PENSWASTAAN PENYENGGARAAN

JALAN PERSEKUTUAN
SEMENANJUNG MALAYSIA

PROJECT QUALITY PLAN

MILL AND PAVE

Lokasi : …………………………………………………

LOGO
SYARIKAT
KONSESI

CAWANGAN SENGGARA FASILITI JALAN

IBU PEJABAT JKR ALAYSIA ALAMAT SYARIKAT
KUALA LUMPUR
 PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL

Revision No. :
MILL AND PAVE

1.0 OBJECTIVE

To outline the method by which mill and pave works is to be carried out as per standard
specifications.

2.0 SCOPE

This procedure shall be applicable for mill and pave works. The scope of work shall include:
a) Supply all necessary materials;
b) Provide all labours and equipment necessary to execute the work; and
c) Execute the work in accordance to drawings and specifications.

3.0 DEFINITION

Mill and pave is defined as a process of removing the prescribed thickness of existing
bituminous layer by using a milling machine and replace it with a new bituminous layer.

The milling process includes milling the existing bituminous layer, removal of milling waste,
clean the surface from all debris and loose materials and dipping of the milling thickness
before receiving the inlay or overlay of ACBC and/or ACWC layer.

The paving process include laying a layer of asphaltic concrete binder course and/or
wearing course on a prepared and accepted bituminous or bitumen primed milled surface.
This work shall consist of cleaning the surface prior to overlaying, furnishing, placing,
shaping and compacting all in accordance to the specification.

4.0 PROCEDURES

4.1 Upon receiving Work Order from the S.O., the Project Manager shall prepare and
submit Project Quality Plan (PQP) which consist of the following for approval by the
S.O.;
a. Traffic Management Plan (TMP)
b. Layout Plan/Strip Map
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 PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL

Revision No. :
MILL AND PAVE

c. Work Program
d. Method Statement
e. Design Mix/Job Mix Formulae
f. Bills of Quantities
g. Plant and Equipment Checklist

4.2 Upon approval of the PQP, the Project Manager shall proceed with site
possession, mobilization of plant and machineries, site demarcation and submit
request to carry out trial lay to the S.O.

4.3 Traffic control and safety shall be set up in accordance with the approved Traffic
Management Plan (TMP) prior to execution of the work.

4.4 The samples submitted for approval shall be accompanied with test results for
physical and mechanical properties of component materials and Marshall
properties of asphaltic concrete mixtures.

4.5 Milling equipment & machineries shall be checked and inspected prior to execution
of the work.

4.6 During milling operation, the depth of milling shall be checked and ascertained that
it is specified.

4.7 All debris and loose materials shall be cleaned using power broom (rotary type)
and/or other suitable equipment before tact coat is applied.

4.8 All other equipment, tool and machines shall be checked and inspected to make
sure they are in satisfactory working condition.

4.9 Tack coat shall be applied uniformly over the entire surface of the milled surface
including on the side of the cut surface.

4.10 Asphaltic concrete binder course and/or wearing course shall be laid in accordance
to the relevant standard specification.

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 PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL

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MILL AND PAVE

4.11 Refer to Flow Chart on page 4.

5.0 PLANT AND EQUIPMENT

i. Paver
ii. Steel wheeled tandem roller
iii. Pneumatic tyred roller
iv. Tipper trucks
v. Bituminous pressure distributor
vi. Power broom
vii. Air compressor
viii. Milling machine

6.0 REFERENCES

i. Standard Specification for Road Works (JKR/SPJ/1988), Section 4 Flexible

Pavement.
ii. Arahan Teknik (Jalan) 2C/85 – Manual on Traffic Control Devices: Temporary Sign
and Work Zones Control.
iii. Standard Specification for Road Works (JKR/SPJ/2008), Section 4 Flexible
Pavement.

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 PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL

Revision No. :
MILL & PAVE

ACTIVITY RESPONSIBILITY REFERENCE

Start

Project Manager Work Order

Receive Work Order from S.O.

Prepare PQP and submit to S.O. for

approval which shall consist of:-
Project Manager Project Quality Plan (PQP)
1. Traffic Management Plan
2. Work Programme
3. Layout Plan / Strip Map
4. Job Mix Formula (JMF)
5. Certificate of Testing & Calibrations
6. ITP
7. Method Statement
8. Bills of Quantities

YES

Approved
by S.O.
NO

Project Manager
Setting-up and site
demarcation

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 PROJECT QUALITY PLAN Reference No. :

WORK INSTRUCTION MANUAL

Revision No. :
MILL & PAVE

ACTIVITY RESPONSIBILITY REFERENCE

Milling

Removal of milling waste Project Manager

Clean milled surface from

debris Project Manager

Dipping Project Manager

NO
YES

Project Manager
Approved
by S.O.

Apply tack coat

Inlay ACWC/ACBC Project Manager

Testing Project Manager Inspection and Test Plan

& S.O.

Approved
by S.O. Rectification of defects
NO

YES

End

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 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE
LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
COMPLIANCE / FREQUENCY OF LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST EXECUTIVE / S.O.
CRITERIA TEST / SUPERVISOR MANAGER
ENGINEER
1.0 Traffic Management
1.1 Traffic control at worksite Arahan Teknik (Jalan) 2C/85 Visual Approved TMP P V C W

2.0 Demarcation
As specified in Work Instruction
2.1 Setting out and demarcation Measurement Approved Layout Plan P V C W
Manual

3.0 Mill and Overlay (ACBC / ACWC)

3.1 Material JKR/SPJ/1988-S4, Clause 4.2.4.2
Aggregate
3.1.1 Coarse Aggregate i. M.S 30 i. ACV < 30%
Crushing Value
Sodium Sulphate
Soundness Test
ii.AASHTO Test Method T104 ii (Weighted Not more than 12%
Average Loss of Once test for each
Property source
P V C W
Weight)
iii. M.S. 30 iii. Flakiness Index Not more than 30%
iv.M.S. 30 iv. Water Absorption Not more than 2%
Polished Stone Not less than 40 (applicable
v. M.S. 30 v.
Value only for wearing coarse)

Sodium Sulphate
Soundness Test
3.1.2 Fine Aggregate i. AASHTO Test Method T104 i (Weighted Not more than 12% Once test for each
Property Average Loss of source
P V C W
Weight)
ii.M.S. 30 ii. Water Absobtion Not more than 2%

Not less than 70% by weight Once test for each

3.1.3 Mineral Filler Grading Sieve analysis P V C W
pass B.S. 75 um sieve source

(Penetration grade 80 Once test for each

3.1.4 Bituminous Binder M.S. 124 Property Manufacturer's certificate P V C W
(Penetration grade 80-100 bitumen) - 100) source
Once test for each
3.1.5 Anti Stripping Agent M.S. 522 Manufacturer's certificate P V C W
source

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 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE

LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
COMPLIANCE / FREQUENCY OF LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST EXECUTIVE / S.O.
CRITERIA TEST / SUPERVISOR MANAGER
ENGINEER
a) Average thickness over
any 100m length ≥ Required
thickness
3.2 Milling Thickness Dipping b) Minimum thickness at any 50m / interval P V C W
point ≥ Required thickness
minus 5mm.
Approved Dumping
3.2.1 Removing of Milling Waste P V C W
Location
JKR/SPJ/1988. SECTION 4,
3.2.2 Surface Cleaned From Debris Visual P V C W
Clause 4.2.4.5.b

JKR/SPJ/1988, SECTION 4,
3.3.1 Prime Coat
Clause 4.2.1
Spray Application Spray Rate 0.5 - 1.0 litres / sq.m 300m2 / test P V C W
Cut Back - Slow Setting MS 159
Emulsion - Slow Setting MS 161

JKR/SPJ/1988, SECTION 4,
3.3.2 Overlay ACBC 28
Clause 4.2.4
BS 812 or equivalent Gradation Within the gradation 1 test/200 ton or at
Grading
JKR/SPJ/1988, Table 4.11 (JMF) (sieve analysis) envelope least 1 test per day.
ASTM D 2172 method E or
+/- 0.2% 1 test/200 ton or at
equivalent. Bitumen Content Bitumen Content (%)
of JMF least 1 test per day.
JKR/SPJ/1988, S-4, Table 4.11
Marshall Properties 1 test/200 ton or at
Property P V C A
JKR/SPJ/1988. S-4, Table 4.10 Test least 1 test per day.
BS 594; 1973, Test 3.4 or ASTM i) Stability > 450 kg
D 1559
ii) Flow 2.0mm - 4.0mm

iii) Stiffness > 112.5 kg/mm

iv) Air Void in Mix 3% - 7%

v) Void in Aggregate
65% - 80%
Filled with Bitumen

7
 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE
LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
FREQUENCY OF LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST COMPLIANCE / CRITERIA EXECUTIVE / S.O.
TEST / SUPERVISOR MANAGER
ENGINEER
JKR/SPJ/1988, SECTION 4, Core Sample i) Density 95% of Marshall density
Clause 4.2.4.5 (i) ii) Thickness a) Average thickness over any 1 core per 250m /
ASTM - Method D 1188/D 2276 100m length ≥ Required thickness lane or at least 2
b) Minimum thickness at any point cores
P V C A
≥ Required thickness minus 5mm.

JKR/SPJ/88, SECTION 4, Laying and

Temperature As per trial lay Every Load
Clause 4.2.4.5 (f & g) rolling

JKR/SPJ/1988, SECTION 4,
Tack Coat Spray
3.4.1 Clause 4.2.2 Spray Rate 0.25 - 0.55 litres / sq.m 300m2 / test P V C W
Emulsion - (RS-1K) Application
MS 161

JKR/SPJ/1988, SECTION 4,
3.4.2 Overlay ACWC 20
Clause 4.2.4
BS 812 or equivalent Gradation 1 test/200 ton or at
Grading Within the gradation envelope
JKR/SPJ/1988, Table 4.11 (JMF) (sieve analysis) least 1 test per day.
ASTM D 2172 method E or
Bitumen +/- 0.2% of 1 test/200 ton or at
equivalent. Bitumen Content (%)
Content JMF least 1 test per day.
JKR/SPJ/1988, S-4, Table 4.11
JKR/SPJ/1988. S-4, Table 4.10 Marshall Properties 1 test/200 ton or at
BS 594; 1973, Test 3.4 or ASTM Test least 1 test per day.
D 1559
i) Stability > 500 kg
ii) Flow > 2.0 mm
iii) Stiffness > 250 kg/mm P V C A

iv) Air Void in Mix 3% - 5%

v) Void in Aggregate
75% - 85%
Filled with Bitumen
JKR/SPJ/1988, SECTION 4, Core Sample i) Density 98% of Marshall density 1 core per 250m /
Clause 4.2.4.5 (i) ii) Thickness a) Average thickness over any lane or at least 2
ASTM - Method D 1188/D 2276 100m length ≥ Required thickness cores
b) Minimum thickness at any point
≥ Required thickness minus 5mm.

JKR/SPJ/1988, SECTION 4, Laying and

Thermometer As per trial lay Every Load
Clause 4.2.4.5 (f & g) rolling

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 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE
LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
COMPLIANCE / FREQUENCY LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST EXECUTIVE / S.O.
CRITERIA OF TEST / SUPERVISOR MANAGER
ENGINEER
1.0 Traffic Management
1.1 Traffic control at worksite Arahan Teknik (Jalan) 2C/85 Visual Approved TMP P V C W

2.0 Demarcation
As specified in Work Instruction
2.1 Setting out and demarcation Manual Measurement Approved Layout Plan P V C W

3.0 Overlay (ACBC / ACWC) JKR/SPJ/2008-S4, Clause 4.3.3

3.1 Material JKR/SPJ/2008-S4, Clause 4.3.3.2

3.1.1 Coarse Aggregate i. ASTM C 131 i. Loss Angeles Abrasion Value Not more than 25%

Weighted Average Loss of

ii.AASHTO Test Method T104 ii Weight in magnesium sulphate Not more than 18%
soundness test Once test for
Property each source
P V C W
iii. M.S. 30 iii. Flakiness Index Not more than 25%
iv.M.S. 30 iv. Water Absorption Not more than 2%
Not less than 40
v. M.S. 30 v. Polished Stone Value
(only applicable for wearing coarse)

Sand Equivalent of aggregate

3.1.2 Fine Aggregate i. ASTM D 2419 i. Not less than 45%
fraction passing 4.75mm sieve
ii. ASTM C 1252 ii. Aggregate Angularity Not less than 45%
iii. Ohio Dept. of Transpot Std. Once test for
iii. Methylene Blue value Not more than 10 mg/g
Test Method Property
each source
P V C W
Weighted Average Loss of
iv. AASHTO Test Method T104 iv. Weight in magnesium sulphate Not more than 20%
soundness test
v. M.S. 30 v. Water Absorption Not more than 2%
Not less than 70% by weight
3.1.3 Mineral Filler Sieve analysis pass B.S. 75 um sieve
Grading
(Approx. 2% by weight of combined
P V C W
Aggregate.)

3.1.4 Bituminous Binder M.S. 124 Property (Penetration grade 60-70 or 80-100) Manufacturer's certificate P V C W
(Penetration grade 60-70 or 80-100)

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 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE
LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
COMPLIANCE / FREQUENCY OF LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST EXECUTIVE / S.O.
CRITERIA TEST / SUPERVISOR MANAGER
ENGINEER
a) Average thickness over
any 100m length ≥ Required
thickness
3.2 Milling Thickness Dipping
b) Minimum thickness at any
50m / interval P V C W
point ≥ Required thickness
minus 5mm.
Approved
3.2.1 Removing of Milling Waste Dumping P V C W
Location
3.2.2 Surface Cleaned From Debris Visual P V C W
JKR/SPJ/2008, SECTION 4,
3.2.1 Prime Coat
Clause 4.2.1 Spray 2
Cut Back MC-70 Slow Setting MS 159 Application
Spray Rate 0.5 - 1.0 litres / sq.m 300m / test P V C W
Emulsion SS-1K - Slow MS 161
Setting
JKR/SPJ/2008, SECTION 4,
3.2.2 Overlay ACBC 28
Clause 4.3.3
BS 812 or equivalent 1 test/200 ton or at
Grading Sieve analysis Within the gradation envelope
JKR/SPJ/2008, Table 4.3.6 (JMF) least 1 test per day.
ASTM D 2172 method E or
Bitumen 1 test/200 ton or at
equivalent. Bitumen Content (%) +/- 0.2% of JMF
Content least 1 test per day.
JKR/SPJ/2008, Table 4.3.6 (JMF)
Property Marshall Properties Test
JKR/SPJ/2008, Table 4.3.5 i) Stability, S > 8000 N
BS 594; 1973, Test 3.4 or ASTM
ii) Flow, F 2.0 - 4.0 mm
D 1559 1 test/200 ton or at
iii) Stiffness, S/F > 2000 N/mm P V C A
least 1 test per day.
iv) Air Void in Mix (VIM) 3% - 7%
v) Void in Aggregate Filled with
65% - 75%
Bitumen (VFB)
JKR/SPJ/2008, S-4, Table 4.3.7 Core Sample i) Density > 95% of Marshall density
ASTM - Method D 1188/D 2276 ii) Thickness a) Average thickness over
any 100m length ≥ Required 1 core per 250m /
thickness lane or at least 2
b) Minimum thickness at any cores
point ≥ Required thickness
minus 5mm.

10
 PROJECT QUALITY PLAN Reference No. :

INSPECTION AND TEST PLAN

Revision No. :
MILL & PAVE
LEGEND
A APPROVED
C CONFIRMED

V VERIFIED

W WITNESSED

P PREPARED
TECHNICAL
COMPLIANCE / FREQUENCY OF LAB TECHNICIAN PROJECT
ITEM DESCRIPTION REQUIREMENT / STANDARD INSPECTION TEST EXECUTIVE / S.O.
CRITERIA TEST / SUPERVISOR MANAGER
ENGINEER

JKR/SPJ/2008, S-4, Clause Laying and

Temperature As per trial lay Every Load P V C A
4.3.3.5 Rolling

Tack Coat JKR/SPJ/2008, S-4, Clause 4.3.2 Spray 2

3.3.1 Spray Rate 0.25 - 0.55 litres / sq.m 300m / test P V C W
Emulsion - (RS-1K) MS 161 Application

JKR/SPJ/2008, SECTION 4,
3.3.2 Overlay ACWC 20
Clause 4.3.3
BS 812 or equivalent 1 test/200 ton or at
Grading Sieve analysis Within the gradation envelope least 1 test per
JKR/SPJ/2008, Table 4.3.6 (JMF)
day.
ASTM D 2172 method E or 1 test/200 ton or at
Bitumen
equivalent. Bitumen Content (%) +/- 0.2% of JMF least 1 test per
Content
JKR/SPJ/2008, Table 4.3.6 (JMF) day.
Property Marshall Properties Test
JKR/SPJ/2008, Table 4.3.5
i) Stability, S > 8000 N
BS 594; 1973, Test 3.4 or ASTM D
1559 ii) Flow, F 2.0 - 4.0 mm 1 test/200 ton or at
iii) Stiffness, S/F > 2000 N/mm least 1 test per
day. P V C A
iv) Air Void in Mix (VIM) 3% - 5%
v) Void in Aggregate Filled
70% - 80%
with Bitumen (VFB)
JKR/SPJ/2008, S-4, Table 4.3.7 Core Sample i) Density > 98% of Marshall density 1 core per 250m /
ASTM - Method D 1188/D 2276 ii) Thickness a) Average thickness over lane or at least 2
any 100m length ≥ Required cores
thickness
b) Minimum thickness at any
point ≥ Required thickness
minus 5mm.

JKR/SPJ/2008, S-4, Clause Laying and

Temperature As per trial lay Every Load
4.3.3.5 Rolling

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