TABLE OF CONTENTS

1.0 General
1.1 Scope
1.2 Related Documents
1.3 Definitions
1.4 Setting Out

2.0 Formation
2.1 Excavation
2.2 Preparation Of Formation
2.3 Protection Of Formation

3.0 Sub Base

3.1 General
3.2 Material
3.3 Compaction

4.0 Roadbase And Surfacing

4.1 Prime Coat
4.2 Base Course
4.3 Wearing Course
4.4 Finish To Shoulders

5.0 Concrete Roads And Paving

5.1 Materials And Workmanship
5.2 Reinforcement
5.3 Membrane
5.4 Compaction
5.5 Joints

6.0 Tolerances
6.1 Asphalted Areas
6.2 Concrete Paving

7.0 Tests
7.1 General
7.2 Density Test
7.3 Moisture-Density Relations
7.4 California Bearing Ratio
7.5 Frequency Of Testing

8.0 Kerbs And Gullies

8.1 Kerbs
8.2 Gullies

9.0 Precast Concrete Paving

9.1 Paving Slabs
9.2 Edge Kerbs
9.3 Laying Paving Slabs

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 9.4 Laying Edge Slabs

1.0 GENERAL

1.1 Scope

This specification describes the materials and workmanship required in

construction of road bases and their surfacings for roads and paved
areas, and the construction of kerbs and hard shoulders. Latest revisions
of the codes specified in this document are to be used.

1.2 Related Documents

1.2.1 Cristal Standard Specifications

SP-Q-01 Specification for concrete materials and
construction
SP-S-02 Specification for earthworks
SP-S-03 Specification for drainage

1.2.2 Codes and Standards

BS 6031 Earthworks
BS 594 Rolled asphalt (hot process) for roads and other
areas

1.2.3 Miscellaneous Specifications

“Specification for Road and Bridge Works”, AASHTO

1.3 Definitions

1.3.1 Formation – the existing ground level, embankment or cut

prepared ready to receive the sub-base.

1.3.2 Sub-base – the layer of road making material laid on top of the
formation and below the surfacing.

1.3.3 Roadbase and surfacing – the road construction laid on the sub-
base which are combined in the case of concrete pavements.

1.4 Setting Out

1.4.1 Before any work is begun, the Sub-contractor shall submit for
Cristal’s approval his proposals for setting out and for controlling
the locations and elevations of the roads and paving to the
dimensions and levels shown on the contract drawings.

1.4.2 The Sub-Contractor shall give Cristal not less than 48 hours
notice in writing of his intention to set out the works to enable
Cristal to make arrangements for checking.

1.4.3 The check by Cristal shall in no way absolve the Sub-Contractor

from his responsibility for setting out the works correctly.

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 1.4.4 Where construction of new works requires closure or diversion
of existing roads details of methods and schedules shall be
submitted by the Subcontractor for Cristal approval.

2.0 FORMATION

2.1 Excavation

2.1.1 Excavation shall generally be in accordance with Specification

SP-S-02.

2.1.2 Excavation shall be carried out on the lines, levels and profiles
required for the work or as shown on the drawings and to the
tolerances indicated in Specification SP-S-02. If the Sub-
Contractor proposes to run construction traffic along the route of
the road construction he shall leave sufficient cover over the
formation level to prevent disturbance of original material below
formation level.

2.2 Preparation of Formation

2.2.1 Preparation and surface treatment of the formation shall be

carried out only after completion of any sub grade drainage and,
unless agreed otherwise by Cristal, immediately prior to laying
the sub-base. The Sub-Contractor shall ensure that adequate
measures are taken to keep the working areas free from running
or standing water at all times once preparation of the formation
has commenced.

2.2.2 The formation shall be trimmed to the required levels and

profiles and proof rolled using a vibratory roller of approximately
10 tons in weight to compact the surface and determine any soft
spots. The latter shall be excavated as directed by Cristal and
backfilled in accordance with Specification SP-S-02, Clause
5.6.3. Notwithstanding, the compaction requirements above the
finished formation shall have a density, for at least a depth of
200mm, of at least 95% of the maximum density as determined
by ASTM D-1557.

2.3 Protection of Formation

2.3.1 The completed formation shall not be used by vehicles and the
Sub-Contractor shall take measures to prevent vehicular access
onto the completed formation.

2.3.2 The Sub-Contractor shall ensure that the formation is not

damaged as a result of weather conditions. Any formation
which is susceptible to deterioration when exposed to wet or
inclement weather shall, if not immediately covered with the
subsequent road construction material, be protected by a layer
of polythene sheeting

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 2.3.3 Temporary ditches or other means shall be employed to effect
the rapid discharge of water from formations and to exclude
water from other areas.

3.0 SUB-BASE

3.1 General

The thickness and extent of the sub-base shall be in accordance with

the drawings.

3.2 Material

The sub-base granular material shall comprise natural gravel, crushed

gravel, crushed slag, and crushed concrete or well burnt non-plastic
shale, with a maximum aggregate size of 37.5 mm. Material shall be
obtained from a source approved by Cristal.

3.3 Compaction

The material must be placed in layers not exceeding 150 mm

compacted thicknesses and within 1% above and 2% below optimum
moisture content.

Each layer must be compacted with a minimum of four passes of a 10

ton vibratory roller to 95% maximum dry density at the optimum
moisture content and achieve a minimum CBR (California Bearing
Ratio) value of 25% when saturated.

4.0 ROADBASE AND SURFACING

4.1 Prime Coat

A prime coat shall be sprayed on the road sub-base prior to the

placement of the base course layer.

The prime coat shall consist of low viscosity medium-curing cut back
bitumen (MC30 or MC70). The application rate shall be 0.9 litres per
square meter.

4.2 Base Course

Base course shall comprise hot-laid and plant mixed asphalt-concrete,

mechanically spread and rolled to a minimum acceptable thickness of
40mm all in accordance with “Specification for Roads and Bridgework”.

4.3 Wearing Course

Wearing course shall comprise hot-laid asphalt-concrete, mechanically

spread and rolled to minimum acceptable thickness of 40mm all in
accordance with “Specification for Roads and Bridgework”.
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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 4.4 Finish of Shoulders

After completion of the road paving the hard shoulder shall be brought up
with sub base material to the correct profile. After compaction, the
surface shall be protected from erosion by spraying with cut-back
bitumen.

5.0 CONCRETE ROADS AND PAVING

5.1 Materials and Workmanship

5.1.1 Generally the materials and workmanship shall be in

accordance with Specification SP-Q.01. The following additional
clauses shall apply.

5.1.2 Unless noted otherwise concrete shall be grade C40.

5.2 Reinforcement

5.2.1 Mesh reinforcement shall be BS4483 and the reference shall be

as stated on the drawings.

Where one layer of reinforcement is shown it shall be placed on

top of the slab with 50mm cover and at least 50mm cover to the
edges. Reinforcement shall not continue through the expansion
joints.

5.3 Membrane

5.3.1 Concrete shall be placed on a 500 micron thick polythene sheet

membrane with laps at least 300mm wide.

5.4 Compaction

5.4.1 The concrete shall be compacted initially by hand held vibrating

pokers and then the surface leveled and compacted using a
hand guided vibrating beam.

5.5 Joints

5.5.1 Joints shall be in accordance with details shown on the drawings

and as described in Specification SP-Q-01. Expansion joints
shall be at a maximum of 30 metres with contraction joints at 10
metres unless shown otherwise on the drawings. Transverse
and longitudinal construction joints shall be placed at a
maximum of 6.0 and 4.5 metres respectively.

5.5.2 Roads wider than 4.5 metres shall have a central longitudinal
joint.

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 5.5.3 The sub-Contractor shall normally construct complete bays
between the contraction or expansion joint locations. Any
additional joints required by the Contractor shall be subject to
Cristal’s approval and shall be at the Sub-Contractor’s expense.

5.5.4 The Sub-Contractor shall submit, for Cristal’s approval, a

drawing showing the location of all joints prior to
commencement of the work.

5.5.5 Finishes to concrete paved areas shall be type K3 and finishes

to concrete roads type K2 as described in Specification SP-Q-
01.

5.5.6 The routes of direct buried cables through concrete paved areas
shall be identified by a red mass concrete strip 100mm thick
over the full width of the trench.

6.0 TOLERANCES

6.1 Asphalt and Concrete Roads and Parking Areas

The completed work and the work at each stage shall not deviate from
the levels, falls, thicknesses and alignments required by the drawings
or specifications by more than the following tolerances:
Formation level +20mm – 30mm
Sub-base level +10mm - 30mm
Roadbase level + 15mm
Basecourse and wearing course levels + 6mm
Local irregularities in levels for wearing Not more than 3mm
course in 6 metres
Irregularities in alignment + 12mm

6.2 Concrete Paving

6.2.1 Plane surfaces shall be true to line to within 3.5mm maximum

deviation in any 3m length.

7.0 TESTS

7.1 General

The following tests shall be carried out by the Sub-Contractor as part of

Sub-Contractor’s quality assurance programme.

The Sub-Contractor shall have the required tests performed by an

approved properly qualified independent agency except as agreed by
Cristal and shall supply Cristal with two copies of all relevant test
certificates.

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 7.2 Density Test

Test for Density of Soil in Place as described in ASTM D1556-64

(AASHTO T.191).

7.3 Moisture Density

Test for Moisture – Density Relations of Soils as described in ASTM

D1157-70 (AASHTO T.180).

7.4 California Bearing Ratio

Determination of the California Bearing Ratio BS 1377 – Test 16.

7.5 Frequency of Testing

The above mentioned tests shall be made at least once every 100
linear metres of road, unless directed otherwise by Cristal.

8.0 KERBS AND GULLIES

8.1 Kerbs

8.1.1 Precast concrete kerbs comply with BS 340, Figure 7.

8.1.2 The kerbs shall be bedded on and backed by 150mm of

concrete grade C20.

8.1.3 Radius kerbs shall be used when the radius is less than twelve
metres.

8.1.4 When reinforced concrete is used for the road construction the
joints in the kerbs shall match the joints in the concrete slab.

8.2 Gullies

8.2.1 Road gullies shall be salt glazed ware to BS 5911 or concrete to

BS 65. The sizes and locations shall be as indicated on the
drawings. All gullies shall have traps and rodding eyes.

8.2.2 Gullies shall be bedded on and surrounded by 150mm thick plan

concrete grade C20.

8.2.3 Gully grating shall conform to BS497, Grade A and shall be

hinged and not less than 450mm square.

9.0 PRECAST CONCRETE PAVING

9.1 Paving slabs shall be 500mm X 500mm X 50mm thick and shall
conform to BS 368.
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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3
 9.2 Edge kerb to paving slabs shall be 50mm X 150mm precast concrete
and shall conform to BS 340.

9.3 Paving slabs shall be laid to a true and even level with 10mm wide
joints staggered in one direction. They shall be laid on 50mm thick
sand bed.

9.4 Edge kerb shall be bedded and haunched with 150mm thickness of
concrete grade C20.

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CEP-II Project Specification for: ROADS AND PAVING Doc No: SP-S-04 Rev No: 3