction factor, slump, vebe or other workability tests shall be carried out
as required during concreting of permanent works to control workability at the
batching plant at the site of the pour. The degree of workability shall be as for
the trial mixes; permitted tolerances shall be in accordance with BS 5328:
2000.
4/18 CONCRETE DESIGN LIMITS
4/18.1 The following will be designated by the Engineer within the limits of the
Specifications.
a) The minimum Cement content in kg. per cubic metre of concrete.
b) The maximum allowable water/cement ratio including surface moisture,

but excluding water absorbed by the aggregates.
c) Slump or Slumps designated at the point of delivery.

d) Changes requested by the Contractor in mix proportioning previously
approved shall be made only with the agreement of the Engineer.
e) 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 shall be made for the
added cement.
f) Failure of the mixed concrete to meet specifications as determined by

the Engineer will be grounds for the Engineer to reject the concrete.
g) Bleeding limitations when tested in accordance with ASTM C232 : 2007.
4/19 CONSISTENCY OF CONCRETE

4/19.1 The consistency of concrete shall be determined in the field by the Slump
Test. The consistency of concrete at the time of delivery will be designated by
the Engineer and shall not vary by more than 25mm from the designated
consistency.
4/20 TOLERANCES IN PROPORTIONING THE MATERIALS
4/20.1 CEMENT
In the case of bagged cement it shall be measured as packed by the

manufacturer: a sack of cement shall weigh fifty (50) kilograms. Measurement
for proportioning all cement shall be accurate to within two (2) percent
throughout the range of use. Only full bags, undamaged or unbroken will be
permitted.
4/20.2 WATER
The mixing water shall be measured by weight or by volume. In either case

the measurement shall be accurate to within one (1) percent throughout the
range of use.
4/20.3 AGGREGATE
The aggregates shall be measured by weight to an accuracy within two (2)

percent through-out the range of use.
4/21 ASSEMBLY AND HANDLING MATERIALS
ASSEMBLY
4/21.1 Aggregates shall be assembled in such quantities that sufficient material

approved by the Engineer is available to complete any continuous pour
necessary for any element. The batching site shall be of adequate size to
permit the stockpiling of sufficient, unsegregated 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 in
such a manner to ensure that no matter foreign to the concrete or matter
capable of changing the desired proportions is included. In the event two (2)
or more sizes or types of coarse or fine aggregates are used on the same
project, only one (1) size or type of each aggregate may be used on one
continuous concrete pour.
STOCKPILING Of AGGREGATES
4/21.2 All aggregates shall be stockpiled before use in order to prevent segregation
of material, to ensure uniform moisture content and to provide uniform
conditions for proportioning plant control.
4/21.3 The use of equipment or methods of handling aggregates which result in the
degradation and contamination 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.
4/21.4 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 one and one-
half (1.5) metres and if two (2) or more layers are required, each successive
layer shall not be allowed to "cone" down over the next lower layer.
4/21.5 Aggregates shall not be stockpiled against the supports of proportioning

hoppers and weighing devices.
SEGREGATION
4/21.6 Segregated 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 re-
mix aggregate piles when ordered by the Engineer.
TRANSPORTING Of AGGREGATES
4/21.7 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
whilst in transit or being dumped.
CEMENT
4/21.8 Cement shall be stored in a dry weather-proof shed with a raised wooden floor
or in a silo and shall be delivered in quantities sufficient to ensure that there is
no suspension or interruption of the work of concreting at any time. If stored in
sheds, each consignment shall be kept separate and distinct.
4/22 MIXING CONCRETE
4/22.1 The weighing and water-dispensing mechanisms shall be maintained in good

order. Their accuracy shall be maintained within the tolerances described in
BS 1305: 1974 and checked against accurate weights and volumes when
required by the Engineer.
4/22.2 The mass of cement and of aggregate indicated by the mechanism employed
shall be within a tolerance of 2% of the respective mass per batch agreed by
the Engineer. The mass of the fine and coarse aggregates shall be adjusted
to allow for the free water contained in them. The water to be added to the
mix shall be reduced by the quantity of free water contained in the fine and
coarse aggregates, which shall be determined by the Contractor by a method
approved by the Engineer immediately before mixing begins and further as the
Engineer requires.

4/22.3 Unless otherwise agreed by the Engineer, concrete shall be mixed in a batch
type mixer manufactured in accordance with BS 1305: 1974. Where
appropriate the batch capacity, method of loading, mixing time and drum
speed shall conform to the details furnished in accordance with the
requirements of BS 3963: 1974 for the mix which corresponds most closely to
the mix proportions being used. The mixing blades of pan mixers shall be
maintained within the tolerances specified by the manufacturer of the mixer
and the blades shall be replaced when it is no longer possible to maintain the
tolerance by adjustment. The period of mixing, judged from the time that all
the ingredients including water are in the mixing drum shall be as ordered by
the Engineer's representative but shall not be less than 2 minutes or 20
revolutions of the drum whichever is the longer.
All plants shall be equipped with an approved automatic cycling and

monitoring system installed as part of the batching equipment. The system
shall include equipment for accurately proportioning the various components
of the mixture by mass. Admixtures may be measured volumetrically. The
automatic proportioning system shall be capable of consistently delivering
each constituent within the tolerances specified. All records of batches shall
show the batch weights, the batch number, the day, the month, the year and
the time of day to the nearest minute for each batch. This information shall be
imprinted on the record so that each batch may be permanently identified.
The Engineer will be provided with a clear and legible copy of all batch records
for concrete supplied for the project.
4/22.4 Mixers which have been out of use for more than 30 minutes shall be
thoroughly cleaned before any fresh concrete is mixed.
4/22.5 The method of discharge from the mixer shall be such as to cause no
segregation whether partial or otherwise of the concrete materials.
4/22.6 The Contractor shall ensure that the constituent materials of the concrete are
sufficiently cool to prevent the concrete from stiffening in the interval between
its discharge from the mixer and compaction in its final position. Precautions
shall include the shading of aggregate stockpiles and the use of chilled water.
4/23 READY MIXED CONCRETE
4/23.1 Ready mixed concrete as defined in BS 5328, batched off the site, may be
used only with the agreement of the engineer and shall comply with all
requirements of the Contract.
4/23.2 The Concrete shall be carried in purpose-made agitators, operating

continuously, or truck mixers. The concrete shall be compacted and in its final
position within 1 hour of the introduction of cement to the aggregates, unless a
longer time is agreed by the Engineer. The time of such introduction shall be
recorded on the delivery note together with the weight of the constituents of
each mix.
4/23.3 When truck mixed concrete is used, water shall be added under the
supervision, either at the Site or at the central batching plant as agreed by the
Engineer but in no circumstances shall water be added in transit.

4/23.4 Unless otherwise agreed by the Engineer, truck mixer units and their mixing
and discharge performance shall comply with the requirements of BS 4251.
Mixing shall continue for the number and rate of revolutions recommended in
accordance with Item 9 in Appendix B of BS 4251 or, in the absence of the
manufacturer's instructions, mixing shall continue for not less than 100
revolutions at a rate of not less than 7 revolutions per minute.
4/23.5 Pumping concrete through delivery pipes may be permitted but only with the
prior approval of the Engineer.
4/23.6 Re-mixing of concrete which has commenced to set shall not be allowed and
in no case shall such concrete be used in the Works.
4/23.7 Coarse aggregate shall be kept in identified stockpiles from which samples
can be collected and tested as specified.
4/23.8 The concrete supplier is required to certify that the Cl content in the mix being
delivered is within the limits specified in Clause 4/15.5. The Cl and SO3
content shall be checked at frequent intervals.
4/24 TRANSPORT AND PLACING
4/24.1 The method of transport and placing concrete shall be to the approval of the
Engineer. Concrete shall be so transported and placed that contamination,
segregation or loss of the constituent materials does not occur. A backup plant
to be proposed by the contractor to be used in case of emergency,
4/24.2 All formwork and reinforcement shall be clean and free from standing water
immediately before placing concrete.
No concrete work shall be stopped or temporarily discontinued within forty-five

(45) centimeters of the top of any finished surface, unless such work is
finished with a coping having a thickness less than forty-five (45) centimeters
in which case the joint shall be made at the under edge of the coping.
Concrete in simple slab spans shall be placed in one (1) continuous operation
for each span, unless otherwise indicated on the drawings or approved by the
Engineer.
4/24.3 Prior to placing any concrete on natural surfaces a blinding layer of Class 15
concrete shall be laid to a minimum of 75 mm thickness unless otherwise
specified on the drawings. This blinding shall be suitably cured prior to
subsequent concrete placement. The blinding shall be clean and free from
any dust or impurities prior to subsequent concrete placement.
4/24.4 No concrete shall be placed in a foundation until the extent of excavation and
the character of bearing material have been approved and no concrete shall
be placed in any structure until the placement of reinforcing steel and the
adequacy of the forms and falsework have been approved.
4/24.5 Concrete shall not be placed in any part of the Works until the Engineer's
approval has been given. If concrete has not started within 24 hours of such

approval being given, approval shall again be requested. Concreting shall

then proceed continuously over the area between construction joints. Fresh
concrete shall not be placed against in-situ concrete which has been in
position for more than 30 minutes unless a construction joint is formed in
accordance with the Specification. When the concrete has been in place for 4
hours, or less as directed by the Engineer, further concrete shall not be placed
against it for a further 20 hours.
4/24.6 Concrete when deposited shall have a temperature of not more than 32 deg. C
unless otherwise specified. Concrete shall be compacted in its final position
within 30 minutes of discharge from the mixer unless carried in purpose made
agitators operating continuously, when the time shall be within one hour of the
introduction of cement to the mix and within 30 minutes of discharge from the
agitator.
4/24.7 Except where otherwise agreed by the Engineer, concrete shall be deposited
in horizontal layers to a compacted depth not exceeding 400mm where
internal vibrators are used or 300mm in all other cases.
4/24.8 Unless otherwise agreed by the Engineer, concrete shall not be dropped into
place from a height exceeding 2m. When trunking or chutes are used they
shall be kept clean and used in such a way as to avoid segregation. Where
steep slopes are required for placing concrete with chutes, the chutes shall be
equipped with baffle boards or be in short lengths that reverse the direction of
the movement. Chutes and the use of chutes must be approved by the
Engineer. All chutes shall be kept clean and free from coating of hardened
concrete by thoroughly flushing with water after each run. The water used for
flushing shall be discharged clear of the concrete already in place.
4/24.9 No concrete shall be placed in flowing water. Underwater concrete shall be

placed in position by tremies, or by pipeline from the mixer.
4/24.10 Full details of the method proposed shall be submitted in advance to the
Engineer and his approval obtained before placing begins. Where the
concrete is placed by the tremie, its size and method of operation shall be in
accordance with BS 8004. During and after concreting under water, pumping
or dewatering operations in the immediate vicinity shall be suspended until the
Engineer permits them to be continued.
4/24.11 Approved measures shall be taken to avoid premature stiffening of concrete

placed in contact with hot, dry surfaces. Surfaces including reinforcement
against which concrete is to be placed shall be shielded against the direct rays
of the sun and shall be sprayed with water to prevent excessive absorption by
the surfaces of water from the fresh concrete.
4/24.12 A complete record shall be kept of the date, time, temperature and conditions
of placing the concrete in each portion of the work and shall be available for
inspection by the Engineer at any time.
4/24.13 Unless otherwise shown on the drawings all concrete placed below ground
level shall have a minimum protection to its outside faces as follows:

Underside- Protected by the laying of a grade 1000 approved polyethylene

sheeting on the blinding concrete. The sheeting shall be returned up the
outside faces of the concrete and suitably sealed.
Sides- Coated with 3 coats of an approved bitumen rubber latex emulsion

flexible damp and vapour-proof liquid membrane conforming to BRE Digest
No. 54.
4/25 COMPACTION OF CONCRETE
4/25.1 All concrete shall be compacted to produce a dense homogeneous mass.

Unless otherwise agreed by the Engineer, it shall be compacted with the
assistance of vibrators. Sufficient vibrators in serviceable condition shall be on
site so that spare equipment is available in the event of breakdown. A 50mm
diameter internal vibrator shall be deemed capable of compacting 20 Cu.
m./hr. Internal vibrators shall be capable of producing not less than 10,000
cycles per minute.
4/25.2 Vibration shall not be applied by way of the reinforcement. Where immersion
vibrators are used, contact with reinforcement and all inserts shall be avoided.
4/25.3 Concrete shall not be subject to vibration between 4 and 24 hours after
placing.
4/25.4 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 its
position in lieu of placing. The vibration at any point shall be of sufficient
duration to accomplish compaction. After initial set of the concrete, the forms
shall not be jarred and no strain shall be placed on the ends of projecting
reinforcement.
4/25.5 Vibrating is required to be done immediately as the concrete is placed.

Vibrators are required to be inserted and withdrawn vertically and should not
be dragged through the concrete. When concrete is poured in layers, the head
of the vibrator is required to penetrate through the top layer and partially
through the layer underneath to ensure joint between two poured concrete.
4/26 CONSTRUCTION JOINTS
4/26.1 The position and detail of any construction joints not described in the Contract
shall be subject to the approval of the Engineer and shall be so arranged to
minimise the formation of shrinkage cracks.
4/26.2 The timetable for the depositing of concrete between construction joints should
be so arranged that no face of concrete shall be left for more than 20 minutes
before fresh concrete is deposited against it. Pauses for meals, servicing of
machines, changes of shift, etc. and the distribution of concrete among the
positions where work may be proceeding simultaneously must be carefully
organised to ensure that the above mentioned interval shall not be exceeded.

4/26.3 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 shall
declare such joint a cold joint and 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
subsequent concrete work until he deems the Contractor has corrected the
cause for the cold joint occurrence.
4/26.4 Where dowels, reinforcing bars or other adequate ties are not required by the
drawings, keys shall be as 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
painted with a thick coat of neat cement mortar, after which the concreting
may proceed.
4/26.5 Expansion joints shall be constructed at the locations, of the materials and to
the dimensions shown on the drawings.
4/26.6 The upper surface of lifts of concrete walls and columns shall be horizontal
and if the formwork extends above the joint on the exposed face, it shall be
cleaned of adhering concrete before the next lift is placed. The concrete
placed immediately above a horizontal construction joint shall not be the first
batch through the mixer and shall be thoroughly compacted and worked
against the existing concrete.
4/26.7 In the case of vertical surfaces, a 1:1 slurry of cement and concreting sand
shall, wherever possible, be well worked into them immediately before the
fresh concrete is placed.
4/26.8 Where sections of the work are carried out in lifts the reinforcement projecting
above the lift being cast shall be adequately supported to prevent movement
of the bars during the casting and setting of the concrete.
4/26.9 Wherever possible laitance and all loose material shall be removed while the
concrete is still green and no further roughening shall then be required.
Where this is not possible, it shall be removed by mechanical means provided
the concrete has been in position for more than 24 hours. The roughened
surface shall then be washed with clean water.
4/27 CURING OF CONCRETE
4/27.1 Immediately after compaction and for 14 days thereafter, concrete shall be
protected from the harmful effects of weather, including rain and rapid
temperature changes, and from drying out. The methods of protection shall be
subject to the Engineer's approval. The Engineer's approval will be conditional
upon the proposed curing method proving to be satisfactory on site. Only

water curing shall be allowed for bridges and retaining walls which shall be
continuously cured for a minimum of 14 days.
4/27.2 The method of curing used shall minimize the loss of moisture from the
concrete. On concrete surfaces which are to be water-proofed, and for bridge
superstructures including piers, abutments, retaining walls and culverts curing
membranes shall not be used. Details of all curing methods to be used shall
be subject to the approval of the Engineer.
4/27.3 For the bridges retaining walls and culverts exposed and stripped concrete
surfaces shall be kept damp using soaked hessian sheeting. Polythene sheet
covering shall be used where directed by the Engineer to minimize
evaporation. The hessian sheeting shall be maintained continuously damp for
a minimum period of 14 days after casting. The water used for this purpose
shall be of the same quality as that allowed in mixing the concrete.
4/27.4 Whenever approved by the Engineer, membrane curing or wet curing of

concrete with an approved liquid may be used as an alternative to curing with
water except that membrane curing liquid shall not be applied to surfaces of
concrete from which the shuttering has been stuck, until the concrete has
been inspected and approved by the Engineer's representative.
4/27.5 Concrete curing compound shall be of an approved type which shall be readily
distinguishable upon the concrete surface for at least four hours after
application. The color, if any, shall become inconspicuous within seven days
after application.
4/28 EARLY LOADING
4/28.1 Concrete shall at no time be subject to loading, including its own weight, which
will induce a compressive stress in it exceeding 0.25 of its compressive
strength at the time of loading or of the specified 28 day strength whichever is
lower.
4/28.2 For the purpose of this Clause, the assessment, of the strength of the concrete
and the stresses produced by the loads shall be subject to the agreement of
the Engineer.
4/28.3 No superstructure load shall be placed upon finished piers or abutments until
the Engineer so permits, but in no case shall any load of any kind be placed
until the curing has been completed. The Contractor shall not place any
temporary loads on deck slabs. Bridge deck slabs shall be opened to traffic or
construction equipment only when so permitted by the Engineer.
4/29 CONCRETING AT NIGHT
4/29.1 No concrete shall be mixed or placed when the light is insufficient, unless an
adequate and approved artificial lighting system is operated and such night
work is approved by the Engineer.

4/30 CONCRETING IN HOT WEATHER
4/30.1 When the rate of evaporation of surface moisture from concrete is expected to
approach 1 Kg/m2 per hour (estimated from the chart in Figure 4-1a or Figure
4-1b) or when the shade air temperature is 35 deg. C and rising, precautions
shall be taken, including the following:-
a. Dampening the forms.
b. Reducing the concrete temperature to the lowest practical level by

procedures such as:-
i. Shading the aggregate.
ii. Cooling the mixing water before use.
iii. Screening the mixing plant and transporting vehicles from wind,
rain and sun.
c. Erecting wind breaks and sunshades at the concrete placing location.
d. Reducing the time between the placing of the concrete and the start of
curing to the minimum possible.
e. Minimizing evaporation (particularly during the first few hours subsequent

to placing the concrete) by suitable means such as applying moisture by
fog spraying.
Alternatively, the following equation developed by ACI can used to predict

evaporation rates:
2.5 –6
E = (Tc2.5 – rTa )(1 + 0.4V) × 10 (in.-lb units)
E = 5([Tc + 18]2.5 – r[Ta + 18]2.5)(V + 4) × 10–6 (SI units)
where
E = evaporation rate, lb/ft2/h (kg/m2/h);
Tc = concrete temperature, °F (°C);
Ta = air temperature, °F (°C);
r = relative humidity in percent/100; and
V = wind velocity, mph (km/h).
Readily solved using commonly available calculators, the equation provides results nearly
identical to those found using the nomographs in Figure 4-1a or Figure 4-1b.

4/30.2 All precautions to be taken shall be subject to the Engineer's approval and the
Contractor shall demonstrate that all approved precautions are available for
use prior to the Engineer granting approval to any concreting operation.
4/30.3 The temperature of the concrete when placed shall not exceed 32 deg.C nor
shall concrete be mixed or placed when the shade air temperature is 40 deg.C
or above, or is expected to reach such a level during concreting, without
special permission from the Engineer.
To use this chart:-
 Enter the air temperature (c)

move up to relative humidity
(b).
 Move right to concrete
temperature (c).
 Move down to wind
velocity (d).
 Move left read approx.
rate of evaporation (e).
Figure 4-1a: Effect of concrete, air temperature, relative humidity and wind on rate of evaporation of
surface moisture from concrete in SI Units (Source, ACI, 1999)

To use this chart:-
 Enter the air temperature (c)

move up to relative humidity
(b).
 Move right to concrete
temperature (c).
 Move down to wind
velocity (d).
 Move left read approx.
rate of evaporation (e).
Figure 4-1b: Effect of concrete, air temperature, relative humidity and wind on rate of evaporation of
surface moisture from concrete in US Unit, (Source, ACI, 1999)
4/31 MINIMUM TEST REQUIREMENTS FOR CONCRETE
4/31.1 Any one set of 6 cubes for each class of concrete and for each particular
application represent a maximum quantity of concrete as shown in Table 4-10.
The point of sampling of fresh concrete shall be at delivery into the
construction unless otherwise directed by the Engineer. Each set of cubes
shall be made from a separate batch.
4/31.2 Portland Cement: One 2 Kg sample for quality test shall be taken from each
1,700 bags or equivalent weight in accordance with BS EN 196 - 7: 2007.
4/31.3 Water: One 1 - gallon sample shall be obtained prior to use from each source
and at least once every week for quality testing.
Table 4- 10: Sample Rate
TYPE OF STRUCTURE SAMPLING TO REPRESENT

A VOLUME OF M3
1. Critical structures e.g. masts, 10
cantilevers, columns
2. Intermediate structures e.g. beams, 50
slabs, bridge decks
3. Heavy concrete construction e.g. 100
breakwaters, solid rafts

4/32 FORMWORK
CONSTRUCTION
4/32.1 Formwork shall include all temporary or permanent forms required for forming
the concrete, together with all temporary constructions required for their
support.
4/32.2 All formwork shall be of such quality and strength as will ensure rigidity
throughout the placing, ramming, vibration and setting of the concrete without
visible deflection.
4/32.3 All formwork shall be so constructed that there shall be no loss of material
from the concrete. After setting, the concrete shall be in the position and of
the shape and dimensions prescribed. The finished surface of exposed
concrete shall be of a quality specified on the drawings and approved by the
Engineer.

4/32.4 Unless otherwise provided on the drawings or directed by the Engineer, all
exposed edges shall be beveled by using dressed, mill-cut, triangular molding,
having twenty (20) millimeters sides.
All curved surfaces shall be formed with approved plywood or steel.
The Contractor shall in all cases request the approval of the formwork by the
Engineer's representative in sufficient time to allow an inspection to be made
and shall not commence concreting until such approval is obtained. The
period between the Contractor's request for approval and his intention to
commence concreting shall be not less than one clear normal working day and
the Engineer's representative may require a longer period if, in his opinion, the
formwork is of such complexity as to require it.
Such approval shall not absolve the Contractor of his responsibilities under the
Contract.
4/32.5 Where internal metal ties are permitted, they or their removable parts shall be
extracted without damage to the concrete and the remaining holes filled with
mortar. No permanently embedded metal part shall have less than 40 mm
cover to the finished concrete surface or the specified cover to the
reinforcement whichever is the greater.
4/32.6 The Contractor shall submit to the Engineer for his approval strength and
deflection calculations and drawings of the formwork he proposes to use. The
Contractor shall ensure that adequate time is given to enable the Engineer to
examine the calculations and drawings and also to inspect the formwork
before concrete is placed within it.
FALSEWORK
4/32.7 Detailed drawings for falsework and centering shall be prepared by the
Contractor and submitted to the Engineer for approval. The drawings must be
approved by the Engineer before the work is started.
4/32.8 The Contractor shall submit to the Engineer for approval at least one (1)
month before commencing work, details of his proposed system of falsework,
including detailed drawings and calculations. Falsework shall be capable of
accommodating temperature changes without causing damage to the
concrete.
4/32.9 Falsework and centering shall be designed and constructed to provide the
necessary rigidity to support all loads placed upon it without appreciable
settlement or deformation. Falsework columns shall be supported on wood 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.

4/32.10 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 splices shall be scabbled in a manner approved by the Engineer.
4/32.11 All steel members shall be in good condition, free from damage, kinks,
corrosion or any other defect which might impair their strength.
4/32.12 The Contractor shall compute the form settlement and deflection required for
bridges so that when the final settlement is complete, the structure will
conform to the required camber, section and grade as shown on the drawings.
4/32.13 The Engineer will check and approve the Contractor's computations. Long,
tapered hardwood wedges or screw jacks shall be used in all falsework
construction and shall be so placed that they can be adjusted to give proper
form alignment. The Contractor shall, if required by the Engineer, provide
means for adjusting forms to offset any excessive settlement, if screw jacks
are used, they shall be adequately braced and secured in such a manner that
will prevent tipping of the jacks in any direction.
4/32.14 The Contractor shall provide means for accurately measuring settlement in
falsework during placement of concrete, and shall provide a competent
observer to observe and correct the settlement.
4/32.15 In designing forms and centering, concrete shall be regarded as a liquid. In

computing vertical loads, a weight of twenty four hundred (2,400) kilograms
per cubic meter shall be assumed, and not less than thirteen hundred and
sixty (1,360) kilograms per cubic meter shall be assumed in computing
horizontal pressure.
4/32.16 The Engineer may refuse permission to proceed with other phases of the work
if he deems the falsework unsafe or inadequate to support properly the loads
to which it will be subjected.
4/32.17 The review or approval of falsework drawings by the Engineer or permission to

proceed with the work shall not relieve the Contractor of the responsibility for
successful erection or satisfactory results.
TOLERANCE
4/32.18 The formwork shall be set to such lines and levels as to ensure that the
following tolerances are not exceeded in the structures as cast.
- For all buried concrete. + 25mm - 12mm
In addition, for concrete surfaces

that are to be waterproofed,
abrupt irregularities in the surface
finish shall not exceed 3mm.

- For soffit edge beams and +/- 3mm but not more
sides of parapet plinths than 3mm in 3.5m.
- For all other concrete +/- 6mm but not more than 3mm in
3.5 m.
PREPARATION OF FORMWORK BEFORE CONCRETING
4/32.19 The inside surfaces of forms shall, except for permanent 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. Different release agents shall not be used in formwork to
concrete which will be visible in the finished works. A panel shall be
constructed utilizing the proposed release agent for the Engineer's approval.
The surface of the panel shall not exhibit discoloration or any significant retard
of the surface mortar strength.
4/32.20 Immediately before concreting all forms shall be thoroughly cleaned out. All
formwork shall be inspected and approved by the Engineer before any
concrete is placed in it but such approval shall not relieve the Contractor of his
responsibilities for the safety, accuracy or efficiency of the work.
REMOVAL OF FORMWORK
4/32.21 The Engineer shall be informed in advance when the Contractor intends to
strike any formwork.
4/32.22 At the time of striking any formwork, the concrete shall be of sufficient age and
strength for it to withstand the effects of striking, including the effect of thermal
shock or the loss of surface durability upon premature exposure, and to be
able to withstand the resulting stresses without adverse effects.
4/32.23 The time at which the formwork is struck shall be the Contractor's
responsibility but the minimum periods between completion of placing
concrete in a section of the works and the removal of forms shall be as
follows:-
Sides of beams, walls and columns 2 days

Soffits of beams and slabs (props left in) 7 days
Removal of props (beams and slabs) 14 days
Soffits of precast beams 7 days
4/32.24 Formwork shall be constructed so that the side forms of members can be
removed without disturbing the soffit forms and, if props are to be left in place
when the soffits forms are removed, these props shall not be disturbed during
the striking.
4/32.25 Formwork shall be removed without damage to the concrete.
4/32.26 Where it is intended to re-use formwork it shall be thoroughly cleaned and

made good to the satisfaction of the Engineer.

4/33 CLASSES OF FINISH
FORMED SURFACES
4/33.1 The class of finish of formed surfaces shall be as shown on the drawings.
4/33.2 Class F1: As struck.
4/33.3 Class F2: The irregularities in the finish shall be no greater than those
obtained from the use of wrought thicknessed square edged boards arranged
in a uniform pattern. The finish is intended to be left as struck but
imperfections such as fins and surface discoloration shall, if required, be made
good by methods approved by the Engineer.
4/33.4 Class F3: The formwork shall be lined with a material approved by the
Engineer to provide a smooth finish of uniform texture and appearance. This
material shall leave no stain on the concrete and shall be so joined and fixed
to its backing that it imparts no blemishes. It shall be of the same style and
obtained from only one source throughout.
4/33.5 The Contractor shall make good any imperfections in the finish as required by
the Engineer. Internal ties and embedded metal parts will not be allowed.
4/33.6 Class F4 : The requirements for Class F4 are as for class F3 except that
internal ties and embedded metal parts will be permitted. The ties shall be
positions as described in the Contract or as agreed by the Engineer.
4/33.7 Permanently exposed concrete surfaces to Classes F4, F3 and F2 finish shall
be protected from rust and stains of all kinds.
4/33.8 Unless otherwise described in the Contract, all formwork joints for exposed
surfaces of concrete to Class F2, F3 and F4 finish shall form a regular pattern
with horizontal and vertical lines continuous throughout each structure and all
construction and movement joints shall coincide with these horizontal or
vertical lines.
4/33.9 REMEDIAL TREATMENT OF SURFACES
An inspection of the concrete surface shall be carried out immediately after

removing the formwork, and any remedial treatment to surfaces proposed by
the Contractor shall be submitted to the Engineer for approval and shall be
carried out without delay. Portions of the structure which can not be finished
or properly repaired to the satisfaction of the Engineer shall be removed.
4/33.10 Any concrete, the surface of which has been treated before being inspected by
the Engineer, shall be rejected.
UNFORMED SURFACES
4/33.11 Class U1 Finish. The concrete shall be uniformly leveled and screeded to
produce a plain surface as described in the Contract. No further work shall be
applied to the surface unless it is used as a first stage for a Class U3 finish.

4/33.12 Class U2 Finish. After the concrete has hardened sufficiently to prevent
laitance from being worked to the surface, a Class U1 finish shall be floated by
hand or machine sufficiently to produce a uniform surface free from screed
marks.
4/33.13 Class U3 Finish. When the moisture has disappeared and the concrete has
hardened sufficiently to prevent laitance from being worked to the surface, a
Class U1 finish shall be steel-trowelled under firm pressure to produce a
dense, smooth uniform surface free from trowel marks.
4/33.14 Class U4 Finish. This finish is for bridge decks that are to receive approved
waterproofing systems. The concrete shall be uniformly leveled and screeded
to produce a plain surface. When the concrete has sufficiently hardened 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 + 5 mm over a 3 m gauge length or have any abrupt
irregularities more than 3 mm.
SPECIAL FINISHES
4/33.15 Where special finishes are specified in the drawings or in a particular

specification the Contractor shall make trial panels for the formed finishes
specified for inspection and approval by the Engineer.
4/34 MORTAR
4/34.1 Mortar shall be mixed by approved mechanical mixers. Mortars containing

plasticizers shall not be overmixed. Mixers shall be kept clean at all times.
4/34.2 Mortar shall be used within thirty minutes after mixing. Hardened mortar shall
not be used in the work and shall be removed immediately from the site.
Mortar shall be prepared in the following proportions with the addition of a
minimum quantity of water for workability.
4/34.3 MORTAR (3:1)
Sand/Cement mortar (3:1) shall be composed of one part of cement to three

parts of sand by volume. This type of mortar shall be used in block work
where high strength is required.
4/34.4 MORTAR (4:1)
Sand/Cement with plasticizer mortar (4:1) shall be composed of one part of

cement to four parts of sand with a mixture of an approved plasticizing agent,
added in accordance with the manufacturer's instructions.
4/34.5 The sand used in mortar must be dry when proportioning. Allowance for
bulking shall be made when gauging by volume. The mean compressive
strength at 28 days for each mortar shall conform to BS 5628: Part I.

4/34.6 Sand shall be natural sand or crushed natural stone or a combination of both
as specified in BS 1200: 1976.
4/35 EXTENT OF POURS
4/35.1 The limit of individual pours and the height of lifts shall be as approved. The
sequence of pours shall be arranged to minimize thermal and shrinkage
strains.
4/35.2 For walls, the length of panel placed at one time shall not exceed 6 m,
adjacent panels shall not be placed within 2 days, but shall be placed as soon
as practicable thereafter. Subsequent vertical lifts shall not be poured within 2
days.
4/35.3 Bridge decks, floors, roofs and ground slabs shall be placed in an approved
sequence of panels. 'Chequerboard' placing shall be avoided. Adjacent
panels shall not be placed within 3 days, and then only provided that the
concrete in the first pour has cooled down to below 38 degrees centigrade or
ambient temperature. Placing of adjacent panels shall take place as soon as
practicable after the above criteria have been satisfied. Panels shall be 5 m x
5 m and any pour exceeding 25 m2 will only be considered for approval if
substantiated by calculations.
4/36 POST-TENSIONED CONCRETE WORKS
4/36.1 General
This work includes, but not by way of limitation, supplying and fixing formwork,
falsework and temporary works; supplying, testing and placing prestressing
steel with all accessories, metal ducts and anchors; supplying concrete of the
class as indicated on the Drawings or specified herein and transporting and
placing it in prepared forms; tamping, vibrating, finishing and curing the
concrete; pointing and jointing with cement mortar; post-tensioning
prestressing steel; pressure grouting ducts; all in accordance with the
specifications and Contract Documents. Post-tensioned concrete work shall
be as indicated on the Drawings, as specified herein and/or included in the
Bills of Quantities.
4/36.1.1 Standards and Codes
Standards and codes shall be as specified in Section 4, Concrete Works of

the General Specifications, and the following in their latest edition shall apply
and govern all works related to post tensioned concrete.
ASTM: American Society for Testing and Materials

A416: Uncoated Stress-Relieved Strands
4/36.1.2 Submittals
1. Shop Drawings - Shop drawings shall be submitted to the Engineer for

approval in accordance with Section 4/9 of General Specifications and as

specified herein. All submissions must be thoroughly checked by the
Contractor for numerical and conceptual errors before submitting to the
Engineer for approval.
Supplementing the requirements for shop drawings specified in Section 4/9,

the Contractor shall include with the shop drawings a description of the
equipment to be used and the procedure for constructing post-tensioned
concrete work. The type and size of ducts and method of holding the ducts in
position, tendon sizes, jack clearances and procedures, stressing sequences,
grout connections and vents, anchorage details and bonding and grouting
procedures shall also be indicated.
Any delays in the Engineer granting his approval consequent to incomplete,

late, inadequate or unchecked submissions shall be entirely the Contractor’s
responsibility.
2. Certificates - Certificates from the manufacturers shall be furnished to the

Engineer certifying that the materials and equipment to be provided comply
with the requirements of these specifications.
3. Test Reports - The Contractor shall furnish to the Engineer six (6) copies of
test reports and certificates as specified herein, unless otherwise directed by
the Engineer.
4/36.1.3 Quality Assurance
1. In the event the Contractor proposes to perform the post-tensioned concrete

work with his own forces, the Contractor shall submit all details of his
qualifications as specified herein and as required by the Engineer for approval
by the Engineer of the Contractor to perform the work.
2. In the event the Contractor is unable to provide acceptable and adequate

information of his qualifications to perform this work and is rejected by the
Engineer for the post-tensioned concrete work, the Contractor will be required
by the Engineer/Employer to subcontract such works.
3. The Contractor will be required to submit to the Engineer for review and
approval, the following information regarding his qualifications or those of the
proposed subcontractor:
a) The Contractor shall submit the name and address of the proposed
organization or subcontractor, along with a complete and detailed
description of their qualifications and experience in the performance of
post-tensioned concrete work.
b) The named proposed organization or subcontractor shall submit

evidence acceptable to the Engineer that the organization or
subcontractor is experienced in the field of prestressing systems.
Further, the Contractor or proposed subcontractor shall submit data
acceptable to the Engineer that they have, within the last five years,
performed such construction or work comparable to the post-tensioned
concrete works as specified in these Particular Specifications and
indicated on the Drawings. The Contractor shall confirm this experience

by citing a minimum of two projects comparable to the current projects

which have been successfully accomplished.
c) Approval by the Engineer of the Contractor’s organization or the

subcontractor for the performance of the post-tensioned concrete works
shall not relieve the Contractor of overall responsibility for such work.
d) In the event the Contractor or an approved subcontractor demonstrates

an inability to perform the work as specified in this Section for Post-
Tensioned Concrete Works subsequent to the approval by the
Engineer, the Engineer reserves the right to rescind such approval and
require that the Contractor submit the name of another subcontractor to
perform the work. All re-submittals shall comply with the requirements
specified herein and all Contract Documents.
4/36.1.4 Sampling and Testing
1. Concrete - Concrete sampling, testing and frequency of testing shall be in

accordance with Section 4, Part 1, Concrete Works, and as amended in
Clause 4/17.
2. Prestressing Steel - All reels of prestressing steel shall be accompanied

by an inspection and test certificate furnished by the supplier indicating the
number of reels in the shipment represented by the certificate, modulus of
elasticity, stress/strain curves, tensile strength, relaxation test results and
strand chemical composition.
For each certificate furnished, a sample, as described herein, shall be

furnished to the Engineer for testing purposes.
The Contractor shall make arrangements with the vendor to furnish the
Engineer, samples as selected at random from the lot of reels represented
by each certificate. Samples shall be not less than 1.20m in length.
All samples submitted shall be accompanied by a certification from the

vendor certifying that the samples were taken from and are representative
of, the lot of reels to be furnished.
All of the above samples shall be tested by an approved laboratory well in

advance of the anticipated date of use. The Contractor shall make no
claim for additional compensation if his work is delayed awaiting approval
of the materials testing.
4/36.1.5 Scheduling of Post-Tensioned Concrete Works
The scheduling of all post-tensioned concrete work shall be such that

construction of each individual superstructure unit can be completed within
a 90-day period commencing with the first concrete pour through
completion of the post-tensioning and duct grouting operations unless
otherwise indicated on the Drawings, or directed by the Engineer.
The Contractor shall have sufficient materials on hand prior to

commencing work on any given superstructure unit to ensure completion
of the unit within the specified 90-day period.

4/36.1.6 Materials, Delivery, Storage and Handling
Prestressing steel shall be protected from physical damage and corrosion

at all times from manufacture to grouting or encasing in concrete.
Physically damaged post-tensioning steel will be rejected by the Engineer.
The development of visible rust or other results of corrosion will be cause
for rejection by the Engineer.
Prestressing steel shall be packaged in containers or shipping forms for

the protection of the steel from physical damage and corrosion during
shipping and storage. The manufacturer shall place a corrosion inhibitor,
which prevents rust or other results of corrosion directly to the steel, and in
the package or form, or shall use a corrosion inhibitor carrier type
packaging material. Corrosion inhibitor shall have no deleterious effect on
steel or concrete or bond strength of steel to concrete.
Shipping packages shall be clearly marked with a statement that the

packages contain high-strength post-tensioning steel, and that care is to
be used in handling; and that shows the type, kind and amount of
corrosion inhibitor contained, including the date packaged and safety
instructions for use. Reel identification tags showing all the relevant details
for the reel shall be securely placed both on the inside and outside of the
packaging.
4/36.2 Concrete and Materials
The concrete and other materials to be furnished and included in the

construction of all Post-Tensioned Concrete Works shall be as specified
herein.
4/36.2.1 Post-Tensioning Systems
1. Post-tensioning systems for concrete box girders shall be of internationally

recognized types acceptable to the Engineer, as indicated on the
Drawings, and as specified in these Particular Specifications.
a) All the anchorage devices must be certified and have been tested
according to the acceptance test requirements for highly aggressive
environments as given in AASHTO Division II – Construction Part
10.
b) Strands shall be uncoated, seven wire, high-tensile, cold drawn, low
relaxation complying with ASTM A416, Grade 270.
c) Wire shall be uncoated, stress-relieved, cold drawn, round, high
tensile steel, complying with ASTM A421:2006, and having a
minimum tensile strength of 1,650 x 106 N/m2. Wire shall not be oil
tempered.
d) Anchorage assemblies, jacks, gauges, grout fittings, and other
related equipment and accessories shall be standard with the
system manufacturer and approved by the Engineer.
e) Ducts for bonded post-tensioning strand shall be flexible,
galvanized, interlocked, mortar and grout tight, and fabricated of not

lighter than 28 gauge steel. Ducts shall be at least 6 mm larger than

the nominal diameter of the strand or wire bundles and the cross
sectional area shall be at least twice that of the net steel area. The
ducts shall have grout openings at each end, and shall be vented at
high points of the ducts at piers.
f) Epoxy bonding agent: complying with the national and international
standards and specifications (latest edition).
g) Bituminous protective coating complying with the national and
international standards and specifications (latest edition).
2. Post-tensioning systems of other manufacturers which are comparable

and equal in all respects to the specified systems may be used, provided
the proposed alternative post-tensioning systems have the prior approval
of the Engineer. The Engineer will be the sole judge as to whether or not
any proposed alternative system of post-tensioning is comparable and
equal to the specified systems.
4/36.2.2 Concrete
Concrete for post-tensioned concrete work shall be Class 45/20 (unless

otherwise indicated on the Drawings) specified in Section 4, Concrete
Works, of these General Specifications.
4/36.2.3 Reinforcement Steel
Reinforcement steel shall comply with the requirements of Section 4,

Concrete Works, of these Standard Specifications and where specifically
indicated on the Drawings or directed in the Particular Specifications.
4/36.2.4 Duct Grout Materials
1. Grout admixture shall be a balanced blend of expanding, fluidifying,

and water-reducing agents containing no calcium chloride, nitrates or
other chemicals causing steel corrosion.
2. Portland cement shall be as specified in Section 4 of General

Specifications.
3. Water shall comply with the requirements of Section 4, Concrete

Properties of Grout - Duct grout shall comply with the requirements given
in the relevant sections of the Specifications with regard to the
following:
 fluidity and bleeding in the plastic condition

 volume change when hardening
 strength when hardened
The tests are specified in Section4, Clause 4/36.2.5.
Fluidity - The fluidity of grout during the injection period shall be

sufficiently high for it to be pumped effectively and adequately to fill

the duct without excessive segregation, but sufficiently low to expel

the air and any water in the duct.
When tested by the methods given in Section PS 4/36.2.5 the grout

shall have the values given in Table 4-11.
Table 4- 11: Fluidity Test Requirements
FLUIDITY(S)
30 min. after mixing or at
Test Immediately end of injection period At duct
Method After Mixing (see Note 1) Outlet
Immersion > 30 < 80 > 30
Tube
Cone < 25 < 25 > 10
Note1: Mixing time shall be measured from the point when all the
materials are in the mixer.
Bleeding - The bleeding of the grout shall be sufficiently low to prevent

excessive segregation and settlement of the grout materials, when tested
by one of the methods given below in Section4, Clause
4/36.2.5.
The grout shall not be subject to bleeding in excess of 2% after 3 hours or

4% maximum when measured at 18C in a covered cylinder approximately
100mm diameter with a height of grout of approximately 100mm, and the
water shall be reabsorbed by the grout during the 24 hours after mixing.
Volume Change - The volume change assessed may be either increased

or decreased. When tested in accordance with the methods given in
Section 4, Clause 4/36.2.5 the volume change of the grout shall be within
the range 0% and +3%. For grouts with expanding agents there shall be
no decrease in volume.
Strength - The compressive strength of grout may be assessed using

either of the specimen shapes and sizes given in Table 4-12 and using the
corresponding procedure given in the same table.
In either case the compressive strength shall be not less than the
compressive strength of the surrounding concrete at 7 and 28 days.
Table 4- 12: Compressive Strength Specimens
Specimen Shape Specimen Dimensions (mm) Test Procedure

Prism 40 x 40 x 160 PS 4/36.2.5
Cylinder 100 dia x 80 height PS 4/36.2.5
Batching and Mixing of Grout - The proportions of materials used in the

mix may be selected on the basis of prior documented experience with
similar materials and equipment, and under comparable field conditions

(weather, temperature, etc.) and shall be verified by tests made on the

grout before grouting begins.
The water content shall be the minimum necessary to obtain the required
workability for proper placement and under no circumstances shall the
water/cement ratio exceed 0.44. The water content of any admixtures
shall be taken into account when calculating the water/cement ratio. The
materials shall be batched by weight with an accuracy of +2% for cement
and admixtures and +1% for water.
All materials shall be batched by mass except in the case of water which
may be batched by mass or volume.
Mixing shall be carried out mechanically to obtain a homogeneous and

stable grout with the plastic properties given in the Specification.
Depending upon environmental or material influences (eg. Temperature,

configuration of the tendon and the properties of the cement use), the w/c
ratio shall be kept as low as possible having regards to the required plastic
properties of the grout.
A sufficient amount of material shall be batched to ensure complete

grouting of a duct making due allowance for overflow. The grout shall be
mixed in a machine capable of producing a homogenous grout and after
mixing, keeping the grout in slow continuous agitation, until it is ready to be
pumped into the duct, Water shall be added to the mixer first, followed by
the cement and if agreed by the Engineer, admixtures. The batch
quantities of cement and admixtures may be added as a whole or in part in
sequence until the total quantities are added.
Temperature at Grouting - Records shall be kept of the maximum and

minimum air temperatures and the temperature of the members to be
grouted.
Ambient temperature during grouting shall not be above 35Co.
Grout temperature at duct inlet and outlet shall not be above 32oC during
mixing or pumping. If necessary cold water shall be used for grout mixing
to maintain recommended temperature.
4/36.2.5 The Testing of Grout
The following tests, listed below, shall comply with the requirements of the
following standards:
a) UAE & DMs Standards, if any

b) International Standards “ISO, BS, ASTM, etc.)
1. General Conditions - The grouts shall be tested by competent

personnel experienced in the subject, and in laboratory conditions of
temperature and humidity as follows:
Temperature (20 ± 2) oC

Humidity > 65% R.H.
The grout for the tests shall be made from the materials specified in
and mixed in accordance with the requirements of these Specifications.
The temperature of the freshly mixed grout is to be given in all test reports.
2. Fluidity Test - Immersion Method (BS EN-445:2007)
Principle - The tests consists of measuring the time a plunger

needs to drop through a defined amount of grout in a tube.
Apparatus
a) Calibrated immersion equipment according to Figure 4-2.
b) Wooden measuring rod according to Figure 4-2.
Calibration Procedures - The immersion equipment shall be calibrated
with glycerol (analytical grade) having a density of 1.23 T/M3 at 20oC. The
temperature of the room, immersion equipment and glycerol shall be (20 +
1) oC during the calibration.
The cylinder shall be filled with about 1.9 litres of glycerol up to
approximately 250mm below the rim. After filling the immersion equipment
the glycerol shall be allowed to rest for about 1 hour. The plunger then
shall be immersed to expel any air bubbles from the glycerol, which may
have been introduced during the filling of the cylinder.
After one hour the plunger shall be positioned so that its stop on the tail
rod lies on the spacer placed at the top of the tube. The spacer shall then
be pulled away to allow the plunger to sink to the top of the tube. The
immersion time (the time taken for the plunger to sink) shall be recorded in
seconds to the nearest second.
The calibration shall be repeated at least 3 times.

The mean value of all measured immersion times shall be (34 + 1)s. If the
mean value deviates for this figure, the weight of the plunger shall be
increased where t > 35s or reduced where t < 33s. This is done by varying
the quantity of the lead pellets in the plunger. Repeated calibration
procedures shall be delayed for at least 30 minutes to ensure expulsion of
any air bubbles that may be have been introduced during a preceding
calibration procedure.
Test Procedure
Preparation - The immersion equipment shall be calibrated before it is

used. Calibration of the immersion equipment shall be performed
subsequently once a year and/or after any damage.Directly before the test,
the inside of the tube and the plunger shall be slightly wetted.
Procedure - The cylinder shall be filled with approximately 1.9 liter of grout
up to approximately 260mm below the rim, so that on introduction the
plunger is fully immersed when its stop on the tail rod lies on the spacer
placed at the top of the tube. The spacer should be pulled away to allow
the plunger to sink to the stop on the tube. Thereafter the plunger should
be raised back to its initial position, the spacer inserted and again pulled
away.

Figure 4- 2: Immersion equipment for determining the immersion time

The immersion time shall be measured, i.e. the time it takes for the plunger
to sink to the point where its tail stop touches on top of the tube. The
immersion times of the grout shall be measured immediately after the
mixing process and after a further 30 minutes. For the latter test, unused
grout from the same mix as that used for the former immersion test shall
be used. The grout is to be kept in motion while carrying out all tests.
Each test shall be carried out three times in succession with the same
filling.
Reporting the Results - The result shall be reported as the average of the
immersion times to the nearest second of the second and third immersion,
i.e ignoring the first immersion time.
3. Fluidity Test - Cone Method
Principle - The fluidity of grout, expressed in seconds, is measured by the

time necessary for a stated quantity of grout to pass through the orifice of
the cone, under stated conditions.
Apparatus - The following apparatus is required for the test:
a) Cone - A cone of dimensions shown in Figure 4-3. The cone shall

be robust and manufactured from materials not reactive with any
duct grout materials specified in these Specifications. The volume
of the cone (excluding the cylindrical portions at top and bottom)
shall be 1.7 liters + 10%.
b) Sieving Medium - The sieving medium aperture shall be 1.5mm
and the medium shall be fitted as shown in Figure 4-3.
c) Stopwatch
d) Container of 1 litre capacity.
Test Procedure
Preparation - The cone shall be mounted with its axis vertical and its
largest diameter uppermost. The sieving medium shall be fixed at the
position indicated in Figure 4-3. During the test the cone shall be
prevented from vibrating. The container under the cone outlet. All
surfaces of the cone shall be clean and slightly moistened. Close the
lower cone orifice.
Procedure - Pour 1.5 liters of the grout through the sieving medium into
the cone sufficiently slowly to prevent the build-up of air in the grout in the
cone. Open the lower cone orifice and at the same time, start the
stopwatch. Measure the time taken to the nearest 0.5s to fill the container.
The presence of lumps on the sieving medium shall be reported. Two
tests shall be carried out, the first immediately after the grout is mixed and
the second 30 minutes thereafter or alternatively at the end of the grouting
period.
Reporting of Results - Report the time taken to the nearest 0.5s. Report
also the presence of lumps.

Figure 4- 3: Cone for Fluidity Test
4. Bleeding Tests
Principle - The test consists in measuring the quantity of water remaining

on the surface of the grout which has been allowed to stand protected from
evaporation.
Apparatus - A transparent I00 ml cylinder 25mm in diameter and 250mm

in height graduated in ml. Alternatively a transparent cylinder 50mm in

diameter and 200mm in height graduated in mm.
Procedure
Preparation - Place the cylinder on a surface free from shocks or

vibration. The grout used may be from the same batch as that used for the
fluidity test.
Procedure for 25mm diameter cylinder

Pour 95ml to l00mI of grout into the cylinder. Note the precise level of the
grout (v) ignoring the meniscus. After 3 hours, measure the quantity of
water on top of the grout (vl) taking appropriate measures to prevent
evaporation. The test is carried out on one sample of grout.
Procedure for 50mm diameter cylinder

Pour grout into the cylinder to a height of approximately 150mm. Note the
height to the top of the grout (h) ignoring the meniscus.
After 3 hours, measure the height of water on top of the grout (hl) taking
appropriate measures to prevent evaporation. The test is carried out on
one sample of grout.
Reporting of Results - Bleeding at the end of 3 hours is given by:
vl /v x I00% for 25mm diameter cylinder, and
hl/h x 100% for 50mm diameter cylinder

where
vl is the volume of water on the surface of the grout after 3
hours (in ml)
v is the initial volume of grout (in ml)
hl is the height of water on the surface of the grout after 3
hours (in mm)
h is the initial height of grout (in mm)
The report shall state the temperature at the time of test.
5. Volume Change Test
Principle - Testing shall be in accordance with the FIP (Federation

International de La Precontrainte) Guide for Good Practice Procedures.
The volume change is measured as a percentage of the volume of grout
between the start and the end of the test. The test measures mainly the
volume change caused by segregation or expansion. The grout used in
this test may have been used for the bleeding test (see Test 4).
Cylinder Method
Apparatus - A transparent cylinder 50mm in diameter and 200mm in

height as required for test 4.

Procedure - Place the cylinder on a surface free from shocks and

vibration. Fill it with the grout to a height (h). Twenty four hours after filling
the cylinder measure the height (h2) to determine the change in volume.
Reporting of Results - The volume change at the end of 24 hours is

given by:
(h2 – h)/h x 100%

where
h = is the initial height of grout (in mm)
h2 = is the height of grout after 24 hours (in mm)
Can Method
Apparatus
a) Three cans, 120mm high and approximately 100mm in diameter,
with lids capable of preventing the loss of moisture.
b) Measuring rod or sliding calipers
c) Plates
 Stop plate for placing on the can with a diameter of 120mm
(see Figure 4-4)
 Stop plate for placing on the grout with a diameter of 96mm
(see Figure 4-5)
d) Filling gauge 100mm high
Procedure - Place the cans on a surface free of vibration and heat

radiation and store for 24 hours. Immediately after mixing pour the grout
into each can using the filling gauge, to a depth of 100mm. The
measurement of the distance from the top edge of the can to the top of the
grout is to be taken:
 immediately after the containers are filled and

 24 hours after the containers are filled by one of the following methods:
a) Measurement with the Stop Plate on the Can - immediately after

the cans have been filled with grout, measure the distance
between the surface of the grout and the stop plate on the can in at
least six places with the depth gauge (first measurement). The
marking must coincide with the top edge of the can (reference
point). Then the cans are sealed by covering with the lid weighted
with approximately 300g until the second measurement is carried
out 24 hours after the filling of the cans.
b) Measurement with the Stop Plate on the Grout - Immediately

after filling the cans, put the stop plate (Figure 4-5) on the fresh
grout and measure with the depth gauge the distance between this
plate and the top edge of the can in at least six places (first
measurement). Then the cans are sealed. The second
measurement shall be carried out 24 hours after the filling of the
cans. In the second measurement the distance between the stop

plate and the top edge of the can is measured at the same places
as for the first measurement. After the second measurement the
cans are sealed as before, and used as necessary for the
compression strength tests (6).
Figure 4- 4: Plate on the Can

Figure 4- 5: Plate on the Grout

Reporting of Results - The difference of the average values between first

and second measurement(s) in mm corresponds at I00mm grout level to
the volume change in percent and is reported as the percentage change in
volume. Report the percentage change in volume as the average of the
three containers to the nearest 0.1 %. Report increase of volume as (+)
and decrease
as (-).
6. Compression Strength Test
a) Compression Strength Test - Prism
Principle of the test - The compression strength of grout in this

test (which is an adaptation to grouts of the mechanical tests described in
BS EN 196-1: 2005) is determined on the broken halves of prisms.
Apparatus
i) Mixer for grout in accordance with the requirements of these
Specifications for hatching and mixing of grout.
ii) Air conditioned cabinet at (20 + 1) oC and (95 ± 5) % relative
humidity.
iii) Test machine and the device in accordance with 4.7 and 4.8 of B.S.
EN 196-1: 2005.
iv) Metal molds in accordance with 4.5 of BS EN 196-1: 2005.
v) Metal straight edge in accordance with figure 3 of BS EN 196-1:
2005.
Procedure
Moulding of the Test Specimens - File moulds and accessories shall

be prepared and the specimens made in accordance with BS EN 196-
1, with the exception noted below.
Each mould (fitted with a hopper) shall be filled with the prepared
grout. As an exception to the procedure in B.S. EN 196-1: 2005 and in
view of the liquidity of the grout the test specimens shall not be
subjected to any vibration or shock so as to prevent rapid deterioration
of the grout (loss of grout, drying out, bleeding or sedimentation).
Remove the hopper gently. Immediately strike off the excess grout
with the metal straight edge held almost vertically and moved slowly,
with a transverse sawing motion once in each direction. Smooth the
surface of the specimens using the same straight edge held almost
flat.
Label or mark moulds to identify the specimens.
Curing of Test Specimens - The curing of test specimens shall be
carried out in accordance with BS EN 196- 1: 2005, until they are
tested.

Compression Test - The compression tests shall be carried out in

accordance with BS EN 196- 1: 2005. The compression strength shall
be measured on six test specimens from three prisms broken in
flexure.
Reporting of Results - The report shall provide all the results of the
compression tests, in MPa. The value obtained for each test shall be
the mean of the individual results.
b) Compression Strength Test - Cylinders

Principle - The compressive strength of grout in this test is determined
on the three cylinders used in the volume change test given in Test 5.
Apparatus
i) The cans as described in Test 5.

ii) An air conditioning cabinet as described in Test 6.
iii) A compression test machine as described in BS EN 196-1: 2005
iv) Implements for sawing and grinding test specimens.
Procedure
After measuring the volume change (see 5.) the three cylinders shall
be stored in the air conditioning cabinet at (20 + 1) oC until they are to
be prepared for test. Immediately prior to test the specimens shall be
carefully demolded.
Each specimen is prepared for test by sawing through the cylinder
near the upper surface and then grinding both circular surfaces of the
cylinder until the disc to be loaded in the test has a thickness of 80mm.
Each specimen shall then be placed in the compression test machine

and loaded, at a uniform rate of 0.5 MPa/s, on its ends until the
maximum load (Fc) is reached.
Reporting of Results - The compressive strength Rc is calculated in

MPa from:
Rc = Fc/A
where
Fc = is the failure load,

A = is the cross sectional area and shall be measured on
three specimens, the mean value of which shall be
reported as the compressive strength.

7. Frequency of Testing - The testing of the grout made from certified

or otherwise quality assured materials shall be carried out prior to the
start of grouting operations and at the following minimum of testing in
the course of grouting.
Bleeding: 2 tests per day. One sample is to be taken at

the mixer and one sample at the duct outlet
when the grout there has a satisfactory fluidity
value.
Volume Change: 1 test per day.
Strength: 1 test per 7 days or a minimum of two tests per

grouting operation whichever is greater.
Fluidity: To be tested at outlet and inlet for each duct

during grouting operation.
4/36.2.6 Built-In Materials
The Contractor shall furnish and install all built-in materials and items as
indicated on the Drawings, as specified herein and as directed by the
Engineer.
Built-in materials shall include, but not by way of limitations, all inserts,
hardware or similar items as indicated on the Drawings or specified in the
Particular Specifications.
4/36.3 Construction
The construction of all Post-Tensioned Concrete Works shall be as

specified herein.
4/36.3.1 Post-Tensioned Method Statement
The Contractor shall submit, to the Engineer for review, complete details of
the method, materials and equipment he proposes to use in the
prestressing operations, including any additions or rearrangement of
reinforcement steel from that indicated on the Drawings.
Such details shall outline the method and sequence of stressing and shall
include complete specifications and details of the prestressing steel and
anchoring devices, working stresses, anchoring stresses, type of ducts,
and all other data pertaining to the prestressing operation, including the
proposed arrangement of the prestressing steel in the members, pressure
grouting materials and equipment.
The Contractor shall not cast any member to be prestressed before the
detailed shop drawings are complete and approved by the Engineer.
4/36.3.2 Formwork and Falsework
1. Formwork, shoring, and removal of forms shall be as specified in

Section 4, Concrete Works, of the General Specifications and as

further specified herein.
2. Formwork shall be marine plywood for all superstructure concrete

work. Treated commercial plywood may be used for internal vertical
and inclined web surface. Treatment of plywood shall be by way of 3
coats of polyurethane varnish or similar approved materials
3. The deck slab forms and all related formwork for concrete box girder
construction, including all supporting falsework, shall be designed
and constructed in order to facilitate removal of all formwork
materials from within the cells of the concrete box girders. The deck
forms shall be suspended from the girder stems which shall be
stripped of all forms prior to placing the deck forms. The deck slab
forms shall in no way interfere with the required concrete bond
between the deck slab and the girder stems.
Stay-in-place deck forms will be permitted for the deck slab of

concrete box girder construction, provided they are galvanized steel
or other non-combustible material acceptable to the Engineer which
will not deteriorate in any way. Further, such stay-in-place deck
forms shall not increase the volume of concrete, the depth of the
deck slab or reduce the dimension of concrete coverage over the
reinforcement steel.
The Contractor shall submit samples of the proposed form material

and all details and design for the use of stay-in-place deck forms.
The decision of the Engineer shall be final for acceptance or rejection
of stay-in-place forms.
A 3cm slip joint shall be placed transversely in the deck forming

between each diaphragm to eliminate resistance of the deck forms to
deck shortening during prestressing.
The Contractor shall submit shop drawings and design calculations

for the forms, and falsework to the Engineer for approval prior to
commencing work.
Prior to erecting falsework for the deck superstructure the Contractor

shall confirm by way of testing the bearing capacity and expected
amount of settlement of the supporting ground.
4. Falsework and forms shall be set to provide the structural camber

indicated in the Drawings for long-term deflection, falsework
settlement, and shall comply with the required lines and grades.
5. Where indicated on the Drawings, the Contractor shall include all

formwork required to produce the concrete surface ornamental
pattern on the vertical surface of the box section of the post-
tensioned concrete Works as indicated on the Drawings, as specified
herein and as approved by the Engineer. The marine plywood forms
supporting the bottom slab of the box girder shall be arranged in a
regular brick pattern as approved by the Engineer.

The Contractor shall include in his shop drawing submittal all details
and a full description of all formwork proposed by the Contractor to
produce the concrete surface ornamental pattern. All details and
proposed methods and formwork material shall be subject to
approval by the Engineer.
The construction of all formwork required to produce the concrete

surface ornamental pattern shall comply with the applicable
requirements of Section 4, Concrete Works, of these Standard
Specifications and as specified herein. All formwork shall produce a
smooth, even surface with clean, straight, true and unbroken lines at
the concrete surface ornamental pattern.
4/36.3.3 Placing Post-Tensioning Systems
1. Anchorage devices, ducts, tendons and other appurtenant post-

tensioning equipment and accessories shall be accurately positioned
in the forms and secured in place as indicated on the drawings and
approved shop drawings. Installation of the post-tensioning system
shall be coordinated with the placement of reinforcing steel and
embedded items as specified elsewhere in these Standard
Specifications. Care shall be exercised to keep ducts and tendons
free of form coating compounds and other substances which might
break or reduce the concrete bond.
2. Field measurements of vertical locations of centers of gravity of the

tendons shall not vary by more than 6 mm from the dimensions
indicated on the Drawings.
4/36.3.4 Concrete Box Girders - The sequence for placing concrete for the cast-
in-place, multi-cell, concrete box girders at bridges shall be as follows:
1. First, the bottom slab, the exterior and interior web portions and the
diaphragm portions shall be placed monolithically as indicated on the
Drawings and as specified herein;
2. Second, the roadway or top slab shall be placed.
Vertical construction joints in all portions of the multiple cell box girders
shall be minimized and, where proposed, shall preferably be placed 0.2 of
the span length on either side of supporting pier. Dependent upon the
volume of the concrete, additional vertical construction joints may be used
all subject to the approval of the Engineer.
A concrete pour sequence plan shall be prepared by the Contractor for

each superstructure and submitted to the Engineer for approval prior to
commencing any bridge superstructure work. The pour sequence plan
shall show the locations of all construction joints which shall be bonded
joints as specified herein. Concrete pours within each element shall be
alternated to eliminate shrinkage to the greatest extent possible.
The placing of concrete in each pour shall start at the low point and shall
proceed upgrade, unless otherwise permitted by the Engineer.

4/36.3.5 Mixing and Placing Concrete
1. Concrete work for box girder superstructure construction shall

comply with the applicable provisions of Section 4, Concrete Works,
of these General Specifications and the Particular Specifications,
herewith.
2. Prior to placing concrete, tendon profiles shall be rechecked to

ensure that proper location and concrete cover will be maintained.
Any ducts found to be damaged shall be repaired or replaced as
3. Prior to placing forms for box girder deck slabs, the Contractor shall
demonstrate, to the satisfaction of the Engineer, that either the
prestressing steel is free and unbonded in the duct or, in the event
prestressing steel has not yet been placed, that all ducts are
unobstructed.
4. The Contractor shall exercise care during concrete placement to

prevent concrete from entering anchorage hardware. Concrete shall
be placed in such a manner that tendon alignment and reinforcement
positions are maintained, and concrete shall be vibrated with
particular attention at tendon anchorage locations to ensure optimum
compaction and penetration at these points.
5. Curing of concrete shall be in accordance with Section 4, Concrete

6. The Contractor shall keep a record showing the date and time of
placement of cast-in-place, post-tensioned concrete in each portion
of the structure. This record shall be available for examination at all
times by the Engineer. Upon completion of construction of each
structure, two copies of such records shall be submitted to the
Engineer.
4/36.3.6 Stressing Operations
1. Post-tensioning of cast-in-place concrete shall be performed as soon

as the last placed concrete has attained a cube compressive
strength of 36 Newtons per square millimeter, or as specified on the
Drawings, or more based on the results of two cube tests.
2. The Contractor shall provide, at no additional cost to the Client, a

Team of one Engineer and two Technicians who are skilled in the
post-tensioning method to give such aid and instruction in the use of
the prestressing equipment and installation of the prestressing steel
as may be necessary to obtain the specified results.
3. Prestressing tendons in continuous span post-tensioned structures

shall be tensioned by jacking at each end of the tendon or at one end
of tendons as indicated on the Drawings. Prestressing tendons in
single span post-tensioned structures may be tensioned by jacking

from one end only as directed by the Engineer.
4. All post-tensioning shall be by means of hydraulic jacks equipped

with accurate reading calibrated hydraulic pressure gauges to permit
the stress in the prestressing steel to be computed at any time. A
certified calibration curve shall be furnished with each jacking system
and independently calibrated master gauge shall be provided on site.
In the event inconsistencies occur between the measured elongation
and the jack gauge reading, the jack gauge shall immediately be
recalibrated. In the event still further discrepancies occur, the cause
shall be determined and reported to the Engineer. An agreement
within five percent shall be satisfactory.
5. The Drawings indicate jacking locations of the tendons. Proper

allowance shall be made for friction losses and one tendon from
each bridge or each of tendons with similar configuration shall be
checked for friction loss at the very start of the post-tensioning.
a) In case the friction losses in tests exceed the computed losses,

all wires shall be relieved and lubricated with water-soluble oil
and retensioned.
b) Each tendon shall be stressed until either the required

elongation or the maximum force is reached. Elongation is the
preferred method of stress determination wherever possible.
The tendons shall be tensioned by jacking to the total forces
indicated on the Drawings.
6. The post-tensioned prestressing steel shall be anchored at an “initial

stress” that will result in the ultimate retention of working forces or
stresses of not less than those indicated on the drawings, but in no
case shall the prestressing steel be tensioned above 80 percent of
the ultimate tensile strength of the wire or strands.
7. Prior to post-tensioning any member, the Contractor shall

demonstrate to the satisfaction of the Engineer that the prestressing
steel is free and unbonded in the duct.
8. The Contractor shall keep records of the elongation and tension

applied to each tendon, and this record shall be submitted to the
Engineer promptly upon the completion of stressing of each member.
At the time of stressing the first member, the stresses in the individual
tendons shall be checked to establish a procedure for ensuring uniform
results. At any later time, a recheck may be ordered by the Engineer if
it appears that the design stresses are not being obtained. The
Contractor shall have written permission from the Engineer before
capping any prestressing anchorage.
9. The effective prestress force “Pf” indicated on the Drawings represents

the force required after all losses of prestress have occurred. The
prestress losses due to creep and shrinkage of concrete, relaxation of
prestressing steel and elastic shortening are assumed to be 227N per
sq. mm, and friction is accounted for using wobble and curvature

coefficients of k = 0.0017 per meter and  = 0.20. Losses due to an

anchor set of 6 mm have been added in case a grip type anchorage is
used.
4/36.3.7 Grouting of Tendons
1. General - After the tensioning of all tendons has been completed

and the total retained stress is equal to or exceeds that indicated on
the Drawings, for each member, and the steel strands or wires have
been anchored, the annular space between the conduit and the
tendons shall be grouted.
2. Grouting - Tendons shall be grouted within 7 days after tensioning

but not before 8 to 12 hours after tensioning. The tendons shall be
protected against corrosion by a plug at each end to prevent the
passage of air, and such plugs shall be left in place until the tendon
is grouted.
3. Grout Mixture - The grouting mixer and pump shall be in top

mechanical condition and of such size and capacity to ensure
continuous grouting of the largest tendon until it is completed and
shall be capable of grouting to a pressure of at least
1.07N per sq. mm. The Contractor shall submit his mix design as per
the requirements of PS 4/16 and the recommendation of the
admixture manufacturer for the approval of the Engineer.
4. Equipment - The grouting equipment shall include a mixer capable

of continuous mechanical colloidal mixing which will produce a grout
free of lumps and undispersed cement. The equipment shall be able
to pump the mixed grout in a manner which will comply with all
provisions of these Standard Specifications. Accessory equipment
which will provide for accurate solid and liquid measures shall be
provided to batch all materials such as flow meter or similar approved
method.
The pump shall be a positive displacement type and be able to

produce an outlet pressure of at least 10.5kg per sq. cm. The pump
shall have seals adequate to prevent introduction of oil, air or other
foreign substance into the grout, and to prevent loss of grout or
water.
a) A pressure gauge having full scale reading of no greater than

2.15N per sq. mm shall be placed at some point in the grout
line between the pump outlet and the duct inlet.
b) The grouting equipment shall contain a screen having clear

openings of 3.2 mm maximum size to screen the grout prior to
its introduction into the grout pump. If a grout with a thixotropic
additive is used, a screen opening of 4.8 mm is satisfactory.
This screen shall be easily accessible for inspection and
cleaning.
c) The grouting equipment shall utilize gravity feed to the pump

inlet from a hopper attached to and directly over it. The hopper
shall be kept at least partially full of grout at all times during the
pumping operation to prevent air from being drawn into the
post-tensioning duct.
d) Under normal conditions, the grouting equipment shall be

capable of continuously grouting the largest tendon on the
project in no more than 20 minutes.
e) The Contractor shall furnish and maintain back-up equipment

and such additional equipment to ensure continuous,
uninterrupted grouting of all tendons. Such back-up equipment
shall be equal to the main grouting equipment and shall be
prepared and ready to operate at the start of any grouting
operations. The Contractor shall submit a description of all
grouting equipment including back-up equipment for approval
by the Engineer prior to commencing work specified in this
Section of these Particular Specifications.
5. Mixing of Grout - Water shall be added to the mixer first, followed by

Portland cement and admixture, unless otherwise required by the
admixture manufacturer.
a) Mixing shall be of such duration as to obtain a uniform

thoroughly blended grout, without excessive temperature
increase or loss of expansive properties of the admixture. The
grout shall be continuously agitated until it is pumped.
b) Water shall not be added to increase grout flowability which has

been decreased by delayed use of the grout.
c) Proportions of materials shall be based on tests made on the

grout before grouting is begun, or may be selected based on
prior documented experience with similar materials and
equipment and under comparable field conditions (weather,
temperature, and similar factors). The water content shall be
the minimum necessary for proper placement.
6. Grouting - Flushing of metal ducts shall be optional. Water used for

flushing ducts may contain slaked lime (calcium hydroxide) or quick-
lime (calcium oxide) in the amount of 12gm per liter.
7. Injection of Grout - All grout and high point vent openings shall be
open when grouting starts. Grout shall be allowed to flow from the
first vent after the inlet pipe until any residual flushing water or
entrapped air has been removed, at which time the vent shall be
capped or otherwise closed. Remaining vents shall be closed in
sequence in the same manner.
a) The pumping pressure at the tendon inlet shall not exceed 1.8N
per sq. mm.
b) If the actual grouting pressure exceeds the maximum

recommended pumping pressure, grout may be injected at any

vent which has been or is ready to be capped, as long as a
one-way flow of grout is maintained. If this procedure is used,
then the vent which is to be used for injection shall be fitted with
a positive shutoff.
c) When one-way flow of grout cannot be maintained as outlined

in the above paragraph, the grout shall be immediately flushed
out of the duct with water.
d) Grout temperature shall be pumped through the duct and

continuously wasted at the outlet pipe until no visible slugs of
water or air are ejected and the efflux time of the ejected grout
shall not be less than the injected grout. To ensure that the
tendon remains filled with grout, the outlet and/or inlet shall be
closed. Plugs, caps or valves thus required shall not be
removed or opened until the grout has set.
e) Grout temperature at duct inlet and outlet shall not be above

32°C during mixing or pumping. If necessary, the mixing water
shall be cooled. Grouting shall not proceed when shade
temperature exceeds 35Co.
f) Grouted tendons or girders shall not be disturbed for 48 hours

after grouting and grouting test results shall be satisfactory as
per manufacturer recommendations before any further step.
4/36.3.8 Protection of End Anchorages
1. As soon as possible after tensioning and grouting is completed,

clean exposed end anchorages, wires and other metal accessories
of rust, displaced mortar, grout and other such materials, then apply
to all such dry metal surfaces a heavy, unbroken coating of epoxy
bonding agent.
2. Install tight-fitting forms and hold in place securely against the

previously placed concrete.
3. After applying epoxy bonding agent, apply a patching mortar

prepared by mixing one part type V, Portland cement to three parts
of clean sand (ASTM C33: 2007) measured by volume, and sufficient
water to provide a stiff but workable consistency. Apply the patching
mortar, and manipulate, finish and cure as specified in Section 4,
Concrete Works. After mortar patches have cured, apply two heavy
brush coats of bituminous protective coating material, applied as
recommended by the manufacturer, including the recommended
thickness.
4/36.3.10 Access Doors
Access doors shall be installed in post-tensioned box girders as located

and as detailed on the Drawings.

All access doors shall be fabricated of steel shapes, plates and

accessories complying with Section 5/45 - Metal Works and Drawings. All
steel shall be galvanized. Access or cover shall be made of GRP to be
mounted to steel frame.
The furnishing and installing of access doors as indicated on the Drawings

and specified herein will not be measured or paid for separately but shall
be considered a subsidiary obligation to and included in the various
concrete Items of work included in the Bills of Quantities.
4/36.3.11 Vent Pipes
The Contractor shall include the unplasticized polyvinylchloride (PVC) vent

pipes in the cells of the concrete box girders as indicated on the Drawings.
The vent pipes shall be of the size as indicated on the approved shop
Drawings and shall be PVC extruded from one hundred percent virgin
materials. The pipe material shall be new and homogeneous throughout
and free from visible cracks, holes, foreign materials, blisters, wrinkles and
dents.
All vent pipes shall be anchored in an approved manner so as to prevent

displacement or movement during the placement of concrete. No
separate payment for vent pipes will be made by the Client.
4/36.3.12 Opening Bridges to Traffic
No equipment or vehicular traffic will be allowed on any bridge

superstructure until the post-tensioning and grouting operation is
completed, falsework has been removed, and all concrete has been cured
for the time required in these Particular Specifications, or as further

1 SECTION 5 ANCILLARY WORKS
TABLE OF CONTENTS
5/1 PAVING DESCRIPTION .............................................................................................. 2

5/2 PAVING BLOCKS ........................................................................................................ 2
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS ................................................ 2
5/4 BLOCK LAYING REQUIREMENTS ............................................................................. 2
5/5 KERBS DESCRIPTION ............................................................................................... 3
5/6 MATERIALS AND MANUFACTURE OF KERBS ......................................................... 4
5/7 KERB LAYING ............................................................................................................. 4
5/8 PAVEMENT MARKING DESCRIPTION ...................................................................... 5
5/9 MATERIALS FOR PAVEMENT MARKINGS ............................................................... 6
5/10 APPLICATION OF THERMOPLASTIC ........................................................................ 7
5/11 PERFORMANCE REQUIREMENTS AND TESTING .................................................. 8
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS.................... 8
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..) ................................ 8
5/14 ROAD SIGNS, DESCRIPTION .................................................................................... 9
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS ..................................................... 9
5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS .......................................... 9
5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR ................................................. 9
5/18 PAVEMENT REPAIRS ............................................................................................... 10
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS ........................................ 10
5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS ................... 12
5/21 METAL BEAM GUARD RAIL SAFETY FENCING ..................................................... 12
5/22 HEAVY DUTY CAT'S EYES (REFLECTIVE STUDS) ................................................ 13
5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS .................................................. 13
5/24 REFLECTIVE STUDS MINIMUM MECHANICAL ...................................................... 13
5/25 REFLECTIVITY .......................................................................................................... 13
5/26 INSTALLATION OF REFLECTIVE STUDS ............................................................... 13
5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION ...................................... 14
5/28 MATERIALS FOR STONE PITCHING ....................................................................... 14
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING ................................ 14
5/30 GABIONS ................................................................................................................... 15
5/31 CHAIN LINK FENCING .............................................................................................. 16
5/32 STEEL AND METAL WORK ...................................................................................... 17
5/33 ALUMINIUM FOR PARAPETS .................................................................................. 17
5/34 FASTENINGS FOR ALUMINIUM PARAPETS .......................................................... 17
5/35 PAINT AND OTHER PROTECTIVE COATINGS ....................................................... 17
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES ......................................... 18
5/37 RUBBERISED BITUMEN EMULSION ....................................................................... 21
5/38 WATERSTOPS .......................................................................................................... 21
5/39 PREFORMED JOINT FILLERS ................................................................................. 21
5/40 COLD APPLIED JOINT SEALANT ............................................................................ 22
5/41 BRIDGE DECK EXPANSION JOINT ......................................................................... 22
5/42 LOCKABLE MEDIAN BOLLARD ............................................................................... 23
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED CONCRETE
SURFACES .......................................................................................................................... 23
5/44 BRIDGE BEARINGS .................................................................................................. 25

5/1 PAVING DESCRIPTION
5/1.1 This work shall consist of covering certain areas (footpaths, parking areas, etc.)
with paving blocks in accordance with the Specifications, the Drawings and the
Engineer's instructions.
5/2 PAVING BLOCKS
5/2.1 Paving blocks shall be concrete blocks, colored where specified, laid on a sand
laying course. Their thickness shall be 6 cm on sidewalks and 8 cm on parking
areas unless otherwise shown on the Drawings or instructed by the Engineer.
5/3 OVERALL REQUIREMENTS FOR PAVING BLOCKS
5/3.1 The materials, dimensions and tolerances, test for compressive strength, test for
water absorption and certificate of compliance for paving blocks shall conform to
the BS EN 1338: 2003. Water absorption and abrasion resistance shall be carried
out in accordance with the requirements of the particular specification.
5/4 BLOCK LAYING REQUIREMENTS
LAYING COURSE
5/4.1 The laying course shall consist of sharp black sand containing not more than 3%
material finer than 75 micron by weight and not more than 10% retained on 4 mm
sieve. The sand shall be obtained from a single source, allowed to drain before
use and shall be covered with suitable sheeting to minimize moisture changes.
(Permissible sulphate (as SO3) and chloride (as CL) shall not exceed 0.3% and
0.5% respectively) (Expressed as a percentage by weight) when tested to BS EN
1744-1: 1998: and BS 812 Part 117: 1988 Appendix C respectively.
5/4.2 The profile of the laying course before compaction shall be similar to that of the
finished surface. During laying, the sand shall be uniform in moisture content and
shall be carefully, screened to form a smooth compacted surface to receive the
paving blocks. The maximum deviation from the design levels shall be +5 mm.
5/4.3 The edge restraints to the paved area shall be laid in advance of the laying
course and all permanent obstacles within the area, such as manhole covers,
shall be adjusted to the correct finished levels.
SURFACE COURSE
5/4.4 The paving blocks shall be laid on the sand laying course in such manner as not
to disturb the blocks already laid. Each block shall be placed firmly against its
neighbour so that they fit closely together. The joints between blocks shall not
exceed 3 mm. Laying of the paving blocks shall commence at right angles to the
main pavement axis starting at one end of the area. The paving blocks shall be
laid in a herringbone pattern unless otherwise shown on the drawings or
instructed by the Engineer at 45o to the main pavement axis.

5/4.5 Where blocks do not fit the edge restraints or other obstructions such as
manholes the gaps shall be filled using cut blocks.
5/4.6 Blocks shall be cut using only a mechanical block splitter.
5/4.7 Dimensional accuracy, uniformity of joint gaps, alignment and squareness shall
be checked after laying the first three rows of blocks and thereafter at regular
intervals. If joints begin to open the blocks shall be knocked together using a
hide mallet.
5/4.8 After each 20 sq.m. or such area that has been agreed with the Engineer, has
been laid the blocks shall be compacted to the required levels using a plate
vibrator.
5/4.9 The plate vibrator shall have a plate area of 0.20 to 0.35 sq.m. and have a
compaction force of 12-24 Kn and a frequency of approximately 75 to 100 Hz.
5/4.10 A minimum of two passes of the plate vibrator shall be made in each direction,
i.e. at 90 degrees to each other. Vibration shall continue until no further
compaction of the sand layer is apparent. The laying course shall have a
compacted thickness of 50 mm. Fine dry sand with a particle size of 0.3mm shall
then be brushed over the paving, and further passes of the plate vibrator made in
each direction, until the sand is no longer absorbed into the joints.
5/4.11 The plate vibrator shall not pass closer than 1 m to a temporarily unrestrained
edge during laying.
5/4.12 No paving shall be left uncompacted overnight except for the 1 m strip at the
temporarily unrestrained edge.
5/4.13 On completion, the finished surface level, shall be within 5 mm of the design level
and the maximum deviation within the compacted surface, measured by a 3 m
straight edge shall not exceed 3 mm. The level of any two adjacent blocks shall
not differ by more than 1 mm. Any areas of paving which do not comply with
these tolerances shall be removed, the sand laying course adjusted and the
paving blocks relaid to the correct levels.
5/5 KERBS DESCRIPTION
5/5.1 This work shall consist of the construction of kerbs in accordance with the
Specifications and in conformity with the lines, grades and typical sections shown
on the Drawings or established by the Engineer. These Specifications refer to the
following types of precast kerbs to be constructed: Non-Mountable Kerbs,
Dropped Kerb, Heel Kerb, Quadrants and Flush Kerb.
All Kerbs and edgings shall be hydraulically pressed and shall comply with the
requirements of BS 7263: 2001 Part 1. They shall be uniform in color, free from
cracks, flaws or other defects and they shall have well defined arises.

5/6 MATERIALS AND MANUFACTURE OF KERBS
5/6.1 Materials shall conform to the requirements specified in Part 4 "Concrete" of the
Specifications and as specified herein.
5/6.2 Kerbs shall be prepared with a concrete mixture containing not less than 400
Kg/m3 of Sulphates Resisting Portland Cement. The aggregate shall meet the
requirements of the General Specifications for concrete work.
5/6.3 Sampling shall be done as per BS 7263: 2001: Part 1: latest edition.
5/6.4 Non-Mountable Kerb, Dropped Kerb, Flush Kerb and Heel Kerb elements shall
only be precast from concrete produced in a fully automatic batching plant.
5/6.5 The Consultant shall collect samples as per standard sampling method and
submit them for testing. All results shall pass before commencing this work.
5/6.6 Elements shall be manufactured to the dimensions shown on the Drawings.
5/6.7 Non-Mountable and Dropped Precast Kerbs shall be formed by elements 900 mm
long where required to be laid in straight lines but may be reduced to 250 mm
long or curved kerbs shall be used where required to be laid to curves depending
on the radii of the curves.
5/6.8 The finished product shall be of solid appearance with clean planar faces, be free
of segregation, honeycombing, pits, broken corners or other defects and there
shall be no evidence of external rendering.
5/6.9 Bull noses and curved faces shall be of constant radius with a smooth change
from radius to plain face.
5/6.10 Tolerances of manufacture shall be three (3) millimeters in any one dimension
and end faces shall be truly perpendicular to the base.
5/6.11 Transverse strength and water absorption requirements shall be in accordance

with BS 7263: 2001: Part 1 or BS EN 1339:2003, AMD 16467:2006.
5/7 KERB LAYING
5/7.1 Elements shall be set to the lines and grades shown on the Drawings. Under no
circumstances will it be permitted for levels to be set by direct measurement from
pavement layers.
5/7.2 Unless otherwise indicated, elements shall be laid either directly onto a wet
concrete base or on to a sand/cement (3:1) mortar bedding, two and half (2.5)
centimeters thick, on a previously laid concrete base on approved subgrade. The
dimensions of the base shall be as shown on the Drawings. The concrete base
shall be constructed of Concrete Class 25/20.
5/7.3 Unless otherwise indicated, after kerbs units have been laid a contiguous backing
of Concrete Class 25/20 shall be poured for the elements using steel forms.

5/7.4 No pavement layers shall be laid against kerbing until such time as the backing is
complete, back filled and approved by the Engineer.
5/7.5 Joints between radius kerbs, shall have a clear width of four (4) millimeters and
be filled with a sand/cement (3:1) mortar with one fifth (1/5) part hydrated lime
and sufficient water to make the mixture plastic and easily smoothed. A grooving
tool shall be used to produce a smooth, circular section groove not more than
three (3) millimeters deep in all joints. Grouted joints shall be cured by an
approved method to the Engineer's satisfaction. Joints between straight kerbs
shall not be filled.
5/7.6 Immediately after any concrete is in place and for 7 days thereafter the kerbs,
base backing and mortared joints shall be fully cured and protected from drying
out and against the harmful effects of weather, including rain and rapid
temperature changes. The method of protection shall be subject to the Engineer's
approval. The use of colored curing membranes will not be permitted. Concrete
not properly cured and protected will be rejected and shall be removed from the
works.
5/7.7 At each 9 meters or as directed by the Engineer or shown on the Drawings, the
joint between kerbs shall be filled with an approved joint filler 10 mm thick to form
an expansion joint. The filler shall extend through the kerb, bed, backing and
channel, and shall be trimmed to the finished shape of the kerb and channel.
5/7.8 At access points the kerbs, including the bed backing, shall be dropped to show a
face of 75 mm or as otherwise shown on the Drawings.
5/7.9 At the end of any kerb run, the end kerb section shall be sloped down to ground
level, if applicable, and angled away from the road at 30 degrees.
5/7.10 All kerbs shall be thoroughly cleaned of all extraneous material prior to approval.
5/7.11 Kerbs shall be laid within a tolerance of plus or minus three (3) millimeters, at
each end of an element, to the lines and grades given on the Drawings.
5/7.12 All kerbs shall be painted unless otherwise directed by the Engineer. (Refer to Sub-
section 5/13 of paint).
5/7.13 Any excavated surface for the concrete bedding shall be watered and compacted
to a minimum of 95% maximum Dry Density (BS 1377 Part 9: 1990 Method 2.2,
AMD 17229: 2007).
5/8 PAVEMENT MARKING DESCRIPTION
5/8.1 This work shall consist of supplying thermoplastic road marking material for
marking of the pavement as outlined herein. It shall include the marking of the
centerline, the shoulder strip or edge, the barrier lines, the cross walks and any
other markings required on the pavement for the control and direction of the
traffic. Refer to the Roads and Transport Authority (RTA) “Dubai Traffic Control
Devices Manual”.

5/8.2 The pavement markings shall be painted on the road to the dimensions and in
the location as shown on the Drawings or as directed by the Engineer.
5/8.3 The Contractor shall set out the markings and obtain the Engineer's approval
before commencing the work.
5/9 MATERIALS FOR PAVEMENT MARKINGS
5/9.1 The materials used shall conform to the B.S. (British Standard) specification for
Road Marking Materials (Superimposed type) BS EN 1824:1998, (part I) & where
modified in this Specification. Glass Beads shall be in accordance with BS EN
1423:1998.
5/9.2 The road marking material shall consist of light colored aggregate, pigment &
extender, bound together with hard wearing resins, plasticized with oil as
necessary.
5/9.3 The grading of various ingredients shall be such that the final product, when in a
molten state, can be sprayed on the surface in accordance with BS 3262 Part
3:1989.
5/9.4 The aggregate shall consist of light colored silica sand, calcite, calcined flint or
quartz, in accordance with paragraph 3 of BS 3262 (Part I).
5/9.5 Glass Beads incorporated in the mixture shall be minimum 70% of spherical &
free from flaws and not less than 80 percent shall be transparent glass. The
grading of the Glass Beads shall be as stated in BS 6088. (Class A).
5/9.6 The pigment material shall be titanium dioxide (in accordance with clause 4 of BS
3262 (Part I), and shall not be less than 10% by weight of the mix for white
pigment.
The lead chromate content of the road marking material shall not exceed 5% by
mass. A suitable yellow pigment should be substituted for all or part of the
titanium dioxide where yellow pigment material specified.
5/9.7 The extender shall be whiting powder added to assist the dispersion the pigment
and impart body to the mixture (in accordance with paragraph 2.3 of BS 3262
Part 1).
5/9.8 The binder shall not contain more than 5 percent of resin or other acidic material,
it shall consist mainly of hydrocarbon resins plasticized with mineral oil.
5/9.9 The viscosity of the melted binder at the spraying temperature must be such as to
produce a thermoplastic mix of the required spraying properties.
5/9.10 The composition and proportion of constituents of the laid material as found on
analysis shall comply with the requirements of Table 5-1 of BS 3262 (Part 1),
reproduced below:

Table 5- 1: The composition and proportion of constituents of the pavement marking

material
Constituents Percent by Mass of Total Mixture

Minimum Maximum
Binder (resin & oil) 18 22
Aggregate, pigment, Extender & Glass 78 82
Beads
Solid Glass Beads 20 -
5/9.11 The grading of the combined aggregate, pigment, extender and where specified
Solid glass beads sampled in accordance with BS EN 1824:1998 shall be as
follows:
a. 100% by mass passes a 2.8mm BS 410 test sieve

b. 65% to 95% by mass passes a 0.600mm BS 410 test sieve.
5/9.12 Capacity of each container shall be not less than 20Kg or not more than 110Kg.
5/9.13 Each container shall be clearly marked with the manufacturer’s name, batch
number and date of manufacture. (Refer to BS EN 1824:1998).
5/9.14 Container shall be made of a material, which does not contaminate the contents
and will protect the contents from contamination.
5/10 APPLICATION OF THERMOPLASTIC
5/10.1 Application shall be by mobile sprayer, either hand propelled or self-propelled.
5/10.2 The road surface shall be dry, and free from loose, detritus, mud, or other
extraneous matter. Where old paint or thermoplastic materials are present, the
manufacturer shall be consulted as to whether or not the surface is suitable.
5/10.3 A tack coat should not be necessary when the thermoplastic is applied to
carriageways. Where it is considered necessary to use a tack coat, this shall be
rubberized type recommended by the manufacturer of the thermoplastic material.
5/10.4 In addition to the glass beads included in the mix, and additional quantity of glass
beads (Class B) shall be sprayed on the thermoplastic line at the time of
application. The rate of application shall be at the rate of about 0.5 Kg/m2.
5/10.5 The thermoplastic material shall be applied in intermittent or continuous lines of

thickness 1.2 ± 0.3mm. For special lettering, arrows or symbols the material shall
be applied by hand methods. The finished lines shall be free from raggedness at
all edges and be true in place with the road surface. The upper surface shall be
level, uniform and free from streaks, blisters, lumps and other defects.
5/10.6 Application of thermoplastic material to new pavement construction should be

preceded by wire brushing to remove bitumen rich surface mortar. Sufficient

compatible mineral oil plasticizer should be incorporated in the thermoplastic

material to reduce levels of early shrinkage in the material and subsequent
cracking of the asphaltic pavement structure.
5/11 PERFORMANCE REQUIREMENTS AND TESTING
5/11.1 The thermoplastic material shall meet the following performance requirements
(Table 5-2):
Table 5- 2: Thermoplastic material performance requirements

THERMOPLASTIC MATERIAL
Property Minimum Maximum
Relative Density BS 3262 : P3:1989, 1.85 (Note1) -

tested at 250o C.
Softening Point BS EN1427:07,BS 2000:07, Part 58 95
Luminance BS EN (White as delivered) 70
1824:1998
(White as re-melted) 65
(Yellow as delivered) 50 -
(Yellow as re-melted) 45 -
Heat Stability (White) 65 -
(BS EN 1824:1998) (Yellow) 45 -
Flow Resistance after 48 hours - 25
BS EN 1824:1998
Skid Resistance BS EN 1824:1998 45 -
Note 1: the value assigned for the relative density of the thermoplastic material outlined in clause 5.3.2.3 of the
Dubai Traffic Control Devices Manual shall be replaced by the value listed in the above table.
5/11.2 The above tests shall be carried out at Dubai Municipality Central Laboratory
(DCL).
5/11.3 Road marking works must be executed by an approved and qualified contractor.
5/12 TRAFFIC CONTROL AND PROTECTION OF PAVEMENT MARKINGS
5/12.1 The Contractor shall control the traffic in such a manner as to protect the freshly
marked surface from damage. The traffic control shall be so arranged as to give
minimum interference to the travelling public, Signs, barricades, flagmen and
control devices shall be supplied by the Contractor and a system of spaced
warning flags or blocks shall be used to protect the fresh marking until it has dried
as required. Any lines, strips or marking, which become blurred or smeared by
the traffic, shall be corrected by the Contractor at his own expense. Time required
to ensure appropriate drying of the fresh mark shall be referred to the
manufacturer’s instructions, standards and shall be approved by the Engineer
according to weather conditions or other parameters.
5/13 ROAD MARKING PAINT (FOR TRAFFIC DIVERSIONS, ETC..)

5/13.1 Road marking paint shall be by an approved manufacturer. It shall be suitable for
applying by brush or mechanical means to cement concrete or bituminous
pavement to give a chemically stable film of uniform thickness and shall be either
chlorinated rubber, epoxy or alkyd based.
5/13.2 White paint shall contain not less than 6% by mass of titanium dioxide as a
pigment, conforming to type A (anatase) or type R (rutile) specified in BS 1851.
5/13.3 Yellow paint shall be standard color BS 381C No.355, except where an
alternative shade has been specified in the Contract, and contain not less than
6% by mass of a suitable yellow pigment.
5/13.4 The paint shall be supplied fresh and ready for use in sealed containers and
stored in accordance with the manufacturer's instructions. The paint shall be
applied without the use of thinners or other additives.
5/13.5 Paint shall be applied at a covering rate recommended by the manufacturer and
5/13.6 Where markings are to be reflectorised with ballotini, it shall be sprayed uniformly
on to the wet paint film at the rate of 400 - 500 g/m2. Ballotini shall comply with
the requirements of BS 3262: 1989 Clause 15.
5/13.7 Road marking materials shall only be applied to surfaces which are clean and
dry. Markings shall be free from raggedness at their edges and shall be uniform
and free from streaks. Carriageway lane and edge lines shall be laid by approved
mechanical means to a regular alignment.
5/14 ROAD SIGNS, DESCRIPTION

(Refer to Roads and Transport Authority “Dubai Traffic Control Devices
Manual" Chapter 5, All Clauses)
5/15 REQUIREMENTS FOR ROAD SIGN MATERIALS

5/16 CONSTRUCTION REQUIREMENTS FOR ROAD SIGNS

5/17 GUARANTEE OF ROAD SIGNS BY CONTRACTOR

(Refer to Roads and Transport Authority "Dubai Traffic Control Devices
Shop drawings that include all the details of the road sign design, material,
installation procedures and road signs construction works outlined in clauses
5/14, 5/15, 5/16 and 5/17 shall be submitted to Traffic Department for a prior
approval.
Traffic information signs works must be executed by an approved and qualified

contractor.

5/18 PAVEMENT REPAIRS
5/18.1 This work shall consist of the various types of repairs to existing pavement
described herein, necessary to correct structural failures, grade elevations, and
deterioration and/or to prepare the existing pavement surface prior to placing
bituminous pavement overlays. The Engineer on site shall investigate and find
out causes of failure and he shall instruct the Contractor on the type of repair.
The Contractor shall provide assistance in such investigation as instructed by the
Engineer.
5/18.2 The materials required for the various pavement repair items shall be as specified
and shall be in accordance with the requirements of Section 3 of these
Specifications.
5/18.3 The Contractor shall be responsible for the supply of all the equipment and labour
necessary to perform the work described for the various types of pavement repair
items in accordance with these Specifications and as directed by the Engineer.
5/19 CONSTRUCTION DETAILS FOR PAVEMENT REPAIRS
REPAIR OF POTHOLES (ISOLATED HOLES IN THE PAVEMENT OF LESS

THAN ONE SQUARE METRE)
5/19.1 The Contractor shall cut the failed pavement back to solid material with
pneumatic asphalt cutting tools. Make the cut square or rectangular with faces
straight and vertical. One pair of faces shall be at right angles to the direction of
traffic.
5.19.2 Remove the cut pavement and loose unsuitable material from the hole and cart
away and dispose at a location designated by the Engineer.
5/19.3 If soil is removed, fill the excavation with granular road-base material which has
been premixed to optimum moisture content. Place the material in 150 mm layers
and compact each layer to not less than 98% of the maximum dry density as
determined according to BS 1377 Part 9: 1990: AMD 17229: 2007, Method
2.1/2.2 with mechanical compactors. The same treatment is to be applied on
subsoil before filling the excavation with granular roadbase material.
5/19.4 Wire broom clean the cut edges of the pavement and paint with tack coat.
5.19.5 Prime the compacted soil or the upper surface of the roadbase layer with a light
coating of prime coat as directed by the Engineer.
5/19.6 Fill the hole with Bituminous Base Course and/or Wearing Course as appropriate
and compact in lifts not exceeding 5 cm to the same level as the adjacent
surface. Vibratory compactors shall be used to compact the hot-mix bituminous
layer.
5/19.7 Check levels of the patch with a straight edge and make corrections as directed
by the Engineer.
REPAIR TO FAILED PAVEMENT

5/19.8 The Contractor shall cut the failed pavement to solid material with pneumatic
asphalt cutting tools. Make the cut square or rectangular with faces straight and
vertical. One pair of faces shall be at right angles to the direction of traffic.
Vertical faces may be stepped where instructed by the Engineer.
5/19.9 Remove the cut pavement and excavate the underlying soil to a depth of not less
than 300 mm. The Engineer may, when deemed necessary order substantially
greater depths of excavation payable as common excavation. Cart away and
dispose all cut pavement and excavated soil at a location designated by the
Engineer.
5/19.10 Thoroughly compact the subsoil with mechanical compactors to not less than
98% of Modified Proctor Density in accordance with the standard test methods
given in Section 2 of the Specification.
5/19.11 Fill the excavation to the bottom of the pavement with granular roadbase material
which has been premixed to the optimum moisture content. Place the materials in
150 mm layers and compact each layer to not less than 98% Modified Proctor
Density with mechanical compactors in accordance with the standard test
methods given in Section 2 of the Specification.
5/19.12 Wire broom clean the edges of the pavement and paint with tack coat.
5/19.13 Lightly prime the compacted road base layer with prime coat as directed by the
Engineer.
5/19.14 Place and compact wearing course or base course as applicable in the
excavation in 50 mm layers to the same level as the adjacent surface. The lower
layer shall be compacted with a vibratory compactor and the top layer shall be
compacted with a steel wheel roller by first compacting the hot-mix bituminous
layer 150 mm from the two traffic edges and then by rolling in the direction of
traffic. The drive wheel of the roller shall be in a forward position. Use of asphalt
pavement finisher will depend on the size of the area being patched.
5/19.15 Check levels of the repair with a straight edge and make corrections as required.
REPAIR OF DEPRESSED PAVEMENT
In case where the pavement has depressed but the asphalt has not fractured and
the pavement appears stable, the Contractor shall:
5/19.16 Cold plane and remove the upper 5 cm of the pavement starting just back from
the depression. Cart away and dispose of the removed pavement at a location
designated by the Engineer.
5/19.17 Wire broom clean the surface and lightly tack the surface and the edges with tack
coat (do not exceed 0.23 liters per square meter of tack coat).
5/19.18 Fill the cut with bituminous base course or wearing course as applicable and
compact with a steel wheeled roller by first compacting the hot asphaltic concrete
150 mm from the two traffic edges and then by rolling in the direction of traffic.
The drive wheel of the roller shall be in the forward position.
5/19.19 Check the level of the repair with a straight edge and make corrections as
required.
5/20 RAISING OR LOWERING MANHOLE COVER TO FINISHED LEVELS
5/20.1 The Contractor shall barricade the immediate work site to protect workmen and
motorists without closing the entire carriageway width to traffic. A single lane
should be closed for such operations.
5/20.2 Cut and remove sufficient asphalt pavement, if any, and concrete from the
manhole to permit removal of the cover and frame without damaging the
reinforcing steel, cart away and dispose of the rubble at a site designated by the
Engineer. Raising or lowering of manhole cover will be executed as per details
shown on the drawings or as otherwise specified.
5/20.3 Before starting any adjustment activity the Contractor shall obtain approval from
the concerned Authority to which the manhole belongs.
5/20.4 The Contractor shall submit to the Engineer for approval shop drawings for each
manhole affected by the work showing existing and new levels and a statement
of the methodology that will be followed.
5/20.5 Payment will be made upon receipt by the Engineer of a certificate issued by the
concerned Authority stating their approval of the works.
5/21 METAL BEAM GUARD RAIL SAFETY FENCING
5/21.1 Safety fencing shall comprise untensioned corrugated rails, channel-section,

posts, blocking-out pieces, nuts, bolts and washers for fixings, and end
anchorages.
5/21.2 Steelwork shall be mild steel Grade 43A to BS 4360, and shall be hot-dip
galvanized after fabricating in accordance with BS 729 to the thickness shown on
the Drawings. Thickness of coating (galvanization) shall be tested as per BS EN
ISO 1461: 1999 at Dubai Central Laboratory.
5/21.3 Fencing shall be erected to the dimensions and tolerances shown on the
drawings to produce a flowing alignment. The Contractor shall adjust the
elevation of any rail as required.
5/21.4 The rail section shall be such that when freely supported over a 3 m clear span,
with the road face uppermost, and centrally loaded with a point load of 1000 Kg,
the deflection measured at the centre of the span shall not exceed 40 mm.
5/21.5 Adjacent rails shall be connected by bolted lap of joints made in the relevant
direction to prevent vehicles striking rail ends.
5/21.6 Guardrail posts may be driven into the ground as detailed on the drawings
provided that:-

i. The accuracy of placing will permit the rail mounting to be erected to

present a flowing alignment.
ii. A representative sampling of driven posts selected by the Engineer shall

satisfactorily withstand a test load of 10 KN applied horizontally at the level
of the centre of the rail with a deflection at that level not exceeding 200 mm.
Where the previous cannot be met all posts shall be set into Class 25/20
concrete or as detailed on the drawings.
iii. Driven posts shall have a protective coating of bituminous paint over the
length which is to penetrate the ground and extend 75mm above the
finished ground level. The bituminous paint shall be of high quality with
excellent adhesion properties. A sample of the paint together with the
manufacturers specifications shall be submitted to the Engineer for approval
prior to use.
5/21.7 The ends of safety fences shall terminate with a mitred end rail and anchorage
flared away from the line of fence.
5/21.8 Site drilling or cutting of beams and posts shall not be permitted without approval.
Flame cutting shall not be permitted.
5/21.9 Minor surface damage to steel components shall be repaired by cleaning with a
wire brush to remove all corrosion products, the application of two coats of rust
inhibiting paint, and two coats of approved cold galvanising paint or similar over
the damaged area.
5/21.10 The horizontal alignment of fences shall not depart from the road alignment by
more than 30 mm overall, and the relative deviation shall not be more than 10mm
in any two successive rail lengths.
5/21.11 The height of the uppermost edge of the rail shall not depart from the dimensions
shown on the drawing by more than 30 mm, nor shall the relative deviation from
this line be more than 5 mm in any two successive rail lengths.
5/22 HEAVY DUTY CAT'S EYES (REFLECTIVE STUDS)

(Refer to Dubai Municipality "Dubai Traffic Control Devices Manual"
Chapter 5, All Clauses)
5/23 REFLECTIVE STUDS OPTICAL REQUIREMENTS

Chapter 5, All Clauses).
5/24 REFLECTIVE STUDS MINIMUM MECHANICAL

AND PHYSICAL PROPERTIES
Chapter 5, All Clauses).
5/25 REFLECTIVITY
5/26 INSTALLATION OF REFLECTIVE STUDS


5/27 STONE PITCHING SLOPE TREATMENT, DESCRIPTION
5/27.1 This work shall consist of the placement of stone pitching on mortar bedding on
slopes at the locations shown on the plans, or as ordered by the Engineer, in
accordance with these Specifications and in conformity with the lines, grades,
thickness and typical cross-section shown on the plans or established by the
Engineer.
5/28 MATERIALS FOR STONE PITCHING

5/28.1 Stone for pitching shall be hard, sound, durable, stones as approved by the
Engineer. Samples of the stone to be used shall be submitted to and approved
by the Engineer before any stone is placed.
5/28.2 Tests for specific gravity and absorption shall be determined in accordance with
ASTM C-127:2007. The minimum apparent specific gravity shall be two and sixty
five hundredths (2.65) and the maximum absorption shall be two (2) percent. The
stone shall not have an abrasion loss greater than thirty (30) percent when tested
in a Los Angeles Abrasion Machine in accordance with ASTM C-535:2009.
5/28.3 The size and shape of the stones shall be such to allow for proper placement.
The widths of the stone shall not be less than one and one-half (1-1/2) times their
respective thickness and lengths of not less than two (2) times their respective
widths. The minimum width shall be 100 mm.
5/29 CONSTRUCTION REQUIREMENTS FOR STONE PITCHING
5/29.1 The bed upon which the stones are to be placed shall be excavated to the
required grades and lines as shown on the plans or as directed and approved by
the Engineer. A footing trench shall be excavated along the toe of the slope as
shown on the plans or as directed by the Engineer. All footings trenches and
excavations shall be approved by the Engineer prior to placement of stones or
concrete. Subgrade or base should be firm and well compacted as approved by
the Engineer. Stones shall be placed on a mortar bed as detailed on the
Drawings.
5/29.2 Stones shall be arranged in such a way that the largest stones are at the bottom
of the slope. The surfaces of the stone shall be cleaned of adhering dirt and clay
and shall be moistened immediately prior to grouting.
5/29.3 The space between stones of stone pitching shall be filled with grout consisting of
one (1) part Portland cement and three (3) parts of fine aggregate, and one-fifth
(1/5) part of hydrated lime with sufficient water to produce a plastic mix as
approved by the Engineer. Immediately after pouring, the grout shall be spaded
and rodded into place with suitable spades, trowels or other approved method,
and broomed into the spaces until the voids are completely filled. The exposed
surface of the rocks shall project not less than 40mm and not more than 80 mm
above the grout surface. The grouted stone pitching shall be cured by an
approved method for a minimum period of four (4) days. Immediately after the
expiration of the curing period, the exposed surfaces shall be cleared of all curing
mediums.
5/29.4 Joints as detailed on the drawings will be provided at a maximum interval of 12

meters.
5/30 GABIONS
DESCRIPTION
5/30.1 Gabions shall consist of furnishing and placing wire mesh boxes rectangular in
shape filled with clean and uniform rocks larger than the mesh openings in
accordance with the drawings, and these Specifications.
Gabions shall be of approved quality.
MATERIALS
5/30.2 Wire mesh shall consist of galvanised steel fabricated in double twist woven
hexagonal shape with the following requirements:-
WIRE DIAMETER MESH SIZE
Boxes 2.7 mm 8 cm x 10 cm
Mattresses 2.2 mm 6 cm x 8 cm
5/30.3 The rocks shall consist of clean solid rock non-friable and resistant to weathering
and frost action meeting the following requirements:-
Absorption (ASTM C128 : 2007a/C127: 2007) Max. 2.0%

Soundness by Magnesium Sulphate Max. 12%
(ASTM C88: 2005) 5 cycles
5/30.4 The rock shall be greater than 150 mm in size.
5/30.5 Excavation required for the placement of gabions shall be made in accordance
with the dimensions as shown on drawings or as directed. Gabions shall be
constructed in units to the dimensions indicated on the drawings.
5/30.6 The sides, ends, and diaphragms of the gabions shall be lifted into a vertical
position, and located together with binding wire to form the base.
5/30.7 The binding shall be carried out in a continuous lacing operation, the wire being
passed through each mesh and around both selvedges which must be tied
together with two round of turns after every second mesh.
5/30.8 Assembled gabions may be placed in position for filling singly, or wired together
in groups suitable for man-handling. The baskets shall be securely wired together
at all corners and edges in the same manner as described above.

Where there are more than one course of gabions, the one in the upper course
must be laced to those below. Gabions shall be slightly over-filled to allow for
subsequent settlement.
5/31 CHAIN LINK FENCING
5/31.1 The chain link fencing shall be PVC coated and erected according to the lines
shown on the drawings or as otherwise directed by the Engineer. The fencing
components shall have a five year corrosion warranty from the manufacturer.
5/31.2 The Contractor shall supply shop drawings showing all fixing and erection details,
for approval prior to erection.
5/31.3 Steel posts, mesh, braces and struts shall conform to the requirements of BS 1722-
1:2006 and they shall be hot-dipped galvanised in accordance with BS EN ISO
1461:99 and then polyester coated to a minimum thickness of 60 microns.
5/31.4 Polyester coating shall conform to the requirements of BS 6496: 1984 and BS
EN 13438: 2005
Table 5- 3: Polyester coating requirements

MECHANICAL TESTS Limit
Flexibility (Conical Mandrel), BS EN Pass 3 mm
ISO 1519:2002 or ASTM D522:1993
Adhesion (2 mm Crosshatch) BS Pass GTO
3900-E6:1992
Erichsen Cupping, BS EN Pass > 7 mm
1520:1995
Hardness (400 gms) BS EN ISO Pass – No Penetration to substrate
1518:2001
Impact Resistance BS 6496 Clause Pass 2.3J direct (front) and reverse
16:1984
Table 5- 4: Chemical and durability tests for the Polyester coating

Chemical and durability Test Limit
Salt spray ASTM B117 @ 35 deg.C, Pass at 1000 hrs, no corrosion area
Acetic Acid/Salt spray BS6496, more than 2 mm from scribe
Clause 15:1984
Cyclic Humidity BS 3900-F2:1973 Pass at 1000 hrs, no blistering or loss
of gloss
Distilled Water Immersion- BS EN Pass - no blistering or loss of gloss
ISO 281251:1995 after 24 hours.
Sulphur Dioxide BS EN ISO Pass - no blistering, loss of gloss, or
3231:1999 discoloration after 240 hours.
Exterior Durability BS 6496, Clause Excellent performance, Slight even
4.10, 12 months Florida 40 deg. loss of gloss, no checking, Cracking
South or flaking.

Chalking None in excess of minimum in ASTM

D 4214:07
5/32 STEEL AND METAL WORK
5/32.1 Steel for the fabrication of bridge parapets and sign gantries shall comply with the
requirements of BS 4, Part 1, BS 5400, BS 4360 and BS 4848 as appropriate.
5/32.2 Fixing bolts and accessories complying with BS 5400, BS 4190 and BS 4320 as
appropriate.
5/33 ALUMINIUM FOR PARAPETS
5/33.1 Extruded sections shall conform to the following requirements:-
Posts Alloy 6082 TE to BS 1474

Other Locations Alloy 6082 TF to BS 1474
5/33.2 Casting shall be in alloy LM6M to BS 1490.
5/34 FASTENINGS FOR ALUMINIUM PARAPETS
5/34.1 Holding down bolts shall be of stainless steel A4-80 to BS 6105.
5/34.2 Aluminium parapets in contact with concrete shall have bearing pads of
rubber/fabric, new and unvulcanised.
5/34.3 All other fastening shall be of stainless steel 315S16 quality to BS 970 Part 4.
5/35 PAINT AND OTHER PROTECTIVE COATINGS
5/35.1 All paints forming any one painting system shall be obtained from one
manufacturer and, unless otherwise agreed by the Engineer, the source of supply
shall not be changed after the Engineer's approval has been given. Paint shall be
supplied in sealed containers of not more than 5 litres capacity and these shall be
used in strict order of delivery.
5/35.2 The Contractor shall obtain from the paint manufacturer paint ready for the use
specified under the contract. The paints shall be adequate in all respects for the
purpose intended.
5/35.3 The system of protection for all non-galvanised steel work shall be as follows:-
- Prime Coat: Inter zinc QHA 027/028 (or equivalent) minimum dry film
thickness 65 microns.
- Second Coat: Intergard EBA 070/EBA 100 JB (or equivalent) natural M.I.O.
minimum dry filter thickness 100 microns.

- Third Coat: Intergard EBA 070/EBA 100 JB (or equivalent) silver grey
M.I.O. minimum dry film thickness 100 microns.
- Fourth Coat: Intergard EFK 724 (or equivalent) epoxy finish grey minimum
dry film thickness 50 microns.
Total dry film thickness - 315 microns (minimum).
The coating shall have a minimum adherence to the steel work of 2.5 MPa
when tested with an adhesive tester.
- All coating thickness shall be verified at DCL
5/35.4 Prior to painting the steel work shall be grit blasted to SA 2-1/2 Swedish Standard
055900 or by other approved method to equivalent standard. Before the steel
surface shows signs of flash rusting the first coat of zinc primer shall be applied. If
the steel does flash rust then the cleaning process is to be repeated.
5/35.5 Steel work specified as galvanised shall be hot-dipped galvanised to the standard
required by BS EN ISO 1461:1999.
5/36 WATERPROOFING MEMBRANES FOR STRUCTURES
WATERPROOFING BRIDGE DECK SLAB - TYPE 1

GENERAL
TYPE 1
5/36.1 Deck waterproofing shall be composed of a proprietary membrane of a polyester

reinforced, SBS (Styrene-Butadiene Styrene) polymer modified bitumen sheet
sprayed or torched applied to primed concrete deck as detailed on the drawings.
MATERIALS
5/36.2 Membranes shall comply with the requirements of Technical Memorandum BE 27

(Bridges) Waterproofing and Surfacing of Bridge Decks and the system shall be
certified by the British Board of Agreement. Tensile properties of bitumen sheet
for waterproofing shall be tested in accordance with BS EN 12311: P1 2000 at
Dubai Central Laboratory. Materials shall have the following physical properties.
- Minimum thickness 1.5 mm
- Flexibility Over 20 mm dia Mandrel - 20 deg.C
- Longitudinal Elongation at Constant

temperature (20 deg.C, 100 mm/min) 54%

- Longitudinal Elongation with Thermal

shock (20 deg. C., 100mm/min) 57%
(-10 deg.C., 10 mm/min) 42%
- Longitudinal Tear Resistance at
Constant Temperature (20 deg.C.,
100 mm/min) 180 N/mm
- Adhesion to Concrete at 20 deg.C > .40 MPa
- Puncture Resistance at 20 deg.C.,

500 mm/min. > 800 N
The following additional tests shall be checked at Dubai Central Laboratory:
1. Low temperature flexibility of modified bituminous sheet material (ASTM

D5417 C-11:2002)
2. Compound stability of modified bituminous sheet material (ASTM D5417 C-
15:2002)
3. Tensile tear strength of bituminous water proofing material (ASTM
D4073:2006).
PREPARATION OF SURFACE
5/36.3 All concrete surfaces to be waterproofed shall be smooth and free from
projections or holes which might cause puncture of the membrane. The surface
shall be dry and immediately before the application of primer or membrane, the
surface shall be thoroughly cleaned of dust and loose materials.
5/36.4 Immediately after cleaning and drying of surface, priming should be applied in
strict compliance with manufacturer's instructions. Primer coat shall be allowed to
cure completely before membrane application. Membrane shall be laid parallel to
traffic direction and tangent to the bridge curve in such a manner that overlaps
are never less than the specified width. In all cases, waterproofing shall begin at
the low point of the surface to be waterproofed.
End laps should be staggered one metre so that at no point are there more than
three thicknesses of membrane. It shall be installed with 100 mm side laps and
150 mm staggered endlaps.
APPLICATION DETAILS
5/36.5 At the edges of the membrane and at any point where it is punctured by
appurtenances such as drains or pipes, suitable provision shall be made to
prevent water from getting between the waterproofing and the waterproofed
surface, as recommended by the manufacturer.
5/36.6 Precautions must be taken to prevent injury to the finished membrane by any
cause.
5/36.7 The bituminous wearing course should be laid as soon as possible after a
minimum period of four hours has elapsed from completion of the membrane.

WATERPROOFING BRIDGE DECK SLAB - TYPE 2
GENERAL
5/36.8 Type 2 deck waterproofing membrane shall consist of a two part rapid curing
liquid applied system based on methacrylate resins. The complete system shall
comprise of a primer to ensure good adhesion to the substrate; the membrane
and a tack coat to ensure good adhesion to the bituminous road surfacing. The
system must be suitable for use in Dubai. The temperature of the bituminous
surfacing at the time of laying onto the waterproofing membrane must be
according to Clause 3/33.
CERTIFICATION
5/36.9 The Type 2 waterproofing membrane system must hold a British Board of
Agreement Certificate.
APPLICATION
5/36.10 Application shall be strictly in accordance with the manufacturer's instructions.
WATERPROOFING OTHER SURFACES
5/36.11 Waterproofing membranes for structures other than top of bridge deck slab, shall
consist of an impervious laminate comprising a 0.3 mm PVC sheet and 1.5 mm of
flexible self adhesive rubber/bitumen compound. The laminate shall withstand
cracking of the substrate up to a crack width of 0.6 mm and shall have a tear
resistance (ASTM D1004: 2009) of 340 N/mm longitudinally and 310 N/mm
transversely, an elongation film (ASTM D638: 2008) of 210% longitudinally and
160% transversely and a backing sheet tensile strength (ASTM D638: 2008) of
4.2 N/mm2 longitudinally and 4.8 N/mm2 transversely. Rubberised mastic and
primer for use with waterproofing membranes shall be special compounds
provided by the manufacturer of the membrane and formulated for its intended
use. Refer to the Waterproofing membrane requirements given in Clause 9.2.2.1-
a in Volume 2. Part 2, Section 9 for more details.
5/36.12 Vertical and horizontal faces shall be made smooth, dry and free from nails or
concrete projections. It shall immediately be primed and allowed to completely
dry before installation of membrane. Installation procedures shall be strictly in
accordance with manufacturer's instructions.
5/36.13 Joints between sheets shall be lapped with end laps of at least 150 mm and side
laps of at least 100 mm. If the work must be left partially complete temporarily,
the exposed edges of outside strips of the membrane shall be finished with a
trowelled bead of mastic.
5/36.14 Waterproofed surfaces to be backfilled or otherwise exposed to possible damage

by plant or other construction operations shall be protected by proprietary
protection boards specifically designed for this purpose and installed strictly in
accordance with the manufacturer recommendations. As an alternative to the
waterproof membrane plus protection boards a composite membrane consisting
of a rubberised bitumen compound and integral geotextile layer (min. 400g/sq.m)
shall be permitted. The protection boards shall be a minimum of 6 mm thick.

5/37 RUBBERISED BITUMEN EMULSION
5/37.1 Rubberised bitumen for application to buried concrete surface as detailed on the
drawings shall comply with D.M. 500 and consist of a water bound emulsion
containing not less than 65% of bitumen with fine particles of rubber dispensed in
the bitumen, the consistency being such that it can be applied to the surface by
brush at normal air temperature. The rubber content of the dried film shall not be
less than 10%.
5/37.2 The Contractor shall submit to the Engineer for approval three samples in one
litre containers of the rubber bitumen emulsion. The Contractor shall also submit
to the Engineer certificates that the material complies with the requirements of the
Specification, and is suitable for the intended purpose.
5/38 WATERSTOPS
5/38.1 Alternatives from those indicated on the drawings will be accepted only if the
Engineer is satisfied that their material and their performance are not inferior. The
waterstop, used must be installed strictly in accordance with the manufacturer
instructions.
5/38.2 Waterstops shall be manufactured either from rubber or from polyvinyl-chloride
(PVC), at the discretion of the Contractor subject to the approval of the Engineer.
PVC waterstops when tested in accordance with BS 2571:1990, the PVC
compound shall exhibit the following properties:-
- Tensile Strength 13.78 N/sq.mm
- Elongation at Break 300%
- BS Softness 45
- Specific Gravity 1.3
For rubber waterstops the rubber compound shall comply with specifications and
standards (latest edition).
5/38.3 No splices will be permitted in straight strips. Strips and special connection pieces
shall be well cured in a manner such that cross section shall be dense,
homogeneous and free from all porosity. All junctions in the special connection
pieces shall be full moulded. During welding or vulcanising periods the joints shall
be securely held by suitable clamps. The materials at the splices shall be dense
and homogeneous throughout the cross section.
5/38.4 If, after placing concrete, waterstops are materially out of position or shape or if
voids are found, the surrounding concrete shall be removed, the waterstop reset,
and the concrete replaced, all at the Contractor's expense.
5/39 PREFORMED JOINT FILLERS

5/39.1 Joint fillers in expansion joints for structures shall consist of a compressive non-
extruding board manufactured from bitumen impregnated fibres.
5/39.2 The physical properties of the materials shall conform to the requirement of
ASTM D-1751: 2008, except asphalt content shall not be less than 10% of the
weight of the finished product in order to get a material that is characterized by
the Low moisture absorption due to bitumen impregnation.
5/40 COLD APPLIED JOINT SEALANT
5/40.1 Cold applied joint sealant shall be a multi-component, gun applied material of a
grade suitable for the hot climate with a service temperature of up to 70 degrees
centigrade and high resistance to ultra-violet exposure.
5/40.2 The compound shall comply with BS EN ISO 11600:03.
5/40.3 The sealant must be suitable for the particular application whether the joint to be
sealed is horizontal or vertical and with the ability to accommodate any
movement at the joint without rupturing or losing adhesion.
5/40.4 The hardness of the joint sealant shall be no less than 20 on the "Shore A" scale.
5/40.5 The Contractor shall supply samples together with the manufacturers literature
relevant to any sealant for any application for the Engineer's approval prior to
use. Only high quality products with demonstrable resilience to the local climate
conditions shall be approved. If a polysulphide based sealant is proposed for
locations exposed to biological attack or wet conditions then it should have a
minimum 40% polymer content. All polysulphide based sealant must utilise a
manganese dioxide curing system.
5/40.6 The mixing, application and curing of the approved sealant shall be strictly in
accordance with the manufacturers recommendations.
5/40.7 The approved sealants shall be delivered to site in sealed containers showing
date of manufacture, batch number and shelf life.
5/41 BRIDGE DECK EXPANSION JOINT
5/41.1 GENERAL
Expansion joint assembly shall be as shown on the drawing.
Full details of the proposed suppliers with their technical specifications,

maintenance manual, design calculations, covering materials, dimensions and
sizes shall be submitted to the Engineer for approval before the Contractor places
an order.
All expansion joints shall be guaranteed by the manufacturer against any defect
in material and workmanship for a period of ten years.
The Contractor shall submit the detailed shop drawings and obtain the Engineer's
approval before manufacture is commenced.
During placing and hardening of concrete or mortar under the expansion joint
components, relative movement between them and the supports to which they
are fixed shall be prevented.
Thorma-Joints shall comprise Thorma-Joint with BJ 200 binder as manufactured

by Prismo Ltd., of Crawley, West Sussex, United Kingdom, or equal approved.
Elastomeric expansion joints shall be waboflex SR Type as manufactured by

Servicised Ltd., or equal and approved.
Installation details shall be as shown on the drawings and as otherwise

recommended by the manufacturer and approved by the Engineer.
5/41.2 All anchoring steel plates, bolts and sockets shall be protected against corrosion.
5/41.3 Joint installation shall be carried out strictly in accordance with manufacturer's
recommendations and in the presence of the manufacturers representatives.
5/42 LOCKABLE MEDIAN BOLLARD

5/42.1 Lockable median bollards shall be as shown on the drawings.
5/42.2 Movable bollard and locking mechanism shall be galvanised steel to BS EN ISO
1461:99 standard and treated with anti-corrosion paint.
5/42.3 Post sleeve shall be 4 mm thick PVC pipe.
5/43 SPECIAL COATING SYSTEM FOR THE PROTECTION OF EXPOSED

CONCRETE SURFACES
GENERAL
5/43.1 The coating system shall be an elastomeric system of single component

products, a weather resistant top coat used in conjunction with a penetrating
primer. The coating shall have the ability to provide in-depth protection for
reinforced concrete structures against corrosion associated with the ingress of
chloride and sulphate ions, carbon dioxide and other air-borne acid gases, and
shall have the ability to allow water vapour to escape from the structure. All dry
film thickness of coating shall be verified by DCL.
PRIMER
5/43.2 The primer shall be a low viscosity reactive silane-siloxane/acrylic blend

dissolved in a penetrating organic carrier. The primer shall have the capability to
penetrate and produce a chemically bound Hydrophobic barrier to prevent the
passage of chloride and sulphate ions. The primer should also be film forming to
condition and stabilise the substrate prior to the application of the topcoat. The
primer should be applied in full accordance with the manufacturers instructions.
TOPCOAT

5/43.3 The top coat shall be a pure aliphatic acrylic resin, decorative, high performance
water based, pigmented coating. It shall have resistance to water, carbon dioxide
and other air-borne acids and have the ability to allow the passage of water
vapour from within the structure.
5/43.4 The top coat shall have elastomeric and flexural capabilities and should be
applied in strict accordance with the manufacturer's instructions.
5/43.5 The system will, during trials, display the following properties when applied in
accordance with the manufacturer's specification to samples obtained from
concrete made without additives.
Reduction in Water Absorption 82% minimum at 28
(measured against a control days
concrete sample in accordance
with ASTM C 642)
Reduction in Chloride Ion 90% minimum at 28

Penetration days.
Water Vapour Transmission > 13g/m2/day
Carbon Dioxide Diffusion Equivalent to 500mm

Resistance of 30 N/mm2 concrete
TRIAL PANELS
5/43.6 Prior to applying the system in the works, trial applications shall be carried out on
trial panels made by the Contractor under Clause 4/33. The trials will
demonstrate the method proposed for applying the system, coverage, coating
thickness, colour and final appearance of the coating. Representatives of the
coating manufacturers shall be present at the trials and the surface preparation
and application of the coating shall be carried out under their direction. The
Contractor shall at his own expense surface coat as many panels as required by
the Engineer until a trial panel has been accepted by the Engineer as
satisfactory. The coated panel, when accepted will form the standard against
which the corresponding coating in the works will be judged. No application of
the coating in the works shall be undertaken until trials have been completed to
the Engineer's satisfaction.
INSPECTION OF CONCRETE
5/43.7 The Contractor shall not proceed with the surface finish or making good of
concrete surfaces until he has received the Engineer's Representative's
permission to do so and he shall not apply cement slurry or mortar or any other
coating to the concrete surfaces from which the shuttering has been struck until
the concrete has been inspected and approved by the Engineer's Representative.
FAULTY CONCRETE WORK
5/43.8 The Contractor shall on the written instruction of the Engineer remove and
reconstruct any such portion of the work which in the opinion of the Engineer is
unsatisfactory as regards quality of concrete, incorrect dimension of the cast
portion, badly placed or insufficient reinforcement, honeycombing or other such
cause as shall render the construction not up to the standard required and which

in the opinion of the Engineer may prejudicially affect the strength or durability of
the construction.
APPROVAL PRIOR TO COATING APPLICATION IN THE WORKS
5/43.9 The Engineer's approval must be obtained prior to applying the coating system in
the works. Before approval is given the Engineer will need to be satisfied as to
the following:-
a. All construction work in the immediate vicinity of the structure to be coated

has been completed.
b. The surface preparation of the structure has been completed.
c. The whole of the structure can be coated in a continuous operation.
d. Adequate measures have been taken to protect the property of third parties,
including vehicles, from coating splatters.
e. The weather conditions accord with the coating manufacturer's directions

for coating application.
5/44 BRIDGE BEARINGS

5/44.1 Bearings for concrete Works, including those that are to be furnished and
included as a part of the Concrete Work under Section 4, Clause 4/36, Post-
Tensioned Concrete Works, of these Specifications, shall be as indicated on the
Drawings, as specified herein and as directed by the Engineer.
5/44.2 Elastomeric Bearings
1. General-Elastomeric bearings shall consist of laminated Elastomeric pads or

assemblies of laminated Elastomeric pads with externally bonded structural
steel bearing plates, structural steel top bearing plate and required stainless
steel and PFC sheets, as indicated on the approved shop drawings and as
specified herein.
Well in advance of their scheduled inclusion in the Works, the Contractor

shall submit a method statement for the approval of the Engineer including
the specifications of all materials, bedding mortar, the corrosion protective
system, and method of handling, transportation, storage and installation. It
shall also include detailed design calculations in support of the sizes and
quality of each component of the bearing, shop drawings, maintenance
manual and replacement scheme for the bearings.
The manufacturer shall submit for approval prequalification of three accredit

independent test facility. Accordingly, the engineer shall nominate the
approved independent test facility, who shall certify the compliance statement
for each bearing. Compliance statement shall be inline with specification as
marked below.
The information supplied should include documentation from the bridge

bearing manufacturer of successful usage in similar environmental conditions

to those experienced in Dubai. The bearings shall be guaranteed for 10
years and the Contractor shall provide the guarantee from the bearing
manufacturer.
Variation in thickness of an individual Elastomeric lamination shall not exceed

3 mm within the width or length of a bearing pad and the variation in
thickness of all elastomer laminations within a bearing pad shall be such that
each metal or fabric lamination will not vary by more than 3 mm from a plane
parallel to the top or bottom surface of the bearing pad.
The total out to out thickness of a bearing pad shall not be less than the
thickness indicated on the approved shop drawings nor more than 6 mm
greater than that thickness. Variation of total thickness within an individual
bearing pad shall not exceed 3 mm.
The length and width of a bearing pad shall not vary more than
3 mm from the dimensions indicated on the approved shop drawings.
The bond between the elastomer and the steel laminate shall be such that,
when a sample is tested for separation, failure shall occur within the
elastomer and not between the elastomer and the steel.
2. Materials - All material used in the manufacture of the bearing assemblies shall
be new and unused with no reclaimed material incorporated into the finished
assembly. All bonding of components shall be done under heat and pressure
during the vulcanizing process. The bond shall be continuous throughout the
plan area with no voids or air spaces greater than 0.25 mm within the bonding
material. The bearing assemblies shall be furnished as complete units from
one manufacturing source.
The materials for the Elastomeric bearings and assemblies shall comply with
the following requirements:
a) Elastomeric Materials - The Elastomeric materials of the compounds

shall be 100% virgin polychloroprene synthetic rubber meeting the
requirements of Table 5-5. The properties of the Elastomeric compounds
shall be determined from test specimens complying with ASTM D3182
through D3190 inclusive and D3192. A variation of ± 10% in tensile
strength and ultimate elongation under "physical properties" will be
permitted when test specimens are cut from the finished product.
b) Internal Steel Laminates - The internal steel laminates for the laminated
Elastomeric bearing pads shall be rolled carbon steel sheets complying
with ASTM A570 or AASHTO M183 (ASTM A36).
c) Laminated Elastomeric Bearing Pads - Laminated Elastomeric bearing

pads shall be individually molded to the required size. Corners and edges
may be rounded with a radius at the corners not exceeding 9 mm and a
radius at the edges not exceeding 6 mm. All edges of the steel
laminations shall be covered with not less than 4 mm and not more than 6
mm of elastomer. The dimensions of the Elastomeric bearing pads shall
be within the following listed tolerances (Table 5-5):

Table 5- 5: Polychloroprene - Synthetic Rubber

ASTM
Standard Physical Properties Value Value
D2240:2005 Hardness, ASTM D2240 50 ± 5 60 ± 5

D412:2006 Tensile strength, min. kg/cm² 156 (2,250 156 (2,250
Ultimate elongation, min. % psi) 400 psi) 350
Heat Resistance
Change in durometer +15 +15
hardness, max. points
D573:2004 Change in tensile strength, -15 -15

70 hr. max. %
@ 100 C
Change in ultimate -40 -40

elongation, max. %
Compressive Set
D395:2003 (08) 22 hours @ 100C, max. % 35 35
Method B
Ozone
D1149:2007 100 pphm ozone in air by No No
volume, 20% strain, 37.7oC Cracks Cracks
± 1C, 100 hours mounting
Procedure D518, Procedure
A
Adhesion to Steel
Bond made during 80% R (Z1) 80% R
vulcanization (Z1)
D429, A:2008 Bond Strength 6.9 kn/m 6.9 kn/m
D429, B: 2008 Peel Strength 6.9 kn/m 6.9 kn/m
D746: 2007 Low Temperature Test -
Durometer Change
Bearing or sample to be
exposed for 96 hrs. @-28°C,
± 2°C. (The specimen shall
have a 24 hr. conditioning
period at room temperature
prior to low temperature
exposure). The durometer
test shall be made at 28°C on +15 (Z2)
an unbuffed surface.
Durometer hardness
increase, Max. ASTM D2240,
30 second reading.
Durometer to be placed in
freezer with test specimen.
Brittleness temp., 3 min., at - No cracks
40°C

Procedure B Structural Steel. The internal

steel laminates for the
laminated elastomeric
bearings shall be rolled mild
steel sheets conforming to
SAE 1020 or AASHTO M183.
Laminated elastomeric
bearings shall be individually
molded to the required size.
Corners and edges may be
rounded with a radius at the
corners not exceeding 9 mm
and a radius at the edges not
exceeding 6 mm. All edges
of the steel laminations shall
be covered with not less than
3 mm and not more than 6
mm of elastomer. The
dimensions of the elastomeric
bearings shall be within the
following listed tolerances:
Fabrication Tolerances
a) Overall Vertical Rubber Dimension.
 Average total rubber thickness 32 mm or -0, + 3 mm
less -0, + 6 mm
 Average total rubber thickness over 32 mm
b) Overall Horizontal Rubber Dimension.
91.4 cm or 0, + 6 mm
less than 91.4 cm 0, + 12 mm
c) Thickness of individual layers of elastomer ± 20% of design value

(Laminated Bearings Only) but not more than ± 3
mm
d) Thickness of Top and Bottom Cover Layer - 0, the smaller of 1.5
(if required) mm and +20% of the
nominal cover layer
thickness
e) Parallelism with Opposite Face Top and .005 radians

Bottom Sides .02 radians
f) Position of exposed connection members ±3mm

holes, slots or inserts
g) Edge cover of embedded laminates or -0, + 3 mm

connection members
h) Size of holes, slots or inserts. ± 3 mm
The rubber laminates shall be of uniform integral units, capable of being

separated by mechanical means into separate, well-defined elastomeric
layers. The ultimate breakdown limit of the elastomeric bearing under
compressive loading shall be not less than 140 kgs/cm². In addition to the
requirements of Table A, the compressive stress-strain relationship of the
finished elastomeric bearings at room temperature shall not exceed the

following limitations:
Stress 35 kgs/sq.cm 56 kgs./sq. cm

Strain* 5% 7%
* Percent of total thickness of all elastomer laminations.
In addition, shear resistance of the bearing shall not exceed 2.80 kgs/cm2 (40
psi) for 60 durometer, Table A compounds at 25% strain of the total effective
rubber thickness after an extended four-day ambient temperature of -28°C.
The Contractor shall furnish to the Engineer a certification for each bearing by
the approved independent test facility that the elastomer, in the elastomeric
bearing pads to be furnished conforms to all of the above requirements. The
certification shall be supported by a certified copy of the results of tests
performed by the approved independent test facility upon samples of the
elastomer to be used in the pads.
3. Bearing Installation - The concrete bearing surfaces on which elastomeric

bearing pads are to be placed shall be wood float finished to a level plane
which shall not vary more than 3 mm from a straightedge placed in any
direction across the area. The finished bearing seat shall not vary more than 3
mm from the elevation shown on the approved shop Drawings.
Concrete or metal surfaces on which the bearing pads are to be set shall be
dry, clean and free from dirt, grease, latency, and contaminants. No bearing
pad shall be placed until the Engineer has inspected and approved the seat
conditions.
All elastomeric bearing pads shall be fixed in position on the bearing seat with
an approved epoxy and applied in accordance with the recommendations of the
manufacturer of the bearing pads.
For expansion bearings only, concrete bond to the top surface of the bearing
pad shall be prevented by the use of polyethylene sheeting or other removable
bond breaking material as approved by the Engineer.
5/44.3 Pot Type Bearings - Guided Expansion and Fixed Bearings
1. General - The Contractor shall furnish and install pot type, guided expansion
and fixed bridge bearings at the locations shown on the Drawings. The bearing
assemblies shall be complete and ready for installation. Expansion bearings
shall have sliding surfaces of polytetrafluorethylene (PTFE) and shall be subject
to the requirements of this specification and as shown on the Drawings.
Fixed bearings shall allow rotation but no longitudinal or transversal movement,

in the bearing plane.
Expansion and fixed bearings shall be capable of supporting the maximum total
vertical and horizontal loads as shown on the Drawings.

The PTFE material consisting of filled or unfilled sheet, as shown on the

approved shop drawings, together with the adhesive materials, stainless steel
mating surface and manufacturing processes shall conform to the requirements
given in these specifications.
The Contractor shall furnish Certified Test Reports, Materials Certificates and a
Certificate of Compliance for each bearing in accordance with the Engineer’s
instructions.
Well in advance of their scheduled inclusion in the Works, the Contractor shall
submit a method statement for the approval of the Engineer including the
specifications of all materials, bedding mortar, the corrosion protective system,
method of handling, transportation, storage and installation. It shall also include
detailed design calculations in support of the sizes and quality of each
component of the bearing, detailed analysis for the stresses in the base element
and in concrete/bearing plinth immediately under the bearing will also be
required to check peak stresses. The Contractor shall provide shop drawings,
maintenance manual and replacement scheme for the bearings.
The information supplied should include documentation from the bridge bearing
manufacturer of successful usage in similar environmental conditions to those
experienced in Dubai. The bearings shall be guaranteed for 10 years and the
Contractor shall provide the guarantee from the bearing manufacturer.
2. Design - PTFE sliding surfaces are designed to translate or rotate by sliding of a

self-lubricating polytetrafluorethylene surface across a smooth hard mating
surface of stainless steel.
Expansion bearings having sliding surfaces of PTFE shall have provision for
rotation or equalization of the stress on the PTFE sliding surface. Rotation shall
be considered the sum of live load rotation, changes in camber during
construction and misalignment of the bearing seats due to construction
tolerances. Rotational capability shall not be less than 1:50. The design,
materials and construction of the means of equalizing the stress or provision for
rotation in the bearing shall be in accordance with these specifications and as
shown on the approved shop drawings.
PTFE sliding surfaces shall have the following minimum and maximum
thickness:
 Unfilled or filled PTFE 0.79 mm minimum, 2.38 mm maximum.
 The PTFE sliding surface must be bonded under factory controlled

conditions to a rigid back-up materials capable of resisting bending
stresses to which the sliding surfaces may be subjected. Alternatively,
PTFE material of twice the thickness specified above may be recessed
for half its thickness in the back-up material.
 The mating stainless steel surface to the PTFE should be an accurate

flat surface as required by the design and shall have a minimum Brinell
hardness of 125 and a surface finish of less than
5 x 10-4mm (20 micro inches) rms (root mean square). The mating
surface shall completely cover the PTFE surface in all operating
positions of the bearing.
 The average bearing pressure on the PTFE sliding surface due to all
loads shall not exceed:
Filled PTFE 246 kg./cm² (3500 PSI)

Unfilled PTFE (Recessed) 246 kg./cm² (3500 PSI)
Unfilled PTFE (Not recessed) 140 kg./cm² (2000 PSI)
The design shall include means to positively locate all elements of the bearings.
Where a thin non-corrosive smooth facing materials is used as a mating
surface, it shall be structurally bonded by an approved adhesive system and
may also be mechanically fastened by means of either screws, or rivets to the
back-up materials or if the material permits, seal welded around the entire
perimeter of the facing material.
3. Description - PTFE Bearing Surfaces. Prefabricated fixed and expansion

bearings having a working surface of PTFE conforming to the design
requirements, shall conform to the following materials, manufacturing and test
requirements.
4. Materials
a) General -The virgin PTFE resin, filled or unfilled PTFE sheets, back-up
materials and all other parts of the fixed or expansion bearings shall have
the friction, mechanical, physical and weathering properties prescribed in
this specification.
b) PTFE Resin - PTFE resin shall be virgin material (not reprocessed)
meeting with requirements of ASTM designation D4894:2007. Specific
Gravity shall be 2.13-2.19. Melting point shall be 327°C (623°F±2).
c) Filler Material - Filler material when used, shall be milled glass fibers,
carbon or other approved inert filler materials.
d) Adhesive Material - Adhesive material shall be an epoxy resin meeting
the requirements of specification MIL-A-8623A or equal, as approved by
the Engineer.
e) Unfilled PTFE Sheet - Finished unfilled PTFE sheet shall be made from
virgin PTFE resin and shall conform to the following requirements:
Mechanical ASTM Method 25% Carbon

Tensile Strength (min) ASTM D4894:2007 197 kg/cm² (2800 PSI)
Elongation (min) ASTM D4895:2004 200%
f) Filled PTFE Sheet - Filled PTFE sheet shall be made from virgin PTFE
resin uniformly blended with inert filler material. Finish filled PTFE sheets
containing glass fiber or carbon shall conform to the following
requirements (Table 5-6 and 5-7).

Table 5- 6: PTFE sheets mechanical requirements

Mechanical ASTM 15% 25% Carbon
Method Glass Fibers
Tensile Strength D4894:2007 140 kg/cm² 91 kg/cm²
(min) (2000 PSI) (1300 PSI)
Elongation (min) D4895:2004 150% 75%
Table 5- 7: PTFE sheets physical requirements

Physical ASTM 15% Glass 25% Carbon
Method Fibers
Specific Gravity (min) D792:2008 2.20 2.10
Melting Point D4894:2007 327°C±10°C 327°C±10°C
g. Surface Treatment - Where PTFE sheets are to be epoxy bonded, one

side of the PTFE sheet shall be factory treated by an approved
manufacturer by the sodium ammonia or sodium nepthalene process.
h. Stainless Steel Mating Surface - Stainless steel mating surfaces when
used shall be 20-gage minimum thickness and conform to ASTM A240:
2009C Type 304 with a surface finish of less than 20 micro inches rms.
Stainless steel mating surfaces shall be polished or rolled as necessary to
meet the friction requirements of this specification.
i) Structural Steel - All structural steel bearing components including
masonry plate, pot base, top plate, sole plate, piston and guide bars shall
conform to the requirements of ASTM A588: 2005.
Anchor studs, as shown on the approved shop drawings, shall be welded
to the sole plates in accordance with requirements of the AWS Welding
Specification.
High tensile strength guide bar bolts shall be as specified by the
manufacturer and shall develop full resistance to the lateral forces. The
friction between the bearing and substructure shall not be considered to
assist in resisting horizontal forces as shown on the Drawings.
All structural steel shall be given a 0.254 mm (10 mil) epoxy coal tar finish
after fabrication in accordance with the paint manufacturer’s specifications.
j. Anchor Bolts - Anchor bolts provided to anchor the masonry plate to the
concrete substructure shall conform to the requirements of ASTM A307:
2007 and shall be galvanized in accordance with the requirements of
ASTM A153.
k. Elastomeric Components - The elastomeric bearing disc, seal rings for
containing elastomer in expansion bearings and seal for fixed bearings
shall be made from neoprene of 50 Durometer A hardness in accordance
with the requirements specified herein for “Elastomeric Bearings.”
5. Manufacturing Requirements
a) General -The virgin PTFE resin, filled or unfilled PTFE sheets,

back-up materials and all other parts of the fixed or expansion
bearings shall have the friction, mechanical, physical and
weathering properties prescribed in this specification.

PTFE material shall be factory bonded, mechanically connected,
or recessed into the back-up material as shown on the approved
shop drawings.
b) PTFE Sheets - The bonding shall be performed at the factory of
the bearing manufacturer of the expansion bearings under
controlled conditions and in accordance with the written
instructions of the manufacturer of the approved adhesive system.
After completion of the bonding operation, the PTFE surface shall
be smooth and free from bubbles. Filled PTFE surfaces shall then
be polished.
6. Testing and Acceptance
a) General - The manufacturer of the bearings shall furnish facilities

for the testing and inspection of materials and of the completed
bearings at an independent test facility approved by the Engineer,
the representative of independent test facility of shall be allowed
free access to the manufacturer’s plant to apply the approved
testing and inspection plan.
For each bearing, certificate from the approved independent test
facility shall be furnished for approval; testing and inspection plan
for each bearing shall be included.
b) PTFE Cold Flow Test - The manufacturer of the bearings shall

demonstrate to the Engineer, by approved methods of testing, that
the cold flow of the PTFE material proposed to be used, filled or
unfilled, will not deform laterally, by more than 1.6 mm radially
(i.e., diameter of the Teflon shall not increase by more than
3.2mm, under a uniform loading of 246kg/cm² (3500 PSI) imposed
continuously for a period of not less than one hundred (100) hours.
The dynamic loading shall include the sliding of the stainless
mating surface in a back and forth motion of 25.4mm.
c) Test Specimens - After the manufacture of all bridge bearings
one bearing from each load range will be selected at random by
the Engineer for testing in accordance with AASHTO Clause 18.7
(Division 2).
If all tests performed on the selected bearing in a given load range

meet specified requirements, all bearings within that load range
will be acceptable. In the event that any test on a bearing in a
given load range does not meet specified requirements, the tested
bearings and all other bearings in that same load range will be
rejected unless each individual bearing is satisfactorily tested and
d) Proof Load Test - A test bearing shall be loaded to 150 percent of

the bearing’s rated design capacity and simultaneously subjected
to a rotation range of 0.02 radian (1.146o) or design rotation,
whichever is greater, for a period of one (1) hour.
The bearing will be visually examined both during the test and
upon disassembly after the test. Any resultant visual defects, such
as extruded or deformed elastomer, polyether urethan or TFE,
damaged seals or limited rings, or cracked steel, shall be cause
for rejection of the lot.
During the test, for pot bearings the steel bearing plate and steel
piston shall maintain continuous and uniform contact for the
duration of the test. Any observed lift-off will be cause for rejection
of the lot.
e) Testing for Coefficient of Friction - The test shall be arranged

so that the coefficient of friction on first movement, on the fifth and
fiftieth cycles and during sliding can be measured. The test
method and equipment shall be subject to the approval of the
Engineer.
The Static Coefficient of Friction shall be determined at breakaway

by dividing the horizontal force to start motion by the vertically
applied force which shall be equivalent to application pressure.
The Dynamic Coefficient of Friction shall be determined by the
same method.
The testing procedure shall be as follows:
i) The bearing shall be loaded with the Maximum Total Load

indicated for the load range and this load shall be applied
continuously for 12 hours immediately prior to measuring the
coefficient of friction.
ii) The bearing load shall be reduced to a Minimum Dead Load

indicated, and the first movement static and dynamic
coefficient of friction for the test bearing shall be determined
at a sliding speed not exceeding 25.4mm per minute.
iii) The bearing shall then be loaded with the Maximum Total
Load and be subjected to 100 movements of the full design
relative movement at a speed of less than 30cms per minute.
If the test facility does not permit the full design movement to
be used, the Engineer may permit a reduced movement to
be used, but this shall not be less than 25.4mm.
iv) The static and dynamic coefficients of friction shall then be
determined again with the bearing loaded with the Minimum
Dead Load.
v) The static and dynamic coefficients of friction between the

polished stainless steel sliding surface and the PTFE bearing
surface when tested as provided herein, at the Minimum
Dead Load, shall not exceed three (3) percent.
vi) In addition to the above requirements, to be acceptable, the

bearings shall show no appreciable sign of failure or other

defects.
Bearings represented by the test specimens passing the
above requirements will be approved for use in the structures
subject to on-site inspection for visible defects.
7. Packaging and Identification Marking - Each bearing shall be

assembled at the plant, shall be marked for identification and shall be
delivered to the construction site as a complete unit. Packaging shall be
accomplished in such a manner so as to ensure that the bearings during
shipment and storage will be protected against damage from handling,
weather or any other hazard. Each completed bearing shall have its
components clearly identified, be securely taped or otherwise fastened
for shipment and marked on its top as to location in each structure in the
project in conformity with the Drawings.
8. Bearing Installation - The Contractor shall certify to the Engineer that a

skilled representative of the bearing manufacturer will be available to
the Contractor to give such aid and instruction in the installation of
bearings as is required to obtain satisfactory results.
The skilled representative shall be present during the initial installation

of the bearings. The representative shall remain on the job until, in the
opinion of the Engineer, the bearing installation is proceeding smoothly
and the workmen are familiar with the work required for each
installation. The Contractor shall also arrange to have the
representative present at such other times as the Engineer may
request.
Anchor bolts shall be cast monolithically with the substructure concrete

by the use of templates to the exact locations and with bolt projections
above bearing seat precisely as shown on the Drawings and approved
shop drawings.
Bearing grout pads shall be placed as shown on the Drawings and as

herein before specified for “Grout Pads” using an epoxy and quartz
sand grout as recommended by the bearing manufacturer. The top
surfaces of the epoxy grout pads shall be perfectly level and any
perceptible deviations from a straightedge shall be ground level or filled
with epoxy mortar and ground until a true level surface is obtained.
The bearings shall be placed at the time of superstructure form erection

and all temporary restraints shall be removed as directed by the bearing
manufacturer.
The bearings shall be set on the exact alignment as shown on the

Drawings for each location and shall be oriented in the proper direction.
Extreme care shall be exercised in aligning both the base and the upper
part of the guided expansion bearing parallel to the expansion axis of
the structure to avoid a wedging action in the bearing during movements
of the superstructure. The location of the upper part of the bearing shall
be adjusted relative to the base to allow for temperature at the time of
erection.

If for any reason the bearings are disassembled, extreme care shall be
used to ensure that the rubber pads and piston rings are properly
seated in the recess with the piston ring gaps 180° apart.
5/44.4 Temporary Bearings at Integral Abutments
5/44.4.1 Temporary bearings shall consist of structural steel base plates, galvanized
anchor bolts, structural steel H-sections and teflon coated sliding plates.
5/44.4.2 The temporary bearing components shall be in accordance with Clause 5/45
Metal Works. The teflon coated sliding plate shall meet all the requirements
given in Clause PS 5/44 Bridge Bearings of the Particular Specifications. All
structural steel welding shall be in accordance with the requirements of the
AWS Welding Specifications. The Contractor shall submit detailed shop
drawings for the bearings assembly for the approval of the Engineer.
5/45 METAL WORKS
5/45.1 Structural Steel

All structural steel shall be new and shall comply with the following specifications
and requirements:
Structural carbon steel shall comply with the specification for steel for bridges and
buildings of ASM A36 and/or AS88, unless otherwise specified herein, indicated on
the Drawings or in the Particular Specifications.
High strength steel bolts and washers shall comply with ASTM A325. All high
strengths nuts shall be of such capacity to develop the bolt strength.
Steel anchor bolts, nuts and washers and assembly bolts, nuts and washers for
round tube post bases shall be ASTM A307.
Steel bolts, nuts and hardened washers shall be galvanized in accordance with
ASTM A153 unless otherwise indicated on the Drawings or in the Particular
Specifications.
5/45.2 Stainless Steel

All stainless steel shall be new and shall comply with the following specifications and
requirements: All members or parts called for on the Drawings to be stainless steel
shall be AISI Type 302, 303, 304 or 316 and complying with ASTM A276. Unless
otherwise indicated on the Drawings or in the Particular Specifications, stainless
steel shall be Type 316 with a mill finish. Unless otherwise indicated on the Drawings
or in the Particular Specifications, all bolts shall be of the same type of stainless steel
as the adjoining parts. Stainless steel pipe rails and posts shall be as indicated on
the Drawings and shall be of AISI Type 304 stainless steel tubing (except Type 312
can be used for curved corners) complying with ASTM A-54. The completed handrail
shall have a surface finish complying with ASTM Designation A480 No. 2B finish.
Unless otherwise indicated on the Drawings, all posts and railings shall be 38 mm
nominal (48 mm outside diameter) stainless steel with 16 gauge wall thickness.
Where possible, the minimum shop fabricated length of handrail shall be 6 meters.
5/45.3 Galvanizing

Shall be by the hot dip process in accordance with ASTM A123 and A385. The
galvanizing coating shall be uniform and bright when the galvanized surface are not
to be painted. All fabrication shall be completed and ready for assembly before
galvanizing. No punching, drilling or cutting shall be permitted after galvanizing.
Precautions shall be taken against embrittlement, warpage and distortion in
accordance with ASTM A143, and in accordance with ASTM A384. All coating
thicknesses shall be specified in mm or microns and shall be verified at DCL.

1 SECTION 6 WORKS IN CONNECTION WITH SERVICES
TABLE OF CONTENTS
6/1 GENERAL REQUIREMENTS ................................................................................. 2

6/2 EXCAVATION FOR EXISTING SERVICES ............................................................ 4
6/3 SERVICES DUCTS ................................................................................................. 5
6/4 EXCAVATION FOR DUCTS ................................................................................... 5
6/5 BEDDING AND LAYING OF DUCTS ...................................................................... 6
6/6 BACKFILLING OF TRENCHES .............................................................................. 7
6/7 TESTING DUCTS.................................................................................................... 7
6/8 MARKING AND RECORDING OF DUCTS ............................................................. 8
6/9 DUBAI ELECTRICITY AND WATER AUTHORITY WORKS ................................... 8
6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES ................. 9
6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES ....................................... 10
6/12 WATER WORKS - GENERAL ............................................................................... 11
6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR ..11
6/14 WATER WORKS - STANDARDS .......................................................................... 12
6/15 WATER WORKS - PIPES ..................................................................................... 12
6/16 WATER WORKS - GRE FITTINGS ....................................................................... 14
6/17 WATER WORKS - PHYSICAL AND CHEMICAL REQUIREMENTS OF GRP
FITTINGS ......................................................................................................................... 15
6/18 WATER WORKS - VALVES .................................................................................. 18
6/19 WATER WORKS - MANHOLE COVERS AND FRAMES ..................................... 19
6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES ................................. 19
6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES ............... 20
6/22 WATER WORKS - PIPE ANCHOR AND THRUST BLOCKS ............................... 22
6/23 WATER WORKS - CLEANING OF PIPELINES .................................................... 23
6/24 WATER WORKS - TESTING PIPELINES ............................................................. 23
6/25 WATER WORKS - FINAL CLEANING AND STERILISATION .............................. 24
6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE............................. 24
6/27 WORKS FOR ETISALAT - GENERAL .................................................................. 24
6/28 MATERIAL SUPPLIED BY ETISALAT .................................................................. 25
6/29 INSTALLATION OF PVC DUCT-(DUCT NO. 54D) AS SUPPLIED BY ETISALAT25
6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPARTMENT (DMD) ......... 28

6/1 GENERAL REQUIREMENTS
6/1.1 This work consists of the provision of new services and/or the searching,
protection, diversion and relocation of the existing services for the following
authorities:
- Dubai Electricity and Water Authority

- Emirates Telecommunications Corporation Ltd.
- Dubai Municipality Roads Lighting Section
- Dubai Municipality Drainage & Irrigation Dept.
- Roads and Transport Authority Roads Department
6/1.2 The full scope of the new works required for the protection, diversion and
relocation of services cannot be determined at the tender stage and the
Contractor shall allow in his rates for any variation in quantities and for the non
continuous and interrupted nature of the work.
6/1.3 The Contractor's attention is particularly drawn to the procedures to be

followed concerning existing services and service diversions laid down in
section 1 of the specifications and all current Administrative orders.
6/1.4 The service ducts shown on the Drawings or as directed by the Engineer are
to be provided so that future services can pass through them without
disturbing the road construction.
6/1.5 Position, types of ducts, pipes, cables, manholes etc. and constructional
details are shown on the Drawings but final locations will be determined on
site by the Engineer after having consulted with the concerned authorities.
6/1.6 The Contractor shall verify the position of services by digging trial trenches
and pits and if ducts, pipes, cables and manholes which are not marked on the
Drawings are found, the Engineer and the concerned Authority will then
instruct on the action to be taken, if any.
6/1.7 All protected services, existing ducts found or newly laid ducts shall be marked
with approved markers (Sub-Section 6/8) of size and type shown on the
Drawings or as indicated by the Engineer. The Location of markers shall be
as shown on the Drawings. No asphalt course with be laid unless the ends of
the ducts or protected services have been exposed and marked with markers.
6/1.8 No work concerning services will be started without having first informed and
obtained approval of the Concerned Authorities. Services works shall be
executed in accordance with the relevant clauses of the Specifications.
6/1.9 The protection of the existing services shall be carried out before the earth
work starts in the vicinity of the services to be protected.
6/1/10 Where new cable/ducts are to be laid along side, over or under the existing,
the Contractor shall take care to interfere as little as possible with the existing
services and connections thereto and any damage shall be repaired by the

Contractor to the approval of the appropriate Authority or by appropriate

Authority at the cost of the Contractor.
6/1.11 If some services have already been protected by the various Departments no
protection will be carried out under this Contract, but such protection can be
extended and/or upgraded as instructed by the Engineer on Site after having
consulted with the Concerned Authority.
6/1.12 All concrete works shall conform to the requirements of Section 4 of the
Specification.
6/1.13 Road crossing ducts shall extend beyond the road line at each side of the road
as shown on the Drawings. When appropriate, the excavation for the road
crossing and laying of ducts, concreting etc., shall only be carried out on half
the width of the road at one time, the other half being left available for traffic.
In this case, the necessary traffic warning signs on self-supporting
tripods/cones shall be provided well ahead of the duct crossing work and all
care and attention exercised to avoid risk of traffic accidents during
preparation and execution of the work.
6/1.14 To prevent soil and/or sand blocking the ducts, the openings at both ends are
to be protected with appropriate blanking caps.
6/1.15 The Contractor shall be responsible for public safety during execution of work.
He will take all steps, including where necessary the provision of ropes, picket
fence, etc., on each side of the trenches and excavations with warning lights
and night watchman etc. to ensure the safety of the public. The Contractor will
be held responsible for any damage to property or injury to persons due to his
negligence. Any instruction from the Engineer concerning the safety aspects
of the work must be carried out immediately, but the Contractor shall remain
responsible for the adequacy of the safety measures.
6/1.16 The Contractor shall after completing each duct, make the necessary
arrangements with the Services Authorities for testing and acceptance of the
work.
6/1.17 The Contractor shall supply continuous warning tape for service Authorities
with the following requirements:
a) The Contractor shall install approved warning tapes during backfilling

work over buried pipes, cables, conduits and ducts, as required.
Warning tapes shall be coloured and inscribed for identification
according to the requirements of the relevant Authority.
b) Warning tape shall be approved high quality, acid and alkali-resistant

polyethylene film 250 mm wide, and with a minimum thickness of 150
microns. Tape shall have minimum tensile strength of 125 kg/sq.cm.
longitudinally and 105 kg/sq.cm. laterally with an elongation factor of
350% .
c) Tape shall be printed with 50 mm high black lettering, alternatively in

Arabic and English. The complete wordings shall be repeated every 2m

along the tape. The colours shall be vivid, glossy and permanent with a
life expectancy of 40 years.
d) Warning tapes shall be placed with the inscriptions facing upwards. The
level of the tape relating to the top of service shall be in accordance with
the requirements of the relevant Authority.
e) Warning tapes over non-metallic services shall be backed with Aluminum

foil to facilitate detection.
6/1.18 All trenches and other excavation shall be maintained in a dry condition and
the Contractor shall arrange a suitable dewatering system for any dewatering
involved, in agreement with the Engineer, to keep the working place clean
and dry. The Contractor shall be deemed to have included in his rates for all
costs associated with this work.
6/2 EXCAVATION FOR EXISTING SERVICES
6/2.1 The Contractor's attention is again drawn TO SECTION 1 of the Specification,

regarding existing services and diversions, which must be strictly adhered to.
6/2.2 The position of existing services as shown on the drawings are for
informational purposes only and do not necessarily show exact locations,
depths, spacings, and smaller services such as house connections which are
not normally indicated on such drawings. The Contractor shall excavate by
hand, take trial pits at regular distance and also at all road intersections to
locate existing services, their number, depth and route direction. As these
services are located the Contractor shall prepare shop drawings indicating the
aforementioned information.
6/2.3 After existing services, according to the Engineer's instruction, have been
exposed and if according to the opinion of the Engineer and after approval of
the concerned authorities it is found necessary to proceed with the lowering or
diversion, thereof, the Contractor shall proceed with the relevant excavation
in co-ordination with the said authorities.
6/2.4 The Contractor shall maintain records of such excavation in a form acceptable
to the Engineer. Two copies of such records shall be submitted to the
Engineer on a weekly basis or as agreed with by the Engineer.
6/2.5 The Contractor shall include all tools, labour, equipment and accessories as
required to complete the hand excavation. The Contractor shall include all
materials, labour and equipment necessary to protect the existing utilities, as
well as any shoring and protection during hand excavation.
6/2.6 All materials removed shall be disposed of by the Contractor in accordance

with the specifications or as directed by the Engineer.

6/2.7 When directed by the Engineer, all such excavation shall be backfilled with
suitable material, placed and compacted, all in accordance with the
requirements of the Specifications. The Contractor shall place fill material and
compact with care to avoid damage to the existing services. The Contractor
shall be responsible for any and all damages caused by his construction
operations.
6/2.8 The works relevant to the lowering of the existing service(s) will be started as
soon as, according to the Engineer, all the necessary precautions have been
taken to prevent any injury to person and/or property or services.
6/2.9 The excavation for lowering the existing service(s) shall be performed by hand
down to the elevation indicated by the Engineer and/or the concerned
authority.
6/2.10 At all times the Contractor shall provide and maintain, at his expense, access
to the adjoining properties to the satisfaction of the Engineer.
6/2.11 Where hedges are damaged or destroyed the whole shall be restored and
reinstated with shrubs of the same kind as the hedge, planted in due season in
an approved manner and fenced on each side with post and rail stock proof
fences finished on top with one strand of galvanised barbed wire, or otherwise
protected as required by the owners or occupiers and the Engineer.
6/2.12 Where fences or walls are damaged or destroyed the whole shall be restored
and reinstated with like materials to the satisfaction of the owners or occupiers
and the Engineers.
6/2/13 The Contractor shall ensure that no trees are damaged or permanently
removed in carrying out the Contract except where directed due to the
presence of permanent works.
6/3 SERVICES DUCTS
6/3.1 The Contractor shall supply (unless otherwise specified) and install all the
necessary service ducts required by the Contract. The duct material shall be
as specified on the Drawings. A sample of the proposed duct shall be
submitted to the Engineer for his approval prior to their use. (For ducts for
works for Etisalat, refer to Sub-Section 6/28).
6/3.2 In general all ducts laying work is subject to the approval of the Engineer and
any particular requirements of the concerned Authority.
6/4 EXCAVATION FOR DUCTS
6/4.1 The trench shall be excavated with the width and to the depth shown on the
drawings or as indicated by the Engineer.
6/4.2 The sides of pits and trenches shall be vertical and adequately supported at all
times. The sides of pits and trenches shall be vertical and adequately

supported at all times. Excavation may be battered with a safe slope, if

considered necessary, but only with the Engineer’s written permission
6/4/3 The bottom of the trench shall be accurately graded. Care shall be taken not
to excavate below the depths indicated. Where rock is encountered, the rock
shall be excavated to the required depth. Uneven surfaces of the bottom of
trench shall be excavated 150 mm deeper. Such depth in rock shall be
backfilled with approved fill material and compacted as specified and/or as
6/4.4 Where ducts are laid in the line of the road construction, the bottom of the
excavation shall be compacted to not less than 95% of its M.D.D, as
determined by BS 1377 Part 4: 1990 (method 3.5, 3.6) or as otherwise
approved by the Engineer. Insitu density tests shall be carried out in
accordance with BS 1377: Part 9: 1990: Method 2.2.
6/4.5 Excavated material shall, if found unsuitable as defined in the Specification, be

disposed of to an approved tip and replaced with suitable material. All surplus
suitable excavated material shall be used in road construction or disposed of
in an approved manner.
6/4.6 Where split ducts are required for existing services crossing the works, hand
excavation shall be carefully undertaken until the position of apparatus to be
protected is fully exposed.
6/5 BEDDING AND LAYING OF DUCTS
6/5.1 As soon as possible after trench excavation, ducts of the required diameter
shall be jointed in accordance with the Drawings and manufacturer's
instructions.
6/5.2 Ducts shall be laid to the lines and levels indicated on the Drawings with the
required depth of cover. Where the specified minimum cover cannot be
achieved, or as otherwise directed by the Engineer, they shall be bedded and
surrounded with 150mm of concrete Class 15/20.
6/5.3 Unless surrounded in concrete, ducts shall be bedded on a layer of sand

150mm thick and fully surrounded with sand to a depth of 300mm above the
duct barrel, well packed and tamped. Filling with suitable material above this
level shall be free from large stones. For multiple ducts, the spaces between
ducts are to be filled with compacted sand and the ducts surrounded to a
depth of 300 mm above the uppermost layer. Trench backfill shall be
compacted to the requirements of the Specifications.
6/5.4 The line of ducts shall be maintained as straight as possible. Short length of
duct, but not less than 600mm, long may be used to achieve any required
deviation in the duct runs.
6/5.5 Ducts shall be cut by the Contractor as necessary only at right angles to their
length using a saw in a simple cutting guide. The inside cut edges shall be
thoroughly rounded off or dressed before installation to prevent damage to
cables drawn through the ducts.

6/5.6 Existing services shall be protected where necessary, unless otherwise

directed by the Engineer, using split uPVC ducts laid as described above, fully
surrounded with 150 mm of concrete Class 15/20. The Contractor shall
consult the Engineer prior to carrying out protection works to agree the exact
method.
6/5.7 The halves of the split ducts shall be wired together and wrapped twice with
polythene sheeting to prevent the ingress of concrete.
6/6 BACKFILLING OF TRENCHES
6/6.1 After the cables/ducts have been laid, the trench refilling shall commence with
approved fill in compacted layers not exceeding 200 mm thick, each layer
being well compacted by hand with iron rammers weighing not less than 5 kg,
until the trench has been filled to a height of 300 mm above the top of the
cable/duct.
6/6.2 The reminder of the trench shall then be refilled in compacted layers not
exceeding 200 mm in thickness, each layer being well compacted, with power
rammers, vibrating plate compactors or other mechanical means of a type to
be approved until the ground is thoroughly consolidated up to the required
level for surface reinstatement. Each layer shall be compacted to not less
than 95% of its maximum dry density as determined by BS1377 Part 4: 1990:
AMD 13925: 2002 (method 3.5, 3.6). Should the quantity of the excavated
material be not sufficient, due to unsuitability or otherwise, for the process of
backfill and fill, the Contractor shall obtain the quantity required of such backfill
and fill from approved borrow pits and transport same to the site of the work at
his own expense.
6/6.3 Trenches shall not be backfilled until all required tests are performed and until
the Engineer has verified that the cables/ducts have been installed in
accordance with the Specification and Drawings.
6/6.4 Lumps and clods shall be broken up before use. Materials shall not be
dropped from a height and where directed, water shall be added to assist in
adequate consolidation.
6/6.5 Where cover to cables/ducts is less than 400 mm, or where ordered by the
Engineer, protection in the form of concrete encasing shall be provided
according to an approved drawing or as ordered by the Engineer.
6/7 TESTING DUCTS
6/7.1 On completion of all ducting, two mops of appropriate sizes connected to each
end of an iron mandrel shall be passed twice each way to clean the ducts and
to remove foreign matter. All proving tests shall be witnessed by the Engineer
and the service Authority. Should any obstruction or other defect be
discovered it shall be removed or rectified immediately to the Engineer's
satisfaction.
All testing is to be complete before commencement of asphalt works.

6/8 MARKING AND RECORDING OF DUCTS
6/8.1 Unless otherwise shown on the Drawings each cable duct of length greater
than 3m shall be provided with a drawcord of approved 15mm diameter nylon
rope. The length of each 15mm drawcord shall be such that at least 1m
extends from each end of the duct. As soon as each duct or set of ducts have
been proved and the draw cords installed the ends shall be plugged with a
wooden or other approved bung and a single coat of bituminous paint shall be
applied over the end of the duct and the bung. The free end of drawcords
shall be stored in an approved manner. The Contractor shall ensure that all
ducts are kept free from dirt, rubble, water and other obstructions.
6/8.2 In kerbless stretches of new roadway the Contractor shall provide suitable cast
aluminum stud duct markers (Type 2) to be fixed into the road surface over the
line of the respective duct or ducts at each end of the duct run, shown on the
Drawings. The head of the stud shall be suitably inscribed in Arabic and
English, with the approved abbreviation of the concerned Authority, such as,
D.E.C, E.T.C., etc. Should the markers not be placed immediately on
completion of duct runs, the Contractor shall expose the end of the duct to
satisfy the Engineer of its position when placing the marker. The stud to be
provided will be as per the products manufactured by approved manufacturers
based in U.A.E. In this regard the Contractor must submit his proposal with
samples for approval.
6/8.3 In kerbed areas of new roadway Type 1 and Type 2 duct markers shall be
used. Type 1 duct marker shall be of concrete construction, in situ or precast
depending on the location, as per the details shown in the Contract drawings,
complete with approved abbreviation cast thereon. The finished product shall
be solid in appearance, free of segregation, honey combing broken edges and
other defects. The cost of these particular markers will be subsidiary to the
relevant duct provision item.
6/8.4 The Contractor shall prepare and maintain up to date drawings for each
Service Authority giving details of each duct laid including precise location,
level, number and type, and these drawings to be submitted to the Engineer.
6/9 DUBAI ELECTRICITY AND WATER AUTHORITY WORKS
6/9.1 ELECTRICITY WORKS - GENERAL : The works relate to the following:
a) The installation, jointing and commissioning of low, medium and high

voltage power cable and pilot/telephone cable.
b) The relocation and protection of existing cables and pilot/telephone

cables.
c) The provision of duct crossing for future development use, all in

accordance with the relevant sections of the Specification and to the
satisfaction and approval of the Engineer and DEWA representative.

6/9.2 Where existing cables require extension of existing protection ducts of

concrete encasement or where shown on the drawings, the Contractor shall
provide such protection by means of split PVC ducts with concrete surround all
as per the relevant clauses of the Specification.
The longitudinal seam of the split duct shall be sealed with waterproof tape to
prevent the ingress of grout. The tape shall be denso or equivalent.
6/9.3 Elsewhere, following lowering as found necessary, additional duct(s) will be

furnished and installed alongside existing cables in accordance with the
requirements of the DEWA and relevant Contract Drawings.
6/9.4 If requested, and upon receipt of authorisation by DEWA Engineer, the

Contractor shall excavate, remove de-energised cable(s), transport to store or
dispose of as directed by DEWA Engineer, and backfill the excavation. The
cost of the excavation shall be paid under the relevant items of the Bill of
Quantities.
6/10 ELECTRICITY WORKS - SUPPLY OF CABLES AND ACCESSORIES
6/10.1 The cables, pilot cables and enclosures, straight through joints, splitter boxes,
jointing accessories, PVC tiles, marker tape and earthing strip required for
installation of cables shall be supplied from DEWA Stores at Aweer, as free
issue items.
6/10.2 The 6.6 KV power cable is 3 core, 300 sq.mm Copper or Aluminum
Conductors PLY/SWA/PVC according to BS6480 - 1988 in drum lengths of
250/400 Metres respectively.
6/10.3 The 33KV power cable is 3 core 400sq.mm. copper stranded CONDUCTOR
HSL type PLY/SWA/PVC and is in drums of 400 metre lengths.
6/10.4 The composite, 33 KV pilot/telephone cable comprises of 6 pilot cores of 2.5

sq. mm. each in two triple sleeves and 8 telephone pairs of 1/1.13 mm in four
quad formations wound on 1000 metre drum lengths.
6/10.5 132 KV pilot cables comprises of 14 pair 1/1.13 mm copper conductor,

polyethylene insulated, paired, polyethylene sheathed, galvanised single wire
armoured, PVC sheathed wound on 1000 metre drum length.
6/10.6 Cable tiles are made of high density PVC compound and are in 1 metre
lengths with provision of interlocking longitudinally. 20 and 15 cms. Wide tiles
shall be laid centrally as a physical cover over 6.6 KV, 33 KV power and
pilot/telephone cables respectively.
6/10.7 Upon taking delivery, if the Contractor feels that material given is of inferior
quality, he should immediately bring to the notice of the DEWA and the
Engineer.

6/11 ELECTRICITY WORKS - INSTALLATION OF CABLES
6/11.1 Trenching with mechanical aids shall be permitted at the discretion of the
Engineer where minimum of services exist, and where location of services is
already effected, otherwise only manual excavation shall be permitted.
6/11.2 The cables are to be laid in trenches to the dimensions shown on the
Drawings. All cables, screens and armouring will be solidly earthed at each
end of the route to the station earthing system. Separate cable tiles are
required for the main cables and for the pilot cables. The tiles for the 33 KV
cables shall be 1000mm long and 200mm wide. The tiles for the pilot and 6.6
KV cables shall be 1000mm long and 150mm wide. The tiles are to be placed
centrally over each cable and are to be laid with ends interlocked with adjacent
tiles. Plastic warning tape shall be installed at the specified level.
6/11.3 Pressure testing of the cables will be carried out by DEC for the whole of each
route. Any failure of the joint or cable due to its mishandling shall be rectified
by the Contractor at no extra charges. All additional material required for
making good the fault/damage shall be at the Contractor's cost. All work is to
be guaranteed for one year by the Contractor.
6/11.4 The Contractor shall remove within a period of 15 days after completion of
route, all the empty cable drums from the works and transport to DEC stores.
6/11.5 Contractor shall supply "As laid drawings" for the cable circuit to a scale of
1:1000 indicating the following:
- Layout of cable work

- Length size, type and grade of cables
- Location of each joint with respect to permanent landmarks available at
site.
- Name of the circuit, Contractor number, date of completion, Name of
Contractor with signature, DEWA's Senior Distribution Construction
Engineer's approval.
6/11.6 After a route/circuit is completed, the Contractor shall take full care to clear the
site completely and leave it neat and tidy. All the remains i.e. excess earth,
stones, tile pieces, rubbish or any unwanted solid waste should be removed to
tip.
6/11.7 Route markers as per the Drawing shall be provided along straight runs of
cable at locations approved by the Engineer and DEC and generally at
intervals not exceeding 100 metres. Markers shall also be provided to identify
the change of the cables route and also for location of every underground
joint.
6/11.8 Even though the circuit may be energised due to compelling reasons, the
taking over date for maintenance/guarantee period shall be the date on which
all the outstanding work pointed out to Contractor is completed satisfactorily
and official taking over certificate issued to the Contractor.

6/12 WATER WORKS - GENERAL
6/12.1 This section deals with the specification for works to be carried out in
connection with Water Service pipework to be ultimately taken over by the
Dubai Electricity and Water Authority. Works shall comply with the current
DEWA standard specification and this will take precedence over the following.
6/12.2 The works include for the supply, installation, testing and commissioning of the
Water Service installation, the layout for which is shown on the Drawings. The
Contractor shall include for all labour, materials, tools and tackle, complete
with all trenching and backfill.
6/12.3 The Contractor shall include for the preparation for all necessary working
Drawings. The Contractor shall be responsible for the location of other
services and the correct setting out of the installation.
6/12.4 The work also involves the exposing of existing water pipe lines for the
purpose of transferring existing house connections if any to the new
distribution system and for the connection of the new system thereto, and the
recovery and disposal of all abandoned existing connection lines, all as
indicated in the Drawings or otherwise directed by the Engineer.
6/12.5 The Contractor shall allow in his programme for the non continuous nature of
the work relating to the water services.
6/13 WATER WORKS - MATERIALS TO BE FURNISHED BY THE CONTRACTOR
6/13.1 All materials shall be provided by the Contractor, unless otherwise specified,
including but not limited to pipes, collars, rubber rings, valves, hydrants and
fittings.
6/13.2 The materials provided by the Contractor shall include all materials for
temporary works, planking and strutting, excavations, shuttering and
formwork, staging and scaffolding, approved filling materials, approved road
surfacing and paving materials, all materials required for repairing the internal
coating of valves, etc., such as primer, coal tar enamel etc., all concrete of
each required class including reinforcing steel and mesh, all surface boxes
etc.
6/13.3 All materials supplied locally by the Contractor shall be of the best quality in
their class and of the respective kinds as described in the Contract and in
accordance with the Engineer's instructions and to the satisfaction of DWD.
They shall be inspected from time to time at the site during the progress of the
work.
6/13.4 Any materials arriving on site found unsuitable shall be rejected. The
Contractor shall replace the rejected material at his own expense.
6/13.5 The Contractor shall, before supplying any local material, prepare and submit,
at his expense, to the Engineer for approval samples of materials which he
proposes to use. Such samples shall be retained by the Engineer. The

materials represented shall not be used in the works unless and until the
samples have been approved in writing by the Engineer.
6/14 WATER WORKS - STANDARDS
6/14.1 All calculations, drawings and submissions shall be in SI (System

International) units. Material items shall be to the latest BS (British Standard)
or equivalent comparable internationally recognised standard of construction
and quality.
6/15 WATER WORKS - PIPES
GENERAL
6/15.1 Asbestos cement (AC) pressure pipe shall conform to the requirements of BS
EN 512:1995. Pipe shall be manufactured in the U.A.E. All pipe and joints
shall be supplied by one manufacturer and certified by DM/DCL.
CLASS
6/15.2 AC pipe shall meet the requirements for class 18 suitable for an operating
pressure of 9 bars.
Pipe wall thickness shall meet all design requirements for class 18 pipe as
follows (Table 6-1):-
Table 6- 1: Pipe wall thickness requirements

Nominal diameter Outside diameter
(mm) (mm) at the end
75 93
80 106
100 126
150 178
225 255
300 344
550 616
600 668
700 780
900 1000
1200 1320
CEMENT
6/15.3 All cement used in the manufacture of asbestos cement pipe and joints shall
be a high sulphate resisting cement conforming to BS 4027: 1996. Copies of
cement mill certificates shall be submitted with each consignment delivered to
site.

JOINTS
6/15.4 Asbestos cements pipe shall be provided with spigot ends to be joined with
'Reka' type couplings with two rubber rings. Rubber rings shall conform to the
requirements of BS 2494. Joints shall be capable of withstanding a test
pressure of 18 bars without any leaks even when deflected to the angle
specified below (Table 6-2):
Table 6- 2: Joints properties (maximum deflection angle)

Nominal diameter mm Max. Joint deflection angle degrees
up to 225 5
250 - 350 4
400 - 550 3
600 - 1000 2
1100 - 1500 1
Copies of test reports showing compliance to these requirements shall be

submitted to DEWA for approval. Joint lubricant shall be an approved
vegetable-based type and shall be supplied by the pipe manufacturer.
LENGTH
6/15.5 Asbestos cement pipe shall be manufactured in 3 metre lengths for diameters
225 (9") and smaller and in 5 meter nominal lengths for larger sizes.
6/15.6 TESTING
Asbestos cement pipes shall be factory tested in accordance, with the BS EN

512:1990 copies of test certificates shall be submitted for each consignment
manufactured, and delivered to site. Sampling and inspection shall be in
accordance with BS EN 512:1990. Witnessing of factory testing by DEWA
representative may be required before any consignment is delivered to site.
All compulsory and optional tests shall be carried out by the manufacturer.
DEWA shall have the right to return up to 1% of pipes and joints delivered to
site for factory testing by the DEWA representative. All pipes testing shall be
performed on immersed samples.
6/15.7 MARKINGS
Each pipe and all joints shall be legibly and indelibly marked with the
following:-
i. The manufacturing standard.

ii. The manufacturer's name.
iii. Manufacturing date.
iv. Nominal diameter (ND) in mm.
v. Pressure rating in bars (class).
vi. Inspection mark.

6/16 WATER WORKS - GRE FITTINGS
6/16.1 All the fittings (bends, adapters, tees, etc.) shall be GRP (Glass Fibre
Reinforced Pressure fitting) which comply with the following specifications:-
GENERAL
6/16.2 This section covers the design, manufacture and testing of glass fibre
reinforced (GRP) pressure fittings for use with Asbestos cement pipelines in
nominal sizes 80 mm and larger. GRP fittings shall be locally manufactured in
the U.A.E.
CONSTRUCTION
6/16.3 GRP fittings shall have the following principal construction:-
- A corrosion resistant, resin rich liner having a minimum thickness of 0.5

mm. The liner surface shall be reinforced with "c" glass mat impregnated
with vinylester or Epoxy Resin.
- A structural wall consisting of continuous glass filament windings and/or

woven rovings and chopped glass reinforcements and may include
fillers, all impregnated with Resin.
- A resin-rich exterior surface having a minimum thickness of 0.25 mm,

impregnated with resin.
6/16.4 No pigments shall be allowed in the GRP fittings.
DESIGN REQUIREMENTS
6/16.5 GRP fittings and flanges shall be designed for service at the following
conditions:-
Maximum Operating Pressure 10 Bars

Minimum Site Test Pressure 15 Bars
Maximum Allowable Vacuum -1 Bar
Minimum Depth of Cover 1.0 Metre
Maximum Depth of Cover 4.0 Metre
Truck Loading (Wheel Load) 100 KN
Maximum Service Temperature 50 Deg.C.
6/16.6 Flanged fittings shall be designed for installation above ground (in Chambers)
with no thrust blocks.
6/16.7 Flanged branches on Spigot Tees and puddle (Wall) flanges shall be designed
to resist End thrust from closed valves.

GRP JOINTS
6/16.8 SPIGOT JOINTS, where specified shall have the same outside diameter (O.D)
as Asbestos Cement (AC) pipe class 18 used by DEWA. The joint dimensions
and tolerances shall be equal to AC pipe spigots such that the joint remains
water tight under all normal operating conditions. The spigot ends shall be
clearly marked with a Home line indicating the proper insertion limit for the AC
couplings.
6/16.9 FLANGED JOINTS, where specified shall be GRP filament wound flanges
manufactured from Vinylester or Epoxy resin. Flanges shall be flat faced and
drilled to BS 5404 PN 10 drilling pattern. Full face rubber gaskets 3 mm
minimum thickness shall be provided by the fitting manufacturer.
6/16.10 LAMINATED OR ADHESIVE JOINTS, used in the fabrication of fittings shall

be equal or superior in strength to the sections they join. The thickness of
laminated joints shall not be less than the wall thickness of the adjoining pipe
section.
6/17 WATER WORKS - PHYSICAL AND CHEMICAL REQUIREMENTS OF GRP

FITTINGS
CHEMICAL REQUIREMENTS
6/17.1 GRP fittings shall not impart any taste, odour or colour to drinking water. All
resins used shall be suitable for use in drinking water systems.
DIMENSIONS
6/17.2 GRP fittings shall be produced in Metric sizes and shall be classified by their
nominal inside diameter (N.D). The actual fitting inside diameter shall not be
less than that shown in the table below (Table 6-3):-
Table 6- 3: GRP fittings dimensions
NOMINAL DIAMETER MINIMUM INSIDE DIAMETER mm

ND (mm)
80 78
100 98
150 148
200 198
225 223
250 248
300 298
550 546
600 595
700 695
750 744
900 892
1200 1190

ELBOWS
6/17.3 Elbows of nominal diameter 300 mm and smaller shall be of the smooth radius
type, having a turning radius of 1.5 times the elbow nominal diameter. Elbows
larger than 300 mm shall be smooth radius of 1.5 times the elbow nominal
diameter. All internal surfaces shall be finished smooth.
FLANGES
6/17.4 The minimum GRP flange wall thickness shall not be less than that shown in
the table below (Table 6-4):-
Table 6- 4: GRP flange wall thickness
NOMINAL DIAMETER MINIMUM INSIDE FLANGE

ND (mm) THICKNESS (mm)
80 32
100 32
150 32
200 37
225 42
300 48
550 68
600 68
700 73
750 77
900 82
1200 106
WALL THICKNESS
6/17.5 The wall thickness of GRP fittings shall be determined by the manufacturer to
meet the design requirements of these specifications but shall in no case be
less than the values shown in the table below (Table 6-5):-
Table 6- 5: Wall thickness of GRP fittings

NOMINAL DIAMETER ND (mm) MINIMUM WALL THICKNESS mm
80 3.2
100 3.2
150 3.2
200 3.2
225 3.4
300 3.6
550 4.4
600 5.7
700 6.3
750 7.3
900 9.5
1200 12.5
(Excluding inner and exterior layer).

MECHANICAL PROPERTIES
6/17.6 GRP fittings shall meet the following minimum strength requirements (Table 6-
6) :-
Table 6- 6: GPR fittings minimum strength requirements
PROPERTY TEST METHOD MINIMUM VALUE

Hoop Tensile Stress ASTM D2290 :04 180 MPa
Axial Tensile Stress for ASTM D 638 :03 40 MPa
spigot fittings
Axial Tensile Stress for ASTM D 638 :03 90 MPa
flanged fittings
Stiffness (EI/D) BS 5480 : 1990 5000 Pa
In addition to factory testing, the following tests shall be carried out at DCL.
1. Initial longitudinal unit tensile strength by tensile strip test in accordance
with BS 5480: Appendix “A”
2. Initial specific stiffness under Ring Deflection Test in accordance with BS
5480: Appendix H.
VISUAL REQUIREMENTS
6/17.7 GRP fittings shall be free from delamination, crazing, dry areas or cracks.
Spigot ends shall be free from end delamination, torn edges, gouges and shall
be finished smooth to ensure water tightness.
TESTING GRP FITTINGS
6/17.8 The following tests shall be carried out by the fitting manufacturer at the
intervals specified. Test results and certificates shall be submitted to DEWA
for each consignment delivered. Witnessing of factory testing by the DEWA
representative may be required.
TEST FREQUENCY
1. Visual Inspection Every Item

2. Dimensions Every Item
3. Hydraulic Pressure Once per 100 Flanged Items
4. Stiffness Once per 100 Equal Items
5. Longitudinal Tensile Stress Once per 100 Equal Items
6. Hoop Tensile Stress Once per 100 Equal Items
SUBMITTALS/DRAWINGS
6/17.9 Prior to start of production, the fittings manufacturer shall submit to DEWA
dimensional drawings of each fitting required for approval.

6/17.10 For flanged fittings, the manufacturer shall submit before delivery, the bolt-
torquing sequence and maximum recommended torque for each flange size
supplied.
MARKINGS
6/17.11 Each fitting shall be indelibly marked with the following:-
- Manufacturer's name or Trademark

- Nominal Diameter (N.D) in mm
- Pressure rating in Bars
- Manufacturing Date
- Inspection Mark
6/18 WATER WORKS - VALVES
6/18.1 Sluice valves supplied shall be suitable for use IN DUBAI, the valves shall be
supplied complete with gaskets and galvanised nuts and bolts. The sluice
valves shall be in accordance with BSI BS 5163-1: 2004, latest edition.
Manufacturer's test certificates are required the nominal pressure shall be 10
bar.
6/18.2 Double spigot valves with bevelled edges are required unless otherwise
indicated. The outside diameters of the machined ends shall fit with the
specified pipes.
6/18.3 Valves greater than 300 mm dia shall be butterfly type valves.
6/18.4 The maximum tolerance shall be + 0.6 mm. It is preferred that the
manufacturer makes an allowance for the 300 microns epoxy coating during
machining.
6/18.5 Valves shall be grey cast iron, metal seated as per BSI BS EN ISO 1452-4:
2010. With a wedge of grey cast iron and gun metal rings, the stem shall be of
high tensile brass with a grey cast iron stem cap. Toraidal sealing rings are
required for stem sealing for all valves of 300 mm dia or less.
6/18.6 Valves up to and including 300 mm dia shall be clockwise closing without hand
wheel.
6/18.7 Where flanges are required they shall be drilled to PN 10 in accordance with
BS 4504 unless stated otherwise.
6/18.8 Additional markings on the valves shall be the year of manufacture and an
individual number which relates directly to the manufacturer's test certificate.
6/18.9 The valves shall be coated externally and internally to 300 microns with an
epoxy coating suitable for use with drinking water, the primer shall be zinc rich
and the preferred colour of the coating is blue.
6/18.10 A certificate verifying the suitability of the epoxy paint for use with drinking
water is required from the manufacturer endorsed by DEWA.

6/18.11 The manufacturer shall supply the original test certificate for each valve
supplied, the certificate shall relate to the individual number cast on each
valve, the certificate shall give the date of test.
6/19 WATER WORKS - MANHOLE COVERS AND FRAMES
6/19.1 The manhole covers and frames shall be in accordance with BS EN 124:
1994: AMD 8589: 1995
6/19.2 The frame shall be square with a circular clear opening of 600 mm diameter
and be single sealed.
6/19.3 The cover shall be badged "DEWA" in English and Arabic and also with the
DEWA logo. The pattern shall have the prior approval of the Dubai Electricity
and Water Authority.
6/19.4 Two keys shall be provided for every 10 Nos. of covers supplied.
6/19.5 The cover and frame shall be coated with suitable heavy duty abrasion
resistant epoxy paint to a minimum DFT of 375 microns and shall be verified
by DCL.
6/19.6 DEWA reserves the right to request a manufacturer's certificate certifying

compliance with the specification.
6/20 WATER WORKS - HANDLING AND STORAGE OF PIPES
6/20.1 Prior to undertaking any work, the Contractor shall submit to the Engineer for
approval, his proposal for the handling and storage of pipes and all fittings
thereto. Such proposals shall ensure that all pipes are properly handled and
stored both by his staff and sub-contractors staff.
6/20.2 The storage surface should be as level and as firm as possible and clear of
rocks or solid objects that might damage the pipes. Stockpiles should not
exceed a certain height. This height is limited for safety and practical reasons
as per the following (Table 6-7):-
Table 6- 7: Stockpiles height (storage of pipes and all fittings)
DN 80-400 450-600 700-1000 1000-1400 > 1500
Layers in 5 4 3 2 1
Stockpile
Height <2m < 2.9 m < 3.0 m < 2.8 m < 2.0m
6/20.3 Asbestos cement coupling rings shall be stored lying flat and particular care
shall be taken to prevent damage to the internal face of the ring or the turned
ends of the pipes which may affect the sealing of the coupling.

6/20.4 Rubber sealer rings and gaskets shall be stored in a cool, dry dark place away
from grease, oil and sunlight until required.
6/21 WATER WORKS - EXCAVATION LAYING AND JOINTING OF PIPES
6/21.1 The trench depth shall be according to the approved shop drawings but never
less than 1.0 m between the ground level and the pipe crown level.
6/21.2 The Contractor shall excavate trenches to a sufficient depth and width
according to the following (Table 6-8):-
Where B: is the width of the trench at the crown pipe level.
Table 6- 8: dimensions of the trenches for pipes
DN (mm) B MIN. (mm) MAX. (mm)

80 - 200 600 700
250 700 800
300 800 900
350 - 2000 DN+600 DN+1000
6/21.3 The side of trenches shall be adequately supported at all times. Trench sides
must be vertical and no battering will be allowed without the express
permission, in writing, of the Engineer.
6/21.4 The Contractor shall thoroughly compact the bottom of the trench formation,
the trench shall be cleaned of all stones, soil and other debris that might have
fallen therein.
6/21.5 Immediately following a prepared trench, pipes shall be laid and jointed on
specified pipe bedding material. Bricks or hard material shall not be placed
under the pipes for temporary support.
6/21.6 Prior to laying, each pipe and fittings shall be carefully examined both inside
and outside for any damage, and all dust, dirt and foreign matter shall be
removed.
6/21.7 For assembling, the Contractor shall adhere to the following conditions:-
PREPARATION OF THE REKA COUPLING
6/21.8 In order to avoid its damage the sealing rubber ring must be fitted into reka
coupling just before laying starts. Ensure that the groove of the rubber ring is
carefully cleaned, the ring is then fitted according to the following:-
a. Lay the coupling horizontally.
b. Fit the ring into the groove.
c. Check that the ring is uniformly and fully seated into the groove all the
way round.

d. For large diameter (600 mm and above) two men are necessary to insert
the ring.
MOUNTING THE COUPLING IN THE PIPE
6/21.9 Clean coupling and pipe with a soft brush and insert them fully. Lubricate the
pipe end and the coupling ring by means of a dry clean piece of cloth or a
sponge. For lubricant use Eternit supplied products soap. In dusty conditions
lubricate generously the coupling only.
6/21.10 For small diameter pipes (DN < 300) the coupling can be mounted by hand.
Use a timber block to protect the coupling and force the coupling into the
correct position as indicated by a black line on the pipe.
6/21.11 For larger diameters and where this method does not work the pulling can be
achieved by means of suitable mechanical devices. The gap between the
pipes (15 mm) is achieved automatically because the coupling stop at the level
of the strap fixed to each end of the pipe. N.B. It is essential to push the
coupling to the home line and not beyond, otherwise the pipes in the coupling
will touch each other and consequently not allow any expansion.
6/21.12 Maximum deflection angles for curved pipelines shall be according to the
following schedule (Table 6-9):-
Table 6- 9: values of maximum deflection angles for curved pipelines
DN O (mm) R (m)
L=3 m L=5 m L=3 m L=5 m
80-250 5 290 963 38.18 57.33
300-350 4 232 399 97.71 71.25
400-600 3 175 262 63.6 95.5
700-1200 2 117 175 95.4 143.25
1300 1 59 88 190.8 286.50
Where: R: Radius of Curvature
O : Offset
L : length of the pipe
BACKFILLING
6/21.13 The Contractor shall backfill the pipes as follows:
The backfilling material shall be brought up on both sides of the pipe first to
the level of the centre of the pipe line and then to height of 30 cm above the
top of the pipe barrel. This backfill material shall be placed in layers each not
more than 15 cm thickness and shall be carefully compacted for the full width
of the trench with hand tools to the satisfaction of the Engineer.

UNDER THE ROAD, PARKING AREAS AND FOOTPATHS
6/21.14 Backfill shall be in layers of thickness not exceeding 150 mm. Backfill shall
have a minimum soaked CBR of 15% (BS 1377 Part 4 : 1990 Method 7, AMD
13925: 2002) and compacted to not less than 95% of the maximum dry
density as determined by BS 1377 Part 4 : 1990 (method 3.5 or 3.6, AMD
13925: 2002). Backfill within 30 cm of road subgrade level shall meet the
requirements of improved subgrade described in Section 2 of the
Specification. Insitu density tests shall be carried out in accordance with BS
1377: Part 9 : 1990: Method 2.2, AMD 17229: 2007.
OUTSIDE THE ROAD
6/21.15 Backfill shall be in layers of thickness not exceeding 250 mm compacted

carefully to a minimum of 90% maximum Dry Density to the finished ground
level. Insitu density tests shall be carried out in accordance with BS 1377:
Part 9 : 1990: Method 2.2, AMD 17229: 2007.
6/21.16 In order to prevent stones and soil from entering the pipe, a suitable cap and
or plug shall be provided with which the last pipe laid shall be closed when
pipe laying is not actually in progress. The plug shall be of the screw up
expanding type or of tapered wood.
6/21.17 Where the cover to pipes is less than 1.0 m or where ordered by the Engineer,
protection in the form of concrete slabs above the pipe shall be provided
according to an approved drawing by DEWA.
6/22 WATER WORKS - PIPE ANCHOR AND THRUST BLOCKS
6/22.1 Pipe anchor and thrust blocks, shall be constructed on pipelines at all bends,
slopes greater than 1/6 and stop ends, tees and as otherwise required by site
conditions.
6/22.2 The thrust blocks shall be designed by the Contractor in accordance with BS
8110. The Structural Use of Concrete. The Contractor shall show that soil
resistance is greater than or equal to 1.2 times the force exerted by the pipe
when tested to 9 bar pressure. The soil resistance shall be calculated as the
frictional resistance of the soil against the thrust block. In calculating the
passive resistance the co-efficient of passive pressure of the soil shall be
factored by 0.5.
6/22.3 The design of thrust blocks shall not be less than the dimensions given on the
drawings. This design is always subject to DEWA approval.
6/22.4 Before any internal pressure is applied to a pipeline, all the permanent
concrete thrust blocks shall have been cast in contact with the undisturbed
ground and cured for a minimum of 7 days.
6/22.5 Concrete Class 30 with Sulphate Resisting Cement shall be used for the
construction of thrust blocks.

6/23 WATER WORKS - CLEANING OF PIPELINES
6/23.1 On completion of construction, and before any sterilisation, internal surfaces of

pipelines shall be cleaned thoroughly by flushing in such a way as to remove
all oil, grit and other deleterious matter.
6/23.2 Flushing of the new pipeline may be carried out by temporary connections to
the existing water system if present in the working area. DEWA will charge for
giving the water to the Contractor as per normal rates. In the absence of
mains water supply tankers shall be used.
6/24 WATER WORKS - TESTING PIPELINES
6/24.1 The Contractor shall provide written notice to the Engineer of any tests two
days before the test is to be carried out. All tests must be witnessed by the
Engineer. The Contractor shall maintain written records of the tests and
provide copies of the records to DEWA prior to the completion of the project.
6/24.2 The Contractor shall provide all, water, fittings, pipe stoppers, test pump,
pressure gauges and the necessary equipment and tools for pipe work testing.
Hydraulic pumps, gauges and apparatus shall be equipped with locking
devices to prevent tampering during the test period.
6/24.3 Prior to hydraulically testing the pipelines the Contractor shall provide
adequate temporary thrust blocks only at the ends of uncompleted sections.
Pipes shall be partially backfilled to about 500 mm above the crown of the
pipe, in order to anchor the pipes during testing. Joints and fittings, however,
shall remain uncovered for inspection until the pipeline has been tested
satisfactorily.
6/24.4 The length of the section of pipeline to be tested may be determined by the
Engineer/Contractor but shall not exceed 500 metres. The levels of the length
of pipe under test shall be such that the minimum test pressure specified is
achieved at all points whilst the maximum test pressure specified is not
exceeded at any point.
6/24.5 Valves shall not be used to isolate sections forming the pipeline whilst testing
operation are in progress.
6/24.6 Before testing the line should be filled slowly and evenly with water through
any convenient top or valve from the lowest point. At every high point an
automatic air release valve must be installed. After expelling all the entrapped
air out of the test portion, all air release valves should be closed. If it is not
possible to fill the line from the lowest point an additional outlet should be
added at the inlet point to release air at that point and this line/section should
be kept filled for 24 hours before the pressure test.
6/24.7 The test pressure shall be 1.5 times the maximum working pressure or 9 bar
whichever is greater. The pressure shall be raised slowly to the specified test
pressure and maintained at that pressure for a period long enough for the
Engineer to examine the whole section under test. There after, for a period of
not less than 4 hours, the leakage of water as measured by the amount drawn
into the pumps to maintain the pressure shall not exceed 0.1 litre per

millimetre of pipe diameter per kilometer of pipeline per 24 hours for each 30
meters head of pressure applied at the lowest point. Expected losses due to
absorption shall be as specified by the pipe manufacturer.
6/24.8 The pipework, joints and connections shall be examined. Should leaks be
detected the pipework shall be repaired to the satisfaction of the Engineer and
the test repeated.
6/25 WATER WORKS - FINAL CLEANING AND STERILISATION
6/25.1 Upon completion of hydraulic tests the Contractor shall flush out the pipework
with chlorinated fresh water and a cleaning swab will be passed through the
pipework, this process will continue until the flushing water runs clear.
6/25.2 The Contractor shall prepare a solution of chlorinated dosing solution using
calcium hydrochloride at a rate of 77g/cu.m. of system water volume, or with
chlorinated water containing between 30 and 50 mg per litre of free chlorine.
The solution shall be slowly pumped into pipeline and a chloride level of 50
p.p.m. shall be maintained for a period of 8 hours. The pipework shall be
flushed out, until the chloride level drops below 0.2 p.p.m. per litre.
6/26 WATER WORKS - CONNECTIONS TO EXISTING PIPELINE
6/26.1 All final connections of new pipelines to existing pipelines will be carried out by
the Dubai Electricity & Water Authority. The Contractor is to provide one week
of notice to DEWA for this work and shall render all necessary assistance.
6/27 WORKS FOR ETISALAT - GENERAL
6/27.1 GENERAL
The works relate to the protection and diversion of existing telephone duct
lines, for major trunk communications services alterations, including demolition
and rebuilding where instructed, to existing telephone manholes and joint
boxes and the provision of duct crossings for future development purposes.
The layout of the works for Etisalat are shown in the Drawings.
6/27.2 Where applicable, all civil works essential to the relocation/replacement of the
existing major coaxial cable systems including duct installation, manhole and
joint box construction shall be carried out by the Contractor within the
stipulated Contract period for sectional completion.
6/27.3 Where applicable, the installation of new Etisalat cables shall be carried out by
Etisalat within the time stipulated in the Contract.
6/27.4 Civil works for Etisalat other than the above shall be carried out by the
Contractor according to his approved programme.
DUCTS
6/27.5 The installation of ducts of the required diameter shall be in accordance with
Etisalat Specifications as per Sub-Section 6/29.

MANHOLES AND JOINT BOXES
6/27.6 The existing manholes to be demolished and rebuilt and the new manholes to
be constructed, if shown on the Drawings, are for information purposes only
and do not necessarily show the exact locations thereof. Exact details and
locations of these manholes will be determined on site in accordance with the
Etisalat Engineer's instructions.
6/27.7 The construction of new manholes shall be performed in accordance with the
Drawings.
6/27.8 Manholes shall be as per types shown on the Drawings or as required by

Etisalat. The concrete mix shall be Class 30 according to the requirements of
Section 4 of this Specification.
6/28 MATERIAL SUPPLIED BY ETISALAT
6/28.1 PVC pipes, draw cord, manhole frames and covers, and all other fixtures and
fittings will be furnished by Etisalat. The Contractor shall make the necessary
arrangements for providing labour and all equipment for loading at the Etisalat
Stores, for transporting to site, unloading, storing and fixing in position the
above mentioned material. The Contractor's responsibility for material
furnished by Etisalat shall begin upon the Contractor's acceptance at the place
of delivery. All such materials can be examined and tested by the Contractor,
and all defective material shall be rejected by him at the time and place of
delivery.
6/28.2 All material found to be defective or damaged at this time will be replaced by
Etisalat. Once accepted by the Contractor at the place of delivery, he has no
right for any claim. All defective or damaged material discovered prior to final
acceptance of the work shall be removed by the Contractor and replaced by
new approved material at his own expense.
6/28.3 In that event, the Contractor shall be responsible for the safe storage of all
material furnished to or by him, accepted by him until it has been incorporated
in the Works and finally accepted by the Employer. Any material lost or stolen
from the site shall be replaced by the Contractor at his own expense.
6/29 INSTALLATION OF PVC DUCT-(DUCT NO. 54D) AS SUPPLIED BY ETISALAT
6/29.1 GENERAL. Duct No. 54D is manufactured from PVC. It is supplied in 6.0
metre effective lengths, has an internal diameter of 90mm and a nominal wall
thickness of 3.25 mm. Each duct length has a tapered socket at one end
which will accept the barrel of the duct. Couplings, Ducts 54A, 300 mm in
length are also available for use with short lengths of duct which have no
socket. Couplings Duct, 54A shall not be used for duct leading into buildings.
6/29.2 TRENCH. The trench shall be excavated to the required width and depth; the
trench bottom shall be free from stones, level and well tamped. The duct shall
be laid at standard depths unless otherwise specified.

6/29.3 FORMATIONS. Duct No. 54D may be laid as a single duct or in multiway
formation as follows:
(a) Up to and including 9 ways in rectangular formation.
(b) Over 9 ways rectangular formation with concrete surround.
(c) The duct bank must be properly secured to the ground before concreting
to avoid displacement due to flotation.
LAYING AND JOINTING
a) For Singleway
6/29.4 The open starting end of the trench shall be blanked off with a board or
boards, to act as an anvil against which the duct can be driven home. The
duct shall be recessed into the wall of jointing chambers 10 mm from the
inside surface. The surface of the duct shall be roughened with glass paper or
sand paper for its length in the jointing chamber wall.
6/29.5 The duct shall be laid on the trench bottom with the socket towards the duct
layer; the spigot end and the inside of the socket of the duct to be jointed shall
be thoroughly cleaned with dry rag.
6/29.6 The spigot end of the duct shall be offered to the socket initially pushed in by
hand and then to achieve proper engagement a suitable wooden batten is
placed across the remote socket and tapped with a hammer. Full engagement
should be ensured. Occasionally, due to variations in size, this cannot be
achieved, in which case, excessive force must not be exerted after a tight joint
has been effected.
6/29.7 When jointing short lengths of duct together with a Coupling, Duct No. 54A,
both spigot ends and the inside of the Coupling shall be thoroughly cleaned
with methylated spirits applied with a clean rag. The spigot ends should be
given a liberal coating of PVC Cement and then fitted into the coupling. This
operation involves using toxic and inflammable materials.
b) For Multiway Up to and Including 9 Ways
6/29.8 The preparatory work and jointing shall be as for singleway.
6/29.9 The first layer of ducts shall be laid on the prepared trench bottom so that their
outer surfaces touch each other and a minimum gap of 75mm remains
between the outside ducts and the sides of the trench timbering where used.
Wooden stakes or an approved alternative shall be driven into the ground at 3
metre intervals along the trench to keep the ducts in the correct position.
Suitable material shall be placed to fill the spaces between the ducts and the
next layer of duct when the latter is bedded down. The second and
subsequent layers of duct shall be laid between the wooden stakes so that
they are vertically above and then bedded down to touch the ducts in the layer
below, the spaces between the ducts being filled in the same way with suitable

fill material. The joints shall be staggered so that no joint touches any other
joint.
6/29.10 At approximately 5 metres from the jointing chamber at each end of the track,
the duct formation shall open to provide a gap between each duct, both
vertically and horizontally, of 25mm using, spacers. Over this 5 metres section
all spaces between the duct and the trench wall shall be filled with well
compacted fill.
c) For Multiway ducts over 9 ways
6/29.11 The preparatory work and jointing shall be as for single-way duct.
6/29.12 The first layer of duct shall be laid on the prepared trench bottom so that their
outer surfaces touch each other and a minimum gap of 75mm remains
between the outside ducts and the sides of the trench, or trench timbering
where used. Mild steel bars, 12 mm diameter and of the required length shall
be driven into the ground at 1.5 metre intervals along the trench to keep the
ducts in the correct position. The second and subsequent layer of duct shall
be laid between the mild steel bars so that they are vertically above and
touching the ducts in the layer below. The joints shall be staggered so that no
joint touches any other joint. On completion of the assembly of the duct nest,
6 mm diameter mild steel bars shall be placed horizontally across the
uppermost layer of ducts and tied to the vertical bars.
6/29.13 Where the total number of layers of duct in any one formation exceeds 8 and
the number of ducts in each layer exceeds 2 the following shall apply.
Between the two layers of duct midway, or approximately midway, from the top
and bottom of the duct nest an intermediate layer of reinforced concrete, 75
mm in depth and with 12 mm mild steel reinforcing bars conforming to the
layout of reinforcing in the top cover detailed on the Drawings shall be placed
across the duct nest. The additional reinforcing required by this sub-
paragraph shall not be required in the 5 metre sections detailed in sub-
paragraph 14 below.
6/29.14 At approximately 5 metres from the jointing chambers at each end of the track
the duct formation shall open out to provide a gap between each duct, both
vertically and horizontally of 25 mm. Banks of spacers shall be placed 325
mm and 1325 mm from the jointing chamber wall to provide this spacing.
Each spacer bank shall enclose all the ducts except those in the bottom layer
on which the spacer bank shall rest. Where sub-paragraph 13 applies, the 75
mm intermediate layer shall be reduced over 5 metre sections to provide the
required 25 mm spacing at the jointing chambers.
6/29.15 Where the total number of layers of duct exceeds three, concreting of spaced
formations shall be in stages such that the number of layers of duct laid and
concreted at each stage shall not exceed three. The concrete shall be brought
to a level which shall not interfere with laying of subsequent layers of ducts
and spacers.
6/29.16 Concrete class and workability as specified by Etisalat and approved by the
Engineer shall be used throughout. The concrete shall be evenly placed
around the duct to give a finished minimum thickness of 75 mm on both sides
and to a depth of 130 mm above the top layer of ducts. Care must be taken to

ensure that each batch, as it is placed, is properly compacted without creating

unbalanced side thrust against the ducts. Each batch shall be vibrated using a
vibrator having a maximum diameter of 51 mm, the vibrator shall be lowered
into the concrete between the wall of the trench and the outside of the duct
nest and shall not touch the duct. In spaced formation sections care must be
taken to ensure that the gaps between the ducts are properly filled with
concrete, the final layer of concrete shall be thoroughly trowelled.
6/29.17 With formations of four or more ducts wide, mild steel reinforcing bars
conforming to the Drawings shall be placed and wired in position before
placing concrete over the uppermost ducts of the completed nest.
6/29.18 In the case of column entry manholes, the duct formation shall open out to
enter the manhole as shown on the appropriate manhole drawing and at right
angles to the entry wall. The distance over which the transformation is made
shall be no greater than is necessary to satisfy the 5 metres minimum bedding
radius for duct No. 54D. The ducts shall be secured in position during
concreting with spacers, built up to the required centres or by reinforcing rods
which may be encased in the concrete. The volume between the separated
duct formations shall be excavated and filled with concrete of the same quality
as that surrounding the duct formations.
ALTERNATIVE METHOD OF JOINTING AND LAYING
6/29.19 Provided that space permits, duct No. 54D may be jointed above ground and
fed into the trench from one end. The leading end of each duct way being
guided into position using a suitable hooked tool made from 6 mm diameter
mild steel reinforcing bar.
6/29.20 BENDS. Normally bends are not supplied since the duct is sufficiently flexible
to provide a minimum bending radius of 5 metres. Tighter bends should not
be attempted otherwise kinking of the duct may result.
6/29.21 VARIATIONS. Any variation of duct formation and/or depth shall only be
carried out with the prior agreement of the Engineer or Etisalat Civil Works
Supervisor.
6/29.22 BACKFILL. (a) Backfilling of trenches where duct No. 54D has been laid
without concrete surround shall be carried out carefully in a manner that shall
not disturb the duct formation. Where duct No. 54D has been laid with
concrete surround the end shuttering and trench supporting timber, if used,
shall be removed not less than 12 hours after the concrete has been placed.
Backfilling of the trench, in accordance with the Specifications shall not be
carried out until a further 48 hours have elapsed.
6/30 WORKS FOR DUBAI MUNICIPALITY DRAINAGE DEPARTMENT (DMD)
6/30.1 All drainage and sewerage to be performed under this contract shall follow the
specifications given in Volume 2 – Part III and IV – Dubai Sewerage and
Drainage Master Plan standard specification. For all other works the
contractor shall refer to the applicable specifications as given in Volume 2 Part
I and II.

1 SECTION 7 ROAD LIGHTING AND TRAFFIC SIGNALS
TABLE OF CONTENT
7A/ ROAD LIGHTING ...........................................................................................................3

7B/ TUNNEL AND UNDERPASS LIGHTING .....................................................................33
7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS .........................................................57

TABLE OF CONTENT
7A/ ROAD LIGHTING ...........................................................................................................3

7A/1 SCOPE ...................................................................................................................3
7A/2 ELECTRICITY SUPPLY .........................................................................................3
7A/3 REGULATIONS AND STANDARDS ......................................................................4
7A/4 CLIMATE ................................................................................................................7
7A/5 GENERAL ...............................................................................................................8
7A/6 CONTRACTOR’S DRAWINGS AND DOCUMENTATION .....................................9
7A/7 INSPECTION, TESTING AND COMMISIONING .................................................10
7A/8 EARTHING ...........................................................................................................12
7A/9 SWITCHBOARDS AND SWITCHGEAR ...............................................................13
7A/10 CABLING ..............................................................................................................18
7A/11 LUMINAIRES ........................................................................................................23
7A/12 LIGHT POLES ......................................................................................................25

7A/ ROAD LIGHTING
7A/1 SCOPE
7A/1.1 The Works include the supply and installation of:
 Traffic management
 Cabling with conduiting and warning tape from DEWA
substation to switchboards
 Duct crossings for service cables
 Civil works of the roadway lighting system (except as otherwise
specified)
 Switchboards including feeder pillars
 Earthing
 Cabling with conduiting and warning tape from switchboards to
luminaires
 Light poles including service cut-outs and foundations with
holding down bolts, nuts and washers
 Luminaires with lamps and lamp control gear
 Road sign illumination
 Under-bridge lighting
 Pedestrian pathway lighting
 Underpass lighting
 Navigation lighting
 Façade lighting
 Tunnel lighting
 Interior lighting of switch rooms, etc.
 Inspection, testing and commissioning
 Manuals and “Record” Drawings
 Maintenance during the Defects Liability Period
 Sundries that is all minor and incidental work and materials,
specified or unspecified, which are required for proper
completion of the works to the true intent and meaning of the
Specification and to the satisfaction of the Engineer.
7A/1.2 Works excluded:
Dubai Electricity and Water Authority will install any new sub-stations required for
the system
The Lighting and Traffic Systems maintenance Section will be responsible for the
maintenance of above ground services.
7A/2 ELECTRICITY SUPPLY

7A/2.1 MAIN POWER SUPPLY:
The Contractor shall contact the supply authority at an early stage of the Contract
to make all the necessary arrangements for the power supply.
The power supply for the light poles will be from new and/or from existing feeder
pillars located as shown on the Drawings. Power supply to new feeder pillars shall
be from new or existing DEWA substations as shown on the drawings.
7A/2.2 CHARACTERISTICS:
Arrangement 3 phase 4 wire

Nominal Voltage 415/240 V +/- 10%
Nominal Frequency 50 Hz +/- 5%
7A/3 REGULATIONS AND STANDARDS
7A/3.1 REGULATIONS
All equipment and workmanship shall comply with the most recent
requirements of:
 BS 7671 Requirements for Electrical Installations, IEE Wiring Regulations
 Occupational Health and Safety Act
 Dubai Electricity and Water Authority’s Safety Manual
 United Arab Emirates Electricity and Water Regulations and Guide
 Requirements of the local electricity supply authority
7A/3.2 STANDARDS
CIE
CIE S 016 Lighting of Work places
CIE 23 International recommendations for motorway lighting
CIE 27 Photometry of luminaires for street lighting
CIE 31 Glare and uniformity in road lighting installations
CIE 32 Lighting in situations requiring special treatment (in road lighting)
CIE 34 Road light luminaire and installation data: photometric,
classification and performance
CIE 37 Exterior lighting in the environment
CIE 66 Road surfaces and lighting
CIE 68 Guide to the Lighting of exterior working areas
CIE 77 Electric light sources
CIE Guide to the lighting of road tunnels and underpasses
88:2004
CIE 100 Fundamentals of the visual task of night driving
CIE 115 Recommendations for the lighting of roads for motor and
pedestrian traffic
CIE 122 Design methods for lighting of roads
CIE 126 Guide to the lighting of urban areas
CIE 140 Road lighting calculations

CIE 180 Road transport lighting for developing countries

CIE S008 Lighting of indoor work places
IEC
CISPR 15 Limits and methods of measurement of radio disturbance

characteristics of electric lighting and similar equipment.
60050-845 International electrotechnical vocabulary
60061 Lamp caps and holders together with gauges for control of
interchangeability and safety
60068 Environmental testing.
60073 Colours of indicating lights and push buttons
60188 High pressure mercury vapour lamps – performance specifications
60192 Low pressure sodium vapour lamps
60238 Edison screw lampholders
60364 Electrical installations in buildings
60439 Low voltage switchgear and control gear assemblies
60502-1 Power cables with extruded insulation and their accessories for
rated voltages from 1kV up to 30kV Part 1: Cables for rated
voltages of 1kV and 3kV.
60529 Degrees of protection provided by enclosures (IP Code).
60598 Luminaires
60898 Specification for circuit breakers for overcurrent protection for
household and similar installations
60923 Auxiliaries for lamps – ballasts for discharge lamps excluding
tubular fluorescent lamps) – Performance requirements
60927 Auxiliaries for lamps – starting devices(excluding tubular
fluorescent lamps) – Performance requirements
60947 Low voltage switchgear and control gear, general rules
60662 High pressure sodium vapour lamps
61000 EMC limits
61008 Residual current operated circuit breakers without integral
overcurrent protection for household and similar use
61009 Residual current operated circuit breakers with integral overcurrent
protection for household and similar use
61048 Auxiliaries for lamps. Capacitors for use in tubular fluorescent and
other discharge lamp circuits. General and safety requirements.
61439 Low voltage switchgear and control gear assemblies
61167 Metal halide lamps – Performance requirements
61247 Lamp control gear
61547 Equipment for general lighting purposes –EMC immunity
requirements
61643 Low-voltage surge protective devices
62035 Discharge lamp[s (excluding tubular fluorescent lamps)
ILE
TR 12 Lighting of pedestrian crossings

TR 23 Lighting of cycle tracks
TR 25 Lighting For traffic calming schemes
BS & EN

40 Lighting columns
88 Low voltage fuses
145 Specification for chromium-nickel-copper-molybdenum corrosion
resistant steel (precipitation hardening/billets, bars, forging, and
parts(1270 MPa to 1470 MPa)
485 Aluminium and aluminium alloys. Sheet, strip and plate.
10257-1 Zinc or zinc alloy coated non-alloy steel wire armouring for either
power cables or telecommunication cables... Land cables.
12373 Aluminium and aluminium alloys. Anodizing. Method for specifying
decorative and protective coatings on aluminium.
1261 Specification for cartridge fuses for a.c. circuits in domestic and
similar premises.
1263 13 A plugs, socket outlets, adaptors and connection units.
1461 Hot dip galvanized coatings on fabricated iron and steel articles
1990 Eurocode. Basis of structural design.
1991-1.4 Eurocode 1 Actions on structures. General actions. Wind actions.
1993.1 Eurocode 3. Design of steel structures. Towers, masts and
chimneys. Towers and masts.
3036 Specification. Semi-enclosed electric fuses (ratings up to 100
Amperes and 240 Volts to earth)
4727 Glossary of electrotechnical, power, telecommunication,
electronics, lighting and colour terms.
4607 Non-metallic conduits and fittings for electrical installations
5467 Electric cables. Thermosetting insulated armoured cables for
voltages of 600/1000 V and 1900/3300 V.
5489 Code of Practice for the design of road lighting
6004 Electric cables. PVC insulated non-armoured cables for voltages
up to and including 450/750 V for electric power, lighting and
internal wiring.
6007 Electric cables. Single core unsheathed heat resisting cables for
voltages up to and including 450/750 V, for internal wiring.
6121 Mechanical cable glands. Code of Practice for selection,
installation and inspection of cable glands and armour glands
60598 Luminaires
6231 Electric cables. Single core PVC insulated flexible cables of rated
voltage 600/1000 V for switchgear and controlgear wiring.
6234 Specification for polyethylene insulation and sheathing of electric
cables.
6346 Electric cables. PVC insulated armoured cables for voltages of
600/1000 V and 1900/3300 V.
6469 Insulating and sheathing materials of electric cables.
6500 Electric cables. Flexible cords rated up to 300/500 V for use with
appliances and equipment intended for domestic, office and similar
environments.
6910.2 Cold pour resin compound and heat shrink cable joints in the
voltage range up to 1000 V a.c. and 1500 V d.c. Code of Practice
for on-site installation.
7430 Code of Practice for earthing
7654 Specification for single-phase street lighting fuses (cut-outs) for
low-voltage public lighting electricity distribution systems. 25 A
rating for highway power supplies and street furniture.
7668 Weldable structural steels. Hot finished structural hollow sections in
weather resistant steels. Specification
7889 Electric cables. Thermosetting insulated unarmoured cables for

voltage of 600.1000 V.
7919 Electric cables. Flexible cables rated up to 450/750 V for use with
appliances and equipment intended for industrial and similar
environments.
7933 Electric cables. Accessories.
9692 Welding and allied processes
1001 Durability of wood and wood based products. Terminology.
1011 Welding. Recommendations for welding of metallic materials
10020 Definition and classification of grades of steel
10025 Hot rolled products of structural steels.
10257 Zinc or zinc alloy coated steel wire for cables armouring either
power cables or telecommunications cables.
12032 Photometric data for luminaires
12373 Aluminium and aluminium alloys. Anodizing. Method for specifying
decorative and protective coatings on aluminium.
13201 Road lighting
13032 Light and lighting. Measurement and presentation of photometric
data of lamps and luminaires.
15614 Specification and qualification of welding procedures for metallic
materials.
50086 Specification for conduit systems for cable management
55011 Industrial, scientific and medical (ISM) radio-frequency equipment.
Electromagnetic disturbance characteristics. Limits and methods of
measurement
60155 Specification for starters for fluorescent lamps
60228 Conductors of insulated cables.
7A/4 CLIMATE
7A/4.1 SUITABILITY
All equipment and material shall be suitable for long term operation in Dubai.
7A/4.2 CONDITIONS
The average prevailing local conditions at Dubai City shall be assumed as follows:
Max. Ambient Temperature 550 C
Min. Ambient Temperature 10 C
Design Ambient Temperature, 500.C
incident light intensity (energy) 780 m/W/cm2
Light intensity (measured under the sun approximately 100,000 Lux
Max. metal temperature under sun 850 C
Min. Barometric Pressure 998 mbar
Max. Barometric Pressure 1030 mbar
Average Barometric Pressure 1015 mbar
Ambient Humidity 100%
Min. Ambient Humidity 20%
Design Ambient Humidity 80%
Max. Design Wind Velocity 160 km/h.
Wind gust factor 1.3
Average Yearly Rainfall 80 to 150mm
The climate of Dubai is relatively mild from November to April, and hot from May to

October with high relative humidity.

Distribution of rainfall is irregular, and the precipitation amounts are normally of no
significance, but attention should be paid to the fact that sudden heavy rainfalls in
a very short period of time can occur.
The prevailing wind directions are from the North and West. Strong winds are
common with maximum velocities exceeding 160 km/hr. and sandstorms and dust
storms occur in the summer months
7A/4.3 RATINGS
In calculating the rating of electrical cables, switch-gear and all items of equipment,
the necessary derating factors shall be determined and applied to ensure that the
equipment will operate satisfactorily and meet its design criteria.
7A/4.4 CORROSION
Particular attention should be paid to the prevailing corrosion conditions. Materials
and equipment shall be suitable for use under the prevailing conditions of a harsh
marine environment.
A considerable amount of salt is contained in the atmosphere which together with
the extremely high ambient humidity can produce severe corrosion problems.
Under certain combinations of the climatic conditions considerable condensation
may take place.
7A/5 GENERAL
7A/5.1 OPERATIONAL LIFE
The road lighting system, apart from consumable items such as lamps, shall have
an economic operational life of at least twenty years.
7A/5.2 WARRANTIES
The following minimum warranty periods shall apply:

 Cables - 10 years
 Luminaires - 5 years (with the exception of lamps)
 Pole galvanizing – 10 years
 Poles - 15 years
 Switchboards and kiosks - 10 years
 Labelling – 10 years
 PLC and dimming control systems – 10 years
 Batteries - 5 years
 Cable ladders and trays - 15 years
7A/5.3 EXISTING ROAD LIGHTING SERVICES
Street lighting services which fall within the site of the works which are damaged

by the Contractor shall be repaired and rectified by the Contractor within 24 hours.
Failure to repair any underground fault within 24 hours can result in fines being
applied in accordance with Local Order No.84/93. The Contractor shall be
responsible for obtaining road closure permission where applicable and to provide
necessary material and manpower.
7A/5.4 CHECK OF EQUIPMENT SUPPLIED BY OTHERS
The Contractor shall ensure that any materials and equipment supplied by others
forming part of his installation shall be new and in accordance with the standards
required. Any defect must be reported in writing within seven days of receipt of the
equipment in order to allow changes to be made or replacements instructed by the
Engineer.
7A/5.5 LAYOUT
Survey and peg, or mark, the locations and routes of electrical equipment. While
the locations and routes are shown on drawings, the Contractor shall coordinate
with other services, liaise with the Roads and Transport Authority Street Lighting
Section Engineer and coordinate activities with the Dubai Electricity and Water
Authority.
The Contractor shall confirm the locations and routes on shop drawings and submit
the shop drawings to the Engineer for review prior to commencement of
construction.
7A/5.6 EXTENSION OF EXISTING DUCTS

Where roads are widened or will cover existing cables, extend existing cable ducts
clear of such roads
7A/5.7 FINAL LEVELS
Where levels will change, raise or lower existing light poles and switchboards, with
foundations, to suit the final levels.
Where there are existing cables and the depth of burial is rendered inadequate by
level changes, excavate and relay the cables to achieve adequate cover.
7A/5.8 SAFETY MEASURES
While working on road lighting services maintain the switchboard’s main switch in
the OFF position. Fit a safety tag inside the switchboard to warn against
energization by others.
7A/6 CONTRACTOR’S DRAWINGS AND DOCUMENTATION
7A/6.1 SHOP DRAWINGS

The contractor shall design and prepare shop drawings of equipment, layouts,
specialised components, switchboards, cut-outs, light poles, and pole foundations.
Switchboard drawings shall include: equipment schedules with dimensions,

ratings, and manufacturer names and reference; and wire and terminal numbers.
Switchboard drawings shall include labelling schedules with wording, colour and
fixing information, dimensions, opening locations, gland plate and cable entries,
door hinges, ventilation design, louvres, and single line diagram.
Pole shop drawings shall include the anchor bolts and reinforcing mesh cage,
outreach arms and mounting brackets and their fixings, and shall be accompanied
with the following data:

 Material specifications,
 Design calculations assuming a wind design velocity of 160 km/h and stating
the mass and windage of the luminaires. Calculations shall include
deflection.
 Deflection at pole top at 160 km/h,
 Impact resistance at 1 m height to shear the flange from the pole
 A Certificate of Structural Adequacy for each type of pole.
 Any deviations from this specification,
 Concrete foundation drawings and calculations, and
 Assembly instructions. Submit shop drawings to the Engineer for review.
7A/6.2 RECORD DRAWINGS
Maintain a complete set of current drawings, with shop drawings, on the site and
mark any changes as works proceed to record the “as-constructed” status of the
works.
Ensure Record Drawings show the final location of equipment, cabling, conduits,
boxes, pits, switchboards, outlets, switches, etc., and any other information which
will assist in future maintenance, and alterations.
Submit the Record Drawings as AutoCAD .dwg files, or Microstation.dgn files, with
a set of paper prints, including shop drawings, to the Engineer for review.
Amend the Record Drawings after review by the Engineer.
Provide bond paper prints of the Record Drawings in each switchboard.
7A/6.3 TUITION AND MANUALS
Provide tuition to the Roads & Transport Authority Street Lighting Section in
operation and maintenance of all components.
Prepare and deliver a tuition program including:
 Course outline
 Course schedule with elements and element durations
 Course notes for each trainee (at least five trainees will participate)
Provide a training room and follow training room tuition with site demonstrations of
operations and maintenance procedures with simple instruction sheets.
Provide three copies of an Operations and Maintenance Manual. Submit a draft
copy to the Engineer for review.
7A/7 INSPECTION, TESTING AND COMMISIONING

7A/7.1 STANDARDS
Test in accordance with BS 7671 Requirements for Electrical Installations, IEE
Wiring Regulations
7A/7.2 FACTORY ACCEPTANCE TESTING
Prepare test schedules and test record forms and submit to the Engineer before
testing.
Factory acceptance testing shall comprise testing by accredited test laboratories.
Test sheets shall be submitted to the Engineer for review before delivery.
For switchboards test in accordance with IEC 64319, including ingress protection.
For cables test in accordance with the relevant standard, including: insulation;
moisture resistance; and fire and smoke performance
For conduit and associated enclosures test in accordance with BS 4607
For luminaires test in accordance with IEC 60598, including: ingress protection;
impact resistance; thermal performance; photometric performance; and electro-
magnetic compliance
For poles and associated components, test to BS 40 (Lighting columns) and to BS
1461(hot dip galvanizing).
Submit completed test records to the Engineer for review.
7A/7.3 SITE ACCEPTANCE TESTING

Prepare test schedules and test record forms and submit to the Engineer before
testing.
Provide test apparatus and test as follows:

 Polarity
 Phase rotation.
 Load balancing of phases.
 Verification of phase, neutral and earth identifications.
 Verification of labelling, and wire & terminal numbering.
 Continuity.
 Earth loop impedance.
 Earth bonds.
 Insulation (Phase-phase; phase-neutral; phase-earth; neutral-earth with a
1000 V insulation tester). Insulation shall exceed 8 megohm per metre
cable length
 Effectiveness of individual earth electrodes. The resistance of any point in
the earth continuity system of the installation to the main earth electrode
shall not exceed 1 ohm, and the resistance to earth at the termination shall
not exceed 0.5 ohm.
 Checking of voltages at transformer, switchboards and each HID luminaire
and setting of appropriate tappings on control gear.
 Checking of RCD's.

Submit the manufacturer’s name and model of proposed test apparatus with
calibration certificates to the Engineer for review.
After cable installation, but before erection of poles, test the cabling.
Submit completed test records to the Engineer for review.

7A/7.4 COMMISIONING
 Test each circuit of each switchboard before connecting electricity supply

 Verify the operation of control circuits and change over switchgear.
 Record and submit test results on printed test sheets.
 Advise of all inspections and tests in time to allow witnessing of such
inspections and tests
 Arrange for any inspection and test by the Dubai Electricity and Water
Authority and assist the Network Operator Inspector by providing access
tools, instruments and attendance
 Inspect the switchboards before they leave the manufacturer's works and
check suitability for application and compliance with specification
 Submit signed test sheets to the Engineer. These sheets shall be printed
and include the manufacturer’s name and model of the test apparatus and
the calibration certificate.
7A/7.5 LIGHTING VALIDATION TESTS
 After 100 hours of operation, replace any faulty components and conduct
lighting measurements in accordance with EN 13201-4 Road Lighting – Part
4: Methods of measuring the light performance of installations
7A/8 EARTHING
7A/8.1 SYSTEM
Comply with BS 60364, BS 7430, and the requirements of the Dubai Electricity &
Water Authority and the UAE Electricity and Water Regulations. Where the
requirements of the UAE Electricity and Water Regulations and Guide differ from
those of the British Standards, the former shall prevail.
The Contractor shall install an earthing system for the full length of each circuit. All
metallic parts of all equipment, other than current carrying conductors, shall be
bonded to form a continuous path by way earth conductors, and / or cable
armouring. The earthing conductors shall have a minimum current carrying
capacity in accordance with BS 60364 and BS 7430. All earth electrodes, earth
cables and earthing leads shall be of copper.
7A/8.2 EARTH ELECTRODES
Earth electrodes shall consist of 16 mm minimum diameter hard drawn copper rod
complete with hardened steel tip and driving cap. Rods shall be capable of being
extended in lengths, as necessary, by the provision of permanent screw
mechanisms. Owing to the highly corrosive nature of the sub-soil at certain
locations the Dubai Electricity and Water Authority shall be consulted regarding the
metal to be used for the earth termination.
Earth electrodes shall be driven vertically to a depth such that it penetrates the
summer water table by minimum of 2 metres and to a minimum depth of 3.0 m.
Provide an earth pit, approximately 300 mm x 300 mm x 300 mm, at each earth
electrode. After installation, fill the pit with sand and install a removable pit lid.
Earth electrode distance should not exceed 5 metres out of centre of foundation of
last pole, and at an agreed location adjacent to each switchboard.
7A/8.3 EARTH LEADS
Connect the earth electrode to the earth stud in the switchboard or light pole with a
70 mm2 copper conductor PVC insulated earth cable. Connect the cable to the
earth electrode with an earthing clamp. After testing wrap in petrolatum
impregnated tape
7A/9 SWITCHBOARDS AND SWITCHGEAR
7A/9.1 FEEDER PILLARS
7A/9.1.1 General
Feeder Pillars shall consist of a single compartment cabinet with one door opening.
All panels shall be suitable for permanent outdoor installation for the control of road
way lighting.
Double door feeder pillars shall measure 1400mm wide, 1300mm high and 300mm
deep.
Feeder pillars shall be of Rittal, or approved alternative, manufacture, rated at 63A,
100A, 160A, 185A, 200A, or as requested by DEWA and shown on approved load
schedules and drawings with IEC class gL/gG fuses.
On each Feeder Pillar, provide two single phase 40 A M.C.B.’s complying with IEC
60947 connected to the outgoing side of the kWh meter for feeding a traffic control
panel.)
For each Feeder Pillar of less than 210A rating, provide 3-phase direct metering.
Construct the Feeder Pillar to facilitate the installation of a 3-phase kWh direct
reading meter. The Dubai Electricity and Water Authority will supply each kWh
meter. Install the meter complete with meter fuses and all connections.
For each Feeder Pillar of 210A rating or above, provide 3-phase current
transformer metering. Supply and install the current transformer metering
complete with current transformers, current transformer links, meter and all
connections. Submit the meter and current transformers to the Dubai Electricity &
Water Authority for review and calibration. Submit a signed Dubai Electricity &
Water Authority test report to the Engineer.
Provide an insulating panel for the kWh Meter.
Provide a document pocket in the Feeder Pillar and insert the Record drawing and
the Dubai Electricity & Water Authority test report. The pocket shall be of marine
grade aluminium welded to the door.
Provide a name plate of marine grade aluminium painted red at least 150 m high
and 300 mm wide 2.5 mm thick, engraved with black paint filled lettering. The
lettering shall read:
“ROADS AND TRANSPORT AUTHORITY
LIGHTING PANEL **** ”
The labelling shall be in English and Arabic with the first row in 50 mm and the

second row in 25 mm high lettering. Secure the label to the door with at least four
4 mm rivets.
7A/9.1.2 Construction
Construction shall be totally enclosed, metal clad, dead front, air insulated, Form 1
of IEC 61439.
Construct the enclosure of marine grade aluminium of minimum thickness of 3 mm
with ingress protection to IP55 of IEC 60529. Provide a channel base frame hot
dip galvanized to BS 1461 with an insulating film between the aluminium and steel.
Secure the base frame to the concrete foundation with six M10 stainless steel
anchor bolts. Provide a stainless steel cover behind the feeder pillar to cover the
cabling, 3 mm thick for 750 mm feeder pillars and 5 mm thick for 1400 mm feeder
pillars.
Provide a sloped sun and rain canopy of marine grade aluminium. The canopy
shall extend 150 mm beyond the footprint of the Feeder Pillar and shall be spaced
150 mm from the top of the Feeder Pillar.
Provide at least four louvres to give diagonal ventilation. The louvres shall have
ingress protection of IP 55 to IEC 60529.
Provide a 10 mm thick Marguard meter reading window opposite the kWh meter.
Provide three stainless steel (Grade AISI 316) lift off pintle hinges per door.
Provide two flush stainless steel locks with a three point latching system. Door
opening shall be 1800 and shall be restrained with a door stay. Doors shall be
equipped with silicone rubber gaskets capable of withstanding the ambient
temperatures for at least ten years. All hinges and locks are to be easily
removable and replaceable.
Coat the enclosure with an epoxy/polyester powder coat, colour beige (RAL 7032).
Provide a fluorescent luminaire at the top of the Feeder Pillar inside the door
operated by a door switch. The luminaire shall have an acrylic diffuser.
Provide a removable gland plate of maximum 1 mm thickness at the base of the
enclosure for compression type brass glands with earth tags. Cable entry shall be
through the base. Provide six factory punched cable entries to suit the cable
number and sizes. Provide at least six cable entries. Any spare entries shall be
sealed.
7A/9.1.3 Dimensions
For small Feeder Pillars, the dimensions shall be::

 Height : 1000 mm (without canopy)
 Width : 750 mm
 Depth : 250 mm
For large Feeder Pillars, the dimensions shall be:
 Height : 1000mm (without canopy)
 Width : 1400mm
7A/9.1.4 Depth : 250mmDepth : 250mm Earthing
Provide a tin plated copper earth bar at least 40 mm x 4 mm shall be solidly bolted
with stainless steel (AISI 316) bolts to the enclosure. Bond the earth bar to the
earth electrode. Bond the enclosure door to the enclosure with 4 mm2 copper
braid. Bond all circuits to the earth bar.

7A/9.1.5 Contactors
Contactors shall comply with IEC 60947 Class AC3, 660 V, and Class II
intermittent duty. Contactors shall be non-latching and be controlled by an
astronomical time switch. Control circuits shall be connected to the Brown phase.
7A/9.1.6 Circuit breakers
Provide a three-phase and neutral (four-pole) moulded case circuit breaker to IEC
60947 as the Main Switch of each Feeder Pillar.
Each Main Switch shall be fault rated at 50 kA at the temperatures inside the
cabinet. Each Main Switch shall be able to accommodate two auxiliary contacts
and an under voltage release, a padlocking device, and shall be equipped with
insulated shrouds to the incoming terminals to provide finger protection. Provide
300 mm clearance between the Main Switch and the gland plate. Terminals shall
be capable of accommodating 185 mm2 cables.
7A/9.1.7 Busbars
Provide tin-plated, phase colour insulated, copper busbars to BS 159. Busbars

shall be rated to match the load and fault ratings of the Main Switch. An earth or
ground bar not less than 40 mm x 4 mm shall be solidly bolted with stainless steel
bolts of grade AISI 316 to the main body of the control cabinet.
7A/9.1.8 Wiring and Cabling
All secondary internal wiring within the control cabinet shall be with heat resisting,
1000V hard grade PVC/XLPE Insulated copper cables of at least 2.5 mm² (7
strand) for control wiring, and 10 mm2 for power wiring, colour coded or sleeved for
easy phase identification, suitable for the circuit rating, arranged neatly and firmly
attached. All the wiring leads shall be so arranged to allow current reading with a
clip-on ammeter on each phase of main incoming and all outgoing circuits. All
wiring shall be housed in wiring trunking. Sufficient vacant area (250 mm x 300
mm minimum) shall be left for future installation of a kWh meter.
All wire terminals into connectors shall have wire ends or straight lugs. All the wires
selected should have the amperage rating at 600 ambient and sufficient allowances
for enclosure de-rating.
Terminals shall be able to accommodate:
 incoming cables (armoured, sector shaped, copper conductors, 4 core,
MDPE insulated and PVC over sheathed)
 outgoing cables (armoured, STET, stranded copper conductors, 4 core,
MDPE insulated and PVC over sheathed)
The outgoing terminals shall be suitable for two cables of 70 mm2, 50 mm2, 35
mm2 and 25 mm2.
Cabling and wiring shall be colour coded as follows:
 Phases - Brown, Black & Grey.
 Neutral - Blue
 Earth - Green/Yellow
7A/9.1.9 Fuse and Fuse Base
There shall be a LV HRC system consisting of fuse bases, fuse cartridge and
accessories complying with BS 88.
Fuse cartridges shall be IEC class gL/gG and the base shall be of modular
construction suitable for DIN-rail mounting. The bases are to be made of thermo
setting, self extinguishing material rated for 100A. Metal parts, contacts and
springs are to be zinc plated and passivated for protection against corrosion. The
fuse bases shall have shielded terminals and be Legrand 21471 single pole, or
approved alternative. Cylindrical cartridge type fuse links suitable for the bases
are to be used. They shall conform to IEC 269-2 and BS 1261 (1986) or DIN 43620
and shall withstand a rupture capacity of 100 kA. Fuses shall be of a low internal
loss and low internal temperature rise. Each fuse shall be protected by an
insulating shield or approved alternative.
Each feeder pillar shall have one 4 A single phase HRC fuse with base for the
internal lighting circuit.
Each feeder pillar shall have one BS 1263 13 A 3 pin switch socket outlet
protected by a residual current device. The socket outlet shall be corrosion
resistant and mounted on a pattress inside the door of the Feeder Pillar.
7A/9.1.10 Cable Glands
Glands shall comply with BS 6121 and shall be the brass compression type with
earth rings and tags, and lock buds, for XLPE/SWE/PVC/MDPE 4 core cables.
Supply matching cable sleeves for each gland. Glands shall be fitted with PVC
shrouds filled with waterproof plastic compound and secured to the cable with PVC
tape.
Glands shall be weatherproof, with inner and outer seals suitable for steel wire
armoured cables.
7A/9.1.11 Control System
The switching of the lighting luminaires shall be through an automatic control

arrangement comprising of an astronomical time switch and selector switch. The
selector switch shall have three positions: ON/OFF/AUTOMATIC.
7A/9.1.12 Samples
Submit a sample Feeder Pillar, fully equipped to the Engineer for review.
7A/9.1.13 Testing
Submit type test certificates to IEC 61439. In addition submit routine test
certificates for each Feeder Pillar for review by the Engineer.
Inspect the switchboards before they leave the manufacturer's works and check
suitability for application and compliance with specification.
Test each circuit of each switchboard before connecting electricity supply.
Test the operation of all residual current devices.
Verify the operation of control circuits.
Record and submit test results on printed test sheets.
Advise of all inspections and tests in time to allow witnessing of such inspections
and tests by the Engineer.
7A/9.2 STREET LIGHT CUT-OUTS

7A/9.2.1 Application
Install street light cut-outs in the base of each light pole. The cut-out serves as a
protective device for the luminaires and pole wiring
7A/9.2.2 Rating
The service cut-out shall be rated at 415V/240V, 50 Hz operation, at 500 C ambient

and 95% relative humidity.
7A/9.2.3 Standard
The street lighting service cut-out shall comply with BS 7654.
The typical arrangement of street lighting services cut-out with dimensions and
materials of construction shall be submitted by the Contactor for review by the
Engineer.
The street lighting service cut-out shall consist of:
Housing with cover
Fuse bases of required numbers
4 Terminals: Brown; Black; Grey; and Blue
Outgoing cable glands
The fuse base shall be DIN rail mounted fully insulated and suitable for 10 mm
diameter X 38 mm cylindrical H.R.C. fuses.
7A/9.2.5 Terminals
4 cable terminals (3 phases and 1 neutral) shall be fixed to a high quality phenolic
fibre board, or glass fibre reinforced insulator. The dielectric strength of the
insulator shall not be less than 2 kV/mm. The flexural strength of the insulator shall
be not less than 1000 kg/cm2 the insulator material to be in accordance to DIN
7735 type 2081 or similar reviewed by the Engineer. Each terminal shall be
capable of accepting two sector shaped copper cables of not less than 35 mm2
each.
Each incoming and outgoing terminal shall be bolted to an electrolytically tinned
H.C.H.D. copper bar of 40 mm Xx 5 mm cross section.
Each cable terminal shall have the provision to connect and to tap off a lugged 4
mm2 phase coloured wire of not less than 10 cm. long.
The wire shall be bolted on to the main terminal by using a M5 x 15 mm slit head
screw with spring washer.
All terminal parts to be made from materials which are not subject to corrosion
when used in combination with each other.
A flexible phase insulating barrier shall be provided between all terminals as well
as on both sides of the end terminals. The phase barrier shall protrude sufficiently
on all sides of the terminal to ensure electrically safety.
Brass cable glands shall be mounted together with a 1 mm thick tinned copper
plate, linking them together. The copper plate shall be bonded to an external earth
stud and to the earth bar.
Neutral and earth bars shall be of nickel plated brass, accepting 10 mm2 cable
sizes. The earth bar shall be solidly bounded to the metal housing.

7A/9.2.6 Housing
The housing consists of a base plate, holding all components and glands, and a
removable cover. The material shall be electrogalvanized sheet steel, polyester
powder coated to a film thickness of min. 100 microns, against corrosion under
Dubai climatic conditions. The plate shall be 3 mm thick and the cover 1.25 mm
thick. Protection class shall be IP 44. The base plate shall have 2 Nos. rear fixing
holes of 7 mm diameter.
The cover fixing screws shall be captive.
7A/9.2.7 Testing
Submit type test certificates to IEC 61439 for review by the Engineer. In addition
submit routine test certificates for each type of cut-out for review by the Engineer.
7A/9.2.8 Samples
Submit a sample of each type of cut out fully equipped for review by the Engineer.
The samples shall be accompanied by the manufacturer’s operating instructions.
7A/10 CABLING
7A/10.1 GENERAL
7A/10.1.1 Insulation Colours
For all cabling insulation colours shall be:

 Neutral - Blue
7A/10.1.2 Manufacturer’s Data Sheets
Submit manufacturer’s data sheets and one metre sample lengths of each size to
the Engineer for review.
Submit test certificates of each size of cable to the Engineer for review.
7A/10.1.3 Earth Cable
Earth cables shall be single-core stranded plain annealed copper core PVC
insulated cable to BS 6004. Insulation colour shall be yellow-green.
7A/10.1.4 Sealing and Drumming
Before dispatch, seal cable ends against moisture ingress. Label cable drums with
a discrete reference number, manufacturer, year, and cable construction. Deliver
drums to site with seals and labelling intact. Submit seals and labels to the
Engineer for review. The drum reference number shall be reference on the test
sheets.

7A/10.1.5 Installation
Install cables in accordance with the following documents: BS 7671; the United
Emirates Electricity Regulations and Guide; and the manufacturer's
recommendations.
Install cables in one length without joints from terminal point to terminal point.
Observe the bending radii requirements of the United Emirates Electricity
Regulations and Guide and the manufacturer’s recommendations
7A/10.2 UNDERGROUND CABLING
Underground cables shall be 4-core stranded copper 600/1000 V

XLPE/SWA/MDPE armoured cables complying with BS 5467 and suitable for
direct burial in saline soil.
7A/10.2.2 Earth Cable
Earth cables shall be single-core stranded plain annealed copper core PVC
insulated cable to BS 6004. Insulation colour shall be yellow-green.
Submit manufacturer’s data sheets and one metre sample lengths of each size to
Submit test certificates of each size of cable to the Engineer for review.
7A/10.2.3 Identification
Emboss the sheath with two lines of lettering:
First Line:
“ROADS & TRANSPORT AUTHORITY ROAD LIGHTING 600/1000 V”.
Lettering shall be upright block characters. The maximum size of the characters
shall be 12 mm and the minimum size 15% of the approximate overall diameter of
the cable or 5 mm whichever is greater. The gap between the end of one legend
and the beginning of the next shall not be greater than 150 mm.
Second Line:
“Manufacturer/year/country of origin/number of cores/cross-section/type/length”.
Lettering shall be equally spaced with the first line along the circumference marked
at regular intervals on the sheath. This shall not affect the spacing between
repetitions of the legend for the voltage designation.
7A/10.2.4 Installation
Lay in the cable trench an earth cable of not less than 16 mm2 for 16, 25 and 35
mm2 4-core cables; 25 mm2 for 4-core 50 mm2 cable; and 35 mm2 for 4-core 70
mm2 cables.
Install the earth cable all the way from the feeder pillar to the last pole of each
circuit, looping the earth cable inside each pole.
Runs shall be neat and free from kinks, care being taken in the routing to avoid risk
of damage to or interference with other equipment.

7A/10.2.5 Direct Burial:
Excavate cable trenches along the cable routes, removing loose rock, stones and
other sharp materials. Supply and install clean sand that has been washed and
sieved along the cable routes. Before laying cables lay a 75 mm bed of level,
compacted, clean sand. After cable laying, backfill and compact with clean sand to
provide 75 mm of cover over the cable. Backfill the cable trench with selected
material and lay the PVC cable warning tape. At the entry and exit duct of each
foundation, allow a loop of 1 metre of cable for future use.
7A/10.2.6 Inspection:
Prior to backfilling and compaction, notify the Engineer to inspect the installation.
Any trenches backfilled and compacted without inspection will not be accepted and
shall be re-excavated at the contractor’s expense and risk for inspection by the
Engineer.
7A/10.2.7 Cables in Ducts
Where cables cross under roads and paved areas draw the cables through the
ducts and seal the ducts with tapered wooden plugs to prevent soil ingress.
7A/10.2.8 Cables In Concrete Trenches:
Install cables in concrete trenches with a cable management system. The cable
management system shall comprise:
Vertical hot dip galvanized steel channels (Unistrut P1000 or approved alternative)
secured with stainless steel (AISI 316) chemical anchors.
Hot dip galvanized cable clamps.
7A/10.2.9 Cables Fixed To Steel Work Or Concrete Walls:
Install XLPE insulated cables installed on steel work in moulded reinforced nylon
hooks and clamps spaced to avoid sagging of cables. Spacing of the cleats shall
not exceed 750 mm. Arrange cleats and cable routes in the neatest and least
obtrusive manner.
All steel work cable supports shall be hot dip galvanized and painted as specified
for Miscellaneous Metal work.
7A/10.2.10 Cables Saddles:
Cable saddles shall be fixed with stainless steel (AISI 316) anchors.
7A/10.2.11 Cable Support Spacing:
Spacing of cable supports shall be prescribed in the United Emirates Electricity

Regulations and Guide, BS 7671, and the manufacturer’s recommendations.
7A/10.2.12 Termination of Cables:
Jointing materials shall comply with BS 7933 and be installed in accordance with
BS 6910.2. Submit proposed termination equipment and material data sheets to
Cable terminations shall be colour coded as follows:

 Neutral – Blue
Coloured tapes and sleeves will not be permitted.
For all cable ends allow at least 300 mm of cable to be cut off immediately before
the termination. Seal cable ends against the ingress of moisture and dirt.
7A/10.3 CABLING IN STRUCTURES
7A/10.3.1 Construction:
Cabling in structures shall comprise stranded copper conductor, PVC insulated,

non-armoured cables to BS 6004.
Cabling shall be sized to the circuit protective device, current load, voltage drop
(which shall not exceed 3% for lighting circuits), and earth loop impedance. For
lighting circuits, the minimum size shall be 4 mm² copper.
Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529.
7A/10.3.2 Installation:
The cabling shall be installed loop-in, draw in system, connecting conductors from
point to point without joints. Cabling may be looped into luminaire terminal blocks,
but shall not be looped through luminaires.
Conductors shall be terminated with crimp lugs.
Cabling shall be installed in compliance with manufacturer’s instructions and using
the manufacturer’s recommended accessories.
7A/10.3.3 Conduit
Conduits shall be uPVC and comply with BS 4607, be suitable for the climatic
conditions, and be at least 20 mm in diameter. Conduit joints shall be cemented.
During construction conduits shall be protected to prevent movement, ingress of
moisture and dirt, and damage. Any open ends shall be capped to keep out dirt
and moisture.
Conduits shall be installed in straight runs, level, and parallel or perpendicular to
the structure, and to avoid the spread of fire and ingress of moisture. Conduits
shall be installed with all requisite accessories. Internal burrs shall be removed
from the conduit ends.
Draw boxes shall be uPVC (or accepted alternative) with an Ingress Protection
rating of IP67. Draw boxes shall be installed in accessible locations at least every
50 m and between every two right angle bends. Gasketted lids shall be provided
where exposed to dust or moisture.
At structural expansion joints maintain continuity with flexible conduit within a
larger sleeve.
Provide conduit bends without deformation.
Provide draw-wires in conduits for future services and in conduit for services to be
installed by other parties.
Conduits installed in concrete shall be: located near the neutral axis; spaced at
least 25 mm apart; tied to the reinforcing steel with tie wire at a maximum spacing
of 600 mm; and be terminated in deep pattern conduit boxes.
Surface mounted conduit shall only be permitted where shown on drawings or
where accepted by the Engineer. Surface mounted conduit shall be installed to

avoid crossovers. Surface mounted conduit shall be saddled, or where in multiple

runs, fixed to pre-drilled stand-off brackets, at a maximum of 1000 mm intervals.
7A/10.4 LANDSCAPED AREAS

In landscaped areas, cabling may be installed by direct burial.
7A/10.5 POLE WIRING
Pole wiring between the cut-out and luminaires shall comprise 850 C rubber
insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to suit the
lamp load but shall be 3 core 2.5 mm2 minimum for lamps circuits up to 250 W and
4 mm2 minimum for lamps circuits of 400 W.
The outer sheath shall be coloured black and be suitable for exposure to strong
sunlight and a marine environment.
Submit manufacturer’s test sheets submit test sheets to the Engineer for review.
7A/10.6 MID HINGED POLE WIRING

7A/10.7 CROWN POLE WIRING

The cable shall be capable of withstanding the mechanical stresses produced by
the anchoring and pulley system and rated for the maximum electrical loading.
Provide guides so that power cables and stainless steel wire ropes are separated
before passing over their respective pulleys. The guides shall to prevent ropes
and cables from leaving the pulley grooves.
7A/10.8 CABLING FOR ADVERTISING FACILITIES
Include cabling from substations to any feeder pillars serving advertising and
bridge banners.
Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529
Provide separate circuits from the feeder pillars to the advertising facilities.
In poles, provide a separate cut-out for the advertising facilities.
Pole wiring between the cut-out and the advertising facilities shall comprise 850 C
rubber insulated flexible cable (450/750 V) to BS 7919. Cables shall be rated to
suit the lamp load but shall be 3 core 2.5 mm2 minimum for lamps circuits up to
250 W and 4 mm2 minimum for lamps circuits of 400 W.

Refer to standard drawings.
7A/11 LUMINAIRES
7A/11.1 GENERAL
Luminaires shall comply with BS EN 60598.

The optical chamber shall be separate from the lamp control gear chamber.
For the optical chamber, Ingress protection shall be IP66 and for the control gear
chamber shall be IP54 of IEC 60529. Provide one-piece silicone rubber gaskets.
Gaskets shall not be exposed to sunlight or lamp flux.
The body shall be made of die-cast aluminium, grade LM6.
The reflector shall be of high purity aluminium, grade S1 with an anodic coating
grade AA10, “Alanod Miro” or approved alternative.
The lenses shall be of borosilicate glass.
Hinges and fastening clips shall be of stainless steel, grade SS316.
Lamp control gear shall be mounted on a gear tray with plug-in connectors. The
gear tray shall be easily removable without the use of tools.
Luminaires shall allow routine maintenance without the use of tools.
Luminaires shall include two adjustable cable entries, a terminal block and an eat
terminal welded to the body.
Luminaires shall be capable of withstanding the wind conditions including a gust
factor. Refer to sub-section on CLIMATE.
Luminaire mass shall not exceed 15 kg for road lighting luminaires up to 400W.
Mounting shall be suitable for post-top, or side entry, for 42 to 76 mm spigots, with
upcast adjustments between 0 and 200 in 50 increments. Mountings incorporate
vibration-resistant locking devices.
Lampholders shall comply with IEC 60061, shall be porcelain and E27 or E40 to
IEC 60238. Wiring to lampholders shall be heat-resistant silicone rubber or glass
fibre insulated cable.
Luminaires shall be labelled with lamp type and wattage next to the lampholder.
Wall mounting luminaires shall be installed at heights not exceeding 5m.
7A/11.2 LAMP CONTROL GEAR
Lamp control gear shall comply IEC 60923 and IEC 60927 and have:
 Efficiency not less than 90%

 Power factor not less than 85%
 Harmonic distortion less than 30%
 A suitability for ambient temperatures listed in 7A/4 CLIMATE
 Metal type capacitors rated for at least 900 C
 Taps for 240 V and 250 V operation
 Nominal arc tube voltage of approximately 100 V
 Ballasts shall incorporate thermal cut-out switches.
 For poles of 20 m in height and under, high pressure sodium vapour lamp
ballasts and ignitors shall suit the specific lamps; ignitors shall be external

bilateral multipulse superimposed ignitors which stop pulsing upon ignition of

the lamp; and shall incorporate electronic timers which stop pulsing after 120
seconds.
 For poles of 20 m in height and under, metal halide lamp ballasts and
ignitors shall suit the specific lamps; ignitors shall be external bilateral
multipulse superimposed ignitors which stop pulsing upon ignition of the
lamp; and shall incorporate electronic timers which stop pulsing after 11
minutes.
 For poles over 20 m in height, high pressure sodium vapour lamp ballasts
and ignitors shall suit the specific lamps; ballasts shall be semi-parallel with
external multi-pulse ignitors which stop pulsing upon ignition of the lamp; and
shall incorporate electronic timers which stop pulsing after 120 seconds.
For poles over 20 m in height, metal halide lamp ballasts and ignitors shall suit the
specific lamps; ballasts shall be semi-parallel with external multi-pulse ignitors
which stop pulsing upon ignition of the lamp; and shall incorporate electronic timers
which stop pulsing after 11 minutes.
7A/11.3 LAMPS
High pressure sodium vapour lamps shall comply with IEC 60662.
Metal halide lamps shall comply with IEC 61167.
Failure rate shall be less than 3% in the first 100 hours of operation.
High pressure sodium lamps shall have a life of 16 000 hours with less than 5%
failure.
Depreciation shall be less than 70% over service life.
Lamps shall comply with the following characteristics:
Flux (lumens) Life (h)

Type Wattage Lampholder
@100 h (50% survival)
High 70 E27 6,600 24,000
pressure 100 E40 10,700 24,000
sodium 150 E40 17,500 24,000
vapour 250 E40 33,200 24,000
400 E40 56,500 24,000
600 E40 90,000 24,000
1000 E40 130,000 24,000
Metal 70 E27 6,400 12,000
Halide 100 E27 8,500 16,000
150 E27 14,000 16,000
250 E40 22,500 16,000
400 E40 40,000 16,000
1000 E40 100,000 16,000
Fluorescent 36 G13 3,350 12,000
58 G13 5,200 12,000
Submit lamp data sheets with test certificates.

7A/11.4 GANTRY SIGN LUMINAIRES
7A/11.4.1 Luminaires
Luminaires shall be metal halide floodlights.
7A/11.4.2 Wiring
Wiring to lighting luminaires shall be by means of PVC cables in a GI pipe. GI pipe

shall be securely fixed to structural steel work by distance saddles and a flexible
conduit from GI pipe to luminaire.
Final connections to lighting luminaires shall be carried out by short lengths of EPR
insulated, butyl sheathed flexible cable.
The interface between the PVC cable system and the flexible cable shall be a
weather-proof 3-pin socket outlet and plug. The control box for each gantry shall
be mounted on the steel structure and shall be complete with all electrical
accessories required. Main power supply shall be taken from the nearest feeder
pillar by XLPE/SWA/MDPE cabling as specified elsewhere.
7A/11.4.3 Control
Arrange control from the relevant Feeder Pillar.
7A/11.4.4 Lighting requirements
The gantry sign lighting shall be as per CIE No. 35 (TC-4.6) 1978, and shall have a
maintained average luminance of 180 candelas per square meter (for white letters)
and the ratio of the maximum luminance of one colour in a specified area to the
minimum luminance in the same area shall not exceed:
 2.5 for the inner zone of each area with a definite colour
 5 for the outer zone of each area with a definite colour
 8 over the total area of the sign face.
Whereas the inner area shall be that area bounded by a similar rectangle of length
and height equal to 70% of the overall length and height of the rectangular area
located symmetrically within the sign.
The maintained average luminance value is to be based upon the total of luminaire
dirt depreciation factor and a lamp lumen depreciation factor of 0.65.
7A/12 LIGHT POLES
7A/12.1 GENERAL
Poles and outreach arms and brackets shall comply with BS 80 and be hot dip
galvanized to BS 1461.
The height of amenity lighting poles shall not exceed 3.5m.
Fasteners shall be hot dip galvanized and threaded parts centrifugally spun to
remove any local excess of zinc. Test the galvanizing coating with suitable
electronic or magnetic measuring apparatus.
Steel shall comply with BS EN ISO 10025 and 10020.
Welding shall comply with BS EN ISO 9692 and 15614.
Poles shall have an octagonal or hexagonal cross section and have a continuous
longitudinal taper. Where poles are made in more than one section, the poles shall
be assembled on site with winches that pull the sections together. Overlap shall
be at least 1.5 times the across flats dimension. Poles shall have indelible
markings to indicate where sufficient overlap between sections has been achieved.
Poles shall be provided with outreach arms and brackets to suit the luminaires.
Poles shall be rated for winds of 160 km/h with gust factor.
Stress shall not exceed 50% of the yield strength of the pole at 160 km/h.
The pole shall be straight within 6 mm in 3 meters.
The pole surface shall be smooth, free of blemishes, protuberances, dents, cracks
or other imperfections. Protect the poles during transport and installation to
maintain the surface finish.
Provide a mounting flange at the base with cabled entry.
For roadways with speed limits in excess of 70 km/h, poles within 6 m of the kerb
or edge of shoulder shall be frangible with slip bases.
Provide a chamber for the cut-out with a flush access door. The door shall provide
easy access to the service cut-out for installation operation and maintenance.
Reinforce the door opening. Secure the door with a positive action stainless steel
(AISI grade 316) lock that forces the door open. All parts of the lock shall be
captive. Provide a 6 mm stainless steel (AISI grade 316) chain to hold the door
captive to the pole. The cut-out chamber shall have ingress protection of IP53 and
be provided with a one-piece silicone rubber gasket. Install warning labels in
English and Arabic inside of the door.
Provide a mounting plate for the cut-out with predrilled mounting holes for the cut-
out.
Provide a 30 mm M8 earth stud in the chamber. Provide hot dip galvanized anchor
bolts, each with two nuts and two washers, and with reinforcing steel cage.
Where poles are mounted to New Jersey Barriers, the gap in the barrier shall be
covered with a 14 mm thick hot dip galvanized steel cover, free of snags and
shaped to conform to the profile of the barrier, rebated at each end into the
concrete of the barrier to present no protrusions, and secured with hot dip
galvanized Allen key button head screws to the New Jersey Barrier.
7A/12.2 ADVERTISING FACILITY POLES
Advertising facility poles , their flanges, holding down nuts and bolts, and
foundations shall be designed to withstand the windage and the mass of the
advertising facilities under the conditions specified under 7A/4 CLIMATE.
7A/12.3 ALTERNATIVE MATERIALS
7A/12.3.1 General
Alternative pole materials such as aluminium and glass reinforced polyester may
be submitted to the Engineer for review.
7A/12.3.2 Glass Reinforced Polyester Poles
Glass reinforced polyester poles shall comply with EN 40-7 and be made of resin
impregnated glass filament mandrel wound with a high impact polyester gel coat
with UV inhibitors. The mass to ratio of glass to resin shall be 70:30. The gel coat
shall be at least 250 microns thick.
Poles shall be capable of withstanding the Max. Design Wind Velocity with a
deflection of less than 5% at the top.

7A/12.3.3 Aluminium Poles
Aluminium Poles shall comply with “The Aluminium Design manual: Specifications
and guidelines for aluminium structures, Part 1 B: Specification for Aluminium
structures , Load and Resistance Factor Design of Buildings and similar type
structures” (issued by the U.S Aluminium Association) and shall be manufactured
of 6061 grade aluminium to T5 or T6 temper with grade 5083 rolled aluminium
plate base plates. The aluminium base shall be effectively insulated from the steel
holding down bolts and concrete foundation.
7A/12.4 MULTI -FUNCTION POLES
Multi-function poles shall comprise a hot dip galvanized steel core with a marine
grade anodised aluminium extrusion outer shell. The base of each pole core shall
have a hot dip galvanized flange for securing to the foundation. The poles shall be
ventilated. The poles shall be capable of supporting:
luminaires and outreach arms,
signage,
traffic signal luminaires and pedestrian push buttons
banner arms
These items shall be capable of being mounted at any height and at any
orientation.
Multi-function poles shall comply with the requirements for aluminium poles.
7A/12.5 POLE FOUNDATIONS (APPLIES TO ALL TYPES OF POLE)
Provide concrete pole foundations. The concrete shall be Class 30 in accordance

with Section 4 of these Specifications. Increase the cement content by 10% if any
part of the foundation is below the water table. Vibrate for at least two minutes.
Submit to the Engineer shop drawings with supporting design calculations for
review prior to construction of the foundations.
Protect the foundation with bituminous paint to ASTM D1187 – Standard
Specification for Asphalt-Base Emulsions for Use as Protective Coatings for Metal.
A sample foundation is to be reviewed by the Engineer and Roads & Transport
Authority Roads Lighting Section before commencement of the work and the same
standard is to be maintained throughout the contract.
No site welding will be permitted. Provide a precision made steel template to
ensure correct horizontal and vertical holding down bolt alignment.
All stainless steel components shall be of Grade AISI 316.
Holding down bolts and their nuts and washers shall be hot dip galvanized steel.
Wrap Denso Self Adhesive Tape on the exposed section of the threaded part of
the holding down bolts before casting the foundations. The tape shall consist of
PVC with a backing of rubber resin pressure sensitive adhesive.
Refer to standard drawings.
7A/12.6 POLE INSTALLATION (APPLIES TO ALL TYPES OF POLE)
Install poles within ± 10 mm of level and ± 100 mm of location.

Erect poles truly vertical within a tolerance of ± 10.
Orientation of outreach arms shall be at right angles to the kerb.
Do not use chain slings without adequate protection and take care so that the

galvanizing and any paint finish are not damaged.

After concreting, thoroughly clean and grease the bolts and check with a template
to ensure accurate placement.
Install the pole with a nut and washer under the pole flange, and a washer and nut
above the pole flange.
Grout the gap between the foundation and the pole flange.
Grout for gaps of less than 40 mm shall comprise 1 part of Portland cement, 2
parts of sand and no more than 0.45 water cement ration by mass.
Grout for gaps of more than 40 mm shall comprise 1 part of Portland cement, 1.5
parts of sand, 1.5 parts of coarse aggregate and no more than 0.45 water cement
ration by mass.
Cut any excess length of holding down bolts and coat with zinc rich paint.
Coat holding down bolts, nuts and washers with bituminous paint to ASTM D1187
– Standard Specification for Asphalt-Base Emulsions for Use as Protective
Coatings for Metal.
On completion of installation, exposed nuts and bolts heads of holding down bolts
shall be capped with grease filled uPVC caps.
7A/12.7 MID-HINGED POLES

The pole shall be hinged approximately midway above the base so that it may be
raised or lowered by means of externally operated lanyard and an internal counter-
weight. Provide a lanyard suitable for each type of mid-hinged pole.
Provide a compartment with access door to accommodate the cut-out and lamp
control gear.
Provide a hinge spindle of stainless steel (AISI grade 316). Ingress protection at
the hinging point shall be IP53 of IEC 60529.
Between the fixed and hinging sections, provide a copper brad earth bond.
Provide cable supports within the pole to avoid stress on the pole wiring.
Provide a means of securing the moved section to the fixed section when the pole
is lowered.
Provide tuition to the Roads & Transport Authority Street Lighting Section in the
operation and maintenance.
Shop drawings shall include calculations of forces encountered by the pole and
foundation during lowering and raising.
7A/12.8 CROWN POLES
7A/12.8.1 Poles
General: Poles shall be equipped with a mobile crown arrangement.

Structure and Construction:
The pole shall not be more than 3 sections, other than the luminaire carriage for 30
and 40 meters high poles respectively.
The pole shall be suitable for supporting the array of luminaires.
The pole shaft shall have a polygonal cross-section, continuously tapered and
longitudinally welded. The shaft shall be delivered in separate sections to be
assembled on site by slip-on joint system.
Pole with luminaire carriage and mobile ring and luminaire shall be able to
withstand the maximum Design Wind Velocity.
Provide a compartment with access door to accommodate the cut-out and lamp
control gear.
All the moving parts of the locking device shall be stainless steel (grade AISI 316).
Assemble the poles in accordance with the manufacturer’s recommendations.
7A/12.8.2 Aviation Lights
Aviation lights shall be provided to the top of any pole exceeding 30 m in height.
The aviation light shall comply with the Civil Aviation requirements and shall be
permanently powered.
The aviation lights shall be fixed to the mobile ring and located to facilitate
maintenance and replacement.
Drawings and samples shall be submitted to the Engineer.
7A/12.8.3 Marine Navigation Lights
Marine navigation lights shall be provided to bridges across navigable waterways.
The marine navigation lights shall comply with the Dubai Ports Authority
requirements and shall be permanently powered.
Drawings and samples shall be submitted to the Engineer.
7A/12.8.4 Lowering and Raising Devices
The lowering raising device with latching mechanism allows for load to be removed
from hoisting unit when luminaires ring is latched in.
The lowering and raising system shall consist of, but not limited to:
 Driving Head
 Mobile Ring
 Hoisting Unit
Driving Head
The driving head shall be made of hot dip galvanised steel and be fixed to the top
of the plate by a flange secured to the most top by at least 6 bolts.
The driving head shall be pre-assembled and tested in the factory prior to shipment
and supplied complete with 3 stainless steel ropes (Grade AISI 316) and
associated double pulley assemblies and electrical power cable. Each steel rope
and power cable shall have its own separate arm, housing the pulleys made of
stainless steel (grade AISI 316) and mounted on self lubricating ball bearings and
seamless axles.
The housing cable, 3 units, shall be made of stainless steel (grade AISI 316). Each
cable shall have a safety factor of not less than 5 times the safe working load of
winch. The hoisting cables shall be of three connectors allowing regulation from
ground.
Provide three latching sleeves assuming correct positioning, entering and locking
of the mobile part of the crown when raised and locked in final position.
The locking system shall take up all horizontal and vertical loads of the mobile part
of the crown without vibration even when exposed under the most severe climatic
conditions.
The top of the driving head shall be covered with a canopy of 3 mm thickness
aluminium sheet.
The latching and unlatching operations shall be regulated by two limit switches
located at the base of the pole, easily accessible through the inspection door.
The mobile part is fastened in raised position to the fixed part of the head gear by

means of 3 positive latching system protected against corrosion, and the

suspension cables shall be tension free. Submit both the latching system and
suspension cables to the Engineer for review.
All bolts, nuts and washers of the pole assembly shall be stainless steel grade AISI
316.
Mobile Ring:
The mobile ring shall be fabricated and coated against corrosion according to the
pole specification. It shall be complete with luminaires and brackets to suit lighting
design requirements consisting of flood lights and control gear boxes.
During lowering and raising operations the mobile ring shall smoothly and without
any sideward movement/rotation slide along the shaft with 3 groups of plastic
rollers at 120 degrees.
Hoisting Unit:
Suitable numbers of drum winches, with base flanges for mounting on holding
down bolts shall be fitted in the bottom of pole for operation by hand and power
tool, for raising and lowering the mobile ring. The winch shall be fitted with a friction
winch clutch, ratchet and pawl, and the handle. Spindle plate shall have a safety
pin locking device. Winches shall be totally enclosed to exclude dust and blown
sand from gears and oil baths.
The mobile ring shall be raised and lowered by means of remote control push
button panel box 10M away. The control box shall conform to IP 55 of IEC 60529,
be of heavy duty construction, be corrosion resistant, be UV resistant and have
proper locking arrangements.
Winch power tools shall be portable, multi-speed, reversible, units incorporating
torque limiting. They shall be supplied with a flexible supply cable and a remote
control switch to allow winches to be operated from a distance of 10 meters. A
supporting system shall be provided to securely locate power tools during
operation. Power tools shall be rated to raise the crown from ground to pole top in
not more than 15 minutes.
One spare winch power tool set shall be handed over to the Engineer on
completion of the contract.
7A/12.8.5 Electrical Equipment
The driving head shall be designed to accommodate a round power cable. Plugs
and sockets shall comply with IEC304-1 and IEC 309-2.
Internal control panels within pole bases shall incorporate a moulded case circuit
breaker main switch, and outgoing MCBs for the pole wiring circuits. The control
panels shall have the facility for terminating incoming power cables and shall be
fitted with weatherproof plug and socket arrangement to allow connection of the
pole wiring rising multi-core cables. Control panels shall be complete with a 16A,
240V weatherproof socket and ELCB of appropriate rating to supply the winch
power tool. Control panels shall receive protective treatment as specified and shall
be sealed to IP 54 of IEC 60529.
On the mobile ring, provide an IP65 distribution enclosure made of 3 mm. thick
aluminium sheet, housing the terminal clamps and a powered socket with cable for
flood lights, ground test
The contractor shall supply and install 2.5 mm2, 3 core butyl rubber insulated and
sheathed flexible cords to be pulled through flexible conduits for the connections
between terminal boxes, control gear boxes and individual flood light fittings.
An earthing terminal shall be provided within the pole base, located so that easy
access for connection/disconnection of the copper earthing tape can be achieved.

7A/12.8.6 Design Information
Prior to the fabrication of any part of the poles or brackets, submit to the Engineer
for review the following:
 Design parameters
 Calculations and data
 General dimensions of all components of the pole include mounting mobile
ring and multiple luminaires array.
 Detailed scale drawings of both pole and luminaires mounting brackets.
 Details of the fixing and locking system between the pole and the luminaires
mounting bracket.
 The total maximum load moments for each section under maximum stresses.
Computation of stresses in the base plate and anchor bolts under maximum
windload with maximum number of luminaires in place.
 Maximum deflection at the top of the pole, under conditions and wind velocity
mentioned earlier.
 Any new treatment method for extra protection against corrosion of the base
plate area and up to the height of 300 mm.
 Detail calculations of the necessary strength for anchor bolts to be used.
 Means of assembling of pole’s sections shall be indicated in details.
 Impact resistance calculations at a height of one meter above the base plate
of the pole.
 Maximum tolerable impact calculations to shear the plate from the pole and
from an impact point one meter above the flange plate
 Materials specification for each parts of the pole.
7A/12.8.7 Test Certificate
The Contractor to provide with each pole a detailed test certificate for:
 pole shaft materials and accessories;
 electrical power supply system;
 hoist system
 galvanizing; and
 Anchor bolts, nuts and washers for both material and galvanizing.
7A/12.8.8 Warranty
The Contractor shall submit to the Engineer a written warranty that the hoisting and
latching systems used in the pole shall work maintenance free for a period of at
least 20 years from date of commissioning.
The Engineer reserves the right to reclaim from Contractor any cost involved for
repair or replacement of any item related to the hoisting and latching system used
during the twenty years period.

TABLE OF CONTENT
7B/ TUNNEL AND UNDERPASS LIGHTING .....................................................................33

7B/1 GENERAL .............................................................................................................33
7B/2 SCOPE OF WORKS .............................................................................................33
7B/3 STANDARDS ........................................................................................................33
7B/4 TUNNEL AND UNDERBRIDGE LIGHTING DISTRIBUTION BOARD .................33
7B/5 TUNNEL AND UNDERBRIDGE LUMINAIRES - GENERAL ................................36
7B/6 TUNNEL AND UNDERBRIDGE LUMINAIRES - CONSTRUCTION ....................36
7B/7 TUNNEL AND UNDERBRIDGE LUMINAIRES – MECHANICAL
REQUIREMENTS ...............................................................................................................37
7B/8 TUNNEL AND UNDERBRIDGE LUMINAIRES – EMERGENCY LUMINAIRES.. 38
7B/9 TUNNEL AND UNDERBRIDGE LUMINAIRES – ELECTRICAL REQUIREMENTS
38
7B/10 TUNNEL AND UNDERBRIDGE LUMINAIRES – PHOTOMETRICAL
REQUIREMENTS ...............................................................................................................39
PERFORMANCE REQUIREMENTS ..................................................................................40
7B/12 TUNNEL AND UNDERBRIDGE LUMINAIRES – DOCUMENTATION
REQUIREMENTS ...............................................................................................................40
7B/13 TUNNEL AND UNDERBRIDGE LIGHTING CLIMATE .........................................41
7B/14 TUNNEL AND UNDERBRIDGE LIGHTING CONTROL .......................................41
7B/15 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLS....................43
7B/16 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLLERS.............44
7B/17 TUNNEL AND UNDERBRIDGE MAIN CONTROL SYSTEM ...............................44
7B/18 TUNNEL AND UNDERBRIDGE PROGRAMABLE LOGIC CONTROLLERS
(PLC’s) 45
7B/19 TUNNEL AND UNDERBRIDGE REMOTE SUPERVISION AND BACK UP
CONTROL SYSTEM...........................................................................................................47
7B/20 TUNNEL AND UNDERBRIDGE CABLING ...........................................................48
7B/21 TUNNEL AND UNDERBRIDGE JUNCTION BOXES ...........................................50
7B/22 TUNNEL AND UNDERBRIDGE CABLE TRAYS ..................................................50
7B/23 TUNNEL AND UNDERBRIDGE INSPECTION TESTING AND COMMISSIONING
51

7B/ TUNNEL AND UNDERPASS LIGHTING
7B/1 GENERAL
This Section specifies the requirements for design, manufacture, supply, factory
testing, packing, insurance, delivery to site, unloading, storage, protection, erection
and installation, wiring and cabling, site testing and commissioning of the complete
equipment for underpass lighting, and control.
7B/2 SCOPE OF WORKS

The Scope of Works shall involve the steps below:
Connect the utility cables to MDB.
Provide the Lighting Distribution Board (LDB) and placement as shown on the
drawings.
Supply and Installation of Lighting Equipment comprising:
 415 V Lighting Distribution Board.
 Lighting fixtures and associated brackets, supports, conduits, trunking, trays
and cabling/wiring for Underpass lighting.
 All the required sizes and lengths of service cables.
 Earthing and bonding of all electronic items and electrical equipment
including supply of earthing materials.
 All jointing and termination, lugs, fuses, lamps, keys, locks, labels and all
necessary material to complete the installation.
 All necessary civil works.
 All Junction boxes for loop-in, loop-out connections for groups of lights.
 All accessories for modular cabling along with cable system.
Provide all labor, plant and materials for the complete erection, adjustment, testing,
painting and putting to work all equipment supplied.
Supply and installation of any material which may not be expressly specified but
which is necessary for the completion of the project.
Reinstatement of the existing conditions of the services and properties that will be
affected during the construction.
7B/3 STANDARDS
All equipment and workmanship shall comply with the most recent documents
published by the CIE, IEC, British Standards, and European Norms. The following
Standards and Codes form part of this Specification:
NFPA 101 Life Safety Code
NFPA 101A Guide on Alternative Approaches to Life Safety
NFPA101B Code for Means of Egress from Buildings and Structures
NFPA 502 Standard for Road Tunnels, Bridges and other Limited Access
Highways
7B/4 TUNNEL AND UNDERBRIDGE LIGHTING DISTRIBUTION BOARD

Construction shall be in accordance with the following standards.
 Publication BS EN 60073: Colors of indicator lights and push buttons.

 Publication BS EN 60529: Degree of protection of enclosures.
 Publication BS EN 60947: Low-voltage switchgear and control-gear.

 Publication IEC 269: Low-voltage fuses.

 Various publications relevant to apparatus, devices and components.
The Contractor shall be responsible for the correct sizing of the electrical
equipment and for the proper selection of materials in accordance with the ambient
conditions. All materials used shall be able to operate normally, during high
temperature conditions.
The Contractor shall guarantee that the LDB supplied by him, inclusive of all
materials and installed equipment, are free from all defects or imperfections and
are capable of proper operation at rated load within the tolerance limits established
by governing construction codes.
The design and construction of electric LDB shall be such to ensure:
 Public safety and personnel under all operating and fault conditions;
 Construction and operating reliability;
 Possibility of future considerations.
Public safety shall be assured by the prevention of direct and indirect contacts with
live or moving parts under any operating and expected fault conditions or
otherwise under maintenance conditions or occasional handling on LDB.
General and partial protection shall ensure that the Public cannot come in to
contact with the live parts of the electric LDB.
The general external protection shall be achieved by means of permanent barriers

or enclosures, which prevent any contact with the live parts.
The spacing, insulation level and mechanical strength shall be consistent with the
stresses they may normally undergo.
The luminaires shall be fed by the LDB as indicated in the Drawings.
The LDB shall contain all the electrical components necessary for automatic
lighting of the luminaire in night hours and day hours.
The LDB foundation shall be made of concrete.
The foundation shall be all, excluding the top surface, bituminous painted.
The LDB cabinet shall be made by zinc plated sheet steel 1.6 mm thickness
minimum. The external side of the LDB shall be epoxy powder coated having the
color pigments as per RTA requirement. The cabinet shall be provided with IP 55
ventilation intakes on the lateral sides.
The LDB cabinet shall be housed inside air-conditioned double walled thermally
insulated Kiosk combined with the MDB and DPS (Drainage Pump Station) panel if
they are closed to each other. Separation shall be maintained between the LDB
and the MDB and DPS in two rooms with different doors and key locks. This is only
one BOQ item and shall not be included under any other scope of work.
The bottom of LDB shall be removable for gland installation.
The LDB shall be fixed to stainless steel grade 316 anchor bolts, with extra wide
washers, spring washers and stainless steel nuts.

The degree of protection required is IP55 according to BS EN Publication No.

60529.
The LDB shall be certified to withstand 50 KA for 1 sec.
Two lugs of appropriate dimension shall be fixed on top of the LDB for easy
handling. The access inside the LDB shall be provided by one or two doors with
180-degree polyamide hinges and fitted with two vertical and one horizontal wedge
actuated by a rotating handle which can be pad locked with a Master lock with key.
Latching devices to fix the door open shall be provided. A danger notice in Arabic
and English languages shall be riveted on the front of the LDB.
The equipment inside the LDB shall be screwed, with easy unfastening access, to
one metallic structure of galvanized steel or equivalent.
Insulated set of busbars of hard drawn tinned copper shall be rigidly supported (air
insulated system will be adopted).
The phase and neutral bar shall be rated as indicated on drawings. The cross
section area of phase and earth bars shall be as per rated and short circuit
currents. The metallic structure of the LDB shall be connected to the earth bar
together with the external cable armoring earth and from this bar the earthing lead
will depart accordingly. All connections shall be obtained with copper tinned lugs
and phosphor bronze bolts, washer, spring washers and nuts.
The Circuit Breakers shall be TPN and 1PN rating as shown on drawings with
Breaking Capacity 50 KA rms. in "SERVICE" as per BS EN 60898 at 415 V, 50 Hz.
The branch circuit breakers shall have direct acting relays with differential current
relay operation at 100 mA of fault.
One door switch operated internal fluorescent lamp (minimum of 15 W) shall be

provided as well as one single-phase internal 13A - 240 V socket both protected by
circuit breaker.
Glands with moisture and humidity seal rings, entry thread seal under the lock nut,
earth tag, plastic shrouds covered, shall protect the incoming and outgoing cables.
Modular cables of determined size stranded and fire rated with sockets shall be
used for lighting circuits. Individual luminaire shall be supplied with 2.5 mm2
flexible and fire rated cables from the socket of modular cable.
Contactors shall be air magnetic type; they shall be compact anti-shock, or

assembled to result insensitive to shocks or vibrations according to BS EN 60947-
4. Contactors shall be suitable for continuous duty and capable of at least 150
duty cycles per hour. Contactors shall close positively with 85% of rated coil
voltage and shall be maintained positively with a voltage-drop up to 65% of the
rated voltage. Rated operational current and for mounting inside LDB shall not be
lower than 130% of the load rated current. Breaking/making capacity shall not be
lower than 8/10 times the rated current up to 100A and 6/8 times the rated current
over 100A. Contactors shall also be capable of withstanding, a current equal to
their breaking capacity for a duration of 5 seconds, with rated voltage of control
coil. Contactors shall be coordinated with the associated protections (thermal and
magnetic) in such a way that permanent damage shall be avoided, under fault

current of any value up to the specified short circuit current. Permanent damages
shall be avoided. No contact chattering and fusion shall occur under full load
current at coil supply voltage equal to 80% of the rated voltage. Each contactor
shall always have at least 2 auxiliary contacts (1NO 1NC) available and wired to
the auxiliary terminal strip.
7B/5 TUNNEL AND UNDERBRIDGE LUMINAIRES - GENERAL
Luminaires shall contain high pressure sodium lamps and operate on 240 Volts,
+/- 10%, 50 Hz
The Underpass lighting luminaires shall follow the latest versions of the following
standards:
 BS 4533: 1971
 BS 4533 Part 2 Section 2.7 : 1971
 BS 4533: Section 102.3: 1990
 BS 1615: 1987
 BS 1470: 1987
 BS EN 60922: 1991 and BS EN 60923: 1991
 BS 6500: 1990
 IEC 598 Part 1 and 2
 BS 4533: Part 103: Section 103.1: 1988
 BS 5489 Part 1, 2 & 3: 1992
 BS 5225: Part 1: 1985
 BS 5101 (Part 1) and (Part 2): 1986
 BS EN 60529: 1992
 BS 6193:1990
 BS 3772:1990
7B/6 TUNNEL AND UNDERBRIDGE LUMINAIRES – CONSTRUCTION
Luminaires shall meet the following minimum construction requirements.
Aluminium (Magnesium-silicon alloy) extruded or Die-cast Aluminium body in one

piece with an anodized finish and side covers in die cast aluminium alloy as per BS
4533 Section 102.3: 1990.
Super purity one-piece aluminium reflector of grade S1 of BS 1470: 1987 with an

anodic coating of not less than grade AA10 of BS 1615: 1987.
Strong, very high thermally resistant, hinged, front glass protector assembly
comprising clean toughened, heat tempered glass plate, fixed into aluminium
frame with rapid closing devices, sufficient to achieve IP65 degree of protection for
enclosure. In the open position, the glass remains suspended from the luminaire.
Front flat glass assembly is to be sealed using neoprene non-rotting type

gaskets/or high quality felt gaskets silicon. The glass shall be capable of opening
180 degrees.
Hinges, mounting clips and fastening bolts shall be of stainless steel grade SS316.
Movable porcelain lamp holder with position markings and anti-vibration fixation
device.
Optical system, electrical control gear and lamp, mounted on "Plug-in" type
reflector gear tray with locating pins to ensure correct alignment when being fitted
into body. (As per BS EN 60922: 1991 and BS EN 60923: 1991).
The luminaire shall be provided with anti-glare grill and clear flat glass.
Two adjustable cable entries and a terminal block for the connection of incoming
supply cables shall be provided in luminaires incorporating auxiliaries. These shall
be situated as close as possible to the point of entry of the supply cable and shall
be readily accessible. Ground wire connection shall be taken through the plug and
socket connector to ensure that ground potential is maintained on the gear tray
when it is being removed from the luminaire for maintenance.
A means of clamping the electrical supply cables shall be provided in the luminaire
where necessary to relieve the termination of strain. The cable clamp arrangement
shall not damage the insulation of the cable.
Protective sheath for power supply cable, and expandable nylon cable grip for
wiring, conforming to BS 4533 Section 102.3: 1990.
Brass earth terminal set-in housing, according to BS 4533 Section 102.3.1990.
The lamp caps and the lamp holders shall meet the requirements of BS 5101:
1986 (Part 1) and BS 5101: 1986 (Part 2) respectively.
The luminaire shall be equipped with two brackets suitable for top/ corner
mounting and shall be of hot dipped galvanized steel. The brackets shall be
adjustable for continuous inclination from 0-180 degree.
Luminaires shall withstand prevailing ambient and lamp temperatures and shall
operate normally under such conditions.
7B/7 TUNNEL AND UNDERBRIDGE LUMINAIRES – MECHANICAL

REQUIREMENTS
Luminaires shall be provided with two separate compartments for the optical
system and for the control gear.
The tightness of the optical compartment shall be IP65, according to the BS EN

60529 standard. This tightness degree shall be achieved by the use of neoprene
gaskets or silicon gasket. The design of the luminaire shall be such that the sealing
gasket will never be exposed to sunlight or to the luminous flux emitted by the
lamp.
The tightness of the control gear compartment shall be IP65 or better, according to
the BS EN 60529 standard.
The opening of the control gear compartment shall allow a complete and easy
visual check of all electrical parts and to be suitable for easy access and easy
maintenance.
The mechanical strength of the body and its accessories and the protector of the
luminaire shall be sufficient to withstand a mechanical shock having an impact
energy complying with BS 4533 Section 102.3: 1990, without any damage.
The luminaire shall be able to withstand a wind speed of 160 km/h without any
damage.
Fixing shall be of an effective locking means using stainless steel bolts grade AISI
316.
The luminaire in general shall comply with the requirements mentioned in BS

4533, Section 102.3: 1990.
All luminaires shall have overall protection against ingress of moisture of IP 65.
All fixings, which carry the weight of the luminaire and internal accessories, shall
be provided with suitable locking devices to prevent the dislodgment of any part of
the luminaire by vibration either in service or in maintenance. Compliance shall be
verified as per BS 4533 Section 102.3: 1990.
7B/8 TUNNEL AND UNDERBRIDGE LUMINAIRES – EMERGENCY

LUMINAIRES
Emergency luminaires shall comply with BS 5266 and EN 60598-2-22 and shall be
of the pictogram type.
Emergency luminaires shall be manufactured with polycarbonate diffusers and
have an ingress protection of IP55 to IEC 60529.
Thermal and photometric test reports shall be submitted. Emergency luminaires
shall be complete with nickel-cadmium batteries, inverter, dual-rate charger,
change-over equipment test switch, etc.
Emergency luminaires shall be wired with an Active, Neutral and Earth conductors
and an additional “unswitched active conductor”.
Refer to Particular Specifications
7B/9 TUNNEL AND UNDERBRIDGE LUMINAIRES – ELECTRICAL

REQUIREMENTS
The electrical accessories such as ballasts, igniters and capacitors shall be pre-
wired and pre-assembled on metallic supports that are fixed into the control gear
compartment for each lamp.
Special care shall be taken to allow easy maintenance and quick replacement of
the accessories. They shall be bolted (and not riveted) on the removable supports.
The supports shall be laid down in the compartment and in no case shall be
suspended by bolts, for security reasons and maintenance facilities.
All electrical accessories shall be able to withstand the temperature existing in the
control gear compartment in continuous operation and without any damage, at
ambient temperature of 50 degree C. Cable connections to the lamp holder within
the luminaire shall be of the heat resistant type with glass fiber or other approved
insulation. The arrangement shall comply with BS 4533 Section 102.3: 1990.

The cable feed terminals and the earth screw shall be fixed inside the control gear
compartment. A cable holder shall be mounted near the terminals. An isolating
conduit shall be fitted to protect the incoming feeder cable. The arrangement in
general shall comply with BS 4533 Section 102.3: 1990.
A separate set of control gear shall be provided for the lamp comprising one
ballast associated with one capacitor and one igniter. The control gear should be
encapsulated in an approved enclosure conforming to IP 65 or better tightness.
Terminals of all ballasts, capacitors and igniters shall be shrouded. The ballast
shall be designed to operate the lamp and control it continuously in ambient
temperatures ranging from 0 degree C to 80 degree C. The igniter shall be
complete with timer no less than T15S (T fifteen seconds). Ballast should have
thermal protection built-in switch.
The capacitor shall be of the biphenyl impregnated type and shall be in a leak
proof metal container fitted with an internal discharge resistor. The permitted
operating temperature of the capacitor shall be marked on its case and shall be 90
Deg. C. The capacitors shall have value sufficient to raise the power factor of the
complete system to 0.85 or better. Each lamp shall operate using only one
capacitor. Any combination of two or more capacitors to have the equivalent value
of capacitance will not be accepted. Capacitors shall comply with the latest BS EN
60922: 1991 and BS EN 60923: 1991.
The control gear shall be supplied by the luminaire manufacturer and shall be
incorporated in a separate compartment in a way that heat emitted by lamp is not
conducted or transferred to the gear components.
The luminaire shall have a screw type lamp holder. The lead at the higher potential
above earth shall be connected to the center contact.
The operating temperature and thermal endurance characteristics shall conform to

Part 2 of BS 4533 Section 102.3: 1990.

REQUIREMENTS
The lamp fitting shall be adjustable to allow the luminous flux distribution to be
adapted to the geometrical installation conditions
The adjusting device of the lamp shall be sufficiently sturdy, and designed in a way
that cannot be disturbed, during its normal lifetime (vibrations) or during
maintenance operations (lamp replacement).
This device shall have permanent markings so that the lamp position
recommended by the manufacturer can be easily realized.
The photometrical classification of the luminaires, according to CIE Nr. 34

publication shall incorporate the following characteristics, depending on the lamp
position adjustment:
 Longitudinal flux control : Throw - intermediate or long

 Transverse flux control : Spread - Narrow or average
 Glare control : SLI - Greater than 3

PERFORMANCE REQUIREMENTS
Computer calculations relating to illuminance and luminance results detail shall be

submitted including the overall luminance uniformity ratio (UO) and longitudinal
luminance uniformity ratio (UI) which has to be achieved in the underpass, values
of glare control mark (G), threshold increment (TI) and specific Luminaire Index.
For the luminance calculation, the road surface to be considered is the R3 type
with QO = 0.07 according to CIE Standards.
The calculations shall be performed in accordance with the latest edition of CIE Nr.
30 publication and shall be based on the data given in the drawings. These
computer calculations shall achieve the requirements of Sub-Section P2/5 and as
shown on drawings.
These results are to be achieved taking into consideration a total maintenance

factor of 0.8 (dust depreciation factor x lamp lumen depreciation factor).
Computer calculations shall determine the maximum spacing of luminaires to be
adopted to achieve the above results.
7B/12 TUNNEL AND UNDERBRIDGE LUMINAIRES – DOCUMENTATION

REQUIREMENTS
The Contractor shall supply the following technical documentation and information
for each type of luminaires for the approval of the Engineer. The approval of the
Engineer does not absolve the Contractor of the contractual obligations regarding
the performance and compliance to the specification requirements.
 Catalogue sheet of the luminaire, ignitor, ballast, capacitor, and lamps.

 Detailed construction drawing of the luminaire, Polar diagram of luminous
intensity in roadway vertical plane and transverse vertical planes.
 Utilization factor curve for actual inclination of luminaire.
 Isolux diagram for actual inclination of luminaire.
 Intensity table, in the C-gamma co-ordinates recommended by CIE Nr. 27
Publication.
 Computer calculation printout showing the illumination and luminance levels.
Longitudinal Uniformity Ratio (UI), overall Uniformity Ratio (UO), specific
luminaire index (SLI), glare control mark (G) and threshold increment (TI).
These calculations shall also show the lighting curve as per CIE 88
recommendations.
 Tightness test certificate conforming to IP65 protection degree for the optical
compartment of the luminaires and the IP65 protection degree for the control
gear compartment. This test certificate shall be issued by an independent
official laboratory.
 Shock test certificate confirming the resistance of the body to impact energy
as per Clause 4.4 Section 1.4 of BS 4533, Part 1. This test certificate shall be
issued by an independent laboratory.

 Wind resistance certificate confirming that no damage will occur to the

luminaire at winds up to 160 Km/h for a short period. This certificate shall be
issued by an independent official laboratory.
 Total weight of the luminaire (with lamp and control gear).
 Power factor of one complete luminaire (under normal working conditions).
 Total electric consumption of the luminaire, including control gear losses
separately indicated.
 Rated lumen output of the lamp under nominal conditions.
 Depreciation curve of the luminous flux with burning hours.
 Luminous flux variation with the main voltage.
 Make and type of ballast and capacitors separately with their electrical
characteristics, e.g., Impedance, power factor, Temperature rise (t),
maximum temperature and power losses.
The contractor shall submit full details of areas using the same type of luminaires
in the Middle East and Gulf Area.
A computer program according to CIE standard on CD (compact disks) full IBM
compatible should be supplied and the matrix program for the offered luminaire.
The supplier shall submit for the Engineer's approval dimensioned drawings of the
control gear arrangements showing the exact positions of ballast, ignitor, lamps
and capacitors within the luminaire.
The contractor shall submit an assembled sample of the proposed luminaire for the
approval of the Engineer.
Single Line Diagrams, General Arrangement drawings for all Lighting Distribution
Boards and Panels.
System configuration diagram for the complete lighting control system.
Electronic (on CD) and hardcopy of the PLC Program shall be handed over to the
Client at the completion of contract. The PLC program printout shall have all the
information about all the computation elements like timing delays and counters,
logical instructions and inputs and outputs.
Contractor shall provide along with tender a recommended list of spare parts for
the complete lighting system including spares for Light fittings, PLCs, Dimming
controllers, etc. for 5 years of trouble-free operation. This list shall be complete
with unit rates.
Contractor to provide along with the tender a detailed description about the Mean
Time Between Failures (MTBF) of the proposed lighting system. This shall show
MTBF of all major parts of the system, such as Light fittings, PLCs, Dimming
controllers, L20 meters, Lighting controllers, etc.
7B/13 TUNNEL AND UNDERBRIDGE LIGHTING CLIMATE

Refer to 7A/4 CLIMATE in this specification
7B/14 TUNNEL AND UNDERBRIDGE LIGHTING CONTROL

The Underpass lighting system shall be controlled automatically by means of a
photometer system consisting of photometers, dimming controllers and a PLC.
Microprocessor based PLC/lighting controllers shall be provided in Underpass

LDB.
LDB shall contain sets of dimming controllers, HMI for Operator/programmer,

Interface for PC, photometer relays and lighting controllers and other items as
necessary.

The lighting control shall be such as to continuously adjust by dimming control,

selected groups of luminaires in conformity with the increase and decrease of
external luminance at the entrance zone.
The photometers shall continuously monitor the external luminance and transmit
the signals to the lighting control unit, which shall process and convert the signals
received to determine the appropriate dimming level.
It is envisaged to have remote access for monitoring and controlling capability for
lighting control from a central SCADA system through operator workstations.
Hence the provision of such remote control SCADA connectivity is to be ensured
by installing all necessary devices, communication interfaces, etc. in the LDB
panels. The devices shall be ready for communication and shall be completely
configured. The actual remote SCADA communications will take place in future
and the communication devices should remain powered Off till such time.
Operator system entry shall be password protected with different levels of

accessibility depending on the level of Authority of the operator.
Lighting controller PLC shall support all functional requirements to achieve this
remote control.
Dimming / Lighting Control shall be generally in line with the Lighting control
schematic drawing included in the Tender drawings. However alternate schemes
with better functionality and with higher specifications may be acceptable subject to
Client/ Engineer’s approval during construction.
Photometers shall be provided for the purpose of sensing the adaptation

Underpass surrounding luminance. The photometers shall give a linear electrical
signal output proportional to the luminance measured. Adaptation of the level of
luminance detected by the photometer to the spectral sensitivity of the human eye
to be ensured. The photometer housing shall be corrosion proof and made of high-
grade stainless steel. The housing shall be equipped with a high-grade steel swivel
base, which can be swivelled +25 degree horizontally and vertically.
A self-limiting heating cable system shall be provided to ensure the absence of

moisture so that it would not affect the operation of the instrument.
Suitable shade shall be provided to prevent solar radiation to the casing.
Cable entry glands for power supply and signals to the photometer control unit
shall be absolutely dustproof and moisture-proof to IP67.
The signal cable interconnecting the photometers and the photometer control units
shall be multi-core armoured cable with shielding, compatible to the control system
proposed.
The photometers shall be mounted on hot dip galvanized steel column pointing in
the drivers' direction of vision, at a height of approximately 4.5m and at safe
stopping distance from the tunnel entrance, to meet the CIE standards
requirements and shall be approved by the Engineer/Client after site inspection.
Provide a suitable Industrial grade PC similar to Siemens PG type laptop,

equipped with all accessories related to MPI operations and software licenses to

interrogate the aforementioned data and to control the PLCs accordingly.
Empirical luminance measurement of all to be conducted on site as below.

 Luminance meters accepting a 20 deg. circular field of view shall be used for
luminance measurement in all zones.
 The luminance meter shall be mounted on a tripod in the centre or at a
suitable location of the eventual approach roads at a height of 1.5 m above
the road surface and with the 20 deg. field centered in that particular zone.
 The meter shall be positioned at the safe stopping distance from the
beginning of the measuring Zone.
 The measurements are to be repeated for each lighting stage for each Zone.
Collected readings are to be submitted to the Engineer/Client along with the
lighting design calculation for comparison and approval.
7B/15 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLS
The Underpass daytime lighting shall be dimmed in four steps and one night step.
The daytime lighting shall be continuously controlled in accordance with the
daylight outside the respective Underpass entrance.
Entrance shall have a photometer to measure the daylight at the respective
entrance. The lighting control system shall control the switching and dimming of
the entrance and exit zones.
The lighting control system shall work independently and shall have PLCs in the
LDB.
Dimming controller shall be controlled by the PLC as will be shown in the Lighting
Control Schematic diagram that will be prepared by the Contractor and submitted
to Engineer for approval. The PLC shall manage the switching of the HPSV lamps
in accordance to the outside light and determine the level of dimming for each
step.
The Lighting Controller PLC shall be located in the LDB as shown in the Lighting
Control Schematic drawings. All necessary cabling and interfaces between the
Lighting controller PLC and all the Dimming Controllers shall be provided.
The system shall be designed to have manual control at LDB level. For this
reason, LDB shall have a 3-position switches installed (AUTO – MANUAL – BY-
PASS). The manual operation shall permit to switch each step ON and OFF and to
adjust the dimming signal using potentiometers on the LDB. The 3- position switch
shall be adequate for ease of operation and manipulating logical groups of
dimming controllers. It shall be possible to remove any one of the dimming
controller out of service without affecting the rest of the lighting.
All data signal transmission in the field shall utilize Modbus or approved equal
protocol and to the future SCADA System by using Profibus or Industrial Ethernet
as applicable.
Dimming Controllers shall meet with following minimum functional specifications:

 Start-up: It shall provide Automatic programmable burn in cycle for the
lamps.
 Soft Start: Switching ON of lamps shall always take place at Zero crossing of
voltage waveform.
 Power: Rating to suit the load as a single unit without paralleling.
 Output Voltage: Stabilized + 1% of RMS value, independent of input voltage.
 Inputs/Outputs As necessary to meet the functional requirements of this
specification.
 Dimming Range: 100-30% of luminous output for HPS lamps

 Site Operation Temperature: 0°C / +60°C

 Humidity: 90% no condensing
 Efficiency: >98% at rated load
 EMC: EN 50081-1, EN 6055-2, EN 60555-3, EN 50082-2, CE conformity
 Harmonics: ≤ 1%
 Output Voltage Waveform: The dimming control shall be achieved using
trailing edge control. Peak voltage has to be maintained at each half-wave at
its maximum level.
7B/16 TUNNEL AND UNDERBRIDGE LIGHTING DIMMING CONTROLLERS
HPSV lamp circuits shall be designed to have minimum four switching steps to
avoid a large difference in the illumination levels while shifting from daytime to
nighttime. The steps shall be continuously stabilized, dimmed and monitored using
appropriate size of Dimming Controller.
A PLC, Dimming Controllers and communication port for use of Fiber optic cabling
for communication with the future central SCADA System, shall be provided for the
Underpass.
The PLC shall be programmed to communicate all instantaneous electrical values,
status of all lighting zones, L20 value, and percentage illumination levels achieved
in various zones inside Underpass, and alarms over an industrial type open
protocol to the future SCADA System. The communication protocol to be used is
subject to approval during construction and shall be compatible with the future
SCADA system of the Airport Tunnel Control Center which will monitor, control,
and receive alarm of this Underpass.
7B/17 TUNNEL AND UNDERBRIDGE MAIN CONTROL SYSTEM
The Underpass daytime lighting shall be dimmed in four steps and one night step.
The daytime lighting shall be continuously controlled in accordance with the
daylight outside the respective Underpass entrance.
Entrance shall have a photometer to measure the daylight at the respective
entrance. The lighting control system shall control the switching and dimming of
the entrance and exit zones.
The lighting control system shall work independently and shall have PLCs in the
LDB.
Dimming controller shall be controlled by the PLC as will be shown in the Lighting
Control Schematic diagram that will be prepared by the Contractor and submitted
to Engineer for approval. The PLC shall manage the switching of the HPSV
lamps in accordance to the outside light and determine the level of dimming for
each step.
The Lighting Controller PLC shall be located in the LDB as shown in the Lighting
Control Schematic drawings. All necessary cabling and interfaces between the
Lighting controller PLC and all the Dimming Controllers shall be provided.
The system shall be designed to have manual control at LDB level. For this
reason, LDB shall have a 3-position switches installed (AUTO – MANUAL – BY-
PASS). The manual operation shall permit to switch each step ON and OFF and
to adjust the dimming signal using potentiometers on the LDB. The 3- position
switch shall be adequate for ease of operation and manipulating logical groups of
dimming controllers. It shall be possible to remove any one of the dimming
controller out of service without affecting the rest of the lighting.

All data signal transmission in the field shall utilize Modbus or approved equal
protocol and to the future SCADA System by using Profibus or Industrial Ethernet
as applicable.
Dimming Controllers shall meet with following minimum functional specifications:
 Start-up: Automatic programmable burn in cycle for the lamps.
 Soft Start: Switching ON of lamps shall always take place at Zero crossing
of voltage waveform.
 Power: Rating to suit the load as a single unit without paralleling.
 Output Voltage: Stabilized + 1% of RMS value, independent of input
voltage.
 Inputs/Outputs As necessary to meet the functional requirements of this
specification.
 Dimming Range: 100-30% of luminous output for HPS lamps
 Efficiency: >98% at rated load
 EMC: EN 50081-1, EN 6055-2, EN 60555-3, EN 50082-2, CE conformity
 Harmonics: ≤ 1%
 Output Voltage Waveform: The dimming control shall be achieved using
trailing edge control. Peak voltage has to be maintained at each half-wave
at its maximum level.
7B/18 TUNNEL AND UNDERBRIDGE PROGRAMABLE LOGIC

CONTROLLERS (PLC’S)
General:
1. Each PLC System shall comprise of a Central Processing Unit (CPU),
Input/Output modules, serial interface module and programming units. PLC’s shall
be installed inside Local Control Panels or in separate cubicles. PLC shall be
suitable for ambient temperature of up to 65C and 95% relative humidity. Power
supply shall be 240 V a.c. 50 Hz. The system shall include at least 25 % spare
capacity for future expansion. Panel mounted display units shall be provided for
man machine interface where specified or shown in the Project Drawings. PLC
shall be of modular construction with plug in I/O cards and facility to install
expansion modules when necessary. The PLC shall have a real time clock with
battery backup.
PLC diagnostic indications shall include the following:
 Power OK
 Low battery
 Forced I/O
 CPU fault
 I/O status indicators
Central Processing Unit. The CPU shall perform the following function:
Scan all inputs, execute relay ladder logic programs and generate outputs for the
final control elements.
Monitor status of the system hardware and provide diagnostic information.
Process scan time shall be 8 milliseconds/kilobyte maximum.
Memory:
Random Access Memory (RAM) for real-time program execution with lithium
battery backup for data retention and EEPROM backup for permanent storage of

program shall be provided. The PLC memory shall be as required for the program
and future requirements subject to a minimum of [16] Mb.
Input/Output Module:Analogue input modules shall be for current, voltage, RTD Pt
100 or thermocouple input type, with a 16 bit resolution. Power supply for 2 wire
transmitters shall be provided where specified. Analogue outputs shall be isolated
4-20 mA d.c with 14 bit resolution, unless otherwise specified. Digital I/Os shall be
optically isolated. Contacts shall be rated 1A at 24 V d.c. The systems shall
support on-line replacement of I/O modules, in case of failure.
Programmer/Simulator:
Supply one programmer/simulator with PLC software for use by the Roads &
Transport Authority. Programming shall be through a lap-top programming unit.
Programming shall be user friendly, self-documenting type, with facility for
identification and comments. PLC programming shall be compliant with IEC 61131-
3 standard on programming languages for PLC’s.
Serial Interface:
PLC shall be provided with serial interface ports for peer to peer communication,
MMI for operator interface, or Telemetry. Communication protocol shall conform to
the seven layer ISO Open Systems Interconnect (OSI) model, subject to approval
by the Engineer.
Programmer/Simulator:
 Programming shall be on relay ladder language.
 Password protected programming through hand held programmer or
personal computer.
A Panel mounted VDU shall be provided for the PLC when specified in the Project
Specification, as per the following specification.
 A panel mounted LCD (liquid crystal display) unit for graphic, numeric and
message display.
 Touch screen front glass with one million cycles minimum operational life.
 240 V a.c. 50Hz power supply.
 Enclosure protected to IP65.
 EEPROM for application program storage.
 Provide restricted access to the PLC database for simulating or forcing
inputs/outputs.
 This display unit shall be able to display the graphical trends of all analogue
values, status of all the dimming controllers, LDB power and luminance value
trends, failure alarms, communication status, Earth leakage relay operation
status, etc. This display unit shall also be programmed to show the savings
achieved due to use of dimming controllers. This shall also display the lamp
usage report with lamp replacement schedule.
 Size of display viewable area of the LCD unit shall minimum 17 inches.
 LCD shall be TFT type with high MTBF value. LCD shall have a resolution of
1400 x 900 minimum. LCD shall have horizontal Dot Pitch spacing of
0.22mm minimum and shall support all display requirements of the operation
and control as described above.
 There shall be a provision to connect keyboard to the PC at the local panel.
This PC shall have the Read/write CD, and 2 nos. USB ports.

7B/19 TUNNEL AND UNDERBRIDGE REMOTE SUPERVISION AND BACK UP

CONTROL SYSTEM
The system shall provide remote access for monitoring and controlling the lighting
system from a central SCADA system (future) through operator workstations in the
Airport Tunnel Control Center.
Remote access and control for the lighting system shall be through the PLC
provided in the lighting control panel.
The communication between the lighting panel and the future central SCADA
system shall use Fiber Optic cables. The PLC shall be capable of supporting this
communication mode over a long distance to the Airport Tunnel control room.
Dimming controllers, the associated software, PLC and all other hardware shall
have open architecture and shall support communication interfacing on industrial
standard open protocols for communication with SCADA systems (future) of other
manufacturers.
It shall be possible to view the complete information and make necessary changes
with password protection based on authority level allocation from remote SCADA
station (future).
The future SCADA systems shall consist of PLC for overall lighting control and a
locally installed Industrial grade PC as operator /programming interface.
The PLC shall meet the requirements of specification section PS11, PS-7A/22.20
and as detailed below.
PLC shall control all dimming controllers of the appropriate Underpass section,
based on L20 measurement. The PLC shall also be programmed to compensate
for the Lumen maintenance factor and age of lamps. PLC shall be mounted in the
controls section of LDBs, as shown in the Lighting Control schematic diagram. For
the purpose, the K factor shall be available for changing locally and remotely,
through password authorization.
Should the Luminance meter (L20) fail or the signal is not available to the PLC,
then the PLC shall control the lighting with hourly historical peak luminance data
averaged over the last 7 days, or using its own astronomical clock.
In case a dimming controller fails during operation, the peak dimming controller
itself shall also be equipped with an automatic by-pass system. A failure shall be
communicated via a LED on the dimming controller PLC. Should the auto-by-pass
fail, each step in the LDB shall have a hard-wire by-pass activated with the Hand-
Auto-Bypass switch.
A Laptop PC with software installed, shall be capable of performing all the

necessary functions of the LDB. The operating environment shall be fully
multitasking, Microsoft / Windows 2000 or the latest operating system subject to
approval.
The Laptop PC shall have most recent processor and shall be similar to Siemens
PG or approved equal and shall be suitable for the purpose of programming and
maintenance of the system. The Laptop PC shall be supplied with pre-installed
operating system and programming software, licensed to RTA.
The alarms that shall be communicated to remote SCADA system (future) on the
communication bus from lighting system shall include, but not be limited to the
following.
 Status of each LDB- Failed.

 Status of each dimming controller- Failed, Vin Fail, Vout Fail, etc.
 Status of each PLC/ Lighting controller- Failed.
 Power supply at each LDB- Fail.
 Each Dimming controller- failed alarm.
 Each circuit failure alarm.
 Mains supply failure alarm.
 Communications failure alarm between Dimming controller and the Lighting
controller PLC.
 Communications failure alarm between Lighting controller PLC and the
SCADA system (future).
 High temperature of dimming controller.
 Loss of L20 signal.
 Any other parameter critical for the monitoring of the Lighting system-
proposed by Manufacturer.
The List of parameters to be displayed and recorded on the SCADA system

(future) from the Lighting control system shall include as a minimum as listed
below. Each of the analog signals shall be provided with a trend indicating the
signal values for the time as necessary. At the end of desired period the values
shall be archived in an off-line storage location. It shall be possible to get a printout
of the desired parameters through PLC/SCADA system.
 Power consumption for each LDB, for every section of Underpass, and for
every dimming stage.
 Reduction in power achieved at each LDB due to dimming.
 Voltage, power and Current at each LDB.
 Input and Output voltage, Current and power of each dimming controller.
 Hours of operation of each stage for each Underpass.
 Circuit wise, Lamp usage report and lamp replacement schedule, with date.
 Current status of all dimming circuits at any given time.
 Status of all LDBs, Dimming controllers and PLCs used in lighting control
system.
 Current and historical L20 values at each entrance, in graphical and
numerical form for 12 last months.
 Dimming controller percentage applied.
 Auto/manual/bypass status of each dimming controller.
 Photometer status.
 Any other parameter as proposed by the lighting system supplier.
Redundancy to be ensured for the optical fibre cables and PLC communications to
the future Central SCADA system.
7B/20 TUNNEL AND UNDERBRIDGE CABLING
General

The 600 Volt Grade Cable are for operating voltage 415/240 V and complying with
IEC Publication 502.
All cables and wires used for underpass lighting shall be FRLS type and meet fire
resistance requirements as per IEC331, IEC332-1, IEC332-3 and BS7864
Underpass lighting cables shall be multi-core, fire resistant modular construction
cabling system with quick connection socket and plug assembly installed on the
cable run at intervals as required for connection to luminaires.
Modular cable system shall comprise of fire resistant feeder cable and fire resistant
socket and plug assembly. Plug and socket assembly shall be 13A, 3 pin type.
Plug shall be sized for 2.5mm2 spur cable connection to the luminaires.
Ingress protection rating for the system shall be IP67 as per IEC standard.
Conductors
Cable conductors shall comprise class 2 stranded clean smooth annealed copper
wires having a conductivity not less than 100% international standard. The surface
of the individual strands shall be smooth and clean before the insulation is applied.
Cable sizes shall be selected based on de-rating factors, voltage drop
considerations (max 3%). The cable sizing calculations shall be submitted for
Engineer’s approval during construction.
Neutral
Cable of all sizes shall have full size neutral, i.e. same wire size as phase
conductor up to 25mm2 and about half size for cable size bigger than 25mm2.
Insulation
The insulation shall be XLPE with mineral ceramic fire resistant tape complying
with the following requirements:
 Normal operating temperature: 90 deg C.
 Chemical resistance: High
 Moisture resistance: High
 Thermal resistively: Low
 Fire resistance: Good
 Insulation thickness: in accordance with IEC publ. 502.1
 Phase identification: Cables shall be color coded. Red, yellow and blue for
phases and black for neutral and yellow / green for earth.
 Protection conductor identification: "YELLOW and GREEN"
Laying Up
The cores of cable shall be laid up and where necessary non-hygroscopic fillers
shall be used to form a compact and circular cable.
Sheath (Bedding)
The sheath shall consist of an extruded layer of low smoke, no halogen compound.
Armor
The armoring shall consist of galvanized round steel wire.
Over sheathing
The over sheathing shall be MDPE not PVC, whenever used outside the
underpass.
Serving
The serving shall be fire retardant and termite resistant and shall comprise of an
extruded black PVC sheath applied over the armor.
Terminations
Terminations shall be by means of mechanical clamps which shall correspond to
the number and cross sectional area of the conductors.
Cable lengths
No joints shall be made in any of the cables. The cables shall be continuous
between termination points throughout the circuit.
Glands
All glands shall be fitted with moulded PVC shrouds to completely cover the
glands.
Earthing tag
Earthing tags shall be fitted to all glands.
Cable ends
The ends of all cables shall be sealed during laying.
Conduits used inside Underpass area shall be fire resistant epoxy coated GI/GRP
conduits.
7B/21 TUNNEL AND UNDERBRIDGE JUNCTION BOXES

Junction boxes shall be manufactured of uPVC and be IP55 of IEC 60529
7B/22 TUNNEL AND UNDERBRIDGE CABLE TRAYS
Cable tray material

Cable trays shall comply with NEMA Standard No VE 1
Install cable tray where noted on drawings, and where more than three large
cables follow the same route
Cable tray shall be manufactured of Grade 316 stainless steel with 90 mm sides
with double folded top edge and 40 mm min. wide folded rungs at max. 300
centres with mechanical couplings that provide earth continuity
Cable trays shall be at least 150 mm wide, unless otherwise noted. Cable trays
shall be wide enough to accommodate cabling in a single layer with 50% spare
width
Cable tray installation

Install cable trays as follows:
 Straight routing parallel, or perpendicular, to structure and coordinated with

other services
 With manufactured splices, bends, and intersections
 Joined with telescopic splice plates, secured to the cable tray using bolts,
washers and anti-vibration locking nuts, and shaped to provide a smooth
surface.
 With 40 mm min. air clearance to structure.
 On manufactured brackets spaced so that deflection is less than 1/360th of
the span when loaded and with at least two brackets per length at 1.5 m
max. spacing
 all lengths and accessories earthed
 Where cut, the edges of the tray shall be smoothed

 In accordance with manufacturer’s recommendations using manufacturer’s

recommended accessories.
 Provide ventilated, peaked sun covers to all exterior cable trays.
 Label cable trays: ‘DANGER 415 VOLTS’ at 2 meter centres by means of
300mm x 40mm high white engraved plastic labels screw-fixed
Secure cables as follows:

 with GKN Type TC clamps for trefoil or quad groups of single core cables
 with GKN Type K clamps for large multi-core power or control cable (greater
than 120mm diameter)
 with UV resistant nylon wire ties for small cable.
 Refer to Particular Specifications.
7B/23 TUNNEL AND UNDERBRIDGE INSPECTION TESTING AND

COMMISSIONING
General
This Section covers particular requirements of Tests on Completion for the
inspection, testing and commissioning.
Equipment Inspection
As required, the Engineer's and Client’s Representative will attend the
manufacturer's works at the Contractors cost to inspect equipment prior to
shipment. Notify the Engineer at least 30 days prior to shipment, so that Factory
inspection can be arranged. Factory inspection shall be made only after the
Manufacturer has performed satisfactory checks, adjustments, tests and
operations on the complete system. Approval of equipment at the factory only
allows the manufacturer to ship the equipment to site, and does not constitute final
acceptance by the Engineer. The items to be inspected shall include all items for
the installation including but not limited to the following major equipment.
 LV and Control Cables

 Lighting Controllers and LDB
 Lighting fittings
The scope of inspection will include type tests, Document control & routine test
and inspections.
Factory Acceptance Tests

The Contractor shall be responsible for the completion of the following minimum
tests to provide assurance that the equipment/plant/material being supplied will
meet the performance requirements of this Specification and the relevant IEC
Standards. Where applicable, all tests shall be carried out in a manner as set down
in relevant IEC Standards. The List provided is an indicative minimum of the tests
required.
The Contractor shall develop full test schedules and sheets for the approval of the
Engineer's representative in accordance with the requirements of this
Specification.
Cables
 Continuity test
 Earth test

 Polarity test
 Dielectric test
 Conductor resistance test
 Insulation resistance test
 Tensile strength and elongation test
 Fire test
 Flame propagation test
 Temperature index test
Lighting Distribution Board
Inspection of the FBA (Factory Built Assemblies) (LDB) including wiring, electrical
and mechanical connections, Communication interfaces with SCADA (future) and
with other controllers, external and internal finish etc. Complete functionality of
photometer, Lighting controllers, and LDB shall be demonstrated during Factory
Acceptance tests on LDBs.
Mechanical tests including checking of all mechanical and electrical connections,

interlock etc.
Continuity and dielectric tests.
Ingress protection test.
Functional checks of all control circuit including the shunt trip operation of breaker
at 70% and 110% of the rated control supply voltage.
Calibration of metering instrument, CT, etc.
Training for RTA Personnel

Training shall be conducted by personnel employed by the Electrical
Subcontractor, familiar with the system supplied, experienced and trained in
developing and implementing instructional courses.
The Contractor shall submit information on the training program for approval prior
to shipment of the equipment. This submittal shall include a course outline, time
required, course schedule, sample workbook and instructor qualification
information, for each level.
The Contractor shall make a workbook on each course available to every person
taking the courses listed herein. The workbook shall be of sufficient detail so at a
later date a trainee could review in detail the major topics of the course.
One copy of each book shall be delivered to the RTA for its library.
The training times shall be scheduled by Employer in advance, so as not to disrupt

the RTA ability to operate the equipment.
Specialized training shall be provided for a minimum of five of the Employer’s

personnel in the operation and maintenance of the system at the manufacturer’s
facility or in Dubai. The training program shall be divided into two segments and
each shall consist of at least five, eight hour working days.

The maintenance training program shall be developed for personnel who have
electronics maintenance and repair experience and a general knowledge of
computer systems, but shall not assume any familiarity with the specific hardware
furnished. As a minimum, the following subjects shall be covered:
 System architecture and layout.

 Hardware components.
 Module switch settings (configuration switches).
 I/O modules.
 Power supplies.
 Data highway.
 Programmer connection.
 Programming and diagnostic techniques.
 Battery replacement and recording.
 Troubleshooting.
 Disassembly.
 Cleaning.
 Component replacement.
 Reassembling.
The operation training program shall include the following topics:
 Power-up, bootstrapping and shutdown of all hardware devices.

 Interpretation of all standard displays.
 Appropriate actions for software and hardware error occurrences.
 Manual data entries.
 Loading of any required software into the system.
System Management:
The training in this area shall cover the following:

 Provide training for clients personnel and Maintenance Contractor for
programming, operation, maintenance & troubleshooting of all parts of
Lighting System including but not limited to following:
 Lighting Controllers
 Lighting Fixtures
 Photometers
 Communication Interfaces
 PLC’s
 The training shall involve classroom training and field demonstrations.
Site Inspection and Testing

The Engineer shall attend the inspection and tests before setting the equipment to
work. The Contractor shall notify the Engineer, in writing, one week before
commencing tests.
A Site Acceptance Test (SAT) shall be conducted as part of the Lighting system
validation and shall include all equipment and software within the Contractor’s
scope of supply. This test shall be conducted after the equipment has been
installed at the Site and the Client is satisfied of the correctness of the installation
and of the operation of the equipment.
Particular Test Requirements:

1. Communication test
The Contractor shall conduct a test to establish the correct functioning and
ability for transmission of data correctly over fiber optic cable to and from
each port on the system. In the event of any problem or deficiency being
identified in any equipment supplied by any party, this shall be reported fully,
in writing, by the Contractor to the Engineer.
2. Hardware test
Demonstrate correct operation of hardware using off-line diagnostics.
3. Functionality test
Demonstrate the system performance and functionality meets the
specification.
4. Test details
The SAT shall be carried out in accordance with a test specification produced
by the Contractor and approved by the Engineer
Test equipment and test software shall be provided by the Contractor to load
the system to the worst case scenario defined in the test specification.
The Contractor shall prepare a test report following the SAT.
5. Underpass Lighting
Illuminance measurements.
Luminance measurements.
Calibration of photometer control unit sensors and control devices.
Test to establish correct operation of Underpass lighting control from LDB
and through SCADA (future).
6. Redundancy Test of the FO “Fiber Optic” communication network and PLC.
System Commissioning:
Where required in the Project Specification, the Contractor shall provide staff to
work in conjunction with the RTA to ensure the satisfactory service operation of all
equipment in the system, to assist the RTA to adjust the configuration data and to
develop/modify application program.
The Lighting Subcontractor shall provide Performance verification test of the
complete Lighting system for a continuous period of 90 calendar days, for all items
under of Lighting system, for demonstration of reliability, repeatability and
operability. In the event of failures during this period, the demonstration shall be
extended for a further 90 days period. The list of parameters to be monitored
during the Performance Verification test shall be approved by the Engineer before
commencing the Test.
The supply system shall be tested in the sequence indicated:

 Continuity of protective conductors, including main and supplementary
equipment bonding.
 Earth electrode resistance.
 Insulation resistance.
 Protection by electrical separation.
 Polarity.
 Earth fault loop impedance.
System Takeover:
The criteria for takeover of the system shall be:
 Submission by the Contractor and approval of as-built drawings.
 Submission by the Contractor of all documentation.
 Submission of operational and maintenance manuals.
 Submission of all software design and support documentation and the
lodging of source codes in a place of secure safe-keeping and storage with a
Third Party.
 Provision of information and examples of each type of report and each item
of user-configurable functionality.
 Issue of all relevant test certificates.
 Successful completion of the SAT.
 System commissioning and issue of Final System Test Certificate by the
Contractor.
 Following satisfactory completion of the above, the Engineer will issue the
System Takeover Certificate.

TABLE OF CONTENT
7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS .........................................................57

7C/1 TRAFFIC SIGNAL SYSTEM GENERAL SPECIFICATIONS ................................57
7C/2 TRAFFIC CONTROLLER SPECIFICATIONS ......................................................63
7C/3 TRAFFIC SIGNAL HEADS AND LAMPS SPECIFICATIONS ..............................87
7C/4 POWER AND SIGNAL CABLES ..........................................................................93
7C/5 PEDESTRIAN PUSH BUTTON ............................................................................96
7C/6 TRAFFIC SIGNAL CANTILEVER POLES ............................................................98
7C/7 POLE FOUNDATIONS .......................................................................................102
7C/8 MANHOLES AND CHAMBERS .......................................................................... 102
7C/9 LOOP DETECTORS ...........................................................................................102

7C/ TRAFFIC SIGNAL SYSTEM SPECIFICATIONS
7C/1 TRAFFIC SIGNAL SYSTEM GENERAL SPECIFICATIONS
7C/1.1 SUMMARY
This section specifies the requirements in general for the design, procurement,
installation, testing, calibration and commission for the Traffic Signaling system.
The traffic signaling system refers to all the equipments such as signal heads,
lamps, gantries, supports, poles/posts, pedestrian push buttons, foundation for
gantries/poles, manholes and chambers, detector loops, signal and power cables,
communications, telephone leased lines, etc. as required to provide a fully
functional Traffic Signal System as per International standards and Dubai Local
Standards. All the necessary civil, electrical and mechanical works shall be
considered to be included in the scope of work for the Contractor.
7C/1.2 REFERENCES
(a) All supplies and services offered in response to this specification shall conform
to the latest International standards.
(b) The design, equipment and installation requirements shall comply with the
latest editions of standards and recommendations laid down by the following:
1. AASHTO Standard Specifications for Structural Supports for Highway Signs,

Luminaires and Traffic Signals.
2. AASHTO Standards for Traffic Signals.
3. RTA Standards on ITS and Traffic Signals
4. ISO1461:1999 Hot dip galvanized coatings on fabricated iron and steel
articles. Specifications and test methods
5. BS 5649: Part 4:1978 or BS EN 40:2004 Lighting columns.
6. EN 12368: 2006, Traffic control equipment. Signal heads
7. MUTCD - Manual on Uniform Traffic Control Devices
8. BS-EN 60529, Specification for Degrees of Protection provided by Enclosures
(IP Code)
9. BS-EN 50293, Electromagnetic Compatibility Road Traffic Signal Systems
Product Standard
10. BS-EN 12675, Traffic Signal Controllers – Functional Safety Requirements
11. IEC 439, Low-voltage switchgear and controlgear assemblies
12. BS 1376, Specification for colours of light signals
13. BS 4300/4, Wrought aluminium and aluminium alloys for general engineering
purposes (supplementary series).
14. BS EN 12373-1, Aluminium and aluminium alloys. Anodizing. Method for
specifying decorative and protective anodic oxidation coatings on aluminium

15. BS 6346, Electric cables. PVC insulated, armoured cables for voltages of
600/1000 V and 1900/3300 V
16. BS-EN 60529:199, Specification for Degrees of Protection provided by
Enclosures (IP Code)
17. BS 729:1986, Specification for hot dip galvanized coating on iron and steel
articles
18. BS 5486 Part 1:1990 Low-voltage switchgear and control gear assemblies.
Requirements for type-tested and partially type-tested assemblies
19. BS EN 124 D400 Gully tops and manhole tops for vehicular and pedestrian
areas
20. BS EN 40-5, Lighting columns, Specification for steel lighting column
21. BS 5649-5, Lighting columns. Specification for base compartments and
cableways
22. BS EN 1011, Specification for Arc Welding of Carbon and Carbon Manganese
Steel
23. Regulations for Electrical Installations as issued by the Dubai Electricity and
Water Authority (DEWA).
24. Regulations for Electrical Installations as issued by the Institution of Electrical
Engineers (IEE), London (for points not included in DEWA Regulations).
25. Recommendations for Lighting Installations as issued by DEWA and the
Chartered Institute of Building Services, London, and CIE.
26. Standards relating to Electrical Installations and equipment as issued by
International Electro technical Commission (IEC) and British Standards
Institute (BSI).
27. Regulations for communications telephone leased lines system installation as
issued by local telecommunications authorities and RTA UTC/ITS.
28. National Electrical Code issued by National Fire Protection Association
(NFPA), USA.
29. NFPA-70-National Electrical Code issued by NFPA, USA.
30. IEC801-4 Susceptibility Of Electronic Equipment And Systems At Higher
Frequencies And Voltages.
31. IEC 60529 IP 65, Ingress Protection
32. IEC 60529 IP 66, Ingress Protection
33. DIN 67527, Traffic control equipment. Signal heads
34. BS EN 12368, Traffic control equipment. Signal heads
7C/1.3 CLIMATIC CONDITIONS
(a) The climate in Dubai in the summer months is hot and humid. A humidity of
100 percent at 50 degree Celsius has been recorded.
(b) Climate
1. Violent sand and dust storms of several hours duration occur and even on
comparatively still days, fine dust is carried in suspension in the atmosphere.

2. All apparatus and equipment shall, therefore, be so designed and constructed

that they operate satisfactorily and without any deleterious effect for prolonged
and continuous periods in the conditions stated above and at the following
ambient temperature conditions:
maximum sun radiation temperature in summer - 85 °C

maximum ambient temperature in summer - 55 °C
average max. ambient temperature in summer - 50 °C
minimum ambient temperature in winter - 10 °C
altitude of Dubai may be taken as - sea level
(c) The temperatures quoted above make no allowance for heat generated from
equipment itself or from any other equipment in the vicinity.
(d) The capacity and ratings of all electrical equipment and materials given are,
unless otherwise indicated, for Dubai climatic conditions as stated in Clause
(a) above. Provide the basis of the derating factors applied in each case.
(e) Where specific sizes are indicated e.g. cable sizes, due allowances shall be
made in the design for the climatic conditions of Dubai and derating shall be
applied.
Where no ratings or sizes are indicated for components and other

accessories, supply equipment, which will give trouble free service in the
ambient conditions stated above.
(f) Degree of Protection – For All outdoor equipment the degree of protection
shall be minimum IP 66 as per IEC 60529.
7C/1.3.1 Temperature
(a) The Traffic Controller in the enclosure shall be designed to operate in external
ambient temperatures of -25°C to +60°C.
(b) The Traffic controller will be subjected to high levels and long periods of solar
radiation. The design of all components of the Traffic Controller shall take into
account the effects of such exposure and must be able to operate satisfactorily
without any malfunctions or failures. Any Hardware restrictions must be clearly
identified in the technical submittal, which shall be subject to approval by RTA.
7C/1.3.2 Atmospheric Conditions
The Controller shall be protected against driving rain and sand, dust conditions and
industrial pollution. The Degree of Ingress Protection shall be minimum IP65 for
the complete enclosure. All openings and entries must be sealed to provide this
rating.
7C/1.3.3 Humidity

The equipment shall withstand a temperature of 50°C with a relative humidity of

95%.
7C/1.4 INSTALLATION OF TRAFFIC SIGNAL EQUIPMENT
7C/1.4.1 Civil Works
The civil engineering contractor or the authority shall carry out civil works
associated with the installation of traffic signals, and supply necessary materials.
The work and material supply will include:
1. The construction of draw pits and channelizing islands.

2.Laying of cable conduits across the carriage-way
3.Moving kerbs and medians and reinstatement
4.Erection of poles, guardrailing and reinstatement to pavements and footways.
7C/1.4.2 Excavation
All excavations shall be in accordance with standards approved by the engineer

and shall have a firm level base and clean workmanlike sides. The exact location
of all signal equipment and channelizing islands and hence of the excavations,
shall be agreed on site by the engineer before excavation begins.
7C/1.4.3 Ducts
Cable ducts shall be 100mm PVC in footways
7C/1.4.4 Draw Pits
Draw pits will be constructed at changes of direction of ducts. Draw pits shall be
located off the carriage-way. The contractor will be responsible for excavation and
reinstatement of routes from draw pits to signal poles and controller cabinets.
7C/1.4.5 Cable Duct and Conduits
Cable ducts and conduits shall be laid with a minimum cover of 150mm under
footways and medians and a minimum of 600mm under carriage-ways. All ducts
and conduits shall be fitted with draw cords.
7C/1.4.6 Median and Kerb Construction
Medians and kerbs may be of two types, pre-cast or cast in place. They should be
constructed in accordance with the drawings.

7C/1.4.7 Pavement Construction
Where new pavement or reinstated pavement is to be constructed, it shall be of the

same type and level as that surrounding. It shall be constructed in accordance with
the contract drawings.
7C/1.4.8 Footway Construction
The footway shall be reinstated or constructed as shown on the contract drawings,

and shall generally use the same materials as the surrounding surface.
7C/1.4.9 Signal Controller
Signal controllers shall be mounted on concrete plinths and secured by four bolts.
The design of the base shall allow the equipment case to be replaced readily when
required. The equipment case shall be sealed at the base and all ducts and
conduits entering the controller shall also be sealed.
7C/1.4.10 Site Clearance
1. Dismantle existing signal installation equipment.
2. It shall be the responsibility of the contractor to dismantle all existing traffic signal
installations at locations where new equipment is to be provided.
3. Return to store all dismantled traffic signal equipment shall be transported to the
store of the RTA.
4. The contractor shall take all necessary precautions in the handling of dismantled
equipment to ensure the delivery to store in a condition that will permit the RTA
to refurbish the equipment.
7C/1.4.11 Installation
1. The traffic signal contractor shall set out the positions of all signal poles and
controller cases in accordance with the contract drawings. If during the course of
setting out or after excavation he discovers any obstructions that will prevent the
placing of any pole or controller in its designated position he shall propose an
alternative position to the engineer and await his decision. If any variation in cable
quantity results from such repositioning he shall notify the engineer accordingly.
2. The traffic signal contractor shall supervise the installation of all signal poles and
controller bases, together with all excavations for cables from draw chambers to
signal poles and controllers.
3. After the signal poles and controller bases at each junction have been installed,
the traffic signal contractor shall assemble and install all the other requirements of
his supply, including the laying and terminating of all cables.
4. The ends of all cables that have been cut to length shall be properly sealed
immediately they are cut, unless they can be terminated the same day.

5. Cable terminations shall be mechanically and electrically sound, and able to

withstand all traffic induced vibration.
6. The armoring of all cables shall be electrically bonded together in the controller
case, and to controller cases and signal poles.
7. Cable ends shall be bound with PVC tape after termination of the conductors.
8. All cables shall be adequately supported on cable clamps or gland plates.
9. The traffic signal contractor shall adjust the direction of beam of all signal faces
as directed by the authority.
10. When each signal installation has been completed and has passed its tests ,
excess cable ducting space shall be sealed with epoxy resin to prevent ingress of
vermin. All damaged paint work on the enclosure shall be made good to the
satisfaction off the Engineer. (For the door seal, please refer to Clause 7C/2.6
(n)).
7C/1.4.12 Testing and Placing in Service
Traffic signal equipment and installation will only be accepted by the Engineer and
RTA/ RLTS following factory acceptance testing at the works depot and site
acceptance testing following installation. The Engineer and RTA/ RLTS may, at
his/her discretion, attend work/depot tests and inspect equipment and materials
before dispatch from the works.
1. Factory acceptance tests (FAT)
FAT shall be carried out at the traffic signal contractor’s works or on the premises
of the local depot. The Contractor shall demonstrate the correct operation of the
equipment. Suitable test facilities and assistance, including dummy loads, test
switches, etc. shall be provided for the tests by the Contractor. These facilities
shall allow the equipment to be tested over the whole of the specified voltage and
environmental ranges. Works tests of controllers shall demonstrate the correct
functioning of all standard functions of the controllers, in addition to those required
in the particular installation to which it is destined.
The traffic signal contractor shall furnish to the Engineer a manufacturer’s

certificate for each controller supplied certifying that it has satisfactorily passed the
appropriate tests and that it conforms with the individual specifications.
The Contractor shall give the Engineer and RTA/ RLTS every opportunity for
observing the FAT.
2. Site acceptance tests (SAT)
Tests after installation shall be carried out by the traffic signal contractor and
observed by the Engineer and RTA/ RLTS representative.
After installation and termination of all cables, but before the insertion of signal
lamps and controller logic units, all signal cables shall be connected together and

subjected to an insulation test. The tests shall be carried out at 500 V D.C. The
resistance to earth of the cable network shall be not less than 1 megaohm.
Provided the above test has been satisfactorily passed, signal lamps and controller
logic shall be inserted and the installation switched on. All timings and functions of
the whole installation shall be tested.
To assist in on-site testing, the traffic signal contractor shall provide and fit
temporary hoods to all signal heads of each installation under test. The hoods shall
prevent the signal aspects being seen by traffic, but shall allow illuminated aspects
to be checked by testing staff.
The entire installation shall be inspected by the Engineer for good workmanship.
When the installation has been inspected and tested and found to be satisfactory ,
a Take-Over Certificate will be issued. The installation will then be placed into
service by the contractor when requested and approved by the Engineer.
7C/1.4.13 Liaison
Provide liaison with Dubai Electricity and Water Authority or RTA Roads
Department/ Road Lighting and Traffic Signals Section in accordance with project
co-ordinations.
7C/2 TRAFFIC CONTROLLER SPECIFICATIONS
7C/2.1 SUMMARY
(a) This section specifies the requirements in general for the design, Procurement,
installation, testing, calibration, and commissioning for the Traffic Signal Controller.
The “traffic Controller” term refers to all the equipments associated with the Traffic
Signal Controls, including but not limited to the equipment such as Controller CPU,
Lamp Cards, Dimming Control transformers, Power Supply unit, Controller
Cabinet, Timers/ Telephone communication, etc. as required to provide a fully
functional Traffic Signal Controller System as per relevant International standards
and Dubai Local Standards. All the necessary Electrical and Mechanical
Equipment for the Traffic Controller, including Supply, installation, testing and
commissioning of the Controller and Electrical equipment, systems, items,
accessories etc. for a complete Traffic Signal Controller System part of the Project,
shall be considered to be included in the scope of work for the Contractor.
(b) The Contractor shall provide a minimum warranty period of 10 years from the
date of commissioning for all equipment, components and services supplied within
this Clause.
7C/2.2 STANDARDS AND REFERENCES
(a) All supplies and services offered in response to this specification shall conform
to the latest International standards.
(b) The design, equipment and installation requirements shall comply with the latest
editions of standards and recommendations laid down in Clause 7C1.2

7C/2.3 CONTROLLER GENERAL REQUIREMENTS
(a) The operation of the controller shall be phase oriented. Timings and demands
shall be associated with phases and the control philosophy shall be designed
to give right-of-way to phases in an optimum manner.
(b) Phases shall be grouped into stages for Manual Control, operation in Urban
Traffic Control Schemes and in Cable less Linking Schemes. The traffic
requirements and safety constraints shall also condition the grouping of
phases into stages.
(c) The controller shall receive change requests for ROW from either/all of the
followings:
I. ‘On-street’ detection equipment and pedestrian push-buttons
II. The UTC computer
III. The Cable less Linking Facility
IV. Manual inputs
V. Special requests, e.g. Ambulance or Civil Defense hurry calls
(d) The controller shall based on the above requests, change the appearance of
phases in accordance with the controller strategy, the current mode operative
and the demand requests for ROW. The controller shall always change stage
cyclically when the stages are demanded.
(e) The Contractor shall submit to the Engineer the layout and construction of the
controller unit and the logic control module for approval.
7C/2.4 MAINS SUPPLY
(a) The Traffic Controller shall be usually provided with Single Phase power
supply from nearby Street Lighting Feeder Pillar. The following table shows the
supply voltages that will be available:
Table C-1 Supply Voltage
Nominal Voltage Minimum Voltage Maximum Voltage

200V to 240V 184V 264V
110V to 120V 92V 132 V
The controller shall be capable of being operated using these values of supply
voltages. If required, Necessary selector switches shall be provided on the
controller.
(b) Frequency of Supply Voltage : 50Hz ±2Hz

(c) In case of Mains Brownout, the Traffic controller shall continue to operate with
up to 50mS loss of mains, without any harmful effects.
(d) The Traffic Controller shall be capable of sustaining a prospective short circuit
current of value 16 KAmps from the supply.
(e) On resumption of supply following a mains failure, the traffic controller shall
restart without operator intervention.
(f) During power failures, the In-Built Primary cell Lithium battery shall provide
support for the following:
1. Clock Synchronization (programmable up to 31 days).
2. Timing Data (greater than one year)
3. A backup facility shall be provided to data integrity of 4 hours if the battery has
failed or is removed for replacement.
(g) Solar Cell Input: Solar cell input operating voltages shall be as follows:
 80V RMS indicates switch to Dim
 less than 40V RMS indicates switch to Bright
(h) The solar cell shall enable the controller to identify the light level and thus dim
the signals when it is dark. The switch shall be set to operate at 55 lux and release
at 110 lux. Time switch control of the change to and from Dim shall also be
provided.
(i) Obtain confirmation from the Supply Authority/ RTA Road Lighting section of
the size and number of cables from Feeder Pillars/ Main Switchboards. Allow for
adequate and appropriate cable glands, lugs and boxes.
7C/2.4.1 Electrical Noise
(a) Supply Transients
i.The Traffic Controller shall be designed to withstand the following transients

on its supply: ±1kV transients with a repetition frequency of 5 kHz applied
according to IEC801-4.
(b) Electrical Interference
i.The Traffic Controller shall be designed to create very little electrical

interference by the use of built in filters and solid state lamp switching control.
The lamp switches shall be switched at zero crossover of the mains’ supply to
reduce any switching transients.
ii.The switching of the signals from dim to bright (or vice versa) shall be
controlled carefully to ensure the switching does not cause interference.

iii. The Traffic Controller design shall also be extremely tolerant of externally
generated electrical interference. Care shall be taken to avoid earth loops
using a ‘Star’ point earthing system to which the cabinet, the cabinet doors,
the internal metal work, the junction cabling and the mains earth should be
connected.
7C/2.4.2 Controller Load
This Contract may accept quartz halogen lamps or LED lamps. The Contractor
shall provide detailed information on the type of lamps proposed.
If the Contractor proposes to use Extra Low Voltage (ELV) lamps such as quartz
halogen or light emitting diodes (LED), the submission shall provide all loading
requirements on the mains power supply.
The Contractor shall provide a detailed calculation on the total power consumption
of the completed controlled junction.
7C/2.4.3 Lamp Drive Capability
The lamp power circuits of each signal phase of the controller shall be capable of
providing the current for 6 signal heads each with 3 signal aspects as a minimum.
7C/2.4.4 Detector Power Supplies
The signal controller shall provide power for vehicle loop detectors. A maximum of
32 loop detectors shall be allowed for.
7C/2.4.5 Audible Supplies
(a) The Audible power supplies on the Traffic Controller shall be designed to
provide a DC voltage between 10V and 24V, and typically provide 50mA at 18V
DC. This shall be provided using a dedicated Audible Power Supply Kit.
(b) This kit shall also provide the controlling signal for ‘Tactile Power Supplies’.
The tactile power supply shall obtain its power directly from the pedestrian green
drive. The controlling signal shall allow the controller to switch off the tactile while
the green is flashing.
(c) Audible and tactile units used must operate correctly over the voltage range 10
to 24V DC. The Contractor shall liaise with the Engineer on the suitability of
audible and tactile units.
(d) The audible and tactile units shall provide 4 modes of operation.
i.Normal Audible
ii.Switched
iii. Muted Audible Output
iv.Pelican With Flashing Green Man
(e) The Audible units shall only be used as directed by RTA / Engineer. However
the Traffic Controller shall have the capability to provide the required outputs as
described above.
7C/2.5 OPERATIONAL REQUIREMENTS
7C/2.5.1 General
The Controller shall be phase oriented. Each vehicular or pedestrian phase shall
have its own set of timings and timers. While operating in the vehicle actuated
mode, phases will be introduced by demands and/or programmable conditions.
Each phase shall be able to control three lantern aspects.
Each Controller shall have the capability to control up to 32 phases. Depending on

the configuration of each junction a Controller may not be fully equipped for 32
phases.
If a junction requires less than 32 “real” phases, the Controller shall have the
facility to utilize the remaining phases as “software” phases.
For traffic efficiency, non-conflicting phases could be grouped into stages. The
Controller shall have facility to support 32 phases. When demands are present for
all stages, the Controller shall cycle sequentially through all the stages as
programmed. Stages may be skipped if there is no demand for the stage.
7C/2.5.2 Vehicular Phase
Each vehicular phase shall have control of the following lantern displays at the
street level:
(a) RED
(b) GREEN
(c) AMBER
(d) Flashing AMBER (for Stand-alone Pedestrian Stream site)
A vehicular phase may control one, two or three lantern aspects

As a minimum requirement, each phase shall be divided into the following timing
intervals:
(e) Red,
(f) Minimum Green,
(g) Variable Initial Green (depending on vehicle detector placement),
(h) Rest Green,
(i) Extension Green,
(j) Amber (intergreen),
(k) Red (intergreen).
The display of the various lanterns shall be controlled by timing intervals

programmed within each phase. The Controller shall provide facilities to allow:
(a) The introduction of the green aspect to be delayed;

(b) The termination of the GREEN to be delayed;

(c) A minimum safe green period to be maintained under all conditions;
(d) The green period to be extended by the associated vehicle detectors, if traffic
demand continues, to a set maximum period;
(e) The green period to be terminated conditionally even demand to extend the
GREEN display still exist;
(f) The rest green period to be held if there is no other conflicting traffic demand;
(g) The green period can be held conditionally or by an UTC System;
(h) Within a stage, any one selected phase or phases be able to be terminated
earlier to allow for conflicting pedestrian phase to be introduced;
(i) The intergreen period to be varied without compromising the safe minimum
intergreen period.
A demand for a vehicular phase shall be introduced by any of the following
conditions:
(a) An actuation of one of a selected group of vehicle detectors associated with

the phase;
(b) a demand for a parallel pedestrian phase;
(c) when a phase terminates due to maximum timer expired and demand on that
phase still exist, a revertive demand should be generated for that phase;
(d) a manual selection of the phase using the operator interface unit;
(e) an artificial demand generated by the UTC system.
Under normal operation, the demand for a phase is reset when the phase is
introduced. In other cases, the demand may also be reset when the demand is
fulfilled by another phase.
These demand conditions and phase termination conditions shall be

programmable in accordance with the junction layout and conditions.
When the Controller is controlled by an UTC system, the Controller shall execute
the system commands independent of local demands. The control system shall
not be able to override the safe minimum green time and intergreen time.
7C/2.5.3 Pedestrian Phase
A pedestrian phase shall control two lantern aspects – RED and GREEN. Each
pedestrian phase shall have control of the following lantern display at the street
level:
(a) RED (Don’t Walk )

(b) GREEN (Walk)
(c) Flashing GREEN Clearance (by flashing the GREEN Walk display)
A demand for a pedestrian phase shall be placed when the associated pedestrian
push button is actuated. The display of the GREEN walk shall cancel the
pedestrian demand.

The Controller shall be capable of introducing a pedestrian phase automatically

when a selected vehicle phase is introduced based on time schedules stored in the
Controller.
When the Controller is controlled by an UTC system, the Controller shall execute
the system commands independent of local demands. The control system shall
not be able to override the pedestrian clearance period.
7C/2.5.4 Stages
A stage is a time period during which compatible phases are allowed to operate
simultaneously. The stages may include both vehicle and pedestrian phases.
Stages are provided to maximize the throughput and minimize delays to traffic at a
junction. A primary requirement is safety. The selected phases should have no
possible conflict with each other.
The Controller shall provide facilities to allow all the stages necessary to be
established. These facilities shall include processes and tools to define:
(a) the phases composition of each stage,

(b) the phases that could operate in two or more sequential stages without
interruption to the GREEN aspects,
(c) the total number of stages,
(d) conditions for the introduction of each stage,
(e) conditions for the termination of each stage,
(f) prohibitive stage transition sequences,
(g) a minimum of four different composition and sequence of stages that are
selectable conditionally.
The algorithms used for the transition of stages shall ensure conflicting displays do
not occur. The minimum GREEN settings and pedestrian clearance settings are
not violated by the transition.
Under vehicle actuated operation, the Controller shall ensure that all phases are
serviced if demands exist for these phases within each signal cycle.
7C/2.5.5 Detection System
The Controller shall provide a minimum of 64 input circuits for the processing of
detectors. The inputs may be assigned to vehicle phases, pedestrian phases or
special functions. The assignment shall depend on the individual junction layouts
and operation.
The input interface circuits shall generate the following status signal for the
Controller:
Open Circuit = Input Active

Closed Circuit = Input Inactive
Inductive loop detectors are used normally for vehicle detection. However, other
types of detectors, e.g. radar, infrared, video may also be used.

Pedestrian push buttons are used for pedestrian detection.
The Controller shall monitor all vehicle detectors and pedestrian push buttons. An
alarm shall be generated by the Controller if a vehicle detector or pedestrian push
button is active or inactive for a predefined period. The predefined alarm period
shall be programmable for up to 4 hours in one minute increments. The alarm
shall not be reset until the input has changed state since the alarm was reported.
7C/2.5.6 Safety Requirements
The Controller shall perform internal software and hardware, and external
hardware checks regularly. The Controller shall be shut down automatically and
orderly when a fault or a malfunction has been detected. The Controller shall
adopt remedial actions to minimize the impact of such faults. The Contractor
should provide the methodology used for these self checking functions and the
remedial actions taken to ameliorate the operation.
The internal checks should include but not limit to software integrity (e.g.
checksum), memory and data communications channels. The Controller hardware
and software shall have built-in software-execution checks (watchdogs) to ensure
that the Controller integrity is maintained.
The external checks should include but not limit to the individual lamp circuits,
electromechanical aspects of the Controller such as:
 circuit cards are inserted properly
 cables are effectively terminated on connectors
 signal lamps are properly inserted into lamp holders.
The Controller shall log all detected faults and malfunctions. The log shall be
stored in non-volatile memory. The log shall have capacity to store up to 6 months
of data.
The Controller shall, as a minimum, continuously monitor and respond to the

following conditions.
(a) Lamp Circuit
The electric current and/or voltage of individual lamp circuits shall be

monitored at intervals no greater than 200 mS during the lamp active period.
The Controller shall take remedial action if the measured value varied from the
expected value.
(b) Red Lamps
The Controller shall monitor failures of vehicle phase RED lamps. When all
the RED lamps have failed Drivers and pedestrian frequently assume that the
phase is in GREEN. In this situation, the Controller shall change its operation
to ensure that dangerous signal displays of conflicting traffic movements and
conflicting vehicle/pedestrian phases cannot occur.
(c) Phase Display Integrity Check
The Controller shall carry out regular checks to ensure that the phase outputs
issued by the Controller Logic Module are identical to the phase displays

presented at the site. The system shall take remedial action if the two sets of
data differ.
(d) Lamp Failure
The Controller shall monitor individual lamps. Failure of one or more lamps
shall be reported and logged. If all lamps of one aspect of a phase have
failed, remedial action shall be taken.
(e) Conflicting Phase Displays
The Controller shall provide facilities to specify phases that create traffic
conflict if they were granted right-of-way simultaneously.
The Controller shall provide an effective conflict monitoring system to ensure

that the GREEN/GREEN (WALK), GREEN/AMBER, AMBER/AMBER lamps of
these conflicting phases will not be active simultaneously. The system shall
reliably detect lamp fault conditions affecting signal displays and take remedial
actions within less than 200 mS.
(f) Prohibited Stage Transition

The Controller shall monitor individual lamps. Failure of one or more lamps
shall be reported and logged. If all lamps of one aspect of a phase have
failed, remedial action shall be taken.
(g) Conflicting Phase Displays
The Controller shall provide facilities to specify phases that create traffic
conflict if they were granted right-of-way simultaneously.
The Controller shall provide an effective conflict monitoring system to ensure

that the GREEN/GREEN (WALK), GREEN/AMBER, AMBER/AMBER lamps of
these conflicting phases will not be active simultaneously. The system shall
reliably detect lamp fault conditions affecting signal displays and take remedial
actions within less than 200 mS.
If prohibited stages transitions has been specified for the junction, the
Controller shall enforce the prohibition effective under all operational modes.
The Contractor shall provide details of the methodologies on achieving these
requirements. The submission should highlight also all additional safety
features provided by the Controller.
7C/2.5.7 Timings
(a) All Controller timings shall be stored in EPROM at configuration time. These
timings shall be subsequently transferred to battery supported RAM during
controller initialization. Once transferred in RAM all the controller timings
should be possible to be varied by handset commands. It shall not be possible
to repeat the loading of Data from EPROM, after first loading the data from
EPROM without a complete controller initialization using a different EPROM.
This shall ensure that accidental overwriting of any configuration data that may
have been set up using the handset does not take place.
(b) Alternatively, the complete controller configuration, including its timings, shall
be loaded directly in the controller’s battery supported RAM from a PC. With
the PC connected to the controller’s handset port, the Traffic Signal controller
configuration utility shall load the configuration data into the controller,
eliminating the requirement for an EPROM.
(c) Certain timings considered to be fixed timings shall not be available for
changing using handset, such as the Amber and Red/Amber periods. These
timings shall, however, be specified as alterable at configuration time to suit
other signal sequences as required by RTA.
(d) Some controller timings are considered to be safety timings and shall only be
changed by an authorized person at the controller, e.g. minimum green, inter
greens and blackout timings. These require the operator to access the specific
higher level using allocated buttons before attempting to modify these timings.
(e) The signal controller shall provide time settings listed in Table C-2. The Table
also lists the maximium and minimum limits of each setting.. All timings are in
seconds unless otherwise marked.. The Contractor must provide the
availability of proposed Controller Timings for RTA and Engineer’s approval
prior to starting the procurement of traffic controller.

Table C-2 Timings Summary
Lower Upper
Resol’n Config’ble Config’ble
Limit Limit
(sec) Lower Limit Upper Limit
(sec) (sec)
General Timing Periods
Minimum green 1 per 1 per
0 255 1
phase phase
Minimum green (8 sets) 0 255 1 1 value 1 value
Green extension 0.0 31.8 0.2 1 value 1 value
Conflicting phase change intergreen 1 per
0 199 1 change 1 value
(32x32)
RLM 1st RED extra Intergreen 0 255 1 1 value 1 value
Starting Intergreen 0 255 1 1 value 1 value
Red/Amber time 0 255 1 1 value 1 value
Leaving amber time (8 sets) 0 31.8 0.2 1 value 1 value
All red extension 0 31.8 0.2 - -
All red maximum 0 255 1 - -
Phase delay 0 255 1 1 value 1 value
Pedestrian window 0 255 1 - -
Pedestrian Clearance Periods

Fixed Clearance Period 0 255 1 1 value 1 value
Extendable Clearance Period 0 255 1 1 value 1 value
Clearance Red Period 0 255 1 1 value 1 value
Hurry Call Timing Period

Hurry call delay 0 255 1 1 value 1 value
Hurry call hold 0 255 1 1 value 1 value
Prevent hurry call 0 255 1 1 value 1 value
Hurry call watchdog (Requires
0 500 2 1 per timer 1 per timer
Special Conditioning)
Hurry call request watchdog
(Requires Special Conditioning)

Table C-2 Timings Summary (continued)
Lower Upper Config’ble Config’ble

Resol’n
Limit Limit Lower Upper
(sec)
(sec) (sec) Limit Limit
Linking Timing Periods
Linked Pedestrian controller
release (conditioning timer)
C.L.F. group offset 0 255 1 1 value 1 value
Plan offsets 0 255 1 1 value 1 value
Detector Timing Period

Call delay period 0 255 1 - -
Cancel delay period 0 255 1 - -
Detector Fault Monitoring 1 254 1 1 value 1 value
Priority Timing Period

Monitor Time 0 2550 10 - -
Emergency gap 0 255 1 - -
Priority extension (4 sets) 0 31.8 0.2 - -
Priority maximum (4 sets) 0 255 1 - -
Priority inhibit (4 sets) 0 255 1 - -
Phase compensation (4 sets) 0 255 1 - -
Priority 1st delay time 0 255 1 1 value 1 value
Priority 2nd delay time 0 255 1 1 value 1 value
Speed Discrimination Period

SDE/SA extra clearance 0 50 1 - -
Conditioning Timers
For each timer, either: 0 255 1 1 per timer 1 per timer
Or: 0 31.6 0.2 1 per timer 1 per timer

(f) All timings, except CLF and Master Time Clock, shall be derived from the crystal
frequency which shall have a tolerance of 35 ppm (parts per million). An additional
error due to random signals not being synchronized to the clock pulse may add up
to 200mS to the time. If the result of the above timings is required to change the
signal lamps, a further error may occur, which may be up to a maximum of 21mS.
The maximum tolerance values shall be submitted for approval by RTA / Engineer.
(g) The set-up accuracy of the real time clock and offsets calculated from it shall be
maximum 1 second.
7C/2.5.8 Master Time Clock and Cable Less Link Facility
The Controller Master Time clock shall have following features.
(a) Master Time Clock

i.Timing Sources – 50Hz Mains (automatically detected)
ii.Option for GPS (Global Positioning System) unit from which the controller
continually checks and updates its clock.
iii. Standby Timing – On board crystal and battery support programmable up to
31 days. Accuracy of standby crystal oscillator is 35 parts per million.
iv.Programmable changeover to mains synchronization.
v.Facilities for synchronizing the real time clock and group timer from existing
U.T.C.
vi.Number of time switch settings – 64
vii.Number of time switch functions – 3
viii.Isolate controller
ix.Introduce a CLF plan
x.Introduce events, such as alternative maximum greens
(b) Cable less Link Facility – The Traffic Controller shall have the following
features for the Cable less link facility.
i.Number of plans : 16
ii.Number of plan influence tables : 16
iii.Number of groups per plan : 32
iv.Number of group influences : 10 types
7C/2.5.9 Modes of Operation
The Controller shall have following modes of operation.
i.Vehicle actuated (Speed Detection Equipment/Speed Assessment should be

able to be added to V.A)
ii.Timetable selected fixed time plans either Cable less linked or in isolation.
iii. Central computer controlled in a traffic control system.

iv.Fixed time
v.Hurry call
vi.Manual
vii.Parallel stage streaming
viii.viii Priority
ix.Part time lamps off
x. Part time lamps flashing, e.g. flashing vehicle ambers
xi.Stand-alone pedestrian stream ‘VA’ (with pre-timed maximum option)
xii.Stand-alone pedestrian stream ‘Fixed Vehicle Period’
The Controller shall provide facilities for any of these modes to be introduced by:
 day-of-time and date as a schedule stored in the Controller;

 an operator manually using the operator interface unit;
 UTC system via the communications channel;
 the mode priority facilities.
The Controller shall provide switches on the Controller Front Panel for the manual
selection of various operating modes.
7C/2.5.9.1 Mode Priority
The Controller shall provide facilities to define the priorities of operating modes.
The operating modes shall be selected based on the prevailing traffic conditions,
current time and date, and the UTC system commands.
The Controller shall operate in the highest priority mode when all the conditions for
this mode are active. When the conditions of the current mode are disabled
partially or fully, the Controller shall search for next highest priority mode. This
new mode of operation shall be adopted when all the conditions for this mode are
active.
While operating in a lower priority mode, the Controller shall continuously monitor
the conditions that will allow the Controller to operate in a high priority mode. This
monitoring shall continue until the highest priority mode has been adopted. If more
than one higher priority mode has been detected, the Controller shall adopt the
mode with the highest priority without adopting the intermediate mode.
When no priority mode conditions can be found, the Controller shall fallback to the
Vehicle Actuated or Fixed Time mode.
The transition from one operating mode to another:

i.shall not affect the safety of the junction,
ii.shall not be violated any minimum safe settings,
iii. shall not skip any demanded phases (except when the Controller is
responding to EMERGENCY VEHICLE or HURRY CALL),
When two or more priority demands or Hurry Calls are activated, the Controller
shall provide a priority conflict resolution strategy to manage the conflicting

requirements. The Contractor shall provide the methodologies for the resolution of
these conflicts.
7C/2.5.9.2 Modes
i.Vehicle Actuated (VA)
This mode of operation allows the Controller to execute its functions autonomously
to achieve the control strategy designed by the traffic engineer. In VA mode, the
introduction and the duration of a phase shall be determined by the prevailing
traffic conditions as presented by the vehicle detectors and pedestrian push
buttons.
During periods of heavy traffic, the Controller shall introduce phases in sequence
as programmed cyclically. A phase shall be extended to its set maximum time.
When a stage has completed, the next stage and the associated phases shall be
introduced accordingly.
When traffic demand has eased, phases may be terminated in accordance with the
phase extension/termination rules. With the absence of demand, a phase or a
stage could be skipped.
The Controller shall provide facilities to allow Speed Discrimination Equipment

(SDE) and Speed Assessment (SA) functions to be incorporated. The SDE shall
allow the Green Extension of the phase to be altered when thresholds have been
reached. The SA shall allow the Gap to be varied to suit the junction geometry.
When the SDE or the SA alters the operation of a phase, facilities shall be
provided to allow the green extension and gap intervals and intergreen time
settings to be changed in accordance with the associated control algorithms.
ii. Time Selected Fixed Time Plans (Cableless Link)
The Controller shall provide a master clock timer. All time schedules and operating
traffic plans shall be synchronized to this master clock.
While operating in this mode, the Controller may be coordinated with other
adjacent junction controllers or operating in isolation.
The Controller shall provide facilities for 32 traffic plans. The maximum cycle time
shall be settable to 255 seconds in one second intervals. Each plan shall specify
the phase/stage sequence and the duration of each stage.
There shall be a minimum of 64 schedules set for the introduction of traffic plans
per week. Each schedule shall have:
A traffic plan
a day code specifying the day/days when this traffic plan is applied (a code may
allow multiple days to be selected)
time of day when the plan will be activated.
iii.Central Computer Controlled

The Central Computer Control Mode is also known as the Urban Traffic Control
(UTC) mode.
While under the control of the UTC system, the Controller shall respond to the
force, release and hold commands of the UTC for the selection and termination of
the phases and stages. The UTC will communicate with the Controller on
operational status, alarms and statistics. The Controller shall respond accordingly.
The Controller shall communicate with the UTC using the Outstation Transmission
Unit (OTU). The OTU requirements are not part of this Specification. The
Controller shall provide a parallel input/output (I/O) port for communication with the
OTU. The specifications for the I/O requirement is included in Clause
PS11/2/12/2. If the Controller operates with an integral OTU, other I/O
arrangement may be acceptable. The Contractor shall provide details on the
operation of the integral OTU.
The operational and technical requirements of the UTC system is not part of this
Specification. The Contractor shall acquire the operational and technical
requirements of the UTC system from the Engineer and ensure that the Controller
complies with these requirements.
iv.Fixed time
The Fixed Time mode allows the Controller to operate with neither vehicle detector
nor pedestrian push button input. The Controller shall cycle through all
phases/stages as programmed.
v.Hurry call
The Hurry Call mode of operation allows emergency vehicles such as fire brigade
and ambulance to gain right of way from their respective base stations.
The Hurry Call mode of operation shall be activated by dedicated push buttons or
vehicle detectors that are strategically located. This mode of operation may also
be used to allow traffic queues to be cleared when queue detectors are triggered.
When a Hurry Call is activated, the Controller shall service this call promptly
providing that other higher priority mode is not in operation. A delay period may be
introduced before the Hurry Call is executed. A delay timer shall be provided. The
timer shall be settable to 255 seconds in one second increments.
The transition to the Hurry Call shall not violate the minimum green and intergreen
time settings.
vi.Manual
The Manual mode of operation allows the stages of the Controller to be executed
sequentially by a traffic officer or police using the controller front panel, a hand held
terminal or a police panel. An officer shall be able to step through the pre-selected
stages in a fixed sequence. Alternatively, an officer shall be able to select up to 8
stages, one at a time, for execution depending on traffic demand. One of the 8
stages shall be an All Red stage.
The Controller shall prevent transition from one stage to another until all minimum
phase green times have expired.
The Controller shall prevent stage transition if the transition is prohibited.
vii.Parallel Stage Streaming
Parallel Stage Streaming allows one controller to control several non-conflicting

groups of phases as if they were controlled by several controllers.
The Controller shall provide a minimum of 8 independent streams. Parallel

streaming shall be available to all modes of operation.
viii. Priority
The Priority mode of operation provides designated vehicles to gain right of way at
the junction expeditiously. The designated vehicles will require dedicated selective
vehicle detectors or transponders that interacts with the Controller. When an input
from these special detection systems is activated, the Controller shall generate a
priority demand. This demand shall initiate a phase/stage transition that will allow
the priority phase to be introduced with minimum delay.
If the Controller is already operating in the priority phase, additional priority

demands shall allow the GREEN time to be extended. A Priority Maximum
Running Period timer shall be provided. This maximum shall be settable up to 255
seconds in one second increments.
A Priority Inhibit Period timer shall be provided to prevent the execution of the
priority phase repeatedly. This timer shall be settable to 255 seconds in one
second increments.
When two or more priority demands are activated, the Controller shall provide a
priority conflict resolution strategy to manage the conflicting requirements.
The transition to the priority phase shall not violate the minimum green and
intergreen time settings.
The priority mode may be introduced for public transport vehicles, emergency
vehicles or special motorcades.
The selective vehicle detectors and transponders are not part of this Specification.
ix.Part Time Lamps Off
The Controller shall provide a Part Time Lamps Off mode. The mode is normally
selected by time of day. The transition from the prevailing mode to Part Time
Lamps Off mode shall not violate the minimum phase green times.

When exiting the Part Time Lamps Off mode, the Controller shall go through the All
Red Stage.
x.Part Time Lamps Flashing
The Controller shall provide a Part Time Flashing mode. The mode is normally
selected by time of day. The transition form the prevailing mode to Part Time
Flashing mode shall not violate the minimum phase green times.
When exiting the Part Time Flashing mode, the Controller shall go through the All
Red Stage.
Stand-alone Pedestrian Stream Vehicle Actuated
This mode of operation is normally set up for sites that have only one vehicle and
one pedestrian phase only.
The site normally rests in the vehicle GREEN. When a pedestrian demand is
registered and if the Controller has satisfied the vehicle termination conditions, the
Controller gives right of way to the pedestrian WALK signal. When the WALK and
CLEARANCE WALK is completed, the Controller reverts back to the vehicle
GREEN.
The Controller shall have the capability to flash the vehicle AMBER signal during
the pedestrian clearance period (The Flashing Green Walk period).
xi.Stand-alone Pedestrian Stream Fixed Time
This mode of operation is the same as (k) above except that, in this mode, the
transition between the vehicle and pedestrian phases are based on pre-
programmed times.
7C/2.6 ENCLOSURE
(a) Housing shall be to standards equivalent to BS EN 60529: 1991.
(b) The enclosure shall be fabricated from high-grade aluminium sheet with
thickness not less than 3mm. The sheet aluminium enclosure shall be
coated with a thermosetting powder of an epoxy resin base modified by
polyester resins. The enclosure shall be provided with a smooth finish and
excellent protection against corrosion for 10 years maintenance free
outdoor use. It should also have excellent chemical protection properties
against acid, salt, water and solvents. All other sheet metal should be hot
dip galvanized in accordance with BS 729:1986.

(c) The panel enclosure shall be made suitable to withstand the dynamic
stresses in the event of a short-circuit. The doors shall be sealed by
Neoprene gaskets to protect against the ingress of moisture and dust in
accordance with IP55 of BS EN 60529. The gasket shall be adequate to
maintain this protection at 60 degree C. ambient.
(d) The panel is to be provided with removable mounting plate made of fiber
with thickness of not less than 5mm.
(e) A pre-fabricated sloped canopy of suitable dimensions to protect the

cabinet from water and direct vertical sunlight shall be provided. The
material shall comply with the requirements mentioned at (b) above. An air
gap not less than 1.5cm shall be present between the canopy and cabinet.
(f) The door shall have robust weatherproof hinges of polyamide type with
suitable and substantial lockable latching device. A metal pocket for the
schematic diagram and the ‘As-built’ diagram shall be provided in the
enclosure door. The enclosure door shall have two locks. One lock shall be
flush type with non-rusting triangular metal insert stainless steel. The other
lock shall have small wing handle with separate keys (two numbers) to
each panel. All keys shall have the same profile and design to match all
doors. Non-rusting materials shall mean stainless steel Grade AISI 316 or
gunmetal.
(g) The door opening shall attain a swing of 180 degree. An anodized
aluminium label, preferably dual colour, bearing ‘ ‘RTA’ in both Arabic and
English, 50mm size in first row, and 25mm size for the second row shall be
attached to the door in a proper location and firmly attached with rivets. All
hinges are to be gunmetal or stainless steel.
(h) The enclosure shall be provided with a door switch-operated internal

illumination lamp circuit complete with fluorescent lamps suitably protected
from accidental damage and located in the topside of the panel.
(i) The panel shall have full size neutral completely bonded to the main shell
and connected to the door by a braided copper wire. Provision shall be
made in the enclosure to terminate the earth copper plate with the earth
electrode outside the panel.
(j) Appropriate mounting openings on the bottom plate anchoring the feeder
pillar to the concrete foundation shall be provided. Dimension, location and
size of anchor bolts to be used are to be specified. A rubber insulation
sheet has to be included, separating the aluminium bottom from the
concrete base. The controller housing panel shall allow building up
equipment complying with IEC 439 and BS EN 60439-1.

(k) Cable gland entry holes are to be factory punched and are to be the
knockout type or sealed with appropriate rubber cover. The number of
cable entry holes shall not be less than three.
(l) The complete pre-assembled panel shall be appropriately packed and

protected from damage during storage, shipment and handling. The panel
dimensions shall be within the range specified herein:
Height : 800mm (without canopy) : Dimensions +/- 5mm

Width : 600mm (without canopy) : Dimensions +/- 5mm
Depth : 300mm (without canopy) : Dimensions +/- 5mm, and consist of the
following.
(m) The enclosure for Traffic Controller shall be a single sided access cabinet
with the following typical dimensions. The dimensions of existing
controllers installed by the RTA are listed in Table C-3. The Contractor
may propose housings with alternative dimensions subject to approval by
the RTA.
Table C-3 Size and Weight of Existing Controllers
Height (above ground level) 1210mm

Width 730mm
Depth 425mm
Approximate weight of bare enclosure 30Kg
Approximate weight with a 16 phase
75Kg
controller
(n) The enclosure door shall be provided with durable and resilient
weatherproof sealing gaskets. The sealing gaskets shall be made o an
ultra-violet stable, closed-cell material. The sealing gasket shall be
securely held in position and shall be readily replaceable while the
controller is in service.
(o) In addition to the screw-locks, the main controller door shall be fitted with a
S18 lock. The key lock must not be operated unless the screw locks are
tight. Therefore, it shall be necessary to unlock the door before undoing the
screw-locks and only lock the door after tightening the screw locks.
(p) The lock used on the Police manual panel shall be a small Yale lock with a
‘900 pattern’ barrel.
(q) There shall be a facility to change the S18 lock to a Yale with an RKA27C
pattern barrel.

7C/2.7 GENERAL ARRANGEMENT HARDWARE
The layout of equipment, cable terminations, power switches and cable access
shall allow easy access to field maintenance and service staff. The Contractor
shall submit layout plans as part of the tender submission.
7C/2.8 HANDSET INTERFACE (RS 232 PORT)
(a) The Traffic Controller shall have the interface kit for interfacing using the
Handset for changing the Controller settings. The settings which are allowed
to be changed using the handset are as described in this specification. The
interface kit shall be based on RS232 protocol for communication. (RS232
CCCIT V24 and V28). One set of Handset with all the necessary hardware
such as connecting cables handset, connectors shall be supplied for each
Traffic Controller.
(b) Method of Connection
The method of connection with the controller and terminal device shall be as
follows.
i. Controller - Cannon DP 25-way female socket connector
ii. Terminal Device - Cannon DP 25-way male plug connector
(c) Pin Allocation

Typical pin allocation for the pins shall be as follows. This is for guidance only.
The actual pin allocation shall be as per Approved Manufacturer’s standard
and shall be subject to RTA and Engineer’s approval.
Pin 1 - Protective ground

Pin 2- Transmit data fro terminal to controller
Pin 3- Received data from controller to terminal
Pin 4- Request to send
Pin 5 - Clear to send
Pin 6- Data set ready
Pin 7 - Signal ground
Pin 9- 5V supply (see below)
Pin 10 - 5V supply (see below)
Pin 18 - 5V supply return
Pin 19 - 5V supply return
Pin 20 - Data terminal ready
(d) Pins 9 and 10 shall be connected to the controller’s 5-Volt logic supply
(protected by a 500mA fuse) and can supply a maximum of 300mA (total).
(e) Bit Format
Bit Format shall be as detailed below.

START BIT 1 2 3 4 5 6 7 PARITY STOP BIT
(SINGEL BIT) (LSB     MSB) (EVEN) (SINGLE BIT)
(a)Baud Rate
Baud rate shall be 1200, 9600 or 19200 Baud – Auto-detected.
(b)Mode
Mode of communication shall be Full duplex.
(c) Character Set
The character set shall follow the ISO Alphabet No. 5 (ASCII)
7C/2.9 INTERFACE TO OUTSTATION TRANSMISSION UNIT (OTU)
While the Controller is operating in the UTC mode, the Controller communicates
with the UTC computer system via the OTU. The OTU may be an integral part of
the Controller or as a stand-alone unit.
This Clause specifies the interface requirements of the Controller when a stand-
alone OTU is installed.
The Controller shall provide a parallel data port for communication with the OTU.
The functions of each bit of the parallel port is described briefly in Table C-4
below.
Table C-4 OTU Parallel Interface Port Bit Description
Bit Function Description

UTC Control Bits
F1…Fn Forces Commands to move to another stage
DX Demands: common Artificial demands to all phases
D1…Dn Demands: Stage Artificial demand to specific stages
PX Demands: Ped stream Artificial demand for a pedestrian
phase
PV Ped stream hold At stand-alone pedestrian stream,
vehicle hold vehicle stage at ROW
SF1, SF2 Switch facility Simulate facilities provided by the
time schedule
SO Solar override Command to override automatic
dimming
SG CLF group sync Reset CLF cycle time


LO Lamps on/off Turn lamps off for Part Time mode
LL Lock link inhibit Override to Local Link to other
adjacent junctions
FM Fallback mode Disable CLF on fallback, run VA or
FT
TS RTC set Set RTC to stored value
TS1 RTC synchronization Synchronize RTC with preset values
TO Take over May be used in conjunction with the
F1…Fn bits
TC Transmission confirm Status bit indicating valid
communication with UTC is
maintained
Controller Reply Bits
G1...Gn Stage confirm Response when Controller reach next
stage
SD1…SD2 Stage Demand Confirm Current demands on stages
WI Wait indicator At stand-alone pedestrian stream, the
WAIT indicator is on (O/C when
WAIT is on)
GX Vehicle stream confirm At stand-alone pedestrian stream,
vehicle is at ROW (O/C when vehicle
is at right of way)
PC Ped stream confirm At stand-alone pedestrian stream,
pedestrian is at ROW (O/C when the
pedestrian is at right of way)
SC1, SC2 Switch facility confirm Switch facility is active
SC Solar override confirm Dimming has been overridden
CS CLF group sync confirm Confirm cycle time has been reset
LE Lamps off Lamps are off for Part Time mode
FR Signals flashing Lamps are flashing for Part Time
mode
LC Local link inhibited Local link is inhibited
FC Fallback confirm Fallback inhibit is active
CC RTC set confirm Stored value has been loaded
RT RTC at configured time RTC has reached preprogrammed
time
CC1 RTC sync confirmed RTC has been resynchronized
TOR UTC control is active, generated by
Take over confirm the OTU
Miscellaneous Controller Status Bits
CF A fault has been logged by the
Controller fault Controller
DF Detector fault A detector fault has been logged


LF One or more lamp fault/s has been
Lamp fault logged
MC Manual control mode Manual mode is selected or operating
RR Remote reconnect Request UTC to takeover control
GR1 First group Indicates Group 1 of the current CLF
confirm plan is active
HC Hurry call confirm A Hurry Call is being activated
TF A handset has been plugged into the
Test facility Controller
The logic states of this parallel I/O port are as follow, unless stated otherwise:
Inputs to the Controller: open circuit when inactive (0)
Outputs from the Controller: closed circuit when inactive (1)
Please note that the descriptions of the communications bits provided by the Table
above are only a summary of their functions. The Contractor must refer to the
Technical and User Manuals of the UTC system for the detailed functional,
operational and technical specifications of the communications interface between
the Controller and the Outstation Transmission Unit.
7C/2.10 INSTALLATION TESTING AND COMMISSIONING
(a) The Traffic Controller installation shall be carried out only by approved
specialist Sub-Contractor having experience in the field of Traffic Signal Systems.
It is preferred that the Installation of Traffic Controller is carried out under direct
supervision of specialist manufacturer of the Traffic Controller.
(b) A set of shop drawings shall be provided as part of the tender. The information
presented on the shop drawings shall include:
i. a scaled junction plan

ii. positions and types of all hardware within the plan
iii. all line markings within the site
iv. phasing diagrams for the operation of the signals
v. positions and dimensions of detector loops
vi. positions of all pedestrian push buttons
vii. positions of all audible and tactile devices
viii. positions, types and alignment of all signal heads
ix. positions of cable pits
x. positions, quantities, dimensions and alignments of cable ducts
xi. property and building boundaries
(c) Prior to starting the installation necessary permits shall be obtained from the
RTA Traffic Signals section.

(d) Installation must be carried out in strict compliance with the approved shop
drawings.
(e) The location of controller shall be as per the approved shop drawings which
shall indicate the exact co-ordinates of the controller and the distances from
the nearby curbstones, road edges, bridges, etc.
(f) The Traffic Controller shall not be powered ON unless a written permission
has been obtained from the RTA, RLTS, Department RTS ITS, IM, TMC(UTC)
as well as from the Dubai Traffic Police Department.
(g) At the time of commissioning of the Traffic Controller presence of Dubai Police
must be ensured at the site.
(h) Telephone communication leased line must be functional and tested prior to
starting the commissioning of Traffic Controller.
(i) Necessary communication with the RTA TMC (Traffic Management Center)
shall be established and all interfaces shall be completed and tested prior to
setting the controller to operation.
Prior to starting the operation of a Traffic Controller at any junction, at least one
week written notice shall be given to the RTA Traffic signal section and Dubai
Police.
7C/3 TRAFFIC SIGNAL HEADS AND LAMPS SPECIFICATIONS
7C/3.1 SUMMARY
(a) This section specifies the requirements in general for the supply, installation,
testing, and commissioning for the traffic signal lamps, signal heads and
associated hardware. The “traffic signal” term refers to all the equipment as
required to provide a fully functional Traffic Signal System.
(b) The Contractor shall submit during construction stage material submittals for
each Item such as traffic signal head, lamps, etc. as per the RTA/RTLS
standards and as per detailed drawings C6 – 1.3 to C6 – 3.3. All the materials
shall be subject to approval by the RTA /RTLS and Engineer during
construction.
(c) The Contractor shall provide a minimum warranty period of 10 years from the
date of commissioning for all equipment, components and services supplied
within this Clause.

7C/3.2 STANDARDS AND REFERENCES.
All supplies and services offered in response to this specification shall conform to
the latest local and International standards as specified in Clause 7C/1.2
7C/3.3 TRAFFIC SIGNAL GENERAL REQUIREMENTS
(a) Construction
1. Signal heads shall have UV stabilized polycarbonate lenses. The color of the
lens shall be Green/ Red/ Amber (yellow) as indicated in the drawings.
2. Signal Head Diameters shall be 100mm, 200mm or 300mm as required as per

the approved drawings.
3. Housing for the signal heads shall be dark green (RAL Code 9005) in color.
Housing shall be manufactured using UV stabilized polycarbonate.
4. The signal heads shall be complete with Internal wiring and terminal blocks for
termination of external cables as well as internal wiring. The terminal blocks
shall be vibration resistant and shall be spring type to allow quick connection.
5. Signal heads shall be complete with visor. The visor shall be suitable for snap
fitting and quick removal / installation. The blades of the visor shall be painted
with black matt finish to ensure that the sunlight entering the signal does not
get reflected.
6. An anti phantom insert shall be provided to ensure sunlight does not reflected
from the reflector inside the signal head.
7.
8. The Signal head should have the possibilities of adding signs and symbols
such as pedestrian, green arrows, etc.
9. The signal lens shall be diffuser type avoiding excessive glare and providing
sufficient light during the day.
10. The front cover shall be attached with the base by use of hinges and shall be
locked in place using the quick release type latches to facilitate quick re-
lamping.
11. The signal head brackets shall be made of aluminium and all the hardware for
fixing the signal heads shall be Stainless Steel SS 316L. The signal heads
shall be attached to the poles using purpose made brackets, clamps, jubilee
clips as appropriate depending on the type of pole and the bracket. Whatever
the type of attachment provided, it shall be designed for quick mounting and
shall not necessitate drilling holes on the pole or mast.
12. Background screens shall be provided for the traffic signal heads to enhance
the visibility during daytime. These background screens shall be attached to

the signal head without drilling the signal head enclosure by using special
clamps.
13. For fixing the signal heads to the whip mast a special purpose made whip
mast attachment shall be provided which shall provide flexibility of installation
and height adjustment.
14. Signal head optical system shall consist of reflector with surface made of
specular aluminium, diffuser made from UV stabilized polycarbonate. The
diffuser shall have cobweb pattern inside to provide distribution of light.
15. The cable entries to the signal head shall also have ingress protection of IP55
minimum and shall ensure no seepage of water and or sand.
16. Number of units at a signal head shall be either 1,2, or 3 as indicated in the
approved drawings.
(b) Structural and Mounting
1. The signal heads shall be suitable for installation on stand posts, gantries or
on the whip posts.
2. All necessary brackets, clamps, caps, shall be provided to ensure that the
installation can be achieved completely without any additional hardware.
3. All hardware used for brackets, supports, shall be hot dip galvanized. Clamps
shall be of stainless steel SS 316 L grade.
4. The entire signal unit comprising of signal head, support brackets, poles,
masts, cantilever shall be capable of withstanding the wind speed of 160
Km/Hr minimum.
(c) Lamps and Lamp holders
1. The lamp used in the optical system shall be of the quartz halogen type and
shall be highly shock resistant. Lamp base shall be BA20s. For LED type
lamps special base shall be provided subject to approval from RTA and
Engineer. The lamp shall be designed for Traffic Signal usage, we shall not
accept general purpose lamps.
2. Lamps shall be rated at 10.5V, 50 Hz with power rating of 30W (at full voltage)
for vehicle aspect and 20 W for Pedestrian aspect
.
3. The lamps provided shall have high luminous efficiency and long service life.
For lamps rated for low voltage necessary transformer and accessories shall
be included within the signal head.
4. The lamp shall only be used in the horizontal position.
5. Luminous flux output of the lamps shall not decrease below 80% of the rated
flux output within six months. Luminous intensity shall be minimum 400 Cd.
6. The lamp holder shall be composed of porcelain and be suitable for the above
lamp type. The spring contact material shall be designed as to maintain
adequate electrical conductivity and to ensure that the lamp remains securely
located under traffic vibrations and under temperatures of 250oC.
7C/3.4 OPTICAL REQUIREMENTS
(a) Distribution of Light:
Each full and restrictive signal shall present a uniform appearance, free from
excessively bright spots or sectors, over the whole area of the lens when
viewed from any direction within the cone of directions for which the
intensities are specified TABLEC-5. The minimum luminance values for red
and green pedestrian signals shall be as set out in TABLE C-6.
Table C-5 Distribution of Non-restrictive red, amber and green light for signals (Candelas
On Geometric 10º on side of 25º on side of

Horizontal/Vertical axis geom. axis geom. Axis
On Geometric axis 950 450 60
10o below geom.
445 236 48
Axis
Table C-6 Minimum values of luminance for red and green pedestrian signals (Candilas)
On Geometric 10º on side of 25º on side of
Horizontal/Vertical axis geom. axis geom. Axis
On Geometric axis 570 270 36
10o below geom. 267 142 29
Axis
(b) Direction of Beam:
i.Light signals intended for traffic:

Light signals shall be directed at a point approximately 150 meters from the
primary signal face and approximately 1.5 meters above ground level at the
center line of the carriage-way allocated to approaching traffic.
ii. Light signals for Pedestrians:
The light signals shall be directed towards the center line of the part of the
carriage-way allocated to pedestrian movement.
(c) Limits of chromaticity of signals:
The colour of the light transmitted by the signals shall comply with the limits
set out
in British Standard 1376:1974, Table-1, or DIN 6163 or an equivalent
specification.
(d) Sun phantom effect:

Phantom images which are caused by extraneous incident light reflected by

the
signal optical system shall comply to the limits specified in DIN 67527 (or
equivalent) Type-1 – “Sufficiently restricted”, but must be capable of being
improved to Type-2 “with low reflectivity” if required.
(e) Optical system arrangements
1. Light signals for Traffic (3 Aspect Head):
Each signal face shall contain three optical systems arranged vertically and
each having a diameter of between 295 and 305mm. The coloured lens of the
upper optical system shall be red, the middle amber and the lower one green.
Arrows or other masks may replace the full colour or be additional to the basic
arrangement.
2. Light Signals for Pedestrians (2 Aspect head)
Each signal face shall contain two optical systems arranged vertically each
having a diameter of between 200 and 215mm. Which shall incorporate
pedestrian symbols approved by the RTA. The upper optical system shall
illuminate a red symbol and the lower one a green symbol. The background for
the symbols shall be obtained by coating the lens or filter with heat resistance
black paint or enamel or by other suitable means.
7C/3.5 MOUNTING REQUIREMENTS
(a) Post-mounted traffic control signals for traffic
The height of the signals shall be such that when erected the center of the amber
optical system shall be between 2433 and 2484 millimeters above the top of tiling
or finished ground level as appropriate.
(b) Light signals for pedestrians:
The height of the signals shall be such that when erected the lower edge of the
housing enclosing the green signal shall be 2530 millimeters above the top tiling or
finished ground level as appropriate.
7C/3.6 SIGNAL HEAD
The signal head shall comply with IP55 and neither corrodible nor brittle over the
temperature ranges normally experienced in Dubai. It shall be of such form as to
resist deterioration over this temperature range and to resist substantial distortion
in wind velocities up to 160 Km/hr including gust factor. External wiring to the
signal head shall be protected by non-flexible conduit.

Signal heads shall be secured to the pole by means of a clamp at the top of the
signal head and pole and by a ribbon clip at the bottom of the signal head. Fixing
requiring the drilling of holes in the pole are not permitted.
(a) Signal head assembly
The signal head, the fixing brackets and the necessary parts thereof shall be
designed such that they shall be capable of horizontal and vertical adjustment in
respect of all approach roads and pedestrian crossings to which the signals apply.
The adjustment shall be such that no signal shall obstruct the view of optical
systems of any other signal head within 25 degree of the axis of the beam. The
signal head assembly shall be capable of being locked securely after adjustment.
A backing board shall be provided with each signal face for the benefit of vehicle
drivers. The signal face shall be centrally located within the backing board and it
shall not exceed a width of 650mm and a height of 1370mm. The backing board
shall have a white border of a width between 70 and 80mm.
(b) All parts of the signal head assembly shall be composed of dark green
coloured ultraviolet-stabilized polycarbonate material, in accordance with RAL
6001, DIN 6163 and the recommendations of C.I.E. The backing board shall have
a white border with a black strip all around on the front face of the board only. All
screws and fixings shall be non-corrodible.
(c) Optical systems:
The optical system shall be in accordance with IP55 and shall be rain proof, and
manufactured from materials which are neither corrodible nor brittle over the
temperature ranges normally experienced in Dubai. It shall be of such form as to
resist deterioration over this temperature range. Means shall be provided so that
when mounted the optical system cannot be rotated from its normal position. The
lenses shall be made of glass. The permanence of the colour of lenses shall be of
the best for the purpose, durable on the prolonged exposure to weather conditions.
Each lens shall have pressed on its flange the word “TOP” if applicable to indicate
the proper positioning of the lens in the door for obtaining the light distribution
required.
(d) Reflector:
The reflector shall be of either thermoplastic polyester with vacuum evaporated

reflective film or aluminium alloy to BS 4300/4:1973 with an anodic coating of not
less than AA5 grade to BS EN 12373-1or an equivalent specification. The reflector
shall be of sufficient thickness to retain its shape during assembly, relamping or
cleaning operations.
(e) Visor:
A visor shall be fitted to each optical system and shall be manufactured from
material which is neither corrodible nor brittle over the temperature range normally
experienced in Dubai. It shall be of such form as to resist deterioration over this
temperature range, to resist substantial distortion in winds at up to 160 Km/hr and
to prevent permanent deformation from the same cause. The visor shall be fully
cylindrical with a length of 428mm while only 5cm space is allowed at the button
side of the visor.
(f) Top pole cap:

The top pole cap shall be composed of green coloured ultraviolet-resistant

polycarbonate material and be to the dimensions shown on the drawings.
7C/3.7 MAINS SUPPLY
The traffic signal heads and lamps shall operate within the same supply conditions
as specified in Clause 7C/2.4.
7C/3.8 ELECTRICAL NOISE
The traffic signal heads and lamps shall operate within the same supply conditions
as specified in Clause 7C/2.4.
7C/3.9 ENVIRONMENTAL CONDITIONS
The traffic signal heads and lamps shall operate in accordance with the climatic
conditions specified in Clause 7C/1.3
7C/3.10 DOCUMENTS TO BE SUBMITTED:
The tenderer shall supply the following technical documentation and information for
each item:
 Catalogue sheets
 Detailed construction drawing
 Tightness test certificate: This certificate shall be issued by an independent
official laboratory.
 Tenderer shall submit with his tender all details of known areas using the
same type of item.
7C/3.11 IMPORTANT NOTES
Each signal head to be packed in a single carton with 3 or 2 visors to be included

in the same carton.
Mounting parts (cantilever type) to be packed separately in nylon bags. Each bag
shall contain the required jubilee clips, stainless steel Grade 316, size 140mm
diameter full thread.
7C/4 POWER AND SIGNAL CABLES
7C/4.1 GENERAL
The Contractor shall provide cabling for the interconnection of all components at
the site to form an operational signal controller junction. These cabling shall
include power supply feeds, signal drive circuits, link with outstation transmission
units and ancillary equipment required to form the controlled junction.

The Contractor shall provide a minimum warranty period of 10 years from the date
of commissioning for all equipment, components and services supplied within this
Clause.
7C/4.2 POWER CABLE CHARACTERISTICS
Junction power cables shall be as follows:

a) Multicore
b) Not smaller than 1.5 mm2 solid copper conductors
c) PVC/Polythene insulated
d) PVC/Polythene bedded
e) PVC/Polythene sheathed
Cables shall be in accordance with B.S.I. specification No. 6346 (metric equivalent
No.
3346) or an equivalent specification.
Note: Each cable shall have a separate earth conductor of adequate size
7C/4.3 CABLING PRACTICE
7C/4.3.1 Jointless Runs
Cables shall be run between the controller and a termination point on the signal
poles
without intermediate jointing during initial installation.
7C/4.3.2 Cabling Use
A separate cable shall be provided between each signal aspect and the controller.
The
right hand primary signal on each approach shall be provided with a separate
cable link
to the controller. All approaches shall be cabled separately as if controlled by
separate
phases.
7C/4.3.3 Mains Supply at Poles
A permanently energized fused mains supply core shall be provided to each signal
pole. The fuse used shall be located in the controller cabinet and be of 13 amps
maximum rating.
7C/4.3.4 Spare Capacity
At least 4 spare cores shall be provided in each cable at the time of installation.
Spare
cores shall be identified on the installation drawing supplied by the Contractor

Each signal cable shall have 2m of spare cable coiled in the draw pit at the
controller base and 3m of spare cable coiled in the draw pit by the pole..
7C/4.3.5 Extra Low Voltage Cables
All cores carrying extra low voltages (e.g. Push-buttons) shall be in separate
cables.
7C/4.3.6 Labelling
A separate 7-Core cable is to be used for each traffic signal phase. Cable cores
shall be identified by number labels as shown in table C-7. All cores shall also be
clearly labelled at the controller as to their function and destination.
Table C-7 Junction Signals Cable Core Allocation
Core No Label Function Allocation

1 Red Signal Lamp
2 Yellow Signal Lamp
3 Green Signal Lamp
4 Neutral
5 Spare
6 Spare
7 Earth
7C/4.3.7 Earth Continuity
To provide earth continuity at each end of the cable, the earth core/conductor wire
shall be clamped to a ring or cable gland which is bonded to earth.
7C/4.3.8 Markings
All signal cables shall be marked at each end to indicate their function and
connection. They shall also be marked in each draw pit they pass through.
Cable marking shall be to the approval of the Engineer and shall be designed to
last the life of the cable.
7C/4.3.9 Installation on Other Properties
Where signal heads are to be installed on existing structures or on the walls of

buildings, their cables shall be installed in galvanised steel conduit (supplied by the
Contractor) up to a height of at least 2m. Above that height they may be in solid or
flexible conduit, at the Contractor’s discretion. The Contractor shall securely fix the
signal head brackets and conduit to the wall or structure.
7C/4.3.10 Linking Cables

Linking cables (if used) shall be to the same specification. No voltage in excess of
42V (D.C.) or RMS (A.C.) shall applied to linking cables.
7C/4.4 CABLE LAYING
7C/4.4.1 Ducting
Cable shall be drawn into ducts, pavement boxes and pole boxes provided under
the main civil engineering contract.
7C/4.4.2 Excavation by Contractor
Where cables pass through excavations made by the Contractor to approach the
base
controllers or poles, where pole boxes are not provided, the following requirements
shall be met:
(a) Before bending upwards, cables shall have a minimum of 750mm of cover.
(b) Trenches shall not be excavated appreciably deeper than the ducts or bases,
except to allow for a 100mm thickness of fines which shall be applied to surround
the
cable.
(c) Backfill shall be free from flint and large stones, and shall be compacted in
layers of 200 mm.
7C/5 PEDESTRIAN PUSH BUTTON
7C/5.1 GENERAL
The pedestrian Push Button shall operate in accordance with BS50293:2001. The
front panel of which is modified for use in Arabic speaking countries. The housing
shall be made of die-cast aluminium.
Clause.
The tenderer shall submit the mechanical, electrical and operational details of the
push button to the Engineer for approval.
7C/5.2 OPERATION
The operation of the pedestrian push button at any time shall result in a demand of
the pedestrian stage and the immediate illumination of WAIT indicator which shall
be written in Arabic, and English languages
The push button shall provide audible signals to assist visually impaired
pedestrians to locate the push button and to indicate to them when it is safe to
cross the road. The unit shall provide a tactile indicator in the form of an arrow to
indicate the direction of the crossing on the front of the unit.
The ‘locating’ audible signal shall have a tone of approximately 1 KHz and with a
repetition rate of 0.5 Hz. The volume of this signal shall be adjustable on site
allowing compensations to ambient noises to be made.
The ‘safe to walk’ crossing audible signal shall have a tone of approximately 50 Hz
at a repetition rate of 8 Hz. The volume of this signal shall be adjustable on site
allowing compensations to ambient noises to be made.
7C/5.3 FRONT PANEL DETAILS
The front panel shall be made up of

 Acrylic sign plate (dimension: 23.2 x 16mm x 6mm thick)
 Screen printed – 5 colour printing: Black Blue Red White Green
 Reverse printing on clear acrylic sheet (3mm thick).
 Printed matter to be provided with a protective 3mm clear acrylic sheet at the
back, i.e. printed matter shall be sandwiched to form a 6mm thickness plate.
 A tactile indicator arrow of approximately 80mm long, 8 mm wide, an arrow
head of 16 mm wide and raised 1.5 mm above the base plate.
7C/5.4 WORKING TEMPERATURES
The following describes the allowable working temperatures for the push button
assembly. The front panel shall withstand to the following temperature ranges.
 Door panel: Maximum working temperature 125oC.
 PVC Wire: 70-85oC.
 Terminal Block (Melamine): 100oC.
7C/5.5 MOUNTING
The push button back side shall be capable for mounting (no flat back surface
mounting is accepted) on a 100mm diameter pole by means of brackets and
screws.
The push button shall be mounted in a position such that the tactile arrow indicator
is pointed at the direction of the crossing.
7C/5.6 COLOUR
The external surface of the push button box carrying the front panel shall be
yellow, colour BS 381C No. 355. This colour shall not be visible in front elevation.
The black of the front panel shall be continued around the front edge of the case,
this boarder shall not be more than 25mm deep.

7C/5.7 INDICATING LIGHT
The push button shall be provided with an internal heavy duty traffic signal lamp
E27 base. The lamp shall be rated 75W. (LED is optional.)
7C/5.8 PUSH BUTTON
The push button shall be aluminium material designed against vandalism.
7C/6 TRAFFIC SIGNAL CANTILEVER POLES
7C/6.1 GENERAL
The Cantilever poles are intended to hold six traffic signal heads and traffic signs
as detailed in the RTA Drawing C6-2.3.
Clause.
7C/6.2 SPECIFIC
The cantilever shall consist of pole and single arm or double arm, each shall be of
one solid piece other than the attachment parts and brackets.
The pole shaft shall have a circular cross section continuously tapered and
longitudinally welded. The welding of the cantilever pole shall be metal-arc-welding
complying with BS EN 1011. No circumferential weld shall be accepted
All pole shafts shall be provided with substantial rigid flange plate, thickness as per
drawing, with an opening for cable entry. The plate shall be welded with the shaft
with 2 butt welds from inside and outside. The weld shall be metal-arc-welding
complying with BS EN 1011 .
The cantilever pole shall be fabricated from a high strength structural steel
complying with the requirements of standards mentioned in the drawing or
equivalent
Poles, flange plates/base plates, doors, brackets, anchor bolts, nuts and washers
shall be protected against corrosion from inside and outside in compliance with the
requirements of BS 729:1971 (the minimum average zinc coating weight on one
side should not be less than 714 g/sq. meter. Minimum 100 microns DFT) and BS
EN 40-5.
All component parts or fasteners shall also receive the same hot-dip galvanized
treatment, threaded components centrifugally spun to remove local excess of zinc.

Coating weight shall be determined by a suitable magnetic or electronic measuring

device. However, in cases of dispute, the Engineer may direct that a stripping test
in accordance with BS 729 be carried out.
Cantilever pole shall be able to withstand a wind-speed of 160 km/hr. including

gust factor.
The single arm rube shall have a minimum rotation of 90 degree at the arm joint
with pole tube where the double arm tube shall have no rotation angle at the arm
joint with pole tube.
The pole tube and arm tube shall be constructed straight. The exterior and interior
surfaces of the poles shall be free from protuberances, dents, cracks or other
imperfections. Appropriate wrapping and packing is to be done before shipping to
maintain this quality and to preserve the finish during shipping and storing.
Wrapping with tape is not acceptable. Anchor bolts shall be packed in wooden
boxes.
The pole to be adequately reinforced and strengthened at the location of the

inspection compartment opening to compensate for loss in section of the post at
this point
A 30mm long threaded stud of corrosion resistant steel carrying 2 nuts and 2
washers to be provided for earth connection. The stud to be located in an easy
accessible place near the inspection cover inside the pole (stud diameter to be of
M8 size) in compliance with Clause 5 of BS 5649: Part 5: 1982 .
The door shall be flush and secured by a positive action lock which forces the door
out when opening. All loose parts of the locking device shall be so arranged that
they are held captive on the door when it is in the open position. All the moving
parts of the locking device shall be stainless steel of Class 316 - material. There
shall be a stainless steel chain (6mm), Class 316 - material strength, between the
pole and the door to ensure the door cannot be lost if incorrectly secured.
100mm thick rubber protector cover to be fixed at the bottom of the pole shaft to
observe the impact of the hit during accidents made by vehicles.
Electrical junction box to be supplied as per drawing and proper arrangement to be

made inside the pole to fix this box.
All bolts, nuts, locking screws and door chain shall be stainless steel Grade
AISI31G.
Tenderer may submit alternative design that shall suit the requirement of the
specification.
7C/6.3 MISCELLANEOUS REQUIREMENTS
Specification compliance statement shall be submitted.
Offered material shall be supplied exactly as indicated on specifications and

drawings.

Shipment will be allowed only after the approval of the free sample given by the
supplier at our RTA Stores at Rashidiya.
All material shall be delivered to Contractor’s Stores on Project Sites and/or RTA
Stores at Rashidiya. The off-loading in the Store yard shall be arranged by the
supplier at no cost to Roads and Transport Authority.
A test certificate from an independent laboratory shall be submitted confirming the

galvanization coating weight and component composition.
7C/6.4 DESIGN INFORMATION
The supplier shall submit for approval the design calculations and data prior to the
fabrication of any part of the cantilever poles.
> General dimensions of all components of the pole.
> Detailed scaled drawings of the pole.
> Details of the fixing and locking system between the pole tube and arm tube.
> The total maximum load moments for each section under maximum stresses.
> Computation of stresses in the base plate and anchor bolts, under maximum
wind-load with maximum loads indicated in the drawing.
> Maximum deflection at the end of the arm tube, under climatic conditions and
wind velocities specified in Section 7C/1.3 CLIMATIC CONDITIONS
Supplier may submit any new treatment method for extra protection against
corrosion of the base plate area and up to the height of 300mm.
Detailed calculations of the necessary strength for anchor bolts to be used should
be submitted for different heights of pole.
Means of assembling the cantilever poles shall be indicated in detail. If special

tools are required, supplier is to include one complete set and the price shall be
included in the tender.
Impact resistance calculations at a height of one meter above the base plate of the
column.
Maximum tolerable impact calculations to shear the plate from the pole from an
impact point one meter above the flange plate.
Material specification for each part of the column.
Tenderer shall provide along with the samples, table showing all data and all test
results mentioned under Clause 7C/6.3 above and indicate deviations from
contract specifications, if any.

7C/6.5 MATERIALS TO BE SUBMITTED WITH THE OFFER
Each tenderer shall submit one number sample cantilever pole tendered for.
The materials to be accompanied by manufacturers assembling and erection

instruction.
The sample materials shall be delivered to Roads and Transport Authority Stores
at Rashidiya soon after the tender opening.
The delivered pole(s), bracket(s) and anchor bolt(s) shall be subject to

nondestructive performance test conducted by Roads and Transport Authority.
The outcome of the performance test shall be considered in the tender evaluation.
7C/6.6 COLLECTION OF TENDER MATERIALS
In case of tender award, the materials for testing supplied by the awarded tenderer
shall be returned to tenderers after completion of delivery.
In all other cases the non-selected materials supplied by tenderers who are not
awarded the contract shall be returned to the same.
Roads and Transport Authority will notify those tenders for collection of their
belongings within ten days after the contract has been awarded
The non-selected sample materials shall be collected from RTA Stores by the
suppliers within one month of notification. Failure to collect within this period will
render the materials to become property of Roads and Transport Authority.
7C/6.7 MISCELLANEOUS REQUIREMENTS

The below mentioned points are to be added to the specification.
 All caps shall be made out of Aluminium.
 Junction box shall be provided with European made terminals.
 Expanding type PVC gland for cables entry.
 Cantilever door to have gasket.
 Red marine ply wood for mounting junction box to be fixed inside the pole.
 All hardware to be stainless steel grade 316.
 Rubber to be one piece as shown on RTA/ RLTS standard drawing C-6-3-3 and
screwed together. Rubber to be impact resistant, non-aging, non-fading, non-
corrosive and reusable and easily replaceable.

7C/6.8 SPECIFICATIONS FOR CANTILEVER POLE BRACKETS
 The brackets material shall be completely stainless steel - Grade 316, or cast
aluminum.
 To securely attach signal heads on high mast arms (cantilever poles) using
stainless steel clips (Grade 316).
 The above clips shall be of 250 mm diameter and shall be of all threaded type. All
attachments (Screws, nuts) to be resistant to corrosion.
 Brackets shall be capable to suit a 3 unit, 300 mm, signal head with a back plate.
All attachments provide stability against wind speed of up to 160 Km./hr.
 The attachment is characterized by swiveling to any required angle by means of a
ball head and height adjustment (or anything else similar) after mounting.
 The brackets shall enable the head to rotate to minimum of 90 degrees.
7C/7 POLE FOUNDATIONS
7C/7.1 FOUNDATION FOR CANTILEVER POLE
The Contractor shall refer to RTA Drawing C6-1.3 for cantilever pole foundation
details.
7C/8 MANHOLES AND CHAMBERS
7C/8.1 MANHOLES
The Contractor shall refer to RTA Drawing C6-3.3 for details of manholes for traffic
signal applications.
7C/8.2 MANHOLE COVER
The Contractor shall supply and install manhole covers comply with BS EN 124
D400 specifications.
7C/9 VEHICLE DETECTORS
7C/9.1 GENERAL
This Clause specifies the supply, installation and testing of vehicle detector loops
for permanent works and temporary works. The following specifications and
installation instructions have to be followed carefully. The loops shall be installed
at positions as presented on the approved shop drawings and RTA/ RTLS
standard details drawing (C6-3 of 3)

It should be noted that reliability of detector loops is of paramount concern to the

RTA/ RLTS. The Contractor must make every effort to ensure that the required
warranty is met and not less than 10 years.
Before commissioning of these loops, the Contractor shall conduct leakage,

continuity, loop characteristic test to the satisfaction of the Engineer and RTA/
RLTS.
The Contractor shall provide feeder cables between each loop and the traffic
signal controller. All feeder cable shall be terminated onto the controller
termination block to complete the detection circuit.
For both types of installation mentioned above, the Contractor shall adhere to the
following procedures.
1) The Contractor shall advise the Engineer and RTA/ RLTS that the loops have
been received and checked. The Contractor may commence installation of the
loops upon approval by the Engineer and RTA/ RLTS.
2) The Contractor shall test the installed loops to the satisfaction of the Engineer.
3) The loop lead-in cables to be kept safely in the nearest bypass chamber
constructed especially for the loop detectors.
4) The Contractor has to ensure that the loops are not damaged at any stage until
the site is handed over to the Engineer.
7C/9.2 LOOPS
Clause.
7C/9.2.1 Specifications
(a) Loops shall be constructed from polypropylene conduit with 3/8" I.D. (9.5 mm)
5/8" O.D. (16mm).
(b) Conduit shall be filled with hot rubberized asphalt which allows the loop to
remain flexible once cooled, prevent incursion of moisture and set the turns of
wire firmly in place.
(c) Loops shall have 130mm expansion/contraction joints at intervals along the
loop to allow for movement of the pavement and to prevent breakage of the
wire and/or conduit due to this movement. Each expansion/contraction joint
shall have a 230mm long schedule 80 polypropylene cover slide to be placed
over the joint.
(d) The encapsulated copper loop wire shall be 20 gauge, stranded, teflon coated,
single conductor. (Military-MIL-W-16878/4 Type E. 200C, 600V) Loop shall
have 4 turns.
(e) Loop shall be one continuous wire through the loop lead-in to prevent loop
malfunctions due to splicing.
(f) Lead-in wires shall be encased in a non conductive 2250 psi flex hose
constructed with a seamless extruded polyester fiber braid reinforcement and

a non-conductive, seamless extruded urethane non-perforated jacket. Fill lead-

in hose completely with hot rubberized asphalt. Twist wires in all lead-ins a
minimum of three turns per foot for the entire length of the lead-in. Attach lead-
ins to loop heads with a schedule 80 CPVC tee.
(g) All loops shall be tested three ways prior to shipment: resistance to ground
(measured in megaohms), resistance (measured in ohms), inductance
(measured in microhenries). All test results (readings) to be sent to Dubai
identified per loop.
(h) Loops shall be shipped fully tested, and documented and ready for installation.
Loops are installed in a grove on the surface of WET-MIX or AGGREGATE

ROADBASE (according to Road Design).
(a) Remove loop from container and unfold 24 hours before installation. Verify
dimensions and test.
(b) Mark on the ground location of loops in accordance to design STOP LINE.
(c) Open loop on the ground and mark the place.
(d) Excavate trench 30 x 30 mm by hand tools.
(e) Slide sleeve over the expansion/contraction joint and tape ends of sleeve
directly to conduit.
(f) Piece Loop in the trench.
(g) Cover Loop with Fine Asphalt mix (remove big size stones.)
(h) Compact asphalt with hand compactors.
(i) Lead cable from curbstone to manhole protect in a 2.54 cm (1”) PVC conduit.
(j) Protect exposed lead wires during construction.
7C/9.3 FEEDER CABLE
A feeder cable is the cable connecting a vehicle detector loop and its associated detector
unit.
The Contractor shall provide a minimum warranty period of 10 years from the date of
commissioning for all equipment, components and services supplied within this Clause.
7C/9.3.1 Cable Specifications
The feeder cable shall be to the following specification:
(a) Core conductors shall

 be of annealed copper
 (at least 7 strands)
 have a nominal cross-section area of 1.5 sq. mm (7/0.5 mm.)
 Comply with the appropriate requirements of AS 1125 or equivalent.

(b) Drain Conductor shall

 ensure electrical continuity of a tape metallic screen throughout the length of
the cable.
 comprise at least 7 strands of 0.25 mm tinned annealed copper conductor.
(c) Insulation:Material: Insulation shall be low density polyethylene, type 03, in

accordance with the requirements of AS 1049 or equivalent. Thickness:
The average thickness of insulation shall be not less than 0.4mm and the
thickness at any point shall not be less than 0.3 mm.
(d) Inner Sheath Materials: Inner sheath material shall be low density
polyethylene, type 03, in accordance with the requirements of AS 1049 or
equivalent.
(e) Thickness: The average thickness of the inner sheath shall be not less than
0.5 mm and the thickness at any point shall not be less than 0.3 mm.
(f) Metallic Screen: The laid-up cores shall be collectively screened with OR
overlapped metallic tape (tape screen). The tape screen shall have
minimum metallic thickness of 0.02 mm and it shall include a drain
conductor. The drain conductor shall comprise at least 7 strands of 0.25
mm tinned annealed copper conductor.
(g) Outer Sheath: Materials: The sheath shall be of V-75 PVC complying with
the requirements of AS 3147 or equivalent. Thickness: The average
thickness of sheath shall be not less than 0.8 mm and the thickness at any
point shall be not less than 0.62 mm.
(h) Overall diameter: The overall diameter over the PVC sheath shall not
exceed 9.0 mm, weight 97 kg/km.
(a) All armoured feeder cables shall be terminated in the equipment housing
using compression type cable connectors approved by the authority, and
each connector shall be bonded to the earth point using 4.5mm2 flexible
earthing cable terminated with crimped connection tags. The contractor
shall ensure that no other earth connection exists along the length of the
cable.
(b) Cables shall not be bent to a radius of less than 12 times their diameter or
less than a radius recommended by the manufacturer whichever is the
greater.
(c) Feeder cables shall be installed in a high impact resistance PVC duct to BS
3506 (Class 6 or 7) The duct shall be level with the base of the slot from
which the feeder cable emerges. The excavated area shall be backfilled
with fine aggregate concrete to this level. The cables shall then be
backfilled with compacted fine cold asphalt and hot oxidized bitumen
R85/40. The kerb stone shall be reinstated. The contractor shall ensure that
cables entering the footway are adequately protected from any abrasive
action.

7C/9.4 LOOP DETECTORS
7C/9.4.1 General
Vehicle detectors are required where specified, to provide count and occupancy
information at selected sites and to register demands in traffic signal controllers for
demand dependent or vehicle actuated stages.
The detector shall be of the auto re-tuning type. Each detector module shall make
up of no less than four independent detector channels.
Clause.
7C/9.4.2 Drift Compensation
The vehicle detecting equipment shall incorporate adequate automatic

compensation against the effects of changes in environmental conditions and
changes in loop dimensions and shall be fully self-tuning. Detectors employing
potentiometers for tuning or sensitivity adjustment will not be acceptable. The
vehicle detecting equipment shall operate correctly as required by this specification
when the loop is installed in the vicinity of electrically and mechanically stable
metallic bodies including materials for road reinforcement. After installation the
vehicle detecting equipment shall continue to operate correctly without the need for
any subsequent manual adjustment for warranty period.
7C/9.4.3 Recovery Time
The vehicle detecting equipment shall regain its specified performance as quickly
as possible after a moving vehicle leaves the loop. For the purposes of
measurement, the recovery time is taken as the time from when the rearmost part
of a vehicle vertically clears the loop to when the detector output restores to the
non indicating state, shall be not more than 100 milliseconds for a passenger car
crossing the loop at a speed of 50 km/hr.
7C/9.4.4 External and Mutual Interference
Adequate precautions shall be taken in the design of the vehicle detecting

equipment to prevent mutual interference between equipments of the same type
when connected to adjacent loops. These precautions shall be at least sufficient to
avoid any interaction between equipments connected to a pair of loops each 3
meters square, with adjacent sides parallel to each other and spaced 0.5 meter
apart throughout their lengths.
7C/9.4.5 Failure Conditions
(a) A disconnection of the loop or feeder connected to vehicle detecting

equipment shall automatically produce an output signal from the equipment
for so long as the disconnection persists.
(b) An interruption of the power supply to the vehicle detecting equipment shall
after an interval not exceeding 5 seconds automatically produce an output
signal from the equipment which shall regain its specified operation within 1
minute of the restoration of the power supply.
7C/9.4.6 Equipment Housing
Vehicle detectors shall preferably be mounted in traffic signal controller cabinets.

Where this is not possible, POLE MOUNTED HOUSINGS MAY BE USED. The
design of the pole mounted housings is subject to approval by the Engineer.
7C/9.4.7 Maximum Loop Configurations
The manufacturer shall specify (and, if required, shall also demonstrate) the upper
limits of the loop and feeder configuration (in terms of number of loops, loop
dimensions, length of feeder, etc.) which when connected to a single vehicle
detector will satisfy the performance requirements of this specification.
Performance Requirements
(a) The zone of detection for a passenger car for the vehicle detection
equipments shall be not less than the physical area of the loop and not
greater than an area whose sides are parallel to the physical sides of the
loop and not further than 200mm from these sides.
The detector shall operate satisfactorily with a feeder up to 60 meters in

length. The feeder is defined as the cable between the loop and the
detector housing.
(b) The equipment shall respond to any type of motor-driven vehicle normally
encountered on public roads travelling at any speed between 5Km/h and
120 Km/h. The associated equipment shall give a single unbroken output
for all motor-driven vehicles with 2 or more road wheels. An exception can
be made for special classes of vehicles such as those having a ground
clearance greater than 0.8 metres. For the purpose of a single unbroken
output signal the vehicle shall traverse the loop in such a way that at least
25% of the loop area is covered by the vehicle.
(c) The presence time shall be:

 For counting applications: Between 2.5 mins. And 20 mins.
 For demand dependent stages or vehicle actuated: Between 30 seconds and
4 minutes.
7C/9.4.8 Output and Fault Conditions
(a) The output from all types of vehicle detecting, equipment shall be an
isolated contact, or the solid state equivalent. This output shall have DC
isolation from earth and from the supply to the detecting equipment. If the
output is polarity conscious, a means shall be provided to protect the output
device against an accidental reversal of current flow. The correct direction
of current flow shall be clearly marked on the relevant output terminals.
(b) While no vehicle is being detected by the detecting equipment, the output
shall continuously allow a current of up to 50 mA to pass with a voltage
drop of no more than 2.5V. The connection of up to 50V DC to the output
terminals for one second shall not damage the output.
(c) While a vehicle is being detected by the detecting equipments, the output
shall continuously present a resistance of at least 100K ohms. The output
must be able to withstand a continuous voltage across it of 50V DC and
must not be damaged by transients of up to 650V peak amplitude for one
millisecond duration.
(d) An interruption of the power supply to the vehicle detecting equipment shall
after an interval not exceeding five seconds automatically produce an
output signal for so long as the interruption persists. The equipment shall
regain its specified operation within twenty seconds of the restoration of the
power supply.

1 SECTION 8 CONCRETE PILE FOUNDATIONS
TABLE OF CONTENT
8/1 DESCRIPTION ........................................................................................................ 1

8/2 MATERIALS ............................................................................................................ 1
8/3 GROUND CONDITIONS ......................................................................................... 2
8/4 TOLERANCES ........................................................................................................ 2
8/5 PILING METHOD AND PROGRAMME ................................................................... 2
8/6 PILING RECORDS .................................................................................................. 3
8/8 CONCRETE FOR PILES......................................................................................... 4
8/9 REINFORCEMENT FOR PILES ............................................................................. 5
8/10 BORING FOR PILES ............................................................................................... 5
8/11 DRILLING FLUID..................................................................................................... 7
8/12 PLACING CONCRETE............................................................................................ 9
8/13 EXTRACTION OF CASING ................................................................................... 11
8/14 TEMPORARY BACKFILLING ............................................................................... 13
8/15 DISPOSAL OF EXCAVATED MATERIAL ............................................................. 13
8/16 CUTTING OFF PILE HEADS ................................................................................ 13
8/17 INTEGRITY TESTING OF PILES .......................................................................... 13
8/18 LOADING TESTS .................................................................................................. 14
8/19 FAILURE OF PILE................................................................................................. 15
8/20 RECTIFICATION OF FAILURE ............................................................................. 15
8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK ...................................... 16
8/22 CLEARANCE OF WORKS .................................................................................... 16
8/1 DESCRIPTION
8/1.1 All pile foundations shall be bored cast-in-place concrete piles and shall be
constructed as indicated on the Drawings and in compliance with these
specifications.
8/2 MATERIALS
8/2.1 The materials for the manufacture of the reinforced concrete shall be in
accordance with Section 4 - "Concrete Works".
8/2.2 The temporary steel casings and the permanent casings or liners shall be
cylindrical, of the diameter indicated on the Drawings and shall be of sufficient
strength to maintain shape and location during boring and placement of
concrete. The casings shall be sufficiently watertight to exclude ground water
during placing of concrete.
8/2.3 In case drilling, bentonite, as supplied to the site and prior to mixing shall be in
accordance with Specification DFCP 4 of the Oil Companies Materials
Association.

8/3 GROUND CONDITIONS
8/3.1 Factual information and reports on site investigation for the Works will be
provided to tenderers. However, in the event that a full report is given,
including interpretations, opinions or conclusions, no responsibility is accepted
by the Employer.
8/3.2 The Contractor shall report immediately to the Engineer any circumstances
which indicates that in the Contractor's opinion the ground conditions differ
from those reported in or which could have been inferred from the site
investigation reports or trial pile results.
8/4 TOLERANCES
8/4.1 SETTING OUT
Setting out of the main grid line shall be carried out by the Contractor. The
installation of marker pins at pile positions as required by the Engineer shall be
accurate to 75 mm in any direction. An additional tolerance for a pile head cut
off below ground level will be permitted in accordance with Sub-Section 8/13.8
and/or 8/16.
8/4.2 VERTICALITY
At the commencement of installation, the equipment governing the alignment

of the bored pile shall be made vertical to a tolerance of within 1 to 100. The
maximum permitted deviation of the finished pile from the vertical is 1 in 75.
8/4.3 RAKE
The equipment governing the direction and angle of rake shall be set to give
the correct alignment of the pile within a tolerance of 1 in 50. The piling rig
shall be set and maintained to attain the required rake. The maximum
permitted deviation of the finished pile from the specified rake is 1 in 25 for
piles raking up to 1:6 and 1 in 15 for piles raking more than 1:6.
8/4.4 FORCIBLE CORRECTIONS TO PILES
Forcible corrections to concrete piles to overcome errors of position or

alignment shall not be made. Forcible corrections may be made to other piles
only if approved and where the pile shaft is not fully embedded in the soil.
8/5 PILING METHOD AND PROGRAMME
8/5.1 The Contractor shall supply for approval all relevant details of the method of
piling and the plant he proposes to use. Any alternative method to that
specified shall be subject to approval.
8/5.2 The Contractor shall inform the Engineer each day of the intended programme
of piling for the following day and shall give adequate notice of his intention to
work outside normal hours and Public Holidays.

8/5.3 The Contractor shall submit to the Engineer his proposed sequence and timing
for boring piles, having regard to the avoidance of damage to adjacent piles.
8/5.4 Any proposals by the Contractor for ground treatment of any nature or for
temporary lowering of the water table by well pointing or any other method
shall be subject to the approval of the Engineer. The Contractor shall however
remain fully responsible for any effects of such ground treatment or control of
the level of water tables upon the existing roads, building and structures in the
vicinity of works.
8/5.5 Any proposals by the Contractor for underpinning, needling and shoring of
existing structures in the vicinity of the works shall be carefully designed by the
Contractor and be subject to approval of the Engineer.
8/6 PILING RECORDS
8/6.1 The Contractor shall keep records as follows for the installation of each pile
and shall submit two signed copies of these records to the Engineer not later
than noon of the next working day after the pile was installed. The signed
records will form a record of the work.
Any unexpected boring conditions shall be noted in the records.
Data to be recorded
a. Contract
b. Pile reference number (location)
c. Pile type
d. Nominal cross-sectional dimensions or diameter.
e. Nominal diameter of under ream/base.
f. Standing groundwater level from direct observation or given site
investigation data.
g. Date and time of boring.
h. Date of concreting
i. Ground level at pile position at commencement of installation of pile
(commencing surface).
j. Working level on which piling base machine stands
k. Depth from ground level at pile position to pile to
l. Toe level.
m. Pile head level as constructed.
n. Pile Cut-off level.
o. Length of temporary casing
p. Length of permanent casing.
q. Soil samples taken and in situ tests carried out during pile formation or
adjacent to pile position.

r Surrounding soil condition of toe to be recorded”. Condition recording

includes, but not limited, to:
- Presence of rock at toe (either local or overall),

- Soft or strong soil or any abnormality in soil profile at the vicinity of
the pile toe.
s Length and details of reinforcement.
t. Concrete mix.
u. Volume of concrete supplied to pile where this can be measured in
practice.
v. All information regarding obstruction delays and other interruptions to the
sequence of work.
8/7 DAMAGE TO ADJACENT SERVICES AND STRUCTURES
8/7.1 If damage will be, or is likely to be, caused to mains, services or adjacent
structures, the Contractor shall submit to the Engineer his proposals for
making surveys, monitoring movements or vibrations, and minimising or
avoiding such damage.
8/7.2 The Contractor shall carry out the work in such a manner and at such times so
as to minimise noise and disturbance.
8/8 CONCRETE FOR PILES
8/8.1 Concrete for piles shall be Class 30 or as shown on the drawings and shall be
in accordance with Section 4 of the Specification and the following
requirements:
8/8.2 When a designed mix is specified the Contractor shall be responsible for
selecting the mix proportions to achieve the required strength and workability,
but the Engineer will be responsible for specifying the minimum cement
content and any other properties required to ensure durability.
8/8.3 The Concrete shall have sufficient workability to enable it to be placed and
compacted by the methods used in forming the piles.
8/8.4 For piles exposed to potentially aggressive ground or groundwater, approved

measures shall be taken to ensure durability. Reference should be made to
Building Research Establishment Design 363 published in the U.K. relating to
sulphate attack.
8/8.5 The cement content in any mix shall not be less than 360 kg/Cu.m. Where
concrete is to be placed under water or drilling mud by tremmie the cement
content shall be not less than 380 kg/Cu.m., or where the pile will be exposed
to sea water 400 kg/Cu.m.

8/8.6 All concrete aggregates, cement and water shall be sampled and tested as
frequently as deemed necessary by the Engineer as detailed under the
relevant clauses in section 4 concrete work. All test samples shall be supplied
by the Contractor at his own expense.
8/8.7 Trial mixes shall be prepared for concrete in accordance with BS 5328,
showing that the proposed mix proportions and manufacture will produce a
concrete of the strength and quality required, having adequate workability for
compaction by the method to be used in placing.
8/8.8 The Contractor shall keep a detailed record of the results of all tests on
concrete and concrete materials. Each test shall be clearly identified with the
piles to which it relates.
8/9 REINFORCEMENT FOR PILES
8/9.1 The reinforcement for the piles shall conform to the requirement of SECTION
4 of the specification.
8/9.2 Reinforcement in the form of a cage shall be assembled with additional

support, such as spreader forks and lacings, necessary to form a cage which
can be lifted and placed without permanent distortion. Intersecting bars shall
be fixed together by approved means. Hoops, links or helical reinforcement
shall fit closely around the main longitudinal bars and be bound to them by
approved wire, the ends of which shall be turned into the interior of the pile.
Reinforcement shall be placed and maintained in position to provide the
specified projection of reinforcement above the final cut-off level.
8/9.3 The cover to all reinforcement in cast-in-place piles shall be not less than
75mm unless otherwise approved by the Engineer. Spacers shall be designed
and manufactured using durable materials which will not lead to corrosion of
the reinforcement or spalling of the concrete cover.
8/9.4 The number of laps in longitudinal steel bars shall be kept to a minimum.
Joints in reinforcement shall be such that the full strength of each bar is
effective across the joint and shall be made so that there is no detrimental
displacement of the reinforcement during the construction of the pile.
8/10 BORING FOR PILES
8/10.1 Prior to boring the Contractor shall check the casing position for each pile
during and immediately after placing the casing, and agree it with the
Engineer.
8/10.2 Where the open bore is unstable, temporary casing, or bentonite suspension
may be used to support the wall of the bore prior to concreting.
8/10.3 Piles shall not be bored so close to other piles which have recently been cast
and which contain workable or unset concrete that a flow of concrete could be
induced from or damage caused to any of the piles.

8/10.4 The Contractor shall carry out the work in such a manner and at such times as
to minimise noise and disturbance.
8/10.5 Any proposals by the Contractor for ground treatment of any nature or for
temporary lowering of the water table by well pointing or any other method
shall be subject to the approval of the Engineer. The Contractor shall however
remain fully responsible for any effects of such ground treatment or control of
the level of water tables upon the existing roads, buildings and structures in
the vicinity of the Works.
8/10.6 Any proposals by the Contractor for underpinning, needling, and shoring
structures in the vicinity of the works shall be carefully designed by the
Contractor and be subject to the approval of the Engineer.
8/10.7 Temporary casings shall be free from significant distortion. They shall be of
uniform cross-section throughout each continuous length. During concreting
they shall be free from internal projections and encrusted concrete which
might adversely affect the proper formation of piles.
8/10.8 Where piles are bored under water or bentonite suspension in an unlined
state, the insertion of a full-length loosely fitting casing to the bottom of the
bore prior to placing concrete will not be permitted.
8/10.9 Where boring takes place through unstable water bearing strata, the process
of excavation and the depth of temporary casing employed shall be such that
soil from outside the area of the pile is not drawn into the pile section and
cavities are not created outside the temporary casing as it is advanced.
8/10.10 Where the use of drilling fluid is specified or approved for maintaining the
stability of a bore, an adequate temporary casing shall be used in conjunction
with the method so as to ensure stability of the strata near ground level until
concrete has been placed. During construction the level of drilling fluid in the
pile excavation shall be maintained within the cased or stable bore so that it is
not less than 1.0 m above the level of external standing groundwater at all
times.
In the event of rapid loss of drilling fluid from a pile excavation, the bore shall
be backfilled without delay and the instruction of the Engineer shall be
obtained before boring at that location is resumed.
8/10.11 All reasonable steps shall be taken to prevent the spillage of bentonite
suspension on the Site in areas outside the immediate vicinity of boring.
Discarded bentonite shall be removed from the Site without undue delay. Any
disposal of the bentonite shall comply with the regulations of the Dubai
Municipality.
8/10.12 Pumping from pile bores shall not be permitted unless the bore has been
sealed against further water entry by casing or unless the soil is stable and will
allow pumping to take place without ground disturbance below or around the
pile.
8/10.13 For a pile constructed in a stable cohesive soil without the use of temporary
casing or other form of support, the pile shall be bored and concrete shall be

placed without such delay as would lead to significant impairment of the soil
strength.
8/10.14 Each pile bore which does not contain standing water or drilling fluid shall be
inspected directly or indirectly prior to concrete being placed in it. This
inspection shall be carried out from the ground surface in the case of piles of
less than 750mm diameter. Torches or other approved means of lighting,
measuring tapes, and a means of measuring verticality shall be provided. For
piles of 750mm diameter or larger, equipment shall be provided by the
Contractor to enable his representative and the Engineer to descend into the
bore for the purpose of inspection. Any method of descent and the equipment
used shall comply with the requirements of BS 8008: 1996+A1, AMD 1: 2008.
8/10.15 On completion of boring and where inspection of a dry pile bore indicates the
necessity, loose disturbed or softened soil shall be removed from the bore.
Where pile bores contain water or drilling fluid, a cleaning process shall be
employed before concrete is placed. Large debris/or accumulated sediment
shall be removed using appropriate approved methods, which shall be
designed to clean while at the same time minimising ground disturbance below
the pile bases.
Water or drilling fluid shall be maintained at such levels throughout and

following the cleaning operation that stability of the bore is preserved.
8/11 DRILLING FLUID
8/11.1 Bentonite, as supplied to the Site and prior to mixing, shall be in accordance
with Specification DFCP 4 of the Oil Companies Materials Association.
8/11.2 A certificate shall be obtained by the Contractor from the manufacture of the
bentonite powder, showing the properties of each consignment delivered to
the Site. This certificate shall be made available to the Engineer on request.
The properties to be given by the manufacturer are the apparent viscosity

range (in centipoises) and the gel strength range (in Newton per square metre)
for solids in water.
8/11.3 Bentonite shall be mixed thoroughly with clean fresh water to make a
suspension which will maintain the stability of the pile bore for the period
necessary to place concrete and complete construction. The temperature of
the water used in mixing the bentonite suspension, and of the suspension
when supplied to the borehole, shall be not lower than 5 deg. C.
8/11.4 Where saline or chemically contaminated groundwater occurs, special

precautions shall be taken to modify the bentonite suspension or pre-hydrate
the bentonite in fresh water so as to render it suitable in all respects for the
construction of piles.
8/11.5 The frequency of testing drilling fluid and the method and procedure of
sampling shall be proposed by the Contractor for approval prior to the

commencement of the work. The frequency may subsequently be varied as

required, depending on the consistency of the results obtained, subject to
approval.
Control tests shall be carried out on the bentonite suspension, using suitable
apparatus. The density of freshly mixed bentonite suspension shall be
measured daily as a check on the quality of suspension being formed. The
measuring device shall be calibrated to read to within 5g/L.
Tests to determine density, viscosity, shear strength and pH value shall be

applied to bentonite supplied to the pile bore. For average soil conditions the
results shall generally be within the ranges in Table 1.
The tests shall be carried out until consistent working pattern has been
established, account being taken of the mixing process, any blending of
freshly mixed bentonite suspension and previously used bentonite suspension.
When the results show consistent behaviour, the tests for shear strength and
pH value may be discontinued, and tests to determine density and viscosity
shall be carried out as agreed with the Engineer.
In the event of a change in the established working pattern, tests for shear
strength and pH value shall be reintroduced for a period if required.
Table 8- 1: Average soil conditions ranges
Property to be Range of results Test Method

measured at 20 deg. C
Density Less than 1.10g/ml Mud density balance
Viscosity 30-90s Marsh cone method

or
less than 20 cP Fann Viscometer
Shear strength 1.4-10N/Sq.m. Rehometer

or
4-40N/Sq.m. Fann Viscometer
pH 9.5 - 12 pH indicator paper

strips
or electrical pH meter

The testing methods pertaining to the above table should confirm to API –
RP13B (standard procedure for testing drilling fluids).
* Where the Fann Viscometer is specified, the fluid sample should be

screened by a number 52 sieve (300 u) prior to testing.
8/12 PLACING CONCRETE
8/12.1 The method of placing and workability of the concrete shall be such that a
continuous monolithic concrete shaft of the full cross-section is formed.
8/12.2 The concrete shall be placed without such interruption as would allow the
previously placed batch to have hardened. The method of placing shall be
approved.
8/12.3 The Contractor shall take all precautions in the design of the mix and placing
of concrete to avoid arching of the concrete in temporary casing. No soil,
liquid or other foreign matter which would adversely affect the performance of
the piles shall be permitted to contaminate the concrete.
8/12.4 Slump measured at the time of discharge into the pile bore shall be in
accordance with the standards shown in Table 2.
The concrete shall be of the workability approved when in its final position and
shall remain sufficiently workable for all pile construction procedures to be
safely completed.
Table 8- 2: concrete Slump for pile foundation
Piling Mix Slump Typical conditions of Use

Workability Minimum Range
mm mm
A 75 75-150 Placed into water free

permanently lined bore of
600mm dia. or over, or where
casing level lies below
temporary casing;
reinforcement widely spaced,
leaving ample room for free
movement of concrete between
bars.
B 100 100-200 Where reinforcement is not

spaced widely; where cut-off
level of concrete is within
temporary casing; where pile
bore is water-free and the
diameter is less than 600mm.

C 150 150 or Where concrete is to be placed

more by tremie under water or drilling
mud or by pumping.
8/12.5 Internal Vibrators shall not be used to compact concrete.
8/12.6 Approved measures shall be taken to ensure that the structural strength of
concrete placed in all piles is not impaired through grout loss, segregation or
bleeding. Concrete shall be directed vertically into the centre of each vertical
pile so that grout is not lost from the initial discharge.
8/12.7 Before placing concrete, measures shall be taken to ensure that there is no
accumulation of silt or other material at the base of the boring, and the
Contractor shall ensure that heavily contaminated bentonite suspension, which
could impair the free flow of concrete from the tremie pipe, has not
accumulated in the bottom of the hole.
8/12.8 Concrete to be placed under water or drilling fluid shall be placed by tremie
and shall not be discharged freely into the water or drilling fluid. Pumping of
concrete may be approved where appropriate.
8/12.9 A sample of the bentonite suspension shall be taken from the base of the
boring using an approved sampling device. If the specific gravity of the
suspension exceeds 1.20 the placing of concrete shall not proceed. In this
event the Contractor shall modify or replace the bentonite as approved to meet
the Specification.
8/12.10 The concrete shall be a rich coherent mix of high workability and cement in
accordance with Subsection 8/8.5 and mix C, Table 2. The concrete shall be
placed in such a manner that segregation does not occur.
8/12.11 The hopper and pipe of the tremie shall be clean and watertight throughout.
The pipe shall extend to the base of the bore and a sliding plug or barrier shall
be placed in the pipe to prevent direct contact between the first charge of
concrete in the tremie and the water or drilling fluid. The pipe shall at all times
penetrate the concrete which has previously been placed and shall not be
withdrawn from the concrete until completion of concreting. A sufficient
quantity of concrete shall be maintained within the pipe to ensure that the
pressure from it exceeds that from the water drilling fluid. The internal
diameter of the pipe of the tremie shall be not less than 150 mm for concrete
made with 20mm aggregate. It shall be so designed that external projections
are minimised, allowing the tremie to pass within reinforcing cages without
causing damage. The internal face of the pipe of the tremie shall be free from
projections.
8/12.12 No concrete shall be placed until all driving within a radius of 4.5 meters has
been completed, nor until all the shells for any one cluster have been
completely driven. If this cannot be done, all driving within above limits shall
be discontinued until the concrete in the last pile cast, has been set for at least
seven days.

8/12.13 Unless designated as basement piles all piles shall be placed with their tops at
least 1 metre above pile cut-off level in their respective pile caps. All
boreholes, except for basement piles or unless otherwise specified, shall be
filled with concrete to the top of the hole so that the Engineer can be assured
that all the bentonite has been displaced by the concrete.
8/13 EXTRACTION OF CASING
8/13.1 Temporary casings shall be extracted while the concrete within them remains
sufficiently workable to ensure that the concrete is not lifted. During extraction
the motion of the casing shall be maintained in an axial direction relative to the
pile.
8/13.2 When the casing is being extracted, a sufficient quantity of concrete shall be
maintained within it to ensure that pressure from external water, drilling fluid or
soil is exceeded and that the pile is neither reduced in section nor
contaminated.
8/13.3 The concrete level within a temporary casing shall be topped up where
necessary during the course of casing extraction in such a way that the base
of the casing is always below the concrete surface until the casting of the pile
has been completed.
8/13.4 Adequate precautions shall be taken in all cases where excess heads of water
or drilling fluid could occur as the casing is withdrawn because of the
displacement of water or fluid by the concrete as it flows into its final position
against the walls of the pile bore. Where two or more discontinuous lengths of
casing (double casing) are used in the construction the proposed method of
working shall be approved by the Engineer.
8/13.5 For piles cast in dry bores using temporary casing and without the use of a
permanent lining, pile heads shall be cast to a level above the specified cut-off
so that, after trimming, a sound concrete connection with the pile can be
made. The casing level shall be within the tolerance above the cut-off level
shown in Table 3 but shall not be above the commencing surface level.
No pile shall be cast with its head below standing water level unless approved
measures are taken to prevent inflow of water causing segregation of the
concrete as temporary casing is extracted; and where applicable, the standing
water level for each pile shall be agreed with the Engineer, and this level is to
be treated as the cut-off level for the purpose of calculating tolerance.
8/13.6 For piles cast in dry bores within the permanent lining tubes or permanent
casings, or where their cut-off levels are in stable ground below the base of
any casing used, pile heads shall be cast to a level above the specified cut-off
so that, after trimming, a sound concrete connection with the pile can be
made. The casting level shall be within the tolerance above the cut-off level
shown in Table 4, but shall not be above the commencing surface level.
8/13.7 For piles cast under water or drilling fluid, the pile heads shall be cast to a
level above the specified cut-off so that, after trimming to remove all debris
and contaminated concrete, a sound concrete connection with the pile can be
made. The casing level shall be within the tolerance above the cut-off level

shown in Table 5, but shall not be above the commencing surface level. Cut-
off levels may be specified below the standing groundwater level, and where
this condition applies the borehole fluid level shall not be reduced below the
standing groundwater level until the concrete has set.
8/13.8 Where the cut-off level of piles lies at depths greater than 10m below the
commencing surface, than the tolerances given in Tables 3 - 5 will be varied
after discussion with the Contractor and before commencement of the piling to
take account of the special conditions which apply.
8/13.9 During extraction of temporary casings, where circumstances are such that
newly placed unset concrete is brought into contact with external groundwater,
precautions shall be taken to ensure that the internal concrete pressure at all
levels within the pile exceeds the external groundwater pressure.
Table 8- 3: Casting tolerance above cut-off level for piles cast in dry bores using
temporary casing and without the use of a permanent lining
Cut-off distance below Casting tolerance above

commencing surface Cut-off Level m
H(m)
0.3+H/12+C/8
0.15 - 10.00 Where C=length of
temporary casing below
the commencing surface *
 If H is greater than C this tolerance is no longer applicable and the tolerances in Table 4 will
apply.
Table 8- 4: Casting tolerance above cut-off level for piles cast in dry bores within
permanent lining tubes or permanent casings, or where their cut-off levels are in
stable ground below the base of any casing used.
Cut-off distance below Casting tolerance above

commencing surface H(m) Cut-off Level m
0.15 - 10.00 0.3+H/10
Table 8- 5: Casting tolerance above Cut-off level for piles cast under water or drilling fluid*.
Cut-off distance below commencing Casting tolerance above Cut-off

surface H,m Level m
0.15 - 10.00 1.0+H/12+C/8

Where C=length of temporary
casing below
the commencing surface
* In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
tolerance is given by deletion of the casing term C/8 in the table.

8/14 TEMPORARY BACKFILLING
8/14.1 After each pile has been cast, any empty bore remaining shall be protected
and shall be carefully backfilled as soon as possible with the approved
materials.
8/15 DISPOSAL OF EXCAVATED MATERIAL
8/15.1 Disposal of excavated material shall be carried out by the Contractor as

necessary to facilitate the works and to the satisfaction of the Engineer.
8/16 CUTTING OFF PILE HEADS
8/16.1 When cutting off and trimming piles to the specified cut-off level, the
Contractor shall take care to avoid shattering or otherwise damaging the rest
of the pile. Any cracked or defective concrete shall be cut away and the pile
repaired in an approved manner to provide a full and sound section at the cut-
off level.
8/17 INTEGRITY TESTING OF PILES
All testing shall be carried out as per Laboratory Testing Clause.
8/17.1 Where integrity-testing is called for but the method is not specified, the method
to be adopted shall be approved by the Engineer and shall be one of the
following:
a. Sonic Method - ASTM – D 5882: 2007

b. Vibration Method - ASTM – D 4945: 2000
c. Sonic Logging - ICE – Section9: 1996
8/17.2 Other methods may be adapted to the approval of the Engineer and subject to
satisfactory evidence of performance.
8/17.3 In the cast-in-place concrete piles, integrity tests shall not be carried out until 7
days or more have elapsed since pile-casting unless otherwise approved.
8/17.4 Where the method of testing requires the positioning of sensing equipment on
the pile head, the head shall be clean, free from water, laitance, loose
concrete, over spilled concrete and blinding concrete, and readily accessible
for the purpose of testing.
8/17.5 The testing shall be carried out by an approved specialist firm in accordance
with the DM Administrative Decision No.(160) for year 2000.
8/17.6 The interpretation of tests shall be carried out by competent persons and the
full test results and findings shall normally be given to the engineer within 10
days of the completion of each phase of testing. Full details of the ground
conditions and construction method shall be made available to the specialist
firm when required in order to facilitate interpretation of the tests.

8/18 LOADING TESTS
All testing shall be carried out as per Laboratory Testing Clause.
8/8.1 Each test pile and working pile to be tested shall be loaded axially to 2.0 times
and 15 times the working load respectively as specified on the Drawings. The
tests shall not be commenced until the concrete has reached 90% of its design
strength and shall be maintained on the pile as aforementioned or for such
further period as the engineer may direct.
8/18.2 Loading tests shall be carried out (according to BS 8004 Clause 7.5.5) at the
date ordered on individual piles selected by the Engineer.
8/18.3 Piles selected by the Engineer shall be tested as follows:
a. The test load shall be applied by a method approved by the Engineer

and shall be measured within an accuracy of 2 percent. Settlements
shall be measured within an accuracy of 0.25mm.
b. The test load and unloading shall be applied in suitable increments and
as smoothly and expeditiously as possible.
c. The load after each increment shall be kept constant until the rate of
settlement does not exceed 0.25 mm per hour.
d. The amount of settlement shall be recorded before the next load

increment.
e. The full test load shall be maintained for 48 hours and the total
settlement recorded.
f. The load after each reduction shall be kept constant until the rate of
recovery does not exceed 0.25 mm per hour.
g. The amount of recovery shall be recorded before the next load reduction.
h. The Contractor shall, within 24 hours of the completion of the test, submit
to the engineer for each pile tested graphs showing:
- Load and settlement plotted above and below a common base line
of time
- Settlement and recovery plotted vertically against a base line of

time.
i. The settlement of the pile under the test load and the recovery of the pile
after its subsequent removal shall be within the limits agreed with the
Engineer.
8/18.4 The temporary caps will be cut away and the debris removed by the
Contractor.
8/18.5 The Contractor shall keep detailed records in collaboration with the Engineer
of the settlement and recovery of the pile as the increment of load are applied
and removed respectively.

8/18.6 The Contractor shall provide the Engineer with two copies of his records of
each test.
8/18.7 If the tests indicate that, in the opinion of the Engineer, the piles are
unsatisfactory for the working load, the Contractor shall at his own expense
replace the tested pile in a suitable position and if necessary support to be
given to the structure to be carried.
8/18.8 The Contractor shall bear the cost of any additional work made necessary as a
result of the unsatisfactory pile or piles. The Contractor shall also satisfy the
Engineer that any piles constructed prior and subsequent to the results of the
tests being known are capable of carrying the specified working load. Further
tests shall be carried out, if required by the engineer, and any piles deemed to
be unsatisfactory by the Engineer shall be replaced or augmented by further
piles. No extra cost will be accepted or extension of time granted in
connection with the foregoing work.
8/18.9 The Contractor shall state in his proposals the measures he intends to take if
the ultimate load of any pile fails to reach the required value under the loading
test, with regard to lengthening, re-driving and retesting of the test pile, and
also to the provision of additional piling to augment or replace the tested pile.
No extra cost will be accepted or extension of time granted in connection with
the foregoing work.
8/19 FAILURE OF PILE
8/19.1 A pile shall be considered to have failed when any of the following conditions
apply:
- On completion of a load test, the residual settlement after rebound

exceeds 6 mm.
- The test load as specified in the contract shall not have been achieved.
- The maximum settlement exceeds 1 % of the least lateral dimension of

the pile under ultimate load.
8/20 RECTIFICATION OF FAILURE
8/20.1 In the event of a pile failing a load test, notwithstanding any contrary proposals
by the Contractor, the Engineer may insist on the following methods of
rectification (as a minimum):
- When a trial pile - an additional trial pile shall be driven as directed by the
Engineer and tested. If this second trial pile fails, the Engineer shall
order such changes in the design of the pile as he considers necessary.
- When part of the main piling operation - a further pile in the same group
shall be tested. If this second test pile fails, the Engineer shall order
such changes in the design of the pile/pile group as he considers
necessary.

8/20.2 In the case of the first pile of the main piling operation failing a test load, but
subsequent piles passing the load test, a new pile shall be driven to replace
the defective pile in a position agreed by the Engineer at the expense of the
Contractor.
8/20.3 In the event of additional works being carried out as a result of new piles being
required under this Clause, the cost of this additional work will be at the
expense of the Contractor.
8/21 PROTECTION OF PILING FROM CHEMICAL ATTACK
8/21.1 All Piles shall have protective sleeve for a minimum depth of 3 m below the cut-
off level of the pile. This sleeve shall be plastic or metal bedded in mastic to
form a fully water-proofed seal to the concrete.
8/22 CLEARANCE OF WORKS
8/22.1 Upon the completion of the works the Contractor shall clear away and remove
from the Site all constructional plant, equipment, surplus materials, rubbish,
etc. and leave the whole of the Site and Works clean and in perfect condition
to the satisfaction of the Engineer.

Part-1-Road Works - Rev

Uploaded by

Copyright:

Available Formats

You might also like

Part-1-Road Works - Rev

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Part-1-Road Works - Rev

Uploaded by

Copyright:

Available Formats

PROJECT:

CONSULTANCY SERVICES FOR ENTRY JUNCTION

CONSULTANCY SERVICES FOR ENTRY JUNCTION

Roads and Transport Authority

SI is the symbol for the International System of Units.

2 SITE CLEARNCE AND EARTHWORKS

6 WORKS IN CONNECTION WITH SERVICES

7 ROADWAY LIGHTING AND TRAFFIC SIGNALS

1/1 SITE ESTABLISHMENT ...................................................................................... 2

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 1

1/1 SITE ESTABLISHMENT

It is the Contractor’s responsibility to obtain all necessary No Objection

1/2 SITE OFFICE FOR THE ENGINEER

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 2

1/3 OFFICES AND FACILITIES FOR THE CONTRACTOR

1/3.3 All temporary accommodation shall be maintained in an efficient condition

1/4 CONSTRUCTION PLANT & WORKSHOP FOR THE CONTRACTOR

1/5 CONTRACTOR’S SITE ORGANISATION

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 3

by the Contractor for this purpose including the supply of a minimum 2

1/6 SURVEYING EQUIPMENT

1/7 LABORATORY TESTING

1 Dubai Municipality – Dubai Central Laboratory (D.C.L) in accordance

2 Independent Laboratory in accordance with Appendix “A2”.

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 4

1/8 PROGRAMME OF WORKS

 Traffic detour scheme preparation, planning, phasing, submittal and

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 5

roads department. Material report shall contain monthly summaries on

1/9 WORK SITE, SETTING OUT AND CROSSSECTIONS

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 6

of the Engineer & DM Planning & Survey Department shall be obtained.

1/10 PROJECT SIGN BOARDS

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 7

1/11 PROJECT PHOTOGRAPHS

1/11.3 One set of photos of digital format to be prepared / processed by an

1/12 QUALITY OF MATERIALS AND SUPPLY

No material shall be supplied to the site before the Engineer’s approval of

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 8

material to confirm its continued suitability for use.

No material shall be supplied on the site before the Engineer’s approval of

1/12.8 Wherever in the Specifications tests on materials, tests on completed work

a. UAE & DM Standards

1/12.9 Where specific material or equipment is referred to in the Contract, it is

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 9

1/12.14 All materials or manufactured items shall be carefully loaded, transported,

1/12.16 Prior to ordering or delivering any material or manufactured items to the

All products/materials shall be certified by Dubai Central Laboratory of

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 10

1/13 APPROVAL BY THE ENGINEER

1/13.3 When items to be incorporated into the Works are to be manufactured or

1/14 EXISTING SERVICES AND SERVICE DIVERSIONS

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 11

concerned parties by issue of formal “Notice of Intent” and must obtain

CD’s containing the drawings data to be supplied to the Engineer in the

If in the execution of the Works, by reason of any subsidence caused by,

Volume 2, Part 1, General Specifications-Roads Works July 2018 Page 12

Drawings must be prepared using a Computer Aided Drafting program